Vari Lite VL3000 Series User manual

VARI ❋ LITE ® - VL3000™ SERIES LUMINAIRE SERVICE MANUAL
6 6 0 2 . 9 6 7 8 . 0 0 1 0 F
Top Assembly
Included Items Kit, Spot
28.9678.0001 Rev H
Refer to Figure 3-9.
No. Item Qty. UM. Description
1 02.8001.0001 1 EA PRODUCT SUPPORT SHEET, VARI-LITE CUSTOMER SERVICE
2 02.8052.0001 1 EA CARD, LIMITED WARRANTY
3 02.8406.0001 1 EA TAG, LAMP NOTICE
4 02.8700.0001 1 EA CARD, PRODUCT REGISTRATION
5 02.9678.0002 1 EA UNPACK/QUICK START SHEET, VL3000
- 04.4037.0001 5 EA LABEL, 2.5 X .5 BARCODE (not shown)
- 07.9678.0036 1 EA CARDBOARD SHIPPING BOX, VL3000 (not shown)
6 08.3000.0001 1 EA CD-ROM, VL3000 PRODUCT DOCUMENTATION, USER
7 22.9661.1636 2 EA FAB ASSY, BRACKET TRUSS HOOK
8 41.6030.4211 1 EA GOBO ASSY, UNEVEN BARS (POS 2-4)
9 41.6030.5011 1 EA GOBO ASSY, NIGHT SKY (POS 1-3)
10 41.6030.5503 1 EA GOBO ASSY, PALM LEAVES (POS 2-2)
11 41.6030.5523 1 EA GOBO ASSY, TRIBAL BREAKUP (POS 1-4)
12 41.6030.6011 1 EA GOBO ASSY, CIRCLE OF OVALS (POS 3-5)
13 41.6030.7002 1 EA GOBO ASSY, PEBBLES (POS 1-5)
14 41.6030.7014 1 EA GOBO ASSY, TRIANGLE BREAKUP (POS 3-4)
15 41.6030.7018 1 EA GOBO ASSY, SHOCK BREAKUP (POS 2-3)
16 41.6030.7029 1 EA GOBO ASSY, ALPHA RAYS (POS 1-2)
17 41.6030.8003 1 EA GAG ASSY, 3-FACET PRISM (POS 3-2)
18 41.6030.8503 1 EA GAG ASSY, GLACIER (POS 1-6)
19 41.6030.8506 1 EA GAG ASSY, DROPLETS (POS 2-6)
20 41.6030.8509 1 EA GAG ASSY, ICE BLOCKS (POS 2-5)
21 41.6030.8801 1 EA GOBO ASSY, MULTI-COLOR CIRCLES (POS 3-3)
22 71.2557.1200 1 EA LAMP, 1200 WATT SHORT ARC, DOUBLE-ENDED

TOP ASSEMBLY : INCLUDED ITEMS KIT, SPOT
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3
Included Items Kit, Spot (continued)
Figure 3-9: Included Items Kit, 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.
6
5
4
7(x2)
1
22*
3
2
16 9 11 13 18
Alpha Rays Night Sky Tribal Break-Up Pebbles Glacier Gag
10 15 8 20 19
Palm Leaves Shock Break-Up Uneven Bars Ice Blocks Gag Droplets Gag
17 12 14 21
3-Facet Prism Circle of Ovals Triangle Break-Up Multi-Colored
Gobo

VARI ❋ LITE ® - VL3000™ SERIES LUMINAIRE SERVICE MANUAL
6 8 0 2 . 9 6 7 8 . 0 0 1 0 F
Included Items Kit, Wash
28.9678.0002 Rev F
Refer to Figure 3-10.
Figure 3-10: Included Items Kit, Wash
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.
No. Item Qty. UM. Description
1 02.8001.0001 1 EA PRODUCT SUPPORT SHEET, VARI-LITE CUSTOMER SERVICE
2 02.8052.0001 1 EA CARD, LIMITED WARRANTY
3 02.8700.0001 1 EA CARD, PRODUCT REGISTRATION
4 02.9678.0002 1 EA UNPACK/QUICK START SHEET, VL3000
- 04.4037.0001 5 EA LABEL, 2.5 X .5 BARCODE (not shown)
- 07.9678.0036 1 EA CARDBOARD SHIPPING BOX, VL3000 (not shown)
5 08.3000.0001 1 EA CD-ROM, VL3000 PRODUCT DOCUMENTATION, USER
6 22.9661.1636 2 EA FAB ASSY, BRACKET TRUSS HOOK
7 71.2557.1200 1 EA LAMP, 1200 WATT SHORT ARC, DOUBLE-ENDED
5
4
3
2
6(x2)
1
7*

T OP ASSEMBLY : VL3000 AND VL3000Q SPOT LUMINAIRE
0 2 . 9 6 7 8 . 0 0 1 0 F 69
3
VL3000 and VL3000Q Spot Luminaire
20.9678.0001 Rev P
20.9678.0003 Rev E
Refer to Figure 3-11
No. Item Qty. UM. Description
- 02.8405.0001 1 EA AC DANGER TAG, VL3000 (not shown)
- 04.9661.0033.01 1 EA LABEL, WARNING - 2000 SERIES (not shown)
- 04.9661.0039 1 EA LABEL, LINE CORD WARNING (not shown)
- 04.9678.0041.01 1 EA LABEL, AC INPUT RATING VL3000 (not shown)
- 04.9678.0061 1 EA LABEL, AC INPUT RATING VL3000Q (not shown)
- 10.9678.0609 1 EA FRONT FILTER, FOAM, ZOOM (not shown)
1 10.9661.0617 1 EA YOKE CROSSMEMBER, HEAT SHIELD
2 10.9686.0732 2 EA COVER, YOKE THERMOFORM
3 10.9678.0670 1 EA INTERCONNECT PCB MOUNT, CYM
4 10.9678.0671 1 EA INTERCONNECT PCB MOUNT, RG
5 10.9678.0658 10 EA PLATE, COUNTERWEIGHT
621.9678.0010.01 1 EA ASSY, GENERIC LUMINAIRE
721.9678.0200 1 EA ASSY, SPOT GOBO
821.9678.8640.01 1 EA ASSY, HOT BOX, SPOT
21.9678.8698.01 1 EA ASSY, HOT BOX, QUIET SPOT
921.9678.0660.01 1 EA ASSY, FAN, TRAY DUCT
21.9678.0659.01 1 EA ASSY, FAN TRAY DUCT, QUIET SPOT
10 21.9678.0678.01 1 EA ASSY, TRANSFER FAN
11 21.9678.8611 2 EA ASSY, HEAD COVER
12 22.9678.0103 1 EA ASSY, SPOT OPTIC
13 22.9678.0402 1 EA ASSY, CLR/DIM/STROB
22.9678.0462 1 EA ASSY, CLR/DIM/STROB, QUIET SPOT
14 22.9678.0149 4 EA ASSY, ROD CLAMP
15 22.9678.0693 2 EA ASSY, GOBO CLAMP
16 22.9678.0694 2 EA ASSY, COLOR CLAMP
17 22.9678.1126 1 EA ASSY, LEAD SCREW EDGE
18 24.9678.3730 1 EA PCB ASSY, VL3000 CONTROLLER
-25.9678.0675 1 EA CABLE ASSY, RELAY TO GOBO INTERLOCK SWITCH (not shown)
-25.9678.0689 1 EA CABLE ASSY, YOKE TO HEAD GND (not shown)
-25.9678.0677 1 EA CABLE ASSY, FRONT HEAD FANS (not shown)

VARI ❋ LITE ® - VL3000™ SERIES LUMINAIRE SERVICE MANUAL
7 0 0 2 . 9 6 7 8 . 0 0 1 0 F
-25.9678.0715 1 EA CABLE ASSY, HEAD CONTROLLER (not shown)
-28.9678.0001 1 EA INCLUDED ITEMS KIT, VL3000 SPOT (not shown)
19 53.2001.0003 4 EA NUT, 10-32 NYLON INSERT
20 53.2002.0003 4 EA NUT, 6-32 HEX ZINC NYLON IN
21 53.6543.0001 8 EA SCREW, 6-32 X 3/8" PPB
22 53.6558.0009 8 EA SCREW, 6-32 X 3/8"LG PPZ SEMS® *
23 53.6616.0001 4 EA SCREW, 6-32 X 3/4" PPZ SEMS
24 53.6579.0001 4 EA SCREW, 10-32 X 1/2" SCB
25 53.6613.0001 2 EA SCREW, 6-32 X 1/2" PPZ
26 53.6614.0003 4 EA SCREW, 6-32 X 5/8" PFZ
27 55.2284.0001 2 EA CARD GUIDE, 3" LONG SNAP IN
28 55.6506.0024 2 EA SPACER, 3/16"RND .1875"LG .141 THRU SS
29 55.6528.0001 2 EA WASHER, #6 FLAT ZINC
30 55.6573.0001 2 EA HARDENED SHAFT, 10MM DIA X 200MM HARDENED
31 55.6616.0001 4 EA STANDOFF, 3/8 "HEX 6-32 THRD
32 55.2150.0002 2 EA STANDOFF, 1/4 " HEX 6-32 1.188"LG MF STL (changed 05-27-03)
33 55.6677.0033 4 EA WASHER, .201" OD .125" ID .032" THK FLAT SS
34 53.6558.0007 4 EA SCREW, 6-32 X 1/4"LG PPZ SEMS EXT ZINC PLT (added 07-07-03)
- 55.6699.0003 .830 FT SLEEVING, 1/2"NOM.DIA. POLY (not shown)
- 55.6699.0004 1.16 FT SLEEVING, 3/4"NOM.DIA. POLY (not shown)
35 53.2202.0008 1 EA NUT, 8-32 HEX SS NYLON INSERT (added 05-24-04)
No. Item Qty. UM. Description
* SEMS®is a registered tradmakrk of Illinois Tool Works (ITW)

TOP ASSEMBLY : VL3000 AND VL3000Q SPOT LUMINAIRE
0 2 . 9 6 7 8 . 0 0 1 0 F 71
3
VL3000 Spot Luminaire (continued)
Figure 3-11: VL3000 and VL3000Q Spot Luminaire
1
30 (x2)
2
6
7
11
8
9
10
12
14 (x4)
13
15 (x2)
16 (x2)
17
18
22 (x2)
21 (x8)
22 (x2)
25 (x2)
23 (x2)
28 (x2)
29 (x2)
32 (x2)
2
11
3
4
5(x10)
19 (x4)
20 (x4)
24 (x4)
26 (x4)
27 (x2)
31 (x4) 33 (x4)
34 (x2)
34 (x2)
35

VARI ❋ LITE ® - VL3000™ SERIES LUMINAIRE SERVICE MANUAL
7 2 0 2 . 9 6 7 8 . 0 0 1 0 F
VL3000 and VL3000Q Wash Luminaire
20.9678.0002 Rev M
20.9678.0004 Rev F
Refer to Figure 3-12
No. Item Qty. UM. Description
- 02.8405.0001 1 EA AC DANGER TAG, VL3000 (not shown)
- 04.9661.0033.01 1 EA LABEL, WARNING - 2000 SERIES (not shown)
- 04.9661.0039 1 EA LABEL, LINE CORD WARNING (not shown)
- 04.9678.0041.01 1 EA LABEL, AC INPUT RATING VL3000 (not shown)
- 04.9678.0061 1 EA LABEL, AC INPUT RATING VL3000Q (not shown)
1 10.9661.0617 1 EA YOKE CROSSMEMBER, HEAT SHIELD
2 10.9678.0670 1 EA INTERCONNECT PCB MOUNT, CYM
3 10.9678.0732 2 EA COVER, YOKE THERMOFORM
421.9678.0010.01 1 EA ASSY, GENERIC LUMINAIRE (changed 05-24-04)
521.9678.0611 2 EA ASSY, HEAD COVER
21.9678.8611 2 EA ASSY, HEAD COVER, VL3000Q WASH
621.9678.8640.02 1 EA ASSY, WASH HOT BOX
21.9678.8698.02 1 EA ASSY, HOT BOX, VL3000Q WASH
721.9678.0660.01 1 EA ASSY, FAN, TRAY/DUCT (changed 03-01-05)
21.9678.0659.01 1 EA ASSY, FAN, TRAY/DUCT, VL3000Q WASH
821.9678.0678.02 1 EA ASSY, TRANSFER FAN (changed 11-11-03)
921.9678.0910 1 EA ASSY, BEAM SPREADER
10 21.9678.0991 2 EA ASSY, LIGHT BAFFLE BEAM SPREAD
11 21.9678.0950 1 EA ASSY, APERATURE BULKHEAD
12 22.9678.0149 2 EA ASSY, ROD CLAMP
13 22.9678.0402 1 EA ASSY, CLR/DIM/STROB
22.9678.0462 1 EA ASSY, CLR/DIM/STROB, VL3000Q WASH
14 22.9678.0693 2 EA ASSY, GOBO CLAMP
15 22.9678.0694 2 EA ASSY, COLOR CLAMP
16 24.9678.3730 1 EA PCB ASSY, VL3000 CONTROLLER
-25.9678.0675 1 EA CABLE ASSY, RELAY TO GOBO FAN (not shown)
-25.9678.0677 1 EA CABLE ASSY, FRONT HEAD FANS (not shown)
-25.9678.0689 1 EA CABLE ASSY, YOKE TO HEAD GND (not shown)
-25.9678.0715 1 EA CABLE ASSY, HEAD CONTROL (not shown)
-28.9678.0002 1 EA INCLUDED ITEMS KIT, VL3000 WASH (not shown)

TOP ASSEMBLY : VL3000 AND VL3000Q WASH LUMINAIRE
0 2 . 9 6 7 8 . 0 0 1 0 F 73
3
17 53.6543.0001 8 EA SCREW, 6-32 X 3/8" PPB
18 53.6558.0009 11 EA SCREW, 6-32 X 3/8" LG PPZ SEMS
19 53.6558.0016 2 EA SCREW, 6-32 X 3/4" PPZ SEMS
20 53.6579.0001 4 EA SCREW, 10-32 X 1/2" SCB
21 53.6613.0001 2 EA SCREW, 6-32 X 1/2" PPZ
22 53.6682.0022 8 EA SCREW, 8-32 X 3/8" LG PPZ SEMS
23 55.2178.0001 1 EA CABLE ANCHOR MOUNT, #8 SCREW MOUNT
24 55.2284.0001 1 EA CARD GUIDE, 3" LONG SNAP IN
25 55.6506.0024 2 EA SPACER, 3/16" RND .1875" LG .141" THRU SS
26 55.6528.0001 2 EA WASHER, #6 FLAT ZINC
27 55.2150.0002 2 EA STANDOFF, 1/4 " HEX 6-32 1.188" LG MF STL (changed 5-27-03)
28 55.6677.0033 4 EA WASHER, .281" OD .125" ID .032" THK FLAT SS
29 53.6558.0007 2 EA SCREW, 6-32 X 1/4"LG PPZ SEMS EXT ZINC PLT (added 7-07-03)
- 55.6699.0003 .83 FT SLEEVING, 1/2"NOM.DIA. POLY (not shown)
- 55.6699.0004 1.16 FT SLEEVING, 3/4"NOM.DIA. POLY (not shown)
No. Item Qty. UM. Description

VARI ❋ LITE ® - VL3000™ SERIES LUMINAIRE SERVICE MANUAL
7 4 0 2 . 9 6 7 8 . 0 0 1 0 F
VL3000 and VL3000Q Wash Luminaire (continued)
Figure 3-12: VL3000 and VL3000Q Wash Luminaire
1
3
2
4
5
6
7
8
9
11
10 (x2)
12 (x2)
13
14 (x2)
15 (x2)
16
18 (x2)
17 (x8)
19 (x4)
20 (x4)
21 (x2)
22 (x8)
19 (x2)
24
25 (x2)
26 (x2)
27 (x2) 3
5
18 (x2)
18 (x2)
29 (x2)
23
28 (x4)

TOP ASSEMBLY : GENERIC LUMINAIRE ASSEMBLIES
0 2 . 9 6 7 8 . 0 0 1 0 F 75
3
Generic Luminaire Assemblies
21.9678.0010.01 Rev G
21.9678.0011.01 Rev C
Refer to Figure 3-13
* Only used with 22.9678.0705 (Yoke Structure) Rev. D or later or 22.9686.0705. For prior versions
of Yoke Structure, use Center of Travel Flag part number: 10.9678.0755.
No. Item Qty. UM. Description
121.9678.0600 1 EA ASSY, HEAD STRUCTURE
21.9678.0601 1 EA ASSY, HEAD STRUCTURE, VL3000 QUIET
221.9678.0700 1 EA ASSY, YOKE
21.9678.0701 1 EA ASSY, YOKE, VL3000 QUIET
3 21.9678.0707 1 EA ASSY, TILT PULLEY
3a - 10.9678.0750 1 EA TIMING PULLEY, 150 TOOTH
3b - 10.9678.0754 * 1 EA FLAG, CENTER OF TRAVEL, TILT
3c - 53.6530.0009 3 EA RIVET, 1/8"OD POP .126-.187GL
4 21.9678.0767 1 EA ASSY, STABILIZER
4a - 10.9678.0757 1 EA STABILIZER, 1.377DIA
4b - 10.9678.0762 1 EA BRACKET, STABLIZER
4c - 53.6610.0003 1 EA SCREW, 6-32 X 7/16" PPZ
4d - 55.6568.0075 1 EA SPRING, EXTSN .375"OD 1.00"LG .041" WIRE DIA
521.9678.0800.01 1 EA ASSY, UPPER ENCLOSURE
6 53.2019.0004 4 EA NUT, 3/8-16 X 7/32"THK HEX JAM GRD5 ZINC PLT
7 53.6505.0020 5 EA BOLT, 1/4-28X 3/4"HX HD GRD 8 ZINC PLT FULL THRD
8 53.6505.0026 4 EA BOLT, 3/8-16 X .500"LG H X HD GRADE 5 BLK 9/16"HEX HEAD X .23
TALL
9 53.6539.0001 4 EA WASHER, 3/8" SPLIT LOCK
10 53.5564.0250 1 EA SCREW, 6-32 X 1/4" PFB UNDERCUT (changed 04-07-06)
11 53.6624.0001 4 EA SCREW, 10-32 X 1/2"LG PFB (changed 12-02-03)
12 53.6513.0044 3 EA SCREW, M5 X 10MM STL CUP PT (changed 10-13-03)
13 54.1206.0014 2 EA RING, RETAINING 1.375"SHAFT 1.291"GRV DIA .056"GRVWD
EXTERNAL
14 54.1255.0001 2 EA BEARING ASSY, BLACK FLUSH MOUNT HOUSING
15 54.2055.0001 1 EA BELT, TIMING S2M 210GROOVE 9MMWIDE URETHANE/KEVLAR
16 55.6549.0001 5 EA WASHER, 1/4" SPLIT LOCK
17 55.6799.0001 2 EA SHIM, 1-3/8"ID, 1-7/8"OD, .010" THK, SS (added 7-14-03)
18 55.6799.0002 2 EA SHIM, 1-3/8"ID, 1-7/8"OD, .005" THK, SS (added 7-14-03)

VARI ❋ LITE ® - VL3000™ SERIES LUMINAIRE SERVICE MANUAL
7 6 0 2 . 9 6 7 8 . 0 0 1 0 F
Generic Luminaire Assemblies (continued)
Figure 3-13: VL3000 and VL3000Q Generic Luminaire Assemblies
1
2
3
4
5
6(x4)
7(x5)
8(x4)
9(x4)
10
11 (x4)
12 (x3)
13 (x2)
15
16 (x5)
3a
3b
3c (x3)
4a
4b
4c
4d
14 (x2)
Detail A
17 (x2)
18 (x2)
Detail A

HEAD ASSEMBLY : HEAD STRUCTURE ASSEMBLY
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3
Head Assembly
Head Structure Assembly
21.9678.0600 Rev C
21.9678.0601 Rev A (VL3000 Quiet)
Refer to Figure 3-1
Figure 3-1: Head Structure Assembly
No. Item Qty. UM. Description
1 10.9678.8620 1 EA FRONT CASTING
2 12.9678.8623 1 EA RIGHT SIDE RAIL, MACHINED
3 12.9678.8625 1 EA LEFT SIDE RAIL, MACHINED
421.9678.0615 1 EA ASSY, BACKEND
21.9678.0616 1 EA ASSY, BACKEND, VL3000 QUIET
5 53.6515.0001 6 EA SCREW, 10-32 X 3/4" SCB CAP
6 53.6515.1000 1 EA SCREW, 10-32 X 1" SOCKET CAP BLACK
7 53.6615.1125 3 EA SCREW, 10-32 X 1.25" SOCKET CAP BLACK
1
2
3
5(x6)
4
6
7(x3)

VARI ❋ LITE ® - VL3000™ SERIES LUMINAIRE SERVICE MANUAL
7 8 0 2 . 9 6 7 8 . 0 0 1 0 F
Head Cover Assembly
21.9678.0611 Rev K (VL3000 Quiet)
21.9678.8611 Rev 0
Refer to Figure 3-2
No. Item Qty. UM. Description
1 10.9678.0612 1 EA HEAD COVER FOAM BAFFLE
2 10.9678.0649 4 EA EJECTOR SPRING, BLACK OXIDE
3 10.9678.0674 1 EA BRACKET, COVER TETHER
4 10.9678.0696 1 EA FOAM FRAME, HEAD COVER (added 10-01-03)
5 12.9678.8610 1 EA HEAD COVER
12.9678.8610 1 EA HEAD COVER, PAINTED, VL3000 QUIET (changed 9-10-03)
6 53.5655.0250 4 EA SCREW, #6 X 1/4" PPZ PLASTIC
7 53.6558.0003 1 EA SCREW, 6-32 X 3/8"LG PPZ PLASTIC THD ROLL
8 55.2233.0016 4 EA RETAINER, SPLIT RING (changed 04-19-05)
9 55.2233.0775 4 EA STUD, 1/4 TURN OPR.775L STEEL BLK ZINC (changed 5-21-03)
10 55.9676.0255 4 EA WASHER, BEVELED SPRING (added 05-15-05)

HEAD ASSEMBLY : HEAD COVER ASSEMBLY
0 2 . 9 6 7 8 . 0 0 1 0 F 79
3
Figure 3-2: Head Cover Assembly
1
5
4
7
10 (x4)
6(x4)
9(x4)
Bottom View
Bottom View
3
2(x4)
8(x4)

VARI ❋ LITE ® - VL3000™ SERIES LUMINAIRE SERVICE MANUAL
8 0 0 2 . 9 6 7 8 . 0 0 1 0 F
Backend Assembly
21.9678.0615 Rev S
21.9678.0616 Rev G (VL3000 Quiet)
Refer to Figure 3-3
No. Item Qty. UM. Description
1 10.9678.0631 1 EA SEPARATION BULKHEAD
2 10.9678.0635 1 EA EXHAUST BULKHEAD
3 10.9678.0637 2 EA CLIP, RETRO-REFLECTOR
4 10.9678.0638 1 EA AIR DIVERTER, STROBE MOTOR
5 10.9678.0653 1 EA LIGHT BAFFLE, EXHAUST
6 12.9678.7152 1 EA REFLECTOR, RETRO SPHERICAL COATED
7 12.9678.0627 1 EA AFT BULKHEAD, MACHINED
821.9678.0619 1 EA FAN ASSY, 80MM
9 21.9678.0673 2 EA TETHER ASSY, COVER
10 22.9678.3655 1 EA DUCT ASSY, 80MM FAN
11 22.9678.0639 1 EA UV FILTER BULKHEAD ASSY
22.9678.0617 1 EA UV FILTER BULKHEAD ASSY, VL3000 QUIET
-25.9678.0012 1 EA CABLE ASSY, AC FAN YOKE TO FAN (not shown)
-25.9678.0014 1 EA CABLE ASSY, BACKCAP INTERLOK TO GOBO INTERLOK (not shown)
12 53.2004.0002 6 EA NUT, 8-32 KEPS ZINC PLATE
13 53.6519.0001 2 EA SCREW, 4-40 X 5/8" PPZ
14 53.6545.0009 4 EA SCREW, 8-32 X 1.375"LG PFZ
15 53.6523.0001 1 EA SCREW, 6-32 X 3/8" SCB (changed 7-18-03)
16 53.6558.0007 6 EA SCREW, 6-32 X 1/4" PPZ SEMS
17 53.6559.0001 4 EA SCREW, 4-40 X 1/4" PFZ
18 53.6609.0001 6 EA SCREW, 6-32 X 3/8" PFZ
19 53.6613.0001 1 EA SCREW, 6-32 X 1/2" PPZ
20 53.6614.0003 2 EA SCREW, 6-32 X 5/8" PFZ
21 53.6616.0001 2 EA SCREW, 6-32 X 3/4" PPZ
- 55.6538.0001 2 EA WASHER, #4 LOCK EXTERNAL TOOTH
22 53.6682.0002 2 EA SCREW, 4-40 X 1/4"LG PPZ SEMS
23 55.2125.0003 4 EA STANDOFF, 3/8"HEX 8-32 1.500"L
24 55.6538.0004 7 EA WASHER,.750" OD, .312" ID, .125" THK, FLAT, TEFLON
25 55.6541.0008 1 EA GROMMET, 1/2"ID 7/8"OD 3/4"GRV
26 55.6706.0001 4 EA GROMMET, 9/32"ID 9/16"OD 1/4T
27 74.1099.0001 1 EA SWITCH, MINIATURE, 5 AMP 150DEG C, NORM OPEN

HEAD ASSEMBLY : BACKEND ASSEMBLY
0 2 . 9 6 7 8 . 0 0 1 0 F 81
3
Figure 3-3: Backend Assembly
28 53.6613.0004 3 EA SCREW, 6-32 X 1/2" SCZ (added 07-18-03)
29 10.9678.1645 1 EA FAN SHIELD, LAMP COOLING (added 12-09-04)
30 25.9678.0691 1 EA CABLE ASSY, AIR DUCT OT SWITCH (cable not shown)
25.9678.0690 1 EA CABLE ASSY, AIR DUCT OT SWITCH, VL3000 QUIET (cable not shown)
31 10.9678.0680 1 EA INSULATOR, TEFLON, TO-220
32 53.2200.0004 1 EA NUT, 4-40 KEPS
No. Item Qty. UM. Description
1
2
3(x2)
4
5
6
7
8
9(x2)
11
10
12 (x2)
13 (x2)
16 (x4)
14 (x4)
15
17 (x4)
18 (x4)
28 (x3)
20 (x2)
23 (x4)
22
24 (x2)
24 (x4)
25
26
27
12 (x2)
12 (x2)
16 (x2)
18 (x2)
21 (x2)
24 (x4)
24 (x3)
26 (x2)
19
Shield Orientation:
80 mm Fan Shield Orientation
Shield must mimic and cover fan housing.
Fan
Fan
Assembly
Shield
29
22
30
31
32

VARI ❋ LITE ® - VL3000™ SERIES LUMINAIRE SERVICE MANUAL
8 2 0 2 . 9 6 7 8 . 0 0 1 0 F
80mm Fan Assembly
21.9678.0619 Rev B
Refer to Figure 3-4
Figure 3-4: 80mm Fan Assembly
No. Item Qty. UM. Description
1 40.7145.0004 1 EA FAN, TUBEAXIAL 80 X 80 X 38mm 28 CFM 230V (added 03/11/04)
2 53.2200.0006 4 EA NUT, 6-32 KEPS SS
3 53.6558.0001 4 EA SCREW, 6-32 X 3/8" PPZ
4 55.7016.0001 1 EA FAN GUARD, 80MM NICKEL PLATED STEEL WIRE
1
2(x4)
3(x4)
4

HEAD ASSEMBLY : UV FILTER BULKHEAD ASSEMBLY
0 2 . 9 6 7 8 . 0 0 1 0 F 83
3
UV Filter Bulkhead Assembly
22.9678.0639 Rev C
22.9678.0617 Rev A (VL3000 Quiet)
Refer to Figure 3-5
Figure 3-5: UV Filter Bulkhead Assembly
No. Item Qty. UM. Description
1 10.9678.0634 1 EA UV FILTER BULKHEAD
2 10.9678.0648 2 EA CLIP, UV GLASS
3 41.9678.0608 1 EA UV/IR FILTER, 3.00" X 3.00" (added 01-08-04)
4 53.6530.0002 4 EA RIVET, 1/8 OD POP,.063-.125 GRIP, ALUM
1
2
3
4(x4)
Install glass with marks
indicating IR coating side of
filter facing up and located
outside of circular cutout in
bulkhead (Item 1).

VARI ❋ LITE ® - VL3000™ SERIES LUMINAIRE SERVICE MANUAL
8 4 0 2 . 9 6 7 8 . 0 0 1 0 F
Notes

HEAD ASSEMBLY : SPOT GOBO ASSEMBLY
0 2 . 9 6 7 8 . 0 0 1 0 F 85
3
Spot Gobo Assembly
21.9678.0200 Rev H (Spot Only)
Refer to Figure 3-6
No. Item Qty. UM. Description
1 10.9678.0215 1 EA BULKHEAD, GOBO MODULE FRONT
2 10.9678.0216 1 EA BULKHEAD, GOBO MODULE REAR
3 10.9678.0225 4 EA SHAFT, GOBO WHEEL
4 10.9678.0231 3 EA PULLEY, MOTOR GOBO WHEEL DRIVE
5 10.9678.0232 3 EA PULLEY, INSEX DRIVE 64 GROOVE
6 10.9678.0244 2 EA MOUNT, INDEX SENSOR LONG
7 10.9678.0245 1 EA MOUNT, INDEX SENSOR SHORT
8 10.9678.0246 3 EA ADJUST PLATE, MOTOR
9 10.9678.0277 1 EA SPACER, WHEEL/IRIS
10 21.9678.0210 2 EA ASSY, ROTATING GOBO WHEEL
11 21.9678.0211 1 EA ASSY, ROTATING EFFECTS WHEEL
12 21.9678.0243 2 EA ASSY, MOTOR LONG SHAFT
13 21.9678.0270 1 EA SUB-ASSY, IRIS
14 24.9663.3231 4 EA PCB ASSY, INDEX SENSOR
15 24.9678.3240 3 EA PCB ASSY, WHEEL POSITION SENSOR (changed 02-11-05)
- 25.9678.2209 1 EA PCB/CABLE ASSY, GOBO INTERCONN (changed 06-28-06) (Not Shown)
16 44.9663.1202 2 EA MOTOR, 17 2.42" SHAFT 11.8MH
17 44.9663.1766 2 EA MOTOR, 17 1.24" SHAFT 11.8MH 5
18 53.5560.0187 12 EA SCREW, 8-32 X .187 " SET CONE (changed 06-21-05)
19 53.6520.0375 8 EA SCREW, 4-40 X 3/8" PPZ SEMS
20 53.6558.0009 4 EA SCREW, 6-32 X 3/8" PPZ SEMS
21 53.5638.0252 8 EA SCREW, 6-32 X 3/8" PFZ UNDERCUT HD
22 53.6613.0001 16 EA SCREW, 6-32 X 1/2" PPZ
23 54.2057.0001 3 EA BELT, TIMING MXL .080"PITCH 14
24 54.2058.0001 3 EA BELT, TIMING MXL .080"PITCH 16
25 55.2150.0002 4 EA STANDOFF, 1/4"HEX 6-32 1.187"L
26 55.2150.0003 4 EA STANDOFF, 1/4"HEX 6-32 1.125"L
27 55.2178.0001 4 EA CABLE ANCHOR MOUNT, #8 SCREW
28 53.6682.0002 6 EA SCREW, 4-40 X 1/4" PPZ SEMS
29 55.6506.0025 1 EA SPACER, 3/8"RND 1/8"LG .257" ID
30 55.6506.0026 1 EA SPACER, 3/8"RND 31/32"LG .257" ID