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PRG Bad Boy Spot Luminaire Service Manual

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SOFTWARE VERSION 1.6
WWW.PRG.COM
®
BAD BOY
SPOT LUMINAIRE
FIELD SERVICE MANUAL

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  • Page 1: Bad Boy Spot Luminaire

    SOFTWARE VERSION 1.6 WWW.PRG.COM ® BAD BOY SPOT LUMINAIRE FIELD 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 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 WARNING: INSTRUCTIONS FOR PROTECTION AGAINST INJURY TO PERSONS Exterior surfaces of the luminaire will be hot during operation. Use appropriate safety equipment (gloves, eye protection, etc.) when handling and adjusting hot equipment and components. Service and maintenance should be performed only by qualified personnel as determined by the high pressure lighting fixture manufacturer. Arc lamps generate intense heat.
  • Page 5 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 This manual has been revised as follows: Version Release Date Notes BASIC September 22, 2009 Initial release. March 3, 2010 Added CMY luminaire information where applicable. Updated Wiring Diagram. Added new Hi-Temp Pinch Fan and May 4, 2010 Ignitor replacement procedures.

  • Page 7: Table Of Contents

    TABLE OF CONTENTS Introduction About This Manual..................................1 Additional Documentation ................................1 Customer Service ..................................2 Chapter 1. Description Features Overview....................................... 4 Features ....................................4 Luminaire Models .................................. 5 Components Exterior Components..................................6 Head and Enclosure Components ............................... 7 Yoke Components ..................................8 Designer Color and Gobo Wheel Configurations ........................
  • Page 8 Parts Breakdown Covers and Included Items................................. 87 Bad Boy Spares Kit ..................................89 Appendix A. Technical Specifications Bad Boy Spot Luminaire................................96 Bad Boy Road Case ................................... 98 AC Line Current / Power vs. Voltage ............................99 Photometric Data..................................100 Narrow Zoom..................................

  • Page 9: Introduction

    Bad Boy® Spot Luminaire User Manual (02.9812.0001.xx) Technical updates regarding this equipment are issued by the PRG Dallas office. These updates are in the form of Technical Bulletins, which contain procedures for equipment upgrades, retrofits, and repairs not found in the existing manual(s).

  • Page 10: Customer Service

    Customer Service Our comprehensive technical services department ensures you get the full benefit of being a PRG customer. Whether your needs are simple or complex, our full-time staff of experienced professionals are on-hand to provide support. For assistance, contact your nearest PRG office:...

  • Page 11: Chapter 1. Description

    DESCRIPTION This chapter contains an overview of luminaire features and components. FEATURES COMPONENTS...

  • Page 12: Features

    Pan range of 540° and a tilt range of 270°. Can be mounted and operated in any orientation. Compatible with all PRG consoles and a wide variety of DMX512 and Art-Net consoles. An internal Ethernet switch allows for daisy-chaining fixtures.

  • Page 13: Luminaire Models

    Luminaire Models The Bad Boy Spot Luminaire is available in two versions: Standard (20.9812.0001) - contains a Quantum Color® system. CMY (20.9812.0002) - contains a CMY color system. The Bad Boy CMY luminaire can be identified by a label on the input panel:...

  • Page 14: Components

    COMPONENTS Exterior Components The following illustration shows the exterior Bad Boy components and controls. Hanging Bracket Assembly (2) - Allows luminaire to be mounted on truss pipe. ACTIVEON LY WHEN FIXTURE IS POWE RED A C IN Upper Enclosure - 200 - 240V A C T HR U C O MM...

  • Page 15: Head And Enclosure Components

    Head and Enclosure Components The following illustration shows the major sub-assemblies located in the Bad Boy Head and Enclosure. Wheel Stack Zoom Controller PCB Assembly Front Lens Aft Assembly (contains lamp, fans, reflector) Lens Groups EMI Ballast Enclosure LVS/Interface Module Figure 1-4: Head and Enclosure Components ®...

  • Page 16: Yoke Components

    Yoke Components Tilt-Side Yoke The following illustration shows the major sub-assemblies located in the Bad Boy Tilt-Side Yoke Leg. R2 / Designer Wheel Head Cover Pan-Side Leg Tilt-Side Leg Ignitor PCB Relay Figure 1-5: Yoke Leg Identification Tilt Drive Assembly Figure 1-6: Tilt-Side Yoke Leg ®...
  • Page 17 Pan-Side Yoke Leg The following illustration shows the major sub-assemblies located in the Bad Boy Pan-Side Yoke Leg. Pan/Tilt Controller PCB Figure 1-7: Pan-Side Yoke Leg ® BAD BOY SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 18: Designer Color And Gobo Wheel Configurations

    Designer Color and Gobo Wheel Configurations Designer Color Wheel Standard Configuration The following drawing shows the standard Bad Boy Designer Color Wheel configuration. Figure 1-8: Designer Color Wheel Standard Configuration ® BAD BOY SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 19 Standard Gobo Wheel Configuration The following drawing shows the standard Bad Boy Designer Gobo Wheel configurations. Figure 1-9: Gobo Wheel Standard Configurations ® BAD BOY SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 20 Notes ® BAD BOY SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 21: Chapter 2. Testing & Troubleshooting

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

  • Page 22: Testing

    TESTING Test Screen The luminaire provides built-in test routines and recalibration options which can be accessed through the Menu Touchscreen. Actions may be applied to specific mechanisms, or in some Press TEST to cases, to all mechanisms at once. At the Home screen, press the bring up Test screen Test panel to bring up the Test screen.

  • Page 23: Mechanical Tests

    Mechanical Tests The Mechanical Test menu provides a method for exercising all luminaire mechanisms individually. Each mechanism has a similar Test screen, Cyan is shown in the example below: The following test functions are available: Test Chase - The mechanism will move back and forth between two positions. The START/STOP button starts and stops the motion, and the SPEED button sets the rate of the motion.

  • Page 24: Group Test

    This feature only available in software version 1.5 The Group Test menu allows multiple Bad Boy Spot Luminaire to be run through a configurable test sequence when chained together via DMX512 or Ethernet. (Refer to the Bad Boy User Manual for more information about daisy- chaining.)

  • Page 25: Troubleshooting

    TROUBLESHOOTING Errors The Status menus can be used to determine if any luminaire mechanisms are reporting errors. The Status panel at the Home screen will report overall luminaire conditions as follows: CALIBRATION (yellow) OK (green) ERROR (red) Press STATUS to LOCKED (white) bring up Status screen Pressing the Status panel will bring up the Status screen (as...
  • Page 26 Mechanism Errors Errors will be shown after the mechanism sub-code, for example: PAN:Comm Error. Error Code Explanation Comm Error Error communicating with motion processor Init Error Error during initialization of motion processor Cal Error Error resetting position values in motion processor at beginning of calibration Cal Timeout An action during calibration took longer than expected No Stop...

  • Page 27: Basic Troubleshooting

    Basic Troubleshooting The following table provides a list of common start-up problems and possible solutions. Refer to the Bad Boy Spot Luminaire User Manual for more information about installation and operation. Symptom Solution(s) Ensure power cable is properly connected to Neutrik input connector. No power to luminaire.

  • Page 28: Component Troubleshooting

    Component Troubleshooting This section provides troubleshooting guidelines for isolating problems down to the Spares Kit Sub-Assembly level. (Refer to page 86 for a list of all spares components.) Lamp Issues Lamp will not strike or there is a loss of lamp output Details : A loud popping sound and/or loss of lamp output is an indication of lamp failure.

  • Page 29: Wheel Stack And/Or Frost (Diffusion) Issues

    Wheel Stack and/or Frost (Diffusion) Issues Status screen is displaying errors for Dimmer, Strobe, Color Wheels, Gobo Wheel, Iris and/or Frost mechanisms Details : Upon power-up, all mechanisms in the fixture will execute a calibration routine. Each mechanism must pass its calibration test or it will disable itself and possibly other mechanisms.

  • Page 30: Fan/Cooling Issues

    Solution : Ensure Diffuser Sensor Cable is properly seated. page 58 Solution : Replace Diffuser Sensor PCB... A mechanism motor appears to have no power during calibration or operation Details : On each of the three Wheel Controller PCB’s there are four (4) motor drivers. There is a 2 Amp Timed (Slo-Blow) Fuse to protect each of the four drivers.

  • Page 31: Lens Issues

    Lens Issues Lenses fail to calibrate or lenses not operating correctly, and Zoom Sensors are good Details : There are four (4) Zoom Sensors, one for each Lens Group 1, 2, 3, and 4. Group 4 is farthest from the lamp. Each sensor contains an LED which is helpful in determining failures.

  • Page 32: Menu Display Issues

    Menu Display Issues If power is applied and the Menu Display Touchscreen does not come up or the fixture does not start the calibration routines Details : The Interface/LVS Module controls several functions. It contains the 24VDC LVS that provides the low voltage power for all the electronic components in the fixture, with the exception of the Ballast.

  • Page 33: Pan/Tilt Issues

    Pan/Tilt Issues Tilt continues to move past center during calibration, and... "TILT: no sensor" is displayed in Status Log and TLT sub-code is red Details : During initial Pan/Tilt calibration at power-up, Tilt will line up between the yoke legs and Pan will rotate looking for its mechanical stop.
  • Page 34 Notes ® BAD BOY SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 35: Chapter 3. Maintenance

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

  • Page 36: 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 envelope (bulb). If you touch the glass with bare fingers, wipe off any fingerprints with alcohol. Heat When lamps are lit, the interior of the luminaires becomes very hot.

  • Page 37: 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 38: Routine Maintenance

    ROUTINE MAINTENANCE Removing the Head Covers To access some interior head components, one or both of the Head Covers may need to be removed. Parts: 21.9812.0630 2 EA ASSY, HEAD COVER Tools: #2 Philips screwdriver (manual screwdriver only) To remove Head Covers: Step 1.

  • Page 39: Removing The Aft Cover

    Removing the Aft Cover To access some interior head components, the Aft Cover may need to be removed. Parts: 21.9812.0612 1 EA ASSY, AFT COVER w/ BAFFLE Tools: 5/32" Allen wrench, T-bar To remove Aft Cover: Step 1. At Aft Cover, remove X, Y, and Z Adjustment Knobs (Figure 3-3). Step 2.

  • Page 40: Removing The Enclosure Covers

    The Upper Enclosure Covers are not identical. One is for the Intake side and one for the Exhaust side. Be sure to re-install covers in the proper location. Exhaust Cover Intake Cover PRG Sticker Mesh Screen Captive Screw (2) Figure 3-4: Removing Upper Enclosure Covers ®...

  • Page 41: Cleaning The Head Electrostatic Filters

    Cleaning the Head Electrostatic Filters The electrostatic filters should be cleaned or replaced when they are dirty. The frequency will depend on how often and in what conditions the luminaire is used. Parts: 10.9812.0661 2 EA HEAD AIR FILTER FOAM 10.9812.0662 2 EA HEAD AIR FILTER ELECTROSTATIC...

  • Page 42: Cleaning The Enclosure Intake Filters

    Cleaning the Enclosure Intake Filters The intake filters should be cleaned or replaced when they are dirty. The frequency will depend on how often and in what conditions the luminaire is used. Parts: 40-9812-0834 2 EA AIR INTAKE FILTER Tools: #2 Phillips screwdriver Compressed air and/or...

  • Page 43: Cleaning The Luminaire Exterior

    Cleaning the 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 44: Cleaning The Lenses

    Cleaning the 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 Hook & Pick tool To clean lenses: CAUTION: Use caution when handling lenses. Avoid scratching optical surfaces. CAUTION: Use ONLY OptiMax™...
  • Page 45 d. Using OptiMax™ Ultra Pure Cleaning Solution and a Micro Fiber cloth, clean both sides of Front Glass and front of Lens Group 4. DO NOT use window cleaner! e. Re-install Front Glass. Notch Front Glass Retaining Ring Front of Lens Group 4 Figure 3-7: Cleaning Front Glass CAUTION: "Done"...
  • Page 46 8-32 x 3/8" PPB Screw (2 ea) Hand tighten only. DO NOT use a CAUTION: power tool on Head Cover screws. R2 / Designer Wheel Head Cover R1 Head Cover Remove to Access Lenses ZOOM LENS ASSEMBLY DETAIL Lenses Figure 3-8: Accessing Zoom Lens Assembly ®...

  • Page 47: Cleaning Gobo, Color And Dimmer Wheels

    Cleaning Gobo, Color and Dimmer 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 dimmer 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 48: Cleaning The Reflector

    Cleaning the Reflector Tools: Micro Fiber cloth (06.6085.0001.0) OptiMax™ Ultra Pure Cleaning Solution (06.6084.0001.0) #2 Phillips screwdriver To clean reflector: CAUTION: Use ONLY OptiMax™ Ultra Pure Cleaning Solution to clean optical components. DO NOT use Window Cleaner on the reflector! WARNING: Remove power from luminaire before this procedure.

  • Page 49: Cleaning The Uv/Ir Window

    Cleaning the UV/IR Window Tools: Micro Fiber cloth (06.6085.0001.0) OptiMax™ Ultra Pure Cleaning Solution (06.6084.0001.0) #2 Phillips screwdriver To clean UV/IR Window: CAUTION: Use ONLY OptiMax™ Ultra Pure Cleaning Solution to clean optical components. DO NOT use Window Cleaner on the UV/IR glass! WARNING: Remove power from luminaire before this procedure.

  • Page 50: Remove And Replace Procedures

    REMOVE AND REPLACE PROCEDURES Replacing the Lamp Parts: 71.2566.1200.0 1 EA LAMP, FASTFIT, PHILIPS MSR GOLD™ Tools: Cotton gloves or finger cots WARNING: Remove power from luminaire before performing any maintenance procedures. CAUTION: Refer to "Proper Lamp Servicing and Operation" on page 28 before handling the lamp.
  • Page 51 CAUTION: Wear cotton gloves or finger cots while servicing lamp. Touching the lamp glass with bare fingers will leave oil and cause the lamp to explode or burn out early. If touched, use alcohol to thoroughly clean glass. Do not touch lamp or CAUTION: reflector with bare fingers.

  • Page 52: Adjusting The Lamp

    Adjusting the Lamp After a new lamp is installed, it will be necessary to align the lamp in order to center and flatten the hot spot. Knobs located at the luminaire’s backcap allow for adjustment. Tools: none WARNING: Backcap may be HOT during lamp operation. To adjust lamp: Step 1.

  • Page 53: Replacing A Gobo

    Replacing a Gobo Parts: Standard or Custom Gobo(s), as required. (Refer to "Standard Gobo Wheel Configuration" on page 11.) Tools: #2 Phillips screwdriver Cotton gloves or finger cots WARNING: Remove power from luminaire before performing any maintenance procedures. To replace a gobo: Step 1.
  • Page 54 Step 5. Using fingers, grasp frame of gobo and pull out of wheel (Figure 3-14). Sun Gear Retaining Plate Gobo Carrier Tongue Locking Tab Open Hole (no gobo) Wheel Note: Drawing is flipped 180° for clarity purposes. Figure 3-14: Replacing a Gobo Step 6.
  • Page 55 CAUTION: The gobos must be seated properly, especially the gear mesh. OPEN OPEN OPEN Figure 3-15: Gobo Positions and Alignment ® BAD BOY SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 56: 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 10.) 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 57 OPEN EXPLODED VIEW Figure 3-17: Installing Designer Color Filter ® BAD BOY SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 58: Replacing The Front Glass

    Replacing the Front Glass Parts: 12.9812.0629 1 EA RETAINER, FRONT GLASS PAINTED 41.9812.0628 1 EA FRONT GLASS Tools: Hook & Pick tool WARNING: Remove power from luminaire before performing any maintenance procedures. To replace the Front Glass: Step 1. Remove power from luminaire and allow components to cool for at least 5 minutes. Step 2.

  • Page 59: Replacing The Wheel Stack

    Replacing the Wheel Stack Parts: 21.9812.0620 1 EA ASSY, WHEEL STACK, LESS GOBOS (standard luminaire version) 21.9812.0696 1 EA ASSY, CMY WHEEL STACK, LESS GOBOS (CMY luminaire version) Tools: #2 Philips screwdriver 9/64" Allen wrench, T-bar WARNING: Remove power from luminaire before performing any maintenance procedures. To replace the Wheel Stack Assembly: Step 1.
  • Page 60 Fan, Power & Control Cables Zoom Controller PCB Fan Wire Harness Twist-Lock Holder Wheel Stack Motherboard Frost Sensor Cable Frost Motor Wheel Stack Cable Assembly Frost Motor Figure 3-19: Disconnecting Wheel Stack Wiring ® BAD BOY SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 61 Step 5. At Wheel Stack Assembly, remove four 8-32 x 1/2" socket head screws (Figure 3-20). 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 62 To pack Wheel Stack Assembly for shipping: If a Wheel Stack Assembly is to be shipped to a PRG Service Center, a Wheel Stack Road Case (20.9812.1229) should be used. This will protect the fragile components of the Wheel Stack Assembly during storage, transport and shipping.

  • Page 63: Replacing The Frost/Diffuser Paddle

    Replacing the Frost/Diffuser Paddle Parts: 22.9812.0557 1 EA ASSY, DIFFUSER PADDLE Tools: #2 Philips screwdriver 2mm Allen wrench Spacer Tool (10.9812.0584) WARNING: Remove power from luminaire before performing any maintenance procedures. To replace the Frost/Diffuser Paddle Assembly: Step 1. Remove power from luminaire and allow components to cool for at least 5 minutes. Step 2.
  • Page 64 Step 7. Test clearance and operation as follows: a. Manually slide Lens Group 3 toward Paddle Assembly until it come to rest on the stop. b. Rotate Paddle Assembly to test clearance. Paddle should not touch lenses. c. If paddle is contacting the lenses, loosen set screw and repeat Steps 6 and 7. ®...

  • Page 65: Replacing The Diffuser Sensor Pcb

    Replacing the Diffuser Sensor PCB Parts: 24.9812.0570 1 EA PCB ASSY, DIFFUSER SENSOR Tools: #2 Philips screwdriver Small slotted screwdriver WARNING: Remove power from luminaire before performing any maintenance procedures. CAUTION: Always use anti-static precautions when working with PCBs. To replace the Diffuser Sensor: Step 1.

  • Page 66: Replacing The Zoom Controller Pcb

    Replacing the Zoom Controller PCB Parts: 24.9812.0511.0 1 EA PCB ASSY, ZOOM CONTROLLER Tools: #1 and #2 Philips screwdrivers WARNING: Remove power from luminaire before performing any maintenance procedures. CAUTION: Always use anti-static precautions when working with PCBs. To replace the Zoom Controller PCB: Step 1.

  • Page 67: Replacing A Zoom Sensor Pcb

    Replacing a Zoom Sensor PCB The Zoom Assembly contains four Zoom Sensor PCBs (one for each Zoom Lens Group). This procedure provides instructions for changing any one of the four sensors. Note that two (2) Zoom Sensor PCBs are 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 68 Use anti-static precautions CAUTION: when working with PC boards. Zoom Sensor Hand tighten only. DO NOT use a R1 Head Cover CAUTION: power tool on Head Cover screws. 8-32 x 3/8" PPB Screw (2 ea) 2-56 x 1/4" PPZ Screw (2) Zoom Sensor Zoom Sensor Figure 3-25: Removing Zoom Sensors 1 &...
  • Page 69 Use anti-static precautions CAUTION: when working with PC boards. Zoom Sensor 2-56 x 1/4" 4-40 x 1/4" PPZ Screw (2) PPB Screw (4) Zoom Sensor Zoom Controller PCB Figure 3-26: Removing Zoom Sensors 2 & 4 ® BAD BOY SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 70: Replacing The Main Head Fan

    Replacing the Main Head Fan Parts: 23.9812.0993 1 EA ASSY, MAIN HEAD FAN Tools: #2 Philips screwdriver 5/32" Allen T-wrench WARNING: Remove power from luminaire before performing any maintenance procedures. To replace the Main Head Fan: Step 1. Remove power from luminaire and allow components to cool for at least 5 minutes. Step 2.
  • Page 71 CAUTION: The Main Head Fan has been upgraded. Be sure to install only the latest hi-temp fan. The hi- temp fan can be identified by a red ring around the spinner. Note: In order to prevent heat from escaping the rear bulkhead area and moving into the main head assembly, aluminum tape has been used to seal the backcap perimeter, fan wire hole, and back side of pinch fan.

  • Page 72: Replacing The Tip Pinch Fan (Original Version)

    Replacing the Tip Pinch Fan (Original Version) The Tip Pinch Fan has been upgraded in most Bad Boy Luminaires. Refer to the procedure on the following page if the new Hi-Temp fan version has already been installed. Parts: 23.9812.0990 1 EA ASSY, TIP PINCH FAN, 12V Tools: #2 Philips screwdriver...

  • Page 73: Replacing The Tip Pinch Fan (Hi-Temp Version)

    Replacing the Tip Pinch Fan (Hi-Temp Version) The Tip Pinch Fan has been upgraded in most Bad Boy Luminaires. If the Hi-Temp fan version has been installed yet, refer to the procedure on the previous page. Parts: 23.9812.0994 1 EA ASSY, HI-TEMP TIP PINCH FAN, 12V Tools: #2 Philips screwdriver...

  • Page 74: Replacing The Uv/Ir Window Assembly

    Replacing the UV/IR Window Assembly Parts: 22.9812.0616 1 EA ASSY, UV/IR WINDOW Tools: #2 Philips screwdriver #1 Philips screwdriver, stubby WARNING: Remove power from luminaire before performing any maintenance procedures. CAUTION: Do not touch UV/IR Window with bare fingers. If dirty, clean with OptiMax™ Ultra Pure Cleaning Solution and a Micro Fiber cloth.

  • Page 75: Replacing The Reflector

    Replacing the Reflector Parts: 42.9812.0160 1 EA REFLECTOR, 36 LUNES, COATED Tools: #2 Phillips screwdriver, long #2 Philips screwdriver, right-angle Cotton gloves or finger cots WARNING: Remove power from luminaire before performing any maintenance procedures. CAUTION: Do not touch reflector with bare fingers. If dirty, clean with OptiMax™ Ultra Pure Cleaning Solution and a Micro Fiber cloth.

  • Page 76: Replacing A 2A Fuse

    Replacing a 2A Fuse 2 Amp fuses are located on the Zoom Controller PCB (4 each) and the Wheel Controller PCB (4 each). Parts: 70.3769.0002.0 8 EA FUSE, 2AMP SLO-BLO Tools: #2 Philips screwdriver Needle-nose pliers, small WARNING: Remove power from luminaire before performing any maintenance procedures. To replace a 2A Fuse: Step 1.

  • Page 77: Replacing The 3A Fuse

    Replacing the 3A Fuse The 3 Amp fuse is located on the Pan/Tilt Controller PCB. Parts: 70.3769.0003.0 1 EA FUSE, 3AMP SLO-BLO Tools: Needle-nose pliers, small WARNING: Remove power from luminaire before performing any maintenance procedures. To replace the 3A Fuse: Step 1.

  • Page 78: Replacing The Emi Ballast Enclosure

    Replacing the EMI Ballast Enclosure Parts: 23.9812.0810 1 EA ASSY, EMI BALLAST ENCLOSURE Tools: #2 Philips screwdriver Wire cutters Tie-Wraps Loctite 242 WARNING: Remove power from luminaire before performing any maintenance procedures. To replace the EMI Ballast Enclosure: Step 1. Remove power from luminaire and allow components to cool for at least 5 minutes. Step 2.
  • Page 79 BALLAST POLARITY CABLE ASSY BALLAST CONTROL 25-9812-0966-02 FROM CHASSIS GND STUD AC NEUT CABLE LAYOUT - REAR VIEW FROM EMI FILTER 10-32 x 3/8" PPB Black SEMS Screw (4) AC LINE EMI Ballast Enclosure TO LEFT TO RIGHT EXTENSION FAN 1 EXTENSION FAN 2 BALLAST CONTROL BALLAST CONTROL...

  • Page 80: Replacing The Interface/Lvs Module

    Replacing the Interface/LVS Module Parts: 23.9812.0812 1 EA ASSY, INTERFACE/LVS MODULE Tools: #2 Philips screwdriver WARNING: Remove power from luminaire before performing any maintenance procedures. To replace the Interface/LVS Module: Step 1. Remove power from luminaire and allow components to cool for at least 5 minutes. Step 2.
  • Page 81 Power Cables: Low Voltage DC Output BLACK AC Line Input Do not disconnect cables WHITE from positions 4 & 5 BLACK GRN/YEL LVS DETAIL 10-32 x 3/8" PPB SEMS Screw (4) CAN Bus Enclosure Interface/LVS Module POWERCON Figure 3-35: Removing Interface/LVS Module ®...

  • Page 82: Replacing The Ignitor Pcb

    Replacing the Ignitor PCB Parts: 24.9812.0775 1 EA PCB ASSY, SOLID STATE IGNITOR Tools: #2 Philips screwdriver 1/4" Nutdriver Loctite 242 WARNING: Remove power from luminaire before performing any maintenance procedures. CAUTION: Always use anti-static precautions when working with PCBs. To replace the Ignitor PCB: Step 1.
  • Page 83 Use Loctite 242 when re-installing standoffs as shown in Step 6. Replace Ignitor PCB by doing steps in reverse. Figure 3-36 Note: Be sure you install the NEW Ignitor (24.9812.0775). This component has been upgraded. ® BAD BOY SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 84: Replacing The Pan/Tilt Controller Pcb

    Replacing the Pan/Tilt Controller PCB Parts: 24.9812.0765 1 EA PCB ASSY, CONTROLLER PAN/TILT Tools: #2 Philips screwdriver 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 Controller PCB: Step 1.

  • Page 85: Replacing The Pan/Tilt Cot Sensor Pcb

    Replacing the Pan/Tilt COT Sensor PCB Parts: 24.9679.0750 1 EA PCB ASSY, PAN/TILT COT SENSOR Tools: #1 and #2 Philips screwdrivers 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 COT (Center of Travel) Sensor PCB: Step 1.
  • Page 86 Step 7. Install standoffs on new Pan/Tilt COT Sensor PCB Assembly. Step 8. Install new Pan/Tilt COT Sensor PCB Assembly by doing steps in reverse. When re-assembling, route Pan/ Tilt COT Sensor cable BEHIND standoffs ® BAD BOY SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 87: Replacing The Pan Drive Assembly

    Replacing the Pan Drive Assembly Parts: 21.9812.0718 1 EA ASSY, PAN DRIVE MECHANISM Tools: #2 Philips screwdriver 5/32" Allen wrench 7/16" Allen wrench Belt Tension Meter WARNING: Remove power from luminaire before performing any maintenance procedures. To replace the Pan Drive Assembly: Step 1.
  • Page 88 Step 7. Move Pan Cable Routing Plate out of the way enough to access belt and pulley. Step 8. At Pan Drive Assembly, loosen (but do not completely remove) four 10-32 x 5/8" socket head screws. This will begin to loosen the belt. Step 9.
  • Page 89 Pan/Tilt PCB Remove screw and rotate bus bar out of the way (optional). Bus Bar Pan Drive Assembly Belt Adjustment Screw (2) Pan Drive Assembly Figure 3-41: Removing Pan Drive Assembly (View 2) ® BAD BOY SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 90: Replacing The Tilt Drive Assembly

    Replacing the Tilt Drive Assembly Parts: 21.9812.0719 1 EA ASSY, TILT DRIVE Tools: #2 Philips screwdriver 7/16" Allen wrench 3/8" Nutdriver Belt Tension Meter WARNING: Remove power from luminaire before performing any maintenance procedures. To replace the Tilt Drive Assembly: Step 1.

  • Page 91: Setting Pan/Tilt Belt Tension

    Step 4. Remove Pan Shield by removing two 6-32 x 3/8" PFSS black screws and four 6-32 x 1/4" PPZ SEMS screws (Figure 3-39). Step 5. At Pan/Tilt Controller PCB, disconnect Tilt Drive Assembly cable harness. Step 6. At Tilt Drive Assembly, loosen (but do not completely remove) four 10-32 nylon insert nuts (Figure 3-42). This will begin to loosen the belt.
  • Page 92 CAUTION: Do not overtighten belt, pulley will break and/or bearings will fail. To set belt tension manually: Step 1. Orient head as shown in Figure 3-43. 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 93: Chapter 4. Illustrated Parts Breakdown

    ILLUSTRATED PARTS BREAKDOWN This chapter provides illustrated parts breakdowns for all luminaire spares components. OVERVIEW PARTS BREAKDOWN...

  • Page 94: Overview

    OVERVIEW About this IPB The Illustrated Parts Breakdown is intended for use with Field Service of the luminaire. The items identified here match the spares assemblies which are supplied with the Bad Boy Spares Kit (28.9812.1000), along with basic components such as Covers and Mounting Brackets.

  • Page 95: Parts Breakdown

    PARTS BREAKDOWN Covers and Included Items 20.9612.0001 Rev A0 Item Description Procedure 21.9812.0020 SUBASSY, BAD BOY 21.9812.0630 ASSY, HEAD COVER page 30 21.9812.0820 ASSY, EXHAUST COVER, UPPER ENCLOSURE page 32 21.9812.0830 ASSY, INTAKE COVER, UPPER ENCLOSURE page 32 21.9812.0863 ASSY, HANGING BRACKET 22.9620.0194 ASSY, LAMP SAFETY CABLE 22.9812.0716...
  • Page 96 Bad Boy Spot Luminaire (continued) Refer to Parts List on previous page. 9 (x4) (x2) (x2) ® BAD BOY SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 97: Bad Boy Spares Kit

    Bad Boy Spares Kit Item Description Procedure 20.9812.1229 ASSY, ROAD CASE, WHEEL STACK page 51 Standard 21.9812.0620 ASSY, WHEEL STACK, LESS GOBOS ( page 51 21.9812.0696 ASSY, CMY WHEEL STACK, LESS GOBOS ( page 51 21.9812.0719 ASSY, TILT DRIVE page 82 23.9812.0810 ASSY, EMI BALLAST ENCLOSURE page 70...
  • Page 98 Bad Boy Spares Kit (continued) Item Description Procedure 21.9812.0718 ASSY, PAN DRIVE page 79 24.9679.0750 PCB ASSY, PAN/TILT COT SENSOR page 77 24.9812.0765 PCB ASSY, CONTROLLER PAN TILT page 76 70.3769.0003.0 FUSE, 3AMP SLO-BLO page 69 (x6) PCB DETAIL (see detail above) ®...
  • Page 99 Bad Boy Spares Kit (continued) Item Description Procedure 24.9812.0510 PCB ASSY, ZOOM SENSOR page 59 ® BAD BOY SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 100 Bad Boy Spares Kit (continued) Item Description Procedure 12.9812.0629 RETAINER, FRONT GLASS PAINTED page 50 22.9812.0557 ASSY, DIFFUSER PADDLE page 55 24.9812.0570 PCB ASSY, DIFFUSER SENSOR page 57 41.9812.0628 FRONT GLASS page 50 70.3769.0002.0 FUSE, 2AMP SLO-BLO page 68 ® BAD BOY SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 101 Bad Boy Spares Kit (continued) Item Description Procedure 22.9812.0616 ASSY, UV/IR WINDOW page 66 23.9812.0990 ASSY, TIP PINCH FAN, 12V (original) page 64 23.9812.0994 ASSY, HI-TEMP TIP PINCH FAN, 12V (new) page 65 23.9812.0993 ASSY, MAIN HEAD FAN page 62 42.9812.0160 REFLECTOR, 36 LUNES, COATED page 67...
  • Page 102 Notes ® BAD BOY SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 103: Appendix A. Technical Specifications

    TECHNICAL SPECIFICATIONS BAD BOY SPOT LUMINAIRE BAD BOY ROAD CASE AC LINE CURRENT / POWER VS. VOLTAGE...

  • Page 104: Bad Boy Spot Luminaire

    -20° to 120°F (-29° to 49°C) COOLING: Forced air. CONTROL: Compatible with all PRG consoles and a wide variety of DMX512 and Art-Net consoles. An internal Ethernet switch allows for daisy-chaining fixtures. POSITIONING: Can be mounted and operated in any orientation.
  • Page 105 30" (762 mm) 15.6" (396mm) 39.125" (994 mm) POSITIONING: Can be mounted in any orientation. 13.5" (343 mm) SPACING: Hangs on 30 inch (762 mm) centers. WEIGHT: 167 lbs (75.8 kg) - includes clamps and rails ® BAD BOY SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 106: Bad Boy Road Case

    Bad Boy Road Case EMPTY WEIGHT: 190 lbs (86.18 kg) LOADED WEIGHT: 357 lbs (161.93 kg) - includes (1) one luminaire with clamps and rails 30.15" (766 mm) ® BAD BOY SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 107: Ac Line Current / Power Vs. Voltage

    AC Line Current / Power vs. Voltage TEST VOLTS FREQ AMPS POWER 50Hz 10.27 1746 1735 0.998 50Hz 9.62 1732 1721 0.995 50Hz 8.56 1712 1713 0.994 60Hz 8.57 1714 1709 0.996 60Hz 8.16 1714 1707 0.997 50Hz 7.77 1709 1704 0.991 50Hz...

  • Page 108: Photometric Data

    added to the UVLO circuit. The voltage must be advanced by a considerable margin before the SMPS recovers (turns on) from an UVLO condition, thus preventing cycling. The Ballast is rated at 200V-240V and drops out due to UVLO at 165V and recovers at 185V. The 24V LVS is rated 100V-240V and drops out at 75V and needs 85V to recover.

  • Page 109: Narrow Zoom

    Narrow Zoom Iris Full Open 8º Full Angle 40,000 beam Lumens Throw Dist (Ft) Beam Dia. (Ft) 10.5 14.0 Illuminance (fc) 12095 5376 1935 Throw Dist (m) Beam Dia. (m) Illuminance (lux) 193520 48380 12095 7741 5376 Multiply throw distance by Tn to find beam diameter. Divide cd (candela) by distance squared to find center beam illuminance.

  • Page 110: Medium Zoom

    Medium Zoom Iris Full Open 34º Full Angle 48,000 beam Lumens Throw Dist (Ft) Beam Dia. (Ft) 12.2 18.3 30.6 45.9 61.1 Illuminance (fc) Throw Dist (m) Beam Dia. (m) 12.2 15.3 18.3 Illuminance (lux) 13600 3400 Multiply throw distance by Tn to find beam diameter. Divide cd (candela) by distance squared to find center beam illuminance.

  • Page 111: Wide Zoom

    Wide Zoom Iris Full Open 56º Full Angle 50,000 beam Lumens Throw Dist (Ft) Beam Dia. (Ft) 21.3 31.9 53.2 79.7 106.3 Illuminance (fc) Throw Dist (m) Beam Dia. (m) 10.6 21.3 26.6 31.9 Illuminance (lux) 5000 1250 Multiply throw distance by Tn to find beam diameter. Divide cd (candela) by distance squared to find center beam illuminance.

  • Page 112: Logarithmic Beam Illuminance Comparison

    Logarithmic Beam Illuminance Comparison 8º, 34º and 56º Zoom settings. (DMX Values 00000, 30192, & 57700) 10000000 WFOV MFOV NFOV 1000000 Candela 100000 Lamp Power = 1400 Watts -30.0 -20.0 -10.0 10.0 20.0 30.0 Deg. Operation at Reduced Power 56º Zoom 140000 140000 140000...

  • Page 113: Bad Boy Luminaire Wiring Diagram

    WIRING DIAGRAMS Bad Boy Luminaire Wiring Diagram Chassis TILT Gnd Screw 2 AXIS AXIS CHASSIS YOKE YOKE HEAD 25-9812-0957 25-9812-0958 24-9812-0510 TYPICAL Red 22x2 EMI Filter PCB +24V Blk 22x2 Blk 14 Blk 22x2 Blk 14 AC Line AC Line Head Lens Group 1 Lens Group 2...
  • Page 114 Bad Boy® Spot Luminaire Field Service Manual Version as of: November 10, 2010 PRG part number: 02.9812.0005 C...
  • Page 115 Production Resource Group Dallas Office 8617 Ambassador Row, Suite 120 Dallas, Texas 75247 www.prg.com...

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