PRG BAD Boy Quick start guide

FIELD SERVICE MANUAL
02.9812.0005
Spot Luminaire
software version 1.5

AutoPar™, Bad Boy™, Mbox Extreme™, PRG Series 400™, Virtuoso®, Virtuoso® DX, Virtuoso® DX2, and Visionary™3D
are trademarks of Production Resource Group, LLC, registered in the U.S. and other countries.
All other brand or product 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 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: September 22, 2009 | PRG part number: 02.9812.0005
Production Resource Group
Dallas Office
8617 Ambassador Row, Suite 120
Dallas, Texas 75247
www.prg.com
Bad Boy™ Spot Luminaire Field Service Manual
©2009 Production Resource Group, LLC. All Rights Reserved.

FOREWORD
02.9812.0005 i
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.
FCC
CAUTION advising of potential damage to product.
WARNING advising of potential injury or death to persons.

BAD BOY™ SPOT LUMINAIRE FIELD SERVICE MANUAL
ii 02.9812.0005
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.
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.

FOREWORD
02.9812.0005 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.

BAD BOY™ SPOT LUMINAIRE FIELD SERVICE MANUAL
iv 02.9812.0005
Revision History
This manual has been revised as follows:
Version Release Date Notes
BASIC September 22, 2009 Initial release.

TABLE OF CONTENTS
02.9812.0005 v
Table of Contents
Introduction
About This Manual .......................................................................................................................... 1
Additional Documentation............................................................................................................... 1
Customer Service ............................................................................................................................. 2
Chapter 1. Description
Features
Overview.......................................................................................................................................... 4
Features...................................................................................................................................... 4
Components
Exterior Components ....................................................................................................................... 5
Head and Enclosure Components .................................................................................................... 6
Yoke Components ............................................................................................................................ 7
Chapter 2. Testing & Troubleshooting
Testing
Test Screen ..................................................................................................................................... 10
Mechanical Tests............................................................................................................................ 11
Group Test...................................................................................................................................... 12
Troubleshooting
Errors.............................................................................................................................................. 13
Basic Troubleshooting ................................................................................................................... 15
Component Troubleshooting.......................................................................................................... 16
Lamp Issues............................................................................................................................. 16
Wheel Stack and/or Frost (Diffusion) Issues........................................................................... 17
Fan/Cooling Issues .................................................................................................................. 18
Lens Issues............................................................................................................................... 19
Menu Display Issues................................................................................................................ 20
Pan/Tilt Issues ......................................................................................................................... 21
Chapter 3. Maintenance
Equipment Handling
Proper Lamp Servicing and Operation........................................................................................... 24
Wheel Stack Road Case Instructions ............................................................................................. 25
Routine Maintenance
Removing the Head Covers ........................................................................................................... 26
Removing the Aft Cover................................................................................................................ 28
Removing the Enclosure Covers.................................................................................................... 29
Cleaning the Head Electrostatic Filters.......................................................................................... 30
Cleaning the Enclosure Intake Filters ............................................................................................ 31

BAD BOY™ SPOT LUMINAIRE FIELD SERVICE MANUAL
vi 02.9812.0005
Cleaning the Luminaire Exterior.................................................................................................... 32
Cleaning the Lenses ....................................................................................................................... 33
Cleaning Gobo, Color and Dimmer Wheels .................................................................................. 36
Cleaning the Reflector ................................................................................................................... 37
Cleaning the UV/IR Window......................................................................................................... 38
Remove and Replace Procedures
Replacing the Lamp ....................................................................................................................... 39
Adjusting the Lamp........................................................................................................................ 41
Replacing a Gobo........................................................................................................................... 42
Replacing a Designer Color Filter ................................................................................................. 45
Replacing the Wheel Stack ............................................................................................................ 47
Replacing the Frost/Diffuser Paddle .............................................................................................. 51
Replacing the Diffuser Sensor PCB............................................................................................... 53
Replacing the Zoom Controller PCB............................................................................................. 55
Replacing a Zoom Sensor PCB...................................................................................................... 57
Replacing the Main Head Fan........................................................................................................ 60
Replacing the Tip Pinch Fan.......................................................................................................... 62
Replacing the UV/IR Window Assembly...................................................................................... 63
Replacing the Reflector.................................................................................................................. 64
Replacing a 2A Fuse ...................................................................................................................... 65
Replacing the 3A Fuse ................................................................................................................... 66
Replacing the EMI Ballast Enclosure............................................................................................ 67
Replacing the Interface/LVS Module............................................................................................. 69
Replacing the Ignitor PCB ............................................................................................................. 71
Replacing the Pan/Tilt Controller PCB.......................................................................................... 73
Replacing the Pan/Tilt COT Sensor PCB ...................................................................................... 74
Replacing the Pan Drive Assembly ............................................................................................... 76
Replacing the Tilt Drive Assembly................................................................................................ 79
Setting Pan/Tilt Belt Tension ......................................................................................................... 81
Chapter 4. Illustrated Parts Breakdown
Overview
About this IPB................................................................................................................................ 84
Parts Breakdown
Covers and Included Items............................................................................................................. 85
Bad Boy Spares Kit........................................................................................................................ 87

TABLE OF CONTENTS
02.9812.0005 vii
Appendix A. Technical Specifications
Bad Boy Spot Luminaire................................................................................................................ 94
Bad Boy Road Case ....................................................................................................................... 96
AC Line Current / Power vs. Voltage ............................................................................................ 97
Photometric Data............................................................................................................................ 98
Narrow Zoom .......................................................................................................................... 99
Medium Zoom....................................................................................................................... 100
Wide Zoom............................................................................................................................ 101
Logarithmic Beam Illuminance Comparison ........................................................................ 102
Appendix B. Wiring Diagrams
Bad Boy Luminaire Wiring Diagram........................................................................................... 103

BAD BOY™ SPOT LUMINAIRE FIELD SERVICE MANUAL
viii 02.9812.0005
Notes