Xenon lamp for HDX. Installation manual

Transcription

1 Xenon lamp for HDX Installation manual R /01 31/05/2012

2 Barco nv Entertainment Division Noordlaan 5, B-8520 Kuurne Phone: Fax: Support: Visit us at the web: Printed in Belgium

3 Changes Barco provides this manual as is without warranty of any kind, either expressed or implied, including but not limited to the implied warranties or merchantability and fitness for a particular purpose. Barco may make improvements and/or changes to the product(s) and/or the program(s) described in this publication at any time without notice. This publication could contain technical inaccuracies or typographical errors. Changes are periodically made to the information in this publication; these changes are incorporated in new editions of this publication. The latest edition of Barco manuals can be downloaded from the Barco web site or from the secured Barco web site Copyright All rights reserved. No part of this document may be copied, reproduced or translated. It shall not otherwise be recorded, transmitted or stored in a retrieval system without the prior written consent of Barco. Disposal Information Waste Electrical and Electronic Equipment This symbol on the product indicates that, under the European Directive 2002/96/EC governing waste from electrical and electronic equipment, this product must not be disposed of with other municipal waste. Please dispose of your waste equipment by handing it over to a designated collection point for the recycling of waste electrical and electronic equipment. To prevent possible harm to the environment or human health from uncontrolled waste disposal, please separate these items from other types of waste and recycle them responsibly to promote the sustainable reuse of material resources. For more information about recycling of this product, please contact your local city office or your municipal waste disposal service. For details, please visit the Barco website at: Guarantee and Compensation Barco provides a guarantee relating to perfect 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 well as 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 complaint, 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 compensation for direct or indirect damage, and also damage attributed to the operation of software as well as to other services provided by Barco, being a component of the system or independent service, will be deemed invalid provided the damage is not proven to be attributed 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 transfer of risks, the goods are subject to influences not agreed upon in the contract, all guarantee claims of the purchaser will be rendered invalid. Not included in the guarantee coverage are system failures which are 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 well as the servicing and maintenance regulations specified in the this manual must be complied with by the customer. Trademarks Brand and product names mentioned in this manual may be trademarks, registered trademarks or copyrights of their respective holders. All brand and product names mentioned in this manual serve as comments or examples and are not to be understood as advertising for the products or their manufacturers.

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5 Table of contents TABLE OF CONTENTS 1. Xenon lamp Safety Introduction Lamp replacement Removing the exhausted xenon lamp from the lamp house Installing the new xenon lamp into the Lamp House Resetting the lamp parameters Realignment of the lamp in the Lamp House...20 R XENON LAMP FOR HDX 31/05/2012 1

6 Table of contents 2 R XENON LAMP FOR HDX 31/05/2012

7 1. Xenon lamp 1. XENON LAMP Purpose of this xenon lamp kit This kit contains a highly pressurized xenon lamp which may only be installed in the Lamp House (R ) of the Barco HDX projector by authorized and qualified technical personnel. This document, included in the kit, contains important information to prevent personal injury while installing the xenon lamp in the Lamp House. Furthermore, it includes several cautions to prevent damage to the xenon lamp or the Barco HDX projector. Ensure that you, the installer, understand and follow all safety guidelines and warnings in this document before installing the xenon lamp. Overview Safety Introduction CAUTION: Only service personnel who have successfully followed the training for HDX xenon lamp replacement (re-lamping) and who are in possession of the Barco HDX xenon lamp replacement certificate are qualified and authorized to replace the xenon lamp of the HDX Lamp House. R XENON LAMP FOR HDX 31/05/2012 3

8 1. Xenon lamp 1.1 Safety WARNING: DO NOT PERMIT UNAUTHORIZED PERSONNEL TO PERFORM OR ATTEMPT ANY PHASE OF XENON LAMP HANDLING OR SERVICE. ONLY TRAINED AND QUALIFIED TECHNICAL SERVICE PERSONNEL ARE ALLOWED TO HANDLE THE XENON LAMP. CAUTION: Xenon compact arc lamps are highly pressurized. When ignited, the normal operating temperature of the bulb increases the pressure to a level at which the bulb may explode if not handled in strict accordance to the manufacturer s instructions. The bulb is stable at room temperature, but may still explode if dropped or otherwise mishandled. Whenever the lamp house, containing a xenon lamp, has to be dismantled or whenever the protective container or cloth has to be removed from the xenon lamp, authorized protective clothing MUST be worn! WARNING: Always wear face protection (full face shield with neck protector) when handling xenon lamps. WARNING: Always wear protective clothing (welder s jacket) when handling xenon lamps. WARNING: Always wear clean leather gloves with wrist protectors when handling xenon lamps. Lamp packaging The xenon lamp is packed in a protective container or wrapped in a protective cloth. Never remove this protective container or protective cloth without wearing adequate protective clothing (face shield, clean cotton gloves, welder s jacket). Image 1-1 Xenon lamp inside protective container. CAUTION: Expired xenon lamps. Dispose of expired bulbs that are beyond warranty in the following manner: wrap the bulb tightly in several layers of canvas or heavy cloth. Place it on hard surface and shatter the envelope with a sharp hammer blow. DO NOT place a non shattered bulb in any ordinary refuse container. When returning a xenon lamp for warranty adjustment, pack it in its original shipping container. Complete and return all required warranty information. The Warranty policy about Barco HDX projector lamps can be found on the secured Barco web site 4 R XENON LAMP FOR HDX 31/05/2012

9 1. Xenon lamp 1.2 Introduction Xenon lamp Xenon lamps are highly pressurized. At room temperature the pressure inside the bulb is between 10 and 15 bar. When ignited, the normal operating temperature of the bulb increases the pressure up to somewhere between 30 and 50 bar. The bulb temperature of an ignited lamp is approximately 700 C and the temperature of the arc is approximately C! To ignite a xenon lamp a voltage of volt is required. Once the lamp is ignited the startup voltage drops to 28 volt. The DC current consumed by the lamp during normal operation can increase to 100 ampere. The maximum light produced by the xenon lamp inside the HDX projector is roughly lumens. The lamp house exist in a reflector, a UV blocker, a lamp anode socket, a lamp cathode socket, a lamp info module, and an XYZadjustment mechanism to align the lamp in the reflector. The lamp info module holds the lamp parameters and keeps track of the lamp history such as lamp power, number of strikes, total lamp run time, etc. For that it is important to reset the lamp parameters after each lamp replacement. TheLampHouseexistinareflector, a UV blocker, a lamp anode socket, a lamp cathode socket, a Lamp Info module, and an XYZ-adjustment mechanism to align the lamp in the reflector. The Lamp Info module holds the lamp parameters and keeps track of the lamp history such as lamp power, number of strikes, total lamp run time, etc. For that it is important to reset the lamp parameters after each lamp replacement. Parts location 1 Image Anode wire. 2 Anode. 3 Bulb. 4 Cathode Cathode adaptor A cathode adaptor is required to mount the xenon lamp in the Lamp House. The cathode adapter has to be mount upon the xenon lamp prior to mount the lamp in the Lamp House. The purpose of the cathode adapter is to position the arc of the xenon lamp in the middle of the reflector inside the Lamp House. The cathode adaptor is not included in the xenon lamp kit. The cathode adaptor comes with the HDX projector and have to be reused by each lamp replacement of the HDX Lamp House. Image 1-3 Anode connector The anode of the xenon lamp is equipped with a wire which has to be connected with the anode connector of the HDX Lamp House. The anode connector has to be connected with the xenon lamp prior to mount the lamp in the Lamp House. The anode connector is not included in the xenon lamp kit. The anode connector comes with the HDX projector and have to be reused by each lamp replacement of the HDX Lamp House. R XENON LAMP FOR HDX 31/05/2012 5

10 1. Xenon lamp Image 1-4 Order info Lamp Comment Order info USHIO xenon lamp of 2.5 kw for HDX 2.5kW PXL25BA2 R R XENON LAMP FOR HDX 31/05/2012

11 2. LAMP REPLACEMENT About this chapter This chapter describes how to replace the xenon lamp from the Lamp House of the Barco HDX projector. The replacement procedures assume that the Lamp House is already removed from the projector. See user guide, which was delivered with the Barco HDX projector, for detailed instructions on how to remove/install the Lamp House from the Barco HDX projector. Below you find the process stages which must be followed when replacing the xenon lamp of the Barco HDX projector. Note that some stages refer to the user guide of the projector. Other stages refer to more detailed procedures included in this document. Process stages: 1. Make sure that you understand and adhere all safety guidelines in the chapter "Safety", page Switch off the projector and let the projector cool down for at least 15 minutes before proceeding to remove the Lamp House. Note that the Lamp House is very hot after operation. Refer to the user guide of the projector for detailed instructions. 3. Remove the Lamp House from the projector. See user guide of the projector for detailed instructions. 4. Remove the exhausted xenon lamp from the Lamp House, see "Removing the exhausted xenon lamp from the lamp house", page Install the new xenon lamp in the Lamp House, see "Installing the new xenon lamp into the Lamp House", page Reinstall the Lamp House in the projector. See user guide of the projector for detailed instructions. 7. Reset the lamp parameters. The LAMP INFO parameters which are stored on a chip inside the Lamp House MUST be updated after each installation of the xenon lamp inside the Lamp House. Neglecting this update will result in poor performance and short life time of the xenon lamp. See "Resetting the lamp parameters", page Realign the xenon lamp in its reflector. For optimal performance of the xenon lamp it is required to realign the lamp after installation in the lamp house. See "Realignment of the lamp in the Lamp House", page 20. R XENON LAMP FOR HDX 31/05/2012 7

12 2.1 Removing the exhausted xenon lamp from the lamp house WARNING: DO NOT PERMIT UNAUTHORIZED PERSONNEL TO PERFORM OR ATTEMPT ANY PHASE OF XENON LAMP HANDLING OR SERVICE. ONLY TRAINED AND QUALIFIED TECHNICAL SERVICE PERSONNEL ARE ALLOWED TO HANDLE THE XENON LAMP. WARNING: This procedure may only be performed by qualified technical service personnel. CAUTION: Xenon compact arc lamps are highly pressurized. When ignited, the normal operating temperature of the bulb increases the pressure to a level at which the bulb may explode if not handled in strict accordance to the manufacturer s instructions. The bulb is stable at room temperature, but may still explode if dropped or otherwise mishandled. Whenever the lamp house, containing a xenon lamp, has to be dismantled or whenever the protective container or cloth has to be removed from the xenon lamp, authorized protective clothing MUST be worn! WARNING: Always wear face protection (full face shield with neck protector) when handling xenon lamps. WARNING: Always wear protective clothing (welder s jacket) when handling xenon lamps. WARNING: Always wear clean leather gloves with wrist protectors when handling xenon lamps. Necessary tools 2mm Allen wrench. 3mm Allen wrench. 17mm nut driver. 17mm open-end wrench. Flat screw driver. Full face shield with neck protection. Leather gloves with wrist protection. Welder s jacket (not included in the safety kit that Barco offers). How to remove the exhausted xenon lamp from the Lamp House? 1. Remove the cathode wire lug (reference 3 of image 2-1) from the cathode socket by unscrewing the nut (reference 1 of image 2-1) of the cathode socket. Use a 17mm nut driver. Note that the wire lug is provide with a plain washer (reference 2 of image 2-1). 2. Release the cathode adapter from the cathode socket by unscrewing the nut (reference 4 of image 2-1). Use a 17mm nut driver. Note: The cathode adapter is not visible from the outside. 8 R XENON LAMP FOR HDX 31/05/2012

13 Image Remove the bracket (reference 2 of image 2-2) from the UV blocker assembly. Use a 3mm Allenwrenchtoloosenthescrew (reference 1 of image 2-2). 2 1 Image Remove the UV blocker assembly from the Lamp House. First slide the UV blocker assembly away from the anode connector and then away from the Lamp House. Caution: Ensure that you wear protective clothing, a full face shield and protective gloves. R XENON LAMP FOR HDX 31/05/2012 9

14 A B Image Slide out the anode connector from the Lamp House. The anode connector remains attached with the lamp anode wire. Image Gently remove the xenon lamp together with the anode connector out of the Lamp House. Do not use excessive force upon the xenon lamp. Normally the xenon lamp will easily slide out the cathode socket of the Lamp House. Image Place the xenon lamp into a protective container prior to proceed with this procedure. 10 R XENON LAMP FOR HDX 31/05/2012

15 Image 2-6 Once the xenon lamp is safely sheltered in its protective container it is save to take out the protective clothing. This will facilitates the next steps in this procedure. 8. Remove the cathode lamp adaptor from the xenon lamp as illustrated. Use a2mmallenwrenchtoloosentheadaptor fixation screw (reference 2 of image 2-7) a few turns. Note: The xenon lamp has a cathode pin with screw thread. So, to remove the cathode adapter you have to turn the adapter counterclockwise. Warning: Ensure that the xenon lamp is safely sheltered in its protective container (reference 1 of image 2-7). 1 2 Image Remove the protection cap from the anode connector. Image Remove the anode wire lug from the anode connector. Use for that a 17mm open end wrench and a 17mm nut driver. Hold one nut (reference 4 of image 2-9) with the open end wrench while releasing the other nut (reference 1 of image 2-9) with the nut driver. Note that there is a plane washer (reference 2 of image 2-9) in front of the wire lug (reference 3 of image 2-9). R XENON LAMP FOR HDX 31/05/

16 Image 2-9 CAUTION: Expired xenon lamps. Dispose of expired bulbs that are beyond warranty in the following manner: wrap the bulb tightly in several layers of canvas or heavy cloth. Place it on hard surface and shatter the envelope with a sharp hammer blow. DO NOT place a non shattered bulb in any ordinary refuse container. When returning a xenon lamp for warranty adjustment, pack it in its original shipping container. Complete and return all required warranty information. 12 R XENON LAMP FOR HDX 31/05/2012

17 2.2 Installing the new xenon lamp into the Lamp House WARNING: DO NOT PERMIT UNAUTHORIZED PERSONNEL TO PERFORM OR ATTEMPT ANY PHASE OF XENON LAMP HANDLING OR SERVICE. ONLY TRAINED AND QUALIFIED TECHNICAL SERVICE PERSONNEL ARE ALLOWED TO HANDLE THE XENON LAMP. WARNING: This procedure may only be performed by qualified technical service personnel. CAUTION: Xenon compact arc lamps are highly pressurized. When ignited, the normal operating temperature of the bulb increases the pressure to a level at which the bulb may explode if not handled in strict accordance to the manufacturer s instructions. The bulb is stable at room temperature, but may still explode if dropped or otherwise mishandled. Whenever the lamp house, containing a xenon lamp, has to be dismantled or whenever the protective container or cloth has to be removed from the xenon lamp, authorized protective clothing MUST be worn! WARNING: Always wear face protection (full face shield with neck protector) when handling xenon lamps. WARNING: Always wear protective clothing (welder s jacket) when handling xenon lamps. WARNING: Always wear clean leather gloves with wrist protectors when handling xenon lamps. This procedure assumes that the lamp house is closed and that there is no xenon lamp installed inside the Lamp House. Necessary tools 3mm Allen wrench. Torque screwdriver. 2mm Allen socket. Torque wrench. 17mm hexagon socket. 17mm open-end wrench. Flat screw driver. Welder s jacket (not included in the safety kit that Barco offers). Full face shield with neck protection. Leather gloves with wrist protection. How to install the new xenon lamp into the Lamp House? 1. Install the lamp cathode adaptor upon the xenon lamp as illustrated. Tighten the adapter fixation screw (reference 2 of image 2-10) with a torque of 1,5 Nm (1,1 lbf*ft). Use for that a torque screwdriver with a 2mm Allen socket. Make sure that there is full contact between the cathode adapter and the lamp base. Note: The xenon lamp has a cathode pin with screw thread (reference 1 of image 2-10). So, to install the cathode adapter you have to turn the adapter clockwise on the lamp socket. Warning: Ensure that the xenon lamp is safely sheltered in its protective container (reference 3 of image 2-10). Caution: Adjust the torque wrench upon the correct value, then fasten the nut slowly until you hear one click and ONE CLICK ONLY! Do not turn further or the preadjusted torque value will be exceeded. R XENON LAMP FOR HDX 31/05/

18 Nm Image Install the anode wire lug (reference 3 of image 2-11) upon the anode connector as illustrated. Use an 17mm open-end wrench to hold the first nut (reference 4 of image 2-11) while fastening the lock nut (reference 1 of image 2-11) on the rod with a torque of 9 Nm (6,64 lbf*ft) using a torque wrench with 17mm hexagon socket. Ensure that there is a flat washer (reference 2 of image 2-11) between the lock nut and the wire lug. Caution: Do not tighten the first nut (reference 4) against the connector housing. There must be some play (1mm) between connector housing and nut. This is important to insert the Lamp House smoothly into the projector. Caution: Adjust the torque wrench upon the correct value, then fasten the nut slowly until you hear one click and ONE CLICK ONLY! Do not turn further or the preadjusted torque value will be exceeded /-1mm 4 9Nm Image Place the protection cap upon the anode connector. Image R XENON LAMP FOR HDX 31/05/2012

19 4. Remove the protective container from the xenon lamp. Warning: Ensure that you wear protective clothing, a full face shield and protective gloves. Tip: Write down the serial number of the lamp. You will need this while updating the lamp parameters after installation of the lamp. The serial number of the lamp is engraved in the neck of the xenon lamp. 5. Gently guide the xenon lamp into position inside the lamp house as illustrated. Anode connector towards the right. While inserting the lamp, rotate it slightly, engaging the pins of the cathode adapter in the foreseen slots. This is to ensure the lamp cathode is completely inserted. Warning: Make sure that the both pins of the cathode adapter are engaged in the foreseen slots. Image Slide the anode connector in its position on the Lamp House as illustrated. Caution: Avoid any tension on the anode wire, so there is no mechanical stress on the lamp. Image Push the anode wire downwards inside the Lamp House. This to ensure that the anode wire will not touches the UV blocker. Image Install the UV blocker assembly as illustrated. Make sure that the notch (reference 1 of image 2-16) of the UV blocker assembly matches with the gap (reference 2 of image 2-16) of the anode connector. R XENON LAMP FOR HDX 31/05/

20 A B 2 1 Image Secure the UV blocker assembly by fastening the bracket as illustrated. Use a 3mm Allen wrench to fasten the screw (reference 1 of image 2-17) of the bracket (reference 2 of image 2-17). 2 1 Image Fasten the cathode side of the xenon lamp with one nut (reference 4 of image 2-18). Use a torque of 17 Nm (12,5 lbf*ft) to tighten the nut. Use for that a torque wrench with a 17mm hexagon socket. Caution: Make sure that the both pins of the cathode adapter remain engaged in the foreseen slots. (see image 2-13) 11.Connect the cathode wire lug (reference 3 of image 2-18) with the cathode socket as illustrated. Place a plain washer (reference 2 of image 2-18) between wire lug and nut (reference 1 of image 2-18). Use a torque of 17 Nm (12,5 lbf*ft) to tighten the nut. Use for that a torque wrench with a 17mm hexagon socket. Caution: Adjust the torque wrench upon the correct value, then fasten the nut slowly until you hear one click and ONE CLICK ONLY! Do not turn further or the preadjusted torque value will be exceeded. 16 R XENON LAMP FOR HDX 31/05/2012

21 17Nm Nm 1 Image 2-18 CAUTION: The LAMP INFO parameters, which are stored on a chip inside the lamp house, MUST be updated after each installation of an xenon lamp inside the lamp house. Neglecting this update will result in poor performance and short life time of the xenon lamp. See procedure "Resetting the lamp parameters", page 18. A realignment of the xenon lamp in its reflector is required after the installation of the xenon lamp in the Lamp House. See procedure "Realignment of the lamp in the Lamp House", page 20. R XENON LAMP FOR HDX 31/05/

22 2.3 Resetting the lamp parameters CAUTION: The LAMP INFO parameters MUST be updated after each installation of an xenon lamp inside the Lamp House. Neglecting this update will result in poor performance and short life time of the xenon lamp. To reset the lamp parameters the projector flash software must be version or later and the Projector Toolset must be version or later. The latest version of the projector flash software and the Projector Toolset can be downloaded from the secured Barco web site This procedure assumes that the projector flash software is version or later and that in the Projector Toolset (version 2.4.2) a Projector Configuration exist for the involved projector. For detailed instructions see user guide of the Projector Toolset which can also be downloaded from the secured Barco web site Necessary tools PC which runs Projector Toolset version or later and has a LAN connection with the projector. Dongle for re-lamping or higher level. Necessary parts Serial number of the installed xenon lamp. How to reset the lamp parameters? 1. Start up the projector but do not ignite the lamp. 2. Start up the Projector Toolset. The PC which runs the Projector Toolset must have a LAN connection with the projector. 3. Plug in the Dongle into one of the USB ports of the PC which runs the Projector Toolset. Note: This Dongle is included in the Safety kit + tools for lamp replacement, order no R XXXXXXXX. 4. Select the Projector Configuration in the left pane (reference 1 of image 2-19) for which you wan to reset the lamp parameters. 5. Activate the Service Module by clicking on the Service icon (reference 2 of image 2-19) in the tool bar of the Projector Toolset. As a result the tab page of the service module for the selected Projector Configuration becomes available in the right pane of the Projector Toolset. 6. Click on the Run Refurb button (reference 3 of image 2-19) to start the refurbishment procedure of the Lamp House. As a result the tab page shows the Refurb input form. Note: This input form shows the remaining number of Refurb credits (reference 4 of image image 2-20). If there are no more Refurb credits available, the Lamp House requires maintenance by a qualified service technician Image Fill out the serial number (reference 4 of image 2-20) of the installed xenon lamp and Click on the Refurb button (reference 5 of image 2-20). As a result a popup window will appear. 18 R XENON LAMP FOR HDX 31/05/2012

23 4 5 Image Read the info of the caution popup windows and click on the OK button if you wan to proceed. Image 2-21 Image 2-22 As a result the lamp parameters are reset (run time hours set to zero) and the number of Refurb credits is decremented with one. Image R XENON LAMP FOR HDX 31/05/

24 2.4 Realignment of the lamp in the Lamp House WARNING: The procedures below may only be performed by Barco trained and qualified technicians. It is recommended to realign the Z-axis of the lamp after the first run time of 100 and 200 hours. Necessary tools 7 mm open-end wrench How to realign the lamp in the Lamp House? 1. Switch off the projector. 2. Let the projector cool down for at least 15 minutes before proceeding to the next step. Warning: The Lamp House is very hot after operation. Let the projector cool down for at least 15 minutes before proceeding to the next step. Failure to do so can cause serious injury. 3. Remove the right projector cover. See the installation manual of the projector. 4. Switch on the projector and startup the lamp. 5. Press Menu to activate the menus and select Lamp Z-axis. Image 2-25 Lamp, Z-axis Image 2-24 Main menu, lamp 6. Press ENTER to display the current light output. Image 2-26 Current light output 7. Release the lock nuts for the X-axis, Y-axis and Z-axis.. 8. Adjust the X, Y and Z-axis for maximum light output. Carefully turn the thumbscrews in one direction, and once over the maximum, turn slightly in the opposite direction to reach the maximum light output again. Do this for each direction and repeat this adjustment cycle minimum twice. 9. Tighten the lock nuts for the X-axis, Y-axis and Z-axis. 20 R XENON LAMP FOR HDX 31/05/2012

25 5 3 4 Image X lock 2 X adjustment 3 Y lock 4 Y adjustment 5 Z lock (3 mm Allen wrench) 6 Z adjustment Switch off the projector. 11.Install the right projector cover. See the installation manual of the projector. R XENON LAMP FOR HDX 31/05/