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Barco DP-3000 Service Manual

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DP-3000

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R59770374/05

01/06/2012

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Page 1 DP-3000 Service manual R59770374/05 01/06/2012...
Page 2 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 Barco Inc. Media and Entertainment Division 11101 Trade Center Drive, Rancho Cordova, California 95670, USA Phone: +1 916 859-2500 Fax: +1 916 859-2515 Support: www.Barco.com/esupport...
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
10.2 Diagnostics .........................160 R59770374 DP-3000 01/06/2012...
Page 6 16.1 Introduction .........................288 R59770374 DP-3000 01/06/2012...
Page 7 Index........................375 R59770374 DP-3000 01/06/2012...
Page 8 Table of contents R59770374 DP-3000 01/06/2012...
Page 9: Safety
Read this chapter attentively. It contains important information to prevent personal injury while servicing the DP-3000 projector. Furthermore, it includes several cautions to prevent damage to the DP-3000 projector. Ensure that you understand and follow all safety guidelines, safety instructions and warnings mentioned in this chapter before servicing the DP-3000 projector. After this chapter, additional “warnings”...
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. R59770374 DP-3000 01/06/2012...
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 R59770374 DP-3000 01/06/2012...
Page 13: General
Overview • Convention projector orientation • Location of the main components of the projector • Convention Power Unit orientation • Location of the main components of the Power Unit • Projector block diagram • Spare part list R59770374 DP-3000 01/06/2012...
Page 14: Convention Projector Orientation
Image 2-1 Top of the projector. Left side of the projector (Light Processor side). Front of the projector. Right side of the projector (Lamp side & Input side). Back side of the projector. R59770374 DP-3000 01/06/2012...
Page 15: Location Of The Main Components Of The Projector
Location of the main components of the projector Housing and air inlet ﬁlters Image 2-2 Top cover. Front cover. Front ﬁlter (slide into front cover). Right side cover (lamps side). Bottom cover. Rear cover. Side ﬁlter. Left side cover (light processor side). R59770374 DP-3000 01/06/2012...
Page 16: Main Internal Components
Sealed Light Processor unit (SLP). Heat exhauster (Outlet Fan). Lens Holder. Lamp House. Control Panel (includes Button Panel). Input & Communication unit (includes Barco Cinema Controller). Cover for future expansion. Image 2-4 SMPS CTRL board. SMPS PFC board. SMPS DCDC board.
Page 17 Cold mirror assembly (rear side). Status lights on projector corners. Image 2-6 Heat exchanger. Start Pulse Generator (SPG). Cold mirror assembly (front side). Status lights on projector corners. Manometer. Card cage Power Backplane. Card cage Signal Backplane. R59770374 DP-3000 01/06/2012...
Page 18: Convention Power Unit Orientation
Convention Power Unit orientation Convention Image 2-7 Top of the Power Unit. Left side of the Power Unit. Front of the Power Unit (air outlet). Right side of the Power Unit. Back side of the Power Unit (air inlet). R59770374 DP-3000 01/06/2012...
Page 19: Location Of The Main Components Of The Power Unit
Main internal components of the Power Unit Image 2-8 Front cover with air outlet grid. Lamp Power Supply (LPS). Power rack. Rear cover with air inlet grid. Cover plate mains connections. Power Unit base assembly. Cover plate power output sockets. R59770374 DP-3000 01/06/2012...
Page 20 Parts of the base of the Power Unit Image 2-9 Mains input distribution strip. Cable gland for mains input cable. Optional entrance for mains input cable. LPS communication board. Mains connection per LPS module. Mains output socket for projector head. Mains input ﬁlter. R59770374 DP-3000 01/06/2012...
Page 21: Projector Block Diagram
Frame Rate Data Unpacking & Overlay Compositor Multiplication Formatter Formatting Frame Store ARM7 MicroController Digital Signal Proc RS-232 Executive Control Subtitle Rendering Overlay Processing Resizer Coef Comp 100baseT Formatter Mass Store Boot Flash Boot Flash Image 2-10 R59770374 DP-3000 01/06/2012...
Page 22: Internal Wiring Diagram
2. General Internal wiring diagram Image 2-11 R59770374 DP-3000 01/06/2012...
Page 23 SMPS PFC ++12V SMPS Fan 4 Cold Mirror Fan top Cold Mirror Fan bottom +22V PUMP (+ Anamorphic) SPG fan +12V ACSAR (DP-3000 not used) Sealed engine internal fan +12V TEC (Peltiers) Δ TEC Red +24V ELEC (Electronics) Δ TEC Green +3.3V...
Page 24: Spare Part List
2. General Spare part list Look at the secured Barco website https://My.Barco.com for the most recently updated spare parts list. Optical spare parts Description Applies to Order No. Reference R9855942 1,2" DC2K Zoom Lens (1,45-2,05 : 1) (Motorized) DP-3000 page 222 R9855943 1,2"...
Page 25 R765564(K) DIMM PC + Software DP-3000 page 285 page 75 R7649632K DP-3000 power unit for 3 x 400V AC + Neutral (EU) DP-3000 EU R7649633K DP-3000 power unit for 3 x 208V AC without neutral (US) DP-3000 US page 75...
Page 26 105 R853189K Lens Holder Motorize DP-3000 R9806800 Safety kit for lamp replacement (One pair of leather gloves and one DP series page 105 full face mask) R856811K DP-3000 page 180 Shutter assembly (Dowser) R859361K Stacking Points DP-3000 R59770374 DP-3000 01/06/2012...
Page 27 2. General Order No. Description Applies to Reference R9856060 Universal pedestal adapter plate DP3-000 Manual No: 26-0603100-00 R9856050 Universal pedestal for DP series DP series Manual No: 26-0603100-00 R59770374 DP-3000 01/06/2012...
Page 28 2. General R59770374 DP-3000 01/06/2012...
Page 29: Preventative Maintenance Actions
Overview • 1 month maintenance actions • Lamp change maintenance actions • 6 month maintenance actions • 1 year maintenance actions • 4 year maintenance actions • 10 year maintenance actions R59770374 DP-3000 01/06/2012...
Page 30: Month Maintenance Actions
’lens ﬁles’ must be updated. See user guide of the Communicator software. Check the porthole (both sides) for dust. Clean the porthole in case dust is clearly visible upon the surface. Use an optical cloth. R59770374 DP-3000 01/06/2012...
Page 31: Lamp Change Maintenance Actions
Visual inspection of the lamp anode and cathode cables of the lamp house. Replace the lamp house in case of degradation, damage, etc. See "Lamps and Lamp House", page 105. Check if all cables are still tightened. See chapter "Lamps and Lamp House", page 105. R59770374 DP-3000 01/06/2012...
Page 32: Month Maintenance Actions
Pressure veriﬁcation of the liquid cooling circuit. This pressure, indicated on the internal manometer, should be between 0,5 and 1 bar. See "Pressure veriﬁcation of the Liquid Cooling Circuit", page 188. If not, corrective action should be taken by certiﬁed service personnel. R59770374 DP-3000 01/06/2012...
Page 33: Year Maintenance Actions
Verify projector date and time and correct if required. See Communicator software. 13 Software Check for the latest version of Barco and TI software. See user Upgrade the projector software with the version guide of the Communicator software. The latest software version latest version.
Page 34 Use an optical cloth. See "Cleaning the lens", page 228. Note that a lens removal requires an update of all used ’lens ﬁles’. See user guide of the Communicator software. R59770374 DP-3000 01/06/2012...
Page 35 34 Air Extraction Check customer air extraction system for adequate extraction. The air extraction system must be capable of removing minimum 10 m³/min or 350 CFM per installed DP-3000 digital projector. 35 Color Measure the color coordinates of the projected image and See user guide of the Communicator calibration calibrated if necessary.
Page 36: Every 4 Years
Replace the pump of the liquid cooling circuit Follow correct pressurize procedure after replacement. See "Replacement of the complete Pump", page 214. Check the lamp fans: vibrations, noise, speed, etc. (speeds: via diagnostics) Replace if needed. See "Fan replacement procedures", page 305. R59770374 DP-3000 01/06/2012...
Page 37: Year 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 Check all fans: vibrations, noise, speed, etc. Replace if needed. See "Fan replacement procedures", page 305. R59770374 DP-3000 01/06/2012...
Page 38 3. Preventative maintenance actions R59770374 DP-3000 01/06/2012...
Page 39: Trouble Shooting
“warning” as soon as possible otherwise, the “warning” state may turn into an “error” state which will switch off the projector consequently. The codes are placed in alphabetical order to make it easier to look up the code and ﬁnd an appropriate solution. Overview • First level troubleshooting • Trouble shooting checklist R59770374 DP-3000 01/06/2012...
Page 40: First Level Troubleshooting
Turn off the Lamp and cool down the Lamp for at least 1 minute if hot. b) Switch off the power of the unit and wait for at least 15 seconds. c) Switch on the power of the unit and respect normal startup procedure. R59770374 DP-3000 01/06/2012...
Page 41: Trouble Shooting Checklist
Replace the SMPS DCDC board. See "Replacement of a Card Cage board", page electronics is about to exceed its 252. maximum limit. If the problem remains, replace the SMPS CTRL board. See "Replacement of a Card Cage board", page 252. R59770374 DP-3000 01/06/2012...
Page 42 Check the external air exhaust system. Note that the installed exhaust blower must system. remove an air volume of 10 m³/min or 350 CFM per installed DP-3000 projector. Blocked air inlet Check if the air inlet at the front and at the left side of the projector is not blocked.
Page 43 Power Backplane. disconnected from the Power Backplane. Defect temperature sensor. Replace the temperature sensor. Malfunction SMPS CTRL board. Replace the SMPS CTRL board. See "Replacement of a Card Cage board", page 252. R59770374 DP-3000 01/06/2012...
Page 44 Check if the wire unit of the fan is not damaged. Repair if possible, otherwise replace with new one. Malfunction SMPS CTRL board. Replace the SMPS CTRL board. See "Replacement of a Card Cage board", page 252. R59770374 DP-3000 01/06/2012...
Page 45 Malfunction SMPS DCDC board. Replace the SMPS DCDC board. See "Replacement of a Card Cage board", page 252. Fan end of life (reference 1 Replace the fan. See "Replacement of the Cold Mirror Top Fan", page 321. image 4-5). R59770374 DP-3000 01/06/2012...
Page 46 Check if the cooling circuit of the Sealed Light Processor is connected with the pump and Sealed Light Processor is mistakenly heat exchanger. See "Excluding the Sealed Light Processor", page 189s excluded from the main liquid cooling circuit. Most likely the other DMD temperatures are too high as well. R59770374 DP-3000 01/06/2012...
Page 47 Code: “eﬁb - i2c failed” (Error) Situation Solution Communication failure with the Check if the Sealed Light Processor unit is well inserted. Formatting Interface Board (EFIB). Note that the Formatting Interface Board is located inside the Sealed Light Processor unit. R59770374 DP-3000 01/06/2012...
Page 48 If the problem remains, replace the whole Sealed Light Processor unit and return the malfunction Sealed Light Processor to factory for repair. Under no circumstances the Sealed Light Processor may be serviced at the ﬁeld. Service on the Sealed Light Processor unit can only be done at factory. R59770374 DP-3000 01/06/2012...
Page 49 If the problem remains, replace the whole Sealed Light Processor unit and return the malfunction Sealed Light Processor to factory for repair. Under no circumstances the Sealed Light Processor may be serviced at the ﬁeld. Service on the Sealed Light Processor unit can only be done at factory. R59770374 DP-3000 01/06/2012...
Page 50 35°C (95°F). Malfunction air extraction system. Check the condition of the air extraction system. The air extraction system must be capable of removing minimum 10 m³/min or 350 CFM per installed DP-3000 digital projector. Malfunction SMPS CTRL board. See Replace the SMPS CTRL board.
Page 51 Replace the fan. See procedure "Replacement of the Card Cage Fans", page 326. wire unit of the slow fan with one of the wire units of the other three fans the same fan has a visible low speed and the warning indicates another fan number. R59770374 DP-3000 01/06/2012...
Page 52 Replace the SMPS CTRL board. See "Replacement of a Card Cage board", page 252. Malfunction SMPS PFC board. Replace the SMPS PFC board. See "Replacement of a Card Cage board", page 252. Defect fan. Replace the fan. See "Replacement of the Card Cage Fans", page 326. R59770374 DP-3000 01/06/2012...
Page 53 Check if the wire unit of the four fans at the front side of the projector are not damaged. Repair if possible, otherwise replace with new one. Malfunction SMPS CTRL board. Replace the SMPS CTRL board. See "Replacement of a Card Cage board", page 252. R59770374 DP-3000 01/06/2012...
Page 54 Defect micro switch. Replace the micro switch. Image 4-7 Image 4-8 Code: “lamp - read run time failed” (Error) Situation Solution Wrong Lamp House inside lamp Replace the Lamp House with a compatible Lamp House for this projector. compartment. R59770374 DP-3000 01/06/2012...
Page 55 Check if the wire unit (reference 5 image 4-11) of the Lamp Info Module is connected with its socket on the module. Malfunction Lamp Info Module. Replace the Lamp Info Module. See "Replacement of the Lamp Info module", page 128. Image 4-9 Image 4-10 R59770374 DP-3000 01/06/2012...
Page 56 105. (almost double). Soon the lamp Note that the lamp is really exhausted and that the light output of the lamp is far below start up will be blocked. the minimum requirements. R59770374 DP-3000 01/06/2012...
Page 57 Check if the wire unit of the anode fan is not damaged. Repair if possible, otherwise replace with new one. Malfunction SMPS CTRL board. Replace the SMPS CTRL board. See "Replacement of a Card Cage board", page 252. R59770374 DP-3000 01/06/2012...
Page 58 Replace the SMPS CTRL board. See "Replacement of a Card Cage board", page 252. Malfunction SMPS PFC board. Replace the SMPS PFC board. See "Replacement of a Card Cage board", page 252. Defect cathode fan (reference 1 Replace the fan. See "Replacement of the Cathode Fan", page 312. image 4-13). R59770374 DP-3000 01/06/2012...
Page 59 Check the insulation of the wire unit of the cathode fan. (reference 2 image 4-13) of the Repair the insulation of the wire unit using shrink sleeve. cathode fan. If not repairable, replace the whole wire unit and/or fan. R59770374 DP-3000 01/06/2012...
Page 60 Power Backplane. Image 4-14 Image 4-15 Code: “lamp house - temperature too high” (Error) This error code is probably proceeded by the warning code: “lamp house - temperature high”. The same troubleshooting table can be applied to. R59770374 DP-3000 01/06/2012...
Page 61 35°C (95°F). Malfunction air extraction system. Check the condition of the air extraction system. The air extraction system must be capable of removing minimum 10 m³/min or 350 CFM per installed DP-3000 digital projector. Defect temperature sensor Replace the defect temperature sensor.
Page 62 Solution Malfunction SMPS CTRL board. Replace the SMPS CTRL board. See "Replacement of a Card Cage board", page 252. Malfunction SMPS PFC board. Replace the SMPS PFC board. See "Replacement of a Card Cage board", page 252. R59770374 DP-3000 01/06/2012...
Page 63 Connection with Shutter (Dowser) motor. Limit switch for Shutter in open position (yellow wire). Limit switch for Shutter in closed position (orange wire). Connection with Zoom motor on the lens. Connection with Horizontal Shift motor of the Lens Holder. R59770374 DP-3000 01/06/2012...
Page 64 The activated lens ﬁle does not Activate a lens ﬁle which do correspond with the mounted lens or mount an other lens correspond with the lens mounted which correspond with the lens ﬁle you wan to activate. on the projector. R59770374 DP-3000 01/06/2012...
Page 65 Interface board of the LPS Power "Replacement of the LPS communication interface", page 92. unit. Malfunction Input & Communication Replace the malfunction Input & Communication unit. See "Installation of the Input & unit. Communication unit", page 280. R59770374 DP-3000 01/06/2012...
Page 66 Check if the LPS communication cable (reference 1 and 2 image 4-19) is well connected be detected during the start up with the LPS Power unit (RACK CONTROL) and the projector head. (initialization) of the projector head due to a disconnected LPS communication cable. R59770374 DP-3000 01/06/2012...
Page 67 Power unit. (brown wire unit) Malfunction of one of the LPS Replace the malfunction LPS module of the Power unit. See "Removal of an LPS modules. The red LED “ERR” of module", page 86. the malfunction LPS module ﬂashes fast. R59770374 DP-3000 01/06/2012...
Page 68 Code: “pfc - temperature low” (Error) Situation Solution Disconnected temperature sensor Check if the wire unit of the temperature sensor is connected with the SMPS PFC board. (reference 1 image 4-24) of the PFC heat sink on the SMPS PFC board. R59770374 DP-3000 01/06/2012...
Page 69 Replace the SMPS CTRL board. See "Replacement of a Card Cage board", page 252. Malfunction SMPS PFC board. Replace the SMPS PFC board. See "Replacement of a Card Cage board", page 252. Fan end of life. Replace the fan. See "Replacement of the SPG Fan", page 325. R59770374 DP-3000 01/06/2012...
Page 70 Replace the SMPS PFC board. See "Replacement of a Card Cage board", page 252. Defect fan inside the Sealed Light Replace the complete Sealed Light Processor unit. See "Removal of the Sealed Light Processor unit. Processor", page 161. Return the malfunction Sealed Light Processor unit to factory for repair. R59770374 DP-3000 01/06/2012...
Page 71 Reboot the projector by switching OFF and ON. Wait a few seconds before switching protocol between the SMPS CTRL ON again. board and the Barco Cinema Controller board. Malfunction SMPS CTRL board. Replace the SMPS CTRL board. See "Replacement of a Card Cage board", page 252.
Page 72 Code: “smps2 primary - temperature low” (Error) Situation Solution Disconnected temperature sensor Check if the wire unit of the temperature sensor is connected with the SMPS DCDC (reference 5 image 4-24) of the board. primary smps heat sink on the SMPS DCDC Board. R59770374 DP-3000 01/06/2012...
Page 73 Replace the SMPS CTRL board. See "Replacement of a Card Cage board", page 252. One of the Peltier elements causes Replace the Sealed Light Processor unit. Return the malfunction Sealed Light Processor a short circuit. to factory for repair. See "Removal of the Sealed Light Processor", page 161. R59770374 DP-3000 01/06/2012...
Page 74 Pump", page 210. Malfunction Peltier element (TEC) of Replace the Sealed Light Processor and return the malfunction Sealed Light Processor the involved channel. to factory for repair. See chapter "Removal of the Sealed Light Processor", page 161. Image 4-27 R59770374 DP-3000 01/06/2012...
Page 75 See "Removal of the Sealed Light Processor", page 161. Processor is disconnected. Defect Peltier element (TEC). Replace the Sealed Light Processor unit. Return the malfunction Sealed Light Processor to factory for repair. See "Removal of the Sealed Light Processor", page 161. R59770374 DP-3000 01/06/2012...
Page 76 TI system status failure. This situation can occurs when the projector is recently installed and did not had the time to acclimate to the normal room temperature. There is also a message that the R59770374 DP-3000 01/06/2012...
Page 77 The cover of the card cage has been Clear the security warning. See procedure "Authorization to clear security warning reinstalled. on DP-3000", page 251. The Sealed Light Processor unit has Clear the security warning. See procedure "Authorization to clear security warning been removed and installed again.
Page 78 If so, remove the rotor and clean the bearings of the pump. See "Cleaning Communicator software. the Pump", page 210. Strap (reference 1 image 4-28) Check if the strap is present. missing on the SENS FLOW socket of the Power Backplane. Image 4-28 R59770374 DP-3000 01/06/2012...
Page 79: Power Unit
• Removing the LPS rack from the base of the Power Unit • Replacement of the LPS communication interface • Replacement of the Mains Filter • Installing the LPS rack upon the base of the Power Unit R59770374 DP-3000 01/06/2012...
Page 80: Introduction
Main internal components of the Power Unit Image 5-1 Front cover with air outlet grid. Lamp Power Supply (LPS). Power rack. Rear cover with air inlet grid. Cover plate mains connections. Power Unit base assembly. Cover plate power output sockets. R59770374 DP-3000 01/06/2012...
Page 81 Mains output socket for projector head. Mains input ﬁlter. Front panel of the Lamp Power Supply MAINS INPUT LAMP OUTPUT ERROR ADDRESS SELECT CTRL IN CTRL OUT Image 5-3 Lamp output pin “-”. Lamp output pin “+”. R59770374 DP-3000 01/06/2012...
Page 82 Diagnostic LED “LVPS OK” (yellow). Mains input. Retaining ﬁxation screws. Diagnostic LED “ERROR” (red). Diagnostic LED “PFC OK” (green). Diagnostic LED “LPS OK” (green). Socket for ADRESS cable. Socket for CTRL IN cable. Socket for CTRL OUT cable. R59770374 DP-3000 01/06/2012...
Page 83: Lps Module Diagnostic Led's
110 volt and you do not hear the SPG module clicking to ignite the lamp. • Replace the LPS modules in case the voltage value on the “LAMP OUT” pins is below 110 volt and the lamp is not ignited. R59770374 DP-3000 01/06/2012...
Page 84 Error detected inside this LPS Replace the LPS module. fast module. Flashing All LPS modules where Check the error logged in the slow ordered to shutdown due to a projector log ﬁle. malfunction somewhere else inside the projector. R59770374 DP-3000 01/06/2012...
Page 85: Connecting The Power Unit With The Projector Head
2. Connect the green/yellow ground wire from the projector head with the chassis (PE) of power unit as illustrated. Place a lock washer B between the nut A and the wire ring lug C. Secure the wire with the strain relief clamp E. Use a 7 mm nut driver to fasten the nuts A and D. R59770374 DP-3000 01/06/2012...
Page 86 7. Reconnect the data cable and power cord. Fasten the thumbscrews of the data cable (reference 6 image 5-10) and secure the power cord (reference 7 image 5-10) with the strain relief bracket which you removed is step 2. Use a PH1 Phillips screwdriver to fasten the bracket. R59770374 DP-3000 01/06/2012...
Page 87 5. Power Unit Image 5-10 8. Reinstall the base cover from the Power Box. ARNING Use cable ties to fasten all cables between the power unit and the projector head. R59770374 DP-3000 01/06/2012...
Page 88: Connecting The Power Unit With The Power Net
Note: The cable gland is default mounted at the rear side of the power unit. But, if required you can reposition the cable gland to the side of the power unit. R59770374 DP-3000 01/06/2012...
Page 89 3 x 400V + N 3 x 208V Image 5-13 4. Reinstall the cover as illustrated. Fasten the two captive screws of the cover using a Phillips screwdriver PH1. Image 5-14 5. Fasten the cable gland using an adjustable wrench. R59770374 DP-3000 01/06/2012...
Page 90: Removal Of An Lps Module
5. Disconnect the CTRL IN (reference 5 image 5-16) and the CTRL OUT (reference 6 image 5-16) wire unit from the LPS module. Image 5-16 6. Disconnect both LAMP OUTPUT power cables from the LPS module. Use a 10 mm nut driver to loosen the nuts (reference 9 image 5-17). R59770374 DP-3000 01/06/2012...
Page 91 7. Loosen the four retaining screws (reference 10 image 5-18) of the disconnected LPS module. Use an 8 mm nut driver or a ﬂat screw driver. Image 5-18 8. Hold the LPS module by its handles and pull out of its compartment. R59770374 DP-3000 01/06/2012...
Page 92: Installation Of An Lps Module
4. Connect the CTRL IN (reference 5image 5-21) and the CTRL OUT wire unit (reference 6) with the LPS module. Make sure that the CTRL OUT of the LPS module below is connected with the CTRL IN socket and the CTRL IN of the LPS module above is connected with the CTRL OUT socket. R59770374 DP-3000 01/06/2012...
Page 93 6. Connect the ADDRESS CONTROL wire unit (reference 3 & 4image 5-21) with the LPS module and the LPS module(s) above. Image 5-21 7. Install the front cover of the Power Unit. Use a 3 mm Allen wrench to fasten the ﬁve screws (reference 1 & 2 image 5-22) as illustrated. Image 5-22 R59770374 DP-3000 01/06/2012...
Page 94: Removing The Lps Rack From The Base Of The Power Unit
4. Disconnect the CTRL IN wire unit (reference 4 image 5-24) from the LPS module at the bottom of the LPS rack. 5. Disconnect both LAMP OUTPUT power cables from the LPS module at the bottom of the power rack. Use a 10 mm nut driver to loosen the nuts (reference 5 image 5-24). R59770374 DP-3000 01/06/2012...
Page 95 6. Loosen the four screws, one in each corner, at the bottom of the LPS rack (reference 1 image 5-25). Use a 3 mm Allen wrench. Image 5-25 7. Hold the LPS rack by its handles at the top and remove it from the base. R59770374 DP-3000 01/06/2012...
Page 96: Replacement Of The Lps Communication Interface
4. Remove the LPS communication interface by loosening the ﬁve Torx screws (reference 1 image 5-28) as illustrated. Use a T10 Torx screwdriver. 5. Install a new LPS communication interface. Make sure to place plastic washers (reference 2 image 5-28) at both sides of the PCB board. R59770374 DP-3000 01/06/2012...
Page 97 5. Power Unit Image 5-28 6. Reconnect the CTRL wire unit and the temperature sensor. 7. Reconnect the data cable with the D-SUB socket. 8. Reinstall the cover. R59770374 DP-3000 01/06/2012...
Page 98: Replacement Of The Mains Filter
Always connect the ground wire (PE, reference 5 image 5-30) with the ground pin of the Mains Filter. EU US Image 5-30 5. Reconnect the wires from the LPS modules with the output pins of the Mains Filter as illustrated. R59770374 DP-3000 01/06/2012...
Page 99 6. Fasten the nuts on the all input and output pins of the Mains Filter with a torque of 3 Nm (2,2 lbf*ft). Make sure to place a washer (reference 2 image 5-32) between the wire lug (reference 1 image 5-32) and the nut (reference 3 image 5-32). Use a torque wrench with a 10 mm hexagon socket. Image 5-32 R59770374 DP-3000 01/06/2012...
Page 100: Installing The Lps Rack Upon The Base Of The Power Unit
Make sure to place the washers and cable eyes in correct order upon the pin as illustrated in image 5-34. First the wire lugs (reference 1), then the plane washers (reference 2), then the lock washers (reference 3) and ﬁnally the nuts (reference 4). R59770374 DP-3000 01/06/2012...
Page 101 LPS rack. Image 5-35 6. Install the front and rear cover of the Power Unit. Use a 3 mm Allen wrench to fasten the 5 screws (reference 1 & 2 image 5-36) per cover. R59770374 DP-3000 01/06/2012...
Page 102 5. Power Unit Image 5-36 R59770374 DP-3000 01/06/2012...
Page 103: Start Pulse Generator
This chapter describes brieﬂy the functionality, the different parts and the replacement procedure of the Start Pulse Generator (SPG) module. Overview • Introduction • Troubleshooting • Removal of the Start Pulse Generator • Installation of the Start Pulse Generator R59770374 DP-3000 01/06/2012...
Page 104: Introduction
Red marked cable lug. Has to be connected with the positive “LAMP OUT” pin of the LPS modules. Black marked cable lug. Has to be connected with the negative “LAMP OUT” pin of the LPS modules. Retaining ﬁxation screws. Ferrite block. R59770374 DP-3000 01/06/2012...
Page 105: Troubleshooting
Replace the LPS module. The diagnostic LED’s of the LPS module indicates a problem with the LPS module. Note: The ambient noise must be low to hear the SPG clicking in an attempt to ignite the lamp. R59770374 DP-3000 01/06/2012...
Page 106: Removal Of The Start Pulse Generator
2. Disconnect the SPG power cables from the Terminal Block. Use a 5mm Allen wrench. 3. Remove the SPG module from the projector by releasing the four retaining screws. Use a 8 mm nut driver. Image 6-3 R59770374 DP-3000 01/06/2012...
Page 107: Installation Of The Start Pulse Generator
Respect the polarity of the SPG power cables. Make sure that the head of the ferrule is completely inserted in the Terminal Block. Warning: There must be 1 cm space between the housing of the Terminal Blocks. Note: The electrical high power connections of the Terminal Blocks must be checked on a yearly bases. R59770374 DP-3000 01/06/2012...
Page 108 Image 6-6 5. Loosen the four retaining screws, which you fastened in step 1, one turn. 6. Install the Lamp House. See "Installing the Lamp House", page 121. 7. Fasten the four retaining screws of the LPS module. R59770374 DP-3000 01/06/2012...
Page 109: Lamps And Lamp House
About this chapter This chapter enumerates all the supported xenon lamps for the DP-3000 digital projector and how to replace the xenon lamp in the Lamp House. Also included are the procedure to reset the lamp parameters, which is required after a xenon lamp replacement, and the procedure to realign the lamp in its reﬂector for optimal performance.
Page 110: Introduction
170 ampere. The maximum light produced by the xenon lamp inside the DP-3000 digital projector is roughly 250000 lumens. The xenon lamp is safely sheltered inside the Lamp House. The Lamp House exist in a reﬂector, a UV blocker, a lamp anode socket, a lamp cathode socket, a Lamp Info module, an adjustable arc stabilizing magnet and an XYZ-adjustment mechanism to align the lamp in the reﬂector.
Page 111 The xenon lamp is packed in a protective container or wrapped in a protective cloth. Never remove this protective container or protective cloth without wearing adequate protective clothing (face chield, clean cotton glovers, welder’s jacket). Image 7-3 R59770374 DP-3000 01/06/2012...
Page 112: Supported Xenon Lamps For The Dp-3000
7. Lamps and Lamp House Supported xenon lamps for the DP-3000 Anode and cathode lamp adapters are used to position the arc of the xenon lamp in the middle of the reﬂector inside the lamp house. The size of the xenon lamp vary from type to type. Because of that different lamp adapters are required.
Page 113 (reference 3 image 7-4) which has to be used with some xenon lamps supported with a three legs spider assembly, is replaced with an anode adaptation bushing (reference 4 image 7-4) in case of an integrated anode support. Image 7-4 Anode adapters, adaptation ring and adaptation bushing R859986K R859985K R859987K R842215K R864132K Image 7-5 R59770374 DP-3000 01/06/2012...
Page 114 7. Lamps and Lamp House Cathode adapters R8436101K R8436081K R859984K R8436111K R8436061K Image 7-6 R59770374 DP-3000 01/06/2012...
Page 115: Removing The Lamp House
Grip the lamp house by the bottom handle and partially slide it out of the lamp compartment. Grip the lamp house by both handles and remove the lamp house completely from the projector. Place the lamp house on a stable support. Warning: Be aware of the weight of the lamp house. R59770374 DP-3000 01/06/2012...
Page 116 7. Lamps and Lamp House Image 7-9 R59770374 DP-3000 01/06/2012...
Page 117: Removal Of The Xenon Lamp
How to remove the xenon lamp out of the Lamp House? 1. Remove the side cover of the Lamp House by releasing the two quarter turn screws (reference 1 image 7-10) at the bottom of the side cover as illustrated. Image 7-10 R59770374 DP-3000 01/06/2012...
Page 118 Place the ﬂat washers (reference 6 & 7 image 7-11) and nut back on the rod after the lug is removed. Note: The most recent Lamp Houses for the DP-3000 makes it possible to remove the anode socket together with the xenon lamp from the Lamp House.
Page 119 8. Remove the adapter(s) from the xenon lamp by releasing the hexagon socket head set screw of the lamp adapter as illustrated. Use for that a 2,5 mm Allen wrench. Image 7-17 Reinstall the UV blocker assembly and the side cover in case you do not intend to install another xenon lamp immediately in the Lamp House. R59770374 DP-3000 01/06/2012...
Page 120: Installation Of The Xenon Lamp
ﬂat surface and the lamp base. Note that some lamp types have a cathode pin with screw threat. Tip: See chapter "Supported xenon lamps for the DP-3000", page 108, to know which cathode adapter your lamp requires. Warning: Install the cathode adapter prior to removing the protective container or protective cloth from the xenon lamp.
Page 121 Tip: See chapter "Supported xenon lamps for the DP-3000", page 108, to know if your lamp requires an anode adapter. If yes, install the appropriate lamp anode adapter upon the anode of the xenon lamp. Fasten the set screw of the anode adapter with a torque of 2,5 Nm (1,84 lbf*ft).
Page 122 15 mm, outside diameter maximum 28 mm, and thickness 2,5 mm. Warning: A torque of 25Nm (18.4 lbf*ft) must be applied to fasten the nuts. Make sure that there is no tension on the anode wire of the xenon lamp. R59770374 DP-3000 01/06/2012...
Page 123 10.Install the side cover of the Lamp House and fasten the two quarter turn screws (reference 1 image 7-27) at the bottom of the cover. Note: Please ensure that the quarter turn screws turning wires are ﬂush with the cover or interference will occur while inserting the Lamp House into the projector. R59770374 DP-3000 01/06/2012...
Page 124 Lamp House. Neglecting this update will result in poor performance and short life time of the xenon lamp. A realignment of the xenon lamp in its reﬂector is required after the installation of the xenon lamp in the Lamp House. R59770374 DP-3000 01/06/2012...
Page 125: Installing The Lamp House
3. Push the Lamp House fully into the slots. 4. Secure the position of the Lamp House by fastening the two retaining screws at the base of the Lamp House as illustrated. Use for that a 10 mm nut driver. Image 7-30 R59770374 DP-3000 01/06/2012...
Page 126 Each xenon lamp replacement requires a reset of the lamp parameters. See procedure "Resetting the lamp parameters", page 123. To ensure maximum light output it is recommended to realign the lamp. See procedure "Realignment of the lamp in its Reﬂector", page 124. R59770374 DP-3000 01/06/2012...
Page 127: Resetting The Lamp Parameters
5. Fill out the serial number of the lamp (8). 6. Click Reset (9). Image 7-32 Reset lamp info AUTION For more information about using the Communicator Touch Panel consult the user’s guide of the Communicator Touch Panel. R59770374 DP-3000 01/06/2012...
Page 128: Realignment Of The Lamp In Its Reflector
Each xenon lamp installation requires a realignment of the lamp in its Reﬂector for optimal performance of the xenon lamp in the DP-3000 digital projector. Furthermore, it is recommended to realign the lamp after the ﬁrst run time of 100 and 200 hours. Especially the Z-axis of the lamp.
Page 129 Do this for each direction and minimum repeat this adjustment cycle twice. 7. Fasten the X-axis lock thumb screw (ref X ) and Y-axis lock thumb screw (ref Y Image 7-35 8. Switch off the projector. 9. Close and lock the door of the lamp compartment. R59770374 DP-3000 01/06/2012...
Page 130: Alignment Of The Arc Stabilizing Magnet
Due to the fact that this adjustment has almost no effect on the newer xenon lamps and the obsolescence of the welding glass, used in the viewport, Barco has decide to replace the welding glass with a sheet metal part in the Lamp Houses produced since March 2009.
Page 131 6. Install the cover of the stabilizing magnet and fasten the two captive screws as illustrated. Use a ﬂat blade screw driver. Image 7-39 7. Reinstall the rear cover and both side covers of the projector head. R59770374 DP-3000 01/06/2012...
Page 132: Replacement Of The Lamp Info Module
Image 7-43 Connections lamp info module on a second generation lamp house 3. Remove the Lamp Info module from the Lamp House by releasing the four spacers as illustrated. Use for that a 6 mm nut driver. R59770374 DP-3000 01/06/2012...
Page 133 1) from the Lamp House with the Lamp Info module. Respect the color marking on the connectors. 6. Reinstall the cover of the Lamp Info module as illustrated. Fasten with four screws (or short spacers) (reference 1). Image 7-46 Lamp info module on lamp house R59770374 DP-3000 01/06/2012...
Page 134 7. Lamps and Lamp House Image 7-47 Lamp info module on second generation lamp house R59770374 DP-3000 01/06/2012...
Page 135: Replacement Of The Uv Blocker
3. Support the xenon lamp inside the lamp house with one hand while removing the UV blocker assembly from the Lamp House. Note that some xenon lamps are installed with an anode adaptation bushing (reference 12 image 7-50). Caution: Ensure that you wear protective clothing, a full face shield and protective gloves. R59770374 DP-3000 01/06/2012...
Page 136 Note: One side of the UV blocker is marked with a white dot on the border. The UV blocker must be mounted so that the glass side with the white dot is the outer side of the Lamp House. 7. Fasten the three spacers which hold the UV blocker. Use a 2,5 mm Allen wrench. Image 7-53 R59770374 DP-3000 01/06/2012...
Page 137 10.Install the side cover of the Lamp House and fasten the two quarter turn screws (reference 1 image 7-57) at the bottom of the cover. Note: Please ensure that the quarter turn screws turning wires are ﬂush with the cover or interference will occur while inserting the Lamp House into the projector. R59770374 DP-3000 01/06/2012...
Page 138 7. Lamps and Lamp House Image 7-57 R59770374 DP-3000 01/06/2012...
Page 139: Replacement Of The Lamp Reflector
Place the plane washers (reference 6 & 7 image 7-59) and nut back on the rod after the lug is removed. Image 7-59 2. Remove the corner plate of the Lamp House as illustrated. Use a 2,5 mm Allen wrench to loosen the four screws (reference 1 image 7-60) which hold the plate. R59770374 DP-3000 01/06/2012...
Page 140 Lamp House. Image 7-62 5. Remove the Reﬂector assembly from the Lamp House by loosening the three hexagon socket head cap screws (reference 5 image 7-63) as illustrated. Use a 3 mm Allen wrench. R59770374 DP-3000 01/06/2012...
Page 141 The Lamp House is now ready to install an xenon lamp. See procedure "Installation of the xenon lamp", page 116. It is recommended for optimal performance to readjust the Cold Mirror after the replacement of the Lamp Reﬂector. See procedure "Adjusting the Cold Mirror", page 145. R59770374 DP-3000 01/06/2012...
Page 142: 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. R59770374 DP-3000 01/06/2012...
Page 143: Cleaning The Reflector Of The Lamp House
If no, wipe off the dust of the Reﬂector ﬁrst with a clean cotton cloth and demineralized water and than with a clean Torayse cloth. Tip: 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. R59770374 DP-3000 01/06/2012...
Page 144 7. Lamps and Lamp House R59770374 DP-3000 01/06/2012...
Page 145: Cold Mirror
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! Overview • Introduction • Replacement of the Cold Mirror • Adjusting the Cold Mirror • Cleaning the Cold Mirror R59770374 DP-3000 01/06/2012...
Page 146: Introduction
• 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. R59770374 DP-3000 01/06/2012...
Page 147: Replacement Of The Cold Mirror
4. Place the mounting parts and Cold Mirror upon the three rods in that order as illustrated. Note that the number and type of mounting parts on the lower rod are slightly different than those on the upper two rods. Caution: Do not touch the new Cold Mirror with bare ﬁngers. Wear latex or cotton gloves. R59770374 DP-3000 01/06/2012...
Page 148 6. Check the Cold Mirror for dirt. If necessary clean the Cold Mirror. See cleaning procedure "Cleaning the Cold Mirror", page 147. 7. Adjust the Cold Mirror for optimal performance. See adjustment procedure "Adjusting the Cold Mirror", page 145. R59770374 DP-3000 01/06/2012...
Page 149: Adjusting The Cold Mirror
Adjust the Lamp House ﬁrst in another projector, which Cold Mirror is correctly adjusted, or have it aligned by Barco before proceeding with the Cold Mirror adjustments. That way any Lamp House will be usable in that projector, or all others, and vise versa.
Page 150 (hold on the screws while securing the nuts). 9. Secure the position of the xenon lamp in its Reﬂector by turning the X and Y axis lock thumb screws (reference LX & LY image 8-7) of the Lamp House. R59770374 DP-3000 01/06/2012...
Page 151: Cleaning The Cold Mirror
2. Is all dust removed from the Cold Mirror? If yes, stop this cleaning procedure. If no, wipe off the dust of the Cold Mirror with a clean cotton cloth and demineralized water. Tip: Use isopropanol alcohol instead of demineralized water to remove ﬁngerprints. R59770374 DP-3000 01/06/2012...
Page 152 8. Cold Mirror R59770374 DP-3000 01/06/2012...
Page 153: Integration Rod
This chapter describes brieﬂy the functionality of the Integration Rod, how to diagnose the Integration Rod, how to replace the Integration Rod and how to adjust the Integration Rod. Overview • Introduction • Integration Rod diagnostic • Removal of the Integration Rod assembly • Installing a new Integration Rod assembly • Adjusting the Integration Rod R59770374 DP-3000 01/06/2012...
Page 154: Introduction
Rod assembly positioning pin for cooling block. Never touch the entrance or exit of the Integration Rod assembly. Greasy ﬁngerprints or other dirt AUTION on the Integration Rod entrance or exit will burn into the rod and cause permanent damage. R59770374 DP-3000 01/06/2012...
Page 155: Integration Rod Diagnostic
5. Do you see spots in the projected image rotate along with the movements of the rod? If yes, these spots are caused by damages to the Integration Rod. Replace the rod assembly. If no, Integration Rod is OK. Re-adjust and secure the Integration Rod and reinstall the side cover of the projector. R59770374 DP-3000 01/06/2012...
Page 156: Removal Of The Integration Rod Assembly
3. Remove the socket head cap screw (reference 3) as illustrated. Use a 2,5 mm Allen wrench. Image 9-6 4. Pull the Integration Rod assembly out of the light pipe. Do not keep the Light Pipe entrance open (no Integration Rod installed) for a long period. This to prevent dust intrusion. R59770374 DP-3000 01/06/2012...
Page 157: Installing A New Integration Rod Assembly
5. Rotate the Integration Rod until the set screws (reference 2 image 9-8) of the Light Pipe are aligned with the set screw (reference 3 image 9-8) of the Integration Rod assembly as illustrated. Image 9-8 6. Fasten the set screws (reference 2 image 9-9). Use a 2 mm Allen wrench. R59770374 DP-3000 01/06/2012...
Page 158 7. Install the cooling block with two hexagon screws (reference 4 image 9-10) as illustrated. Use a 2,5 mm Allen wrench. Caution: Align the positioning pin (reference 5 image 9-10) of the Integration Rod with its corresponding slot on the cooling block while approaching the Integration Rod. Image 9-10 The Integration Rod must be adjusted after installation. R59770374 DP-3000 01/06/2012...
Page 159: Adjusting The Integration Rod
Place a 2 mm Allen wrench in one of the holes on the outer side of the adjustment ring. The Allen wrench function as an extension bar of the adjustment ring. This allows a more precise adjustment. Image 9-13 7. Fasten the rod focus set screw (reference 2 image 9-12) which you released in step 2. R59770374 DP-3000 01/06/2012...
Page 160 Then rotate the Integration Rod back until the projected light beam matches the projected outline of the DMD’s. This way of focusing the Integration Rod has to be done quickly. Otherwise, the sealing between the DMD’s and the prism will be damaged. R59770374 DP-3000 01/06/2012...
Page 161: Sealed Light Processor Assembly
Adjusting the Light Pipe Zoom Lens • Adjusting the Notch Filter • Cleaning the Notch Filter • Cleaning the Prism exit side • Replacement of the Dowser (Shutter) • Replacement of the Light Sensor Module • Replacement of the Notch Filter R59770374 DP-3000 01/06/2012...
Page 162: Introduction
DMD’s. Image 10-1 Note that the Light Processor and Light Pipe assembly includes: Light Processor, Light Pipe, cooling circuit for the DMD’s and light pipe entrance, Integration Rod, Formatter Interface Board (FIB) and motorized shutter (dowser). R59770374 DP-3000 01/06/2012...
Page 163 Sealed compartment. Includes Light Processor (prism + DMD’s) and Formatter Interface Board (FIB). Cooling block for the Integration Rod entrance. Shutter assembly (Dowser). Notch ﬁlter. CLO assembly. Light Pipe assembly. Includes Integration Rod. Integration Rod assembly. Adjustment handle of the Light Pipe zoom lens. R59770374 DP-3000 01/06/2012...
Page 164: Diagnostics
Blocked dowser (shutter). Dowser does not respond when pressing the “PAUSE” button. • Leakage in liquid cooling circuit. Check the projector log ﬁles for errors or warnings and look for a solution in the chapter "Trouble shooting checklist", page 37. R59770374 DP-3000 01/06/2012...
Page 165: Removal Of The Sealed Light Processor
4. Disconnect the three wire units (reference 1, 2 & 3 image 10-5) of the dowser (shutter) from the lens distribution board. Note: Former projector versions only have one wire unit (reference 1 image 10-5) for the dowser. Newer versions have three wire units. R59770374 DP-3000 01/06/2012...
Page 166 Sometimes a little cooling liquid will be spilled. Wrap a small cloth around the valved ﬁtting while uncoupling to absorb the spilled cooling liquid. Image 10-7 7. Release the two retaining screws (reference 3 image 10-8) at the bottom of the Sealed Light Processor. Use for that a ﬂat screwdriver or a 10 mm nut driver. R59770374 DP-3000 01/06/2012...
Page 167 8. Gently remove the Sealed Light Processor out of its compartment. Image 10-9 AUTION Never open the sealed compartment of the Light Processor unit. Always send the Sealed Light Processor as a whole back to factory for repair. R59770374 DP-3000 01/06/2012...
Page 168: Installation Of The Sealed Light Processor
Remove the left projector cover. Remove the Light Processor. Cut the cable tie (reference 1, image 10-10) and remove the clamp (reference 2, image 10-10) by ﬁrst removing the screw. Use a T10 Torx screwdriver. Image 10-10 R59770374 DP-3000 01/06/2012...
Page 169 Note that the bottom of the Sealed Light Processor is equipped with guides and positioning pins. Image 10-11 Fasten the two retaining screws (reference 3 image 10-12) at the bottom of the Sealed Light Processor as illustrated. Use for that a ﬂat screwdriver or a 10 mm nut driver. Image 10-12 R59770374 DP-3000 01/06/2012...
Page 170 Plug with two pins and orange wire into J62 (reference 3 image 10-14) Note: Former projector versions only have one wire unit ((reference 1 image 10-14) for the dowser. Newer versions have three wire units. Image 10-14 Newer version. R59770374 DP-3000 01/06/2012...
Page 171 Reconnect the wire (reference 4 image 10-15) unit of the Light Sensor (CLO) which is located at the left side of the Light Pipe. Image 10-15 Reconnect the wire (reference 4 image 10-16) unit of the Light Sensor (CLO) which is located at the left side of the Light Pipe. Image 10-16 Install the cross bar as illustrated. Image 10-17 R59770374 DP-3000 01/06/2012...
Page 172 Remove the Light Processor and proceed with the next stage (How to loosen the ﬁxation screws of the backplane?). Image 10-19 (If the check failed) How to loosen the ﬁxation screws of the backplane? For more detailed information about the steps below, consult the service manual of your projector. R59770374 DP-3000 01/06/2012...
Page 173 3 screws in the lower part of the Card Cage (reference 5, image 10-20). Image 10-20 Tip: Ensure you did not forget any screw by ﬁddling at the backplane. It should move a little bit. Try to install the Sealed Light Processor again. R59770374 DP-3000 01/06/2012...
Page 174 Install all boards back in the Card Cage. Install the Card Cage cover. Install the right cover of the projector. Install the top cover of the projector. Install the exhaust system on top of the projector. Plug the power cord back in. R59770374 DP-3000 01/06/2012...
Page 175: Adjusting The Convergence
2. To translate RED vertically in the Y - direction, turn both [1] and [2] anti-clockwise. Turn screws in equal increments. 3. To translate RED horizontally in the X + direction, turn [3] clockwise. 4. To translate RED horizontally in the X - direction, turn [3] anti-clockwise. R59770374 DP-3000 01/06/2012...
Page 176: Converging The Green Pattern Onto The Blue Pattern
Slight corrections to Y may be required after rotation. 5. To translate GREEN horizontally in the X + direction, turn [6] clockwise. 6. To translate GREEN horizontally in the X - direction, turn [6] anti-clockwise. R59770374 DP-3000 01/06/2012...
Page 177 10. Sealed Light Processor Assembly Green Image 10-23 R59770374 DP-3000 01/06/2012...
Page 178: Adjusting The Fold Mirror
Projecting a misaligned light spot for more then 10 seconds may cause irreversible damage to the Light Processor. Therefore, it is important to maximum dim the light output and adjust the light spot as quickly as possible. R59770374 DP-3000 01/06/2012...
Page 179 Turn the three adjustment screws of the Fold Mirror equally counterclockwise to achieve a higher contrast of the projected image. Then, readjust the adjustment screws individual until the light spot matches with the outline of the DMDs. Take into account that a higher contrast is at the expense of brightness. R59770374 DP-3000 01/06/2012...
Page 180: Adjusting The Light Pipe Zoom Lens
(reference 2) matches the projected outline (reference 3) of the DMDs upon the screen (reference 4). Image 10-27 4. Fasten the hexagon socket head cap screw. User a 2,5 mm Allen wrench. R59770374 DP-3000 01/06/2012...
Page 181: Adjusting The Notch Filter
5. Fasten the lock nut, reference 1 of image 10-29, to secure the position of the Notch Filter. Use for that a 6 mm open-end wrench. Make sure that the position of the Notch Filter remains unchanged while fastening the lock nut. R59770374 DP-3000 01/06/2012...
Page 182: Cleaning The Notch Filter
2. Is all dust removed from the Notch Filter? If yes, stop this cleaning procedure. If no, wipe off the dust of the Notch Filter with a clean cotton cloth and demineralized water. Tip: Use isopropanol alcohol instead of demineralized water to remove ﬁngerprints. R59770374 DP-3000 01/06/2012...
Page 183: Cleaning The Prism Exit Side
2. Is all dust removed from the Prism exit? 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. R59770374 DP-3000 01/06/2012...
Page 184: Replacement Of The Dowser (Shutter)
2. Make sure that the mounting holes M1 and M2 (image 10-30) on the Sealed Light Processor are free. Image 10-30 3. Fasten the new Dowser with two Torx screws (A) upon the Sealed Light Processor as illustrated. Use for that a TX10 Torx screwdriver. Image 10-31 R59770374 DP-3000 01/06/2012...
Page 185: Replacement Of The Light Sensor Module
4. Reconnect the wire unit (reference 4 image 10-32) with Light Sensor Module. 5. Place a light meter in the center of the screen and calibrate the Light Sensor Module. For detailed instructions see user guide of the Communicator software. R59770374 DP-3000 01/06/2012...
Page 186: Replacement Of The Notch Filter
Do not touch the Notch Filter with bare ﬁngers. To clean the Notch Filter see procedure "Cleaning the Notch Filter", page 178. 3. Fasten the Notch Filter with four hexagon head cap screws (reference 1). Use for that a 2,5 mm Allen wrench. 4. Readjust the Notch Filter. See procedure "Adjusting the Notch Filter", page 177. R59770374 DP-3000 01/06/2012...
Page 187: Liquid Cooling Circuit
Do not change the air pressure of a calibrated Liquid Cooling Circuit (see marking on pressure vessel), unless stated explicitly in the servicing procedure. 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. ARNING Hazardous product: Blue antifreeze diluted 1,2 ethanediol (1/3 ethanediol –...
Page 188: Introduction
Parts of the Liquid Cooling Circuit Image 11-1 Sealed Light Processor. Outlet of the cooling circuit. Pressure vessel. Transparent tube for visual check. Manometer. Fan assembly. Heat exchanger. Cooling block Light Pipe Entrance. Valve. Inlet of the cooling circuit. Cooler pump. R59770374 DP-3000 01/06/2012...
Page 189 Empty bottle with a volume of 1 liter. Air pump with Shrader type air hose ﬁtting. AUTION To avoid damage to the connector seal, always depress the connector tab of the female valved ﬁtting prior to inserting the male valved ﬁtting. R59770374 DP-3000 01/06/2012...
Page 190: Diagnostics
No custom serviceable parts inside the Sealed Light Processor. DMD is too high in temperature while the other two DMD’s Take contact with a Barco service center to return the Sealed have a normal and almost equal temperature. Light Processor.
Page 191 Drain the Liquid Cooling Circuit, replace the pump, ﬁll and vibrations when touching the pump. pressurize the Liquid Cooling Circuit. Tip: It’s not necessary to drain the cooling circuit of the Sealed Light Processor. Bypass this part of the cooling circuit. R59770374 DP-3000 01/06/2012...
Page 192: Pressure Verification Of The Liquid Cooling Circuit
4. This pressure should be between 0,5 and 1 bar. If the pressure, indicated on the manometer, is out of range take necessary corrective action. Image 11-3 5. Close and lock the door of the projector. R59770374 DP-3000 01/06/2012...
Page 193: Excluding The Sealed Light Processor
4. You may connect the tube which comes from the cooling block on the Light Pipe entrance with the unused valved ﬁtting of the Sealed Light Processor. This to prevent that the tube is hanging loose. AUTION Do not forget to include the cooling circuit of the Sealed Light Processor afterwards. R59770374 DP-3000 01/06/2012...
Page 194: Draining The Liquid Cooling Circuit
Note: Circuit is pressurized, so ﬁrst insert tube end into empty bottle. Image 11-6 2. Close the valve. Image 11-7 3. Fill the syringe with air. Press in the valve of the male ﬁtting when extracting air. Image 11-8 R59770374 DP-3000 01/06/2012...
Page 195 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 11-9 5. Disconnect the syringe from the cooling circuit and repeat from 3 until all cooling liquid is drained. R59770374 DP-3000 01/06/2012...
Page 196: Filling The Liquid Cooling Circuit
2. Couple a plastic tube, which contains a male valved ﬁtting, to the outlet of the cooling circuit and lead the tube end to an empty bottle. Image 11-11 3. Fill the syringe with cooling liquid as follows: R59770374 DP-3000 01/06/2012...
Page 197 Position the empty bottle above the liquid circuit (on top of projector). Image 11-13 5. Disconnect the syringe from the cooling circuit and repeat from 3 until cooling liquid comes out the outlet of the cooling circuit. R59770374 DP-3000 01/06/2012...
Page 198 6. Proceed with expelling the air from the Liquid Cooling Circuit. See procedure "Expelling air from the Liquid Cooling Circuit", page 197. Tip: You can use the bottle with the remaining fresh cooling liquid and the same tubes for the expelling procedure. 7. Pressurize the Liquid Cooling Circuit. See procedure "Pressurizing the Liquid Cooling Circuit", page 199. R59770374 DP-3000 01/06/2012...
Page 199: Refreshing 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. R59770374 DP-3000 01/06/2012...
Page 200 7. Proceed with expelling the air from the Liquid Cooling Circuit. See procedure "Expelling air from the Liquid Cooling Circuit", page 197. Tip: You can use the bottle with the remaining fresh cooling liquid and the same tubes for the expelling procedure. 8. Pressurize the Liquid Cooling Circuit. See procedure "Pressurizing the Liquid Cooling Circuit", page 199. R59770374 DP-3000 01/06/2012...
Page 201: Expelling Air From The Liquid Cooling Circuit
3. Push the male valved ﬁtting of the ﬁlled tube into the inlet of the cooling circuit. Make sure that the inlet of the ﬁlled tube remains immersed. 4. Couple a second plastic tube to the outlet of the cooling circuit and immerge the tube end without ﬁtting in the same bottle wherein the ﬁrst tube is immersed. R59770374 DP-3000 01/06/2012...
Page 202 Sometimes a little cooling liquid will be spilled. Wrap a small cloth around the valved ﬁtting while uncoupling to absorb the spilled cooling liquid. 9. Pressurize the Liquid Cooling Circuit. See procedure "Pressurizing the Liquid Cooling Circuit", page 199. Check within 24 hours if the pressure remains 1 bar. If not, search for leakage. R59770374 DP-3000 01/06/2012...
Page 203: Pressurizing The Liquid Cooling Circuit
2. Couple the syringe to the inlet of the cooling circuit and press the cooling liquid inside the circuit until the manometer indicates 1 bar pressure. Ensure that no air bubbles are injected into the circuit. Caution: Maximum 1 bar of pressure is allowed on the Liquid Cooling Circuit. More pressure than 1 bar may damage the circuit. R59770374 DP-3000 01/06/2012...
Page 204 5. Disconnect the syringe from the cooling circuit. Make sure that the pressure remains 1 bar. 6. Check that the valve is open. Image 11-24 Check within 24 hours whether the pressure has stabilized close to 1 bar. If not, search for leakage. R59770374 DP-3000 01/06/2012...
Page 205: Calibrating The Liquid Cooling Circuit
Push the piston in until all air bubbles inside the syringe and tubes are expelled. Ensure that the tube end in the bottle remains emerged. e) Pull out the piston to ﬁll the tubes and syringe completely with cooling liquid. f) Disconnect the ﬁlled syringe from the tube. R59770374 DP-3000 01/06/2012...
Page 206 Release the plunger. Note that cooling liquid is pressed into syringe while the pressure drops. d) Now ﬁll the syringe by slowly pumping air into the vessel (connect air pump to valve). e) Stop once 75 ml has been expelled. f) Disconnect the syringe from the cooling circuit. R59770374 DP-3000 01/06/2012...
Page 207 Presta valve type (B) has to be removed. Futhermore, the pin (C) inside the Shrader valve has to be removed as well. Check within 24 hours whether the pressure has stabilized close to 1 bar. If not, search for leakage. R59770374 DP-3000 01/06/2012...
Page 208: Removal Of The Pump
Pump is required to replace the Cathode Fan. Image 11-32 2. Release the Manifold of the Liquid Cooling Circuit by loosening the two hexagon socket head cap screws (reference 2 im- age 11-33). Use a 3 mm Allen wrench. R59770374 DP-3000 01/06/2012...
Page 209 5. Gently pull the Pump with tubing out of its compartment as illustrated. Note: The Mains Input Filter must be removed prior to removing the Pump. Otherwise, the Mains Input Filter gets in the way of the Pump’s tubing. R59770374 DP-3000 01/06/2012...
Page 210 11. Liquid Cooling Circuit Image 11-36 6. Disconnect the wire unit (reference 1 image 11-37) of the Pump. Image 11-37 The Pump is now accessible for maintenance or for replacement. R59770374 DP-3000 01/06/2012...
Page 211: Installing The Pump
3. Fasten the two screws (reference 3 image 11-40) of the Pump. Use a T20 Torx driver. The plain washers and ﬁxation screws must be captured by the provided slots in the metal mounting plate as illustrated. R59770374 DP-3000 01/06/2012...
Page 212 6. Secure the valve of the Liquid Cooling Circuit with two cable ties (reference 1 image 11-43) as illustrated. 7. Attach the tube (reference 2 image 11-43) of the Liquid Cooling Circuit with a cable tie to the assembly of the Cathode Fan (reference 3 image 11-43). R59770374 DP-3000 01/06/2012...
Page 213 Sealed Light Processor, and Lamp House has to be reinstalled. See the corresponding chapters of the in- volved parts for detailed installation instructions. Prior to inserting the Lamp House check if the Liquid Cooling Circuit is ﬁlled and pressurized. See procedure "Filling the Liquid Cooling Circuit", page 192. R59770374 DP-3000 01/06/2012...
Page 214: Cleaning The Pump
Caution: Make sure the sealing ring of the Pump motor is not damaged and is on its place. 7. Fasten the four screws (reference 1 image 11-44) of the Pump house crosswise using a PH2 Phillips screwdriver. R59770374 DP-3000 01/06/2012...
Page 215 Reinstall the Pump (see "Installing the Pump", page 207) and reﬁll the Liquid Cooling Circuit (see "Filling the Liquid Cooling Circuit", page 192) in case the pump is successfully cleaned. If cleaning is not possible, replace the pump completely. See "Replacement of the complete Pump", page 214. R59770374 DP-3000 01/06/2012...
Page 216: Replacement Of The Pump Motor And Rotor
Pump rotor (reference 3 image 11-46) and the inner side of the Pump motor (reference 4 image 11-46) are visible. Image 11-46 3. Replace the Pump motor and Pump rotor. Image 11-47 4. Clean the Pump house with a clean soft cloth. Use cotton swabs to clean the bearing of the Pump house. R59770374 DP-3000 01/06/2012...
Page 217 Image 11-48 Reinstall the Pump (see "Installing the Pump", page 207) and reﬁll the Liquid Cooling Circuit, then expel all air from the circuit and ﬁnally pressurize the cooling circuit. See "Filling the Liquid Cooling Circuit", page 192. R59770374 DP-3000 01/06/2012...
Page 218: Replacement Of The Complete Pump
5. Reinstall the rubber vibration rings (feet, reference 3 image 11-50) of the old Pump upon the new Pump. Use a T20 Torx driver and a 7 mm open-end wrench. Image 11-50 R59770374 DP-3000 01/06/2012...
Page 219 11. Liquid Cooling Circuit Reinstall the Pump (see "Installing the Pump", page 207) and reﬁll the Liquid Cooling Circuit, then expel all air from the circuit and ﬁnally pressurize the cooling circuit. See "Filling the Liquid Cooling Circuit", page 192. R59770374 DP-3000 01/06/2012...
Page 220: Replacement Of The Heat Exchanger
Three at the top and two at the bottom of the assembly. Use a 3 mm Allen wrench. Note: The Heat Exchanger assembly remains attached to the projector with the tubes of the Liquid Cooling Circuit. Image 11-52 4. Remove the tubes (reference 4 & 5) from the Heat Exchanger. R59770374 DP-3000 01/06/2012...
Page 221 10.Reinstall the temperature sensor as illustrated in image 11-51 (reference 1). Proceed with reﬁlling the Liquid Cooling Circuit, then expel all air from the circuit and ﬁnally pressurize the cooling circuit. See "Filling the Liquid Cooling Circuit", page 192. R59770374 DP-3000 01/06/2012...
Page 222 11. Liquid Cooling Circuit R59770374 DP-3000 01/06/2012...
Page 223: Lenses And Lens Holder
Removal of the Lens Holder • Installation of the Lens Holder • Replacement of the vertical shift motor • Replacement of the horizontal shift motor • Replacement of the focus motor • Replacement of the Lens Signal Distribution board R59770374 DP-3000 01/06/2012...
Page 224: Introduction
Adjustment screw to tilt the Lens Holder front plate (Scheimpﬂug). Lens Holder zoom motor. AUTION The adjustment screws the motorized vertical shift, horizontal shift and focus adjustment may only be used in case the corresponding motor fails. Always turn these adjustment screws very slowly! R59770374 DP-3000 01/06/2012...
Page 225 12. Lenses and Lens Holder Location of the Lens Holder motors Image 12-2 Lens Holder vertical shift motor. Lens Holder horizontal shift motor. Lens Holder zoom motor. R59770374 DP-3000 01/06/2012...
Page 226: Available Lenses
12. Lenses and Lens Holder 12.2 Available lenses Which lenses are available for my projector? The table below is subject to changes and was last updated on 01/06/2012. Consult my.barco.com for the most recent information about available lenses. Product Number...
Page 227 12. Lenses and Lens Holder Image 12-9 Image 12-10 Image 12-11 R9855946 R9855947 R9856294 Image 12-12 Image 12-13 R9856297 R9856300 R59770374 DP-3000 01/06/2012...
Page 228: Lens Selection
2. Login on my.barco.com. If you are not yet registered click on Sign up for my.barco.com and follow the instructions. With the created login and password, it is possible to enter the my.barco.com. When your login is correct, the my.barco.com start page is displayed.
Page 229: Lens Installation
7. Secure the Lens in the Lens Holder by sliding the Lens lock handle to the right as illustrated. Ensure the Lens touches the front plate of the Lens hHolder. Image 12-17 8. Check if the Lens is really secured by trying to pull the lens out of the Lens Holder. R59770374 DP-3000 01/06/2012...
Page 230 12. Lenses and Lens Holder AUTION Never transport the projector with a Lens mounted in the Lens Holder. Always remove the Lens before transporting the projector. Neglecting this can damage the Lens Holder and Prism. R59770374 DP-3000 01/06/2012...
Page 231: Lens Removal
It’s recommended to place the foam rubber of the original projector packaging, back in the Lens opening to prevent intrusion of dust. Note that this foam rubber is packed in a plastic bag to prevent the dust, emitted by the foam, from entering the projector. R59770374 DP-3000 01/06/2012...
Page 232: 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. R59770374 DP-3000 01/06/2012...
Page 233: Adjusting The Lens Holder
5. Adjust with the Lens zoom and Lens shift controls for optimal image matching on the screen. Tip: For optimal image quality is recommended to tilt the projector forward to obtain an on-axis projection instead of shifting the image downwards. R59770374 DP-3000 01/06/2012...
Page 234 If not, turn the adjustment screw in the opposite direction and check again. Note: A simultaneous readjustment of the focus will be necessary to get the mid left and mid right of the projected pattern equally focused as the centre. R59770374 DP-3000 01/06/2012...
Page 235 6. Fasten the four lock screws (reference A, B, C and D of image 12-25) of the Lens Holder adjustment mechanism. Use for that a 8 mm nut driver. As a result, the positions of the Swing and Tilt mechanisms are secured. Image 12-25 7. Reinstall the front and side cover of the projector. R59770374 DP-3000 01/06/2012...
Page 236: Removal Of The Lens Holder
2. Loosen the GND wire lug (reference 3) from the projector chassis. Use a T20 Torx screwdriver. Image 12-27 3. Remove the 8 hexagon socket head cap screws (reference 1) which are located at the bottom of the projector base and secure the Lens Holder. Use a 3 mm Allen wrench. R59770374 DP-3000 01/06/2012...
Page 237 12. Lenses and Lens Holder Image 12-28 4. Lift up the Lens Holder and remove it from the projector base. R59770374 DP-3000 01/06/2012...
Page 238: Installation Of The Lens Holder
3. Reconnect the ﬂat cable (reference 1 image 12-30) with the Lens Signal Distribution board and secure the ﬂat cable on top of the Lens Holder (reference 2 image 12-30). Image 12-30 4. Connect the GND wire lug (reference 3) with the projector chassis as illustrated. Use a T20 Torx screwdriver. R59770374 DP-3000 01/06/2012...
Page 239 Proceed with reinstalling the bottom cover, the Sealed Light Processor and the Lens of the projector. See corresponding installation procedures. The Lens Holder has to be adjusted after installation. See procedure "Adjusting the Lens Holder", page 229. R59770374 DP-3000 01/06/2012...
Page 240: Replacement Of The Vertical Shift Motor
3. Loosen the set screw (reference 2 image 12-33) a few turns and remove the motor with wire unit. Image 12-33 4. Remove the bracket (reference 4 image 12-34) from the motor and reinstall it on the new motor. Use a PH0 Phillips screwdriver for the three screws (reference 5 image 12-34). R59770374 DP-3000 01/06/2012...
Page 241 Make sure the plain surface (reference 3 image 12-33) on the axis of the motor is facing the set screw. The small side of the bracket (reference 4 image 12-33) must mate with the frame of the Lens Holder. R59770374 DP-3000 01/06/2012...
Page 242: Replacement Of The Horizontal Shift Motor
Image 12-36 4. Remove the bracket (reference 4 image 12-37) from the motor and reinstall it on the new motor. Use a PH0 Phillips screwdriver for the three screws (reference 5 image 12-37). R59770374 DP-3000 01/06/2012...
Page 243 Make sure the plain surface (reference 3 image 12-38) on the axis of the motor is facing the set screw. The small side of the bracket (reference 4 image 12-38) must mate with the frame of the Lens Holder. Image 12-38 R59770374 DP-3000 01/06/2012...
Page 244: Replacement Of The Focus Motor
Note: You have to turn the Lens Holder to access the focus motor at the bottom side of the Lens Holder. 4. Loosen the set screw (reference 2 image 12-41) a few turns and remove the motor with wire unit. R59770374 DP-3000 01/06/2012...
Page 245 Make sure the plain surface (reference 3 image 12-43) on the axis of the motor is facing the set screw. The small side of the bracket (reference 4 image 12-43) must mate with the frame of the Lens Holder. Image 12-43 R59770374 DP-3000 01/06/2012...
Page 246: Replacement Of The Lens Signal Distribution Board
Reference 5 image 12-44: Connection with horizontal end stop switches. Reference 6 image 12-44: Connection with focus end stop switches. Reference 7 image 12-44: Connection with focus motor. 5. Reconnect the ﬂat cable (reference 8 image 12-44) with Lens Signal Distribution board. R59770374 DP-3000 01/06/2012...
Page 247: Card Cage
Overview • Introduction • Card Cage diagnostic • Removal of the Card Cage cover • Installation of the Card Cage cover • Authorization to clear security warning on DP-3000 • Replacement of a Card Cage board R59770374 DP-3000 01/06/2012...
Page 248: Introduction
Signal Distribution Backplane. Connection for Rack Control (Power Unit) SMPS CTRL board. SMPS PFC board. SMPS DCDC board. TI Cinema Processor board. TI Cinema Interface board (with GORE protection) Slot for the Input & Communication unit. Card Cage cover. R59770374 DP-3000 01/06/2012...
Page 249: Card Cage Diagnostic
Indicates that the +24V_ELEK supply is present on the SMPS CTRL board. Note that the +24V_ELEK supply is generated on the SMPS DCDC board and enters the SMPS CTRL board via the Power Backplane. The +3.3V, the +5V and the +12V power supplies are derived from the +24V_ELEK. R59770374 DP-3000 01/06/2012...
Page 250 This board (reference 3 image 13-4) generates the supply voltages for the projector electronics, for the pump of the liquid cooling circuit, for the thermoelectric cooling (TEC). The +12V_ACSAR is also generated on this board, but has currently no use (future expansion). R59770374 DP-3000 01/06/2012...
Page 251 Indicates that built-in diagnostic test failed. See System Status for details on which test failed. OFF = OK ; ON = FAIL TI Cinema Interface board The TI Cinema Interface board is enclosed with a GORE protection. There are no diagnostic LED’s visible on this board R59770374 DP-3000 01/06/2012...
Page 252: Removal Of The Card Cage Cover
T20 Torx driver for the two screws (reference 1 image 13-8) at the bottom corners and a PH1 Phillips screwdriver for the 5 black screws (reference 2 image 13-8) at the bottom center. 4. Remove the Card Cage cover away from the Card Cage. R59770374 DP-3000 01/06/2012...
Page 253 13. Card Cage Image 13-8 R59770374 DP-3000 01/06/2012...
Page 254: Installation Of The Card Cage Cover
4. Lower and secure the Control Panel. Use a ﬂat screw driver to fasten the two screws at the bottom corners of the Control Panel. Image 13-10 5. Reinstall the right side cover of the projector. 6. Execute the authorization process to clear the security warning. See procedure "Authorization to clear security warning on DP-3000", page 251. R59770374 DP-3000 01/06/2012...
Page 255: Authorization To Clear Security Warning On Dp-3000
13. Card Cage 13.5 Authorization to clear security warning on DP-3000 The authorization to clear the security warning on the DP-3000 digital projector has to be done after all covers of the projector are correct installed. Necessary tools • Security key (Dallas iButton®).
Page 256: Replacement Of A Card Cage Board
Note that the security kit is very sensitive. A small scratch will permanently disable the TI Cinema Interface board. Never try to dismantle the security kit. Consult Barco in case of damage. The security kit is needed to protect the decrypting key.
Page 257 TI ﬁrmware of all TI boards. See chapter "Updating TI Boards", page 255. At startup the projector will request an authorization because of the removal of the Card Cage cover. See procedure "Authorization to clear security warning on DP-3000", page 251. R59770374 DP-3000 01/06/2012...
Page 258 13. Card Cage R59770374 DP-3000 01/06/2012...
Page 259: Updating Ti Boards
Make a serial connection (RS232) • Make an Ethernet connection (10/100 BASE-T) • Installation of the new software release • Logging of the operation • Special functions • Factory Install Options • Recovery option - Stay in Boot option R59770374 DP-3000 01/06/2012...
Page 260: Installation Of The Update Package
14.1 Installation of the Update Package How to install? 1. Download the Update package from the secured Barco web site and copy this ﬁle (.zip format) into a new directory. 2. Unzip the package ﬁle into this directory. Image 14-1 Unzipped package ﬁle...
Page 261: Start Up The Update Program
2. Double click on DLP Cinema(TM) Firmware Installation Program v2.01(12).exe to start up the update program. Note: The version indication in the startup ﬁle can be different for other releases. The start up window will be displayed. Image 14-2 Start up of update program R59770374 DP-3000 01/06/2012...
Page 262: Make A Serial Connection (Rs232)
The connection will be established. A login message will be displayed. Click OK to continue. 5. Enter the userid and password. Image 14-4 Login window Defaults are: User Id: Service Password: Heal Thyself Both are case sensitive. When correct, the Current Projector Info of the selected projector will be ﬁlled out. R59770374 DP-3000 01/06/2012...
Page 263: Make An Ethernet Connection (10/100 Base-T)
2. Click in the IP address input ﬁeld and ﬁll out directly the IP address of the projector (1a). Note: The IP address must be the TI/Cinema IP address. To read out that address, look for the Cinema IP address via the touch panel or look for the TI IP address via the Communicator software. R59770374 DP-3000 01/06/2012...
Page 264 The program will prompt the user to login to the projector. 5. Enter the userid and password. Defaults are: UserId: Service Password: Heal Thyself Both are case sensitive. When correct, the Current Projector Info of the selected projector will be ﬁlled out. R59770374 DP-3000 01/06/2012...
Page 265: Installation Of The New Software Release
A browser window opens (2). 2. Browse to the directory that contains the Release to be installed. Note: The release ﬁles are indicated as .dlpcinema . 3. Click on the ﬁle to select (3) and click Open (4). R59770374 DP-3000 01/06/2012...
Page 266 Do not reset or switch off the projector during an installation operation. A reset during some operations may leave the affected board in the projector in a non-functional state, requiring factory recovery. In case of failures, always send a copy of this log ﬁle to your Barco representative. AUTION Log ﬁles are not saved automatically.
Page 267: Logging Of The Operation
14.6 Logging of the operation What is possible? The program maintains a log of all operations performed. To show this log, click on Show Log. Image 14-8 Show logging started The log window opens. Image 14-9 Log info R59770374 DP-3000 01/06/2012...
Page 268 Dump to ﬁle : the log will be dumped into a ﬁle on the hard disk. A name and location will be asked ﬁrst. • Clear log : the log will be cleared. All information will be removed. Log ﬁles are not saved automatically to disk. To save the ﬁle execute a Dump to ﬁle. R59770374 DP-3000 01/06/2012...
Page 269: Special Functions
Disk-Chip and install all ﬁles (no other ﬂash components are touched). This is intended for special ﬁle-system recovery only. (see note) Note : with these options you will loose all default MACRO, PCF and SCREEN ﬁles. These options should not be used. R59770374 DP-3000 01/06/2012...
Page 270: Factory Install Options
For special factory-install operations, select Factory Installation >> to open the dialog window to select the function to perform. Before click on Factory Installation, a connection to the projector must be present and a release ﬁle must be selected. R59770374 DP-3000 01/06/2012...
Page 271: Recovery Option - Stay In Boot Option
When the boot application is successfully started, a message will be displayed. The current projector info will indicated that the boot application is running. 3. Click on Select Release Installation ﬁle and select the release ﬁle. The content of the ﬁle will be displayed. 4. Click on Start Auto Install. R59770374 DP-3000 01/06/2012...
Page 272 14. Updating TI Boards Image 14-12 Start auto install of ARM application The veriﬁcation and installation process will be started. It installs the ARM_main_app. R59770374 DP-3000 01/06/2012...
Page 273: Input & Communication Unit
Overview • Introduction • Control ports of the DP-3000 digital projector • Data source input ports of the DP-3000 digital projector • About General Purpose Inputs & Outputs (GPIO) • Removal of the Input & Communication unit • Installation of the Input & Communication unit •...
Page 274: Introduction
The “DATA INPUT” board (DVI & HDSDI) is mounted with spacers upon the communication board and has its own board to board connector, which ﬁts directly into the signal backplane of the Card Cage. Parts location Image 15-1 Communication input interface board. RS232/422 + General purpose IN/OUT board. DVI input board. DIMM PC. Ethernet card. R59770374 DP-3000 01/06/2012...
Page 275 (not used) Image 15-2 Block diagram data input board (DVI & HDSDI) Data input Cinema input board Receiver Sender Receiver DVI (A) Receiver Sender Receiver DVI (B) FPGA HDSDI Receiver SMPTE 292 HDSDI Receiver SMPTE 292 Image 15-3 R59770374 DP-3000 01/06/2012...
Page 276: Control Ports Of The Dp-3000 Digital Projector
Ethernet network communication The DP-3000 digital projector can be connected to a LAN (local area network) using one of the 10/100 base T ports (reference C of image 15-4) on the communication interface. Once connected to the LAN, users are capable of accessing the projector from any location, inside or outside (if allowed) their company network using the control software (Communicator touch panel).
Page 277 This 25 pins D-SUB connector (reference E of image 15-4) must be connected, using a data cable which is delivered with the projector, with the power unit of the DP-3000 digital projector. Through this connection the projector can communicate with the power unit.
Page 278: Data Source Input Ports Of The Dp-3000 Digital Projector
15. Input & Communication unit 15.3 Data source input ports of the DP-3000 digital projector Location of the data source input ports Image 15-5 HDSDI input port for channel B. HDSDI input port for channel A. DVI input port for channel B.
Page 279: About General Purpose Inputs & Outputs (Gpio)
(edge transition at each vsync). Output transistor • Maximum output driving voltage : V = 70 V • Maximum current : I = 30 mA • Maximum power dissipation : 120 mW R59770374 DP-3000 01/06/2012...
Page 280 15. Input & Communication unit Output from projector Internal projector GPOut P GPOut P Max 120 mW GPOut N GPOut N Image 15-7 R59770374 DP-3000 01/06/2012...
Page 281: Removal Of The Input & Communication Unit
3. Disconnected the two grey ﬂat cables (reference 4) from the Control Panel and release the screws (reference 5) of the ferrite block assembly. Note: In case the ﬂat cables has to be replaced you must reuse the ferrite block which is mounted around the ﬂat cables. R59770374 DP-3000 01/06/2012...
Page 282 5. Release the four screws, which fasten the Input & Communication unit, as illustrated. Use a PH2 Phillips screwdriver. Image 15-12 6. Pull out the Input & Communication unit. Caution: Pay attention not to damage the two grey ﬂat cables, which are attached to the communication board. R59770374 DP-3000 01/06/2012...
Page 283 15. Input & Communication unit Image 15-13 R59770374 DP-3000 01/06/2012...
Page 284: Installation Of The Input & Communication Unit
3. Reconnect the two grey ﬂat cables (reference 5 image 15-16) with the Control Panel and fasten the ferrite block assembly with two nuts (reference 4 image 15-16). Use a 5,5 mm nut driver the fasten the nuts. R59770374 DP-3000 01/06/2012...
Page 285 5. Reinstall the cable clamp (reference 3 image 15-18) of the power socket. Image 15-18 6. Reconnect the power cord (reference 1 image 15-19), the “RACK CONTROL” cable (reference 2 image 15-19) and all other data source cables. R59770374 DP-3000 01/06/2012...
Page 286 15. Input & Communication unit Image 15-19 After the installation of the Input & Communication unit the Card Cage cover has to be installed. See proce- dure "Installation of the Card Cage cover", page 250. R59770374 DP-3000 01/06/2012...
Page 287: Replacement Of The Dvi Input Board
3. Remove the four Phillips screws ref C image 15-20 at the front side of the DVI input board. Image 15-20 4. Remove the ﬁve Torx screws, which fasten the DVI board with the communication interface, and remove the board. Image 15-21 5. Reverse this procedure to reinstall the DVI input board. R59770374 DP-3000 01/06/2012...
Page 288: Replacement Of The Gpio Board
TX10 Torx screwdriver. How to replace the GPIO board 1. Release the four screws, which fasten the GPIO board with the communication interface, as illustrated. Image 15-22 2. Replace the GPIO board and fasten the board. Image 15-23 R59770374 DP-3000 01/06/2012...
Page 289: Replacement Of The Dimm Pc
3. Insert a new DIMM PC into the socket on the communication board. Tip: Ensure there is no dust in the socket on the communication board. Use compressed air to blow out the dust. 4. Press down the DIMM PC R59770374 DP-3000 01/06/2012...
Page 290 15. Input & Communication unit R59770374 DP-3000 01/06/2012...
Page 291: Control Panel
This chapter describes the Control Panel of the projector. It contains replacement procedures for the Local Keypad, the Button module and the Status Lights on the rear projector corners. Overview • Introduction • Local keypad of the DP-3000 digital projector • Replacement of the Button module • Replacement of the Local Keypad •...
Page 292: Introduction
Card Cage. The mains parts of the Control Panel are the Button model and the Local Keypad. Parts location of the Control Panel Image 16-1 Fixation screw. Local Keypad. Status LED’s. Infra red receiver. Socket for security key (Dallas® button). Fixation screw. Backlight. Ferrite and support for ﬂat cables. Button module. R59770374 DP-3000 01/06/2012...
Page 293: Local Keypad Of The Dp-3000 Digital Projector
16. Control Panel 16.2 Local keypad of the DP-3000 digital projector Identiﬁcation of the keys Image 16-2 Numeric keyboard. Marker area for macro name. Standby/Operation switch. Dowser Open/Close switch. Test Pattern toggle switch. Lens holder shift left/right & up/down keys.
Page 294 16. Control Panel Image 16-3 Infra red signal received. Received infra red signal is OK. Power status of projector head. Projector fault status. R59770374 DP-3000 01/06/2012...
Page 295: Replacement Of The Button Module
1. Release the two retaining screws which fasten the Control Panel to the projector chassis. Use for that a ﬂat screwdriver. Image 16-4 2. Pivot the Control Panel upwards and lock the position with the provided support as illustrated. Image 16-5 3. Disconnect the two ﬂat cables (reference 1image 16-6) from the Button module. R59770374 DP-3000 01/06/2012...
Page 296 7. Reconnect the two ﬂat cables (reference 1image 16-6) with the Button module. 8. Lower and secure the Control Panel. Use a ﬂat screw driver to fasten the two screws at the bottom corners of the Control Panel. R59770374 DP-3000 01/06/2012...
Page 297 16. Control Panel Image 16-9 R59770374 DP-3000 01/06/2012...
Page 298: Replacement Of The Local Keypad
1. Release the two retaining screws which fasten the Control Panel to the projector chassis. Use for that a ﬂat screwdriver. Image 16-10 2. Pivot the Control Panel upwards and lock the position with the provided support as illustrated. Image 16-11 3. Disconnect the two ﬂat cables (reference 1image 16-12) from the Button module. R59770374 DP-3000 01/06/2012...
Page 299 16-14) which fasten the assembly. Note that there are washers (reference 2 image 16-14) located between the Button module assembly and the Control Panel. Image 16-14 6. Peel off the Local Keypad from its support plate. R59770374 DP-3000 01/06/2012...
Page 300 10.Reconnect the two ﬂat cables (reference 1image 16-12) with the Button module. 11. Lower and secure the Control Panel. Use a ﬂat screw driver to fasten the two screws at the bottom corners of the Control Panel. Image 16-16 R59770374 DP-3000 01/06/2012...
Page 301: Replacement Of The Status Lights
5. Remove the plastic corner cap from the Status Light module (reference 4image 16-17) by loosen the screw (reference 5im- age 16-17) at the bottom of the Status Light module. Use a T10 Torx driver. Image 16-17 6. Reverse this procedure to install a new Status Light module. R59770374 DP-3000 01/06/2012...
Page 302 16. Control Panel R59770374 DP-3000 01/06/2012...
Page 303: Communicator Touch Panel
17. Communicator Touch Panel 17. COMMUNICATOR TOUCH PANEL Overview • Introduction • Installing the touch panel interface • Reposition the touch panel interface R59770374 DP-3000 01/06/2012...
Page 304: Introduction
The Touch Panel interface can also be installed further away from the DP-3000 projector. For that you can use a serial (RS232) cable up to 10 meter or an Ethernet cable up to 50 meter to realize a direct data communication between the DP-3000 projector and the Communicator Touch Panel.
Page 305: Installing The Touch Panel Interface
• 10 mm wrench. How to install the touch panel interface upon the DP-3000 projector? 1. Assemble the mounting plate and the swivel arm together as illustrated. First the nut (N) upon the rod of the mounting plate, then the lock washer (L), and then fasten mounting plate and swivel arm together. When arm is mounted, turn nut (N) against the arm to secure the position.
Page 306 Plug one end of the Ethernet cable into the RJ45 socket of the touch panel and the other end into one of the Ethernet ports of the projector (Port 1 or Port 2). To power adapter To RS232IN To Port1 or Port2 Image 17-6 R59770374 DP-3000 01/06/2012...
Page 307 To power adapter Image 17-7 6. Fasten the plug of the power adapter cord together with the with the SUB-D plug of the RS232 cable as illustrated. Use for that one cable tie. CABLE TIE Image 17-8 R59770374 DP-3000 01/06/2012...
Page 308: Reposition The Touch Panel Interface
Image 17-9 3. Move the touch panel interface into the desired position. 4. Fasten the central swivel clamp by turning the big black knob clockwise. AUTION Never release the central swivel lock without supporting the Touch Panel interface. R59770374 DP-3000 01/06/2012...
Page 309: Fan Replacement Procedures
Replacement of the Cathode Fan • Replacement of the Outlet Fan • Replacement of the Cold Mirror Top Fan • Replacement of the Cold Mirror Bottom Fan • Replacement of the SPG Fan • Replacement of the Card Cage Fans R59770374 DP-3000 01/06/2012...
Page 310: Replacement Of The Anode Fan
2. Remove the two cable ties which fasten the wire unit of the Anode Fan. One cable tie is accessible from the projector bottom (reference 4 image 18-3) and the other cable tie is accessible via the Lamp House compartment (reference 5 image 18-3). R59770374 DP-3000 01/06/2012...
Page 311 5. Loosen the four hexagon socket head cap screws which fasten the Anode Fan assembly. One screw is accessible via the Lamp House compartment, the other three screws are accessible via the compartment of the Sealed Light Processor unit. R59770374 DP-3000 01/06/2012...
Page 312 How to install the Anode Fan? 1. Install the air channel outlet extension on the Anode Fan with four Torx screws (reference 1 image 18-9). Use a T20 Torx driver. Provide each screw with a washer (reference 2 image 18-9). R59770374 DP-3000 01/06/2012...
Page 313 Sealed Light Processor unit. Caution: Make sure that the metal grid (reference 5 image 18-11) is correctly placed. Image 18-11 4. Insert the two screws at the bottom of the outlet channel. use a T20 Torx driver. R59770374 DP-3000 01/06/2012...
Page 314 7. Install the temperature sensor (reference 1 image 18-15) on the Anode Fan outlet channel by pushing the winglet (reference 2 image 18-15) upon the sensor. Make sure that there is an O-ring (reference 3 image 18-15) present on the sensor. R59770374 DP-3000 01/06/2012...
Page 315 18. Fan replacement procedures Image 18-15 R59770374 DP-3000 01/06/2012...
Page 316: Replacement Of The Cathode Fan
(reference 2) at the left, the two screws (reference 3) at the top and the two screws at the left (reference 4) of the Cathode fan assembly. Use a T20 Torx driver for the screws at the top and a 3 mm Allen wrench for the other screws. R59770374 DP-3000 01/06/2012...
Page 317 Image 18-20 5. Remove the mounting plate from the Cathode Fan. Use a 5 mm open-end wrench to loosen the three spacers (reference 9) and use a T20 Torx driver to loosen the remaining screw (reference 10). R59770374 DP-3000 01/06/2012...
Page 318 7. Reassemble the Cathode Fan assembly as illustrated. Use three Torx screws T20 (reference 5) to fasten the top of the assembly. Use four hexagon socket head cap screws (reference 6) to fasten the outlet of the Cathode Fan. Three provided with a plain washer (reference 7) and one with a cable tie holder (reference 8). Image 18-23 R59770374 DP-3000 01/06/2012...
Page 319 10.Reconnect the wire unit (reference 1 image 18-17) of the Cathode Fan. After the Cathode Fan assembly is installed, the Pump of the Liquid Cooling Circuit has to be reinstalled. See corresponding chapter "Installing the Pump", page 207, for detailed installation instructions. R59770374 DP-3000 01/06/2012...
Page 320: Replacement Of The Outlet Fan
Note: To remove the assembly slide the assembly a few mm away from the rear of the projector and then lift it up. Image 18-26 3. Cut all cable ties which fasten the wire units to the Outlet Fan assembly as illustrated. R59770374 DP-3000 01/06/2012...
Page 321 5 screws at the left side of the Outlet Fan assembly (reference 7 image 18-28). c) 3 screws at the front side of the Outlet Fan assembly (reference 8 image 18-29). d) 4 screws at the bottom side of the Outlet Fan assembly (reference 9 image 18-29). Image 18-28 Image 18-29 R59770374 DP-3000 01/06/2012...
Page 322 Do not damage the wire unit (reference 10 image 18-30) of the airﬂow switch and make sure that the three foam blocks (reference 11 image 18-30) are placed as illustrated in image 18-30. 8. Attach the wire units with cable ties (reference 15 & 16 image 18-32) to the Outlet Fan assembly. R59770374 DP-3000 01/06/2012...
Page 323 Outlet Fan assembly (reference 3 image 18-34). c) the wire unit of the Outlet Fan (reference 4 image 18-34). Image 18-34 11. Fasten the wire three with cable ties as illustrated. R59770374 DP-3000 01/06/2012...
Page 324 18. Fan replacement procedures Image 18-35 R59770374 DP-3000 01/06/2012...
Page 325: Replacement Of The Cold Mirror Top Fan
2. Release the three screws (A, B & C) of the fan cover as illustrated. Use a T10 Torx driver. Caution: Do not touch the Cold Mirror. Image 18-37 3. Release the two screws (D & E) as illustrated. Use a 3 mm Allen wrench. Caution: Do not touch the Cold Mirror. R59770374 DP-3000 01/06/2012...
Page 326 Ensure that the wire unit is placed in the recess at the side of the fan cover. Image 18-39 5. Secure the fan cover with the three screws (A, B & C) as illustrated. Image 18-40 6. Reconnect the wire unit of the fan. R59770374 DP-3000 01/06/2012...
Page 327 18. Fan replacement procedures Image 18-41 R59770374 DP-3000 01/06/2012...
Page 328: Replacement Of The Cold Mirror Bottom Fan
Make sure that the airﬂow of the Cold Mirror Bottom Fan is upwards. 4. Reconnect the wire (reference 1 image 18-42) unit of the Cold Mirror Bottom Fan. Use two cable ties to join the wire units together as illustrated in image 18-42. R59770374 DP-3000 01/06/2012...
Page 329: Replacement Of The Spg Fan
Make sure that the airﬂow of the SPG fan is upwards. 4. Reconnect the wire unit (reference 1 image 18-44) of the SPG Fan. Use two cable ties to join the wire units together as illustrated in image 18-44. R59770374 DP-3000 01/06/2012...
Page 330: Replacement Of The Card Cage Fans
4. Reconnect the wire unit with the new Card Cage Fan. AUTION One of the Card Cage Fans is equipped with a temperature sensor. Remove the temperature sensor prior to removing the fan and reinstall the temperature sensor upon the new Card Cage Fan. R59770374 DP-3000 01/06/2012...
Page 331: Projector Covers
Installation of the top cover • Installation of the rear cover • Installation of the front cover • Installation of the left cover • Installation of the right cover • Cleaning the dust ﬁlters • Cleaning the exterior of the projector R59770374 DP-3000 01/06/2012...
Page 332: Removal Of The Right Cover
1. Unlock the door of the Lamp House using an adapted lock key as illustrated. It’s not necessary to open the Lamp House door. Image 19-1 2. Release the four retaining screws as illustrated. Use a ﬂat screw driver. Image 19-2 3. Remove the side cover. Image 19-3 R59770374 DP-3000 01/06/2012...
Page 333: Removal Of The Left Cover
19.2 Removal of the left cover Necessary tools Flat screwdriver. How to remove the left cover of the projector? 1. Release the four retaining screws as illustrated. Use a ﬂat screw driver. Image 19-4 2. Remove the side cover. Image 19-5 R59770374 DP-3000 01/06/2012...
Page 334: Removal Of The
1. Remove the black dust cap from the lens holder by pulling out the ﬁve knobs (N) as illustrated. Note that the dust cap remains attached to the front cover. Image 19-6 2. Release the four thumbscrews (two on each side) as illustrated. Image 19-7 3. Remove the front cover. R59770374 DP-3000 01/06/2012...
Page 335: Removal Of The Rear Cover
To remove the rear cover you have to remove the left and right cover ﬁrst. Necessary tools No tools. How to remove the rear cover of the projector? 1. Release the four thumbscrews (two on each side) as illustrated. Image 19-8 2. Remove the rear cover. R59770374 DP-3000 01/06/2012...
Page 336: Removal Of The Top Cover
How to remove the top cover of the projector? 1. Disconnect the hot air outlet of the projector from the exhaust system. 2. Lift up the top cover after removing the right, the left, the front and the rear cover. Image 19-9 R59770374 DP-3000 01/06/2012...
Page 337: Removal Of The Bottom Cover
Do not damage the power cables, which are leading through a hole in the bottom cover. Turn the four feet 10 cm out to have easy access to the bottom of the projector. Pay attention, as feet can be completely removed! R59770374 DP-3000 01/06/2012...
Page 338: Installation Of The Bottom Cover
1. Place the bottom cover into position and fasten with ten (10) screws using a ﬂat chubby screwdriver. Image 19-11 AUTION Do not damage the power cables, which are leading through a hole in the bottom cover. R59770374 DP-3000 01/06/2012...
Page 339: Installation Of The Top Cover
3. Reconnect the wire unit of the connector mounted on the top cover with the Power Backplane. 4. Reconnect the hot air outlet of the projector with the exhaust system. The top cover will be secured after the front and rear cover are installed. R59770374 DP-3000 01/06/2012...
Page 340: Installation Of The Rear Cover
The rear cover can not be installed if the side covers are installed. Necessary tools No tools. How to install the rear cover of the projector? 1. Place the rear cover into position and fasten with four thumbscrews as illustrated. Image 19-13 R59770374 DP-3000 01/06/2012...
Page 341: Installation Of The
How to install the front cover of the projector? 1. Place the front cover into position and fasten with four thumbscrews as illustrated. Image 19-14 2. Attach the dust cap to the lens holder by pushing in the ﬁve knobs (N) as illustrated. Image 19-15 R59770374 DP-3000 01/06/2012...
Page 342: Installation Of The Left Cover
Flat screwdriver. • Lamp house door lock key. How to install the left cover of the projector? 1. Place the left cover into position. 2. Secure the left cover by fastening the four screws as illustrated. Image 19-16 R59770374 DP-3000 01/06/2012...
Page 343: Installation Of The Right Cover
1. Check if the lock of the Lamp House door stands in the unlock position. 2. Place the left cover into position. 3. Secure the right cover by fastening the four screws as illustrated. Image 19-17 4. Lock the Lamp House door. R59770374 DP-3000 01/06/2012...
Page 344: Cleaning The Dust Filters
7. Reinstall both ﬁlters. 8. Reinstall the side cover of the projector head. Clean the air inlet and outlet of the power unit with a vacuum cleaner as well, while you are cleaning the dust ﬁlters of the projector head. R59770374 DP-3000 01/06/2012...
Page 345: Cleaning The Exterior Of The Projector
How to clean the exterior of the projector head? 1. Switch off the projector and unplug the power cord. 2. Clean the housing of the projector with a damp cloth. Stubborn stains may be removed with a cloth lightly dampened with a mild detergent solution. R59770374 DP-3000 01/06/2012...
Page 346 19. Projector covers R59770374 DP-3000 01/06/2012...
Page 347: Anamorphic Lens And Holder
Overview • Mounting the anamorphic lens in its holder • Alignment of the Anamorphic Lens position • Anamorphic lens holder locking motor replacements • Anamorphic lens holder rotation motor replacements • Anamorphic lens holder shift motor replacements R59770374 DP-3000 01/06/2012...
Page 348: Mounting The Anamorphic Lens In Its Holder
The above adjustment is a coarse adjustment. The ﬁnal adjustment of the anamorphic lens position has to be performed Tip: while displaying a picture (horizontal display of the picture top side) 4. Secure the lens in its holder by tightening the 2 screws (A). R59770374 DP-3000 01/06/2012...
Page 349 A. Anamorphic lens and holder Image A-3 Lens securing R59770374 DP-3000 01/06/2012...
Page 350: Alignment Of The Anamorphic Lens Position
• Removing the Anamorphic lens holder driver cover • Distance between Anamorphic and Prime lens • Remounting the Anamorphic lens holder driver cover • Image centering on Anamorphic lens • Horizontal alignment of the image top line R59770374 DP-3000 01/06/2012...
Page 351: Removing The Anamorphic Lens Holder Driver Cover
Removing the Anamorphic lens holder driver cover How to remove! 1. Remove the 5 screws (A), securing the cover to frame. Image A-5 Removal cover securing screws 2. Slide the cover backwards to remove. Image A-6 Cover removal R59770374 DP-3000 01/06/2012...
Page 352: Distance Between Anamorphic And Prime Lens
Secure the position of the rail lock by tightening the rail lock screws (B). 4. Check the previous alignment by moving the lens driver unit OUT and IN, using the D-Cine Communicator SHIFT OUT and SHIFT IN arrow button. R59770374 DP-3000 01/06/2012...
Page 353 A. Anamorphic lens and holder Image A-9 Check lens calibration The calibration is correct if the lens driver unit stops with the anamorphic lens 5 mm in front of the prime lens. If not, repeat the calibration procedure. R59770374 DP-3000 01/06/2012...
Page 354: Remounting The Anamorphic Lens Holder Driver Cover
How to proceed 1. Place the bottom of the cover from the rear side into the cover guides (A). Image A-10 2. Move the cover to the front. 3. Secure the cover with 5 screws (image A-5). R59770374 DP-3000 01/06/2012...
Page 355: Image Centering On Anamorphic Lens
5. Move the lens support, previously putting the lens centering guides (B) in the desired direction, till the lens spot is in center of the lens. 6. Secure the position of the lens holder by tightening the respective nuts (A). R59770374 DP-3000 01/06/2012...
Page 356: Horizontal Alignment Of The Image Top Line
Fine alignment anamorphic lens position in its holder 2. Slightly, rotate (B) the lens in its holder until the image top line (C) runs horizontally. 3. Secure the position of the lens by tightening the lens ﬁxation screws (A). R59770374 DP-3000 01/06/2012...
Page 357: Anamorphic Lens Holder Locking Motor Replacements
• Removing the motor • Preparation of the new motor • Mounting the motor Before starting Remove the anamorphic lens holder driver cover to get access to the motors. When the motor is replaced, remount this cover. R59770374 DP-3000 01/06/2012...
Page 358: Preparations To Remove The Motor
3. Switch off the power of the projector and unplug from the wall outlet. 4. Cut the wire ties. 5. Unplug the plug from the driver module (plug with green wires) Image A-15 Remove plug with green wires R59770374 DP-3000 01/06/2012...
Page 359: Removing The Motor
A. Anamorphic lens and holder A.3.2 Removing the motor Necessary tools Allen key 3mm How to remove ? 1. Turn out the hexagon socket set screw (A). Image A-16 2. Slide the motor backwards (B). R59770374 DP-3000 01/06/2012...
Page 360: Preparation Of The New Motor
1. Check if the ﬂat side of the axle is turn upwards so that it can be inserted. If the axle is not in the correct position, turn it with the hand or with a small tool until it is in its correct position. R59770374 DP-3000 01/06/2012...
Page 361: Mounting The Motor
Ensure that the L-shape support plate is on the correct side. 2. Turn in the new hexagon socket set screw (B). 3. Plug the motor plug (green wires) into the socket on the motor driver board (image A-15). 4. Tie the cables together as before. R59770374 DP-3000 01/06/2012...
Page 362: Anamorphic Lens Holder Rotation Motor Replacements
Removing the motor • Mounting the motor • Remounting the Anamorphic lens holder front cover Before starting Remove the anamorphic lens holder driver cover to get access to the motors. When the motor is replaced, remount this cover. R59770374 DP-3000 01/06/2012...
Page 363: Removing The Anamorphic Lens Holder Front Cover
A. Anamorphic lens and holder A.4.1 Removing the Anamorphic lens holder front cover How to remove ? 1. Remove the 4 screws, securing the front cover. Image A-18 2. Take off the front cover. R59770374 DP-3000 01/06/2012...
Page 364: Removing The Motor
4. Slide off the gear wheel and the spacer. 5. Turn out the 4 hexagon socket head screws (B) ﬁxing the motor to the frame (2 on top and 2 at the bottom). 6. Side out the motor. R59770374 DP-3000 01/06/2012...
Page 365: Mounting The Motor
5. Fixate this position by turning in a new hexagon socket set screw with cup point. 6. Secure this position by turning on a nut on the hexagon socket set screw. 7. Plug the connector into its socket on the motor driver board. 8. Tie the wires together as before. R59770374 DP-3000 01/06/2012...
Page 366: Remounting The Anamorphic Lens Holder Front Cover
A. Anamorphic lens and holder A.4.4 Remounting the Anamorphic lens holder front cover How to mount ? 1. Slide the front cover on its place. Image A-22 Mounting the front cover 2. Turn in the 4 screws, securing the front cover. R59770374 DP-3000 01/06/2012...
Page 367: Anamorphic Lens Holder Shift Motor Replacements
Removing the motor • Preparation before inserting the new motor • Mounting the motor Before starting Remove the anamorphic lens holder driver cover to get access to the motors. When the motor is replaced, remount this cover. R59770374 DP-3000 01/06/2012...
Page 368: Preparations To Remove The Motor
2. Connect a PC to the DP100 and start the DCine communicator software. 3. Select tab Projector Setup and click on Lens conﬁg. 4. Click on the arrow down just below the lens holder buttons to expand the lens calibration window. R59770374 DP-3000 01/06/2012...
Page 369 5. Click on the Shift out or Shift in button until the ﬁxation screw is on top. 6. Switch off the power of the projector and unplug from the wall outlet. 7. Cut the wire ties. 8. Unplug the plug from the driver module (plug with black wires). Image A-25 R59770374 DP-3000 01/06/2012...
Page 370: Removing The Motor
1. Turn out the hexagon socket set screw. 2. Slide off the gear wheel. 3. Take off the spacer. 4. Turn out the 4 hexagon socket screws holding the motor to the support (2 on top and 2 at the bottom). Image A-26 R59770374 DP-3000 01/06/2012...
Page 371: Preparation Before Inserting The New Motor
6. Click on the arrow down just below the lens holder buttons to expand the lens calibration window. Image A-27 7. Click on the Shift out or Shift in button until the ﬂat side of the axle is to the upper side. R59770374 DP-3000 01/06/2012...
Page 372: Mounting The Motor
5. Turn in a new hexagon socket set screw with cup point (D) and ﬁxate this position. 6. Plug the motor plug into the socket. 7. Tie the cables together as before. R59770374 DP-3000 01/06/2012...
Page 373: Pin Configurations
B. Pin configurations B. PIN CONFIGURATIONS Overview • Pin conﬁguration of the Input & Communication ports R59770374 DP-3000 01/06/2012...
Page 374: Pin Configuration Of The Input & Communication Ports
— (not connected) — RI : Ring Indicator — (not connected) — 10/100 Base-T network ports Description TXD+ TXD- RXD+ ++2,5VA ++2,5VA RXD- — GNDM Remote input port Image B-2 Sleeve (shield). Ring. Tip. Description RC5 in n.c. or GND R59770374 DP-3000 01/06/2012...
Page 375: General Purpose Input/Output Port (Gpio)
SMPTE 292 IN Channel B Description Description Input A HD-SDI Input B HD-SDI DVI input ports Description Description RX2– — (not connected) — RX2+ RX2 Shield — (not connected) — Hot Plug Detect — (not connected) — RX0– R59770374 DP-3000 01/06/2012...
Page 376 B. Pin configurations Description Description DDC Clock RX0+ DDC Data RX0 Shield — (not connected) — — (not connected) — RX1– — (not connected) — TMDS Clock Shield RX1 Shiled TMDS RXC+ — (not connected) — TMDS RSC- R59770374 DP-3000 01/06/2012...
Page 377: Glossary
SMPTE Society of Motion Picture and Television Engineers - A global organization, based in the United States, that sets standards for baseband visual communications. This includes ﬁlm as well as video standards. R59770374 DP-3000 01/06/2012...
Page 378 Glossary R59770374 DP-3000 01/06/2012...
Page 379: Index
++5v - voltage low Clean 138–139, 147, 178–179, 210, 340 +12v - voltage high Cold Mirror +12v - voltage low Dust ﬁlters +24v - voltage high Notch Filter +24v - voltage low Prism +3.3v - voltage high Pump R59770374 DP-3000 01/06/2012...
Page 380 - requested target not reached HD-SDI input lens zoom position - requested target not reached Heat Exchanger lps - at least one could not be detected Replace lps - communication failed Horizontal shift motor lps - not detected R59770374 DP-3000 01/06/2012...
Page 381 UV blocker Clean Lamp info module ON/OFF switch Replace Orientation 10, 14 Left cover 329, 338 Convention 10, 14 Install Remove lens cleaning Pin conﬁgurations Lens 225, 227 Ports Install Pins Removal Position Lens holder Touch panel R59770374 DP-3000 01/06/2012...
Page 382 Button module Position Card Cage board Touch Panel Cathode Fan Introduction Cold Mirror Trouble shooting 35, 37 Cold Mirror Bottom Fan Checklist Cold Mirror Top Fan Troubleshooting 36, 101 Dowser First level Flowchart Heat Exchanger Lamp info module R59770374 DP-3000 01/06/2012...
Page 383 Index UV blocker Clean Update 255–257 Program Start up TI boards Install package Vertical shift motor TI Boards R59770374 DP-3000 01/06/2012...