PROJECTION HEAD Parts & Module Replacement This document includes: 1 2 3 4 Ordering Parts ....................................................................................... page 1 Index of Replaceable Parts & Modules ................................................ page 2 Module Replacement Procedures ......................................................... page 5 CP2000-X Interconnect Diagram........................................................
PARTS & MODULE REPLACEMENT Availability Parts identified throughout may not be available separately. In addition, some parts stocked as inventory are available only until the current supply lasts. All part numbers are subject-to-change. 2 Index of Replaceable Parts & Modules CP2000-X projection head replaceable parts and modules are listed in Table 1. Please refer to this table for each component/module name, part number, and the page number on which its replacement procedure begins.
PARTS & MODULE REPLACEMENT Table 1.
PARTS & MODULE REPLACEMENT Table 2.
PARTS & MODULE REPLACEMENT 3 Module Replacement Procedures This section provides instructions for replacing CP2000-X modules and service assemblies, many of which are similar to those in the CP2000 and/or Roadie 25K and accessed with a few minor differences. WARNINGS Read ALL instructions prior to disassembly. Module Replacement Procedures must be performed by qualified service personnel only. Non-insulated dangerous voltages may be exposed. Always disconnect from AC prior to disassembly.
PARTS & MODULE REPLACEMENT REMOVING THE COVERS (1-5 minutes each) WARNINGS • Fully disconnect from AC before removing a cover, particularly those at the front of the projection head. • Never operate the projector or run its fans without all covers installed. Front Lid Remove the front lid for service procedures of the opto-electronic processing modules residing in the projection head. Unlock the lid. 2) Raise the lid and pull its two tabs out from the opposite side from the latch. Set aside.
PARTS & MODULE REPLACEMENT Igniter Door See right. Unlock igniter door near top edge, and lower the door. If desired, release the tether and spring mechanism located near the rear corner and remove the door entirely. Figure 5. Igniter Door Rear Panel NOTE: If the TPC is mounted to the projector, remove the TPC first by loosening its ball arm/clamp, and disconnecting the cable. Remove 12 Phillips screws securing the rear panel to the projection head frame. Remove panel and set aside. Figure 6.
PARTS & MODULE REPLACEMENT AC DISTRIBUTION MODULE (ACDM) (15 minutes) The AC Distribution Module is located in the igniter area between the lamp blower and the liquid cooling system. To remove: Remove igniter door. 2) Remove lamp blower vane switch bracket (one 3/8” nut). 3) Remove the ACDM mounting plate (3 screws), and lift the assembly from its slotted-hole mount on the interior wall. See right. 4) Disconnect 2 ACDM ground wires from the projector floor (1 screw).
PARTS & MODULE REPLACEMENT 3) 4) 5) 6) 7) Disconnect 6 flex cables (3 pairs) and 3 power cables from the EFIB. See right. Disconnect the other end of the 6 flex cables from the light engine (see light engine instructions). Figure 9. EFIB Connectors Discard, as the flex cables should not be re-used. Release 2 side ejectors to unseat the EFIB from the motherboard. Pull straight up from card cage. When re-installing, orient the EFIB so that its components face the front of the projector.
PARTS & MODULE REPLACEMENT ETHERNET HUB POWER SUPPLY (10 minutes) The Ethernet hub power supply is Velcro™-mounted on the underside of the projector (see Figure 10.), protected by the belly pan. To move or replace: Remove the belly pan. See Removing the Covers. 2) Disconnect the Ethernet hub power supply. 3) Release the Velcro™ strap securing the power supply to the interface plate, and replace with new Figure 10. Belly Pan Area for TPC Power and Ethernet power supply.
PARTS & MODULE REPLACEMENT Remove Lamp Blower Vane Switch/mounting bracket assembly (3/8” nut). 3) Disconnect the blower from the ACDM. 4) Remove 2 screws (5/32”) securing the fan in place. See Figure 11. 5) Rotate the blower and lift out at the top of the projection head. 2) Figure 11.
PARTS & MODULE REPLACEMENT FANS (SIDE INTAKES) (20 minutes each) Two identical “intake” fans are mounted side-by-side on the lamp side of the projection head. Although the filtered air actually enters on the opposite side of the projector—the igniter side—these fans pull the air across the front area of the projection head and are considered intake fans. Either fan can be replaced independently after removing the louvered exhaust grille/shield from the projector.
PARTS & MODULE REPLACEMENT For each pair of flex cables, connect the top cable from the EFIB to the top connector on the corresponding modular formatter in the light engine. Bottom cables connect to the corresponding bottom connector. Figure 15. Flex Cable Connections FOLD MIRROR Refer to the Roadie 25K Parts & Module Replacement Booklet. IGNITER Refer to the Roadie 25K Parts & Module Replacement Booklet.
PARTS & MODULE REPLACEMENT IMPORTANT Back up configuration data files (source, screen, MCGD and TCGD) before removing the Interface Bd. Remove the projector front lid. See Removing the Covers. 2) Remove card cage lid (6 screws). This may be a snug fit—pull up firmly. 1) Figure 16. Interface Board in CP2000-X Card Cage Release 2 side ejectors to unseat the Interface from the motherboard. 4) Pull straight up from card cage.
PARTS & MODULE REPLACEMENT LAMINAR AIRFLOW DEVICE (LAD) (20 minutes) The Laminar Airflow Device (LAD) consists of a small fan and filter mounted in a plastic frame and secured to the floor of the projection head, adjacent to the corner brace on the operator’s side. To remove the LAD for fan replacement: NOTE: To replace the filter only, open the projector lid and skip to Step 8. 1) 2) 3) 4) 5) 6) 7) Remove the projector front lid. See Removing the Covers. Disconnect the LAD fan from the SSM P7.
PARTS & MODULE REPLACEMENT without the air hoses connected to the LAD. This will prevent any old filter dirt or new shavings that have rubbed off the filter lining from being deposited directly on the DMDs. Then reconnect LAD hoses as shown. LAMP BALLAST Refer to the Roadie 25K Ballast Service Instructions supplied with the ballast.
PARTS & MODULE REPLACEMENT 6) Remove the sensor flag (see right). Remove the small floor insert surrounding the cathode post (see Figure 21). Remove 2 screws (7/64”) securing the top and bottom of the lamp cooling compartment to the projection head firewall. See Figure 22. Figure 21. Flag and Shield Remove 4 screws (3/16”) securing the LampLOC Figure 22. Lamp Cooling Compartment module—including its Screws mounting plate—to the projection head floor. See Figure 23. Figure 23.
PARTS & MODULE REPLACEMENT Tilt the LampLOC/duct assembly towards the rear of the projector. At this point, the duct can be pulled off the LampLOC module and out of the projector (Figure 24). It is a tight fit—pull blower away for better clearance. 8) Remove the LampLOC module from the projector, and swap in a new module. 7) After installation, doublecheck SDB connections, then reset LampLOC. Figure 24.
PARTS & MODULE REPLACEMENT Remove 2 screws (5/32”) securing the LSM to the projector. See Figure 25. 3) Disconnect the LSM harness, and remove the sensor from projector. 2) Figure 25. Light Sensor Module Checking Light Sensor Module Readings: After installation, make sure to reset LampLOC and, if desired, recalibrate the min/max footlamberts. Also check light output readings during adjustment of LampLOC.
PARTS & MODULE REPLACEMENT LIQUID COOLING SYSTEM (40 minutes) NOTE: See also Pump and Fan, Heat Exchanger. The liquid cooling system consists of a pump, coolant reservoir, and heat exchanger/fan linked together with clear hoses and mounted between the lamp blower and the igniter. To access and replace this system: Remove the projector lid, igniter door, rear lid and belly pan. See Removing the Covers. 2) Disconnect the pump motor and heat exchanger/fan from the ACDM.
PARTS & MODULE REPLACEMENT Remove four 5/32” hex screws securing the pump mounting bracket to the base the projector. The interior screw nearest the heat exchanger is very difficult to reach. 6) To remove the pump assembly, tilt it toward the front and middle of the projector—this may take several tries, but the entire heat exchanger/pump assembly can be removed via the igniter door opening. 5) Re-installation: Figure 29.
PARTS & MODULE REPLACEMENT 1. 2. 3. 4. 5. Remove the belly pan so that the hosing under the projector is visible. Fill the reservoir ¾ full. Power up the projector. Close the douser/shutter. Watch closely for airlocks in the lines, particularly to and from the pump—you may have to pinch the hoses repeatedly to eliminate airlocks and encourage flow. 6. Run as necessary to eliminate all air bubbles. Make sure the pump is not running “dry”. 7.
PARTS & MODULE REPLACEMENT LOW VOLTAGE POWER SUPPLY (LVPS) (30 minutes) The Low Voltage Power Supply (LVPS) is mounted to the floor of the projection head, adjacent to the electronics card cage and under the integrator. To replace the LVPS: Remove the projector front lid and exhaust grille. See Removing the Covers. 2) With the exhaust grille out, remove the LVPS access panel. 3) Remove the single screw (7/64”) securing the black “snood” to the douser mounting plate. The integrator can remain in place.
PARTS & MODULE REPLACEMENT MOTHERBOARD (25 minutes) The motherboard is located on the floor of the card cage—the Processor Board, Interface Board and EFIB all plug into it. To replace this PCB: 1) 2) 3) 4) 5) Remove the projector front lid and belly pan. See Removing the Covers. Remove card cage lid (6 screws). This is a snug fit—pull up firmly. Remove the Processor Board, Interface Board and EFIB from the card cage. From the underside, disconnect 10 nuts with stand-offs, and remove 3 connectors.
PARTS & MODULE REPLACEMENT PUMP (30 minutes) The pump is part of the liquid cooling system. To replace the pump only: Remove the projector rear lid, belly pan and igniter door. See Removing the Covers. 2) Fully drain all coolant from the system (refer to separate instructions). 3) Disconnect pump from the ACDM, and remove both hoses from the pump. NOTE: Later units have gear clamps that can be loosened and reused.
PARTS & MODULE REPLACEMENT REFLECTOR(S) Refer to the CP2000/XP2000 Parts & Module Replacement Booklet, noting the following differences: To access the top mounting screw at the firewall, move the liquid cooling reservoir aside first. To lift out the cast reflector mount (with reflectors still attached), tilt the assembly towards the front and rotate the innermost side up. Remove anode yoke to avoid possible damage to the reflectors.
PARTS & MODULE REPLACEMENT 3) Remove 6 Phillips screws securing the SSM to the projector floor. See right. When re-installing the SSM, make sure to: Connect the green GND wire to a mounting screw on the SSM. Connect all harnessing correctly. TEMPERATURE SENSORS Refer to the Thermal Sensor Installation Instructions supplied with the thermal sensor service kit. Figure 38.SSM Mounting Screws TOUCH PANEL CONTROLLER (TPC) Refer to the CP2000/XP2000 Parts & Module Replacement Booklet.
PARTS & MODULE REPLACEMENT Figure 39. Vane Switch in Exhaust Duct Remove 2 nuts (¼”) securing the vane switch to its mounting bracket. 3) Disconnect the harness from the switch, and remove the switch. 2) NOTE The Interlock Kit contains both vane switches: lamp fan and exhaust duct. Use the longer one in the exhaust duct. Installing the new vane switch: For best results, a small drop of silicone should be added at the slot for the vane “feather” to keep it from falling out during use.
PARTS & MODULE REPLACEMENT Remove the 2 hex screws (3/32”) securing the lamp vane switch to its mounting bracket. 3) Disconnect the harness from the switch, and remove the switch. 4) Swap the new switch on to the bracket, and re-install. 2) NOTE The Interlock Kit contains both vane switches: lamp fan and exhaust duct. Use the smaller one at the lamp fan.
