Philips VL3015LT Service Manual

All other brand or product names which may be mentioned in this manual are trademarks or registered trademarks of their respective companies or
organizations.

Philips Vari-Lite
A Philips Group Company
10911 Petal Street
Dallas, Texas 75238 USA

This manual is for informational use only and is subject to change without notice. Philips Vari-Lite assumes no responsibility or liability for any claims
resulting from errors or inaccuracies that may appear in this manual.

Version as of: 04 June 2013

Part number: 02.9698.0010 0

VL3015LT Spot Luminaires Service Manual

©2013, Vari-Lite, a Philips group company. All Rights Reserved.

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),
[phone], or [e-mail] 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:

Philips Vari-Lite
10911 Petal Street
Dallas, Texas 75238 USA
Attention: Warranty Service (RMA# _______)

FOREWORD

As stated in the warranty, it is required that the shipment be insured and FOB our service center*.

Note: *When returning products to Philips Vari-Lite for repairs (warranty or out-of-warranty) from a
country other than the USA, “Philips Lighting Controls Division”, must appear in the address block as
the Importer of Record (IOR) on all shipping documentation, Commercial Invoices, etc. This must be
done in order to clear customs in a timely manner and prevent returns.

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VARI❋LITE - VL3015LT SPOT 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, Philips Lighting B.V. 10911 Petal Street, Dallas, Texas 75238 USA, declare under our
responsibility for the products:

Product Range Professional Stag e Luminaire

Product Code VL3015LT Spot

The designated products are in conformity with the essential requirements of the following European
Directives and harmonized standards:

Low Voltage Directive (LVD), 2006/95/EC

EN 60589-2-17:1984+A1:1987+A2:1990 used in conjunction with 60598-1:2008/A11:2009

Electromagnetic Compatibility Directive (EMC), 2004/108/EC

EN 55022:2010, EN55024:2010

ii 02.9698.0010 0

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 RADIAT ION, AND INJURY TO PERSONS CAN BE
FOUND BELOW.

WARNING:
INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST FIRE

1. VARI❋LITE lumi naires have been designed for use with specific lamp types. VL3015LT Spot
Luminaires is supplied with an Osram HTI 1500 D7/60 metal halide lamp or other lamps as
approved by Vari-Lite. Installing another type of lamp not approved by Vari-Lite 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.

FOREWORD

CAUTION advising of potential damage to product.

WARNING advising of potential injury or death to persons.

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.

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VARI❋LITE - VL3015LT SPOT LUMINAIRE SERVICE MANUAL

WARNING:
INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST EXCESSIVE EXPOSURE
TO UV RADIATION

1. Many VARI❋LITE lum i naires 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.

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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 bestimmte n Lampentyps.
Achten Sie auf den Lampentyp (Osram HTI 1500 D7/60 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 ­Scheinwerfer von brennbarem Material oder beleuchteten Objekten.

FOREWORD

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.

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VARI❋LITE - VL3015LT SPOT 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, Linse n 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 denaturi ertem 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 02.9698.0010 0

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.

FOREWORD

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 HTI 1500 D7/60 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 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.

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VARI❋LITE - VL3015LT SPOT 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.

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Aviso sobre Seguridad

Es muy importante leer TODA la in formación e instrucciones sobre seguridad que se indica en es te
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.
T ome nota del tipo d e lámpara (Osram HTI 1500 D7/60 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 de materiales combustibles u objetos iluminados
para las luminarias VARI❋LITE .

FOREWORD

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 VA RI❋LITE .

3. El servicio debe ser realizado solamente por personal calificado .

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VARI❋LITE - VL3015LT SPOT 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.

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FOREWORD

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VARI❋LITE - VL3015LT SPOT LUMINAIRE SERVICE MANUAL

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Table of Contents

Introduction

About This Manual ...................................................... ............................................................. 1

Additional Documentation........................................................................................................ 1

Customer Service...................................................................................................................... 2

Technical Bulletins and Notices................................................................................................ 2

Chapter 1. Description

Features

Product Features........................................................................................................................ 4

Technical Specifications ........................................................................................................... 4

Components

External Luminaire Components.............................................................................................. 5

Head and Yoke Components..................................................................................................... 6

Enclosure Components ............................................................................................................. 7

Principles of Operation

Functional Block Diagram........................................................................................................ 8

TABLE OF CONTENTS

Chapter 2. Maintenance

Testing

Luminaire Self-Tests............................................................................................................... 10

Calibration Sequence - VL3015LT Spot Luminaire........................................ ..... .................. 10

Auto Recalibration.................................................................................................................. 11

Partial Recalibration................................................................................................................ 11

Sensor Testing......................................................................................................................... 11

Troubleshooting

Error Messages........................................................................................................................ 13

Troubleshooting Guide............................................................................................................ 14

Maintenance Procedures

Lamp Replacement ................................................................................................................. 16

Align Lamp............................................................................................................................. 17

Gobo Replacement - Gobo Wheels 1, 2, and 3....................................................................... 18

Fixed Color Filter Replacement.............................................................................................. 21

Ballast Assembly Replacement............................................................................................... 23

Color/Dimmer/Strobe Assembly Replacement....................................................................... 25

Gobo/Iris Assembly Replacement .......................................................................................... 26

Reflector / UV Glass Assembly Replacement........................................................................ 27

Main Control Board (MCB) Replacement.............................................................................. 29

Ignitor Board Replacement..................................................................................................... 30

Fan Regulator Board Replacement......................................................................................... 31

Interconnect PCB Assembly Replacement............................................................................. 32

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VARI❋LITE - VL3015LT SPOT LUMINAIRE SERVICE MANUAL

Zoom Optics Assembly Replacement..................................................................................... 33

Frost / Prism Assembly Replacement..................................................................................... 34

Zoom Optics / Frost / Prism - Cable Routing Reference........................................................ 35

Zoom Optics - Zoom (Actuator) Motor Replacement............................................................ 38

Tilt Motor Assembly and Tilt Belt Replacement.................................................................... 40

Tilt Encoder PCB Replacement.............................................................................................. 42

Tilt EOT Sensor Replacement ................................................................................................ 43

Tilt Lock Replacement............................................................................................................ 44

Pan Motor Assembly/Pan Belt Replacement.......................................................................... 45

Pan Encoder PCB Replacement.............................................................................................. 47

Power Supply (LVS) Replacement ......................................................................................... 48

Display PCB Assembly Replacement..................................................................................... 49

PowerCon AC Input Connector Assembly Replacement....................................................... 50

DMX PCB Assembly Replacement........................................................................................ 51

Upper Enclosure Fan Assembly Replacement........................................................................ 52

Fan Regulator Board (Upper Enclosure) Replacement........................................................... 53

Pan Lock Replacement........................................................................................................... . 54

Gobo Timing Adjustments.................................................................................................. .... 56

Gobo Gear Planet Alignment.................................................................................................. 58

Gobo Gear Planet Alignment (continued) ............................................................ .... .............. 59

Chapter 3. Illustrated Parts Breakdown

Drawing Trees

VL3015LT Spot Luminaire..................................................................................................... 62

Top Assembly

Included Items Kit, VL3015LT Spot ...................................................................................... 65

VL3015LT Spot Luminaire..................................................................................................... 67

Generic Luminaire Assembly ................................................................................................. 70

Head Cover Assembly ............................................................................................................ 73

Gobo Clamp (with Cover Support) Assembly........................................................................ 74

Gobo Clamp Assembly..................................................... .... ..... .... ......................................... 75

Color Clamp Assembly........................................................................................................... 76

Head Assembly

Head Structure Assembly........................................................................................................ 77

Reflector Mount Assembly..................................................................................................... 79

VL3015LT Optic Assembly.................................................................................................... 80

Frost / Prism Bulkhead Assembly........................................................................................... 83

Prism Assembly ...................................................................................................................... 85

Backend Assembly.................................................................................................................. 87

Hot Box Assembly.................................................................................................................. 90

80MM DC Fan Assembly.............................................................................................. ..... .... 92

Color / Gobo Access Fan Assembly....................................................................................... 93

Gobo Module Assembly ................................................... .... .................................................. 95

Rotating Gobo Wheel Assembly............................................................................................. 98

Iris Sub-Assembly................................................................................................................... 99

Color/Strobe Module Assembly............................................................................................ 101

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TABLE OF CONTENTS

Strobe System Assembly ...................................................................................................... 104

Top Strobe Blade Assembly.................................................................................................. 106

Bottom Strobe Blade Assembly............................................................................................ 107

Fixed Color Wheel 2 Assembly............................................................................................ 108

Fixed Color Wheel 1 Assembly............................................................................................ 110

Yoke Assembly

Yoke Assembly ..................................................................................................................... 113

Tilt Motor Assembly............................................................................................................. 115

Yoke Fan Assembly .............................................................................................................. 117

Enclosure Assembly

Upper Enclosure Assembly................................................................................................... 119

Stabilizer Assembly .............................................................................................................. 125

Pan Motor Assembly............................................................................... ..... ......................... 126

Ventilation Cover Assembly ................................................................................................. 128

Input Panel Assembly ........................................................................................................... 129

Machined Pan Tube Assembly.............................................................................................. 130

High Flow Exhaust Fan Assembly........................................................................................ 131

Fan Regulator Board Assembly............................................................................................ 132

Note: Cables are only available as complete assemblies. The information contained in this

section is for reference only.

Cable Assemblies

LVS Chassis Ground Cable Assembly.................................................................................. 133

Chassis To Yoke Ground Cable Assembly ........................................................................... 134

Head to Back Cap Ground Cable Assembly......................................................................... 135

Ignitor to Relay Cable Assembly.......................................................................................... 136

Yoke Fan Cable Assembly.................................................................................................... 137

Data I/O Link Cable Assembly............................................................................................. 138

Ballast to Controller Cable Assembly................................................................................... 139

Lamp Supply to Relay Cable Assembly............................................................................... 140

Display Cable Assembly....................................................................................................... 141

AC Input Connector/Cable Assembly................................................................................... 142

Iris Fan Cable Assembly....................................................................................................... 143

36V Interconnect Cable Assembly ....................................................................................... 144

36V Yoke Reg PCB Cable Assembly................................................................................... 145

24V Relay to Interconnect Cable Assembly......................................................................... 146

Optics (MCB to Interconnect) Cable Assembly................................................................... 147

Gobo (MCB to Interconnect) Cable Assembly..................................................................... 148

Interconnect to Gobo Cable Assembly ................................................................................. 149

Color (MCB to Interconnect) Cable Assembly..................................................................... 150

Interconnect to Color Cable Assembly................................................................................. 151

OT Switch to Backcap Interlok Cable Assembly ................................................................. 152

Transfer Fan to Interconnect Cable Assembly...................................................................... 153

Lamp and Bulkhead Fans Cable Assembly .......................................................................... 154

Yoke Fan to Volt Reg PCB Cable Assembly ........................................................................ 155

Pan / Tilt Cable Assembly..................................................................................................... 156

Fan Exhaust Cable Assembly ............................................................................................... 157

02.9698.0010 0 xv

VARI❋LITE - VL3015LT SPOT LUMINAIRE SERVICE MANUAL

Ballast Power Cable Assembly............................................................................................. 158

36V Supply Cable Assembly................................................................................................ 159

Optics Bulkhead Cable Assembly......................................................................................... 160

Ignitor to Lamp Socket Cable Assembly.............................................................................. 161

LVS Chassis Ground Cable Assembly.................................................................................. 162

Appendix A. Technical Notices & Bulletins

VL3015LT Spot Luminaires................................................................................................. 163

Technical Notices............................................................................................................ 163

Technical Bulletins.......................................................................................................... 163

xvi 02.9698.0010 0

Introduction

About This Manual

This manual provides descriptions, repair procedures, and illustrated parts breakdowns for all
configurations of the VL3015LT Spot Luminaires. The manual is intended for use by Vari-Lite
personnel and Authorized VARI❋LITE Service Centers and technicians only.

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:

INTRODUCTION : ABOUT THIS MANUAL

Model Part Number Source

VL3015LT Spot Luminaire 20.9698.0001 1500 Watt 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 VL3015LT Spot Luminaire User’s
Manual. This manual is only available in electronic (PDF) format:

• VL3015LT Spot Luminaire User’s Manual (02.9698.0002)

Note: The user’s manual is available on the Philips Vari-Lite web site at www.vari-lite.com in the
Product Downloads Section.

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 Inc.
315 South Crouse Avenue Suite 200
Syracuse, NY 13210
Tel: [phone] or [phone]
Fax: [phone] or [phone]

www.usitt.org

02.9698.0010 0 1

VARI❋LITE - VL3015LT SPOT 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)

e-mail: [e-mail]

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, T exas USA office. They are documentation supplements that contain procedures for equipmen t
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 (Series 3000 Lumin aires 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 02.9698.0010 0

CHAPTER 1.

Description

This chapter contains descriptions of luminaire features and components.

• Features

• Components

• Principles of Operation

02.9698.0010 0 3

VARI❋LITE - VL3015LT SPOT LUMINAIRE SERVICE MANUAL

Features

Product Features

All VL3015LT Spot Luminaires have the following standard features:

• Color System: Six color control wheels total. A three filter CYM cross fading system, two fixed
color wheels with five interchangeable color filters each capable of continuous wheel rotation for
additional effects, and a variable CTO color temperature correction wheel.

• Zoom Optics: A 13-element 10:1 zoom optics system, covering a range from 6° to 60°.

• Beam Size Control: A mechanical iris provides continuous beam size control for rapid and smooth
timed beam angle changes.

• Intensity Control: Full field dimming designed for smooth timed fades as well as quick dimming
effects.

• Strobe: High-performance dual blade strobe system capable of ultra-fast operation.

• Rotating Gobo Wheels: Three gobo/effects wheels combine to each offer four rotatable, indexable
gobo positions and one open position.

• Edge and Pattern Focus: Variable beam focus to soften edges of gobos or spots. Remarkable depth
of field capability allows morphing effects between all pattern and effects wheels.

• Frost & Prism Capability: Independent rotating and indexing 3-facet prism as well as an
independent variable frost glass.

• Pan and Tilt: Smooth, time-controlled continuous motion by way of three-phase stepper motor
systems.

• Range: Pan - 540°, Tilt - 270°.

• Accuracy: 0.3° resolution.

• Source: Triple wattage, double-ended lamp. The lamp is capable of operation at 900W, 1200W or
1650W - mode selectable from fixture or console. / Color Temperature: 6000K at 1650W and
6300K at 900W and 1200W

Technical Specifications

For additional technical specifications and information, please refer to VL3015LT Spot Luminaire
User’s Manual (02.9698.0002) and the product specification sheet. These documents can be found in
the product downloads section of the Vari-Lite web site at www.vari-lite.com.

4 02.9698.0010 0

Components

External Luminaire Components

The following illustration shows the external luminaire components and controls.

Head Assembly

Houses color, gobos, strobe, iris
and zoom lens mechanisms

COMPONENTS : EXTERNAL LUMINAIRE COMPONENTS

Backcap Assembly

Provides access to lamp
for replacement and
provides controls for
beam adjustment.

1

Input Panel

Provides DMX In and Thru,
and AC Power connections.
(see detail below)

Input Panel Components

Product Label ID

~

DATA IN

AC IN

DATA THRU

Menu Display

Used to input manual
commands, program, test,
set defaults and access
internal status information.

ENTERMENU

Yoke Assembly

Houses Master Control
Board (MCB), tilt motor,

ignitor, and cooling fans.

Upper Enclosure Assembly

Houses power supply, ballast,
and display board.

Beam Adjustment Controls

CAUTION:

RISK OF FIRE. USE ONLY 1500 WATT, H TYPE 100V METAL HALIDE LAMP,

SFc10-4 BASE.

RISQUE D'INCENDIE. UTILISER UNIQUEMENT UNE LAMPA HALOGENE EN METAL DE

RISK OF EXPOSURE TO EXCESSIVE ULTRAVIOLET RADIATION. DO NOT OPERATE
WITHOUT COMPLETE LAMP ENCLOSURE IN PLACE OR WHEN LENS IS DAMAGED.

DO NOT OPEN FOR 5 MINUTES

ATTENTION:

TYPE H, 1500 WATT, 100V ET UN SUPPORT SFc10-4.

CAUTION:

DISCONNECT FIXTURE

BEFORE RELAMPING
CAUTION:

HOT LAMP

AFTER SWITCHING OFF.

X

AC Input

Data In Data Thru

YZ

02.9698.0010 0 5

VARI❋LITE - VL3015LT SPOT LUMINAIRE SERVICE MANUAL

Head and Yoke Components

The following illustration shows the major sub-assemblies which are located in the luminaire head and
yoke assemblies.

Rotating Gobo Assembly

Contains three rotating gobo
/ effects wheels, and iris
mechanism.

Head Fan
Assembly

Color Assembly

Contains fixed color wheel,
dimmer mechanism, strobe
mechanism, CYM color mixer

and CTO color correction.

Yoke Arm
Cover

Spot Optics Assembly

Houses zoom lenses
and edge mechanisms.

Head Cover

(attached by tether)

Front Cover

Head Cover

(attached by tether)

Backend Assembly

Houses lamp and reflector.
Provides knobs for lamp
adjustment.

Head Fan Assembly

Main Control Board (MCB)

Enclosure Assembly

see page 7

6 02.9698.0010 0

Luminaire control circuit board.

Yoke Arm Cover

COMPONENTS : ENCLOSURE COMPONENTS

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.)

1

Universal Arc Ballast

Module 1200W / 1650W

Pan Tube Assembly

Enclosure Top Covers

Luminaire Handles

Fan Assembly

36 VDC / Low-Voltage
Power Supply

Input Panel Assembly

Contains DMX Input, PCB
AC Input, and Menu Display

Input Connector Wiring

Wire* Connection

Green/Yellow AC Ground

Blue AC Neutral

Enclosure Bottom
Ventilation Cover

02.9698.0010 0 7

Brown AC Line

* International (Harmonized) Standard

VARI❋LITE - VL3015LT SPOT LUMINAIRE SERVICE MANUAL

Principles of Operation

Functional Block Diagram

HEAD / YOKE
ASSEMBLIES

RELAY

24V
IN

IGNITOR

INTERCONNECT

PCB

15V

24V 24V

TRANSFER FAN

LAMP

ZOOM / E DGE

15V

LAMP
FAN 2

CONN.

DAUGHTER

COLOR

36VINPUT (FROM MCB TO INTERCONNECT)

CONN.

GOBO/IRIS

FAN

ASSEMBLY

COLOR/GOBO ACCESS

FAN ASSEM BLY

CONN.

VOLTAGE
REG. PCB

(YOKE)

36V OUT

36VIN36V

MAINCONTROL

BOARD (MCB)

DAUGHTER

BOARD

LAMP

OUT

CTRL

IN

NOTE:

Information contained hereinis for
reference only and may be changed
at anytime without notice.

TILTEOT
SENSOR

TILT

DISPINDMX

PAN/ TILT HARNESS

MOTOR

ENCODER

TILT

OPTICS

COLOR

COLOR

24V 36V

24V

O/T

SWITCH

O/T

SWITCH

BACK
CAP

SWITCH

LAMP
OUT

LAMP

IN

GOBO GOBO

CONN.

CONN.

ZOOMOPTICSASSEMBLY

GOBO/IRIS

FAN

GOBO ASS EMBLY

ASSEMBLY

COLOR / STROBE ASSEMBLY

LAMP

FAN 1

YOKE FAN 1 YOKE FAN 2

PAN TUBE
ASSEMBLY

ENCLOSURE
ASSEMBLY

COMMON

MODE
CHOKE

TERMINA L

BLOCK

BALLAST

FAN 2

POWERCON(AC INPUT)

LAMPWIRES TO RELAY

CONN.

EMIG ROUND

EMI FILTER

1200W/1650WBALLAST

LVSGROUND

LVS TO E MI

DMX

LAMP
OUT

LAMP

CONTROL

AC

INPUT

BALLASTPOWER

36V LOW-VOLTAGE SUP PLY(LV S)

AC
INPUT

LINE/NEUTRAL/GROUND
CONNECTIONS

BALLAST

FAN 1

YOKE TOCHA SSISG ROUND

LVS TO M CB POW ER

36V
OUT

LCDDI SPLAY

VOLTAGE
REG. PCB
(BALLAST)

PAN
MOTOR

PAN
ENCODER

8 02.9698.0010 0

CHAPTER 2.

Maintenance

This chapter contains test, service, and standard maintenance procedures.

• Testing

• Troubleshooting

• Maintenance Procedures

WARNING: All maintenance procedures are to be performed with power

removed from the luminaire. Never remove cover or backcap while lamp is in oper­ation.

WARNING: Maintenance, repairs, and adjustments should only be performed by
a qualified, factory-trained service technician at an Authorized VARI❋LITE
Service Center.

02.9698.0010 0 9

VARI❋LITE - VL3015LT SPOT LUMINAIRES 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 VL3015LT Spot Luminaire User’s
Manual (02.9698.0002). This manual is available on the Vari-Lite web site, in the product download
section, at www.vari-lite.com.

Calibration Sequence - VL3015LT Spot Luminaire

The following is an outline of the luminaire’s standard calibration sequence:

Phase 1

• Tilt

•Strobe

• Color Wheel 1

• Color Wheel 2

• Iris

•Dimmer

Phase 2

•Pan

•CTO

•Cyan

• Yellow

•Magenta

Phase 3

• Move Tilt

• Gobo1

• Gobo2

• Gobo3

•Prism

• Gobo1 Index

• Gobo2 Index

• Gobo3 Index

Phase 4

• Lens A

• Lens B

• Lens C

•Prism

• Prism Index

•Frost

10 02.9698.0010 0

TESTING : AUTO RECALIBRATION

2

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 and edge. Pan and tilt are corrected continuously if required by encoders fitted to the motor
shaft.

Note: Colors (CTO and CYM) will only auto recalibrate when the dimmer has been closed for 3
seconds.

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 color: Color wheel, CYM, CTO, Dimmer

• Hold DMX value 114 for 3 seconds then 0 recals gobos: Gobo wheels and Index

• Hold DMX value 128 for 3 seconds then 0 recals lenses: Edge, Zoom, and Shutter

• Hold DMX value 140 for 3 seconds then 0 recals Dimmer and Strobe

Sensor Testing

Most mechanisms within the VL3015LT Spot Luminaires are equipped with either optical or magnetic
sensors. The VL3015LT Spot Luminaire 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).

02.9698.0010 0 11

VARI❋LITE - VL3015LT SPOT LUMINAIRES SERVICE MANUAL

• Low value - 0 volts, or up to approximately 0.2 volts.

Notes regarding specific mechanisms:

• The four color mixers will read high when the tab is in the optical sensor.

• The fixed color wheel will read low when the magnet is at the sensor and high at other times.

• The optical sensor will read high when the sensor is closed, or the tab is in the sensor.

• The gobo wheel reads low when the magnet is at the sensor.

• The gobo index/rotation reads low when the slot is in the sensor.

• Tilt sensor will 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 a PWM signal to the out line (which can be metered with a simple
DC voltage multi meter and will read approx. 4vdc). When the lamp on command is given, this
will change depending on which lamp level is selected within the menu or from the console (refer
to the VL3015LT Spot Luminaire User's Manual). On at full power will be one-half (1/2) PWM
(which will meter at approximately 2vdc). On at Medium Power (1200W) will be no PWM signal
(0vdc). On at Standby power will be one-quarter (1/4) PWM (which will meter at approximately
1vdc). When the douse command is given the reading should change back to the full PWM (which
again will meter at approximately 4vdc). Likewise, the standby circuit goes to standby when
approximately 3vdc is received on the standby line. Equally, if approximately 3vdc is applied to
the standby line, the lamp will go into standby mode, and if the full PWM is applied to the out line,
the lamp will douse.

12 02.9698.0010 0