Barco Galaxy NW-7 EX Installation guide

Engine kit

Installation Manual

Galaxy NH-12, Galaxy NW-12, Galaxy NW-7, NH-12, NW-12

R850601K

R8506011K

R59770591/00

26/08/2010

Barco nv Simulation Division

Noordlaan 5, B-8520 Kuurne

Phone: +32 56.36.82.11

Fax: +32 56.36.84.86

E-mail: [email protected]

Visit us at the web: www.barco.com

Printed in Belgium

stored in a retrieval system without the prior written consent of Barco.

Changes

Barco p rovides this manua l ’as is’ without warranty of any kind, either expressed or implied, including but not limited to the implied war-

ranties or m erchantability and ﬁtness for a particular purpose. Barco may make improvements and/or cha nges 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 periodic

ally m ade to the information in this

publication; these changes are incorporated in new editions of this publication.

Trademarks

Brand and product name s mentioned in this manual m ay be trademarks, registered trademarks or copyrights of their respective holders.

All brand and product n ames mentioned in this man ual serve as commen ts or examples and are not to be understood as adv ertising for

the products or their m anufacturers.

Disposal Information

This equipment has required the ex traction and use of natural resources for its produc tion. It may contain hazardous substances for health

and env ironme nt. In order to av oid the d issemination of those substances in the env ironment and to diminish the pressure on natural

resources, we encourage you to use the appropriate take-back systems. Those systems will reuse or recycle most of the materials of yo ur

end of life equipment in a sound way.

The crossed-out wheeled bin symbol invites you to use those syste

ms. If you need more information on the collection, reuse and recycling

systems, please contact y our local or regional wa ste administrator. You can also contact us for m ore information on the environmental

performances of ou r products.

Table of contents
TABLE OF CON TENTS
Safety instructions................................................................................................. 3
1 Safety during kit installation .......................................................................................................... 3
Kit description ...................................................................................................... 5
1 Kit information ........................................................................................................................ 5
2 Kit content ............................................................................................................................ 6
Engine replacement................................................................................................ 7
1 Preparing the projector ............................................................................................................... 7
1.1 How to prepare the projector before replacing? . ............................................................................. 7
1.2 Shifting the lens holder to nominal position ................................................................................... 7
1.2.1 Removing the c able basket . . . .......................................................................................... 7
1.2.2 Removing the r ear cover ................................................................................................ 8
1.2.3 Removing the top cover ................................................................................................. 9
1.2.4 Procedure to shift the lens holder to nominal position ................................................................10
2 Removing the engine ................................................................................................................ 11
2.1 Removing engine fan cover 1 ................................................................................................ 11
2.2 Removing the engine fan cover 2 . . . ......................................................................................... 11
2.3 Removing the engine controller frame ass embly . ........................................................................... 12
2.4 Removing fan unit 2...........................................................................................................13
2.5 Removing the engine .........................................................................................................13
3 Replacing with the new engine ...................................................................................................... 16
3.1 Installing t he new e ngine . . . ..................................................................................................17
3.2 Installing the fan unit 2 ........................................................................................................ 21
3.3 Installing the engine c ontroller frame ass embly . . ...........................................................................21
3.4 Installing t he engine fan cover 2..............................................................................................22
3.5 Installing t he engine fan cover 1..............................................................................................23
3.6 Installing t he top cover ........................................................................................................24
3.7 Installing the rear cove r ....................................................................................................... 25
4 Alignment procedure ................................................................................................................ 26
4.1 Folding mirror alignment......................................................................................................26
4.2 Integrating rod alignment .....................................................................................................27
4.2.1 Description of the integrating rod alignment...........................................................................27
4.2.2 Integrating rod rotation alignment . . . ...................................................................................28
4.2.3 Integrating rod shift alignment . ........................................................................................ 30
4.3 Cold mirror alignment .........................................................................................................31
4.4 Scheimpﬂug adjustment ......................................................................................................33
4.4.1 Description of the Scheimpﬂug adjustment............................................................................ 33
4.4.2 Adjusting the Scheimpﬂug .............................................................................................36
4.5 Convergence adjustment . . . ..................................................................................................38
4.5.1 Introduction .............................................................................................................38
4.5.2 Convergence controls of the red channel . . ...........................................................................38
4.5.3 Convergence controls of the green chann el...........................................................................41
4.5.4 Adjusting the convergence . . .. . ........................................................................................ 42
4.5.5 Example of convergence correction ...................................................................................46
Index......................................................................................................................47
List of images...........................................................................................................49
R59770591 ENGINE KIT 26/08/2010 1

Table of contents

2 R59770591 ENGINE KIT 26/08/2010

1. Safety instructions

1. SAFETY INSTRUCTIONS

1.1 Safety during kit installation

WARNING: The procedures below may only be performed by Barco trained and qualiﬁed t echnicians.

WARNING: Power down the projector and remove the power cord form the wall outlet before removing any

of the projector co vers.

WARNING: T he projector m ust be cooled do wn before rem oving any of the p rojector covers: wait for the cool

down cycle to ﬁnish after swi tching the projector to standby (the sound of the fans comes to a very low level)

and wait for 15 mo re m inutes before start ing any of t he pro cedures b elow.

CAUTION: Wear a wrist band wh ich is connected to the ground while handling the electrostatic discharge

sensitive parts.

CAUTION: Do not t ouch any of the glass parts!

R59770591 ENGINE KIT 26/08/2010 3

1. Safety instructions

4 R59770591 ENGINE KIT 26/08/2010

2. Kit description

2. KIT DESCRIPTION

Overview

• Kit information

• Kit conte nt

For the latest updates of this manual, browse to www.barco.com (public) or https://my.barco.com (secured)

or intranet (Barco employees only).

Overview

The engine unit consists of the following parts:

Image 2-1

• light pipe — makes the light beam hom ogeneous and sets the correct aspect ratio to the light beam

• prism and formatters — the prism splits up the hom ogeneous white light into red, green and blue light beams and dire cts them

to the DMD’s. Next, this prism merg es the processed light beam s into one full color video image, wh ich is projected via the

projector lens onto the screen

• cooling circuit — keeps the temperature o

f the engine within its limits

2.1 Kit information

Scope

The projector type determines the k it to be used:

Projector type

Type of display

Kit numb er Description

NH-12, Galaxy NH-12, iD LH-12

HDTV R850601K Engine

NW-12, Galaxy NW-12, G alaxy NW-7 WUXGA

R8506011K Engine

R59770591 ENGINE KIT 26/08/2010 5

2. Kit description

2.2 Kit content

Kit overview

Kit number

Content

Article number

Quan ti ty

Engine R850601 1

Wooden board R732622 1

Hexagon head screw B360192 2

Washer V3673776 4

Nut

G116900

2

R850686 — thickness: 0.1MM 1

R8506861 — thickness: 0.2MM 1

R8506862 — thickness: 0.3MM 1

Sheet metals (shims)

R8506863 — thickness: 0.5MM 1

R850601K

Installation manual R59770591 1

Engine R8506011 1

Wooden board R732622 1

Hexagon head screw B360192 2

Washer V3673776 4

Nut

G116900

2

R850686 — thickness: 0.1MM 1

R8506861 — thickness: 0.2MM 1

R8506862 — thickness: 0.3MM 1

Sheet metals (shims)

R8506863 — thickness: 0.5MM 1

R8506011K

Installation manual R59770591 1

6 R59770591 ENGINE KIT 26/08/2010

3. Engine replacement

3. ENGINE R EPLACEMENT

Overview

• Preparing the projector

• Rem oving the engine

• Replacing with the new engine

• Alignment proced ure

3.1 Preparing the projector

3.1.1 How to prepare the projector before replacing?

Overview

1. Shift the lens h older to nominal position. S ee "Shifting the lens holder to nominal position", page 7.

2. Leave the projector to cool down

3. Power down the projector

4. U nplug the power cord from the wall outlet

3.1.2 Shifting the lens holder to nominal position

Overview

• Rem oving the cable basket

• Rem oving the rear cover

• Rem oving the top cover

• Procedure to shift the lens holder to nominal pos ition

Description

The nominal position of the lens holder is the position of no vertical shift and no horizontal shift. T his is on-axis projection whe re the

projection lens ce nter is coincident with the image center.

The lens need to be shifted to n om inal position in order to reach the screw s ﬁxing the engine to the lens holder.

Steps to follow:

1. remove the cable basket

2. remove the rear cover

3. remove the top co ver

4. shift the lens ho lder

3.1.2.1 Removing the cable basket

Necessary tools

No tools.

How to remove the cable basket?

1. Push the m etal joggle to the front side of the projector

R59770591 ENGINE KIT 26/08/2010

7

3. Engine replacement

Image 3-1

Cable basket: push the joggle

2. First lift the cable basket, then bring it forward to remove it

Image 3-2

Cable basket: lift, then pull to remove it

3.1.2.2 Removing the rear cover

Necessary tools

Phillips Ph2

How to remove the rear cover?

1. R emove the ﬁx ing screw

Image 3-3

Rear cover: ﬁxing screw

2. Lift the b ack side of the rear cover and pull it backward to remove it

8

R59770591 ENGINE KIT 26/08/2010

3. Engine replacement

Image 3-4

Tilt the back side of t he rear cover

Image 3-5

Pull the rear cover backward

Image 3- 6

Rear cover removed

3.1.2.3 Removing the top cover

Necessary tools

Phillips s crew dr iver Ph2

How to remove the top cover?

1. R emove the four ﬁxing screws

- two at the front side of the projector

- one at the left side

- one at the right side

Image 3-7

Top cover: front screws

Image 3-8

Top cover: l eft screw

Image 3-9

Top cover: right screw

2. Lift the top cover to remove it

R59770591 ENGINE KIT 26/08/2010

9

3. Engine replacement

Image 3-10

Top cover: lift to remove

3.1.2.4 Procedure to shift the lens holder to nominal position

How to shift the l ens holder to nominal position?

1. Shift up or dow n until screw head V is centered between both end of course switches at the side of the lens ho lder

Y

End of course switch

Reference point V

Y

Image 3-11

Vertical shift: nominal position

2. Shift left or right until screw head H is centered b etween both end of course switches at the top of the lens holder

XX

End of course switch

Reference point H

Image 3-12

Horizontal shift: nominal position

10 R59770591 ENGINE KIT 26/08/2010

3. Engine replacement

3.2 Removing the engine

Overview

You need to perform all of the following procedures in the same order to rem ove the engine of the projector.

1. Remove the engine fan cover 1

2. Remove the engine fan cover 2

3. Remove the engine controller frame assembly

4. Remove fan unit 2

5. Remove the engine

3.2.1 Removing engine fan cover 1

Necessary tools

Torx screw d river T20

How to remove the engine fan c over 1?

1. R emove the ﬁxin g screws (7x)

Image 3-13

Engine fan cover 1: ﬁxing screws

2. Lift the engine fan cover 1 to remove it

Image 3-14

Engine fan cover: lift to remove

3.2.2 Removing the engine fan c over 2

To make it p ossible to remove or install the engine fan cover 2, mak e sure the engine fan cover 1 has been

removed ﬁrst!

R59770591 ENGINE KIT 26/08/2010 11

3. Engine replacement

Necessary tools

Torx screw d river T20

How to remove the engine fan c over 2?

1. R emove the four ﬁxing screws

Image 3-15

Engine fan cover 2: ﬁxing screws

2. Lift the engine fan cover 2 to remove it

3.2.3 Removing the e ngine controller frame assembly

Necessary tools

Torx screw d river T20

How to remove the engine controller frame assembly?

1. U nplug the c onnectors of the engine c ontroller:

- J5: I2C from the PMP

- J30: from DMD temperature switch

- J101: power and pulses from fan LPS vertical

- J102: power and pulses from fan LPS top

- J104: power to the cooling pump

- J110: fan s upply to the X-fan supply

- J120: fan pulses towards the pow er box

- J130: +12V from the pow er box

- J220: from the lens shift safety switch

- J230: signals from the CLO /LFR sensor

- J400: to the LFR light feedback board

- J402: I2C to the LPS

- J403: data from the lamp info receiver

2. U nplug the fan cold mirror connector: J512 on the X- fan sup ply

3. Release the screws ﬁxing the engine controller fram e assembly

Tip: Do no t remov e these screws, just unscrew them a single revolution

12

R59770591 ENGINE KIT 26/08/2010

3. Engine replacement

Image 3-16

Engine controller frame assembly: ﬁxing screws

4. Slide out the engine controller frame unit by lifting it

3.2.4 Removing fan unit 2

Overview

The fan engine top and fan engine bottom — the assembly of those two fa

ns is called FA N un it 2.

Necessary tools

Torx screw d river T20

How to remove fan unit 2?

1. U nplug both fan engine top and fan engine bottom:

- connector J400 on the X- fan supply (blue wire)

- connector J401 on the X -fan supply (red wire)

2. Remov e the screws ﬁxing fan unit 2

Image 3-17

Fan unit 2: ﬁxing screws

3. Lift and tilt fan unit 2 to remove it

3.2.5 Removing the engine

Necessary tools

Torx screw d river T20

How to re move the engine?

1. R emove both screws ﬁxing the engine to the lens holder

R59770591 ENGINE KIT 26/08/2010

13

3. Engine replacement

Image 3-18

Screws ﬁxing the engine to the lens holder

Note: In the dr awing ab ove, the lens holder has been lifted for visibility. In reality, the lens holder can stay in the projector.

2. R emove both screws ﬁxing the engine to the projector frame

Image 3-19

Engine: location of the ﬁxing screws 1 a nd 2 (top view)

14 R59770591 ENGINE KIT 26/08/2010

3. Engine replacement

Image 3-20

Engine: ﬁxing screw 1 (3D view)

Image 3-21

Engine: ﬁxing screw 2 (3D view)

3. U nplug the connectors on the preformatter board:

- 6 signal cables

o

2 signals cables going to the red formatter

o

2 signal cables going to the gr een formatter

o

2 signal cables going to the blue forma tter

- 3 power cables

o

1 cable to the green formatter

o

1 cable to the red formatter

o

1 cable to the blue formatter

GREEN

BLUE

POWER

G R B

RED

Image 3-22

Engine: connectors

4. R elease the screws ﬁxing the grounding wires next to the connectors mentioned in the previous step:

- 3 grounding wires (signal)

- grounding wires (power)

5. U nplug the a dditional power wires on each of the formatter boards if they are present

R59770591 ENGINE KIT 26/08/2010

15

3. Engine replacement

Image 3-23

Power cables connected to the preformatter board

Image 3-24

R: Power cable connected to the Red formatter board

G: Power cable connected to the Green formatter board

B: Power cable connected to the Blue formatter board

6. Fix the handle to the engine ( if available)

7. Gently lift the eng ine to remove it

3.3 Replacin g with the new engine

Overview

• Installing the new engine

• Installing the fan unit 2

• Installing the engine con troller frame assemb ly

• Installing the engine fan cover 2

• Installing the engine fan cover

1

• Installing the top cover

• Installing the rea r cover

16

R59770591 ENGINE KIT 26/08/2010

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