Lens issues – PRG Bad Boy Field Service Manual User Manual
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BAD BOY
®
SPOT LUMINAIRE FIELD SERVICE MANUAL
23
Lens Issues
Lenses fail to calibrate or lenses not operating correctly, and Zoom Sensors are good
Details: There are four (4) Zoom Sensors, one for each Lens Group 1, 2, 3, and 4. Group 4 is farthest from the lamp. Each
sensor contains an LED which is helpful in determining failures. After calibration, the status of each Lens Group will be
displayed on the Status screen by the color of its name abbreviation or "sub-code." These are:
+ Lens Group 1 - LN1
+ Lens Group 2 - LN2
+ Lens Group 3 - LN3
+ Lens Group 4 - LN4
WARNING: Before starting this test, it is highly recommended you remove all tools and body parts from the lens travel areas.
The moving lens groups will pinch fingers between several contact points in the assembly and can cause extreme discomfort.
The motors are fused to stop, but injury can occur.
Procedure: Before the Zoom calibration starts, all four of the LED’s on the sensors should be red. If any are not red, stop here
and change that sensor (
). When you get all four LED’s on red, start the calibration process. Once calibration starts,
each lens starting with Group 1 will travel toward its sensor one by one. There is a spring-loaded gold plated pin at the end of
a screw that will come into contact with each lens group’s sensor. The gold sensor pin has been precisely set for optimum
performance of that lens group. (Do not adjust any of the gold pins on any lens group for any reason. They are factory set.)
When the spring loaded gold tip of the screw touches the gold pad on the Zoom Sensor, the LED will turn green and the lens
group will stop moving. Immediately, Group 2 will duplicate the movement towards its sensor. If each lens group 1 through 4
sequentially locates its sensor and the red LED’s each turn green, then the Zoom Assembly is functioning properly. If any of
the four sensors does not change from red to green, the calibration process will stop, ensuring the lens groups do not collide.
In addition, all four lens sub-codes in the Status screen will turn red, indicating a failure to calibrate. The most common sensor
failures will be defined by an incorrect LED color when the gold pin touches the gold pad on the sensor. These would be a
failure to turn green from red, turning from red to yellow (both green and red) or the red LED turns off after contact with the
gold pin during the calibration procedure.
Solution: Ensure all Zoom Lens Sensor cables are properly seated.
Solution: Replace Zoom Controller 2A Fuse...
Solution: Replace Zoom Controller PCB...
Lenses fail to calibrate or lenses not operating correctly, and Zoom Controller PCB is good
Details: There are four (4) Zoom Sensors, one for each Lens Group 1, 2, 3, and 4. Group 4 is farthest from the lamp. During
Zoom calibration, a gold, spring-loaded screw will move with each lens group towards its EOT sensor. When the pin touches
the gold pad on the Zoom Sensor, the red LED on the sensor should turn green and the lens group will stop moving. This
repeats for the other three lens groups. The Zoom Controller PCB has four (4) motor drivers. There is a 2 Amp Timed (Slo-
Blow) Fuse to protect each of the four drivers. They provide power for both the motors.
Procedure: Check for blown fuses. Replace any blown fuses and recalibrate the fixture. If the LED on the Zoom Sensor stays
red, turns off, or changes to yellow, both red and green on, it has failed and needs to be replaced.
Solution: Replace Zoom Controller 2A Fuse...
Solution: Replace Zoom Sensor PCB...
A zoom lens motor appears to have no power during calibration or operation
Details: The Zoom Controller PCB has four (4) motor drivers. There is a 2 Amp Timed (Slo-Blow) Fuse to protect each of the
four drivers. They provide power for both the motors. The silkscreen on the Motherboard PCB has each mechanism identified
near the driver for each of the three Wheel Controller PCBs and the Zoom Controller.
Procedure: If during calibration or operation, you observe a mechanism servo motor or stepper motor that appears to have no
power, locate the the driver for that motor. Verify all cables are installed properly. With power off, visually inspect the driver for
damage. If the driver chip has visible damage, then replace the driver’s PCB. If not, carefully remove the fuse. Check for
continuity to determine if the fuse is open. If the fuse has blown, then inspect the mechanism for shorts or other problems.
Replace any blown fuses and recalibrate the fixture.