Philips Vari-Lite VL3500 Series Service Manual
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Philips Vari-Lite VL3500 Series 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: 10-June-2009 Part number: 02.9678.0018 B VL3500™ & VL3500™Q Spot Luminaire Service Manual ©2003-2009, Vari-Lite, a Philips group company. All Rights Reserved.

  • Page 3: How To Obtain Warranty Service

    OREWORD How To Obtain Warranty Service A copy of the Vari-Lite Limited Warranty was included in the shipping package for this VARIFLITE® 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: Compliance Notice

    VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Compliance Notice This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of FCC Rules. These limits are designed to provide reasonable protection against harmful interference when this equipment is operated in a commercial environment.

  • Page 5: Safety Notice

    OREWORD Safety Notice It is extremely important to read ALL safety information and instructions provided in this manual and any accompanying documentation before installing and operating the products described herein. Heed all cautions and warnings during installation and use of this product. Safety symbols used throughout this manual are as follows: CAUTION advising of potential damage to product.
  • Page 6 VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL WARNING: INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST EXCESSIVE EXPOSURE TO UV RADIATION 1. Many VARIFLITE® 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™ S UMINAIRE ERVICE ANUAL WARNUNG: HINWEISE ZUM SCHUTZ GEGEN ÜBERHÖHTE UV-STRAHLUNG 1. Viele VARIFLITE®-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: Notes De Sécurité

    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™ S UMINAIRE ERVICE ANUAL AVERTISSEMENT: DIRECTIVES POUR SE PROTÉGER CONTRE UNE EXPOSITION EXCESSIVE AUX RAYONS UV 1. Plusieurs luminaires VARIFLITE® 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™ S UMINAIRE ERVICE ANUAL ADVERTENCIA: INSTRUCCIONES PARA PROTECCIÓN CONTINUA CONTRA LA EXPOSICIÓN EXCESIVA DE RADIACIÓN ULTRA VIOLETA 1. Muchas luminarias VARIFLITE® usan un tipo de lámpara que produce radiación UV. NO mire directamente a la lámpara. 2.
  • Page 13 OREWORD 02.96 78.001 8 B...
  • Page 14 VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL 02.967 8.0018 B...

  • Page 15: Illustrated Parts Breakdown

    HAPTER Illustrated Parts Breakdown This chapter contains illustrated parts breakdowns for all VL3500™ Spot Luminaire assemblies. Note: The VL3500 Series Luminaires share many common assemblies and parts of the VARIFLITE Series 3000 Luminaires. ® • Drawing Trees • Top Assembly •...

  • Page 16: Drawing Trees

    VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Drawing Trees VL3500 Spot Luminaire VL3500 Spot Luminaire 20.9678.0019 Rev H (VL3500 Only) Generic Luminaire Assembly Head Cover Assembly Edge Lead Screw Assembly 21.9678.0010.02 Rev H (VL3500 21.9678.8611 Rev - 22.9678.1126 Rev B Only) Head Structure Assembly Hot Box Assembly...
  • Page 17 : VL3500 S RAWING REES UMINAIRE VL3500 Spot Luminaire (continued) continued from previous page continued from previous page Spot Optic Assembly Color/Dimmer/Strobe 22.9678.0103 Rev S Assembly 22.9678.0402 Rev N (VL3500) Motor/Adapter Plate Assembly Interconnect Light Shield Group 4 Lens Assembly Fixed Color Wheel Assembly 21.9678.0331 Rev 0 Assembly...
  • Page 18 VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL VL3500 Spot Luminaire (continued) continued from page 44 Upper Enclosure Assembly 21.9678.0800.02 Rev NN (VL3500 Only) Pan EOT Sensor Electrical Ventilation Cover Assembly - Assembly Standard 23.9678.0687 Rev A 21.9678.1254 Rev 0 LVS Chassis Ground Cable Pan Pulley Assembly Assembly...
  • Page 19 : VL3500Q S RAWING REES UMINAIRE VL3500Q Spot Luminaire VL3500Q Spot Luminaire 20.9678.0020 Rev I (VL3500Q Only) Generic Luminaire Assembly Head Cover Assembly Edge Lead Screw Assembly 21.9678.0011.02 Rev C (VL3500Q 21.9678.8611 Rev - 22.9678.1126 Rev B Only) Head Structure Assembly Hot Box Assembly VL3500 Controller PCB Assembly 21.9678.8698.01 Rev F...
  • Page 20 VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL VL3500Q Spot Luminaire (continued) continued from previous page continued from previous page Spot Optic Assembly Color/Dimmer/Strobe 22.9678.0103 Rev S Assembly 22.9678.0462 Rev E (VL3500Q) Motor/Adapter Plate Assembly Interconnect Light Shield Group 4 Lens Assembly Fixed Color Wheel Assembly 21.9678.0331 Rev 0 Assembly...
  • Page 21 : VL3500Q S RAWING REES UMINAIRE VL3500Q Spot Luminaire (continued) continued from page 44 Upper Enclosure Assembly 21.9678.0801.02 Rev Z (VL3500Q Only) Pan EOT Sensor Electrical Ventilation Cover Assembly - Assembly VL3500 Quiet 23.9678.0687 Rev A 21.9686.0840.02 Rev B (VL3500Q) LVS Chassis Ground Cable Pan Pulley Assembly Assembly...

  • Page 22: Top Assembly

    VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Top Assembly Included Items Kit, Spot 28.9678.0020 Rev E Refer to Figure 3-7. Item Qty. Description 02.8001.0001 PRODUCT SUPPORT SHEET, VARI-LITE CUSTOMER SERVICE 02.8052.0001 CARD, LIMITED WARRANTY 02.8406.0001 TAG, LAMP NOTICE 02.8700.0001 CARD, PRODUCT REGISTRATION 02.9678.0002 UNPACK/QUICK START SHEET, VL3000...
  • Page 23 SSEMBLY NCLUDED TEMS Included Items Kit, Spot (continued) (x2) Night Sky Palm Leaves Tribal Break-Up Circle of Ovals Pebbles Triangle Break-Up Shock Break-Up Alpha Rays Glacier Gag Ice Blocks Gag Multi-Colored Gobo Figure 3-7: Included Items Kit, Spot Note: * = Do not handle lamp with bare hands. When handling, it is best to wear clean cotton gloves in order to keep the lamp’s glass as dirt and grease free as possible.
  • Page 24 VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL VL3500 Spot Series Luminaire 20.9678.0019 Rev H (VL3500 Only) 20.9678.0020 Rev I (VL3500Q Only) Refer to Figure 3-8 Item Qty. Description AC DANGER TAG, VL3000 (not shown) 02.8405.0001 04.9661.0033.01 LABEL, WARNING - 2000 SERIES (not shown) LABEL, LINE CORD WARNING (not shown) 04.9661.0039 04.9678.0063...
  • Page 25 : VL3500 S SSEMBLY ERIES UMINAIRE Item Qty. Description 25.9678.0677 CABLE ASSY, FRONT HEAD FANS (not shown) 25.9661.1520 CABLE ASSY, YOKE TO HEAD GND (not shown) CABLE ASSY, HEAD CONTROL (not shown) 25.9678.1715 28.9678.0020 INCLUDED ITEMS KIT, VL3500 SHUTTER (not shown) 53.2001.0003 NUT, 10-32 NYLON INSERT 53.2002.0003...
  • Page 26 VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL VL3500 Spot Series Luminaire (continued) (x2) (x2) (x4) (x2) (x4) (x2) (x4) (x2) (x2) (x2) (x2) (x2) 18,30 (x2) (x2) (x4) (x2) (x8) (x2) (x4) (x2) (x4) (x4) (x4), (x6) 8,22 (x4) Figure 3-8: VL3500 Series Spot Luminaire 02 .9 678 .00 18 B...

  • Page 27: Generic Luminaire Assembly

    SSEMBLY ENERIC UMINAIRE SSEMBLY Generic Luminaire Assembly 21.9678.0010.02 Rev H (VL3500 Only) 21.9678.0011.02 Rev C (VL3500Q Only) Refer to Figure 3-9 Item Qty. Description 21.9678.0600 ASSY, HEAD STRUCTURE 21.9678.0601 ASSEMBLY, HEAD STRUCTURE, QUIET 21.9678.0700 ASSY, YOKE 21.9678.0701 ASSEMBLY, YOKE, QUIET 21.9678.0707 ASSEMBLY, TILT PULLEY - 10.9678.0750...
  • Page 28 VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Generic Luminaire Assembly (continued) (x3) (x2) (x4) (x4) (x4) (x2) Detail A (x4) (x5) (x5) (x3) Detail A (x2) (x2) Figure 3-9: Generic Luminaire Assembly 02 .9 678 .00 18 B...

  • Page 29: Head Structure Assembly

    SSEMBLY TRUCTURE SSEMBLY Head Assembly Head Structure Assembly 21.9678.0600 Rev C (VL3500 Only) 21.9678.0601 Rev 0 (VL3500Q Only) Refer to Figure 3-1 Item Qty. Description 10.9678.8620 FRONT CASTING 12.9678.8623 RIGHT SIDE RAIL, MACHINED 12.9678.8625 LEFT SIDE RAIL, MACHINED ASSY, BACKEND (VL3500 ONLY) 21.9678.0615 21.9678.0616 ASSEMBLY, BACKEND (VL350OQ ONLY)

  • Page 30: Head Cover Assembly

    VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Head Cover Assembly 21.9678.8611 Rev - Refer to Figure 3-2 Item Qty. Description 10.9678.0612 HEAD COVER FOAM BAFFLE 10.9678.0649 EJECTOR SPRING, BLACK OXIDE 10.9678.0674 BRACKET, COVER TETHER 10.9678.0696 FOAM FRAME, HEAD COVER 12.9678.8610 HEAD COVER, PAINTED 53.6558.0003...

  • Page 31: Backcap Assembly

    SSEMBLY ACKCAP SSEMBLY Backcap Assembly 21.9678.0615 Rev T (VL3500 Only) 21.9678.0616 Rev H (VL3500Q Only) Refer to Figure 3-3 Item Qty. Description 10.9678.0631 SEPARATION BULKHEAD 10.9678.8635 EXHAUST BULKHEAD 10.9678.0637 CLIP, RETRO-REFLECTOR 10.9678.0638 AIR DIVERTER, STROBE MOTOR 10.9678.0653 LIGHT BAFFLE, EXHAUST 12.9678.7152 REFLECTOR, RETRO SPHERICAL COATED 12.9678.0627...
  • Page 32 VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Item Qty. Description 74.1099.0001 SWITCH, MINIATURE 5AMP 150DEG 10.9678.0680 INSULATOR, TEFLON TO-220 (not shown) 53.2200.0004 NUT, 4-40 KEPS SS 53.6613.0004 SCREW, 6-32 X 1/2" SCZ 10.9678.1645 FAN SHIELD, LAMP COOLING 55.6538.0001 WASHER, #4 LOCK, INTERNAL TOOTH (x4) (x3) (x2)

  • Page 33: 80Mm Fan Assembly

    : 80 SSEMBLY SSEMBLY 80mm Fan Assembly 21.9678.0619 Rev B (VL3500 and VL3500 Quiet) Refer to Figure 3-4 Item Qty. Description 40.7145.0004 FAN, TUBEAXIAL 80 X 80 X 38MM 230V 28 CFM 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 34: Uv Filter Bulkhead Assembly

    VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL UV Filter Bulkhead Assembly 22.9678.0617 Rev D (VL3500 Q) 22.9678.0639 Rev G (VL3500) Refer to Figure 3-5 Item Qty. Description 10.9678.0634 UV FILTER BULKHEAD 10.9678.0648 CLIP, UV GLASS 41.9678.0608 UV/IR FILTER, 3.00" X 3.00" 41.9678.1160 UV/IR FILTER, 3.00"...
  • Page 35 SSEMBLY HUTTER SSEMBLY Gobo/Shutter Assembly 21.9678.1200 Rev G Refer to Figure 3-6 Item Qty. Description 10.9678.0338 PULLEY, ZOOM MOTOR 10.9678.0225 SHAFT, GOBO WHEEL 10.9678.0231 PULLEY, MOTOR GOBO WHEEL DRIVE 10.9678.0232 PULLEY, INDEX DRIVE 64 GROOVE 10.9678.0246 ADJUST PLATE, MOTOR 10.9678.1215 BULKHEAD, SHUTTER MODULE FRONT 10.9678.1244 MOUNT, INDEX SENSOR LONG...
  • Page 36 VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Item Qty. Description 55.6506.0033 SPACER, 3/8" RND 1-1/8" LG.257"ID THRU AL 55.6520.0001 WASHER WAVE SPRING.265" ID.367" OD.006" THK (x2) (x6) (x2) (x4) (x3) (x4) (x4) (x2) (x4) (x4) (x2) (x2) (x6) (x8) 3,17 (x2) 4,17...
  • Page 37 SSEMBLY OTATING HEEL SSEMBLY HUTTER Rotating Gobo Wheel Assembly, Shutter 21.9678.1205 Rev B Refer to Figure 3-7 Item Qty. Description 10.9678.1216 BULKHEAD, SHUTTER MODULE, REAR 10.9678.1225 SHAFT, GOBO WHEEL, CANTILEVER 21.9678.1210 ASSY, ROTATING GOBO WHEEL 21.9678.1410 ASSY, FIXED GOBO WHEEL 24.9678.3240 ASSY, PCB, WHEEL POSITION SENSOR 53.6520.0001...

  • Page 38: Fixed Gobo Wheel Assembly

    VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Fixed Gobo Wheel Assembly 21.9678.1410 Rev B Refer to Figure 3-8 Item Qty. Description 10.9678.0250 MAGNET TAPE.375"W x.625" L x.0035" THICK 10.9678.1412 PLATE, ROTATING GOBO WHEEL 10.9678.1425 FIXED GOBO RETAINING WIRE 22.9678.1415 ASSY, PULLEY, FIXED WHEEL HUB 53.6601.0002 SCREW, 4-40 X 3/16"...

  • Page 39: Rotating Gobo Wheel Assembly

    SSEMBLY OTATING HEEL SSEMBLY Rotating Gobo Wheel Assembly 21.9678.1210 Rev 0 Refer to Figure 3-9 Item Qty. Description 10.9678.0250 MAGNET TAPE.375"W x.625" L x.0035" THICK 10.9663.1211 SPACER, TEFLON GOBO GEAR 10.9663.1240 BEARING, GOBO WHEEL BORE 10.9678.0220 PLATE, ROTATING GOBO WHEEL 10.9678.0224 RETAINING RING, PLANET 12.9678.1223...

  • Page 40: Roller Pivot Rotate Assembly

    VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Roller Pivot Rotate Assembly 21.9678.1555 Rev 0 Refer to Figure 3-10 Item Qty. Description 10.9678.1551 ROLLER PIVOT, SHUTTER ROTATE 22.9678.1550 ASSY, SHUTTER ROTATE, ROLLER 53.6609.0001 SCREW, 6-32 X 3/8" PFZ Flange side of bearing Figure 3-10: Roller Pivot Rotate Assembly 02 .9 678 .00 18 B...
  • Page 41 SSEMBLY HUTTER OTATE OLLER SSEMBLY Shutter Rotate Roller Assembly 22.9678.1550 Rev B Refer to Figure 3-11 Item Qty. Description 10.9678.1552 ROLLER SHUTTER ROTATE 54.1259.0005 BEARING, FLANGED,.25" ID,.625" OD,.0001 Figure 3-11: Shutter Rotate Roller Assembly 02.96 78.001 8 B...

  • Page 42: Long Shaft Motor Assembly

    VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Long Shaft Motor Assembly 21.9678.0243 Rev 0 Refer to Figure 3-12 Item Qty. Description 10.9678.0330 PLATE, MOTOR ADAPTER 44.9678.0249 MOTOR, STEPPER 42MM X 34MM 60MM SHAFT 53.6513.0002 SCREW, 3MM X 5MM LG PFZ METRIC (x4) Note orientation of adapter plate in relation to the motor.

  • Page 43: Shutter Assembly

    SSEMBLY HUTTER SSEMBLY Shutter Assembly 21.9678.1510 Rev J Refer to Figure 3-13 Item Qty. Description 10.9678.1526 PIVOT, SHUTTER BLADE, SHORT 10.9678.1527 PIVOT, SHUTTER BLADE, LONG 10.9678.1528 CAM STOP 10.9678.1529 CABLE CLAMP, SHUTTER 10.9678.1532 GLIDE, BLADE PIVOT 10.9678.1534 ACTUATOR ARM, BEARING, SHUTTER 10.9678.1535 GLIDE SHEET, SHUTTER, BOTTOM 10.9678.1536...
  • Page 44 VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Shutter Assembly (continued) 4, 28 (x2) (x4) (x6) (x8) (x4) (x3) (x16) (x3) (x8) (x4) (x2) (x16) (x2) (x16) (x8) (x8) (x2) (x2) (x2) (x16) Figure 3-13: Shutter Assembly 02 .9 678 .00 18 B...

  • Page 45: Shutter Motor Disk Assembly

    SSEMBLY HUTTER OTOR SSEMBLY Shutter Motor Disk Assembly 21.9678.1515 Rev E Refer to Figure 3-14 Item Qty. Description 10.9678.1560 BASE PLATE, SHUTTER 44.9678.1517 MOTOR, PANCAKE, SIZE 16,.47" SHAFT 53.2202.0030 NUT, M3 X.5 HEX NYLOC ZINC 53.6513.0029 SCREW, M3 X 12 PFZ 53.6513.0045 SCREW, M3 X 16 PFZ 55.2178.0001...
  • Page 46 VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Shutter Motor Disk Assembly (continued) (x8) (x8) (x8) (x8) (x4) (x4) Frame 4A Frame 4B (x10) Frame 3B Frame 1A Frame 1B Frame 3A Frame 2A Frame 2B Figure 3-14: Shutter Motor Disk Assembly 02 .9 678 .00 18 B...

  • Page 47: Hot Box Assembly

    SSEMBLY SSEMBLY Hot Box Assembly 21.9678.8698.01 Rev F Refer to Figure 3-15 Item Qty. Description 10.9678.0043.03 LABEL PLATE, VL3000 BACKCAP, BLACK 10.9678.0641 HOT BOX 10.9686.0642 BACKCAP PLATE 10.9678.0643 LAMP ADJUST STOP 10.9678.0645 KNOB, LAMP ADJ MOLDED 10.9678.0646 TILT PLATE, XYZ ADJUSTMENT 10.9678.1648 GASKET, PRIMARY REFLECTOR 10.9678.2647...
  • Page 48 VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Hot Box Assembly (continued) (x4) (x4) (x4) (x4) (x4) (x2) (x4) (x8) (x4) (x3) (x3) (x3) (x3) Figure 3-15: Hot Box Assembly 02 .9 678 .00 18 B...
  • Page 49 SSEMBLY TANDARD SSEMBLY Dual Fan Tray Duct (Standard) Assembly 21.9678.0660.03 Rev B (VL3500 Only) Refer to Figure 3-16 Item Qty. Description 10.9678.0665 SPRING, EXTENSION ELONGATED HOOKS 22.9678.0661 ASSY, FAN TRAY 22.9678.1265 DUCT ASSY, SHUTTER/GOBO 23.9678.0684 FAN ASSY, HEAD FRONT 53.5506.1375 SCREW, 6-32 X 1 3/8"LG PPB 53.6519.0001 SCREW, 4-40 X 5/8"...
  • Page 50 VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Dual Fan Tray Duct (Quiet) Assembly 21.9678.0659.03 Rev D (VL3500Q Only) Refer to Figure 3-17 Item Qty. Description 10.9678.0665 SPRING, EXTENSION ELONGATED HO 22.9678.0661 ASSY, FAN TRAY 22.9678.1265 DUCT ASSY, SHUTTER/GOBO 23.9678.0699 FAN ASSY, HEAD FRONT 53.5506.1375 SCREW, 6-32 X 1 3/8"LG PPB...
  • Page 51 SSEMBLY RONT TANDARD SSEMBLY Head Front Fan (Standard) Assembly 23.9678.0684 Rev 0 (VL3500 Only) Refer to Figure 3-18 Item Qty. Description 40.7125.0001 FAN, 24V FAL6F24LH 52.6523.0002 CONN, HOUSING 2POS PLUG SHROUDED WIRE TO WIRE 52.8347.0001 CONTACT, 24-30AWG MALE CRIMP (x2) Figure 3-18: Head Front Fan Assembly - VL3500 Only 02.96 78.001 8 B...
  • Page 52 VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Head Front Fan (Quiet) Assembly 23.9678.0699 Rev A (VL3500Q Only) Refer to Figure 3-19 Item Qty. Description 40.7125.0001 FAN, 24V FAL6F24LH 52.6523.0002 CONN, HOUSING 2POS PLUG SHROUDED WIRE TO WIRE 52.8347.0001 CONTACT, 24-30AWG MALE CRIMP 55.2186.0001 CABLE TIE,.10 X 4"...

  • Page 53: Transfer Fan Assembly

    SSEMBLY RANSFER SSEMBLY Transfer Fan Assembly 21.9678.1263 Rev 0 Refer to Figure 3-20 Item Qty. Description 10.9678.0679 TRANSFER FAN TRAY 22.9678.1280 SHIELD ASSY, SHUTTER ROTATE HARNESS 23.9678.0695 ASSY, TRANSFER FAN 53.6558.0001 SCREW, 6-32 X.375" LG PPZ 53.6571.0003 SCREW, 6-32 X 1.500" LG PPB 55.2179.0001 CABLE ANCHOR, #6 SCREW MOUNT 55.2186.0001...
  • Page 54 VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Notes 02 .9 678 .00 18 B...

  • Page 55: Spot Optic Assembly

    SSEMBLY PTIC SSEMBLY Spot Optic Assembly 22.9678.0103 Rev S Refer to Figure 3-21 Figure 3-22 Item Qty. Description 10.9678.1131 FORWARD PULLEY SHAFT (changed 12-15-04) 10.9678.0127 PULLEY, IDLER 10.9678.0129 SPACER, ROLLER CAM 10.9678.0153 CABLE CLAMP, CAST 10.9678.0156 BARREL STRAP, G1 & G2 10.9678.0157 BARREL STRAP, G3 10.9678.0171...
  • Page 56 VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Item Qty. Description 23.9678.1120 LINEAR ACTUATOR ASSEMBLY - 44.9678.0119 LINEAR ACTUATOR EDGE DRIVE - 52.6467.0004 4 POS 30-24 AWG CRIMP PHR - 52.6467.0024 CONTACT, SOCKET 30-24AWG CRIMP (REEL) PH (JST) 24.9678.3112 PCB ASSY, VL3000 ZOOM SENSOR 53.2004.0002 NUT, 8-32 KEPS ZINC PLATE 53.2213.0001...
  • Page 57 SSEMBLY PTIC SSEMBLY Spot Optic Assembly (continued) (x2) (x2) (x2) (x2) (x2) (x4) (x3) (x2) Detail F-F Detail E-E (x6) Figure 3-21: Spot Optic Assembly View 1 02.96 78.001 8 B...
  • Page 58 VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Spot Optic Assembly (continued) * Interconnect PCB and Zoom Motor removed for clarity. Detail A-A Detail B-B Detail C-C (x3) (x3) Optical Sensor (x2) (x3) (x6) Detail G3-G3 Detail G2-G2 Detail G1-G1 (x2) (x5) Figure 3-22: Spot Optic Assembly View 2...

  • Page 59: Group 4 Lens Assembly

    SSEMBLY ROUP SSEMBLY Group 4 Lens Assembly 22.9678.0199 Rev 0 Refer to Figure 3-23 Item Qty. Description 12.9678.0198 RING BLOCK, MACHINED G4 22.9678.0174 LENS ASSY, GROUP 4 53.6558.0001 SCREW, 6-32 X 3/8" PPZ 55.3303.0006 WASHER, #6 LOCK INT.TOOTH SS 55.6763.0500 PIN, DOWEL 0.5"...

  • Page 60: Right Edge Bearing Assembly

    VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Right Edge Bearing Assembly 22.9678.1103 Rev C Refer to Figure 3-24 Item Qty. Description 12.9678.1102 EDGE BEARING, MACHINED RIGHT 54.2056.0001 RING, RETAINING EXTERNAL 19MM 55.6776.0010 LINEAR BUSHING, 10MM STEEL W/PHENOLIC CAGE (x4) (x2) Figure 3-24: Right Edge Bearing Assembly 02 .9 678 .00 18 B...

  • Page 61: Left Edge Bearing Assembly

    SSEMBLY EARING SSEMBLY Left Edge Bearing Assembly 22.9678.1105 Rev C Refer to Figure 3-25 Item Qty. Description 12.9678.1104 EDGE BEARING, MACHINE LEFT 54.2056.0001 RING, RETAINING EXTERNAL 19MM 55.6776.0010 LINEAR BUSHING, 10MM STEEL W/PHENOLIC CAGE (x4) (x2) Figure 3-25: Left Edge Bearing Assembly 02.96 78.001 8 B...

  • Page 62: Zoom Cam Assembly

    VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Zoom Cam Assembly 22.9678.1106 Rev B Refer to Figure 3-26 Item Qty. Description 10.9678.1107 ZOOM TIMING CAM 10.9678.1108 PULLEY FLANGE 10.9678.1118 TIMING PULLEY, ZOOM 53.6613.0008 SCREW, 6-32 X 1/2" PPZ (changed 11-08-04) 54.1259.0004 BEARING, RADIAL FLANGED .25"ID .625"OD (changed 06-25-03) 55.6763.0500...

  • Page 63: Zoom Motor Tensioning Assembly

    SSEMBLY OTOR ENSIONING SSEMBLY Zoom Motor Tensioning Assembly 22.9678.1113 Rev B Refer to Figure 3-27 Item Qty. Description 10.9678.0338 PULLEY, ZOOM MOTOR 10.9678.1111 BRACKET, ZOOM TENSION SHEETMETAL 44.9663.1326 MOTOR, 17 .53" SHAFT 11.8MH 5.5 OHM 53.5559.0250 SCREW, 6-32 X 1/4" SET CONE POINT 53.6522.0001 SCREW, 6-32 X 1/4"...

  • Page 64: Interconnect Light Shield Assembly

    VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Interconnect Light Shield Assembly 22.9678.1115 Rev D Refer to Figure 3-28 Item Qty. Description 10.9678.1114 SHIELD, INTERCONNECT MOUNT/LIGHT 24.9678.3116 PCB ASSY, ZOOM INTERCONNECT 53.6558.0009 SCREW, 6-32 X 3/8" PPZ SEMS (x4) Figure 3-28: Interconnect Light Shield Assembly 02 .9 678 .00 18 B...

  • Page 65: Rod Clamp Assembly

    SSEMBLY LAMP SSEMBLY Rod Clamp Assembly 22.9678.0149 Rev B Refer to Figure 3-29 Item Qty. Description 10.9678.0151 CLAMP, OPTIC ROD CAST 53.2008.0006 SPRING CLIP, 6-32 53.6616.0001 SCREW, 6-32 X 3/4" PPZ 55.6528.0001 WASHER, #6 FLAT ZINC 55.6538.0001 WASHER, #6 LOCK INTERNAL TOOTH (x2) (x2) (x2)

  • Page 66: Color/Dimmer/Strobe Assembly

    VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Color/Dimmer/Strobe Assembly 22.9678.0402 Rev N (VL3500) 22.9678.0462 Rev E (VL3500Q) Item Qty. Description 10.9678.0324 PULLEY, FIXED COLOR WHEEL 10.9678.0337 DRIVE PULLEY, FIXED COLOR WHEEL 10.9678.0456 SHAFT, COLOR WHEEL 10.9678.0457.07 SPACER, COLOR WHEEL L.357 10.9678.0457.02 SPACER, COLOR WHEEL L.190 10.9678.0457.03...
  • Page 67 SSEMBLY OLOR IMMER TROBE SSEMBLY Item Qty. Description 53.5638.0252 SCREW, 6-32 X 1/4"LG PFS UNDERCUT HEAD 53.6558.0001 SCREW, 6-32 X 3/8" PPZ 53.6597.0001 SCREW, 4-40 X 3/16" PPZ 53.6608.0003 SCREW, 6-32 X 3/16"LG PPZ 54.2036.0017 BELT, TIMING N=150 W=.125 URETHANE/KEVLAR 54.2059.0001 TIMING BELT, MXL PITCH 150 TOOTH SI/KEVLAR 54.2060.0001...
  • Page 68 VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Color/Dimmer/Strobe Assembly (continued) (x8) (x4) (x5) Dimmer (x10) Yellow (x4) (x4) Cyan (x2) (x2) Magenta (x2) (x2) (x2) (x4) (x4) (x5) (x5) (x1) (x2) (x5) (x5) (x12) (x5) Figure 3-30: Color/Dimmer/Strobe Assembly 02 .9 678 .00 18 B...

  • Page 69: Motor/Adapter Plate Assembly

    SSEMBLY OTOR DAPTER LATE SSEMBLY Motor/Adapter Plate Assembly 21.9678.0331 Rev 0 Refer to Figure 3-31 Item Qty. Description 10.9678.0330 PLATE, MOTOR ADAPTER 44.5031.0001 MOTOR, STEPPER 42MM X 40MM,10 53.6513.0002 SCREW, 3MM X 5MM LG PFZ METR (x4) Note orientation of adapter plate in relation to the motor. Figure 3-31: Motor/Adapter Plate Assembly 02.96 78.001 8 B...

  • Page 70: Fixed Color Wheel Assembly

    VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Fixed Color Wheel Assembly 21.9678.0334 Rev D Refer to Figure 3-32 Item Qty. Description 10.9678.0322 SPIN SHAFT, COLOR WHEEL 10.9678.0332 SLIDING RETAINER 10.9678.0333 RETAINER CLIP 22.9678.1336 FAB ASSY, FIXED WHEEL/CLIP (changed 9-03-03) 41.9678.0305.01 COLOR FILTER, DEEP RED VL3000 41.9678.0305.02...
  • Page 71 SSEMBLY IXED OLOR HEEL SSEMBLY Fixed Color Wheel Assembly (continued) (x6) (x6) (x6) (x6) (x3) POS 2 ORANGE POS 3 POS 1 KELLY CONGO GREEN BLUE POS 4 DARK OPEN FUSHIA POS 6 POS 5 DEEP MAGENTA Figure 3-32: Fixed Color Wheel Assembly 02.96 78.001 8 B...

  • Page 72: Strobe Assembly

    VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Strobe Assembly 22.9678.0403 Rev F (VL3500 Only) Refer to Figure 3-33 Item Qty. Description 10.9678.0491 BUMPER STOP, STROBE (changed on 6-18-03) 10.9678.0465 STROBE BULKHEAD 22.9678.0468 ASSY, LEFT STROBE BLADE 22.9678.0467 ASSY, RIGHT STROBE BLADE 44.5029.0001 MOTOR, STEPPER 42MM X 34MM -AR 53.6513.0032...
  • Page 73 SSEMBLY TROBE UIET SSEMBLY Strobe (Quiet) Assembly 22.9678.0463 Rev B (VL3500Q Only) Refer to Figure 3-33 Item Qty. Description 10.9678.0491 BUMPER STOP, STROBE 10.9678.0465 STROBE BULKHEAD 22.9678.0467 ASSEMBLY, RIGHT STROBE BLADE 22.9678.0468 ASSEMBLY, LEFT STROBE BLADE 23.9678.0499 ASSEMBLY, STROBE MOTOR, VL3000Q 53.6520.0001 SCREW, #4-40 X 3/8 PPZ 53.6609.0500...

  • Page 74: Right Strobe Blade Assembly

    VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Right Strobe Blade Assembly 22.9678.0467 Rev C Refer to Figure 3-35 Item Qty. Description 10.9678.0464 STROBE BLADE (changed 07-29-04) 10.9678.0432 HUB, STROBE BLADE 10.9678.0466 STROBE BLADE, DAMPER 53.5559.0250 SCREW, 6-32 X 1/4" SET CONE POINT 53.6597.0001 SCREW, 4-40 X 3/16"...

  • Page 75: Left Strobe Blade Assembly

    SSEMBLY TROBE LADE SSEMBLY Left Strobe Blade Assembly 22.9678.0468 Rev C Refer to Figure 3-36 Item Qty. Description 10.9678.0464 STROBE BLADE (changed 07-29-04) 10.9678.0432 HUB, STROBE BLADE 10.9678.0466 STROBE BLADE, DAMPER 53.5559.0250 SCREW, 6-32 X 1/4" SET CONE POINT 53.6597.0001 SCREW, 4-40 X 3/16"...
  • Page 76 VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Strobe Motor (Quiet) Assembly 23.9678.0499 Rev A (VL3500Q Only) Refer to Figure 3-37 Item Qty. Description 44.5035.0001 STEPPER MOTOR, 2 PHASE, PK 52.6524.0004 CONNECTOR, HOUSING, 4 POS RECEPT 52.8346.0001 CONTACT, 24-30 AWG FEMALE CRIMP 55.2200.0003 0.25 HEAT SHRINK, 3/16"...

  • Page 77: Dimmer Wheel Assembly

    SSEMBLY IMMER HEEL SSEMBLY Dimmer Wheel Assembly 22.9678.0435 Rev D Refer to Figure 3-38 Item Qty. Description 55.2256.0001 MAGNET, 2:17 SMCO 2MM X 2MM Coated Side Copper RTV Bead Dimmer Wheel Magnet Glueing Magnet to Dimmer Wheel Assembly Step 1. Make sure surface is clean and oil free Step 2.

  • Page 78: Gobo Clamp Assembly

    VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Gobo Clamp Assembly 22.9678.0693 Rev A Refer to Figure 3-39 Item Qty. Description 12.9678.0691 GOBO CLAMP 53.6685.0625 SCREW, CAPTIVE PANEL, 6-32 X 0.625"LG PPS ZINC PLATED 55.6538.0001 WASHER, #6 LOCK INTERNAL TOOTH 53.6613.1126 SCREW, 6-32 X 1.125 LG PPZ (x2)

  • Page 79: Color Clamp Assembly

    SSEMBLY OLOR LAMP SSEMBLY Color Clamp Assembly 22.9678.0694 Rev A Refer to Figure 3-40 Item Qty. Description 12.9678.0692 COLOR CLAMP 53.6685.0625 SCREW, CAPTIVE PANEL, 6-32 X.625"LG PPS ZINC PLATED 55.6538.0001 WASHER, #6 LOCK INTERNAL TOOTH 53.6613.1126 SCREW, 6-32 X 1.125 LG PPZ (x2) (x2) * Note: Install item 4 with Loctite®...

  • Page 80: Edge Lead Screw Assembly

    VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Edge Lead Screw Assembly 22.9678.1126 Rev B Refer to Figure 3-41 Item Qty. Description 10.9678.1119 LEAD SCREW, EDGE 55.6616.0007 STANDOFF, 3/8" HEX THRD 0.562" LG * Note: Apply one drop of Loctite® 272 to the threads of item 1. Figure 3-41: Edge Lead Screw Assembly 02 .9 678 .00 18 B...

  • Page 81: Yoke Assembly

    SSEMBLY SSEMBLY Yoke Assembly Yoke Assembly 21.9678.0700 Rev J (VL3500) 21.9678.0701 Rev B (VL3500Q) Refer to Figure 3-42 Item Qty. Description 10.9678.0764 PLATE, TILT ENCODER MOUNT 10.9678.0756 IGNITOR SHIELD 21.9678.0765 ASSY, TILT MOTOR 22.9661.0609 ASSY, YOKE FAN 22.9678.0609 ASSY, YOKE FAN, VL3500 QUIET 22.9686.0705 ASSY, YOKE STRUCTURE 23.9650.3327...
  • Page 82 VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Yoke Assembly (continued) (x2) (x2) (x2) (x4) (x3) (x2) (x4) (x8) (x2) (x2) (x2) (x2) Figure 3-42: Yoke Assembly 02 .9 678 .00 18 B...

  • Page 83: Tilt Motor Assembly

    SSEMBLY OTOR SSEMBLY Tilt Motor Assembly 21.9678.0765 Rev E Refer to Figure 3-43 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 84 VARI LITE® - VL3500™ S 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 6. Apply one drop of Loctite 603 to motor shaft. Step 7.

  • Page 85: Yoke Fan Assembly

    SSEMBLY SSEMBLY Yoke Fan Assembly 22.9661.0609 Rev C (VL3500) 22.9678.0609 Rev A (VL3500Q) Refer to Figure 3-44 Item Qty. Description 10.9661.0646 FAN TRAY 40.7113.0001 FAN, +24V 80 X 80 X 25MM, 32CFM 53.2200.0006 NUT, 6-32 KEPS SS 55.2179.0003 CABLE SADDLE, .75 X .75 4WAY, VL3500 QUIET (NOT SHOWN) 55.2186.0001 CABLE TIE, .10 WD X 4"...
  • Page 86 VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Notes 02 .9 678 .00 18 B...

  • Page 87: Head/Yoke Pcb Assemblies

    PCB A SSEMBLIES HUTTER ABLE NTERCONNECT SSEMBLY Head/Yoke PCB Assemblies Shutter Cable Interconnect Assembly 21.9678.1246 Rev A Refer to Figure 3-45 Item Qty. Description 10.9678.1245 MOUNT, CABLE INTERCONNECT, SHUTTER 52.6670.0034 HEADER, MOD II, 34 PIN, DUAL SIDED 52.6670.0040 HEADER, MOD II, 40 PIN, DUAL SIDED 53.6520.0002 SCREW, 4-40 X 7/16"...
  • Page 88 VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Color Sensor PCB #1 Mount Assembly 22.9678.0481 Rev B Refer to Figure 3-46 Item Qty. Description 10.9678.0482 PCB MOUNT, COLOR SENSOR #1 24.9678.3480 PCB ASSY, COLOR SENSOR #1 53.6558.0001 SCREW, 6-32 X 3/8" PPZ 55.3303.0006 WASHER, #6 LOCK INT.TOOTH SS (x2)
  • Page 89 PCB A PCB #2 M SSEMBLIES OLOR ENSOR OUNT SSEMBLY Color Sensor PCB #2 Mount Assembly 22.9678.0489 Rev B Refer to Figure 3-47 Item Qty. Description 10.9678.0452 PCB MOUNT, COLOR SENSOR #2 24.9678.3454 PCB ASSY, COLOR SENSOR #2 53.6558.0007 SCREW, 6-32 X 1/4" SEMS (x2) Figure 3-47: Color Sense PCB #2 Mount Assembly 02.96 78.001 8 B...

  • Page 90: Color Interconnect Pcb/Cable Assembly

    VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Color Interconnect PCB/Cable Assembly 25.9678.1409 Rev B (VL3500 Only) Refer to Figure 3-48 Figure 3-49 Item Qty. Description 24.9678.3409 PCB ASSY, COLOR INTERCONNECT 28.9678.0409 WIRE KIT, COLOR INTERCONNECT - 04.9678.0409.00 LABEL SET, COLOR HARNESS - 11.9678.0409 PCB, COLOR INTERCONNECT - 52.6467.0003...
  • Page 91 PCB A PCB/C SSEMBLIES OLOR NTERCONNECT ABLE SSEMBLY Color Interconnect PCB/Cable Assembly (continued) Figure 3-49: Color Interconnect PCB Assembly Wire Chart - VL3500 Only 02.96 78.001 8 B...

  • Page 92: Color Interconnect (Quiet) Pcb/Cable Assembly

    VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Color Interconnect (Quiet) PCB/Cable Assembly 25.9678.1419 Rev A (VL3500Q Only) Refer to Figure 3-50 Figure 3-51 Item Qty. Description 24.9678.0409 PCB ASSY, COLOR INTERCONNECT 28.9678.0419 WIRE KIT, COLOR INTERCONNECT - 04.9678.0409.00 LABEL SET, COLOR HARNESS - 11.9678.0409 PCB, COLOR INTERCONNECT - 52.6467.0003...
  • Page 93 PCB A ) PCB/C SSEMBLIES OLOR NTERCONNECT UIET ABLE SSEMBLY Color Interconnect PCB/Cable Assembly (continued) Figure 3-51: Color Interconnect PCB Assembly Wire Chart - VL3500Q Only 02.96 78.001 8 B...
  • Page 94 VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL VL3500 Controller PCB Assembly 24.9678.4730 Rev F Refer to Figure 3-52 Note: Available only as an assembly. Includes 24.9678.3732, Motor Driver (Piggy Back) PCB. Figure 3-52: VL3500 Controller PCB 02 .9 678 .00 18 B...
  • Page 95 PCB A ) PCB SSEMBLIES OTOR RIVER IGGY Motor Driver (Piggy Back) PCB 24.9678.1732 Rev C Refer to Figure 3-53 Note: Available only as an assembly. Included with 24.9678.4730, VL3500 Controller PCB Assembly. Figure 3-53: Motor Driver (Piggy Back) PCB 02.96 78.001 8 B...

  • Page 96: Arc Zoom Interconnect Pcb Assembly

    VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Arc Zoom Interconnect PCB Assembly 24.9678.1116 Rev 0 Refer to Figure 3-54 Ref. Item Qty. Description 04.9678.1116.00 LABEL SET ZOOM HARNESS 11.9678.1116 PCB ZOOM INTERCONNECT 52.6259.0004 HDR 4POS NT\MTA100 SD RT ANG 52.6260.0003 HEADER, 2POS MTA-100 SHROUDED 52.6447.0009...
  • Page 97 PCB A PCB A SSEMBLIES NTERCONNECT SSEMBLY Zoom Interconnect PCB Assembly (continued) Figure 3-54: Arc Zoom Interconnect PCB Assembly 02.96 78.001 8 B...
  • Page 98 VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Notes 02 .9 678 .00 18 B...

  • Page 99: Upper Enclosure Assembly

    NCLOSURE SSEMBLY PPER NCLOSURE SSEMBLY Enclosure Assembly Upper Enclosure Assembly 21.9678.0800.02 Rev NN (VL3500 Only) 21.9678.0801.02 Rev Z (VL3500Q Only) Refer to Figure 3-55 Figure 3-56 Item Qty. Description 04.9640.0374 LABEL, P.E. GROUND 04.9661.1218.01 LABEL, PATENT, VL2201 & VL2400 SERIES LUM. 04.9678.0040.01 LABEL, VL3000 COMPLIANCE 04.9678.0045...
  • Page 100 VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Item Qty. Description 21.9678.0864 ASSY, PAN MOTOR 21.9678.0881 ASSY, PAN TUBE 22.9678.0851 ASSY, UPPER ENCLOSURE 23.9678.0686 FAN ASSY, UPPER ENCLOSURE 23.9678.0687 ELEC ASSY, PAN EOT SENSOR 25.9661.1514 CABLE ASSY, LVS CHASSIS GND (not shown) 25.9661.1520 CABLE ASSY, CHASSIS TO YOKE GND (not shown) 25.9678.0811...
  • Page 101 NCLOSURE SSEMBLY PPER NCLOSURE SSEMBLY Item Qty. Description 53.6626.0001 SCREW, 10-32 X 1/2" PPZ 53.6634.1000 SCREW, 3/8-16 X 1.00" LG SOC SCREW, 1/4-20 X 1/2"LG SOC (VL3500 Only) 53.6653.0502 54.1206.0014 RING, RETAINING 54.1255.0001 BEARING ASSY, BLACK FLUSH MOU 54.2055.0001 BELT, TIMING S2M 210GROOVE 9MM 55.2150.0003 STANDOFF, 1/4"HEX 6-32 1.125"L 55.2178.0001...
  • Page 102 VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Upper Enclosure Assembly (continued) (x2) (x2) (x4) (x2) (x4) (x2) (x4) (x4) (x4) Figure 3-55: Upper Enclosure Assembly Part 1 02 .9 678 .00 18 B...
  • Page 103 NCLOSURE SSEMBLY PPER NCLOSURE SSEMBLY Upper Enclosure Assembly (continued) (x3) 55, 69 (x3) 73, 4 (x4) (x4) (x4) (x2) (x2) 10, 55 (x2) (x2) (x2) (x2) 45, 58 Part is shown exploded for clarity Electronics (x2) (x4) Assembly (x3) (x4) (x2) (x2) (x2)

  • Page 104: Ventilation Cover Assembly - Standard

    VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Ventilation Cover Assembly - Standard 21.9678.1254 Rev 0 Refer to Figure 3-57 Item Qty. Description 10.9661.1249 POST, TRUSS HOOK 10.9678.8350 COVER, VENTILATION 10.9678.0893 12" AIR SEAL, UPPER ENCLOSURE 10.9678.0894 6" AIR SEAL, UPPER ENCLOSURE 10.9678.0896 4.5"...
  • Page 105 - VL3500 Q NCLOSURE SSEMBLY ENTILATION OVER SSEMBLY UIET Ventilation Cover Assembly - VL3500 Quiet 21.9686.0840.02 Rev B (VL3500Q) Refer to Figure 3-58 Item Qty. Description 10.9686.1249 POST, TRUSS HOOK 10.9678.0850 POST, TRUSS HOOK, SHORT, EARLY PRODUCTION 10.9678.0833 SPACER, 1.25 ", EARLY PRODUCTION 10.9686.0883 COVER, VENTILATION 10.9678.0837...
  • Page 106 VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Ventilation Cover Assembly - VL3500 Quiet (continued) (x4) (x4) (x4) (x4) Current Production (x2) Early Production (x4) (x4) Figure 3-58: Ventilation Cover Assembly - VL3500 Quiet 02 .9 678 .00 18 B...

  • Page 107: Panel Assembly

    NCLOSURE SSEMBLY ANEL SSEMBLY Panel Assembly 21.9678.0805 Rev N Refer to Figure 3-59 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 PCB ASSY, VL3000 DISPLAY 51-0541...
  • Page 108 VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL DMX Input PCB 24.9663.3895 Rev 0 Refer to Figure 3-60 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 109: Ac Input Pigtail Cable Assembly

    : AC I NCLOSURE SSEMBLY NPUT IGTAIL ABLE SSEMBLY AC Input Pigtail Cable Assembly 25.9678.0810 Rev C Refer to Figure 3-61 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 110: Pan Pulley Assembly

    VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Pan Pulley Assembly 21.9678.0807 Rev E Refer to Figure 3-62 Item Qty. Description 10.9678.0750 TIMING PULLEY, 2MM GT 150 TOOTH 10.9678.0855 PAN FLAG 53.6530.0009 RIVET, 1/8"OD POP 0.126-0.187GL (changed 10-05-06) (x2) Figure 3-62: Pan Pulley Assembly 02 .9 678 .00 18 B...

  • Page 111: Pan Motor Assembly

    NCLOSURE SSEMBLY OTOR SSEMBLY Pan Motor Assembly 21.9678.0864 Rev E Refer to Figure 3-63 Item Qty. Description 10.9678.0865 PLATE, PAN MOTOR MOUNT 21.9678.0828 ASSY, DRIVE PULLEY, PAN - 10.9686.8720 CODEWHEEL, 120 COUNT LARGE ID - 10.9678.0749 TIMING PULLEY, 2MM GT 17 TOOTH - 53.5560.0250 SCREW, 8-32 X 1/4"...
  • Page 112 VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Pan Motor Assembly (continued) Detail A Pressure-Sensitive Adhesive See Detail A (x2) (x2) (x2) (x4) Drive Pulley Detail & Installation (x4) 0.875" Step 1. Apply one drop of Loctite 603 to motor shaft. Step 2.

  • Page 113: Pan Tube Assembly

    NCLOSURE SSEMBLY SSEMBLY Pan Tube Assembly 21.9678.0881 Rev 0 Refer to Figure 3-64 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 3-64: Pan Tube Assembly...
  • Page 114 VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Notes 02 .9 678 .00 18 B...

  • Page 115: Cable Assemblies

    EOT S ABLE SSEMBLIES ENSOR LECTRICAL SSEMBLY Cable Assemblies Cables are only available as complete assemblies. The information contained in this Note: section is for reference only. Pan EOT Sensor Electrical Assembly 23.9678.0687 Rev A Refer to Figure 3-65 Item Qty.

  • Page 116: Lvs Chassis Ground Cable Assembly

    VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL LVS Chassis Ground Cable Assembly 25.9661.1514 Rev A Refer to Figure 3-66 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 3-66: LVS Chassis Ground Cable Assembly 02 .9 678 .00 18 B...

  • Page 117: 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 3-67 Item Qty. Description 52.8250.0006 TERM, #8, RING, 10AWG 73.7089.0504 15.17 WIRE, 22 AWG 300V 200C TEF GRN/YEL UL1180 (7 x 26.0" LG) (x2) Figure 3-67: Chassis To Yoke Ground Cable Assembly 02.96 78.001 8 B...

  • Page 118: Head To Back Cap Ground Cable Assembly

    VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Head to Back Cap Ground Cable Assembly 25.9661.1522 Rev C Refer to Figure 3-68. Item Qty. Description 52.8250.0014 TERM, RING #10 16-14 AWG NON-INS. REEL 73.7130.0001 1.33 WIRE, 7/64" TUBULAR BRAID TINNED COPPER (x2) Figure 3-68: Head to Back Cap Ground Cable Assembly 02 .9 678 .00 18 B...

  • Page 119: 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 3-69. Item Qty. Description 52.8231.0005 TERM, RING #6 BLUE 16-14 AWG REEL PIDG (changed 03-23-06) 52.8312.0001 RECP, FASTON 1/4" 18-14 AWG INSULATED VO 73.7101.0009 0.42 WIRE, 14 AWG 15KV 150C SILICONE 41/30 STRANDING...

  • Page 120: Lvs To Yoke Ac Fan Cable Assembly

    VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL LVS to Yoke AC Fan Cable Assembly 25.9678.0843 Rev A Refer to Figure 3-70 Item Qty. Description 52.6664.0001 CONTACT, 22-26AWG FEMALE MATE-N-LOK 2 52.6664.0002 CONN, HOUSING 2 POS CAP MATE-N-LOK 2 52.8231.0008 TERM, SPADE #6 RED 22-16AWG INSERT 55.2186.0001 CABLE TIE, 0.10"...

  • Page 121: Yoke To Ac Fan Cable Assembly

    AC F ABLE SSEMBLIES OKE TO ABLE SSEMBLY Yoke to AC Fan Cable Assembly 25.9678.0012 Rev A Refer to Figure 3-71 Item Qty. Description 52.6665.0001 CONTACT, 22-26AWG MALE MATE-N-LOK 2 52.6665.0002 CONN, HOUSING 2 POS PLUG MATE-N-LOK 2 52.8413.0001 RECEPT, FASTON .110 SERIES 22-18AWG INSULATED 55.2186.0002 CABLE TIE, .09"WD 3.750"LG TEFZEL 55.2260.0208...
  • Page 122 VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Backcap Interlock to Gobo Fan Interlock Cable Assembly 25.9678.0014 Rev B Refer to Figure 3-72 Item Qty. Description 52.8414.0001 RECEPT, FASTON .187 SERIES 24-20 AWG UNINSUL 73.7089.0000 2.00 WIRE. 22AWG 300V 200C TEF BLK UL1180 Figure 3-72: Backcap Interlok to Gobo Fan Interlok Cable Assembly 02 .9 678 .00 18 B...

  • Page 123: Relay To Gobo Fan Interlock Cable Assembly

    ABLE SSEMBLIES ELAY TO NTERLOCK ABLE SSEMBLY Relay to Gobo Fan Interlock Cable Assembly 25.9678.0675 Rev B Refer to Figure 3-73. Item Qty. Description 52.8230.0003 RECEPT, 1/4" FASTON 22-18AWG (TAPE MOUNT) 52.8414.0001 RECEPT, FASTON 0.187 SERIES 24-20 AWG UNINSUL 73.7089.0000 2.00 WIRE.

  • Page 124: Front Head Fans Cable Assembly

    VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Front Head Fans Cable Assembly 25.9678.0677 Rev B Refer to Figure 3-74 Item Qty. Description 52.6396.3104 RECEPT, 4POS MTA100 W/POL TAB BLU CLSD END (changed 05-03-06) 52.6524.0002 CONN, HOUSING 2POS RECEPTACLE 52.8346.0001 CONTACT, 24-30AWG FEMALE CRIMP 73.5126.0002 2.67...
  • Page 125 ABLE SSEMBLIES AN AND ELAY TANDARD ABLE SSEMBLY Yoke Fan and Relay (Standard) Cable Assembly 25.9678.0681 Rev C (VL3500 Only) Refer to Figure 3-75 Item Qty. Description 52.6396.3103 RECEPT, 3 POS MTA100 W/ POL TAB BLU CLSD END (changed 05-01-06) 52.6423.0003 HOUSING, 3 POS MT RECEPT, 2MM 52.8230.0003...

  • Page 126: Air Duct Ot Switch Cable Assembly

    VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Air Duct OT Switch Cable Assembly 25.9678.0690 Rev 0 (VL3500Q) 25.9678.0691 Rev 0 Refer to Figure 3-76 Item Qty. Description 52.8237.0002 TERM, RING #4 24-20AWG 52.8414.0001 RECEPT, FASTON .187 SERIES, 24-20AWG UNISUL 55.2198.0002 .083 HEATSHRINK, 1/8"...
  • Page 127 ABLE SSEMBLIES AN AND ELAY UIET ABLE SSEMBLY Yoke Fan and Relay (Quiet) Cable Assembly 25.9678.0781 Rev A (VL3500Q Only) Refer to Figure 3-75 Item Qty. Description 52.6423.0003 HOUSING, 3 POS MT RECEPT, 2MM 52.8230.0003 RECEPT, 1/4" FASTON 22-18AWG 52.6396.3103 RECEPT, 3 POS MTA100 W/ POL TAB BLU CLSD END 55.2186.0001 CABLE TIE, .10 X 4"...
  • Page 128 VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Yoke Fan (Standard) Cable Assembly 25.9678.0758 Rev A (VL3500 Only) Refer to Figure 3-78 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 0.50 WIRE, 26AWG 2COND 300V 80C ...
  • Page 129 ABLE SSEMBLIES UIET ABLE SSEMBLY Yoke Fan (Quiet) Cable Assembly 25.9678.0759 Rev A (VL3500Q Only) Refer to Figure 3-78 Item Qty. Description 52.6396.3102 RECEPT, 2 POS MTA100 W/POL TAB BLUE CLSD END 52.6423.0003 HOUSING, 3 POS MT RECEPT, 2MM CT 28-26 AWG 55.2186.0001 CABLE TIE, .10 X 4"...

  • Page 130: Ignitor To Lamp Socket Cable Assembly

    VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Ignitor to Lamp Socket Cable Assembly 25.9678.0789 Rev B Refer to Figure 3-80. 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 131: Head Controller Cable Assembly

    ABLE SSEMBLIES ONTROLLER ABLE SSEMBLY Head Controller Cable Assembly 25.9678.1715 Rev A Refer to Figure 3-81 Item Qty. Description 52.6610.0014 CONN HOUSING, 14 POS DBL ROW UNLOADED 52.6610.0024 CONN HOUSING, 24 POS DBL ROW UNLOADED 52.6610.0034 CONN HOUSING, 34 POS DBL ROW UNLOADED 52.6610.0040 CONN HOUSING, 40 POS DBL ROW UNLOADED 52.6610.0017...
  • Page 132 VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Head Controller Cable Assembly (continued) 4,9,14 1,6,11 1,6,11 5,10,15 (x11) 3,8,13 2,7,12 4,9,14 Figure 3-81: Head Controller Cable Assembly 02 .9 678 .00 18 B...
  • Page 133 ABLE SSEMBLIES HUTTER ABLE SSEMBLY Shutter Disk Cable Assembly 25.9678.1717 Rev A Refer to Figure 3-81 Item Qty. Description 04.9678.1717.00 LABEL SET, SHUTTER DISK HARNESS 52.6610.0040 CONN, HOUSING, 40-POS DBL ROW UNLOADED 52.6224.1040 COVER, FRONT 40-POS MT LATCH 52.6224.2040 COVER, BACK 40-POS MT 52.6696.0001 RECEPTACLE, WIRE TO WIRE, 4-POS 2 MM PITCH 28-24 AWG 52.6694.0001...
  • Page 134 VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Shutter Disk Cable Assembly (continued) (X8), (X8) 9, 10, 11, 12 2, 3, 4, 7 Figure 3-82: Shutter Disk Cable Assembly 02 .9 678 .00 18 B...

  • Page 135: 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 3-83 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 136: Ac Input Splitter Cable Assembly

    VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL AC Input Splitter Cable Assembly 25.9678.0812 Rev E Refer to Figure 3-84 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 RECP, FASTON .187"...
  • Page 137 : AC I ABLE SSEMBLIES NPUT PLITTER ABLE SSEMBLY AC Input Splitter Cable Assembly (continued) (x2) (x2) 5, 9 5, 10 11, 6 Note: Heatshrink not shown for clarity. (x3) Figure 3-84: AC Input Splitter Cable Assembly 02.96 78.001 8 B...

  • Page 138: Data I/O Link Cable Assembly

    VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Data I/O Link Cable Assembly 25.9678.0813 Rev A Refer to Figure 3-85 Item Qty. Description 52.6396.2904 RECEPT, 4 POS MTA100 W/POL TAB RED CLSD END (changed 05-03-06) 52.6396.2905 RECEPT, 5 POS MTA100 W/POL TAB RED CLSD END (changed 05-03-06) 73.5122.0259 2.17 CBL, 22AWG STRND 4COND PVC INSUL...

  • Page 139: Display Cable Assembly

    ABLE SSEMBLIES ISPLAY ABLE SSEMBLY Display Cable Assembly 25.9678.1825 Rev C Refer to Figure 3-86 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" WD 4" LG SMALL 73.7130.0004 0.958 WIRE, TUBULAR BRAID, 1/8"...

  • Page 140: Ballast To Controller Cable Assembly

    VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Ballast to Controller Cable Assembly 25.9678.0816 Rev A Refer to Figure 3-87 Item Qty. Description 52.6396.3002 RECEPT, 2 POS MTA100 W/POL TAB WHT CLSD END (changed 05-03-06) 52.6396.3005 RECEPT, 5 POS MTA100 W/POL TAB WHT CLSD END (changed 05-03-06) 52.6396.3008 RECEPT, 8 POS MTA100 W/POL TAB WHT CLSD END (changed 05-03-06) 73.5124.1289...

  • Page 141: Dc Output Cable Assembly

    : DC O ABLE SSEMBLIES UTPUT ABLE SSEMBLY DC Output Cable Assembly 25.9678.0821 Rev E Refer to Figure 3-88 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 CONTACT, CRIMP, 18-22 AWG SL-156 (not shown) 52.8323.0002 52.8274.1614...

  • Page 142: Pan/Tilt Control Cable Assembly

    VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Pan/Tilt Control Cable Assembly 25.9678.0818 Rev B Refer to Figure 3-89 Item Qty. Description 52.6610.0008 CONN, HOUSING, 20 POS DBL ROW UNLOADED (changed 05-03-06) 52.6224.1020 COVER, FRONT 20 POS MT LATCHING 52.6224.2020 COVER, BACK 20 POS MT 52.6524.0005 CONN, HOUSING 5 POS RECEPTACLE...

  • Page 143: 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 3-90 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, 22 AWG BLK 300V TEFLON STRANDED...

  • Page 144: Gobo/Rotate Interconnect Cable Assembly

    VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL Gobo/Rotate Interconnect Cable Assembly 25.9678.1209 Rev A Refer to Figure 3-91 Figure 3-92 Item Qty. Description 25.9678.1209 CABLE ASSY, GOBO/ROTATE INTERCONNECT Figure 3-91: Gobo/Rotate Interconnect Cable Assembly 02 .9 678 .00 18 B...
  • Page 145 ABLE SSEMBLIES OTATE NTERCONNECT ABLE SSEMBLY Gobo/Rotate Interconnect Cable Assembly (continued) Figure 3-92: Gobo/Rotate Interconnect Cable Assembly Wire Chart 02.96 78.001 8 B...
  • Page 146 VARI LITE® - VL3500™ S UMINAIRE ERVICE ANUAL LVS Chassis Ground Cable Assembly 25.9678.1716 Rev A Refer to Figure 3-93 Item Qty. Description 52.8231.0005 TERMINAL, RING, #6 BLUE, 16-14 AWG REEL PIDG 52.8231.0008 TERMINAL, SPADE, #6 RED, 22-16 AWG INSERT 73.3516.0504 1.08 WIRE, 16 AWG 300V 105 DEG C PVC ...
  • Page 147 VARIFLITE® - VL3500™ S UMINAIRE ERVICE ANUAL Notes 02 .9 678 .00 18 B...
  • Page 149 Vari-Lite 10911 Petal Street Dallas, Texas 75238 USA 1.877.VARI-LITE F Fax 1.214.647.8038 www.vari-lite.com Date: 10-June-2009 / Manual Part Number: 02.9678.0018 B ©2003-2009 A Philips Group Company. All rights reserved. Printed in the U.S.A.

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