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

INTRODUCTION
02.9812.0005 1
Introduction
About This Manual
This manual provides testing, troubleshooting, maintenance procedures, and illustrated parts
breakdowns for the following equipment:
• Bad Boy™ Spot Luminaire (20.9612.0001)
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)
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

BAD BOY™ SPOT LUMINAIRE FIELD SERVICE MANUAL
202.9812.0005
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: [email protected]
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
7777 West Side Avenue
North Bergen, New Jersey 07047
Ph: 201.758.4000
Fx: 201.758.4312
PRG Orlando
1902 Cypress Lake Dr.
Orlando, Florida 32837
Phone: [phone]
Fax: [phone]
PRG Canada
2480 Tedlo Street
Mississauga, Ontario L5A 3V3 Canada
Ph: 905.270.9050
Fx: 905.270.2590
PRG Asia
Asagami Fukagawa Logistics Center B-4F
2-2-1 Shiohama, Koto-ku, Tokyo, Japan 135-0043
Ph: 81.3.5683.0011
Fx: 81.3.5683.0330
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

02.9812.0005 3
1.
Description
This chapter contains an overview of luminaire features and components.
• Features
• Components

BAD BOY™ SPOT LUMINAIRE FIELD SERVICE MANUAL
402.9812.0005
Features
Overview
The Bad Boy™ Spot Luminaire from PRG Lighting combines the
qualities of a traditional automated light with a large venue fixture.
Bad Boy is the ideal choice whenever a big-beam look is required, for
example, when playing in front of high-brightness LED screens.
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.
• 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).
• 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.

DESCRIPTION : COMPONENTS
02.9812.0005 5
1
Components
Exterior Components
The following illustration shows the exterior Bad Boy™ luminaire components and controls.
Figure 1-1: Exterior Components
200 -240 VAC
15A Max
50 / 60 Hz
COMM
IN
DM X
THR U
ETHERNET
AC IN
ISPOWERED
ACTIVE ONLY
WHEN F IXTU RE
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 ERED
ACT IVE ON LY
WHEN 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

BAD BOY™ SPOT LUMINAIRE FIELD SERVICE MANUAL
602.9812.0005
Head and Enclosure Components
The following illustration shows the major sub-assemblies located in the Bad Boy™ Head and
Enclosure.
Figure 1-2: 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

DESCRIPTION : COMPONENTS
02.9812.0005 7
1
Yoke Components
Tilt-Side Yoke
The following illustration shows the major sub-assemblies located in the Tilt-Side Yoke Leg.
Figure 1-4: Tilt-Side Yoke Leg
Ignitor PCB
Relay
Tilt Drive
Assembly
Tilt-Side LegPan-Side Leg
R2 / Designer Wheel
Head Cover
Figure 1-3: Yoke Leg Identification

BAD BOY™ SPOT LUMINAIRE FIELD SERVICE MANUAL
802.9812.0005
Pan-Side Yoke Leg
The following illustration shows the major sub-assemblies located in the Pan-Side Yoke Leg.
Figure 1-5: Pan-Side Yoke Leg
Pan/Tilt
Controller PCB

02.9812.0005 9
2.
Testing & Troubleshooting
This chapter provides testing and troubleshooting procedures for the luminaire.
• Testing
• Troubleshooting

BAD BOY™ SPOT LUMINAIRE FIELD SERVICE MANUAL
10 02.9812.0005
Testing
Test Screen
The luminaire provides built-in test routines and
recalibration options which can be accessed through the
Menu Touchscreen. Actions may be applied to specific
mechanisms, or in some cases, to all mechanisms at
once. At the Home screen, press the Test panel to bring
up the Test screen.
Options are as follows:
•Re-Cal - press to bring up Recalibration Screen.
•Re-Call ALL - press to bring up Re-Cal ALL Yes/
No options.
•Disable - press to bring up Disable Screen.
•Mech Test - press to bring up Mech Test Screen.
(See "Mechanical Tests" on page 11 for more
explanation of this screen.)
•Clean Lenses- press to position lenses so that all
surfaces may be cleaned with a cloth. (Note that
pressing the button does not actually clean the
lenses.) Refer to "Cleaning the Lenses" on page 33
for complete lens cleaning instructions.
•Group Test - allows multiple Bad Boy luminaires
to be run through a configurable test sequence
when chained together via DMX512 or Ethernet.
(See "Group Test" on page 12 for more explanation
of this screen.)
Press TEST to
bring up Test screen
Test Sub-Menu Screens