Cooling liquid refurbishment Installation manual For XLM, DP90 and DP100 R59770032/01 07/12/2006
Barco nv Events Noordlaan 5, B-8520 Kuurne Phone: +32 56.36.89.70 Fax: +32 56.36.88.24 E-mail: sales.events@barco.com Visit us at the web: www.barco.
1. Liquid Cooling Circuit 1. LIQUID COOLING CIRCUIT Overview • Safety • Introduction • Diagnostics 1.1 Safety WARNING: Hazardous product: Blue antifreeze diluted 1,2 ethanediol (1/3 ethanediol – 2/3 Demi water). Not for household use. Keep out of reach of children. Harmful by oral intake. Avoid exposure to pregnant women. Avoid contact with eyes, skin and clothing. Avoid inhale of the noxious fumes. Handling the cooling liquid • Avoid contact of the liquid with Eyes, Skin and Clothing.
1. Liquid Cooling Circuit Parts of the liquid cooling circuit K B J C D E F A G H I Image 1-1 A B C D E F G H I J H 2 DMD - Peltier cooling block. Manometer. Pressure vessel. Outlet cooling circuit Inlet cooling circuit Vane Pump. Cooling block light pipe entrance. Flow switch. Heat exchanger. Transparent tube for visual check.
1. Liquid Cooling Circuit Block diagram of the cooling circuit Pressure relief valve (3 Bar) Outlet Manometer Vane Heat Exchanger Inlet Expansion Vat Pump Engine Light Pipe entry Outlet Inlet Vane Waterflow Sensor to SMPS Control Image 1-2 Block diagram cooling circuit Order info liquid cooling 1.3 Order number Description R395198K Complete liquid cooling refill kit.
1. Liquid Cooling Circuit Too high ambient temperature An Error or warning message “Ambient temp high” is displayed on the local LCD panel or touch panel. See manual of the projector for accessing error messages. Possible cause Solution Ambient temperature of the projector is too high. Measure the ambient temperature nearby the projector. In case the measured temperature is higher than 40 °C take the necessary measurements to ensure that the ambient temperature is below 40 °C.
1. Liquid Cooling Circuit Possible cause Solution Defect pump. When the projector is running, you don’t feel any vibrations when touching the pump Drain the liquid cooling circuit, replace the pump, fill and pressurize the liquid cooling circuit. Tip: It’s not necessary to drain the cooling circuit of the light processor. Bypass this part of the cooling circuit. Defect flow switch. The pump is functioning normally but the projector displays a water flow error.
1.
2. Servicing the liquid cooling circuit 2. SERVICING THE LIQUID COOLING CIRCUIT WARNING: All procedures in this chapter may only be performed by “qualified service technicians” . Definition of “qualified service technicians” or ”qualified technicians”: Persons having appropriate technical training and experience necessary to be aware of hazards to which they are exposed in performing a task and of measures to minimize the danger to themselves or other persons.
2. Servicing the liquid cooling circuit 2.1 Preparation for cooling liquid replacement What has to be done 1. Switch off the projector. 2. Remove the lamp unit to access the cooling liquid in- and outlet. 3. If excluding the light processor is required while handling the cooling circuit procedures, disconnect the circuit at the flow switch (a). Disconnect the input of the light processor circuit and connect this tube to the flow switch (b). b a Image 2-2 Excluding light processor 2.
2. Servicing the liquid cooling circuit OUT Image 2-3 Drain complete circuit 2. Close the valve. 3. Fill the syringe with air. Press in the valve of the male fitting when extracting air. Image 2-4 4. Couple the air filled syringe to the inlet of the cooling circuit and force air into the circuit via the syringe. Liquid will be expelled from the circuit exit side into the empty bottle. OUT IN Image 2-5 Draining cooling liquid completely 5.
2. Servicing the liquid cooling circuit 2.3 Filling the liquid cooling circuit This procedure can only be used to fill an empty (drained) cooling circuit. Necessary tools • 60 cm of plastic tube with male valved fitting. • 60 cm of plastic tube with female valved fitting. • Syringe connected with short tube with male valved fitting. • Bottle with cooling liquid. • Empty bottle with a volume of 1 liter. • Cloths. How to fill the liquid cooling circuit ? 1. Close the vane. 2.
2. Servicing the liquid cooling circuit a b c d e f M F Image 2-7 4. Couple the filled syringe to the inlet of the cooling circuit and press the cooling liquid inside the circuit. Caution: Position the empty bottle above the liquid circuit (on top of projector). a OUT b Image 2-8 Filling cooling liquid circuit 5. Disconnect the syringe from the cooling circuit and repeat from step 3 until cooling liquid comes out the outlet of the cooling circuit.
2. Servicing the liquid cooling circuit 2.4 Refreshing the liquid cooling circuit Over time the cooling liquid may show deterioration and hence less effective cooling characteristics. To maintain sound cooling properties, we advise ANNUAL replacement of the cooling liquid. Necessary tools • 2 x 60 cm of plastic tube with male valved fitting. • Syringe equipped with male valved fitting. • Female/female tube adapter (short tube with female valved fitting at both sides).
2. Servicing the liquid cooling circuit OUT IN Image 2-10 Refresh cooling circuit 5. Switch on the projector. After projector boot-up procedure, the internal pump will automatically start sucking-up the fresh liquid Note: Make sure that the end of the plastic tube remains immersed in the bottle with fresh cooling liquid. 6. Switch off the projector after 2/3 of the fresh cooling liquid is sucked up into the circuit. 7. Proceed with expelling the air from the liquid cooling circuit.
2. Servicing the liquid cooling circuit M a b c d F F M Image 2-11 Caution: It’s important that there is no air inside the tube. The pump is not self priming and hence is only capable of sucking through small volumes of air. 3. Push the male valved fitting of the filled tube into the inlet of the cooling circuit. Make sure that the inlet of the filled tube remains immersed. 4.
2. Servicing the liquid cooling circuit 7. Uncouple the two plastic tubes. Note: Make sure that both ends of the plastic tubes in the bottle remains immersed until the plastic tubes are uncouple from the liquid cooling circuit. Tip: Sometimes a little cooling liquid will be spilled. Wrap a small cloth around the valved fitting while uncoupling to absorb the spilled cooling liquid. 8. Pressurize the liquid cooling circuit. See procedure "Pressurizing the liquid cooling circuit", page 15.
2. Servicing the liquid cooling circuit a b c d e f M F Image 2-13 2. Couple the syringe to the inlet of the cooling circuit and press the cooling liquid inside the circuit until the manometer indicates 1 bar pressure. Ensure that no air bubbles are injected into the circuit. Caution: Maximum 1 bar of pressure is allowed on the liquid cooling circuit. More pressure than 1 bar may damage the circuit. IN Image 2-14 Pressurize cooling circuit 3.
2. Servicing the liquid cooling circuit Check within 24 hours whether the pressure has stabilized close to 1 bar. If not, search for leakage. 2.7 Calibrating the liquid cooling circuit To check if the pressure vessel is correctly calibrated you may connect the syringe with the cooling circuit and measure the amount of liquid that is automatically expelled. The pressure would have dropped from 1 to 0 bar. The expelled amount of cooling liquid should be between 50 and 70 ml.
2. Servicing the liquid cooling circuit a b c d e f M F Image 2-16 3. Fill the pressure vessel with liquid as follows: a) Couple the syringe with the inlet of the cooling circuit. b) Increase the pressure by pushing in the piston of the syringe (maximum 1 bar indicated on the manometer). c) While pressing, expel air from the pressure vessel. d) Continue expelling air while pressurizing the circuit (up to 1 bar) until the valve of the vessel becomes hard to push in.
2. Servicing the liquid cooling circuit 4. Now that the pressure vessel is liquid filled you have to increase the pressure to 1 bar by pushing in the piston of the syringe. Then immediately extract 75 ml back into the syringe by doing the following: a) Taking note of the liquid level already in the syringe, release the plunger. b) Now fill the syringe by slowly pumping air into the vessel (connect air pump to valve). c) Stop once 75 ml has been expelled. d) Disconnect the syringe from the cooling circuit.
2. Servicing the liquid cooling circuit The air hose fitting of the air pump must be of the Shrader valve type (A) to match with the pressure vessel, so the Presta valve type (B) has to be removed. Futhermore, the pin (C) inside the Shrader valve has to be removed as well. A B A B A C C Check within 24 hours whether the pressure has stabilized close to 1 bar. If not, search for leakage.
