Barco RLM G5, R9010020 Service Manual

RLM G5

Service Manual

R9010020

R5976766/00
22/04/2004

Barco nv Events

aan 5, B-8520 Kuurne

Noordl
Phone: [phone]
Fax: [phone]

[e-mail]

E-mail:
Visit us at the web: www.barco.com

PrintedinBelgium

Copyright ©

All rights reserved. No part of this document may be copied, reproduced or translated. It shall n ot otherwise be recorded, transmitted or
stored in a retrieval system without the prior written consent of Barco.

Guarantee and Compensation

Barco provides aguaranteerelatingtoperfect manufacturing as part of the legally stipulated terms of guarantee. On receipt, the purchaser
must immediately inspect all delivered goods for damage incurred during transport, as wellas for material and manufacturing faults Barco
must be informed immediately in writing of any complaints.

The period of guarantee begins on the date of transfer of risks, in the case of special systems and software on the date of commissioning,
at latest 30 days after the transfer of risks. In the event of justified notice of compliant, Barco can repair the fault or provide a replacement
at its own discretion within an appropriate period. If this measure proves to be impossible or unsuccessful, the purchaser can demand a
reduction in the purchase price or cancellation of the contract. All other claims, in particular those relating to c ompensation for direct or
indirectdamage, and also damage attributed to the operationof software as well asto other services provided by Barco, being a component
ofthe system or independent service, will be deemed invalid p rovided the damage is not proven to beattributed to the absence of properties
guaranteed in writing or due to the intent or gross negligence or part of Barco.

If the purchaser or a third party carries out modifications or repairs on goods delivered by Barco, or if the goods are handled incorrectly,
in particular if the systems are commissioned operated incorrectly or if, after the transfe
agreed upon in the contract, all guarantee claims of the purchaser will be rend ered invalid. Not included in the guarantee coverage are
system failures which a re attributed to programs or special electronic circuitry provided by the purchaser, e.g. interfaces. Normal wear as
well as normal maintenance are not subject to the guarantee provided by Barco either.

The environmental conditions as wellas the servicing and maintenance regulations specified in the this manual must be complied with by
the customer.

r of risks, the goods are subject to influences not

Changes

Barco provides this manual ’as is’ without warranty of any kind, either expressed or implied, including but not limited to the implied w ar­ranties or merchantability an d fitness for a particular purpose. Barc
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 p ublication.

o may make improvements and/or changes to the product(s) and/or the

Federal Communications Commission (FCC Statement)

This equipment has been tested and found to comp ly with the li
These limits are designed to provide reasonable protection against harmful interference when the equ ipment is operated in a commercial
environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with
the instruction manual, may cause harmful interferenc
cause harmful interference, in which case the user will be responsible for correcting any interference.

e to radio communications. Operation of this equipment in a residential area may

mits for a class A digital device, pursuant to Part 15 of the FCC rules.

Table of contents

TABLE OF CONTENTS

1. General Information................................................................................................. 3

1.1 RLMR5 Performer .................................................................................................................... 3

2. Safety.................................................................................................................. 5

2.1 Safety Instructions .................................................................................................................... 5

3. Safety Symbols ...................................................................................................... 9

3.1 Overview used Safety Symbols....................................................................................................... 9

4. Block Diagram RLM R5 Performer .............................................................................. 11

4.1 Simplified Block Diagram ............................................................................................................ 11

4.2 Expanded Block Diagram............................................................................................................12

5. Technical Informations ............................................................................................13

5.1 Conventions..........................................................................................................................13

5.2 Connector Removal Instructions.....................................................................................................13

6. Spare Parts list .....................................................................................................15

6.1 Spare Parts list ....................................................................................................................... 15

7. Projector Cover Removal to access Modules.................................................................17

7.1 Top Access Modules ................................................................................................................. 17

7.1.1 Removal of the Rear cover.................................................................................................... 17

7.1.2 Removal of the Button panel cover ........................................................................................... 17

7.1.3 Removal of the top cover...................................................................................................... 18

7.1.4 Top shield removal............................................................................................................. 19

7.2 Side Access Modules ................................................................................................................20

7.2.1 Side Cover left.................................................................................................................20

7.2.1.1 Removal of the Side cover..............................................................................................20

7.2.1.2 Side shield removal ..................................................................................................... 21

7.2.2 Side Cover Right............................................................................................................... 21

7.2.2.1 Removal of the Side cover..............................................................................................21

7.2.2.2 Side Shield removal.....................................................................................................21

7.2.2.3 PMP Shield Removal ................................................................................................... 22

8. Module/Unit Identification ........................................................................................23

8.1 Top View Projector ...................................................................................................................23

8.2 Overview installed FANS.............................................................................................................24

8.2.1 Location of the Fansin the projector.......................................................................................... 24

8.2.2 Function of the installed Fans.................................................................................................25

8.2.3 Order number for the Fans .................................................................................................... 25

8.3 Power Box Complete.................................................................................................................26

8.3.1 Power BoxAccess.............................................................................................................26

8.3.2 Parts of the Power Box Assembly ............................................................................................ 27

8.3.3 Power Box Swapping.......................................................................................................... 28

8.4 Input Box Complete ..................................................................................................................31

8.4.1 Input Box Swapping ...........................................................................................................31

8.4.2 Parts of the inputBox Assembly ..............................................................................................33

8.5 Lamp Box.............................................................................................................................33

8.5.1 Lamp unitRemoval............................................................................................................33

8.5.2 Parts of the Lamp box .........................................................................................................34

8.6 IR Receiver Front .................................................................................................................... 35

8.6.1 IR Receiver Front swapping...................................................................................................35

8.7 Motor/Control Board.................................................................................................................. 35

8.7.1 Motor/Control board swapping ................................................................................................35

8.7.2 Motor/Control board connections ............................................................................................. 36

8.8 Keypad & LED+IR Board ............................................................................................................ 37

8.8.1 Keypad swapping..............................................................................................................37

8.8.2 LED+IR Board ................................................................................................................. 37

8.9 Sealed Engine........................................................................................................................ 37

8.9.1 Sealed Engineremoval........................................................................................................38

8.9.2 Sealed Engine mounting ...................................................................................................... 41

8.10 Lens Holder........................................................................................................................... 41

8.10.1 Lens Holder swapping......................................................................................................... 41

8.11 Light Pipe.............................................................................................................................42

8.11.1 Parts tobe removed to allow Light Pipe swapping ........................................................................... 42

8.11.1.1 Light pipe Focus adjustable screw cover removal. ....................................................................42

8.11.1.2 Lamp burner blower FAN 9 removal.................................................................................... 43

8.11.1.3 Lamp House removal................................................................................................... 43

8.11.2 Replacement of the Light pipe ................................................................................................44

8.11.2.1 Light pipe Removal .....................................................................................................44

8.11.2.2 Light pipe Mounting .....................................................................................................44

8.12 Cold mirror............................................................................................................................ 45

R5976766 RLM G5 22/04/2004

1

Table of contents

9. Technical Board Information .....................................................................................47

9.1 Power Supply Circuit................................................................................................................. 47

9.1.1 Overview Power Supply Circuit ............................................................................................... 47

9.1.2 PFC (Power Factor Correction)............................................................................................... 47

9.1.3 Format Power board........................................................................................................... 49

9.1.4 OEM Power Board.............................................................................................................51

9.1.5 StandBy Power Supply bo ard .................................................................................................52

9.1.6 MCU Board ....................................................................................................................54

9.2 Random Boards......................................................................................................................55

9.2.1 Motor/Control Board........................................................................................................... 55

9.2.2 Input Box Backplane........................................................................................................... 56

9.2.3 Lamp Power Supply ........................................................................................................... 56

9.2.4 Pixel MapProcessor Board ...................................................................................................57

9.2.5 Formatter Interface Board..................................................................................................... 58

9.2.6 KeyPad......................................................................................................................... 58

9.2.7 LED + IRBoard................................................................................................................59

10.Mechanical Parts Identification..................................................................................61

10.1 Projector Lamp box ..................................................................................................................61

10.2 Projector Power Box .................................................................................................................62

10.3 Shutter................................................................................................................................ 64

10.4 Projector Input Box................................................................................................................... 64

10.5 Lens Holder........................................................................................................................... 66

10.6 Rigging Assembly....................................................................................................................66

10.7 Projector Bottom Assembly.......................................................................................................... 68

10.8 Projector Top Cover Assembly....................................................................................................... 69

10.9 Projector Front Assembly ............................................................................................................70

10.10Projector Assembly................................................................................................................... 71

11.Light Pad adjustment..............................................................................................73

11.1 Lens Holder (Scheimpflug)........................................................................................................... 73

11.2 Illumination System ..................................................................................................................75

12.Projector Suspension/Stacking..................................................................................79

12.1 Stacking Projectors................................................................................................................... 79

12.2 Projector Suspension ................................................................................................................ 80

13.Maintenance of the Projector ....................................................................................83

13.1 Air Filters .............................................................................................................................83

13.2 Cleaning the lens.....................................................................................................................84

14.SoftwareUpdate....................................................................................................87

14.1 Installation requireme nts .............................................................................................................87

14.2 Interconnection PC/Projector ........................................................................................................ 87

14.3 Projector Software Update Procedure............................................................................................... 88

15.Troubleshooter RLM R5 Performer..............................................................................95

15.1 Start-up without audible relay click ..................................................................................................95

15.2 Led 1, 2 and 3 light up Red continuously............................................................................................96

A. Technical Specifications ..........................................................................................99

A.1 RLM R5 Performer ................................................................................................................... 99

Index.................................................................................................................... 101

2 R5976766 RLM G5 22/04/2004

1. GENERAL INFORMATION

1.1 RLM R5 Performer

Commercial Brochure

See next pages for contents.

1. General Information

Image 1-1
Front page brochure RLM G5P

R5976766 RLM G5 22/04/2004 3

1. General Information

4 R5976766 RLM G5 22/04/2004

RLM G5 Performer

With its compact design and sealed optics, the RLM G5
PERFORMER is an ideal all-round projector suitable to both the
rental as well as staging markets.

Feature-rich and ready to use, the RLM G5 PERFORMER allows
everything from seamless switching to picture-in-picture
and enables you to show up to 4 sources simultaneously
on-screen.

Add sealed optics, a dedicated lens range and compatibility
with the existing SLM Projector lenses and the RLM G5
PERFORMER becomes the ideal staging or corporate rental
projector.

Ready for the Road

The RLM G5 PERFORMERs sealed optics, which makes it dust
and smoke resistant allows it to maintain optimal performance
in normal rental environments while also offering protection
in harsh staging environments where smoke machines are
frequently used.

The RLM G5 PERFORMER comes with a
dedicated rental frame which facilitates
handling, stacking and truss-mounting.
The special frame also offers protection
to the projector whilst making it easy to
handle and carry.

With the renowned SLM interlocking system, the RLM
G5 PERFORMER can be snap-locked together with another
unit, offering double brightness and redundancy, perfect for
demanding events.

The RLM G5 PERFORMER has an extensive range of mounting
points and slots to accommodate different clamps and adapt to
various truss systems and dimensions.

Advanced Image Processing

The RLM G5 PERFORMER allows seamless transitions from source to source, with special effects such as dissolve, horizontal and
vertical blind, box in and out, etc ...

Extensive PIP capabilities which offer up to 4 sources on-screen simultane­ously while also allowing you to position and resize windows via an intuitive
on-screen menu.
Save and load your preferred settings at any time.

Pre-load your company logo and display it during intermission or when there
is no signal.

Optical System

Featuring a dual lamp system with auto-sensing, the RLM G5
PERFORMERÕs optical system also allows smart lamp switching in
single lamp mode to make optimum use of available lamp life.

With a full lens range accommodating any requirement, the RLM G5
PERFORMER is also compatible with the SLM high brightness lens
range by using the TLD/RLM lens adapter.

SLM lenses Throw ratio on SLM Throw ratio on RLM Order Information

¥ TLD HB (0.8) 0.8 : 1 1.0 : 1 R9842040
¥ TLD HB (1.6 - 2.0) 1.6 - 2.0 : 1 2.0 - 2.5 : 1 R9842060
¥ TLD HB (2.0 - 2.8) 2.0 - 2.8 : 1 2.5 - 3.5 : 1 R9842080
¥ TLD HB (2.8 - 5.0) 2.8 - 5.0 : 1 3.5 - 6.3 : 1 R9842100
¥ TLD HB (5.0 - 8.O) 5.0 - 8.0 : 1 6.3 - 10.0 : 1 R9842120

RLM G5 Performer specifications

¥ Dimensions

Barco

Noordlaan 5, 8520 Kuurne - Belgium

Tel. [phone] - Fax + 32 56 36 88 24

3240 Town Point Drive - Kennesaw, GA 30144

Tel. [phone]
Fax [phone]

email: [e-mail]

Ref. no. R599608 - January Ô04

Barco Projection Systems is an ISO 9001 registered company.
The information and data given are typical of the equipment described.
However any individual item is subject to change without notice.

684,4mm (26.9Ó)

31mm (1.2Ó)

251mm (9.9Ó)

LENSES

RLD - Type Order information

¥ RLD (0.8) R9832640
¥ RLD (1.5 - 1.8) R9832642
¥ RLD (1.8 - 2.25) R9832643
¥ RLD (2.25 - 3.0) R9832644
¥ RLD (3.0 - 4.5) R9832645
¥ RLD (4.5 - 7.0) R9832646

¥Light Output (ANSI)** 4000
¥Resolution 1024 x 768 (native)

1600 x 1200 (max)
¥Contrast Ratio - full field 900 : 1
¥Brightness Uniformity 90%
¥Lamp 2 x 250 W UHP
¥Lamp Lifetime (max) 1500 Hrs
¥Lamp Lifetime (typ) 1000 Hrs
¥ Noise Level (dba) 20¡C (68¡F) < 43

40¡C (104¡F) < 50
¥Max. Ambient Temp 40¡C (104¡F)
¥Mains Voltage 92-240 V
¥Power Consumption 1000 W
¥Weight 25 kg (56 lbs)
¥Weight Frame 5 kg (11 lbs)

FEATURES

¥Seamless Source Switching Standard: box-in/out, etc ...
¥ScenergiX Standard horizontal and vertical

electronic edge blending
¥Network Connection Optional
¥Sealed DLP Core Standard
¥Advanced Picture in Picture Up to 4 sources simultaneously

(2 data, 1 video and 1 SDI)
¥Digital Zoom Standard
¥Light Shutter Standard
¥Built-in Radio Remote Transceiver Optional

ORDER INFORMATION

¥Projector Body R9010020
¥Spare Dual Lamp (including housing) R9841880
¥TLD/RLM lens adapter R9832650

INPUTS

¥1x Configurable 5-Wire (BNC) Composite Video, S-video, Component

Video, RGBHV, RGBS, RGsB
¥1x Composite Video (BNC) Up to 7 Composite Videos, using all

connectors on top input board
¥1x S-Video (4-pin mini-DIN) Up to 3 S-Videos when combining BNCs
¥1x Analog RGB (D15 connector)
¥1x SDI With active loop-through
¥1x DVI (Digital Visual Interface)
¥1x RS-232
¥1x XLR For 2-way communication using

rugged remote

** Optical specifications measured with RLD (4.5 - 7 : 1), on axis at 220V

2. SAFETY

2.1 Safety Instructions

WARNING: Before Removing/Replacing any projector components, turn off the Main Power Switch and un-

plug the Main AC power cable.

2. Safety

R5976766 RLM G5 22/04/2004 5

2. Safety

Safety Instructions

1. Before returning an instrument to the customer,always make a safety check of the entire instrument, including, but not limited
to, the following items:

a) Be sure that no built-in protective devices are defective and/or have been defeated during servicing. (1) Protective shields

are provided on this chassis to protect both the technician and the customer. Correctly replace all missing protective shields,
including any removed for servicing convenience. (2) When reinstalling the chassis and/or other assembly in the cabinet,
be sure to put back in place 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
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 in correctly 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
with American National Standards Institute (ANSI) C101.0 Leakage Current for Appliances and Underwriters Laboratories
(UL) 1410, (50.7). With the instrument AC switch first in the on position and then in the off position, measure from a known
earth ground (metal waterpipe, conduit, etc.) to all exposed metal parts of the instrument
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 1.5 mA. Reverse the instrument power cord plug in the
outlet and repeat test. ANY MEASUREMENTS NOT WITHIN THE LIMITS SPECIFIED HEREIN IND
SHOCK HAZARD THAT MUST BE ELIMINATED BEFORE RETURNING THE INSTRUMENT TO THE CUSTOMER OR
BEFORE CONNECTING ACCESSORIES.

(antennas, handle bracke t, metal

ICATE A POTENTIAL

AC Leakage Test

Leakage Current Tester

be

complies

Reading should

not be above

Device Under Test

1.5 mA

+-

Test all exposed metal surfaces

2-Wired cord
Also test with plug reversed

(Using AC Adapter plug as required)

Earth
Ground

Image 2-1
AC Leakage Test

d) Ultraviolet Radiation exposure - Warning: This lamp can cause serious skin burn and eye inflammation from shortwave

ultraviolet radiation if not operated in enclosed fixtures. DO NOT opera te this lamp in a fixture w ith 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 ve

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 ­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 safet y characteristics of this apparatus and create a hazard to the user. Any design alterations
or additions may void the
damage resulting therefrom.

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 of 1000 hours. Do not remove, install, or otherwise
handle the lamp in any manner without first putting on shatterproof goggles equipped with side shields. People not so equipped
must be kept safely away while lamps are handled. Keep the lamp away from your body. For continued explosion protection,
replace the lamp only with one of the same type number. Always replace the lamp before the rated life time.

ntilated equipment.

Do not alter or add to the mechanical or electricaldesign of this apparatus. Design alterations an d

manufacturer’s warranty and may make you, the servicer responsible for personal injury or property

6

R5976766 RLM G5 22/04/2004

2. Safety

5. Hot Chassis Warning - This projector chassis has two ground systems: the primary ground system is formed by the negative
voltage of the rectified mains (power) and is only used as a reference in primary circuits; the secondary ground system is
connected to earth ground via the earth conductor in the mains (power) lead. Separation between p rimary 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 compo­nents, parts, or wiring that meet original specifications. Additionally, determine the cause of overheating and/or damage a
necessary, take corrective action to remove any potential safety hazard.

8. PRODUCT SAFETY NOTICE - Many electricaland mechanical parts have special safety-related characteristics some of which
are ofte n 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 charac­teristics a s 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 wheneverappropriate. For the latest information,
always consult the appropriate c urrent 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 w rist 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 elect rically shorted together by conductive foam, aluminium foil or

comparable conductive material).
e) Immediately beforeremoving theprotective material from the leads of a r

tothe chassisor circuitassembly into which the device will be installed. CAUTION: Be sure nopower isapplied tothe 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 s ufficient to

damage an ES device).

eplacement ES device, touchthe protective material

nd, if

R5976766 RLM G5 22/04/2004

7

2. Safety

8 R5976766 RLM G5 22/04/2004

3. SAFETY SYMBOLS

3.1 Overview used Safety Symbols

Overview

WARNING

CAUTION

3. Safety Symbols

The lightning flash and arrowhead symbol within the
equilateral triangle indicates non-insulated “dangerous
voltage” within the projector’s enclosure thatmay be sufficient
magnitude to constitute a risk of electric shock.

The exclamation point within the equilateral triangle
indicates related operating/maintenance instructions in the
documentation accompanying the projector.

The WARNING sign denotes a hazard. It calls atten tion to a
procedure, practice, or the like, if not correctly performed or
adhered to, could result in personal injury. Do not proceed
beyond a WARNING sign until the indicated conditions are
fully understood and met.

The CAUTION sign denotes a hazard. It calls the attention
to an operating procedure, or the like, which, if not correctly
performed or adhered to, could result in damage to or
destruction of part or all of the product. Do not proceed
beyond a CAUTION sign until the indicated c ondition s are
fully understood and met.

or

Indicate earth (ground) terminal

R5976766 RLM G5 22/04/2004 9

3. Safety Symbols

10 R5976766 RLM G5 22/04/2004

R5976766 RLM G5 22/04/2004 11

4.1 Simplified Block Diagram

4. BLOCK DIAGRAM RLM R5 PERFORMER

Block diagra

mRLMR5Performer

Image 4-1

SOURCE

INPUT

Remote
Control

KEYPAD

FRONT-END

BOARDS

OEM Power

FRONT IR

RECEIVER

IR/LED

Module
Control

PIXEL MAP

PROCESSOR

Micro

Controller

Standby

Power

Block diagram RLM G5 Performer

FORMATTER

G

Module
Control

FAN

Drivers

Module
Control

INTERFACE

Lamp

Info

Formatter

Power

FORMATTER

DMD

DMD

DMD

FORMATTER

R

OPTICAL

ENGINE

B

LPS 1

Dual

Lamp

Module

Shutter

Up/Down

Right/Left

LPS 2

MOTOR
DRIVER

Zoom

Focus

PROJECTION

LENS

Block diagram

4. Block Diagram RLM R5 Performer

Mains Input

(85 - 264V AC)

EMC

Filter

Power Board

PFC

Power

Switch

4. Block Diagram RLM R5 Performer

4.2 Expanded Block Diagram

Block diagram

12 R5976766 RLM G5 22/04/2004

Note 1 : CN3 of Formatter Board R/G/B Channel

CN3 --- JST S12B-ZR-SM3-TF

123456789101112

5V-IN

GND

3V3VDD-IN

2V5V-IN

3V3VDD-IN

GND

GND

2V5V-IN

2V5V-IN

GND

GND

GND

Note 2 : Vender List of Motor Adj connector

FOCUS Connector : JWT A2001-H02-2P

ZOOM Connector : JWT A2001-H02-3P

UP/DOWN Connector : JWT A2001-H02-4P

LEFT/RIGHT Connector : JWT A2001-H02-5P

Lens Holder

Lens

1

4

2

3

J1

1

4

2

3

J2

3~6

9~12

1

2

8

7

Motor--­___Focus
___Zoom

+

-

+

-

Motor Adaptor

3~6

9~12

1

2

8

7

3~6

9~12

1

2

8

7

3~6

9~12

1

2

8

7

1 2

1 2

12

To Customer
FRONTEND

SYSTEM

1 2 3

1 2 3

1 2 3

To Customer
FRONTEND

SYSTEM

1 2 3 4 5

1 2 3 4 5

1 2 3 4 5

NC

NC

Left/Right Motor

+

-

To Customer
FRONTEND

SYSTEM

1 2 3 4

1 2 3 4

1 2 3 4

NC

NC

Up/Down Motor

+

-

To Customer
FRONTEND

SYSTEM

SHUTTER

Sealing

1 12

1 12

1 12

To FORMAT

Power B/D

Formatter B/D

B_Channel

CN4

1

30

121

CN3

DMD

1 12

1 12

1 12

To FORMAT

Power B/D

CN4

1

30

CN3

121

Formatter B/D

G_Channel

DMD

OPTICAL

ENGINE

1 12

1 12

1 12

To FORMAT

Power B/D

CN4

1

30

CN3

121

Formatter B/D

R_Channel

DMD

31 51

31

J306

51

J305

30

1

J302

41

J303

30

1

J301

J300

30

1

60

1

J600

J304

1

6

POWER
SWITCH

On Off

CN10

1

2

CN5

3

4

2

1

5

N

Null

L

L

N

J550

1

6

10

1

6

++24V

GND

GND

GND

++3V3

++5V

CN16

1

2

3

4

5

6

J1

1

2

3

4

5

6

PG

/PD

GND

1

2

3

CN19

1

2

3

PG

/PD

GND

1

2

3

CN39

1

2

3

375V

GND

1

2

CN29

+15V

+5V

GND

CN100

1

2

3

STANDBY

BOARD

LPS 1

51

1

2

31

51

1

2

31

FAN DRIVERS

J10 / J11 / J12 / J13

J21 / J20 / J19 / J18

J14 / J15 / J16 / J17

5

1

1

5

J900

1

2

J4

LAMP M

odul

e

LAMP1

LAMP2

Lamp Info

on Board

5

1

6

J1

R G B & Video Input

To Fornmatter Board R

Channel CN3

To Fornmatter Board G

Channel CN3

To Fornmatter Board B

Channel CN3

PG

/PD

GND

CN28

1

2

3

121 121121

375V

GND

1

3

CN20

21

5

1

3

21

RLM G5 performer

Input backplane

Pixel Map Processor

J401

J401

J501 J501

J402 J402 J502 J502

J503

J503

Digital Video Input

SDI & IEEE11394 Input

Signal board PC

J411

J412

J411

J412

J301

CN35

J409 CN34

+3.3V

+3.3V

GND

GND

GND

GND

-5V

+5V

+5V

GND

+15V

GND

From PFC Board

CN59

To Motor Board

J504

+3.3V

+3.3V

GND

GND

GND

GND

-5V

+5V

+5V

GND

+15V

GND

J421

J421

J422

J422

J431

J431

PFC

Board

to OEM Board

J58

CN55

CN59

CN61

CN60

375V
GND

375V
GND

375V
GND

375V

Null

GND

++15V

++5V

GND

CN23 CN24

CN62

CN27

GND

++5V

CN99

CN15J419

CN12

CN18

GND

++5V

++5V
GND

FORMAT

POWER BOARD

OEM BOARD

GND

++5V

CN33

CN36

CN32

+3.3V

+3.3V

+3.3V

+3.3V

+3.3V_SENSE+

+3.3V_SENSE-

+3.3V

GND

GND

GND

GND

GND

+15V

GND

+15V

GND

+15V

GND

+15V

GND

PIXEL MAP PROCESSOR

BOARD

J519 J509

J505 J600

+3.3V

+3.3V

+3.3V

+3.3V

+3.3V_SENSE+

+3.3V_SENSE-

+3.3V

GND

GND

GND

GND

GND

+15V

GND

+15V

GND

+15V

GND

+15V

GND

++5V

SCL_STDBY

SDA_STDBY

POWER_FAIL_I

IRQ[4]

RxD1

RxD2

TxD1

TxD2

GND

++5V

SCL_STDBY

SDA_STDBY

POWER_FAIL_I

IRQ[4]

RxD1

RxD2

TxD1

TxD2

GND

J505

J506

MCU

BOARD

J25 J203

J213

LPS 2

CN1

CN1

CN2

CN2

Solid state
temp relay

Lamp_Overtemp

Sense

J504

J20

J10

J13

J16

J24

J26

J21

J23

J520

GND

5V

15V

From OEM Board

CN100

To Lens Pressure

Sensor

To R channel
NTC Sensor

To G channel

NTC Sensor

To B channel

NTC Sensor

Motor Board

UP/DOWN
To Lens Holder
Up/Down Motor

connector

LEFT/RIGHT

To Lens Holder

Left/Right Motor

connector

ZOOM

To Lens Holder

Zoom connector

FOCUS

To Lens Holder

Focus connector

ADAPTOR

BOARD

Front IR

Board

LED+IR

Board

Keypad

Board

ZOOM

FOCUS

UP/DOWN

LEFT/RIGHT

J550

1 ++5V
2 IR_Keyboard
3 IR_Receiver
4 Backlight 1
5 Backlight 2
6 GD

J26

J24

J901

1 +5V

2 GND

3 IR

J307

1 +5V
2 GND
3 SCL_Stdby
4 SDA_Stdby
5 RCS_IR

5. Technical Informations

5. TECHNICAL INFORMATIONS

5.1 Conventions

Projector Orientation

References to location (left, right, front, rear, top, bottom) on the projector are made as shown in the image below.

Image 5-1
Projector orientation convention

Spare abbre vi ations

Each available spare is indicated with one of the following abbreviations:

Abbreviation Description

NR Non repairable
CO Consumable
FR Factory Repairable
LR Locally repairable

5.2 Connector Removal Instructions

When needed, remove cable straps to easily disconnect a connector, when f inish e d always replace with new
cable straps and tie up the cables to their initial position.

WARNING: Always respect the ES (Electrostatically Sen s iti ve) Instructions .

Do not use any kind of tools when disconnecting a connector.

R5976766 RLM G5 22/04/2004 13

5. Technical Informations

14 R5976766 RLM G5 22/04/2004

6. SPARE PARTS LIST

6.1 Spare Parts list

Which spare are available for the RLM R5 Performer

The following spares can be ordered:

6. Spare Parts list

Art. Number Description

B401045K

B401040K

B401033K

B401034K

B401042K

B401041K

B401043K

B401030K All ’loose’ cables in one kit NR
B400816K IR Receiver NR "IR Receiver Front

B400823K

B401038K Lens holder Asembly NR "Lens Holder swapping",

All dust filters at the bottom
of the projector

Cold mirror (C omplete
assembly)

Input module (Complete
assembly)

Power Box (Complete
assembly)

4 Fans for cooling the lamp
house

3 Fans for cooling the Power
Bow

3 Fans for cooling the engine
(outside)

Lamp Power Supply

Category

CO

NR

FR

FR

NR

NR

NR

NR

Page

"Air Filters", page 83

"Input Box Swapping", page
31

"Power Box Swapping", page
28

"Parts of the Lamp box",
page 34

"Parts of the Power Box
Assembly", page 27

"Sealed Engine", pa ge 37

swapping", page 35
"Lamp Power Supply", page

56

page 41

B401039K Light Pipe assembly NR "Light pipe Removal", page

B401035K

B401044K

B401032K

B401031K Power boards:

B401037K
B401036K
B400823K

R9841880 lamp unit NR "Lamp unit Removal", page

R5976766 RLM G5 22/04/2004 15

Local Keypad+ IR/LED Board

Mains connector+On/Off
switch

Motor Control Board

PFC-MCU-Formatter­OEM - Standby

Sealed Engine
Shutter assembly
lamp Power Supply

NR

NR

FR

FR

FR
NR
NR

44
"Keypad & LED+IR Board",

page 37

"Motor/Control board
swapping", page 35

"Power Box Complete", page
26

"Sealed Engine", pa ge 37
"Shutter", page 64
"Lamp Power Supply", page

56

33

6. Spare Parts list

16 R5976766 RLM G5 22/04/2004

7. Projector Cover Removal to access Modules

7. PROJECTOR COVER REMOVAL TO ACCESS
MODULES

Overview

• Top Access Modules

• Side Access Modules

7.1 Top Access Modules

Overview

• Removal of the Rear cover

• Removal of the Button panel cover

• Removal of the top cover

• Top shield removal

7.1.1 Removal of the Rear cover
How to remove the rear cover

1. Turn the cover lock screw (A) half a turn counterclockwise to release cover. (image 7-

2. While lifting up the cover bottom for removal, slightly press on the cover top side (B) to unlock .

1)

B

A

Image 7-1
Rear cover removal

7.1.2 Removal of the Button panel cover
How to remove the button panel cover

1. Carefully release the bottom of the cover by pulling it backwards (A). (image 7-2)

2. Press the left lip (B) on top of the cove r inwards (image 7-2).

3. Pull (C) the left side of the cover top upwards to release the lip (B) (image 7-2).

4. Carefully pull (D) the right side of the cover to

5. Remove the cover.

p upwards to release the matching lip (E) (image 7-2).

R5976766 RLM G5 22/04/2004

17

7. Projector Cover Removal to access Modules

Image 7-2
Button panel cover removal

7.1.3 Removal of the top cover
Howtoremovethetopcover

1. Remove the screw (A) securing both plates blocking the slots for the rear cover guides. (image 7-3)

2. Pull out the respective plugs, connecting Control panel (A) and LED panel (B) to projector electronic. (image 7-4)

3. Loosen the top cover by turning the cover lock screw (A) half a turn counterclockwise. (image 7-5)

4. Liftup the top ofthe cover a little and move the cover backwards to slide both rear cover guides (A) out of theirslot (B). (image 7-6)

5. Remove the top cover.

Image 7-3
Blocking plates removal

Image 7-4
Disconnection LED and Control panel

18 R5976766 RLM G5 22/04/2004

Image 7-5
Unlock top cover

7. Projector Cover Removal to access Modules

Image 7-6
Top cover removal

7.1.4 Top shield removal
How to remove the projector top shield

1. Remove the 11 screws (A) fastening the projector top shield. (image 7-7)

2. Carefully lift up the projector top shield a little (wire saddle clips hinder shield removal).

3. Pull out the wires out of the wire saddle clips (B) ( im age 7-7).

4. Remove projector top shield (image 7-7).

R5976766 RLM G5 22/04/2004

19

7. Projector Cover Removal to access Modules

A

A

B

Image 7-7
To p shield removal

7.2 Side Access Modules

7.2.1 Side Cover left
Overview

• Removal of the Side cover

• Side shield removal

7.2.1.1 Removal of the Side cover
How to remove the side cover

1. Remove the 4 screws (A) securing the side cover to projector base plate. (imag e 7-8)

2. Carefully move backwards the side cover to remove.

Image 7-8
Left side cover removal

20 R5976766 RLM G5 22/04/2004

7. Projector Cover Removal to access Modules

7.2.1.2 Side shield removal
How to remove the side shield

1. Remove the 4 screws (A) securing side shield to lamp house a nd Temperature/lens motor control board. (image 7-9)

2. Remove the side shield upwards (image 7-9).

Image 7-9
Side shield removal

7.2.2 Side Cover Right
Overview

• Removal of the Side cover

• Side Sh ield removal

• PMP Sh ield Removal

7.2.2.1 Removal of the Side cover
How to remove the side cover

1. Remove the 4 screws (A) securing the side cover to projector base plat

2. Carefully move backwards the side cover to remove.

A

e. (image 7-10)

Image 7-10
Side cover removal

7.2.2.2 Side Shield removal
How to remove the side shield

1. Remove the 7 screws (A1 & A2) securing s ide shield (A) to Po wer assembly and Input assembly. (image 7-11,image 7-12)

2. Move backwards the shield (A) to remove.

R5976766 RLM G5 22/04/2004

21

7. Projector Cover Removal to access Modules

A

Image 7-11
Side shield rem oval 1

A1

B

A

Image 7-12
Side shield rem oval 2

7.2.2.3 PMP Shield Removal
How to remove the PMP shield

1. Remove the 6 screws (B1) securing shield (B) to base frame (image 7-12).

2. Move the shield towards the engine to remove.

B1

A2

22

R5976766 RLM G5 22/04/2004

8. Module/Unit Identification

8. MODULE/UNIT IDENTIFICATION

8.1 Top View Projector

Overview Modules/Units-1

After removing the projector covers and the shield on top of the projector, the following modules or units can be identified:

U1

M2
U3
U4

U5

U6

Image 8-1
Module/Units identification

Module (Mx) or Unit (Ux)

U1 Lens

U2 Power box complete B401034K

Description

Order Number

R9832640 RLD(0.8 )
R9832642 RLD(1.5-1.8)
R9832643 RLD(1.8-2.2 5)
R9832644 RLD(2.25-3.0)
R9832645 RLD(3.0-4.5)
R9832646 RLD(4.5-7.0)

U2

M1

U3 Lens block B401038K
U4
U5 Light pipe B401039K
U6 Lamp assembly
M1
M2 Motor control unit B401032K

Sealed Engine

SMPS control unit (part of kit B401034K)

Overview Modules/Units-2

emoving the Pixel Map Processor (PMP) cover the following modules or unit can be identified:

After r

R5976766 RLM G5 22/04/2004

B401037K

see further

23

8. Module/Unit Identification

Image 8-2
Modules/units identification

M3

M4

U7

Module (Mx) or Unit (Ux)

M3 Pixel Map Processor
M4
U7 Input unit cpl B401033K

Description

Formatter Interface

8.2 Overview installed FANS

8.2.1 Location of t
Location F

he Fans in the projector

ANS in projector

The arrow o

n some located Fans indicates the produced air flow from the Fan.

Order Number

(R764284)

--

24 R5976766 RLM G5 22/04/2004

8. Module/Unit Identification

Image 8-3
FAN location in projector

8.2.2 Function of the installed Fans
Function of the FANS

FAN number Function

1–2–3
4
5
6
7
8
9

10
11

Cooling Power Modules
Cooling P rism
Cooling DMD Red
Cooling DMD Green
Cooling DMD Blue
Cooling Lamp
Cooling lamp burner up

Cooling lamp burner bottom
Exhaust fan

8.2.3 Order number for the Fans
How to order a Fan

The 11 installed fans are divided in 3 groups and a specific kit number is allocated to each of them.

R5976766 RLM G5 22/04/2004

25

8. Module/Unit Identification

Group Contents

I
II
III

Fan 4 is not added to on e of the above kits because the fan is
there is no guarantee about the sealing after the sealed engin e has been opened.

Fan 1/2/3
Fan 8/9/10/11
Fan 5/6/7

Kit number

B401041K
B401042K
B401043K

mounted inside the sealed engine. In the field

8.3 Power Box Complete

Overview

• Power Box Access

• Parts of the Power Box Asse m bly

• Power Box Swapping

8.3.1 Power Box Access
Access to Power Boards

1. Disconnect the Fan, built-in in the power box cover, by pulling out the Fan wire plug (A) on the SMPS control board. (image 8-4)

2. Remove the 8 screws (B) securing the power box cover.

3. Lift up the cover and move backwards to remove. (image 8-5)

Image 8-4
SMPS box cov

A

B

er removal

26 R5976766 RLM G5 22/04/2004

Image 8-5
SMPS box cover removed (Fan not disconnected)

8.3.2 Parts of the Power Box Assembly

8. Module/Unit Identification

Which boards belong to the Power box cpl

A

Image 8-6
Parts of the power box cpl

Unit / Board

A Power box cpl B401034K

Description Partnumber

1

A

2

A

3

A

4

A

5

A

6

A

7

A

8

A

A1

SMPS MCU board Part of kit B401034K

A2

StandBy Power Supply Part of kit B401034K

A3

OEM Power supply Part of kit B401034K

A4

Lamp Power Supply 2

A5

Lamp Power Supply 1

A6

Formatter Power Supply Part of kit B401034K

R5976766 RLM G5 22/04/2004 27

B400823K
B400823K

8. Module/Unit Identification

Unit / Board

A7
A8 Fan

2

Image 8-7
Overview Fans in power box

Description Partnumber

Power Factor Corrector board Part of kit B401034K

Part of kit B401041K

1

3

Unit / Board

1-2 -3 Fan

Description Partnumber

8.3.3 Power Box Swapping
How to swap the Power Box

1. Remove the power box cover (see "Power Box Access", page 26).

2. Loosen the forma

3. Proceed to the electrical disconnection of the power box:

- Disconnect plug J

- Disconnect plugs J301, J409 and J419 on the backplane of the input box. (image 8-9)

- Disconnect plugs J505, J519 and J509 on the PMP board (image 8-8).

- Disconnect the plugs J23, J24 and J62 on the formatter power board. (image 8-10)

- Disconnect the FAN plugs on the SMPs control board. (image 8-11)

- Disconnect the lamp power plugs as follows: (image 8-12)

o

Remove the 2 screws secur

o

Remove the bracket by tilting it fully to the right followed by pulling it upwards.

o

Pull out the lamp power plugs.

4. Proceed to the mechanical disconnection of the power box:

- Remove the 3 screws (C, D and E) securing the power box to the projector base frame. (image 8-1 3)

- Loosen the 2 captive screws (A and B) securing the power box to the projector base frame (image 8-13).

5. Move the power box upwards to remove.

tter interface board (see "Input Box Swapping", page 31).

304 on the formatter interface board. (image 8-8)

ing bracket onto the lamp power connectors.

kit B401041K (3 x FAN)

28

R5976766 RLM G5 22/04/2004

J304

J505

J519

J509

Image 8-8
Disconnection PMP and Formatter interface

8. Module/Unit Identification

Image 8-9
Disconnection Input box

J301
J409

J419

Image 8-10
Disconnection Formatter power supply

J62

J23

J24

R5976766 RLM G5 22/04/2004 29

8. Module/Unit Identification

J900

J4

J10

J15

J18

J19

J20

J21

J16

J17

Image 8-11
Disconnection Fans

Image 8-12
Disconnection of the lamp power supply

A

A

30 R5976766 RLM G5 22/04/2004

8. Module/Unit Identification

C

A

B

Image 8-13
Power box fixation

D

E

8.4 Input Box Complete

Overview

• Input Box Swapping

• Parts of the input Box Assembly

8.4.1 Input Box Swapping
Access to Input boards

1. Remove the 3 screws securing the PMP board to the input box (1) and to the formatter interface board (2 & 3). (image 8-14)

2. Carefully unplug, by pulling the PMP board upwards, the PMP board from the input backplane (B) and the formatter interface

board (A) (image 8-14).

move the 2 screws (3&4) securing the formatter interface board to the power box. (image 8-15)

3. Re

4. Remove the 2 screws (1&2) securing the formatter interface board to the input box (image 8-15).

5. Loosen the 2 captive screw (1&2) securing the input box to projector bottom. (image 8-16)

6. Disconnect input box by pulling out the 3 respective power plugs (A,B&C).

7. Pull the input box upwards to take out the projector main frame.

R5976766 RLM G5 22/04/2004

31

8. Module/Unit Identification

B

1

A

Image 8-14
PMP removal

Image 8-15
Formatter interface

B

2

A

3

1

2

3

4

Image 8-16
Input box removal

1

A

2

B

C

32 R5976766 RLM G5 22/04/2004

8.4.2 Parts of the input Box Assembly

A

Which boards belong to the Input box cpl

Image 8-17
Parts of the input box cpl

A
A

A
A

A

8. Module/Unit Identification

1

2
3

4
5

Unit / Board

A Input box cpl B401033K

Description Partnumber

A1 Input backplane board
A2

RGBHV/Composite Video/S-Video input board Part of kit B401033K

A3

DVI/Computer/RS232C/RC input board Part of kit B401033K

A4

SDI In-/Output board Part of kit B401033K

A5 2-Way hardwired Remote+Ehernet

8.5 Lamp Box

Overview

• Lamp unit Removal

• Parts of the Lamp box

8.5.1 Lamp unit Removal

CAUTION: Let cool down the projector before handling the lamp house to avoid burning.

Part of kit B401033K

Part of kit B401033K

How to remo

1. Loosen the 2 spring screws (E) securing the fan door to the lamp house. (image 8-18)

2. Rotate (F) th e fan door counterclockwise to open. (image 8-19)

3. Loosen the 2 spring screws (G) securing Lamp unit onto base plate. (image 8-20)

4. Disconnect the lamp plug (H) by pulling the lamp unit to the right.

5. Take the lamp unit out (I) the lamp house. (image 8-21)

R5976766 RLM G5 22/04/2004

ve the lamp unit from lamp house

33

8. Module/Unit Identification

Image 8-18
Loosen fan door

Image 8-19
Open fan door

Image 8-20
Loosen lamp unit

8.5.2 Parts of the Lamp box
Which parts belong to the lamp box?

CD

B

A

Image 8-21
Take out lamp unit

E

Image 8-22
Parts of the lamp box

34 R5976766 RLM G5 22/04/2004

8. Module/Unit Identification

Unit / Board

A
B
C Cooling lamp Part of kit B401042K
D Exhaust Fan
E Lamp unit kit R9841880

Description Partnumber

Cooling lamp burner top Part of kit B401042K
Cooling lamp burner b ottom Part of kit B401042K

Part of kit B401042K

8.6 IR Receiver Front

8.6.1 IR Receiver Front swapping
How to swap the IR Receiver front

To access the IR Receiver front, the engine and t

1. Disconnect the IR Receiver board. (image 8-23)

2. Remove the 2 screws securing the board to fro

3. Remove the board.

he lens holder have to be removed.

nt cover.

1

Image 8-23
IR Receiver removal

8.7 Motor/Control Board

8.7.1 Motor/Con
How to rem

To access the motor control board, only the top cover of the projector has to be removed.

1. Remove the

2. Slide the motor control board out the board slots (A&B) to remove (image 8-24).

3. Pull out all the plugs to allow board swapping (Order No kit: B401032K).

trol board swapping

ove the motor-control board

2 screws (1&2) , securing the board on top and bottom. (image 8-24)

A

2

R5976766 RLM G5 22/04/2004

35

8. Module/Unit Identification

L

1

2

Image 8-24
Motor control board removal

8.7.2 Motor/Control board connections
Connections

Lens Holder

Motor Up/Down

J24

Lens Holder

Motor Left/Right

J26

A

B

ens Zoom

Motor

J21

Lens Focus

Motor

J23

Shutter Motor

J28

Prism Switch

J20

From Formatter

Adapter

J520

J520

1 IRQ DMD
2 SDA
3 SCL
4 GND

Image 8-25
Motor/Control board connections

J504

1 +15V
2 +5VD
3 GND

From OEM

Power Supply

J504

J24

1 D Rev
2 REV
3 FW
4 D Fw

J26

1 D Rev
2 REV
3 FW
4 D Fw

NTC Sensor R

J10

J20

1 +5VD
2 GND

NTC Sensor G

J13

J10/13/16

1 +5VD
2 GND

J28

1 D Rev
2 REV
3 FW
4 D Fwd

NTC Sensor B

J16

1 Mtr Fwd
2 +5VD
3 Cha A
4 Cha B
5 GND
6 Mtr Rev

J21

J23

1 Mtr Fwd
2 +5VD
3 Cha A
4 Cha B
5 GND
6 Mtr Rev

36 R5976766 RLM G5 22/04/2004

8. Module/Unit Identification

8.8 Keypad & LED+IR Board

8.8.1 Keypad swapping
HowtoswaptheKeypad

The keypad is mounted onto the inside of the top cover. To remove the top cover, keypad board has to be disconnected (see top
cover removal)

1. Remove the 5 screws (A), securing the keypad board to top cover. (image 8-26)

2. Remove the keypad board.

A

Image 8-26
Keypad removal

8.8.2 LED+IR Board
How to swap the LED+IR board

The LED+IR board is mounted onto the inside of the top cover. To remove the top cover, LED+IR board has to be disconnected
(see top cover removal)

1. Remove the 4 screws (A), securing theLED+IR board to top cover. (image 8-27)

2. Remove the LED+IR board.

A

Image 8-27
LED+IR board removal

8.9 Sealed Engine

Overview

• Sealed En gine removal

• Sealed Eng ine mounting

R5976766 RLM G5 22/04/2004

37

8. Module/Unit Identification

8.9.1 Sealed Engine removal
How to remove the Sealed Engine

1. Proceed to the disconnection of the following cables:

- Disconnect the Prism switch (3) near the switch itself. (image 8-28)

- Disconnect the 3 Cables on the formatter interface (2) connecting video data to th e formatter boards in the Sealed engine
(image 8-28).

- Disconnect the shutter cable (6) from the motor and temperature control board. (image 8-29)

- Disconnect the 3 temp. sensor cables (4) from the motor and temp. control board.

- Disconnect the 3 power cables (1) to the formatter boards in the Sealed engine from the formatter power supply (image 8-29).

- Disconnect the 2 cables (5) to the DMD R & G cooling fan from the SMPS/Fan control board (image 8-29).

- Disconnect the cable to t he Prism cooling fan (5) from the SMPS/Fan control board (image 8-29).

2. Removethe coolingFan of the DMD Blue, mounted on the sealed engine, by removing the 3fixation screws (1 to 3). (image8-30)

3. Remove the 3 screws, securing the sealed engine to the base frame. (image 8-31)

Note: To loosen the screw 3, a long crosshead screwdriver is required.

4. Carefully remove upwards the sealed engine out of the projector (image 8-28). image 8-32)

5. Removethe Shutter asse m bly from the sealed engine, for reuse on the new one, by loosening the 2 fixation screws. (image8-33)

1

5

B

G

4

2

R

3

6

Image 8-28
Sealed engine cable disconnection overview

38 R5976766 RLM G5 22/04/2004

F

ormatter Power Supply

1

5

8. Module/Unit Identification

4
6

Image 8-29
Sealed engine cable disconnection detail

Image 8-30
Removal cooling Fan DMD blue

SMPs/Fan Control
Board

2

1

3

Motor Control
Board

R5976766 RLM G5 22/04/2004 39

8. Module/Unit Identification

1

Image 8-31
Sealed engine removal from base plate

1

3

2

2

Base plate

3

Image 8-32
Sealed engine removed

1

2

Image 8-33
Shutter removal

40 R5976766 RLM G5 22/04/2004

8. Module/Unit Identification

8.9.2 Sealed Engine mounting
How to mount the Sealed engine

1. Place the sealed engine on its mounting base, lining up the 2 center pins (1 & 2) on the engine front plate with the holes in the

mounting base . (image 8-34)

2. Secure the sealed engine onto the mounting base with 3 screws (A, B & C ) (image 8-31).

3. Goback to thechapter ’Sealedengine removal’to reinstallall cable connections and Fan mounting (see "Sealed Engine removal",

page 38).

A

12

C

1

B

Image 8-34
Sealing engine mount

8.10 Lens Holder

8.10.1 Lens Holder swapping
How to swap the lens holder

1. Disconnect the lens holder motor wires from the motor control board. (image 8-35)

2. Remove the 5 screws (1=long - 2 to 5 short) securing the

3. Move lens holder upwards to remove.

lens holder to bottom frame. (image 8-36)

2

Lens Holder

Motor Up/Down

J24

Lens Holder

Motor Left/Right

J26

Image 8-35
Lens holder motor disconnec

tion

Lens Zoom

Motor

J21

Lens Focus

Motor

J23

R5976766 RLM G5 22/04/2004 41

8. Module/Unit Identification

4

5

Image 8-36
Lens holder removal

2
3

8.11 Light Pipe

Overview

• Parts to be removed to allow Light Pipe swapping

• Replacement of the Light pipe

8.11.1 Parts to be removed to allow Light Pipe swapping
Overview

• Light pipe Focus adjustable screw cover removal.

• Lamp b

• Lamp House removal

urner blower FAN 9 removal

1

8.11.1.1 Light pipe Focus adjustable screw cover removal.
How to remove the cover

1. Remove the 5 screws (A) securing the cover to the lamp house and the projector base plate. (image 8-37)

2. Remove the cover.

Image 8-37
Light pipe focus adjust screw cover

42 R5976766 RLM G5 22/04/2004

8.11.1.2 Lamp burner blower FAN 9 removal
How to remove the lamp burner blower FAN 9

1. Remove the 2 screws (A) securing the blower to the lamp house. (image 8-38)

2. Remove the blower out of the base plate.

Image 8-38
FAN 9 removal

8.11.1.3 Lamp House removal

8. Module/Unit Identification

How to remove the lamp house

1. Remove the 3 screws (A) securing left side of the lamp house to the base plate. (image 8-39)

2. Remove the 2 screws (A) securing rear side of the lamp house to the base plate (image 8-39).

3. Move the lamp house upwards to remove from projector frame (Access to rear fan on lamp house). (image 8-40)

Image 8-39
Lamp house removal

Image 8-40
Access to rear fan on lamp hous

e

R5976766 RLM G5 22/04/2004 43

8. Module/Unit Identification

8.11.2 Replacement of the Light pipe

8.11.2.1 Light pipe Removal
How to remove the light pipe

1. Remove the 2 screws (A) securing the light pipe protection cover to base plate. (image 8-41)

2. Remove the protection cover.

3. Remove the 4 screws (A) securing the light pipe to base plate. (image 8-42)

4. Remove the light pipe.

A

Image 8-41
Light pipe protection cover removal

Image 8-42
Light pipe removal

8.11.2.2 Light pipe Mounting
How to mount the light pipe

1. Placethe light pip e on the base plate, lining up the fixa tion holes with the h oles in the base plate and reuse the 4 screws to secure

(image 8-42).

2. Put the protection cover back on its place and reuse the 2 screws to secure (image 8-41).

44

R5976766 RLM G5 22/04/2004

8. Module/Unit Identification

8.12 Cold mirror

Howtoreplacethecoldmirror

1. Remove the 2 screws securing the cold mirror bracket to projector base. (image 8-43)

2. Install the new cold mirror (Order No kit: B401040K) unit and reuse the 2 screws to secure on projector base.

3. Proceed to the adjustment of the cold mirror position (see "Light Pad adjustment", page 73).

Image 8-43
Replacement of the cold mirror

R5976766 RLM G5 22/04/2004 45

8. Module/Unit Identification

46 R5976766 RLM G5 22/04/2004

9. TECHNICAL BOARD INFORMATION

Overview

• Power Supply Circuit

• Random Boards

9.1 Power Supply Circuit

9.1.1 Overview Power Supply Circuit
Block diagram

9. Technical Board Information

2.5V

3.3V

5V

3.3V
5V

24V

-5V

3.3V

5V

15V

Lamp 1

Lamp 2

Power Supply to
PMP and
Input Backlane

PFC Board

AC Input

Image 9-1
Block diagram Power Supply circuit

EMI
Filter

Rectifier
and
AC/DC
Boost up
converter

Format

Power

Board

StandBy

Power
Board

OEM
Power
Board

Lamp

Power 1&2

Board

Overview

The power supply circuit consists of the Format, OEM, StandBy power board and a PFC board. As shown in the block diagram, the
system required voltage is converted from the Format, OEM, StandBy power board, and the output voltage DC380V of PFC board
is applied to the lamp power, and other power boards.

9.1.2 PFC (Power Factor Correction)
Block Diagram

PFC Board

EMI

AC Input

Image 9-2
Block diagram PFC

Filter

Rectifier

Vdc Monitor

IC325/326

PFC Controller

IC321

Regulator

IC20

Driver
IC322

18V from Standby

R5976766 RLM G5 22/04/2004 47

Boost

converter

Driver
IC323

380V DC Output

9. Technical Board Information

Description

PFC board is main for shaping the AC input line current waveform to correspond to that of the AC input line voltage, and boost input
rectified voltage to 380V DC for preregulator, it consist of EMI filter, rectifier, boost converter, dual driver, V DC monitor and PFC
controller.

Line voltage can directly input from 90V AC to 264V AC and boost to 380V DC for the output, there are differential choke L1, L3,
common choke FL2, and CX2, CX3 capacitors to form a EMI filter that can reduce noise and interference, then fed through retifier
CR1 to filter capacitor C810.

The PFC boost converter operated at average mod e control a nd using new zero-current-zero-voltage switched (ZC-ZVS) active
snubber circuit thatincludes snubber inductor L802, clampdiode D802, clamp capacitor C 803, C804, main switch Q801 and auxiliary
switch Q802. ZC-ZVS techniques can reduce thereverse-recovery-related losses ofrectifier and also provides soft switching ofmain
switch (Q801) turns off with ZCS, whereas the auxiliary switch (Q802) turns on with ZVS, it is noticed that Q802 is turned on after
Q801 being turned on, and both of them are using IG BT. This application is shown to be significantly improved the conversion
efficiency especially at low line operation.

The output of the PFC controller IC321 is fed into dual driver IC322 and IC323, the same phase of output from IC322 a
are together drive to main switch Q801. The signal after delayed is in series with IC322 and IC323 then fed to drive auxiliary switch
Q802. T he power supply +15V for IC321 comes from standby and through regulator IC20.

IC321 provides all the function necessary for active power factor corrected preregulator, such as voltage error amplifier (pin 7 & 11),
multiplier (pins 5, 6, 7 & 8), current amplifier (pin 3, 4 & 5), oscillator (pin 12 & 14), power limit (pin 2) and O V P (pin 10, under 1.9V
DC is active), reference voltage (7.5V DC at pin 9) and pin 16 for the output.

When over current or short circuit occurs at 380V DC output,minus voltage drop accross R811 an R812 will be detected, and trigger
pin 2 of IC321 to stop PFC operation immediately. If over voltage happens at 380V DC out
increase at the same time, IC327 is triggered, Q322 and Q357 turn on and o perate as a SCR latched, so voltage at pin 10 of IC321
is clamped to ground to stop PFC operation.

IC325/326 act as protection to stop PFC operation while low line voltage is detected. It will force pin 10 b elow 1.9V DC voltage,
trigger IC321 to OVP and stop PFC operation immediately.

put, voltage at pin 10 of IC321 will be

nd IC32 3

Pin assignment Connectors on Board

J2

J57

J61
J60
J59
J58

J55

J56

J2 (nc)

1 ++15V StdBy
2 GND P*

J57 (nc)

1 380V
2 nc
3 GND P*

J61

1 380V
2 nc
3 GND P*

J60

1 380V
2 nc
3 GND P*

J5

1/2 Mains (L)
3 nc
4/5 Mains (N)

J59

1 380V
2 nc
3 GND P*

Image 9-3
Pin assignment connectors on board

48 R5976766 RLM G5 22/04/2004

J58

1 380V
2 nc
3 GND P*
4 ++15V StdBy

J55

1 380V
2 nc
3 GND P*

J56 (nc)

1 380V
2 nc
3 GND P*

J101

1 Power Switch
2 Power Switch

* Primary ground

9.1.3 Format Power board
Block diagram

Format Power Board

9. Technical Board Information

DC 380V from PFC

IC7

5

F

4

S

3

X

2

L(M)

T2

1

+B

7

D

1

C

D14

C53

ISO3

4

3

ISO4

4

3

1

2

3

COL

AUX

5

4

GND

1

2

GND

GND

GND

D11

D

D

3

1

5

1

IC4

DC/DC Converter

IC6

Linear regulator

IC8

TL431CLP

D81

D82

D83

D84

5V from Standby

2.5V

IC500

5V

9

>>Input

12

OV/UV

16

Protec

3.3V

Output

V

3

Image 9-4
Block diagram Format power board

Description

The format power board repeats operation which turns on an off at pin 7 of IC7, and the pulse appears in secondary sides through
the converter transformer T2 . At the time, the voltage of 3.3V at the secondary side is detected by IC8, the negative feedback to IC7
is carried out at photo coupler ISO3 and then the voltage is stabilized. Other outputs are determined by the turn ratio of secondary
side of T2, and the voltage rectified, smoothed through the series regulator (5V is stabilized at IC6, 2.5V is stabilized at IC4). The
voltage rectified ans smooth ed by D14 and C53 at primary winding of T2 is supplied as a power supply v oltage of IC7 on primary
side.

The format power board is a flyback voltage mode controlled and switched by a hybrid IC7, which has 6 pins that includes pi 5 (F) for
frequency setting (short to C i
line sense; pin 3 (X) for external current limit (on-off controls, current limiting) and pin 1 (C) 5.7Vdc for control feedback. Main control
loop comes from 3.3Vdc output that was connected to error amplifier IC3, isolated photo-coupler ISO3 and feedback to control pin
1 in the primary side. In add

IC500 is a protection IC for sensing OV and UV in the output voltage. Once abnormal voltage was detected , it will be shut down
the IC7 by ISO4 immediately.

s 66kHz, to S is 132kHz); pin 7 (D) for drain of MOSFET; pin 4 (S) fo source of MOSFET; pin 2 (L) for

ition, the others output also regulated by dropper and dc-to-dc converter for +5V and +2.5V separately.

R5976766 RLM G5 22/04/2004

49

9. Technical Board Information

Pin assignment Connectors on Board

J27
J62

J24

J23

J27

1 ++5V
2 GND

Image 9-5
Pin assignment connectors on board

J23

1 +5Va
2 GND
3/4 3.3Va
5/6 GND
7 2.5Va
8 2.5Va
9 2.5Va
10/11/12 GND

J28

J26

J24

1 +5Va
2 GND
3/4 3.3Va
5/6 GND
7 2.5Va
8 2.5Va
9 2.5Va
10/11/12 GND

D71 (Power Good)

J62

1 +5Va
2 GND
3/4 3.3Va
5/6 GND
7 2.5Va
8 2.5Va
9 2.5Va
10/11/12 GND

J26

1 ++5V
2 GND

J28

1 PG
2 /PD
3 GND

J20

1 375V
2 NC
3 GND P*

* Primary ground

50 R5976766 RLM G5 22/04/2004

9.1.4 OEM Power Board
Block diagram

OEM Power Board

9. Technical Board Information

DC 380V from PFC

IC7

5

F

4

S

3

X

2

L(M)

T3

1

+B

7

D

COL

3

D21

D

2

2

IC9

Linear regulator

IC10

Linear regulator

15V

5V

IC500

GND

10

9

>>Input

1

C

AUX

D25

5

D

2

4

D

2

6

IC11

Linear regulator

C85

4

GND

ISO5

4

3

ISO6

4

3

1

2

1

TL431CLP

2

IC13

GND

5V from Standby

13

-5V

12

3.3V

OV/UV

Protec

16

Output

V

1

Image 9-6
Block diagram OEM power board

Description

The OEM power board repeats operation which turns on and off at pin 7 pf IC12, and the pulse appears in secondary sides through
the converter transformer T3. At the time, the voltage of 3.3V at the secondary side is detected by IC13, the negative feedback to
IC12 is carried out at photo coupler ISO5 and then the voltage is stabilized.

Other outputs are determined by the turn ratio of secondary side of T3, and the voltage rectified, smoothed through the series
regulators (-5V is stablized at IC
and C85 at primary windings of T3 is supplied a s a power supply voltage of IC12 on primary side.

11, 5V is stabilized at IC10, 1 5V is stabilized at IC9). The voltage rectified and smoothed by D25

R5976766 RLM G5 22/04/2004

51

9. Technical Board Information

Pin assignment Connectors on board

J36
J35

J100

J33
J34

J39 D70 (Power Good)

J39

1 PG
2 /PD
3 GND

J32

J36

1-5 3.3V (3.5A)
6 3.3V sense+
7 3.3V sense ­8-12 GND

* Primary ground

Image 9-7
Pin assignment connectors on board

J35

1 3.3V (1.5A)
2 3.3V (1.5A)
3 GND
4 GND

J100

1 +15V
2 +5V
3 GND

9.1.5 StandBy Power Supply board
Block diagram

StandBy Power Board

DC 380V from PFC

IC7

7

D

J33

1 ++5V (1A)
2 GND

3

COL

1

+B

J29

J34

1-2 GND
3 -5V (0.2A)
4-5 +5V (1.3A)
6 GND
7 + 15V (0.5A)
8 GND

T1

D1

D

2

IC1

Linear regulator

J32

1 +15V (0.5A)
2/4/6/8 GND
3 +5V 0.7A
5 -5V 0.2A
7 ++5V (1A)

24V

3.3V

J29

1 375V
2 NC
3 GND P*

5

F

4

S

3

X

2

L(M)

Image 9-8
Standby power supply

GND

1

C

FB

D4

C16

ISO1

4

3

ISO2

4

3

1

2

8

7

GND

1

TL431CLP

2

GND

GND

IC3

D

5

5V

IC500

12

>>Input

9

OV/UV

Protec

16

Output

V

1

52 R5976766 RLM G5 22/04/2004

9. Technical Board Information

Description Standby power board

The s tandby power board repeats operation which turns on and off at pin 7 of IC2, and the p ulseappears in secondary sides through
the converter transformer T1. At the time, the voltage of 5V at the secondary side is detected by IC3, the negative feedback to IC2 is
carried out at photo coupler ISO1, and the voltage is stabilized. Other outputs are determined by the turn ratio of secondary side of
T1, and the voltage rectified, smoothed through the series regulator (3.3V is stabilized at IC1). On the one hand the voltage rectified
and smoothed by D4 and C16 at primary winding of T1 is supplied as a power supply voltage of IC2 on primary side, and on the
other the voltage of 18V rectified and smoothed By D7 and C28 at primary winding of T1 and stabilized to 15V at IC20 is supplied
as a power supply voltage of IC321 on primary side.

The operation of IC2 is similar to that of IC7 described previously.

Over-Voltage Protection (OVP)

The output voltages of -5V, 3.3V, 5V and 15V are sensed by the pin 13, pin 12, pin 9, pin 10 of IC500 on DNA control board. When
these outp ut voltages are more than 124% of their standard value, the over-voltage protection is created. For example, on the format
DC-DC converter the pin 1 of IC500 will be high and the pin 3 of IC500 will be low then the photo coupler ISO4 will turn off. So the
pin 3 of IC7 is open and IC7 stops to oscillate. The process of over-voltage protection on standby and OEM DC-DC converter is the
same with the OVP on format DC-DC converter. When the voltage of 2.5 V exceeds 3.6V the four series d iode D81, D82, D83 and
D84 will turn on, the n the pin 12 of IC500 will sense the OVP,and IC7 stops to oscillate. When the voltage of 24V exceeds 42V th e
zener diode D85 turns on, then the high voltage make the voltage of 3.3V create the over-voltage protection.

Short Circuit Protection

On -5V, 3.3V, 5V and 15V lines, the short circuit protection is carried out by detectin
10 of IC500, then the under-voltage protection (UVP) is created when the output voltages are less than 80% of their standard value.
For example, on the OEM power board the pin 1 o f I C500 will be high and the pin 3 of IC500 will be low, the photo coupler ISO6 will
turn off. The the pin 3 of IC12 is open and IC12 stops to oscillate. The p
power boardis the same with the UVP on OEM power board. So that the process of short circuit protection is in the same way as
the over-voltage protection described previously, and the short circuit protection is carried out.

rocess of u nder-voltage protection on standby and format

g the voltage drop at pin 13, pin 12, pin 9 and pin

Pin assignment Connectors on Board

J19

J18

J15

J16

J18

1 ++5V
2 GND

Image 9-9
Pin assignment connectors on board

J15

1 ++5V (9A)
2 GND

J16

1 ++24V (1A)
2/4/6 GND
3 ++3.3V (1A)
5 ++5V (1A)

D72 (Power Good)

J19

1 PG
2 NC
3 GND

J12

1 375V
2 NC
3 GND P*

* Primary ground

R5976766 RLM G5 22/04/2004 53

9. Technical Board Information

9.1.6 MCU Board
Pin assignment Connectors on Board

J24

1 <StdBy PG
2 >StdBy_SW
3 GND

J25

1 <Formatter PG
2 >Formatter_SW
3 GND

J3

J213
J203

J506

J902

Not connected

J3
J902
J901
J903
J5
J908

J203

1 <Lamp1_Off
2 GND
3 ++5V
4 >SCI1
5 >UHP_RXD1

J213

1 <Lamp2_Off
2 GND
3 ++5V
4 >SCI2
5 >UHP_RXD2

J900

1 ++5V
2 GND
3 >SCL_0
4 >SDA_0
5 R_GND

J26

1 <OEM PG
2 >OEM_SW
3 GND

J24

J25

J903 J5

J901 J900

J505

1 ++5V
2 >SDA_StdBy
3 >SCL_StdBy
4 reserved
5 <n-PWR_INT
6 >RXD1
7 >RXD2
8 <TXD1
9 <TXD2
10 GND

J506

1 ++5V
2 GND
3 >LampSync
4 >Lamp_enable
5 <Lamp_status
6 <Powergood_++3.3_1

J1

1 ++24V
2 GND
3 ++3.3V
4 GND
5 ++5V
6 GND

J1J26

J505

J14

1 <FAN3_PLUG1
2 ++FAN3
3 GND

J15 J16

J4

J4

1 Lamp_Overtemp_Sense
2 GND

J18

1 <FAN5_PLUG1
2 ++FAN5
3 GND

J21

1 <FAN1_CTRL2
2 ++FAN1
3 GND

J10J908

J15

1 <FAN3_PLUG2
2 ++FAN3
3 GND

J17

J14

J12J11

J908

1 VDAC_TEC1
2 GND

J19

1 <FAN5_PLUG2
2 ++FAN5
3 GND

J10

1 <FAN6_PLUG1
2 ++FAN6
3 GND

J12

1 <FAN2_CTRL1
2 ++FAN2
3 GND

J16

1 <FAN4_PLUG1
2 ++FAN4
3 GND

J17

1 <FAN4_PLUG2
2 ++FAN4
3 GND

J18
J19

J20
J21

J13

J20

1 <FAN1_CTRL1
2 ++FAN1
3 GND

J11

1 <FAN6_PLUG2
2 ++FAN6
3 GND

J13

1 <FAN2_CTRL2
2 ++FAN2
3 GND

Image 9-10
Pin assignment conne

54 R5976766 RLM G5 22/04/2004

ctors on board

9.2 Random Boards

L

Overview

• Motor/Control Board

• Input Box Backplane

• Lamp Power Supply

• Pixel Map Processor Board

• Formatter Interface Board

•KeyPad

• LED + IR Board

9.2.1 Motor/Control Board
Pin assignment Connectors on Board

Lens Holder

Motor Up/Down

J24

Lens Holder

Motor Left/Right

J26

9. Technical Board Information

ens Zoom

Motor

J21

Lens Focus

Motor

J23

Shutter Motor

J28

From Formatter

Adapter

J520

J520

1 IRQ DMD
2 SDA
3 SCL
4 GND

Image 9-11
Pin assignment connectors on board

J504

1 +15V
2 +5VD
3 GND

From OEM

Power Supply

J504

J24

1 D Rev
2 REV
3 FW
4 D Fw

J26

1 D Rev
2 REV
3 FW
4 D Fw

NTC Sensor R

J10

J20

1 +5VD
2 GND

NTC Sensor G

J13

J10/13/16

1 +5VD
2 GND

J28

1 D Rev
2 REV
3 FW
4 D Fwd

NTC Sensor B

J16

1 Mtr Fwd
2 +5VD
3 Cha A
4 Cha B
5 GND
6 Mtr Rev

J21

Prism Switch

J20

J23

1 Mtr Fwd
2 +5VD
3 Cha A
4 Cha B
5 GND
6 Mtr Rev

R5976766 RLM G5 22/04/2004 55

9. Technical Board Information

9.2.2 Input Box Backplane
Pin assignment Connectors on Input Backplane

from OEM power supply

J301

1 3.3V (1.5A)
2 3.3V (1.5A)
3 GND
4 GND

from OEM power supply

J409

1-2 GND
3 -5V (0.2A)
4-5 +5V (1.3A)
6 GND
7 + 15V (0.5A)
8 GND

Image 9-12
Pin assignment connectors on input backplane

9.2.3 Lamp Power Supply
Pin assignment Connectors on Board

from PFC power supply

J_LPS1

1 380V
2 GND P*

from PFC power supply

J_LPS2

1 380V
2 GND P*

J301
J409

J419

from Standby power supply

J419

1 ++5V (9A)
2 GND

* Primary ground

Image 9-13

56 R5976766 RLM G5 22/04/2004

9.2.4 Pixel Map Processor Board
Pin assignment Connectors on Board

9. Technical Board Information

from OEM power supply

J509

1 +15V (0.5A)
2/4/6/8 GND
3 +5V 0.7A
5 -5V 0.2A
7 ++5V (1A)

J509
J519

J550
J505

J519

1-5 3.3V (3.5A)
6 3.3V sense+
7 3.3V sense ­8-12 GND

from MCU Board

J505

1 ++5V
2 >SDA_StdBy
3 >SCL_StdBy
4 reserved
5 <n-PWR_INT
6 >RXD1
7 >RXD2
8 <TXD1
9 <TXD2
10 GND

J550

1 ++5V
2 IR_Keyboard
3 IR_Receiver
4 Backlight 1
5 Backlight 0
6 GND

Image 9-14
Pin assignment connectors on board

R5976766 RLM G5 22/04/2004 57

9. Technical Board Information

9.2.5 Formatter Interface Board
Pin assignment Connectors on Board

from Led-IR board

J307

1 +5V
2 GND
3 SCL_StdBy
5 SDA_StdBy
6 RCS_IR

J307

J306
J304

J303

DMD Blue

J302

DMD Green

J301

to PMP Board

DMD Red

J300

from MCU board

J304

1 ++5V
2 GND
3 >LampSync
4 >Lamp_enable
5 <Lamp_status
6 <Powergood_++3.3_1

from Front IR board

J306

1 +5V
2 GND
3 IR

from Motor/Control board

J303

1 IRQ_DMD
2 SDA
3 SCL
5 GND

Image 9-15
Pin assignment connectors on Formatter interface board

9.2.6 KeyPad
Pin assignment Connectors on Board

from PMP Board

J550

1 nc
2 nc
3 nc
4nc
5 ++5V
6 IR_Keyboard
7 IR_Receiver
8 Backlight R
9 Backlight G
10 GND

Image 9-16
Pin assignment connector on keypad

58 R5976766 RLM G5 22/04/2004

9.2.7 LED + IR Board
Pin assignment Connectors on Board

Image 9-17
Pin assignment connector on LED+IR board

9. Technical Board Information

from Formatter interface
board

J307

1 +5V
2 GND
3 SCL_StdBy
5 SDA_StdBy
6 RCS_IR

R5976766 RLM G5 22/04/2004 59

9. Technical Board Information

60 R5976766 RLM G5 22/04/2004

10. Mechanical Parts Identification

10. MECHANICAL PARTS IDENTIFICATION

Overview

• Projector Lamp box

• Projector Power Box

• Shutter

• Projector Input Box

• Lens Holder

• Rigging Assembly

• Projector Bottom Assembly

• Projector Top Cover Assembly

• Projector Front Assembly

•ProjectorAssembly

10.1 Projector Lamp box

Exploded view

The exploded view of the lamp box is added by way of illustration.

R5976766 RLM G5 22/04/2004

61

10. Mechanical Parts Identification

ITEM REF. DESCRIPTION QUANTITY

2633 3105 280 800 SCREW M M3*0.5*25 NON-H HEXI S 3
2634 3110 111 100 CASE NUT M3*0.5 S20C 3
2636 3250 204 000 MIRROR IR FILTER BOROFLOAT HEX 1
2637 3422 001 300  SPACER SUPPORT NY66 94V2 4
2638 3455 033 001 BRACKET SECC T=0.8 LBOX WALL 1
2639 3455 033 300 BRACKET SECC T=0.8 LBOX DOOR 1
2640 3455 033 401 BRACKET SECC T=0.8 LBOX SLOT 1
2641 3455 033 501 BRACKET SECC T=1.0 BALAST PLUG 1
2642 3455 033 601  BRACKET SECC T=0.8 LBOX CHANNEL 1
2643 3455 034 400 PLATE MIRROR AL 1

ITEM REF. DESCRIPTION QUANTITY

2644 3455 034 500  BRACKET MIRROR W TILT AL 1
2645 3455 035 002 PLATE SUPPORT RM LAMP AL 1
2646 3455 049 300 BARCKET AL5052 T0.8 FAN FIXER TO 1
2647 3455 049 400 BRACKET AL5052 T0.8 FAN FIXER BTM 1
2649 3462 004 500 SPRING SUS304 ID5.0 H12 MIRROR 3
2650 3620 005 811 DC FAN ASSY WFB1212M-R00 (450) 1
2708 3620 618 811 DC FAN ASS GB1206PHV1-AY-R00 2
2709 3620 822 511 DC FAN ASSY AFB0812MD-R00 (300) 1
2756 3797 037 400 LAMP ASSY 1

Image 10-1
Lamp box exploded view

10.2 Projector Power Box

Exploded view

The exploded view of the power box is added by way of illustration.

62

R5976766 RLM G5 22/04/2004

ITEM REF. DESCRIPTION QUANTITY

52 3455 042 101 CAP DOOR SECC T0.6 1
86 0990 072 300 POWER SUPPLY 250W/200W(CTL)PU 2
87 3100 300 600  SCREW M M3*0.5*6 PAN C S+P S20 15
88 3100 310 600 SCREW M M3*0.5*6 PAN C S+P S20 20
89 3105 055 700  SCREW M#4-40*14 HEX H BRASS NI 2
90 3109 021 700 SCREW T M4*0.7* PAN CS S18C 1
91 3202 317 200 LABEL CAUTION 50*60 POWER ASSY 1
92 3240 195 000 BUSHING SIRUB OD8 ID4 H4. 8 ORG 12
93 3350 146 900 RIVET SNAP NYLON66 94V-2 12
94 3371 007 901 BRACKET SECC T=0.8,PBOX FORMAT  1
95 3371 008 000  BRACKET SECC T=0.8,P BOX POWER 1
96 3371 008 100 BRACKET SECC T=0.8,P BOX BALLAST 1
97 3371 008 201 BRACKET SECC T=0.8,P BOX TOP 1
98 3371 008 300 BRACKET SECC T=0.8,P BOX OEM 1
99 3371 008 400  BRACKET SECC T=0.8,P BOX STDBY 1
100 3371 008 501 BRACKET SECC T=0.8,P BOX CAP 1

10. Mechanical Parts Identification

ITEM REF. DESCRIPTION QUANTITY

101 3371 008 600 BRACKET SECC T=0.8,P BOX AC 1
102 3371 008 701 BRACKET SECC T=0.8,P BOX DOOR 1
103 3371 008 800 BRACKET SECC T=0.8,P BOX BOTOM 1
104 3421 137 500  RAIL NY66 UL 94V-2 PG CG-11A 6
105 3422 005 600  STAND OFF NY66 94 V2 8
106 3455 032 901 BRACKET SECC T=0.8,P BOX-BTM FI 1
107 3460 040 000 CABLE CLIP SPTE+PVC TUBE L=60 1
108 3468 107 000  CLIP SUS304 D1.8mm 1
109 3600 635 000  SWITCH ASSY DXE-50 1
110 3610 635 000 SOCKET ASSY DXE-50 1
111 3620 005 411 DCFAN ASSY WFB1212L-R00(320)12 1
169 3620 822 411 DC FAN ASSY AFB0812L-R00(220) 1
218 3620 907 911 DC FAN ASSY AFB0912L-R00(250)9 1
281 5600 200 169 FORMATTER BD ASSY 1
536 5600 200 170  STANDBY BD ASSY 1
735 5600 200 171 PFC BD ASSY 1
1016 5600 200 178 OEM BD ASSY 1
3279 5600 200 179 MCU BD ASSY 1

Image 10-2
Power supply box assembly

R5976766 RLM G5 22/04/2004 63

10. Mechanical Parts Identification

10.3 Shutter

Exploded view

B401036K

ITEM REF. DESCRIPTION QUANTITY

2574 3100 300 600 SCREW M M3*0.5*6 PAN C S+P S20 3
2575 3105 147 700 SCREW M M2.5*0.45*16 FF C S18C 2
2576 3105 261 600  SCREW M M2.5*0.45*6 PAN C S+P S20C NI 2
2577 3109 013 900 SCEW T M3*0.5*8 PAN C S S18C 1
2578 3110 361 100 WASHER SPCC OD6 ID2.7 T0.5 ZN 1
2579 3455 027 900 BRACKET PLATE SHUTTER SECC T=1 1
2580 3455 028 002 BRACKET SHUTTER AL T=0.5 1

Image 10-3
Exploded view of the Shutter assembly

10.4 Projector Input Box

Exploded view

The exploded view of the lamp box is added by way of illustration.

ITEM REF. DESCRIPTION QUANTITY

2581 3455 035 800 PIN CU L9.5 1
2582 3455 041 700 CONDUIT CU SHUTTER 1
2583 3670 411 800 WIRE WITH HOUSING GES602N201AM 1
2584 XXB360620 NUT M2.5 STZN 2
2585 XXB4400011D MOTOR WITH GEAR 12V L100 1
2586 XXR817481 BRACKET SHUTTER MOTOR T=1 1
2587 XXR817482 LINKAGE SHUTTER T=1X 1
2588 XXR819046 PLATE SHUTTER MOTOR T=1.5 1
2589 XXR819353 GEAR SHUTTER 1
2590 XXV367501 WASHER SPRING D5 STZN 2

64

R5976766 RLM G5 22/04/2004

10. Mechanical Parts Identification

ITEM REF. DESCRIPTION QUANTITY

2820  3797 037 500 Input box as sembly 1
2821 3100 000 600 SCREW M M3*0.5*6 FLAT C S20C ZN 4
2822 3100 300 600 SCREW M M3*0.5*6 PAN C S+P S20C ZN 18
2823 3109 012 100 SCREW T 3*1.27*6 PAN C S20C 3
2824 3109 093 500 SCREW T 2.6*0.9*8 PAN C S20C NI 1
2825 3240 971 900  SPONGE PORON L32C 40*12*6 1
2826 3371 007 702 BRACKET I/O AL5052 T1.5 161*14 1
2827 3455 023 900 FRAME SIDE SECC T=1.0F/C 1
2828 3455 024 601 FRAME I/O AL5052 T1.5 125*104 1
2829 3455 046 400 PLATE ADAPTER SECC 112.6*74.1 1
2830 3455 046 500 BRACKET SECC 135.2*20 T.6 2

ITEM REF. DESCRIPTION QUANTITY

2831 3461 413 300 STAND OFF BRASS M3*0.5 L34+4 2
2832 3461 414 900 STAND OFF BRASS M3*5 L12+4 2
2833 5600 200 181 VIDEO BOARD ASSEMBLY 1
2834 5600 200 182 VGA BOARD ASSEMBLY 1
2835 5600 200 183 I/P BACKPLANE BOARD ASSEMBLY 1
2836 5600 200 184 PIXEL MAP PROCESSOR BOARD ASSY 1
2837 5600 200 246 SDI BOARD ASSEMBLY 1
2838 5600 200 250 XLR BOARD ASSEMBLY 1
2839 XXB337229 CONNECTOR XLR PLUG 1
2840 XXR804658 FRAME PCB FIX DPL 4
2841 XXV3125035 NUT#4-40 D-SUB 6
2842 XXZ3495032 WIRE WITH HOUSING WLR L60 1

Image 10-4
Exploded view Input box

R5976766 RLM G5 22/04/2004 65

10. Mechanical Parts Identification

10.5 Lens Holder

Exploded view

ITEM REF. DESCRIPTION QUANTITY

1241 3100 001 600  SCREW M M3*0.5*16 FLAT C S20C 4
1242 3100 300 800 SCREW M M3*0.5*8 PAN C S+P S20 2
1243 3100 310 600 SCREW M M3*0.5*6 PAN C S+P S20 1
1244 3105 049 100 SCREW M M2*0.4*6 FLAT C S10C N 1
1245 3105 120 100 SCREW M M4*0.7*12 PAN C S+P S1 4
1246 3109 013 900 SCREW T M3*0.5*8 PAN C S S18C 2
1247 3109 921 300 SCREW M M3*0.5*3 HEXI S18C 5
1248 3110 113 700 NUT M3*0.5*3.9 SAE1008 HEXH+NY 4
1249 3110 110 100 NUT S17C ZN M3*0.5*2.4 1
1250 3450 000 601 LENS SUPPORT AZ91D BLK OXIDE A 1

ITEM REF. DESCRIPTION QUANTITY

1251 3450 202 400 PLATE TRIP XGA AL T=2.5 1
1252 3455 023 400  BARACKET LENS COVER SECC T=1.0 1
1253 XXB3587466 BEARING BALL R1 D013 W03 1
1254 XXB358747  BUSH D08 D10 L08 1
1255 XXB361346 SPRING D15 L32 3
1256 XXG181500 SCREW SET M3X10 1
1257 XXR366246 NUT D985 M6 STZN 3
1258 XXR814654 FRAME BEARING LENS  1
1259 XXR815224 BUSH AXLE ADJUST 1
1260 XXR817082 FRAME SALVATOR LENS HOLDER 1
1261 XXR829734 FRAME SALVATOR LENS HOLDER 1
1262 XXV3673806 WASHER SPRING D12 6
1263 XXZ3483136 CABLE BRAID L140 2

Image 10-5
Exploded view lens holder

10.6 Rigging Assembly

Parts of the Rigging assembly

The exploded view of the lamp box is added by way of illustration.

66

R5976766 RLM G5 22/04/2004

10. Mechanical Parts Identification

ITEM REF. DESCRIPTION QUANTITY

2871  XXA576078 CLIPS D8 SPTH 4
2872 XXB356331 FOOT INSERT D9.5 BLACK RIGGING 4
2873 XXB361710 SCREW D923 M3X10ST 16
2874 XXB362626 NUT HEX SOCKET DOWEL M6X20 8
2875 XXG116090 SCREW H EX SOCKET M5*8 2
2876 XXG192900 SCREW SET M4X6 4
2877 XXR828347 BOTTOM PLATE RIGGING ASSY 1
2878 XXR828351 LOCKING CUP RIGGING 4
2879 XXR828352 LOCKING RING 4

Image 10-6
Rigging exploded view

ITEM REF. DESCRIPTION QUANTITY

2880 XXR828353 INTERLOCKING FOOT AXIX RIGGING 4
2881 XXR828354 LOCK ADJ RIGGING 4
2882 XXR828355 LOOKING HOOK RIGGING 4
2883 XXR828356 MOUNTING PLATE RIGING 4
2885 XXR828362 HANDLE FRAME RIGGING ASSY 2
2886 XXR828363 ROD TREADED M6 RIGGING 8
2887 XXR828842 FRAME EXTRA STACKING RIGGING ASSY 1
2888 XXV312007 SPRING D5.5 L9 RIGGING 16
2889 XXV3623197 SCREW 4X8 STZN 12
2890 3461 412 900  STAND OFF STELL M8 3

R5976766 RLM G5 22/04/2004 67

10. Mechanical Parts Identification

10.7 Projector Bottom Assembly

Parts of the projector bottom assembly

ITEM REF. DESCRIPTION QUANTITY

5 3100 300 600 SCREW M M3*0.5*6 PAN C S+S20C ZN 2
7 3105 094 100  SCREW M M8*1.25*15 ROUND C+S S20C 3
9 3105 120 600 SCREW M M4*0.7*8 PAN C S+S10C ZN 15
18 3371 007 600 BOTTOM AL 500mm T=3.0 PAINT ING 1
27 3391 201 100 COVER FILTER L PC+ABS 94V-0 PAINTING 3
28 3391 201 300 94-0 PAINTI 94-0 PAINTI 2
32 3455 023 700 PLATE FEET SECC T=5.0 BOTOM 3
33 3455 023 800 PLATE EYE SECC T=5.0 BOTTOM 2
35 3455 024 101 BRACKET STOP SECC T=0.7 BOTT OM  2 
39 3455 026 501 BRACKET FEET SECC T=1.0 2
53 3455 047 200 BRACKET SECC T=1.0 SUPPORT REAR FOOT 1
1912 XXR 722 567 F OOT PLASTIC D60 3
1916 XXR 818 903 F R AME FOOT SALVATOR 3

Image 10-7
Bottom assembly

68 R5976766 RLM G5 22/04/2004

10.8 Projector Top Cover Assembly

Parts of the projector top assembly

10. Mechanical Parts Identification

ITEM REF. DESCRIPTION QUANTITY

5 3100 300 600 SCREW M M3*0.5*6 PAN C S+S20C ZN 4
9 3105 120 600 SCREW M M4*0.7*8 PAN C S+S10C ZN 1
10 3105 120 700 SCREW M M4*0.7*10 PAN C S+S10C ZN YEL 9 
11 3106 164 300 SCREW TAPPING 0D=4*8 NI PLATED 6
12 3106 170 400 SCREW T M 3*1.058*8 PAN C S18C ZN  17
19 3390 003 900  IR WINDOW PC 94V-0 TRANSPARENT 1
20 3390 004 000 LED WINDOW PC 94V-0 TRANSPARENT  1
21 3390 105 000 TOP COVER PC+ABS 94V-5 PAINTING 1
31 3455 023 500 BRACKET AXIAL SECC T=1.2 2
37 3455 024 400  PLATE SPRING SUS301 T=0.5 T/C 2
38 3455 024 500 BRACKET TOP SECC T=1.2 I/O 1
47 3455 028 500  SPRING RETAINERS STEEL PANEX 4MM 2
1914 XXR 724 409 RUBBER LOC AL KEYPAD  1

Image 10-8
Top cover assembly

R5976766 RLM G5 22/04/2004 69

10. Mechanical Parts Identification

10.9 Projector Front Assembly

Parts of the front cover assembly

ITEM REF. DESCRIPTION QUANTITY

5 3100 300 600 SCREW M M3*0.5*6 PAN C S+P S20C ZN 2
9 3105 120 600 SCREW M M4*0.7*8 PAN C S+P S10C ZN 8
16 3240 973 100 RUBBER SPONGE 100SM 450*30 T10 1
22 3390 105 100 FRONT COVER PC+ABS 94V-5 PAINTING 1
29 3395 005 200 COVER PLUG PC+ABS 94V-0 3
34 3455 024 000 BRACKET MIDDLE SECC T+1.0 F /C 1
41 3455 026 700 FRAME LEFT SECC T+1.0 1

ITEM REF. DESCRIPTION QUANTITY

42 3455 026 800  BRACKET FRONT SECC T+1.2 1
43 3455 026 901  BRACKET RIGHT SECC T+1.2 1
45 3455 028 300  STUDS PANEX STEE WING L10 1
46 3455 028 400  RECPTACLES STEEL RIVET 4MM 2
2986 5600 200 161 IR BOARD ASSY 1
1911 XXR720 901 IR WIN DOW REC 26 1

Image 10-9
Front cover exploded view

70 R5976766 RLM G5 22/04/2004

10.10Projector Assembly

Parts of the projector assembly

10. Mechanical Parts Identification

ITEM REF. DESCRIPTION

3 3797 035 900 POWER BOX
17 3240 973 200 RUBBER SPONGE 100SM 241*48 T2
18 3371 007 600 BOTTOM AL 500mm T=3.0 PAINTING
21 3390 105 000 TOP COVER PC+ABS 94V-5 PAINTING
22 3390 105 100 FRONT COVER PC+ABS 94V-5 PAINTING
23 3390 105 200 LEFT COVER PC+ABS 94V-5 PAINTING
24 3390 105 300  RIGHT COVER PC+ABS 94V-5 PAINTING
25 3390 105 501 TOP COVER #1 PC+ABS 94V-5 PAINTING
26 3390 106 700 COVER TOP #3 PC+ABS 94V-0
36 3455 024 300 BRACKET WIND-2 SECC T=1.2 F/C
40 3455 026 600 BRACKET S SECC T=1.0 
44 3455 028 200 STUDS PANEX STEEL SLOT L19
46 3455 028 400 RECEPTACLES STEEL RIVET 4MM
48 3455 032 501 SHIELD INPUT SPTE T0.3
49 3455 032 601 SHIELD LEFT SPTE T0.3
50 3455 032 701 SHIELD RIGHT SPTE T0.3
51 3455 100 501 COVER FRONTEND SECC
2627 3797 037 300 LAMP MODU LE ASSY

Image 10-10
Projector assembl

y exploded view

R5976766 RLM G5 22/04/2004 71

10. Mechanical Parts Identification

72 R5976766 RLM G5 22/04/2004

11. LIGHT PAD ADJUSTMENT

Overview

• Lens Holder (Scheimpflug)

• Illumination System

11.1 Lens Holder (Scheimpflug)

Adjustment controls on the Lens Holder

The following adjustment controls and locks are provided on the front of the lens holder:

• A, B and C: 3 x M10 nuts for the adjustment of the lens position.

• 1, 2 and 3: 3 x M2.5 Allen head screw close to the M10 nuts, securing the respective adjustment screw.

• 4: Additional M2.5 Allen head screw, securing the entire lens holder to avoid vibrations in the picture.

11. Light Pad adjustment

1

A

2

B

3

4

C

Image 11-1
Adjustment controls on lens holder (lens removed)

Necessary tools

• Nut driver of 8 mm and 10 mm

•Allenkeyof2.5mm

How to adjust the lens holder

1. Put a TLD 0.8 lens (with optical adapter) or a RLD 0.8 lens into the lens holder of the projector, the latter placed at 2 m from the

screen (A lens with a fixed nominal focus position would be best, but in absence of this, you can use the TLD 0.8).

2. Ensure the projector axis is perpendicular onto the screen and the projector is leveled.

3. Looking at the screen, turn the focus barrel counterclockwise until you hit the mechanical stop.

The lens is at near focus.

4. Loosen the lens lock screws 1 to 4 (turning counterclockwise), using an Allen key of 2.5 mm and turn the screw lock nut a few

turn counterclockwise.

5. Search for the in focus picture by moving a white paper perpendicular on the projector axis (image 11-2)

In focus picture is found before the screen or not:

- Before the screen (1): turn the nuts A, B and C equally clockwise until the picture is in focus on the screen center (3).

- Not before the screen (2) (meaning in focus picture is located behind the screen) : turn the nuts A, B and C equally counter­clockwise until the pictu re is in focus on the screen center (3).

R5976766 RLM G5 22/04/2004

73

11. Light Pad adjustment

6. Proceed to overall focus, using the adjustable nuts A, B and C. Added picture indicates the picture rotation around the vertical,
horizontal or diagonal axis when turning the respective nut. (image 11-3)

Tip: The adjustment of the nuts A, B and C have an influence each other. Therefore, some iterations will be probably nece s-

sary.

7. Secure the position of the lens holder by tightening screw ( 4) as follo ws:

- Drive in the screw until you feel mechanical resistance and

- From this position, add a half turn.

8. Repeat step 6.

9. Secure the position of the adjustable nuts by tightening the matching screw 1, 2 and 3.

10.Finally, secure the lens lock screws by tightening the matching nut.

Image 11-2
In focus picture search

B

A

C

Image 11-3
Overall focus adjustment

C

B

A

C

B

B

A

C

A

74 R5976766 RLM G5 22/04/2004

11.2 Illumination System

Overview adjustment controls

11. Light Pad adjustment

B C E

A

D

Cold Mirror

Image 11-4
Overview adjustment controls

A Rod rotation
B Light spot size adjustment
C Fixation screw light spot sharpness adjustment ring
D Light spot sharpness adjustment
E Cold mirror adjustment screws

Nominal setting of the controls

1. Ensure the projector is turned off.

2. Loosen the screw A and B. (image 11-5)

3. Rotate the screw A and B in the middle of its adjustment range.

4. Loosen screw C.

5. Rotate the ring (D), causing the rod to move hor

6. Place the cold mirror in its nominal position, mirror support parallel to heat sink with 5.5 mm spacing, by adjusting the 3 screws
(E), accessible through the holes in the lamp house, with an Allen key of 1.5 mm. (image 11-6)

izontally,until the screw (C) is in the middle of the horizontal adjustment range.

C

A

Image 11-5
Nominal setting of the controls

R5976766 RLM G5 22/04/2004 75

B

D

11. Light Pad adjustment

Image 11-6
Nominal setting of the cold mirror

E

m

m

5

.

5

E

Cold Mirror

Alignment of the Illumination path

1. Turn on the projector and displays a white test pattern (See manual).

2. Adjust the folding mirror until the DMD is illuminated by the light spot symmetrically. (image 11-7)

3. Rotate th

e rod until dark borders are visible in the corners of the image. (image 11-8)

4. Adjust the horizontal position of the rod, by turning the ring (D), for sharp outline at the dark borders.

5. Rotate the rod back to its nominal position.

6. Adjust the light spot size lens (B) until the light spot on the DMD is slightly larger than the DMD size. (image 11-9)

7. Repeat the adjustment of the border sharpness, step 3 to 5 in this procedure.

8. Finally, secure the position of the controls by tightening and fixing with appropriate glue the respective screws (A), (B) and (C).

DMD

A

Light spot

B

DMD

Image 11-7
Folding mirror adjustment

76 R5976766 RLM G5 22/04/2004

C

11. Light Pad adjustment

Light spot

D

DMD

A

Image 11-8
Light spot sharpness adjustment

A

B

B

C

D

A

Light spot

1

D

DMD

DMD

B

B

Image 11-9
Light spot size adjustment

DMD

2

DMD

3

Alignment of the Cold mirror

1. Place a light meter at the center of th e screen.

2. Adjust the 2 tilt screws (E1) and (E2), using an Allen key of 1.5 mm, for maximum light reading on the light meter. (image 11-10)

3. Search for different Z-positions of the cold mirror, turning the z-screw (E3) forwards and backwards, the m axim um light reading
on the light meter.

Note: For each Z-position of the cold mirror, readjust the tilt screws for maximum light reading on the light meter.

4. When the cold mirror position with the global maximum in light output is found, fix the adjustment screws with appropriate glue.

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77

11. Light Pad adjustment

Image 11-10
Cold mirror position alignment

E

3

1

1

3

E

2

Cold Mirror

2

78 R5976766 RLM G5 22/04/2004

12. Projector Suspension/Stacking

12. PROJECTOR SUSPENSION/STACKING

12.1 Stacking Projectors

How to stack projectors

Up to 2 projectors can be stacked on each other without using extra tools or accessories.

1. Put the second projector on the first one, matching the rigging points of the second projector with the rigging sockets of the first
projector. (image 12-1 )

2. Secure the ringing points in the rigging socket as follows:

- Press and keep the lock ring (1) in the rigging socket downwards.

- Rotate the rigging foot a little counterclockwise until the lock pins (3) match the notches in the rigging socket.

- Rotate the rigging foot in a way the lock pins m ove below the pin blocker (4) fully.

- Loosen the lock ring (1). (image 12-2)

4

1

3

Image 12-2
Securing the rigging assembly

Image 12-1
Stacking projectors

Ceiling mounted stacked projectors

For ceiling mounted configurations, mount a security cable between the lowest projector and the upper projector.

2

Image 12-3
Mounting the security chain

R5976766 RLM G5 22/04/2004 79

12. Projector Suspension/Stacking

CAUTION: Be sure the safety worki ng loud of the used security cables and appropriate connectors are suffi-

cient to support one projector. Refer to the supplier of the security cable for safety details

12.2 Projector Suspension

What is provided?

Slots (A) are provided on the fo ur sides of the stacking frame (bottom side) which allow the mounting of four doughty clamps in
combination with a hinge joint.

Consult a professional structural engineer prior t o suspending the ceiling mount from a structure n ot intended
for that use. Always ensure the working load limit of the structure supporting the projecto r.

A

x4

Image 12-4
Rigging assembly

Necessary tools

Wrench of 17mm

How to m ount the doughty clamps

1. Refer to the installed trussing to determine

2. Push with the head of the cup square neck bo lt the leaf spring downwards (1) to slide the bolt head in the slot (2). (image 12-5)

3. Secure the position of the bolt with a washer (3) and nut (4).

4. Turn a second nut on the bolt (later used to fix the hinge joint).

5. Turnthe hinge joint (5) on the bolt to the end in a way the hinge joint faces the lens (Forward- or backwards projector pivoting).

6. Secure the position of the hinge joint by tightening the second nut (4).

7. Turn the doughty clamp on the hinge joint ful

theplaceoftheclampsintheslotsontherearofthestackingframe.

ly (6).

80

R5976766 RLM G5 22/04/2004

(6)

Image 12-5
Mounting the doughty clamps

How to hook the clamp onto the truss beam

1. Open the clamp by loosening the clamp lock. (image 12-6)

2. Hook the clamp onto the truss beam.
The built-in clamp trigger automatically shuts the clamp around the truss beam.

3. Secure the position of the clamp by tightening the clamp lock.

12. Projector Suspension/Stacking

(5)
(4)
(3)

(1)

(2)

D

Image 12-6
Projector mounting onto a trus

When theprojector is mounted o
small level differences in the clamp height, usin g a wrench of 17 mm.

A

B

C

s

nto the truss, the adjustable spacers (A) in the clamp assembly allow to adapt

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12. Projector Suspension/Stacking

82 R5976766 RLM G5 22/04/2004

13. Maintenance of the Projector

A

13. MAINTENANCE OF THE PROJECTOR

13.1 Air Filters

About maintaining the air filters

It is recommended that you replace the air filters (located at the bottom of the projector) when you replace the lamp - or sooner, in
dusty or dirty environment. In the latter case, check monthly if replacement is required.

A clogged filter reduces the air flow, and can lead to overheating and failure of the projector.

Location of the air filters

The air filters, in total 5 filters, are located into the bottom of the projector.

The 2 exterior filters (4 & 5) are obstructed by the mounted stacking frame. To be able to remove these filters,
loosen a few turn the frame screw (A) nearest the rear side of the projector.

1

2

3

4
5

Image 13-1
Location of air filters

Replacement of the air filters

1. Press the lip (A) of the filter lock (2 for filters 1 to 3 and 1 for filter 4 & 5) to release and next,

2. Lift up front (B) of air filter and move forwards (C) to remove. (image 13-2, image 13-3)

Tip: For the filters 4 & 5, when the lock is r

clips are free, and next remove the filter to the outside.

eleased, move the filter a little to the inside of the projector until the filter center

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83

13. Maintenance of the Projector

Image 13-2

B

A

C

Image 13-3

Available kit

All the 5 air filters are assembled to 1 kit, order number R401045K

13.2 Cleaning the lens

To minimize the possibility of damaging the optical coating or scratching exposed lens surface, we have de­veloped recommenda ti ons for cleaning the lens. FIRST, we recommend you try to remove any material from
the lens by blowing it o ff with clean, dry deionized air. DO NOT use any liqu id to clean the lenses.

84 R5976766 RLM G5 22/04/2004

13. Maintenance of the Projector

Necessary tools

TorayseeTMcloth (delivered together with the lens kit). Order number : R379058.

Howtocleanthelens?

Proceed as follow :

1. Always wipe lenses with a CLEAN Toraysee

2. Always wipe lenses in a 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 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.

TM

cloth.

WARNING: Do not use fabric softener when washing the cleaning cloth or softener sheets w hen drying the

cloth.
Do not use liquid cleaners on the cloth as doing so will contaminate the cloth.

CAUTION: Other lenses can also be cleaned safely with this Toraysee

TM

cloth.

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13. Maintenance of the Projector

86 R5976766 RLM G5 22/04/2004

14. SOFTWARE UPDATE

Overview

• Installation requirements

• Interconnection PC/Projector

• Projector Software Update Procedure

14.1 Installation requirements

Computer hardware

• Standard PC with one free serial port (COM1 or COM2)

• RS232 straight communication cable.

Computer Software

• Windows 2000, Windows NT, Win 95, Win 98 , Win ME or Win XP.

• Barco LCD/DLP Projector Code Control (Download program)

14. Software Update

14.2 Interconnection PC/Projector

Connection PC to Projector

1. Connect one side o f the RS232 communication cable to the free COM port of your PC. (image 14-1)

2. Connect the other side of the RS232 communication cable to the RS232 IN of you projector.

B

C

A

R/PR

G/Y B/PB Hs/Cs Vs VIDEO

DVI ANALOG RGB RS 232 C

10 BASE-T

Image 14-1
Software update via RS232

A PC + Barco download program
B RS232 straight cable
C RS232 input projector

SDI

IN

TWO WAY

HARDWIRED REMOTE

PUSH

2 1

S-VIDEO

R.C.

SDI

OUT

3

R5976766 RLM G5 22/04/2004

87

14. Software Update

14.3 Projector Software Update Procedure

How to download the projector software?

1. Go to the Barco Partnerzone (htpp:/www.partnerzone.events.barco.com) and login. (image 14-2)

Note: If you don’t have a login, start the registration procedure to get a log in (Username + password).

2. Once entered the partnerzone, select the desired market “partnerzone events”. (image 14-3)
The Home page of the market partnerzone events is displayed, showing the software updates list.

3. Select “more software u pdates”. (image 14-4)
A tap page is displayed showing the 4 different product ranges.

4. Select tap “Projector”. (image 14-5)
A page with all the P RO JECTO R products is displayed showing the software which can be downloaded.

5. In the software summary of the RLM G5, select item “RLM G5”. (image 14-6)
A pop up window is displayed asking to save the software for update to your disk.

6. Confirm “Save to disk” (image 14-7, image 14-8)
A dialog window opens asking where to save the software file. Using the browse button, browse to the desired directory on your

PC and press “Save”.

Image 14-2
PartnerZone Access to

88 R5976766 RLM G5 22/04/2004

14. Software Update

Image 14-3
PartnerZone Software updates

Image 14-4
PartnerZone Product selection

R5976766 RLM G5 22/04/2004 89

14. Software Update

Image 14-5
PartnerZone Product Software download

Image 14-6
File download

Image 14-7
Softwaresourcesave

Image 14-8
Software source downloading

90 R5976766 RLM G5 22/04/2004

14. Software Update

How to UnZip the downloaded Zip file

The downloadedfile is a compressed merged file. Extracting the merged files can be performed using the software program WinZip.

1. Click the downloaded file R32...... and press the right button on the mouse. (image 14-9)

The select window displays a various of possibilities to extract the zip file.

2. Click “Extract to folder D\........... ”

The Zip file will be extracted, as a sub directory, in the directory where the downloaded Zip file has been saved.

3. Click the sub directory to display the extracted files.
The following files become available:

- RlmG5.101.txt: file contains version information and installation procedure.

- RlmG5-Performer.101.bin: source file

- CodeControl.exe: download program

Image 14-9
UnZip the downloaded file

How to update the projector software?

1. Switch the projector into StandBy mode.

2. Double click “CodeControl.exe” to start the download program. (image 14-10)
A dialog window opens asking to fill o ut the following parameters:

- Projector address (2)

- Communication parameters, port (3) and Baudrate (1)

- Source file (4)

3. Set the projector address. (For a switched on projector, the projector address can be displayed on the screen by pressing the
address setting button on the remote control or on the identification screen via scrolling in the menu bar “General-Identification”.)

4. Set the PC communication port number on which the RS232 cable is connected to.

5. Set the Baudrate of the PC equal to the Baudrate of the projector as follows:

- Click “Detect”. The PC tries to communicate with the projector on differents Baudrat es until the projector returns an acknowl-

edgement. The detected Baudrate is filled out in the Baudra

- Set, if a value lower than 9600 b/s is filled out, the Baudrate in the drop down menu to minimum 9600 b/s or recommended

115200 b/s. Simultaneously the Baudrate of the projector is set at the sam e value. (image 14-11)

Tip: The m inimum Baudrate to be used is 9600 b/s

The recommended Baudrate is 115200 b/s

6. Click the Browse button and browse to the previously downloaded source file (xxx.bin). (image 14-12)

7. Click the Download button to start the download process.

- A successful download is indicated with a green spot in the right bottom corner of the download interface.

- A failed download is indicated with a red spot in the right bottom corner of the download interface. (image 14-13)

te drop down box.

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91