PRG Bad Boy Spot Luminaire User manual

SOFTWARE VERSION 1.6
WWW.PRG.COM
BAD BOY®SPOT LUMINAIRE
FIELD SERVICE MANUAL

AutoPar®, Bad Boy®, PRG Series 400®, Mbox Extreme®, 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.
Bad Boy® Spot Luminaire Field Service Manual
Version as of: November 10, 2010
PRG part number: 02.9812.0005 C
Production Resource Group
Dallas Office
8617 Ambassador Row, Suite 120
Dallas, Texas 75247
www.prg.com
Bad Boy® Spot Luminaire Field Service Manual
©2009-2010 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 September 22, 2009 Initial release.
A March 3, 2010 Added 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 to Maintenance and
IPB sections. Added Designer Color and Gobo Wheel stan-
dard configurations to Description section.
C2 November 10, 2010 Updated book format. (No change to technical information.)

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
Features
Overview....................................................................................................................................................................................... 4
Features ................................................................................................................................................................................ 4
Luminaire Models.................................................................................................................................................................. 5
Components
Exterior Components.................................................................................................................................................................... 6
Head and Enclosure Components ............................................................................................................................................... 7
Yoke Components ........................................................................................................................................................................ 8
Designer Color and Gobo Wheel Configurations ....................................................................................................................... 10
Chapter 2. Testing & Troubleshooting
Testin g
Test Screen................................................................................................................................................................................. 14
Mechanical Tests........................................................................................................................................................................ 15
Group Test .................................................................................................................................................................................. 16
Troubleshooting
Errors .......................................................................................................................................................................................... 17
Basic Troubleshooting ................................................................................................................................................................ 19
Component Troubleshooting...................................................................................................................................................... 20
Lamp Issues ........................................................................................................................................................................ 20
Wheel Stack 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
Wheel Stack Road Case Instructions......................................................................................................................................... 29
Routine Maintenance
Removing the Head Covers ....................................................................................................................................................... 30
Removing the Aft Cover ............................................................................................................................................................. 31
Removing the Enclosure Covers ................................................................................................................................................ 32
Cleaning the Head Electrostatic Filters ...................................................................................................................................... 33
Cleaning the Enclosure Intake Filters ......................................................................................................................................... 34
Cleaning the Luminaire Exterior ................................................................................................................................................. 35
Cleaning the Lenses ................................................................................................................................................................... 36
Cleaning Gobo, Color and Dimmer Wheels ............................................................................................................................... 39
Cleaning the Reflector................................................................................................................................................................ 40
Cleaning the UV/IR Window ....................................................................................................................................................... 41
Remove and Replace Procedures
Replacing the Lamp ................................................................................................................................................................... 42
Adjusting the Lamp .................................................................................................................................................................... 44
Replacing a Gobo....................................................................................................................................................................... 45
Replacing a Designer Color Filter............................................................................................................................................... 48
Replacing the Front Glass .......................................................................................................................................................... 50

VI BAD BOY®SPOT LUMINAIRE FIELD SERVICE MANUAL
Replacing the Wheel Stack......................................................................................................................................................... 51
Replacing the Frost/Diffuser Paddle........................................................................................................................................... 55
Replacing the Diffuser Sensor PCB............................................................................................................................................ 57
Replacing the Zoom Controller PCB .......................................................................................................................................... 58
Replacing a Zoom Sensor PCB.................................................................................................................................................. 59
Replacing the Main Head Fan .................................................................................................................................................... 62
Replacing the Tip Pinch Fan (Original Version)........................................................................................................................... 64
Replacing the Tip Pinch Fan (Hi-Temp Version) ......................................................................................................................... 65
Replacing the UV/IR Window Assembly..................................................................................................................................... 66
Replacing the Reflector .............................................................................................................................................................. 67
Replacing a 2A Fuse................................................................................................................................................................... 68
Replacing the 3A Fuse................................................................................................................................................................ 69
Replacing the EMI Ballast Enclosure.......................................................................................................................................... 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
Replacing the Tilt Drive Assembly.............................................................................................................................................. 82
Setting Pan/Tilt Belt Tension....................................................................................................................................................... 83
Chapter 4. Illustrated Parts Breakdown
Overview
About this IPB............................................................................................................................................................................. 86
Parts Breakdown
Covers and Included Items......................................................................................................................................................... 87
Bad Boy Spares Kit .................................................................................................................................................................... 89
Appendix A. Technical Specifications
Bad Boy Spot Luminaire............................................................................................................................................................. 96
Bad Boy Road Case ................................................................................................................................................................... 98
AC Line Current / Power vs. Voltage .......................................................................................................................................... 99
Photometric Data...................................................................................................................................................................... 100
Narrow Zoom..................................................................................................................................................................... 101
Medium Zoom ................................................................................................................................................................... 102
Wide Zoom ........................................................................................................................................................................ 103
Logarithmic Beam Illuminance Comparison ..................................................................................................................... 104
Appendix B. Wiring Diagrams
Bad Boy Luminaire Wiring Diagram.......................................................................................................................................... 105

BAD BOY®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:
+ Bad Boy® Spot Luminaire (20.9812.0001)
+ Bad Boy™ CMY Spot Luminaire (20.9812.0002)
This manual is intended for use in field servicing and is not a comprehensive shop-level manual.
WARNING: It is important to read ALL accompanying safety instructions to avoid damage to the product
and potential injury to yourself or others.
Additional Documentation
For installation and operation instructions, refer to the following PRG manual:
+ Bad Boy® Spot Luminaire User Manual (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, 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

2BAD BOY®SPOT LUMINAIRE FIELD SERVICE MANUAL
Customer Service
Our comprehensive technical services department ensures you get the full benefit of being a PRG customer. Whether
your needs are simple or complex, our full-time staff of experienced professionals are on-hand to provide support. For
assistance, contact your nearest PRG office:
For additional resources and documentation, please visit our website at: www.prg.com
PRG Dallas (International Service)
8617 Ambassador Row, Suite 120
Dallas, Texas 75247
Ph: 214.630.1963
Fx: 214.630.5867
Service Fx: 214.638.2125
Service Email: [e-mail]
PRG Atlanta
1053 Willingham Dr.
Atlanta, Georgia 30344
Ph: 404.214.4800
Fx: 404.214.4801
PRG Chicago
90 Rawls Rd.
Des Plaines, Illinois 60018
Ph: 847.227.5171
Fx: 847.557.9033
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: 818.252.2620
PRG Nashville
8351 Eastgate Blvd.
Mount Juliet, Tennessee 37122
Ph: 615.834.3190
Fx: 615.834.3192
PRG New Jersey
915 Secaucus Rd.
Secaucus, New Jersey 07094
Ph: 201.758.4000
Fx: 201.758.4312
PRG Orlando
1902 Cypress Lake Dr.
Orlando, Florida 32837
Ph: 407.855.8060
Fx: 407.855.8059
PRG Canada
2480 Tedlo Street
Mississauga, Ontario L5A 3V3 Canada
Ph: 905.270.9050
Fx: 905.270.2590
PRG Asia
KI Building, 2nd Floor
6-4-2 Kiba, Koto-ku
Tokyo, 135-0042, Japan
Ph: 81 3 5665 3377
Fx: 81 3 5665 3517
PRG Europe
The Cofton Centre
Grovely Lane
Longbridge, Birmingham
B31 4PT, England
Ph: +44 (0) 845.470.6400
Fx: +44 (0) 845.470.6401
Essential Lighting
Unit E
Imber Court Trading Estate
Orchard Lane
East Molesey, Surrey
KT8 0BY, England
Ph: +44 (0) 208.335.6000
Fx: +44 (0) 208.398.7205

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

4BAD BOY®SPOT LUMINAIRE FIELD SERVICE MANUAL
FEATURES
Overview
The Bad Boy Spot Luminaire from PRG Lighting combines the qualities of a
traditional automated light with a large venue fixture.
Features
+ Philips MSR Gold™ FastFit lamp that can be set to levels 900W, 1200W, or
1400W.
+ Built-in LCD touchscreen display which provides access to control,
configuration, status, and testing functions.
+ Zoom lens system consisting of four groups of lenses - each independently
controlled for accuracy while maintaining focus during zoom changes.
+ Zoom range of 8:1 from a narrow spot of 7° to a wide flood of 56°.
+ Edge control for gobo focus and gobo morphing.
+ Mechanical iris which provides continuous beam size control for both rapid
changes and smooth timed beam angle changes.
+ 8-inch diameter front lens which produces a large, full beam that easily can be
varied by the luminaire’s zoom lens and beam size iris.
+ Full-field dimming from 0 to 100% with accurate slow-speed control as well as fast bumps.
+ Standard Version
- Quantum Color® system featuring four (4) color wheels 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 system featuring three (3) cross-fading color wheels (Cyan, Magenta, and Yellow), plus
one (1) designer wheel with user-changeable color filters.
+ Instantaneous color bumps and flashes as well as smooth control for timed color changes.
+ Two (2) indexable, rotating gobo wheels with seven (7) gobos per wheel. Gobos are individually calibrated so the
unit will automatically index the orientation of each gobo regardless of placement.
+ Variable frost for smooth diffusion.
+ Servo-powered, lightning fast strobe mechanism.
+ Precision glass reflector with dichroic cold mirror coating.
+ On-board battery to address and configure fixture without main power.
+ Three-phase, high-speed servo motors for pan and tilt to provide repeatable, precise responses.
+ Pan and tilt locking mechanisms which automatically unlock when power is applied to the fixture.
+ Pan range of 540° and a tilt range of 270°.
+ Can be mounted and operated in any orientation.
+ Compatible with all PRG consoles and a wide variety of DMX512 and Art-Net consoles. An internal Ethernet
switch allows for daisy-chaining fixtures.

BAD BOY®SPOT LUMINAIRE FIELD SERVICE MANUAL 5
Luminaire Models
The Bad Boy Spot Luminaire is available in two versions:
+ Standard (20.9812.0001) - contains a Quantum Color® system.
+ CMY (20.9812.0002) - contains a CMY color system.
The 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 Wheel Stack can
be identified by a label on the outer plate:
Figure 1-2: CMY Wheel Stack Label
YM
COMM
C
200 - 240 V A C
E T H E RNE TDMX
IN
THR U
15 A M a x
50 / 60 H z
IS POWERED
ACTIVEONLY
WHEN FIXTURE
AC IN
C
MY
C
MY

6BAD BOY®SPOT LUMINAIRE FIELD SERVICE MANUAL
COMPONENTS
Exterior Components
The following illustration shows the exterior Bad Boy components and controls.
Figure 1-3: Exterior Components
COMM
200 -240V AC
ETHERNE TDMX
IN
THR U
15 A Ma x
50 / 60 H z
IS POWERED
ACTI V E O NLY
WHEN FIXTURE
AC IN
CONFIG
addr 043
univ A
1400w
ETHERNET
COMM
IN
DMX
THRU
15A Max
AC IN
200 -240 VAC
50 / 60 Hz
LAMP
hrs 125
temp 34C
INFO
01:34
TEST
COMM
DMX
STATUS
OK
IS POW E RED
ACT IVE ON LY
WHE N 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 (see detail below).
Hanging Bracket Assembly (2) -
Allows luminaire to be mounted on truss pipe.
Yoke Assembly -
Houses Master Control Board (MCB) .
FRONT VIEW
Power Connector
Front Lens -
8-inch diameter front lens.
Head Assembly -
Houses Color, Gobo, Zoom, Iris,
Frost, and Strobe mechanisms.
Ethernet Thru
Ethernet Input
Menu Touchscreen -
Used to configure
luminaire address
and other options.
Also, provides status
information and
testing.
Comm LED
Battery Wake Switch *
* Not available on all units

BAD BOY®SPOT LUMINAIRE FIELD SERVICE MANUAL 7
Head and Enclosure Components
The following 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
Assembly
Enclosure
Front Lens
Aft Assembly
(contains lamp, fans, reflector)
Lens Groups

8BAD BOY®SPOT LUMINAIRE FIELD SERVICE MANUAL
Yoke Components
Tilt-Side 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 LegPan-Side Leg
R2 / Designer Wheel
Head Cover
Figure 1-5: Yoke Leg Identification

BAD BOY®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
Controller PCB

10 BAD BOY®SPOT LUMINAIRE FIELD SERVICE 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: Designer Color Wheel Standard Configuration

BAD BOY®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 Configurations

12 BAD BOY®SPOT LUMINAIRE FIELD SERVICE MANUAL
Notes