Barco FLM series Service Manual Download Page 14

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2. General info

Light processor side - Front side

Image 2-4

Reference

Description

IR receiver

Heat exc fan

Light processor assembly (light pro light pipe)

Anode fan

Start pulse generator

Cold mirror assembly

Cold mirror fan

Man pressure vessel

R59770072 FLM SERIES 19/03/2007

Summary of Contents for FLM series

Page 1: ...FLM series Service manual R59770072 00 19 03 2007...

Page 2: ...Barco nv Events Noordlaan 5 B 8520 Kuurne Phone 32 56 36 89 70 Fax 32 56 36 88 24 E mail sales events barco com Visit us at the web www barco com Printed in Belgium...

Page 3: ...3 6 3 Removal of the lamp cover 74 6 4 Removal of the input cover 75 6 5 Removal of the back cover 76 6 6 Removal of the top cover 77 6 7 Installation of the top cover 78 6 8 Installation of the back...

Page 4: ...heat exchanger assembly 182 17 3 Assembling the new heat exchanger 184 17 4 Mounting the heat exchanger assembly into the projector 186 18 Cooling pump 189 18 1 Maintaining the cooling pump 190 18 1 1...

Page 5: ...t on the DMD 279 25 3 Remove a Peltier element on the heat pipe cooling block 282 25 4 Mounting a Peltier element on the heat pipe cooling block 284 26 Power input 287 26 1 Getting access to the power...

Page 6: ...Table of contents 4 R59770072 FLM SERIES 19 03 2007...

Page 7: ...o prevent damage to the FLM projector Ensure that you understand and follow all safety guidelines safety instructions and warnings mentioned in this chapter before servicing the FLM projector After th...

Page 8: ...first in the on position and then in the off position measure from a known earth ground metal waterpipe conduit etc to all exposed metal parts of the instrument antennas handle bracket metal cabinet...

Page 9: ...ned by replacing them with components rated for higher voltage wattage etc Use of a substitute replacement that does not have the same safety charac teristics as the recommended replacement part in BA...

Page 10: ...1 Safety 8 R59770072 FLM SERIES 19 03 2007...

Page 11: ...2 General info 2 GENERAL INFO Overview Location of modules Spare part kits R59770072 FLM SERIES 19 03 2007 9...

Page 12: ...ide Lamp side or Input side Rear Image 2 1 Projector orientation Rear side and Lamp side B A C E D F Image 2 2 Reference Description A IR receiver B Lamp power supply unit LPS unit C Lamp unit D Catho...

Page 13: ...Lamp side G H I J K Image 2 3 Reference Description G Backplane H Signal distribution board I Motor control board J Switched mode power supply SMPS unit K Formatter interface board R59770072 FLM SERIE...

Page 14: ...Image 2 4 Reference Description L IR receiver M Heat exchanger fan N Light processor assembly light processor light pipe O Anode fan P Start pulse generator Q Cold mirror assembly R Cold mirror fan S...

Page 15: ...ication unit DVI HDSDI SDI 5 cable input included x R9854540 Lamp house 3 5 kW lamp included x R9854541 Lamp house refurbished 3 5 kW lamp included x R9854420 Lamp house 3 kW lamp included x x R985452...

Page 16: ...4K Switched mode power supply x x x R764869K Keypad unit x x x V322203K LCD panel 160x80 6H LED BL x x x B3722365K Mains switch 35A UL CSA x x x B3580251K Motor DC 12V D17 134 1 x x x B3580252K Motor...

Page 17: ...ich causing the warning as soon as possible otherwise the warning state may turn into an error state which will switch off the projector consequently The codes are placed in ascending order to make it...

Page 18: ...damaged Warning Never attempt to repair the lamp house Reinstall a new lamp house and send the damaged lamp house back to factory for repair Check if the blue socket ref B image 3 1 in the upper left...

Page 19: ...he Formatter Interface Board and the three formatter boards are not damaged A damaged wire unit can cause a short circuit in the local power supply of the Formatter Interface Board Check if none of th...

Page 20: ...hannel The projector fails to start Check if the data cables between the Formatter Interface Board FIB and the formatter board of the blue channel are plugged in properly Check if none of the wires ca...

Page 21: ...trl init failed Situation Solution The Formatter Interface Board failed to initialize The orange LED PWRGood lights up The green status LED FPGA DONE on the Formatter Interface Board remains off image...

Page 22: ...gged in properly Reboot the projector If the problem remains contact Barco for further instructions The formatter board of the involved channel is malfunctioning and has to be replaced at the factory...

Page 23: ...r is connected properly with the CTRL IN socket of the LPS module Check if the address wire unit ref A image 3 7 is plugged in between the LPS units Check if the wire unit ref H image 3 8 is plugged i...

Page 24: ...was switched off Let cool down the lamp for at least 3 minutes before switching the projector from standby to operating mode Lamp with many strikes maximum run time exceeded The Lamp Power Supply and...

Page 25: ...ctioning of one of the LPS units The red LED ERR of the malfunctioning LPS unit flashes fast Replace the LPS module Error 2201 PFC start failed This error is generated by the LPS unit with address 0x2...

Page 26: ...D s of the LPS module indicates a problem with the LPS module Note The ambient noise must be low to hear the SPG clicking in an attempt to ignite the lamp Check the cabling of the LPS module Replace t...

Page 27: ...ror 2802 LPS start failed The same troubleshooting checklist can be applied to as for Error 2202 The only difference is that this error is generated by the LPS unit with address 0x28 Error 2803 BOOST...

Page 28: ...projector Use only original Barco spare parts for servicing If the problem persists contact Barco for further instructions I2C related error One of the boards with an I2C address causes a hardware err...

Page 29: ...iled Situation Solution The controller was unable to initialize the FPGA of the Pixel Map Processor PMP Reboot the projector If the problem persists reinstall the PMP firmware using the Projector Tool...

Page 30: ...software If the problem persists contact Barco for further instructions Error 5097 Flash management full Situation Solution The reserved memory for flash management has reached its limits Check if th...

Page 31: ...Board the error code is changed to 7659 Engine air temp open Repair the insulation of the wire unit using shrink sleeve If not repairable replace the whole wire unit and temperature sensor Defect tem...

Page 32: ...ef E image 3 10 causing an open circuit Repair the wire unit If not repairable replace the hole wire unit and temperature sensor Defect temperature sensor ref E image 3 10 of the light processor Repla...

Page 33: ...ock blue channel Error 7663 Blue block temp open This error may be preceded by a warning This error can only appear on the FLM HD series Situation Solution Wire unit ref B BL image 3 11 of the tempera...

Page 34: ...d and expel all air Pressurize the circuit See FLM liquid cooling circuit page 153 Malfunction pump of the water cooling circuit You don t feel any vibrations when touching the pump after activating t...

Page 35: ...ing This error can only appear on the FLM HD series Situation Solution Wire unit ref G BL image 3 11 of the temperature sensor is disconnected from the Formatter Interface Board FIB Plug in the wire u...

Page 36: ...eplace the pump if infinite See Cooling pump replacement page 197 Drain the liquid cooling circuit open the pump and check if the pump is not blocked If so remove the rotor ref R image 3 13 and clean...

Page 37: ...cessor is mistakenly excluded from the main liquid cooling circuit Reconnect the cooling circuit of the light processor with the pump and heat exchanger Water cooling pump electrical disconnected Chec...

Page 38: ...light processor H Image 3 16 Error 7675 Front block temp open This error may be preceded by a warning This error can only appear on the FLM HD series Situation Solution Wire unit of the temperature s...

Page 39: ...Replace the pump if infinite See Cooling pump replacement page 197 Drain the liquid cooling circuit open the pump and check if the pump is not blocked If so remove the rotor ref R image 3 13 and clea...

Page 40: ...the malfunction light processor Defect temperature sensor which measures the temperature at the front of the DMD of the blue channel Replace the light processor Contact Barco for further instructions...

Page 41: ...e temperature sensor from the Formatter Interface Board FIB the error code is changed to 7689 Green front DMD temp open Repair the insulation of the wire unit using shrink sleeve If not repairable rep...

Page 42: ...ltier element mounted on the common cooling block of the heat pipes are mistakenly switched Check if all wire units of the TEC s are plugged into their respective sockets on the Formatter Interface Bo...

Page 43: ...mperature sensor which measures the temperature at the front of the DMD of the red channel Replace the light processor Contact Barco for further instructions to repair the malfunction light processor...

Page 44: ...nd temperature sensor Defect temperature sensor which measures the temperature of the cooling block at the light pipe entrance Replace the temperature sensor L Image 3 19 L Temperature sensor on light...

Page 45: ...unit ref Cimage 3 13 of the pump is properly connected Blocked high density filter of the heat exchanger Replace the blocked high density filter with a new one See chapter Dust filters page 85 No or...

Page 46: ...to the ceiling Blocked front filter Replace the high density filter at the front side of the projector with a new one Malfunction SMPS module Replace the SMPS module Error 7931 PFC HS high temp This e...

Page 47: ...s Note to exit the Refill mode you have to switch off the projector Clean the bearings of the cooling pump See chapter Maintaining the cooling pump page 190 Replace the cooling pump See procedure Cool...

Page 48: ...ow This is a warning Situation Solution The 5 volt supply voltage for the Pixel Map Processor is too low Replace the Fan Motor control board Error 7942 5V FIB voltage high This is a warning Situation...

Page 49: ...supply voltage VMTR for the motors is too low Replace the Fan Motor control board Error 7954 VTEC voltage high This is a warning Situation Solution The supply voltage for the thermoelectric cooling Pe...

Page 50: ...density filter of the projector is too high Replace the Fan Motor control board Error 7963 Fan 6 voltage low This error may be preceded by a warning Situation Solution The supply voltage for the SMPS...

Page 51: ...e the Fan Motor control board Error 7969 Fan 3 voltage low This error may be preceded by a warning Situation Solution The supply voltage for the fan of the light processor is too low Replace the Fan M...

Page 52: ...cuit of the SMPS unit is too high This error may be preceded by a warning Situation Solution Ambient temperature too high Check the ambient temperature Make sure that the ambient temperature does not...

Page 53: ...Malfunction TEC of the involved DMD Use the diode test of a multi meter to check out the TEC Polarity doesn t matter The TEC is not OK in case the measured value is higher then 0 01 volt Remove the l...

Page 54: ...his error may be preceded by a warning Situation Solution Blocked high density filter of the heat exchanger The other DMD temperatures are too high as well Replace the blocked high density filter of t...

Page 55: ...ire unit Check if the wire unit of the fan is not damaged Repair if possible otherwise replace with new one Fan end of life Replace the fan See SMPS fans page 270 Error 7989 Fan speed smps 1 too low T...

Page 56: ...e the fan See Light processor compartment fan page 244 Error 7997 Fan speed anode too low This error may be preceded by a warning Situation Solution Disconnected wire unit Reconnect the wire unit of t...

Page 57: ...utter assembly Replace the shutter assembly See Shutter replacement page 203 SH Image 3 23 Error 8001 Closing shutter failed This is a warning Situation Solution Disconnected wire unit of the shutter...

Page 58: ...PROM error Error 8002 Lamp EEPROM This is a warning Situation Solution The projector is unable to read out the lamp EEPROM during the start up of the projector Place a new lamp house in the projector...

Page 59: ...ituation Solution The initialization of the scaler on the Pixel Map Processor PMP failed Try to reinstall the latest software version of the PMP and restart the projector Replace the Pixel Map Process...

Page 60: ...ror Error 10498 Unsupported module Situation Solution Input slot contains an input module which is not supported by the projector due to obsolete firmware Replace the unsupported input module with a s...

Page 61: ...es an overview of the different lenses lens formulas and the procedure how to install a new lens Overview Available lenses Lens selection Lens formulas for FLM R20 Lens formulas for FLM HD projectors...

Page 62: ...oximately 20 less light output compared to the TLD HB lenses but 25 more contrast Image 4 1 R9840900 TLD fixed lens 0 8 1 R9842040 TLD HB fixed lens 0 8 1 Image 4 2 R9840770 TLD fixed lens 1 2 1 Image...

Page 63: ...the projector screen distance PD 3 Use the lens formulas to find the best corresponding PD with regard to the measured projector screen distance for the required screen width SW Tip Divide PD by SW t...

Page 64: ...5 12 TLD 2 0 2 8 1 TLD HB 2 0 2 8 1 1 82 2 55 PDmin 1 85 x SW 0 17 PDmax 2 62 x SW 0 24 PDmin 1 85 x SW 6 69 PDmax 2 62 x SW 9 45 TLD 2 8 5 0 1 TLD HB 2 8 5 0 1 2 55 4 55 PDmin 2 58 x SW 0 16 PDmax 4...

Page 65: ...1 6 2 0 1 1 35 1 70 PDmin 1 36 x SW 0 09 PDmax 1 71 x SW 0 13 PDmin 1 36 x SW 3 54 PDmax 1 71 x SW 5 12 TLD 2 0 2 8 1 TLD HB 2 0 2 8 1 1 70 2 42 PDmin 1 71 x SW 0 17 PDmax 242 x SW 0 24 PDmin 1 71 x...

Page 66: ...e lens holder stands in the On Axis position horizontal and vertical mid position Note The lens holder is placed default in the On Axis position at factory 5 Gently insert the lens in such a way that...

Page 67: ...rying to pull the lens out of the lens holder CAUTION Never transport the projector with a lens mounted in the lens holder Always remove the lens before transporting the projector Neglecting this can...

Page 68: ...lens out of the lens holder Image 4 13 It s recommended to place the lens caps of the original lens packaging back on both sides of the removed lens to protect the lens It s recommended to place the f...

Page 69: ...mounting parts are required to mount the FLM carrying handle on top of the FLM projector S F W Image 5 2 S Spacer x3 F Hexagon socket head bolt M10 x 30 x3 W Washer x3 Order info Order No Description...

Page 70: ...ector upside down 2 Remove the bottom carrying handle by releasing the four hexagon socket head screws H H W Image 5 3 3 Install the new carrying handle as illustrated Reuse the four hexagon socket he...

Page 71: ...jector 1 Remove all three eyebolts on top of the projector Image 5 5 2 Remove the plastic cap C at the front of the projector top cover C Image 5 6 3 Mount four spacers S on top of the projector as il...

Page 72: ...rying handle F W Image 5 8 Note The hexagon bolts which fasten the bottom carrying handle are longer then the hexagon bolts M10 x 30 which fasten the top carrying handle 70 R59770072 FLM SERIES 19 03...

Page 73: ...p actions and illustrations how to remove or install the projector covers Note that some covers may only be removed by qualified service personnel see remarks above each procedure WARNING Always switc...

Page 74: ...lens holder See image 6 1 3 Release the captive screw at the middle bottom of the front cover using a flat screw driver Image 6 1 4 Remove the front cover from the projector doing the following a sta...

Page 75: ...s or similar Necessary tools 7 mm flat screw driver How to remove the side cover of the projector 1 Release the captive screw at the middle bottom of the side cover using a flat screw driver Image 6 3...

Page 76: ...over of the projector 1 Release the two captive screws at the top and bottom right side of the lamp cover using a flat screw driver Image 6 5 2 Remove the lamp cover from the projector doing the follo...

Page 77: ...er of the projector 1 Release the two captive screws at the top and bottom left side of the input cover using a flat screw driver Image 6 7 2 Remove the input cover from the projector doing the follow...

Page 78: ...flat screwdriver How to remove the back cover from the projector 1 Release the two captive screws at the bottom corners of the back cover using a flat screw driver Image 6 9 2 Remove the back cover of...

Page 79: ...he top cover first all side covers must be removed How to remove the top cover from the projector 1 Turn out the 3 eye bolt A A A A B Image 6 11 Top cover removal 2 Remove the front interlocking adapt...

Page 80: ...the top cover 1 Place the cover on the projector so that the holes matches the fixation holes in the frame B B B A Image 6 12 Mount top cover 2 Push the interlocking adapter A on its place turn in th...

Page 81: ...the LPS module is correctly installed 2 Install the back cover of the projector doing the following a Bring the back cover towards it final position b then gently push the locking studs of the top co...

Page 82: ...f the projector doing the following a first hook in the side of the front cover at the front filter b then gently push the other side of the front cover into position c ensure that the locking studs i...

Page 83: ...essure is out of range inform the responsible and qualified technician so he may take necessary corrective action 1 0 5 Image 6 17 3 Install the side cover of the projector doing the following a Bring...

Page 84: ...the projector doing the following a Bring the lamp cover towards its final position A b then gently push the locking stud at the left top corner B into its receiver c then gently push the locking stud...

Page 85: ...r of the projector doing the following a Bring the input cover towards its final position A b then gently push the locking stud at the right top corner B into its receiver c then gently push the locki...

Page 86: ...6 Removal and installation of projector covers 84 R59770072 FLM SERIES 19 03 2007...

Page 87: ...d under the heat exchanger C Top high density filter located above the cold mirror CAUTION All HEPA filters of the FLM projector must be replaced on a regular basis depending on the envi ronment condi...

Page 88: ...Remove the HEPA dust filter on the front side by pulling the two spring clamps away from the filter and then moving the filter forwards 2 1 Image 7 2 3 Insert a new HEPA1 filter by pulling the two spr...

Page 89: ...g a 2 5 mm Allen key as illustrated A A Image 7 3 3 Remove the filter F on the bottom side by pulling out the filter holder H as illustrated F H H Image 7 4 4 Place a new HEPA dust filter in the filte...

Page 90: ...moval of the side cover page 73 2 Remove the filter F on the bottom side by pulling out the filter holder H as illustrated F H Image 7 6 3 Place a new HEPA dust filter in the filter holder 4 Reinstall...

Page 91: ...s high internal pressure the lamp may explode in either hot or cold states if improperly handled Available kits For FLM R20 Performer and FLM HD14 Order info Description R9854420 FLM lamp house 3kW la...

Page 92: ...7 mm flat screw driver How to remove the lamp house of the projector 1 Switch off the projector and unplug the power cord at the projector side 2 Remove the lamp cover see Removal of the lamp cover pa...

Page 93: ...ector is switched off and the power cord at the projector side is unplugged 2 Remove the lamp cover if not removed yet See Removal of the lamp cover page 74 3 Clasp the lamp house by its handles and g...

Page 94: ...Lamp and lamp house While starting up the projector the electronics detect if a lamp is installed If no lamp is installed it is not possible to start up the projector 92 R59770072 FLM SERIES 19 03 200...

Page 95: ...Removal of the lamp cover page 74 2 Connect the projector to the local power net start up the projector enter the menu structure and select Lamp Z axis for more explanation consult the owner s manual...

Page 96: ...8 Lamp and lamp house 94 R59770072 FLM SERIES 19 03 2007...

Page 97: ...VI input module 5 HDSDI SDI input module 6 Communication unit 7 Pixel Map Processor PMP Order info Order number Description R848591K Input communication unit for FLM R20 R9854430 5 Cable input module...

Page 98: ...tion unit from the projector 1 Ensure that no cables are connected to one of the ports of the input communication unit 2 Remove the input cover see Removal of the input cover page 75 3 Release the fou...

Page 99: ...rojector side is unplugged 2 Hold the input communication unit by its handles and gently slide the unit into the guides at the bottom of the input commu nication socket inside the projector Image 9 4...

Page 100: ...ug the power cord at the projector side 2 Release the two captive screws of the input module using a Phillips screw driver PH1 Image 9 6 3 Pull the input module out of the input communication unit via...

Page 101: ...h off the projector and unplug the power cord at the projector side 2 Slide the input module into the guides of the input slot G Image 9 8 3 Push the input module forward until you feel that the conne...

Page 102: ...9 Input communication unit 100 R59770072 FLM SERIES 19 03 2007...

Page 103: ...the lens onto the screen The Formatting Interface Board FIB which is the interface between the Pixel Mapping Processor PMP and the Formatting boards of the DMD s The light pipe which transforms the li...

Page 104: ...the projected image These artifacts are also visible on the internal service patterns of the FIB or Formatter boards A crack in the prism which can result in convergence problems and may disables you...

Page 105: ...the light processor Necessary tools 5 mm flat screw driver 10 mm nut driver How to remove the light processor of the projector 1 Remove the lens 2 Release the two captive screws at the bottom of the...

Page 106: ...ht processor and the other valved fitting is located in the tube coming from the light pipe entrance and leading to the heat exchanger Tip Sometimes a little cooling liquid will be spilled Wrap a smal...

Page 107: ...10 Light processor light pipe assembly Image 10 5 6 Place the light processor which includes the FIB on a stable table R59770072 FLM SERIES 19 03 2007 105...

Page 108: ...the light processor by the handles and gently slide the light processor into the compartment of the projector Note The bottom of the light processor is equipped with guides G and positioning pins P G...

Page 109: ...ntly on each block Image 10 8 4 Couple up the cooling circuit from the light processor with the cooling circuit of the projector Caution To avoid damage to the connector seal always depress the connec...

Page 110: ...ometer of the liquid cooling circuit FLM liquid cooling circuit page 153 Barco provides a liquid cooling refill kit for the FLM projector See FLM liquid cooling circuit page 153 for further instructio...

Page 111: ...g light into a homogeneous rectangle shaped beam of light Image 11 1 The entrance and exit side of the integration rod are coated to achieve optimal performance Clearly the rod may never be contam ina...

Page 112: ...11 Integration rod Overview Rod diagnostic Removal of the integration rod assembly Installing a new integration rod assembly Adjusting the integration rod 110 R59770072 FLM SERIES 19 03 2007...

Page 113: ...ion rod of the FLM projector 1 Remove the side cover of the projector See users manual of the projector to do so Caution Remove the side cover of the projector only in a clean and dust free area Never...

Page 114: ...rod from the light pipe 1 Remove the cooling block at the light pipe entrance by releasing the two socket head screws as illustrated Use a 2 5 mm Allen key Note Note that the screws which fasten the c...

Page 115: ...dust particles present on the exit side of the integration rod assembly If necessary remove the dust with compressed air Note The exit side of the rod is much more critical than the entrance side of...

Page 116: ...key Caution Ensure that the mask M is placed in portrait like the entrance of the integration rod Ensure that the shining side of the mask M is facing the lamp W S M Image 11 11 The integration rod m...

Page 117: ...ct Lamp Power Dimming 0 c Select Alignment Contrast enhancement High contrast d Select Alignment Internal patterns Full white screen e Make sure that you have a 2 mm Allen key within reach for the nex...

Page 118: ...e the integration rod and try to blow away the dust If this doesn t help replace the integration rod D Image 11 16 10 Fasten the two set screws A which you released in step 8 and reinstall the project...

Page 119: ...h the same round type kit R849250K Squared frame with a round UV glass This type must be replace with the squared type kit R8492501K Squared frame with a squared UV glass This type must be replace wit...

Page 120: ...Image 12 3 UV filter replacement 3 Take out the UV glass from its holder 4 Place a new UV glass in the holder with the black mark at one of the borders towards the cold mirror Note Do not touch the gl...

Page 121: ...isible light and absorbs the infra red light Due to this absorbing a lot of heat is produced The fan above the cold mirror blows cold air on the heat sink so that the hot air is transported to the out...

Page 122: ...it is removed the cold mirror becomes visible at the end of the lamp compartment Possible damages Cold mirror is broken replace with new one Coating peels off replace with new one Cold mirror is dirty...

Page 123: ...ols Allen key 3 mm Flat screwdriver 7 mm How to remove the cold mirror assembly 1 Remove the lamp door and the opposite side cover 2 Remove the lamp house 3 At the opposite side of the lamp turn out t...

Page 124: ...ctor a little backwards 1 1 2 2 3 3 Image 13 4 Cold mirror assembly removal 6 On the same plate turn out both indicated screws 2 7 At the left side of the cold mirror assembly turn out both indicated...

Page 125: ...13 Cold mirror assembly Image 13 5 Remove of cold mirror R59770072 FLM SERIES 19 03 2007 123...

Page 126: ...al service personnel Necessary tools Allen key 3 mm Flat screwdriver 7 mm How to mount 1 Insert the assembly in the projector and make the electrical connection of the fan Image 13 6 Insert assembly e...

Page 127: ...turn in both indicated screws 2 4 Place the connector on its place Turn in the upper screws 3 5 Push the lower screws 4 first through the eye of the ground wire and then turn it in 6 Insert the cover...

Page 128: ...13 Cold mirror assembly Image 13 8 Mount cover plate 7 Reinsert the lamp house and close the lamp door 126 R59770072 FLM SERIES 19 03 2007...

Page 129: ...you adjust in the correct direction Repeat step 3 in the same direction as many times as necessary until the new maximum is lower then the previous one Then go to step 5 If no you adjust in the wrong...

Page 130: ...13 Cold mirror assembly 8 Reinstall the side cover 128 R59770072 FLM SERIES 19 03 2007...

Page 131: ...at the motors required for horizontal and vertical shift are built in Parts F G H H A D E D E A D A B C Image 14 1 A Lock screws of the focus adjustment plate B Screws with retaining springs for press...

Page 132: ...lens holder 1 Remove the plastic cable ties from the wire three and disconnect all the wire units from the lens holder Image 14 2 2 Disconnect the two EMC wire units A at the top of the lens holder a...

Page 133: ...14 Lens holder F Image 14 4 R59770072 FLM SERIES 19 03 2007 131...

Page 134: ...age 14 5 2 Install the lens holder and secure with 8 hexagon socket screws F as illustrated Use a 3 mm Allen key Note Ensure that the positioning pins of the lens holder matches the positioning holes...

Page 135: ...lustrated Use a 5 5 mm nut driver Caution Make sure that the switch remains in the correct position N N Image 14 9 6 Reinstall the front plate which you removed in step 3 Use a 3 mm Allen key the fast...

Page 136: ...14 Lens holder Image 14 10 The lens holder has to be adjusted after installation 134 R59770072 FLM SERIES 19 03 2007...

Page 137: ...all three adjustment points have to be alternately and repeatedly adjusted until the projected image is completely focused on the screen Scheimpflug principle The plane of sharp focus can be changed...

Page 138: ...ont plate b The two screws of the lens holder tilt mechanism c The two screws of the lens holder swing mechanism Image 14 13 2 Rotate the focus shift plate of the lens holder until the centre F of the...

Page 139: ...e adjustment screw in the opposite direction and check again Note A simultaneous readjustment of the focus shift plate will be necessary to get the mid top and mid bottom of the projected pattern equa...

Page 140: ...14 Lens holder 138 R59770072 FLM SERIES 19 03 2007...

Page 141: ...side the lens holder Image 15 1 Order information Order number Description B3580251K Motor DC 12V D17 134 1 for vertical shift FLM B3580252K Motor DC 12V D17 134 1 for horizontal shift FLM Overview Re...

Page 142: ...page 130 for more explanation on how to build out Necessary tools Allen key 3 mm Allen key 2 5 mm Allen key 2 mm Allen key 1 5 mm How to build out 1 Remove the 4 screws a and take off cover b a a a a...

Page 143: ...5 Disassemble everything mounted on the axe components B to F 6 Turn out both screws G 7 Turn out the axe fixation screw H 8 Slide out the axe I 9 Take out the motor unit Turn out both screws on the...

Page 144: ...15 Vertical and Horizontal shift motors Image 15 4 Removing motor Image 15 5 Motor assembly 142 R59770072 FLM SERIES 19 03 2007...

Page 145: ...he small plate with 2 screws on the motor Fold the wires in the same direction of the rounded side of the plate Image 15 6 2 Insert the motor in its compartment with the rounded side of the mounted pl...

Page 146: ...er Continue with the connection piece E and finally turn again a squared nut F on the axe Fasten both squared nuts so that there is no play anymore but so that when pulling or pushing on the connectio...

Page 147: ...ake sure that both block on the axe are parallel with each other 8 Guide all cables in the groove place the cover plate d on its place and turn in the 4 screws Insert the lens holder in the projector...

Page 148: ...t see Removing the lens holder page 130 for more explanation on how to build out Necessary tools Allen key 3 mm Allen key 2 5 mm Allen key 2 mm Allen key 1 5 mm How to remove 1 Remove the 4 screws a a...

Page 149: ...the motor axe as follow Remove first square nut A Slide off the interconnection piece B Slide off both washers C and D Remove the second square nut E A B C D E F G H Image 15 12 Disassemble the motor...

Page 150: ...15 Vertical and Horizontal shift motors Image 15 13 Remove motor Image 15 14 148 R59770072 FLM SERIES 19 03 2007...

Page 151: ...Fixate the small plate with 2 screws on the motor Fold the wires in the same direction of the rounded side of the plate Image 15 15 2 Insert the motor in its compartment with the rounded side of the m...

Page 152: ...both squared nuts so that there is no play anymore but so that when pulling or pushing on the connection piece it still can move up or down 5 Pivot the assembly back on its place Make sure that connec...

Page 153: ...shift motors Image 15 19 Cover plate Insert the lens holder in the projector see Installing the lens holder page 132 for a detailed description Then reinstall all covers and insert the lens R59770072...

Page 154: ...15 Vertical and Horizontal shift motors 152 R59770072 FLM SERIES 19 03 2007...

Page 155: ...lved fitting B Two plastic tubes of 60 cm with male valved fitting C 60 cm plastic tube with female valved fitting D Female valved fitting to create female female valved fitting adaptor E Bottle with...

Page 156: ...iquid cooling circuit CAUTION To avoid damage to the connector seal always depress the connector tab of the female valved fitting prior to inserting the male valved fitting 154 R59770072 FLM SERIES 19...

Page 157: ...Avoid inhale of the noxious fumes Handling the cooling liquid Avoid contact of the liquid with Eyes Skin and Clothing Avoid inhaling of the noxious fumes Conserve the product in the original package...

Page 158: ...a small pressure on the cooling liquid The required pressure exerted via the pressure vessel serves to prevent cavitation and hence ensures the good working condition of the pump Note that the pressu...

Page 159: ...emperature is below 40 C Blocked high density filter at the front side of the projector Replace the blocked high density filter at the front side of the projector with a new high density filter One of...

Page 160: ...e pump is sucking air and sounds noisier then normal Fill the cooling circuit with liquid and expel all air Pressurize the circuit Defect pump You don t feel any vibrations when touching the pump afte...

Page 161: ...age 73 2 Check the pressure indicated on the internal manometer of the liquid cooling circuit 1 0 5 Image 16 3 3 This pressure should be between 0 5 and 1 bar If the pressure indicated on the manomete...

Page 162: ...d fitting Empty bottle with a volume of 1 liter Cloths How to drain the liquid cooling circuit 1 Interrupt the liquid cooling circuit by uncoupling the valved fitting at the heat exchanger Tip Sometim...

Page 163: ...e syringe with air Press in the valve of the male fitting when extracting air Image 16 7 4 Couple the air filled syringe to the inlet of the cooling circuit and force air into the circuit via the syri...

Page 164: ...ning complete cooling circuit OUT IN Image 16 9 Draining cooling circuit excluding light processor circuit 5 Disconnect the syringe from the cooling circuit and repeat from step 3 until all cooling li...

Page 165: ...ith a volume of 1 liter Cloths How to fill the liquid cooling circuit 1 Interrupt the liquid cooling circuit by uncoupling the valved fitting at the heat exchanger Tip Sometimes a little cooling liqui...

Page 166: ...ling out the piston c Turn the syringe upside down so that the air inside the syringe is located at the outlet d Push the piston in until all air bubbles inside the syringe and tubes are expelled Ensu...

Page 167: ...led syringe to the inlet of the cooling circuit and press the cooling liquid inside the circuit Caution Position the empty bottle above the liquid circuit on top of projector IN OUT a b Image 16 14 Fi...

Page 168: ...16 15 Filling part of cooling liquid circuit light processor excluded 5 Disconnect the syringe from the cooling circuit and repeat from step 3 until cooling liquid comes out the exit side of the cooli...

Page 169: ...h sides Bottle with 1 liter cooling liquid Empty bottle with a volume of one liter Cloths How to refresh the liquid cooling circuit 1 Interrupt the liquid cooling circuit by uncoupling the valved fitt...

Page 170: ...by pulling out the piston d Disconnect the filled tube from the syringe Make sure that the tube remains immersed b a c d M F F M Image 16 18 Caution It s important that there is no air inside the tube...

Page 171: ...bottle with fresh cooling liquid Image 16 20 Image 16 21 Image 16 22 6 Switch off the projector after 2 3 of the fresh cooling liquid is sucked up into the circuit 7 Proceed with expelling the air fr...

Page 172: ...fitting to the male M fitting of the syringe using a female female F tube adapter b Emerge the tube end and make sure that the piston of the syringe is completely pressed in c Extract cooling liquid...

Page 173: ...at you don t inject air bubbles Caution Make sure that air bubbles coming out of the tube in the bottle doesn t enter the other tube in the bottle Image 16 26 Image 16 27 Image 16 28 6 Switch off the...

Page 174: ...it 1 Interrupt the liquid cooling circuit by uncoupling the valved fitting at the heat exchanger if not yet done Tip Sometimes a little cooling liquid will be spilled Wrap a small cloth around the val...

Page 175: ...inge but make sure that the tube of the syringe remains filled with cooling liquid b Couple the syringe plunger completely pressed in with the inlet of the cooling circuit Keep holding the syringe ver...

Page 176: ...16 FLM liquid cooling circuit Check within 24 hours whether the pressure has stabilized close to 1 bar If not search for leakage 174 R59770072 FLM SERIES 19 03 2007...

Page 177: ...pelling air from the vessel Secondly a predefined volume of cooling liquid is extracted from the circuit Finally the liquid cooling circuit has to be pressurized to 1 bar by pumping air into the vesse...

Page 178: ...tside the syringe and tube before disconnecting a b c d e f M F Image 16 34 4 Fill the pressure vessel with liquid as follows a Couple the syringe with the inlet of the cooling circuit Keep holding th...

Page 179: ...f Disconnect the syringe from the cooling circuit IN 75 ml Image 16 36 7 Close up the liquid cooling circuit which you interrupted in step 2 8 Pump up the air pressure to 1 bar and reinstall the valv...

Page 180: ...16 FLM liquid cooling circuit 178 R59770072 FLM SERIES 19 03 2007...

Page 181: ...ts inside the projector is extracted to the ambient in the heat exchanger Image 17 1 Order info Order number Description B4009232K Heat exchanger assembly for FLM projector Overview Removing the defec...

Page 182: ...uit from the complete circuit Press on the connector tab 1 and pull out the male valved fitting 2 Tip Sometimes a little cooling liquid will be spilled Wrap a small cloth around the valved fitting whi...

Page 183: ...the light processor circuit Note The procedure for draining is described in the service manual and in the installation manual included in the kit of the heat exchanger 6 Pull out the complete assembl...

Page 184: ...plier Push both clip tongs to each other in order to open the clip and move the clip away from the hose when releasing the both clip tongs it camps again 1 2 3 4 Image 17 6 Image 17 7 2 Pull off both...

Page 185: ...B Image 17 8 Disassembling heat exchanger A Dust filter assembly B Heat exchanger fan assembly 4 Loosen on both sides the nuts holding the dust filter assembly to the heat exchanger R59770072 FLM SER...

Page 186: ...embly on the dust filter assembly and secure by fastening the four nuts 2 on each side 3 Push the tube valved fitting 1 through the hole in the plate on the input of the heat exchanger 2 1 4 3 Image 1...

Page 187: ...4 Push both clip tongs together and slide the clip on the hose Release the tongs and it clamps automatically Take care not to bend the soft copper tubes of the heat exchanger while sliding the hoses o...

Page 188: ...ow to mount heat exchanger assembly into the projector 1 Slide the heat exchanger assembly into the projector Make sure the guides match the grooves of the assembly Image 17 11 2 Fasten both screws 3...

Page 189: ...damage to the connector seal always depress the connector tab of the female valved fitting prior to inserting the male valved fitting After installation of the heat exchanger you have to refill the c...

Page 190: ...17 Heat exchanger 188 R59770072 FLM SERIES 19 03 2007...

Page 191: ...be drained and refilled again when a new pump is installed the tools available in the refill kit syringe bottle with cooling liquid empty bottle air pump are necessary to execute this job If you have...

Page 192: ...ppen Due to crystallization inside the pump the rotor can be jammed This crystallization can be easily remove and the pump can be reused again First always drain the pump cooling circuit before starti...

Page 193: ...n the cooling pump 1 After the pump cooling circuit is drained remove the 4 screws on the pump body Image 18 2 Remove pump cover 2 Slide the pump cover with hose backwards 3 Take the rotor between thu...

Page 194: ...ow to clean the pump 1 Slide out the rotor 2 Clean both side of the rotor with a cloth Image 18 3 Image 18 4 3 Clean with a soft cloth or with a cotton swab inside the pump body 4 Reinsert the rotor a...

Page 195: ...the 4 screws Tip To optimize the sealing and to save the sealing ring turn in the screws crosswise How to fill the circuit and expel the air To fill the cooling circuit see Filling the liquid cooling...

Page 196: ...st by draining the cooling circuit and without cutting hoses Order info Order number Description Quantity B4009521DK Cooling pump 1 Note you have to order a complete cooling pump but you only have to...

Page 197: ...lips head screwdriver Cloths How to remove the body 1 Disconnect the pump electrically Image 18 6 Electrical disconnection 2 Remove the 4 screws on the pump body and slide the pump cover with hoses ba...

Page 198: ...dy Make sure the sealing ring is not damaged and is on its place 4 Turn in the 4 screws Tip To optimize the sealing and to save the sealing ring turn in the screws crosswise 5 Reinstall the connection...

Page 199: ...ment About this chapter This part describes how to replace the complete cooling pump Order info Order number Description Quantity B4009521DK Cooling pump 1 Overview Removing the pump Mounting the new...

Page 200: ...key 3 mm Universal plier How to remove the pump 1 Disconnect the pump electrically Image 18 8 Electrical disconnection 2 Cut both hoses 1 2 just next to the clip Remove both clips with a universal pl...

Page 201: ...age 18 10 Note It is almost impossible to remove first the clip and then to pull off the hose 3 Turn out both bolts 3 securing the pump to the seating of the pump 4 Take out the pump R59770072 FLM SER...

Page 202: ...Place the pump on its seating A 1 4 2 3 5 6 7 1 1 A B C Image 18 11 Pump mounting 2 Secure by turning both bolts 3 Mounting the hose coming from the light processor First slide a clip over the hose en...

Page 203: ...ver the connection and tighten the clip C7 9 Connect the connector of the pump wire with the power connect Note If the connector of the new cooling pump has 3 wires instead of 2 connect first the adap...

Page 204: ...18 Cooling pump 202 R59770072 FLM SERIES 19 03 2007...

Page 205: ...ribes how to replace the shutter Functionality A shutter is used to shut out the light when the projector is switched to pause or to standby Image 19 1 Order info Order number Description R849151K FLM...

Page 206: ...out of its compartment first Necessary tools 2 5 mm Allen key How to replace the shutter 1 Disconnect the shutter Image 19 2 Shutter connection 2 Turn out both indicated screws securing the shutter f...

Page 207: ...he shutter assembly 4 Place the new shutter on its place so that the fixation holes match the holes in the light assembly Image 19 4 Mounting shutter 5 Turn in both screws 6 Reinstall the connection R...

Page 208: ...19 Shutter replacement 206 R59770072 FLM SERIES 19 03 2007...

Page 209: ...9 C218 R501 R608 C600 R810 R20 R1 C317 D661 C627 C323 R942 C216 R811 M200 R200 C640 M640 C513 C961 R502 R944 J701 R602 R932 C607 R710 Q900 C903 R510 R903 SH6 D963 R626 D901 C904 781882 1 C313 M804 C82...

Page 210: ...d 1 Remove the indicated screws 9x securing the cover plate of the FIB box 3x 3x Image 20 2 Screws indication 2 Turn out the 2 times 3 screws securing the ground cable of each data cable 3 Take off bo...

Page 211: ...61 R502 R944 J701 R602 R932 C607 R710 Q900 C903 R510 R903 SH6 D963 R626 D901 C904 781882 1 C313 M804 C827 R662 C422 C511 D660 Q620 D623 R724 R906 SH5 R303 C310 R723 R3 C6 C620 C4 C624 C202 I930 J290 I...

Page 212: ...20 Formatter Interface Board 210 R59770072 FLM SERIES 19 03 2007...

Page 213: ...C812 C535 R414 I102 R410 C518 C179 R406 C577 C424 Q901 R522 C202 M134 C265 X400 C101 C138 C358 C340 C526 C552 R504 C339 C338 MH9 R155 C868 C190 R415 M18 R529 M111 C426 R868 R127 R976 R539 R292 C861 C...

Page 214: ...P board Red During start up LED 0 and LED 1 are red When the FPGAs on the PMP are correctly configured LED 0 turns off after a few seconds If it remains red FPGAs on PMP are not correctly configured R...

Page 215: ...ench 6 mm Torx screwdriver Tx10 Philips screwdriver How to build out 1 Remove all input units A and the communication unit B Use a Philips screwdriver to loosen all screws A B Image 21 3 Input communi...

Page 216: ...ocessor board Image 21 5 Fixation pin removal 4 Pull out the PMP assembly Image 21 6 Assembly removal 5 Disconnect the plug and turn out the 13 indicated screws Take off the board 214 R59770072 FLM SE...

Page 217: ...21 Pixel map processor board Image 21 7 PMP removal R59770072 FLM SERIES 19 03 2007 215...

Page 218: ...ew PMP board on the support plate and turn in the 13 screws Image 21 8 Mount PMP 2 Plug in the connector 3 Turn the assembly with the board towards the inputs and slide the assembly on its place Image...

Page 219: ...he assembly in the cabinet by turning in the indicated screws 6 Reinsert the communication unit and all inputs and secure with the fixation screws Reinstall the Communication input unit and close the...

Page 220: ...21 Pixel map processor board 218 R59770072 FLM SERIES 19 03 2007...

Page 221: ...same menus as the on screen menus even when the lamp is not ignited A second function is to display error and warning codes which can be used by the operator when calling for a service intervention or...

Page 222: ...remove the panel 1 Remove all input modules A and the communication module B A B Image 22 2 Input and communication modules removal 2 Lay down the module on its handles and remove the 4 screws a Remov...

Page 223: ...age 22 4 Disconnect PMP 4 Remove the 4 screws of the LCD cover plate and take off this plate Image 22 5 Remove LCD cover 5 Disconnect the flat cable between the LCD panel and the keypad unit R59770072...

Page 224: ...2 LCD panel replacement Image 22 6 Connection LCD keypad 6 Remove the 4 fixation screws of the LCD panel Image 22 7 Remove LCD panel 7 Remove the defective LCD panel 222 R59770072 FLM SERIES 19 03 200...

Page 225: ...an new LCD assembly with the flat cable connector facing the keypad unit on its place and turn in the 4 screws Image 22 8 LCD panel 2 Reestablish the connection between the LCD panel and the keypad un...

Page 226: ...MP and the keypad unit if it was removed Image 22 11 Connection PMP keypad unit 5 Place the housing back and secure with the 8 nuts a a a a Image 22 12 Close housing 6 Mount the handles by turning in...

Page 227: ...22 LCD panel replacement Reinsert the Input communication unit and close the input cover R59770072 FLM SERIES 19 03 2007 225...

Page 228: ...22 LCD panel replacement 226 R59770072 FLM SERIES 19 03 2007...

Page 229: ...ENT About this chapter This chapter gives the procedures how to replace the keypad board Order information Order number Description R764869K Keypad unit Overview Removing the keypad unit Mounting the...

Page 230: ...the communication module B A B Image 23 1 Input and communication modules removal 2 Lay down the module on its handles and remove the 4 screws a Remove the 8 indicated nuts a a a a Image 23 2 Remove h...

Page 231: ...23 Keypad board replacement Image 23 3 5 Turn out the 4 fixation screws and take off the module Image 23 4 Remove keypad unit R59770072 FLM SERIES 19 03 2007 229...

Page 232: ...TorX screwdriver Tx10 How to mount 1 Place the new unit on the fixation studs and turn in the 4 screws Image 23 5 Mount keypad board 2 Reestablish the connections coming from the LCD panel C keypad B...

Page 233: ...a a a a Image 23 7 Close housing 4 Mount the handles by turning in screws a 5 Reinstall the communication unit and all inputs Reinsert the Input communication unit and close the input cover R59770072...

Page 234: ...23 Keypad board replacement 232 R59770072 FLM SERIES 19 03 2007...

Page 235: ...ight processor compartment fan Order number Description B3245964DK Axial fan 59LS 50 MDL Order info Cathode fan Anode fan Order number Description B3245651DK Radial fan 24V 143D175CP Order info SMPS f...

Page 236: ...replace the heat exchanger fan Image 24 4 Order info fan Order number Description B3245964DK Axial fan 59LS 50 MDL Overview Building out the heat exchanger assembly Replacing the old fan with a new fa...

Page 237: ...he connector tab 1 and pull out the male valved fitting 2 Tip Sometimes a little cooling liquid will be spilled Wrap a small cloth around the valved fitting while uncoupling to absorb the spilled cool...

Page 238: ...n replacements 5 Disconnect the heat exchanger fan connector in the near of the flow switch 6 Pull out the complete assembly Image 24 8 Removing heat exchanger assembly 236 R59770072 FLM SERIES 19 03...

Page 239: ...p screws A on top of the fan A B C D Image 24 9 Fan replacement 2 Take off the fan cover plate B 3 Remove the fan C 4 Place a new fan C on the assembly with the arrow indication on the fan upwards 5 P...

Page 240: ...electrical connections Place wire tires where necessary Image 24 11 Electrical connection 4 Couple up the cooling circuit from the light pipe entrance to the heat exchanger 5 Check the pressure indic...

Page 241: ...mirror fan without removing the cold mirror itself Readjustment of the cold mirror is in that case not necessary Image 24 12 Order info fan Order number Description B3245964DK Axial fan 59LS 50 MDL O...

Page 242: ...procedure Necessary tools Allen key 3 mm Allen key 2 5 mm Allen key with ball head 2 5 mm How to remove the fan 1 Slide out the dust filter Image 24 13 Remove dust filter 2 Disconnect the fan Image 24...

Page 243: ...placements A A A A Image 24 15 Cold mirror fan removal 4 Slide out the fan and the protection grid Be careful not to drop the rubber cushioning rings A inside the projector R59770072 FLM SERIES 19 03...

Page 244: ...Slide in the fan with the arrow indication downside Insert the 4 rubber cushioning rings A between the fan and the fan plate A A A A Image 24 16 Cold mirror fan 2 Put the protection grid on the fan an...

Page 245: ...24 Fan replacements Image 24 17 Mount top dust filter Reinstall all covers start with the top cover R59770072 FLM SERIES 19 03 2007 243...

Page 246: ...describes how to replace the light processor compartment fan Image 24 18 Order info fan Order number Description B3245964DK Axial fan 59LS 50 MDL Overview Remove of the top plate Removal of the axial...

Page 247: ...key 3 mm How to remove the top plate 1 Remove both interlocking adapters in the same way as the front interlocking adapter 2 Turn out all screws 43 pieces on the top plate except those indicate A Ima...

Page 248: ...Connector is situated in compartment below the cooling channel 2 Cut the cable tie a and pull the cable out of the cable guide Image 24 21 Fan connector 3 Turn out the 4 hexagon socket head cap screws...

Page 249: ...ndication on the fan pointing to the mounting plate Image 24 23 Mounting axial fan 2 Secure the fan with the 4 hexagon socket head cap screws 3 Guide the cable through the cable guide and pull the con...

Page 250: ...or frame A Image 24 24 Mounting top plate 2 Turn in the screws which will be covered by the small plate 3 Push the joggle of the small plate A behind the big plate and lay down this small plate 4 Turn...

Page 251: ...apter This chapter describes how to replace the cathode fan Image 24 25 Order info fan Order number Description B3245651DK Radial fan 24V 143D175CP Overview Removal of the fan assembly Fan replacement...

Page 252: ...Flat screws driver 7 mm Nut driver 7 mm How to remove the fan 1 Turn out the 5 indicated screws with an Allen key 3 mm Image 24 26 Partial lamp house removal 2 Slide out the side panel of the lamp ca...

Page 253: ...he side plate of the air channel and take the plate away Cut the foam rubber as it is stuck on the different plates Image 24 30 Side plate air channel 5 Turn out the 4 screws holding the fan assembly...

Page 254: ...24 Fan replacements Image 24 31 Removing fan assembly 6 Slide the assembly upwards and take out the fan assembly 252 R59770072 FLM SERIES 19 03 2007...

Page 255: ...Take a new fan and slide plate A over the cable Place the plate on the fan so that the fixation holes matches the holes in the fan A D B C Image 24 33 Assembling the fan assembly 5 Put fixation plate...

Page 256: ...the projector with the fixation plate towards the lamp cabinet and the cable to the inside of the projector Image 24 34 Mount fan assembly 2 Slide the assembly downwards until the fixation holes matc...

Page 257: ...e air channel 4 Connect the fan and push the connector and cable behind the plate Image 24 36 Image 24 37 5 Insert the side panel of the lamp cabinet and secure with 5 screws Image 24 38 Insert side p...

Page 258: ...Image 24 39 Partial lamp house installation 6 Reinsert the lamp house see Installation of the lamp house page 91 and reinstall the lamp cover see Installation of the lamp cover page 82 256 R59770072 F...

Page 259: ...ribes how to replace the anode fan Image 24 40 Order info fan Order number Description B3245651DK Radial fan 24V 143D175CP Overview Access to the anode fan Removing the anode fan Fan replacement Mount...

Page 260: ...onnecting them from the cooling circuit Once the heat exchanger is slide out it can be rotated so that the way is free to take out the anode fan Necessary tools Allen key 3 mm Flat screwdriver 3 mm Ho...

Page 261: ...Image 24 42 Turning out the heat exchanger 4 Rotate this assembly together with the connected hose and flow switch not available in FLM HD versions If necessary disconnect the cables R59770072 FLM SE...

Page 262: ...o remove the anode fan 1 Turn out the 4 screws of the fan security grid and take off that grid A Take out also the air channel plate B A B Image 24 43 Removing grid and channel plate 2 Pull out the fa...

Page 263: ...24 Fan replacements 3 Turn out the 3 indicated fixation bolts Image 24 45 4 Slide out the fan assembly R59770072 FLM SERIES 19 03 2007 261...

Page 264: ...bly Image 24 46 2 Turn out the 4 fixation screws and remove the lock washers A B Image 24 47 Fan removal 3 Take off plate B and then plate A 4 Take the new fan and push the cable through the hole in p...

Page 265: ...ate B and place plate B on plate A so that the fixation holes match the holes in plate A 6 Secure with 4 screws Insert lock washer between each screw and the plate 7 Insert the assembly in its cabinet...

Page 266: ...3 mm Allen key 5 mm How to mount 1 Slide in the assembly into the projector Image 24 50 Mounting anode fan assembly 2 Turn in the 3 indicated fixation screws 3 Place the air channel plate B on the fix...

Page 267: ...24 Fan replacements A B Image 24 51 4 Turn in the 4 fixation screws 5 Reconnect the fan R59770072 FLM SERIES 19 03 2007 265...

Page 268: ...and slide it into the projector Image 24 52 2 Fasten both fixation screws 3 Connect those cables which where disconnected and tie up the cables where necessary 4 Insert the light processor assembly se...

Page 269: ...out this chapter This chapter describes how to replace the mains input fan Image 24 53 Order information Order number Description B32466391D Axial fan 24V 37LS43 92L120 Overview Replacing the mains in...

Page 270: ...24 6 1 Replacing the mains input fan Remove the back cover Necessary tools Allen key 3 mm How to replace the fan 1 Disconnect the fan Image 24 54 Fan connection 2 Turn out the 4 screws 268 R59770072 F...

Page 271: ...and remove the fan 4 Place a new fan with the arrow indication pointing away from the projector 5 Place the cover grid on it and insert the 4 screws 6 Reestablish the connection 7 Reinstall the back...

Page 272: ...bes how to replace one or both SMPS fans which are located behind the front dust filter Image 24 56 Order information Order number Description B32466391D Axial fan 24V 37LS43 92L120 Overview Replacing...

Page 273: ...fan 1 Remove the HEPA dust filter on the front side by pulling the two spring clamps away from the filter and then moving the filter forwards 2 1 Image 24 57 Remove dust filter 2 Disconnect the fan I...

Page 274: ...ards the SMPS 5 Secure with the 4 screws 6 Reestablish the connection 7 Insert the HEPA filter by pulling the two spring clamps away and move the filter into position 8 Reinstall the front cover of th...

Page 275: ...lling the two spring clamps away from the filter and then moving the filter forwards 2 1 Image 24 60 Remove dust filter 2 Disconnect the fan It can be necessary to cut the cable tie Image 24 61 Fan co...

Page 276: ...back on its place and secure with the 6 screws Do not forget the insert the clips for the filter at the right side before turning in the screws 8 Reestablish the connection 9 Insert the HEPA filter by...

Page 277: ...block only for HD projectors Order information Order number Description V3220004D Peltier for DMD mounting V3220006D Peltier for front cooling only for FLM HD projectors Overview Remove a Peltier elem...

Page 278: ...see Removal of the light processor page 103 Necessary tools Allen key 2 5 mm Torque key 2 5 mm How to remove 1 Turn out the 4 indicated screws and remove also the 4 washers Image 25 1 Remove cooling b...

Page 279: ...18 C216 R200 C202 J290 J270 C217 J281 J272 MH5 C206 C201 1 FAN7 4 NTC BLUE SENSOR LIGHT A BC 16 A BC AB CD WHITE NTC GREEN PRISM TEC GREEN TEC RED FAN7 1 FAN7 2 FAN7 3 NTC RED CATEYE ORANGE YELLOW SHU...

Page 280: ...25 Peltier replacement Or remove the spiral around the cable tree take out the Peltier wires and then take off the Peltier element Image 25 4 278 R59770072 FLM SERIES 19 03 2007...

Page 281: ...es of the new Peltier element 2 Place the Peltier element on the DMD slide it a little bit up and down to ensure a good contact and finally slide it against the upright sides of both studs Note Make s...

Page 282: ...back around the cable tree J251 C214 C215 C204 J250 C212 J211 C211 J260 C210 C207 J291 C213 J261 J252 J263 C205 C208 J262 J271 J201 EDGE J213 C209 J280 C203 J212 C200 C218 C216 R200 C202 J290 J270 C2...

Page 283: ...25 Peltier replacement Reinsert the Light processor assembly and reinstall the side cover R59770072 FLM SERIES 19 03 2007 281...

Page 284: ...esponding Peltier element TEC J279 J291 M179 C329 C335 M178 R479 J7 R497 J274 C459 R541 C419 C332 M165 R536 M176 J282 C399 C477 SH6 S100 C310 C464 J277 C401 M167 J278 D111 C458 J253 J901 I112 J276 C32...

Page 285: ...ote Do not remove the hoses Image 25 10 Remove cooling block 4 Cut the connector of the old wires and pull the wires out of the cable tree Then take off the Peltier element Or remove the spiral around...

Page 286: ...k around the cable tree Close the FIB cover and turn in the 3 screws J279 J291 M179 C329 C335 M178 R479 J7 R497 J274 C459 R541 C419 C332 M165 R536 M176 J282 C399 C477 SH6 S100 C310 C464 J277 C401 M167...

Page 287: ...25 Peltier replacement Red Green Blue Image 25 13 Mount cooling block 5 Reinsert the light processor assembly and reinstall the side cover R59770072 FLM SERIES 19 03 2007 285...

Page 288: ...25 Peltier replacement 286 R59770072 FLM SERIES 19 03 2007...

Page 289: ...ilter Image 26 2 Order info mains filter Order number Description B305838 Mains filter Order info mains switch Order number Description B3722365K Mains switch with automatic fuse 35A Overview Getting...

Page 290: ...e lamp cover Necessary tools Allen key 3mm How to get access 1 Unplug the fan connection Image 26 3 Fan connection 2 Just loosen the 9 indicated screws Do not turn them out Image 26 4 Shield 3 Move th...

Page 291: ...6 Power input Image 26 5 4 Turn out the 6 indicated screws of the mains filter cover plate Image 26 6 Mains input cover plate 5 Take off the mains filter cover plate R59770072 FLM SERIES 19 03 2007 28...

Page 292: ...bout this chapter This chapter describes how to replace the mains filter Image 26 7 Order information Order number Description B305838 Mains filter Overview Removing the mains filter Mounting a new ma...

Page 293: ...slide off all eye connections Do not drop the lock washers in the projector a a b b b b c Image 26 8 Mains filter removal 2 Turn out the 4 screws b 3 Slide the mains filter to the left or upwards to t...

Page 294: ...the mains filter on its position Secure screw c image 26 8 4 Turn in the 4 fixation screws b image 26 8 5 Slide the free eye connection of the both brown wires coming from the LPS over the top pin of...

Page 295: ...e 26 11 Functionality Next to its function to switch on and off the projector the mains switch contains also the main automatic fuse Order information Order number Description B3722365K Mains switch w...

Page 296: ...Screwdriver 7 mm Allen key 2 5 mm How to remove the mains switch 1 Remove the indicated connection screws at the back side of the mains switch and slide off the eye connectors Do not drop the washers...

Page 297: ...mpletely 4 Turn out the next bottom screw b slide a lock washer followed by a washer over the screw Then slide the first eye connector coming from the mains input also over the screw followed by the e...

Page 298: ...mains filter cover plate on its place Image 26 14 Mount mains filter cover plate 2 Turn in the 6 indicated fixation screws 3 Place the shield plate over the screws and move the plate to the right Ima...

Page 299: ...um 2500 watts and maximum 100 amps In normal situation each LPS unit deliver the half of the required power So for a 3 kW lamp having an arc voltage of 28 volt each LPS unit deliver 53 57 amps at 28 v...

Page 300: ...27 Lamp power supply Overview LPS diagnostic LED s Removing the LPS module Installing the LPS module 298 R59770072 FLM SERIES 19 03 2007...

Page 301: ...ide the projector LAMP OUT MAINS INPUT LAMP OUT MAINS INPUT LAMP ON LVPS OK ERR PFC OK LPS OK Image 27 2 Diagnostic Or Gr Gr Gr Re LVPS OK PFC OK LPS OK LAMP OK ERR Diagnostic Action OFF OFF OFF OFF O...

Page 302: ...jector is not blocked If the problem remains replace the whole LPS module ON OFF OFF OFF Flashing fast Error detected inside this LPS unit In case the other LPS unit operates normally the LPS module a...

Page 303: ...cover of the FLM projector 2 Disconnect the MAINS INPUT from both LPS units Image 27 3 3 Disconnect the grey wire unit from the CTRL IN socket Image 27 4 4 Disconnect both LAMP OUT power cables at the...

Page 304: ...aptive screws which fasten the LPS module to the projector chassis Use for that a flat screwdriver 6 x 10 mm Image 27 6 6 Hold fast the LPS module by its handles pull the LPS module out of its compart...

Page 305: ...the grey wire unit in the upper right corner of the LPS compartment while sliding in the LPS Image 27 8 2 Fasten the four captive screws of the LPS module Image 27 9 3 Connect the power cables coming...

Page 306: ...socket and cables Red marked cables with the pin black marked cables with the pin Image 27 11 4 Connect the grey wire unit with the CTRL IN socket as illustrated Image 27 12 5 Connect the mains input...

Page 307: ...e lamp The negative connection from LPS to lamp is direct and is connected to the chassis at the lamp side The full lamp current passes through the secondary of the superimposing transformer Parts B A...

Page 308: ...remains replace the SPG module You can not hear the SPG module three times clicking in an attempt to ignite the lamp The voltage on the LAMP OUT pins of the LPS module is first 140 volt during the at...

Page 309: ...bles from the LAMP OUT pins of the LPS module Use for that a 10 mm nut driver Caution Do not loose the washers which fits between the fixation nuts and the cable eye Tip Place the washers and nuts bac...

Page 310: ...the start pulse generator from the projector Caution Do not damage the ferrite blocks while removing the SPG module Note The ferrite blocks have to be reused upon the SPG module which you want to inst...

Page 311: ...ojector Caution Gently guide the thick wires through the frame opening Make sure that the lamp house is removed from the projector Image 28 6 2 Fasten the 3 captive screws S of the start pulse generat...

Page 312: ...s in correct order upon the pin as illustrated Always use a plain washer between the output pin and the cable eyes E2 L N P W E1 Image 28 9 P LPS output pin W Plain washer L Lock washer E1 Cable eye f...

Page 313: ...ables are provided with ferrite blocks C Reuse the ferrite blocks of the removed SPG module in case no ferrite blocks are present upon the installed SPG module C C Image 28 11 5 Reinstall the lamp hou...

Page 314: ...28 Start pulse generator 312 R59770072 FLM SERIES 19 03 2007...

Page 315: ...er information Re convergence toolkit Order number Description R8471961K FLM Re convergence toolkit Overview Action of the convergence controls Re converging Green on Blue Readjustment of the plungers...

Page 316: ...adjusted indicated in the drawing with the prohibition sign 1 2 3 2 3 1 3 1 or DMD Image 29 1 Influence of the controls on the convergences Adjusting the control s 2 Move the respective convergence pa...

Page 317: ...causes already many pixel shift Before starting the re convergence remove both side covers front cover and top cover Location of the lock down screws G1 G2 G3 G4 Image 29 2 Lock down screws green Loc...

Page 318: ...square drive socket with a soldered hexagon key onto a ratchet 4 Carefully release the 4 lock down screws holding the DMD unit onto Prism frame Tip Release the lock down screws in a way the DMD assem...

Page 319: ...pattern with the Blue line of the Blue convergence pattern in the center at the top of the image Adjust the control Gb2 for coincidence of the diagonal Green line of the Green convergence pattern with...

Page 320: ...MD assembly a readjust ment of the plungers can be necessary Convergence screw is end of course 1 Turn the plunger A a few turns counterclockwise A B Image 29 7 Readjustment plunger 2 Continue with th...

Page 321: ...ing Red on Blue CAUTION Be cautious when adjusting the convergence controls because a small turn causes already many pixel shift Location of the lock down screws R1 R2 R3 R4 Image 29 9 Lock down screw...

Page 322: ...ry tools 2x R847204 steel screwdriver with 1 16 ended hex blade R847205 square drive socket with soldered hexagon key of 2 5 mm R847203 Steel screwdriver with 0 05 ended hex blade Allen key 3 mm Allen...

Page 323: ...adjustment Rb2 Rb3 adjustment Rb2 or Rb3 adjustment Rb3 top image Rb2 bottom image Image 29 11 4 Continue with re converging the center at the Top and the Bottom of the image as follows using tool R8...

Page 324: ...onvergence adjustment If necessary to readjust the plungers see Readjustment of the plungers page 318 Close the convergence cover reinstall all covers of the projector 322 R59770072 FLM SERIES 19 03 2...

Page 325: ...he DMD plane the principal lens plane and the sharp focus plane will intersect in a line below the projector for downward lens tilt TEC Thermoelectric cooling uses the Peltier effect to create a heat...

Page 326: ...Glossary 324 R59770072 FLM SERIES 19 03 2007...

Page 327: ...319 Adjustment 313 FLM 313 Green 315 Re adjust 315 Red 319 Re adjust 319 Convergence controls 314 Action 314 Cooling circuit 153 159 160 163 167 170 172 175 Calibrate 175 Drain 160 Expel air 170 Fill...

Page 328: ...29 Expel air 170 Cooling circuit 170 F Fan 233 235 237 238 Heat exchanger 234 235 237 238 Build in assembly 238 Build out assembly 235 Fan replacement 237 FIB 207 209 Mount 209 Remove 208 Fill 163 Co...

Page 329: ...6 279 Mount 279 Replace 276 Replacement 275 Pixel map processor 211 PMP 211 213 216 Build out 213 Diagnostics 212 Mounting 216 Power input 287 288 290 296 Close compartment 296 Get access 288 Mains fi...

Page 330: ...nstall 309 Remove 307 Troubleshooting 306 Start pulse generator 305 T Top cover 77 78 Installation 78 Remove 77 Top plate 245 248 Mount 248 Remove 245 Troubleshooting 15 306 SPG 306 U UV filter 117 11...

Page 331: ...n Noordlaan 5 B 8520 Kuurne Phone 32 56 36 89 70 Fax 32 56 36 88 24 E mail service mne barco com Web www barco com From Date Please correct the following points in this documentation R59770072 00 page...

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Barco FLM series, Service Manual

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