Barco Training 2013 - 2

Barco Digital Cinema
Certified Expert Training Course — Series 2
Advanced Diagnostics and Service
Barco Confidential
March - 2013 Copyright © Barco

Facility Guidelines
 House Rules
– Please be sure to sign in and out each day
– Please turn in your badge at the end of each day
– Please ensure that your badge is visible all times
– Be sure you are escorted when leaving the classroom areas
– No pictures outside of the training room
– Audio and/or video recording of the training course is not permitted without
prior approval.
– Switch your mobile phone to silent please
– Smoking is allowed in designated areas only
– Use only the main entrance of the training center
Barco Confidential 2
Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco

Course Overview
 Day 1
– Section 1: Introduction to the Service Course
– Section 2: Installation and Error Overview
– Section 3: Spare Parts Identification
– Section 4: Board and Module Functionality
– Section 5: Flow Charts and Block Diagrams
 Day 2
– Section 6: Board and Module Replacement
– Section 7: Liquid and Air Cooling System Maintenance
– Section 8: Light Processor Repair
– Section 9: Optical Alignment
 Day 3
– Section 10: Subsystem Diagnostics & On-Site Debugging
– Section 11: Projector Firmware Updates
– Section 12: Error Code Solutions and Log Files
– Section 13: Special Features
– Section 14: Scheduled Maintenance
 Day 4
– Section 15: Testing and Certification
A minimum of 80% is required on each exam in order to be Certified.

Day 1: Agenda
Section 1: Introduction to the Service Course

Section 2: Installation and Error Overview
Section 3: Spare Part Identification
Section 4: Board and Module Functionality
Section 5: System Flow Charts and Block Diagrams

Section 1
 IntroductionIntroduction
to Service Course
to the Service Course

Section 1 Tools and Calibration Equipment
Introduction
to the  Safety Gear
Service Course  Metric hex keys (Allen wrenches – 3mm/5mm)
 Screwdrivers (Long & short)
 Multi-meter
 Anti-static mat, appx: 2’ x 3’ (60cm x 90cm)
 ESD wrist strap
 Cooling liquid kit (R395198K)
 Metric open ended wrenches
 Level
 Torque wrenches
 Metric socket set or nut drivers
 Wire cutters
 Color spectrometer (w/reflected light meter)
 Laptop
All Barco
 Spotting scope (optional)
parts are  Anemometer (optional)
metric  Convergence camera (optional)
 Wireless router

Section 1 General Safety
Introduction
to the
Service Course  Always refer to latest installation or service manual for the most
Safety current safety procedures.
 Read and comply with all caution and safety precautions, as noted
inside the projector compartments.
 On the projector’s internal components, do not use chemicals that
are not listed in the service manual.
 High pressure Xenon lamps are used in the projector. These lamps
pose the risk of explosion. Always handle lamps with protective
gear, as listed in the installation and service manual.

Section 1 Lamp safety
Introduction
to the
Service Course
Safety

Section 1 Electrical Safety
Introduction
to the
Service Course  Isolate mains power prior to removing any projector components.
Safety On B series, when the mains switch is OFF, only the head is
switched off and NOT the LPS units.
 Prior to returning the projector to the customer, replace all
protective shields that cover the projector devices.
 Do not apply any alterations to the electrical design of the projector.
 With AC turned off at the main breaker, pull on the main power cord
leads at the input terminal on projector to ensure a tight connection.
 Prior to start up:
– Check proper grounding
– Check main power cord for damage
– Check internal wiring for damage near sharp edges, hot areas and high voltage
areas of the projector

Section 1 Secure the Extraction
Introduction  Do not operate the projector without the extraction hose connected!
to the – UV light is not filtered out of the projector’s exhaust port!
Service Course  The lamp can cause serious skin burn and eye inflammation if the projector is
Safety operated without UV filter on front of Lamp House
 Do not look directly into the light path of the projector
 Glass dust will come out if the lamp explodes

Section 1 Electrostatic Discharge (ESD) Safety
Introduction
to the
Service Course  Dissipate static electricity prior to handling any boards or modules
Safety inside projector.
 Utilize anti-static devices when servicing a projector: wrist strap,
static mat, etc.
 Hold boards by the edges only — try not to touch chips or modules.
 Avoid carpeted areas that are cool and dry.
 Connect wrist strap to non painted area of projector frame (Chassis)
 Place boards on static free materials (static bag, pink foam, etc.)

Section 2
 Introduction to Service Course

Installation and Error Overview

Section 2 Communicator advanced functions
Installation
and Error
Overview  Input Configuration:
Setup for HFR, 4K, 3G, IMB, IMS
 3D Configuration:
Setup for HFR, alternative 3D content
 File Manager
 Miscellaneous settings
 Retrieve Certificate
 10S features

Section 2 Projector Configuration Errors
Installation
and Error
Overview  Macro executing files that don’t exist, or which are corrupt
– e.g., no screen file, no lens file, no MCGD file
 Macro needs to be pointed at correct file
– e.g., wrong screen file, wrong lens file, wrong MCGD file, wrong PCF file
 Lens has been changed without creating new lens files
 Lens cannot reach target or lens moves past target
 Lens homing has not been executed

Section 2 Optical Alignment Errors
Installation
and Error
Overview  Overshooting image
 Undershooting image
 Light uniformity
 Convergence adjustment
 Focus uniformity
 Keystone

Section 2 Server and Automation Communication
Installation
and Error
Overview  Check server / projector control
 Check Ethernet based automation system control (if applicable)
 Check SNMP reporting (if applicable)

Section 2 Projector Installation
Installation
and Error
Overview  Install a projector without any errors
– Find the IP address of the projector and establish a connection to your laptop
– Install and “home” the lens
– Align the lamp to maximum brightness
– Align the image to the screen
– Check for Keystone, Vignetting, Focus and Scheimpflug
– Set up the projector for Flat and Scope with proper masking
– Save Lens, Screen and MCGD files into the Flat and Scope Macros
– Calibrate colors with color meter
– Calibrate CLO to 14FL for 2D on Flat & Scope by using LSC files

Section 3
Part Identification

Section 3
Spare Part
Identification
DP2K-19B, 23B and 32B Parts
5 6 7 8
1. Left side cover
2. SPG/Cold Mirror air inlet filter
3. Heat Exchanger air inlet filter
4. Rear cover 1
5. Card Cage air inlet filter 2
6. Front cover
3
7. Lamp cover
8. Input (Card Cage) cover 4

Section 3 DP2K-19B, 23B and 32B Parts
Spare Part
Identification
1 2 3
1. Mounting plate reservoir liquid 4

cooling
2. Reservoir liquid cooling 5
3. Liquid cooling assembly (fans +
heat exchanger) 6
4. Projection lens
5. Lens Holder
6. Lamp House 7
7. Fan Anode cooling
8. Fan assembly, SPG and Cold 8
Mirror
9. Lamp Power Supply (LPS) units
9

Spare Part
Identification
1 2 3 4
1. Cover plate, Light Processor

2. Light Processor
3. Dowser (shutter)
4. Top cover plate, Light Processor
5. Top cover plate, Card Cage
5 6 7 8 9 10 11
6. Fan Control board
7. ICP board
8. HD-SDI board
9. Cinema Controller board
10. SMPS board
11 .Cover plate, SMPS compartment
12. Mains Input Protection Cover
13. Cathode Fan
12 13

Spare Part
Identification
1. Start pulse generator (SPG) unit

2. Cold mirror assembly
3. Support bracket for Button assembly
4. Button assembly

Spare Part
Identification
1 3
2
4
1. Security switches Card Cage

2. Signal Backplane
3. Fans for Card Cage
4. Fans for SMPS compartment

Spare Part
Identification
2 3 4
1. Security switches, Light Processor

2. Fan for Light Processor cooling
3. Air flow switch
4. Temperature sensor air outlet, Lamp
House
5. Status Light 1
6. connections UPS
7. Star-Delta switch board (200V/400V)
8. Power Input distribution strip 5
9. EMC shield lens hole
10.Detection switch Light Processor
6
7
8
9 10

Section 3 DP2K-15C and 20C Parts
2
Spare Part
Identification 1
1. Rear cover
2. Top cover 3
3. Left cover (Light Processor side)
4. Sealed compartment cover
(Light Processor side)
5. Lamp cover
6. Input cover (Input and
Communication unit)
7. Front cover
5
6
7

9
Section 3 DP2K-15C and 20C Parts (continued)
Spare Part 8
Identification
8. Lamp Power Supply (LPS)
9. Convergence cover plate 10
10.Backplane + Light Processor
compartment fan
11.Lens holder assembly
12.Front dust filter (cleanable) 11
13.Button panel 19
14.Fan controller board 20
15.Integrated Cinema Processor
board (ICP)
16.HD-SDI board or Media Block
17.Cinema Controller board
18.Switch Mode Power Supply 14 12
board (SMPS) 13
19.Lamp House 15
20.Fan for Lamp info module
16
17
Barco Confidential
18
26

Spare Part 21. Dust filter cold mirror

Identification 22. Light processor (assembly)
23. Light pipe
24. Water cooling circuit (reservoir)
21 25. Water cooling pump
26. Dust filter heat exchanger
27. Heat exchanger
28. Anode fan assembly
22
23
24
28
25
27
26

Spare Part
Identification
28. Anode fan assembly
29. Start pulse generator (SPG)
30. Cold mirror assembly
31. SPG cover plate
29
30
31
28

Section 3 S-series Parts
Spare Part
Identification

Section 3 S-series Parts (Continued)
Spare Part
Identification

Section 3 S-series Parts (Continued)
Spare Part
Identification

Section 4
Board and Module Functionality

Section 4 Fan Controller (B and C series)
Board and
Module
Functionality  Monitors and controls all fans
 Monitors and controls
(enables/disables) all voltages
provided by SMPS board
 Monitors all temperature sensors
 Contains ambient temperature sensor
 Controls and monitors Peltiers on rear
of DMDs, as well as Peltiers for active
front cooling
 Monitors pump speed
Part Number
R765530K

Board and
Module
Functionality  Front panel LEDs can be used to monitor output voltages of SMPS
board
Part Number
R765530K

Board and
Module
Functionality  Contains all hardware protection monitoring for the projector
 Controls error line to the LPS, and will shut down the lamp or
prevent the lamp from starting up
– Conditions include:
 DMD over temp
 Lamp over temp
 Lamp cooling down
 Lamp House not connected
 Light Processor not connected
 Ambient temp. below 10°C
 Low fan speed
 Exhaust fan and cathode fan not working (DP2K-C series)
 Cathode fan not working (DP2K-B series)
Part Number
 On the S series, all fan controller functions are included on the
R765530K
Cinema controller

Section 4 Integrated Cinema Processor (ICP) (B, C and S series)
Board and
Module
Functionality
Certificate Battery
Boot Button (lifetime 10 years)
(see service manual
section 14.6)
Part Number 1 2 3 4
R7655825K
Real Time Clock
Supply Enabled ICP Status LEDs (RTC) Battery
Barco Confidential (Lifetime 6 years) 36

Board and
Module
Functionality
1. ICP Power — ON when powered. blue during normal operation

2. ICP software state — blinking green during normal operation
3. ICP operating system state — solid green during normal operation
4. ICP FMT configuration state — solid green during normal operation
5. ICP MAIN configuration state — solid green during normal operation
6. Cinema content port selected — When on, LED 7 is off (Not enabled by TI)
Part Number
7. Alternative content port selection — When on, LED 6 is off (Not enabled by TI)
R7655825K 8. USB — for future use

Board and
Module
Functionality  Stores screen files
 Central hub for communication within the TI subsystem, processes
all external commands via Ethernet (ICP is a slave to cinema
controller)
 Generates and stores test patterns
 Processes all reserved TI GPIO port commands. Other GPIO
commands from Cinema Controller
 Handles scaling (resizing)
 Generates and overlays electronic masking
 Processes subtitling and metadata
Part Number
R7655825K

Board and
Module  Handles source selection and image orientation
Functionality  Passes frame rate multiplication 3D synchronous output reference from formatters
to GPO port
 Handles TI error reporting and generation, and storage of TI log files including
enigma log
 Contains projector clock and date
 Contains simple de-interlacer (line insertion)
 Also contains a certificate — but only for enabling the marriage
 Handles all color correction from measured to target colors
 Handles color space conversion, and gamma correction according to look up table
(DeGamma LUT) as defined by PCF file
 Contains DC/DC converter
– Converts +12V to +5V, +3.3V, +2.5V, +1.8V & +1.2V to be used on the ICP
– Converts +12V to +2.5V & +3.3V for the formatters
Part Number
 Expected Battery lifetime:
R7655825K
- RTC: 6 years
- Secure Processor: 10 years

Section 4 HD-SDI Board with Enigma Decryptor (B, C and S series)
Board and
Module
Functionality
Enigma Link
Decryptor
A B HD-SDI inputs

Section 4 HD-SDI Board without Enigma Decryptor (B, C and S series)
Board and
Module
Functionality
 Contains HD-SDI inputs for external servers or devices

Part Number
R765534K
 Contains test generator and CRC (cyclic redundancy check)
(CRC performs checks on incoming HD signals)

Section 4
Quad HD-SDI Board (Post Production)
Board and
Module
Functionality
Part Number
3G-SDI is a more recent interface, consisting of a single 2.970 Gbit/s
R7681060K serial link which is standardized in SMPTE 424M.

Section 4 Projector File System (continued)
Board and Input: HDSDI (SMTE 292) or 3G (SMPTE 424)

Module
Functionality Intro:
Serial Digital Interface(SDI)

is a family of video interfaces standardized by SMPTE which are used in
broadcast and post-production.
High-Definition Serial Digital Interface (HD-SDI),

is standardized in SMPTE 292M; this provides a nominal data rate of 1.485 Gbit/s.
3G-SDI,
consisting of a single 2.970 Gbit/s serial link, is standardized in SMPTE 424M


Module
Functionality What is 3G SDI mapping?
The SMPTE has described three different mapping schemes for transporting
uncompressed video, ancillary data such as the audio data, the audio control packets, the
payload ID, the time code, etc. into a serial digital interface operating at a nominal rate
of 3 Gbit/s.
These are defined as Level A, Level B Dual Link (B-DL) and Level B Dual Stream (B-DS).
Level A Is the direct mapping of an uncompressed 1080p/50 video stream into a serial
digital interface operating at a nominal rate of 3 Gbit/s.
Level B-DL Is the dual-link mapping of a 1080p/50 video stream into a serial digital
interface operating at a nominal rate of 3 Gbit/s.
Level B-DS Is the dual-stream mapping of two independent 1080i/50 (or 1080p/25)
video streams into a single serial digital interface operating at a nominal rate of 3 Gbit/s.


Module
Functionality
Level A and Level B-DL support 1080p/50 and the design will be more robust if one
format (Level A or Level B-DL) is used throughout
Level B-DS carries two 1.5G-SDI streams on a single coax cable and while the ITU and
SMPTE are discussing standards, Level B-DS is being used by some organizations to carry
the left and right eye signals of stereoscopic 3DTV.
Level B-DL carries 1.5Gb/s signals it is subject to the same 3Gb/s installation
requirements as Level A and Level B-DL.
Conclusion
Level B makes it possible to show 2D & 3D with one single connection where you need a
dual connection on Level A when you like to show 3D


Module
Functionality - HDSDI single mode:
 Input A or B
 Source mode: 4:2:2 10 bits/color
 Non-DCI format, only for alternative content
- HDSDI Dual mode – 2D:
 Input A + B
 Source mode: 4:4:4 10 or 12 bits/color
 DCI standard
- HDSDI Dual mode – 3D/HFR:
 Input A + B
 Source mode: 4:2:2 10 bits/color OE frame
 DCI standard
 3D: A – left image / B – right image
 HFR: A – even frames – B – uneven frames


Module
Functionality - 3G Level A - single mode:
 Input A or B
 Source mode:
4:4:4 10 or 12 bits/color – max 30 fps
4:2:2 10 bits/color – max 60 fps
 Color space: RGB or XYZ
 2D
- 3G Level A - Dual mode:
 Input A + B
 Source mode: 4:4:4 12 bits/color
 Color space: RGB or XYZ
 3D: A – left image / B – right image
- 3G Level B – Dual stream:
 Input A or B – only single mode
 Source Mode: 4:2:2 10 bits/color
 Color space: YCbCr
Barco Confidential  3D 47


Module
Functionality - 3G Level B – Dual link:
 Input A or B – only single mode
 Max 30fps
 Color space: YCbCr
 2D
- 3G – 4K:
 Quad input Board: A+B+C+D
 Each input delivers native 2K
- 3G – 4K:
 Input A + B
 Both inputs are delivering a resolution of 2048 x 2160 on Horizontal Spanning (HS)

Section 4 Link Decryptor Unit (Enigma) (B, C and S series)
Board and
Module  Handles secure communication (decryption) between content server
Functionality and Enigma, to enable Cinelink decryption
 Handles bit rate and packing for source settings
 Handles monitoring of security access intrusion
 Contains Link Decryptor clock and date
 (Max. 15 min. drift allowed per year)
 Stores projector certificate
 Battery shelf life: 6 months
– Note: a Battery Charger Kit is
available:
– p/n R98523485
Part Number
B401632K

Section 4 IMB (Integrated Media Block) (B, C and S series)
Board and  Replaces HD-SDI board

Module – Different models manufactured by
Doremi, GDC, Dolby and Qube
Functionality
 Contains:
– HD-SDI/3G inputs for e-cinema
servers and alternative content
– PCI Express (PCIe) video input for
Doremi and 1st generation of GDC
servers
– Ethernet data stream for
Qube/Dolby/current GDC servers
– HDMI input for alternative content
 Functions:
– Decrypts and decompresses the
image & audio
– Monitors security access intrusion
 Includes connections for GPI, GPO,

AES Audio, Debug
Needed for 4K, HFR 3D, Blu-ray 3D,…


Section 4 IMS (Integrated Media Server) (B, C and S series)
Board and
Module
Functionality

Section 4 IMS (Integrated Media Server) (B, C and S series)
Board and
Module Integrated Media Server (IMS1000)
Functionality – JPEG2000 2K & 4K DCI playout
– High Frame Rates 3D up to 120fps (60fps per eye)
– JPEG 2000 bitrates up to 500Mbps
– Dolby3D colorcorrection
– MPEG2
– 2 x 3GSDI inputs
– 1x HDMI 1.4a input (BluRay 3D / 4K)
– 16x AES/EBU audio channels (2x RJ45)
– 4x GPI, 6x GPO (2x RJ45)
– 2x ETH for management & ingest
– 3x frontaccessible USB for ingest
– 1x eSATA port for fast ingest
Integrated storage (IMS1000)
– 2 TB effective storage (RAID5)
– 3 x hotswappable 2.5" harddrives

Section 4 Cinema Controller (B,C & S series)
Board and
Module
Functionality
Part Number
B & C series S series
R7655331K
B & C series

Section 4 Cinema Controller (B, C & S series)
Board and
Module  Stores security keys
Functionality  Controls lamp power supply
 Contains Power PC running Linux
 Contains router-based Ethernet sub-system with 8 ports total
– 4 x external (3 x RJ-45 + 1 x Touch Panel)
– 4 x internal (ICP, Enigma (IMB), Power PC, 4th port is not used)
 Stores macros, and links from macro to key assignments
 Handles all communication to Barco modules inside the projector (LPS, CLO, Dowser) and to external
world
 Handles all internal Barco firmware updates
 Stores Barco IP address and host name
 Handles reporting of errors, version info and Barco logs to Communicator
 3D sync connector for connecting standardized 3D interface (On B&C series it’s implemented on a
daughter card)
 Controls ICP board
 Controls Dolby 3D color wheel
Part Number
 Controls and monitors keypad
R7655331K  Controls and monitors status lights
B & C series  Stores macros, input selection, lens file, lamp file and LSC file

Board and
Module  Stores lens files and lens type
Functionality  Controls the lens motors
 Contains lens motor drivers (DC + stepper).
Note: - Lens motors are DC
- Lens Shift motors (on the lens holder) are stepper motors
- Focus motor on the B series is stepper motor as well
 Lens notes:
– On B series, focus adjustment is done on the lens holder, not on the lens
– On C series, focus and zoom motors are both on the lens
– In both B and C series, Lens Shift is located on the lens holder — not on the lens.
 Communicates with Crypto Memory Module
 Contains alternative content input of two DVI ports (HDCP compliant)
 Contains RS-232 port
 Contains GPIO Port
 Contains 3D interface
Part Number  Runs basic Web Server allowing to retrieve information through browser
 Controls GPIO ports
R7655331K
 Stores SNMP key
B & C series

Board and What is SNMP?

Module
Functionality  SNMP (Simple Network Management Protocol) — a set of rules that allow a
computer to get statistics from another computer across the Internet
 An SNMP “device” tracks statistics that measure its activity
 Device data is kept in a database called a MIB (Management Information Base)
 In an SNMP application, an administrative computer (Manager) monitors a group of
devices on a network
 An SNMP network consists of three components:
– Managed Device — a network device with an SNMP interface. Communication can be
unidirectional (read-only) or bidirectional. Examples: routers, access servers, switches,
bridges, hubs, telephones, IP video cameras, computer hosts, etc. In our world:
projectors, servers, switches, audio processors, etc.
– Agent — a software module that runs on a managed device. It has local knowledge of
management information, with the ability to translates that information via SNMP
– Network Management System (NMS) — software that runs on the manager. It
executes applications that monitor and control managed devices

Section 4 Cinema Controller (S-series)
Board and
Module
Functionality
 A lot of commonalities versus Series 2. No changes to LAN, GPIO and 3D connectivity and specifications
 Peripheral Port and DVI inputs removed
 Formal RS232 (DB9) replaced by USB IN (Virtual comport)
 USB OUT to power handheld devices (No other functionality supported for now...)
 Front LED’s display the status of the power supply
 Contains the complete Fan Controller from B and C series.
 RTC battery: faster readout in logs for correct date and time
 Field replaceable – battery type CR1220 – Li coin cell
 Supports all functionality from S2 controller and fancontroller
 Stores lamp information (No Lamp Info Module on the S-series lamphouse...)
 Runs webserver (Communicator Lite)
 Lenspositions stored in external EEPROM (No loss of lensposition when power switched off during lensmovement...)
 Contains all S2 fancontroller hardware (Also TEC hardware, but not used on DP2K-xxS)
Part Number  Powered from seperate standby power supply (++12V)
R7681039K  Power Interrupt detection: when you get no “mains” or “+12V” power projector will be resetted
 All fans speed controlled (4 wires...)
S - series
 Supports “Sleep” mode

Section 4 Cinema Controller (S-series) - Blockschematic
Board and
Module
Functionality

Section 4 Cinema Controller (S-series) – PCB functional blocks
Board and
Module
Functionality
Router with Integrated TEC Circuitry

Switch
µSD CARD
PowerPC CPU Platform (Future use)
Motor Drivers
MAIN FPGA
Unmanaged Switch Fancontrol MCU
RTC Battery
Lifetime: 8 years
GPIO/3D

Board and GPIO

Module
Functionality  Fixed GPI structure:
– GPI 1: 3D input reference (to ICP). The rising edge triggers the 3D L/R input
reference. This reference indicates which frames are Right and Left, depending on the
used polarity
– GPI 2: 3D display reference (to ICP). The rising edge triggers the 3D L/R display
reference. It specifies which frame of eye data is displayed during a specific frame
– GPI 3-4: reserved
– GPI 5-8: available for macros (handled by Cinema Controller)
 Fixed GPO Structure:
– GPO 1: 3D output reference (from ICP). Indicates the polarity of the outgoing
reference signal on GPO 1. Provides an external reference to the start of dark time for
each displayed frame, and specifies which frame of eye data (left or right) is displayed.
It synchronizes external polarizer systems, or active polarity glasses.
– GPO 2-3: reserved
– GPO 4-8: 4 mode configurable: low, high, toggle, continuous toggle (FPGA Cinema
Controller).
Part Number
R7655331K Additional GPIO information can be found in the
Communicator User Manual

Board and
GPIO Connector
Module
Functionality
1 3D Input Reference P 20 3D Input Reference N
2 3D Display Reference P 21 3D Display Reference N
3 GPIN 3 P (reserved) 22 GPIN 3 N (reserved)
4 GPIN 4 P (reserved) 23 GPIN 4 N (reserved)
5 GPIN 5 P 24 GPIN 5 N
9 3D Output Reference P 28 3D Output Reference N
10 GPOUT 2 P (reserved) 29 GPOUT 2 N (reserved)
11 GPOUT 3 P (reserved) 30 GPOUT 3 N (reserved)
12 GPOUT 4 P 31 GPOUT 4 N
17 reserved 36 reserved
18 reserved 37 reserved
19 reserved
Part Number
R7655331K

Section 4 Cinema Controller (B, C & S series) GPIO Connector
Input voltage
Board and The inputs can be directly driven from a TTL or CMOS output.
Module • The shape of the pulse must be rectangular.
Functionality • The duration of the pulse must be at least 1.6 milliseconds (shorter pulses are considered as a switch bounce)
• Minimum voltage : Vmin = 3,3 V
• Maximum voltage : Vmax = 24 V
External power supply
When interfacing with contact closure outputs, an external power supply needs to be provided. Depending upon the configuration a suitable pull-up
resistor needs to be added as well.
Cables
When long cable connections are required the use of shielded cables with twisted pairs is recommended. One twisted pair is to be assigned to each GP
Input pair.
Part Number How to make the connection
When the power supply used to provide the DC voltage is isolated from ground (for example in the case of an AC adapter) it is
R7655331K
recommended that the minus pole of that power supply is connected to ground (or to the projector chassis). This will avoid high
common mode voltages at the projector GP Inputs. If that same power supply is used for other parts of the system, take care
Barco Confidential not to create ground loops. In any case when shielded cables are used that shield should be connected to the projector chassis. 62

Board and GPIO Connector

Module
General Purpose outputs
Functionality Eight (8) opto-isolated outputs are available, where four are dedicated for TI. The other general purpose outputs can be controlled
via software.
About an output
The output can generate a falling edge, rising edge, toggle or continuous toggle.
• Generate Falling Edge – generate a falling edge on the external GPO port if the present state of the output is high. If the
present state of the external GPO is low, no edge will be generated.
• Generate Rising Edge – generate a rising edge on the external GPO port if the present state of the output is low. If the present
state of the external GPO is high, no edge will be generated.
• Generate Toggle – generate a toggle on the external GPO port. If the present state of the output is low, a rising edge will be
generated, followed by a falling edge. If the present state of the output is high, a falling edge will be generated, followed by a
rising edge. The rate of toggle will be the vertical sync rate (edge transition at each vsync). Pulse width = 20 milliseconds.
• Generate Continuous Toggle - This command will generate a continuous toggle of the external GPO port. This toggle will
continue until a Generate Falling Edge, Generate Rising Edge, or Generate Toggle command is received. The rate of toggle is
24Hz. .
Output transistor
• Maximum output driving voltage : Vmax = 70 V
• Maximum current : Imax = 30 mA
• Maximum power dissipation : 120 mW
Part Number
R7655331K
GPIO and projector Sleep mode (S-series only)

Barco Confidential Enter or leave Sleep mode can also be done with GPIO via two predefined Macros (not editable). 63

Section 4 Cinema Controller (B, C & S series) 3D Interface Connector
Board and
Module  3D mode: enable or disable 3D system
Functionality  SYNC: same as GPO 1
 INPUT REF: same as GPI 1
 DISPLAY REF: same as GPI 2
 RX/TX: gives commands to external 3D
system
Pin Name
1 +12V
2 Grnd
3 Grnd
4 RS232 RX
5 RS232 TX
6 CONN_3D_MODE +
7 CONN_SYNC + 15 -
8 3D Input Reference +
9 +12V
10 3D Input Reference –
11 3D Display Reference +
Part Number 12 3D Display Reference
R7655331K 13 CONN_3D MODE –
14 CONN_SYNC –
Barco Confidential 15 –
64

Section 4 Focus stepper motor Driver board (B-series only)
Board and
Module
Functionality – For B series only
– Mounted on the lensholder
– Drives the focus stepper motor
Part Number
R7655331K

Section 4 Switch Mode Power Supply (SMPS) (B & C series)
Board and
Module
Functionality
++12V SMPS
+VTEC SMPS
PFC
(Power Factor Corrector)
+24V SMPS
Primary Power Supply

+395V
Mains
Filter
Part Number
R765529K

Section 4 Switch Mode Power Supply (SMPS) (B & C series)
Board and
Module
Functionality
++12V +VTEC +24V

Fuse Fuse Fuse
Primary
Fuse
Part Number
Mains
R765529K Fuses

Section 4 Switch Mode Power Supply (SMPS) (S-series)
Board and
Module
Functionality
++12V +VTEC +24V

Primary Fuse Fuse Fuse
Fuse
Part Number
Mains
R7655K Fuses

Section 4 Switch Mode Power Supply (B, C & S series)
Board and
Module
Functionality  Accepts incoming AC 200-240V from power mains, and converts to a common voltage of 395 VDC
 Converts 395 VDC to multiple levels of DC for distribution to required boards and modules
 Status lights on front of board verify active voltage output
– DC voltage outputs: ++12V, +VTEC, +24V
 Output voltages can be monitored with Fan Controller Board LEDs, and also with the Communicator
 For B & C series:

 ++12V, +12V -> on whenever the projector is powered
 +24V and +VTEC controlled by cinemacontroller
 For S series:
 ++12V -> on whenever the projector is powered
 +12V, +24V and +VTEC controlled by cinemacontroller
Part Number
R765529K

Section 4
Switch Mode Power Supply (B & C series)
Board and
Module
Functionality  LED: ++15 VM
++12V LED ++15VM LED Action

On On Normal
Off On Check ++12V Fuse
Off Off Check Mains power
and replace SMPS if
required
Bottom View: SMPS Board

Part Number
R765529K

Section 4
Signal Backplane - B & C series
Board and Light Processor
Module Connections
Functionality
SMPS
Connector
Fans
Connector
LPS comm.
Tamper Switch Connector
Connectors
Lens motors
Crypto Connector
Memory
Part Number
R7655325K

Section 4
Signal Backplane (B & C series)
Board and
Module
Functionality  Provides cable connection between the following components:
– SMPS Board
– Pump
– Lens Motors and Holder
– Light Processor
– Light Sensor
– Dolby 3D Controller
– Fans
– Security Switches
– Temperature Sensors
– Touch Panel
– Keypad
– Prism switch sensor
Part Number
– Dowser
R765532K
Handout backplane chart and spreadsheet

Section 4
Signal Backplane (S-series)
Board and
Module
Functionality

Section 4
Board and
Module • Connections accessible
Functionality through engine
compartment (TOP)
• Connections
accessible
through lamp
compartment
(SIDE)
• Connections behind front

dust filter

Section 4
Board and
Module Button ICP Engine Engine Air CLO
Functionality Module Fan Fan Temp Module

Section 4
Board and
Module
Functionality
Temp Air Out Lamphouse

(Temp Lamp) Switch
Tail Light
Lamp Info
Module (NC)
LPS Control
SMPS Power Exhaust Relay

(NC)
Anode Fan
Kathode Fan
SMPS Control
Cold Mirror Fan
Spare Channel (NC)
Light Pipe Fan
Pumps (NC)

Section 4
Board and
Module
Functionality
Lens Motors
Lens Encoders
Shift Motors
Shift EOL Switches
Ambient Temp
Touch Panel
Elec Fan Top

Elec Fan Bottom
SMPS Fan Left
SMPS Fan Right
Spare Chan (NC)
Pumps (NC)

Section 4
Prism Switch
Board and
Module DMD Fans
Functionality
Lightpipe Temp
Formatter LVDS + PWR
DMD Temp
TEC’s (NC)
3D Module
Security Switches
Cateye (NC)
• All accessible through

engine compartment
Barco Confidential (TOP) 78

Section 4 Crypto Memory (B, C and S series)
Board and
Module
Functionality
 Stores the following:
– Projector serial number
– Projector type
 Important: This is not a spare part!

Section 4 Light Processor
Board and
Module
Functionality
2K-B series - R868361FK 2K-12C series - R862414FK

4K-B series - R8760150FK 2K-15/20C series - R862416FK
R8761913K 2K-S series N/A as spare part


Section 4 Light Processor (4K Series)
Board and
Due to market availability of higher performance components, the cooling solution of 4K
Module
light processors has been improved.
Functionality
As part of this improvement, the front cooling block has been replaced by air-cooled heat
exchanger to improve efficiency.
The tubing order is changed. First, it brings the cool water directly to the light processor and
then to the entry of the integrator rod. The tube towards the light processor has become
slightly longer, while the tube towards the integrator rod entry becomes slightly shorter.
Examples of an old and a new light processor view
Old New Old New

Section 4 Light Processor (B, C & S series)
Board and
Module
Functionality  Creates image on the screen with light provided by the light source,
using the prism and 3 separate DMDs (one for each color)
 Light pipe balances light uniformity, contrast, size of light source in
Part Numbers
reference to DMD shape
2K-B series
 New molded light pipe for better cooling
R868361FK  Light Processor contains:
4K-B series – Formatters
R8760150FK – DMDs
2K-12C series – Convergence adjustment
R862414FK
– Light path
2K-15C series – Prism
2K-20C series
R862416FK – Light sensor
– Temperature sensors
S series
R8761913K – Cooling devices
(Without light pipe) – Dowser (Except for S series)

Section 4 Formatters (B, C & S series)
Board and
Module
Functionality  Drives the DMDs directly
 Handles frame rate multiplication for 3D & HFR

Section 4 Lamp House (B, C & S series)
Board and
Module
Functionality Alignment Model Part Number
Manual DP2K-32B R868530K
Manual DP2K-19B/23B R865556K
Manual DP2K-12C/15C/20C R8552642K
Manual DP2K-S R8761710
B Series C Series S Series
Z-axis mechanics can be lubricated with High-temperature and long-lasting lubricant (Barco order no: B1909289K)

Section 4 Lamp Info Module (B & C series)
Board and
Module
Functionality
S Series

Part Number
Note:
R765356K
 The Lamp Info Module is identical for B & C series
 Lamp info is stored on the Cinema controller for S - series

Section 4 Lamp Info Module (B & C series)
Board and
Module
Functionality  Lamp Info Module stores information about the lamp, after the user
programs it via the Communicator or Touch Panel
 Stored information includes:
– Lamp type
– Hours
– Article number
– Serial number
– Last used power value set by user
– Number of lamp strikes
– Lamp history
– Maximum and minimum operational current values
Part Number
R765356K

Section 4
Start Pulse Generator (SPG / Igniter) (B, C & S series)
Board and
Module
Functionality
Part Number Part Number Part Number

R765787K R7648225K R7681046K
 Provides initial charge required to ignite lamp from DC voltage

supplied by the LPS (140V).
 Capacitors on SPG are charged up to the boost voltage and
discharged into the SPG’s coil, resulting in an ignition voltage of
up to 40kV for the C & S series, and 50kV for the B series
 Provides connection from the LPS to the Lamp House, to power up
Barco Confidential the lamp 87

Section 4 Lamp Power Supply (LPS)
Board and
Module
Functionality
DP2K-xxC (older Version)

DP2K-12C
Part Number
(1 X LPS + fixation frame)
R7655231K
DP2K-15C / 20C
Part Number
(2 X LPS + fixation frame)
R7655232K
DP2K-xxC (new Version)


Section 4 Lamp Power Supply (B, C & S series)
Board and
Module
Functionality
Part Number B – C and S series

R765523K

Board and
Module
Functionality  Can contain multiple LPS modules which run in parallel
 Each LPS can deliver a maximum of 2.5kw in isolation
– 2 LPS modules provide 4.5kw
– 3 LPS modules provide 7.5kw
 Provides 150 VDC boost voltage to SPG to ignite the lamp. This can
be measured at the moment the lamp strike is attempted
 After Lamp ignition, provides 20-50 VDC to drive the lamp with the
corresponding current — dependent on lamp type (up to 180A)
 Controlled via RS-232. Commands received from Cinema Controller
 Also controlled via external error line from Fan Controller, which
shuts down the lamp in case of projector failure

Board and
Module Lamp strike mechanism
Functionality 1. Lamp on command to main program (dp60)
2. LPS startup from 0V to 150V in 300msec
3. LPS high voltage remains for ~1,35sec
4. a. SPG fires with high voltage (>40KV)
b. LPS capacitors provide peak current to lamp for a very short time (~10ms)
5. a. LPS remains in constant current mode for 10 sec
LPS does not log anything during this phase
b. Main program idle for 10sec but checks lamp strike status bits
No log updates during these 10 seconds
6. Main program changes LPS to constant power mode OR sends lamp off command
when lamp did not strike
Visible in LPS logs
7. Failing lamp strike readable in controller logs

Section 4 Lamp Power Supply - LEDs (B, C & S series)
Board and
Module
Functionality
If On – LPS is on and functioning If On – LVPS OK, mains voltage > 200VAC and Heartbeat Status and
correctly. Internal low voltage power supply is OK. Internal Use LED’s.
If On – PFC (Internal to LPS) has If Off – Mains voltage not present, Fuse F100
powered up correctly. in LPS module has blown or Internal power
supply is not OK.
If On - Error detected (LPS
Hardware fault); Neither PFC or If On – LPS Providing is power to lamp.
Barco Confidential LPS will start. 92

Section 4 Lamp Power Supply - LEDs and Diagnostics (B, C & S series)
Board and
Module
Functionality  Status LEDs on the LPS unit
– The LPS module contains 16 status LEDs (8 per LPS unit): 4 orange, 3 green, 1 red.
– The orange “LVPS OK” LED lights immediately after the projector is switched on. At the
same time, the heartbeat LED starts blinking (the right-hand orange LED in the upper
row). All other LEDs remain off. This is the unit’s standby status.
– Once the command is sent to the LPS to start the lamp, the green LEDs light up, one
after the other: “PFC OK,” then “LPS OK,” then (when the lamp is ignited) “LAMP ON.”
– The red “ERR” LED remains off, unless an LPS error is detected, or when
both LPS units are ordered to shut down due to a projector malfunction.

Board and
Module
Functionality
7 8
1
2
3
4 5 6

Board and
Module
The orange LEDs next to the CTRL connectors:
Functionality
LED 1 is the heartbeat LED.
LED 2 is for internal use only
LED 3 is transmission

Board and
Module
Functionality

Section 4 Keypad Module (B & C series)
1 2 3 4 5
Board and
Module
Functionality  Provides communication to Cinema Controller
to control the following:
(1) Macro labels
(2)
(3)
Numeric keyboard
Lamp on/off switch
6
(4) Dowser open/close switch
(5)
(6)
Test pattern switch
Lens shift up/down, left/right
7
(7) Lens focus
Part Number (8) Lens zoom 8
Keypad
Keypad
R724350K Test patterns:
 Barco alignment, Focus Green, Full Screen
White, Color Bars, and Off (on the fifth press)
Part Number
Button Interface
 Note: During boot-up, Barco/TI communication
R765535K
is confirmed when the Test Pattern button turns
green
Button Interface

Section 4 Keypad Module (S – series)
Board and
Module
1 2 1 2 3 4 5 6 7 8 9
Functionality
Part Number
Keypad
R8761878
10 11 12
Part Number
(1) Macro labels
Button Interface (2) Numeric keyboard
(3) Lamp on/off switch
R7681044 (8) Lens zoom
(4) Dowser open/close switch
(5) Test pattern switch (9) Lens shift up/down, left/right
(10) Sleep function
(6) Security key (11) User-defined button
(7) Lens focus (12) Media buttons
Installation and Basic Maintenance — Updated November 20 - 2012 Copyright © Barco

Board and
Module
Functionality
 Start marriage procedure by pressing “key” button and enter pin code
 Default pin 12345612
 Pin codes can be added/changed with communicator (Same procedure as for B & C series)
Hardware:
 Powered from standby supply (++12V)
 Communicates with Cinema Controller using RS422

Board and
Module
Functionality
 Enter/leave sleep mode

 Pressing the “Sleep”-button for 3 secs
 Projector command (USB/Ethernet)
 Trigger dedicated macro with GPIO
 Communicator
 Sleep request ignored with lamp on
 If projector still too hot:
 Electronics shut down immediately
 Finishes aftercool (+24V stays on...)
 Finally enters “Sleep” mode

Board and
Module  During Sleep:
Functionality
 Cinemacontroller and Button Module powered, all other electronics switched off (+12V/+24V)
 Router and external switch fully functional
 USB-A and USB-B interface active
 GPIO active
 Flashing tail light (10sec off, 1sec on...) which shows the status info
(green -> ok , red -> error, yellow -> warning and blue -> notification)
 No Fans
 LPS completely switched off
 Total power consumption less than 15W

Section 4 Keypad Module – PCB functional blocks (S series)
Board and
Module
Functionality
RGB LED’s
LED Drivers ++12V -> 5V

Section 4 Security Tamper Switches (B-series)
Board and
Module
Functionality

Section 4 Security Tamper Switches (C-series)
Board and
Module
Functionality

Section 4 Security Tamper Switches (S-series)
Board and
Module
Functionality
Top side Engine side

Section 4 Security Tamper Switches (B, C & S series)
Board and
Module
Functionality  Provides feedback to TI Enigma board in case a service door is
tampered with
 The following items are protected:
– B series (4 switches)
 DLP Light Processor Cover
 Cable connection area enclosed by cover above the keypad
– C series (2 switches)
 DLP Light Processor Cover
– S series (2 switches)
 DLP Light Processor Side Cover
 DLP Light Processor Top Cover
Handout 4.1 + 4.2

Section 4 Status Light Description (B, C & S series)
Board and
Module
Functionality
Green = OK (Flashing Green = projector is booting up)
Slow flashing in sleep mode (S series only)
Yellow = warning, check communication software for warning description

(e.g., lens over shift, over temp, etc.)
Slow flashing in sleep warning mode (S series only)
Red = Problem could prevent normal operation (e.g. DCI security error)
Slow flashing in sleep error mode (S series only)
Blue = Maintenance action required (e.g., change lamp, clean filters)
Slow flashing in sleep maintenance mode (S series only)

Section 5
 Introduction to Service
System Course
Flow Charts and Block Diagrams

Section 5 Block Diagram (B & C series)
Flow Charts
and Block
Diagrams

Section 5 Communication flow (B & C series)
Flow Charts
and Block
Diagrams
Ethernet
I2C
RS-232

Section 5 Video path (B & C series)
Flow Charts Light Processor
and Block
Diagrams
Green Formatter
Blue Formatter
Red Formatter
TI ICP – Integrated
Cinema Processor
Signal Backplane
HD-SDI Input Board
A
TI Enigma B
(or)
Series 2 Integrated
Media Block
Cinema Controller
Electronics Box
Video

Section 5 Electrical (B & C series)
Flow Charts
and Block
Diagrams

Section 5 Tamper Switches (B, C & S series)
Flow Charts
and Block
Diagrams The cinema
controller has a
relay with the
contacts Normally
Open. The MPC
(Motorolla Power
PC) software will
close the contact
when a wrong
security code has
been entered.
Except for S series
Handout 5.1

Section 5 Mains power wiring (B series)
Flow Charts
and Block
Diagrams

Section 5 Mains power wiring (S series)
Flow Charts
and Block
Diagrams

Section 5 Boot Sequence (B, C & S series)
Flow Charts
and Block
Diagrams  Projector receives 200V/240V AC into SMPS board and LPS
 LPS is powered up and goes into standby
 SMPS converts AC to 390VDC from which ++12VDC (standby voltage) is made
 Fan Controller (B & C series), Cinema Controller, Button Module receive ++12V
and boot up
 Cinema Controller Linux processor begins bootup process
 Main application starts up
– Log file indicates “Main–Starting Application” or “busy box started”
 Open communication ports (Serial, Ethernet, I2C, etc.)
 Open communication to Lamp Info
 Detect Integrated Cinema Processor
 Detect IMB or IMS (if inserted)
 Detect Lamp Power Supplies
 Write lamp info into LPS
– Continued …

Flow Charts
and Block
Diagrams  Initialize Fan Controller board (B & C series)
 Status light goes solid green
 Internal power on command initiated
– Log file indicates “Load FCB File Operational”
 Check status of Fan Controller info
 Fan Controller initializes fans, pump and TEC control
 Initialize Dowser
 Activate last state of macro, lamp and dowser buttons
– TI is activated later
 Clear Fan Controller errors
 Initialize Lens Motors (writes last lens values to Cinema Controller)
– Continued …

Flow Charts
and Block
Diagrams  Initialize Lens type
 Activate last input settings (DVI, HD-SDI, etc.)
 Check TI security tamper switch information.
– Errors (if any) are logged to Enigma log file
 Boot up sequence finalized at this point
 Communication from Barco to TI can be verified by “Test Pattern” button
turning green
 Nothing happens to TI until a Macro is selected to configure the video path
 TI will resume with same settings as before the projector was shut down
Handout 5.2

Day 2: Agenda
Section 6: Board and Module Replacement

Section 7: Liquid and Air Cooling System Maintenance
Section 8: Light Processor Repair
Section 9: Optical Alignment

Section 6
 Introduction Board
to Service
and Course
Module Replacement

Section 6 Lens Holder Replacement (B, C & S series)
Board and
Module
Replacement  Remove lens holder
grounding wire connected to
the projector frame (If
applicable)
 Disconnect wire harness and
any other lens control cables

Board and
Module
Replacement  Remove 4 hex screws that
secure lens holder to projector
 Remove lens holder from
projector then replace with new
lens holder

Board and
Module
Replacement  Push a spindle or T10 screw
driver through holes “a and b”
 Then seat lens holder on to
projector frame
 Replace 4 hex screws into new
lens holder
 Reconnect all wiring and then
test lens functions

Section 6 Signal Backplane Replacement (B & C series)
Board and
Module
Replacement

Board and
Module
Replacement  Remove side cover lamp house, side
cover card cage and front cover Light
 Remove all boards from signal Processor
backplane, and place boards on Connections
static free material
 Disconnect all signal backplane wires
(Light Processor harness)
 Remove metal shelves from the card
cage, then disconnect and remove
the SMPS
SMPS
Connections

Board and
Module
Replacement  Disconnect all cables from signal
backplane at the front of projector
behind the filter
 Remove all screws out of the signal
backplane, that attach it to the card
cage
 Remove backplane from the card cage
 Remove Crypto Memory card from the
backplane that was just removed, and
insert it into the new backplane
 Insert new backplane and reconnect all
cabling
 Replace all electronic modules, shelves,
security covers, and the side and front
covers Front
 Reauthorize projector with security key Connections

Section 6 Reflector Replacement (C series)
Board and
Module
Replacement  Remove Lamp from Lamphouse by following proper Barco procedures, as noted in
installation manual
 Note: Do not touch the Reflector glass while unpacking device
 Disconnect Cathode Cable from Cathode Terminal in front of the Lamphouse
 Guide the Cathode Cable out of the Lamphouse
 Place Lamphouse face down, and ensure that you protect the UV Blocker on front
of Lamphouse
 Remove bottom profiles from Lamphouse as shown in the figure below.
Profile
Removal

Section 6 Reflector Replacement (C series)
Board and
Module
Replacement  Remove Cathode side of the Lamphouse by removing 8 screws
 Remove Reflector by removing 8 screws

Section 6 Reflector Replacement (B series)
Board and  Remove Lamp from Lamphouse by following proper Barco procedures, as noted in installation manual
Module  Note: Do not touch the Reflector glass while unpacking device
 Disconnect Cathode Cable from Cathode Terminal in front of the Lamphouse
Replacement  Guide the Cathode Cable out of the Lamphouse
 Place Lamphouse face down, and ensure that you protect the UV Blocker on front of Lamphouse
 Remove bottom profiles from Lamphouse as shown in the figure below.

Board and
Lamp Reflector assembly for S/M Lamp House and for XL Lamp House
Module
The Lamp Reflector assembly of the Lamp House has three major parts. One metal mounting ring, one spheric glass mirror and
Replacement one elliptic glass mirror. Both mirrors are assembled on the metal ring and are perfectly aligned with each other. The S/M Lamp
House and the XL Lamp House have a different Reflector assembly. Nevertheless, the same replacement procedure is applicable
for both projector types.
A1 Spheric glass mirror S/M Lamp House

A2 Metal mounting ring S/M Lamp House
A3 Elliptic glass mirror S/M Lamp House
B1 Spheric glass mirror XL Lamp House
B2 Metal mounting ring XL Lamp House
B3 Elliptic glass mirror XL Lamp House
Remove the corner plate of the Lamp House as illustrated. Use a 2,5 mm Allen wrench to loosen the four
Barco Confidential screws which hold the plate. 130

Board and Remove the front assembly of the Lamp House by loosening the 8 indicated screws (reference 3 image 7-108). Use a 2,5 mm
Module Allen wrench.
Caution: Do not damage the wire unit The front assembly is still connected via the wire unit of the Lamp Info module with the
Replacement base of the Lamp House. This wire unit has some play so that you can turn the front assembly away from the Lamp House.
Remove the Reflector assembly from the Lamp House by loosening the three hexagon socket head cap screws as illustrated. Use
a 3 mm Allen wrench
- Place a new Reflector assembly in the Lamp House and fasten with 3 hexagon head cap screws. Use a 3 mm Allen wrench to
fasten the screws
.
- Reinstall the front assembly of the Lamp House. Use a 2,5 mm Allen wrench to fasten the 8 hexagon head cap screws
Caution: Take care that the wire unit of the Lamp Info module does not get jammed.
– Fasten the wire unit with a cable tie
– Reinstall the corner plate of the Lamp House. Use a 2,5 mm Allen wrench to fasten the 4 hexagon head cap screws
– Reconnect the cathode wire with the Lamp House. Make sure to place a plane washer between the nuts and the wire lug.
Use a torque of 25 Nm to fasten the nuts.
Block the first nut with a 22 mm open-end wrench while applying a torque of 25 Nm on the second nut
with a torque wrench.

Section 6 Reflector Replacement (S series)
Board and
Module
Replacement
1 Air inlet cathode cooling. 8 Cathode connection with igniter (SPG).

2 Air inlet anode cooling. 9 Removable front cover (with UV blocker).
3 Positioning pin. 10 Adjustment screw vertical lamp alignment.
4 Airoutlet. 11 Adjustment screw for lamp Z-alignment.
5 Removable side cover. 12 Lamp cathode fixation screw.
6 Anode connection with igniter (SPG). 13 Adjustment screw horizontal lamp alignment.
7 UV blocker (with incorporated anode lamp support). 14 Lamp House fixation screw.

Section 6 Lamp Power Supply Replacement (B & C series)
Board and
Module
Replacement  Turn off power to projector
 Remove projector rear cover
 Disconnect LPS wiring
– RS-232 communication
cable
– Address cable
– Igniter DC cables
– AC cables
 Loosen 4 captive screws DP2K-C
 Slide out LPS by handles
 Clean out empty compartment
air intake prior to reassembly
 Insert new LPS and reconnect
all cabling
 Screw in 4 captive screws
securing LPS module
 Replace projector rear cover
DP*K-B

Section 6 Lamp Power Supply Replacement (S series)
Board and
Module
Replacement
– Remove mains power

cables and ground wire.
– Remove Fixation screw
– Remove Control Cable

and Lamp Power Cables.

Section 6 Light Processor Replacement (B & C series) DP2K-B
Board and  Power off the projector
Module  Remove lens out of the projector
Replacement  Remove left side cover
 Remove security panel
 Remove top projector cover
 Remove top security panel
 Disconnect Cooling hoses
 Loose Captive Bolts
Captive Bolts
Cooling Hoses
DP2K-C
Captive Bolts

Section 6 Light Processor Replacement (B series)
Board and
Module
Replacement  Release both EMC cables by turning out both hand screws at the left and right side
of the light processor.

Section 6 Light Processor Replacement (C & B series)
Board and
Module
Replacement  Disconnect Light Processor
wiring harness cables from top
of signal backplane
DP2K-C

Section 6 Light Processor Replacement (C series)
Board and
Module
Replacement  Disconnect 2 cooling hoses (N/A
for DP2K-12C)
 Loosen 3 captive bolts that hold
the Light Processor in place
 Carefully pull Light Processor out
using handles
 Replace Light Processor
 Reconnect cooling hoses Captive
 Tighten 3 captive bolts Bolts
– Note: If the top screw is not
properly tightened, the image
can be unstable
 Reconnect wiring harness cables
back into signal backplane
 Replace all projector covers
 Power projector on and DP2K-C
reauthorize with security key

Section 6 Light Processor Replacement (B & C series)
Board and
Module
Replacement
General Rule
In DP2K-15C and 20C,
orange cables go to
orange connectors

Section 6 Light Processor Replacement (S series)
Board and
Module
Replacement
1) Remove all connectors from Backplane
3) Remove the light processor
2) Remove the 3 mounting screws

Barco Confidential holding the light processor. 140

Section 6 Light Processor Replacement (S series & DP4KP)
Board and Spatial Color Calibration

Module Intro: Barco has introduced the Spatial Color Calibration (SCC) file on the DP4K-P and DP2K-S
Replacement
series digital cinema projector. The SCC file contains information to improve the color uniformity
from the left to the right of the image. The uniformity is measured at the factory
and stored in a LUT-SCC file on the ICP board. This LUT-SCC file is activated on the projector
at factory.
Impact on service
As the LUT-SCC file is Light Processor specific, when replacing the Light Processor of the
projector a new LUT-SCC file should be uploaded and set as active file. When replacing the
Integrated Cinema Processor (ICP) board the backed up LUT-SCC file should be uploaded
and activated.
More details can be found on Info T 1071

Section 6 Lightpipe Replacement (S series)
Board and
Module
Replacement

Section 7

Light Processor Repair

Section 7 Light Processor Components (B series)
Light
Processor
1
Repair  Three major Light Processor
sub-assemblies 2
1. Light Processor Unit
2. Dowser
3
3. Light Pipe Assembly
 Light pipe sub-assemblies DP*K-B

1. Light Sensor Module
2. Folding Mirror
3. Light Pipe Zoom Lens
Adjustment 1
4. Integrator Rod
2 3 4
DP*K-B

Section 7 Light Processor Components (B & C series)
1 3
Light
Processor 2
 Light Processor Sub-assemblies
Repair
1. Convergence Adjustment
2. Red Formatter 5
3. Green Formatter
4. Blue Formatter (not shown) 7
5. Prism Exit DP2K-
6 15&20C
6. Light Pipe assembly
7. Light Sensor
1
8. Formatter fans (DP4K-B only)
2 3
8
5
DP4K-B 6 DP*K-B

Section 7 Light Processor Components (S series)
Light
Processor
Repair

Section 7 Component Replacement (B,C & S series)
Light
Processor
Repair  Light Processor repair considerations
– Light Processors are extremely static sensitive. Use a static wrist strap when
working on individual components
– Watch integrator rod glass when removing cooling block
– Don’t introduce dust into the light path
– Calibrate colors after Light Processor replacement
 Practice replacement of the following components:
– Light Pipe
– Temperature sensors
– Dowser (Except S series)
– Light sensor
Hands On Replacement of Light Processor Components


Section 8
 Introduction
Liquid to Service
and CourseSystem Maintenance
Air Cooling

Section 8 In This Section
Liquid and Air
Cooling
Maintenance  Liquid Cooling System Basics
 Liquid Cooling Circuit
 Replacing the Cooling Liquid
 Cleaning Cooling System Components

Section 8 Liquid Cooling System Basics (B & C series)
Liquid and Air

Cooling
Maintenance  Projector should always have a sufficient cool-down period, prior to service of
cooling system
 If cooling system is empty, pump will have to be primed to enable liquid flow
 Cooling liquid is a harmful product — Do not get on skin, eyes, etc.
– Contents include 1/3 Ethanediol, 2/3 demineralized water
 Basic troubleshooting rules:
– Ambient temperature of room must be below 35C / 95F
– Dirty air filters can cause over temp errors
– Always look for liquid flowing rapidly when in refill mode
– If temperature sensor reports unrealistic value, then sensor might be bad (e.g., zero
degrees when lamp is on, unrealistic high temp, etc.)
– Defective temp. sensors (open and shorts) are detected and reported by the projector

9
Section 8 Liquid Cooling Circuit (B & C series)
Liquid and Air 1. Red DMD Cooling Block

Cooling
2. Green DMD Cooling Block
Maintenance 6
3. Blue DMD Cooling Block DP2K-15&20C
(not shown)
4. Integrator Rod Cooling Block 7
5. Input Valve Fitting
6. Integrator Rod Output Valve 8 10
Fitting
7. Heat Exchanger Fan 1
8. Heat Exchanger 2
11
9. liquid Reservoir
5
10. Pump
11. Formatter Fans (DK4K-B only) DP4K-B
Barco Confidential DP2K-B 4 151

Section 8 Replacing the Cooling Liquid (B & C series)
Liquid and Air

Cooling
Maintenance  Cooling Kit tools:
1. Female and male connector for DP2K projector
2. Tube 60 cm with male DP connector
3. Tube 60 cm with female DP connector
4. Filler cap with pressure valve
5. Bottle with cooling liquid
6. Empty bottle
7. Air pump
Cooling Kit
Part Number
R395198K

Section 8 Cooling Liquid Refill (B & C series)
Liquid and Air

Cooling
Maintenance  The projector is liquid cooled. It is important that the liquid level is
checked at regular intervals. We advise to check every 3 months. The
liquid level must be between min. and max. Significant drop in liquid level
indicates a major leakage and requires immediate attention.
– Remove the side cover on the light engine side of the projector.
– Using a flashlight, look through the small circular window in the
security cover and check the liquid cooling level in the reservoir.
 If the level is somewhere between Min. and Max., no action is required.
 If the level is lower than Min., check for leakage and start the refill
procedure.

Section 8 Cooling Liquid Refresh (B & C series)
Liquid and Air

Cooling
Maintenance  To refill cooling liquid:
1. Remove the engine side cover.
2. Remove the top cover.
3. Open the cap of the cooling
liquid reservoir by turning it
counter-clockwise.
4. Fill the reservoir with cooling
liquid until the level is equal
with the “Max.” indication on the
reservoir. Look through the
small window to see the
indication.
5. Close the reservoir with the cap
by turning the cap clockwise.
6. Reinstall all covers.

Section 8 Draining the Liquid Cooling Circuit (B & C series)
Liquid and Air

Cooling
Maintenance  To drain the liquid cooling circuit:
1. Remove the side engine side cover and top cover.
2. Open the sealed compartment.
3. Remove the cap.
4. Replace the cap (3) with the pressure valve cap (4).
4

Liquid and Air

Cooling
Maintenance 5. Disconnect the liquid cooling circuit between the light processor and the pump
by uncoupling the two valve fittings.

Liquid and Air

Cooling
Maintenance 6. Take a 60cm tube with female connector 8
and connect it to the male fitting that
goes to the light processor.
7. Insert the open end of the tube into an
empty bottle.
8. Connect a air pump to the cap and start
pumping until no more liquid comes out
of the tube.
9. Disconnect the extension tube.
10. Take a 60cm long tube with a male
connector and connect it to the female
6
connector that goes to the pump.
11. Insert the open end of the tube into an
empty bottle.

Liquid and Air

Cooling
Maintenance 12. Start pumping again until all 13
liquid is out of the circuit.
13. Disconnect the air pump
and remove the pressure
valve cap.
12

Liquid and Air

14. To fill the circuit, bring the free end of the connected
Cooling
extension tube a few centimeters above the opening. 14
Maintenance
Note: Ensure that the original tube is still below the reservoir.
15. Fill up the reservoir slowly with fresh cooling liquid
until liquid is visible inside the extension tube.
BE CAREFUL not to overfill the reservoir.
16. Uncouple the extension tube and pour out the tube
into the bottle.
17. Reestablish the connection with the light processor
cooling circuit.
18. Fill up the reservoir to the minimum indicator.
19. Start up the refill mode. (Installation  Advanced  Refill mode)
– Note: Air bubbles will be visible inside the reservoir. The cooling
circuit will be filled with liquid and the air will be pushed out.
20. When the liquid level in the reservoir does not lower anymore.
21. Stop the refill mode. Fill up the reservoir until the level is equal with the
Max indication on the reservoir.
22. Close the reservoir with the cap and reinstall all covers.
23. Clear the security warning.

Section 8 Cleaning Cooling System Components (B & C series)
Liquid and Air

Cooling
Maintenance
 Air filters and entrances must be cleaned monthly by
operator
 liquid in cooling system must be replaced once a year
 Pump can be cleaned every 1-2 years (optional)
– Drain cooling system
– Prepare to catch excess liquid Screw Removal
– Remove 4 screws from pump
– Pull out pump shaft
– Wipe clean with soft clean cloth
– Replace pump shaft and screws
– Replace cooling circuit
Pump Shaft Removal

Pass Pump Around and Disassemble

Section 9

Optical Alignment

Section 9 In This Section
Optical
Alignment
 Convergence Basics
 Convergence Adjustments
 Allowed Tolerances in Pixels
 Cold Mirror Alignment
 Integrator Rod Alignment
 Scheimpflug Adjustment

Section 9 Convergence Basics (B, C & S series)
Optical
Alignment
 DMD convergence must be performed by a
certified service technician only!
 DMD convergence is performed by aligning
Red and Green DMDs to the Blue DMD for B & C series.
 DMD convergence is performed by aligning
Green and Blue DMDs to the Red DMD for S series
 The reference DMD is stationary and is not adjustable
 Activate the appropriate “Convergence pattern”
test pattern to check DMD alignment
 Make small corrections to adjustment points only.
Minor adjustments create large pixel shifts!
!!! Turning the convergence knobs too hard can cause permanent damage !!!

Section 9 Convergence Adjustments (B & C series)
Optical
Alignment
 Extended control knobs
– As the DMD of the blue channel is not
accessible in the projector, the image of this
DMD is the reference
– Red and green will be aligned on blue when
a small convergence drift is recognized
– The blue channel’s DMD is fixed and cannot
be adjusted
– The red and green channels are each
equipped with three extended control knobs
for convergence adjustment
– The adjustment knobs are numbered from 1
to 6 and have the same color as the channel
which they effect
 1, 2 and 3 for red
 4, 5 and 6 for green

Section 9 Convergence Adjustments (C series)
Optical
Alignment
 Convergence test pattern

Optical
Alignment
 To converge Red on Blue:
1. Slightly turn the red colored control
knob (1) until the red pattern in the
center of the projected image
converges with the blue pattern. Note
that a turn of a few degrees
corresponds with one full pixel.
 Note: When you start turning the knob,
a little resistance can be felt. This
resistance is part of the internal locking
mechanism of the adjustment.
lower left of the projected image
converges with the blue pattern.
upper right of the projected image
converges with the blue pattern.

Optical
Alignment
 To converge Green on Blue:
1. Slightly turn the green colored control knob
(4) until the green pattern in the center of
the projected image converges with the blue
pattern. Note that a turn of a few degrees
corresponds with one full pixel
 Note: When you start turning the knob, a
little resistance can be felt. This resistance
is part of the internal locking mechanism of
the adjustment.
(5) until the green pattern in the lower left
of the projected image converges with the
blue pattern
(6) until the green pattern in the upper right
of the projected image converges with the
blue pattern

Section 9 Color/DMD Convergence 2K (B, C and S series)
Optical Specifications in pixels

Alignment
• ¼ pixel in the center of the screen.
• ½ pixel at the edge center

Section 9 Color/DMD Convergence 4K (B series)
Optical Specifications in pixels

Alignment
• 1 pixel in the center of the screen.
• 1 pixel at the edge center

Section 9 Cold Mirror Alignment (B, C and S series)
Optical
Alignment
 Cold mirror alignment corrects for poor light uniformity
 Alignment should only be performed with an aligned lamp
 Usually light uniformity issues originate from lamp alignment, not
from cold mirror alignment

Optical  To adjust the cold mirror:

Alignment 1. Loosen 3 locking nuts (4) to the adjustment points
2. Check nominal position of cold mirror by measuring distance between devices
shown below. If distance is not correct then adjust accordingly
Note: Nominal distance (A) between adjustment screw head and mounting plate:
 S series: 26mm for 2 screw
Tools
Note: screw on SPG side has an extra washer so longer distance required
10mm Wrench
 C series: 32mm
7mm Wrench
 B series: 12mm 
Vernier Caliper
Projected Light
Meter (Lux Meter)

Optical
Alignment
3. De-activate the CLO
4. Place the light meter in the center of the image and
project a white test pattern
5. Using a 7mm nut driver, turn screw (2) in or out until
the maximum light output is measured.
6. Turn the adjustment screw (3) in or out until the
maximum light output is measured.
7. Repeat steps 5 and 6 until the maximum light output
is measured.
8. Adjust the X, Y and Z axes of the xenon lamp for
maximum light output. Carefully turn the
thumbscrew for maximum output, and once over the
maximum, turn slightly in the opposite direction to
reach maximum again. Repeat for each axis, and
repeat this adjustment cycle twice.
9. Turn the screws (1), (2) and (3) equally until the
maximum light output is measured.
10. Repeat from step 5 until the maximum light output
is measured.

Optical
Alignment
11. Check the brightness uniformity. In most
cases, it will be OK.
12. If not OK, turn slightly on screws (2) and (3)
until a uniform brightness is obtained.
– Screw 2 will correct the difference between
the left and the right side of the projected
image.
– Screw 3 will correct the difference between
the top and the bottom side of the projected
image.
– Check again and repeat if necessary.
13.When the adjustment is finished, secure the
position of the cold mirror by turning the lock
nuts (4) against the plate. Hold the screws
while securing the nuts.

Section 9 Integrator Rod Alignment (B, C & S series)
Optical
Alignment
 Integrator rod is made of fused silica
 Function:
– Matches the shape of the light path to the shape of the DMD, to neutralize the effects of
hotspots created by the light source
– Focuses light beam onto the DMD
 Integrator rod must never be contaminated with dirt, dust or grease
 Contamination can cause permanent damage
 Important: Only align the integrator rod with a white test pattern on minimum light
output. The DMD can be damaged if alignment is done with maximum light output.
 Make the adjustment as short as possible
 Procedure for Integrator Rod adjustment:
– C Series: rotate, focus, adjust folding mirror
– B & S Series: rotate, zoom, focus, adjust folding mirror
 Usually, an unaligned Integrator Rod creates blurry edges or blue/yellow streaks on
edges of image

Section 9 Integrator Rod Alignment (C series)
Optical
Alignment
 Switch on the projector
 Make sure the DMD image is in focus
 Set test pattern to “full screen white”
 Adjust the folding mirror nuts until the upper and left edge of the rod can be seen
on the screen
Rod edges
Adjust Folding
Mirror screws

Optical
Alignment
 Loosen the lock nut of the rod fixation
 Rotate the lever until the rod is parallel to the DMD image
 Focus the image by turning the focus knob until the left top corner is sharp
 If the rod does not move backwards by itself, rotate the knob counter clockwise
and push on the lever and the cooling block to push the rod backwards
 The best way is to adjust the focus by first turning the focus knob counter-
clockwise and fine tune by turning clockwise
Rotation Lever Lock Nut Focus Knob
Rotate forward Push

Focus Knob
(clockwise) backwards

Optical
Alignment
 Use a pressure of 2Nm to fixate the rod holder with the Lock nut
 Note that there is no zoom adjustment on the “C” series
Rotation Lever Lock Nut
Focus this corner
Focus Knob

Section 9 Integrator Rod Alignment (B series)
Optical
Alignment
The entrance and exit side of the Integrator Rod are coated to achieve optimal
performance.
1 Aluminum tube.
2 Fixation screw rod assembly.
3 Rod adjustment ring.
4 Set screw for rod focus adjustment.
5 Rod exit.
6 Fixation screws for cooling block.
7 Rod entrance.
8 Rod assembly positioning pin for cooling block.

Optical How to adjust the Integrator Rod?

Alignment
1. Check if the rod rotation set screws (1) and the rod focus set screw (2) are aligned.
2. Loosen the rod focus set screw (2)

Optical
3. Start up the projector but do not activate the lamp yet.
Alignment
4. Set up the projector using the Communicator software to display a white internal pattern
with maximum dimming. Do not activate the lamp yet.
a) Switch on the projector. Do not activate the lamp yet.
b) Select : Control Service > Light output mode > Normal mode > Lamp dimming > 0
c) Select : Control > Test patterns > Focus green
5. Activate the lamp and adjust the Image focus if needed.
6. Select : Control > Test patterns > full white
7. Gently rotate the rod adjustment ring back or forward to a position which projects the sharpest
possible edges on the screen.
Click: Place a 2 mm Allen wrench in one of the holes on the outer side of the adjustment ring. The Allen
wrench function as an extension bar of the adjustment ring. This allows a more precise adjustment.
Barco Confidential 8. Fasten the rod focus set screw which you released in step 2. 180

Optical
Alignment 9. Loosen the two rod rotation set screws as illustrated. Use a 2 mm Allen wrench.
10. Gently rotate the rod adjustment ring (reference 3 image 9-15) until the projected light beam
matches the projected outline of the DMD’s.
11.Fasten the two rod rotation set screws which you released in step 9.

Section 9 Light pipe (B series)
Optical
Alignment

Section 9 Integrator Rod Alignment (S series)
Optical Alignment procedure is similar to the B series projectors.

Alignment

Section 9 Scheimpflug Adjustment (B, C & S series)
Optical
Alignment
 Scheimpflug adjustment corrects focus uniformity, even when
the projector is not perpendicular to the screen
 What has to be done ?
– The lens holder has to be adjusted so that the “sharp focus plane” of
the projected image falls together with the plane of the screen
(Fp1→Fp2).
– This is achieved by changing the distance between the DMD plane and
the lens plane (Lp1→Lp2).

Section 9 Scheimpflug Adjustment (B, C & S series)
Optical
Alignment
– The closer the lens plane comes to the DMD plane, the further the sharp
focus plane will be.
– It can sometimes happen that you won’t be able to get a complete
focused image on the screen due to a tilt (or swing) of the lens plane
with respect to the DMD plane. This is also known as Sheimpflug’s law.
– To solve this, the lens plane must be placed parallel with the DMD plane.
This can be achieved by turning the lens holder to remove the tilt (or
swing) between lens plane and DMD plane (Lp3→Lp4).

Section 9 Scheimpflug and Back focal length adjustment (B, C & S series)
Optical - Scheimpflug adjustment corrects focus uniformity, even when the projector is not perpendicular to the screen
Alignment - Back Focal Length adjustment is only needed when proper center focus can’t be achieved simultaneously on
Flat and Scope.
1
Scheimpflug adjustment nuts No1: Influences the sharp focus plane in the lower left corner of the projected image.2
2 Scheimpflug adjustment nuts No2: Influences the sharp focus plane in the lower right corner of the projected image.
3
Scheimpflug adjustment nuts No3: Influences the sharp focus plane in the upper right corner of the projected image.
4
Scheimpflug nut No 4: Without adjustment functionality.
11
Set screw for nut No1.
12 Set screw for nut No2.
13 Set screw for nut No3.
14
Set screw for nut No4.
21
Lock nut. 21
22 22
Lock nut.
23
Lock nut.
24 24
Lock nut. 23

Section 9 Back focal length adjustment (B, C & S series)
Optical
Alignment Back focal lenghth adjustment is only needed when proper
Center focus can’t be achieved simultaneously on Flat and
Scope.
1. Select a screen file “no masking” or “no crop”

2. Project a green focus pattern.
3. Loosen the locknuts (21, 22, 23 and 24).
4. Loosen the 4 set screws (11, 12, 13 and 14) by 1 cm.
5. Fully loosen adjustment nut 4.
6. Optimize the focus of the image:
• Place the zoom lens in TELE position (smallest projected image) and adjust
focus using the lens focus barrel or the motorized focus control.
• Place the zoom lens in WIDE position (largest projected image) and adjust
focus by turning equally on nuts (1), (2) and (3).

Section 9 Scheimpflug adjustment (B, C & S series)
Optical
Alignment
 To adjust Scheimpflug:
1. Select a screen file “no masking” or “no crop”
2. Project a green focus pattern.
3. Loosen the locknuts (21, 22, 23 and 24).
4. Loosen the 4 set screws (11, 12, 13 and 14) by 1 cm.
5. Fully loosen locknut 4.

Optical
Alignment
6. Optimize the center focus of the image
1 2

Optical
Alignment
7. Sharpen bottom left corner of the screen by adjusting nut (1).

Optical
Alignment
8. Sharpen top right corner of the screen by adjusting nut (3).
Repeat from step 7 until the projected focus pattern is as sharp as possible in the
center, bottom left and top right of the screen.

Optical
Alignment
9. Sharpen bottom right corner of the screen by adjusting nut (2).
Use the button panel focus buttons to adjust the center focus and repeat
from point 9. until overall focus is achieved.

Optical
Alignment
– Turn in set screws 11,12 and 13. Tighten lightly by hand.

(Any image movement can affect the Scheimpflug adjustment)
– Tighten alignment nut 1,2,3 and 4 lightly by hand.
– Tighten set screws A, B and C. so that little image shift can be noticed on the screen.
– Tighten alignment nut 1,2 and 3 one after the other together with set screws A, B and C
so the image shifts back to its previous position.
– Tighten alignment nut 4 followed by set screws D so the image doesn’t shift.
– Fasten lock nuts a, b, c and d.

Day 3: Agenda
Section 10: Subsystem Diagnostics & On-Site Debugging

Section 11: Projector Firmware Updates
Section 12: Error Code Solutions and Log Files
Section 13: Special Touch Panel Features
Section 14: Scheduled Maintenance

Section 10
Subsystem Course & On-site Debugging
Diagnostics

Section 10 Basic Concepts (B, C & S series)
Subsystem
Diagnostics  Don’t over think the problem
&  Don’t aimlessly change parts
On-site  When stuck on a problem, ask outside advice to gain a new perspective
Debugging  Check Info-T’s
 Were new components installed recently?
 Start from the beginning (Server, Test patterns, etc.)
 Discard your ego — accept that something you did could have been wrong
 Think about the whole system.
– If you leave a part out, Murphy’s law will guarantee THAT will be the problem
 Write down steps that you’ve taken
 Don’t temporarily treat symptoms
 Only change one part at a time (don’t cause multiple problems)
 If you question a users information, have the user recreate the step with you to verify its
accuracy
 Always check the log files (TI and Barco)
 After an issue is resolved, document steps of resolution for later use
 When in doubt, always refer to the service manual or a Barco technician
 Try always to follow the same procedure

Section 10
Questions to Think About (B, C & S series)
Subsystem
Diagnostics
 When is the problem occurring?
&
On-site  When did the problem start?
Debugging  Can the problem be recreated?
– If so how? What keys were pressed, etc.
 Is the problem restricted to one projector?
 Are there multiple problems or just one?
 Are the problems related?
 Can you prevent the problem from happening again?

Section 10
Image related issues
 Understand hardware video path architecture!
Subsystem – Lens
Diagnostics – Engine
&  3 formatters interfacing with ICP over backplane
On-site – LVDS Cables to backplane
 Lightpipe
Debugging  Prism
 Optional 3D wheel
– ELCA box
 ICP connected to backplane - ICP has test patterns
 HDSDI/Engima connected over backplane to ICP - HDSDI has test patterns
 Controller with DVI connected over different path to ICP - DVI has test patterns
 Understand difference between optical & digital issue

– Some are less trivial than others! If unsure, a simple test mostly reveals the answer!
 Understand potential defects with their consequence on screen
– Bad connection
– Wrong settings
– Environmental effect
– Hardware failure
– Software bug
 Understand the known issues
 Combine this information to eliminate possible root causes
– Example: a rainbow effect on screen does not require an ICP swap.

Section 10 Projector Self Tests (B, C & S series)
Subsystem
Diagnostics
&  Use the Projector Self Test Menu to debug
On-site – On Communicator, press Diagnostics > Tests > Self Tests
Debugging
– Select the desired tests, and press Start Tests

Section 10 Projector Self Tests – Diagnostic Tool (B, C & S series)
Subsystem
Diagnostics
The diagnostic tool can be used to test the
&
On-site
in and out going connections on the
Debugging communication connectors such as on the
anamorphic connector, GPIO connector, 3D
connector and RS232 connector of the
projector. The outgoing voltages on this
connector can be tested with the same
tool.
Part Number
R9801025

Section 10 Communications Subsystem (B, C & S series)
Subsystem
Diagnostics
&  Any external command sent via Ethernet
On-site or serial will always be routed through
Debugging the Cinema Controller, then to the Signal
Backplane, then to the end device
 Cinema Controller contains multi-port
internal Ethernet router connected to all
internal Ethernet devices
 Once the Cinema Controller receives a
command, it converts it into the
necessary protocol to control the end
device
 TI controls its own devices with
commands to perform functions coming
Ethernet from the Cinema controller, or from
I2C
RS-232 cinema server/IMB/IMS.

Section 10 Communications Subsystem (B, C & S series)
Subsystem Electronics Box

Button Module
Diagnostics Signal Backplane
&  Decryption is handled by the TI Enigma Fan Control Board
On-site decryption device or IMB/IMS

TI ICP – Integrated
Debugging  Cinema Controller and ICP are always Cinema Processor Touch Panel
considered to be a point of failure in the

Lamp Info &
HD-SDI Input Board Series 2 Motor Control
Integrated
communication subsystem
TI Enigma (or)
Media Block
 I²C communication between Fan Cinema Controller
Controller and Cinema Controller is used

by the Fan Controller to send back error
reporting to Cinema Controller (B & C series
only)
 Cinema Controller receives error Lamp Power
Supplies
reporting and sends it to communicator
Optional 3D Controller
and log files
Green Formatter
Blue Formatter
Red Formatter
Light Sensor
Shutter
Ethernet
I2C
RS-232
Light Processor
Handout 10.1

Section 10 Video Subsystem (B, C & S series)
Subsystem
Diagnostics
&  If decryption link is present, video is sent from
server via HD-SDI cables to the HD-SDI board.
On-site Video is decrypted on TI Enigma or Media Block,
Debugging and then sent to the Signal Backplane
 When using an IMB or IMS all decoding and
decrypting happens on this board
 Video signal is sent to the ICP
 TI ICP Board adds scaling, subtitle overlay,
image cropping and applies all color correction.
Also divides video signal into Red, Green and
Blue signals
 Formatter applies any 3D/HFR frame rate
multiplication if needed and turns signal into
pulses to drive or cycle DMD mirrors.
 DMDs are reflecting the light provided by the
prism back to the prism and reflect it trough the
lens towards the screen
Video Signal
Handout 10.2

Section 10 Image Related Issues: Optical  Digital
Subsystem  Liquid in prism air gaps Bad connection ICP
( seen in Rental market)
Diagnostics
&
On-site
Debugging
 Bad rod alignment Bad setting ICP (LUT DG Bypass)

Section 10 Image Related Issues: Digital but NOT the ICP
Subsystem Bad cables or connections
Diagnostics
&
On-site
Debugging

Section 10 Image Related Issues (continued)
Subsystem Horizontal line(s) mostly point to a formatter failure

Diagnostics
&
On-site
Debugging
But Not always
Bad ICP connection

Section 10 Image Related Issues: Broken Washer on prism
Subsystem • One color far out of focus typically points to
Diagnostics broken washer
&
On-site
Debugging
• All colors out of focus typically point to a

prism issue
For example:
• Deformation due to
heat
• Coating/dirt issue

Section 10 Image Related Issues: Hardware   Settings
Subsystem  ICP hardware issues: asymmetric artifacts, not filling the entire screen
Diagnostics
&
On-site
Debugging
 ICP settings issue: one color wrong, entire screen

Section 10 Image Related Issues
Subsystem  DMD failure: Row of dead pixels, not common in Cinema Market, more seen when using laser devices in Rental Market
Diagnostics
&
On-site
Debugging
 ICP FW issue: Split screen: part of image is at wrong position, mostly also black horizontal bar

Section 10 Lamp Subsystem (B, C & S series)

Button Module

&  Command is sent from keypad (I2C) or Fan Control Board
On-site Ethernet/serial to strike the lamp
Debugging  Command is received by Cinema Touch Panel
Controller Lamp Info &

Motor Control
 Cinema Controller performs the Pump
following:
Laptop
– Checks for fan controller errors, Cinema Controller

6x Fans
lamp house switch and detection • Anode Fan
Switched Mode
of LPS Power Supply • Cathode Fan
• Fan 1, 1-6
– Instructs to switch TECs, fans and pump • Fan 2, 1-4
• ICP Fan
on or off (Except 12C & S series) • Engine Fan
– Checks lamp info settings and writes Lamp Power

Supplies
Start Pulse
Generator (SPG)
values to LPS unit(s) Lamp
Communication – Sets LPS unit(s) on to strike lamp and Mains
checks lamp state afterwards. Attempts

Filter 60A
AC Power
Mains Switch
DC Power
3 more strikes if lamp is not on & Fuse 35A
Mains
Input

Section 10 Lamp Subsystem (B, C & S series)
Button Module

&  LPS units boost output voltage to Fan Control Board
On-site 140V to ignite the lamp
Debugging  SPG builds up charge and releases Touch Panel
40-50kV Lamp Info &

Motor Control
 Cinema Controller sets dimming Pump
values on LPS
Laptop
 LPS outputs operation voltage

Cinema Controller
6x Fans
(20-50VDC) Switched Mode • Anode Fan
• Cathode Fan
Cinema Controller reads lamp
Power Supply
 • Fan 1, 1-6
• Fan 2, 1-4
status, updates keypad lamp button • ICP Fan
• Engine Fan
color and saves lamp status (for Lamp Power Start Pulse
UPS use) Supplies Generator (SPG)
Lamp
Mains
Communication
Filter 60A
AC Power
DC Power Mains Switch
& Fuse 35A
Mains
Handout 10.3 Input

Section 10 Monitoring Subsystem (B, C & S series)
Subsystem
Diagnostics  Security switches are monitored
& by the Enigma or IMB/IMS board
On-site  Pump is monitored and
Debugging controlled by the Fan Controller
(no pump in 12C & S series)
 LPS has onboard monitoring of
its own temperatures
 All separate fan channels are
monitored and controlled by the
Fan Controller (Cinema controller for
the S series)
 All temperature sensors, light
processor switch (not present on S
Switches series) and lamp house switch are
Communication monitored by the Fan Controller.
Sensors
Fans, Pump (Cinema controller for the S series)
 This data is sent to Cinema
Note: In this diagram,
Controller for reporting and all devices sharing lines
Barco Confidential logging are all separate channels 212

Section 10 Monitoring Subsystem series (B, C & S series)
Subsystem
Diagnostics
&  Prism sensor is monitored by
On-site Fan Controller. (Cinema controller
for the S series) If the sensor is
Debugging pressed in by the lens, the
Cinema Controller stops lens
shift in that direction
 DP2K-12C and DP4K-xxB has
3 fans built onto the Light
Processor
 B series has air flow sensor
 Fan Controller (Cinema controller
for the S series) will not allow LPS
to initiate if:
– Lamp switch and/or Light
Processor switches are open
Switches – There is rear DMD or lamp
Communication over temp
Sensors
Fans, Pump
– Lamp fans are not spinning
Note: In this diagram,

Handout 10.4
all devices sharing lines
Barco Confidential are all separate channels 213

Section 10 Decryption Subsystem (B, C & S series)
Subsystem
Diagnostics
&  Server handshakes with Enigma
On-site via Ethernet
Debugging  Server sends decryption keys to
TI Enigma via Ethernet
 With IMB/IMS keys are stored on
the media block itself
 Content begins playing via
encrypted data link (video
cables)
 Enigma/Media Block decrypts
data against decryption key and
sends to ICP
 ICP processes incoming data and
Ethernet sends it to the formatter boards
Video Signal
Note: The Cinelink 2 protocol is only valid with an enigma, with an IMB the ethernet
Barco Confidential connection just provides the link to the Security Manager 214

Section 10 Decryption Subsystem (B, C & S series)
Subsystem
Diagnostics
&  To troubleshoot:
On-site – Server and projector IP scheme
Debugging must be in same general IP
subnet
– Server must be pointed at
projector IP address
– If video connection or Ethernet is
lost, this results in a black screen
(no Cinelink static)
– Projector switches and security
key must be active in the
projector for decryption to work
– Always run latest version of
Enigma or SM firmware to ensure
proper decryption method
Ethernet
Video Signal
Handout 10.5

Section 10 Lens Subsystem (B, C & S series)
Subsystem
Diagnostics
&  Command is sent from keypad (I2C) or
Ethernet (manual lens command or macro
On-site containing lens file)
Debugging  Lens command is received by Cinema
Controller. Communication between Cinema
Controller and Lens = SPI (Serial Peripheral
Interface)
 Cinema Controller drives DC motors of lenses
and stepper motors of the lens holder to
move the device in the required direction
 Cinema Controller monitors position by
positional encoders on the lens and by
counting pulses on the stepper motors
 Lens and lens holder move in all directions at
the same time (this was not the case in
Series 1)
24 V DC
I2C
Ethernet

Section 10 Lens Subsystem – Home & return (B, C & S series)
Subsystem
Diagnostics
&
On-site
Debugging
24 V DC
I2C
Ethernet

Section 10 On-site Debugging - Image Issues
Subsystem  First figure out if problem is permanent or intermittent
Diagnostics – Look in logs if the problem is always present under some
& conditions or started happening at some point and remained
On-site  If permanent check what happened shortly before the issue first appeared
 Understand that logs are not endless and the ‘start’ of the issue may not be
Debugging visible anymore in the logs
 Some directions based on the failure mode:
– Intermittent
 Under some conditions
– With some functional settings (2D/3D/HFR/…)
» More likely to be a software bug
– With some environmental parameters (humidity/temperature/…)
» More likely to be a hardware failure
 Under any condition
– More likely to be a connectivity issue
– Permanent
 Under some conditions
– With some functional settings (2D/3D/HFR/…)
» Most likely software bug or out-of-spec/wrong setting
– With some environmental parameters (humidity/temperature/…)
» More likely hardware failure
 Under any condition
– Hardware failure or software corruption

Section 10 On-site Debugging - Image Issues (continued)
Subsystem Real complaint: “intermittent green flashing on screen”

Diagnostics – Field actions:
&  Run self test => signature test failure
On-site  Re-seat ICP: same problem
Debugging  Recovery tool ICP: same problem
 Swap ICP
– Risk: probably did not solve the problem & will happen again
– Proposed analysis, step by step
 Check logs for signature test failures
– In the logs it appeared to be green only
 Check wiring of LVDS cable towards green formatter
– If cable is badly connected => solved
 Still unclear: try to eliminate parts by applying some configuration changes
– Swap cables between two colors
– Swap two colors, for example Red and Green
– Swap other colors if still unclear
– Meanwhile: visual inspection of all parts

 Stress on cables?
– Cooling tubes sometimes push on LVDS cables to formatters
 Dirty or bended contacts?
 Oxidation of contacts?

Section 10 On-site Debugging - Image Issues (continued)
Subsystem Real complaint: “image flickering always on 3D”

Diagnostics – Field actions:
&  Swap ICP
On-site – Proposed analysis
Debugging  Problem is permanent and only under certain conditions
>> Most likely software bug or out-of-spec/wrong setting
– “always”
– “on 3D”
unlikely to be a connectivity issue although the effect “flickering” can be the same
 Analysis of which files are used in their “2D” macro(= working mode) and in their “3D” macro
(= failure mode)
 Request clone package !
 Check the settings of the different used files
– In this example “No3D.3D” and “RealD.3D”
– L/R input reference of “RealD.3D” = line interleaved
 From the projector log file one could know they are using a Doremi IMB
 Request diagnostic package
– Wrong L/R input reference setting for their setup, should be frame sequential
– Important to ask to verify configuration settings + ask clone package,

Barco Confidential diagnostic package, server diagnostics, … 220

Section 11
 Introduction toProjector
Service Course
Firmware Updates

Section 11 DC update companion (B, C & S series)
Firmware
Upgrades
• Barco DC package update:

- Projector software
- Touch panel software
• Enigma link decryptor software
• Integrated Cinema Processor (ICP) software

Firmware
Upgrades
How to launch
1.While in the Maintenance tab page,

tip on Software update (1).
2. Tip on Launch DC update
companion (2).
The DC update companion window
starts up (3).
3. Tip Next to continue (4).

Firmware
Upgrades
4. Read the licence agreement

and check accept. Tip Next
to continue.
5. Continue with the specific
procedure for each type of
package.

Firmware Projector or touch panel update

Upgrades How to update
1. Select package type. Click on the drop down box and select Barco DC Package.
2. Browse for the package file name. Click on Browse to open the Browser window.
3. Browse for the desired file, select the file and Click on OK.
4. To read the release notes, Click on Show Release Notes.
5. Enter the device IP address or Click on Browse to open a device selection window.
6. Select the desired IP address and Click Select.
7. Click Next to continue. The necessary information is gathered.
8. The current installed version is shown next to the package version.
9. Select the way the wizard will update the package. Click the desired radio button.
10.If automatically is selected the wizard gathered the information.
Then Click Next to start the update .
11.If custom update (for advanced users) is selected, the wizard starts collecting the information of
the different software modules.
12.Select the modules to update and Click Next to start the update.

Firmware The ICP board contains 2 slots to store software before this software can be installed.
Upgrades Therefore it is recommended to store the previous version of the software in a location and
the current version in the other. When a new update becomes available, overwrite always
the oldest version. These 2 loaded versions make it possible to switch on an easy way
between the current version and the previous one.
How to upgrade
- Select package type. Click on the drop down box and select ICP Package .
- Browse the package file name. Click on Browse to open the Browser window.
- Select the location where to find the package.
- Browse for the desired file, select the file and Click on OK.
- Enter the device IP address or Click on Browse to open a device selection window.
- Click Next to continue. The necessary information will be gathered.
- Select the way the wizard will update the package. Check the desired radio button.
- If automatically is selected the wizard will load the software in the oldest slot and
install the software immediately.
- If custom update (for advanced users) is selected, the wizard displays the selection
for slot A or slot B. Check the radio button of your choice and Click Next.
- The software will be loaded to the selected slot and will be installed immediately
- When the update is finished, a status window will be displayed.

Firmware
Link decryptor software update
Upgrades
How to update
- Select package type. Click on the drop down box and select Enigma Link Decryptor
Package.
- Browse the package file name. Click on Browse to open the Browser window.
- Select the location where to find the package.
- Browse for the desired file, select the file and Click on OK.
- Enter the device IP address or Click on Browse to open a device selection window.
Note: The IP of the connected projector is already filled out. When using the DC
Update Companion as stand alone program, then this field is blank.
- Click Next to continue. The necessary information is gathered.
- The current installed version is shown next to the package version.
- Click Next to start the software update.
When the update is finished, a status window will be displayed.

Section 11 DC update companion without using communicator.
Firmware Go to the Communicator directory and select “DcUpdateCompanion.exe” or start
Upgrades application via Start  Programs  Barco  Communicator

Section 11
Firmware Upgrades (B, C & S series)
Firmware
Upgrades
ICP Update Information
Phenomenon
1. The file system on the ICP board goes corrupt during normal use of the projector (if the
ICP firmware version is below 3.0).
2. While upgrading ICP’s to solve the specified problem above result sometimes in a non
operational ICP, an ICP with corrupt files, a failed upgrade.
Cause
1. Root cause of the problem is some critical timing in the ICP firmware that drives the Flash
Disk. The chance that the File System can go corrupt is in relation with the amount of
power cycles (projector switched OFF/ON) or reboots (software system reset) of the
projector. More cycles or reboots lead to a potential higher failure rate of the File System.
2. This problem is eliminated since ICP firmware version 3.0. However, the Flash Disk on the
ICP board with version below and till version 3.1 which is not upgraded according to this
Info-T, could have had corrupt files which were needed for the upgrade process. In such a
case, failing upgrades, non working ICP’s, ICP’s with corrupt files can be the result.

Section 11
Firmware
Upgrades

Section 11
DC update companion
Firmware
Upgrades
Enigma and ICP Update Information
 Important:
– Enigma link decryption or ICP update can be performed remotely, but hard
reset is required once the update is successful in case the update is done with
the TI Enigma and ICP update program.
– Updates must always be performed over Ethernet and not RS-232
– When performing TI Enigma link decryption and ICP update, do not restart
projector if update fails. Instead, try to reload update or load older version
– If the ICP is replaced, then a “re-install” of the ICP software is required!

Section 11
DC update companion – Command Line Interface
Firmware
Upgrades It is possible to use the “DC Update companion” software through a Shell
using the command line interface. The commands are supported on
Windows, Linux and Mac OS X platform.
The DcUpdateCompanion application resides in the root folder of the installed

Communicator application software.
On Windows :
Open the command prompt by starting “cmd.exe” and change directory to the
directory where resides the DcUpdateCompanion.exe binary.
On Linux/Mac OS X:
Open a shell (terminal window) and change directory to the directory where resides
the DcUpdate- Companion binary

Section 11
Firmware
Upgrades Starting an upgrade
Use the “-silent” argument in order to use the command line mode.
Extra arguments or needed in order to specify the update type.
Example 1 : Upgrade of package version 1.6.68 on Projector with IP address 10.192.32.68

DcUpdateCompanion.exe -silent -verbose -ip 10.192.32.68 –f R33023607_R_1_6_68.zip -type barco
Example 2 : Upgrade of package version 4.3.13 on DC Touch Panel with IP address 10.192.8.207
DcUpdateCompanion.exe -silent -verbose -ip 10.192.8.207 -f DCTPUPDATEPKG_D_4_3_13.zip -type barco
Example 3 : Upgrade of package version 2.2.291 on ICP device of Projector with IP address 10.192.32.68
DcUpdateCompanion.exe -silent -verbose -ip 10.192.32.68 -f Prod2.2.291.release -type icp

Section 11
Firmware Return values
Upgrades
The application will return an error code when it has finished. In order to check if the
upgrade has been done successfully, you can check on the resulted error code.
Arguments to use when executing an upgrade:
Log files
Log files are being created in the subfolder “log_updater” (created relatively from
where you start the commands).
All log files contain the serial number of the projector in the filename.
When an upgrade has failed, the filename starts with the “failed_” prefix.
Note: More examples of commands can be found in “Communicator User Guide – Command Line Interface”

Section 11
Firmware
Upgrades
Enigma and ICP Update Information “Info-t 1033”
LINK DECRYPTOR SECURITY LOG GETS FULL
Phenomenon
The following warning or error message from the link decryptor can occur:
• Code 5835: “TI-link-decryptor - security log is almost full” (Warning)
• Code 5836: “TI-link-decryptor - security log is full” (Error)
Cause
The root cause of these errors can have several reasons:
• Older versions than V1.6 for the Link decriptor software can create an internal error in
the log by storing log entries with a timestamp in the future. Since the server is not
able to clean the log entries in the future the log file will run full.
• Due to not correctly ending of the movie or due to insufficient waiting untill actions are
completely finished, the server does not clean up the log files
Solution
To prevent entries with timestamps in the future you have to upgrade the link decryptor software to 1.6 or
higher.
Correct usage to clean up the log files can be found in the "Doremi correct use", page 7

Section 11
Firmware
Upgrades
 Ensure no power disruptions during update
 Do not power down projector
 Always use latest version of DC update companion to run update
 If update is not taken then run update again or load older version
 If update is not accepted after all processes above, replace
applicable board (that which did not take the update)
– Communicator indications:
 If question marks (?) are reported in the “Version Info” button of the
Communicator, there is mismatched firmware versions
 If an asterisk (*) is located next to the version of firmware in the Communicator,
the projector is reporting incomplete software
 If version of firmware reports 0.0.0 then the device is unresponsive

Section 11
ICP & Enigma control program
Firmware
Upgrades
User ID and Password
User ID: Service

Password: Heal Thyself

Section 11 ACS-2048 Update
Firmware
Upgrades
1. Make an Ethernet connection
from ACS-2048 to your laptop.
2. Open a web browser on your
laptop and enter the IP address
of the ACS-2048.
3. Click the firmware upgrade link
to continue the upgrade process.
4. Click the browse button and
navigate to the folder on your PC
where you saved the package.
5. In the upload dialog, select the
ACS2048_##_##.tar.gz file.
6. If the upload was successful,
click Restart ACS-2048 to
complete the procedure.

Section 12
Error Course and Log Files
Code Solutions

Section 12 Service Manual Code Descriptions
Error Code
Solutions and
Log Files  For accurate up-to-date code descriptions, see the Service Manual or the Diagnostic
Companion
 Service manuals can be found on my.barco.com
 Find code description and use steps to identify solution
– Example: Code 5005: “lamp power supplies – communication failed” (Error)

Section 12 Log File Descriptions
Error Code
Solutions and
Log Files  Use diagnostics package to
save all log files to a zip file.
 The Diagnostics Package
Reader can be used to view
all information contained in
the package.
 The Diagnostics Package
Reader can be found in your
programs menu (in Windows)

Section 12 Log File Descriptions (continued)
Error Code
Solutions and
Log Files  ICP (TI) Log File — records the following events:
– TI system initialization
– Reading of TI board status
– Opening of TCP connection
– Failure of TI boards
 Security Log File — records the following events (only available via the Enigma
control program):
– Handshakes with server
– Monitoring of security switches
– Monitoring of key exchange
 Projector Log — records the following events:
– Lamp control commands
– Booting of Barco software
– Detection of TI boards
– Log on details of users
– Detection of Barco modules (LPS, FCB, etc.)
– Authorizing of security key

Section 12 DPxK Log File Analysis (continued)
Error Code Log Mark Messages

Solutions and
Log Files
 Every hour, the Cinema Controller inserts an unique entry in the Barco and TI log files. This
synchronizes events in both log files, when the clocks are not aligned.
 It is used to merge both log files, for better analysis by use of the Diagnostics reader.
– Feb 3 02:41:16 localhost local0.info dp60[233]: log mark - 00000076c752 - 14
 Each Barco entry into a TI log is proceeded with a B
 What does the identifier mean? (e.g., id:0000003c1b84 – 8)
– 003c1b84-8  the first 4 bytes give a hex interpretation of how many times the system has been
booted, 3c hex is 60 in decimal, it means this system has been booted 60 times. Every boot cycle
this timer is increased.
– 1b84  the last two bytes, are random unique 2 bytes.
– 8  the last digit indicates the number of hours passed in this boot cycle (in a decimal value).
Every boot cycle this number will be reset to 0.

Error Code Ethernet Communication Messages

Solutions and
Log Files
Apr 6 14:05:19 localhost local0.info dp60[233]: main - closing connection of 150.158.197.64:43680 (keep-alive time expired)
 after 15 minutes of inactivity projector will close connection.
Apr 6 14:08:55 localhost local0.info dp60[233]: main - accepted connection from 150.158.192.133:43680
 connection from communicator from pc with ip address 150.158.192.133
Apr 6 14:08:55 localhost local0.info dp60[233]: main - accepted connection from 150.158.192.133:43680
Apr 6 14:08:55 localhost local0.info dp60[233]: main - closing connection from 150.158.192.133:43680
Apr 6 14:08:58 localhost local0.info dp60[233]: log (port = 150.158.192.133:43680:1e) - logon-phmt-barco-default
 communicator inserts in log file, who did logon to projector
Apr 6 14:09:07 localhost local0.info dp60[233]: command (port = 150.158.192.133:43680:1e) - set lamp on
 Command messages also indicate originator.
Apr 6 14:09:07 localhost local0.info dp60[233]: system - load fcb file "lamp-on“
 set fan controller board on lamp-on state
Apr 6 14:09:20 localhost local0.info dp60[233]: command (port = 150.158.192.133:43680:1e) - set dowser open
Note
Bold annotations
are NOT in the log file

Error Code Command Messages (B & C series)

Solutions and
External commands received by the Cinema Controller are preceded with the command (port = xxx) string, where xxx can be:
Log Files
/dev/ttyS0:0 Command comes from the serial connection labeled (“RS232 IN").
This could be from an touch panel which is connected through a RS232 cable, or from a communicator which is connected serially.
/dev/ttyS1:0 Command comes from LPS – RS command
/dev/ttyS2:0 Command comes from a touch panel attached to dedicated cable on the back of the projector.
/dev/ttyS4:0 Command comes from the 3D interface
10.36.62.17:43680 Command comes from a remote machine with ip address, followed by the local of the remote machine
that send this command internal
button is triggered from the keypad, attached to the projector.
Examples:
command (port = /dev/ttyS2:0) - set network ip-address to 10.140.162.141 (dhcp off)

From the touch panel, the ip address of the projector was set to 10.140.162.141
command (port = 10.36.62.17:43680) - set network ip-address to 10.36.62.62 (dhcp off)
From a device on ip address 10.36.63.17, the ip address of the projector was changed to 10.36.62.62
command (port = /dev/ttyS0:0) - set dowser open
From a touch panel or PC, connected serially (connector labeled “RS232"), the dowser was set open.
command (port = /dev/ttyS0:0) - set lamp off
From a touch panel or PC, connected serially (connector labeled “RS232"), the lamp was powered off.
command (port = internal) - set lamp off
For an internal reason the state of the lamp was set off.
command (port = button) - set dowser closed
The dowser was closed from the keypad.
Barco Confidential Command (port=gpi) – command send via the GPI interface over the DB37 connector 245

Error Code Command Messages (S series)

Solutions and
Log Files External commands received by the Cinema Controller are preceded with the command (port = xxx) string, where xxx can be:
/dev/ttyPSC1:0 Command comes from the button panel
/dev/ttyPSC2:0 Command comes from the serial connection labeled (“RS232 IN").
This could be from an touch panel which is connected through a RS232 cable, or from a communicator which is connected serially.
/dev/ttyPSC3:0 Command comes from the light sensor module
/dev/ttyPSC4:0 Command comes from the 3D interface
/dev/ttyPSC6:0 Command comes from LPS – RS command
/dev/ttyPSC7:0 Command comes from a touch panel attached to dedicated cable on the back of the projector.
10.36.62.17:43680 Command comes from a remote machine with ip address, followed by the local of the remote machine that send this
command internal button is triggered from the keypad, attached to the projector.

Error Code Series 2 Specific Error Messages

Solutions and
ti-icp - icp board not detected - No ICP detected. ICP well connected ? Replace ICP.
Log Files
ti-icp - read system status failed - ICP not responding to system status command – Well connected ? Replace ICP
- Do you still have communication with ICP control program ?
ti-icp - key error - ICP replace ICP (Key: private key which is stored on enigma and ICP)
You can get the above errors when you did a software update with the TI update program without rebooting the projector
ti-icp - self test = fail - ICP self test @ startup – go to detailed ICP status on Communicator
- This can be even one of the formatters disconnected.
ti-icp - satellite firmware mismatch - ICP switched between DP2K-xxC, DP2K-xxS or DP2K-xxB platform.
Install “release software” from slot.
Note: A new ICP board contains satellite firmware of a B projector, when you install the board into a “C” or “S”
projector then you need to perform the same procedure
ti-icp - system status = fail - Go to detailed status ICP with Communicator.
ti-link-decryptor - logical marriage tamper event. -ICP – Link decryptor – not married
- initiate marriage through security key mechanism
Situation: When installing an ICP or enigma which was not married with the other board
ti-link-decryptor - physical marriage tamper event. -ICP – Link decryptor – marriage physically broken
-initiate marriage through security key mechanism
Situation: When you take out ICP or enigma
ti-link-decryptor - service door tamper event. - Service door tamper – clear service door tamper by security
key or Communicator.

Error Code Series 2 Specific Error Messages

Solutions and
ti-link-decryptor - no communication - Upgrade to latest Barco package
Log Files - Do you still have communication with Enigma control program ?
- consistent - Replace Link decryptor.
ti-link-decryptor - security log error
ti-link-decryptor - security log warning
ti-link-decryptor - system error - Go to detailed status Link decryptor with Communicator.
imb - logical marriage tamper event - ICP – Media block – not married – initiate marriage through security key
imb - physical marriage tamper event - ICP – Media block – marriage physically broken – initiate marriage
through security key mechanism
imb - service door tamper event - Service door tamper – clear service door tamper by security key or
Communicator.

Section 12 How-to read Log-files - introduction
Error Code  Diagnostic package includes most information you need

Solutions and – Controller logs
Log Files – ICP logs
– LPS logs, though limited
– General information of hardware/software installed
– Does NOT include Enigma logs & projector settings/macros
 Enigma logs
– Enigma logs can be extracted with the ICP & Enigma Control program. These logs are useful when
 Log full warnings are being investigated
 Certificate problems are reported
 Encrypted content issues are reported
 Various settings can be extracted in a clone package
– Try to make a clone package when there are issues with
 Image problems (colors, positions, sizes…), 2D or 3D, no image
 Macro execution problems
 The combination of a clone package, diagnostic package of every system (CCB, ICP,
IMB, Server, …) is mandatory for fault analysis!
– Detailed report/diagnostics of the DC Server
– Log File of DC Update Companion / ICP Update Recovery Tool
 Useful when the update/recovery fails
– Log File of Communicator
Barco Confidential  For e.g. useful when making/applying a clone package fails 249

Section 12 How-to read Log-files - continued
Error Code
Solutions and  Start with version information
Log Files – Check version installed during event of failure
 Are there any mismatches (indicated by a *)
 Are there any modules that returned 0.0.0
– typically indicates module (communication) failure
– Upgrade attempt will almost certainly fail
– Does error description match with known issues of this version?
 Use information in “release notes”, “knowledge base”, “info-T”…
 Understand Time information

– When projector boots, only ICP has up-to-date time information (RTC = Real Time Clock)
– Controller synchronizes time with ICP
 First logs messages with default time stamp (starting Dec 31 17:00:00)
– Fully running system has synchronized time meaning log information can be investigated side-by-
side
 ICP logs, Controller logs, LPS logs

Error Code  Example of time synchronization

Solutions and
Dec 31 17:00:13 localhost local0.info dp60[233]: main - ti-icp board detected
Log Files Dec 31 17:00:16 localhost local0.info dp60[233]: main - image media block "BARCO IMB R765534" detected
Dec 31 17:00:16 localhost local0.debug dp60[233]: main - use controller-based lamp info module (1st generation)
Dec 31 17:00:18 localhost local0.info dp60[233]: lamp power supplies - 2 lamp power supplies detected
Dec 31 17:00:18 localhost local0.info dp60[233]: network - lan ip-address is 192.168.254.242 (dhcp off)
Dec 31 17:00:18 localhost local0.info dp60[233]: command (port = internal) - set power on
Dec 31 17:00:18 localhost local0.info dp60[233]: system - load fcb file "operational"
Dec 31 17:00:18 localhost local0.info dp60[233]: ti-icp - wait until ready
Dec 31 17:00:44 localhost local0.info dp60[233]: system - synchronize date to 20110603142544
Jun 3 14:25:44 localhost local0.info dp60[233]: system - ti-link-decryptor login started...
Jun 3 14:26:01 localhost cron.warn crond[76]: time disparity of 21785545 minutes detected
Jun 3 14:26:10 localhost local0.info dp60[233]: system - ti-link-decryptor login successful
 Use time information

– To verify if problem is permanent or intermittent
 Ask yourself the question: Does it happen every time or not?
 Check logs for similar events and look if error is always present
– To verify the first action that may have led to the failure
 ! Be aware of drifting clocks over time. On-times of hundreds of hours will eventually make
clocks drift away (there is no re-synchronization) for seconds or even minutes.

Error Code  Use time information – continued

Solutions and – Example 1: two simultaneous actions
Log Files
907=Dec 31 17:01:16 localhost local0.info dp60[234]: ti-icp - wait until ready
2908=Dec 31 17:01:16 localhost local0.info dp60[234]: system - synchronize date to 20120513160109
2909=May 13 16:01:10 localhost local0.info dp60[234]: system - image media block login started...
2910=May 13 16:01:16 localhost local0.info dp60[234]: system - image media block login successful
2911=May 13 16:01:17 localhost local0.info dp60[234]: command (port = internal) - select light sensor calibration file 'flat'
2912=May 13 16:01:17 localhost local0.info dp60[234]: system - load lens encoder file "R9855958"
2913=May 13 16:01:17 localhost local0.info dp60[234]: system - lens file '.init' not found  lens couldn’t initialize, probably projector has been switched off
while lens was still performing adjustments
2914=May 13 16:01:17 localhost local0.info dp60[234]: system - lens home and return will be executed  Home and return starts
2915=May 13 16:01:17 localhost local0.info dp60[234]: command (port = internal) - set dowser closed
2916=May 13 16:01:18 localhost local0.info dp60[234]: ti-icp - type 0x41 detected
2917=May 13 16:01:20 localhost local0.info dp60[234]: command (port = event) - lens home and return
2918=May 13 16:01:20 localhost local0.info dp60[234]: log mark - 000000d5e1c8 - 0
2919=May 13 16:01:20 localhost local0.debug dp60[234]: system - use controller-based lamp info module (1st generation)
2920=May 13 16:01:23 localhost local0.debug dp60[234]: dvi 0x89=0x00c2 0x91-
0x9f=0x0085046504380896077e325c00310000000000000000a12b080008001315
2921=May 13 16:01:49 localhost local0.info dp60[234]: main - accepted connection from 10.142.246.75:43680
2922=May 13 16:01:49 localhost local0.info dp60[234]: command (port = 10.142.246.75:43680:29) - set lamp on
2923=May 13 16:01:49 localhost local0.info dp60[234]: system - load fcb file "lamp-on"
2924=May 13 16:01:54 localhost cron.warn crond[77]: time disparity of 22282440 minutes detected
2925=May 13 16:02:02 localhost local0.info dp60[234]: main - closing connection from 10.142.246.75:43680
2926=May 13 16:02:11 localhost local0.info dp60[234]: command (port = button) - execute macro 'FLAT'
2927=May 13 16:02:15 localhost local0.info dp60[234]: command (port = macro) - execute lens file 'flat'
2928=May 13 16:02:15 localhost local0.err dp60[234]: system - execute lens file "flat" failed  lens file can’t be activated because Home & return is running
2929=May 13 16:02:16 localhost local0.info dp60[234]: command (port = macro) - select light sensor calibration file 'flat'
2930=May 13 16:02:16 localhost local0.info dp60[234]: command (port = button) - set dowser open
Barco Confidential 2931=May 13 16:02:17 localhost local0.debug dp60[234]: dvi 0x89=0x0040 0x91-
252
0x9f=0x0085046504380896077e325c00310000000000000000dade080008001aa0

Section 12 How-to read Log-files – example 1 continued
Error Code 2932=May 13 16:02:18 localhost local0.info dp60[234]: command (port = button) - set dowser closed
2933=May 13 16:02:19 localhost local0.info dp60[234]: command (port = button) - set dowser open
Solutions and 2934=May 13 16:02:26 localhost local0.info dp60[234]: command (port = button) - execute macro 'FLAT'
Log Files 2935=May 13 16:02:30 localhost local0.info dp60[234]: command (port = macro) - execute lens file 'flat'
2936=May 13 16:02:30 localhost local0.err dp60[234]: system - execute lens file "flat" failed  They tried to activate preset again so also
a reactivation of the lensfile but “Home and return” is still in progress
2937=May 13 16:02:30 localhost local0.info dp60[234]: command (port = macro) - select light sensor calibration file 'flat'
2938=May 13 16:02:31 localhost local0.info dp60[234]: system - lens home and return finished  At this stage Home and return is
finished, this is the time when you can activate the preset
2939=May 13 16:02:32 localhost local0.debug dp60[234]: dvi 0x89=0x0040 0x91-
0x9f=0x0085046504380896077e325c003100000000000000007c01080008001b2a
2940=May 13 16:02:41 localhost local0.debug dp60[234]: lenspositions - file = ".init", z = +191, f = +16737920, v = +8387949, h =
+330
2941=May 13 16:02:41 localhost local0.debug dp60[234]: lenspositions - file = ".active", z = +191, f = +16737920, v = +8387949, h =
+330
...
2955=May 13 16:05:17 localhost local0.info dp60[234]: command (port = 10.142.246.75:43680:30) - execute macro 'FLAT'
2958=May 13 16:05:19 localhost local0.info dp60[234]: command (port = 10.142.246.75:43680:30) - set lamp on
2959=May 13 16:05:19 localhost local0.info dp60[234]: lamp - lamp is already on
2961=May 13 16:05:19 localhost local0.info dp60[234]: command (port = macro) - execute lens file 'flat'
2962=May 13 16:05:20 localhost local0.debug dp60[234]: lenspositions - file = ".active", z = +191, f = +16737920, v = +8387949, h =
+330
2963=May 13 16:05:20 localhost local0.debug dp60[234]: lenspositions - file = "flat", z = -199, f = +16741312, v = +8387938, h = -335
2964=May 13 16:05:20 localhost local0.info dp60[234]: system - execute lens file "flat" handled successfully

Section 12 How-to read Log-files - Time information, example 2: intermittent failure
Error Code 8129=Feb 1 10:40:07 localhost local0.info dp60[234]: command (port = internal) - set dowser closed
Solutions and 8130=Feb 1 10:40:08 localhost local0.info dp60[234]: ti-icp - type 0x41 detected
8131=Feb 1 10:40:10 localhost user.err kernel: i2c-algo-mpc5xxx.o: arbitration lost in xfer!  I²C failure because of dowser
Log Files command
8132=Feb 1 10:40:11 localhost local0.err dp60[234]: light sensor - no communication (#5003)  because of previous I²C error you
can’t read out the status of the light sensor
8133=Feb 1 10:40:12 localhost local0.info dp60[234]: main - accepted connection from 192.168.2.129:43680
8134=Feb 1 10:40:12 localhost local0.info dp60[234]: log mark - 00000091c752 - 0
8135=Feb 1 10:40:14 localhost local0.debug dp60[234]: dvi 0x89=0x00c3 0x91-
0x9f=0x0000000000000000000000000085046504380896077e3248080008000001
8136=Feb 1 10:40:14 localhost local0.debug dp60[234]: hd-sdi 0x83=0x0000 0x90-
0x9b=0x0081046504380abe08000fff0081046504380abe08000fff
8137=Feb 1 10:40:15 localhost user.err kernel: i2c-algo-mpc5xxx.o: arbitration lost in xfer!
…
Reboot
…
8429=Feb 1 10:50:48 localhost local0.info dp60[234]: command (port = button) - set dowser open
8430=Feb 1 10:51:10 localhost local0.info clo[214]: power - write 6425 (range = 4000 - 6500, lumens @ 5960 = 346, target
lumens = 400)
8431=Feb 1 10:51:25 localhost local0.info clo[214]: power - write 6500 (range = 4000 - 6500, lumens @ 6425 = 375, target
lumens = 400)
Solution:
 Update to latest Barco Firmware which fixes this I²C interference when performing such a command,
Barco Confidential in this case rebooting the unit solves it also 254

Section 12 How-to read Log-files – Example 3: lamp strike failure (LPS hardware failure)
Error Code
– Controller log
Solutions and 4563=Aug 21 10:57:15 localhost local0.info dp60[233]: log mark - 00000109c2f2 - 1
Log Files 4564=Aug 21 11:55:32 localhost local0.info dp60[233]: command (port = 192.168.1.129:43680:28) - set lamp on
4565=Aug 21 11:55:32 localhost local0.info dp60[233]: system - load fcb file "lamp-on"
4566=Aug 21 11:55:56 localhost local0.err dp60[233]: lamp - lamp on with error (one or more lamp power supplies failed to start up)
4567=Aug 21 11:55:58 localhost local0.info dp60[233]: command (port = 192.168.1.129:43680:28) - set dowser open
4568=Aug 21 11:56:00 localhost local0.info dp60[233]: command (port = 192.168.1.129:43680:28) - execute macro 'PLANO 3D'
4569=Aug 21 11:56:03 localhost local0.info dp60[233]: lamp power supplies - redundancy executed  LPS system is not running on full power
– LPS log
55=Aug 21 11:55:33 2011 localhost local0.info dp60[233]: lps[22] - Command received: trafo range high output
56=Aug 21 11:55:34 2011 localhost local0.info dp60[233]: lps[22] - Command received: power control
57=Aug 21 11:55:34 2011 localhost local0.info dp60[233]: lps[22] - Par: CPCC - P: 1500W - Ix: 60A - I: 60A - Vx: 35V
58=Aug 21 11:55:34 2011 localhost local0.info dp60[233]: lps[22] - Change: CPCC - P: 1500W - Ix: 60A - I: 60A - Vx: 35V
59=Aug 21 11:55:34 2011 localhost local0.info dp60[233]: lps[22] - Temperature heatsink 1 - no data available
60=Aug 21 11:55:34 2011 localhost local0.info dp60[233]: lps[22] - Temperature heatsink 2 - no data available
61=Aug 21 11:55:34 2011 localhost local0.info dp60[233]: lps[22] - Mains voltage - no data available
62=Aug 21 11:55:34 2011 localhost local0.info dp60[233]: lps[22] - Voltage +24V too low: 0.0 V  Power issue on LPS with adress “22”
63=Aug 21 11:55:34 2011 localhost local0.info dp60[233]: lps[22] - Limit(s) exceeded: switch-on command rejected
…
Solution: Replace faulty LPS, error LED will be active
- Controller Log
local host local0.err dp60[234]: lamp run time - exceeds maximum (#5657)  lamp is running over warranty runtime which can cause also lamp
strike failures
Solution: Replace lamp


Section 12 How-to read Log-files – Example 4: lamp strike failure (software failure)
Error Code
Solutions and
Log Files – LPS log
11=Nov 30 00:00:00 1999 localhost local0.info dp60[1085]: lps[22] - Starting software version: 01.01.003
12=Nov 30 00:00:07 1999 localhost local0.info dp60[1085]: lps[22] - Fan test completed successfully, all fans working
13=Nov 30 00:00:08 1999 localhost local0.info dp60[1085]: lps[22] - Primary microcontroller communication error
14=Nov 30 00:00:08 1999 localhost local0.info dp60[1085]: lps[22] - Primary microcontroller communication restored.
15=Sep 7 08:30:41 2012 localhost local0.info dp60[1085]: lps[22] - Date & time sync: 12/09/07 - 08:30:41
16=Sep 7 08:31:15 2012 localhost local0.info dp60[1085]: lps[22] - Limit(s) exceeded: switch-on command rejected
17=Sep 7 08:31:15 2012 localhost local0.info dp60[1085]: lps[22] - Ambient temperature: 26.6°C
18=Sep 7 08:31:15 2012 localhost local0.info dp60[1085]: lps[22] - Mains voltage: 299.7 V
19=Sep 7 08:31:31 2012 localhost local0.info dp60[1085]: lps[22] - Limit(s) exceeded: switch-on command rejected
20=Sep 7 08:31:31 2012 localhost local0.info dp60[1085]: lps[22] - Ambient temperature: 26.7°C
21=Sep 7 08:31:31 2012 localhost local0.info dp60[1085]: lps[22] - Mains voltage: 300.6 V…
Solution:
Update Barco firmware which fixes software bug in LPS FW 1.1.3 where the error “LPS internal error” is reported instead of the “LPS
mains input voltage too low / too high”, “LPS Failure Fan 1 / 2”, etc …
So it is important to read the LPS log file, was not necessary to replace the LPS module

Section 12 How-to read Log-files - Using time information
Error Code
Board swaps cannot be detected in logs (yet)
Solutions and
 There is no failsafe way to detect when a module has been replaced which makes interpretations of log entries
Log Files more difficult
 There are however a few tricks that can be used in order to better understand the system changes done
– Time information of sequential boots can be used to find (mis)matches
» Example: for every boot of the ICP, look for a boot of the Cinema Controller Board (CCB), LPS…
– Check on-times for mismatches to determine if a board has been swapped
» Example: a problematic ICP may reboot from itself and will not only have more boot counts, but
also lower on-times
Ignore some error-messages
 Example: Controller log reads ICP : system status failed error but the ICP logs show “installation commands” at
the same time
 Above shows 2 different scenarios on that time, in this case ICP board has been swapped
 Example: Controller log shows “lens – target not reached” errors, but the Home & Return function is still busy
 Before activating a preset wait always until Home & return is finished
 Example: Controller log reports a communication error, immediately followed by a boot. The error can probably
be ignored because there was a power failure
 No real problem, communication errors are caused by the reboot of the projector
General rule: Evaluate error messages in their time context!


Error Code  Understand projector hardware architecture to

Solutions and – Compare information of modules that are on the same system bus to easy finding the root cause of
Log Files failure
 I2C: Fan controller board, Light Sensor, lamp info module
 RS232: LPS, ICP, external interface
 Ethernet: Enigma/IMB/IMS, Debug LAN, external interface ,(ICP from outside)
– Link hardware faults that can give same type of errors
 Problem with security switches versus dallas key issue keypad
– Both may cause marriage to always fail
 Problem with end switches lens holder versus defect lens
– Both may cause Home & Return to always fail
– Eg. When B-series unit has extreme physical tilt then this might cause problems to
reach the end switch of the vertical shift

Section 12 How-to read Log-files – Example 5: lost lens files
Error Code – Customer complaints the lens files suddenly got lost
– Software architecture
Solutions and
 Initialization lens file is loaded at boot
Log Files – If it does not exist, Home & Return is automatically executed
 Lens files can be changed/saved/executed
– Saving a lens file is not realtime (buffering,…)
Oct 19 10:06:31 localhost local0.info dp60[233]: command (port = button) - execute macro 'PRESHOW_FLAT'
Oct 19 10:06:33 localhost local0.info dp60[233]: command (port = macro) - execute lens file 'flat'
Oct 19 10:06:33 localhost local0.debug dp60[233]: lenspositions - file = ".active", z = +26041, f = +16724416, v = -8388208, h =
+8384963
Oct 19 10:06:33 localhost local0.debug dp60[233]: lenspositions - file = "flat", z = +26041, f = +16724416, v = -8388208, h =
+8384963
Oct 19 10:06:33 localhost local0.info dp60[233]: system - execute lens file "flat" handled successfully
Oct 19 10:06:33 localhost local0.info dp60[233]: command (port = macro) - select light sensor calibration file 'flat'
Oct 19 10:06:36 localhost local0.debug dp60[233]: dvi 0x89=0x00c2 0x91-
0x9f=0x0085046504380896077e324700310000000000000000cc69080008000fa7
Dec 31 17:00:08 localhost syslog.info syslogd started: BusyBox v1.2.2 <- REBOOT
…
Oct 19 10:10:04 localhost local0.info dp60[233]: system - load lens encoder file "R9855943"
Oct 19 10:10:05 localhost local0.info dp60[233]: system - lens file '.init' not found
Oct 19 10:10:05 localhost local0.info dp60[233]: system - lens home and return will be executed
Oct 19 10:10:08 localhost local0.info dp60[233]: command (port = event) - lens home and return
...
Oct 19 10:11:16 localhost local0.err dp60[233]: system - lens home and return finished (failed stage 3)
Oct 19 10:11:17 localhost local0.info dp60[233]: main - accepted connection from 10.142.34.35:43680

Section 12 How-to read Log-files – Example 5
Error Code  Root cause

Solutions and – Customer executes a lens file, successfully
– Customer power cycles projector shortly after command
Log Files
 .init file for lens is not written to non volatile memory yet
– Next boot, .init file is not found and H & R is executed
 Home & Return fails and lens initialization is not complete
 Lens is not useable until Home & Return succeeds
 Additional risks
– Most customers are not aware of this automatic H & R
 Further messes up system in order to understand issue by continuously trying to create new lens files…
– When power is lost during the actual writing of the .init file it may get corrupted
 Best practice is not to power cycle projector immediately following macro’s/upgrades/…

– Difficult to explain / educate operator/projectionist
 Fixed in the S series

– After power is removed, clean shutdown can be done . (3 seconds of power left)
– Same fix is not possible on B & C series

Section 12 How-to read Log-files - Lamp on failure
Error Code
Solutions and – Hardware architecture
Log Files  i2c communication to fan controller and lamp info module
 RS communication to LPS unit(s)
 Lamp strike & FAN’s turning on generate huge field of interference
– Software architecture
 Receive lamp-on command
 Check lamp info module
 Load fan controller profile
 Send lamp-on command to LPS unit(s)
 10 seconds dead time
 Check LPS error flags
– Leave lamp on or report error + switch off lamp
Use this knowledge on the next example

Section 12 How-to read Log-files – Example 6: Lamp on failure
Error Code
localhost local0.info dp60[233]: command (port = 10.141.154.66:43680:27) - set lamp on
Solutions and
localhost local0.info dp60[233]: system - load fcb file "lamp-on"
Log Files localhost user.err kernel: i2c-algo-mpc5xxx.o: Timeout waiting for Bus Busy  I²C bus error
localhost local0.debug dp60[233]: i2c - message 0 failed with EIO (slave address = 0x2e)
localhost local0.debug dp60[233]: i2c - message 1 failed with EIO (slave address = 0x2e)
localhost local0.err dp60[233]: lamp - lamp on failed (no or invalid lim data)  Data from Lamp Info Module can’t be retrieved
localhost local0.info dp60[233]: system - load fcb file "aftercool"
localhost local0.info dp60[233]: main - accepted connection from 10.141.154.66:43680
localhost local0.info dp60[233]: main - closing connection from 10.141.154.66:43680
localhost local0.info dp60[233]: command (port = 10.141.154.66:43680:29) - set dowser open
– Investigation
 Lamp on command received – main program is running
 Fan controller profile command sent
 i2c bus error !
 Error message: Lamp on failed (no or invalid lim data)
– Main program could not retrieve information from lamp info module
» Lamp is not on because of software step failure
» No need to look at LPS logs and/or lamp
– Typical actions taken
 FW upgrade even though there is nothing in the release notes about this
 LPS swap even though it will show no error
 controller swap even though problem is intermittent
– Solution
 No HW or SW issue,
Barco Confidential  Reboot unit as this is a random failure because of an I²C bus failure 262

Section 12 How-to read Log-files – Example 7: Corrupt controller
Error Code
Solutions and 2 examles of logs indicating corrupt files on controller
Log Files
Dec 31 17:00:07 localhost user.warn kernel: eth0: Phy @ 0x0, type LXT971 (0x001378e2)
Dec 31 17:00:07 localhost cron.notice crond[76]: crond 2.3.2 dillon, started, log level 9
Dec 31 17:00:07 localhost authpriv.info dropbear[87]: Running in background
Dec 31 17:00:07 localhost daemon.notice proftpd[88]: localhost - ProFTPD 1.3.0a (stable) (built Thu Aug 20 08:55:24 CEST 2009) standalone mode STARTUP
Dec 31 17:00:08 localhost user.info kernel: i2c-dev.o: i2c /dev entries driver module version 2.6.1 (20010830)
Dec 31 17:00:08 localhost user.debug kernel: i2c-core.o: driver i2c-dev dummy driver registered.
Dec 31 17:00:08 localhost user.debug kernel: i2c-dev.o: Registered 'Icecube I2C module #1 interface' as minor 0
Dec 31 17:00:08 localhost user.debug kernel: i2c-core.o: adapter Icecube I2C module #1 interface registered as adapter 0.
Dec 31 17:00:08 localhost user.info kernel: i2c-icecube.o: I2C module #1 installed
Dec 31 17:00:08 localhost user.debug kernel: i2c-dev.o: Registered 'Icecube I2C module #2 interface' as minor 1
Dec 31 17:00:08 localhost user.debug kernel: i2c-core.o: adapter Icecube I2C module #2 interface registered as adapter 1.
Dec 31 17:00:08 localhost user.info kernel: i2c-icecube.o: I2C module #2 installed
Dec 31 17:00:08 localhost user.info kernel: i2c-proc.o version 2.6.1 (20010830)
Dec 31 17:00:09 localhost user.warn kernel: Data CRC 6c9643c2 != calculated CRC 3b69ad8f for node at 00463700
Dec 31 17:00:12 localhost local0.info clo[206]: main - starting application (version 1.4.5)
Dec 31 17:00:12 localhost local0.info router[216]: main - starting application (version 1.0.1)
Dec 31 17:00:12 localhost local0.info license-manager[213]: main - starting application (version 1.0.1)
Dec 31 17:00:12 localhost local0.info router[222]: network – wan ip-address is 192.168.100.2

Section 12 How-to read Log-files – Example 7: Corrupt Controller (continued)
Error Code
Solutions and Dec 31 17:00:08 localhost user.info kernel: IP Protocols: ICMP, UDP, TCP
Dec 31 17:00:08 localhost user.info kernel: IP: routing cache hash table of 512 buckets, 4Kbytes
Log Files Dec 31 17:00:08 localhost user.info kernel: TCP: Hash tables configured (established 4096 bind 8192)
Dec 31 17:00:08 localhost user.info kernel: NET4: Unix domain sockets 1.0/SMP for Linux NET4.0.
Dec 31 17:00:08 localhost user.notice kernel: jffs2_scan_eraseblock(): Node at 0x0060f5a0 {0x1985, 0xea6b, 0x00008184) has invalid CRC
0x3f8be08e (calculated 0x28aa7fde)
Dec 31 17:00:08 localhost user.notice kernel: jffs2_scan_eraseblock(): Magic bitmask 0x1985 not found at 0x0060f5a8: 0x3f8b instead
Dec 31 17:00:08 localhost user.notice kernel: jffs2_scan_eraseblock(): Magic bitmask 0x1985 not found at 0x0060f5ac: 0x0001 instead
Dec 31 17:00:08 localhost user.notice kernel: jffs2_scan_eraseblock(): Magic bitmask 0x1985 not found at 0x0060f5bc: 0x0001 instead
Dec 31 17:00:08 localhost user.warn kernel: VFS: Mounted root (jffs2 filesystem).
Dec 31 17:00:08 localhost user.info kernel: Freeing unused kernel memory: 72k init
Dec 31 17:00:08 localhost user.warn kernel: Warning: unable to open an initial console.
Dec 31 17:00:08 localhost user.warn kernel: eth0: Phy @ 0x0, type LXT971 (0x001378e2)
Dec 31 17:00:08 localhost cron.notice crond[77]: crond 2.3.2 dillon, started, log level 9
- Root cause: file corruption on the controller,

– Solution: replace cinema controller
– Risks & difficulties
 Logs are not endless, CRC error from the past may not be visible anymore
 It is not correct to assume there will be a file corrupted when such error is detected in the logs. It is only an
indicator
 Random files may get corrupted resulting in random failure modes
 If software upgrade works, it will only fix very few cases
 Fixed on S series

Section 12 How-to read Log-files – Example 8 : How-to find upgrade information
Error Code
Solutions and
 Example: How-to find upgrade information
Log Files – Look for install scripts, install package logs
May 12 17:01:57 localhost daemon.info proftpd[251]: localhost (192.168.31.65[192.168.31.65]) - FTP session opened.
May 12 17:01:57 localhost authpriv.notice proftpd[251]: localhost (192.168.31.65[192.168.31.65]) - USER upgrade: Login
successful.
May 12 17:02:01 localhost authpriv.info dropbear[260]: Child connection from 192.168.31.65:64141
May 12 17:02:02 localhost authpriv.notice dropbear[260]: password auth succeeded for 'root' from 192.168.31.65:64141
May 12 17:02:03 localhost user.info root: install - install package "55-dp60-1.5.44.tar.gz"
May 12 17:02:18 localhost user.err root: install - install package "55-dp60-1.5.44.tar.gz" failed (7)
May 12 17:02:23 localhost user.info root: install - install package "55-readprofile-1.1.2.tar.gz"
May 12 17:02:24 localhost user.info root: install - install package "55-readprofile-1.1.2.tar.gz" successful
May 12 17:02:27 localhost user.info root: install - install package "56-snmpagent-2.3.1.tar.gz"
May 12 17:03:46 localhost user.info root: install - install package "56-snmpagent-2.3.1.tar.gz" successful
May 12 17:03:49 localhost authpriv.info dropbear[370]: Child connection from 192.168.31.65:64241
Hint: when investigating issues look if there has been a software upgrade done
 If yes, compare behavior before & after
– Did it start after upgrade? Did it get worse or improve?
 Check release notes if something changed matching the complaint

Section 12 How-to read Log-files – Example 9: How-to find an ICP update in controller logs
This is not a 100% failsafe way but sometimes you want to know if the customer installed a new ICP version.
Error Code 6201=Nov
The example below shows a typical log when this happened
15 11:03:25 localhost local0.info dp60[234]: main - accepted connection from 10.66.73.132:43680
Solutions and 6202=Nov 15 11:09:33 localhost local0.err dp60[234]: ti-icp - execute ti command 0x04 0x62 0x00 failed
Log Files 6203=Nov

6206=Nov
15
15
11:10:56
11:16:38
localhost
localhost
local0.err dp60[234]: ti-icp - execute ti command 0x04 0x11 0x00 failed…
local0.err dp60[234]: ti-icp - execute ti command 0x04 0x9b 0x00 failed
6207=Nov 15 11:16:56 localhost local0.info dp60[234]: ti-icp - read system status ok (#0)
6208=Nov 15 11:16:56 localhost local0.info dp60[234]: ti-icp - system status = ok (#0)
6209=Nov 15 11:16:56 localhost local0.debug dp60[234]: ti-icp - self test = ok (#0)
6210=Nov 15 11:16:56 localhost local0.info dp60[234]: ti-icp - certificate error solved (#0)
…
6218=Nov 15 11:27:36 localhost local0.info dp60[234]: ti-icp - key error solved (#0)
6219=Nov 15 11:27:41 localhost local0.err dp60[234]: ti-icp - certificate eror (#5815)
6220=Nov 15 11:28:41 localhost local0.err dp60[234]: ti-icp - read system status failed (#5807)
6221=Nov 15 11:29:02 localhost local0.info dp60[234]: ti-icp - read system status ok (#0)
6222=Nov 15 11:29:02 localhost local0.info dp60[234]: ti-icp - system status = ok (#0)
6223=Nov 15 11:29:02 localhost local0.debug dp60[234]: ti-icp - self test = ok (#0)
6224=Nov 15 11:29:02 localhost local0.info dp60[234]: ti-icp - certificate error solved (#0)
6225=Nov 15 11:29:02 localhost local0.info dp60[234]: ti-icp - key error solved (#0)
6227=Nov 15 11:29:39 localhost local0.info dp60[234]: command (port = 10.66.73.132:43680:32) - restart all
In the ICP logs the update looks like the example below:
User 'Service' of group 'Service' logged into External
Executing /TI/bin/LoadCommand >> /tmp/other
Install thread for application init
Executing /TI/bin/VerifyCommand >> /tmp/other
INSTALL: Load State Successful. Starting Install.
Executing /TI/bin/InstallCommand >> /tmp/other
ICP application 4.1(432) init
Solution: Always perform a reboot after a TI update,

via DC Update companion this goes automatically but not via ICP control Program!

Section 12 How-to read Log-files – Example 10: Missing subtitles
Two types of problems:
Error Code
Solutions and – Type A: file problems
Log Files  Subtitle_Manager_Verify_File--Unable to retrieve file size from server
 SubtitleError--File not found: http://10.86.52.42/subtitles/subtitle337/arial.ttf
 SubtitleManager--begin loading subtitle file /repository/secondary/5bd7e1ee-6e06-46aa-a8d0-
 056946810857/Blitz0513_R5_38.png.
 SubtitleManager--Unable to retrieve file http://192.168.100.20/repository/secondary/5bd7e1ee-
 6e06-46aa-a8d0-056946810857/Blitz0513_R5_38.png; will try again.
 SubtitleError--File not found: http://192.168.100.20/repository/secondary/5bd7e1ee-6e06-46aaa8d0-
056946810857/Blitz0513_R5_38.png
– Type B: XML errors, parsing errors, font errors
 XML Parse: ERROR on line 69 , column 113
 XML Parse: Error string = parsing aborted
 XML Parse: Error Info string = Bad Subtitle Failure
 XML Parse: Parser returned with error.The error occured in: /subtitles/subtitle5/92ee4830-254e-4776-b65b-
7e73e62279f8_sub.xml
 SubtitleError--Subtitle-XML Parsing Error
 Subtitle_Render_Thread--DisplayRenderedText FontFusion status: 4
 Subtitle_Render_Thread--DisplayRenderedText FontFusion interrupted by Subtitle Disable
Type A: potentially firmware related, fixed in FW 1.9.95
Type B: in many cases caused by bad DCP: the film studio needs to be contacted.
Potentially also caused by ICP FW or server issue.

Section 12 How-to read Log-files – Example 11: Enigma Log full warning
Error Code – Bug in Enigma 1.4 causes log entries with invalid date code
Solutions and – The block of memory containing this log cannot be erased and causes the log full problem
Log Files – Enigma 1.6 does not have this issue anymore BUT installing 1.6 on an already
contaminated 1.4 will NOT fix the issue!
 Even if there is no log (almost) full warning yet!
How to know the log is contaminated?

- Use ICP & Enigma Control program v1,02 (119)
- Connect to Enigma and display security log
- Look at the 2 bottom lines
-There should not be any date code older than the
Installation date of the Enigma and/or a
future date
Eg.: It would have been faulty if the log was

taken on the 10th of November which means
that the newest entry is more recent then the
actual date.

Section 12 How-to read Log-files – Example 11: Enigma Log full warning - continued
Error Code
Solutions and – What are the steps taken for adding/removing logs
Log Files  Every action that involves adding/playing/checking encrypted content must be logged in the
enigma (IMB)
 The server can only READ the logs on the Enigma (traceability)
 The enigma itself is responsible for CLEARING the logs that are READ
– Can only clear in sectors of 512 logs
 DCI rules say only the oldest logs may be removed to free up space
– Why this complex log mechanism
 To prevent copying of encrypted movies & traceability of actions
– What has been done to prevent this log full issues
 Server manufacturers improved their FW to be able to cover the full range of date logs.
– Note that the ICP & Enigma control program is limited to 0xFFCE.42CE in seconds and
cannot retrieve all logs
 Server manufacturers also added log purging (full range) at boot. Drawback is that this takes
time (enigma is slow!), but at least decreases the chance of a lost show.
– Upcoming Enigma 1.7
 Adds a ASM (Auditorium Security Messages) command to return only the UNREAD logs
– This speeds up the reading/clearing since not all ~8192 logs need to be transferred.

Section 12 How-to read Log-files – Example 11: Enigma Log full warning - continued
Error Code
Solutions and  Did you know Enigma log full problems are sometimes caused by the server or TMS
Log Files  The figure below shows a field case where a (temporarily) malfunctioning module adds too many logs in
a short time
– All logs at the peak originate from same deviceConnected ID
 Unfortunately the server and ICP logs do not contain the loggings at that timestamp anymore.
 In general, this example shows the importance of gathering ALL logs immediate
after the issue occurred to do root cause analysis.

Section 12 ICP – Board Connection Issues
Error Code  Fact: ICP board may suffer from bad connections
Solutions and - Soldering of the PCI connectors on backplane has some level of freedom in alignment
Log Files - We have seen some variations in PCI board thickness
- We’ve heard of several issues where ICP board was not connected well into Elcabox
Customers forget sometimes to lock it completely
 Result: (intermittent) image corruption occurs
- Color overlay
- Horizontal lines
- Corrupted image
 Difficulties
- Formatter failure also causes horizontal lines
- Wrong ICP settings also causes color overlay
- Bad LVDS cable connection also causes corrupted images
- Bad FMT FPGA (=chip on ICP board controlling the LVDS lines towards the formatters) soldering
causes same effects
 Indications of connection issue
ICP signature test failures (intermittent)
 14.09.2011 09:30:19.133 Signature Test Fail. Good data (LS byte first) is:
 14.09.2011 09:30:19.133 47 c7 6f c2 b7 79 12 d7 Green
 14.09.2011 09:30:19.134 47 c7 6f c2 b7 79 12 d7 Red
 14.09.2011 09:30:19.134 47 c7 6f c2 b7 79 12 d7 Blue
 14.09.2011 09:30:19.134 Signature Test Fail. Bad data (LS byte first) is:
 14.09.2011 09:30:19.134 47 c7 6f c2 b7 79 12 d7 Green
 14.09.2011 09:30:19.134 00 00 00 00 00 00 00 00 Red  No communication towards the Red formatter
 14.09.2011 09:30:19.134 47 c7 6f c2 b7 79 12 d7 Blue

Section 12 High Frame Rate
Error Code
Solutions and  Dynamic reconfiguration of IMB
Log Files – When HFR clip/movie is about to start after non-HFR content the IMB firmware
needs to be changed
 Causes temporarily communication loss (restart IMB)
 Causes temporarily red taillight
 After reconfiguration IMB sends command for restoring communication
 Taillight turns green again, communication restored
– When the process fails, logs could look like this

Nov 14 10:07:43 localhost local0.info dp60[236]: command (port = imb) - image media block logout
Nov 14 10:07:43 localhost local0.err dp60[236]: system - image media block logout failure
Nov 14 10:07:43 localhost local0.info dp60[236]: command (port = imb) - close image media block connection
Nov 14 10:08:29 localhost local0.info dp60[236]: command (port = internal) - open image media block connection
Nov 14 10:08:29 localhost local0.crit dp60[236]: system - open image media block connection failed (no communication to image
media block possible)
Nov 14 10:08:29 localhost local0.debug dp60[236]: system - socketfile2.open failed (no communication to image media block
possible)
Be aware that even with this kind of RED taillight (error : IMB - no communication)
the show will still play correctly!
 Reason is that the external interface (server – IMB) will be functional

Section 13

Special Features

Section 13 Communicator Lite (S-series)
Special
Features
Top navigation
bar
Home page:
welcome
message,
device info,…
Module
overview
Username: projectionist
Barco Confidential Password: default 274

Section 13 Communicator Lite (S-series) - Application overview
Special
– Home page:
Features
 Shows platform information
 Shows current user login status
 Links to the different modules
– Settings page
 Language selection
 Theme selection
– About page
 Shows projector information, also certificate
and license status
 Shows version information
– Module pages:
 Control
 Diagnosis
 Maintenance

Section 13 Communicator Lite (S-series) - “Control” module
Special
 Projector control
Features
– Lamp on/off
– Presets
 Test patterns
– Buttons
– Select other from file
 Lens control
– Shift
– Zoom
– Focus
 Light output:
– manual/CLO
– Measured footlambert
– Lamp power and current
 Standby mode

Section 13
Communicator Lite (S-series) - “Diagnostics” module
Special
Features
 Actual status => Icon in status
panel
 Log
– Log file Barco projector
 Version info
– Versions Barco modules, ICP, Enigma
 Device info:
– Device name, serial number, etc.
 Monitoring:
– Temperature
– Fan speeds
– Voltages

Section 13
Communicator Lite (S-series) - “Maintenance” module
Special
Features
 Smart maintenance
– Confirm Maintenance Type A,B,C,D
 Lamp maintenance
– Info lamp
– Change lamp:
 From history
 From new list
 Lens maintenance
– Change lens: select type of lens
– Home lens with last ‘home and return’
information

Section 13 Change Touch Panel Logo
Special
Features  The custom logo in the left top corner can be
changed by a user with service technician
rights. The new logo can be selected from the
predefined list, or via USB stick connected to
the Touch Panel
 Touch Panel software provides an area of 90 x
90 pixels. Any image larger than that will be
scaled to match the area
 The file must be a bitmap (.bmp, .jpeg, .jpg,
.png, etc.)
 To change the logo, ensure that you are logged
in as a service technician:
1. Press and hold for more than 2 seconds on the
current logo (1)
2. The “Open Icon File” window opens (2).
3. Select Touch Panel or USB (3).
4. Browse to the desired file, press to select (4).
5. Press OK (5) to load the new logo in the upper
left corner of the Touch Panel (6).

Section 13 Control Server Via VNC
Special
Features
 With server control, you can remotely control a
server via VNC. Version 3.3 of VNC protocol is used.
 Once a connection is made, the Configuration and
Control pane shows the server’s current active screen
in a 640 x 480 window.
 You can now control the server via the Touch Panel.
All server functions available.
 To start up:
1. In the Control Menu, press Server.
2. If there was no previous connection, the Server
overview window is displayed.
3. If there was a previous connection during this session,
server content will be displayed.
4. To display the connection properties, first disconnect.
5. Press Connection properties. The VNC viewer
Connection window opens.
6. When a DNS server is available, enter the host name
of the server.
7. When no DNS server is available, enter the IP address
of the server. That address contains 4 octets with a
maximum value of 255 and separated by a dot (.)

Section 13 Control Server Via VNC (continued)
Special
Features  Display or port
– Using Display
 If connecting to a Windows or Mac server, the display
number must be 0 (zero)
 If connecting to a Linux or Unix server, the number of the
display must be specified.
– Using Port
 By default, the VNC client connects to a VNC server on
TCP/IP port 5900. If another port must be used, enable the
Use as port and enter the port number.
 Password
– If the VNC server is installed with a password, enter this
word next to Password. An asterisk is printed for each
entered character.
– When the check box next to Show Password is checked,
all characters are displayed as typed.
 Note the following settings:
– Doremi server
 Use as port (Port number 5900)
 Default password: adminvnc
– GDC server
 Use as Port
 Default password: gdcvnc
 Use as Display
Barco Confidential  Display number = 0 281

Section 13 User Access Settings - Reset default settings
Special
Features
 What is possible?
– When the access settings were changed, it is
possible to return to the default settings by
pressing Reset to Default Settings
 To reset:
1. Go to “Service Technician” mode
2. Select Touch panel
3. Select User
4. Highlight the users
5. While Shift key is pressed, double-click in the
gray area next to the User icon. The “User
Access Settings” window opens.
6. Press Reset to Default Settings.
7. A restart message opens. Before the default user
settings are applied, the application should be
restarted.
8. To restart the application, press Yes.

Section 13 User Access Settings (continued)
Special
Features  You can define what each type of user can do with the Touch Panel, such as different settings
for users and service technicians.
 Setup is performed in a user management XML file which can be edited externally, then
uploaded via “Load custom settings.” Each item can have a “Read,” “Read/Write,” or both
attributes. This attribute can be 50, 100 or 150. The value defines the access level.
– 50 default user access level
– 100 theatre technician access level
– 150 service technician access level
 When an attribute is set to 50, the default user, theatre technician and service technician
have access. When set to 150, only the service technician has access. The higher the value,
the less people with access rights.
 The default access file is given below. This file can be used as starting point to create your
own file.
 Copy and paste the file below in an XML editor or notepad and edit the file. Only the lines
which are different to the current setting should be included in the file.
 When finished, save the file on a USB stick or upload it on the Touch Panel so that it can be
loaded as new settings.
NOTE: The original XML file (user_accessmanagement.xml) can be found in the

folder where the Communicator is stored

Special
Features
Settings that can be modified
– Control related
– Configuration related
– Diagnostics related
– Diagnostics companion related
– Installation related
– Maintenance related
– Touchpanel related

Special
Features  Load Custom settings
 What can be done?
 The externally created user access definition
file can be loaded as new settings.
 To load:
1. Go to “Service Technician” mode
2. Select Touch panel
3. Select User
4. Highlight the users
5. While Shift key is pressed, double-click in the
gray area next to User (1). The User Access
settings window opens.
6. Press Upload New Setting File (2). The
“Open User Access File” window opens (3).
7. Press the storage location at the left side (4a)
[Touch Panel or USB storage], or press the
drop down box and select the storage location
(4b).
8. Select the desired file (5).
9. Press OK (6). A restart message opens.
Before the new user settings are applied, the
application should be restarted.
10.Press Yes to restart the application (7).

Section 14

Scheduled Maintenance

Section 14 Maintenance by an Operator (B, C & S series)
Scheduled
Maintenance
–When the taillight becomes blue

Section 14
Maintenance by an Operator (B & C series)
Scheduled
Maintenance Filter cleaning (info-t 1027)
In some conditions the metal mesh filters on the projectors are sticky and are getting
clogged by dust and grease. Because of the grease the cleaning methods with a vacuum
cleaner or compressed air is no longer sufficient.
Cleaning procedure
Necessary tools
• Bucket with hotwater.
• Sodium carbonate, 30 gram (handful) per liter hot water.
• Soft brush or cloth.
• Compressed air.
How to clean metal mesh filters?
1.Make a solution with a ratio of 30 gram (a handful) sodium carbonate to 1 liter hot water.
2.Soak the metal mesh filters in the solution for 30 to 60 minutes. The grease should be
dissolved after 1 hour.
3. If there is still grease present after that 1 hour remove it by gently wiping off the grease
from the metal mesh filter. Use a soft brush or cloth.
Caution:Do not damage the metal mesh filter while wiping off the grease!
4. If the metal mesh filter is still clogged repeat this procedure from step 1.
5. Rinse the metal mesh filter with clean water to flush all grease residue away.
6.Dry the metal mesh filter with compressed air. Ensure that the metal mesh filter is clean
and dry.

Section 14
Maintenance by an Operator (S-series)
Scheduled About filter washing and drying
Maintenance For environments where popcorn grease and such can contaminate the filters, Barco advises the client to
purchase one extra sets of filters to cover drying time, as well as taking following extra precautions and
instructions pertaining to filter cleaning and drying.
Cleansing agent
To clean sticky, greasy dust filters we suggest usage of Sodium carbonate crystals (Na2CO3). Sodium
carbonate (Often called washing soda, soda crystals, or sal soda in the detergent section of stores) is
widely used to effectively remove oil, grease, alcohol stains … The product itself is relatively safe, sodium
carbonate is used in toothpastes and as a food additive (E500).
Necessary tools
• Bucket with hot water.
• Sodium carbonate, 30 gram (handful) per liter hot water.
How to wash and dry the dust filters?
1. Make a solution with a ratio of 30 gram (a handful) sodium carbonate to 1 liter hot water.
2. Soak the dust filters in the solution for 30 to 60 minutes. The grease should be dissolved after 1 hour.
3. If the dust filter is still clogged repeat this procedure from step 1.
4. Rinse the dust filters with clean water to flush all grease residue away.
5. Shake out all excess liquid by repeatedly swinging the filter to-and-fro in a centrifugal action.
6. Then allow the filters to dry thoroughly. Typically this can take up to 24h and more, depending on the
drying conditions.
Note: Drying time of the dust filters can be up to 24h or more. Drying time can be shorter when being done in
a well-ventilated area.
Barco Confidential Tip: To speed-up drying, allow the filter(s) to dry at 50°C max in a well ventilated room. 289

Section 14
Maintenance by an Operator (B, C & S series)
Scheduled When the taillight becomes blue
Maintenance

Section 14 Maintenance by a Certified Service Technician (B, C & S series)
Scheduled When the taillight becomes blue

Maintenance
 Interval: 1 year
– Perform all operator duties
– Replace cooling liquid
– Firmware updates if needed
– File system backup (clone)
– Check / clean reflector
– Check color accuracy
– Check power cables/connections inspect for damage
– When needed:
 Clean the UV blocker (= UV filter)
 Clean cold mirror
 Clean filters

Scheduled
Maintenance
 Interval: 1 year
– Visually inspect lamp house and all lamp connections
– Remove LPS and vacuum, then blow out with dry air
– Vacuum all internal fans and air intakes
– Clean all projector covers
– Vacuum LPS compartment and intakes
– Inspect Prism exit for optical problems and clean
– Backup log files and certificate
– Verify correct date and time
– Perform all latest Info-T’s when needed
– Calibrate CLO sensor (LSC files)
– Check site extraction system for proper airflow
Refer to Barco service manual for latest maintenance duties


Scheduled
Lamp change maintenance actions
Maintenance
 Interval: at each lamp replacement

– Check the UV blocker of the Lamp House for dust.
– Check the Reflector of the Lamp House for dust.
– Visual inspection of the lamp anode and cathode connectors of the Lamp House.
– Visual inspection of the lamp anode and cathode cables of the Lamp House.
– Check if all cables are still tightened.

Section 14
Cleaning Optics
Scheduled
Maintenance
 Cleanable Optics:
– Cold Mirror
– DMD Prism Exit Window
– UV Blocker
– Reflector
– Lens
 Optical Cleaning Procedure:
– Wipe dust off device with a Torayse cloth or a soft lens cloth. Only wipe in
one direction
– If device is still dirty, dampen the cloth with Demineralized water and wipe
surface
– If device is still dirty (e.g. fingerprints), use Isopropyl Alcohol to dampen cloth
and wipe surface

Section 14
Technical Bulletins
Scheduled
Maintenance
 Info-T’s are tech bulletins that are posted to inform service technicians of
modifications for Barco products. They are designed to increase reliability or
correct any known issues.
 Info T’s have four priority levels:

– Level A: “Must” modification, Barco will provide all components necessary to complete
modification at no charge
– Level B: Improves the reliability of a product
– Level C: Improves the general working condition of the product
– Level D: For information only

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Barco Digital Cinema

Certified Expert Training Course — Series 2

Advanced Diagnostics and Service

March - 2013 Copyright © Barco

Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco

A minimum of 80% is required on each exam in order to be Certified.

Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco

Section 1: Introduction to the Service Course

Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco

Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco

Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco

Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco

Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco

Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco

Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco

Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco

 Introduction to Service Course

Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco

Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco

Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco

Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco

Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco

Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco

Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco

Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco

1. Mounting plate reservoir liquid 4

Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco

1. Cover plate, Light Processor

Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco

1. Start pulse generator (SPG) unit

Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco

1. Security switches Card Cage

Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco

1. Security switches, Light Processor

Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco

Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco

Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco

Spare Part 21. Dust filter cold mirror

Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco

Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco

Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco

Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco

Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco

Board and Module Functionality

Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco

Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco

Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco

Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco

Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco

1. ICP Power — ON when powered. blue during normal operation

Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco

Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco

Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco

Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco

 Contains HD-SDI inputs for external servers or devices

Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco

Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco

Board and Input: HDSDI (SMTE 292) or 3G (SMPTE 424)

Serial Digital Interface(SDI)

High-Definition Serial Digital Interface (HD-SDI),

Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco

Board and Input: HDSDI (SMTE 292) or 3G (SMPTE 424)

Advanced Diagnostics and Service — Revised March 6 - 2013 Copyright © Barco