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SUBJECT: New-Style Ballast Conversion Procedure - VL3500 Wash / Wash FX
SERIES: 3000
DISTRIBUTION: Service Centers
STATUS: Routine
Introduction
Purpose
Note: This version of this technical bulletin supersedes all previous versions and contains
instructions for an optional improvement. This procedure is not necessary to achieve proper
operation. Owners and users are not required to inspect or replace their ballasts. Use this procedure
only when replacing an older-style universal wattage ballast with a new-style universal wattage
ballast.
IMPORTANT! Before performing the procedure contained herein, you must insure that the
procedure described in Vari-Lite Technical Bulletin S3K-018 (VL3500 Wash / FX Internal Lens
Cable Change Procedure) is completed on units manufactured prior to December 1, 2009.
Vari-Lite has made a change in the universal wattage ballast used in all Series 3000 Luminaires.
See Vari-Lite Technical Notice TN-320 (an update of TN-304) for additional information.
This bulletin is only for VL3500 Wash and VL3500 Wash FX Luminaires. For all other Series
3000 fixtures, refer to Technical Bulletin S3K-014B.
The new ballast (part number 69.9679.1216 - 1200W/1650W Universal Ballast) replaces all
previous versions of the ballast. This technical bulletin contains the procedure for replacing the
current ballast with a new ballast.
Note: For luminaires produced AFTER July 6, 2010 will have an old-style universal (1200/1500
watt) ballast (69.9686.1215) installed. For luminaires produced AFTER July 6, 2012 will have a
new-style universal (1200/1650 watt) ballast (69.9679.1216) installed. In the event of a ballast
failure in luminaires manufactured AFTER July 6, 2012, only the ballast will be changed. If the
fixture was manufactured BEFORE July 6, 2012, you must follow the procedure contained
herein to adapt the new-style ballast to the fixture.
WARNING: This procedure is optional and should only be performed by a trained and qualified
service technician or at an Authorized VARI❋LITE Service facility.
17 AUGUST 2012
BULLETIN NO. S3K-023B
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Parts
28.9686.1811
1 EA
VL3500 WASH / WASH FX EXHAUST FAN AND CABLE
CONVERSION KIT COMPRISED OF THE FOLLOWING:
10.9686.1812
1 EA
ROCKER SWITCH COVER PLATE
21.9679.0811
1 EA
ASSEMBLY, EXHAUST FAN, HIGH FLOW
25.9679.0002
1 EA
CABLE ASSY, FILTER TO LVS WIRES
25.9679.0003
1 EA
CABLE ASSY, BALLAST POWER
55.2186.0001
2 EA
CABLE TIE, 0.10" WD X 4.00" LG
69.9679.1216
1 EA
ASSEMBLY, UNIVERSAL BALLAST, 1200W/1650W
Tool and Supplies
•
•
•
17 AUGUST 2012
#2 Phillips Screwdriver
3/16" Allen Driver
Diagonal Cutters
BULLETIN NO. S3K-023B
Page 3 of 6
Procedures
New-Style Ballast Replacement Procedure
To install a new-style ballast in a VL3500 Wash or VL3500 Wash FX luminaire (for
fixtures manufactured BEFORE July 6, 2012):
Step 1. Disconnect luminaire AC input cable from power source.
WARNING: Make sure all power is removed from luminaire before performing this modification.
Step
2. Remove Ballast and LVS from fixture. Refer to and follow the removal procedures in
the current version of the VL3500 Wash / Wash FX Service Manual.
CAUTION: Please make note of 80MM fan wiring if converted from AC to DC fans (as outlined
in technical bulletin S3K-020B).
Step
3. At panel assembly, remove AC power rocker switch (74.2000.0002) as follows:
Panel Assembly
Rocker Switch
Figure 1: Panel Assembly
a. Disconnect all wiring at back of rocker switch.
17 AUGUST 2012
BULLETIN NO. S3K-023B
Page 4 of 6
b. As illustrated in Figure 2, remove switch by pressing in retaining tabs on side of
switch.
Panel Assembly
Rocker Switch
Tabs (one on
each side of
switch)
Rocker Switch
Figure 2: Rocker Switch Removal
c. Pass switch out through the panel assembly.
d. Discard switch.
Step
4. At ballast assembly disconnect AC Input Splitter Cable Assembly (25.9678.0812) and
replace with Ballast Power Cable Assembly (25.9679.0003) provided with kit.
To Ballast
To LVS
Figure 3: Ballast Power Cable Assembly (25.9679.0003)
17 AUGUST 2012
BULLETIN NO. S3K-023B
Page 5 of 6
Step
5. At LVS, disconnect EMI Filter to Power Switch Cable Assembly (25.9678.0811) and
replace with Filter to LVS Cable Assembly (25.9679.0002) provided with kit.
To LVS
To Filter
Figure 4: Filter to LVS Cable Assembly (25.9679.0002)
Step
6. Cover the hole in the input panel using 10.9686.1812 (ROCKER SWITCH COVER
PLATE).
a. Position cover plate to completely cover rocker switch mounting hole and "AC
POWER" text on panel assembly.
b. Peel off the adhesive backing and affix over the opening as shown in Figure 5.
Rocker Switch Cover Plate
Adhesive Side
Panel Assembly
Figure 5: Rocker Switch Cover Plate Installation
Step
17 AUGUST 2012
7. Replace LVS following procedure in Service Manual.
BULLETIN NO. S3K-023B
Page 6 of 6
Step
8. Install new 1650W Ballast (69.9679.1216) per procedure in Service Manual, replacing
the original Exhaust Fan Assembly (21.9686.0811) with the new High Flow Exhaust
Fan Assembly (21.9679.0811). Discard old Exhaust Fan Assembly.
Note: The High Flow Exhaust Fan Assembly (21.9679.0811) is used in other applications and
contains a TACH wire (yellow). This yellow wire, in this application is not connected or used.
Step
9. Connect the fan to wiring harness using the VL3500W FAN EXHAUST CABLE ASSY
ADAPTER (25.9686.1811 - shown in Figure 6) and secure using cable ties provided.
BLK
BLK
1
1
2
2
3
RED
RED
Connection to Fan Assembly
Connection to Luminaire Wiring
Figure 6: VL3500W Fan Exhaust Cable Assembly
Step 10. Continue reassembling fixture per Service Manual instructions.
Step 11. Once reassembly is complete, power luminaire and test operation.
17 AUGUST 2012
BULLETIN NO. S3K-023B
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