Barco F90 Service Manual
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Barco F90 Service Manual

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F90
Service Manual
723–0016/02
01/12/2017

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  • Page 1 Service Manual 723–0016/02 01/12/2017...
  • Page 2 Barco Fredrikstad AS Habornveien 53, N-1630 Gamle Fredrikstad, Norway Phone: +47 6930 4550 Fax: +47 6930 4580 Support: Support.fre@barco.com Visit us at the web: www.barco.com Printed in Norway...

  • Page 3: Table Of Contents

    10.5 Focus: Relay tube lens focus adjustment ..................44 723–0016 F90 01/12/2017...
  • Page 4 20.2.3 Change the Color Wheel cassette................... . 89 723–0016 F90 01/12/2017...
  • Page 5 26.5.3 Remove the Bottom laser driver PCB board ................138 723–0016 F90 01/12/2017...
  • Page 6 Table of contents 723–0016 F90 01/12/2017...

  • Page 7: Introduction

    This document is intended to describe fault resolution, low frequency maintenance and parts replacement procedures for the Barco F90. Only partners named in service agreement with Barco Fredrikstad AS may carry out procedures detailed in this document. In- formation contained herein is subject to change without further notice; please refer to online documentation for updated information.
  • Page 8 1. Introduction 723–0016 F90 01/12/2017...

  • Page 9: General Safety

    SERVICE PERSONNEL. When an interchangeable lens with throw ratio above a certain level is installed, the F90 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 10 2. General safety 723–0016 F90 01/12/2017...

  • Page 11: Important Safety Instructions

    Conference of Governmental Industrial Hygienists (ACGIH) recommends occupational UV exposure for an 8 hour day to be less than 0.1 micro-watts per square centimeters of effective UV radiation. An evaluation of the workplace is advised to assure employees are not exposed to cumulative radiation levels exceeding these government guidelines. 723–0016 F90 01/12/2017...

  • Page 12: 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 13: 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 con- ditions: •...

  • Page 14: Laser Safety

    Protective googles has to be used by persons inside the test area. Warning Labels Warning Labels Warning labels are positioned inside the projector, where extra Safety precautions are necessary. Image 3-1 Image 3-2 Image 3-3 High voltage warning. Located on the Powersupply. 723–0016 F90 01/12/2017...

  • Page 15: Dlp System General Description

    Optical Principle The F90 illumination consists of two identical light paths combined using a dual rod system. Each path 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 16: The Dmd Device

    The DMD and the sophisticated electronics that surround it are what we call Digital Light Processing™ technology. The F90 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 17: Single Chip Dlp Projection System

    DMD. The switching of the mirrors and the proportion of time they are ’on’ or ’off’ is coordinated according to the color shining on them. The human visual system integrates the sequential color and sees a full-color image. 723–0016 F90 01/12/2017...
  • Page 18 4. DLP System General Description 723–0016 F90 01/12/2017...

  • Page 19: Gp6 System Functional Description

    About The F90 projector series is a high brightness single chip laser phosphor projector. The electronics system is based on the Barco Pulse platform, which offers advanced functionality such as pixel shift and complex warp and blend adjustments. Electronic platform About There are two main electronic PCB’s in the unit;...
  • Page 20 Air inlet temp. sensor Air out temp. sensor Communication with Thermal Hub Board and PSU unit Communication with the Laser Driver PCB’s. Laser Driver Powered by 390V from PSU. Provide 36V pr cable to the Laser Clusters 723–0016 F90 01/12/2017...

  • Page 21: Block Diagram Gp6 Platform

    5. GP6 system functional description Block diagram GP6 Platform System Overview Image 5-1 723–0016 F90 01/12/2017...
  • Page 22 5. GP6 system functional description Main Board Overview Image 5-2 723–0016 F90 01/12/2017...

  • Page 23: Wiring Matrix

    Axial Inlet / LD 504-0544-02 Blower Phosphor CW Board Blower Phosphor 504-0625-00 Blower Op cs (RER) Thermal Hub Board Blower Op cs (RER) 502-0372-00 Liquid Cooler Liquid Cooler 529-0013-00 Flex 40p PCB Main Board Keypad Image 5-3 723–0016 F90 01/12/2017...

  • Page 24: Firmware

    84°C lasers will be shut down by the laser drivers. Each loop can be measured with a multimeter in order to detect an open circuit in the loop. This must be performed with the projector switched off / disconnected from the power source. 723–0016 F90 01/12/2017...
  • Page 25 5. GP6 system functional description 723–0016 F90 01/12/2017 Image 5-5...

  • Page 26: Laser Driver Principle And Error Codes

    0 1 2 Cluster Left Cluster Left Cluster right Cluster right Image 5-7 Error Codes regarding the Laser drivers Error Message Possible root cause / Components to be replaced #e20400 environment.laser.board1.bank0.errorinput Laser cluster left #e20400 environment.laser.board1.bank1.errorinput Laser cluster left 723–0016 F90 01/12/2017...
  • Page 27 Laser driver board 0 (Lower) #e20400 environment.laser.board0.heatsink1.errorinput Laser driver board 0 (Lower) #e20400 environment.laser.board0.heatsink2.errorinput Laser driver board 0 (Lower) #e20400 environment.laser.board0.heatsink3.errorinput Laser driver board 0 (Lower) #e20400 environment.laser.board0.heatsink4.errorinput Laser driver board 0 (Lower) #e20400 environment.laser.board0.heatsink5.errorinput Laser driver board 0 (Lower) 723–0016 F90 01/12/2017...
  • Page 28 5. GP6 system functional description 723–0016 F90 01/12/2017...

  • Page 29: Gp6 Periodical Maintenance

    GP6 / GP7 Dumplight R8781693 XPS actuator assembly Service Kits available. In order to simplify the ordering of service components, complete service kits are available from the Barco service center, see table below for more details. Available complete service kits 20 000 hours...
  • Page 30 (Radiator and pumps) (5 pcs) 504–0625–xx Fan Blower 38x37(1 pc Fan Optics) Color GP6 Color wheel cassette R9801431 Wheel Brightness (2 pcs) Brightness Color wheel GP6 Color wheel cassette, R9801432 Color Color (2 pcs) Phosphor GP6 Phosphor wheel R9801433 wheel 723–0016 F90 01/12/2017...

  • Page 31: Osd / Display Menu

    The exception is the service menu, where more specific adjustments and settings, and also the status of the projector are available. Image 7-1 Service Menu To enter the service menu, go to System settings / Service. The menu shown below will then appear. 723–0016 F90 01/12/2017...
  • Page 32 Return and OK ( ). Image 7-3 When inside the Service menu, this menu will appear. Each choice in this menu has sub–menus. Each sub-menu, and its function and handling, will be described in separate chapters. 723–0016 F90 01/12/2017...

  • Page 33: Troubleshooting Tools

    7. OSD / display menu Image 7-4 Troubleshooting tools The Barco Prospector application can be used for troubleshooting and diagnostics. 723–0016 F90 01/12/2017...
  • Page 34 7. OSD / display menu 723–0016 F90 01/12/2017...

  • Page 35: Thermal Management System

    The power supply unit, laser drivers and optics is cooled by internal fans. Environmental sensors provide the system with ambient data including temperature, humidity, pressure and dew point, enabling the cooling system to react dynamically to environmental changes. 723–0016 F90 01/12/2017...
  • Page 36 8. Thermal management system Image 8-1 723–0016 F90 01/12/2017...

  • Page 37: Liquid Cooling Pumps

    Approx. Nominal RPM (25degC, 0m asl) 504-0624-xx Fan Blower 126x127x31 1500 8.3.6 Fan Optics Located in the front bottom of the projector Part Number Description Approx. Nominal RPM (25degC, 0m asl) 504-0625-xx Fan Radial Optics 138x42, 3 3000 723–0016 F90 01/12/2017...

  • Page 38: Thermal Sensors

    System thermal diagram Figures in the nominal settings and lifetime settings charts may vary due to different operation conditions, including mounting posi- tion, saturation of filters (if optional dust filter is installed and filter saturation sensor activates) etc. 723–0016 F90 01/12/2017...

  • Page 39: Nominal Setting

    43,4 43,7 44,0 45,4 50,7 Driver board1bank3 °C 38,2 42,8 45,2 44,8 44,4 45,8 50,7 Driver board1bank4 °C 41,7 46,4 48,0 46,7 45,4 45,9 50,6 Driver board1bank5 °C 46,0 51,0 53,0 50,1 47,0 47,0 51,0 Image 8-2 723–0016 F90 01/12/2017...

  • Page 40: Long Lifetime Setting

    35,0 38,3 41,7 46,4 51,5 Driver board1bank3 °C 26,5 31,5 35,7 39,1 42,1 46,6 51,7 Driver board1bank4 °C 26,5 31,6 35,8 39,3 41,8 46,7 51,7 Driver board1bank5 °C 26,3 31,5 36,1 39,4 42,1 47,4 51,9 Image 8-3 723–0016 F90 01/12/2017...

  • Page 41: Fan And Pump Number Location

    Naming of the pumps vs the fans Fan name Corresponding pump goes to: Pump No Connector No Fan 1 Left Cluster, Back Fan 2 Left Cluster, Top Fan 3 Right Cluster, Back Fan 4 Left Cluster, Top Fan 5 723–0016 F90 01/12/2017...
  • Page 42 8. Thermal management system 723–0016 F90 01/12/2017...

  • Page 43: Lenses And Adjustment

    2. Disable the Lens Shift function by entering the menu Home/System Settings/Service/Lens Features, and disable the Horizontal and Vertical lens shift by toggling the switches in the menu. Image 9-1 3. Remove the lens from the Projector. 4. Unscrew the 14 screws indicated in the illustration below. 5. Carefully remove the front cover 723–0016 F90 01/12/2017...
  • Page 44 Tighten the screws with a sufficient torque. The green circles indicate the lock for the vertical shift, and the red circles indicate the lock for the horizontal shift. All four locking positions must be used to achieve a sufficient locking. Image 9-3 723–0016 F90 01/12/2017...

  • Page 45: Optical Adjustments

    Location of the lightning mirror knobs Image 10-1 10.3 Lightning mirror: Horizontal (x) Adjustment Turn knob (A) with fingers to adjust mirror horizontally until full image is projected, no vertical bands are present in edge of image 723–0016 F90 01/12/2017...

  • Page 46: Lighting Mirror: Vertical (Y) Adjustment

    • - Adjust by pushing stub laterally up/down (2) to find the focal point where vertical band • - Turn stub screw CW to lock adjustment. Finalize operation by repeating mirror horizontal adjustment. Image 10-4 Image 10-5 723–0016 F90 01/12/2017...

  • Page 47: Color Uniformity, Ti Loop Mirrors Adjustment

    Before starting the adjustment, outer side cover right and frame radiator right protection grid must be removed (see chapter 17.3.5). The lower right screw (1) adjusts the Horizontal (X) uniformity while the upper left screw (2) is for Vertical uniformity (Y). 723–0016 F90 01/12/2017...

  • Page 48: Color Uniformity, Final Verification

    10.6.3 Color uniformity, Final verification. Use Prospector and enable both laser clusters. Measure on each side of image and center using a radio spectrometer. Aim is to have max 0,005 differences Cx and Cy between these three points. Image 10-9 723–0016 F90 01/12/2017...

  • Page 49: Colorwheels

    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). Set to full screen. Disable the OSD during this process, and use only the LCD panel on the projector in order to have a clean, red picture on the screen. 723–0016 F90 01/12/2017...

  • Page 50: Index Adjustment Procedure

    4. Find the average value by adding the two values, and divide by 2 (A+B)/2. 5. Move the Clean Up Wheel slider to the calculated point, and the index are now set to the optimal value. Image 11-2 Picture distortion 723–0016 F90 01/12/2017...

  • Page 51: Phosphor Wheel

    The IP Address for the projector is displayed in the OSD Menu: System/Setting/Communication/LAN. The following screen will appear; you are now working in Prospector. Image 12-1 12.3 Calibrating the phosphor wheel The calibration of the Phosphor wheels is performed via the Prospector application in the projector. 723–0016 F90 01/12/2017...
  • Page 52 10. Move the slider until this average value is shown on the right side of the slider. 11. The phosphor wheel is now calibrated for the left laser channel. 12. The new settings are automatically saved when leaving the menus. 13. Exit Prospector 723–0016 F90 01/12/2017...

  • Page 53: Laser Pulsing Adjustment

    Add the x and y value into the menu and write down the red lux/foot lambert value. Take the red luminance value and divide it by white RED/WHITE Write the result into the red luminance field in prospector 723–0016 F90 01/12/2017...
  • Page 54 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. 723–0016 F90 01/12/2017...

  • Page 55: Xps Actuator

    3. Refer to chapter "Lens shift assembly and optical actuator", page 126 for how to access the XPS actuator. 4. Tighten the four screws with a torque of 0,3Nm, and connect the cable to the XPS actuator unit. Reassemble the Aperture XPS actuator. 5. Reassemble the prism housing in reverse order.. Image 14-3 Image 14-4 723–0016 F90 01/12/2017...

  • Page 56: Calibrating The Xps Actuator

    Ideally, the inner cross shall be positioned in the middle of the outer cross. If not, adjust the “Gain” slider, until the center cross is exactly in the center of the outer cross. Exit the Pixel Shift Menu. 723–0016 F90 01/12/2017...
  • Page 57 14. 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 14-6 723–0016 F90 01/12/2017...
  • Page 58 14. XPS actuator 723–0016 F90 01/12/2017...

  • Page 59: Light Engine

    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). 723–0016 F90 01/12/2017...
  • Page 60 15. Light engine 723–0016 F90 01/12/2017...

  • Page 61: Power Supply Unit (Psu)

    (11,25 — 11,85V) 12V-1 12,36V +/- 3,45% Mainboard (11,94 — 12,8V) 12V-2 8,64A Thermal Hub 12,36V +/- 3,45% 11,91 — 12,8V) 24V +/- 1V Thermal Hub Laser driver supply 380V +/- 3,42% 4,13A Laser Driver (367 — 393V) 723–0016 F90 01/12/2017...

  • Page 62: Connectors

    16. Power Supply Unit (PSU) 16.3 Connectors Image 16-1 16.3.1 PSU Control connector (HDMI-C) Image 16-2 723–0016 F90 01/12/2017...

  • Page 63: Mainboard Connector

    12V-2_GND Pin 4 +24V Pin 5 +24V Pin 6 24V_GND SEEN FROM ABOVE Pin 7 SGND (Shield GND) http://www.molex.com/pdm_docs/sd/430451206_sd.pdf Pin8 +12V-2 Pin9 12V-2_GND Pin10 12V-2_GND Pin11 +24V Pin12 24V_GND Pin13 24V_GND Pin14 SGND (Shield GND) Image 16-4 723–0016 F90 01/12/2017...

  • Page 64: Laser Driver Connector

    “Power good” output is High (3,3V) when all output voltages are present. The “Power good” output will toggle Low (0V) when the 24V output decreases below 19V. Min time for POWER_GOOD to 12V power start decreasing is 1 ms (based on TI mirror park requirements). 723–0016 F90 01/12/2017...

  • Page 65: Troubleshooting

    FPGA not configured NA FPGA_Done FPGA failure — no data loaded DS 3 SW signalling / Not Specified Busy Not specified general purpose DS 7 SW signalling / Not specified Flag Not specified general purpose Image 17-1 723–0016 F90 01/12/2017...

  • Page 66: Main Board Led's

    1V45 1V45 Voltage outside spec DS34 Supply voltage fail SW signalling / Yellow Boot St. Not specified general purpose DS35 SW signalling / Not specified general purpose DS36 SW signalling / Blue Not specified general purpose 723–0016 F90 01/12/2017...

  • Page 67: Available Diagnostic Tools

    17. Troubleshooting Image 17-2 17.3 Available Diagnostic Tools 17.3.1 Prospector Notifications in Pulse Prospector. PROSPECTOR, internal web interface which provides a real time operation overview including voltage levels, temperatures fan speeds and more. 723–0016 F90 01/12/2017...

  • Page 68: Pd Diagnostic

    17.3.2 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 platform (e.g F70, F80 & F90).

  • Page 69: Explanation Of The Codes

    Mainpower (*) For further details, see diagram that details wiring layout from laser driver to Appotronics laser bank in section . Physical sub location Can be sensor number, bank number, coordinate, ID, ... Physical sub location 0..FFFh 723–0016 F90 01/12/2017...

  • Page 70: Troubleshooting Checklist

    Code E0000500: “Barometric pressure lower limit reached” (Error) Situation Solution Environmental pressure not within Ensure that environmental conditions comply with the operation requirements of the range as normally supported by the projector. See installation manual of the projector for detailed installation requirements. projector. 723–0016 F90 01/12/2017...
  • Page 71 For this error the same troubleshooting table can be applied to as for code E1000201: “LaserDriver A heatsink 1 temperature ex- ceeded”. Code E1100300: “LaserDriver A bank 2 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”. 723–0016 F90 01/12/2017...
  • Page 72 For this error the same troubleshooting table can be applied to as for code E1000300: “LaserDriver A bank 6 temperature reading failure”. Code E1500400: “LaserDriver A heatsink 6 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”. 723–0016 F90 01/12/2017...
  • Page 73 For this error the same troubleshooting table can be applied to as for code E1000300: “LaserDriver A bank 1 temperature reading failure”. Code E2300400: “LaserDriver B heatsink 4 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”. 723–0016 F90 01/12/2017...
  • Page 74 Remove the fan from the radiator assembly and verify if the fan is not blocked. Wiring issue Check the connection towards the thermal hub board. If problem persists, replace the fan. Fan end of life. Replace the fan. 723–0016 F90 01/12/2017...
  • Page 75 Potential malfunction of the PSU: Replace the PSU.. Main 12V voltage exceeded. Code E9000200: “PSU Standby 12V lower limit reached” (Error) Situation Solution Potential malfunction of the PSU: Replace the PSU. See service procedure . 12V_Stby Minimal voltage not available. 723–0016 F90 01/12/2017...
  • Page 76 Code L80003: “Autodimming: Set maximum illumination power limit for source ’laser’ to 20 %” (Warning) Situation Solution An error has caused the Light This warning will appear together with other errors. Solve those errors first. Source to be dimmed to its minimum output 723–0016 F90 01/12/2017...

  • Page 77: 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.barco.com. Please refer to the chapter dedicated to the download of the Projector Toolset in the Installation manual.
  • Page 78 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. Click on All products (A-Z) at the right side of this page to display the Alphabetical product listing page.
  • Page 79 Search for words “Error”, “Warning” in the text file for guidance in toward finding the faulty component. Image 17-9 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 723–0016 F90 01/12/2017...
  • Page 80 “code”: “xxxxx” = unique numeric code of the event (which indicates also the source of the event). • “severity”: “xxxx” = the severity can be : INFO, WARNING, ERROR. • “message”: “xxxxxxxxxxxxxxxxxxxxx” = the actual event message 723–0016 F90 01/12/2017...

  • Page 81: Assembly Hierarchy

    18. Assembly Hierarchy 18. ASSEMBLY HIERARCHY 18.1 Hierarchy overview This section describes which parts need to be removed in order to access faulty parts Image 18-1 723–0016 F90 01/12/2017...
  • Page 82 18. Assembly Hierarchy 723–0016 F90 01/12/2017...

  • Page 83: Disassembly / Assembly Instructions

    2. Remove 9 screws T20 M4x10 indicated by red circles. 3. Remove 2 screws T10 M3x8 indicated by green circles. Note: Total number of screws to be removed: 14 pcs. 4. Gently remove the back cover from its position by pulling it slightly back, and upwards. 723–0016 F90 01/12/2017...

  • Page 84: Remove The Main Top Cover

    3. When body trim is removed, two more T20 M4x10 screws become visible. Remove them. Image 19-6 Image 19-7 4. Disconnect the LED Cable in the rear end of the top cover by simultaneously pressing down the tab on the top of the connector, indicated by the arrow, and pull out. 723–0016 F90 01/12/2017...

  • Page 85: Remove The Side Cover Left

    5. 6. Carefully remove the side panel from the unit. 19.2.5 Remove the Side cover right 1. 1. Remove M4x10 screws on the right side indicated with red circles. Use a TX20 screwdriver. Carefully lift out the right cover. 723–0016 F90 01/12/2017...

  • Page 86: Removing Peripheral"Mini" Pcb's

    1. Remove 2 screws (Tx10 M3X6) and release the USB PCB from the metal USB bracket. Note: For information: The bracket is secured to the Cover Left with two screws (TX10 M3x8). Image 19-14 19.3.3 PCB IR Front 1. Pull the IR Cover incl. PCB IR up and out of the holder. 723–0016 F90 01/12/2017...

  • Page 87: Pcb Inlet Temp Sensor Board No1

    1. This PCB is similar to the PCB inlet board, ref. 18.3.4, and located the back side of the radiator fans. 2. Disconnect the cable and remove one screw (T8 M2,5x6) Note: Do not touch components on the board directly during handling; always hold the board edges! 723–0016 F90 01/12/2017...

  • Page 88: Display And Keypad Module

    2. Remove 6 screws indicated by the blue circles, to remove the complete display and keypad module from the side cover. 3. For splitting the keypad from the PCB, remove the screws indicated by the red circles. 4. Reassemble the module in reverse order. Image 19-18 Image 19-19 Location of the display/keypad module 723–0016 F90 01/12/2017...

  • Page 89: Scheduled Operations

    The projector covers must not be removed when performing this procedure. AUTION Heavy lifting! Barco recommends two persons carry out this procedure. 1. With the unit covers still installed, place the unit on its right side. 2. Release 7pcs ( TX10 M3x8 washer) used to secure the Bottom Cover Image 20-1 3.

  • Page 90: Fan Phosphor Wheels (2 Pcs)

    1. Remove the 2 screws holding the PW duct bracket in place (Tx10 M3X6). 2. Lift fan from PW compartment. 3. Carefully pull the fan free from the rubber holder. 4. Install the new fan, ensuring that the rubber holder is firmly in place. Rubber holder Image 20-6 Image 20-5 723–0016 F90 01/12/2017...

  • Page 91: Change The Color Wheel Cassette

    "Index adjustment procedure", page 48 20.2.4 Cooling Fans The projector top covers and left side covers must be removed before this procedure. 20.2.4.1 Fan PSU 1. Disconnect the fan cable from the PCB thermal hub connector J33. 723–0016 F90 01/12/2017...

  • Page 92: Fan Pcb

    Reinstall the fan. 20.2.4.3 Fan Optics 1. 1. Disconnect the fan cable from the PCB thermal hub, connector J35. 2. 2. Remove three screws (Tx10 M3x10) from the fan house. 3. 3. Lift out the fan housing. 723–0016 F90 01/12/2017...

  • Page 93: Laser Clusters Blue (2Pcs)

    About In order to ease access to the laser clusters, the PSU may be removed. See "PSU", page 136 The GP6 has two blue laser clusters, which provide blue laser light to two separate so-called “TI Loops”. 723–0016 F90 01/12/2017...
  • Page 94 80°C - 90°C (176°F). Preheat the pump and copper plate for approximately 2 minutes. . 4. 4. When the copper plate has reached the wanted temperature, carefully pull the bracket in order to release the pump from the laser Cluster. 723–0016 F90 01/12/2017...
  • Page 95 The line between the cluster and the interface will be narrow and paralell. Tighten up the clamps on each side, and ensure correct position and fit also for the clamps. Note: All clamp screws must be tighten with a 3,1Nm torque. 723–0016 F90 01/12/2017...

  • Page 96: Cleaning The Cooling Pump Surface

    3. 3. Add new gasket to the copper surfaces of the cooling pump, use a plastic card to make the new gasket stick properly. 4. 4. Remove the thin plastic film from new gaskets and mount cooling pump to the Laser cluster. 5. 5. Tighten screws in diagonal sequence. 723–0016 F90 01/12/2017...

  • Page 97: Cooling Pump Connection Map

    In order to activate the new thermal conductive change material (gasket) used on the laser clusters, the unit should be kept with lasers running at full power for 1 hr. 20.3 40000 hours service The 40.000 hours service comprises the following parts, in addition to the parts included in the 20.000 hr. service: 723–0016 F90 01/12/2017...

  • Page 98: Fan Laser Driver

    The cooling of the two Laser Clusters and the DMD is based on a liquid cooling system consisting of the following main components. • Radiator and Cooling pump (Liquid Cooler) 5 pcs • Cooling fans (119x25 24V PWM) 5pcs 723–0016 F90 01/12/2017...
  • Page 99 For illustration purposes the in the service manual, the complete inlet cooling system has been split in three frames/sections: 1. Frame radiator left (Cooling of Left Laser Cluster) 2. Frame radiator center (Cooling of Right Laser cluster 3. Frame radiator right (Cooling of DMD) Image 20-33 723–0016 F90 01/12/2017...

  • Page 100: Remove Frame Radiator Left Module

    If pumps aren’t replaced, but temporarily released from cluster or DMD heatsink, new heat phase pads must be added following instructions in section "Laser Clusters Blue (2pcs)", page 91. 9. Reassemble in reverse order. 20.3.4 Remove Frame radiator center module 1. Remove 3 screws (Tx10 M4x8) securing frame radiator center. 723–0016 F90 01/12/2017...

  • Page 101: Frame Radiator Right Module

    2. Remove 1 screw (Tx10 M3x8) securing left radiator frame to the hosuing bottom. 3. Follow the same procedure as described in "Remove Frame Radiator Left Module", page 98, step 3 and forward. Image 20-39 Image 20-38 723–0016 F90 01/12/2017...

  • Page 102: Reassembly Of Radiator Modules

    3. Add new gasket to the copper surface of the new cooling pump, use a plastic card to make the new gasket stick properly. 4. Remove the thin plastic film from new gasket and mount cooling pump to the Laser cluster. Mount screws in diagonal order. 723–0016 F90 01/12/2017...
  • Page 103 20. Scheduled operations Image 20-43 Image 20-42 723–0016 F90 01/12/2017...
  • Page 104 20. Scheduled operations 723–0016 F90 01/12/2017...

  • Page 105: Dmd, Dmd Board, Clga & Dmd Heatsink Elements

    21.2 DMD Board, CLGA & DMD heatsink elements 1. Remove the liquid cooling pump as described above in section "Laser Clusters Blue (2pcs)", page 91. 2. Remove 4 spacers (4mm hex) in a diagonal order, remove the complete DMD assembly. 723–0016 F90 01/12/2017...

  • Page 106: Gp6 Pcb Dmd Board

    21.3 GP6 PCB DMD Board 1. Remove 4 screws (Tx8 M25x10) diagonally 2. Carefully remove the DMD backer plate. 3. Remove 4 spacers (4mm hex) and release the DMD board. 723–0016 F90 01/12/2017...

  • Page 107: Clga & Dmd

    1. lean the surface of the Peltier element and heatsink Stud. Use plastic card or similar to remove old phase change material, clean with Brake and clutch cleaner (Isopropanol may be used but is not equally effective). 2. Add the phase change material onto the Peltier element and stud before assembling the heatsink assemblies together. 723–0016 F90 01/12/2017...

  • Page 108: Gp6 Heatsink Dmd Front & Rear Assemblies

    21.7 GP6 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 109 5. Add phase change material (390 Gasket TIM Peltier) on Peltier. Remove thin plastic film. 6. Add a thin layer of Thermal Paste (Shin Etzu from Barco). 7. Remove 2 screws (Tx08 M2.5x6) and move over bracket heat pipe to the new Heatsink DMD front Assy...

  • Page 110: Remove The Laser Interface

    1. 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). 2. Remove two screws securing the laser interface to the base plate (Tx20 M4x12) Image 21-14 Image 21-15 723–0016 F90 01/12/2017...

  • Page 111: Install New Laser Interface

    4. Fasten the two screws securing the new laser interface to the base plate (Tx20 M4x12)with 1,5nm Torque. Caution: There shall be no bias between the laser interface and the TI Loop. This is a safety issue. This will be obtained using the method described above. 723–0016 F90 01/12/2017...
  • Page 112 21. DMD, DMD Board, CLGA & DMD heatsink elements 723–0016 F90 01/12/2017...

  • Page 113: Ti Loop

    In order to do service inside TI loop for right channel, the entire compartment needs to be disconnected from base plate and removed from the complete engine. Beyond this, the procedures for service and repair of the modules are equal. TI Loop left TI Loop left TI Loop right TI Loop right Image 22-1 723–0016 F90 01/12/2017...

  • Page 114: Overview Engine Assembly

    2. Remove 3 screws (TX8 M2.5x6) marked with green circles, and then the PW Cover. Once the cover is removed, the 5th TX10 M3X6 screw will be visible and you will be able to remove Engine Blue Loop Top. Image 22-4 Image 22-3 723–0016 F90 01/12/2017...

  • Page 115: Overview Of Ti Loop Left

    3. Gently lift out the lens. The trace for focus adjustment screw should be pointing UP through Engine Blue Loop Top in TI Loop Left 4. Mount the lens back in the trace in Engine Blue Loop bottom, see picture. 723–0016 F90 01/12/2017...

  • Page 116: Mirrors Blue

    2. 2. Remove the clip holding lens in place. 3. 3. Lift out the lens. Note: The Blue Loop lenses are NOT directional. Image 22-10 22.2.7 390 Blue loop lens 4 1. 1. Remove screw (Tx08 M2.5x6) 723–0016 F90 01/12/2017...

  • Page 117: Diffusor Blue Loop

    1. Place a cloth or similar on the entrance floor to protect the lens in case it falls when screws/clips is released. 2. Remove 4 screws (Tx8 M2.5x6) releasing the clip and lens. 3. Assemble in reverse order. Image 22-15 Image 22-14 Image 22-13 723–0016 F90 01/12/2017...

  • Page 118: Converging Lens (Exit)

    You may need to use a screw driver or similar to gently bend loose the light path from the remaining optical engine. Most components inside TI Loop right are mounted following same procedure as documented for left loop. Exceptions are documented in the following chapter. 723–0016 F90 01/12/2017...

  • Page 119: Rod Carrier Assy

    It is recommended that you remove Color wheel prior to removing the rod carrier assembly. 1. Remove 3 screws (Tx08 M2.5x6) and lift off Illumination engine cover. 2. Remove 3 screws (Tx8 M25x10) securing rod assembly to Illumination engine Front. 3. Carefully lift out rod assembly holding hollow rod. 723–0016 F90 01/12/2017...
  • Page 120 Washer wedge (pointy end) must point toward Rod exit side, to ensure Rod is pressed correctly against exit of hollow rod Do NOT touch surfaces of glass rod with bare hands. This will drastically reduce light output, and may destroy the component. Image 22-25 723–0016 F90 01/12/2017...

  • Page 121: Illumination Engine Front

    Adjustable mirror and CLO can only be accessed after removing the complete engine core, including lens shift. 23.1 Iris assembly Location of the Iris assembly Image 23-1 Location of the iris assembly Image 23-2 Complete Iris assembly 723–0016 F90 01/12/2017...

  • Page 122: Relay Tube Assy

    See Optical adjustment chapter 10.2 for adjustment of relay tube lens after service. Image 23-6 Image 23-5 23.3 PCB CLO (Constant Light Output). 1. Remove Fan Optics. 2. Remove 4 screws (Tx10 M3x6) securing the PCB to the CLO holder (TX10 I min, 8 I EWI) 723–0016 F90 01/12/2017...

  • Page 123: Folding Mirror Assembly

    Image 23-7 23.4 Folding Mirror assembly In some F90-W13 units the complete mirror assembly cannot be removed without lifting the entire optical engine 10mm as the mirror conflicts the bottom base plate. Mirror can also be removed with mirror assembly mounted inside the Illumination Engine.
  • Page 124 23. Illumination Engine front Tip: See Optical adjustment, "Optical adjustments", page 43for adjustment of mirror after service. 723–0016 F90 01/12/2017...

  • Page 125: Lens Shift Assembly

    If lens shift needs to come out, see "Lens shift assembly and optical actuator", page 126 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 723–0016 F90 01/12/2017...

  • Page 126: Lens Shift Assembly Motors

    2. Remove 4 screws (M3x8 Tx10) to release lens shift motor from holder. - Motor for horizontal shift (left) connects to PCB lens hub connector J1 - Motor for vertical shift (lower) connects to PCB lens hub connector J2 Image 24-3 723–0016 F90 01/12/2017...

  • Page 127: Lens Position Sensors (Horizontal And Vertical)

    - 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). Connects to PCB lens Hub J40 Image 24-5 723–0016 F90 01/12/2017...

  • Page 128: Lens Lock Screws

    24.6 Lens shift assembly and optical actuator 1. Remove 4 screws (TX20 M4x12) available from inside lens opening. Image 24-7 2. Remove 2 screws (TX20 M4x12) securing the assembly to the base plate and remove the complete assy. 723–0016 F90 01/12/2017...

  • Page 129: Tir Prism

    24.7 TIR Prism Use cotton gloves or finger nuts whenever handling the TIR prism 24.7.1 Remove the TIR prism 1. Remove 4 screws (TX8 M2,5x6) 2. Carefully pull out the Prism Clip Prism using a flat screwdriver. 723–0016 F90 01/12/2017...

  • Page 130: Cleaning The Tir Prism

    3. Lift the prism out carefully. Image 24-13 24.7.2 Cleaning the TIR prism 1. Use ionized air when cleaning the TIR prism. 2. If the unit is extremely dirty, use a nonabrasive optical wipe and optical cleaning solvent to clear the surface. 723–0016 F90 01/12/2017...

  • Page 131: Reassemble The Tir Prism

    24.7.3 Reassemble the TIR prism 1. Insert the prism in the engine housing. 2. Gravity naturally places the prism in the correct position towards the contact faces. 3. Push in the Prism Clip and fasten the 4 screws. Image 24-15 723–0016 F90 01/12/2017...
  • Page 132 24. Lens shift assembly 723–0016 F90 01/12/2017...

  • Page 133: Prism Housing

    4. Remove 2 screws (TX20 M4x12) securing the assembly to the base plate and remove the complete assy. 5. Once the engine core with lens shift is removed, the dumplight bracket is loose and can be removed. Image 25-4 Image 25-3 723–0016 F90 01/12/2017...
  • Page 134 25. Prism Housing Image 25-5 723–0016 F90 01/12/2017...

  • Page 135: Technical Operations

    5. Remove 14 screws (T10 M3x6) and lift out PCB Bracket bottom. 26.2 PCB Main 1. Remove 10 screws (Tx10 M3x6) to release bracket PCB Top 2. Disconnect all cables, remove 8 screws (Tx10 M3x6) on top of PCB main. 723–0016 F90 01/12/2017...

  • Page 136: Pcb Thermal Hub Board

    1. Disconnect all cables, remove 4 screws (Tx10 M3x6) 2. Release 2 screws (Tx10 M3x8) towards the lens. Image 26-4 3. Release 7 screws (Tx10 M3x6) and remove Bracket Hub Top. 4. Remove 8 screws (Tx10 M3x10), disconnect all cables and remove the board. 723–0016 F90 01/12/2017...
  • Page 137 26. Technical Operations Image 26-5 Image 26-6 Cable overview (from clockwise), as shown in Figure 21-1, Cable overview GP6 1. CLO (F90 4K only, Constant light output) 19. LedIR-R (FS90 only) 2. M_Iris i20. FanIR-R (FS90 only) 21. Pump 1234 3.

  • Page 138: Psu

    Image 26-7 Image 26-8 26.4 PSU Removing the PSU to access the laser clusters in not essential but will make the procedure easier. The PSU can be removed without first removing PCB Main and sheet metal brackets. 723–0016 F90 01/12/2017...

  • Page 139: Pcb Laser Drivers

    2. Remove 4 screws TX10 (Tx10 M3x6) 2 pcs on the Black PCB Hub board bracket and 2 securing Fan Laser driver to the bottom. 3. Remove 6 pcs screws (Tx20 M4x8) securing Laser driver cage to Bottom assy 723–0016 F90 01/12/2017...

  • Page 140: Remove The Laser Driver Pcb Board

    3. 3. Remove 14 screws (Tx10 M3x6) and carefully lift out the PCB Laser driver. Image 26-13 26.5.3 Remove the Bottom laser driver PCB board 1. Remove 14 spacers (50mm M3x45) 2. Disconnect Power inlet socket before removing the PCB. 3. Lift out the PCB Laser Driver. 723–0016 F90 01/12/2017...
  • Page 141 26. Technical Operations Image 26-14 4. For further access to the optical engine, remove the bracket frame center 4 screws (T10 M3x6) and 1pcs (T20 M4x10). Image 26-15 723–0016 F90 01/12/2017...

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