Prg Bad Boy Field Service Manual Manual de usuario

SOFTWARE VERSION 1.6WWW.PRG.COMBAD BOY® SPOT LUMINAIREFIELD SERVICE MANUAL

2 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALCustomer ServiceFor technical assistance, contact the PRG International Service Center or contact your n

92 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALBad Boy Spares Kit (continued)No. Item Qty UM Description Procedure13 12.9812.0629 1 EA RETAINER, FRONT

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 93Bad Boy Spares Kit (continued)No. Item Qty UM Description Procedure16 22.9812.0616 1 EA ASSY, UV/IR WIN

94 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALNotes

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

96 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALBad Boy Spot LuminaireSOURCE: Philips MSR Gold™ 1200W FastFit Lamp. Can be set to levels 900W, 1200W, o

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 97(762 mm)30"15.6"(396mm)(343 mm)13.5"39.125"(994 mm)POSITIONING:Can be mounted in an

98 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALBad Boy Road CaseEMPTY WEIGHT: 190 lbs (86.18 kg)LOADED WEIGHT: 357 lbs (161.93 kg) - includes (1) one

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 99AC Line Current / Power vs. VoltageNotes: + Tested while running all motors except Intensity/Iris/Fros

100 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALadded to the UVLO circuit. The voltage must be advanced by a considerable margin before the SMPS recov

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 101Narrow ZoomIris Full Open8º Full Angle40,000 beam LumensThrow Dist (Ft) 20 30 50 75 100Beam Dia. (Ft)

1.DESCRIPTIONThis chapter contains an overview of luminaire features and components.+FEATURES+ COMPONENTS

102 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALMedium ZoomIris Full Open34º Full Angle48,000 beam LumensThrow Dist (Ft) 20 30 50 75 100Beam Dia. (Ft)

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 103Wide Zoom130000120000110000100000900008000070000600005000040000300002000010000030.020.010.00.0-10.0-20

104 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALLogarithmic Beam Illuminance Comparison14000012000010000080000600004000020000030.020.010.00.0-10.0-20.

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 105WIRING DIAGRAMSBad Boy Luminaire Wiring DiagramRJ-45ConnectorLegendMother Board PCBBad Boy WheelR1 Sen

Bad Boy® Spot Luminaire Field Service ManualVersion as of: June 23, 2011PRG part number: 02.9812.0005 E

Production Resource GroupDallas Office8617 Ambassador Row, Suite 120Dallas, Texas 75247www.prg.com

4 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALFEATURESOverviewThe Bad Boy Spot Luminaire from PRG Lighting combines the qualities of a traditional aut

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 5Luminaire ModelsThe Bad Boy Spot Luminaire is available in two versions: + Standard (20.9812.0001) - co

6 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALCOMPONENTSExterior ComponentsThe following illustration shows the exterior Bad Boy components and contro

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 7Head and Enclosure ComponentsThe following illustration shows the major sub-assemblies located in the Ba

8 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALYoke ComponentsTilt-Side YokeThe following illustration shows the major sub-assemblies located in the Ba

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 9Pan-Side Yoke LegThe following illustration shows the major sub-assemblies located in the Bad Boy Pan-Si

10 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALDesigner Color and Gobo Wheel ConfigurationsDesigner Color Wheel Standard ConfigurationThe following dr

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 11Standard Gobo Wheel ConfigurationThe following drawing shows the standard Bad Boy Designer Gobo Wheel c

AutoPar®, Bad Boy®, PRG Series 400®, Mbox Extreme®, OHM™, V476™, V676™, Virtuoso®, Virtuoso® DX, Virtuoso® DX2, and VL6C+™ are trademarks of Productio

12 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALNotes

2.TESTING & TROUBLESHOOTINGThis chapter provides testing and troubleshooting procedures for the luminaire. +TESTING+ TROUBLESHOOTING

14 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALTESTINGTest ScreenThe luminaire provides built-in test routines and recalibration options which can be

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 15Mechanical TestsThe Mechanical Test menu provides a method for exercising all luminaire mechanisms indi

16 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALGroup TestThis feature only available in software version 1.5The Group Test menu allows multiple Bad Bo

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 17TROUBLESHOOTINGErrorsThe Status menus can be used to determine if any luminaire mechanisms are reportin

18 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALMechanism Errors Errors will be shown after the mechanism sub-code, for example: PAN:Comm Error.Other E

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 19Basic TroubleshootingThe following table provides a list of common start-up problems and possible solut

20 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALComponent TroubleshootingThis section provides troubleshooting guidelines for isolating problems down t

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 21Wheel Stack and/or Frost (Diffusion) IssuesStatus screen is displaying errors for Dimmer, Strobe, Color

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL IFOREWORDCompliance NoticeThis device complies with Part 15 of the FCC rules. Operation is subject to the

22 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALFan/Cooling IssuesSolution: Ensure Diffuser Sensor Cable is properly seated.Solution: Replace Diffuser

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 23Lens IssuesLenses fail to calibrate or lenses not operating correctly, and Zoom Sensors are goodDetails

24 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALMenu Display IssuesIf power is applied and the Menu Display Touchscreen does not come up or the fixture

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 25Pan/Tilt IssuesTilt continues to move past center during calibration, and..."TILT: no sensor"

26 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALNotes

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

28 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALEQUIPMENT HANDLINGProper Lamp Servicing and OperationServicing + When handling a lamp, hold it by the

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 29Wheel Stack Road Case InstructionsA special road case is provided for shipping Bad Boy Wheel Stack Asse

30 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALROUTINE MAINTENANCERemoving the Head CoversTo access some interior head components, one or both of the

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 31Removing the Aft CoverTo access some interior head components, the Aft Cover may need to be removed. Pa

II BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALWARNING: INSTRUCTIONS FOR PROTECTION AGAINST INJURY TO PERSONS1) Exterior surfaces of the luminaire wil

32 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALRemoving the Enclosure CoversTo access interior enclosure components, one or both of the Upper Enclosur

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 33Cleaning the Head Electrostatic FiltersThe electrostatic filters should be cleaned or replaced when the

34 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALCleaning the Enclosure Intake FiltersThe intake filters should be cleaned or replaced when they are dir

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 35Cleaning the Luminaire ExteriorTools:Lint-free clothWindow cleanerVacuum cleaner with brush nozzle or c

36 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALCleaning the LensesTools:(2) Micro Fiber cloths (06.6085.0001.0)OptiMax™ Ultra Pure Cleaning Solution (

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 37d. Using OptiMax™ Ultra Pure Cleaning Solution and a Micro Fiber cloth, clean both sides of Front Glass

38 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALFigure 3-8: Accessing Zoom Lens AssemblyR2 / Designer WheelHead CoverR1 Head CoverRemove to Access Len

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 39Cleaning Gobo, Color and Dimmer WheelsTools:Micro Fiber cloth (06.6085.0001.0)OptiMax™ Ultra Pure Clean

40 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALCleaning the ReflectorTools:Micro Fiber cloth (06.6085.0001.0)OptiMax™ Ultra Pure Cleaning Solution (06

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 41Cleaning the UV/IR WindowTools:Micro Fiber cloth (06.6085.0001.0)OptiMax™ Ultra Pure Cleaning Solution

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL IIINotes de sécuritéAvant de procéder à l’installation des produits décrits dans ce guide et de les mettr

42 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALREMOVE AND REPLACE PROCEDURESReplacing the LampParts:71.2566.1200.0 1 EA LAMP, FASTFIT, PHILIPS MSR GOL

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 43CAUTION: Wear cotton gloves or finger cots while servicing lamp. Touching the lamp glass with bare fin

44 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALAdjusting the LampAfter a new lamp is installed, it will be necessary to align the lamp in order to cen

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 45Replacing a GoboParts:Standard or Custom Gobo(s), as required.(Refer to "Standard Gobo Wheel Confi

46 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALStep 5. Using fingers, grasp frame of gobo and pull out of wheel (Figure 3-14).Figure 3-14: Replacing

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 47CAUTION: The gobos must be seated properly, especially the gear mesh.Figure 3-15: Gobo Positions and

48 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALReplacing a Designer Color FilterParts:Designer Color Filter(s), as required.(Refer to "Designer C

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 49Figure 3-17: Installing Designer Color Filter6547OPEN123EXPLODED VIEW

50 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALReplacing the Front GlassParts:12.9812.0629 1 EA RETAINER, FRONT GLASS PAINTED41.9812.0628 1 EA FRONT G

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 51Replacing the Wheel StackParts:21.9812.0620 1 EA ASSY, WHEEL STACK, LESS GOBOS (standard luminaire vers

IV BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALRevision HistoryThis manual has been revised as follows:Version Release Date NotesBASIC September 22, 2

52 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALFigure 3-19: Disconnecting Wheel Stack WiringJ6J2 J3J4J29J28J1J49J40J30Frost MotorFrost Sensor Frost M

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 53Step 5. At Wheel Stack Assembly, remove four 8-32 x 1/2" socket head screws (Figure 3-20).Step 6.

54 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALTo pack Wheel Stack Assembly for shipping:If a Wheel Stack Assembly is to be shipped to a PRG Service C

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 55Replacing the Frost/Diffuser PaddleParts:22.9812.0557 1 EA ASSY, DIFFUSER PADDLETools:#2 Philips screwd

56 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALStep 7. Test clearance and operation as follows:a. Manually slide Lens Group 3 toward Paddle Assembly u

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 57Replacing the Diffuser Sensor PCBParts:24.9812.0570 1 EA PCB ASSY, DIFFUSER SENSORTools:#2 Philips scr

58 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALReplacing the Zoom Controller PCBParts:24.9812.0511.0 1 EA PCB ASSY, ZOOM CONTROLLERTools:#1 and #2 Ph

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 59Replacing a Zoom Sensor PCBThe Zoom Assembly contains four Zoom Sensor PCBs (one for each Zoom Lens Gro

60 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALFigure 3-25: Removing Zoom Sensors 1 & 3R1 Head Cover8-32 x 3/8" PPB Screw (2 ea)Zoom Sensor2

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 61]Figure 3-26: Removing Zoom Sensors 2 & 4Zoom Sensor2-56 x 1/4"PPZ Screw (2)Zoom Controller P

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL VTABLE OF CONTENTSIntroductionAbout This Manual...

62 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALReplacing the Main Head FanParts:23.9812.0993 1 EA ASSY, MAIN HEAD FANTools:#2 Philips screwdriver5/32&

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 63CAUTION: The Main Head Fan has been upgraded. Be sure to install only the latest hi-temp fan. The hi-t

64 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALReplacing the Tip Pinch Fan (Original Version)The Tip Pinch Fan has been upgraded in most Bad Boy Lumin

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 65Replacing the Tip Pinch Fan (Hi-Temp Version)The Tip Pinch Fan has been upgraded in most Bad Boy Lumina

66 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALReplacing the UV/IR Window AssemblyParts:22.9812.0616 1 EA ASSY, UV/IR WINDOWTools:#2 Philips screwdriv

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 67Replacing the ReflectorParts:42.9812.0160 1 EA REFLECTOR, 36 LUNES, COATEDTools:#2 Phillips screwdriver

68 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALReplacing a 2A Fuse2 Amp fuses are located on the Zoom Controller PCB (4 each) and the Wheel Controller

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 69Replacing the 3A FuseThe 3 Amp fuse is located on the Pan/Tilt Controller PCB.Parts:70.3769.0003.0 1 EA

70 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALReplacing the EMI Ballast EnclosureParts:23.9812.0810 1 EA ASSY, EMI BALLAST ENCLOSURETools:#2 Philips

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 71Figure 3-34: Removing EMI Ballast EnclosureFRONT VIEW1 2WHITEBLACKCABLE LAYOUT - REAR VIEW25-9812-0987

VI BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALReplacing the Wheel Stack...

72 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALReplacing the Interface/LVS ModuleParts:23.9812.0812 1 EA ASSY, INTERFACE/LVS MODULETools:#2 Philips sc

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 73Figure 3-35: Removing Interface/LVS Module678CN3LVS DETAILNLPOWERCONGNDWHITEBLACKGRN/YELGNDLVSGNDNBLKW

74 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALReplacing the Ignitor PCBParts:24.9812.0775 1 EA PCB ASSY, SOLID STATE IGNITORTools:#2 Philips screwdr

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 75Step 6. Replace Ignitor PCB by doing steps in reverse. Use Loctite 242 when re-installing standoffs as

76 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALReplacing the Pan/Tilt Controller PCBParts:24.9812.0765 1 EA PCB ASSY, CONTROLLER PAN/TILTTools:#2 Phil

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 77Replacing the Pan/Tilt COT Sensor PCBParts:24.9679.0750 1 EA PCB ASSY, PAN/TILT COT SENSORTools:#1 and

78 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALStep 7. Install standoffs on new Pan/Tilt COT Sensor PCB Assembly.Step 8. Install new Pan/Tilt COT Sens

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 79Replacing the Pan Drive AssemblyParts:21.9812.0718 1 EA ASSY, PAN DRIVE MECHANISMTools:#2 Philips screw

80 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALStep 7. Move Pan Cable Routing Plate out of the way enough to access belt and pulley.Step 8. At Pan Dri

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 81Figure 3-41: Removing Pan Drive Assembly (View 2)J10J11J6J1PANJ8J12J3J2J14J15J7TILTJ16J9J13BAPan Drive

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 1INTRODUCTIONAbout This ManualThis manual provides testing, troubleshooting, maintenance procedures, and

82 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALReplacing the Tilt Drive AssemblyParts:21.9812.0719 1 EA ASSY, TILT DRIVETools:#2 Philips screwdriver7/

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 83Step 4. Remove Pan Shield by removing two 6-32 x 3/8" PFSS black screws and four 6-32 x 1/4"

84 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALCAUTION: Do not overtighten belt, pulley will break and/or bearings will fail.To set belt tension manu

4.ILLUSTRATED PARTS BREAKDOWNThis chapter provides illustrated parts breakdowns for all luminaire spares components.+OVERVIEW+ PARTS BREAKDOWN

86 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALOVERVIEWAbout this IPBThe Illustrated Parts Breakdown is intended for use with Field Service of the lum

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 87PARTS BREAKDOWNCovers and Included Items20.9612.0001 Rev A0Refer to illustration on next page.No. Item

88 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALBad Boy Spot Luminaire (continued)Refer to Parts List on previous page.12345 (x2)6 (x2)789 (x4)1027

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 89Bad Boy Spares KitNo. Item Qty UM Description Procedure1 20.9812.1229 1 EA ASSY, ROAD CASE, WHEEL STACK

90 BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALBad Boy Spares Kit (continued)No. Item Qty UM Description Procedure8 21.9812.0718 1 EA ASSY, PAN DRIVE

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL 91Bad Boy Spares Kit (continued)No. Item Qty UM Description Procedure12 24.9812.0510 1 EA PCB ASSY, ZOOM