Barco DML-1200 User manual

DML-1200
User guide
R9050120
R59770208/04
06/11/2009

Barco nv Media & Entertainment Division
Noordlaan 5, B-8520 Kuurne
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
Visit us at the web: www.barco.com
Printed in Belgium

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.
This publication could contain technical inaccuracies or typographical errors. Changes are periodically made to the information in this
publication; these changes are incorporated in new editions of this publication.
Copyright ©
All rights reserved. No part of this document may be copied, reproduced or translated. It shall not otherwise be recorded, transmitted or
stored in a retrieval system without the prior written consent of Barco.
Trademarks
Brand and product names mentioned in this manual may be trademarks, registered trademarks or copyrights of their respective holders.
All brand and product names mentioned in this manual serve as comments or examples and are not to be understood as advertising for
the products or their manufacturers.
Federal Communications Commission (FCC Statement)
This equipment has been tested and found to comply with the limits for a class A digital device, pursuant to Part 15 of the FCC rules.
These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial
environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with
the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area may
cause harmful interference, in which case the user will be responsible for correcting any interference at his own expense
EN55022/CISPR22 Class A ITE (Information Technology Equipment)
Class A ITE is a category of all other ITE which satisfies the class A ITE limits but not the class B ITE limits. Such equipment should not
be restricted in its sale but the following warning shall be included in the instructions for use:
Warning : This is a class A product. In a domestic environment this product may cause radio interference in which case the user may be
required to take adequate measures.
Disposal Information
This equipment has required the extraction and use of natural resources for its production. It may contain hazardous substances for health
and environment. In order to avoid the dissemination of those substances in the environment and to diminish the pressure on natural
resources, we encourage you to use the appropriate take-back systems. Those systems will reuse or recycle most of the materials of your
end of life equipment in a sound way.
The crossed-out wheeled bin symbol invites you to use those systems. If you need more information on the collection, reuse and recycling
systems, please contact your local or regional waste administrator. You can also contact us for more information on the environmental
performances of our products.
Software License Agreement
You should carefully read the following terms and conditions before using this software. Your use of this software indicates your acceptance
of this license agreement and warranty.
Terms and Conditions:
1. No redistribution of the software is allowed.
2. Reverse-Engineering. You may not reverse engineer, decompile, disassemble or alter anyhow this software product.
Disclaimer of Warranty:
This software and the accompanying files are sold “as is” and without warranties as to performance or merchantability or any other war-
ranties whether expressed or implied. In no event shall Barco be liable for damage of any kind, loss of data, loss of profits, business
interruption or other pecuniary loss arising directly or indirectly. Any liability of the seller will be exclusively limited to replacement of the
product or refund of purchase price.

GNU-GPL code
If you would like a copy of the GPL source code contained in this product shipped to you on CD, please contact Barco. The cost of preparing
and mailing a CD will be charged.

Table of contents
TABLE OF CONTENTS
1. Safety................................................................................................................. 3
1.1 General ............................................................................................................................... 3
1.2 Important safety instructions ......................................................................................................... 3
1.3 Important warnings concerning DML flight cases ................................................................................... 6
1.4 Recycling guidelines.................................................................................................................. 6
2. General............................................................................................................... 9
2.1 Installation requirements . . . .......................................................................................................... 9
2.2 Unpacking the device ................................................................................................................ 9
2.3 Projector air inlets and outlets.......................................................................................................12
3. Physical installation ..............................................................................................13
3.1 Pan and tilt locking ..................................................................................................................13
3.2 Mounting the DML-1200 upright . . ..................................................................................................15
3.3 Truss mounting of the DML-1200 ...................................................................................................15
4. Connections........................................................................................................19
4.1 Power connection . . .................................................................................................................19
4.2 Input connections . . ..................................................................................................................20
4.3 Communication connections ........................................................................................................21
4.4 Linking DML-1200’s .................................................................................................................24
5. Start up of the Adjustment mode...............................................................................27
5.1 About the adjustment mode .........................................................................................................27
5.2 Start up of the adjustment mode....................................................................................................27
5.3 Navigation and adjustments.........................................................................................................27
6. Input menu .........................................................................................................29
6.1 Input selection .......................................................................................................................29
6.2 Auto Image Alignment...............................................................................................................29
6.3 Reset to factory presets............................................................................................................. 30
6.4 Image load mode . . . .................................................................................................................30
6.5 Aspect ratio ..........................................................................................................................31
6.6 No input signal .......................................................................................................................32
6.7 No source selected..................................................................................................................32
7. Lamp menu.........................................................................................................35
7.1 Overview flow........................................................................................................................35
7.2 Identification .........................................................................................................................35
7.3 Status and run time overview lamps................................................................................................36
7.4 High altitude mode...................................................................................................................36
7.5 Lamp mode .......................................................................................................................... 37
7.6 Lamp power..........................................................................................................................38
8. Control menu.......................................................................................................39
8.1 Overview flow........................................................................................................................39
8.2 Startup ...............................................................................................................................40
8.3 Standby ..............................................................................................................................40
8.4 Demo mode..........................................................................................................................41
8.5 DMX data ............................................................................................................................42
8.6 DMX address ........................................................................................................................42
8.7 DMX universe........................................................................................................................43
8.8 Media player on - off.................................................................................................................43
8.9 LCD contrast......................................................................................................................... 44
8.10 Pan and Tilt encoder ................................................................................................................44
8.11 Network .............................................................................................................................. 45
8.12 Auto shutdown....................................................................................................................... 45
8.13 Status LEDs .........................................................................................................................46
8.14 DMX priority..........................................................................................................................47
9. Service menu.......................................................................................................49
9.1 Overview flow........................................................................................................................49
9.2 Identification .........................................................................................................................49
9.3 Diagnosis ............................................................................................................................50
9.3.1 Version table ..................................................................................................................50
9.3.2 Voltages .......................................................................................................................51
9.3.3 Temperatures ................................................................................................................. 51
9.3.4 Fan speeds. . ..................................................................................................................52
9.3.5 Device status..................................................................................................................53
9.3.6 Error logging ..................................................................................................................53
9.4 Service patterns .....................................................................................................................54
9.5 Calibration ...........................................................................................................................55
9.5.1 Index delay....................................................................................................................55
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Table of contents
9.5.2 Aperture calibration ........................................................................................................... 56
9.5.3 Device calibration.............................................................................................................57
10. Moving light control via DMX ...................................................................................59
10.1 Pan - Tilt .............................................................................................................................59
10.2 Intensity..............................................................................................................................59
10.3 Optical zoom - focus.................................................................................................................59
10.4 Shutter - Strobe......................................................................................................................59
10.5 Cyan - Magenta - Yellow ............................................................................................................60
10.6 CTO (Color temperature origin) . . . ..................................................................................................60
10.7 Mode selection.......................................................................................................................60
10.8 Iris....................................................................................................................................61
10.9 Control channel ......................................................................................................................61
11. Image control via DMX ...........................................................................................63
11.1 Introduction ..........................................................................................................................63
11.2 Source selection.....................................................................................................................63
11.3 Brightness - Contrast - Saturation ..................................................................................................63
11.4 Orientation ........................................................................................................................... 63
11.5 Blanking..............................................................................................................................64
11.6 Soft edge.............................................................................................................................65
11.7 Warping ..............................................................................................................................65
12. Maintenance........................................................................................................67
12.1 Cleaning the lens . . . .................................................................................................................67
12.2 Cleaning the exterior of the DML-1200 . . . . . ........................................................................................67
12.3 Level check of cooling liquid ........................................................................................................67
12.4 Safety cable check ..................................................................................................................69
13. Servicing............................................................................................................73
13.1 Removal of the front cover ..........................................................................................................73
13.2 Opening the top cover on the lamp units side . . . ...................................................................................74
13.3 Opening the top cover on the LPS box side ........................................................................................76
13.4 Remove the yoke covers and shields...............................................................................................77
13.5 Remove top cover of base unit......................................................................................................79
13.6 Replacement of the dust filters on the front side ...................................................................................80
13.7 Replacement of the dust filter at the inside of the head............................................................................81
13.8 Replacement of the dust filter in the base ..........................................................................................82
13.9 Removal of a lamp unit..............................................................................................................83
13.10 Mounting a new lamp unit . . .........................................................................................................85
13.11 Top-up the reservoir with cooling liquid.............................................................................................86
A. DMX chart............................................................................................................91
A.1 DMX chart, Digital moving luminiere................................................................................................91
A.2 DMX chart, Image ................................................................................................................... 92
B. Dimensions ..........................................................................................................95
B.1 Dimensions of the DML-1200 .......................................................................................................95
B.2 Dimensions flight case ..............................................................................................................96
C. Troubleshooting ... ..... . .... .... .... ...... .... .... ...... .... .... .... ...... .... .... ...... .... .... ...... .... .... .... . 97
C.1 Error list..............................................................................................................................97
D. Specifications ..................................................................................................... 101
D.1 Specifications of the DML-1200 . . . .................................................................................................101
E. Order info .......................................................................................................... 103
E.1 Spare part order info ...............................................................................................................103
Glossary ............................................................................................................... 105
Index.................................................................................................................... 107
2R59770208 DML-1200 06/11/2009

1. Safety
1. SAFETY
1.1 General
Personal protection
Take care of the following warnings and cautions:
WARNING:Ensure you understand and follow all the safety guidelines, safety instructions, warnings and
cautions mentioned in this manual.
WARNING:Be aware of suspended loads.
WARNING:Wear a hard hat to reduce the risk of personal injury.
WARNING:Be careful while working with heavy loads.
WARNING:Mind your fingers while working with heavy loads.
CAUTION:High pressure lamp may explode if improperly handled.
1.2 Important safety instructions
To prevent the risk of electrical shock
• This product should be operated from a mono phase AC power source. Power input voltage range must be between 200-240
V,10A 50-60Hz
•Warning: This apparatus must be grounded (earthed) via the supplied 3 conductor AC power cable.
Mount a plug to the delivered power cord but take care of the local regulations about power cords and power plugs. Do not
defeat the purpose of the grounding-type plug.
• Do not allow anything to rest on the power cord. Do not locate this product where persons will walk on the cord. To disconnect
the cord, pull it out by the plug. Never pull the cord itself.
• If an extension cord is used with this product, make sure that the total of the ampere ratings on the products plugged into the
extension cord does not exceed the extension cord ampere rating.
• Use only the power cord supplied with your device. While appearing to be similar, other power cords have not been safety
tested at the factory and may not be used to power the device. For a replacement power cord, contact your dealer.
• Never push objects of any kind into this product through cabinet slots as they may touch dangerous voltage points or short out
parts that could result in a risk of fire or electrical shock.
• Never spill liquid of any kind on the product. Should any liquid or solid object fall into the cabinet, unplug the set and have it
checked by qualified service personnel before resuming operations.
• Lightning - For added protection for this video product during a lightning storm, or when it is left unattended and unused for long
periods of time, unplug it from the wall outlet. This will prevent damage to the device due to lightning and AC power-line surges.
• Do not guide the power cord over the base unit of the device. Ensure that the power cord cannot make contact with moving
head.
R59770208 DML-1200 06/11/2009 3

1. Safety
To prevent personal injury
• When power is supplied to the device, the device starts a homing procedure which includes a movement of the head.
• When opening one of the shell covers of the projector head while power is supplied to the device, the movement of the head
(pan and tilt) is blocked by the software.
• To reduce the lamp heat of the projector head, switch the device first to standby and let the projector lamp cool down for at least
5 minutes. Then the device may be disconnected from the power outlet.
• Isolated electrically before re-lamping. Caution : hot lamps.
• The customer should never attempt to disassemble the lamp casing. See "Recycling guidelines", page 6 for more information
about handling a used lamp.
• To prevent injury and physical damage, always read this manual and all labels on the system before inserting the lamp casing,
connecting to the wall outlet or adjusting the projector.
• To prevent injury, take note of the weight of the projector. Minimum 2 persons are needed to lift up the device. No twist is
allowed. When lifting out of the flight case, a 3rd person has to push away the flight case while the first 2 are lifting up the
device.
• To prevent injury, ensure that the lens and all cover plates are correctly installed. See installation procedures.
• Warning: high intensity light beam. NEVER look into the lens ! High luminance could result in injury to the eye.
• Before attempting to remove any of the device’s covers, you must disconnect from the wall outlet.
• When performing setup work to a ceiling mounted device, to prevent injury caused by falling objects or the system, set out a
keep out area.
• Consult a professional structural engineer prior to suspending the device from a structure not intended for that use. Always
ensure that the working load limit of the structure can handle the load of the device.
• The power input at the base of the device is considered as the disconnect device. When required to switch off the device, to
access parts inside, always disconnect the power cord at the base of the device. In case the power input at the base of the
device is not accessible (e.g. ceiling mount), the socket outlet supplying the device shall be installed nearby the device and be
easily accessible, or a readily accessible general disconnect device shall be incorporated in the fixed wiring.
• Do not place this equipment on an unstable cart, stand, or table. The product may fall, causing serious damage to it and
possible injury to the user.
• When mounting the device to the ceiling or to a rigging system, always mount the delivered security cables and connectors.
Before mounting the security cable, inspect the cable and connector. Do not use when visible damage is detected.
Stretch the security cable completely. If necessary, turn the security cable a few times around the truss before closing the
connection so that the cable is stretched as much as possible.
Connector may not be mounted under bending stress.
• It is hazardous to operate without lens or shield. Shields, lenses or utra-vilolet screens shall be changed if they have become
visible damaged to such an extent that their effectiveness is impaired. For example by cracks or deep scratches.
•Mercury Vapor Warnings: Keep the following warnings in mind when using the projector. The lamp used in the projector
contains mercury. In case of a lamp rupture, explosion there will be a mercury vapor emission. In order to minimize the potential
risk of inhaling mercury vapors:
- Ensure the projector is installed only in ventilated rooms.
- Replace the lamp module before the end of its operational life.
- Promptly ventilate the room after a lamp rupture, explosion has occurred, evacuate the room (particularly in case of a preg-
nant woman).
- Seek medical attention if unusual health conditions occur after a lamp rupture, explosion, such as headache, fatigue, short-
ness of breath, chest-tightening coughing or nausea.
•Cooling liquid circuit. The device head contains a cooling circuit filled with Blue antifreeze diluted 1,2 ethanediol (1/3 ethane-
diol – 2/3 Demi water).
When the cooling circuit leaks, switch off the device and contact a service technician.
The liquid is not for household use. Keep out of reach of children. Harmful by oral intake. Avoid exposure to pregnant women.
Avoid contact with eyes, skin and clothing. Avoid inhale of the noxious fumes.
•Restricted Access Location The DML must be installed in a Restricted Access Location, where access can only be gained
by persons who have been instructed about the reasons for the restriction applied to the location and about the precautions
that shall be taken.
Reasons for the applied restrictions: moving head in all directions, air outlet can reach high temperatures and light output may
cause eye injury when looking directly into the lens.
•Maximum temperature of enclosure : 90°C (194 °F)
4R59770208 DML-1200 06/11/2009

1. Safety
To prevent device damage
• The DML has been designed for use with a specific lamp type. See installation instructions for its correct lamp type.
• If the air filters are not regularly replaced, the air flow inside the device (projector head and base) could be disrupted, causing
overheating. Overheating may lead to the device shutting down during operation.
• In order to ensure that correct airflow is maintained, and that the device complies with electromagnetic compatibility (EMC)
requirements, and for safety requirements, it should always be operated with all of it’s covers in place.
• Slots and openings in the cabinet are provided for ventilation. To ensure reliable operation of the product and to protect it from
overheating, these openings must not be blocked or covered. The openings should never be blocked by placing the product
on a bed, sofa, rug, or other similar surface. This product should never be placed near or over a radiator or heat register. The
device should not be placed in a built-in installation or enclosure unless proper ventilation is provided.
• The device must always be mounted in a manner which ensures free flow of air into its air inlets and unimpeded evacuation of
the hot air exhausted from its cooling system. Heat sensitive materials should not be placed in the path of the exhausted air.
Leave at least a free safety area of 2 meter (80”) around the projector head.
• Ensure that nothing can be spilled on, or dropped inside the device. If this does happen, switch off and unplug the mains supply
immediately. Do not operate the device again until it has been checked by qualified service technicians.
• Consult a professional structural engineer when you have the intention to use this device as ceiling mounted device. Always
ensure the working load limit of the structure supporting the device.
• Do not mount the DML on a wall. Use it always in a ceiling mount or floor mount installation. When mounting on a chariot with
wheels, always use wheels with brakes.
• Moving head. Make sure the head cannot touch any other materials.
• Do not use this equipment near water.
•Special Care for Laser Beams: Special care should be used when DLP projectors are used in the same room as high power
laser equipment. Direct or indirect hitting of a laser beam on to the lens can severely damage the Digital Mirror DevicesTM in
which case there is a loss of warranty.
• Never place a DML in direct sun light. Sun light on the lens can severly damage the Digital Mirror DevicesTM in which case
there is a loss of warranty.
• Save the original packing material; they will come in handy if you ever have to ship your equipment. For maximum protection,
repack your set as it was originally packed at the factory.
• Unplug this product from the wall outlet before cleaning. Do not use liquid cleaners or aerosol cleaners. Use a damp cloth for
cleaning. Never use strong solvents, such as thinner or benzine, or abrasive cleaners, since these will damage the cabinet.
Stubborn stains may be removed with a cloth lightly dampened with mild detergent solution.
• To ensure the highest optical performance and resolution, the projection lenses are specially treated with an anti-reflective
coating, therefore, avoid touching the lens. To remove dust on the lens, use a soft dry cloth. Do not use a damp cloth, detergent
solution, or thinner.
• Never use the device when not all four lamps are installed.
• Rated maximum ambient temperature, ta= 40 °C (104°F)..
• The lamps shall be replaced if they have become damaged or thermally deformed.
To prevent battery explosion
• Danger of explosion if battery is incorrectly installed.
• Replace only with the same or equivalent type recommended by the manufacturer.
• Dispose of used batteries according to the manufacturer’s instruction.
To prevent fire hazard
•Internal fuses provided. Contact a service technician to replace. Only replace with the same type and value.
• Warning “Risk of fire”. Do not place flammable or combustible materials near the device !
This device radiates heat on its external surfaces and from ventilation ducts during normal operation, which is both normal and
safe. Exposing flammable or combustible materials into close proximity of this projector could result in the spontaneous ignition
of that material, resulting in a fire. For this reason, it is absolutely necessary to leave an “exclusion zone” around all external
surfaces of the projector whereby no flammable or combustible materials are present.
•
2 m
. (Only in light mode) Do not illuminate objects within 2 meter (6.6 feet). Objects within this range can scorch, melt or
ignite from the heat projected by the light beam. Leave at least a free safety area of 2 meter (80”) to all combustible parts
• Do not cover the device or the lens with any material while the device is in operation.
• Mount the device in a well ventilated area away from sources of ignition and out of direct sun light.
• Never expose the device to rain or moisture.
• In the event of fire, use sand, CO2, or dry powder fire extinguishers; never use water on an electrical fire.
• This product should never be placed near or over a radiator or heat register.
• This device should not be placed in a built-in installation or enclosure unless proper ventilation is provided.
• The operation room must be well ventilated or cooled in order to avoid build up of heat.
R59770208 DML-1200 06/11/2009 5

1. Safety
On servicing
• Do not attempt to service this product yourself, as opening or removing covers may expose you to dangerous voltage potentials
and risk of electric shock.
• Refer all servicing to qualified service personnel.
• Fence off a restricted area of at least 3 meters around the projector using an eye-catching fence and “KEEP OUT” signs. This
to prevent unauthorized persons coming near the projector during servicing.
• Unplug this product from the wall outlet and refer servicing to qualified service technicians under the following conditions:
- When the power cord or plug is damaged or frayed.
- If liquid has been spilled into the equipment.
- If the product has been exposed to rain or water.
- If the product does not operate normally when the operating instructions are followed. Adjust only those controls that are
covered by the operating instructions since improper adjustment of the other controls may result in damage and will often
require extensive work by a qualified technician to restore the product to normal operation.
- If the product has been dropped or the cabinet has been damaged.
- If the product exhibits a distinct change in performance, indicating a need for service.
• Replacement parts: When replacement parts are required, be sure the service technician has used original Barco replace-
ment parts. Unauthorized substitutions may result in degraded performance and reliability, fire, electric shock or other hazards.
Unauthorized substitutions may void warranty.
• Safety check: Upon completion of any service or repairs to this device, ask the service technician to perform safety checks to
determine that the product is in proper operating condition.
• Lamp replacement: high pressure lamp may explode if improperly handled.
1.3 Important warnings concerning DML flight cases
Important warnings concerning stacking/transporting DML rental flight cases
• Stack maximum two (2) DML rental flight cases high. Never higher.
• The surface on which a flight case is standing must be level to ensure that the total load is evenly spread out among the four
wheels. The surface must also be able to support the load safely.
• Before stacking or transporting flight cases, check the wheels and their fixation screws for wear or defects.
• Before stacking or transporting flight cases, check that the six lock handles on each flight case are in good working order and
locked securely.
• When stacked, make sure the wheels of the upper flight case are precisely positioned in the stacking dishes of the flight case
below.
•Stackedflight cases may not be moved. Before stacking, the lower flight case must already be in its final resting position before
placing the second upon it.
• Never stack loaded flight cases in a truck or other transport medium, unless each flight case is rigidly strapped tight.
• In the event of a wheel breaking, flight cases must be rigidly strapped tight to prevent a stack collapsing.
• Use an appropriate forklift to raise flight cases and take the necessary precautions to avoid personnel injury.
1.4 Recycling guidelines
WARNING:Do not break or crush lamps because this may pose health and environmental risks when mercury
vapors are released.
CAUTION:To avoid breaking the lamps, repack carefully when storing and transporting them.
6R59770208 DML-1200 06/11/2009