VL3000Q Spot Luminaire VL3000Q Wash Luminaire CAUTION:

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1 AFTER SWITCHING OFF. Page 1 of 13 SUBJECT: VL3000 To VL3000Q Luminaire Conversion (Rev A) SERIES: 3000 DISTRIBUTION: Service Centers Only STATUS: Advanced Introduction 2 Hours Purpose This technical bulletin includes instructions for converting a standard VL3000 luminaire to a VL3000Q model. The VL3000Q model achieves quieter operation through modification of the color/dimmer/strobe assembly, UV filter and fan wiring. Both the VL3000 wash luminaire and VL3000 spot luminaire can be converted using these procedures. Once converted, the luminaire will become one of the following: Vari-Lite Model Vari-Lite Part Number VL3000Q Spot Luminaire VL3000Q Wash Luminaire Note: The label on the luminaire s backcap will darken upon operation of the converted luminaire. This is normal and does not indicate a problem. CAUTION: RISK OF FIRE. USE ONLY 1200 WATT, H TYPE 100V METAL HALIDE LAMP, SFc10-4 BASE. ATTENTION: RISQUE D'INCENDIE. UTILISER UNIQUEMENT UNE LAMPA HALOGENE EN METAL DE TYPE H, 1200 WATT, 100V ET UN SUPPORT SFc10-4. CAUTION: 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: HOT LAMP DO NOT OPEN FOR 5 MINUTES Backcap Label! WARNING: THIS CONVERSION SHOULD ONLY BE PERFORMED BY A TRAINED AND QUALIFIED VARI-LITE AUTHORIZED SERVICE FACILITY. VARI LITE, VL1000, VL2000, and VL3000 are trademarks of Genlyte Thomas Group LLC

2 Page 2 of 13 Parts KIT, VL3000 TO VL3000Q RETROFIT (SPOT)* KIT, VL3000 TO VL3000Q RETROFIT (WASH)* Comprising of: EA LABEL, VL3000Q COMPLIANCE, RETROFIT EA LABEL, AC INPUT RATING, VL3000Q EA ASSY, COVER, VENTILATION EA BULKHEAD ASSY, UV FILTER EA ASSEMBLY, STROBE MOTOR, VL3000Q EA ARC BALLAST ASSEMBLY, 1200W EA JUMPER, VL3000Q INTERCONNECT EA CABLE ASSEMBLY, IGNITOR TO LAMP SOCKET EA FAN, TUBAXIAL, 80X80X32mm 230 VAC 21CFM EA SCREW, 6-32 X 1/4" SET CONE POINT EA SCREW, 6-32 X 1/4" LG, PFS UNDERCUT HEAD EA SCREW, 4-40 X 3/8" PPZ EA SCREW, 4-40 X 1/4" PFZ EA CABLE ANCHOR, #8 SCREW MOUNT EA SADDLE, CABLE.75 X.75, 4-WAY ADH BACK WHITE EA CABLE TIE,.10 X 4" SMALL FT HEATSHRINK, 1/8" CLEAR KYNAR UL 600V EA WASHER, #4 LOCK INTERNAL TOOTH EA SPACER, 1/4" RND, #4 THRU EA SILICONE GROMMET, 9/32" ID, 9/16" OD, 1/4" THK EA RES, 5W, 5%, 200 OHM WIREWOUND EA RES, 10W, 5%, 68 OHM WIREWOUND EA SWITCH, THERMAL, 15 AMP 295 DEGREE F, OPEN Note: * = The composition of parts for both conversion kits are the same. When upgrading a VL3000 wash luminaire, you will have one resistor, one cable tie and one cable saddle left over.

3 Page 3 of 13 Tools and Supplies #1 and #2 Phillips screwdrivers #0 flat head screwdriver Wire cutters Wire Strippers 1/16" Allen wrench Soldering iron, solder, and flux Heat gun Drill and 7/16" bit Clean, non-abrasive, oil free cloth #6 Nut Driver #8 Nut Driver Loctite 242 3/16" Hex Driver External Snap-Ring Pliers

4 Page 4 of 13 Procedures Convert Luminaire WARNING: Remove power from luminaire before modification. To convert a standard VL3000 spot or wash luminaire to a VL3000Q model: Step 1. Prepare heatshrink ( ) by cutting into 20 pieces, each 3/4-inch long. Step 2. Remove power from luminaire. Step 3. Remove top and bottom head covers by loosening four 1/4-turn screws (Figure 1). Top Head Cover * 1/4-Turn Screw Bottom Head Cover * * Head covers are attached by tethers. Figure 1: Removing Head Covers Step Step 4. Remove color/dimmer/strobe assembly. Refer to VL3000 Service Manual as needed. 5. Remove gobo assembly. Refer to VL3000 Service Manual as needed. Note: The kit includes four extra 6-32 x 1/4" set screws ( ) in case they are damaged while disassembling the strobe bulkhead in the following step. Use Loctite 242 as necessary. Step 6. Modify Color/Dimmer/Strobe Assembly as follows:

5 Page 5 of 13 a. Remove strobe bulkhead from color/dimmer/strobe assembly (Figure 2) by removing four (4) 6-32 Keps nuts (see Figure 3 for locations). Set Screws Blade Color/Dimmer/Strobe Assembly Metric Screw (replace) #4 Lock Washer (add) Flat Washer (save) Spacer (discard) Grommet (replace with and ) See Detail A Detail B Viewing Direction Strobe Motors (replace) Plate Grommet Lock Washer Strobe Bulkhead Spacer Screw Detail B Set blade assemblies according to dimensions shown Motor Detail A New Motor Mounting Configuration Figure 2: Replacing Strobe Motors b. Remove strobe blades from motor shafts by loosening set screws. A heat gun may be required to loosen the screws since Loctite is applied at the factory. c. Remove both strobe motors. Discard current Metric mounting screws, grommets, and spacers (these will be replaced.) Save flat washers. d. Noting orientation of wire connectors, install new motors ( ) with new 4-40 x 3/8" PPZ screws ( ), #4 internal tooth lock washers ( ) and silicone grommets ( ) with spacers ( ). e. Re-install blades. Refer to height adjustment dimensions in Figure 2. Apply Loctite 242 if using new screws to install the blades. f. Remove Fixed Color Wheel Assembly:

6 Page 6 of Screws (x8) ( ) Front Color Bulkhead 8-32 Hex Nut Fixed Color Wheel Pulley Rear Color Bulkhead 6-32 Keps Nut Plate Motor Timing Belt Color Wheel Sensor Fixed Color Wheel Figure 3: Color/Dimmer/Strobe Assembly 6-32 Keps Nuts (x4) 1) Remove Front Color Bulkhead by removing eight (8) #6-32 screws (see Figure 3). 2) Use snap-ring pliers to hold pulley in place and use 11/32" nutdriver to remove nut from color wheel shaft. 3) Loosen, but do not remove, 6-32 Keps Nut on Plate Motor, slide motor to create slack in timing belt. Slip off Timing Belt. Unscrew Pulley by holding with slipring pliers and turning fixed color wheel. 4) Remove Fixed Color Wheel Assembly. DO NOT TOUCH FILTERS - place on a clean, grease free cloth. IMPORTANT: BE CAREFUL NOT TO TURN OVER REAR COLOR BULKHEAD ASSEMBLY - THE WHEELS, BELTS, AND PULLIES ARE SECURED BY THE FRONT COLOR BULKHEAD. g. Create new air ventilation hole as follows: 1) At color bulkhead, remove color wheel sensor by removing two 4-40 x 3/16" PPZ screws (Figure 4). 2) Drill a 7/16" hole in plate at location shown in Figure 4.

7 Page 7 of 13 3) Deburr hole edges and clean up any metal shavings. Fixed Color Wheel Removed 0.30" Color Bulkhead 0.43" 1) Remove wheel sensor under this location. 2) Drill new ventilation hole using 7/16" bit Figure 4: Creating New Air Ventilation Hole Step h. Re-install color wheel sensor. i. Re-install fixed color wheel, rear color, and front color bulkhead assemblies. Use supplied eight (8) #6-32 x 1/4-inch screws (part no ) on the front color bulkhead. Apply Loctite 242 to each screw. j. Re-install strobe bulkhead onto color/dimmer/strobe assembly. 7. Modify strobe wiring as follows: a. At color/dimmer/strobe assembly, locate cables marked "STRB #1" and "STRB #2". b. Measure 5-1/2 inches from tip of connector and cut wires. (There are four wires per cable.) Remove cable ties as required. c. Strip each wire 1/4-inch and slip one piece of heatshrink on each. d. Solder one VL3000Q interconnect jumper onto each cable, matching wire colors. e. Position heatshrink over splice and heat to secure in place. f. Connect cables to strobe motors and replace cable ties to secure in place. Note: The kit includes four extra 4-40 x 1/4" PFZ screws ( ) in case the UV filter bulkhead mounting screws are damaged during the following procedure. Use Loctite 242 as necessary. Step 8. Install new UV filter bulkhead as follows: a. At head assembly, disconnect all backend wiring (EXCEPT - safety disconnect switch and ground strap). Cut cable ties as required. b. Remove air diverter (Figure 5). c. Remove UV filter bulkhead.

8 Page 8 of 13 d. Install new UV filter bulkhead ( ). e. Re-install diverter. Fan Grille 6-32 x 3/8" PPZ Screw Keps Nut Fan Thermal Switch Air Diverter UV Filter Bulkhead Figure 5: Backend Assembly Components Step 9. Replace thermal switch as follows: a. At backend assembly, remove thermal switch by removing two screws and washers. b. Install new thermal switch ( ). Step 10. Replace backend fan as follows: a. At backend assembly, remove fan. b. Remove grille from old fan and install on new fan ( ). c. Install new fan into backend assembly. Step 11. Replace lamp wires as follows: a. Remove yoke arm cover from yoke arm which houses ignitor board. b. At rear of luminaire, loosen four 1/4-turn screws and slide lamp box back on hinge. Note: Before disconnecting, take note of the existing lamp wire s routing, from the ignitor board, through the tilt tube, and to the lamp socket.

9 Page 9 of 13 c. At ignitor board, disconnect lamp wires from terminals marked "TO BULB". d. At lamp socket, disconnect lamp wires from both terminals and remove lamp wires from luminaire, cutting cable ties as necessary (Figure 6). Lamp Box Insert #0 flat screwdriver to loosen lamp wire terminals Figure 6: Disconnecting Lamp Wires at Socket e. Install new lamp wire assembly ( ). Ensure length from ring terminals to sleeving is the same as previous lamp wire assembly. f. At ignitor board, connect new lamp wires. g. Route wires through tilt tube, along side rail and to lamp socket. Ensure splice in lamp wires is at least 2 inches from tilt tube. h. Route wires as shown in Figure 7. Pull sleeving on each wire so that it will touch lamp socket (it should cover entire length of wire) and connect to socket terminals. i. Constrain lamp wires along side rail as old lamp wires were constrained, using blue cable ties ( ) to secure in place. Route shorter lamp wire straight to socket terminal. Route longer lamp wire under lamp adjustment plate and loop back as shown. Cut-Away View Figure 7: Routing Lamp Wires at Socket Step 12. Install head and yoke fan resistors as follows: a. To create slack to facilitate installation/soldering of resistors, remove MCB (Main Control Board) from Yoke. Unplug connectors from MCB to create slack for resistor installation. The fans may be removed if desired to make easier access. b. At each fan, clip RED wire at a distance of 2-1/2 inches from fan (Figure 8). Strip each wire 1/4-inch and slip one piece of heatshrink on each.

10 Page 10 of 13 c. Clip leads of appropriate resistor to a length of 3/8-inch and solder between red wires. Refer to Figure 8 for location of each resistor type. d. Position heatshrink over splice (ensuring it covers the entire resistor lead) and heat to secure in place.on the transfer fan, install #8 screw mount cable anchor as show in Figure e. On Transfer Fan, install #8 screw mount cable anchor ( ) as shown in Figure 9. Secure resisitor wiring with cable anchor so it does not interfere with any moving assembly or path. Head Assembly Bottom View Fan - install 10W 5% 68 ohm resistor ( ) Fans - install Yoke View 5W 5% 200 ohm resistors ( ) Fan - install 10W 5% 68 ohm resistor ( ) SPOT MODEL ONLY Installing Resistors Fan 2.5" BLACK RED MTA Connector Heatshrink Resistor Heatshrink Figure 8: Installing Resistors on Head and Yoke Fans

11 Page 11 of 13 Head Assembly Top View Do not mount resistor between zoom motor and fan. Zoom Box Motor Transfer Fan - install 10W 5% 68 ohm resistor ( ) Install #8 Screw Mount Cable Anchor ( ) Transfer Fan Figure 9: Installing Screw Mount Cable Anchor on Transfer Fan Step 13. Re-install backend, gobo, and color/dimmer/strobe assemblies into head assembly. Reconnect all wiring and install cable ties as required. Step 14. Install fan cable saddles as follows: a. At each new fan resistor (except transfer fan as described in step 12e), using a cable tie, secure to an adhesive cable saddle ( ). Peel backing and attach cable saddle to side of fan so that it will not interfere with wheel movement or installation of head covers.! WARNING: POSITION RESISTOR SO THAT IT WILL NOT COME INTO CONTACT WITH THE ZOOM MOTOR ON THE ZOOM BOX ASSEMBLY. Step 15. At enclosure, remove top covers (as indicated) and bottom vent cover as shown in Figure 10. Discard old bottom vent cover and bolts. Save top covers and screws. Step 16. Remove and replace ballast assembly with new ballast as follows: a. Identify and remove 5 screws securing ballast assembly (these are located on the underside of the heatsink frame of the upper enclosure). b. Disconnect all ballast assembly cables. c. Carefully lift and remove ballast from upper enclosure (note orientation of ballast).

12 Page 12 of 13 d. Position and install new ballast assembly ( ). e. Secure new ballast assembly with 5 screws (removed in step a.). f. Reconnect all cables to new ballast assembly- be sure replace any tie wraps cut during ballast assembly removal. Top Covers Ballast Assembly Bottom Cover NOTE: Head not shown for clarity. Figure 10: Ballast Assembly Replacement Step 17. Install new enclosure bottom ventilation cover ( ) as shown in Figure 11 using new hardware. Ensure guide shafts of enclosure are seated properly inside of countersunk area of the spacers (see detailed area in Figure 11) before tightening screws.

13 Page 13 of 13 Step 18. Replace top covers. Make sure spacer is oriented as shown. Countersunk End NOTE: Head not shown for clarity. Top Covers New Ventilation Cover ( ) Figure 11: Installing New Ventilation Cover Step 19. At enclosure, apply new labels over existing labels, as shown in Figure 12. AC PWR ~ AC IN DATA IN DATA THRU MENU ENTER MODEL VL3000Q VAC 10A 50/60Hz NOTE: Head not shown for clarity. T A = 40 0 C =195 0 T MAX C MIN. DISTANCE FROM HEAD TO 2.0M FLAMMABLE OBJECTS: 0.25M Figure 12: Applying New Labels Step 20. Power up and test luminaire. IMPORTANT: MAKE SURE ALL FANS ARE FULLY OPERATIONAL. FAILURE TO DO SO CAN DAMAGE LUMINAIRE. Step 21. Re-install top cover and head covers.

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