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Barco HDF W series, Service Manual

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6. Removal and installation of the projector covers

6. REMOVAL AND INSTALLATION OF THE PROJECTOR

COVERS

About this chapter

Most maintenance and servicing procedures demand removing one or more of the projector covers to gain access to the parts to
maintain or to service. To avoid redundancy, all procedures about cover removing or installing are grouped together in this chapter.
The maintenance and servicing procedures also refer to this chapter if required. The procedures in this chapter describe, with
detailed step by step actions and illustrations, how to remove or install the projector covers. Note that some covers may only be
removed by quali

fi

ed service personnel, see remarks above each procedure.

W

ARNING

:

Always switch off the projector and unplug the power cord at the projector side before removing

one of the covers.

R5905312 HDF W SERIES 24/01/2013

97

Summary of Contents for HDF W series

Page 1: ...HDF W series Service manual R5905312 01 24 01 2013 ...

Page 2: ...Barco nv Noordlaan 5 B 8520 Kuurne Phone 32 56 36 82 11 Fax 32 56 36 883 86 Support www barco com esupport Visit us at the web www barco com Printed in Belgium ...

Page 3: ...rporated in new editions of this publication The latest edition of Barco manuals can be downloaded from the Barco web site www barco com or from the secured Barco web site https my barco com Copyright All rights reserved No part of this document may be copied reproduced or translated It shall not otherwise be recorded transmitted or stored in a retrieval system without the prior written consent of...

Page 4: ......

Page 5: ...r 113 7 5 Removing the mains switch 114 7 6 Mounting the new mains switch 115 8 Lamp and lamp house 117 8 1 Introduction HDF Lamp Lamp House 118 8 2 Removal of the lamp house 119 8 3 Installation of the lamp house 121 8 4 Removing the xenon lamp from the lamp house 123 8 5 Installing the xenon lamp in the lamp house 127 8 6 Resetting the lamp parameters 133 8 7 Realignment of the lamp in its refle...

Page 6: ...uid cooling circuit 239 15 1 Draining the liquid cooling circuit 240 15 2 Filling the liquid cooling circuit 244 15 3 Refreshing the liquid cooling circuit 249 15 4 Expelling air from the liquid cooling circuit 253 15 5 Pressure verification of the liquid cooling circuit 256 15 6 Cleaning the cooling pump 257 15 7 Replacement of the pump motor and rotor 259 15 8 Replacement of the complete cooling...

Page 7: ...agnostic LEDs 315 19 6 Communication Interface board Diagnostic LEDs 317 19 7 Pixel Mapping Processor Diagnostic LEDs 319 19 8 5 Cable Input board Diagnostic LEDs 321 19 9 LPS module diagnostic LED s 322 Index 325 R5905312 HDF W SERIES 24 01 2013 3 ...

Page 8: ...Table of contents 4 R5905312 HDF W SERIES 24 01 2013 ...

Page 9: ...tor Ensure that you understand and follow all safety guidelines safety instructions and warnings mentioned in this chapter before servicing the HDF projector After this chapter addi tional warnings and cautions are given depending on the service procedure Read and follow these warnings and cautions as well WARNING This manual is only intended for qualified service personnel Overview Safety Instruc...

Page 10: ...n 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 screwheads metallic overlays control shafts etc especially any exposed metal parts that offer an electrical return path to the chassis Any current measured must not exceed 3 5 mA Reverse the instrument power cord plug in the outlet and ...

Page 11: ...ined 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 BARCO service data parts list might create shock fire and or other hazards Product Safety is under review continuously and new instructions are issued whenever appropriate For the latest information al...

Page 12: ...1 Safety 8 R5905312 HDF W SERIES 24 01 2013 ...

Page 13: ...2 General 2 GENERAL Overview Convention projector orientation Location of the main components of the projector Spare parts for HDF series Projector block diagram R5905312 HDF W SERIES 24 01 2013 9 ...

Page 14: ...ector as the side at your left hand when standing behind the projector and looking at the projection screen in front of the projector 1 5 4 3 2 Image 2 1 1 Front side lens side 2 Right side projector lamp input side 3 Back side 4 Top side 5 Left side light processor side 10 R5905312 HDF W SERIES 24 01 2013 ...

Page 15: ...on of the main components of the projector Housing 1 2 3 4 5 6 Image 2 2 1 Rear cover 2 Top cover 3 Side cover side light processor 4 Front cover 5 Input communication cover 6 Lamp cover R5905312 HDF W SERIES 24 01 2013 11 ...

Page 16: ...ith lamp 2 Lamp power supply LPS 3 Start pulse generator SPG 4 Light processor cover plate 5 Light processor 6 Cold mirror assembly 7 Anode fan assembly 8 Lens holder 9 Input communication unit 10 Switched mode power supply SMPS 11 SMPS cover plate 12 R5905312 HDF W SERIES 24 01 2013 ...

Page 17: ...12 13 16 17 14 15 Image 2 4 12 Front filter 13 Top filter 14 Start pulse generator SPG 15 SPG cover plate 16 Water cooling circuit with heath exchanger 17 Heat exchanger filter R5905312 HDF W SERIES 24 01 2013 13 ...

Page 18: ... Managing spare parts is one of the key processes The spare parts list is subject to change No spare parts list is included in this manual to ensure that no spare parts are ordered based upon outdated information Up to date information regarding spare parts and much more is available on the secured Barco web site https my barco com 14 R5905312 HDF W SERIES 24 01 2013 ...

Page 19: ...face Keypad LCD Deinterlacing WARP 5 Cable input Sat RED Sat GREEN Sat BLUE Dual DVI input 3G SDI input WIFI GSM CTRL FIB Input selector OSD Blending PiP Test paterns Ethernet USB DMX RS232 Wired IR IR Image 2 5 CTRL Controller FIB Formatter Interface Board OSD On Screen Display PiP Picture in Picture CLO Constant Light Output SPG Start Pulse Generator LIM Lamp Info Module Sat Satellite IR Infra r...

Page 20: ...PS SMPS Power Distribution Board PROM I C I C RS232 RS485 RS485 I C I C I C SPI RS232 RS232 RS485 RS485 RS485 RC5 I C HighSpeed PROM µC FPGA FPGA config SPI PROM µC FPGA FPGA config I C PROM PROM IR IR PROM µC PROM PROM PROM PROM µC PROM µC CTRL FIB Baud 115200 Baud 250000 SW Image 2 6 16 R5905312 HDF W SERIES 24 01 2013 ...

Page 21: ...32 RS232 I C I C USB USB USB A IN RS232 RS485 I C SPI SPI SPI High Speed SATA SPI I C SPI I C SPI I C SPI I C RC5 I C PROM Keypad LCD Config PROM PROM FPGA Input 1 FPGA CTRL Deinterlacing WARP SW PROM Input 1 FPGA Input 1 FPGA Input 1 FPGA PROM PROM PROM FPGA ASIC PROM FIB Image 2 7 R5905312 HDF W SERIES 24 01 2013 17 ...

Page 22: ...d LCD Deinterlacing WARP 5 Cable input Sat RED Sat GREEN Sat BLUE Dual DVI input 3G SDI input WIFI GSM IR 12V 3 3V 3 3V 5V 5V 5V 5V 5V 5V 5V 12V 12V 24V 5V 24V 12V 12V 12V XLR_VOUT XLR_VOUT 5V 5V 12V 12V 5V 12V 3 3V 12V 12V 12V 2 5V 2 5V 3 3V 3 3V 12V 2 5V 3 3V 2 5V 12V 24V DC DC DC DC DC DC DC DC 12V 5V 5V 12V 5V DC DC 3 3V 2 5V 1 2V DC DC DC DC DC DC Image 2 8 18 R5905312 HDF W SERIES 24 01 2013...

Page 23: ...tionist to annually and 4 yearly maintenance actions which must be done by certified service personnel who are familiar with potential hazards of the product and all product safety checks Overview 1 month maintenance actions 3 month maintenance actions 2 year or 1500 hours runtime maintenance actions 10 year or 10000 hours runtime maintenance actions Lamp change maintenance actions R5905312 HDF W ...

Page 24: ...ential hazards associated with the product No Maintenance action Remarks 1 Check the dust filters Clean a dirty filter or replace a damaged filter immediately 3 Check the surface of the lens output side for dust it is not needed to remove the lens from the projector Only clean if necessary Clean the lens output side in case dust is clearly visible upon the surface 20 R5905312 HDF W SERIES 24 01 20...

Page 25: ...d by a trained projectionist who is familiar with potential hazards associated with the product No Maintenance action Remarks 1 Clean the air vents inlets of the projector front and rear side of the projector Use a vacuum cleaner 2 Clean the cabinet of the projector Removal overall dust accumulation on projector covers R5905312 HDF W SERIES 24 01 2013 21 ...

Page 26: ...f a porthole is used check the porthole both sides for dust Only clean the porthole in case dust is clearly visible upon the surface Use an optical cloth 8 Dust in general Clean the projector exterior housing Report on cleanliness of booth 9 Dust in general Check the condition hot state of the Light Pipe and prism by looking for artifacts in the projected full white and full black patterns If arti...

Page 27: ...n case of degradation damage etc 21 Lens holder Check the Lens Holder shift functionality up down left right Lubricate where needed Use the local keypad to shift 22 Lens holder Check the focus uniformity Adjust the Lens Holder Scheimpflug ONLY if needed 23 Lens Check the optic surfaces of the lens input and output for dust Only clean the input and or output side in case dust is clearly visible upo...

Page 28: ...10 year maintenance actions listed below may ONLY be performed by certified service personnel who are familiar with potential hazards of the product and all product safety checks No Maintenance action Remarks 1 Replace the Liquid Cooling Assembly 2 Check all fans vibrations noise speed etc speeds via diagnostics Replace if needed 24 R5905312 HDF W SERIES 24 01 2013 ...

Page 29: ...the Reflector of the Lamp House for dust Only clean the Reflector in case dust is clearly visible upon the surface of the Reflector Take the Lamp House to another room and use compressed air to blow away the dust Use an optical cloth 3 Visual inspection of the lamp anode and cathode connectors of the Lamp House Replace the Lamp House in case of degradation damage etc 4 Visual inspection of the lam...

Page 30: ...3 Preventative maintenance actions 26 R5905312 HDF W SERIES 24 01 2013 ...

Page 31: ...oblem inside the projector This companion gives for each error warning code possible solutions which can be followed one by one to solve the problem Some solutions contain pictures to help find the location of defect parts The full content of the Diagnostic Companion is described in the chapter Troubleshooting page 31 Overview Access to the Diagnostic Companion Working with the Diagnostic Companio...

Page 32: ...o access the Diagnostic Companion 1 Press Menu to activate the menus and select Service Diagnosis Image 4 1 Main menu service Image 4 2 Service diagnosis 2 Enter 8888 An expanded diagnosis menu opens Image 4 3 Extended diagnosis menu 28 R5905312 HDF W SERIES 24 01 2013 ...

Page 33: ...Companion and press ENTER to display the error overview Image 4 4 Extended diagnosis menu Image 4 5 Error logging 2 Use the or key to select the desired error code and press ENTER The possible situations are displayed Image 4 6 Situations for selected error R5905312 HDF W SERIES 24 01 2013 29 ...

Page 34: ...ey to select a situation and press ENTER to view a solution description Image 4 7 Solution for selected situation 4 With a solution description selected press ENTER to view location images when available 30 R5905312 HDF W SERIES 24 01 2013 ...

Page 35: ...5 Troubleshooting 5 TROUBLESHOOTING R5905312 HDF W SERIES 24 01 2013 31 ...

Page 36: ...5 Troubleshooting 32 R5905312 HDF W SERIES 24 01 2013 ...

Page 37: ...oot the projector 2 Ensure the latest projector software is installed 3 Replace the PMP board See Replacing the PMP board page 156 Input Communication unit is replaced by a unit used in a Barco HDQ projector Restart the projector and wait for at least 15 to 20 minutes until the formaters are automatically reprogrammed with the correct software to support the current light processor resolution DO N...

Page 38: ...e CTLB IN port of the first LPS unit in the LPS rack of the projector 2 Check if the CTLB IN LPS control wire unit is connected with the Power Distribution board reference 9 image 5 4 3 Check if the yellow wire unit reference 3 image 5 4 image 5 5 between the Power distribution board and the rear side of the Input Communication unit is properly connected 1 2 Image 5 3 9 3 Image 5 4 3 Image 5 5 34 ...

Page 39: ...oth LPS modules See Lamp Power Supply page 169 Code 2010 LPS start up fail LPS power stage Error Situation Solution Failure in the circuitry of the Lamp Power Supply LPS Replace one or both LPS modules See Lamp Power Supply page 169 Code 2011 LPS boost voltage generation failed Error Situation Solution LPS modules fail to generate the boost voltage to ignite the lamp Replace one or both LPS module...

Page 40: ...ide of the projector is not blocked 3 Check the filter at the front side of the projector 4 Replace one or both LPS modules See Lamp Power Supply page 169 Code 2019 LPS temperature primary heatsink 2 too high Error Situation Solution The temperature of the primary heatsink 2 inside the LPS module has exceeded the maximum temperature allowed 1 Check the ambient temperature of the projector Ensure t...

Page 41: ...ply page 169 Code 2025 LPS temperature heatsink output diode too high Error Situation Solution The temperature of the heatsink of the output diode inside the LPS module has exceeded the maximum temperature allowed 1 Check the ambient temperature of the projector Ensure that the ambient temperature is within spec Maximum 40 C 104 F 2 Ensure that the front side air inlet side of the projector is not...

Page 42: ... inside the LPS module Replace one or both LPS modules See Lamp Power Supply page 169 Code 2031 LPS internal error Error Situation Solution Mains input disconnected from one of the LPS power input pins Check if the wire units reference 1 2 3 image 5 1 of the mains voltage are connected with the power input pins of the LPS module Check both LPS units Malfunction of one of the LPS modules Replace on...

Page 43: ...l the latest projector software Code 6001 Board id input 1 unknown module type Warning Situation Solution The input board inserted in this slot is not supported by the software of the projector Check if the version of the installed projector software is the latest available version The latest version can be downloaded from https my barco com To support a new type of input board most likely require...

Page 44: ...alled projector software is the latest available version The latest version can be downloaded from https my barco com Input board has invalid firmware Replace the input board Corrupt projector software Reinstall the latest projector software Code 6008 Board id input 2 unknown module type Warning Situation Solution The input board inserted in this slot is not supported by the software of the projec...

Page 45: ...tor software Check if the version of the installed projector software is the latest available version The latest version can be downloaded from https my barco com Input board has invalid firmware Replace the input board Corrupt projector software Reinstall the latest projector software Code 6015 Board id input 3 unknown module type Warning Situation Solution The input board inserted in this slot i...

Page 46: ... if the version of the installed projector software is the latest available version The latest version can be downloaded from https my barco com Input board has invalid firmware Replace the input board Corrupt projector software Reinstall the latest projector software Code 6022 Board id input 4 unknown module type Warning Situation Solution The input board inserted in this slot is not supported by...

Page 47: ...f the version of the installed projector software is the latest available version The latest version can be downloaded from https my barco com Corrupt projector software Reinstall the latest projector software Code 6029 Board id pmp not accessable Error Situation Solution Only the ID parameters of the pixel mapping processor PMP board and one of the other boards in the projector are not accessible...

Page 48: ...ce the Communication Interface board The Board ID of all other boards are also NOT accessible This may indicate a malfunction I C functionality on the PMP board 1 Reboot the projector 2 Replace the PMP board See Replacing the PMP board page 156 Malfunction Communication Interface Replace the Communication Interface board Code 6034 Board id communication interface read error Error Situation Solutio...

Page 49: ...l communication line Code 6039 Board id power backplane write error Error Situation Solution Malfunction I C communication on the PMP board The input boards the Display board and the WARP module also have Board id read errors Remove disconnect the other boards from the I C communication line one by one and check if this error remains Replace the board which makes this error goes away If none of th...

Page 50: ...e 15 to see which boards are connected to the same internal communication line 1 Image 5 7 2 Image 5 8 Code 6043 Board id display module write error Error Situation Solution Malfunction Display Module The projector can not write to the installed Display Module Replace the Display Module See Replacing the LCD Display Interface page 161 Code 6044 Board id fan control board unknown format Warning Sit...

Page 51: ...ntrol board has invalid firmware Replace the Motor Control board See Replacing the motor control board MCB page 283 Corrupt projector software Reinstall the latest projector software Code 6049 Board id motor control board not accessible Error Situation Solution Only the ID parameters of the Motor Control board are not accessible The ID parameters of all other boards are accessible Ignore this erro...

Page 52: ...e accessible Ignore this error message unless other functionality of the Lamp Info module fails as well If so replace the Lamp Info module See XXXXX The Board ID of all other boards are also NOT accessible This may indicates a malfunction I C functionality on the PMP board 1 Reboot the projector 2 Replace the PMP board See Replacing the PMP board page 156 Malfunction Lamp Info module reference 3 X...

Page 53: ...If the problem remains replace the PMP 1 Image 5 11 2 Image 5 12 6 Image 5 13 3 Image 5 14 Code 6055 Board id lamp info module write error Error Situation Solution Malfunction Lamp Info Module The projector can not write to the installed Lamp Info Module Replace the Lamp Info Module See XXXX LAMP HOUSE Code 6056 Board id light sensor module unknown format Warning Situation Solution Old projector s...

Page 54: ...er board read errors appears replace the Light Sensor Module CLO See XXXX Malfunction internal RS485 communication line The FCB MCB and LIM also reports read errors Disconnect the boards one by one from the internal RS485 line until this error disappears Replace the board which makes this error goes away See chapter XXXX to know which boards are using the internal RS485 communication line If the p...

Page 55: ...not known by the projector software Check if the version of the installed projector software is the latest available version The latest version can be downloaded from https my barco com Formatter board of the GREEN channel has invalid firmware Replace the Light Processor See HDF Light Processor page 189 Corrupt projector software Reinstall the latest projector software Code 6065 Board id formatter...

Page 56: ...Situation Solution Malfunction Formatter board of the BLUE channel The projector can not write to the installed Formatter board of the BLUE channel Replace the Light Processor See HDF Light Processor page 189 Code 6072 Board id warp unknown format Warning Situation Solution Old projector software installed The ID parameters of the Warp board are written in a format which is not known by the projec...

Page 57: ...7500 Setting FCB mode Error Mode adjustment on the Fan Control Board failed Error occurred after writing and reading the Mode of the Fan Control Board Situation Solution No communication with Fan Control Board Check if the yellow wire unit reference 3 image 5 4 image 5 5 between the Power Distribution board and the rear side of the Input Communication unit is properly connected Malfunction Fan Con...

Page 58: ...the pump and heat exchanger See reference 1 2 image 5 17 The wire unit of the temperature sensor NTC of the DMD in the RED channel is disconnected from the Power Distribution board Check if the wire unit reference 19 image 5 16 of the temperature sensor of the DMD in the RED channel is connected with the power distribution board The wire units of two temperature sensors NTC s have been swapped Whi...

Page 59: ...om the Power Backplane Check if the wire unit reference 19 image 5 16 of the temperature sensor of the DMD in the RED channel is connected with the power distribution board Damaged wire unit of the temperature sensor reference 19 image 5 19 and image 5 18 which measures the temperature of the DMD of the RED channel Repair or replace the wire unit Defect temperature sensor reference 19 image 5 19 w...

Page 60: ...or This error code is probably preceded by the warning code 7607 Green DMD temp low The same troubleshooting table can be applied to Code 7607 Green DMD temp low Warning Situation Solution The electronics of the Light Processor Unit remains off due to a low DMD temperature Make sure that the ambient temperature is within specs higher then 10 C 50 F Let the projector acclimate Do not ignite the lam...

Page 61: ...nction Fan Control board Replace the Fan Control Board See Replacing the Fan control board page 278 Defect temperature sensor reference 18 image 5 20 which measures the temperature of the DMD of the GREEN channel Replace the temperature sensor on the cooling block of the GREEN channel Code 7609 Green DMD temp high Error This error code is probably preceded by the warning code 7608 Green DMD temp h...

Page 62: ...the pump and heat exchanger See reference 1 2 image 5 17 The wire unit of the temperature sensor NTC of the DMD in the BLUE channel is disconnected from the Power Backplane Check if the wire unit reference 19 image 5 18 of the temperature sensor of the DMD in the BLUE channel is connected with the power distribution board The wire units of two temperature sensors NTC s have been swapped While the ...

Page 63: ...ge 5 21 and image 5 18 which measures the temperature of the DMD of the BLUE channel Repair or replace the wire unit Defect temperature sensor reference 17 image 5 21 which measures the temperature of the DMD of the BLUE channel Replace the temperature sensor on the cooling block of the BLUE channel Code 7618 Ambient temp low Error This error code is probably preceded by the warning code 7619 Ambi...

Page 64: ... Code 7621 Ambient temp high Error This error code is probably preceded by the warning code 7620 Ambient temp high The same troubleshooting table can be applied to Code 7622 Ambient temp short Error Situation Solution Damaged wire unit of the ambient temperature sensor reference 10 image 5 22 and image 5 23 Repair or replace the wire unit Defect temperature sensor reference 10 image 5 22 which mea...

Page 65: ...ufficient free area at the front of the projector so that fresh air can freely enter the air inlet channel The wire unit of the Lamp Info Module LIM is disconnected from the Power Distribution board Check if the wire unit reference 5 image 5 25 of the Lamp Info Module is connected with the power distribution board The wire unit of the temperature sensor inside the Lamp House is disconnected from t...

Page 66: ... with the power distribution board The wire unit of the temperature sensor inside the Lamp House is disconnected from the Lamp Info Module Check if the wire unit reference 1 image 5 26 of the temperature sensor inside the Lamp House is connected with the Lamp Info Module The temperature sensor and Lamp Info Module of the Lamp House are located under the top cover plate of the Lamp House Safely rem...

Page 67: ...lets are not blocked Provide a sufficient free area at the front of the projector so that fresh air can freely enter the air inlet channel The wire unit of the temperature sensor NTC of the air outlet is disconnected from the Power distribution board Check if the wire unit reference 11 image 5 28 of the temperature sensor is connected with the power distribution board Malfunction Fan Control board...

Page 68: ...the temperature sensor at the air outlet channel Code 7636 Engine air temp low Error This error code is probably preceded by the warning code 7637 Engine air temp low The same troubleshooting table can be applied to Code 7637 Engine air temp low Warning Situation Solution The ambient temperature in the area of the projector is almost below the minimum required operating temperature of the projecto...

Page 69: ...6 image 5 29 and image 5 30 Repair or replace the wire unit Defect temperature sensor reference 16 image 5 29 which measures the temperature inside the Light Processor compartment Replace the temperature sensor mounted on the Light Processor assembly reference 16image 5 29 Code 7641 Engine air temp open Error Situation Solution The wire unit of the temperature sensor NTC of the Light Processor com...

Page 70: ...high as well Ensure that the air inlets of the projector are not blocked Replace a dirty filter with a new one The wire unit of the temperature sensor NTC of the cooling block of the light pipe is disconnected from the Power Distribution board Check if the wire unit reference 16 image 5 32 of the temperature sensor of the cooling block of the Light Pipe is connected with the Power Distribution boa...

Page 71: ...ooling block of the Light Pipe reference 16image 5 31 Code 7696 Power supply secondary temp low Error This error code is probably preceded by the warning code 7697 Power supply secondary temp low The same troubleshooting table can be applied to Code 7697 Power supply secondary temp low Warning Situation Solution The ambient temperature in the area of secondary side of the SMPS is almost below the ...

Page 72: ...the SMPS is disconnected from the Power Distribution board Check if the wire unit reference 1 image 5 33 of the SMPS control is connected with the power distribution board The wire unit of the temperature sensor on the SMPS is damaged Check if the wire unit reference 1 image 5 34 of the temperature sensor on the SMPS is not damaged Replace sensor and wires if necessary Defect temperature sensor re...

Page 73: ...page 278 Defect temperature sensor reference 2image 5 34 which measures the temperature at the primary side of the SMPS Replace the temperature sensor Code 7705 Power supply primary DCDC temp high Error This error code is probably preceded by the warning code 7704 Power supply primary DCDC temp high The same troubleshooting table can be applied to Code 7706 Power supply primary DCDC temp open Erro...

Page 74: ...Warning Situation Solution The wire unit of the SMPS is disconnected from the Power Distribution board Check if the wire unit reference 3 image 5 33 of the SMPS control is connected with the power distribution board The wire unit of the temperature sensor on the SMPS is damaged Check if the wire unit reference 3 image 5 35 of the temperature sensor on the SMPS is not damaged Replace sensor and wir...

Page 75: ...ied to the projector have been interrupted for a short period Check the commercial power net Code 7721 Lamp switch open Error Situation Solution The Lamp House is not correctly installed Check if the Lamp House is properly installed Make sure that all three fixation screws reference 1 2 3 image 5 36 of the Lamp House are fastened See installation procedure XXXX Defect micro switch reference 4 imag...

Page 76: ...ins reinstall the software and firmware of the Fan Control Board 3 If the problem remains replace the Fan Control Board See Replacing the Fan control board page 278 Code 7729 Lamp power supply interrupt Error Situation Solution Something went wrong in one of the Lamp Power Supply modules and the firmware of one the Lamp Power Supplies decided to switch off this Lamp Power Supply to avoid projector...

Page 77: ...d Check if the wire unit reference 6 image 5 42 is plugged in the Power Distribution board 6 Image 5 42 Code 7800 2 5V voltage high Error Situation Solution Malfunction Fan Control Board Replace the Fan Control Board See Replacing the Fan control board page 278 Code 7801 2 5V voltage low Error Situation Solution Malfunction Fan Control Board Replace the Fan Control Board See Replacing the Fan cont...

Page 78: ...s of the Switched mode power supply is below specs 1 Check if the mains voltage applied to the projector is within specs See mains voltage meter above the projector ON OFF switch reference 1 image 5 43 Minimum input voltage is 200V AC 2 Ensure that the mains voltage doesn t drop below spec when the lamp is ignited If this is the case use a better power cord extension cable between the commercial n...

Page 79: ...ire unit of the pump 1 Repair the insulation of the wire unit using shrink sleeve 2 If not repairable replace the wire unit Wire unit disconnected from the Power distribution board Reconnect the wire unit to the Power distribution board Malfunction pump or pump end of life Replace the pump See Replacement of the complete cooling pump page 263 Malfunction Power distribution board Replace the Power ...

Page 80: ...ence 1 image 5 45 Repair the insulation of the wire unit using shrink sleeve Malfunction Fan Control Board Replace the Fan Control Board See Replacing the Fan control board page 278 1 Image 5 45 23 Image 5 46 3 Image 5 47 Code 7820 Xlr overload Error This error code is probably preceded by the warning code 7819 Xlr overload The same troubleshooting table can be applied to Code 7900 Fan speed cold ...

Page 81: ...lution Malfunction Cold Mirror fan reference 1 image 5 48 Replace the Fan See Cold mirror fan page 291 Malfunction Fan Control board Replace the Fan Control Board See Replacing the Fan control board page 278 Code 7903 Fan speed cold mirror too high Error This error code is probably preceded by the warning code 7902 Fan speed cold mirror too high The same troubleshooting table can be applied to Cod...

Page 82: ... Fan See Replacement of the Light processor compartment fan page 293 Malfunction Fan Control board Replace the Fan Control Board See Replacing the Fan control board page 278 Code 7907 Fan speed engine too high Error This error code is probably preceded by the warning code 7906 Fan speed engine too high The same troubleshooting table can be applied to Code 7928 Fan speed electronics top too low Err...

Page 83: ...the fan can turn freely Damaged wire unit reference 4image 5 51 and reference 20image 5 49 Check if the wire unit of the fan is not damaged Repair if possible otherwise replace with new one Malfunction Fan Control board Replace the Fan Control Board See Replacing the Fan control board page 278 Electronic bottom fan end of life Replace the fan See Replacement of the Card Cage electronics fans page ...

Page 84: ...n Control board Replace the Fan Control Board See Replacing the Fan control board page 278 Code 7939 Fan speed heat exchanger front too high Error This error code is probably preceded by the warning code 7938 Fan speed heat exchanger too high The same troubleshooting table can be applied to Code 7940 Fan speed mains input too low Error This error code is probably preceded by the warning code 7940 ...

Page 85: ...de is probably preceded by the warning code 7945 Fan speed lamp anode too low The same troubleshooting table can be applied to Code 7945 Fan speed lamp anode too low Warning Situation Solution Partial blocked lamp anode fan reference 1image 5 54 Fan is still turning but something slows down the fan speed Unblock the fan Ensure that the fan can turn freely Damaged wire unit reference 2image 5 54 an...

Page 86: ... fan can turn freely Damaged wire unit reference 2image 5 55 and reference 20image 5 49 Check if the wire unit of the fan is not damaged Repair if possible otherwise replace with new one Malfunction Fan Control board Replace the Fan Control Board See Replacing the Fan control board page 278 Lamp cathode fan end of life Replace the fan See Lamp cathode fan page 296 1 2 Image 5 55 Code 7950 Fan spee...

Page 87: ...ing code 7954 Fan speed power supply left too high The same troubleshooting table can be applied to Code 7956 Fan speed power supply right too low Error This error code is probably preceded by the warning code 7957 Fan speed power supply right too low The same troubleshooting table can be applied to Code 7957 Fan speed power supply right too low Warning Situation Solution Partial blocked power sup...

Page 88: ...ace if necessary Corrupt firmware software Reload the latest firmware and software version of the Motor Control Board Malfunction Motor Control Board Check the diagnostic LEDs of the Motor Control Board Replace the Motor Control Board if necessary See Replacing the motor control board MCB page 283 Code 8103 Horizontal lens shift end of range Error This error code is probably preceded by the warnin...

Page 89: ...install a suitable lens Code 8109 Lens zoom end of range Error This error code is probably preceded by the warning code 8108 Lens zoom end of range The same troubleshooting table can be applied to Code 8110 Shutter time out Warning Situation Solution Wire unit disconnected 1 Check if the yellow wire unit from the shutter assembly is connected with the Motor Control Board 2 Check if the yellow wire...

Page 90: ...e applied to Code 8122 Shutter current too high Warning Situation Solution The LED ERROR CH7 8 on the Motor Control Board lit up indicating that there is a problem with the shutter See also Motor Control Board Diagnostic LEDs page 310 Check if the wire unit of the DC motor of the Shutter is not damaged causing a short circuit the DC motor of the Shutter is not malfunctioning Code 8123 Shutter curr...

Page 91: ...he same troubleshooting table can be applied to Code 8502 Reading lamp info module Error Situation Solution Damaged Lamp Info module sockets 1 Check if the blue socket at the front of the Lamp House reference 1 image 5 11 is not damaged If damaged replace the Lamp Info module 2 Check if the blue socket inside the Lamp House compartment reference 2 image 5 12 is not damaged If damaged replace the m...

Page 92: ...ge 123 Code 8600 Check cooling liquid level Warning Situation Solution One of more DMDs have a high temperature 1 Check the level of the liquid cooling Add cooling liquid if appropriate See Liquid cooling circuit page 239 2 Check dust filters Ensure that the projector air inlets are not blocked 3 Make sure that the ambient temperature is within specs lower then 40 C 104 F Code 8601 Check dust filt...

Page 93: ...ree Wire unit of the Lamp Info module socket is disconnected from the Power Backplane Reconnect the wire unit reference 6 image 5 42 with the Power Distribution board Malfunction Lamp Info Module The projector can not read from the installed Lamp Info Module In case no other board read errors appears replace the Lamp House The Lamp Info Module is located inside the Lamp House behind the blue socke...

Page 94: ...n case of an old lamp replace with a new lamp 2 Check the connections between the LPS module and the SPG unit 3 Replace the LPS module See Removal of a LPS module page 172 and Installation of a LPS module page 174 Code 8708 Engine startup failed Error Situation Solution The projector fails to startup the Light Processor Check for error warning messages in the projector notifications and solve thes...

Page 95: ...co Code 100005 Invalid filedescriptor Error Situation Solution Internal projector software error First solve error warning messages with ID number below 100000 If problem remains contact Barco Code 100006 No memory Error Situation Solution Internal projector software error First solve error warning messages with ID number below 100000 If problem remains contact Barco Code 100007 Non blocked signal...

Page 96: ...ode 100016 Transmit overflow Error Situation Solution Internal projector software error First solve error warning messages with ID number below 100000 If problem remains contact Barco Code 100017 Read failed Error Situation Solution Internal projector software error First solve error warning messages with ID number below 100000 If problem remains contact Barco Code 100018 Write failed Error Situat...

Page 97: ...Code 100027 Lim write failed Error Situation Solution Internal projector software error First solve error warning messages with ID number below 100000 If problem remains contact Barco Code 100028 Lsm write failed Error Situation Solution Internal projector software error First solve error warning messages with ID number below 100000 If problem remains contact Barco Code 100029 Fcb read failed Erro...

Page 98: ...rror Situation Solution Internal projector software error First solve error warning messages with ID number below 100000 If problem remains contact Barco Code 100039 Lim reply no ack Error Situation Solution Internal projector software error First solve error warning messages with ID number below 100000 If problem remains contact Barco Code 100040 Lsm reply no ack Error Situation Solution Internal...

Page 99: ...00049 Init 5 cable adc failed input 1 Error Situation Solution Internal projector software error First solve error warning messages with ID number below 100000 If problem remains contact Barco Code 100050 Init 5 cable adc failed input 2 Error Situation Solution Internal projector software error First solve error warning messages with ID number below 100000 If problem remains contact Barco Code 100...

Page 100: ...nternal projector software error First solve error warning messages with ID number below 100000 If problem remains contact Barco Code 103000 Storage successful restoring Info Situation Solution The projector settings were successfully stored in the backup device No actions required Code 103001 Storage successful restoring with fall back mgt file Warning Situation Solution The projector settings we...

Page 101: ...installing are grouped together in this chapter The maintenance and servicing procedures also refer to this chapter if required The procedures in this chapter describe with detailed step by step 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 switch off t...

Page 102: ...move the rubber dust ring from the lens holder 3 Release the captive screw at the middle bottom of the front cover using a flat screw driver Image 6 1 Captive screw 4 Remove the front cover from the projector as follows a standing in front of the projector pull the right side of the front cover toward you until the latches release left side is hinged b then slide the front cover to the right to re...

Page 103: ...nes or similar Necessary tools 7 mm flat screw driver How to remove the side cover 1 Release the captive screw at the middle bottom of the side cover using a flat screw driver Image 6 3 Captive screw 2 Remove the side cover from the projector as follows a gently pull out the bottom corners A of the side cover b then gently pull out the top corners B of the side cover c then move the side cover awa...

Page 104: ...ease the two captive screws at the top and bottom right side of the lamp cover using a flat screw driver Image 6 5 Captive screws unlocking 2 Remove the lamp cover from the projector as follows a gently pull out the left bottom corner A of the lamp cover b then gently pull out the left top corner B of the lamp cover c then move the lamp cover away from the projector C B A C Image 6 6 Lamp cover re...

Page 105: ... the two captive screws at the top and bottom left side of the input cover using a flat screw driver Image 6 7 Captive screws input cover 2 Remove the input cover from the projector as follows a gently pull out the right bottom corner A of the input cover b then gently pull out the right top corner B of the input cover c then move the input cover away from the projector C B A C Image 6 8 Input cov...

Page 106: ...all the front cover of 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 in the corners click into their receivers Image 6 9 Front cover installation 4 Secure the front cover by locking the captive screw in the middle at the bottom of the front cover Im...

Page 107: ...d 1 bar If the pressure is out of range inform the responsible and qualified technician so he may take necessary corrective action 1 0 5 Image 6 11 3 Install the side cover of the projector doing the following a Bring the side cover towards its final position A b then gently push the locking studs of the top corners B into their receivers c then gently push the locking studs of the bottom corners ...

Page 108: ... lamp cover of the projector as follows 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 at the left bottom corner C into its receiver B C A Image 6 14 Lamp cover installaion 2 Secure the lamp cover by locking the two captive screws at the right side of the lamp cover Image 6 15 Ca...

Page 109: ...put cover of the projector as follows 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 locking stud at the right bottom corner C into its receiver B C A Image 6 16 Input cover installation 2 Secure the input cover by locking the two captive screws at the left side of the input cover Image 6 1...

Page 110: ...6 Removal and installation of the projector covers 106 R5905312 HDF W SERIES 24 01 2013 ...

Page 111: ...7 Power Input 7 POWER INPUT R5905312 HDF W SERIES 24 01 2013 107 ...

Page 112: ...7 Power Input 108 R5905312 HDF W SERIES 24 01 2013 ...

Page 113: ... 6mm flat screwdriver Necessary parts Miniature Fuse 5 x 20 mm Time Lag T H 250 VAC UL 115 V 300 VDC How to replace the fuse of the voltmeter 1 Remove the back cover of the projector 2 Open the fuse holder and pull out the fuse seating and fuse Use a 6mm flat screwdriver 3 Place a new fuse of 1A 250VAC in the fuse seating 4 Insert the fuse seating with new fuse in the fuse holder 1 Image 7 1 R5905...

Page 114: ...e lamp cover Necessary tools Allen key 3mm How to get access 1 Unplug the fan connection Image 7 2 Fan connection 2 Just loosen the 9 indicated screws Do not turn them out Image 7 3 Shield 3 Move the shield plate to the left and take out the plate 110 R5905312 HDF W SERIES 24 01 2013 ...

Page 115: ...7 Power Input Image 7 4 4 Turn out the 6 indicated screws of the mains filter cover plate Image 7 5 Mains input cover plate 5 Take off the mains filter cover plate R5905312 HDF W SERIES 24 01 2013 111 ...

Page 116: ...n the projector a a b b b b c Image 7 6 Mains filter removal 2 Turn out the 4 screws b 3 Slide the mains filter to the left or upwards to take it out As it can get stuck behind the plate loosen screw c a little so that the plate can move a little 4 Remove the nuts on the line side and slide off all eye connections Do not drop the lock washers in the projector The mains filter can be replaced 112 R...

Page 117: ...and secure with a nut 3 Place the mains filter on its position Secure screw c image 7 6 4 Turn in the 4 fixation screws b image 7 6 5 Slide the free eye connection of the both brown wires coming from the LPS over the top pin of the mains filter Then slide the eye connection of the black wire coming from the SMPS over the top pin followed by a washer A and a lock washer B Secure with a nut A B Brow...

Page 118: ...itch 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 inside the projector Image 7 9 Mains switch replacement 2 Turn out both screws on the front side of the mains switch 3 Slide out the mains switch 114 R5905312 HDF W SERIES 24 01 2013 ...

Page 119: ...nd tighten completely 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 eye connector coming from the voltmeter Turn in the screw and tighten completely 5 Turn out the first top screw c slide a lock washer followed by a washer over the screw Then slide the eye...

Page 120: ...7 Power Input 116 R5905312 HDF W SERIES 24 01 2013 ...

Page 121: ...er s instructions The bulb is stable at room temperature but may still explode if dropped or otherwise mishandled Whenever the lamp house containing a xenon lamp has to be dismantled or whenever the protective container or cloth has to be removed from the xenon lamp authorized protective clothing MUST be worn WARNING Always wear face protection full face shield when handling xenon lamps WARNING Al...

Page 122: ... socket a lamp cathode socket a Lamp Info module and an XYZ adjustment mechanism to align the lamp in the reflector The Lamp House can handle xenon lamps up to 4000 Watt The xenon lamp and Lamp House can be removed from the projector as a whole which allows a fast lamp replacement in cases when time is critical The Lamp Info module holds the lamp parameters and keeps track of the lamp history such...

Page 123: ...ither hot or cold states if improperly handled Necessary tools 7 mm flat screw driver How to remove the lamp house 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 page 100 3 Release the three spring lock screws of the lamp house as illustrated Image 8 3 Unlock lamp house 4 Clasp the lamp house by the handles and pull ...

Page 124: ...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 120 R5905312 HDF W SERIES 24 01 2013 ...

Page 125: ...ouse of the projector 1 Ensure the projector 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 100 3 Clasp the lamp house by its handles and gently slide the lamp house into its socket Note that the compartment is provided with guides G to position the lamp house correctly C G Image 8 5 Insert lamp ho...

Page 126: ...p cover of the projector see Installation of the lamp cover page 104 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 122 R5905312 HDF W SERIES 24 01 2013 ...

Page 127: ...he lamp house containing a xenon lamp has to be dismantled or whenever the protective container or cloth has to be removed from the xenon lamp authorized protective clothing MUST be worn WARNING Always wear face protection full face shield when handling xenon lamps WARNING Always wear protective clothing welder s jacket when handling xenon lamps WARNING Always wear clean leather gloves with wrist ...

Page 128: ... one hand while removing the UV blocker assembly from the Lamp House Note that some xenon lamps are installed with an anode adaptation bushing Caution Ensure that you wear protective clothing a full face shield and protective gloves Image 8 10 5 Slide the white anode socket which is connected via a thick wire with the xenon lamp upwards away from its position and then remove the xenon lamp with an...

Page 129: ...t a plain washer reference 5 is provided between the lock nut reference 4 and the anode wire lug reference 6 5 7 7 6 4 4 Image 8 13 Note The electrical connection pins of older Lamp Houses may contain two flat washers one on each side of the wire lug New Lamp Houses can contain only one flat washer due to the shorter thread clearance of the new improved connection pins 8 Remove the cathode lamp ad...

Page 130: ...in several layers of canvas or heavy cloth Place it on hard surface and shatter the envelope with a sharp hammer blow DO NOT place a non shattered bulb in any ordinary refuse container When returning a xenon lamp for warranty adjustment pack it in its original shipping container Complete and return all required warranty information 126 R5905312 HDF W SERIES 24 01 2013 ...

Page 131: ...dismantled or whenever the protective container or cloth has to be removed from the xenon lamp authorized protective clothing MUST be worn WARNING Always wear face protection full face shield when handling xenon lamps WARNING Always wear protective clothing welder s jacket when handling xenon lamps WARNING Always wear clean leather gloves with wrist protectors when handling xenon lamps Necessary t...

Page 132: ...ontainer or protective cloth while mounting the adapter 2 5 Nm 2 1 3 Image 8 16 Mount cathode adaptor 3 Install the anode wire lug 6 upon the anode socket Use an 17 mm open end wrench to hold the first nut 7 while fastening the lock nut 4 on the rod with a torque of 9 Nm 6 64 lbf ft using a torque wrench with 17 mm hexagon socket Ensure that there is a flat washer 5 between the lock nut and the wi...

Page 133: ...neck of the xenon lamp 5 Gently guide the xenon lamp into position inside the Lamp House as illustrated Anode socket hanging vertical down While inserting the lamp rotate it slightly engaging the pins of the cathode adapter in the foreseen slots This is to ensure the lamp cathode is completely inserted Image 8 18 Lamp bulb installation Warning Make sure that the both pins of the cathode adapter ar...

Page 134: ...ated Note Please ensure that the thumb screws turning wires are flush with the cover or interference will occur while inserting the lamp house into the projector Image 8 22 Secure UV blocker 9 Fasten the cathode side of the xenon lamp using a hexagon socket head screw M6 x 40 and a plain washer as illustrated Use a torque of 2 5 Nm 1 84 lbf ft to fasten the hexagon socket head screw Use for that a...

Page 135: ...wire lug Caution This cathode connection must be checked with every lamp change Caution Do not tighten the first nut reference 1 against the connector housing There must be some play 1 mm maximum This is important to insert the Lamp House smoothly into the projector 1 2 3 4 9Nm Image 8 24 Check cathode connection 11 Reinstall the side cover of the Lamp House as illustrated Note Please ensure that ...

Page 136: ...se Neglecting this update will result in poor performance and short life time of the xenon lamp See procedure Resetting the lamp parameters A realignment of the xenon lamp in its reflector is required after the installation of the xenon lamp in the lamp house See procedure Realignment of the lamp in its reflector page 135 132 R5905312 HDF W SERIES 24 01 2013 ...

Page 137: ...stalled xenon lamp How to reset the lamp parameters 1 Start up the projector but do not ignite the lamp 2 Start up the Projector Toolset The PC which runs the Projector Toolset must have a LAN connection with the projector 3 Plug in the Dongle into one of the USB ports of the PC which runs the Projector Toolset Note This Dongle is included in the Safety kit tools for lamp replacement order no R985...

Page 138: ...tion popup windows and click on the OK button if you wan to proceed Image 8 28 Image 8 29 As a result the lamp parameters are reset run time hours set to zero and the number of Refurb credits is decremented with one 6 Image 8 30 134 R5905312 HDF W SERIES 24 01 2013 ...

Page 139: ... personnel Necessary tools Light meter How to align 1 Remove the cover of the lamp compartment to gain access to the X Y and Z axis adjustment screws of the lamp 2 Place a light meter in the center of the projection screen 3 Loosen the locking screws x y and z 4 Switch on the projector and start up the lamp 5 Adjust the X axis the Y axis and the Z axis for maximum light output Carefully turn the t...

Page 140: ...e working with isopropanol Exclusive keep in original container tightly closed at a cool well ventilated and fireproof storage space Necessary tools Clean Toraysee cloth Clean cotton cloth Demineralized water Isopropanol alcohol How to clean the UV blocker of the Lamp House 1 Wipe off the dust of both sides of the UV blocker Use for that a clean Toraysee cloth Tip Limit the number of wipe movement...

Page 141: ...t a cool well ventilated and fireproof storage space Necessary tools Compressed air Clean Toraysee cloth Clean cotton cloth Demineralized water Isopropanol alcohol How to clean the Reflector of the Lamp House 1 Try to blow away the dust with compressed air 2 Is all dust removed from the Reflector If yes stop this cleaning procedure If no wipe off the dust of the Reflector Use for that a clean Tora...

Page 142: ...pic 2 Remove fixation screws 1 and 2 of the lamp info cover 3 1 2 3 Image 8 32 Lamp info cover 3 Take off the cover from the inside 4 Remove both fixation screws 1 and 2 of the lamp info module disconnect the cable Take out the unit 1 2 Image 8 33 5 Insert a new module and insert the connection 6 Turn in the fixation screws 7 Mount the cover and fixate with both screws 8 Install the lamp see Insta...

Page 143: ...mp Reflector has been replaced In case a readjustment is required follow the instructions in this chapter precisely Only qualified technicians who have experience with adjusting the Cold Mirror may adjust the Cold Mirror A misaligned Cold Mirror may cause irreversible damage to other parts of the projector R5905312 HDF W SERIES 24 01 2013 139 ...

Page 144: ...ntegration Rod entrance for optimal performance 1 2 3 4 5 Image 9 1 1 LEFT RIGHT adjustment screw 2 UP DOWN adjustment screw 3 Cold Mirror 4 Cold Mirror fan 5 Cold Mirror heatsink Diagnostic The easiest way to check the condition of the Cold Mirror is by removing the Lamp House When the Lamp House is removed the Cold Mirror becomes visible at the end of the lamp house compartment In case the Cold ...

Page 145: ...on Unit Installation of the Input Communication Unit Removal of an input module Installation of an input module Removal of the intermediate board guidance Installation of the WIFI module on the Communication module Installation of the GSM module on the Communication module Replacing the PMP board Replacing the Warp module Replacing the Deinterlacing module Replacing the LCD Display Interface Repla...

Page 146: ...on unit contains 7 sockets One socket for the control connection with the Power Backplane and six sockets for the RGB data connections directly with the satellite formatter boards on the Light Processor unit CAUTION The six sockets at the rear side of the Input Communication unit are equipped with a latch to capture the inserted plug These latches are fragile Always open the latch before pulling o...

Page 147: ...oes not match projector resolution Press OK to reprogram the firmware This will take several ninutes The following can be done 1 Accept to reprogram and click OK to continue with the process Wait for about 15 to 20 minutes so that the procedure can be completed When starting the update process do not switch off the projector before the process is finished When switching off during the update proce...

Page 148: ...ector cover 4 Release the 4 captive screws in the corners of the Input Communication Unit 5 Pull the Input Communication Unit partly out of its compartment until the hinge cylinder reference 1 is at the right place 6 Tip over the Input Communication Unit 7 Disconnect the wires a Disconnect the left connector reference 2 by pulling it out of its socket b Disconnect the RGB connectors reference 3 by...

Page 149: ...n the left connector reference 2 b Plug in the RGB connectors reference 3 according to the schematic printed on the top side of the Input Communication Unit and the board Push the connector until the little tab reference 4 clicks in the socket Tip R stands for RED G stands for GREEN and B stands for BLUE Every color has 2 cables marked with 1 and 2 4 Bring the Input Communication Unit to a vertica...

Page 150: ...Communication Unit of the projector How to remove an input module 1 Switch off the projector and unplug the power cord at the projector back side 2 Release the captive screws of the input module Image 10 2 3 Pull the input module out of the Input Communication Unit using the handles Image 10 3 CAUTION Ensure that all unused input slots of the Input Communication Unit are always covered with a dumm...

Page 151: ...unication Unit of the projector How to install an input module 1 Switch off the projector and unplug the power cord at the projector back side 2 Push the input module in the Input Communication Unit using the handles Image 10 4 3 Tighten the captive screws of the input module Image 10 5 4 Plug in the power cord at the projector back side A second DUAL LINK DVI I HDCP 3G DUAL HDSDI input module can...

Page 152: ...t See instructions above Note It is not necessary to disconnect the electrical wires The Input Communication Unit can be placed near the projector 2 Remove the 2 free input slot covers by removing the 4 screws reference 1 image 10 6 1 Image 10 6 3 Remove the 2 screws reference 2 image 10 6 on the bottom side of the Input Communication Unit 1 Image 10 7 4 Remove the intermediate board guidance refe...

Page 153: ...10 Card Cage 1 Image 10 8 To install the intermediate board guidance reverse the steps described above R5905312 HDF W SERIES 24 01 2013 149 ...

Page 154: ...module from the Input Communication Unit See Removal of an input module page 146 2 Remove the drive fastener reference 1 image 10 9 from the front side of the Communication module 1 Image 10 9 3 Position the 4 plastic spacers reference 2 image 10 10 on the holes of the WIFI module 4 Position the WIFI module reference 3 image 10 10 on the spacers 5 Install the screws reference 4 image 10 10 and sec...

Page 155: ... 7 image 10 13 in the hole on the front side of the Communication module 8 Plug in the antenna wire connector reference 8 image 10 13 on the WIFI module 9 Secure the antenna wire by installing the lock washer and nut reference 9 image 10 13 8 9 7 Image 10 13 10 Install the antenna reference 10 image 10 14 by screwing it on its base R5905312 HDF W SERIES 24 01 2013 151 ...

Page 156: ...10 Card Cage 10 Image 10 14 11 Install the Communication module on the Input Communication Unit See Installation of an input module page 147 152 R5905312 HDF W SERIES 24 01 2013 ...

Page 157: ...146 2 Remove the drive fastener reference 1 image 10 15 from the front side of the Communication module 1 Image 10 15 3 Slide in the SIM card into the SIM card holder reference 2 image 10 16 2 Image 10 16 4 Position the 2 plastic spacers reference 3 image 10 17 on the holes of the GSM module 5 Position the GSM module reference 4 image 10 17 on the spacers while plugging in the board to board conne...

Page 158: ...ntenna reference 7 image 10 19 in the hole on the front side of the Communication module 8 Plug in the antenna wire connector reference 8 image 10 19 on the GSM module 7 8 Image 10 19 9 Secure the antenna wire by installing the lock washer and nut reference 9 image 10 20 9 Image 10 20 10 Install the antenna reference 10 image 10 21 by screwing it on its base 154 R5905312 HDF W SERIES 24 01 2013 ...

Page 159: ...10 Card Cage 10 Image 10 21 11 Install the Communication module on the Input Communication Unit See Installation of an input module page 147 R5905312 HDF W SERIES 24 01 2013 155 ...

Page 160: ...s from the Input Communication unit See service procedure Removal of an input module page 146 2 Remove the top cover of the Input Communication unit Use a 5 5mm nut driver to loosen the four nuts reference 1 im age 10 22 and use a 2 5mm Allen wrench to loosen the eight screws at the sides and the rear reference 2 image 10 22 2 1 Image 10 22 3 Disconnect the gray flat cable reference 1 image 10 23 ...

Page 161: ...e 10 25 5 Remove the Warp module from the PMP board assembly See Replacing the Warp module page 159 6 Remove the Deinterlacing module from the PMP board assembly See Replacing the Deinterlacing module page 160 7 Replace the PMP board Use a T10 Torx driver to loosen fasten the 8 screws reference 8 image 10 26 and use a 5 5mm nut driver to loosen fasten the five spacers reference 9 image 10 26 as il...

Page 162: ...the bottom as illustrated 11 Connect the gray flat cable reference 1 image 10 23 and the red cable reference 2 image 10 24 from the LCD Display Interface with the PMP board 12 Install the top cover of the Input Communication unit Use a 5 5mm nut driver to fasten the four nuts reference 1 image 10 22 and use a 2 5mm Allen wrench to fasten the eight screws at the sides and the rear reference 2 image...

Page 163: ... board assembly from the Input Communication unit See first steps of the service procedure Replacing the PMP board page 156 2 Replace the Warp module from the PMP board assembly Use a T10 Torx driver to loosen fasten the four screws reference 4 4 Image 10 27 3 Install the complete PMP board assembly back on the Input Communication unit See service procedure Replacing the PMP board page 156 R590531...

Page 164: ...ve the Warp module from the PMP board assembly See Replacing the Warp module page 159 3 Replace the Deinterlacing module from the PMP board assembly Use a T10 Torx driver to loosen fasten the screws reference 5 and use a 5 5mm nut driver to loosen fasten the spacer reference 6 Note that the spacer contains a plain washer reference 7 6 5 6 7 5 Image 10 28 4 Reinstall the Warp module See Replacing t...

Page 165: ...erence 5 image 10 29 from the LCD Display Interface 4 5 Image 10 29 3 Disconnect the small flex cable reference 1 image 10 30 of the LCD Display from the LCD Display Interface board Ensure to disconnect the small flex prior to disconnect the large flex reference 2 image 10 30 Caution Open the latch of the socket prior to pull out the flex cables Note that the latch of the smallest socket reference...

Page 166: ...rom the LCD Display Interface Open the latch of the cable socket before inserting the flex cable Ensure to lock afterwards 8 Connect the two flex cables of the LCD Display from the LCD Display Interface board First insert the large flex and then the small flex Open the latch of the cable sockets before inserting the flex cables Ensure to lock afterwards 9 Connect the red cable and gray cable with ...

Page 167: ...rface first See service procedure Replacing the LCD Display Interface page 161 3 Replace the LCD Display use a 5 5mm nut driver to loosen fasten the four screws of the mounting plate at the rear side of the LCD Display Caution Ensure that the port view and the screen of the LCD Display are clean 1 Image 10 34 4 Install the LCD Display Interface See service procedure Replacing the LCD Display Inter...

Page 168: ...play Interface page 161 3 Peel off the Local Keypad from the front side of the Input Communication unit 4 Stick a new Local Keypad upon the front side Make sure to position the new Local Keypad correctly Make sure to guide the flex cable of the Local Keypad through the opening reference 1 image 10 35 in the frame 1 Image 10 35 5 Install the LCD Display Interface See service procedure Replacing the...

Page 169: ...plug the power cord at UPS INLET for removal of all power from the projector 2 Remove the input cover 3 Remove the 5 screws reference 1 image 10 36 unplug the electrical connector reference 2 image 10 36 and remove the backlight 4 Bring the new backlight into position install the 5 screws reference 1 image 10 36 and plug in the electrical connector reference 2 image 10 36 1 1 1 1 1 2 Image 10 36 R...

Page 170: ...g screws reference 1 to 4 off the cover of the SMPS compartment 2 3 1 4 Image 10 37 2 Remove the cover of the SMPS compartment Image 10 38 3 Pull out the SMPS board 3 or 4 centimeters out of its compartment and disconnect the following connectors Mains input reference 1 Ground wire reference 2 Control connector blue wires reference 3 Power out connector black wires reference 4 1 2 3 4 Image 10 39 ...

Page 171: ...s Mains input reference 1 Ground wire reference 2 Control connector blue wires reference 3 Power out connector black wires reference 4 Caution Support the bottom of the SMPS board while plugging in the wire units 1 2 3 4 Image 10 41 7 Place the cover on its place and fasten the 4 retaining screws reference 1 to 4 image 10 37 R5905312 HDF W SERIES 24 01 2013 167 ...

Page 172: ...10 Card Cage 168 R5905312 HDF W SERIES 24 01 2013 ...

Page 173: ...y the different parts the diagnostic LED s the replacement of the Lamp power supply module the replacement of a large Lamp Power Supply LPS with a 2 single modules Lamp power supplies Overview LPS module diagnostic LED s Removal of a LPS module Installation of a LPS module R5905312 HDF W SERIES 24 01 2013 169 ...

Page 174: ...IN PFC OK LPS OK MAINS INPUT 3 2 1 4 5 6 7 8 Image 11 1 1 Diagnostic LED LPS HEARTBEAT orange 2 internal use only 3 Diagnostic LED LPS TRANS orange 4 Diagnostic LED ERROR red 5 Diagnostic LED PFC OK green 6 Diagnostic LED LPS OK green 7 Diagnostic LED LAMP ON green 8 Diagnostic LED LVPS OK yellow Diagnostic About the orange LEDs next to the CTRL connectors LED 2 is only for internal use LED 1 is t...

Page 175: ...olt and the lamp is not ignited ON ON ON ON OFF LPS unit is operating normally Projector lamp is ignited ON OFF OFF OFF ON LPS internal temperature is too high Check if the LPS air inlet at the bottom side of the projector is not blocked Check if the air outlet at the rear of the projector is not blocked If the problem remains replace the whole LPS module Flashing fast Error detected inside this L...

Page 176: ...PS module remove the CTLB OUT 2 and CTLB IN 1 connections For the right LPS module remove the CTLB IN connection 2 3 Disconnect the LAMP OUT cables from the LPS module Use a 10 mm nut driver Note Do not loose the washers 4 Disconnect the MAINS INPUT cables 5 Disconnect the grounding wires PE wires 4 from both LPS modules 4 4 Image 11 3 Grounding wires 6 Release the 4 captive screws 1 and take off ...

Page 177: ...11 Lamp Power Supply Image 11 4 Fixation screws Image 11 5 Fixation plate 7 Slide out the defective LPS module Image 11 6 Remove LPS unit R5905312 HDF W SERIES 24 01 2013 173 ...

Page 178: ...in the left position when seen from the backside of the unit For a LPS unit to be built in at the right side of the LPS compartment the positioning pin must be in the right position when seen from the backside of the unit To move the pin to the left or the right pull on the pin and slide it to the left or to the right 2 Take the new LPS module and slide in the LPS module in the LPS compartment so ...

Page 179: ...ets of the LPS module as illustrated Insert at the same time the connector coming from he second LPS unit Fasten the nuts with a torque of 4Nm 2 95 lbf ft If it is the left LPS module push the high power cables through the handle of the this LPS module before connecting to the LAMP OUT socket Warning Make sure to place the washers and cable eyes in correct order upon the pin as illustrated Always ...

Page 180: ...y of the socket and cables Red marked cables with the pin black marked cables with the pin Image 11 13 High power connection left 7 Connect the mains input cables with the MAINS INPUT sockets of the new LPS module as illustrated Plug the connector of the blue or white wire into the socket labeled with N N N Image 11 14 Mains input connection left and right LPS module 176 R5905312 HDF W SERIES 24 0...

Page 181: ...RESS connector of the right LPS unit 3 Make sure that the indication Left and Right is at the correct side When the right LPS module is replaced connect the wire unit coming from CTLB OUT socket of the left LPS with the CTLB IN socket 2 Make the connection between the ADDRESS connector of the left LPS unit and the ADDRESS connector of the right LPS unit 3 Make sure that the indication Left and Rig...

Page 182: ...11 Lamp Power Supply 178 R5905312 HDF W SERIES 24 01 2013 ...

Page 183: ...12 Start Pulse Generator 12 START PULSE GENERATOR R5905312 HDF W SERIES 24 01 2013 179 ...

Page 184: ...12 Start Pulse Generator 180 R5905312 HDF W SERIES 24 01 2013 ...

Page 185: ...e by a superimposing transformer which is in series with the positive connection from the LPS to the 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 D E B A C Image 12 1 A Black marked cable lug Has to be connected with the negative LAMP OUT pin of the ...

Page 186: ...he 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 attempt to ignite and then drops to 0 volt Note The ambient noise must be low to hear the SPG clicking in an attempt to ignite the lamp Check the cabling of the SPG module Replace the SPG module You can not hear the SPG module three times clicking in a...

Page 187: ...OUT pins of the LPS module Use for that a 10 mm nut driver Caution Do not loose the washers which fit between the fixation nuts and the cable eye Tip Place the washers and nuts back upon the output pins Image 12 2 Disconnect SPG cables 2 Remove the cover of the start pulse generator as illustrated This cover is secured with 5 hexagon socket head cap screws Use for that a 3 mm Allen key Image 12 3 ...

Page 188: ...move 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 install Image 12 5 Remove SPG 184 R5905312 HDF W SERIES 24 01 2013 ...

Page 189: ...Gently guide the thick wires through the frame opening Make sure that the lamp house is removed from the projector Image 12 6 Install SPG 2 Fasten the 3 captive screws S of the start pulse generator as illustrated using a flat screw driver 1 1 1 Image 12 7 SPG fixation screws 3 Install the cover of the start pulse generator as illustrated The cover has to be fasten with 5 hexagon socket head cap s...

Page 190: ...able eyes in correct order upon the pin as illustrated Always use a plain washer between the output pin and the cable eyes P W E1 E2 L N Image 12 9 P LPS output pin W Plain washer L Lock washer E1 Cable eye from SPG module E2 Cable eye from LPS unit N Nut Warning Respect the polarity of the socket and cables Red marked cables with the pin black marked cables with the pin 186 R5905312 HDF W SERIES ...

Page 191: ...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 12 11 5 Reinstall the lamp house and the covers of the projector R5905312 HDF W SERIES 24 01 2013 187 ...

Page 192: ...12 Start Pulse Generator 188 R5905312 HDF W SERIES 24 01 2013 ...

Page 193: ...ocessor before entering the projector into the dust free area CAUTION Wear a wrist band which is connected to the ground while handling the electrostatic discharge sensitive parts CAUTION Remove the projector lens before removing the Light Processor Overview Introduction HDF Light Processor Diagnostic Removing the Light Processor Installing the Light Processor Replacement of the shutter Cleaning t...

Page 194: ...s its own cooling block The Light Processor is equipped with 4 temperature sensors Each channel has one temperature sensor on its cooling block These temperature sensors helps to protect the Light Processor for overheating The red and green channel are equipped with three extended adjustment knobs to convergence the DMD with the DMD of the blue channel which is the reference channel for convergenc...

Page 195: ...ht Processor Check this list to ensure the problem is caused by the Light Processor Artifacts in the projected image These artifacts are also visible on the internal service patterns of the Satellite boards A crack in the prism which can result in convergence problems and may disables you to focus the projected image Unacceptable amount of dark bright or flat state pixels on one or more DMDs Block...

Page 196: ...plate Turn out both fixation screws 1 2 slide the plate to the side of the projector and take off the plate 1 1 2 Image 13 2 Convergence cover 3 Disconnect the formatter cables DMD temperature sensor cables prism etc as indicated on the drawing from the power distri bution board Fans chassis White plug multi color wires Formatter DMD back DMD front DMD block TEC back Shutter Pump Lightpipe Engine ...

Page 197: ...coupling both valved fitting Once valved fitting is located in the tube coming from the pump and leading to the light processor The second valved fitting is located in the tube coming from the light pipe entrance and leading to the heat exchanger To interrupt a valved fitting press on the knob 1 and pull out the connector 2 R5905312 HDF W SERIES 24 01 2013 193 ...

Page 198: ...ake the light processor unit by its handle and gently pull out the light processor assembly of its compartment Pull the cables through the hole in the plate Note Support the light processor while taking it out 194 R5905312 HDF W SERIES 24 01 2013 ...

Page 199: ...13 HDF Light Processor 1 Image 13 6 8 Place the light processor assembly on a stable table R5905312 HDF W SERIES 24 01 2013 195 ...

Page 200: ...e Image 13 7 corner bracket light processor assembly 3 Take the light processor assembly by its handles and gently slide in the assembly into the compartment of the projector Make sure that the positioning pins P at the backside of the assemble match the positioning holes H in the projector Note While inserting the assembly guide the cables to the Input Communication side trough the indicated hole...

Page 201: ...13 HDF Light Processor H H H P P P Image 13 9 Light processor insertion 4 Secure the light processor assembly by fastening both captive screws 1 2 R5905312 HDF W SERIES 24 01 2013 197 ...

Page 202: ... head screw 3 6 Close the cooling circuit Plug in the connector with the tube coming from the pump into the connector going to the light processor Plug in the connector mounted on the tube coming from the light pipe cooling block into the connector mounted on the tube going to the heat exchanger 198 R5905312 HDF W SERIES 24 01 2013 ...

Page 203: ...13 HDF Light Processor Image 13 11 Close cooing circuit 7 Couple the electrical connectors with the Power Distribution Board For the location of the connections see R5905312 HDF W SERIES 24 01 2013 199 ...

Page 204: ... connector group B C D corresponds with a bunch of wires with 3 connectors and represents a specific color B red C green D blue This color must correspond with the colored cable tie 3 mounted on each bunch of wires 2 Couple the 3 connectors of each bunch first the biggest connector then the green and orange connector according to the color of the connector seats 4 on the board 1 3 4 Image 13 14 Co...

Page 205: ...13 HDF Light Processor Drive in both fixation screws S 1 S F H H F 1 2 Image 13 15 Light processor cover mounting R5905312 HDF W SERIES 24 01 2013 201 ...

Page 206: ...ht Processor has to be removed from the projector before replacing the dowser This procedure as sumes that the Light Processor is already removed from the projector Necessary tools 2 5 mm Allen wrench How to replace the dowser of the Light Processor 1 Disconnect the wire unit of the shutter Image 13 16 Dowser connection 2 Remove the shutter assembly from the Light Processor by releasing both hexag...

Page 207: ...13 HDF Light Processor 1 Image 13 18 Mount new dowser 4 Reconnect the wire unit of the dowser image 13 16 R5905312 HDF W SERIES 24 01 2013 203 ...

Page 208: ... well ventilated area Keep away from sources of ignitions Do not smoke while working with isopropanol Exclusive keep in original container tightly closed at a cool well ventilated and fireproof storage space Necessary tools Clean Toraysee cloth Clean cotton cloth Demineralized water Isopropanol alcohol How to clean the clean the Prism exit side 1 Wipe off the dust of the Prism exit Use for that a ...

Page 209: ... the light sensor module replacement Necessary tools 7mm flat screwdriver T10 Torx driver How to replace 1 Disconnect the light sensor cable reference 1 image 13 19 1 2 2 Image 13 19 2 Turn out both screws reference 2 image 13 19 and take off the light sensor module 3 Place a new module on the light pipe sockets and drive in both fixation screws reference 2 image 13 19 4 Plug in the cable into the...

Page 210: ...emoved from the Light Pipe This procedure assumes that the left side cover is already removed from the projector In most cases the Fold Mirror can be correctly aligned by turning the upper two adjustment screws of the Fold Mirror These upper two screws can be accessed with a nut driver through the holes of the Fold Mirror cover So the removal of the Fold Mirror cover is unnecessary How to adjust t...

Page 211: ...13 HDF Light Processor C A B 4 5 6 B A C Image 13 21 Fold mirror adjustment 5 Reinstall the cover of the Fold Mirror 6 Reconnect the Light Sensor Module R5905312 HDF W SERIES 24 01 2013 207 ...

Page 212: ...Necessary tools 7mm flat screwdriver 2 5mm Allen wrench How to replace 1 Disconnect the wire unit reference 1 image 13 22 of the High Contrast plate 1 Image 13 22 2 Turn out the 4 screws reference 1 to 4 image 13 23 1 2 3 4 Image 13 23 3 Slide out the high contrast plate assembly 4 Insert a new high contrast plate assembly 5 Drive in the 4 screws image 13 23 6 Reconnect the cable of the high contr...

Page 213: ...e channel is fixed and can not be adjusted The red and green channel have pivot plates equipped with three extended control knobs for convergence adjustment The adjustment knobs are numbered from 1 to 6 and have the same color as the channel which they effect 1 5 6 4 2 3 Image 13 24 1 Red channel knob number 1 2 Red channel knob number 2 3 Red channel knob number 3 4 Green channel knob number 4 5 ...

Page 214: ...rection indicated by the arrow marked on the knob The three convergence control knobs of one channel stand in relation with each other So a change to one of them will also effect the adjustment results of the two others Therefore all three control knobs have to be alternately and repeatedly adjusted until the projected color is perfectly converged with the blue reference color of the test pattern ...

Page 215: ...sponds with one full pixel The direction on the control knob corresponds with the direction of the arrow of the test pattern 1 Image 13 26 2 Slightly turn the red colored control knob number 2 until the red pattern in the lower left of the projected image converges with the blue pattern 2 5 Image 13 27 3 Slightly turn the red colored control knob number 3 until the red pattern in the upper right o...

Page 216: ...13 HDF Light Processor 5 Repeat from step 2 until full coincidence is obtained of the red pattern in the center lower left and upper right of the projected image 212 R5905312 HDF W SERIES 24 01 2013 ...

Page 217: ...ponds with one full pixel The direction on the control knob corresponds with the direction of the arrow of the test pattern 4 Image 13 29 2 Slightly turn the green colored control knob number 5 until the green pattern in the lower left of the projected image converges with the blue pattern 2 5 Image 13 30 3 Slightly turn the green colored control knob number 6 until the green pattern in the upper ...

Page 218: ...13 HDF Light Processor 5 Repeat from step 2 until full coincidence is obtained of the green pattern in the center lower left and upper right of the projected image 214 R5905312 HDF W SERIES 24 01 2013 ...

Page 219: ...ecting this can damage the Lens Holder and Prism Overview Introduction Lens Holder Available lenses Lens selection Lens installation Lens removal Lens safety cable Cleaning the lens Removing the Lens Holder Mounting a new Lens Holder Scheimpflug adjustment Replacement of the Vertical Shift stepper motor Replacement of the Horizontal Shift stepper motor R5905312 HDF W SERIES 24 01 2013 215 ...

Page 220: ... the screen The motors required for horizontal and vertical shift are built in in the Lens Holder The Lens Holder always has an electrical socket for the zoom and focus functionality of the motorized Lens Parts identification of the Lens Holder 5 4 1 6 2 3 Image 14 1 1 Lens Holder front plate 2 Electrical socket Lens connection 3 Lens lock handle 4 Lens Holder Vertical Shift motor 5 Adjustment scr...

Page 221: ...s 0 8 1 Image 14 3 R9840770 TLD fixed lens 1 2 1 Image 14 4 R9840775 TLD 1 2 1 fixed lens Image 14 5 R9852010 TLD HB zoom lens 1 6 2 0 1 Image 14 6 R9842080 TLD HB zoom lens 2 0 2 8 1 Image 14 7 R9862030 TLD HB zoom lens 2 8 4 5 1 Image 14 8 R9842120 TLD HB zoom lens 5 0 8 0 1 Image 14 9 R9862000 TLD lens 0 73 1 Image 14 10 R9862005 TLD zoom lens 1 16 1 49 1 R5905312 HDF W SERIES 24 01 2013 217 ...

Page 222: ...010 TLD zoom lens 1 5 2 0 1 Image 14 12 R9862020 TLD zoom lens 2 0 2 8 1 Image 14 13 R9862030 TLD zoom lens 2 8 4 5 1 Image 14 14 R9862040 TLD zoom lens 4 5 7 5 1 Image 14 15 R9829997 TLD zoom lens 7 5 11 0 1 218 R5905312 HDF W SERIES 24 01 2013 ...

Page 223: ...room 3 Start up the Lens Calculator on the Barco website http www barco com en tools lenscalculator to determine the possible lenses for your configuration The Lens Calculator window opens Image 14 16 Lens calculator The Lens Calculator can also be used to determine the position of the projector when the lens type and screen width is known R5905312 HDF W SERIES 24 01 2013 219 ...

Page 224: ...s 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 the lens connector matches the socket B Image 14 18 Lens insertion 6 Insert the lens until the connector seats into the socket Warning Do not release the Lens yet as the Lens may fall out of the Lens Holde...

Page 225: ...14 Lenses and Lens Holder Image 14 19 Lock lens 8 Check if the lens is really secured by trying to pull the lens out of the lens holder R5905312 HDF W SERIES 24 01 2013 221 ...

Page 226: ...holder Image 14 21 Lens removal It s recommended to place the Lens caps of the original Lens packaging back on both sides of the removed Lens to protect the optics of the Lens It s recommended to place the foam rubber of the original projector packaging back into the Lens opening to prevent intrusion of dust Note that this foam rubber is packed in a plastic bag to prevent the dust emitted by the f...

Page 227: ...ns Make sure the cable is mounted between the motor part and the mounting flange 1 2 3 3 Image 14 22 Lens safety cable 1 Lens motor block 2 Mounting flange 3 Clamp 2 Insert both cable sides into the clamp Strap the cable and make sure that the clamp is positioned on 45 from the bottom to avoid interference of the cable with the lens locking mechanism Secure the cable by fixating the nut of the cla...

Page 228: ...14 Lenses and Lens Holder Image 14 23 Clamp position 3 Turn the cable with hook lock around the carry handle and hook the hook lock around the cable Image 14 24 224 R5905312 HDF W SERIES 24 01 2013 ...

Page 229: ... CLEAN Toraysee cloth 2 Wipe lenses in a one single direction Warning Do not wipe back and forwards across the lens surface as this tends to grind dirt into the coating 3 Do not leave the cleaning cloth in either an open room or lab coat pocket as doing so can contaminate the cloth 4 If smears occur when cleaning lenses replace the cloth Smears are the first indication of a dirty cloth CAUTION Do ...

Page 230: ...remove the Lens Holder from the projector 1 Remove the lens front cover from the projector 2 Disconnect all wire units reference 1 image 14 32 of the wire three from the Lens Holder 1 Image 14 25 3 Disconnect the EMC wire unit reference 2 image 14 26 of the Lens Holder from the frame 2 Image 14 26 4 Disconnect the wire unit reference 3 image 14 27 of the horizontal shift motor and the wire unit re...

Page 231: ...ge 14 29 Use a 5mm Allen wrench 5 5 5 5 Image 14 29 7 Connect the wire unit reference 3 image 14 30 of the horizontal shift motor and the wire unit reference 4 image 14 31 of the vertical shift motor 3 Image 14 30 4 Image 14 31 8 Mount the EMC wire unit reference 2 image 14 32 of the Lens Holder to the projector frame by driving in the fixation screw R5905312 HDF W SERIES 24 01 2013 227 ...

Page 232: ...ens Holder 2 Image 14 32 9 Connect all wire units reference 1 image 14 33 of the wire three from the Lens Holder 1 Image 14 33 10 If necessary strap the cables with some cable ties 228 R5905312 HDF W SERIES 24 01 2013 ...

Page 233: ...5 mm Allen wrench How to mount 1 Place the Lens Holder on the projector chassis and fasten with the 4 screws reference 5 image 14 34 Use a 5 mm Allen wrench Note One motor must point the right side of the projector and the other one must point to the top of the projector 5 5 5 5 Image 14 34 R5905312 HDF W SERIES 24 01 2013 229 ...

Page 234: ...ane Lp3 Lp4 SCREEN DMD Lp1 Lp2 Fp1 Fp2 SCREEN DMD Lp3 Lp4 Fp3 Fp4 Scheimpflug Image 14 35 Scheimpflug principle Scheimpflug principle The plane of sharp focus can be changed so that any plane can be brought into sharp focus When the DMD plane and lens plane are parallel the plane of sharp focus will also be parallel to these two planes If however the lens plane is tilted with respect to the DMD pl...

Page 235: ... nut 4 See image 14 36 5 Optimize the focus of the projected image as follows a Place the zoom lens in TELE position smallest projected image and adjust the focus using the lens focus barrel or motorized focus control b Place the zoom lens in WIDE position largest projected image and adjust the focus by turning equally on nut 1 2 and 3 c Repeat steps a and b until the projected image is as sharp a...

Page 236: ...e screen by adjusting nut 1 1 F Image 14 39 Left bottom focusing 7 Sharpen bottom right corner of the screen by adjusting nut 2 2 F Image 14 40 Right bottom focusing 8 Sharpen top right corner of the screen by adjusting nut 3 232 R5905312 HDF W SERIES 24 01 2013 ...

Page 237: ...ly by hand Tip Any movement of the image will affect the Scheimpflug adjustment 2 Fasten lock nuts a b and c 3 Turn in set screw D lightly by hand allowing the image to move slightly 1 3 to 1 2 of a square 1 3 to 1 2 Image 14 42 4 Fasten lock nut d 5 Tighten nut 4 until the offset of the image movement created in step 3 is canceled Tip The amount of image movement in step 3 will determine how tigh...

Page 238: ...illustrated It s not necessary to disconnect the Ground wire from the front plate Just turn the front plate away for accessing the stepper motor Caution Do not loosen the three big springs of the adjustment mechanism 2 Image 14 43 2 Remove the Vertical stepper motor from the assembly by loosing the four screws reference 9 as indicated Use a 3mm Allen wrench 9 Image 14 44 3 Remove bracket and other...

Page 239: ...n the four big nuts reference 7 image 14 43 Fasten the big nuts crosswise bit by bit Ensure that the upper two rods and the lower left rod contain a big spring Proceed with reinstalling the Lens Holder and calibrate the Motor Control Board See procedure Lenses and Lens Holder page 215 and Calibrate Motor Control Board page 286 The Lens Holder has to be adjusted after installation See procedure Sch...

Page 240: ... illustrated It s not necessary to disconnect the Ground wire from the front plate Just turn the front plate away for accessing the stepper motor Caution Do not loosen the three big springs of the adjustment mechanism 2 Image 14 46 2 Remove the Horizontal stepper motor from the assembly by loosing the four screws reference 9 as indicated Use a 3mm Allen wrench 9 Image 14 47 3 Remove bracket and ot...

Page 241: ...n the four big nuts reference 2 image 14 46 Fasten the big nuts crosswise bit by bit Ensure that the upper two rods and the lower left rod contain a big spring Proceed with reinstalling the Lens Holder and calibrate the Motor Control Board See procedure Lenses and Lens Holder page 215 and Calibrate Motor Control Board page 286 The Lens Holder has to be adjusted after installation See procedure Sch...

Page 242: ...14 Lenses and Lens Holder 238 R5905312 HDF W SERIES 24 01 2013 ...

Page 243: ...hanediol 1 3 ethanediol 2 3 Demi water Not for household use Keep out of reach of children Harmful by oral intake Avoid exposure to pregnant women Avoid contact with eyes skin and clothing Avoid inhalation of the noxious fumes WARNING Only use Barco approved cooling liquid to refill the liquid cooling circuit of the projector Neglect ing this may lead to irreversible damage of the projector Overvi...

Page 244: ...the liquid cooling circuit by uncoupling the valved fitting at the heat exchanger Tip Sometimes a little cooling liquid will be spilled Wrap a small cloth around the valved fitting while uncoupling to absorb the spilled cooling liquid 1 2 Image 15 1 Uncouple heat exchanger 2 Insert the plastic tube which contains a female valved fitting into an empty bottle and then couple the female valved fittin...

Page 245: ...mage 15 2 Draining complete circuit OUT NO OUT Image 15 3 Draining circuit excluding light processor circuit 3 Fill the syringe with air Press in the valve of the male fitting when extracting air R5905312 HDF W SERIES 24 01 2013 241 ...

Page 246: ...lled syringe to the inlet of the cooling circuit and force air into the circuit via the syringe Liquid will be expelled from the circuit exit side into the empty bottle IN OUT Image 15 5 Draining complete cooling circuit 242 R5905312 HDF W SERIES 24 01 2013 ...

Page 247: ...it OUT IN Image 15 6 Draining cooling circuit excluding light processor circuit 5 Disconnect the syringe from the cooling circuit and repeat from step 3 until all cooling liquid is drained R5905312 HDF W SERIES 24 01 2013 243 ...

Page 248: ...connected with short tube with male valved fitting Bottle with cooling liquid Empty bottle with 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 1 2 Image 15 7 Uncouple heat exchanger 2 Couple a plastic tube which contains a female valved fitting to the exit side of the cooling circuit an...

Page 249: ...OUT Image 15 8 Filling complete cooling liquid circuit OUT NO OUT Image 15 9 Filling part of cooling liquid circuit light processor excluded 3 Fill the syringe with cooling liquid as follows R5905312 HDF W SERIES 24 01 2013 245 ...

Page 250: ...es are expelled Ensure that the tube end in the bottle remains emerged e Pull out the piston to fill the tubes and syringe completely with cooling liquid Keep holding the syringe upside down f Disconnect the filled syringe from the tube Make sure that there is no air inside the tube or syringe If necessary push the air outside the syringe and tube before disconnecting a b c d e f M F Image 15 10 4...

Page 251: ...15 Liquid cooling circuit IN OUT a b Image 15 11 Filling complete cooling liquid circuit R5905312 HDF W SERIES 24 01 2013 247 ...

Page 252: ...5 12 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 cooling circuit 248 R5905312 HDF W SERIES 24 01 2013 ...

Page 253: ...emale female tube adapter short tube with female valved fittings at both 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 fitting at the heat exchanger 1 2 Image 15 13 Uncouple heat exchanger 2 Insert the tube end of the plastic tube which contains a fema...

Page 254: ...ut 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 15 15 Caution It s important that there is no air inside the tube The pump is not self priming and hence is only capable of sucking through small volumes of air 4 Push the male valved fitting of the filled tube into the female valved fitting at the heat exchanger This is the e...

Page 255: ...h cooling liquid in the bottle is sucked into the cooling circuit while the old cooling liquid is pressed out of the circuit into the empty bottle Note Make sure that the end of the plastic tube remains immersed in the bottle with fresh cooling liquid Image 15 17 Main menu service Image 15 18 Service refill mode R5905312 HDF W SERIES 24 01 2013 251 ...

Page 256: ...ng liquid is sucked up into the circuit 7 Proceed with expelling the air from the liquid cooling circuit Tip You can use the bottle with the remaining fresh cooling liquid and the same tubes for the expelling procedure 8 Pressurize the liquid cooling circuit 252 R5905312 HDF W SERIES 24 01 2013 ...

Page 257: ...uit 1 Interrupt the liquid cooling circuit by uncoupling the valved fitting at the heat exchanger 1 2 Image 15 20 Uncouple heat exchanger 2 Fill a plastic tube which contains a male fitting with cooling liquid as follows a Connect a tube which contains a male M 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 t...

Page 258: ... female valved fitting at the heat exchanger This is the entrance of the liquid cooling circuit Make sure that the inlet of the filled tube remains immersed 4 Couple the other plastic tube which contains the female valved fitting to the other side of the cooling circuit and immerge the tube end without fitting in the same bottle wherein the first tube is immersed This is the exit of the liquid coo...

Page 259: ...hat 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 15 23 Main menu service Image 15 24 Service refill mode Image 15 25 6 Switch off the projector after all air bubbles are expelled This will take approximately 10 minutes Tip Air bubbles may no longer come out the exit of the tube in the bottle wi...

Page 260: ...ing circuit 1 Remove the side cover of the projector see Removal of the side cover page 99 2 Look through the small window and check the pressure indicated on the internal manometer of the liquid cooling circuit 1 0 5 Image 15 26 Pressure check 3 This pressure should be between 0 5 and 1 bar If the pressure indicated on the manometer is out of range inform the respon sible and qualified technician...

Page 261: ... This procedure assumes that the Light Processor is removed from the projector see chapter Light processor removal and that the liquid cooling circuit is drained see Draining the liquid cooling circuit Necessary tools PH2 Phillips screwdriver Soft cloths Cotton swabs Q tips ear buds How to clean 1 Remove the four screws reference 1 which fasten the pump house to the pump motor 1 1 1 1 Image 15 27 ...

Page 262: ...urn it smoothly If not successful stop this procedure and replace the pump completely 6 Slide the pump house with hose back on the pump motor Caution Make sure the sealing ring of the Pump motor is not damaged and is on its place 7 Fasten the four screws reference 1 of the pump house crosswise 1 1 1 1 Image 15 30 Pump house close Refill the liquid cooling circuit in case the pump is successfully c...

Page 263: ...have to use the pump motor and pump rotor This procedure assumes that the Light Processor is removed from the projector see chapter Light processor removal and that the liquid cooling circuit is drained see Draining the liquid cooling circuit Necessary tools 3 mm Allen wrench with ball point 7 mm open end wrench PH2 Phillips screwdriver Cloths Cotton swab How to replace the pump motor and pump rot...

Page 264: ... reference 3 when releasing the screw 2 2 3 3 Image 15 34 Pump removal 5 Replace the pump motor and pump rotor Image 15 35 Pump motor rotor 6 Secure the pump motor with two hexagon socket head cap screws reference 2 Use a 3 mm Allen wrench to fasten the screws and a 7 mm open end wrench to hold the nut reference 3 while fasten the screw Caution Make sure that the pump is mounted upon two rubber vi...

Page 265: ...mp house with hose on the new pump motor Caution Make sure that the new Pump motor is provide with a new rotor and a new sealing ring Image 15 37 Pump house installation 9 Fasten the four screws reference 1 of the pump house crosswise using a PH2 Phillips screwdriver 1 1 1 1 Image 15 38 Pump house fixation 10 Reconnect the wire unit of the pump R5905312 HDF W SERIES 24 01 2013 261 ...

Page 266: ...15 Liquid cooling circuit Image 15 39 Electrical connection 262 R5905312 HDF W SERIES 24 01 2013 ...

Page 267: ...p Image 15 40 Electrical disconnection 2 Cut both hoses from the pump house Cut just next to the clip to have a minimal loss in length of the hose Image 15 41 hose cutting 3 Remove both clips from the pump house Use an universal pair of pliers to push both clip tongs to each other in order to open the clip Note It is almost impossible to remove first the clip and then to pull off the hose 4 Releas...

Page 268: ...erence 7 9 and push the hoses over their respective nipple of the pump house Note that the thick nipple reference 6 is the input side of the pump house and has to be connected with the thick hose that comes from the pressure vessel The small nipple reference 8 is the output side of the pump house and should be connected with the hose that comes from the Light Processor 7 6 9 8 Image 15 44 Hose con...

Page 269: ...15 Liquid cooling circuit Image 15 45 Electrical connection R5905312 HDF W SERIES 24 01 2013 265 ...

Page 270: ...15 Liquid cooling circuit 266 R5905312 HDF W SERIES 24 01 2013 ...

Page 271: ...via the cooling circuit in the different parts inside the projector is extracted to the ambient in the heat exchanger Image 16 1 Overview Removing the defective heat exchanger Disassembling the heat exchanger assembly Assembling the new heat exchanger Mounting the heat exchanger assembly into the projector R5905312 HDF W SERIES 24 01 2013 267 ...

Page 272: ... valved fitting Once valved fitting is located in the tube coming from the pump and leading to the light processor The second valved fitting is located in the tube coming from the light pipe entrance and leading to the heat exchanger To interrupt a valved fitting press on the knob 1 and pull out the connector 2 1 2 Image 16 2 Open cooling tube 2 Loosen both indicated screws 268 R5905312 HDF W SERI...

Page 273: ... tie s 4 Disconnect the heat exchanger fan 2 1 2 Image 16 4 Heat exchanger fan 5 Drain the cooling circuit Exclude the light processor circuit Note The procedure for draining is described in the service manual 6 Pull out the complete assembly R5905312 HDF W SERIES 24 01 2013 269 ...

Page 274: ...16 Heat exchanger Image 16 5 Remove assembly 270 R5905312 HDF W SERIES 24 01 2013 ...

Page 275: ...l 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 16 6 Image 16 7 2 Pull off both tube assembly 2 4 3 Loosen on both sides the nuts holding the fan assembly to the heat exchanger R5905312 HDF W SERIES 24 01 2013 271 ...

Page 276: ...A B Image 16 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 272 R5905312 HDF W SERIES 24 01 2013 ...

Page 277: ...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 16 10 4 Secure with a clip 2 Push both clip tongs together and slide the clip on the hose Release the tongs and it clamps automatically 5 Push the tube coming from the flow switch on the output of the ...

Page 278: ...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 onto 274 R5905312 HDF W SERIES 24 01 2013 ...

Page 279: ...eat 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 16 11 2 Fasten both screws 3 Reinstall the electrical connection 2 1 2 Image 16 12 4 Couple up the hose coming from the light pipe entrance to the heat exchanger R5905312 HDF W SERIES 24 01 2013 275 ...

Page 280: ...16 Heat exchanger Image 16 13 276 R5905312 HDF W SERIES 24 01 2013 ...

Page 281: ...ACEMENT PROCEDURE Overview Replacing the Fan control board Replacing the Power distribution board Connections on the Power distribution board Replacing the motor control board MCB Calibrate Motor Control Board R5905312 HDF W SERIES 24 01 2013 277 ...

Page 282: ...0 Torx screwdriver Allen key How to replace 1 Turn out both fixation screw 1 of the fan control board cover 1 1 Image 17 1 2 Remove the cover 3 Remove the 4 fixation screws 2 of the fan control board 2 2 2 2 Image 17 2 4 Left up the board on the front side a little and pull it out of its sockets Note Make sure not to damage components on the back side of the 278 R5905312 HDF W SERIES 24 01 2013 ...

Page 283: ...ment procedure Image 17 3 5 Insert a new board and push it until it fits into its sockets 6 Turn in the 4 fixation screws 7 Mount the cover plate by driving in both fixation screws R5905312 HDF W SERIES 24 01 2013 279 ...

Page 284: ... T10 Torx L shape screwdriver Allen keys How to replace 1 Disconnect all connectors on the power distribution board Formatter power cables DMD cables fan cables lamp info module etc 2 Remove the screws of the power distribution board 1 1 1 1 1 1 Image 17 4 Remove screws 3 Take out the Power Distribution board 4 Insert a new Power distribution board 5 Secure with the 5 removed screws 6 Reconnect al...

Page 285: ...of the wire units are also color labeled and correspond with the color labeling on the sockets Other wire units have uniform colored wires which corresponds with the color labeling on the sockets on the board Plugs that cannot be inserted in a wrong position are not marked Image 17 5 Image 17 6 R5905312 HDF W SERIES 24 01 2013 281 ...

Page 286: ...MD block TEC back Shutter IR front Input Communication Black plug yellow wires IR rear CLO I2C Motor control XLR Front Lamp info Black plug 4 wires Switch Lamp LPS Relay LPS Control White wires Front Illum Switch Airflow Switch Engine Pump Lightpipe Engine air Front block Prism Image 17 7 Power distribution board 282 R5905312 HDF W SERIES 24 01 2013 ...

Page 287: ...essary tools T10 Torx screwdriver How to remove 1 Remove the front cover and the Input Communication cover 2 Remove the Input Communication unit 3 Remove the front air filter 4 To get access to the board the Light processor fan cover must be removed First turn out both screws 1 inside the Input Communication compartment 1 1 Image 17 8 5 Behind the front filter compartment turn out screw 2 3 4 and ...

Page 288: ...17 9 6 Remove the cover 7 Disconnect the wire units 1 to 4 from the motor control board 4 3 2 1 Image 17 10 Connections 8 Replace the motor control board Use a T10 Torx screwdriver to loosen fasten the five screws 284 R5905312 HDF W SERIES 24 01 2013 ...

Page 289: ...t black socket 10 Reinstall the light processor fan cover Make sure that the ground wire is mounted on the distance spacer 11 Mount the front filter Input Communication unit and reinstall the covers 12 Start the calibration procedure for the motor control board See Calibrate Motor Control Board page 286 R5905312 HDF W SERIES 24 01 2013 285 ...

Page 290: ...ill not be calibrated Note The Lens zoom and focus can also be calibrated separately 2 Start up the projector No need to ignite the lamp 3 Press the MENU button and enter the Alignment menu Image 17 12 4 Select Lens in the Alignment menu using the UP DOWN arrow buttons Do NOT enter the Lens menu Image 17 13 5 Press four times the numeric key 9 As a result the popup menu Calibrate All appears with ...

Page 291: ...e the most important fans inside the projector Overview Replacement of the Card Cage electronics fans Replacement of the SMPS fans Replacing the heat exchanger fan Cold mirror fan Replacement of the Light processor compartment fan Mains input fan Lamp cathode fan Lamp anode fan R5905312 HDF W SERIES 24 01 2013 287 ...

Page 292: ...r and front dust filter are already removed Necessary tools 3 mm Allen wrench How to replace the fans of the Card Cage boards compartment 1 Disconnect the wire unit reference 3 or 4 of image 18 1 of the fan reference 1 or 2 of image 18 1 which you want to replace 3 4 1 2 Image 18 1 2 Replace the fan Use a 3 mm Allen wrench to loosen fasten the four screws reference 1 or reference 2 image 18 2 of t...

Page 293: ... and front dust filter are already removed Necessary tools 3 mm Allen wrench How to replace the fans 1 Disconnect the wire unit reference 2 or 4 of image 18 3 of the fan reference 1 or 3 of image 18 3 which you want to replace 1 3 2 4 Image 18 3 2 Replace the fan Use a 3 mm Allen wrench to loosen fasten the four screws reference 1 or reference 2 image 18 4 of the left or right fan Ensure that the ...

Page 294: ... tubes is required Necessary tools Allen key 3 mm How to replace 1 Turn out the 4 socket head cap screws A on top of the fan A B C D Image 18 5 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 Place the fan cover plate on the fan B 6 Insert the 4 socket head cap screws A and secure the fan positio...

Page 295: ...e Start Pulse Generator as illustrated This cover is secured with 5 hexagon socket head cap screws Use a 3 mm Allen wrench Image 18 6 Remove SPG cover 2 Disconnect the fan wire reference 1 Tip Pull out the top filter for easy access to the fan wire connection 1 Image 18 7 Electrical disconnection 3 Turn out the 2 hexagon socket head cap screws at the right side reference 2 R5905312 HDF W SERIES 24...

Page 296: ...old mirror assembly 6 Turn out the 4 fixation screws reference 1 Take off the fan protection grid reference 2 and remove the fan reference 3 1 2 3 Image 18 9 7 Place new fan on the assembly with the arrow pointing to downwards 8 Place the protection grid on the fan and drive in the 4 fixation screws 9 Re install the cold mirror assembly 292 R5905312 HDF W SERIES 24 01 2013 ...

Page 297: ...ation unit and remove the front dust filter Necessary tools Allen key 3 mm How to replace 1 Remove the Light processor fan cover First turn out both screws 1 inside the Input Communication compartment 1 1 Image 18 10 2 Behind the front filter compartment turn out screw 2 3 4 and 5 Remove screw 6 which fixates the sensor Turn out the distance spacer 7 2 4 6 7 3 5 Image 18 11 R5905312 HDF W SERIES 2...

Page 298: ...1 2 2 Image 18 12 5 Turn out the 4 fixation screws 2 on top reference 2 of image 18 12and 2 at the bottom 6 Take off the safety grill and remove the fan 7 Place the safety grill on the new fan and mount the new fan Make sure the air flow is towards the light processor compartment 294 R5905312 HDF W SERIES 24 01 2013 ...

Page 299: ...onnect the power cable reference 1 of image 18 13 of the mains input fan connector is situated left on top of the fan 1 2 2 2 2 Image 18 13 2 Turn out the 4 fixation screws reference 2 of image 18 13 3 Take off the grid and the fan 4 Place the grid on a new fan and mount the fan 5 Drive in the 4 screw and reconnect the power cable R5905312 HDF W SERIES 24 01 2013 295 ...

Page 300: ...mp cover 2 Remove the lamp house Necessary tools 3 mm Allen wrench 7 mm flat screwdriver 7 mm nut driver How to replace 1 Remove the left side panel of the lamp compartment by removing the six indicated screws reference 1 1 1 1 Image 18 14 Side panel lamp house removal 2 Pull out the wire unit with connector from behind the plate and disconnect the power cable of the cathode fan 296 R5905312 HDF W...

Page 301: ...age 18 16 Small side plate removal 4 Remove the cathode fan assembly out of its compartment by releasing the five indicated screws reference 4 Cut the foam rubber reference 5 as it is stuck on different plates Tip Lift up and slightly turn the fan assembly to remove 4 4 5 Image 18 17 Cathode fan assembly removal 5 Disassemble the cathode fan assembly by removing the five indicated screws reference...

Page 302: ... a washer reference 7 Note that the wire unit of the fan must be guided trough the hole of the lower plate 6 7 Image 18 19 Assembling the unit 7 Install the fan assembly back in its compartment with five screws reference 8 Use a 3 mm Allen wrench Caution Make sure that the wire unit of the fan does not get jammed 8 8 Image 18 20 Cathode fan assembly mounting 298 R5905312 HDF W SERIES 24 01 2013 ...

Page 303: ...reference 9 9 Image 18 21 Small side plate mounting 9 Reconnect the wire unit of the cathode fan and hide the connector behind the plate Image 18 22 Cathode fan power connection 10 Reinstall the left side panel of the lamp compartment with six screws reference 10 R5905312 HDF W SERIES 24 01 2013 299 ...

Page 304: ...18 Fan replacement procedures 100 1 10 Image 18 23 Side panel lamp house installation 300 R5905312 HDF W SERIES 24 01 2013 ...

Page 305: ...he heat exchanger and the wire unit of the pump reference C as illustrated Use a set of pliers to cut the cable tie reference D which fasten the wire unit of the pump with the tubing C B D A Image 18 24 Electrical disconnection 2 Pull out the tube out of the tube fixation 3 Release the two fixation screws of the heat exchanger assembly and pull out the assembly Image 18 25 Remove heat exchanger as...

Page 306: ...reference 3 and then the 4 big screws in the middle reference 4 as illustrated Use a 2 5 mm and a 3 mm Allen wrench 3 4 5 Image 18 28 Remove fan 7 Install a new anode fan inside the fan house as follows a Guide the wire unit of the anode fan through the holes in mounting plates b Fasten the two mounting plates upon the fan with four hexagon socket head cap screws reference 6 as illustrated Provide...

Page 307: ...Allen wrench 9 9 Image 18 30 Insert fan assembly 9 Reinstall the anode fan bezel and security guard Use a 3 mm Allen wrench to secure the four hexagon socket head cap screws reference 10 10 Image 18 31 Mount fan security guard 10 Slide the heat exchanger assembly in its place and fasten the two fixation screws Use a 2 5 mm Allen wrench R5905312 HDF W SERIES 24 01 2013 303 ...

Page 308: ...plate 12 Reconnect the wire unit of the anode fan reference B the wire unit of the heat exchanger fan reference A and the wire unit of the pump reference C Use a cable tie reference D to secure the wire unit of the pump with the tubing C B D A Image 18 33 Electrical connection 304 R5905312 HDF W SERIES 24 01 2013 ...

Page 309: ...19 Board Diagnostic LED s 19 BOARD DIAGNOSTIC LED S R5905312 HDF W SERIES 24 01 2013 305 ...

Page 310: ...19 Board Diagnostic LED s 306 R5905312 HDF W SERIES 24 01 2013 ...

Page 311: ...NDERTEMP red 9 FPGA HEARTBEAT green 10 LPS COMM yellow 11 EXT WATCHDOG red 12 FPGA CONFIG red 13 FCB HEARTBEAT green 14 FCB COMM yellow 15 SWITCH FORCE BOOT View on the diagnostic LEDs The Fan Control Board is located behind the Input Communication unit To view the diagnostic LEDs of the Fan Control Board the Input Communication unit has to be placed in the service position as illustrated below mo...

Page 312: ... by the Fan Control Board to prevent projector damage In other words this is a hardware protection which switches off the lamp to prevent projector damage in case the software protection should fail Note that this hardware protection is the second protection Normally if one of these temperatures is about to exceed the hardware maximum level the Fan Control Board FCB software should have noticed th...

Page 313: ...e Fan Control Board is corrupt If this is the case try to reload the firmware and or software of the Fan Control Board 12 FPGA CONFIG red This LED lit up during the start up of the Fan Control Board and in case the FPGA of the Fan Control Board is not correctly loaded with the firmware If this is the case try to reload the firmware and or software of the Fan Control Board If the problem remains re...

Page 314: ... projector has to be removed Description of the diagnostic LEDs Ref Description LED color Comment 1 ERROR red This LED lit up in case there are communication problems If there are repeatedly communication problems try to reload the firmware and software of the Motor Control board If the problems remains replace the Motor Control Board 2 MCB COMM yellow This LED lit up each time the PMP board which...

Page 315: ...ertical shift is malfunctioning 8 ERROR CH7 8 red This LED lit up in case there are problems with operating the Shutter or Contrast plate of the projector This is caused by over current or over temperature of the driver Possible problems are the wire unit of the DC motor of the Shutter is damaged causing a short circuit the wire unit of the DC motor of the Contrast plate is damaged causing a short...

Page 316: ...he diagnostic LEDs of the Power Distribution board the Input Communication unit has to be placed in the service position as illustrated below moved forward and tilted For a better view it is recommended to remove the top cover of the projector as well Image 19 5 CAUTION Only operate the projector for a few minutes while the Input Communication unit is moved and tilted in it s service position This...

Page 317: ... 5V and 3 3V on the Switched mode power supply 2 POWER CTRL BAD red This LED lit up in case the standby voltage 12V form the Switched mode power supply is to low the white CONTROL wire unit is disconnected from the Switched mode power supply the Switched mode power supply is defect signal with mains frequency is missing 3 12V Main green This LED lit up in normal condition and indicates that the 3 ...

Page 318: ...FPGA CONFIG red This LED lit up during the start up of the Display Interface Board and in case the FPGA of the Display Interface Board is not correctly loaded with the firmware If this is the case try to reload the firmware and or software of the Display Interface Board If the problem remains replace the Display Interface Board 2 HEARTBEAT green This LED flashes once a second in normal operation w...

Page 319: ...eeding the maximum permitted internal temper ature limit due to insufficient airflow Description of the diagnostic LEDs Ref Description LED color Comment 1 12V OK green This LED lit up in normal condition and indicates that the 12V from the Power Box is available 2 FPGA CONFIG red This LED lit up during the start up of the DVI HDSDI Input module and in case the FPGA of the DVI HDSDI Input module i...

Page 320: ...D it up when the DVI input is selected 9 SYNC DVI yellow This LED lit up when a valid input sync is detected for the applied DVI source 10 SEL SDI 1 green This LED it up when the SDI 1 input is selected 11 SYNC DVI 1 yellow This LED lit up when a valid input sync is detected for the applied SDI source 12 SEL SDI 21 green This LED it up when the SDI 2 input is selected 13 SYNC DVI 2 yellow This LED...

Page 321: ... is moved and tilted in it s service position This to minimize the risk of exceeding the maximum permitted internal temper ature limit due to insufficient airflow Description of the diagnostic LEDs Ref Description LED color Comment 1 5V OK green This LED lit up in normal condition and indicates that the 5V standby voltage from the PMP is available The 5V is generated on the PMP and derived from th...

Page 322: ...the is switched off RED no communication with Lamp Info Module Check if the Lamp House is correctly mounted ORANGE the lamp is switched ON in ECO mode ORANGE GREEN the lamp is switched ON in CLO mode GREEN the lamp is switched ON in normal mode 8 IR green red This two color LED indicates the flowing GREEN the projector receives IR signal RED the received IR signal is acknowledged 9 WIFI SEL orange...

Page 323: ...G green 19 FIB FPGA CONFIG green 20 SCALER HEARTBEAT red 21 SCALER SYSTEM RESET yellow 22 SCALER MEMORY READY green 23 SCALER HEARTBEAT green View on the diagnostic LEDs The Pixel Mapping Processor is located inside the Input Communication unit None of the LEDs are visible without opening the projector To view the diagnostic LEDs the Input Communication unit has to be placed in the service positio...

Page 324: ...up in normal condition and indicates that the 12V standby voltage from the Power Backplane is available The 12V is generated on the Power Box 13 LOCAL STBY OK green This LED lit up in normal condition and indicates that all local standby voltage derived from the 12V are available 14 PMP HEARTBEAT green This LED flashes once a second in normal operation which indicates that the PMP board works prop...

Page 325: ...t the output clock of the DCM is stable 3 GP_LED3 red not used future expansion 4 CONV ADC SELECTED green There are two AD convertors on the board ADC98001 and ADV7802 This LED is to indicate which AD convertor is used This LED lit up incase the ADC is used and otherwise ADV is used 5 SYNC yellow This LED lit up when a valid and stable input sync is detected for the applied source 6 SEL green This...

Page 326: ...LB IN PFC OK LPS OK MAINS INPUT 3 2 1 4 5 6 7 8 Image 19 11 1 Diagnostic LED LPS HEARTBEAT orange 2 internal use only 3 Diagnostic LED LPS TRANS orange 4 Diagnostic LED ERROR red 5 Diagnostic LED PFC OK green 6 Diagnostic LED LPS OK green 7 Diagnostic LED LAMP ON green 8 Diagnostic LED LVPS OK yellow Diagnostic About the orange LEDs next to the CTRL connectors LED 2 is only for internal use LED 1 ...

Page 327: ...e the voltage value on the LAMP OUT pins is below 140 volt and the lamp is not ignited ON ON ON ON OFF LPS unit is operating normally Projector lamp is ignited ON OFF OFF OFF ON LPS internal temperature is too high Check if the LPS air inlet inside the projector is not blocked Check if the air outlet at the rear of the projector is not blocked If the problem remains replace the LPS module Flashing...

Page 328: ...19 Board Diagnostic LED s 324 R5905312 HDF W SERIES 24 01 2013 ...

Page 329: ... 59 Ambient temp open 60 Ambient temp short 60 Blue DMD temp high 58 Blue DMD temp low 58 Blue DMD temp open 59 Blue DMD temp short 59 Blue form start failed 33 Board id communication interface not accessible 44 Board id communication interface read error 44 Board id communication interface unknown format 44 Board id communication interface write error 44 Board id display module not accessible 45 ...

Page 330: ...ine too low 77 78 Fan speed heat exchanger front too high 80 Fan speed heat exchanger front too low 79 80 Fan speed lamp anode too high 82 Fan speed lamp anode too low 81 Fan speed lamp cathode too high 82 Fan speed lamp cathode too low 82 Fan speed mains input too high 81 Fan speed mains input too low 80 81 Fan speed power supply left too high 83 Fan speed power supply left too low 82 83 Fan spee...

Page 331: ...67 68 Power supply secondary temp low 67 Power supply secondary temp open 68 Power supply secondary temp short 68 Projector type invalid 90 Pump voltage high 75 Pump voltage low 75 Read failed 92 Read lamp status failed 35 Reading lamp info module 87 Recieve Overflow 92 Recieve Parity 92 Red DMD temp high 54 55 Red DMD temp low 53 54 Red DMD temp open 55 Red DMD temp short 56 Red form start failed...

Page 332: ...16 41 6017 41 6018 42 6019 42 6020 42 6021 42 6022 42 6024 42 6025 43 6026 43 6027 43 6028 43 6029 43 6030 43 6031 44 6032 44 6033 44 6034 44 6035 44 6036 45 6037 45 6038 45 6039 45 6040 45 6041 45 6042 46 6043 46 6044 46 6045 46 6046 47 6047 47 6048 47 6049 47 6050 47 6051 48 6052 48 6053 48 6054 48 6055 49 6056 49 6057 50 6058 50 6059 50 6060 50 6061 51 6062 51 6063 51 6064 51 6065 51 6066 51 60...

Page 333: ...0 76 7901 77 7902 77 7903 77 7904 77 7905 78 7906 78 7907 78 7928 78 7929 78 7930 79 7931 79 7932 79 7933 79 7934 79 7935 79 7936 79 7937 80 7938 80 7939 80 7940 80 7941 80 7942 81 7943 81 7944 81 7945 81 7946 82 7947 82 7948 82 7949 82 7950 82 7951 82 7952 82 7953 83 7954 83 7955 83 7956 83 7957 83 7958 83 8000 84 8001 84 8101 84 8102 84 8103 84 8104 84 8105 84 85 8106 85 8107 85 8108 85 8109 85 ...

Page 334: ...odule 146 147 install 145 147 Install 102 105 121 127 156 159 161 163 165 185 202 205 263 backlight 165 CLO 205 Deinterlacing module 160 Dowser 202 Front cover 102 Input cover 105 Lamp 127 Lamp cover 104 Lamp house 121 LCD Display 163 LCD Display Interface 161 Light Sensor 205 Local Keypad 164 Local Keypad backlight 165 PMP board 156 Pump complete 263 Shutter 202 Side cover 103 SPG 185 Warp module...

Page 335: ... Pixel Mapping Processor 319 Diagnostic LED 319 PMP board 156 Replace 156 Power distribution 280 281 Connections 281 Replace 280 Power Distribution 312 Diagnostic LED 312 Power input 110 112 115 Get access 110 Mains filter 112 113 Mount 113 Mains switch 114 115 Mount 115 Remove 114 Power Input 107 Pressure 256 Cooling circuit 256 Preventative 19 Maintenance actions 19 Prism 204 Clean 204 Projector...

Page 336: ...all 103 Remove 99 SMPS 166 Replace 166 SMPS fans 289 Replacement 289 Spare parts 14 SPG 181 183 185 Install 185 Introduction 181 Remove 183 Troubleshooting 182 Start Pulse Generator 179 T Test Pattern 210 Convergence 210 Troubleshooting 31 33 182 Checklist 33 SPG 182 U UV blocker 136 Clean 136 V Vertical Shift 234 Stepper motor 234 Replace 234 W Warp module 159 Replace 159 WIFI module 150 module 1...

Page 337: ...ordlaan 5 B 8520 Kuurne Phone 32 56 36 82 11 Fax 32 56 36 88 24 Support www Barco com esupport Web www barco com From Date Please correct the following points in this documentation R5905312 01 page wrong correct R5905312 HDF W SERIES 24 01 2013 ...

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