PRG Best Boy 4000 User manual

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

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.
PRG assumes no responsibility or liability for any claims resulting from errors or inaccuracies that may appear in this manual.
Best Boy 4000® Spot Luminaire Field Service Manual
Version as of: November 6, 2012
PRG part number: 02.9816.0005 A
Production Resource Group, LLC
Dallas Office
8617 Ambassador Row, Suite 120
Dallas, Texas 75247
www.prg.com
Best Boy 4000® Spot Luminaire Field Service Manual
©2012 Production Resource Group, LLC. All Rights Reserved.

BAD BOY®SPOT LUMINAIRE FIELD SERVICE MANUAL I
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.
Conforms to:
UL STD 1573
Certified to:
CAN/CSA STD E598-1
CAN/CSA STD E598-2-17
Safety Notice
It is extremely important to read ALL safety information and instructions provided in this manual and any
accompanying documentation before installing and operating the products described herein. Heed all cautions and
warnings during installation and use of this product.
Safety symbols used throughout this manual are as follows:
GENERAL INFORMATION PERTAINING TO PROTECTION AGAINST ELECTRICAL SHOCK, FIRE, EXPOSURE TO
EXCESSIVE UV RADIATION, AND INJURY TO PERSONS CAN BE FOUND BELOW.
WARNING: INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST FIRE
1) PRG luminaires have been 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 instructions are followed. See
instructions detailed in this manual.
3) Replace fuses with same type and rating only.
4) Minimum distance from head to any flammable object is 2m.
WARNING: INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST ELECTRICAL SHOCK
1) PRG luminaires are designed for dry locations only. Exposure to rain or moisture may damage luminaire.
2) Disconnect power before servicing any PRG equipment.
3) Servicing to be performed by qualified personnel only.
WARNING: INSTRUCTIONS FOR CONTINUED PROTECTION AGAINST EXPOSURE TO EXCESSIVE
ULTRAVIOLET RADIATION
1) PRG luminaires may use an HID type lamp which produces UV radiation. DO NOT look directly at lamp.
2) It is hazardous to operate luminaires without complete lamp enclosure in place or when lens is damaged.
Lenses or UV shields shall be changed if they have become visibly damaged to such an extent that their
effectiveness is impaired.
CAUTION advising of potential damage to product.
WARNING advising of potential injury or death to persons.

II BAD BOY®SPOT LUMINAIRE FIELD SERVICE MANUAL
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.
3) Arc lamps emit ultraviolet radiation which can cause serious skin burn and eye inflammation. Additionally, arc
lamps operate under high pressure at very high temperatures. Should the lamp break, there can exist a danger
of personal injury and/or fire from broken lamp particles being discharged.
4) The lamp shall be changed if it has become damaged or thermally deformed.
5) If lamp is touched with bare hands, clean lamp with denatured alcohol and wipe with lint-free cloth before
installing or powering up the luminaire.
6) Serious injury may result from the generation of ozone by this lamp system. A proper means of venting must be
provided.

BAD BOY®SPOT LUMINAIRE FIELD SERVICE MANUAL III
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.
Les symboles de sécurité utilisés dans ce guide sont les suivants :
CETTE SECTION CONTIENT DES INFORMATIONS GÉNÉRALES POUR SE PROTÉGER CONTRE LES DÉCHARGES
ÉLECTRIQUES, LES INCENDIES, L’EXPOSITION EXCESSIVE AUX RAYONS UV ET TOUT AUTRE ACCIDENT
POUVANT ENTRAÎNER DES BLESSURES.
AVERTISSEMENT: RISQUE D’ EXPLOSION.
1) Le service et le maintenance ne devront être assurés que par des personnes qualifiées comme precisé par le
frabricant des lampes à haute pression.
2) Des vêtement de protection et les procédures précisées dans le manuel du frabricant doit être fournies.
AVERTISSEMENT: RÉGLAGE DES LAMPES
1) Chaleur intense. Débrancher le matériel et laisser refroidir pendant 5 minutes avant de rallumer.
2) Risque l’incendie. N’utilise que des Philips MSR Gold™ FastFit Lamp.
AVERTISSEMENT: DIRECTIVES POUR SE PROTÉGER CONTRE UNE EXPOSITION EXCESSIVE AUX RAYONS
UV
1) Risque d’explosion en cas de radiation ultraviolet imprantes.
2) Ne pas intervener en l’absence de confinement de la lampe en place ou quand la lentille est abîmée.
AVERTISSEMENT: DIRECTIVES POUR SE PROTÉGER CONTRE LES ACCIDENTS POUVANT ENTRAÎNER DES
BLESSURES
1) Chaleur intense. Eviter tout contact avec des personnes ou des tissues. Attention, de graves blessures
peuvent résulter de production d’ozone par cette lampe. Un système de ventilation adapté doit être fournies
2) La température de surface = 300.c
La temperature de l’ambiance = 50.c
3) Ne convient pas pour un usage résidential.
4) Utilisable seulement dans les locaux secs.
ATTENTION Ce symbole annonce que l’appareil risque d’être endommagé.
AVERTISSEMENT Ce symbole annonce qu’il y a risque d’accident grave ou même fatal.

IV BAD BOY®SPOT LUMINAIRE FIELD SERVICE MANUAL
Revision History
This manual has been revised as follows:
Version Release Date Notes
BASIC July 11, 2012 Initial release.
A November 6, 2012 Revised various maintenance procedures to add Loctite #246.

BAD BOY®SPOT LUMINAIRE FIELD SERVICE MANUAL V
TABLE OF CONTENTS
Introduction
About This Manual........................................................................................................................................................................ 1
Additional Documentation............................................................................................................................................................ 1
Customer Service......................................................................................................................................................................... 2
Chapter 1. Description
Components
Exterior Components.................................................................................................................................................................... 4
Head and Enclosure Components ............................................................................................................................................... 5
Yoke Components ........................................................................................................................................................................ 6
Designer Color Wheel Standard Configuration ............................................................................................................................ 8
Effect Wheel Standard Configuration........................................................................................................................................... 8
Gobo Wheel Standard Configurations ......................................................................................................................................... 9
About Moiré Gobos............................................................................................................................................................... 9
Chapter 2. Testing & Troubleshooting
Testin g
About This Section ..................................................................................................................................................................... 12
Test Screen................................................................................................................................................................................. 12
Mechanical Tests........................................................................................................................................................................ 14
Group Tests ................................................................................................................................................................................ 15
Troubleshooting
Errors .......................................................................................................................................................................................... 16
Status Indications................................................................................................................................................................ 16
Comm LED.......................................................................................................................................................................... 16
Basic Troubleshooting ................................................................................................................................................................ 19
Chapter 3. Maintenance
Equipment Handling
Proper Lamp Servicing and Operation....................................................................................................................................... 22
Wheel Stack Road Case Instructions......................................................................................................................................... 23
Routine Maintenance
Removing Head Covers.............................................................................................................................................................. 24
Removing Aft Cover ................................................................................................................................................................... 25
Removing Yoke Leg Covers ....................................................................................................................................................... 26
Removing Upper Enclosure Covers ........................................................................................................................................... 27
Cleaning Intake Filters ................................................................................................................................................................ 28
Cleaning Lenses ......................................................................................................................................................................... 29
Cleaning Luminaire Exterior........................................................................................................................................................ 31
Cleaning Gobo, Color, and Effect Wheels.................................................................................................................................. 32

VI BAD BOY®SPOT LUMINAIRE FIELD SERVICE MANUAL
Remove and Replace Procedures
Replacing Lamp.......................................................................................................................................................................... 33
Adjusting Lamp........................................................................................................................................................................... 35
Replacing a Gobo in Gobo Wheel 1 ........................................................................................................................................... 36
Replacing a Gobo in Gobo Wheel 2 ........................................................................................................................................... 38
Replacing a Designer Color Filter ............................................................................................................................................... 40
Replacing Front Glass ................................................................................................................................................................ 42
Replacing Light Shield................................................................................................................................................................ 43
Replacing Head Fan ................................................................................................................................................................... 45
Replacing Lamp Pinch Fan......................................................................................................................................................... 47
Replacing Rear Housing Fan...................................................................................................................................................... 49
Replacing Head Controller PCB ................................................................................................................................................. 51
Replacing Wheel Stack............................................................................................................................................................... 53
Replacing Gag EOT Sensor........................................................................................................................................................ 55
Replacing Gag Wheel Motor....................................................................................................................................................... 56
Replacing Gag Index Motor........................................................................................................................................................ 57
Replacing a Zoom Sensor .......................................................................................................................................................... 58
Replacing a Zoom Lens Motor ................................................................................................................................................... 61
Replacing Reflector .................................................................................................................................................................... 65
Replacing UV/IR Filter................................................................................................................................................................. 68
Replacing AR Glass.................................................................................................................................................................... 70
Replacing Ignitor......................................................................................................................................................................... 72
Replacing Interface/LVS Assembly............................................................................................................................................. 73
Replacing Upper Enclosure Fan................................................................................................................................................. 75
Replacing Ballast........................................................................................................................................................................ 77
Replacing Ballast Fan................................................................................................................................................................. 79
Replacing Yoke Fan .................................................................................................................................................................... 80
Replacing Pan/Tilt Driver PCB.................................................................................................................................................... 82
Replacing Tilt COT Sensor ......................................................................................................................................................... 84
Replacing Tilt Drive Mechanism ................................................................................................................................................. 87
Replacing Pan Drive Mechanism................................................................................................................................................ 89
Setting Pan/Tilt Belt Tension....................................................................................................................................................... 92
Chapter 4. Illustrated Parts Breakdown
Overview
About this IPB............................................................................................................................................................................. 96
Torque Chart ............................................................................................................................................................................... 97
Parts Breakdown
Covers and Included Items......................................................................................................................................................... 98
Best Boy Spares Kit.................................................................................................................................................................. 100
Appendix A. Technical Specifications
Best Boy 4000 Spot Luminaire................................................................................................................................................. 108
Best Boy Road Case ................................................................................................................................................................ 110

BEST BOY 4000®SPOT LUMINAIRE FIELD SERVICE MANUAL 1
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.
Additional Documentation
For installation and operation instructions, refer to the following PRG manual:
+ Best Boy 4000® Spot Luminaire User Manual (02.9816.0001.xx)
Technical updates regarding this equipment are issued by the PRG Dallas office. These updates are in the form of
Technical Bulletins, which contain procedures for equipment upgrades, retrofits, and repairs not found in the existing
manual(s).
For more information regarding DMX512 systems, refer to the DMX512/1990 & AMX 192 Standards publication
available from United States Institute for Theatre Technology, Inc. (USITT).
USITT
6443 Ridings Road
Syracuse, NY 13206-1111 USA
1-800-93USITT
www.usitt.org
For more information regarding Art-Net protocol, refer to the specification for Art-Net II Ethernet Communication
Standard available from Artistic Licence Ltd.
Artistic Licence (UK) Ltd (Registered Office)
24 Forward Drive, Christchurch Avenue,
Harrow, Middlesex, HA3 8NT, United Kingdom
[phone] (phone)
[phone] (fax)
www.artisticlicence.com

2BEST BOY 4000®SPOT LUMINAIRE FIELD SERVICE MANUAL
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: [phone]
Fax: [phone]
Service Fax: [phone]
Service Email: [e-mail]
For additional resources and documentation, please visit our website at: www.prg.com

1.
DESCRIPTION
This chapter contains an overview of luminaire components.
+COMPONENTS

4BEST BOY 4000®SPOT LUMINAIRE FIELD SERVICE MANUAL
COMPONENTS
Exterior Components
The following illustration shows the exterior Best Boy components and controls.
Figure 1-1: Exterior Components
Neutrik® AC
DMX512 Input
DMX512 Thru
Upper Enclosure Detail
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).
Hanging Bracket Assembly (2) -
Allows luminaire to be mounted on truss pipe.
Yoke Assembly - Houses Yoke Driver
Control Board, and Pan & Tilt servos.
FRONT VIEW
Power Connector
Front Lens
Head Assembly -
Houses Color, Gobo, Effect, Zoom, Iris,
Frost, Dimmer, and Strobe mechanisms.
Ethernet Port
Ethernet Port
Menu Touchscreen -
Used to configure luminaire address
and other options. Also, provides
status information and testing.
Comm LED
Battery Wake Switch
Light Shield -
Blocks light spill.

BEST BOY 4000®SPOT LUMINAIRE FIELD SERVICE MANUAL 5
Head and Enclosure Components
The following illustration shows the major sub-assemblies located in the Best Boy Head and Enclosure.
Figure 1-2: Head and Enclosure Components
Wheel Stack
LVS/Interface Module
EMI Ballast
Head Controller PCB
Assembly
Enclosure
Front Lens
Aft Assembly
(contains lamp, reflector, rear fan)
Head Fan Assembly
Zoom Assembly

6BEST BOY 4000®SPOT LUMINAIRE FIELD SERVICE MANUAL
Yoke Components
Tilt-Side Yoke
The following illustration shows the major sub-assemblies located in the Best Boy Tilt-Side Yoke Leg.
J7J2
J6
J9
J12
J14
J11
J13
J10
J15
J5
J8
J4
24-9816-0765 Yoke Driver
Tilt
Pan
Figure 1-4: Tilt-Side Yoke Leg
Pan/Tilt Driver
Driver PCB
Tilt Drive
Mechanism
100 -240 VAC
12A Max
50/ 60 Hz
IN
DMX
THRU
ETHERNET
AC IN
COMM
WAKE
R1
Tilt-Side Leg Pan-Side Leg
Figure 1-3: Yoke Leg Identification
R1 Head Cover

BEST BOY 4000®SPOT LUMINAIRE FIELD SERVICE MANUAL 7
Pan-Side Yoke Leg
The following illustration shows the major sub-assemblies located in the Best Boy Pan-Side Yoke Leg.
Figure 1-5: Pan-Side Yoke Leg
LAMP
T4
IGN
T1
IGN
Ignitor
Yoke Fan Assembly
Fan Filter
Pan Drive Mechanism
Note: The yoke plenum cover is not shown for clarity.

8BEST BOY 4000®SPOT LUMINAIRE FIELD SERVICE MANUAL
Designer Color Wheel Standard Configuration
The following drawing shows the standard Designer Color Wheel configuration.
Figure 1-6: Designer Color Wheel Standard Configuration
Effect Wheel Standard Configuration
The following drawing shows the standard Effect Wheel configuration.
Figure 1-7: Effect Wheel Standard Configuration
POSITION #7
UV BLUE
POSITION #6
GREEN
POSITION #5
ORANGE
POSITION #4
ROSY MAGENTA
POSITION #3
FOLLIES PINK
POSITION #2
TURQUOISE
POSITION #1
DEEP RED
OPEN
OPEN
VARIABLE
DIFFUSION
POSITION #1
4-FACET PRISM
POSITION #2
EXTRUDER
POSITION #3
OBLONG

BEST BOY 4000®SPOT LUMINAIRE FIELD SERVICE MANUAL 9
Gobo Wheel Standard Configurations
The following drawings show the standard Gobo Wheel configurations.
Figure 1-8: Gobo Wheel Standard Configurations
About Moiré Gobos
Moiré gobos contain two pieces of glass: one that is fixed and another that rotates. Since the two pieces of glass are
very close together, it creates an interesting interference effect (which is referred to as the "moiré"). Due to this
construction they do not contain sensors, and therefore cannot be calibrated to a certain orientation at startup as with
standard gobos.
CAUTION: Moiré gobo positions MUST be set using the menu system.
GOBO WHEEL 1
GOBO WHEEL 2
OPEN
POSITION #1
COLOR FRAGMENTS
POSITION #2
OAK FOLIAGE 1
POSITION #3
CRACKLE LINEAR
POSITION #4
GHOST DUST
POSITION #5
FIREWATER MOIRÉ
POSITION #6
DIGITAL STRAW
POSITION #1
JUST ROCKS
OPEN
POSITION #2
PIN HOLE BREAKUP
POSITION #3
NICE SLITS
POSITION #4
SLATE WALL 4
POSITION #5
KALEIDOSCOPE MOIRÉ
POSITION #6
CLUBBED SPIRAL

10 BEST BOY 4000®SPOT LUMINAIRE FIELD SERVICE MANUAL
Notes

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

12 BEST BOY 4000®SPOT LUMINAIRE FIELD SERVICE MANUAL
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. (During
recalibration, intensity goes out until all mechanism calibrations are
complete and back in position, then fades in.)
+ Recal All - press to bring up Recalibrate All Yes/No options.
+ Disable - press to bring up Disable Screen, which allows specific
mechanisms to be disabled during testing.
+ Moiré Positions - press to bring up Moiré Gobos screen, which
provides a way to specify the wheel positions containing Moiré
gobos. Moiré gobos contain two pieces of glass: one that is fixed
and another that rotates. Due to this construction they do not
contain sensors, and therefore cannot be calibrated to a certain orientation at startup as with standard gobos.
+ Mech Test - press to bring up Mechanical Tests Screen. (See "Mechanical Tests" on page 14 for more
explanation.)
+ Group Test - press to bring up Group Tests screen, which allows multiple luminaires to be run through a
configurable test sequence when chained together via DMX512 or Ethernet. (See "Group Tests" on page 15 for
more explanation.)
+ Clean Lenses - press to bring up Cleaning Lenses screen. This feature will position lenses so that all surfaces
may be cleaned with a cloth. (Note that pressing the buttons does not actually clean the lenses.)
+ Fuse Map - press to bring up Fuse Map screen. The Fuse Map provides the circuit board location for all
mechanism fuses.
Test Screen