DP-3000 R59770374 03 Service PDF

DP-3000
Service manual
R59770374/03
16/08/2010
Barco nv Media & Entertainment Division
Noordlaan 5, B-8520 Kuurne
Phone: +32 56.36.82.11
Fax: +32 56.36.883.86
E-mail: [email protected]
Visit us at the web: www.barco.com
Barco Inc. Media and Entertainment Division
11101 Trade Center Drive, Rancho Cordova, California 95670, USA
Phone: +1 916 859-2500
Fax: +1 916 859-2515
E-mail: [email protected]
Visit us at the web: www.barco.com
Printed in Belgium
Changes
Barco provides this manual ’as is’ without warranty of any kind, either expressed or implied, including but not limited to the implied war-
ranties or merchantability and fitness for a particular purpose. Barco may make improvements and/or changes to the product(s) and/or the
program(s) described in this publication at any time without notice.
This publication could contain technical inaccuracies or typographical errors. Changes are periodically made to the information in this
publication; these changes are incorporated in new editions of this publication.
Copyright ©
All rights reserved. No part of this document may be copied, reproduced or translated. It shall not otherwise be recorded, transmitted or
stored in a retrieval system without the prior written consent of Barco.
Trademarks
Brand and product names mentioned in this manual may be trademarks, registered trademarks or copyrights of their respective holders.
All brand and product names mentioned in this manual serve as comments or examples and are not to be understood as advertising for
the products or their manufacturers.
Table of contents
TABLE OF CONTENTS
1. Safety .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 5
1.1 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2. General . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 9
2.1 Convention projector orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2 Location of the main components of the projector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3 Convention Power Unit orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.4 Location of the main components of the Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.5 Projector block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.6 Spare part list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3. Preventative maintenance actions .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 25

3.1 1 month maintenance actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2 Lamp change maintenance actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.3 6 month maintenance actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.4 1 year maintenance actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.5 4 year maintenance actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.6 10 year maintenance actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4. Trouble shooting . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 35
4.1 First level troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.2 Trouble shooting checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5. Power Unit . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 75
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5.2 LPS module diagnostic LED’s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
5.3 Connecting the power unit with the projector head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5.4 Connecting the power unit with the power net. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
5.5 Removal of an LPS module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5.6 Installation of an LPS module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
5.7 Removing the LPS rack from the base of the Power Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5.8 Replacement of the LPS communication interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5.9 Replacement of the Mains Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
5.10 Installing the LPS rack upon the base of the Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
6. Start Pulse Generator.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 99

6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
6.2 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
6.3 Removal of the Start Pulse Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
6.4 Installation of the Start Pulse Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
7. Lamps and Lamp House .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 105

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
7.2 Supported xenon lamps for the DP-3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
7.3 Removing the lamp house . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
7.4 Removal of the xenon lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
7.5 Installation of the xenon lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
7.6 Installing the Lamp House. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
7.7 Resetting the lamp parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
7.8 Realignment of the lamp in its Reflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
7.9 Alignment of the arc stabilizing magnet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
7.10 Replacement of the Lamp Info module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
7.11 Replacement of the UV blocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
7.12 Replacement of the Lamp Reflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
7.13 Cleaning the UV blocker of the Lamp House . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
7.14 Cleaning the Reflector of the Lamp House . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
8. Cold Mirror .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 139

8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
8.2 Replacement of the Cold Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
8.3 Adjusting the Cold Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
8.4 Cleaning the Cold Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
9. Integration Rod . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 147

9.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148
9.2 Integration Rod diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149
9.3 Removal of the Integration Rod assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150
9.4 Installing a new Integration Rod assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
9.5 Adjusting the Integration Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
10. Sealed Light Processor Assembly .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 155

10.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
10.2 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
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10.3 Removal of the Sealed Light Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159

10.4 Installation of the Sealed Light Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
10.5 Adjusting the convergence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165
10.6 Adjusting the Fold Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
10.7 Adjusting the Light Pipe Zoom Lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
10.8 Adjusting the Notch Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171
10.9 Cleaning the Notch Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172
10.10 Cleaning the Prism exit side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
10.11 Replacement of the Dowser (Shutter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .174
10.12 Replacement of the Light Sensor Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175
10.13 Replacement of the Notch Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
11. Liquid Cooling Circuit . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 177

11.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178
11.2 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180
11.3 Pressure verification of the Liquid Cooling Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182
11.4 Excluding the Sealed Light Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .183
11.5 Draining the Liquid Cooling Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184
11.6 Filling the Liquid Cooling Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186
11.7 Refreshing the Liquid Cooling Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
11.8 Expelling air from the Liquid Cooling Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191
11.9 Pressurizing the Liquid Cooling Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193
11.10 Calibrating the Liquid Cooling Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195
11.11 Removal of the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198
11.12 Installing the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
11.13 Cleaning the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204
11.14 Replacement of the Pump motor and rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206
11.15 Replacement of the complete Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .208
11.16 Replacement of the Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210
12. Lenses and Lens Holder .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 213

12.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214
12.2 Available lenses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .216
12.3 Lens selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .217
12.4 Lens formulas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .218
12.5 Lens installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219
12.6 Lens removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221
12.7 Cleaning the lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .222
12.8 Adjusting the Lens Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .223
12.9 Removal of the Lens Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226
12.10 Installation of the Lens Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .228
12.11 Replacement of the vertical shift motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230
12.12 Replacement of the horizontal shift motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .232
12.13 Replacement of the focus motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .234
12.14 Replacement of the Lens Signal Distribution board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .236
13. Card Cage.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 237

13.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .238
13.2 Card Cage diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .239
13.3 Removal of the Card Cage cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .242
13.4 Installation of the Card Cage cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .244
13.5 Authorization to clear security warning on DP-3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .245
13.6 Replacement of a Card Cage board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .246
14. Updating TI Boards .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 249

14.1 Installation of the Update Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250
14.2 Start up the update program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .251
14.3 Make a serial connection (RS232) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .252
14.4 Make an Ethernet connection (10/100 BASE-T) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253
14.5 Installation of the new software release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .255
14.6 Logging of the operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257
14.7 Special functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .259
14.8 Factory Install Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260
14.9 Recovery option - Stay in Boot option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .261
15. Input & Communication unit . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 263

15.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .264
15.2 Control ports of the DP-3000 digital projector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .266
15.3 Data source input ports of the DP-3000 digital projector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .268
15.4 About General Purpose Inputs & Outputs (GPIO). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .269
15.5 Removal of the Input & Communication unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .271
15.6 Installation of the Input & Communication unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .274
15.7 Replacement of the DVI input board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .277
15.8 Replacement of the GPIO board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .278
15.9 Replacement of the DIMM PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .279
2 R59770374 DP-3000 16/08/2010

Table of contents
16. Control Panel.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 281

16.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .282
16.2 Local keypad of the DP-3000 digital projector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .283
16.3 Replacement of the Button module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .285
16.4 Replacement of the Local Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .288
16.5 Replacement of the Status Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .291
17. Communicator Touch Panel .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 293

17.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .294
17.2 Installing the touch panel interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .295
17.3 Reposition the touch panel interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .298
18. Fan replacement procedures. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 299

18.1 Replacement of the Anode Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .300
18.2 Replacement of the Cathode Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .306
18.3 Replacement of the Outlet Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .310
18.4 Replacement of the Cold Mirror Top Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .315
18.5 Replacement of the Cold Mirror Bottom Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .318
18.6 Replacement of the SPG Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .319
18.7 Replacement of the Card Cage Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .320
19. Projector covers .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 321

19.1 Removal of the right cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .322
19.2 Removal of the left cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .323
19.3 Removal of the front cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .324
19.4 Removal of the rear cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325
19.5 Removal of the top cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .326
19.6 Removal of the bottom cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .327
19.7 Installation of the bottom cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .328
19.8 Installation of the top cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .329
19.9 Installation of the rear cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .330
19.10 Installation of the front cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .331
19.11 Installation of the left cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .332
19.12 Installation of the right cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .333
19.13 Cleaning the dust filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .334
19.14 Cleaning the exterior of the projector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .335
A. Anamorphic lens and holder .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 337

A.1 Mounting the anamorphic lens in its holder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .338
A.2 Alignment of the Anamorphic Lens position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .340
A.2.1 Removing the Anamorphic lens holder driver cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .341
A.2.2 Distance between Anamorphic and Prime lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .342
A.2.3 Remounting the Anamorphic lens holder driver cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .344
A.2.4 Image centering on Anamorphic lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .345
A.2.5 Horizontal alignment of the image top line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .346
A.3 Anamorphic lens holder locking motor replacements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .347
A.3.1 Preparations to remove the motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .348
A.3.2 Removing the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .349
A.3.3 Preparation of the new motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .350
A.3.4 Mounting the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .351
A.4 Anamorphic lens holder rotation motor replacements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .352
A.4.1 Removing the Anamorphic lens holder front cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .353
A.4.4 Remounting the Anamorphic lens holder front cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .356
A.5 Anamorphic lens holder shift motor replacements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .357
A.5.1 Preparations to remove the motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .358
A.5.3 Preparation before inserting the new motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .361
B. Pin configurations . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 363

B.1 Pin configuration of the Input & Communication ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .364
Glossary .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 367
Index. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 369
R59770374 DP-3000 16/08/2010 3

Table of contents
4 R59770374 DP-3000 16/08/2010

1. Safety
1. SAFETY
About this chapter
Read this chapter attentively. It contains important information to prevent personal injury while servicing the DP-3000 projector.
Furthermore, it includes several cautions to prevent damage to the DP-3000 projector. Ensure that you understand and follow all
safety guidelines, safety instructions and warnings mentioned in this chapter before servicing the DP-3000 projector. After this
chapter, additional “warnings” and “cautions” are given depending on the service procedure. Read and follow these “warnings” and
“cautions” as well.
WARNING: This manual is only intended for qualified service personnel.
Overview
• Safety Instructions
R59770374 DP-3000 16/08/2010 5

1. Safety
1.1 Safety Instructions
WARNING: Before removing/replacing any projector components, disconnect the power to the circuit mains
terminals and unplug the power cord at UPS INLET.
Safety Instructions
1. Before returning an instrument to the customer, always make a safety check of the entire instrument, including, but not limited
to, the following items:
a) Be sure that no built-in protective devices are defective and/or have been defeated during servicing. (1) Protective shields
are provided on this chassis to protect both the technician and the customer. Correctly replace all missing protective shields,
including any removed for servicing convenience. (2) When reinstalling the chassis and/or other assembly in the cabinet,
be sure to put back in place all protective devices, including, but not limited to, insulating materials, barriers, covers/shields,
and isolation resistor/capacitor networks. Do not operate this instrument or permit it to be operated without all protective
devices correctly installed and functioning. Servicers who defeat safety features or fail to perform safety checks may be
liable for any resulting damage.
b) Be sure that there are no cabinet openings through which an adult or child might be able to insert their fingers and contact a
hazardous voltage. Such openings include, but are not limited to, (1) excessively wide cabinet ventilation slots, and (2) an
improperly fitted and/or incorrectly secured cover panels.
c) Leakage Current Hot Check. With the instrument completely reassembled, plug the AC line cord directly into a 220 V AC
outlet (Do not use an isolation transformer during this test). Use a leakage current tester or a metering system that is
designed to comply with the new IEC, ANSI and UL standards. With the instrument AC switch first in the on position and
then in the off position, measure from a known earth ground (metal waterpipe, conduit, etc.) to all exposed metal parts
of the instrument (antennas, handle bracket, metal cabinet, screwheads, metallic overlays, control shafts, etc.). especially
any exposed metal parts that offer an electrical return path to the chassis. Any current measured must not exceed 3,5 mA.
Reverse the instrument power cord plug in the outlet and repeat test. ANY MEASUREMENTS NOT WITHIN THE LIMITS
SPECIFIED HEREIN INDICATE A POTENTIAL SHOCK HAZARD THAT MUST BE ELIMINATED BEFORE RETURNING
THE INSTRUMENT TO THE CUSTOMER OR BEFORE CONNECTING ACCESSORIES.
AC Leakage Test Leakage Current Tester
Reading should
not be above
3,5 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
Image 1-1
d) Ultraviolet Radiation exposure - Warning: This lamp can cause serious skin burn and eye inflammation from shortwave
ultraviolet radiation if not operated in enclosed fixtures. DO NOT operate this lamp in a fixture with a missing or broken lens
cover.
e) Ozone: Operating lamp generates ozone gas which is harmful to the respiratory system. Therefore the lamp should be
operated in adequately ventilated equipment.
2. Read and comply with all caution and safety-related notes on or inside the projector cabinet or on the projector chassis, or on
the picture tube.
3. Design Alteration Warning - Do not alter or add to the mechanical or electrical design of this apparatus. Design alterations and
additions, including, but not limited to, circuit modifications and the addition of items such as auxiliary audio and/or video output
connections, might alter the safety characteristics of this apparatus and create a hazard to the user. Any design alterations
or additions may void the manufacturer’s warranty and may make you, the servicer responsible for personal injury or property
damage resulting therefrom.
6 R59770374 DP-3000 16/08/2010

1. Safety
4. Lamp explosion Protection Warning – The lamp in this projector operates with a high internal pressure and there is a slight risk
that the lamp may explode, particularly if it is used beyond its rated life. Do not remove, install, or otherwise handle the lamp
in any manner without first putting on shatterproof goggles equipped with side shields. People not so equipped must be kept
safely away while lamps are handled. Keep the lamp away from your body. For continued explosion protection, replace the
lamp only with one of the same type number. Always replace the lamp before the rated life time.
5. Hot Chassis Warning - This projector chassis has two ground systems: the primary ground system is formed by the negative
voltage of the rectified mains (power) and is only used as a reference in primary circuits; the secondary ground system is
connected to earth ground via the earth conductor in the mains (power) lead. Separation between primary and secondary
circuits is performed by the safety isolation transformers. Components bridging this transformers are also safety components
and must never be defeated or altercated. All user-accessible conductive parts must be connected to earth ground, or are kept
at SELV (Safety Extra Low Voltage).
6. Observe original lead dress. Always inspect in all areas for pinched, out-of-face, or frayed wiring. Do not change spacing
between components, and between components and the printed-circuit board. Check AC power cord for damage. Take extra
care to assure correct lead dress in the following areas:
a) near sharp edges
b) near thermally hot parts - be sure that leads and components do not touch thermally hot parts
c) the AC supply
d) high voltage
7. Components, parts, and/or wiring that appear to have overheated or are otherwise damaged should be replaced with compo-
nents, parts, or wiring that meet original specifications. Additionally, determine the cause of overheating and/or damage and, if
necessary, take corrective action to remove any potential safety hazard.
8. PRODUCT SAFETY NOTICE - Many electrical and mechanical parts have special safety-related characteristics some of which
are often not evident from visual inspection, nor can the protection they give necessarily be obtained by replacing them with
components rated for higher voltage, wattage, etc. Use of a substitute replacement that does not have the same safety charac-
teristics as the recommended replacement part in BARCO service data parts list might create shock, fire, and/or other hazards.
Product Safety is under review continuously and new instructions are issued whenever appropriate. For the latest information,
always consult the appropriate current BARCO service literature.
9. Do not spray chemical on or near this instrument or any of its assemblies.
10. Electrostatically Sensitive (ES) Devices Some semiconductor (solid state) devices can be damaged easily by static electricity.
Such components commonly are called Electrostatically Sensitive (ES) Devices. Examples of typical ES devices are integrated
circuits and some field-effect transistors and semiconductor "chip" components. The following techniques should be used to
help reduce the incidence of component damage caused by static electricity:
a) Immediately before handling any semiconductor-equipped assembly, drain off any electrostatic charge on your body by
touching a known earth ground. Wear a commercially available high impedance discharging wrist strap device.
b) After removing an electrical assembly equipped with ES devices, place the assembly on a static dissipative surface such as
a 3M No 8210 table mat, to prevent electrostatic charge buildup or exposure of the assembly.
c) Do not use freon-propelled chemicals. These can generate electrical charges sufficient to damage ES devices.
d) Do not remove a replacement ES device from its protective package until immediately before you are ready to install it
(Most replacement ES devices are packaged with leads electrically shorted together by conductive foam, aluminium foil or
comparable conductive material).
e) Immediately before removing the protective material from the leads of a replacement ES device, touch the protective material
to the chassis or circuit assembly into which the device will be installed. CAUTION: Be sure no power is applied to the chassis
or circuit, and observe all other safety precautions.
f) Minimize bodily motions when handling unpacked replacement ES devices (Otherwise harmless motion such as the brush-
ing together of your clothes fabric or the lifting of your foot from a carpeted floor can generate static electricity sufficient to
damage an ES device).
R59770374 DP-3000 16/08/2010 7

1. Safety
8 R59770374 DP-3000 16/08/2010

2. General
2. GENERAL
About this chapter
This chapter contains some general information on projector level such as the location of the main components, internal wiring
diagram, spare parts list, etc.
Overview
• Convention projector orientation
• Location of the main components of the projector
• Convention Power Unit orientation
• Location of the main components of the Power Unit
• Projector block diagram
• Spare part list
R59770374 DP-3000 16/08/2010 9

2. General
2.1 Convention projector orientation

Convention
This manual refer to the left side of the projector as the side at your left hand when standing behind the projector and looking at the
projection screen in front of the projector.
B
T
Image 2-1
T Top of the projector.
L Left side of the projector (Light Processor side).
F Front of the projector.
R Right side of the projector (Lamp side & Input side).
B Back side of the projector.
10 R59770374 DP-3000 16/08/2010

2. General
2.2 Location of the main components of the projector

Housing and air inlet filters
2
8
7
3
4
6
5
Image 2-2
1 Top cover.
2 Front cover.
3 Front filter (slide into front cover).
4 Right side cover (lamps side).
5 Bottom cover.
6 Rear cover.
7 Side filter.
8 Left side cover (light processor side).
R59770374 DP-3000 16/08/2010 11

2. General
Main internal components
9 10 11
12 13 14 15
Image 2-3
9 Sealed Light Processor unit (SLP).
10 Heat exhauster (Outlet Fan).
11 Lens Holder.
12 Lamp House.
13 Control Panel (includes Button Panel).
14 Input & Communication unit (includes Barco Cinema Controller).
15 Cover for future expansion.
16 17 18
19
20 21
Image 2-4
16 SMPS CTRL board.
17 SMPS PFC board.
18 SMPS DCDC board.
19 TI Cinema Processor board.
20 TI Cinema Interface board.
21 Card cage securing cover.
12 R59770374 DP-3000 16/08/2010

2. General
31
22
23
30
29
24 25 26 27 28
Image 2-5
22 Fans card cage power compartment.
23 Fans heat exchanger of liquid cooling circuit.
24 Heat exchanger.
25 Pump.
26 Fan for lamp cathode cooling.
27 Mains input filter.
28 Electrical connector for lamp house (lamp info).
29 Start Pulse Generator (SPG).
30 Cold mirror assembly (rear side).
31 Status lights on projector corners.
31 34
24
33
29 30 32
Image 2-6
24 Heat exchanger.
29 Start Pulse Generator (SPG).
30 Cold mirror assembly (front side).
31 Status lights on projector corners.
32 Manometer.
33 Card cage Power Backplane.
34 Card cage Signal Backplane.
R59770374 DP-3000 16/08/2010 13

2. General
2.3 Convention Power Unit orientation

Convention
T
B
R
Image 2-7
T Top of the Power Unit.
L Left side of the Power Unit.
F Front of the Power Unit (air outlet).
R Right side of the Power Unit.
B Back side of the Power Unit (air inlet).
14 R59770374 DP-3000 16/08/2010

2. General
2.4 Location of the main components of the Power Unit

Main internal components of the Power Unit
6
7
Image 2-8
1 Front cover with air outlet grid.
2 Lamp Power Supply (LPS).
3 Power rack.
4 Rear cover with air inlet grid.
5 Cover plate mains connections.
6 Power Unit base assembly.
7 Cover plate power output sockets.
R59770374 DP-3000 16/08/2010 15

2. General
Parts of the base of the Power Unit
13
14 12
15
9
10
Image 2-9
8 Mains input distribution strip.
9 Cable gland for mains input cable.
10 Optional entrance for mains input cable.
12 LPS communication board.
13 Mains connection per LPS module.
14 Mains output socket for projector head.
16 R59770374 DP-3000 16/08/2010

2. General
2.5 Projector block diagram

Signal flow Card Cage and Sealed Light Processor
Interface Board Processor Board EFIB Board Formatter
Input Processing Data Processing

16-bit
HD-SDI Input Select Resizer Processing
DVI Interface CSC1 - Color Space
HD-SDI Interface Convert DeGamma
Local Link Decryption CLUT – 3D Color Proc P7 Color Proc
Test Pattern Generator Image cropping Frame Rate
Data Unpacking & Overlay Compositor Multiplication Formatter
DVI
Formatting
Frame Store
ARM7 MicroController Digital Signal Proc

RS-232
Executive Control Subtitle Rendering
Overlay Processing
Resizer Coef Comp
100baseT Formatter
Mass Store Boot Flash Boot Flash
Image 2-10
R59770374 DP-3000 16/08/2010 17

18
2. General
Image 2-11
Internal wiring diagram
Airflow Switch
Lamp Mount Switch
Engine Mount Switch
Ambient Temperature
Lamp Temperature
P
PUMP
R764803 - R781922
LPS Temp.
Mains Filter
B3058273
R59770374 DP-3000 16/08/2010

2. General
Projector power circuitry
++5V
Lens Signal Distribution +5V CLO
+12V
+5V
+12V
++5V
Lamp
+3.3V
+24V ELEC Info
+12V TEC
+12V ACSAR
+22V PUMP
++12V
++5V PUSH
+16..24V Fan ohters Anamorphic

+16..24V Fan Anode
SMPS CTRL +16..24V Fan Cathode
+16..24V Fan Top Pump
230VAC
+380VM
+16..24V Fan Top (Exhaust)

Top Fan
+16..24V Fan Anode Anode Fan
+16..24V Fan Cathode Cathode Fan
SMPS Fan 1
+16..24V Fan others
Power Backplane
SMPS Fan 2
++5V SMPS Fan 3

STBY
SMPS PFC ++12V SMPS Fan 4
Cold Mirror
Fan top
Cold Mirror
Fan bottom
+22V PUMP (+ Anamorphic) SPG fan
+12V ACSAR (DP-3000 not used) Sealed engine

internal fan
+12V TEC (Peltiers)

ΔT TEC Red
+24V ELEC (Electronics) ΔT TEC Green
+3.3V ΔT TEC Blue
+5V
SMPS DCDC +12V
+3.3V
Signal Backplane
TI Cinema Processor +5V

+12V
Sealed
Light
+3.3V Processor
TI Cinema Interface +5V
+12V
Data Input & Communication ++5V

++12V
+3.3V
Barco Cinema Controller +5V
++5V
Button Module ++12V
Image 2-12
R59770374 DP-3000 16/08/2010 19

2. General
2.6 Spare part list
Look at the secured Barco website https://My.Barco.com for the most recently updated spare parts list.
Optical spare parts

Order No. Description Applies to Reference
R9855942 1,2" DC2K Zoom Lens (1,45-2,05 : 1) (Motorized) DP-3000 page 216
R9855946 1,2" DC2K Zoom Lens (2,15-3,6 :1) (Motorized) DP-3000 page 216
R9855947 1,2" DC2K Zoom Lens (2,8-5,5 :1) (Motorized) DP-3000 page 216
R9806790 Anamorphic Lens + Motorized Lens Holder DP90, DP100 and Manual No:
DP-3000 R5976797.
R9806110 Anamorphic Lens 1.25x for 2,39 display format DP90, DP100 and Manual No:
DP-3000 R5976797.
R828887K Cold mirror DP90, DP100, page 141
DP-3000 and XLM
R856961(K) Integration Rod DP-3000 page 147
R828289K Lamp House Reflector set DP-3000 page 134
R9855950 Lamp Xenon Osram 3kW DHS DP-3000 page 105
R9855949 Lamp Xenon Osram 4,5kW DHP DP-3000 page 105
R9806860 Lamp Xenon Osram 6,5kW DHP DP-3000 page 105
R9806864 Lamp Xenon Osram 6,5kW DHP (4 pieces) DP-3000 page 105
R98064901 Lamp Xenon Osram 6kW HP DP-3000 page 105
R9855953 Lamp Xenon Ushio 3kW DXL30BA DP-3000 page 105
R9855952 Lamp Xenon Ushio 4,5kW DXL45BA DP-3000 page 105
R9806520 Lamp Xenon Ushio 6,0kW DXL60BA2 DP-3000 page 105
R9855951 Lamp Xenon Ushio 6,5kW DXL65BA DP-3000 page 105
R857103K Sealed Light Processor + Light Pipe + Shutter assembly DP-3000 page 155
R857088(K) Notch Filter DP-3000 page 176
R863206K UV blocker with screwed anode support for lamp house DP-3000 page 130
Electrical spare parts

R9861300 ACS-2048 (Alternative Content Switcher) DP-1200, DP-1500, Manual No:
DP-2000, DP-3000 26-0603000-00
R829436K Air flow switch DP90, DP100, page 310
DP-3000
R846905K Anamorphic Lens Holder motor kit (lock) DP90, DP100,DP- Manual No:
3000 R5976802
R846906K Anamorphic Lens Holder motor kit (rotor) DP90, DP100,DP- Manual No:
3000 R5976803
R846907K Anamorphic Lens Holder motor kit (trans) DP90, DP100, Manual No:
DP-3000 R5976804
R764396K Backlight for the Input & Communication unit DP90, DP100, page 281
DP-3000
R765319(K) Button Module DP-3000 page 285
20 R59770374 DP-3000 16/08/2010

2. General

R9855853 Communicator Touch Panel DP90, DP100, "Communicator
DP-3000 Touch Panel",
page 293
Manual No:
R59770129
R764491K Corner status light unit DP90, DP100, page 291
DP-3000
R765564(K) DIMM PC + Software DP-3000 page 279
R7649632K DP-3000 power unit for 3 x 400V AC + Neutral (EU) DP-3000 EU page 75
R7649633K DP-3000 power unit for 3 x 208V AC without neutral (US) DP-3000 US page 75
R764443K DVI input unit DP90, DP100, page 277
DP-3000
B32455191DK Fan axial 24V (28 l/s @ 41db) DP50, DP90, DP100, "Replacement
DP-3000 of the Card
• Small fans above heat exchanger. Used to cool the power Cage Fans",
boards in the upper compartment of the card cage. page 320
• Small fan below Start Pulse Generator. "Replacement
of the SPG
Fan", page 319
B3245961DK Fan axial 24V (59 l/s @ 50 db) DP50, DP90, DP100, "Replacement
DP-3000 of the Cold
• Fan mounted underneath the optical base below the Cold Mirror. Mirror Bottom
• Fans (large) mounted on the heat exchanger assembly. Fan", page 318
"Replacement
of the Card
Cage Fans",
page 320
B3246271DK Fan centrifugal 24V 280 l/s 73dB (Outlet Fan) DP90, DP100, page 310
DP-3000
B3245959DK Fan radial 24V (10 l/s @ 50 db). Fan cooling Cold Mirror. Fan is DP30, DP50, DP90, page 315
mounted above the Cold Mirror. DP100, DP-3000
B324639DK Fan radial 24V 56LS 400 (Cathode Fan) DP90, DP100, page 306
DP-3000
B3245631DK Fan radial 24V 63LS MNL (Anode Fan) DP90, DP100, page 300
DP-3000
R8285302K Input & Communication drawer DP-3000 page 263
R764163K Input & Communication Interface board DP90, DP100, page 263
DP-3000
R765365K Lamp Info Module DP90, DP100, page 128
DP-1500, DP-2000,
DP-3000
R7633705K Lamp Power Supply unit (LPS) DP90, DP-3000 page 88
R764154K Lens Signal Distribution board DP90, DP100, page 236
DP-3000
R764684K Light sensor (CLO) DP90, DP100, page 175
DP-3000
R724934K Local Keypad DP-1200, DP-1500, page 288
DP-2000, DP-3000
R764804K LPS Interface board DP90, DP-3000 page 92
B3588520DK Motor for lens holder horizontal shift DP90, DP100, page 232
DP-3000
B3588521DK Motor for lens holder vertical shift or focus DP90, DP100, page 230 &
DP-3000 page 234
B3058273K Net Filter 3 Phase DP100, DP-3000 page 94
R764150K Power Backplane DP90, DP100, page 237
DP-3000
R765360(K) RS232/422 + General Purpose board DP-3000 page 278
R765095K Signal Distribution Backplane DCI DP90, DP100, page 237
DP-3000
R59770374 DP-3000 16/08/2010 21

2. General

R765177(K) SMPS CTRL board DP-3000 page 242
R764151K SMPS PFC board DP90, DP100, page 242
DP-3000
R764152K SMPS DCDC board DP90, DP100, page 242
DP-3000
R764429K SPG sub unit DP90, DP100, page 99
DP-3000
R7642762K Start Pulse Generator (SPG) module DP90, DP100, page 99
DP-3000
B401643K TI Cinema Interface board DCI & ROHS S1 + SK (Security Kit) DP90, DP100, page 242
DP-1500, DP-2000,
DP-3000
B401634K TI Cinema Interface Board HDCP S1 DP90, DP100, page 242
DP-1200, DP-1500,
DP-2000, DP-3000
B401254K TI Cinema Processor Board ROHS DP90, DP100, page 242
DP-1200, DP-1500,
DP-2000, DP-3000
R765314K Touch Panel display DP-1200, DP-1500, page 293
DP-2000, DP-3000
Mechanical spare parts

R864132K Anode Adaptation Bushing (for integrated anode support) DP-3000 page 108
R842215K Anode Adaptation Ring (for three leg anode support) DP-3000 page 108
R859985K Anode Adapter (No:5) DP-3000 page 108
R8436061K Cathode Adapter (No:3) with engagement pins DP-3000 page 108
B1909086K Cooling liquid 1 liter DP series page 186
B400952K Cooling Liquid pump DP90, DP100, page 206 &
DP-3000 page 208
R395198K Cooling liquid refill & calibration kit (2 liter) DP series page 177
R829828K Dust filter front side DP90, DP100, page 334
DP-3000
R8298281K Dust filter kit DP90, DP100, page 334
DP-3000
R841545K Dust filter left side panel DP90, DP100, page 334
DP-3000
B400924K Heat Exchanger DP90, DP100, page 210
DP-3000
R9855990 Lamp House DP-3000 page 121
R843613K Lamp House Cathode nut DP-3000 page 105
R853189K Lens Holder Motorize DP-3000
R9806800 Safety kit for lamp replacement (One pair of leather gloves and one DP series page 105
full face mask)
R856811K Shutter assembly (Dowser) DP-3000 page 174
R859361K Stacking Points DP-3000
22 R59770374 DP-3000 16/08/2010

2. General

R9856060 Universal pedestal adapter plate DP3-000 Manual No:
26-0603100-00
R9856050 Universal pedestal for DP series DP series Manual No:
26-0603100-00
R59770374 DP-3000 16/08/2010 23

2. General
24 R59770374 DP-3000 16/08/2010

3. Preventative maintenance actions
3. PREVENTATIVE MAINTENANCE ACTIONS

Maintenance program
The maintenance program is subdivided in time frames going from monthly maintenance actions which can be done by a trained
projectionist to annually and 4 yearly maintenance actions which must be done by certified service personnel who are familiar with
potential hazards of the product and all product safety checks.
Overview
• 1 month maintenance actions
• Lamp change maintenance actions
• 6 month maintenance actions
• 1 year maintenance actions
R59770374 DP-3000 16/08/2010 25

3.1 1 month maintenance actions

Every month
The 1 month maintenance actions, listed below, may be performed by a trained projectionist who is familiar
with potential hazards associated with the product.
No. Maintenance action Remarks

1 Clean the front and side dust filters of the projector. Use a vacuum cleaner. Replace
damaged filters immediately. See
chapter "Cleaning the dust filters", page
334.
2 Check the surface of the lens output side for dust. (it is not needed to remove Clean the lens output side in case
the lens from the projector). Only clean if necessary. dust is clearly visible upon the surface.
See "Cleaning the lens", page 222.
Note that if the lens was removed from
the projector, all used ’lens files’ must
be updated. See user guide of the
Communicator software.
3 Check the porthole (both sides) for dust. Clean the porthole in case dust is clearly
visible upon the surface. Use an optical
cloth.
26 R59770374 DP-3000 16/08/2010

3.2 Lamp change maintenance actions

Maintenance actions at every lamp change
The maintenance actions, listed below, which are required at every lamp change may be performed by a trained
projectionist who is familiar with potential hazards associated with the xenon lamp.

1 Check the UV blocker of the lamp house for dust. Only clean the UV blocker in case dust
is clearly visible upon the surface of the
UV blocker (both sides). Use an optical
cloth. See "Cleaning the UV blocker of
the Lamp House", page 137.
2 Check the reflector of the lamp house for dust. Only clean the reflector in case dust
is clearly visible upon the surface of
the reflector. Take the lamp house to
another room and use compressed air
to blow away the dust. Use an optical
cloth. See "Cleaning the Reflector of the
Lamp House", page 138.
3 Visual inspection of the lamp anode and cathode connectors of the lamp house. Replace the lamp house in case of
degradation, damage, etc. See "Lamps
and Lamp House", page 105.
4 Visual inspection of the lamp anode and cathode cables of the lamp house. Replace the lamp house in case of
degradation, damage, etc. See "Lamps
5 Check if all cables are still tightened. See chapter "Lamps and Lamp House",
page 105.
R59770374 DP-3000 16/08/2010 27

3.3 6 month maintenance actions

Every 6 month
The 6 month maintenance actions, listed below, may be performed by a trained projectionist who is familiar
with potential hazards associated with the product.

1 Clean the air vents/inlets of the projector: Use a vacuum cleaner.
• air inlet grid of the electronic compartment (front side projector).

• air inlet grid of the Lamp Power Supply (separate power unit of the
projector).
• air inlet grid of the Cold Mirror (left side of the projector).
2 Clean the cabinet of the projector. (Removal overall dust accumulation on See cleaning procedure "Cleaning the
projector covers) exterior of the projector", page 335.
3 Pressure verification of the liquid cooling circuit. This pressure, indicated on the internal
manometer, should be between 0,5 and
1 bar. See "Pressure verification of the
Liquid Cooling Circuit", page 182. If not,
corrective action should be taken by
certified service personnel.
28 R59770374 DP-3000 16/08/2010

3.4 1 year maintenance actions

Every year
The 1 year maintenance actions, listed below, may ONLY be performed by certified service personnel who are
familiar with potential hazards of the product and all product safety checks.
No. Component Maintenance action Remarks

1 Dust in Clean the metal mesh grid of the fan below the Cold Mirror. Use a vacuum cleaner and brush.
general
2 Dust in Remove all dust inside the lamp compartment. Use a vacuum cleaner. Do NOT touch
general the Cold Mirror.
3 Dust in Check the Cold Mirror for dust, burn damage, degradation, Only clean the Cold Mirror in case dust
general cracks, etc. is clearly visible upon the surface of the
Cold Mirror. See "Cleaning the Cold
Mirror", page 145.
Replace the Cold Mirror in case of burn
damage, degradation, cracks, etc. See
"Replacement of the Cold Mirror", page
141.
4 Dust in Clean the metal mesh grid on top of the lamp house. Use a vacuum cleaner.
general
5 Dust in Check the mask and the integrator entry for burn damage, Replace the integration rod and mask
general degradation, cracks, etc. Remove the lamp house and look at the in case of burn damage, degradation,
mask and integrator entry via the Cold Mirror. cracks, etc. See "Integration Rod",
page 147.
6 Dust in Open the dowser (shutter) and check the prism exit side for dust, Only clean the prism exit side in case
general discoloration, damage, degradation, cracks, etc. dust is clearly visible upon the surface
of prism. See "Cleaning the Prism exit
side", page 173.
Replace the complete Sealed Light
Processor Unit in case of degradation,
cracks, etc. See "Sealed Light
Processor Assembly", page 155.
7 Dust in Check the porthole (both sides) for dust. Only clean the porthole in case dust is
general clearly visible upon the surface. Use
an optical cloth.
8 Dust in Clean the projector exterior (housing). Report on cleanliness of See cleaning procedure "Cleaning the
general booth! exterior of the projector", page 335.
9 Dust in Check the condition (hot state) of the light pipe and prism by If artifacts are visible diagnose the
general looking for artifacts in the projected full white and full black integration rod. See "Integration Rod
patterns. diagnostic", page 149.
Replace the integration rod In case the
integration rod causes the artifacts.
See "Removal of the Integration Rod
assembly", page 150.
Replace the complete Sealed Light
Processor Unit in case the prism
causes the artifacts. See "Removal of
the Sealed Light Processor", page 159.
10 Diagnostics Check actual diagnostics/self tests after 1 hour play with black Note any irregularities and follow up.
image. See user guide of the Communicator software. Take the necessary measurements if
required.
11 Diagnostics Check and save TI and projector log/history files. See user guide Note any irregularities and follow up.
of the Communicator software.
12 Diagnostics Verify projector date and time and correct if required. See Communicator software.
13 Software Check for the latest version of Barco and TI software. See user Upgrade the projector software with the
version guide of the Communicator software. The latest software version latest version. See user guide of the
can be downloaded from the secured Barco web site. projector toolset.
14 Info-T’s Check if all Info-T’s are implemented. Note that the Info-T’s are If not, implement all Info-T’s and update
listed on the secured Barco web site. the projector service docket.
15 Cooling Check the condition of the tubing of the liquid cooling circuit for Replace damaged parts immediately.
circuit degradation, UV cracking, kinking of tubes, leakage. See "Liquid Cooling Circuit", page 177.
R59770374 DP-3000 16/08/2010 29


16 Cooling Replace the liquid of the cooling circuit. (drain, refill, expel air See chapter "Liquid Cooling Circuit",
circuit and pressurize) page 177.
17 Cooling Check calibration of the liquid cooling circuit. Connect syringe to circuit to determine
circuit compensation volume (50 - 70 ml).
See "Pressurizing the Liquid Cooling
Circuit", page 193.
18 Electrical Check the torque values/general condition of all critical electrical Do not release the nuts to check the
connections connections and components. Use a torque wrench to verify the torque. Just verify. See chapters
torque values of the critical electrical connections listed: "Installation of an LPS module", page
88, "Installation of the Start Pulse
• Nuts (x2) of the SPG socket inside the lamp house: 25 Nm. Generator", page 103 and "Installation
• Cathode cable nut for the lamp cathode socket: 17 Nm. of the xenon lamp", page 116.
• Hexagon socket head cap screw at the lamp cathode socket
: 5 Nm.
• Nuts of the LAMP OUT ports of each LPS unit:
a) Copper nuts and rods (old LPS) : 8 Nm.
b) Brass nuts and rods : 4 Nm.
c) Nickel plated brass nuts and rods : 4 Nm
d) Nickel plated steel nuts and rods : 8 Nm
19 Lamp Module Check the UV blocker of the lamp house for dust, burn damage, Only clean the UV blocker in case dust
degradation, cracks, etc. Note that in case of a passive 3D is clearly visible upon the surface of the
projection system the UV blocker has an adapted 3D coating. UV blocker (both sides). See "Cleaning
the UV blocker of the Lamp House",
page 137.
Replace the UV blocker in case of burn
"Replacement of the UV blocker", page
130.
20 Lamp Module Check the reflector of the lamp house for dust, degradation, Only clean the reflector in case dust
cracks, etc. is clearly visible upon the surface of
the reflector. Take the lamp house to
another room and use compressed air
to blow away the dust from the reflector.
See "Cleaning the Reflector of the
Lamp House", page 138.
Replace the reflector in case of burn
"Replacement of the Lamp Reflector",
page 134.
21 Lamp Module Visual inspection of the lamp anode and cathode connectors of Replace the lamp house in case of
the lamp house. degradation, damage, etc. See "Lamps
22 Lamp Module Visual inspection of the lamp anode and cathode cables of the Replace the lamp house in case of
lamp house. degradation, damage, etc. See "Lamps
23 Lamp Module Check motors (not yet available) and manual adjustments.
Lubricate if needed.
24 Lamp Module Check the positional integrity of automatic lamp alignment/CLO. Perform auto alignment. Manual
adjustment afterwards should not
improve light output.
25 Lens holder Check the lens holder shift functionality (up/down & left/right). In case of a motorized lens holder use
Lubricate where needed. the local keypad and the Communicator
software to shift.
26 Lens holder Check the positional integrity of motorized adjustments by Verify correct alignment on screen
switching Macro’s. between flat and scope.
27 Lens holder Check the focus uniformity. Adjust the lens holder (Scheimpflug)
ONLY if needed. See "Adjusting the
Lens Holder", page 223
28 Lens Check the optic surfaces of the lens input and output for dust. Only clean the input and/or output side
in case dust is clearly visible upon the
surfaces. Use an optical cloth. See
"Cleaning the lens", page 222. Note
that a lens removal requires an update
of all used ’lens files’. See user guide
of the Communicator software.
30 R59770374 DP-3000 16/08/2010


29 Lens Check the lens Zoom & Focus motors. Use the local keypad and the
Communicator software to Zoom and
to Focus.
30 Shutter Check the functionality of the Dowser (shutter). Loose Use the local keypad and the
components, wear and tear. Communicator software to Open and
Close the shutter.
Replace the shutter if needed. See
"Replacement of the Dowser (Shutter)",
page 174.
31 Electronic Check the general condition of the electronic boards: Status Blow out dust.
boards LED’s, dust, connections, etc.
Boards to check: LPS, SMPS PFC, SMPS CTRL, TI Interface
Board, TI Processor Board, Input & Communication Board.
32 Security Check the Tamper Switch Activation Report and Security Logs for Report if intruded.
security infringements.
33 Security Verify if the Dallas key is present and working. Report if missing, lost or damaged.
34 Air Extraction Check customer air extraction system for adequate extraction. The air extraction system must be
capable of removing minimum 10
m³/min or 350 CFM per installed
DP-3000 digital projector.
35 Color Measure the color coordinates of the projected image and See user guide of the Communicator
calibration calibrated if necessary. software.
36 Documenta- Check if the projector manuals are present and up-to-date. Download current manual version from
tion https://My.Barco.com.
37 Documenta- Update projector service docket. List all maintenance actions and
tion remarks.
R59770374 DP-3000 16/08/2010 31


Every 4 years
The 4 year maintenance actions, listed below, may ONLY be performed by certified service personnel who are
familiar with potential hazards of the product and all product safety checks.

1 Replace the pump of the liquid cooling circuit Follow correct pressurize procedure
after replacement. See "Replacement
of the complete Pump", page 208.
2 Check the lamp fans: vibrations, noise, speed, etc. (speeds: via diagnostics) Replace if needed. See "Fan
replacement procedures", page 299.
32 R59770374 DP-3000 16/08/2010


Every 10 years
The 10 year maintenance actions, listed below, may ONLY be performed by certified service personnel who
are familiar with potential hazards of the product and all product safety checks.

1 Check all fans: vibrations, noise, speed, etc. Replace if needed. See "Fan
replacement procedures", page 299.
R59770374 DP-3000 16/08/2010 33

34 R59770374 DP-3000 16/08/2010

4. Trouble shooting
4. TROUBLE SHOOTING
About this chapter
This chapter enumerates all possible error codes which can appear on the Touch Panel display of the cinema projector or in the
projector log files. Note that some codes have a warning and an error state. Some only have an error state, others have only a
warning state. In case of a “warning” the projector remains to operate. Nevertheless, it is recommended to solve the problem which
causing the “warning” as soon as possible otherwise, the “warning” state may turn into an “error” state which will switch off the
projector consequently.
The codes are placed in alphabetical order to make it easier to look up the code and find an appropriate solution.
Overview
• First level troubleshooting
• Trouble shooting checklist
R59770374 DP-3000 16/08/2010 35

4. Trouble shooting
4.1 First level troubleshooting

First level troubleshooting flowchart
Refer to N Sound
server present
diagnostics
Y
Check mains Check fuses N Power

voltage at inside indication
projector inlet 19" rack
Y
Red
Check Check error Status flashing
NOK Red
exhaust Airflow condition on indication
system touch panel
OK Green System is
Check filling Projector still booting,
NOK Ignite lamp
Liquid reset N Image power might
and pressure also try Lamp on
flow procedure black have been
liquid cooling touchpanel ?
interrupted
OK OK Y
N N
Lamp Ignition
Open dowser Switch off the
Check NOK Ambient runtime pulse ? N Dowser
also try projector for
air filter temp open?
Y touchpanel at least 15 sec
NOK
properly restart
OK NOK Y
Turn off the projector
Replace lamp lamp
NOK Lamp Y response
and set N Refer to
runtime other buttons
lamp runtime ? service
Cool down
diagnostics
OK and wait
2 minutes Remove lens Y
Projector
and push open
Others reset
dowser Random Y
procedure Subtitles
NOK Try to manually nois image
OK?
ignite lamp
Projector N
N
reset Check selection Check Ethernet
2x
procedure of appropriate connection
Replace lamp macro/input to the server
Contact
Check coax Refer to
Barco
connection service
to server diagnostics
Projector Test Y
N Freeze Subtitles
reset pattern?
procedure frame OK? Y
Y N
N
Contact Test
Barco pattern?
N Y
Projector Refer to
reset service
procedure diagnostics
Refer to Reselect
Y Y Wrong
server Test pattern correct
OK? macro color
diagnostics
N N
Projector Projector Refer to Y
reset reset server Drop out
procedure procedure diagnostics
Other
Projector
reset
procedure
Contact
Barco
Image 4-1
Projector reset procedure:

a) Turn off the Lamp and cool down the Lamp for at least 1 minute if hot.
b) Switch off the power of the unit and wait for at least 15 seconds.
c) Switch on the power of the unit and respect normal startup procedure.
36 R59770374 DP-3000 16/08/2010

4. Trouble shooting
4.2 Trouble shooting checklist

Code: “++5v - voltage high” (Warning)
Situation Solution
The ++5 volt supply voltage for the Replace the SMPS PFC board. See "Replacement of a Card Cage board", page 246.
electronics is about to exceed its
maximum limit.
Code: “++5v - voltage low” (Warning)

Situation Solution
The ++5 volt supply voltage for 1. Check if the SMPS PFC board is working properly. If not, replace the SMPS PFC
the electronics is almost below its board. See "Replacement of a Card Cage board", page 246.
minimum limit.
2. Check if the SMPS CTRL board is working properly. If not, replace the SMPS CTRL
board. See "Replacement of a Card Cage board", page 246.
3. Check the Power Backplane for bad connections. Note that the ++5V standby
supply is generated on the PFC board and enters the SMPS CTRL board via the
Power Backplane.
Code: “++12v - voltage high” (Warning)

Situation Solution
The ++12 volt supply voltage for the Replace the SMPS PFC board. See "Replacement of a Card Cage board", page 246.
electronics is about to exceed its
maximum limit.
Code: “++12v - voltage low” (Warning)

Situation Solution
The ++12 volt supply voltage for 1. Check if the SMPS PFC board is working properly. If not, replace the SMPS PFC
the electronics is almost below its board. See "Replacement of a Card Cage board", page 246.
minimum limit.
2. Check if the SMPS CTRL board is working properly. If not, replace the SMPS CTRL
board. See "Replacement of a Card Cage board", page 246.
3. Check the Power Backplane for bad connections. Note that the ++12V standby
supply is generated on the PFC board and enters the SMPS CTRL board via the
Power Backplane.
Code: “+3.3v - voltage high” (Warning)

Situation Solution
The +3.3 volt supply voltage for the 1. Replace the SMPS DCDC board. See "Replacement of a Card Cage board", page
electronics is about to exceed its 246.
maximum limit.
2. If the problem remains, replace the SMPS CTRL board. See "Replacement of a
Card Cage board", page 246.
Code: “+3.3v - voltage low” (Warning)

Situation Solution
The +3.3 volt supply voltage for 1. Replace the SMPS DCDC board. See "Replacement of a Card Cage board", page
the electronics is almost below its 246.
minimum limit.
2. If the problem remains replace the SMPS CTRL board. See "Replacement of a
3. Check the Power Backplane for bad connections. Note that the +3.3V is derived
from the +24V on the SMPS DCDC board.
Code: “+5v - voltage high” (Error)

Situation Solution
The +5 volt supply voltage for the 1. Replace the SMPS DCDC board. See "Replacement of a Card Cage board", page
maximum limit.
R59770374 DP-3000 16/08/2010 37

4. Trouble shooting
Code: “+5v - voltage low” (Error)

Situation Solution
The +5 volt supply voltage for 1. Replace the SMPS DCDC board. See "Replacement of a Card Cage board", page
minimum limit.
3. Check the Power Backplane for bad connections. Note that the +5V is derived from
the +24V on the SMPS DCDC board.

Situation Solution
The +12 volt supply voltage for the 1. Replace the SMPS DCDC board. See "Replacement of a Card Cage board", page
maximum limit.
Code: “+12v - voltage low ” (Error)

Situation Solution
The +12 volt supply voltage for 1. Replace the SMPS DCDC board. See "Replacement of a Card Cage board", page
minimum limit.
3. Check the Power Backplane for bad connections. Note that the +12V is derived
from the +24V on the SMPS DCDC board.

Situation Solution
The +24 volt supply voltage for the 1. Replace the SMPS CTRL board. See "Replacement of a Card Cage board", page
maximum limit.
2. If the problem remains, replace the SMPS DCDC board. See "Replacement of a
Code: “+24v - voltage low” (Error)

Situation Solution
The +24 volt supply voltage for 1. Check if the SMPS DCDC board is working properly. If not, replace the SMPS
the electronics is almost below its DCDC board. See "Replacement of a Card Cage board", page 246.
minimum limit.
2. Check the Power Backplane for bad connections. Note that the +24V supply is
generated on the SMPS DCDC board and enters the SMPS CTRL board via the
Power Backplane.
Code: “airflow - not ok” (Error)

Situation Solution
Blocked outlet of the air exhaust. Check if the outlet of the air exhaust on top of the projector is not blocked.
Failure of the external air exhaust Check the external air exhaust system. Note that the installed exhaust blower must
system. remove an air volume of 10 m³/min or 350 CFM per installed DP-3000 projector.
Blocked air inlet 1. Check if the air inlet at the front and at the left side of the projector is not blocked.
2. Check both dust filters of the projector. Clean if necessary or replace if damaged.
38 R59770374 DP-3000 16/08/2010

4. Trouble shooting
Situation Solution
Disconnected air flow switch. Check the wire unit of the air flow switch (reference 1 image 4-2) in the air outlet channel
of the projector and check if the wire unit (reference 2 image 4-2) is connected with the
Power Backplane.
Defect air flow switch. Replace the air flow switch. The air flow switch is located inside the Outlet Fan assembly.
To disassembly the Outlet Fan assembly see page 310.
Image 4-2
Code: “ambient - temperature too high” (Error)

This error code is probably proceeded by the warning code: “ambient - temperature high”. The same troubleshooting table can be
applied.
Code: “ambient - temperature too low” (Error)

This error code is probably proceeded by the warning code: “ambient - temperature low”. The same troubleshooting table can be
applied.
Code: “ambient - temperature high” (Warning)

Situation Solution
Blocked air filter at the front side Clean the air filters of the projector. Replace if damaged. See procedure "Cleaning
and/or left side of the projector. the dust filters", page 334.
Ambient temperature too high. Check the ambient temperature at the air inlets of the projector. Make sure that the
ambient temperature does not exceed 35°C (95°F).
Code: “ambient - temperature low” (Warning)

Situation Solution
Low ambient temperature. Note that Check the ambient temperature at the air inlets of the projector. Make sure that the
a too low ambient temperature may ambient temperature is higher then 10°C (50°F).
prevent the Sealed Light Processor
to start up. Tip: Ignite the lamp to warm up the Sealed Light Processor of the projector.
Damaged wire unit of the Repair the wire unit if possible or replace.
temperature sensor at the air
inlet (reference 1 image 4-3) causes
an open circuit.
Wire unit (reference 2 image 4-3) Remove the top cover of the projector and check if the wire unit of the temperature
of the temperature sensor is sensor is well inserted in the Power Backplane.
disconnected from the Power
Backplane.
Defect temperature sensor. Replace the temperature sensor.
Malfunction SMPS CTRL board. Replace the SMPS CTRL board. See "Replacement of a Card Cage board", page 246.
R59770374 DP-3000 16/08/2010 39

4. Trouble shooting
1 2
Image 4-3
Code: “Cold Mirror bottom fan - speed high” (Warning)

Situation Solution
Defect wire unit (reference 2 Check the wire unit of the fan (reference 1 image 4-4) for damage. Repair if possible,
image 4-4) causing a disruption in otherwise replace with new one.
the feedback circuit of the fan speed.
Malfunction SMPS DCDC board. Replace the SMPS DCDC board. See "Replacement of a Card Cage board", page 246..
Defect fan (reference 1 image 4-4). Replace the fan. See "Replacement of the Cold Mirror Bottom Fan", page 318.
1
3
Image 4-4
Code: “Cold Mirror bottom fan - speed low” (Warning)

Situation Solution
Wire unit (reference 2 image 4-4) of Remove the left cover of the projector and check the connection of the wire unit of the
the Cold Mirror fan disconnected. fan below the Cold Mirror.
Wire unit (reference 3 image 4-4) Remove the top cover of the projector and check if the wire unit (reference 3 image 4-4)
disconnected from the Power is inserted in the Power Backplane.
Backplane.
Blocked fan (reference 1 image 4-4). Unblock the fan. Ensure that the fan can turn freely.
Damaged wire unit. Check if the wire unit of the fan is not damaged. Repair if possible, otherwise replace
with new one.
40 R59770374 DP-3000 16/08/2010

4. Trouble shooting
Situation Solution
Malfunction SMPS DCDC board. Replace the SMPS DCDC board. See "Replacement of a Card Cage board", page 246.
Fan end of life. Replace the fan. See "Replacement of the Cold Mirror Bottom Fan", page 318.
Code: “Cold Mirror top fan - speed high” (Warning)

Situation Solution
Malfunction SMPS CTRL board. Replace the SMPS CTRL board. See "Replacement of a Card Cage board", page 246
Defect fan (reference 1 image 4-5). Replace the fan. See "Replacement of the Cold Mirror Top Fan", page 315.
Image 4-5
Code: “Cold Mirror top fan - speed low” (Warning)

Situation Solution
Wire unit (reference 1 image 4-5) of Remove the left cover of the projector and check the connection of the wire unit
the Cold Mirror top fan disconnected. (reference 2 image 4-5) of the fan above the Cold Mirror.
disconnected from the Power is inserted in the Power Backplane.
Backplane.
Blocked fan. Unblock the fan. Ensure that the fan can turn freely.
with new one.
Fan end of life (reference 1 Replace the fan. See "Replacement of the Cold Mirror Top Fan", page 315.
image 4-5).
R59770374 DP-3000 16/08/2010 41

4. Trouble shooting
Code: “dmd blue - temperature too high” (Error)

This error code is probably proceeded by the warning code: “dmd blue - temperature high”. The same troubleshooting table can be
applied to.
Code: “dmd blue - temperature too low” (Error)

Situation Solution
The electronics of the Sealed Light Check the ambient temperature at the air inlets of the projector. Make sure that the
Processor remains off due to a too ambient temperature is higher then 10°C (50°F).
low DMD temperature.
Tip: Turning on the lamp will heat up the Sealed Light Processor and the DMD’s.
Code: “dmd blue - temperature high” (Warning)

Situation Solution
Blocked air inlet filters. The other Clean the blocked air inlet filters. Replace damaged filters immediately. See procedure
DMD temperatures are too high as "Cleaning the dust filters", page 334.
well.
The liquid cooling circuit of the Check if the cooling circuit of the Sealed Light Processor is connected with the pump and
Sealed Light Processor is mistakenly heat exchanger. See "Excluding the Sealed Light Processor", page 183.
excluded from the main liquid cooling
circuit. Most likely the other DMD
temperatures are too high as well.
The LED “+24V” on the SMPS
DCDC board remains off. See "Card
Cage diagnostic", page 239
Failure of one of the components Replace the whole Sealed Light Processor unit and return the malfunction Sealed Light
inside the Sealed Light Processor Processor to factory for repair. Do not open and service the Sealed Light Processor
(Peltier, DMD, Temp sense, etc.). yourself. See "Sealed Light Processor Assembly", page 155.
Code: “dmd blue - temperature low” (Warning)

Situation Solution
The temperature of the DMD is close Check the ambient temperature at the air inlets of the projector. Make sure that the
to the minimum allowed temperature. ambient temperature is higher then 10°C (50°F).
In case the temperature drops further
the Sealed Light Processor will shut Tip: Turning on the lamp will heat up the Sealed Light Processor and the DMD’s.
down to protect the DMD.
Code: “dmd red - temperature too high” (Error)

This error code is probably proceeded by the warning code: “dmd red - temperature high”. The same troubleshooting table can be
applied to.
Code: “dmd red - temperature too low” (Error)

Situation Solution
Code: “dmd red - temperature high” (Warning)

Situation Solution
well.
The liquid cooling circuit of the Check if the cooling circuit of the Sealed Light Processor is connected with the pump and
Sealed Light Processor is mistakenly heat exchanger. See "Excluding the Sealed Light Processor", page 183s
42 R59770374 DP-3000 16/08/2010

4. Trouble shooting
Situation Solution
Failure of one of the components Replace the whole Light Processor unit and return the malfunction Light Processor to
inside the Sealed Light Processor factory for repair. Do not open and service the Sealed Light Processor yourself. See
(Peltier, DMD, Temp sense, etc.). "Sealed Light Processor Assembly", page 155.
Code: “dmd red - temperature low” (Warning)

Situation Solution
Code: “dmd green - temperature too high” (Error)

This error code is probably proceeded by the warning code: “dmd green - temperature high”. The same troubleshooting table can
be applied to.
Code: “dmd green - temperature too low” (Error)

Situation Solution
Code: “dmd green - temperature high” (Warning)

Situation Solution
well.
The liquid cooling circuit of the Check if the cooling circuit of the Sealed Light Processor is connected with the pump
Sealed Light Processor is mistakenly and heat exchanger.
Failure of one of the components Replace the whole Light Processor unit and return the malfunction Light Processor to
inside the Sealed Light Processor factory for repair. Do not open and service the Sealed Light Processor yourself. See
(Peltier, DMD, Temp sense, etc.). "Sealed Light Processor Assembly", page 155.
Code: “dmd green - temperature low” (Warning)

Situation Solution
Code: “efib - i2c failed” (Error)

Situation Solution
Communication failure with the Check if the Sealed Light Processor unit is well inserted.
Formatting Interface Board (EFIB).
Note that the Formatting Interface
Board is located inside the Sealed
Light Processor unit.
R59770374 DP-3000 16/08/2010 43

4. Trouble shooting
Situation Solution
Defect SMPS CTRL board. See Replace the SMPS CTRL board. See "Replacement of a Card Cage board", page 246.
"Card Cage diagnostic", page 239
Malfunction Formatting Interface 1. Reboot the projector.

Board (EFIB).
2. If the problem remains, replace the whole Sealed Light Processor unit and return the
malfunction Sealed Light Processor to factory for repair. Under no circumstances
the Sealed Light Processor may be serviced at the field. Service on the Sealed
Light Processor unit can only be done at factory.
Code: “efib - command/parameter error” (Error)

Situation Solution
Board (EFIB).
Code: “efib - system failure” (Error)

Situation Solution
Board (EFIB).
Code: “efib - flash update error” (Error)

Situation Solution
Board (EFIB).
Code: “efib - flash mailbox download error” (Error)

Situation Solution
Board (EFIB).
44 R59770374 DP-3000 16/08/2010

4. Trouble shooting
Code: “efib - sequence data error” (Error)

Situation Solution
Board (EFIB).
Code: “efib - modular formatter sequence error” (Error)

Situation Solution
Board (EFIB).
Code: “efib - modular formatter/dmd mismatch error” (Error)

Situation Solution
Board (EFIB).
Code: “efib - modular formatter architecture error” (Error)

Situation Solution
Board (EFIB).
Code: “efib - modular formatter green link communication error” (Error)

Situation Solution
Board (EFIB).
R59770374 DP-3000 16/08/2010 45

4. Trouble shooting
Code: “efib - modular formatter red link communication error” (Error)

Situation Solution
Board (EFIB).
Code: “efib - modular formatter blue link communication error” (Error)

Situation Solution
Board (EFIB).
Code: “elcabox - temperature high” (Warning)

Situation Solution
Blocked air inlet at the front side of Make sure that the air inlet at the front of the projector is free so that fresh air can easily
the projector. flow into the projector.
Filthy air filter at the front side of the Clean the front air filters of the projector. Replace if damaged. See procedure "Cleaning
projector the dust filters", page 334.
Malfunction air extraction system. Check the condition of the air extraction system. The air extraction system must be
capable of removing minimum 10 m³/min or 350 CFM per installed DP-3000 digital
projector.
Malfunction SMPS CTRL board. See Replace the SMPS CTRL board. See "Replacement of a Card Cage board", page 246.
Card Cage Diagnostic "Card Cage
diagnostic", page 239.
Defect temperature sensor on the Replace the SMPS CTRL board. See "Replacement of a Card Cage board", page 246.
SMPS CTRL board.
Code: “elcabox - temperature low” (Warning)

Situation Solution
Low ambient temperature. Note that Check the ambient temperature at the air inlets of the projector. Make sure that the
a too low ambient temperature may ambient temperature is higher then 10°C (50°F).
prevent the Sealed Light Processor
to start up. Tip: Ignite the lamp to warm up the Sealed Light Processor of the projector.
Malfunction SMPS CTRL board. See Replace the SMPS CTRL board. See "Replacement of a Card Cage board", page 246.
Card Cage Diagnostic "Card Cage
Defect temperature sensor on the Replace the SMPS CTRL board. See "Replacement of a Card Cage board", page 246.
SMPS CTRL board.
46 R59770374 DP-3000 16/08/2010

4. Trouble shooting
Code: “elcabox fan1 - speed high” (Warning)

Situation Solution
Defect wire unit (reference 1 Check the wire unit of the fan for damage. Repair if possible, otherwise replace with
image 4-6) causing a disruption in new one.
Defect fan. Replace the fan. See "Replacement of the Card Cage Fans", page 320.
2 2 2 2
1
Image 4-6
Code: “elcabox fan1 - speed low” (Warning)

Situation Solution
Wire unit (reference 1 image 4-6) of Remove the front cover of the projector and check the connections of the four fans.
the fan is disconnected.
Wire unit (reference 2 image 4-6) Remove the top cover of the projector and check if the four wire units (reference 2
of the fan is disconnected from the image 4-6) are inserted in the Power Backplane. Note that the sockets for those four
Power Backplane. wire units are hidden behind the flat cable from the Lens Signal Distribution.
Blocked fan. Check if none of the four fans at the front side of the projector are blocked. Ensure that
the fans can turn freely.
Damaged wire unit. Check if the wire unit of the four fans at the front side of the projector are not damaged.
Repair if possible, otherwise replace with new one.
Malfunction SMPS PFC board. Replace the SMPS PFC board. See "Replacement of a Card Cage board", page 246.
None of the four Card Cage fans are
working.
Fan end of life. When switching the Replace the fan. See procedure "Replacement of the Card Cage Fans", page 320.
wire unit of the slow fan with one of
the wire units of the other three fans
the same fan has a visible low speed
and the warning indicates another
fan number.
R59770374 DP-3000 16/08/2010 47

4. Trouble shooting

Situation Solution

Situation Solution
working.
Fan end of life. When switching the Replace the fan. See fan replacement procedures "Replacement of the Card Cage
wire unit of the slow fan with one of Fans", page 320.
fan number.

Situation Solution
48 R59770374 DP-3000 16/08/2010

4. Trouble shooting

Situation Solution
working.
fan number.

Situation Solution
Defect fan. Replace the fan. See "Replacement of the Card Cage Fans", page 320

Situation Solution
R59770374 DP-3000 16/08/2010 49

4. Trouble shooting
Situation Solution
working.
fan number.
Code: “engine - not connected” (Error)

Situation Solution
The Sealed Light Processor Unit is Check if the Sealed Light Processor Unit is properly installed. Ensure that both fixation
not correctly installed. screws (reference 1 & 2 image 4-7) at the foot of the Sealed Light Processor Unit are
fastened. See "Installation of the Sealed Light Processor", page 162.
Wire unit of the micro switch Check if the wire unit (reference 4 image 4-8) is plugged in on the Power Backplane.
(reference 3 image 4-8)
Backplane.
Defect micro switch. Replace the micro switch.
2
1
Image 4-7
Image 4-8
Code: “lamp - read run time failed” (Error)

Situation Solution
Wrong Lamp House inside lamp Replace the Lamp House with a compatible Lamp House for this projector.
compartment.
50 R59770374 DP-3000 16/08/2010

4. Trouble shooting
Situation Solution
No communication with the Lamp 1. Check if the blue socket (reference 1 image 4-9) of the lamp house is not damaged.
House.
2. Check if the blue socket (reference 2 image 4-9) in the lower right corner of the lamp
compartment is not damaged.
3. Check wiring at the rear side of the blue socket (reference 3 image 4-10) inside
the projector. The rear side of the blue socket inside the projector is visible after
removal of the left side cover (Sealed Light Processor side).
4. Check if the wire unit coming from the blue socket in the lamp compartment is
plugged into its socket (reference 4 image 4-10) on the Power Backplane.
5. Check if the wire unit (reference 5 image 4-11) of the Lamp Info Module is connected
with its socket on the module.
Malfunction Lamp Info Module. Replace the Lamp Info Module. See "Replacement of the Lamp Info module", page 128.
Image 4-9
4
3
Image 4-10
R59770374 DP-3000 16/08/2010 51

4. Trouble shooting
Image 4-11
Code: “lamp - read run time limits failed” (Error)

Situation Solution
Wrong Lamp House inside lamp Replace the Lamp House with a compatible Lamp House for this projector.
compartment.
No communication with the Lamp 1. Check if the blue socket (reference 1 image 4-9) of the lamp house is not damaged.
House.
2. Check if the blue socket (reference 2 image 4-9) in the lower right corner of the lamp
compartment is not damaged.
3. Check wiring at the rear side of the blue socket (reference 3 image 4-10) inside
the projector. The rear side of the blue socket inside the projector is visible after
removal of the left side cover (Sealed Light Processor side).
4. Check if the wire unit coming from the blue socket in the lamp compartment is
plugged into its socket (reference 4 image 4-10) on the Power Backplane.
5. Check if the wire unit (reference 5 image 4-11) of the Lamp Info Module is connected
with its socket on the module.
Malfunction Lamp Info Module. Replace the Lamp Info Module. See "Replacement of the Lamp Info module", page 128.
Code: “lamp - run time warning” (Warning)

Situation Solution
The lamp inside the lamp house is Replace the lamp as soon as possible with a new lamp. See "Lamps and Lamp House",
about to exceed its maximum run page 105.
time. Within 30 hours the lamp will
exceeds its maximum run time
Code: “lamp - run time exceeds maximum” (Error)

Situation Solution
The lamp inside the lamp house has Replace the lamp immediately with a new lamp. See "Lamps and Lamp House", page
exceeded its maximum run time. 105.
Code: “lamp - run time too high - soon no startup” (Error)

Situation Solution
The lamp inside the lamp is far Replace the lamp immediately with a new lamp. See "Lamps and Lamp House", page
beyond its maximum run time 105.
(almost double). Soon the lamp
start up will be blocked. Note that the lamp is really exhausted and that the light output of the lamp is far below
the minimum requirements.
52 R59770374 DP-3000 16/08/2010

4. Trouble shooting
Code: “lamp - run time too high - startup blocked” (Error)

Situation Solution
The lamp inside the lamp is far Replace the exhausted lamp. See "Lamps and Lamp House", page 105.
beyond its maximum run time
(more then double). The projector
refuses to strike the lamp. This to
prevent damage to other parts of the
projector.
Code: “lamp anode fan - speed high” (Error)

Situation Solution
Defect anode fan (reference 1 Replace the fan. See "Replacement of the Anode Fan", page 300.
image 4-12).
Image 4-12
Code: “lamp anode fan - speed low” (Error)

Situation Solution
Wire unit (reference 2 image 4-12) of Remove the left side cover of the projector and the Sealed Light Processor and check
the fan is disconnected. the connection of the fan.
of the fan is disconnected from the is inserted in the Power Backplane.
Power Backplane.
Blocked fan (reference 1 Check if the fan is not blocked. Ensure that the fan can turn freely.
image 4-12).
Damaged wire unit. Check if the wire unit of the anode fan is not damaged. Repair if possible, otherwise
replace with new one.
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4. Trouble shooting
Situation Solution
Anode fan (reference 1 image 4-12) Replace the anode fan. See fan replacement procedures "Replacement of the Anode
end of life. Fan", page 300.
Code: “lamp anode fan - voltage high” (Error)

Situation Solution
Code: “lamp anode fan - voltage low” (Error)

Situation Solution
Damaged insulation of the wire unit Check the insulation of the wire unit of the anode fan.
(reference 2 image 4-12) of the 1. Repair the insulation of the wire unit using shrink sleeve.
anode fan.
2. If not repairable, replace the whole wire unit and/or fan.
Malfunction Power Backplane (bad Replace the Power Backplane. See chapter "Card Cage", page 237.
connection)
Code: “lamp cathode fan - speed high” (Error)

Situation Solution
Defect wire unit (reference 2 Remove the left side cover of the projector and the Sealed Light Processor and check
image 4-13) causing a disruption in the wire unit of the fan for damage. Repair if possible, otherwise replace with new one.
Defect cathode fan (reference 1 Replace the fan. See "Replacement of the Cathode Fan", page 306.
image 4-13).
54 R59770374 DP-3000 16/08/2010

4. Trouble shooting
Image 4-13
Code: “lamp cathode fan - speed low” (Error)

Situation Solution
Wire unit (reference 2 image 4-13) of Remove the left side cover of the projector and the Sealed Light Processor and check
the fan is disconnected. the connection of the fan.
Wire unit (reference 3 image 4-13 Remove the top cover of the projector and check if the wire unit (reference 2 image 4-13)
Power Backplane.
Blocked fan. Check if the fan is not blocked. Ensure that the fan can turn freely.
Damaged wire unit (reference 2 Check if the wire unit of the four fans at the front side of the projector are not damaged.
image 4-13). Repair if possible, otherwise replace with new one.
Malfunction SMPS PFC board. Replace the SMPS PFC board. See "Replacement of a Card Cage board", page 246..
Cathode fan (reference 1 Replace the fan. See fan replacement procedures "Replacement of the Cathode Fan",
image 4-13) end of life. page 306.
Code: “lamp cathode fan - voltage high” (Error)

Situation Solution
Code: “lamp cathode fan - voltage low” (Error)

Situation Solution
Damaged insulation of the wire unit Check the insulation of the wire unit of the cathode fan.
(reference 2 image 4-13) of the 1. Repair the insulation of the wire unit using shrink sleeve.
cathode fan.
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4. Trouble shooting
Situation Solution
Malfunction Power Backplane (bad Replace the Power Backplane.

connection)
Code: “lamp house - not connected” (Error)

Situation Solution
Lamp House is not correctly installed. Check if the Lamp House is properly installed. Make sure that both fixation screws
(reference 1 & 2 image 4-14) at the base of the Lamp House are fastened. See
"Installing the Lamp House", page 121.
Defect micro switch (reference 3 Replace the micro switch.

image 4-15).
Wire unit of the micro switch Check if the wire unit (reference 4 image 4-15) is plugged in on the Power Backplane.
Backplane.
1 2
Image 4-14
Image 4-15
Code: “lamp house - temperature too high” (Error)

This error code is probably proceeded by the warning code: “lamp house - temperature high”. The same troubleshooting table can
be applied to.
56 R59770374 DP-3000 16/08/2010

4. Trouble shooting
Code: “lamp house - temperature high” (Warning)

Situation Solution
Blocked air inlet at the front side of Make sure that the air inlet at the front of the projector is free so that fresh air can easily
the projector. flow into the projector.
Filthy air filter at the front side of the Clean the front air filters of the projector. Replace if damaged. See procedure "Cleaning
projector the dust filters", page 334
Malfunction air extraction system. Check the condition of the air extraction system. The air extraction system must be
capable of removing minimum 10 m³/min or 350 CFM per installed DP-3000 digital
projector.
Defect temperature sensor Replace the defect temperature sensor.

3
1
Image 4-16
Code: “lamp house - temperature low” (Error)

Situation Solution
Disconnected temperature sensor Check the wire unit of the temperature sensor at the base of the Lamp House
(reference 1 image 4-16) inside compartment.
the air channel of the lamp anode
cooling.
Wire unit (reference 3 image 4-16)of Check if the wire unit of the temperature sensor is connected with the Power Backplane.
the temperature sensor disconnected
from the Power Backplane.
Defect temperature sensor Replace the temperature sensor.

(reference 1 image 4-16).
Code: “lamp top fan - speed high” (Error)

Situation Solution
R59770374 DP-3000 16/08/2010 57

4. Trouble shooting
Situation Solution
Defect top fan. The top fan is located Replace the Outlet Fan. See "Replacement of the Outlet Fan", page 310.
inside the exhaust box (reference
1 image 4-17) on top of the Lamp
House compartment.
1
3
Image 4-17
Code: “lamp top fan - speed low” (Error)

Situation Solution
Wire unit (reference 2 image 4-17) of Check the connection of the fan.
Power Backplane.
Blocked fan. Check if the fan is not blocked. Ensure that the fan can turn freely.
Damaged wire unit (reference 2 Check if the wire unit of the fan is not damaged. Repair if possible, otherwise replace
image 4-17). with new one.
Fan end of life. Replace the fan. See fan replacement procedures "Replacement of the Outlet Fan",
page 310.
Code: “lamp top fan - voltage high” (Error)

Situation Solution
58 R59770374 DP-3000 16/08/2010

4. Trouble shooting
Code: “lamp top fan - voltage low” (Error)

Situation Solution
Damaged insulation of the wire unit Check the insulation of the wire unit of the fan.
(reference 2 image 4-17) of the lamp 1. Repair the insulation of the wire unit using shrink sleeve.
top fan.

connection)
Code: “lens focus position - requested target not reached” (Error)
This error may occur if the projector is switched off while the lens file is still active. See also Info-T 761:
Storing lens positions in the DP series.
Situation Solution
The activated lens file does not Activate a lens file which do correspond with the mounted lens or mount an other lens
correspond with the lens mounted which correspond with the lens file you wan to activate.
on the projector.
Corrupt lens file. Delete current lens file and create a new lens file. Note that each time the lens is
removed a new lens file has to be created.
The final lens position lays very Position the lens manually, or reposition the projector so that the lens position lays further
close to the mechanical limits which away from the mechanical limits, or try to use another lens which range is more suitable.
disable the motorized lens position.
Disconnected wire unit (reference 6 Check if all wire units of the Lens Holder are connected with the Lens Signal Distribution
image 4-18) of the focus motor of the board. See reference image 4-18.
motorized Lens Holder.
Disconnected wire unit, of the focus Check if all wire units of the Lens Holder are connected with the Lens Signal Distribution
limit switch (reference 7 image 4-18). board. See reference image 4-18.
Malfunction focus motor of the Lens Use the local keypad to focus the image on the screen. If unsuccessful, replace the
Holder. focus motor of the Lens Holder. See "Replacement of the focus motor", page 234.
Disconnected flat cable of the Lens Check if the flat cable is connected with Lens Signal Distribution board (reference 11
Signal Distribution board. image 4-18) and with the Power Backplane (reference 12 image 4-18).
1 11
12
2
3
10
9
8
5
7
6
Image 4-18
1 Connection with Shutter (Dowser) motor.
2 Limit switch for Shutter in open position (yellow wire).
3 Limit switch for Shutter in closed position (orange wire).
4 Connection with Zoom motor on the lens.
5 Connection with Horizontal Shift motor of the Lens Holder.
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4. Trouble shooting
6 Connection with Focus motor on the Lens Holder.

7 Limit switch for Focus.
8 Limit switch for Horizontal Shift.
9 Connection with Vertical Shift motor of the Lens Holder.
10 Limit switch for Vertical Shift.
11 Lens Signal Distribution flat cable from Power Backplane.
12 Lens Signal Distribution flat cable from Lens Signal Distribution board.
Code: “lens horizontal shift position - requested target not reached” (Error)
Situation Solution
on the projector.
image 4-18) of the horizontal shift board. See reference image 4-18.
motor of the motorized Lens Holder.
Disconnected wire unit, of the Check if all wire units of the Lens Holder are connected with the Lens Signal Distribution
horizontal shift limit switch (reference board. See reference image 4-18.
8 image 4-18).
Malfunction horizontal shift motor of Use the local keypad to shift the image horizontal on the screen. If unsuccessful, replace
the Lens Holder. the horizontal shift motor of the Lens Holder. See "Replacement of the horizontal shift
motor", page 232.
Code: “lens vertical shift position - requested target not reached” (Error)
Situation Solution
on the projector.
Disconnected wire unit (reference Check if all wire units of the Lens Holder are connected with the Lens Signal Distribution
9 image 4-18) of the vertical shift board. See reference image 4-18.
motor of the motorized Lens Holder.
Disconnected wire unit, of the Check if all wire units of the Lens Holder are connected with the Lens Signal Distribution
vertical shift limit switch (reference board. See reference image 4-18.
10 image 4-18).
Malfunction vertical shift motor of the Use the local keypad to shift the image horizontal on the screen. If unsuccessful,
Lens Holder. replace the horizontal shift motor of the Lens Holder. See "Replacement of the vertical
shift motor", page 230.
Code: “lens zoom position - requested target not reached” (Error)

Situation Solution
Manual lens installed. Replace the manual lens with a motorized lens.
on the projector.
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4. Trouble shooting
Situation Solution
image 4-18) of the zoom motor of board. See reference image 4-18.
the installed lens .
Malfunction zoom motor of the Use the local keypad to zoom the image on the screen. If unsuccessful, replace the
installed lens. installed lens. See "Lenses and Lens Holder", page 213.
Code: “lps - communication failed” (Error)

Situation Solution
Power interruption of the LPS Power Check the mains power of the LPS Power unit.
unit.
LPS communication cable Remove the cover plate of the LPS Power unit to see the connections of the LPS Power
disconnected from the LPS Power unit. Check if the LPS communication cable (reference 1 of image 4-19) is inserted in its
unit. socket. Make sure that the thumbscrews have been tightened.
LPS communication cable Check if the LPS communication cable (reference 2 image 4-19) is connected with the
disconnected form the projector projector head. Make sure that the thumbscrews have been tightened.
head.
Disconnected wire units from the Check if all wire units (reference 1, 2 and 3 image 4-20) are connected with the Power
LPS communication interface board Backplane and the communication interface board of the projector.
inside the projector head and the
Power Backplane.
Disconnected wire unit between the Reconnect the wire units (reference 3 image 4-21) between the “CTRL IN” and “CTRL
“CTRL IN” and “CTRL OUT” sockets OUT” sockets of the LPS modules and make sure that the first wire unit in the loop is
of one of the LPS modules and the connected with the LPS communication interface of the Power Unit.
LPS communication interface inside
the LPS Power unit. (brown wire
units)
Malfunction of one of the LPS Replace the malfunction LPS module of the Power unit. See "Removal of an LPS
modules. The red LED “ERR” of module", page 86.
the malfunction LPS module flashes
fast.
Malfunction LPS Communication Replace the LPS Communication Interface board of the projector head.
Interface board of the projector head.
Malfunction LPS Communication Replace the LPS Communication Interface board of the LPS Power unit. See
Interface board of the LPS Power "Replacement of the LPS communication interface", page 92.
unit.
Malfunction Input & Communication Replace the malfunction Input & Communication unit. See "Installation of the Input &
unit. Communication unit", page 274.
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4. Trouble shooting
Image 4-19
3
1
1 2
Image 4-20
1 Wire unit for LPS detection.
2 Wire unit for rack (Power Unit) temperature sensor.
3 Wire unit for LPS control signals.
3
2
3
Image 4-21
3 Wire units for LPS control signals between LPS units and LPS communication interface.
Code: “lps - not detected” (Error)

Situation Solution
None of the LPS modules could Check if the LPS communication cable (reference 1 and 2 image 4-19) is well connected
be detected during the start up with the LPS Power unit (RACK CONTROL) and the projector head.
(initialization) of the projector
head due to a disconnected LPS
communication cable.
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4. Trouble shooting
Situation Solution
The LPS Power unit is not connected Check the wire unit (reference 1 image 4-22) of the mains power of the LPS Power unit.
with the power net.
Disconnected wire units from the Check if all wire units (reference 1, 2 and 3 image 4-20) are connected with the Power
LPS communication interface board Backplane and the communication interface board of the projector.
inside the projector head and the
Power Backplane.
Disconnected CTRL wire (reference Reconnect the wire unit (reference 3 image 4-21) with the LPS communication interface
3 image 4-21) of the LPS of the Power Unit.
communication interface inside
the LPS Power unit. (brown wire
units)
Malfunction LPS Communication Replace the LPS Communication Interface board of the projector head.
Interface board of the projector head.
Malfunction LPS Communication Replace the LPS Communication Interface board of the LPS Power unit. See
Interface board of the LPS Power "Replacement of the LPS communication interface", page 92.
unit.
fast.
Malfunction Input & Communication Replace the malfunction Input & Communication unit. See "Input & Communication
unit. unit", page 263.
Image 4-22
Code: “lps - at least one could not be detected” (Error)

Situation Solution
Disconnected wire unit (reference Reconnect the wire unit with the ADDRESS sockets of the LPS modules. See
1 image 4-23) of the “ADDRESS” "Installation of an LPS module", page 88
sockets between the LPS modules
inside the LPS Power unit. (black
wire unit)
Disconnected wire unit (reference Reconnect the wire unit between the “CTRL IN” and “CTRL OUT” sockets of the LPS
2 image 4-23) between the “CTRL modules. See "Installation of an LPS module", page 88
IN” and “CTRL OUT” sockets of one
of the LPS modules inside the LPS
Power unit. (brown wire unit)
fast.
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4. Trouble shooting
1
2
Image 4-23
Code: “pfc - temperature high” (Error)

Situation Solution
The temperature of the heat sink Check the ambient temperature at the front air inlet of the projector. Make sure that the
(reference 1 image 4-24) of the PFC ambient temperature does not exceed 35°C (95°F).
circuitry on the SMPS PFC board is
too high due to an too high ambient
temperature.
The temperature of the heat sink Check the dust filter at the front of the projector. Clean if necessary or replace if
(reference 1 image 4-24) of the PFC damaged. Make sure that the air inlet at the front side of the projector is not blocked.
circuitry on the SMPS PFC board is
too high due to a blocked air inlet
2 4
5
3
Image 4-24
1 SMPS PFC board: temperature sensor PFC heat sink.
2 SMPS PFC board: temperature sensor SMPS1 secondary heat sink.
3 SMPS PFC board: temperature sensor SMPS1 primary heat sink.
4 SMPS DCDC board: temperature sensor SMPS2 secondary heat sink.
5 SMPS DCDC board: temperature sensor SMPS2 primary heat sink.
Code: “pfc - temperature low” (Error)

Situation Solution
Disconnected temperature sensor Check if the wire unit of the temperature sensor is connected with the SMPS PFC board.
(reference 1 image 4-24) of the PFC
heat sink on the SMPS PFC board.
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4. Trouble shooting
Situation Solution
Code: “pulse generator fan - speed high” (Error)

Situation Solution
Defect fan. Replace the fan. See "Replacement of the SPG Fan", page 319.
Image 4-25
Code: “pulse generator fan - speed low” (Error)

Situation Solution
Wire unit (reference 2 image 4-25) Remove the left cover of the projector and check the connection of the wire unit of
of the Start Pulse Generator (SPG) the fan below the SPG.
fan disconnected.
Wire unit (reference 3 image 4-25) Remove the top cover of the projector and check if the wire unit is inserted in the Power
disconnected from the Power Backplane.
Backplane.
Blocked fan. Unblock the fan. Ensure that the fan can turn freely.
with new one.
Fan end of life. Replace the fan. See "Replacement of the SPG Fan", page 319.
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4. Trouble shooting
Code: “rack - temperature high” (Error)

Situation Solution
The temperature inside the Power Clean the grid of the air inlet with a vacuum cleaner. Make sure that there is sufficient
unit (LPS) is too high due to a free space in front of the air inlet so that fresh air can easily flow into the Power unit.
blocked air inlet.
Ambient temperature too high. Check the ambient temperature at the air inlet of the Power unit. Make sure that the
Malfunction LPS module. Check the diagnostic LED’s of all LPS modules. See "LPS module diagnostic LED’s",
page 79. Replace defect LPS modules. See "Removal of an LPS module", page 86.
Code: “rack - temperature low” (Error)

Situation Solution
Disconnected wire unit (reference Check if the wire unit of the temperature sensor is connected with the LPS communication
2 image 4-26) of the temperature board inside the Power unit.
sensor (reference 1 image 4-26) of
the Power unit.
Wire unit (reference 2image 4-20) of Remove the top cover of the projector and check if the wire unit is connected with the
the temperature sensor disconnected Power Backplane.
from the Power Backplane.
Wire unit (reference 2 image 4-20 Check if the wire unit is connected with the LPS communication board in the projector
disconnected from the LPS head. The LPS communication board is located behind the RACK CONTROL socket.
communication board in the
projector head.

Image 4-26
Code: “sealing fan - speed high” (Error)

Situation Solution
Defect fan inside the Sealed Light Replace the complete Sealed Light Processor unit. See "Removal of the Sealed Light
Processor unit. Processor", page 159. Return the malfunction Sealed Light Processor unit to factory
for repair.
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4. Trouble shooting
Code: “sealing fan - speed low” (Error)

Situation Solution
Fan inside the sealed compartment Replace the complete Sealed Light Processor unit. See "Removal of the Sealed Light
is end of life. Processor", page 159. Return the malfunction Sealed Light Processor unit to factory
for repair.
Code: “smps - i2c failed” (Error)

Situation Solution
Failure of the I²C communication Reboot the projector by switching OFF and ON. Wait a few seconds before switching
protocol between the SMPS CTRL ON again.
board and the Barco Cinema
Controller board.
Malfunction Input & Communication Replace the Input & Communication Interface. See "Removal of the Input &
Interface. Communication unit", page 271.
Code: “smps1 primary - temperature high” (Error)

Situation Solution
(reference 3 image 4-24) of the ambient temperature does not exceed 35°C (95°F).
primary smps circuitry on the SMPS
PFC board is too high due to an too
high ambient temperature.
(reference 3 image 4-24) of the damaged. Make sure that the air inlet at the front side of the projector is not blocked.
PFC board is too high due to a
blocked air inlet.
Code: “smps1 primary - temperature low” (Error)

Situation Solution
(reference 3 image 4-24) of the
primary smps heat sink on the SMPS
PFC board.
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4. Trouble shooting
Code: “smps1 secondary - temperature high” (Error)

Situation Solution
secondary smps circuitry on the
SMPS PFC board is too high due to
an too high ambient temperature.
SMPS PFC board is too high due to
a blocked air inlet.
Code: “smps1 secondary - temperature low” (Error)

Situation Solution
(reference 2 image 4-24 of the
secondary smps heat sink on the
SMPS PFC board.

Code: “smps2 primary - temperature high” (Error)

Situation Solution
PFC board is too high due to an too
high ambient temperature.
PFC board is too high due to a
blocked air inlet.
Code: “smps2 primary - temperature low” (Error)

Situation Solution
Disconnected temperature sensor Check if the wire unit of the temperature sensor is connected with the SMPS DCDC
(reference 5 image 4-24) of the board.
primary smps heat sink on the SMPS
DCDC Board.
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4. Trouble shooting
Situation Solution
Code: “smps2 secondary - temperature high” (Error)

Situation Solution
SMPS DCDC board is too high due
to an too high ambient temperature.
SMPS DCDC board is too high due
to a blocked air inlet.
Code: “smps2 secondary - temperature low” (Error)

Situation Solution
Disconnected temperature sensor Check if the wire unit of the temperature sensor is connected with the SMPS DCDC
(reference 4 image 4-24) of the board.
secondary smps heat sink on the
SMPS DCDC board.
Code: “tec - voltage high” (Error)

Situation Solution
Code: “tec - voltage low” (Error)

Situation Solution
The +VTEC diagnostic LED remains
off.
One of the Peltier elements causes Replace the Sealed Light Processor unit. Return the malfunction Sealed Light Processor
a short circuit. to factory for repair. See "Removal of the Sealed Light Processor", page 159.
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4. Trouble shooting
Code: “tec blue - not connected” (Error)

Situation Solution
The wire unit of the Peltier element Replace the Sealed Light Processor unit. Return the malfunction Sealed Light Processor
(TEC) inside the Sealed Light to factory for repair. See "Removal of the Sealed Light Processor", page 159.
Processor is disconnected.
Defect Peltier element (TEC). Replace the Sealed Light Processor unit. Return the malfunction Sealed Light Processor
to factory for repair. See "Removal of the Sealed Light Processor", page 159.
Code: “tec blue - temperature high” (Warning)

Situation Solution
Too high ambient temperature. The Check the ambient temperature at the front air inlet of the projector. Make sure that the
other DMD temperatures are too ambient temperature does not exceed 35°C (95°F).
high as well.
Blocked air inlet filter at the front of Clean the air inlet filter. Replace in case of damage. See "Cleaning the dust filters",
the projector. page 334.
Malfunction SMPS CTRL board. The Replace the SMPS CTRL board. See "Replacement of a Card Cage board", page 246.
LED “+VTEC” on the SMPS CTRL
board remains off.
Interruption of the liquid cooling Check if the loop of the liquid cooling circuit is closed. See chapter "Liquid Cooling
circuit. Circuit", page 177.
The liquid cooling circuit of the Check of the cooling circuit of the Sealed Light Processor is connected with the pump
Sealed Light Processor is mistakenly and heat exchanger. See chapter "Liquid Cooling Circuit", page 177.
No or insufficient liquid inside the Fill the cooling circuit with liquid and expel all air. Pressurize the circuit. See "Filling the
cooling circuit. The pump is sucking Liquid Cooling Circuit", page 186.
air and sounds noisier then normal.
The pump of the water cooling is Check if the wire unit of the pump is properly connected with the pump (reference 1
electrical disconnected. image 4-27) and with the Power Backplane (reference 2 image 4-27).
Malfunction pump of the cooling 1. Check the electrical resistance of the pump winding. Replace the pump if infinite.
circuit. You don’t feel any vibrations See "Replacement of the Pump motor and rotor", page 206.
when touching the pump after
activating the “Refill mode” via the 2. Drain the liquid cooling circuit, open the pump and check if the pump rotor is not
Communicator software. blocked. If so, remove the rotor and clean the bearings of the pump. See "Cleaning
the Pump", page 204.
Malfunction Peltier element (TEC) of Replace the Sealed Light Processor and return the malfunction Sealed Light Processor
the involved channel. to factory for repair. See chapter "Removal of the Sealed Light Processor", page 159.
Image 4-27
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4. Trouble shooting
Code: “tec blue - temperature too high” (Error)

This error code is probably proceeded by the warning code: “tec blue - temperature high”. The same troubleshooting table can be
applied to.
Code: “tec green - not connected” (Error)

Situation Solution
Code: “tec green - temperature high” (Warning)

Situation Solution
high as well.
the projector. page 334.
board remains off. See "Card Cage
the involved channel. to factory for repair. See "Removal of the Sealed Light Processor", page 159.
Code: “tec green - temperature too high” (Error)

This error code is probably proceeded by the warning code: “tec green - temperature high”. The same troubleshooting table can be
applied to.
Code: “tec red - not connected” (Warning)

Situation Solution
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4. Trouble shooting
Code: “tec red - temperature high” (Error)

Situation Solution
high as well.
the projector. page 334..
board remains off. See "Card Cage
the involved channel. to factory for repair. See "Removal of the Sealed Light Processor", page 159.
Code: “tec red - temperature too high” (Error)

This error code is probably proceeded by the warning code: “tec red - temperature high”. The same troubleshooting table can be
applied to.
Code: “ti - boards - interface board security enclosure error - replace interface board” (Error)
Situation Solution
The GORE protection of the Replace the TI Cinema Interface board.
TI Cinema Interface board has
been triggered and therefore the
TI Cinema Interface board is
irreversible out of order.
Code: “ti - system status = fail” (Error)

Situation Solution
The TI system status failure is Activate the lamp to warm up the Sealed Light Processor Unit. After a few seconds the
caused by the projector which is temperature of the DMD’s should be higher then 10°C (50°F) which allows a successful
too cold. The DMD’s should not be start up of the Sealed Light Processor Unit.
operated at a temperature lower
then 10°C (50°F). The projector has Or let the projector acclimate to the normal room temperature which should be higher
some protections for that. Below that then 10°C (50°F) and lower then 35°C (95°F).
temperature, the engine is switched
of, and the result is a TI system
status failure.
This situation can occurs when the
projector is recently installed and
did not had the time to acclimate
to the normal room temperature.
There is also a message that the
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4. Trouble shooting
Situation Solution
temperatures are too low. See log
files.
The projector is set for DHCP and 1. Check the network.

thus requires an address from the
DHCP server but the projector does 2. Check if the DHCP server is operational.
not receive an address.
Code: “ti - system status read failed” (Error)

Situation Solution
(no info available) (no info available)
Code: “ti - security error, please authorize” (Error)

Situation Solution
The cover of the card cage has been Clear the security warning. See procedure "Authorization to clear security warning
reinstalled. on DP-3000", page 245.
The Sealed Light Processor unit has Clear the security warning. See procedure "Authorization to clear security warning
been removed and installed again. on DP-3000", page 245.
Code: “other fans - voltage high” (Error)

Situation Solution
Code: “other fans - voltage low” (Error)

Situation Solution
Damaged insulation of the wire unit Check the insulation of the wire unit.
of one of the following fans: 1. Repair the insulation of the wire unit using shrink sleeve.
• Fan on top of the Cold Mirror. 2. If not repairable, replace the whole wire unit and/or fan.
• Fan at the bottom of the Cold
Mirror.
• Fan at the bottom of the Start
Pulse Generator (SPG).
• The four fans at the front side
of the projector.

connection)
Code: “water - flow not ok” (Error)

Situation Solution
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4. Trouble shooting
Situation Solution
excluded from the main liquid
cooling circuit. Most likely the DMD
temperatures are too high.
The maintenance valve of the cooling Close the valve of the cooling circuit. See chapter "Liquid Cooling Circuit", page 177.
circuit is open causing a bypass of
the cooling liquid.
The pump of the water cooling is Check if the wire unit (reference 1 & 2 image 4-27) of the pump is properly connected.
electrical disconnected.
Strap (reference 1 image 4-28) Check if the strap is present.
missing on the SENS FLOW socket
of the Power Backplane.
Image 4-28
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5. Power Unit
5. POWER UNIT
About this chapter
This chapter describes the different parts of the Power Unit and their replacement procedures.
Overview
• Introduction
• LPS module diagnostic LED’s
• Connecting the power unit with the projector head
• Connecting the power unit with the power net
• Removal of an LPS module
• Installation of an LPS module
• Removing the LPS rack from the base of the Power Unit
• Replacement of the LPS communication interface
• Replacement of the Mains Filter
• Installing the LPS rack upon the base of the Power Unit
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5. Power Unit
5.1 Introduction
Functionality of the Power Unit
The power unit is separated from the projector head. The base of the power unit houses the power input/output ports, the mains
input filter, the LPS communication board and a temperature sensor. Upon the base a power rack with three LPS slots is mounted.
Each slot contains one Lamp Power Supply (LPS) module connected with each other in parallel. The three LPS modules together
can supply maximum 7000 watt to the xenon lamp inside the projector head. The maximum current that the power unit can supply
is limited upon 170 ampere.
To ignite the lamp the voltage on the output pins of the LPS modules is brought up to 110 volt. This boots voltage will trigger the Start
Pulse Generator (SPG) to ignite the lamp. Once the lamp is ignited the voltage on the output pins of the LPS modules is dropped to
the typical arc voltage of the lamp e.g. 39 volt for a 6,5 kW lamp.
One LPS module can deliver maximum 2500 watts and maximum 100 amps. In normal situation, each LPS module delivers 1/3 of
the required power. So, for a 6,5 kW lamp having an arc voltage of 39 volt, each LPS module deliver 55,3 amps at 39 volt which is
equal to 6500 watt.
When one of the three LPS modules suddenly fails during the event the other LPS modules will continue delivering 55,3 amps at
39 volt. As a result the projector light output will be reduced. In case the projector starts up and one LPS module remains down the
other LPS modules will run on their maximum power and deliver each 64,1 amps at 39 volt which is equal to 5000 watt in total.
In case on of the LPS modules fails an error will be logged in the projector log file.
Main internal components of the Power Unit
6
7
Image 5-1
1 Front cover with air outlet grid.
2 Lamp Power Supply (LPS).
3 Power rack.
4 Rear cover with air inlet grid.
5 Cover plate mains connections.
6 Power Unit base assembly.
7 Cover plate power output sockets.
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5. Power Unit
Parts of the base of the Power Unit
13
14 12
15
9
10
Image 5-2
8 Mains input distribution strip.
9 Cable gland for mains input cable.
10 Optional entrance for mains input cable.
12 LPS communication board.
13 Mains connection per LPS module.
14 Mains output socket for projector head.
Front panel of the Lamp Power Supply

1 2 3 4 5
MAINS
INPUT
- LAMP OUTPUT +
6 6
PFC LPS
ERROR OK OK
ADDRESS SELECT CTRL IN CTRL OUT
7 8 9 10 11 12
Image 5-3
1 Lamp output pin “-”.
2 Lamp output pin “+”.
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5. Power Unit
3 Diagnostic LED “LAMP ON” (green).

4 Diagnostic LED “LVPS OK” (yellow).
5 Mains input.
6 Retaining fixation screws.
7 Diagnostic LED “ERROR” (red).
8 Diagnostic LED “PFC OK” (green).
9 Diagnostic LED “LPS OK” (green).
10 Socket for ADRESS cable.
11 Socket for CTRL IN cable.
12 Socket for CTRL OUT cable.
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5. Power Unit
5.2 LPS module diagnostic LED’s

Status LED’s on the LPS module
One LPS module contains in total 5 status LED’s. One orange, three green and one red LED. The orange LED “LVPS OK” lights
up immediately after the projector is switched on. All other status LED’s of the LPS module remains off. This is the standby status
of the LPS module. Once the command is send to the LPS modules to start up the projector lamp the green LED’s are lighting up
one after the other. First the green LED “PFC OK”, then the green LED “LPS OK” and finally, when the lamp is ignited, the green
LED “LAMP ON”.
The red LED “ERR” remains off unless an error is detected inside the LPS module or all LPS modules where ordered to shutdown
due to a malfunction somewhere else inside the projector.
3 4
MAINS
INPUT
- LAMP OUTPUT +
PFC LPS
ERROR OK OK
ADDRESS SELECT CTRL IN CTRL OUT
7 8 9
Image 5-4
3 Diagnostic LED “LAMP ON” (green).
4 Diagnostic LED “LVPS OK” (yellow).
7 Diagnostic LED “ERROR” (red).
8 Diagnostic LED “PFC OK” (green).
9 Diagnostic LED “LPS OK” (green).
Diagnostic
Or. Gr. Gr. Gr. Re. Diagnostic Action
LVPS OK PFC OK LPS OK LAMP OK ERROR
OFF OFF OFF OFF OFF No input voltage. Switch on the projector.
ON OFF OFF OFF OFF Standby modus of LPS —
module.
ON ON ON OFF OFF PFC and LPS seems to work
normally but the lamp is not • Install another xenon
ignited. This situation can be lamp in case the voltage
the result of a bad lamp or on the “LAMP OUT” pins
SPG module. is 110 volt and you hear
the SPG module three
times clicking to ignite
the lamp.
• Replace the SPG module
in case the voltage value
on the “LAMP OUT” pins
is 110 volt and you do
not hear the SPG module
clicking to ignite the
lamp.
• Replace the LPS
modules in case the
voltage value on the
“LAMP OUT” pins is
below 110 volt and the
lamp is not ignited.
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5. Power Unit
Or. Gr. Gr. Gr. Re. Diagnostic Action

LVPS OK PFC OK LPS OK LAMP OK ERROR
ON ON ON ON OFF LPS module is operating —
normally. Projector lamp is
ignited.
ON OFF OFF OFF ON LPS internal temperature is to
high. • Check if the power unit
air inlet is not blocked.
• Check if the power unit
air outlet is not blocked.
• If the problem remains,
replace the LPS module.
ON OFF OFF OFF Flashing Error detected inside this LPS Replace the LPS module.
fast module.
ON OFF OFF OFF Flashing All LPS modules where Check the error logged in the
slow ordered to shutdown due to a projector log file.
malfunction somewhere else
inside the projector.
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5. Power Unit
5.3 Connecting the power unit with the projector head

What has to be done?
Three loose cables are entering the bottom plate of the projector head. These cables (2 x LPS power + PE) have to be connected
with the output side of the power unit. Furthermore, a power cord (reference P of image 5-5) and a data cable (reference D of
image 5-5) have to be installed between the power unit and the input & communication unit of the projector head. This power cord
is required to supply the electronics of the projector head with power. The data cable is needed for the communication between the
power unit and the projector head.
P D
-+
PE
Image 5-5
Necessary tools
• Phillips screwdriver PH1.
• Torque wrench with 10mm hexagon socket (4Nm).
• 3 mm Allen wrench.
• 7 mm nut driver.
Necessary parts
• Power cord (5 meter, sockets C13/C14).
• Data cable (5 meter, D-SUB 15 pins).
How to connect the power unit with the projector head?

1. Remove the cover from the output side of the power unit by releasing the three captive screws as illustrated. Use for that a
Phillips screwdriver PH1.
Image 5-6
2. Connect the green/yellow ground wire from the projector head with the chassis (PE) of power unit as illustrated. Place a lock
washer B between the nut A and the wire ring lug C. Secure the wire with the strain relief clamp E. Use a 7 mm nut driver to
fasten the nuts A and D.
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5. Power Unit
A D
B E
PE
Image 5-7
3. Remove the front cover from the Power Box. Use 3mm Allen wrench to release the 5 screws of the front cover.
4. Connect the long power cables, coming from the projector head, with the output pins of the lowest LPS unit in the Power Box.
Guide the power cables trough the opening at the base as illustrated prior to connect the wire lugs. Fasten the nuts with a torque
of 4Nm (2.95 lbt*ft). Use a torque wrench with a 10mm hexagon socket. Respect the polarity of the pins and the cables.
Caution: Make sure to place the plain washers, and cable eyes in correct order upon the pins of the LPS units. First the wire
lugs (short and long cable), then the plain washer and finally the nut.
Note: The electrical high power connections of the LPS units must be checked on a yearly bases.
4Nm
- +
Image 5-8
5. Secure the LPS power cables with two strain relief clamps (reference 5 image 5-9). Use a 4 mm Allen wrench.
Image 5-9
6. Reinstall the front cover of the Power Box.

7. Reconnect the data cable and power cord. Fasten the thumbscrews of the data cable (reference 6 image 5-10) and secure the
power cord (reference 7 image 5-10) with the strain relief bracket which you removed is step 2. Use a PH1 Phillips screwdriver
to fasten the bracket.
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5. Power Unit
6 7
Image 5-10
8. Reinstall the base cover from the Power Box.
WARNING: Use cable ties to fasten all cables between the power unit and the projector head.
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5. Power Unit
5.4 Connecting the power unit with the power net
WARNING: Make sure that the voltage range of the power unit matches with the voltage of the local power
net. Note that there exist two types of power units. One for a 3 x 400V AC + Neutral power net and one for a 3
x 208V AC power net. The power unit for a 3 x 400V AC + Neutral power net has a five-way distribution strip.
The power unit for a 3 x 208V AC power net has a four-way distribution strip. The power input distribution
strip is located behind the sealed compartment at the base of the power unit.
WARNING: The cross-sectional area of the conductors in the power supply cord shall not be less than 4 mm²
or 10 AWG.
WARNING: The projector casing must be grounded, because of high voltages impressed during the ignition
cycle.
Necessary tools
• Phillips screwdriver PH1.
• Flat blade screwdriver 4 x 120.
• Adjustable wrench.
How to connect the main power net with the power unit?
1. Remove the cover from the power input compartment of the power unit by releasing the two captive screws as illustrated. Use
for that a Phillips screwdriver PH1.
Image 5-11
2. Insert the power supply cord through the cable gland as illustrated. When using a flexible power cord, make sure that each
conductor end is provide with an end sleeve.
Note: The cable gland is default mounted at the rear side of the power unit. But, if required you can reposition the cable gland
to the side of the power unit.
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5. Power Unit
Image 5-12
This illustration shows a power cord and a power unit for a 3 x 400V AC + Neutral power net.
3. Connect the conductors of the power cord with the distribution strip. When having a neutral conductor N (blue wire), make
sure to connect the neutral N conductor with the blue socket of the power strip. Always connect the ground wire (PE) with the
yellow/green socket of the distribution strip. Use a flat blade screwdriver to fasten all screws of the distribution strip.
N PE PE
F F
EU US
3 x 400V + N 3 x 208V
Image 5-13
4. Reinstall the cover as illustrated. Fasten the two captive screws of the cover using a Phillips screwdriver PH1.
Image 5-14
5. Fasten the cable gland using an adjustable wrench.
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5. Power Unit
5.5 Removal of an LPS module
This procedure describes how to remove the LPS module located in the middle of the power rack. Neverthe-
less, the same procedure is applicable upon the other LPS modules in the power rack.
Necessary tools
• 8 mm nut driver or flat screw driver.
How to remove an LPS module from the Power Unit?

1. Make sure that the power to the Power Unit is switched off.
2. Remove the front cover of the Power Unit by loosening (a few turns) the four hexagon socket button screws (reference 1 im-
age 5-15) at the sides of the cover and removing the screw (reference 2 image 5-15) at the top of the cover. Use a 3 mm Allen
wrench.
Image 5-15
3. Disconnect the ADDRESS CONTROL wire unit (reference 3 & 4 image 5-16) form the LPS module and the LPS module(s) above.
4. Disconnect the MAINS INPUT cables (reference 7 & 8 image 5-16) form the LPS module and the LPS module(s) above.
5. Disconnect the CTRL IN (reference 5 image 5-16) and the CTRL OUT (reference 6 image 5-16) wire unit from the LPS module.
5 6
7
Image 5-16
6. Disconnect both LAMP OUTPUT power cables from the LPS module. Use a 10 mm nut driver to loosen the nuts (reference 9
image 5-17).
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5. Power Unit
Image 5-17
7. Loosen the four retaining screws (reference 10 image 5-18) of the disconnected LPS module. Use an 8 mm nut driver or a flat
screw driver.
10
Image 5-18
8. Hold the LPS module by its handles and pull out of its compartment.
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5. Power Unit
5.6 Installation of an LPS module
This procedure describes how to install the LPS module located in the middle of the power rack. Nevertheless,
the same procedure is applicable upon the other LPS modules in the power rack.
Necessary tools
• Torque wrench with a 10 mm hexagon socket.
How to remove an LPS module from the Power Unit?

1. Hold the LPS module by its handles and slide it into its compartment as illustrated.
2. Fasten the four retaining screws (reference 1 image 5-19) of the LPS module. Use an 8 mm nut driver or a flat screw driver.
Image 5-19
3. Connect the LAMP OUTPUT power cables with the LPS module as illustrated. Respect the polarity of the socket and cables.
Use torque wrench with a 10 mm hexagon socket to fasten the nuts on the pins with a torque of:
- 8 Nm (5.9 lbt*ft) in case of copper nuts and rods (old LPS).
- 4 Nm (2.95 lbt*ft) in case of brass nuts and rods.
- 4 Nm (2.95 lbt*ft) in case of nickel plated brass nuts and rods.
- 8 Nm (5.9 lbt*ft) in case of nickel plated steel nuts and rods.
Caution: Make sure to place the washers and cable eyes in correct order upon the pin as illustrated in image 5-20. First the
wire lugs (reference 1 & 2), then the plane washer (reference 3), then the lock washer (reference 4) and finally the
nut (reference 5).
- +
4Nm / 8Nm
2 - +
3
4
5
- +
Image 5-20
4. Connect the CTRL IN (reference 5image 5-21) and the CTRL OUT wire unit (reference 6) with the LPS module. Make sure that
the CTRL OUT of the LPS module below is connected with the CTRL IN socket and the CTRL IN of the LPS module above is
connected with the CTRL OUT socket.
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5. Power Unit
5. Connect the MAINS INPUT cables (reference 7 & 8image 5-21) with the LPS modules.
6. Connect the ADDRESS CONTROL wire unit (reference 3 & 4image 5-21) with the LPS module and the LPS module(s) above.
5 6
7
Image 5-21
7. Install the front cover of the Power Unit. Use a 3 mm Allen wrench to fasten the five screws (reference 1 & 2 image 5-22) as
illustrated.
1
2
Image 5-22
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5. Power Unit
5.7 Removing the LPS rack from the base of the Power Unit
Why removing the LPS rack form the base of the Power Unit?
To access the parts inside the base of the Power Unit, such as the LPS communication interface and Mains Input filter, the LPS rack
on top of the base has to be removed.
Necessary tools
How to remove the LPS rack form the base of the Power Unit?
1. Make sure that the power to the Power Unit is switched off.
2. Remove the front and rear cover of the Power Unit. Use a 3 mm Allen wrench to loosen the 5 screws (reference 1 & 2 image 5-23)
per cover.
Image 5-23
3. Disconnect the MAINS INPUT cables (reference 1, 2 & 3 image 5-24) from each LPS module in the power rack.
4. Disconnect the CTRL IN wire unit (reference 4 image 5-24) from the LPS module at the bottom of the LPS rack.
5. Disconnect both LAMP OUTPUT power cables from the LPS module at the bottom of the power rack. Use a 10 mm nut driver
to loosen the nuts (reference 5 image 5-24).
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5. Power Unit
3
4
Image 5-24
6. Loosen the four screws, one in each corner, at the bottom of the LPS rack (reference 1 image 5-25). Use a 3 mm Allen wrench.
1
1
x4
1
Image 5-25
7. Hold the LPS rack by its handles at the top and remove it from the base.
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5. Power Unit
5.8 Replacement of the LPS communication interface
To access the LPS communication interface the LPS rack has to be removed from the base of the Power Unit.
This procedure assumes that the LPS rack is already removed. See "Removing the LPS rack from the base
of the Power Unit", page 90.
Necessary tools
• PH1 Phillips screwdriver.
• T10 Torx screwdriver.
How to replace the LPS communication interface from the Power Unit?
1. Remove the cover of the output side of the Power Unit by releasing the three retaining screws (reference 1 image 5-26). Use a
Phillips screwdriver PH1.
2. Disconnect the data cable (reference 2 image 5-26) from the D-SUB socket as illustrated.
Image 5-26
3. Disconnect the wire unit of the temperature sensor (reference 2 image 5-27) and the CTRL wire unit (reference 1 image 5-27).
1 2
Image 5-27
4. Remove the LPS communication interface by loosening the five Torx screws (reference 1 image 5-28) as illustrated. Use a T10
Torx screwdriver.
5. Install a new LPS communication interface. Make sure to place plastic washers (reference 2 image 5-28) at both sides of the
PCB board.
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5. Power Unit
2
1
1
Image 5-28
6. Reconnect the CTRL wire unit and the temperature sensor.

7. Reconnect the data cable with the D-SUB socket.
8. Reinstall the cover.
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5. Power Unit
5.9 Replacement of the Mains Filter
To access the Mains Filter the LPS rack has to be removed from the base of the Power Unit. This procedure
assumes that the LPS rack is already removed. See "Removing the LPS rack from the base of the Power Unit",
page 90.
Necessary tools
• 10 mm open-end wrench.
How to replace the Mains Filter from the Power Unit?

1. Disconnect all the wires from the input and output pins of the Mains Filter. Use a 10 mm open-end wrench to loosen the nuts of
the pins.
2. Remove the Mains Filter from the base of the Power Unit by loosen the four screws (reference 1 image 5-29) at the bottom of
the base. Use a 3 mm Allen wrench.
3. Install a new Mains Filter in the base of the Power Unit. Make sure that the input pins of the Mains Filter are facing the power
distribution strip.
Image 5-29
4. Reconnect the wires from the power distribution strip with the input pins of the Mains Filter. When having a neutral conductor
N (blue wire), make sure to connect the neutral N conductor with the neutral N pin (reference 4 image 5-30) of the Mains Filter.
Always connect the ground wire (PE, reference 5 image 5-30) with the ground pin of the Mains Filter.
4 4
3 3
2 2
1 1
EU US
5 5
Image 5-30
5. Reconnect the wires from the LPS modules with the output pins of the Mains Filter as illustrated.
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5. Power Unit
EU US
4 3 2 1
3 2 1
Image 5-31
6. Fasten the nuts on the all input and output pins of the Mains Filter with a torque of 3 Nm (2,2 lbf*ft). Make sure to place a washer
(reference 2 image 5-32) between the wire lug (reference 1 image 5-32) and the nut (reference 3 image 5-32). Use a torque
wrench with a 10 mm hexagon socket.
3Nm
1
2
3
Image 5-32
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5. Power Unit
5.10 Installing the LPS rack upon the base of the Power Unit
Necessary tools
How to install the LPS rack upon the base of the Power Unit?
1. Hold the LPS rack by its handles at the top and place it upon the base. Make sure that the LPS rack is correctly aligned.
2. Secure the LPS rack with four screws, one in each corner, at the bottom of the LPS rack (reference 1 image 5-33). Use a 3 mm
Allen wrench.
1
1
x4
1
Image 5-33
3. Connect the LAMP OUTPUT power cables with the LPS module as illustrated. Respect the polarity of the socket and cables.
Use torque wrench with a 10 mm hexagon socket to fasten the nuts on the pins with a torque of:
- 8 Nm (5.9 lbt*ft) in case of copper nuts and rods (old LPS).
- 4 Nm (2.95 lbt*ft) in case of brass nuts and rods.
- 4 Nm (2.95 lbt*ft) in case of nickel plated brass nuts and rods.
- 8 Nm (5.9 lbt*ft) in case of nickel plated steel nuts and rods.
Caution: Make sure to place the washers and cable eyes in correct order upon the pin as illustrated in image 5-34. First the
wire lugs (reference 1), then the plane washers (reference 2), then the lock washers (reference 3) and finally the nuts
(reference 4).
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5. Power Unit
4Nm / 8Nm
-
+
2
3
1
4
Image 5-34
4. Connect the three MAINS INPUT cables (reference 1, 2 & 3 image 5-35) with the LPS modules in the power rack.
5. Connect the wire unit (reference 4 image 5-35) from the LPS communication interface with the CTRL IN socket of the LPS module
at the bottom of the LPS rack.
3
4
Image 5-35
6. Install the front and rear cover of the Power Unit. Use a 3 mm Allen wrench to fasten the 5 screws (reference 1 & 2 image 5-36)
per cover.
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5. Power Unit
Image 5-36
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6. Start Pulse Generator
6. START PULSE GENERATOR

About this chapter
This chapter describes briefly the functionality, the different parts and the replacement procedure of the Start Pulse Generator (SPG)
module.
Overview
• Introduction
• Troubleshooting
• Removal of the Start Pulse Generator
• Installation of the Start Pulse Generator
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6.1 Introduction
Functionality of the Start Pulse Generator
The purpose of the Start Pulse Generator (SPG) is to ignite the lamp with a burst of high voltage peaks. The SPG superimposes
high voltage peaks onto the normal dc start-up voltage of the lamp supplied by the Lamp Power Supply modules from the projector
Power Unit. Once the lamp is started up and illuminating the high voltage is removed and the lamp voltage drops to the arc voltage.
The high voltage peaks are added to the lamp voltage by a superimposing transformer which is in series with the positive connection
from the LPS to the lamp. The negative connection from LPS to lamp is direct and is connected to the chassis at the lamp side. The
full lamp current passes through the secondary of the superimposing transformer.
Parts
3
4
Image 6-1
1 Positive connection pin from SPG to Lamp House.
2 Negative connection pin from SPG to Lamp House.
3 Red marked cable lug. Has to be connected with the positive “LAMP OUT” pin of the LPS modules.
4 Black marked cable lug. Has to be connected with the negative “LAMP OUT” pin of the LPS modules.
6 Retaining fixation screws.
6 Ferrite block.
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6.2 Troubleshooting
Lamp fails to ignite after you switched the projector from standby to operation
Situation Solution
You can hear the SPG module three times clicking in an attempt to ignite
the lamp. The voltage on the “LAMP OUT” pins of the LPS modules • The LPS modules and SPG seem the work
of the Power Unit is first 110 volt during the attempt to ignite and then normally but the lamp is bad. Install another
drops to 0 volt. lamp house.
Note: The ambient noise must be low to hear the SPG clicking in an • If the problem remains, replace the SPG
attempt to ignite the lamp. module.
You can not hear the SPG module three times clicking in an attempt
to ignite the lamp. The voltage on the “LAMP OUT” pins of the LPS • Check the cabling of the SPG module.
modules of the Power Unit is first 110 volt during the attempt to ignite • Replace the SPG module.
and then drops to 0 volt.
Note: The ambient noise must be low to hear the SPG clicking in an
attempt to ignite the lamp.
You can not hear the SPG module three times clicking in an attempt
to ignite the lamp. The voltage on the “LAMP OUT” pins of the LPS • Check the cabling of the LPS module.
modules of the Power Unit is below 110 volt during the attempt to ignite. • Replace the LPS module.
The diagnostic LED’s of the LPS module indicates a problem with the
LPS module.
Note: The ambient noise must be low to hear the SPG clicking in an
attempt to ignite the lamp.
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6.3 Removal of the Start Pulse Generator
To remove the Start Pulse Generator, the left cover, the right cover, the rear cover and the Lamp House have
to be removed first. This procedure assumes that the left cover, the right cover, the rear cover and the Lamp
House are already removed.
Necessary tools
• 4mm Allen wrench.
• 5mm Allen wrench.
• 8mm nut driver.
How to remove the Start Pulse Generator?

1. Remove the strain relief clamps of the SPG power cables (reference 9 of image 6-2). Use a 4 mm Allen wrench.
Image 6-2
2. Disconnect the SPG power cables from the Terminal Block. Use a 5mm Allen wrench.
3. Remove the SPG module from the projector by releasing the four retaining screws. Use a 8 mm nut driver.
Image 6-3
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6.4 Installation of the Start Pulse Generator
To install the Start Pulse Generator, the left cover, the right cover, the rear cover and the Lamp House have
House are already removed.
Necessary tools
• Torque wrench with 17 mm hexagon socket.
How to install the Start Pulse Generator?

1. Place the SPG module into position and fasten the four retaining screws. Use a 8 mm nut driver.
Image 6-4
2. Make sure that the SPG power cables are equipped with a ferrite block.
3. Connect the SPG power cables with the Terminal Block as illustrated. Fasten the cables with at torque of 10Nm (7.4 lbf*ft). Use
torque wrench with a 5 mm Allen socket.
Warning: Respect the polarity of the SPG power cables. Make sure that the head of the ferrule is completely inserted in the
Terminal Block.
Warning: There must be 1 cm space between the housing of the Terminal Blocks.
Note: The electrical high power connections of the Terminal Blocks must be checked on a yearly bases.
R59770374 DP-3000 16/08/2010 103

10Nm
-
+
Image 6-5
4. Reinstall the strain relief clamps of the SPG power cables (reference 9 of image 6-6). Use a 4 mm Allen wrench.
Image 6-6
5. Loosen the four retaining screws, which you fastened in step 1, one turn.
6. Install the Lamp House. See "Installing the Lamp House", page 121.
7. Fasten the four retaining screws of the LPS module.
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7. Lamps and Lamp House
7. LAMPS AND LAMP HOUSE

About this chapter
This chapter enumerates all the supported xenon lamps for the DP-3000 digital projector and how to replace the xenon lamp in the
Lamp House. Also included are the procedure to reset the lamp parameters, which is required after a xenon lamp replacement, and
the procedure to realign the lamp in its reflector for optimal performance.
Also included in this chapter are the replacement procedures for the UV blocker, Lamp Reflector and the Lamp Info module.
WARNING: DO NOT PERMIT UNAUTHORIZED PERSONNEL TO PERFORM OR ATTEMPT ANY PHASE OF

XENON LAMP HANDLING OR SERVICE. ONLY TRAINED AND QUALIFIED TECHNICAL SERVICE PERSONNEL
ARE ALLOWED TO HANDLE THE XENON LAMP.
CAUTION: Xenon compact arc lamps are highly pressurized. When ignited, the normal operating temperature
of the bulb increases the pressure to a level at which the bulb may explode if not handled in strict accordance
to the manufacturer’s instructions. The bulb is stable at room temperature, but may still explode if dropped or
otherwise mishandled. Whenever the lamp house, containing a xenon lamp, has to be dismantled or whenever
the protective container or cloth has to be removed from the xenon lamp, authorized protective clothing MUST
be worn!
WARNING: Always wear face protection (full face shield with neck protector) when handling xenon lamps.
WARNING: Always wear protective clothing (welder’s jacket) when handling xenon lamps.
WARNING: Always wear clean leather gloves with wrist protectors when handling xenon lamps.
Overview
• Introduction
• Supported xenon lamps for the DP-3000
• Removing the lamp house
• Removal of the xenon lamp
• Installation of the xenon lamp
• Installing the Lamp House
• Resetting the lamp parameters
• Realignment of the lamp in its Reflector
• Alignment of the arc stabilizing magnet
• Replacement of the Lamp Info module
• Replacement of the UV blocker
• Replacement of the Lamp Reflector
• Cleaning the UV blocker of the Lamp House
• Cleaning the Reflector of the Lamp House
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7.1 Introduction
Lamp and Lamp House
Xenon lamps are highly pressurized. At room temperature the pressure inside the bulb is between 10 and 15 bar. When ignited, the
normal operating temperature of the bulb increases the pressure up to somewhere between 30 and 50 bar. The bulb temperature of
an ignited lamp is approximately 700°C and the temperature of the arc is approximately 12000°C! To ignite a xenon lamp a voltage
of 40000 volt is required. Once the lamp is ignited the startup voltage drops to a level between 20 and 42 volt. The DC current
consumed by the lamp during normal operation can increase to 170 ampere. The maximum light produced by the xenon lamp inside
the DP-3000 digital projector is roughly 250000 lumens.
The xenon lamp is safely sheltered inside the Lamp House. The Lamp House exist in a reflector, a UV blocker, a lamp anode socket,
a lamp cathode socket, a Lamp Info module, an adjustable arc stabilizing magnet and an XYZ-adjustment mechanism to align the
lamp in the reflector. The Lamp House can handle xenon lamps up to 6500 Watt. The xenon lamp and Lamp House can be removed
from the projector as a whole, which allows a fast lamp replacement in cases when time is critical.
The Lamp Info module holds the lamp parameters and keeps track of the lamp history such as lamp power, number of strikes, total
lamp run time, etc. For that it is important to reset the lamp parameters after each lamp replacement.
Parts identification xenon lamp
1 2 3 4
Image 7-1
1 Cathode of the xenon lamp.
2 Envelope (bulb) of the xenon lamp.
3 Anode of the xenon lamp.
4 Anode wire of the xenon lamp.
Parts identification Lamp House
10
9 22
8
11 21
1
20
7 12
2 19
13
3
18
14
4 5 6 15 16 17
Image 7-2
1 Air inlet cathode cooling.
2 Adjustment screw horizontal lamp alignment.
3 Positioning pin.
4 Connection Lamp Info module.
5 Positioning pin.
6 UV blocker.
7 Cathode connection with SPG.
8 Anode connection with SPG.
9 Removable front cover.
10 Air out let.
11 Removable side cover.
12 Viewing port lamp arc.
13 Lamp Info module.
14 Lock screw horizontal lamp alignment.
15 Lamp House fixation screw.
16 Arc stabilizing magnet.
17 Lock screw vertical lamp alignment.
18 Lamp House fixation screw.
19 Adjustment screw horizontal lamp alignment.
20 Lamp cathode fixation screw.
21 Adjustment screw for lamp Z-alignment.
22 Adjustment screw vertical lamp alignment.
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Protective packaging
The xenon lamp is packed in a protective container or wrapped in a protective cloth. Never remove this protective container or
protective cloth without wearing adequate protective clothing (face chield, clean cotton glovers, welder’s jacket).
Image 7-3
R59770374 DP-3000 16/08/2010 107

7.2 Supported xenon lamps for the DP-3000
Anode and cathode lamp adapters are used to position the arc of the xenon lamp in the middle of the reflector
inside the lamp house. The size of the xenon lamp vary from type to type. Because of that different lamp
adapters are required. Futhermore, some lamp types require an anode adaptation ring to fit precisely into
the anode support assembly. The table below shows for each supported xenon lamp which anode/cathode
adapters have to be used and if an anode adaptation ring/bushing is required.
List of supported lamp types and their respective anode/cathode adapters:

Lamp type Supplier Cathode Anode Anode adaptation ring Barco Order No.
adapter adapter or bushing
2000W OSRAM XBO R8436061K R859987K - -
HS-OFR
2500W OSRAM XBO R8436061K R859987K - -
HS OFR
3000W OSRAM XBO R8436061K R859987K - -
HS-OFR
3000W OSRAM XBO R8436061K R859987K - R9855950
DHS OFR
4000W OSRAM XBO R8436081K R859986K - -
HS-OFR
4500W OSRAM XBO R8436081K R859986K - -
HS-OFR
4500W OSRAM XBO R8436081K R859986K - R9855949
DHP-OFR
5000W OSRAM XBO R8436081K - R842215K or -
HBM-OFR R864132K
HS-OFR R864132K
HP-OFR R864132K
6000W OSRAM XBO R8436081K - R842215K or R98064901
DHP-OFR R864132K
6500W OSRAM XBO R8436081K - R842215K or R9806860
DHP-OFR R864132K
UXL-20SC USHIO R8436061K R859987K - -
UXL-25SC USHIO R8436061K R859987K - -
UXL-30SC USHIO R8436061K R859987K - -
DXL-30BA USHIO R859984K R859985K - R9855953

UXL-40SC USHIO R8436101K R859986K - -
DXL-45BA USHIO R8436111K - - R9855952

UXL-50SC USHIO R8436101K R859986K - -
UXL-60SC USHIO R8436101K - R842215K or -
R864132K
DXL-60BA2 USHIO R8436111K - - R9806520
DXL-65BA USHIO R8436111K - - R9855951
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WARNING: Always use the right adapter(s) for the xenon lamp. Neglecting this may result in poor perfor-
mance of the lamp and damage to the xenon lamp and Lamp House. Some adapters looks the same, therefore
check the engraved item number upon the adapter to ensure you uses the right adapter.
Types of lamp anode support

There are two types of lamp anode supports. The oldest type consist in three legs spider assembly (reference 1 image 7-4) which
is attached to the metal front cover. The current type of lamp anode support (reference 2 image 7-4) is integrated on the UV blocker
of the Lamp House. The lamp replacement procedure is basically the same for both types. Important to know is that the anode
adaptation ring (reference 3 image 7-4) which has to be used with some xenon lamps supported with a three legs spider assembly,
is replaced with an anode adaptation bushing (reference 4 image 7-4) in case of an integrated anode support.
1 2
2
1
Image 7-4
Anode adapters, adaptation ring and adaptation bushing
R859986K R859985K R859987K R842215K R864132K

Image 7-5
R59770374 DP-3000 16/08/2010 109

Cathode adapters
R8436101K R8436081K R859984K R8436111K R8436061K

Image 7-6
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7.3 Removing the lamp house
WARNING: The lamp house is very hot after operation. To avoid burns, let the projector cool down for at least
15 minutes before proceeding to remove the lamp house.
Necessary tools
• Square lock key.
How to remove the lamp house from the projector?

1. Open the door of the lamp compartment as illustrated. Use the square lock key, delivered with the projector, to unlock the door.
Turn the key clockwise to unlock.
Image 7-7
2. Release the two captive screws at the base of the lamp house as illustrated. Use for that a 10 mm nut driver.
Image 7-8
3. Remove the lamp house as follows:

- Grip the lamp house by the bottom handle and partially slide it out of the lamp compartment.
- Grip the lamp house by both handles and remove the lamp house completely from the projector.
- Place the lamp house on a stable support.
Warning: Be aware of the weight of the lamp house.
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Image 7-9
112 R59770374 DP-3000 16/08/2010

7.4 Removal of the xenon lamp

WARNING: This procedure may only be performed by qualified technical service personnel.
be worn!
Necessary tools
• Two open-end wrenches of 22 mm.
• Lamp protective container or protective cloth with two binders.
• Flat blade screw driver.
• 2,5 mm Allen wrench.
How to remove the xenon lamp out of the Lamp House?

1. Remove the side cover of the Lamp House by releasing the two quarter turn screws (reference 1 image 7-10) at the bottom of
the side cover as illustrated.
Image 7-10
R59770374 DP-3000 16/08/2010 113

2. Remove the anode wire lug (reference 3 image 7-11) from the anode socket. Use for that two open ended spanners of 22 mm.
Hold the first nut (reference 4) with one spanner while releasing the second nut (reference 5 image 7-11) with the other spanner.
Tip: Place the flat washers (reference 6 & 7 image 7-11) and nut back on the rod after the lug is removed.
Note: The most recent Lamp Houses for the DP-3000 makes it possible to remove the anode socket together with the xenon
lamp from the Lamp House. The anode socket can be release from the xenon lamp once the xenon lamp is safely
sheltered in its protective container or wrapped in a protective cloth.
4 6 7 5
Image 7-11
3. Remove the hexagon socket head cap screw (reference 9) which fasten the cathode of the xenon lamp. Use a 5 mm Allen
wrench.
Note: The cathode wire remains in its position after the screw (reference 9) and washer (reference 10) are removed.
10
9
Image 7-12
4. Release the four quarter turn screws (reference 2 image 7-13) of the UV blocker assembly as illustrated. Make sure that the
anode support remains in its position while releasing the screws.
Caution: Ensure that you wear protective clothing, a full face shield and protective gloves.
2
Image 7-13
5. Support the xenon lamp inside the Lamp House with one hand while removing the UV blocker assembly from the lamp house.
Note that some xenon lamps are installed with an anode adaptation bushing (reference 12 image 7-14).
Warning: Supporting the xenon lamp with one hand to prevents it from bumping against the chassis of the Lamp House.
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12
Image 7-14
6. Gently remove the xenon lamp out of the Lamp House. Do not use excessive force upon the xenon lamp. Normally the xenon
lamp will easily slide out the cathode socket of the Lamp House.
Warning: Supporting the xenon lamp with one hand while pulling it out with other hand prevents it from bumping against the
chassis of the Lamp House.
Image 7-15
7. Place the xenon lamp in its protective container or wrap the xenon lamp in a protective cloth and secure with two binders.
Image 7-16
Left: Xenon lamp wrapped in a protective cloth. Right: Xenon lamp captured in a protective container.
8. Remove the adapter(s) from the xenon lamp by releasing the hexagon socket head set screw of the lamp adapter as illustrated.
Use for that a 2,5 mm Allen wrench.
Image 7-17
Reinstall the UV blocker assembly and the side cover in case you do not intend to install another xenon lamp
immediately in the Lamp House.
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7.5 Installation of the xenon lamp

be worn!
This procedure assumes that the anode support assembly and the side cover are already removed from the
Lamp House due to the removal of the xenon lamp. Futhermore, this procedure is applicable upon a Lamp
House equipped with an UV blocker with an integrated anode support instead of a three leg anode support. It
is recommended to upgrade the Lamp House with an integrated anode support before installing a new xenon
lamp.
Necessary tools
• Torque wrench with a 2,5 mm Allen socket.
• Torque wrench with a 5 mm Allen socket.
How to install the xenon lamp into the Lamp House?

1. Install the appropriate lamp cathode adapter upon the cathode of the xenon lamp. Fasten the set screw of the cathode adapter
with a torque of 2,5 Nm (1,84 lbf*ft). Use for that a torque wrench with a 2,5 mm Allen socket. Make sure that there is full contact
between the adapter flat surface and the lamp base. Note that some lamp types have a cathode pin with screw threat.
Tip: See chapter "Supported xenon lamps for the DP-3000", page 108, to know which cathode adapter your lamp requires.
Warning: Install the cathode adapter prior to removing the protective container or protective cloth from the xenon lamp.
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2,5 Nm
Image 7-18
2. Does the xenon lamp which you want to install requires an anode adapter?
Tip: See chapter "Supported xenon lamps for the DP-3000", page 108, to know if your lamp requires an anode adapter.
If yes, install the appropriate lamp anode adapter upon the anode of the xenon lamp. Fasten the set screw of the anode adapter
with a torque of 2,5 Nm (1,84 lbf*ft). Use for that a torque wrench with a 2,5 mm Allen socket. Make sure that there is full contact
between the adapter flat surface and the lamp base.
2,5 Nm
Image 7-19
If no, make sure that there is no anode adapter installed upon the anode of the xenon lamp.
3. Does the xenon lamp which you want to install requires an anode adaptation bushing inside the anode support?
Tip: See chapter "Supported xenon lamps for the DP-3000", page 108, to know if your lamp requires an anode adaptation
bushing.
If yes, insert the anode adaptation bushing (ref 4 of image 7-20) into the integrated anode support of the UV blocker.
Image 7-20
If no, make sure that there is no anode adaptation bushing inserted into the anode support.
4. Remove the protective packing from the xenon lamp and gently insert the xenon lamp into the Lamp House as illustrated. Lamp
cathode first, Make sure that the wire of the lamp anode is upwards oriented. While inserting the lamp, rotate it slightly, engag-
ing the pins (reference 11 of image 7-21) of the cathode adapter in the foreseen slots. This is to ensure the lamp cathode is
completely inserted. Keep supporting the anode of the lamp with one hand once the xenon lamp is in position.
Tip: Write down the serial number of the xenon lamp. You will need this while updating the lamp parameters after installation
of the xenon lamp. The serial number of the xenon lamp is engraved in the neck of the xenon lamp.
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11
Image 7-21
5. Install the UV blocker assembly as illustrated. Use the opening at the side of the Lamp House to guide the anode pin of the
xenon lamp into the anode supporting mechanism of the UV blocker. Make sure that the tick wire of the lamp anode is upwards
oriented.
Image 7-22
6. Secure the UV blocker by fastening the four quarter turn screws (reference 2 image 7-23) as illustrated.
Note: Ensure that the quarter turn screws turning wires are flush with the cover or interference will occur while inserting the
Lamp House into the projector.
2
Image 7-23
7. Install the anode wire lug (reference 3 image 7-24) upon the anode socket inside the Lamp House as illustrated. Use an open-end
wrench of 22 mm to hold the first nut (reference 4 image 7-24) while fastening the second nut (reference 5 image 7-24) with a
torque of 25 Nm (18,4 lbf*ft) using a torque wrench. Ensure that there is a flat washer (reference 6 & 7 image 7-24) at both sides
of the wire lug (reference 3 image 7-24).
Tip: Use flat washers instead of star washers: Flat washer specifications: DIN125A silver finished flat washer with inside
diameter 15 mm, outside diameter maximum 28 mm, and thickness 2,5 mm.
Warning: A torque of 25 Nm (18,4 lbf*ft) must be applied to fasten the nuts. Make sure that there is no tension on the anode
wire of the xenon lamp.
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4 6 7 5
25 Nm
Image 7-24
8. Check the cathode connection inside the lamp house. Use an 22 mm open-end wrench to hold the first nut while fastening the
second nut on the rod with a torque of 25 Nm (18,4 lbf*ft) using a torque wrench with 22 mm hexagon socket. Ensure that there
is a flat washer at both sides of the wire lug.
Caution: These cathode connections must be checked with every lamp change!
25 Nm
Image 7-25
9. Secure the xenon lamp cathode with the hexagon socket head cap screw (reference 9 image 7-26) and washer (reference 10
image 7-26) as illustrated. Fasten the screw with a torque of 5 Nm (3,7 lbf*ft). Use a torque wrench with a 5 mm Allen socket.
Caution: Make sure that both pins (reference 11 of image 7-26) of the cathode adapter remain engaged in the foreseen slots.
10
9
5 Nm
11
Image 7-26
10.Install the side cover of the Lamp House and fasten the two quarter turn screws (reference 1 image 7-27) at the bottom of the
cover.
Note: Please ensure that the quarter turn screws turning wires are flush with the cover or interference will occur while inserting
the Lamp House into the projector.
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Image 7-27
CAUTION: The “LAMP INFO” parameters which are stored on a chip inside the Lamp House MUST be updated
after each installation of an xenon lamp inside the Lamp House. Neglecting this update will result in poor
performance and short life time of the xenon lamp.
A realignment of the xenon lamp in its reflector is required after the installation of the xenon lamp in the Lamp
House.
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7.6 Installing the Lamp House

Necessary tools
• Square lock key.
How to install the Lamp House into the projector?

1. Check if the six quarter turn screws turning wires (reference 1image 7-28) are flush with the cover or interference will occur while
inserting the Lamp House into the projector.
Image 7-28
2. Grip the Lamp House by both handles and place the front of the Lamp House on the base plate inside the lamp compartment of
the projector, lining up the foot of the Lamp House with the slots on the base.
Warning: Be aware of the weight of the Lamp House.
Image 7-29
3. Push the Lamp House fully into the slots.

4. Secure the position of the Lamp House by fastening the two retaining screws at the base of the Lamp House as illustrated. Use
for that a 10 mm nut driver.
Image 7-30
R59770374 DP-3000 16/08/2010 121

5. Close the door of the lamp compartment. Use the square lock key, delivered with the projector, to lock the door. Turn the key
counterclockwise to lock.
Image 7-31
Each xenon lamp replacement requires a reset of the lamp parameters. See procedure "Resetting the lamp
parameters", page 123.
To ensure maximum light output it is recommended to realign the lamp. See procedure "Realignment of the
lamp in its Reflector", page 124.
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7.7 Resetting the lamp parameters
CAUTION: The “LAMP INFO” parameters MUST be updated after each installation of an xenon lamp inside
the Lamp House. Neglecting this update will result in poor performance and short life time of the xenon lamp.
How to reset the lamp parameters?

1. Start up the projector but do not ignite the lamp.
2. Go via the Communicator touch panel to the menu “Installation” > “Lamp” > “Lamp information”.
3. While the Lamp information window is displayed, tap on Reset (1).
A reset message is displayed (2).
4. Tap on Select (3) to display a list of possible article numbers (4). Select a article number (5) and tap OK (6).
The software will validate the selected article number (7).
5. Fill out the serial number of the lamp (8).
6. Click Reset (9).
Image 7-32
Reset lamp info
CAUTION: For more information about using the Communicator Touch Panel consult the user’s guide of the
Communicator Touch Panel.
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7.8 Realignment of the lamp in its Reflector

What has to be done?
The arc of the xenon lamp has to be placed in the center of the Reflector for maximum light output.
X Z
Y
Image 7-33
Each xenon lamp installation requires a realignment of the lamp in its Reflector for optimal performance of
the xenon lamp in the DP-3000 digital projector. Furthermore, it is recommended to realign the lamp after the
first run time of 100 and 200 hours. Especially the Z-axis of the lamp.
Necessary tools
Square lock key.
How to realign the lamp in its reflector?

1. Open the door of the lamp compartment to gain access to the X-, Y-, and Z-axis adjustment thumbscrews of the lamp.
2. Switch on the projector and start up the lamp.
3. Go via the Communicator touch panel to the menu “Installation” > “Lamp” > “Light output”.
4. Set the “Light output mode” in normal mode and the “Lamp Dimming” on maximum (255).
Note: This window on the Communicator touch panel shows in the upper left corner the measured value of the built-in light
sensor of the projector.
Image 7-34
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5. Release the X-axis lock thumb screw (ref X L ) and Y-axis lock thumb screw (ref Y L ).
6. Adjust the X-axis (ref X A ), the Y-axis (ref Y A ) and the Z-axis (ref Z A ) for maximum current light output (Footlambert Measured).
Carefully turn the thumbscrew for maximum light output. Once over the maximum, turn slightly in opposite direction to reach the
maximum light output again. Do this for each direction and minimum repeat this adjustment cycle twice.
7. Fasten the X-axis lock thumb screw (ref X L ) and Y-axis lock thumb screw (ref Y L ).
YA
ZA
XL
XA
YL
Image 7-35
8. Switch off the projector.

9. Close and lock the door of the lamp compartment.
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7.9 Alignment of the arc stabilizing magnet
A realignment of the acre stabilizing magnet is seldom. It can happen that a realignment is required after the
installation of a xenon lamp from another supplier. Due to the fact that this adjustment has almost no effect
on the newer xenon lamps and the obsolescence of the welding glass, used in the viewport, Barco has decide
to replace the welding glass with a sheet metal part in the Lamp Houses produced since March 2009.
Necessary tools
Flat blade screw driver.
How to align the arc stabilizing magnet?

1. Remove both side covers and the rear cover of the projector head.
2. Remove the cover of the stabilizing magnet by releasing the two captive screws as illustrated. Use a flat blade screw driver. The
stabilizing magnet is located at the rear left bottom of the Lamp House.
Image 7-36
3. Power up the projector, ignite the lamp and open the dowser as follows:
- Push the main switch on the input & communication unit into the “I” position.
- Press the STANDBY button on the local keypad.
- Press the DOWSER button on the local keypad.
4. Look through the arc viewing port at the rear side of the projector and observe the arc of the xenon lamp in the Lamp House.
- The normal arc, when viewed through the arc viewing port, will appear as in figure A. This represents the correct magnet
position.
- Figure B shows the position of the arc when the magnet is to low.
- Figure C shows the position of the arc when the magnet is to high.
Caution: Observe all safety precautions when working in the lamp house compartment.
Image 7-37
5. If required, reposition the arc stabilizing magnet as follows:
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- Loosen the two hexagon socket head cap screws, using an Allen wrench of 3 mm.
- Place a flat screw driver between the two screws and raise the magnet to lower the arc or lower the magnets to raise the arc.
- Hold the magnet into position and tighten the two hexagon socket head cap screws, using an Allen wrench of 3 mm.
Warning: The Lamp House is very hot during operation. To avoid burns, use a screw driver to reposition the arc stabilizing
magnet.
Image 7-38
6. Install the cover of the stabilizing magnet and fasten the two captive screws as illustrated. Use a flat blade screw driver.
Image 7-39
7. Reinstall the rear cover and both side covers of the projector head.
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7.10 Replacement of the Lamp Info module
This procedure requires that the Lamp House is removed from the projector. See procedure "Removing the
lamp house", page 111.
Necessary tools
6 mm nut driver.
How to replace the Lamp Info module?

1. Remove the cover of the Lamp Info module by releasing the four short spacers as illustrated. Use for that a 6 mm nut driver.
Image 7-40
2. Disconnect the wire unit W1 from the Lamp Info module as illustrated.
W1
Image 7-41
3. Remove the Lamp Info module from the Lamp House by releasing the four spacers S as illustrated. Use for that a 6 mm nut
driver.
128 R59770374 DP-3000 16/08/2010

Image 7-42
4. Reinstall a new Lamp Info module and fasten with four spacers S as illustrated in image 7-42. Use for that a 6 mm nut driver.
Note: Make sure that the Lamp Info module is correctly oriented. The socket for the wire unit must be at the left side.
5. Reconnect the wire unit W1 as illustrated.
W1
Image 7-43
6. Reinstall the cover of the Lamp Info module as illustrated. Fasten with four short spares. Use for that a 6 mm nut driver.
Image 7-44
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7.11 Replacement of the UV blocker
This procedure requires that the Lamp House is removed from the projector. Futhermore, this procedure is
applicable upon a Lamp House equipped with an UV blocker with an integrated anode support instead of a
three leg anode support. It is recommended to replace a three leg anode support with an integrated anode
support. The three leg anode support is no longer available.
CAUTION: The person that performs this procedure MUST be wearing a full face shield with neck protector, a
welder’s jacket and clean leather gloves with wrist protectors. This is required to safely dismantle or assemble
the lamp house, which contains a xenon lamp.
Necessary tools
• Latex or cotton gloves.
How to replace the UV blocker with integrated anode support?

1. Remove the side cover of the Lamp House by releasing the two quarter turn screws (reference 1 image 7-45) at the bottom of
the side cover as illustrated.
Image 7-45
2. Release the four quarter turn screws (reference 2 image 7-46) of the UV blocker assembly as illustrated. Make sure that the
anode support remains in its position while releasing the screws.
2
Image 7-46
3. Support the xenon lamp inside the lamp house with one hand while removing the UV blocker assembly from the Lamp House.
Note that some xenon lamps are installed with an anode adaptation bushing (reference 12 image 7-47).
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12
Image 7-47
4. Remove one of the three washers (reference 2 image 7-48) which secure the UV blocker. Use a 2,5 mm Allen wrench to loosen
the hexagon socket head cap screw (reference 1 image 7-48).
5. Loosen the fixation screws of the remaining two washers with a few turns. Use a 2,5 mm Allen wrench.
1
2
2x
2x
Image 7-48
6. Replace the UV blocker with integrated anode support with a new one.
Caution: Do not touch the new UV blocker with bare fingers. Wear latex or cotton gloves.
Image 7-49
7. Fasten the three spacers which hold the UV blocker. Use a 2,5 mm Allen wrench.
2
1
Image 7-50
R59770374 DP-3000 16/08/2010 131

8. Install the UV blocker assembly as illustrated. Make sure that the xenon lamp is properly supported by the lamp supporting
mechanism. Use the opening at the side of the Lamp House to guide the supporting pin of the xenon lamp into the supporting
mechanism. Make sure that the tick wire of the lamp anode is upwards oriented.
Caution: Do not forget to use an anode adaptation bushing in case one is needed for the xenon lamp inside the Lamp House.
Image 7-51
Tip: Check if the UV blocker is clean. If not, see procedure "Cleaning the UV blocker of the Lamp House", page 137, before
installing the UV blocker assembly on the Lamp House.
Image 7-52
9. Secure the UV blocker by fastening the four quarter turn screws (reference 2 image 7-53) as illustrated.
2
Image 7-53
10.Install the side cover of the Lamp House and fasten the two quarter turn screws (reference 1 image 7-54) at the bottom of the
cover.
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Image 7-54
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7.12 Replacement of the Lamp Reflector

Lamp Reflector assembly
The Lamp Reflector assembly of the Lamp House has three major parts. One metal mounting ring, one spheric glass mirror and
one elliptic glass mirror. Both mirrors are assembled on the metal ring and are perfectly aligned with each other.
1 4
3
5
Image 7-55
1 Elliptic glass mirror.
2 Spheric glass mirror.
3 Metal mounting ring
4 View port hole.
5 Bottom side of the assembly.
This procedure assumes that there is no lamp installed inside the Lamp House and that the side cover of the
Lamp House is already removed. See procedure "Removal of the xenon lamp", page 113.
CAUTION: Do not touch the glass of the reflector assembly while unpacking and installing. Hold fast the
reflector assembly by its metal mounting ring.
Necessary tools
• Two 22 mm open-end wrenches.
• Torque wrench with 22 mm hexagon socket.
How to replace the Reflector of the Lamp House?

1. Disconnect the cathode wire lug (reference 3 image 7-56) from the Lamp House as illustrated. Use two 22 mm open-end wrenches
to release the nuts (reference 4 & 5 image 7-56).
Tip: Place the plane washers (reference 6 & 7 image 7-56) and nut back on the rod after the lug is removed.
4 6 3 7 5
Image 7-56
2. Remove the corner plate of the Lamp House as illustrated. Use a 2,5 mm Allen wrench to loosen the four screws (reference 1
image 7-57) which hold the plate.
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1 1
Image 7-57
3. Cut the cable tie (reference 2 image 7-58) of the wire unit from the Lamp Info module. This gives the wire unit more play when
removing the front assembly of the Lamp House.
Image 7-58
4. Remove the front assembly of the Lamp House by loosening the 8 indicated screws (reference 3 image 7-59). Use a 2,5 mm
Allen wrench.
Caution: Do not damage the wire unit (reference 4 image 7-59). The front assembly is still connected via the wire unit of the
Lamp Info module with the base of the Lamp House. This wire unit has some play so that you can turn the front
assembly away from the Lamp House.
3 3 4
Image 7-59
5. Remove the Reflector assembly from the Lamp House by loosening the three hexagon socket head cap screws (reference 5
image 7-60) as illustrated. Use a 3 mm Allen wrench.
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Image 7-60
6. Place a new Reflector assembly in the Lamp House and fasten with 3 hexagon head cap screws. Align the view port hole
(reference 6 image 7-60) to your right. Use a 3 mm Allen wrench to fasten the screws (reference 5 image 7-60).
Caution: Do not touch the glass of the Reflector assembly. Hold fast the Reflector assembly by its metal mounting ring.
7. Reinstall the front assembly of the Lamp House. Use a 2,5 mm Allen wrench to fasten the 8 hexagon head cap screws (reference
3 image 7-59).
Caution: Take care that the wire unit (reference 4 image 7-59) of the Lamp Info module does not get jammed.
8. Fasten the wire unit with a cable tie (reference 2 image 7-58).
9. Reinstall the corner plate of the Lamp House. Use a 2,5 mm Allen wrench to fasten the 4 hexagon head cap screws (reference
1 image 7-57).
10.Reconnect the cathode wire with the Lamp House. Make sure to place a plane washer (reference 6 and 7 image 7-61) between
the nuts and the wire lug (reference 3 image 7-61). Use a torque of 25 Nm (18,4 lbf*ft) to fasten the nuts (reference 4 and 5
image 7-61). Block the first nut (reference 4 image 7-61) with a 22 mm open-end wrench while applying a torque of 25 Nm on
the second nut (reference 5 image 7-61) with a torque wrench.
4 6 3 7 5
25 Nm
Image 7-61
The Lamp House is now ready to install an xenon lamp. See procedure "Installation of the xenon lamp", page
116.
It is recommended for optimal performance to readjust the Cold Mirror after the replacement of the Lamp
Reflector. See procedure "Adjusting the Cold Mirror", page 143.
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7.13 Cleaning the UV blocker of the Lamp House

When cleaning the UV blocker?
Only clean the UV blocker of the Lamp House in case it is really necessary. This means in case dust is clearly visible upon the
surface of the UV blocker.
This procedure requires that the UV blocker is removed from the Lamp House.
WARNING: ISOPROPANOL ALCOHOL (200–661–7).

Hazardous product. Irritating to eyes and skin. Always use in a well ventilated area. Vapors may cause drowsi-
ness and dizziness. Avoid contact with skin and eyes. In case of contact with the eyes, rinse immediately with
plenty of water and seek medical advise.
CAUTION: ISOPROPANOL ALCOHOL (200–661–7).

Hazardous product. Lightly flammable. Always use in a well ventilated area. Keep away from sources of
ignitions. Do not smoke while working with isopropanol. Exclusive keep in original container tightly closed
at a cool, well ventilated and fireproof storage space.
Necessary tools
• Clean Torayse cloth.
• Clean cotton cloth.
• Demineralized water.
• Isopropanol alcohol.
How to clean the UV blocker of the Lamp House?

1. Wipe off the dust of both sides of the UV blocker. Use for that a clean Torayse cloth.
Tip: Limit the number of wipe movements. This to protect the optical coating. It is better to wipe of the dust with one good
wipe movement than with 10 soft wipe movements.
2. Is all dust removed from the UV blocker?
If yes, stop this cleaning procedure.
If no, wipe off the dust of the UV blocker with a clean cotton cloth and demineralized water.
Tip: Use isopropanol alcohol instead of demineralized water to remove fingerprints.
CAUTION: Never reinstall a UV blocker with is cracked or has a damaged coating. Neglecting this will result
in irreversible damage of optical parts in the projector.
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7.14 Cleaning the Reflector of the Lamp House

When cleaning the Reflector?
Only clean the Reflector of the Lamp House in case it is really necessary. This means in case dust is clearly visible upon the surface
of the Reflector.
This procedure requires that the xenon lamp is removed from the Lamp House.


Necessary tools
• Compressed air.
How to clean the Reflector of the Lamp House?

1. Try to blow away the dust with compressed air.
2. Is all dust removed from the Reflector?
If no, wipe off the dust of the Reflector. Use for that a clean Torayse cloth.
wipe movement then with 10 soft wipe movements.
3. Is all dust removed from the Reflector?
If no, wipe off the dust of the Reflector first with a clean cotton cloth and demineralized water and than with a clean Torayse cloth.
CAUTION: Never use a Lamp House which Reflector is cracked or has a damaged coating. Neglecting this
will result in irreversible damage of the projector.
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8. Cold Mirror
8. COLD MIRROR
About this chapter
This chapter describes how to replace the Cold Mirror. It also describes the adjustments for the Cold Mirror and when an adjustment
or cleaning is needed.
CAUTION: Normally the Cold Mirror should never be readjusted in the field except when the Cold Mirror or
Lamp Reflector has been replaced. In case a readjustment is required follow the instructions in this chapter
precisely. Only qualified technicians who have experience with adjusting the Cold Mirror may adjust the Cold
Mirror. A misaligned Cold Mirror may cause irreversible damage to other parts of the projector!
Overview
• Introduction
• Replacement of the Cold Mirror
• Adjusting the Cold Mirror
• Cleaning the Cold Mirror
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8. Cold Mirror
8.1 Introduction
Functionality of the Cold Mirror
The location of the Cold Mirror in the light path is between the light source (xenon lamp) and the light pipe. The Cold Mirror reflects
the visible light and absorbs the infra red light. Due to this absorbing, a lot of heat is produced. The Cold Mirror is mounted with the
rear side upon a big heat sink. The fan below the heat sink blows cold air and the fan above extracts hot air from the Cold Mirror
and heat sink. The hot air is transported to the outside of the projector. The Cold Mirror has three adjustment screws to modify the
position of the Cold Mirror so that the centre of the light spot is precisely reflected in the centre of the integration rod entrance for
optimal performance.
2
Image 8-1
1 Cold Mirror.
2 Heat sink.
3 Mounting plate.
4 Adjustment screws.
Diagnostic
The easiest way to check the condition of the Cold Mirror is by removing the Lamp House. When the Lamp House is removed, the
Cold Mirror becomes visible at the end of the lamp compartment. In case the Cold Mirror is not damaged but dirt is clearly visible
upon the surface of the mirror it is recommended to clean the Cold Mirror. Always replace the Cold Mirror with a new one in case
the Cold Mirror is damaged. Possible damages are:
• Cold Mirror is broken.

• Coating peels off.
• Cold Mirror is cracked.
The light output on the screen will be lower than the normal light output in case of a damaged or dirty Cold
Mirror.
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8. Cold Mirror
8.2 Replacement of the Cold Mirror
The Lamp House has to be removed to get access to Cold Mirror. This procedure assumes that the Lamp
House is already removed.
Necessary tools
• Latex or cotton gloves
• Slide caliper.
How to replace the Cold Mirror?

1. Remove the nut (reference 10image 8-2) from each fixation point. Use a 7 mm open-end wrench.
Note: When the nut is removed, support the mirror so that it cannot drop.
10
Image 8-2
2. Slide off all other small components and take off the Cold Mirror. See left side image 8-4.
3. Check if the three adjustment screws at the rear side of the Cold Mirror are 20,5 mm from the fixation plate. Adjust if necessary.
Use a 7 mm open-end wrench for the lock nuts (reference 1 image 8-3) and a 7 mm Allen wrench for the adjustment screws
1
20
,5
Image 8-3
4. Place the mounting parts and Cold Mirror upon the three rods in that order as illustrated. Note that the number and type of
mounting parts on the lower rod are slightly different than those on the upper two rods.
Caution: Do not touch the new Cold Mirror with bare fingers. Wear latex or cotton gloves.
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8. Cold Mirror
1 2 3 4 5 6 7 8 9 10
2 11 7 8 12 10
Image 8-4
5. Turn the lock nut on each rod as far as illustrated. Use a 7 mm open-end wrench.
- Upper right rod (reference 1 image 8-5): turn until the rod is 0,8 mm out of the lock nut.
- Lower rod (reference 2 image 8-5): turn until the rod is 11,4 mm out of the lock nut.
- Upper left rod (reference 3 image 8-5): turn until the rod is 1,5 mm out of the lock nut.
3 1 1 0,8
1,5
2
2
11,4
Image 8-5
6. Check the Cold Mirror for dirt. If necessary clean the Cold Mirror. See cleaning procedure "Cleaning the Cold Mirror", page 145.
7. Adjust the Cold Mirror for optimal performance. See adjustment procedure "Adjusting the Cold Mirror", page 143.
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8. Cold Mirror
8.3 Adjusting the Cold Mirror

Important note!
The position of the xenon lamp in its Reflector effects the position of the Cold Mirror with respect to the entrance of the Integration
Rod. Hence the adjustment of the Cold Mirror requires simultaneous adjustment of the xenon lamp in its Reflector for maximum
light output. This procedure describes how to do so. However, if you are 100% sure that the xenon lamp is perfectly aligned in the
Lamp House you can skip the adjustments on the Lamp House.
Adjust the Lamp House first in another projector, which Cold Mirror is correctly adjusted, or have it aligned by
Barco before proceeding with the Cold Mirror adjustments. That way any Lamp House will be usable in that
projector, or all others, and vise versa.
Once the Cold Mirror and xenon lamp are optimally adjusted, the Cold Mirror should never be adjusted again. A xenon lamp re-
placement only requires realignment of the xenon lamp in its Reflector. Only when the Cold Mirror or Reflector is replaced, should
the Cold Mirror be readjusted.
Necessary tools
• Light meter.
• Slide caliper.
How to setup the projector for adjusting the Cold Mirror?

1. Open the door of the lamp compartment and remove the left cover of the projector.
2. Loosen the three lock nuts (reference 4 image 8-6) of the Cold Mirror adjustment screws. Use for that a 7 mm open-end wrench.
Image 8-6
3. Release the X and Y axis lock thumb screws (reference LX & LY image 8-7) of the Lamp House.
Tip: If you are 100% sure that the xenon lamp is perfectly aligned in the Lamp House you can skip the adjustments on the
Lamp House. See “Important note!” above.
LY
LX
Image 8-7
4. Check the nominal position of the Cold Mirror and if required adjust. The distance between the head of the each adjustment
screw and the assembly plate should be 20,5 mm for nominal position. This nominal position is the best position to start the
adjustment procedure. Use a 7 mm open-end wrench for the lock nuts (reference 1 image 8-8) and a 7 mm Allen wrench for the
adjustment screws (reference 2 image 8-8).
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8. Cold Mirror
20
,5
2
Image 8-8
5. Project a white test pattern.

Tip: Start the adjustment procedure with a dimmed xenon lamp.
6. Place the light meter in the center of the projected image.
How to adjust the Cold Mirror?

1. Turn the adjustment screw 2 (reference 2 image 8-9) in or out until the maximum light output is measured. Use for that a 7 mm
nut driver.
2 X
Image 8-9
2. Turn the adjustment screw 3 (reference 3 image 8-9) in or out until the maximum light output is measured.
3. Repeat step 1 and 2 until the maximum light output is measured.
4. Adjust the X-axis, Y-axis and Z-axis (reference X, Y & Z image 8-9) of the xenon lamp in the Lamp House for maximum light
output. Carefully turn the thumbscrew for maximum light output. Once over the maximum, turn slightly in opposite direction to
reach the maximum light output again. Do this for each direction and minimum repeat this adjustment cycle twice.
Tip: If you are 100% sure that the xenon lamp is perfectly aligned in the Lamp House you can skip the adjustments on the
Lamp House. See “Important note!” above.
5. Turn the adjustment screw 1, 2 and 3 (reference 1, 2 & 3 image 8-9) equally in or out until the maximum light output is measured.
6. Repeat from step 1 until the maximum light output is measured.
7. Check the brightness uniformity. In most cases it will be OK.
If not OK, turn slightly on the adjustment screws 2 and 3 (reference 2 & 3 image 8-9) until a uniform brightness is obtained.
- Screw 2 (reference 2 image 8-9) will correct the difference between the left and the right side of the projected image.
- Screw 3 (reference 3 image 8-9) will correct the difference between the top and the bottom side of the projected image.
Check again and repeat if necessary.
8. When the adjustment is finished, secure the position of the Cold Mirror by turning the lock nuts (reference 4 image 8-6) against
the plate (hold on the screws while securing the nuts).
9. Secure the position of the xenon lamp in its Reflector by turning the X and Y axis lock thumb screws (reference LX & LY image 8-7)
of the Lamp House.
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8. Cold Mirror
8.4 Cleaning the Cold Mirror

When cleaning the Cold Mirror?
Only clean the Cold Mirror in case it is really necessary. This means in case dust is clearly visible upon the surface of the Cold Mirror.
This procedure requires that the Lamp House is removed from the projector.


Necessary tools
How to clean the Cold Mirror?

1. Wipe off the dust of the Cold Mirror. Use for that a clean Torayse cloth.
2. Is all dust removed from the Cold Mirror?
If no, wipe off the dust of the Cold Mirror with a clean cotton cloth and demineralized water.
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8. Cold Mirror
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9. Integration Rod
9. INTEGRATION ROD
About this chapter
This chapter describes briefly the functionality of the Integration Rod, how to diagnose the Integration Rod, how to replace the
Integration Rod and how to adjust the Integration Rod.
Overview
• Introduction
• Integration Rod diagnostic
• Removal of the Integration Rod assembly
• Installing a new Integration Rod assembly
• Adjusting the Integration Rod
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9. Integration Rod
9.1 Introduction
Functionality of the Integration Rod
The Integration Rod is made of fused silica and is approximately 13 centimeter long. The cross-section of the rod has the same
aspect ratio as the active surface of the DMD’s used in the Light Processor. The function of the Integration Rod is to match the
shape of the light path to the shape of the DMD’s and to neutralize the hot spot effect caused by the light source. Futhermore, the
Integration Rod ensures that the light beam is focused on the DMD’s, which results in an optimally focused light beam on the screen.
The Integration Rod is located at the entrance of the Light Pipe. The light emitted by the lamp is reflected via the Cold Mirror into
the rod, which integrates the incoming light into a homogeneous rectangle shaped beam of light.
Image 9-1
The entrance and exit side of the Integration Rod are coated to achieve optimal performance. Clearly the rod may never be con-
taminated with grease, dirt, liquid or the such. for optimal protection the rod is mounted inside an aluminium tube, which requires
replacing together with the rod. This aluminum tube also contains an adjustment mechanism to position the rod inside the Light
Pipe. The Integration Rod, the aluminium tube and the adjustment mechanism together form the “Integration Rod assembly”.
Parts
8
1 2 3 4 5
Image 9-2
1 Aluminium tube.
2 Fixation screw rod assembly.
3 Rod adjustment ring.
4 Set screw for rod focus adjustment.
5 Rod exit.
6 Fixation screws for cooling block.
7 Rod entrance.
8 Rod assembly positioning pin for cooling block.
CAUTION: Never touch the entrance or exit of the Integration Rod assembly. Greasy fingerprints or other dirt
on the Integration Rod entrance or exit will burn into the rod and cause permanent damage.
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9. Integration Rod
9.2 Integration Rod diagnostic

General
Due to bad environmental conditions the Integration Rod may become contaminated with grease, dust, dirt or other particles, which
will burn into the rod and cause permanent damage. As a result spots may become visible in the projected image on the screen. To
confirm that these spots are caused by a damages to the rod please diagnose the rod as described in the following procedure.
Necessary tools
• 7 mm flat screw driver.
How to diagnose the Integration Rod of the projector?

1. Remove the side cover of the projector.
2. Switch on the projector and project a white test pattern. See users manual of the projector to do so. Make sure that the projected
white test pattern is focused.
3. Loosen the two set screws (reference 1 image 9-3) a few turns. Use a 2 mm Allen wrench. It’s not necessary to remove the set
screws.
1
Image 9-3
4. Gently rotate the adjustment ring (reference 2 image 9-4) of the Integration Rod assembly back and forward while watching the
projected image.
Image 9-4
5. Do you see spots in the projected image rotate along with the movements of the rod?
If yes, these spots are caused by damages to the Integration Rod. Replace the rod assembly.
If no, Integration Rod is OK. Re-adjust and secure the Integration Rod and reinstall the side cover of the projector.
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9. Integration Rod
9.3 Removal of the Integration Rod assembly
To remove the Integration Rod assembly from the Light Pipe the Light Processor unit has to be removed from
the projector first. This procedure assumes that the Light Processor is already removed from the projector.
CAUTION: All servicing to the Light Processor unit has to be done in a dust free area. Use compressed air to
blow away all dust on the outside of the Light Processor unit before entering the unit into the dust free area.
Necessary tools
• Compressed air.
How to remove the integration rod from the light pipe?

1. Remove the cooling block at the Light Pipe entrance by releasing the two socket head cap screws (reference 1 image 9-5) as
illustrated. Use a 2,5 mm Allen wrench.
Image 9-5
2. Loosen the two set screws (reference 2) a few turns. Use a 2 mm Allen key. It’s not necessary to remove the set screws.
3. Remove the socket head cap screw (reference 3) as illustrated. Use a 2,5 mm Allen wrench.
2 3
Image 9-6
4. Pull the Integration Rod assembly out of the light pipe.
Do not keep the Light Pipe entrance open (no Integration Rod installed) for a long period. This to prevent dust
intrusion.
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9. Integration Rod
9.4 Installing a new Integration Rod assembly

Necessary tools
• Compressed air.
Necessary parts
Integration rod assembly.
How to install a new the Integration Rod assembly?

1. Check if there are no dust particles present on the exit side of the Integration Rod assembly. If necessary remove the dust with
compressed air.
Caution: Never touch the entrance or exit side of the integration rod assembly.
Note: The exit side of the rod is much more critical than the entrance side of the rod.
2. Check if the inner side of the Light Pipe entrance is dust free. If necessary remove the dust with compressed air.
3. Gently slide the Integration Rod into the light pipe as illustrated in image 9-7.
4. Secure the Integration Rod with a hexagon socket head cap screw (reference 1 image 9-7). Use a 2,5 mm Allen wrench.
Image 9-7
5. Rotate the Integration Rod until the set screws (reference 2 image 9-8) of the Light Pipe are aligned with the set screw (reference
3 image 9-8) of the Integration Rod assembly as illustrated.
2
3
Image 9-8
6. Fasten the set screws (reference 2 image 9-9). Use a 2 mm Allen wrench.
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9. Integration Rod
Image 9-9
7. Install the cooling block with two hexagon screws (reference 4 image 9-10) as illustrated. Use a 2,5 mm Allen wrench.
Caution: Align the positioning pin (reference 5 image 9-10) of the Integration Rod with its corresponding slot on the cooling
block while approaching the Integration Rod.
Image 9-10
The Integration Rod must be adjusted after installation.
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9. Integration Rod
9.5 Adjusting the Integration Rod
To adjust the Integration Rod you have to remove the side cover (Light Processor side) first.
Necessary tools
2 mm Allen wrench.
How to adjust the Integration Rod of the projector?

1. Check if the rod rotation set screws (reference 1 image 9-11) and the rod focus set screw (reference 2 image 9-11) are aligned.
If not see procedure "Installing a new Integration Rod assembly", page 151, to align the set screws.
2
1
Image 9-11
2. Loosen the rod focus set screw (reference 2 image 9-12). Use a 2 mm Allen wrench.
Image 9-12
3. Start up the projector but do not activate the lamp yet.

4. Set up the projector using the Communicator software to display a white internal pattern with a maximum contrast and a maximum
dimming. Do not activate the lamp yet.
a) Switch on the projector. Do not activate the lamp yet.
b) Select : Control Service > Light output mode > Normal mode > Lamp dimming > 0
c) Select : Control > Test patterns > Full white
d) Make sure that you have a 2 mm Allen wrench within reach for the next steps.
Caution: Maximum ten (10) seconds are allowed of minimum light output on an non-adjusted Integration Rod. Otherwise, the
DMD’s be damaged.
5. Activate the lamp and zoom the projector lens in or out until the projected image is focused.
Note: Dialog windows must be displayed sharp instead of blurry. This is independent of the focus of the light beam.
6. Gently rotate the rod adjustment ring (reference 3 image 9-13) back or forward to a position which projects the sharpest possible
edges on the screen.
Tip: Place a 2 mm Allen wrench in one of the holes on the outer side of the adjustment ring. The Allen wrench function as an
extension bar of the adjustment ring. This allows a more precise adjustment.
3
Image 9-13
7. Fasten the rod focus set screw (reference 2 image 9-12) which you released in step 2.
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9. Integration Rod
8. Loosen the two rod rotation set screws (reference 1 image 9-14) as illustrated. Use a 2 mm Allen wrench.
1
Image 9-14
9. Gently rotate the rod adjustment ring (reference 3 image 9-15) until the projected light beam matches the projected outline of the
DMD’s.
Note: No spots in the projected image may move along with the movements of the Integration Rod. Spots which move with the
movements of the Integration Rod indicates that the exit side of the Integration Rod is contaminated with dust. If this is
the case, remove the Integration Rod and try to blow away the dust. If this doesn’t help replace the Integration Rod.
3
Image 9-15
10.Fasten the two rod rotation set screws (reference 1 image 9-14) which you released in step 8 and reinstall the projector side
cover.
When you are familiar with this adjustment procedure you can optimize the focus position of the Integration
Rod by first rotate the Integration Rod until you clearly see the sloped edges on the screen and then focus-
ing these edges as sharp ad possible. Then rotate the Integration Rod back until the projected light beam
matches the projected outline of the DMD’s. This way of focusing the Integration Rod has to be done quickly.
Otherwise, the sealing between the DMD’s and the prism will be damaged.
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10. Sealed Light Processor Assembly
10. SEALED LIGHT PROCESSOR ASSEMBLY

About this chapter
This chapter gives a brief introduction of the Sealed Light Processor assembly. Futhermore, this chapter includes the replacement
procedure of the whole Light Processor or sub assemblies e.g. Shutter, Light Sensor module and notch filter. The convergence
adjustment procedure is also included in this chapter. Note that the service information about the Integration Rod and the Liquid
Cooling Circuit are grouped in a separate chapters in this manual, see page 147 and page 177.
CAUTION: Never dismantle the housing of the Sealed Light Processor. Note that the housing is foreseen with
temper evidence labels.
Overview
• Introduction
• Diagnostics
• Removal of the Sealed Light Processor
• Installation of the Sealed Light Processor
• Adjusting the convergence
• Adjusting the Fold Mirror
• Adjusting the Light Pipe Zoom Lens
• Adjusting the Notch Filter
• Cleaning the Notch Filter
• Cleaning the Prism exit side
• Replacement of the Dowser (Shutter)
• Replacement of the Light Sensor Module
• Replacement of the Notch Filter
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10.1 Introduction
Sealed Light Processor & Light Pipe
The Light Processor and Light Pipe have three major parts, namely:
• The Light Processor. The prism of the Light Processor first splits up the homogeneous white light coming from the Light Pipe
into red, green and blue light. Then integrates the video information on the three DMD’s with the red green and blue light beams.
Next, the prism merges the three integrated light beams back in to one full color video image, which is projected via the lens
onto the screen.
• The Formatting Interface Board (FIB), which is the interface between the Pixel Mapping Processor (PMP) and the Formatting
boards of the DMD’s. The Formatting Interface Board is located inside the sealed housing of the Light Processor.
• The Light Pipe, which transforms the light emitted by the lamp into a homogeneous light beam and focuses this beam precisely
on the active surface of the DMD’s.
Image 10-1
Note that the Light Processor and Light Pipe assembly includes: Light Processor, Light Pipe, cooling circuit for the DMD’s and light
pipe entrance, Integration Rod, Formatter Interface Board (FIB) and motorized shutter (dowser).
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Parts
1
6 7
8
Image 10-2
1 Sealed compartment. Includes Light Processor (prism + DMD’s) and Formatter Interface Board (FIB).
2 Cooling block for the Integration Rod entrance.
3 Shutter assembly (Dowser).
4 Notch filter.
5 CLO assembly.
6 Light Pipe assembly. Includes Integration Rod.
7 Integration Rod assembly.
8 Adjustment handle of the Light Pipe zoom lens.
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10.2 Diagnostics
Troubleshooting of the Sealed Light Processor and Light Pipe
There are several reasons why removal or replacing of the Light Processor is required. Nevertheless, try to avoid unnecessary re-
moval of the Light Processor. The list below gives an overview of the most common problems which require removal or replacement
of the Light Processor. Check this list to ensure the problem is caused by the Light Processor.
• Artifacts in the projected image. These artifacts are also visible on the internal service patterns of the FIB or Formatter boards.
• A crack in the prism, which can result in convergence problems and may disables you to focus the projected image.
• Defect Peltier element, which causes a too high DMD temperature.
• Damaged Integration Rod, which causes permanent spots in the projected image.
• Unacceptable amount of dark, bright or flat state pixels on one or more DMDs.
• Blocked dowser (shutter). Dowser does not respond when pressing the “PAUSE” button.
• Leakage in liquid cooling circuit.
Check the projector log files for errors or warnings and look for a solution in the chapter "Trouble shooting
checklist", page 37.
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10.3 Removal of the Sealed Light Processor
To access the Sealed Light Processor you have to remove the left cover of the projector first.
CAUTION: Remove the lens before removing the Sealed Light Processor.
Necessary tools
• 3 mm Allen key.
• Flat screwdriver or a 10 mm nut driver.
How to remove the Sealed Light Processor from the projector?

1. Remove the lens and the left cover of the projector.
2. Release the two upper and the two lower hexagon socket screws (reference 1 & 2 image 10-3) which fasten the cross bar with
the projector base, as illustrated.
Image 10-3
3. Remove the cross bar.
Image 10-4
4. Disconnect the three wire units (reference 1, 2 & 3 image 10-5) of the dowser (shutter) from the lens distribution board.
Note: Former projector versions only have one wire unit (reference 1 image 10-5) for the dowser. Newer versions have three
wire units.
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Image 10-5
Newer version.
5. Disconnect the wire unit (reference 1 image 10-6) from the Light Sensor (CLO module) which is located at the left side of the
Light Pipe.
Image 10-6
6. Uncouple the cooling circuit from the Sealed Light Processor by unplugging the two valved fittings as illustrated. One valved
fitting is located on the sealed compartment and the other valved fitting is located at the base of the projector.
Tip: Sometimes a little cooling liquid will be spilled. Wrap a small cloth around the valved fitting while uncoupling to absorb
the spilled cooling liquid.
Image 10-7
7. Release the two retaining screws (reference 3 image 10-8) at the bottom of the Sealed Light Processor. Use for that a flat
screwdriver or a 10 mm nut driver.
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3
Image 10-8
8. Gently remove the Sealed Light Processor out of its compartment.
Image 10-9
CAUTION: Never open the sealed compartment of the Light Processor unit. Always send the Sealed Light
Processor as a whole back to factory for repair.
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10.4 Installation of the Sealed Light Processor
WARNING: Make sure that there is no lens mounted in the Lens Holder while installing the Sealed Light Pro-
cessor.
Necessary tools
• Flat screwdriver or a 10 mm nut driver.
How to install the Sealed Light Processor?

1. Firmly hold the Sealed Light Processor and gently slide the Sealed Light Processor into its compartment.
Note: The bottom of the Sealed Light Processor is equipped with guides and positioning pins.
Image 10-10
2. Fasten the two retaining screws (reference 3 image 10-11) at the bottom of the Sealed Light Processor as illustrated. Use for
that a flat screwdriver or a 10 mm nut driver.
3
Image 10-11
3. Couple up the cooling circuit from the Sealed Light Processor with the cooling circuit of the projector.
Caution: To avoid damage to the connector seal, always depress the connector tab of the female valved fitting prior to inserting
the male valved fitting.
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Image 10-12
4. Reconnect the wire unit of the dowser assembly (shutter) with the distribution board located at the side of the Lens Holder. Make
sure to connect the three plugs of the wire unit as follows:
- Plug with four pins into J6 (reference 1 image 10-13).
- Plug with two pins and yellow wire into J61 (reference 2 image 10-13).
- Plug with two pins and orange wire into J62 (reference 3 image 10-13).
Note: Former projector versions only have one wire unit ((reference 1 image 10-13) for the dowser. Newer versions have three
wire units.
Image 10-13
Newer version.
5. Reconnect the wire (reference 4 image 10-14) unit of the Light Sensor (CLO) which is located at the left side of the Light Pipe.
Image 10-14
6. Install the cross bar as illustrated.
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Image 10-15
7. Fasten the cross bar with the projector base using two screws at the top and two screws at the bottom of the cross bar. Use for
that a 3 mm Allen wrench.
Image 10-16
8. Reinstall the projector side cover.
It is recommended, after each reinstallation of the Sealed Light Processor, to check the pressure indicated on
the internal manometer of the liquid cooling circuit. This manometer is located inside the compartment of the
Lamp House. This pressure should be between 0,5 and 1 bar. Take the necessary corrective action in case
the pressure is out of range.
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10.5 Adjusting the convergence

Definitions-Abbreviations
• X: Horizontal direction on the screen, with origin in the centre of the screen and + to the right
• Y: Vertical direction on the screen, with origin in the centre of the screen and + to the top
• Z rotation: Tilting of the X and Y axes in their plane: + is clockwise rotation
• [1] ; [2] ; [3] ; [4] ; [5] ; [6] : these are the 6 adjustments available as they appear on the standard convergence adjustment
screen.
Convergence Test pattern

For the manual correction of the DMD convergence, a typical convergence test pattern is generated.
Image 10-17
Convergence test pattern
Work Instructions:
• GREEN and RED DMD’s are to be adjusted with reference to the BLUE dmd.
• Each adjustment allows for approximately 10 pixels maximum displacement to either side of the nominal BLUE position
• Rotation is limited to approximately +/- 5pixels on the left screen flank and +/- 5 pixels on the right screen flank
• One turn of an adjustment screw relates to an approx. 5-pixel displacement on the screen.
Take Care:
• In rear cases it can happen that the nominal position falls in the dead zone where the mechanism changes from a pushing to
a pulling function. The dead zone is due to inherent tolerances within the mechanism. Approximately 2 turns are required to
get out of the dead zone. If it so happens that the nominal position of an adjustment falls within this dead zone, it is preferable
to continue screwing through the dead zone for another 2 turns. Then return to the required nominal position. The dead zone
should now be displaced away from the required end position. The DMD is now securely held in the nominal position.
• Each adjustment is limited to approximately 10 pixels displacement. DO NOT try to force the adjustment beyond this point. The
system has an end of travel in both directions, but with excessive force one could cause damage.
Converging the RED pattern onto the BLUE pattern

Start with aligning the RED DMD in the vertical directions [1] and [2] and then proceed with the horizontal direction [3]
1. To translate RED vertically in the Y + direction, turn both [1] and [2] clockwise. Turn screws in equal increments.
2. To translate RED vertically in the Y - direction, turn both [1] and [2] anti-clockwise. Turn screws in equal increments.
3. To translate RED horizontally in the X + direction, turn [3] clockwise.
4. To translate RED horizontally in the X - direction, turn [3] anti-clockwise.
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5. For clockwise rotations of RED, turning [1] anti-clockwise would generally suffice. If much rotation is required, [2] may also be
turned in the opposite direction. Slight corrections to Y may be required after rotation.
6. For anti-clockwise rotations of RED, turning [1] clockwise would generally suffice. If much rotation is required, [2] may also be
turned in the opposite direction. Slight corrections to Y may be required after rotation.
1 2 3
Red
2 1
Image 10-18
Converging the GREEN pattern onto the BLUE pattern

Next , align the GREEN DMD in the vertical directions [4] and [5] and then proceed with the horizontal direction [6].
1. To translate GREEN vertically in the Y + direction, turn both [4] and [5] clockwise. Turn screws in equal increments.
2. To translate GREEN vertically in the Y - direction, turn both [4] and [5] anti-clockwise. Turn screws in equal increments.
3. For clockwise rotations of GREEN, turning [5] anti-clockwise would generally suffice. If much rotation is required, [4] may also
be turned in the opposite direction. Slight corrections to Y may be required after rotation.
4. For anti-clockwise rotations of GREEN, turning [5] clockwise would generally suffice. If much rotation is required, [4] may also
be turned in the opposite direction. Slight corrections to Y may be required after rotation.
5. To translate GREEN horizontally in the X + direction, turn [6] clockwise.
6. To translate GREEN horizontally in the X - direction, turn [6] anti-clockwise.
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6
5
Green
1
4 5
4 5
Image 10-19
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10.6 Adjusting the Fold Mirror

Purpose of the Fold Mirror
The Fold Mirror is folding up the light path of the projector to make the projector more compact. The Fold Mirror is located at the
left side of the Light Pipe and reflects the light, which entrance the Light Pipe via the Integration Rod, upon the prism of the Sealed
Light Processor. The position of the light spot upon the DMD’s can be adjusted with the Fold Mirror.
CAUTION: Normally the Fold Mirror should never be readjusted in the field. In case a readjustment is required
follow the instructions in this chapter precisely. Only qualified technicians who have experience with adjust-
ing the Fold Mirror may adjust the Fold Mirror. A misaligned Fold Mirror may cause irreversible damage to
other parts of the projector!
To access all three adjustment screws of the Fold Mirror the left side cover has to be removed from the pro-
jector and the Fold Mirror cover plate has be removed from the Light Pipe. This procedure assumes that the
left side cover is already removed from the projector.
In most cases the Fold Mirror can be correctly aligned by turning the upper two adjustment screws of the Fold
Mirror. These upper two screws can be accessed with a nut driver through the holes of the Fold Mirror cover.
So, the removal of the Fold Mirror cover is unnecessary.
Necessary tools
5,5 mm nut driver.
How to adjust the Fold Mirror?

1. Disconnect the wire unit (reference 4 image 10-20) from the Light Sensor Module.
Image 10-20
2. Remove the Fold Mirror cover and the Light Sensor Module as a whole from the Light Pipe as illustrated. Do this by loosening
the four screws (reference 1 image 10-21), which fasten the cover plate, a few turns. Use a 5,5 mm nut driver.
1
Image 10-21
3. Start up de projector and display a white test pattern with maximum dimming.
Caution: Projecting a misaligned light spot for more then 10 seconds may cause irreversible damage to the Light Processor.
Therefor, it is important to maximum dim the light output and adjust the light spot as quickly as possible.
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4. Turn the adjustment screws A, B or C in or out until the light spot (5) matches with the outline of the DMDs (4). Use for that a 5,5
mm open end wrench. The illustration below shows the movements of the light spot (5) upon the screen (6) for each adjustment
screw.
-
B
+ B - +
+
+ - -
A
A C -
- +
+
4
C 5
6
Image 10-22
5. Reinstall the cover of the Fold Mirror.

6. Reconnect the Light Sensor Module.
7. Place a light meter in the center of the screen and calibrate the Light Sensor Module. For detailed instructions see user guide of
the Communicator software.
Turn the three adjustment screws of the Fold Mirror equally counterclockwise to achieve a higher contrast
of the projected image. Then, readjust the adjustment screws individual until the light spot matches with the
outline of the DMDs. Take into account that a higher contrast is at the expense of brightness.
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10.7 Adjusting the Light Pipe Zoom Lens

Purpose of the Light Pipe Zoom Lens
The Light Pipe Zoom Lens is located inside the Light Pipe between the Integration Rod and the Fold Mirror. The light spot upon the
DMDs can be reduced or enlarged with the Light Pipe Zoom Lens to fit with the outline of the DMDs.
The left cover has to be removed from the projector to adjust the Light Pipe Zoom Lens. This procedure
assumes that the left cover is already removed from the projector.
Necessary tools
2,5 mm Allen wrench.
How to adjust the Light Pipe Zoom Lens?

1. Release the hexagon socket head cap screw (reference 1 of image 10-23). Use a 2,5 mm Allen wrench.
2. Start up de projector and display a white test pattern with maximum dimming.
Caution: Projecting a light spot which is larger then the DMD outline for more then 10 seconds may cause irreversible damage
to the Sealed Light Processor. Therefor, it is important to maximum dim the light output and adjust the light spot as
quickly as possible.
3. Adjust the position of the Light Pipe Zoom Lens by moving the hexagon socket head cap screw (reference 1) as illustrated until
the size of the light spot (reference 2) matches the projected outline (reference 3) of the DMDs upon the screen (reference 4).
3
2
1 4
3
2
Image 10-23
4. Fasten the hexagon socket head cap screw. User a 2,5 mm Allen wrench.
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10.8 Adjusting the Notch Filter

Purpose of the Notch Filter
The Notch Filter is a coated glass plate located at the end of the Light Pipe assembly. The Notch Filter applies some small color
corrections of the light coming out of the Light Pipe, which is emitted by the xenon lamp of the projector. This is done to achieve an
optimal color calibration of the native colors. The Notch Filter can slightly turn, with respect to the light path, which allows a small
adjustment of the native colors. Note that, next to the pure optical color calibration by the Notch Filter there is also a software color
calibration.
0.9
520
0.8 540
0.7
560
0.6
500
0.5 580
y
0.4 600
620
0.3
490 700
0.2
480
0.1
470
460 380
0.0
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
x
Image 10-24
Color triangle.
To access the Notch Filter the left side cover has to be removed from the projector. This procedure assumes
that the left side cover is already removed from the projector.
Necessary tools
• Colorimeter (e.g. CS-200 chroma meter from Konica Minolta or the PR-650 SpectraScan® from Photo Research)
How to adjust the Notch Filter?

1. Release the lock nut (reference 1) of the Notch Filter. Use for that a 6 mm open-end wrench.
Image 10-25
2. Start up the projector and display an uncorrected red test pattern.

Tip: See user guide of the Communicator software for detail instructions about color calibration
3. Measure the X and Y values of the projected red test pattern. Use for that a colorimeter. Make sure that the red test pattern is
uncorrected.
4. Slightly rotate the thumb screw (reference 2 of image 10-25) of the Notch Filter until the measured X and Y values are within the
required specs.
Note: The adjustment range of the Notch Filter is limited. For most projectors the mid position of the thumbscrew gives also
the most optimal result.
5. Fasten the lock nut, reference 1 of image 10-25, to secure the position of the Notch Filter. Use for that a 6 mm open-end wrench.
Make sure that the position of the Notch Filter remains unchanged while fastening the lock nut.
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10.9 Cleaning the Notch Filter

When cleaning the Notch Filter?
Only clean the Notch Filter in case it is really necessary. This means in case dust is clearly visible upon the surface of the Notch
Filter.
This procedure requires that the Notch Filter is removed from the Light Pipe.


Necessary tools
How to clean the Notch Filter?

1. Wipe off the dust of both sides of the Notch Filter. Use for that a clean Torayse cloth.
2. Is all dust removed from the Notch Filter?
If no, wipe off the dust of the Notch Filter with a clean cotton cloth and demineralized water.
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10.10 Cleaning the Prism exit side

When cleaning the Prism exit side?
Only clean the Prism exit in case it is really necessary. This means in case dust is clearly visible upon the surface of the Prism exit.
This procedure requires that the lens is removed from the projector.


Necessary tools
How to clean the clean the Prism exit side?

1. Wipe off the dust of the Prism exit. Use for that a clean Torayse cloth.
2. Is all dust removed from the Prism exit?
If no, wipe off the dust of the Prism exit with a clean cotton cloth and demineralized water.
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10.11 Replacement of the Dowser (Shutter)

Dowser
The Dowser (Shutter) of the projector is mounted upon the Sealed Light Processor just above the light output path of the Prism.
The Dowser assembly has an “open” and a “close” state. In the “close” state the Dowser blade shuts off the light beam between the
Light Processor (DMD’s) and lens. In the “open” state, the Dowser blade is retracted from the light path.
The lens and the Sealed Light Processor have to be removed from the projector before replacing the Dowser.
This procedure assumes that the Sealed Light Processor is already removed from the projector.
Necessary tools
TX10 Torx screwdriver.
Necessary parts
• Two Torx screw M3 x 8.
• Dowser assembly.
How to replace the Dowser of the Sealed Light Processor?

1. Prepare the Sealed Light Processor by removing the damaged dowser.
2. Make sure that the mounting holes M1 and M2 (image 10-26) on the Sealed Light Processor are free.
M2
M1
Image 10-26
3. Fasten the new Dowser with two Torx screws (A) upon the Sealed Light Processor as illustrated. Use for that a TX10 Torx
screwdriver.
Image 10-27
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10.12 Replacement of the Light Sensor Module

Purpose of the Light Sensor in the Light Pipe
To obtain a Constant Light Output (CLO) from the projector a Light Sensor is mounted just behind the Fold Mirror. On a regular
base the controller of the projector read the measured values of this light sensor and, if required, sends corrective information to the
Lamp Power Supply (LPS).
The left cover has to be removed from the projector to replace the Light Sensor Module. This procedure as-
sumes that the left cover is already removed from the projector.
Necessary tools
• TX10 Torx screw driver.
• Light meter.
How to replace the Light Sensor Module of the Light Processor?

1. Disconnect the wire unit (reference 4 image 10-28) from the Light Sensor Module.
Image 10-28
2. Remove the Light Sensor Module by releasing the two Torx screws (reference 1 image 10-29). Use a TX10 Torx screw driver.
Note: The plastic spacer (reference 2 image 10-29) underneath the Light Sensor Module comes loose with the module.
Image 10-29
3. Install a new Light Sensor Module. Make sure to reuse the plastic spacer (reference 2 image 10-29). Use a TX20 Torx screw
driver to fasten both screws (reference 1 image 10-29).
4. Reconnect the wire unit (reference 4 image 10-28) with Light Sensor Module.
5. Place a light meter in the center of the screen and calibrate the Light Sensor Module. For detailed instructions see user guide of
the Communicator software.
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10.13 Replacement of the Notch Filter
To access the Notch Filter the left side cover has to be removed from the projector. This procedure assumes
that the left side cover is already removed from the projector.
Necessary tools
2,5 mm Allen wrench.
How to replace the Notch Filter?

1. Remove the Notch Filter from the Light Pipe by releasing the four hexagon head cap screws (reference 1 image 10-30) as illus-
trated. Use for that a 2,5 mm Allen wrench.
Image 10-30
2. Insert a new Notch Filter. Make sure that the positioning hole (reference 2 image 10-30) of the Notch Filter fits upon its positioning
pin inside the Light Pipe.
Caution: Do not touch the Notch Filter with bare fingers. To clean the Notch Filter see procedure "Cleaning the Notch Filter",
page 172.
3. Fasten the Notch Filter with four hexagon head cap screws (reference 1). Use for that a 2,5 mm Allen wrench.
4. Readjust the Notch Filter. See procedure "Adjusting the Notch Filter", page 171.
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11. Liquid Cooling Circuit
11. LIQUID COOLING CIRCUIT

About this chapter
This chapter describes how to diagnoses and maintain the Liquid Cooling Circuit of the projector.
WARNING: All actions performed on the Liquid Cooling Circuit should occur in normal ambient conditions
(approximately 25 °C). The projector should have sufficiently cooled down (minimum 2 hours).
WARNING: Do not change the air pressure of a calibrated Liquid Cooling Circuit (see marking on pressure
vessel), unless stated explicitly in the servicing procedure.
WARNING: Hazardous product: Blue antifreeze diluted 1,2 ethanediol (1/3 ethanediol – 2/3 Demi water).
Not for household use. Keep out of reach of children. Harmful by oral intake. Avoid exposure to pregnant
women. Avoid contact with eyes, skin and clothing. Avoid inhalation of the noxious fumes.
Handling the cooling liquid

• Avoid contact of the liquid with Eyes, Skin and Clothing.
• Avoid inhaling noxious fumes.
• Conserve the product in the original package and in a well ventilated room.
Personal protection rules

• Handle the cooling liquid in a well ventilated room.
• Under no circumstances eat, drink and smoke while handling the liquid.
• Wear gloves (Butylrubber, PVC....) and Goggles.
• Wear suitable protection clothing.
Overview
• Introduction
• Diagnostics
• Pressure verification of the Liquid Cooling Circuit
• Excluding the Sealed Light Processor
• Draining the Liquid Cooling Circuit
• Filling the Liquid Cooling Circuit
• Refreshing the Liquid Cooling Circuit
• Expelling air from the Liquid Cooling Circuit
• Pressurizing the Liquid Cooling Circuit
• Calibrating the Liquid Cooling Circuit
• Removal of the Pump
• Installing the Pump
• Cleaning the Pump
• Replacement of the Pump motor and rotor
• Replacement of the complete Pump
• Replacement of the Heat Exchanger
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11.1 Introduction
Functionality
Much heat has to be extracted from the DMD’s and from the Light Pipe entrance during operation of the projector. The Liquid Cooling
Circuit takes care of this. The Liquid Cooling Circuit is a closed loop of flexible tubing comprising of a pump, three cooling blocks for
the DMD’s, a cooling block for the Light Pipe entrance, a heat exchanger, a pressure vessel and a manometer. The cooling liquid
inside the circuit absorbs the heat of the cooling blocks. Via the pump, the heated-up liquid is transported to the heat exchanger,
which in turn cools down the liquid.
The pressure vessel in the circuit makes it possible to put a small pressure on the cooling liquid. The required pressure exerted via
the pressure vessel serves to prevent cavitation and hence ensures the good working condition of the pump. Note that the pressure
doesn’t influence the cooling capacity of the system.
Parts of the Liquid Cooling Circuit
1 2 3 4 5 6 7
8 9 10 11
Image 11-1
1 Sealed Light Processor.
2 Outlet of the cooling circuit.
3 Pressure vessel.
4 Transparent tube for visual check.
5 Manometer.
6 Fan assembly.
7 Heat exchanger.
8 Cooling block Light Pipe Entrance.
9 Valve.
10 Inlet of the cooling circuit.
11 Cooler pump.
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Tools used in the liquid cooling servicing procedures
1 2 3 4 5 6 7
cm cm cm
60 60 60
60
cm
1L
Image 11-2
1 Syringe with plastic tube (60 cm) and male valved fitting.
2 Two plastic tubes of 60 cm with male valved fitting.
3 60 cm plastic tube with female valved fitting.
4 Female/female valved fitting adaptor.
5 Bottle with 1 liter cooling liquid.
6 Empty bottle with a volume of 1 liter.
7 Air pump with Shrader type air hose fitting.
CAUTION: To avoid damage to the connector seal, always depress the connector tab of the female valved
fitting prior to inserting the male valved fitting.
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11.2 Diagnostics
General
Over extended periods there may be small losses of pressure in the liquid cooling system of the projector. It is therefor recommended
to check the pressure at regular intervals. In case the pressure drops below 0,5 bar it is recommended to restore the pressure of
the liquid cooling system.
CAUTION: In case of a rapid loss in pressure check the liquid cooling circuit for leakage. Solve the problem
before starting up the projector.
Troubleshooting cooling loop

• Any significant or rapid drop in pressure indicates a leakage of liquid. If this be the case, verify whether the circuit shows any
visible sign of liquid leakage.
• As critical components rely on this liquid cooling, it is essential that any leakage is detected timely.
• Periodic checking of the liquid cooling pressure is essential to guarantee overall good performance of the projector and the
pump.
• The factory pressure preset is approximately 1 bar in the ’Projector Off’ status at a room temperature of 25 °C. This may drop
slightly during operation.
Too high ambient temperature

An Error or warning message “Ambient temp high” is displayed on the Communicator Touch Panel. See manual of the Communicator
for accessing error messages.
Possible cause Solution

Ambient temperature of the projector is too high. Measure the ambient temperature nearby the projector. In
case the measured temperature is higher than 35°C (95°F)
take the necessary measurements to ensure that the ambient
temperature is below 35°C (95°F).
Blocked filter at the front side and the left side of the projector Clean the blocked filter.
One of the DMD’s is too high in temperature

An Error or warning message “DMD temp high” is displayed on the Communicator Touch Panel. See manual of the Communicator

Malfunction Peltier element of the involved DMD. Only one No custom serviceable parts inside the Sealed Light Processor.
DMD is too high in temperature while the other two DMD’s Take contact with a Barco service center to return the Sealed
have a normal and almost equal temperature. Light Processor.
The wire units of two Peltier elements or there respective No custom serviceable parts inside the Sealed Light Processor.
temperature sensors (NTC’s) have been swapped. While the Take contact with a Barco service center to return the Sealed
temperature of one DMD is too high, the other will most likely Light Processor.
be to low.
Poor assembly of DMD or Peltier + cooler block. Take contact with a Barco service center to return the Sealed
Light Processor.
All DMD’s are too high in temperature

An Error or warning message “DMD temp high” is displayed on the Communicator Touch Panel. See manual of the Communicator

The Liquid Cooling Circuit of the Sealed Light Processor is Check of the cooling circuit of the Sealed Light Processor is
mistakenly excluded from the main liquid cooling circuit. connected with the pump and heat exchanger.
None of the wire units of the Peltier elements or there Take contact with a Barco service center to return the Sealed
respective temperature sensors (NTC’s) are connected. Light Processor.
Blocked filter of the heat exchanger. Clean the blocked filter.
No flow of the cooling liquid

An Error message “water - flow not ok” is displayed on the Communicator Touch Panel. See manual of the Communicator for
accessing error messages.
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Interruption of the Liquid Cooling Circuit. Check if the loop of the Liquid Cooling Circuit is closed.
The liquid cooling circuit of the Sealed Light Processor is Check of the cooling circuit of the Sealed Light Processor is
mistakenly excluded from the main liquid cooling circuit. Most connected with the pump and heat exchanger.
likely the DMD temperatures are too high.
The maintenance valve of the cooling circuit is open causing a Close the valve of the cooling circuit.
bypass of the cooling liquid.
No or insufficient liquid inside the cooling circuit. The pump is Fill the cooling circuit with liquid and expel all air. Pressurize
sucking air and sounds noisier then normal. the circuit.
The pump of the water cooling is electrical disconnected. Check if the wire unit of the pump is properly connected.
Malfunction pump of the cooling circuit. You don’t feel any 1. Check the electrical resistance of the pump winding.
vibrations when touching the pump after activating the “Refill Replace the pump if infinite.
mode” via the Communicator software.
2. Drain the liquid cooling circuit, open the pump and check
if the pump rotor is not blocked. If so, remove the rotor
and clean the bearings of the pump.
Defect pump. When the projector is running, you don’t feel any Drain the Liquid Cooling Circuit, replace the pump, fill and
vibrations when touching the pump. pressurize the Liquid Cooling Circuit.
Tip: It’s not necessary to drain the cooling circuit of the Sealed
Light Processor. Bypass this part of the cooling circuit.
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11.3 Pressure verification of the Liquid Cooling Circuit
CAUTION: The pressure of the Liquid Cooling Circuit should be checked regularly. This pressure, indicated
on the internal manometer, should be between 0,5 and 1 bar. If not, corrective action should be taken by
qualified technical service personnel.
How to check the pressure of the Liquid Cooling Circuit?

2. Open the door of the lamp compartment.
3. Check the pressure indicated on the internal manometer of the Liquid Cooling Circuit. The manometer is located at the upper
left side of the lamp compartment.
4. This pressure should be between 0,5 and 1 bar. If the pressure, indicated on the manometer, is out of range take necessary
corrective action.
Image 11-3
5. Close and lock the door of the projector.
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11.4 Excluding the Sealed Light Processor

When excluding the Liquid Cooling Circuit of the Sealed Light Processor?
When service actions are required to the pump, heat exchanger, or other parts of the Liquid Cooling Circuit which are not mounted
inside the Sealed Light Processor then the cooling circuit of the Sealed Light Processor can be excluded from the cooling circuit of
the projector. Excluding the Sealed Light Processor will minimize the risque on air bubbles in the cooling system.
The service procedures for the liquid cooling system such as draining and filling are described for the whole cooling circuit. Never-
theless, you can use the same procedures and exclude the Sealed Light Processor if applicable.
CAUTION: Do not exclude the Liquid Cooling Circuit of the Sealed Light Processor when expelling air from,
pressurizing, or calibrating the liquid cooling circuit.
How to exclude the Liquid Cooling Circuit of the Sealed Light Processor?
1. Interrupt the Liquid Cooling Circuit by uncoupling the valved fitting below the Sealed Light Processor. The tube which you are
uncoupling comes from the cooling block on the Light Pipe entrance and goes to the heat exchanger.
2. Interrupt the Liquid Cooling Circuit by uncoupling the valved fitting at the Sealed Light Processor unit. The tube which you are
uncoupling comes from the pump exit.
Image 11-4
3. Couple the tube that comes from the pump exit with he valved fitting which goes to the heat exchanger.
Image 11-5
Left: Sealed Light Processor included. Right: Sealed Light Processor excluded.
4. You may connect the tube which comes from the cooling block on the Light Pipe entrance with the unused valved fitting of the
Sealed Light Processor. This to prevent that the tube is hanging loose.
CAUTION: Do not forget to include the cooling circuit of the Sealed Light Processor afterwards.
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11.5 Draining the Liquid Cooling Circuit
In case of part replacement, consider only draining that part of the cooling circuit which contains the defec-
tive part. E.g. in case of pump replacement; it is preferred to bypass the cooling circuit of the Sealed Light
Processor. This is to exclude the Sealed Light Processor from the problem.
Necessary tools
• 60 cm of plastic tube with male valved fitting.
• Syringe connected with short tube with male valved fitting.
• Empty bottle with a volume of 1 liter.
• Cloths.
How to drain the Liquid Cooling Circuit ?

1. Insert a plastic tube, which contains a male valved fitting, into an empty bottle and then couple the male valved fitting withe the
outlet (upper female valved fitting) of the Liquid Cooling Circuit.
Note: Circuit is pressurized, so first insert tube end into empty bottle.
OUT
Image 11-6
2. Close the valve.
Image 11-7
3. Fill the syringe with air. Press in the valve of the male fitting when extracting air.
Image 11-8
184 R59770374 DP-3000 16/08/2010

4. Couple the air filled syringe to the inlet of the cooling circuit and force air into the circuit via the syringe. Liquid will be expelled
from the circuit exit side into the empty bottle.
IN
OUT
Image 11-9
5. Disconnect the syringe from the cooling circuit and repeat from 3 until all cooling liquid is drained.
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11.6 Filling the Liquid Cooling Circuit
This procedure can only be used to fill an empty (drained) cooling circuit.
Necessary tools
• 60 cm of plastic tube with male valved fitting.
• 60 cm of plastic tube with female valved fitting.
• Bottle with cooling liquid.
• Empty bottle with a volume of 1 liter.
• Cloths.
How to fill the Liquid Cooling Circuit ?

1. Check if the valve is closed. If not, close the valve.
Image 11-10
2. Couple a plastic tube, which contains a male valved fitting, to the outlet of the cooling circuit and lead the tube end to an empty
bottle.
OUT
Image 11-11
3. Fill the syringe with cooling liquid as follows:
186 R59770374 DP-3000 16/08/2010

a) Couple the female (F) fitting of a plastic tube to male (M) fitting of the syringe and emerge the tube end. Make sure that the
piston of the syringe is completely pressed in.
b) Extract cooling liquid into the syringe by pulling out the piston.
c) Turn the syringe upside down, so that the air inside the syringe is located at the outlet.
d) Push the piston in until all air bubbles inside the syringe and tubes are expelled. Ensure that the tube end in the bottle remains
emerged.
e) Pull out the piston to fill the tubes and syringe completely with cooling liquid.
f) Disconnect the filled syringe from the tube.
a b c d e f
M
Image 11-12
4. Couple the filled syringe to the inlet of the cooling circuit and press the cooling liquid inside the circuit.
Caution: Position the empty bottle above the liquid circuit (on top of projector).
OUT
a
b
IN
Image 11-13
5. Disconnect the syringe from the cooling circuit and repeat from 3 until cooling liquid comes out the outlet of the cooling circuit.
R59770374 DP-3000 16/08/2010 187

6. Proceed with expelling the air from the Liquid Cooling Circuit. See procedure "Expelling air from the Liquid Cooling Circuit", page
191.
Tip: You can use the bottle with the remaining fresh cooling liquid and the same tubes for the expelling procedure.
7. Pressurize the Liquid Cooling Circuit. See procedure "Pressurizing the Liquid Cooling Circuit", page 193.
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11.7 Refreshing the Liquid Cooling Circuit
Over time the cooling liquid may show deterioration and hence less effective cooling characteristics. To main-
tain sound cooling properties, we advise ANNUAL replacement of the cooling liquid.
Necessary tools
• 2 x 60 cm of plastic tube with male valved fitting.
• Syringe equipped with male valved fitting.
• Female/female tube adapter (short tube with female valved fitting at both sides).
• Bottle with 1 liter cooling liquid.
• Empty bottle with a volume of one liter.
• Cloths.
How to refresh the Liquid Cooling Circuit ?

1. Insert a plastic tube, which contains a male valved fitting, into an empty bottle and then couple the male valved fitting withe the
outlet (upper female valved fitting) of the Liquid Cooling Circuit.
Note: Circuit is pressurized, so first insert tube end into empty bottle.
OUT
Image 11-14
2. Close the valve.
Image 11-15
3. Fill a plastic tube, which contains a male fitting, with cooling liquid as follows:
a) Connect a tube, which contains a male (M) fitting, to the male (M) fitting of the syringe using a female/female (F) adapter.
b) Emerge the tube end and make sure that the piston of the syringe is completely pressed in.
c) Extract cooling liquid into the syringe by pulling out the piston.
d) Disconnect the filled tube from the syringe. Make sure that the tube remains immersed.
R59770374 DP-3000 16/08/2010 189

a M
b c d
F
F
Image 11-16
Caution: It’s important that there is no air inside the tube. The pump is not self priming and hence is only capable of sucking
through small volumes of air.
4. Push the male valved fitting of the filled tube into the inlet of the cooling circuit. Make sure that the inlet of the filled tube remains
immersed.
IN OUT
Image 11-17
5. Switch on the projector. After projector boot-up procedure, the internal pump will automatically start sucking-up the fresh liquid
Note: Make sure that the end of the plastic tube remains immersed in the bottle with fresh cooling liquid.
6. Switch off the projector after 2/3 of the fresh cooling liquid is sucked up into the circuit.
7. Proceed with expelling the air from the Liquid Cooling Circuit. See procedure "Expelling air from the Liquid Cooling Circuit", page
191.
Tip: You can use the bottle with the remaining fresh cooling liquid and the same tubes for the expelling procedure.
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11.8 Expelling air from the Liquid Cooling Circuit

Necessary tools
• 2 x 60 cm of plastic tube with male valved fitting.
• Bottle with cooling liquid (minimum 1/3 liter).
• Syringe equipped with male valved fitting.
• Female/female tube adapter (short tube with female valved fittings at both sides).
• Cloths.
How to expel the air from the Liquid Cooling Circuit?

1. Close the valve.
Image 11-18
2. Fill a plastic tube, which contains a male fitting, with cooling liquid as follows:
a) Connect a tube, which contains a male (M) fitting, to the male (M) fitting of the syringe using a female/female (F) tube adapter.
b) Emerge the tube end and make sure that the piston of the syringe is completely pressed in.
c) Extract cooling liquid into the syringe by pulling out the piston.
d) Disconnect the filled tube from the syringe. Make sure that the tube remains immersed.
a M
b c d
F
F
Image 11-19
Caution: It’s important that there is no air inside the tube. The pump is not self priming and hence is only capable of sucking
through small volumes of air.
3. Push the male valved fitting of the filled tube into the inlet of the cooling circuit. Make sure that the inlet of the filled tube remains
immersed.
4. Couple a second plastic tube to the outlet of the cooling circuit and immerge the tube end without fitting in the same bottle wherein
the first tube is immersed.
R59770374 DP-3000 16/08/2010 191

IN OUT
Image 11-20
5. Switch on the projector. After projector boot-up procedure, the internal pump will automatically start sucking-up the fresh liquid
while air bubbles are pressed out of the circuit.
Caution: Switch off the projector immediately in case the pump is sucking air (no circulation of liquid). Bypass the cooling
circuit of the Light Processor and inject cooling liquid into the main cooling circuit using a syringe. Ensure that you
don’t inject air bubbles.
Caution: Make sure that air bubbles coming out of the tube in the bottle doesn’t enter the other tube in the bottle.
6. Open the valve after 10 minutes and proceed 2 or 3 minutes with expelling air from the cooling circuit.
Tip: You may repeat this action a few times (open and close the valve) to make sure that all air bubbles are expelled.
Image 11-21
7. Switch off the projector after all air bubbles are expelled.
Tip: Air bubbles may no longer come out the exit of the tube in the bottle with cooling liquid.
8. Uncouple the two plastic tubes.
Note: Make sure that both ends of the plastic tubes in the bottle remains immersed until the plastic tubes are uncouple from
the liquid cooling circuit.
Tip: Sometimes a little cooling liquid will be spilled. Wrap a small cloth around the valved fitting while uncoupling to absorb
the spilled cooling liquid.
Check within 24 hours if the pressure remains 1 bar. If not, search for leakage.
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11.9 Pressurizing the Liquid Cooling Circuit
Before pressurizing the Liquid Cooling Circuit ensure that the circuit is filled with cooling liquid and that all
air bubbles are expelled.
CAUTION: This procedure is only valid in case the Liquid Cooling Circuit is calibrated. This means that the
pressure vessel was not subject to any modifications, i.e. releasing or increasing pressure via the valve of the
vessel. In case the pressure vessel was subject to modifications use the calibration procedure to pressurize
the Liquid Cooling Circuit.
WARNING: All actions performed on the Liquid Cooling Circuit should occur in normal ambient conditions
(approximately 25 °C). The projector should have sufficiently cooled down (minimum 2 hours).
Necessary tools
• Cloths.
How to pressurize the Liquid Cooling Circuit?

immersed.
a b c d e f
M
Image 11-22
2. Couple the syringe to the inlet of the cooling circuit and press the cooling liquid inside the circuit until the manometer indicates 1
bar pressure. Ensure that no air bubbles are injected into the circuit.
Caution: Maximum 1 bar of pressure is allowed on the Liquid Cooling Circuit. More pressure than 1 bar may damage the
circuit.
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1 bar
IN
Image 11-23
3. Disconnect the syringe from the inlet of the cooling circuit while pressurizing the cooling circuit to 1 bar by pushing the piston of
the syringe. When this is done properly, the manometer should indicate 1 bar after the syringe is disconnected.
4. Check if the cooling circuit was correctly calibrated. Proceed as follows:
a) Taking note of the liquid level in the syringe, while pressurizing the cooling circuit up to 1 bar (see previous step).
b) Release the plunger. As a result the pressure of the cooling circuit will drop from 1 to 0 bar and cooling liquid is automatically
expelled from the circuit into the syringe.
c) Check if the amount of expelled liquid is between 50 and 70 ml. If not, start the procedure "Calibrating the Liquid Cooling
Circuit", page 195.
d) Push the plunger of the syringe to reinject the expelled liquid back into the circuit. The pressure would hence return to 1 bar.
5. Disconnect the syringe from the cooling circuit. Make sure that the pressure remains 1 bar.
6. Check that the valve is open.
Image 11-24
Check within 24 hours whether the pressure has stabilized close to 1 bar. If not, search for leakage.
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11.10 Calibrating the Liquid Cooling Circuit
To check if the pressure vessel is correctly calibrated you may connect the syringe with the cooling circuit
and measure the amount of liquid that is automatically expelled. The pressure would have dropped from 1 to
0 bar. The expelled amount of cooling liquid should be between 50 and 70 ml. Make sure that there are no air
bubbles in the syringe while doing this. Reinject the expelled liquid back into the circuit. The pressure would
hence return to 1 bar.
A calibrated Liquid Cooling Circuit means that the ratio between the volume of cooling liquid in the circuit and
the volume of air in the pressure vessel is defined. This is achieved by first filling the vessel completely with
liquid consequently expelling air from the vessel. Secondly a predefined volume of cooling liquid is extracted
from the circuit. Finally the liquid cooling circuit has to be pressurized to 1 bar by pumping air into the vessel.
Make sure that all air is expelled from the Liquid Cooling Circuit and that the cooling circuit of the Sealed Light
Processor is included before starting the calibration procedure
Necessary tools
• Air pump.
• Cloths.
How to calibrate the Liquid Cooling Circuit?

1. Remove the valve cap of the pressure vessel and release the pressure.
Image 11-25

emerged.
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a b c d e f
M
Image 11-26
3. Fill the pressure vessel with liquid as follows:

a) Couple the syringe with the inlet of the cooling circuit. Keep holding the syringe vertical with the outlet downwards.
b) Increase the pressure by pushing in the piston of the syringe (maximum 1 bar indicated on the manometer).
c) While pressing, expel air from the pressure vessel.
d) Continue expelling air while pressurizing the circuit (up to 1 bar) until the valve of the vessel becomes hard to push in. This
indicates that the pressure vessel is completely filled with cooling liquid.
1 bar
IN
Image 11-27
4. Now that the pressure vessel is liquid filled you have to increase the pressure to 1 bar by pushing in the piston of the syringe.
Then immediately disconnected the syringe. When this is done properly, the manometer should indicate 1 bar.
5. Extract 75 ml back into the syringe by doing the following:
a) First empty the syringe but make sure that the tube of the syringe remains filled with cooling liquid.
b) Couple the syringe (plunger completely pressed in) with the inlet of the cooling circuit. Keep holding the syringe vertical with
the outlet downwards.
c) Release the plunger. Note that cooling liquid is pressed into syringe while the pressure drops.
d) Now fill the syringe by slowly pumping air into the vessel (connect air pump to valve).
e) Stop once 75 ml has been expelled.
f) Disconnect the syringe from the cooling circuit.
196 R59770374 DP-3000 16/08/2010

75 ml
Image 11-28
6. Pump up the air pressure to 1 bar (on manometer) and reinstall the valve cap tightly on the pressure vessel.
1 bar
Image 11-29
7. Mark the pressure vessel with the calibration date for future reference.
8. Check that the valve is open.
Image 11-30
The air hose fitting of the air pump must be of the Shrader valve type (A) to match with the pressure vessel,
so the Presta valve type (B) has to be removed. Futhermore, the pin (C) inside the Shrader valve has to be
removed as well.
A
B A B A C C
Check within 24 hours whether the pressure has stabilized close to 1 bar. If not, search for leakage.
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11.11 Removal of the Pump

Where is the Pump located?
The Pump (reference 2 image 11-31) of the Liquid Cooling System is located below the Cathode Fan (reference 1 image 11-31) and
between the compartment of the Lamp House and the Card Cage. To access the Pump, for service purposes, the Pump has to be
removed from its location prior to disconnecting the tubes from the Pump. For that the valve (reference 3 image 11-31) of the Liquid
Cooling Circuit and the Mains Input Filter (reference 4 image 11-31) has to be detached from the projector base first.
4
1
Image 11-31
Removing the Pump (and tubing) from its mounting location is required when the Pump needs cleaning or parts of the Pump or the
whole Pump has to be replaced. Prior to removing the Pump from its mounting location the Liquid Cooling Circuit has to be drained
first. The Pump must also be removed from its mounting location in case the Cathode Fan has to be replaced. In this case the
Liquid Cooling Circuit has not to be drained.
To access the Pump, both projector side covers (1), the Sealed Light Processor (2), the Lamp House (3), the
Mains Input Filter (4), the Input & Communication unit (5) and the Card Cage cover (6) has to be removed.
This procedures assumes that all these parts are already removed from the projector. See the corresponding
chapters of the involved parts for detailed removal instructions.
Necessary tools
• T20 Torx driver (short).
• Set of cutting pliers.
How to remove the Pump from its mounting location?

1. Loosen the socket of the INLET and OUTLET valves. Use a short T20 Torx driver the loosen the two screws (reference 1 im-
age 11-32) a few turns and then slide the socket away from its position.
Tip: Do not forget to drain the Liquid Cooling Circuit prior to removing the Pump in case the removal of the Pump is required
for maintenance of the Pump or other parts of the cooling circuit. The Liquid Cooling Circuit does not have to be drained
in case the removal of the Pump is required to replace the Cathode Fan.
Image 11-32
2. Release the Manifold of the Liquid Cooling Circuit by loosening the two hexagon socket head cap screws (reference 2 im-
age 11-33). Use a 3 mm Allen wrench.
198 R59770374 DP-3000 16/08/2010

Image 11-33
3. Cut the two cable ties (reference 1 image 11-34) which fasten the valve of the Liquid Cooling circuit and the cable tie (reference
2 image 11-34) which fasten the tube at the air outlet channel (reference 3 image 11-34) of the Cathode Fan.
3 2
Image 11-34
4. Loosen the two screws (reference 3 image 11-35) a few turns which secure the Pump as illustrated.
Image 11-35
5. Gently pull the Pump with tubing out of its compartment as illustrated.
Note: The Mains Input Filter must be removed prior to removing the Pump. Otherwise, the Mains Input Filter gets in the way
of the Pump’s tubing.
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Image 11-36
6. Disconnect the wire unit (reference 1 image 11-37) of the Pump.
Image 11-37
The Pump is now accessible for maintenance or for replacement.
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11.12 Installing the Pump

Necessary tools
• T20 Torx driver (short).
Necessary parts
3 cable ties (to fixate the tubing).
How to install the Pump of the Liquid Cooling Circuit?

1. Connect the wire unit (reference 1 image 11-38) of the Pump.
Image 11-38
2. Place the Pump in its mounting position as illustrated. Make sure that both feet of the Pump are equipped with a rubber absorber,
plain washer and fixation screw.
Image 11-39
3. Fasten the two screws (reference 3 image 11-40) of the Pump. Use a T20 Torx driver. The plain washers and fixation screws
must be captured by the provided slots in the metal mounting plate as illustrated.
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Image 11-40
4. Install the Manifold of the Liquid Cooling Circuit. Use a 3 mm Allen wrench to fasten the two screws (reference 2 image 11-41)
of the Manifold.
Image 11-41
5. Install the bracket of the INLET and OUTLET valves of the Liquid Cooling Circuit. Use a (short) T20 Torx driver to fasten the two
screws (reference 1 image 11-42) of the bracket.
Image 11-42
6. Secure the valve of the Liquid Cooling Circuit with two cable ties (reference 1 image 11-43) as illustrated.
7. Attach the tube (reference 2 image 11-43) of the Liquid Cooling Circuit with a cable tie to the assembly of the Cathode Fan
202 R59770374 DP-3000 16/08/2010

3 2
Image 11-43
After the Pump is installed, the Mains Input Filter, the Card Cage cover, the Input & Communication unit, the
Sealed Light Processor, and Lamp House has to be reinstalled. See the corresponding chapters of the in-
volved parts for detailed installation instructions.
Prior to inserting the Lamp House check if the Liquid Cooling Circuit is filled and pressurized. See procedure
"Filling the Liquid Cooling Circuit", page 186.
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11.13 Cleaning the Pump

What can happen?
Due to crystallization inside the Pump, the rotor can be jammed. This crystallization can be easily removed and the Pump can be
reused again. In most cases it will be sufficient to clean the Pump instead of replacing it with a new one. However, note that the
bearings of the Pump are subject to wear. Because of that the complete Pump (Pump house included) has to be replaced every 4
years.
This procedure assumes that the Liquid Cooling Circuit is drained (see "Draining the Liquid Cooling Circuit",
page 184) and that the Pump is removed from its mounting location (see "Removal of the Pump", page 198).
Necessary tools
• Soft cloths.
• Cotton swabs (Q-tips, ear buds).
How to clean the Pump?

1. Remove the four screws (reference 1 image 11-44) which fasten the Pump house to the Pump motor. Use a PH2 Phillips screw-
driver.
Tip: Lay a cloth underneath the Pump to absorb the remaining liquid in the pump house.
2. Slide the Pump house (reference 2 image 11-44) with hose backwards. Use a cloth to absorb the remaining cooling liquid. Now
the Pump rotor (reference 3 image 11-44) and the inner side of the Pump motor (reference 4 image 11-44) are visible.
1 2 3 4
Image 11-44
3. Take the Pump rotor between thumb and finger and slide it out of the Pump motor.
Image 11-45
4. Clean the Pump house, the Pump rotor and the Pump motor with a clean soft cloth. Use cotton swabs to clean the bearing inside
the Pump motor and Pump house.
Caution: The bearings of the Pump are fragile. Be careful when cleaning.
5. Reinsert the rotor and try to turn it smoothly. If not successful stop this procedure and replace the Pump completely. See "Re-
placement of the complete Pump", page 208.
6. Slide the Pump house with hose back on the Pump motor.
Caution: Make sure the sealing ring of the Pump motor is not damaged and is on its place.
7. Fasten the four screws (reference 1 image 11-44) of the Pump house crosswise using a PH2 Phillips screwdriver.
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Reinstall the Pump (see "Installing the Pump", page 201) and refill the Liquid Cooling Circuit (see "Filling
the Liquid Cooling Circuit", page 186) in case the pump is successfully cleaned. If cleaning is not possible,
replace the pump completely. See "Replacement of the complete Pump", page 208.
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11.14 Replacement of the Pump motor and rotor

When replacing the Pump motor and Pump rotor?
In case of an electrical failure of the Pump you can replace the Pump motor and Pump rotor without replacing the Pump house.
This way you do not have to cut the hoses from the Pump house which simplify the replacement procedure. However, note that the
bearings of the Pump are subject to wear. Because of that the complete Pump (Pump house included) has to be replaced every 4
years.
You have to order a complete Pump but you only have to use the Pump motor and Pump rotor.
Necessary tools
• Cloths.
• Cotton swab.
How to replace the Pump motor and Pump rotor?

1. Remove the four screws (reference 1 image 11-46) which fasten the Pump house to the Pump motor. Use a PH2 Phillips screw-
driver.
Tip: Lay a cloth underneath the Pump to absorb the remaining liquid in the pump house.
2. Slide the Pump house (reference 2 image 11-46) with hose backwards. Use a cloth to absorb the remaining cooling liquid. Now
the Pump rotor (reference 3 image 11-46) and the inner side of the Pump motor (reference 4 image 11-46) are visible.
1 2 3 4
Image 11-46
3. Replace the Pump motor and Pump rotor.
Image 11-47
4. Clean the Pump house with a clean soft cloth. Use cotton swabs to clean the bearing of the Pump house.
206 R59770374 DP-3000 16/08/2010

5. Slide the Pump house with hose on the new pump motor.
Caution: Make sure that the new Pump motor is provide with a new rotor and a new sealing ring.
6. Fasten the four screws (reference 1 image 11-46) of the Pump house crosswise using a PH2 Phillips screwdriver.
7. Reinstall the rubber vibration rings (feet, reference 3 image 11-48) of the old Pump motor upon the new Pump motor. Use a T20
Torx driver and a 7 mm open-end wrench.
Image 11-48
Reinstall the Pump (see "Installing the Pump", page 201) and refill the Liquid Cooling Circuit, then expel all air
from the circuit and finally pressurize the cooling circuit. See "Filling the Liquid Cooling Circuit", page 186.
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11.15 Replacement of the complete Pump
Necessary tools
• Cloths.
• Universal plier.
• Knife.
• T20 Torx driver.
How to replace the complete Pump of the Liquid Cooling Circuit?

1. Cut both hoses (reference 1 image 11-49) from the Pump house. Cut just next to the clip (reference 2 image 11-49) to have a
minimal loss in length of the hose.
Image 11-49
2. Remove both clips (reference 2 image 11-49) from the Pump house. Use an universal plier to push both clip tongs to each other
in order to open the clip.
Note: It is almost impossible to remove first the clip and then to pull off the hose.
3. Provide both hoses with a clip and push the hoses over their respective nipple of the Pump house. Note that the thick nipple is
the input side of the Pump house and has to be connected with the thick hose that comes from the pressure vessel. The small
nipple is the output side of the Pump house and has to be connected with the hose that comes from the Sealed Light Processor.
4. Slide the clip (reference 2 image 11-49) of both hoses over the connection. Use an universal plier to push both clip tongs to each
other in order to open the clip and to move the clip over the connection.
5. Reinstall the rubber vibration rings (feet, reference 3 image 11-50) of the old Pump upon the new Pump. Use a T20 Torx driver
and a 7 mm open-end wrench.
Image 11-50
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Reinstall the Pump (see "Installing the Pump", page 201) and refill the Liquid Cooling Circuit, then expel all air
from the circuit and finally pressurize the cooling circuit. See "Filling the Liquid Cooling Circuit", page 186.
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11.16 Replacement of the Heat Exchanger
To replace the Heat Exchanger, the projector front cover has to be removed and the Liquid Cooling Circuit
has to be drained. This procedure assumes that the projector front cover is already removed and the Liquid
Cooling Circuit drained. See procedure "Draining the Liquid Cooling Circuit", page 184.
Necessary tools
• Set of universal pliers.
• 3 mm Allen Wrench.
• Electric drill with a 4 mm bit.
Necessary parts
• 6 aluminium blind rivets (D=3,2 mm & L=7,4 mm)
• Cable tie.
How to replace the Heat Exchanger of the Liquid Cooling Circuit?

1. Release the temperature sensor (reference 1 image 11-51) by cutting the cable tie.
2. Disconnect the wires units (reference 2 image 11-51) from the four fans and guide all wire units through the cable gland away
from the Heat Exchanger assembly.
Image 11-51
3. Release the Heat Exchanger assembly from the projector by loosening the six hexagon socket head cap screws (reference 3).
Three at the top and two at the bottom of the assembly. Use a 3 mm Allen wrench.
Note: The Heat Exchanger assembly remains attached to the projector with the tubes of the Liquid Cooling Circuit.
Image 11-52
4. Remove the tubes (reference 4 & 5) from the Heat Exchanger.
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5
4
Image 11-53
5. Separate the Heat Exchanger from the fan assembly by drilling out the six blind rivets (reference 6 & 7) which fasten the Heat
Exchanger. Use a 4 mm bit.
Image 11-54
6. Install a new Heat Exchanger upon the fan assembly using six blind rivets (D=3,2 mm & L=7,4 mm).
7. Reconnect the tubes (reference 4 & 5 image 11-53) of the Liquid Cooling Circuit with the new Heat Exchanger. Make sure to
place a clip upon each tube prior to connecting. Use an universal plier to push both clip tongs to each other in order to open the
clip and to move the clip over the connection.
8. Reinstall the Heat Exchanger assembly. Fasten the assembly with three screws at the top and two screws at the bottom (refer-
ence 3 image 11-52).
9. Guide wire units of the fans through the cable gland and reconnect them with the four fans. See reference 2 image 11-51.
10.Reinstall the temperature sensor as illustrated in image 11-51 (reference 1).
Proceed with refilling the Liquid Cooling Circuit, then expel all air from the circuit and finally pressurize the
cooling circuit. See "Filling the Liquid Cooling Circuit", page 186.
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12. Lenses and Lens Holder
12. LENSES AND LENS HOLDER

About this chapter
This chapter describes how to replace the complete Lens Holder or single parts of the Lens Holder like the DC motors for lens shift.
Note that the focus and shift functionality are built into the Lens Holder. The DC motor for the zoom functionality is built into the
Lens. Included in this chapter are the adjustment procedures for the Lens Holder (Scheimpflug) and Lens cleaning procedure.
CAUTION: Never transport the projector with the Lens mounted on it! Always remove the Lens before trans-
porting the projector.
Overview
• Introduction
• Available lenses
• Lens selection
• Lens formulas
• Lens installation
• Lens removal
• Cleaning the lens
• Adjusting the Lens Holder
• Removal of the Lens Holder
• Installation of the Lens Holder
• Replacement of the vertical shift motor
• Replacement of the horizontal shift motor
• Replacement of the focus motor
• Replacement of the Lens Signal Distribution board
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12.1 Introduction
Lenses and Lens Holder
Next to securing the Lens, the Lens Holder makes it possible to shift, tilt and swing the lens plane with respect to the DMD plane
of the projector. This adjustment mechanism ensures that the projected image can be perfectly focused on the screen. The motors
required for horizontal and vertical shift and to zoom are built-in in the Lens Holder. The Lens Holder always has an electrical socket
for the focus functionality of the motorized Lens.
Parts identification of the Lens Holder

1 2 3
11
12
4
10
13
5
14
8 7 6 15
Image 12-1
1 Lens Holder front plate.
2 Lens lock handle.
3 Adjustment screw to swing the Lens Holder front plate (Scheimpflug).
4 Lock screws of the swing mechanism.
5 Lock screws of the rotate mechanism.
6 Adjustment screws to rotate the Lens Holder front plate.
7 Lock screws of the tilt mechanism.
8 Adjustment screw for manual focus adjustment.
9 Lens Holder horizontal shift motor.
10 Lens Holder vertical shift motor.
11 Adjustment screw for manual vertical shift adjustment.
12 Lens Signal Distribution board.
13 Adjustment screw for manual horizontal shift adjustment.
14 Adjustment screw to tilt the Lens Holder front plate (Scheimpflug).
15 Lens Holder zoom motor.
CAUTION: The adjustment screws the motorized vertical shift, horizontal shift and focus adjustment may only
be used in case the corresponding motor fails. Always turn these adjustment screws very slowly!
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Location of the Lens Holder motors
Image 12-2
1 Lens Holder vertical shift motor.
2 Lens Holder horizontal shift motor.
3 Lens Holder zoom motor.
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12.2 Available lenses

Overview
Lens Type Product Number Image
1,2" DC2K Zoom (1,25–1,45 : 1) Motorized R9855958
1,2" DC2K Zoom (1,45–2,05 : 1) Motorized R9855942 image 12-3
1,2" DC2K Zoom (2,15–3,6 :1) Motorized R9855946 image 12-6
1,2" DC2K Zoom (2,8–5,5 :1) Motorized R9855947 image 12-7
Image 12-3 Image 12-4 Image 12-5

R9855942: 1,2" DC2K Zoom (1,45–2,05 : 1) R9855943: 1,2" DC2K Zoom (1,6–2,35 : 1) R9855945: 1,2" DC2K Zoom (1,8–2,8 : 1)
Image 12-6 Image 12-7

R9855946: 1,2" DC2K Zoom (2,15–3,6 : 1) R9855947: 1,2" DC2K Zoom (2,8–5,5 :1)
216 R59770374 DP-3000 16/08/2010

12.3 Lens selection

How to select the right Lens for your application?
1. Determine the required screen width (SW).
2. Determine the position of the projector in the projection room with regard to the screen and measure the projector-screen distance
PD.
Note: To be precise, PD is the perpendicular distance between the front plate of the Lens Holder and the screen.
3. Use the lens formulas (see "Lens formulas", page 218) to find the best corresponding PD with regard to the measured projector-
screen distance for the required screen width SW.
Tip: Divide PD by SW to determine the approximate throw ratio. Choose a Lens, which captures the calculated throw ratio.
Use the lens formula of the chosen Lens to recalculate exactly.
SCREEN
SW
PD
Image 12-8
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12.4 Lens formulas

Formulas
Lens Throw ratio for 1,2" DC2K Zoom Formulas
1,2" DC2K Zoom (1,25–1,45:1) 1,25- 1,45 PD min=1,25 x SW
PD max=1,45 x SW
1,2" DC2K Zoom (1,45–2,05:1) 1,45 - 2,05 PD min=1,45 x SW
PD max=2,05 x SW
PD max=2,35 x SW
PD max=2,8 x SW
PD max=3,6 x SW
PD max=5,5 x SW
PD min: Minimum distance between projector and screen. PD max: Maximum distance between projector and screen. SW: Screen
Width.
Due to production tolerances the real distances can differ by 2% from these calculated values.
For critical situations (fixed installs that use the lens at one of its extreme zoom positions) this should be
taken into account.
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12.5 Lens installation

How to install a Lens into the projector Lens Holder?
1. Remove the foam rubber in the opening of the Lens Holder if not removed yet.
2. Take the Lens out of its packing material and remove the Lens caps on both sides.
3. Place the Lens Holder in the “unlocked” position by moving the Lens lock handle (A) to the left as illustrated.
Image 12-9
4. Ensure that the Lens Holder stands in the On-Axis position (horizontal and vertical mid position).
Note: The Lens Holder is placed default in the On-Axis position at factory.
5. Gently insert the Lens into the Lens Holder.
Image 12-10
6. Make sure that:

a) the pin P on the Lens Holder matches with the sleeve in the Lens.
b) in case of a motorized Lens, the lens connector matches the electrical socket S on the Lens Holder.
Warning: Do not release the Lens yet, as the Lens may fall out of the Lens Holder.
7. Secure the Lens in the Lens Holder by sliding the Lens lock handle to the right as illustrated. Ensure the Lens touches the front
plate of the Lens hHolder.
Image 12-11
8. Check if the Lens is really secured by trying to pull the lens out of the Lens Holder.
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CAUTION: Never transport the projector with a Lens mounted in the Lens Holder. Always remove the Lens
before transporting the projector. Neglecting this can damage the Lens Holder and Prism.
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12.6 Lens removal

How to remove a lens from the projector Lens Holder?
1. Support the Lens with one hand while you unlock the Lens Holder by sliding the lock handle to the left (unlock position) as
illustrated.
2. Gently pull the Lens out of the Lens Holder.
Image 12-12
It’s recommended to place the Lens caps of the original Lens packaging, back on both sides of the removed
Lens to protect the optics of the Lens.
It’s recommended to place the foam rubber of the original projector packaging, back in the Lens opening to
prevent intrusion of dust. Note that this foam rubber is packed in a plastic bag to prevent the dust, emitted by
the foam, from entering the projector.
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12.7 Cleaning the lens
To minimize the possibility of damage to optical coatings, or scratches to lens surfaces, we have developed
recommendations for cleaning. FIRST, we recommend you try to remove any material from the lens by blowing
it off with clean, dry deionized air. DO NOT use any liquid to clean the lenses.
Necessary tools
Toraysee TM cloth (delivered together with the lens kit). Order number : R379058.
How to clean the lens ?

1. Always wipe lenses with a CLEAN Toraysee TM cloth.
2. Wipe lenses in a one single direction.
Warning: Do not wipe back and forwards across the lens surface as this tends to grind dirt into the coating.
3. Do not leave the cleaning cloth in either an open room or lab coat pocket, as doing so can contaminate the cloth.
4. If smears occur when cleaning lenses, replace the cloth. Smears are the first indication of a dirty cloth.
CAUTION: Do not use fabric softener when washing the cleaning cloth or softener sheets when drying the
cloth.
Do not use liquid cleaners on the cloth as doing so will contaminate the cloth.
Other lenses can also be cleaned safely with this Toraysee TM cloth.
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12.8 Adjusting the Lens Holder

Why adjusting the Lens Holder?
The Lens Holder has to be adjusted so that the “sharp focus plane” of the projected image falls together with the plane of the
screen (Fp1→Fp2). This is achieved by changing the distance between the DMD plane and the lens plane (Lp1→Lp2). The closer
the lens plane comes to the DMD plane the further the sharp focus plane will be. It can happen that you won’t be able to get a
complete focused image on the screen due to a tilt (or swing) of the lens plane with respect to the DMD plane. This is also know
as Sheimpflug’s law. To solve this the lens plane must be placed parallel with the DMD plane. This can be achieved by turning the
Lens Holder to remove the tilt (or swing) between lens plane and DMD plane (Lp3→Lp4).
Lp1 Fp1
Lp2 Fp2
Fp4
DMD DMD
SCREEN
Lp3 Fp3
(Scheimpflug)
SCREEN
Lp4
Image 12-13
The Lens Holder has three adjustment mechanisms. The first mechanism allows to shift the Lens back and forward, the second
mechanism allows to tilt the Lens and the third mechanism allows to swing the Lens. Note that all three adjustment mechanisms
stand in relation with each other. So, a change to one of them will also effect the adjustment result of the two others. Therefore,
all three adjustment points have to be alternately and repeatedly adjusted until the projected image is completely focused on the
screen.
Scheimpflug principle
The "plane of sharp focus" can be changed so that any plane can be brought into sharp focus. When the DMD plane
and lens plane are parallel, the plane of sharp focus will also be parallel to these two planes. If, however, the lens
plane is tilted with respect to the DMD plane, the plane of sharp focus will also be tilted according to geometrical and
optical properties. The DMD plane, the principal lens plane and the sharp focus plane will intersect in a line below the
projector for downward lens tilt.
Necessary tools
• Flat blade stubby screw driver 40 x 6,5.
• White paper sheet.
How to set up the projector for Lens Holder adjustment?

1. Install the projector in its final position in the projection room.
Inclined screen
PD
Image 12-14
2. Remove the front and left cover of the projector.

3. Install an 1,2" DC2K Zoom Lens which throw ratio covers the projection distance PD.
4. Switch on the projector and project the internal green focus pattern on the screen.
5. Adjust with the Lens zoom and Lens shift controls for optimal image matching on the screen.
Tip: For optimal image quality is recommended to tilt the projector forward to obtain an on-axis projection instead of shifting
the image downwards.
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6. Adjust the Lens focus until the centre (F) of the projected pattern is most sharp on the screen.
How to adjust the Lens Holder?

1. Loosen (not remove) the four lock screws (reference A, B, C and D of image 12-15) of the Lens Holder adjustment mechanism.
Use for that a 8 mm nut driver. As a result, the Swing (reference S) and the Tilt (reference T) mechanisms of the Lens Holder
come loose for adjustment.
S
A C
C
D
B A D
B
Image 12-15
2. Adjust the Lens focus until the centre (F) of the projected pattern is most sharp on the screen.
Image 12-16
3. Adjust the screw S (bit by bit) of the Lens Holder swing mechanism until the mid left and mid right of the projected pattern is most
sharp on the screen. Use for that a 40 x 6,5 flat blade stubby screw driver.
Tip: Use a white paper to search for the “sharp focus plane” at the left or right side of the projected pattern. Turn the adjustment
screw a bit and check if the sharp focus plane has come closer to the screen. If not, turn the adjustment screw in the
opposite direction and check again.
Note: A simultaneous readjustment of the focus will be necessary to get the mid left and mid right of the projected pattern
equally focused as the centre.
F F F
S
Image 12-17
4. Adjust the screw T (bit by bit) of the Lens Holder tilt mechanism until the mid top and mid bottom of the projected pattern is most
sharp on the screen. Use for that 8 mm nut driver or a flat screw driver.
Tip: Use a white paper to search for the “sharp focus plane” at the top or bottom side of the projected pattern. Turn the
adjustment screw a bit and check if the sharp focus plane has come closer to the screen. If not, turn the adjustment
screw in the opposite direction and check again.
Note: A simultaneous readjustment of the focus will be necessary to get the mid left and mid right of the projected pattern
equally focused as the centre.
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Image 12-18
5. Repeat from step 2 until the projected focus pattern is as sharp as possible in the centre, left, right, top and bottom of the screen.
6. Fasten the four lock screws (reference A, B, C and D of image 12-19) of the Lens Holder adjustment mechanism. Use for that a
8 mm nut driver. As a result, the positions of the Swing and Tilt mechanisms are secured.
A C
C
D
B A D
B
Image 12-19
7. Reinstall the front and side cover of the projector.
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12.9 Removal of the Lens Holder
To remove the Lens Holder you have the remove the Lens, the front cover, the Sealed Light Processor and the
bottom cover first. This procedure assumes that these parts are already removed.
Necessary tools
How to remove the Lens Holder?

1. Disconnect the flat cable (reference 1) from the Lens Signal Distribution board and detach the flat cable from the top of the Lens
Holder (reference 2).
Image 12-20
2. Loosen the GND wire lug (reference 3) from the projector chassis. Use a T20 Torx screwdriver.
Image 12-21
3. Remove the 8 hexagon socket head cap screws (reference 1) which are located at the bottom of the projector base and secure
the Lens Holder. Use a 3 mm Allen wrench.
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1 x8
Image 12-22
4. Lift up the Lens Holder and remove it from the projector base.
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12.10 Installation of the Lens Holder

Necessary tools
3 mm Allen wrench.
How to install the Lens Holder

1. Place the Lens Holder in its position on the projector base.
Note: Make sure that the positioning pin (reference 2 image 12-23) on the projector base matches the positioning hole of the
Lens Holder.
2. Fasten the Lens Holder with 8 hexagon socket head cap screws (reference 1 image 12-23). Use a 3 mm Allen wrench.
8x 1
Image 12-23
3. Reconnect the flat cable (reference 1 image 12-24) with the Lens Signal Distribution board and secure the flat cable on top of
the Lens Holder (reference 2 image 12-24).
Image 12-24
4. Connect the GND wire lug (reference 3) with the projector chassis as illustrated. Use a T20 Torx screwdriver.
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Image 12-25
Proceed with reinstalling the bottom cover, the Sealed Light Processor and the Lens of the projector. See
corresponding installation procedures.
The Lens Holder has to be adjusted after installation. See procedure "Adjusting the Lens Holder", page 223.
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12.11 Replacement of the vertical shift motor
It is not necessary to remove the Lens Holder from the projector chassis to replace the vertical shift motor.
This procedure assumes that the Lens Holder is removed from the projector chassis.
Necessary tools
• 7 mm nut driver or open-end wrench.
How to replace the vertical shift motor of the Lens Holder?

1. Disconnect the wire unit (reference 2) of the vertical shift motor from the Lens Signal Distribution board.
Image 12-26
2. Slowly rotate the axis (reference 1 image 12-27) of the vertical shift motor until the set screw (reference 2 image 12-27) is ac-
cessible. Use a 7 mm nut driver or open-end wrench.
3. Loosen the set screw (reference 2 image 12-27) a few turns and remove the motor with wire unit.
2
1
4
3
Image 12-27
4. Remove the bracket (reference 4 image 12-28) from the motor and reinstall it on the new motor. Use a PH0 Phillips screwdriver
for the three screws (reference 5 image 12-28).
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Image 12-28
5. Guide the wire unit of the new motor into position and connect the wire unit with the Lens Signal Distribution board (reference 2
image 12-27).
6. Place the new motor in position and fasten the axis of the motor with the set screw (reference 2 image 12-27).
Caution: Make sure the plain surface (reference 3 image 12-27) on the axis of the motor is facing the set screw. The small
side of the bracket (reference 4 image 12-27) must mate with the frame of the Lens Holder.
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12.12 Replacement of the horizontal shift motor
It is not necessary to remove the Lens Holder from the projector chassis to replace the horizontal shift motor.
This procedure assumes that the Lens Holder is removed from the projector chassis.
Necessary tools
How to replace the horizontal shift motor of the Lens Holder?

1. Disconnect the wire unit (reference 4 image 12-29) of the horizontal shift motor from the Lens Signal Distribution board.
Image 12-29
2. Slowly rotate the axis (reference 1 image 12-30) of the vertical shift motor until the set screw (reference 2 image 12-30) is ac-
cessible. Use a 7 mm nut driver or open-end wrench.
Note: In some cases the gap where the wire unit of the motor comes out can be to small for the plug of the wire unit. Release
the two lock screws of the Lens Holder tilt mechanism (Scheimpflug adjustment) and rotate the tilt axis to increase the
gap. This operation requires a readjustment of the Lens Holder. See "Adjusting the Lens Holder", page 223, for more
information of the tilt axis and adjustment.
Image 12-30
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Image 12-31
image 12-29).
3 2
Image 12-32
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12.13 Replacement of the focus motor
To replace the focus motor of the Lens Holder the Lens Holder has to be removed from the projector. This
procedure assumes that the Lens Holder is already removed from the projector chassis.
Necessary tools
Necessary parts
3 cable ties.
How to replace the focus motor of the Lens Holder?

1. Disconnect the wire unit (reference 7 image 12-33) of the focus motor from the Lens Signal Distribution board.
Image 12-33
2. Cut the cable ties (reference 1 & 2 image 12-34) which fasten the wire unit of the focus motor.
1 2
Image 12-34
3. Slowly rotate the axis (reference 1 image 12-35) of the focus motor until the set screw (reference 2 image 12-35) is accessible.
Use a 7 mm nut driver or open-end wrench.
Note: You have to turn the Lens Holder to access the focus motor at the bottom side of the Lens Holder.
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Image 12-35
Image 12-36
image 12-33).
7. Secure the wire unit of the focus motor with three cable ties as illustrated in image 12-34.
2 3
Image 12-37
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12.14 Replacement of the Lens Signal Distribution board
To replace the Lens Signal Distribution board from the Lens Holder the Sealed Light Processor has to be
removed first. This procedure assumes that the Sealed Light Processor is already removed.
Necessary tools
T10 Torx screwdriver.
How to replace the Lens Signal Distribution board?

1. Disconnect the flat cable and all other wire units (reference 1 to 8 image 12-38) from the Lens Signal Distribution board.
Note: The wire units of the Dowser are already disconnected because the Sealed Light Processor is removed.
2
3
4 8
5
Image 12-38
2. Remove the Lens Signal Distribution board from the Lens Holder by loosening the four Torx screws (reference 1 image 12-39).
Use a T10 Torx screwdriver.
Image 12-39
3. Install a new Lens Signal Distribution board and fasten the board with four Torx screws.
4. Reconnect the other wire units (reference 1 to 7 image 12-38) with the Lens Signal Distribution board.
- Reference 1 image 12-38: Connection with zoom motor.
- Reference 2 image 12-38: Connection with vertical shift motor.
- Reference 3 image 12-38: Connection with vertical end stop switches.
- Reference 4 image 12-38: Connection with horizontal motor.
- Reference 5 image 12-38: Connection with horizontal end stop switches.
- Reference 6 image 12-38: Connection with focus end stop switches.
- Reference 7 image 12-38: Connection with focus motor.
5. Reconnect the flat cable (reference 8 image 12-38) with Lens Signal Distribution board.
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13. Card Cage
13. CARD CAGE

About this chapter
This chapter gives a brief introduction of the Card Cage and how to access the Card Case and the boards which are housing in this
cage. The diagnostic LEDs of each board are described in this chapter as well. Futhermore, the board replacement procedures are
included.
Overview
• Introduction
• Card Cage diagnostic
• Removal of the Card Cage cover
• Installation of the Card Cage cover
• Authorization to clear security warning on DP-3000
• Replacement of a Card Cage board
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13. Card Cage
13.1 Introduction
Introduction of the Card Cage
The Card Cage is located at the right side of the projector, behind the Control Panel. The upper compartment of the Card Cage is
sealed with a cover. This sealed compartment has five slots wherein the three power boards and two TI Cinema boards fit. The lower
compartment has one slot wherein the Input & Communication unit fits. The power boards have board to board connectors with the
Card Cage Power Backplane. The two TI Cinema boards and the Input & Communication unit have board to board connectors with
the Card Cage Signal Distribution Backplane. Both backplanes are connected with each other via board to board connectors.
The Power Backplane extends a few centimeters above the Card Cage housing. This part of the Power Backplane is used to connect
power and control signals to other electronic parts (fans, sensors, pump, switches, etc.) inside the projector.
CAUTION: The Card Cage cover may only be removed by qualified service personnel. Opening the Card Cage
will result in an authorization request upon startup.
Parts location
1
7 11
8
9
10
2 3 4
Image 13-1
1 Power Backplane.
2 Power input socket for projector electronics (not for the xenon lamp).
3 Signal Distribution Backplane.
4 Connection for Rack Control (Power Unit)
5 SMPS CTRL board.
6 SMPS PFC board.
7 SMPS DCDC board.
8 TI Cinema Processor board.
9 TI Cinema Interface board (with GORE protection)
10 Slot for the Input & Communication unit.
11 Card Cage cover.
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13. Card Cage
13.2 Card Cage diagnostic

General
The Card Cage boards provide numerous LED indicators to provide various types of information about the system. These are defined
per Card Cage board in the next sub-chapters. Note that these LED’s are only visible when the Card Cage cover is removed.
SMPS CTRL board

The main function of the SMPS CTRL board (reference 1 image 13-2) is to monitor the temperature on different locations inside the
projector and to drive the fans, the TEC’s (Peltiers) and the pump dependent on these measured values. In case one of the cooling
elements appears to be insufficient which result in a too high Lamp House temperature or DMD temperature then the DIMM PC on
the “Input & Communication unit” will send a command to the LPS modules, located in the Power Unit, to shutdown. In case the
DIMM PC fails then the SMPS CTRL board will shutdown the LPS modules (second protection level).
++12V
TEC R CTRL ON ++5V STAT
TEC G CTRL ON +24V ELEK HEART BEAT
TEC B CTRL ON +12V ACSAR PWR GOOD
TEC B TARGET ON
TEC G TARGET ON +12V
TEC R TARGET ON +5V
+3.3V
Image 13-2
LED Description
TEC B TARGET ON Indicates that the TEC for the blue channel is active. Note that the TEC voltage comes from the
(Yellow) +12V TEC on the SMPS DCDC board.
TEC G TARGET ON Indicates that the TEC for the green channel is active. Note that the TEC voltage comes from the
(Yellow) +12V TEC on the SMPS DCDC board.
TEC R TARGET ON Indicates that the TEC for the red channel is active. Note that the TEC voltage comes from the +12V
(Yellow) TEC on the SMPS DCDC board.
++12V (Green) Indicates that the ++12V standby supply is present on the SMPS CTRL board. Note that the ++12V
standby supply is generated on the SMPS PFC board and enters the SMPS CTRL board via the
Power Backplane.
++5V (Green) Indicates that the ++5V standby supply is present on the SMPS CTRL board. Note that the ++5V
standby supply is generated on the SMPS PFC board and via the Power Backplane enters the SMPS
CTRL board.
+24V_ELEK Indicates that the +24V_ELEK supply is present on the SMPS CTRL board. Note that the +24V_ELEK
supply is generated on the SMPS DCDC board and enters the SMPS CTRL board via the Power
Backplane. The +3.3V, the +5V and the +12V power supplies are derived from the +24V_ELEK.
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13. Card Cage
LED Description
+12V_ACSAR Indicates that the +12V_ACSAR supply is present on the SMPS CTRL board. Note that the
+12V_ACSAR supply is generated on the SMPS DCDC board and enters the SMPS CTRL board via
the Power Backplane. The + 12V_ACSAR is currently not used but available for future expansion.
STAT (Red) Indicates the status of the SMPS CTRL board.
HEART BEAT Indicates the heart beat of the SMPS CTRL board.
POWER GOOD Indicates that the measured values of the +3.3V, the +5V and the +12V power supplies are within
(Yellow) tolerance. Note that these three voltages are derived from the +24V_ELEK.
+3.3V Indicates that the +3.3V supply is within tolerance. Note that the +3.3V is derived from the +24V_ELEK
on the SMPS CTRL board.
+5V Indicates that the +5V supply is within tolerance. Note that the +5V is derived from the +24V_ELEK
+12V Indicates that the +12V supply is within tolerance. Note that the +12V is derived from the +24V_ELEK
SMPS PFC board (Power Factor Corrector)

The main function of this board (reference 2 image 13-3) is to reduce the line current distortion and to improve the power factor.
The SMPS PFC board also generates the ++5V and the ++12V standby supplies. Futhermore, the supply voltages for the four fan
groups are generated on this board as well.
FAN 0
2 FAN 1
2
FAN 2
FAN 3
Image 13-3
LED Description
FAN_0 (Green) Indicates that the supply voltage for the Outlet Fan in the heat exhauster on top of the projector
is present.
FAN_1 (Green) Indicates that the supply voltage for the Anode Fan of the lamp anode cooling is present.
FAN_2 (Green) Indicates that the supply voltage for the Cathode Fan of the lamp cathode cooling is present.
FAN_3 (Green) Indicates that the supply voltage for all fans (except for the Outlet Fan, the Anode Fan and the Cathode
Fan) is present.
SMPS DCDC board

This board (reference 3 image 13-4) generates the supply voltages for the projector electronics, for the pump of the liquid cooling
circuit, for the thermoelectric cooling (TEC). The +12V_ACSAR is also generated on this board, but has currently no use (future
expansion).
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13. Card Cage
3
3
+24V ELEK
+24V PUMP
+12V ACSAR
+12V TEC
Image 13-4
LED Description
+24V ELEK (Green) Indicates that the +24V supply voltage for the projector electronics is present.
+24V PUMP (Green) Indicates that the +24V supply voltage for the pump of the liquid cooling circuit is present.
+12V ACSAR (Green) Indicates that the +12V supply voltage for future expansion is present.
+12V TEC (Green) Indicates that the +12V supply voltage for the TEC’s (Peltier element) is present.
TI Cinema Processor board
DIAG FAIL
FLASH V ID MODE
+12V
+5V
4 +3.3V
LOCAL PWR GOOD
Image 13-5
LED Description
LOCAL PWR GOOD Indicates the on-board 1.8V DC and 1.5V DC regulators are operating properly. OFF = FAIL ; ON = OK
(Green)
+3.3V Indicates presence of external 3.3V DC supply. OFF = FAIL ; ON = OK
+5V Indicates presence of external 5V DC supply. OFF = FAIL ; ON = OK
12V Indicates presence of external 12V DC supply. OFF = FAIL ; ON = OK
FLASH V ID MODE Indicates that FLASH memory is in an unprotected state. OFF = Protected ; ON = Unprotected
• FLASH memory protection is not being used, therefore, this LED has no meaning.
• In certain Series-0 Pre-Production Processor boards (with MSN numbers starting with “0123”),
FLASH protection of some sectors was used. Updating the FLASH on these boards required
using the “TEMP UNPROTECT” button which would unprotect the FLASH and illuminate this LED.
DIAG FAIL Indicates that built-in diagnostic test failed. See System Status for details on which test failed. OFF =
OK ; ON = FAIL
TI Cinema Interface board

The TI Cinema Interface board is enclosed with a GORE protection. There are no diagnostic LED’s visible on this board
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13. Card Cage
13.3 Removal of the Card Cage cover
To remove the Card Cage cover, you have to remove the right cover of the projector first. This procedure
assumes that the right cover of the projector is already removed.
CAUTION: The Card Cage cover may only be removed by qualified service personnel. Opening the Card Cage
will result in an authorization request upon startup.
Necessary tools
• Flat screwdriver.
How to remove the cover of the Card Cage?

1. Release the two retaining screws which fasten the Control Panel to the projector chassis. Use for that a flat screwdriver.
Image 13-6
2. Pivot the Control Panel upwards and lock the position with the provided support as illustrated.
Image 13-7
3. Loosen the 21 screws which fasten the Card Cage cover. Use a T10 Torx driver for the upper 14 screws (reference 3 image 13-8),
a T20 Torx driver for the two screws (reference 1 image 13-8) at the bottom corners and a PH1 Phillips screwdriver for the 5 black
screws (reference 2 image 13-8) at the bottom center.
4. Remove the Card Cage cover away from the Card Cage.
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13. Card Cage
3 x14
1 2 1
Image 13-8
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13. Card Cage
13.4 Installation of the Card Cage cover

Necessary tools
How to install the cover of the Card Cage?

1. Check if the handles of all boards are completely sunken in the Card Cage.
2. Place the Card Cage cover into position. Make sure that the four small vertical slots of the cover fits upon the corresponding pins
of the Card Cage.
Caution: Do not damage the four micro switches of the security enclosure while positioning the Card Cage cover.
3. Fasten the Card Cage cover with 21 screws in total:
- 5 x M2 black Phillips screws PH1 for the bottom center of the cover. (reference 1 image 13-9)
- 2 x M3 Torx screws T20 for the bottom corners of the cover. (reference 2 image 13-9)
- 14 x M2 Torx screws T10 for the upper part of the cover. (reference 3 image 13-9)
3 x14
1 2 1
Image 13-9
4. Lower and secure the Control Panel. Use a flat screw driver to fasten the two screws at the bottom corners of the Control Panel.
Image 13-10
5. Reinstall the right side cover of the projector.

6. Execute the authorization process to clear the security warning. See procedure "Authorization to clear security warning on
DP-3000", page 245.
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13. Card Cage
13.5 Authorization to clear security warning on DP-3000
The authorization to clear the security warning on the DP-3000 digital projector has to be done after all covers
of the projector are correct installed.
Necessary tools
• Security key (Dallas iButton®).
• Authorization pin code (8 digits).
Authorization procedure to clear security warning on DP-3000

1. Start up the projector (standby mode).
2. Initiate authorization by holding the security key in the security socket D.
Image 13-11
The backlight color of the numeric keys 1 to 10 changes to orange.

3. Start entering the pin code within 5 seconds.
The backlight color of the numeric keys 1 to 10 changes temporally to green in case the code is correct. Otherwise the backlight
color changes for a few seconds to red. Finally the backlight color changes back to blue (normal operation color).
Restart the procedure in case of an invalid attempt. Maximum five (5) attempts are permitted.
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13. Card Cage
13.6 Replacement of a Card Cage board
CAUTION: Handle the TI Cinema Interface board which is enclosed with a security kit (black housing around
the board) with care. Note that the security kit is very sensitive. A small scratch will permanently disable the
TI Cinema Interface board. Never try to dismantle the security kit. Consult Barco in case of damage. The
security kit is needed to protect the decrypting key.
CAUTION: Remove the mains power from projector and wait at least 2 minutes before replacing one of the
power boards (SMPS PFC and SMPS DCDC). Neglect will result in electrical damage of the input circuitry of
the power boards.
Before swapping the TI Cinema Interface board, try to make a copy of the created macro files, so you can
restore them later in the new TI Cinema Interface board. See chapters “Cloning” and “Restoring” in the user
guide of the Communicator software.
To replace one of the Card Cage boards the cover of the Card Cage has to be removed first. This procedure
assumes that the cover of the Card Cage is already removed. See procedure "Removal of the Card Cage
cover", page 242. Note that opening the Card Cage will result in an authorization request upon startup.
How to replace one of the Card Cage boards?

1. Do you wan to remove one of the TI Cinema boards?
If yes, detach the wire unit (reference 1image 13-12) of the TI Cinema Interface board from the inner side of the Card Cage.
Image 13-12
2. Unlock and pull out the board which you wan to remove from the Card Cage.
Caution: Make sure that the projector is at least 2 minutes removed from the mains power before removing on of the Power
Boards.
Image 13-13
3. Insert the new board in the Card Cage. The handles of the board must be completely sunken in the Card Cage. Otherwise, the
Card Cage cover will not fit and because of that disables the authorization process.
Caution: Make sure that the projector is at least 2 minutes removed from the mains power before inserting a new Power Board.
4. Did you replace one of the TI Cinema boards?
If yes, attach the wire unit (reference 1image 13-12) of the TI Cinema Interface board with the cable clamp inside the Card Cage.
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13. Card Cage
Check the version of the TI software. Download the latest version of the “TI software release” from the secured
Barco web site https://My.Barco.com and update the TI firmware of all TI boards. See chapter "Updating TI
Boards", page 249.
At startup the projector will request an authorization because of the removal of the Card Cage cover. See
procedure "Authorization to clear security warning on DP-3000", page 245.
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13. Card Cage
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14. Updating TI Boards
14. UPDATING TI BOARDS

About this chapter
If one of the TI boards, such as the Formatting Interface Board; the TI Interface Board; or the TI Processor Board, is replaced with
a new one then the TI firmware must be updated. This chapter contains the procedures for updating the TI firmware.
Overview
• Installation of the Update Package
• Start up the update program
• Make a serial connection (RS232)
• Make an Ethernet connection (10/100 BASE-T)
• Installation of the new software release
• Logging of the operation
• Special functions
• Factory Install Options
• Recovery option - Stay in Boot option
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14.1 Installation of the Update Package

How to install?
1. Download the Update package from the secured Barco web site and copy this file (.zip format) into a new directory.
2. Unzip the package file into this directory.
Image 14-1
Unzipped package file
The directory contains:

- An update program file (.exe)
- Software update file (.dlpcinema)
- read me and instruction files (.txt and .doc)
- a configuration files directory containing configuration files.
- a recovery files directory containing recovery files.
- a processor board binary files directory with binary files for the processor board.
- an interface board binary files directory with binary files for the interface board.
- a formatter sub system directory.
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14.2 Start up the update program

How to start up ?
1. Browse to the installation directory of the TI update software.
2. Double click on DLP Cinema(TM) Firmware Installation Program v2.01(12).exe to start up the update program.
Note: The version indication in the startup file can be different for other releases.
The start up window will be displayed.
Image 14-2
Start up of update program
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14.3 Make a serial connection (RS232)

Necessary parts
A fully wired straight serial cable
Software connection
1. Connect the local PC with the RS232 port of the Input & Communication unit.
2. Select first the PC com-port by clicking on the combo box just below PC com-port # (1).
Image 14-3
Serial connection setup
3. Select the baud rate by clicking on the combo box just below Baud Rate (2).
4. Check the radio button in front of Serial Port (3).
The connection will be established. A login message will be displayed. Click OK to continue.
5. Enter the userid and password.
Image 14-4
Login window
Defaults are:
- User Id: Service
- Password: Heal Thyself
Both are case sensitive.
When correct, the Current Projector Info of the selected projector will be filled out.
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14.4 Make an Ethernet connection (10/100 BASE-T)
A crossed or non crossed Ethernet cable can be used. the projector switched automatically for the correct
cable.
The PC’s IP Address MUST be within the same subnet as the projector’s IP Address in order for communica-
tion to be possible. This requires checking the PC’s and projector’s Subnet-Mask settings.
IP address examples
First example
• PC IP Address : 192.168.100.5
• PC Subnet Mask : 255.255.255.0
• Projector IP Address : 192.168.100.2
• Projector Subnet Mask: 255.255.255.0
Result : Communication possible. PC address is in the subnet range of the projector’s IP address.
Second example
• PC IP Address : 10.16.236.100
• PC Subnet Mask : 255.255.255.0
Result : No communication possible. PC address is not in the subnet range of the projector’s IP address.
Third example
• PC IP Address : 192.168.200.1
• PC Subnet Mask : 255.255.255.0
Result : No communication possible. PC address is not in the subnet range of the projector’s IP address. The third group in the PC
IP address and Projector IP address must be the same.
Fourth example
• PC IP Address : 192.168.200.1
• PC Subnet Mask : 255.255.0.0
Remark : Communication possible. PC address is in the subnet range of the projector’s IP address. The third group in the IP¨
addresses can be any value as the third group in the subnet mask is 0.
Software connection
1. Connect the local PC with one of the Ethernet ports (100/10 BASE-T) of the Input & Communication unit.
2. Click in the IP address input field and fill out directly the IP address of the projector (1a).
Note: The IP address must be the TI/Cinema IP address. To read out that address, look for the Cinema IP address via the
touch panel or look for the TI IP address via the Communicator software.
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Image 14-5
Make Ethernet connection
Or,
click in the host name input field just below the IP address and fill out the host name of the projector to perform a DNS-lookup
(requires the local network to be configured to support this) (1b).
Or,
click on Projector Search (1c).
The projector scans the network and build up a list of available projectors with host name and IP address (only possible for
projectors on the local subnet AND that have Release 5.1 or later installed).
3. Select the desired projector out of the list (1d) and click OK (1e).
The IP address and host name will be filled out.
4. Check the radio button in front of Ethernet Port (2).
The program will prompt the user to login to the projector.
5. Enter the userid and password.
Defaults are:
- UserId: Service
- Password: Heal Thyself
Both are case sensitive.
When correct, the Current Projector Info of the selected projector will be filled out.
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14.5 Installation of the new software release

How to install ?
1. Click on Select Release Installation File (1).
Image 14-6
Select Release file
A browser window opens (2).

2. Browse to the directory that contains the Release to be installed.
Note: The release files are indicated as .dlpcinema .
3. Click on the file to select (3) and click Open (4).
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Or,
double click on the file (3).
The content of the file will be displayed in Selected release (5) after a validation. A comparison with the actual loaded software
is possible.
Image 14-7
Start auto-install
4. Click on Start Auto-Install (6).

The verification and installation process will be started. It installs anything that does not exactly match the release.
It includes also the resetting of the projector and the re-connection to verify the installation.
A success or error dialog box will be displayed when completed.
CAUTION: Do not reset or switch off the projector during an installation operation. A reset during some
operations may leave the affected board in the projector in a non-functional state, requiring factory recovery.
In case of failures, always send a copy of this log file to your Barco representative.
CAUTION: Log files are not saved automatically. A Dump log to file has to be done.
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14.6 Logging of the operation

What is possible?
The program maintains a log of all operations performed.
To show this log, click on Show Log.
Image 14-8
Show logging started
The log window opens.
Image 14-9
Log info
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By clicking on one of the buttons, the following is possible with the log:
• Dump to file : the log will be dumped into a file on the hard disk. A name and location will be asked first.
• Clear log : the log will be cleared. All information will be removed.
Log files are not saved automatically to disk. To save the file execute a Dump to file.
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14.7 Special functions

Overview
To select a special installation and/or verification function, click on <<Special Operations>>. Before clicking on Special Operations,
a connection to the projector must be present and a release file must be selected.
Image 14-10
Special operations
Auto-Install Cinema Boards Only will only verify and install components related to the Interface and Processor
boards.
Use only if cinema boards are replaced (interface board, processor board)
Auto-Install Formatter Subsystem Only will only verify and install components related to the Formatter subsystem.
Use only when the engine was replaced.
Verify Release Only will check all components of a Release supported by this program. No changes
will be made to the projector.
Force Cinema Re-Install will reinstall all Cinema components (Disk-Chip and flash) whether or not they are
up to date. This rarely needed and is intended for special recovery purposes only.
(see note)
Fill-System Install Only will format the Disk-Chip and install all files (no other flash components are
touched). This is intended for special file-system recovery only.
(see note)
Note : with these options you will loose all default MACRO, PCF and SCREEN files. These options should not be used.
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14.8 Factory Install Options
CAUTION: Never use these options in the field. Only for factory use.
Overview
These options are intended for factory use for brand new boards.
For special factory-install operations, select Factory Installation >> to open the dialog window to select the function to perform.
Before click on Factory Installation, a connection to the projector must be present and a release file must be selected.
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14.9 Recovery option - Stay in Boot option

Problem
The main software of the interface board can get corrupt when the projector was reset while a software update was busy. In that
case the projector might be in a state where it tries to load the main software continuously, but it fails as the software is corrupt.
It is possible to force the projector to load only its boot application and not to start its main application. This is called Stay in Boot.
The Stay in Boot option can be activated only when connected via a Serial connection (RS232/RS422).
How to activate
1. Check Stay in Boot App.
Image 14-11
Stay in boot mode
A message will be displayed to indicate that a recovery will take place.

2. Click OK to continue.
When the boot application is successfully started, a message will be displayed. The current projector info will indicated that the
boot application is running.
3. Click on Select Release Installation file and select the release file.
The content of the file will be displayed.
4. Click on Start Auto Install.
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Image 14-12
Start auto install of ARM application
The verification and installation process will be started. It installs the ARM_main_app.
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15. Input & Communication unit
15. INPUT & COMMUNICATION UNIT

About this chapter
This chapter describes the functionality of the Input & Communication unit. It includes block diagrams and board replacement pro-
cedures.
Overview
• Introduction
• Control ports of the DP-3000 digital projector
• Data source input ports of the DP-3000 digital projector
• About General Purpose Inputs & Outputs (GPIO)
• Removal of the Input & Communication unit
• Installation of the Input & Communication unit
• Replacement of the DVI input board
• Replacement of the GPIO board
• Replacement of the DIMM PC
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15.1 Introduction
Introduction of the Input & Communication unit
The Input & Communication unit is located at the right side of the projector below the Control Panel and can be removed from the
projector like a drawer (after removal of the Card Cage cover!). The communication interface is the largest board of the assembly and
is located at the bottom of the drawer. This board contains a DIMM PC, an Ethernet card and a General Purpose Input/Output board
(GPIO). The DIMM PC function as main controller of the projector. The communication board has two board to board connectors,
which fit directly into the signal backplane of the Card Cage. Furthermore, two grey flat cables join the Control Panel with the
Communication Interface.
The “DATA INPUT” board (DVI & HDSDI) is mounted with spacers upon the communication board and has its own board to board
connector, which fits directly into the signal backplane of the Card Cage.
Parts location
3
2
Image 15-1
1 Communication input interface board.
2 RS232/422 + General purpose IN/OUT board.
3 DVI input board.
4 DIMM PC.
5 Ethernet card.
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Block diagram communication board
RS232/422
IN (TI)
Control panel
Cinema processor board

General
GPIO status LED
Purpose board status
Input & LED
Output Button IR
(GPIO) status panel rec
LED
Matrix
Error
Input &
RS232/422
Serial in communication
Filter
RS232/422
Serial out
I²C SMPS CTRL
I²C
enable I²C LPS
10/100 I²C I²C LAMP INFO

BASE T HUB
I²C CLO
HUB Ethernet
10/100 card I²C VIDEO
BASE T
Cinema input board

DIMM PC ISA BUS
Input & Main controller Interrupt

FPGA High Speed I²C
communication
OEM RS232
ACSAR2
(not used)
Image 15-2
Block diagram data input board (DVI & HDSDI)

Signal backplane
Data input Cinema input board
DVI (A) Receiver Sender Receiver
DVI (B) Receiver Sender Receiver
FPGA
HDSDI
SMPTE 292 Receiver
(A)
HDSDI
SMPTE 292 Receiver
(B)
Image 15-3
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15.2 Control ports of the DP-3000 digital projector

Location of the control ports
G F E
O
I
A B C D
Image 15-4
A Power input socket + ON/OFF switch of the projector head.
B Mini-jack socket for wired remote control.
C Ethernet ports 1 & 2.
D RS232/RS422 serial communication ports.
E Power unit (rack) control port.
F General purpose input/output port (GPIO).
G RS232/RS422 communication port for the TI boards.
Power input & ON/OFF switch

The front panel of the input & communication unit is provided with a power input socket (type IEC/EN 60320-1 C14) and a power
ON/OFF switch (reference A of image 15-4). This power input socket provides power to all the electronic boards of the projector
head. Note that these electronic boards consumes in total about 400 watt. This power can be extracted from the separated power
unit, which has an dedicated power output socket for the projector head. A power cord, delivered with the projector, has to be
installed between the power unit and the projector head. See chapter "Connecting the power unit with the projector head", page 81.
Note that this dedicated power output socket on the separated power unit is protected by a non resettable fuse of 250V - T 10A H.
Wired remote control

If desired the optional remote control unit can be wired and plugged into the 3,5 mm mini jack socket (reference B of image 15-4)
on the communication interface.
Ethernet network communication

The DP-3000 digital projector can be connected to a LAN (local area network) using one of the 10/100 base T ports (reference C of
image 15-4) on the communication interface. Once connected to the LAN, users are capable of accessing the projector from any
location, inside or outside (if allowed) their company network using the control software (Communicator touch panel). This toolset
locates the projector on the network in case there is a DHCP server or the user can insert the correct IP-address of the projector to
access the projector. Once accessed, it is possible to check and manipulate all the projector settings. Remote diagnostics, control
and monitoring of the projector can then become a daily and very simple operation. The network connectivity permits to detect
potential errors and consequently improve the time to servicing.
As there is a need to daisy chain projectors when they are in Ethernet network, an Ethernet switch is build in, the incoming network
is hereby available for the internal PC and for the next device in the chain. In this way a ’star’ network interconnection can be avoid.
The switch used is a stand alone 10/100Mbit Ethernet switch. This assures no influence on the network speed. Whenever a slow
(10Mbit) device is connected the speed between the 100Mbit devices remains 100Mbit.
Both Ethernet ports are equipped with a yellow and a green LED. The yellow LED lights up in case the port is connected with a
100Mbit network. The green LED blinks in case there is network activity.
The connectors used for both Ethernet ports are of the type RJ45, which is compatible with standard RJ45
cable connector. Straight (most common) as well as cross linked network cables can be used. The 2 ports
are functionally identical. Both ports are connected via the projector hub (Auto sensing enabled).
RS232/422 serial communication

The communication interface of the DP-3000 supports RS232 and RS422 serial communication (reference D of image 15-4). You
can use the RS232/RS422 input port to connect a local PC to your DP-3000 digital projector. This way you can configure and control
your DP-3000 digital projector from your local PC.
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Do not forget to set the projector’s baud rate (default = 115200) to match that of the computer.
The communication interface has also an active RS232/RS422 loop through output port. Whenever the projector has no power, a
passive loop through is created from the RS232/RS422 input port to the RS232/RS422 output port. So, the following projector in
the daisy chain will still receive his RS232/RS422 commands.
Advantages of using RS232/RS422 serial communication:
• easy adjustment of the projector via PC (or MAC).

• allow storage of multiple projector configurations and set ups.
• wide range of control possibilities.
• address range from 0 to 255.
• sending data to the projector (update).
• copying data from the projector (backup).
RS232
An Electronic Industries Association (EIA) serial digital interface standard specifying the characteristics of the commu-
nication path between two devices using either D-SUB 9 pins or D-SUB 25 pins connectors. This standard is used for
relatively short-range communications and does not specify balanced control lines. RS-232 is a serial control standard
with a set number of conductors, data rate, word length and type of connector to be used. The standard specifies com-
ponent connection standards with regard to computer interface. It is also called RS-232-C, which is the third version
of the RS-232 standard, and is functionally identical to the CCITT V.24 standard. Logical ’0’ is > + 3V, Logical ’1’ is < -
3V. The range between -3V and +3V is the transition zone.
RS422
An EIA serial digital interface standard that specifies the electrical characteristics of balanced (differential) voltage,
digital interface circuits. This standard is usable over longer distances than RS-232. This signal governs the asyn-
chronous transmission of computer data at speeds of up to 920,000 bits per second. It is also used as the serial port
standard for Macintosh computers. When the difference between the 2 lines is < - 0.2V that equals with a logical ’0’.
When the difference is > +0.2V that equals to a logical ’1’..
POWER UNIT CONTROL (RACK CONTROL)

This 25 pins D-SUB connector (reference E of image 15-4) must be connected, using a data cable which is delivered with the
projector, with the power unit of the DP-3000 digital projector. Through this connection the projector can communicate with the
power unit.
GENERAL PURPOSE IN/OUT (GPIO)

This female 37 pins D-SUB connector (reference F of image 15-4) can be used to send or receive trigger signals from other devices.
These input/output pins can be programmed by macros created via the Communicator touch panel. See user’s guide of the Touch
panel, section Macro editor, for more information about this functionality. For more information on how to connect with the GPIO
pins see chapter "About General Purpose Inputs & Outputs (GPIO)", page 269.
RS232/RS422 communication port for the TI boards

This female 9 pins D-SUB connector (reference G of image 15-4) is only used for service purposes. Do not use this connector to
communicate with the projector.
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15.3 Data source input ports of the DP-3000 digital projector

Location of the data source input ports
H I J K
O
I
Image 15-5
H HDSDI input port for channel B.
I HDSDI input port for channel A.
J DVI input port for channel B.
K DVI input port for channel A.
SMPTE 292 IN
The two BNC connectors (reference H & I of image 15-5) accept HD-SDI signals which comply with the SMPTE 292 standard. It
is likely that for “Cinema” inputs, these two BNC connectors will be used in a dual 292 configuration. These BNC connectors can,
however, also be used as two separate, individually selectable, SMPTE 292 ports.
SMPTE
Society of Motion Picture and Television Engineers - A global organization, based in the United States, that sets stan-
dards for baseband visual communications. This includes film as well as video standards.
DVI IN
A DVI source can be applied upon the DVI connectors (reference J & K of image 15-5). The DVI connectors can be combined to
one DVI input with two channels.
DVI
Digital Visual Interface is a display interface developed in response to the proliferation of digital flat panel displays.
The digital video connectivity standard that was developed by DDWG (Digital Display Work Group). This connection
standard offers two different connectors: one with 24 pins that handles digital video signals only, and one with 29 pins
that handles both digital and analog video. This standard uses TMDS (Transition Minimized Differential Signal) from
Silicon Image and DDC (Display Data Channel) from VESA (Video Electronics Standards Association).
DVI can be single or dual link.
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15.4 About General Purpose Inputs & Outputs (GPIO)

General Purpose inputs
Eight (8) opto-isolated general purpose inputs are available. These inputs are used to trigger the execution of macro files. For more
explanation about the association of a macro to a GPI, consult the user guide of the Communicator touch panel.
Input voltage
The inputs can be directly driven from a TTL or CMOS output.
• Minimum voltage : V min = 3,3 V

• Maximum voltage : V max = 24 V
External power supply

When interfacing with contact closure outputs, an external power supply needs to be provided. Depending upon the configuration a
suitable pull-up resistor needs to be added as well.
Input to projector Internal projector Input to projector Internal projector

GPIn P 820R GPIn P 820R
+5V +5V
10k 10k
to to
+24V 1k1 +24V 1k1
4.7V 4.7V
GPIn N GPIn N
Image 15-6
Left diagram: with pull-up resistor. Right diagram: without pull-up resistor.
Cables
When long cable connections are required the use of shielded cables with twisted pairs is recommended. One twisted pair is to be
assigned to each GP Input pair.
How to make the connection

When the power supply used to provide the DC voltage is isolated from ground (for example in the case of an AC adapter) it is
recommended that the minus pole of that power supply is connected to ground (or to the projector chassis). This will avoid high
common mode voltages at the projector GP Inputs. If that same power supply is used for other parts of the system, take care not to
create ground loops. In any case when shielded cables are used that shield should be connected to the projector chassis.
General Purpose outputs

Eight (8) opto-isolated outputs are available, where seven are general purpose and one for a fixed purpose. The seven general
purpose outputs can be controlled via software while the fixed output provides the status of the system. When this output is closed
(current is flowing), then the system is OK.
About an output
The output can generate a falling edge, rising edge, toggle or continuous toggle.
• Generate Falling Edge – generate a falling edge on the external GPO port if the present state of the output is high. If the
present state of the external GPO is low, no edge will be generated.
• Generate Rising Edge – generate a rising edge on the external GPO port if the present state of the output is low. If the present
state of the external GPO is high, no edge will be generated.
• Generate Toggle – generate a toggle on the external GPO port. If the present state of the output is low, a rising edge will be
generated, followed by a falling edge. If the present state of the output is high, a falling edge will be generated, followed by a
rising edge. The rate of toggle will be the vertical sync rate (edge transition at each vsync).
• Generate Continuous Toggle - This command will generate a continuous toggle of the external GPO port. This toggle will
continue until a Generate Falling Edge, Generate Rising Edge, or Generate Toggle command is received. The rate of toggle
will be the vertical sync rate (edge transition at each vsync).
Output transistor
• Maximum output driving voltage : V max = 70 V
• Maximum current : I max = 30 mA
• Maximum power dissipation : 120 mW
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Output from projector Internal projector
GPOut P
Max 120 mW
GPOut N
Image 15-7
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15.5 Removal of the Input & Communication unit
To remove the Input & Communication unit the cover of the Card Cage has to be removed first. Because
the two grey flat cables, which make a connection between the communication board and the Control Panel,
passes behind the extension of the Card Cage cover. This procedure assumes that the Control Panel is turned
open and that the Card Cage cover is already removed. See "Removal of the Card Cage cover", page 242.
Necessary tools
• 5,5 mm nut driver.
How to remove the Input & Communication unit?

1. Disconnect the power cord (reference 1 image 15-8), the “RACK CONTROL” cable (reference 2 image 15-8) and all other cables
from the Input & Communication unit.
1 2
Image 15-8
2. Remove the cable clamp (reference 3 image 15-8) from the power input socket.
Image 15-9
3. Disconnected the two grey flat cables (reference 4) from the Control Panel and release the screws (reference 5) of the ferrite
block assembly.
Note: In case the flat cables has to be replaced you must reuse the ferrite block which is mounted around the flat cables.
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4 4
Image 15-10
4. Remove the two grey flat cables from the flat cable holders (reference 6 image 15-11).
Image 15-11
5. Release the four screws, which fasten the Input & Communication unit, as illustrated. Use a PH2 Phillips screwdriver.
Image 15-12
6. Pull out the Input & Communication unit.

Caution: Pay attention not to damage the two grey flat cables, which are attached to the communication board.
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Image 15-13
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15.6 Installation of the Input & Communication unit
To install the Input & Communication unit the Card Cage cover has to be removed. Because the two grey flat
cables, which make a connection between the communication board and the Control Panel, passes behind
the extension of the Card Cage cover.
Necessary tools
How to install the input & communication unit?

1. Gently insert the Input & Communication unit into its slot.
Caution: Pay attention not to damage the two grey flat cables, which are attached to the communication board.
Caution: Ensure that the Input & Communication unit is completely inserted. The front cover of the unit must touch the projector
chassis.
Image 15-14
2. Fasten the Input & Communication unit with four screws as illustrated. Use a PH2 Phillips screwdriver to fasten the four M4 x 15
cross head screws.
Image 15-15
3. Reconnect the two grey flat cables (reference 5 image 15-16) with the Control Panel and fasten the ferrite block assembly with
two nuts (reference 4 image 15-16). Use a 5,5 mm nut driver the fasten the nuts.
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4 4
Image 15-16
4. Place the two grey flat cables into the flat cable holders (reference 6 image 15-17) as illustrated.
Image 15-17
5. Reinstall the cable clamp (reference 3 image 15-18) of the power socket.
Image 15-18
6. Reconnect the power cord (reference 1 image 15-19), the “RACK CONTROL” cable (reference 2 image 15-19) and all other data
source cables.
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1 2
Image 15-19
After the installation of the Input & Communication unit the Card Cage cover has to be installed. See proce-
dure "Installation of the Card Cage cover", page 244.
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15.7 Replacement of the DVI input board
To replace the DVI input board the “Input & Communication unit” has to be removed from the projector.
Necessary tools
• Small Phillips screwdriver.
• TX10 Torx screwdriver.
How to replace the DVI input board?

1. Remove the screw ref A image 15-20 above the two BNC sockets at the front side of the DVI input board.
2. Remove the four screws ref B image 15-20 of the DVI sockets at the front side of the DVI input board.
3. Remove the four Phillips screws ref C image 15-20 at the front side of the DVI input board.
A B B B B
C C C C
Image 15-20
4. Remove the five Torx screws, which fasten the DVI board with the communication interface, and remove the board.
Image 15-21
5. Reverse this procedure to reinstall the DVI input board.
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15.8 Replacement of the GPIO board
To replace the GPIO board the “Input & Communication unit” has to be removed from the projector.
Necessary tools
TX10 Torx screwdriver.
How to replace the GPIO board

1. Release the four screws, which fasten the GPIO board with the communication interface, as illustrated.
Image 15-22
2. Replace the GPIO board and fasten the board.
Image 15-23
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15.9 Replacement of the DIMM PC
The DIMM PC is located on the communication board. Before you can remove the DIMM PC you have to
remove the input & communication unit from the projector first.
CAUTION: Electrostatic Sensitive Device (ESD). To avoid equipment damage from electrostatic discharge,
use static control precautions in servicing this equipment. Field service or maintenance personnel should
be properly grounded before servicing. Wear an ESD wristlet when servicing this equipment. The use of
antistatic gloves is recommended.
Necessary tools
No tools.
How to replace the DIMM PC?

1. Gently pull open the latches of the DIMM PC socket unitl the DIMM PC jumps up.
2. Remove the DIMM PC out of the socket.
Note: The bottom of the DIMM PC is glued to the communication board for transport reasons. So, be carefully while removing.
The glue becomes redundant once the projector is installed.
3. Insert a new DIMM PC into the socket on the communication board.
Tip: Ensure there is no dust in the socket on the communication board. Use compressed air to blow out the dust.
4. Press down the DIMM PC
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16. Control Panel
16. CONTROL PANEL

About this chapter
This chapter describes the Control Panel of the projector. It contains replacement procedures for the Local Keypad, the Button
module and the Status Lights on the rear projector corners.
Overview
• Introduction
• Local keypad of the DP-3000 digital projector
• Replacement of the Button module
• Replacement of the Local Keypad
• Replacement of the Status Lights
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16. Control Panel
16.1 Introduction
Introduction
The Control Panel is located at the right side of the projector in front of the Card Cage. The Control Panel can pivot upwards away
from the Card Cage. The mains parts of the Control Panel are the Button model and the Local Keypad.
Parts location of the Control Panel
6
5
4
3 9
2
1 8
Image 16-1
1 Fixation screw.
2 Local Keypad.
3 Status LED’s.
4 Infra red receiver.
5 Socket for security key (Dallas® button).
6 Fixation screw.
7 Backlight.
8 Ferrite and support for flat cables.
9 Button module.
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16. Control Panel
16.2 Local keypad of the DP-3000 digital projector

Identification of the keys
A B C D E
Image 16-2
A Numeric keyboard.
B Marker area for macro name.
C Standby/Operation switch.
D Dowser Open/Close switch.
E Test Pattern toggle switch.
F Lens holder shift left/right & up/down keys.
G Lens focus keys.
H Lens zoom keys.
Numeric keys: All the numeric keys (A) of the local keypad have a blue backlight during normal operation. Only when the autho-
rization process is activated with the security key, then the backlight color of the numeric keys 1 to 10 changes to orange. Each key
can be linked to a macro which allows you to setup the projector to your requirements with one push on a button. Note that each
numeric key has a marker area (B) where you can write down the name of the macro.
Standby key: Standby key (C) switches ON or OFF the lamp and lamp electronics. The lamp cooling fans remain active for about 5
minutes. The speed of the other fans is reduced. The backlight color of the standby key remains red in standby mode and changes
to green in operation mode.
Dowser key: The dowser key (D) opens or closes the dowser. The backlight color of the dowser key is green when the dowser is
open and red when the dowser is closed.
Pattern key: The pattern key (E) gives you direct access key to the internal test patterns of the projector.
Shift keys: The shift keys (F) allows you to shift the lens up/down or left/right. This functionality is only available in case of a
motorized lens shift
Focus keys: The focus keys (G) allows you to focus the projected image on the screen. This functionality is only available in case
of a motorized lens and lens holder.
Zoom keys: The zoom keys (H) allows you to zoom in or out the projected image on the screen. This functionality is only available
in case of a motorized lens and lens holder.
Projector status LED’s and IR-receiver

There are three LED’s and an IR-receiver located below the local keypad. The IR-receiver makes it possible to use a remote control
unit (optional) to send the same commands to the projector as the local keypad. The red LED (ref A of image 16-3) marked with “IR”
lights up in case the projector receives an infra red signal from a remote control unit. The green LED (ref B of image 16-3) marked
with “OK” lights up when the received infra red signal is acknowledge by the projector. The bicolored LED (ref C of image 16-3)
marked with the standby symbol lights up red when the projector head is starting up and changes to green when the electronic
boards of the projector head are operational.
A status light is built-in on both corners on the rear top of the projector head (ref E of image 16-3). In normal operation mode,
meaning NO errors, the color of the status lights is GREEN. In case an ERROR occurs the color of the status lights changes to RED.
Refer to the Communicator touch panel for the type of error. Note that when the maximum lamp run time is exceeded, the status
lights will light up green. As long as the status lights are flashing, the device is still booting up and not ready for use.
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16. Control Panel
A B C D E
Image 16-3
A Infra red signal received.
B Received infra red signal is OK.
C Power status of projector head.
E Projector fault status.
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16. Control Panel
16.3 Replacement of the Button module
To replace the Button module the right cover of the projector has to be removed. This procedure assumes
that the right cover is already removed.
Necessary tools
• Flat screw driver.
How to replace the Button module of the Control Panel?

Image 16-4
Image 16-5
3. Disconnect the two flat cables (reference 1image 16-6) from the Button module.
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16. Control Panel
Image 16-6
4. Disconnect the four remaining wire units (reference 2, 3, 4 and 5 image 16-7) from the Button module.
4
5
Image 16-7
5. Replace the Button module. Use a 5,5 mm nut driver to loosen the 10 nuts (reference 1 image 16-8) which fasten the Button
module.
Image 16-8
6. Reconnect the four wire units (reference 2, 3, 4 and 5 image 16-7) with the Button module.
7. Reconnect the two flat cables (reference 1image 16-6) with the Button module.
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16. Control Panel
Image 16-9
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16. Control Panel
16.4 Replacement of the Local Keypad
To replace the Local Keypad the right cover of the projector has to be removed. This procedure assumes that
the right cover is already removed.
Necessary tools
How to replace the Local Keypad of the Control Panel?

Image 16-10
Image 16-11
3. Disconnect the two flat cables (reference 1image 16-12) from the Button module.
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16. Control Panel
Image 16-12
4. Disconnect the four remaining wire units (reference 2, 3, 4 and 5 image 16-13) from the Button module.
4
5
Image 16-13
5. Remove the Button module assembly from the Control Panel. Use a 5,5 mm nut driver to loosen the 4 nuts (reference 1 im-
age 16-14) which fasten the assembly. Note that there are washers (reference 2 image 16-14) located between the Button
module assembly and the Control Panel.
Image 16-14
6. Peel off the Local Keypad from its support plate.
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16. Control Panel
7. Stick a new Local Keypad upon the support plate. Make sure to position the new Local Keypad correctly within the marks upon
the support plate.
Image 16-15
8. Reinstall the Local Keypad assembly. Fasten with 4 nuts (reference1 image 16-14). Make sure to place four washers (reference
2 image 16-14) between the assembly and the Control Panel.
9. Reconnect the four wire units (reference 2, 3, 4 and 5 image 16-13) with the Button module.
10.Reconnect the two flat cables (reference 1image 16-12) with the Button module.
Image 16-16
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16. Control Panel
16.5 Replacement of the Status Lights

Necessary tools
How to replace the Status Light of the projector rear corner?

1. Remove the big plastic screw (reference 1image 16-17). Use a big flat screw driver.
2. Remove the hexagons socket head cap screw (reference 2 image 16-17) which fasten the Status Light corner assembly. Use a
3 mm Allen wrench.
3. Pull out the Status Light corner assembly (reference 3 image 16-17) which fasten the Status Light corner assembly).
4. Disconnect the wire unit from the Status Light module.
5. Remove the plastic corner cap from the Status Light module (reference 4image 16-17) by loosen the screw (reference 5im-
age 16-17) at the bottom of the Status Light module. Use a T10 Torx driver.
1 2
Image 16-17
6. Reverse this procedure to install a new Status Light module.
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16. Control Panel
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17. Communicator Touch Panel
17. COMMUNICATOR TOUCH PANEL

Overview
• Introduction
• Installing the touch panel interface
• Reposition the touch panel interface
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17.1 Introduction
Communicator Touch Panel for digital cinema projectors
The Communicator Touch Panel is designed for multi-user command and control, the Communicator enables users to learn quickly
and operate efficiently - using an elegant and flexible touch panel interface. The interface’s commonality means that operators
can intuitively use any model in the product line, without restriction, and its user-friendly nature translates directly into a short and
enjoyable learning curve.
Image 17-1
Flexible touch panel interface

The touch panel interface can be mounted upon a swivel arm which easily fits on top of the DP-3000 projector. One central locking
mechanism of the swivel arm allows an instant fixation of the touch panel interface in any position.
The touch panel interface can also be installed further away from the DP-3000 projector. For that you can use a serial (RS232) cable
up to 10 meter or an Ethernet cable up to 50 meter to realize a direct data communication between the DP-3000 projector and the
Communicator Touch Panel.
The touch panel interface can also be connected with a Local Area Network (LAN) just like the DP-3000 projector. In this case both
devices can communicate with each other as well.
The touch panel interface requires a voltage supply +12 VDC and 1,5 ampere. Note that the DP-3000 projector has a 12 VDC
output which can be used to power up the touch panel interface. Nevertheless, the use of a separate +12 VDC adaptor (1,5 ampere
minimum) is required in case the touch panel interface is installed more then a few meters away from the DP-3000 projector.
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17.2 Installing the touch panel interface

Necessary tools
• 17 mm wrench.
• 10 mm wrench.
How to install the touch panel interface upon the DP-3000 projector?
1. Assemble the mounting plate and the swivel arm together as illustrated. First the nut (N) upon the rod of the mounting plate, then
the lock washer (L), and then fasten mounting plate and swivel arm together. When arm is mounted, turn nut (N) against the arm
to secure the position.
N
L
Image 17-2
2. Place the touch panel interface upon the mounting plate of the swivel arm and fasten the two wing nuts (W) as illustrated.
Image 17-3
3. On one of the back corners of the projector, turn out the screw of the hook light.
Image 17-4
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4. Turn in the adapter piece (A) between projector and swivel arm. Slide a washer (B) over the base of the swivel arm and insert
the base of the swivel arm into the mounting hole of the adapter.
Image 17-5
5. Insert the secondary side of the adapter into the power socket. Use the correct power cord to power the adapter.
Plug the SUB-D plug of the RS232 cable into the SUB-D socket of the touch panel. Plug the other end into the RS232IN connector
on the communication panel of the projector.
Plug one end of the Ethernet cable into the RJ45 socket of the touch panel and the other end into one of the Ethernet ports of
the projector (Port 1 or Port 2).
To power
adapter To RS232IN To Port1 or Port2
Image 17-6
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To power
adapter
Image 17-7
6. Fasten the plug of the power adapter cord together with the with the SUB-D plug of the RS232 cable as illustrated. Use for that
one cable tie.
CABLE TIE
Image 17-8
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17.3 Reposition the touch panel interface

How to reposition the touch panel interface?
1. Hold fast the touch panel interface.
2. Release the central swivel clamp by turning the big black knob (K) counterclockwise.
Image 17-9
3. Move the touch panel interface into the desired position.

4. Fasten the central swivel clamp by turning the big black knob clockwise.
CAUTION: Never release the central swivel lock without supporting the touch panel interface.
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18. Fan replacement procedures
18. FAN REPLACEMENT PROCEDURES

About this chapter
This chapter contains the replacement procedures of all fans in the projector. Note that the fans of the Power Unit can not be
replaced. The Lamp Power Supply module has to be replaced as a whole.
Overview
• Replacement of the Anode Fan
• Replacement of the Cathode Fan
• Replacement of the Outlet Fan
• Replacement of the Cold Mirror Top Fan
• Replacement of the Cold Mirror Bottom Fan
• Replacement of the SPG Fan
• Replacement of the Card Cage Fans
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18.1 Replacement of the Anode Fan

Where is the Anode Fan located?
The Anode Fan (reference 1 image 18-1) is located at the bottom of the projector, underneath the optical base. You can see a part of
the Anode fan via the compartment of the Lamp House. The Anode Fan has to be accessed via the projector bottom. The outlet of
the Anode Fan is provided with an extension (reference 2 image 18-1) which guide the fresh air upwards to the anode of the xenon
lamp. This extension and the Anode Fan have to be removed as a whole from the projector. Note that the outlet extension contains
a temperature sensor (reference 3 image 18-1) which has to be disconnected prior to removing the Anode Fan.
3
Image 18-1
To replace the Anode Fan, the Lamp House, left cover, the bottom cover and the Sealed Light Processor unit
have to be removed first. This procedure assumes that the Lamp House, the left cover, bottom cover and the
Sealed Light Processor unit are already removed from the projector.
Necessary tools
• Side cutter.
How to remove the Anode fan?

1. Remove the temperature sensor (reference 1 image 18-2) from the Anode Fan outlet channel by pulling off the winglet (reference
2 image 18-2) from the sensor. Note that there is an O-ring (reference 3 image 18-2) present on the sensor. Do not loose this
O-ring.
1 2 1
Image 18-2
2. Remove the two cable ties which fasten the wire unit of the Anode Fan. One cable tie is accessible from the projector bottom
(reference 4 image 18-3) and the other cable tie is accessible via the Lamp House compartment (reference 5 image 18-3).
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4 5
Image 18-3
3. Disconnect the wire unit (reference 6 image 18-4) of the Anode Fan.
Image 18-4
4. Loosen the two screws at the bottom of the outlet channel. use a T20 Torx driver.
Image 18-5
5. Loosen the four hexagon socket head cap screws which fasten the Anode Fan assembly. One screw is accessible via the Lamp
House compartment, the other three screws are accessible via the compartment of the Sealed Light Processor unit.
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Image 18-6
6. Remove the Anode fan from the projector.
Image 18-7
7. Remove the air channel outlet extension from the Anode Fan by loosen the four Torx screws (reference 1 image 18-8). Use a
T20 Torx driver. Do not loosen the washers (reference 2 image 18-8).
1
2
Image 18-8
How to install the Anode Fan?

1. Install the air channel outlet extension on the Anode Fan with four Torx screws (reference 1 image 18-9). Use a T20 Torx driver.
Provide each screw with a washer (reference 2 image 18-9).
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1
2
Image 18-9
2. Place the Anode fan assembly in its position.
Image 18-10
3. Fasten the Anode fan assembly with four hexagon socket head cap screws (reference 3 image 18-11) and washers (reference
4 image 18-11). One screw has to be inserted via the Lamp House compartment, the other three screws can be inserted via the
compartment of the Sealed Light Processor unit.
Caution: Make sure that the metal grid (reference 5 image 18-11) is correctly placed.
3
4
Image 18-11
4. Insert the two screws at the bottom of the outlet channel. use a T20 Torx driver.
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Image 18-12
5. Connect the wire unit (reference 6 image 18-13) of the Anode Fan.
Image 18-13
6. Fasten the wire unit of the Anode Fan with two cable ties as illustrated.
4 5
Image 18-14
7. Install the temperature sensor (reference 1 image 18-15) on the Anode Fan outlet channel by pushing the winglet (reference 2
image 18-15) upon the sensor. Make sure that there is an O-ring (reference 3 image 18-15) present on the sensor.
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1 1 2
Image 18-15
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18.2 Replacement of the Cathode Fan

Where is the Cathode Fan located?
The Cathode Fan (reference 1) is located above the Pump of the Liquid Cooling System (reference 2) and between the compartment
of the Lamp House and the Card Cage. To replace the Cathode Fan, the Pump has to be removed from its location first. It is not
needed to drain the Liquid Cooling Circuit.
Image 18-16
To replace the Cathode Fan, the Pump of the Liquid Cooling Circuit has to be removed first. This procedure
assumes that the Pump is already removed. See chapter "Removal of the Pump", page 198.
Necessary tools
How to replace the Cathode Fan?

1. Disconnect the wire unit (reference 1) of the Cathode Fan.
Image 18-17
2. Release the Cathode Fan assembly from the projector base by loosening the three screws (reference 1) at the bottom, the two
screws (reference 2) at the left, the two screws (reference 3) at the top and the two screws at the left (reference 4) of the Cathode
fan assembly. Use a T20 Torx driver for the screws at the top and a 3 mm Allen wrench for the other screws.
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1
4
Image 18-18
3. Remove the Cathode Fan assembly from the projector.
Image 18-19
4. Disassemble the Cathode Fan assembly. Use a T20 Torx driver to loosen the three screws (reference 5) at the top and a 3 mm
Allen wrench to loosen the four screws (reference 6) at the fan outlet.
6
8
Image 18-20
5. Remove the mounting plate from the Cathode Fan. Use a 5 mm open-end wrench to loosen the three spacers (reference 9) and
use a T20 Torx driver to loosen the remaining screw (reference 10).
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10
Image 18-21
6. Install a new Cathode Fan on the mounting plate. Use three spacers (reference 9) and one Torx T20 screw (reference 10) to
fasten the Cathode Fan.
9 10
Image 18-22
7. Reassemble the Cathode Fan assembly as illustrated. Use three Torx screws T20 (reference 5) to fasten the top of the assembly.
Use four hexagon socket head cap screws (reference 6) to fasten the outlet of the Cathode Fan. Three provided with a plain
washer (reference 7) and one with a cable tie holder (reference 8).
6
8
Image 18-23
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8. Place the Cathode Fan assembly in its mounting position in the projector.
Image 18-24
9. Secure the Cathode Fan assembly with three screws (reference 1 image 18-18) at the bottom, two screws (reference 2 im-
age 18-18) at the left, two screws (reference 3 image 18-18) at the top and two screws at the left (reference 4 image 18-18) of
the Cathode fan assembly. Use a T20 Torx driver for the screws at the top and a 3 mm Allen wrench for the other screws.
10.Reconnect the wire unit (reference 1 image 18-17) of the Cathode Fan.
After the Cathode Fan assembly is installed, the Pump of the Liquid Cooling Circuit has to be reinstalled. See
corresponding chapter "Installing the Pump", page 201, for detailed installation instructions.
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18.3 Replacement of the Outlet Fan

Where is the Outlet Fan located?
The Outlet Fan is located inside the air exhaust channel above the Lamp House compartment.
To remove Outlet Fan assembly from the projector, the left cover, the right cover, the rear cover, the top cover
and the Lamp House has to be removed first. This procedure assumes that the left cover, the right cover, the
rear cover, the top cover and the Lamp House are already removed from the projector.
Necessary tools
• Side cutter.
Necessary parts
Cable ties.
How to replace the Outlet Fan of the air exhaust?

1. Disconnect the wire tree, which is attached to the housing of the Outlet Fan assembly, from the Power Backplane. Use a side
cutter to cut the cable tie (reference 1image 18-25) which fasten the wire tree the projector. The wire three exist in three wire
units:
a) the wire unit of the Cold Mirror top fan (reference 2image 18-25).
b) the airflow switch inside the exhaust channel of the Outlet Fan assembly (reference 3image 18-25).
c) the wire unit of the Outlet Fan (reference 4image 18-25).
2
3
4
Image 18-25
2. Remove the Outlet Fan assembly from the projector by loosening the six screws (reference 5 image 18-26) on top of the assembly.
Use a T20 Torx driver.
Note: To remove the assembly slide the assembly a few mm away from the rear of the projector and then lift it up.
Image 18-26
3. Cut all cable ties which fasten the wire units to the Outlet Fan assembly as illustrated.
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Image 18-27
4. Remove the 19 indicated Torx screws. Use a T10 Torx driver.

a) 7 screws on top of the Outlet Fan assembly (reference 6 image 18-28).
b) 5 screws at the left side of the Outlet Fan assembly (reference 7 image 18-28).
c) 3 screws at the front side of the Outlet Fan assembly (reference 8 image 18-29).
d) 4 screws at the bottom side of the Outlet Fan assembly (reference 9 image 18-29).
Image 18-28
Image 18-29
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5. Open the assembly.

Caution: The two parts of the Outlet Fan assembly are still connected with each other via the wire unit (reference 10 im-
age 18-30) of the airflow switch. Do not damage this wire unit while separating the two parts of the Outlet Fan
assembly.
Note: Inside the Outlet Fan assembly there are three triangle shaped foam blocks (reference 11 image 18-30).
10
11
Image 18-30
6. Replace the Outlet Fan as illustrated. Use a T20 Torx driver to loosen/fasten the four screws (reference 12 image 18-31).
Note: The wire unit (ref 13image 18-31) of the Outlet Fan is guided through the opening of the housing and through the fixation
plate.
12
13
Image 18-31
7. Assembly the two parts of the Outlet Fan assembly back together. Use in total 19 T10 Torx screws:
a) 7 screws on top of the Outlet Fan assembly (reference 6 image 18-28).
b) 5 screws at the left side of the Outlet Fan assembly (reference 7 image 18-28).
c) 3 screws at the front side of the Outlet Fan assembly (reference 8 image 18-29).
d) 4 screws at the bottom side of the Outlet Fan assembly (reference 9 image 18-29).
Caution: Do not damage the wire unit (reference 10 image 18-30) of the airflow switch and make sure that the three foam
blocks (reference 11 image 18-30) are placed as illustrated in image 18-30.
8. Attach the wire units with cable ties (reference 15 & 16 image 18-32) to the Outlet Fan assembly.
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15
16
Image 18-32
9. Reinstall the Outlet Fan assembly on top of the projector. Use a T20 Torx driver to fasten the six Torx screws (reference 5) as
illustrated.
Image 18-33
10.Reconnect the three wire units with the Power Backplane.

a) the wire unit of the Cold Mirror top fan (reference 2 image 18-34).
b) the airflow switch inside the exhaust channel of the Outlet Fan assembly (reference 3 image 18-34).
c) the wire unit of the Outlet Fan (reference 4 image 18-34).
3
4
Image 18-34
11. Fasten the wire three with cable ties as illustrated.
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Image 18-35
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18.4 Replacement of the Cold Mirror Top Fan
To replace the Cold Mirror Top Fan, the left cover, the right cover, the rear cover and the Lamp House have
House are already removed from the projector.
Necessary tools
• Side cutter.
Necessary parts
Cable tie.
How to replace the Cold Mirror Top Fan?

1. Disconnect the wire unit of the fan.
Image 18-36
2. Release the three screws (A, B & C) of the fan cover as illustrated. Use a T10 Torx driver.
Caution: Do not touch the Cold Mirror.
A C
B
Image 18-37
3. Release the two screws (D & E) as illustrated. Use a 3 mm Allen wrench.

Caution: Do not touch the Cold Mirror.
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Image 18-38
4. Replace the fan inside the fan cover and fasten the fan cover with the screws D & E as illustrated.
Caution: Ensure that the wire unit is placed in the recess at the side of the fan cover.
Image 18-39
5. Secure the fan cover with the three screws (A, B & C) as illustrated.
A C
B
Image 18-40
6. Reconnect the wire unit of the fan.
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Image 18-41
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18.5 Replacement of the Cold Mirror Bottom Fan
To replace the Cold Mirror Bottom Fan, the left cover and the bottom cover have to be removed first. This
procedure assumes that the left cover and the bottom cover are already removed from the projector.
Necessary tools
• Side cutter.
How to replace the Cold Mirror Bottom Fan?

1. Disconnect the wire unit (reference 1 image 18-42) of the Cold Mirror Bottom Fan. Cut the cable ties to release the wire unit.
Image 18-42
2. Remove the Cold Mirror Bottom Fan from the projector by releasing the four hexagon socket head cap screws (reference 2
image 18-43). Use a 3 mm Allen wrench.
Image 18-43
3. Install a new Cold Mirror Bottom Fan. Fasten with the four hexagon socket head cap screws (reference 2 image 18-43).
Caution: Make sure that the airflow of the Cold Mirror Bottom Fan is upwards.
4. Reconnect the wire (reference 1 image 18-42) unit of the Cold Mirror Bottom Fan. Use two cable ties to join the wire units together
as illustrated in image 18-42.
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18.6 Replacement of the SPG Fan
To replace the SPG Fan, the left cover and the bottom cover have to be removed first. This procedure assumes
that the left cover and the bottom cover are already removed from the projector.
Necessary tools
• Side cutter.
How to replace the Fan of the Start Pulse Generator?

1. Disconnect the wire unit (reference 1 image 18-44) of the SPG Fan. Cut the cable ties to release the wire unit.
Image 18-44
2. Remove the SPG Fan from the projector by releasing the four hexagon socket head cap screws (reference 2 image 18-45). Use
a 3 mm Allen wrench.
Image 18-45
3. Install a new SPG Fan. Fasten with the four hexagon socket head cap screws (reference 2 image 18-45).
Caution: Make sure that the airflow of the SPG fan is upwards.
4. Reconnect the wire unit (reference 1 image 18-44) of the SPG Fan. Use two cable ties to join the wire units together as illustrated
in image 18-44.
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18.7 Replacement of the Card Cage Fans

Where are the Card Cage Fans located?
The four fans of the Card Cage are located at the front of the projector, behind the Front Dust Filter. Sometimes these fans are
referred to as the “elcabox fans” or the “SMPS fans”. Note that there are two types of Card Cage Fans. Two small fans (upper) and
two big fans (lower).
To replace one or more of the Card Cage Fans, the projector front cover has to be removed. This procedure
assumes that the projector front cover is already removed. Futhermore, this procedure describes how to
replace the lowest fan of all Card Cage Fans. Nevertheless, the same procedure is applicable upon all four
Card Cage Fans.
Necessary tools
3 mm Allen wrench.
How to replace one of the fans of the Card Cage?

1. Disconnect the wire (reference 2 image 18-46) unit from the Card Cage Fan which you wan to replace.
Note: One fan is equipped with a temperature sensor (reference 1 image 18-46). Remove this temperature sensor prior to
removing the fan in case you wan to replace this fan. Reinstall the temperature sensor afterwards the new fan is installed.
Image 18-46
2. Loosen the four screws (reference 3 image 18-47) which fasten the Card Cage Fan. Use a 3 mm Allen wrench.
Image 18-47
3. Install a new fan. Make sure that the air flow of the fan is towards the Card Cage.
4. Reconnect the wire unit with the new Card Cage Fan.
CAUTION: One of the Card Cage Fans is equipped with a temperature sensor. Remove the temperature sensor
prior to removing the fan and reinstall the temperature sensor upon the new Card Cage Fan.
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19. Projector covers
19. PROJECTOR COVERS

About this chapter
Most maintenance and servicing procedures demand removing one or more of the projector covers to gain access to the parts to
maintain or to service. To avoid redundancy, all procedures about cover removing or installing are grouped together in this chapter.
The maintenance and servicing procedures also refer to this chapter if required. The procedures in this chapter describe, with
detailed step by step actions and illustrations, how to remove or install the projector covers.
WARNING: Always switch off the projector and unplug the power cord at the projector side before removing
one of the covers, unless otherwise stated.
Overview
• Removal of the right cover
• Removal of the left cover
• Removal of the front cover
• Removal of the rear cover
• Removal of the top cover
• Removal of the bottom cover
• Installation of the bottom cover
• Installation of the top cover
• Installation of the rear cover
• Installation of the front cover
• Installation of the left cover
• Installation of the right cover
• Cleaning the dust filters
• Cleaning the exterior of the projector
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19.1 Removal of the right cover

Necessary tools
• Lamp door lock key.
How to remove the right cover of the projector?

1. Unlock the door of the Lamp House using an adapted lock key as illustrated. It’s not necessary to open the Lamp House door.
Image 19-1
2. Release the four retaining screws as illustrated. Use a flat screw driver.
Image 19-2
3. Remove the side cover.
Image 19-3
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19.2 Removal of the left cover

Necessary tools
Flat screwdriver.
How to remove the left cover of the projector?

1. Release the four retaining screws as illustrated. Use a flat screw driver.
Image 19-4
2. Remove the side cover.
Image 19-5
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19.3 Removal of the front cover
To remove the front cover you have to remove the left and right cover first.
Necessary tools
No tools.
How to remove the front cover of the projector?

1. Remove the black dust cap from the lens holder by pulling out the five knobs (N) as illustrated. Note that the dust cap remains
attached to the front cover.
Image 19-6
2. Release the four thumbscrews (two on each side) as illustrated.
x4
Image 19-7
3. Remove the front cover.
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19.4 Removal of the rear cover
To remove the rear cover you have to remove the left and right cover first.
Necessary tools
No tools.
How to remove the rear cover of the projector?

1. Release the four thumbscrews (two on each side) as illustrated.
x4
Image 19-8
2. Remove the rear cover.
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19.5 Removal of the top cover
To remove the top cover you have to remove the side covers first.
Necessary tools
No tools.
How to remove the top cover of the projector?

1. Disconnect the hot air outlet of the projector from the exhaust system.
2. Lift up the top cover after removing the right, the left, the front and the rear cover.
Image 19-9
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19.6 Removal of the bottom cover

Necessary tools
Flat chubby screwdriver.
How to remove the bottom cover of the projector?

1. Release the ten hexagon head screws as illustrated, using a flat chubby screwdriver.
Image 19-10
2. Lower the bottom cover.
CAUTION: Do not damage the power cables, which are leading through a hole in the bottom cover.
Turn the four feet 10 cm out to have easy access to the bottom of the projector. Pay attention, as feet can be
completely removed!
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19.7 Installation of the bottom cover

Necessary tools
Flat chubby screwdriver.
How to install the bottom cover of the projector?

1. Place the bottom cover into position and fasten with ten (10) screws using a flat chubby screwdriver.
Image 19-11
CAUTION: Do not damage the power cables, which are leading through a hole in the bottom cover.
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19.8 Installation of the top cover
Install the front and rear cover prior to installing the top cover. The side covers have to be installed after the
top cover is installed.
Necessary tools
No tools.
How to install the top cover of the projector?

1. Make sure that the front, rear and both side covers are not installed yet.
2. Place the top cover into position.
Image 19-12
3. Reconnect the wire unit of the connector mounted on the top cover with the Power Backplane.
4. Reconnect the hot air outlet of the projector with the exhaust system.
The top cover will be secured after the front and rear cover are installed.
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19.9 Installation of the rear cover
The rear cover can not be installed if the side covers are installed.
Necessary tools
No tools.
How to install the rear cover of the projector?

1. Place the rear cover into position and fasten with four thumbscrews as illustrated.
x4
Image 19-13
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19.10 Installation of the front cover
The front cover can not be installed if the side covers are installed.
Necessary tools
No tools.
How to install the front cover of the projector?

1. Place the front cover into position and fasten with four thumbscrews as illustrated.
x4
Image 19-14
2. Attach the dust cap to the lens holder by pushing in the five knobs (N) as illustrated.
Image 19-15
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19.11 Installation of the left cover
Ensure that the top, the front and the rear cover are installed before installing the left cover.
Necessary tools
• Lamp house door lock key.
How to install the left cover of the projector?

1. Place the left cover into position.
2. Secure the left cover by fastening the four screws as illustrated.
Image 19-16
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19.12 Installation of the right cover
Ensure that the top, the front and the rear cover are installed before installing the right cover.
Necessary tools
Flat screwdriver.
How to install the right cover of the projector?

1. Check if the lock of the Lamp House door stands in the unlock position.
2. Place the left cover into position.
3. Secure the right cover by fastening the four screws as illustrated.
Image 19-17
4. Lock the Lamp House door.
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19.13 Cleaning the dust filters
Clean the dust filters of the projector head monthly. More frequent cleaning is required in case the projector
head is installed in a dusty or otherwise contaminated area. If the dust filters are not regularly cleaned, the
air flow inside the projector could be disrupted and cause overheating. Overheating may lead to the projector
shutting down by itself.
Necessary tools
• Vacuum cleaner.
• Compressed air.
How to clean the dust filters of the projector head?

2. Take the front filter by its decorative bar H and remove the front filter F from the projector head as illustrated.
H F
Image 19-18
3. Remove the left side cover of the projector head.

4. Remove the dust filter G from the inner side of the left cover C as illustrated.
G
Image 19-19
5. Remove the dust from the filters with a vacuum cleaner.

6. Blow stubborn dust away with compressed air in another room our outside.
7. Reinstall both filters.
8. Reinstall the side cover of the projector head.
Clean the air inlet and outlet of the power unit with a vacuum cleaner as well, while you are cleaning the dust
filters of the projector head.
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19.14 Cleaning the exterior of the projector

Necessary tools
• Damp cloth.
• Mild detergent solution.
How to clean the exterior of the projector head?

1. Switch off the projector and unplug the power cord.
2. Clean the housing of the projector with a damp cloth. Stubborn stains may be removed with a cloth lightly dampened with a mild
detergent solution.
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A. Anamorphic lens and holder
A. ANAMORPHIC LENS AND HOLDER

About this chapter
This chapter describes how to mount and align an anamorphic lens in the anamorphic lens holder. Procedures are also given to
replace the motors inside the anamorphic lens holder.
Overview
• Mounting the anamorphic lens in its holder
• Alignment of the Anamorphic Lens position
• Anamorphic lens holder locking motor replacements
• Anamorphic lens holder rotation motor replacements
• Anamorphic lens holder shift motor replacements
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A.1 Mounting the anamorphic lens in its holder

How to proceed
1. Loosen the 2 screws (A) squeezing the lens holder rings around the installed lens.
A
Image A-1
Loosen lens fixation
2. Carefully, slide the anamorphic lens (covers removed) into the lens holder to the end.
Image A-2
Lens mounting
3. Turn the anamorphic lens in the lens holder in such a way the visual rectangular shape inside the lens is vertical orientated.
Tip: The above adjustment is a coarse adjustment. The final adjustment of the anamorphic lens position has to be performed
while displaying a picture (horizontal display of the picture top side)
4. Secure the lens in its holder by tightening the 2 screws (A).
338 R59770374 DP-3000 16/08/2010

Image A-3
A
Lens securing
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A.2 Alignment of the Anamorphic Lens position

What has to be aligned?
As the position of the anamorphic lens is 5 mm in front of the installed prime lens, for each new installed prime lens this alignment
has to be repeated.
Image A-4
Anamorphic lens position with respect to the installed prime lens
Overview
• Removing the Anamorphic lens holder driver cover
• Distance between Anamorphic and Prime lens
• Remounting the Anamorphic lens holder driver cover
• Image centering on Anamorphic lens
• Horizontal alignment of the image top line
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A.2.1 Removing the Anamorphic lens holder driver cover
How to remove!
1. Remove the 5 screws (A), securing the cover to frame.
Image A-5
Removal cover securing screws
2. Slide the cover backwards to remove.
Image A-6
Cover removal
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A.2.2 Distance between Anamorphic and Prime lens
How to proceed!
1. Loosen the securing screws (B) of the rail lock, blocking the SHIFT IN range of the lens driver unit, on the rack rail and move the
lock (A) to the left (away from the end course switch)
B
Image A-7
Calibration anamorphic lens
2. Using the D-Cine Communicator, click the SHIFT IN arrow button till the rear of the anamorphic lens is 5 mm in front of the prime
lens (image A-4).
3. Put back the rail lock as follows:
- Slide the rail lock (B) to the right till the lever (C) of the end course switch enables the switch.
B
C
A
B
Image A-8
Securing the position of the rail lock
- Secure the position of the rail lock by tightening the rail lock screws (B).
4. Check the previous alignment by moving the lens driver unit OUT and IN, using the D-Cine Communicator SHIFT OUT and
SHIFT IN arrow button.
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Image A-9
Check lens calibration
The calibration is correct if the lens driver unit stops with the anamorphic lens 5 mm in front of the prime lens. If not, repeat the
calibration procedure.
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A.2.3 Remounting the Anamorphic lens holder driver cover
How to proceed
1. Place the bottom of the cover from the rear side into the cover guides (A).
Image A-10
2. Move the cover to the front.

3. Secure the cover with 5 screws (image A-5).
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A.2.4 Image centering on Anamorphic lens
How to proceed
1. Start image projection.
2. D-Cine Communicator, in the “Control Interface Set Up”, click Test Pattern to display the shortcuts of the predefined test patterns.
Image A-11
Set up interface
3. Click the shortcut, displayed with a square white label.

A Full white test pattern replaces the previous projected image.
Image A-12
Test pattern shortcuts
4. Loosen the nut on each lens centering guide (B).
Image A-13
5. Move the lens support, previously putting the lens centering guides (B) in the desired direction, till the lens spot is in center of
the lens.
6. Secure the position of the lens holder by tightening the respective nuts (A).
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A.2.5 Horizontal alignment of the image top line
How to proceed!
After image centering, proceed to the horizontal alignment of the image top line (fine adjustment of the anamorphic lens in its holder)
1. Loosen the 2 screws (A), squeezing the lens holder rings around the lens.
A
Image A-14
Fine alignment anamorphic lens position in its holder
2. Slightly, rotate (B) the lens in its holder until the image top line (C) runs horizontally.
3. Secure the position of the lens by tightening the lens fixation screws (A).
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A.3 Anamorphic lens holder locking motor replacements

Order information
Order number Description
R846905K Anamorphic lens holder locking motor
Overview
• Preparations to remove the motor
• Removing the motor
• Preparation of the new motor
• Mounting the motor
Before starting
Remove the anamorphic lens holder driver cover to get access to the motors. When the motor is replaced, remount this cover.
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A.3.1 Preparations to remove the motor
Preparations
1. Check if the fixation screw on the axle is accessible.
If yes, go to step 3
If no, continue with the next step.
2. Turn the axle with the hand or by using a small tool until the screw is accessible from the top side.
3. Switch off the power of the projector and unplug from the wall outlet.
4. Cut the wire ties.
5. Unplug the plug from the driver module (plug with green wires)
Image A-15
Remove plug with green wires
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A.3.2 Removing the motor
Necessary tools
Allen key 3mm
How to remove ?
1. Turn out the hexagon socket set screw (A).
Image A-16
2. Slide the motor backwards (B).
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A.3.3 Preparation of the new motor
Motor check
1. Check if the flat side of the axle is turn upwards so that it can be inserted.
If the axle is not in the correct position, turn it with the hand or with a small tool until it is in its correct position.
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A.3.4 Mounting the motor
Necessary tools
Allen key 3mm
How to mount ?
1. Slide the axle into its socket (A).
Image A-17
Ensure that the L-shape support plate is on the correct side.

2. Turn in the new hexagon socket set screw (B).
3. Plug the motor plug (green wires) into the socket on the motor driver board (image A-15).
4. Tie the cables together as before.
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A.4 Anamorphic lens holder rotation motor replacements

Order information
R846906K Anamorphic lens holder rotation motor
Overview
• Removing the Anamorphic lens holder front cover
• Remounting the Anamorphic lens holder front cover
Before starting
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A.4.1 Removing the Anamorphic lens holder front cover
How to remove ?
1. Remove the 4 screws, securing the front cover.
Image A-18
2. Take off the front cover.
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Necessary tools
• Nut driver 5mm
• Allen key 5mm
How to remove ?
1. Cut the wire ties and unplug the orange wires from the motor driver board.
Image A-19
Plug out the orange wires
2. Remove the lock nut on the axle side (A).
B A
Image A-20
Removing the motor
3. Turn out the hexagon socket head cap screw fixing the gear wheel to the axle (A).
4. Slide off the gear wheel and the spacer.
5. Turn out the 4 hexagon socket head screws (B) fixing the motor to the frame (2 on top and 2 at the bottom).
6. Side out the motor.
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How to mount ?
1. Slide the axle of the new motor with the flat side trough the axle hole so that the fixation holes matches the holes in the frame.
2. Turn in the 4 fixation screws.
3. Slide the new spacer motor- gear wheel over the axle so that the hole matches the flat side of the axle.
Image A-21
Mounting new motor
4. Slide the new gear wheel over the spacer so that the fixation hole in the gear wheel matches the hole in the spacer and that the
teeth of new gear wheel matches the teeth of the existing gear wheel.
5. Fixate this position by turning in a new hexagon socket set screw with cup point.
6. Secure this position by turning on a nut on the hexagon socket set screw.
7. Plug the connector into its socket on the motor driver board.
8. Tie the wires together as before.
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A.4.4 Remounting the Anamorphic lens holder front cover
How to mount ?
1. Slide the front cover on its place.
Image A-22
Mounting the front cover
2. Turn in the 4 screws, securing the front cover.
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A.5 Anamorphic lens holder shift motor replacements

Order information
R846907K Anamorphic lens holder shift motor
Overview
• Preparations to remove the motor
• Preparation before inserting the new motor
Before starting
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A.5.1 Preparations to remove the motor
Preparations
1. Check if the gear fixation screw is on top of the axle.
If yes, go to step 6
If no, continue with the next step.
Image A-23
2. Connect a PC to the DP100 and start the DCine communicator software.

3. Select tab Projector Setup and click on Lens config.
4. Click on the arrow down just below the lens holder buttons to expand the lens calibration window.
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Image A-24
5. Click on the Shift out or Shift in button until the fixation screw is on top.
6. Switch off the power of the projector and unplug from the wall outlet.
7. Cut the wire ties.
8. Unplug the plug from the driver module (plug with black wires).
Image A-25
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Necessary tools
• Allen key 5mm
• Allen key 4mm
How to remove ?
1. Turn out the hexagon socket set screw.
2. Slide off the gear wheel.
3. Take off the spacer.
4. Turn out the 4 hexagon socket screws holding the motor to the support (2 on top and 2 at the bottom).
Image A-26
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A.5.3 Preparation before inserting the new motor
Motor check
1. Check if the flat side of the axle is turned to the upper side.
2. If not, connect the plug of the motor into the its socket.
If yes, skip this procedure.
3. Switch on the projector and use the DCine communicator software to turn the motor axle.
4. Connect a PC to the DP100 and start the DCine communicator software.
5. Select tab Projector Setup and click on Lens config.
6. Click on the arrow down just below the lens holder buttons to expand the lens calibration window.
Image A-27
7. Click on the Shift out or Shift in button until the flat side of the axle is to the upper side.
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How to mount ?
1. Place the motor against the support.
C
B
Image A-28
2. Fixate this position with the 4 new hexagon socket head cap screws (M4 x 20) (A).
3. Slide a new spacer over the motor axle (B). The hole of the spacer must match the flat side of the axle.
4. Slide the new gear wheel (C) over the axle so that the fixation hole matches the hole in the spacer and the teeth of the gear wheel
matches the teeth of the tooth rack.
5. Turn in a new hexagon socket set screw with cup point (D) and fixate this position.
6. Plug the motor plug into the socket.
7. Tie the cables together as before.
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B. Pin configurations
B. PIN CONFIGURATIONS
Overview
• Pin configuration of the Input & Communication ports
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B.1 Pin configuration of the Input & Communication ports

RS232/422 Serial communication ports
A B
1 2 3 4 5 5 4 3 2 1
6 7 8 9 9 8 7 6
Image B-1
A Pin numbering male D-SUB 9 pins connector.
B Pin numbering female D-SUB 9 pins connector.
RS232/422 input port RS232/422 output port

Pin Description Pin Description
1 DCD : Data Carrier Detect 1 — (not connected) —
2 RXD- : Receive Data 2 RXD- : Receive Data
3 TXD- : Transmitted Data 3 TXD- : Transmitted Data
4 DTR : Data Terminal Ready [RS232] 4 DTR : Data Terminal Ready [RS232]
TXD+ : Transmitted Data [RS422] TXD+ : Transmitted Data [RS422]
5 GND : Ground 5 GND : Ground
6 DSR : Data Set Ready [RS232] 6 DSR : Data Set Ready [RS232]
RXD+ : Received Data [RS422] RXD+ : Received Data [RS422]
7 RTS : Request To Send 7 — (not connected) —
8 CTS : Clear To Send 8 — (not connected) —
9 RI : Ring Indicator 9 — (not connected) —
10/100 Base-T network ports

Pin Description
1 TXD+
2 TXD-
3 RXD+
4 ++2,5VA
5 ++2,5VA
6 RXD-
7 —
8 GNDM
Remote input port
S R T
Image B-2
S Sleeve (shield).
R Ring.
T Tip.
Pin Description
S GND
T RC5 in
R n.c. or GND
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General purpose input/output port (GPIO)

1 GPIN 1 P 20 GPIN 1 N
9 GPOUT 1 P 28 GPOUT 1 N
16 Projector Good P 35 Projector Good N
17 — (not connected) — 36 — (not connected) —
18 TCODE+ 37 TCODE-
19 TCODE SHIELD
RS232/422 input port for TI boards

Pin Description
1 TRSE+ : Request To Send (RTS)
2 RXE- : Receive Data (RD, RX or RXD)
3 TXE- : Transmitted Data (TD, TX or TXD)
4 TXE+ : Data Terminal Ready (DTR)
5 GND : Ground
6 RXE : Data Set Ready (DSR)
7 RTSE- : Request To Send (RTS)
8 CTSE : Clear To Send (CTS)
9 CTSE+ : Clear To Send (CTS)
SMPTE 292 input ports

SMPTE 292 IN Channel A SMPTE 292 IN Channel B
1 Input A HD-SDI 1 Input B HD-SDI
2 GND 2 GND
DVI input ports

1 RX2– 13 — (not connected) —
2 RX2+ 14 +5V
3 RX2 Shield 15 GND
4 — (not connected) — 16 Hot Plug Detect
5 — (not connected) — 17 RX0–
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6 DDC Clock 18 RX0+
7 DDC Data 19 RX0 Shield
8 — (not connected) — 20 — (not connected) —
9 RX1– 21 — (not connected) —
10 RX+ 22 TMDS Clock Shield
11 RX1 Shiled 23 TMDS RXC+
12 — (not connected) — 24 TMDS RSC-
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Glossary
GLOSSARY
DVI
Digital Visual Interface is a display interface developed in response to the proliferation of digital flat panel displays.
The digital video connectivity standard that was developed by DDWG (Digital Display Work Group). This connection standard offers
two different connectors: one with 24 pins that handles digital video signals only, and one with 29 pins that handles both digital
and analog video. This standard uses TMDS (Transition Minimized Differential Signal) from Silicon Image and DDC (Display Data
Channel) from VESA (Video Electronics Standards Association).
DVI can be single or dual link.
RS232
An Electronic Industries Association (EIA) serial digital interface standard specifying the characteristics of the communication path
between two devices using either D-SUB 9 pins or D-SUB 25 pins connectors. This standard is used for relatively short-range
communications and does not specify balanced control lines. RS-232 is a serial control standard with a set number of conductors,
data rate, word length and type of connector to be used. The standard specifies component connection standards with regard to
computer interface. It is also called RS-232-C, which is the third version of the RS-232 standard, and is functionally identical to the
CCITT V.24 standard. Logical ’0’ is > + 3V, Logical ’1’ is < - 3V. The range between -3V and +3V is the transition zone.
RS422
An EIA serial digital interface standard that specifies the electrical characteristics of balanced (differential) voltage, digital interface
circuits. This standard is usable over longer distances than RS-232. This signal governs the asynchronous transmission of computer
data at speeds of up to 920,000 bits per second. It is also used as the serial port standard for Macintosh computers. When the
difference between the 2 lines is < - 0.2V that equals with a logical ’0’. When the difference is > +0.2V that equals to a logical ’1’..
Scheimpflug principle
The "plane of sharp focus" can be changed so that any plane can be brought into sharp focus. When the DMD plane and lens plane
are parallel, the plane of sharp focus will also be parallel to these two planes. If, however, the lens plane is tilted with respect to the
DMD plane, the plane of sharp focus will also be tilted according to geometrical and optical properties. The DMD plane, the principal
lens plane and the sharp focus plane will intersect in a line below the projector for downward lens tilt.
SMPTE
Society of Motion Picture and Television Engineers - A global organization, based in the United States, that sets standards for
baseband visual communications. This includes film as well as video standards.
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Glossary
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Index
INDEX
A Reflector 138
Access 90 UV blocker 137
Power Unit base 90 cleaning 222
Adaptation ring 109 lens 222
Adapters 109 Cleaning 335
Anode 109 Exterior 335
Adaptors 110 Cold Mirror 139, 141, 143, 145
Cathode 110 Adjust 143
Adjust 143, 153, 165, 168, 170–171, 223 Clean 145
Cold Mirror 143 Replace 141
Convergence 165 Cold Mirror Bottom Fan 318
Fold Mirror 168 Replace 318
Lens Holder 223 Cold Mirror Top Fan 315
Light Pipe Zoom Lens 170 Replace 315
Notch Filter 171 Communication interface 92
Rod 153 Power Unit 92
Scheimpflug 223 Replace 92
Air exhaust 310 Connect 81, 84
Fan 310 Power LPS 81
Replace 310 Power net 84
Align 126 Control Panel 281
Arc 126 Control ports 266
Stabilizing magnet 126 Convention 10, 14
Alignment 346 Orientation 10, 14
Image top line 346 Convergence 165
Anamorphic lens 337–338 Adjust 165
Mounting in its support 338 Cooling circuit 182–184, 186, 189, 191, 193, 195
Anamorphic lens holder 337, 347, 352, 357 Calibrate 195
Motor replacements 347, 352, 357 Drain 184
Locking motor 347 Exclude 183
Rotation motor 352 Light Processor 183
Shift motor 357 Expel air 191
Anamorphic lens position 340 Fill 186
Alignment 340 Light Processor 183
Anode adaptation 109 Exclude 183
Anode Fan 300, 310 Pressure 182
Replace 300, 310 Pressurize 193
Anode support 109 Refresh 189
Authorization 245 Cooling Circuit. 178
Security warning 245 Introduction 178
Covers 321
B
Block diagram 17
D
Board 246 Diagnostics 158, 180
Replace 246 DIMM PC 279
Bottom cover 327–328 Replacement 279
Install 328 Distance 342
Remove 327 Anamorphic/Prime lens 342
Button module 285 Dowser 174
Replace 285 Drain 184
Cooling circuit 184
Dust filters 334
C Clean 334
DVI input 268
Calibrate 195 DVI input board 277
Cooling circuit 195 Replacement 277
Card cage 239
Diagnostic 239
Card Cage 237–238, 320
Fan 320
E
Introduction 238 elcabox 320
Card Cage cover 242, 244 Fan 320
Install 244 Error code name 37–50, 52–73
Remove 242 ++12v - voltage high 37
Cathode Fan 306 ++12v - voltage low 37
Replace 306 ++5v - voltage high 37
Clean 137–138, 145, 172–173, 204, 334 ++5v - voltage low 37
Cold Mirror 145 +12v - voltage high 38
Dust filters 334 +12v - voltage low 38
Notch Filter 172 +24v - voltage high 38
Prism 173 +24v - voltage low 38
Pump 204 +3.3v - voltage high 37
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Index
+3.3v - voltage low 37 other fans - voltage high 73

+5v - voltage high 37 other fans - voltage low 73
+5v - voltage low 38 pfc - temperature high 64
airflow - not ok 38 pfc - temperature low 64
ambient - temperature high 39 pulse generator fan - speed high 65
ambient - temperature low 39 pulse generator fan - speed low 65
ambient - temperature too high 39 rack - temperature high 66
Cold Mirror bottom fan - speed high 40 rack - temperature low 66
Cold Mirror bottom fan - speed low 40 sealing fan - speed high 66
Cold Mirror top fan - speed high 41 sealing fan - speed low 67
Cold Mirror top fan - speed low 41 smps - i2c failed 67
dmd blue - temperature high 42 smps1 primary - temperature high 67
dmd blue - temperature low 42 smps1 primary - temperature low 67
dmd blue - temperature too high 42 smps1 secondary - temperature high 68
dmd blue - temperature too low 42 smps1 secondary - temperature low 68
dmd green - temperature high 43 smps2 primary - temperature high 68
dmd green - temperature low 43 smps2 primary - temperature low 68
dmd green - temperature too high 43 smps2 secondary - temperature high 69
dmd green - temperature too low 43 smps2 secondary - temperature low 69
dmd red - temperature high 42 tec - voltage high 69
dmd red - temperature low 43 tec - voltage low 69
dmd red - temperature too high 42 tec blue - not connected 70
dmd red - temperature too low 42 tec blue - temperature high 70
efib - command/parameter error 44 tec blue - temperature too high 71
efib - flash mailbox download error 44 tec green - not connected 71
efib - flash update error 44 tec green - temperature high 71
efib - i2c failed 43 tec green - temperature too high 71
efib - modular formatter architecture error 45 tec red - not connected 71
efib - modular formatter blue link communication error 46 tec red - temperature high 72
efib - modular formatter green link communication error 45 tec red - temperature too high 72
efib - modular formatter red link communication error 46 ti - security error, please authorize 73
efib - modular formatter sequence error 45 ti - system status = fail 72
efib - modular formatter/dmd mismatch error 45 ti - system status read failed 73
efib - sequence data error 45 ti-boards - interface board security enclosure error 72
efib - system failure 44 water - flow not ok 73
elcabox - temperature high 46 Ethernet 266
elcabox - temperature low 46 Expel air 191
elcabox fan1 - speed high 47 Cooling circuit 191
elcabox fan1 - speed low 47 Exterior 335
elcabox fan2 - speed high 48 Cleaning 335
elcabox fan2 - speed low 48
elcabox fan3 - speed high 48
elcabox fan3 - speed low 49 F
elcabox fan4 - speed high 49 Fan 299, 320
elcabox fan4 - speed low 49 Card Cage 320
engine - not connected 50 elcabox 320
lamp - read run time failed 50 Replace 299
lamp - read run time limits failed 52 SMPS 320
lamp - run time exceeds maximum 52 Fill 186
lamp - run time too high - soon no startup 52 Cooling circuit 186
lamp - run time too high - startup blocked 53 Flowchart 36
lamp - run time warning 52 Troubleshooting 36
lamp anode fan - speed high 53 Focus motor 234
lamp anode fan - speed low 53 Fold Mirror 168
lamp anode fan - voltage high 54 Adjust 168
lamp anode fan - voltage low 54 Front cover 324, 331
lamp cathode fan - speed high 54 Install 331
lamp cathode fan - speed low 55 Remove 324
lamp cathode fan - voltage high 55
lamp cathode fan - voltage low 55
lamp house - not connected 56 G
lamp house - temperature high 57
lamp house - temperature low 57 General 9
lamp house - temperature too high 56 General Purpose I/O 267, 269
lamp top fan - speed high 57 GPIO 267, 269
lamp top fan - speed low 58 GPIO board 278
lamp top fan - voltage high 58 Replacement 278
lamp top fan - voltage low 59
lens focus position - requested target not reached 59
lens horizontal shift position - requested target not reached 60 H
lens vertical shift position - requested target not reached 60 HD-SDI input 268
lens zoom position - requested target not reached 60 Heat Exchanger 210
lps - at least one could not be detected 63 Replace 210
lps - communication failed 61 Horizontal shift motor 232
lps - not detected 62
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Index
I Lens formulas 218

Image centering 345 Lens holder 213
Anamorphic lens 345 Lens Holder 223, 226, 228
Input & communication 271, 274 Adjust 223
Remove 271, 274 Install 228
Input & Communication 263–264 Remove 226
Introduction 263–264 Lens Signal Distribution 236
Input ports 268 Lenses 213, 216, 218
Install 88, 96, 116, 121, 130, 151, 175, 201, 208, 228, 230, 232, Available 216
234, 236, 244, 295, 328–333 Formulas 218
Bottom cover 328 Light Pipe Zoom Lens 170
Card Cage cover 244 Adjust 170
Focus motor 234 Light Processor 155–156, 159, 162
Front cover 331 Install 162
Horizontal shift motor 232 Introduction 156
Lamp 116 Remove 159
Lamp house 121 Light Sensor 175
Left cover 332 Liquid Cooling 177–178
Lens Holder 228 Introduction 178
Lens Signal Distribution 236 Local keypad 283
Light Sensor 175 Local Keypad 288
LPS 88 Replace 288
LPS rack 96 Location 11, 15
Pump 201 Main components 11, 15
Pump (complete) 208 LPS 79, 86, 88
Rear cover 330 Diagnostic 79
Right cover 333 Install 88
Rod 151 Remove 86
Top cover 329 LPS rack 96
Touch panel 295 Install 96
UV blocker 130
Vertical shift motor 230
Integration Rod 147–149 M
Diagnostic 149 Main components 11, 15
Introduction 148 Location 11, 15
Introduction 76, 100, 106, 140, 148, 178, 214, 238, 264, 282 Mains Filter 94
Card Cage 238 Power Unit 94
Input & Communication 264 Replace 94
Integration Rod 148 Maintenance 27–29, 32–33
Lens 214 1 year 29
Lens holder 214 10 year 33
Liquid Cooling 178 4 year 32
SPG 100 6 month 28
IR-receiver 283 Lamp change 27
Maintenance program 25–26
1 Month 26
K Motor 348–351, 354–355, 358, 360–362
Keypad 283 Mount 355
Mounting 351, 361–362
Preparation 361
L Preparation 350
Preparations 358
Lamp 105, 108, 113, 123–124 Remove 348–349, 354, 360
Realignment 124 Preparations 348
Remove 113 Mounting 356
Reset 123 Anamorphic lens holder front cover 356
Supported 108
Lamp house 105, 111, 134
Reflector 134
Remove 111
N
Lamp House 137–138 Notch Filter 171–172, 176
Reflector 138 Adjust 171
Clean 138 Clean 172
UV blocker 137 Replace 176
Clean 137
Lamp info module 128
Replace 128 O
Left cover 323, 332 ON/OFF switch 266
Install 332 Orientation 10, 14
Remove 323 Convention 10, 14
lens 222
cleaning 222
Lens 217, 219, 221 P
Install 219 Pin configurations 363
Removal 221 Ports 364
Selection 217 Pins 364
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Index
Position 298 Heat Exchanger 210

Touch panel 298 Lamp info module 128
Power input 266 Light Sensor 175
Power Unit 75, 92, 94 Local Keypad 288
Communication interface 92 Outlet Fan 310
Mains Filter 94 Pump (complete) 208
Power Unit base 90 Pump motor 206
Access 90 Pump rotor 206
Power unit control 267 Reflector 134
Pressure 182 Shutter 174
Cooling circuit 182 SPG Fan 319
Pressurize 193 Status Lights 291
Cooling circuit 193 Replace Notch Filter 176
Prism 173 Reset 123
Clean 173 Lamp 123
Pump 198, 201, 204, 208 Right cover 322, 333
Clean 204 Install 333
Install 201 Remove 322
Remove 198 Rod 149–151, 153
Replace 208 Adjust 153
Pump motor 206 Diagnostic 149
Pump rotor 206 Install 151
Remove 150
RS232 266
R RS422 266
Rack control 267
Realignment 124
Lamp 124 S
Rear cover 325, 330 Safety 5–6
Install 330 Instructions 6
Remove 325 Scheimpflug 223
Reflector 134, 138 Serial communication 266
Clean 138 Shutter 174
Replace 134 SMPS 320
Refresh 189 Fan 320
Cooling circuit 189 SMPTE 292 268
Remote control 266 Spare parts 20
Remounting 344 SPG 99–103
Anamorphic lens holder driver cover 344 Introduction 100
Remove 86, 102–103, 111, 113, 150, 175, 198, 208, 226, 230, 232, Remove 102–103
234, 236, 242, 322–327 Troubleshooting 101
Bottom cover 327 SPG Fan 319
Card Cage cover 242 Replace 319
Focus motor 234 Start Pulse Generator 99
Front cover 324 Status LED 283
Horizontal shift motor 232 Status Lights 291
Lamp 113 Replace 291
Lamp house 111 Supported 108
Left cover 323 Lamps 108
Lens Holder 226
Lens Signal Distribution 236
Light Sensor 175 T
LPS 86 TI Boards 249
Pump 198 Update 249
Pump (complete) 208 TI update 252–253, 255, 257, 259–261
Rear cover 325 Connection 252–253
Right cover 322 Ethernet 253
Rod 150 Serial 252
SPG 102–103 Factory install options 260
Top cover 326 Installation 255
Vertical shift motor 230 Logging 257
Removing 341, 353 Special functions 259
Anamorphic lens holder driver cover 341 Stay in Boot 261
Anamorphic lens holder front cover 353 Top cover 326, 329
Replace 128, 134, 141, 174–175, 206, 208, 210, 246, 285, 288, Install 329
291, 299–300, 306, 310, 315, 318–319 Remove 326
Air exhaust 310 Touch panel 293–295, 298
Anode Fan 300 Install 295
Button module 285 Introduction 294
Card Cage board 246 Position 298
Cathode Fan 306 Trouble shooting 35, 37
Cold Mirror 141 Checklist 37
Cold Mirror Bottom Fan 318 Troubleshooting 36, 101
Cold Mirror Top Fan 315 First level 36
Dowser 174 Flowchart 36
Fan 299
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Index
SPG 101 Install package 250

TI Boards 249
UV blocker 137
U Clean 137
Update 249–251
Program 251
Start up 251 V
TI boards 250 Vertical shift motor 230
R59770374 DP-3000 16/08/2010 373

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DP-3000

3. Preventative maintenance actions .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 25

6. Start Pulse Generator.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 99

7. Lamps and Lamp House .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 105

8. Cold Mirror .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 139

9. Integration Rod . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 147

10. Sealed Light Processor Assembly .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 155

R59770374 DP-3000 16/08/2010 1

10.3 Removal of the Sealed Light Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159

11. Liquid Cooling Circuit . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 177

12. Lenses and Lens Holder .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 213

13. Card Cage.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 237

14. Updating TI Boards .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 249

15. Input & Communication unit . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 263

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16. Control Panel.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 281

17. Communicator Touch Panel .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 293

18. Fan replacement procedures. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 299

19. Projector covers .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 321

A. Anamorphic lens and holder .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 337

B. Pin configurations . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 363

R59770374 DP-3000 16/08/2010 3

4 R59770374 DP-3000 16/08/2010

WARNING: This manual is only intended for qualified service personnel.

R59770374 DP-3000 16/08/2010 5

1.1 Safety Instructions

AC Leakage Test Leakage Current Tester

Device Under Test

Test all exposed metal surfaces

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R59770374 DP-3000 16/08/2010 7

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2.1 Convention projector orientation

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2.2 Location of the main components of the projector

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Main internal components

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2.3 Convention Power Unit orientation

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2.4 Location of the main components of the Power Unit

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Parts of the base of the Power Unit

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2.5 Projector block diagram

Interface Board Processor Board EFIB Board Formatter

Input Processing Data Processing

ARM7 MicroController Digital Signal Proc

Mass Store Boot Flash Boot Flash

R59770374 DP-3000 16/08/2010 17

R59770374 DP-3000 16/08/2010

Projector power circuitry

+16..24V Fan ohters Anamorphic

+16..24V Fan Top (Exhaust)

+16..24V Fan Anode Anode Fan

+16..24V Fan Cathode Cathode Fan

++5V SMPS Fan 3