Barco HDF W series User manual

HDF W series
Service manual
R5905312/01
24/01/2013

Barco nv
Noordlaan 5, B-8520 Kuurne
Phone: [phone]
Fax: [phone]
Support: www.barco.com/esupport
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.
The latest edition of Barco manuals can be downloaded from the Barco web site www.barco.com or from the secured Barco web site
https://my.barco.com.
Copyright ©
All rights reserved. No part of this document may be copied, reproduced or translated. It shall not otherwise be recorded, transmitted or
stored in a retrieval system without the prior written consent of Barco.
Trademarks
Brand and product names mentioned in this manual may be trademarks, registered trademarks or copyrights of their respective holders.
All brand and product names mentioned in this manual serve as comments or examples and are not to be understood as advertising for
the products or their manufacturers.

Table of contents
TABLE OF CONTENTS
1. Safety................................................................................................................. 5
1.1 Safety Instructions.................................................................................................................... 6
2. General............................................................................................................... 9
2.1 Convention projector orientation ....................................................................................................10
2.2 Location of the main components of the projector ................................................................................. 11
2.3 Spare parts for HDF series..........................................................................................................14
2.4 Projector block diagram ............................................................................................................. 15
3. Preventative maintenance actions .............................................................................19
3.1 1 month maintenance actions.......................................................................................................20
3.2 3 month maintenance actions.......................................................................................................21
3.3 2 year (or 1500 hours runtime) maintenance actions . . . ...........................................................................22
3.4 10 year (or 10000 hours runtime) maintenance actions............................................................................ 24
3.5 Lamp change maintenance actions................................................................................................. 25
4. Diagnostic Companion ...... .. .. .. .. .................... .. .. .. .................... .. .. .. .. .................... .. .27
4.1 Access to the Diagnostic Companion...............................................................................................28
4.2 Working with the Diagnostic Companion . .. ........................................................................................29
5. Troubleshooting .. .. .. .. ...................... .. .. .. .. ...................... .. .. .. ...................... .. .. .. .. ... 31
5.1 Troubleshooting checklist . . .........................................................................................................33
6. Removal and installation of the projector covers ...........................................................97
6.1 Removal of the front cover ..........................................................................................................98
6.2 Removal of the side cover...........................................................................................................99
6.3 Removal of the lamp cover........................................................................................................ .100
6.4 Removal of the input cover.........................................................................................................101
6.5 Installation of the front cover.......................................................................................................102
6.6 Installation of the side cover .......................................................................................................103
6.7 Installation of the lamp cover.......................................................................................................104
6.8 Installation of the input cover.......................................................................................................105
7. Power Input.......................................................... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 107
7.1 Replacing the input voltmeter’s fuse ...............................................................................................109
7.2 Getting access to the power elements.............................................................................................110
7.3 Removing the mains filter ..........................................................................................................112
7.4 Mounting a new mains filter........................................................................................................113
7.5 Removing the mains switch........................................................................................................114
7.6 Mounting the new mains switch. . . .................................................................................................115
8. Lamp and lamp house................. .. .. .. .. .. ........................ .. .. .. .. .. .......................... .. . 117
8.1 Introduction HDF Lamp & Lamp House . . . . .......................................................................................118
8.2 Removal of the lamp house ........................................................................................................119
8.3 Installation of the lamp house ......................................................................................................121
8.4 Removing the xenon lamp from the lamp house ..................................................................................123
8.5 Installing the xenon lamp in the lamp house ......................................................................................127
8.6 Resetting the lamp parameters . . . .................................................................................................133
8.7 Realignment of the lamp in its reflector............................................................................................135
8.8 Cleaning the UV blocker of the Lamp House ......................................................................................136
8.9 Cleaning the Reflector of the Lamp House........................................................................................137
8.10 Lamp info module replacement . . ..................................................................................................138
9. HDF Cold Mirror ................................................................................................. 139
9.1 Introduction HDF Cold Mirror.......................................................................................................140
10. Card Cage......................................................................................................... 141
10.1 Introduction HDF Input & Communication unit . ...................................................................................142
10.2 Removal of the Input & Communication Unit......................................................................................144
10.3 Installation of the Input & Communication Unit . . ..................................................................................145
10.4 Removal of an input module .......................................................................................................146
10.5 Installation of an input module .....................................................................................................147
10.6 Removal of the intermediate board guidance . . . ..................................................................................148
10.7 Installation of the WIFI module on the Communication module ..................................................................150
10.8 Installation of the GSM module on the Communication module ..................................................................153
10.9 Replacing the PMP board . . ........................................................................................................156
10.10 Replacing the Warp module........................................................................................................159
10.11 Replacing the Deinterlacing module ...............................................................................................160
10.12 Replacing the LCD Display Interface ..............................................................................................161
10.13 Replacing the LCD Display.........................................................................................................163
10.14 Replacing the Local Keypad .......................................................................................................164
10.15 Replacing the Local Keypad backlight.............................................................................................165
10.16 Replacement of the SMPS board . .................................................................................................166
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Table of contents
11. Lamp Power Supply ............................................................................................ 169
11.1 LPS module diagnostic LED’s......................................................................................................170
11.2 Removal of a LPS module . ........................................................................................................172
11.3 Installation of a LPS module .......................................................................................................174
12. Start Pulse Generator........................................................................................... 179
12.1 Introduction .........................................................................................................................181
12.2 Troubleshooting.....................................................................................................................182
12.3 Removal of the start pulse generator ..............................................................................................183
12.4 Installation of the start pulse generator . . . . . .......................................................................................185
13. HDF Light Processor ........................................................................................... 189
13.1 Introduction HDF Light Processor..................................................................................................190
13.2 Diagnostic...........................................................................................................................191
13.3 Removing the Light Processor.....................................................................................................192
13.4 Installing the Light Processor ......................................................................................................196
13.5 Replacement of the shutter ........................................................................................................202
13.6 Cleaning the Prism exit side .......................................................................................................204
13.7 Light Sensor module replacement .................................................................................................205
13.8 Adjusting the Fold Mirror ...........................................................................................................206
13.9 High Contrast plate replacement. . .................................................................................................208
13.10 Convergence controls ..............................................................................................................209
13.11 Converging the red pattern onto the blue pattern .................................................................................211
13.12 Converging the green pattern onto the blue pattern ..............................................................................213
14. Lenses and Lens Holder ....................................................................................... 215
14.1 Introduction Lens Holder . . . ........................................................................................................216
14.2 Available lenses ....................................................................................................................217
14.3 Lens selection ......................................................................................................................219
14.4 Lens installation ....................................................................................................................220
14.5 Lens removal .......................................................................................................................222
14.6 Lens safety cable . . . ................................................................................................................223
14.7 Cleaning the lens . . . ................................................................................................................225
14.8 Removing the Lens Holder . ........................................................................................................226
14.9 Mounting a new Lens Holder.......................................................................................................229
14.10 Scheimpflug adjustment............................................................................................................230
14.11 Replacement of the Vertical Shift stepper motor ..................................................................................234
14.12 Replacement of the Horizontal Shift stepper motor ...............................................................................236
15. Liquid cooling circuit........................................................................................... 239
15.1 Draining the liquid cooling circuit...................................................................................................240
15.2 Filling the liquid cooling circuit .....................................................................................................244
15.3 Refreshing the liquid cooling circuit................................................................................................249
15.4 Expelling air from the liquid cooling circuit.........................................................................................253
15.5 Pressure verification of the liquid cooling circuit...................................................................................256
15.6 Cleaning the cooling pump .........................................................................................................257
15.7 Replacement of the pump motor and rotor ........................................................................................259
15.8 Replacement of the complete cooling pump.......................................................................................263
16. Heat exchanger .................................................................................................. 267
16.1 Removing the defective heat exchanger . . . .......................................................................................268
16.2 Disassembling the heat exchanger assembly . . . ..................................................................................271
16.3 Assembling the new heat exchanger ..............................................................................................273
16.4 Mounting the heat exchanger assembly into the projector........................................................................275
17. Board replacement procedure ................................................................................ 277
17.1 Replacing the Fan control board . . .................................................................................................278
17.2 Replacing the Power distribution board............................................................................................280
17.3 Connections on the Power distribution board . . . ..................................................................................281
17.4 Replacing the motor control board (MCB) . . .......................................................................................283
17.5 Calibrate Motor Control Board .....................................................................................................286
18. Fan replacement procedures.................................................................................. 287
18.1 Replacement of the Card Cage electronics fans ..................................................................................288
18.2 Replacement of the SMPS fans. . . .................................................................................................289
18.3 Replacing the heat exchanger fan .................................................................................................290
18.4 Cold mirror fan......................................................................................................................291
18.5 Replacement of the Light processor compartment fan . ...........................................................................293
18.6 Mains input fan .....................................................................................................................295
18.7 Lamp cathode fan . . ................................................................................................................296
18.8 Lamp anode fan ....................................................................................................................301
19. Board Diagnostic LED’s. .. .. .. .. .. ............................ .. .. .. .. .. ............................ .. .. .. .. .. . 305
19.1 Fan Control Board (FCB) Diagnostic LEDs........................................................................................307
19.2 Motor Control Board Diagnostic LEDs .............................................................................................310
19.3 Power Distribution Board Diagnostic LEDs . .......................................................................................312
19.4 Display Interface Diagnostic LEDs.................................................................................................314
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Table of contents
19.5 DVI/HDSDI Input board Diagnostic LEDs . . .......................................................................................315
19.6 Communication Interface board Diagnostic LEDs.................................................................................317
19.7 Pixel Mapping Processor Diagnostic LEDs . .......................................................................................319
19.8 5 Cable Input board Diagnostic LEDs .............................................................................................321
19.9 LPS module diagnostic LED’s......................................................................................................322
Index.................................................................................................................... 325
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Table of contents
4R5905312 HDF W SERIES 24/01/2013

1. Safety
1. SAFETY
About this chapter
Read this chapter attentively. It contains important information to prevent personal injury while servicing the HDF projector. Fur-
thermore, it includes several cautions to prevent damage to the HDF projector. Ensure that you understand and follow all safety
guidelines, safety instructions and warnings mentioned in this chapter before servicing the HDF projector. After this chapter, addi-
tional “warnings” and “cautions” are given depending on the service procedure. Read and follow these “warnings” and “cautions” as
well.
WARNING:This manual is only intended for qualified service personnel.
Overview
• Safety Instructions
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1. Safety
1.1 Safety Instructions
WARNING:Before removing/replacing any projector components, disconnect the power to the unit mains
terminals.
Safety Instructions
1. Before returning an instrument to the customer, always make a safety check of the entire instrument, including, but not limited
to, the following items:
a) Be sure that no built-in protective devices are defective and/or have been defeated during servicing. (1) Protective shields
are provided on this chassis to protect both the technician and the customer. Correctly replace all missing protective shields,
including any removed for servicing convenience. (2) When reinstalling the chassis and/or other assembly in the cabinet,
be sure to put back in place all protective devices, including, but not limited to, insulating materials, barriers, covers/shields,
and isolation resistor/capacitor networks. Do not operate this instrument or permit it to be operated without all protective
devices correctly installed and functioning. Service people who defeat safety features or fail to perform safety checks may
be liable for any resulting damage.
b) Be sure that there are no cabinet openings through which an adult or child might be able to insert their fingers and contact a
hazardous voltage. Such openings include, but are not limited to, (1) excessively wide cabinet ventilation slots, and (2) an
improperly fitted and/or incorrectly secured cover panels.
c) Leakage Current Hot Check. With the instrument completely reassembled, plug the AC line cord directly into a 220 V AC
outlet (Do not use an isolation transformer during this test). Use a leakage current tester or a metering system that is
designed to comply with the new IEC, ANSI and UL standards. With the instrument AC switch first in the on position and
then in the off position, measure from a known earth ground (metal waterpipe, conduit, etc.) to all exposed metal parts
of the instrument (antennas, handle bracket, metal cabinet, screwheads, metallic overlays, control shafts, etc.). especially
any exposed metal parts that offer an electrical return path to the chassis. Any current measured must not exceed 3,5 mA.
Reverse the instrument power cord plug in the outlet and repeat test. ANY MEASUREMENTS NOT WITHIN THE LIMITS
SPECIFIED HEREIN INDICATE A POTENTIAL SHOCK HAZARD THAT MUST BE ELIMINATED BEFORE RETURNING
THE INSTRUMENT TO THE CUSTOMER OR BEFORE CONNECTING ACCESSORIES.
Leakage Current Tester
Reading should
not be above
3,5 mA
Test all exposed metal surfaces
Earth
Ground
+-
2-Wired cord
Also test with plug reversed
(Using AC Adapter plug as required)
AC Leakage Test
Device Under Test
Image 1-1
d) Ultraviolet Radiation exposure - Warning: This lamp can cause serious skin burn and eye inflammation from shortwave
ultraviolet radiation if not operated in enclosed fixtures. DO NOT operate this lamp in a fixture with a missing or broken lens
cover.
e) Ozone: Operating lamp generates ozone gas which is harmful to the respiratory system. Therefore the lamp should be
operated in adequately ventilated equipment.
2. Read and comply with all caution and safety-related notes on or inside the projector cabinet or on the projector chassis, or on
the picture tube.
3. Design Alteration Warning - Do not alter or add to the mechanical or electrical design of this apparatus. Design alterations and
additions, including, but not limited to, circuit modifications and the addition of items such as auxiliary audio and/or video output
connections, might alter the safety characteristics of this apparatus and create a hazard to the user. Any design alterations
or additions may void the manufacturer’s warranty and may make you, the servicer responsible for personal injury or property
damage resulting therefrom.
6R5905312 HDF W SERIES 24/01/2013

1. Safety
4. Lamp explosion Protection Warning – The lamp in this projector operates with a high internal pressure and there is a slight risk
that the lamp may explode, particularly if it is used beyond its rated life. Do not remove, install, or otherwise handle the lamp
in any manner without first putting on shatterproof goggles equipped with side shields. People not so equipped must be kept
safely away while lamps are handled. Keep the lamp away from your body. For continued explosion protection, replace the
lamp only with one of the same type number. Always replace the lamp before the rated life time.
5. Hot Chassis Warning - This projector chassis has two ground systems: the primary ground system is formed by the negative
voltage of the rectified mains (power) and is only used as a reference in primary circuits; the secondary ground system is
connected to earth ground via the earth conductor in the mains (power) lead. Separation between primary and secondary
circuits is performed by the safety isolation transformers. Components bridging these transformers are also safety components
and must never be defeated or altercated. All user-accessible conductive parts must be connected to earth ground, or are kept
at SELV (Safety Extra Low Voltage).
6. Observe original lead dress. Always inspect in all areas for pinched, out-of-face, or frayed wiring. Do not change spacing
between components, and between components and the printed-circuit board. Check AC power cord for damage. Take extra
care to assure correct lead dress in the following areas:
a) near sharp edges
b) near thermally hot parts - be sure that leads and components do not touch thermally hot parts
c) the AC supply
d) high voltage
7. Components, parts, and/or wiring that appear to have overheated or are otherwise damaged should be replaced with compo-
nents, parts, or wiring that meet original specifications. Additionally, determine the cause of overheating and/or damage and, if
necessary, take corrective action to remove any potential safety hazard.
8. PRODUCT SAFETY NOTICE - Many electrical and mechanical parts have special safety-related characteristics some of which
are often not evident from visual inspection, nor can the protection they give necessarily be obtained by replacing them with
components rated for higher voltage, wattage, etc. Use of a substitute replacement that does not have the same safety charac-
teristics as the recommended replacement part in BARCO service data parts list might create shock, fire, and/or other hazards.
Product Safety is under review continuously and new instructions are issued whenever appropriate. For the latest information,
always consult the appropriate current BARCO service literature.
9. Do not spray chemical on or near this instrument or any of its assemblies.
10. Electrostatically Sensitive (ES) Devices Some semiconductor (solid state) devices can be damaged easily by static electricity.
Such components commonly are called Electrostatically Sensitive (ES) Devices. Examples of typical ES devices are integrated
circuits and some field-effect transistors and semiconductor "chip" components. The following techniques should be used to
help reduce the incidence of component damage caused by static electricity:
a) Immediately before handling any semiconductor-equipped assembly, drain off any electrostatic charge on your body by
touching a known earth ground. Wear a commercially available high impedance discharging wrist strap device.
b) After removing an electrical assembly equipped with ES devices, place the assembly on a static dissipative surface such as
a 3M No 8210 table mat, to prevent electrostatic charge buildup or exposure of the assembly.
c) Do not use freon-propelled chemicals. These can generate electrical charges sufficient to damage ES devices.
d) Do not remove a replacement ES device from its protective package until immediately before you are ready to install it
(Most replacement ES devices are packaged with leads electrically shorted together by conductive foam, aluminium foil or
comparable conductive material).
e) Immediately before removing the protective material from the leads of a replacement ES device, touch the protective material
to the chassis or circuit assembly into which the device will be installed. CAUTION: Be sure no power is applied to the chassis
or circuit, and observe all other safety precautions.
f) Minimize bodily motions when handling unpacked replacement ES devices (Otherwise harmless motion such as the brush-
ing together of your clothes fabric or the lifting of your foot from a carpeted floor can generate static electricity sufficient to
damage an ES device).
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1. Safety
8R5905312 HDF W SERIES 24/01/2013

2. General
2. GENERAL
Overview
• Convention projector orientation
• Location of the main components of the projector
• Spare parts for HDF series
• Projector block diagram
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2. General
2.1 Convention projector orientation
Convention
This manual refers to the left side of the projector as the side at your left hand when standing behind the projector and looking at
the projection screen in front of the projector.
1
5
4
3
2
Image 2-1
1Front side (lens side)
2Right side projector (lamp & input side)
3Backside
4 Top side
5Left side (light processor side)
10 R5905312 HDF W SERIES 24/01/2013

2. General
2.2 Location of the main components of the projector
Housing
1
2
3
4
5
6
Image 2-2
1 Rear cover
2Topcover
3Side cover (side light processor)
4 Front cover
5Input & communication cover
6 Lamp cover
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2. General
Main internal components
2
3
1
6
57
4
9
10
11
8
Image 2-3
1 Lamp house with lamp
2 Lamp power supply (LPS)
3 Start pulse generator (SPG)
4 Light processor cover plate
5Light processor
6 Cold mirror assembly
7Anode fan assembly
8 Lens holder
9 Input & communication unit
10 Switched mode power supply (SMPS)
11 SMPS cover plate
12 R5905312 HDF W SERIES 24/01/2013

2. General
12
13
16
17
14 15
Image 2-4
12 Front filter
13 To p filter
14 Start pulse generator (SPG)
15 SPG cover plate
16 Water cooling circuit with heath exchanger
17 Heat exchanger filter
R5905312 HDF W SERIES 24/01/2013 13

2. General
2.3 Spare parts for HDF series
Up to date information regarding spare parts for HDF series
Barco continuously improves its service procedures for the customer. Managing spare parts is one of the key processes. The spare
parts list is subject to change. No spare parts list is included in this manual to ensure that no spare parts are ordered based upon
outdated information. Up to date information regarding spare parts, and much more, is available on the secured Barco web site
https://my.barco.com.
14 R5905312 HDF W SERIES 24/01/2013

2. General
2.4 Projector block diagram
Basic block diagram
Fan Control
Board
Motor Control
Board
Switched
mode power
supply
Lamp Power
Supply
LIM SPG
CLO
Power
Distribution
Board
IR
IR
Input &
Communication
Unit
Pixel
Mapping
Processor
Display Interface
Keypad
LCD
Deinterlacing
WARP
5 Cable input Sat. RED
Sat. GREEN
Sat. BLUE
Dual DVI input
3G SDI input
WIFI GSM
+ CTRL
+ FIB
+ Input selector
+ OSD
+ Blending
+ PiP
+ Test paterns
Ethernet, USB, DMX,
RS232, Wired IR IR
Image 2-5
CTRLController
FIB Formatter Interface Board
OSD On Screen Display
PiP Picture in Picture
CLO Constant Light Output
SPG Start Pulse Generator
LIM Lamp Info Module
Sat Satellite
IR Infra red Receiver
R5905312 HDF W SERIES 24/01/2013 15

2. General
Block diagram internal communication (Power distribution board)
PMP
(+ CTRL)
(+ FIB)
MCB
FCB
LIM
CLO
Sat. R
Sat. G
Sat. B
LPS
SMPS
Power
Distribution
Board PROM
I²C I²C
RS232
RS485
RS485
I²C
I²C
I²C
SPI
RS232
RS232
RS485
RS485
RS485
RC5
I²C
HighSpeed
PROM
µC
FPGA FPGA config
SPI
PROM
µC
FPGA FPGA config
I²C
PROM
PROM
IR IR
PROM
µC
PROM
PROM
PROM
PROM
µC
PROM
µC
CTRL
FIB
Baud:115200
Baud:250000
SW
Image 2-6
16 R5905312 HDF W SERIES 24/01/2013