Philips VL3000 Service Manual
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Philips VL3000 Service Manual

Spot & wash; q spot & wash luminaires
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  • Page 2 Genlyte Thomas Group LLC and is registered in the United States and other countries. ™ ™ VL1000™, VL2000™, VL2201™, VL2202™, VL2400™ (and the individual product designations), VL3000™, VL3500™, Series 1000 , Series 2000 ™ ™...
  • Page 3 OREWORD How To Obtain Warranty Service A copy of the Vari-Lite Limited Warranty was included in the shipping package for this VARI❋LITE® product. To obtain warranty service, please contact customer service at 1-877-VARI-LITE (1-877- 827-4548) or customerservice@genlytecontrols.com and request a Return Material Authori- zation (RMA) for warranty service.
  • Page 4 ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Compliance Notice This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of FCC Rules. These limits are designed to provide reasonable protection against harmful interference when this equipment is operated in a commercial environment.

  • Page 5: Safety Notice

    OREWORD Safety Notice It is extremely important to read ALL safety information and instructions provided in this manual and any accompanying documentation before installing and operating the products described herein. Heed all cautions and warnings during installation and use of this product. Safety symbols used throughout this manual are as follows: CAUTION advising of potential damage to product.
  • Page 6 ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL WARNING: INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST EXCESSIVE EXPOSURE TO UV RADIATION 1. Many VARI❋LITE® luminaires use a lamp that produces UV radiation. DO NOT look directly at lamp. 2. It is hazardous to operate luminaires without lens or shield. Shields, lenses, or ultraviolet screens shall be changed if they have become visibly damaged to such an extent that their effectiveness is impaired.
  • Page 7 OREWORD Sicherheitshinweise Es ist äußerst wichtig, ALLE Sicherheitsinformationen und -hinweise in diesem Handbuch und dem beiliegenden Informationsmaterial zu lesen, bevor Sie die hierin beschriebenen Produkte installieren bzw. bedienen. Halten Sie bei der Installation und dem Einsatz dieses Produkts alle Warnhinweise und Vorsichtsmaßnahmen ein.
  • Page 8 ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL WARNUNG: HINWEISE ZUM SCHUTZ GEGEN ÜBERHÖHTE UV-STRAHLUNG 1. Viele VARI❋LITE®-Scheinwerfer verwenden die Lampentyp, der UV-Strahlen abgibt. SCHAUEN SIE NICHT direkt in die Lampe. 2. Es ist gefährlich, Leuchten ohne Linsen oder Blenden zu bedienen. Blenden, Linsen oder Ultraviolettschirme müssen ausgetauscht werden, sofern deren Schutzwirkung durch sichtbare...
  • Page 9 OREWORD Notes de sécurité Avant de procéder à l’installation des produits décrits dans ce guide et de les mettre en marche, il est extrêmement important de lire TOUS les renseignements et TOUTES les directives de sécurité contenues dans ce guide ainsi que toute documentation jointe. Tenir compte de tous les avertissements et suivre toutes les précautions pendant l’installation et l’utilisation de cet appareil.
  • Page 10 ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL AVERTISSEMENT: DIRECTIVES POUR SE PROTÉGER CONTRE UNE EXPOSITION EXCESSIVE AUX RAYONS UV 1. Plusieurs luminaires VARI❋LITE® utilisent une lampe qui produit des rayons UV. NE PAS fixer son regard sur la lampe.
  • Page 11 OREWORD Aviso sobre Seguridad Es muy importante leer TODA la información e instrucciones sobre seguridad que se indica en este manual así como en los documentos adjuntos antes de instalar y operar los productos descritos. Se debe prestar atención a todos los avisos y advertencias durante la instalación y uso de este producto. Los símbolos de seguridad usados en este manual son los siguientes: CUIDADO, indica posibles daños al producto.
  • Page 12 ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL ADVERTENCIA: INSTRUCCIONES PARA PROTECCIÓN CONTINUA CONTRA LA EXPOSICIÓN EXCESIVA DE RADIACIÓN ULTRA VIOLETA 1. Muchas luminarias VARI❋LITE® usan un tipo de lámpara que produce radiación UV. NO mire directamente a la lámpara.
  • Page 13 OREWORD 02.96 78.001 0 G...
  • Page 14 ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL 02 .9 678.00 10 G...

  • Page 15: Table Of Contents

    Technical Specifications ......................4 Components External Luminaire Components ....................5 VL3000 Spot Luminaire Head and Yoke Components............. 6 VL3000 Wash Luminaire Head and Yoke Components ............7 Enclosure Components ......................8 Principles of Operation VL3000 and VL3000Q Spot Luminaire ................... 9 Functional Block Diagram ....................
  • Page 16 VL3000Q Wash Luminaire ..................... 67 Top Assembly Included Items Kit, Spot ......................70 Included Items Kit, Wash......................72 VL3000 and VL3000Q Spot Luminaire ................. 73 VL3000 and VL3000Q Wash Luminaire................76 Generic Luminaire Assemblies....................79 Head Assembly Head Structure Assembly......................81 Head Cover Assembly ......................
  • Page 17 ABLE OF ONTENTS Gobo/Color Fan Assembly - VL3000Q Only ................. 96 Dual Fan Tray/Duct Assembly - VL3000 Only..............98 Head Front Fan Assembly..................... 100 Head Front Fan Assembly - VL3000Q Only ................ 101 Transfer Fan Assembly ......................102 Spot Optic Assembly ......................103 Group 4 Lens Mount Assembly ....................
  • Page 18 DC Output Cable Assembly....................193 Pan/Tilt Control Cable Assembly ..................194 Lamp Supply to Relay Cable Assembly ................195 LVS to Yoke AC Fan Cable Assembly ................. 196 Appendix A. Technical Bulletins VL3000 & VL3000Q Technical Bulletins ................197 02 .9 678.00 10 G...

  • Page 19: Introduction

    About This Manual This manual provides descriptions, repair procedures, and illustrated parts breakdowns for all configurations of the VL3000™. The manual is intended for use by Vari-Lite personnel and by Vari- Lite’s customers/clients. WARNING: It is important to read ALL accompanying safety and installation instructions to avoid damage to the product and potential injury to yourself or others.

  • Page 20: Customer Service

    Bulletins are categorized by assembly or subassembly, and identified by a number such as S3K-001 (VL3000 Series Luminaires Technical Bulletin number 1). A list of technical bulletins for these products is found in “VL3000 &...

  • Page 21: Chapter 1. Description

    HAPTER Description This chapter contains descriptions of luminaire features and components. • Features • Components • Principles of Operation 02.96 78.001 0 G...

  • Page 22: Features

    Two, six-position gobo wheels with five rotatable, indexable gobo positions and one open position. • Five-position gobo wheel with four rotatable, indexable positions and one open position. • VL3000Q only: 50% audible reduction in noise output from the VL3000 luminaires. VL3000 and VL3000Q Wash Luminaires • Zoomable beam spreader mechanism. •...

  • Page 23: Components

    OMPONENTS XTERNAL UMINAIRE OMPONENTS Components External Luminaire Components The following illustration shows the external luminaire components and controls. Upper Enclosure Assembly Houses power supply, ballast, and display board. AC Input Cable Truss Hook Bracket Attaches to enclosure base to allow truss hook installation. Input Panel Provides DMX In and Thru, and AC Power connections.

  • Page 24: Vl3000 Spot Luminaire Head And Yoke Components

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL VL3000 Spot Luminaire Head and Yoke Components The following illustration shows the major sub-assemblies that are located in the luminaire head and yoke assemblies. Head Covers (attached by tether) Gobo Assembly...

  • Page 25: Vl3000 Wash Luminaire Head And Yoke Components

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

  • Page 26: Enclosure Components

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Enclosure Components The following illustration shows the major sub-assemblies that are located in the luminaire enclosure assembly. (Yoke and head assemblies not shown for clarity.) Enclosure Top Covers 1200W Arc Ballast Module 150W +24V/6.3A...

  • Page 27: Principles Of Operation

    : VL3000 VL3000Q S RINCIPLES OF PERATION UMINAIRE Principles of Operation VL3000 and VL3000Q Spot Luminaire Functional Block Diagram 02.96 78.001 0 G...

  • Page 28: Vl3000 And Vl3000Q Wash Luminaire

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL VL3000 and VL3000Q Wash Luminaire Functional Block Diagram 02.96 78.001 0 G...

  • Page 29: Chapter 2. Maintenance

    HAPTER Maintenance This chapter contains test, service, and standard maintenance procedures. • Testing • Troubleshooting • Maintenance Procedures 02.96 78.001 0 G...

  • Page 30: Testing

    Testing Luminaire Self-Tests The luminaire is capable of running self tests by using the TEST menu functions. For detailed instructions regarding the luminaire’s self-test function, refer to the VL3000 User’s Manual for your luminaire (02.9678.0001 or 02.9678.0005). Calibration Sequence The following is an outline of the luminaire’s standard calibration sequence: Phase 1 •...

  • Page 31: Auto Recalibration

    Most mechanisms within the VL3000 luminaire are equipped with either optical or magnetic sensors. The VL3000 master control board (MCB) has labeled test points for reading DC voltages at each sensor. Testing is best performed with a digital voltmeter for sensor readings or an oscilloscope for pan/tilt encoder readings.
  • Page 32 ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Notes regarding specific mechanisms: • The four color mixers and dimmer will read high when the tab is in the optical sensor. • The fixed color wheel will read low when the magnet is at the sensor and high at other times.

  • Page 33: Troubleshooting Error Messages

    ROUBLESHOOTING RROR ESSAGES Troubleshooting Error Messages If a problem occurs during luminaire calibration, at the end of the calibration sequence the Menu Display will cycle through any applicable error message(s), one a time until the end of the list is reached.

  • Page 34: Troubleshooting Guide

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Troubleshooting Guide If a problem is suspected, try recalibrating the luminaire to prompt an error message. Refer to “Error Messages” on page 56 for more information. The chart below provides possible causes and remedies for each message.
  • Page 35 ROUBLESHOOTING ROUBLESHOOTING UIDE Table 2-2: Troubleshooting Guide (Continued) Message Description Symptom Possible Cause and Remedy Pan No Pan Sensor Not Found Luminaire will not pan EOT flag attached to large pulley is not engaging the Sens EOT sensor... - ensure flag is attached to the large pulley. - ensure that flag passes through the sensor at a depth sufficient to engage the sensor beam.

  • Page 36: Maintenance Procedures

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Maintenance Procedures Lamp Replacement VL Part No: 71.2557.1200 WARNING: Ensure that power is removed from luminaire when installing lamp. CAUTION: Wear cotton gloves or other covering while installing lamp. Touching lamp glass or lamp holder contacts with bare fingers will leave oil and may cause the lamp to explode or reduce lamp life.

  • Page 37: Align Lamp

    Align Lamp The design of the VL3000 luminaire optical system allows for a flat or peaked field. A flat field is one where there is no detectable hot spot and a peaked field is one where the intensity of the beam is greater at the center of the beam than at the perimeter.

  • Page 38: Lamp Power Cut-Off Switch

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Lamp Power Cut-Off Switch The lower fan duct assembly is equipped with a lamp power cut-off switch. If the hinged duct is raised during operation, the relay automatically disengages and the lamp will douse. When the duct is closed, lamp power is restored.

  • Page 39: Gobo Replacement

    AINTENANCE ROCEDURES EPLACEMENT Gobo Replacement WARNING: Remove power from luminaire before performing maintenance. Gobos can be HOT after operation. Allow to cool before replacing. WARNING: Users of VARI❋LITE luminaires should not install or use metal gobos. The use of metal gobos in any VARI❋LITE product may damage the luminaire and could void the luminaire’s warranty.
  • Page 40 ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Gobo Replacement (continued) Top Head Cover * 1/4-Turn Screw Gobo Wheel (see detail) Bottom Head Cover * * Head covers are attached by tethers. Do not touch glass with bare fingers.

  • Page 41: Color Filter Replacement

    AINTENANCE ROCEDURES OLOR ILTER EPLACEMENT Color Filter Replacement WARNING: Remove power from luminaire before performing maintenance. Filters may be HOT after operation. Allow to cool before replacing. Repair/Replacement Procedure Step 1. Remove power from luminaire. Step 2. Remove top head cover by loosening four 1/4-turn screws as shown in Figure 2-5.

  • Page 42: Beam Spreader (Wash Only)

    Step 8. Lift Beam Spreader assembly up through fixture. Step 9. Replace by performing steps 2 through 8 in reverse order. Transfer Fan Assembly Top Head Cover Beam Spreader Figure 2-6: VL3000 Wash Beam Spreader Assembly Replacement 02.96 78.001 0 G...

  • Page 43: Color/Dimmer/Strobe Assembly

    Step 6. Pull assembly straight up and out of luminaire. Step 7. Replace assembly by performing steps 2 through 6 in reverse order. Top Head Cover Color/Dimmer/Strobe Assembly Clamp Figure 2-7: VL3000 Color/Dimmer/Strobe Assembly Replacement 02.96 78.001 0 G...

  • Page 44: Strobe Assembly Replacement

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Strobe Assembly Replacement VL Part No: 22.9678.0403 VL Part No: 22.9678.0453 (Q Version) Repair/Replacement Procedure Step 1. Disconnect luminaire AC input cable from power source. Step 2. Remove top head cover by loosening four 1/4 turn captive stud connectors.

  • Page 45: Main Control Board (Mcb) Pcb Replacement

    Step 5. Disconnect upper enclosure connectors J1, J2, J3, J4 and J12 at back of MCB. Step 6. Install replacement assembly by performing Steps 2-5 in reverse order. Step 7. Configure using menu functions as necessary. Yoke Leg Cover Main Controller Board Figure 2-9: VL3000 Main Control Board Replacement 02.96 78.001 0 G...

  • Page 46: Motor Driver Ic Replacement For Socketed Mcbs

    Step 4. Using C.K. PLCC extractor tool (see above), replace required stepper motor driver (loca- tions: U27-U30, U32-U44). Step 5. Reinstall Main Control Board PCB performing Steps 2-6 in reverse order from page Stepper Motor Drivers (locations: U27-U30, U32-U44) Figure 2-10: VL3000 Series Motor Drivers on Main Control Board 02.96 78.001 0 G...

  • Page 47: Ignitor Board Replacement

    Step 5. Replace by performing steps 2 through 4 in reverse. Note: Make sure and orient ignitor properly (as shown in Figure 2-11). "From Relay" Connections Ignitor Board "To Bulb (Lamp)" Connections NOTE: Some components not shown for clarity. Figure 2-11: VL3000 Ignitor Board Replacement 02.96 78.001 0 G...

  • Page 48: Pan Motor Assembly/Pan Belt Replacement

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Pan Motor Assembly/Pan Belt Replacement VL Part No: 21.9678.0864 (Pan Motor) VL Part No: 54.2055.0001 (Pan Belt) Repair/Replacement Procedure (Pan Motor) Step 1. Using console or internal menus, run lens as far to the rear as possible.
  • Page 49 Pan Motor Assembly, you must tighten in a CLOCKWISE pattern starting with screw in lower left-hand side from spring. NOTE: Head not shown for clarity. Bottom Cover Enclosure Bottom View Pan Belt Pan Motor Assembly Figure 2-12: VL3000 Pan Motor Assembly Replacement 02.96 78.001 0 G...

  • Page 50: Pan Encoder Pcb Replacement

    Step 7. Replace by performing steps 3 through 6 in reverse order. Note: Make sure the encoder disk passes through the optical sensor. NOTE: Head not shown for clarity. Enclosure Bottom View Encoder Disk Encoder Pan Motor Bottom Cover Assembly Figure 2-13: VL3000 Pan Encoder PCB Replacement 02.96 78.001 0 G...

  • Page 51: Pan Eot Sensor Replacement

    Step 6. Disconnect wiring from encoder PCB and remove sensor. Step 7. Replace sensor by performing steps 3 through 6 in reverse order. NOTE: Head not shown for clarity. Enclosure Bottom View Sensor Bottom Cover Pan Motor Assembly Figure 2-14: VL3000 Pan EOT Sensor Replacement 02.96 78.001 0 G...

  • Page 52: Low Voltage Power Supply (Lvs) Replacement

    Step 5. Loosen two 6-32x3/8" LG PPZ screws and slide LVS towards upper enclosure fan to remove. Step 6. Replace by performing steps 2 through 5 in reverse order. Top Cover Power Supply (LVS) Bottom Cover NOTE: Head not shown for clarity. Figure 2-15: VL3000 Power Supply (LVS) Replacement 02.96 78.001 0 G...

  • Page 53: Gobo Assembly Replacement

    Step 8. Pull Gobo Assembly straight out of fixture. Step 9. Replace by performing steps 3 through 8 in reverse order. Top Head Cover Gobo Assembly Optic Assembly Clamp (Must be all the way forward.) Figure 2-16: VL3000 Spot Gobo Assembly Replacement 02.96 78.001 0 G...

  • Page 54: Gobo Timing Adjustments

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Gobo Timing Adjustments The index timing belt must be aligned so that the mechanism "clocks" properly. This belt is installed around the index gear and top gear of the gobo wheel. The wheel position belt is installed around the wheel position gear and bottom gear of the gobo wheel, and does not require alignment.
  • Page 55 AINTENANCE ROCEDURES IMING DJUSTMENTS Gobo Timing Adjustments (continued) Position index pulley so large flange is Insert a 3" long #4 or M3 screw (or 0.125" diameter centered in optical sensor pin) completely through aligned holes in wheels and both bulkheads as shown. This will lock the wheels in the "open"...

  • Page 56: Gobo Gear Planet Alignment

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Gobo Gear Planet Alignment Each gear of the gobo wheel assembly must be aligned so that the gobos will index correctly. Use the following procedure to re-align the gears in the event the gobo wheel is disassembled.
  • Page 57 AINTENANCE ROCEDURES LANET LIGNMENT Gobo Gear Planet Alignment (continued) 1) Start with center gear timing 2) Rotate center gear clockwise until timing mark mark facing Position 1 (open). is directly across from Position 6. Rotate Position 6 gear until timing marks align. Alignment Mark open Align both marks...

  • Page 58: Spot Optic Assembly Replacement

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Spot Optic Assembly Replacement VL Part No: 22.9678.0103 Repair/Replacement Procedure To remove spot optics assembly: Step 1. Disconnect luminaire AC input cable from power source. Step 2. Remove both top and bottom head covers by loosening four quarter-turn captive locking screws.
  • Page 59 Motor (see detail) Edge Screw Clamp (Secure this side first when reinstalling.) Optic Assembly Side View Motor Edge Screw Thread all the way into motor as shown before re-installing. Figure 2-22: VL3000 Spot Optic Assembly Replacement 02.96 78.001 0 G...

  • Page 60: Tilt Motor Assembly And Tilt Belt Replacement

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Tilt Motor Assembly and Tilt Belt Replacement VL Part No: 21.9678.0765 (Tilt Motor) VL Part No: 54.2055.0001 (Tilt Belt) Repair/Replacement Procedure To remove and replace tilt motor: Step 1. Disconnect luminaire AC input cable from power source.
  • Page 61 PPZ screws that mount Pan Motor Assembly, you must tighten in a CLOCKWISE pattern starting with screw in lower left-hand side from spring. NOTE: Head not shown for clarity. Tilt Motor Assembly Sensor Bracket Tilt Belt Spring Figure 2-23: VL3000 Tilt Motor Assembly Replacement 02.96 78.001 0 G...

  • Page 62: Tilt Encoder Pcb Replacement

    Assembly, you must tighten in a CLOCKWISE pattern starting with screw in lower left-hand side from spring. NOTE: Tilt Motor Assembly Detail Head not shown for clarity. Tilt Encoder Tilt Motor Assembly Tilt Belt Spring Sensor Bracket Figure 2-24: VL3000 Tilt Encoder PCB Replacement 02.96 78.001 0 G...

  • Page 63: Tilt Eot Sensor Replacement

    Step 5. At sensor, remove two 6-32x3/8" PPZ screws and remove sensor from bracket. Step 6. Replace by performing steps 2 through 5 in reverse order. Tilt Motor Assembly NOTE: Head not shown for clarity. Sensor Sensor Bracket Tilt Belt Spring Figure 2-25: VL3000 Tilt EOT Sensor Replacement 02.96 78.001 0 G...

  • Page 64: Ballast Assembly Replacement

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Ballast Assembly Replacement VL Part No: 23.9678.1269 (Old Style) VL Part No: 12.9678.1862 (New Style) Note: Vari-Lite offers a conversion kit for converting old-style ballasts to new-style ballasts. For information on the kit (VL Part No: 28.9678.0100), see Technical Bulletin S3K-014, "Series 3000™...
  • Page 65 AINTENANCE ROCEDURES ALLAST SSEMBLY EPLACEMENT Table 3: VL3000 Ballast Connector Locations Location Connector J102 2-Pos Connector J103 3-Pos Mate N Lok J108 Red 1+ (Choke) J109 Dark Blue 2– (Choke) J110 Orange 3+ (Choke) J111 Orange 4– (Choke) J112 8-Pos MTA...
  • Page 66 Route Lamp to Supply Cable as shown - same as original cable assembly. Back of Display 1200-Watt Ballast Assembly Lamp Supply to Relay Cable Assembly Cable must be routed through Ferrite Figure 2-27: VL3000 Ballast Replacement (New Style) 02.96 78.001 0 G...

  • Page 67: 80Mm Fan Replacement

    : 80MM F AINTENANCE ROCEDURES EPLACEMENT 80MM Fan Replacement VL Part No: 21.9678.0619 Repair/Replacement Procedure Step 1. Disconnect luminaire AC input cable from power source. Step 2. Remove top head cover by loosening four quarter-turn captive locking screws. Top cover is identifiable as the cover on top when back label is such that words are displayed correct side Step 3.
  • Page 68 ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL 80MM Fan Replacement (continued) Note: Fixtures manufactured before 02/17/05 do NOT have a heat shield installed between the 80MM fan and the lamp house. 80 mm Fan Assembly Note: Other components removed for clarity.

  • Page 69: Transfer Fan Assembly Replacement

    Step 4. At transfer fan assembly, loosen four 6-32 x 3/8" PPZ screws and slide assembly off Gobo assembly. Step 5. Replace by performing steps 2 through 4 in reverse order. Top Head Cover Transfer Fan Assembly Figure 2-17: VL3000 Transfer Fan Assembly Replacement 02.96 78.001 0 G...

  • Page 70: Gobo/Color (Dual) Fan Assembly Replacement

    Step 6. Replace by performing steps 2 through 5 in reverse order. Note: Some early-production wash fixtures only have one fan mounted to dual fan assembly. All current production fixtures have two fans. Gobo/Color Fan Assembly Gobo/Color Fan Assembly Figure 2-18: VL3000 Gobo/Color (Dual) Fan Assembly Replacement 02.96 78.001 0 G...

  • Page 71: Yoke Fan Assembly (X2) Replacement

    Step 5. Replace by performing steps 2 through 4 in reverse order. Yoke Fan Assembly Yoke Assembly Screws (2 per side) Screws (2 per side) Yoke Fan Assembly NOTE: Some components not shown for clarity. Figure 2-19: VL3000 Yoke Fan Assembly Replacement 02.96 78.001 0 G...

  • Page 72: Upper Enclosure Fan Assembly Replacement

    Step 6. At fan, remove three 6-32x3/8" PPZ screws and remove fan. Step 7. Replace by performing steps 2 through 6 in reverse order. Fan Assembly Display Cover NOTE: Some components not shown for clarity. Fan Assembly Figure 2-20: VL3000 Upper Enclosure Fan Assembly Replacement 02.96 78.001 0 G...

  • Page 73: Display Pcb Assembly Replacement

    Step 8. Replace by performing steps 2 through 7 in reverse order. LVS Power Supply Display Display Panel Assembly Display Cover Display Panel Assembly NOTE: Display PCB Some components not shown for clarity. Figure 2-21: VL3000 Display PCB Assembly Replacement 02.96 78.001 0 G...
  • Page 74 ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Notes 02.96 78.001 0 G...

  • Page 75: Chapter 3. Illustrated Parts Breakdown

    HAPTER Illustrated Parts Breakdown This chapter contains illustrated parts breakdowns for all VL3000 and VL3000Q luminaire assemblies. • Drawing Trees • Top Assembly • Head Assembly • Yoke Assembly • Head/Yoke PCB Assemblies • Enclosure Assembly • Cable Assemblies 02.96 78.001 0 G...

  • Page 76: Drawing Trees

    23.9678.0684 Rev 0 21.9678.0700 Rev J 28.9678.0001 Rev J (VL3000) Continued on page 59 Upper Enclosure Assembly Continued on page 59 21.9678.0800.01 Rev NN (VL3000) Continued on page 60 Figure 3-1: VL3000 Spot Luminaire Drawing Tree Part 1 02.96 78.001 0 G...
  • Page 77 22.9678.0481 Rev B Interconnect Light Shield Color Sense PCB #2 Assembly Mount Assembly 22.9678.1115 Rev C 22.9678.0489 Rev B Color Interconnect PCB/ Cable Assembly 25.9678.1409 Rev 0 (VL3000 Only) Figure 3-2: VL3000 Spot Luminaire Drawing Tree Part 2 02.96 78.001 0 G...
  • Page 78 25.9678.0818 Rev B Assembly 25.9678.0821 Display Cable Assembly 25.9678.1825 Lamp Supply to Relay Cable Assembly LVS to Yoke AC Fan 25.9678.0829 Rev A Cable Assembly 25.9678.0843 Rev A Figure 3-3: VL3000 Spot Luminaire Drawing Tree Part 3 02.96 78.001 0 G...

  • Page 79: Vl3000Q Spot Luminaire

    Long Shaft Motor 80mm Fan Assembly Assembly Assembly 21.9678.0619 Rev B 22.9678.1126 Rev B 21.9678.0243 Rev 0 Iris Assembly VL3000 Controller PCB UV Filter Bulkhead 21.9678.0270 Rev A 24.9678.3730 Rev 0 Assembly 22.9678.0617 Rev A (VL3000Q) Hot Box Assembly Relay to Gobo Fan 21.9678.8698.01 Rev F...
  • Page 80 ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL VL3000Q Spot Luminaire (continued) Continued from page 61 Continued from page 61 Color/Dimmer/Strobe Yoke Assembly Assembly Transfer Fan Assembly 21.9678.0701 Rev B 22.9678.0462 Rev E 21.9678.0678.01 Rev D (VL3000Q) (VL3000Q)
  • Page 81 VL3000Q Spot Luminaire (continued) Continued from page 61 Upper Enclosure Assembly 21.9678.0801.01 Rev Z (VL3000Q) Ventilation Cover Panel Assembly Assembly - VL3000 Quiet 21.9678.0805 Rev N 21.9686.0840.02 Rev B (VL3000Q) DMX Input PCB 24.9663.3895 Pan Pulley Assembly 21.9678.0807 Rev E...

  • Page 82: Vl3000 Wash Luminaire

    Included Items Kit, Wash 21.9678.0700 Rev J 28.9678.0002 Rev F (VL3000) Continued on page 65 Upper Enclosure Assembly Continued on page 65 21.9678.0800.01 Rev NN (VL3000) Continued on page 66 Figure 3-7: VL3000 Wash Luminaire Drawing Tree Part 1 02.96 78.001 0 G...
  • Page 83 Color Sensor PCB #1 Mount Assembly 22.9678.0481 Rev B Color Sense PCB #2 Mount Assembly 22.9678.0489 Rev B Color Interconnect PCB/ Cable Assembly 25.9678.1409 Rev 0 (VL3000 Only) Figure 3-8: VL3000 Wash Luminaire Drawing Tree Part 2 02.96 78.001 0 G...
  • Page 84 25.9678.0818 Rev B Assembly 25.9678.0821 Display Cable Assembly 25.9678.1825 Lamp Supply to Relay Cable Assembly LVS to Yoke AC Fan 25.9678.0829 Rev A Cable Assembly 25.9678.0843 Rev A Figure 3-9: VL3000 Wash Luminaire Drawing Tree Part 3 02.96 78.001 0 G...

  • Page 85: Vl3000Q Wash Luminaire

    Edge Lead Screw (Wash Only) 80mm Fan Assembly Assembly 21.9678.0619 Rev B 22.9678.1126 Rev B Condenser Lens Assembly 21.9678.0940 Rev C VL3000 Controller PCB UV Filter Bulkhead (Wash Only) 24.9678.3730 Rev 0 Assembly Hot Box Assembly 22.9678.0617 Rev A 21.9678.8698.02 Rev F...
  • Page 86 ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL VL3000Q Wash Luminaire (continued) Continued from page 67 Continued from page 67 Color/Dimmer/Strobe Yoke Assembly Assembly Transfer Fan Assembly 21.9678.0700 Rev J 22.9678.0402 Rev N 21.9678.0678.02 Rev D (VL3000) (VL3000)
  • Page 87 VL3000Q Wash Luminaire (continued) Continued from page 67 Upper Enclosure Assembly 21.9678.0801.01 Rev Z (VL3000Q) Ventilation Cover Panel Assembly Assembly - VL3000 Quiet 21.9678.0805 Rev N 21.9686.0840.02 Rev B (VL3000Q) DMX Input PCB 24.9663.3895 Pan Pulley Assembly 21.9678.0807 Rev E...

  • Page 88: Top Assembly

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Top Assembly Included Items Kit, Spot 28.9678.0001 Rev J Refer to Figure 3-13. 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...
  • Page 89 SSEMBLY NCLUDED TEMS Included Items Kit, Spot (continued) (x2) Alpha Rays Night Sky Tribal Break-Up Pebbles Glacier Gag Palm Leaves Shock Break-Up Uneven Bars Ice Blocks Gag Droplets Gag 3-Facet Prism Circle of Ovals Triangle Break-Up Multi-Colored Gobo Figure 3-13: Included Items Kit, Spot Note: * = Do not handle lamp with bare hands.

  • Page 90: Included Items Kit, Wash

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Included Items Kit, Wash 28.9678.0002 Rev F Refer to Figure 3-14. Item Qty. Description 02.8001.0001 PRODUCT SUPPORT SHEET, VARI-LITE CUSTOMER SERVICE 02.8052.0001 CARD, LIMITED WARRANTY 02.8700.0001 CARD, PRODUCT REGISTRATION 02.9678.0002 UNPACK/QUICK START SHEET, VL3000 04.4037.0001...

  • Page 91: Vl3000 And Vl3000Q Spot Luminaire

    AC DANGER TAG, VL3000 (not shown) 04.9661.0033.01 LABEL, WARNING - 2000 SERIES (not shown) 04.9661.0039 LABEL, LINE CORD WARNING (not shown) 04.9678.0041.01 LABEL, AC INPUT RATING VL3000 (not shown) 04.9678.0061 LABEL, AC INPUT RATING VL3000Q (not shown) 10.9678.0609 FRONT FILTER, FOAM, ZOOM (not shown) 10.9686.0617 YOKE CROSSMEMBER, HEAT SHIELD (changed 02-27-07) 10.9686.0732...
  • Page 92 Description 25.9678.0677 CABLE ASSY, FRONT HEAD FANS (not shown) 25.9678.0715 CABLE ASSY, HEAD CONTROLLER (not shown) 28.9678.0001 INCLUDED ITEMS KIT, VL3000 SPOT (not shown) 53.2001.0003 NUT, 10-32 NYLON INSERT 53.2002.0003 NUT, 6-32 HEX ZINC NYLON IN 53.6523.0013 SCREW, 6-32 X 3/8" PTB 53.6558.0009...
  • Page 93 (x2) (x4) (x4) Figure 3-15: VL3000 and VL3000Q Spot Luminaire * Only used with 22.9678.0705 (Yoke Structure) Rev. D or later or 22.9686.0705. For prior versions of Yoke Structure, use Center of Travel Flag part number: 10.9678.0755. 02.96 78.001 0 G...

  • Page 94: Vl3000 And Vl3000Q Wash Luminaire

    AC DANGER TAG, VL3000 (not shown) 04.9661.0033.01 LABEL, WARNING - 2000 SERIES (not shown) 04.9661.0039 LABEL, LINE CORD WARNING (not shown) 04.9678.0041.01 LABEL, AC INPUT RATING VL3000 (not shown) 04.9678.0061 LABEL, AC INPUT RATING VL3000Q (not shown) 10.9686.0617 YOKE CROSSMEMBER, HEAT SHIELD (changed 02-27-07) 10.9678.0670 INTERCONNECT PCB MOUNT, CYM 10.9678.0732...
  • Page 95 : VL3000 VL3000Q W SSEMBLY UMINAIRE Item Qty. Description 53.6523.0013 SCREW, 6-32 X 3/8" PPB 53.6558.0009 SCREW, 6-32 X 3/8" LG PPZ SEMS 53.6558.0016 SCREW, 6-32 X 3/4" PPZ SEMS 53.6579.0001 SCREW, 10-32 X 1/2" SCB 53.6613.0001 SCREW, 6-32 X 1/2" PPZ 53.6682.0022...
  • Page 96 LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL VL3000 and VL3000Q Wash Luminaire (continued) (x2) (x8) (x2) (x2) (x2) (x4) (x2) (x2) (x2) 23, 18 (x2) (x2) (x2) (x8) (x2) (x2) (x4) (x2) (x4) Figure 3-16: VL3000 and VL3000Q Wash Luminaire 02.96 78.001 0 G...

  • Page 97: Generic Luminaire Assemblies

    21.9678.0011.01 Rev C (VL3000Q) Refer to Figure 3-17 Item Qty. Description 21.9678.0600 ASSY, HEAD STRUCTURE 21.9678.0601 ASSY, HEAD STRUCTURE, VL3000 QUIET 21.9678.0700 ASSY, YOKE 21.9678.0701 ASSY, YOKE, VL3000 QUIET 21.9678.0707 ASSY, TILT PULLEY - 10.9678.0750 TIMING PULLEY, 150 TOOTH - 10.9678.0754 * FLAG, CENTER OF TRAVEL, TILT - 53.6530.0009...
  • Page 98 Generic Luminaire Assemblies (continued) Detail A (x3) (x2) (x4) (x4) (x4) (x2) Detail C (x4) (x5) Detail B (x5) Detail C Detail A Detail B (x2) (x2) (x3) Figure 3-17: VL3000 and VL3000Q Generic Luminaire Assemblies 02.96 78.001 0 G...

  • Page 99: Head Assembly

    SSEMBLY TRUCTURE SSEMBLY Head Assembly Head Structure Assembly 21.9678.0600 Rev C (VL3000) 21.9678.0601 Rev A (VL3000Q) Refer to Figure 3-1 Item Qty. Description 10.9678.8620 FRONT CASTING 12.9678.8623 RIGHT SIDE RAIL, MACHINED 12.9678.8625 LEFT SIDE RAIL, MACHINED 21.9678.0615 ASSY, BACKEND 21.9678.0616 ASSY, BACKEND, VL3000 QUIET 53.6515.0001...

  • Page 100: Head Cover Assembly

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Head Cover Assembly 21.9678.8611 Rev 0 Refer to Figure 3-2 Item Qty. Description 10.9678.0612 HEAD COVER FOAM BAFFLE 10.9678.0649 EJECTOR SPRING, BLACK OXIDE 10.9678.0674 BRACKET, COVER TETHER 10.9678.0696 FOAM FRAME, HEAD COVER (added 10-01-03) 12.9678.8610...

  • Page 101: Backend Assembly

    TETHER ASSY, COVER 22.9678.3655 DUCT ASSY, 80MM FAN 22.9678.0639 UV FILTER BULKHEAD ASSY 22.9678.0617 UV FILTER BULKHEAD ASSY, VL3000 QUIET 25.9678.0012 CABLE ASSY, AC FAN YOKE TO FAN (not shown) 25.9678.0014 CABLE ASSY, BACKCAP INTERLOK TO GOBO INTERLOK (not shown) 53.2004.0002 NUT, 8-32 KEPS ZINC PLATE 53.6519.0001...
  • Page 102 SCREW, 6-32 X 1/2" SCZ (added 07-18-03) 10.9678.1645 FAN SHIELD, LAMP COOLING (added 12-09-04) 25.9678.0691 CABLE ASSY, AIR DUCT OT SWITCH (cable not shown) 25.9678.0690 CABLE ASSY, AIR DUCT OT SWITCH, VL3000 QUIET (cable not shown) 10.9678.0680 INSULATOR, TEFLON, TO-220 53.2200.0004 NUT, 4-40 KEPS (x3)

  • Page 103: 80Mm Fan Assembly

    : 80 SSEMBLY SSEMBLY 80mm Fan Assembly 21.9678.0619 Rev B Refer to Figure 3-4 Item Qty. Description 40.7145.0004 FAN, TUBEAXIAL 80 X 80 X 38mm 28 CFM 230V (added 03/11/04) 53.2200.0006 NUT, 6-32 KEPS SS 53.6558.0001 SCREW, 6-32 X 3/8" PPZ 55.7016.0001 FAN GUARD, 80MM NICKEL PLATED STEEL WIRE (x4)

  • Page 104: Uv Filter Bulkhead Assembly

    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" (VL3000 Only) 41.9678.1160 UV/IR FILTER, ENHANCED (VL3000Q Only) 53.6530.0002 RIVET, 1/8 OD POP,.063-.125 GRIP, ALUM (x4) UV Filter Installation Install filter with marks indicating IR coating side of filter facing up and located outside of circular cutout in bulkhead.

  • Page 105: Spot Gobo Assembly

    SSEMBLY SSEMBLY Spot Gobo Assembly 21.9678.0200 Rev K (Spot Only) Refer to Figure 3-6 Item Qty. Description 10.9678.0215 BULKHEAD, GOBO MODULE FRONT 10.9678.0216 BULKHEAD, GOBO MODULE REAR 10.9678.0225 SHAFT, GOBO WHEEL 10.9678.0231 PULLEY, MOTOR GOBO WHEEL DRIVE 10.9678.0232 PULLEY, INSEX DRIVE 64 GROOVE 10.9678.0244 MOUNT, INDEX SENSOR LONG 10.9678.0245...
  • Page 106 ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Item Qty. Description 53.6609.0001 SCREW, 6-32 X 3/8" PFZ 55.6506.0030 SPACER, 3/8" RND 3/8" LG .257" ID THRU ALUM 55.2110.0002 WASHER, .400" OD .260 ID .010" THK FLAT SS (added 4-29-03) 10.9678.0457.02...

  • Page 107: Rotating Gobo Wheel Assembly

    SSEMBLY OTATING HEEL SSEMBLY Rotating Gobo Wheel Assembly 21.9678.0210 Rev B Refer to Figure 3-7 Item Qty. Description 10.9663.1211 SPACER, TEFLON GOBO GEAR 10.9663.1240 BEARING, GOBO WHEEL BORE 10.9678.0220 PLATE, ROTATING GOBO WHEEL 10.9678.0224 RETAINING RING, PLANET 22.9678.0230 ASSY, PLANET GEAR - 10.9678.0263 CLIP WIRE, PLANET - 10.9678.0282...

  • Page 108: Rotating Effects Wheel Assembly

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

  • Page 109: Long Shaft Motor Assembly

    SSEMBLY HAFT OTOR SSEMBLY Long Shaft Motor Assembly 21.9678.0243 Rev 0 Refer to Figure 3-9 Item Qty. Description 10.9678.0330 PLATE, MOTOR ADAPTER 44.9678.0249 MOTOR, STEPPER 42MM X 34MM 60MM SHAFT 53.6513.0002 SCREW, 3MM X 5MM LG PFZ METRIC (x4) Note orientation of motor plate adapter when mounting.

  • Page 110: Iris Assembly

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Iris Assembly 21.9678.0270 Rev A Refer to Figure 3-10 Item Qty. Description 10.9678.0272 BULKHEAD, IRIS 10.9678.0273 MOTOR MOUNT, IRIS 10.9678.0274 APERTURE, IRIS 10.9678.0276 CRANK, IRIS 10.9678.0279 DIVERTER, GOBO AIR 10.9678.0280 ADJUSTABLE IRIS STOP (changed 09-17-03) 22.9678.0271...
  • Page 111 SSEMBLY SSEMBLY Iris Assembly (continued) (x4) Detail A (x2) (x3) Detail A (x2) (x3) (x2) Figure 3-10: Iris Assembly 02.96 78.001 0 G...

  • Page 112: Hot Box Assembly

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Hot Box Assembly 21.9678.8640.01 Rev H (VL3000 Spot) 21.9678.8640.02 Rev H (VL3000 Wash) 21.9678.8698.01 Rev F (VL3000Q Spot) 21.9678.8698.02 Rev F (VL3000Q Wash) Refer to Figure 3-11 Item Qty. Description 10.9678.0043.03...
  • Page 113 SSEMBLY SSEMBLY Hot Box Assembly (continued) (x4) (x4) (x4) (x4) (x4) (x2) (x4) (x8) (x4) (x3) (x3) (x3) (x3) Wash Version Spot Version Figure 3-11: Hot Box Assembly 02.96 78.001 0 G...

  • Page 114: Gobo/Color Fan Assembly - Vl3000Q Only

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Gobo/Color Fan Assembly - VL3000Q Only 21.9678.0659.01 Rev D Refer to Figure 3-13 Item Qty. Description 10.9678.0665 SPRING, EXTENSION ELONGATED HO 22.9678.0661 ASSY, FAN TRAY 22.9678.0665 DUCT ASSY 23.9678.0699 FAN ASSY, HEAD FRONT 53.5506.1375...
  • Page 115 - VL3000Q O SSEMBLY OLOR SSEMBLY Gobo/Color Fan Assembly - VL3000Q Only (continued) (x3) (x2) (x2) (x2) (x3) Spring installed as shown Figure 3-12: Gobo/Color Fan Assembly - VL3000Q 02.96 78.001 0 G...

  • Page 116: Dual Fan Tray/Duct Assembly - Vl3000 Only

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Dual Fan Tray/Duct Assembly - VL3000 Only 21.9678.0660.01 Rev B Refer to Figure 3-13 Item Qty. Description 10.9678.0665 SPRING, EXTENSION ELONGATED HOOK (changed 06-29-06) 22.9678.0661 ASSY, FAN TRAY 22.9678.0665 DUCT ASSY 23.9678.0684...
  • Page 117 - VL3000 O SSEMBLY SSEMBLY Dual Fan Tray/Duct Assembly - VL3000 Only (continued) (x3) (x2) (x2) (x2) (x3) Spring installed as shown Figure 3-13: Dual Fan Tray/Duct Assembly - VL3000 02.96 78.001 0 G...

  • Page 118: Head Front Fan Assembly

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Head Front Fan Assembly 23.9678.0684 Rev 0 Refer to Figure 3-14 Item Qty. Description 40.7125.0001 FAN, 24V FAL6F24LH 52.6523.0002 CONN, HOUSING 2POS PLUG SHROUDED WIRE TO WIRE 52.8347.0001 CONTACT, 24-30AWG MALE CRIMP...

  • Page 119: Head Front Fan Assembly - Vl3000Q Only

    - VL3000Q O SSEMBLY RONT SSEMBLY Head Front Fan Assembly - VL3000Q Only 23.9678.0699 Rev A Refer to Figure 3-14 Item Qty. Description 40.7125.0001 FAN, 24V FAL6F24LH 52.6523.0002 CONN, HOUSING 2POS PLUG SHROUDED WIRE TO WIRE 52.8347.0001 CONTACT, 24-30AWG MALE CRIMP 55.2186.0001 CABLE TIE, .10 X 4"...

  • Page 120: Transfer Fan Assembly

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Transfer Fan Assembly 21.9678.0678.01 Rev D (Spot) 21.9678.0678.02 Rev D (Wash) Refer to Figure 3-16 Item Qty. Description 10.9678.0679 TRANSFER FAN TRAY 23.9678.0695 FAN ASSY, TRANSFER 53.6571.0003 SCREW, 6-32 X 1-1/2"LG PPB (changed 07-16-07) 55.6543.0001...

  • Page 121: Spot Optic Assembly

    SSEMBLY PTIC SSEMBLY Spot Optic Assembly 22.9678.0103 Rev S (Spot Only) Refer to Figure 3-17 Figure 3-18 Item Qty. Description 10.9678.1131 FORWARD PULLEY SHAFT (changed 12-15-04) 10.9678.0127 PULLEY, IDLER 10.9678.0129 SPACER, ROLLER CAM 10.9678.0153 CABLE CLAMP, CAST 10.9678.0156 BARREL STRAP, G1 & G2 10.9678.0157 BARREL STRAP, G3 10.9678.0171...
  • Page 122 ❋ VARI LITE® - VL3000™ & VL3000™Q S 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...
  • Page 123 SSEMBLY PTIC SSEMBLY Spot Optic Assembly (continued) (x2) (x2) (x2) (x2) (x2) (x4) (x3) (x2) Detail F-F Detail E-E (x6) Figure 3-17: Spot Optic Assembly View 1 02.96 78.001 0 G...
  • Page 124 ❋ VARI LITE® - VL3000™ & VL3000™Q S 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) (x2) Detail G3-G3 Detail G2-G2...

  • Page 125: Group 4 Lens Mount Assembly

    SSEMBLY ROUP OUNT SSEMBLY Group 4 Lens Mount Assembly 22.9678.0199 Rev 0 Refer to Figure 3-19 Item Qty. Description 12.9678.0198 RING BLOCK, MACHINED G4 22.9678.0174 LENS ASSY, GROUP 4 53.6558.0001 SCREW, 6-32 X 3/8" PPZ 55.3303.0006 WASHER, #6 LOCK INT.TOOTH SS 55.6763.0500 PIN, DOWEL .5"LG .125"DIA 303SS (x4)

  • Page 126: Right Edge Bearing Assembly

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Right Edge Bearing Assembly 22.9678.1103 Rev C Refer to Figure 3-20 Item Qty. Description 12.9678.1102 EDGE BEARING, MACHINED CASTING RIGHT 54.2056.0001 RING, RETAINING EXTERNAL 19MM 55.6776.0010 LINEAR BUSHING, 10MM STEEL W/PHENOLIC CAGE Figure 3-20: Right Edge Bearing Assembly 02.96 78.001 0 G...

  • Page 127: Left Edge Bearing Assembly

    SSEMBLY EARING SSEMBLY Left Edge Bearing Assembly 22.9678.1105 Rev C Refer to Figure 3-21 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 Figure 3-21: Left Edge Bearing Assembly 02.96 78.001 0 G...

  • Page 128: Zoom Cam Assembly

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Zoom Cam Assembly 22.9678.1106 Rev B Refer to Figure 3-22 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...

  • Page 129: Zoom Motor Tensioning Assembly

    SSEMBLY OTOR ENSIONING SSEMBLY Zoom Motor Tensioning Assembly 22.9678.1113 Rev B Refer to Figure 3-23 Item Qty. Description 10.9678.0338 PULLEY, ZOOM MOTOR (changed 03-07-06) 10.9678.1111 BRACKET, ZOOM TENSION SHEETMETAL 44.9663.1326 MOTOR, 17 .53" SHAFT 11.8MH 5.5 OHM 53.5559.0250 SCREW, 6-32 X 1/4" SET CONE POINT 53.6522.0001 SCREW, 6-32 X 1/4"...

  • Page 130: Interconnect Light Shield Assembly

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Interconnect Light Shield Assembly 22.9678.1115 Rev C Refer to Figure 3-24 Item Qty. Description 10.9678.1114 SHIELD, INTERCONNECT MOUNT/LIGHT 24.9678.3116 PCB ASSY, ZOOM INTERCONNECT (changed 03-07-06) 53.6558.0009 SCREW, 6-32 X 3/8" PPZ SEMS...

  • Page 131: Rod Clamp Assembly

    SSEMBLY LAMP SSEMBLY Rod Clamp Assembly 22.9678.0149 Rev B Refer to Figure 3-25 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 132: Color/Dimmer/Strobe Assembly

    ASSY, COLOR SENSE PCB #2 MOUNT 24.9678.3240 PCB ASSY, WHEEL POSITION SENSOR (changed 02-14-05) 25.9678.1409 PCB/CABLE ASSY, COLOR INTERCNT (not shown) 25.9678.1419 PCB/CABLE ASSY, COLOR INTERCNT (not shown) (VL3000 QUIET) 44.9678.0455 COLOR MOTOR 53.2202.0008 NUT, 8-32 HEX SS, NYLON INSERT 53.2200.0006 NUT, 6-32 KEPS SS 02.96 78.001 0 G...
  • Page 133 WASHER, #8 FLAT ZINC 55.6528.0001 WASHER, #6 FLAT ZINC 55.2110.0002 SPACER, 0.010 LG 55.2186.0002 CABLE TIE, 0.09WD, 0.375 LG, TEFZEL (not shown) 10.9678.0457.06 SPACER, COLOR WHEEL, 0.015 L 55.6520.0001 WASHER, WAVE SPRING, 1/4" DIA (added 05-17-04) (VL3000 only) 02.96 78.001 0 G...
  • Page 134 ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Color/Dimmer/Strobe Assembly (continued) (x4) (x5) (x10) Dimmer Yellow (x4) (x4) Cyan (x2) (x2) Magenta (x2) (x2) (x2) (x2) (x4) (x5) (x5) (x1) (x2) (x5) (x5) (x12) (x5) Figure 3-26: Color/Dimmer/Strobe Assembly...

  • Page 135: Motor/Adapter Plate Assembly

    SSEMBLY OTOR DAPTER LATE SSEMBLY Motor/Adapter Plate Assembly 21.9678.0331 Rev 0 Refer to Figure 3-27 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 3-27: Motor/Adapter Plate Assembly 02.96 78.001 0 G...

  • Page 136: Fixed Color Wheel Assembly

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Fixed Color Wheel Assembly 21.9678.0334 Rev D Refer to Figure 3-28 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...
  • Page 137 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 OPEN DARK FUSHIA POS 6 POS 5 DEEP MAGENTA Figure 3-28: Fixed Color Wheel Assembly 02.96 78.001 0 G...

  • Page 138: Strobe Assembly

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Strobe Assembly 22.9678.0403 Rev F Refer to Figure 3-29 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...

  • Page 139: Strobe Assembly (Vl3000 Quiet)

    (VL3000 Q SSEMBLY TROBE SSEMBLY UIET Strobe Assembly (VL3000 Quiet) 22.9678.0463 Rev B Refer to Figure 3-29 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...

  • Page 140: Right Strobe Blade Assembly

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Right Strobe Blade Assembly 22.9678.0467 Rev C Refer to Figure 3-31 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...

  • Page 141: Left Strobe Blade Assembly

    SSEMBLY TROBE LADE SSEMBLY Left Strobe Blade Assembly 22.9678.0468 Rev C Refer to Figure 3-32 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 142: Vl3000Q Strobe Motor Assembly

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL VL3000Q Strobe Motor Assembly 23.9678.0499 Rev A (VL3000Q) Refer to Figure 3-33 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...

  • Page 143: Dimmer Wheel Assembly

    SSEMBLY IMMER HEEL SSEMBLY Dimmer Wheel Assembly 22.9678.0435 Rev E Refer to Figure 3-34 Item Qty. Description 55.2256.0001 MAGNET, 2:17 SMCO 2MM X 2MM Coated Side Dimmer Wheel Magnet Install South Dimmer Wheel Magnet Pole NUVASIL RTV Dimmer Wheel Copper RTV Bead (2 beads - one on each side of magnet) Gluing Magnet to Dimmer Wheel Assembly Step...

  • Page 144: Gobo Clamp Assembly

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Gobo Clamp Assembly 22.9678.0693 Rev A Refer to Figure 3-35 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...

  • Page 145: Color Clamp Assembly

    SSEMBLY OLOR LAMP SSEMBLY Color Clamp Assembly 22.9678.0694 Rev A Refer to Figure 3-36 Item Qty. Description 12.9678.0692 COLOR CLAMP 53.6685.0625 SCREW, CAPTIVE PANEL, 6-32 X.625"LG PPS ZINC PLATED 55.6538.0001 WASHER, #6 LOCK INTERNAL TOOTH 53.6613.1126 SCREW, 6-32 X 1.125 LG PPZ (x2) (x2) Figure 3-36: Color Clamp Assembly...

  • Page 146: Edge Lead Screw Assembly

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Edge Lead Screw Assembly 22.9678.1126 Rev B Refer to Figure 3-37 Item Qty. Description 10.9678.1119 LEAD SCREW, EDGE 55.6616.0007 STANDOFF, 3/8" HEX THRD 0.562" LG Figure 3-37: Edge Lead Screw Assembly...

  • Page 147: Beam Spreader Assembly

    SSEMBLY PREADER SSEMBLY Beam Spreader Assembly 21.9678.0910 Rev A (Wash Only) Refer to Figure 3-38 Item Qty. Description 10.9678.0945 TUBE, WASH LIGHT BAFFLE 21.9678.0920 ASSY, CONCAVE LENS STATIONARY 21.9678.0930 ASSY, CONVEX LENS TRANSLATING 21.9678.0940 ASSY, CONDENSER LENS 24.9678.3916 PCB ASSY, ZOOM INTERCONNECT WASH 53.6520.0375 SCREW, 4-40 X 3/8"...

  • Page 148: Stationary Concave Lens Assembly

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Stationary Concave Lens Assembly 21.9678.0920 Rev A (Wash Only) Refer to Figure 3-39 Item Qty. Description 10.9678.0927 BEARING SHAFT, BEAM SPREADER 10.9678.0928 LENS CLAMP, BEAM SPREADER 12.9678.0168 MASKED, CONCAVE LENS ARRAY MEDIUM 12.9678.0925...

  • Page 149: Translating Convex Lens Assembly

    SSEMBLY RANSLATING ONVEX SSEMBLY Translating Convex Lens Assembly 21.9678.0930 Rev B (Wash Only) Refer to Figure 3-40 Item Qty. Description 10.9678.0936 STOP, BEAM SPREADER 10.9678.0938 LENS CLAMP, CONVEX 12.9678.0166 MASKED, CONVEX LENS ARRAY MEDIUM 12.9678.0939 CONVEX LENS MOUNT, MACHINED, ADJUSTABLE 53.6515.0375 SCREW, 10-32 X 3/8"...

  • Page 150: Condenser Lens Assembly

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Condenser Lens Assembly 21.9678.0940 Rev C (Wash Only) Refer to Figure 3-41 Item Qty. Description 10.9678.0928 LENS CLAMP, BEAM SPREADER 10.9678.0941 HOUSING, BEAM SPREADER 10.9678.0942 LEAD SCREW, BEAM SPREADER 10.9678.0944 CONDENSER LENS MOUNT 23.9678.1120...

  • Page 151: Aperture Bulkhead Assembly

    SSEMBLY PERTURE ULKHEAD SSEMBLY Aperture Bulkhead Assembly 21.9678.0950 Rev B (Wash Only) Refer to Figure 3-42 Item Qty. Description 10.9678.0225 SHAFT, GOBO WHEEL 10.9678.0952 WASH BULKHEAD 10.9678.0953 WASH APERTURE PLATE 53.6609.0001 SCREW, 6-32 X 3/8" PFZ (changed 11-11-03) 53.6613.0001 SCREW, 6-32 X 1/2" PPZ 55.2150.0002 STANDOFF, 1/4"HEX 6-32 1.187"L 55.6769.0004...

  • Page 152: Beam Spreader Light Baffle Assembly

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Beam Spreader Light Baffle Assembly 21.9678.0991 Rev A (Wash Only) Refer to Figure 3-43 Item Qty. Description 10.9678.0658 PLATE, COUNTERWEIGHT 10.9678.0990 LIGHT BAFFLE, BEAM SPREADER 53.6616.0001 SCREW, 6-32 X 3/4" PPZ...

  • Page 153: Yoke Assembly Yoke Assembly

    CABLE ASSY, IGNITOR TO RELAY (NOT SHOWN) 25.9678.0681 CABLE ASSY, YOKE FAN AND RELAY (NOT SHOWN) 25.9678.0781 CABLE ASSY, YOKE FAN AND RELAY, VL3000 QUIET (NOT SHOWN) 25.9678.0758 CABLE ASSY, YOKE FAN (NOT SHOWN) 25.9678.0759 CABLE ASSY, YOKE FAN, VL3000 QUIET (NOT SHOWN) 53.2019.0004...
  • Page 154 ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Yoke Assembly (continued) (x2) (x2) (x2) (x4) (x3) (x2) (x4) (x8) (x2) (x2) (x2) (x2) Figure 3-44: Yoke Assembly 02.96 78.001 0 G...

  • Page 155: Tilt Motor Assembly

    SSEMBLY OTOR SSEMBLY Tilt Motor Assembly 21.9678.0765 Rev E Refer to Figure 3-45 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 156 ❋ VARI LITE® - VL3000™ & VL3000™Q S 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.

  • Page 157: Yoke Fan Assembly

    NUT, 6-32 KEPS SS 55.2179.0003 CABLE SADDLE, .75 X .75 4WAY, VL3000 QUIET (NOT SHOWN) 55.2186.0001 CABLE TIE, .10 WD X 4" LG, VL3000 QUIET (NOT SHOWN) Direction of air flow Wire Connection Orientation Figure 3-46: Yoke Fan Assembly 02.96 78.001 0 G...
  • Page 158 ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Notes 02.96 78.001 0 G...

  • Page 159: Head/Yoke Pcb Assemblies Color Sensor Pcb #1 Mount Assembly

    Figure 3-47 Item Qty. Description 10.9678.0482 PCB MOUNT, COLOR SENSOR #1 24.9678.3480 PCB ASSY, VL3000 COLOR SENSOR #1 53.6558.0001 SCREW, 6-32 X 3/8" PPZ 55.3303.0006 WASHER, #6 LOCK INT.TOOTH SS (x2) (x2) Figure 3-47: Color Sensor #1 PCB Mount Assembly...

  • Page 160: Color Sense Pcb #2 Mount Assembly

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Color Sense PCB #2 Mount Assembly 22.9678.0489 Rev B Refer to Figure 3-48 Item Qty. Description 10.9678.0452 PCB MOUNT, COLOR SENSE #2 24.9678.3454 PCB ASSY, COLOR SENSOR #2 53.6558.0007 SCREW, 6-32 X 1/4" SEMS...

  • Page 161: Vl3000 Controller Pcb

    VL3000 Controller PCB 24.9678.3730 Rev 0 Note: This item is only available as an assembly. Refer to Figure 3-48 Item Qty. Description 85.3773.002 IC, DRIVER (FOR USE WITH CARDS WITH SOCKETS ONLY) Figure 3-49: VL3000 Controller PCB 02.96 78.001 0 G...

  • Page 162: Zoom Interconnect Pcb Assembly

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Zoom Interconnect PCB Assembly 24.9678.3116 Rev 0 (Spot Only) Refer to Figure 3-50 Ref. Item Qty. Description 04.9678.1116.00 LABEL SET ZOOM HARNESS (Not Shown) 11.9678.1116 PCB ZOOM INTERCONNECT 52.6259.0008 HDR 4POS NT\MTA100 SD RT ANG 52.6260.0015...
  • Page 163 PCB A PCB A SSEMBLIES NTERCONNECT SSEMBLY Zoom Interconnect PCB Assembly (continued) Figure 3-50: Zoom Interconnect PCB Assembly 02.96 78.001 0 G...
  • Page 164 ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Notes 02.96 78.001 0 G...

  • Page 165: Enclosure Assembly Upper Enclosure Assembly

    MACHINED, COVER SIDE 12.9678.0842 AIR DUCT, UPPER ENCLOSURE MOD 12.9678.1862 SHIELDED BALLAST, CCI 21.9678.1254 ASSY, COVER - VENTILATION 21.9686.0840.02 ASSY, COVER - VENT, VL3000 QUIET, ALUMINUM (not shown) 21.9678.0767 ASSY, STABILIZER - 10.9678.0757 STABILIZER, 1.377DIA - 10.9678.0762 BRACKET, STABLIZER - 53.6610.0003 SCREW, 6-32 X 7/16"...
  • Page 166 ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Item Qty. Description 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...
  • Page 167 NCLOSURE SSEMBLY PPER NCLOSURE SSEMBLY Item Qty. Description 53.6653.0502 SCREW, 1/4-20 X 1/2"LG SOC ( NOT USED ON VL3000Q 54.1206.0014 RING, RETAINING 54.1255.0001 BEARING ASSY, BLACK FLUSH MOU 54.2055.0001 BELT, TIMING S2M 210GROOVE 9MM 55.2150.0003 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...
  • Page 168 ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Upper Enclosure Assembly (continued) (x2) (x2) (x2) (x4) (x2) (x4) (x4) (x2) (x4) (x4) Figure 3-51: Upper Enclosure Assembly Part 1 02.96 78.001 0 G...
  • Page 169 NCLOSURE SSEMBLY PPER NCLOSURE SSEMBLY Upper Enclosure Assembly (continued) Electronics Assembly Run Lamp Wires Through Ferrite 55, 69 (x3) 73, 4 (x4) (x2) 10, 55 (x2) (x2) 45, 58 (x4) (x4) (x3) (x2) Figure 3-52: Upper Enclosure Assembly Part 2 02.96 78.001 0 G...
  • Page 170 ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Upper Enclosure Assembly (continued) (x2) (x4) Choke and Duct (x4) Assembly (x2) (x2) (x2) 52, 77*, 78* (x2) (x2) Part is shown exploded for clarity (x2) Note: *Shims used as required to Detail A remove any slack in pan tube assembly.

  • Page 171: Ventilation Cover Assembly - Standard

    NCLOSURE SSEMBLY ENTILATION OVER SSEMBLY TANDARD Ventilation Cover Assembly - Standard 21.9678.1254 Rev 0 (VL3000) Refer to Figure 3-54 Item Qty. Description 10.9661.1249 POST, TRUSS HOOK 10.9678.8350 COVER, VENTILATION 10.9678.0893 12" AIR SEAL, UPPER ENCLOSURE (changed 05-11-05) 10.9678.0894 6" AIR SEAL, UPPER ENCLOSURE (changed 05-11-05) 10.9678.0896...

  • Page 172: Ventilation Cover Assembly - Vl3000 Quiet

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Ventilation Cover Assembly - VL3000 Quiet 21.9686.0840.02 Rev B (VL3000Q) Refer to Figure 3-55 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...
  • Page 173 - VL3000 Q NCLOSURE SSEMBLY ENTILATION OVER SSEMBLY UIET Ventilation Cover Assembly - VL3000 Quiet (continued) (x4) (x4) (x4) (x4) Current Production (x2) Early Production (x4) (x4) Figure 3-55: Ventilation Cover Assembly - VL3000Q 02.96 78.001 0 G...

  • Page 174: Panel Assembly

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Panel Assembly 21.9678.0805 Rev N Refer to Figure 3-56 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...

  • Page 175: Dmx Input Pcb

    : DMX I NCLOSURE SSEMBLY NPUT DMX Input PCB 24.9663.3895 Rev 0 Refer to Figure 3-57 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 176: Ac Input Pigtail Cable Assembly

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL AC Input Pigtail Cable Assembly 25.9678.0810 Rev B Refer to Figure 3-58 Item Qty. Description 52.6274.2313 STRAIN RELIEF, SKINTOP FLEX TYPE PG13 BLK 52.6401.2321 CONN, PLUG "CE MARKED" 20A 250V TWIST-LOCK MALE LINE, 3-WIRE 52.8231.0005...

  • Page 177: Pan Pulley Assembly

    NCLOSURE SSEMBLY ULLEY SSEMBLY Pan Pulley Assembly 21.9678.0807 Rev E Refer to Figure 3-59 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 3-59: Pan Pulley Assembly 02.96 78.001 0 G...

  • Page 178: Pan Motor Assembly

    CODEWHEEL, 120 COUNT LARGE ID - 10.9678.0749 TIMING PULLEY, 2MM GT 17 TOOTH - 53.5560.0250 SCREW, 8-32 X 1/4" SET FLAT POINT 24.9678.9729 PCB ASSY, VL3000 PAN ENCODER (changed 06-27-07) 44.9678.0680 MOTOR, 3 PHASE SIZE 23 HIGH TORQUE 53.2200.0008 NUT, 8-32 KEPS SS 53.6546.0001 SCREW, 8-32 X 5/8"...
  • Page 179 NCLOSURE SSEMBLY OTOR SSEMBLY 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. Install drive pulley on motor shaft using twisting motion to insure coverage of shaft with loctite.

  • Page 180: Pan Tube Assembly

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Pan Tube Assembly 21.9678.0881 Rev 0 Refer to Figure 3-61 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...

  • Page 181: Cable Assemblies

    EOT S ABLE SSEMBLIES ENSOR LECTRICAL SSEMBLY Cable Assemblies Pan EOT Sensor Electrical Assembly 23.9678.0687 Rev A Refer to Figure 3-62 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 3-62: Pan EOT Sensor Electrical Assembly 02.96 78.001 0 G...

  • Page 182: Lvs Chassis Ground Cable Assembly

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL LVS Chassis Ground Cable Assembly 25.9661.1514 Rev A Refer to Figure 3-63 Item Qty. Description 52.8231.0005 TERM, RING #6 BLUE 16-14 AWG REEL PIDG 52.8271.0001 FASTON RECEPT, 16-14 AWG (REEL) 73.3516.0504...

  • Page 183: 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 3-64 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 3-64: Chassis To Yoke Ground Cable Assembly 02.96 78.001 0 G...

  • Page 184: Head To Back Cap Ground Cable Assembly

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Head to Back Cap Ground Cable Assembly 25.9661.1522 Rev B Refer to Figure 3-65. Item Qty. Description 52.8311.0003 TERM, RING #6 14-16 AWG NON-INS. TAPE 73.7130.0001 1.33 WIRE, 7/64" TUBULAR BRAID TINNED COPPER...

  • Page 185: Relay To Ignitor Cable Assembly

    ABLE SSEMBLIES ELAY TO GNITOR ABLE SSEMBLY Relay to Ignitor Cable Assembly 25.9661.1526 Rev C Refer to Figure 3-66. 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 186: Yoke To Ac Fan Cable Assembly

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Yoke to AC Fan Cable Assembly 25.9678.0012 Rev A Refer to Figure 3-67 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...

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

    ABLE SSEMBLIES ACKCAP NTERLOK TO NTERLOK ABLE SSEMBLY Backcap Interlok to Gobo Fan Interlok Cable Assembly 25.9678.0014 Rev B Refer to Figure 3-68 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 3-68: Backcap Interlok to Gobo Fan Interlok Cable Assembly 02.96 78.001 0 G...

  • Page 188: Air Duct Ot Switch Cable Assembly

    55.2198.0002 .083 HEATSHRINK, 1/8" BLACK 55.2260.0133 .375 SLEEVING, FIBERGLASS, .133" ID 63.2047.5130 THERMOSTAT, 130º TO-220 OPEN ON RISE (VL3000 Only) 63.2047.5120 THERMOSTAT, 120º TO-220 OPEN ON RISE (VL3000Q Only) 73.7089.0000 1.48 WIRE, 22AWG BLK 300V 200C TEFLON STRANDED (4.5") Side View (x2, 0.5"...

  • Page 189: 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 3-70. 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 190: Front Head Fans Cable Assembly

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Front Head Fans Cable Assembly 25.9678.0677 Rev B Refer to Figure 3-71 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...

  • Page 191: Yoke Fan And Relay Cable Assembly

    ABLE SSEMBLIES AN AND ELAY ABLE SSEMBLY Yoke Fan and Relay Cable Assembly 25.9678.0681 Rev C Refer to Figure 3-72 Item Qty. Description 52.6396.3103 RECEPT, 3 POS MTA100 W/ POL TAB BLU CLSD END (changed 05-01-06) 52.6423.0003 HOUSING, 3 POS MT RECEPT, 2MM 52.8230.0003 RECEPT, 1/4"...

  • Page 192: Yoke Fan And Relay Cable Assembly - Vl3000Q

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Yoke Fan and Relay Cable Assembly - VL3000Q 25.9678.0781 Rev A Refer to Figure 3-72 Item Qty. Description 52.6423.0003 HOUSING, 3 POS MT RECEPT, 2MM 52.8230.0003 RECEPT, 1/4" FASTON 22-18AWG 52.6396.3103...

  • Page 193: Ot Switch To Interlok Cable Assembly

    : OT S ABLE SSEMBLIES WITCH TO NTERLOK ABLE SSEMBLY OT Switch to Interlok Cable Assembly 25.9678.0682 Rev C Refer to Figure 3-74 Item Qty. Description 52.8371.0001 RECEPT, FASTON 24-20AWG UNISUL TIN PLT BRS .250 X .032 TAB 52.8414.0001 RECEPT, FASTON, 0.187 SERIES 24-20 AWG UNISUL 73.7089.0000 0.79 WIRE, 22AWG 300V 200C TEF BLK UL1180...

  • Page 194: Ignitor To Lamp Socket Cable Assembly

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Ignitor to Lamp Socket Cable Assembly 25.9678.0789 Rev B Refer to Figure 3-75. 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...

  • Page 195: Head Controller Cable Assembly

    ABLE SSEMBLIES ONTROLLER ABLE SSEMBLY Head Controller Cable Assembly 25.9678.0715 Rev C Refer to Figure 3-76 Item Qty. Description 52.6224.1014 COVER, FRONT 14 POS MT LATCHING 52.6224.1040 COVER, FRONT 40 POS MT LATCHING 52.6224.1050 COVER, FRONT 50 POS MT LATCHING 52.6224.2014 COVER, BACK 14 POS MT 52.6224.2040...
  • Page 196 ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Head Controller Cable Assembly (continued) 9, 2, 5 9, 2, 5 7, 1, 4 7, 1, 4 (x11) 8, 3, 6 8, 3, 6 Figure 3-76: Head Controller Cable Assembly...

  • Page 197: Color Interconnect Pcb/Cable Assembly

    WIRE, 26AWG 4COND 300V200C TEF - 73.2326.7001 2.01 WIRE, 26AWG 7COND 300V 200C TE - 73.2326.5001 WIRE, 26AWG 5COND 300V 200C TE - 73.2326.3003 1.04 WIRE, 26AWG 3COND 300V 200C TEF Figure 3-77: Color Interconnect PCB/Cable Assembly - VL3000 Only 02.96 78.001 0 G...
  • Page 198 ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Color Interconnect PCB/Cable Assembly (continued) Figure 3-78: Color Interconnect PCB Assembly Wire Chart - VL3000 Only 02.96 78.001 0 G...

  • Page 199: Color Interconnect (Quiet) Pcb/Cable Assembly

    ) PCB/C ABLE SSEMBLIES OLOR NTERCONNECT UIET ABLE SSEMBLY Color Interconnect (Quiet) PCB/Cable Assembly 25.9678.1419 Rev A (VL3000Q Only) Refer to Figure 3-79 Figure 3-80 Item Qty. Description 24.9678.1419 PCB ASSY, COLOR INTERCONNECT 28.9678.1419 WIRE KIT, COLOR INTERCONNECT - 04.9678.0409.00 LABEL SET, COLOR HARNESS - 11.9678.0409 PCB, COLOR INTERCONNECT...
  • Page 200 ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Color Interconnect PCB/Cable Assembly (continued) Figure 3-80: Color Interconnect PCB Assembly Wire Chart - VL3000Q Only 02.96 78.001 0 G...

  • Page 201: Gobo Interconnect Pcb/Cable Assembly

    PCB/C ABLE SSEMBLIES NTERCONNECT ABLE SSEMBLY Gobo Interconnect PCB/Cable Assembly 25.9678.2209 Rev 0 Refer to Figure 3-81. Note: This cable must be ordered as an assembly. Figure 3-81: Gobo Interconnect PCB/Cable Assembly 02.96 78.001 0 G...
  • Page 202 ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Gobo Interconnect PCB/Cable Assembly (continued) Figure 3-82: Gobo Interconnect PCB/Cable Assembly 02.96 78.001 0 G...

  • Page 203: Yoke Fan Cable Assembly

    ABLE SSEMBLIES ABLE SSEMBLY Yoke Fan Cable Assembly 25.9678.0758 Rev A Refer to Figure 3-83 Item Qty. Description 52.6396.3102 RECEPT, 2 POS MTA100 W/POL TAB BLUE CLSD END (changed 05-02-06) 52.6423.0003 HOUSING, 3POS MT RECEPT, 2MM CT 28-26 AWG 73.5126.0002 0.50 WIRE, 26AWG 2COND 300V 80C <BLK-RED>...

  • Page 204: Yoke Fan Cable Assembly - Vl3000Q

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Yoke Fan Cable Assembly - VL3000Q 25.9678.0759 Rev A Refer to Figure 3-83 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...

  • Page 205: 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 3-85 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 206: Ac Input Splitter Cable Assembly

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL AC Input Splitter Cable Assembly 25.9678.0812 Rev E Refer to Figure 3-86 Item Qty. Description 52.6231.0001 PLUG HOUSING, MNLOK PLUG 3 POS 52.8231.0005 TERM, RING #6 BLUE 16-14 AWG REEL PIDG 52.8231.0008...
  • Page 207 : 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 3-86: AC Input Splitter Cable Assembly 02.96 78.001 0 G...

  • Page 208: Data I/O Link Cable Assembly

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Data I/O Link Cable Assembly 25.9678.0813 Rev A Refer to Figure 3-87 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...

  • Page 209: Display Cable Assembly

    ABLE SSEMBLIES ISPLAY ABLE SSEMBLY Display Cable Assembly 25.9678.1825 Rev C Refer to Figure 3-88 Item Qty. Description 52.6396.2406 RECEPT, 6 POS MTA100 W/POL TAB WHT CLSD END 73.5116.0123 1.02 WIRE, 24AWG 4COND TW <BLK-BRN-RED-ORN> 55.2186.0001 CABLE TIE, .10" WD 4" LG SMALL 73.7130.0004 0.958 WIRE, TUBULAR BRAID, 1/8"...

  • Page 210: Ballast To Controller Cable Assembly

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Ballast to Controller Cable Assembly 25.9678.0816 Rev A Refer to Figure 3-89 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...

  • Page 211: Dc Output Cable Assembly

    : DC O ABLE SSEMBLIES UTPUT ABLE SSEMBLY DC Output Cable Assembly 25.9678.0821 Rev E Refer to Figure 3-90 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 212: Pan/Tilt Control Cable Assembly

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Pan/Tilt Control Cable Assembly 25.9678.0818 Rev B Refer to Figure 3-91 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...

  • Page 213: 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 3-92 Item Qty. Description 52.8245.0001 TERM, RING #10 16 - 14 AWG REEL PIDG 52.8312.0001 RECP, FASTON 1/4" 18-14 AWG INSULATED VO 55.2183.0001 0.33 HEATSHRINK, 1/2"...

  • Page 214: Lvs To Yoke Ac Fan Cable Assembly

    ❋ VARI LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL LVS to Yoke AC Fan Cable Assembly 25.9678.0843 Rev A Refer to Figure 3-93 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...

  • Page 215: Appendix A. Technical Bulletins

    Technical Bulletins VL3000 & VL3000Q Technical Bulletins The following table identifies the current technical bulletins associated with the VL3000 series luminaires. These improvements have been incorporated into this manual (where applicable) and are available on the Vari-Lite web site at www.vari-lite.com. Please note that not all bulletins or notices are applicable to all versions of the fixtures included in this manual.
  • Page 216 VARI❋LITE® - VL3000™ & VL3000™Q S ERVICE ANUAL Notes 02.96 78.001 0 G...
  • Page 218 Vari-Lite 10911 Petal Street Dallas, Texas 75238 USA 1.877.VARI-LITE ❋ Fax 1.214.647.8038 www.vari-lite.com Date: 08 May 2009 / Manual Part Number: 02.9678.0010 G ©2003-2009 A Philips Group Company. All rights reserved. Printed in the U.S.A.

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