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PRG BEST BOY HP SPOT LUMINAIRE Service Manual

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SOFTWARE VERSION
3.03
WWW.PRG.COM
®
BEST BOY
HP SPOT LUMINAIRE
SERVICE MANUAL

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Summary of Contents for PRG BEST BOY HP SPOT LUMINAIRE

  • Page 1 SOFTWARE VERSION 3.03 WWW.PRG.COM ® BEST BOY HP SPOT LUMINAIRE SERVICE MANUAL...
  • Page 2 All other brand names which may be mentioned in this manual are trademarks or registered trademarks of their respective companies. This manual is for informational use only and is subject to change without notice. Please check www.prg.com for the latest version.

  • Page 3: Foreword

    PRG luminaires have been designed for use only with specific lamps. Note lamp type before replacing. Installing another type of lamp may be hazardous. PRG luminaires may be mounted on any type of surface as long as mounting instructions are followed. See instructions detailed in this manual.
  • Page 4 INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST EXPOSURE TO EXCESSIVE ULTRAVIOLET RADIATION PRG luminaires may use an HID type lamp which produces UV radiation. DO NOT look directly at lamp. It is hazardous to operate luminaires without complete lamp enclosure in place or when lens is damaged.

  • Page 5: Notes De Sécurité

    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.

  • Page 6: Revision History

    Revision History This manual has been revised as follows: Version Release Date Notes REV A 1 September 2019 Release of Best Boy HP Spot SERVICE Manual ® SERVICE MANUAL FOREWORD PAGE BEST BOY HP SPOT LUMINAIRE...

  • Page 7: Table Of Contents

    TABLE OF CONTENTS Foreword Compliance Notice ..................................i Safety Notice ....................................i Notes de sécurité ..................................iii Revision History................................... iv Introduction About This Manual..................................1 Additional Documentation ................................1 Technical Bulletins and Technical Notices: TBs and TNs..................... 1 Lighting Communication: DMX512, Streaming ACN (sACN) and Art-Net Protocols ............1 Training Videos .....................................
  • Page 8 Routine Maintenance Removing Head Covers................................34 Removing Aft Cover..................................35 Removing Yoke Leg Covers ............................... 37 Removing Upper Enclosure Covers ............................38 Cleaning Luminaire Exterior................................ 39 Cleaning Lenses ..................................40 Cleaning Gobo, Color, and Effect Wheels..........................43 Remove and Replace Procedures Replacing Lamp..................................
  • Page 9 Ballast Assembly ..................................207 Interface/LVS Assembly ................................210 Best Boy HP Spares List Quick Access Spares List................................. 218 Appendix A. Technical Specifications Best Boy HP Spot Luminaire..............................226 Best Boy Road Case ................................228 ® SERVICE MANUAL TABLE OF CONTENTS...
  • Page 10 ® VIII SERVICE MANUAL TABLE OF CONTENTS PAGE BEST BOY HP SPOT LUMINAIRE...

  • Page 11: Introduction

    For more information about Art-Net, refer to the following document available from Artistic License Engineering at www.artisticlicence.com. Training Videos Best Boy Training Videos are available on the PRG website. For a list of videos, refer to the following webpage: https://www.prg.com/news_media/videos#SearchTerm=Best+Boy ®...

  • Page 12: Customer Service And Technical Assistance

    Customer Service and Technical Assistance For technical assistance, contact the PRG International Service Center or contact your nearest PRG office. Contact information for all PRG office locations can be found on our website at: www.prg.com PRG Dallas (International Service) 8617 Ambassador Row, Suite 120...

  • Page 13: Chapter 1. Description

    DESCRIPTION ® This chapter contains an overview of Best Boy HP spot luminaire components. + COMPONENTS...

  • Page 14: Components

    COMPONENTS Exterior Components The following illustration shows the exterior Best Boy HP components and controls. Hanging Bracket Assembly (2) - FRONT VIEW Allows luminaire to be mounted on truss pipe. Upper Enclosure - ACIN 200-240VA C BA D B ST THR U - 015 -011...

  • Page 15: Head And Enclosure Components

    Head and Enclosure Components The following illustration shows the major sub-assemblies located in the Best Boy HP Head and Enclosure. Head Fan Assembly Head Controller PCB Wheel Stack Assembly Front Lens Aft Assembly (contains lamp, reflector, rear fan) EMI Ballast Enclosure Zoom Assembly LVS/Interface Module...

  • Page 16: Yoke Components

    Yoke Components Tilt-Side Yoke The following illustration shows the major sub-assemblies located in the Best Boy HP Tilt-Side Yoke Leg. R1 Head Cover Tilt-Side Leg Pan-Side Leg Pan/Tilt Driver Driver PCB Figure 1-3: Yoke Leg Identification Tilt Drive Mechanism Figure 1-4: Tilt-Side Yoke Leg ®...
  • Page 17 Pan-Side Yoke Leg The following illustration shows the major sub-assemblies located in the Best Boy HP Pan-Side Yoke Leg. FANS 1-4 F AN 5 Fan Controller PCB HP F AN CON TROLLE R -0640 REV S/N:0009 Ignitor PIC Kit 24VD C IN WARNING HIGH VOLTAGE DO NOT ATTEMPT...

  • Page 18: Designer Color Wheel Standard Configuration

    Designer Color Wheel Standard Configuration The following drawing shows the standard Designer Color Wheel configuration. POSITION #7 POSITION #1 UV BLUE DEEP RED (22.9816.0324.07) (22.9816.0324.01) OPEN POSITION #6 POSITION #2 REAL GREEN TURQUOISE (22.9816.0324.06) (22.9816.0324.02) POSITION #5 POSITION #3 ORANGE FOLLIES PINK (22.9816.0324.05) (22.9816.0324.03)

  • Page 19: Gobo Wheel Standard Configurations

    Gobo Wheel Standard Configurations The following drawings show the standard Gobo Wheel configurations. GOBO WHEEL 1 POSITION #1 POSITION #6 OPEN JUST ROCKS CLUBBED SPIRAL (17.1131.1007.01) (17.1131.1030.00) POSITION #2 POSITION #5 PIN HOLE BREAKUP KALEIDOSCOPE MOIRÉ (17.1131.1002.00) (17.7101.0400.00) POSITION #3 POSITION #4 SLITS SLATE WALL 4...

  • Page 20: Gobo Wheel Beam Fx Configurations

    Gobo Wheel Beam FX Configurations The Best Boy Beam FX luminaire features a different set of gobos to achieve both hard-edged and soft-edged aerial effects. The following drawings show the Beam FX configurations. ATTENTION Make sure that you specify that you want to use Beam FX gobos in your Best Boy HP. They are not a standard configuration item, and will need to be installed.

  • Page 21: Chapter 2. Testing & Troubleshooting

    TESTING & TROUBLESHOOTING This chapter provides testing and troubleshooting procedures for the luminaire. + TESTING + TROUBLESHOOTING...

  • Page 22: Testing

    About This Section The following section provides instructions for using the test and recalibration features of the Bad Boy menu system. For complete menu operating instructions, refer to the Best Boy HP Spot Luminaire User Manual (02.9816.0001). Test Screen The Test menu provides options for using the luminaire’s self-test features.
  • Page 23 Test Sub-Menu Screens Recalibrate Screens - Specifies a Disable Screen - Specifies mechanisms Mechanical Tests Screen - Specifies specific mechanism for recalibration. to be excluded from tests. mechanisms to be tested. Cleaning Lenses Screen - Positions Moiré Gobos Screen - Provides a way to Group Tests Screen - Allows multiple lenses so that they may be easily cleaned specify which wheel positions contain...

  • Page 24: Mechanical Tests

    Mechanical Tests The Mechanical Tests menu provides a method for exercising all luminaire mechanisms individually. Each mechanism has a similar Test screen. Cyan is shown in the example to the right. The following test functions are available: Test Chase - The mechanism will move back and forth between two positions.

  • Page 25: Group Tests

    Group Tests The Group Test menu allows multiple Best Boy HP Luminaires to be run through a configurable test sequence while chained together via DMX512 or Ethernet. To perform a group test: Step 1. At Group Test screen, select options to run: Pan/Tilt, Intensity, Colors, Gobos, Zoom, and/or Framing. Step 2.

  • Page 26: Troubleshooting

    TROUBLESHOOTING Errors Status Indications The STATUS panel at the Home screen will report overall luminaire conditions as follows: CALIBRATION (yellow) (green) ERROR (red) LOCKED (white) Pressing the STATUS panel will bring up a detailed Status screen as shown below: The Status screen will indicate which specific mechanisms, if any, have errors. It also provides a log of systems activity.
  • Page 27 Mechanism Errors Errors will be shown after the mechanism code, for example: PAN:Comm Error. Error Code Explanation Solution Error resetting position values in motion Check CAN cables/connections, Cal Error processor at beginning of calibration motor control board An action during calibration Check CAN cables/connections, Cal Timeout took longer than expected...
  • Page 28 Other Errors Error Code Explanation Solution Ballast Errors: Parity, Overrun, Check ballast comm cable/connections Bad Header, Msg Too Long, Various ballast errors Check Mains fuses, located on LVS Ballast Comm Error Ballast Heat Sink Over Temp Ballast too hot Check fans Ballast Lamp EOL H/L Voltage Lamp life limit exceeded Check lamp...

  • Page 29: Basic Troubleshooting

    Basic Troubleshooting The following table provides a list of common start-up problems and possible solutions. Refer to the Best Boy HP Spot Luminaire User Manual for more information about installation and operation. Symptom Solution(s) Ensure power cable is properly connected to Neutrik input connector.

  • Page 30: Best Boy Hp Fuses

    Bottom of Shutter Rotate 2A Slow Head PCB SLO-BLO CERAMIC MDA-15-R Interface/LVS Zoom Lens 1 2A Slow Head PCB PRG # 70.3773.0001.0 Zoom Lens 2 2A Slow Head PCB Zoom Lens 3 2A Slow Head PCB ® SERVICE MANUAL TROUBLESHOOTING...
  • Page 31 YOKE PCB Strobe Dimmer Tilt WHEELSTACK PCB Gobo Wheel 1 Gobo Wheel 2 Des Color Wheel Gobo Wheel 2 Please note: Shutter Blades Fuse F21 is hidden under connections inside the yellow box. Figure 2-3: Yoke PCB and Wheelstack PCB Fuse Detail ®...
  • Page 32 HEAD PCB Head Fan Effects Wheel Effects Index Gobo 1 Index Gobo 2 Index Cyan Wheel Beam Iris Yoke Fan Rear Fan Magenta Yellow Wheel Zoom Lens 1 Lamp Fan Shutter Rotate Zoom Lens 3 Zoom Lens 2 Ballast & Chassis Fans NOTE: the MAINS fuses are on the bottom MAIN CTRL PCB...

  • Page 33: Best Boy Hp Menu Map

    Best Boy HP Menu Map ® SERVICE MANUAL TROUBLESHOOTING BEST BOY HP SPOT LUMINAIRE PAGE...

  • Page 34: Best Boy Hp Menu Quickstart

    Best Boy HP Menu Quickstart ® SERVICE MANUAL TROUBLESHOOTING PAGE BEST BOY HP SPOT LUMINAIRE...
  • Page 35 Best Boy HP Menu Quickstart, Con’t ® SERVICE MANUAL TROUBLESHOOTING BEST BOY HP SPOT LUMINAIRE PAGE...
  • Page 36 Best Boy HP Menu Quickstart, Con’t ® SERVICE MANUAL TROUBLESHOOTING PAGE BEST BOY HP SPOT LUMINAIRE...
  • Page 37 Best Boy HP Menu Quickstart, Con’t ® SERVICE MANUAL TROUBLESHOOTING BEST BOY HP SPOT LUMINAIRE PAGE...
  • Page 38 Best Boy HP Menu Quickstart, Con’t ® SERVICE MANUAL TROUBLESHOOTING PAGE BEST BOY HP SPOT LUMINAIRE...
  • Page 39 Best Boy HP Menu Quickstart, Con’t ® SERVICE MANUAL TROUBLESHOOTING BEST BOY HP SPOT LUMINAIRE PAGE...
  • Page 40 Best Boy HP Menu Quickstart, Con’t ® SERVICE MANUAL TROUBLESHOOTING PAGE BEST BOY HP SPOT LUMINAIRE...

  • Page 41: Chapter 3. Maintenance

    MAINTENANCE This chapter provides maintenance procedures for the luminaire. + EQUIPMENT HANDLING + ROUTINE MAINTENANCE + REMOVE AND REPLACE PROCEDURES...

  • Page 42: Equipment Handling

    EQUIPMENT HANDLING Proper Lamp Servicing and Operation Servicing When handling a lamp, hold it by the ceramic base while wearing cotton gloves or finger cots. Do not touch the glass part of the envelope (bulb), the reflector, or the retro reflector. If you touch glass with bare fingers, wipe off any fingerprints with alcohol.

  • Page 43: Wheel Stack Road Case Instructions

    Wheel Stack Assembly during storage, transport and shipping. Pre-printed labels (addressed to the PRG Dallas office) are provided for ease of shipping. The labels can be found in a plastic bag taped to the inside of all wheel stack road cases.

  • Page 44: Routine Maintenance

    ROUTINE MAINTENANCE Removing Head Covers To access some interior head components, one or both of the Head Covers may need to be removed. A label on the backcap indicates which wheel components the head cover provides access to. Parts: 22.9817.0630 EA, ASSY HEAD COVER, BEST BOY HP SPOT Tools: #2 Philips screwdriver...

  • Page 45: Removing Aft Cover

    Removing Aft Cover To access some interior components, the Aft Cover may need to be removed. Tools: #2 Phillips screwdriver WARNING! Remove power from luminaire before performing any maintenance procedures. To remove Aft Cover: Step 1. Remove top head cover and Wheel Stack. (Refer to "Replacing Wheel Stack"...
  • Page 46 Step 6. Remove Aft Cover by removing four 10-32 x 3/8" PPSS screws. 10-32 x 3/8" PPSS Screw (4) Aft Cover Figure 3-4: Removing Aft Cover ® SERVICE MANUAL MAINTENANCE PAGE BEST BOY HP SPOT LUMINAIRE...

  • Page 47: Removing Yoke Leg Covers

    Removing Yoke Leg Covers To access some interior components, one or more of the Yoke Leg Covers may need to be removed. Tools: #2 Philips screwdriver WARNING! Remove power from luminaire before performing any maintenance procedures. To remove yoke leg covers: Step 1.

  • Page 48: Removing Upper Enclosure Covers

    Removing Upper Enclosure Covers To access some interior components, one or both of the Upper Enclosure Covers may need to be removed. Tools: #2 Phillips screwdriver WARNING! Remove power from luminaire before performing any maintenance procedures. To remove upper enclosure covers: Step 1.

  • Page 49: Cleaning Luminaire Exterior

    Cleaning Luminaire Exterior Tools: Lint-free cloth Window cleaner Vacuum cleaner with brush nozzle or compressed air #2 Phillips screwdriver To clean luminaire: WARNING! Remove power from luminaire before this procedure. CAUTION: Use ONLY OptiMax™ Ultra Pure Cleaning Solution to clean optical components. DO NOT use Window Cleaner on lens! Step 1.

  • Page 50: Cleaning Lenses

    Cleaning Lenses Tools: (2) Micro Fiber cloths (06.6085.0001.0) OptiMax™ Ultra Pure Cleaning Solution (06.6084.0001.0) Cotton gloves or finger cots #2 Phillips screwdriver 3/16" flat screwdriver To clean lenses: CAUTION: Use caution when handling lenses. Avoid scratching optical surfaces. CAUTION: Use ONLY OptiMax™ Ultra Pure Cleaning Solution to clean optical components. DO NOT use Window Cleaner on lenses! Wear cotton gloves or finger cots when handling lenses/glass.
  • Page 51 Step 3. At menu TEST screen, press "Clean Lenses.” The Cleaning Lenses screen will open. Step 4. Press “Pos 1" to position lenses in first cleaning configuration. CAUTION: When cleaning, do not allow the cleaning cloth to come into contact with the lens carrier rail. The rail has lubrication that will contaminate the cleaning cloth.
  • Page 52 CAUTION: Be extremely careful when removing Retaining Ring and Front Glass in next step. The glass can be easily chipped or cracked. Step 8. To clean backside of Front Glass and front of Lens Group , remove Front Glass as follows: a.

  • Page 53: Cleaning Gobo, Color, And Effect Wheels

    Cleaning Gobo, Color, and Effect Wheels Tools: Micro Fiber cloth (06.6085.0001.0) OptiMax™ Ultra Pure Cleaning Solution (06.6084.0001.0) Cotton gloves or finger cots #2 Phillips screwdriver To clean gobo, color and effect wheels: CAUTION: Use ONLY OptiMax™ Ultra Pure Cleaning Solution to clean optical components. DO NOT use Window Cleaner on gobo, color, or dimmer wheels! Wear cotton gloves or finger cots when handling optical components.

  • Page 54: Remove And Replace Procedures

    REMOVE AND REPLACE PROCEDURES Replacing Lamp Parts: 71.2550.1500.0 / 2.3749D-11 1 EA LAMP, HTI 1500W/D7/60 Tools: Cotton gloves or finger cots Alcohol wipe (supplied with new lamp) WARNING! Remove power from luminaire before performing any maintenance procedures. CAUTION: Refer to "Proper Lamp Servicing and Operation"...
  • Page 55 CAUTION: Allow lamp to cool before servicing. Captive Screw (2 per side) Pull lamp box out using handles Install lamp with nipple facing rear of fixture Lamp Box (towards reflector) TOP VIEW Lamp Box Rotate lamp box to access lamp Grip lamp at each end to remove/install Lamp...

  • Page 56: Adjusting Lamp

    Adjusting Lamp After a new lamp is installed, the lamp must be aligned to optimize the beam. Adjustment controls are located on the backcap. Tools: #2 Phillips screwdriver optional : 5/16"-1/2" telescoping gauge (http://www.mcmaster.com/#inside-micrometers/=r6gx02 - item # 2081A6) WARNING! Backcap WILL be HOT during lamp operation. To adjust lamp: Step 1.
  • Page 57 CAUTION: Allow lamp to cool before servicing, at least five minutes after dousing. Step 5. (Optional) Lamp alignment can be double-checked and/or adjusted by measuring the distance of the lamp plate from the rear door. a. First, open the lamp access door (refer to "Remove and Replace Procedures"...

  • Page 58: Replacing A Gobo In Gobo Wheel 1

    Replacing a Gobo in Gobo Wheel 1 Due to the complex gear alignment, it is best to remove ALL gobos from the wheel even when replacing or swapping only one gobo. This way all gobos can be re-installed at one time with the proper alignment. Recalibrating a single gobo can be a difficult process.
  • Page 59 Step 4. Re-install all gobos (making changes as necessary) by doing the following: a. Rotate gobo wheel so that first position is accessible. Refer to Figure 3-13 for wheel positions. b. Align gobo’s magnet with alignment mark on sun gear as shown in Figure 3-12. c.

  • Page 60: Replacing A Gobo In Gobo Wheel 2

    Replacing a Gobo in Gobo Wheel 2 Due to the complex gear alignment, it is best to remove ALL gobos from the wheel even when replacing or swapping only one gobo. This way all gobos can be re-installed at one time with the proper alignment. Recalibrating a single gobo can be a difficult process.
  • Page 61 Step 4. Re-install all gobos (making changes as necessary) by doing the following: a. Rotate gobo wheel so that first position is accessible. Refer to Figure 3-15 for wheel positions. b. Align gobo’s magnet with alignment mark on sun gear as shown in Figure 3-14. c.

  • Page 62: Replacing A Designer Color Filter

    Replacing a Designer Color Filter Parts: Designer Color Filter(s), as required. (Refer to "Designer Color Wheel Standard Configuration" on page 8.) Tools: #2 Phillips screwdriver Cotton gloves or finger cots WARNING! Remove power from luminaire before performing any maintenance procedures. To replace a designer color filter: Step 1.
  • Page 63 Step 5. Noting proper orientation of carrier, insert new designer color filter into position and push until carrier clicks into place. Refer to Figure 3-17 for wheel positions. Step 6. Replace Head Cover. OPEN Figure 3-17: Designer Color Wheel Positions ®...

  • Page 64: Replacing Front Glass

    Replacing Front Glass Parts: 41.9816.0628 / 2.37493-R10 1 EA FRONT GLASS Tools: Flat screwdriver Cotton gloves or finger cots WARNING! Remove power from luminaire before performing any maintenance procedures. To replace front glass: Step 1. Remove power from luminaire and allow components to cool for at least 5 minutes. CAUTION: Be extremely careful when removing Retaining Ring and Front Glass in next step.

  • Page 65: Replacing Light Shield

    Replacing Light Shield Parts: 10.9816.0029 / 2.37493-R20 1 EA LENS HOOD, FLEXIBLE 55.0078.1000.0 1 EA BALL LOKT TIE, 316SS, .310" X .010" X 39.4" COATED (STEEL BAND) Tools: Tensioning Tool (07.4035.0001.0) Flat screwdriver Large wire cutters WARNING! Remove power from luminaire before performing any maintenance procedures. To replace light shield: Step 1.
  • Page 66 Step 9. Using a flat screwdriver, press down on sharp edges of belt (left by the cutter) as shown in Detail B. (This should remove the cutting hazard.) R2 / Designer Wheel Head Cover Light Shield Fit notch into groove DETAIL A Front Ring DETAIL B...

  • Page 67: Replacing Head Fan

    Replacing Head Fan Parts: 25.9816.0996.A 1 EA CABLE ASSY, HEAD FAN, 24V NO SENSOR, ALTERNATE Tools: #2 Phillips screwdriver Wire cutters Cable Ties WARNING! Remove power from luminaire before performing any maintenance procedures. To replace the head fan: Step 1. Remove power from luminaire. Step 2.
  • Page 68 Step 5. At bottom side of Head Fan Assembly, cut cable tie which secure cables to mounting bracket. Step 6. At Fan, remove two 6-32 x 1-1/4" screws and one 6-32 x 1-3/8" screw. (The cable anchor mount and #6 flat washer will also become loose when the screw is removed.) Step 7.

  • Page 69: Replacing Head Controller Pcb

    Replacing Head Controller PCB Parts: 24.9816.0640 1 EA HEAD CONTROLLER, BEST BOY Tools: #2 Phillips screwdriver WARNING! Remove power from luminaire before performing any maintenance procedures. CAUTION: Always use anti-static precautions when working with PCBs. To replace the Head Controller PCB: Step 1.
  • Page 70 Step 5. At Head Controller PCB, remove two 6-32 x 1/4" screws and one 6-32 x 5/16" PFB screw (Figure 3-23). Step 6. Slide Head Controller PCB up and out of Head Assembly. Step 7. Replace PCB by doing steps in reverse. When re-installing, insert PCB into slot of rails/retainers as shown in Detail A below.

  • Page 71: Replacing Wheel Stack

    Replacing Wheel Stack Parts: 21.9817.0200 1 EA ASSY, WHEEL STACK BEST BOY HP SPOT Tools: #2 Phillips screwdriver WARNING! Remove power from luminaire before performing any maintenance procedures. To replace the wheel stack: Step 1. Remove power from luminaire. Step 2. Remove R1 Head Cover. (Refer to "Removing Head Covers"...
  • Page 72 Step 4. Disconnect four cables. Step 5. At Wheel Stack, loosen captive screws (Figure 3-25). Step 6. Verify that Lens Group 1 will not interfere with removal of Wheel Stack Assembly. If lenses are in the way, turn Group 1 pulley until lenses are clear. Step 7.

  • Page 73: Replacing Gobo Index 1 Motor

    Replacing Gobo Index 1 Motor Parts: 23.9816.0211.01 1 EA MOTOR ASSY, GOBO INDEX 1 Tools: #2 Phillips screwdriver Loctite #242 (06.6008.0001) WARNING! Remove power from luminaire before performing any maintenance procedures. To replace Gobo Index 1 Motor: Step 1. Remove power from luminaire. Step 2.

  • Page 74: Replacing Gobo Index 2 Motor

    Replacing Gobo Index 2 Motor Parts: 23.9816.0231.02 1 EA MOTOR ASSY, GOBO INDEX 2 Tools: #2 Phillips screwdriver Loctite #242 (06.6008.0001) WARNING! Remove power from luminaire before performing any maintenance procedures. To replace Gobo Index 2 Motor: Step 1. Remove power from luminaire. Step 2.

  • Page 75: Replacing Gag Eot Sensor

    Replacing Gag EOT Sensor Parts: 25.9816.0988 / 2.3749A-P45 1 EA CABLE ASSY, GAG EOT SENSOR Tools: #2 Phillips screwdriver Wire cutters Loctite #242 (06.6008.0001) Cable Ties WARNING! Remove power from luminaire before performing any maintenance procedures. To replace the gag sensor: Step 1.

  • Page 76: Replacing Gag Wheel Motor

    Replacing Gag Wheel Motor Parts: 23.9816.0568 / 2.37493-P7F 1 EA ASSY, MOTOR GAG WHEEL Tools: #2 Phillips screwdriver Wire cutters Cable Ties WARNING! Remove power from luminaire before performing any maintenance procedures. To replace the gag wheel motor: Step 1. Remove power from luminaire. Step 2.

  • Page 77: Replacing Gag Index Motor

    Replacing Gag Index Motor Parts: 23.9816.0569 / 2.37493-P7H 1 EA MOTOR ASSY, GAG INDEX (EXT SHAFT) Tools: #2 Phillips screwdriver Wire cutters Cable Ties WARNING! Remove power from luminaire before performing any maintenance procedures. To replace the gag index motor: Step 1.

  • Page 78: Replacing A Zoom Sensor

    Replacing a Zoom Sensor The Zoom Assembly contains three Zoom Sensor PCBs (one for each Zoom Lens Group). This procedure provides instructions for changing any one of the three sensors. Note that one (1) Zoom Sensor PCB is located on the top side of the Head Assembly (under the R1 cover) and two (2) Zoom Sensor PCBs are located on the bottom side of the Head Assembly (under the R2 cover).
  • Page 79 CAUTION: NEVER touch or adjust the brass spring-loaded standoff. It is set at the factory. 2-56 x 3/16" PPSS Screw (2) - Apply Loctite 222 Lens Group 3 Zoom Sensor (G3) Use anti-static precautions CAUTION: when working with PC boards. 3/16"...
  • Page 80 CAUTION: NEVER touch or adjust the brass spring-loaded standoff. It is set at the factory. Use anti-static precautions Zoom Sensor (G2) CAUTION: when working with PC boards. 2-56 x 3/16" PPSS Screw (2) - Apply Loctite 222 Lens Group 2 Figure 3-32: Removing Zoom Sensor 2 ®...

  • Page 81: Replacing A Zoom Lens Motor

    Replacing a Zoom Lens Motor Parts: 23.9816.0530.01 / 2.3749A-R25 1 EA MOTOR ASSY, ZOOM LENS GROUP 1 23.9816.0530.02 / 2.3749A-R30 1 EA MOTOR ASSY, ZOOM LENS GROUP 2 23.9816.0530.03 / 2.3749A-R35 1 EA MOTOR ASSY, ZOOM LENS GROUP 3 Tools: #2 Phillips screwdriver Wire cutters Loctite #242 (06.6008.0001)
  • Page 82 CAUTION: NEVER touch or adjust the brass spring-loaded standoff. It is set at the factory. 6-32 x 3/8" Socket Head Screw (2) - Apply Loctite 242 Zoom Lens Group 1 Motor Cable Tie Set Screw - Torque to 2 in-lbs - Apply Loctite 425 to threads Zoom G1 Cable Head Controller PCB...
  • Page 83 CAUTION: NEVER touch or adjust the brass spring-loaded standoff. It is set at the factory. Zoom G2 Cable Head Controller PCB Cable Tie Set Screw - Torque to 2 in-lbs - Apply Loctite 425 to threads Zoom Lens Group 2 Motor 6-32 x 3/8"...
  • Page 84 CAUTION: NEVER touch or adjust the brass spring-loaded standoff. It is set at the factory. Set Screw - Torque to 2 in-lbs - Apply Loctite 425 to threads Cable Tie 6-32 x 3/8" Socket Head Screw (2) - Apply Loctite 242 Zoom Lens Group 3 Motor Zoom G3 Cable...

  • Page 85: Replacing Zoom Lens Lead Screws

    Replacing Zoom Lens Lead Screws Best Boy HP uses precision lead screws to drive the fixture’s zoom lens system. As the lead screws age, the coating on the metal that aids in smooth operation wears off of the lead screws. See the example below, Figure 3-36: Intact Coating Worn Coating Figure 3-36: Lead Screw with Coating Worn from Threads...
  • Page 86 REMEMBER: LENS GROUP 1 IS CLOSEST TO THE LAMP LENS GROUP 3 IS FURTHEST FROM THE LAMP LENS GROUP 2 IS IN THE MIDDLE Step 6. Prior to removing the Group 3 Light Shield from the front of the fixture, you must remove at least one of the cable bundles secured to the top and bottom of the Light Shield.
  • Page 87 Step 12. Once the lead screw is loose from the threads of the Group 3 lens carrier, pull it straight out. Group 3 Lead Screw Lead Screw Bearing Lead Screw Set Screw Group 3 Carrier Motor Shaft Set Screw Motor Shaft Group 3 Motor Figure 3-39: Group 3 Lens Motor Assembly Detail Push bearing down with fingers,...
  • Page 88 Step 13. To reinstall a new lead screw, carefully thread the new lead screw, shaft end first, down through the lead screw nut. Once you’re screwed in so that the exposed shaft begins to come in contact with the bearing, hold onto the Lens carrier assembly and keep threading to properly seat the lead screw.

  • Page 89: Replacing Back Head Fans

    Replacing Back Head Fans There are four fans located on the Aft bulkhead as shown below: Fan #2 (Pinch) Fan #1 (Pinch) FAN #1 FAN #2 San Ace B76 MO DEL 10 9BD 24 HD 2 DC 24V == 0.17A FAN 3 FAN 4 Fan #4 (Plenum)
  • Page 90 Parts: 25.9815.0994 / 2.3749D-P87 4 EA CABLE ASSY, HEAD FAN Tools: #2 Phillips screwdriver Wire cutters Cable Ties Loctite #242 (06.6008.0001) WARNING! Remove power from luminaire before performing any maintenance procedures. To replace Fan #1 or Fan #2: Step 1. Remove power from luminaire. Step 2.
  • Page 91 FAN #2 FAN #1 8-32 x 1-1/2" PPZ Screw (2) - Apply Loctite 242 Cable Anchor Cable Anchor 8-32 x 1-1/2" PPZ Screw (2) - Apply Loctite 242 FAN #1 FAN #2 San Ace B76 MODEL 109BD24HD 2 DC 24V == 0.17A Head Fan Head Fan Cable...
  • Page 92 To replace Fan #3 or Fan #4: Step 1. Remove power from luminaire. Step 2. Remove head covers. (Refer to "Removing Head Covers" on page 34.) Step 3. Remove Aft Cover. (Refer to "Removing Aft Cover" on page 35.) Step 4. At required fan, cut cable ties which secure Head Fan Cable to Head Assembly (Figure 3-43). Step 5.

  • Page 93: Replacing Door Closure Safety Switch

    Replacing Door Closure Safety Switch Parts: 12.2003.0001.0 / 2.PRG-74200300010 1 EA SWITCH SAFETY, HIGH TEMP Tools: #1 and #2 Phillips screwdrivers WARNING! Remove power from luminaire before performing any maintenance procedures. To replace door closure safety switch: Step 1. Remove power from luminaire.
  • Page 94 6-32 x 5/16" PPSS Screw (4) XYZ Assembly WIRING Door Closure Safety Switch 4-40 x 5/8" PPZ Screw (2) Figure 3-44: Replacing Door Closure Safety Switch ® SERVICE MANUAL MAINTENANCE PAGE BEST BOY HP SPOT LUMINAIRE...

  • Page 95: Replacing Reflector

    Replacing Reflector Tools: 42.9816.0170 / 3749D-P091 EA REFLECTOR, STEPPED, 10 LUNES, COATED #1 and #2 Phillips screwdrivers WARNING! Remove power from luminaire before performing any maintenance procedures. To replace reflector: Step 1. If luminaire is powered-up, douse lamp and allow fans to run for at least 5 minutes. Step 2.
  • Page 96 Step 6. At Lamp Box, remove Flipper Duct by removing four 6-32 x 1/4" PPSS screws (Figure 3-46). Step 7. At Reflector, in alternating fashion, gradually loosen 4-40 x 1/4" PPSS screws until all four clips are loose. (Don’t completely remove screws or clips.) Step 8.

  • Page 97: Replacing Retro-Reflector

    Replacing Retro-Reflector Parts: 42.9815.0161 / 2.PRG-4298150161 1 EA RETRO-REFLECTOR, WASH Tools: #1 and #2 Phillips screwdrivers Wire cutters Cable Ties Loctite #242 (06.6008.0001) WARNING! Remove power from luminaire before performing any maintenance procedures. To replace retro-reflector: Step 1. Remove power from luminaire.
  • Page 98 Step 6. Remove entire High Temp Switch Bracket Assembly as follows: a. At High Temp Safety Switch, disconnect two wires. b. Remove High Temp Safety Switch Bracket Assembly by removing two 4-40 x 3/8" PPSS screws. Step 7. Remove UV/IR Assembly by removing four 8-32 x 7/16" PPSS screws (Figure 3-48). Step 8.

  • Page 99: Replacing Ignitor

    Replacing Ignitor Parts: 12.9815.0787 / 2.3749D-P36 1 EA IGNITOR, MODIFIED Tools: #1 Phillips screwdriver Loctite #242 (06.6008.0001) WARNING! Remove power from luminaire before performing any maintenance procedures. To replace the ignitor: Step 1. Remove power from luminaire. Step 2. Remove pan-side yoke leg cover. (Refer to "Removing Yoke Leg Covers"...

  • Page 100: Replacing Fan Controller Pcb

    Replacing Fan Controller PCB Parts: 24.9817.0640 / 2.3749D-P42 1 EA PCB, FAN CONTROLLER, BEST BOY HP SPOT Tools: #1 Phillips screwdriver Loctite #242 (06.6008.0001) WARNING! Remove power from luminaire before performing any maintenance procedures. To replace the Fan Controller PCB: Step 1.

  • Page 101: Replacing Interface/Lvs Assembly

    Replacing Interface/LVS Assembly Parts: 21.9817.0811 1 EA ASSY, INTERFACE/LVS, BEST BOY HP SPOT Tools: #2 Phillips screwdriver 5/32" Allen wrench, T-bar WARNING! Remove power from luminaire before performing any maintenance procedures. To replace the Interface/LVS assembly: Step 1. Remove power from luminaire. Step 2.
  • Page 102 Step 6. Flip Interface/LVS Assembly upside down as shown in Figure 3-52. Step 7. Disconnect AC cables and LVS DC Output cables. Step 8. Remove Interface/LVS Assembly Step 9. Replace component by doing steps in reverse. Interface/LVS Assembly LVS DC Output Cables TOP VIEW - CABLE LAYOUT AC Cables...

  • Page 103: Replacing Upper Enclosure Fan

    Replacing Upper Enclosure Fan Parts: 25.9816.0992 / 2.3749A-R05 1 EA CABLE ASSY, UE CHASSIS FAN Tools: #2 Phillips screwdriver 11/32" nutdriver 5/32" Allen wrench, T-bar WARNING! Remove power from luminaire before performing any maintenance procedures. To replace the enclosure fan: Step 1.
  • Page 104 6-32 x 2-1/4" PPB Screw (2) 5/16" OD 7/8" Long #6 Standoff (2) Cable Anchor 6-32 Nylon Hex Nut (2) Upper Enclosure Fan Interface/LVS Assembly FAN 2 10-32 x 3/4" Socket Screw (4) Ground Wire 10-32 x 3/8" PPB Screw Fan Cable Figure 3-53: Removing Upper Enclosure Fan ®...

  • Page 105: Replacing Ballast

    Replacing Ballast Parts: 21.9817.0810 1 EA ASSY, BALLAST, BEST BOY HP SPOT Tools: #2 Phillips screwdriver 5/32" Allen wrench, T-bar WARNING! Remove power from luminaire before performing any maintenance procedures. To replace the ballast: Step 1. Remove power from luminaire. Step 2.
  • Page 106 Ballast 10-32 x 3/4" Socket Screw (4) FAN CABLE Ballast 10-32 x 3/4" Socket Screw (4) Interface/LVS Assembly 25-9816-09 56 FROM BALLAST UPPER ENCLOSURE GND #4 Enclosure 10-32 x 3/4" GROUND WIRE Socket Screw (4) TAB 4 TAB 6 RELAY WIRES HOT RELAY DETAIL GROUND MAIN CONTROL...

  • Page 107: Replacing Ballast Fan

    Replacing Ballast Fan Parts: 25.9816.0991 / 2.3749A-R10 1 EA CABLE ASSY, BALLAST HEATSINK FAN BEST BOY Tools: #2 Phillips screwdriver Loctite #242 (06.6008.0001) WARNING! Remove power from luminaire before performing any maintenance procedures. To replace the ballast fan: Step 1. Remove power from luminaire. Step 2.

  • Page 108: Replacing Pan/Tilt Driver Pcb

    Replacing Pan/Tilt Driver PCB Parts: 24.9816.0765 / 2.3749A-P55 1 EA PCB ASSY, YOKE DRIVER Tools: #2 Phillips screwdriver Sonic Tension Meter Loctite #242 (06.6008.0001) WARNING! Remove power from luminaire before performing any maintenance procedures. CAUTION: Always use anti-static precautions when working with PCBs. To replace the Pan/Tilt Driver PCB: Step 1.
  • Page 109 Step 5. At Pan/Tilt Driver PCB, disconnect all cables (Figure 3-57). Step 6. Remove Pan/Tilt Driver PCB by removing four 6-32 x .250 PPSS screws. Step 7. Replace Pan/Tilt Driver PCB by doing steps in reverse. Apply Loctite 242 to 6-32 x .250 PPSS screws. Step 8.

  • Page 110: Replacing Tilt Cot Sensor

    Replacing Tilt COT Sensor Parts: 25.9816.0981 / 2.3749A-P30 1 EA CABLE ASSY, TILT COT SENSOR Tools: #1 and #2 Phillips screwdrivers 1/4" nutdriver Wire cutters Loctite #242 (06.6008.0001) Cable Ties WARNING! Remove power from luminaire before performing any maintenance procedures. CAUTION: Always use anti-static precautions when working with PCBs.
  • Page 111 Step 4. At Tilt-Side Yoke Leg, disconnect Tilt COT Sensor Cable from Pan/Tilt Driver PCB (Figure 3-59). Step 5. Cut all cable ties which secure Tilt COT Sensor Cable to yoke and crossmember. Note placements. Step 6. At Tilt COT Sensor PCB, remove two 4-40 x 1/4" PFSS screws which secure standoffs to yoke. Step 7.

  • Page 112: Replacing Tilt Drive Mechanism

    Replacing Tilt Drive Mechanism Parts: 21.9816.0719 / 2.3749A-P75 1 EA ASSY, TILT DRIVE MECHANISM Tools: #2 Phillips screwdriver 3/8" nutdriver Wire cutters Sonic Tension Meter Cable Ties WARNING! Remove power from luminaire before performing any maintenance procedures. To replace the tilt drive mechanism: Step 1.
  • Page 113 Step 5. Remove Yoke Cover Mounting Bracket by removing four 8-32 x 1/2" PFB screws. Step 6. At Tilt Mechanism, loosen four 10-32 nylon insert nuts and move Tilt Mechanism enough so that Timing Belt can be removed. Step 7. To remove Tilt Mechanism, fully remove four 10-32 nylon insert nuts and #10 flat washers. Step 8.

  • Page 114: Replacing Pan Drive Mechanism

    Replacing Pan Drive Mechanism Parts: 21.9816.0718 / 2.3749A-P70 1 EA ASSY, PAN DRIVE MECHANISM Tools: #2 Phillips screwdriver 5/32" Allen wrench, T-bar Wire cutters Cable Ties WARNING! Remove power from luminaire before performing any maintenance procedures. To replace the pan drive mechanism: Step 1.
  • Page 115 Step 4. At Pan/Tilt Driver PCB, disconnect pan drive cables (Figure 3-60).. Step 5. Cut cable ties which secure cables to luminaire. Note placement for re-installation. Step 6. Remove Yoke Cover Mounting Bracket by removing four 8-32 x 1/2" PFB screws. Step 7.

  • Page 116: Setting Pan/Tilt Belt Tension

    Setting Pan/Tilt Belt Tension Loose pan/tilt drive belts can create calibration problems. When the luminaire reaches the end of travel, excess belt slack can produce a vibration causing the encoder to continue producing a movement output signal to the processor (even though the luminaire is at its stop).
  • Page 117 CAUTION: Do not over-tighten belt! Pulley will break and/or bearings will fail. To set belt tension manually: Step 1. Orient head as shown in Figure 3-64. Step 2. Manually move the luminaire head back and forth (tilt) or around (pan), noting the tension created on one side of belt and deflections on the other.
  • Page 118 MAINTENANCE NOTES ® SERVICE MANUAL MAINTENANCE PAGE BEST BOY HP SPOT LUMINAIRE...

  • Page 119: Chapter 4. Illustrated Parts Breakdown

    ILLUSTRATED PARTS BREAKDOWN This chapter provides illustrated parts breakdowns for the luminaire sub-assemblies. + OVERVIEW + TOP ASSEMBLY + HEAD + ZOOM OPTICS + WHEEL STACK + YOKE + UPPER ENCLOSURE + BEST BOY HP SPARES LIST...

  • Page 120: Overview

    This Illustrated Parts Breakdown is intended for use with Shop and Field Service level operation of the luminaire. All subassembly breakdowns are included, except those not suitable for repair outside of PRG Manufacturing. If a breakdown is not shown for a particular subassembly, please order the entire subassembly as a replacement item.

  • Page 121: Drawing Tree

    Drawing Tree The following diagram represents the breakdown of sub-assemblies in the luminaire. TOP ASSEMBLY Covers and Included Items 20.9817.0001 Head Cover Assembly Upper Enclosure Interface Upper Enclosure Ballast Yoke Arm Cover Cover Assembly Cover Assembly 22.9817.0630 Assembly 21.9816.0820 21.9816.0830 22.9816.0716 Luminaire Hook Bracket...

  • Page 122: Top Assembly

    TOP ASSEMBLY Covers and Included Items 20.9817.0001 Revision: Item Description Procedure 10.9816.0029 LENS HOOD, FLEXIBLE page 55 21.9816.0820 page 38 ASSY, UE INTERFACE COVER 21.9816.0830 page 38 ASSY, UE BALLAST COVER 21.9816.0863 ASSY, HOOK BRACKET 21.9817.0020 SUB-ASSEMBLY, LUMINAIRE w/o COVERS 22.9816.0033 ASSY, SAFETY CABLE HEAVY DUTY 22.9816.0716...
  • Page 123 Covers and Included Items (continued) Refer to Parts List for "Covers and Included Items" on page 112. EXPL ODED VIEW 1st STAGE EXPL ODED VIEW 2nd STAGE ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN BEST BOY HP SPOT LUMINAIRE PAGE...

  • Page 124: Head Cover Assembly

    Head Cover Assembly 22.9817.0630 Revision: Rev B0 Item Description Procedure 04.9812.0630 LABEL, HEAD COVER PRG 10.9816.0637 RAIN MOD SHIELD SIMPLIFIED, BEST BOY 10.9817.0661 FILTER AIR, FOAM, BEST BOY HP SPOT 12.5665.0001.0 SCREW, BLK ZINC PLATED(COMES IN AS/53.5 12.9817.0630 MODIFIED HEAD COVERS, BEST BOY HP SPOT 22.9816.0631...
  • Page 125 Head Cover Assembly (continued) Refer to Parts List for "Head Cover Assembly" on page 114. NOTICE HOLES ORIENTATION SIDE VIEW APPLY BLACK SEALANT #709 1 FRONT SIDE VIEW BOTTOM VIEW EXTERIOR ISO VIEW 1st STAGE ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN BEST BOY HP SPOT LUMINAIRE PAGE...
  • Page 126 Head Cover Assembly (continued) Refer to Parts List for "Head Cover Assembly" on page 114. APPLY BLACK SEALANT #7091 AS NEEDED TO FILL GAPS EXTERIOR ISO VIEW 2nd STAGE "C" DETAIL INTERIOR ISO VIEW FINAL STAGE ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN PAGE BEST BOY HP SPOT LUMINAIRE...

  • Page 127: Upper Enclosure Interface Cover Assembly

    Upper Enclosure Interface Cover Assembly 21.9816.0820 Revision: Rev B0 Item Description Procedure page 38 10.9816.0820 COVER, UPPER ENCLOSURE, INTERFACE 53.5510.0661.0 SCREW, CAPTIVE 10-32 X 3/4" PHILLIPS FILLISTER HD SS BZ 55.6623.0027.0 WASHER, NYLON RETAINER 10-32 .312"OD .167"ID .020TH ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN BEST BOY HP SPOT LUMINAIRE...

  • Page 128: Upper Enclosure Ballast Cover Assembly

    Upper Enclosure Ballast Cover Assembly 21.9816.0830 Revision: Rev B0 Item Description Procedure page 38 10.9816.0830 COVER, UPPER ENCLOSURE, BALLAST 53.5510.0661.0 SCREW, 10-32 X 5/6" CAPTIVE 55.6623.0027.0 WASHER, NYLON RETAINER 10-32 .312"OD .167"ID .020TH ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN PAGE BEST BOY HP SPOT LUMINAIRE...

  • Page 129: Hook Bracket Assembly

    Hook Bracket Assembly 21.9816.0863 Revision: Rev C0 Item Description Procedure 10.9816.0863 HOOK BRACKET, BEST BOY 10.9816.0864 SPRING, HOOK BRACKET BEST BOY 53.6553.0010.0 SCREW, 10-32 X 3/16" PPBZ 53.7015.9596.0 SCREW, 18-8 1/2" X 1" FLAT HEAD SOCKET 55.6872.0001.0 MEGA-CLAW, TRUSS HOOK, 2" ROUND TUBE BL ®...

  • Page 130: Yoke Arm Cover Assembly

    Yoke Arm Cover Assembly 22.9816.0716 Revision: Rev C0 Item Description Procedure page 37 10.9816.0716 COVER, YOKE ARM ASSY, BEST BOY 10.9816.0715 YOKE ARM VENT COVER 10.9816.0752 YOKE VENT FLANGE, BEST BOY 10.9816.0767 GASKET, YOKE VENT FLANGE 12.6574.0010.0 SCREW, BLK ZINC, 25MM LG, SOUTHCO FAST 53.6522.0002 SCREW, 6-32 X 1/4"...

  • Page 131: Luminaire Subassembly

    Luminaire Subassembly 21.9817.0020 Revision: Rev C0 Item UM Qty Description Procedure 25.9816.0962 CABLE ASSY, BALLAST OUTPUT TO RELAY 10.9815.0795 IGNITOR SAFETY CAPS 10.9816.0711 PAN PULLEY, BEST BOY 10.9816.0712 TILT PULLEY, BEST BOY 10.9816.0713 PAN TUBE BEARING CLAMP, BEST BOY 10.9816.0737 PAN BEARING CLAMP, BEST BOY 10.9816.0738 YOKE COVER MOUNTING BRACKET, BEST BOY...
  • Page 132 Item UM Qty Description Procedure 25.9816.0980.04 CABLE ASSY, CAN BUS DATA, BEST BOY HP SPOT page 54 41.9816.0628 GLASS, FRONT, BESTBOY 53.2202.0006 NUT, 6-32 HEX SS NYLON INSERT 53.2202.0010 NUT, 10-32 HEX SS NYLON INSERT 53.6522.0004.0 SCREW, 6-32 X 1/4" SEMS 53.5606.0312 SCREW, 6-32 X 5/16"...
  • Page 133 Luminaire Subassembly (continued) Refer to Parts List for "Luminaire Subassembly" on page 121. STOP B OLT A REA NOTICE OVA L ORIENT ATION "A" DETAIL INTERFACE/ LVS SIDE BA LLAS T SID E PULL EY C LOCKING O RIENTATION DE TAIL EXPLODED VIEW 1st STAGE ®...
  • Page 134 Luminaire Subassembly (continued) Refer to Parts List for "Luminaire Subassembly" on page 121. TO H EAD CON TROLLER PCB FAN PCB DC PWR IN J27 IGNITOR WHEEL STA CK PC B INPUT TAB S DC PWR IN J2 TO YOKE DRIV ER PCB DC PWR IN J14 CON2-...
  • Page 135 Luminaire Subassembly (continued) Refer to Parts List for "Luminaire Subassembly" on page 121. 25-9817-0992 FROM UPPER ENCLOSURE NOTICE: FEEDCABLE THRU FERRITE 25-9816-0956 FROM BALLAST FAN 2 UPPER ENCLOSURE 25-9816-0991 GND#4 FROM BALLAST 25-9816-0990 FAN 1 TO UPPER ENCLOSURE CANBUS "C" DETAIL "D"...
  • Page 136 Luminaire Subassembly (continued) Refer to Parts List for "Luminaire Subassembly" on page 121. 25-9816-09 81 TILT C OT SENS OR FANS 1-4 FAN 5 HP FAN CONTROLLER -0640 RE V S/N:0009 PICKit 24VDC IN WAR NING HI G H V O LTA GE "J"...
  • Page 137 Luminaire Subassembly (continued) Refer to Parts List for "Luminaire Subassembly" on page 121. GND CABLE DETAIL BOTTTOM VIEW NOTICE ORIENTATION "H" SEE DETAIL EXPLODED VIEW 5th STAGE "H" DETAIL "H" SEE DETAIL EXPLODED VIEW EXPLODED VIEW 6th STAGE ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN BEST BOY HP SPOT LUMINAIRE...
  • Page 138 Luminaire Subassembly (continued) Refer to Parts List for "Luminaire Subassembly" on page 121. TO FAN # 1 LAMP P INCH1 TO FAN # 2 LAMP P INCH2 FROM BACK FANS PCB J1 TO FAN # 3 BACK FANS BACK CAP TO FAN # 4 BACK CAP FAN #1...
  • Page 139 Luminaire Subassembly (continued) Refer to Parts List for "Luminaire Subassembly" on page 121. EXP LOD ED VIEW 7th STAG E ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN BEST BOY HP SPOT LUMINAIRE PAGE...
  • Page 140 Luminaire Subassembly (continued) Refer to Parts List for "Luminaire Subassembly" on page 121. 25-9816-0976 FROM HEAD FAN ASSY 25-9816-0996 FROM HEAD FAN ASSY "A" DETAIL CABLE LAYOUT EXPLODED VIEW 6th STAGE EXPLODED VIEW "B" DETAIL 7th STAGE CABLE LAYOUT ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN PAGE...
  • Page 141 Luminaire Subassembly (continued) Refer to Parts List for "Luminaire Subassembly" on page 121. GR IP LAMP A T EA CH EN D TO INSTALL ROTATE 90° TO ACC ESS LAM P PU LL LA M P BOX OUT NIPPLE (INSTAL L TOWARDS REFLECTOR) EXPLO DED VIEW 3rd STAGE EXPLO DED VIE W...
  • Page 142 Luminaire Subassembly (continued) Refer to Parts List for "Luminaire Subassembly" on page 121. WH EEL STACK 25-9816-0976 FROM PCB J6 HEAD FAN ASSY 25-9816-0996 F ROM HEAD FAN ASSY B ES T BOY H EA D C ON TROLL ER 2 4 -9 8 16 -0 64 0 REV 25-9816-0993 F ROM PAN YO KE LEG ASSY...

  • Page 143: Wheel Stack

    WHEEL STACK Wheel Stack Assembly 21.9817.0200 Revision: Rev C0 Item UM Description Procedure 10.9816.0203 RAIL MOUNT, WHEEL STACK 10.9816.0204 7MM AXLE, WHEEL STACK 10.9816.0205 FRONT PLATE, BEST BOY 10.9816.0206 SENSOR BAR, WHEEL STACK 10.9816.0214 CRANK ARM, IRIS WHEEL STACK 10.9816.0215.01 WHEEL SPACERS, WHEEL STACK .238x.002 10.9816.0215.02 WHEEL SPACERS, WHEEL STACK .110 x .002...
  • Page 144 Item UM Description Procedure 24.9816.0220 PCB ASSY, WHEEL CONTROLLER 24.9816.0221 ASSY, BEST BOY R1 SENSOR 24.9816.0222 ASSY, BEST BOY R2 SENSOR 25.9816.0970 SHUTTER PCB DC & CAN BUS 25.9816.0982 CABLE ASSY, IRIS EOT BEST BOY 25.9816.0983 CABLE ASSY, R1 SENSOR 25.9816.0984 CABLE ASSY, WHEEL STACK EOT SENSOR 2 25.9816.0985...
  • Page 145 Item UM Description Procedure 55.6704.0026.0 STANDOFF, 5/16 HEX X 1-3/8 X 632, FF ALUM 55.6704.0027.0 STANDOFF, 5/16 HEX X 1-15/32 X 632, FF ALUM 55.6704.0029.0 STANDOFF, 5/16 HEX X 1-5/8 X 632, FF ALUM 55.6704.0030.0 STANDOFF, 5/16 HEX X 1-13/16 X 632, FF ALUM 55.6704.0031.0 STANDOFF, 3/8"...
  • Page 146 Wheel Stack Assembly (continued) Refer to Parts List for "Wheel Stack" on page 133. NOTES: ISOMETRIC VIEW ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN PAGE BEST BOY HP SPOT LUMINAIRE...
  • Page 147 Wheel Stack Assembly (continued) Refer to Parts List for "Wheel Stack" on page 133. G. W. #2 ISOMETRIC VIEW G. W. #2 1st STAGE "A" DETAIL INDEX #2 INDEX #1 SHUTTER FAN 5 FAN 6 EXPLODED VIEW 1st STAGE ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN BEST BOY...
  • Page 148 Wheel Stack Assembly (continued) Refer to Parts List for "Wheel Stack" on page 133. ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN PAGE BEST BOY HP SPOT LUMINAIRE...
  • Page 149 Wheel Stack Assembly (continued) Refer to Parts List for "Wheel Stack" on page 133. STRB CYAN DES C IRIS FAN 6 FAN 5 SHUTTER G. W. #2 EXPLODED VIEW 3rd STAGE G. W. #1 ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN BEST BOY HP SPOT LUMINAIRE PAGE...
  • Page 150 Wheel Stack Assembly (continued) Refer to Parts List for "Wheel Stack" on page 133. GOBO WHEEL #1 GOBO WHEEL #2 GREEN GREEN EXPLODED VIEW 4th STAGE ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN PAGE BEST BOY HP SPOT LUMINAIRE...
  • Page 151 Wheel Stack Assembly (continued) Refer to Parts List for "Wheel Stack" on page 133. AMBER DESIGNER GREEN EXPLODED VIEW 5th STAGE ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN BEST BOY HP SPOT LUMINAIRE PAGE...
  • Page 152 Wheel Stack Assembly (continued) Refer to Parts List for "Wheel Stack" on page 133. CYAN MAGENTA PURPLE ORANGE EXPLODED VIEW 6th STAGE ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN PAGE BEST BOY HP SPOT LUMINAIRE...
  • Page 153 Wheel Stack Assembly (continued) Refer to Parts List for "Wheel Stack" on page 133. DIMMER YELLOW YELLOW EXPLODED VIEW 7th STAGE ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN BEST BOY HP SPOT LUMINAIRE PAGE...
  • Page 154 Wheel Stack Assembly (continued) Refer to Parts List for "Wheel Stack" on page 133. STROBE YELLOW EXPLODED VIEW 8th STAGE ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN PAGE BEST BOY HP SPOT LUMINAIRE...
  • Page 155 Wheel Stack Assembly (continued) Refer to Parts List for "Wheel Stack" on page 133. EXPLODED VIEW 9th STAGE ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN BEST BOY HP SPOT LUMINAIRE PAGE...
  • Page 156 Wheel Stack Assembly (continued) Refer to Parts List for "Wheel Stack" on page 133. Note: Rotate this motor out of position while mounting Framing Assy; rotate back to re-engage with sector gear once Framing Assy is mounted. EXPLODED VIEW 10th STAGE ®...
  • Page 157 Wheel Stack Assembly (continued) Refer to Parts List for "Wheel Stack" on page 133. FAN 8 FAN 6 "B" DETAIL FAN 8 DIMMER FAN 7 ISOMETRIC VIEW 10th STAGE ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN BEST BOY HP SPOT LUMINAIRE PAGE...
  • Page 158 Wheel Stack Assembly (continued) Refer to Parts List for "Wheel Stack" on page 133. FAN 5 FAN 5 FAN 7 FAN 7 "C" DETAIL EXPLODED VIEW FINAL STAGE ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN PAGE BEST BOY HP SPOT LUMINAIRE...

  • Page 159: Designer Color Wheel Assembly

    Designer Color Wheel Assembly 22.9816.0320 Revision: Rev B0 Item Description Procedure 10.9816.0319 MOUNT, MAGNET 10.9816.0321 WHEEL, DESIGNER COLOR 10.9816.0322 HUB SPACER, DESIGNER COLOR WHEEL 10.9816.0323 SPRING, DESIGNER COLOR WHEEL 10.9816.0338 PULLEY, COMMON, BEST BOY 10.9816.0348 SPACER, DESIGNER COLOR WHEEL See Table Below page 52 22.9816.0324.xx ASSY, DESIGNER COLOR PANELS -...
  • Page 160 Designer Color Wheel (continued) Refer to Parts List for "Designer Color Wheel Assembly" on page 149. ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN PAGE BEST BOY HP SPOT LUMINAIRE...

  • Page 161: Gobo Wheel 1 Assembly (Standard Load)

    Gobo Wheel 1 Assembly (Standard Load) 22.9816.0380 Revision: Rev A0 Item Description Procedure page 48 17.1131.1007.01 GOBO ASSY, JUST ROCKS page 48 17.1131.1002.00 GOBO ASSY, PINHOLE BREAKUP page 48 17.1131.1001.00 GOBO ASSY, SLITS 17.1131.1006.01 GOBO ASSY, SLATE WALL 4 page 48 page 48 17.7101.0400.00 GOBO ASSY, KALEIDOSCOPE MOIRE...

  • Page 162: Gobo Wheel 2 Assembly (Standard Load)

    Gobo Wheel 2 Assembly (Standard Load) 22.9816.0390 Revision: Rev A0 Item Description Procedure page 50 17.1131.5000.00 GOBO ASSY, CHICLETS page 50 17.1131.1010.00 GOBO ASSY, OAK FOLIAGE 1 page 50 17.1131.1013.00 GOBO ASSY, CRACKLE LINEAR 17.1131.1022.04 GOBO ASSY, GHOST DUST page 50 page 50 17.7101.0401.00 GOBO ASSY, FIREWATER ANIMATION...

  • Page 163: Head

    HEAD Head Assembly 21.9817.0600 Revision: Rev A0 Item Description Procedure 04.9816.0052 LABEL, FUSE REFERENCE 06.6083.0001.0 RTV, 3145 CLEAR 305ML TUBE 10.9816.1611.02 SIDE RAIL, MACHINED 10.9816.0613 TUBE, TILT, BEST BOY 10.9816.0620 PLATE, FAST LEAD RECEPTACLE 10.9816.0641 BRACKET, HEAD MOTOR AND FAN DRIVER 10.9816.0642 GASKET, SIDE RAIL (LH) 10.9816.0643...
  • Page 164 Head Assembly (continued) Refer to Parts List for "Head Assembly" on page 153. ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN PAGE BEST BOY HP SPOT LUMINAIRE...
  • Page 165 Head Assembly (continued) Refer to Parts List for "Head Assembly" on page 153. EXPLODED VIEW 2nd STAGE EXPLODED VIEW 1st STAGE ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN BEST BOY HP SPOT LUMINAIRE PAGE...
  • Page 166 Head Assembly (continued) Refer to Parts List for "Head Assembly" on page 153. ASSEMBLED ISO VIEW SIDE RAIL & BRACKET EXPLODED VIEW 3rd STAGE EXPLODED VIEW ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN PAGE BEST BOY HP SPOT LUMINAIRE...
  • Page 167 Head Assembly (continued) Refer to Parts List for "Head Assembly" on page 153. "AA" SEC TION CRITICAL! NOTICE ORIENTATION EXPLODED VIEW 4th STAGE FUSE LOCATION YOKE PCB PAN - F1 DIMMER - F3 TILT - F2 STROBE - F4 HEAD PCB EFFECTS WHEEL - F5 MAGENTA WHEEL - F11 EFFECTS INDEX - F6...
  • Page 168 Head Assembly (continued) Refer to Parts List for "Head Assembly" on page 153. 23-9816-0530-03 23-9816-0530-01 FROM ZOO M ASS Y FROM ZOO M ASS Y 25-9816-0986 FROM ZOOM ASS EMB LY BEST BOY HEAD CONTROLLER 24-9816-0640 REV 23-9816-0568 FROM ZOOM ASS EMBLY 23-9816-0569 FROM ZOOM ASS EMBLY 23-9816-0530-02...

  • Page 169: Zoom Optics

    ZOOM OPTICS Zoom Assembly 21.9816.0500 Revision: Rev H0 Item Description Procedure 10.9816.1521.02 BLOCK, BEARING G1,G3, MACHINED 10.9816.1522.02 CARRIER, LENS G1, MACHINED 10.9816.0523 STRAP, LENS G1 BEST BOY 10.9816.1524.02 BLOCK, BEARING, G2, MACHINED 10.9816.1525.02 CARRIER, LENS G2, MACHINED 10.9816.0526 STRAP, LENS G2 BEST BOY 10.9816.1528.02 CARRIER, LENS G3, MACHINED 10.9816.0529...
  • Page 170 Item Description Procedure 53.5534.0187 SCREW, 4-40 X 3/16" PFSS 53.5534.0250 SCREW, 4-40 X 1/4" PFSS 53.5660.0003.0 COUPLING, MOTOR-LEADSCREW, SUPERSHORT 4mm X 4mm 53.5808.0700 SCREW, M3 X 10MM SCSS 53.6513.0060.0 SCREW, 18-8 M3 X 8MM LG SOCKET HEAD CAP SS METRIC 53.6515.0005.0 SCREW, 10-32 X 3/4"...
  • Page 171 Zoom Assembly (continued) Refer to Parts List for "Zoom Assembly" on page 159. ISOMETRIC VIEW ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN BEST BOY HP SPOT LUMINAIRE PAGE...
  • Page 172 Zoom Assembly (continued) Refer to Parts List for "Zoom Assembly" on page 159. EXPLODED VIEW 1st STAGE EXPLODED VIEW GROUP 2 SUBASS Y EXPLODED VIEW GROUP 1 & 3 SUBASSY EXPLODED VIEW 2nd STAGE ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN PAGE BEST BOY HP SPOT LUMINAIRE...
  • Page 173 Zoom Assembly (continued) Refer to Parts List for "Zoom Assembly" on page 159. INDEX EXPLODED VIEW GROUP 1 SUBASSY 3rd STAGE WHEEL ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN BEST BOY HP SPOT LUMINAIRE PAGE...
  • Page 174 Zoom Assembly (continued) Refer to Parts List for "Zoom Assembly" on page 159. EXPLODED VIEW GROUP 3 SUBASS Y EXPLODED VIEW GROUP 2 SUBASSY 4th STAGE ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN PAGE BEST BOY HP SPOT LUMINAIRE...
  • Page 175 Zoom Assembly (continued) Refer to Parts List for "Zoom Assembly" on page 159. "A" SEE DETAIL NEXT STEP "A" DETAIL CRITICAL! EXPLODED VIEW 5th STAGE ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN BEST BOY HP SPOT LUMINAIRE PAGE...
  • Page 176 Zoom Assembly (continued) Refer to Parts List for "Zoom Assembly" on page 159. FINAL STEP EXPLODED VIEW 6th STAGE ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN PAGE BEST BOY HP SPOT LUMINAIRE...
  • Page 177 Zoom Assembly (continued) Refer to Parts List for "Zoom Assembly" on page 159. NEXT STEP "A" DETAIL CRITICAL! "A" SEE DETAIL EXPLODED VIEW 7th STAGE ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN BEST BOY HP SPOT LUMINAIRE PAGE...
  • Page 178 Zoom Assembly (continued) Refer to Parts List for "Zoom Assembly" on page 159. FROM HEAD CONTROLLER PCB J5 ZOOM LENS G1 & G3 EOT EXPLODED VIEW 8th STAGE ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN PAGE BEST BOY HP SPOT LUMINAIRE...
  • Page 179 Zoom Assembly (continued) Refer to Parts List for "Zoom Assembly" on page 159. GROUP 3 FRONT VIEW EXPLODED VIEW 9th STAGE GROUP 3 SUBASSY GROUP 2 SUBASSY GROUP 1 FRONT VIEW EXPLODED VIEW 10th STAGE GROUP 1 SUBASSY ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN BEST BOY HP SPOT LUMINAIRE...
  • Page 180 Zoom Assembly (continued) Refer to Parts List for "Zoom Assembly" on page 159. ZOOM ZOOM ZOOM SIDE VIEW - CABLE LAYOUT 11th STAGE ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN PAGE BEST BOY HP SPOT LUMINAIRE...
  • Page 181 Zoom Assembly (continued) Refer to Parts List for "Zoom Assembly" on page 159. "B" SEE DET AI L "B" "C" DETAIL DETAIL CRITICAL! CRITICAL! "C" SEE DET AI L CL EAN LENSE S O NL Y WI TH MICR OFI BER CLOTH & OPTI- MAX CLEAN ER CAUTION: LENS PINCH POINT...

  • Page 182: Gag Wheel Assembly

    Gag Wheel Assembly 21.9816.0550 Revision: Rev E0 Item Description Procedure 10.9816.0552 ASSY, GAG SUN GEAR BEST BOY 10.9816.0554 SHAFT, GAG WHEEL, BEST BOY 10.9816.0558 PULLEY, GAG WHEEL DRIVE BEST BOY 22.9816.0545 SUB-ASSEMBLY, GAG WHEEL 53.6528.0002.0 WASHER, .140"ID, .312"OD .057-.067" THK NYLON 53.5506.0250 SCREW, 6-32 X 1/4"...

  • Page 183: Gag Wheel Sub Assembly

    Gag Wheel Sub Assembly 22.9816.0545 Revision: Rev A0 Item Description Procedure 06.6083.0001.0 RTV, 3145 CLEAR 305ML TUBE 10.9816.0551 WHEEL, GAG, BEST BOY 10.9816.0557 HOLDER, MAGNET, GAG WHEEL 10.9816.0571 SLIP RING, GAG BEST BOY 22.9816.8001 ASSY, 4 FACET PRISM GAG 22.9816.8002 ASSY, EXTRUDER GAG 22.9816.8003 ASSY, ELONGATOR GAG...
  • Page 184 Gag Wheel Sub Assembly (continued) Refer to Parts List for "Gag Wheel Sub Assembly" on page 173. EXPLODED VIEW 1st STAGE EXPLODED VIEW 2nd STAGE MAGNET DETAIL EXPLODED VIEW FINAL STAGE ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN PAGE BEST BOY HP SPOT LUMINAIRE...

  • Page 185: Aft Bulkhead Assembly

    Aft Bulkhead Assembly 22.9817.0608 Revision: Rev D0 Item Description Procedure 10.9817.0608 AFT BULKHEAD, BEST BOY HP SPOT 10.9815.0623 DEFLECTOR, MAIN 10.9815.0624 BRACKET, MOUNTING LAMP HOLDER 10.9817.0625 BRACKET, HEAD COVER AFT MOUNTING, BEST BOY HP SPOT 10.9817.0626 BRACKET, MOUNTING SAFETY SWITCH, BEST BOY HP SPOT 10.9815.0627 REFLECTOR MOUNTING CLIP 10.9817.0632...
  • Page 186 Aft Bulkhead Assembly (continued) Refer to Parts List for "Aft Bulkhead Assembly" on page 175. EXPLODED FRONT VIEW 1s t STA G E FAN 3 FAN 4 EXPLODED REAR VIEW 2nd ST AG E EXPLODED REAR VIEW 3rd STA G E ®...
  • Page 187 Aft Bulkhead Assembly (continued) Refer to Parts List for "Aft Bulkhead Assembly" on page 175. EXPLODED REAR VIEW 5th STAGE FAN 1 EXPLODED VIEW 4th STAGE FAN 2 EXPLODED REAR VIEW 6th STAGE ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN BEST BOY HP SPOT LUMINAIRE PAGE...
  • Page 188 Aft Bulkhead Assembly (continued) Refer to Parts List for "Aft Bulkhead Assembly" on page 175. EXPLODED R EAR VIEW 7th STAGE ISOMETRIC R EAR VIEW 7th STAGE EXPLODED R EAR VIEW 8th STAGE ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN PAGE BEST BOY HP SPOT LUMINAIRE...
  • Page 189 Aft Bulkhead Assembly (continued) Refer to Parts List for "Aft Bulkhead Assembly" on page 175. EXPLODED REAR V IE W 9th STAGE EXPLODED REAR V IEW FINAL STAGE ISOMETRIC REAR VIEW FINAL S TAGE ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN BEST BOY HP SPOT LUMINAIRE PAGE...

  • Page 190: Lamp Box Assembly

    Lamp Box Assembly 22.9817.0620 Revision: Rev D0 Item Description Procedure 10.9815.0627 REFLECTOR MOUNTING CLIP 10.9815.0628 REFLECTOR, ALIGNMENT PIN 10.9815.0686 BAFFLE, LOWER, LAMP BOX 10.9817.0620 REFLECTOR MOUNT, BEST BOY HP SPOT 22.9817.0634 ASSEMBLY, FLIPPER DUCT, BEST BOY HP page 85 42.9816.0170 REFLECTOR, STEPPED, 10 LUNES, COATED 53.5504.0250 SCREW, 4-40 X 1/4"...
  • Page 191 Lamp Box Assembly (continued) Refer to Parts List for "Lamp Box Assembly" on page 180. EXPLODED VIEW 1st STAG E ISOMETRIC VIEW FIN AL STA GE EXPLODED VIEW 2nd STA GE ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN BEST BOY HP SPOT LUMINAIRE PAGE...

  • Page 192: Xyz Assembly

    XYZ Assembly 21.9817.0670 Revision: Rev A2 Item Description Procedure 10.9817.0621 PLATE, BACK LAMP HOLDER, BEST BOY HP SPOT 10.9815.0629 PLATE, XYZ 53.5508.0375 SCREW, 8-32 X 3/8" PPSS 12.5665.0001.0 SCREW, BLK ZINC PLATED(COMES IN AS/53.5665.0001.0) 53.5666.0001.0 RETAINER, FAST LEAD SCREW #9 SS (SOUTHCO 09-6-1) 53.6621.0001 SCREW, 8-32 X 1"...
  • Page 193 XYZ Assembly (continued) Refer to Parts List for "XYZ Assembly" on page 182. 0.446" EXPLODED VIEW SCALE 3:8 MEASUREMENT POINT S CAUTION DO N OTOPE R ATE WITHOUT COM PLE TELAM P EN CL OSURE INPLA CEORWH ENLENS IS DA MAG ED. RIS K OF E XPO SUR E TO E XCESSIVE SOU RCEDERA YON N EMENT UV U LTR AVIO LETRADI A TION...

  • Page 194: Head Fan Assembly

    Head Fan Assembly 22.9816.0634 Revision: Rev B0 Item Description Procedure 10.9816.0635 MOUNT, HEAD FAN ASSY BEST BOY 10.9816.0636 DUCT, HEAD FAN ASSY, BEST BOY 25.9816.0976 CABLE ASSY, HEAD EXTERNAL TEMP SENSOR 25.9816.0996.A CABLE ASSY, HEAD FAN, 24V NO SENSOR 53.5506.1375 SCREW, 6-32 X 1 3/8"LG PPBZ 53.6571.0002 SCREW, 6-32 X 1 1/4"LG PPB...
  • Page 195 Head Fan Assembly (continued) Refer to Parts List for "Head Fan Assembly" on page 184. CABLE LAYOUT - BOTTOM VIEW EXPL ODED VIEW ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN BEST BOY HP SPOT LUMINAIRE PAGE...

  • Page 196: Yoke

    YOKE Yoke Assembly 21.9817.0700 Revision: Rev A0 Item Description Procedure 21.9816.0701 ASSEMBLY, YOKE LEG TILT 21.9817.0702 ASSY, YOKE LEG PAN, BEST BOY HP SPOT 21.9816.0703 ASSEMBLY, CROSSMEMBER 53.6697.0003.0 SCREW, 10-32 X 3/8" PFSS 53.6624.0003 SCREW, 10-32 X 1/2" PFSS ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN PAGE...

  • Page 197: Yoke Leg Tilt Assembly

    Yoke Leg Tilt Assembly 21.9816.0701 Revision: Rev F0 Item Description Procedure 10.9816.0732 GASKET, PAN/SIDE SHIELD, FLAT 10.9816.0736 PAN BEARING RETAINER, BEST BOY 10.9816.0747 YOKE LEG, BESTBOY 10.9816.0760 TILT STOP PLATE, BESTBOY 10.9816.1748.02 HANDLE, YOKE, AS MACHINED 22.9816.0750 ASSY, YOKE SIDE SHIELD 24.9816.0765 PCB ASSY, YOKE DRIVER 53.6552.0002...
  • Page 198 Yoke Leg Tilt Assembly (continued) Refer to Parts List for "Yoke Leg Tilt Assembly" on page 187. FRONT VIEW "B" SEE DETAIL 9.52" EXPLODED VIEW 2nd STAGE "B" DETAIL ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN PAGE BEST BOY HP SPOT LUMINAIRE...

  • Page 199: Yoke Leg Pan Assembly

    Yoke Leg Pan Assembly 21.9817.0702 Revision: Rev C0 Item Description Procedure 04.9816.0053 LABEL, HIGH VOLTAGE WARNING 10.9816.0732 GASKET, PAN/SIDE SHIELD, FLAT 10.9816.0736 PAN BEARING RETAINER, BEST BOY 10.9816.0747 YOKE LEG, BESTBOY 10.9816.1748.02 HANDLE, YOKE, AS MACHINED 10.9817.0764 BRACKET, IGNITOR BEST BOY HP SPOT page 74 12.9815.0787 IGNITOR, MODIFIED...
  • Page 200 Refer to Parts List for "Yoke Leg Pan Assembly" on page 189. Also refer to illustrations on the following pages. WARNING HIGH VOLTAGE DO NOT ATTEMPT TO MEASURE OUTPUT OF IGNITOR ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN PAGE BEST BOY HP SPOT LUMINAIRE...
  • Page 201 Yoke Leg Pan Assembly (continued) Refer to Parts List for "Yoke Leg Pan Assembly" on page 189. EXPLODED VIEW 1st STAGE "A" SEE DETAIL 9.52" EXPLODED VIEW 2nd STAGE "A" DETAIL ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN BEST BOY HP SPOT LUMINAIRE PAGE...
  • Page 202 Yoke Leg Pan Assembly (continued) Refer to Parts List for "Yoke Leg Pan Assembly" on page 189. "A" DETAIL INSTALL WITH LABEL ON THIS SIDE EXPLODED VIEW FINAL STAGE ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN PAGE BEST BOY HP SPOT LUMINAIRE...

  • Page 203: Yoke Side Shield Assembly

    Yoke Side Shield Assembly 22.9816.0750 Revision: Rev A0 Item Description Procedure 10.9816.0750 YOKE SIDE SHIELD 55.6738.0006.0 TUBING, SILICONE .250"OD X .150" ID 55.9816.0325.0 O RING, 3.25"ID X 3.50" OD, 1/8" SEC EXPLODED VIEW 1st STAGE ISOMETRIC VIEW "A" DETAIL ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN BEST BOY...

  • Page 204: Yoke Crossmember Assembly

    Yoke Crossmember Assembly 21.9816.0703 Revision: Rev B1 Item Description Procedure 22.9816.0735 ASSY, SEALING RING, YOKE COVER 10.9816.0736 PAN BEARING RETAINER, BEST BOY 10.9816.0739 YOKE LOWER CROSS MEMBER, BEST BOY 10.9816.0762 YOKE UPPER CROSS MEMBER, BEST BOY 53.6624.0003 SCREW, 10-32 X 1/2" PFSS 53.6653.0042.0 SCREW, 1/4-20 x 3/8"...
  • Page 205 Yoke Crossmember (continued) Refer to Parts List for "Yoke Crossmember Assembly" on page 194. EXPLODED VIEW FINAL S TAGE EXPLODED VIEW 2nd S TAGE ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN BEST BOY HP SPOT LUMINAIRE PAGE...

  • Page 206: Pan Drive Mechanism

    Pan Drive Mechanism 21.9816.0718 Revision: Rev B2 Item Description Procedure 10.9816.0714 ASSY, FINAL DRIVE PULLEY, BEST BOY 10.9816.0721 HYBRID PULLEY ASSY, PAN/TILT, BEST BOY 10.9816.0740 PAN DRIVE CHASSIS PLATE, BESTBOY 10.9816.0741 PAN DRIVE TOP PLATE, BESTBOY page 104 22.9816.0725 ASSY, MOTOR PAN page 106 22.9816.0729 ASSY, BELT TENSIONER, INTERMEDIATE...
  • Page 207 Pan Drive Mechanism (continued) Refer to Parts List for "Pan Drive Mechanism" on page 196. 1st STAGE "A" 2nd STAGE 3rd STAGE ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN BEST BOY HP SPOT LUMINAIRE PAGE...
  • Page 208 Pan Drive Mechanism (continued) Refer to Parts List for "Pan Drive Mechanism" on page 196. 4th STAGE "A" DETAIL FINAL STAGE CRITICAL! ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN PAGE BEST BOY HP SPOT LUMINAIRE...

  • Page 209: Tilt Drive Mechanism

    Tilt Drive Mechanism 21.9816.0719 Revision: Rev E1 Item Description Procedure 10.9816.0714 ASSY, FINAL DRIVE PULLEY, BEST BOY 10.9816.0721 HYBRID PULLEY ASSY, PAN/TILT, BEST BOY 10.9816.0743 PLATE, TILT DRIVE CHASSIS BEST BOY 10.9816.0744 PLATE, TILT DRIVE TOP BEST BOY 10.9816.0745 SPACER, PAN/TILT BEARING page 102 22.9816.0727 ASSY, MOTOR TILT...
  • Page 210 Tilt Drive Mechanism (continued) Refer to Parts List for "Tilt Drive Mechanism" on page 199. 1st STAGE "A" 2nd STAGE 3rd STAGE ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN PAGE BEST BOY HP SPOT LUMINAIRE...
  • Page 211 Tilt Drive Mechanism (continued) Refer to Parts List for "Tilt Drive Mechanism" on page 199. 4th STAGE "A" DETAIL FINAL STAGE CRITICAL! ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN BEST BOY HP SPOT LUMINAIRE PAGE...

  • Page 212: Pan Shield Assembly

    Pan Shield Assembly 22.9816.0749 Revision: Rev A0 Item Description Procedure 10.9816.0749 PAN SHIELD 55.6738.0004.01 TUBING, SILICONE .250" OD X .187" ID EXPLODED VIEW 1st STAGE DETAIL "A" ISOMETRIC VIEW ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN PAGE BEST BOY HP SPOT LUMINAIRE...

  • Page 213: Upper Enclosure

    UPPER ENCLOSURE Upper Enclosure Assembly 21.9817.0800 Revision: Rev B0 Item Description Procedure 04.9640.0374 LABEL, NO. 5019 P.E. GROUND 04.9817.0040 LABEL, COMPLIANCE, BEST BOY HP SPOT 04.9812.0049 LABEL, AIR FILTERS 10.9815.0823 GASKET, LOWER, UE BOX 10.9815.0824 GASKET, MAIN SHORT UE BOX 10.9816.0824 GASKET, UPPER, UE BOX, BEST BOY 10.9817.0825...
  • Page 214 Upper Enclosure Assembly (continued) BALLAST GND INTERFACE GND "A" DETAIL EXPLODED VIEW 1st STAGE Also refer to illustrations on the following pages. ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN PAGE BEST BOY HP SPOT LUMINAIRE...
  • Page 215 ISO REAR VIEW 2nd STAGE BA LLAST SIDE REFE RENC E "A" DETAIL 2nd STAGE Serial Number PRG Bar Code GUIDE LI NE BOTTOM VIEW INTER FAC E SIDE LABE L LAYOUT RE FERE NCE ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN...
  • Page 216 Upper Enclosure Assembly (continued) Refer to Parts List for "Upper Enclosure Assembly" on page 203. "B" DETAIL 3rd STAGE "C" DETAIL 4th STAGE EXPLODED FRONT VIEW FINAL STAGE ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN PAGE BEST BOY HP SPOT LUMINAIRE...

  • Page 217: Ballast Assembly

    Ballast Assembly 21.9817.0810 Revision: Rev B0 Item Description Procedure 04.9815.0047 LABEL, CAUTION, 1650W BALLAST 25.9816.0955 CABLE ASSY, FUSE BLOCK TO BALLAST AC IN 25.9816.0956 CABLE ASSY, BALLAST AC GND 25.9816.0991 CABLE ASSY, BALLAST HEATSINK FAN BEST BOY 25.9817.0966 CABLE ASSY, BALLAST CONTROL SERIAL LINK 53.6575.0005 SCREW, 8-32 X 1 1/2"...
  • Page 218 Ballast Assembly (continued) Refer to Parts List for "Ballast Assembly" on page 207. FINAL STAGE BALLAST TRIM BALLAST AC LINE INPUT CABLE LAYOUT DETAIL SCALE 1:1 ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN PAGE BEST BOY HP SPOT LUMINAIRE...
  • Page 219 Ballast Assembly (continued) Refer to Parts List for "Ballast Assembly" on page 207. TOP VIEW REAR VIEW BALLAST OUTPUT CABLE LAYOUT DETAIL SCALE 1:1 ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN BEST BOY HP SPOT LUMINAIRE PAGE...

  • Page 220: Interface/Lvs Assembly

    Interface/LVS Assembly 21.9817.0811 Revision: Rev B0 Item Description Procedure 06.6018.0002 VELCRO HOOK, 1"W BLACK ADHESIVE BACK 200F 0.125 06.6018.0006 VELCRO LOOP, 1"W BLACK ADHESIVE BACK 200F 10.9816.0654 GROMMET, 3/4"ID, 1.1/8"OD, .08GRV, FOR 1" OPENING 10.9816.0812 CHASSIS, INTERFACE BEST BOY 10.9816.0817 INTERFACE FRONT PANEL, BEST BOY 10.9816.0851 CHASSIS, LVPS, CPU, BEST BOY...
  • Page 221 Item Description Procedure 69.3132.0002.0 POWER SUPPLY, 250W +24V/10.4A OUT +5V/0.5A AUX CCM250PS24 70.3772.0001.0 FUSE BLOCK, 2-POLE .25 X 1.25" 0 DEG .250" FASTON S-8201-2-R 70.3773.0001.0 FUSE, 15A 250V .25 X 1.25" SLO-BLO CERAMIC MDA-15-R 72.9816.0873 LCD, W/TOUCHSCREEN OVERLAY, BEST BOY 73.7200.0018.0 CABLE ASSY, 25 POS DOUBLE ROW, 18"L, DOUBLE END 53.6577.0016.0...
  • Page 222 Interface/LVS Assembly (continued) Refer to Parts List for "Interface/LVS Assembly" on page 210. TOUCHSCREEN LCD DETAIL TOUCHSCREEN LCD DETAIL CAB LE LAY OUT -1st CAB LE LAY O UT -2nd EXPLODED VIEW 1st STAGE ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN PAGE BEST BOY HP SPOT LUMINAIRE...
  • Page 223 Interface/LVS Assembly (continued) Refer to Parts List for "Interface/LVS Assembly" on page 210. EXPLODED VIEW 2nd STAGE ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN BEST BOY HP SPOT LUMINAIRE PAGE...
  • Page 224 Interface/LVS Assembly (continued) Refer to Parts List for "Interface/LVS Assembly" on page 210. "A" DETAIL 3rd STAGE EXPLODED VIEW 4th STAGE NEUTRIK POWERCON MAIN CONTRO L PCB DC PWR IN TO MAIN CONTROL P CB LVS STATUS TOP VIEW - CABLE LAYOUT 5th STAGE ®...
  • Page 225 Interface/LVS Assembly (continued) Refer to Parts List for "Interface/LVS Assembly" on page 210. EXPLODED VIEW 6th STAGE EXPLODED VIEW 8th STAGE EXPLODED VIEW 7th STAGE ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN BEST BOY HP SPOT LUMINAIRE PAGE...
  • Page 226 Interface/LVS Assembly (continued) Refer to Parts List for "Interface/LVS Assembly" on page 210. EXPLO DED VIEW 9th STAGE "B" DETAIL EXPLO DED VIEW 11th STAG E 10 th S TAG E ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN PAGE BEST BOY HP SPOT LUMINAIRE...
  • Page 227 Interface/LVS Assembly (continued) Refer to Parts List for "Interface/LVS Assembly" on page 210. ISOMETRIC VIEW FINAL STAGE AC IN 200 -240 VAC THRU -015 -011 COMM ETHERNET WAKE 50 / 60 Hz 12A Max FRONT VIEW ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN BEST BOY HP SPOT LUMINAIRE PAGE...

  • Page 228: Best Boy Hp Spares List

    BEST BOY HP SPARES LIST Quick Access Spares List This section lists major common components for easy access in ordering replacements. See the images on the proceeding pages for image details linked to this list. PRG P/N TEAM Ecode Description Procedure page 55 10.9816.0029...
  • Page 229 Best Boy HP Quick Access Spares List, Con’t Refer to Parts List for "Quick Access Spares List" on page 218. Click a red callout number to go to that procedure. (x2) (x2) (x2) ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN BEST BOY HP SPOT LUMINAIRE PAGE...
  • Page 230 Best Boy HP Quick Access Spares List, Con’t Refer to Parts List for "Quick Access Spares List" on page 218. Click a red callout number to go to that procedure. ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN PAGE BEST BOY HP SPOT LUMINAIRE...
  • Page 231 Best Boy HP Quick Access Spares List, Con’t Refer to Parts List for "Quick Access Spares List" on page 218. Click a red callout number to go to that procedure. ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN BEST BOY HP SPOT LUMINAIRE PAGE...
  • Page 232 Best Boy HP Quick Access Spares List, Con’t Refer to Parts List for "Quick Access Spares List" on page 218. Click a red callout number to go to that procedure. ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN PAGE BEST BOY HP SPOT LUMINAIRE...
  • Page 233 Best Boy HP Quick Access Spares List, Con’t Refer to Parts List for "Quick Access Spares List" on page 218. Click a red callout number to go to that procedure. ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN BEST BOY HP SPOT LUMINAIRE PAGE...
  • Page 234 Best Boy HP Quick Access Spares List, Con’t Refer to Parts List for "Quick Access Spares List" on page 218. Click a red callout number to go to that procedure. INDEX #2 INDEX #1 INDEX #1 ® SERVICE MANUAL ILLUSTRATED PARTS BULLETIN PAGE BEST BOY HP SPOT LUMINAIRE...

  • Page 235: Appendix A. Technical Specifications

    TECHNICAL SPECIFICATIONS + BEST BOY HP SPOT LUMINAIRE + BEST BOY ROAD CASE...

  • Page 236: Best Boy Hp Spot Luminaire

    Two (2) indexable, rotating gobo wheels with six (6) gobos per wheel. Gobos are individually calibrated so the unit will automatically index the orientation of each gobo regardless of initial placement. Both gobo wheels accept PRG Moiré Gobos™ for advanced gobo rotator effects.
  • Page 237 12.5" (318 mm) 3.88" *33" (99 mm) *(838 mm) 28" (711 mm) *41.5" 5.78" *(1054 mm) (147 mm) 39.0" (991 mm) 35.16" 19.15" (893 mm) (486 mm) 22.6" (574 mm) *31.6" *(803 mm) 28.5" 27.0" (724 mm) (686 mm) 16.75" (425 mm) 18.64"...

  • Page 238: Best Boy Road Case

    Best Boy Road Case EMPTY WEIGHT: 171 lbs (77.56 kg) LOADED WEIGHT: 389 lbs (176.45 kg) 24" (610 mm) 52" (1321 mm) 39.5" (1003 mm) 33.8" (859 mm) 21" (533 mm) 12.8" (325 mm) ® SERVICE MANUAL APPENDIX A: TECHNICAL SPECIFICATIONS PAGE BEST BOY HP SPOT LUMINAIRE...
  • Page 239 FOR CUSTOMER SERVICE AND TECHNICAL SUPPORT: PRG Dallas (International Service) 8617 Ambassador Row, Suite 120 Address Dallas, Texas 75247 USA 214-630-1963 Phone 214-630-5867 214-638-2125 Service Fax orders@prg.com Service Email BEST BOY bestboysupport@prg.com Direct Support ® BEST BOY HP SPOT LUMINAIRE SERVICE MANUAL...
  • Page 240 Best Boy® HP Spot Luminaire Service Manual Version as of: September 1, 2019 Written by J. Hutchison PRG part number: 02.9817.0001.1 ® BEST BOY HP SPOT LUMINAIRE SERVICE MANUAL...
  • Page 241 Production Resource Group, LLC Dallas Office 8617 Ambassador Row, Suite 120 Dallas, Texas 75247 www.prg.com ® BEST BOY HP SPOT LUMINAIRE SERVICE MANUAL...

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