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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:

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 Series 3000

luminaires require an Osram HMI 1200 W/S metal halide lamp. 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.

CAUTION

advising of potential damage to product.

WARNING

advising of potential injury or death to persons.

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Summary of Contents for VL3000

Page 1: ......

Page 2: ...3 081 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 U...

Page 3: ... 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 W...

Page 4: ...nes 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 harmonize...

Page 5: ...een designed for use with specific lamp types The Series 3000 luminaires require an Osram HMI 1200 W S metal halide lamp 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 ...

Page 6: ...hich 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 t...

Page 7: ...typ Osram HMI 1200 W S metal halide lamp 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 Schei...

Page 8: ... 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 wi...

Page 9: ...tilisés uniquement avec certaines type de lampes Vérifier le type de lampe Osram HMI 1200 W S metal halide lamp 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 ent...

Page 10: ...s 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 ...

Page 11: ... usadas solamente con algunas lámparas Tome nota del tipo de lámpara Osram HMI 1200 W S metal halide lamp 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...

Page 12: ...uras 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 ...

Page 13: ...FOREWORD 02 9678 0010 G xi ...

Page 14: ...VARI LITE VL3000 VL3000 Q SERVICE MANUAL xii 02 9678 0010 G ...

Page 15: ...oke Components 7 Enclosure Components 8 Principles of Operation VL3000 and VL3000Q Spot Luminaire 9 Functional Block Diagram 9 VL3000 and VL3000Q Wash Luminaire 10 Functional Block Diagram 10 Chapter 2 Maintenance Testing Luminaire Self Tests 12 Calibration Sequence 12 Auto Recalibration 13 Sensor Testing 13 Troubleshooting Error Messages 15 Troubleshooting Guide 16 Maintenance Procedures Lamp Rep...

Page 16: ...9 Transfer Fan Assembly Replacement 51 Gobo Color Dual Fan Assembly Replacement 52 Yoke Fan Assembly x2 Replacement 53 Upper Enclosure Fan Assembly Replacement 54 Display PCB Assembly Replacement 55 Chapter 3 Illustrated Parts Breakdown Drawing Trees VL3000 Spot Luminaire 58 VL3000Q Spot Luminaire 61 VL3000 Wash Luminaire 64 VL3000Q Wash Luminaire 67 Top Assembly Included Items Kit Spot 70 Include...

Page 17: ...Left Strobe Blade Assembly 123 VL3000Q Strobe Motor Assembly 124 Dimmer Wheel Assembly 125 Gobo Clamp Assembly 126 Color Clamp Assembly 127 Edge Lead Screw Assembly 128 Beam Spreader Assembly 129 Stationary Concave Lens Assembly 130 Translating Convex Lens Assembly 131 Condenser Lens Assembly 132 Aperture Bulkhead Assembly 133 Beam Spreader Light Baffle Assembly 134 Yoke Assembly Yoke Assembly 135...

Page 18: ...bly 173 Yoke Fan and Relay Cable Assembly VL3000Q 174 OT Switch to Interlok Cable Assembly 175 Ignitor to Lamp Socket Cable Assembly 176 Head Controller Cable Assembly 177 Color Interconnect PCB Cable Assembly 179 Color Interconnect Quiet PCB Cable Assembly 181 Gobo Interconnect PCB Cable Assembly 183 Yoke Fan Cable Assembly 185 Yoke Fan Cable Assembly VL3000Q 186 EMI Filter to Power Switch Cable ...

Page 19: ...ranty card included in the product shipping package for more information Additional Documentation For complete installation and operation instructions refer to the luminaire s user manual This manual is available in both printed and electronic PDF formats VL3000 Series Luminaire User s Manual 02 9678 0001 and VL3000Q Series Luminaire User s Manual 02 9678 0005 For more information regarding DMX512...

Page 20: ...ebsite 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 ...

Page 21: ...02 9678 0010 G 3 CHAPTER 1 Description This chapter contains descriptions of luminaire features and components Features Components Principles of Operation ...

Page 22: ...3000Q Spot Luminaires 13 element 6 1 zoom optics system with 10 to 60 range Variable beam focus to morph between gobo wheels Two six position gobo wheels with five rotatable indexable gobo positions and one open position Five position gobo wheel with four rotatable indexable positions and one open position VL3000Q only 50 audible reduction in noise output from the VL3000 luminaires VL3000 and VL30...

Page 23: ... to lamp for replacement and provides controls for internal status information beam adjustment see detail below Upper Enclosure Assembly Houses power supply ballast and display board Truss Hook Bracket Attaches to enclosure base to allow truss hook installation CAUTION RISK OF EXPOSURE TO EXCESSIVE ULTRAVIOLET RADIATION DO NOT OPERATE WITHOUT COMPLETE LAMP ENCLOSURE IN PLACE OR WHEN LENS IS DAMAGE...

Page 24: ...Arm Houses lamp and reflector Provides knobs for lamp Backend Assembly adjustment Main Controller Board MCB Luminaire control circuit board Contains three rotating gobo wheels and beam Gobo Assembly size iris mechanism Contains lamp power cut off switch so that it Fan Assembly cannot be disengaged Contains fixed color wheel dimmer mechanism strobe Color Assembly mechanism CYM color mixer Enclosure...

Page 25: ...semblies Houses lens configuration Beam Spreader Assembly Yoke Arm Houses lamp and reflector Provides knobs for lamp Backend Assembly adjustment Main Controller Board MCB Luminaire control circuit board Enclosure Assembly see next page Head Covers attached by tether Cover Used in wash version only Aperture Assembly Contains fixed color wheel dimmer mechanism strobe Color Assembly mechanism CYM col...

Page 26: ... for clarity Enclosure Top Covers 150W 24V 6 3A Input Panel Assembly 1200W Arc Ballast Module Enclosure Bottom Ventilation Cover Power Supply Fan Assembly containing DMX Input PCB and Menu Display Wire Connection Green Yellow AC Ground Blue AC Neutral Brown AC Line International Harmonized Standard AC Input Cable Requires standard AC power distribution from 200 264 VAC 50 60 Hz 7 to 12 A depending...

Page 27: ...PRINCIPLES OF OPERATION VL3000 AND VL3000Q SPOT LUMINAIRE 02 9678 0010 G 9 1 Principles of Operation VL3000 and VL3000Q Spot Luminaire Functional Block Diagram ...

Page 28: ...VARI LITE VL3000 VL3000 Q SERVICE MANUAL 10 02 9678 0010 G VL3000 and VL3000Q Wash Luminaire Functional Block Diagram ...

Page 29: ...02 9678 0010 G 11 CHAPTER 2 Maintenance This chapter contains test service and standard maintenance procedures Testing Troubleshooting Maintenance Procedures ...

Page 30: ...the luminaire s self test function refer to the VL3000 User s Manual for your luminaire 02 9678 0001 or 02 9678 0005 Calibration Sequence The following is an outline of the luminaire s standard calibration sequence Phase 1 Strobe Phase 2 Tilt Gobo1 Gobo2 Gobo3 Phase 3 Gobo1 Index Gobo2 Index Gobo3 Index Color Wheel Dimmer Phase 4 Edge Beam Spreader wash only CTO Blue Amber Magenta Phase 5 Pan Zoom...

Page 31: ...chanisms within the VL3000 luminaire are equipped with either optical or magnetic sensors The VL3000 master control board MCB has labeled test points for reading DC voltages at each sensor Testing is best performed with a digital voltmeter for sensor readings or an oscilloscope for pan tilt encoder readings The values can be used to determine whether a circuit is opening correctly or for further t...

Page 32: ...nsor 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 str...

Page 33: ...isplay will now scroll through any error messages or display OK if there are no errors Table 2 1 Error Messages Display Message OK No Errors Found Pan No Sens Pan sensor not found Pan Encoder Fail Pan encoder failure Tilt No Sens Tilt sensor not found Tilt Encoder Fail Tilt encoder failure Index1 No Sens Gobo 1 Index sensor not found Gobo1 No Sens Rotating Gobo 1 sensor not found Index2 No Sens Go...

Page 34: ...aves oddly Profile not set correctly check Setup menu for correct type spot or wash No Sens Mechanism failed to find sensor reported for Blue Amber Magenta Col Wheel CTO Gobo1 Index1 Gobo2 Index2 Gobo3 Index3 Zoom and Edge No control continuous recalibration and or mechanism at wrong position Motor power not connected connect motor power Sensor not connected connect sensor Interconnect board not c...

Page 35: ... 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 Color Dimmer or Strobe Failure Color dimmer or strobe mechanisms will not move MCB connector disconnected check MCB connector at J11 Check Interconnect board n a Zoom E...

Page 36: ...ack it is hinged Step 3 One side at a time gently pry pull up at metal connection of lamp lamp from lamp socket Step 4 Position new lamp with dimple side down towards reflector One side at a time press lamp into lamp socket connector Ensure lamp is seated fully in place Note Dimple on lamp must be towards reflector as described above Position lamp before lamp is seated into lamp holder Because of ...

Page 37: ...enu Display select Lamp from Test menu If using console set intensity to 100 open beam size iris and focus for hard edge Note Allow five minutes for lamp to achieve full temperature pressure Step 2 Position beam on a white wall at a distance of 10 to 20 feet Step 3 At backcap using X Y and Z adjustment screws adjust beam as required Figure 2 2 Lamp Alignment CAUTION RISK OF EXPOSURE TO EXCESSIVE U...

Page 38: ...peration the relay automatically disengages and the lamp will douse When the duct is closed lamp power is restored The fan duct assembly is located on the bottom half of the luminaire head as shown below Figure 2 3 Fan Duct Assembly View Top Head Cover Bottom Head Cover 1 4 Turn Screw Hinged Duct Head covers are attached by tethers Bottom of Head View Disengages lamp power when raised Assembly ...

Page 39: ...3 also raise hinged fan duct assembly Fan duct has a lamp cutoff switch which will disengage power to lamp Step 4 Rotate gobo wheel until required gobo position is accessible CAUTION Do not push on gobo glass Press on gobo carrier only CAUTION Do not touch gobos with bare fingers Wear cotton gloves or other covering while replacing Clean with isopropyl alcohol and soft cloth if required Step 5 Rem...

Page 40: ...nued Figure 2 4 Gobo Replacement Press from this side Front of luminaire Gobo Wheel Gobo Assembly Carrier Top Head Cover Bottom Head Cover 1 4 Turn Screw Gobo Wheel see detail CAUTION Do not touch glass with bare fingers Press on gobo carrier only Head covers are attached by tethers ...

Page 41: ...or other covering while replacing Clean with isopropyl alcohol and soft cloth if required Step 3 Rotate color wheel until required filter position is accessible Step 4 Press spring lock back until color filter is free and remove filter Step 5 Install new filter coated side must be oriented towards lamp ensuring that it is securely in position Step 6 Replace head cover Figure 2 5 Color Filter Repla...

Page 42: ... Step 4 Remove transfer fan see procedure on page 51 Step 5 At Beam Spreader remove eight four per side 6 32x3 8 PPZ screws from beam spreader covers and remove covers Step 6 Loosen four screws on mounting clamps and remove two clamps screws are captive and will not come out Step 7 At front noise ring of fixture remove four 10 32x1 2 SCB Allen head screws using 5 32 Allen Wrench Step 8 Lift Beam S...

Page 43: ...follows maneuver head so the printing on the label on the rear of the head assembly is oriented correctly Step 3 Disconnect wiring harness from interconnect PCB Step 4 Remove interconnect PCB by pushing top of PCB off studs Step 5 Loosen four captive screws two per clamp Note Do NOT remove long phillips head screw it serves as a handle Step 6 Pull assembly straight up and out of luminaire Step 7 R...

Page 44: ...ur 1 4 turn captive stud connectors Step 3 Remove Color Dimmer Strobe Assembly See Color Dimmer Strobe Assembly on page 25 Step 4 Disconnect wiring from strobe motors Step 5 Cut wire tie holding wiring harness to strobe assembly Step 6 Remove four 6 32 KEPS nuts and lift strobe assembly straight up Step 7 Replace assembly by performing steps 2 through 6 in reverse order Figure 2 8 VL3000 Color Dim...

Page 45: ...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 32x3 8 PTB screws 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 ...

Page 46: ...number 126 453 Step 1 Disconnect luminaire AC input cable from power source CAUTION Always use anti static precautions when working with PCBs Step 2 Remove Main Control Board PCB following procedure on page 27 Step 3 Remove heatsink from Main Control Board PCB If thermal compound is used remove and replace with thermal pad Vari Lite part number 10 9678 0885 Thermal Transfer Kit Step 4 Using C K PL...

Page 47: ...i static precautions when working with PCBs Step 3 Disconnect ignitor PCB wires by removing four screws which secure wire ring terminals to PCB and remove ignitor PCB Step 4 Remove four 6 32x3 8 LG PPZ SEMS 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 Figure 2 11 VL3000 Ignitor Board Repla...

Page 48: ...2x1 4 PPB screws and pan motor side cover Step 9 At side of enclosure remove two 6 32x3 8 PFZ screws and two 6 32 KEPS nuts that hold two cable saddles Pull wiring out of way of pan motor Step 10 Loosen but do not remove four 10 32x3 4 SCB Cap screws Step 11 Move pan motor assembly toward pan pulley and remove belt Step 12 Remove four 10 32x3 4 SCB Cap screws Step 13 Pull assembly out be mindful o...

Page 49: ...e 30 Step 6 Pass wire through routing hole in chassis Step 7 Remove belt Step 8 Replace by performing steps 2 through 7 in reverse 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 Figure 2 12 VL3000 Pan Motor Assembly Re...

Page 50: ...s side ensuring that lens does not come into contact with any surface Step 4 At bottom of enclosure remove four 1 4 20x1 2 socket screws and 1 4 split lock washers and remove ventilation cover Step 5 At encoder PCB remove two 4 40x1 4 PPZ screws Step 6 Disconnect wiring from encoder board Step 7 Replace by performing steps 3 through 6 in reverse order Note Make sure the encoder disk passes through...

Page 51: ...ep 3 Carefully lay luminaire on its side ensuring that lens does not come into contact with any surface Step 4 At bottom of enclosure remove four 1 4 20x1 2 socket screws and 1 4 split lock washers and remove ventilation cover Step 5 At pan sensor remove two 6 32x3 8 PPZ screws Step 6 Disconnect wiring from encoder PCB and remove sensor Step 7 Replace sensor by performing steps 3 through 6 in reve...

Page 52: ... and remove cover Step 3 At power supply disconnect wiring Step 4 Remove one 6 32x3 8 LG PPZ screw Step 5 Loosen two 6 32x3 8 LG PPZ screws and slide LVS towards upper enclosure fan to remove Step 6 Replace by performing steps 2 through 5 in reverse order Figure 2 15 VL3000 Power Supply LVS Replacement Location Connector N White AC Wires L Black AC Wires V Red DC Wires V Red DC Wires V Black DC Wi...

Page 53: ... Disconnect head cable from Color Assembly Interconnect PCB remove wiring from Transfer Fan clips Step 5 Disconnect Transfer Fan wiring from Zoom Interconnect PCB Step 6 Disconnect head cable from Gobo Assembly Interconnect PCB Step 7 At Gobo Assembly clamps loosen four 6 32 captive screws two per clamp and remove clamp Note the large Phillips screw in the middle is used as a handle DO NOT try to ...

Page 54: ...k with notch in wheel Loosen index belt just enough to slip teeth and rotate index pulley to center slot in optical sensor Reset tension on belt and verify that pulley slot is still centered in sensor and sensor is centered between two guide marks on pulley flange Step 4 To time Gobo Wheel 2 first align outside planet gear timing mark with mark in sun gear Notch in wheel should be centered between...

Page 55: ...elt and verify that pulley slot is still centered in sensor and sensor is centered between two guide marks on pulley flange First align outside planet gear timing mark with mark in sun gear Notch in wheel should be centered between opposite planet gear teeth Loosen index belt just enough to slip teeth and rotate index pulley to center slot in optical sensor Reset tension on belt and verify that pu...

Page 56: ...ear as follows Step 3 Rotate center gear clockwise until timing mark is directly facing Position 6 Step 4 Lift edge of center gear slightly so that it will not turn while at same time rotating Position 6 gear until timing mark is directly across from center gear timing mark Lower center gear into place and verify alignment Step 5 Set remaining planet gears by following same procedure When all gear...

Page 57: ...en 1 2 3 4 5 6 Alignment Mark 1 Start with center gear timing mark facing Position 1 open 2 Rotate center gear clockwise until timing mark is directly across from Position 6 Rotate Position 6 gear until timing marks align Align both marks 6 5 3 Align remaining gobo gears using the same method 4 Verify alignment of all marks and adjust as necessary ...

Page 58: ... from casting Step 8 Remove guide rods from bearings Step 9 Carefully pull Optics Assembly from fixture To re install spot optics assembly Step 10 Thread Actuator shaft into motor until hex head of shaft touches motor Step 11 Insert guide rods into bearings Step 12 Carefully place optics assembly back into fixture Step 13 Align guide rods to be flush with lamp side bracket Step 14 Install but DO N...

Page 59: ...e way into linear actuator motor before re installing Secure right side optic assembly clamps first when re installing Figure 2 22 VL3000 Spot Optic Assembly Replacement Spot Optic Assembly Top Head Cover Fan Guide Rod Linear Actuator Motor see detail Thread all the way into motor as shown before re installing Optic Assembly Side View Edge Screw Edge Screw Motor Clamp Secure this side first when r...

Page 60: ...2 PPZ screws that mount Pan Motor Assembly you must tighten in a CLOCKWISE pattern starting with screw in lower left hand side from spring To remove and replace tilt motor belt Step 8 Disconnect luminaire AC input cable from power source Step 9 At tilt side leg remove yoke leg cover by removing four 6 32x3 8 PTB screws Step 10 At tilt motor assembly loosen four 10 32x1 2 PPZ screws Step 11 Remove ...

Page 61: ...Make sure wiring is not pinched during installation When tightening four 10 32x1 2 PPZ screws that mount Pan Motor Assembly you must tighten in a CLOCKWISE pattern starting with screw in lower left hand side from spring Figure 2 23 VL3000 Tilt Motor Assembly Replacement Tilt Motor Head not shown for clarity NOTE Assembly Spring Sensor Bracket Tilt Belt ...

Page 62: ...Step 6 Disconnect wiring and remove tilt assembly Step 7 On tilt assembly remove two 4 40x1 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 and wiring is not pinched during installation When tightening four 10 32x1 2 PPZ screws that mount Pan Motor Assembly you must ...

Page 63: ...leg cover by removing four 6 32x3 8 PTB screws Step 3 At sensor bracket remove two 10 32x1 2 PPZ screws and remove bracket Step 4 Disconnect wiring from Tilt Encoder PCB Step 5 At sensor remove two 6 32x3 8 PPZ screws and remove sensor from bracket Step 6 Replace by performing steps 2 through 5 in reverse order Figure 2 25 VL3000 Tilt EOT Sensor Replacement Tilt Motor Head not shown for clarity NO...

Page 64: ...remove four 6 32x3 8 PPZ screws CAUTION Be careful not to damage lens during next step Step 5 Carefully lay luminaire on its side ensuring that lens does not come into contact with any surface Step 6 At bottom of enclosure remove four 1 4 20 x 1 2 socket screws and 1 4 split lock washers and remove ventilation cover Step 7 Remove both handles by removing two 10 32x5 8 PPB screws at each Step 8 At ...

Page 65: ...nector J103 3 Pos Mate N Lok J108 Red 1 Choke J109 Dark Blue 2 Choke J110 Orange 3 Choke J111 Orange 4 Choke J112 8 Pos MTA J113 3 Pos MTA J202 Lamp Wires Black J203 Lamp Wires White J204 Light Blue Choke J205 Red Choke 1 Some components not shown for clarity NOTE Front Cover 6 32 3 8 PPZ Screw 8 Side Cover 2 APS Side Bracket 10 32x5 8 PPB Screw 2 Handle 8 32 3 8 PFZ Screw 3 Ballast Module Ferrite...

Page 66: ...Remove both handles by removing two 10 32x5 8 PPB screws at each Step 8 At enclosure bottom remove four 6 32x1 4 PPB screws and both side covers Step 9 At enclosure bottom remove two 6 32x3 8 PPB screws APS side bracket and front cover from ballast side Step 10 At ballast disconnect the following cable assemblies a Lamp wires b AC input c Control wiring Step 11 Pull lamp wires through ferrite core...

Page 67: ...er turn captive locking screws Top cover is identifiable as the cover on top when back label is such that words are displayed correct side up Step 3 At 80MM fan remove three 6 32 x 1 2 SCZ Allen screws and one 6 32 x 3 8 SCB Allen screw Step 4 Disconnect wiring from 80MM fan Step 5 Replace by performing steps 2 through 4 in reverse order Note Be sure and orient fan properly air should flow TOWARDS...

Page 68: ... 80MM fan and the lamp house Figure 2 28 VL3000 80MM Fan Replacement 80MM Fan Assembly Shield Orientation 80 mm Fan Shield Orientation Shield must mimic and cover fan housing Fan Fan Assembly Shield Fan Shield Note fan air flow indicator 80 mm Fan Assembly 80 mm Fan Assembly Series 3000 Back End Assembly Front of Luminaire see note above Note Other components removed for clarity ...

Page 69: ...over by loosening four quarter turn captive locking screws Top cover is identifiable as the cover on top when back label is such that words are displayed correct side up Step 3 Disconnect transfer fan wiring from zoom interconnect PCB Step 4 At transfer fan assembly loosen four 6 32 x 3 8 PPZ screws and slide assembly off Gobo assembly Step 5 Replace by performing steps 2 through 4 in reverse orde...

Page 70: ...g screws Step 3 Disconnect fan wiring from zoom interconnect pcb Step 4 At fan duct micro switch remove two 4 40x5 8 PPZ screws and remove micro switch Step 5 At Fan assembly remove four 6 32x3 8 PPZ screws and remove fan assembly Step 6 Replace by performing steps 2 through 5 in reverse order Note Some early production wash fixtures only have one fan mounted to dual fan assembly All current produ...

Page 71: ...urce Step 2 Remove yoke cover from side with fan being replaced by removing four 6 32 x 3 8 PTB screws Step 3 Disconnect wiring from fan Step 4 Remove four 4 40x1 4 PFSS screws two per side of yoke and remove fan Step 5 Replace by performing steps 2 through 4 in reverse order Figure 2 19 VL3000 Yoke Fan Assembly Replacement Yoke Fan Assembly Some components not shown for clarity NOTE Yoke Assembly...

Page 72: ...ver Step 3 At power supply disconnect wiring Step 4 Remove one 6 32x3 8 LG PPZ screw Step 5 Loosen two 6 32x3 8 LG PPZ screws and slide LVS towards upper enclosure fan to remove Step 6 At fan remove three 6 32x3 8 PPZ screws and remove fan Step 7 Replace by performing steps 2 through 6 in reverse order Figure 2 20 VL3000 Upper Enclosure Fan Assembly Replacement Location Connector N White AC Wires ...

Page 73: ... 5 Loosen two 6 32x3 8 LG PPZ screws and slide LVS towards upper enclosure fan to remove Step 6 At Display PCB remove two 6 32x3 8 PPZ screws remove Display stiffener bracket and lift PCB out of slot on bottom of chassis Step 7 Carefully disconnect wiring from PCB Step 8 Replace by performing steps 2 through 7 in reverse order Figure 2 21 VL3000 Display PCB Assembly Replacement Location Connector ...

Page 74: ...VARI LITE VL3000 VL3000 Q SERVICE MANUAL 56 02 9678 0010 G Notes ...

Page 75: ...rated Parts Breakdown This chapter contains illustrated parts breakdowns for all VL3000 and VL3000Q luminaire assemblies Drawing Trees Top Assembly Head Assembly Yoke Assembly Head Yoke PCB Assemblies Enclosure Assembly Cable Assemblies ...

Page 76: ...ontroller Cable Assembly 25 9678 0715 Rev C Relay to Gobo Fan Interlock Cable Assembly 25 9678 0675 Rev B Included Items Kit Spot 28 9678 0001 Rev J Spot Gobo Assembly 21 9678 0200 Rev K Spot Only Dual Fan Tray Duct Assembly VL3000 Only 21 9678 0660 01 Rev B Yoke Assembly 21 9678 0700 Rev J VL3000 80mm Fan Assembly 21 9678 0619 Rev B UV Filter Bulkhead Assembly 22 9678 0639 Rev G VL3000 Backcap In...

Page 77: ...y 22 9678 1113 Rev B Interconnect Light Shield Assembly 22 9678 1115 Rev C Tilt Motor Assembly 21 9678 0765 Yoke Fan Assembly 22 9661 0609 Rev C VL3000 Yoke Fan Cable Assembly 25 9678 0758 Rev A Yoke Fan and Relay Cable Assembly 25 9678 0681 Rev C Relay to Ignitor Cable Assembly 25 9661 1526 Rev C Motor Adapter Plate Assembly 21 9678 0331 Rev 0 Fixed Color Wheel Assembly 21 9678 0334 Rev D Strobe ...

Page 78: ...ay Cable Assembly 25 9678 1825 Ballast to Controller Cable Assembly 25 9678 0816 Rev A DC Output Cable Assembly 25 9678 0821 Pan Tilt Control Cable Assembly 25 9678 0818 Rev B LVS to Yoke AC Fan Cable Assembly 25 9678 0843 Rev A Chassis To Yoke Ground Cable Assembly 25 9661 1520 Rev C LVS Chassis Ground Cable Assembly 25 9661 1514 Rev A Lamp Supply to Relay Cable Assembly 25 9678 0829 Rev A Contin...

Page 79: ...Cable Assembly 25 9678 0715 Rev C Relay to Gobo Fan Interlock Cable Assembly 25 9678 0675 Rev B Included Items Kit Spot 28 9678 0001 Rev J Spot Gobo Assembly 21 9678 0200 Rev K Spot Only Gobo Color Fan Assembly VL3000Q Only 21 9678 0659 01 Rev D Yoke Assembly 21 9678 0701 Rev B VL3000Q 80mm Fan Assembly 21 9678 0619 Rev B UV Filter Bulkhead Assembly 22 9678 0617 Rev A VL3000Q Backcap Interlok to G...

Page 80: ...t Light Shield Assembly 22 9678 1115 Rev C Tilt Motor Assembly 21 9678 0765 Yoke Fan Assembly 22 9678 0609 Rev A VL3000Q Yoke Fan Cable Assembly 25 9678 0758 Rev A Yoke Fan and Relay Cable Assembly 25 9678 0681 Rev C Relay to Ignitor Cable Assembly 25 9661 1526 Rev C Motor Adapter Plate Assembly 21 9678 0331 Rev 0 Fixed Color Wheel Assembly 21 9678 0334 Rev D Strobe Assembly VL3000 Quiet 22 9678 0...

Page 81: ...able Assembly 25 9678 1825 Ballast to Controller Cable Assembly 25 9678 0816 Rev A DC Output Cable Assembly 25 9678 0821 Pan Tilt Control Cable Assembly 25 9678 0818 Rev B LVS to Yoke AC Fan Cable Assembly 25 9678 0843 Rev A Chassis To Yoke Ground Cable Assembly 25 9661 1520 Rev C LVS Chassis Ground Cable Assembly 25 9661 1514 Rev A Lamp Supply to Relay Cable Assembly 25 9678 0829 Rev A Continued ...

Page 82: ... Cable Assembly 25 9678 0715 Rev C Relay to Gobo Fan Interlock Cable Assembly 25 9678 0675 Rev B Included Items Kit Wash 28 9678 0002 Rev F Beam Spreader Assembly 21 9678 0910 Rev A Wash Only Dual Fan Tray Duct Assembly VL3000 Only 21 9678 0660 01 Rev B Yoke Assembly 21 9678 0700 Rev J VL3000 80mm Fan Assembly 21 9678 0619 Rev B UV Filter Bulkhead Assembly 22 9678 0639 Rev G VL3000 Backcap Interlo...

Page 83: ...mbly 25 9661 1526 Rev C Motor Adapter Plate Assembly 21 9678 0331 Rev 0 Fixed Color Wheel Assembly 21 9678 0334 Rev D Strobe Assembly 22 9678 0403 Rev F Left Strobe Blade Assembly 22 9678 0468 Rev C Right Strobe Blade Assembly 22 9678 0467 Rev C Dimmer Wheel Assembly 22 9678 0435 Rev D Color Sensor PCB 1 Mount Assembly 22 9678 0481 Rev B Color Sense PCB 2 Mount Assembly 22 9678 0489 Rev B Color In...

Page 84: ...ay Cable Assembly 25 9678 1825 Ballast to Controller Cable Assembly 25 9678 0816 Rev A DC Output Cable Assembly 25 9678 0821 Pan Tilt Control Cable Assembly 25 9678 0818 Rev B LVS to Yoke AC Fan Cable Assembly 25 9678 0843 Rev A Chassis To Yoke Ground Cable Assembly 25 9661 1520 Rev C LVS Chassis Ground Cable Assembly 25 9661 1514 Rev A Lamp Supply to Relay Cable Assembly 25 9678 0829 Rev A Contin...

Page 85: ... Assembly VL3000Q Only 21 9678 0659 01 Rev D Head to Back Cap Ground Cable Assembly 25 9661 1522 Rev B Ignitor to Lamp Socket Cable Assembly 25 9678 0789 Head Front Fan Assembly VL3000Q Only 23 9678 0699 Rev A Continued on page 68 Continued on page 69 Continued on page 68 Stationary Concave Lens Assembly 21 9678 0920 Rev A Wash Only Translating Convex Lens Assembly 21 9678 0930 Rev B Wash Only Con...

Page 86: ...ssembly 25 9661 1526 Rev C Motor Adapter Plate Assembly 21 9678 0331 Rev 0 Fixed Color Wheel Assembly 21 9678 0334 Rev D Strobe Assembly 22 9678 0403 Rev F Left Strobe Blade Assembly 22 9678 0468 Rev C Right Strobe Blade Assembly 22 9678 0467 Rev C Dimmer Wheel Assembly 22 9678 0435 Rev D Color Sensor PCB 1 Mount Assembly 22 9678 0481 Rev B Color Sense PCB 2 Mount Assembly 22 9678 0489 Rev B Color...

Page 87: ...678 0813 Rev A Display Cable Assembly 25 9678 1825 Ballast to Controller Cable Assembly 25 9678 0816 Rev A DC Output Cable Assembly 25 9678 0821 Pan Tilt Control Cable Assembly 25 9678 0818 Rev B LVS to Yoke AC Fan Cable Assembly 25 9678 0843 Rev A Chassis To Yoke Ground Cable Assembly 25 9661 1520 Rev C LVS Chassis Ground Cable Assembly 25 9661 1514 Rev A Lamp Supply to Relay Cable Assembly 25 96...

Page 88: ...B ASSY BRACKET TRUSS HOOK 8 41 6030 4211 1 EA GOBO ASSY UNEVEN BARS POS 2 4 9 41 6030 5011 1 EA GOBO ASSY NIGHT SKY POS 1 3 10 41 6030 5503 1 EA GOBO ASSY PALM LEAVES POS 2 2 11 41 6030 5523 1 EA GOBO ASSY TRIBAL BREAKUP POS 1 4 12 41 6030 6011 1 EA GOBO ASSY CIRCLE OF OVALS POS 3 5 13 41 6030 7002 1 EA GOBO ASSY PEBBLES POS 1 5 14 41 6030 7014 1 EA GOBO ASSY TRIANGLE BREAKUP POS 3 4 15 41 6030 70...

Page 89: ...en handling it is best to wear clean cotton gloves in order to keep the lamp s glass as dirt and grease free as possible 6 5 4 7 x2 1 22 3 2 16 9 11 13 18 Alpha Rays Night Sky Tribal Break Up Pebbles Glacier Gag 10 15 8 20 19 Palm Leaves Shock Break Up Uneven Bars Ice Blocks Gag Droplets Gag 17 12 14 21 3 Facet Prism Circle of Ovals Triangle Break Up Multi Colored Gobo ...

Page 90: ... Item Qty UM Description 1 02 8001 0001 1 EA PRODUCT SUPPORT SHEET VARI LITE CUSTOMER SERVICE 2 02 8052 0001 1 EA CARD LIMITED WARRANTY 3 02 8700 0001 1 EA CARD PRODUCT REGISTRATION 4 02 9678 0002 1 EA UNPACK QUICK START SHEET VL3000 04 4037 0001 5 EA LABEL 2 5 X 5 BARCODE not shown 07 9678 0036 1 EA CARDBOARD SHIPPING BOX VL3000 not shown 5 08 3000 0001 1 EA CD ROM VL3000 PRODUCT DOCUMENTATION US...

Page 91: ...RG 5 10 9678 0658 10 EA PLATE COUNTERWEIGHT 6 21 9678 0010 01 1 EA ASSY GENERIC LUMINAIRE VL3000 Only 21 9678 0011 01 1 EA ASSY GENERIC LUMINAIRE VL3000Q Only 7 21 9678 0200 1 EA ASSY SPOT GOBO 8 21 9678 8640 01 1 EA ASSY HOT BOX SPOT VL3000 Spot Only 21 9678 8698 01 1 EA ASSY HOT BOX QUIET SPOT VL3000Q Spot Only 9 21 9678 0660 01 1 EA ASSY FAN TRAY DUCT 21 9678 0659 01 1 EA ASSY FAN TRAY DUCT QUI...

Page 92: ... 6 32 X 1 2 PPZ 26 53 6614 0003 4 EA SCREW 6 32 X 5 8 PFZ 27 55 2284 0001 2 EA CARD GUIDE 3 LONG SNAP IN 28 55 6506 0024 2 EA SPACER 3 16 RND 1875 LG 0 141 THRU SS 29 55 6528 0001 2 EA WASHER 6 FLAT ZINC 30 55 6573 0001 2 EA HARDENED SHAFT 10MM DIA X 200MM HARDENED 31 55 6616 0001 4 EA STANDOFF 3 8 HEX 6 32 THRD 32 55 2150 0002 2 EA STANDOFF 1 4 HEX 6 32 1 188 LG MF STL changed 05 27 03 33 55 6677...

Page 93: ...1 30 x2 2 6 7 11 8 9 10 12 14 x4 13 15 x2 16 x2 17 18 22 x2 21 x8 22 x2 25 x2 23 x2 28 x2 29 x2 32 x2 2 11 3 4 5 x10 19 x4 20 x4 24 x4 26 x4 27 x2 31 x4 33 x2 34 x2 34 x2 35 22 x4 33 x2 Only used with 22 9678 0705 Yoke Structure Rev D or later or 22 9686 0705 For prior versions of Yoke Structure use Center of Travel Flag part number 10 9678 0755 ...

Page 94: ...21 9678 8611 2 EA ASSY HEAD COVER 6 21 9678 8640 02 1 EA ASSY WASH HOT BOX 21 9678 8698 02 1 EA ASSY HOT BOX VL3000Q WASH 7 21 9678 0660 01 1 EA ASSY FAN TRAY DUCT changed 03 01 05 21 9678 0659 01 1 EA ASSY FAN TRAY DUCT VL3000Q WASH 8 21 9678 0678 02 1 EA ASSY TRANSFER FAN changed 11 11 03 9 21 9678 0910 1 EA ASSY BEAM SPREADER 10 21 9678 0991 2 EA ASSY LIGHT BAFFLE BEAM SPREAD 11 21 9678 0950 1 ...

Page 95: ...3 55 2178 0001 1 EA CABLE ANCHOR MOUNT 8 SCREW MOUNT 24 55 2284 0001 1 EA CARD GUIDE 3 LONG SNAP IN 25 55 6506 0024 2 EA SPACER 3 16 RND 1875 LG 141 THRU SS 26 55 6528 0001 2 EA WASHER 6 FLAT ZINC 27 55 2150 0002 2 EA STANDOFF 1 4 HEX 6 32 1 188 LG MF STL changed 5 27 03 28 55 6677 0033 4 EA WASHER 281 OD 125 ID 032 THK FLAT SS 29 53 6558 0007 2 EA SCREW 6 32 X 1 4 LG PPZ SEMS EXT ZINC PLT added 7...

Page 96: ...9678 0010 G VL3000 and VL3000Q Wash Luminaire continued Figure 3 16 VL3000 and VL3000Q Wash Luminaire 1 3 2 4 5 6 7 8 9 11 10 x2 12 x2 13 14 x2 15 x2 16 18 x2 17 x8 18 x4 20 x4 21 x2 22 x8 19 x2 24 25 x2 26 x2 27 x2 3 5 18 x2 18 x2 29 x2 23 18 28 x4 ...

Page 97: ... WIRE DIA 5 21 9678 0800 01 1 EA ASSY UPPER ENCLOSURE 21 9678 0801 01 1 EA ASSY UPPER ENCLOSURE VL3000Q 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 ...

Page 98: ...eric Luminaire Assemblies continued Figure 3 17 VL3000 and VL3000Q Generic Luminaire Assemblies 1 2 3 4 5 6 x4 7 x5 8 x4 9 x4 10 11 x4 12 x3 13 x2 15 16 x5 3a 3b 3c x3 4a 4b 4c 4d 14 x2 Detail C 17 18 Detail B Detail A Detail C Detail B Detail A 13 6 14 9 x2 8 x2 ...

Page 99: ...y No Item Qty UM Description 1 10 9678 8620 1 EA FRONT CASTING 2 12 9678 8623 1 EA RIGHT SIDE RAIL MACHINED 3 12 9678 8625 1 EA LEFT SIDE RAIL MACHINED 4 21 9678 0615 1 EA ASSY BACKEND 21 9678 0616 1 EA ASSY BACKEND VL3000 QUIET 5 53 6515 0001 6 EA SCREW 10 32 X 3 4 SCB CAP 6 53 6515 1000 1 EA SCREW 10 32 X 1 SOCKET CAP BLACK 7 53 6515 1125 3 EA SCREW 10 32 X 1 25 SOCKET CAP BLACK 1 2 3 5 x6 4 6 7...

Page 100: ...8 0674 1 EA BRACKET COVER TETHER 4 10 9678 0696 1 EA FOAM FRAME HEAD COVER added 10 01 03 5 12 9678 8610 1 EA HEAD COVER 6 53 5655 0250 4 EA SCREW 6 X 1 4 PPZ PLASTIC 7 53 6558 0003 1 EA SCREW 6 32 X 3 8 LG PPZ PLASTIC THD ROLL 8 55 2233 0016 4 EA RETAINER SPLIT RING changed 04 19 05 9 55 2233 0775 4 EA STUD 1 4 TURN OPR 775L STEEL BLK ZINC changed 5 21 03 10 55 9676 0255 4 EA WASHER BEVELED SPRIN...

Page 101: ...YOKE TO FAN not shown 25 9678 0014 1 EA CABLE ASSY BACKCAP INTERLOK TO GOBO INTERLOK not shown 12 53 2004 0002 6 EA NUT 8 32 KEPS ZINC PLATE 13 53 6519 0001 2 EA SCREW 4 40 X 5 8 PPZ 14 53 6545 0009 4 EA SCREW 8 32 X 1 375 LG PFZ 15 53 6523 0001 1 EA SCREW 6 32 X 3 8 SCB changed 7 18 03 16 53 6558 0007 6 EA SCREW 6 32 X 1 4 PPZ SEMS 17 53 6559 0001 4 EA SCREW 4 40 X 1 4 PFZ 18 53 6609 0001 6 EA SC...

Page 102: ...690 1 EA CABLE ASSY AIR DUCT OT SWITCH VL3000 QUIET cable not shown 31 10 9678 0680 1 EA INSULATOR TEFLON TO 220 32 53 2200 0004 1 EA NUT 4 40 KEPS No Item Qty UM Description 1 2 3 x2 4 5 6 7 8 9 x2 11 10 12 x2 13 x2 16 x4 14 x4 15 17 x4 18 x4 28 x3 20 x2 23 x4 24 x2 24 x4 25 26 27 12 x2 12 x2 16 x2 18 x2 21 x2 24 x4 24 x3 26 x2 19 Shield Orientation 80 mm Fan Shield Orientation Shield must mimic ...

Page 103: ...to Figure 3 4 Figure 3 4 80mm Fan Assembly No Item Qty UM Description 1 40 7145 0004 1 EA FAN TUBEAXIAL 80 X 80 X 38mm 28 CFM 230V added 03 11 04 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 1 2 x4 3 x4 4 ...

Page 104: ...NHANCED VL3000Q Only 4 53 6530 0002 4 EA RIVET 1 8 OD POP 063 125 GRIP ALUM 1 2 3 4 x4 UV Filter Installation 1 Install filter with marks indicating IR coating side of filter facing up and located outside of circular cutout in bulkhead 2 Apply a drop of Loctite 5083 NUVA SIL Curing Silicone to each corner of filter Drop size to produce 0 25 diameter circle of adhesive when filter is secured 3 Posi...

Page 105: ...3231 4 EA PCB ASSY INDEX SENSOR 15 24 9678 3240 3 EA PCB ASSY WHEEL POSITION SENSOR changed 02 11 05 25 9678 2209 1 EA PCB CABLE ASSY GOBO INTERCONN changed 06 28 06 Not Shown 16 44 9663 1202 2 EA MOTOR 17 2 42 SHAFT 11 8MH 17 44 9663 1766 2 EA MOTOR 17 1 24 SHAFT 11 8MH 5 18 53 5560 0187 12 EA SCREW 8 32 X 187 SET CONE changed 06 21 05 19 53 6520 0375 8 EA SCREW 4 40 X 3 8 PPZ SEMS 20 53 6558 000...

Page 106: ...d 4 29 03 34 10 9678 0457 02 2 EA SPACER RND 3 8 OD 257 ID 190 LG AL added 4 29 03 35 55 6520 0001 2 EA WASHER WAVE SPRING 265 ID 367 OD 006 THK added 4 29 03 36 10 9678 0457 04 1 EA SPACER RND 3 8 OD 257 ID 031 LG AL added 6 09 03 No Item Qty UM Description 1 2 3 x4 4 x3 5 x3 6 x2 7 8 x3 9 10 x2 11 12 13 14 x3 15 x3 16 17 18 x6 19 x2 20 x8 21 x8 22 x4 23 x3 24 x3 25 x4 26 x4 27 x4 28 x6 29 30 31 ...

Page 107: ...ANET 5 22 9678 0230 5 EA ASSY PLANET GEAR 5a 10 9678 0263 2 EA CLIP WIRE PLANET 5b 10 9678 0282 1 EA PLANET GEAR HOBBED CASTING 6 22 9678 0233 1 EA SUN GEAR MOLDED ELASTOMERIC INTEGRAL BEARING 7 22 9678 0234 1 EA ASSY PULLEY GOBO WHEEL HUB 7a 10 9678 0227 1 EA PULLEY HUB GOBO WHEEL 7b 54 1259 0004 2 EA BEARING RAD FLANGED 25 ID 625 OD 0005 changed 6 26 03 8 53 6650 0001 3 EA SCREW 2 56 X 5 16 9 55...

Page 108: ... 9678 0230 4 EA ASSY PLANET GEAR 5a 10 9678 0263 2 EA CLIP WIRE PLANET 5b 10 9678 0282 1 EA PLANET GEAR HOBBED CASTING 6 22 9678 0233 1 EA SUN GEAR MOLDED ELASTOMERIC INTEGRAL BEARING 7 22 9678 0234 1 EA ASSY PULLEY GOBO WHEEL HUB 7a 10 9678 0227 1 EA PULLEY HUB GOBO WHEEL 7b 54 1259 0001 2 EA BEARING RAD FLANGED 25 ID 625 OD 8 53 6650 0001 3 EA SCREW 2 56 X 5 16 9 55 2256 0001 1 EA MAGNET 2 17 SM...

Page 109: ... Rev 0 Refer to Figure 3 9 Figure 3 9 Long Shaft Motor Assembly No Item Qty UM Description 1 10 9678 0330 1 EA PLATE MOTOR ADAPTER 2 44 9678 0249 1 EA MOTOR STEPPER 42MM X 34MM 60MM SHAFT 3 53 6513 0002 4 EA SCREW 3MM X 5MM LG PFZ METRIC 1 2 3 x4 Note orientation of motor plate adapter when mounting ...

Page 110: ...NK ASSY IRIS 7a 53 6605 0004 1 EA STUD 2 56 X 1 0 LG FULL THREAD STAINLESS STEEL 7b 54 1217 0005 2 EA KWIK LINK 2 56 SPRING STEEL 8 22 9678 0275 1 EA IRIS 49MM OD 9 44 9678 0278 1 EA MOTOR 17 94 SHAFT 11 8MH 5 5OHM 10 53 5558 0125 2 EA SCREW 8 32 X 125 SET SS 11 53 6513 0042 3 EA SCREW M2 X 4 X 4MM LG PFB METRIC 12 53 6530 0013 2 EA RIVET 1 8 OD POP 0 328 AL CSK HD STL MNDRL 13 53 6558 0001 2 EA S...

Page 111: ...HEAD ASSEMBLY IRIS ASSEMBLY 02 9678 0010 G 93 3 Iris Assembly continued Figure 3 10 Iris Assembly 1 2 3 4 5 7 8 9 10 x2 11 x3 6 12 x2 13 x2 14 x3 16 x4 15 7a 7b 7b Detail A Detail A ...

Page 112: ... 4 EA CLAMP PRIMARY REFLECTOR 9 12 9678 7155 1 EA REFLECTOR PRIMARY SMOOTH Wash Only 12 9678 7151 1 EA REFLECTOR PRI 40 LUNE DUAL CURVATURE Spot Only 25 9661 1522 1 EA CABLE ASSY HEAD TO BACKCAP GROUND Not Shown 25 9678 0789 1 EA CABLE ASSY IGNITOR TO LAMP SOCKET Not Shown 10 53 2030 0001 3 EA NUT ACORN 10 32THD 3 8 WIDE 3 16 THD DP BLK ZINC 11 53 5508 0375 2 EA SCREW 8 32 X 3 8 PPSS 12 53 6530 00...

Page 113: ...BLY HOT BOX ASSEMBLY 02 9678 0010 G 95 3 Hot Box Assembly continued Figure 3 11 Hot Box Assembly 1 3 5 x3 10 x3 13 x4 12 x8 15 x4 14 x4 Wash Version Spot Version 16 x3 4 17 x3 6 19 11 x2 18 x4 17 x4 8 x4 2 7 x4 9 ...

Page 114: ...8 0665 1 EA DUCT ASSY 4 23 9678 0699 2 EA FAN ASSY HEAD FRONT 5 53 5506 1375 6 EA SCREW 6 32 X 1 3 8 LG PPB 6 53 6519 0001 2 EA SCREW 4 40 X 5 8 PPZ 7 53 6530 0006 2 EA RIVET 1 8 OD POP 188 250GL 8 55 2179 0003 2 EA SADDLE CABLE 75 X 75 4 WAY ADH BACK WHT 9 55 2186 0001 2 EA CABLE TIE 10 WD X 4 LG SMALL not shown 10 55 6538 0002 2 EA WASHER 6 NYLON NATURAL 11 55 6818 0002 1 EA STANDOFF 45 DEG NYLO...

Page 115: ...BO COLOR FAN ASSEMBLY VL3000Q ONLY 02 9678 0010 G 97 3 Gobo Color Fan Assembly VL3000Q Only continued Figure 3 12 Gobo Color Fan Assembly VL3000Q 1 2 3 4 5 x3 6 x2 7 x2 8 11 10 x2 5 x3 4 Spring installed as shown 8 12 ...

Page 116: ...ONGATED HOOK changed 06 29 06 2 22 9678 0661 1 EA ASSY FAN TRAY 3 22 9678 0665 1 EA DUCT ASSY 4 23 9678 0684 2 EA FAN ASSY HEAD FRONT 5 53 5506 1375 6 EA SCREW 6 32 X 1 3 8 LG PPB 6 53 6519 0001 2 EA SCREW 4 40 X 5 8 PPZ 7 53 6530 0006 2 EA RIVET 1 8 OD POP 188 250GL 8 55 6538 0002 2 EA WASHER 6 NYLON NATURAL 9 55 6818 0002 1 EA STANDOFF 45 DEG NYLON 6 6 KUR 10 74 1099 0001 1 EA SWITCH MINIATURE 5...

Page 117: ...L FAN TRAY DUCT ASSEMBLY VL3000 ONLY 02 9678 0010 G 99 3 Dual Fan Tray Duct Assembly VL3000 Only continued Figure 3 13 Dual Fan Tray Duct Assembly VL3000 1 2 3 4 5 x3 6 x2 7 x2 8 x2 9 10 5 x3 4 Spring installed as shown ...

Page 118: ...an Assembly 23 9678 0684 Rev 0 Refer to Figure 3 14 Figure 3 14 Head Front Fan Assembly No Item Qty UM Description 1 40 7125 0001 1 EA FAN 24V FAL6F24LH 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 1 2 3 x2 ...

Page 119: ... Assembly VL3000Q Only No Item Qty UM Description 1 40 7125 0001 1 EA FAN 24V FAL6F24LH 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 4 55 2186 0001 1 EA CABLE TIE 10 X 4 SMALL 5 55 2268 0125 1 EA HEATSHRINK 1 8 CLEAR KYNAR UL 600V 150 DEG C 6 60 8440 6801 1 EA RESISTOR 10W 5 68 OHM WIREWOUND 1 2 3 x2 6 4 5 5 ...

Page 120: ...78 0679 1 EA TRANSFER FAN TRAY 2 23 9678 0695 1 EA FAN ASSY TRANSFER 3 53 6571 0003 3 EA SCREW 6 32 X 1 1 2 LG PPB changed 07 16 07 4 55 6543 0001 2 12 FT GROMMET STRIP SERRATED POLYETHYLENE 5 55 6769 0004 3 EA TWIST LOK 0 55 ID NOM WHT 85 C MAX FLAME RET added 11 11 03 Spot Only 55 6769 0004 2 EA TWIST LOK 0 55 ID NOM WHT 85 C MAX FLAME RET added 11 11 03 Wash Only 1 2 3 x3 4 5 Spot Only 5 Spot W...

Page 121: ... 1 EA LENS MOUNT MACHINE G3 12 12 9678 1179 01 1 EA LENS MOUNT MACHINE G1 13 12 9678 1179 02 1 EA LENS MOUNT MACHINE G2 14 21 9678 0110 1 EA ASSY ZOOM BOX 15 21 9678 0113 1 EA ASSY RAIL CARRIAGE 16 22 9678 1181 1 EA LENS ASSY GROUP 1 17 22 9678 0182 1 EA LENS ASSY GROUP 2 18 22 9678 0183 1 EA LENS ASSY GROUP 3 19 22 9678 0199 1 EA ASSY LENS MOUNT G4 20 22 9678 1103 1 EA ASSY EDGE BEARING RIGHT 21 ...

Page 122: ...9 0001 6 EA SCREW 6 32 X 3 8 PFZ 37 53 6613 0008 4 EA SCREW 6 32 X 1 2 LG PPZ SEMS added 3 03 04 38 53 6614 0003 2 EA SCREW 6 32 X 5 8 PFZ 39 53 6617 0003 1 EA SCREW 6 32 X 1 PPB SEMS changed 3 03 04 40 53 6682 0025 2 EA SCREW 8 32 X 5 8 LNG PPZ SEMS changed 11 19 03 41 54 1261 0001 6 EA BUSHING LOW DAMP THERMOPLASTIC 189 ID 5 OD 42 55 2234 0001 1 EA RING RETAINING E STYLE GRV 188 DIA changed 02 0...

Page 123: ...OPTIC ASSEMBLY 02 9678 0010 G 105 3 Spot Optic Assembly continued Figure 3 17 Spot Optic Assembly View 1 23 33 x2 24 36 x2 21 33 x2 36 x4 20 26 35 33 x3 48 34 40 x2 41 x6 49 Detail F F Detail E E F E E F 25 9 33 x2 38 x2 ...

Page 124: ...2 44 37 4 Interconnect PCB and Zoom Motor removed for clarity Detail A A Detail B B Detail C C 28 47 46 7 39 48 46 2 46 42 45 43 45 1 6 10 19 18 11 3 13 5 35 33 x2 33 x3 15 32 x6 27 3 50 3 Optical Sensor G3 G2 G1 G3 G2 G1 G H G H Detail G3 G3 Detail G2 G2 Detail G1 G1 A A B B C C 37 x3 48 x3 12 16 14 17 31 x5 22 9 30 x2 52 51 8 ...

Page 125: ...o Figure 3 19 Figure 3 19 Group 4 Lens Mount Assembly No Item Qty UM Description 1 12 9678 0198 2 EA RING BLOCK MACHINED G4 2 22 9678 0174 1 EA LENS ASSY GROUP 4 3 53 6558 0001 4 EA SCREW 6 32 X 3 8 PPZ 4 55 3303 0006 4 EA WASHER 6 LOCK INT TOOTH SS 5 55 6763 0500 4 EA PIN DOWEL 5 LG 125 DIA 303SS 2 3 x4 4 x4 5 x4 1 1 ...

Page 126: ... 22 9678 1103 Rev C Refer to Figure 3 20 Figure 3 20 Right Edge Bearing Assembly No Item Qty UM Description 1 12 9678 1102 1 EA EDGE BEARING MACHINED CASTING RIGHT 2 54 2056 0001 4 EA RING RETAINING EXTERNAL 19MM 3 55 6776 0010 2 EA LINEAR BUSHING 10MM STEEL W PHENOLIC CAGE 1 3 2 2 2 2 3 ...

Page 127: ...sembly 22 9678 1105 Rev C Refer to Figure 3 21 Figure 3 21 Left Edge Bearing Assembly No Item Qty UM Description 1 12 9678 1104 1 EA EDGE BEARING MACHINE LEFT 2 54 2056 0001 4 EA RING RETAINING EXTERNAL 19MM 3 55 6776 0010 2 EA LINEAR BUSHING 10MM STEEL W PHENOLIC CAGE 1 3 2 2 2 2 3 ...

Page 128: ...sembly No Item Qty UM Description 1 10 9678 1107 1 EA ZOOM TIMING CAM 2 10 9678 1108 1 EA PULLEY FLANGE 3 10 9678 1118 1 EA TIMING PULLEY ZOOM 4 53 6613 0008 2 EA SCREW 6 32 X 1 2 PPZ changed 11 08 04 5 54 1259 0004 2 EA BEARING RADIAL FLANGED 25 ID 625 OD changed 06 25 03 6 55 6763 0500 2 EA PIN DOWEL 5 LG 125 DIA 303SS 1 2 3 4 x2 5 x2 6 x2 ...

Page 129: ...cription 1 10 9678 0338 1 EA PULLEY ZOOM MOTOR changed 03 07 06 2 10 9678 1111 1 EA BRACKET ZOOM TENSION SHEETMETAL 3 44 9663 1326 1 EA MOTOR 17 53 SHAFT 11 8MH 5 5 OHM 4 53 5559 0250 2 EA SCREW 6 32 X 1 4 SET CONE POINT 5 53 6522 0001 2 EA SCREW 6 32 X 1 4 PPZ 6 55 3303 0006 2 EA WASHER 6 LOCK INT TOOTH SS 0 150 1 2 3 4 x2 5 x2 6 x2 Set pulley height from bracket as indicated Pulley Installation ...

Page 130: ...embly 22 9678 1115 Rev C Refer to Figure 3 24 Figure 3 24 Interconnect Light Shield Assembly No Item Qty UM Description 1 10 9678 1114 1 EA SHIELD INTERCONNECT MOUNT LIGHT 2 24 9678 3116 1 EA PCB ASSY ZOOM INTERCONNECT changed 03 07 06 3 53 6558 0009 4 EA SCREW 6 32 X 3 8 PPZ SEMS 1 2 3 x4 ...

Page 131: ...embly No Item Qty UM Description 1 10 9678 0151 1 EA CLAMP OPTIC ROD CAST 2 53 2008 0006 2 EA SPRING CLIP 6 32 3 53 6616 0001 2 EA SCREW 6 32 X 3 4 PPZ 4 55 6528 0001 2 EA WASHER 6 FLAT ZINC 5 55 6538 0001 2 EA WASHER 6 LOCK INTERNAL TOOTH 1 3 x2 4 x2 5 x2 2 x2 0 10 Set spring clip from clamp surface as indicated Spring Clip Installation ...

Page 132: ...D COLOR WHEEL 12 22 9678 0335 1 EA ASSY BEARING BLOCK FIXED WHEEL 10 9678 0323 1 EA WHEEL MOUNT 54 1259 0004 2 EA BEARING RADIAL FLANGED 0 25 ID 0 625 OD changed 6 25 03 13 22 9678 0403 1 EA ASSY STROBE 22 9678 0463 1 EA ASSY STROBE VL3000 QUIET 14 22 9678 0435 1 EA ASSY DIMMER WHEEL 15 22 9678 0472 1 EA ASSY CYAN WHEEL 16 22 9678 0474 1 EA ASSY YELLOW WHEEL 17 22 9678 0476 1 EA ASSY MAGENTA WHEEL...

Page 133: ...OOTH SI KEVLAR 33 54 2060 0001 1 EA BELT TIMING MXL PITCH 165 TOOTH SI KEVLAR 34 55 2132 0011 4 EA STANDOFF 1 4 HEX 6 32 X 1 093 L SS 35 55 2132 0012 4 EA STANDOFF 1 4 HEX 6 32 X 0 75 LG SS 36 55 3303 0004 2 EA WASHER 4 LOCK INT TOOTH SS 37 55 3303 0006 6 EA WASHER 6 LOCK INT TOOTH SS 38 55 6503 0004 1 EA WASHER 8 FLAT ZINC 39 55 6528 0001 2 EA WASHER 6 FLAT ZINC 40 55 2110 0002 2 EA SPACER 0 010 ...

Page 134: ...mbly continued Figure 3 26 Color Dimmer Strobe Assembly 1 2 3 x2 4 5 6 7 8 9 x5 10 11 12 13 14 15 16 17 18 19 20 21 22 23 x5 24 25 5 6 6 25 x2 25 x5 25 x4 26 x10 26 x2 27 x12 28 x5 29 x2 30 x5 31 32 x4 33 34 x4 35 x4 36 x2 37 x1 38 39 x2 28 x2 37 x5 7 42 CTO Magenta Cyan Yellow Dimmer ...

Page 135: ...331 Rev 0 Refer to Figure 3 27 Figure 3 27 Motor Adapter Plate Assembly No Item Qty UM Description 1 10 9678 0330 1 EA PLATE MOTOR ADAPTER 2 44 5031 0001 1 EA MOTOR STEPPER 42MM X 40MM 10 3 53 6513 0002 4 EA SCREW 3MM X 5MM LG PFZ METR 1 2 3 x4 Note orientation of adapter plate in relation to the motor ...

Page 136: ...5 01 1 EA COLOR FILTER DEEP RED VL3000 6 41 9678 0305 02 1 EA COLOR FILTER KELLY GREEN VL3000 7 41 9678 0305 03 1 EA COLOR FILTER CONGO BLUE VL3000 8 41 9678 0305 04 1 EA COLOR FILTER MAGENTA VL3000 9 41 9678 0305 05 1 EA COLOR FILTER ORANGE VL3000 10 41 9678 0305 06 1 EA COLOR FILTER DARK FUSHIA VL3000 11 53 6534 0001 6 EA RIVET 3 32 OD POP 3 32 GRIP RANGE 12 53 6608 1857 3 EA SCREW 6 32 X 3 16 L...

Page 137: ... 9678 0010 G 119 3 Fixed Color Wheel Assembly continued Figure 3 28 Fixed Color Wheel Assembly 1 2 x6 3 x6 4 11 x6 12 x3 13 14 x6 OPEN POS 1 CONGO BLUE POS 2 ORANGE POS 3 KELLY POS 4 DARK POS 5 MAGENTA POS 6 DEEP GREEN FUSHIA RED 5 6 7 8 9 10 15 ...

Page 138: ...SSY RIGHT STROBE BLADE 5 44 5029 0001 2 EA MOTOR STEPPER 42MM X 34MM AR 6 53 6513 0032 8 EA SCREW M3X10MM SEMS PPZ EXT TO 7 53 6609 0500 4 EA SCREW 6 32 X 1 2 LG PFZ 8 55 6659 0001 8 EA SPACER 1 4 RND 4 THRU 3 16 AL changed 03 01 04 9 55 3306 0006 8 EA WASHER 0 375 OD 0 149 ID 0 025 THK SS changed 08 12 03 10 55 6706 0001 8 EA GROMMET 9 32 ID 9 16 OD 1 4T SILICON RED changed 03 01 04 Set blade ass...

Page 139: ...678 0499 2 EA ASSEMBLY STROBE MOTOR VL3000Q 6 53 6520 0001 8 EA SCREW 4 40 X 3 8 PPZ 7 53 6609 0500 4 EA SCREW 6 32 X 1 2 LG PFZ 8 55 3306 0006 8 EA WASHER 375 OD 149 ID 025 THK SS 9 55 6537 0001 8 EA WASHER 4 INTERNAL LOCK TOOTH 10 55 6659 0001 8 EA SPACER 1 4 RND 4 THRU 3 16 AL 11 55 6706 0001 8 EA GROMMET 9 32 ID 9 16 OD 1 4 TH SILICONE 389 410 455 355 1 x2 2 4 3 5 x2 6 x8 7 x4 10 x8 9 x8 11 x8...

Page 140: ...obe Blade Assembly No Item Qty UM Description 1 10 9678 0464 1 EA STROBE BLADE changed 07 29 04 2 10 9678 0432 1 EA HUB STROBE BLADE 3 10 9678 0466 1 EA STROBE BLADE DAMPER 4 53 5559 0250 2 EA SCREW 6 32 X 1 4 SET CONE POINT 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 2 3 4 x2 5 x3 6 x3 Reflective Side ...

Page 141: ...Strobe Blade Assembly No Item Qty UM Description 1 10 9678 0464 1 EA STROBE BLADE changed 07 29 04 2 10 9678 0432 1 EA HUB STROBE BLADE 3 10 9678 0466 1 EA STROBE BLADE DAMPER 4 53 5559 0250 2 EA SCREW 6 32 X 1 4 SET CONE POINT 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 4 x2 2 3 1 5 x3 6 x3 Black Side ...

Page 142: ...L3000Q Strobe Motor Assembly No Item Qty UM Description 1 44 5035 0001 1 EA STEPPER MOTOR 2 PHASE PK 2 52 6524 0004 1 EA CONNECTOR HOUSING 4 POS RECEPT 3 52 8346 0001 4 EA CONTACT 24 30 AWG FEMALE CRIMP 4 55 2200 0003 0 25 FT HEAT SHRINK 3 16 VITON 1 2 4 4 Green 3 Black 2 Red 1 Blue 3 of heatshrink from this surface 3 50 3 x4 Heatshrink Wiring Pin Out ...

Page 143: ...to fully cure For best results run through a UV curing oven twice Step 5 Apply two fillet beads of Copper RTV on long sides of magnet as shown Step 6 Allow to cure in for at least 24 hours at room temperature For best results run through a UV curing oven twice Copper RTV Bead 2 beads Dimmer Wheel Magnet NUVASIL RTV Dimmer Wheel one on each side of magnet see install detail Dimmer Wheel Magnet Inst...

Page 144: ...ev A Refer to Figure 3 35 Figure 3 35 Gobo Clamp Assembly No Item Qty UM Description 1 12 9678 0691 1 EA GOBO CLAMP 2 53 6685 0625 2 EA SCREW CAPTIVE PANEL 6 32 X 0 625 LG PPS ZINC PLATED 3 55 6538 0001 2 EA WASHER 6 LOCK INTERNAL TOOTH 4 53 6613 1126 1 EA SCREW 6 32 X 1 125 LG PPZ 1 2 x2 3 x2 4 ...

Page 145: ... A Refer to Figure 3 36 Figure 3 36 Color Clamp Assembly No Item Qty UM Description 1 12 9678 0692 1 EA COLOR CLAMP 2 53 6685 0625 2 EA SCREW CAPTIVE PANEL 6 32 X 625 LG PPS ZINC PLATED 3 55 6538 0001 2 EA WASHER 6 LOCK INTERNAL TOOTH 4 53 6613 1126 1 EA SCREW 6 32 X 1 125 LG PPZ 1 2 x2 3 x2 4 ...

Page 146: ...L 128 02 9678 0010 G Edge Lead Screw Assembly 22 9678 1126 Rev B Refer to Figure 3 37 Figure 3 37 Edge Lead Screw Assembly No Item Qty UM Description 1 10 9678 1119 1 EA LEAD SCREW EDGE 2 55 6616 0007 1 EA STANDOFF 3 8 HEX THRD 0 562 LG 1 2 ...

Page 147: ...tion 1 10 9678 0945 1 EA TUBE WASH LIGHT BAFFLE 2 21 9678 0920 1 EA ASSY CONCAVE LENS STATIONARY 3 21 9678 0930 1 EA ASSY CONVEX LENS TRANSLATING 4 21 9678 0940 1 EA ASSY CONDENSER LENS 5 24 9678 3916 1 EA PCB ASSY ZOOM INTERCONNECT WASH 6 53 6520 0375 4 EA SCREW 4 40 X 3 8 PPZ SEMS 7 53 6682 0022 2 EA SCREW 8 32 X 3 8 PPZ 8 53 6558 0009 4 EA SCREW 6 32 X 3 8 PPZ 1 2 3 4 5 6 x4 7 x2 8 x4 ...

Page 148: ...ns Assembly No Item Qty UM Description 1 10 9678 0927 2 EA BEARING SHAFT BEAM SPREADER 2 10 9678 0928 2 EA LENS CLAMP BEAM SPREADER 3 12 9678 0168 1 EA MASKED CONCAVE LENS ARRAY MEDIUM 4 12 9678 0925 1 EA CONCAVE LENS MOUNT MACHINED 5 42 9678 1169 1 EA DIFFUSION LENS FRONT WASH 6 53 6530 0002 4 EA RIVET 1 8 OD POP 063 125 GR LENGTH 1 x2 2 5 3 4 6 x2 Etched side of lens 2 6 x2 ...

Page 149: ...BEAM SPREADER 2 10 9678 0938 2 EA LENS CLAMP CONVEX 3 12 9678 0166 1 EA MASKED CONVEX LENS ARRAY MEDIUM 4 12 9678 0939 1 EA CONVEX LENS MOUNT MACHINED ADJUSTABLE 5 53 6515 0375 4 EA SCREW 10 32 X 3 8 LG SCB 6 53 6545 0003 2 EA SCREW 8 32 X 3 8 PFZ 7 54 2056 0001 4 EA RING RETAINING EXTERNAL 19MM SHAFT 8 55 2114 0001 4 EA WASHER LOCK 10 INTERNAL TOOTH 9 55 6776 0010 2 EA LINEAR BUSHING 10MM STEEL W...

Page 150: ...M SPREADER 3 10 9678 0942 1 EA LEAD SCREW BEAM SPREADER 4 10 9678 0944 1 EA CONDENSER LENS MOUNT 5 23 9678 1120 1 EA LINEAR ACTUATOR ASSEMBLY 6 42 9678 0174 1 EA 127MM CONDENSER LENS 7 53 6552 0001 4 EA SCREW 8 32 X 1 2 PFZ 8 53 6596 0002 4 EA SCREW 4 40 X 5 16 PPZ SEMS changed 3 03 04 9 53 6613 0008 4 EA SCREW 6 32 X 1 2 PPZ SEMS changed 3 03 04 10 55 6616 0007 1 EA STANDOFF 3 8 HEX 8 32 0 562 LG...

Page 151: ...78 0225 2 EA SHAFT GOBO WHEEL 2 10 9678 0952 1 EA WASH BULKHEAD 3 10 9678 0953 1 EA WASH APERTURE PLATE 4 53 6609 0001 4 EA SCREW 6 32 X 3 8 PFZ changed 11 11 03 5 53 6613 0001 4 EA SCREW 6 32 X 1 2 PPZ 6 55 2150 0002 2 EA STANDOFF 1 4 HEX 6 32 1 187 L 7 55 6769 0004 3 EA TWIST LOK 0 55 ID NOM WHITE 85 DEG C MAX FLAME RET NYL 8 53 5638 0252 2 EA SCREW 6 32 X 1 4 PFZ UNDERCUT HD 1 x2 2 3 8 x2 5 x4 ...

Page 152: ... Baffle Assembly 21 9678 0991 Rev A Wash Only Refer to Figure 3 43 Figure 3 43 Beam Spreader Light Baffle Assembly No Item Qty UM Description 1 10 9678 0658 8 EA PLATE COUNTERWEIGHT 2 10 9678 0990 1 EA LIGHT BAFFLE BEAM SPREADER 3 53 6616 0001 4 EA SCREW 6 32 X 3 4 PPZ 1 x8 2 3 x4 ...

Page 153: ...AND RELAY NOT SHOWN 25 9678 0781 1 EA CABLE ASSY YOKE FAN AND RELAY VL3000 QUIET NOT SHOWN 25 9678 0758 1 EA CABLE ASSY YOKE FAN NOT SHOWN 25 9678 0759 1 EA CABLE ASSY YOKE FAN VL3000 QUIET NOT SHOWN 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...

Page 154: ... VL3000 VL3000 Q SERVICE MANUAL 136 02 9678 0010 G Yoke Assembly continued Figure 3 44 Yoke Assembly 2 1 3 4 5 6 8 9 10 11 x8 12 x2 13 x3 14 x4 15 x2 16 19 7 13 x2 13 x4 14 x2 4 13 13 x2 17 19 20 x2 21 x2 18 x2 ...

Page 155: ...CODEWHEEL 120 COUNT LARGE ID 2b 10 9678 1749 1 EA TIMING PULLEY 17 TOOTH SHORTENED 2c 53 5560 0250 2 EA SCREW 8 32 X 1 4 SET CONE POINT 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 66...

Page 156: ...eplacement motor Item 4 also order the pulley Item 2 Contact Vari Lite Customer Service for installation information 2 1 3 Step 6 Apply one drop of Loctite 603 to motor shaft Step 7 Install drive pulley on motor shaft using twisting motion to insure coverage of shaft with loctite Step 8 Do not allow Loctite to drip into motor bearing Step 9 Set pulley height as shown above Step 10 Apply Loctite 24...

Page 157: ... 46 Yoke Fan Assembly No Item Qty UM Description 1 10 9661 0646 1 EA FAN TRAY 2 40 7113 0001 1 EA FAN 24V 80 X 80 X 25MM 32CFM 3 53 2200 0006 1 EA NUT 6 32 KEPS SS 4 55 2179 0003 1 EA CABLE SADDLE 75 X 75 4WAY VL3000 QUIET NOT SHOWN 5 55 2186 0001 1 EA CABLE TIE 10 WD X 4 LG VL3000 QUIET NOT SHOWN 1 2 3 Direction of air flow Wire Connection Orientation ...

Page 158: ...VARI LITE VL3000 VL3000 Q SERVICE MANUAL 140 02 9678 0010 G Notes ...

Page 159: ...Mount Assembly 22 9678 0481 Rev B Refer to Figure 3 47 Figure 3 47 Color Sensor 1 PCB Mount Assembly No Item Qty UM Description 1 10 9678 0482 1 EA PCB MOUNT COLOR SENSOR 1 2 24 9678 3480 1 EA PCB ASSY VL3000 COLOR SENSOR 1 3 53 6558 0001 2 EA SCREW 6 32 X 3 8 PPZ 4 55 3303 0006 2 EA WASHER 6 LOCK INT TOOTH SS 1 2 3 x2 4 x2 ...

Page 160: ... PCB 2 Mount Assembly 22 9678 0489 Rev B Refer to Figure 3 48 Figure 3 48 Color Sense PCB 2 Mount Assembly No Item Qty UM Description 1 10 9678 0452 1 EA PCB MOUNT COLOR SENSE 2 2 24 9678 3454 1 EA PCB ASSY COLOR SENSOR 2 3 53 6558 0007 2 EA SCREW 6 32 X 1 4 SEMS 1 2 3 x2 ...

Page 161: ...678 0010 G 143 3 VL3000 Controller PCB 24 9678 3730 Rev 0 Note This item is only available as an assembly Refer to Figure 3 48 Figure 3 49 VL3000 Controller PCB No Item Qty UM Description 85 3773 002 AR EA IC DRIVER FOR USE WITH CARDS WITH SOCKETS ONLY ...

Page 162: ...2 6260 0015 1 EA HEADER 2POS MTA 100 SHROUDED J2 52 6447 0009 1 EA HEADER SHROUDED 4 POSITION 52 6467 0009 1 EA CONN FEM PLUG 3POS 30 24AWG 52 6467 0010 3 EA CONTACT SOCKET 30 24AWG CRIMP J1 52 6598 0029 1 EA HDR 14P 2ROW AMP MODU R A 52 6662 0007 1 EA HOUSING 6POS 125V 2A 2 00 52 8388 0003 4 EA CONTACT 24 30AWG FEMALE CRI 55 2186 0001 1 EA CABLE TIE 0 10 WD 4 00 LG SMALL R1 60 1440 2703 1 EA RES ...

Page 163: ...HEAD YOKE PCB ASSEMBLIES ZOOM INTERCONNECT PCB ASSEMBLY 02 9678 0010 G 145 3 Zoom Interconnect PCB Assembly continued Figure 3 50 Zoom Interconnect PCB Assembly ...

Page 164: ...VARI LITE VL3000 VL3000 Q SERVICE MANUAL 146 02 9678 0010 G Notes ...

Page 165: ... 2 EA HANDLE CAST ENCLOSURE 10 10 9678 0869 1 EA BRACKET LVS 11 10 9678 0886 1 EA SPACER PAN BEARING 0 235 THK 12 10 9678 0892 1 EA BUSHING WIRE PROTECTION PAN 13 10 9678 1876 1 EA AIR DIST PLENUM 1200W S W BALLAST P S 14 12 9686 1236 2 EA MACHINED COVER FRONT 15 12 9686 1238 2 EA MACHINED COVER SIDE 16 12 9678 0842 1 EA AIR DUCT UPPER ENCLOSURE MOD 17 12 9678 1862 1 EA SHIELDED BALLAST CCI 18 21 ...

Page 166: ... EA TERMINAL STRIP 300V 12AWG 20A 28 53 2001 0003 1 EA NUT 10 32 NYLON INSERT 29 53 2019 0004 4 EA NUT 3 8 16 X 7 32 THK HEX 30 53 2200 0006 4 EA NUT 6 32 KEPS SS 31 53 6505 0022 3 EA BOLT 3 8 16 X 3 4 LG CARR 32 53 6513 0044 3 EA SCREW M5 X 10MM STL CUP PT 33 53 6515 0001 4 EA SCREW 10 32 X 3 4 SCB CAP 34 53 6522 0001 1 EA SCREW 6 32 X 1 4 PPZ 35 53 6522 0004 2 EA SCREW 6 32 X 1 4 SOC HD 36 53 65...

Page 167: ...IP SERRATED 062 63 55 6543 0002 1 54 FT GROMMET STRIP SERRATED 125 64 55 6549 0001 4 EA WASHER 1 4 SPLIT LOCK NOT USED ON VL3000Q 65 55 6568 0074 2 EA SPRING CPRSN 420 OD 750 LG 0 055 DIA WIRE 66 55 6575 0001 4 EA SCREW 10 32 X 3 4 PPB 67 55 6577 0005 2 EA STANDOFF 1 2 HEX 6 32 X 1 625 L 68 55 6580 0002 2 EA CABLE TIE 0 18 WD 8 0 LG 69 55 2132 0012 1 EA STANDOFF 1 4 HEX 6 32 X 3 4 LG 70 55 6677 00...

Page 168: ...000 VL3000 Q SERVICE MANUAL 150 02 9678 0010 G Upper Enclosure Assembly continued Figure 3 51 Upper Enclosure Assembly Part 1 2 3 5 8 x2 9 9 18 14 15 15 20 44 x4 42 x4 43 x4 43 x2 66 x2 50 x4 14 59 64 x4 66 x2 43 x2 ...

Page 169: ... 3 Upper Enclosure Assembly continued Figure 3 52 Upper Enclosure Assembly Part 2 Electronics Assembly 17 34 42 x3 76 42 42 62 x3 30 x2 13 55 69 73 4 Run Lamp Wires Through Ferrite 63 x4 10 55 39 x4 40 x4 63 x2 37 x2 25 43 56 57 68 45 58 70 75 1 27 41 67 x2 74 36 ...

Page 170: ...bly Choke and Duct Assembly 6 12 23 16 38 49 21 30 x2 19 19a 19b 19c 19d 22 7 24 26 28 29 x2 29 x2 31 x2 31 53 33 x4 32 x2 42 51 51 38 x2 54 x2 Part is shown exploded for clarity 72 63 38 43 56 62 43 57 x2 55 x2 47 x2 56 62 35 x2 61 x2 46 x2 47 x2 48 60 x4 65 x2 42 11 Detail A Detail A 52 77 78 Note Shims used as required to remove any slack in pan tube assembly ...

Page 171: ...ion Cover Assembly No Item Qty UM Description 1 10 9661 1249 4 EA POST TRUSS HOOK 2 10 9678 8350 1 EA COVER VENTILATION 3 10 9678 0893 1 EA 12 AIR SEAL UPPER ENCLOSURE changed 05 11 05 4 10 9678 0894 1 EA 6 AIR SEAL UPPER ENCLOSURE changed 05 11 05 5 10 9678 0896 1 EA 4 5 AIR SEAL UPPER ENCLOSURE changed 05 11 05 6 54 1206 0015 4 EA RING RETAINING PRESS ON 1 SH 1 x4 2 3 6 x4 4 5 ...

Page 172: ...Y PRODUCTION 1b 10 9678 0833 4 EA SPACER 1 25 EARLY PRODUCTION 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 RETA...

Page 173: ...N COVER ASSEMBLY VL3000 QUIET 02 9678 0010 G 155 3 Ventilation Cover Assembly VL3000 Quiet continued Figure 3 55 Ventilation Cover Assembly VL3000Q Early Production Current Production 1a x4 1b x4 1 x4 2 8 x4 9 x4 10 x4 6 3 4 5 7 x2 ...

Page 174: ... DISPLAY BOARD 4 10 9686 0820 1 EA FILLER PANEL DMX CONNECTOR 5 24 9663 3895 1 EA PCB ASSY DMX INPUT 6 25 9678 0810 1 EA CABLE ASSY AC INPUT PIGTAIL 7 24 9678 3825 1 EA PCB ASSY VL3000 DISPLAY 8 51 0541 4 EA SCREW 4 X 3 8 H L BLK ZINC PLT 9 53 6558 0009 2 EA SCREW 6 32 X 3 8 LG PPZ SEMS EXT ZINC PLT 10 55 2284 0001 1 EA CARD GUIDE SNAP IN 3 LONG NYLON NATURAL 11 74 2000 0002 1 EA SWITCH ROCKER 2 P...

Page 175: ...Input PCB No Item Qty UM Description Ref 1 17 9663 3895 1 EA 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 2 3 4 5 ...

Page 176: ... 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 UL 600V 150DEG C 6 55 2268 0500 0 13 FT HEATSHRINK 1 2 CLEAR KYNAR UL 600V 150DEG C 7 73 9636 0153 4 00 FT CORDAGE 1 5 3 750V 60C EU...

Page 177: ...ley Assembly 21 9678 0807 Rev E Refer to Figure 3 59 Figure 3 59 Pan Pulley Assembly No Item Qty UM Description 1 10 9678 0750 1 EA TIMING PULLEY 2MM GT 150 TOOTH 2 10 9678 0855 1 EA PAN FLAG 3 53 6530 0009 2 EA RIVET 1 8 OD POP 0 126 0 187GL changed 10 05 06 1 2 3 x2 ...

Page 178: ... CODEWHEEL 120 COUNT LARGE ID 10 9678 0749 1 EA TIMING PULLEY 2MM GT 17 TOOTH 53 5560 0250 2 EA SCREW 8 32 X 1 4 SET FLAT POINT 3 24 9678 9729 1 EA PCB ASSY VL3000 PAN ENCODER changed 06 27 07 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 2 EA SCREW 4 40 X 1 4 LG PPZ SEMS EXT 8 55 2132 0014 2 EA ST...

Page 179: ... Item 2 Contact Vari Lite Customer Service for installation information 2 Step 1 Apply one drop of Loctite 603 to motor shaft Step 2 Install drive pulley on motor shaft using twisting motion to insure coverage of shaft with loctite Step 3 Do not allow Loctite to drip into motor bearing Step 4 Set pulley height as shown above Step 5 Apply Loctite 242 to pulley set screws Insure set screws are align...

Page 180: ...Assembly 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 1 2 3 4 5 6 3 ...

Page 181: ...EOT Sensor Electrical Assembly 23 9678 0687 Rev A Refer to Figure 3 62 Figure 3 62 Pan EOT Sensor Electrical Assembly 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 3 2 x4 ...

Page 182: ...bly 25 9661 1514 Rev A Refer to Figure 3 63 Figure 3 63 LVS Chassis Ground Cable Assembly No Item Qty UM Description 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 73 3516 0504 3 5 IN WIRE 16 AWG 300V 105C PVC GRN YEL UL1569 1 2 3 ...

Page 183: ... Chassis To Yoke Ground Cable Assembly 25 9661 1520 Rev C Refer to Figure 3 64 Figure 3 64 Chassis To Yoke Ground Cable Assembly No Item Qty UM Description 1 52 8250 0006 2 EA TERM 8 RING 10AWG 2 73 7089 0504 15 17 FT WIRE 22 AWG 300V 200C TEF GRN YEL UL1180 1 x2 2 7 x 26 0 LG ...

Page 184: ...ack Cap Ground Cable Assembly 25 9661 1522 Rev B Refer to Figure 3 65 Figure 3 65 Head to Back Cap Ground Cable Assembly No Item Qty UM Description 1 52 8311 0003 2 EA TERM RING 6 14 16 AWG NON INS TAPE 2 73 7130 0001 1 33 FT WIRE 7 64 TUBULAR BRAID TINNED COPPER 1 x2 2 ...

Page 185: ...1526 Rev C Refer to Figure 3 66 Figure 3 66 Ignitor to Relay Cable Assembly No Item Qty UM Description 1 52 8231 0005 1 EA TERM RING 6 BLUE 16 14 AWG REEL PIDG changed 03 23 06 2 52 8312 0001 1 EA RECP FASTON 1 4 18 14 AWG INSULATED VO 3 73 7101 0009 0 42 FT WIRE 14 AWG 15KV 150C SILICONE 41 30 STRANDING 2 3 1 ...

Page 186: ...AWG MALE MATE N LOK 2 2 52 6665 0002 1 EA CONN HOUSING 2 POS PLUG MATE N LOK 2 3 52 8413 0001 2 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 58 FT SLEEVING FIBERGLASS 0 208 ID 6 55 2200 0003 0 25 FT HEATSHRINK 3 16 VITON 7 73 6222 0009 3 00 FT WIRE 22AWG 600V 200C TFE WHT UL1199 19STRAND 8 73 6222 0010 3 00 FT WIRE 22AWG 600V 2...

Page 187: ...terlok to Gobo Fan Interlok Cable Assembly 25 9678 0014 Rev B Refer to Figure 3 68 Figure 3 68 Backcap Interlok to Gobo Fan Interlok Cable Assembly No Item Qty UM Description 1 52 8414 0001 2 EA RECEPT FASTON 187 SERIES 24 20 AWG UNINSUL 2 73 7089 0000 2 00 FT WIRE 22AWG 300V 200C TEF BLK UL1180 1 2 1 ...

Page 188: ...8237 0002 1 EA TERM RING 4 24 20AWG 2 52 8414 0001 1 EA RECEPT FASTON 187 SERIES 24 20AWG UNISUL 3 55 2198 0002 083 FT HEATSHRINK 1 8 BLACK 4 55 2260 0133 375 FT SLEEVING FIBERGLASS 133 ID 5 63 2047 5130 1 EA THERMOSTAT 130º TO 220 OPEN ON RISE VL3000 Only 63 2047 5120 1 EA THERMOSTAT 120º TO 220 OPEN ON RISE VL3000Q Only 6 73 7089 0000 1 48 FT WIRE 22AWG BLK 300V 200C TEFLON STRANDED Side View To...

Page 189: ...ssembly 25 9678 0675 Rev B Refer to Figure 3 70 Figure 3 70 Relay to Gobo Fan Interlock Cable Assembly No Item Qty UM Description 1 52 8230 0003 1 EA RECEPT 1 4 FASTON 22 18AWG TAPE MOUNT 2 52 8414 0001 1 EA RECEPT FASTON 0 187 SERIES 24 20 AWG UNINSUL 3 73 7089 0000 2 00 FT WIRE 22AWG 300V 200C TEF BLK UL1180 1 3 2 ...

Page 190: ...e 3 71 Figure 3 71 Front Head Fans Cable Assembly No Item Qty UM Description 1 52 6396 3104 1 EA RECEPT 4POS MTA100 W POL TAB BLU CLSD END changed 05 03 06 2 52 6524 0002 2 EA CONN HOUSING 2POS RECEPTACLE 3 52 8346 0001 4 EA CONTACT 24 30AWG FEMALE CRIMP 4 73 5126 0002 2 67 FT WIRE 26AWG 2COND 300V 80C BLK RED 4 1 2 x2 3 x4 ...

Page 191: ...2 Yoke Fan and Relay Cable Assembly No Item Qty UM Description 1 52 6396 3103 1 EA RECEPT 3 POS MTA100 W POL TAB BLU CLSD END changed 05 01 06 2 52 6423 0003 1 EA HOUSING 3 POS MT RECEPT 2MM 3 52 8230 0003 1 EA RECEPT 1 4 FASTON 22 18AWG 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 RED BLK 1 3 5 4 2 ...

Page 192: ... 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 55 2186 0001 1 EA CABLE TIE 10 X 4 SMALL 5 55 2268 0125 1 IN HEATSHRINK 1 8 CLEAR KYNAR UL 600V 150O C 6 60 7440 2002 1 EA RESISITOR 5W 5 200 OHM WIREWOUND 7 73 3526 0002 1 25 FT WIRE 26AWG 300V 105C PVC RED 8 73 5126 0002 1 50 FT WIRE 26AWG 2 COND 300V ...

Page 193: ...9678 0682 Rev C Refer to Figure 3 74 Figure 3 74 OT Switch to Interlok Cable Assembly No Item Qty UM Description 1 52 8371 0001 1 EA RECEPT FASTON 24 20AWG UNISUL TIN PLT BRS 250 X 032 TAB 2 52 8414 0001 1 EA RECEPT FASTON 0 187 SERIES 24 20 AWG UNISUL 3 73 7089 0000 0 79 FT WIRE 22AWG 300V 200C TEF BLK UL1180 1 3 2 ...

Page 194: ... 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 5 73 7190 0001 3 66 FT WIRE 250 DEG C 6 55 2200 0003 33 FT HEAT SHRINK TUBING 2 X 2 7 52 8274 1614 2 EA CONN BUTT SPLICE 16 14 PIDG 7 6 2 x3 1 From Ignitor Output To Arc Lamp Socket 7 6 3 1 x 44 each 3 1 x 48 each 5 1 x 20 each 5 1 x 24...

Page 195: ... 22 AWG DBL ROW UNLOADED changed 05 01 06 9 52 6610 0040 2 EA CONN HOUSING 40 POS 26 22 AWG DBL ROW UNLOADED changed 05 01 06 10 52 8351 0004 180 EA CONTACT 26 22 AWG RECP MTE REEL added 05 01 06 11 55 2186 0001 11 EA CABLE TIE 0 10 WD 4 00 LG SMALL 12 55 6699 0004 1 75 FT SLEEVING 3 4 NOM DIA POLY EXP BRAIDED 13 73 3026 0009 1 83 FT WIRE 26 AWG 300V 80C WHT 14 73 5116 0123 35 17 FT WIRE 24 AWG 4C...

Page 196: ...VARI LITE VL3000 VL3000 Q SERVICE MANUAL 178 02 9678 0010 G Head Controller Cable Assembly continued Figure 3 76 Head Controller Cable Assembly 11 x11 7 1 4 9 2 5 12 9 2 5 7 1 4 8 3 6 8 3 6 12 ...

Page 197: ...678 0409 1 EA PCB COLOR INTERCONNECT 52 6467 0003 1 EA CONN FEM PLUG 3POS 30 24 AWG 52 6467 0005 1 EA CONN FEM PLUG 5POS 30 24AWG 52 6467 0007 1 EA CONN FEM PLUG 7POS 30 24AWG 52 6467 0024 1 EA CONTACT SOCKET 30 24AWG CRIMP 52 6661 0006 1 EA CONN RECEPT 6CIR WIRE TO 52 6467 0011 5 EA CONN FEM PLUG 11 POS 30 24AWG 52 8387 0001 3 EA CONTACT 26 28AWG FEMALE CRIM 55 2186 0002 20 EA CABLE TIE 09 WD 3 7...

Page 198: ...VARI LITE VL3000 VL3000 Q SERVICE MANUAL 180 02 9678 0010 G Color Interconnect PCB Cable Assembly continued Figure 3 78 Color Interconnect PCB Assembly Wire Chart VL3000 Only ...

Page 199: ... 6467 0003 1 EA CONN FEM PLUG 3POS 30 24 AWG 52 6467 0005 1 EA CONN FEM PLUG 5POS 30 24AWG 52 6467 0007 1 EA CONN FEM PLUG 7POS 30 24AWG 52 6467 0024 19 EA CONTACT SOCKET 30 24AWG CRIMP 52 6661 0006 5 EA CONN RECEPT 6CIR WIRE TO 52 6467 0011 1 EA CONN FEM PLUG 11 POS 30 24AWG 52 6523 0004 2 EA CONN HOUSING 4 POS PLUG 52 8347 0001 8 EA CONTACT 24 30AWG MALE CRIMP 52 8387 0001 20 EA CONTACT 26 28AWG...

Page 200: ...VARI LITE VL3000 VL3000 Q SERVICE MANUAL 182 02 9678 0010 G Color Interconnect PCB Cable Assembly continued Figure 3 80 Color Interconnect PCB Assembly Wire Chart VL3000Q Only ...

Page 201: ...NTERCONNECT PCB CABLE ASSEMBLY 02 9678 0010 G 183 3 Gobo Interconnect PCB Cable Assembly 25 9678 2209 Rev 0 Refer to Figure 3 81 Note This cable must be ordered as an assembly Figure 3 81 Gobo Interconnect PCB Cable Assembly ...

Page 202: ...VARI LITE VL3000 VL3000 Q SERVICE MANUAL 184 02 9678 0010 G Gobo Interconnect PCB Cable Assembly continued Figure 3 82 Gobo Interconnect PCB Cable Assembly ...

Page 203: ...A Refer to Figure 3 83 Figure 3 83 Yoke Fan Cable Assembly No Item Qty UM Description 1 52 6396 3102 1 EA RECEPT 2 POS MTA100 W POL TAB BLUE CLSD END changed 05 02 06 2 52 6423 0003 1 EA HOUSING 3POS MT RECEPT 2MM CT 28 26 AWG 3 73 5126 0002 0 50 FT WIRE 26AWG 2COND 300V 80C BLK RED UL1061 19STRND 1 2 3 ...

Page 204: ... UM Description 1 52 6396 3102 1 EA RECEPT 2 POS MTA100 W POL TAB BLUE CLSD END 2 52 6423 0003 1 EA HOUSING 3 POS MT RECEPT 2MM CT 28 26 AWG 3 55 2186 0001 1 EA CABLE TIE 10 X 4 SMALL 4 55 2268 0125 1 EA HEASTRINK 1 8 CLEAR KYNAR UL 600V 150O C 5 60 7440 2002 1 EA RESISTOR 5W 5 200 OHM WIREWOUND 6 73 5126 0002 5 FT WIRE 26AWG 2COND 300V 80C BLK RED UL1061 19STRND 1 2 3 4 6 5 4 6 ...

Page 205: ...wer Switch Cable Assembly 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 0 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 1 x2 2 x2 4 3 5 White Black White Black ...

Page 206: ... 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 WI...

Page 207: ...C INPUT SPLITTER CABLE ASSEMBLY 02 9678 0010 G 189 3 AC Input Splitter Cable Assembly continued Figure 3 86 AC Input Splitter Cable Assembly 3 x2 4 x2 12 5 9 5 10 13 11 6 2 1 7 x3 8 Note Heatshrink not shown for clarity ...

Page 208: ...Refer to Figure 3 87 Figure 3 87 Data I O Link Cable Assembly No Item Qty UM Description 1 52 6396 2904 1 EA RECEPT 4 POS MTA100 W POL TAB RED CLSD END changed 05 03 06 2 52 6396 2905 1 EA RECEPT 5 POS MTA100 W POL TAB RED CLSD END changed 05 03 06 3 73 5122 0259 2 17 FT CBL 22AWG STRND 4COND PVC INSUL 2 1 3 ...

Page 209: ...6 2 EA RECEPT 6 POS MTA100 W POL TAB WHT CLSD END 2 73 5116 0123 1 02 FT WIRE 24AWG 4COND TW BLK BRN RED ORN 3 55 2186 0001 4 EA CABLE TIE 10 WD 4 LG SMALL 4 73 7130 0004 0 958 FT WIRE TUBULAR BRAID 1 8 X 23 LG 5 73 6224 0005 0 208 FT WIRE 24AWG 600V 200C TFE GRN 2 5 LG 6 55 6699 0009 2 08 FT SLEEVING 3 8 NOM DIA POLY EXP 7 55 6621 0001 1 EA SLEEVE NYLON THIN WALL 6 SCR 1 0 LG 6 1 2 5 1 3 x3 3 4 7...

Page 210: ... Controller Cable Assembly No Item Qty UM Description 1 52 6396 3002 1 EA RECEPT 2 POS MTA100 W POL TAB WHT CLSD END changed 05 03 06 2 52 6396 3005 1 EA RECEPT 5 POS MTA100 W POL TAB WHT CLSD END changed 05 03 06 3 52 6396 3008 1 EA RECEPT 8 POS MTA100 W POL TAB WHT CLSD END changed 05 03 06 4 73 5124 1289 3 67 FT WIRE 24AWG 5COND BLK BRN RED GRN WHT 2 3 1 4 ...

Page 211: ...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 RE...

Page 212: ... MT 4 52 6524 0005 2 EA CONN HOUSING 5 POS RECEPTACLE 5 52 6588 0007 2 EA HOUSING 7 POS XH 250V 3A 2 5MM PITCH USE SXH CONTACTS 6 52 7007 0001 6 EA CONTACT 28 22 AWG PHOSPHOR BRONZE TIN PLT SXH 7 52 8346 0001 10 EA CONTACT 24 30 AWG FEMALE CRIMP 8 55 2186 0001 6 EA CABLE TIE 0 10 WD 4 00 LG SMALL 9 73 5119 0246 6 08 FT WIRE 24 AWG 3COND TW 600V 200C RED YEL BLU UL1213 10 73 5124 1289 6 17 FT WIRE ...

Page 213: ...ON 1 4 18 14 AWG INSULATED VO 3 55 2183 0001 0 33 FT HEATSHRINK 1 2 BLACK 4 55 2186 0001 3 EA CABLE TIE 0 10 WD 4 00 LG SMALL 5 55 6699 0003 3 19 FT SLEEVING 1 2 NOM DIA POLY EXP BRAIDED 6 73 3516 0504 0 58 FT WIRE 16 AWG 300V 105 DEG C PVC GRN YEL UL 1569 7 73 7089 0000 34 41 FT WIRE 22 AWG BLK 300V UL1180 TEFLON 19 34 STRANDED 8 73 7089 0009 34 41 FT WIRE 22 AWG WHT 300V UL1180 TEFLON 19 34 STRA...

Page 214: ... 0001 2 EA CONTACT 22 26AWG FEMALE MATE N LOK 2 2 52 6664 0002 1 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 0 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 2 17 FT WIRE 22 AWG 600V 200C TFE WHT UL1199 19STRAND 7 73 6222 0010 2 17 FT WIRE 22 AWG 600V 200C TFE BLK UL1199 1...

Page 215: ...nd application Technical Bulletin Description Model s S3K 001 Tilt Sensor Wire Routing Spot and Wash S3K 002 Improving Lamp and Reflector Cooling Spot and Wash S3K 003 Cancelled Not Applicable S3K 004 Light Baffle Retrofit Spot S3K 005 Front End Filter Installation Spot S3K 006 Lanyard Safety Cable Retrofit Spot and Wash S3K 007 LVS DC Output Cable Replacement Spot and Wash S3K 008 Zoom Box Assemb...

Page 216: ...VARI LITE VL3000 VL3000 Q SERVICE MANUAL 198 02 9678 0010 G Notes ...

Page 217: ......

Page 218: ...1 Petal Street Dallas Texas 75238 USA 1 877 VARI LITE Fax 1 214 647 8038 www vari lite com Date 08 May 2009 Manual Part Number 02 9678 0010 G 2003 2009 A Philips Group Company All rights reserved Printed in the U S A ...

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