Vl3500™ Wash Luminaire - Vari-lite

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Manual VL3500™ Wash Luminaire Service 02.9686.0010 VARI❋LITE® is a trademark owned by 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™, Series 3000™, DICHRO❋TUNE™, VARI❋IMAGE™, VARI❋BRITE™, and the Vari-Lite Asterisk are also trademarks owned by Genlyte Thomas Group LLC. VARI❋LITE® products are protected by one or more of the following patents, and other pending patent applications worldwide: U. S. Patents No. 6,809,869; 6,796,682; 6,769,792; 6,578,987; 6,550,939; 6,282,027; 6,123,436; 6,113,252; 6,046,861; 6,031,749; 6,011,640; 5,969,868; 5,959,768; 5,934,794; 5,882,107; 5,829,868; 5,825,548; 5,798,619; 5,774,273; 5,769,527; 5,758,956; 5,728,994; 5,640,061; 5,590,954; 5,454,477; 5,432,691; 5,367,444; 5,329,431; 5,307,295; 5,282,121; 5,278,742; 5,209,560; 5,186,536; 5,073,847; 5,010,459; 4,980,806; 4,972,306; 4,800,474; 4,779,176; 4,701,833; 4,602,321; U. S. Design Patents No. 524,245; 457,678; 452,339; 451,890; 442,944; 439,356; 420,332; 417,300; 415,301; 414,888; 413,995; 377,338; 366,712; 359,574; 350,408; 347,113; Australia Patents No. 693,691; 683,695; 667,109; 649,264; 646,588; 586,095; 576,400; Australia Design Patents No. 128,796; 128,795; Canada Patents No. 2,070,670; 2,050,375; 1,270,675; 1,259,058; Canada Design Patents No. 81,234; 81,233; 76,046; European (UK) Patents No. 0 652 400; 0 586 049; 0 565 218; 0 547 732; 0 534 710; 0 495 305; 0 474 202; 0 379 970; 0 253 082; 0 253 081; 0 248 974; 0 192 882; Germany Patents No. 694 25 943.8; 693 14 122.0; 692 08 615.3; 692 07 692.1; 691 31 478.0; 691 21 029.2; 690 33 385.4; 37 89 166.9; 37 68 727.1; 37 51 804.6; 37 50 201.8; 35 87 270.5; Germany Design Patents No. M 98 01 745.4; M 96 04 515.9; M 96 04 514.0; M 94 07 689.8; M 94 02 951.2; M 499 03 583.6; M 498 11 203.9; G 93 12 884.3; Spain Patents No. 2 090 191; 2 084 289; 2 020 960; 0 548 328; Spain Utility Model Patent No. 2.031.748; Spain Design Patents No. 0.137.502; 0.137.501; 0.133.573; Greece Patent No. 910.400.544; Japan Patents No. 2,843,696; 2,059,669; 2,055,324; 2,002,168; 1,966,525; 1,889,481; 1,792,721; 1,770,241; Japan Design Patents No. 985,985-1; 985,985; 947,552; 945,436-1; 945,436; 1,106,089; 1,077,598; 1,072,598; 1,060,414; 1,002,123; Korea Patents No. 76,310; 42,639; 283,770; 181,180; Korea Design Patents No. 209,896; 209,895; Mexico Patent No. 180,148; Taiwan Patents No. 78,726; 66,975; 65,380; 28,275; United Kingdom Design Registrations No. 2082526; 2072562; 2056387; 2056386; 2042174; 2038212; 2033108; 2029499. All other brand or product names which may be mentioned in this manual are trademarks or registered trademarks of their respective companies or organizations. Vari-Lite A Genlyte Group Company 10911 Petal Street Dallas, Texas 75238 This manual is for informational use only and is subject to change without notice. Genlyte Group assumes no responsibility or liability for any claims resulting from errors or inaccuracies that may appear in this manual. Version as of: 07-Nov-2007 Part number: 02.9686.0010 0 VL3500™ Wash Luminaire Service Manual ©2003-2007 Genlyte Group LLC. All Rights Reserved. FOREWORD How To Obtain Warranty Service A copy of the Vari-Lite Limited Warranty was included in the shipping package for this VARI❋LITE® product. To obtain warranty service, please contact customer service at 1-877-VARI-LITE (1-877-827-4548), +1-214-647-7880, or [email protected] and request a Return Material Authorization (RMA) for warranty service. You will need to provide the model and serial number of the item being returned, a description of the problem or failure and the name of the registered user or organization. If available, you should have your sales invoice to establish the date of sale as the beginning of the warranty period. Once you obtain the RMA, pack the unit in a secure shipping container or in its original packing box. Fill out the RMA form included at the end of this manual and place in shipping container along with a copy of your invoice (if available). Write the RMA number legibly on or near the shipping address label and return the unit, freight prepaid to: Vari-Lite 10911 Petal Street Dallas, Texas 75238 USA Attention: Warranty Service As stated in the warranty, it is required that the shipment be insured and FOB our service center. Note: The Series 3500 Luminaires share many common assemblies and parts of the Vari-Lite Series 3000 Luminaires. 02.96 86.001 0 0 i VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Compliance Notice FCC 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. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with Vari-Lite system, service, and safety guidelines, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference, in which case the user will be required to correct the interference at his/her own expense. Declaration of Conformity We declare, under our sole responsibility, that this product complies with the relevant clauses of the following standards and harmonized documents: Safety EN 60598-1:2000 Luminaire Safety Standard, General Requirements EN 60598-2-17:1989 Specification for Luminaires for Stage and Studio Lighting EMC EN 61000-6-4:2001 Emission Standard for industrial environments EN 61000-6-2:2001 Immunity for industrial environments We certify that the product conforms to the protection requirements of council directives: 73/23/EEC (LVD) and 89/336/EEC (EMC) ii 0 2.9686 .0 010 0 FOREWORD 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. WARNING advising of potential injury or death to persons. GENERAL INFORMATION PERTAINING TO PROTECTION AGAINST ELECTRICAL SHOCK, FIRE, EXPOSURE TO EXCESSIVE UV RADIATION, AND INJURY TO PERSONS CAN BE FOUND BELOW. WARNING: INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST FIRE 1. VARI❋LITE® luminaires have been designed for use with specific lamp types. The VL3500™ Wash Luminaire requires the Osram SharXS® HTI® 1500 W/D7/60 . Installing another type of lamp may be hazardous. 2. Luminaires may be mounted on any type of surface as long as mounting instructions are followed. See instructions detailed in this manual. 3. Note distance requirement from combustible materials or illuminated objects for VARI❋LITE® luminaires. WARNING: INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST ELECTRICAL SHOCK 1. VARI❋LITE® luminaires are designed for dry locations only. Exposure to rain or moisture may damage luminaire. 2. Disconnect power before servicing any VARI❋LITE® equipment. 3. Servicing to be performed by qualified personnel only. 02.96 86.001 0 0 iii VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL 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. For example, by cracks or deep scratches. WARNING: INSTRUCTIONS FOR PROTECTION AGAINST INJURY TO PERSONS 1. Exterior surfaces of the luminaire will be hot during operation. Use appropriate safety equipment (gloves, eye protection, etc.) when handling and adjusting hot equipment and components. 2. Luminaires will have a hot lamp when operating. Disconnect power and allow lamp to cool before replacing. 3. Arc lamps emit ultraviolet radiation which can cause serious skin burn and eye inflammation. Additionally, arc lamps operate under high pressure at very high temperatures. Should the lamp break, there can exist a danger of personal injury and/or fire from broken lamp particles being discharged. 4. Wear eye protection when relamping. 5. Appropriate safety equipment (gloves, eye protection) should be used when handling damaged lamps. 6. If lamp is touched with bare hands, clean lamp with denatured alcohol and wipe with lint-free cloth before installing or powering up the luminaire. 7. The lamp shall be changed if it has become damaged or thermally deformed. WARNING: RF INTERFERENCE 1. This is a Class A product. In a domestic environment this product may cause radio interference, in which case, the user may be required to take adequate measures. ARC LAMP CHARACTERISTIC CONSIDERATIONS 1. Arc lamps require a period of time to relight after a power interruption or a severe voltage dip. In some cases, the lamp will automatically relight after it has cooled depending on Lamp Power-Up State configuration setting. 2. Burning position is universal. iv 0 2.9686 .0 010 0 FOREWORD 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. Folgende Sicherheitssymbole werden in diesem Handbuch verwendet: VORSICHT - weist auf möglichen Produktschaden hin. WARNUNG - weist auf mögliche Körperverletzung und Lebensbedrohung hin. NACHSTEHEND FINDEN SIE ALLGEMEINE HINWEISE ÜBER SICHERHEITSVORKEHRUNGEN GEGEN ELEKTROSCHOCK, FEUER, ÜBERHÖHTE UVSTRAHLUNG UND KÖRPERVERLETZUNGEN. WARNUNG: HINWEISE ZUM FEUERSCHUTZ 1. VARI❋LITE®-Scheinwerfer sind ausschließlich für den Einsatz mit bestimmten Lampentyps. Achten Sie auf den Lampentyp (Osram SharXS® HTI® 1500 W/D7/60 ), bevor Sie die jeweiligen Lampen ersetzen. Die Installation eines anderen Lampentyps kann gefährlich sein. 2. Scheinwerfer können auf jeder beliebigen Oberfläche montiert werden, solange Sie die Montageanweisungen befolgen. Detaillierte Hinweise finden Sie in diesem Handbuch. 3. Beachten Sie die Einhaltung des erforderlichen Sicherheitsabstandes der VARI❋LITE®Scheinwerfer von brennbarem Material oder beleuchteten Objekten. WARNUNG: HINWEISE ZUM SCHUTZ GEGEN ELEKTROSCHOCK 1. VARI❋LITE®-Scheinwerfer eignen sich ausschließlich für trockene Standorte. Regen oder Feuchtigkeit können die Scheinwerfer beschädigen. 2. Unterbrechen Sie die Stromzufuhr, bevor Sie mit der Arbeit an VARI❋LITE®-Geräten beginnen. 3. Die Geräte sollten nur von qualifiziertem Personal gewartet werden. 02.96 86.001 0 0 v VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL WARNUNG: HINWEISE ZUM SCHUTZ GEGEN ÜBERHÖHTE UV-STRAHLUNG 1. Viele VARI❋LITE®-Scheinwerfer verwenden die Lampentyp, der UV-Strahlen abgibt. SCHAUEN SIE NICHT direkt in die Lampe. 2. Es ist gefährlich, Leuchten ohne Linsen oder Blenden zu bedienen. Blenden, Linsen oder Ultraviolettschirme müssen ausgetauscht werden, sofern deren Schutzwirkung durch sichtbare Beschädigung (z. B. Sprünge oder Schrammen) eingeschränkt ist. WARNUNG: HINWEISE ZUM SCHUTZ GEGEN KÖRPERVERLETZUNGEN 1. Bei Betrieb sind die Außenflächen der Scheinwerfer heiß. Verwenden Sie bei der Bedienung von aufgeheizter Apparatur die jeweils geeignete Sicherheitsausrüstung (Handschuhe, Augenschutz etc.). 2. Bei Betrieb der Scheinwerfer ist die Lampe heiß. Unterbrechen Sie die Stromzufuhr und lassen Sie die Lampe abkühlen, wenn Sie diese austauschen. 3. Bogenlampen senden ultraviolette Strahlen aus, die Hautverbrennungen und Augenentzündungen verursachen können. Der Betrieb von Bogenlampen erfolgt unter Hochdruck und bei hohen Temperaturen. Sollte die Lampe zerbrechen, besteht die Gefahr von Körperverletzung bzw. von Feuer, das von Lampenteilen ausgelöst werden kann. 4. Tragen Sie beim Austausch der Lampen einen Augenschutz. 5. Die geeignete Sicherheitsausrüstung (Handschuhe, Augenschutz) sollte beim Umgang mit beschädigten Lampen verwendet werden. 6. Wenn die Lampe mit bloßen Händen berührt wird, reinigen Sie sie mit denaturiertem Alkohol und einem flusenfreien Tuch, bevor Sie die Scheinwerfer installieren oder in Betrieb nehmen. 7. Wenn die Lampe beschädigt oder durch Hitzeeinwirkung deformiert ist, muß diese ausgetauscht werden. WARNUNG: HF-INTERFERENZ 1. Es handelt sich um ein Produkt der Klasse A. In einer Wohnumgebung kann das Produkt Hochfrequenzstörungen verursachen. In diesem Fall müssen eventuell geeignete Maßnahmen getroffen werden. BESONDERHEITEN VON BOGENLAMPEN 1. Bogenlampen benötigen eine gewisse Zeitdauer, um nach einem Stromausfall oder einem Spannungsgefälle wieder aufzuleuchten. In einigen Fällen wird die Lampe nach Abkühlung automatisch wieder aufleuchten, je nach der Systemkonfigurationseinstellung des Lampeneinschaltungsstatus. 2. Die Brennposition ist Universal. vi 0 2.9686 .0 010 0 FOREWORD 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. Les symboles de sécurité utilisés dans ce guide sont les suivants : ATTENTION Ce symbole annonce que l’appareil risque d’être endommagé. AVERTISSEMENT Ce symbole annonce qu’il y a risque d’accident grave ou même fatal. CETTE SECTION CONTIENT DES INFORMATIONS GÉNÉRALES POUR SE PROTÉGER CONTRE LES DÉCHARGES ÉLECTRIQUES , LES INCENDIES, L’EXPOSITION EXCESSIVE AUX RAYONS UV ET TOUT AUTRE ACCIDENT POUVANT ENTRAÎNER DES BLESSURES. AVERTISSEMENT: DIRECTIVES POUR SE PROTÉGER CONTRE LES INCENDIES 1. Les luminaires VARI❋LITE® ont été conçus pour être utilisés uniquement avec certaines type de lampes. Vérifier le type de lampe (Osram SharXS® HTI® 1500 W/D7/60 ) avant de remplacer les lampes. L’installation d’un autre type de lampe peut poser un danger. 2. Les luminaires peuvent être fixés sur tout type de surface tant que les directives de montage sont respectées. Voir les explications détaillées dans ce guide. 3. Vérifier la distance à respecter entre les matériaux combustibles ou les objets illuminés et les luminaires VARI❋LITE®. AVERTISSEMENT: DIRECTIVES POUR SE PROTÉGER CONTRE LES DÉCHARGES ÉLECTRIQUES 1. Les luminaires VARI❋LITE® sont conçus pour une utilisation au sec uniquement. Une exposition à la pluie et à l’humidité risque d’endommager le luminaire. 2. Débrancher l’appareil avant de procéder à la révision de tout matériel VARI❋LITE®. 3. Les révisions doivent être effectuées uniquement par des personnes qualifiées. 02.96 86.001 0 0 vii VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL AVERTISSEMENT: DIRECTIVES POUR SE PROTÉGER CONTRE UNE EXPOSITION EXCESSIVE AUX RAYONS UV 1. Plusieurs luminaires VARI❋LITE® utilisent une lampe qui produit des rayons UV. NE PAS fixer son regard sur la lampe. 2. L’utilisation des luminaires sans lentille ou blindage pose des risques. Tous blindages, lentilles ou écrans ultraviolet visiblement endommagés au point que leur efficacité en est affectée doivent être remplacés, par exemple s’il y a des fissures ou de profondes rayures. AVERTISSEMENT: DIRECTIVES POUR SE PROTÉGER CONTRE LES ACCIDENTS POUVANT ENTRAÎNER DES BLESSURES 1. Les surfaces externes du luminaire deviennent brûlantes quand l’appareil est en marche. Pour manœuvrer ou ajuster des appareils brûlants et leurs composants, se protéger suffisamment (gants, protection pour les yeux, etc.). 2. La lampe du luminaire est brûlante lorqu’il est en marche. Débrancher le courant et attendre que la lampe ait refroidi avant de la remplacer. 3. Les lampes à arc émettent des rayons ultraviolets pouvant causer de graves brûlures sur la peau et une inflammation des yeux. De plus, les lampes à arc fonctionnent sous haute tension à de très hautes températures. Si la lampe se casse, les particules de la lampe cassée peuvent causer blessures et/ou incendie en s’éparpillant. 4. Se protéger les yeux pour remplacer la lampe. 5. Utiliser des appareils de protection appropriés (gants, protection des yeux) pour manier des lampes endommagées. 6. Si la lampe a été touchée avec des mains nues, la nettoyer avec de l’alcool dénaturé et l’essuyer avec un chiffon non-pelucheux avant d’installer ou de brancher le luminaire. 7. Si la lampe a été endommagée ou a reçu une déformation thermique, elle doit être remplacée. AVERTISSEMENT: INTERFÉRENCE RF 1. Cet appareil est de Classe A. Dans un environnement domestique, cet appareil peut causer des interférences radio, et si c’est le cas, l’utilisateur peut avoir à prendre des mesures adéquates. CONSIDÉRATIONS DES CARACTÉRISTIQUES DE LAMPES À ARC 1. Après une interruption de courant ou une baisse importante de voltage, les lampes à arc mettent du temps avant de se rallumer. Dans certains cas, la lampe se rallumera automatiquemet après s’être refroidie. Cela dépend de la manière dont le système est réglé pour le statut de mise en marche de la lampe. 2. La position Brûler est Universelle. viii 0 2.9686 .0 010 0 FOREWORD 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. ADVERTENCIA, indica posibles lesiones o muerte a las personas. LA INFORMACIÓN GENERAL RELACIONADA A LA PROTECCIÓN CONTRAGOLPES DE CORRIENTE ELÉCTRICA, INCENDIO, EXPOSICIÓN EXCESIVA A RADIACIÓN ULTRA VIOLETA Y LESIONES A LAS PERSONAS SE PUEDE ENCONTRAR SEGUIDAMENTE: ADVERTENCIA: INSTRUCCIONES PARA PROTECCIÓN CONTINUA CONTRA INCENDIO 1. Las luminarias VARI❋LITE® han sido diseñadas para ser usadas solamente con algunas lámparas. Tome nota del tipo de lámpara (Osram SharXS® HTI® 1500 W/D7/60 ) antes de reemplazarla. Instalación de otro tipo de lámpara puede ser peligroso. 2. Las luminarias se pueden instalar en cualquier tipo de superficie siempre que se sigan las instrucciones de instalación. Vea las instrucciones detalladas en este manual. 3. Tome nota de los requerimientos de distancia de materiales combustibles u objetos iluminados para las luminarias VARI❋LITE®. ADVERTENCIA: INSTRUCCIONES PARA PROTECCIÓN CONTINUA CONTRA CHOQUE ELÉCTRICO 1. Las luminarias VARI❋LITE® están diseñadas solamente para lugares secos. La exposición a la lluvia o humedad pueden dañar la luminaria. 2. Desconecte la energía antes de dar servicio a cualquier equipo de VARI❋LITE®. 3. El servicio debe ser realizado solamente por personal calificado. 02.96 86.001 0 0 ix VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL ADVERTENCIA: INSTRUCCIONES PARA PROTECCIÓN CONTINUA CONTRA LA EXPOSICIÓN EXCESIVA DE RADIACIÓN ULTRA VIOLETA 1. Muchas luminarias VARI❋LITE® usan un tipo de lámpara que produce radiación UV. NO mire directamente a la lámpara. 2. Es peligroso operar luminarias sin lentes o protectores. Debe cambiar los protectores, lentes o pantallas ultravioletas si se aprecia que han sido dañadas, y que su efectividad pudiera estar deteriorada. Por ejemplo, si tuvieran rajaduras o raspaduras profundas. ADVERTENCIA: INSTRUCCIONES PARA PROTECCIÓN CONTRA LESIONES DE PERSONAS 1. Las superficies exteriores de las luminarias están calientes durante su operación. Use un equipo de seguridad apropiado (guantes, protección para los ojos, etc.) cuando haga ajustes en el equipo y componentes que están calientes. 2. Cuando las luminarias están en operación la lámpara estará muy caliente. Desconecte la energía y deje que la lámpara se enfríe antes de reemplazarla. 3. Las lámparas de arco emiten radiaciones ultravioletas que pueden ocasionar serias quemaduras a la piel e inflamación a los ojos. Además, las lámparas de arco operan a alta presión y muy alta temperatura. Si la lámpara se rompe, puede existir el peligro de lesiones al personal o un incendio ocasionado por las partículas de la lámpara rota que se caen. 4. Use protección para los ojos cuando vuelve a colocar una lámpara nueva. 5. Use un equipo de seguridad apropiado (guantes, protección para los ojos, etc.) cuando trabaje con lámparas dañadas. 6. Si toca la lámpara con las manos, limpie la lámpara con alcohol desnaturalizado y con tela sin pelusas antes de instalar o volver a conectar la luminaria. 7. Cambie la lámpara si está dañada o deformada termicamente. ADVERTENCIA: INTERFERENCIA RF 1. Este es un producto de Clase A. En el ambiente de la casa este producto puede ocasionar radiointerferencia, en cuyo caso, el usuario debe tomar las medidas adecuadas. CONSIDERACIONES SOBRE LAS CARACTERÍSTICAS DE LA LÁMPARA DE ARCO 1. Las lámparas de arco requieren un período de tiempo para volver a iluminarse después de una interrupción de energía o de una severa caída de voltaje. En algunos casos, la lámpara se volverá a iluminar en forma automática después que se ha enfriado dependiendo de la configuración del sistema de energía de la lámpara. 2. La posición de encendido es universal. x 0 2.9686 .0 010 0 FOREWORD 02.96 86.001 0 0 xi VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL xii 0 2.9686 .0 010 0 TABLE OF CONTENTS Table of Contents Introduction About This Manual .................................................................................................................... 1 Additional Documentation......................................................................................................... 1 Customer Service....................................................................................................................... 2 Technical Bulletins and Notices ................................................................................................ 2 Chapter 1. Description Features Standard Features....................................................................................................................... 4 Specific Features........................................................................................................................ 4 Technical Specifications............................................................................................................ 4 Components External Luminaire Components............................................................................................... 5 VL3500 Wash Luminaire Head and Yoke Components ........................................................... 6 Enclosure Components .............................................................................................................. 7 Chapter 2. Maintenance Testing Luminaire Self-Tests ............................................................................................................... 10 Calibration Sequence ............................................................................................................... 10 Auto Recalibration................................................................................................................... 10 Partial Recalibration ................................................................................................................ 11 Sensor Testing ......................................................................................................................... 11 Warnings and Cautions Exceptional Safety Information for the VL3500 Wash........................................................... 13 Troubleshooting Error Messages ........................................................................................................................ 14 Troubleshooting Guide ............................................................................................................ 15 Maintenance Procedures Lamp Replacement .................................................................................................................. 17 Align Lamp.............................................................................................................................. 19 Internal Lens Replacement ...................................................................................................... 20 Internal Lens Replacement (continued)................................................................................... 21 Front Lens Assembly Removal ............................................................................................... 22 Front Lens Assembly Removal (continued) ............................................................................ 23 Color Filter Replacement......................................................................................................... 24 Color Filter Replacement (continued) ..................................................................................... 25 Ballast Assembly Replacement ............................................................................................... 26 Color/Dimmer/Strobe Assembly Replacement ....................................................................... 28 02.96 86.001 0 0 xiii VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Split Lens Assembly Replacement .......................................................................................... 30 Reflector Replacement............................................................................................................. 32 Main Control Board (MCB) Replacement .............................................................................. 34 Ignitor Board Replacement...................................................................................................... 35 Pan Motor Assembly Replacement ......................................................................................... 36 Pan Encoder Replacement ....................................................................................................... 38 Pan EOT Sensor Replacement................................................................................................. 40 Power Supply (LVS) Replacement.......................................................................................... 42 Tilt Motor Assembly Replacement.......................................................................................... 44 Tilt Encoder Replacement ....................................................................................................... 46 Tilt EOT Sensor Replacement ................................................................................................. 47 Chapter 3. Illustrated Parts Breakdown Drawing Trees VL3500™ Wash Luminaire .................................................................................................... 50 Top Assembly VL3500 Wash Included Items Kit........................................................................................... 52 VL3500™ Wash Luminaire ................................................................................................... 54 Generic Luminaire Assembly .................................................................................................. 56 Head Assembly Head Structure Assembly ........................................................................................................ 59 Front Stippled Lens Assembly................................................................................................. 60 Front Clear Lens Assembly ..................................................................................................... 61 Front Fresnel Lens Assembly .................................................................................................. 62 Head Cover Assembly ............................................................................................................. 63 Backend Assembly .................................................................................................................. 64 80mm Fan Assembly ............................................................................................................... 66 Dual Fan Duct Assembly......................................................................................................... 67 Reflector Mount Assembly...................................................................................................... 68 Hot Box Assembly................................................................................................................... 69 Dual Fan Tray Assembly ......................................................................................................... 71 Head Front Fan Assembly ....................................................................................................... 72 Internal Lens Assembly ........................................................................................................... 73 Internal Lens Rail Assembly ................................................................................................... 75 Internal Lens Splitter Assembly .............................................................................................. 77 Actuator Assembly .................................................................................................................. 79 Fresnel Internal Lenses ............................................................................................................ 80 Internal Lens Mounting Kit ..................................................................................................... 81 Color/Effect/Strobe Module ................................................................................................... 82 Fixed Color Wheel Assemblies ............................................................................................... 85 Strobe System Assembly ......................................................................................................... 87 Rear Strobe Blade Assembly ................................................................................................... 89 Front Strobe Blade Assembly.................................................................................................. 90 Yoke Assembly Yoke Assembly........................................................................................................................ 91 Tilt Motor Assembly................................................................................................................ 93 xiv 0 2.9686 .0 010 0 TABLE OF CONTENTS Relay Electrical Assembly....................................................................................................... 94 Yoke Fan Assembly................................................................................................................. 95 Head/Yoke PCB Assemblies Head Cable Interconnect.......................................................................................................... 97 Color Sensor PCB Offset Assembly........................................................................................ 98 Color Sensor PCB Inline Assembly ........................................................................................ 99 Solid State Ignitor PCB ......................................................................................................... 100 Wheel Position Sensor PCB Assembly ................................................................................. 101 Pan/Tilt Encoder PCB............................................................................................................ 102 VL3500 Wash Controller PCB Assembly............................................................................. 103 Enclosure Assembly Upper Enclosure Assembly ................................................................................................... 105 Ventilation Cover Assembly.................................................................................................. 111 Exhaust Fan Assembly .......................................................................................................... 113 Panel Assembly ..................................................................................................................... 114 DMX Input PCB .................................................................................................................... 115 Display PCB .......................................................................................................................... 116 Pan Pulley Assembly ............................................................................................................. 117 Pan Motor Assembly ............................................................................................................. 118 Pan Tube Assembly ............................................................................................................... 120 1500W Arc Ballast Module Assembly .................................................................................. 121 Cable Assemblies Pan EOT Sensor Electrical Assembly ................................................................................... 123 LVS Chassis Ground Cable Assembly .................................................................................. 124 Chassis To Yoke Ground Cable Assembly ........................................................................... 125 Ignitor to Relay Cable Assembly........................................................................................... 126 LVS to Yoke Dual AC Fan Cable Assembly ........................................................................ 127 Yoke to Dual AC Fan Cable Assembly................................................................................. 128 OT Switch 1 to OT Switch 2 Cable Assembly ...................................................................... 129 Backcap Interlok to OT Switch 1 Cable Assembly ............................................................... 130 OT Switch to Ground Cable Assembly ................................................................................. 131 Tilt Harness Cable Assembly ................................................................................................ 132 Internal Lens Interconnect Cable Assembly.......................................................................... 133 Color Harness Cable Assembly ............................................................................................. 134 Internal-Lens Split Motor Cable Assembly........................................................................... 135 Zoom Motor Cable ................................................................................................................ 136 Transfer Fans Cable Assembly.............................................................................................. 137 Upper Enclosure Fans Cable Assembly ................................................................................ 138 Yoke Fan and Relay Cable Assembly ................................................................................... 139 Yoke Fan Cable Assembly .................................................................................................... 140 OT Switch to Interlok Cable Assembly................................................................................. 141 OT Switch 1 to OT Switch 2 Cable Assembly ...................................................................... 142 Ignitor to Lamp Socket Cable Assembly............................................................................... 143 Chassis to Yoke Ground Cable Assembly............................................................................. 144 Zoom Motor Cable Assembly ............................................................................................... 145 AC Input Pigtail Cable Assembly.......................................................................................... 146 EMI Filter to Power Switch Cable Assembly........................................................................ 147 AC Input Splitter Cable Assembly ........................................................................................ 148 02.96 86.001 0 0 xv VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Data I/O Link Cable Assembly.............................................................................................. 150 Display Cable Assembly........................................................................................................ 151 Ballast to Controller Cable Assembly ................................................................................... 152 DC Output Cable Assembly .................................................................................................. 153 Pan/Tilt Control Cable Assembly.......................................................................................... 154 Lamp Supply to Relay Cable Assembly................................................................................ 155 Appendix A. Technical Bulletins VL3500™ Wash Luminaire Technical Bulletins .................................................................. 157 Appendix B. Schematics and Wiring Diagrams Schematics and Diagrams List............................................................................................... 159 VL3500 Wash Wiring Diagram (Sheet 1 of 3)...................................................................... 161 VL3500 Wash Wiring Diagram (Sheet 2 of 3)...................................................................... 162 VL3500 Wash Wiring Diagram (Sheet 3 of 3)...................................................................... 163 Solid State Ignitor PCB (Sheet 1 of 1)................................................................................... 164 DMX Input PCB (Sheet 1 of 1) ............................................................................................. 165 Color Sensor Offset PCB (Sheet 1 of 1)................................................................................ 166 Color Sensor Inline PCB (Sheet 1 of 1)................................................................................. 167 Pan/Tilt Encoder PCB (Sheet 1 of 1)..................................................................................... 168 VL3500 Controller PCB (Sheet 1 of 10) ............................................................................... 169 VL3500 Controller PCB (Sheet 2 of 10) ............................................................................... 170 VL3500 Controller PCB (Sheet 3 of 10) ............................................................................... 171 VL3500 Controller PCB (Sheet 4 of 10) ............................................................................... 172 VL3500 Controller PCB (Sheet 5 of 10) ............................................................................... 173 VL3500 Controller PCB (Sheet 6 of 10) ............................................................................... 174 VL3500 Controller PCB (Sheet 7 of 10) ............................................................................... 175 VL3500 Controller PCB (Sheet 8 of 10) ............................................................................... 176 VL3500 Controller PCB (Sheet 9 of 10) ............................................................................... 177 VL3500 Controller PCB (Sheet 10 of 10) ............................................................................. 178 Display PCB (Sheet 1 of 1) ................................................................................................... 179 xvi 0 2.9686 .0 010 0 INTRODUCTION : ABOUT THIS MANUAL Introduction About This Manual Note: The VL3500™ Wash Luminaires share many common assemblies and parts of the Vari-Lite Series 3000 Luminaires. This manual provides descriptions, repair procedures, and illustrated parts breakdowns for all configurations of the VL3500™ Wash Luminaire. The manual is intended for use by Vari-Lite personnel and by Vari-Lite’s customers/clients. 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. This manual covers the following models: Model Part Number Source VL3500™ Wash Luminaire 20.9686.0001 Arc Note: Performing maintenance procedures may void the product warranty. Refer to the Vari-Lite Limited Warranty card included in the product shipping package for more information. Additional Documentation For complete installation and operation instructions, refer to the VL3500™ Wash Luminaire User’s Manual. This manual is available in both printed and electronic (PDF) formats: • VL3500™ Wash Luminaire User’s Manual (02.9686.0001) • For more information regarding DMX512 systems, refer to the DMX512/1990 & AMX 192 Standards publication available from United States Institute for Theatre Technology, Inc. (USITT). USITT 6443 Ridings Road Syracuse, NY 13206-1111 USA 1-800-93USITT www.usitt.org 02.96 86.001 0 0 1 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Customer Service Our Goal At Vari-Lite, we are committed to providing you the highest quality in customer service. Our comprehensive resources are available to help your business succeed and ensure you get the full benefit of being a Vari-Lite customer. Whether your needs are telephone troubleshooting assistance, product training or technical service, our full-time staff of experienced professionals are on-hand to provide support. How to Reach Us For assistance in your area, call the dealer from which your product(s) was purchased. or Contact an Authorized Service Center. or Contact the Vari-Lite Customer Service Department, 9am - 6pm CST Monday through Friday, at the following: phone: 1-877-VARI-LITE (1-877-827-4548) email: [email protected] Additional Resources For additional resources and documentation, please visit our website at: www.vari-lite.com and follow the Support link. Technical Bulletins and Notices Technical bulletins concerning the latest changes to VARI❋LITE equipment are issued from the Dallas, Texas USA office. They are documentation supplements that contain procedures for equipment upgrades, retrofits, and repairs not found in the existing manuals. Operator technical bulletins are also issued to document changes in control software. Technical bulletins are integrated into the appropriate equipment manuals as those manuals are revised. Bulletins are categorized by assembly or subassembly, and identified by a number such as S3K-001 (VL3000 Series Luminaires Technical Bulletin number 1). Technical notices are also issued from the Dallas, Texas USA office. They are non-procedural documents that contain information regarding product support issues, current equipment problems, software bugs, and documentation corrections. All technical notices begin with the prefix TN and are numbered sequentially, such as TN-138 (Tech Notice number 138). 2 0 2.9686 .0 010 0 CHAPTER 1. Description This chapter contains descriptions of luminaire features and components. • Features • Components 02.96 86.001 0 0 3 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Features Standard Features All VL3000 series luminaire have the following standard features: • Three filter CYM color mixing system. • Variable CTO color correction. • Full field dimming system. • Dual blade strobe system. • Repositional pan/tilt system. • Control by DMX512 protocol. • Fan cooled. • UV/IR glass. • 1200W lamp source. Specific Features VL3500 Wash Luminaire • VARI❋BRITETM mode - produces a tight, intense column of light. • Zoomable beam optics mechanism for continuous beam size control with a 10° to 50° range, which depends on lens configuration. • Dual five-position (plus open) fixed color wheels. • Interchangeable lenses: Fresnel, Plano Convex Stippled, Plano Convex Clear. • 1500W, double-ended, short arc lamp. • Five-position aperture wheel: 52, 40, 35, 30, and 25 mm. WARNING: Some exceptional conditions apply to the safe operation of the VL3500™ Wash Luminaire. See “Warnings and Cautions” on page 13. Technical Specifications For technical specifications, refer to VL3500™ Wash Luminaire User’s Manual (02.9686.0001). 4 02 .9 686.00 10 0 1 COMPONENTS : EXTERNAL LUMINAIRE COMPONENTS Components External Luminaire Components The following illustration shows the external luminaire components and controls. Head Assembly Houses color, strobe, and beam spreader mechanisms Front Lens Assembly AC Input Cable Backcap Assembly Provides access to lamp for replacement and provides controls for beam adjustment. Input Panel Provides DMX In and Thru, and AC Power connections. (see detail below) Yoke Assembly Houses Master Control Board (MCB). Upper Enclosure Assembly Houses power supply, ballast, and display board. Beam Adjustment Controls Input Panel Components Menu Display Used to input manual commands, program, test, set defaults and access internal status information. Product Label ID Main Power Switch CAUTION: RISK OF FIRE. USE ONLY 1500 WATT, H TYPE 100V METAL HALIDE LAMP, SFc10-4 BASE. ATTENTION: RISQUE D'INCENDIE. UTILISER UNIQUEMENT UNE LAMP A HALOGENE EN METAL DE TYPE H, 1500 WATT, 100V ET UN SUPPORT SFc10-4. CAUTION: RISK OF EXPOSURE TO EXCESSIVE ULTRAVIOLET RADIATION. DO NOT OPERATE WITHOUT COMPLETE LAMP ENCLOSURE IN PLACE OR WHEN LENS IS DAMAGED. DISCONNECT FIXTURE BEFORE RELAMPING CAUTION: HOT LAMP LUMINAIRE MUST REMAIN POWERED ON FOR 5 MINUTES AFTER DOUSING LAMP. DO NOT OPEN FOR 5 MINUTES AFTER SWITCHING OFF. AC PWR ~ AC IN DATA IN X DATA THRU MENU ENTER AC Input Cable 02.96 86.001 0 0 Data In Data Thru Y Z 5 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL VL3500 Wash Luminaire Head and Yoke Components The following illustration shows the major sub-assemblies, which are located in the luminaire head and yoke assemblies. Color Assembly Contains fixed color wheel, dimmer mechanism, aperture wheel, strobe mechanism, color mixer and CTO color correction. Head Cover (attached by tether) Front Lens Assembly Head Fan Assemblies Optics Assembly Houses zoom lenses and Vari*Brite mechanism. Yoke Arm Cover Main Controller Board (MCB) Luminaire control circuit board. Yoke Arm Cover Backend Assembly Houses lamp. Provides knobs for lamp adjustment. Enclosure Assembly see page 7 6 02 .9 686.00 10 0 COMPONENTS : ENCLOSURE COMPONENTS 1 Enclosure Components The following illustration shows the major sub-assemblies, which are located in the luminaire enclosure assembly. (Yoke and head assemblies not shown for clarity.) Enclosure Top Covers 1500W Arc Ballast Module Fan Input Panel Assembly containing DMX Input PCB and Menu Display 150W +24V/6.3A Power Supply AC Input Cable Requires standard AC power distribution from 200-264 VAC, 50/60 Hz, 7 to 12 A depending on the AC supply voltage. Enclosure Bottom Ventilation Cover Wire* Connection Green/Yellow AC Ground Blue AC Neutral Brown AC Line * International (Harmonized) Standard 02.96 86.001 0 0 7 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Notes 8 02 .9 686.00 10 0 CHAPTER 2. Maintenance This chapter contains test, service, and standard maintenance procedures. • Testing • Warnings and Cautions • Troubleshooting • Maintenance Procedures WARNING: As with any repairs or maintenance to Vari-Lite luminaires, service should only be performed by a trained and qualified service technician or at an Authorized Vari-Lite Service facility. 02.96 86.001 0 0 9 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Testing Luminaire Self-Tests The luminaire is capable of running self tests by using the TEST menu functions. For detailed instructions regarding the luminaire’s self-test function, refer to the VL3500™ Wash Luminaire User’s Manual (02.9686.0001). Calibration Sequence The following is an outline of the luminaire’s standard calibration sequence: Phase 1 • Tilt • Strobe • Color Wheel 1 • Color Wheel 2 Phase 2 • Dimmer Phase 3 • Aperture Phase 4 • VARI❋BRITE • CTO • Amber • Magenta Phase 5 • Pan • Zoom • Cyan Auto Recalibration Most mechanisms with sensors will check their sensor when at a zero position, if the sensor is not detected within 3 seconds, the mechanism will recalibrate. This applies to all except pan and tilt, and zoom. Pan and tilt are corrected continuously if required by encoders fitted to the motor shaft. Note: Colors (CTO and CYM) only auto recalibrate when the dimmer has been closed for 3 seconds. 10 02 .9 686.00 10 0 TESTING : PARTIAL RECALIBRATION 2 Partial Recalibration It is possible to recalibrate sections of the luminaire from a console. This allows greater flexibility and speed by only forcing a recalibration on specific mechanisms. Partial recalibration values (on the control channel) are as follows: • Hold DMX value 102 for 3 seconds then 0 recals: Strobe, Color Wheel 1, Color Wheel 2, CYM, CTO, and Dimmer. • Hold DMX value 128 for 3 seconds then 0 recals: Zoom, Dimmer, Aperture, and Internal Lenses. • Hold DMX value 140 for 3 seconds then 0 recals Dimmer and Strobe . Sensor Testing Most mechanisms within the VL3500™ Wash Luminaire are equipped with either optical or magnetic sensors. The VL3500 Wash master control board (MCB) has labeled test points for reading DC voltages at each sensor. Testing is best performed with a digital voltmeter for sensor readings or an Oscilloscope for pan/tilt encoder readings. The values can be used to determine whether a circuit is opening correctly or needs further troubleshooting. Guidelines: • The values will change depending on whether the sensor reading is Open or Closed. • The values will be different depending on the type of sensor: optical or magnetic. • As a general rule, if a change occurs from 5v to 0v or visa versa, then it is working. • An Open reading occurs when the sensor is not aligned - tab not at sensor (typically a non-zero DMX value). • A Closed reading occurs when the sensor is aligned -tab in or at sensor (typically a zero DMX value). • Optical sensors read high when the sensor is Closed. • Magnetic sensors read Low when the sensor is Closed. • High value - 5 volts (typically 4.9 volts). • Low value - 0 volts, or up to approximately 0.2 volts. Notes regarding specific mechanisms: • The two fixed color wheels and four color mixers read high when the tab is in the optical sensor. • Pan and tilt sensors read high when the tab is in the sensor. The mechanism calibrates to the edge and its tab covers 50% of travel. Pan and tilt encoders are best read with a scope to read the encoder ticks. Notes regarding lamp control: • The douse command applies 5v to the out line. When the start command is given, this drops to 0v. This can be measured at the MCB at the ballast connection. The Out pin of the 5-pin connector should read 0v when the lamp is striking or On (Config>Lamp>Power>On). When the douse command is given (Config>Lamp>Power>Off), the reading should changed to 5v. Likewise, the 02.96 86.001 0 0 11 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL standby circuit goes to standby when 5v is received on the standby line. Equally, if 5v is applied to the standby line, the lamp will go into standby mode, and if 5v is applied to the Out line, the lamp will douse. 12 02 .9 686.00 10 0 WARNINGS AND CAUTIONS : EXCEPTIONAL SAFETY INFORMATION FOR THE VL3500 WASH 2 Warnings and Cautions Exceptional Safety Information for the VL3500 Wash The light intensity and power density of the VL3500™ Wash Luminaire exceeds other fixtures typically used in this application. The warnings and cautions that follow are critically important to the safe operation of the VL3500 Wash. This product is for commercial use only. If you have any questions about the safe installation and operation of the VL3500™ Wash Luminaire, please contact VARI❋LITE customer service at 1-877-VARI-LITE (1-877-827-4548), +1-214-647-7880, or [email protected]. WARNING: Light Beam Projects Intense Heat Do not illuminate objects within 3.5 m (11.5 feet) of the VL3500™ Wash Luminaire. Objects within this range can scorch, melt, or ignite from the heat projected by the light beam. WARNING: High Intensity Light Output Do not look directly into the light beam. Avoid looking at nearby surfaces illuminated by the beam. It is hazardous to operate luminaires without lens or shield. Shields, lenses, or ultraviolet screens must be changed if they have become visibly damaged to such an extent that their effectiveness is impaired. For example, by cracks, deep scratches, or coating breakdown. WARNING: Hot Exterior Surfaces The exterior surfaces of the luminaire can get very hot—up to 170ºC (338ºF). Do not touch any surface of the luminaire while it is operating. Keep all combustible materials a minimum of 200 mm (8 inches) away from the luminaire. To maintain cooling fan operation after the lamp is doused, keep the luminaire powered on for 5 minutes. Wait an additional 5 minutes before touching the luminaire. CAUTION: Operating Environment Do not operate the luminaire when the ambient temperature exceeds 40ºC (104ºF). Do not attempt to bypass thermostatic switches. WARNING: Approved Lamp Type One lamp is specified for safe use in the VL3500™ Wash Luminaire: Osram SharXS® HTI® 1500 W/D7/60 Installing any other type of lamp can be hazardous. 02.96 86.001 0 0 13 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Troubleshooting Error Messages If a problem occurs during luminaire calibration, at the end of the calibration sequence the Menu Display will cycle through any applicable error message(s), one at a time until the end of the list is reached. To review the error messages again, it will be necessary to access them using the Status function. (Refer to “Troubleshooting Guide” on page 15 for a list of possible causes and remedies associated with the error messages.) To access error messages: Step 1. Press [Menu]. Step 2. Press [Up] / [Down] arrows until Fixture appears. Press [Enter]. Step 3. Press [Up]/ [Down] arrows to access Status. Press [Enter]. (Display will now scroll through any error messages or display OK if no errors.) Table 2-1: Error Messages Display OK Pan/No Sens Message No Errors Found Pan sensor not found. Pan/Encoder/Fail Pan encoder failure. Tilt/No Sens Tilt sensor not found. Tilt/Encoder/Fail Tilt encoder failure. Dimmer/No Sens Dimmer sensor not found. Cyan/No Sens Yellow/No Sens Cyan sensor not found. Yellow sensor not found. Magenta/No Sens Magenta sensor not found. ColWheel/No Sens Color wheel sensor not found. ColWheel2/No Sens Color wheel sensor not found. CTO/No Sens Aperture/No Sens CTO sensor not found. Aperture sensor not found. WARNING: As with any repairs or maintenance to Vari-Lite luminaires, service should only be performed by a trained and qualified service technician or at an Authorized Vari-Lite Service facility. 14 02 .9 686.00 10 0 TROUBLESHOOTING : TROUBLESHOOTING GUIDE 2 Troubleshooting Guide If a problem is suspected, try recalibrating the luminaire to prompt an error message. Refer to “Error Messages” on page 14 for more information. The chart below provides possible causes and remedies for each message. Table 2-2: Troubleshooting Guide Message Symptom Description Possible Cause and Remedy n/a No response to DMX data DMX Failure MCB connector disconnected... n/a Lamp douses frequently Lamp Douse Fan failure... - check MCB DATA IN connection. - check fans for proper connection and operation. n/a Lamp will not strike Lamp Strike Failure Lamp cutout switch disengaged... - check lamp cutout switches at lamp box and fan ducts. Bad lamp... - replace lamp. Low input voltage... - check input power (must be 200 to 264 VAC) n/a Lamp does not strike upon start-up Lamp Off option is configured n/a Luminaire behaves oddly Profile Not Matched No Sens No control, continuous recalibration, and/or mechanism at wrong position Mechanism failed to find sensor (reported for Blue, Amber, Magenta, ColWheel1, ColWheel2, CTO, or Aperture) Reconfigure lamp startup option in Lamp config menu Profile not set correctly... - check start DMX address Motor power not connected... - connect motor power. Sensor not connected... - connect sensor. Interconnect board not connected securely... - check connection, inspect for bent pins. Movement restricted or impeded... - remove obstruction, check cable routing, and/or check voltage at MCB test point. n/a Luminaire does not power-up No power Switch not turned on... - verify switch is turned on. Not plugged in... - ensure A/C cable is connected to power source. Pan/ Encoder/ Fail Luminaire will not pan Pan Encoder Failure MCB pan/tilt connector disconnected... - connect MCB pan/tilt connector (J8). Pan motor disconnected - connect pan motor power. Encoder faulty... - replace pan end-of-travel/encoder sensor assembly. 02.96 86.001 0 0 15 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Table 2-2: Troubleshooting Guide (Continued) Message Pan No Sens Symptom Luminaire will not pan Description Pan Sensor Not Found Possible Cause and Remedy EOT flag attached to large pulley is not engaging the 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. Pan belt disconnected, extremely loose or not installed properly... - properly install belt between pan motor and large pulley. Tilt/ Encoder/ Fail Luminaire will not tilt Tilt Encoder Failure MCB pan/tilt connector disconnected... - connect MCB pan/tilt connector (J8). Tilt motor disconnected - connect tilt motor power. Encoder faulty... - replace tilt end-of-travel/encoder sensor assembly. Tilt No Sens Luminaire will not tilt Tilt Sensor Not Found EOT flag attached to large pulley is not engaging the 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. Tilt belt disconnected, extremely loose or not installed properly... - properly install belt between tilt motor and large pulley. n/a n/a n/a Color, dimmer or strobe mechanisms will not move Color, Dimmer, or Strobe Failure Zoom/Edge or beam spreader mechanisms will not move Zoom/Edge or Beam Spreader Failure Aperture mechanism will not move Aperture Failure MCB connector disconnected... - check MCB connector at J11. Check Interconnect board. MCB connector disconnected... - check MCB connector at J10. Check Interconnect board. MCB connector disconnected... - check MCB connector at J9. Check Interconnect board. n/a n/a 16 Self tests will not run or software download does not work. DMX Data Input Erratic control of luminaire DMX Termination Detecting DMX data... - disconnect DMX input cable. No DMX termination or termination not correct... - check DMX terminator. 02 .9 686.00 10 0 MAINTENANCE PROCEDURES : LAMP REPLACEMENT 2 Maintenance Procedures WARNING: As with any repairs or maintenance to Vari-Lite luminaires, service should only be performed by a trained and qualified service technician or at an Authorized Vari-Lite Service facility. Lamp Replacement VL Part No: 71.9686.1502 WARNING: Ensure that power is removed from luminaire when installing lamp. Always wear eye protection when opening lamp box and replacing lamps. CAUTION: Wear cotton gloves or other covering while installing lamp. Touching lamp glass with bare fingers will leave oil and may cause the lamp to explode or reduce lamp life. If touched, use alcohol and cotton cloth to thoroughly clean glass portion of lamp. To install lamp: Step 1. Remove power from luminaire. Step 2. At rear of luminaire head, loosen four 1/4-turn screws and slide hinged lamp box back and out. Step 3. Remove current lamp. Step 4. Position new lamp with dimple side toward lamp socket. Insert lamp in connector. Ensure lamp is fully seated in place. Step 5. Close lamp box and re-tighten 1/4-turn screws. Step 6. Align lamp for flat field after power up, as detailed in “Align Lamp” on page 19. 02.96 86.001 0 0 17 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Lamp (dimple side towards socket) CAUTION: Allow lamp to cool before servicing. CAUTION: Do not touch lamp or reflector with bare fingers. Lamp Connector Lamp Box * Luminaire Head Not Shown For Clarity Figure 2-1: Lamp Replacement 18 02 .9 686.00 10 0 MAINTENANCE PROCEDURES : ALIGN LAMP 2 Align Lamp The design of the VL3500 Wash luminaire optical system allows for a flat or peaked field. A flat field has no detectable hot spot. A peaked field has more intensity at the center of the beam than at the perimeter. After you install a new lamp, align the lamp to optimize the beam. Use the knobs on the luminaire backcap to make the adjustments. WARNING: Backcap and adjustment knobs are HOT during lamp operation. Wear gloves to prevent burns. To align lamp: Step 1. Strike lamp. Step 2. At Menu Display, select Test and then select Lamp. This setting facilitates lamp alignment by disabling the pan and tilt motors, opening the dimmer, and opening the internal lenses. Step 3. Position beam on a white wall at a distance of 12 to 20 feet. Step 4. At backcap, using X, Y and Z adjustment screws, adjust beam as required. CAUTION: RISK OF FIRE. USE ONLY 1500 WATT, H TYPE 100V METAL HALIDE LAMP, SFc10-4 BASE. ATTENTION: RISQUE D'INCENDIE. UTILISER UNIQUEMENT UNE LAMP A HALOGENE EN METAL DE TYPE H, 1500 WATT, 100V ET UN SUPPORT SFc10-4. CAUTION: RISK OF EXPOSURE TO EXCESSIVE ULTRAVIOLET RADIATION. DO NOT OPERATE WITHOUT COMPLETE LAMP ENCLOSURE IN PLACE OR WHEN LENS IS DAMAGED. Backcap X (Horizontal) DISCONNECT FIXTURE BEFORE RELAMPING CAUTION: HOT LAMP LUMINAIRE MUST REMAIN POWERED ON FOR 5 MINUTES AFTER DOUSING LAMP. DO NOT OPEN FOR 5 MINUTES AFTER SWITCHING OFF. Z (Focus) Y (Vertical) Figure 2-2: Lamp Alignment 02.96 86.001 0 0 19 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Internal Lens Replacement Tools: • #2 Phillips screwdriver • Lint-Free Cotton Gloves To replace the internal lens assembly: Step 1. Using a control console, close the internal lens assembly. Move internal lens assembly to front of head (close to the front lens) WARNING: Remove power from luminaire before performing maintenance. Internal fixture components and assemblies can be HOT after operation. Allow to adequately cool before replacing. Step 2. Remove power from luminaire. Step 3. As shown in Figure 2-3, remove the bottom head cover by loosening four 1/4-turn screws. CAUTION: Wear cotton gloves or other covering while replacing lenses. If required, clean any fingerprints or debris from the lenses with isopropyl alcohol and a soft cloth. Step 4. At the internal lens assembly, remove the two retaining knobs and the cross strap securing the lens. Step 5. Slide each section of lens assembly, straight up, and off the hinge rods. Step 6. Slide the replacement lens assemblies onto the hinge rods. CAUTION: As shown in Detail A in Figure 2-3, insure that each lens is aligned and inserted into the keyed carrier. Step 7. Secure lens assembly by replacing the cross strap and retaining knobs. Hand tighten only. Step 8. Replace head cover. Step 9. Apply power the luminaire and test the function of the internal lens assembly. 20 02 .9 686.00 10 0 MAINTENANCE PROCEDURES : INTERNAL LENS REPLACEMENT (CONTINUED) 2 Internal Lens Replacement (continued) Head Cover * CAUTION: Clean any fingerprints on lenses with isopropyl alcohol and a lint-free cloth. Retaining Knobs 1/4-Turn Screw Internal Lens Assembly Detail A Lens Assembly Retaining Knobs Post * Head covers are attached by tethers. Keyed Carrier Note: Some components not shown for clarity. Figure 2-3: Internal Lens Replacement 02.96 86.001 0 0 21 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Front Lens Assembly Removal Tools: • 5/32" Allen wrench • lint-free cotton gloves To replace the front lens assembly: WARNING: Remove power from luminaire before performing maintenance. Internal fixture components, assemblies, and the front lens can be HOT after operation. Allow components to adequately cool before replacing. Step 1. Remove power from luminaire. CAUTION: The luminaire head is a precisely balanced unit. The weight of the front lens assembly is counter-balanced inside the head. Removal of the front lens assembly can result in instantaneous uncontrolled head movement. To avoid uncontrolled movement when the luminaire is sitting on upper enclosure, point the head straight up. To avoid uncontrolled movement when the luminaire is hanging, point the head up at an angle until it rests against the tilt stops as shown here. Step 2. As shown in Figure 2-4, remove front lens assembly by loosening the four captive 10-32 Allen head cap screws. CAUTION: Wear cotton gloves or other covering while handling the front lens assembly. Clean any fingerprints or debris from lenses with isopropyl alcohol and soft cloth if required. Step 3. Carefully position replacement front lens assembly so captive screws align with guide pins and mounting holes as illustrated in Figure 2-4. Step 4. Tighten each captive screw to secure the front lens assembly to luminaire head. Step 5. The luminaire is ready for operation. 22 02 .9 686.00 10 0 MAINTENANCE PROCEDURES : FRONT LENS ASSEMBLY REMOVAL (CONTINUED) 2 Front Lens Assembly Removal (continued) CAUTION: Clean any fingerprints on lenses with isopropyl alcohol and a lint-free cloth. Front Lens Assembly Mounting Holes Front Lens Assembly Guide Pins Front Lens Assembly Captive Screws CAUTION Lens is heavy. Horizontal orientation shown for clarity. If lens is removed as shown, head assembly will instantaneously rotate to face upwards. See Caution on page 22. Figure 2-4: Front Lens Assembly Removal 02.96 86.001 0 0 23 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Color Filter Replacement Tools: • #2 Philips screwdriver • lint-free cotton gloves WARNING: Remove power from luminaire before performing maintenance. Filters can be HOT after operation. Allow the fixture to cool before replacing filters. To replace a color filter on Color Wheel 1: Step 1. Remove power from luminaire. Step 2. Remove bottom head cover by loosening the four 1/4-turn screws. Step 3. As shown in Figure 2-5, open door on the cooling-air duct. CAUTION: Do not touch filters with bare fingers. Wear cotton gloves or other covering while replacing filters. To clean filters, use glass cleaner and soft cloth. Step 4. Rotate Color Wheel 1 until the filter you are changing is accessible. Step 5. To improve access to the filter, rotate the mixed color wheels to position the cut-outs next to the filter you are changing. Step 6. Gently press the color filter toward the lamp until it is free of the lock pins. Remove the filter from the wheel. Step 7. Slide the new filter (orientation does not matter) under the spring clip until it is securely retained by the lock pins. Step 8. Close the air-duct door. Replace the head cover. To replace a color filter on Color Wheel 2: Step 1. Remove power from luminaire. Step 2. Remove top head cover by loosening the four 1/4-turn screws. CAUTION: Do not touch filters with bare fingers. Wear cotton gloves or other covering while replacing filters. To clean filters, use glass cleaner and soft cloth. Step 3. Rotate Color Wheel 2 until the filter you are changing is accessible. Step 4. To improve access to the filter, rotate the mixed color wheels to position the cut-outs next to the filter you are changing. Step 5. As shown in Figure 2-5, gently press the color filter toward the lens until it is free of the lock pins. Remove the filter. Step 6. Slide the new filter (orientation does not matter) under the spring clip until it is securely retained by the lock pins. Step 7. Replace the head cover. 24 02 .9 686.00 10 0 MAINTENANCE PROCEDURES : COLOR FILTER REPLACEMENT (CONTINUED) 2 Color Filter Replacement (continued) Assembly With Color Wheels (Do not remove. See detail) CAUTION: Do not touch filters with bare fingers. Wear cotton gloves. Color Filter 3 1 2 Lock Pins Air Duct Door Color Wheel 1 Color Filter 2 Lock Pins 1 Color Wheel 2 Figure 2-5: Replacing a Color Filter 02.96 86.001 0 0 25 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Ballast Assembly Replacement VL Part No: 23.9686.1500 Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Place the luminaire on the upper enclosure. Step 2. As shown in Figure 2-6, at the upper enclosure, remove four 6-32 x 1/4" screws and remove both top covers. Step 3. In each top corner, remove four 6-32 x 3/8" screws. CAUTION: During the next step, do allow the front lens to contact anything that could damage the lens coating. Step 4. Set the luminaire on the front lens casting to access the ventilation cover. Step 5. At bottom of the enclosure, remove four 1/4-20 x 1 5/8" socket screws and 1/4" split lock washers. Remove the ventilation cover. Step 6. Remove both handles by removing two 10-32 x 5/8" screws for each handle. Step 7. At bottom of the enclosure, remove four 6-32 x 1/4" screws and remove both side covers. Step 8. Remove two 6-32 x 3/8" screws, the APS end bracket, and the end cover from ballast side. Step 9. At bottom of the enclosure, disconnect the exhaust fan cable. Step 10. At the exhaust fan, remove four 8/32 x 3/8" screws. Remove the exhaust fan. Step 11. At the ballast, disconnect the following cable assemblies: a. AC input at the wiring connector (attached ferrite remains with the ballast) b. lamp wires c. control wiring Step 12. Hold the ballast assembly to prevent it from falling. At bottom of enclosure, remove three 832 x 3/8" flat-head screws and four 8/32 x 3/8" philister-head screws, which secure the ballast assembly to the enclosure. Step 13. Carefully remove the ballast from the enclosure to avoid damage to cable assemblies. 26 02 .9 686.00 10 0 MAINTENANCE PROCEDURES : BALLAST ASSEMBLY REPLACEMENT 2 Top Cover NOTE: Head not shown for clarity. Ballast Assembly (includes attached ferrite) Chassis ferrite (Do not remove) End Cover APS end bracket Exhaust fan Left Side Cover Ventilation Cover Figure 2-6: Ballast Assembly Replacement Step 14. Follow Steps 2-13 in reverse order to install the replacement ballast. When reinstalling ventilation cover, be sure standoffs are seated flush to chassis. 02.96 86.001 0 0 27 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Color/Dimmer/Strobe Assembly Replacement VL Part No: 21.9686.0400 Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. As shown in Figure 2-7, stand the luminaire on the upper enclosure. Use the orientation of the backcap label to determine the top and bottom of luminaire head. WARNING: Before performing this modification, remove all power sources from the luminaire. Step 2. Loosen the four quarter-turn fasteners and remove the top head cover. Likewise, remove the bottom head cover. Step 3. Tilt the luminaire so the top of the backcap faces upward and front lens points downward. The Head-cable Interconnect must be facing up and the fans facing down. CAUTION: Be careful not to damage wiring during the next step. Step 4. Note the location of the wire ties on the head cable assembly. Carefully cut the two wire ties that hold head cable assembly together. Cut the two wire ties that attach the head cable assembly to the Color/Effect/Strobe module. Step 5. At the Head Cable Interconnect, disconnect the head cables from both sides of the headers (4 cables). Disconnect the fan cable connector. Step 6. At the yoke on the MCB side, remove four 6-32 x 5/16" PPB screws and remove the yoke cover. Carefully pass the cable assemblies you disconnected in Step 5 back through the tilt tube. Step 7. As shown in Figure 2-7, remove the four 6-32 x 3/8" PPZ SEMS screws that hold the Color/ Effect/Strobe module to the two attachment points on each side rail. CAUTION: Be careful not to damage the wires or the module during the next step. Step 8. To clear the opening between the attachment points on the right side rail, lift the Color/ Effect/Strobe module up and tilt it slightly toward the rear to enable the two motors on the bottom of the module to pass through the openings between the attachment points. Step 9. Replace color/dimmer/strobe assembly in reverse order. 28 02 .9 686.00 10 0 MAINTENANCE PROCEDURES : COLOR/DIMMER/STROBE ASSEMBLY REPLACEMENT Screws 2 Top Head Cover Color/Dimmer/Strobe Assembly Figure 2-7: Color/Dimmer/Strobe Assembly Replacement 02.96 86.001 0 0 29 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Internal Lens Assembly Replacement VL Part No: 21.9686.2150 Repair Procedure Step 1. At the control console or the luminaire menu, close the split lens assembly. Step 2. Disconnect luminaire AC input cable from power source. Step 3. Remove the Color/Dimmer/Strobe Assembly. See “Color/Dimmer/Strobe Assembly Replacement” on page 28 for complete instructions. Step 4. At the interconnect board, disconnect the zoom motor and split lens motor connectors. Step 5. As shown in Figure 2-8, remove the two 6-32 x 3/8" PPZ SEMS screws and remove the interconnect board. Step 6. Remove one 6-32 x 3/8" PPZ SEMS screw and remove the #8 cable saddle. Step 7. Remove the three 6-32 x 3/8" PPB screws. Step 8. Remove the split lens assembly. Step 9. Replace the split lens assembly in reverse order. 30 02 .9 686.00 10 0 MAINTENANCE PROCEDURES : INTERNAL LENS ASSEMBLY REPLACEMENT 2 Interconnect Board Cable Saddle Internal Lens Assembly Figure 2-8: Internal Lens Assembly Replacement 02.96 86.001 0 0 31 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Reflector Replacement VL Part No: 42.9686.0120 Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Step 2. Remove the Color/Dimmer/Strobe Assembly. See “Color/Dimmer/Strobe Assembly Replacement” on page 28 for complete instructions. Step 3. As shown in Figure 2-9, remove four 4-40 x 1 3/8" PPZ screws. Step 4. Carefully remove the UV/Reflector assembly. Step 5. Remove the springs from the reflector clamp and remove the reflector. Step 6. Replace the reflector and UV/Reflector assembly in reverse order. Make sure the mark on the reflector lines up with the mark on the top-left reflector support; see the illustration in Figure 2-9. 32 02 .9 686.00 10 0 MAINTENANCE PROCEDURES : REFLECTOR REPLACEMENT 2 Disconnect Springs Reflector Clamp UV/Reflector Assembly 4-40 x 1 3/8" screws (4) Assembly Removal Spring not shown for clarity Reflector Alignment Figure 2-9: Reflector Replacement 02.96 86.001 0 0 33 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Main Control Board (MCB) Replacement VL Part No: 24.9686.0429 Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Note: To determine which yoke leg is which without having to remove the covers, rotate yoke counterclockwise until it stops, then look at the luminaire while facing the input panel. The tilt-side leg is the leg to the left; the board-side leg is the leg to the right. Step 2. At board-side leg, remove yoke leg cover by removing four 6-32 x 5/16" screws. ESD CAUTION: Always use anti-static precautions when working with PCBs. Step 3. Disconnect wiring harness connectors J8, J9, J10 and J11. Step 4. Remove four (4) 6-32 screws securing MCB PCB 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 (MCB) Figure 2-10: Main Controller Board (MCB) Replacement 34 02 .9 686.00 10 0 MAINTENANCE PROCEDURES : IGNITOR BOARD REPLACEMENT 2 Ignitor Board Replacement VL Part No: 24.9661.3126 Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Step 2. At tilt-side leg, remove yoke leg cover by removing four 6-32 x 5/16" screws. ESD CAUTION: Always use anti-static precautions when working with PCBs. Step 3. Disconnect ignitor PCB wires by removing four screws that secure wire ring terminals to PCB and remove ignitor PCB. Step 4. Remove four 6-32 x 3/8" screws and remove ignitor PCB. Step 5. Replace by performing steps 2 through 4 in reverse. Note: Make sure and orient ignitor properly (as shown in Figure 2-11). Mounting Plate Ignitor Board Remove Ignitor Board Mounting Screws Figure 2-11: Ignitor Board Replacement 02.96 86.001 0 0 35 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Pan Motor Assembly Replacement VL Part No: 21.9686.0864 Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Place the luminaire on the upper enclosure. Step 2. As shown in Figure 2-6, at the upper enclosure, remove four 6-32 x 1/4" screws and remove both top covers. Step 3. In the corners on the pan-motor side, remove two 6-32 x 3/8" screws. CAUTION: During the next step, do allow the front lens to contact anything that could damage the lens coating. Step 4. To provide access to the ventilation cover, set the luminaire on the front lens casting. Position the head so the pan-pulley sensor tab is inside the optical sensor. Step 5. At bottom of the enclosure, remove four 1/4-20 x 1/2" socket screws and 1/4" split lock washers. Remove the ventilation cover. Step 6. Remove the handle on the pan-motor side by removing two 10-32 x 5/8" PPB screws. Step 7. At the enclosure bottom, remove two 6-32 x 1/4" PPB screws and the pan-motor side cover. Step 8. At the side of the enclosure, remove two 6-32 x 3/8" PFZ screws and two 6-32 KEPS nuts that hold two cable saddles. Pull the cables out of way of the pan motor. Step 9. Disconnect the wiring from the pan-encoder PCB. Step 10. At the encoder PCB, remove two 4-40 z 1/4" screws and remove the PCB. Step 11. As shown in Figure 2-12, loosen (but do not remove) four 10-32 x 3/4" SCB cap screws. Step 12. Move pan motor assembly toward pan pulley and remove the belt from the pan pulley. Step 13. Carefully remove the belt from around the code wheel and pass it through the tension rollers. Step 14. Remove the four 10-32 x 3/4" SCB Cap screws loosened in Step 11. Step 15. Pull motor assembly out of the enclosure. Remove the tension springs from the enclosure. Step 16. Disconnect the motor wiring. Step 17. Replace by performing steps 2 through 16 in reverse order. 36 02 .9 686.00 10 0 MAINTENANCE PROCEDURES : PAN MOTOR ASSEMBLY REPLACEMENT 2 Note: Make sure wiring is not pinched during installation. When tightening four 10-32x3/4" SCB Cap screws that mount Pan Motor Assembly, you must tighten in a CLOCKWISE pattern starting with screw in lower left-hand side from spring. NOTE: Head not shown for clarity. Ventilation Cover Pan Motor Assembly Encoder Wheel Tensioning spring Tensioning spring Belt Figure 2-12: Pan Motor Assembly Replacement 02.96 86.001 0 0 37 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Pan Encoder Replacement VL Part No: 24.9678.9729 Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Place the luminaire on the upper enclosure. CAUTION: During the next step, do allow the front lens to contact anything that could damage the lens coating. Step 2. To provide access to the ventilation cover, set the luminaire on the front lens casting. Step 3. At bottom of the enclosure, remove four 1/4-20 x 1/2" socket screws and 1/4" split lock washers. Remove the ventilation cover. Step 4. As shown in Figure 2-13, at encoder board, remove two 4-40 x 1/4" PPZ screws. Step 5. Disconnect wiring from encoder board. Step 6. Replace by performing steps 2 through 5 in reverse order. 38 02 .9 686.00 10 0 MAINTENANCE PROCEDURES : PAN ENCODER REPLACEMENT 2 Note: Make sure the encoder disk is centered in the optical sensor gap. Ventilation Cover Encoder Pan Motor Assembly Figure 2-13: Pan Encoder Replacement 02.96 86.001 0 0 39 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Pan EOT Sensor Replacement VL Part No: 23.9678.0687 Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Place the luminaire on the upper enclosure. CAUTION: During the next step, do allow the front lens to contact anything that could damage the lens coating. Step 2. To provide access to the ventilation cover, set the luminaire on the front lens casting. Step 3. At bottom of the enclosure, remove four 1/4-20 x 1/2" socket screws and 1/4" split lock washers. Remove the ventilation cover. Step 4. As shown in Figure 2-14, at the pan sensor, remove two 6-32 x 3/8" PPZ screws. Step 5. Disconnect wiring from the encoder PCB and remove the sensor. Step 6. Replace sensor by performing steps 3 through 5 in reverse order. 40 02 .9 686.00 10 0 MAINTENANCE PROCEDURES : PAN EOT SENSOR REPLACEMENT 2 Ventilation Cover Sensor Figure 2-14: Pan EOT Sensor Replacement 02.96 86.001 0 0 41 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Power Supply (LVS) Replacement VL Part No: 69.3177.0151 Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Step 2. As shown in Figure 2-15, at the enclosure, remove two 6-32 x 1/4" LG PPZ screws from the display-side top cover and remove the cover. Step 3. At power supply, disconnect wiring: Location Connector N White AC Wires L Black AC Wires V+ Red DC Wires V- Black DC Wires Step 4. Remove one 6-32 x 3/8" LG PPZ screw at the wiring end of the LVS. Step 5. Loosen two 6-32 x 3/8" LG PPZ screws and slide the LVS towards upper enclosure fan to remove it. Step 6. Replace by performing steps 2 through 5 in reverse order. 42 02 .9 686.00 10 0 MAINTENANCE PROCEDURES : POWER SUPPLY (LVS) REPLACEMENT 2 Display-Side Top Cover Power Supply (LVS) NOTE: Head not shown for clarity. Fan Assembly Figure 2-15: Power Supply (LVS) Replacement 02.96 86.001 0 0 43 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Tilt Motor Assembly Replacement VL Part No: 21.9678.0765 Repair Procedure To remove and replace the tilt motor assembly: Step 1. Disconnect luminaire AC input cable from power source. Step 2. As shown in Figure 2-16, at the tilt-side leg, remove yoke leg cover by removing four 6-32 x 5/16" PPB screws. Step 3. At tilt motor assembly, loosen four 10-32 x 1/2" PPZ screws. Step 4. Remove belt from tilt pulley. Step 5. Remove four 10-32 x 1/2" PPZ screws. Remove tensioning springs. Step 6. Disconnect wiring and remove the tilt motor assembly. Step 7. Replace by performing steps 2 through 6 in reverse order. Note: Make sure wiring is not pinched during installation. When tightening four 10-32 x 1/2" PPZ screws that fasten the tilt motor assembly, you must tighten then in a CLOCKWISE pattern starting with the screw in lower left-hand side. To remove and replace the tilt motor belt: Step 1 Disconnect luminaire AC input cable from power source. Step 2. As shown in Figure 2-16, at the tilt-side leg, remove yoke leg cover by removing four 6-32 x 5/16" PPB screws. Step 3. At tilt motor assembly, loosen four 10-32 x 1/2" PPZ screws. Step 4. Remove belt from tilt pulley. Step 5. Remove four 10-32 x 1/2" PPZ screws. Be mindful of tensioning springs. Step 6. Disconnect the following wiring and remove tilt assembly: a. Disconnect lamp wire from ignitor. b. Remove ignitor assembly mounting bracket (leave ignitor attached to bracket) by removing three 6-32 x 3/8" PPZ screws and 1/4" standoff. c. Disconnect ground wire from stud using 3/8" nut driver. d. At interconnect, disconnect 80mm fan wiring. Step 7. Remove belt. Step 8. Replace by performing steps 2 through 7 in reverse order. - See next page for further instructions - 44 02 .9 686.00 10 0 MAINTENANCE PROCEDURES : TILT MOTOR ASSEMBLY REPLACEMENT 2 WARNING: Make sure wiring is not pinched during installation. When tightening four 10-32 x 1/2" PPZ screws that fasten the tilt motor assembly, you must tighten then in a CLOCKWISE pattern starting with the screw in lower left-hand side. Yoke Cover Tilt Motor Assembly Springs Tilt Belt Figure 2-16: Tilt Motor Assembly Replacement 02.96 86.001 0 0 45 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Tilt Encoder Replacement VL Part No: 24.9661.9629 Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Step 2. As shown in Figure 2-16, at the tilt-side leg, remove yoke leg cover by removing four 6-32 x 5/16" PPB screws. Step 3. At tilt motor assembly, loosen four 10-32 x 1/2" PPZ screws. Step 4. Remove belt from tilt pulley. Step 5. Remove four 10-32 x 1/2" PPZ screws. Remove tensioning springs. Step 6. Disconnect wiring and remove the tilt motor assembly. Step 7. As shown in Figure 2-17, at the tilt assembly, remove two 4-40 x 1/4" LG PPZ screws and remove encoder PCB. Step 8. Replace by performing steps 2 through 7 in reverse order. Note: Make sure encoder disk passes through sensor when installing encoder PCB. Do not pinch wiring during installation. When tightening four 10-32 x 1/2" PPZ screws that fasten the tilt motor assembly, you must tighten then in a CLOCKWISE pattern starting with the screw in lower left-hand side. 1) 2) Tilt Encoder Tilt Motor Assembly Springs Yoke Cover Tilt Motor Assembly Detail Figure 2-17: Tilt Encoder Replacement 46 02 .9 686.00 10 0 MAINTENANCE PROCEDURES : TILT EOT SENSOR REPLACEMENT 2 Tilt EOT Sensor Replacement VL Part No: 23.9661.1253 Repair Procedure Step 1. Disconnect luminaire AC input cable from power source. Step 2. At tilt-side leg, remove yoke leg cover by removing four 6-32 x 5/16" PPB screws. Step 3. As shown in Figure 2-18, at the sensor bracket, remove two 10-32 x 1/2" PPZ screws and remove bracket. Step 4. Disconnect wiring from tilt encoder board. Step 5. At sensor, remove two 6-32 x 3/8" PPZ screws and remove sensor from bracket. Step 6. Replace by performing steps 2 through 5 in reverse order. Sensor Sensor Bracket Figure 2-18: Tilt EOT Sensor Replacement 02.96 86.001 0 0 47 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Notes 48 02 .9 686.00 10 0 CHAPTER 3. Illustrated Parts Breakdown This chapter contains illustrated parts breakdowns for the VL3500 Wash assemblies. Note: The VL3500 Series Luminiares share many common assemblies and parts of the Vari-Lite Series 3000 Luminaires. • Drawing Trees • Top Assembly • Yoke Assembly • Head/Yoke PCB Assemblies • Enclosure Assembly • Cable Assemblies 02.96 86.001 0 0 49 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Drawing Trees VL3500™ Wash Luminaire VL3500™ Wash Luminaire 20.9686.0001 Generic Luminaire Assembly 21.9686.0010 Head Structure Assembly 21.9686.0600 Front Stippled Lens Assembly 21.9686.0617 Dual Fan Tray Assembly 21.9686.0660 Upper Enclosure Fans Cable Assembly 25.9686.0210 Head Cable Interconnect 21.9686.1121 VL3500 Wash Controller PCB Assembly 24.9686.0429 Head Cover Assembly 21.9686.0611 VL3500 Wash Included Items Kit 28.9686.0001 Color/Effect/Strobe Module 21.9686.0400 Transfer Fans Cable Assembly 25.9686.0209 Internal Lens Assembly 21.9686.2150 continued next page Fixed Color Wheel Assemblies 21.9686.0480 21.9686.0484 Reflector Mount Assembly 21.9686.0605 Color Sensor PCB Offset Assembly 24.9686.0427 Backend Assembly 21.9686.0615 Yoke Assembly 21.9686.0700 Dual Fan Duct Assembly 22.9686.0674 Tilt Motor Assembly 21.9678.0765 Relay Electrical Assembly 23.9650.3327 Yoke Fan Cable Assembly 25.9678.0758 Yoke Fan Assembly 22.9661.0609 Hot Box Assembly 21.9686.0680 80mm Fan Assembly 21.9686.6619 OT Switch to Interlok Cable Assembly 25.9686.0201 Solid State Ignitor PCB 24.9661.3126 OT Switch 1 to OT Switch 2 Cable Assembly 25.9686.0013 Yoke Fan and Relay Cable Assembly 25.9678.0681 Ignitor to Relay Cable Assembly 25.9661.1526 Ignitor to Relay Cable Assembly 25.9661.1526 Yoke to Dual AC Fan Cable Assembly 25.9686.0012 Color Sensor PCB Inline Assembly 24.9686.0428 Strobe System Assembly 21.9686.0404 Color Harness Cable Assembly 25.9686.0205 Upper Enclosure Assembly 21.9686.0800 continued next page Figure 3-1: VL3500™ Wash Luminaire Subassembly Drawing Tree Part 1 50 02 .9 686.00 10 0 DRAWING TREES : VL3500™ WASH LUMINAIRE 3 VL3500™ Wash Luminaire (continued) continued from previous page continued from previous page Internal Lens Assembly 21.9686.2150 Internal Lens Rail Assembly 21.9686.2140 Actuator Assembly 21.9686.2142 Internal Lens Splitter Assembly 21.9686.2144 Fresnel Internal Lenses 21.9686.0620 Upper Enclosure Assembly 21.9686.0800 Panel Assembly 21.9686.0805 DMX Input PCB 24.9663.3895 Display PCB 24.9678.3825 Pan Pulley Assembly 21.9686.0807 Pan Motor Assembly 21.9686.0864 Chassis To Yoke Ground Cable Assembly 25.9661.1520 EMI Filter to Power Switch Cable Assembly 25.9678.0811 AC Input Pigtail Cable Assembly 25.9678.0810 Data I/O Link Cable Assembly 25.9678.0813 Pan Tube Assembly 21.9678.0881 Display Cable Assembly 25.9678.1825 1500W Arc Ballast Module Assembly 23.9686.1500 Exhaust Fan Assembly 21.9686.0811 Ballast to Controller Cable Assembly 25.9678.0816 Ventilation Cover Assembly 21.9686.0840.02 DC Output Cable Assembly 25.9678.0821 LVS Chassis Ground Cable Assembly 25.9661.1514 Pan/Tilt Control Cable Assembly 25.9678.0818 LVS Power Supply, 150W 69.3177.0151 Lamp Supply to Relay Cable Assembly 25.9678.0829 LVS to Yoke Dual AC Fan Cable Assembly 25.9686.0843 AC Input Splitter Cable Assembly 25.9678.0812 LVS Chassis Ground Cable Assembly 25.9661.1514 Figure 3-2: VL3500™ Wash Luminaire Subassembly Drawing Tree Part 2 02.96 86.001 0 0 51 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Top Assembly VL3500 Wash Included Items Kit 28.9686.0001 Rev A Refer to Figure 3-3. No. Item Qty. UM. 1 02.8001.0001 1 EA SHEET, VARI-LITE CUSTOMER SERVICE 2 02.8052.0001 1 EA CARD, LIMITED WARRANTY (09-09-02) 3 02.8001.0002 1 EA CERTIFICATE, VARI❋LITE QA 4 02.8700.0001 1 EA CARD, PRODUCT REGISTRATION 5 04.4037.0001 5 EA LABEL, 2.5 X .5 BARCODE (not shown) 6 08.3500.0002 1 EA CD-ROM, VL3500 WASH PRODUCT DOCUMENTATION 7 02.9686.0001 1 EA UNPACK/QUICK START SHEET, VL3500 WASH 8 22.9661.1636 2 EA FAB ASSY, BRACKET TRUSS HOOK 9 71.9686.1502 1 EA LAMP, 1500 WATT SHORT ARC, DOUBLE-ENDED (IN LUMINAIRE) 10 21.9686.0620 1 EA INTERNAL LENS, FRESNEL 11 21.9686.0619 1 EA FRONT LENS ASSEMBLY, FRESNEL 12 21.9686.0618 1 EA FRONT LENS ASSEMBLY, CLEAR PC 52 Description 02 .9 686.00 10 0 TOP ASSEMBLY : VL3500 WASH INCLUDED ITEMS KIT 1 2 3 4 6 7 8 (x2) 3 9* 13 10 14 1 Set of internal Fresnel Lenses (Buxom lenses are installed in luminaire) Fresnel and Clear PC Front Lens Assemblies (Stippled PC lens is installed on luminaire.) Figure 3-3: VL3500 Wash Included Items Kit Note: * = Do not handle lamp with bare hands. To keep the lamp glass as free from dirt and grease as possible, wear clean cotton gloves. 02.96 86.001 0 0 53 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL VL3500™ Wash Luminaire 20.9686.0001 Rev G Refer to Figure 3-4 No. Item Qty. UM. - 02.8405.0001 1 EA AC DANGER TAG, VL3500 (not shown) - 04.9661.0033.01 1 EA LABEL, WARNING - 2000 SERIES (not shown) 54 Description - 04.9661.0039 1 EA LABEL, LINE CORD WARNING (not shown) - 04.9686.0061 1 EA LABEL, AC INPUT RATING VL3500 WASH (not shown) 1 10.9686.0617 1 EA YOKE CROSSMEMBER, HEAT SHIELD 2 10.9686.0168 1 EA ZOOM MOUNTING BRACKET, LEFT 3 10.9686.0169 1 EA ZOOM MOUNTING BRACKET, RIGHT 4 10.9686.0732 2 EA COVER, YOKE THERMOFORM 5 21.9686.0010 1 EA ASSY, GENERIC LUMINAIRE 6 21.9686.0611 2 EA ASSY, HEAD COVER 7 21.9686.0660 1 EA ASSY, DUAL FAN TRAY DUCT 8 21.9686.2150 1 EA ASSY, SPLIT LENS 9 21.9686.0400 1 EA ASSY, COLOR/DIMMER/STROBE 10 24.9686.0429 1 EA PCB ASSY, VL3500 WASH CONTROLLER - 21.9686.1121 1 EA CABLE ASSY, HEAD CABLE INTERCONNECT (not shown) - 25.9686.0209 1 EA CABLE ASSY, TRANSFER FANS (not shown) - 25.9686.0210 1 EA CABLE ASSY, UPPER ENCLOSURE FANS (not shown) - 28.9686.0001 1 EA INCLUDED ITEMS KIT, VL3500 WASH (not shown) 11 53.6523.0013 8 EA SCREW, 6-32 X 3/8" PTB 12 53.6543.0001 10 EA SCREW, 6-32 X 3/8" PPB 13 53.6545.0007 10 EA SCREW, 8-32 X 3/8" LG PFB (not shown) 14 53.6558.0007 4 EA SCREW, 6-32 X 1/4" LG PPZ SEMS EXT ZINC PLT (not shown) 15 53.6558.0009 4 EA SCREW, 6-32 X 3/8" LG PPZ SEMS 16 55.6677.0033 4 EA WASHER, .201" OD .125" ID .032" THK FLAT SS 02 .9 686.00 10 0 TOP ASSEMBLY : VL3500™ WASH LUMINAIRE 3 VL3500™ Wash Luminaire (continued) 6 (x2) 7 8 9 3 4 (x2) 2 15 (x4) 16 (x4) 13 (x10) 5 10 11 (x8) 1 Figure 3-4: VL3500™ Wash Luminaire 02.96 86.001 0 0 55 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Generic Luminaire Assembly 21.9686.0010 Rev C Refer to Figure 3-5 No. Item Qty. UM. 1 21.9686.0600 1 EA ASSY, HEAD STRUCTURE, VL3500 WASH 2 21.9686.0700 1 EA ASSY, YOKE 3 21.9678.0707 1 EA ASSY, DRIVEN PULLEY 3a - 10.9678.0750 1 EA TIMING PULLEY, 150 TOOTH 3b - 10.9678.0754 1 EA FLAG, CENTER OF TRAVEL, TILT 3c - 53.6530.0009 3 EA RIVET, 1/8"OD POP .126-.187G 1 EA ASSY, STABILIZER 4 56 Description 21.9678.0767 4a - 10.9678.0757 1 EA STABILIZER, 1.377DIA 4b - 10.9678.0762 1 EA BRACKET, STABLIZER 4c - 53.6610.0003 1 EA SCREW, 6-32 X 7/16" PPZ 4d - 55.6568.0075 1 EA SPRING, EXTSN .375"OD 1.00"LG .041" WIRE DIA 5 21.9686.0800 1 EA ASSY, UPPER ENCLOSURE, VL3500 WASH 6 53.2019.0004 4 EA NUT, 3/8-16 X 7/32"THK HEX JAM GRD5 ZINC PLT 7 53.6505.0020 5 EA BOLT, 1/4-28X 3/4"HX HD GRD 8 ZINC PLT FULL THRD 8 53.6505.0026 4 EA BOLT, 3/8-16 X .500"LG H X HD GRADE 5 BLK 9/16"HEX HEAD X .23 TALL 9 53.6539.0001 4 EA WASHER, 3/8" SPLIT LOCK 10 53.5564.0250 1 EA SCREW, 6-32 X 1/4" PFB UNDERCUT 11 53.6624.0001 4 EA SCREW, 10-32 X 1/2"LG PFB 12 53.6513.0044 3 EA SCREW, M5 X 10MM STL CUP PT 13 54.1206.0014 2 EA RING, RETAINING 1.375"SHAFT 1.291"GRV DIA .056"GRVWD EXTERNAL 14 54.1255.0001 2 EA BEARING ASSY, BLACK FLUSH MOUNT HOUSING 15 54.2055.0001 1 EA BELT, TIMING S2M 210GROOVE 9MMWIDE URETHANE/KEVLAR 16 55.6549.0001 5 EA WASHER, 1/4" SPLIT LOCK 17 55.6799.0001 2 EA SHIM, 1-3/8"ID, 1-7/8"OD, .010" THK, SS 18 55.6799.0002 2 EA SHIM, 1-3/8"ID, 1-7/8"OD, .005" THK, SS 19 25.9686.0204 1 EA CABLE ASSY, VARI-BRITE INTERCONNECT (NOT SHOWN) 20 25.9686.0203 1 EA CABLE ASSY, TILT HARNESS (NOT SHOWN) 21 10.9686.0629 1 EA PLUG, TILT TUBE - 25.9686.0203 1 EA CABLE, TILT HARNESS (not shown) - 25.9686.0204 1 EA CABLE ASSY, VARI-BRITE INTERCONNECT (not shown) 02 .9 686.00 10 0 3 TOP ASSEMBLY : GENERIC LUMINAIRE ASSEMBLY Generic Luminaire Assembly (continued) 12 (x3) 1 3 15 13 (x2) 10 14 (x2) 21 Detail A 3c (x3) 3a 2 3b 4 6 (x4) 7 (x5) 16 (x5) 11 (x4) 4c 4a 5 9 (x4) 8 (x4) Detail A 4b 4d 18 (x2) 17 (x2) Figure 3-5: Generic Luminaire Assembly - VL3500 Wash 02.96 86.001 0 0 57 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Notes 58 02 .9 686.00 10 0 HEAD ASSEMBLY : HEAD STRUCTURE ASSEMBLY 3 Head Assembly Head Structure Assembly 21.9686.0600 Rev B Refer to Figure 3-1 No. Item Qty. UM. Description 1 21.9686.0615 1 EA ASSY, BACKEND 2 12.9686.0623 1 EA RIGHT SIDE RAIL, MACHINED 3 12.9686.0625 1 EA LEFT SIDE RAIL, MACHINED 4 21.9686.0617 1 EA ASSEMBLY, FRONT CASTING/LENS 5 53.6515.0001 6 EA SCREW, 10-32 X 3/4" SCB CAP 6 10.9686.0619 2 EA RETAINER, WIRING HARNESS 7 53.6558.0007 8 EA SCREW, #6-32 X 1/4" PPZ SEMS 8 10.9686.0639 2 EA LIGHT BAFFLE, FRONT 9 53.6682.0002 4 EA SCREW, 4-40 X 1/4 PPZ SEMS 3 4 9 (x4) 8 7 (x8) 6 2 1 5 (x6) Figure 3-1: Head Structure Assembly 02.96 86.001 0 0 59 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Front Stippled Lens Assembly 21.9686.0617 Rev B Refer to Figure 3-2 No. Item Qty. UM. Description 1 12.9686.0627 1 EA CASTING, CONVEX LENS 2 42.9686.0101 1 EA LENS, ASPHERIC PLANO CONVEX STIPPLED 3 10.9686.0641 4 EA CLIP, FRONT LENS 4 53.6685.1125 4 EA SCREW, CAPTIVE, SH CAP 10-32 1.125 LG BLK ZN 5 53.6598.0312 8 EA SCREW, 4-40 X 5/16" PFB 2 1 3 (x4) 4 (x4) 5 (x8) Figure 3-2: Front Stippled Lens Assembly 60 02 .9 686.00 10 0 HEAD ASSEMBLY : FRONT CLEAR LENS ASSEMBLY 3 Front Clear Lens Assembly 21.9686.0618 Rev C Refer to Figure 3-3 No. Item Qty. UM. Description 1 12.9686.0627 1 EA CASTING, CONVEX LENS 2 42.9686.0121 1 EA LENS, ASPHERIC PLANO CONVEX CLEAR 3 10.9686.0641 4 EA CLIP, FRONT LENS 4 53.6685.1125 4 EA SCREW, CAPTIVE, SH CAP 10-32 1.125 LG BLK ZN 5 53.6598.0312 8 EA SCREW, 4-40 X 5/16" PFB 2 1 3 (x4) 4 (x4) 5 (x8) Figure 3-3: Front Clear Lens Assembly 02.96 86.001 0 0 61 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Front Fresnel Lens Assembly 21.9686.0619 Rev D Refer to Figure 3-4 No. Item Qty. UM. 1 12.9686.0629 1 EA CASTING, MACHINED, FRESNEL LENS 2 42.9686.0102 1 EA LENS, FRESNEL 230 MM DIA 3 10.9686.0641 4 EA CLIP, FRONT LENS 4 53.6685.1500 4 EA SCREW, CAPTIVE, SH CAP 10-32 1.5 LG BLK ZN 5 53.6598.0312 8 EA SCREW, 4-40 X 5/16" PFB 6 10.9686.0682 4 EA COUNTERWEIGHT, FRONT, SHORT, THIN 7 10.9686.0638 36 EA COUNTERWEIGHT, FRONT, LONG 8 53.6618.0001 8 EA SCREW, 6-32 X 1.5 PPZ 2 Description 7 (x36) 1 3 (x4) 4 (x4) 5 (x8) 6 (x4) 8 (x8) Figure 3-4: Front Fresnel Lens Assembly 62 02 .9 686.00 10 0 HEAD ASSEMBLY : HEAD COVER ASSEMBLY 3 Head Cover Assembly 21.9686.0611 Rev B Refer to Figure 3-5 No. Item Qty. UM. Description 1 10.9678.0612 1 EA HEAD COVER FOAM BAFFLE 2 10.9678.0674 1 EA BRACKET, COVER TETHER 3 10.9678.0696 1 EA FOAM FRAME, HEAD COVER 4 10.9686.0610 1 EA HEAD COVER, VL3500 WASH 5 53.5606.0375 1 EA SCREW, 6-32 X 3/8, PPSS 6 53.6683.0015 4 EA SCREW, #6 X 1/4" PPZ PLASTIC 7 55.2233.0003 4 EA RETAINER, PUSH-ON TYPE 8 55.2233.0775 4 EA STUD, 1/4 TURN .775L STEEL BLK ZINC 9 10.9678.0649 4 EA EJECTOR SPRING, BLACK OXIDE 10 55.9676.0255 4 EA BELLEVILLE SPRING WASHER 5 2 4 7 (x4) 3 10 (x4) 8 (x4) 6 (x4) 1 9 (x4) Bottom View Figure 3-5: Head Cover Assembly 02.96 86.001 0 0 63 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Backend Assembly 21.9686.0615 Rev M Refer to Figure 3-6 No. Item Qty. UM. 1 10.9678.0653 1 EA LIGHT BAFFLE, EXHAUST 2 10.9686.0635 1 EA EXHAUST BULKHEAD 3 10.9686.0636 10 EA COUNTERWEIGHT, REAR 4 10.9686.0671 1 EA SEPARATION BULKHEAD 5 12.9678.0627 1 EA REAR CROSS-CASTING, MACHINED 6 10.9686.0659 1 EA INSULATOR, FAN, THIN 7 21.9678.0673 1 EA TETHER ASSY, COVERED 8 21.9686.0673 1 EA TETHER ASSY, BARE 64 Description 9 21.9686.0605 1 EA ASSEMBLY, REFLECTOR MOUNT 10 22.9686.0674 1 EA ASSEMBLY, DUAL FAN DUCT 11 21.9686.0680 1 EA ASSEMBLY, HOT BOX 12 21.9686.6619 2 EA FAN ASSY, AC 80MM 36CFM 13 53.2002.0001 2 EA NUT, 6-32 KEPS ZINC PLATED 14 53.2004.0002 4 EA NUT, 8-32 KEPS ZINC PLATE 15 53.6545.0009 4 EA SCREW, 8-32 X 1.375"LG PFZ 16 53.6519.0001 2 EA SCREW, 4-40 X 5/8" PPZ 17 53.6558.0007 2 EA SCREW, 6-32 X 1/4" PPZ SEMS 18 53.6581.0001 4 EA SCREW, 4-40 X 1 3/8" PPZ 19 53.6609.0001 10 EA SCREW, 6-32 X 3/8" PFZ 20 53.6614.0003 4 EA SCREW, 6-32 X 5/8" PFZ 21 53.6617.0001 10 EA SCREW, 6-32 X 1" PPB 22 55.2125.0003 4 EA STANDOFF, 3/8"HEX 8-32 1.500"L 23 55.6706.0001 1 EA GROMMET, 9/32"ID 9/16"OD 1/4T 24 74.1099.0001 1 EA SWITCH, MINIATURE 5AMP 150DEG 25 55.6541.0008 1 EA GROMMET, 1/2"ID 7/8"OD 3/4"GRV 26 55.6506.0024 2 EA SPACER, 3/16 RND, .188 LG, .141 THRU 27 55.6528.0001 2 EA WASHER, #6 FLAT, ZINC 28 55.6538.0004 4 EA WASHER, .750" OD, .312" ID, .125 THK 29 53.6613.0001 2 EA SCREW, 6-32 X 1/2" PPZ 30 55.6677.0042 2 EA WASHER, .500" OD, .145" ID, .031" THICK 31 10.9678.1645 2 EA FAN LIGHT SHIELD 02 .9 686.00 10 0 HEAD ASSEMBLY : BACKEND ASSEMBLY No. Item Qty. UM. 32 55.6658.0500 2 EA STANDOFF, 6-32 X 1/2" LG, 1/4" HEX, ZINC 33 25.9686.0012 1 EA YOKE TO DUAL AC FAN CABLE ASSY (not shown) 34 25.9686.0201 1 EA CABLE ASSY, OT SWITCH TO BACKCAP INTERLOCK (not shown) 3 Description 21 (x10) 12 (x2) 13 (x2) 31 (x2) 25 24 6 16 (x2) 30 (x2) 10 32 (x2) 5 28 (x4) 7 3 (x10) 20 (x4) 19 (x10) 23 14 (x4) 4 18 (x4) 2 11 9 15 (x4) 26 (x2) 22 (x4) 8 27 (x2) 29 (x2) 17 (x2) 1 Figure 3-6: Backend Assembly 02.96 86.001 0 0 65 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL 80mm Fan Assembly 21.9686.6619 Rev A Refer to Figure 3-7 No. Item Qty. UM. Description 1 40.7144.0001 1 EA FAN, TUBEAXIAL 80 X 80 X 38 MM, 230V, 36 CFM, BBEARING, 95°C 2 53.2200.0006 4 EA NUT, 6-32 KEPS SS 3 53.6558.0001 4 EA SCREW, 6-32 X 3/8" PPZ 4 55.7016.0001 1 EA FAN GUARD, 80MM NICKEL PLATED STEEL WIRE 4 3 (x4) 1 2 (x4) Figure 3-7: 80mm Fan Assembly 66 02 .9 686.00 10 0 HEAD ASSEMBLY : DUAL FAN DUCT ASSEMBLY 3 Dual Fan Duct Assembly 22.9686.0674 Rev B Refer to Figure 3-8 No. Item Qty. UM. Description 1 10.9686.1672 1 EA DUAL FAN DUCT 2 10.9686.0673 1 EA TURNING VANE, FAN DUCT 3 53.6558.0001 2 EA SCREW, 6-32 X 3/8" PPZ 4 53.6604.0002 4 EA SCREW, 4-40 X 1/4 THREAD FORMING 5 74.1090.0001 1 EA OT1 THERMAL SWITCH, LIMIT, 199°C 6 74.1090.0001 1 EA OT2 THERMAL SWITCH, LIMIT, 199°C 7 25.9678.0015 1 EA CABLE ASSY, OT SWITCH 2 TO GND (NOT SHOWN) 8 25.9686.0013 1 EA CABLE ASSY, OT SWITCH 1 TO OT SWITCH 2 (NOT SHOWN) 9 25.9686.0014 1 EA CABLE ASSY, BACKCAP INTRLK TO OT SWITCH 1 (NOT SHOWN) 4 (x4) 5 1 6 2 3 (x2) Figure 3-8: Dual Fan Duct Assembly 02.96 86.001 0 0 67 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Reflector Mount Assembly 21.9686.0605 Rev C Refer to Figure 3-9 No. Item Qty. UM. Description 1 10.9686.0632 1 EA REFLECTOR CLAMP 2 10.9686.0633 2 EA CLIP, UV REFLECTOR 3 12.9686.0631 1 EA REFLECTOR MOUNT, MACHINED CASTING 4 42.9686.0105 2 EA UV/IR BLOCKING FILTER 5 42.9686.0120 1 EA REFLECTOR, ELIPTICAL 6 53.6530.0002 4 EA RIVET, 1/8 OD POP, .063-.125 GRIP, ALUM 7 53.6683.0015 4 EA SCREW, 6-32 X 5/8, PPB, SEMS 8 10.9686.0644 4 EA SPRING, REFLECTOR MOUNT 6 (x4) 4 (x2) 2 (x2) Align tabs on reflector and top-left support 5 3 7 (x4) 8 (x4) 1 Note: Install filter with marks indicating IR coating side of the glass facing up and located outside of circular cutout in reflector mount (Item 2). Figure 3-9: Reflector Mount Assembly 68 02 .9 686.00 10 0 HEAD ASSEMBLY : HOT BOX ASSEMBLY 3 Hot Box Assembly 21.9686.0680 Rev D Refer to Figure 3-10 No. Item Qty. UM. Description 1 10.9678.0043-04 1 EA LABEL PLATE, VL3500 WASH BACKCAP, BLACK 2 10.9686.0642 1 EA BACKCAP PLATE 3 10.9678.0643 1 EA LAMP ADJUST STOP 4 10.9678.0645 3 EA KNOB, LAMP ADJ MOLDED 5 10.9686.0681 1 EA HOT BOX 6 22.9686.0649 1 EA ASSEMBLY, TILT PLATE, LONG VANE 7 53.2030.0001 3 EA NUT, ACORN 10-32THD 3/8 WIDE 8 53.5508.0375 2 EA SCREW, 8-32 X 3/8" PPSS 9 53.6530.0013 8 EA RIVET, 1/8"OD .063" - .125"GL CSK HD ALUM 10 55.6546.0004 3 EA WASHER, TEFLON, .201ID X .438OD X .04 THK 11 55.2233.0003 4 EA RETAINER, PUSH-ON TYPE 12 55.2233.0006 4 EA STUD, 1/4 TURN OPR .455L STEEL 13 55.6568.0035 3 EA SPRING, CPRSN .300"OD .875"LG .035"WIRE DIA SS 14 71.2561.0002 1 EA LAMPHOLDER, SFC10-4 WITH PREFOCUS SHARX 15 25.9678.0789 1 EA CABLE ASSY, IGNITOR TO LAMP SOCKET (NOT SHOWN) 02.96 86.001 0 0 69 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Hot Box Assembly (continued) 5 8 (x2) 6 9 (x8) 11 (x4) 3 12 (x4) 1 14 13 (x3) 2 10 (x3) 7 (x3) 4 (x3) Figure 3-10: Hot Box Assembly 70 02 .9 686.00 10 0 HEAD ASSEMBLY : DUAL FAN TRAY ASSEMBLY 3 Dual Fan Tray Assembly 21.9686.0660 Rev B Refer to Figure 3-11 No. Item Qty. UM. Description 1 22.9686.0661 1 EA ASSY, FAN TRAY 2 23.9686.0684 2 EA FAN ASSY, HEAD FRONT 3 53.5506.1375 4 EA SCREW, 6-32 X 1 3/8"LG PPB 4 55.6818.0002 1 EA STANDOFF, 45 DEG NYLON 6/6 KUR 3 (x4) 2 (x2) 4 1 Figure 3-11: Dual Fan Tray Assembly 02.96 86.001 0 0 71 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Head Front Fan Assembly 23.9686.0684 Rev 0 Refer to Figure 3-12 No. Item Qty. UM. 1 12.9686.0664 1 EA FAN, COOLING, 24V MODIFIED 2 52.6523.0002 1 EA CONN, HOUSING 2POS PLUG SHROUDED WIRE TO WIRE 3 52.8347.0001 2 EA CONTACT, 24-30AWG MALE CRIMP 2 3 (x2) Description 1 Figure 3-12: Head Front Fan Assembly 72 02 .9 686.00 10 0 HEAD ASSEMBLY : INTERNAL LENS ASSEMBLY 3 Internal Lens Assembly 21.9686.2150 Rev G Refer to Figure 3-13 No. Item Qty. UM. Description 1 21.9686.2140 1 EA ASSEMBLY, INTERNAL LENS RAIL 2 21.9686.2144 1 EA ASSEMBLY, INTERNAL LENS SPLITTER 3 21.9686.2142 1 EA ACTUATOR ASSEMBLY 4 53.6607.0001 1 EA SCREW, 6-32 X 1/4 PPB 5 53.6513.0046 4 EA SCREW, M3 X 6 LG SOC CAP, LOW PROFILE, BLK 6 53.6513.0032 4 EA SCREW, M3 X 5 X 10MM LG, PPZ, METRIC 7 21.9686.3102 1 EA ASSEMBLY, SPLIT ZOOM BUXOM, RIGHT 8 21.9686.3101 1 EA ASSEMBLY, SPLIT ZOOM BUXOM, LEFT 9 21.9686.3105 2 EA INTERNAL LENS MOUNTING KIT 10 10.9686.2180 1 EA CROSS STRAP, BEAM SPLITTER 11 10.9686.2190 1 EA BUMPER, LENS 12 10.9686.7135 2 EA KNOB, HEX, ALUMINUM 13 10.9686.1155 1 EA CLAMP, BELT, FRONT 02.96 86.001 0 0 73 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL 11 10 7 9 (x2) 12 (x2) 5 (x4) 8 2 4 13 6 (x4) 3 1 Figure 3-13: Internal Lens Assembly 74 02 .9 686.00 10 0 HEAD ASSEMBLY : INTERNAL LENS RAIL ASSEMBLY 3 Internal Lens Rail Assembly 21.9686.2140 Rev H Refer to Figure 3-14 No. Item Qty. UM. Description 1 10.9678.0128 1 EA PULLEY, ZOOM MOTOR 2 10.9678.1131 1 EA FORWARD PULLEY SHAFT, BEARING 3 10.9686.1170 1 EA MOUNT, RAIL 4 10.9686.3171 1 EA MOUNTING PLATE, SPLIT LENS ZOOM ASSY 5 10.9686.1182 1 EA BLOCK, MOUNTING, IDLER PULLEY 6 55.2234.0001 1 EA E-RING, .188 SHAFT DIA. 7 22.9686.1154 1 EA LINEAR RAIL, 12MM, 2 LONG CARRIAGE 8 44.9663.1766 1 EA MOTOR, 17 1.24" SHAFT 11.8MH 5.5 OHM 9 53.2200.0006 1 EA NUT, 6-32 KEPS SS 10 53.6523.0001 5 EA SCREW, 6-32 X 3/8" SCB ALLEN 11 53.6543.0001 7 EA SCREW, 6-32 X 3/8" PPB 12 53.6614.0001 2 EA SCREW, 6-32 X 5/8" PPB 13 54.1262.0001 2 EA BEARING, FLANGED .1875 BORE 14 54.2064.0192 1 EA BELT, TIMING, MXL (.080), 192 GRV, 1/4" WIDE 15 54.2053.0001 1 EA MXT T BELT PULLEY, 20 GRV .25WD 16 10.9686.2130 1 EA END OF TRAVEL STOP 17 10.9686.1173 1 EA PAD, ISOLATION, ZOOM MOTOR 18 55.6568.0016 1 EA SPRING, EXTSN 0.125" OD, 0.500" LG 19 10.9621.0097 1 EA STABILIZER, STEPPER, GOBO WHEEL 20 53.6598.0312 1 EA SCREW, 4-40 X 5/16 PFB 02.96 86.001 0 0 75 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL 6 13 (x2) 14 15 10 (x5) 1 2 5 7 20 3 19 18 1 4 9 16 12 (x2) 17 11 (x7) 8 Figure 3-14: Internal Lens Rail Assembly 76 02 .9 686.00 10 0 HEAD ASSEMBLY : INTERNAL LENS SPLITTER ASSEMBLY 3 Internal Lens Splitter Assembly 21.9686.2144 Rev D Refer to Figure 3-15 No. Item Qty. UM. Description 1 10.9686.2175 1 EA MOUNT, ZOOM LENS 2 10.9686.1179 2 EA HINGE ROD 3 21.9686.2160 2 EA PIVOT ASSY, INTERNAL LENS 4 10.9686.2189 1 EA EOT STOP, VARI-BRITE 5 10.9686.1156 1 EA BELT CLAMP, BACK 6 10.9686.1159 2 EA SPACER, PIVOT 7 10.9686.1176 1 EA MOTOR MOUNT 1, SPLIT LENS MOTOR 8 44.9686.0164 1 EA MOTOR, SPLIT LENS 9 53.6524.0002 4 EA SCREW, 6-32 X 5/16" PPB 10 53.6592.0250 2 EA SCREW, 4-40 X 1/4" LG PPB SEMS 11 53.6607.0001 2 EA SCREW, 6-32 X 1/4" PPB 12 54.2007.0001 2 EA RING, RETAINING EXTERNAL 1/4" 02.96 86.001 0 0 77 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL 12 (x2) 3 (x2) 6 (x2) 2 (x2) 4 9 (x2) 7 1 5 10 (x2) 11 (x2) 8 9 (x2) Figure 3-15: Internal Lens Splitter Assembly 78 02 .9 686.00 10 0 HEAD ASSEMBLY : ACTUATOR ASSEMBLY 3 Actuator Assembly 21.9686.2142 Rev F Refer to Figure 3-16 No. Item Qty. UM. Description 1 10.9686.2190 1 EA BUMPER, LENS 2 10.9686.1158 4 EA SPACER, PIVOT LINK 3 10.9686.4189 1 EA MOUNT, LEAD SCREW 4 10.9686.4188 1 EA PLATE, LINKAGE ACTUATOR 5 21.9686.2130 2 EA ASSEMBLY, PIVOT LINK 6 53.6607.0001 2 EA SCREW, 6-32 X 1/4" PPB 7 53.6678.0013 2 EA SCREW, SHLDR 4-40TH .125DIA .188 SHLDR 6 (x2) 7 (x2) 1 5 (x2) 4 2 (x4) 3 Figure 3-16: Actuator Assembly 02.96 86.001 0 0 79 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Fresnel Internal Lenses 21.9686.0620 Rev A Refer to Figure 3-17 No. Item Qty. UM. Description 1 21.9686.3103 1 EA LENS, ZOOM, FRESNEL, LEFT 2 21.9686.3104 1 EA LENS, ZOOM, FRESNEL, RIGHT 3 21.9686.3105 2 EA KIT, SPLIT LENS MOUNTING 2 3 (x2) 1 Figure 3-17: Fresnel Internal Lenses 80 02 .9 686.00 10 0 HEAD ASSEMBLY : INTERNAL LENS MOUNTING KIT 3 Internal Lens Mounting Kit 21.9686.3105 Rev A Refer to Figure 3-18 No. Item Qty. UM. 1 10.9686.1141 1 EA INTERNAL LENS PIVOT ADAPTER 2 10.9686.2181 1 EA SPACER, LENS MOUNTING 3 53.6524.0002 2 EA SCREW, 6-32 X 5/16 PPB 4 54.1259.0006 1 EA BEARING, FLANGED, EXTENDED RACE 0.25" ID 5 54.1259.0007 1 EA BEARING, FLANGED, 0.25" ID 1 Description 3 5 4 Important: Extended race bearing must be installed in the top of the pivot adapter. 2 Figure 3-18: Internal Lens Mounting Kit 02.96 86.001 0 0 81 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Color/Effect/Strobe Module 21.9686.0400 Rev G Refer to Figure 3-20 and Figure 3-20 No. Item Qty. UM. 1 10.9686.0468 6 EA PULLEY, COLOR WHEEL DRIVE MOTOR, WITH FLANGES 2 10.9676.0230.02 3 EA SPACER, COLOR WHEEL .043" LG 3 10.9686.0446 1 EA MOTOR ADJUST PLATE 4 10.9686.0420 1 EA BULKHEAD, COLOR MODULE, FRONT 5 10.9686.0421 1 EA BULKHEAD, COLOR MODULE, REAR 6 10.9686.0422 2 EA SHAFT, COLOR WHEEL, FRONT 7 10.9686.0432 2 EA SHAFT, COLOR WHEEL, REAR 8 10.9686.0433 5 EA SPACER, COLOR SYSTEM HALVES 82 Description 9 10.9686.0457.01 2 EA SPACER, COLOR WHEEL .322" LG 10 10.9686.0457.02 2 EA SPACER, COLOR WHEEL .125 LG 11 21.9686.0404 1 EA ASSEMBLY, STROBE SYSTEM 12 21.9686.0480 1 EA ASSY, FIXED COLOR WHEEL #2 13 21.9686.0484 1 EA ASSY, FIXED COLOR WHEEL #1 14 22.9686.0410 1 EA ASSY, COLOR WHEEL, CYAN 15 22.9686.0411 1 EA ASSY, COLOR WHEEL, YELLOW 16 22.9686.0412 1 EA ASSY, COLOR WHEEL, MAGENTA 17 22.9686.0413 1 EA ASSY, COLOR WHEEL, CTO 18 22.9686.0414 1 EA ASSY, DIMMER WHEEL 19 22.9686.0490 1 EA ASSY, APERTURE WHEEL 20 24.9686.0427 1 EA BOARD. ASMB COLOR WHEEL SENSOR, TRIPLE 21 24.9686.0428 1 EA BOARD. ASMB COLOR WHEEL SENSOR, QUAD 22 44.9663.1766 8 EA MOTOR, 17 1.24" SHAFT 11.8MH 5.5 OHM 23 54.2057.0001 8 EA BELT, TIMING MXL .188W 144 GRV URETH/KEVLAR 24 53.6609.0001 14 EA SCREW, 6-32 X 3/8" PFZ 25 53.6613.0001 16 EA SCREW, 6-32 X 1/2" PPZ 26 55.6669.0014 6 EA STANDOFF, 1/4 "HEX 6-32 5/8" 27 10.9686.0457.03 1 EA SPACER, COLOR WHEEL, .490" LG 28 10.9686.0457.04 1 EA SPACER, COLOR WHEEL, .090" LG 29 10.9686.0457.05 1 EA SPACER, COLOR WHEEL, .271" LG 30 53.6525.0188 4 EA SCREW, 6-32 X 3/16" PPZ SEMS 31 53.6558.0009 6 EA SCREW, 6-32 X 3/8"LG PPZ SEM 02 .9 686.00 10 0 HEAD ASSEMBLY : COLOR/EFFECT/STROBE MODULE No. Item Qty. UM. 32 10.9678.0246 6 EA ADJUST PLATE, MOTOR 33 25.9686.0205 1 EA CABLE ASSY, COLOR HARNESS (not shown) 34 10.9686.0442 1 EA BLOCKING PLATE, AIR, DIMMER 35 10.9686.0443 1 EA AIR DIVERTER, DIMMER 36 10.9686.0444 1 EA AIR DIVERTER, DIMMER, BELT SIDE 37 53.6530.006 6 EA RIVET, 1/8" OD POP, .188 - .250 LG 38 10.9686.2468 2 EA PULLEY, MOTOR, NO FLANGES, FOR CTO AND DIMMER WHEELS 39 10.9686.0447 1 EA MOTOR ADJUST PLATE, CABLE GUIDE 3 Description 26 (x6) 11 31 (x6) Color Effect Section; see Figure 3-20 for the illustrated parts breakdown. Figure 3-19: Color Effect and Strobe Module 02.96 86.001 0 0 83 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Color/Effect/Strobe Module (continued) 25 (x16) 24 (x14) 32 (x6) 28 15 22 (x8) 9 4 10 19 1 (x6) 30 (x4) 20 9 13 2 16 39 10 38 6 (2) 17 8 (x5) 2 36 35 12 34 21 27 14 2 23 (x8) 18 38 29 7 (2) 37 (6) 5 3 (x2) Figure 3-20: Color Effect Section 84 02 .9 686.00 10 0 HEAD ASSEMBLY : FIXED COLOR WHEEL ASSEMBLIES 3 Fixed Color Wheel Assemblies 21.9686.0484 Rev G Wheel #1 21.9686.0480 Rev G Wheel #2 Refer to Figure 3-21 No. Item Qty. UM. 1 10.9686.0487 1 EA WHEEL, FIXED COLOR 1 (#1) 1 EA WHEEL, FIXED COLOR 2 (#2) -10.9686.0481 Description 2 10.9686.0482 1 EA SPACER PLATE, FIXED COLOR 3 10.9686.0483 1 EA SPRING PLATE, FIXED COLOR 4 21.9686.0419 1 EA TIMING PULLEY WITH BEARINGS 5 41.9686.0490 1 EA COLOR FILTER, RED (#1) 1 EA COLOR FILTER, BLUE (#2) 1 EA COLOR FILTER, YELLOW (#1) 1 EA COLOR FILTER, AMBER (#2) 1 EA COLOR FILTER, MAGENTA (#1) 1 EA COLOR FILTER, DARK FUSHIA (#2) 1 EA COLOR FILTER, KELLY GREEN (#1) 1 EA COLOR FILTER, ORANGE (#2) 1 EA COLOR FILTER, CONGO BLUE (#1) 1 EA COLOR FILTER, GREEN (#2) 4 EA SCREW, 4-40 X 5/16 " PFB -41.9686.0495 6 41.9686.0491 -41.9686.0496 7 41.9686.0492 -41.9686.0497 8 41.9686.0493 -41.9686.0498 9 41.9686.0494 -41.9686.0499 10 53.6598.0312 02.96 86.001 0 0 85 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Fixed Color Wheel Assemblies (continued) POS 1 OPEN 1 9 10 (x4) 8 Note: RTV beads should be applied at all positions where a filter can be used. 2 5 1 5 TIMING TAB TIMING TAB 4 3 POS 1 OPEN 6 FIXED COLOR WHEEL # 1 7 6 2 10 (x4) 9 4 3 7 8 FIXED COLOR WHEEL # 2 Figure 3-21: Fixed Color Wheel Assemblies 86 02 .9 686.00 10 0 HEAD ASSEMBLY : STROBE SYSTEM ASSEMBLY 3 Strobe System Assembly 21.9686.0404 Rev F Refer to Figure 3-22 No. Item Qty. UM. Description 1 10.9678.0491 4 EA BUMPER STOP, STROBE 2 10.9686.0435 1 EA STROBE BULKHEAD, COLOR ACCESS 3 22.9686.0437 1 EA REAR STROBE BLADE ASSEMBLY 4 22.9686.0438 1 EA FRONT STROBE BLADE ASSEMBLY 5 44.5029.0001 2 EA MOTOR, STEPPER 42MM X 34MM - AR6 6 53.6513.0026 8 EA SCREW, M3 X .5 X 12MM LG PP 7 53.6609.0001 4 EA SCREW, 6-32 X 3/8" LG PFZ 8 55.3303.0004 8 EA WASHER, #4 LOCK INT. TOOTH SS 9 55.3306.0006 8 EA WASHER, .375 OD .149 ID .025 THK 10 55.6659.0001 8 EA SPACER, 1/4" RND 4 THRU 3/16" 11 55.6706.0001 8 EA GROMMET, 9/32"ID 9/16"OD 1/4T 12 53.6558.0007 4 EA SCREW, 6-32 X 1/4" PPZ SEMS 13 10.9686.0440 1 EA SHIELD, STROBE MOTOR/HARNESS 14 21.9686.0404 1 EA ASSY, AIR DUCT 15 10.9686.0438 1 EA SPRING, COLOR ACCESS 16 55.2023.0002 1 EA HINGE,1.00"LG X 1.00"WD, ZINC STEEL 17 53.6558.0001 4 EA SCREW, 6-32 X 3/8" PPZ 18 10.9686.1450 1 EA REFLECTOR, STROBE BULKHEAD 02.96 86.001 0 0 87 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL .400 .410 .455 .355 4 Set blade assemblies according to dimensions shown 2 5 (x2) 3 1 (x4) 13 7 (x4) 18 6 (x8) 8 (x8) 9 (x8) 10 (x8) 11 (x8) 15 12 (x4) 17 (x4) 16 14 Figure 3-22: Strobe System Assembly 88 02 .9 686.00 10 0 HEAD ASSEMBLY : REAR STROBE BLADE ASSEMBLY 3 Rear Strobe Blade Assembly 22.9686.0437 Rev 0 Refer to Figure 3-23 No. Item Qty. UM. Description 1 10.9678.0432 1 EA HUB, STROBE BLADE 2 10.9678.0466 1 EA STROBE BLADE, DAMPER 3 10.9686.0431 1 EA STROBE BLADE 4 53.5558.0188 2 EA SCREW, 8-32 X .188 LG SET SS BRASS TIP UNC-2A 5 53.6597.0001 3 EA SCREW, 4-40 X 3/16" PPZ 6 55.3303.0004 3 EA WASHER, #4 LOCK INT. TOOTH SS 1 4 (x2) 2 5 (x3) 3 6 (x3) Figure 3-23: Rear Strobe Blade Assembly 02.96 86.001 0 0 89 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Front Strobe Blade Assembly 22.9686.0438 Rev 0 Refer to Figure 3-24 No. Item Qty. UM. Description 1 10.9678.0432 1 EA HUB, STROBE BLADE 2 10.9678.0466 1 EA STROBE BLADE DAMPER 3 10.9686.0431 1 EA STROBE BLADE 4 53.5558.0188 2 EA SCREW, 8-32 X .188 LG SET SS BRASS TIP UNC-2A 5 53.6597.0001 3 EA SCREW, 4-40 X 3/16" PPZ 6 55.3303.0004 3 EA WASHER, #4 LOCK INT. TOOTH SS 1 4 (x2) 2 3 5 (x3) 6 (x3) Figure 3-24: Front Strobe Blade Assembly 90 02 .9 686.00 10 0 YOKE ASSEMBLY : YOKE ASSEMBLY 3 Yoke Assembly Yoke Assembly 21.9686.0700 Rev A Refer to Figure 3-25 No. Item Qty. UM. 1 10.9678.0764 1 EA PLATE, TILT ENCODER MOUNT 2 10.9678.0756 1 EA IGNITOR SHIELD 3 21.9678.0765 1 EA ASSY, TILT MOTOR 4 22.9661.0609 2 EA ASSY, YOKE FAN 5 22.9686.0705 1 EA ASSY, YOKE STRUCTURE 6 23.9650.3327 1 EA ELEC ASSY, RELAY 7 23.9661.1253 1 EA ELEC ASSY, PAN EOT SENSOR 8 24.9661.3126 1 EA PCB ASSY, SOLID STATE IGNITOR - 25.9661.1526 2 EA CABLE ASSY, IGNITOR TO RELAY - 25.9678.0681 1 EA CABLE ASSY, YOKE FAN AND RELAY - 25.9678.0758 1 EA CABLE ASSY, YOKE FAN 9 53.2019.0004 2 EA NUT, 3/8-16 X 7/32" THK HEX 10 53.2200.0006 1 EA NUT, 6-32 KEPS SS 11 53.5634.0250 8 EA SCREW, 4-40 X 1/4" PFSS BL 12 53.6539.0001 2 EA WASHER, 3/8" SPLIT LOCK 13 53.6558.0009 12 EA SCREW, 6-32 X 3/8"LG PPZ SEM 14 53.6626.0001 6 EA SCREW, 10-32 X 1/2" PPZ 15 53.6634.0003 2 EA SCREW, 3/8-16 X 1/2"LG SOC 16 55.2150.0002 1 EA STANDOFF, 1/4" HEX 6-32 1.187"L 17 55.2178.0001 1 EA CABLE ANCHOR MOUNT, #8 SCREW MOUNT 18 55.6528.0001 2 EA WASHER, #6 FLAT ZINC 19 55.6541.0002 2 EA GROMMET, 1 "ID 1 3/4"OD 1 3/ 20 55.6568.0074 2 EA SPRING, CPRSN .420"OD .750"LG 21 55.6658.0004 2 EA STANDOFF, 1/4" HEX 6-32 .750"LG, F-F, AL 02.96 86.001 0 0 Description 91 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Yoke Assembly (cont.) 4 19 5 9 19 21 (x2) 13 (x2) 18 (x2) 6 10 13 (x4) 2 13 (x3) 4 14 (x4) 20 (x2) 11 (x8) 8 15 (x2) 12 (x2) 3 7 13 17 16 13 (x2) 1 14 (x2) Figure 3-25: Yoke Assembly 92 02 .9 686.00 10 0 YOKE ASSEMBLY : TILT MOTOR ASSEMBLY 3 Tilt Motor Assembly 21.9678.0765 Rev E Refer to Figure 3-26 No. Item Qty. UM. Description 1 10.9678.0763 1 EA PLATE, TILT MOTOR MOUNT 2 21.9678.0708 1 EA ASSY, DRIVE PULLEY 3 24.9661.9629 1 EA PCB ASSY, PAN/TILT ENCODER 4 44.9678.0680 1 EA MOTOR, 3 PHASE SIZE 23 HIGH TORQUE 5 53.2200.0006 2 EA NUT, 6-32 KEPS SS 6 53.2200.0008 4 EA NUT, 8-32 KEPS SS 7 53.6525.0001 2 EA SCREW, 6-32 X 5/16" PPZ 8 53.6546.0001 4 EA SCREW, 8-32 X 5/8" PPB 9 53.6682.0002 2 EA SCREW, 4-40 X 1/4"LG PPZ SEMS-EXT 2 9 (x2) 3 7 (x2) Note: Vari-Lite recommends that this motor be replaced as a complete assembly. Although you can replace only the motor, the pulley (Item 2) is bonded to the motor shaft during assembly and cannot be removed intact. If you order a replacement motor (Item 4), also order the pulley (Item 2). Contact Vari-Lite Customer Service for installation information. 6 (x4) 5 (x2) 1 8 (x4) 4 Figure 3-26: Tilt Motor Assembly 02.96 86.001 0 0 93 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Relay Electrical Assembly 23.9650.3327 Rev B Refer to Figure 3-27 No. Item Qty. UM. 1 23.9650.3327 1 EA Description ELECTRICAL ASSEMBLY, RELAY 1 Figure 3-27: Relay Electrical Assembly 94 02 .9 686.00 10 0 YOKE ASSEMBLY : YOKE FAN ASSEMBLY 3 Yoke Fan Assembly 22.9661.0609 Rev C Refer to Figure 3-28 No. Item Qty. UM. 1 10.9661.0646 1 EA FAN TRAY 2 40.7113.0001 1 EA FAN, +24V 80MM X 80MM X 25MM, 32 CFM 3 53.2200.0006 4 EA NUT, 6-32 KEPS SS Direction of Air Flow Description 2 3 (x4) 1 Figure 3-28: Yoke Fan Assembly 02.96 86.001 0 0 95 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Notes 96 02 .9 686.00 10 0 HEAD/YOKE PCB ASSEMBLIES : HEAD CABLE INTERCONNECT 3 Head/Yoke PCB Assemblies Head Cable Interconnect 21.9686.1121 Rev A Refer to Figure 3-29 No. Item Qty. UM. Description 1 10.9686.1120 1 EA BRACKET, HEAD CABLE INTERCONNECT 2 53.6520.0002 4 EA SCREW, 4-40 X 7/16 PPZ 3 55.6621.0001 4 EA WASHER, #4 FLAT ZINC 4 52.6670.0040 1 EA HEADER ASSY, MOD 11 40 POS MTG 5 52.6670.0034 1 EA HEADER ASSY, MOD 11 34 POS MTG 6 23.9686.0208 1 EA CABLE ASSY, ZOOM MOTOR (CABLE PORTION NOT SHOWN) 7 25.9686.0207 1 EA CABLE ASSY, VARI-BRITE MOTOR (NOT SHOWN) 6 1 4 5 3 (x4) 2 (x4) Figure 3-29: Head Cable Interconnect 02.96 86.001 0 0 97 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Color Sensor PCB Offset Assembly 24.9686.0427 Rev B Refer to Figure 3-30 Figure 3-30: Color Sensor PCB Offset Assembly 98 02 .9 686.00 10 0 HEAD/YOKE PCB ASSEMBLIES : COLOR SENSOR PCB INLINE ASSEMBLY 3 Color Sensor PCB Inline Assembly 24.9686.0428 Rev C Refer to Figure 3-31 Figure 3-31: Color Sensor PCB Inline Assembly 02.96 86.001 0 0 99 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Solid State Ignitor PCB 24.9661.3126 Rev A Refer to Figure 3-32 3 Figure 3-32: Solid State Ignitor PCB 100 02 .9 686.00 10 0 HEAD/YOKE PCB ASSEMBLIES : WHEEL POSITION SENSOR PCB ASSEMBLY 3 Wheel Position Sensor PCB Assembly 24.9661.9629 Rev A Refer to Figure 3-33 Figure 3-33: Wheel Position Sensor PCB Assembly 02.96 86.001 0 0 101 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Pan/Tilt Encoder PCB 24.9678.9729 Rev A Refer to Figure 3-34 Figure 3-34: Pan/Tilt Encoder PCB 102 02 .9 686.00 10 0 HEAD/YOKE PCB ASSEMBLIES : VL3500 WASH CONTROLLER PCB ASSEMBLY 3 VL3500 Wash Controller PCB Assembly 24.9686.0429 Rev B Refer to Figure 3-35 Item UM. Description 10.9661.1275 1 EA HEATSINK, MAIN CONTROLLER 10.9678.0731 1 EA HEATSINK, CONTROLLER 10.9678.0746 1 EA GROMMET, PCB EDGE 10.9678.0885 1 EA KIT, THERMAL TRANSFER MAIN CONTROLLER 53.2200.0006 3 EA NUT, 6-32 KEPS SS 53.6616.0001 3 EA SCREW, 6-20 X 3/4"LG PPZ 53.6404.0003 2 EA SCREW, 4-40 X 1" PPZ 55.3303.0004 2 EA WASHER, #4 LOCK INT.TOOTH SS 55.6538.0002 3 EA WASHER, #6 NYLON NATURAL 55.2179.0001 1 EA CABLE ANCHOR MOUNT, #6 SCREW 02.96 86.001 0 0 Ref. 103 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL VL3500 Controller PCB Assembly (continued) Top Side Note: Heatsink not shown Bottom Side Figure 3-35: VL3500 Wash Controller PCB Assembly 104 02 .9 686.00 10 0 ENCLOSURE ASSEMBLY : UPPER ENCLOSURE ASSEMBLY 3 Enclosure Assembly Upper Enclosure Assembly 21.9686.0800 Rev H Refer to Figure 3-36 and Figure 3-37 No. Item Qty. UM. Description 1 04.9640.0374 1 EA LABEL, P.E. GROUND 2 04.9661.1218.01 1 EA LABEL, PATENT, VL2201 & VL2400 SERIES LUM. 3 04.9686.0040 1 EA LABEL, VL3500 WASH SERIES COMPLIANCE 4 06.6032.0009 1 EA CABLE MARKER TIE 5 10.9661.1258 1 EA BRACKET, APS SIDE 6 10.9678.1876 1 EA AIR DISTRIBUTION PLENUM 7 10.9678.0820 1 EA LANYARD, PAN TUBE 8 10.9686.0839 2 EA COVER, TOP 9 10.9686.0846 2 EA HANDLE, CAST ENCLOSURE 10 10.9678.0869 1 EA BRACKET, LVS 11 10.9678.0892 1 EA BUSHING, WIRE PROTECTION PAN 12 10.9678.0886 1 EA SPACER, PAN BEARING, .235" THK 13 12.9686.1236 2 EA MACHINED, COVER FRONT 14 12.9686.1238 2 EA MACHINED, COVER SIDE 15 12.9678.0842 1 EA AIR DUCT, UPPER ENCLOSURE MOD 16 21.9686.0840.02 1 EA ASSY, COVER - VENTILATION 17 21.9678.0767 1 EA ASSY, STABILIZER 17a - 10.9678.0757 1 EA STABILIZER, 1.377DIA 17b - 10.9678.0762 1 EA BRACKET, STABLIZER 17c - 53.6610.0003 1 EA SCREW, 6-32 X 7/16" PPZ 17d - 55.6568.0075 1 EA SPRING, EXTSN .375"OD 1.00"LG .041" WIRE DIA 18 21.9686.0805 1 EA ASSY, PANEL 19 21.9686.0807 1 EA ASSY, PAN PULLEY 20 21.9686.0864 1 EA ASSY, PAN MOTOR 21 21.9678.0881 1 EA ASSY, PAN TUBE 22 22.9686.0851 1 EA ASSY, UPPER ENCLOSURE 23 23.9686.1500 1 EA ASSY, BALLAST MODULE, 1500W ARC (INCLUDES ATTACHED FERRITE) 24 23.9686.0824 1 EA FAN ASSY, UPPER ENCLOSURE 02.96 86.001 0 0 105 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL No. Item Qty. UM. 25 21.9686.0811 1 EA FAN ASSY, EXHAUST 26 23.9678.0687 1 EA ELEC ASSY, PAN EOT SENSOR - 25.9661.1514 1 EA CABLE ASSY, LVS CHASSIS GROUND (not shown) - 25.9661.1520 1 EA CABLE ASSY, CHASSIS TO YOKE GROUND (not shown) - 25.9678.0811 1 EA CABLE ASSY, EMI FILTER TO POWER (not shown) - 25.9678.0812 1 EA CABLE ASSY, AC INPUT SPLITTER (not shown) - 25.9678.0813 1 EA CABLE ASSY, DATA I/O LINK (not shown) - 25.9678.1825 1 EA CABLE ASSY, DISPLAY (not shown) - 25.9678.0816 1 EA CABLE ASSY, BALLAST TO CONTROL (not shown) - 25.9678.0821 1 EA CABLE ASSY, DC OUTPUT (not shown) - 25.9678.0818 1 EA CABLE ASSY, PAN/TILT CONTROL (not shown) - 25.9678.0829 1 EA CABLE ASSY, LAMP SUPPLY TO RELAY (not shown) - 25.9686.0843 1 EA CABLE ASSY, DUAL AC FAN LVS TO YOKE (not shown) 27 53.2001.0003 1 EA NUT, 10-32 NYLON INSERT 28 53.2019.0004 4 EA NUT, 3/8-16 X 7/32" THK HEX 29 53.2200.0006 4 EA NUT, 6-32 KEPS SS 30 53.6505.0022 3 EA BOLT, 3/8-16 X 3/4"LG CARR 31 53.6515.0001 4 EA SCREW, 10-32 X 3/4" SCB CAP 32 53.6522.0001 1 EA SCREW, 6-32 X 1/4" PFZ 33 53.6522.0004 2 EA SCREW, 6-32 X 1/4" SOC HD 34 53.6525.0188 2 EA SCREW, 6-32 X 3/16" PPZ SEMS 35 53.6530.0023 2 EA RIVET, 1/8"OD POP .376-.500GRP 36 53.6539.0001 4 EA WASHER, 3/8" SPLIT LOCK 37 53.6545.0003 4 EA SCREW, 8-32 X 3/8" PFZ 38 53.6682.0022 4 EA SCREW, 8-32 X 3/8" LG PPZ SEMS 39 53.6556.0002 1 EA SCREW, 4-40 X 3/4"LG PPB 40 53.6558.0009 13 EA SCREW, 6-32 X 3/8"LG PPZ SEMS 41 53.6558.0010 11 EA SCREW, 6-32 X 1/4"LG PPZ BLACK 42 53.6558.0015 4 EA SCREW, 6-32 X 3/8" PPB SEMS EXT 43 53.6571.0003 1 EA SCREW, 6-32 X 1-1/2"LG PPB 44 53.6591.0001 2 EA SCREW, 6-32 X 1/4" PFZ 45 53.6609.0001 4 EA SCREW, 6-32 X 3/8" PFZ 46 53.6626.0001 1 EA SCREW, 10-32 X 1/2" PPZ 47 55.6575.0001 4 EA SCREW, 10-32 X 3/4" PPB 48 53.6634.1000 1 EA SCREW, 3/8-16 X 1.00" LG SOC 49 53.6653.0027 4 EA SCREW, 1/4-20 X 1 5/8"LG SOC 50 53.6513.0044 3 EA SCREW, M5 X 10MM STL CUP PT 51 54.1206.0014 2 EA RING, RETAINING 106 Description 02 .9 686.00 10 0 ENCLOSURE ASSEMBLY : UPPER ENCLOSURE ASSEMBLY No. Item Qty. UM. 52 54.1255.0001 1 EA BEARING ASSY, BLACK FLUSH MOU 53 54.2067.0001 1 EA BELT, TIMING S2M, 448 MM, 244 TEETH 54 55.2150.0003 2 EA STANDOFF, 1/4"HEX 6-32 1.125"L 55 55.2178.0001 3 EA CABLE ANCHOR MOUNT, #8 SCREW 56 55.2179.0001 3 EA CABLE ANCHOR MOUNT, #6 SCREW 57 55.2186.0001 5 EA CABLE TIE, .10"WD 4.00"LG SMALL (NOT SHOWN) 58 55.2261.0001 1 EA SLEEVE, NYLON THIN WALL #6 SCR 59 55.2267.0001 2 FT RUBBER STRIP, SPONGE CLSD CELL 60 55.6503.0004 4 EA WASHER #8 FLAT 61 55.6532.0004 2 EA BRACKET, 6-32 THREADED HOLES 62 55.6543.0001 3.75 IN GROMMET STRIP, SERRATED .062" 63 55.6543.0002 1.54 FT GROMMET STRIP, SERRATED .125" 64 55.6549.0001 4 EA WASHER, 1/4" SPLIT LOCK 65 55.6658.0009 1 EA STANDOFF, 1/4" HEX 6-32 X 3/4" 66 55.6568.0074 2 EA SPRING, CPRSN .420"OD .750"LG 67 55.6577.0005 2 EA STANDOFF, 1/2" HEX 6-32 1.625"L 68 55.6580.0002 2 EA CABLE TIE, .18" WD X 8.0" LG (NOT SHOWN) 69 55.6677.0044 1 EA WASHER, .877"OD.170"ID.093"THK 70 55.6699.0010 0.5 FT SLEEVING, 5/16" NON DIA WOVEN POLY ROUNDIT (NOT SHOWN) 71 55.6775.0009 1 EA BUSHING, SNAP .750"ID 1"MT H 72 67.4018.0001 1 EA FERRITE, 26X28.5 X 13MM CYL 73 67.9686.1500 1 EA FILTER, EMI 1500W BALLAST 74 68.4541.0004 1 EA FERRITE, CLAMP ON, AXIAL (NOT SHOWN) 75 68.9678.0827 1 EA CHOKE, COMMON MODE 76 69.3177.0151 1 EA LVS POWER SUPPLY, 150W +24V/6.3A 02.96 86.001 0 0 3 Description 107 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Upper Enclosure Assembly (continued) 47 (x4) 59 2 14 5 13 18 3 8 (x2) 41 (x4) 13 40 (x4) 14 41 (x4) 42 (x4) 9 (x2) 64 (x4) 16 49 (x4) Figure 3-36: Upper Enclosure Assembly 108 02 .9 686.00 10 0 ENCLOSURE ASSEMBLY : UPPER ENCLOSURE ASSEMBLY 3 Upper Enclosure (Standard) Assembly (continued) 7 27 11 19 53 50 (x3) 60 (x4) 31 (x4) 66 (x2) 20 51 (x2) 28 40 (x2) 26 54 (x2) 36 52 12 30 38 (x4) 17c Part is shown exploded for clarity 63 25 17a 17 71 44 (x2) 33 (x2) 29 (x2) 45 (x2) 55 (x2) 46 17b 61 (x2) 22 17d 28 36 45 (x2) 41 56 57 (x5) 37 63 (x3) 21 24 36 40 (x3) 48 15 30 6 Figure 3-37: Upper Enclosure Mechanical Components 02.96 86.001 0 0 109 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL 76 40 (x3) 62 72 4 67 32 34 (x2) 55 65 23 73 56 39 10 41 41 56 1 35 (x2) 29 (x2) 58 43 69 37 75 38 Figure 3-38: Upper Enclosure Electrical Components 110 02 .9 686.00 10 0 ENCLOSURE ASSEMBLY : VENTILATION COVER ASSEMBLY 3 Ventilation Cover Assembly 21.9686.0840.02 Rev B Refer to Figure 3-39 No. Item Qty. UM. 1 10.9686.1249 4 EA POST, TRUSS HOOK 1a 10.9678.0850 4 EA POST, TRUSS HOOK, SHORT, EARLY PRODUCTION 1b 10.9678.0833 4 EA SPACER, 1.25 " 2 10.9686.0883 1 EA COVER, VENTILATION 3 10.9678.0837 1 EA AIR SEAL, FAN SIDE 4 10.9678.0838 1 EA AIR SEAL, APS SIDE 5 10.9678.0835 1 EA AIR SEAL, SHORT STRIP 6 10.9678.0836 1 EA AIR SEAL, LONG STRIP 7 10.9678.0887 2 EA RAIN COVER SOUND INSULATION, ALUMINUM COVER 8 53.6653.0027 4 EA SCREW, 1/4-20 X 1 5/8 SOC HEAD 9 54.1206.0015 4 EA RING, RETAINING, PRESS-ON, 1" SH 10 55.6549.0001 4 EA WASHER, 1/4" SPLIT LOCK 02.96 86.001 0 0 Description 111 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Ventilation Cover Assembly (continued) 4 3 5 6 7 (x2) 9 (x4) 1b (x4) 2 1 (x4) 1a (x4) 10 (x4) Early production 8 (x4) Current Figure 3-39: Ventilation Cover Assembly 112 02 .9 686.00 10 0 ENCLOSURE ASSEMBLY : EXHAUST FAN ASSEMBLY 3 Exhaust Fan Assembly 21.9686.0811 Rev B Refer to Figure 3-40 No. Item Qty. UM. 1 40.7140.0001 1 EA BLOWER, CENTRIFUGAL, 24VDC 9CFM 3" X 3" 2 10.9686.0810 1 EA MOUNTING PLATE, EXHAUST FAN 3 55.6576.0001 2 EA SCREW, #10-16 X 3/8 TYPE B PFZ 4 52.6523.0002 1 EA CONN, HOUSING, 2 POS PLUG SHROUDED (NOT SHOWN) 5 52.8347.0001 2 EA CONTACT, 24-30 AWG MALE CRIMP (NOT SHOWN) 3 Description 2 1 Figure 3-40: Exhaust Fan Assembly 02.96 86.001 0 0 113 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Panel Assembly 21.9686.0805 Rev A Refer to Figure 3-41 No. Item Qty. UM. Description 1 10.9678.0852.01 1 EA LAYOUT, ENCLOSURE OVERLAY 2 10.9678.0859 1 EA BRACKET, INPUT 3 24.9663.3895 1 EA PCB ASSY, DMX INPUT 4 24.9678.3825 1 EA PCB ASSY, VL3000 DISPLAY 5 25.9678.0810 1 EA CABLE ASSY, AC INPUT PIGTAIL 6 51.0541 4 EA SCREW, 4- X 3/8" H/L BLK ZINC PLT 7 53.6558.0009 2 EA SCREW, 6-32 X 3/8"LG PPZ SEMS EXT ZINC PLT 8 55.2284.0001 1 EA CARD GUIDE, SNAP-IN 3" LONG 9 74.2000.0002 1 EA SWITCH, ROCKER, 2 POLE, HIGH CURRENT, BLACK 10 10.9678.0872 1 EA STIFFENER, DISPLAY CARD (not shown) 8 2 1 9 5 7 4 6 (x4) 3 included with item 5 Figure 3-41: Panel Assembly 114 02 .9 686.00 10 0 3 ENCLOSURE ASSEMBLY : DMX INPUT PCB DMX Input PCB 24.9663.3895 Rev 0 Refer to Figure 3-42 No. Item Qty. UM. 1 17.9663.3895 1 EA Description Ref. PCB FAB, DMX INPUT - 2 52.6259.0006 1 EA HEADER, 5POS MTA FRCT LOK STRT POST J3 3 52.6625.0006 1 EA CONN, RECEPT XLR 5PIN FEMALE PC MT VERTICAL J1 4 52.6626.0006 1 EA CONN, RECEPT XLR 5PIN MALE PC MT VERTICAL J2 5 62.3039.0102 1 EA CAP, 1000P 250V 20% CDE X-Y C1 1 5 2 4 3 Figure 3-42: DMX Input PCB 02.96 86.001 0 0 115 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Display PCB 24.9678.3825 Rev A Refer to Figure 3-43 Figure 3-43: Display PCB 116 02 .9 686.00 10 0 ENCLOSURE ASSEMBLY : PAN PULLEY ASSEMBLY 3 Pan Pulley Assembly 21.9686.0807 Rev B Refer to Figure 3-44 No. Item Qty. UM. Description 1 10.9686.0750 1 EA TIMING PULLEY, 170 TOOTH 2 10.9678.0855 1 EA PAN FLAG 3 53.6530.0009 2 EA RIVET, 1/8"OD POP .126-.187 GL 3 (x2) 2 1 Figure 3-44: Pan Pulley Assembly 02.96 86.001 0 0 117 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Pan Motor Assembly 21.9686.0864 Rev C Refer to Figure 3-45 No. Item Qty. UM. Description 1 10.9686.0865 1 EA PLATE, PAN MOTOR MOUNT 2 21.9686.0828 1 EA ASSY, DRIVE PULLEY, PAN - 10.9686.8720 1 EA CODEWHEEL, 120 COUNT LARGE ID - 10.9686.0749 1 EA TIMING PULLEY, 2MM GT 15 TOOTH - 53.5560.0250 1 EA SCREW, 8-32 X 1/4" SET CONE POINT 3 24.9678.9729 1 EA PCB ASSY, VL2203 PAN/TILT ENCODER 4 44.9678.0680 1 EA MOTOR, 3 PHASE SIZE 23 HIGH TORQUE 5 53.2200.0008 4 EA NUT, 8-32 KEPS SS 6 53.6546.0001 4 EA SCREW, 8-32 X 5/8" PPB 7 53.6682.0002 4 EA SCREW, 4-40 X 1/4"LG PPZ SEMS-EXT 8 10.9686.0840 2 EA STANDOFF, 1/4" 4-40/8-32 0.791" LG AL 9 10.9686.0457.01 2 EA SPACER, COLOR, .322 LG 10 54.1259.0009 6 EA BEARING, 1/4" ID, 1/2" OD EXT. INNER RACE 11 53.6575.0009 2 EA SCREW, 8-32 X 3/8" LG PPZ SEMS 12 10.9686.0841 1 EA ADAPTOR PLATE, PAN SENSOR PCB 118 02 .9 686.00 10 0 ENCLOSURE ASSEMBLY : PAN MOTOR ASSEMBLY Note: Vari-Lite recommends that this motor be replaced as a complete assembly. Although you can replace only the motor, the pulley (Item 2) is bonded to the motor shaft during assembly and cannot be removed intact. If you order a replacement motor (Item 4), also order the pulley (Item 2). Contact Vari-Lite Customer Service for installation information. 2 3 7 (x4) 3 12 10 (x6) 9 (x2) 5 (x4) 8 (x2) 1 Connector oriented on this side 11 (x2) 4 6 (x4) Figure 3-45: Pan Motor Assembly 02.96 86.001 0 0 119 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Pan Tube Assembly 21.9678.0881 Rev 0 Refer to Figure 3-46 No. Item Qty. UM. Description 1 10.9678.0809 1 EA PAN TOGGLE STOP 2 10.9678.0847 1 EA SILICONE FOAM WASHER 3 10.9678.0848 2 EA WASHER, PAN TEFLON 4 12.9678.0877 1 EA PAN TUBE, MACHINED 5 54.1206.0021 1 EA RING, RETAINING 1.562"SHAFT 1.468"GRV DIA .068"GRVWD EXTERNAL 6 54.1255.0002 1 EA BEARING ASSY, FLUSH MOUNT HOUSING LARGE 5 6 3 1 3 2 4 Figure 3-46: Pan Tube Assembly 120 02 .9 686.00 10 0 ENCLOSURE ASSEMBLY : 1500W ARC BALLAST MODULE ASSEMBLY 3 1500W Arc Ballast Module Assembly 23.9686.1500 Rev 0 Refer to Figure 3-47. Figure 3-47: 1500W Arc Ballast Module Assembly (Side View) 02.96 86.001 0 0 121 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Notes 122 02 .9 686.00 10 0 CABLE ASSEMBLIES : PAN EOT SENSOR ELECTRICAL ASSEMBLY 3 Cable Assemblies Pan EOT Sensor Electrical Assembly 23.9678.0687 Rev A Refer to Figure 3-48 No. Item Qty. UM. Description 1 52.6524.0006 1 EA CONN, HOUSING 6 POS RECEPTACLE 2 52.8346.0001 4 EA CONTACT, 24-30AWG FEMALE CRIMP 3 86.7002.0003 1 EA SWITCH, SLOTTED OPTICAL 1 2 (x4) 3 Figure 3-48: Pan EOT Sensor Electrical Assembly 02.96 86.001 0 0 123 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL LVS Chassis Ground Cable Assembly 25.9661.1514 Rev A Refer to Figure 3-49 No. Item Qty. UM. 1 52.8231.0005 1 EA TERM, RING #6 BLUE 16-14 AWG REEL PIDG 2 52.8271.0001 1 EA FASTON RECEPT, 16-14 AWG (REEL) 3.5 IN WIRE, 16 AWG 300V 105C PVC GRN/YEL UL1569 3 73.3516.0504 1 Description 3 2 Figure 3-49: LVS Chassis Ground Cable Assembly 124 02 .9 686.00 10 0 CABLE ASSEMBLIES : CHASSIS TO YOKE GROUND CABLE ASSEMBLY 3 Chassis To Yoke Ground Cable Assembly 25.9661.1520 Rev C Refer to Figure 3-50 No. Item Qty. UM. Description 1 52.8250.0006 2 EA TERM, #8, RING, 10AWG 2 73.7089.0504 15.17 FT WIRE, 22AWG 300V 200C TEF GRN/YEL UL1180 1 (x2) 2 Figure 3-50: Chassis To Yoke Ground Cable Assembly 02.96 86.001 0 0 125 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Ignitor to Relay Cable Assembly 25.9661.1526 Rev C Refer to Figure 3-51. No. Item Qty. UM. Description 1 52.8231.0005 1 EA TERM, RING #6 BLUE 16-14 AWG (LOOSE) PIDG 2 52.8312.0001 1 EA RECP, FASTON 1/4" 18-14 AWG INSULATED VO 3 73.7101.0009 0.42 FT WIRE, 14AWG 15KV 150C SILICONE 41/30 STRANDING 1 2 3 Figure 3-51: Ignitor to Relay Cable Assembly 126 02 .9 686.00 10 0 CABLE ASSEMBLIES : LVS TO YOKE DUAL AC FAN CABLE ASSEMBLY 3 LVS to Yoke Dual AC Fan Cable Assembly 25.9686.0843 Rev A Refer to Figure 3-52 No. Item Qty. UM. Description 1 52.6664.0001 4 EA CONTACT, 22-26AWG FEMALE MATE-N-LOK 2 2 52.6664.0002 2 EA CONN, HOUSING 2 POS CAP MATE-N-LOK 2 3 52.8231.0008 2 EA TERM, SPADE #6 RED 22-16AWG INSERT 4 55.2186.0001 2 EA CABLE TIE, .10" WD 4.00"LG SMALL 5 55.6699.0002 2.08 FT SLEEVING, 1/4" NOM.DIA. POLY EXP BRAIDED 6 73.6222.0009 4.34 FT WIRE, 22AWG 600V 200C TFE WHT UL1199 7 73.6222.0010 4.34 FT WIRE, 22AWG 600V 200C TFE BLK UL1199 4 (x2) 1, 2 5 7 6 3 2 (A) 3 (A) 3 (B) 2 (B) 1, 2 Figure 3-52: LVS to Yoke Dual AC Fan Cable Assembly 02.96 86.001 0 0 127 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Yoke to Dual AC Fan Cable Assembly 25.9686.0012 Rev A Refer to Figure 3-53 No. Item Qty. UM. Description 1 52.6665.0001 4 EA CONTACT, 22-26AWG MALE MATE-N-LOK 2 2 52.6665.0002 2 EA CONN, HOUSING 2 POS PLUG MATE-N-LOC 2 3 52.8413.0001 4 EA RECEPT, FASTON .110 SERIES 22-18AWG INSULATED 4 55.2186.0002 2 EA CABLE TIE, .09"WD 3.750"LG TEFZEL 5 55.2260.0208 2.75 FT SLEEVING, FIBERGLASS 0.208 ID 6 55.2200.0003 0.50 FT HEATSHRINK, TEFLON NATURAL COLOR 7 73.6222.0009 6.33 FT WIRE, 22AWG 600V 200C TFE WHT UL1199 19STRAND 8 73.6222.0010 6.33 FT WIRE, 22AWG 600V 200C TFE BLK UL1199 4 (x2) 1, 2 (x2) 5 8 7 6 3 (x4) 2 (A) 2 (B) Figure 3-53: Yoke to Dual AC Fan Cable Assembly 128 02 .9 686.00 10 0 CABLE ASSEMBLIES : OT SWITCH 1 TO OT SWITCH 2 CABLE ASSEMBLY 3 OT Switch 1 to OT Switch 2 Cable Assembly 25.9686.0013 Rev A Refer to Figure 3-55 No. Item Qty. UM. 1 52.8371.0001 2 EA RECEPT, FASTON, 24-20 AWG UNINSUL 2 73.7089.0000 0.42 FT WIRE. 22AWG 300V 200C TEF BLK UL1180 1 Description 3 1 Figure 3-54: OT Switch 1 to OT Switch 2 Cable Assembly 02.96 86.001 0 0 129 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Backcap Interlok to OT Switch 1 Cable Assembly 25.9686.0014 Rev A Refer to Figure 3-55 No. Item Qty. UM. Description 1 52.8414.0001 1 EA RECEPT, FASTON, .187 SERIES 24-20 AWG UNINSUL 2 52.8371.0001 1 EA RECEPT, FASTON, 24-20 AWG UNINSUL 3 73.7089.0000 0.33 FT WIRE. 22AWG 300V 200C TEF BLK UL1180 2 3 1 Figure 3-55: Backcap Interlok to OT Switch 1 Cable Assembly 130 02 .9 686.00 10 0 CABLE ASSEMBLIES : OT SWITCH TO GROUND CABLE ASSEMBLY 3 OT Switch to Ground Cable Assembly 25.9678.0015 Rev A Refer to Figure 3-56 No. Item Qty. UM. 1 52.8237.0002 1 EA TERM, RING #4 24-20AWG 2 52.8371.0001 1 EA RECEPT, FASTON 24-20AWG UNISUL TIN PLT BRS .250 X .032 TAB 3 73.7089.0000 0.25 FT WIRE, 22AWG BLK 300V 200C TEFLON STRANDED 2 Description 3 1 Figure 3-56: OT Switch to Ground Cable Assembly 02.96 86.001 0 0 131 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Tilt Harness Cable Assembly 25.9686.0203 Rev G Refer to Figure 3-61 No. Item Qty. UM. 1 52.6610.0040 2 EA CONNECTOR, HOUSING 40 POS, 26-22 AWG DBL ROW UNLOADED 2 52.6224.1040 2 EA COVER, FRONT 40 POS MT LATCHING 3 52.6224.2040 2 EA COVER, BACK 40 POS MT 4 52.6610.0034 1 EA CONNECTOR, HOUSING 34 POS, 26-22 AWG DBL ROW UNLOADED 5 52.6224.1034 1 EA COVER, FRONT 34 POS MT LATCHING 6 52.6224.2034 1 EA COVER, BACK 34 POS MT 7 52.6610.0017 1 EA CONNECTOR, HOUSING 50 POS, 26-22 AWG DBL ROW UNLOADED 8 52.6224.1050 1 EA COVER, FRONT 50 POS MT LATCHING 9 52.6224.2050 1 EA COVER, BACK 50 POS MT 10 52.8351.0004 110 EA CONTACT, 26-22 AWG RECP MTE 11 52.6524.0004 2 EA CONNECTOR, HOUSING 4 POS RECEPTACLE 30-24 AWG 12 52.8346.0001 6 EA CONTACT, 24-30 AWG FEMALE CRIMP 13 73.5116.0123 25.8 FT WIRE, 24 AWG, 4 COND TW, 300V 80C (BLK-BRN-RED-ORN) 14 73.5126.0002 1.9 FT WIRE, 26 AWG, 2 COND TW, 300V 80C (BLK-RED) 15 55.2186.0001 2 EA CABLE TIE, .10 X 4" SMALL 16 55.6699.0011 1.13 FT SLEEVING, 3/4" NOM. DIA WOVEN POLY, ROUNDIT 200D 7 8 9 10 (x110) Description 11 (x2) 12 (x6) 15 4 5 6 10 (x110) 16 13, 14 1 (x2) 2 (x2) 3 (x2) 10 (x110) Figure 3-57: Tilt Harness Cable Assembly 132 02 .9 686.00 10 0 CABLE ASSEMBLIES : INTERNAL LENS INTERCONNECT CABLE ASSEMBLY 3 Internal Lens Interconnect Cable Assembly 25.9686.0204 Rev 0 Refer to Figure 3-61 No. Item Qty. UM. 1 52.6610.0014 2 EA CONNECTOR, HOUSING 14 POS, 26-22 AWG 2 52.6224.1014 2 EA COVER, FRONT 14 POS MT LATCHING 3 52.6224.2014 2 EA COVER, BACK 14 POS MT 4 55.2186.0001 4 EA CABLE TIE, .10 X 4" SMALL 5 55.6699.0004 0.6 FT SLEEVING, 3/4" NOM. DIA POLY EXP BRAID 6 73.5116.0123 4.0 FT WIRE, 24 AWG, 4 COND TW, 300V 80C (BLK-BRN-RED-ORN) 7 73.5126.0002 2.0 FT WIRE, 26 AWG, 2 COND TW, 300V 80C (BLK-RED) 8 73.5126.0007 2.0 FT WIRE, 26 AWG, 2 COND TW, 300V 80C (BLK-ORN) 9 73.3026.0009 2.0 FT WIRE, 26 AWG 300V 80C WHT 10 52.8351.0004 26 EA CONTACT, 26-22 AWG RECP MTE 4 (x4) 6, 7, 8, 9 Description 5 1 (x2) 2 (x2) 3 (x2) 10 (x26) Figure 3-58: Internal Lens Interconnect Cable Assembly 02.96 86.001 0 0 133 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Color Harness Cable Assembly 25.9686.0205 Rev E Refer to Figure 3-59 No. Item Qty. UM. 1 52.6610.0040 1 EA CONNECTOR, HOUSING 40 POS, 26-22 AWG DBL ROW UNLOADED 2 52.6224.1040 1 EA COVER, FRONT 40 POS MT LATCHING 3 52.6224.2040 1 EA COVER, BACK 40 POS MT 4 52.6610.0034 1 EA CONNECTOR, HOUSING 34 POS, 26-22 AWG DBL ROW UNLOADED 5 52.6224.1034 1 EA COVER, FRONT 34 POS MT LATCHING 6 52.6224.2034 1 EA COVER, BACK 34 POS MT 7 52.8351.0004 52 EA CONTACT, 26-22 AWG RECP MTE 8 52.6467.0011 2 EA CONNECTOR, FEMALE PLUG 11 POS, 30-24 AWG 9 52.6467.0024 20 EA CONTACT, SOCKET 30-24 AWG CRIMP 10 52.6662.0006 8 EA HOUSING, 6 POS 125/2A 2.0 MM PITCH 11 52.8388.0001 32 EA CONTACT, 24-30 AWG FEMALE CRIMP 2.0 MM PITCH 12 55.2186.0001 8 EA CABLE TIE, .10 X 4" SMALL 13 73.2324.0123 13.33 FT WIRE, 24 AWG, 4 COND TW, 300V 200C TEF (BLK-BRN-RED-ORN) 14 73.2328.5000 3.29 FT WIRE, 26 AWG, 6 COND TW, 300V 200C TEF UL1180 15 52.6467.0001 2 EA CONN, FEMALE PLUG, 6 POS 24-30 AWG 1 10, 11 2 3 7 (x52) 13 Description 10, 11 15, 9 14 8, 9 10, 11 13 13 13 13 12 (x8) 8, 9 13 4 5 6 7 (x52) 10, 11 13 14 15, 9 10, 11 Figure 3-59: Color Harness Cable Assembly 134 02 .9 686.00 10 0 CABLE ASSEMBLIES : INTERNAL-LENS SPLIT MOTOR CABLE ASSEMBLY 3 Internal-Lens Split Motor Cable Assembly 25.9686.0206 Rev 0 Refer to Figure 3-60 No. Item Qty. UM. 1 52.6467.0004 1 EA CONNECTOR, FEM PLUG 4 POS, 30-24 AWG 2 52.6467.0024 4 EA CONTACT, 24-30 AWG FEMALE CRIMP 2.00 MM PITCH 3 52.6696.0001 1 EA RECEPT, WIRE TO WIRE 4 POS, 2 MM PITCH 28-24 AWG 4 52.6694.0001 4 EA CRIMP, TERMINAL WIRE-TO-WIRE FEMALE 2 MM PITCH 28-24 AWG 5 73.2326.0123 0.7 FT WIRE, 26 AWG, 4 COND, 300V 200C TEF UL1180 (BLK-BRN-RED-ORN) 3 4 (x4) Description 5 1 2 (x4) Figure 3-60: Internal-Lens Split Motor Cable Assembly 02.96 86.001 0 0 135 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Zoom Motor Cable 25.9686.0207 Rev 0 Refer to Figure 3-61 No. Item Qty. UM. Description 1 52.662.0006 1 EA HOUSING, 6 POS, 125/2A 2.00 MM PITCH 2 52.6467.0024 4 EA CONTACT, 24-30 AWG FEMALE CRIMP 2.00 MM PITCH 3 73.2326.0123 0.75 FT WIRE, 26 AWG, 4 COND, 300V 200C TEF UL1180 (BLK-BRN-RED-ORN) 3 1 2 (x4) Figure 3-61: Zoom Motor Cable 136 02 .9 686.00 10 0 CABLE ASSEMBLIES : TRANSFER FANS CABLE ASSEMBLY 3 Transfer Fans Cable Assembly 25.9686.0209 Rev B Refer to Figure 3-62 No. Item Qty. UM. Description 1 52.6523.0004 1 EA CONN, HOUSING 4POS RECEPTACLE 2 52.6524.0002 2 EA CONN, HOUSING 2POS RECEPTACLE 3 52.8347.0001 4 EA CONTACT, 24-30AWG MALE CRIMP 4 52.8346.0001 4 EA CONTACT, 24-30AWG FEMALE CRIMP 5 73.2324.0200 2.21 FT WIRE, 26AWG 2COND 300V 200C UL1213 6 52.8274.0001 2 EA CONNECTOR, BUTT SPLICE, 22-18 AWG INSULATED 1 3 (x4) 5 4 (x4) 2 (x2) 6 (x2) Figure 3-62: Transfer Fans Cable Assembly 02.96 86.001 0 0 137 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Upper Enclosure Fans Cable Assembly 25.9686.0210 Rev B Refer to Figure 3-63 No. Item Qty. UM. 1 52.6523.0004 1 EA CONN, HOUSING 4POS RECEPTACLE 2 52.6524.0002 2 EA CONN, HOUSING 2POS RECEPTACLE 3 52.8347.0001 4 EA CONTACT, 24-30AWG MALE CRIMP 4 52.8346.0001 4 EA CONTACT, 24-30AWG FEMALE CRIMP 5 73.5126.0002 2.67 FT WIRE, 26AWG 2COND 300V 80C 1 3 (x4) Description 5 4 (x4) 2 (x2) Figure 3-63: Upper Enclosure Fans Cable Assembly 138 02 .9 686.00 10 0 CABLE ASSEMBLIES : YOKE FAN AND RELAY CABLE ASSEMBLY 3 Yoke Fan and Relay Cable Assembly 25.9678.0681 Rev C Refer to Figure 3-64 No. Item Qty. UM. Description 1 52.6423.0003 1 EA HOUSING, 3 POS MT RECEPT, 2MM 2 52.8230.0003 1 EA RECEPT, 1/4" FASTON 22-18AWG 3 52.6396.3103 1 EA RECEPT, 3 POS MTA100 W/ POL TAB BLU CLSD END 4 73.3526.0002 1.25 FT WIRE, 26AWG 300V 105C PVC RED 5 73.5126.0002 1.50 FT WIRE, 26AWG 2 COND 300V 80C 3 1 5 4 2 Figure 3-64: Yoke Fan and Relay Cable Assembly 02.96 86.001 0 0 139 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Yoke Fan Cable Assembly 25.9678.0758 Rev A Refer to Figure 3-65 No. Item Qty. UM. Description 1 52.6396.3102 1 EA RECEPT, 2POS MTA100 W/POL TAB BLUE CLSD END 2 52.6423.0003 1 EA HOUSING, 3POS MT RECEPT, 2MM CT 28-26 AWG 3 73.5126.0002 .5 FT WIRE, 26AWG 2COND 300V 80C UL1061, 19STRND 2 1 3 Figure 3-65: Yoke Fan Cable Assembly 140 02 .9 686.00 10 0 CABLE ASSEMBLIES : OT SWITCH TO INTERLOK CABLE ASSEMBLY 3 OT Switch to Interlok Cable Assembly 25.9686.0201 Rev A Refer to Figure 3-66 No. Item Qty. UM. Description 1 52.8230.0003 1 EA RECEPT, FASTON 22-18AWG 1/4" 2 52.8414.0001 1 EA RECEPT, FASTON, .187 SERIES 24-20 AWG UNISUL 3 73.7089.0000 3.00 FT WIRE. 22AWG 300V 200C TEF BLK UL1180 1 3 2 Figure 3-66: OT Switch to Interlok Cable Assembly 02.96 86.001 0 0 141 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL OT Switch 1 to OT Switch 2 Cable Assembly 25.9686.0013 Rev A Refer to Figure 3-67 No. Item Qty. UM. Description 1 52.8371.0001 2 EA RECEPT, FASTON 24-20AWG UNISUL TIN 2 73.7089.0000 0.42 FT WIRE. 22AWG 300V 200C TEF BLK UL1180 1 2 1 Figure 3-67: OT Switch 1 to OT Switch 2 Cable Assembly 142 02 .9 686.00 10 0 CABLE ASSEMBLIES : IGNITOR TO LAMP SOCKET CABLE ASSEMBLY 3 Ignitor to Lamp Socket Cable Assembly 25.9678.0789 Rev B Refer to Figure 3-68. No. Item Qty. UM. Description 1 52.8231.0005 2 EA TERM, RING #6 BLUE 16-14 AWG REEL PIDG 2 55.2186.0001 3 EA CABLE TIE, .10"WD 4.00"LG SMALL 3 55.2260.0133 6.83 FT SLEEVING, FIBERGLASS .133" ID 4 73.7100.0001 2.84 FT WIRE, 16AWG 20KVDC 41/32 STRD 200C SILICONE 2 X 17" (NOT SHOWN) 5 73.7190.0001 3.66 FT WIRE, 250 DEG C 6 55.2200.0003 .33 FT HEAT SHRINK TUBING 2 X 2" (NOT SHOWN) 7 52.8274.1614 2 EA CONN, BUTT SPLICE, 16-14 PIDG 3 (1 x 44" each) 1 (x2) 7 2 (x3) 5 (1 x 20" each) 5 (1 x 24" each) From Ignitor Output To Arc Lamp Socket 3 (1 x 48" each) 7 Figure 3-68: Ignitor to Lamp Socket Cable Assembly 02.96 86.001 0 0 143 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Chassis to Yoke Ground Cable Assembly 25.9661.1520 Rev C Refer to Figure 3-69 No. Item Qty. UM. 1 52.8250.0006 2 EA TERM, RING #8, 10AWG 2 73.7089.0504 15.17 FT WIRE, 22AWG 300V 200C TEF GRN/YEL UL1180 1 (x2) Description 2 Yoke Ground Head Ground Figure 3-69: Chassis to Yoke Ground Cable Assembly 144 02 .9 686.00 10 0 CABLE ASSEMBLIES : ZOOM MOTOR CABLE ASSEMBLY 3 Zoom Motor Cable Assembly 23.9686.0208 Rev 0 Refer to Figure 3-70 No. Item Qty. UM. Description 1 25.9686.0207 1 EA CABLE ASSY, ZOOM MOTOR 2 24.9678.5916 1 EA PCB ASSY, ZOOM INTERCONNECT 2 1 Figure 3-70: Zoom Motor Cable Assembly 02.96 86.001 0 0 145 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL AC Input Pigtail Cable Assembly 25.9678.0810 Rev B Refer to Figure 3-71 No. Item Qty. UM. Description 1 52.6274.2313 1 EA STRAIN RELIEF, SKINTOP FLEX TYPE PG13 BLK 2 52.6401.2321 1 EA CONN, PLUG "CE MARKED" 20A 250V TWIST-LOCK MALE LINE, 3-WIRE 3 52.8231.0005 1 EA TERM, RING #6 BLUE 16-14 AWG REEL PIDG 4 52.8298.1160 2 EA FERRULE, WIRE 1X16 AWG L2=8MM BLACK 5 55.2268.0187 0.92 FT HEATSHRINK, 3/16" CLEAR KYNAR VDE UL 600V 150DEG C 6 55.2268.0500 0.13 FT HEATSHRINK, 1/2" CLEAR KYNAR VDE UL 600V 150DEG C 7 73.9636.0153 4.00 FT CORDAGE, 1.5/3 750V 60C EURO BLK HD-22 11MMOD 4 (x2) 2 7 1 6 5 3 Figure 3-71: AC Input Pigtail Cable Assembly 146 02 .9 686.00 10 0 CABLE ASSEMBLIES : EMI FILTER TO POWER SWITCH CABLE ASSEMBLY 3 EMI Filter to Power Switch Cable Assembly 25.9678.0811 Rev C Refer to Figure 3-72 No. Item Qty. UM. Description 1 52.8313.0001 2 EA RCPT, FASTON 1/4" 18-14 AWG FLAG DBL CRP (REEL) 2 52.8392.0001 2 EA RECP, FASTON .187"X0.32" 16-14 AWG FLAG DBL CRP 3 55.2186.0001 1 EA CABLE TIE, .10"WD 4.00"LG SMALL 4 73.6016.0009 0.83 FT WIRE, 16AWG 600V 105C PVC WHT UL1015 5 73.6016.0010 0.83 FT WIRE, 16AWG 600V 105C PVC BLK UL1015 2 (x2) 1 (x2) 4 White 3 White Black Black 5 Figure 3-72: EMI Filter to Power Switch Cable Assembly 02.96 86.001 0 0 147 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL AC Input Splitter Cable Assembly 25.9678.0812 Rev E Refer to Figure 3-73 No. Item Qty. UM. Description 1 52.6231.0001 1 EA PLUG HOUSING, MNLOK PLUG 3 POS 2 52.8231.0005 1 EA TERM, RING #6 BLUE 16-14 AWG REEL PIDG 3 52.8231.0008 2 EA TERM, SPADE #6 RED 22-16 AWG INSERT 4 52.8392.0001 2 EA RECP, FASTON .187" X 0.32" 16-14 AWG FLAG DBL CRP 5 52.8270.0001 2 EA CONTACT PIN, 20-14 AWG MNLOK (REEL) 6 52.8314.0001 1 EA PIN, GND 20-14 AWG MNLOK .060"- .130"INS DIA 7 55.2186.0001 3 EA CABLE TIE, .10" WD, 4.00" LG, SMALL 8 55.6699.0003 1.50 FT SLEEVING, 1/2" NOM. DIA. POLY EXP BRAIDED 9 73.6016.0009 1.83 FT WIRE, 16 AWG 600V 105C PVC WHT UL1015 10 73.6016.0010 1.83 FT WIRE, 16 AWG 600V 105C PVC BLK UL1015 11 73.6016.0504 2.08 FT WIRE, 16 AWG 600V 105C PVC GRN/YEL UL1015 12 73.6018.0009 1.00 FT WIRE, 18 AWG 600V 105C PVC WHT UL1015 13 73.6018.0010 1.00 FT WIRE, 18 AWG 600V 105C PVC BLK UL1015 148 02 .9 686.00 10 0 CABLE ASSEMBLIES : AC INPUT SPLITTER CABLE ASSEMBLY 3 AC Input Splitter Cable Assembly (continued) 4 (x2) 3 (x2) 12 2 5, 9 13 5, 10 11, 6 1 7 (x3) 8 Figure 3-73: AC Input Splitter Cable Assembly 02.96 86.001 0 0 149 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Data I/O Link Cable Assembly 25.9678.0813 Rev A Refer to Figure 3-74 No. Item Qty. UM. Description 1 52.6396.2904 1 EA RECEPT, 4 POS MTA100 W/POL TAB RED CLSD END 2 52.6396.2905 1 EA RECEPT, 5 POS MTA100 W/POL TAB RED CLSD END 3 73.5122.0259 2.17 FT CBL, 22AWG STRND 4COND PVC INSUL 2 1 3 Figure 3-74: Data I/O Link Cable Assembly 150 02 .9 686.00 10 0 CABLE ASSEMBLIES : DISPLAY CABLE ASSEMBLY 3 Display Cable Assembly 25.9678.1825 Rev C Refer to Figure 3-75 No. Item Qty. UM. Description 1 52.6396.2406 2 EA RECEPT, 6 POS MTA100 W/POL TAB WHT CLSD END 2 73.5116.0123 1.02 FT WIRE, 24AWG 4COND TW 3 55.2186.0001 4 EA CABLE TIE, .10" WD 4" LG SMALL (NOT SHOWN) 4 73.7130.0004 .958 FT WIRE, TUBULAR BRAID, 1/8" X 23" LG (NOT SHOWN) 5 73.6224.0005 .208 FT WIRE, 24AWG 600V 200C TFE GRN 2.5" LG 6 55.6699.0009 .208 FT SLEEVING, 3/8" NOM DIA POLY EXP 7 55.6621.0001 1 EA SLEEVE, NYLON THIN WALL #6 SCR 1.0" LG (NOT SHOWN) 1 (x2) 2 GRN 5 6 Figure 3-75: Display Cable Assembly 02.96 86.001 0 0 151 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Ballast to Controller Cable Assembly 25.9678.0816 Rev A Refer to Figure 3-76 No. Item Qty. UM. Description 1 52.6396.3002 1 EA RECEPT, 2 POS MTA100 W/POL TAB WHT CLSD END 2 52.6396.3005 1 EA RECEPT, 5 POS MTA100 W/POL TAB WHT CLSD END 3 52.6396.3008 1 EA RECEPT, 8 POS MTA100 W/POL TAB WHT CLSD END 4 73.5124.1289 3.67 FT WIRE, 24AWG 5COND 2 3 4 1 Figure 3-76: Ballast to Controller Cable Assembly 152 02 .9 686.00 10 0 CABLE ASSEMBLIES : DC OUTPUT CABLE ASSEMBLY 3 DC Output Cable Assembly 25.9678.0821 Rev E Refer to Figure 3-77 No. Item Qty. UM. Description 1 52.6464.0002 1 EA CONN, HOUSING, SL-156 2 POS 2 52.6464.0003 1 EA CONN, HOUSING, SL-156 3 POS 3 52.8231.0004 2 EA TERM, RING #6 BLUE 12-10 AWG INSRT 4 52.8323.0002 4 EA CONTACT, CRIMP, 18-22 AWG SL-156 (not shown) 5 52.8274.1614 2 EA CONN BUTT SPLICE 16-14 BLUE .150" OD MAX 6 55.2186.0001 4 EA CABLE TIE, .01" x 4.00" SMALL 7 55.6699.0003 2.08 FT SLEEVING, 1/2" NOM DIA POLY EXP BRAID 8 73.3518.0002 1.58 FT WIRE, 18 AWG 300V 105C PVC RED 9 73.3518.0010 1.58 FT WIRE, 18 AWG 300V 105C PVC BLK 10 73.7060.0001 2.08 FT WIRE, 18 AWG HI VOLT RED YOKE LMP 11 73.7060.0002 2.08 FT WIRE, 18 AWG HI VOLT BLK YOKE LMP 1, 4 2, 4 6 9 5 (x2) 3 (x2) 8 6 6 11 6 9 8 10 7 Figure 3-77: DC Output Cable Assembly 02.96 86.001 0 0 153 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Pan/Tilt Control Cable Assembly 25.9678.0818 Rev B Refer to Figure 3-78 No. Item Qty. UM. Description 1 52.6610.0008 1 EA HOUSING, 20POS UNLOADED DBL ROW 2 52.6224.1020 1 EA COVER, FRONT 20POS MT LATCHING 3 52.6224.2020 1 EA COVER, BACK 20POS MT 4 52.6524.0005 2 EA CONN, HOUSING 5POS RECEPTACLE 5 52.6588.0007 2 EA HOUSING, 7POS XH 250V/3A 2.5MMPITCH 6 52.7007.0001 6 EA CONTACT, 28-22AWG PHOSPHOR BRONZE TIN-PLT 7 52.8346.0001 10 EA CONTACT, 24-30AWG FEMALE CRIMP 8 55.2186.0001 6 EA CABLE TIE, .10"WD 4.00"LG SMALL 9 73.5119.0246 6.08 FT WIRE, 24AWG 3COND TW 600V 200C 10 73.5124.1289 6.17 FT WIRE, 24AWG 5COND 300V 80C (BLK-BRN-RED-GRY-WHT) 11 52.8351.0004 16 EA CONTACT, 26-22 AWG RECP MTE (REEL) (NOT SHOWN) 7 (x10) 4 (x2) 10 1 2 3 8 (x6) 9 5 (x2) 6 (x6) Figure 3-78: Pan/Tilt Control Cable Assembly 154 02 .9 686.00 10 0 CABLE ASSEMBLIES : LAMP SUPPLY TO RELAY CABLE ASSEMBLY 3 Lamp Supply to Relay Cable Assembly 25.9678.0829 Rev A Refer to Figure 3-79 No. Item Qty. UM. Description 1 52.8312.0001 4 EA RECP, FASTON 1/4" 18-14 AWG INSULATED VO 2 55.2186.0001 3 EA CABLE TIE, .10"WD 4.00"LG SMALL 3 55.6699.0003 3.19 FT SLEEVING, 1/2" NOM. DIA POLY EXP BRAIDED 4 73.7089.0000 34.41 FT WIRE, 22AWG BLK 300V TEFLON STRANDED 5 73.7089.0009 34.41 FT WIRE, 22AWG WHT 300V TEFLON STRANDED 6 73.3516.0504 .58 FT WIRE, 16 AWG 300V 105C PVC GRN/YEL UL1569 7 52.8245.0001 1 EA TERM, RING, #10 16-14 AWG REEL PIDG 8 73.7130.0005 2.08 FT WIRE, TUBULAR BRAID, 7/16" (NOT SHOWN) 9 55.2183.0001 .33 FT HEATSHRINK 1/2" BLACK (NOT SHOWN) 5 (x7) 1 (x2) To Relay 1 (x2) From Lamp Supply 7 4 (x7) 6 3 2 (x3) Figure 3-79: Lamp Supply to Relay Cable Assembly 02.96 86.001 0 0 155 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Notes 156 02 .9 686.00 10 0 APPENDIX A : VL3500™ WASH LUMINAIRE TECHNICAL BULLETINS A APPENDIX A. Technical Bulletins VL3500™ Wash Luminaire Technical Bulletins The following table identifies the current technical bulletins associated with the VL3500™ Wash Luminaires. These improvements have been incorporated into this manual (where applicable) and are available on the Vari-Lite web site at www.vari-lite.com. Technical Bulletin Description Model(s) TN-264 Split Lens Rail Change VL3500 Wash TN-274 Pack-up Cues VL3500 Wash TN-275 Lamp Part Number Change VL3500 Wash Technical Bulletins, Software Updates, support, and other information is available online at http://www.vari-lite.com (under the Support Tab). To request access to the password-protected support areas, please contact Vari-Lite Customer Service at 1-877-827-4548 or [email protected]. 02.96 86.001 0 0 157 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Notes 158 02 .9 686.00 10 0 APPENDIX B : SCHEMATICS AND DIAGRAMS LIST B APPENDIX B. Schematics and Wiring Diagrams Schematics and Diagrams List The following list includes the schematics and diagrams included in Appendix B: • VL3500 Wash Wiring Diagram (Sheet 1 of 3) • Solid State Ignitor PCB (Sheet 1 of 1) • DMX Input PCB (Sheet 1 of 1) • Color Sensor Offset PCB (Sheet 1 of 1) • Color Sensor Inline PCB (Sheet 1 of 1) • Pan/Tilt Encoder PCB (Sheet 1 of 1) • VL3500 Controller PCB (Sheet 1 of 10) • Display PCB (Sheet 1 of 1) 02.96 86.001 0 0 159 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL Notes 160 02 .9 686.00 10 0 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS VL3500 Wash Wiring Diagram (Sheet 1 of 3) 02.96 86.001 0 0 161 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS VL3500 Wash Wiring Diagram (Sheet 2 of 3) 02.96 86.001 0 0 162 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS VL3500 Wash Wiring Diagram (Sheet 3 of 3) 02.96 86.001 0 0 163 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS Solid State Ignitor PCB (Sheet 1 of 1) 8 7 6 5 4 3 1 2 REVISIONS DESCRIPTION REV NOTES: UNLESS OTHERWISE SPECIFIED 1. ALL CAPACITOR VALUES ARE IN MICROFARADS. 2. ALL RESISTOR VALUES ARE IN OHMS. DATE 1 ENGINEERING PROTOTYPE 2 ENG RELEASE PER EO #09082 A REL. TO PROD. PER EO #09089 APPD 7/16/02 9/16/02 B.C. B.C. D D REFERENCE DESIGNATORS LAST USED C10 D6 J4 L1 Q3 R19 U1 NOT USED J4 8191 J2 8191 L1 1 C3,C7,C9 1 2 2 4 3 3 2 1 3 4 D5 MUR8100E R17 10K 5% 1/4W C2 10UF 20% 50V D4 C10 0.1UF 20% 50V R4 820K 5% 1W MUR8100E R2,R5,R12,R13,R16 R6 51K 5% 1W D3 1N4937 D6 1N5955B 4 R3 820K 5% 1W D2 1N4747A C C 16 8-BYPASS R9 6.8 5% 1W R8 6.8 5% 1W U1 MC14536BCP 6 VCC 9 A 10 B R11 7.15K 1% 1/4W 11 13 C C4 4.7UF 20% 50V DECODE_OUT 12 D 2 4 OUT1 OSC_INH 15 5 MONO-IN OUT2 C8 0.1UF 20% 50V C5 330PF 5% 200V RESET 14 SET 3 8 GND R1 51K 5% 1/4W IN1 R14 20 5% 1/4W CLOCK_INH Q3 2N4403 R7 120K 5% 1/4W R10 100K 5% 1/4W Q1 IXBH15N160 C6 100PF 10% 200V R15 2K 5% 1/4W 7 C1 1000PF 10% 3KV Q2 2N4401 1 J3 8191 B J1 8191 1 1 2 2 3 3 4 4 B D1 2ML MOUNTING HOLES MTG1 MTG2 MTG3 MTG4 NEXT 24-9661-1126 DRAWN BY A PCB NO. 8 02.96 86.001 0 0 11.9661.1126 CONFIDENTIAL DSN 7 6 164 5 4 3 6-27-02 201 REGAL ROW DALLAS, TEXAS 75247 B.C. SOLID STATE IGNITOR CHK ALL INFORMATION CONTAINED HEREIN IS THE SOLE AND EXCLUSIVE PROPERTYDOC OF VARI-LITE, INC. AND MAY NOT BE USED, DISCLOSED, OR REPRODUCED MFG IN ANY MANNER WITHOUT, THE ADVANCE WRITTEN CONSENT OF VARI-LITE, INC. Filename: SSIGNITOR Date/Time: 11-14-2002_14:21 R B. CURBO ASSY eProduct Designer 2.0 2 SIZE REVISION D A SHEET DRAWING NUMBER 14-9661-1126 1 OF 1 1 A VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS DMX Input PCB (Sheet 1 of 1) 8 7 6 5 4 3 1 2 REVISIONS REV A DESCRIPTION DATE Released per EO #09110 APPD 9/27/01 MTD J1 NC5FBV D SHIELD 1 DMX/VL_IN- 2 DMX/VL_IN+ 3 VL_OUT- 4 VL_OUT+ 5 CHASSIS 6 D J2 NC5MBV C SHIELD 1 DMX/VL_IN- 2 DMX/VL_IN+ 3 VL_OUT- 4 VL_OUT+ 5 CHASSIS 6 C J3 640456-5 B SHIELD 1 DMX/VL_IN+ 2 DMX/VL_IN- 3 VL_OUT+ 4 VL_OUT- 5 B C1 1000PF 20% 250V CHASSIS DRAWN BY NEXT A PCB NO. Filename: Date/Time: 8 02.96 86.001 0 0 7 6 5 165 4 R MARC DYBLE ASSY 11-9663-1830 CONFIDENTIAL DSN MTD 09/01 VL1000 DMX INPUT BOARD CHK ALL INFORMATION CONTAINED HEREIN IS THE SOLE AND EXCLUSIVE PROPERTY DOC OF VARI-LITE, INC. AND MAY NOT BE USED, DISCLOSED, OR REPRODUCED MFG IN ANY MANNER WITHOUT, THE ADVANCE WRITTEN CONSENT OF VARI-LITE, INC. ViewDraw for Windows 7.5 3 201 REGAL ROW DALLAS, TEXAS 75247 2 SIZE REVISION B A DRAWING NUMBER SHEET 14-9663-1830 1 OF 1 1 A VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS Color Sensor Offset PCB (Sheet 1 of 1) 5 4 3 2 B0 R3 1 ECO # REV. NO GL-402 DESCRIPTION APPROVED DATE 2/5/07 RELEASE FAE R1 D D APERTURE U3 R7 U1 R5 FIXED1 1 3 1 3 4 2 4 2 C C R4 R2 U4 R8 MAG U2 R6 AMBER 1 3 1 3 4 2 4 2 B B +5V D1 2 DRAWN BY : 1 2 3 4 5 6 1 GENLYTE CONTROLS - 10911 PETAL ST. - DALLAS, TEXAS 75238 J1 BLACK BROWN GRAY BLUE WHITE RED A INFORMATION AND DESIGN DISCLOSED ON THIS DOCUMENT ARE CONSIDERED PROPRIETARY AND SHALL NOT BE REPRODUCED OR DISCLOSED WITHOUT WRITTEN CONSENT. CHECKED BY : PROJECT ENGR. : Title DOC. CONTROL : Size B C 2007 Genlyte Group LLC Date: 5 02.96 86.001 0 0 4 3 166 2 SCHEMATIC COLOR WHEEL SENSOR OFFSET Document Number Rev 14-9686-0427 Monday, April 02, 2007 SHEET 1 B0 1 OF 1 A VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS Color Sensor Inline PCB (Sheet 1 of 1) 5 4 3 2 B0 1 ECO # REV. NO GL-403 DESCRIPTION APPROVED DATE 2/5/07 RELEASE FAE D D R3 R1 U3 R7 FIXED2 U1 R5 CYAN 1 3 1 3 4 2 4 2 C C R4 R2 U4 R8 DIM U2 R6 CTO 1 3 1 3 4 2 4 2 B B +5V D1 1 2 DRAWN BY : FAE GENLYTE CONTROLS - 10911 PETAL ST. - DALLAS, TEXAS 75238 INFORMATION AND DESIGN DISCLOSED ON THIS DOCUMENT ARE CONSIDERED PROPRIETARY AND SHALL NOT BE REPRODUCED OR DISCLOSED WITHOUT WRITTEN CONSENT. CHECKED BY : 1 2 3 4 5 6 A PROJECT ENGR. : J1 BLACK BROWN BLUE WHITE GRAY RED Title Size B C 2006 Genlyte Group LLC Date: 5 02.96 86.001 0 0 4 3 167 SCHEMATIC COLOR WHEEL SENSOR INLINE DOC. CONTROL : 2 Rev Document Number 14-9686-0428 Monday, April 02, 2007 SHEET 1 1 B0 OF 1 A VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS Pan/Tilt Encoder PCB (Sheet 1 of 1) 5 4 3 2 1 ECO # REV. NO GL-363 A0 DESCRIPTION APPROVED DATE RELEASE 9/14/06 FAE D D +5V +5V J1 1 2 3 4 5 C C R1 S1 3 1 4 2 5 Place C1 close to S1 C1 J2 6 R2 1 2 3 4 5 6 B B DRAWN BY : FAE GENLYTE CONTROLS - 10911 PETAL ST. - DALLAS, TEXAS 75238 INFORMATION AND DESIGN DISCLOSED ON THIS DOCUMENT ARE CONSIDERED PROPRIETARY AND SHALL NOT BE REPRODUCED OR DISCLOSED WITHOUT WRITTEN CONSENT. CHECKED BY : A PROJECT ENGR. : Title DOC. CONTROL : Size B C 2006 Genlyte Group LLC Date: 5 02.96 86.001 0 0 4 3 168 2 A SCHEMATIC VL3000 PAN / TILT ENCODER Document Number Rev 14-9678-9729 Thursday, October 26, 2006 SHEET 1 A0 1 OF 1 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS VL3500 Controller PCB (Sheet 1 of 10) 8 7 6 5 4 3 2 NOTES: UNLESS OTHERWISE SPECIFIED 1.) ALL CAPACITOR VALUES ARE IN MICROFARADS. 2.) ALL RESISTOR VALUES ARE IN OHMS. 1 REV. NO ECO # A0 NONE VR2 +24V NONE NONE CHANGED CATHODES TO PIN 1 CHANGED SHEET 2, 3 AND 4 3/16/04 C1 NONE CHANGED VALUE ON VR1 AND VR4 4/27/04 C2 NONE CHANGED COMP VALUES & U20 GND C3 NONE On/Off NONE S04- CHANGED MORE COMP VALUES U21-9 TO N/C & RENAMED TPs ADDED TP - FXDG RENAME SHUT TO FRAME RENAME NETS TO: FXDG & FXDC U6-5 ISO GND/ U6-8 ISO VCC 5/11/04 5/25/04 6/14/04 D VCC FB 4 Out 2 L2 Gnd TAB 5 C3 3 + Vin VCC + C6 + C5 D2 VCC 6 C4 + 1 1/9/04 MODIFIED NET NAMES AND U16 B0 E0 APPROVED DATE 12/12/03 C0 D0 D DESCRIPTION PROTO VERSION +24V REFERENCE DESIGNATORS +24V NOT USED C VR1 +24V + 5 On/Off C2 FB 4 Out 2 +3.3V TAB C1 Vin 3 + 1 +3.3V L1 + C8 + C7 D1 +3.3V 6 C242 D92 FB1 J13 L2 PTC4 R304 S1 U45 VR4 Y1 Z4 PP2 TP1 Gnd LAST USED C +2.5V +2.5V +1.8V +3.3V +1.8V R14 VR3 4 SD Sense 5 3 C14 Vout CONNECT SENSE AT LOAD + C15 TAB 1 + +2.5V VIN GND 6 2 GND 1/10W B B +3.3V R15 Vout 4 SD Sense 5 CONNECT SENSE AT LOAD C17 TAB + 6 C16 +1.8V VIN 1 3 + VR4 2 GND 1/10W A A GENLYTE Title SCHEMATIC Size D D ate: 8 02.96 86.001 0 0 7 6 5 169 4 3 2 VL3500 CONTROLLER Document Number Rev E0 14-9678-1730 Thursday, July 15, 2004 Sheet 1 1 of 10 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS VL3500 Controller PCB (Sheet 2 of 10) 8 7 6 5 4 3 2 1 +3.3V D[0..3 1] +1.8V +1.8V +1.8V +1.8V 3/B3,3/A3 R52 +1.8V CS_MTR- 2/B4,3/A6 C69 C51 C44 C45 C46 A[0 ..24] CS_UART- U17 2/B4,3/A6 R51 CS_FLASH- +1.8V +1.8V +1.8V +1.8V 2/C4,2/C4 +1.8V R62 C68 C67 C48 C49 TIN0 C47 2/B5 R63 +3.3V +3.3V C28 +3.3V C27 +3.3V C55 +3.3V C54 +3.3V C77 R36 +3.3V C53 HIZ- 2/A5 C43 R29 DSI +3.3V +3.3V +3.3V +3.3V +3.3V +3.3V 2/B4,2/B7 +3.3V R38 C26 C18 C25 C52 C50 C21 BKPT- C66 R37 TA- 2/C5,2/B7,3/D6 R54 AS- 2/C5 R55 R/W- 2/C4, 2/B5, 2/B8, 2/C6 IRQ7- 5VIN 2 3 4 2/C5 R59 RX_INT- U9 1 2/C4,2/C4,3/A6 R58 +3.3V 2/C5,3/C3 3.3VIN 8 5VRST 3.3VRST 7 5VTOL 3.3VTOL 6 GND R60 TX_INT- 2/C5,3/C3 R61 IRQ1- 5 PBRST 2/B5 S1 A0 2 A0 D1 A1 3 A1 A1 25 A0 DQ0 29 D16 144 D2 A2 5 A2 A2 24 A1 DQ1 31 D17 D3 143 A3 6 A3 A3 23 DQ2 33 D18 R57 RSTI- C 140 D4 A4 8 D5 A5 9 A4 A4 A5 A5 22 21 A2 A3 DQ3 35 A4 DQ4 38 D6 A6 11 A6 A6 20 A5 DQ5 40 D21 138 D7 A7 12 A7 A7 19 A6 DQ6 42 D22 A8 A8 18 A7 DQ7 44 D23 A9 8 A8 DQ8 30 D24 A 10 7 A9 DQ9 32 D25 136 D8 A8 14 D9 135 D9 A9 15 A9 D10 134 D10 A10 16 A 10 D11 132 D12 131 D11 D12 A11 18 A 11 A 11 6 A12 19 A 12 A 12 5 130 D13 A13 20 A 13 128 D14 A14 22 A 14 127 D15 A15 23 A 13 A 14 A 15 A 15 A10 A11 DQ10 34 D26 DQ11 36 D27 NC4 14 D18 123 D18 A18 27 A 18 A 18 17 A17 NC5 16 D19 122 D19 A19 28 A 19 D23 116 D23 A23 34 A 23 D24 115 D24 A24/PP8 35 D25 114 D25 A25/PP9 36 112 D26 A26/PP10 38 DCLK D27 111 D27 A27/PP11 39 DATA D28 110 D28 A28/PP12 40 108 D29 A29/PP13 42 D30 107 D30 A30/PP14 43 106 D31 A31/PP15 2/C4,2/C6,3/A6 CS_FLASH- 26 CE- VCC 37 OE- 28 OE- NC1 9 R/W- 11 WE- NC2 10 RSTI- 12 RESET- NC3 13 A 24 D26 D29 2/C6 INIT_DONE CONF_DONE STATUSCONFIG- 44 +3.3V A9 31 A6 DQ6 11 D6 A 17 32 A7 DQ7 13 D7 A 18 33 A8 DQ8 42 A 19 34 A9 DQ9 44 D9 A 20 22 A10 DQ10 45 D10 A 21 35 A11 DQ11 47 D11 A 24 36 NC/A12 DQ12 48 D12 A 22 D31 20 A 23 A 21 19 CS 2/B4 CAS3- 15 DQML 2/B4 CAS2- 39 DQMH 16 WE 2/B2,2/B3 SRAS- 18 RAS 15 RY/BY- GND1 27 2/B2,2/B4 47 BYTE- GND2 46 2/A6 2/B5 74 BR 76 BG 75 BD R299 66 198 2/C6 2/B7,2/C6,3/D6 RSTI- PST6 PST4 PST2 PST0 CKE CLK1 38 CLK 1 1 3 5 7 9 11 13 15 17 19 21 23 25 BKPTDSCLK 2/D6, 2/B4 2/B4, 2/C6 DSI DSO PST7 PST5 PST3 PST1 2/D6,2/B4 2/B4 2/A4 2/A4 2/A4 2/A4 TIP/PP7 62 AS TA- 64 TA CS0 50 CS1 51 IRQ3/6 CS2 54 IRQ1/2 CS3 55 PSTCLK TA- 2/A4 2/A4 IRQ1- 72 TIN0 CS4 56 DREGQ0/PP6 CS5 58 200 DREGQ1/PP5 CS6 80 TIN1 TIN0 MTR_ENABLER/W- A12 A13 A14 V3.3_2 27 V3.3_3 V3.3_Q2 9 V3.3_Q3 43 V3.3_Q4 49 A15 D22 A16 D23 A17 D24 A18 D25 A19 GND1 GNDQ2 12 41 GND2 GNDQ3 46 GND3 D26 6 28 54 D21 3 V3.3_Q1 A20 D27 A22 D29 52 GNDQ4 S DA 5 SDA A23 D30 25-40.5MHz A24 D31 D2 BE = R/W 2/A4 D3 2/C4,2/C6,3/A6 R39 PAR PORT 2/C4,2/C7,2/B8,2/C6 7 2/D6 2/D6 +3.3V R70 4 3 VCC 1 REF 4 GND 2 +3.3V A BE0 96 BE1 98 TOUT1 BE2 99 BE3 100 TXD1 RAS0 83 RXD1 RAS1 84 TX_EN_B- 164 RTS1 CAS0 86 CAS0- 163 CTS1 CAS1 87 CAS1CAS2- 161 CAS2 88 TXDB TXD2 CAS3- 160 CAS3 90 RXDB RXD2 CTS2 103 102 8 RSTI- 67 EDGESEL HIZ- SDA1 4 A0 DQ0 2 D16 24 A1 DQ1 4 D17 A 13 25 A2 DQ2 5 D18 A 12 26 A3 DQ3 7 D19 A 11 29 A4 DQ4 8 D20 A 10 30 A5 DQ5 10 D21 2/C4 RAS0- 2/B2,2/C2 2/B2 2/B2 CLK1 3 CLK1 2/C2 CLK2 2 CLK2 2/B2 CLK3 5 CLK3 3/A6 CLK4 7 +1.8V FB1 C242 SRAS- 2/C2 2/B2,2/C2 2/C2 SCAS- S _RAS- 92 SCAS 94 S _CAS- SCKE 95 CLK_EN DRAMW 91 D RAMWR- BCLKO 170 2/B2,2/C2 NC RSTI 172 RSTO- BKP/TMS 154 BKPT- DS0/TD0 151 DSO DS1/TD1 153 DSI DSCLK/TRST 149 DSCLK RSTO EDGESEL MTMOD0 177 MTMOD1 181 MTMOD2 182 MTMOD3 TCK 150 TCK PST/CLK 184 PSTCLK PSTDDATA0 186 PST0 PSTDDATA1 187 PST1 PSTDDATA2 189 PST2 HIZ CLKIN 180 PVDD 178 PGND C19 DRAMW- 3 SCL1 SCL0 GND EN 5 R298 R68 DQ6 11 D22 A7 DQ7 13 D23 A 18 33 A8 DQ8 42 D24 A 19 34 A9 DQ9 44 D25 22 A10 DQ10 45 D26 A 21 35 A11 DQ11 47 D27 A 24 36 NC/A12 DQ12 48 D28 DQ13 50 D29 DQ14 51 D30 DQ15 53 2/B2,2/C2 D31 PSTDDATA3 190 PST3 PSTDDATA4 192 PST4 PSTDDATA5 193 PST5 PSTDDATA6 195 PST6 PSTDDATA7 196 PST7 A 22 20 BA0 A 23 21 BA1 2/B2,2/B3 RAS0- 19 CS 2/B4 CAS1- 15 DQML 2/B4 CAS0- 39 DQMH 2/B2,2/B3 DRAMW- 16 WE 2/B2,2/B3 SRAS- 18 RAS 2/B7 2/B2,2/B3 SCAS- 17 CAS 2/B2,2/B4 CLK_EN 37 CKE CLK2 38 CLK VCC +24V +24V B A 20 2/D6,2/B7 +3.3V +3.3V +2.5V +2.5V 40 NC +1.8V +1.8V 2/D6,2/B7 +3.3V 2/B7,2/C6 2/B8 2/A6 2/B7 V3.3_Q1 3 V3.3_Q2 9 V3.3_Q3 43 V3.3_Q4 49 +3.3V 2/B8 1 2/B7 MTR_ENABLE- V3.3_1 14 V3.3_2 27 V3.3_3 GNDQ1 6 2/B8 28 GND1 GNDQ2 12 2/B7 41 GND2 GNDQ3 46 54 GND3 GNDQ4 52 2/C4 2/B8 2/B7 +3.3V 2/B8 R297 2/B7 1 2 GND A MTR_EN- 5/C2,6/C8,7/C8,8/C8,9/C8 U45 V3.3 PINS: 7,13,21,29,37,45, 52,65,81,89,97,113,121,129, 137,145,167,191,205 FB2 A6 32 3/A6 V1.8 PINS: 1,57,73,105,152, 157,171,175,185,197 1 2 31 2/B2,2/C2 R65 4 SDA0 A9 A 17 R66 SCL 176 155 U23 VCC 23 A 14 R AS_0- SRAS SDA 168 174 + 7 A 15 2/D6,3/A6 R67 R69 6 U14 2/D6,3/A6 R64 165 158 VCC PLACE RESISTORS CLOSE TO MICROPROCESSOR 166 C LK0 CLKOUT +3.3V 8 OE OE- TIN1 U12 6 1 SCL_OUT CS_UART- TOUT0 +3.3V Y1 SDA_OUT CS_MTR- 60 UART_IN SCL WC- AUTO ACK D7 59 78 RTS2 R41 D6 49 82 159 16 BIT BUS 2/D6,2/C4 SCL 6 SCL CS_FLASH- UART_OUT_B S DA VCC CPU GND PINS: 4,10,17,25,33,41,48, 53,61,69,77,85,93,101,104, 109,117,125,133,141,148,156, 162,169,173,183,188,194,201,208 GENLYTE Title DO NOT STUFF SCHEMATIC VL3500 CONTROLLER Size Document Number D D ate: 8 02.96 86.001 0 0 C A21 D28 R32 D4 CS7 79 R71 10/D2 A11 D20 R42 199 U22 10/D2 A10 R40 IRQ5/4 +3.3V VSS 47 IRQ7 4/D8 E2 63 46 SIZ1 71 4/D8 4 R/W SIZ0 70 4/D5 3 D16 R34 68 4/C5 E1 202 RX_INT- 3/D6,4/C5 E0 TM2/PP4 TX_INT- 2/C6 B 2 PP2 IRQ7- 2/D6 1 PP1 1 203 2/C6,3/C3 2/C6 2 4 6 8 10 12 14 16 18 20 22 24 26 2/D6 VCC 1 204 A7 A9 V3.3_1 14 D0 CLK IN = 206 A5 D12 A8 GNDQ1 D1 TT1/PP1 A4 D11 40 NC R30 10/C2 TM1/PP3 TS AS- LAMP_STBY A3 D10 CAS 37 3/A2,3/B7,3/B3 TM0/PP2 2/C6,3/C3 J6 R35 8 207 A2 D9 D5 +3.3V 2/A4 2/A4 2/A4 2/A4 TT0/PP0 A1 D8 D18 CLK_EN 3/B3 3/C7,3/B3 A0 D7 A6 +3.3V 3/A2,3/B3 +3.3V D6 D17 3/C7,3/A2,3/A3 3/A2,3/C7,3/B3 D5 D19 R31 EDGESEL 2/C4, 2/B5, 2/B7, 2/C6 17 D4 D15 DRAMW- SCAS- D D3 D14 2/B2,2/B3 2/B2,2/B3 D2 D13 RAS0- PLL MULT = 4X TCK BA1 D1 +3.3V R33 2/B4 21 2/B2,2/B3 A 19 A 20 BA0 D0 D8 DQ15 43 A16 A 22 D5 D15 DQ14 48 32 10 53 A14 A 17 A22 DQ5 D30 2 A 17 D22 A5 D14 26 118 D4 30 51 A17 D22 DQ4 A 10 50 D17 2/B4 A4 8 DQ14 124 A 21 29 DQ13 D17 31 D3 A 11 D29 45 A21 7 41 A-1/DQ15 D21 DQ3 DQ13 A15 119 A3 A13 1 D21 26 3 A 16 2/D6,2/C4 D2 A 12 D13 A 16 A 20 D1 5 D28 24 30 D0 4 DQ2 39 A16 A20 2 DQ1 A2 DQ12 D16 D20 DQ0 A1 25 A12 126 120 A0 24 A 13 4 D16 D20 23 A 14 D20 139 D8 A 15 D19 D7 D31 2/C4,2/B5,2/C7,2/B8 142 D3 D6 D15 2/B4,2/B7 R56 RSTI- D0 146 D14 DSCLK VCC 147 D2 D13 2/B4,2/B7 U18 D1 D5 2/B5 U24 D0 D4 TIN1 D 2/C3,3/D6,3/A3 R53 7 6 5 170 4 3 2 Rev E0 14-9678-1730 Sheet Thursday, July 15, 2004 1 2 of 10 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS VL3500 Controller PCB (Sheet 3 of 10) 10/A1 +2.5V 10/A2 2/C5, 2/D3, 2/B1 D27 D6 D27 2/C5, 2/D3, 2/B1 D28 D7 D28 2/C4, 3/A2 DATA A1 DATA 10/A1 10/A1 PWM_OUT_44 A4 A3 A2 PWM_PH_44 GND PWM_PH_44 PWM_OUT_44 4/D5 4/C5 2/A6 4/C7 LAMP_ONA5 LAMP_ON- LED_TX- TX_EN_A- 2/B5,4/C5 4/D6 A7 A6 LED_TX- TX_EN_A- 2/D4, 2/C3, 3/A3 2/D4, 2/C3, 3/A3 UART_OUT_A UART_OUT_A CLK3 A9 A8 CLK3 UART_IN A10 UART_IN 2/D1 3/B3 A3 D19 A1 A11 A12 A1 A14 A13 A3 D19 GND 3/B7 2/D1, 3/A3 2/D1, 3/A3 D22 CE- D20 A15 B1 A16 CE- D22 D20 10/A2 10/A2 4/D6 2/C4, 3/C7, 3/A2 PWM_PH_37 PWM_PH_39 DCLK B3 B4 B2 DCLK PWM_PH_37 PWM_PH_39 PWM_PH_40 4/D5 4/D6 B5 B6 LED_RX- 2/B4 10/A1 PWM_PH_40 LED_RX- LED_STATUS B7 LED_STATUS 2/C5, 2/D3, 2/B1 2/C5, 2/D3, 2/B1 2/C5, 2/D3, 2/B1 TX_EN_C- RSTO- TX_EN_C- B9 B8 RSTO- D24 D25 B10 D26 D26 B11 B12 B13 B14 A6 N/C D24 A6 TCKA B15 TCKA D25 3/B7 2/D4, 2/C3, 3/D6 10/A2 3/B7 TDIA PWM_PH_41 C2 R12 PWM3_OUT_5 D18 E13 D18 A9 E14 A9 4/B8 5/C8 C R13 R14 PWM3_OUT_3 5/D8 PWM_PH_33 R15 PWM_PH_33 9/B4 MSEL0 PWM_PH_18 3/B7 PWM_OUT_36 PWM_PH_18 P2 PWM_PH_35 PWM_PH_17 P3 PWM_PH_17 F4 PWM_PH_36 PWM_OUT_18 P4 PWM_OUT_18 F5 +2.5V PWM_OUT_17 P5 PWM_OUT_17 F6 GND CYAN_IN P6 CYAN_IN 4/A8 F7 +2.5V AMB_IN P7 AMB_IN 4/A8 F8 +3.3V PHASE_B_2 P8 F9 +2.5V N/C P9 F10 +3.3V PHASE_B_1 P10 PHASE_B_2 PHASE_B_1 PWM3_OUT_2 F11 GND PWM3_OUT_2 P11 F12 +2.5V PWM3_OUT_4 P12 PWM3_OUT_4 PWM_OUT_25 PWM_OUT_6 F13 PWM_OUT_6 PWM_OUT_25 P13 PWM_PH_5 F14 PWM_PH_5 PWM_OUT_26 P14 F15 TX_INT- TMSA P15 TMSA PWM_PH_26 TX_INT- F16 PWM_OUT_26 PWM_PH_26 P16 G1 PWM_OUT_27 PWM_PH_2 N16 PWM_PH_2 G2 PWM_OUT_28 PWM_PH_1 N15 PWM_PH_1 PWM_PH_27 G3 PWM_PH_27 PWM_OUT_2 N14 PWM_OUT_2 PWM_PH_28 G4 PWM_PH_28 PWM_OUT_1 N13 PWM_OUT_1 G5 N/C +3.3V N12 G6 +3.3V G7 GND G8 +3.3V PWM_OUT_27 PWM_OUT_28 PWM_OUT_5 CS_UART- PWM3_OUT_1 PHASE_A_1 FIX_GOBO_IN N11 N10 N9 G9 GND G10 GND MAG_IN N7 G11 +3.3V EDGE_IN N6 G12 N/C PWM_OUT_21 N5 G13 PWM_OUT_5 N/C CONFIG- PWM3_OUT_1 PHASE_A_1 N4 CONFIG- PWM_OUT_22 N3 PWM_OUT_22 PWM_PH_21 N2 PWM_PH_21 INIT_DONE G16 INIT_DONE PWM_PH_22 N1 PWM_PH_22 PWM_PH_12 PWM_OUT_19 H1 PWM_OUT_19 PWM_PH_12 M16 PWM_OUT_20 H2 PWM_OUT_20 PWM_PH_11 M15 PWM_PH_11 PWM_PH_32 PWM_PH_31 5/B8 8/B5 +2.5V 8/B5 3/B7 +2.5V 8/B4 7/D3 7/D3 +1.8V 7/C5 7/D5 +1.8V 4/B8 PWM_PH_25 GND 4/A8 8/B8 2/C4,3/C7 8/B8 8/B7 8/B7 6/D3 6/D3 6/C5 DO NOT STUFF 6/D3 8/B4 DATA DCLK N/C M6 GND M5 PWM_OUT_29 M4 PWM_OUT_29 9/B8 PWM_OUT_30 M3 PWM_OUT_30 9/B8 PWM_PH_29 M2 PWM_PH_30 M1 STATUS2/C4,3/C8,3/D3 CONF_DONE PWM_PH_29 PWM_PH_30 2/C4,3/D5,3/C8 1 2 3 4 VCC2 8 DCLK VCC1 7 OE CASC 6 CS GND 5 DATA A 9/B7 SOCKET IS XU15 9/B7 FPGA GENLYTE SCHEMATIC 9/D4 9/D4 9/C5 8/D4 8/D4 8/C5 8/D5 9/D5 6/D8 6/D7 6/D7 6/D7 7/B3 7/B5 7/B3 7/B5 7/D7 7/D7 7/D7 7/D8 Title Size VL3500 CONTROLLER Document Number D D ate: 02.96 86.001 0 0 7 +3.3V U15 2/C4, 3/D3 2/C4,3/C8,3/D4 +3.3V +2.5V 8 B 5/D8 L16 L15 PWM_PH_31 +3.3V 5/C8 PWM_PH_32 PWM_OUT_32 N/C L14 PWM_OUT_32 L13 +2.5V L12 +3.3V GND GND L11 L10 L9 L8 L7 L6 L5 L4 L3 L2 L1 PWM_PH_23 K15 K14 K16 PWM_PH_24 PWM_PH_23 PWM_OUT_24 K13 K11 K9 PWM_OUT_31 K12 PWM_OUT_23 PWM_OUT_15 K10 PWM_PH_14 K8 PWM_OUT_14 H16 K7 H15 PWM_PH_14 K6 PWM_OUT_13 PWM_OUT_14 K5 H14 K4 PWM_OUT_13 PWM_OUT_7 PWM_PH_13 N/C M7 N/C N/C +2.5V +2.5V GND H10 +2.5V M8 N/C M9 N/C N/C M10 N/C GND N/C PWM_PH_25 GND H9 PWM_PH_24 +2.5V H8 PWM_OUT_24 H7 PWM_OUT_23 M11 PWM_OUT_31 +2.5V +3.3V +2.5V GND H6 +2.5V PWM_OUT_11 M12 +3.3V M13 GND GND PWM_OUT_11 N/C +3.3V M14 PWM_PH_20 H5 GND PWM_OUT_12 H4 PWM_OUT_7 PWM_PH_19 PWM_PH_20 PWM_OUT_8 H3 PWM_OUT_12 PWM_PH_7 PWM_PH_19 N/C +3.3V 4/B8 4/A8 PWM_PH_6 +3.3V +24V 4/B8 MAG_IN EDGE_IN PWM_OUT_21 N/C H13 7/B8 N8 G15 H12 +24V 7/B7 7/B8 4/B8 G14 H11 7/B7 FXDG_IN PWM_PH_6 PWM_PH_13 VCC R16 P1 F3 CS_UART- VCC 5/B8 F2 J1 6/B3 4/B8 PWM_PH_35 PWM_PH_8 6/B5 4/A8 N/C +3.3V K3 6/B5 4/A8 4/B8 PWM3_OUT_3 MSELO K2 D31 P_COT_IN 3/B7 PWM_PH_36 2/D6, 2/B4 A B16 PWM3_OUT_5 PWM_OUT_35 D 2/C4,3/A2,3/C7 PWM_OUT_36 5/B4 6/B3 D15 C1 GND K1 D30 N/C E12 PWM_PH_7 D29 D14 TDIA PWM3_EN_1 PWM_OUT_8 D13 PWM_PH_41 R11 PWM_PH_8 D28 GOBO1_POS_IN R10 PHASE_PH_4 D27 D12 R9 P_COT_IN PWM3_EN_1 PWM_OUT_4 D11 GOBO_POS_IN N/C J16 A24 A12 R8 N/C J15 A11 N/C ZOOM_IN FXDC_IN SPARE_IN N/C PWM_PH_4 D26 R7 E9 PWM_OUT_4 D25 D10 R5 R6 SPARE_IN E11 PWM_PH_3 D24 D9 A23 ZOOM_IN FXD_COLOR_IN E10 PWM_OUT_3 D8 A22 4/C7 R/W- N/C A21 10/A2 E8 8/D7 A10 C3 N/C 8/D7 A9 N/C E7 8/C8 A8 D30 R4 +3.3V STATUS- J14 D23 PWM_PH_43 N/C GND E6 8/D8 D22 LAMP_CNTL PWM_OUT_40 E5 2/C4 D21 C5 E4 5/C4 D7 C4 PWM_OUT_40 5/C2 D6 PWM_PH_43 10/A1 D16 D5 C7 R3 R44 A20 C6 N/C INSTALL ONLY WITH EPC1 A19 D30 PWM_PH_38 R47 A18 2/D4, 2/C3, 3/D6 E3 9/D7 A7 9/B5 PWM_PH_38 9/D7 A6 PWM_PH_34 10/A1 3/A3 A5 T15 MSEL1 9/D8 D20 PWM_PH_34 STATUS- 9/C8 D19 T PWM_OUT_34 9/B5 T16 5/C2 D4 R PWM_OUT_34 R2 10/A1 K T14 R1 A5 4/B8 P +2.5V CS_MTR- J 9/B5 MSEL1 F1 H 4/A8 PWM_OUT_33 PWM_OUT_38 E16 G 4/A8 N PWM_OUT_37 A5 F 6/B8 5/B8 E2 PWM_OUT_35 E 6/B8 M E1 E15 D 6/B7 5/B8 PWM3_OUT_6 D16 2/C5,2/C6 D3 2/D4, 2/C3, 3/A3 RX_INT- 6/B7 L RX_INT- CS_MTR- A 4/B8 PWM_OUT_37 R/W- 2 1 4/B8 PWM_OUT_38 MSEL1 A17 A7 D21 R45 A16 C8 D15 3/B3 A4 A7 D23 D21 MSEL0 A3 2/D1, 3/B3 D14 R46 D18 C9 D23 3/B3 D17 N/C T13 TDIA D2 2/D1, 3/B3 PWM_OUT_33 10/A1 D1 A0 A4 10/A2 A15 D16 D13 10/A2 A14 D17 A4 2/B4,2/D6 A2 C10 PWM3_EN_2 2/D4, 2/C3, 3/A3 A1 C11 T12 2/D4, 2/C3, 3/A3 D0 C12 PWM3_EN_2 5/B4 A13 A0 +3.3V TMSA A0 2/D4, 2/C3, 3/A3 D12 2/C4,3/A2,3/B3 B 2/D4, 2/C3, 3/A3 T11 2/C4,3/A2,3/A3 TCKA T_COT_IN PWM3_OUT_6 DCLK 3/B3 CTO_IN N/C R50 R28 T6 D11 2/C4,2/C4,2/C6 CE- CTO_IN PHASE_A_2 2/C4,3/B3 R49 DIMMER_IN T10 CONFIG- 3/B3 T5 PHASE_A_2 R43 3/B3 DIMMER_IN D31 STATUS- R48 PWM_OUT_9 D10 10/A1 R23 T4 D31 10/A2 CONF_DONE PWM_OUT_9 2/C5, 2/D3, 2/B1 2/C5,2/C6 R27 PWM_OUT_10 GOBO1_IDX_IN 2/D1, 3/A3 C T3 T7 2/C5, 2/D3, 2/B1 2/C4,3/A2,3/B3 PWM_OUT_10 T9 10/A2 R22 PWM_PH_9 T8 C35 +3.3V T2 GND J13 C60 PWM_PH_9 T_COT_IN J12 C63 PWM_PH_10 GOBO1_IDX_IN U16 3 C T1 D29 +2.5V 5 4 B PWM_PH_10 TA- PWM_PH_3 C42 +2.5V 16 15 14 13 12 11 10 9 8 7 6 +2.5V D9 PWM_OUT_3 C56 +2.5V 1 ALTERA EP1K100FC256-3 +3.3V D8 TA- +2.5V C36 +2.5V 2 D29 +2.5V +2.5V 3 2/C5, 2/D3, 2/B1 2/C5,2/B7,2/C6 +2.5V GND PWM_OUT_43 4 LAMP_CNTL D5 D16 PWM_OUT_43 D17 PWM_PH_42 J11 C59 D4 J10 C30 PWM_PH_42 GND C32 PWM_OUT_41 GND C40 D3 +2.5V C34 PWM_OUT_41 J9 C37 PWM_OUT_42 +3.3V +2.5V D2 J8 +2.5V PWM_OUT_42 J7 +2.5V PWM_OUT_39 J6 D D1 A2 2/C4 3/A1 10/A2 PWM_OUT_39 A8 CONF_DONE 10/A1 +2.5V C15 N/C 10/A2 +2.5V CONF_DONE C39 PWM_PH_15 C33 PWM_OUT_16 C58 +3.3V PWM_OUT_15 C38 +3.3V J3 C64 +3.3V J2 C65 +3.3V PWM_PH_15 +3.3V PWM_OUT_16 +3.3V C16 +2.5V C14 +3.3V C13 C61 A2 +3.3V C29 N/C +3.3V C31 A8 +3.3V C57 PWM_PH_16 +3.3V C62 5 J4 +3.3V C41 6 PWM_PH_16 +3.3V 7 J5 8 6 5 171 4 3 2 Rev E0 14-9678-1730 Sheet Thursday, July 15, 2004 1 3 of 10 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS VL3500 Controller PCB (Sheet 4 of 10) 8 7 6 5 4 3 2 1 DO NOT STUFF VCC +3.3V R11 VCC +24V VCC R16 VCC 2/B5 TXDB RXDB C2+ 5 C2- 11 TX1 10 TX2 12 RXD1 9 RXD2 16 U5 V- 6 D6 R9 U10C TX_EN_C- NC1 VCC 8 R17 2 AN1 BIAS 7 9 RX 8 3 K1 OUT 6 4 NC2 GND 5 10 D7 J7 TXD1 TXD2 7 RX1 13 RX2 8 POWER LED_TX- 1 2 3 14 C12 1 D3 LED_RX- ISO_VCC ISO_VCC R8 U6 2 3 RE DE 4 D B A 7 6 R 1 VCC ISO_VCC U1 1 R13 VCC LED_STATUS 1 VIN+ VOUT+ 4 2 VIN- VOUT- 3 VCC STATUS ISO_VCC U3 D8 1 VCC U10D TX_EN_A- R18 2 3 12 3 D4 11 TX_EN_B- 1 1 R19 C20 D 8 2 15 2/B5 C1- 4 ISO_VCC R12 TX V+ 5 3 C1+ GND 1 VCC U13 D VCC C24 C23 GND C22 13 4 2 C11 VCC 8 AN1 BIAS 7 K1 OUT 6 GND 5 NC1 NC2 ISO_VCC R3 VCC VCC 1 1 U8 LAMP_CNTL 3/C6 2 R10 ISO_VCC 10/D2 U7 U10A R24 UART_OUT_A VCC UART_OUT_B D5 U10B 1 3 R20 6 NC1 VCC 8 2 AN1 BIAS 7 3 K1 OUT 6 4 NC2 GND 5 5 3 C13 1 4 2 R5 +24V R2 1 VCC FTC3 1 NC1 4 DE Y 9 5 D Z 10 2 R A 12 CI+ 3 REB B 11 CI- VCC1 14 ISO_VCC VCC R26 LAMP_ON- 3/C6 LAMP_ON_IN- R21 10/D2 6 GND1 NC2 10/C2 COMOUT10/C2 7 GND2 VCC2 COMIN+ 8 VCC NC1 1 7 BIAS AN1 2 6 OUT K1 3 5 GND NC2 4 +2.5V R1 Z1 C9 PHASE_B_1 P_COT_IN 3/C3 PHASE_A_2 Z3 +1.8V 1 1 1 1 1 20 OA0 DA0 2 16 OA1 DA1 4 14 OA2 DA2 6 12 OA3 DA3 8 3 OB0 DB0 17 5 OB1 DB1 15 7 OB2 DB2 13 9 OB3 DB3 11 2OE 19 1OE 1 PHASE_A1 4/B6 PHASE_B1 4/B6 P_COT 4/B6 GND VCC VCC PHASE_A2 4/B5 EDGE PANA AMB PANB C240 C241 CYAN TILTA TILTB SPARE R105 R106 R76 MAG R260 R257 R207 R186 R83 R75 4/B7 ENCODER_A1 PHASE_A1 10/D5 R73 10 GND 3/C3 Z4 +1.8V 18 VCC PHASE_A_1 3/C3 Z2 R7 1 +3.3V 3/C3 +2.5V 10/C2 FTC2 1 8 C 10/C2 COMIN- 13 R6 UART_IN U21 +3.3V FTC4 FTC1 R4 C10 U2 +3.3V COMOUT+ 1 VCC R25 +24V ISO_VCC U4 2 C ISO_VCC ISO_VCC VCC LAMP_CNTL_OUT 4 ENCODER_A2 PHASE_A2 4/B7 B 10/C5 B R72 4/B7 ENCODER_B1 PHASE_B1 10/D5 R82 +3.3V ENCODER_B2 PHASE_B2 4/B7 10/C5 R184 3/D3 PHASE_B_2 3/D3 FXDG_IN 3/D3 GOBO1_POS_IN 3/D3 SPARE_IN 3/D3 GOBO1_IDX_IN 16 OA0 OA1 DA0 2 DA1 4 T_COT PHASE_B2 FXDG 14 OA2 DA2 6 12 OA3 DA3 8 GOBO1_POS 3 OB0 DB0 17 SPARE 5 OB1 DB1 15 7 OB2 DB2 13 9 OB3 DB3 11 2OE 19 1OE 1 4/B7 4/A7 PAN_COT_SENS P_COT 4/B6 4/A6 R253 R102 10/A5 4/A7 10/B3 4/B7 4/A6 R256 R101 4/A7 GOBO1_IDX_SENS 4/B7 MAG_SENS MAGENTA 10/A5 10/B5 R206 R103 DIMMER_SENS DIMMER FXDG_SENS FXDG 4/B7 4/A7 10/A3 10/B3 R254 R104 4/B7 AMB_SENS AMBER GOBO1_POS_SENS GOBO1_POS 4/A6 10/A5 4/A7 10/C3 4/B7 GOBO1_IDX GOBO1_IDX 10/B5 CYAN_SENS CYAN TILT_COT_SENS T_COT 4/B6 EDGE_SENS R205 R74 4/B5 EDGE 10/C3 4/A7 SPARE_SENS SPARE CTO_SENS CTO 10/A3 10/B5 R255 10 GND 3/D3 18 VCC T_COT_IN 20 R81 U20 FXDC_SENS FXDC 10/A3 4/A7 R183 4/A7 ZOOM_SENS ZOOM 10/B3 +3.3V C238 MAG_IN A 3/A6 FXDC_IN 3/A6 CYAN_IN 3/B6 DIMMER_IN 3/B6 AMB_IN 3/B6 CTO_IN 16 OA0 OA1 DA0 2 DA1 4 14 OA2 DA2 6 12 OA3 DA3 8 3 OB0 DB0 17 5 OB1 DB1 15 7 OB2 DB2 13 9 OB3 R108 R259 R258 R208 R107 DB3 11 2OE 19 1OE 1 ZOOM EDGE IDX 4/B2 TCOT CTO FXDG ZOOM FXDC 4/A3 GOBO1 MAGENTA DIM PCOT A 4/B2 VCC FXDC 4/A3 CYAN 4/B2 DIMMER 4/B3 AMBER USER I/O 4/B2 CTO 4/A3 GENLYTE Title 10 GND 3/B6 18 VCC ZOOM_IN 3/A6 R185 20 VCC U19 EDGE_IN 3/A6 C239 SCHEMATIC Size D D ate: 8 02.96 86.001 0 0 7 6 5 172 4 3 2 VL3500 CONTROLLER Document Number Rev E0 14-9678-1730 Thursday, July 15, 2004 Sheet 1 4 of 10 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS VL3500 Controller PCB (Sheet 5 of 10) 8 7 6 5 +24V D +24V 4 3 2 1 +24V D TILT D87 D89 D91 +24V U11 PWM3_OUT_1 3/D3 PWM3_OUT_2 3/A6 PWM3_OUT_3 3/A5 U25 7 IN1 8 EN1 4 IN2 3 EN2 14 IN3 13 EN3 OUT1 6 OUT2 5 OUT3 15 SENSE1 PWM3_EN_1 2 3/A6 4 R77 VCC 19 VREF 16 VCP 17 VBOOT 18 1 GNDA 10 GNDB 11 GNDC VSSA 9 20 GNDD VSSB 12 C82 10/D3 TILT_PHB_OUT 10/D3 TILT_PHC_OUT 10/D3 D10 2 SENSE2 VCC TILT_PHA_OUT D88 D90 D92 C71 D9 VCC + C70 + C72 C79 + C80 + C236 VCC VCC +24V FRAME 2A VCC +24V C92 + C76 +24V C C MTR_EN- C88 C87 R91 PWM_PH_6 R98 PWM_OUT_6 3/C6 C94 C95 PHASE1 21 DIS1 18 VR1 1 3/C6 R100 20 R99 4 VMM2 MA1 11 MB1 8 MA2 5 MB2 7 10/D7,10/C5 +3.3V PHASE2 24 DIS2 27 VR2 22 RC GND10 28 GND2 GND09 17 3 GND3 GND08 16 9 GND4 GND07 15 13 GND5 GND6 14 10 19 E1 C1 C90 10/D7,10/C3 +3.3V FRAME2A_OUT1B GND1 25 2 FRAME2A_OUT1A U27 FRAME2A_OUT2A FRAME2A_OUT2B 10/D7,10/C5 10/D7,10/C3 +2.5V +2.5V +1.8V E2 PWM_PH_5 +1.8V 6 2/A3,6/C8,7/C8,8/C8,9/C8 +24V C2 3/C6 R92 26 3/C6 R90 PWM_OUT_5 VMM1 VCC 23 12 R95 R94 R96 GND C89 R79 C93 R80 B B +24V +24V +24V PAN D85 D86 D84 +24V U31 PWM3_OUT_4 3/D3 PWM3_OUT_5 3/A6 PWM3_OUT_6 3/D3 U26 7 IN1 8 EN1 4 IN2 3 EN2 14 IN3 13 EN3 OUT1 6 OUT2 5 OUT3 15 SENSE1 PWM3_EN_2 3/A6 2 4 R78 VCC C86 10/D3 PAN_PHB_OUT 10/D3 PAN_PHC_OUT 10/D3 D12 2 SENSE2 19 VREF 16 VCC PAN_PHA_OUT VCP 17 VBOOT 18 1 GNDA 10 GNDB 11 GNDC VSSA 9 20 GNDD VSSB 12 D81 D82 D83 C74 D11 + C73 + C75 + C84 + C237 C83 A A GENLYTE Title SCHEMATIC Size VL3500 CONTROLLER Document Number D D ate: 8 02.96 86.001 0 0 7 6 5 173 4 3 2 Rev E0 14-9678-1730 Thursday, July 15, 2004 Sheet 1 5 of 10 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS VL3500 Controller PCB (Sheet 6 of 10) 8 7 6 5 4 3 VCC 1 VCC +24V VCC 2 +24V +24V C101 VCC C78 + +24V C119 C85 + D D 24 DIS2 27 VR2 22 RC GND10 28 2 GND2 GND09 17 3 GND3 GND08 9 GND4 GND07 15 GND6 14 13 GND5 10 19 E1 C1 C99 ROT1_OUT2A ROT1_OUT2B C114 R132 10/D7,10/C3 1 3/C3 PWM_PH_12 10/D7,10/C3 R140 R141 PWM_OUT_12 3/C3 C122 16 C121 R139 4 VMM2 VMM1 VR1 11 MB1 8 MA2 5 MB2 7 FXDG_OUT1A FXDG_OUT1B 10/C7,10/C3 10/C7,10/C3 GND1 25 PHASE2 24 DIS2 27 VR2 22 FXDG_OUT2A FXDG_OUT2B RC GND10 28 2 GND2 GND09 17 3 GND3 GND08 9 GND4 GND07 15 13 GND5 GND6 14 C117 10/C7,10/C3 10/C7,10/C3 16 E2 PHASE2 18 MA1 U30 6 MB2 7 C115 GND1 25 23 VCC 4 5 3/C3 DIS1 C2 R117 MA2 10/D7,10/C3 PHASE1 21 C1 C103 8 20 19 C104 MB1 PWM_PH_11 E2 R118 PWM_OUT_8 3/C3 R133 PWM_OUT_11 26 1 PWM_PH_8 3/C6 R119 VR1 ROT1_OUT1B 6 R110 10/D7,10/C3 R131 C2 C96 ROT1_OUT1A 11 MA1 U28 E1 DIS1 10 PHASE1 21 18 C97 3/C6 20 26 3/C6 PWM_PH_7 FIXED GOBO VMM2 23 3/C6 R111 R109 PWM_OUT_7 VMM1 VCC GOBO1 ROTATE 12 R136 12 R114 VCC R113 R115 R135 R137 VCC C98 R84 C102 R85 C116 R88 C120 R89 C C +24V +24V 2/A3,5/C2,6/C8,7/C8,8/C8 MTR_EN- +3.3V +3.3V VCC VCC +24V VCC +24V +24V C110 + VCC SHUT ROT C81 +2.5V +24V C128 + C91 +2.5V GOBO1 INDEX PHASE2 C123 R143 10/C7,10/C5 22 MB2 7 RC GND10 28 2 GND2 GND09 17 3 GND3 GND08 16 9 GND4 GND07 15 13 GND5 GND6 14 C1 19 IDX1_OUT2B PWM_PH_14 10/C7,10/C3 R151 R152 3/C6 PWM_OUT_14 C131 C130 R124 R150 VR1 C111 VMM1 4 MB1 8 MA2 5 MB2 7 PHASE2 24 DIS2 27 VR2 22 SHUT_ROT_OUT1B +1.8V 10/C7,10/C3 SHUT_ROT_OUT2A 10/C7,10/C3 B GND RC GND10 28 2 GND2 GND09 17 3 GND3 GND08 9 GND4 GND07 15 13 GND5 GND6 14 C125 10/C7,10/C3 U32 R146 R87 SHUT_ROT_OUT1A GND1 25 C126 R126 R86 DIS1 18 1 3/C6 DIS2 VR2 C107 IDX1_OUT2A 21 VMM2 23 VCC 4 VMM1 C124 GND1 27 C108 PWM_OUT_13 11 SHUT_ROT_OUT2B 10/C7,10/C3 16 E2 R128 3/C6 +1.8V MA1 6 C112 10/C7,10/C5 PHASE1 C1 C113 5 R144 R142 IDX1_OUT1B 20 19 R129 R130 PWM_OUT_10 3/C3 MA2 U29 PWM_PH_13 C2 24 3/C3 26 25 8 10/D7,10/C3 E2 PWM_PH_10 MB1 IDX1_OUT1A E1 1 3/B3 B 11 10 VR1 MA1 6 R121 DIS1 18 C2 C105 21 26 C106 PHASE1 E1 R122 PWM_OUT_9 3/C6 20 VMM2 23 VCC R120 PWM_PH_9 10 3/C6 12 R147 12 R125 R148 R93 C129 R97 A A GENLYTE Title SCHEMATIC Size 8 02.96 86.001 0 0 7 6 5 174 4 3 2 VL3500 CONTROLLER Document Number D D ate: Rev E0 14-9678-1730 Sheet Thursday, July 15, 2004 1 6 of 10 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS VL3500 Controller PCB (Sheet 7 of 10) 5 4 3 2 VCC D VCC +24V VCC 1 +24V +24V C136 VCC C100 + D +24V C155 C118 + FRAME 1A C133 C132 R157 R191 PWM_PH_16 R190 PWM_OUT_16 C140 C139 R162 PHASE1 21 DIS1 18 VR1 MA1 11 MB1 8 MA2 5 MB2 7 3/C3 10/B7,10/C3 R169 FRAME1A_OUT1B 10/B7,10/C5 3/B3 C150 GND1 25 PHASE2 24 DIS2 27 VR2 22 FRAME1A_OUT2A FRAME1A_OUT2B RC GND10 28 2 GND2 GND09 17 3 GND3 GND08 9 GND4 GND07 15 13 GND5 GND6 14 C135 PWM_PH_1 R170 PWM_OUT_1 C151 R171 PWM_PH_2 10/B7,10/C3 R200 R199 PWM_OUT_2 3/C6 C158 16 C157 20 PHASE1 21 DIS1 18 VR1 1 3/C3 10/B7,10/C5 R175 4 VMM1 FRAME1A_OUT1A U33 VMM2 23 VCC 4 VMM1 20 1 3/C6 3/C6 PWM_PH_15 R158 PWM_OUT_15 VMM2 23 12 ZOOM VCC 3/C6 R187 3/B6 R173 12 R160 MA1 11 MB1 8 MA2 5 MB2 7 ZOOM_OUT1B 10/B7,10/B3 10/B7,10/B5 GND1 25 PHASE2 24 DIS2 27 VR2 22 RC GND10 28 2 GND2 GND09 17 3 GND3 GND08 9 GND4 GND07 15 13 GND5 GND6 14 C154 ZOOM_OUT1A U35 ZOOM_OUT2A ZOOM_OUT2B 10/B7,10/B5 10/B7,10/B3 16 C R161 E2 C2 VCC 6 26 E1 C1 R159 10 19 6 E2 C2 26 10 19 E1 C1 VCC R172 C R174 +24V C134 R112 C138 R116 C153 R134 C156 R138 +24V +3.3V 2/A3,5/C2,6/C8,8/C8,9/C8 MTR_EN+3.3V +2.5V +2.5V VCC VCC DIS1 1 R168 MA2 5 3/C6 C160 GND1 25 PHASE2 24 DIS2 27 VR2 22 MB2 RC GND10 28 GND2 GND09 17 3 GND3 GND08 9 GND4 GND07 15 13 GND5 GND6 14 C1 19 FRAME1B_OUT2A FRAME1B_OUT2B 7 2 C145 10/B7,10/B5 R165 R123 R176 PWM_PH_4 10/B7,10/B3 R204 3/B6 R182 PWM_OUT_4 C167 16 C166 PHASE1 21 DIS1 18 VR1 1 3/D6 R181 C147 VMM1 4 MA1 11 MB1 8 MA2 5 MB2 7 PHASE2 24 DIS2 27 VR2 22 RC GND10 28 2 GND2 GND09 17 3 GND3 GND08 9 GND4 GND07 15 13 GND5 GND6 14 C161 10/A7,10/B3 B GND R178 R127 EDGE_OUT1A U36 EDGE_OUT1B 10/A7,10/B5 GND1 25 C162 R167 C143 C159 10/B7,10/B5 20 VMM2 23 VCC VMM1 VMM2 8 PWM_PH_3 C1 C149 3/D3 R177 PWM_OUT_3 19 C144 10/B7,10/B3 E2 R193 PWM_OUT_18 MB1 FRAME1B_OUT1B 6 R194 PWM_PH_18 C2 3/C3 VR1 E1 R163 FRAME1B_OUT1A 11 R201 26 C141 MA1 U34 EDGE_OUT2A EDGE_OUT2B 10/A7,10/B5 10/A7,10/B3 16 E2 PHASE1 21 18 C142 3/C6 20 C127 +1.8V 4 12 23 VCC 3/C6 PWM_PH_17 + R179 EDGE 10 3/B3 R164 PWM_OUT_17 +1.8V C164 6 R166 B R192 VCC C109 12 + +24V C2 C146 E1 FRAME 1B +24V 26 VCC +24V 10 +24V R180 R145 C165 R149 A A GENLYTE Title SCHEMATIC Size VL3500 CONTROLLER Document Number D D ate: 5 02.96 86.001 0 0 4 3 175 2 Rev E0 14-9678-1730 Thursday, July 15, 2004 1 Sheet 7 of 10 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS VL3500 Controller PCB (Sheet 8 of 10) 5 4 3 2 VCC VCC +24V D +24V +24V C173 VCC C137 + 3/C6 R209 C169 C168 R210 R219 PWM_PH_20 R218 PWM_OUT_20 C176 C175 R217 PHASE1 21 DIS1 18 VR1 MA1 11 MB1 8 MA2 5 MB2 7 10/D6,10/A3 10/D6,10/A5 3/C6 C196 24 DIS2 27 VR2 22 RC GND10 28 2 GND2 GND09 17 3 GND3 GND08 9 GND4 GND07 15 13 GND5 GND6 14 C171 AMB_OUT2A AMB_OUT2B PWM_PH_23 R244 PWM_OUT_23 GND1 PHASE2 VCC 3/B6 R242 AMB_OUT1B C195 R243 PWM_PH_24 10/D6,10/A3 R252 3/B6 R251 PWM_OUT_24 C203 16 C202 PHASE1 21 DIS1 18 VR1 1 3/B6 10/D6,10/A5 20 R250 4 VMM2 AMB_OUT1A U37 25 12 23 4 VMM1 20 1 3/B3 3/C6 PWM_PH_19 R211 PWM_OUT_19 MAGENTA VMM2 23 VCC AMBER 3/C6 D C163 + R247 12 R214 +24V C200 VMM1 VCC 1 MA1 11 MB1 8 MA2 5 MB2 7 MAG_OUT1A 10/C6,10/A3 U40 MAG_OUT1B 10/C6,10/A5 GND1 25 PHASE2 24 DIS2 27 VR2 22 MAG_OUT2A MAG_OUT2B RC GND10 28 2 GND2 GND09 17 3 GND3 GND08 9 GND4 GND07 15 13 GND5 GND6 14 C198 10/C6,10/A5 10/C6,10/A3 16 R215 6 E2 C2 26 E1 C1 R213 10 19 6 E2 C2 26 10 19 E1 C1 VCC VCC R246 R248 C C +24V C170 R188 C174 R189 C197 R202 C201 R203 +24V +3.3V 2/A3,5/C2,6/C8,7/C8,9/C8 MTR_EN+3.3V +2.5V VCC +24V +24V C182 + VCC C148 3/C3 3/B3 DIS2 C187 27 VR2 22 MA2 MB2 5 7 RC GND10 28 2 GND2 GND09 17 3 GND3 GND08 9 GND4 GND07 15 13 GND5 GND6 14 E1 10 19 CYAN_OUT2A CYAN_OUT2B R224 R195 C186 R232 10/D6,10/A5 PWM_PH_26 10/D6,10/A3 R241 3/C3 R240 PWM_OUT_26 C194 16 C193 20 PHASE1 21 DIS1 18 VR1 1 3/C3 R239 C189 R226 C179 C183 4 12 VMM2 PWM_PH_25 R233 PWM_OUT_25 MA1 11 MB1 8 MA2 5 MB2 7 10/D6,10/A3 B GND DIM_OUT1B 10/D6,10/A5 GND1 25 PHASE2 24 DIS2 27 VR2 22 RC GND10 28 2 GND2 GND09 17 3 GND3 GND08 9 GND4 GND07 15 13 GND5 GND6 14 R235 R196 DIM_OUT1A U39 C188 DIM_OUT2A DIM_OUT2B 10/D6,10/A5 10/D6,10/A3 16 E2 10/D6,10/A5 6 10/D6,10/A3 R231 CYAN_OUT1B VMM1 CYAN_OUT1A C2 PHASE2 24 23 VCC VMM1 4 8 GND1 25 C1 C180 11 MB1 26 R228 MA1 U38 E1 R229 C184 VR1 C1 PWM_PH_22 PWM_OUT_22 C185 DIS1 18 19 R230 PHASE1 21 1 3/B3 +1.8V C152 +1.8V E2 R221 + 6 C177 20 C2 C178 3/B3 PWM_PH_21 R222 PWM_OUT_21 26 3/B3 R220 3/C6 C191 DIMMER VMM2 23 VCC CYAN B +24V R236 12 R225 10 VCC +2.5V VCC +24V R237 R197 C192 R198 A A GENLYTE Title SCHEMATIC Size D D ate: 5 02.96 86.001 0 0 4 3 176 2 VL3500 CONTROLLER Document Number Rev 14-9678-1730 Thursday, July 15, 2004 1 Sheet 8 E0 of 10 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS VL3500 Controller PCB (Sheet 9 of 10) 8 7 6 5 4 3 VCC 1 VCC +24V VCC 2 +24V +24V C208 VCC C172 + +24V C232 C199 + D D VR2 22 RC 13 28 GND2 GND09 17 GND3 GND08 16 GND4 GND07 15 GND5 GND6 14 E1 10 19 R264 C R288 PWM_PH_32 10/C6,10/A3 R293 R296 PWM_OUT_32 C234 C235 R295 R212 24 DIS2 27 VR2 22 RC 9 13 C209 11 MB1 8 MA2 5 MB2 7 STROBE1_OUT1B STROBE1_OUT2A STROBE1_OUT2B GND10 28 GND2 GND09 17 GND3 GND08 GND4 GND07 15 GND5 GND6 14 R291 R216 STROBE1_OUT1A 10/B6,10/A3 10/B6,10/A5 GND1 PHASE2 3 MA1 U44 25 2 4 VMM1 VR1 C231 R266 C206 DIS1 18 1 3/B6 3/B6 PHASE1 21 VMM2 23 VCC GND10 C1 C207 FXDC_OUT2B C228 10/C6,10/A5 20 10/B6,10/A5 10/B6,10/A3 16 E2 DIS2 27 9 4 VMM1 24 FXDC_OUT2A PWM_PH_31 R289 PWM_OUT_31 C229 PHASE2 3 7 3/B6 6 R268 MB2 3/B6 10/C6,10/A5 C2 C210 5 10/C6,10/A3 R290 FXDC_OUT1B 26 C211 MA2 FXDC_OUT1A GND1 25 2 8 E1 R269 PWM_OUT_28 11 MB1 C1 R267 PWM_PH_28 MA1 U41 10 1 3/B6 3/B6 VR1 19 R261 DIS1 18 E2 C204 PHASE1 21 6 C205 20 C2 R262 PWM_OUT_27 26 PWM_PH_27 3/B6 R263 3/B6 STROBE1 VMM2 23 VCC FXD COLOR 12 R292 12 R265 R294 C230 R245 C233 VCC VCC R249 C +24V 2/A3,5/C2,6/C8,7/C8,8/C8 +24V MTR_EN- +3.3V +3.3V VCC VCC +24V +24V +24V +24V +2.5V VCC C216 + VCC C181 C224 + C190 +2.5V R277 25 PHASE2 24 DIS2 27 VR2 22 5 MB2 7 RC GND10 28 GND2 GND09 17 3 GND3 GND08 16 9 GND4 GND07 15 13 GND5 GND6 14 E1 10 19 R273 R280 PWM_OUT_33 CTO_OUT2B C220 R223 R279 10/B6,10/A5 3/B6 R285 3/B6 PWM_PH_34 R287 PWM_OUT_34 C227 C226 21 DIS1 18 VR1 1 10/B6,10/A3 R286 C223 R275 C214 C217 4 VMM1 VMM2 23 VCC VMM1 VMM2 MA2 2 C1 C215 3/B6 +1.8V MA1 11 MB1 8 10/B6,10/A3 U43 +1.8V STROBE2_OUT1B 10/B6,10/A5 GND1 25 PHASE2 24 DIS2 27 VR2 22 MA2 5 MB2 7 RC GND10 28 2 GND2 GND09 17 3 GND3 GND08 9 GND4 GND07 15 13 GND5 GND6 14 R282 R227 STROBE2_OUT1A STROBE2_OUT2A STROBE2_OUT2B B 10/B6,10/A5 10/B6,10/A3 GND 16 E2 C218 10/B6,10/A5 C221 CTO_OUT2A PHASE1 6 C219 R281 CTO_OUT1B GND1 20 C2 R278 PWM_OUT_30 8 U42 PWM_PH_33 E1 PWM_PH_30 MB1 3/B6 10 R276 VR1 1 3/B6 3/B6 DIS1 18 10/B6,10/A3 C1 B 21 CTO_OUT1A 19 R270 11 E2 C212 MA1 6 C213 PHASE1 C2 R271 PWM_OUT_29 20 26 R272 3/B6 PWM_PH_29 4 12 23 VCC 3/B6 12 R283 STROBE2 26 R274 CTO R284 C222 R234 C225 R238 A A GENLYTE Title SCHEMATIC Size D D ate: 8 02.96 86.001 0 0 7 6 5 177 4 3 2 VL3500 CONTROLLER Document Number Rev E0 14-9678-1730 Thursday, July 15, 2004 Sheet 1 9 of 10 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS VL3500 Controller PCB (Sheet 10 of 10) 8 7 6 5 4 3 2 1 +24V VCC +24V DIA. .166" FRAME2A_OUT1A D14 D49 D50 AMB_OUT1B 8/D5,10/A5 5/C1,10/C5 D52 AMB_OUT2A DIA. .250" MNTG2 1 2 3 4 5 6 8/D5,10/A3 FRAME2A_OUT2A D15 AMB_OUT1A FRAME2A_OUT1B 5/C1,10/C5 D16 DIA. .166" MNTG1 5/C1,10/C3 1 2 3 4 5 6 1 2 3 4 5 6 D51 6/D5,10/C3 D53 VCC D54 D56 CYAN_OUT1B CYAN_OUT2A 8/B5,10/A5 ROT1_OUT2B 6/D5,10/C3 D55 CYAN_OUT2B 8/B5,10/A3 IDX1_OUT1A 6/B5,10/C3 D22 ENCODER_A1 D57 DIM_OUT1A 4/B4 8/B2,10/A3 IDX1_OUT1B 4/B4 6/B5,10/C5 D58 DIM_OUT1B 4/B4 8/B2,10/A5 D24 IDX1_OUT2A D23 ENCODER_B1 ENCODER_A2 ENCODER_B2 4/B4 6/B5,10/C5 D60 DIM_OUT2A D59 D61 D62 6/D2,10/C5 D64 5/C2,10/D7 MAG_OUT1B 6/D5,10/D7 6/D5,10/D7 MAG_OUT2A 8/D2,10/A5 FXDG_OUT2B 6/D2,10/C3 D63 6/B5,10/C7 6/B5,10/C7 MAG_OUT2B 6/D2,10/C7 SHUT_ROT_OUT1A 6/B2,10/C3 D65 6/D2,10/C7 FXDC_OUT1A C 9/D5,10/A3 SHUT_ROT_OUT1B SHUT_ROT_OUT2A D31 6/B2,10/C5 D66 6/B2,10/C5 D68 FXDC_OUT1B 6/B2,10/C7 6/B2,10/C7 9/D5,10/A5 VCC FRAME1A_OUT1A D34 7/D5,10/B7 7/D5,10/B7 FXDC_OUT2A 9/D5,10/A5 SHUT_ROT_OUT2B 6/B2,10/C3 D67 7/B5,10/B7 FXDC_OUT2B 7/D5,10/C3 D69 7/B5,10/B7 R300 9/D5,10/A3 D33 FRAME2A_OUT2A FRAME2A_OUT1B ROT1_OUT2A ROT1_OUT1B IDX1_OUT2A IDX1_OUT1B FXDG_OUT2A FXDG_OUT1B SHUT_ROT_OUT2A SHUT_ROT_OUT1B FRAME1A_OUT2A FRAME1A_OUT1B FRAME1B_OUT2A FRAME1B_OUT1B VCC_R300 CTO_OUT1A 9/B5,10/A3 4/A3 FRAME1A_OUT1B GOBO1_POS_SENS D70 VCC_R301 CTO_OUT1B 9/B5,10/A5 FRAME1A_OUT2A D35 7/D5,10/C5 D72 VCC_R302 CTO_OUT2B D73 STROBE2_OUT1A 9/B2,10/A3 FRAME1B_OUT1B 7/B5,10/B5 FRAME1B_OUT2A D39 EDGE_SENS 9/B5,10/A3 7/B5,10/B3 D38 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 D74 PAN_PHC_OUT PAN_PHB_OUT 7/B5,10/B5 TILT_PHA_OUT TILT_COT_SENS PAN_COT_SENS 4/C6 4/B3 2/C4 LAMP_ON_INLAMP_STBY 2 3 3 4 4 5 5 VCC BALLAST CONTROL +24V 2 2 +3.3V 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 10 11 11 12 12 13 13 14 14 15 15 16 16 17 17 18 18 19 19 20 20 21 21 22 22 23 23 24 24 25 25 26 26 28 28 27 27 J5 FRAME2A_OUT2B FRAME2A_OUT1A ROT1_OUT2B ROT1_OUT1A IDX1_OUT2B IDX1_OUT1A FXDG_OUT2B FXDG_OUT1A SHUT_ROT_OUT2B SHUT_ROT_OUT1A FRAME1A_OUT2B FRAME1A_OUT1A FRAME1B_OUT2B FRAME1B_OUT1A 5/C1,10/D7 COMIN+ 5/C1,10/D7 4/C1 6/D5,10/D7 4/C1 6/D5,10/D7 4/C1 6/B5,10/C7 4/C1 COMINCOMOUT+ COMOUT- +3.3V 1 1 2 2 3 3 4 4 +2.5V 6/D2,10/C7 C 6/B2,10/C7 +1.8V 6/B2,10/C7 7/D5,10/B7 VCC +24V VCC J3 7/D5,10/B7 7/B5,10/B7 7/B5,10/B7 1 1 2 2 3 3 29 29 30 30 GOBO1_IDX_SENS 31 31 32 32 VCC_R304 33 33 34 34 35 35 36 36 FXDG_SENS 37 37 38 38 VCC_R303 39 39 40 40 41 41 42 42 43 43 44 44 45 45 46 46 1 1 47 47 48 48 2 2 49 49 50 50 1 1 2 2 3 3 4/A3 +1.8V POWER IN R304 GND 4/B4 R303 SPARE_SENS 4/B4 +24V J1 J12 +24V J10 D77 STROBE1_OUT1A 9/D2,10/A3 7/D2,10/B8 D78 7/D2,10/B8 STROBE1_OUT1B D80 7/B2,10/B8 STROBE1_OUT2A 7/B2,10/B8 ZOOM_OUT2A ZOOM_OUT1B EDGE_OUT2A EDGE_OUT1B 9/D2,10/A5 ZOOM_OUT2B D79 STROBE1_OUT2B 9/D2,10/A3 EDGE_OUT1B +2.5V 6/D2,10/C7 ZOOM / EDGE VCC STROBE2_OUT2B ZOOM_OUT1B EDGE_OUT1A DMX IN / COMM 6/B5,10/C7 9/B2,10/A5 7/D2,10/B3 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 10 11 11 12 12 13 13 14 14 7/B2,10/B3 ZOOM_OUT2B ZOOM_OUT1A EDGE_OUT2B EDGE_OUT1A ZOOM_SENS 7/D2,10/A7 7/D2,10/B7 B ZOOM 7/B2,10/A7 7/B2,10/A7 EDGE 4/A2 FRAME REF. 7/B2,10/B5 EDGE_OUT2A VCC 7/B2,10/B5 D47 4/B3 1 2 TP1 9/D2,10/A5 D48 4/C6 1 STROBE2_OUT2A D75 7/D2,10/B5 D46 LAMP_CNTL_OUT STROBE2_OUT1B ZOOM_OUT2A D45 TILT 5/B4 FRAME1B_OUT2B 7/D2,10/B5 D43 5/B4 TILT_PHC_OUT 9/B2,10/A3 D44 J2 5/B4 TILT_PHB_OUT YOKE FANS/RELAY D76 7/D2,10/B3 B PAN 5/D4 5/C4 1 ZOOM_OUT1A D42 VCC 5/C4 PAN_PHA_OUT 9/B2,10/A5 7/B5,10/B3 D41 6 DISPLAY CONTROL D 1 R302 9/B5,10/A5 D71 FRAME1B_OUT1A D40 4/B1 CTO_OUT2A FRAME1A_OUT2B 7/D5,10/C3 D37 2 3 R301 7/D5,10/C5 D36 5 6 J9 8/D2,10/A3 D32 4 5 GOBO / SHUTTER 5/C2,10/D7 8/D2,10/A5 D30 1 MAG_OUT1A 8/D2,10/A3 6/D2,10/C5 D27 3 4 +24V FXDG_OUT1B FXDG_OUT2A D29 3 8/B2,10/A5 8/B2,10/A3 6/D2,10/C3 D28 SCL_OUT 2/A8 DIM_OUT2B FXDG_OUT1A D26 2/A8 2 IDX1_OUT2B 6/B5,10/C3 D25 SDA_OUT 1 2 3 4 5 6 1 2 J8 8/B5,10/A5 6/D5,10/C5 D21 1 2 3 4 5 6 1 PAN / TILT 8/B5,10/A3 ROT1_OUT2A D19 1 2 3 4 5 6 MNTG7 CYAN_OUT1A ROT1_OUT1B 6/D5,10/C5 D20 1 2 3 4 5 6 J4 DIA. .250" MNTG6 8/D5,10/A5 ROT1_OUT1A D18 DIA. .166" MNTG5 AMB_OUT2B 8/D5,10/A3 D17 DIA. .166" MNTG4 FRAME2A_OUT2B 5/C1,10/C3 D DIA. .250" MNTG3 1 D13 2B PWM_OUT_35 2B PWM_PH_35 3A PWM_OUT_37 3A PWM_PH_37 FRAME REF. COLOR/DIMMER/STROBE EDGE_OUT2B 7/B2,10/B3 +24V J11 8/B5,10/D6 8/B5,10/D6 8/D5,10/D6 8/D5,10/D6 8/D2,10/C6 8/D2,10/C6 8/B2,10/C6 8/B2,10/C6 9/B5,10/B6 9/B5,10/B6 9/D5,10/C6 A 9/D5,10/C6 9/D2,10/B6 9/D2,10/B6 9/B2,10/B6 9/B2,10/B6 CYAN_OUT2A CYAN_OUT1B AMB_OUT2A AMB_OUT1B MAG_OUT2A MAG_OUT1B DIM_OUT2A DIM_OUT1B CTO_OUT2A CTO_OUT1B FXDC_OUT2A FXDC_OUT1B STROBE1_OUT2A STROBE1_OUT1B STROBE2_OUT2A STROBE2_OUT1B CYAN_SENS 4/B1 AMB_SENS 4/B1 MAG_SENS 4/B1 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 10 11 11 12 12 13 13 14 14 15 15 16 16 17 17 18 18 19 19 20 20 21 21 22 22 23 23 24 24 25 25 26 26 27 27 28 28 29 29 30 30 31 31 32 32 34 34 33 33 35 35 36 36 37 37 38 38 39 39 40 40 AMB_OUT2B AMB_OUT1A MAG_OUT2B MAG_OUT1A DIM_OUT2B DIM_OUT1A CTO_OUT2B CTO_OUT1A FXDC_OUT2B FXDC_OUT1A STROBE1_OUT2B STROBE1_OUT1A STROBE2_OUT2B 8/B5,10/D6 8/B5,10/D6 8/D5,10/D6 8/D5,10/D6 PWM_OUT_41 4A PWM_PH_41 4B PWM_OUT_43 FIXED COLOR 4B PWM_PH_43 1 3 5 7 9 11 13 15 17 19 21 23 25 2 4 6 8 10 12 14 16 18 20 22 24 26 TO PIGGY BACK 9/D2,10/A6 9/D2,10/B6 02.96 86.001 0 0 5 178 4 3B PWM_PH_40 3B PWM_OUT_42 4A PWM_PH_42 4A PWM_OUT_44 4B PWM_PH_44 4B A 9/B2,10/B6 STROBE2 4/B1 FXDC_SENS 4/A2 GENLYTE 4/A2 Title SCHEMATIC D ate: 6 3A PWM_OUT_40 CTO_SENS VL3500 CONTROLLER Document Number D 7 3A PWM_PH_38 MTR_EN- STROBE1 Size 8 2B PWM_OUT_38 9/B2,10/B6 STROBE2_OUT1A DIMMER_SENS 4A CTO 9/D5,10/C6 9/D5,10/C6 PWM_PH_39 DIMMER 9/B5,10/B6 9/B5,10/B6 3B MAGENTA 8/B2,10/C6 8/B2,10/D6 PWM_OUT_39 AMBER 8/D2,10/C6 8/D2,10/C6 3B CYAN 2B PWM_PH_36 +24V J13 CYAN_OUT2B CYAN_OUT1A VCC PWM_OUT_36 3 2 Rev E0 14-9678-1730 Sheet Thursday, July 15, 2004 1 10 of 10 VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL SCHEMATICS AND WIRING DIAGRAMS Display PCB (Sheet 1 of 1) 8 7 6 5 4 3 1 2 REVISIONS DESCRIPTION REV NOTES: UNLESS OTHERWISE SPECIFIED TEW1 1. ALL CAPACITOR VALUES ARE IN MICROFARADS. 2. ALL RESISTOR VALUES ARE IN OHMS. D DATE APPD RELEASED TO ENGINEERING PER EO #09054 5-29-02 2 REVISED PER EO #09057 A RELEASED FOR PRODUCTION PER EO #09088 8-15-02 TEW T.E.W. VCC REFERENCE DESIGNATORS U5 VCC VCC ICM7555ISA 1 LAST USED NOT USED 8 GND VCC TRIG DIS 2 7 3 6 OUT THRES 4 C12 D1 J1 R15 S5 U5 VR1 5 RESET J1 644488-6 R4 U1 PCA9554PW VCC VCC 1 2 2 3 3 15 4 14 5 13 6 16 A0 IO0_0 A1 IO0_1 A2 IO0_2 SDA IO0_3 SCL IO0_4 INT- IO0_5 VDD IO0_6 VSS IO0_7 8 4 10 5 11 6 12 7 13 9 14 10 15 11 16 12 17 6 5 4 8 U2 PCA9554PW VCC 9 1 IO0_0 A1 IO0_1 A2 IO0_2 R8 36K 5% 1/10W D1 CLK 7 D2 D4 D5 19 LED+ D6 C6 0.01UF 10% 50V C11 10UF 20% 35V D3 20 LED- D1 BAT54SLT1 D7 CS1 VCC CS2 A0 VDD RD VSS WR 35V 20% 10UF C10 2 1 3 VLCD R5 10K R6 750 5% 1/10W 5% 1/10W 6 15 7 SDA IO0_3 SCL IO0_4 INT- IO0_5 14 VCC 9 13 10 16 C8 10UF 20% 35V 11 VDD IO0_6 VSS IO0_7 8 R15 1K RES 5 3 VCC D0 18 4 A0 2 C CV U3 AGM1232G 1 D R7 1K 5% 1/10W 12 U4 PCA9554PW VCC VCC VCC C7 0.1UF 20% 50V VCC C3 0.1UF 20% 50V VCC C12 0.1UF 20% 50V VCC C9 0.1UF 20% 50V C C4 0.1UF 20% 50V Tilt Switch S5 1 5% 1/10W 4 A0 IO0_0 A1 IO0_1 2 3 IO0_2 15 C13 0.01UF 7 SDA IO0_3 SCL IO0_4 INT- IO0_5 VDD IO0_6 VSS IO0_7 14 9 13 5% 1/10W 2 107.1001 6 A2 R14 1K 1 5 10 16 8 VR1 LP3964EMP-ADJ VCC 10% 50V 11 2 3 VIN 12 OUT 1 4 SD ADJ GND R3 10K C5 100UF 20% 10V VCC C1 100PF 10% 50V 5 R1 27K 5% 1/10W C2 22UF 20% 35V 5% 1/10W R13 10K 5% 1/10W B R2 10K 5% 1/10W R9 10K 1 B 3 2 4 5% 1/10W S1 TL1105SPF160Q R10 10K 1 3 2 4 5% 1/10W S2 TL1105SPF160Q R11 10K 1 3 2 4 5% 1/10W S3 TL1105SPF160Q R12 10K 1 3 2 4 MOUNTING HOLES 5% 1/10W S4 TL1105SPF160Q MTG1 MTG2 NEXT 24-9678-0825 DRAWN BY A PCB NO. 8 02.96 86.001 0 0 11.9678.0825 CONFIDENTIAL DSN 7 6 5 179 4 3 5/29/02 201 REGAL ROW DALLAS, TEXAS 75247 T. WALSH VL3000 DISPLAY CHK ALL INFORMATION CONTAINED HEREIN IS THE SOLE AND EXCLUSIVE PROPERTYDOC OF VARI-LITE, INC. AND MAY NOT BE USED, DISCLOSED, OR REPRODUCED MFG IN ANY MANNER WITHOUT, THE ADVANCE WRITTEN CONSENT OF VARI-LITE, INC. Filename: 9678-0825_2203_DISPLAY Date/Time: 11-12-2002_11:28 R T. WALSH ASSY eProduct Designer 2.0 2 SIZE REVISION D A SHEET DRAWING NUMBER 14-9678-0825 1 OF 1 1 A Vari-Lite 10911 Petal Street Dallas, Texas 75238 Toll Free 1-877-VARI-LITE Tel 214.647.7880 Fax 214.647.8038 www.vari-lite.com ©2001-2007 Genlyte Thomas Group LLC. All rights reserved. Printed in the U.S.A.