Barco DP-1500 User manual

DP-1500
Installation manual
R59770091/06
06/01/2009

Barco Inc. Media and Entertainment Division
11101 Trade Center Drive, Rancho Cordova, California 95670, USA
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
Visit us at the web: www.barco.com
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.
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.
Guarantee and Compensation
Barco provides a guarantee relating to perfect manufacturing as part of the legally stipulated terms of guarantee. On receipt, the purchaser
must immediately inspect all delivered goods for damage incurred during transport, as well as for material and manufacturing faults Barco
must be informed immediately in writing of any complaints.
The period of guarantee begins on the date of transfer of risks, in the case of special systems and software on the date of commissioning,
at latest 30 days after the transfer of risks. In the event of justified notice of complaint, Barco can repair the fault or provide a replacement
at its own discretion within an appropriate period. If this measure proves to be impossible or unsuccessful, the purchaser can demand a
reduction in the purchase price or cancellation of the contract. All other claims, in particular those relating to compensation for direct or
indirect damage, and also damage attributed to the operation of software as well as to other services provided by Barco, being a component
of the system or independent service, will be deemed invalid provided the damage is not proven to be attributed to the absence of properties
guaranteed in writing or due to the intent or gross negligence or part of Barco.
If the purchaser or a third party carries out modifications or repairs on goods delivered by Barco, or if the goods are handled incorrectly,
in particular if the systems are commissioned operated incorrectly or if, after the transfer of risks, the goods are subject to influences not
agreed upon in the contract, all guarantee claims of the purchaser will be rendered invalid. Not included in the guarantee coverage are
system failures which are attributed to programs or special electronic circuitry provided by the purchaser, e.g. interfaces. Normal wear as
well as normal maintenance are not subject to the guarantee provided by Barco either.
The environmental conditions as well as the servicing and maintenance regulations specified in the this manual must be complied with by
the customer.
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.

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.
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 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.

Table of contents
TABLE OF CONTENTS
1. Operating conditions .............................................................................................. 3
1.1 Certification ........................................................................................................................... 4
1.2 Physical Environment ................................................................................................................ 5
1.3 Heat Dissipation/Cooling ............................................................................................................. 6
1.4 Input Power . . ......................................................................................................................... 7
1.5 Initial Inspection ...................................................................................................................... 8
1.6 Mutual Agreement.................................................................................................................... 9
2. Safety instructions................................................................................................11
2.1 General considerations..............................................................................................................12
2.2 Restricted Access Location .........................................................................................................13
2.3 Electrical Safety .....................................................................................................................14
2.4 Heat and Fire Hazards .............................................................................................................. 15
2.5 Safety on Installation ................................................................................................................16
2.6 Protection from Ultraviolet Radiation................................................................................................17
2.7 Protection on Servicing..............................................................................................................18
2.8 Safety on Cleaning . .................................................................................................................19
2.9 Safety on Shipping ..................................................................................................................20
3. Mechanical set up of the DP-1500..............................................................................21
3.1 Unpacking the projector .............................................................................................................22
3.2 Positioning the DP-1500 at port window . . . . ........................................................................................24
3.3 Installation of the exhaust system. ..................................................................................................27
4. Electrical set up of the DP-1500 ................................................................................29
4.1 Power requirements .................................................................................................................30
4.2 Connecting the main AC power . . ...................................................................................................31
5. Lenses & lens holder .............................................................................................33
5.1 Available lenses ..................................................................................................................... 34
5.2 Lens selection .......................................................................................................................35
5.3 Lens formulas........................................................................................................................36
5.4 Lens removal ........................................................................................................................37
5.5 Lens installation .....................................................................................................................38
5.6 Lens shift, zoom & focus . . . .........................................................................................................40
5.7 Scheimpflug adjustment.............................................................................................................41
6. Lamp & lamp house............ .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. .............. .... .... ...45
6.1 Introduction ..........................................................................................................................46
6.2 Removal of the lamp house .........................................................................................................47
6.3 Removal of the xenon bulb lamp.. ..................................................................................................49
6.4 Installation of the xenon bulb lamp..................................................................................................52
6.5 Installation of the lamp house .......................................................................................................57
6.6 Resetting the lamp parameters . . ...................................................................................................59
6.7 Realignment of the lamp in its reflector.............................................................................................60
7. Input & communication unit.....................................................................................63
7.1 Introduction ..........................................................................................................................64
7.2 Local Keypad of the DP-1500 projector . . . . ........................................................................................65
7.3 Communication ports of the DP-1500 projector . ...................................................................................66
7.4 About General Purpose Inputs & Outputs (GPIO)..................................................................................68
7.5 Source input ports of the DP-1500 projector .......................................................................................70
8. Communicator touch panel......................................................................................71
8.1 Introduction ..........................................................................................................................72
8.2 Installing the touch panel interface..................................................................................................74
8.3 Reposition the touch panel interface................................................................................................76
9. Starting up..........................................................................................................77
9.1 Switching on the DP-1500 projector ................................................................................................78
9.2 Switching off the DP-1500 projector ................................................................................................79
10. Projector registration.............................................................................................81
10.1 Introduction ..........................................................................................................................82
10.2 Download the certificate file.........................................................................................................83
10.3 Registration of new projector........................................................................................................84
10.4 Update registration of an existing projector. ........................................................................................90
11. Maintenance........................................................................................................91
11.1 Cleaning the lens . . . .................................................................................................................92
11.2 Cleaning the exterior of the projector ...............................................................................................93
11.3 Replacement of the dust filter on the front side ....................................................................................94
11.4 Replacement of the dust filter on the bottom side..................................................................................96
11.5 Replacement of the dust filter on the top side......................................................................................97
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Table of contents
11.6 Pressure verification of the liquid cooling circuit....................................................................................98
12. Servicing............................................................................................................99
12.1 Removal of the Input & Communication unit ......................................................................................100
12.2 Installation of the Input & Communication unit . ...................................................................................101
12.3 Convergence (with extenders) .....................................................................................................103
12.3.1 Convergence controls .......................................................................................................104
12.3.2 Preparing for convergence adjustment......................................................................................106
12.3.3 Converging the red pattern onto the blue pattern...........................................................................107
12.3.4 Converging the green pattern onto the blue pattern........................................................................109
12.4 Convergence (old system) . ........................................................................................................111
12.4.1 Action of the convergence controls... .......................................................................................112
12.4.2 Re-converging Green on Blue...............................................................................................113
12.4.3 Readjustment of the plungers ...............................................................................................116
12.4.4 Re-converging Red on Blue .................................................................................................117
12.5 Authorization to clear security warning ............................................................................................121
13. Removal and installation of projector covers.............................................................. 123
13.1 Removal of the lamp cover.........................................................................................................124
13.2 Removal of the input cover.........................................................................................................125
13.3 Removal of the front cover .........................................................................................................126
13.4 Removal of the side cover..........................................................................................................127
13.5 Removal of the rear cover..........................................................................................................128
13.6 Removal of the top cover...........................................................................................................129
13.7 Open the sealed compartment .....................................................................................................130
13.8 Close the sealed compartment.....................................................................................................131
13.9 Installation of the top cover.........................................................................................................132
13.10 Installation of the rear cover........................................................................................................133
13.11 Installation of the side cover .......................................................................................................134
13.12 Installation of the front cover.......................................................................................................135
13.13 Installation of the input cover.......................................................................................................136
13.14 Installation of the lamp cover.......................................................................................................137
A. Specifications ..................................................................................................... 139
A.1 Specifications of the DP-1500......................................................................................................141
B. Dimensions ........................................................................................................ 143
B.1 Dimensions of the DP-1500 ........................................................................................................144
B.2 Centre of gravity of the DP-1500. ..................................................................................................145
B.3 Dimensions of the universal pedestal............................................................................................. .146
C. Pin configurations................................................................................................ 147
C.1 Pin configurations of the communication ports . . ..................................................................................148
C.2 Pin configurations of the inputs . . . .................................................................................................149
D. Order info .......................................................................................................... 151
D.1 Spare part order info ...............................................................................................................153
Glossary ............................................................................................................... 155
Index.................................................................................................................... 157
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1. Operating conditions
1. OPERATING CONDITIONS
Overview
•Certification
• Physical Environment
• Heat Dissipation/Cooling
• Input Power
• Initial Inspection
• Mutual Agreement
R59770091 DP-1500 06/01/2009 3

1. Operating conditions
1.1 Certification
Guarantee
Barco provides a guarantee relating to perfect manufacturing as part of the legally stipulated terms of guarantee.
Observing the specification as mentioned below, are critical for the performances of the projector. Neglecting can results in warranty
loss.
4R59770091 DP-1500 06/01/2009

1. Operating conditions
1.2 Physical Environment
Physical Environment Requirements
Table below summarizes the physical environment in which the DP-1500 may be safely operated or stored.
Environment Operating Non-Operating
Ambient Temperature 10°C (50°F) to 35°C (95°F) -15°C (5°F) to 60°C (140°F)
Humidity 5% to 85% RH Non-condensed 5% to 95% RH Non-Condensed
Altitude -60 (-197Ft) to 3000m (9843Ft) -60 (-197Ft) to 10000m (32810Ft)
R59770091 DP-1500 06/01/2009 5

1. Operating conditions
1.3 Heat Dissipation/Cooling
Thermal Management
The projector is fan cooled and must be installed with sufficient space mainly in the front and at the bottom (minimum 5 cm) and on
the sides to ensure sufficient air flow.
It should be used in an area where the ambient temperature, as measured at the projector air inlet, does not exceed +35°C (+95°F).
Besides, the installation of an exhaust system is MANDATORY. The installed exhaust blower must remove an air volume of 6.65 m3
per min. (235 CFM)
6R59770091 DP-1500 06/01/2009

1. Operating conditions
1.4 Input Power
Input power requirements
The DP-1500 projector operates from a nominal mono phase power net with a separate earth ground PE. The DP-1500 projector
requires 200–240 VAC, 50–60 Hz, 20 amps at 200 VAC with a separate earth ground PE. A label on the rear of the projector head
indicates the nominal line voltage for which the projector was set at the factory.
To protect operating personnel, the National Electrical Manufacturers Association (NEMA) recommends that the instrument panel
and cabinet be grounded. In no event shall this projector be operated without an adequate cabinet ground connection.
AC power supply cord specification: Certified cord, 4.0 mm², 10AWG, min. 300V. Installation according to the local electrical code
and regulations by qualified technical personnel only.
R59770091 DP-1500 06/01/2009 7

1. Operating conditions
1.5 Initial Inspection
General
Before shipment, the projector was inspected and found to be free of mechanical and electrical defects. As soon as the projector is
unpacked, inspect for any damage that may have occurred in transit. Save all packing material until the inspection is completed. If
damage is found, file claim with carrier immediately. The Barco Sales and Service office should be notified as soon as possible.
Mechanical check
This check should confirm that there are no broken knobs or connectors, that the cabinet and panel surfaces are free of dents and
scratches, and that the meter face and operating panel are not scratched of cracked. The Barco Sales and Service office should be
notified as soon as possible.
8R59770091 DP-1500 06/01/2009

1. Operating conditions
1.6 Mutual Agreement
Contracting parties
Unless otherwise agreed, signing the document means acceptance of above items, especially the unconditional acceptance of the
operating conditions.
For the Buyer For the Manufacturer
Firm: Firm: Barco
Name: Name:
Sign: Sign:
R59770091 DP-1500 06/01/2009 9

1. Operating conditions
10 R59770091 DP-1500 06/01/2009

2. Safety instructions
2. SAFETY INSTRUCTIONS
Overview
• General considerations
• Restricted Access Location
• Electrical Safety
• Heat and Fire Hazards
• Safety on Installation
• Protection from Ultraviolet Radiation
• Protection on Servicing
• Safety on Cleaning
• Safety on Shipping
R59770091 DP-1500 06/01/2009 11

2. Safety instructions
2.1 General considerations
Users definition
Throughout this manual, the term SERVICE PERSONNEL refers to persons having appropriate technical training and experience
necessary to be knowledgeable of potential hazards to which they are exposed (including, but not limited to HIGH VOLTAGE ELEC-
TRIC and ELECTRONIC CIRCUITRY and HIGH BRIGHTNESS PROJECTORS) in performing a task, and of measures to minimize
the potential risk to themselves or other persons. The term USER and OPERATOR refers to any person other than SERVICE PER-
SONNEL, AUTHORIZED to operate professional projection systems located in RESTRICTED ACCESS LOCATIONS.
The DLP Cinema Systems are intended "FOR PROFESSIONAL USE ONLY" by AUTHORIZED PERSONNEL familiar with poten-
tial hazards associated with high voltage, high intensity light beams, ultraviolet exposure and high temperatures generated by the
lamp and associated circuits. Only qualified SERVICE PERSONNEL, knowledgeable of such risks, are allowed to perform service
functions inside the product enclosure.
General Safety Instructions
• This equipment is intended for installation in a restricted access location.
• Before operating your projector please read this manual thoroughly, and retain it for future reference.
• Installation and preliminary adjustments should be performed by qualified Barco personnel or authorized Barco service dealers.
• All warnings on the projector and in the documentation manuals should be adhered to.
• All instructions for operating and use of this equipment must be followed precisely.
• All local installations codes should be adhered to.
Owner’s record
The part number and the serial number are printed on a label which is stuck on the respective part. Record these numbers in the
spaces provided below. Refer to them whenever you call upon your Barco custom service engineer regarding this product.
NAME PART NUMBER SERIAL NUMBER SUPPLIER
DP-1500 projector R9004443
1.4 - 2.05 : 1 (motorized) R9855931
1.4 - 2.05 : 1 (manual) R98559311
1.6 - 2.5 : 1 (motorized) R9855932 &R9855933
1.6 - 2.5 : 1 (manual) R98559321 &
R98559331
1.9 - 3.2 : 1 (motorized) R98559934 &
R9855935
1.9 - 3.2 : 1 (manual) R985599341 &
R98559351
2.4 - 3.9 : 1 (motorized) R9855936
Prime Lens
2.4 - 3.9 : 1 (manual) R96559361
Touch panel R9855910
12 R59770091 DP-1500 06/01/2009

2. Safety instructions
2.2 Restricted Access Location
Installation in a Restricted Access Location
The DP-1500 can only be installed in a Restricted Access Location.
What is a Restricted Access Location (Definition) ?
Definition of a Restricted Access Location:
A location for equipment where both of the following paragraphs apply:
• Access can only be gained by SERVICE PERSONS or by USERS who have been instructed about the reasons for the restriction
applied to the location and about the precautions that shall be taken.
• Access is through the use of the TOOL or lock and key, or other means of security, and is controlled by the authority responsible
for the location.
What are the Reasons for the Applied Restriction?
The Air exhaust on the top of the Projector can reach high temperatures due to the High Light Output Range of the installed lamp.
R59770091 DP-1500 06/01/2009 13

2. Safety instructions
2.3 Electrical Safety
Safety Warning
TO PREVENT FIRE OR ELECTRICAL SHOCK HAZARD, DO NOT EXPOSE THIS PROJECTOR TO RAIN OR MOISTURE.
Rating & Grounding
• This product should be operated from an AC power source. Check if the mains voltage and capacity matches the projector
electrical ratings.
• This product is equipped with a three-terminal barrier strip for the connection of a mono phase line with a separate earth ground
PE. If you are unable to install the AC Requirements, contact your electrician. Do not defeat the purpose of the grounding.
• Always use a general disconnect switch to switch off the complete installation.
• Warning: High leakage current. Earth connection essential before connecting supply.
General about the Projector
• Do not allow anything to rest on the power cord. Do not locate this product where persons will walk on the cord.
• Do not operate appliance with a damaged cord or if the appliance has been dropped or damaged - until it has been examined
by a qualified serviceman.
• Position the cord so that it will not be tripped over, pulled, or contact hot surfaces.
• If an extension cord is necessary, a cord with a current rating at least equal to that of the appliance should be used. A cord
rated for less amperage than the appliance may overheat.
• Let appliance cool completely before storing. Remove cord from appliance when storing.
• 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 and disconnect media and communication cables. This will prevent damage
to the projector due to lightning and AC power-line surges.
14 R59770091 DP-1500 06/01/2009

2. Safety instructions
2.4 Heat and Fire Hazards
Warning Risk of Fire
Warning Risk of Fire: Do Not Place Flammable or Combustible Materials Near Projector !
Barco large screen projection products are designed and manufactured to meet the most stringent safety regulations. This projector
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. The exclusion zone must be not less than 40 cm (16”) for all DLP
Cinema projectors. The exclusion zone on the lens side must be at least 5 m. Do not cover the projector or the lens with any
material while the projector is in operation. Keep flammable and combustible materials away from the projector at all times. Mount
the projector in a well ventilated area away from sources of ignition and out of direct sun light. Never expose the projector to rain
or moisture. In the event of fire, use sand, CO2, or dry powder fire extinguishers; never use water on an electrical fire. Always
have service performed on this projector by authorized Barco service personnel. Always insist on genuine Barco replacement parts.
Never use non-Barco replacement parts as they may degrade the safety of this projector.
Slots and Openings
Slots and openings in the cabinet and the sides are provided for ventilation; to ensure reliable operation of the projector and to
protect it from overheating, these openings must not be blocked or covered. The openings should never be blocked by placing the
product too close to walls, or other similar surface. This product should never be placed near or over a radiator or heat register. This
projector should not be placed in a built-in installation or enclosure unless proper ventilation is provided.
Projection Room
Projection rooms must be well ventilated or cooled in order to avoid build up of heat. It is necessary to vent hot exhaust air from
console to the outside of the building. The minimum exhaust airflow requirement is 6.65 m3/min or 235 CFM.
Replaceable Batteries
The projector electronic is provided with a replaceable battery.
CAUTION:Risk of explosion if battery is replaced by an incorrect type. For disposal of used batteries, always
consult federal, state, local and provincial hazardous waste disposal rules and regulations to ensure proper
disposal.
R59770091 DP-1500 06/01/2009 15

2. Safety instructions
2.5 Safety on Installation
Personal Injury or Property Damage
WARNING: To minimize risks of personal injury or property damage, due electrical shock, fire, energy hazards, mechanical and heat
hazards, Ultraviolet an Infrared energy hazards, and/or chemical hazards this equipment must be installed and/or serviced ONLY
by SERVICE PERSONNEL.
• To prevent risk of fire or electric shock, do not immerse or expose this appliance in water or other liquids.
• To prevent the risk of electric shock, do not disassemble this appliance, but always take it to an authorized, trained service
person when service or repair work is required.
• The use of an accessory attachment not recommended by the manufacturer may cause a risk of fire, electric shock, or injury
to persons.
Projector Damage
If the Air Filters are not regularly replaced (A "clean" booth would be monthly-minimum), the air flow inside the projector could be
disrupted, causing overheating. Overheating may lead to the projector shutting down during operation.
In order to ensure that correct airflow is maintained, and that the projector complies with Electromagnetic Compatibility requirements,
it should always be operated with all of it’s covers in place.
Ensure that nothing can be spilled on, or dropped inside the projector. If this does happen, switch off and unplug the mains supply
immediately. Do not operate the projector again until it has been checked by qualified service personnel.
The projector 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 or on
the lamp house.
16 R59770091 DP-1500 06/01/2009