PRG Bad Boy Spot Luminaire Service Manual Download Page 113

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BAD BOY

SPOT LUMINAIRE FIELD SERVICE MANUAL

105

WIRING DIAGRAMS

Bad Boy Luminaire Wiring Diagram

RJ-45

Connector

Legend

Mother Board PCB

Bad Boy Wheel

R1 Sensors

Butt Splice

#6 Ring

#10 Ring

Pico

SPOX

Molex

AMP

Latch

Molex

MFJ

MTA

156

MTA

100

3 Yellow
4 Magenta
5 R1 Wheel
6 R1 Index
7 Gnd

2 Strobe

1 +5V

J35

4 Des Col

7 Gnd

6 R2 Index

5 R2 Wheel

R2 Sensors

J50

2 Dimmer
3 Cyan

1 +5V

J49

3 Gnd

2 Sense

1 +12V

Pinch Fan

Gnd

+24V

J41

J40

Main Fan

4 Gnd

2 +12V

3 Sense

Iris Fan

J27

Iris-Gobo Fan

J38

2 V
3 U

1 W

3
4

Sensor

J51

1
2

Red 26
N/C

Blk 26

Wht 26

25-9812-0988

Diffuser

Gobo

12VDC

Fan 1

23-9812-0989-02

J37

Sense 3

Blk 26

Gnd 4

N/C

Yel 26

+24V 1
+12V 2

Red 26

J36

23-9812-0989-01

Yel 26

Red 26

Blk 26

N/C

Gobo

Fan 2

12VDC

J13

Gnd 3

Sense 2

+5V 1

Iris Sensor

24-9812-0650

J48

-9812

-0

24-9812-0649

Dimmer

J19

J18

J42

J46

J30

J32

J17

Strobe

J25

J21

R2 Wheel

J22

J24

J44

R1 Wheel

J20

J31

R2 Index

J23

R1 Index

J47

J43

Magenta

J16

Cyan

J12

J15

J52

Iris

J11

J54

J10

J45

Designer

J14

Yellow

J53

Diffusser

Dimmer

Motor Assy

ed 20

Blk

Wht

rn 26

l 2

n 26

y 2

u 2

23-9812-0669-04

25-9812-0965

Wht 22x12

Lamp

Relay

Lamp

From

Relay

From

Butt Splice

10-12 AWG

24-9679-1275

Arc Ignitor PCB

25-9812-0964

Bulkhead

Gnd Screw

Rear

1200 Fast Fit

MSR Gold

Lamp Socket

Gnd Screw

25-9812-0959

Arc

Lamp

Philips #

Blk 12

Wht 12

25-9812-0963

Blk 22x12

Wht 22x12

Blk 22x12

AXIS

PAN

25-9812-0952

25-9812-0951

PowerCon

AC Input

AC Neut

AC Gnd

AC Line

Wht 14

Grn/Yel 14

Blk 14

69-3180-1400-0

Ballast

Control

Manual

On/Off

Gnd 6

Power Hi/Lo 3

Lamp Status 4
Lamp On/Off 5

Power Adjust 2

Gnd 1

Brn 24

Orn 24

Gry 24

Brn 24

G/Y 24

Lamp On/Off 1
Lamp On/Off 2

EMI Filter PCB

Grn/Yel 14

Arc Ballast

1400W

25-9812-0955

Wht 14

Blk 14

25-9812-0956

Blk 14

Wht 14

Grn/Yel 14

AC Gnd

AC Neut

AC Line

AC Neut

+24V

DC Gnd

Gnd Line

Neut

Chassis

Gnd Screw 1

5J2

5J1

Gnd

Line

Neut

25-9812-0954

Ignitor 2 Ignitor 1

(BLK)

(WHT)

Ballast

Block

Terminal

23-9812-0995-02

Adjust Status 4

Orn 24

N/C 7

Gnd 6

Lamp On/Off 5

Backup

Ethernet

Can - 2

Wht 24

G/Y 24
Brn 24

Gry 24

Gnd 1

Power Adjust 2

N/C 3

Ballast Control

Blk 24

Gnd 3

Red 24

CAN Bus

Can + 1

J10

Blk 26
Blk 26
Red 26

Red 26

+3.7V 1

Gnd 3

Gnd 2

+3.7V 4

Battery

J11

RJ-45

Port B

J12

RJ-45

4 Iso Gnd

3 DMX +

J14

2 DMX -

1 Chas Gnd

DMX Input

J13

1 LED

Gnd

LED

2
3

Input

DMX

LED

R/G

Ethernet Ports

DMX

PCB

Cat 5

Orn 22
Grn 22

Brn 22

G/Y 22

Wht 24

Blk 24

2
3

Comm

24-9812-0871

PCB

Display

Panel

Ribbon

Cable

Ribbon Cable

Display

Ethernet

Port A

25-9812-0961

Port 2

d 18

Blk

d 18

Gnd

+24V

25-9812-0960

Thru

DMX

24-9812-0842

Ballast

24VDC

Fan 2

Wht 26

23-9812-0987-03

Blk 26

RIGHT EXT 5"

Red 26

Gnd 2

+24V 1

2 Fail

4 N/C

3 Gnd

1 +24V

Fan 2

Output

CN1

Low Voltage Supply

69-3131-0001-0

+24V/600W

Input

YOKE

Block

Terminal

B A

Lens Group 2

Group 4

Red 22x2

Blk 22x2

Red 22x2

J17

24-9812-0511

Controller PCB

Zoom

Lens Group 3

Lens Group 1

J13

J15

EOT

LG2

EOT

LG3

EOT

LG4

+12V 2

+24V 1

Sense 3

Gnd 4

J26

24-9812

-0

J33

J34

3 N/C

25-9812-0966-01

4 Adjust Status
5 Lamp On/Off

1 Gnd
2 Power Adjust

25-9812-0966-02

J10

J18

J12

J14

J11

J16

25-9812-0969

Red 22x4

25-9812-0969

Blk 22x4

25-9812-0968

25-9812-0980-01

Red 22x10

Red 22x8

Blk 22x10

Blk 22x8

Blk 22x10

Red 22x2

Blk 22x2

Red 22x2

Blk 22x2

Red 22x2

Red 24

Blk 24

Wht 24

2
3

25-9812-0980-02

+12V 2

Gnd 4

Sense 3

+24V 1

Fan

12VDC

Tip Pinch

Blk 24

Red 24
Whtl 24

Iris

12VDC

Fan

Yel 26
Red 26

Blk 26

23-9812-0991

23-9812-0994

23-9812-0992

Iris-Gobo

Fan

12VDC

23-9812-0993

Main

12VDC

Fan

Wht 26

Red 26

Blk 26

25-9812-0983

Sensor

PCB

Wheel

Gry 24
Blk 24

Red 24

Wht 24

Brn 24
Yel 24
Vio 24

24-9812-0658

Red 24

24-9812-0655

PCB

Wheel

Sensor

Gry 24
Blk 24

Brn 24

Wht 24

Vio 24

Yel 24

25-9812-0983

24-9812-0570

Diffuser

Sensor PCB

1 +5V

3 Gnd

2 Sense

Bus

CAN

J29

J28

1 Red 24
2 Wht 24
3 Blk 24

Bus

CAN

Max Spd 5

Spd Cntl 4

Gnd 2

J39

+24V 1

Tach 3

Gobo Fan 1

Gobo Fan 2

25-9812-0982

Wht 26
Blk 26

Red 26

24-9812-0653

Iris

Sensor PCB

1 +5V

3 Gnd

2 Sense

26x3

25-9812-0984

26x3

Sensors

EOT

LG2
LG1

LG3

LG4

25-9812-0958

25-9812-0957

Yoke

Gnd Stud

Head

TILT

AXIS

PAN

25-9812-0962

25-9812-0975

25-9812-0977

Orn 22

Bulkhead

Mounting

Rear

25-9812-0976

Red 22

25-9812-0980-03

25-981

2-09

-0

25-9812

-0

25-9812-0973

25-

9812-

25-9812-0970

25-9812-0996

Jumper

25-9812-0981

TYPICAL

23-9812-0669-03

23-9812-0669-02

23-9812-0668-01

TYPICAL

25-9812-0985-02

23-9812-0668-03

Gnd Screw 2

Chassis

Blk 12

Wht 12

Red 22x2

Blk 22x2

Can +
Can -
Gnd

2 Wht 24
3 Blk 24

1 Red 24

HOT

Switch

Relay

23-9812-3327

HOT

Screw

Fan 1

24VDC

Ballast

LEFT EXT 8"

23-9812-0987-02

Gnd 2

+24V 1

Output

Fan 1

Red 26

Blk 26

Wht 26

4 N/C

1 +24V

3 Gnd

2 Fail

23-9812-0987-01

DMX LED

HEAD

Orn 28

Red 20

Red 26 1

Blu 26 2

Brake

J15

Tilt

J14

Gry 26

Yel 26
Brn 26

Grn 26

Blu 26

Wht 20

Blk 20

Encode

Yel/Wht 28

Blue 28

Yel 28

Orn/Wht 28

Blu/Wht 28

Blk 28

Red 28

21-9812-0719

Mechanism

Tilt Drive

Tilt Motor

J13

Wht 26 2

Red 26

Tilt COT

Sensor

Pan/Tilt

Controller PCB

24-9812-0773

Bus

CAN

Ribbon

Cable

25-9

812-0

-0

J16

J12

J11

Brake

Pan

J10

Sensor PCB

25-9812-0979

Sense

+5V

Tilt COT

Pan Motor

YOKE

LVS Status

1 Gnd
2 DC OK
3 N/C

25-9812-0967

G/Y 24
Gry 24

1 I Monitor

5 Remote On
4 Power Good

2 I Share

3 Control Gnd

6 V Sense -

7 V Sense +

Lines

Control

LVS

G/Y 24

Gry 24

CN3

Port 1

Controller PCB

24-9812-0870

Main

25-9812-0953

73-7200-0006-0

9
8
7
6
5
4
3

1
2
3
4
5

N/C 4

Gnd
+24V

+24V
Gnd

3
2

+24V

Gnd

4
3
2
1

Red 24 1

Wht 24 2

Blk 24 3

3
2
1

Blk

Wht 24

Red 24

2
1

1 N/C

4 Gnd
3 Sense
2 +12V

Yel 26
Red 26

Blk 26

Motor

R2 Index

Stepper

44-5036-0001

l 2

Red 26

u 2

1 11

25-9812-0973

Bus

CAN

23-9812-0669-09

Lens Group 4

Cable

Ribbon

TYPICAL

Motor Assy

lu 26

y 2

rn 26

l 2

Grn 26

Red 20

t 2

k 2

t 2

LG1

EOT

ed 2

24-9812-0510

TYPICAL

Ribbon

Cable

.187 Faston

.250 Faston

(Not Used)
Use J40

Main Fan

Encode

25-9

812-0

-0

1 Red 26
2 Blu 26

Yel/Wht 28

Orn/Wht 28

Blu/Wht 28

Blk 28
Red 28

Yel 28

Blue 28

Orn 28

21-9812-0718

Pan Drive

Mechanism

Ribbon

Cable

Red 20

Blk 20

Grn 26

Wht 20

Gry 26

Brn 26

Blu 26

Yel 26

3
2

7
6
5

9
8

3
4

23-9812-0995-01

Battery

Backup

Pack

Red 24
Orn 24

Blk 24

Red 24

2 (Gnd)

(+3.7V) 1

Wake Switch

Encoder

Position

Encoder

AXIS

TILT

YOKE

CHASSIS

HEAD

YOKE

CHASSIS

YOKE

25-9812-0997

Summary of Contents for Bad Boy Spot Luminaire

Page 1: ...SOFTWARE VERSION 1 6 WWW PRG COM BAD BOY SPOT LUMINAIRE FIELD SERVICE MANUAL...

Page 2: ...onal use only and is subject to change without notice Please check www prg com for the latest version PRG assumes no responsibility or liability for any claims resulting from errors or inaccuracies th...

Page 3: ...en designed for use only with specific lamps Note lamp type before replacing Installing another type of lamp may be hazardous 2 PRG luminaires may be mounted on any type of surface as long as mounting...

Page 4: ...llow lamp to cool for 5 minutes before relamping 3 Arc lamps emit ultraviolet radiation which can cause serious skin burn and eye inflammation Additionally arc lamps operate under high pressure at ver...

Page 5: ...es proc dures pr cis es dans le manuel du frabricant doit tre fournies AVERTISSEMENT R GLAGE DES LAMPES 1 Chaleur intense D brancher le mat riel et laisser refroidir pendant 5 minutes avant de rallume...

Page 6: ...CMY luminaire information where applicable 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...

Page 7: ...tack and or Frost Diffusion Issues 21 Fan Cooling Issues 22 Lens Issues 23 Menu Display Issues 24 Pan Tilt Issues 25 Chapter 3 Maintenance Equipment Handling Proper Lamp Servicing and Operation 28 Whe...

Page 8: ...osure 70 Replacing the Interface LVS Module 72 Replacing the Ignitor PCB 74 Replacing the Pan Tilt Controller PCB 76 Replacing the Pan Tilt COT Sensor PCB 77 Replacing the Pan Drive Assembly 79 Replac...

Page 9: ...l 02 9812 0001 xx Technical updates regarding this equipment are issued by the PRG Dallas office These updates are in the form of Technical Bulletins which contain procedures for equipment upgrades re...

Page 10: ...47 557 9033 PRG Las Vegas 6050 South Valley View Blvd Las Vegas Nevada 89118 Ph 702 942 4774 Fx 702 942 4775 PRG Los Angeles 9111 Sunland Blvd Sun Valley California 91352 Ph 818 252 2600 Fx 818 252 26...

Page 11: ...1 DESCRIPTION This chapter contains an overview of luminaire features and components FEATURES COMPONENTS...

Page 12: ...s with seven discrete colors on each wheel one 1 designer wheel with user changeable color filters and three 3 fixed color wheels organized into Cyan Magenta and Yellow CYM CMY Version CMY color syste...

Page 13: ...he Bad Boy CMY luminaire can be identified by a label on the input panel Figure 1 1 Identifying CMY Version Depending on the Bad Boy luminaire model the Wheel Stack Assembly will be different The CMY...

Page 14: ...FIXTURE Neutrik AC DMX512 Input DMX512 Thru Upper Enclosure Detail Upper Enclosure Houses power supply ballast and provides Data In and Thru and AC power connections Also houses the Menu Touchscreen s...

Page 15: ...lowing illustration shows the major sub assemblies located in the Bad Boy Head and Enclosure Figure 1 4 Head and Enclosure Components Wheel Stack LVS Interface Module EMI Ballast Zoom Controller PCB A...

Page 16: ...ide Yoke The following illustration shows the major sub assemblies located in the Bad Boy Tilt Side Yoke Leg Figure 1 6 Tilt Side Yoke Leg Ignitor PCB Relay Tilt Drive Assembly Tilt Side Leg Pan Side...

Page 17: ...SPOT LUMINAIRE FIELD SERVICE MANUAL 9 Pan Side Yoke Leg The following illustration shows the major sub assemblies located in the Bad Boy Pan Side Yoke Leg Figure 1 7 Pan Side Yoke Leg Pan Tilt Control...

Page 18: ...CE MANUAL Designer Color and Gobo Wheel Configurations Designer Color Wheel Standard Configuration The following drawing shows the standard Bad Boy Designer Color Wheel configuration Figure 1 8 Design...

Page 19: ...OY SPOT LUMINAIRE FIELD SERVICE MANUAL 11 Standard Gobo Wheel Configuration The following drawing shows the standard Bad Boy Designer Gobo Wheel configurations Figure 1 9 Gobo Wheel Standard Configura...

Page 20: ...12 BAD BOY SPOT LUMINAIRE FIELD SERVICE MANUAL Notes...

Page 21: ...2 TESTING TROUBLESHOOTING This chapter provides testing and troubleshooting procedures for the luminaire TESTING TROUBLESHOOTING...

Page 22: ...Yes No options Disable press to bring up Disable Screen Mech Test press to bring up Mech Test Screen See Mechanical Tests on page 15 for more explanation of this screen Clean Lenses press to position...

Page 23: ...POSITION and sensor SENSOR are shown if available for that mechanism STATUS indicates whether the mechanism is in an error state or normal operating state Utility Functions Press RE CAL to recalibrate...

Page 24: ...are run at once or sequentially tests are run one at a time as each one finishes Step 3 Press START to begin testing All Bad Boy luminaires connected to the main fixture now referred to as the Master...

Page 25: ...s It also provides a log of systems activity The Status panel operates as follows Mechanisms displays mechanism status Mechanism names sub code abbreviations will be shown in yellow if calibrated gree...

Page 26: ...Spin Error Error while sending spin command to motion processor Stop Spin Error Error while sending stop spin command to motion processor Spin Stop Timeout Spinning mechanism did not come to rest in...

Page 27: ...s setting is correct DMX512 control not working correctly throughout daisy chain Ensure data cables are correctly configured Ensure termination connector is installed at last luminaire in data link La...

Page 28: ...power input Apply power again and verify 208 VAC is present at the input terminals on the ballast The input terminals are on either side of the two fuses If you have 208 VAC coming into the ballast yo...

Page 29: ...that appears to have no power locate the Wheel Controller PCB and the driver for that motor Check the driver and fuse for that motor If cables are secure and there are no blown fuses replace the Whee...

Page 30: ...s are installed properly With power off visually inspect the driver for damage If the driver chip has visible damage then replace the driver s PCB If not carefully remove the fuse Check for continuity...

Page 31: ...en the gold pin touches the gold pad on the sensor These would be a failure to turn green from red turning from red to yellow both green and red or the red LED turns off after contact with the gold pi...

Page 32: ...if the fixture When power is applied to the fixture the LVS will supply 24VDC to all the mechanisms Next the MCB will display the Menu fixture status detect the external communication and initiate the...

Page 33: ...p the Pan moves all the way around to the pan stop and stops moving then rotates 180 degrees and stops again If it reaches the first stop and the pan motor continues to run the Pan Drive Assembly has...

Page 34: ...26 BAD BOY SPOT LUMINAIRE FIELD SERVICE MANUAL Notes...

Page 35: ...3 MAINTENANCE This chapter provides maintenance procedures for the luminaire EQUIPMENT HANDLING ROUTINE MAINTENANCE REMOVE AND REPLACE PROCEDURES...

Page 36: ...at least 3 minutes It takes about 3 minutes for the fill components mercury and halogen metal compounds in the lamp tubes to vaporize completely If the lamps are switched off earlier than 3 minutes t...

Page 37: ...ck 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 o...

Page 38: ...NOT use a power screwdriver when re installing the 8 32 x 3 PPB screws This may damage the hole threads Use a manual screwdriver only Step 3 Replace Head Cover as follows a Set cover in place and slid...

Page 39: ...lows a Slide cover into place b Re install X Y and Z Adjustment Knobs Note that each knob is different Be sure to install the correct knob in the correct location c Re install four 10 32 x 3 8 socket...

Page 40: ...PPER 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...

Page 41: ...water To clean head filters WARNING Remove power from luminaire before performing any maintenance procedures Step 1 Remove power from luminaire Step 2 At each mesh cover loosen one captive screw Figu...

Page 42: ...ce procedures Step 1 Remove power from luminaire Step 2 Remove Intake Cover by first loosening two captive screws then pulling away from Upper Enclosure as shown in Figure 3 6 Figure 3 6 Removing Encl...

Page 43: ...iMax 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...

Page 44: ...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 cott...

Page 45: ...er e Re install Front Glass 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 th...

Page 46: ...NUAL Figure 3 8 Accessing Zoom Lens Assembly R2 Designer Wheel Head Cover R1 Head Cover Remove to Access Lenses ZOOM LENS ASSEMBLY DETAIL Lenses 8 32 x 3 8 PPB Screw 2 ea CAUTION Hand tighten only DO...

Page 47: ...ch gobo Refer to Replacing a Gobo on page 45 b Using OptiMax Ultra Pure Cleaning Solution and a Micro Fiber cloth carefully clean gobos DO NOT use window cleaner Step 4 To clean Designer Wheel a Remov...

Page 48: ...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 Refer to Replacing the Wheel Stack on pag...

Page 49: ...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...

Page 50: ...at least 5 minutes Step 2 Remove power from luminaire Step 3 At rear of luminaire rotate backcap counter clockwise to remove it will still be connected by a tether Refer to Figure 3 11 on next page St...

Page 51: ...l and cause the lamp to explode or burn out early If touched use alcohol to thoroughly clean glass Figure 3 11 Replacing the Lamp Backcap Lamp Lamp Base CAUTION Do not touch lamp or reflector with bar...

Page 52: ...tep 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 Using control console open beam...

Page 53: ...Wheel 1 R1 or Rotating Gobo Wheel 2 R2 as shown in Figure 3 13 Doors are identified by a label Turn captive screw to open door CAUTION Do not touch gobos with bare fingers Wear cotton gloves or finge...

Page 54: ...e tongue of the gobo clip goes under the retaining plate under the sun gear Press and gently rotate the gobo bearing to help mesh the gobo gear to the sun gear Refer to Figure 3 15 on next page for an...

Page 55: ...SPOT LUMINAIRE FIELD SERVICE MANUAL 47 CAUTION The gobos must be seated properly especially the gear mesh Figure 3 15 Gobo Positions and Alignment 2 5 7 6 OPEN 1 2 3 OPEN 1 2 3 4 5 6 7 4 1 2 3 4 5 6...

Page 56: ...cotton gloves or finger cots when handling Step 3 Rotate wheel until desired designer color filter is accessible Step 4 Rotate Color and Gobo 2 Wheels so that their open position lines up next to the...

Page 57: ...BAD BOY SPOT LUMINAIRE FIELD SERVICE MANUAL 49 Figure 3 17 Installing Designer Color Filter 6 5 4 7 OPEN 1 2 3 EXPLODED VIEW...

Page 58: ...ition 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 Insert hook pick tool under notch in Fron...

Page 59: ...east 5 minutes Step 2 Remove both Head Covers Refer to Removing the Head Covers on page 30 Step 3 At top of head assembly disconnect the following Wheel Stack wiring Figure 3 19 a From Zoom Controller...

Page 60: ...ure 3 19 Disconnecting Wheel Stack Wiring J6 J2 J3 J4 J29 J28 J1 J49 J40 J30 Frost Motor Frost Sensor Frost Motor Fan Power Zoom Controller PCB Wheel Stack Twist Lock Holder Fan Wire Harness Control C...

Page 61: ...p 1 pulley until lenses are clear Step 7 Grasp Wheel Stack Assembly on either side and lift straight up and out of luminaire head Figure 3 20 Removing Wheel Stack Assembly Step 8 Replace Wheel Stack A...

Page 62: ...ng 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...

Page 63: ...d Cover Refer to Removing the Head Covers on page 30 Figure 3 22 Removing Frost Diffuser Paddle Assembly Step 3 Disconnect Frost Sensor Cable Step 4 Rotate Frost Diffuser Paddle Assembly to access set...

Page 64: ...e 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...

Page 65: ...to cool for at least 5 minutes Step 2 Remove R1 Head Cover Refer to Removing the Head Covers on page 30 Step 3 At Diffuser Sensor disconnect cable Figure 3 23 Step 4 Remove Diffuser Sensor by removin...

Page 66: ...Removing the Head Covers on page 30 Step 3 At Zoom Controller PCB disconnect all cables Step 4 Remove Zoom Controller PCB by removing four 4 40 x 1 4 PPB screws Note the placement of the tie wrap whic...

Page 67: ...Remove power from luminaire and allow components to cool for at least 5 minutes Step 2 To remove Zoom Sensors 1 or 3 a Remove R1 Head Cover Refer to Removing the Head Covers on page 30 b At required...

Page 68: ...Removing Zoom Sensors 1 3 R1 Head Cover 8 32 x 3 8 PPB Screw 2 ea Zoom Sensor 2 56 x 1 4 PPZ Screw 2 Zoom Sensor Zoom Sensor CAUTION Hand tighten only DO NOT use a power tool on Head Cover screws CAUT...

Page 69: ...IRE FIELD SERVICE MANUAL 61 Figure 3 26 Removing Zoom Sensors 2 4 Zoom Sensor 2 56 x 1 4 PPZ Screw 2 Zoom Controller PCB 4 40 x 1 4 PPB Screw 4 Zoom Sensor CAUTION Use anti static precautions when wor...

Page 70: ...rs Refer to Removing the Head Covers on page 30 Step 3 Remove lamp Refer to Replacing the Lamp on page 42 Step 4 Remove X Y Z Adjustment Knobs and Aft Cover Refer to Removing the Aft Cover on page 31...

Page 71: ...er 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 app...

Page 72: ...llow 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 Wheel Stack Assembly Refer to Replacing the Wheel Stack on page 51 S...

Page 73: ...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 Wheel Stack Assembly Refer to Replacing the Whee...

Page 74: ...o 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 Remove Head Covers Refer to Removing the Head Covers on...

Page 75: ...olution and a Micro Fiber cloth To replace the Reflector Step 1 Remove power from luminaire and allow components to cool for at least 5 minutes Step 2 Remove Aft Cover Refer to Removing the Aft Cover...

Page 76: ...ARNING 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 Remov...

Page 77: ...minaire 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 Le...

Page 78: ...ing Figure 3 34 a APS Cable b Two Fan Cables c Ground Cable d Lamp Power Ballast Output Cables white and black Step 4 At EMI Ballast Enclosure remove four 10 32 x 3 8 PPB Black SEMS screws Assembly wi...

Page 79: ...FILTER FROM PCB CHASSIS GND STUD FROM TO LEFT EXTENSION FAN 1 BALLAST CONTROL BLK L WHT SIDE VIEW TO BALLAST CONTROL CABLE ASSY 25 9812 0966 02 N BALLAST POLARITY 2 1 EXTENSION FAN 2 TO RIGHT BALLAST...

Page 80: ...Step 3 At Interface LVS Module remove four 10 32 x 3 8 PPB SEMS screws Figure 3 35 Step 4 At left side of Interface LVS Module disconnect the following wiring a Fan cable b APS Control Line cable c N...

Page 81: ...8 CN3 LVS DETAIL N L POWERCON GND WHITE BLACK GRN YEL GND LVS GND N BLK WHT N WHT BLK GND Fan Fan CAN Bus Low Voltage DC Output AC Line Input L CN1 N 2 1 3 4 5 FAN 1 RED BLACK 10 32 x 3 8 PPB SEMS Scr...

Page 82: ...Cover Step 3 At Ignitor Cover remove four 6 32 nylon insert nuts and four 6 nylon washers Remove Ignitor Cover Figure 3 36 Removing Ignitor PCB CAUTION Be careful to maintain correct polarity of the l...

Page 83: ...SERVICE MANUAL 75 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...

Page 84: ...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 disconnec...

Page 85: ...just allow to it hang out of the way during this procedure Note The Counterweight was added as a retrofit If the Counterweight is not present it should be added Refer to technical bulletin BAD 001 for...

Page 86: ...LD SERVICE MANUAL 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 S...

Page 87: ...ep 2 Remove both Yoke Covers by loosening four captive screws Figure 3 39 Figure 3 39 Removing Yoke Covers Handle and Pan Shield Step 3 At Pan Side Yoke Leg remove Yoke Handle by removing two 10 32 x...

Page 88: ...cket head screws and two 10 flat washers from Pan Drive Assembly Step 11 At Bus Bar remove screw on left hand side and loosen screw on right hand side Rotate Bus Bar up and out of the way This will ma...

Page 89: ...Figure 3 41 Removing Pan Drive Assembly View 2 J10 J11 J6 J1 PAN J8 J12 J3 J2 J14 J15 J7 TILT J16 J9 J13 B A Pan Drive Assembly Pan Tilt PCB Bus Bar Belt Adjustment Screw 2 Pan Drive Assembly Remove s...

Page 90: ...ce 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...

Page 91: ...er 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...

Page 92: ...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 7 16 Allen wrench tighten belt adjustment screw until no bila...

Page 93: ...4 ILLUSTRATED PARTS BREAKDOWN This chapter provides illustrated parts breakdowns for all luminaire spares components OVERVIEW PARTS BREAKDOWN...

Page 94: ...2 0620 1 ASSY WHEEL STACK LESS GOBOS 21 9812 0718 1 ASSY PAN DRIVE 21 9812 0719 1 ASSY TILT DRIVE 22 9812 0616 1 ASSY UV IR WINDOW 22 9812 0557 1 ASSY DIFFUSER PADDLE 23 9812 0810 1 ASSY EMI BALLAST E...

Page 95: ...CKET 6 22 9620 0194 2 EA ASSY LAMP SAFETY CABLE 7 22 9812 0716 2 EA ASSY YOKE ARM COVER 8 25 9812 0902 5 1 EA CABLE ASSY AC LINE CORD 2 5 14 3 L6 20 9 53 6545 0001 4 EA SCREW 8 32 x 3 8 PPB 10 71 2566...

Page 96: ...88 BAD BOY SPOT LUMINAIRE FIELD SERVICE MANUAL Bad Boy Spot Luminaire continued Refer to Parts List on previous page 1 2 3 4 5 x2 6 x2 7 8 9 x4 10 2 7...

Page 97: ...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 0775 1 EA PCB ASSY...

Page 98: ...m 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...

Page 99: ...BAD BOY SPOT LUMINAIRE FIELD SERVICE MANUAL 91 Bad Boy Spares Kit continued No Item Qty UM Description Procedure 12 24 9812 0510 1 EA PCB ASSY ZOOM SENSOR page 59 12 12 12 12...

Page 100: ...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...

Page 101: ...ge 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 0160 1 E...

Page 102: ...94 BAD BOY SPOT LUMINAIRE FIELD SERVICE MANUAL Notes...

Page 103: ...A TECHNICAL SPECIFICATIONS BAD BOY SPOT LUMINAIRE BAD BOY ROAD CASE AC LINE CURRENT POWER VS VOLTAGE...

Page 104: ...l iris provides continuous beam size control for both rapid changes and smooth timed beam angle changes EDGE CONTROL Maintains gobo focus and allows gobo morphing INTENSITY Full field dimming from 0 t...

Page 105: ...UMINAIRE FIELD SERVICE MANUAL 97 762 mm 30 15 6 396mm 343 mm 13 5 39 125 994 mm POSITIONING Can be mounted in any orientation SPACING Hangs on 30 inch 762 mm centers WEIGHT 167 lbs 75 8 kg includes cl...

Page 106: ...98 BAD BOY SPOT LUMINAIRE FIELD SERVICE MANUAL 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 766 mm 30 15...

Page 107: ...ause the input current to rise Enter the UVLO It is a dedicated electronic circuit added to the SMPS to monitor its input voltage and shut down the PWM if leaving it on would cause damage Every high p...

Page 108: ...n 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...

Page 109: ...hrow Dist m 5 10 20 25 30 Beam Dia m 0 7 1 4 2 8 3 5 4 2 Illuminance lux 193520 48380 12095 7741 5376 5000000 4000000 3000000 2000000 1000000 0 5 0 4 0 3 0 2 0 1 0 0 0 1 0 2 0 3 0 4 0 5 0 Degrees Cand...

Page 110: ...ist m 5 10 20 25 30 Beam Dia m 3 1 6 1 12 2 15 3 18 3 Illuminance lux 13600 3400 850 544 378 Multiply throw distance by Tn to find beam diameter Divide cd candela by distance squared to find center be...

Page 111: ...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 5 10 20 25 30 Beam Dia m 5 3 10 6 21 3 26 6 31 9 Illuminance lux 5000 1250 312 200 139...

Page 112: ...0 100000 30 0 20 0 10 0 0 0 10 0 20 0 30 0 Deg WFOV MFOV NFOV Lamp Power 1400 Watts Candela 140000 120000 100000 80000 60000 40000 20000 0 30 0 20 0 10 0 0 0 10 0 20 0 30 0 140000 120000 100000 80000...

Page 113: ...ust 25 9812 0966 02 J10 J18 J12 J14 J11 J8 J16 25 9812 0969 Red 22x4 Red 22x4 Red 22x4 25 9812 0969 Blk 22x4 Blk 22x4 Blk 22x4 25 9812 0968 25 9812 0980 01 Red 22x10 Red 22x10 Red 22x8 Blk 22x10 Blk 2...

Page 114: ...Bad Boy Spot Luminaire Field Service Manual Version as of November 10 2010 PRG part number 02 9812 0005 C...

Page 115: ...Production Resource Group Dallas Office 8617 Ambassador Row Suite 120 Dallas Texas 75247 www prg com...

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