Service Manual

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SOFTWARE VERSION 1.15

WWW.PRG.COM

BEST BOY 4000

SPOT LUMINAIRE

FIELD SERVICE MANUAL

Summary of content (120 pages)

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SOFTWARE VERSION 1.15 WWW.PRG.
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AutoPar®, Bad Boy®, Best Boy 4000®, PRG Series 400®, MBOX®, 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.
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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.
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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.
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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.
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Revision History This manual has been revised as follows: IV Version Release Date Notes BASIC July 11, 2012 Initial release. A November 6, 2012 Revised various maintenance procedures to add Loctite #246.
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TABLE OF CONTENTS Introduction About This Manual........................................................................................................................................................................ 1 Additional Documentation ............................................................................................................................................................ 1 Customer Service ............................................................................................
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Remove and Replace Procedures Replacing Lamp.......................................................................................................................................................................... 33 Adjusting Lamp........................................................................................................................................................................... 35 Replacing a Gobo in Gobo Wheel 1 ........................................................................
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INTRODUCTION About This Manual This manual provides testing, troubleshooting, maintenance procedures, and illustrated parts breakdowns for the following equipment: + Best Boy 4000® Spot Luminaire 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.
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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.
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1. DESCRIPTION This chapter contains an overview of luminaire components.
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COMPONENTS Exterior Components The following illustration shows the exterior Best Boy components and controls. Hanging Bracket Assembly (2) Allows luminaire to be mounted on truss pipe. FRONT VIEW Upper Enclosure Houses power supply, ballast, Master Control Board (MCB), and provides Data In and Thru, and AC power connections. Also houses the Menu Touchscreen (see detail below). Yoke Assembly - Houses Yoke Driver Control Board, and Pan & Tilt servos.
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Head and Enclosure Components The following illustration shows the major sub-assemblies located in the Best Boy Head and Enclosure.
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Yoke Components Tilt-Side Yoke The following illustration shows the major sub-assemblies located in the Best Boy Tilt-Side Yoke Leg.
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Pan-Side Yoke Leg 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.
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Designer Color Wheel Standard Configuration The following drawing shows the standard Designer Color Wheel configuration. POSITION #7 UV BLUE OPEN POSITION #1 DEEP RED POSITION #2 TURQUOISE POSITION #6 GREEN POSITION #3 FOLLIES PINK POSITION #5 ORANGE POSITION #4 ROSY MAGENTA Figure 1-6: Designer Color Wheel Standard Configuration Effect Wheel Standard Configuration The following drawing shows the standard Effect Wheel configuration.
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Gobo Wheel Standard Configurations The following drawings show the standard Gobo Wheel configurations.
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Notes 10 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL
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2. TESTING & TROUBLESHOOTING This chapter provides testing and troubleshooting procedures for the luminaire.
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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. + Recalibrate - press to bring up Recalibration Screen.
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Test Sub-Menu Screens Recalibrate Screens - Specifies a specific mechanism for recalibration. Disable Screen - Specifies mechanisms to be excluded from tests. Mechanical Tests Screen - Specifies mechanisms to be tested. Cleaning Lenses Screen - Positions lenses so that they may be easily cleaned with a cloth. Moiré Gobos Screen - Provides a way to specify which wheel positions contain Moiré gobos (M). Group Tests Screen - Allows multiple luminaires to be tested when daisychained together.
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Mechanical Tests The Mechanical Tests menu provides a method for exercising all luminaire mechanisms individually. Each mechanism has a similar Test screen. Cyan is shown in the example to the right. The following test functions are available: + Test Chase - The mechanism will move back and forth between two positions. The START/STOP button starts and stops the motion, and the SPEED button sets the rate of the motion.
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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 daisychaining.) To perform a group test: Step 1. At Group Test screen, select options to run: Pan/Tilt, Intensity, Colors, Gobos, Zoom, and/or Framing. Step 2.
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TROUBLESHOOTING Errors Status Indications The STATUS panel at the Home screen will report overall luminaire conditions as follows: + CALIBRATION (yellow) + OK (green) + ERROR (red) + LOCKED (white) Pressing the STATUS panel will bring up a detailed Status screen as shown below: The Status screen will indicate which specific mechanisms, if any, have errors. It also provides a log of systems activity. The Status screen operates as follows: + Mechanisms - displays mechanism status.
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Mechanism Errors Errors will be shown after the mechanism code, for example: PAN:Comm Error.
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Other Errors 18 Error Code Explanation Solution Ballast Errors: Parity, Overrun, Bad Header, Msg Too Long Various ballast errors Check ballast comm cable/connections Ballast Heat Sink Over Temp Ballast too hot Check fans Ballast Short Detected Short circuit on ballast output Check wiring Ballast Timeout: Lamp Strike Lamp failed to strike Check igniter, lamp CAN Comm Error Stopped receiving CAN messages from motion processor Check CAN cables/connections, motor control board Crossload Time
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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. 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.
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Notes 20 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL
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3. MAINTENANCE This chapter provides maintenance procedures for the luminaire.
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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.
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Wheel Stack Road Case Instructions Parts: 20.9816.1229 / 2.3749A-P05 CASE, WHEEL STACK A special road case is provided for shipping Best Boy Wheel Stack Assembly. 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.
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ROUTINE MAINTENANCE Removing Head Covers To access some interior components, one or both of the Head Covers may need to be removed. A label on the backcap indicates which wheel components the head cover provides access to. Tools & Supplies: #2 Philips screwdriver To remove Head Covers: Step 1. At cover, loosen four captive screws (Figure 3-2). (Cover will still be secured by a safety lanyard.) Step 2. Unclip lanyard to completely remove cover.
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Removing Aft Cover To access some interior components, the Aft Cover may need to be removed. Tools & Supplies: #2 Philips screwdriver Loctite #246 (06.6019.0001.01) WARNING: Remove power from luminaire before performing any maintenance procedures. To remove Aft Cover: Step 1. Remove power from luminaire and allow it to cool for at least 5 minutes. Step 2. At Aft Cover, remove X, Y, and Z adjustment knobs. Step 3. Remove four 8-32 x 1/2" PFB screws. Step 4. Carefully remove Aft Cover. Step 5.
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Removing Yoke Leg Covers To access some interior components, one or more of the Yoke Leg Covers may need to be removed. Tools & Supplies: #2 Philips screwdriver WARNING: Remove power from luminaire before performing any maintenance procedures. To remove yoke leg covers: Step 1. At yoke leg cover, loosen four captive screws (Figure 3-4). Step 2. Remove cover by pulling away from yoke leg.
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Removing Upper Enclosure Covers To access some interior components, one or both of the Upper Enclosure Covers may need to be removed. Tools & Supplies: none WARNING: Remove power from luminaire before performing any maintenance procedures. To remove upper enclosure covers: Step 1. At cover, pull outward to remove.
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Cleaning Intake Filters The filters should be cleaned or replaced when they become dirty. The frequency will depend on how often and in what conditions the luminaire is used. Parts: 10.9816.0788 10.9816.0789 1 EA 1 EA YOKE FAN, AIR FILTER, FOAM YOKE FAN, AIR FILTER, ELECTROSTATIC Tools & Supplies: #2 Phillips screwdriver Compressed air and/or water To clean or replace filters: WARNING: Remove power from luminaire before performing any maintenance procedures. Step 1. Remove power from luminaire. Step 2.
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Cleaning Lenses Tools & 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 3/16" flat screwdriver To clean lenses: CAUTION: Use caution when handling lenses. Avoid scratching optical surfaces. CAUTION: Use ONLY OptiMax™ Ultra Pure Cleaning Solution to clean optical components. DO NOT use Window Cleaner on lenses! Wear cotton gloves or finger cots when handling lenses/glass. Step 1.
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Step 3. At menu TEST screen, press "Clean Lenses." The Cleaning Lenses screen will open. Step 4. Press "Pos1" to position lenses in first cleaning configuration. CAUTION: When cleaning, do not allow the cleaning cloth to come into contact with the lens carrier rail. The rail has lubrication that will contaminate the cleaning cloth. Wear cotton gloves or finger cots. Step 5. If lenses are only dusty, use Micro Fiber cloth to carefully wipe lens surfaces.
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CAUTION: Be extremely careful when removing Retaining Ring and Front Glass in next step. The glass can be easily chipped or cracked. Wear cotton gloves or finger cots when handling the glass. Step 8. To clean backside of Front Glass and front of Lens Group , remove Front Glass as follows: a. 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.) b.
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Cleaning Gobo, Color, and Effect Wheels Tools & 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 effect wheels: CAUTION: Use ONLY OptiMax™ Ultra Pure Cleaning Solution to clean optical components. DO NOT use Window Cleaner on gobo, color, or dimmer wheels! Wear cotton gloves or finger cots when handling optical components.
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REMOVE AND REPLACE PROCEDURES Replacing Lamp Parts: 71.2528.0700 / 2.3749A-02 1 EA LAMP, 700 W SHORT ARC, PHILIPS MSR700SA Tools & Supplies: Cotton gloves or finger cots Alcohol wipe (supplied with new lamp) WARNING: Remove power from luminaire before performing any maintenance procedures. CAUTION: Refer to "Proper Lamp Servicing and Operation" on page 22 before handling the lamp. CAUTION: Wear cotton gloves or finger cots while servicing lamp.
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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. Clean with alcohol wipe after installing. CAUTION: Allow lamp to cool before servicing. Access Door Latch Thumbscrew (2) Turn thumbscrews in an alternating fashion until loose.
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Adjusting 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 & Supplies: 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.
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Replacing a Gobo in Gobo Wheel 1 Due to the complex gear alignment, it is best to remove ALL gobos from the wheel even when replacing or swapping only one gobo. This way all gobos can be re-installed at one time with the proper alignment. Recalibrating a single gobo can be a difficult process. Parts: Standard or Custom Gobo(s), as required. (Refer to "Gobo Wheel Standard Configurations" on page 9.
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Step 4. Re-install all gobos (making changes as necessary) by doing the following: a. Rotate gobo wheel so that first position is accessible. Refer to Figure 3-12 for wheel positions. b. Align gobo’s magnet with alignment mark on sun gear as shown in Figure 3-11. c. Carefully insert gobo, ensuring that carrier tab goes under retaining plate (under sun gear). Press until tongue is secured by locking tab. d. Rotate gobo wheel to next position and install next gobo in same manner. Repeat for remaining gobos.
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Replacing a Gobo in Gobo Wheel 2 Due to the complex gear alignment, it is best to remove ALL gobos from the wheel even when replacing or swapping only one gobo. This way all gobos can be re-installed at one time with the proper alignment. Recalibrating a single gobo can be a difficult process. Parts: Standard or Custom Gobo(s), as required. (Refer to "Gobo Wheel Standard Configurations" on page 9.
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Step 4. Re-install all gobos (making changes as necessary) by doing the following: a. Rotate gobo wheel so that first position is accessible. Refer to Figure 3-14 for wheel positions. b. Align gobo’s magnet with alignment mark on sun gear as shown in Figure 3-13. c. Carefully insert gobo, ensuring that carrier tab goes under retaining plate (under sun gear). Press until tongue is secured by locking tab. d. Rotate gobo wheel to next position and install next gobo in same manner. Repeat for remaining gobos.
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Replacing a Designer Color Filter Parts: Designer Color Filter(s), as required. (Refer to "Designer Color Wheel Standard Configuration" on page 8.) Tools & 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. Remove power from luminaire. Step 2. Remove R2/Designer Head Cover. (Refer to "Removing Head Covers" on page 24.
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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.
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Replacing Front Glass Parts: 41.9816.0628 / 2.37493-R10 1 EA FRONT GLASS Tools & Supplies: Flat screwdriver Cotton gloves or finger cots WARNING: Remove power from luminaire before performing any maintenance procedures. To replace front glass: Step 1. Remove power from luminaire and allow components to cool for at least 5 minutes. CAUTION: Be extremely careful when removing Retaining Ring and Front Glass in next step. The glass can be easily chipped or cracked.
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Replacing Light Shield Parts: 10.9816.0029 / 2.37493-R20 55.0078.1000.0 1 EA 1 EA LENS HOOD, FLEXIBLE BALL LOKT TIE, 316SS, .310" X .010" X 39.4" COATED (STEEL BAND) Tools & Supplies: Tensioning Tool (07.4035.0001.0) Flat screwdriver Large wire cutters WARNING: Remove power from luminaire before performing any maintenance procedures. To replace light shield: Step 1. Remove power from luminaire and allow components to cool for at least 5 minutes. Step 2.
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Step 9. Using a flat screwdriver, press down on sharp edges of belt (left by the cutter) as shown in Detail B. (This should remove the cutting hazard.
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Replacing Head Fan Parts: 25.9816.0996 / 2.3749A-P85 1 EA FAN ASSY, HEAD, 60mm BLOWER Tools & Supplies: #2 Phillips screwdriver Wire cutters Cable Ties WARNING: Remove power from luminaire before performing any maintenance procedures. To replace the head fan: Step 1. Remove power from luminaire. Step 2. Remove R1 Head Cover. (Refer to "Removing Head Covers" on page 24.) Step 3. At Head Fan Assembly, loosen two 6-32 x 1/4" screws and two 6-32 Nylon Insert Hex Nuts. Step 4.
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Step 5. At bottom side of Head Fan Assembly, cut cable tie which secure cables to mounting bracket. Step 6. At Fan, remove two 6-32 x 1-1/4" screws and one 6-32 x 1-3/8" screw. (The cable anchor mount and #6 flat washer will also become loose when the screw is removed.) Step 7. Replace Fan by doing steps in reverse. Apply Loctite 242 to 6-32 screws when installing. Step 8. Re-secure cables with a cable tie. Step 9. Verify that Kapton tape is protecting fan leads at top of fan.
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Replacing Lamp Pinch Fan Parts: 25.9816.0994 / 2.3749A-P80 1 EA ASSY, LAMP PINCH FAN Tools & Supplies: #2 Phillips screwdriver Wire cutters and cable ties Loctite #246 (06.6019.0001.01) WARNING: Remove power from luminaire before performing any maintenance procedures. To replace the lamp pinch fan: Step 1. Remove power from luminaire. Step 2. Remove Aft Cover. (Refer to "Removing Aft Cover" on page 25.) Step 3. At Aft Bulkhead, locate Lamp Pinch Fan cables as shown in Figure 3-21.
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Step 4. Remove Thermal Divider by removing three 6-32 x 1/4" PPSS screws (Figure 3-22). Step 5. Remove Base Pinch Air Duct by removing two 6-32 x 1/4" PPSS screws. Step 6. Remove Intake Baffle by removing three 6-32 x 1/4" PPSS screws. Step 7. Remove Lamp Pinch Fan by removing two 6-32 x 5/16" PFB screws. Step 8. Replace component by doing steps in reverse. Apply Loctite 246 to all threaded screws.
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Replacing Rear Housing Fan Parts: 25.9816.0995 / 2.3749A-P95 1 EA ASSY, REAR HOUSING FAN Tools & Supplies: #2 Phillips screwdriver Wire cutters Cable Ties Loctite #246 (06.6019.0001.01) WARNING: Remove power from luminaire before performing any maintenance procedures. To replace the rear housing fan: Step 1. Remove power from luminaire. Step 2. Remove Aft Cover. (Refer to "Removing Aft Cover" on page 25.) Step 3. At Aft Bulkhead, locate Rear Housing Fan cable as shown in Figure 3-23.
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Step 4. At Rear Housing Fan Assembly, remove two 6-32 x 1/4" PPSS screws. Step 5. Tilt and slide fan assembly out of bulkhead. Step 6. Remove mounting bracket from fan assembly by removing two 6-32 x 5/16" PFB screws (Figure 3-24). Step 7. Install mounting bracket on new Rear Housing Fan Assembly. Apply Loctite 246 to screws. Step 8. Install new Rear Housing Fan Assembly by doing steps in reverse. Apply Loctite 246 to all threaded screws.
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Replacing Head Controller PCB Parts: 24.9816.0640 / 2.3749A-P50 1 EA PCB ASSY, HEAD MOTOR AND FAN DRIVER Tools & Supplies: #2 Phillips screwdriver WARNING: Remove power from luminaire before performing any maintenance procedures. CAUTION: Always use anti-static precautions when working with PCBs. To replace the Head Controller PCB: Step 1. Remove power from luminaire. Step 2. Remove both Head Covers. (Refer to "Removing Head Covers" on page 24.) Step 3. Remove Head Fan and Bracket Assembly.
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Step 5. At bottom of Head Controller PCB, remove two 6-32 x 1/4" screws (Figure 3-26). Step 6. Slide Head Controller PCB up and out of Head Assembly. Step 7. Replace PCB by doing steps in reverse. When re-installing, insert PCB into slot of rails/retainers as shown in Detail A below. Use anti-static precautions CAUTION: when working with PC boards. Head Controller PCB DETAIL "A" CRITICAL! Insert PCB into slot of rails/retainers when re-installing.
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Replacing Wheel Stack Parts: 21.9816.0200 / 2.3749A-P01 1 EA ASSY, WHEEL STACK Tools & Supplies: #2 Phillips screwdriver WARNING: Remove power from luminaire before performing any maintenance procedures. To replace the wheel stack: Step 1. Remove power from luminaire. Step 2. Remove R1 Head Cover. (Refer to "Removing Head Covers" on page 24.) Step 3. Move Head Fan Duct to up position (Figure 3-27).
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Step 4. Disconnect four cables. Step 5. At Wheel Stack, loosen captive screws. 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. Step 8. Install new Wheel Stack by doing steps in reverse.
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Replacing Gag EOT Sensor Parts: 25.9816.0988 / 2.3749A-P45 1 EA CABLE ASSY, GAG EOT SENSOR Tools & Supplies: #2 Phillips screwdriver Wire cutters Loctite #242 (06.6008.0001) Cable Ties WARNING: Remove power from luminaire before performing any maintenance procedures. To replace the gag sensor: Step 1. Remove power from luminaire. Step 2. Remove R2 Head Cover. (Refer to "Removing Head Covers" on page 24.) Step 3. Move Lens Group away from Wheel Stack. Step 4.
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Replacing Gag Wheel Motor Parts: 23.9816.0568 / 2.37493-P7F 1 EA ASSY, MOTOR GAG WHEEL Tools & Supplies: #2 Phillips screwdriver Wire cutters Cable Ties WARNING: Remove power from luminaire before performing any maintenance procedures. To replace the gag wheel motor: Step 1. Remove power from luminaire. Step 2. Remove R1 Head Cover. (Refer to "Removing Head Covers" on page 24.) Step 3. Move Lens Group away from Wheel Stack. Gag Wheel Motor Step 4.
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Replacing Gag Index Motor Parts: 23.9816.0569 / 2.37493-P7H 1 EA MOTOR ASSY, GAG INDEX (EXT SHAFT) Tools & Supplies: #2 Phillips screwdriver Wire cutters Cable Ties WARNING: Remove power from luminaire before performing any maintenance procedures. To replace the gag index motor: Step 1. Remove power from luminaire. Step 2. Remove R1 Head Cover. (Refer to "Removing Head Covers" on page 24.) Step 3. Move Lens Group away from Wheel Stack. Gag Wheel Index Motor Step 4.
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Replacing a Zoom Sensor The Zoom Assembly contains three Zoom Sensor PCBs (one for each Zoom Lens Group). This procedure provides instructions for changing any one of the three sensors. Note that one (1) Zoom Sensor PCB is located on the top side of the Head Assembly (under the R1 cover) and two (2) Zoom Sensor PCBs are located on the bottom side of the Head Assembly (under the R2 cover). Parts: 24.9812.0510 / 2.
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CAUTION: NEVER touch or adjust the brass spring-loaded standoff. It is set at the factory. 2-56 x 3/16" PPSS Screw (2) - Apply Loctite 222 Lens Group 3 Zoom Sensor (G3) Use anti-static precautions CAUTION: when working with PC boards.
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CAUTION: NEVER touch or adjust the brass spring-loaded standoff. It is set at the factory. Use anti-static precautions CAUTION: when working with PC boards.
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Replacing a Zoom Lens Motor Parts: 23.9816.0530.01 / 2.3749A-R25 23.9816.0530.02 / 2.3749A-R30 23.9816.0530.03 / 2.3749A-R35 1 EA 1 EA 1 EA MOTOR ASSY, ZOOM LENS GROUP 1 MOTOR ASSY, ZOOM LENS GROUP 2 MOTOR ASSY, ZOOM LENS GROUP 3 Tools & Supplies: #2 Phillips screwdriver Wire cutters Loctite #242 (06.6008.0001) Loctite #425 (06.6008.0003) Cable Ties WARNING: Remove power from luminaire before performing any maintenance procedures. To replace a zoom lens motor: Step 1. Remove power from luminaire. Step 2.
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CAUTION: NEVER touch or adjust the brass spring-loaded standoff. It is set at the factory.
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CAUTION: NEVER touch or adjust the brass spring-loaded standoff. It is set at the factory.
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CAUTION: NEVER touch or adjust the brass spring-loaded standoff. It is set at the factory.
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Replacing Reflector Parts: 42.9816.0161 / 2.3749A-P90 1 EA REFLECTOR, BEST BOY, 40 LUNE Tools & Supplies: #2 Phillips screwdriver Cotton gloves or finger cots Loctite #246 (06.6019.0001.01) WARNING: Remove power from luminaire before performing any maintenance procedures. To replace the reflector: Step 1. Remove power from lamp and allow lamp to cool for at least 5 minutes. Step 2. Remove Aft Cover. (Refer to "Removing Aft Cover" on page 25.
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Step 5. At Thermal Switch, disconnect two wires (Figure 3-38). Step 6. Remove Thermal Switch Bracket and XYZ Assembly by removing four 8-32 x 1/2" SCBZ screws.
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Step 7. At Reflector, in an alternating fashion, gradually loosen three 6-32 x 1/4" PPSS screws until all three mounting clips are free (Figure 3-39). Step 8. Remove Reflector. Step 9. Verify reflector gasket (10.9816.0615) is still in place and is in good condition.
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Replacing UV/IR Filter Parts: 41.9816.0226 / 2.37493-P92 2 EA FILTER, UV/IR Tools & Supplies: #2 Phillips screwdriver Cotton gloves or finger cots Dow Corning #3145 RTV Adhesive (06.6003.0001.0) Loctite #242 (06.6008.0001) WARNING: Remove power from luminaire before performing any maintenance procedures. To replace the UV/IR filter: Step 1. Remove power from lamp and allow lamp to cool for at least 5 minutes. Step 2. Remove Head Covers. (Refer to "Removing Head Covers" on page 24.) Step 3.
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CAUTION: Wear cotton gloves or finger cots while handling glass filters.
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Replacing AR Glass Parts: 41.9816.0606 / 2.37493-R15 1 EA LENS, COVER, AFT BULKHEAD (AR GLASS) Tools & Supplies: #2 Phillips screwdriver Cotton gloves or finger cots Dow Corning #3145 RTV Adhesive (06.6003.0001.0) Loctite #246 (06.6019.0001.01) WARNING: Remove power from luminaire before performing any maintenance procedures. To replace the AR glass: Step 1. Remove power from lamp and allow lamp to cool for at least 5 minutes. Step 2. Remove Head Covers. (Refer to "Removing Head Covers" on page 24.
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Aft Bulkhead (detail) 6-32 x 5/16" PFB Screw (14) - Hand tighten before torquing - Apply Loctite 246 Aft Bulkhead Cover AD HE N FA J7 AR Glass T EX MP TE J6 Aft Bulkhead Cover (reverse view) RTV Adhesive Figure 3-41: Removing AR Glass BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 71
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Replacing Ignitor Parts: 69.3180.0805.1 / 2.3749A-P35 1 EA IGNITOR, BEST BOY, WITH LABEL Tools & Supplies: #2 Phillips screwdriver Loctite #242 (06.6008.0001) WARNING: Remove power from luminaire before performing any maintenance procedures. To replace the ignitor: Step 1. Remove power from luminaire. Step 2. Remove pan-side yoke leg cover. (Refer to "Removing Yoke Leg Covers" on page 26.) Step 3. At Ignitor, disconnect four cables. Step 4. Remove Ignitor by removing four 6-32 x 1-1/4" PPB screws. Step 5.
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Replacing Interface/LVS Assembly Parts: 21.9816.0811 / 2.3749A-P15 1 EA ASSY, INTERFACE/LVS Tools & Supplies: #2 Phillips screwdriver 5/32" Allen wrench, T-bar WARNING: Remove power from luminaire before performing any maintenance procedures. To replace the Interface/LVS assembly: Step 1. Remove power from luminaire. Step 2. Remove Interface/LVS-side Cover. (Refer to "Removing Upper Enclosure Covers" on page 27.) Step 3.
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Step 6. Flip Interface/LVS Assembly upside down as shown in Figure 3-44. Step 7. Disconnect AC cables and LVS DC Output cables. Step 8. Remove Interface/LVS Assembly Step 9. Replace component by doing steps in reverse.
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Replacing Upper Enclosure Fan Parts: 25.9816.0992 / 2.3749A-R05 1 EA CABLE ASSY, UE CHASSIS FAN Tools & Supplies: #2 Phillips screwdriver 11/32" nutdriver 5/32" Allen wrench, T-bar WARNING: Remove power from luminaire before performing any maintenance procedures. To replace the enclosure fan: Step 1. Remove power from luminaire. Step 2. Remove Interface/LVS-side Cover. (Refer to "Removing Upper Enclosure Covers" on page 27.) Step 3.
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CH FA AS N J8 1/4" Hex Standoff (2) Upper Enclosure Fan 8-32 Hex Nut (2) MAIN CONTROL J2 CH FA AS J8 N Interface/LVS Assembly 10-32 x 3/4" Socket Screw (4) FAN 2 Ground Wire J8 10-32 x 3/8" PPB Screw Fan Cable Figure 3-45: Removing Upper Enclosure Fan 76 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL
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Replacing Ballast Parts: 21.9816.0810 / 2.3749A-P10 1 EA ASSY, BALLAST Tools & Supplies: #2 Phillips screwdriver 5/32" Allen wrench, T-bar WARNING: Remove power from luminaire before performing any maintenance procedures. To replace the ballast: Step 1. Remove power from luminaire. Step 2. Remove both Enclosure Covers. (Refer to "Removing Upper Enclosure Covers" on page 27.) Step 3. To disconnect wiring, partially remove Interface/LVS Assembly as follows: a.
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Ballast 10-32 x 3/4" Socket Screw (4) FAN CABLE Ballast 10-32 x 3/4" Socket Screw (4) Interface/LVS Assembly 25-9816-0956 FROM BALLAST UPPER ENCLOSURE GND #4 MAIN CONTROL J2 Enclosure GROUND WIRE RLY T4 WHT L N BLK 10-32 x 3/4" Socket Screw (4) TAB 4 RLY T6 TAB 6 N WHT FUSE BLK GROUND WIRE L MAIN CONTROL CABLE AC LINE F1 J2 AC NEUT F2 HOT RELAY DETAIL FUSE RELAY WIRES AC WIRES Figure 3-46: Removing Ballast 78 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL
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Replacing Ballast Fan Parts: 25.9816.0991 / 2.3749A-R10 1 EA CABLE ASSY, BALLAST HEATSINK Tools & Supplies: #2 Phillips screwdriver Loctite #242 (06.6008.0001) WARNING: Remove power from luminaire before performing any maintenance procedures. To replace the ballast fan: Step 1. Remove power from luminaire. Step 2. Remove Ballast-side Enclosure Cover. (Refer to "Removing Upper Enclosure Covers" on page 27.) Step 3. Disconnect Fan Cable connector by twisting. Step 4.
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Replacing Yoke Fan Parts: 25.9816.0993 / 2.3749A-R01 1 EA CABLE ASSY, YOKE FAN Tools & Supplies: #2 Phillips screwdriver Wire cutters Loctite #242 (06.6008.0001) Cable Ties WARNING: Remove power from luminaire before performing any maintenance procedures. To replace the yoke fan: Step 1. Remove power from luminaire. Step 2. Remove R2 Head Cover and pan-side yoke leg cover by loosening four captive screws (Figure 3-48).
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Step 3. At Head Controller PCB, disconnect Yoke Fan cable at position J16. Step 4. Cut cable tie which secures cable to Head Assembly. Step 5. Remove Yoke Plenum Cover. Step 6. At Yoke Fan, remove one 8-32 x 1-3/8" PPSS screw and two 8-32 x 5/16" PPSS screws. Step 7. Feed Yoke Fan cable through yoke arm and remove assembly. Step 8. Replace Yoke Fan by doing steps in reverse. Apply Loctite 242 to screws.
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Replacing Pan/Tilt Driver PCB Parts: 24.9816.0765 / 2.3749A-P55 1 EA PCB ASSY, PAN/TILT DRIVER Tools & Supplies: #2 Phillips screwdriver Sonic Tension Meter Loctite #242 (06.6008.0001) WARNING: Remove power from luminaire before performing any maintenance procedures. CAUTION: Always use anti-static precautions when working with PCBs. To replace the Pan/Tilt Driver PCB: Step 1. Remove power from luminaire. Step 2. Remove tilt-side yoke leg cover. (Refer to "Removing Yoke Leg Covers" on page 26.) Step 3.
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Step 5. At Pan/Tilt Driver PCB, disconnect all cables (Figure 3-51). Step 6. Remove Pan/Tilt Driver PCB by removing four 6-32 x .250 PPSS screws. Step 7. Replace Pan/Tilt Driver PCB by doing steps in reverse. Apply Loctite 242 to 6-32 x .250 PPSS screws. Step 8. Set proper belt tension. Refer to "Setting Pan/Tilt Belt Tension" on page 92. Use anti-static precautions CAUTION: when working with PC boards.
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Replacing Tilt COT Sensor Parts: 25.9816.0981 / 2.3749A-P30 1 EA CABLE ASSY, TILT COT SENSOR Tools & Supplies: #1 and #2 Phillips screwdrivers 1/4" nutdriver Wire cutters Loctite #242 (06.6008.0001) Cable Ties WARNING: Remove power from luminaire before performing any maintenance procedures. CAUTION: Always use anti-static precautions when working with PCBs. To replace the tilt COT sensor: Step 1. Remove power from luminaire. Step 2.
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Step 4. At Tilt-Side Yoke Leg, disconnect Tilt COT Sensor Cable from Pan/Tilt Driver PCB (Figure 3-53). Step 5. Cut all cable ties which secure Tilt COT Sensor Cable to yoke and crossmember. Step 6. Remove Yoke Plenum Cover.
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Step 7. At Tilt COT Sensor PCB, remove two 4-40 x 1/4" PFSS screws which secure standoffs to yoke. Step 8. Remove Tilt COT Sensor Cable Assembly. Step 9. Remove two 1/4" Hex Standoffs from PCB by removing two 4-40 x 1/4" PPSS screws. Step 10. Install 1/4" Hex Standoffs on new Tilt COT Sensor PCB, applying Loctite 242 to screws/standoffs. Step 11. Install new Tilt COT Sensor Cable Assembly by doing steps in reverse. Use anti-static precautions CAUTION: when working with PC boards.
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Replacing Tilt Drive Mechanism Parts: 21.9816.0719 / 2.3749A-P75 1 EA ASSY, TILT DRIVE MECHANISM Tools & Supplies: #2 Phillips screwdriver Wire cutters Sonic Tension Meter Cable Ties WARNING: Remove power from luminaire before performing any maintenance procedures. To replace the tilt drive mechanism: Step 1. Remove power from luminaire. Step 2. Remove tilt-side yoke leg cover. (Refer to "Removing Yoke Leg Covers" on page 26.) Step 3. At Pan/Tilt Driver PCB, disconnect pan and tilt drive cables. Step 4.
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Step 5. Remove Yoke Cover Mounting Bracket by removing four 8-32 x 1/2" PFB screws. Step 6. At Tilt Mechanism, loosen four 10-32 nylon insert nuts and move Tilt Mechanism enough so that Timing Belt can be removed. Step 7. To remove Tilt Mechanism, fully remove four 10-32 nylon insert nuts and #10 flat washers. Step 8. Replace component by doing steps in reverse. Step 9. Set proper belt tension. Refer to "Setting Pan/Tilt Belt Tension" on page 92.
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Replacing Pan Drive Mechanism Parts: 21.9816.0718 / 2.3749A-P70 1 EA ASSY, PAN DRIVE MECHANISM Tools & Supplies: #2 Phillips screwdriver 5/32" Allen wrench, T-bar Wire cutters Cable Ties WARNING: Remove power from luminaire before performing any maintenance procedures. To replace the pan drive mechanism: Step 1. Remove power from luminaire. Step 2. Remove both Yoke Leg Covers by loosening four captive screws each (Figure 3-52). Step 3. Remove Pan Shield by removing six 8-32 x 1/2" PPB screws.
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Step 4. At Pan/Tilt Driver PCB, disconnect pan drive cables. Step 5. Cut cable ties which secure cables to luminaire.
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Step 6. Remove Yoke Cover Mounting Bracket by removing four 8-32 x 1/2" PFB screws. Step 7. Loose Pan Mechanism Tension Bolts and remove Timing Belt. Step 8. Remove four 10-32 x 5/8" socket head screws and #10 flat washers that secure Pan Mechanism to crossmember. Step 9. Remove Pan Mechanism. Step 10. Replace Pan Mechanism by doing steps in reverse. Step 11. Set proper belt tension. Refer to "Setting Pan/Tilt Belt Tension" on page 92.
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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. Bilateral deflection may be observed by loosening the tension adjustment bolt(s) and rotating the head assembly.
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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 3-60. 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. .
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Notes 94 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL
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4. ILLUSTRATED PARTS BREAKDOWN This chapter provides illustrated parts breakdowns for all luminaire spares components.
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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 Best Boy Spares Kit, along with basic components such as Covers and Mounting Brackets. This IPB is not a complete shop-level breakdown. The Best Boy Spares Kit includes the following items: 28.9816.2000 / 2.3749A-P00 PRG P/N TEAM Ecode Qty Each Description 20.9816.1229 2.3749A-P05 1 CASE, WHEEL STACK * 21.
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Additional replacement items are as follows: PRG P/N TEAM Ecode Qty Each Description 10.9816.0029 2.37493-R20 1 LENS HOOD, FLEXIBLE (LIGHT SHIELD) 28.9812.1302 2.37493-T70 1 KIT, BAD BOY OPTICS CLEANING 41.9816.0226 2.37493-P92 2 FILTER, UV/IR 41.9816.0606 2.37493-R15 1 LENS, COVER, AFT BULKHEAD (AR GLASS) 41.9816.0628 2.37493-R10 1 FRONT GLASS Torque Chart Unless otherwise specified, torque all fasteners as called out below: TORQUE CHART SCREW SIZE TORQUE IN-LBS 2-56 2.
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PARTS BREAKDOWN Covers and Included Items 20.9816.0001 Rev A0 No. PRG P/N TEAM Ecode Qty UM Description 1 10.9816.0029 2.37493-R20 1 EA LENS HOOD, FLEXIBLE 2 21.9816.0020 - 1 EA SUB-ASSEMBLY, LUMINAIRE W/O COVERS 3 22.9816.0630 - 2 EA HEAD COVER ASSEMBLY, BEST BOY page 24 4 21.9816.0820 - 1 EA ASSY, EXHAUST COVER, UPPER ENCLOSURE page 27 5 21.9816.0830 - 1 EA ASSY, INTERFACE COVER, UPPER ENCLOSURE page 27 6 21.9816.0863 - 2 EA ASSY, HOOK BRACKET - 7 22.9816.
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Covers and Included Items (continued) Refer to Parts List on previous page.
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Best Boy Spares Kit 28.9816.2000 Rev A0 (2.3749A-P00) No. PRG P/N TEAM Ecode Qty UM Description 1 20.9816.1229 2.3749A-P05 1 EA CASE, WHEEL STACK page 23 2 21.9816.0200 2.3749A-P01 1 EA ASSY, WHEEL STACK page 53 3 21.9816.0718 2.3749A-P70 1 EA ASSY, PAN DRIVE MECHANISM page 89 4 21.9816.0719 2.3749A-P75 1 EA ASSY, TILT DRIVE MECHANISM page 87 5 21.9816.0810 2.3749A-P10 1 EA ASSY, BALLAST, BEST BOY page 77 6 21.9816.0811 2.
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Best Boy Spares Kit (continued) Refer to Parts List on previous page.
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Best Boy Spares Kit (continued) No. PRG P/N TEAM Ecode Qty UM Description Procedure 11 25.9816.0981 2.3749A-P30 1 EA CABLE ASSY, TILT COT SENSOR, PCB page 84 12 25.9816.0993 2.3749A-R01 1 EA CABLE ASSY, YOKE FAN page 80 13 69.3180.0805.1 2.
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Best Boy Spares Kit (continued) No. PRG P/N TEAM Ecode Qty UM Description Procedure 14 23.9816.0530.01 2.3749A-R25 1 EA MOTOR ASSY, ZOOM LENS GROUP 1 page 61 15 23.9816.0530.02 2.3749A-R30 1 EA MOTOR ASSY, ZOOM LENS GROUP 2 page 61 16 23.9816.0530.03 2.3749A-R35 1 EA MOTOR ASSY, ZOOM LENS GROUP 3 page 61 17 24.9812.0510 2.3749A-P40 3 EA PCB ASSY, ZOOM SENSOR page 58 18 71.2528.0700 2.
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Best Boy Spares Kit (continued) No. PRG P/N TEAM Ecode Qty UM Description 19 23.9816.0568 2.37493-P7F 1 EA ASSY, MOTOR GAG WHEEL page 56 20 23.9816.0569 2.37493-P7H 1 EA MOTOR ASSY, GAG INDEX (EXT SHAFT) page 57 21 25.9816.0988 2.3749A-P45 1 EA CABLE ASSY, GAG EOT SENSOR page 55 22 25.9816.0994 2.3749A-P80 1 EA ASSY, LAMP PINCH FAN page 47 23 25.9816.0995 2.3749A-P95 1 EA ASSY, REAR HOUSING FAN page 49 24 25.9816.0992 2.
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Best Boy Spares Kit (continued) Refer to Parts List on previous page.
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Notes 106 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL
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A.
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Best Boy 4000 Spot Luminaire SOURCE: MSR 700SA lamp OUTPUT: 20,000 lumens INPUT CURRENT: Minimum 90V, Maximum 270V. 12.0A @ 90V, 10.6A @ 100V, 9.7A @110V, 8.8A @ 120V, 5.8A @180V, 5.3A @ 200V, 5.0A @ 208V, 4.8A @ 220V, 4.4A @ 240V, 4.0A @ 270V Auto-sensing voltage input range is 90V-264V, 50/60Hz OPTICAL EFFICIENCY: 31% REFLECTOR: Precision glass reflector with cold mirror coating. ZOOM RANGE: 8:1 from a tight spot of 8° to a very wide flood of 64° maintaining focus throughout.
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12.5" (318 mm ) 3.88" (99 mm) *41.5" *(1054 mm ) 39.0" (991 mm ) *33" *(838 mm) 28" (711 mm ) 5.78" (147 mm) 35.16" (893 mm ) 19.15" (486 mm ) 22.6" (574 mm ) *31.6" *(803 mm) 27.0" (686 mm ) 28.5" (724 mm ) 16.75" (425 mm ) 18.64" (473 mm) 32.43" (824 mm ) 26.8" (681 mm ) *31.5" *(800 mm) 11.4" (290 mm) * Dimensions with Light Shield extended.
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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.
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Best Boy 4000® Spot Luminaire Field Service Manual Version as of: November 6, 2012 PRG part number: 02.9816.
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Production Resource Group, LLC Dallas Office 8617 Ambassador Row, Suite 120 Dallas, Texas 75247 www.prg.