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 [email protected] and request a Return Material Authorization
(RMA) for warranty service. You will need to provide the model and serial number of the item being
returned, a description of the problem or failure and the name of the registered user or organization. If
available, you should have your sales invoice to establish the date of sale as the beginning of the
warranty period.

Once you obtain the RMA, pack the unit in a secure shipping container or in its original packing box.
Fill out the RMA form included at the end of this manual and place in shipping container along with a
copy of your invoice (if available). Write the RMA number legibly on or near the shipping address
label and return the unit, freight prepaid to:

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: [email protected]

Additional Resources

For additional resources and documentation, please visit our website at www.vari-lite.com and follow
the Support link.

Technical Bulletins and Notices

Technical bulletins concerning the latest changes to VARI❋LITE equipment are issued from the
Dallas, 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

Troubleshooting

Error Messages

If a problem occurs during luminaire calibration, at the end of the calibration sequence the Menu
Display will cycle through any applicable error message(s) until the end of the list is reached. To
review the error messages again, it will be necessary to access them using the Status function.

To access error messages:

Step 1. Press [Menu].
Step 2. Press [Up] / [Down] arrows until Fixture appears. Press [Enter].
Step 3. Press [Up]/ [Down] arrows to access Status. Press [Enter]. (Display will now scroll

through any error messages or display OK if no errors.)

TROUBLESHOOTING : ERROR MESSAGES

2

Table 2-1: Error Messages

Display Message

OK No Errors 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.

RotGobo1/No Sens Rotating Gobo wheel 1 sensor not found.

Index2/No Sens Gobo 2 Index sensor not found.

RotGobo2/No Sens Rotating Gobo wheel 2 sensor not found.

Index3/No Sens Gobo 3 Index sensor not found.

RotGobo3/No Sens Rotating Gobo wheel 3 sensor not found.

Dimmer/No Sens Dimmer sensor not found.

Cyan/No Sens Cyan sensor not found.

Yellow/No Sens Yellow sensor not found.

Magenta/No Sens Magenta sensor not found.
ColWheel1/No Sens Color wheel 1 sensor not found.
ColWheel2/No Sens Color wheel 2 sensor not found.

CTO/No Sens CTO sensor not found.

Frost/No Sens Frost sensor not found.

Prism/No Sens Prism sensor not found.

WARNING: As with any repairs or maintenance to VARI❋LITE luminaires, service should only be
performed by a trained and qualified service technician or at an Authorized VARI❋LITE Service
facility.

02.9698.0010 0 13

VARI❋LITE - VL3015LT SPOT LUMINAIRES SERVICE MANUAL

Troubleshooting Guide

If a problem is suspected, try recalibrating the luminaire to prompt an error message. Refer to “Error

Messages” on page 13 for more information. The chart below provides possible causes and remedies

for each message.

Table 2-2: Troubleshooting Guide

Message Symptom Description Possible Cause and Remedy

n/a No response to DMX

data

n/a Lamp douses frequently Lamp Douse Fan failure...

n/a Lamp will not strike Lamp Strike Failure Lamp cutout switch disengaged...

No Sens No control, continuous

recalibration, and/or

mechanism at wrong

position

n/a Luminaire does not

power-up

Pan/

Encoder/

Fail

Tilt/

Encoder/

Fail

Luminaire will not pan Pan Encoder Fail ure MCB pan/tilt connector disconnected...

Luminaire will not tilt Tilt Encoder Failure MCB pan/tilt connector disconnected...

DMX Failure MCB connector disconnected...

- check MCB DATA IN connection.

- check fans for proper connection and
operation.

- check lamp cutout switch at lamp box.

Bad lamp...

- replace lamp.

Low input voltage...

- check input power (must be 200 to 264 VAC)

Mechanism failed to find

sensor (reported for Blue,

Amber, Magenta, Col-

Wheel, CTO, Gobo1,

Index1, and Gobo2)

Motor power not connected...

- connect motor power.

Sensor not connected...

- connect sensor.

Interconnect board not connected securely...

- check connection, inspect for bent pins.

Movement restricted or impeded...

- remove obstruction, check cable routing,
and/or check voltage at MCB test point.

No power Not plugged in...

- ensure A/C cable is connected to power
source.

- ensure A/C cable properly constructed.

- connect MCB pan/tilt connector (J8).

Pan motor disconnected

- connect pan motor power.

Encoder faulty ...

- replace pan end-of-travel/encoder sensor
assembly.

- connect MCB pan/tilt connector (J8).

Tilt motor disconnected

- connect tilt motor power.

Encoder faulty ...

- replace tilt end-of-travel/encoder sensor
assembly.

14 02.9698.0010 0

TROUBLESHOOTING : TROUBLESHOOTING GUIDE

Table 2-2: Troubleshooting Guide (Continued)

Message Symptom Description Possible Cause and Remedy

Tilt No

Sens

n/a Color , dimmer or strobe

n/a Zoom/Edge or beam

n/a Gobo or iris mecha-

n/a Self tests will not run or

n/a Erratic control of

Luminaire will not tilt Tilt Sensor Not Found EOT flag attached to large pulley is not engaging the

EOT sensor...

- ensure flag is attached to the large pulley.

- ensure that flag passes thro ugh 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.

mechanisms will not

move

spreader mechanisms

will not move

nisms will not move

software download does

not work.

luminaire

Color, Dimmer, or Strobe

Failure

Zoom/Edge or Beam

Spreader Failure

Gobos or Iris Failure MCB connector disconnected...

DMX Data Input Detecting DMX data...

DMX Termination No DMX termination or termination not correct...

MCB connector disconnected...

- check MCB connector at J11.

Check Interconnect board.
MCB connector disconnected...

- check MCB connector at J10.

Check Interconnect board.

- check MCB connector at J9.

Check Interconnect board.

- disconnect DMX input cable.

- check DMX terminator.

2

02.9698.0010 0 15

VARI❋LITE - VL3015LT SPOT LUMINAIRES SERVICE MANUAL

Maintenance Procedures

WARNING: As with any repairs or maintenance to VARI❋LITE luminaires, service should only be
performed by a trained and qualified service technician or at an Authorized VARI❋LITE Service
facility.

Lamp Replacement

Vari-Lite Part No: 71.9686.1502

WARNING: Ensure that power is removed from luminaire when installing lamp.

CAUTION: Wear cotton gloves or other covering while installing lamp. Touching lamp glass with

bare fingers will leave oil and may cause the lamp to explode or reduce lamp life. If touched, use
alcohol and cotton cloth to thoroughly clean glass portion of lamp.

To remove and replace lamp:

Step 1. Ensure power is removed from luminaire.
Step 2. At rear of luminaire head, loosen four 1/4-turn screws and slide lamp box back and out (it is

hinged).

Step 3. One side at a time, using a small flat-blade screwdriver, carefully pry lamp from socket and

remove current lamp.

Step 4. Position new lamp with dimple side down. One side at a time, press lamp lock lever forward

and insert lamp connector. Ensure lamp is seated fully in place.

Lamp Connector

Lamp (dimple, on lamp,

CAUTION:

CAUTION:

Allow lamp to cool
before servicing.

Do not touch lamp or
reflector with bare fingers.

Luminaire Head Not Shown For Clarity

towards socket)

Lamp Box

Figure 2-1: Removing and Installing Lamp

Step 5. Close lamp box and re-tighten 1/4-turn screws.
Step 6. Align lamp as detailed in “Align Lamp” on page 17.
Step 7. Reset lamp hours counter via menu system. Refer to user’s manual for menu system

operation.

16 02.9698.0010 0

MAINTENANCE PROCEDURES : ALIGN LAMP

Align Lamp

The design of the VL3015LT Spot Luminaire optical system allows for a flat or peaked field. A flat
field is one where there is no detectable hot spot and a peaked field is one where the intensity of the
beam is greater at the center of the beam than at the perimeter.

After a new lamp is installed, it will be necessary to align the lamp to optimize the beam. Knobs
located at the luminaire’s backcap will allow adjustment.

WARNING: Backcap and adjustment knobs will be HOT during lamp operation. Wear gloves to
prevent burns.

To align / optimize lamp:

Step 1. Power-up luminaire.
Step 2. At Menu Display, select Lamp from Config menu (refer to user’s manual for menu

operation). (If using console, set intensity to 100%, open beam size iris and focus for hard
edge.)

2

Step 3. Position beam on a white wall at a distance of 10 to 20 feet.
Step 4. At backcap, using X, Y and Z adjustment knobs, adjust beam as required.

CAUTION:

SFc10-4 BASE.

ATTENTION:

CAUTION:

Backcap

Y

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

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

DO NOT OPEN FOR 5 MINUTES

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

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

DISCONNECT FIXTURE

BEFORE RELAMPING

HOT LAMP

CAUTION:

AFTER SWITCHING OFF.

X

Z

Figure 2-2: Aligning Lamp - Lamp Alignment Knobs

02.9698.0010 0 17

VARI❋LITE - VL3015LT SPOT LUMINAIRES SERVICE MANUAL

Gobo Replacement - Gobo Wheels 1, 2, and 3

Tools:

#2 Phillips Screwdriver and Lint Free Cotton Gloves

WARNING: Remove power from luminaire before performing maintenance. Gobos may be HOT
after operation. Allow to cool before replacing.

WARNING: Users of VARI❋LITE luminaires should not install or use metal gobos. The use of metal
gobos in any VARI❋LITE product may damage the luminaire and could void the luminaire’s warranty.

Overview of Gobos and Gags used in VL3015LT Spot Luminaire

Due to the immense energy and light produced by VL3015LT spot luminaires, Vari-Lite recommends
to users and owners of this fixture follow the guidelines outlined below when loading gobos or gags in
any of the three rotating gobo wheels.

Gobo / Gag Use and Positioning

Vari-Lite has purposely selected a set of standard gobos and gags for this fixture and positioned them
within the fixture to offer optimum versatility / performance. The gobos supplied - in the standard
factory configuration - have been tested in their respective original positions to protect their service
life (including when morphed between wheels 1 and 3).

Note: For standard factory gobo / gag loads and position, please refer to “VL3015LT Spot Gobo/

Effects Control” on page 30 of this manual.

Users can load their own patterns (gobos or gags). When using custom gobos or gags, Vari-Lite
recommends the following guidelines:

• When morphing gobos, gobos should be morphed between wheels 1 and 3 only, never in wheel 2.

• Rotating gobo wheel 2 has been designated the gag (effects) wheel. Wheel 2
should only house clear type gags or gobos that permit minimum unabated light
transmission.

• Under no circumstances should owners or users use or install metal gobos. Using
metal gobos in the VL3015LT spot luminaire will void the fixture’s warranty.

Note: Va ri-Lite cannot guarantee the service life of any custom gobos or gags when used in
conjunction with this fixture. Owners and users employing custom gobos and gags do so at their own
risk.

18 02.9698.0010 0

MAINTENANCE PROCEDURES : GOBO REPLACEMENT - GOBO WHEELS 1, 2, AND 3

2

To Install or Replace Gobos

WARNING: Remove power from luminaire before performing maintenance. Gobos may be HOT
after operation. Allow to cool before replacing.

To replace a rotating gobo:

Step 1. Remove power from luminaire.
Step 2. As illustrated in Figure 2-3, remove top and/or bottom head cover by loosening four 1/4-turn

screws to access the three gobos wheels.
a. To access Wheel 1 and 3, remove bottom cover as shown in Figure 2-3.
b. To access Wheel 2, remove top cover as shown in Figure 2-3.

Top Head Cover *

1/4-Turn Screw (4 per head cover)

Gobo Wheel

Bottom Head Cover *

* Head covers are attached by tethers.

Figure 2-3: Head Covers - Removal

02.9698.0010 0 19

VARI❋LITE - VL3015LT SPOT LUMINAIRES SERVICE MANUAL

Step 3. If removing gobos via bottom of head assembly, undo fan tray assembly with thumb screw

to access.

Step 4. Rotate desired 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. To clean, refer to the cleaning instructions contained in the product user’s manual.

Step 5. Remove current gobo by carefully pressing on edges of gobo carrier with fingers, pressing

gobo toward front end of luminaire (toward lens), and out of wheel.

R

OTATING GOBO WHEELS

CAUTION:

Do not touch glass with bare fingers.
Press on gobo carrier only.

Rotating Gobo Wheel

Figure 2-4: Replacing Gobos

Step 6. Install new gobo as follows:

a. Align three tabs on gobo carrier with three notches in wheel (gobo can only be oriented

in one direction).

Front of luminaire

Gobo Assembly

Carrier

Press from this side

b. Insert gobo carrier into wheel, ensuring that carrier snaps into place.

Step 7. Replace cover(s).

20 02.9698.0010 0

MAINTENANCE PROCEDURES : FIXED COLOR FILTER REPLACEMENT

2

Fixed Color Filter Replacement

Tools:

#2 Phillips Screwdriver and Lint Free Cotton Gloves

WARNING: Remove power from luminaire before performing maintenance. Filters may be HOT
after operation. Allow to cool before replacing.

To replace a fixed color filter on Color Wheel 1 (closest to the lamp):

Step 1. Remove power from luminaire.
Step 2. Remove bottom (relative to backcap label) head cover by loosening the four 1/4-turn screws.
Step 3. Undo fan tray assembly with thumb screw to access filters.

CAUTION: Do not touch filters with bare fingers. Wear cotton gloves or other covering while
replacing filters. To clean filters, use isopropyl alcohol and soft cloth. Strong cleaning solutions can
damage coating. Fingerprints or other grease deposits on filters can cause the glass to break.

Step 4. As shown in Figure 2-5, rotate Color Wheel 1 until the filter you are changing is accessible.
Step 5. T o improve access to the filter, rotate the mixed color wheels to position the cut-outs next to

the filter you are changing.
Step 6. Gently press the color filter toward the lamp until it is free of the lock pins. Remove filter.
Step 7. Orienting coated side of filter towards lamp, slide new filter under the spring clip until it is

securely retained by the lock pins.
Step 8. Replace the head cover.

To replace a fixed color filter on Color Wheel 2 (closest to the lens assembly):

Step 1. Remove power from luminaire.
Step 2. Remove top (relative to backcap label) head cover by loosening the four 1/4-turn screws.

CAUTION: Do not touch filters with bare fingers. Wear cotton gloves or other covering while
replacing filters. To clean filters, use isopropyl alcohol and soft cloth. Strong cleaning solutions can
damage coating. Fingerprints or other grease deposits on filters can cause the glass to break.

Step 3. Rotate Color Wheel 2 until the filter you are changing is accessible.
Step 4. T o improve access to the filter, rotate the mixed color wheels to position the cut-outs next to

the filter you are changing.
Step 5. As shown in Figure 2-5, gently press the color filter toward the lens until it is free of the lock

pins. Remove the filter.

02.9698.0010 0 21

VARI❋LITE - VL3015LT SPOT LUMINAIRES SERVICE MANUAL

Fixed Color Filter Replacement (continued)

Step 6. Orienting coated side of filter towards lamp, slide new filter under the spring clip until it is

securely retained by the lock pins.
Step 7. Replace the head cover.

Color Wheel

(see detail)

Top Head Cover *

1/4-Turn Screw

Bottom Head Cover *

* Head covers are attached by tethers.

F

IXED COLOR WHEELS

Color Filter

NOTE:

Drawing exploded for clarity.

Color Filter

Fixed Color Wheel

Assembly With Color Wheels

(Note, shown removed for clarity only.

Do not remove assembly)

Do not touch filter with bare fingers.

CAUTION:

Wear cotton gloves.

Figure 2-5: Replacing a Color Filter

22 02.9698.0010 0

MAINTENANCE PROCEDURES : BALLAST ASSEMBLY REPLACEMENT

2

Ballast Assembly Replacement

Vari-Lite Part No: 69.9679.1216

To remove and replace ballast assembly:

Step 1. Remove power from luminaire.

WARNING: You must remove all power from luminaire before performing maintenance. Fixture
may be very HOT after operation. Allow it to cool completely before performing any maintenance.

Step 2. At each top enclosure cover, remove two 6-32 x 1/4" PPB screws and remove cover.
Step 3. In each corner from top, remove four 6-32 x 3/8" PPZ screws.

CAUTION: Be careful not to damage lens during next step.

Step 4. Carefully lay luminaire on its side, ensuring that lens does not come into contact with any

surface.
Step 5. At bottom of enclosure, remove four 1/4-20 x 3/4" socket screws and 1/4" split lock washers

and remove ventilation cover.

NOTE:

Drawing exploded for clarity.

1200 / 1650 Watt
Ballast Assembly

Figure 2-6: Ballast Cover / Handle Removal

Front Cover

APS Side Bracket

Handle (x2)

Side Cover (x2)

Step 6. Remove both handles by removing two 10-32 x 3/4" SCB screws at each.
Step 7. At enclosure bottom, remove four 6-32 x 1/4" PPB screws and both side covers.
Step 8. At enclosure bottom, remove two 6-32 x 3/8" PPB screws, APS side bracket and front cover

from ballast side.

02.9698.0010 0 23

VARI❋LITE - VL3015LT SPOT LUMINAIRES SERVICE MANUAL

Step 9. At bottom of enclosure, disconnect exhaust fan cable.
Step 10. At exhaust fan, remove four 8/32 x 3/8" screws. Remove exhaust fan from enclosure

assembly.
Step 11. At ballast, disconnect following cable assemblies:

a. Lamp wires

b. AC input

c. Control wiring
Step 12. Pull lamp wires through ferrite core.
Step 13. At bottom of enclosure, remove three 8-32x3/8" PFZ screws and four 8/32x3/8" PPZ screws

which secure ballast module to enclosure.
Step 14. Remove ballast module.
Step 15. Install replacement assembly by performing previous steps in reverse order.

NOTE:

Some components not shown for clarity.

Route Lamp to Supply Cable as shown ­same as original cable assembly.

Back of Display

1200 / 1650 Watt
Ballast Assembly

Lamp Supply to Relay

Cable Assembly

Cable must be routed through Ferrite

Figure 2-7: Ballast Replacement

24 02.9698.0010 0

MAINTENANCE PROCEDURES : COLOR/DIMMER/STROBE ASSEMBLY REPLACEMENT

2

Color/Dimmer/Strobe Assembly Replacement

Vari-Lite Part No: 21.9698.0400

To remove and replace color/dimmer/strobe assembly:

Step 1. Remove power from luminaire.

WARNING: You must remove all power from luminaire before performing maintenance. Fixture
may be very HOT after operation. Allow it to cool completely before performing any maintenance.

Step 2. Remove top head cover by loosening four 1/4 turn captive stud connectors.

Note: The top cover is easily identified as follows - maneuver head so the printing on the label on the
rear of the head assembly is oriented correctly.

Step 3. At interconnect board, note positions and disconnect the following wiring:

a. Fan wiring J13 and J16

b. Wiring at J6 and J7
Step 4. Loosen four captive screws (two per clamp) and remove clamps. (Note: Do NOT remove

long phillips head screw, it serves as a handle.)
Step 5. Pull assembly straight up and out of luminaire.
Step 6. Replace assembly by performing previous steps in reverse order.

Note: Always tighten MCB-side clamps FIRST when installing.

NOTE:

Drawing exploded for clarity.

Clamp

Color/Dimmer/Strobe Assembly

Top Head Cover

Figure 2-8: Color/Dimmer/Strobe Assembly Replacement

02.9698.0010 0 25

VARI❋LITE - VL3015LT SPOT LUMINAIRES SERVICE MANUAL

Gobo/Iris Assembly Replacement

Vari-Lite Part No: 21.9698.0200

To remove and replace gobo/iris assembly:

Step 1. Run Zoom to full forward position (DMX 255).
Step 2. Remove power from luminaire.

WARNING: You must remove all power from luminaire before performing maintenance. Fixture
may be very HOT after operation. Allow it to cool completely before performing any maintenance.

Step 3. Remove top head cover by loosening four quarter-turn captive locking screws. Top cover is

identifiable as the cover on top when back label is such that words are displayed correct side

up.

Note: Before disconnecting any wiring/cables, make note of all wire/cable routing.

Step 4. Remove Color/Dimmer/Strobe Assembly as described in “Color/Dimmer/Strobe Assembly

Replacement” on page 25.

Step 5. Disconnect head cable from Color Assembly Interconnect PCB, remove wiring from

Transfer Fan clips.
Step 6. At interconnect board, disconnect the wiring at J10, J11, J3, and J12.
Step 7. At Gobo / Iris 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 loosen that screw).
Step 8. Pull Gobo / Iris Assembly straight out of fixture.

Top Head Cover

Clamp

NOTE:

Drawing exploded for clarity.

Zoom Assembly

(Must be all the way forward.)

Gobo/Iris Assembly

Figure 2-9: Gobo/Iris Assembly Replacement

Step 9. Replace by performing previous steps in reverse order.

Note: Always tighten MCB-side clamps FIRST when installing.

26 02.9698.0010 0

MAINTENANCE PROCEDURES : REFLECTOR / UV GLASS ASSEMBLY REPLACEMENT

2

Reflector / UV Glass Assembly Replacement

Vari-Lite Part No: 42.9686.0120 (Reflector)
Vari-Lite Part No: 21.9686.0606 (Assy, UV Glass)

To remove and replace reflector / UV glass assembly:

Step 1. Disconnect luminaire AC input cable from power source.

WARNING: You must remove all power from luminaire before performing maintenance. Fixture
may be very HOT after operation. Allow it to cool completely before performing any maintenance.

Step 2. Remove both Color/Dimmer/Strobe and Gobo/Iris Assemblies. See “Color/Dimmer/Strobe

Assembly Replacement” on page 25 and “Gobo/Iris Assembly Replacement” on page 26 for

removal instructions.
Step 3. Open dual fan assembly.
Step 4. Remove two 3-62 x 1/4" PPZ screws securing air diverter. Remove air diverter and set aside.
Step 5. As shown in Figure 2-10, remove four 4-40 x 1 3/8" PPZ screws.
Step 6. Carefully remove UV/Reflector assembly.
Step 7. Remove the springs from the reflector clamp and remove the reflector.
Step 8. Replace the reflector and UV/Reflector assembly in reverse order.

Note: Make sure the mark on the reflector lines up with the mark on the top-left reflector support; see
"Reflector Alignment" illustration in Figure 2-10.

02.9698.0010 0 27

VARI❋LITE - VL3015LT SPOT LUMINAIRES SERVICE MANUAL

Reflector Replacement (continued)

Disconnect Springs

Reflector Clamp

UV/Reflector Assembly

4-40 x 1 3/8"

screws (4)

Assembly Removal

Spring not shown
for clarity

Reflector Alignment

Figure 2-10: Reflector / UV Glass Assembly Removal

28 02.9698.0010 0

MAINTENANCE PROCEDURES : MAIN CONTROL BOARD (MCB) REPLACEMENT

2

Main Control Board (MCB) Replacement

Vari-Lite Part No: 24.9698.0700

To remove and replace main control board (MCB):

Step 1. Remove power from luminaire.

WARNING: You must remove all power from luminaire before performing maintenance. Fixture
may be very HOT after operation. Allow it to cool completely before performing any maintenance.

Note: To determine which yoke leg is which without having to remove the covers, rotate yoke
counterclockwise until it stops, then look at the luminaire while facing the input panel. The tilt-side leg
is the leg to the left; the board-side leg is the leg to the right.

Step 2. At board-side leg, remove yoke leg cover by removing four 6-32x3/8" PTB screws.

ESD

CAUTION: Always use anti-static precautions when working with PCBs.

Step 3. Disconnect wiring harness connectors J2 (on daughter board) J8, J9, J10, J11 and J12.
Step 4. Remove two 6-32 x 3/8" PPZ screws and remove daughter board.
Step 5. Remove two 6-32 x 1/4" standoffs, two 6-32 x 3/4" PPZ screws, and gently tilt MCB away

from yoke assembly
Step 6. Disconnect wiring harness connectors J1, J2, J3, J4, and J5 at back of MCB.
Step 7. Install replacement assembly by performing previous steps in reverse order.
Step 8. Configure using menu functions as necessary.

Main Control Board (MCB)

Yoke Leg Cover

NOTE:

Drawing exploded for clarity.

Figure 2-11: Main Control Board (MCB) Replacement

02.9698.0010 0 29

VARI❋LITE - VL3015LT SPOT LUMINAIRES SERVICE MANUAL

Ignitor Board Replacement

Vari-Lite Part No: 24.9661.3126

To remove and replace ignitor board assembly:

Step 1. Remove power from luminaire.

WARNING: You must remove all power from luminaire before performing maintenance. Fixture
may be very HOT after operation. Allow it to cool completely before performing any maintenance.

Step 2. At tilt-side leg, remove yoke leg cover by removing four 6-32x3/8" PTB screws.

ESD

CAUTION: Always use anti-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.

WARNING: Ensure that only these screws are used for wire ring terminals (removed in Step 3). DO
NOT USE SUBSTITUTES!

Step 4. Remove four 6-32 x 3/8"LG PPZ SEMS screws and remove ignitor PCB.
Step 5. Replace by performing previous steps in reverse.

Note: Make sure and orient ignitor properly (as shown in Figure 2-12).

"From Relay" Connections*

Ignitor Board

NOTE:

Some components not shown for clarity.

"To Bulb (Lamp)" Connections*

6-32 x 3/*" PPZ Sems Screw (x4)

WARNING: *Ensure that only these screws are
used for wire ring terminals.

Figure 2-12: Ignitor Board Replacement

30 02.9698.0010 0

MAINTENANCE PROCEDURES : FAN REGULATOR BOARD REPLACEMENT

2

Fan Regulator Board Replacement

Vari-Lite Part No: 24.9698.1690

To remove and replace fan regulator board:

Step 1. Remove power from luminaire.

WARNING: You must remove all power from luminaire before performing maintenance. Fixture
may be very HOT after operation. Allow it to cool completely before performing any maintenance.

Note: To determine which yoke leg is which without having to remove the covers, rotate yoke
counterclockwise until it stops, then look at the luminaire while facing the input panel. The tilt-side leg
is the leg to the left; the board-side leg is the leg to the right.

Step 2. At board-side leg, remove yoke leg cover by removing four 6-32x3/8" PTB screws.

ESD

CAUTION: Always use anti-static precautions when working with PCBs.

Step 3. Remove MCB by following removal instructions “Main Control Board (MCB)

Replacement” on page 29.

Step 4. Disconnect wiring from Fan Regulator Board.

Yoke Leg Cover

NOTE:

Drawing exploded for clarity.

Main Control Board (MCB)

Fan Regulator Board

Figure 2-13: Fan Regulator Board Replacement

Step 5. Remove two 4-40x1/4" PPSS screws and remove board.
Step 6. Replace in reverse order.

02.9698.0010 0 31

VARI❋LITE - VL3015LT SPOT LUMINAIRES SERVICE MANUAL

Interconnect PCB Assembly Replacement

Vari-Lite Part No: 24.9698.2680

To remove and replace interconnect PCB assembly board:

Step 1. Remove power from luminaire.

WARNING: You must remove all power from luminaire before performing maintenance. Fixture
may be very HOT after operation. Allow it to cool completely before performing any maintenance.

Step 2. Remove top head cover by loosening four quarter-turn captive locking screws. Top cover is

identifiable as the cover on top when back label is such that words are displayed correct side

up.

Note: Before disconnecting any wiring/cables, make note of all wire/cable routing.

Step 3. Disconnect all wiring from interconnect PCB assembly.
Step 4. Remove six 6-32 x 1/4" PPZ SEMS screws and remove interconnect PCB assembly.

Top Head Cover

Interconnect PCB Assembly

NOTE:

Drawing exploded for clarity.

Figure 2-14: Interconnect PCB Assembly Replacement

Step 5. Replace in reverse order.

32 02.9698.0010 0

MAINTENANCE PROCEDURES : ZOOM OPTICS ASSEMBLY REPLACEMENT

2

Zoom Optics Assembly Replacement

Vari-Lite Part No: 21.9698.0100

To remove and replace zoom optics assembly:

Step 1. Remove power from luminaire.

WARNING: You must remove all power from luminaire before performing maintenance. Fixture
may be very HOT after operation. Allow it to cool completely before performing any maintenance.

Step 2. Remove both head covers by loosening four quarter-turn captive locking screws on each

cover.
Step 3. Remove both Color/Dimmer/Strobe and Gobo/Iris Assemblies. See “Color/Dimmer/Strobe

Assembly Replacement” on page 25 and “Gobo/Iris Assembly Replacement” on page 26 for

removal instructions.
Step 4. Remove front cover by removing four 10-32 x 1/2" PPB screws.
Step 5. At interconnect PCB assembly, disconnect optics wiring harness from J1. Noting placement,

cut cable ties holding optics wiring harness to interconnect board mount.
Step 6. Open dual fan assembly
Step 7. At bottom of optics, remove four 6-32 x 1/2" PPZ SEMS screws.

CAUTION: Make sure to support optics from this point on!

Step 8. At front, remove four 10-32 x 1/2" PPB screws and carefully remove optics assembly from

luminaire head.

Top Head Cover

Front Cover

NOTE:

Drawing exploded for clarity.

Zoom Optics Assembly

Bottom Head Cover

Figure 2-15: Zoom Optics Assembly Replacement

Step 9. Replace in reverse order. For cable wiring, refer to photos and descriptions contained in

“Zoom Optics / Frost / Prism - Cable Routing Reference” on page 35.

02.9698.0010 0 33

VARI❋LITE - VL3015LT SPOT LUMINAIRES SERVICE MANUAL

Frost / Prism Assembly Replacement

Vari-Lite Part No: 21.9698.1351

To remove and replace frost / prism assembly:

Step 1. Remove power from luminaire.

WARNING: You must remove all power from luminaire before performing maintenance. Fixture
may be very HOT after operation. Allow it to cool completely before performing any maintenance.

Step 2. Remove both head covers by loosening four quarter-turn captive locking screws on each

cover.
Step 3. At Frost/Prism assembly, disconnect all wiring and cut all cable ties. Make note of

placement (refer to photos and descriptions contained in “Zoom Optics / Frost / Prism -

Cable Routing Reference” on page 35 for additional information).

Step 4. Remove four 6-32 x 3/8" PFZ screws and remove assembly from lens carrier.

Top Head Cover

Bottom Head Cover

Frost / Prism Assembly

NOTE:

Image reversed for clarity.

Screws

Figure 2-16: Frost / Prism Assembly Replacement

Step 5. Replace in reverse order.

34 02.9698.0010 0

MAINTENANCE PROCEDURES : ZOOM OPTICS / FROST / PRISM - CABLE ROUTING REFERENCE

Zoom Optics / Frost / Prism - Cable Routing Reference

The photos and descriptions below show cable routing in and around the zoom optics, frost, and prism
assemblies. For additional information or assistance, please contact Vari-Lite Technical support.

This section contains information for:

• “Lens Group C Motor Cable” on page 35 (below)

• “Lens Group B Motor Cable” on page 35 (below)

• “Lens Group A Motor Cable” on page 36

• “Lens Group Motor Cables” on page 36

• “Frost Motor and Sensor Cables” on page 36

• “Prism Sensor Cable” on page 37

• “Frost Sensor Cable” on page 37

2

Lens Group C Motor Cable

Lens group C motor cable should run wire through cable tie saddle
installed low on carrier. It should be secured so cable goes out and away
from lens and cannot be caught during movement. It should run to
farthest forward cable tie saddle on mount. There should be slack to allow
free mechanism movement.

Lens Group B Motor Cable

The lens group B motor cable should have enough slack when group is
pushed all the way forward. It should be bundled with other wires and
mounted on carrier as shown.

02.9698.0010 0 35

VARI❋LITE - VL3015LT SPOT LUMINAIRES SERVICE MANUAL

Lens Group A Motor Cable

The motor cable for lens group A should be tied directly off onto the
mount. There should be slack.

Lens Group Motor Cables

Tie off along mount as shown. When all lenses are pushed back, a little
slack should still exist in cables to allow free mechanism movement. If
cables are pulled tight, the lenses may not calibrate correctly.

The cable harness should be neatly tied along the inside of the mount. Tie
down tightly so harness cannot be snagged by lens groups.

Tied tightly
to bulkhead

Cables routed to
back of lens group

Cables secured using
both cable saddles

Slack for free lens movement

Frost Motor and Sensor Cables

All cables should be routed to the back of the
lens group. Frost motor and sensor cables
should be neatly routed over the lens using
the wire tie holes on the plate. Both cable tie
saddles should be used to secure cables on
lens carrier. Cables should be tight along
lens group so they do not fall into the beam.
Slack should be left at bottom so lens group
can travel freely.

36 02.9698.0010 0

MAINTENANCE PROCEDURES : ZOOM OPTICS / FROST / PRISM - CABLE ROUTING REFERENCE

Prism Sensor Cable

Prism sensor cable should be secured next to motor connection and
under motor as shown.

After securing cables, insure prism assembly moves freely (in and out)
without coming into contact with cables.

2

Frost Sensor Cable

Frost sensor cable should be secured next to motor connection and under
motor as shown.

After securing cables, insure frost assembly moves freely (in and out)
without coming into contact with cables.

02.9698.0010 0 37

VARI❋LITE - VL3015LT SPOT LUMINAIRES SERVICE MANUAL

Zoom Optics - Zoom (Actuator) Motor Replacement

Vari-Lite Part No: 44.9698.0147 (Motor Assembly)
Vari-Lite Part No: 10.9698.0146 (Shaft)

To remove and replace a zoom actuator motor:

Step 1. Remove power from luminaire.

WARNING: You must remove all power from luminaire before performing maintenance. Fixture
may be very HOT after operation. Allow it to cool completely before performing any maintenance.

Step 2. Remove optics from fixture following procedure described in “Zoom Optics Assembly

Replacement” on page 33.

Step 3. Remove zoom tray light baffle by removing two 8-32 x 3/8" PPB SEMS screws.

Note: In next step, do not disconnect wiring, just move mount to side.

Step 4. Remove zoom mount by removing three 8-32 x 3/8" PPB SEMS screws. Move aside.

NOTE:

Drawing exploded and parts
removed for clarity.

Lens Assembly (x3)

Linear Rail Truck (x3)

Linear Rail

Zoom Actuator Motor Assembly

Figure 2-17: Zoom Optics - Zoom (Actuator) Motor Replacement

38 02.9698.0010 0

MAINTENANCE PROCEDURES : ZOOM OPTICS - ZOOM (ACTUATOR) MOTOR REPLACEMENT

2

Step 5. Using slotted screwdriver to hold lead screw at front (DO NOT USE PLIERS ON LEAD

SCREW OR YOU MAY DAMAGE IT!) remove two 8-32 KEPS nuts.

Step 6. Carefully thread lead screw out of motor to be replaced. Note, you may have to thread out of

other motors first, depending on which you are replacing.

Step 7. At motor to be replaced, disconnect wiring.
Step 8. Remove lens from mount at motor to be replaced by:

a. Removing one 8-32 x 5/8" PPZ SEMS screw and nut.

b. Noting orientation of lens, lift lens strap and remove lens.

c. Remove lens mount from rail truck by removing four M3 x 8mm PPZ SEMS screws.

d. Carefully remove lens mount, with motor attached from linear rail.
Step 9. At motor, remove four M3 x 0.5 x 8mm LG, PFZ screws and remove m oto r.
Step 10. Replace following the steps in reverse order.

Note: When installing lens mount to rail truck (as removed in step 8), start all four screws but do not
tighten. Slide lens mount against the lens next to it to ensure the trucks line up square to each other, and
then tighten the four screws.

02.9698.0010 0 39

VARI❋LITE - VL3015LT SPOT LUMINAIRES SERVICE MANUAL

Tilt Motor Assembly and Tilt Belt Replacement

Vari-Lite Part No: 21.9698.0765 (Tilt Motor)
Vari-Lite Part No: 54.9698.0224 (Tilt Belt)

To remove and replace tilt motor:

Step 1. Remove power from luminaire.

WARNING: You must remove all power from luminaire before performing maintenance. Fixture
may be very HOT after operation. Allow it to cool completely before performing any maintenance.

Step 2. At tilt-side leg, remove yoke leg cover by removing four 6-32 x 3/8" PTB screws.
Step 3. Referring to Figure 2-18 on page 41, remove two 10-32 x 1/2" PPZ screws and remove tilt

sensor bracket. Disconnect wiring from encoder.
Step 4. Disconnect wiring and remove tilt assembly.
Step 5. Remove four 10-32 x 1/2" PPZ screws. Be mindful of tensioning springs.
Step 6. Remove belt from tilt pulley.
Step 7. Replace by performing previous steps in reverse order.

Note: Make sure wiring is not pinched during installation. When tightening four 10-32 x 1/2" 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 1. Follow instructions outlined in, "To remove and replace tilt motor:" above.

WARNING: You must remove all power from luminaire before performing maintenance. Fixture
may be very HOT after operation. Allow it to cool completely before performing any maintenance.

Step 2. At tilt-side leg, remove yoke leg cover by removing four 6-32x3/8" PTB screws.
Step 3. Disconnect the following wiring and remove tilt assembly:

a. Disconnect lamp wire from ignitor.

b. Disconnect black and red wires from relay.

c. Remove ignitor assembly mounting bracket (leave ignitor attached to bracket) by

removing three 6-32x3/8" PPZ screws and 1/4" standoff.

d. Disconnect ground wire from stud using 3/8" nut driver.
Step 4. Referring to Figure 2-18 on page 41, remove tilt belt.
Step 5. Replace by performing previous steps in reverse order.

40 02.9698.0010 0

MAINTENANCE PROCEDURES : TILT MOTOR ASSEMBLY AND TILT BELT REPLACEMENT

WARNING: Make sure wiring is not pinched during installation. When tightening four 10-32 x 1/2"
PPZ screws that mount Pan Motor Assembly, you must tighten in a CLOCKWISE pattern starting with
screw in lower left-hand side from spring.

NOTE:

Head not shown for clarity.

2

Sensor
Bracket

Tilt Motor
Assembly

Tilt Belt

Spring

Figure 2-18: Tilt Motor Assembly Replacement

02.9698.0010 0 41

VARI❋LITE - VL3015LT SPOT LUMINAIRES SERVICE MANUAL

Tilt Encoder PCB Replacement

Vari-Lite Part No: 24.9661.5000

To remove and replace tilt encoder PCB:

Step 1. Remove power from luminaire.

WARNING: You must remove all power from luminaire before performing maintenance. Fixture
may be very HOT after operation. Allow it to cool completely before performing any maintenance.

Step 2. At tilt-side leg, remove yoke leg cover by removing four 6-32x3/8" PTB screws.
Step 3. At tilt motor assembly, loosen four 10-32x1/2" PPZ screws.
Step 4. Remove belt from tilt pulley.
Step 5. Remove four 10-32x1/2" PPZ screws. Be mindful of tensioning springs.
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 tighten in a CLOCKWISE pattern starting with screw in lo wer left-hand side from
spring.

NOTE:

Head not shown for clarity.

Tilt Motor Assembly Detail

Tilt Motor
Assembly

Tilt Encoder

Tilt Belt

Spring

Sensor Bracket

Figure 2-19: Tilt Encoder PCB Replacement

42 02.9698.0010 0

MAINTENANCE PROCEDURES : TILT EOT SENSOR REPLACEMENT

Tilt EOT Sensor Replacement

Vari-Lite Part No: 23.9661.1253

To remove and replace tilt EOT sensor:

Step 1. Remove power from luminaire.

WARNING: You must remove all power from luminaire before performing maintenance. Fixture
may be very HOT after operation. Allow it to cool completely before performing any maintenance.

Step 2. At tilt-side leg, remove yoke leg cover by removing four 6-32 x 3/8" PTB screws.
Step 3. At sensor bracket, remove two 10-32 x 1/2" PPZ screws and remove bracket.
Step 4. Disconnect wiring from Tilt Encoder PCB.
Step 5. At sensor, remove two 6-32 x 3/8" PPZ screws and remove sensor from bracket.
Step 6. Replace by performing previous steps in reverse order.

2

Tilt EOT Sensor

Sensor
Bracket

Tilt Motor
Assembly

Tilt Belt

Spring

Figure 2-20: Tilt EOT Sensor Replacement

NOTE:

Head not shown for clarity.

02.9698.0010 0 43

VARI❋LITE - VL3015LT SPOT LUMINAIRES SERVICE MANUAL

Tilt Lock R eplacement

Vari-Lite Part No: 10.9698.1765

To remove and replace tilt lock:

Step 1. Remove power from luminaire.

WARNING: You must remove all power from luminaire before performing maintenance. Fixture
may be very HOT after operation. Allow it to cool completely before performing any maintenance.

Step 2. Remove Tilt Motor and Belt following instructions outlined in “Tilt Motor Assembly and

Tilt Belt Replacement” on page 40.

Step 3. Remove Pan Tube Wire Protection Bushing.
Step 4. Using a 2.5 mm Allen Wrench, remove Tilt Pulley by removing three M5 x 10MM STL

CUP PT screws.
Step 5. At Tilt Lock, remove four 6-32x3/16" PPZ screws and washers. Noting orientation remove

tilt lock plate.
Step 6. Replace in reverse order.

NOTE:

Drawing exploded for clarity.

Tilt Lock Plate

Figure 2-21: Tilt Lock Replacement

44 02.9698.0010 0

MAINTENANCE PROCEDURES : PAN MOTOR ASSEMBLY/PAN BELT REPLACEMENT

Pan Motor Assembly/Pan Belt Replacement

Vari-Lite Part No: 21.9698.0864 (Pan Motor)
Vari-Lite Part No: 54.9698.0224 (Pan Belt)

To remove and replace pan motor assembly:

Step 1. Remove power from luminaire.

WARNING: You must remove all power from luminaire before performing maintenance. Fixture
may be very HOT after operation. Allow it to cool completely before performing any maintenance.

Step 2. At each top enclosure cover, remove two 6-32 x 1/4" PPB screws and remove cover.
Step 3. In each corner from top, remove four 6-32 x 3/8" PPZ screws.

CAUTION: Be careful not to damage lens during next step.

2

Step 4. Carefully lay luminaire on its side, ensuring that lens does not come into contact with any

surface.
Step 5. At bottom of enclosure, remove four 1/4-20 x 3/4" socket screws and 1/4" split lock washers

and remove ventilation cover.
Step 6. Remove pan motor side handle by removing two 10-32 x 3/4" SCB screws.
Step 7. At enclosure bottom, remove two 6-32 x 1/4" PPB screws and pan motor side cover.
Step 8. At side of enclosure, remove two 6-32 x 3/8" PFZ screws and two 6-32 KEPS nuts that hold

two cable saddles. Pull wiring out of way of pan motor.
Step 9. Disconnect wiring from pan encoder PCB.
Step 10. At pan encoder PCB, remove two 4-40 x 1/4" screws and remov e pan encoder PCB.
Step 11. Loosen (but do not remove) four 10-32 x 3/4" SCB Cap screws.
Step 12. Move pan motor assembly toward pan pulley and remove belt from pan pulley.
Step 13. Carefully remove pan belt from around encoder wheel and pass it through tension rollers.
Step 14. Remove four 10-32 x 3/4" SCB Cap screws.
Step 15. Pull assembly out (be mindful of tension springs).
Step 16. Disconnect wiring.
Step 17. Replace by performing previous steps in reverse order.

Note: Make sure wiring is not pinched during installation. When tightening four 10-32 x 3/4" 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.

02.9698.0010 0 45

VARI❋LITE - VL3015LT SPOT LUMINAIRES SERVICE MANUAL

To remove and replace pan belt:

Step 1. Remove power from luminaire.

WARNING: You must remove all power from luminaire before performing maintenance. Fixture
may be very HOT after operation. Allow it to cool completely before performing any maintenance.

Step 2. At each top enclosure cover, remove two 6-32x1/4" PPB screws and remove cover.
Step 3. Disconnect the following cable assemblies:

a. Disconnect lamp wire from J202 and J203 at ballast.

b. Disconnect DC wire from LVS and fan DC regulator board.

c. Disconnect DMX wire from DMX PCB.

d. Disconnect Display wire from Display.

e. Remove ground wire from chassis.
Step 4. Remove pan motor assembly. See “To remove and replace pan motor assembly:” on

page 45.

Bottom
Cover

Step 5. Pass wire through routing hole in chassis
Step 6. Remove belt.
Step 7. Replace by performing previous steps in reverse.

Note: Make sure wiring is not pinched during installation. When tightening four 10-32 x 3/4" 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.

Pan Encoder PCB

Pan Encoder Wheel

Pan Motor Assembly

Pan Belt

Enclosure Bottom View

Figure 2-22: Pan Motor Assembly Replacement

46 02.9698.0010 0

MAINTENANCE PROCEDURES : PAN ENCODER PCB REPLACEMENT

2

Pan Encoder PCB R eplacement

Vari-Lite Part No: 24.9678.5000

To remove and replace pan encoder PCB:

Step 1. Remove power from luminaire.

WARNING: You must remove all power from luminaire before performing maintenance. Fixture
may be very HOT after operation. Allow it to cool completely before performing any maintenance.

CAUTION: Be careful not to damage lens during next step.

Step 2. Carefully lay luminaire on its side, ensuring that lens does not come into contact with any

surface.
Step 3. At bottom of enclosure, remove four 1/4-20 x 3/4" socket screws and 1/4" split lock washers

and remove ventilation cover.
Step 4. At encoder PCB, remove two 4-40 x 1/4" PPZ screws.
Step 5. Disconnect wiring from encoder board.
Step 6. Replace by performing previous steps in reverse order.

Note: Make sure the encoder disk passes through the optical sensor.

NOTE:

Head not shown for clarity.

Bottom Cover

Pan Motor
Assembly

Encoder Disk

Encoder PCB

Enclosure Bottom View

Figure 2-23: Pan Encoder PCB Replacement

02.9698.0010 0 47

VARI❋LITE - VL3015LT SPOT LUMINAIRES SERVICE MANUAL

Power Supply (LVS) Replacement

Vari-Lite Part No: 69.9698.0036

To remove and replace LVS:

Step 1. Remove power from luminaire.

WARNING: You must remove all power from luminaire before performing maintenance. Fixture
may be very HOT after operation. Allow it to cool completely before performing any maintenance.

Step 2. At enclosure, remove two 6-32 x 1/4" LG PPB screws from display side cover and rem ov e

cover.

Display Side Cover

NOTE:

Head not shown for clarity.

LVS AC and DC Connections

AC Input

Line

Neutral

Ground

Power Supply (LVS)

NOTE:

Drawing exploded for clarity.

Power Supply (LVS)

DC Output

VDC +
VDC -

Figure 2-24: Power Supply (LVS) Replacement

Step 3. At power supply, disconnect wiring (Including ground wire - ground wire, green/yellow AC

ground wire, is a ring terminal. You remove the screw to remove ground wire):

Location Connector

N White AC Wires
L Black AC Wires
V + Orange DC Wires*
V - Black DC Wires*

*Ring terminal connection. Must remove screw completely to remove wire.

Step 4. Remove one 6-32 x 3/8" LG PPZ screw. Note, this is the same screw mounting FAN DC

regulator board.
Step 5. Loosen two 6-32 x 3/8" LG PPZ screws and slide LVS towards upper enclosure fan to

remove.
Step 6. Replace by performing previous steps in reverse order.

48 02.9698.0010 0

MAINTENANCE PROCEDURES : DISPLAY PCB ASSEMBLY REPLACEMENT

2

Display PCB Assembly Replacement

VL Part No: 24.9678.3825

To remove and replace display PCB assembly:

Step 1. Remove power from luminaire.

WARNING: You must remove all power from luminaire before performing maintenance. Fixture
may be very HOT after operation. Allow it to cool completely before performing any maintenance.

Step 2. Remove LVS following instructions in “Power Supply (LVS) Replacement” on page 48.
Step 3. At Display PCB, remove two 6-32 x 3/8" PPZ screws, remove Display stiffener bracket and

lift PCB out of slot on bottom of chassis.
Step 4. Carefully disconnect wiring from PCB.

Note: When installing, check that all four menu buttons press in before tightening two 6-32 x 3/8"
PPZ screws.

Step 5. Replace by performing steps in reverse order.

LVS Power Supply

Display Panel
Assembly

Display
Cover

NOTE:

Some components not shown for clarity.

NOTE:

Drawing exploded for clarity.

Display

Display Panel Assembly

Display
PCB

Figure 2-25: Display PCB Assembly Replacement

02.9698.0010 0 49

VARI❋LITE - VL3015LT SPOT LUMINAIRES SERVICE MANUAL

Po werCon AC Input Connector Assembly Replacement

VL Part No: 25.9679.0001

To remove and replace PowerCon AC input connector assembly:

Step 1. Remove power from luminaire.

WARNING: You must remove all power from luminaire before performing maintenance. Fixture
may be very HOT after operation. Allow it to cool completely before performing any maintenance.

Step 2. Remove LVS following instructions in “Power Supply (LVS) Replacement” on page 48.
Step 3. Disconnect wiring from PowerCon connector.
Step 4. At front panel, remove two 4-40 x 3/8" PFB screws
Step 5. Pull Connector to inside of enclosure. Remove connector from Neutrik backing plate. Plate

will be used for new connector
Step 6. Replace in reverse order

Note: Brown wire is Line, Blue wire is Neutral and Green/Yellow wire is Earth (Ground).

Step 7. Replace by performing steps in reverse order.

LVS Power Supply

Display Panel Assembly

Screws

Display

Display Panel
Assembly

Cover

NOTE:

Some components not shown for clarity.

NOTE:

Drawing exploded for clarity.

PowerCon Connector

Backing Plate

Figure 2-26: PowerCon AC Input Connector Assembly Replacement

50 02.9698.0010 0

MAINTENANCE PROCEDURES : DMX PCB ASSEMBLY REPLACEMENT

2

DMX PCB Assembly Replacement

VL Part No: 24.9664.4895

To remove and replace DMX PCB assembly:

Step 1. Remove power from luminaire.

WARNING: You must remove all power from luminaire before performing maintenance. Fixture
may be very HOT after operation. Allow it to cool completely before performing any maintenance.

Step 2. Remove LVS following instructions in “Power Supply (LVS) Replacement” on page 48.
Step 3. At DMX PCB assembly, disconnect wiring from PCB.
Step 4. At front panel, remove four 4-40 x 3/8" PFB screws
Step 5. Remove PCB to inside of enclosure.

Note: When installing, always ensure the release for the female XLR is on the outside of the panel and
moves freely when pushed.

Step 6. Replace by performing steps in reverse order.

Display Panel
Assembly

Display
Cover

LVS Power Supply

NOTE:

Some components not shown for clarity.

DMX PCB
Assembly

Display Panel Assembly

Screws

NOTE:

Drawing exploded for clarity.

Figure 2-27: DMX PCB Assembly Replacement

02.9698.0010 0 51

VARI❋LITE - VL3015LT SPOT LUMINAIRES SERVICE MANUAL

Upper Enclosure Fan Assembly Replacement

VL Part No: 23.9698.0686

To remove and replace upper enclosure fan assembly:

Step 1. Remove power from luminaire.

WARNING: You must remove all power from luminaire before performing maintenance. Fixture
may be very HOT after operation. Allow it to cool completely before performing any maintenance.

Step 2. Remove LVS following instructions in “Power Supply (LVS) Replacement” on page 48.
Step 3. Disconnect fan wiring from voltage regulator board.
Step 4. Note placement of and cut cable ties as required. Also note wire routing.
Step 5. At fan, remove three 6-32 x 3/8" PPZ screws and remove fan.
Step 6. Replace by performing steps in reverse order.

NOTE:

Drawing exploded for clarity.

Figure 2-28: Upper Enclosure Fan Assembly Replacement

Fan Assembly

NOTE:

Some components not shown for clarity.

Display Cover

Fan Assembly

52 02.9698.0010 0

MAINTENANCE PROCEDURES : FAN REGULATOR BOARD (UPPER ENCLOSURE) REPLACEMENT

Fan Regulator Board (Upper Enclosure) Replacement

VL Part No: 24.9698.1690

To remove and replace fan regulator board in the upper enclosure:

Step 1. Remove power from luminaire.

WARNING: You must remove all power from luminaire before performing maintenance. Fixture
may be very HOT after operation. Allow it to cool completely before performing any maintenance.

Step 2. At enclosure, remove two 6-32x1/4" PPB SEMS screws from display side cover and remove

cover.
Step 3. At Fan Regulator Board Assembly (22.9698.0690), remove one 6-32 x 3/8" PPZ SEMS

screw securing assembly to LVS.
Step 4. Disconnect wiring from Fan Regulator Board.
Step 5. Remove two 4-40x1/4" PPSS screws and remove Regulator Board from mounting plate

2

Step 6. Replace by performing steps in reverse order.

Fan Regulator

Display Cover

NOTE:

Drawing exploded for clarity.

Mounting Plate

NOTE:

Some components not shown for clarity.

Fan Regulator Board Assembly (upper enclosure)

Fan Regulator

Board

Fan Regulator Board Assembly

Figure 2-29: Fan Regulator Board (Upper Enclosure) Replacement

02.9698.0010 0 53

VARI❋LITE - VL3015LT SPOT LUMINAIRES SERVICE MANUAL

Pan Lock Replacement

VL Part No: 10.9698.0820

To remove and replace pan lock:

Step 1. Remove power from luminaire.

WARNING: You must remove all power from luminaire before performing maintenance. Fixture
may be very HOT after operation. Allow it to cool completely before performing any maintenance.

Step 2. At each top enclosure cover, remove two 6-32 x 1/4" PPB screws and remove cover.

NOTE:

Head not shown for clarity.

Top Covers

NOTE:

Drawing exploded for clarity.

Bottom Cover

Display Side Handle

Display Cover

Figure 2-30: Enclosure Covers Removal

Step 3. At display side front cover, remove two 6-32 x 3/8" PPZ screws from each corner.

CAUTION: Be careful not to damage lens in the next step.

Step 4. Carefully lay luminaire on its side, ensuring that lens does not come into contact with any

surface.
Step 5. At bottom of enclosure, remove four 1/4-20 x 3/4" socket screws and 1/4" split lock washers

and remove ventilation cover.
Step 6. Remove handle on display side front cover by removing two 10-32 x 3/4" SCB screws.

54 02.9698.0010 0

MAINTENANCE PROCEDURES : PAN LOCK REPLACEMENT

2

Step 7. At enclosure bottom, remove two 6-32 x 1/4" PPB screws and remove cover without handle.
Step 8. Remove two 6-32 x 3/8" PFZ screws from enclosure side and remove Upper Enclosure Air

Duct.
Step 9. Remove two 10-32 Hex nuts holding pan lock in place.

Note: When removing, note placement of springs, flat washers, glides, pan lock spring (especially
note orientation) and pan lock cover.

Step 10. Replace in reverse order.

10-32 Hex Nut

Washer
Spring

Spring Plate

Glide Plate

Pan Lock

Glide Plate

NOTE:

Some components not shown for clarity.

Figure 2-31: Pan Lock Removal and Replacement

02.9698.0010 0 55

VARI❋LITE - VL3015LT SPOT LUMINAIRES SERVICE MANUAL

Gobo Timing Adjustments

The index timing belt must be aligned so that the mechanism "clocks" properly. This belt is installed
around the index gear (top gear) of the gobo wheel. The wheel position belt is installed around the
wheel position gear (bottom gear) of the gobo wheel, and does not require alignment. Each belt is also
routed around one motor pulley.

For the following steps, refer to Figure 2-33 and Figure 2-34.

To time gobo wheels:

Step 1. Align all holes in wheels as shown below.
Step 2. Insert a 3" long #4 or M3 screw (or 0.125" diameter pin) completely through aligned holes

in wheel and bulkhead plates as shown. This will lock the wheels in the "open" position.

Insert screw or pin here

Align

Figure 2-32: Gobo Wheel - Timing Adjustments

Step 3. To time each gobo wheel, first align planet gear timing mark with hole in wheel. Loosen

index belt just enough to slip teeth and rotate index pulley to center slot in optical sensor as

shown. 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.

56 02.9698.0010 0

MAINTENANCE PROCEDURES : GOBO TIMING ADJUSTMENTS

Gobo Timing Adjustments (continued)

Position index pulley so large flange is

1)

centered in optical sensor

Insert a 3" long #4 or M3 screw (or

2)

0.125" diameter pin) completely
through aligned holes in wheels and
both bulkheads as shown. This will lock
the wheels in the "open" position.

Adjust individual wheels as follows...

3)

First align planet gear timing mark with
hole 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.

2

Align

Figure 2-33: Gobo Timing Adjustments

02.9698.0010 0 57

VARI❋LITE - VL3015LT SPOT LUMINAIRES SERVICE MANUAL

Gobo Gear Planet Alignment

Each gear of the gobo wheel assembly must be aligned so that the gobos will index correctly. Use the
following procedure to re-align the gears in the event the gobo wheel is disassembled.

To re-align gobo gears:

Step 1. Place center (sun) gear at starting point so that timing mark is directly facing Position 1

(open) as shown in Figure 2-34.
Step 2. Set Position 6 planet gear 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 gears are aligned, rotate

center gear in full rotation to verify alignments and to verify that assembly spins freely.

When rotating, marks should align perfectly at each gear as they pass. Adjust as necessary

and recheck. There should be no drag in the movement.

- See next page for further instructions -

58 02.9698.0010 0

MAINTENANCE PROCEDURES : GOBO GEAR PLANET ALIGNMENT (CONTINUED)

Gobo Gear Planet Alignment (continued)

2

1) Start with center gear timing
mark facing Position 1 (open).

Alignment Mark

1

open

2

5

3

4

2) Rotate center gear clockwise until timing

mark is directly across from Position 2.
Rotate Position 2 gear until timing marks
align.

2

Align both marks

3

3) Align remaining gobo gears using

the same method.

4) Verify alignment of all marks and
adjust as necessary.

Align Marks

Figure 2-34: Aligning Gobo Planet Gears

02.9698.0010 0 59

VARI❋LITE - VL3015LT SPOT LUMINAIRES SERVICE MANUAL

Notes

60 02.9698.0010 0

CHAPTER 3.

Illustrated Parts Breakdown

This chapter contains illustrated parts breakdowns for all VL3015LT Spot Luminaire assemblies.

• Drawing Trees

• Top Assembly

• Head Assembly

• Yoke Assembly

• Enclosure Assembly

• Cable Assemblies

02.9698.0010 0 61

VARI❋LITE - VL3015LT SPOT LUMINAIRE SERVICE MANUAL

Drawing Trees

VL3015LT Spot Luminaire

VL3015LT Spot Luminaire

20.9698.0001 Rev. N

Generic Luminaire Assembly

21.9698.0010 Rev. M

Head Structure Assembly

21.9698.0600 Rev. E

Backend Assembly

21.9698.0615 Rev J

Color / Gobo Access Fan

Assembly

21.9698.0620 Rev E

80MM DC Fan Assembly

21.9698.0616 Rev B

Hot Box Assembly

21.9686.0680 Rev H

Head to Back Cap Ground Cable

Assembly

25.9661.1522 Rev C

Reflector Mount Assembly

21.9686.0605 Rev . D

Gobo Clamp Assembly

22.9678.0693 Rev A

Color Clamp Assembly

22.9678.0694 Rev A

36V Interconnect Cable Assembly

25.9698.001 1 Rev 0

36V Yoke Reg PCB Cable

Assembly

25.9698.0012 Rev A

Gobo (MCB to Interconnect) Cable

Transfer Fan to Interconnect Cable

Assembly

25.9698.0209 Rev B

Assembly

25.9698.0622 Rev D

Gobo Clamp (with Cover Support)

Included Items Kit, VL3015LT Spot

Color (MCB to Interconnect) Cable

Assembly

22.9698.0693 Rev A

Head Cover Assembly

21.9698.0611 Rev. D

28.9698.0001 Rev. F

Optics (MCB to Interconnect)

Cable Assembly

25.9698.0109 Rev A

Assembly

25.9698.0409 Rev C

OT Switch to Backcap Interlok

Cable Assembly

25.9698.0601 Rev B

Lamp and Bulkhead Fans Cable

Ignitor to Lamp Socket Cable

Assembly

25.9698.0650 Rev A

Assembly

25.9698.1688 Rev A

VL3015LT Optic Assembly

21.9698.0100 Rev V

Frost / Prism Bulkhead Assembly

21.9698.1351 Rev. E

Optics Bulkhead Cable Assembly

25.9698.1110 Rev B

Prism Assembly

21.9698.0311 Rev. G

Continued Next Page

Continued Next Page

Figure 3-1: VL3015LT Spot Luminaire Subassembly Drawing Tree Part 1

62 02.9698.0010 0

DRAWING TREES : VL3015LT SPOT LUMINAIRE

VL3015LT Spot Luminaire (continued)

3

Continued From Previous Page

Generic Luminaire Assembly

21.9698.0010 Rev. M

Yoke Assembly

21.9698.0765 Rev D

Tilt Motor Assembly

21.9698.0765 Rev D

Yoke Fan Assembly

22.9661.0609 Rev D

Ignitor to Relay Cable Assembly

25.9661.1526 Rev C

Yoke Fan Cable Assembly

25.9678.0758 Rev A

Color/Strobe Module Assembly

21.9698.0400 Rev E

Fixed Color Wheel 2 Assembly

21.9686.1480 Rev A

Fixed Color Wheel 1 Assembly

21.9698.1484 Rev B

Strobe System Assembly

21.9698.2404 Rev D

Top Strobe Blade Assembly

21.9698.2437 Rev B

Continued From Previous Page

VL3015LT Spot Luminaire

20.9698.0001 Rev. N

Gobo Module Assembly

21.9698.0200 Rev H

Rotating Gobo Wheel Assembly

21.9698.021 1 Rev B

Iris Sub-Assembly

21.9698.0270 Rev H

Interconnect to Gobo Cable

25.9698.0210 Rev B

Iris Fan Cable Assembly

25.9679.0007 Rev A

Assembly

24V Relay to Interconnect Cable

Yoke Fan t o Volt Reg PCB Cable

Upper Enclosure Assembly

21.9698.0800 Rev. N

Assembly

25.9698.0015 Rev A

Assembly

25.9698.0681 Rev B

Continued Next Page

Figure 3-2: VL3015LT Spot Luminaire Subassembly Drawing Tree Part 2

Bottom Strobe Blade Assembly

21.9698.2438 Rev B

Interconnect to Color Cable

Assembly

25.9698.0410 Rev B

02.9698.0010 0 63

VARI❋LITE - VL3015LT SPOT LUMINAIRE SERVICE MANUAL

VL3015LT Spot Luminaire (continued)

Continued From Previous Page

Upper Enclosure Assembly

21.9698.0800 Rev . N

Stabilizer Assembly

21.9678.0767 Rev 0

Machined Pan Tube Assembly

21.9698.0881 Rev 0

High Flow Exhaust Fan Assembly

21.9679.0811 Rev A

Pan Motor Assembly

21.9698.0864 Rev E

Ventilation Cover Assembly

21.9698.0840 Rev D

Fan Regulator Board Assembly

22.9698.0690 Rev B

36V Supply Cable Assembly

25.9698.1010 Rev B

LVS Chassis Ground Cable

Assembly

25.9698.2514 Rev A

LVS Chassis Ground Cable

Assembly

25.9661.1514 Rev A

Chassis To Yoke Ground Cable

Fan Exhaust Cable Assembly

Assembly

25.9661.1520 Rev C

Ballast to Controller Cable

Assembly

25.9678.0816 Rev A

Display Cable Assembly

25.9678.1825 Rev A

25.9698.0832 Rev B

Figure 3-3: VL3015LT Spot Luminaire Subassembly Drawing Tree Part 3

Input Panel Assembly

21.9698.0805 Rev C

Data I/O Link Cable Assembly

25.9678.0813 Rev A

Lamp Supply to Relay Cable

Assembly

25.9678.0829 Rev A

Pan / Tilt Cable Assembly

25.9698.0801 Rev A

Ballast Power Cable Assembly

25.9698.1003 Rev B

AC Input Connector/Cable

Assembly

25.9679.0001 Rev 0

64 02.9698.0010 0

TOP ASSEMBLY : INCLUDED ITEMS KIT, VL3015LT SPOT

Top Assembly

Included Items Kit, VL3015LT Spot

28.9698.0001 Rev. F

Refer to Figure 3-4.

No. Item Qty. UM. Description

1 02.8001.0002 1 EA VARI-LITE QUALITY ASSURANCE CERT.
2 02.8052.0001 1 EA CARD, LIMITED WARRANTY
3 02.8406.0001 1 EA TAG, LAMP NOTICE
4 02.8700.0001 1 EA CARD, PRODUCT REGISTRATION
5 02.9698.0001 1 EA UNPACK/QUICK ST ART SHEET, VL3015LT

- 04.4037.0001 5 EA LABEL, 2.5 X .5 BARCODE (not shown)

- 07.9686.0001 1 EA CARDBOARD SHIPPING BOX (not shown)

6 08.3015.1001 1 EA CD-ROM, VL3015LT PRODUCT DOCUMENTATION, USER
7 22.9661.1636 2 EA FAB ASSY, BRACKET TRUSS HOOK
8 41.6098.7029 1 EA GOBO ASSY, ALPHA RAYS (POS 1-2)

9 41.6098.5011 1 EA GOBO ASSY, NIGHT SKY (POS 1-3)
10 41.6098.4003 1 EA GOBO ASSY, RAY (POS 1-4)
11 41.6098.7015 1 EA GOBO ASSY, BLOCK BREAKUP (POS 1-5)
12 41.6098.8513 1 EA GAG ASSY, PLOWED (POS 2-2)
13 41.6098.8506. 1 EA GAG ASSY, DROPLETS (POS 2-3)
14 41.6098.8511 1 EA GAG ASSY, ON THE ROCKS (POS 2-4)
15 41.6098.8512 1 EA GAG ASSY, PANGEA (POS 2-5)
16 41.6098.6011 1 EA GOBO ASSY, CIRCLE OF OVALS (POS 3-2)
17 41.6098.8801 1 EA GOBO ASSY, MULTI-COLOR CIRCLES (POS 3-3)
18 41.6098.7002 1 EA GOBO ASSY, PEBBLES (POS 3-4)
19 41.6098.4211 1 EA GOBO ASSY, UNEVEN BARS (POS 3-5)
20 71.9686.1502 1 EA LAMP, 1500 WATT SHORT ARC, DOUBLE-ENDED, HTI 1500 D7/60

3

02.9698.0010 0 65

VARI❋LITE - VL3015LT SPOT LUMINAIRE SERVICE MANUAL

Included Items Kit, VL3015LT Spot (continued)

1

5

2

6

8

Alpha Rays

12 13 14 15

3

7

(x2)

9

Night Sky

4

20*

10

Ray

11

Block Breakup

Plowed Gag Droplets Gag On the Rocks Gag Pangea Gag

16 17 18 19

Circle of Ovals Multi-Color Circles Pebbles Uneven Bars

Figure 3-4: Included Items Kit, VL3015LT Spot

Note: * = Do not handle lamp with bare hands. When handling, it is best to wear clean cotton gloves

in order to keep the lamp’s glass as dirt and grease free as possible.

66 02.9698.0010 0

TOP ASSEMBLY : VL3015LT SPOT LUMINAIRE

VL3015LT Spot Luminaire

20.9698.0001 Rev. N

Refer to Figure 3-5

No. Item Qty. UM. Description

- 04.9698.0061 1 EA LABEL, AC INPUT RATING VL3015LT (not shown)

1 10.9686.0617 1 EA YOKE CROSS MEMBER, HEAT SHIELD

2 10.9698.1679 1 EA MOUNT, TRANSFER FAN, LT

3 10.9698.2125 1 EA MOUNT, INTERCONNECT BOARD

4 12.9698.0614 1 EA PAINTED FRONT COVER, VL3015LT

5 12.9698.0732 2 EA PAINTED YOKE ARM COVER

6 21.9698.0010 1 EA ASSY, GENERIC LUMINAIRE, VL3015LT

7 21.9698.0200 1 EA ASSY, GOBO MODULE

8 21.9698.0400 1 EA ASSY, COLOR / STROBE MODULE

9 21.9698.0611 2 EA ASSY, HEAD COVER, VL3015LT
10 22.9698.0693 2 EA ASSY, GOBO CLAMP W/ COVER SUPPORT
11 22.9678.0694 2 EA ASSY, COLOR CLAMP
12 22.9698.1690 1 EA LT FAN VOLTAGE REGULATOR ASSY, YOKE ARM
13 24.9698.0700 1 EA MCB ASSY, MAIN CONTROLLER, VL3015LT
14 24.9698.2680 1 EA ASSY, INTERCONNECT PCB

- 25.9698.0011 1 EA CABLE ASSY, 36V INTERCONNECT (not shown)

- 25.9698.0012 1 EA CABLE ASSY, YOKE VOLTAGE REG BOARD (not shown)

- 25.9698.0109 1 EA CABLE ASSY, OPTICS, MCB TO INTERCONNECT (not shown)

- 25.9698.0209 1 EA CABLE ASSY, GOBO, MCB TO INTERCONNECT (not shown)

- 25.9698.0409 1 EA CABLE ASSY , COLOR, MCB TO INTERCONNECT (not shown)

- 25.9698.0622 1 EA CABLE ASSY, TRANSFER FAN TO INTERCONNECT (not shown)

- 28.9698.0001 1 EA INCLUDED ITEM KIT, VL3015 SPOT (not shown)

15 40.7113.0012 1 EA FAN, TUBAXIAL, 80 MM, 24VDC, HIGH SPEED
16 53.6523.0013 8 EA SCREW, 6-32 X 3/8" PTB
17 53.6558.0007 8 EA SCREW, 6-32 X 1/4" PPZ SEMS
18 53.6558.0009 2 EA SCREW, 6-32 X 3/8" PPZ SEMS
19 53.6558.0016 2 EA SCREW, 6-32 X 3/4" PPZ SEMS
20 53.6571.0002 4 EA SCREW, 6-32 X 1-1/4" PPB
21 53.6613.0008 4 EA SCREW, 6-32 X 1/2" PPZ SEMS
22 53.6625.0001 4 EA SCREW, 10-32 X 1/2" PPB
23 55.2150.0002 2 EA STANDOFF, 1/4" HEX 6-32 X 1.187" MF

3

02.9698.0010 0 67

VARI❋LITE - VL3015LT SPOT LUMINAIRE SERVICE MANUAL

No. Item Qty. UM. Description

24 55.2233.2001 8 EA DZUS RAPIER MINI CLIP-ON RETAINER
25 55.6677.0033 4 EA WASHER, 0.281" OD, 0.125" ID, 0.032" THK
26 22.9678.0693 1 EA ASSY, GOBO CLAMP

68 02.9698.0010 0

TOP ASSEMBLY : VL3015LT SPOT LUMINAIRE

VL3015LT Spot Luminaire (continued)

3

24 (x8)

11 (x2)

8

10 (x2)

2, 15

18 (x4)

26

17 (x8)

7

9 (x2)

22 (x4)

4

14

3

21 (x4)

16 (x8)

19 (x2)

6

1

18 (x2)

12

23 (x2)

25 (x4)

13

5 (x2)

Figure 3-5: VL3015LT Spot Luminaire

02.9698.0010 0 69

VARI❋LITE - VL3015LT SPOT LUMINAIRE SERVICE MANUAL

Generic Luminaire Assembly

21.9698.0010 Rev. M

Refer to Figure 3-6

No. Item Qty. UM. Description

1 10.9698.0002 2 EA GROMMET, PROTECT, 2.9 INCHES

2 10.9698.0701 1 EA YOKE ARM AIR PLENUM, MCB COOLING

3 10.9698.0768 4 EA FOAM SPRING, TILT LOCK

4 10.9698.0769 4 EA STANDOFF, TILT LOCK

5 10.9698.1766 1 EA SPRING, TILT LOCK

6 10.9698.2765 1 EA PLATE, TILT LOCK, FOUR SLOTS, W/ TAB

7 21.9678.0767 1 EA ASSY, STABILIZER
7a - 10.9678.0757 1 EA STABILIZER, 1.377 DIA
7b - 10.9678.0762 1 EA BRACKET, STABILIZER
7c - 53.6610.0003 1 EA SCREW, 6-32 X 7/16" PPZ
7d - 55.6568.0075 1 EA SPRING, EXTSN 0.375" OD 1.00" LG 0.041" WIRE DIA

8 21.9698.0600 1 EA ASSY, HEAD/OP TICS

9 21.9698.0700 1 EA ASSY, YOKE
10 21.9698.0707 1 EA ASSY, DRIVEN PULLEY
11 21.9698.0800 1 EA UPPER ENCLOSURE
12 53.2019.0004 4 EA NUT, 3/8-16 X 7/32" THK HEX JAM G
13 53.5565.0250 1 EA SCREW, #6-32 X 1/4" PFB UNDERCUT
14 53.6505.0020 5 EA BOLT, 1/4-28 X 3/4" HEX HD GRD 8
15 53.6505.0026 4 EA BOLT, 1/4-20 X 1/2" HEX HD
16 53.6513.0044 3 EA SCREW, M5 X 10MM STL CUP PT
17 53.6539.0001 4 EA WASHER, 3/8" SPLIT LOCK
18 53.6553.0010 4 EA SCREW, 10-32 X 5/8" PFB
19 53.6558.0007 1 EA SCREW, 6-32 X 1/4" PPZ SEMS
20 53.6587.0001 2 EA SCREW, 4-40 X 1/8" PPZ
21 53.6683.0015 4 EA SCREW, 6-32 X 3/16" PPZ SEMS
22 54.1206.0014 2 EA RING , RETAINING, 1.375" SHAFT
23 54.1255.0001 2 EA BEARING/HOUSING ASSY
24 54.9698.0224 1 EA BELT, TIMING, S2M 210GRV 15MM WIDE URTH/KVLR
25 55.2179.0001 1 EA CABLE ANCHOR MOUNT, #6 SCREW MTG
26 55.6549.0001 5 EA WASHER, 1/4" SPLIT LOCK
27 55.6677.0035 8 EA WASHER, PROTECTIVE

70 02.9698.0010 0

TOP ASSEMBLY : GENERIC LUMINAIRE ASSEMBLY

No. Item Qty. UM. Description

28 55.6677.0045 4 EA WASHER, 0.260"ID, 0.500"OD, 0.030" THK
29 55.6799.0001 2 EA SHIM, 1-3/8" ID 1-7/8"OD, 0.010" THK, SS
30 55.6799.0002 2 EA SHIM, 1-3/8" ID 1-7/8"OD, 0.005" THK, SS

3

02.9698.0010 0 71

VARI❋LITE - VL3015LT SPOT LUMINAIRE SERVICE MANUAL

Generic Luminaire Assembly (continued)

16 (x3)

24

20 (x2)

14 (x5), 26 (x5)

10

21 (x4)

5

6

27 (x8)

28 (x4)

3 (x4)

Detail

B

4 (x4)
12 (x2)

22

17 (x2)

15 (x2)

8

15 (x2)

13

17 (x2)
23 (x2)

22

12 (x2)

7

Detail A

19

25

Detail

B

18 (x4)

Note position and orientation
of safety tether.

Detail A

7b

7c

7d

11

Detail B

7a

30 (x2)

Figure 3-6: Generic Luminaire Assembly

2

1

9

29 (x2)

INSTALL ITEMS 24 & 25 AS SHOWN
BETWEEN ITEM 19 AND ITEM 5. IF

SNAP RING WILL NOT SEAT IN
GROOVE PROPERLY WITH BOTH
ITEMS 24 & 25 INSTALLED, RE MOVE
ITEM 25 (.005" THK) AND LEAVE ITEM
24 (.010" THK).

72 02.9698.0010 0

TOP ASSEMBLY : HEAD COVER ASSEMBLY

Head Cover Assembly

21.9698.0611 Rev. D

Refer to Figure 3-7

No. Item Qty. UM. Description

1 10.9678.0674 1 EA BRACKET, COVER TETHER
2 10.9698.0612 1 EA FOAM BAFFLE, HEAD COVER
3 10.9698.0696 1 EA FOAM FRAME, HEAD COVER
4 12.9698.0610 1 EA PAINTED HEAD COVER, VL3015LT
5 53.5655.0250 4 EA SCREW, #6 X 1/4" PPZ PLASTIC THD
6 53.6558.0003 1 EA SCREW, 6-32 X 3/8" PPZ PLASTIC THD
7 55.2233.2003 4 EA DZUS RAPIER 1/4-TURN STUD RETAINER, 5 MM
8 55.2233.2008 4 EA DZUS RAPIER 1/4-TURN STUD, 5 MM, 14MM
9 55.6599.0001 4 EA WASHER, FLAT BLACK, #10

3

3

5 (x4)

7 (x4)

6

1

9 (x4)

8 (x4)

2*

4

Bottom View

*Note, secure foam by driving four screws (item 5) through frame into foam to cover.

Figure 3-7: Head Cover Assembly

02.9698.0010 0 73

VARI❋LITE - VL3015LT SPOT LUMINAIRE SERVICE MANUAL

Gobo Clamp (with Cover Support) Assembly

22.9698.0693 Rev A

Refer to Figure 3-8

No. Item Qty. UM. Description

1 10.9698.0626 1 EA COVER SUPPORT, CLAMP
2 12.9678.0691 1 EA GOBO CLAMP
3 53.6525.0188 1 EA SCREW, 6-32 X 3/16" LG PPZ SEMS
4 53.6685.0625 2 EA SCREW, CAPTIVE PANEL, 6-32 X 0.625" LG PPS ZINC PLATED
5 55.6538.0001 2 EA WASHER, #6 LOCK INTERNAL TOOTH

4 (x2)

2

5 (x2)

3 *

1

* Note: Install item 3 with Loctite 242 (Blue) thread locker.

Figure 3-8: Gobo Clamp (with Cover Support) Assembly

74 02.9698.0010 0

TOP ASSEMBLY : GOBO CLAMP ASSEMBLY

Gobo Clamp Assembly

22.9678.0693 Rev A

Refer to Figure 3-9

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

3

2 (x2)

1

3 (x2)

4 *

* Note: Install item 4 with Loctite 242.

Figure 3-9: Gobo Clamp Assembly

02.9698.0010 0 75

VARI❋LITE - VL3015LT SPOT LUMINAIRE SERVICE MANUAL

Color Clamp Assembly

22.9678.0694 Rev A

Refer to Figure 3-10

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

4 *

1

3 (x2)

2 (x2)

* Note: Install item 4 with Loctite 242 (Blue) thread locker.

Figure 3-10: Color Clamp Assembly

76 02.9698.0010 0

HEAD ASSEMBLY : HEAD STRUCTURE ASSEMBLY

Head Assembly

Head Structure Assembly

21.9698.0600 Rev. E

Refer to Figure 3-11

No. Item Qty. UM. Description

1 10.9698.0627 1 EA COVER SUPPORT, SIDE RAIL
2 12.9698.0623 1 EA SIDE RAIL, MACHINED
3 12.9698.0625 1 EA SIDE RAIL, MACHINED
4 21.9686.0605 1 EA ASSY, REFLECTOR MOUNT
5 21.9698.0100 1EAASSY, LT OPTICS
6 21.9698.0615 1 EA ASSY, BACK END
7 53.6515.0001 6 EA SCREW, 10-32 X 3/4, SCB
8 53.6581.0001 4 EA SCREW, 4-40 X 1-3/8" PPZ

9 53.6613.0008 4 EA SCREW, 6-32 X 1/2" PPZ SEMS
10 55.6682.0037 4 EA SCREW, 10-32 X 1/2" PPZ SEMS
11 55.2203.0001 2 EA SCREW, 4-40 X 1/4" PPZ
12 55.2233.2007 8 EA DZUS RAPIER MINI CLIP-ON RETAINER, BLK

3

02.9698.0010 0 77

VARI❋LITE - VL3015LT SPOT LUMINAIRE SERVICE MANUAL

Head Structure Assembly (continued)

6

4

8 (x4)

7 (x6)

11 (x2)

1

12 (x8)

3

10 (x4)

2

9 (x4)

5

Figure 3-11: Head Structure Assembly

78 02.9698.0010 0

HEAD ASSEMBLY : REFLECTOR MOUNT ASSEMBLY

Reflector Mount Assembly

21.9686.0605 Rev. D

Refer to Figure 3-12

No. Item Qty. UM. Description

1 10.9686.0632 1 EA REFLECTOR CLAMP

2 10.9686.0644 4 EA SPRING, REFLECTOR MOUNT

3 21.9686.0606 1 EA ASSY, UV GLASS

4 42.9686.0120 1 EA REFLECTOR, ELLIP TICAL

5 53.6683.0015 4 EA SCREW, 6-32 X 5/8" PPB SEMS

3

5 (x4)

1

4

2 (x4)

3

Figure 3-12: Reflector Mount Assembly

02.9698.0010 0 79

VARI❋LITE - VL3015LT SPOT LUMINAIRE SERVICE MANUAL

VL3015LT Optic Assembly

21.9698.0100 Rev V

Refer to Figure 3-13

No. Item Qty. UM. Description

1 10.9689.0175 1 EA STRAP, GROUP 2

2 10.9689.0176 2 EA STRAP, GROUP 3/4

3 10.9698.0120 1 EA ZOOM MOUNT, BSL OPTICS

4 10.9698.0123 1 EA LIGHT BAFFLE, ZOOM TRAY

5 10.9698.0126 1 EA STOP PLATE, GROUP 2

6 10.9698.0143 1 EA RAIL COVER, ZOOM

7 10.9698.0144 1 EA FLOCKING PIECE, RAIL COVER

8 10.9698.0145 1 EA FLOCKING PIECE, ZOOM SUPPORT

9 10.9698.1121 1 EA MOUNT, LEAD SCREW, ZOOM
10 10.9698.2119 1 EA SUPPORT, FRONT RAIL, SHORT
11 12.9698.0116 1 EA MOUNT, FRONT LENS GROUP
12 12.9698.0131 2 EA MOUNT, EDGE/COMP LENS GROUPS, MACHINED
13 12.9698.1133 1 EA MOUNT, ZOOM LENS GROUP, MACHINED
14 21.9698.1351 1 EA ASSY , FROST/PRISM BULKHEAD
15 22.9698.0120 1 EA LINEAR RAIL, 344 MM, 3 CARRIAGE
16 22.9698.0151 1 EA LENS ASSY, GROUP 1
17 22.9698.0152 1 EA LENS ASSY, GROUP 2
18 22.9698.0153 1 EA LENS ASSY, GROUP 3
19 22.9698.0154 1 EA LENS ASSY, GROUP 4
20 10.9698.0146 1 EA SHAFT, ZOOM MOTOR ASSY, VL3015LT
21 44.9698.0147 3 EA MOTOR ASSY, ZOOM ACTUATOR

- 25.9698.1110 1 EA CABLE ASSY, OPTICS BULKHEAD (not shown)

22 53.2004.0002 2 EA NUT, 8-32 KEPS ZINC PLATED
23 53.2202.0008 3 EA NUT, 8-32 HEX SS NYLON INSERT
24 53.6513.0023 8 EA SCREW, M3 0.5 X 8 MM LG, PFZ, METRIC
25 53.6513.0034 4 EA SCREW, M3 0.5 X 10 MM LG, PFZ, METRIC
26 53.6522.0004 8 EA SCREW, #6-32 X 1/4" SOC HD
27 53.6523.0001 3 EA SCREW, 6-32 X 3/8" SCB
28 53.6558.0007 3 EA SCREW, 6-32 X 1/4" PPZ SEMS
29 53.6558.0009 4 EA SCREW, 6-32 X 3/8" PPZ SEMS
30 53.6575.0009 8 EA SCREW, 8-32 X 3/8" PPB SEMS

80 02.9698.0010 0

HEAD ASSEMBLY : VL3015LT OPTIC ASSEMBLY

No. Item Qty. UM. Description

31 53.6576.0038 12 EA SCREW, M3 X 8 MM PPZ SEMS
32 53.6594.0003 2 EA SCREW, 10-32 X 1.50" PPZ
33 53.6609.0001 4 EA SCREW, 6-32 X 3/8" PFZ
34 53.6682.0025 3 EA SCREW, 8-32 X 5/8" PPZ SEMS
35 55.2178.0001 3 EA CABLE ANCHOR MOUNT, #8 SCREW

3

02.9698.0010 0 81

VARI❋LITE - VL3015LT SPOT LUMINAIRE SERVICE MANUAL

VL3015LT Optic Assembly (continued)

28 (x3)

26 (x8)

2

33 (x4)

31 (x12)

16

1

17

13

23 (x3)

29 (x4)

11

30 (x8)

18

14

27 (x3)

2

34 (x3)

15

32 (x2)

19

12 (x2)

24 (x8)

22 **

(x2)

9

35 (x3)

25 (x4)

5

10

3

7 *

4

8

6

*Apply UV Curing RTV to front and back of edge
of flocking piece to secure it to rail cover in
position. Cure with one pass through UV oven.

21 (x3)

20

**Use Loctite 242 on both nuts. Ensure shaft
is tight and held when tightening first nut.
Tighten second nut against first as jam nut.

Figure 3-13: VL3015LT Optic Assembly

82 02.9698.0010 0