Prg Best Boy Field Service Manual Bedienungsanleitung

SOFTWARE VERSION 1.15WWW.PRG.COMBEST BOY 4000® SPOT LUMINAIREFIELD SERVICE MANUAL

2 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALCustomer ServiceFor technical assistance, contact the PRG International Service Center or contact

92 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALSetting Pan/Tilt Belt TensionLoose pan/tilt drive belts can create calibration problems. When the

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 93CAUTION: Do not overtighten belt, pulley will break and/or bearings will fail.To set belt tensio

94 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALNotes

4.ILLUSTRATED PARTS BREAKDOWNThis chapter provides illustrated parts breakdowns for all luminaire spares components.+OVERVIEW+ PARTS BREAKDOWN

96 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALOVERVIEWAbout this IPBThe Illustrated Parts Breakdown is intended for use with Field Service of t

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 97Additional replacement items are as follows:Torque ChartUnless otherwise specified, torque all fa

98 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALPARTS BREAKDOWNCovers and Included Items20.9816.0001 Rev A0Refer to illustration on next page.No.

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 99Covers and Included Items (continued)Refer to Parts List on previous page.123456 (x2)7 (x2)8 (x2)

100 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALBest Boy Spares Kit28.9816.2000 Rev A0 (2.3749A-P00)Refer to illustration on next page.No. PRG P

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 101Best Boy Spares Kit (continued)Refer to Parts List on previous page.12345678910

1.DESCRIPTIONThis chapter contains an overview of luminaire components.+COMPONENTS

102 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALBest Boy Spares Kit (continued)No. PRG P/N TEAM Ecode Qty UM Description Procedure11 25.9816.098

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 103Best Boy Spares Kit (continued)No. PRG P/N TEAM Ecode Qty UM Description Procedure14 23.9816.053

104 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALBest Boy Spares Kit (continued)Refer to illustration on next page.No. PRG P/N TEAM Ecode Qty UM

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 105Best Boy Spares Kit (continued)Refer to Parts List on previous page.FANJ8CHAS19202122232425

106 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALNotes

A. TECHNICAL SPECIFICATIONS+ BEST BOY 4000 SPOT LUMINAIRE+ BEST BOY ROAD CASE

108 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALBest Boy 4000 Spot LuminaireSOURCE: MSR 700SA lampOUTPUT: 20,000 lumensINPUT CURRENT: Minimum

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 10926.8"(681 mm)(711 mm)28"16.75"(425 mm)(290 mm)11.4"35.16"(893 mm)(991 m

110 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALBest Boy Road CaseEMPTY WEIGHT: 171 lbs (77.56 kg)LOADED WEIGHT: 389 lbs (176.45 kg)52"(132

Best Boy 4000® Spot Luminaire Field Service ManualVersion as of: November 6, 2012PRG part number: 02.9816.0005 A

4 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALCOMPONENTSExterior ComponentsThe following illustration shows the exterior Best Boy components and

Production Resource Group, LLCDallas Office8617 Ambassador Row, Suite 120Dallas, Texas 75247www.prg.com

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 5Head and Enclosure ComponentsThe following illustration shows the major sub-assemblies located in

6 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALYoke ComponentsTilt-Side YokeThe following illustration shows the major sub-assemblies located in

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 7Pan-Side Yoke LegThe following illustration shows the major sub-assemblies located in the Best Boy

8 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALDesigner Color Wheel Standard ConfigurationThe following drawing shows the standard Designer Color

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 9Gobo Wheel Standard ConfigurationsThe following drawings show the standard Gobo Wheel configuratio

10 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALNotes

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

AutoPar®, Bad Boy®, Best Boy 4000®, PRG Series 400®, MBOX®, MBOX Extreme®, OHM™, V476®, V676®, Virtuoso®, Virtuoso® DX, Virtuoso® DX2, and VL6C+™ are

12 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALTESTINGAbout This SectionThe following section provides instructions for using the test and recal

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 13Test Sub-Menu ScreensDisable Screen - Specifies mechanisms to be excluded from tests.Moiré Gobos

14 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALMechanical TestsThe Mechanical Tests menu provides a method for exercising all luminaire mechanis

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 15Group TestsThe Group Test menu allows multiple Best Boy 4000 Luminaires to be run through a confi

16 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALTROUBLESHOOTINGErrorsStatus IndicationsThe STATUS panel at the Home screen will report overall lu

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 17Mechanism Errors Errors will be shown after the mechanism code, for example: PAN:Comm Error.Error

18 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALOther ErrorsError Code Explanation SolutionBallast Errors: Parity, Overrun, Bad Header, Msg Too L

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 19Basic TroubleshootingThe following table provides a list of common start-up problems and possible

20 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALNotes

3.MAINTENANCEThis chapter provides maintenance procedures for the luminaire. +EQUIPMENT HANDLING+ ROUTINE MAINTENANCE+ REMOVE AND REPLACE PROCEDURES

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL IFOREWORDCompliance NoticeThis device complies with Part 15 of the FCC rules. Operation is subject to the

22 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALEQUIPMENT HANDLINGProper Lamp Servicing and OperationServicing + When handling a lamp, hold it b

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 23Wheel Stack Road Case InstructionsParts:20.9816.1229 / 2.3749A-P05 CASE, WHEEL STACKA special roa

24 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALROUTINE MAINTENANCERemoving Head CoversTo access some interior components, one or both of the Hea

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 25Removing Aft CoverTo access some interior components, the Aft Cover may need to be removed.Tools

26 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALRemoving Yoke Leg CoversTo access some interior components, one or more of the Yoke Leg Covers ma

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 27Removing Upper Enclosure CoversTo access some interior components, one or both of the Upper Enclo

28 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALCleaning Intake FiltersThe filters should be cleaned or replaced when they become dirty. The freq

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 29Cleaning LensesTools & Supplies:(2) Micro Fiber cloths (06.6085.0001.0)OptiMax™ Ultra Pure Cl

30 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALStep 3. At menu TEST screen, press "Clean Lenses." The Cleaning Lenses screen will open

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 31CAUTION: Be extremely careful when removing Retaining Ring and Front Glass in next step. The gla

II BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALWARNING: INSTRUCTIONS FOR PROTECTION AGAINST INJURY TO PERSONS1) Exterior surfaces of the luminaire wil

32 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALCleaning Gobo, Color, and Effect WheelsTools & Supplies:Micro Fiber cloth (06.6085.0001.0)Opt

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 33REMOVE AND REPLACE PROCEDURESReplacing LampParts:71.2528.0700 / 2.3749A-02 1 EA LAMP, 700 W SHORT

34 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALCAUTION: Wear cotton gloves or finger cots while servicing lamp. Touching the lamp glass with ba

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 35Adjusting LampAfter a new lamp is installed, it will be necessary to align the lamp in order to c

36 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALReplacing a Gobo in Gobo Wheel 1Due to the complex gear alignment, it is best to remove ALL gobos

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 37Step 4. Re-install all gobos (making changes as necessary) by doing the following:a. Rotate gobo

38 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALReplacing a Gobo in Gobo Wheel 2Due to the complex gear alignment, it is best to remove ALL gobos

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 39Step 4. Re-install all gobos (making changes as necessary) by doing the following:a. Rotate gobo

40 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALReplacing a Designer Color FilterParts:Designer Color Filter(s), as required. (Refer to "Des

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 41Step 5. Noting proper orientation of carrier, insert new designer color filter into position and

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL IIINotes de sécuritéAvant de procéder à l’installation des produits décrits dans ce guide et de les mettr

42 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALReplacing Front GlassParts:41.9816.0628 / 2.37493-R10 1 EA FRONT GLASSTools & Supplies:Flat s

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 43Replacing Light ShieldParts:10.9816.0029 / 2.37493-R20 1 EA LENS HOOD, FLEXIBLE55.0078.1000.0 1 E

44 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALStep 9. Using a flat screwdriver, press down on sharp edges of belt (left by the cutter) as shown

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 45Replacing Head FanParts:25.9816.0996 / 2.3749A-P85 1 EA FAN ASSY, HEAD, 60mm BLOWERTools & Su

46 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALStep 5. At bottom side of Head Fan Assembly, cut cable tie which secure cables to mounting bracke

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 47Replacing Lamp Pinch FanParts:25.9816.0994 / 2.3749A-P80 1 EA ASSY, LAMP PINCH FANTools & Sup

48 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALStep 4. Remove Thermal Divider by removing three 6-32 x 1/4" PPSS screws (Figure 3-22).Step

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 49Replacing Rear Housing FanParts:25.9816.0995 / 2.3749A-P95 1 EA ASSY, REAR HOUSING FANTools &

50 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALStep 4. At Rear Housing Fan Assembly, remove two 6-32 x 1/4" PPSS screws.Step 5. Tilt and sl

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 51Replacing Head Controller PCBParts:24.9816.0640 / 2.3749A-P50 1 EA PCB ASSY, HEAD MOTOR AND FAN D

IV BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALRevision HistoryThis manual has been revised as follows:Version Release Date NotesBASIC July 11, 2012 I

52 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALStep 5. At bottom of Head Controller PCB, remove two 6-32 x 1/4" screws (Figure 3-26).Step 6

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 53Replacing Wheel StackParts:21.9816.0200 / 2.3749A-P01 1 EA ASSY, WHEEL STACKTools & Supplies:

54 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALStep 4. Disconnect four cables.Step 5. At Wheel Stack, loosen captive screws.Step 6. Verify that

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 55Replacing Gag EOT SensorParts:25.9816.0988 / 2.3749A-P45 1 EA CABLE ASSY, GAG EOT SENSORTools &am

56 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALReplacing Gag Wheel MotorParts:23.9816.0568 / 2.37493-P7F 1 EA ASSY, MOTOR GAG WHEELTools & S

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 57Replacing Gag Index MotorParts:23.9816.0569 / 2.37493-P7H 1 EA MOTOR ASSY, GAG INDEX (EXT SHAFT)T

58 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALReplacing a Zoom SensorThe Zoom Assembly contains three Zoom Sensor PCBs (one for each Zoom Lens

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 59CAUTION: NEVER touch or adjust the brass spring-loaded standoff. It is set at the factory. Figur

60 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALCAUTION: NEVER touch or adjust the brass spring-loaded standoff. It is set at the factory. Figur

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 61Replacing a Zoom Lens MotorParts:23.9816.0530.01 / 2.3749A-R25 1 EA MOTOR ASSY, ZOOM LENS GROUP 1

BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUAL VTABLE OF CONTENTSIntroductionAbout This Manual...

62 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALCAUTION: NEVER touch or adjust the brass spring-loaded standoff. It is set at the factory. Figur

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 63CAUTION: NEVER touch or adjust the brass spring-loaded standoff. It is set at the factory. Figur

64 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALCAUTION: NEVER touch or adjust the brass spring-loaded standoff. It is set at the factory. Figur

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 65Replacing ReflectorParts:42.9816.0161 / 2.3749A-P90 1 EA REFLECTOR, BEST BOY, 40 LUNETools &

66 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALStep 5. At Thermal Switch, disconnect two wires (Figure 3-38).Step 6. Remove Thermal Switch Brack

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 67Step 7. At Reflector, in an alternating fashion, gradually loosen three 6-32 x 1/4" PPSS scr

68 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALReplacing UV/IR FilterParts:41.9816.0226 / 2.37493-P92 2 EA FILTER, UV/IRTools & Supplies:#2

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 69CAUTION: Wear cotton gloves or finger cots while handling glass filters.Figure 3-40: Removing U

70 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALReplacing AR GlassParts:41.9816.0606 / 2.37493-R15 1 EA LENS, COVER, AFT BULKHEAD (AR GLASS)Tools

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 71Figure 3-41: Removing AR GlassFANJ7HEADTEMPJ6EXTAft Bulkhead CoverRTV AdhesiveAft Bulkhead (deta

VI BAD BOY® SPOT LUMINAIRE FIELD SERVICE MANUALRemove and Replace ProceduresReplacing Lamp...

72 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALReplacing IgnitorParts:69.3180.0805.1 / 2.3749A-P35 1 EA IGNITOR, BEST BOY, WITH LABELTools &

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 73Replacing Interface/LVS AssemblyParts:21.9816.0811 / 2.3749A-P15 1 EA ASSY, INTERFACE/LVSTools &a

74 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALStep 6. Flip Interface/LVS Assembly upside down as shown in Figure 3-44.Step 7. Disconnect AC cab

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 75Replacing Upper Enclosure FanParts:25.9816.0992 / 2.3749A-R05 1 EA CABLE ASSY, UE CHASSIS FANTool

76 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALFigure 3-45: Removing Upper Enclosure FanFANJ8CHASJ8FAN 2MAINCONTROLJ2FANJ8CHASUpper Enclosure F

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 77Replacing BallastParts:21.9816.0810 / 2.3749A-P10 1 EA ASSY, BALLASTTools & Supplies:#2 Phill

78 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALFigure 3-46: Removing BallastJ2MAINCONTROLJ2WHTBLKT4T6RLYRLYHOT RELAY DETAILTAB 4TAB 6GND #425-9

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 79Replacing Ballast FanParts:25.9816.0991 / 2.3749A-R10 1 EA CABLE ASSY, BALLAST HEATSINKTools &

80 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALReplacing Yoke FanParts:25.9816.0993 / 2.3749A-R01 1 EA CABLE ASSY, YOKE FANTools & Supplies:

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 81Step 3. At Head Controller PCB, disconnect Yoke Fan cable at position J16.Step 4. Cut cable tie w

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 1INTRODUCTIONAbout This ManualThis manual provides testing, troubleshooting, maintenance procedures

82 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALReplacing Pan/Tilt Driver PCBParts:24.9816.0765 / 2.3749A-P55 1 EA PCB ASSY, PAN/TILT DRIVERTools

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 83Step 5. At Pan/Tilt Driver PCB, disconnect all cables (Figure 3-51).Step 6. Remove Pan/Tilt Drive

84 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALReplacing Tilt COT SensorParts:25.9816.0981 / 2.3749A-P30 1 EA CABLE ASSY, TILT COT SENSORTools &

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 85Step 4. At Tilt-Side Yoke Leg, disconnect Tilt COT Sensor Cable from Pan/Tilt Driver PCB (Figure

86 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALStep 7. At Tilt COT Sensor PCB, remove two 4-40 x 1/4" PFSS screws which secure standoffs to

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 87Replacing Tilt Drive MechanismParts:21.9816.0719 / 2.3749A-P75 1 EA ASSY, TILT DRIVE MECHANISMToo

88 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALStep 5. Remove Yoke Cover Mounting Bracket by removing four 8-32 x 1/2" PFB screws.Step 6. A

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 89Replacing Pan Drive MechanismParts:21.9816.0718 / 2.3749A-P70 1 EA ASSY, PAN DRIVE MECHANISMTools

90 BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUALStep 4. At Pan/Tilt Driver PCB, disconnect pan drive cables.Step 5. Cut cable ties which secure c

BEST BOY 4000® SPOT LUMINAIRE FIELD SERVICE MANUAL 91Step 6. Remove Yoke Cover Mounting Bracket by removing four 8-32 x 1/2" PFB screws.Step 7. L