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Overview DR120 Service manual [v00]

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1. 44 Electronic spares and servicing Image 7 20 PMP connections Image 7 21 board to board to formatter connector removed 7 7 The formatter Service sheet e a van bates Rantis gt Amerface R 47P 1047 DIBUFO IPBIOMELP KOREA Image 7 22 m t y 3313353 2 y a R5976794 OVERVIEW DR120 06 07 2004 7 Electronic spares and servicing R76760K Formatter wihout DLP chip 7 7 1 Description of the formatter White peaking WP The white segment interval of the color wheel is used for brightness contrast ratio enhancement therefore the lamp and the DMD must be synchronized to the color wheel in order to temporarily peak the lamp s drive signal during the white interval this is called White peaking Description The formatter board is a digital image processing unit where the image data is 100 digital from the input port to the image projected on the display screen Digital input is accepted from the 30 bit RGB image input port up to the native DMD resolution The formatter performs 2 main tasks e Image processing The formatter processes the digital input and converts the data into a bit plane output format to drive the DMD image bus and provides de gamma white peaking color space conversion contrast and brightness image adjustments color coordinate adjustment allowing independent adjustment of primary and secondary colors and white poin
2. R5976794 OVERVIEW DR120 06 07 2004 _ BI 10 Troubleshooting 2 One or more of the secondary supply Switched Mode voltages is NOK Power supply U SMPS doesn t start SMPS page 30 U UNDERTEMP_AMB 1 Ambient temperature is too low approx Fan control page lt 5 C 37 ibili Software version doesn t support the Warp board version 3 4 SW incompatibility 10 2 History and diagnostics using the OSD menu 10 2 1 Shutdown History What can be done The Projector will keep a history of the 5 recent failures along with the Lamp Runtime on which the failure happened that caused a shutdown of the projector Following Failures are logged PWR_GOOD FAILED e OVERTEMP PFC OCCURED e UNDERVOLTAGE FAILED FAN 1 FAILED FAN 2 FAILED e OVERTEMP_LAMP OCCURED e OVERTEMP_AMB OCCURED How to display the Shutdown History info 1 Push the cursor key f or to highlight Shutdown History menu 10 1 2 Press ENTER to select The Shutdown History information screen will be displayed menu 10 2 3 Press EXIT to return to the Service Mode menu SERVICE SHUTDOWN HISTORY BARCO LOGO Most recent on top PRESET INPUT BALANCE FAN 1 FAILED 37 hrs I2C DIAGNOSIS NO INFO NO INFO NO INFO NO INFO LIGHT SENSOR SHUTDOWN HISTORY dis NR Select with y or Select with y or then lt ENTER gt then lt ENTER gt lt EXIT gt to retu
3. When to replace the lamp The lamp must be replaced at the end of lifetime Necessary tools hexagonal ball driver 5 Start up 1 Push the cursor key f or to highlight Reset Lamp Run Time menu 9 1 2 Press ENTER The following warning will be displayed Risk of electrical shock Reset lamp run time is reserved to qualified service personnel menu 9 2 3 Press ENTER See menu 9 3 R5976794 OVERVIEW DR120 06 07 2004 nsss OS lS 9 Optical Spares and servicing procedures 74 4 Enter the serial number of the new lamp 5 Press ENTER SERVICE IDENTIFICATION CHANGE PASSWORD CHANGE PROJ ADDRESS CHANGE BAUDRATE PC RESET LAMP RUNTIME LAMP RUNTIME HISTORY LIGHT OUTPUT VOLTAGE DIAGNOSTICS ORE Select with or then lt ENTER gt lt EXIT gt to return WARNING RISK OF ELECTRICAL SHOCK RESET LAMP RUN TIME S is reserved to qualified rvice personnel lt ENTER gt to accept lt EXIT gt to return Menu 9 1 Menu 9 2 How to replace the lamp 1 Unscrew the hexagonal screw image 9 6 Open the side door image 9 7 Disconnect the lamp image 9 8 Remove the lamp image 9 10 Mount the new lamp Move lamp locking handle upwards PS ea a pp Close and secure the side door Enter serial number lt ENTER gt to accept lt EXIT gt to return Menu 9 3 Use the long screwdriver to
4. 12C DIAGNOSIS INPUT SELECTOR 16H LIGHT SENSOR 1CH FORMATTER 34H FAN CONTROL 72H POWER SUPPLY 78H MOTOR DRIVER 7AH POWER SUPPLY CONTROL 7CH VOLTAGE DIAGNOSTICS 90H VOLTAGE DIAGNOSTICS 92H with or gt to return DCA I2C DIAGNOSIS DCA LIGHT SENSOR 1CH FORMATTER 34H FAN CONTROL 72H POWER SUPPLY 78H MOTOR DRIVER 7AH POWER SUPPLY CONTROL 7CH VOLTAGE DIAGNOSTICS 90H VOLTAGE DIAGNOSTICS 92H VOLTAGE DIAGNOSTICS 94H Scroll with or lt EXIT gt to return Menu 10 8 Menu 10 9 R5976794 OVERVIEW DR120 06 07 2004 INDEX A access 17 72 boards 17 right side 72 B back view 19 board 17 location 17 board location 17 C color wheel 67 68 adjustment 68 replacement 67 color wheel and sensor 66 description 66 color wheel motor 66 color wheel sensor 66 comms interface 42 replacing 42 Connector 7 Instructions 7 control 37 fan 37 conventions 7 CPU 52 D diagnostics 90 dimmer sensor 60 DLP chip 80 dustfilter 59 E electronic 27 spares and servicing 27 electronic spares 41 54 lamp driver 54 RGB input 41 error history 90 F fan 37 control 37 fan ctrl 38 connections 38 fan replacement 64 65 big lamp fan 64 lamp top fan 65 formatter 45 47 48 50 connections 48 description 45 diagnostics 4 7 replacement 50 G general 7 i
5. Case 5 The image shows a sharp illuminated area rotated with respect to the DMD active area represented by a light hairline for clarity with respect to the DMD active area 78 R5976794 OVERVIEW DR120 06 07 2004 9 Optical Spares and servicing procedures Image 9 21 With a BLACK test pattern the illuminated area around the DMD active area overfill becomes much more visible This can be used for fine tuning of the centering rotation of the illuminated area First of all the folding mirror has to be set in NOMINAL position with screws A B and C Once the mirror is in nominal position only screws A and B should be used for fine adjustment How to adjust the lightpipe folding mirror 1 Adjust roughly the folding mirror screws A and B only and the lightpipe rotation in order to have something similar to CASE 2 here above The important thing is that you must see one of the two corners that has to be sharply imaged that is one of those along the short diagonal of the parallelogram shaped illuminated area image 9 22 Adjust the sharpness in this corner with the lightpipe Z axis adjustment mechanism sheet metal plate Lock the lightpipe Z axis adjustment mechanism Adjust the folding mirror and the lighpipe rotation you may need a few iterations in order to get the illuminated area perfectly centered and aligned with the DMD active area When adjusting the lightpipe rotation it is necessary to keep
6. fe Full ight on Se a ae oo enable Upload as de aut Image 8 19 Measurements and adjustments On the right you can see the oscilloscope image FULL LIGHT ON checked The upper curve is a signal from the formatter where you see a rectangular signal every rotation of the Color Wheel On the bottom the signal from the photodiode is seen Note that the diode has some wavelength dependent sensitivity and this combined with the respective lamp efficiency for different colors results in a plot where the signal from the red segment is lower than the one from blue green and white If we uncheck the FULL LIGHT ON option the white segment and the spokes are removed WP 0 Tek Rum AO Samp be LETFIE Bik Fun 444545 sam pla Ear ce LT l el E T i AN m E ANIA ss PRE a M 35 395 Ek Fane 3 y i i i z R l CJ E aa f N Er i i Eej ju a El U Eu TPS RED EIT ke RED lz E E a i al SUD ttm I Im tht J XIV Thi ae Image 8 20 left image WP 10 right image WP 0 Here the color wheel index corresponds to a certain time difference between the onset of the timing mark index and the onset of the red segment time x coordinates on the image If we enter 9000 instead of 12500 the formatter thinks that the red segment starts earlier On the other hand if we would enter a value larger than 12500 the formatter will think the red segment starts later and
7. Do not use any kind of tools when disconnecting a connector R5976794 OVERVIEW DR120 06 07 2004 zz o o o 7 2 General Information Board To Board Connector Used here to connect the PMP connection unit Conhead FB PMP to the the PMP e Board To Board Connectors are mounted directly on the Board do not use any tools when disconnecting these connectors e To disconnect carefully lift the board e a La ln kur U EEEN an t 2 a e FF Se g Bl E 3 Y E ri Zn ak AA aa f A 3 E zz SR E u a 3 A u Y Image 2 2 board to board disconnected Mini Coax Connector Used here to connect the RGB input signal to the PMP board Do not bend the mini coax connector when pulling it out of the mini coax socket pull it out in a straight way BS H A MO GSE Image 2 3 Be extra careful when dis connecting the mini coax keep in mind the mini coax socket is just soldered on the board R5976794 OVERVIEW DR120 06 07 2004 2 General Information Flat Cable Connector Type 1 This type of connector can be found on the CPU the RGB Input e Do not use any tools when dis connecting a flat cable connector otherwise damage may occur on the mini locks e Disconnect by simultaneously pulling out the 2 mini locks on both sides of the flat cable connector s F 3 7 T Sas Fe 2 u LL INTL Image 2
8. LI CJ BV 5 Image 7 9 a Voltage diagnostics on projector 34 R5976794 OVERVIEW DR120 06 07 2004 7 Electronic spares and servicing 7 2 3 Connections Connector overview 3151 OO J 00 Image 7 11 20 119 We MCG M0 Image 7 10 Connector layout J1 to from PFC Value PWM signal representing the t of the PFC heatsink R5976794 OVERVIEW DR120 06 07 2004 _ 385 7 Electronic spares and servicing 36 J110 to communication interface J150 to PMP PWR GOOD 2 voltage monitoring for Formatter eee LL 3 Lamp Enable lamp ctrl signal from formatter active high 4 Lamp Litz feedback from LPS active low J151 to lamp driver CC 1 Lamp enable lamp ctrl signal from formatter active high ENS CTO MEN 3 Lamp litz feedback from LPS low lamp lit J200 to PMP CO WA CO CA C WA R5976794 OVERVIEW DR120 06 07 2004 7 Electronic spares and servicing J460 to controller CN ETT CT J700 24 input CS CET CN CE CEA E EN 1 3 Fan control Service sheet J np TR STEPPER PPL Oa ET tr o MN oe gt m 3 4 e p M y ej h f 5 h A P WZ veert N La Pa z 0 a LAP N N u w ACET a T 4 he raj rea Image 7 12 R5976794 OVERVIEW DR120 06 07 2004 _ 37 Electronic spares and servicing ETT CET A 7 3 1 38 The fan control module kit is delivered along with the fan connector module Conn
9. from SMPS J503 to from color wheel sensor via interconnection unit CN CET CN J501 to color wheel motor via interconnecton unit CN CSC Jee OUT C phase C motor Color Wheel OUT A phase A motor Color Wheel OUT B phase B motor Color Wheel CENTER centertap motor Color Wheel 7 7 4 Interconnection unit Description The interconnection unit links the formatter to the various peripherals For the location of the unit image 8 9 3102 J104 to formatter de nalor whia 1 color wheel sensor Sensor 3101 On 2103 to color wheel alie to formatter motor El Sd Color Wheel motor 3113 AA Pt FE h _ 8 ia 114 to dimmer motor 7 hg Mh LE RE J111 J112 to dimmer to dimmer driver driver via via fan control board fan control board Image 7 27 R5976794 OVERVIEW DR120 06 07 2004 _ a 409 Electronic spares and servicing 7 7 5 Replacing the formatter 50 CAUTION When replacing the formatter board or DLP chip always check the DMD bias switch on the board Never power up the projector with inadequate settings How to remove the formatter board 1 Open the backside panel 2 Remove the 2 flat cables image 7 28 Tip refer to the General information chapter for connector guidelines 3 Remove the heatsinkr by removing the 2 screws image 7 29 4 Unscrew the 2 bottom screws retaining the hole mechanical assembly image 7 30 Tip for more info about the assembly ima
10. gt PER5976794 OVERVIEW DR 120 06 07 2004 9 BOARD LOCATION Overview Board Access Projector Front section Projector Back section 5 1 Board Access 5 Board Location Unfolding the projector The projector allows a quick access of most board and optical elements Basically the projector s general configuration can be summarized as follows En a a B a A Ll i IMAGEADATA PROCESING Ml j r C I Ir LJ FE nf Ee ik a a E pny LL a s 1 a r i JER ie i N fi ih el Ah Er i en k a 11H Bee Image 5 1 Top view of the projector all panels opened 5 2 Projector Front section Front view The projector s front section contains mainly the power control boards R5976794 OVERVIEW DR120 06 07 2004 17 5 Board Location Image 5 2 i p Mrd oo it Image 5 3 Image 5 4 CET ETT OOO R5976794 OVERVIEW DR120 06 07 2004 18 5 Board Location CNC nen ese O em eme CENT CN The fan connector board is delivered along with the fan ctrl board in the same spare kit R763942K How to access the front section 1 Loosen the 2 screws on the topside 2 Rotate the front panel image 5 5 Ole eae ee em ak ar a Image 5 5 A Front view panel opened B Right view panel opened 5 3 Projector Back section Back view The back section of the projector con
11. page 50 2 The optical path is now visible and servicing or adjustments can be done See image 9 1 Image 9 1 9 1 2 Access via the front side When to acces the optical components via the front side The access of the following optical components is made possible via the front side of the projector e Color wheel sensor Dimmer These components are protected by a black cover which has to be removed R5976794 OVERVIEW DR120 06 07 2004 A 71 9 Optical Spares and servicing procedures How to access the optical components via the front side 1 Open the front panel 2 Loosen and remove the 2 screws retaining the black cover image 9 2 See image 9 3 Image 9 2 Image 9 3 location of the color wheel and dimmer 9 1 3 Access via the right side When to access the projector via the right side The lamp is located at the right side of the projector and can be accessed via the right side door 6 I i i E PDS Image 9 4 TQ Ez gl 3 _ i_ xI xz R5976794 OVERVIEW DR120 06 07 2004 9 Optical Spares and servicing procedures 9 2 UHP lamp Service sheet Image 9 5 9 2 1 Description Lamp description The lamp used in the OverView DR120 is a 120W UHP Ultra High Pressure lamp ECC ECTS 9 2 2 Lamp replacement CAUTION Do not touch the cover glass with your fingers If the lamp is touched finger prints can be removed by cleaning the lamp with alcohol
12. a PC 2 Open the software wm_optics exe In the upper left part of the window four symbols appear image 4 4 3 The symbol on the left a connector leads you to a new window Communication settings See image 4 5 4 Define the communication parameters to establish a connection between the computer and the projector This includes the projector address and the computer s communication port used Note When the second symbol from the left is highlighted this indicates that there is no connection to the projector yet If this button is pressed the program tries to connect to the projector If the communication settings are correct the third symbol from the left will become highlighted while the second one will become transparent The third symbol indicates that a running connection is present The uttermost right button the key is a button that has to be pressed to enable some extra features in some versions of the software lifetime test demo mode It also makes it possible to download data to the projector and make this data the default values to be used with this projector 5 Press Comm settings This leads us to an additional window where the projector s baud rate has to be entered The rest of the parameters should not be changed R5976794 OVERVIEW DR120 06 07 2004 4 Software Image 4 5 Image 4 4 R5976794 OVERVIEW DR120 06 07 2004 OS 4 Software 16 zzz ooooro _ ooooccHHHHQQQV MsSbSIMtlt
13. and centre bottom areas R5976794 OVERVIEW DR120 06 07 2004 83 9 Optical Spares and servicing procedures Image must be titted CLOCKWISE Lens must be tilted CLOCKWISE _Projector Optical axis projection lens Screen Floor Image 9 27 Lens must be tilted clockwise mae 9 28 Centre Top Scheimpflug Adjustment Centre Bottom Scheimpflug Adjustment 1 Screw bolt B max 1 8th of a turn and unscrew bolt C by approximately the same amount image 9 29 image 9 30 2 Check if the bottom area of the image is still focused in front of the screen 3 Repeat steps 1 and 2 until the centre bottom of the image is focused on the screen together with the centre and centre top areas Image must be tilted COUNTERCLOCKWISE Lens must be tilted COUNTERCLOCKWISE Projector Optical axis projection lens Screen Floor Image 9 29 Lens must be tilted counterclockwise 84 R5976794 OVERVIEW DR120 06 07 2004 9 Optical Spares and servicing procedures Image 9 30 Centre Bottom Scheimpflug Adjustment 9 5 1 3 Left Right Scheimpflug Adjustment How to start the Left Right Scheimpflug Adjustment 1 By using the same piece of white cardboard find out whether the centre left or centre right area of the image is focused in front of the screen 2 ls the centre left area of the image focused in front of the screen If yes Proceed with the Centre Left Scheimpflug Adjustment If no The centre right
14. be read via IPC To control the SMPS a PCF 8574 has also been added This can again via I C switch on the PFC and the SMPS The control signals temperature PFC undervoltage and power good can be read A very interesting feature of the PCF8574 is the interrupt line INT that goes low in case of a change of input signal This can be used to detect a change in one of the signals monitored however this only lasts for the time the change is present R5976794 OVERVIEW DR120 06 07 2004 7 Electronic spares and servicing The speed with which the IC s are polled is not high enough to be sure that every short change on any input will be detected so an extra flip flop is added to hold the OR ed interrupt line 1603 until it can be read by 1602 The software can then take appropriate actions and the flip flop will be reset Undervoltage To detect a coming voltage drop due to a failure of the mains or any other cause that switches off the projector a circuit has been added that checks the 380VM line from the PFC 1703 As soon as the output voltage of the PFC drops below a predetermined level this is detected by the IC and a signal undervoltage is fed to the secondary side via 1702 This level is depending on the output voltage of the PFC which is switched between 290 VDC when the input voltage is between 85 and 140 VAC and 375 VDC with input voltages over 140 VAC The circuit responsible for the level setting is set around Q700
15. names mentioned in this manual may be trademarks registered trademarks or copyrights of their respective holders All brand and product names mentioned in this manual serve as comments or examples and are not to be understood as advertising for the products or their manufactures Table of contents TABLE OF CONTENTS OO 3 121 Sale Instruclions nn a aaa AAA EA ae 3 2 General INTO Ma lO Nic di 7 2 1 IMIEICORNECHOR diag FANN Na ts a A A A AEO ete 7 2 2 CONYEMUO S Len den ee dee ta O E Abebe ree ee NP AR DAE R lees 7 2 3 CONNECIONIASTUCAONS carol ir a benede tee nt 7 9 DDare parts Ist uns ee OER ERLE EOG ARANA 11 9 17 Spare pans S nossa dra op a ar AUE OP EA ME BAS tO GOA ee rau PASA 11 E a kk O 13 A1 OS AA E A EEE STE URL ACEON 13 4 2 Oplical ealibration solware cir E A Id 14 dl Board LOCA MON or road OR SK ace es 17 e A BOGATO O A RD SO betten then AE A kette o ee ARE AC a 17 3 2 FIOJECIOL ETONCSSCIONN A RAR 17 5 3 Projector BACK SECION eo ZOT AR EA EA AE AA A W WRO AWA hebt EE 19 0 GompenentlecCaton reiner 23 6 1 Pplica COMPONEMIST it e OD e A ndi 23 6 2 M amp chanlical Component location an DAR be o AA A ARS 24 1 Electronic spares and SErVICING a a 27 dal ROWer Factor CONECO Pra a lands ne re GE o 27 AL DOSCHDUOM wa deco aaa a reelle unerkannt 27 Piz SCONNECNORS ea e Pewee eneen si ds rasa ria cod 28 KAMA Diagnostics ofthe PFO Gesi nan o ota CAE aa 29 71 4 Replacing ine PFG tnt nen
16. not bend the flat cable otherwise internal cable damage may occur e Insert the flat cable in a straight way into the flat cable connector Disconnect by simultaneously pulling out the 2 mini locks on both sides of the flat cable connector MO zzz 4 O O O O O QRQ gt Q 9 ouOMVtDPPER5976794 OVERVIEW DR 120 06 07 2004 3 Spare parts list 3 SPARE PARTS LIST 3 1 Spare parts list Which spares are available for the OverView DR120 Following spares can be ordered Table 3 1 R5976794 OVERVIEW DR120 06 07 2004 _ 1 3 Spare parts list 12 AAA _ _ ooooooo cc aaw RP R5976794 OVERVIEW DR 120 06 07 2004 4 Software 4 SOFTWARE Overview e Software upgrade Optical calibration software 4 1 Software upgrade Description The software upgrade of the projector is done via the RS232 interface The last up to date software can be downloaded from the Barco s secured website EIRIC IRS 232 IN RS 232 OUT eee E H C dp Computer Image 4 1 Necessary tools Barco LCD DLP Projector Code Control Program download program How to upgrade the software 1 Connect the PC to the projector via the RS232 port 2 Switch the projector to standby 3 Start the download program image 4 2 Tip The download program can also be downloaded from the secured website 4 set the address 5 set the communication port 6 set the baudrate Tip The minimal baudrate is 9600 b s recommended baudrate 115
17. sharpness of the image in the central part of the screen If the image is sharp central part only then no focus adjustment is necessary Necessary tools e M5 hexagonal key cardboard What should be adjusted With the aid of a piece of white cardboard find out whether the sharp image is in front or behind the screen 1 Hold the cardboard parallel to the screen plane and displace it from the screen towards the projector along the line joining the centre of the screen and the projection lens 2 If it is possible to find a sharp image between the projector and the screen then the image is in front of the screen Otherwise the image is behind the screen When the image is in front of the screen 1 Screw slightly all bolts A B and C by the same amount projection lens gets deeper in the projector until the central part of the image appears sharp on the screen image 9 35 Tip Proceed by quite small steps 1 8th to 1 4th of a turn maximum as the image moves very quickly Image 9 35 Focus Scheimpflug adjustment screws When the image is behind the screen 1 Unscrew all bolts A B and C by the same amount projection lens gets outer of the projector until the image central part appears sharp on the screen image 9 35 R5976794 OVERVIEW DR120 06 07 2004 _ __ __ __ __ _ _ _ A AAAAoHap a R R ge 9 Optical Spares and servicing procedures 88 R5976794 OVERVIEW DR120 06 07 2004 10 Troubleshooting 10 TROU
18. the lighpipe holder slightly pressed against the Z axis adjustment mechanism in order to keep the focus For fine adjustment switch to a BLACK image test pattern in order to clearly see the illumination overfill At the end of the adjustment always check on a WHITE image that no shadows or dark colored fringes are visible in the DMD active area Lock the lightpipe rotation and check one more time the absence of any artifact at the edge of the DMD active area WHITE image Image 9 22 R5976794 OVERVIEW DR120 06 07 2004 _ 79 9 Optical Spares and servicing procedures 9 4 DLP chip and accessories 80 Description me ECC oem 2 Image 9 23 DMD fixation system The DLP chip is in a certain way the component which forms the link between the optical system and the electronic part of the projector it must be placed in the optical path and at the same time it must be connected to the formatter from which it receives its control signals To achieve this the DLP chip is placed between the optical path and the formatter A mechanical sandwiching assembly allows the DLP chip to make contact with the formatter s bottom PCB by securing it between both formatter and prisma bridge At the same time it fixes the formatter to the projector frame i e to remove the formatter one must remove the DLP chip and its assembly R5976794 OVERVIEW DR120 06 07 2004 9 Optical Spares and servicing procedures I
19. 1 see Access via the backside page 71 CAUTION Never touch the gold contacts on the chip on the interposer or on the formatter Fingerprints may damage the chip When replacing the DLP chip interposer assembly be sure that the sign screened on chip is located at the top right corner Lens holder adjustments 9 5 1 9 5 1 82 Introduction Focus zoom adjustments are possible on the lens itself but adjusting the lens holder allows a good margin afterwards Overview e Scheimpflug Adjustment Focus adjustment Scheimpflug Adjustment Overview e Scheimpflug Adjustment Overview e Top Bottom Scheimpflug Adjustment e Left Right Scheimpflug Adjustment 1 Scheimpflug Adjustment Overview Why performing the Scheimpflug Adjustment Scheimpflug Adjustment is needed If an image is still unsharp even after the focus adjustment This means the image lies in a plane which is not parallel to the screen plane as the deviation between the image plane and the screen plane can be in both the Top Bottom and Left Right directions it is necessary to proceed in two distinct steps in following order R5976794 OVERVIEW DR120 06 07 2004 Scheimpflug Adjustment Overview Scheimpflug Adjustment for the BarcoReality SIM4 Image is sharp non Sona everywhere Adjustment Yes Scheimpflug Centre Top Adjustment of the image No Centre Bottom is not necessary Scheimpflug Adjustment is focused in fr
20. 200 b s The baudrate is detected as soon as a baudrate value is chosen The detection is displayed in the window 7 Click the Browse button and select the previously downloaded source file bin image 4 3 8 Press the Download button to start the download process A successful download is indicated with a green spot in the right bottom corner of the download interface R5976794 OVERVIEW DR120 06 07 2004 _ _ 13 4 Software 4 2 BARCO LCD DLP Projector Code Control Open a binary file El ER Look in a Soft El cil E El m Proj Addr z i Communication Parameters 7 Port COM1 Ml Baudrate jk 5200 7 Source File J Wondel SXGANQ300_V00 26 bin Browse Fiename Files of type Binary files bin gt Cancel Open as read only Help Image 4 3 Download program browser Image 4 2 download interface If the download has not been terminated successfully restart the projector main switch restart the download program exit start and repeat the download procedure Optical calibration software 14 What can be done The optical calibration software wm_optics exe is used for the calibration of following parts e Color wheel to determine and or store the color wheel index Color wheel index adjustment page 68 Light sensor Light sensor calibration page 57 e Primary Color Modulation Setup 1 Connect the projector the RS232 cable to
21. 3 lumen is reached While adjusting the dimmer position the value in the PULSE COUNTER field will change accordingly Finally when the dimmer position is adjusted in such a way that the requirement is fulfilled the sensor can be calibrated To do this enter the measured ANSI Light Output in the LUMENS field in the CALIBRATION PARAMETERS sub window In addition copy the PULSE COUNTER field into the PULSES field to send this information to the projector press the UPLOAD button Exit the software The correct operation of the sensor can now be checked with the projector menu Go to SERVICE and select and enter LIGHT SENSOR menu 7 1 On top of your background image a window as shown in the inserted screenshot will appear In this window the counted number of pulses and the calibrated light output is shown menu 7 2 SERVICE LIGHT SENSOR BARCO LOGO Light Output A U 1110 PRESET INPUT BALANCE Pulse Count 3035 I2C DIAGNOSIS LIGHT SENSOR SHUTDOWN HISTORY Select with or then lt ENTER gt lt EXIT gt to return lt EXIT gt to return Menu 7 1 Menu 7 2 tah ana Lakin Se ae Aamo oon E mm 1 Urea per 1120 Luren Pas arim j j Faller maigi iraskre lipbsxj T Pen Image 7 45 Notice the A U written beside Light Output A This is necessary because white peaking has no impact on the light sensor performance despite its huge influence on the
22. 4 e Do not touch the contacts of the flat cable when removing inserting the flat cable otherwise damage may occur by oxidation of these contacts Do not bend the flat cable otherwise internal cable damage may occur Insert the flat cable in a straight way into the flat cable connector e Connect the flat cable by simultaneously pushing the mini locks on both sides of the flat cable connector Flat Cable Connector Type 4 This type of connector can be found on the formatter Do not use any tools when dis connecting a flat cable connector otherwise damage may occur on the lock Disconnect by pushing the lock upwards r LJ i T TH d a a LEI i Image 2 5 Do not touch the contacts of the flat cable when removing inserting the flat cable otherwise damage my occur by oxidation of these contacts e Do not bend the flat cable otherwise internal cable damage may occur Insert the flat cable in a straight way into the flat cable connector e Connect the flat cable by pushing the lock downwards Flat Cable Connector Type 5 Used on the interconnection unit R5976794 OVERVIEW DR120 06 07 2004 _ 9 2 General Information e Do not use any tools when dis connecting a flat cable connector otherwise damage may occur on the lock Do not touch the contacts of the flat cable when removing inserting the flat cable otherwise damage my occur by oxidation of these contacts Do
23. A ee PA AA 60 83 Dimmer Motor ands SENSO sio roz O dA ads RI 2 Deans ER EG ZG URO M AO SA APA AD 60 OAS FAS rn ehehe eve SRO emia beweende eb A RO NA dY Are 62 84 1 Replacing ihe Power Fali czai ki ee A anne AO 62 8 4 2 Replacing the big lamp fan wassszcoikucd ilo adi o A rra riadas aras mirga 64 04 2 Replacing the Lamp OP TAA sm ae En R es 65 8 5 Color wheel motor and SeNSOl asza nota zas e E O A AEG OWA pi GAGA o 66 89 1 ZBeSCHDUO sions tenoren tr raalte a ieee SEAN dE de 66 9 5 2 FREPIAEINO Me COO WAS ett ene aten eel A a ee 67 0 5 0 Color wheel index ad US MAENE arenden ier AA A en ek helen erde kde 68 9 Optical Spares and Servicing procedures cc cece cece cece eee ennen enenen en venenennnnenenen enen vens 71 9 1 Accessing the Optical Components sii A ns A AA one it ee 71 9 1 1 ACCESS via WE DAcKSIde chon Hana A A ORA ee a 71 91 2 ACCESS Via the Ton IG 71 duo ACCESS Vid Ine TOM SIGS ts nadie 12 92 UAP IAD a aient AAN Aia 73 R5976794 OVERVIEW DR120 06 07 2004 _ OO Table of contents 9 221 DES DIN A Ai 13 92 2 LAMP Te place MEN tt A A A A ee wens 13 9 97 ORAR A Pe Oe rie ieee nne 76 Ial Replacing MING MIMI A En e do AOC eh Ra ot tat 76 9 5 2 lt AQJUSUNJ Ne IgRIDIDE mir datada idilio as Scie abate 76 94 IDEPCHIP AnASACCESSONES Len renee desa ed id da 80 95 MEAS holder ad US IMSS aventurien berte wensen tabe ele 82 951 ScheimpllUg Adjustmehtr sneer oetan eenen
24. BLESHOOTING Overview e Troubleshooting using the display History and diagnostics using the OSD menu 10 1 Troubleshooting using the display Error codes The OverView DR120 uses 7 segment LED display located on the front input panel which allows the user to be informed of the possible error occurred during operation or in the start up phase 2 type of errors may occur e Yi error has occurred during operations and causes the projector to shut down or not in some cases a warning message is shown on the screen OSD U error has occurred during the start up of the projector the projector will remain in standby Image 10 1 LED Display Overview Y1 PWR_GOOD 1 One or more of secondary supply voltages Diagnostics on NOK SMPS page 33 a OVERTEMP_PFC UAT 2 PFC heatsink too hot Power fan not cooling sa control page enough UNDERVOLTAGE 1 PFC output voltage too low PFC lt 375VDC Power Factor Corrector PFC page 27 FAN FAIL 1 Fan fail circuit 1 Power fan blocked ou control page ea or broken Mi 1 Fan fail circuit 2 lamp lamp top or Warp fan Fan control page blocked disconnected or broken 37 Y6 OVERTEMP_LAMP 1 Lamp housing is too hot 2 lamp temp sensor switch broken EE EE PFC doesn t start 1 PFC output voltage too low PFC lt 375VDC Power Factor Corrector PFC page 27 fans don t start I 1 Fans may have been blocked during start up So 2 mains voltage too low
25. DverView DR120 Service Manual R9642530 R5976794 00 BARCO 06 07 2004 Visibly yours Barco Control Rooms GmbH An der Rossweid 5 D 76229 Karlsruhe Phone 49 721 6201 O Fax 49 721 6201 298 E mail doc seufert com Visit us at the web www barco com Barco nv Control Rooms Noordlaan 5 B 8520 Kuurne Phone 32 56 36 82 11 Fax 32 56 36 83 55 E mail info barco com Visit us at the web www barco com Printed in Belgium Copyright O All rights reserved No part of this document may be copied reproduced or translated It shall not otherwise be recorded transmitted or stored in a retrieval system without the prior written consent of Barco Changes Barco provides this manual as is without warranty of any kind either expressed or implied including but not limited to the implied war ranties or merchantability and fitness for a particular purpose Barco may make improvements and or changes to the product s and or the program s described in this publication at any time without notice This publication could contain technical inaccuracies or typographical errors Changes are periodically made to the information in this publication these changes are incorporated in new editions of this publication 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
26. J ADDRESS 8V 8 87 CHANGE BAUDRATE PC 8V 8 87 RESET LAMP RUNTIME 15 5V 15 39 LAMP RUNTIME HISTORY 5V 5 13 LIGHT OUTPU 3 3V 3 26 2 5V 2 61 ORE Select with or then lt ENTER gt lt EXIT gt to return lt EXIT gt to return Menu 10 5 Menu 10 6 10 2 3 12C Diagnosis What can be done This info screen will give an overview of the Data Command and Address status of the I C controlled IC s Green box OK Red Box Error the Box in the menu is shown as Following IC s are shown in the 12C info screen Input Selector Light Sensor Formatter e Fan Control Power Supply Motor Driver Power Supply Control e Voltage Diagnostics 3x R5976794 OVERVIEW DR120 06 07 2004 _ _o gt ooo DD 10 92 Troubleshooting How to consult the 12C Diagnoses 1 Push the cursor key f or to highlight 2C Diagnosis menu 10 7 2 Press ENTER select The IFC info screen will be displayed menu 10 8 3 Push the cursor key to scroll down and display the bottom line of the 12C info screen menu 10 9 4 Press EXIT to return to the Service Mode menu SERVICE BARCO LOGO PR ESET INPUT BALANCE lt I2C DIAGNOSIS LIGHT SENSOR SHUTDOWN HISTORY Select with y or then lt ENTER gt EXIT gt to return Menu 10 7 Scroll lt EXI
27. able bE Lamp litz WP A B Lamp supply P ua white segment t 0 Image 7 24 P Plateau B Pulse amplitude R5976794 OVERVIEW DR120 06 07 2004 7 Electronic spares and servicing 7 7 2 Diagnostics of the formatter Measuring points BILL U m F Image 7 25 Measuring sans point PWRGOOD o high power good Indicates the presence of the different voltages on SMPS see Diagnostics on SMPS page 33 Normally high Normally low Lamp lit feedback signal switched in permanent mode for white peaking lamp age compensation Normally high Sync valid indicates a valid sync signal at the RGB input Normally high Lamp enable signal switched in permanent mode for white peaking during white segment interval R5976794 OVERVIEW DR120 06 07 2004 _ O O O O OK GT Electronic spares and servicing 7 7 3 Connections 48 Connection overview A 1 ATEN E u F r 7 Image 7 26 J1 flat cable connector from PMP via PMP connector unit po poem m Green Red image data 2x10 bit J11 flat cable connector from PMP via PMP connector unit en omen Te Blue image data 10 bit 22 POWERGOOD active high is high when all the voltages are present SMPS LAMPEN active high enable signal for the lamp 29 LAMPLITZ active low feedback signal from the lamp 34 SYNCVAL sync valid signal active high R5976794 OVERVIEW DR120 06 07 2004 7 Electronic spares and servicing J5
28. age 8 3 5 Lift and remove the cabinet upwards Image 8 3 Dimmer Motor and Sensor 60 Description The dimmer motor is used to dim the light output of the projector It is placed just before the color wheel It consists of a bipolar 2 phase stepping motor fully controlled by the stepper motor driver board with its onboard 8 bit microcontroller Feedback from the motor is achieved through an optical sensor mounted on the mechanical frame R5976794 OVERVIEW DR120 06 07 2004 microprocessor 8 Mechanical Spares and servicing 5V 12V constant current driver bipolar 2 phase stepper motor opt sensor Image 8 4 How does the dimming and sensing work The dimmer motor actions the dimming plate so as to place it in the required position depending on this position more or less light may pass through the profile and enter the lightpipe The angular position of the plate is taken when the black dot passes in front of the sensor hereby preventing the reflection of the emitted signal the rest of plate surface is made of reflective material Max dimming Min dimming a Lamp light beam sensor B Image 8 5 How to replace the Dimmer motor 1 2 Remove the front panel Remove the black cover by loosening the 2 screws image 8 6 See image 8 7 Remove the dimmer and color wheel plate image 8 8 Remove the motor connector 4 wires black red green blue a
29. al 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 R5976794 OVERVIEW DR120 06 07 2004 AAA 1 Safety 6 A _K_ ooo o oooooooooQRnnnoo R597 6794 OVERVIEW DR 120 06 07 2004 2 General Information 2 GENERAL INFORMATION Overview Interconnection diagram Conventions Connector Instructions 2 1 Interconnection diagram Interconnection diagram 2 2 Conventions Projector orientation In the following procedures references to location left right front rear top bottom on the projector are made as shown in the following image TOP LEFT BOTTOM Image 2 1 Spare abbreviations Each available spare is indicated with one of the following abbreviations 2 3 Connector instructions When needed remove cable straps to easily disconnect a connector when finished always replace with new cable straps and tie up the cables to their initial position A WARNING Always respect the ES Electrostatically Sensitive Instructions
30. 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 Servicers who defeat safety features or fail to perform safety checks may be liable for any resulting damage 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 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 complies with American National Standards Institute ANSI C101 0 Leakage Current for Appliances and Underwriters Laboratories UL 1410 50 7 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
31. and13 and pin 4 5 and 2 I60 creates the Vin_High signal this signal is routed to Q40 which switches the level by pulling down the 375VDC to 290VDC Another output Vin_High_1 of this circuit is connected to the SMPS where it is used to detect undervoltage The undervoltage protection circuit has been added to prevent that in case of extreme low mains voltage some harm is done to the PFC 160 pin 6 7 and 1 and pin 8 9 and 14 by switching it off The output voltage is adjusted with P1 To check the temperature of the heatsink a LM35D temperature sensor has been thermally connected to it 151 The output voltage is amplified 10 times and then converted into a PWM signal T_PFC by the second half of 150 to make it possible to transfer the signal to the secondary side of the SMPS R5976794 OVERVIEW DR120 06 07 2004 _ _ 0 27 Electronic spares and servicing 7 1 2 Connections Connector overview To Lamp driver To SMPS 110 JA WAL Mains Image 7 2 Connector layout J1 connector layout J2 connector layout TEL J3 connector layout J10 connector layout o e E NENEZZNEEME J20 connector layout supply from PFC 375VDC 15VM 15VM 7 T_PFC PWM signal representing the heatsink temperature signal PB eeen R5976794 OVERVIEW DR120 06 07 2004 7 Electronic spares and servicing Vin HIGH 1 High Low signal 1 1 3 Diagnostics of the PFC Fuses on the PFC module The pfc module contains 5 f
32. area of the image is focused in front of the screen proceed with the Centre Right Scheimpflug Adjustment Centre Left Scheimpflug Adjustment 1 Screw bolt A max 1 8th of a turn and unscrew bolts B and C by the same amount image 9 31 image 9 32 2 Check if the left area of the image is still focused in front of the screen 3 Repeat steps 1 and 2 until the centre left area of the image is focused on the screen together with the centre and the centre right areas Projector Image must be tilted CLOCKWISE Lens must be tilted CLOCKWISE Sereen Image 9 31 Lens must be tilted clockwise R5976794 OVERVIEW DR120 06 07 2004 _ 85 9 Optical Spares and servicing procedures 86 Image 9 32 Centre Left Scheimpflug Adjustment Centre Right Scheimpflug Adjustment 1 Unscrew bolt A max 1 8 of a turn and screw bolts B and C by the same amount image 9 33 image 9 34 2 Check if the right area of the image is still focused in front of the screen 3 Repeat steps 1 and 2 until the centre right area of the image is focused on the screen together with the centre and the centre left areas Image must be tilted COUNTERCLOCKWISE Lens must be tilted COUNTERCLOCKWISE Screen Image 9 33 Lens must be tilted counterclockwise Image 9 34 Centre Right Scheimpflug Adjustment R5976794 OVERVIEW DR120 06 07 2004 9 Optical Spares and servicing procedures 9 5 2 Focus adjustment When is it necessary Check the
33. as a result it will also include a part of the green segment R5976794 OVERVIEW DR120 06 07 2004 _ 6 8 Mechanical Spares and servicing Tak Bun 30655 ample GQ Tek Hur JOES ame A 15 HI az y m m eee n Tk 5E Zn _CWM 9000 APE CWI 1 6000 PPE oe I H i efen ka EU Eu L da Li xl LH m 118 2 4 u A ae eS oe aH sM gad f I 1 1 i s A ri i rf h ll ubi HUT ami E I ors A m a La H H i zza R MN _ ja ml MA NRM NAWE Ehi tm CRT F aT vr she a CK TVE MRE DE W Tm CHI A TIN RA oy JD Td Mew 2002 12 11 21 I5 neg Image 8 21 On the left we see the result for CWI 9000 On the right CWI 16000 is shown The purpose of the tool is to change the color wheel index until the correct position is found i e until the color segment are separated and no slope slope indicated with rectangle on images present between them when WP 0 When the FULL LIGHT ON option is checked and unchecked it is easy to see whether the separate color signals are flat or if they have a slope at one of their outer positions Storing as default When this correct position has been found click the UPLOAD AS DEFAULT button to program this value in the projector This value will be selected when the button on the remote co
34. ation of the projector The feedback voltage for the mains supply is taken on R159 and returned to the primary through optocoupler 1150 3 4 5 6 For the formatter board a stable 12 V is also required and this one is obtained by using a simple down converter from 15 5 V to 12 V 1270 L270 D270 To prevent that more windings have to be added to the main transformer to obtain 5V and 8 V the standby voltages 5V and 8V are switched by means of a MOSFET using 15 5 V as the command signal Q360 361 and Q350 Voltages monitoring For the formatter a signal Power good is required This signal should be high when all the supply voltages are within the limits 2 5 V 3 3 V 5V and 12 V To check for this the voltages are fed to a set of window comparators 1500 501 checking both under and upper limit of the voltages The output of the comparators are OR ed to obtain one single signal PWR_GOOD The signal undervoltage is combined with power good by means of D501 and D502 The signal PWR_GOOD_2 is finally brought to the formatter via the PMP This means that in case of an unexpected situation when there is a voltage drop the DMD mirrors can be parked in a safe way having sufficient energy built up in the storage capacitors All voltages can be checked by means of an ADC to see if the values are within tolerances and to have a possibility of logging the possible problems 1600 601 602 These values of DAC s can
35. control The control circuit allows a precise speed control through a digital frequency locked loop and linear current control while the position of the color wheel is determined at any time by means of a sensor print mounted on the same metallic frame allowing hereby 66 5 zz o R5976794 OVERVIEW DR 120 06 07 2004 8 Mechanical Spares and servicing the synchronization with the lamp and the DMD for lamp power boost and DMD modulation at the right moment white segment passage Speed regulation is adapted to the vertical refresh rates of the incoming signal For a 50 Hz vertical frequency signal the speed corresponds to 150 Hz i e a 3 revolution per frame For a 60 Hz that would be 180 Hz The three switched signals are 120 phase delayed with respect to each other lamp a BACK EMF VOLTAGE OUTC driver Synchronization via lamp enable Color wheel Motor control commutation current control sensor color wheel position pulse centertap voltage Image 8 16 Color wheel control 8 5 2 Replacing the color wheel Color wheel Connections The 3 drive signals and the centertap signal are connected to the formater via the interconnection unit using a flat cable while the sensor pulse signal is connected using a yellow 3 wire cable also via the interconnection unit Image 8 17 A sensor B sensor connection C motor flat cable connection How to replace the color wheel 1 Follow step 1 to 5 of dimm
36. crews A image 7 17 Loosen and remove the board screws le a Remove the board Image 7 14 R5976794 OVERVIEW DR120 06 07 2004 _ 4l Electronic spares and servicing Image 7 15 RGB power and I2C connections Image 7 16 RGB input coax cables Image 7 17 7 5 The communication interface board CEE KEEEEEEMA Description Replacing the communication interface board 1 Remove the front section refer to the RGB input removal procedure 2 Disconnect the power cable green wires the data flat cable see connector instructions for more info on how to remove flat cable connectors of type 1 and the display connection cable yellow wires image 7 18 3 Loosen the 4 screws image 7 19 aD R5976794 OVERVIEW DR120 06 07 2004 7 Electronic spares and servicing Image 7 18 comm s interface connections Image 7 19 7 6 The Pixel Map Processor PMP Description ETT CET R763925K Conhead FB PMP How to replace the PMP 1 Disconnect the 2 flat cables to from controller the control signal cable and the mini coax cables image 7 20 2 Loosen and remove the screws 3 Remove carefully the PMP Caution The PMP is connected to the formatter and to the SMPS using a board to board connector when removing the PMP be careful not to damage the board to board connection image 7 21 R5976794 OVERVIEW DR120 06 07 2004 _ _
37. ding mirror used to displace the illuminated area with respect to the DMD active area Az zz gl OQ O K E OOoooo S R507 6794 OVERVIEW DR120 06 07 2004 9 Optical Spares and servicing procedures Image 9 14 Lightpipe adjustments R Rotation T Translation Different cases where lightpipe folding mirror adjustments are required Lighpipe Folding mirror we O OO R5976794 OVERVIEW DR120 06 07 2004 _ TT 9 Optical Spares and servicing procedures Image 9 15 Image 9 16 Case 2 The image shows a blurred illuminated area decentered with respect to Case 1 The image shows a blurred illuminated area slightly rotated and decentered with respect to the DMD active area represented by a light hairline the DMD active area represented by a light hairline for clarity for clarity Image 9 18 Case 4 The image shows a sharp illuminated area decentered with respect to Image 917 f co the DMD active area represented by a light hairline for clarity Note that the Case 3 because the illuminated area is not sharp enough some shadowing is visible in illuminated area will never be perfectly sharp In practice it is necessary to find the top left and bottom right corner of the image In practice this shadow can exhibit out the sharpest situation some irregular patterning fringes and some coloration as well Image 9 19 Image 9 20 Case 6 The image shows a sharp illuminated area which is correctly aligned
38. dle 3 metallic frame Image 7 44 7 11 3 Light sensor calibration Objective Calibration of the light sensor is necessary for Constant Light Output CLO feature on the OverView DR120 To calibrate the light sensor the Optical Calibration software is used Refer to the software chapter for setup The button LIGHT SENSOR opens the window shown we will explain how to use this window to calibrate the sensor R5976794 OVERVIEW DR120 06 07 2004 57 Electronic spares and servicing 58 Necessary tools light meter optical calibration software How to calibrate the light sensor 1 aS 2 E Press the Light sensor tab button See image 7 45 It is necessary to initialize the sensor before starting the calibration procedure Pressing the INITIALIZE button will do this When this is done the PULSE COUNTER field in the PROJECTOR CONTROL sub window will be filled in This value that appears corresponds to the frequency the sensor generates due to the light flux it receives As the projector will be operated mostly at a regime of 800 1400 Im we will do the calibration of the sensor at 1100 Im It is however likely that the screen lumens are higher than this value when the internal pattern is generated By using the DIMMER POS field we can turn the dimming wheel and lower the light throughput This value which can be altered by pressing the arrow buttons needs to be adjusted until an ANSI Light Output of 1100
39. echanical Spares and servicing Image 8 11 Power fan removal R fixation rubbers P fixation plate S fixation screws 8 4 2 Replacing the big lamp fan How to replace the big lamp fan 1 Loosen the 4 screws and remove the fixation plate image 8 12 2 Remove the fan assembly 3 Remove the screws to remove the fan image 8 13 64 zz R5976794 OVERVIEW DR120 06 07 2004 8 Mechanical Spares and servicing N SNS IN ROTEN Q PE Y PY N Image 8 12 Image 8 13 8 4 3 Replacing the Lamp top fan How to replace the lamp top fan i Disconnect the fan from the interconnection unit 2 Loosen the 4 screws and remove the fixation plate image 8 12 3 Loosen the 2 screws to remove the fan image 8 14 65 R5976794 OVERVIEW DR120 06 07 2004 8 Mechanical Spares and servicing Image 8 14 8 5 Color wheel motor and sensor Service sheet nn Vaere Image 8 15 8 5 1 Description Spokes transmission regions between two different color segments Order information ETT CO EEE R764101K Color wheel sensor Color wheel control The color wheel motor is a 3 phase brushless DC motor The 3 windings are powered by a motor drive circuit on the formatter board the other side of the windings are put together and form the centertap the voltage of this point is monitored and allows the simulation of the back EMF allowing ideal dynamic start up torque
40. ections Connector overview di i 1420 JOS JOB egte qa mn ji r 7 a je i Image 7 13 A fan connector module B fan control module Connector layout J400 J800 to from fan connection board CH ESO CA fan_supply_2 lamp1 lamp top Warp R5976794 OVERVIEW DR120 06 07 2004 7 Electronic spares and servicing J402 to from SMPS ea AE J420 from ambient sensor High in normal condition Low in case lamp overtemperature J703 to dimmer via interconnection unit ECO CT CTI eZ e E ee ee J705 from stepper motor driver 2 JA R5976794 OVERVIEW DR120 06 07 2004 _ 89 7 Electronic spares and servicing 40 ce COI E J709 from dimmer sensor via interconnexion unit CO CAT CTI REF3 Position feedback pulses from dimmer fe EE J711 from light sensor CH WO CI KO CNA WA fes BEE EEE COW CIS EEE fee EEE J803 to lamp top fan m CIS CON Eer CE gt J805 to lamp fan m eee am femme je EEE J806 to pfc power fan CH WO WA R5976794 OVERVIEW DR120 06 07 2004 7 Electronic spares and servicing J807 to Warp fan CO CAT CTI 7 4 The RGB input Description How to replace the RGB input 1 Remove the 5 screws on the front panel image 7 14 Disconnect the power supply cables green wires and the I2C cable connector yellow wires image 7 15 Disconnect the 5 mini coax cables image 7 16 Loosen the 3 front s
41. en eileen ar dae dn vii Pmt eed eee eed 82 9 5 1 1 Scheimpfl g Adj stmentOVeMEW s ae a AAA ASS aa bare 82 9512 1OB gt BONOM SCREMPNUGACJUSI Me zanosi idad daba ido iaa tera 83 oa LerteRiohtschelmpil g Adjustment ss kreieren 85 9 92 FOCUS aQlUstment nee ini rear AOR AAA 87 AOCIFOUDIECSNOOUMNG een ee 89 10 2 Treubleshooung Using ne CISDIAY une en N ei n 89 10 2 History and diagnostics using he OSD Mensen a ee 90 10 21 SNOIOOWNHISIO aaa as ee ee dada 90 10 2 2 VONAGE DIGGMOSUCS re se A EAN 91 102 A A O NA ERA ER 91 e AA iedeen deman are ae enk denten dee treten Ano RR an A 93 Qe R5976794 OVERVIEW DR120 06 07 2004 1 Safety 1 SAFETY 1 1 Safety Instructions WARNING Before Removing Replacing any projector components turn off the Main Power Switch and un plug the Main AC power cable R5976794 OVERVIEW DR120 06 07 2004 _ 8 1 Safety 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
42. er removal procedure Dimmer Motor and Sensor page 60 for more info on the interconnection unit see Interconnection unit page 49 ce R5976794 OVERVIEW DR120 06 07 2004 _ 67 8 Mechanical Spares and servicing 8 5 3 Color wheel index adjustment 68 The following procedure is only necessary when the index value is not communicated label on the color wheel If the index value is written on the color wheel label one can put this value in the projector via the OSD custom value or use the calibration software to upload the index value as default value into the projector see Storing as default Objective When replacing the color wheel the color wheel index has to be readjusted The physical meaning of the COLOR WHEEL INDEX value is described in the image below The black arrow corresponds to the rotation sense of the color wheel The white rectangle describes the position of the timing index mark on the color wheel This mark rotates along with the Color wheel The black rectangle corresponds to the position of the sensor and the grey rectangle corresponds to the position of the entrance of the light pipe The latter two are fixed and are not related to the position of the color segments R G B W The color wheel index value is a value that tells the formatter for how long the color wheel has to rotate before the light coming through the light pipe is completely red onset of the red segment This value i
43. f 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 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 of 1000 hours 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 R5976794 OVERVIEW DR120 06 07 2004 1 Safety 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 this transformers are also safety components and must never be defeated or altercated All user accessible conductive parts must be connected to ea
44. ge 9 24 5 Remove the 2 top screws while retaining the assembly to prevent it from falling image 7 31 See image 7 32 6 Remove all the mechanical parts Leave the DLP chip and sustain it by retaining the formatter board against the projector frame so as to prevent the DLP chip from falling image 7 33 7 Pass your finger through the hole to prevent the DLP chip from falling and remove the formatter board image 7 34 8 Remove the DLP chip placed in the DLP interposer See image 7 35 Image 7 28 Image 7 29 3 Image 7 30 Image 7 31 R5976794 OVERVIEW DR120 06 07 2004 7 Electronic spares and servicing Image 7 33 Image 7 32 mechanical assembly removed Image 7 34 Image 7 35 CAUTION The removed DLP chip and its accessories have to be handled with caution and placed in a safe place CAUTION Never touch the gold contacts on the chip on the interposer or on the formatter Fingerprints may damage the chip DMD bias setting The DMD chip used in the projector has to be matched to the formatter in order to allow the right biasing of the chip Therefore a switch S2 is provided on the formatter board this switch has to be positionned depending on the type of DMD ON Image 7 36 S2 switch R5976794 OVERVIEW DR120 06 07 2004 _ 51 Electronic spares and servicing Place the switch in the adequate position depending on the type of DLP chip see formatter screening DMD type bias o s
45. jector behind the black cover Image 6 7 the dimmer sensor is located at the back section of the projector R5976794 OVERVIEW DR120 06 07 2004 A 25 6 Component location EN E CT 26 R5976794 OVERVIEW DR120 06 07 2004 7 7 Electronic spares and servicing ELECTRONIC SPARES AND SERVICING Overview e Power Factor Corrector PFC Switched Mode Power supply SMPS e Fan control e The RGB input The communication interface board e The Pixel Map Processor PMP The formatter e The Controller CPU e UHP lamp driver The Stepper Motor Driver Light sensor 7 1 Power Factor Corrector PFC Service sheet Image 7 1 C WOW KO 7 1 1 Description Functional description The mains voltage is applied to J1 and J2 The EMC filtering is done by the combination of C1 C2 and L1 VDR1 is a protection against high voltage spikes that can occur on the mains input while NTC1 limits the inrush current This resistor is shorted by means of RL1 once the standby supply is running The converter circuit is build around the L4981A 11 Q1 L3 and D12 These components form a typical boost step up converter which converts the mains input voltage in a DC voltage of about 380VDC and corrects power factor This DC output voltage is switched between 2 levels depending on the input voltage insuring this way a better efficiency at 85 VAC The detection of the input voltage level happens with 160 pin 10 11
46. mage 9 24 DLP chip fixation assembly DLP chip interposer contact housing formatter backer plate stud spring stud retainer heatsink NOOR WD A thermal pad as well as an insulator plate are used and inserted respectively between the stud and the DLP chip and between backer plate and interposer Image 9 25 A thermal pad B insulator pad R5976794 OVERVIEW DR120 06 07 2004 _W 2 81 9 Optical Spares and servicing procedures 9 5 CAUTION For long term storage greater than one week sockets should be stored in conditions between 40 and 80 degrees F and between 30 and 60 per cent relative humidity Interposer handling Precautions e Sockets should always be handled by the outer frame only Contacts should not be touched with fingers tools wipes or any other devices e Sockets should be left in the manufacturer s original shipping trays with tray covers intact until assembly The socket should not be exposed to liquids or dry chemicals e Once the DLP chip has been laid into place it should be pressed into the socket downward or z axis force perpendicular to the mating surface of the contact housing using uniform gentle finger pressure applied to the top of the module The module should NOT be inserted into the socket by first engaging one corner or edge of the module into the contact array and wiping the module corner or edge across the array How to remove the DLP chip and its interposer
47. move locking handle downwards to unlock the lamp image 9 9 Image 9 6 Location of side door screw Image 9 7 side door open R5976794 OVERVIEW DR120 06 07 2004 9 Optical Spares and servicing procedures Image 9 8 Lamp disconnected Image 9 9 Lamp locking handle Image 9 10 Lamp removed When replacing the lamp it is strongly recommended to check and clean or replace if necessary the dustfil Z ters R5976794 OVERVIEW DR120 06 07 2004 _ 7 5 9 Optical Spares and servicing procedures 9 3 Lightpipe Overview Replacing the lightpipe e Adjusting the lightpipe Service sheet 9 3 1 Replacing the lightpipe How to remove the lightpipe 1 Remove the formatter to access the optical path Access via the backside page 71 2 Loosen the 2 screws image 9 11 Caution Retain the plate while unscrewing to prevent the lightpipe from falling See image 9 12 image 9 13 Image 9 11 Image 9 12 Image 9 13 lightpipe and its plate removed Re placing the new lightpipe 1 Mount the lightpipe by reversing above procedure 9 3 2 Adjusting the lightpipe Which adjustments are possible Translation of the lightpipe along the optical axis Z axis used to adjust the sharpness of the illuminated area on the DMD e Rotation of the lightpipe used to align make parallel the edges of the illuminated area with the edges of the DMD active area e Tilting of the fol
48. n 5 B 8520 Kuurne Phone 32 56 36 82 11 Fax 32 56 36 83 55 E mail info barco com Web www barco com From Date Please correct the following points in this documentation R5976794 00 page wrong correct R5976794 OVERVIEW DR120 06 07 2004
49. nd the Color wheel sensor connector 3 yellow wires on the inter connection unit image 8 9 Disconnect gently the flat cable Loosen the 2 screws of the motor Replace the motor R5976794 OVERVIEW DR120 06 07 2004 OOOO 61 8 Mechanical Spares and servicing T TU U A DENY Image 8 6 black cover screws mA A BERGER Image 8 8 Image 8 9 location of the interconnection unit A interconnection unit B flat cable for the color wheel motor control Replacing the dimmer sensor 1 Loosen and remove the 2 screws 8 4 Fans 8 4 1 Replacing the Power Fan Fan interconnection unit All the fans are connected to the fan control unit via the fan interconnection unit i e they have to be disconnected from this inter connection unit when replacing them 62 Eg OO ROI76794 OVERVIEW DR120 06 07 2004 W EAP IE Image 8 10 Fan interconnection unit view To Warp fan To PFC power fan To lamp fan To lamp top fan UOU gt cable straps and tie up the cables to their initial position How to replace the power fan 1 Disconnect the fan from the fan interconnection unit Loosen and remove the 4 screws S image 8 11 2 3 Remove the fixation rubbers and plate 4 Remove the fan 5 Remove the fan wire R5976794 OVERVIEW DR120 06 07 2004 8 Mechanical Spares and servicing When needed remove cable straps to easily disconnect a connector when finished always replace with new 63 8 M
50. not exceed 1 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 AC Leakage Test b C Leakage Current Tester Reading should not be above 1 5 mA Device Under Test Test all exposed metal surfaces 2 Wired cord Also test with plug reversed Using AC Adapter plug as required Earth Ground nn Image 1 1 AC Leakage Test 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 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 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 o
51. nterconnection 7 general info 7 12 Diagnosis 91 R5976794 OVERVIEW DR120 06 07 2004 Index interconnection unit 49 L lamp 54 73 description 73 driver 54 Lens 82 Scheimpflug 82 Adjustment 82 lens holder 87 adjustments 87 focus 87 light sensor 56 description 56 Light sensor 56 57 Calibration 57 Replacing 56 lightpipe 76 adjustment 76 replacement 76 location 23 24 component 24 mechanical 24 optical 23 mechanical 62 fans 62 mechanical spares 60 dimmer motor 60 O optical 23 71 73 76 82 access 71 backside 71 frontside 71 lamp 73 lens holder 82 adjustments 82 lightpipe 76 path 23 procedures 71 spares 71 P pfc 27 29 connections 28 description 27 diagnostics 29 PFC 27 30 replacement 30 PMP 43 R replacement 62 73 power fan 62 right side 73 RGB input 41 S safety 3 Safety 3 Instructions 3 Scheimpflug 82 83 85 Adjustment 82 83 85 93 Index Left Right 85 Overview 82 Top Bottom 83 sensor 56 light 56 Shutdown History 90 smps 30 31 33 35 connections 35 description 31 diagnostics 33 software 13 14 calibration 14 upgrade 13 spare parts 11 list 11 spares 44 electronic 44 94 formatter 44 spares and servicing stepper motor driver T top housing 60 troubleshooting 89 display 89 V view 17 front 17 Voltage Diagnostics 27 59 55 91 R5976794 OVERVIEW DR120 06 07 2004 Revision Sheet To k Barco nv Control Rooms Noordlaa
52. ntrol is pressed in the menu COLOR WHEEL INDEX INSTALLATION INPUT SLOTS NO SIGNAL MENU POSITION CENTER 800 PERIPHERAL COLOR WHEEL INDEX CONFIGURATION OSD COLOR INTERNAL PATTERNS DYNACOLOR ACTIVE 3D CONF SCALED PATTERNS SYSTE INK Select with or then lt ENTER gt lt EXIT gt to return Menu 8 1 Ag O i A_ 3 S R507 6794 OVERVIEW DR120 06 07 2004 9 Optical Spares and servicing procedures 9 OPTICAL SPARES AND SERVICING PROCEDURES Overview Accessing the optical components e UHP lamp Lightpipe DLP chip and accessories Lens holder adjustments 9 1 Accessing the optical components CAUTION The access of the optical components is reserved to qualified Barco technicians only A The removal of the DMD chip and its accessories is very critical and requires the needed precautions and skills 9 1 1 Access via the backside When to access the optical components via the backside The access of the following optical components is made possible via the backside of the projector e lightpipe DLP chip Therefore the back panel the formatter and its DMD chip and accessories have to be removed When servicing the color wheel or dimmer one must access these components via the front side of the projector How to remove the formatter board 1 Remove the formatter board see Replacing the formatter
53. ont of the screen Yes Centre Top Scheimpflug Adjustment Left Right Scheimpflug Adjustment l Centre Left of the image is focused in front of the screen No Centre Right Scheimpflug Adjustment Yes Centre Left Scheimpflug Adjustment Image 9 26 Scheimpflug Adjustment Overview Necessary Tools Piece of white cardboard M5 Hexagonal Allen key 9 5 1 2 Top Bottom Scheimpflug Adjustment How to start the Top Bottom Scheimpflug Adjustment 1 of white cardboard parallel to the screen plane and displace it from the centre of the screen and the projection lens ls the centre top area of the image focused in front of the screen If yes Proceed with the Centre Top Scheimpflug Adjustment 9 Optical Spares and servicing procedures Find out whether the centre top or centre bottom area of the image is focused in front of the screen To do this hold the piece screen towards the projector along the line joining the If no The centre bottom area of the image is focused in front of the screen proceed with the Centre Bottom Scheimpflug Ad justment Centre Top Scheimpflug Adjustment 1 2 Check if the top area of the image is still focused in front of the screen Unscrew bolt B max 1 8 of a turn and screw bolt C by approximately the same amount image 9 27 image 9 28 3 Repeat steps 1 and until the centre top of the image is focused on the screen together with the centre
54. or examples and are not to be understood as advertising for the products or their manufactures Federal Communications Commission FCC Statement This equipment has been tested and found to comply with the limits for a class B digital device pursuant to Part 15 of the FCC rules These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a residential environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instruction manual may cause harmful interference to radio communications Operation of this equipment in a residential area is likely to cause harmful interference in which case the user is encouraged to try to correct the interference by one or more of the following measures Introduction to the user If this equipment does cause interference to radio or television reception the user may try to correct the interference by one or more of the following measures Re orientation of the receiving antenna for the radio or television Relocate the equipment with respect to the receiver e Plug the equipment into a different outlet so that the equipment and receiver are on different branch circuits Fasten cables connectors to the equipment by mounting screws The use of shielded cables is required to comply within the limits of Part 15 of FCC rules and EN55022 Trademarks Brand and product
55. r Motor Driver Description Ce U For more info about the stepper motor driver Dimmer Motor and Sensor page 60 CS How to replace the stepper motor driver 1 Disconnect both connections on the board image 7 42 Note Note that connection A is not necessary for the OverView DR120 i e if this connection is not made this will not influence the good operation of the projector 2 Loosen and remove the 3 screws 3 Remove the board R5976794 OVERVIEW DR120 06 07 2004 _ 55 Electronic spares and servicing Image 7 42 Stepper motor driver connections and screws 7 11 Light sensor Service sheet 7 11 1 Description Function of the light sensor In the OverView DR120 the light sensor is located behind the folding mirror that reflects light coming from the light pipe towards the TIR prism The sensor sees an amount of light proportional to the amount of light coming from the lamp It returns an ON OFF signal with a frequency proportional to the amount of light 7 11 2 Replacing the light sensor Necessary tools Torx 10 How to remove the light sensor 1 Loosen the screws and remove the grid 2top screws the handle 3x M4 bottom screws and the metallic frame 4 screws image 7 43 2 Loosen the 2 screws image 7 44 3 Remove the board DO Eg 3 ooo R5976794 OVERVIEW DR120 06 07 2004 7 Electronic spares and servicing Image 7 43 1 grid plate 2 han
56. rn lt EXIT gt to return Menu 10 1 Menu 10 2 GO R5976794 OVERVIEW DR120 06 07 2004 10 Troubleshooting How to display the Detailed Shutdown History info 1 Push the cursor key f or to highlight the desired Shutdown e g the most recent menu 10 3 2 Press ENTER to select The Detailed Shutdown History showing the Voltage Diagnostics measured on the time the Shutdown happened will be dis played menu 10 4 3 Press EXIT to return to the Shutdown History information screen SHUTDOWN HISTORY DETAILED SHUTDOWN HISTORY 1 FAN 1 FAILED 1 FAN 1 FAILED 37 hrs 2 NO INFO 4 24V 27 56 3 NO INFO 5V 5 20 4 NO INFO 8V 8 87 5 NO INFO 8V 8 87 15 25V 152 39 DVE 55 13 3 3V3 3 26 2 5V 2 61 12V 11 98 Select with or then lt ENTER gt LAMP RUNTIME 37 hrs lt EXIT gt to return lt EXIT gt to return Menu 10 3 Menu 10 4 10 2 2 Voltage Diagnostics What can be done The Voltage Diagnostics info screen will display in real time the numeric values of the different voltages used in the projector How to consult Voltage Diagnostics 1 Push the cursor key f or to highlight Voltage Diagnostics menu 10 5 2 Press ENTER to select The Voltage Diagnostics info screen will be displayed menu 10 6 SERVICE VOLTAGE DIAGNOSTICS IDENTIFICATION 24V 27 56 CHANGE PASSWORD 5V 5 20 CHANGE PRO
57. rth 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 cons
58. s called A here When the value of A is not indicated on the new color wheel use the following procedure to determine this delay Here a difference of 15000 in timing index mark corresponds to 1ms one complete rotation of the color wheel takes 1 180 s 5 56 ms when an internal pattern is shown i e a 60Hz signal In addition we put a fast photo sensor in front of the projector This way we can visualize the color sequential signal on an oscilloscope In the setup that has to be used a connection with the formatter color wheel timing mark also has to be made visible on the oscilloscope sensor Image 8 18 A color wheel index delay R5976794 OVERVIEW DR120 06 07 2004 8 Mechanical Spares and servicing Necessary tools e PC with Optical Calibration software WM_optics exe oscilloscope RS232 cable e fast photodiode How to start up the CW index adjustment 1 When a connection is made with the projector press the color wheel index tab a dialogbox appears image 8 19 2 With the ENABLE checkbox checked on an internal pattern will appear This will be a completely white screen R 255 G 255 B 255 The checkbox FULL LIGHT ON switches to a signal in which the white peaking value is set to 10 if unchecked WP 0 This means that either all light is transmitted either the light from the white segment and the light from the spokes is completely removed Color wheel index Parameters 12500 Color wheel index
59. screen lumens white peaking happens on the DMD after the light has passed the folding mirror This means that a measured light output of 1021 can correspond to only 650 screen lumens when white peak ing 0 but also to 1020 screen lumens when white peaking 10 This was the reason for the use of an internal pattern with white peaking equal to 10 If the values seen on the screen are realistic taking the only just preformed calibration in mind the calibration was successful R5976794 OVERVIEW DR120 06 07 2004 8 Mechanical Spares and servicing 8 MECHANICAL SPARES AND SERVICING 8 1 Dustfilter Description Image 8 1 8 1 1 Replacing Cleaning the Dustfilter Necessary tools flat screwdriver new filter or cleaning cloth How to remove the filter de Take out the 2 screws on top Release the grid from under the top cabinet image 8 2 2 3 4 Take out the dustfilter by holding the grid under an angle Clean the removed filter using a dry cloth or place the new filter Image 8 2 F filter G grid R5976794 OVERVIEW DR120 06 07 2004 59 8 Mechanical Spares and servicing 8 2 Top housing 8 3 Description How to remove the top housing 1 Open side door 2 Loosen 3 screws on backside A 3 Loosen top screws of input tray 4 Shift top cabinet against door im
60. t System level control color wheel and lamp are synchronized with the data processing process PWRGOOD SYNC VALID RESET R G B 3x10 bits LAMPEN ANDED Color wheel el Image System level processing control Lamp 2 control color wheel position pulse Lamplitz Lamp enable Image 7 23 Lamp control and feedback To achieve the best color reproduction the lamp has to be synchronized with the color wheel This is done in permanent mode once the lamp is started up via the switching of the Lamp enable line each time the white segment passes in front of the CW sensor White peaking WP is then achieved by boosting the lamp supply during that short interval Following graphic show a vertical refresh rate of 50Hz this implies a color wheel frequency of 150 Hz 3x Vireg the white segment passes thus 3 times per frame Each time the white segment passes in front of the sensor Lamp enable is switched and the lamp supply is boosted R5976794 OVERVIEW DR120 06 07 2004 n 5 7 Electronic spares and servicing 46 The Lamp Litz line being the feedback signal from the lamp driver is also modulated in permanent mode to achieve the best lamp management This is done by modulating the number of pulses of the Lamp Litz line in function of the ratio of the plateau amplitude P to the pulse amplitude B of the lamp drive signal since this ratio gives an image of the lamp age Vsync PE Lamp en
61. tains mainly the image and data processing boards R5976794 OVERVIEW DR120 06 07 2005 gt 19 5 Board Location 20 Image 5 6 R764108K Formatter DLP chip excl R763769K How to access the back section z 1 Loosen the 3 screws on the topside 2 Rotate the back panel image 5 8 R5976794 OVERVIEW DR120 06 07 2004 5 Board Location Image 5 8 R5976794 OVERVIEW DR120 06 07 2004 _ 21 5 Board Location 22 R5976794 OVERVIEW DR120 06 07 2004 6 COMPONENT LOCATION Overview Optical Components Mechanical component location 6 1 Optical Components 6 Component location Schematic description of the optical path 2 Dimmer position I 5 color wheel sensor 4 Color wheel 6 lightpipe Condenser 1 amp 2 1 Lamp 3 dimmer sensor Image 6 1 7 Relay lens 1 IN 9 Folding mirror 8 Relay lens 2 ro Light sensor 11 Relay lens 3 LX A EN 1 00 IP 14 lens 12 Prism Image 6 2 R5976794 OVERVIEW DR120 06 07 2004 screen 23 6 Component location 6 2 Mechanical component location Fan location Image 6 3 right view door open Image 6 4 lamp top fan location lamp removed 24 Image 6 5 back view panel open R5976794 OVERVIEW DR120 06 07 2004 6 Component location CO ETC CT me Dimmer Motor and Sensor location Image 6 6 dimmer motor is located at the front section of the pro
62. te ndi be dk ian led Wsad dain an 30 EZ DWiichied Mode FoOWersubply SMP S e ee en aa a a a a ta as 30 721 Desctipion ortie SMP S 2 24 2 A ee REA ee 31 zaz DidGnoesilesOn SMES uee E E AGGA A R aa At rp oda ee ee 33 20 GONIECHONS asrin tania a a il tos 35 OR RANCIO rea ed iaa ARS A L A e id cl e e eh le Ct AO 37 KO COMMECHONS AA teren cn seen reiner see eta ade wens 38 2 4 ThE RGB INDUL une oda AU a il UR AAA R mE EAS 41 Lo The communicaton interface Board siria A A ee 42 6 The Pixel Map Processor RMP Fans nee ea ers ee 43 A KHEIOLMAUEL AAA A een rare ren encore haben erde 44 ELA DESCHPUSH OL the formaler a re ee a oem a ian ae ence Sate een AW mace onde 45 dts Diagnostics ol the formaler an a ee a ee ur aa 47 AA na ee irren 48 TETE ia AAA ee ee ee NA A A 49 7 7 5 Replacing the fOMAOR ermee nadtadraeth drenten iras waere dee 50 Le The Gontroller GPUl rar ic Ed E are U OGR OE WORA AO 52 RA ORF AMPERE ee 54 flo The Stepper Motor DAVE a rei Bin 55 FAT ALIGNUSCNSON er O ASAS A ARANA AAA A AA 56 RANA Dege ION ss een are a cesses er A A ca 56 MUZ Replacing he lant Sensor a nen RS ts A PR ER weken 56 INS IGNCSENSONCANDIANON ictericia atid 57 8 Mechanical Spares and servicing 2 a ee A iene eereedaeaanabads 59 Sot Dustin nacos sata een ts a ESRO AL OBOZOWA AO is 59 8 1 1 Replacing Cleaning the Dustfilter vee aa aaa nana zakazana rr ro 59 8 2 OD OU RAA GOA eene EA OGAR A
63. ult 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 materi
64. uses 2 at the mains inputs 3 at the PFC output Image 7 3 A lamp driver supply section B mains supply section Value A et Fuse replacement 1 Turn the fuse housing counter clockwise image 7 3 2 Remove the unscrewed part and remove the fuse from it image 7 4 Image 7 4 fuse removed from its housing IN WARNING Always replace with the same type of fuse R5976794 OVERVIEW DR120 06 07 2004 _ 29 7 Electronic spares and servicing 7 1 4 Replacing the PFC Necessary tools No tools How to remove the PFC 1 Open the front panel 2 Slide the PFC board to the right so as to remove it from the projector image 7 5 Image 7 5 7 2 Switched Mode Power supply SMPS Overview e Description of the SMPS Diagnostics on SMPS e Connections SO R5976794 OVERVIEW DR120 06 07 2004 7 Electronic spares and servicing Service sheet N de a gt me Ss P Vis AY ITI over Tir vr Image 7 6 CT CET 7 2 1 Description of the SMPS Functional description The standby and mains power supplies are built around the TOP240 series of IC s that are fully integrated SMPS controllers and switching devices here in a flyback configuration Both supplies are using secondary feedback to be able to get stable supply voltages 5 and 15 5 V Start up During start up the standb
65. which is switched by the Vin_HIGH_1 signal coming from the PFC that way R725 is added to influence the voltage levels of the inputs of comparator 1703 Temperature sensing The PWM signal T_PFC generated on the PFC is transferred to the secondary side by means of an optocoupler where it is integrated by R415 C411 to obtain a DC signal again This signal is buffered by 1400 and used to control the speed of the fan FAN_PFC_CTRL for the power The same signal is also level shifted 1400 and buffered OVERTEMP_PFC to have it fed to a comparator where overtemperature of the heatsink is detected 7 2 2 Diagnostics on SMPS 0 3 3 lt O maj er gt D Q D 5 D 0 eb D o lt O Q D 0 Labels Purpose 5V Controller Fan ctrl Standby 8V used internally 24V Fan ctrl 15VM PFC 15 5V RGB input PMP Flex4 Operational 15VM U F 12V Formatter comms int RGB input 5V PMP formatter RGB input 2 5V Formatter do 3 3V PMP Flex4 Formatter Refer to the interconnection diagram for more detail about the supply voltages and their use LED Diagnostics The OverView DR120 allows a rapid diagnostics of the main voltages and SMPS diagnostic signals via a number of LED s located at the front side of the projector on the SMPS so as to allow rapid checking R5976794 OVERVIEW DR120 06 07 2004 _ 833 Electronic spares and servicing HEY o LTP E 15 5V 24V
66. witch 1 left position switch 2 right position 26V OFF 1 8 The Controller CPU Description EI CPU How to Replace the CPU 1 Remove the 3 flat cables the power and 12C connector image 7 37 2 Loosen and remove the 4 screws image 7 38 3 Place the news CPU connect and fix it as described here FE B Image 7 37 52 E zz zz O _ R5976794 OVERVIEW DR120 06 07 2004 Electronic spares and servicing LO 411 Tee LE Image 7 38 A CAUTION When replacing the CPU the projector settings should be reloaded contact Barco to get these settings R5976794 OVERVIEW DR120 06 07 2004 53 7 Electronic spares and servicing 7 9 UHP lamp driver Service sheet Image 7 39 Description The lamp driver is connected to the PFC with a 4 pin power connector which delivers the 365VDC supply voltage 2 wires for the lamp driver The control signal Lamp_enable comes from the formatter via the SMPS on its turn the driver generates a feedback signal Lamp_Litz for the formatter For more detail about these signals see the formatter section Replacing the Lamp driver 1 Open the front panel 2 Unscrew the 4 synthetic nuts image 7 40 3 Disconnect the driver at the lamp and at the PFC image 7 41 4 Remove the Lamp driver 4 zz 0 o ROI76794 OVERVIEW DR120 06 07 2004 7 Electronic spares and servicing Image 7 40 Image 7 41 LPS connections 7 10 The Steppe
67. y supply starts first powering the controller via the 5V standby supply The IC has an internal start up circuit which level is determined by R21 22 and 23 The converter should start with an input voltage of around 110 VDC present on its line sense input to be sure that the projector always powers up also when mains is 110Vac The PFC can start as soon as the controller asks for it via the PFC_ON line The SMPS_ON line coming from the controller will finally act on the ext curr limit input of the second TOP IC 150 via Q50 and that way allow the main SMPS to deliver its power R5976794 OVERVIEW DR120 06 07 2004 __ 8 Electronic spares and servicing 32 The SMPS_ON command from the controller can be bypassed with the 1 switch forcing the 15 5V Note that S2 allows to force the PFC ON Image 7 7 Standby supply Built around 120 T20 and delivers all the standby supplies 5V e 8V e 24V 15VM voltage coming from the primary circuit used The feedback voltage for the standby supply 5V is taken on R129 and returned to the primary through optocoupler 1120 1 2 5 6 Note that the 5V is adjusted with P1 in the feedback On the 5 V output an overvoltage protection circuit is added to prevent serious damage in case of a feedback problem Z125 D125 Mains supply The main SMPS is built around 150 T50 and this converter delivers 15 5 V for the parts that are only powered during oper

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