Barco FLM series Service Manual
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Barco FLM series Service Manual

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FLM series
Service manual
R59770072/00
19/03/2007

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  • Page 1 FLM series Service manual R59770072/00 19/03/2007...
  • Page 2 Barco nv Events Noordlaan 5, B-8520 Kuurne Phone: +32 56.36.89.70 Fax: +32 56.36.88.24 E-mail: sales.events@barco.com Visit us at the web: www.barco.com Printed in Belgium...

  • Page 3: Table Of Contents

    11.4 Adjusting the integration rod ..................... . . 115 R59770072 FLM SERIES 19/03/2007...
  • Page 4 24.2.2 Mounting a new cold mirror fan....................242 R59770072 FLM SERIES 19/03/2007...
  • Page 5 Index........................325 R59770072 FLM SERIES 19/03/2007...
  • Page 6 Table of contents R59770072 FLM SERIES 19/03/2007...

  • Page 7: Safety

    FLM 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. Overview • Safety Instructions R59770072 FLM SERIES 19/03/2007...

  • Page 8: Safety Instructions

    Any design alterations or additions may void the manufacturer’s warranty and may make you, the servicer responsible for personal injury or property damage resulting therefrom. R59770072 FLM SERIES 19/03/2007...
  • Page 9 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, always consult the appropriate current BARCO service literature.
  • Page 10 1. Safety R59770072 FLM SERIES 19/03/2007...

  • Page 11: General Info

    2. General info 2. GENERAL INFO Overview • Location of modules • Spare part kits R59770072 FLM SERIES 19/03/2007...

  • Page 12: Location Of Modules

    Front Light processor side Image 2-1 Projector orientation Rear side and Lamp side Image 2-2 Reference Description IR receiver Lamp power supply unit (LPS) unit Lamp unit Cathode fan assembly Input & communication unit Backlight unit R59770072 FLM SERIES 19/03/2007...
  • Page 13 2. General info Lamp side Image 2-3 Reference Description Backplane Signal distribution board Motor control board Switched mode power supply (SMPS) unit Formatter interface board R59770072 FLM SERIES 19/03/2007...
  • Page 14 Light processor side - Front side Image 2-4 Reference Description IR receiver Heat exchanger + fan Light processor assembly (light processor + light pipe) Anode fan Start pulse generator Cold mirror assembly Cold mirror fan Manometer + pressure vessel R59770072 FLM SERIES 19/03/2007...

  • Page 15: Spare Part Kits

    Light processor & light pipe (shutter included) R849250K IR UV filter R8492501K IR UV filter R849151K Shutter blizzard assembly R764773K Communication interface R764775K Fan & motor control unit R764760K Formatter interface board R765132K Formatter interface board R764833K Lamp power supply (LPS) R59770072 FLM SERIES 19/03/2007...
  • Page 16 LCD panel 160x80 6H$LED BL B3722365K Mains switch 35A UL/CSA B3580251K Motor DC 12V D17 + 134:1 B3580252K Motor DC 12V D17 + 134:1 R764240K Projector tilt switch R848914K Carry handle (without parts for top mounting) R59770072 FLM SERIES 19/03/2007...

  • Page 17: Troubleshooting

    7658 → 7999 : Temperature, fan & motor related errors • 8000 → 8001: Shutter related errors • 8002 : Lamp EEPROM error • 9198 → 9398: CPU related errors • 10498 : Input module related error R59770072 FLM SERIES 19/03/2007...

  • Page 18: 1000 → 1017 : Lamp Parameters Related Errors

    Check if the wire unit coming from the blue socket in the lamp compartment is plugged into its socket (ref D image 3-2) on the backplane behind the input & communication unit. Image 3-1 Image 3-2 R59770072 FLM SERIES 19/03/2007...

  • Page 19: 1692 → 1699 : Formatter Related Errors

    Replace the Formatter Interface Board. The status LED’s of the Formatter • If the problem remains contact Barco for further instructions. The formatter boards Interface Board (FIB) are visible are malfunctioning and have to be replaced at the factory. through the filter grid behind the front filter.
  • Page 20 Check if none of the wires came loose from the plugs on the wire unit. • Reboot the projector. If the problem remains contact Barco for further instructions. The formatter board of the blue channel is malfunctioning and has to be replaced at the factory.
  • Page 21 Check if none of the wires came loose from the plugs on the wire unit. • Reboot the projector. If the problem remains contact Barco for further instructions. The formatter board of the green channel is malfunctioning and has to be replaced at the factory.
  • Page 22 • Reboot the projector. If the problem remains contact Barco for further instructions. the formatter board of the missing The formatter board of the involved channel is malfunctioning and has to be color.

  • Page 23: 2000 → 2808 : Lamp Power Supply (Lps) Related Errors

    Check if the pins of the sockets of the SMPS and/or Fan & Motor control board are not damaged or bend over. Image 3-7 LPS address wire unit. LPS control wire unit. G LPS grey wire unit. Image 3-8 LPS grey wire unit. R59770072 FLM SERIES 19/03/2007...
  • Page 24 SPG clicking in an attempt to ignite the lamp. Error 2004 : “Lamp goes out” Situation Solution Exhausted lamp. Lamp with Replace the exhausted lamp with a new one. many strikes, maximum run time exceeded. R59770072 FLM SERIES 19/03/2007...
  • Page 25 140 volt, which is required to trigger the SPG, on the “LAMP OUT” pins of the LPS unit. Error 2206 : “Lamp ignition failed” This error is generated by the LPS unit with address 0x20. R59770072 FLM SERIES 19/03/2007...
  • Page 26 LPS unit with address 0x22. Error 2503 : “BOOST start failed” The same troubleshooting checklist can be applied to as for Error 2203. The only difference is that this error is generated by the LPS unit with address 0x22. R59770072 FLM SERIES 19/03/2007...
  • Page 27 LPS unit with address 0x28 Error 2808 : “Lamp power range” The same troubleshooting checklist can be applied to as for Error 2208. The only difference is that this error is generated by the LPS unit with address 0x28. R59770072 FLM SERIES 19/03/2007...

  • Page 28: 4000 : Incompatible Hardware Error

    Error 4000 : “Incompatible hardware” Situation Solution One or more parts of the projector • Reinstall the original parts of the projector. Use only original Barco spare parts are replaced with incompatible for servicing. parts. • If the problem persists, contact Barco for further instructions.

  • Page 29: 4198 : Pixel Map Related Error

    The controller was unable to • Reboot the projector. initialize the FPGA of the Pixel Map Processor (PMP). • If the problem persists, reinstall the PMP firmware using the Projector Toolset. • If the problem persists, replace the PMP. R59770072 FLM SERIES 19/03/2007...

  • Page 30: 5095 → 5098 : Flash Memory Related Errors

    Check if the latest projector software is installed. the internal backup device has failed. • Reinstall the latest projector software. • If the problem persists, contact Barco for further instructions. Error 5096 : “Storing unsuccessful” Situation Solution Storing the custom settings from the •...

  • Page 31: 7658 → 7999 : Temperature, Fan & Motor Related Errors

    “Engine air temp open”. Damaged socket (ref E image 3-10) Check if no pins are bent over of the socket for the wire unit of the temperature sensor on the FIB. (E). Image 3-10 Engine air temperature sense. R59770072 FLM SERIES 19/03/2007...
  • Page 32 Make sure that the plate, on which the projector is mounted for transport, is removed. Error 7662 : “Blue block temp short” This error may be preceded by a warning. This error can only appear on the FLM HD series. R59770072 FLM SERIES 19/03/2007...
  • Page 33 This error may be preceded by a warning. This error can only appear on the FLM HD series. Temperature of the water cooling block of the blue channel is to high. If this problem persist the projector will shut down the lamp. R59770072 FLM SERIES 19/03/2007...
  • Page 34 Image 3-13 Pump liquid cooling circuit. Electrical connection pump. Rotor of pump. Error 7666 : “Green block temp short” This error may be preceded by a warning. This error can only appear on the FLM HD series. R59770072 FLM SERIES 19/03/2007...
  • Page 35 If this problem persist the projector will shut down the lamp. Situation Solution Interruption of the liquid cooling Check if the loop of the liquid cooling circuit is closed. circuit. R59770072 FLM SERIES 19/03/2007...
  • Page 36 3-15) on the water cooling block of the red channel. When disconnecting the wire unit of the temperature sensor from the Formatter Interface Board (FIB) the error code is changed to 7671 : “Red block temp open”. Image 3-15 R59770072 FLM SERIES 19/03/2007...
  • Page 37 Note: to exit the “Refill mode” you have to switch off the projector. Error 7674 : “Front block temp short” This error may be preceded by a warning. This error can only appear on the FLM HD series. R59770072 FLM SERIES 19/03/2007...
  • Page 38 (ref H image 3-16), which measures • If not repairable, replace the light processor. Contact Barco for further instructions the temperature of the common to repair the malfunction light processor. water cooling block of the heat pipes.
  • Page 39 TEC (Thermoelectric cooler) located between DMD and cooling block. Wire unit leading to the temperature sensor at the back side of the DMD. Wire unit leading to the temperature sensor at the front of the DMD R59770072 FLM SERIES 19/03/2007...
  • Page 40 (ref D image 3-17) which measures • If not repairable, replace the light processor. Contact Barco for further instructions the temperature at the front of the to repair the malfunction light processor. DMD of the blue channel. When...
  • Page 41 (ref D image 3-17) which measures • If not repairable, replace the light processor. Contact Barco for further instructions the temperature at the front of to repair the malfunction light processor. the DMD of the green channel.
  • Page 42 Repair the wire unit. temperature sensor which measures the temperature at • If not repairable, replace the light processor. Contact Barco for further instructions the front of the DMD of the green to repair the malfunction light processor. channel. Defect temperature sensor which Replace the light processor.
  • Page 43 (ref D image 3-17) which measures • If not repairable, replace the light processor. Contact Barco for further instructions the temperature at the front of the to repair the malfunction light processor. DMD of the red channel. When...
  • Page 44 Situation Solution The temperature on the front side of If this warning persist, contact Barco for further instructions. the DMD of the red channel is low. Error 7696 : “Light pipe temp short” This error may be preceded by a warning. This error can only appear on the FLM HD series.
  • Page 45 Replace lamp house with new lamp house. Misalignment of the cold mirror. Readjust the cold mirror, see "Adjusting the cold mirror", page 127. Error 7927 : “fan speed mains input too low” This error may be preceded by a warning. R59770072 FLM SERIES 19/03/2007...
  • Page 46 Check if the light processor is properly installed. Ensure that both fixation screws at the installed foot of the light processor are fastened. Check if the formatter interface board is well inserted and secured. See procedure "Installing the light processor", page 106. Error 7936 : “Tilt” This is a warning. R59770072 FLM SERIES 19/03/2007...
  • Page 47 Check if the lamp house is properly installed. Ensure that the three fixation screws of installed in its compartment. the lamp house are fastened. See procedure "Installation of the lamp house", page 91. Error 7939 : “Prism” This is a warning. R59770072 FLM SERIES 19/03/2007...
  • Page 48 This is a warning. Situation Solution The +5 volt supply voltage for the Replace the Fan & Motor control board. Formatter Interface Board is too low. Error 7944 : “5V voltage high” This is a warning. R59770072 FLM SERIES 19/03/2007...
  • Page 49 This is a warning. Situation Solution The supply voltage “30V” from which Replace the Fan & Motor control board. all fan supplies are subdivided is too high. Error 7957 : “30V voltage low” This is a warning. R59770072 FLM SERIES 19/03/2007...
  • Page 50 This error may be preceded by a warning. Situation Solution The supply voltage for the “mains Replace the Fan & Motor control board. input” fan, which is located behind the rear cover of the projector, is too low. R59770072 FLM SERIES 19/03/2007...
  • Page 51 Replace the Fan & Motor control board. cools the anode of the lamp is too low. The fan for the lamp anode cooling is mounted underneath the light processor. Error 7972 : “Fan 1 voltage high” This is a warning. R59770072 FLM SERIES 19/03/2007...
  • Page 52 Check the speed and voltage (using the service menu) of the lamp anode fan or lamp cathode fan. cathode fan. Replace any malfunctioning fan. Error 7980 : “Blue DMD temp high” This error may be preceded by a warning. R59770072 FLM SERIES 19/03/2007...
  • Page 53 Malfunction TEC of the involved Remove the light processor from its compartment and replace the malfunction TEC. DMD. Use the “diode test” of a If problem persist contact Barco for further instructions. multi-meter to check out the TEC. Polarity doesn’t matter. The TEC is not OK in case the measured value is higher then 0,01 volt.
  • Page 54 Malfunction TEC of the involved Remove the light processor from its compartment and replace the malfunction TEC. DMD. Use the “diode test” of a If problem persist contact Barco for further instructions. multi-meter to check out the TEC. Polarity doesn’t matter. The TEC is not OK in case the measured value is higher then 0,01 volt.
  • Page 55 Malfunction TEC of the involved Remove the light processor from its compartment and replace the malfunction TEC. DMD. Use the “diode test” of a If problem persist contact Barco for further instructions. multi-meter to check out the TEC. Polarity doesn’t matter. The TEC is not OK in case the measured value is higher then 0,01 volt.
  • Page 56 Unblock the fan. Ensure that the fan can turn freely. Damaged wire unit. Check if the wire unit of the fan is not damaged. Repair if possible, otherwise replace with new one. Fan end of life. Replace the fan. See "Cathode fan replacement", page 249. R59770072 FLM SERIES 19/03/2007...

  • Page 57: 8000 → 8001: Shutter Related Errors

    Twisted shutter plate. Replace the shutter assembly. See "Shutter replacement", page 203. Malfunction motor of the shutter Replace the shutter assembly. See "Shutter replacement", page 203. assembly. Defect end of range switch. Replace the defect switch. R59770072 FLM SERIES 19/03/2007...

  • Page 58: 8002 : Lamp Eeprom Error

    Error 8002 : “Lamp EEPROM” This is a warning. Situation Solution The projector is unable to read out Place a new lamp house in the projector. the lamp EEPROM during the start up of the projector. R59770072 FLM SERIES 19/03/2007...

  • Page 59: 9198 → 9398: Cpu Related Errors

    Replace the Pixel Map Processor (PMP) if the problem persist. Error 9398 : “Maximum image files reached” Situation Solution The maximum allowed number of Delete some unnecessary custom made image files. image files has been reached. R59770072 FLM SERIES 19/03/2007...

  • Page 60: 10498 : Input Module Related Error

    3.11 10498 : Input module related error Error 10498 : “Unsupported module” Situation Solution Input slot contains an input module Replace the unsupported input module with a supported version. which is not supported by the projector due to obsolete firmware. R59770072 FLM SERIES 19/03/2007...

  • Page 61: About Lenses

    This chapter gives an overview of the different lenses, lens formulas and the procedure how to install a new lens. Overview • Available lenses • Lens selection • Lens formulas for FLM R20+ • Lens formulas for FLM HD projectors • Lens installation • Lens removal R59770072 FLM SERIES 19/03/2007...

  • Page 62: Available Lenses

    TLD HB zoom lens (2.0 - 2.8 : 1) TLD HB zoom lens (2.8 - 5.0 : 1) Image 4-7 R9840910: TLD zoom lens (5.0 - 8.0 : 1) ; R9842120: TLD HB zoom lens (5.0 - 8.0 : 1) R59770072 FLM SERIES 19/03/2007...

  • Page 63: Lens Selection

    SW. Tip: Divide PD by SW to determine the approximately required throw ratio. Choose a lens, which captures the calculated throw ratio. Use the lens formula of the chosen lens to recalculate exactly. Image 4-8 R59770072 FLM SERIES 19/03/2007...

  • Page 64: Lens Formulas For Flm R20

    The throw ratio of TLD (HB) lenses is slightly reduced when used on FLM projectors. The reason of this decrease is the larger active field of the SXGA+ DMD chip set used in the FLM projector. R59770072 FLM SERIES 19/03/2007...

  • Page 65: Lens Formulas For Flm Hd Projectors

    4.35 – 6.95 = (4.17 x SW ) - 0.01 = (4.17 x SW ) - 0.39 TLD HB (5.0 – 8.0 : 1) = (6.95 x SW ) - 0.29 = (6.95 x SW ) - 11.42 R59770072 FLM SERIES 19/03/2007...

  • Page 66: Lens Installation

    7. Secure the lens in the lens holder by sliding the lens lock handle into the “locked” position, which is away from the lens power supply socket. Ensure the lens touches the front plate of the lens holder. R59770072 FLM SERIES 19/03/2007...
  • Page 67 8. Check if the lens is really secured by trying to pull the lens out of the lens holder. AUTION Never transport the projector with a lens mounted in the lens holder. Always remove the lens before transporting the projector. Neglecting this can damage the lens holder and prism. R59770072 FLM SERIES 19/03/2007...

  • Page 68: Lens Removal

    It’s recommended to place the foam rubber of the original projector packaging, back in the lens opening to prevent intrusion of dust. Note that this foam rubber is packed in a plastic bag to prevent that dust, emitted by the foam, enters the projector. R59770072 FLM SERIES 19/03/2007...

  • Page 69: Carrying Handle

    FLM carrying handle without parts for top mounting (spare kit to replace carrying handle at the bottom of the FLM projector. Fixation screws not included) Overview • Replacement of the bottom carrying handle • Installing the carrying handle on top of the projector R59770072 FLM SERIES 19/03/2007...

  • Page 70: Replacement Of The Bottom Carrying Handle

    3. Install the new carrying handle as illustrated. Reuse the four hexagon socket head screws (H) and washers (W) which you removed in the previous step. Image 5-4 4. Place the projector back on its feet. R59770072 FLM SERIES 19/03/2007...

  • Page 71: Installing The Carrying Handle On Top Of The Projector

    3. Mount four spacers (S) on top of the projector as illustrated. Image 5-7 4. Place the carrying handle upon the spacers with the adjustable feet upwards as illustrated. 5. Fasten the carrying handle using four hexagon socket head bolts M10 x 30 (F) and washers (W). R59770072 FLM SERIES 19/03/2007...
  • Page 72 5. Carrying handle Image 5-8 Note: The hexagon bolts which fasten the bottom carrying handle are longer then the hexagon bolts (M10 x 30) which fasten the top carrying handle. R59770072 FLM SERIES 19/03/2007...

  • Page 73: Removal And Installation Of Projector Covers

    • Installation of the top cover • Installation of the back cover • Installation of the front cover • Installation of the side cover • Installation of the lamp cover • Installation of the input cover R59770072 FLM SERIES 19/03/2007...

  • Page 74: Removal Of The

    (left side is hinged) b) then slide the front cover to the right to release it from the hinging points. Image 6-2 R59770072 FLM SERIES 19/03/2007...

  • Page 75: Removal Of The Side Cover

    (A) of the side cover, b) then gently pull out the top corners (B) of the side cover, c) then move the side cover away from the projector (C). Image 6-4 R59770072 FLM SERIES 19/03/2007...

  • Page 76: Removal Of The Lamp Cover

    (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). Image 6-6 R59770072 FLM SERIES 19/03/2007...

  • Page 77: Removal Of The Input Cover

    (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). Image 6-8 R59770072 FLM SERIES 19/03/2007...

  • Page 78: Removal Of The

    Image 6-9 2. Remove the back cover of the projector doing the following: a) gently pull out the top corners of the back cover, b) then move the back cover away from the projector. Image 6-10 R59770072 FLM SERIES 19/03/2007...

  • Page 79: Removal Of The Top Cover

    How to remove the top cover from the projector 1. Turn out the 3 eye bolt (A). Image 6-11 Top cover removal 2. Remove the front interlocking adapter (B) using a 8 mm Allen key. 3. Take off the top cover. R59770072 FLM SERIES 19/03/2007...

  • Page 80: Installation Of The Top Cover

    1. Place the cover on the projector so that the holes matches the fixation holes in the frame. Image 6-12 Mount top cover 2. Push the interlocking adapter (A) on its place, turn in the bolt with an Allen key of 8 mm. 3. Turn in the 3 eye bolts (B). R59770072 FLM SERIES 19/03/2007...

  • Page 81: Installation Of The

    Image 6-13 3. Secure the back cover by locking the captive screws at the bottom corners of the back cover. Image 6-14 R59770072 FLM SERIES 19/03/2007...

  • Page 82: Installation Of The

    Image 6-15 4. Secure the front cover by locking the captive screw in the middle at the bottom of the front cover. Image 6-16 5. Reinstall the rubber dust ring around the lens holder. See image 6-16. R59770072 FLM SERIES 19/03/2007...

  • Page 83: Installation Of The Side Cover

    (C) into their receivers. Image 6-18 4. Secure the side cover by locking the captive screw in the middle at the bottom of the side cover. Image 6-19 R59770072 FLM SERIES 19/03/2007...

  • Page 84: Installation Of The Lamp Cover

    (C) into its receiver. Image 6-20 2. Secure the lamp cover by locking the two captive screws at the right side of the lamp cover. Image 6-21 R59770072 FLM SERIES 19/03/2007...

  • Page 85: Installation Of The Input Cover

    (C) into its receiver. Image 6-22 2. Secure the input cover by locking the two captive screws at the left side of the input cover. R59770072 FLM SERIES 19/03/2007...
  • Page 86 6. Removal and installation of projector covers R59770072 FLM SERIES 19/03/2007...

  • Page 87: Dust Filters

    FLM front, bottom and top filters (24 pieces each) Overview • Replacement of the dust filter on the front side • Replacement of the dust filter on the bottom side • Replacement of the dust filter on the top side R59770072 FLM SERIES 19/03/2007...

  • Page 88: Replacement Of The Dust Filter On The Front Side

    4. Reinstall the front cover of the projector, see "Installation of the front cover", page 80. AUTION Never install a used HEPA filter. Always install a new HEPA filter. 1. High Efficiency Particulate Arrestant R59770072 FLM SERIES 19/03/2007...

  • Page 89: Replacement Of The Dust Filter On The Bottom Side

    6. Fasten the two wedge lock screws (A) using a 2.5 mm Allen key as illustrated. Image 7-5 7. Reinstall the side cover of the projector, see "Installation of the side cover", page 81. AUTION Never install a used HEPA filter. Always install a new HEPA filter. R59770072 FLM SERIES 19/03/2007...

  • Page 90: Replacement Of The Dust Filter On The Top Side

    4. Reinstall the filter holder containing the new HEPA filter. 5. Reinstall the side cover of the projector, see "Installation of the side cover", page 81. AUTION Never install a used HEPA filter. Always install a new HEPA filter. R59770072 FLM SERIES 19/03/2007...

  • Page 91: Lamp And Lamp House

    Image 8-1 AUTION Never attempt to disassemble the lamp from its housing or to dispose of it. Return it to Barco. Due to its high internal pressure, the lamp may explode in either hot or cold states if improperly handled.

  • Page 92: Removal Of The Lamp House

    This procedure may only be performed by qualified technical service personnel. AUTION Never attempt to disassemble the lamp from its housing or to dispose of it. Return it to Barco. Due to its high internal pressure, the lamp may explode in either hot or cold states if improperly handled.

  • Page 93: Installation Of The Lamp House

    This procedure may only be performed by qualified technical service personnel. AUTION Never attempt to disassemble the lamp from its housing or to dispose of it. Return it to Barco. Due to its high internal pressure, the lamp may explode in either hot or cold states if improperly handled.
  • Page 94 8. 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. R59770072 FLM SERIES 19/03/2007...

  • Page 95: Realignment Of The Lamp In Its Reflector

    Image 8-9 4. Switch off the projector, wait five minutes and unplug the power cord at the projector side. 5. Reinstall the cover of the lamp, see "Installation of the lamp cover", page 82. R59770072 FLM SERIES 19/03/2007...
  • Page 96 8. Lamp and lamp house R59770072 FLM SERIES 19/03/2007...

  • Page 97: Input & Communication Unit

    R848607 Cover plate for unused input slot. Overview • Removal of the input & communication unit • Installation of the input & communication unit • Removal of an input module • Installation of an input module R59770072 FLM SERIES 19/03/2007...

  • Page 98: Removal Of The Input & Communication Unit

    3. Release the four captive screws in the corners of the input and communication unit as illustrated. Image 9-2 4. Pull the input & communication unit out of its compartment, using the side handles provided. Image 9-3 R59770072 FLM SERIES 19/03/2007...

  • Page 99: Installation Of The Input & Communication Unit

    3. Push the input & communication unit forward until you feel the connectors of the unit fit in their sockets. The back of the front plate of the unit must touch the chassis of the projector. 4. Secure the input & communication unit by fastening the four captive screws in the corners of the unit. Image 9-5 R59770072 FLM SERIES 19/03/2007...

  • Page 100: Removal Of An Input Module

    Ensure that all unused input slots of the input & communication unit are always covered with a dummy front plate. After removing one of the input modules, immediately replace with an other one or install a dummy front cover on the unused input slot. R59770072 FLM SERIES 19/03/2007...

  • Page 101: Installation Of An Input Module

    & communication unit. 4. Secure the input module by fastening both captive screws in the top corners of the module. Image 9-9 R59770072 FLM SERIES 19/03/2007...
  • Page 102 9. Input & communication unit R59770072 FLM SERIES 19/03/2007...

  • Page 103: Light Processor + Light Pipe Assembly

    Light pipe. Order info Order number Description R849622K FLM R20+ light processor + light pipe. R853761K FLM HD light processor + light pipe. Overview • Diagnostics • Removal of the light processor • Installing the light processor R59770072 FLM SERIES 19/03/2007...

  • Page 104: Diagnostics

    Unacceptable amount of dark, bright or flat state pixels on one or more DMDs. • Blocked shutter. Shutter does not respond when pressing the “PAUSE” button. • Blocked contrast enhancement plate, which disables you to adjust the contrast. • Leakage in liquid cooling circuit. R59770072 FLM SERIES 19/03/2007...

  • Page 105: Removal Of The Light Processor

    3. Release the two captive screws at the right side of the light processor as illustrated. Use a 5 mm flat screw driver. Note: The Formatting Interface Board (FIB) is attached to the light processor and has to be removed from the projector together with the light processor. R59770072 FLM SERIES 19/03/2007...
  • Page 106 Sometimes a little cooling liquid will be spilled. Wrap a small cloth around the valved fitting while uncoupling to absorb the spilled cooling liquid. Image 10-4 5. Hold the light processor by the handles and gently pull the light processor out of its compartment. R59770072 FLM SERIES 19/03/2007...
  • Page 107 10. Light processor + light pipe assembly Image 10-5 6. Place the light processor, which includes the FIB, on a stable table. R59770072 FLM SERIES 19/03/2007...

  • Page 108: Installing The Light Processor

    Note: The bottom of the light processor is equipped with guides (G) and positioning pins (P). Image 10-6 2. Fasten the two captive screws at the bottom of the light processor as illustrated. Use a 10 mm nut driver or a 5 mm flat screw driver. Image 10-7 R59770072 FLM SERIES 19/03/2007...
  • Page 109 Caution: Makes sure that the tube coming from the pump is leading to the cooling circuit of the DMD’s and that the tube coming from the light pipe entrance is leading to the heat exchanger. R59770072 FLM SERIES 19/03/2007...
  • Page 110 5. Check the pressure indicated on the internal manometer of the liquid cooling circuit, "FLM liquid cooling circuit", page 153. Barco provides a liquid cooling refill kit for the FLM projector. See "FLM liquid cooling circuit", page 153 for further instructions on how to obtain the correct pressure in the cooling circuit.

  • Page 111: Integration Rod

    Never touch the entrance or exit of the integration rod assembly. Greasy fingerprints or other dirt on the integration rod entrance or exit will burn into the rod and cause permanent damage. Order info Order number Description R854296K FLM R20+ (SXGA+) integration rod assembly. R855831K FLM HD integration rod assembly. R59770072 FLM SERIES 19/03/2007...
  • Page 112 11. Integration rod Overview • Rod diagnostic • Removal of the integration rod assembly • Installing a new integration rod assembly • Adjusting the integration rod R59770072 FLM SERIES 19/03/2007...

  • Page 113: Rod Diagnostic

    If yes, these spots are caused by damages to the integration rod. Replace the rod assembly. If no, integration rod is OK. Re-adjust and secure the integration rod and reinstall the side cover of the projector. R59770072 FLM SERIES 19/03/2007...

  • Page 114: Removal Of The Integration Rod Assembly

    3. Remove the socket head screw (B) as illustrated. Use a 2,5 mm Allen key. Image 11-6 4. Pull the integration rod assembly out of the light pipe. Do not keep the light pipe entrance open (no integration rod installed) for a long period. This to prevent dust intrusion. R59770072 FLM SERIES 19/03/2007...

  • Page 115: Installing A New Integration Rod Assembly

    6. Rotate the integration rod until the set screws (A) of the light pipe are aligned with the set screw (B) of the integration rod assembly as illustrated. Image 11-9 7. Fasten the set screws (A). Use a 2 mm Allen key. R59770072 FLM SERIES 19/03/2007...
  • Page 116 Ensure that the shining side of the mask (M) is facing the lamp. Image 11-11 The integration rod must be adjusted after installation. Follow the procedure "Adjusting the integration rod", page 115, after the light processor is reinstalled in the projector. R59770072 FLM SERIES 19/03/2007...

  • Page 117: Adjusting The Integration Rod

    Place a 2 mm Allen key in one of the holes on the outer side of the adjustment ring (D). The Allen key function as an extension bar of the adjustment ring. This allows a more precise adjustment. R59770072 FLM SERIES 19/03/2007...
  • Page 118 Then rotate the rod back until the projected light beam matches the projected outline of the DMD’s. This way of focusing the integration rod has to be done quickly. Otherwise, the sealing between the DMD’s and the prism will be damaged. R59770072 FLM SERIES 19/03/2007...

  • Page 119: Uv Filter

    About the UV filter Visible light goes through this UV filter. UV light and IR light is reflected towards the cold mirror. The following type of UV filters can be found in the FLM series projectors: • Round frame with a round UV glass. This type must be replace with the same round type = kit R849250K.

  • Page 120: Uv Filter Replacement

    5. Put the frame back and fasten the screws. Do not fasten to hard, because the glass might break. 6. Reinsert the lamp, see "Installation of the lamp house", page 91 and install the lamp cover, see "Installation of the lamp cover", page 82. R59770072 FLM SERIES 19/03/2007...

  • Page 121: Cold Mirror Assembly

    Image 13-1 Order info Order number Description R848645K Cold mirror + fan assembly Overview • Diagnostic • Removal of the cold mirror assembly • Mounting the new cold mirror + fan assembly • Adjusting the cold mirror R59770072 FLM SERIES 19/03/2007...

  • Page 122: Diagnostic

    Cold mirror is dirty due to the ambient conditions. Clean the mirror with alcohol, replacement is not necessary. In all these cases, the light output on the screen can be lower than the normal light output. R59770072 FLM SERIES 19/03/2007...

  • Page 123: Removal Of The Cold Mirror Assembly

    3. At the opposite side of the lamp, turn out the 5 indicated screws of metal cover plate (one top right, 2 at the bottom and 2 left). Image 13-2 Cover plate 4. Take out the plate. R59770072 FLM SERIES 19/03/2007...
  • Page 124 6. On the same plate, turn out both indicated screws 2. 7. At the left side of the cold mirror assembly, turn out both indicated screws 3. 8. Slide out the assembly and disconnect the fan cable. R59770072 FLM SERIES 19/03/2007...
  • Page 125 13. Cold mirror assembly Image 13-5 Remove of cold mirror R59770072 FLM SERIES 19/03/2007...

  • Page 126: Mounting The New Cold Mirror + Fan Assembly

    1. Insert the assembly in the projector and make the electrical connection of the fan. Image 13-6 Insert assembly + electrical connection 2. At the left side of the cold mirror assembly, turn in both indicated screws 1. R59770072 FLM SERIES 19/03/2007...
  • Page 127 4. Place the connector on its place. Turn in the upper screws 3. 5. Push the lower screws 4 first through the eye of the ground wire and then turn it in. 6. Insert the cover plate and turn in the 5 indicated screws. R59770072 FLM SERIES 19/03/2007...
  • Page 128 13. Cold mirror assembly Image 13-8 Mount cover plate 7. Reinsert the lamp house and close the lamp door. R59770072 FLM SERIES 19/03/2007...

  • Page 129: Adjusting The Cold Mirror

    Screw 2 will correct the difference between the top and the bottom side of the projected image. Check again and repeat if necessary. 7. When the adjustment is finished, secure the position by turning the security nuts (A) against the plate (hold on the screws while securing the nuts). R59770072 FLM SERIES 19/03/2007...
  • Page 130 13. Cold mirror assembly 8. Reinstall the side cover. R59770072 FLM SERIES 19/03/2007...

  • Page 131: Lens Holder

    G Lens holder swing adjustment screw. Lock screws of the swing mechanism. Order info Order No. Description R848500K FLM lens holder. Overview • Removing the lens holder • Installing the lens holder • Adjusting the lens holder R59770072 FLM SERIES 19/03/2007...

  • Page 132: Removing The Lens Holder

    2. Disconnect the two EMC wire units (A) at the top of the lens holder and the EMC wire unit (B) at the left bottom of the lens holder. Use a 5,5 mm nut driver. Image 14-3 3. Release the 8 hexagon socket screws (F) and remove the lens holder as illustrated. Use a 3 mm Allen key. R59770072 FLM SERIES 19/03/2007...
  • Page 133 14. Lens holder Image 14-4 R59770072 FLM SERIES 19/03/2007...

  • Page 134: Installing The Lens Holder

    Note: There is a wire unit attached to the front plate and lens holder. So, you won’t be able to remove the front plate but just shift it a little to the left to gain access to the fixation screws of the mid position switch. R59770072 FLM SERIES 19/03/2007...
  • Page 135 7. Connect the wire units from the lens holder with their respective wire units of the projector. Make sure that you connect the wire units of the same color with each other. Tie the wire units together with two cable ties. R59770072 FLM SERIES 19/03/2007...
  • Page 136 14. Lens holder Image 14-10 The lens holder has to be adjusted after installation. R59770072 FLM SERIES 19/03/2007...

  • Page 137: Adjusting The Lens Holder

    1. Place the projector in a table mount on-Axis configuration with a projector screen distance (PD) of 1,5 meter. See owners manual of the projector for detailed installation procedures. Tip: To place the lens holder in the On-Axis position select: Alignment > Lens > Mid position. R59770072 FLM SERIES 19/03/2007...
  • Page 138 If not, turn the adjustment screw in the opposite direction and check again. Note: A simultaneous readjustment of the focus shift plate will be necessary to get the mid left and mid right of the projected pattern equally focused as the centre. R59770072 FLM SERIES 19/03/2007...
  • Page 139 6. Fasten all lock screws of the lens holder adjustment mechanism. Image 14-17 7. Reinstall the top cover, the side cover and the front cover of the projector. See owners manual of the projector for detailed cover installation procedures. R59770072 FLM SERIES 19/03/2007...
  • Page 140 14. Lens holder R59770072 FLM SERIES 19/03/2007...

  • Page 141: Vertical And Horizontal Shift Motors

    Motor DC 12V D17 + 134:1 for horizontal shift FLM Overview • Removing the vertical shift motor • Mounting a new vertical shift motor • Removal of the horizontal lens motor • Mounting the new horizontal lens motor R59770072 FLM SERIES 19/03/2007...

  • Page 142: Removing The Vertical Shift Motor

    1. Remove the 4 screws a and take off cover b. Image 15-2 Motor access 2. Turn out screw c. 3. Loosen screw d (at the back side of this block) and slide the axe out of that block (e). 4. Take off block A. R59770072 FLM SERIES 19/03/2007...
  • Page 143 6. Turn out both screws G. 7. Turn out the axe fixation screw H. 8. Slide out the axe I. 9. Take out the motor unit. Turn out both screws on the motor unit and remove the plate. R59770072 FLM SERIES 19/03/2007...
  • Page 144 15. Vertical and Horizontal shift motors Image 15-5 Motor assembly Image 15-4 Removing motor R59770072 FLM SERIES 19/03/2007...

  • Page 145: Mounting A New Vertical Shift Motor

    2. Insert the motor in its compartment with the rounded side of the mounted plate upwards. Image 15-7 Mount motor 3. Slide the axe on the motor, turn in both fixation screws A and fixate the axe on the motor with the set screw B. R59770072 FLM SERIES 19/03/2007...
  • Page 146 5. Place block G on its place. 6. Side the axe combination (a) back through the hole in the block so that the end of the axe is equal with the side of the block. R59770072 FLM SERIES 19/03/2007...
  • Page 147 8. Guide all cables in the groove, place the cover plate (d) on its place and turn in the 4 screws. Insert the lens holder in the projector, see "Installing the lens holder", page 132 for a detailed description. Then, reinstall all covers and insert the lens. R59770072 FLM SERIES 19/03/2007...

  • Page 148: Removal Of The Horizontal Lens Motor

    Allen key 1.5 mm How to remove 1. Remove the 4 screws a and take off cover b. Image 15-10 Remove motor cover plate 2. Turn out screw c. 3. Loosen both screws d and push out axe e. R59770072 FLM SERIES 19/03/2007...
  • Page 149 6. Turn out both screws F. 7. Turn out the set screws G and take out the axe H. 8. Pull out the motor and turn out both screws on the motor unit and remove the plate. R59770072 FLM SERIES 19/03/2007...
  • Page 150 15. Vertical and Horizontal shift motors Image 15-14 Image 15-13 Remove motor R59770072 FLM SERIES 19/03/2007...

  • Page 151: Mounting The New Horizontal Lens Motor

    2. Insert the motor in its compartment with the rounded side of the mounted plate upwards. Image 15-16 Mount new motor 3. Turn in both axe fixation screws A and secure the axe on the motor axe with the set screw B. R59770072 FLM SERIES 19/03/2007...
  • Page 152 6. Insert the big axe G, fasten both screws H and turn in the connection screw I. 7. Guide all cables in the groove, place the cover plate on its place and turn in the 4 screws. R59770072 FLM SERIES 19/03/2007...
  • Page 153 15. Vertical and Horizontal shift motors Image 15-19 Cover plate Insert the lens holder in the projector, see "Installing the lens holder", page 132 for a detailed description. Then, reinstall all covers and insert the lens. R59770072 FLM SERIES 19/03/2007...
  • Page 154 15. Vertical and Horizontal shift motors R59770072 FLM SERIES 19/03/2007...

  • Page 155: Flm Liquid Cooling Circuit

    Draining the liquid cooling circuit • Filling the liquid cooling circuit • Refreshing the liquid cooling circuit • Expelling air from the liquid cooling circuit • Pressurizing the liquid cooling circuit • Calibrating the liquid cooling circuit R59770072 FLM SERIES 19/03/2007...
  • Page 156 16. FLM liquid cooling circuit AUTION To avoid damage to the connector seal, always depress the connector tab of the female valved fitting prior to inserting the male valved fitting. R59770072 FLM SERIES 19/03/2007...

  • Page 157: Safety

    Personal protection rules • Handle the cooling liquid in a well ventilated room. • Under no circumstances eat, drink and smoke while handling the liquid. • Wear gloves (Butylrubber, PVC..) and Goggles. • Wear suitable protection clothing. R59770072 FLM SERIES 19/03/2007...

  • Page 158: Introduction

    R395198K Complete liquid cooling refill kit. Includes tubes, valved fittings, syringe, air pump, two plastic bottles of 1 liter filled with cooling liquid. B1909086K Four bottles of 1 liter filled with cooling liquid. (no additional tools) R59770072 FLM SERIES 19/03/2007...

  • Page 159: Diagnostics

    Possible cause Solution The liquid cooling circuit of the light processor is mistakenly Check of the cooling circuit of the light processor is connected excluded from the main liquid cooling circuit. with the pump and heat exchanger. R59770072 FLM SERIES 19/03/2007...
  • Page 160 Drain the liquid cooling circuit, replace the flow switch, fill and “Refill mode” but the projector displays a water flow error. pressurize the liquid cooling circuit. Tip: It’s not necessary to drain the cooling circuit of the light processor. Bypass this part of the cooling circuit. R59770072 FLM SERIES 19/03/2007...

  • Page 161: Pressure Verification Of The Liquid Cooling Circuit

    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 technicians, so they may take necessary corrective action. 4. Reinstall the side cover of the projector, see "Installation of the side cover", page 81. R59770072 FLM SERIES 19/03/2007...

  • Page 162: Draining The Liquid Cooling Circuit

    2. Insert the plastic tube, which contains a female valved fitting, into an empty bottle and then couple the female valved fitting with the exit side of the cooling circuit. Note: Circuit is pressurized, so first insert tube end into empty bottle. Image 16-5 Draining complete circuit R59770072 FLM SERIES 19/03/2007...
  • Page 163 Image 16-7 4. Couple the air filled 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. R59770072 FLM SERIES 19/03/2007...
  • Page 164 16. FLM liquid cooling circuit Image 16-8 Draining complete cooling circuit Image 16-9 Draining cooling circuit, excluding light processor circuit 5. Disconnect the syringe from the cooling circuit and repeat from step 3 until all cooling liquid is drained. R59770072 FLM SERIES 19/03/2007...

  • Page 165: Filling The Liquid Cooling Circuit

    Image 16-10 2. Couple a plastic tube, which contains a female valved fitting, to the exit side of the cooling circuit and lead the tube end to an empty bottle. Image 16-11 Filling complete cooling liquid circuit R59770072 FLM SERIES 19/03/2007...
  • Page 166 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. R59770072 FLM SERIES 19/03/2007...
  • Page 167 4. Couple the filled syringe to the inlet of the cooling circuit and press the cooling liquid inside the circuit. Caution: Position the empty bottle above the liquid circuit (on top of projector). Image 16-14 Filling complete cooling liquid circuit R59770072 FLM SERIES 19/03/2007...
  • Page 168 Image 16-15 Filling part of cooling liquid circuit, light processor excluded 5. Disconnect the syringe from the cooling circuit and repeat from step 3 until cooling liquid comes out the exit side of the cooling circuit. R59770072 FLM SERIES 19/03/2007...

  • Page 169: Refreshing The Liquid Cooling Circuit

    2. Insert the tube end of the plastic tube, which contains a female valved fitting, into an empty bottle and then couple the female valved fitting with the exit side of the cooling circuit. Note: Circuit is pressurized, so first insert tube end into empty bottle. Image 16-17 R59770072 FLM SERIES 19/03/2007...
  • Page 170 4. Push the male valved fitting of the filled tube into the 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. Image 16-19 R59770072 FLM SERIES 19/03/2007...
  • Page 171 170. 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. See procedure "Pressurizing the liquid cooling circuit", page 172. R59770072 FLM SERIES 19/03/2007...

  • Page 172: Expelling Air From The Liquid Cooling Circuit

    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 cooling circuit. R59770072 FLM SERIES 19/03/2007...
  • Page 173 Note: Make sure that both ends of the plastic tubes in the bottle remains immersed until the plastic tubes are uncouple from the liquid cooling circuit. 8. Pressurize the liquid cooling circuit. See procedure "Pressurizing the liquid cooling circuit", page 172. Check within 24 hours if the pressure remains 1 bar. If not, search for leakage. R59770072 FLM SERIES 19/03/2007...

  • Page 174: Pressurizing The Liquid Cooling Circuit

    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. R59770072 FLM SERIES 19/03/2007...
  • Page 175 Push the plunger of the syringe to reinject the expelled liquid back into the circuit. The pressure would hence return to 1 bar. 6. Disconnect the syringe from the cooling circuit. Make sure that the pressure remains 1 bar. 7. Close up the liquid cooling circuit which you interrupted in step 1. R59770072 FLM SERIES 19/03/2007...
  • Page 176 16. FLM liquid cooling circuit Check within 24 hours whether the pressure has stabilized close to 1 bar. If not, search for leakage. R59770072 FLM SERIES 19/03/2007...

  • Page 177: Calibrating The Liquid Cooling Circuit

    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. Image 16-33 3. Fill the syringe with cooling liquid as follows: R59770072 FLM SERIES 19/03/2007...
  • Page 178 5. Now that the pressure vessel is liquid filled you have to increase the pressure to 1 bar by pushing in the piston of the syringe. Then immediately disconnected the syringe. When this is done properly, the manometer should indicate 1 bar. 6. Extract 75 ml back into the syringe by doing the following: R59770072 FLM SERIES 19/03/2007...
  • Page 179 Presta valve type (B) has to be removed. Futhermore, the pin (C) inside the Shrader valve has to be removed as well. Check within 24 hours whether the pressure has stabilized close to 1 bar. If not, search for leakage. R59770072 FLM SERIES 19/03/2007...
  • Page 180 16. FLM liquid cooling circuit R59770072 FLM SERIES 19/03/2007...

  • Page 181: Heat Exchanger

    Description B4009232K Heat exchanger assembly for FLM projector. Overview • Removing the defective heat exchanger • Disassembling the heat exchanger assembly • Assembling the new heat exchanger Mounting the heat exchanger assembly into the projector • R59770072 FLM SERIES 19/03/2007...

  • Page 182: Removing The Defective Heat Exchanger

    Sometimes a little cooling liquid will be spilled. Wrap a small cloth around the valved fitting while uncoupling to absorb the spilled cooling liquid. Image 17-2 2. Loosen both indicated screws. Image 17-3 3. Cut the necessary cable tie(s). 4. Disconnect the heat exchanger fan and the connector in the near of the flow switch. R59770072 FLM SERIES 19/03/2007...
  • Page 183 5. Drain the cooling circuit. Exclude the light processor circuit. Note: The procedure for draining is described in the service manual and in the installation manual included in the kit of the heat exchanger. 6. Pull out the complete assembly. Image 17-5 Remove assembly R59770072 FLM SERIES 19/03/2007...

  • Page 184: Disassembling The Heat Exchanger Assembly

    (when releasing the both clip tongs, it camps again. Image 17-6 Image 17-7 2. Pull off both tube assembly (2 & 4). 3. Loosen on both sides the nuts holding the fan assembly to the heat exchanger. R59770072 FLM SERIES 19/03/2007...
  • Page 185 17. Heat exchanger Image 17-8 Disassembling heat exchanger Dust filter assembly Heat exchanger fan assembly 4. Loosen on both sides the nuts holding the dust filter assembly to the heat exchanger. R59770072 FLM SERIES 19/03/2007...

  • Page 186: Assembling The New Heat Exchanger

    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 heat exchanger (3). R59770072 FLM SERIES 19/03/2007...
  • Page 187 6. Secure with a clip (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 R59770072 FLM SERIES 19/03/2007...

  • Page 188: Mounting The Heat Exchanger Assembly Into The Projector

    1. Slide the heat exchanger assembly into the projector. Make sure the guides match the grooves of the assembly. Image 17-11 2. Fasten both screws. 3. Reinstall both electrical connections. Place cable ties where necessary. Image 17-12 Electrical connection R59770072 FLM SERIES 19/03/2007...
  • Page 189 To avoid damage to the connector seal, always depress the connector tab of the female valved fitting prior to inserting the male valved fitting. After installation of the heat exchanger you have to refill the cooling circuit, then expel all air and finally pres- surize the cooling circuit. R59770072 FLM SERIES 19/03/2007...
  • Page 190 17. Heat exchanger R59770072 FLM SERIES 19/03/2007...

  • Page 191: Cooling Pump

    . Order information Order number Description Quantity B4009521DK Cooling pump Overview • Maintaining the cooling pump • Cooling pump body replacement • Cooling pump replacement R59770072 FLM SERIES 19/03/2007...

  • Page 192: Maintaining The Cooling Pump

    Due to crystallization inside the pump, the rotor can be jammed. This crystallization can be easily remove and the pump can be reused again. First always drain the pump cooling circuit before starting the procedure. Overview • Opening the cooling pump and rotor movement • Cleaning pump • Closing the pump R59770072 FLM SERIES 19/03/2007...

  • Page 193: Opening The Cooling Pump And Rotor Movement

    2. Slide the pump cover with hose backwards. 3. Take the rotor between thumb and finger and try to rotate smoothly. If the you feel any resistance or you cannot rotate it, then the try to clean the pump. R59770072 FLM SERIES 19/03/2007...

  • Page 194: Cleaning Pump

    4. Reinsert the rotor and turn and try to run it smoothly. If it is successful, the pump can be closed. If cleaning is not possible, replace the cooling pump body or replace the complete pump. R59770072 FLM SERIES 19/03/2007...

  • Page 195: Closing The Pump

    To fill the cooling circuit, see "Filling the liquid cooling circuit", page 163 with excluded light processor. For expelling air, see "Expelling air from the liquid cooling circuit", page 170. For pressurizing the cooling circuit, see "Pressurizing the liquid cooling circuit", page 172. R59770072 FLM SERIES 19/03/2007...

  • Page 196: Cooling Pump Body Replacement

    Cooling pump Note : you have to order a complete cooling pump but you only have to use the body part of the pump. Overview • Removing the pump body • Mounting the new pump body R59770072 FLM SERIES 19/03/2007...

  • Page 197: Removing The Pump Body

    2. Remove the 4 screws on the pump body and slide the pump cover with hoses backwards. Image 18-7 Remove pump cover 3. Turn out both bolts (3) securing the pump body to the seating of the pump. 4. Take out the pump body. R59770072 FLM SERIES 19/03/2007...

  • Page 198: Mounting The New Pump Body

    5. Reinstall the connection. If the connector of the new pump body has 3 wires and the original installed pump only had 2 wires, then inserts the adapter between the connectors. After the pump is installed you have to fill the cooling circuit with cooling liquid, then expel all air from the circuit and finally pressurize the cooling circuit. R59770072 FLM SERIES 19/03/2007...

  • Page 199: Cooling Pump Replacement

    18.3 Cooling pump replacement About this chapter This part describes how to replace the complete cooling pump. Order info Order number Description Quantity B4009521DK Cooling pump Overview • Removing the pump • Mounting the new pump R59770072 FLM SERIES 19/03/2007...

  • Page 200: Removing The Pump

    2. Cut both hoses (1, 2) just next to the clip. Remove both clips with a universal plier. Push both clip tongs to each other in order to open the clip. Image 18-9 Removing the pump R59770072 FLM SERIES 19/03/2007...
  • Page 201 Note: It is almost impossible to remove first the clip and then to pull off the hose. 3. Turn out both bolts (3) securing the pump to the seating of the pump. 4. Take out the pump. R59770072 FLM SERIES 19/03/2007...

  • Page 202: Mounting The New Pump

    2. Secure by turning both bolts. 3. Mounting the hose coming from the light processor. First, slide a clip over the hose end (B2). 4. Push the hose end as far as possible on the output nipple of the pump (B3). R59770072 FLM SERIES 19/03/2007...
  • Page 203 Note: If the connector of the new cooling pump has 3 wires instead of 2, connect first the adapter to the connector of teh pump and then make the connection. After the pump is installed you have to fill the cooling circuit with cooling liquid, then expel all air from the circuit and finally pressurize the cooling circuit. R59770072 FLM SERIES 19/03/2007...
  • Page 204 18. Cooling pump R59770072 FLM SERIES 19/03/2007...

  • Page 205: Shutter Replacement

    This chapter describes how to replace the shutter. Functionality A shutter is used to shut out the light when the projector is switched to pause or to standby. Image 19-1 Order info Order number Description R849151K FLM shutter assembly Overview • Shutter replacement R59770072 FLM SERIES 19/03/2007...

  • Page 206: Shutter Replacement

    2,5 mm Allen key. How to replace the shutter? 1. Disconnect the shutter. Image 19-2 Shutter connection 2. Turn out both indicated screws securing the shutter fixation plate to the light processor assembly Image 19-3 Shutter removal R59770072 FLM SERIES 19/03/2007...
  • Page 207 3. Take off the shutter assembly. 4. Place the new shutter on its place so that the fixation holes match the holes in the light assembly. Image 19-4 Mounting shutter 5. Turn in both screws. 6. Reinstall the connection. R59770072 FLM SERIES 19/03/2007...
  • Page 208 19. Shutter replacement R59770072 FLM SERIES 19/03/2007...

  • Page 209: Formatter Interface Board

    R503 C208 PRISM J260 SHUTTER (YELLOW) J280 J290 J250 J251 J252 J702 J701 J700 Image 20-1 Order info Description Order number R764760K FLM R20+ FIB unit Overview • Removing the FIB • Mounting a new FIB R59770072 FLM SERIES 19/03/2007...

  • Page 210: Removing The Fib

    4. Unplug all cables. Be careful not to damage the wires and connectors. 5. Turn out the 7 indicated screws securing the board in the box. Image 20-3 FIB removal 6. Take out the defective FIB. R59770072 FLM SERIES 19/03/2007...

  • Page 211: Mounting A New Fib

    4. Turn in the fixation screws. For the 2 times 3 screws at the right side, do not forget to push the screw first through the eye connection of the ground cable before inserting in the fixation hole. R59770072 FLM SERIES 19/03/2007...
  • Page 212 20. Formatter Interface Board R59770072 FLM SERIES 19/03/2007...

  • Page 213: Pixel Map Processor Board

    R969 R957 R958 R959 R973 R974 R972 Image 21-1 Order information Order number Description R764767K Pixel map processor board for FLM R20+ Overview • Diagnostics • Building out the PMP • Mounting a new PMP board R59770072 FLM SERIES 19/03/2007...

  • Page 214: Diagnostics

    • If it remains red, FPGAs on the FIB board are not correctly configured. Problem is situated on the FIB board. If both power LEDs are red, then the FPGAs on the FIB are correctly configured. R59770072 FLM SERIES 19/03/2007...

  • Page 215: Building Out The Pmp

    1. Remove all input units (A) and the communication unit (B). Use a Philips screwdriver to loosen all screws. Image 21-3 Input & communication units removal 2. Turn the unit and remove all indicated screws. Image 21-4 PMP removal 3. Turn out the fixation pin with a 6 mm wrench. R59770072 FLM SERIES 19/03/2007...
  • Page 216 21. Pixel map processor board Image 21-5 Fixation pin removal 4. Pull out the PMP assembly. Image 21-6 Assembly removal 5. Disconnect the plug and turn out the 13 indicated screws. Take off the board. R59770072 FLM SERIES 19/03/2007...
  • Page 217 21. Pixel map processor board Image 21-7 PMP removal R59770072 FLM SERIES 19/03/2007...

  • Page 218: Mounting A New Pmp Board

    3. Turn the assembly with the board towards the inputs and slide the assembly on its place. Image 21-9 Mount PMP in cabinet 4. Place the lock washer between the board and the fixation pin and turn in this pin. Secure with a 6 mm wrench. R59770072 FLM SERIES 19/03/2007...
  • Page 219 5. Secure the assembly in the cabinet by turning in the indicated screws. 6. Reinsert the communication unit and all inputs and secure with the fixation screws. Reinstall the Communication & input unit and close the Communication & input cover. R59770072 FLM SERIES 19/03/2007...
  • Page 220 21. Pixel map processor board R59770072 FLM SERIES 19/03/2007...

  • Page 221: Lcd Panel Replacement

    A second function is to display error and warning codes which can be used by the operator when calling for a service intervention or by the service technician to determine what is wrong with the projector. Image 22-1 Order information Description Order number V322203K LCD panel Overview • Removing the LCD panel • Mounting a new LCD panel R59770072 FLM SERIES 19/03/2007...

  • Page 222: Removing The Lcd Panel

    2. Lay down the module on its handles and remove the 4 screws a. Remove the 8 indicated nuts. Image 22-3 Remove housing 3. Take off the complete housing. Disconnect the plug coming from the PMP board (not necessary but handy). R59770072 FLM SERIES 19/03/2007...
  • Page 223 Image 22-4 Disconnect PMP 4. Remove the 4 screws of the LCD cover plate and take off this plate. Image 22-5 Remove LCD cover 5. Disconnect the flat cable between the LCD panel and the keypad unit R59770072 FLM SERIES 19/03/2007...
  • Page 224 22. LCD panel replacement Image 22-6 Connection LCD - keypad 6. Remove the 4 fixation screws of the LCD panel. Image 22-7 Remove LCD panel 7. Remove the defective LCD panel. R59770072 FLM SERIES 19/03/2007...

  • Page 225: Mounting A New Lcd Panel

    Image 22-8 LCD panel 2. Reestablish the connection between the LCD panel and the keypad unit. Image 22-9 Connection LCD panel - keypad unit 3. Put the LCD panel cover back and secure with the 4 nuts. R59770072 FLM SERIES 19/03/2007...
  • Page 226 Connection PMP - keypad unit 5. Place the housing back and secure with the 8 nuts. Image 22-12 Close housing 6. Mount the handles by turning in screws a. 7. Reinstall the communication unit and all inputs. R59770072 FLM SERIES 19/03/2007...
  • Page 227 22. LCD panel replacement Reinsert the Input & communication unit and close the input cover. R59770072 FLM SERIES 19/03/2007...
  • Page 228 22. LCD panel replacement R59770072 FLM SERIES 19/03/2007...

  • Page 229: Keypad Board Replacement

    23. KEYPAD BOARD REPLACEMENT About this chapter This chapter gives the procedures how to replace the keypad board. Order information Order number Description R764869K Keypad unit Overview • Removing the keypad unit • Mounting the new keypad unit R59770072 FLM SERIES 19/03/2007...

  • Page 230: Removing The Keypad Unit

    3. Take off the complete housing. 4. Disconnect the plug coming from the PMP board (A). Disconnect the plug coming from the keypad itself (B) Disconnect the flat cable between the LCD panel and the keypad unit (C). R59770072 FLM SERIES 19/03/2007...
  • Page 231 23. Keypad board replacement Image 23-3 5. Turn out the 4 fixation screws and take off the module. Image 23-4 Remove keypad unit R59770072 FLM SERIES 19/03/2007...

  • Page 232: Mounting The New Keypad Unit

    1. Place the new unit on the fixation studs and turn in the 4 screws. Image 23-5 Mount keypad board 2. Reestablish the connections coming from the LCD panel (C), keypad (B) and PMP (A). Image 23-6 3. Place the housing back and secure with the 8 nuts. R59770072 FLM SERIES 19/03/2007...
  • Page 233 23. Keypad board replacement Image 23-7 Close housing 4. Mount the handles by turning in screws a. 5. Reinstall the communication unit and all inputs. Reinsert the Input & communication unit and close the input cover. R59770072 FLM SERIES 19/03/2007...
  • Page 234 23. Keypad board replacement R59770072 FLM SERIES 19/03/2007...

  • Page 235: Fan Replacements

    Order number B32466391D Axial fan 24V 37LS43 92L120 Overview • Heat exchanger fan • Cold mirror fan • Light processor compartment fan • Cathode fan replacement • Anode fan replacement • Mains input fan • SMPS fans R59770072 FLM SERIES 19/03/2007...

  • Page 236: Heat Exchanger Fan

    Order info fan Order number Description B3245964DK Axial fan 59LS 50$MDL Overview • Building out the heat exchanger assembly • Replacing the old fan with a new fan • Mounting the heat exchange assembly into the projector R59770072 FLM SERIES 19/03/2007...

  • Page 237: Building Out The Heat Exchanger Assembly

    Image 24-5 Interrupt cooling circuit 3. Loosen both indicated screws. Image 24-6 4. Cut the necessary wire tire(s). Note: Otherwise, it is not possible to take out the heat exchange assembly. Image 24-7 R59770072 FLM SERIES 19/03/2007...
  • Page 238 24. Fan replacements 5. Disconnect the heat exchanger fan, connector in the near of the flow switch. 6. Pull out the complete assembly. Image 24-8 Removing heat exchanger assembly R59770072 FLM SERIES 19/03/2007...

  • Page 239: Replacing The Old Fan With A New Fan

    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 position. R59770072 FLM SERIES 19/03/2007...

  • Page 240: Mounting The Heat Exchange Assembly Into The Projector

    5. Check the pressure indicated on the internal manometer. If the pressure is lower than 1 bar, follow the procedure to pressurize the circuit, see "Pressurizing the liquid cooling circuit", page 172. 6. Reinstall the side cover, see "Installation of the side cover", page 81. R59770072 FLM SERIES 19/03/2007...

  • Page 241: Cold Mirror Fan

    This chapter describes how to replace the cold mirror fan without removing the cold mirror itself. Readjustment of the cold mirror is in that case not necessary. Image 24-12 Order info fan Order number Description B3245964DK Axial fan 59LS 50$MDL Overview • Removal of the cold mirror fan • Mounting a new cold mirror fan R59770072 FLM SERIES 19/03/2007...

  • Page 242: Removal Of The Cold Mirror Fan

    How to remove the fan 1. Slide out the dust filter. Image 24-13 Remove dust filter 2. Disconnect the fan. Image 24-14 Connector fan cold mirror 3. Remove the 4 screws with a ball end Allen key. R59770072 FLM SERIES 19/03/2007...
  • Page 243 24. Fan replacements Image 24-15 Cold mirror fan removal 4. Slide out the fan and the protection grid. Be careful not to drop the rubber cushioning rings (A) inside the projector. R59770072 FLM SERIES 19/03/2007...

  • Page 244: Mounting A New Cold Mirror Fan

    1. Slide in the fan with the arrow indication downside. Insert the 4 rubber cushioning rings (A) between the fan and the fan plate. Image 24-16 Cold mirror fan 2. Put the protection grid on the fan and secure with the four screws using a ball end Allen key. 3. Make the electrical connection. 4. Reinsert the dust filter. R59770072 FLM SERIES 19/03/2007...
  • Page 245 24. Fan replacements Image 24-17 Mount top dust filter Reinstall all covers, start with the top cover. R59770072 FLM SERIES 19/03/2007...

  • Page 246: Light Processor Compartment Fan

    Image 24-18 Order info fan Order number Description B3245964DK Axial fan 59LS 50$MDL Overview • Remove of the top plate • Removal of the axial fan • Mounting a new axial fan • Mounting the top plate R59770072 FLM SERIES 19/03/2007...

  • Page 247: Remove Of The Top Plate

    2. Turn out all screws (43 pieces) on the top plate, except those indicate. Image 24-19 Top plate removal 3. First take off plate A and turn out screw covered by this plate. 4. Take off the top cover plate. Image 24-20 Top cover plate removal R59770072 FLM SERIES 19/03/2007...

  • Page 248: Removal Of The Axial Fan

    2. Cut the cable tie (a) and pull the cable out of the cable guide. Image 24-21 Fan connector 3. Turn out the 4 hexagon socket head cap screws holding the fan to the mounting plate. Use a 3 mm Allen key. Image 24-22 4. Take out the fan. R59770072 FLM SERIES 19/03/2007...

  • Page 249: Mounting A New Axial Fan

    2. Secure the fan with the 4 hexagon socket head cap screws. 3. Guide the cable through the cable guide and pull the connector into its socket. 4. Secure the cables with a cable tie where necessary. R59770072 FLM SERIES 19/03/2007...

  • Page 250: Mounting The Top Plate

    3. Push the joggle of the small plate (A) behind the big plate and lay down this small plate. 4. Turn in all screws. Reinstall the light processor assembly and the Input & communication unit. Install all cover of the projector. R59770072 FLM SERIES 19/03/2007...

  • Page 251: Cathode Fan Replacement

    This chapter describes how to replace the cathode fan. Image 24-25 Order info fan Order number Description B3245651DK Radial fan 24V 143D175CP Overview • Removal of the fan assembly • Fan replacement • Mounting the fan assembly R59770072 FLM SERIES 19/03/2007...

  • Page 252: Removal Of The Fan Assembly

    1. Turn out the 5 indicated screws with an Allen key 3 mm. Image 24-26 Partial lamp house removal 2. Slide out the side panel of the lamp cabinet. Image 24-27 3. Pull out the cable with connector from behind the plate and disconnect the fan. R59770072 FLM SERIES 19/03/2007...
  • Page 253 4. Turn out the 3 screws of the side plate of the air channel and take the plate away. Cut the foam rubber as it is stuck on the different plates. Image 24-30 Side plate air channel 5. Turn out the 4 screws holding the fan assembly to the frame and cut the foam rubber. R59770072 FLM SERIES 19/03/2007...
  • Page 254 24. Fan replacements Image 24-31 Removing fan assembly 6. Slide the assembly upwards and take out the fan assembly. R59770072 FLM SERIES 19/03/2007...

  • Page 255: Fan Replacement

    A. 6. Turn in the 4 screws C, but insert a lock washer between each screw and the plate. Turn in screw B. The fan assembly is ready to be mounted in the projector. R59770072 FLM SERIES 19/03/2007...

  • Page 256: Mounting The Fan Assembly

    2. Slide the assembly downwards until the fixation holes matches with the holes in the frame and turn in the 4 screws. 3. Put the side plate of the air channel on its place. Secure by turning in the 3 screws. R59770072 FLM SERIES 19/03/2007...
  • Page 257 4. Connect the fan and push the connector and cable behind the plate. Image 24-36 Image 24-37 5. Insert the side panel of the lamp cabinet and secure with 5 screws. Image 24-38 Insert side panel R59770072 FLM SERIES 19/03/2007...
  • Page 258 24. Fan replacements Image 24-39 Partial lamp house installation 6. Reinsert the lamp house, see "Installation of the lamp house", page 91 and reinstall the lamp cover, see "Installation of the lamp cover", page 82. R59770072 FLM SERIES 19/03/2007...

  • Page 259: Anode Fan Replacement

    Image 24-40 Order info fan Order number Description B3245651DK Radial fan 24V 143D175CP Overview • Access to the anode fan • Removing the anode fan • Fan replacement • Mounting the fan assembly • Finalizing the replacement R59770072 FLM SERIES 19/03/2007...

  • Page 260: Access To The Anode Fan

    Flat screwdriver 3 mm How to take out 1. Loosen both indicated screws. Image 24-41 Removing heat exchanger 2. Cut the necessary cable ties so that the cables become free. 3. Pull out the heat exchanger assembly. R59770072 FLM SERIES 19/03/2007...
  • Page 261 24. Fan replacements Image 24-42 Turning out the heat exchanger 4. Rotate this assembly, together with the connected hose and flow switch (not available in FLM HD versions). If necessary, disconnect the cables. R59770072 FLM SERIES 19/03/2007...

  • Page 262: Removing The Anode Fan

    1. Turn out the 4 screws of the fan security grid and take off that grid (A) . Take out also the air channel plate B. Image 24-43 Removing grid and channel plate 2. Pull out the fan cable and disconnect the fan. Image 24-44 Disconnecting the fan R59770072 FLM SERIES 19/03/2007...
  • Page 263 24. Fan replacements 3. Turn out the 3 indicated fixation bolts. Image 24-45 4. Slide out the fan assembly. R59770072 FLM SERIES 19/03/2007...

  • Page 264: Fan Replacement

    3. Take off plate B and then plate A. 4. Take the new fan and push the cable through the hole in plate A. Position the plate on the fan so that the fixation holes in the plate match the holes in the fan. R59770072 FLM SERIES 19/03/2007...
  • Page 265 5. Push the cable through the hole in plate B and place plate B on plate A so that the fixation holes match the holes in plate A. 6. Secure with 4 screws. Insert lock washer between each screw and the plate. 7. Insert the assembly in its cabinet and turn in the 11 screws. Image 24-49 Fan assembly R59770072 FLM SERIES 19/03/2007...

  • Page 266: Mounting The Fan Assembly

    1. Slide in the assembly into the projector. Image 24-50 Mounting anode fan assembly 2. Turn in the 3 indicated fixation screws. 3. Place the air channel plate B on the fixation holes. Put the fan cover grid A on it. R59770072 FLM SERIES 19/03/2007...
  • Page 267 24. Fan replacements Image 24-51 4. Turn in the 4 fixation screws. 5. Reconnect the fan. R59770072 FLM SERIES 19/03/2007...

  • Page 268: Finalizing The Replacement

    3. Connect those cables which where disconnected and tie up the cables where necessary. 4. Insert the light processor assembly, see "Installing the light processor", page 106. 5. Install the side cover, see "Installation of the side cover", page 81. R59770072 FLM SERIES 19/03/2007...

  • Page 269: Mains Input Fan

    24.6 Mains input fan About this chapter This chapter describes how to replace the mains input fan. Image 24-53 Order information Order number Description B32466391D Axial fan 24V 37LS43 92L120 Overview • Replacing the mains input fan R59770072 FLM SERIES 19/03/2007...

  • Page 270: Replacing The Mains Input Fan

    24. Fan replacements 24.6.1 Replacing the mains input fan Remove the back cover Necessary tools Allen key 3 mm How to replace the fan 1. Disconnect the fan. Image 24-54 Fan connection 2. Turn out the 4 screws. R59770072 FLM SERIES 19/03/2007...
  • Page 271 4. Place a new fan with the arrow indication pointing away from the projector. 5. Place the cover grid on it and insert the 4 screws. 6. Reestablish the connection. 7. Reinstall the back cover, see "Installation of the back cover", page 79. R59770072 FLM SERIES 19/03/2007...

  • Page 272: Smps Fans

    This chapter describes how to replace one or both SMPS fans which are located behind the front dust filter. Image 24-56 Order information Order number Description B32466391D Axial fan 24V 37LS43 92L120 Overview • Replacing the right fan • Replacing the left fan R59770072 FLM SERIES 19/03/2007...

  • Page 273: Replacing The Right Fan

    1. Remove the HEPA dust filter on the front side by pulling the two spring clamps away from the filter and then moving the filter forwards. Image 24-57 Remove dust filter 2. Disconnect the fan. It can be necessary to cut the cable tie. Image 24-58 Fan connection 3. Turn out the 4 screws and take out the fan. R59770072 FLM SERIES 19/03/2007...
  • Page 274 7. Insert the HEPA filter by pulling the two spring clamps away and move the filter into position. 8. Reinstall the front cover of the projector, see "Installation of the front cover", page 80 and insert the lens. R59770072 FLM SERIES 19/03/2007...

  • Page 275: Replacing The Left Fan

    Image 24-61 Fan connection 3. To access to the fan screws, remove the metal frame before the fans. Turn out the 6 indicated screws. Both clips for the filter will be remove at the same time. R59770072 FLM SERIES 19/03/2007...
  • Page 276 9. Insert the HEPA filter by pulling the two spring clamps away and move the filter into position. 10.Reinstall the front cover of the projector, see "Installation of the front cover", page 80 and insert the lens. R59770072 FLM SERIES 19/03/2007...

  • Page 277: Peltier Replacement

    Remove a Peltier element from the DMD • Mounting a Peltier element on the DMD • Remove a Peltier element on the heat pipe cooling block • Mounting a Peltier element on the heat pipe cooling block R59770072 FLM SERIES 19/03/2007...

  • Page 278: Remove A Peltier Element From The Dmd

    1. Turn out the 4 indicated screws and remove also the 4 washers Image 25-1 Remove cooling block 2. Take off the cooling block. Due to the thermal paste, it is possible that it sticks on the Peltier element. R59770072 FLM SERIES 19/03/2007...
  • Page 279 TEC GREEN TEC Gree TEC RED TEC Red C204 Image 25-3 TEC connections 4. Cut the connector of the old wires and pull the wires out of the cable tree. Then take off the Peltier element. R59770072 FLM SERIES 19/03/2007...
  • Page 280 25. Peltier replacement remove the spiral around the cable tree, take out the Peltier wires and then take off the Peltier element. Image 25-4 R59770072 FLM SERIES 19/03/2007...

  • Page 281: Mounting A Peltier Element On The Dmd

    Note: Make sure that the Peltier element is not laying on the studs. Image 25-5 3. Place the cooling unit on the Peltier element. Insert a washer between the plate and the cooling element. R59770072 FLM SERIES 19/03/2007...
  • Page 282 TEC Blue TEC BLUE C214 C205 C207 C206 J291 LIGHT SENSOR C217 C215 FAN7-4 WHITE C218 C216 FAN7-3 FAN7-2 FAN7-1 BLUE GREEN TEC Gree TEC GREEN TEC RED TEC Red C204 Image 25-7 R59770072 FLM SERIES 19/03/2007...
  • Page 283 25. Peltier replacement Reinsert the Light processor assembly and reinstall the side cover. R59770072 FLM SERIES 19/03/2007...

  • Page 284: Remove A Peltier Element On The Heat Pipe Cooling Block

    R542 R541 TEC FRONT GREEN C459 R536 C457 C458 CONTR PROGRAM PORT TEC FRONT RED 3.3VC M179 J901 1 : ON = FORCE ISP TEC BLUE R479 C310 C326 C325 C324 J291 Image 25-9 Peltier connection R59770072 FLM SERIES 19/03/2007...
  • Page 285 4. Cut the connector of the old wires and pull the wires out of the cable tree. Then take off the Peltier element. remove the spiral around the cable tree, take out the Peltier wires and then take off the Peltier element. R59770072 FLM SERIES 19/03/2007...

  • Page 286: Mounting A Peltier Element On The Heat Pipe Cooling Block

    TEC BLUE R479 C310 C326 C324 C325 J291 Image 25-12 Peltier connection 4. Place the cooling block back on its place. Insert the screws and turn in the screws with a torque key set to 0.6 Nm. R59770072 FLM SERIES 19/03/2007...
  • Page 287 25. Peltier replacement Green Blue Image 25-13 Mount cooling block 5. Reinsert the light processor assembly and reinstall the side cover. R59770072 FLM SERIES 19/03/2007...
  • Page 288 25. Peltier replacement R59770072 FLM SERIES 19/03/2007...

  • Page 289: Power Input

    Order info mains switch Order number Description B3722365K Mains switch with automatic fuse 35A Overview • Getting access to the power elements • Mains filter replacement • Mains switch replacement • Closing the power input compartment R59770072 FLM SERIES 19/03/2007...

  • Page 290: Getting Access To The Power Elements

    1. Unplug the fan connection. Image 26-3 Fan connection 2. Just loosen the 9 indicated screws. Do not turn them out. Image 26-4 Shield 3. Move the shield plate to the left and take out the plate. R59770072 FLM SERIES 19/03/2007...
  • Page 291 26. Power input Image 26-5 4. Turn out the 6 indicated screws of the mains filter cover plate. Image 26-6 Mains input cover plate 5. Take off the mains filter cover plate. R59770072 FLM SERIES 19/03/2007...

  • Page 292: Mains Filter Replacement

    26.2 Mains filter replacement About this chapter This chapter describes how to replace the mains filter. Image 26-7 Order information Order number Description B305838 Mains filter Overview • Removing the mains filter • Mounting a new mains filter R59770072 FLM SERIES 19/03/2007...

  • Page 293: Removing The Mains Filter

    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. R59770072 FLM SERIES 19/03/2007...

  • Page 294: Mounting A New Mains Filter

    (coming from the SMPS) over the bottom pin followed by a washer (A) and a lock washer (B). Secure with a nut. 7. Continue with "Closing the power input compartment ", page 296. R59770072 FLM SERIES 19/03/2007...

  • Page 295: Mains Switch Replacement

    Next to its function to switch on and off the projector, the mains switch contains also the main automatic fuse. Order information Order number Description B3722365K Mains switch with automatic fuse 35A Overview • Removing the mains switch • Mounting the new mains switch R59770072 FLM SERIES 19/03/2007...

  • Page 296: Removing The Mains Switch

    1. Remove the indicated connection screws at the back side of the mains switch and slide off the eye connectors. Do not drop the washers inside the projector. Image 26-12 Mains switch replacement 2. Turn out both screws on the front side of the mains switch. 3. Slide out the mains switch. R59770072 FLM SERIES 19/03/2007...

  • Page 297: Mounting The New Mains Switch

    6. Turn out the first top screw (d), slide a lock washer, followed by a washer over the screw. Then slide the eye connector coming from the mains filter over the screw. Turn in the screw and tighten completely. 7. Continue with "Closing the power input compartment ", page 296. R59770072 FLM SERIES 19/03/2007...

  • Page 298: Closing The Power Input Compartment

    Mount mains filter cover plate 2. Turn in the 6 indicated fixation screws. 3. Place the shield plate over the screws and move the plate to the right. Image 26-15 Mounting shield plate 4. Secure all indicated screws. R59770072 FLM SERIES 19/03/2007...

  • Page 299: Lamp Power Supply

    H Socket for “CTRL OUT” cable. Lamp output pin “+”. Status LED’s: “LAMP ON / LVPS OK”. Socket for CTRL IN” cable. Mains input. Order info Order number Description R764833K Lamp Power Supply (LPS) module for the FLM projector series. R59770072 FLM SERIES 19/03/2007...
  • Page 300 27. Lamp power supply Overview • LPS diagnostic LED’s • Removing the LPS module • Installing the LPS module R59770072 FLM SERIES 19/03/2007...

  • Page 301: Lps Diagnostic Led's

    • Replace the LPS module in case the voltage value on the “LAMP OUT” pins is below 140 volt and the lamp is not ignited. — LPS unit is operating normally. Projector lamp is ignited. R59770072 FLM SERIES 19/03/2007...
  • Page 302 LPS module as a whole works at 50%. Flashing Both LPS units where Check the error message slow ordered to shutdown due to a on the LCD panel of the malfunction somewhere else projector. inside the projector. R59770072 FLM SERIES 19/03/2007...

  • Page 303: Removing The Lps Module

    4. Disconnect both “LAMP OUT” power cables at the left side from the LPS module. Use for that a 10 mm nut driver. Caution: Do not loose the washers which fits between the fixation nuts and the cable eye. Tip: Place the washers and nuts back upon the output pins. R59770072 FLM SERIES 19/03/2007...
  • Page 304 5. Release the four captive screws which fasten the LPS module to the projector chassis. Use for that a flat screwdriver (6 x 10 mm). Image 27-6 6. Hold fast the LPS module by its handles pull the LPS module out of its compartment. Image 27-7 R59770072 FLM SERIES 19/03/2007...

  • Page 305: Installing The Lps Module

    3. Connect the power cables coming from the SPG module with the “LAMP OUT” sockets of the LPS module as illustrated. Warning: Make sure to place the washers and cable eyes in correct order upon the pin as illustrated. Always use a plain washer between the output pin and the cable eyes. Image 27-10 R59770072 FLM SERIES 19/03/2007...
  • Page 306 4. Connect the grey wire unit with the “CTRL IN” socket as illustrated. Image 27-12 5. Connect the mains input cables with the “MAINS INPUT” sockets of the LPS module as illustrated. Image 27-13 6. Reinstall the back cover of the FLM projector. R59770072 FLM SERIES 19/03/2007...

  • Page 307: Start Pulse Generator

    Positive connection pin from SPG to lamp house. Order info Order number Description R764822K Start Pulse Generator (SPG) for the FLM projector series. Overview • Troubleshooting • Removal of the start pulse generator • Installation of the start pulse generator R59770072 FLM SERIES 19/03/2007...

  • Page 308: Troubleshooting

    • Replace the LPS module. LED’s of the LPS module indicates a problem with the LPS module. Note: The ambient noise must be low to hear the SPG clicking in an attempt to ignite the lamp. R59770072 FLM SERIES 19/03/2007...

  • Page 309: Removal Of The Start Pulse Generator

    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 28-3 3. Release the 3 captive screws (S) of the start pulse generator as illustrated. Use for that a flat screw driver. R59770072 FLM SERIES 19/03/2007...
  • Page 310 4. Remove 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 28-5 R59770072 FLM SERIES 19/03/2007...

  • Page 311: Installation Of The Start Pulse Generator

    2. Fasten the 3 captive screws (S) of the start pulse generator as illustrated, using a flat screw driver. Image 28-7 3. Install the cover of the start pulse generator as illustrated. The cover has to be fasten with 5 hexagon socket head cap screws. Use for that a 3 mm Allen key. R59770072 FLM SERIES 19/03/2007...
  • Page 312 E1 Cable eye from SPG module. E2 Cable eye from LPS unit. Nut. Warning: Respect the polarity of the socket and cables. Red marked cables with the “+” pin, black marked cables with the “-” pin. R59770072 FLM SERIES 19/03/2007...
  • Page 313 Warning: Make sure that both SPG cables 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. Image 28-11 5. Reinstall the lamp house and the covers of the projector. R59770072 FLM SERIES 19/03/2007...
  • Page 314 28. Start pulse generator R59770072 FLM SERIES 19/03/2007...

  • Page 315: Convergence Adjustment

    Press the Lens button on the remote control or the local keypad to display the lens menu. Toggle with this button until the relevant convergence pattern is displayed. The following 2 test patterns are relevant to re-convergence Green on Red DMD and Red on the Blue DMD (Blue=reference). R59770072 FLM SERIES 19/03/2007...

  • Page 316: Action Of The Convergence Controls

    (2): Move the respective convergence pattern up or downwards 45° diagonally (Top-Left/Bottom-Right). • (1) & (2) simultaneously: Move the respective convergence pattern up or downwards -45° diagonally (Top-Right/Bottom-Left). • (1) or (3) separately: rotate the convergence pattern respectively +X° or -X°. R59770072 FLM SERIES 19/03/2007...

  • Page 317: Re-Converging Green On Blue

    Before starting the re-convergence, remove both side covers, front cover and top cover. Location of the lock-down screws G1 G2 Image 29-2 Lock down screws green Location of the convergence adjustable screws Image 29-3 Convergence screws green R59770072 FLM SERIES 19/03/2007...
  • Page 318 Blue convergence pattern. Adjust the control Gb2 & Gb3 simultaneously until the crossing of the center Green convergence pattern coincide with the Top right/Bottom left diagonal line of the center Blue convergence pattern. R59770072 FLM SERIES 19/03/2007...
  • Page 319 7. Because the different adjustments interact, step 4 and 5 have to be repeated until full coincidence of both convergence pattern is obtained. 8. Carefully secure the position of the DMD assembly by tightening the 4 lock-down screws. R59770072 FLM SERIES 19/03/2007...

  • Page 320: Readjustment Of The Plungers

    Image 29-7 Readjustment plunger 2. Continue with the fine convergence adjustment Convergence screw sense no resistance 1. Turn the plunger clockwise until resistance is sensed again. Image 29-8 Readjustment plunger 2. Continue with the fine convergence adjustment R59770072 FLM SERIES 19/03/2007...

  • Page 321: Re-Converging Red On Blue

    29. Convergence adjustment 29.4 Re-converging Red on Blue AUTION Be cautious when adjusting the convergence controls, because a small turn causes already many pixel shift. Location of the lock-down screws Image 29-9 Lock down screws red R59770072 FLM SERIES 19/03/2007...
  • Page 322 • R847203 : Steel screwdriver with 0.05” ended hex blade • Allen key 3 mm • Allen key 2.5 mm How to re-converge 1. Put the square drive socket, with soldered hexagon key, onto a ratchet. R59770072 FLM SERIES 19/03/2007...
  • Page 323 6. Carefully secure the position of the DMD assembly by tightening the 4 lock-down screws. 7. Is the projector an FLM HD projector? If yes, Secure the 4 screws on the heat pipes for red and green (Cr an Cg). R59770072 FLM SERIES 19/03/2007...
  • Page 324 29. Convergence adjustment If necessary to readjust the plungers, see "Readjustment of the plungers", page 318. Close the convergence cover, reinstall all covers of the projector. R59770072 FLM SERIES 19/03/2007...

  • Page 325: Glossary

    (from cold to hot), with consumption of electrical energy. Such instrument is also called Peltier device, Peltier diode, Peltier heat pump, solid state refrigerator or thermoelectric cooler (TEC). R59770072 FLM SERIES 19/03/2007...
  • Page 326 Glossary R59770072 FLM SERIES 19/03/2007...

  • Page 327: Index

    153, 159–160, 163, 167, 170, 172, 175 5098 Calibrate 7658 Drain 7659 Expel air 7660 Fill 7662 Pressure 7663 Pressurize 7664 Refresh 7666 Cooling pump 189–197 7667 Body mounting 7668 Body removal 7670 Body replacement 7671 Cleaning 7672 Cleaning pump 192–193 R59770072 FLM SERIES 19/03/2007...
  • Page 328 Back cover 7989 Carrying handle 7991 Front cover 7993 Input & communication unit 7995 Input cover 7997 Input module 7999 Lamp cover 8000 Lamp house 8001 Lens holder 8002 Light processor 9198 9199 Side cover 9398 R59770072 FLM SERIES 19/03/2007...
  • Page 329 139–140, 143 Front Mounting Removal 109, 111–113, 115 Mounting Adjust Pump Diagnostic Install Remove Peltier 275–276, 279, 282, 284 Cooling block 282, 284 Mount Safety 5–6, 155 Replace Instructions 276, 279 Scheimpflug Mount Shutter 203–204 Replace R59770072 FLM SERIES 19/03/2007...
  • Page 330 Replace right fan Spare part kits 305–307, 309 Install Remove UV filter 117–118 Troubleshooting Replacement Start pulse generator Vertical shift 139–140, 143 Top cover 77–78 Motor 139–140, 143 Installation Mount Remove Removal Top plate 245, 248 R59770072 FLM SERIES 19/03/2007...
  • Page 331 Revision Sheet Barco nv Events/Documentation Noordlaan 5, B-8520 Kuurne Phone: +32 56.36.89.70, Fax: +32 56.36.88.24 E-mail: service.mne@barco.com, Web: www.barco.com From: Date: Please correct the following points in this documentation (R59770072/00): page wrong correct R59770072 FLM 19/03/2007 SERIES...

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