Barco R1306981K(R12) User manual

BARCO PROJECTION SYSTEMS
Date:29.05.2001
INSTALLATION MANUAL
Replacement of the DLP UHB (Engine) in the
ELM series projectors
R1306981K(R12)
R1306991K(G10)
Art.No.:R5976199Rev: 00
KIT ENGINE
ELM

Due to constant research, the information in this manual is subject to change without notice.
Produced by BARCO NV, May 2001.
All rights reserved.
Trademarks are the rights of their respective owners.
BARCO n.v./Projection Systems
Noordlaan 5
B-8520 Kuurne
Belgium
Tel : [phone]
Fax : [phone]
E-mail : [email protected]
Visite Barco at the web : http://www.barco.com
Printed in Belgium

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Service and Assembly Warnings
Who This installation must be performed by authorized technical personnel only, trained
concerning Ultraviolet Radiation and Electrical shock hazards and protective measures
described on this note.
General
CAUTION
Before attempting to remove any of the projectors covers, the
projector has to be turned off and disconnected from the wall
outlet to minimize the risk of electric shock.
Before starting with the Replacement of the Engine, always let
cool down the projector after operation in order to reduce the heat
on the cold mirror and to avoid burns.
WARNING
Ultraviolet Radiation (UV) Hazards
The lamp contained in this product is an intense source of light and heat. One compo-
nent of the light emitted from this lamp is ultraviolet light. Ultraviolet (UV) light or UV
radiation from this lamp can produce similar effects on the skin and eyes that sunlight
does. Prolonged exposures to low levels of ultraviolet radiation can tan the skin, but
significant exposures can cause sunburns and chronic exposures have been linked to
skin cancer. Eye exposure to significant levels of UV radiation can cause photokeratitus
or welders flash. Chronic eye exposure to significant levels of UV radiation can result
in cataracts.
Protect yourself and your employees by making them aware of the hazards and how to
protect themselves. The best method of protection is to avoid or prevent exposure to
the UV radiation from the lamp. Enclosing the UV radiation is the preferred method.
Another effective method uses distance. Increasing the distance from the lamp, de-
creases the potential hazard from the UV radiation.
Protecting the skin can accomplished by wearing tightly woven garments and gloves.
Protecting the eyes from UV can be accomplished by wearing safety glasses that are
designed to provide UV protection. In addition to the UV, the visible light from the lamp
is intense and should be considered when choosing protective eyewear.
Note: Some medications are known to make individuals extra sensitive to UV radiation.
(The American Conference of Governmental Industrial Hygienists (ACGIH) recom-
mends occupational UV exposure for an 8-hour day to be less than 0.1 microwatts per
square centimeters of effective UV radiation. An evaluation of the workplace is advised)
PRODUCT CARE
Installation Kit: - The Engine is designed for use ONLY with the BARCO ELM series
projectors.
Replacement parts - When replacement parts are required, be sure the service
technician has used original BARCO replacement parts or authorized replacement
parts which have the same characteristics as the BARCO original part.
Unauthorized substitutions may result in degraded performance and reliability, fire,
electric shock or other hazards. Unauthorized substitutions may void warranty.
Under no circumstances are BARCO parts repairable by anyone other than BARCO.

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Contents of the Kit
Kit Contents The kit contains the following items :
Art. No Description Quantity Art. No Description Quantity
R1306981 DLP SXGA UHB (R12) 1
or
R1306991 DLP XGA UHB (G10) 1
R5976199 MAN INS G10/R12ELM ENGINE 1
Illustration
Warning
ATTENTION
OBSERVE PRECAUTIONS
FOR HANDLING
ELECTROSTATIC
DISCHARGE
SENSITIVE
DEVICES
R818727 FRM G10 ELM FIX PLT PACKAG 1
R818727
Remark In the following chapters we will (for practical reasons) refer to DLP (S)XGA UHB as
Engine.

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Removing the top and side projector covers
What has to be
done
To access the Engine the top and the side projector covers have to be removed.
Necessary Tools Screwdriver 5 mm - Allen Key 5mm
Warning ! Refer to Service and Assembly WARNINGS in front of document.
Removing the top
cover
To remove the top cover, follow the next procedure:
1
2
3
4
5
1
1&2
1&2
1
1
Unplug the Power cord plug from the projector power input
connector (A).
Remove the linch pin (B) from the clevis pin (C) on each
stud (D).
Slide the clevis pin out of the stud.
Remove the 4 bolts (E) holding top cover to main frame.
Remove the metal top cover.
Step Action Image
Illustrations
A
D C B
Image 1
E
Image 2
to be continued on next page

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Removing the top and side projector covers (Continued)
Illustrations
Image 2
Removing the
side covers
To remove side covers, follow the next procedure:
1
2
3
1
1
3
On the Signal input side of the projector, turn the indicated
bolts (A) a quarter turn counter clockwise to unlock.
Flip the bottom of the side cover (B) a little towards you
and pull it downwards to remove.
Do the same for the other side cover (bolts C on image 3)
Step Action Image
A
Image 1
B
C

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Access to the Engine module
What has to be
done
The studs and crossbar above the Formatter box and the cover of the box itself have
to be removed to access the module
Necessary Tools Small screw driver flat-blade 4.5mm
Removing the
studs
To remove the studs and crossbar, follow the next procedure:
1
2
3
2
1
Remove the 3 bolts (A) fixating each stud to main frame
Remove the bolt (B) fixating the wrist band (C) to cross
bar.
Remove both studs and crossbar.
Step Action Picture
To be continued on next page
Illustrations
A
B
Picture 1
C
Picture 2
Picture 3

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Access to the Engine (continued)
Removing the
Formatter box
cover
To remove the Formatter box cover, follow the next procedure:
1
2
3
4
1&2
2
1
Loosen the 6 spring screws (A) fastening the box cover to
frame.
Remove the bolt (B) fixating the wrist band (C) to frame.
Disconnect the connectors (D) of the 2 FANS assuring top
cooling for the engine.
Remove the box cover now.
Step Action Picture
Illustrations
AB
C
D
A
Image 1
Image 2
To be continued on next page

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Access to the Engine (continued)
Illustration
Location of the
Engine (Right
view of the
Projector)
Image 3
Remark Depending on the projector the picture may not always coincide with the reality (metallic
frame slightly different etc,...). However, the procedure for removing the Engine re-
mains the same for every G10 or R12 ELM projector.

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Formatter module Disconnection
What has to be
done
The 3 flex foil connectors have to be removed from the module.
WARNING Take all necessary precautions while handling the Static-Sensitive Formatter
module.
Removing the
connectors
To remove the connectors, follow the next procedure:
1
2
3
1
1
2
Push for each flexfoil connector the lock clips (A) outside
to unlock.
Carefully unplug the 3 flexfoil connectors (B) from module
Unlock the module by pulling upwards both module locks
(C)
Step Action Picture
Illustrations
Picture 1
A
B

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Removing the Cables
What has to be
done
The remaining cables connected to the engine have to be removed.
Necessary Tools none
To be continued on next page
Removing the
studs
To remove those cables, follow the next procedure:
1
2
3
1
2&3
4(next
page)
Remove the bleu cable connector (A) coming from the
Temp & Motor Control module.
Untie the cables from the frame by unlocking the clips (B).
Depending on the projector, these cables can be fixed
under or above the metallic frame ( see 2&3)
Remove the 8 connectors (C) on the module
Step Action Picture
Illustrations
A
Image 1
Picture 3
B
Picture 2

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Removing the Cables (Continued)
Illustrations
Picture 4
C

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Removing the Engine
What has to be
done
The Engine has to be removed.
To be continued on next page
Necessary Tools Hexagon ball driver 2.5 or L-shaped driver (2.5) + pliers
Removing the
Engine
To remove the Engine, follow the next procedure:
1
2
3
4
5
1
2&3(next
page)
4(next
page)
4&5(next
Loosen the 2 screws (A).
For the third screw (B) located on the backside use a long
hexagon ball driver or the L-shaped dirver (a) in combina-
tion with the pliers (b) to unlock the screw.
Lift gently the engine from its place.
Place the engine on the support plate, by aligning it with
the guiding holes (C) and fix it with the 3 screws.
Insert the 3 flexfoil connectors in the slots (D) of the
support plate and tie each of them with the cable ties (F).
Step Action Picture
Illustrations
Image 1
Image 2
B
A

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Removing the Engine (Continued)
Illustrations
CD
Image 5
Image 3
D
Image 4
F
a
b

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Mounting the Engine
To be continued on next page
Removing the
Engine
To remove the Engine, follow the next procedure:
1
2
3
4
1
1
2&3(next
page)
4(next
page)
Unpack gently the engine and put it on a table
Loosen the 3 screws and remove the flexfoil plugs from
their place.
Put the engine on the lightpipe (A) and aligne it with the
guiding pins (inclined arrows on image 2).
Tighten the 3 screws (B).
For the third screw located on the backside handle as
explained in chapter Removing the Engine.
Step Action Picture
Illustrations
Image 1
D
F
What has to be
done The new Engine has to be Mounted.
Necessary Tools Hexagon ball driver (2.5mm) or L-shaped driver
pliers

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Mounting the Engine (Continued)
Illustrations
Image 3
Image 2
A
B
Image 4

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Formatter Module Connection
What has to be
done
The Formatter module has to be connected to the engine.
WARNING Take all necessary precautions while handling the Static-Sensitive Formatter
module.
to be continued on next page
Connection of
the module
To reconnect the Formatter module, follow the next procedure:
1
2
3
4
5
1
1&2(next
page)
2
3
3
Slide the module slightly upwards to facilitate the following
operations.
Caution: Inspect the plug for pin damage and be sure the
plug fits correctly the connector to avoid damage to the
pins.
Carefully insert the 3 flexfoil plugs (C) into their respective
connector.
Be aware that the red channel plug (connector in the
middle (!)on image 3 ) has to be plugged with the text on it
upside down.
Lock each plug by pushing the plug clips (D) to the inside.
Slide the module fully downwards until the module seats.
Lock the module in its frame by pushing the 2 module locks
(B) downwards.
Step Action Image
Illustrations
Picture 1

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Formatter Module Connection (Continued)
D
Image 2
C
Illustrations
B
Image 3
!

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Replacing the Cables
What has to be
done
The remaining cables have to be connected to the engine.
Necessary Tools none
To be continued on next page
Connecting the
Cables
To connect these cables, follow the next procedure:
1
2
3
1
2
3&4(next
page)
Reconnect the bleu cable connector (A) coming from the
Temp & Motor Control module.
Plug the 8 connectors on the module (B)
Tighten the cables on the frame by locking the clips (C).
Depending on the projector these cables can be fixed
under or above the metallic frame ( see Image 3&4)
Step Action Picture
Illustrations
A
Image 1
Picture 2
B

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Replacing the Cables (Continued)
Illustrations
Picture 4
C
Picture 3