Barco F70 Service Manual
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Barco F70 Service Manual

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  • Page 1 Service manual ENABLING BRIGHT OUTCOMES...
  • Page 2 Barco Fredrikstad AS Habornveien 53, N-1630 Gamle Fredrikstad, Norway Support.fre@barco.com www.barco.com Registered office: Barco NV President Kennedypark 35, 8500 Kortrijk, Belgium www.barco.com/en/support www.barco.com...

  • Page 3: Table Of Contents

    Table of contents 1 Introduction...........................................9 Scope and limitations ..................................10 Copyright .......................................10 Trademarks ......................................10 Required Handtools..................................10 2 General safety ........................................11 General Safety Instructions.................................12 Notice on safety ....................................12 Users Definition....................................12 3 Important Safety Instructions................................15 To prevent the risk of electrical shock............................16 To prevent personal injury................................16 To prevent fire hazard..................................17 To prevent projector damage ..............................17...
  • Page 4 7 OSD / display menu ......................................41 Service Menu ......................................42 Troubleshooting tools ..................................43 8 Thermal management system................................45 Ventilation and cooling...................................46 Liquid cooling system ..................................47 Fans..........................................48 8.3.1 Fan overview ..................................48 8.3.2 Fan Inlet/Outlet................................49 8.3.3 FAN Phosphor wheel..............................49 8.3.4 Fan Optics..................................49 8.3.5 Fan PSU....................................49 8.3.6 Fan PCB Scaler ................................49 8.3.7...
  • Page 5 15.7 Power supply diagnostics................................82 15.7.1 Power good output................................82 15.7.2 AC input voltage monitoring.............................82 15.7.3 Power supply ID................................82 15.7.4 Temperature monitoring .............................82 15.7.5 Consumption monitoring............................82 15.7.6 Weight of PSU .................................82 16 Troubleshooting......................................83 16.1 Status LED indications...................................84 16.2 LED’s on Thermal Hub and Mainboard..........................84 16.2.1 Thermal Hub Board LED’s.
  • Page 6 18.2.12 XPS Actuator Assy..............................128 18.3 40000 hours service..................................128 18.3.1 Liquid cooling system, generic handling instructions................128 18.3.2 Fan outlet..................................129 18.3.3 Fan Inlet ................................... 129 18.3.4 Liquid cooling pumps ..............................130 18.3.5 Liquid cooling pump for DMD..........................131 18.3.6 Cleaning the cooling pump surface ........................
  • Page 7 22.5.3 Reassemble the TIR prism............................ 163 23 Prism Housing......................................165 23.1 Prism Housing ....................................166 723–0018 /02...
  • Page 8 723–0018 /02...

  • Page 9: Introduction

    Introduction Overview • Scope and limitations • Copyright • Trademarks • Required Handtools 723–0018 /02...

  • Page 10: Scope And Limitations

    This document is intended to describe fault resolution, low frequency maintenance and parts replacement procedures for the Barco F70. Only partners named in service agreement with Barco Fredrikstad AS may carry out procedures detailed in this document. Information contained herein is subject to change without further notice;...

  • Page 11: General Safety

    General safety 723–0018 /02...

  • Page 12: General Safety Instructions

    SERVICE PERSONNEL. When an interchangeable lens with throw ratio above a certain level is installed, the F70 / 90 series projector becomes RG3. Refer to the manual for the lens list and hazard distance before operation. Such combination of projector and lens are intended for professional use only, and are not intended for consumer use.
  • Page 13 General safety FOR PROFESSIONALLY USE ONLY, means installation only can be carried out by BARCO AUTHORIZED PERSONNEL familiar with potential hazards associated with high intensity light beams. This product operates on mains voltage. Do not open products without first unplugging the power cord.
  • Page 14 General safety 723–0018 /02...

  • Page 15: Important Safety Instructions

    Important Safety Instructions WARNING: to service personnel: After operation of the protective device, the equipment is still under voltage if it is connected to an IT- power distribution system. 723–0018 /02...

  • Page 16: To Prevent The Risk Of Electrical Shock

    Important Safety Instructions 3.1 To prevent the risk of electrical shock Electrical Shock • This product should be operated from a mono phase AC power source. • This apparatus must be grounded (earthed) via the supplied 3 conductor AC power cable. If none of the supplied power cables are the correct one, consult your dealer.

  • Page 17: To Prevent Fire Hazard

    Never use water on an electrical fire. • Always have service performed on this projector by authorized Barco service personnel. Always insist on genuine Barco re- placement parts. Never use non-Barco replacement parts as they may degrade the safety of this projector.

  • Page 18: On Servicing

    Attempts to alter the factory-set internal controls or to change other control settings not specially discussed in this manual can lead to permanent damage to the projector and cancellation of the warranty. • Unplug this product from the wall outlet and refer servicing to BARCO authorized service technicians under the following conditions: •...

  • Page 19: Precautions During Lens Shift

    Important Safety Instructions 3.7 Precautions during lens shift Lens shift For Lens shift procedure, see User Guide. WARNING: When changing lens, always close the shutter to avoid accidentally staring in to the lens opening. This light can be harmful to the eyes. Close the shutter by pressing the shutter button on the keypad panel.
  • Page 20 Important Safety Instructions Image 3-2 Image 3-3: High voltage warning. Located on spots where precautions must be taken. 723–0018 /02...

  • Page 21: Dlp System General Description

    DLP System General Description 723–0018 /02...

  • Page 22: Gp7Optical Principle

    4.1 GP7optical principle Optical Principle The F70 illumination consists of one light paths that includes the following: 48 blue 455 nm Laser Diodes (LD) grouped into 3 banks consisting of 8 (2x4 array) LDs. The individual laser beams are combined using mirrors and a focusing lens.
  • Page 23 DLP System General Description Image 4-2 The phosphor absorbs the blue laser light, and emits a broad band yellow light which is reflected back towards the dichroic mirror, where it is transmitted, and focused onto the dual rod system. A small portion of the blue light is transmitted through a clear segment of the PW, and is relayed around to the back of the dichroic mirror.

  • Page 24: The Dmd Device

    Digital Light Processing™ technology. The F70 / 90 DMD chip is part of the Texas Instrument DLP9000 family and features over 4 million micromirrors on each chip, offering a dazzling high resolution 2560 x 1600 (WQXGA) array.

  • Page 25: Adding Color

    DLP System General Description 4.4 Adding Color Adding color Image 4-6 The on and off states of each micro mirror on the DMD chip are coordinated with the three basic building blocks of color – Red, Green & Blue (RGB). For example, a mirror responsible for projecting a purple pixel will only reflect red and blue light to the projection surface.
  • Page 26 DLP System General Description 723–0018 /02...

  • Page 27: Gp7 System Functional Description

    About The GP7 platform projector series is a high brightness single chip laser phosphor projector. The electronics system is based on the Barco Pulse processing platform, which offers advanced functionality such as pixel shift and complex warp and blend adjustments.

  • Page 28: Electronic Platform

    GP7 system functional description 5.1 Electronic platform About There are two main electronic PCB’s in the unit; PCB Mainboard and PCB Thermal Hub Board. In addition there is a power supply and a keyboard/display PCB, and some peripheral PCB’s, such as USB interface, IR receiver, thermal sensors.

  • Page 29: Block Diagram Gp7 Platform

    GP7 system functional description 5.3 Block diagram GP7 Platform System Overview Image 5-1 723–0018 /02...
  • Page 30 GP7 system functional description Main Board Overview Image 5-2 723–0018 /02...

  • Page 31: Wiring Matrix

    GP7 system functional description 5.4 Wiring Matrix Note: Cables with no Connection 2, indicates that they ends up in a complete module assy. Cable Routing Connection 1 Connection 2 Cable art. no.,specifications, quantity From Partnumber Description Quantity PCB Name Conn. No. PCB Name Conn.

  • Page 32: Firmware

    GP7 system functional description Note: Cables with no Connection 2, indicates that they ends up in a complete module assy. Cable Routing Connection 1 Connection 2 Cable art. no.,specifications, quantity From Partnumber Description Quantity PCB Name Conn. No. PCB Name Conn.

  • Page 33: System Safety Loop

    GP7 system functional description firmware on a USB memory stick and inserting it in the system’s USB port. When system powers up, it will automatically detect and load the upgrade without more intervention by the user. System firmware consists of the following parameters, and will load a combination of pre-sets, based on the part number it is named with, as well as the color wheel cassette ID it is currently equipped with.

  • Page 34: Laser Driver Principle And Error Codes

    Board 1 is the upper board. Each board has four outputs, named 0 – 3, where output 0 – 2 are used in the F70 projector. This drives the laser cluster, which consist of six laser banks. (3 + 3).
  • Page 35 GP7 system functional description Block schematic diagram for the Laser driver system. Laser driver board Upper (1) Laser driver board Lower (0) 0 1 2 0 1 2 Laser Cluster Image 5-7 Error Codes regarding the Laser drivers Error message Possible root cause / Component to be replaced #e20400 environment.laser.board1.bank0.error Laser Cluster Left...
  • Page 36 GP7 system functional description 723–0018 /02...

  • Page 37: Gp7 Periodic Maintenance

    GP7 periodic maintenance About Moving parts typically have limited lifecycle and need to be replaced within specified intervals. By following these intervals, the projector will maintain optimal performance. The service components and their intervals are specified in the table below. The GP7 Low Frequency Maintenance (LFM) schedule has 2 main service intervals: 20.000 hours and 40.000 hours.

  • Page 38: Service Interval Matrix

    502-0372-xx 6.2 Service kits available 20000 hour kit In order to simplify the ordering of service components, complete service kits are available from Barco service center. See the tables below for more details. Available complete service kits. 20000 hour service...
  • Page 39 GP7 periodic maintenance 40000 hour kit Available complete service kits. 40000 hour service Component Consisting of Kit needed pr service Kit art. no. GP7 Cooling Kit 40K hrs Fan Axial 119x25 (5 pcs) R9802228 Liquid cooler (3 pcs) 723–0018 /02...
  • Page 40 GP7 periodic maintenance 723–0018 /02...

  • Page 41: Osd / Display Menu

    OSD / display menu To enter the menu, press the menu key on either the projector keypad or remote control. The main menu, shown below, will then appear on the screen and the display. If another menu appears, press the “back” key (Remote Control) or the arrow key ( <–) on the keypad, until this menu appears.

  • Page 42: Service Menu

    OSD / display menu 7.1 Service Menu To enter the service menu, go to System settings / Service. The menu shown below will then appear. Image 7-2 Enter the service code [132912] using the arrow keys to select the numbers, and confirm each number by the confirm key.

  • Page 43: Troubleshooting Tools

    OSD / display menu Image 7-4 7.2 Troubleshooting tools The Barco Prospector application can be used for troubleshooting and diagnostics. 723–0018 /02...
  • Page 44 OSD / display menu 723–0018 /02...

  • Page 45: Thermal Management System

    Thermal management system About The Thermal Management System consists of three sub-systems designed to provide cooling and status monitoring for the projector. 723–0018 /02...

  • Page 46: Ventilation And Cooling

    Thermal management system 8.1 Ventilation and cooling The projector is ventilated by open, unfiltered, air-intakes on the left side (seen from the front) and air-exhaust at the rear, allowing for multiple units to be stacked in tiled systems. The absence of filters means there is no risk of clogging and more air is continually moved through the system, resulting in lower operating temperatures over time and longer time between maintenance procedures.

  • Page 47: Liquid Cooling System

    Thermal management system Schematic thermal overview Image 8-2 8.2 Liquid cooling system The primary cooling system comprises three (3) liquid cooling pumps, two for the laser cluster and one for cooling of the DMD. 723–0018 /02...

  • Page 48: Fans

    All nominal RPM values are recorded in Desktop mode. All nominal RPM values are recorded in Desktop mode at 25°C, 0m above sea level 8.3.1 Fan overview Description Barco Part # Function 535-0004-XX 119x119x25 Axial Fan Inlet...

  • Page 49: Fan Inlet/Outlet

    Thermal management system 8.3.2 Fan Inlet/Outlet Inlet/outlet fans 1, 2, 3, 4, 5 are all axial-flow fans which operate by increasing the pressure of air flowing through it. These are rotary fans connected to PCB main and driven directly from the FPGA. There are five axial fans (119x119x25) in the system: 2 pcs on right side of unit cooling two radiators for laser cluster and 3 at the rear of unit where 1 cools DMD radiator and the final 2 fans are standalone fans providing a cooling airflow to vent heat out of the system.

  • Page 50: Fan And Pump. Numbering And Location

    Thermal management system Part Number Description Approx. Nominal RPM (25degC, 0m asl) 504-0001-xx Fan 70x20 Axial 2150 Pin 1: 12V DC Pin 2: TACHO YELLOW Pin 3: BLACK 8.3.7 Fan and pump. Numbering and location. Image 8-4 723–0018 /02...

  • Page 51: Thermal Sensors

    Thermal management system Image 8-5 8.4 Thermal Sensors The Projector is equipped with a range of thermal sensors. Temp sensors provide the thermal profile which guides the fans to the optimal RPM with least possible audible noise. These are both bimetal and thermocouple (P/N based) sensors, in order to have both immediate thermal shutdown (bimetal), and also as a reading of the real time temperature.

  • Page 52: System Thermal Diagram

    Thermal management system 8.6 System thermal diagram Figures in the nominal settings and lifetime settings charts may vary due to different operation conditions, including mounting position, saturation of filters (if optional dust filter is installed and filter saturation sensor activates) etc. Nominal Settings Image 8-6 723–0018 /02...
  • Page 53 Thermal management system Long Lifetime setting. (0m asl) Image 8-7 723–0018 /02...
  • Page 54 Thermal management system 723–0018 /02...

  • Page 55: Lenses And Adjustment

    Lenses and adjustment Refer to User Manual for details regarding available lenses, lens replacement and handling. 723–0018 /02...

  • Page 56: Scheimpflug Adjustment

    Lenses and adjustment 9.1 Scheimpflug adjustment See User Guide for more information. 9.2 Locking the lens position. The mechanically lens lock is particularly important in moving platform applications in order to avoid that the lens comes out of position during operation. See the procedure explained below to perform this. CAUTION: It is of great importance to disable the Lens Shift function when the mechanically lens lock is performed.
  • Page 57 Lenses and adjustment Image 9-2 Insert M4 pan head screws (e.g. DIN7985 Torx. Not supplied) with a maximum length of 15mm in the threaded holes, indicated by the red and green circles in the illustration below. Tighten the screws with a sufficient torque according to good workmanship.
  • Page 58 Lenses and adjustment 723–0018 /02...

  • Page 59: Optical Adjustments

    Optical adjustments 723–0018 /02...

  • Page 60: Perfecting The Lighting Path

    Optical adjustments 10.1 Perfecting the lighting path • Test Image: Full White • Tool: 1,5mm hex key The projection system provides traditional facilities to adjust x & y orientation of the lighting mirror to ensure the DMD active image area is illuminated and available light is fully utilized. Additionally, the system has facilities to adjust the focus plane of the light beam at rod exit side (rod focus) towards the DMD by adjusting Relay tube focus.

  • Page 61: Lighting Mirror: Vertical (Y) Adjustment

    Optical adjustments Image 10-2 10.4 Lighting Mirror: Vertical (y) Adjustment Turn knob (B) with fingers to adjust mirror vertically until no horizontal band is present in upper or lower edge of image Image 10-3 10.5 Focus: Relay tube lens focus adjustment Adjust NUBs (A&B) until the edges of both bands are visible in the projected image (See above picture A).

  • Page 62: Color Uniformity, Ti Loop Mirrors Adjustment

    Optical adjustments 10.6 Color Uniformity, TI Loop mirrors adjustment • Use full white test image • Tool: 1,5mm hex Purpose of adjustment is to even the center the brightness. Adjust one leg at the time. Turn off right laser cluster while adjusting left mirror and vice versa. This can be done by use of Prospector web interface (see chapter 11, PW adjustment).

  • Page 63: Colorwheels

    Colorwheels The GP7 models may be equipped with 2 different Color wheels to provide optimal characteristics to accommodate the requirements of a multitude of applications. Available colorwheels Available Colorwheels COLOR: For great depth of colour and broad Gamut. ‘Color’ color wheels can achieve Rec.

  • Page 64: Replacing The Colorwheel Assy

    Colorwheels 11.1 Replacing the colorwheel assy See chapter 18.2.3 Colorwheel Cassette 11.2 Colorwheel index adjustment The calibration of the color wheel is performed via the service menu. Home/System Settings/Service/Color wheel. This window appears on the LCD Image 11-1 As a reference color picture, use an external source, for instance a PC and a program, for instance paint, that will give a clear red picture (255,0,0).
  • Page 65 Colorwheels Image 11-2: Picture distortion 723–0018 /02...
  • Page 66 Colorwheels 723–0018 /02...

  • Page 67: Phosphor Wheel

    Phosphor wheel 723–0018 /02...

  • Page 68: Replace The Phosphor Wheel Assembly

    Phosphor wheel 12.1 Replace the phosphor wheel assembly See chapter “Phosphor wheel”, page 117 12.2 Entering Prospector diagnostic tool Prospector Tool To access the web interface, use a web browser and enter http//xxxxxx:9999, where xxxxxx is the IP address for the projector, and 9999 are the code for entering Prospector. As an example: http//192.168.1.100:9999. The IP Address for the projector is displayed in the OSD Menu: System/Setting/Communication/LAN.
  • Page 69 Phosphor wheel Image 12-2 .Go to Prospector menu: Introspection/Illumination/Laser/Singlegroupofbanks. Set GroupID to 0 or 1 (left or right channel) Set Power to 3500 Enter Run. Return to Service menu, and use the mouse or [PC] arrow keys to move the slider until the test picture become slightly lighter (yellow color starts to intrude in to the picture).
  • Page 70 Phosphor wheel 723–0018 /02...

  • Page 71: Laser Pulsing Adjustment

    Laser pulsing adjustment 723–0018 /02...

  • Page 72: Procedure

    Laser pulsing adjustment 13.1 Procedure Enter Prospector, and select login. Enter the service code. Select the Service menu/Native RealColorP7 Click on the white radio button, and enable the “Test Pattern” switch Image 13-1 Go to the Laser pulsing slider. d. Measure what the y white value is and increase the blue laser value if the y value is higher than 0.329 and reduce it if’s lower than 0.329 The goal is to set the laser pulse value so that the white ypoint is 0.329 Go back to the native RealColor P7 menu item and update the x and y value for white to match the value you read from the meter.
  • Page 73 Laser pulsing adjustment Image 13-2 Repeat the same procedure for Green and Blue. Note: Do not use C1 if you use brilliant color video mode C1 is used only if you use brilliant color native mode You have now defined the projector, the projector now know exactly what it can do. 723–0018 /02...
  • Page 74 Laser pulsing adjustment 723–0018 /02...

  • Page 75: Xps Actuator

    XPS actuator Overview • XPS actuator replacement • Calibrating the XPS actuator 723–0018 /02...

  • Page 76: Xps Actuator Replacement

    XPS actuator 14.1 XPS actuator replacement To access to the XPS actuator unit, refer to“Lens shift assembly and optical actuator”, page 160 The XPS actuator replacement part is delivered as a complete assembly, part no. R8781693 General The XPS actuator unit has an expected lifecycle of 20.000 hours. How to replace the XPS actuator Before installing the new XPS actuator part, note the resonance frequency for the new unit.
  • Page 77 XPS actuator Image 14-5 When this menu is entered, the following things happen: • The resolution for the unit changes to 4K-UHD, and the XPS actuator are switched on. • The Xpr-cross test picture occurs on the screen. Select the Resonance slider, and set the Resonance to the same value as on the new XPS actuator. Observe the cross pattern in the test picture.
  • Page 78 XPS actuator XPR-Cross Test pattern views. Center cross position in 4K/WQXGA Optimal Center Cross position in Mode, with gain out of adjustment 4K/WQXGA Mode Image 14-6 723–0018 /02...

  • Page 79: Power Supply Unit (Psu)

    Power Supply Unit (PSU) Image 15-1 723–0018 /02...

  • Page 80: Ac Input

    Power Supply Unit (PSU) 15.1 AC Input Label Marking: 100-240V, 50-60Hz, 12A 15.2 Output specification The output connectors contain output voltages from 5 different internal converters. Below is the specified output voltage and output current capacity of each converter. Connector output Output name Voltage level Capacity...

  • Page 81: Mainboard Connector J4

    Power Supply Unit (PSU) 15.4 Mainboard connector J4 PIN number Output name Pin 1 +12V-1 Pin 2 +12V-1 Pin 3 12V-1_GND Pin 4 +11,5V_STB Pin 5 SGND (Shield GND) MOLEX MICROFIT – HEADER SEEN FROM ABOVE Pin 6 +12V-1 Pin 7 12V-1_GND Pin 8 12V-1_GND...

  • Page 82: Laser Driver Connector J2

    Power Supply Unit (PSU) 15.6 Laser driver connector J2: 390V LAMP DRIVERS Output name Pin 1 +385V - 1 Pin 2 Not used Pin 3 385V_GND Pin 4 Not used Pin 5 Not used Pin 6 SGND (Shield GND) MOLEX MICROFIT – HEADER SEEN FROM ABOVE Pin 7 +385V - 2 Pin 8...

  • Page 83: Troubleshooting

    Troubleshooting 723–0018 /02...

  • Page 84: Status Led Indications

    Troubleshooting 16.1 Status LED indications The status LED on the rear top of the projector, has only one indication; constant red illumination. This indicates a major system failure. A more complementary indication will come on later versions of the software. 16.2 LED’s on Thermal Hub and Mainboard.

  • Page 85: Main Board Led's

    Troubleshooting 16.2.2 Main Board LED’s Main Board failure indications Ref. Des. Illumination (Component Silk screen print Function Failure color when Comment No.) failure Supply voltage Voltage outside fail spec Reset main M_Re Constant reset active mode. No function DS11 DLP FPGA not FPGA failure —...

  • Page 86: Available Diagnostic Tools

    Troubleshooting Image 16-2 16.3 Available Diagnostic Tools 16.3.1 Prospector Notifications in Pulse Prospector. PROSPECTOR, internal web interface which provides a real time operation overview including voltage levels, temperatures fan speeds and more. 723–0018 /02...

  • Page 87: Pd Diagnostic

    Possible to download notifications-file to local computer 16.3.2 pd Diagnostic The pdDiagnostics tool is a custom tool initially developed by Barco for use with projectors based on the Titanium processing platform (GP9). It also supports the new products based on Pulse processing platforms.

  • Page 88: Explanation Of The Codes

    Troubleshooting Overview • Explanation of the codes • Troubleshooting checklist • Log files 16.4.1 Explanation of the codes Overview An unique numeric code which indicates the source of the error (the board or functional part that notifies the problem) and the sensor or sub location that shares the information. X0000000 Code X0000000: “XXX - xx xxxxxxx”...

  • Page 89: Troubleshooting Checklist

    Troubleshooting Physical sub location Can be sensor number, bank number, coordinate, ID, ... Physical sub location 0..FFFh Optional indicator Optional indicator Value Comments High Type Type Description Note / Recommendation INFO Messages of this type informs the user about an event or status change.
  • Page 90 Troubleshooting Code E0000301: “Mainboard FPGA temperature exceeded” (Error) For this error the same troubleshooting table can be applied to as for code E0000101: “Mainboard sensor temperature exceeded”. Code E0000401: “Mainboard Scaler FPGA temperature exceeded” (Error) For this error the same troubleshooting table can be applied to as for code E0000101: “Mainboard sensor temperature exceeded”.
  • Page 91 Troubleshooting Code E1000201: “LaserDriver A heatsink 1 temperature exceeded” (Error) Situation Solution This error appears alone: check for clogged vents OR the laser bank connected to the affected driver Insufficient air flow through output may be partly or entirely short-circuited. laser driver housing.
  • Page 92 Troubleshooting Code E1200400: “LaserDriver A heatsink 3 temperature reading failure” (Error) For this error the same troubleshooting table can be applied to as for code E1000400: “LaserDriver A heatsink 1 temperature reading failure”. Code E1300101: “LaserDriver A bank 4 temperature exceeded” (Error) For this error the same troubleshooting table can be applied to as for code E1000101: “LaserDriver A bank 4 temperature exceeded”.
  • Page 93 Troubleshooting Code E2000101: “LaserDriver B bank 1 temperature exceeded” (Error) For this error the same troubleshooting table can be applied to as for code E1000101: “LaserDriver A bank 1 temperature exceeded”. Code E2000201: “LaserDriver B heatsink 1 temperature exceeded” (Error) For this error the same troubleshooting table can be applied to as for code E1000201: “LaserDriver A heatsink 1 temperature exceeded”.
  • Page 94 Troubleshooting Code E2300201: “LaserDriver B heatsink 4 temperature exceeded” (Error) For this error the same troubleshooting table can be applied to as for code E1000201: “LaserDriver A heatsink 1 temperature exceeded”. Code E2300300: “LaserDriver B bank 4 temperature reading failure” (Error) For this error the same troubleshooting table can be applied to as for code E1000300: “LaserDriver A bank 1 temperature reading failure”.
  • Page 95 Troubleshooting Code E4000400: “Radiator Fan 1 speed too low” (Error) Situation Solution Blocked fan Remove the fan from the radiator assembly and verify if the fan is not blocked. To access the fan, see service procedure Wiring issue Check the connection towards the thermal hub board. If problem persists, replace the fan.
  • Page 96 Troubleshooting Code E8000001: “Colorwheel temperature exceeded” (Error) Situation Solution ColorWheel temperature Check if the cooling circuit of the Light source is connected with the pump exceeded. and heat exchanger. Code E9000000: “PSU mainpower low limit reached” (Error) Situation Solution Internal Power Supply not Check if the power cord correctly plug into the power input socket of the functioning well due to projector and if it is correctly plug into a grounded AC outlet.
  • Page 97 Troubleshooting Code E9000300: “PSU ThermalHub low limit reached” (Error) Situation Solution Potential malfunction of the Replace the PSU. See service procedure . PSU: Thermal Hub 12V voltage to low. Code E9000301: “PSU ThermalHub high limit reached” (Error) Situation Solution Potential malfunction of the Replace the PSU.

  • Page 98: Log Files

    Creating and downloading log files with PToolset A diagnostic package can be created with the Projector Toolset, the software tool to set up, manage and control Barco projectors. The program and all necessary plug-ins, as well as the Reference manual can be downloaded from my.
  • Page 99 Troubleshooting Image 16-5 • Full Log functionality (Log02): The full log functionality is password protected, and only meant for engineering purposes. This contains only the system logs per date. • Notification log (Log03): The notification.0 log, shows you a preview of the service log ( also named notifications0, and included in the standard logfile).
  • Page 100 Another way to create a diagnostic package is use PulseLogExtractor, an application that automatically provide a log file and copy it on an USB stick. How to download PulseLogExtractor Go to the Barco website www.barco.com, or on the secured Barco web site https://www.barco.com/en/signin. Click on Products to display the All Product categories page.
  • Page 101 Troubleshooting Image 16-9 Note: Please refer to the Troubleshooting list above in this manual for further info on Error codes. Log file analysis Example of log file content Image 16-10 Format : {”timestamp”: “xxxx-xx-xxxxx: xx: xx. xxxxxxz”, “code”: “xxxxx”, “severity”: “xxxx”, “message”: “xxxxxxxxxxxxxxxxxxxxx”}...
  • Page 102 Troubleshooting 723–0018 /02...

  • Page 103: Assembly Hierarchy

    Assembly hierarchy This section describes which parts need to be removed in order to access faulty parts 723–0018 /02...
  • Page 104 Assembly hierarchy Image 17-1 723–0018 /02...

  • Page 105: Disassembly / Assembly Instructions

    Assembly hierarchy 17.1 Disassembly / Assembly instructions This section describes disassembly and assembly of projector following guidelines set forth in assembly hierarchy. Additional information how the unit assembles may be found on the product exploded views. Unless otherwise indicated, re-assembly in reverse order. 17.2 Safety Precautions Warning! When changing lens, always close the shutter to avoid accidentally staring in to the lens opening.

  • Page 106: Remove The Rear Cover

    Assembly hierarchy Image 17-2 17.3.2 Remove the Rear Cover Remove 5 screws TX20 M4x10 w/Lockwasher, indicated with 1 in the figure below Remove 4 screws TX10 M3x8 w/Lockwasher securing rear cover to IO bracket, indicated with 2 in the figure below.

  • Page 107: Remove The

    Assembly hierarchy Image 17-4 17.3.3 Remove the front cover Remove 4 screws holding the lens rubber gasket. Remove 4 screws 6mm HEX screws indicated by “1”. Remove 4screws TX20 M4x10 indicated by “2”. Disconnect the cables going to the two PCB Lens connectors- Gently remove the front cover from its position by pulling it slightly back, and upwards.

  • Page 108: Removing Peripheral Pcbs

    Assembly hierarchy Image 17-7: Left sidecover Image 17-8: Right sidecover 17.4 Removing peripheral PCBs 17.4.1 Removal of display and keypad module Remove the PCB Main cover, see chapter 19.1.1 1. Disconnect the Flex Cable from PCB main (J20) by gently lifting up the tab on the connector and remove cable from the connector.

  • Page 109: Pcb Gp6/Gp7 Ir Receiver And Led Board Top

    Assembly hierarchy 17.4.2 PCB GP6/GP7 IR Receiver and LED Board TOP This PCB contains both the IR Receiver and the status indicator LED. 1. Remove 2 screws (TX8 PT25x8) securing the PCB IR Receiver board to top cover. Lift up the PCB. The LED lens can now also be removed.

  • Page 110: Switch Air/Smoke Filter

    Assembly hierarchy Image 17-16: Location of IR PCB 17.4.5 Switch Air/smoke filter 1. Remove 3 screws TX10 M2x8 releasing IR Holder front from side-frame & bracket lens support. 2. Carefully open clips securing the switch and lift out. Image 17-17 Image 17-18 Note: Ensure the switch is placed flat on bracket floor with the two side locks properly holding the switch...
  • Page 111 Assembly hierarchy Image 17-19: Release 5 screws. Remove 2 screws which holds the fan bracket, and pull the bracket out. Release the cable. Image 17-20 Release the screw and remove the Temp sensor board 723–0018 /02...

  • Page 112: Pcb Temp Sensor Board #2 (Outlet)

    Assembly hierarchy Image 17-21: Temp sensor board Inlet This PCB is located on the FAN FPGA Scaler Airguide Disconnect the cable and remove one screw (T8 M2,5x6) The sensor PCB is identical to below PCB Inlet sensor: 504-0609-XX GP6 PCB Temp, Pres & Hum Board Image 17-22 17.4.7 PCB temp sensor board #2 (Outlet) This PCB is located underneath the PCB main.
  • Page 113 Assembly hierarchy Image 17-23 723–0018 /02...
  • Page 114 Assembly hierarchy 723–0018 /02...

  • Page 115: Scheduled Operations

    Scheduled operations 723–0018 /02...

  • Page 116: Scheduled Operations Matrix

    Scheduled operations 18.1 Scheduled operations matrix About This section outlines replacement of parts which have a pre-defined life cycle, where replacement is required at regular intervals. Such parts adhere to a life cycle management system which prompts the user when replacement is due.

  • Page 117: Phosphor Wheel

    Scheduled operations 18.2.1 Phosphor wheel Release 5 captive screws securing PW cover for the Phosphor wheel compartment. Image 18-2 Release 3 screws (Tx8 M2.5x6) securing the phosphor wheels. Carefully lift out the Phosphor Wheel Assembly, and disconnect the HDMI connector and the power cable. Image 18-3 Image 18-4 18.2.2 Fan Phosphor wheel...

  • Page 118: Colorwheel Cassette

    Scheduled operations Image 18-6 18.2.3 Colorwheel cassette The system is automatically configured with the correct CW algorithms following the product ID of the CW cassette. The cassette contains no serviceable parts, and further de-assembly should not be attempted. CW index fine-tuning and RealColor measured coordinate calibration may be executed after replacement of CW cassette as there are no facilities to automatically align these properties in the system.

  • Page 119: Fan Psu

    Scheduled operations Image 18-9 Image 18-10 If PSU has a malfunction, 4 cables must be disconnected. Image 18-11 4. Release 12 screws TX10 M3x8 w/washer to release PSU from its bracket. Note: A new cable tie must be mounted securing HDMI cable in connector. 5.

  • Page 120: Fan Pcb Scaler

    Scheduled operations Image 18-13 Image 18-14 Note: Bracket fan, spacers and rubber shall be reused. Fan PSU connects to PCB HUB J22. For ease of service, a connector approximate to fan PSU will be implemented in fan cable. 18.2.6 Fan PCB Scaler Access to fan provides that right side panel is removed.

  • Page 121: Fan Optics

    Scheduled operations Image 18-15 Assemble 1. Thread new rubber straps through mounting hole in replacement fan. 2. Cut off excess rubber strap from fan and push fan in place. - Fan connects to PCB main Conn J23 Image 18-16 18.2.7 Fan Optics Access to fan provides that top, front and left side covers have been removed.

  • Page 122: Laser Cluster

    Scheduled operations Image 18-17 Image 18-18 Cables coming from PSU should all be routed under illumination Engine (A). Only power supply to PCB lens hub should be routed up via fan house (B) Image 18-19 18.2.8 Laser Cluster The GP7 platform products have one laser cluster which provide blue laser light to the projection system. Laser cluster shall also be replaced after 20K hrs.

  • Page 123: Remove The Liquid Cooling Pumps On Laser Cluster

    Scheduled operations pump is directly cooling coupled to the cluster; a thermal conductive gasket is used between the pump and the cluster ensuring good thermal connection. In order to access the laser clusters, PCB main including sheet metal brackets and main PSU should be removed, following the steps in “Technical operations”, page 133 18.2.9 Remove the Liquid cooling pumps on Laser Cluster.
  • Page 124 Scheduled operations Image 18-22 Release 4 screws TX10 in diagonal order. Gently bend loose the pump from laser cluster with flat screwdriver. Image 18-23 It may be necessary to pre-heat laser cluster in order for pump to loosen. If so, use an adjustable heat gun set to 80°C/176°F.

  • Page 125: Remove The Laser Cluster

    Scheduled operations Image 18-24 18.2.10 Remove the laser cluster Disconnect 3+3 power connectors on the laser cluster, indicated by green ovals in the picture Image 18-25 Loosen , but do not unscrew fully, the two screws (Tx20 M50x45) and carefully lift out the laser cluster. It is recommended to hold the cluster with one hand while loosen and removing the locking clamp.

  • Page 126: Cleaning The Cooling Pump Surface

    Scheduled operations Image 18-26 Image 18-27 Position the new laser cluster to the Laser Interface. Ensure that the cluster is properly in place. The cluster will “fall” into position, and it will not be possible to rotate it vertically when it is in correct position Tighten up the clamps on each side, and ensure correct position and fit also for the clamps.
  • Page 127 Scheduled operations Image 18-28 Image 18-29 3. Add new gasket to the copper surfaces of the cooling pump, use a plastic card to make the new gasket stick properly. 4. Remove the thin plastic film from new gaskets and mount cooling pump to the Laser cluster. 5.

  • Page 128: Xps Actuator Assy

    Scheduled operations 18.2.12 XPS Actuator Assy XPS Actuator Assy (Pixel shift device) is delivered from the factory preassembled onto the Dump light bracket with heatsink. See chapter “Prism Housing” and follow the steps describing how to remove the complete dump light bracket incl.

  • Page 129: Fan Outlet

    Scheduled operations Image 18-34 18.3.2 Fan outlet Release 4 Screws (TX10 M40x41) securing each fan. All fans connect directly to PCB main. Image 18-35 • Fan1: Connects to PCB Main Conn. J65 • Fan2: Connects to PCB Main Conn. J64 •...

  • Page 130: Liquid Cooling Pumps

    Scheduled operations Fans can be removed from frame without disconnecting the liquid pumps from the laser cluster. Fans are secured with 4+4 screws (TX10 M40x41). Image 18-36 Image 18-37 18.3.4 Liquid cooling pumps Remove complete PCB Main Assembly first as described in chapter. Laser cluster and DMD are cooled by a liquid thermal system.

  • Page 131: Liquid Cooling Pump For Dmd

    Scheduled operations Image 18-39 Image 18-40 Note: Handle pumps and tubing with care! See “Liquid cooling system, generic handling instructions.”, page 128describing preferred handling. 18.3.5 Liquid cooling pump for DMD. Release 3 screws TX20 at right hand side of exhaust fan frame Release 2 screws (TX20) throug left aluminum frame and lift out frame including fans Image 18-41 Image 18-42...

  • Page 132: Cleaning The Cooling Pump Surface

    Scheduled operations Image 18-43 Image 18-44 The Liquid Cooling pump can now be removed by releasing 4 screws TX10 in a diagonal order Clean DMD heatsink before mounting new pump. Remove the protection film on new pump assembling in reverse order Image 18-45 18.3.6 Cleaning the cooling pump surface It is important to perform the cleaning and gasket replacement procedure properly.

  • Page 133: Technical Operations

    Technical operations This section outlines replacement of parts without any pre-defined life cycle. 723–0018 /02...

  • Page 134: Pcb Main

    Technical operations 19.1 PCB Main About If purpose of the service event is to replace the PCB main, the board may be removed from the unit following the following described process: 19.1.1 PCB removal preparations Release 8 screws (Tx10 M3x6 w/Lockwasher), remove PCB Bracket top. Release 8 screws (Tx10 M3x6 w/Lockwasher) around the edges of the board Release 2 nylon (plastic) screws securing the center of the board Image 19-1...

  • Page 135: Pcb Main Assembly Removal

    Technical operations microSD card Image 19-4 Note: In order to maintain system dynamic data, µSD card must be transferred from original PCB main over to the new replacement board. 19.1.2 PCB Main assembly removal In order to access TI loop, laser drivers etc, PCB main can be removed mounted in Bracket main bottom. Remove 5 screws (Tx10 M3x6 w/Lockwasher), disconnect all cables and gently remove PCB Main.

  • Page 136: Pcb Laser Driver Boards

    Technical operations Image 19-5 19.2 PCB Laser driver boards About The projector is equipped with two Laser drivers. The complete cage containing both laser drivers can be removed as one assy. This is also necessary if one of the Laser drivers are faulty and needs to be replaced. 1.

  • Page 137: Dmd, Dmd Board And Clga & Dmd Heatsink Elements

    Technical operations Replacing the Laser driver The individual laser drivers are mounted “back to back” inside the metal cage. The cage can be split opened from either side for access to the laser drivers inside. - With cage open, laser drivers can be removed by releasing 10 screws TX10. Image 19-8 19.3 DMD, DMD board and CLGA &...

  • Page 138: Gp7 Pcb Dmd Board

    Technical operations Image 19-11 Heatsink stud and cooling surface may be bonded to DMD and Front side heatsink by the thermal paste. Some force may be required to split the two heatsink assemblies. 19.4 GP7 PCB DMD Board Remove 4 screws (Tx8 M25x10) diagonally Carefully remove the DMD backer plate.

  • Page 139: Re-Assembly After Pcb Dmd Or Dmd/Clga Repair

    Technical operations Important! Do not use wipes to clean the CLGA, as microscopic particles from the wipes may catch on the C shaped springs and cause contact problems (more often than not, this will manifest itself as vertical lines). Carefully remove the CLGA interface including the DMD. Avoid getting fingerprints on the DMD front glass and surface or rear connection points.

  • Page 140: Gp7 Heatsink Dmd Front & Rear Assemblies

    Technical operations Image 19-14 Heat Paste: 302-0086-00 Shin ETSU 7762 19.7 GP7 Heatsink DMD Front & Rear Assemblies The DMD Peltier cooling system is split in two assemblies each available for service: - GP7Heatsink DMD FRONT ASSY - GP7 Heatsink DMD REAR ASSY Image 19-15 Image 19-16 Unlike the GP6 platform, the GP7 has only the single set cooling for DMD.

  • Page 141: Gp7 Heatsink Dmd Front Assembly

    Technical operations 19.8 GP7 Heatsink DMD Front assembly The Heatsink DMD Front Assy from Barco has the Peltier element already mounted. If the Peltier element is placed on Heatsink DMD REAR ASSY, it must be removed following below instructions, and recycled.

  • Page 142: Install New Laser Interface

    Technical operations Image 19-19 Remove Safety Switch and Bimetal switch. Release two screws (TX20 M50X45) opening the Dow Tail clamps. This will release the laser interface form the TI loop (not necessary to open fully). Remove two screws securing the laser interface to the base plate (Tx20 M4x12) Image 19-20 19.10 Install new laser interface Position the new Laser Interface to the TI loop.

  • Page 143: Pcb Thermal Hub Board

    Technical operations 19.11 PCB Thermal Hub Board 19.11.1 PCB Thermal Hub board To allow easier access during the following procedures, the PCB lens hub board including bracket Hub board top and bottom can be removed. Disconnect all cables. Release 2 screws (Tx10 M3x8) towards the lens. Image 19-21 Release 7 screws (Tx10 M3x6) and remove Bracket Hub Top.

  • Page 144: Pcb Thermal Hub, Complete Assy Removal

    Technical operations Cable overview (from clockwise), as shown in figure below. 11. Lenspos-V (Vert.) 30. NTC R (NTC DMD rear) 12. Lens 2 31. DPS 13. Wobbulator (Pixelshift) 4K only 32. Peltier R (Peltier DMD Rear) 14. SW 33. Power Hub 15.

  • Page 145: Ti Loop

    TI loop WARNING: The TI loops modules are critical components, both with regards to laser safety and proper handling of the components inside the module. Use rubber finger cots while handling optical components to avoid staining or otherwise damaging optical coating. Imprints from the unprotected fingers will cause overheating and damage of optical components.

  • Page 146: General

    TI loop 20.1 General WARNING: The TI loops modules are critical components, both with regards to laser safety and proper handling of the components inside the module. Use rubber finger cots while handling optical components to avoid staining or otherwise damaging optical coating. Imprints from the unprotected fingers will cause overheating and damage of optical components.

  • Page 147: Overview Inside The Ti Loop

    TI loop Image 20-2 20.3.2 Overview inside the TI Loop Image 20-3 Dichroic filter B/Y Blue loop lens 3 Barrel Phosphor lens Blue loop lens 4 Blue depolarizer Diffuser blue loop Mirror blue roundabout RGBY Converging lens 20.3.3 Dichroic Filter B/Y Gently lift out the mirror by pulling the two wedges.

  • Page 148: Barrel Pw Lens Assy

    TI loop Image 20-4 20.3.4 Barrel PW lens Assy Remove screw (TX08 M2.5x6) Remove the clip holding lens in place. Gently lift out the lens. Mount the lens back in the trace in Engine Blue Loop bottom, see picture. Image 20-5 Image 20-6 20.3.5 Mirrors Blue Use the wedges to gently pull out the blue mirrors.

  • Page 149: Blue Loop Lens 3

    TI loop Image 20-7 20.3.6 390 Blue Loop Lens 3 1. Remove screw (Tx08 M2.5x6) 2. Remove the clip holding lens in place. 3. Lift out the lens. Image 20-8 Note: The Blue Loop lenses are NOT directional. 20.3.7 390 Blue Loop Lens 4 Remove screw (Tx08 M2.5x6) Remove the clip holding lens in place.

  • Page 150: Rgby Converging Lenses

    TI loop Image 20-10 20.3.9 390 RGBY Converging Lenses Each TI Loop is equipped with 2 Converging Lenses, one at the entrance and one at the exit of the loop. • NOTE Always use finger cots or gloves when handling lens elements •...
  • Page 151 TI loop 2. Remove 4 screws (Tx8 M2.5x6) releasing the clip and lens. 3. Assemble in reverse order. Image 20-12 Image 20-13 Image 20-14 Converging Lens (Exit) Release two screws (TX20 m50X45) holding the Dow Tail clamps. This releases the TI loop form the Illumination Engine Front.

  • Page 152: Rod Carrier

    TI loop Image 20-15 Image 20-16 20.3.10 Rod carrier The exit hollow rod shapes the spherical light into a rectangular frame before the Illumination Engine. Remove 4 screws (TX10 M3x8) and remove rod cover. Remove 1 screw (TX10 M3x8), remove clip ROD and finally the rod. Image 20-17 Image 20-18 Do NOT touch surfaces of glass rod with fingers.

  • Page 153: Illumination Engine

    Illumination Engine About The illumination Engine contains the Relay Tube Assy (Lens), Motorized Iris Assy, Folding Mirror assembly and CLO sensor (Constant Light Output). GP7 Iris assy and Relay Tube assy can be removed without removing illumination engine. Adjustable mirror and CLO can only be accessed after removing the complete engine core, including lens shift.

  • Page 154: Iris Assembly

    Take note of cable routing of limit switch through groove in Illumination Iris cover, as illustrated (green) in picture below. Iris connects to PCB Thermal HUB conn: J4 Note: This cable is not present on newer models of the F70 Projector. Image 21-2 Remove 2 screws and release Iris assembly from the cover Image 21-3 21.2 Relay tube assembly...

  • Page 155: Pcb Clo (Constant Light Output)

    Illumination Engine Image 21-4 Image 21-5 21.3 PCB CLO (Constant Light Output) Tool needed This operation requires a special tool, see picture below. Image 21-6 Procedure Remove Fan Optics, see above. Remove 4 screws (Tx10 M3x6) securing the PCB to the CLO holder. - PCB CLO connects to PCB thermal hub conn J30 723–0018 /02...

  • Page 156: Folding Mirror Assembl

    Illumination Engine Image 21-7 21.4 Folding mirror assembl 1. Remove 3 screws (TX8 M2.5x6) and lift out mirror assembly. Use the same tool as for the CLO removal. 2. To release mirror, push mirror towards the clips to release mirror from the two retainers. The rear side of mirror has a bluish reflection.

  • Page 157: Lens Shift Assembly

    Lens shift assembly About The lens shift assembly is a complex device offered as one complete assembly in the unlikely event of mechanical malfunction. Only the following components are separately available. Partnumber complete Lens shift assembly: 950–0003. 400-0909-xx Lens shift Motors 534-0031-xx Lens position sensors (390 Sensor Optical End H) 504-0087-xx PCB Lens conn (Pogo pin board).
  • Page 158 Lens shift assembly These components are all accessible/removable without taking out the complete lens shift assembly (provides that the lens shift mechanism is centered). If lens shift needs to come out, see “Lens shift assembly and optical actuator”, page 160 Dependent on the position of the lens shift mechanism, it may be necessary to manually turn the lead screw to expose the screws 8mm hex nut Image 22-2...

  • Page 159: Lens Shift Assembly Motors

    Lens shift assembly 22.1 Lens shift assembly motors 1. Remove 4 screws (M3x8 TX10 W/Lockw.) to remove lens shift motors with lead screw from lens shft assy. Dependent on the position of the lens shift mechanism, it may be necessary to manually turn leadscrew to expose the screws (8mm hex).

  • Page 160: Pcb Lens Connectors

    Lens shift assembly Image 22-4 22.3 PCB lens connectors 1. Release 2 screws (M3x8 TX10) to remove each PCB lens conn. - Left PCB is traditional PCB lens communication. Connects to PCB Lens Hub J7 Top PCB is responsible for logical communication, storing of lens positions (Next EN6x series lens generation).
  • Page 161 Lens shift assembly Image 22-6 Remove 2 screws (TX20 M4x12) securing the assembly to the base plate and remove the complete assy. Image 22-7 Image 22-8 With the lens shift assembly removed, the GP6/7 Dumpl. XPS Actuator assy is loose and can be removed. Note: See “XPS actuator”, page 75 for details tuning new actuator if it has been replaced.

  • Page 162: Tir Prism

    Lens shift assembly Image 22-9 22.5 TIR Prism Use cotton gloves or finger nuts whenever handling the TIR prism 22.5.1 Remove the TIR prism Remove 4 screws (TX8 M2,5x6) Carefully pull out the Prism Clip Prism using a flat screwdriver. Image 22-10 Image 22-11 Lift the prism out carefully.

  • Page 163: Cleaning The Tir Prism

    Lens shift assembly Image 22-12 22.5.2 Cleaning the TIR prism Use ionized air when cleaning the TIR prism. If the unit is extremely dirty, use a nonabrasive optical wipe and optical cleaning solvent to clear the surface. Image 22-13 22.5.3 Reassemble the TIR prism Insert the prism in the engine housing.
  • Page 164 Lens shift assembly Image 22-14 723–0018 /02...
  • Page 165 Prism Housing 723–0018 /02...
  • Page 166 Prism Housing 23.1 Prism Housing In order to access prism housing, Engine Core including lens shift assembly and Dump light Assy must be removed first. Push in the two straps that secure the bellow outer to lens shift assy. Gently remove complete bellow and lens ring; the lens shift cable is routed via the bellow and must be disconnected.
  • Page 167 Prism Housing Image 23-5 723–0018 /02...
  • Page 168 723–0018 /02 | 2019-04-24 Barco Fredrikstad AS | Habornveien 53, N-1630 Gamle Fredrikstad, Norway Registered office: Barco NV | President Kennedypark 35, 8500 Kortrijk, Belgium www.barco.com...

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