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PRG BAD Boy Field Service Manual

Spot luminaire
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Spot Luminaire
software version 1.5
02.9812.0005

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Summary of Contents for PRG BAD Boy

  • Page 1 Spot Luminaire software version 1.5 02.9812.0005...
  • Page 2 All other brand or product 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 latest version.

  • Page 3: Safety Notice

    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 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 OREWORD 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. Tenir compte de tous les avertissements et suivre toutes les précautions pendant l’installation et l’utilisation de cet appareil.
  • Page 6 ™ S UMINAIRE IELD ERVICE ANUAL Revision History This manual has been revised as follows: Version Release Date Notes BASIC September 22, 2009 Initial release. 02.9812.0005...

  • Page 7: Table Of Contents

    ABLE OF ONTENTS Table of Contents Introduction About This Manual .......................... 1 Additional Documentation....................... 1 Customer Service ..........................2 Chapter 1. Description Features Overview............................4 Features............................4 Components Exterior Components ........................5 Head and Enclosure Components ....................6 Yoke Components ..........................7 Chapter 2.
  • Page 8 Replacing the Pan Drive Assembly ....................76 Replacing the Tilt Drive Assembly....................79 Setting Pan/Tilt Belt Tension ......................81 Chapter 4. Illustrated Parts Breakdown Overview About this IPB..........................84 Parts Breakdown Covers and Included Items......................85 Bad Boy Spares Kit........................87 02.9812.0005...
  • Page 9 ABLE OF ONTENTS Appendix A. Technical Specifications Bad Boy Spot Luminaire........................ 94 Bad Boy Road Case ........................96 AC Line Current / Power vs. Voltage .................... 97 Photometric Data..........................98 Narrow Zoom .......................... 99 Medium Zoom ........................100 Wide Zoom..........................101 Logarithmic Beam Illuminance Comparison ................
  • Page 10 ™ S UMINAIRE IELD ERVICE ANUAL Notes viii 02.9812.0005...

  • Page 11: About This Manual

    • Bad Boy™ Spot Luminaire User Manual (02.9812.0001) 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 12: Customer Service

    ANUAL 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 13: Chapter 1. Description

    Description This chapter contains an overview of luminaire features and components. • Features • Components 0 2 . 9 81 2 . 0 00 5...

  • Page 14: Features Overview

    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. 02.9812.0005...

  • Page 15: Components

    ESCRIPTION OMPONENTS Components Exterior Components The following illustration shows the exterior Bad Boy™ luminaire components and controls. Hanging Bracket Assembly (2) - Allows luminaire to be mounted on truss pipe. AC T IV E O NL Y W H E N FI X TUR E...

  • Page 16: Head And Enclosure Components

    ™ S UMINAIRE IELD ERVICE ANUAL 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...

  • Page 17: Yoke Components

    ESCRIPTION OMPONENTS Yoke Components Tilt-Side Yoke The following illustration shows the major sub-assemblies located in the Tilt-Side Yoke Leg. R2 / Designer Wheel Head Cover Pan-Side Leg Tilt-Side Leg Ignitor PCB Relay Tilt Drive Figure 1-3: Yoke Leg Identification Assembly Figure 1-4: Tilt-Side Yoke Leg 0 2.
  • Page 18 ™ S UMINAIRE IELD ERVICE ANUAL Pan-Side Yoke Leg The following illustration shows the major sub-assemblies located in the Pan-Side Yoke Leg. Pan/Tilt Controller PCB Figure 1-5: Pan-Side Yoke Leg 02.9812.0005...

  • Page 19: Chapter 2. Testing & Troubleshooting

    Testing & Troubleshooting This chapter provides testing and troubleshooting procedures for the luminaire. • Testing • Troubleshooting 0 2 . 9 81 2 . 0 00 5...

  • Page 20: Testing

    Refer to "Cleaning the Lenses" on page 33 for complete lens cleaning instructions. • Group Test - allows multiple Bad Boy luminaires to be run through a configurable test sequence when chained together via DMX512 or Ethernet. (See "Group Test"...

  • Page 21: Mechanical Tests

    (applies to gobo wheel only, see Control Channel table for zero wheel mechanism found in the Bad Boy™ Spot Luminaire User Manual). * Due to small variations in sensor and sensor board positions, the open position on a gobo wheel might not be precisely aligned with the optical axis, creating a slight blockage on one side of the open beam.

  • Page 22: Group Test

    Step 3. Press START to begin testing. All Bad Boy luminaires connected to the main fixture (now referred to as the "Master") will become "Slaves" and follow the test routine set on the Master in an endless loop.

  • Page 23: Troubleshooting

    & T ESTING ROUBLESHOOTING ROUBLESHOOTING 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) •...
  • Page 24 ™ S UMINAIRE IELD ERVICE ANUAL 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...

  • Page 25: Basic Troubleshooting

    ROUBLESHOOTING 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.

  • Page 26: Component Troubleshooting

    ™ S UMINAIRE IELD ERVICE ANUAL Component Troubleshooting This section provides troubleshooting guidelines for isolating problems down to the Spares Kit Sub- Assembly level. (Refer to page 84 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 27: Wheel Stack And/Or Frost (Diffusion) Issues

    & T ESTING ROUBLESHOOTING ROUBLESHOOTING Lamp will not strike, but there are no fan errors on the Status screen and Ballast is okay Details: If the lamp does not strike after the command is given, but there are no fan errors on the Status screen and the Ballast is known-good, it may indicate that the Ignitor PCB has failed.

  • Page 28: Fan/Cooling Issues

    ™ S UMINAIRE IELD ERVICE ANUAL Output beam is not diffusing or has a different degree of diffusion than other fixtures, and the Status screen does not indicate a frost calibration error (FRO: Cal Error) Details: The most common cause of this problem is that one or more of the two diffusion filters have detached from the paddle frame.

  • Page 29: Lens Issues

    & T ESTING ROUBLESHOOTING ROUBLESHOOTING 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.

  • Page 30: Menu Display Issues

    ™ S UMINAIRE IELD ERVICE ANUAL A zoom lens motor appears to have no power during calibration or operation Details: The Zoom Controller PCB has four (4) motor drivers. There is a 2 Amp Timed (Slo-Blow) Fuse to pro- tect each of the four drivers. They provide power for both the motors. The silkscreen on the Motherboard PCB has each mechanism identified near the driver for each of the three Wheel Controller PCBs and the Zoom Controller.

  • Page 31: Pan/Tilt Issues

    & T ESTING ROUBLESHOOTING ROUBLESHOOTING If power is applied to the fixture and calibration completes, and you can see the Status for the mecha- nisms displayed on the touchscreen, but you have no external control of the fixture 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 32 ™ S UMINAIRE IELD ERVICE ANUAL Pan motor does not stop running after calibration, or... "Pan Aux Encoder Fail" is displayed in Status Log and PAN sub-code is red Details: Upon power-up, the Pan moves all the way around to the pan stop and stops moving, then rotates 180 degrees and stops again.

  • Page 33: Chapter 3. Maintenance

    Maintenance This chapter provides maintenance procedures for the luminaire. • Equipment Handling • Routine Maintenance • Remove and Replace Procedures 0 2 . 9 81 2 . 0 00 5...

  • Page 34: Equipment Handling

    If system will be unattended for more than 3-4 hours, luminaire lamps should be doused. • The Bad Boy lamp indicator (available on the menu Home screen) displays total lamp hours. Lamp hours are shown in green if under threshold, yellow at 750 hours, and red at 900 hours. It is mandatory that the lamp be changed before 900 hours.

  • Page 35: Wheel Stack Road Case Instructions

    QUIPMENT ANDLING Wheel Stack Road Case Instructions A special road case is provided for shipping Bad Boy™ Wheel Stack Assemblies. The case is necessary to protect the fragile components of the Wheel Stack Assembly during storage, transport and shipping. Pre-printed labels (addressed to the PRG Dallas office) are provided for ease of shipping.

  • Page 36: Routine Maintenance

    ™ S UMINAIRE IELD ERVICE ANUAL 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 and Supplies: #2 Philips screwdriver (manual screwdriver only) To remove Head Covers: Step 1.
  • Page 37 AINTENANCE OUTINE AINTENANCE Step 3. Replace Head Cover as follows: a. Set cover in place and slide rear corners under lip of Aft Cover. b. At front of Head Cover, press with equal pressure on both sides until leading edge of cover snaps into place under front ring casting.

  • Page 38: Removing The Aft Cover

    ™ S UMINAIRE IELD ERVICE ANUAL 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 and Supplies: 5/32" Allen wrench, T-bar To remove Aft Cover: Step 1.

  • Page 39: Removing The Enclosure Covers

    CAUTION: 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 40: Cleaning The Head Electrostatic Filters

    ™ S UMINAIRE IELD ERVICE ANUAL 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. Tools and Supplies: Parts: #2 Phillips screwdriver 10.9812.0661...

  • Page 41: Cleaning The Enclosure Intake Filters

    AINTENANCE OUTINE AINTENANCE 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. Tools and Supplies: Parts: #2 Phillips screwdriver 40-9812-0834 2 EA AIR INTAKE FILTER Compressed air and/or water...

  • Page 42: Bad Boy ™ Spot Luminaire Field Service Manual

    ™ S UMINAIRE IELD ERVICE ANUAL Cleaning the Luminaire Exterior Tools and Supplies: 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 43: Cleaning The Lenses

    AINTENANCE OUTINE AINTENANCE Cleaning the Lenses Tools and Supplies: (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 44 ™ S UMINAIRE IELD ERVICE ANUAL Step 7. As in Step 5 above, clean remaining lens surfaces and front of luminaire Front Glass. Step 8. To clean backside of Front Glass and front of Lens Group 4, remove Front Glass as follows: a.
  • Page 45 AINTENANCE OUTINE AINTENANCE 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 0 2.

  • Page 46: Cleaning Gobo, Color And Dimmer Wheels

    ™ S UMINAIRE IELD ERVICE ANUAL Cleaning Gobo, Color and Dimmer Wheels Tools and Supplies: 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™...

  • Page 47: Cleaning The Reflector

    AINTENANCE OUTINE AINTENANCE Cleaning the Reflector Tools and Supplies: 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 48: Cleaning The Uv/Ir Window

    ™ S UMINAIRE IELD ERVICE ANUAL Cleaning the UV/IR Window Tools and Supplies: 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 49: Remove And Replace Procedures

    45 degrees clockwise to lock in place. You will hear a click when properly seated. Step 6. Replace backcap. Step 7. Reset Lamp Hours. Refer to the Bad Boy User Manual (02.9812.0001). Step 8. Optimize lamp. (Refer to "Adjusting the Lamp"...
  • Page 50 ™ S UMINAIRE IELD ERVICE ANUAL 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.

  • Page 51: Adjusting The Lamp

    AINTENANCE EMOVE AND EPLACE ROCEDURES 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 and Supplies: none WARNING: Backcap may be HOT during lamp operation.

  • Page 52: Replacing A Gobo

    ™ S UMINAIRE IELD ERVICE ANUAL Replacing a Gobo Parts: Standard or Custom Gobo(s), as required Tools and Supplies: #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 53 AINTENANCE EMOVE AND EPLACE ROCEDURES 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 54 ™ S UMINAIRE IELD ERVICE ANUAL OPEN OPEN OPEN CAUTION: The gobos must be seated properly, especially the gear mesh. Figure 3-15: Gobo Positions and Alignment 02.9812.0005...

  • Page 55: Replacing A Designer Color Filter

    AINTENANCE EMOVE AND EPLACE ROCEDURES Replacing a Designer Color Filter Parts: Designer Color Filter(s), as required Tools and Supplies: #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 56 ™ S UMINAIRE IELD ERVICE ANUAL Step 7. Close head cover access door. OPEN EXPLODED VIEW Figure 3-17: Designer Color Filter Positions 02.9812.0005...

  • Page 57: Replacing The Wheel Stack

    AINTENANCE EMOVE AND EPLACE ROCEDURES Replacing the Wheel Stack Parts: 21.9812.0620 1 EA ASSY, WHEEL STACK, LESS GOBOS Tools and Supplies: #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 58 ™ S UMINAIRE IELD ERVICE ANUAL 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 3-18: Disconnecting Wheel Stack Wiring 02.9812.0005...
  • Page 59 AINTENANCE EMOVE AND EPLACE ROCEDURES Step 5. At Wheel Stack Assembly, remove four 8-32 x 1/2" socket head screws (Figure 3-19). 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 60 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 61: Replacing The Frost/Diffuser Paddle

    AINTENANCE EMOVE AND EPLACE ROCEDURES Replacing the Frost/Diffuser Paddle Parts: 22.9812.0557 1 EA ASSY, DIFFUSER PADDLE Tools and Supplies: #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.
  • Page 62 ™ S UMINAIRE IELD ERVICE ANUAL Step 6. Replace Frost/Diffuser Paddle Assembly as follows: a. Slide new Paddle Assembly onto motor shaft. b. Insert Spacer Tool between Paddle Assembly and motor, aligning the tool’s notch over the motor shaft. c. Tighten set screw. d.

  • Page 63: Replacing The Diffuser Sensor Pcb

    AINTENANCE EMOVE AND EPLACE ROCEDURES Replacing the Diffuser Sensor PCB Parts: 24.9812.0570 1 EA PCB ASSY, DIFFUSER SENSOR Tools and Supplies: #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 64 ™ S UMINAIRE IELD ERVICE ANUAL Step 5. Replace Diffuser Sensor by doing steps in reverse. Make sure header is below 4-40- x 3/16" screws as shown in Figure 3-22. Diffuser Sensor Use anti-static precautions CAUTION: when working with PC boards. HEADER SIDE ORIENTATION REAR VIEW...

  • Page 65: Replacing The Zoom Controller Pcb

    AINTENANCE EMOVE AND EPLACE ROCEDURES Replacing the Zoom Controller PCB Parts: 24.9812.0511.0 1 EA PCB ASSY, ZOOM CONTROLLER Tools and Supplies: #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 66 ™ S UMINAIRE IELD ERVICE ANUAL Zoom Controller PCB Wiring 4-40 x 1/4" PPB Screw (4) Zoom Controller PCB Use anti-static precautions CAUTION: when working with PC boards. Figure 3-23: Removing Zoom Controller PCB 02.9812.0005...

  • Page 67: Replacing A Zoom Sensor Pcb

    AINTENANCE EMOVE AND EPLACE ROCEDURES 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 ™ S UMINAIRE IELD ERVICE ANUAL Step 5. Replace a Zoom Sensor by doing steps in reverse. 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"...
  • Page 69 AINTENANCE EMOVE AND EPLACE ROCEDURES 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 3-25: Removing Zoom Sensors 2 & 4 0 2.

  • Page 70: Replacing The Main Head Fan

    ™ S UMINAIRE IELD ERVICE ANUAL Replacing the Main Head Fan Parts: 23.9812.0993 1 EA ASSY, MAIN HEAD FAN Tools and Supplies: #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.
  • Page 71 AINTENANCE EMOVE AND EPLACE ROCEDURES Step 5. At Motherboard PCB, disconnect Main Head Fan Cable (labeled HI TEMP). Step 6. Release cable from twist-lock cable ties and feed through hole in Aft Assembly. Step 7. Remove Main Head Fan by removing three 6-32 x 1/4" PPB screws. CAUTION: The Main Head Fan has been upgraded.

  • Page 72: Replacing The Tip Pinch Fan

    ™ S UMINAIRE IELD ERVICE ANUAL Replacing the Tip Pinch Fan Parts: 23.9812.0990 1 EA ASSY, FAN CABLE TIP PINCH 12V Tools and Supplies: #2 Philips screwdriver WARNING: Remove power from luminaire before performing any maintenance procedures. To replace the Tip Pinch Fan: Step 1.

  • Page 73: Replacing The Uv/Ir Window Assembly

    AINTENANCE EMOVE AND EPLACE ROCEDURES Replacing the UV/IR Window Assembly Parts: 22.9812.0616 1 EA ASSY, UV/IR WINDOW Tools and Supplies: #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 74: Replacing The Reflector

    ™ S UMINAIRE IELD ERVICE ANUAL Replacing the Reflector Parts: 42.9812.0160 1 EA REFLECTOR, 36 LUNES, COATED Tools and Supplies: #2 Phillips screwdriver, long or #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.

  • Page 75: Replacing A 2A Fuse

    AINTENANCE EMOVE AND EPLACE ROCEDURES 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 and Supplies: #2 Philips screwdriver Needle-nose pliers, small WARNING: Remove power from luminaire before performing any maintenance procedures.

  • Page 76: Replacing The 3A Fuse

    ™ S UMINAIRE IELD ERVICE ANUAL 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 and Supplies: Needle-nose pliers, small WARNING: Remove power from luminaire before performing any maintenance procedures. To replace the 3A Fuse: Step 1.

  • Page 77: Replacing The Emi Ballast Enclosure

    AINTENANCE EMOVE AND EPLACE ROCEDURES Replacing the EMI Ballast Enclosure Parts: 23.9812.0810 1 EA ASSY, EMI BALLAST ENCLOSURE Tools and Supplies: #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.
  • Page 78 ™ S UMINAIRE IELD ERVICE ANUAL 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...

  • Page 79: Replacing The Interface/Lvs Module

    AINTENANCE EMOVE AND EPLACE ROCEDURES Replacing the Interface/LVS Module Parts: 23.9812.0812 1 EA ASSY, INTERFACE/LVS MODULE Tools and Supplies: #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 80 ™ S UMINAIRE IELD ERVICE ANUAL Power Cables: BLACK Do not disconnect cables from positions 4 & 5 LVS DETAIL 10-32 x 3/8" PPB SEMS Screw (4) CAN Bus Enclosure Interface/LVS Module EMI Filter Figure 3-33: Removing Interface/LVS Module 02.9812.0005...

  • Page 81: Replacing The Ignitor Pcb

    AINTENANCE EMOVE AND EPLACE ROCEDURES Replacing the Ignitor PCB Parts: 24.9679.1275 1 EA PCB ASSY, SOLID STATE IGNITOR Tools and Supplies: #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 82 ™ S UMINAIRE IELD ERVICE ANUAL CAUTION: Be careful to maintain correct polarity of the lamp wires. Step 4. At Ignitor PCB, disconnect input and output cables. Step 5. Remove four 1/4" 6-32 hex standoffs and remove Ignitor PCB. Step 6. Replace Ignitor PCB by doing steps in reverse. Use Loctite 242 when re-installing standoffs as shown in Figure 3-34.

  • Page 83: Replacing The Pan/Tilt Controller Pcb

    AINTENANCE EMOVE AND EPLACE ROCEDURES Replacing the Pan/Tilt Controller PCB Parts: 24.9812.0765 1 EA PCB ASSY, CONTROLLER PAN/TILT Tools and Supplies: #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 84: Replacing The Pan/Tilt Cot Sensor Pcb

    ™ S UMINAIRE IELD ERVICE ANUAL Replacing the Pan/Tilt COT Sensor PCB Parts: 24.9679.0750 1 EA PCB ASSY, PAN/TILT COT SENSOR Tools and Supplies: #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 85 AINTENANCE EMOVE AND EPLACE ROCEDURES Step 4. At Pan/Tilt Controller PCB, disconnect Pan/Tilt COT Sensor cable. Step 5. At outside of yoke leg, remove two 4-40 x 3/8" PFZ screws (which secure standoff to yoke leg). This will free Pan/Tilt COT Sensor PCB Assembly. Step 6.

  • Page 86: Replacing The Pan Drive Assembly

    ™ S UMINAIRE IELD ERVICE ANUAL Replacing the Pan Drive Assembly Parts: 21.9812.0718 1 EA ASSY, PAN DRIVE MECHANISM Tools and Supplies: #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 87 AINTENANCE EMOVE AND EPLACE ROCEDURES Step 3. At Pan-Side Yoke Leg, remove Yoke Handle by removing two 10-32 x 5/8" PFZ screws. 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.
  • Page 88 ™ S UMINAIRE IELD ERVICE ANUAL 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 3-39: Removing Pan Drive Assembly (View 2) 02.9812.0005...

  • Page 89: Replacing The Tilt Drive Assembly

    AINTENANCE EMOVE AND EPLACE ROCEDURES Replacing the Tilt Drive Assembly Parts: 21.9812.0719 1 EA ASSY, TILT DRIVE Tools and Supplies: #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 90 ™ S UMINAIRE IELD ERVICE ANUAL 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 3-37). Step 5. At Pan/Tilt Controller PCB, disconnect Tilt Drive Assembly cable harness. Step 6.

  • Page 91: Setting Pan/Tilt Belt Tension

    AINTENANCE EMOVE AND EPLACE ROCEDURES 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). When properly set, the belt should not show bilateral deflection.
  • Page 92 ™ S UMINAIRE IELD ERVICE ANUAL 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 3-41. 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 0 2 . 9 81 2 . 0 00 5...

  • Page 94: Overview

    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. This IPB is not a complete shop-level breakdown.

  • Page 95: Parts Breakdown

    ARTS REAKDOWN 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 26 21.9812.0820 ASSY, EXHAUST COVER, UPPER ENCLOSURE page 29 21.9812.0830 ASSY, INTAKE COVER, UPPER ENCLOSURE page 29 21.9812.0863...
  • Page 96 ™ S UMINAIRE IELD ERVICE ANUAL Bad Boy Spot Luminaire (continued) Refer to Parts List on previous page. 9 (x4) (x2) (x2) 02.9812.0005...

  • Page 97: Bad Boy Spares Kit

    LLUSTRATED ARTS REAKDOWN ARTS REAKDOWN Bad Boy Spares Kit Item Description Procedure 20.9812.1229 ASSY, ROAD CASE, WHEEL STACK page 47 21.9812.0620 ASSY, WHEEL STACK, LESS GOBOS page 47 21.9812.0719 ASSY, TILT DRIVE page 79 23.9812.0810 ASSY, EMI BALLAST ENCLOSURE page 67 23.9812.0812...
  • Page 98 ™ S UMINAIRE IELD ERVICE ANUAL Bad Boy Spares Kit (continued) Item Description Procedure 21.9812.0718 ASSY, PAN DRIVE page 76 24.9679.0750 PCB ASSY, PAN/TILT COT SENSOR page 74 24.9812.0765 PCB ASSY, CONTROLLER PAN TILT page 73 70.3769.0003.0 FUSE, 3AMP SLO-BLO...
  • Page 99 LLUSTRATED ARTS REAKDOWN ARTS REAKDOWN Bad Boy Spares Kit (continued) Item Description Procedure 24.9812.0510 PCB ASSY, ZOOM SENSOR page 57 0 2. 9 8 1 2. 0 0 05...
  • Page 100 ™ S UMINAIRE IELD ERVICE ANUAL Bad Boy Spares Kit (continued) Item Description Procedure 22.9812.0557 ASSY, DIFFUSER PADDLE page 51 24.9812.0570 PCB ASSY, DIFFUSER SENSOR page 53 70.3769.0002.0 FUSE, 2AMP SLO-BLO page 65 02.9812.0005...
  • Page 101 LLUSTRATED ARTS REAKDOWN ARTS REAKDOWN Bad Boy Spares Kit (continued) Item Description Procedure 22.9812.0616 ASSY, UV/IR WINDOW page 63 23.9812.0990 ASSY, FAN CABLE TIP PINCH 12V page 62 23.9812.0993 ASSY, MAIN HEAD FAN page 60 42.9812.0160 REFLECTOR, 36 LUNES, COATED page 64 0 2.
  • Page 102 ™ S UMINAIRE IELD ERVICE ANUAL Notes 02.9812.0005...

  • Page 103: Appendix A. Technical Specifications

    PPENDIX Technical Specifications • Bad Boy Spot Luminaire • Bad Boy Road Case • AC Line Current / Power vs. Voltage 0 2 . 9 81 2 . 0 00 5...

  • 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 TECHNICAL PECIFICATIONS 30" (762 mm) 15.6" (396mm) 39.125" (994 mm) POSITIONING: Can be mounted in any orientation. 13.5" SPACING: (343 mm) Hangs on 30 inch (762 mm) centers. WEIGHT: 167 lbs (75.8 kg) - includes clamps and rails 0 2. 9 8 1 2. 0 0 05...

  • Page 106: Bad Boy Road Case

    ™ S UMINAIRE IELD ERVICE ANUAL Bad Boy Road Case EMPTY WEIGHT: 90 lbs (40.8 kg) LOADED WEIGHT: 257 lbs (116.6 kg) - includes (1) one luminaire with clamps and rails 30.15" (766 mm) 02.9812.0005...

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

    Modulator). Input power is held constant by the PWM at a value equal to the load power divided by the efficiency of the SMPS (usually .85 to .95). The Bad Boy Electronic Ballast and the 24V DC LVS (Low-Voltage Supply) are both SMPS units.

  • Page 108: Photometric Data

    ™ S UMINAIRE IELD ERVICE ANUAL The UVLO is not adjustable, it is set by the manufacturer to what he considers a safe value for his selection of components. We have chosen vendors that provide a conservative margin for a more reliable product.

  • Page 109: Narrow Zoom

    TECHNICAL PECIFICATIONS 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

    ™ S UMINAIRE IELD ERVICE ANUAL 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.

  • Page 111: Wide Zoom

    TECHNICAL PECIFICATIONS 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.

  • Page 112: Logarithmic Beam Illuminance Comparison

    ™ S UMINAIRE IELD ERVICE ANUAL 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.

  • Page 113: Bad Boy Luminaire Wiring Diagram

    ™ S UMINAIRE IELD ERVICE ANUAL IRING IAGRAMS Wiring Diagrams Bad Boy Luminaire Wiring Diagram Chassis TILT CHASSIS YOKE HEAD Gnd Screw 2 AXIS AXIS 25-9812-0957 25-9812-0958 24-9812-0510 TYPICAL Red 22x2 EMI Filter PCB +24V Blk 22x2 Blk 14 Blk 22x2...

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