Page 1 of 8 SUBJECT: VL3500 Wash and VL3500 Wash FX 80 mm DC Fan Assembly SERIES: 3000 DISTRIBUTION: Authorized Service Centers & Dealers STATUS: Routine Purpose Vari-Lite has implemented a design improvement for VL3500 Wash and VL3500 Wash FX luminaires that improves the cooling capacity and life of the dual 80 mm fan assembly used in the Backend Assembly (Vari-Lite assembly number 21.9686.0615). The new fans are powered by DC and run directly from the luminaire s Low-Voltage Supply (LVS). Note: This bulletin (S3K-020) is only for VL3500 Wash and VL3500 Wash FX luminaires, refer to Vari-Lite technical bulletin S3K-019 for all other Series 3000 TM fixture that use backend assembly 21.9678.0615. All VL3500 Wash and VL3500 Wash FX luminaires manufactured after 04/11/10 will already have the new 80 mm DC fans installed. Read this procedure, in its entirety, before attempting any work. WARNING: The procedure contained within this bulletin should only be performed by Authorized VARI LITE Service Centers and Dealers. Parts 28.9686.0606 1 EA 80MM DC FAN LAMP COOLING KIT (VL3500 WASH) CONSISTING OF: 10.9678.1649 2 EA FAN SHIELD, LAMP COOLING, DC 10.9686.0636 2 EA COUNTERWEIGHT, REAR 40.7113.0009 2 EA FAN, TUBAXIAL, 80MM, 24VDC, LAMP COOLING 53.2002.0001 4 EA NUT, 6-32 KEPS, ZINC 53.6558.0001 4 EA SCREW, 6-32 X 3/8" LG PPZ 53.6613.0008 3 EA SCREW, 6-32 X 1/2" LG PPB 53.6614.0008 1 EA SCREW, 6-32 X 5/8" LG PPB 55.2186.0001 4 EA CABLE TIE, 0.10" WD X 4.00" LG, SMALL 55.6538.0001 1 EA #6 LOCK WASHER, ZINC VARI LITE, VLX, VL500, VL1000, VL2000, VL2500, VL3000, and VL3500 are trademarks of Vari-Lite, a Philips group company.
Page 2 of 8 55.6658.0500 1 EA STANDOFF, 1/4" HEX 6-32 X 0.50" LG ZINC 55.6669.0001 3 EA STANDOFF, 1/4" HEX 6-32 X 0.625" FF Tools #2 Phillips Screwdriver 7/16" Wrench or Needle Nose Pliers VL3500 Wash and VL3500 Wash FX Luminaires New-Style 80 MM Fan Assembly Replacement Procedure To install new-style 80 mm DC fan assemblies into luminaire: WARNING: Completely remove all power from luminaire before performing maintenance. Assemblies within the luminaire head may be HOT after operation. Allow to cool before proceeding. 1. Set luminaire on upper enclosure to have free access to luminaire head and enclosure assemblies. 2. COMPLETELY disconnect luminaire AC input cable from power source. WARNING: DO NOT reconnect power to luminaire until all steps of this procedure are complete and as instructed to do so. 3. As illustrated in Figure 1-1, at luminaire enclosure, remove top cover (cover is closest to AC input cable assembly) over Low-Voltage Supply (LVS) to access LVS. Top Cover Low-Voltage Power Supply (LVS) NOTE: Head not shown for clarity. Figure 1-1: VL3500 Wash / VL3500 Wash FX Low-Voltage Power Supply (LVS)
Page 3 of 8 4. At LVS, relocate spade connectors (with thin wires) as shown in Figure 1-2. WARNING: There are two Black and two White wires connected to "L" (Black wires) and "N" (White wires) terminals (each is crimped into a spade connector). It is important that only the smaller / thinner wires be relocated as indicated in Figure 1-2. The larger / thicker wires carry AC voltage from the supply source to power luminaire. Relocating the larger / thicker wires will damage the luminaire. Note: Some components removed for clarity. Wire Detail Twin THIN Black Wires Spade Connectors Twin THIN White Wires Low-Voltage Power Supply (LVS) Twin THIN Black Wires* - OLD Location (from "L" terminal) Twin THIN White Wires* - OLD Location (from "N" terminal) Twin THIN Black Wires* - NEW Location (to "-" terminal) Twin THIN White Wires* - NEW Location (to "+" terminal) Low-Voltage Power Supply (LVS) + + - - L N * See Wire Detail Figure 1-2: Series 3000 Low-Voltage Power Supply (LVS) Connections 5. Reinstall top cover on upper enclosure. Note, DO NOT connect power to luminaire until instructed to do so. 6. Remove top head and bottom head covers by loosening four quarter-turn captive locking screws (on each cover) as shown in Figure 1-3.
Page 4 of 8 Top Head Cover* 1/4-Turn Screw (4 per cover) Bottom Head Cover* * Head covers are attached by tethers. Figure 1-3: Top Head Cover Removal 7. At backend assembly, remove 80 mm fans, heat shields, and chrome fan guards as follows: a. Disconnect fans from cable assembly. b. At fan assembly, remove two 6-32 KEPS nuts and two 1/4" Hex Standoffs securing fans, shields, and insulator to Separation Bulkhead (see Figure 1-5 for details). c. As shown in Figure 1-4, remove chrome fan guards from each fan by removing four 6-32 x 3/8" PPZ screws and associated 6-32 KEPS nuts. Set chrome fan guards aside to be installed on replacement fans. Chrome Fan Guard 6-32 x 3/8" Screw (x4) 6-32 KEPS Nut (x4) Old Fan Assembly Figure 1-4: Chrome Fan Guard Removal Note: After removing old-style fans, only the chrome fan guards and dual fan insulator will be used to install the new-style fans. Old-style fans, fan shields, eight 6-32 x 3/8" PPZ screws, and eight #6 KEPS nuts will not be reused. Only the Screws, nuts, and shields, supplied with kit, should be used for new-style fan installation.
Page 5 of 8. Dual Fan Insulator Fan Shield (x2) 6-32 KEPS Nut (x2) 80 mm Fan Assembly (x2) Chrome Fan Guard (x2) 1/4" Standoff 6-32 x 0.50" (x2) Note: Other components removed for clarity. Figure 1-5: VL3500 Wash / VL3500 Wash FX 80 mm Fan Assembly Removal
Page 6 of 8 8. Install new-style 80 mm DC fans as follows: a. As shown in Figure 1-6, using two 6-32 x 3/8" PPZ screws and two 6-32 KEPS nuts, secure chrome fan guard to new 80 mm fan assembly. Repeat on other fan. Note orientation of fan - fan wires exit here 6-32 KEPS Nut (x2) Chrome Fan Guard 6-32 x 3/8" PPZ Screws (Note positions, install as shown) Figure 1-6: Fan Guard Installation b. Align and slip dual fan insulator (removed in 7) over threaded studs on Separator Bulkhead. c. Position new-style fan heatshield (10.9678.1649, 2 each) over threaded studs on Separator Bulkhead. Be sure reflective side is down towards lamp housing. Note: 80 mm fan on right-hand side in Figure 1-7 is rotated 90-degrees (versus left-hand fan). Fan shield will have to be oriented same as fan. Refer to Fan Shield note in Figure 1-7. d. Position 80 mm fan assemblies as shown in Figure 1-7 and slide onto Separator Bulkhead threaded studs. e. Install standoffs as illustrated in Figure 1-7. Be sure to install and tighten 6-32 x 0.050" standoff as shown first. This allows easier access to tighten neighboring (longer) standoff on other fan assembly. f. Install three 6-32 x 1/2" PPB and one 6-32 x 5/8" PPB (with #6 lock washer) screws as shown in Figure 1-7. g. Connect fan assemblies. Use tie wraps as needed to secure wiring.
Page 7 of 8 h. SEE DETAIL Fan Shield 10.9678.1649 Fan Shield Struts Air Flow Direction Note: Some components removed for clarity. Application Notes: (A) Install reflective side down towards lamp housing. (B) Align and cover fan struts with shield struts. Fan Installation Detail Fan Shield (x2)* (10.9678.1649) 1/4" Hex 6-32 x 0.50" Standoff (x1) - tighten first Note, this fan is rotated 90-degree clockwise. Fan Insulator (from removed fan assemblies) 6-32 x 5/8" PPB Screw (x1) / #6 Lock Washer (x1) 6-32 x 1/2" PPB Screw (x3) 1/4" Hex 6-32 x 0.625" Standoff (x3) Notes: *Reflective side down towards lamp housing. **Fan label side down towards lamp housing. Figure 1-7: VL3500 Wash and VL3500 Wash FX 80 mm Fan Installation
Page 8 of 8 9. At luminaire head backend (in two places), install additional counterweights (part number 10.9678.0636) as follows: a. Rotate luminaire head so lens is pointing up. Steady luminaire head so it does not move. b. Starting one either side of luminaire head, remove seven 6-32 x 1" PPB screws securing counterweights and shown in Figure 1-8. Make sure existing counterweights do not move. c. Position one additional counterweight over existing counterweight plate holes and secure using seven 6-32 x 1" PPB screws removed from previous step. d. Repeat additional counterweight installation on other side of luminaire backend assembly. Existing Counterweights 6-32 x 1" PPB Screws (x7) Install Luminaire Head Counterweights (2 places as indicated) Note: Some components removed for clarity. Figure 1-8: VL3500 Wash and VL3500 Wash FX Luminaire Head Counterweights 10. Connect power to luminaire and make sure fans operate properly (note, air flow should be towards lamp housing). 11. After testing, turn off power to luminaire and reinstall top and bottom head covers on luminaire head assembly.