Philips VL3500 WASH, VL3500 WASH FX LUMINAIRES Service Manual

VARI❋LITE® is a trademark owned by Genlyte Thomas Group LLC and is registered in the United States and other countries.
VL1000™, VL2000™, VL2201™, VL2202™, VL2400™ (and the individual product designations), VL3000™, VL3500™, Series 1000

Series 3000

™

, DICHRO❋TUNE™, VARI❋IMAGE™, VARI❋BRITE™, and the Vari-Lite Asterisk are also trademarks owned by Genlyte Thomas

™

, Series 2000™,

Group LLC.
VARI❋LITE® products are protected by one or more of the following patents, and other pending patent applications worldwide:
U. S. Patents No. 6,809,869; 6,796,682; 6,769,792; 6,578 ,987; 6,550,939; 6,282,027; 6,123,436; 6,113,252; 6,046,861; 6,031,749; 6,011,640; 5,969,868;

5,959,768; 5,934,794; 5,882,107; 5,8 29,868; 5,8 25,548; 5,7 98,619; 5,774,27 3; 5,769,52 7; 5,758,95 6; 5,728,99 4; 5,640,06 1; 5,590, 954; 5,45 4,477; 5,43 2,691;
5,367,444; 5,329,431; 5,307,295; 5,2 82,121; 5,2 78,742; 5,2 09,560; 5,186,53 6; 5,073,84 7; 5,010,45 9; 4,980,80 6; 4,972,30 6; 4,800, 474; 4,77 9,176; 4,70 1,833;
4,602,321;

U. S. Design Patents No. 524,245; 457,678; 452, 339; 451,890; 442,944; 439,356; 420,332; 417,300; 415 ,301; 414,888; 413,995; 377,338; 366,712; 359,574;
350,408; 347,113;

Australia Patents No. 693,691; 683,695; 667,109; 649,264; 646,588; 586,095; 576,400;
Australia Design Patents No. 128,796; 128,795;
Canada Patents No. 2,070,670; 2,050,375; 1,270,675; 1,259,058;
Canada Design Patents No. 81,234; 81,233; 76,046;
European (UK) Patents No. 0 652 400; 0 586 049; 0 565 218; 0 547 732; 0 534 710 ; 0 495 305; 0 474 202; 0 379 970; 0 253 082; 0 253 08 1; 0 248 974 ; 0 192

882;
Germany Patents No. 694 25 943.8; 693 14 122.0; 692 08 615.3; 692 07 692.1; 691 31 478.0; 691 21 029.2; 690 33 385.4; 37 89 166.9; 37 68 727.1; 37 51

804.6; 37 50 201.8; 35 87 270.5;
Germany Design Patents No. M 98 01 745.4; M 96 04 515.9; M 96 04 514.0; M 94 07 689.8; M 94 02 95 1.2; M 4 99 03 583. 6; M 498 1 1 203.9; G 93 12 884.3;
Spain Patents No. 2 090 191; 2 084 289; 2 020 960; 0 548 328;
Spain Utility Model Patent No. 2.031.748;
Spain Design Patents No. 0.137.502; 0.137.501; 0.133.573;
Greece Patent No. 910.400.544;
Japan Patents No. 2,843,696; 2,059,669; 2,055,324; 2,002,168; 1,966,525; 1,889,481; 1,792,721; 1,770,241;
Japan Design Patents No. 985,985-1; 985,985; 947,552; 945,436-1; 945,436; 1,106,089; 1,077,598; 1, 072,598; 1,060,414; 1,002,123;
Korea Patents No. 76,310; 42,639; 283,770; 181,180;
Korea Design Patents No. 209,896; 209,895;
Mexico Patent No. 180,148;
Taiwan Patents No. 78, 726; 66,975; 65,380; 28,275;
United Kingdom Design Registrations No. 2082526; 2072562; 2056387; 2056386; 2042174; 2038212; 2033108; 2029499.

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

Vari-Lite
10911 Petal Street
Dallas, Texas 75238 USA

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

Version as of: 19-May-2009
Part number: 02.9686.0010 A

VL3500™ Wash and VL3500™ Wash FX Luminaires Service Manual
©2003-2009 Vari-Lite, a Philips group company. All Rights Reserved.

How To Obtain Warranty Service

A copy of the Vari-Lite Limited Warranty was included in the shipping package for this
VARI❋LITE® product.

To obtain warranty service, please contact customer service at 1-877-VARI-LITE (1-877-827-4548),
[phone], or [e-mail]
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 register ed
user or organization. If available, you should have your sales invoice to establish the date of sale as

the beginning of the warranty period.
Once you obtain the RMA, pack the unit in a secure shipping container or in its original packing box.

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

Vari-Lite
10911 Petal Street
Dallas, Texas 75238 USA
Attention: Warranty Service

FOREWORD

and request a Return Material

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

Note: The VL3500™ W ash and VL3500™ Wash FX Luminaires share many common assemblies and
parts of the Vari-Lite Series 3000 Luminaires.

02.9686.0010 A i

VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL

Compliance Notice

FCC

This equipment has been tested and found to comply with the limits for a Class A digital device
pursuant to Part 15 of FCC Rules. These limits are designed to provide reasonable protection against
harmful interference when this equipment is operated in a commercial environment. This equipment
generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance
with Vari-Lite system, service, and safety guidelines, may cause harmful interference to radio
communications. Operation of this equipment in a residential area is likely to cause harmful
interference, in which case the user will be required to correct the interference at his/her own expense.

Declaration of Conformity

We declare, under our sole responsibility, that this product complies with the relevant clauses of the
following standards and harmonized documents:

Safety

EN 60598-1:2000 Luminaire Safety Standard, General Requirements
EN 60598-2-17:1989 Specification for Luminaires for Stage and Studio Lighting

EMC

EN 61000-6-4:2001 Emission Standard for industrial environments
EN 61000-6-2:2001 Immunity for industrial environments

We certify that the product conforms to the protection requirements of council directives: 73/23/EEC
(LVD) and 89/336/EEC (EMC)

ii 02.9686.0010 A

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 PERT AINING T O PROTECTION AGAINST ELECTRICAL SHOCK,
FIRE, EXPOSURE TO EXCESSIVE UV RADIATION, AND INJURY TO PERSONS CAN BE
FOUND BELOW.

WARNING:
INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST FIRE

1. VARI❋LITE
Wash Luminaire requires the Osram SharXS
lamp may be hazardous.

2. Luminaires may be mounted on any type of surface as long as mounting instructions are followed.
See instructions detailed in this manual.

3. Note distance requirement from combustible materials or illuminated objects for VARI❋LITE
luminaires.

FOREWORD

CAUTION advising of potential damage to product.

WARNING advising of potential injury or death to persons.

®

luminaires have been designed for use with specific lamp types. The VL3500™

®

HTI® 1500 W/D7/60 . Installing another type of

®

WARNING:
INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST ELECTRICAL SHOCK

1. VARI❋LITE

®

luminaires are designed for dry locations only. Exposure to rain or moisture may

damage luminaire.

2. Disconnect power before servicing any VARI❋LITE

®

equipment.

3. Servicing to be performed by qualified personnel only.

02.9686.0010 A iii

VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL

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

1. Many VARI❋LITE® luminaires use a lamp that produces UV radiation. DO NOT look directly at
lamp.

2. It is hazardous to operate luminaires without lens or shield. Shields, lenses, or ultraviolet screens
shall be changed if they have become visibly damaged to such an extent that their effectiveness is
impaired. For example, by cracks or deep scratches.

WARNING:
INSTRUCTIONS FOR PROTECTION AGAINST INJURY TO PERSONS

1. Exterior surfaces of the luminaire will be hot during operation. Use appropriate safety equipment
(gloves, eye protection, etc.) when handling and adjusting hot equipment and components.

2. Luminaires will have a hot lamp when operating. Disconnect power and allow lamp to cool before
replacing.

3. Arc lamps emit ultraviolet radiation which can cause serious skin burn and eye inflammation.
Additionally, arc lamps operate under high pressure at very high temperatures. Should the lamp
break, there can exist a danger of personal injury and/or fire from broken lamp particles being
discharged.

4. Wear eye protection when relamping.

5. Appropriate safety equipment (gloves, eye protection) should be used when handling damaged
lamps.

6. If lamp is touched with bare hands, clean lamp with denatured alcohol and wipe with lint-free
cloth before installing or powering up the luminaire.

7. The lamp shall be changed if it has become damaged or thermally deformed.

WARNING:
RF INTERFERENCE

1. This is a Class A product. In a domestic environment this product may cause radio interference, in
which case, the user may be required to take adequate measures.

ARC LAMP CHARACTERISTIC CONSIDERATIONS

1. Arc lamps require a period of time to relight after a power interruption or a severe voltage dip. In
some cases, the lamp will automatically relight after it has cooled depending on Lamp Power-Up
State configuration setting.

2. Burning position is universal.

iv 02.9686.0010 A

Sicherheitshinweise

Es ist äußerst wichtig, ALLE Sicherheitsinformationen und -hinweise in diesem Handbuch und dem
beiliegenden Informationsmaterial zu lesen, bevor Sie die hierin beschriebenen Produkte installieren
bzw. bedienen. Halten Sie bei der Installation und dem Einsatz dieses Produkts alle Warnhinweise und
Vorsichtsmaßnahmen ein.

Folgende Sicherheitssymbole werden in diesem Handbuch verwendet:

VORSICHT - weist auf möglichen Produktschaden hin.

WARNUNG - weist auf mögliche Körperverletzung und Lebensbedrohung hin.

NACHSTEHEND FINDEN SIE ALLGEMEINE HINWEISE ÜBER
SICHERHEITSVORKEHRUNGEN GEGEN ELEKTROSCHOCK, FEUER, ÜBERHÖHTE UV­STRAHLUNG UND KÖRPERVERLETZUNGEN.

WARNUNG:
HINWEISE ZUM FEUERSCHUTZ

1. VARI❋LITE®-Scheinwerfer sind ausschließlich für den Einsatz mit bestimmten Lampentyps.
Achten Sie auf den Lampentyp (Osram SharXS
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

®

HTI® 1500 W/D7/60 ), bevor Sie die jeweiligen

WARNUNG:
HINWEISE ZUM SCHUTZ GEGEN ELEKTROSCHOCK

1. VARI❋LITE®-Scheinwerfer eignen sich ausschließlich für trockene Standorte. Regen oder
Feuchtigkeit können die Scheinwerfer beschädigen.

2. Unterbrechen Sie die Stromzufuhr, bevor Sie mit der Arbeit an VARI❋LITE®-Geräten beginnen.

3. Die Geräte sollten nur von qualifiziertem Personal gewartet werden.

02.9686.0010 A v

VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL

WARNUNG:
HINWEISE ZUM SCHUTZ GEGEN ÜBERHÖHTE UV-STRAHLUNG

1. Viele VARI❋LITE®-Scheinwerfer verwenden die Lampentyp, der UV-Strahlen abgibt.
SCHAUEN SIE NICHT direkt in die Lampe.

2. Es ist gefährlich, Leuchten ohne Linsen oder Blenden zu bedienen. Blenden, 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 denaturiertem Alkohol und
einem flusenfreien Tuch, bevor Sie die Scheinwerfer installieren oder in Betrieb nehmen.

7. Wenn die Lampe beschädigt oder durch Hitzeeinwirkung deformiert ist, muß diese ausgetauscht
werden.

WARNUNG:
HF-INTERFERENZ

1. Es handelt sich um ein Produkt der Klasse A. In einer Wohnumgebung kann das Produkt Hochfre­quenzstörungen verursachen. In diesem Fall müssen eventuell geeignete Maßnahmen getroffen
werden.

BESONDERHEITEN VON BOGENLAMPEN

1. Bogenlampen benötigen eine gewisse Zeitdauer, um nach einem Stromausfall oder einem
Spannungsgefälle wieder aufzuleuchten. In einigen Fällen wird die Lampe nach Abkühlung
automatisch wieder aufleuchten, je nach der Systemkonfigurationseinstellung des Lampenein­schaltungsstatus.

2. Die Brennposition ist Universal.

vi 02.9686.0010 A

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 SharXS

®

HTI® 1500 W/D7/60 ) avant de remplacer les

lampes. L’installation d’un autre type de lampe peut poser un danger.

2. Les luminaires peuvent être fixés sur tout type de surface tant que les directives de montage sont
respectées. Voir les explications détaillées dans ce guide.

3. Vérifier la distance à respecter entre les matériaux combustibles ou les objets illuminés et les
luminaires VARI❋LITE®.

AVERTISSEMENT:
DIRECTIVES POUR SE PROTÉGER CONTRE LES DÉCHARGES ÉLECTRIQUES

1. Les luminaires VARI❋LITE® sont conçus pour une utilisation au sec uniquement. Une
exposition à la pluie et à l’humidité risque d’endommager le luminaire.

2. Débrancher l’appareil avant de procéder à la révision de tout matériel VARI❋LITE®.

3. Les révisions doivent être effectuées uniquement par des personnes qualifiées.

02.9686.0010 A vii

VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL

AVERTISSEMENT:
DIRECTIVES POUR SE PROTÉGER CONTRE UNE EXPOSITION EXCESSIVE AUX
RAYONS UV

1. Plusieurs luminaires VARI❋LITE® utilisent une lampe qui produit des rayons UV. NE PAS fixer
son regard sur la lampe.

2. L’utilisation des luminaires sans lentille ou blindage pose des risques. T ous blindages, lentilles ou
écrans ultraviolet visiblement endommagés au point que leur efficacité en est affectée doivent être
remplacés, par exemple s’il y a des fissures ou de profondes rayures.

AVERTISSEMENT:
DIRECTIVES POUR SE PROTÉGER CONTRE LES ACCIDENTS POUVANT ENTRAÎNER
DES BLESSURES

1. Les surfaces externes du luminaire deviennent brûlantes quand l’appareil est en marche. Pour
manœuvrer ou ajuster des appareils brûlants et leurs composants, se protéger suffisamment (gants,
protection pour les yeux, etc.).

2. La lampe du luminaire est brûlante lorqu’il est en marche. Débrancher le courant et attendre que la
lampe ait refroidi avant de la remplacer.

3. Les lampes à arc émettent des rayons ultraviolets pouvant causer de graves brûlures sur la peau et
une inflammation des yeux. De plus, les lampes à arc fonctionnent sous haute tension à de très
hautes températures. Si la lampe se casse, les particules de la lampe cassée peuvent causer
blessures et/ou incendie en s’éparpillant.

4. Se protéger les yeux pour remplacer la lampe.

5. Utiliser des appareils de protection appropriés (gants, protection des yeux) pour manier des lampes
endommagées.

6. Si la lampe a été touchée avec des mains nues, la nettoyer avec de l’alcool dénaturé et l’essuyer
avec un chiffon non-pelucheux avant d’installer ou de brancher le luminaire.

7. Si la lampe a été endommagée ou a reçu une déformation thermique, elle doit être remplacée.

AVERTISSEMENT:
INTERFÉRENCE RF

1. Cet appareil est de Classe A. Dans un environnement domestique, cet appareil peut causer des
interférences radio, et si c’est le cas, l’utilisateur peut avoir à prendre des mesures adéquates.

CONSIDÉRATIONS DES CARACTÉRISTIQUES DE LAMPES À ARC

1. Après une interruption de courant ou une baisse importante de voltage, les lampes à arc mettent du
temps avant de se rallumer. Dans certains cas, la lampe se rallumera automatiquemet après s’être
refroidie. Cela dépend de la manière dont le système est réglé pour le statut de mise en marche de
la lampe.

2. La position Brûler est Universelle.

viii 02.9686.0010 A

Aviso sobre Seguridad

Es muy importante leer TODA la in formación e instrucciones sobre seguridad que se indica en este
manual así como en los documentos adjuntos antes de instalar y operar los productos descritos. Se
debe prestar atención a todos los avisos y advertencias durante la instalación y uso de este producto.

Los símbolos de seguridad usados en este manual son los siguientes:

CUIDADO, indica posibles daños al producto.

ADVERTENCIA, indica posibles lesiones o muerte a las personas.

LA INFORMACIÓN GENERAL RELACIONADA A LA PROTECCIÓN CONTRAGOLPES DE
CORRIENTE ELÉCTRICA, INCENDIO, EXPOSICIÓN EXCESIVA A RADIACIÓN ULTRA
VIOLETA Y LESIONES A LAS PERSONAS SE PUEDE ENCONTRAR SEGUIDAMENTE:

ADVERTENCIA:
INSTRUCCIONES PARA PROTECCIÓN CONTINUA CONTRA INCENDIO

1. Las luminarias VARI❋LITE® han sido diseñadas para ser usadas solamente con algunas
lámparas. Tome nota del tipo de lámpara (Osram SharXS
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

®

HTI® 1500 W/D7/60 ) antes de

ADVERTENCIA:
INSTRUCCIONES PARA PROTECCIÓN CONTINUA CONTRA CHOQUE ELÉCTRICO

1. Las luminarias VARI❋LITE® están diseñadas solamente para lugares secos. La exposición a la
lluvia o humedad pueden dañar la luminaria.

2. Desconecte la energía antes de dar servicio a cualquier equipo de VARI❋LITE®.

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

02.9686.0010 A ix

VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL

ADVERTENCIA:
INSTRUCCIONES PARA PROTECCIÓN CONTINUA CONTRA LA EXPOSICIÓN
EXCESIVA DE RADIACIÓN ULTRA VIOLETA

1. Muchas luminarias VARI❋LITE® usan un tipo de lámpara que produce radiación UV. NO mire
directamente a la lámpara.

2. Es peligroso operar luminarias sin lentes o protectores. Debe cambiar los protectores, lentes o
pantallas ultravioletas si se aprecia que han sido dañadas, y que su efectividad pudiera estar
deteriorada. Por ejemplo, si tuvieran rajaduras o raspaduras profundas.

ADVERTENCIA:
INSTRUCCIONES PARA PROTECCIÓN CONTRA LESIONES DE PERSONAS

1. Las superficies exteriores de las luminarias están calientes durante su operación. Use un equipo de
seguridad apropiado (guantes, protección para los ojos, etc.) cuando haga ajustes en el equipo y
componentes que están calientes.

2. Cuando las luminarias están en operación la lámpara estará muy caliente. Desconecte la energía y
deje que la lámpara se enfríe antes de reemplazarla.

3. Las lámparas de arco emiten radiaciones ultravioletas que pueden ocasionar serias quemaduras a la
piel e inflamación a los ojos. Además, las lámparas de arco operan a alta presión y muy alta
temperatura. Si la lámpara se rompe, puede existir el peligro de lesiones al personal o un incendio
ocasionado por las partículas de la lámpara rota que se caen.

4. Use protección para los ojos cuando vuelve a colocar una lámpara nueva.

5. Use un equipo de seguridad apropiado (guantes, protección para los ojos, etc.) cuando trabaje con
lámparas dañadas.

6. Si toca la lámpara con las manos, limpie la lámpara con alcohol desnaturalizado y con tela sin
pelusas antes de instalar o volver a conectar la luminaria.

7. Cambie la lámpara si está dañada o deformada termicamente.

ADVERTENCIA:
INTERFERENCIA RF

1. Este es un producto de Clase A. En el ambiente de la casa este producto puede ocasionar
radiointerferencia, en cuyo caso, el usuario debe tomar las medidas adecuadas.

CONSIDERACIONES SOBRE LAS CARACTERÍSTICAS DE LA LÁMPARA DE ARCO

1. Las lámparas de arco requieren un período de tiempo para volver a iluminarse después de una
interrupción de energía o de una severa caída de voltaje. En algunos casos, la lámpara se volverá a
iluminar en forma automática después que se ha enfriado dependiendo de la configuración del
sistema de energía de la lámpara.

2. La posición de encendido es universal.

x 02.9686.0010 A

FOREWORD

02.9686.0010 A xi

VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL

xii 02.9686.0010 A

TABLE OF CONTENTS

Table of Contents

Table of Contents

IntroductionIntroduction 1

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

Additional Documentation......................................................................................................... 2

Customer Service....................................................................................................................... 3

Technical Bulletins and Notices ................................................................................................ 4

Chapter 1. Description

Features

VL3500 Wash & VL3500 Wash FX Standard Features............................................................ 6

Technical Specifications............................................................................................................ 6

Components

External Luminaire Components............................................................................................... 7

Luminaire Head and Yoke Components.................................................................................... 8

Enclosure Components.............................................................................................................. 9

Chapter 2. Maintenance

Testing

Luminaire Self-Tests................................................................................................... ..... ... . .... 12

Calibration Sequence............................................................................................................... 12

Auto Recalibration................................................................................................................... 13

Partial Recalibration ................................................................................................................ 13

Sensor Testing.......................................................................................................................... 13

Warnings and Cautions

Exceptional Safety Information for the VL3500 Luminaires................................. .... ..... ........ 15

Troubleshooting

Error Messages ........................................................................................................................ 16

Troubleshooting Guide............................................................................................................ 17

Maintenance Procedures

Lamp Replacement.................................................................................................................. 19

Align Lamp.............................................................................................................................. 20

Internal Lens Replacement...................................................................................................... 21

Front Lens Assembly Removal ........................................................................................... .... 23

Color Filter Replacement......................................................................................................... 25

Effects Pattern Replacement - VL3500 Wash FX Only.......................................................... 27

Ballast Assembly Replacement ................................................................ ..... .... ...................... 29

Color/Dimmer/Strobe Assembly Replacement ....................................................................... 31

Color/Dimmer/Strobe Assembly Replacement (continued).................................................... 32

Internal Lens Assembly Replacement......................................... .... ........................................ 33

02.9686.0010 A xiii

VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL

Reflector Replacement............................................................................................................. 35

Main Control Board (MCB) Replacement .............................................................................. 37

Ignitor Board Replacement...................................................................................................... 38

Pan Motor Assembly Replacement ......................................................................................... 39

Pan Encoder Replacement....................................................................................................... 41

Pan EOT Sensor Replacement................................................................................................. 43

Power Supply (LVS) Replacement.......................................................................................... 45

Tilt Motor Assembly Replacement.......................................................................................... 47

Tilt Encoder Replacement ....................................................................................................... 49

Tilt EOT Sensor Replacement................................................................................................. 50

Chapter 3. Illustrated Parts Breakdown

Drawing Tree (VL3500 Wash)

VL3500™ Wash Luminaire............................................................................... ..... .... ............. 52

Drawing Tree (VL3500 Wash FX)

VL3500™ Wash FX Luminaire ...................................................... ........................................ 54

Top Assembly

Included Items Kit ....................................................................... .... ..... ................................... 56

VL3500™ Wash / VL3500™ Wash FX Luminaires .............................................................. 58

Generic Luminaire Assembly.................................................................................................. 60

Head Assembly

Head Structure Assembly........................................................................................................ 63

Front Stippled Lens Assembly......................................................... ..... .... ............................... 64

Polished PC Clear Front Lens Assembly..................................... .... ........................................ 65

Front Clear Lens Assembly..................................................................................................... 66

Front Fresnel Lens Assembly.................................................................................................. 67

Head Cover Assembly............................................................................................................. 68

Backend Assembly .................................................................................................................. 69

80mm Fan Assembly............................................................................................................... 71

Dual Fan Duct Assembly......................................................................................................... 72

Reflector Mount Assembly...................................................................................................... 73

Hot Box Assembly................................................................................................................... 75

Dual Fan Tray Assembly......................................................................................................... 77

Head Front Fan Assembly....................................................................................................... 78

Internal Lens Assembly........................................................................................................... 79

Internal Lens Rail Assembly ................................................................................................... 81

Internal Lens Splitter Assembly ............................................................... ............................... 83

Actuator Assembly .................................................................................................................. 85

Fresnel Internal Lenses............................................................................................................ 86

Color/Effect/Strobe Module ................................................................ .... ............................... 87

Color/Rotating Effect/Strobe Module ...................................................... ..... .... ...................... 90

VL3500 Wash Fixed Color Wheel 1 Assembly...................................................... .... ............. 93

VL3500 Wash Fixed Color Wheel 2 Assembly...................................................... .... ............. 95

VL3500 Wash FX Fixed Color Wheel 1 Assembly ................................................................ 97

VL3500 Wash FX Fixed Color Wheel 2 Assembly ................................................................ 99

VL3500 Wash FX Rotating Effect Wheel Assembly............................................................ 101

xiv 02.9686.0010 A

TABLE OF CONTENTS

VL3500 Wash Strobe System Assembly............................................................................... 103

VL3500 Wash FX Strobe System Assembly......................................................................... 105

Rear Strobe Blade Assembly................................................................................................. 107

Front Strobe Blade Assembly................................................................................................ 108

Yoke Assembly

Yoke Assembly...................................................................................................................... 109

Tilt Motor Assembly.............................................................................................................. 111

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

Head/Yoke PCB Assemblies

Head Cable Interconnect........................................................................................................ 115

VL3500 Wash Controller PCB Assembly............................................................................. 116

Enclosure Assembly

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

Ventilation Cover Assembly.................................................................................................. 125

Exhaust Fan Assembly .......................................................................................................... 127

Panel Assembly ..................................................................................................................... 128

DMX Input PCB.................................................................................................................... 129

Pan Pulley Assembly............................................................................................................. 130

Pan Motor Assembly ............................................................................................................. 131

Pan Tube Assembly............................................................................................................... 133

Cable Assemblies

Pan EOT Sensor Electrical Assembly ................................................................................... 135

LVS Chassis Ground Cable Assembly .................................................................................. 136

Ignitor to Relay Cable Assembly........................................................................................... 137

Yoke to Dual AC Fan Cable Assembly................................................................................. 138

LVS to Yoke Dual AC Fan Cable Assembly......................................................................... 139

OT Switch 1 to OT Switch 2 Cable Assembly...................................................................... 140

Backcap Interlok to OT Switch 1 Cable Assembly............................................................... 141

OT Switch to Ground Cable Assembly................................................................................. 142

Tilt Harness Cable Assembly ................................................................................................ 143

Internal Lens Interconnect Cable Assembly.......................................................................... 145

VL3500 Wash Color Harness Cable Assembly..................................................................... 146

VL3500 Wash FX Color Harness Cable Assembly............................................................... 148

Internal-Lens Split Motor Cable Assembly........................................................................... 151

Transfer Fans Cable Assembly.............................................................................................. 152

Upper Enclosure Fans Cable Assembly ................................................................................ 153

Yoke Fan and Relay Cable Assembly.................................................................................... 154

Yoke Fan Cable Assembly..................................................................................................... 155

OT Switch to Backcap Interlok Cable Assembly.................................................................. 156

Ignitor to Lamp Socket Cable Assembly............................................................................... 157

Chassis to Yoke Ground Cable Assembly............................................................................. 158

Zoom Motor Cable Assembly ............................................................................................... 159

Zoom Motor Cable ................................................................................................................ 160

AC Input Pigtail Cable Assembly.......................................................................................... 161

EMI Filter to Power Switch Cable Assembly........................................................................ 162

AC Input Splitter Cable Assembly........................................................................................ 163

Data I/O Link Cable Assembly.............................................................................................. 165

Display Cable Assembly........................................................................................................ 166

02.9686.0010 A xv

VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL

Ballast to Controller Cable Assembly ................................................................................... 167

DC Output Cable Assembly .................................................................................................. 168

Pan/Tilt Control Cable Assembly.......................................................................................... 169

Lamp Supply to Relay Cable Assembly................................................................................ 171

Appendix A. Technical Bulletins and Notices

Product Technical Bulletins and Notices............................................................................... 173

xvi 02.9686.0010 A

Introduction

About This Manual

Note: The VL3500™ W ash and VL3500™ Wash FX Luminaires share many common assemblies and
parts of the Va ri-Lite Series 3000 Luminaires.

This manual provides descriptions, repair procedures, and illustrated parts breakdowns for all
configurations of the VL3500™ Wash Luminaire. The manual is intended for use by Vari-Lite
personnel and by Vari-Lite’s customers/clients.

WARNING: It is important to read ALL accompanying safety and installation instructions to avoid
damage to the product and potential injury to yourself or others.

This manual covers the following models:

INTRODUCTION : ABOUT THIS MANUAL

Model Part Number Source

VL3500™ Wash Luminaire 20.9686.0001 Arc
VL3500™ Wash FX Luminaire 20.9686.0011 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.

02.9686.0010 A 1

VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL

Additional Documentation

For complete installation and operation instructions, refer to the VL3500™ Wash & VL3500™ Wash
FX Luminaires User’s Manual. This manual is available in both printed and electronic (PDF) formats:

• VL3500™ Wash & VL3500™ Wash FX Luminaires User’s Manual (02.9686.0001)

• For more information regarding DMX512 systems, refer to the DMX512/1990 & AMX 192
Standards publication available from United States Institute for Theatre Technology, Inc.
(USITT).

USITT
6443 Ridings Road
Syracuse, NY 13206-1111 USA
1-800-93USITT
www.usitt.org

2 02.9686.0010 A

INTRODUCTION : CUSTOMER SERVICE

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 Obtain Support or 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) or 1-214-647-7880

E-mail: [e-mail]

Additional Resources

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

02.9686.0010 A 3

VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL

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 (VL3000 Series Luminaires Technical
Bulletin number 1).

Technical notices are also issued from the Dallas, Texas USA office. They are non-procedural
documents that contain information regarding product support issues, current equipment problems,
software bugs, and documentation corrections. All technical notices begin with the prefix TN and are
numbered sequentially, such as TN-138 (Tech Notice number 138).

4 02.9686.0010 A

CHAPTER 1.

Description

This chapter contains descriptions of luminaire features and components.

• Features

• Components

02.9686.0010 A 5

VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL

Features

VL3500 Wash & VL3500 Wash FX Standard Features

• Three-filter CYM color mixing system.

• Variable CTO color correction wheel.

• Full field dimming system.

• Dual blade strobe system.

• Fan cooled.

• UV/IR glass.

• Dual wattage, double-ended lamp capable of operation at
900W (Standby Mode), 1200W or 1500W – mode
selectable from fixture or console.

•VARI❋BRITE™ mode - produces a tight, intense column of light.

• Zoomable beam optics mechanism for continuous beam size control with 10° to 50° range ­dependent on the lens configuration.

• Dual, five-position (plus open) fixed color wheels.

• Five-position aperture wheel: 52, 40, 35, 30, and 25 mm (VL3500 Wash only).

• One rotating FX pattern wheel with four rotatable and indexable positions and one open position
(VL3500 Wash FX only).

• Interchangeable front lenses: Fresnel and Plano Convex Stipple (standard on both models).

• Additional Plano Convex Clear front lens (VL3500 Wash only).

• Additional ULTRA Clear front lens (VL3500 Wash FX only).

• Repositional pan/tilt system.

• Control by DMX512 protocol.

WARNING: Some exceptional conditions apply to the safe operation of the VL3500™ Wash
Luminaire. See “Warnings and Cautions” on page 15.

Technical Specifications

For technical specifications, refer to VL3500™ Wash and VL3500™ Wash FX Luminaires User’s
Manual (02.9686.0001).

6 02.9686.0010 A

Components

External Luminaire Components

The following illustration shows the external luminaire components and controls.

COMPONENTS : EXTERNAL LUMINAIRE COMPONENTS

1

Head Assembly

Houses color, strobe, and
beam spreader mechanisms

Front Lens Assembly

Input Panel Components

Product Label ID

Main Power
Switch

AC PWR

AC IN

~

DATA IN

DATA THRU

AC Input Cable

Backcap Assembly

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

Yoke Assembly

Houses Master Control
Board (MCB).

Upper Enclosure Assembly

Houses power supply, ballast,
and display board.

Menu Display

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

Input Panel

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

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 LAMP A 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.

DISCONNECT FIXTURE

BEFORE RELAMPING

CAUTION:

LUMINAIRE MUST REMAIN

POWERED ON FOR 5 MINUTES

AFTER DOUSING LAMP.

DO NOT OPEN FOR 5 MINUTES

AFTER SWITCHING OFF.

ATTENTION:

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

CAUTION:

HOT LAMP

X

ENTERMENU

AC Input Cable

Data In

Data Thru

YZ

02.9686.0010 A 7

VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL

Luminaire Head and Yoke Components

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

Color Assembly

VL3500™ Wash Luminaire -contains fixed
color wheels, dimmer mechanism, aperture
wheel, CYM color wheels, CTO (color
correction) wheel and strobe mechanism.

VL3500™ Wash FX Luminaire -contains
rotating effects mechanism, fixed color
wheels, dimmer mechanism, CYM color
wheels, CTO (color correction) wheel and
strobe mechanism.

Backend Assembly

Houses reflector and lamp.
Provides knobs for lamp adjustment.

Head Covers

(attached by tether)

Optics Assembly

Houses zoom lenses
and Vari*Brite mechanism.

Front Lens
Assembly

Yoke Arm Cover

Enclosure Assembly

See page 9

Head Fan

Main Controller Board (MCB)

Luminaire control circuit board.

8 02.9686.0010 A

Assemblies

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.)

Enclosure Top Covers

1500W Arc Ballast Module

Enclosure Fan
Assembly

1

Enclosure Bottom
Ventilation Cover

Input Panel Assembly
containing DMX Input PCB
and Menu Display

150W +24V/6.3A
Power Supply

AC Input Cable
Requires standard AC

power distribution from
200-264 VAC, 50/60 Hz,
7 to 12 A depending on
the AC supply voltage.

Wire* Connection

Green/Yellow AC Ground

Blue AC Neutral

Brown AC Line

* International (Harmonized) Standard

02.9686.0010 A 9

VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL

Notes

10 02.9686.0010 A

CHAPTER 2.

Maintenance

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

• Testing

• Warnings and Cautions

• Troubleshooting

• Maintenance Procedures

WARNING: As with any repairs or maintenance to Vari-Lite luminaires,

service should only be performed by a trained and qualified service technician or
at an Authorized Vari-Lite Service facility.

02.9686.0010 A 11

VARI❋LITE® - VL3500™ WASH LUMINAIRE SERVICE MANUAL

Testing

Luminaire Self-Tests

The luminaire is capable of running self tests by using the TEST menu functions. For detailed
instructions regarding the luminaire’ s self-test function, refer to the VL3500™ Wash Luminaire User’s
Manual (02.9686.0001).

Calibration Sequence

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

VL3500 WASH
Phase 1 Phase 1

• Tilt • Tilt

• Strobe • Strobe

• Color Wheel 1 • Color Wheel 1

• Color Wheel 2 • Color Wheel 2

Phase 2 Phase 2

• Dimmer • Dimmer

Phase 3 Phase 3

•Aperture •FX Wheel

Phase 4 Phase 4

•VARI❋BRITE • VARI❋BRITE

•CTO •CTO

•Amber •Amber

• Magenta • Magenta

Phase 5 Phase 5

•Pan •Pan

VL3500 WASH FX

•Zoom •Zoom

•Cyan •Cyan

Phase 6

•FX Index

12 02.9686.0010 A