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ULC-30A

Service manual

R5906015/01
01/02/2018

Summary of Contents for ULC-30A

Page 1: ...ULC 30A Service manual R5906015 01 01 02 2018...

Page 2: ...Barco NV President Kennedypark 35 8500 Kortrijk Belgium Phone 32 56 36 82 11 Fax 32 56 36 883 86 Support www barco com en support Visit us at the web www barco com Printed in Belgium...

Page 3: ...rers Changes Barco provides this manual as is without warranty of any kind either expressed or implied including but not limited to the implied war ranties or merchantability and fitness for a particu...

Page 4: ......

Page 5: ...ary pump replacement process 37 8 2 Disconnecting the primary pump wiring 38 8 3 Removing the primary pump unit 40 8 4 Installing the primary pump unit 43 8 5 Connecting the primary pump wiring 45 9 S...

Page 6: ...Table of contents Index 97 2 R5906015 ULC 30A 01 02 2018...

Page 7: ...30A After this chapter additional warnings and cautions are given depending on the servicing procedure Read and follow these warnings and cautions as well WARNING This manual is only intended for qua...

Page 8: ...NT TO THE CUSTOMER OR BEFORE CONNECTING ACCESSORIES Leakage Current Tester Reading should not be above 3 5 mA Test all exposed metal surfaces Earth Ground 2 Wired cord Also test with plug reversed Usi...

Page 9: ...3M No 8210 table mat to prevent electrostatic charge buildup or exposure of the assembly c Do not use freon propelled chemicals These can generate electrical charges sufficient to damage ES devices d...

Page 10: ...1 Safety 6 R5906015 ULC 30A 01 02 2018...

Page 11: ...ctured for the purpose of cooling the lasers and DMD of the laser projector Cooling is estab lished by means of a liquid solution made of glycol and demineralized water A circulation pump forces the c...

Page 12: ...ondary cooling unit F Electronic equipment unit G Coolant tank 2 3 Covers WARNING Always install all covers before using the chiller About the covers Safety covers can be removed by a 3 mm hex screwdr...

Page 13: ...pen end 1 Open ended tube male connector to open end 20 Spare cover screws 2 aluminium caps used when removing the refrigeration module to prevent fluid from leaking 2 red plastic caps to cover the by...

Page 14: ...o serial ports at the rear side of the chiller Plug the other end of the cable into a USB port of the PC Image 2 5 Launch the Chiller service tool The service tool will automatically search for any co...

Page 15: ...fo on this procedure see also Replacing the logic board page 75 SD logging status For more info see also SD logging status page 67 Air removal procedure For more info on this procedure see also First...

Page 16: ...on The flow tests are best performed when connected to a projector While the tests can be performed using the bypass tube instead the end result may trigger unnecessary errors or warnings 12 R5906015...

Page 17: ...or adequate extraction Check for InfoT s Check if any Info T have been released that need an intervention on the ULC 30A Check runtime Check runtime to verify if any runtime driven interventions are r...

Page 18: ...l tool needed Includes refill tool Service SW cable to connect laptop to chiller Replace together with Secondary cooling unit Draining and refill tool kit Replace filter cap Replace together with prim...

Page 19: ...witching off power and locking the switch Necessary tools Small padlock How to switch off power and lock the switch 1 Switch off power Image 4 1 2 Lock the power switch using a user provided padlock P...

Page 20: ...4 Switching on off power 2 Switch on the power switch Image 4 3 WARNING Always install all covers before using the chiller 16 R5906015 ULC 30A 01 02 2018...

Page 21: ...ver See Switching off power and locking the switch page 15 Overview Removing a cover Installing a cover 5 1 Removing a cover Overview All covers can be removed in a manner similar to the following pro...

Page 22: ...r 1 Install the cover Image 5 3 Installing the cover 2 Install the 14 screws First install the 3 screws reference 1 image 5 4 Then install the 11 remaining screws reference 2 image 5 4 Note This seque...

Page 23: ...5 Covers 1 1 1 2 2 2 2 2 2 2 2 2 2 2 Image 5 4 Installing the 14 screws R5906015 ULC 30A 01 02 2018 19...

Page 24: ...5 Covers 20 R5906015 ULC 30A 01 02 2018...

Page 25: ...t 6 1 Removal of the fan unit This procedure assumes the rear cover has been removed For more info see Covers page 8 Necessary tools Nut spanner 8 mm How to remove the fan unit 1 Unplug the cable conn...

Page 26: ...unit Necessary tools Nut spanner 8 mm How to install the fan unit 1 Install the fan unit Image 6 4 Installing the fan unit 2 Install the 6 screws reference 1 image 6 5 using the nut spanner 8 mm 1 1 1...

Page 27: ...6 Fan unit 3 Plug in the cable connector Image 6 6 Plugging in the cable connector R5906015 ULC 30A 01 02 2018 23...

Page 28: ...6 Fan unit 24 R5906015 ULC 30A 01 02 2018...

Page 29: ...ank Replacing the tank cap assembly Cooling liquid visual check 7 1 First use of the Chiller service kit Air removal procedure About the Chiller service kit bypass tube Ensure the bypass tube has no a...

Page 30: ...has been removed For more info see Covers page 8 How to drain the coolant circuit of a single ULC 30A chiller 1 Remove the fan unit See procedure Removal of the fan unit page 21 2 If requested by the...

Page 31: ...upler located on a small support on the bottom of the chiller and connect it to the previous location of hose E on the lower coupler of the pump D D D Image 7 5 Redirecting hose D 7 Switch on power Th...

Page 32: ...ped into the external container 11 Switch off power See procedure Switching off power and locking the switch page 15 12 Remove the service kit hoses 13 Disconnect hose D pressurization pump suction li...

Page 33: ...ge 7 10 Connecting service kit hose to upper quick coupler 4 Manually fill the tank using half of the liquid collected while draining the chiller Coolant procedures page 25 See procedure Adding coolan...

Page 34: ...metal quick connector of the chiller create a loop Image 7 12 Connecting service hose to lower quick coupler 9 Connect hose F chiller tank return line to the upper coupler of the pump F Image 7 13 Co...

Page 35: ...glycol 70 demineralized water This procedure assumes that power has been switched off Unless otherwise stated power must be off prior to start with this procedure To switch off power see procedure Sw...

Page 36: ...eep watching to make sure you do not overfill 5 Re install the tank cap assembly Image 7 17 Installing the tank cap assembly Note Make sure the O ring in the tank cap is correctly positioned Note Remo...

Page 37: ...ower must be off prior to start with this procedure To switch off power see procedure Switching off power and locking the switch page 15 How to replace 1 Remove the coolant return hose Image 7 19 Remo...

Page 38: ...ge may occur Keep a cloth or towels ready 4 Tighten the tank cap ring Image 7 22 Tightening the tank cap ring Note Make sure the O ring in the tank cap is correctly positioned 5 Install the coolant re...

Page 39: ...d 3 Switch on the power The chiller will notice a pressure difference due to the open ended hose and the pump will activate As a result cooling fluid will fill the container 4 Switch off the power aft...

Page 40: ...7 Coolant procedures 36 R5906015 ULC 30A 01 02 2018...

Page 41: ...ese instructions to avoid electrical shocks CAUTION It is important to follow the Service Tool wizard step by step Do not click too rapidly through the replacement process wizard This could cause unwa...

Page 42: ...16 Finish the replacement process by finishing the wizard disconnecting the PC cable installing the covers and connecting the chiller back to the projector other chiller s and the power net 8 2 Disco...

Page 43: ...your chiller is located in a dimly lit area This will make it easier to reconnect the wiring afterwards 4 3 1 2 Image 8 4 Removing the pump motor wiring 5 Loosen the cable gland and remove the cable...

Page 44: ...itched off Unless otherwise stated power must be off prior to start with this procedure To switch off power see procedure Switching off power and locking the switch page 15 How to remove the primary p...

Page 45: ...onto the coupler image 8 9 e Install the cap included in the service kit onto the pump fitting image 8 9 Image 8 9 Installing plug and cap Note Always use the plugs and caps included in the service ki...

Page 46: ...f the screws is not necessary 6 Remove the primary pump unit a First move the primary pump unit 10 cm towards the front of the chiller Image 8 12 Removing the primary pump unit step 1 of 2 b Then tilt...

Page 47: ...tch page 15 How to install the primary pump unit 1 Mount the primary pump unit a Tilt the front side of the primary pump unit inwards the left side of the chiller and move to the front for 10 cm Image...

Page 48: ...p cable connector Image 8 18 Plugging the primary pump Unit cable connector 5 Connect the two open type quick couplers of the refrigeration unit Note First remove the caps and plugs Check the cleanlin...

Page 49: ...of the primary pump replacement process For more info see Primary pump replacement process page 37 8 5 Connecting the primary pump wiring Necessary tools Phillips screwdriver PH2 Nut spanner 7 mm Thi...

Page 50: ...motor wiring 1 Cable ID 1 to motor connection U 2 Cable ID 2 to motor connection V 3 Cable ID 3 to motor connection W 4 Cable ID 4 to motor housing connection GND 5 Tighten the cable gland to fix the...

Page 51: ...nstalled on site Image 9 1 Overview Removing the Secondary cooling unit Installing the Secondary cooling unit 9 1 Removing the Secondary cooling unit Necessary tools Allen wrench 4 mm Wire cutters Thi...

Page 52: ...ler tank return line from the DMD return line F Image 9 3 Disconnecting hose F 5 Disconnect the hose G of the DMD send line from the upper coupler of the pump G Image 9 4 Disconnecting DMD send line 6...

Page 53: ...r 7 Remove the 2 cable ties Image 9 6 Removing cable ties 8 Remove the two insulation shells from the hose couplers of the secondary unit Image 9 7 Removing insulation shells 9 Disconnect the two hose...

Page 54: ...2 1 Image 9 10 Removing two screws 11 Remove the secondary cooling unit Image 9 11 Removing Secondary cooling unit 12 If no further service of the chiller is required do the following Place the screw...

Page 55: ...C 30A chiller How to install the Secondary cooling unit 1 Remove the Fan unit See procedure Removal of the fan unit page 21 2 Remove the five screws and the washers image 9 13 and image 9 14 3 Mount t...

Page 56: ...oses 6 Install the two insulation shells onto the hose couplers Image 9 16 Installing insulation shells 7 Install new cable ties Image 9 17 Installing cable ties 8 Plug in the cable connector of the S...

Page 57: ...MD send line onto the upper coupler of the pump G Image 9 19 Connecting DMD send line 10 Connect hose F chiller tank return line onto the DMD return line F Image 9 20 Connecting hose F 11 If no furthe...

Page 58: ...12 If no further service of the chiller is required install the Fan unit See procedure Installation of the fan unit page 22 13 If no further service of the chiller is required install all covers See...

Page 59: ...izard step by step Do not click too rapidly through the replacement process wizard This could cause unwanted effects such as gross spillage of coolant How to replace 1 Make sure the chiller is disconn...

Page 60: ...l wizard only Ensure all required steps have been per formed prior to pump removal For more info see Refrigeration unit replacement process page 55 Necessary tools Flat screwdriver Allen wrench 4 mm N...

Page 61: ...the pump fitting image 10 4 Use a cloth or towels to catch spillages before plugging the couplers using the service kit plugs and caps c Close the clip of the coupler image 10 4 Image 10 4 Removing th...

Page 62: ...2 image 10 7 In order to do so remove the nut reference 1 from the compressor 2 1 Image 10 7 Removing the nut and wiring cover from the compressor 8 Disconnect the compressor wiring Image 10 8 Disconn...

Page 63: ...nnected to the compressor thermal switch Image 10 10 12 Remove the 5 screws at the bottom of the refrigeration Unit Use the nut spanner 8 mm to remove the screws 1 1 1 1 1 Image 10 11 Removing the 5 s...

Page 64: ...Before shipping the defective refrigeration unit it is important to use the original packaging that came with the replacement refrigeration unit Install the 6 screws 1 1 1 1 1 1 Image 10 14 Preparing...

Page 65: ...ff power and locking the switch page 15 How to install the refrigeration unit 1 Install the refrigeration unit Image 10 15 Installing the refrigeration Unit 2 Install the 3 screws reference 1 image 10...

Page 66: ...2 1 Image 10 18 Removing the nut and wiring cover from the compressor 5 Connect the compressor wiring 3 1 2 Image 10 19 Connecting the compressor wiring 1 Cable ID 1 2 Cable ID 2 3 Cable ID 3 Image 1...

Page 67: ...ng connection cover and nut 8 If a thermal switch is present in the compressor connect the two wires to the thermal switch contacts Image 10 22 Or If a thermal switch is not present use the jumper to...

Page 68: ...hen the connector is correctly inserted Image 10 25 Connecting the quick coupler 11 Insulate the refrigeration Unit quick couplers a Apply contact glue to all mating surfaces of the insulation shells...

Page 69: ...10 Refrigeration unit 13 Perform the filling procedure see procedure Filling the coolant circuit page 28 R5906015 ULC 30A 01 02 2018 65...

Page 70: ...10 Refrigeration unit 66 R5906015 ULC 30A 01 02 2018...

Page 71: ...ojector you can enable the SD card logging for a certain amount of time e g an entire day to create a log dump of the entire chiller process not active projector starting up playing etc How to de acti...

Page 72: ...zard 2 Use the wizard to store a backup of the logic board parameters on your computer 3 Remove all covers See procedure Removing a cover page 17 4 Unplug the 3 cable connectors Image 11 1 Unplugging...

Page 73: ...e ground GND cable from the compressor 1 Image 11 4 Disconnecting the compressor GND cable 8 Reinstall the compressor wiring connection cover and nut 9 If present remove the cables connected to the co...

Page 74: ...If the secondary cooling unit has been installed unplug the cable connector to the secondary cooling unit Image 11 7 Unplugging the cable connector 13 Remove the Barco nameplate at the front of the c...

Page 75: ...screwdriver Allen wrench 3 mm Nut spanner 7 mm Nut spanner 8 mm Wire cutters This procedure assumes that power has been switched off Unless otherwise stated power must be off prior to start with this...

Page 76: ...s 1 1 Image 11 12 Installing the 2 screws 3 Install the 10 screws reference 1 image 11 13 Use an 8 mm nut spanner to install the screws 1 1 1 1 1 1 1 1 1 1 Image 11 13 Installing the 10 screws 4 Insta...

Page 77: ...ugging in the DMD cable connector 7 Connect the main pump motor wiring See Connecting the primary pump wiring page 45 8 Remove the compressor wiring connection cover reference 2 image 11 16 In order t...

Page 78: ...stall the screw reference 1 image 11 19 and ground GND cable onto the compressor 1 Image 11 19 Connecting the compressor GND cable 11 Reinstall the compressor wiring connection cover and nut 12 In cas...

Page 79: ...logic board The logic board contains the central processing unit CPU and manages all inputs and outputs needed to control the chiller com ponents and communicate with the projector s Necessary tools...

Page 80: ...e logic board as illustrated Image 11 24 Removing the logic board 6 Install the 6 screws reference 1 image 11 25 using the nut spanner 5 5 mm 1 1 1 1 1 1 Image 11 25 Installing 6 screws 7 Plug in the...

Page 81: ...pump inverter Installing the J1000 pump inverter Removing the V1000 pump inverter Installing the V1000 pump inverter 11 5 1 Removing the J1000 pump inverter Necessary tools Phillips screwdriver PH1 A...

Page 82: ...crew reference 1 image 11 28 of the front cover of the pump inverter 1 Image 11 28 Removing the screw 5 Remove the front cover of the pump inverter Image 11 29 Removing the cover 6 Remove the 8 wires...

Page 83: ...the pump inverter Image 11 32 Removing the pump inverter 11 5 2 Installing the J1000 pump inverter This procedure assumes that power has been switched off Unless otherwise stated power must be off pri...

Page 84: ...1 image 11 34 1 1 Image 11 34 Installing the 2 screws 3 Connect the 8 wires from the pump inverter Use the Phillips screwdriver PH2 to install the screws 5 8 7 6 1 2 3 4 Image 11 35 Connecting the wir...

Page 85: ...e screw reference 1 image 11 37 of the front cover of the pump inverter 1 Image 11 37 Installing the screw 6 Plug in the cable connector at the front cover of the pump inverter Image 11 38 Plugging in...

Page 86: ...the switch page 15 How to remove the pump inverter 1 Remove the front cover See procedure Removing a cover page 17 2 After switching off power wait for at least 1 minute to allow the inverter capacit...

Page 87: ...he screwdriver down 1 turn the control wire 2 45 3 and pull it out of the terminal 45 1 3 2 Image 11 42 Removing the control wires 7 Use a small flat screwdriver to open the wiring terminals and remov...

Page 88: ...hed off Unless otherwise stated power must be off prior to start with this procedure To switch off power see procedure Switching off power and locking the switch page 15 How to install the pump invert...

Page 89: ...stall the screws 5 8 7 6 1 2 3 4 Image 11 47 Connecting the wires 1 Pump motor connection 1 U 2 Pump motor connection 2 V 3 Pump motor connection 3 W 4 PMP INV N 5 PMP INV L 6 DC REACT 7 8 GND 4 Use a...

Page 90: ...l the front cover of the pump inverter Image 11 51 Installing the cover 6 Install the screw reference 1 image 11 37 of the front cover of the pump inverter Use a PH1 screwdriver 1 Image 11 52 installi...

Page 91: ...11 Electronics Unit Image 11 53 Plugging in the cable connector 8 Install the front cover See procedure Installing a cover page 18 R5906015 ULC 30A 01 02 2018 87...

Page 92: ...11 Electronics Unit 88 R5906015 ULC 30A 01 02 2018...

Page 93: ...ew Removing the pressurization Unit Installing the pressurization Unit 12 1 Removing the pressurization Unit Necessary tools Nut spanner 8 mm This procedure assumes that power has been switched off Un...

Page 94: ...bility 4 Remove the 4 nuts reference 1 image 12 3 Use the nut spanner 8 mm to remove the nuts 1 1 1 1 Image 12 3 Removing the 4 nuts Note Only these 4 screws must be removed The other screws must not...

Page 95: ...To switch off power see procedure Switching off power and locking the switch page 15 How to install the pressurization Unit 1 Install the pressurization Unit Image 12 5 Removing the pressurization Un...

Page 96: ...te Reinstall the surrounding DMD hoses if removed 4 Plug in the cable connector Image 12 8 Plugging in the cable connector 5 If no further service is required install the Fan unit See procedure Instal...

Page 97: ...s A B A Image 13 1 2 Remove the front cover B 3 Lift the fasteners C C D D C E Image 13 2 4 Remove the filter D 5 Take a new filter and insert it at the back of the cover Lift up the fasteners to moun...

Page 98: ...ect to greasy air This procedure assumes that the dust filters are removed from the chiller See procedure Replacing the filter page 93 Necessary tools Vacuum cleaner with soft brush suction nuzzle How...

Page 99: ...e Health Effects Hazardous in case of skin contact irritant of eye contact irritant of ingestion of inhalation lung irritant Potential Chronic Health Effects Slightly hazardous in case of skin contact...

Page 100: ...A Appendix 96 R5906015 ULC 30A 01 02 2018...

Page 101: ...61 Secondary cooling unit 51 M Main parts 7 Maintenance 13 Preventive 13 3 yearly 13 30000 hours 13 Monthly 13 Yearly 13 P Pain pump unit 43 Installation 43 Power 15 Switching off 15 Switching on 15...

Page 102: ...p assembly 33 Replacement 33 Technical info 8 Covers 8 Technical information 7 Main parts 7 U ULC 30A 15 21 37 47 55 67 77 89 DMD Cooling Expansion Unit 47 Electronics Unit 67 Fan unit 21 Pressurizati...

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Barco ULC-30A, Service Manual

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