SOFTWARE VERSION 1.6 WWW.PRG.
AutoPar®, Bad Boy®, PRG Series 400®, Mbox Extreme®, OHM™, V476™, V676™, Virtuoso®, Virtuoso® DX, Virtuoso® DX2, and VL6C+™ are trademarks of Production Resource Group, LLC, registered in the U.S. and other countries. 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.
FOREWORD Compliance Notice This device complies with Part 15 of the FCC rules. Operation is subject to the following two conditions: 1) This device may not cause harmful interference, and 2) This device must accept any interference received, including interference that may cause undesired operation.
WARNING: INSTRUCTIONS FOR PROTECTION AGAINST INJURY TO PERSONS 1) 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. 2) Arc lamps generate intense heat. Disconnect power and allow lamp to cool for 5 minutes before relamping.
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.
Revision History This manual has been revised as follows: IV Version Release Date Notes BASIC September 22, 2009 A March 3, 2010 B May 4, 2010 Updated Wiring Diagram. Added new Hi-Temp Pinch Fan and Ignitor replacement procedures. C1 July 16, 2010 Added Front Lens and Retaining Ring info to Maintenance and IPB sections. Added Designer Color and Gobo Wheel standard configurations to Description section.
TABLE OF CONTENTS Introduction About This Manual........................................................................................................................................................................ 1 Additional Documentation ............................................................................................................................................................ 1 Customer Service ............................................................................................
Replacing the Wheel Stack......................................................................................................................................................... Replacing the Frost/Diffuser Paddle........................................................................................................................................... Replacing the Diffuser Sensor PCB.............................................................................................................................
INTRODUCTION About This Manual This manual provides testing, troubleshooting, maintenance procedures, and illustrated parts breakdowns for the following equipment: + Bad Boy® Spot Luminaire (20.9812.0001) + Bad Boy™ CMY Spot Luminaire (20.9812.0002) This manual is intended for use in field servicing and is not a comprehensive shop-level manual. WARNING: It is important to read ALL accompanying safety instructions to avoid damage to the product and potential injury to yourself or others.
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 Fax: 214.630.5867 Service Fax: 214.638.2125 Service Email: orders@prg.com For additional resources and documentation, please visit our website at: www.prg.
1. DESCRIPTION This chapter contains an overview of luminaire features and components.
FEATURES Overview The Bad Boy Spot Luminaire from PRG Lighting combines the qualities of a traditional automated light with a large venue fixture. Features + Philips MSR Gold™ FastFit lamp that can be set to levels 900W, 1200W, or 1400W. + Built-in LCD touchscreen display which provides access to control, configuration, status, and testing functions. + Zoom lens system consisting of four groups of lenses - each independently controlled for accuracy while maintaining focus during zoom changes.
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.
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. ACTIVEONLY WHEN FIXTURE IS POWE RED A C IN 200 - 240V A C Upper Enclosure Houses power supply, ballast, and provides Data In and Thru, and AC power connections. Also houses the Menu Touchscreen (see detail below).
Head and Enclosure Components The following illustration shows the major sub-assemblies located in the Bad Boy Head and Enclosure.
Yoke Components Tilt-Side Yoke The following illustration shows the major sub-assemblies located in the Bad Boy Tilt-Side Yoke Leg.
Pan-Side Yoke Leg The following illustration shows the major sub-assemblies located in the Bad Boy Pan-Side Yoke Leg.
Designer Color and Gobo Wheel Configurations Designer Color Wheel Standard Configuration The following drawing shows the standard Bad Boy Designer Color Wheel configuration.
Standard Gobo Wheel Configuration The following drawing shows the standard Bad Boy Designer Gobo Wheel configurations.
Notes 12 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL
2. TESTING & TROUBLESHOOTING This chapter provides testing and troubleshooting procedures for the luminaire.
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 cases, to all mechanisms at once. At the Home screen, press the Test panel to bring up the Test screen. Options are as follows: + Re-Cal - press to bring up Recalibration Screen. + Re-Call ALL - press to bring up Re-Cal ALL Yes/No options. + Disable - press to bring up Disable Screen.
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.
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 daisychaining.) To perform a group test: Step 1. At Group Tests screen, select options to run: Pan/Tilt, Intensity, Colors, Gobos, and/or Zoom. Step 2.
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) + LOCKED (white) Press STATUS to bring up Status screen Pressing the Status panel will bring up the Status screen (as shown at right). The Status screen will indicate which specific mechanisms, if any, have errors.
Mechanism Errors Errors will be shown after the mechanism sub-code, for example: PAN:Comm Error.
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. Ensure power is switched on at source (mains, disconnect box, etc.) Ensure DMX512 or Ethernet data cable is properly connected. No console control.
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. Procedure: Remove backcap and inspect lamp (page 42). Solution: Replace Lamp...
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. The Wheel Stack Assembly contains 12 separate functions that it will test.
Solution: Ensure Diffuser Sensor Cable is properly seated. Solution: Replace Diffuser Sensor PCB... page 58 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. They provide power for the motors. The silkscreen on the Motherboard PCB has each mechanism identified near the driver for each of the three Wheel Controller PCBs.
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. After calibration, the status of each Lens Group will be displayed on the Status screen by the color of its name abbreviation or "sub-code.
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. It contains the Master Control PCB that runs the Menu Touchscreen user interface and controls the DMX and Ethernet communications.
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. If Tilt continues to move past center, it is an indication that the COT sensor has failed or is unplugged from the Pan/Tilt Controller PCB.
Notes 26 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL
3. MAINTENANCE This chapter provides maintenance procedures for the luminaire.
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. To aid in the airflow circulation within the luminaires, after dousing the lamps, wait 5 minutes before removing power to the luminaires.
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. The labels can be found in a plastic bag taped to the inside of all wheel stack road cases.
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. At Head Cover, remove two 8-32 x 3/8" PPB screws (Figure 3-2). Step 2. Remove Head Cover from luminaire. R2 / Designer Wheel Head Cover Front Ring Casting Aft Cover 8-32 x 3/8" PPB Screw (2 ea) R1 Head Cover Hand tighten only.
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. Remove four 10-32 x 3/8" socket head screws. Step 3. Carefully remove Aft Cover from luminaire.
Removing the Enclosure Covers To access interior enclosure components, one or both of the Upper Enclosure Covers may need to be removed. Parts: 21.9812.0820 21.9812.0830 1 EA 1 EA ASSY, INTAKE COVER, UPPER ENCLOSURE ASSY, EXHAUST COVER, UPPER ENCLOSURE Tools: #2 Philips screwdriver To remove Upper Enclosure Covers: Step 1. At Upper Enclosure Cover, loosen two captive screws. Step 2. Remove cover by pulling straight out until lip clears yoke support. CAUTION: The Upper Enclosure Covers are not identical.
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 10.9812.0662 2 EA 2 EA HEAD AIR FILTER FOAM HEAD AIR FILTER ELECTROSTATIC Tools: #2 Phillips screwdriver Compressed air and/or water To clean head filters: WARNING: Remove power from luminaire before performing any maintenance procedures. Step 1. Remove power from luminaire. Step 2.
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 water To clean enclosure intake filters: WARNING: Remove power from luminaire before performing any maintenance procedures. Step 1. Remove power from luminaire. Step 2.
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. Remove power from luminaire. Step 2. Using vacuum cleaner with brush nozzle or compressed air, clean dust from external components.
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™ Ultra Pure Cleaning Solution to clean optical components. DO NOT use Window Cleaner on lenses! Wear cotton gloves or finger cots when handling lenses/glass. Step 1.
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" MUST BE pressed at the menu to complete the procedure. If the lens motors are left in the cleaning configuration for too long, they may be damaged due to overheating. Step 9. At menu, press "Done.
Hand tighten only. DO NOT use a CAUTION: power tool on Head Cover screws.
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.
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. Step 1. Remove power from luminaire and allow components to cool for at least 5 minutes. Step 2. Remove Wheel Stack Assembly.
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. Step 1. Remove power from luminaire and allow components to cool for at least 5 minutes. Step 2. Access UV/IR Window Assembly as required.
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. To replace lamp: Step 1. Remove power from lamp and allow lamp to cool for at least 5 minutes. Step 2. Remove power from luminaire. Step 3.
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. CAUTION: Do not touch lamp or reflector with bare fingers. CAUTION: Allow lamp to cool before servicing. Backcap Lamp Base Lamp DETAIL A: LAMP ORIENTATION Turn 45° Clockwise. Base will click when properly seated.
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. Power up luminaire and allow to warm up for at least ten minutes. Step 2. Set intensity to 100%. Step 3. Position beam on a white wall at a distance of 10' to 20'. Step 4.
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. Remove power from luminaire. Step 2. Locate appropriate head cover door for access to Rotating Gobo Wheel 1 (R1) or Rotating Gobo Wheel 2 (R2) as shown in Figure 3-13. (Doors are identified by a label.
Step 5. Using fingers, grasp frame of gobo and pull out of wheel (Figure 3-14). Sun Gear Retaining Plate Gobo Carrier Tab 3 Tongue Locking Tab 2 4 1 Open Hole (no gobo) 5 6 7 Wheel Note: Drawing is flipped 180° for clarity purposes. Figure 3-14: Replacing a Gobo Step 6. Noting proper orientation, insert new gobo into wheel. Ensure that the "tongue" of the gobo clip goes under the retaining plate (under the sun gear).
CAUTION: The gobos must be seated properly, especially the gear mesh.
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. Remove power from luminaire. Designer Color Filter Step 2. Locate appropriate head cover door for access to Designer Color Wheel as shown in Figure 3-13 on page 45.
4 5 3 6 2 7 1 OPEN EXPLODED VIEW Figure 3-17: Installing Designer Color Filter BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 49
Replacing the Front Glass Parts: 12.9812.0629 41.9812.0628 1 EA 1 EA RETAINER, FRONT GLASS PAINTED 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. Position luminaire head so that Front Glass is facing upward. (To prevent it from falling onto the floor when the Retaining Ring is removed in the next step.) Step 3.
Replacing the Wheel Stack Parts: 21.9812.0620 21.9812.0696 1 EA 1 EA ASSY, WHEEL STACK, LESS GOBOS (standard luminaire version) 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. Remove power from luminaire and allow components to cool for at least 5 minutes. Step 2. Remove both Head Covers.
Fan, Power & Control Cables Zoom Controller PCB J4 Fan Wire Harness J1 J2 J3 J6 Twist-Lock Holder J28 Wheel Stack Motherboard J29 J40 J49 J30 Frost Sensor Cable Frost Motor Cable Wheel Stack Assembly Frost Motor Figure 3-19: Disconnecting Wheel Stack Wiring 52 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL
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. Grasp Wheel Stack Assembly on either side and lift straight up and out of luminaire head. Wheel Stack Assembly 8-32 x 1/2" SCB Screw (4) NOTE: Depending on the Bad Boy luminaire model, the Wheel Stack Assembly will be different.
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. Step 1. Carefully lower Wheel Stack Assembly into road case as shown in Figure 3-21. Step 2. Document luminaire serial number and reason for failure. Step 3. Apply a pre-printed shipping label to top of case.
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. Remove R2/Designer Wheel Head Cover. (Refer to "Removing the Head Covers" on page 30.
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.
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. Remove power from luminaire and allow components to cool for at least 5 minutes. Step 2. Remove R1 Head Cover. (Refer to "Removing the Head Covers" on page 30.) Step 3.
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. Remove power from luminaire and allow components to cool for at least 5 minutes. Step 2. Remove R2/Designer Wheel Head Cover. (Refer to "Removing the Head Covers" on page 30.) Step 3.
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). Parts: 24.9812.0510 4 EA 24.9812.
Use anti-static precautions CAUTION: when working with PC boards. Zoom Sensor R1 Head Cover Hand tighten only. DO NOT use a CAUTION: power tool on Head Cover screws.
] Use anti-static precautions CAUTION: when working with PC boards.
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. Remove Head Covers. (Refer to "Removing the Head Covers" on page 30.) Step 3. Remove lamp. (Refer to "Replacing the Lamp" on page 42.) Step 4.
CAUTION: The Main Head Fan has been upgraded. Be sure to install only the latest hi-temp fan. The hitemp 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. Re-apply new tape before re-installing the Aft Cover. Refer to technical bulletin BAD-002 for more information. Step 8.
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 WARNING: Remove power from luminaire before performing any maintenance procedures. To replace the Tip Pinch Fan: Step 1. Remove power from luminaire and allow components to cool for at least 5 minutes. Step 2.
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 not 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 WARNING: Remove power from luminaire before performing any maintenance procedures. To replace the Tip Pinch Fan: Step 1. Remove power from luminaire and allow components to cool for at least 5 minutes. Step 2.
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. To replace the UV/IR Window Assembly: Step 1. Remove power from luminaire and allow components to cool for at least 5 minutes. Step 2.
Replacing the Reflector Parts: 42.9812.0160 1 EA REFLECTOR, 36 LUNES, COATED Tools: #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. If dirty, clean with OptiMax™ Ultra Pure Cleaning Solution and a Micro Fiber cloth. To replace the Reflector: Step 1.
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. Remove power from luminaire and allow components to cool for at least 5 minutes. Step 2. Remove Head Cover(s) as required. (Refer to "Removing the Head Covers" on page 30.
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. Remove power from luminaire and allow components to cool for at least 5 minutes. Step 2. At Pan Yoke Leg, remove Yoke Leg Cover. Step 3. At Pan/Tilt Controller PCB, use needle-nose pliers to carefully remove and replace 3A fuse.
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. Remove both Upper Enclosure Covers. (Refer to "Removing the Enclosure Covers" on page 32.) Step 3.
1 2 BALLAST POLARITY TO CABLE ASSY BALLAST CONTROL 25-9812-0966-02 FROM CHASSIS GND STUD AC NEUT FROM EMI FILTER PCB WHT N BLK L CABLE LAYOUT - REAR VIEW 10-32 x 3/8" PPB Black SEMS Screw (4) AC LINE TO LEFT EXTENSION FAN 1 BALLAST CONTROL 25-9812-0987-02 EMI Ballast Enclosure TO RIGHT EXTENSION FAN 2 BALLAST CONTROL 25-9812-0987-03 BLACK WHITE 1 Fan 2 FRONT VIEW SIDE VIEW LAMP WIRES APS Fan EMI Ground EMI Output Cables EMI Filter EMI Filter Ground (Loctite 242) Figure 3-34: Removin
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. Remove Intake Cover. (Refer to "Removing the Enclosure Covers" on page 32.) Step 3. At Interface/LVS Module, remove four 10-32 x 3/8" PPB SEMS screws (Figure 3-35). Step 4.
Power Cables: CN3 FAN 1 Low Voltage DC Output BLACK 8 7 6 AC Line Input WHITE 5 CN1 N 4 L 3 Do not disconnect cables from positions 4 & 5 RED BLACK 2 GRN/YEL 1 LVS DETAIL 10-32 x 3/8" PPB SEMS Screw (4) CAN Bus Enclosure Fan Fan N L GND Interface/LVS Module WHT BLK N WHT BLK N GND LVS GND POWERCON GND Figure 3-35: Removing Interface/LVS Module BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 73
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. Remove power from luminaire and allow components to cool for at least 5 minutes. Step 2. At Tilt Yoke Leg, remove Yoke Leg Cover. Step 3.
Step 6. Replace Ignitor PCB by doing steps in reverse. Use Loctite 242 when re-installing standoffs as shown in Figure 3-36. Note: Be sure you install the NEW Ignitor (24.9812.0775). This component has been upgraded.
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. Remove power from luminaire and allow components to cool for at least 5 minutes. Step 2. At Tilt Yoke Leg, remove Yoke Cover. Step 3. At Pan/Tilt Controller PCB, disconnect all cables.
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. Remove power from luminaire and allow components to cool for at least 5 minutes. Step 2. At Pan Yoke Leg, remove Yoke Leg Cover. Step 3.
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.
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" open-ended wrench Sonic Tension Meter, Model 507C (07.3082.1052.0) WARNING: Remove power from luminaire before performing any maintenance procedures. To replace the Pan Drive Assembly: Step 1. Remove power from luminaire and allow components to cool for at least 5 minutes. Step 2. Remove both Yoke Covers by loosening four captive screws (Figure 3-39).
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. Release belt tension by loosening two belt adjustment screws and slip belt off of pan pulley (Figure 3-41). Step 10. Remove four 10-32 x 5/8" socket head screws and two #10 flat washers from Pan Drive Assembly. Step 11.
Pan/Tilt PCB J2 J3 J6 J10 J11 J8 J13 PAN J12 J7 Remove screw and rotate bus bar out of the way (optional).
Replacing the Tilt Drive Assembly Parts: 21.9812.0719 1 EA ASSY, TILT DRIVE Tools: #2 Philips screwdriver 7/16" open-ended wrench 3/8" Nutdriver Sonic Tension Meter, Model 507C (07.3082.1052.0) WARNING: Remove power from luminaire before performing any maintenance procedures. To replace the Tilt Drive Assembly: Step 1. Remove power from luminaire and allow components to cool for at least 5 minutes. Step 2. Remove both Yoke Covers by loosening four captive screws (Figure 3-39). Step 3.
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. Step 7. Release belt tension by loosening two belt adjustment screws and slip belt off of tilt pulley. Step 8.
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. Step 3. Using wrench, tighten belt adjustment bolt(s) until no bilateral deflection occurs. .
4. ILLUSTRATED PARTS BREAKDOWN This chapter provides illustrated parts breakdowns for all luminaire spares components.
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. This IPB is not a complete shop-level breakdown. The Bad Boy Spares Kit includes the following items: 28.9812.1000 Rev A0 Item Qty Each Description 20.9812.1229 1 ASSY, ROAD CASE, WHEEL STACK * 21.9812.
PARTS BREAKDOWN Covers and Included Items 20.9612.0001 Rev A0 No. Item Qty UM Description Procedure 1 21.9812.0020 1 EA SUBASSY, BAD BOY - 2 21.9812.0630 2 EA ASSY, HEAD COVER page 30 3 21.9812.0820 1 EA ASSY, EXHAUST COVER, UPPER ENCLOSURE page 32 4 21.9812.0830 1 EA ASSY, INTAKE COVER, UPPER ENCLOSURE page 32 5 21.9812.0863 2 EA ASSY, HANGING BRACKET - 6 22.9620.0194 2 EA ASSY, LAMP SAFETY CABLE - 7 22.9812.0716 2 EA ASSY, YOKE ARM COVER - 8 25.9812.0902.
Bad Boy Spot Luminaire (continued) Refer to Parts List on previous page.
Bad Boy Spares Kit No. Item Qty UM Description Procedure 1 20.9812.1229 1 EA ASSY, ROAD CASE, WHEEL STACK page 51 21.9812.0620 1 EA ASSY, WHEEL STACK, LESS GOBOS (Standard) page 51 21.9812.0696 1 EA ASSY, CMY WHEEL STACK, LESS GOBOS (CMY) * page 51 3 21.9812.0719 1 EA ASSY, TILT DRIVE page 82 4 23.9812.0810 1 EA ASSY, EMI BALLAST ENCLOSURE page 70 5 23.9812.0812 1 EA ASSY, INTERFACE/LVS MODULE page 72 6 24.9812.
Bad Boy Spares Kit (continued) No. Item Qty UM Description Procedure 8 21.9812.0718 1 EA ASSY, PAN DRIVE page 79 9 24.9679.0750 1 EA PCB ASSY, PAN/TILT COT SENSOR page 77 10 24.9812.0765 1 EA PCB ASSY, CONTROLLER PAN TILT page 76 11 70.3769.0003.
Bad Boy Spares Kit (continued) No. Item Qty UM Description Procedure 12 24.9812.
Bad Boy Spares Kit (continued) No. Item Qty UM Description Procedure 13 12.9812.0629 1 EA RETAINER, FRONT GLASS PAINTED page 50 14 22.9812.0557 1 EA ASSY, DIFFUSER PADDLE page 55 15 24.9812.0570 1 EA PCB ASSY, DIFFUSER SENSOR page 57 16 41.9812.0628 1 EA FRONT GLASS page 50 17 70.3769.0002.
Bad Boy Spares Kit (continued) No. Item Qty UM Description Procedure 16 22.9812.0616 1 EA ASSY, UV/IR WINDOW page 66 17a 23.9812.0990 1 EA ASSY, TIP PINCH FAN, 12V (original) page 64 17b 23.9812.0994 1 EA ASSY, HI-TEMP TIP PINCH FAN, 12V (new) page 65 18 23.9812.0993 1 EA ASSY, MAIN HEAD FAN page 62 19 42.9812.
Notes 94 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL
A. TECHNICAL SPECIFICATIONS + BAD BOY SPOT LUMINAIRE + BAD BOY ROAD CASE + AC LINE CURRENT / POWER VS.
Bad Boy Spot Luminaire SOURCE: Philips MSR Gold™ 1200W FastFit Lamp. Can be set to levels 900W, 1200W, or 1400W. OUTPUT: 48,000 lumens OPTICAL EFFICIENCY: 40% REFLECTOR: Precision glass reflector with dichroic cold mirror coating. OPERATING TEMP: -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.
30" (762 mm) 15.6" (396mm) 39.125" (994 mm) POSITIONING: Can be mounted in any orientation. SPACING: 13.5" (343 mm) Hangs on 30 inch (762 mm) centers. WEIGHT: 167 lbs (75.
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.
AC Line Current / Power vs. Voltage TEST VOLTS FREQ AMPS VA POWER PF 1 170 50Hz 10.27 1746 1735 0.998 2 180 50Hz 9.62 1732 1721 0.995 3 200 50Hz 8.56 1712 1713 0.994 4 200 60Hz 8.57 1714 1709 0.996 5 210 60Hz 8.16 1714 1707 0.997 6 220 50Hz 7.77 1709 1704 0.991 7 230 50Hz 7.47 1718 1708 0.998 8 240 50Hz 7.14 1714 1705 0.993 9 240 60Hz 7.16 1718 1702 0.996 10 250 50Hz 6.83 1708 1704 0.992 11 260 50Hz 6.62 1721 1701 0.
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. In the US, we use a 120V line cord to tech a light if we don't need to strike the lamp. Photometric Data Refer to the charts on the following pages.
Narrow Zoom Iris Full Open 8º Full Angle 40,000 beam Lumens Throw Dist (Ft) 20 30 50 75 100 Beam Dia. (Ft) 2.8 4.2 7.0 10.5 14.0 12095 5376 1935 860 484 Illuminance (fc) Throw Dist (m) Beam Dia. (m) Illuminance (lux) 5 10 20 25 30 0.7 1.4 2.8 3.5 4.2 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. Dist. in Ft. = foot candles Dist. in meters = lux 5000000 Tn = 0.
Medium Zoom Iris Full Open 34º Full Angle 48,000 beam Lumens Throw Dist (Ft) 20 30 50 75 100 Beam Dia. (Ft) 12.2 18.3 30.6 45.9 61.1 Illuminance (fc) 850 378 136 60 34 Throw Dist (m) 5 10 20 25 30 3.1 6.1 12.2 15.3 18.3 13600 3400 850 544 378 Beam Dia. (m) Illuminance (lux) Multiply throw distance by Tn to find beam diameter. Divide cd (candela) by distance squared to find center beam illuminance. Dist. in Ft. = foot candles Dist. in meters = lux 350000 Tn = 0.
Wide Zoom Iris Full Open 56º Full Angle 50,000 beam Lumens Throw Dist (Ft) 20 30 50 75 100 Beam Dia. (Ft) 21.3 31.9 53.2 79.7 106.3 Illuminance (fc) 312 139 50 22 12 Throw Dist (m) Beam Dia. (m) Illuminance (lux) 5 10 20 25 30 5.3 10.6 21.3 26.6 31.9 5000 1250 312 200 139 Multiply throw distance by Tn to find beam diameter. Divide cd (candela) by distance squared to find center beam illuminance. Dist. in Ft. = foot candles Dist. in meters = lux 130000 120000 Tn = 1.
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 0.0 Deg. 10.0 20.0 30.
WIRING DIAGRAMS Bad Boy Luminaire Wiring Diagram AC Gnd G Wht 14 Wht 14 25-9812-0954 Grn/Yel 14 25-9812-0952 G PowerCon AC Input Grn/Yel 14 AC Line AC Line N AC Neut G AC Gnd AC Neut Ballast Terminal Block Blk 12 25-9812-0956 Grn/Yel 14 25-9812-0962 Wht 12 Chassis Gnd Screw 1 G L N CN1 AC AC AC Gnd Line Neut Connector Legend G L N AC Gnd AC Line AC Neut Butt Splice 7 V Sense + 6 V Sense 5 Remote On 4 Power Good 3 Control Gnd 2 I Share 1 I Monitor .
Bad Boy® Spot Luminaire Field Service Manual Version as of: June 23, 2011 PRG part number: 02.9812.
Production Resource Group Dallas Office 8617 Ambassador Row, Suite 120 Dallas, Texas 75247 www.prg.
