Barco R9851620 User manual

ILite LED Replacement Kit
Installation Manual
R5976460/03
29/03/2007

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

Table of contents
TABLE OF CONTENTS
1. Safety................................................................................................................. 3
1.1 Servicing safety instructions ......................................................................................................... 4
2. General............................................................................................................... 5
2.1 ILite LED replacement kits ........................................................................................................... 6
2.2 Contents of the ILite LED replacement kit........................................................................................... 7
2.3 Storage guidelines.................................................................................................................... 9
3. Replacing a bad LED from an ILite LED board...............................................................11
3.1 LED replacement process...........................................................................................................12
3.2 Removing the cover .................................................................................................................13
3.3 Removing the power assembly .....................................................................................................14
3.4 Removing the controller unit ........................................................................................................ 15
3.5 Removing the LED driver............................................................................................................ 16
3.6 Removing a LED module. ........................................................................................................... 17
3.7 Removing the mask .................................................................................................................18
3.8 Creating a mould and small stick ...................................................................................................20
3.9 Replacing a bad LED................................................................................................................21
3.10 Installing a new mask................................................................................................................25
3.11 Installing a LED module . . ...........................................................................................................27
3.12 Installing the LED driver.............................................................................................................28
3.13 Installing the controller unit..........................................................................................................29
3.14 Installing the power assembly.......................................................................................................30
3.15 Installing the cover...................................................................................................................31
Index......................................................................................................................33
R5976460 ILITE LED REPLACEMENT KIT 29/03/2007 1

Table of contents
2R5976460 ILITE LED REPLACEMENT KIT 29/03/2007

1. Safety
1. SAFETY
Overview
• Servicing safety instructions
R5976460 ILITE LED REPLACEMENT KIT 29/03/2007 3

1. Safety
1.1 Servicing safety instructions
WARNING:Servicing must be done by authorized and qualified technical personnel only, which are thor-
oughly familiar with the product and all of the proper safety checks of this product.
Safety precautions:
• Follow all servicing and safety instructions mentioned in the servicing procedures.
• Unplug the tile AC power cord from the AC power source and wait about 10 minutes before start any servicing to the tile. This
to allow the capacitors to discharge.
• Some boards contains electrostatically sensitive devices (ESD). Take the necessary precautions to prevent the incidence of
component damage caused by static electricity.
• Do not modify and/or replicate any component. Barco uses specific materials and manufacturing processes in order to achieve
part strength. No other parts then Barco parts are allowed.
Hazardous products:
This kit contains hazardous products. These products are labeled with a hazard sign. Make sure you understand the hazard labels.
Take the necessary precautions to work with these products and handle appropriate with these products.
WARNING:SOLDERING FLUX (IF 2005 M).
Hazardous product. Irritating to eyes and skin. Always use in a well ventilated area. Vapors may cause drowsi-
ness and dizziness. Avoid contact with skin and eyes. In case of contact with the eyes, rinse immediately with
plenty of water and seek medical advise.
CAUTION:SOLDERING FLUX (IF 2005 M).
Hazardous product. Highly flammable. Always use in a well ventilated area. Keep away from sources of
ignitions. Do not smoke while working with soldering flux. Exclusive keep in original container tightly closed
at a cool, well ventilated and fireproof storage space.
4R5976460 ILITE LED REPLACEMENT KIT 29/03/2007

2. General
2. GENERAL
Overview
• ILite LED replacement kits
• Contents of the ILite LED replacement kit
• Storage guidelines
R5976460 ILITE LED REPLACEMENT KIT 29/03/2007 5

2. General
2.1 ILite LED replacement kits
Purpose of the kits
The ILite LED replacement kits are compound and designed to replace a bad LED on a ILite LED module. Each ILite LED replace-
ment kit contains, next to the LED’s, also masks with the same pitch of the tiles wherefore the kit was designed. For some derived
products like XP, MD and LD an adapted LED replacement kit was required. Below you will find a list with all available ILite LED
replacement kits. Ensure you use the right kit to repair your ILite display.
Overview of available kits
Kit No. Usable for
R9851620 ILite 6
ILite 6 XP
R9852870 ILite 6 MD
R9851621 ILite 8
R9852880 ILite 8 MD
ILite 8 LD
R9851622 ILite 10
R9852890 ILite10MD
ILite10LD
R9852900 ILite12MD
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2. General
2.2 Contents of the ILite LED replacement kit
Contents
Description Image
Installation manual (this manual)
Spare LED’s (80 pieces) image 2-1
Mask (40 pieces) image 2-2
Solder removing wick (1,5 meter) image 2-3
Small bottle with soldering flux (1,5 centiliter) image 2-4
Syringe with silicone (3,5 centiliter) image 2-5
Small box with plastic needles for syringe image 2-6
Tissues image 2-7
Tweezer image 2-8
Scratch tool image 2-9
The LED replacement kits for the ILite 8 (and derived products) doesn’t contain a syringe with silicone, tissues,
tweezer and scratch tool. Because the mask of the 8 millimeter pitch is fasten with screws instead of silicone.
Image 2-1
Spare LED’s.
Image 2-2
Mask (e.g. ILite 6).
Image 2-3
Solder removing wick.
Image 2-4
Soldering flux.
Image 2-5
Syringe with silicone.
Image 2-6
Plastic needles.
R5976460 ILITE LED REPLACEMENT KIT 29/03/2007 7

2. General
Image 2-7
Tissues.
Image 2-8
Tweezer.
Image 2-9
Scratch tool.
8R5976460 ILITE LED REPLACEMENT KIT 29/03/2007

2. General
2.3 Storage guidelines
Flux
Close immediate after use. Exclusive keep in original container tightly closed at a cool, well ventilated and fireproof storage space.
Storage temperature between 5°C and 15°C. Keep away from sources of ignitions.
Syringe with silicone
Remove the plastic needle and place the stop back on the syringe for storage. The storage life is ±12 months after fabrication date.
When unopened stored in a dry area between 5°C and 25°C,
ILite LED’s
Keep the LED’s in the anti static bag for storage.
R5976460 ILITE LED REPLACEMENT KIT 29/03/2007 9

2. General
10 R5976460 ILITE LED REPLACEMENT KIT 29/03/2007

3. Replacing a bad LED from an ILite LED board
3. REPLACING A BAD LED FROM AN ILITE LED BOARD
Overview
• LED replacement process
• Removing the cover
• Removing the power assembly
• Removing the controller unit
• Removing the LED driver
• Removing a LED module
• Removing the mask
• Creating a mould and small stick
• Replacing a bad LED
• Installing a new mask
• Installing a LED module
• Installing the LED driver
• Installing the controller unit
• Installing the power assembly
• Installing the cover
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3. Replacing a bad LED from an ILite LED board
3.1 LED replacement process
Never swap a LED module or LED driver or controller from an ILite tile, because measurement results of the
LED module are stored on the LED driver and controller. So, these boards are matched to each other during
the factory measurement process. Even a swap among the LED modules or LED drivers of the same tile
is not allowed. Neglecting this will result in poor video images displayed on the LED wall. The swapped
LED modules or LED drivers will become visible as quadrants with different light output. Always return the
complete ILite tile to factory for repair and re-measurement in case of a malfunction controller or one or more
malfunction LED modules or LED drivers.
Process stages:
1. Identify and mark bad LED(’s).
This is done by marking, with a suitable marker pen, any mall function LED’s while the tile is operating.
2. Disassemble the LED module(s) from the tile. See following procedures:
a) "Removing the cover", page 13.
b) "Removing the power assembly", page 14.
c) "Removing the controller unit", page 15.
d) "Removing the LED driver", page 16.
e) "Removing a LED module", page 17.
3. Remove the mask from the LED module and create a mould and small stick out of the removed mask. See following procedures:
a) "Removing the mask", page 18.
b) "Creating a mould and small stick", page 20.
4. Replace the marked bad LED’s and install a new mask. See following procedures:
a) "Replacing a bad LED", page 21.
b) "Installing a new mask", page 25.
5. Reinstall the LED module and reassemble the tile. See following procedures:
a) "Installing a LED module", page 27.
b) "Installing the LED driver", page 28.
c) "Installing the controller unit", page 29.
d) "Installing the power assembly", page 30.
e) "Installing the cover", page 31
6. Harden the silicone on the LED module in the tile.
Place the tile on a flat clean surface for at least 24 hours to harden the silicone. Screen side facing the surface.
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3. Replacing a bad LED from an ILite LED board
3.2 Removing the cover
It’s not necessary to remove the re-sync unit first. The re-sync unit is attached to the cover and comes off
with the cover.
Necessary tools
• Torx T20.
•7mmnutdriver.
How to remove the cover ?
1. Release the six screws (P) of the ILite cover (L), one in each corner and one under each handle.
P
F
L
Image 3-1
2. Remove the cover from the rest of the tile (L).
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3. Replacing a bad LED from an ILite LED board
3.3 Removing the power assembly
The power unit and fan mounted upon the power support plate forms the power assembly. Before you can
remove the power assembly, you have to remove the cover from the ILite tile first.
Necessary tools
• Torx T20.
•7mmnutdriver.
How to remove the power assembly from the ILite tile ?
1. Release the eight screws (P) which attach the power assembly (I) to the rest of the ILite tile (F). Three screws on the power
supply unit, one above the fan, two left on the support plate and two right on the support plate.
P
I
F
Image 3-2
2. Remove the power assembly out of the ILite tile.
Caution: Be careful with the board to board connectors between the power unit and the controller unit underneath.
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3. Replacing a bad LED from an ILite LED board
3.4 Removing the controller unit
CAUTION:Electrostatic Sensitive Device (ESD). To avoid equipment damage from electrostatic discharge,
use static control precautions in servicing this equipment. Field service or maintenance personnel should
be properly grounded before servicing. Wear an ESD wristlet when servicing this equipment. The use of
antistatic gloves is recommended.
Before you can remove the controller unit from the module base plate, you have to remove the power assembly
from the ILite tile first.
Necessary tools
• Torx T20.
•7mmnutdriver.
How to remove the controller unit from the module base plate ?
1. Release the six screws (P) which attach the controller unit (H) to the module base plate (F).
P
H
F
Image 3-3
2. Remove the controller unit (H) from the module base plate (F).
Caution: Be careful with the board to board connectors between the controller unit and the LED drivers underneath.
R5976460 ILITE LED REPLACEMENT KIT 29/03/2007 15

3. Replacing a bad LED from an ILite LED board
3.5 Removing the LED driver
CAUTION:Electrostatic Sensitive Device (ESD). To avoid equipment damage from electrostatic discharge,
use static control precautions in servicing this equipment. Field service or maintenance personnel should
be properly grounded before servicing. Wear an ESD wristlet when servicing this equipment. The use of
antistatic gloves is recommended.
Before you can remove the LED driver from the module base plate, you have to remove the controller unit
from the ILite tile first.
Necessary tools
• Torx T20.
•7mmnutdriver.
How to remove the LED driver from the module base plate ?
1. Release the four screws (P) of the LED driver (G) you want to remove from the module base plate (F).
P
G
F
Image 3-4
2. Remove the LED driver (G) from the module base plate (F).
Caution: Be careful with the board to board connectors between the LED driver and the LED modules underneath.
Tip: Mark the original position of the LED driver in the module base plate with a unique sign and place the same sign upon
the LED driver. This will prevent an accidental swap of LED drivers in case you removed more than one LED driver from
the module base plate.
16 R5976460 ILITE LED REPLACEMENT KIT 29/03/2007