Page 1 HDF W series Service manual R5905312/01 24/01/2013...
Page 2 Barco nv Noordlaan 5, B-8520 Kuurne Phone: +32 56.36.82.11 Fax: +32 56.36.883.86 Support: www.barco.com/esupport Visit us at the web: www.barco.com Printed in Belgium...
Page 3 Changes Barco provides this manual ’as is’ without warranty of any kind, either expressed or implied, including but not limited to the implied war- ranties or merchantability and ﬁtness for a particular purpose. Barco may make improvements and/or changes to the product(s) and/or the program(s) described in this publication at any time without notice.
Page 5: Table Of Contents
10.16 Replacement of the SMPS board ....................166 R5905312 HDF W SERIES 24/01/2013...
Page 6 19.4 Display Interface Diagnostic LEDs ....................314 R5905312 HDF W SERIES 24/01/2013...
Page 7 Index........................325 R5905312 HDF W SERIES 24/01/2013...
Page 8 Table of contents R5905312 HDF W SERIES 24/01/2013...
Page 9: Safety
HDF projector. After this chapter, addi- tional “warnings” and “cautions” are given depending on the service procedure. Read and follow these “warnings” and “cautions” as well. ARNING This manual is only intended for qualiﬁed service personnel. Overview • Safety Instructions R5905312 HDF W SERIES 24/01/2013...
Page 10: 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. R5905312 HDF W SERIES 24/01/2013...
Page 11 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 12 1. Safety R5905312 HDF W SERIES 24/01/2013...
Page 13: General
2. General 2. GENERAL Overview • Convention projector orientation • Location of the main components of the projector • Spare parts for HDF series • Projector block diagram R5905312 HDF W SERIES 24/01/2013...
Page 14: Convention Projector Orientation
This manual refers to the left side of the projector as the side at your left hand when standing behind the projector and looking at the projection screen in front of the projector. Image 2-1 Front side (lens side) Right side projector (lamp & input side) Back side Top side Left side (light processor side) R5905312 HDF W SERIES 24/01/2013...
Page 15: Location Of The Main Components Of The Projector
2. General Location of the main components of the projector Housing Image 2-2 Rear cover Top cover Side cover (side light processor) Front cover Input & communication cover Lamp cover R5905312 HDF W SERIES 24/01/2013...
Page 16 Lamp power supply (LPS) Start pulse generator (SPG) Light processor cover plate Light processor Cold mirror assembly Anode fan assembly Lens holder Input & communication unit 10 Switched mode power supply (SMPS) 11 SMPS cover plate R5905312 HDF W SERIES 24/01/2013...
Page 17 2. General Image 2-4 12 Front ﬁlter 13 Top ﬁlter 14 Start pulse generator (SPG) 15 SPG cover plate 16 Water cooling circuit with heath exchanger 17 Heat exchanger ﬁlter R5905312 HDF W SERIES 24/01/2013...
Page 18: Spare Parts For Hdf Series
Up to date information regarding spare parts for HDF series Barco continuously improves its service procedures for the customer. Managing spare parts is one of the key processes. The spare parts list is subject to change. No spare parts list is included in this manual to ensure that no spare parts are ordered based upon outdated information.
Page 19: Projector Block Diagram
Sat. BLUE Image 2-5 CTRL Controller FIB Formatter Interface Board OSD On Screen Display PiP Picture in Picture CLO Constant Light Output SPG Start Pulse Generator LIM Lamp Info Module Sat Satellite Infra red Receiver R5905312 HDF W SERIES 24/01/2013...
Page 20 PROM µC RS485 FPGA FPGA config RS485 µC PROM RS485 I²C Sat. R PROM (+ CTRL) CTRL I²C (+ FIB) I²C Sat. G PROM PROM I²C RS232 PROM I²C Sat. B PROM HighSpeed Image 2-6 R5905312 HDF W SERIES 24/01/2013...
Page 21 PROM Input 1 FPGA I²C I²C RS232 PROM PROM Input 1 CTRL FPGA WIFI I²C PROM High Speed Input 1 FPGA (+ CTRL) (SATA) (+ FIB) I²C Config DSPL PROM FPGA PROM Keypad Image 2-7 R5905312 HDF W SERIES 24/01/2013...
Page 22 +12V +12V +12V DC/DC +12V DC/DC DC/DC WIFI Sat. RED +12V 5 Cable input Sat. GREEN +12V Dual DVI input DC/DC DC/DC DC/DC +3.3V +2.5V +1.2V Sat. BLUE 3G SDI input WARP Deinterlacing Image 2-8 R5905312 HDF W SERIES 24/01/2013...
Page 23: Preventative Maintenance Actions
Overview • 1 month maintenance actions • 3 month maintenance actions • 2 year (or 1500 hours runtime) maintenance actions • 10 year (or 10000 hours runtime) maintenance actions • Lamp change maintenance actions R5905312 HDF W SERIES 24/01/2013...
Page 24: Month Maintenance Actions
Check the surface of the lens output side for dust. (it is not needed to remove Clean the lens output side in case dust the lens from the projector). Only clean if necessary. is clearly visible upon the surface. R5905312 HDF W SERIES 24/01/2013...
Page 25: Month Maintenance Actions
Maintenance action Remarks Clean the air vents/inlets of the projector (front and rear side of the projector). Use a vacuum cleaner. Clean the cabinet of the projector. Removal overall dust accumulation on projector covers. R5905312 HDF W SERIES 24/01/2013...
Page 26: Year (Or 1500 Hours Runtime) Maintenance Actions
Projector Toolset. The latest Projector software can be latest version. See user guide of the downloaded from the secured Barco web site. projector toolset. 13 Info-T’s Check if all Info-T’s are implemented. Note that the Info-T’s are If not, implement all Info-T’s and update...
Page 27 & Communication module (ELCABOX) : dust, connections, etc. 27 Documenta- Check if the projector manuals are present and up-to-date. Download current manual version from tion https://My.Barco.com. 28 Documenta- Update projector service docket. List all maintenance actions and tion remarks. R5905312 HDF W SERIES 24/01/2013...
Page 28: Year (Or 10000 Hours Runtime) Maintenance Actions
The 10 year maintenance actions, listed below, may ONLY be performed by certiﬁed service personnel who are familiar with potential hazards of the product and all product safety checks. Maintenance action Remarks Replace the Liquid Cooling Assembly. Check all fans: vibrations, noise, speed, etc. (speeds: via diagnostics) Replace if needed. R5905312 HDF W SERIES 24/01/2013...
Page 29: Lamp Change Maintenance Actions
Replace the Lamp House in case of degradation, damage, etc. Check if all cables are still tightened. Check level of cooling liquid. Take corrective actions if necessary. Check the general condition of the Lamp House. Replace if necessary. R5905312 HDF W SERIES 24/01/2013...
Page 30 3. Preventative maintenance actions R5905312 HDF W SERIES 24/01/2013...
Page 31: Diagnostic Companion
Some solutions contain pictures to help ﬁnd the location of defect parts. The full content of the Diagnostic Companion is described in the chapter "Troubleshooting", page 31. Overview • Access to the Diagnostic Companion • Working with the Diagnostic Companion R5905312 HDF W SERIES 24/01/2013...
Page 32: Access To The Diagnostic Companion
1. Press Menu to activate the menus and select Service → Diagnosis . Image 4-1 Main menu, service Image 4-2 Service, diagnosis 2. Enter 8888. An expanded diagnosis menu opens. Image 4-3 Extended diagnosis menu R5905312 HDF W SERIES 24/01/2013...
Page 33: Working With The Diagnostic Companion
Image 4-4 Extended diagnosis menu Image 4-5 Error logging 2. Use the ▲ or ▼ key to select the desired error code and press ENTER. The possible situations are displayed. Image 4-6 Situations for selected error R5905312 HDF W SERIES 24/01/2013...
Page 34 3. Use the ▲ or ▼ key to select a situation and press ENTER to view a solution description. Image 4-7 Solution for selected situation 4. With a solution description selected, press ENTER to view location images when available. R5905312 HDF W SERIES 24/01/2013...
Page 35: Troubleshooting
5. Troubleshooting 5. TROUBLESHOOTING R5905312 HDF W SERIES 24/01/2013...
Page 36 5. Troubleshooting R5905312 HDF W SERIES 24/01/2013...
Page 37: Troubleshooting Checklist
5. Troubleshooting Troubleshooting checklist Code 1691: “Form. PWRGood” (Error) This error code is not documented because it can normally not appear in the ﬁeld. If this code does appear contact Barco for further instructions. Code 1692: “Formatter start failed” (Error)
Page 38 Check if the yellow wire unit (reference 3 image 5-4 & image 5-5) between the Power distribution board and the rear side of the Input & Communication unit is properly connected. Image 5-3 Image 5-4 Image 5-5 R5905312 HDF W SERIES 24/01/2013...
Page 39 LPS module are Ensure that the latest version of projector software is installed. corrupt of not valid. Reboot the projector. If the problem persist, contact Barco for further instructions. Code 2008: “LPS failure fan 1 & 2” (Error) Situation Solution The supply voltage or the drivers for Replace one or both LPS modules.
Page 40 Ensure that the front side, air inlet side, of the projector is not blocked. Check the ﬁlter at the front side of the projector. Replace one or both LPS modules. See "Lamp Power Supply", page 169. R5905312 HDF W SERIES 24/01/2013...
Page 41 Check if the power distribution system of the building is able to deliver the required power for the projector. R5905312 HDF W SERIES 24/01/2013...
Page 42 If this failure was detected during the startup of the LPS module then the lamp can not be ignited. If this failure occurs during an event then the event can continue until the lamp is switched off. R5905312 HDF W SERIES 24/01/2013...
Page 43 Check if the version of the installed projector software is the latest available version. The is not supported by the software of latest version can be downloaded from https://my.barco.com. To support a new type of the projector. input board most likely requires an update of the projector software.
Page 44 Check if the version of the installed projector software is the latest available version. The is not supported by the software of latest version can be downloaded from https://my.barco.com. To support a new type of the projector. input board most likely requires an update of the projector software.
Page 45 Check if the version of the installed projector software is the latest available version. The is not supported by the software of latest version can be downloaded from https://my.barco.com. To support a new type of the projector. input board most likely requires an update of the projector software.
Page 46 Check if the version of the installed projector software is the latest available version. The is not supported by the software of latest version can be downloaded from https://my.barco.com. To support a new type of the projector. input board most likely requires an update of the projector software.
Page 47 Check if the version of the installed projector software is the latest available version. The ID parameters of the pmp board latest version can be downloaded from https://my.barco.com. are written in a format which is not known by the projector software.
Page 48 Check if the version of the installed projector software is the latest available version. The ID parameters of the communication latest version can be downloaded from https://my.barco.com. interface are written in a format which is not known by the projector software.
Page 49 Check if the version of the installed projector software is the latest available version. The The ID parameters of the Power latest version can be downloaded from https://my.barco.com. Distribution are written in a format which is not known by the projector software.
Page 50 Check if the version of the installed projector software is the latest available version. The ID parameters of the Fan Control latest version can be downloaded from https://my.barco.com. board are written in a format which is not known by the projector software.
Page 51 Check if the version of the installed projector software is the latest available version. The ID parameters of the Motor Control latest version can be downloaded from https://my.barco.com. board are written in a format which is not known by the projector software.
Page 52 Check if the version of the installed projector software is the latest available version. The The ID parameters of the Lamp latest version can be downloaded from https://my.barco.com. Info Module are written in a format which is not known by the projector software.
Page 53 Check if the version of the installed projector software is the latest available version. The ID parameters of the Light Sensor latest version can be downloaded from https://my.barco.com. Module are written in a format which is not known by the projector software.
Page 54 Check if the version of the installed projector software is the latest available version. The The ID parameters of the Formatter latest version can be downloaded from https://my.barco.com. board of the RED channel are written in a format which is not known by the projector software.
Page 55 Check if the version of the installed projector software is the latest available version. The The ID parameters of the Formatter latest version can be downloaded from https://my.barco.com. board of the GREEN channel are written in a format which is not known by the projector software.
Page 56 Check if the version of the installed projector software is the latest available version. The The ID parameters of the Formatter latest version can be downloaded from https://my.barco.com. board of the BLUE channel are written in a format which is not known by the projector software.
Page 57 Check if the version of the installed projector software is the latest available version. The The ID parameters of one of the latest version can be downloaded from https://my.barco.com. LPS modules are written in a format which is not known by the projector software.
Page 58 Replace the Fan Control Board. See "Replacing the Fan control board", page 278. Defect temperature sensor Replace the temperature sensor on the cooling block of the RED channel. (reference 19 XXXX) which measures the temperature of the DMD of the RED channel. R5905312 HDF W SERIES 24/01/2013...
Page 59 DMD of the RED channel. Defect temperature sensor Replace the temperature sensor on the cooling block of the RED channel. (reference 19 image 5-19 which measures the temperature of the DMD of the RED channel. R5905312 HDF W SERIES 24/01/2013...
Page 60 DMD temperature. Defect temperature sensor Replace the temperature sensor on the cooling block of the GREEN channel. (reference 18 image 5-20) which measures the temperature of the DMD of the GREEN channel. Image 5-20 R5905312 HDF W SERIES 24/01/2013...
Page 61 DMD of the GREEN channel. Defect temperature sensor Replace the temperature sensor on the cooling block of the GREEN channel. (reference 18 image 5-20) which measures the temperature of the DMD of the GREEN channel. R5905312 HDF W SERIES 24/01/2013...
Page 62 DMD of the BLUE channel. Code 7615: “Blue DMD temp high” (Error) This error code is probably preceded by the warning code 7614: “Blue DMD temp high”. The same troubleshooting table can be applied to. R5905312 HDF W SERIES 24/01/2013...
Page 63 Defect temperature sensor Replace the temperature sensor at the air inlet channel. (reference 10 image 5-22) which measures the temperature at the air inlet (projector front side). Image 5-22 R5905312 HDF W SERIES 24/01/2013...
Page 64 (reference 10 image 5-22 and image 5-23). Defect temperature sensor Replace the temperature sensor at the air inlet channel. (reference 10image 5-22) which measures the temperature at the air inlet (projector front side). R5905312 HDF W SERIES 24/01/2013...
Page 65 Lamp House is located under the top cover plate of the Lamp House. Safely remove the measures the temperature inside the lamp from the Lamp House prior to remove the top cover of the Lamp House. Lamp House. R5905312 HDF W SERIES 24/01/2013...
Page 66 Lamp House prior to remove the top cover of the Lamp House. Lamp House. Code 7630: “Air out temp low” (Error) This error code is probably preceded by the warning code 7631: “Air out temp low”. The same troubleshooting table can be applied R5905312 HDF W SERIES 24/01/2013...
Page 67 (projector rear side). Image 5-28 Code 7633: “Air out temp high” (Error) This error code is probably preceded by the warning code 7632: “Air out temp high”. The same troubleshooting table can be applied R5905312 HDF W SERIES 24/01/2013...
Page 68 Blocked ﬁlter of the Light Ensure that the air inlets of the projector are not blocked. Replace a dirty ﬁlter with a Processor compartment. The new one. DMD temperatures are probably too high as well. R5905312 HDF W SERIES 24/01/2013...
Page 69 Light Processor compartment. Code 7690: “Rod in temp low” (Error) This error code is probably preceded by the warning code 7691: “Rod in temp low”. The same troubleshooting table can be applied R5905312 HDF W SERIES 24/01/2013...
Page 70 Light Pipe. Image 5-32 Code 7693: “Rod in temp high” (Error) This error code is probably preceded by the warning code 7693: “Rod in temp high”. The same troubleshooting table can be applied R5905312 HDF W SERIES 24/01/2013...
Page 71 Ensure that the air inlet at the front bottom of the projector is not blocked. Provide a sufﬁcient free area at the front of the projector so that fresh air can freely enter the air inlet channel. R5905312 HDF W SERIES 24/01/2013...
Page 72 Code 7702: “Power supply primary DCDC temp low” (Error) This error code is probably preceded by the warning code 77023: “Power supply primary DCDC temp low”. The same troubleshoot- ing table can be applied to. R5905312 HDF W SERIES 24/01/2013...
Page 73 SMPS. Code 7708: “Power supply primary PFC temp low” (Error) This error code is probably preceded by the warning code 7708: “Power supply primary PFC temp low”. The same troubleshooting table can be applied to. R5905312 HDF W SERIES 24/01/2013...
Page 74 Defect temperature sensor Replace the temperature sensor mounted on the heatsink of the primary side of the (reference 3image 5-35) which SMPS (reference 3image 5-35). measures the temperature at heatsink of the primary side of the SMPS. R5905312 HDF W SERIES 24/01/2013...
Page 75 Wire unit of the micro switch Check if the wire unit (reference 6 image 5-38) is plugged in the Power Distribution board. (reference 5 image 5-37) disconnected from the Power distribution board. Image 5-36 Image 5-37 Image 5-38 R5905312 HDF W SERIES 24/01/2013...
Page 76 Check the diagnostic LEDs of the Lamp Power Supply. See "LPS module diagnostic LED’s", page 170. Replace the Lamp Power Supply. See "Removal of a LPS module", page 172 and "Installation of a LPS module", page 174. Image 5-39 Image 5-40 R5905312 HDF W SERIES 24/01/2013...
Page 77 Code 7802: “12V voltage low” (Error) Situation Solution Malfunction Switched mode power Check the 12V LED on the SMPS board. Replace SMPS board. supply Short circuit or bad connection. Check projector wiring for short circuits or bad connections. R5905312 HDF W SERIES 24/01/2013...
Page 78 Malfunction Switched mode power Replace the Switched mode power supply. See "Replacement of the SMPS board", supply page 166. Malfunction Fan Control Board. Replace the Fan Control Board. See "Replacing the Fan control board", page 278. R5905312 HDF W SERIES 24/01/2013...
Page 79 Replace the Fan Control Board. See "Replacing the Fan control board", page 278. Code 7818: “Altitude high” (Error) Situation Solution Malfunction Fan Control Board. Replace the Fan Control Board. See "Replacing the Fan control board", page 278. R5905312 HDF W SERIES 24/01/2013...
Page 80 5-48) disconnected. Wire unit of the fan (reference 20 Remove the Input & Communication unit and check if the wire unit is inserted in the image 5-49) disconnected from the Power Distribution board. Power Distribution board. R5905312 HDF W SERIES 24/01/2013...
Page 81 Power Distribution board. Blocked fan. 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. R5905312 HDF W SERIES 24/01/2013...
Page 82 Malfunction Fan Control board. Replace the Fan Control Board. See "Replacing the Fan control board", page 278. Electronic top fan end of life. Replace the fan. See "Replacement of the Card Cage electronics fans", page 288. R5905312 HDF W SERIES 24/01/2013...
Page 83 Code 7936: “Fan speed heat exchanger front too low” (Error) This error code is probably preceded by the warning code 7937: “Fan speed heat exchanger too low”. The same troubleshooting table can be applied to. R5905312 HDF W SERIES 24/01/2013...
Page 84 20image 5-49) Malfunction Fan Control board. Replace the Fan Control Board. See "Replacing the Fan control board", page 278. Mains input fan end of life. Replace the fan. See "Mains input fan", page 295. R5905312 HDF W SERIES 24/01/2013...
Page 85 20image 5-49) Malfunction Fan Control board. Replace the Fan Control Board. See "Replacing the Fan control board", page 278. Lamp anode fan end of life. Replace the fan. See "Lamp anode fan", page 301. Image 5-54 R5905312 HDF W SERIES 24/01/2013...
Page 86 Code 7952: “Fan speed power supply left too low” (Error) This error code is probably preceded by the warning code 7953: “Fan speed power supply left too low”. The same troubleshooting table can be applied to. R5905312 HDF W SERIES 24/01/2013...
Page 87 Malfunction power supply right fan Replace the Fan. See "Replacement of the SMPS fans", page 289. (reference 3image 5-56). Malfunction Fan Control board. Replace the Fan Control Board. See "Replacing the Fan control board", page 278. R5905312 HDF W SERIES 24/01/2013...
Page 88 Vertical Lens Shift not calibrated. Calibrate the Vertical Lens Shift. End-loop switch disconnected. Check the wiring of the two end-loop switches of the Vertical Shift. Malfunction end-loop switch. Check the two end-loop switches and replace if necessary. R5905312 HDF W SERIES 24/01/2013...
Page 89 See "Replacement of the Vertical Shift stepper motor", page 234. Code 8117: “Vertical lens shift driver” (Error) This error code is probably preceded by the warning code 8116: “Vertical lens shift driver”. The same troubleshooting table can be applied to. R5905312 HDF W SERIES 24/01/2013...
Page 90 Replace the horizontal shift motor. See "Replacement of the Horizontal Shift stepper motor", page 236. Code 8129: “Horizontal lens shift stopped” (Error) This error code is probably preceded by the warning code 8128: “Horizontal lens shift stopped”. The same troubleshooting table can be applied to. R5905312 HDF W SERIES 24/01/2013...
Page 91 HDF projector. Tilt sensor is not calibrated. Calibrate the tilt sensor. See installation manual of the HDF projector for tilt sensor calibration procedure. R5905312 HDF W SERIES 24/01/2013...
Page 92 Check the level of the liquid cooling. Add cooling liquid if appropriate. See "Liquid cooling circuit", page 239 • Ensure that all preventative maintenance actions are done. See service manual chapter "Preventative maintenance actions", page 19. R5905312 HDF W SERIES 24/01/2013...
Page 93 One of the projector cooling systems Check for ﬁlthy dust ﬁlters, blocked air inlets and outlets, liquid cooling level, etc. Check fails which disable the start up of the also other error/warning messages. See projector notiﬁcations. lamp. R5905312 HDF W SERIES 24/01/2013...
Page 94 The projector does not support the ﬁle system on the USB stick. Ensure that the projector data from the USB device USB stick has a FAT ﬁle system. connected with projector. Defect USB device. Use another USB device. R5905312 HDF W SERIES 24/01/2013...
Page 95 First solve error/warning messages with ID number below 100000. If problem remains, contact Barco. Code 100010: “Break condition” (Error) Situation Solution Internal projector software error. First solve error/warning messages with ID number below 100000. If problem remains, contact Barco. R5905312 HDF W SERIES 24/01/2013...
Page 96 First solve error/warning messages with ID number below 100000. If problem remains, contact Barco. Code 100021: “Lseek failed” (Error) Situation Solution Internal projector software error. First solve error/warning messages with ID number below 100000. If problem remains, contact Barco. R5905312 HDF W SERIES 24/01/2013...
Page 97 First solve error/warning messages with ID number below 100000. If problem remains, contact Barco. Code 100032: “Fib read failed” (Error) Situation Solution Internal projector software error. First solve error/warning messages with ID number below 100000. If problem remains, contact Barco. R5905312 HDF W SERIES 24/01/2013...
Page 98 First solve error/warning messages with ID number below 100000. If problem remains, contact Barco. Code 100043: “Init 5-cable ﬁrmware failed, input 3” (Error) Situation Solution Internal projector software error. First solve error/warning messages with ID number below 100000. If problem remains, contact Barco. R5905312 HDF W SERIES 24/01/2013...
Page 99 First solve error/warning messages with ID number below 100000. If problem remains, contact Barco. Code 100054: “Init dvi ﬁrmware failed, input 3” (Error) Situation Solution Internal projector software error. First solve error/warning messages with ID number below 100000. If problem remains, contact Barco. R5905312 HDF W SERIES 24/01/2013...
Page 100 Note from the backup device. this can only be done at factory or by qualiﬁed Barco service technicians. To solve this issue save the projector Custom Settings and reboot the projector. If this error persists, contact Barco for further actions.
Page 101: Removal And Installation Of The Projector Covers
Note that some covers may only be removed by qualiﬁed service personnel, see remarks above each procedure. ARNING Always switch off the projector and unplug the power cord at the projector side before removing one of the covers. R5905312 HDF W SERIES 24/01/2013...
Page 102: 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 R5905312 HDF W SERIES 24/01/2013...
Page 103: 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 Cover removal R5905312 HDF W SERIES 24/01/2013...
Page 104: 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 Lamp cover removal R5905312 HDF W SERIES 24/01/2013...
Page 105: 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 Input cover removal R5905312 HDF W SERIES 24/01/2013...
Page 106: Installation Of The
4. Secure the front cover by locking the captive screw in the middle at the bottom of the front cover. Image 6-10 Front cover, dust ring 5. Reinstall the rubber dust ring around the lens holder. R5905312 HDF W SERIES 24/01/2013...
Page 107: Installation Of The Side Cover
(C) into their receivers. Image 6-12 Mount side cover 4. Secure the side cover by locking the captive screw in the middle at the bottom of the side cover. Image 6-13 Fixate captive screw R5905312 HDF W SERIES 24/01/2013...
Page 108: Installation Of The Lamp Cover
(C) into its receiver. Image 6-14 Lamp cover installaion 2. Secure the lamp cover by locking the two captive screws at the right side of the lamp cover. Image 6-15 Captive screw locking R5905312 HDF W SERIES 24/01/2013...
Page 109: Installation Of The Input Cover
(C) into its receiver. Image 6-16 Input cover, installation 2. Secure the input cover by locking the two captive screws at the left side of the input cover. Image 6-17 Captive screws, locking R5905312 HDF W SERIES 24/01/2013...
Page 110 6. Removal and installation of the projector covers R5905312 HDF W SERIES 24/01/2013...
Page 111: Power Input
7. Power Input 7. POWER INPUT R5905312 HDF W SERIES 24/01/2013...
Page 112 7. Power Input R5905312 HDF W SERIES 24/01/2013...
Page 113: Replacing The Input Voltmeter's Fuse
2. Open the fuse holder and pull out the fuse seating and fuse. Use a 6mm ﬂat screwdriver. 3. Place a new fuse of 1A/250VAC in the fuse seating. 4. Insert the fuse seating with new fuse in the fuse holder. Image 7-1 R5905312 HDF W SERIES 24/01/2013...
Page 114: Getting Access To The Power Elements
1. Unplug the fan connection. Image 7-2 Fan connection 2. Just loosen the 9 indicated screws. Do not turn them out. Image 7-3 Shield 3. Move the shield plate to the left and take out the plate. R5905312 HDF W SERIES 24/01/2013...
Page 115 7. Power Input Image 7-4 4. Turn out the 6 indicated screws of the mains ﬁlter cover plate. Image 7-5 Mains input cover plate 5. Take off the mains ﬁlter cover plate. R5905312 HDF W SERIES 24/01/2013...
Page 116: 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. R5905312 HDF W SERIES 24/01/2013...
Page 117: Mounting A New Mains Filter
6. Slide the free eye connection of the both Blue wires (coming from the LPS) over the top pin of the mains ﬁlter. Then slide the eye connection of the white wire (coming from the SMPS) over the bottom pin followed by a washer (A) and a lock washer (B). Secure with a nut. R5905312 HDF W SERIES 24/01/2013...
Page 118: 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 7-9 Mains switch replacement 2. Turn out both screws on the front side of the mains switch. 3. Slide out the mains switch. R5905312 HDF W SERIES 24/01/2013...
Page 119: 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. Reinstall the removed covers.. R5905312 HDF W SERIES 24/01/2013...
Page 120 7. Power Input R5905312 HDF W SERIES 24/01/2013...
Page 121: Lamp And Lamp House
• Resetting the lamp parameters • Realignment of the lamp in its reﬂector • Cleaning the UV blocker of the Lamp House • Cleaning the Reﬂector of the Lamp House • Lamp info module replacement R5905312 HDF W SERIES 24/01/2013...
Page 122: Introduction Hdf Lamp & Lamp House
Parts identiﬁcation Lamp House Image 8-2 Lamp House ﬁxation screw. Adjustment screw Z-alignment. Adjustment screw vertical lamp alignment. Adjustment screw horizontal lamp alignment. UV blocker. Anode connection with SPG. Cathode connection with SPG. Connection Lamp info module R5905312 HDF W SERIES 24/01/2013...
Page 123: 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 124 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. R5905312 HDF W SERIES 24/01/2013...
Page 125: 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 126 6. Reinstall the lamp cover of the projector, see "Installation of the lamp cover", page 104. While starting up the projector, the electronics detect if a lamp is installed. If no lamp is installed, it is not possible to start up the projector. R5905312 HDF W SERIES 24/01/2013...
Page 127: Removing The Xenon Lamp From The Lamp House
1. Release the xenon lamp from its socket by removing the hexagon socket head cap screw and washer as illustrated. Use a 5 mm Allen wrench. Image 8-7 Lamp ﬁxation screw 2. Remove the Lamp House side cover by releasing the two retaining thumbscrews as illustrated. R5905312 HDF W SERIES 24/01/2013...
Page 128 5. Slide the white anode socket, which is connected via a thick wire with the xenon lamp, upwards away from its position and then remove the xenon lamp with anode socket from the Lamp House. R5905312 HDF W SERIES 24/01/2013...
Page 129 Lamp Houses can contain only one ﬂat washer due to the shorter thread clearance of the new improved connection pins. 8. Remove the cathode lamp adaptor (reference 11) from the xenon lamp (reference 13) as illustrated. Use a 5 mm Allen wrench to release the adaptor ﬁxation screw (reference 12) of the adaptor. R5905312 HDF W SERIES 24/01/2013...
Page 130 Place it on hard surface and shatter the envelope with a sharp hammer blow. DO NOT place a non shattered bulb in any ordinary refuse container. When returning a xenon lamp for warranty adjustment, pack it in its original shipping container. Complete and return all required warranty information. R5905312 HDF W SERIES 24/01/2013...
Page 131: Installing The Xenon Lamp In The Lamp House
ARNING Always wear clean leather gloves with wrist protectors when handling xenon lamps. Necessary tools • Welder’s jacket (not included in the safety kit that Barco offers). • Full face shield with neck protection. • Leather gloves with wrist protection.
Page 132 ﬂat washer (5) between the lock nut and the wire lug. Caution: Do not tighten the ﬁrst nut (reference 1) against the connector housing. There must be some play (1 mm maximum). This is important to insert the Lamp House smoothly into the projector. R5905312 HDF W SERIES 24/01/2013...
Page 133 Make sure that the both pins of the cathode adapter are engaged in the foreseen slots. Image 8-19 6. Insert the anode socket into position as illustrated. Caution: Avoid any tension on the anode wire, ensuring there is no mechanical stress on the lamp. R5905312 HDF W SERIES 24/01/2013...
Page 134 2,5 Nm (1,84 lbf*ft) to fasten the hexagon socket head screw. Use for that a torque wrench with a 5 mm Allen socket. Caution: Make sure that the both pins of the cathode adapter remain engaged in the foreseen slots. Use one hand to keep the xenon lamp into position while inserting the hexagon socket head screw. R5905312 HDF W SERIES 24/01/2013...
Page 135 11. Reinstall the side cover of the Lamp House as illustrated. Note: Please ensure that the thumb screws turning wires are ﬂash with the cover or interference will occur while inserting the Lamp House into the projector. R5905312 HDF W SERIES 24/01/2013...
Page 136 “Resetting the lamp parameters”. A realignment of the xenon lamp in its reﬂector is required after the installation of the xenon lamp in the lamp house. See procedure "Realignment of the lamp in its reﬂector", page 135. R5905312 HDF W SERIES 24/01/2013...
Page 137: Resetting The Lamp Parameters
2.5.5 or later. The latest version of the projector ﬂash software and the Projector Toolset can be downloaded from the secured Barco web site https://My.Barco.com. This procedure assumes that the projector ﬂash software is version 1.9 or later and that in the Projector Toolset (version 2.5.5) a Projector Conﬁguration exist for the involved projector.
Page 138 8. Read the info of the caution popup windows and click on the “OK” button if you wan to proceed. Image 8-28 Image 8-29 As a result the lamp parameters are reset (run time hours set to zero) and the number of Refurb credits is decremented with one. Image 8-30 R5905312 HDF W SERIES 24/01/2013...
Page 139: Realignment Of The Lamp In Its Reﬂector
Do this for each direction and repeat this adjustment cycle twice. Image 8-31 Lamp alignment 6. Turn the lock nuts against the plate to secure the current position. 7. Switch off the projector and reinstall the cover of the lamp compartment. R5905312 HDF W SERIES 24/01/2013...
Page 140: Cleaning The Uv Blocker Of The Lamp House
Use isopropanol alcohol instead of demineralized water to remove ﬁngerprints. AUTION Never reinstall a UV blocker which is cracked or has a damaged coating. Neglecting this will result in irreversible damage of optical parts in the projector. R5905312 HDF W SERIES 24/01/2013...
Page 141: Cleaning The Reﬂector Of The Lamp House
Use isopropanol alcohol instead of demineralized water to remove ﬁngerprints. AUTION Never use a Lamp House which Reﬂector is cracked or has a damaged coating. Neglecting this will result in irreversible damage of the projector. R5905312 HDF W SERIES 24/01/2013...
Page 142: Lamp Info Module Replacement
6. Turn in the ﬁxation screws. 7. Mount the cover and ﬁxate with both screws. 8. Install the lamp (see "Installing the xenon lamp in the lamp house", page 127 and insert the lamp house in the projector. R5905312 HDF W SERIES 24/01/2013...
Page 143: Hdf Cold Mirror
Lamp Reﬂector has been replaced. In case a readjustment is required follow the instructions in this chapter precisely. Only qualiﬁed technicians who have experience with adjusting the Cold Mirror may adjust the Cold Mirror. A misaligned Cold Mirror may cause irreversible damage to other parts of the projector! R5905312 HDF W SERIES 24/01/2013...
Page 144: Introduction Hdf Cold Mirror
Cold Mirror is broken. • Coating peels off. • Cold Mirror is cracked. The light output on the screen will be lower than the normal light output in case of a damaged or dirty Cold Mirror. R5905312 HDF W SERIES 24/01/2013...
Page 145: Card Cage
Replacing the Warp module • Replacing the Deinterlacing module • Replacing the LCD Display Interface • Replacing the LCD Display • Replacing the Local Keypad • Replacing the Local Keypad backlight • Replacement of the SMPS board R5905312 HDF W SERIES 24/01/2013...
Page 146: Introduction Hdf Input & Communication Unit
Local Keypad. LCD Display. Unused input slots. Communication module. DVI/HDXDI input module. Input & Communication unit exchange between projector families The same Input & Communication unit is used in the HDX, HDF and HDQ families. R5905312 HDF W SERIES 24/01/2013...
Page 147 When starting the update process, do not switch off the projector before the process is ﬁnished. When switching off during the update process, the PMP board inside the Input & Communication unit will be corrupt and needs be recovered in a Barco service center.
Page 148: Removal Of The Input & Communication Unit
10.2 Removal of the Input & Communication Unit ARNING The procedures below may only be performed by Barco trained and qualiﬁed technicians. AUTION The connector seats are fragile. Make sure to push the little tab when pulling the connector out or the connector can get damaged.
Page 149: Installation Of The Input & Communication Unit
10. Card Cage 10.3 Installation of the Input & Communication Unit ARNING The procedures below may only be performed by Barco trained and qualiﬁed technicians. Necessary tools 7 mm ﬂat screwdriver How to install the Input & Communication Unit? 1. Position the Input & Communication Unit in front of its compartment and slide it in a little until the hinge cylinder (reference 1) is at the right place.
Page 150: Removal Of An Input Module
10. Card Cage 10.4 Removal of an input module ARNING The procedures below may only be performed by Barco trained and qualiﬁed technicians. AUTION Always wear a wrist band which is connected to the ground while handling the electrostatic dis- charge (ESD) sensitive parts.
Page 151: Installation Of An Input Module
10. Card Cage 10.5 Installation of an input module ARNING The procedures below may only be performed by Barco trained and qualiﬁed technicians. AUTION Always wear a wrist band which is connected to the ground while handling the electrostatic dis- charge (ESD) sensitive parts.
Page 152: Removal Of The Intermediate Board Guidance
2. Remove the 2 free input slot covers by removing the 4 screws (reference 1, image 10-6). Image 10-6 3. Remove the 2 screws (reference 2, image 10-6) on the bottom side of the Input & Communication Unit. Image 10-7 4. Remove the intermediate board guidance (reference 3, image 10-6). R5905312 HDF W SERIES 24/01/2013...
Page 153 10. Card Cage Image 10-8 To install the intermediate board guidance, reverse the steps described above. R5905312 HDF W SERIES 24/01/2013...
Page 154: Installation Of The Wifi Module On The Communication Module
4. Position the WIFI module (reference 3, image 10-10) on the spacers. 5. Install the screws (reference 4, image 10-10) and secure by tightening the nuts (reference 5, image 10-11) on the backside of the Communication board. Image 10-10 R5905312 HDF W SERIES 24/01/2013...
Page 155 8. Plug in the antenna wire connector (reference 8, image 10-13) on the WIFI module. 9. Secure the antenna wire by installing the lock washer and nut (reference 9, image 10-13). Image 10-13 10.Install the antenna (reference 10, image 10-14) by screwing it on its base. R5905312 HDF W SERIES 24/01/2013...
Page 156 10. Card Cage Image 10-14 11. Install the Communication module on the Input & Communication Unit. See "Installation of an input module", page 147. R5905312 HDF W SERIES 24/01/2013...
Page 157: Installation Of The Gsm Module On The Communication Module
4. Position the 2 plastic spacers (reference 3, image 10-17) on the holes of the GSM module. 5. Position the GSM module (reference 4, image 10-17) on the spacers, while plugging in the board to board connectors on the Communication board and GSM module. Image 10-17 R5905312 HDF W SERIES 24/01/2013...
Page 158 8. Plug in the antenna wire connector (reference 8, image 10-19) on the GSM module. Image 10-19 9. Secure the antenna wire by installing the lock washer and nut (reference 9, image 10-20). Image 10-20 10.Install the antenna (reference 10, image 10-21) by screwing it on its base. R5905312 HDF W SERIES 24/01/2013...
Page 159 10. Card Cage Image 10-21 11. Install the Communication module on the Input & Communication Unit. See "Installation of an input module", page 147. R5905312 HDF W SERIES 24/01/2013...
Page 160: Replacing The Pmp Board
10-22) and use a 2.5mm Allen wrench to loosen the eight screws at the sides and the rear (reference 2 image 10-22). Image 10-22 3. Disconnect the gray ﬂat cable (reference 1 image 10-23) and red cable (reference 2 image 10-24) from the PMP board. R5905312 HDF W SERIES 24/01/2013...
Page 161 7. Replace the PMP board. Use a T10 Torx driver to loosen/fasten the 8 screws (reference 8 image 10-26) and use a 5.5mm nut driver to loosen/fasten the ﬁve spacers (reference 9 image 10-26) as illustrated. R5905312 HDF W SERIES 24/01/2013...
Page 162 2.5mm Allen wrench to fasten the eight screws at the sides and the rear (reference 2 image 10-22). 13.Install the input board back in the Input & Communication unit. See "Installation of an input module", page 147. R5905312 HDF W SERIES 24/01/2013...
Page 163: Replacing The Warp Module
2. Replace the Warp module from the PMP board assembly. Use a T10 Torx driver to loosen/fasten the four screws (reference 4). Image 10-27 3. Install the complete PMP board assembly back on the Input & Communication unit. See service procedure "Replacing the PMP board", page 156. R5905312 HDF W SERIES 24/01/2013...
Page 164: Replacing The Deinterlacing Module
4. Reinstall the Warp module. See "Replacing the Warp module", page 159. 5. Install the complete PMP board assembly back on the Input & Communication unit. See service procedure "Replacing the PMP board", page 156. R5905312 HDF W SERIES 24/01/2013...
Page 165: Replacing The Lcd Display Interface
10-30) pivots upwards! Image 10-30 4. Disconnect the large ﬂex (reference 2 image 10-31) of the LCD Display from the LCD Display Interface board. Unlock the latch of the cable socket before pulling out the ﬂex cable. R5905312 HDF W SERIES 24/01/2013...
Page 166 9. Connect the red cable and gray cable with the LCD Display Interface. 10.Install the complete PMP board assembly back on the Input & Communication unit. See service procedure "Replacing the PMP board", page 156. R5905312 HDF W SERIES 24/01/2013...
Page 167: Replacing The Lcd Display
4. Install the LCD Display Interface. See service procedure "Replacing the LCD Display Interface", page 161. 5. Install the complete PMP board assembly back on the Input & Communication unit. See service procedure "Replacing the PMP board", page 156. R5905312 HDF W SERIES 24/01/2013...
Page 168: Replacing The Local Keypad
5. Install the LCD Display Interface. See service procedure "Replacing the LCD Display Interface", page 161. 6. Install the complete PMP board assembly back on the Input & Communication unit. See service procedure "Replacing the PMP board", page 156. R5905312 HDF W SERIES 24/01/2013...
Page 169: Replacing The Local Keypad Backlight
3. Remove the 5 screws (reference 1 image 10-36), unplug the electrical connector (reference 2 image 10-36) and remove the backlight. 4. Bring the new backlight into position, install the 5 screws (reference 1 image 10-36) and plug in the electrical connector (reference 2 image 10-36). Image 10-36 R5905312 HDF W SERIES 24/01/2013...
Page 170: Replacement Of The Smps Board
3. Pull out the SMPS board 3 or 4 centimeters out of its compartment and disconnect the following connectors: Mains input (reference 1 ) Ground wire (reference 2) Control connector (blue wires) (reference 3) Power out connector (black wires) (reference 4) Image 10-39 4. Pull the SMPS board completely out of its compartment. R5905312 HDF W SERIES 24/01/2013...
Page 171 Caution: Support the bottom of the SMPS board while plugging in the wire units. Image 10-41 7. Place the cover on its place and fasten the 4 retaining screws (reference 1 to 4 image 10-37). R5905312 HDF W SERIES 24/01/2013...
Page 172 10. Card Cage R5905312 HDF W SERIES 24/01/2013...
Page 173: Lamp Power Supply
Lamp Power Supply (LPS) with a 2 single modules Lamp power supplies. Overview • LPS module diagnostic LED’s • Removal of a LPS module • Installation of a LPS module R5905312 HDF W SERIES 24/01/2013...
Page 174: Lps Module Diagnostic Led's
LPS) If the problem is not solved, replace LPS No mains voltage present at input of LPS mains Check main voltage. terminals About the diagnostic LEDs, ERR, PFC, LPS, Lamp ON and LVPS. R5905312 HDF W SERIES 24/01/2013...
Page 175 LED 3 (Yellow left) : ﬂashing few times / second • ERR : OFF • PFC OK : ON (green) • LPS OK : ON (green) • LAMP ON : ON (green) • LVPS OK : ON (yellow/orange) R5905312 HDF W SERIES 24/01/2013...
Page 176: Removal Of A Lps Module
4. Disconnect the MAINS INPUT cables. 5. Disconnect the grounding wires (PE wires) (4) from both LPS modules. Image 11-3 Grounding wires 6. Release the 4 captive screws (1) and take off the ﬁxation frame. R5905312 HDF W SERIES 24/01/2013...
Page 177 11. Lamp Power Supply Image 11-4 Fixation screws Image 11-5 Fixation plate 7. Slide out the defective LPS module. Image 11-6 Remove LPS unit R5905312 HDF W SERIES 24/01/2013...
Page 178: Installation Of A Lps Module
2. Take the new LPS module and slide in the LPS module in the LPS compartment so that the LAMP OUT connection points are to the upper side. Image 11-8 LPS module insertion 3. Slide the ﬁxation frame on the front of the LPS units in such a way that the ﬁxation pins match the ﬁxation holes. R5905312 HDF W SERIES 24/01/2013...
Page 179 If it is the left LPS module, push the high power cables through the handle of the this LPS module before connecting to the LAMP OUT socket. Warning: Make sure to place the washers and cable eyes in correct order upon the pin as illustrated. Always use a plain washer between the output pin and the cable eyes. R5905312 HDF W SERIES 24/01/2013...
Page 180 7. Connect the mains input cables with the MAINS INPUT sockets of the new LPS module as illustrated. Plug the connector of the blue (or white) wire into the socket labeled with N. Image 11-14 Mains input connection, left and right LPS module R5905312 HDF W SERIES 24/01/2013...
Page 181 Make the connection between the ADDRESS connector of the left LPS unit and the ADDRESS connector of the right LPS unit (3). Make sure that the indication Left and Right is at the correct side. Image 11-15 Communication connections R5905312 HDF W SERIES 24/01/2013...
Page 182 11. Lamp Power Supply R5905312 HDF W SERIES 24/01/2013...
Page 183: Start Pulse Generator
12. Start Pulse Generator 12. START PULSE GENERATOR R5905312 HDF W SERIES 24/01/2013...
Page 184 12. Start Pulse Generator R5905312 HDF W SERIES 24/01/2013...
Page 185: Introduction
Red marked cable lug. Has to be connected with the positive “LAMP OUT” pin of the LPS module. Ferrite block. Negative connection pin from SPG to lamp house. Positive connection pin from SPG to lamp house. R5905312 HDF W SERIES 24/01/2013...
Page 186: Troubleshooting
140 volt during the attempt to ignite. The diagnostic LED’s of • Replace the LPS module. 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. R5905312 HDF W SERIES 24/01/2013...
Page 187: 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 12-3 SPG cover removal 3. Release the 3 captive screws (1) of the start pulse generator as illustrated. Use for that a ﬂat screw driver. R5905312 HDF W SERIES 24/01/2013...
Page 188 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 12-5 Remove SPG R5905312 HDF W SERIES 24/01/2013...
Page 189: Installation Of The Start Pulse Generator
SPG ﬁxation screws 3. Install the cover of the start pulse generator as illustrated. The cover has to be fasten with 5 hexagon socket head cap screws. Use for that a 3 mm Allen key. R5905312 HDF W SERIES 24/01/2013...
Page 190 Lock washer. Cable eye from SPG module. 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. R5905312 HDF W SERIES 24/01/2013...
Page 191 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 12-11 5. Reinstall the lamp house and the covers of the projector. R5905312 HDF W SERIES 24/01/2013...
Page 192 12. Start Pulse Generator R5905312 HDF W SERIES 24/01/2013...
Page 193: Hdf Light Processor
Light Sensor module replacement • Adjusting the Fold Mirror • High Contrast plate replacement • Convergence controls • Converging the red pattern onto the blue pattern • Converging the green pattern onto the blue pattern R5905312 HDF W SERIES 24/01/2013...
Page 194: Introduction Hdf Light Processor
Note that the Light Processor Unit is equipped with a motorized shutter (dowser) in front of the prism exit. Image 13-1 Light processor unit Light processor unit Light pipe Cooling circuit Cooling block DMD Convergence adjustment knob R5905312 HDF W SERIES 24/01/2013...
Page 195: Diagnostic
A crack in the prism, which can result in convergence problems and may disables you to focus the projected image. • Unacceptable amount of dark, bright or ﬂat state pixels on one or more DMDs. • Blocked Shutter (dowser). Shutter does not respond when pressing the “PAUSE” button. • Leakage in liquid cooling circuit. R5905312 HDF W SERIES 24/01/2013...
Page 196: Removing The Light Processor
White plug, multi color wires Image 13-3 4. Release both captive screws at the base of the light processor (1 and 2). Use a 7 mm ﬂat screw driver or a 10 mm nut driver. R5905312 HDF W SERIES 24/01/2013...
Page 197 The second valved ﬁtting is located in the tube coming from the light pipe entrance and leading to the heat exchanger. To interrupt a valved ﬁtting, press on the knob (1) and pull out the connector (2). R5905312 HDF W SERIES 24/01/2013...
Page 198 7. Take the light processor unit by its handle and gently pull out the light processor assembly of its compartment. Pull the cables through the hole in the plate. Note: Support the light processor while taking it out. R5905312 HDF W SERIES 24/01/2013...
Page 199 13. HDF Light Processor Image 13-6 8. Place the light processor assembly on a stable table. R5905312 HDF W SERIES 24/01/2013...
Page 200: Installing The Light Processor
Make sure that the positioning pins (P) at the backside of the assemble match the positioning holes (H) in the projector. Note: While inserting the assembly, guide the cables to the Input & Communication side trough the indicated hole. Image 13-8 Cable gap back plane R5905312 HDF W SERIES 24/01/2013...
Page 201 13. HDF Light Processor Image 13-9 Light processor insertion 4. Secure the light processor assembly by fastening both captive screws (1 & 2). R5905312 HDF W SERIES 24/01/2013...
Page 202 Plug in the connector with the tube coming from the pump into the connector going to the light processor. Plug in the connector, mounted on the tube coming from the light pipe cooling block into the connector, mounted on the tube going to the heat exchanger. R5905312 HDF W SERIES 24/01/2013...
Page 203 13. HDF Light Processor Image 13-11 Close cooing circuit 7. Couple the electrical connectors with the Power Distribution Board. For the location of the connections, see . R5905312 HDF W SERIES 24/01/2013...
Page 204 8. Place the light processor cover on top of the projector (1) so that the hooks (H) on both sides match with the holes (F). Slide the cover backwards until the hooks slide under the top frame (2). R5905312 HDF W SERIES 24/01/2013...
Page 205 13. HDF Light Processor Drive in both ﬁxation screws. Image 13-15 Light processor cover mounting R5905312 HDF W SERIES 24/01/2013...
Page 206: Replacement Of The Shutter
13-17). Use a 2,5 mm Allen wrench. Image 13-17 Remove ﬁxation screws 3. Place a new shutter assembly in position and fasten with two hexagon socket head cap screws (reference 1 image 13-18). Use a 2,5 mm Allen wrench. R5905312 HDF W SERIES 24/01/2013...
Page 207 13. HDF Light Processor Image 13-18 Mount new dowser 4. Reconnect the wire unit of the dowser image 13-16. R5905312 HDF W SERIES 24/01/2013...
Page 208: Cleaning The Prism Exit Side
If yes, stop this cleaning procedure. If no, wipe off the dust of the Prism exit with a clean cotton cloth and demineralized water. Tip: Use isopropanol alcohol instead of demineralized water to remove ﬁngerprints. R5905312 HDF W SERIES 24/01/2013...
Page 209: Light Sensor Module Replacement
3. Place a new module on the light pipe sockets and drive in both ﬁxation screws (reference 2 image 13-19). 4. Plug in the cable into the light sensor module socket (reference 1 image 13-19). R5905312 HDF W SERIES 24/01/2013...
Page 210: Adjusting The Fold Mirror
4. Turn the adjustment screws A, B or C in or out until the light spot (5) matches with the outline of the DMDs (4). Use a 5,5 mm open end wrench. The illustration below shows the movements of the light spot (5) upon the screen (6) for each adjustment screw. R5905312 HDF W SERIES 24/01/2013...
Page 211 13. HDF Light Processor Image 13-21 Fold mirror, adjustment 5. Reinstall the cover of the Fold Mirror. 6. Reconnect the Light Sensor Module. R5905312 HDF W SERIES 24/01/2013...
Page 212: High Contrast Plate Replacement
6. Reconnect the cable of the high contrast plate. A full calibration of the Motor Control Board is required in case the Motor Control Board has been replaced or in case of any service intervention on the High Contrast plate or Lens Holder. R5905312 HDF W SERIES 24/01/2013...
Page 213: Convergence Controls
The adjustment knobs are numbered from 1 to 6 and have the same color as the channel which they effect. Image 13-24 Red channel, knob number 1. Red channel, knob number 2. Red channel, knob number 3. Green channel, knob number 4. Green channel, knob number 5. Green channel, knob number 6. R5905312 HDF W SERIES 24/01/2013...
Page 214 The adjustment range is limited to approximately 30 pixels in both directions. • One turn (360°) of a control knob relates to an approximately 30 pixel displacement on the screen. • When changing the adjustment direction there will be some play. R5905312 HDF W SERIES 24/01/2013...
Page 215: Converging The Red Pattern Onto The Blue Pattern
3. Slightly turn the red colored control knob number 3 until the red pattern in the upper right of the projected image converges with the blue pattern. Image 13-28 4. Repeat step 3 and 4 until coincidence is obtained of the red pattern in the lower left and upper right of the projected image. R5905312 HDF W SERIES 24/01/2013...
Page 216 13. HDF Light Processor 5. Repeat from step 2 until full coincidence is obtained of the red pattern in the center, lower left and upper right of the projected image. R5905312 HDF W SERIES 24/01/2013...
Page 217: Converging The Green Pattern Onto The Blue Pattern
3. Slightly turn the green colored control knob number 6 until the green pattern in the upper right of the projected image converges with the blue pattern. Image 13-31 4. Repeat step 3 and 4 until coincidence is obtained of the green pattern in the lower left and upper right of the projected image. R5905312 HDF W SERIES 24/01/2013...
Page 218 13. HDF Light Processor 5. Repeat from step 2 until full coincidence is obtained of the green pattern in the center, lower left and upper right of the projected image. R5905312 HDF W SERIES 24/01/2013...
Page 219: Lenses And Lens Holder
Lens safety cable • Cleaning the lens • Removing the Lens Holder • Mounting a new Lens Holder • Scheimpﬂug adjustment • Replacement of the Vertical Shift stepper motor • Replacement of the Horizontal Shift stepper motor R5905312 HDF W SERIES 24/01/2013...
Page 220: Introduction Lens Holder
Parts identiﬁcation of the Lens Holder Image 14-1 Lens Holder front plate. Electrical socket Lens connection. Lens lock handle. Lens Holder Vertical Shift motor. Adjustment screw Lens Holder front plate (Scheimpﬂug). Lens Holder Horizontal Shift motor. R5905312 HDF W SERIES 24/01/2013...
Page 221: Available Lenses
R9862030: TLD HB zoom lens (2.8 - 4,5 : 1) Image 14-8 Image 14-9 Image 14-10 R9842120: TLD HB zoom lens (5.0 - 8.0 : 1) R9862000: TLD+ lens (0.73 : 1) R9862005: TLD+ zoom lens (1.16 - 1.49 : 1) R5905312 HDF W SERIES 24/01/2013...
Page 222 R9862020: TLD+ zoom lens (2.0 - 2.8 : 1) R9862030: TLD+ zoom lens (2.8 - 4.5 : 1) Image 14-14 Image 14-15 R9862040: TLD+ zoom lens (4.5 - 7.5 : 1) R9829997: TLD+ zoom lens (7.5 - 11.0 : 1) R5905312 HDF W SERIES 24/01/2013...
Page 223: Lens Selection
How to select the right lens 1. Determine the required screen width (SW). 2. Determine the approximate position of the projector in the room. 3. Start up the Lens Calculator on the Barco website: http://www.barco.com/en/tools/lenscalculator to determine the possible lenses for your conﬁguration.
Page 224: 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. R5905312 HDF W SERIES 24/01/2013...
Page 225 14. Lenses and Lens Holder Image 14-19 Lock lens 8. Check if the lens is really secured by trying to pull the lens out of the lens holder. R5905312 HDF W SERIES 24/01/2013...
Page 226: Lens Removal
It’s recommended to place the foam rubber of the original projector packaging, back into the Lens opening to prevent intrusion of dust. Note that this foam rubber is packed in a plastic bag to prevent the dust, emitted by the foam, from entering the projector. R5905312 HDF W SERIES 24/01/2013...
Page 227: Lens Safety Cable
Strap the cable and make sure that the clamp is positioned on 45° from the bottom to avoid interference of the cable with the lens locking mechanism. Secure the cable by ﬁxating the nut of the clamp. R5905312 HDF W SERIES 24/01/2013...
Page 228 14. Lenses and Lens Holder Image 14-23 Clamp position 3. Turn the cable with hook lock around the carry handle and hook the hook lock around the cable. Image 14-24 R5905312 HDF W SERIES 24/01/2013...
Page 229: Cleaning The Lens
Do not use fabric softener when washing the cleaning cloth or softener sheets when drying the cloth. Do not use liquid cleaners on the cloth as doing so will contaminate the cloth. Other lenses can also be cleaned safely with this Toraysee ® cloth. R5905312 HDF W SERIES 24/01/2013...
Page 230: Removing The Lens Holder
3. Disconnect the EMC wire unit (reference 2 image 14-26) of the Lens Holder from the frame. Image 14-26 4. Disconnect the wire unit (reference 3 image 14-27) of the horizontal shift motor and the wire unit (reference 4 image 14-28) of the vertical shift motor. R5905312 HDF W SERIES 24/01/2013...
Page 231 7. Connect the wire unit (reference 3 image 14-30) of the horizontal shift motor and the wire unit (reference 4 image 14-31) of the vertical shift motor. Image 14-30 Image 14-31 8. Mount the EMC wire unit (reference 2 image 14-32) of the Lens Holder to the projector frame by driving in the ﬁxation screw. R5905312 HDF W SERIES 24/01/2013...
Page 232 14. Lenses and Lens Holder Image 14-32 9. Connect all wire units (reference 1 image 14-33) of the wire three from the Lens Holder. Image 14-33 10.If necessary, strap the cables with some cable ties. R5905312 HDF W SERIES 24/01/2013...
Page 233: Mounting A New Lens Holder
1. Place the Lens Holder on the projector chassis and fasten with the 4 screws (reference 5 image 14-34). Use a 5 mm Allen wrench. Note: One motor must point the right side of the projector and the other one must point to the top of the projector. Image 14-34 R5905312 HDF W SERIES 24/01/2013...
Page 234: Scheimpﬂug Adjustment
Scheimpﬂug adjustment nuts A, B, C and D Set screws a, b, c and d lock nuts 1, 2 and 3 are adjustment points. 4 is a locking point and NOT used during Scheimpﬂug adjustment. R5905312 HDF W SERIES 24/01/2013...
Page 235 Place the zoom lens in WIDE position (largest projected image) and adjust the focus by turning equally on nut 1, 2 and 3. c) Repeat steps “a” and “b” until the projected image is as sharp as possible. Image 14-38 Center focusing R5905312 HDF W SERIES 24/01/2013...
Page 236 6. Sharpen bottom left corner of the screen by adjusting nut 1. Image 14-39 Left bottom focusing 7. Sharpen bottom right corner of the screen by adjusting nut 2. Image 14-40 Right bottom focusing 8. Sharpen top right corner of the screen by adjusting nut 3 R5905312 HDF W SERIES 24/01/2013...
Page 237 5. Tighten nut 4 until the offset of the image movement created in step 3 is canceled. Tip: The amount of image movement in step 3 will determine how tight the nut in step 5 will need to be turned to return the image to its original position. R5905312 HDF W SERIES 24/01/2013...
Page 238: Replacement Of The Vertical Shift Stepper Motor
3. Remove bracket and other parts from the old stepper motor and install these parts on the new stepper motor as illustrated. Use a 2.5mm Allen wrench for the four screws (reference 10) and a 10mm open end wrench (reference 11). R5905312 HDF W SERIES 24/01/2013...
Page 239 Proceed with reinstalling the Lens Holder and calibrate the Motor Control Board. See procedure "Lenses and Lens Holder", page 215, and "Calibrate Motor Control Board", page 286 The Lens Holder has to be adjusted after installation. See procedure "Scheimpﬂug adjustment", page 230. R5905312 HDF W SERIES 24/01/2013...
Page 240: Replacement Of The Horizontal Shift Stepper Motor
3. Remove bracket and other parts from the old stepper motor and install these parts on the new stepper motor as illustrated. Use a 2.5mm Allen wrench for the four screws (reference 10) and a 10mm open end wrench (reference 11). R5905312 HDF W SERIES 24/01/2013...
Page 241 Proceed with reinstalling the Lens Holder and calibrate the Motor Control Board. See procedure "Lenses and Lens Holder", page 215, and "Calibrate Motor Control Board", page 286 The Lens Holder has to be adjusted after installation. See procedure "Scheimpﬂug adjustment", page 230. R5905312 HDF W SERIES 24/01/2013...
Page 242 14. Lenses and Lens Holder R5905312 HDF W SERIES 24/01/2013...
Page 243: Liquid Cooling Circuit
Avoid contact with eyes, skin and clothing. Avoid inhalation of the noxious fumes. ARNING Only use Barco approved cooling liquid to reﬁll the liquid cooling circuit of the projector. Neglect- ing this may lead to irreversible damage of the projector.
Page 244: 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. R5905312 HDF W SERIES 24/01/2013...
Page 245 15. Liquid cooling circuit Image 15-2 Draining complete circuit NO OUT Image 15-3 Draining circuit, excluding light processor circuit 3. Fill the syringe with air. Press in the valve of the male ﬁtting when extracting air. R5905312 HDF W SERIES 24/01/2013...
Page 246 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. Image 15-5 Draining complete cooling circuit R5905312 HDF W SERIES 24/01/2013...
Page 247 15. Liquid cooling circuit Image 15-6 Draining cooling circuit, excluding light processor circuit 5. Disconnect the syringe from the cooling circuit and repeat from step 3 until all cooling liquid is drained. R5905312 HDF W SERIES 24/01/2013...
Page 248: Filling The Liquid Cooling Circuit
1. Interrupt the liquid cooling circuit by uncoupling the valved ﬁtting at the heat exchanger. Image 15-7 Uncouple heat exchanger 2. Couple a plastic tube, which contains a female valved ﬁtting, to the exit side of the cooling circuit and lead the tube end to an empty bottle. R5905312 HDF W SERIES 24/01/2013...
Page 249 15. Liquid cooling circuit Image 15-8 Filling complete cooling liquid circuit NO OUT Image 15-9 Filling part of cooling liquid circuit, light processor excluded 3. Fill the syringe with cooling liquid as follows: R5905312 HDF W SERIES 24/01/2013...
Page 250 Image 15-10 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). R5905312 HDF W SERIES 24/01/2013...
Page 251 15. Liquid cooling circuit Image 15-11 Filling complete cooling liquid circuit R5905312 HDF W SERIES 24/01/2013...
Page 252 Image 15-12 Filling part of cooling liquid circuit, light processor excluded 5. Disconnect the syringe from the cooling circuit and repeat from step 3 until cooling liquid comes out the exit side of the cooling circuit. R5905312 HDF W SERIES 24/01/2013...
Page 253: 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. R5905312 HDF W SERIES 24/01/2013...
Page 254 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 and that the full bottle is located above the projector. R5905312 HDF W SERIES 24/01/2013...
Page 255 Note: Make sure that the end of the plastic tube remains immersed in the bottle with fresh cooling liquid. Image 15-17 Main menu, service Image 15-18 Service, reﬁll mode R5905312 HDF W SERIES 24/01/2013...
Page 256 7. Proceed with expelling the air from the liquid cooling circuit. Tip: You can use the bottle with the remaining fresh cooling liquid and the same tubes for the expelling procedure. 8. Pressurize the liquid cooling circuit. R5905312 HDF W SERIES 24/01/2013...
Page 257: Expelling Air From The Liquid Cooling Circuit
Emerge the tube end and make sure that the piston of the syringe is completely pressed in. c) Extract cooling liquid into the syringe by pulling out the piston. d) Disconnect the ﬁlled tube from the syringe. Make sure that the tube remains immersed. R5905312 HDF W SERIES 24/01/2013...
Page 258 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. Image 15-22 R5905312 HDF W SERIES 24/01/2013...
Page 259 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. Check within 24 hours if the pressure remains 1 bar. If not, search for leakage. R5905312 HDF W SERIES 24/01/2013...
Page 260: 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 103. R5905312 HDF W SERIES 24/01/2013...
Page 261: Cleaning The Cooling Pump
2. Slide the pump house with hose backwards. Use a cloth to absorb the remaining cooling liquid. Image 15-28 Pump house removal 3. Take the rotor between thumb and ﬁnger and slide it out of the pump motor. R5905312 HDF W SERIES 24/01/2013...
Page 262 7. Fasten the four screws (reference 1) of the pump house crosswise. Image 15-30 Pump house, close Reﬁll the liquid cooling circuit in case the pump is successfully cleaned. If cleaning is not possible, replace the pump completely. R5905312 HDF W SERIES 24/01/2013...
Page 263: Replacement Of The Pump Motor And Rotor
2. Remove the four screws (reference 1) which fasten the pump house to the pump motor. Image 15-32 Pump house, ﬁxation 3. Slide the pump house with hose backwards. Use a cloth to absorb the remaining cooling liquid. R5905312 HDF W SERIES 24/01/2013...
Page 264 6. Secure the pump motor with two hexagon socket head cap screws (reference 2). Use a 3 mm Allen wrench to fasten the screws and a 7 mm open-end wrench to hold the nut (reference 3) while fasten the screw. Caution: Make sure that the pump is mounted upon two rubber vibration rings (reference 4). R5905312 HDF W SERIES 24/01/2013...
Page 265 Make sure that the new Pump motor is provide with a new rotor and a new sealing ring. Image 15-37 Pump house, installation 9. Fasten the four screws (reference 1) of the pump house crosswise using a PH2 Phillips screwdriver. Image 15-38 Pump house, ﬁxation 10.Reconnect the wire unit of the pump. R5905312 HDF W SERIES 24/01/2013...
Page 266 15. Liquid cooling circuit Image 15-39 Electrical connection R5905312 HDF W SERIES 24/01/2013...
Page 267: Replacement Of The Complete Cooling Pump
4. Release the two hexagon socket head cap screws (reference 2) which fasten the pump motor to the seating of the pump. Use a 3 mm Allen wrench to release the screws and a 7 mm open-end wrench to hold the nut (reference 3) when releasing the screw. R5905312 HDF W SERIES 24/01/2013...
Page 268 7. Slide the clip of both hoses over the connection. Use an universal pair of pliers to push both clip tongs to each other in order to open the clip and to move the clip over the connection. 8. Reconnect the wire unit of the pump. R5905312 HDF W SERIES 24/01/2013...
Page 269 15. Liquid cooling circuit Image 15-45 Electrical connection R5905312 HDF W SERIES 24/01/2013...
Page 270 15. Liquid cooling circuit R5905312 HDF W SERIES 24/01/2013...
Page 271: Heat Exchanger
The heat collected, via the cooling circuit in the different parts inside the projector is extracted to the ambient in the heat exchanger. Image 16-1 Overview • Removing the defective heat exchanger • Disassembling the heat exchanger assembly • Assembling the new heat exchanger • Mounting the heat exchanger assembly into the projector R5905312 HDF W SERIES 24/01/2013...
Page 272: Removing The Defective Heat Exchanger
The second valved ﬁtting is located in the tube coming from the light pipe entrance and leading to the heat exchanger. To interrupt a valved ﬁtting, press on the knob (1) and pull out the connector (2). Image 16-2 Open cooling tube 2. Loosen both indicated screws. R5905312 HDF W SERIES 24/01/2013...
Page 273 4. Disconnect the heat exchanger fan (2). Image 16-4 Heat exchanger fan 5. Drain the cooling circuit. Exclude the light processor circuit. Note: The procedure for draining is described in the service manual. 6. Pull out the complete assembly. R5905312 HDF W SERIES 24/01/2013...
Page 274 16. Heat exchanger Image 16-5 Remove assembly R5905312 HDF W SERIES 24/01/2013...
Page 275: Disassembling The Heat Exchanger Assembly
(when releasing the both clip tongs, it camps again. Image 16-6 Image 16-7 2. Pull off both tube assembly (2 & 4). 3. Loosen on both sides the nuts holding the fan assembly to the heat exchanger. R5905312 HDF W SERIES 24/01/2013...
Page 276 16. Heat exchanger Image 16-8 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. R5905312 HDF W SERIES 24/01/2013...
Page 277: 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). R5905312 HDF W SERIES 24/01/2013...
Page 278 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 R5905312 HDF W SERIES 24/01/2013...
Page 279: 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 16-11 2. Fasten both screws. 3. Reinstall the electrical connection (2). Image 16-12 4. Couple up the hose coming from the light pipe entrance to the heat exchanger. R5905312 HDF W SERIES 24/01/2013...
Page 280 16. Heat exchanger Image 16-13 R5905312 HDF W SERIES 24/01/2013...
Page 281: Board Replacement Procedure
17. BOARD REPLACEMENT PROCEDURE Overview • Replacing the Fan control board • Replacing the Power distribution board • Connections on the Power distribution board • Replacing the motor control board (MCB) • Calibrate Motor Control Board R5905312 HDF W SERIES 24/01/2013...
Page 282: Replacing The Fan Control Board
3. Remove the 4 ﬁxation screws (2) of the fan control board. Image 17-2 4. Left up the board on the front side a little and pull it out of its sockets. Note: Make sure not to damage components on the back side of the R5905312 HDF W SERIES 24/01/2013...
Page 283 17. Board replacement procedure Image 17-3 5. Insert a new board and push it until it ﬁts into its sockets. 6. Turn in the 4 ﬁxation screws. 7. Mount the cover plate by driving in both ﬁxation screws. R5905312 HDF W SERIES 24/01/2013...
Page 284: Replacing The Power Distribution Board
5. Secure with the 5 removed screws. 6. Reconnect all connectors. See "Connections on the Power distribution board", page 281 Note: Connectors on the Power distribution board are color coded, equal to the used wires in the wires units. R5905312 HDF W SERIES 24/01/2013...
Page 285: Connections On The Power Distribution Board
Other wire units have uniform colored wires which corresponds with the color labeling on the sockets on the board. Plugs that cannot be inserted in a wrong position are not marked. Image 17-5 Image 17-6 R5905312 HDF W SERIES 24/01/2013...
Page 286 Engine air Pump IR front DMD block Lightpipe Prism Fans chassis Input & Communication SMPS control TEC back Black plug - yellow wires White plug, multi color wires Blue wires Image 17-7 Power distribution board R5905312 HDF W SERIES 24/01/2013...
Page 287: Replacing The Motor Control Board (Mcb)
First, turn out both screws 1 inside the Input & Communication compartment. Image 17-8 5. Behind the front ﬁlter compartment, turn out screw 2,3,4 and 5. Remove screw 6 which ﬁxates the ground wire. Turn out the distance spacer (7). R5905312 HDF W SERIES 24/01/2013...
Page 288 6. Remove the cover. 7. Disconnect the wire units (1 to 4) from the motor control board. Image 17-10 Connections 8. Replace the motor control board. Use a T10 Torx screwdriver to loosen/fasten the ﬁve screws. R5905312 HDF W SERIES 24/01/2013...
Page 289 Make sure that the ground wire is mounted on the distance spacer. 11. Mount the front ﬁlter, Input & Communication unit and reinstall the covers. 12.Start the calibration procedure for the motor control board. See "Calibrate Motor Control Board", page 286. R5905312 HDF W SERIES 24/01/2013...
Page 290: Calibrate Motor Control Board
As a result the popup menu Calibrate All appears with the request to start the calibration. Image 17-14 6. Press the ENTER key to start the calibration. As a result the popup menu with the message “Calibrating motor board” appears and remains until the calibration is done. R5905312 HDF W SERIES 24/01/2013...
Page 291: Fan Replacement Procedures
Replacement of the SMPS fans • Replacing the heat exchanger fan • Cold mirror fan • Replacement of the Light processor compartment fan • Mains input fan • Lamp cathode fan • Lamp anode fan R5905312 HDF W SERIES 24/01/2013...
Page 292: Replacement Of The Card Cage Electronics Fans
2. Replace the fan. Use a 3 mm Allen wrench to loosen/fasten the four screws (reference 1 or reference 2 image 18-2) of the upper or lower fan. Ensure that the airﬂow of the fan is towards the Card Cage compartment. Image 18-2 3. Reconnect the wire unit of the fan. R5905312 HDF W SERIES 24/01/2013...
Page 293: Replacement Of The Smps Fans
2. Replace the fan. Use a 3 mm Allen wrench to loosen/fasten the four screws (reference 1 or reference 2 image 18-4) of the left or right fan. Ensure that the airﬂow of the fan is towards the SMPS compartment. Image 18-4 R5905312 HDF W SERIES 24/01/2013...
Page 294: Replacing The Heat Exchanger 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. R5905312 HDF W SERIES 24/01/2013...
Page 295: Cold Mirror Fan
2. Disconnect the fan wire (reference 1). Tip: Pull out the top ﬁlter for easy access to the fan wire connection. Image 18-7 Electrical disconnection 3. Turn out the 2 hexagon socket head cap screws at the right side (reference 2). R5905312 HDF W SERIES 24/01/2013...
Page 296 Image 18-9 7. Place new fan on the assembly with the arrow pointing to downwards. 8. Place the protection grid on the fan and drive in the 4 ﬁxation screws. 9. Re-install the cold mirror assembly. R5905312 HDF W SERIES 24/01/2013...
Page 297: Replacement Of The Light Processor Compartment Fan
First, turn out both screws 1 inside the Input & Communication compartment. Image 18-10 2. Behind the front ﬁlter compartment, turn out screw 2,3,4 and 5. Remove screw 6 which ﬁxates the sensor. Turn out the distance spacer (7). Image 18-11 R5905312 HDF W SERIES 24/01/2013...
Page 298 6. Take off the safety grill and remove the fan. 7. Place the safety grill on the new fan and mount the new fan. Make sure the air ﬂow is towards the light processor compartment. R5905312 HDF W SERIES 24/01/2013...
Page 299: Mains Input Fan
2. Turn out the 4 ﬁxation screws (reference 2 of .image 18-13) 3. Take off the grid and the fan. 4. Place the grid on a new fan and mount the fan. 5. Drive in the 4 screw and reconnect the power cable. R5905312 HDF W SERIES 24/01/2013...
Page 300: Lamp Cathode Fan
1. Remove the left side panel of the lamp compartment by removing the six indicated screws (reference 1). Image 18-14 Side panel lamp house, removal 2. Pull out the wire unit with connector from behind the plate and disconnect the power cable of the cathode fan. R5905312 HDF W SERIES 24/01/2013...
Page 301 (reference 5) as it is stuck on different plates. Tip: Lift up and slightly turn the fan assembly to remove. Image 18-17 Cathode fan assembly removal 5. Disassemble the cathode fan assembly by removing the ﬁve indicated screws (reference 6). R5905312 HDF W SERIES 24/01/2013...
Page 302 7. Install the fan assembly back in its compartment with ﬁve screws (reference 8). Use a 3 mm Allen wrench. Caution: Make sure that the wire unit of the fan does not get jammed. Image 18-20 Cathode fan assembly, mounting R5905312 HDF W SERIES 24/01/2013...
Page 303 9. Reconnect the wire unit of the cathode fan and hide the connector behind the plate. Image 18-22 Cathode fan, power connection 10.Reinstall the left side panel of the lamp compartment with six screws (reference 10). R5905312 HDF W SERIES 24/01/2013...
Page 304 18. Fan replacement procedures Image 18-23 Side panel lamp house, installation R5905312 HDF W SERIES 24/01/2013...
Page 305: Lamp Anode Fan
3. Release the two ﬁxation screws of the heat exchanger assembly and pull out the assembly. Image 18-25 Remove heat exchanger assembly 4. Remove the anode fan security guard and fan bezel by releasing the four hexagon socket head cap screws (reference 1). Use a 3 mm Allen wrench. R5905312 HDF W SERIES 24/01/2013...
Page 306 Fasten the two mounting plates upon the fan with four hexagon socket head cap screws (reference 6) as illustrated. Provide each screw with a washer (reference 7). c) Close the anode fan house with 11 screws (reference 8). R5905312 HDF W SERIES 24/01/2013...
Page 307 9. Reinstall the anode fan bezel and security guard. Use a 3 mm Allen wrench to secure the four hexagon socket head cap screws (reference 10). Image 18-31 Mount fan security guard 10.Slide the heat exchanger assembly in its place and fasten the two ﬁxation screws. Use a 2,5 mm Allen wrench. R5905312 HDF W SERIES 24/01/2013...
Page 308 12.Reconnect the wire unit of the anode fan (reference B), the wire unit of the heat exchanger fan (reference A) and the wire unit of the pump (reference C). Use a cable tie (reference D) to secure the wire unit of the pump with the tubing. Image 18-33 Electrical connection R5905312 HDF W SERIES 24/01/2013...
Page 309: Board Diagnostic Led's
19. Board Diagnostic LED’s 19. BOARD DIAGNOSTIC LED’S R5905312 HDF W SERIES 24/01/2013...
Page 310 19. Board Diagnostic LED’s R5905312 HDF W SERIES 24/01/2013...
Page 311: Fan Control Board (Fcb) Diagnostic Leds
The Fan Control Board is located behind the Input & Communication unit. To view the diagnostic LEDs of the Fan Control Board the Input & Communication unit has to be placed in the service position as illustrated below (moved forward and tilted). R5905312 HDF W SERIES 24/01/2013...
Page 312 This LED only lit up in case one of the temperatures of the DMD BACK, or AMBIENT OUT is below the minimum allowed temperature. These minimum allowed temperature values are built in the hardware of the Fan Control Board. R5905312 HDF W SERIES 24/01/2013...
Page 313 Fan Control Board. 15 SWITCH FORCE Keeping this switch pressed while powering the projector will force the Fan Control Board to run in BOOT boot mode. As a result the FCB HEARTBEAT ﬂashes twice a second. R5905312 HDF W SERIES 24/01/2013...
Page 314: Motor Control Board Diagnostic Leds
This LED ﬂashes once a second in normal operation which indicates that the Motor Control Board (green) works properly. In boot mode this LED ﬂashes twice a second. ERROR CH3 (red) Channel 3 is currently not used and thus this LED has no purpose (future expansion) R5905312 HDF W SERIES 24/01/2013...
Page 315 +3.3V is derived from the +12V which is generated by the Power Box. 12 SWITCH FORCE Keeping this switch pressed while powering the projector will force the Motor Control Board to run BOOT in boot mode. As a result the MCB HEARTBEAT ﬂashes twice a second. R5905312 HDF W SERIES 24/01/2013...
Page 316: Power Distribution Board Diagnostic Leds
Only operate the projector for a few minutes while the Input & Communication unit is moved and tilted in it’s service position. This to minimize the risk of exceeding the maximum permitted internal temper- ature limit due to insufﬁcient airﬂow. R5905312 HDF W SERIES 24/01/2013...
Page 317 This LED lit up in normal condition and indicates that the +12V STBY (green) This LED lit up in normal condition and indicates that the ++12V standby from the Switched mode power supply is available. R5905312 HDF W SERIES 24/01/2013...
Page 318: Display Interface Diagnostic Leds
The ++5V is generated on the PMP and derived from the ++12V from the Power Box. ++3.3V/++1.2V OK This LED lit up in normal condition and indicates that the local generated ++3.3V and ++1.2V (green) standby voltages are available. These voltages are derived from the ++5V standby voltage. R5905312 HDF W SERIES 24/01/2013...
Page 319: Dvi/Hdsdi Input Board Diagnostic Leds
This LED lit up in case something has changed to the applied SDI source. Once the projector INPUT (red) has recognized the SDI source and conﬁgured the projector correctly for this source then this LED goes out. R5905312 HDF W SERIES 24/01/2013...
Page 320 12 SEL SDI 21 (green) This LED it up when the SDI 2 input is selected. 13 SYNC DVI 2 (yellow) This LED lit up when a valid input sync is detected for the applied SDI source. R5905312 HDF W SERIES 24/01/2013...
Page 321: Communication Interface Board Diagnostic Leds
• OFF: the projector is switched off or is starting up. • RED: the projector is put in STANDBY. • ORANGE: the projector is put in ECO STANDBY. • GREEN: the projector is OPERATIONAL. R5905312 HDF W SERIES 24/01/2013...
Page 322 • RED: the received IR signal is acknowledged. WIFI SEL (orange) This LED lit up in case WiFi is selected. 10 ACT (orange) This LED lit up in case WiFi is connected with an Ethernet. R5905312 HDF W SERIES 24/01/2013...
Page 323: Pixel Mapping Processor Diagnostic Leds
Only operate the projector for a few minutes while the Input & Communication unit is moved and tilted in it’s service position. This to minimize the risk of exceeding the maximum permitted internal temper- ature limit due to insufﬁcient airﬂow. R5905312 HDF W SERIES 24/01/2013...
Page 324 In normal condition this LED is off. RESET (yellow) 22 SCALER MEMORY In normal condition this LED lit up. READY (green) 23 SCALER HEARTBEAT This LED ﬂashes once a second in normal operation which indicates that the SCALER works (green) properly. R5905312 HDF W SERIES 24/01/2013...
Page 325: Cable Input Board Diagnostic Leds
Backplane is available. The +5V is derived from the +12V which is generated by the Power Box. +12V OK (green) This LED lit up in normal condition and indicates that the +12V supply voltage from the Power Backplane is available. The +12V is generated on the Power Box. R5905312 HDF W SERIES 24/01/2013...
Page 326: Lps Module Diagnostic Led's
LPS) If the problem is not solved, replace LPS No mains voltage present at input of LPS mains Check main voltage. terminals About the diagnostic LEDs, ERR, PFC, LPS, Lamp ON and LVPS. R5905312 HDF W SERIES 24/01/2013...
Page 327 LED 3 (Yellow left) : ﬂashing few times / second • ERR : OFF • PFC OK : ON (green) • LPS OK : ON (green) • LAMP ON : ON (green) • LVPS OK : ON (yellow/orange) R5905312 HDF W SERIES 24/01/2013...
Page 328 19. Board Diagnostic LED’s R5905312 HDF W SERIES 24/01/2013...
Page 329: Index
305, 307, 310, 312, 314–315, 317, 319, 321 Board id: input 2 unknown format 5 Cable Input Board id: input 2 unknown module type Communication Interface board Board id: input 2 write error Display Interface Board id: input 3 empty DVI/HDSDI Input R5905312 HDF W SERIES 24/01/2013...
Page 330 Lim read failed Fan speed mains input too high Lim reply no ack Fan speed mains input too low 80–81 Lim write failed Fan speed power supply left too high LPS boost voltage generation failed R5905312 HDF W SERIES 24/01/2013...
Page 331 Red form. start failed 100049 Rod in temp high 100050 Rod in temp low 65–66 100051 Rod in temp open 100052 Rod in temp short 100053 Rs485 selection 100054 Setting FCB mode 100055 Setting XLR control 100056 R5905312 HDF W SERIES 24/01/2013...
Page 332 7605 6011 7606 6012 7607 6013 7608 6014 7609 6015 7610 6016 7611 6017 7612 6018 7613 6019 7614 6020 7615 6021 7616 6022 7617 6024 7618 6025 7619 6026 7620 6027 7621 6028 7622 R5905312 HDF W SERIES 24/01/2013...
Page 333 8135 7813 8502 7815 8520 7817 8521 7818 8550 7819 8551 7820 8552 7900 8553 7901 8600 7902 8601 7903 8602 7904 8603 7905 8604 7906 8605 7907 8620 7928 8621 7929 8700 7930 8701 R5905312 HDF W SERIES 24/01/2013...
Page 334 Replace input 144–145 LCD Display Interface unit 144–145 Replace Input & Communication unit lens Introduction cleaning Input cover 101, 105 Lens 217, 220, 222–223, 230 Install Available Remove Installation input module 146–147 Removal input 146–147 R5905312 HDF W SERIES 24/01/2013...
Page 335 Warp module Mount Replace 109, 166, 202, 234, 236, 259, 263, 288 Lens Holder Fan Card Cage Electronics Horizontal Shift Stepper motor Pump (complete) Pixel Mapping Processor Pump motor Diagnostic LED Pump rotor PMP board Shutter R5905312 HDF W SERIES 24/01/2013...
Page 336 Service Diagnosis Diagnostic Companion Shutter Vertical Shift Side cover 99, 103 Stepper motor Install Replace Remove SMPS Replace SMPS fans Replacement Warp module Spare parts Replace 181–183, 185 WIFI module Install module Introduction WIFI Remove R5905312 HDF W SERIES 24/01/2013...
Page 337 Revision Sheet Barco nv/Documentation Noordlaan 5, B-8520 Kuurne Phone: +32 56.36.82.11, Fax: +32 56.36.88.24 Support: www.Barco.com/esupport, Web: www.barco.com From: Date: Please correct the following points in this documentation (R5905312/01): page wrong correct R5905312 HDF W 24/01/2013 SERIES...

Barco HDF W Series Service Manual

1 Safety

2 General

3 Preventative Maintenance Actions

4 Diagnostic Companion

5 Troubleshooting

6 Removal and Installation of the Projector Covers

7 Power Input

8 Lamp and Lamp House

9 HDF Cold Mirror

10 Card Cage

11 Lamp Power Supply

12 Start Pulse Generator

13 HDF Light Processor

14 Lenses and Lens Holder

15 Liquid Cooling Circuit

16 Heat Exchanger

17 Board Replacement Procedure

18 Fan Replacement Procedures

19 Board Diagnostic Led's

Index

Quick Links

Troubleshooting

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Summary of Contents for Barco HDF W Series