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PRG Best Boy 4000 Service Manual

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SOFTWARE VERSION 1.15
WWW.PRG.COM
®
BEST BOY 4000
SPOT LUMINAIRE
FIELD SERVICE MANUAL

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Summary of Contents for PRG Best Boy 4000

  • Page 1: Best Boy 4000 Spot Luminaire

    SOFTWARE VERSION 1.15 WWW.PRG.COM ® BEST BOY 4000 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 July 11, 2012 Initial release. November 6, 2012 Revised various maintenance procedures to add Loctite #246. ® BAD BOY SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 7: Table Of Contents

    TABLE OF CONTENTS Introduction About This Manual..................................1 Additional Documentation ................................1 Customer Service ..................................2 Chapter 1. Description Components Exterior Components..................................4 Head and Enclosure Components ............................... 5 Yoke Components ..................................6 Designer Color Wheel Standard Configuration ..........................8 Effect Wheel Standard Configuration ............................
  • Page 8 Torque Chart ....................................97 Parts Breakdown Covers and Included Items................................. 98 Best Boy Spares Kit.................................. 100 Appendix A. Technical Specifications Best Boy 4000 Spot Luminaire ..............................108 Best Boy Road Case ................................110 ® BAD BOY SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 9: Introduction

    Best Boy 4000® Spot Luminaire User Manual (02.9816.0001.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 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/about-us/locations/ PRG Dallas (International Service) 8617 Ambassador Row, Suite 120 Dallas, Texas 75247 USA Phone: 214.630.1963...

  • Page 11: Chapter 1. Description

    DESCRIPTION This chapter contains an overview of luminaire components. COMPONENTS...

  • Page 12: Components

    Menu Touchscreen - Used to configure luminaire address and other options. Also, provides status information and testing. Battery Wake Switch Neutrik® AC DMX512 Input Ethernet Port Power Connector Figure 1-1: Exterior Components ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 13: Head And Enclosure Components

    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 Figure 1-2: Head and Enclosure Components ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 14: Yoke Components

    The following illustration shows the major sub-assemblies located in the Best Boy 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 ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 15 The following illustration shows the major sub-assemblies located in the Best Boy Pan-Side Yoke Leg. Note: The yoke plenum cover is not shown for clarity. Yoke Fan Assembly Fan Filter Ignitor LAMP Pan Drive Mechanism Figure 1-5: Pan-Side Yoke Leg ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 16: Designer Color Wheel Standard Configuration

    Effect Wheel Standard Configuration The following drawing shows the standard Effect Wheel configuration. POSITION #1 OPEN 4-FACET PRISM VARIABLE DIFFUSION POSITION #2 EXTRUDER POSITION #3 OBLONG Figure 1-7: Effect Wheel Standard Configuration ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 17: Gobo Wheel Standard Configurations

    CAUTION: Moiré gobo positions MUST be set using the menu system. ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 18 Notes ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 19: Chapter 2. Testing & Troubleshooting

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

  • Page 20: 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 4000 Spot Luminaire User Manual (02.9816.0001.xx). Test Screen The Test menu provides options for using the luminaire’s self-test features.
  • Page 21 Moiré gobos (M). chained together. Fuse Map - Provides the circuit board location for all mechanism fuses. ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 22: Mechanical Tests

    DMX to get the proper alignment and send the HOME OFFSET command to store the current position as the new "home" position. This position is stored in persistent memory and will be used going forward as the home position. ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 23: Group Tests

    Group Tests The Group Test menu allows multiple Best Boy 4000 Luminaires to be run through a configurable test sequence when chained together via DMX512 or Ethernet. (Refer to the Best Boy User Manual for more information about daisy- chaining.) To perform a group test: Step 1.

  • Page 24: Troubleshooting

    In the case of a mechanism error, the Comm LED on the input panel will flash either red or green (depending on the comm state). AC IN 100 -240 VAC THRU Comm LED COMM ETHERNET WAKE 50 / 60 Hz 12A Max Figure 2-1: Comm LED ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 25 Error while sending spin command to Check CAN cables/connections, motor Spin Error motion processor control board Error while sending stop spin command Check CAN cables/connections, motor Stop Spin Error to motion processor control board ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 26 Tip Fan Error Fan not running properly Check fan Upper Enclosure fans not running UPE Fans Error Check fan, fan cabling properly Yoke Fan Error Fan not running properly Check fan ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 27: Basic Troubleshooting

    Basic Troubleshooting The following table provides a list of common start-up problems and possible solutions. Refer to the Best Boy 4000 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 28 Notes ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 29: Chapter 3. Maintenance

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

  • Page 30: Equipment Handling

    It is mandatory that the lamp be changed green if under threshold, yellow at 650 hours, and red at 750 hours. before 750 hours. Lamp hours CAUTION: It is mandatory that the lamp be changed before 750 hours. ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 31: 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 32: Routine Maintenance

    Captive Screw (4) R1 Head Cover Figure 3-2: Removing Head Covers Step 3. Replace covers as follows: a. Attach lanyard clip. b. Fit cover in place. c. Tighten four captive screws. ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 33: Removing Aft Cover

    Step 5. Replace Aft Cover by doing steps in reverse. Apply Loctite 246 to threads of screws. 8-32 x 1/2" PFB Screw (4) Aft Cover - Apply Loctite 246 X Knob Z Knob Y Knob Figure 3-3: Removing Aft Cover ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 34: Removing Yoke Leg Covers

    Step 2. Remove cover by pulling away from yoke leg. TILT-SIDE COVER PAN-SIDE COVER Tilt-Side Yoke Pan-Side Yoke Leg Cover Leg Cover Captive Captive Screw (4) Screw (4) Figure 3-4: Removing Yoke Leg Covers ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 35: Removing Upper Enclosure Covers

    Remove power from luminaire before performing any maintenance procedures. To remove upper enclosure covers: Step 1. At cover, pull outward to remove. Ballast-Side Upper Enclosure Cover Interface/LVS-Side Upper Enclosure Cover Figure 3-5: Removing Upper Enclosure Covers ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 36: Cleaning Intake Filters

    Step 4. Clean filters with compressed air and/or by washing with water. Replace as necessary. Step 5. Re-install components. Foam Filter Electrostatic Filter Figure 3-6: Removing Air Filters Note: If the filters do not get clean after multiple attempts, they should be replaced. ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 37: Cleaning Lenses

    Step 1. Apply power to luminaire and set intensity to 20%. (A beam will be necessary to see dirt and dust on the lenses.) Step 2. Remove R2/Designer Head Cover to access Zoom Lens Assembly. (Refer to "Removing Head Covers" page 24.) ZOOM LENS ASSEMBLY DETAIL Lenses Figure 3-7: Accessing Zoom Lens Assembly ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 38 Do not handle front CAUTION: glass with bare hands. Notch Front Glass Front Lens Note: Ensure gasket under Front Glass is not damaged or missing before reinstalling. Retaining Ring Figure 3-8: Removing Front Glass ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 39: Cleaning Luminaire Exterior

    DO NOT allow fans or blower to spin at high speeds, as this will damage their bearings. Step 3. Using window cleaner and a clean, lint-free cloth, wipe outside surface of luminaire. DO NOT use window cleaner on lens! ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 40: Cleaning Gobo, Color, And Effect Wheels

    Using OptiMax™ Ultra Pure Cleaning Solution and a Micro Fiber cloth, carefully clean Effect Wheel. DO NOT use window cleaner! b. Rotate wheel to access all surfaces. Step 7. Replace Head Covers. ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 41: Remove And Replace Procedures

    Step 11. Tighten two thumbscrews in an alternating fashion until fully secure. Step 12. Close access door. Step 13. Reset Lamp Hours. (Refer to Best Boy User Manual.) Step 14. Optimize lamp. (Refer to "Adjusting Lamp" on page 35.) ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 42 Metal Lamp Wire Access Door Pull straight outward Keyed Hole Insert straight in, aligning metal wire with keyed hole. Glass Bulb Lamp Base Socket Figure 3-9: Replacing the Lamp ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 43: Adjusting Lamp

    Step 6. At backcap, using horizontal (X) and vertical (Y) knobs, adjust hot spot to center of beam (Figure 3-10). Step 7. Using focus (Z) knob, adjust beam to flatten hot spot. Figure 3-10: Adjusting the Lamp Note: Be sure to reset Lamp Hours when installing a new lamp. ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 44: Replacing A Gobo In Gobo Wheel 1

    Step 3. Using fingers, grasp frame of each gobo and pull out of wheel (Figure 3-11). Remove ALL gobos. Sun Gear Alignment Mark Carrier Tab Gobo Magnet Locking Tongue Note: Some components are shown exploded for clarity. Wheel Figure 3-11: Replacing a Gobo (Wheel 1) ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 45 Adjust as necessary. Step 6. Replace Head Cover. Figure 3-12: Gobo Wheel 1 Positions ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 46: Replacing A Gobo In Gobo Wheel 2

    Step 3. Using fingers, grasp frame of each gobo and pull out of wheel (Figure 3-13). Remove ALL gobos. Sun Gear Alignment Mark Magnet Carrier Tab Gobo Locking Tongue Note: Some components are Wheel shown exploded for clarity. Figure 3-13: Replacing a Gobo (Wheel 2) ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 47 Adjust as necessary. Step 6. Replace Head Cover. Figure 3-14: Gobo Wheel 2 Positions ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 48: Replacing A Designer Color Filter

    Step 3. Rotate wheel until desired designer color filter is accessible (Figure 3-15). Step 4. Using fingers, grasp frame of color filter and pull straight out of wheel hub. Designer Color Filter Carrier Wheel Hub Figure 3-15: Removing a Designer Color Filter ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 49 Step 5. Noting proper orientation of carrier, insert new designer color filter into position and push until carrier clicks into place. Refer to Figure 3-16 for wheel positions. Step 6. Replace Head Cover. OPEN Figure 3-16: Designer Color Wheel Positions ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 50: Replacing Front Glass

    Do not handle front glass with bare hands. CAUTION: Notch Front Glass Front Lens Note: Ensure gasket under Front Glass is not damaged or missing before reinstalling. Retaining Ring Figure 3-17: Removing Front Glass ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 51: Replacing Light Shield

    Detail B. Step 8. Fully tighten belt, then press silver arm of Tensioning Tool to cut excess. ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 52 Steel Band Light Shield Fastener Clip Side Rail Press down on sharp corners Installation Tool Wrap band around outside edge, flush with ridge Figure 3-18: Installing Light Shield with Steel Band ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 53: Replacing Head Fan

    Step 4. Disconnect two fan cables and remove Head Fan Assembly. 6-32 x 1/4" SEMS Screw (2) Head Fan Assembly 6-32 Nylon Insert Hex Nut (2) Figure 3-19: Removing Head Fan Assembly ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 54 Assembly Cable Tie Cable Anchor Mount 6-32 x 1-1/4" Screw (2) Cable Tie (Loctite 242) #6 Flat Washer 6-32 x 1-3/8" Screw (Loctite 242) Figure 3-20: Removing Head Fan From Bracket ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 55: Replacing Lamp Pinch Fan

    Cable Tie Head Assembly FAN # 1 Note: Some head components not shown for clarity. FAN # 2 Lamp Pinch Fan Aft Bulkhead Cable Tie Figure 3-21: Disconnecting Lamp Pinch Fan Cables ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 56 Intake Baffle Base Pinch Air Duct 6-32 x 1/4" PPSS Screw (2) 6-32 x 1/4" PPSS Screw (3) - Apply Loctite 246 - Apply Loctite 246 Figure 3-22: Removing Lamp Pinch Fan ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 57: Replacing Rear Housing Fan

    Rear Housing Fan Assembly 6-32 x 1/4" PPSS Screw (2) Aft Bulkhead - Apply Loctite 246 FAN # 1 Cable Tie Figure 3-23: Removing Rear Housing Fan ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 58 Step 8. Install new Rear Housing Fan Assembly by doing steps in reverse. Apply Loctite 246 to all threaded screws. 6-32 x 5/16" PFB Screw (2) Mounting Bracket - Apply Loctite 246 Rear Housing Fan Assembly Figure 3-24: Removing Fan Mounting Bracket ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 59: Replacing Head Controller Pcb

    "Replacing Head Fan" on page 45.) Step 4. At Head Controller PCB, disconnect all cables (Figure 3-25). BEST BOY HEAD CONTROLLER 24-9816-0640 REV YOKE BACK FANS Figure 3-25: Head Controller PCB Cable Connections ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 60 CAUTION: when working with PC boards. Head Controller PCB "A" DETAIL CRITICAL! Insert PCB into slot of rails/retainers when re-installing. 6-32 x 1/4" Screw (2) Figure 3-26: Removing Head Controller PCB ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 61: Replacing Wheel Stack

    "Removing Head Covers" on page 24.) Step 3. Move Head Fan Duct to up position (Figure 3-27). Wheel Stack POWER IN CANBUS Fan Assembly Air Duct Figure 3-27: Disconnecting Wheel Stack Cables ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 62 Step 7. Grasp Wheel Stack Assembly on either side and lift straight up and out of luminaire head. Step 8. Install new Wheel Stack by doing steps in reverse. Wheel Stack Captive Screw Lens Group 1 Figure 3-28: Removing Wheel Stack ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 63: Replacing Gag Eot Sensor

    - Apply Loctite 242 Use anti-static precautions CAUTION: when working with PC boards. Gag EOT Sensor PCB Cable Tie Gag EOT Sensor Cable ZOOM INDEX Figure 3-29: Removing Gag Sensor Cable Assembly ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 64: Replacing Gag Wheel Motor

    Step 9. Install new Gag Wheel Motor by doing steps in reverse. Step 10. Adjust belt tension by rotating motor mount. INDEX WHEEL Gag Wheel Cable Head Controller PCB Figure 3-30: Removing Gag Wheel Motor ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 65: Replacing Gag Index Motor

    Index Motor by doing steps in reverse. Step 9. Adjust belt tension by rotating motor mount. INDEX WHEEL Gag Index Cable Head Controller PCB Figure 3-31: Removing Gag Wheel Index Motor ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 66: Replacing A Zoom Sensor

    At Zoom Sensor, disconnect cable from header (Figure 3-33). c. Remove Zoom Sensor by removing two 2-56 x 3/16" PPSS screws. Step 6. Replace a Zoom Sensor by doing steps in reverse. Apply Loctite 222 to all screws. ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 67 Use anti-static precautions CAUTION: when working with PC boards. 3/16" Hex Standoff (2) Lens Group 1 2-56 x 3/16" PPSS Screw (2) Zoom Sensor (G1) Figure 3-32: Removing Zoom Sensors 1 & 3 ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 68 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 3-33: Removing Zoom Sensor 2 ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 69: Replacing A Zoom Lens Motor

    Step 7. Install new Zoom Lens Motor by doing steps in reverse. Do the following: a. Apply Loctite 242 to threads of 6-32 x 3/8" socket head screws. b. Torque set screw to 2 in-lbs and apply a drop of Loctite 425 to threads. ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 70 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 Figure 3-34: Removing Zoom Lens Group 1 Motor ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 71 - Torque to 2 in-lbs - Apply Loctite 425 to threads Zoom Lens Group 2 Motor 6-32 x 3/8" Socket Head Screw (2) - Apply Loctite 242 Figure 3-35: Removing Zoom Lens Group 2 Motor ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 72 Cable Tie 6-32 x 3/8" Socket Head Screw (2) - Apply Loctite 242 Zoom Lens Group 3 Motor Zoom G3 Cable Head Controller PCB Figure 3-36: Removing Zoom Lens Group 3 Motor ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 73: Replacing Reflector

    Step 4. Pull lamp socket straight out of luminaire. Allow lamp to cool CAUTION: before servicing. Thumbscrew (2) Turn thumbscrews in an alternating fashion until loose. Pull straight outward Lamp Base Socket Glass Bulb Figure 3-37: Removing Lamp Socket ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 74 Step 6. Remove Thermal Switch Bracket and XYZ Assembly by removing four 8-32 x 1/2" SCBZ screws. DETAIL A Thermal Switch Wires Thermal Reflector Switch Thermal Switch Bracket 8-32 x 1/2" SCBZ Screw (4) - Apply Loctite 246 XYZ Assembly Figure 3-38: Removing XYZ Assembly ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 75 Step 12. Re-install Lamp and Lamp Socket. (Refer to "Replacing Lamp" on page 33 for important instructions!) Step 13. Re-install Aft Cover. Step 14. Optimize lamp. (Refer to "Adjusting Lamp" on page 35.) ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 76: Replacing Uv/Ir Filter

    Step 8. Install two UV/IR Filters. Allow adhesive to dry. Step 9. Re-install Wheel Stack Rear Plate. Apply Loctite 242 to threads of all screws. Step 10. Re-install Wheel Stack into Head Assembly. Step 11. Re-install Head Covers. ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 77 8-32 x 5/16" PFSS Screw (4) - Apply Loctite 242 - Apply Loctite 242 Wheel Stack Rear Plate Captive Screw UV/IR Filter (2) DETAIL UV/IR Filter RTV Adhesive Figure 3-40: Removing UV/IR Filter ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 78: Replacing Ar Glass

    Hand tighten all screws before Step 9. Re-install Aft Bulkhead Cover. Apply Loctite 246 to threads of all screws. torquing! Step 10. Re-install Wheel Stack into Head Assembly. Step 11. Re-install Head Covers. ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 79 6-32 x 5/16" PFB Screw (14) Aft Bulkhead (detail) - Hand tighten before torquing - Apply Loctite 246 Aft Bulkhead Cover AR Glass Aft Bulkhead Cover (reverse view) RTV Adhesive Figure 3-41: Removing AR Glass ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 80: Replacing Ignitor

    Step 5. Replace Ignitor by doing steps in reverse. Apply Loctite 242 to 6-32 x 1-1/4" PPB screws. LAMP Ignitor 6-32 x 1-1/4" PPB Screw (4) - Apply Loctite 242 Use anti-static precautions CAUTION: when working with PC boards. Figure 3-42: Removing the Ignitor ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 81: Replacing Interface/Lvs Assembly

    Step 5. At Main Controller PCB, disconnect four cables as shown in Figure 3-43. Enclosure WIRING CONNECTIONS Interface/LVS Assembly 10-32 x 3/4" Socket Screw (4) Ground Wire FAN 2 10-32 x 3/8" PPB Screw FAN 1 CANBUS Main Controller Figure 3-43: Disconnecting Interface/LVS Cables ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 82 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 Figure 3-44: Removing Interface/LVS Assembly ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 83: Replacing Upper Enclosure Fan

    Step 5. Pull Interface/LVS Assembly out of enclosure enough to disconnect Upper Enclosure Fan Cable. Step 6. Remove fan by removing two 8-32 hex nuts. Step 7. Install new Upper Enclosure Fan by doing steps in reverse. ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 84 Upper Enclosure Fan 8-32 Hex Nut (2) Interface/LVS Assembly 10-32 x 3/4" Socket Screw (4) FAN 2 Ground Wire 10-32 x 3/8" PPB Screw Fan Cable Figure 3-45: Removing Upper Enclosure Fan ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 85: Replacing Ballast

    Step 6. Twist Fan Cable connector to disconnect. CAUTION: Use caution when removing the Ballast from the enclosure. Step 7. Remove Ballast from enclosure. Step 8. Install new Ballast by doing steps in reverse. ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 86 GND #4 Enclosure GROUND WIRE 10-32 x 3/4" Socket Screw (4) TAB 4 TAB 6 HOT RELAY DETAIL RELAY WIRES GROUND WIRE MAIN CONTROL CABLE AC WIRES Figure 3-46: Removing Ballast ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 87: Replacing Ballast Fan

    Step 6. Install new Ballast Fan by doing steps in reverse. Apply Loctite 242 to screws. Ballast Mesh #8 Washer 8-32 x 1-1/2" PPZ Screw (4) - Apply Loctite 242 Fan Cable DETAIL A Figure 3-47: Removing Ballast Fan ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 88: Replacing Yoke Fan

    Step 2. Remove R2 Head Cover and pan-side yoke leg cover by loosening four captive screws (Figure 3-48). R2 / Designer Wheel Head Cover Captive Screw (4) Yoke Leg Cover Captive Screw (4) Figure 3-48: Removing Head and Yoke Covers ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 89 Step 8. Replace Yoke Fan by doing steps in reverse. Apply Loctite 242 to screws. Cable Tie Yoke Fan Cable Plenum Cover Yoke Fan 8-32 x 1-3/8" PPSS Screw 8-32 x 5/16" PPSS Screw (2) Figure 3-49: Removing Yoke Fan ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 90: Replacing Pan/Tilt Driver Pcb

    Step 3. At Tilt Drive Mechanism, loosen four 10-32 hex nuts so that Timing Belt becomes loose (Figure 3-50). Step 4. Remove Timing Belt. Timing Belt 10-32 Hex Nut (4) Tilt Drive Mechanism Tilt-Side Yoke Leg Figure 3-50: Removing Timing Belt ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 91 Use anti-static precautions CAUTION: when working with PC boards. Pan/Tilt Driver PCB Pan/Tilt Driver PCB 6-32 x .250 PPSS Screw (4) - Apply Loctite 242 Figure 3-51: Removing Pan/Tile Driver PCB ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 92: Replacing Tilt Cot Sensor

    Step 3. Remove Pan Shield by removing six 8-32 x 1/2" PPB screws. Yoke Leg Cover Pan Shield 8-32 x 1/2" PPB Screw (6) Captive Screw (4) Yoke Leg Cover Figure 3-52: Removing Yoke Leg Covers and Pan Shield ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 93 Step 5. Cut all cable ties which secure Tilt COT Sensor Cable to yoke and crossmember. Step 6. Remove Yoke Plenum Cover. Pan/Tilt Driver PCB Tilt COT Sensor Cable Tilt-Side Yoke Leg Plenum Cover Cable Tie Figure 3-53: Disconnecting Tilt COT Sensor Cable ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 94 1/4" Hex Standoff (2) - Apply Loctite 242 Tilt COT Sensor PCB Cable Assembly 4-40 x 1/4" PPSS Screw (2) - Apply Loctite 242 Figure 3-54: Removing Tilt COT Sensor PCB ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 95: Replacing Tilt Drive Mechanism

    Step 3. At Pan/Tilt Driver PCB, disconnect pan and tilt drive cables. Step 4. Cut cable ties which secure cables to luminaire. Pan/Tilt Driver PCB Figure 3-55: Tilt-Side Yoke Leg with Pan/Tilt Driver PCB ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 96 "Setting Pan/Tilt Belt Tension" on page 92. Timing Belt 8-32 x 1/2" PFB Screw (4) #10 Flat Washer (4) Yoke Cover Mounting Bracket 10-32 Nut (4) Figure 3-56: Removing Tilt Mechanism ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 97: Replacing Pan Drive Mechanism

    Step 3. Remove Pan Shield by removing six 8-32 x 1/2" PPB screws. Yoke Leg Cover Pan Shield 8-32 x 1/2" PPB Screw (6) Yoke Leg Cover Captive Screw (4) Figure 3-57: Removing Yoke Leg Covers and Pan Shield ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 98 Step 4. At Pan/Tilt Driver PCB, disconnect pan drive cables. Step 5. Cut cable ties which secure cables to luminaire. Pan/Tilt Driver PCB Figure 3-58: Tilt-Side Yoke Leg with Pan/Tilt Driver PCB ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 99 Tension Bolt (2) Cable Tie 10-32 x 5/8" Screw (4) Pan Mechanism #10 Flat Washer (4) Yoke Cover Mounting Bracket 8-32 x 1/2" PFB Screw (4) Figure 3-59: Removing Pan Drive Mechanism ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 100: Setting Pan/Tilt Belt Tension

    Step 1. Set Pan and Tilt presets on the Tension Meter as given above. Step 2. Orient head as shown in Figure 3-60 on next page. Step 3. Slowly tighten belt adjustment bolt(s). Use Tension Meter to verify correct tension. ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 101 PAN MECHANISM Orient head as shown TILT MECHANISM Driven Pulley Tension Side Feed Side of Belt of Belt Deflections are present when belt is loose. Drive Pulley Figure 3-60: Belt Tension Adjustment ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 102 Notes ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 103: Chapter 4. Illustrated Parts Breakdown

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

  • Page 104: Overview

    IGNITOR, BEST BOY, WITH LABEL 71.2528.0700 2.3749A-02 LAMP, 700 W SHORT ARC, PHILIPS MSR700SA * For more information about Wheel Stack Road Case, refer to "Wheel Stack Road Case Instructions" on page 23. ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 105: Torque Chart

    FRONT GLASS Torque Chart Unless otherwise specified, torque all fasteners as called out below: TORQUE CHART SCREW TORQUE SIZE IN-LBS 2-56 2.20 4-40 4.70 6-32 8.70 8-32 17.80 10-32 29.70 1/4-20 65.00 ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 106: Parts Breakdown

    ASSEMBLY, YOKE ARM COVER page 26 25.9812.0902.5 CABLE ASSY, AC LINE CORD 2.5' 14/3 L6 55.0078.1000.0 BALL LOKT TIE, 316SS, .310" X .010" page 43 Refer to illustration on next page. ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 107 Covers and Included Items (continued) Refer to Parts List on previous page. (x2) (x2) (x2) ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 108: Best Boy Spares Kit

    2.3749A-P55 PCB ASSY, PAN/TILT DRIVE page 82 25.9816.0996 2.3749A-P85 FAN ASSY, HEAD, 60mm BLOWER page 45 25.9816.0991 2.3749A-R10 CABLE ASSY, BALLAST HEATSINK FAN page 79 Refer to illustration on next page. ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 109 Best Boy Spares Kit (continued) Refer to Parts List on previous page. ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 110 TEAM Ecode Description Procedure 25.9816.0981 2.3749A-P30 CABLE ASSY, TILT COT SENSOR, PCB page 84 25.9816.0993 2.3749A-R01 CABLE ASSY, YOKE FAN page 80 69.3180.0805.1 2.3749A-P35 IGNITOR, BEST BOY, WITH LABEL page 72 ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 111 61 23.9816.0530.03 2.3749A-R35 MOTOR ASSY, ZOOM LENS GROUP 3 page 61 24.9812.0510 2.3749A-P40 PCB ASSY, ZOOM SENSOR page 58 71.2528.0700 2.3749A-02 LAMP, 700 W SHORT ARC, PHILIPS MSR700SA page 33 ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 112 2.3749A-P95 ASSY, REAR HOUSING FAN page 49 25.9816.0992 2.3749A-R05 CABLE ASSY, UE CHASSIS FAN page 75 42.9816.0161 2.3749A-P90 REFLECTOR, BEST BOY, 40 LUNE page 65 Refer to illustration on next page. ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 113 Best Boy Spares Kit (continued) Refer to Parts List on previous page. ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 114 Notes ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 115: Appendix A. Technical Specifications

    TECHNICAL SPECIFICATIONS BEST BOY 4000 SPOT LUMINAIRE BEST BOY ROAD CASE...

  • Page 116: Best Boy 4000 Spot Luminaire

    OPERATING TEMP: -20° to 120°F (-29° to 49°C) CONTROL: Compatible with all PRG consoles and a wide variety of DMX512 and Art-Net consoles. DMX CHANNELS: 45 DMX512 channels required per unit. ETHERNET BYPASS: A relay allows Ethernet signals to pass through daisy-chained luminaires even if power is removed.
  • Page 117 (724 mm ) (686 mm ) 16.75" (425 mm ) 18.64" (473 mm) 32.43" (824 mm ) 26.8" 11.4" (681 mm ) (290 mm) *31.5" *(800 mm) * Dimensions with Light Shield extended. ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...

  • Page 118: 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) ® BEST BOY 4000 SPOT LUMINAIRE FIELD SERVICE MANUAL...
  • Page 119 Best Boy 4000® Spot Luminaire Field Service Manual Version as of: November 6, 2012 PRG part number: 02.9816.0005 A...
  • Page 120 Production Resource Group, LLC Dallas Office 8617 Ambassador Row, Suite 120 Dallas, Texas 75247 www.prg.com...

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