Barco F90 series User manual

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

Barco Fredrikstad AS
Habornveien 53, N-1630 Gamle Fredrikstad, Norway
Phone: [phone]
Fax: [phone]
Support: [email protected]
Visit us at the web: www.barco.com
Printed in Norway

Table of contents
TABLE OF CONTENTS
1. Introduction ......................................................................................................... 5
1.1 Scope and limitations................................................................................................................. 5
1.2 Copyright.............................................................................................................................. 5
1.3 Trademarks . . ......................................................................................................................... 5
1.4 Required Handtools .................................................................................................................. 5
2. General safety....................................................................................................... 7
2.1 General Safety Instructions .......................................................................................................... 7
2.2 Notice on safety ...................................................................................................................... 7
2.3 Users Definition....................................................................................................................... 7
3. Important Safety Instructions.................................................................................... 9
3.1 To prevent the risk of electrical shock................................................................................................ 9
3.2 To prevent personal injury. ........................................................................................................... 9
3.3 To prevent fire hazard ...............................................................................................................10
3.4 To prevent projector damage........................................................................................................10
3.5 On Servicing......................................................................................................................... 11
3.6 To prevent battery explosion ........................................................................................................ 11
3.7 Precautions during lens shift........................................................................................................ 11
3.8 Laser Safety ......................................................................................................................... 12
3.9 Warning Labels ......................................................................................................................12
4. DLP System General Description ..............................................................................13
4.1 F90 optical principle .................................................................................................................13
4.2 The DMD Device ....................................................................................................................14
4.3 The Grayscale image................................................................................................................14
4.4 Adding Color......................................................................................................................... 14
4.5 Single chip DLP projection system..................................................................................................15
5. GP6 system functional description ............................................................................17
5.1 Electronic platform...................................................................................................................17
5.2 I/O’s and processing tasks: .........................................................................................................17
5.3 Block diagram GP6 Platform........................................................................................................19
5.4 Wiring Matrix.........................................................................................................................21
5.5 Firmware.............................................................................................................................22
5.6 System Safety Loop.................................................................................................................22
5.7 Laser driver Principle and error codes ..............................................................................................24
6. GP6 periodical maintenance ....................................................................................27
6.1 Service Interval Matrix...............................................................................................................27
6.2 Service Kits available................................................................................................................27
7. OSD / display menu...............................................................................................29
7.1 Service Menu ........................................................................................................................29
7.2 Troubleshooting tools................................................................................................................31
8. Thermal management system...................................................................................33
8.1 Ventilation and cooling ..............................................................................................................33
8.2 Liquid Cooling Pumps ...............................................................................................................35
8.3 Fans..................................................................................................................................35
8.3.1 Fan Radiator ..................................................................................................................35
8.3.2 Fan Laser Driver ..............................................................................................................35
8.3.3 Fan PSU.......................................................................................................................35
8.3.4 Fan Phosphor Internal 1, 2 ...................................................................................................35
8.3.5 Fan PCB Main ................................................................................................................35
8.3.6 Fan Optics.....................................................................................................................35
8.4 Thermal sensors.....................................................................................................................36
8.5 Engine heatsink......................................................................................................................36
8.6 System thermal diagram ............................................................................................................36
8.6.1 Nominal setting................................................................................................................37
8.6.2 Long lifetime setting. . .........................................................................................................38
8.6.3 Fan and pump number location ..............................................................................................39
9. Lenses and adjustment ..........................................................................................41
9.1 Scheimplflug adjustment ............................................................................................................41
9.2 Locking the lens position. ...........................................................................................................41
10. Optical adjustments ..............................................................................................43
10.1 Perfecting the lightning path ........................................................................................................43
10.2 Lightning Mirror adjustment: ........................................................................................................43
10.3 Lightning mirror: Horizontal (x) Adjustment......................................................................................... 43
10.4 Lighting Mirror: Vertical (y) Adjustment.............................................................................................44
10.5 Focus: Relay tube lens focus adjustment . . ........................................................................................44
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Table of contents
10.6 Color Uniformity, TI Loop mirrors adjustment.......................................................................................45
10.6.1 Color Uniformity, left TI Loop mirror: . ........................................................................................45
10.6.2 Color Uniformity, Right TI Loop mirror: .......................................................................................45
10.6.3 Color uniformity, Final verification. ...........................................................................................46
11. Colorwheels........................................................................................................47
11.1 Replace the colorwheel assy........................................................................................................47
11.2 Colorwheel index adjustment .......................................................................................................47
11.3 Index adjustment procedure ........................................................................................................48
12. Phosphor wheel .. .. .. ...... .. .. .. .. .. .. .. .. .. ...... .. .. .. .. .. .. .. .. .. ...... .. .. .. .. .. .. .. .. .. ...... .. .. .. .. .. .. .. .49
12.1 Replace the phosphor wheel assy ..................................................................................................49
12.2 Entering Prospector diagnostic tool.................................................................................................49
12.3 Calibrating the phosphor wheel . . ...................................................................................................49
13. Laser pulsing adjustment........................................................................................51
13.1 Procedure ............................................................................................................................51
14. XPS actuator .......................................................................................................53
14.1 XPS actuator replacement ..........................................................................................................53
14.2 Calibrating the XPS actuator........................................................................................................54
15. Light engine........................................................................................................57
15.1 CLGA ................................................................................................................................ 57
16. Power Supply Unit (PSU) ... .. .. .. .... . ..... .. .. .. .... .. .. .. .... .. .. .. .... .. .. .. .... .. .. .. .... .. .. .. .... . ..... .. .59
16.1 AC Input..............................................................................................................................59
16.2 Output specification .................................................................................................................59
16.3 Connectors. . . ........................................................................................................................60
16.3.1 PSU Control connector (HDMI-C) . . . . ........................................................................................60
16.3.2 Mainboard connector:.........................................................................................................61
16.3.3 Thermal Hub Connector ......................................................................................................61
16.3.4 Laser driver connector: .......................................................................................................62
16.4 Power supply diagnostic . . . .........................................................................................................62
16.4.1 Power good output............................................................................................................62
17. Troubleshooting .... . . ...... .. ...... .. ...... .. ...... .. ...... .. ...... .. ...... .. .. ...... .. ...... .. ...... .. ...... .. ...63
17.1 Status LED indications ..............................................................................................................63
17.2 LED’s on Thermal Hub and Mainboard. . . . . ........................................................................................63
17.2.1 Thermal Hub Board LED’s....................................................................................................63
17.2.2 Main Board LED’s.............................................................................................................64
17.3 Available Diagnostic Tools . .........................................................................................................65
17.3.1 Prospector.....................................................................................................................65
17.3.2 pd Diagnostic. ................................................................................................................. 66
17.3.3 Log Extractor..................................................................................................................66
17.3.4 OSD ...........................................................................................................................66
17.3.5 LCD............................................................................................................................ 66
17.4 Troubleshooting......................................................................................................................66
17.4.1 Explanation of the codes . . . .................................................................................................. 67
17.4.2 Troubleshooting checklist. . . ..................................................................................................68
17.4.3 Log files .......................................................................................................................75
18. Assembly Hierarchy ..............................................................................................79
18.1 Hierarchy overview ..................................................................................................................79
19. Disassembly / Assembly instructions.........................................................................81
19.1 Safety Precautions .................................................................................................................. 81
19.2 Remove the projector covers........................................................................................................ 81
19.2.1 Remove the rear top cover ...................................................................................................81
19.2.2 Remove the rear cover .......................................................................................................81
19.2.3 Remove the main top cover ..................................................................................................82
19.2.4 Remove the Side cover left...................................................................................................83
19.2.5 Remove the Side cover right .................................................................................................83
19.3 Removing peripheral”mini” PCB’s...................................................................................................84
19.3.1 PCB GP6 IR Receiver and LED Board TOP.................................................................................84
19.3.2 PCB Front USB & Trigger board . . . . . ........................................................................................84
19.3.3 PCB IR Front..................................................................................................................84
19.3.4 PCB Inlet temp sensor board No1............................................................................................85
19.3.5 PCB Inlet temp sensor board No2............................................................................................85
19.4 Display and keypad Module. ........................................................................................................86
20. Scheduled operations ............................................................................................87
20.1 About................................................................................................................................. 87
20.2 20000 hours LFM Service . . .........................................................................................................87
20.2.1 Phosphor wheels (2 pcs) . . . ..................................................................................................87
20.2.2 Fan Phosphor wheels (2 pcs) ................................................................................................88
20.2.3 Change the Color Wheel cassette. . . . ........................................................................................89
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20.2.4 Cooling Fans..................................................................................................................89
20.2.4.1 Fan PSU................................................................................................................89
20.2.4.2 Fan PCB................................................................................................................90
20.2.4.3 Fan Optics..............................................................................................................90
20.2.5 Laser Clusters Blue (2pcs) ...................................................................................................91
20.2.6 Cleaning the cooling pump surface .. ........................................................................................94
20.2.7 Cooling pump connection map ...............................................................................................95
20.3 40000 hours service .................................................................................................................95
20.3.1 Fan laser driver ............................................................................................................... 96
20.3.2 Liquid Cooling System 40.000hrs . . . . ........................................................................................96
20.3.3 Remove Frame Radiator Left Module........................................................................................ 98
20.3.4 Remove Frame radiator center module . . . ...................................................................................98
20.3.5 Frame radiator right module ..................................................................................................99
20.3.6 Reassembly of radiator modules . . . . . .......................................................................................100
21. DMD, DMD Board, CLGA & DMD heatsink elements...................................................... 103
21.1 DMD assembly .....................................................................................................................103
21.2 DMD Board, CLGA & DMD heatsink elements. . ..................................................................................103
21.3 GP6 PCB DMD Board..............................................................................................................104
21.4 CLGA & DMD.......................................................................................................................105
21.5 Re-assembly after PCB DMD or DMD/CLGA repair ..............................................................................105
21.6 GP6 Heatsink DMD Front & Rear Assemblies ....................................................................................106
21.7 GP6 Heatsink DMD Front assembly...............................................................................................106
21.8 Remove the Laser Interface........................................................................................................108
21.9 Install new Laser Interface .........................................................................................................109
22. TI Loop .............................................................................................................111
22.1 General .............................................................................................................................111
22.2 Overview Engine assembly ........................................................................................................112
22.2.1 TI Loop Left . . ................................................................................................................112
22.2.2 Overview of TI loop left ......................................................................................................113
22.2.3 Dichroic Filter B/Y............................................................................................................113
22.2.4 Barrel PW Lens assy ........................................................................................................113
22.2.5 Mirrors Blue ..................................................................................................................114
22.2.6 390 Blue loop lens 3 .........................................................................................................114
22.2.7 390 Blue loop lens 4 .........................................................................................................114
22.2.8 Diffusor blue loop ............................................................................................................115
22.2.9 390 RGBY Converging Lenses..............................................................................................115
22.2.9.1 Converging Lens (Entrance) . . . .......................................................................................115
22.2.9.2 Converging Lens (Exit)................................................................................................116
22.2.10 Adjusting Mirror ..............................................................................................................116
22.3 TI Loop Right .......................................................................................................................116
22.4 Rod Carrier Assy ...................................................................................................................117
23. Illumination Engine front....................................................................................... 119
23.1 Iris assembly........................................................................................................................119
23.2 Relay Tube assy....................................................................................................................120
23.3 PCB CLO (Constant Light Output). ................................................................................................120
23.4 Folding Mirror assembly............................................................................................................121
23.4.1 Removing Folding Mirror assembly .........................................................................................121
24. Lens shift assembly ............................................................................................ 123
24.1 Lens shift assembly motors ........................................................................................................124
24.2 Lens position sensors (Horizontal and Vertical) ...................................................................................125
24.3 PCB lens connectors ...............................................................................................................125
24.4 Lens Lock screws. . . ................................................................................................................126
24.5 Scheimpflug screws ................................................................................................................126
24.6 Lens shift assembly and optical actuator .. . .......................................................................................126
24.7 TIR Prism ...........................................................................................................................127
24.7.1 Remove the TIR prism.......................................................................................................127
24.7.2 Cleaning the TIR prism ......................................................................................................128
24.7.3 Reassemble the TIR prism ..................................................................................................129
25. Prism Housing ................................................................................................... 131
25.1 Prism Housing ......................................................................................................................131
26. Technical Operations ........................................................................................... 133
26.1 PCB Bracket bottom and Bracket fan..............................................................................................133
26.2 PCB Main ...........................................................................................................................133
26.3 PCB Thermal Hub board.......................................................................................................... .134
26.4 PSU .................................................................................................................................136
26.5 PCB Laser Drivers..................................................................................................................137
26.5.1 Remove the Laser driver cage ..............................................................................................137
26.5.2 Remove the Laser driver PCB board. .......................................................................................138
26.5.3 Remove the Bottom laser driver PCB board................................................................................138
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Table of contents
4723–0016 F90 01/12/2017

1. Introduction
1. INTRODUCTION
Overview
• Scope and limitations
• Copyright
• Trademarks
• Required Handtools
1.1 Scope and limitations
Scope
This document is intended to describe fault resolution, low frequency maintenance and parts replacement procedures for the Barco
F90. Only partners named in service agreement with Barco Fredrikstad AS may carry out procedures detailed in this document. In-
formation contained herein is subject to change without further notice; please refer to online documentation for updated information.
1.2 Copyright
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 prior written consent of Barco.
1.3 Trademarks
Trademarks
Brands and product names mentioned in this manual may be trademarks, registered trademarks or copyrights of their respective
holders. All brands and product names mentioned in this manual serve as comments or examples and are not to be understood as
advertising for the product or their manufacturers.
1.4 Required Handtools
Required Handtools
The following tools are needed for servicing the unit:
• Screwdriver,s, Torx6, 8, 10, 20.
• Allen Key, Size 1.5, 2, 3, 5mm
• Scalpel
• Screwdriver, Flat head 4mm
• Ionized pressurized air for cleaning optical components
• Adjustable thermal heater for releasing Cooling system.
• Suitable cleaner for thermal transfer compound, (Brake / clutch cleaner). Isopropanol can be used, but are not as powerful as
brake cleaner.
Unless otherwise indicated in the procedure, screw torque to be applied is 0.3 Nm.
723–0016 F90 01/12/2017 5

1. Introduction
6723–0016 F90 01/12/2017

2. General safety
2. GENERAL SAFETY
2.1 General Safety Instructions
General Safety Instructions.
• The projector is Class 1 laser product that conforms with IEC EN 60825-1:2014. For Northern America, the projector is class
3R laser product up to throw ratio 2.33. The projector conforms with IEC 60825–1:2007, and with performance standards for
laser products under 21 CFR 1040, except with respect to those characteristics authorized by Variance Number 2016–V-0144
effective March 6, 2017
• This projector is Risk Group 2 (RG2) according to IEC EN 62471-5. This projector may become Risk Group 3 (RG3) when an
interchangeable lens with throw ratio greater than 3.15 is installed. For Northern America, installation requirements according
to Risk group 3 (RG3) must be followed when interchangeable lens with throw ratio greater than 2.33 is installed. Refer to the
manual for the lens list and throw ratio before operation. Such combination of projector and lens are intended for professional
use only, and are not intended for consumer use.
• For RG3, no direct exposure to the beam shall be permitted. For RG3, operators shall control access to the beam within the
hazard distance or install the product at a height that will prevent eye exposure within the hazard distance.
• This projector has a built-in Class 4 laser cluster. Disassembly or modification is very dangerous and should never be attempted.
• Any operation or adjustment not specifically instructed by the user’s guide creates the risk of hazardous laser radiation expo-
sure.
• Do not open or disassemble the projector as this may cause damage by the exposure of laser radiation.
• Do not stare into beam when the projector is on. The bright light may result in permanent eye damage.
• Not following the prescribed control, adjustment or operation procedure may cause damage by the exposure of laser radiation.
• Before operating this equipment please read this manual thoroughly and retain it for future reference.
• Installation and preliminary adjustments should be performed by properly trained and qualified personnel.
• 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 installation codes should be adhered to.
2.2 Notice on safety
Safety
This equipment is built in accordance with the requirements of the international safety standards IEC60950-1, as basis for National
safety regulation world wide. The safety standard covers information technology equipment including electrical business equipment
intended to operate in “normal” environments (offices and homes). This safety standard imposes important requirements on the
use of safety critical components, materials and insulation, in order to protect the user or operator against risk of electric shock and
energy hazard and having access to live parts. Safety standards also impose limits to the internal and external temperature rises,
radiation levels, mechanical stability and strength, enclosure construction and protection against the risk of fire. Simulated single
fault condition testing reduce the risk of hazards and contribute to ensure the safety of the equipment to the user even when the
equipment’s normal operation fails..
2.3 Users Definition
Definition
Throughout this manual, the term SERVICE PERSONNEL refers to Barco authorized 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 ELECTRIC and ELECTRONIC CIRCUITRY and HIGH BRIGHTNESS PROJECTORS) in performing a task, and of mea-
sures to minimize the potential risk to themselves or other persons. Only Barco authorized SERVICE PERSONNEL, knowledgeable
of such risks, are allowed to perform service functions inside the product enclosure. The term USER and OPERATOR refers to any
person other than SERVICE PERSONNEL. When an interchangeable lens with throw ratio above a certain level is installed, the
F90 series projector becomes RG3. Refer to the manual for the lens list and hazard distance before operation. Such combination
of projector and lens are intended for professional use only, and are not intended for consumer use.
FOR PROFESSIONALLY USE ONLY, means installation only can be carried out by BARCO AUTHORIZED PERSONNEL familiar
with potential hazards associated with high intensity light beams.
This product operates on mains voltage. Do not open products without first unplugging the power cord.
It is advised against operating the product with housing top off, as there is a risk of injury caused by high voltage elements, cuts
caused by glass fragments in the event of a ruptured lamp or UV radiation burns.
723–0016 F90 01/12/2017 7

2. General safety
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3. Important Safety Instructions
3. IMPORTANT SAFETY INSTRUCTIONS
WARNING:to service personnel: After operation of the protective device, the equipment is still under voltage
if it is connected to an IT- power distribution system.
3.1 To prevent the risk of electrical shock
Electrical Shock
• This product should be operated from a mono phase AC power source.
• This apparatus must be grounded (earthed) via the supplied 3 conductor AC power cable. If none of the supplied power cables
are the correct one, consult your dealer. If you are unable to insert the plug into the outlet, contact your electrician to replace
your obsolete outlet. 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.
• 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.
• Do not operate the projector with a damaged cord. Replace the cord. Do not operate the projector if the projector has been
dropped or damaged - until it has been examined and approved for operation by a qualified service technician.
• 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 projector should be used. A cord rated
for less amperage than the projector may overheat.
• 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.
• Make sure that no objects enter into the vents and opening of the set.
• Do not expose this projector to rain or moisture.
• The projector is designed for indoor use only. Never operate the unit outdoors.
• Do not immerse or expose this projector in water or other liquids.
• Do not spill liquid of any kind on this projector.
• Should any liquid or solid object fall into the cabinet, unplug the set and have it checked by qualified service personnel before
resuming operations.
• Do not disassemble this projector; always take it to an authorized trained service person when service or repair work is required.
• Do not use an accessory attachment which is not recommended by the manufacturer.
• 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.
3.2 To prevent personal injury.
Personal injury
• To prevent injury and physical damage, always read this manual and all labels on the system before connecting to the wall
outlet or adjusting the projector.
• To prevent injury, take note of the weight of the projector.
• To prevent injury, ensure that the lens and all covers are correctly installed. See installation procedures.
• Warning: high intensity light beam. NEVER look into the lens! High luminance could result in damage to the eye.
• Warning: extremely high brightness laser: This projector uses extremely high brightness laser. Never attempt to look directly
into the lens or at the laser.
• Always switch off the projector and disconnect from the mains power supply before attempting to remove any of the projector
covers or access parts inside the projector.
• 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.
• It is hazardous to operate without lens or lens cap. Lenses, shields or ultra violet screens shall be changed if they have become
visibly damaged, for example with cracks or deep scratches, to such an extent that their effectiveness is impaired.
• Exposure to UV radiation: Some medications are known to make individuals extra sensitive to UV radiation. The American
Conference of Governmental Industrial Hygienists (ACGIH) recommends occupational UV exposure for an 8 hour day to be
less than 0.1 micro-watts per square centimeters of effective UV radiation. An evaluation of the workplace is advised to assure
employees are not exposed to cumulative radiation levels exceeding these government guidelines.
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3. Important Safety Instructions
3.3 To prevent fire hazard
Fire Hazard
• Barco 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,
resultinginafire. 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 in the exhaust area must be not
less than 100 cm (40”). The exclusion zone on the intake area must not be less than 50 cm (20”). The exclusion zone on the
lens side within the light beam must be at least 1,5 m.
• Do not place flammable or combustible materials near the projector!
• Slots and openings in this equipment 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 projector too close to walls, or other similar surface. Allow for sufficient
distance to walls and ceilings to avoid overheating. Minimum safety distance to the exhaust area of the unit must not be less
than 100 cm (40”) and to the intake area, not less than 50 cm (20”).
• This projector 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.
• 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 re-
placement parts. Never use non-Barco replacement parts as they may degrade the safety of this projector.
• Projection rooms must be well ventilated or cooled in order to avoid heat buildup.
• Let the projector cool down completely before storing. Remove cord from the projector when storing.
3.4 To prevent projector damage
Preventing Projector Damage.
• To ensure correct airflow is maintained, and that the projector complies with Electromagnetic Compatibility (EMC) requirements,
it should only be operated when all of its covers in place.
• Always remove lens cap before switching on the projector. If the lens cap is not removed, it may melt due to the high energy
light emitted through the lens. Melting the lens cap will permanently damage the surface of the projection lens.
• The projector must always be installed in a manner, which ensures free flow of air into its air inlets and unimpeded evacuation
of the hot air from its cooling system.
• 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. 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 BARCO authorized service personnel..
• Do not block the projector cooling fans or free air movement around the projector. Minimum safety distance to the exhaust area
of the unit must not be less than 100 cm (40”) and to the intake area, not less than 50 cm (20”)
• 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 Devices™ in
which case there is a loss of warranty.
• Never place the projector in direct sun light. Sun light on the lens can severely damage the Digital Mirror Devices™ in which
case there is a loss of warranty.
• Save the original shipping carton and 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
10 723–0016 F90 01/12/2017

3. Important Safety Instructions
3.5 On Servicing
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 BARCO authorized repair centers.
• Attempts to alter the factory-set internal controls or to change other control settings not specially discussed in this manual can
lead to permanent damage to the projector and cancellation of the warranty.
• Unplug this product from the wall outlet and refer servicing to BARCO authorized service technicians under the following con-
ditions:
• 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 projector, ask the service technician to perform safety checks
to determine that the product is in proper operating condition.
• Possible explosion hazard: Always keep in mind the caution below:
3.6 To prevent battery explosion
This applies to the batteries in the remote control.
• Danger of explosion if battery is incorrectly installed.
• Replace only with the same or equivalent type recommended by the manufacturer.
• For disposal of used batteries, always consult federal, state, local and provincial hazardous waste disposal rules and regulations
to ensure proper disposal.
3.7 Precautions during lens shift
Lens shift
For Lens shift procedure, see User Guide.
WARNING:When changing lens, always close the shutter to avoid accidentally staring in to the lens opening.
This light can be harmful to the eyes.
Close the shutter by pressing the shutter button on the keypad panel. The key will illuminate red when the
shutter is closed.
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3. Important Safety Instructions
3.8 Laser Safety
WARNING:Class 1 laser RG2 Product. This projector may become RG3. Refer User Manual before operating.
Do not stare into beam. This projector has a Class 4 laser cluster. Do not attempt to disassemble or modify
this projector.
Special precautions have to be taken in order to protect persons and environment. Laser radiation is defined
as harmful to persons and objects, and must be handled according to instructions given.
All power must be switched off during service and replacement of optical components.
After reassembly of Cluster, Laser interface and TI Loop, the unit must be properly tested against leak of light
due to improper reassembly of the parts.
This test must take place in a closed area / room, with only service personnel present. The area / room must
have safety signs and warnings indicating that there is a restricted / danger area, with access only to certified
personnel. Protective googles has to be used by persons inside the test area.
3.9 Warning Labels
Warning Labels
Warning labels are positioned inside the projector, where extra Safety precautions are necessary.
Image 3-1 Image 3-2
Image 3-3
High voltage warning. Located on the Powersupply.
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4. DLP System General Description
4. DLP SYSTEM GENERAL DESCRIPTION
4.1 F90 optical principle
Optical Principle
The F90 illumination consists of two identical light paths combined using a dual rod system. Each path includes the following:
48 blue 455 nm Laser Diodes (LD) grouped into 3 banks consisting of 8 (2x4 array) LDs. The individual laser beams are combined
using mirrors and a focusing lens.
The light is focused on a static diffuser placed just before the entrance of a glass integrating rod.
The scattered light is then reflected multiple times in the integrating rod, creating uniform luminance at the rod exit.
The rod exit surface is then imaged onto the rotating Phosphor Wheel (PW) by the use of collimating lenses and a dichroic mirror
which only reflects blue and IR light.
Image 4-1
The phosphor absorbs the blue laser light, and emits a broad band yellow light which is reflected back towards the dichroic mirror,
where it is transmitted, and focused onto the dual rod system.
A small portion of the blue light is transmitted through a clear segment of the PW, and is relayed around to the back of the dichroic
mirror. There it is reflected a second time and combined with the yellow light from the PW before it is focused on the dual rod system.
The dual rod system consists of two solid integrating rods (one for each illumination path) and a hollow integrating rod combining
the two seamlessly. This exit surface is imaged onto the DMD using traditional relay optics and TIR prism.
To create Red and Green color, a color wheel is placed after the hollow rod exit surface, which is synchronized with the PWs in
each illumination path. This is again synchronized with the DMD producing time sequential Red, Green and Blue colors on the wall
perceived by the human eye as white light.
By using the internal illumination iris the contrast ratio can be increased, and by sliding in the motorized color filter (located next to
the iris) a broader color gamut can be achieved.
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4. DLP System General Description
4.2 The DMD Device
DMD Device
Image 4-2
At the heart of every DLP™ projection system is an optical semiconductor known as the Digital Micromirror Device, or DMD chip,
which was invented by Dr. Larry Hornbeck of Texas Instruments in 1987.
The DMD chip is probably the world’s most sophisticated light switch. It contains a rectangular array of hinge-mounted microscopic
mirrors, each measuring less than one-fifth the width of a human hair, and corresponding to one pixel in a projected image.
When a DMD chip is coordinated with a digital video or graphic signal, a light source, and a projection lens, its mirrors can reflect an
all-digital image onto a screen or other surface. The DMD and the sophisticated electronics that surround it are what we call Digital
Light Processing™ technology.
The F90 DMD chip is part of the Texas Instrument DLP9000 family and features over 4 million micromirrors on each chip, offering a
dazzling high resolution 2560 x 1600 (WQXGA) array.
4.3 The Grayscale image
Grayscale
Image 4-3
Image 4-4
A DMD panel’s micro-mirrors are mounted on tiny hinges that enable them to tilt either toward the light source in a DLP™ projection
system (ON) or away from it (OFF)-creating a light or dark pixel on the projection surface.
The bit-streamed image code entering the semiconductor directs each mirror to switch on and off up to several thousand times
per second. When a mirror is switched on more frequently than off, it reflects a light grey pixel; a mirror that’s switched off more
frequently reflects a darker grey pixel.
Inthisway,themirrorsinaDLP™projectionsystemcanreflect pixels in up to 1,024 shades of grey to convert the video or graphic
signal entering the DMD into a highly detailed grayscale image.
4.4 Adding Color
Adding color
Image 4-5
The on and off states of each micro mirror on the DMD chip are coordinated with the three basic building blocks of color – Red,
Green & Blue (RGB). For example, a mirror responsible for projecting a purple pixel will only reflect red and blue light to the projection
surface. The switching of the mirrors and the proportion of time they are ’on’ or ’off’ is coordinated according to the color shining on
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4. DLP System General Description
them. To an observer, these rapidly alternating flashes are not seen in the image; instead they see the projected image as a full and
correct color image.
4.5 Single chip DLP projection system
Single chip DLP projection system
Image 4-6
Televisions, home theatre systems and business projectors using DLP™ technology rely on a single DMD chip configuration like the
one described above. White light passes through a color wheel filter, causing red, green and blue light to be shone in sequence on
the surface of the DMD. The switching of the mirrors and the proportion of time they are ’on’ or ’off’ is coordinated according to the
color shining on them. The human visual system integrates the sequential color and sees a full-color image.
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4. DLP System General Description
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5. GP6 system functional description
5. GP6 SYSTEM FUNCTIONAL DESCRIPTION
About
The F90 projector series is a high brightness single chip laser phosphor projector.
The electronics system is based on the Barco Pulse platform, which offers advanced functionality such as pixel shift and complex
warp and blend adjustments.
5.1 Electronic platform
About
There are two main electronic PCB’s in the unit; PCB Mainboard and PCB Thermal Hub Board.
In addition there is a power supply and a keyboard/display PCB, and some peripheral PCB’s, such as USB interface, IR receiver,
thermal sensors.
Calibrations and settings for the unit are saved in a SD card on the Mainboard. When replacing the mainboard, this SD card must be
transferred to the new mainboard, in order to maintain the settings for the unit. Nevertheless, some calibrations has to be performed
again, such as the Constant Light Output, (especially in multi projector setup), and Lens Shift Motors.
It is crucial that all SD card data is transferred to the replacement PCB in the event of repair. Failure to do
this will compromise system dynamic data and lead to incorrect LFM notifications as well as possible network
control conflicts.
5.2 I/O’s and processing tasks:
I/O’s and processing tasks:
In the matrix below is listed the different PCB’s, and their main tasks. In order to localize a malfunction in the projector, it is an
advantage to know which function that is controlled by which PCB.
Together with the block diagram and the troubleshooting matrix, this can be a helpful tool in diagnostic.
See also the “Block diagram GP6 Platform” for an overview of the system.
PCB Tasks
Thermal Hub board Typical tasks as fans, cooling pumps and temperature sensors
are connected here.
DMD Peltier elements, Front and Rear.
Thermal monitoring
Lens shift
Zoom and focus motors
Lens position sensors.
CLO sensor
IR front sensor
Optical actuator
Air filter sensor
Pixel Shift
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5. GP6 system functional description
PCB Tasks
Main Board Typical tasks, Main signal input, Scaling and control board.
Process all I/O from the Back Panel, keypad, LCD screen.
Peripheral PCB, i.e. IR Sensors, USB input
Keyboard & Display
Phosphor wheels
Color wheels
Safety Switches
Air inlet temp. sensor
Air out temp. sensor
Communication with Thermal Hub Board and PSU unit
Communication with the Laser Driver PCB’s.
Laser Driver Powered by 390V from PSU.
Provide 36V pr cable to the Laser Clusters
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