Barco ULC-30A Manuale utente

ULC-30A

Service manual

R5906015/01

01/02/2018

Barco NV

President Kennedypark 35, 8500 Kortrijk, Belgium

Phone: +32 56.36.82.11

Fax: +32 56.36.883.86

Support: www.barco.com/en/support

Visit us at the web: www.barco.com

Printed in Belgium

stored in a retrieval system without the prior written consent of Barco.

Trademarks

Brand and product names mentioned in this manual may be trademarks, registered trademarks or copyrights of their respective holders.

All brand and product names mentioned in this manual serve as comments or examples and are not to be understood as advertising for

the products or their manufacturers.

Changes

Barco provides this manual ’as is’ without warranty of any kind, either expressed or implied, including but not limited to the implied war-

ranties or merchantability and ﬁtness for a particular purpose. Barco may make improvements and/or changes to the product(s) and/or the

program(s) described in this publication at any time without notice.

This publication could contain technical inaccuracies or typographical errors. Changes are periodically made to the information in this

publication; these changes are incorporated in new editions of this publication.

The latest edition of Barco manuals can be downloaded from the Barco web site www.barco.com or from the secured Barco web site

https://www.barco.com/en/signin.

Table of contents
TABLE OF CONTENTS
Safety................................................................................................................. 3
1 Servicing safety instructions ......................................................................................................... 3
General information................................................................................................ 7
1 Conventions .......................................................................................................................... 7
2 General description. .................................................................................................................. 7
3 Covers ................................................................................................................................ 8
4 Service kit............................................................................................................................. 9
5 Chiller service tool . . .................................................................................................................. 9
Preventive maintenance .........................................................................................13
1 Monthly maintenance................................................................................................................13
2 Yearly maintenance..................................................................................................................13
3 3 yearly maintenance................................................................................................................13
4 30000 hours maintenance. . ......................................................................................................... 13
Switching on/off power...........................................................................................15
1 Switching off power and locking the switch.........................................................................................15
2 Switching on power..................................................................................................................15
Covers...............................................................................................................17
1 Removing a cover ...................................................................................................................17
2 Installing a cover.....................................................................................................................18
Fan unit .............................................................................................................21
1 Removal of the fan unit..............................................................................................................21
2 Installation of the fan unit............................................................................................................ 22
Coolant procedures...............................................................................................25
1 First use of the Chiller service kit — Air removal procedure .. .....................................................................25
2 Draining the coolant circuit..........................................................................................................26
3 Filling the coolant circuit.............................................................................................................28
4 Adding coolant to the tank...........................................................................................................31
5 Replacing the tank cap assembly...................................................................................................33
6 Cooling liquid visual check ..........................................................................................................35
Primary pump unit ................................................................................................37
1 Primary pump replacement process ................................................................................................37
2 Disconnecting the primary pump wiring . .. . ........................................................................................38
3 Removing the primary pump unit . ..................................................................................................40
4 Installing the primary pump unit.. ...................................................................................................43
5 Connecting the primary pump wiring................................................................................................45
Secondary cooling unit...........................................................................................47
1 Removing the Secondary cooling unit .............................................................................................. 47
2 Installing the Secondary cooling unit ...............................................................................................51
Refrigeration unit..................................................................................................55
1 Refrigeration unit replacement process. . . . . ........................................................................................55
2 Removing the refrigeration unit .....................................................................................................56
3 Installing the refrigeration unit.......................................................................................................61
Electronics Unit....................................................................................................67
1 SD logging status . . . .................................................................................................................67
2 Removing the electronics unit.......................................................................................................67
3 Installing the electronics unit ........................................................................................................71
4 Replacing the logic board . . .........................................................................................................75
5 Pump inverter replacement .........................................................................................................77
5.1 Removing the J1000 pump inverter . . ........................................................................................77
5.2 Installing the J1000 pump inverter ... ........................................................................................79
5.3 Removing the V1000 pump inverter. . ........................................................................................ 82
5.4 Installing the V1000 pump inverter .. . ........................................................................................84
Pressurization Unit................................................................................................89
1 Removing the pressurization Unit...................................................................................................89
2 Installing the pressurization Unit .................................................................................................... 91
Air ﬁlter..............................................................................................................93
1 Replacing the ﬁlter...................................................................................................................93
2 Vacuum cleaning of the dust ﬁlters .................................................................................................94
A. Appendix .............................................................................................................95
A.1 Hazards..............................................................................................................................95
R5906015 ULC-30A 01/02/2018 1

Table of contents

Index......................................................................................................................97

2R5906015 ULC-30A 01/02/2018

1. Safety

1. SAFETY

About this chapter

Read this chapter attentively. It contains important information to prevent personal injury while servicing the ULC-30A on-site. Fur-

thermore, it includes several cautions to prevent damage of the ULC-30A components. Ensure you understand and follow all the

safety guidelines, safety instructions and warnings mentioned in this chapter before performing any servicing on the ULC-30A. After

this chapter additional “warnings” and “cautions” are given depending on the servicing procedure. Read and follow these “warnings”

and “cautions” as well.

WARNING:This manual is only intended for qualiﬁed service personnel.

Overview

• Servicing safety instructions

1.1 Servicing safety instructions

WARNING:Before removing/replacing any chiller components, switch off power. See "Switching off power

and locking the switch", page 15.

Personal protection

WARNING:Ensure you understand and follow all the safety guidelines, safety instructions, warnings and

cautions mentioned in this manual.

R5906015 ULC-30A 01/02/2018 3

1. Safety

Safety Instructions

1. Before returning the chiller to the customer, always make a safety check of the entire chiller, including, but not limited to, the

following items:

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

are provided on this chassis to protect both the technician and the customer. Correctly replace all missing protective shields,

including any removed for servicing convenience. (2) When reinstalling the chassis and/or other assembly in the cabinet,

be sure to put back in place all protective devices, including, but not limited to, insulating materials, barriers, covers/shields,

and isolation resistor/capacitor networks. Do not operate this chiller or permit it to be operated without all protective devices

correctly installed and functioning. Service people who defeat safety features or fail to perform safety checks may be liable

for any resulting damage.

b) Be sure that there are no cabinet openings through which an adult or child might be able to insert their ﬁngers and contact a

hazardous voltage. Such openings include, but are not limited to, (1) excessively wide cabinet ventilation slots, and (2) an

improperly ﬁtted and/or incorrectly secured cover panels.

c) Leakage Current Hot Check. With the chiller completely reassembled, plug the AC line cord directly into a 220 V AC outlet

(Do not use an isolation transformer during this test). Use a leakage current tester or a metering system that is designed

to comply with the new IEC, ANSI and UL standards. With the chiller AC switch ﬁrst in the on position and then in the

off position, measure from a known earth ground (metal waterpipe, conduit, etc.) to all exposed metal parts of the chiller

(antennas, handle bracket, metal cabinet, screwheads, metallic overlays, control shafts, etc.). especially any exposed metal

parts that offer an electrical return path to the chassis. Any current measured must not exceed 3,5 mA. Reverse the chiller

power cord plug in the outlet and repeat test. ANY MEASUREMENTS NOT WITHIN THE LIMITS SPECIFIED HEREIN

INDICATE A POTENTIAL SHOCK HAZARD THAT MUST BE ELIMINATED BEFORE RETURNING THE INSTRUMENT

TO THE CUSTOMER OR BEFORE CONNECTING ACCESSORIES.

Leakage Current Tester

Reading should

not be above

3,5 mA

Test all exposed metal surfaces

Earth

Ground

2-Wired cord

Also test with plug reversed

(Using AC Adapter plug as required)

AC Leakage Test

Device Under Test

Image 1-1

2. Read and comply with all caution and safety-related notes on or inside the chiller.

3. Design Alteration Warning - Do not alter or add to the mechanical or electrical design of this apparatus. Design alterations and

additions, including, but not limited to, circuit modiﬁcations and the addition of items such as auxiliary audio and/or video output

connections, might alter the safety characteristics of this apparatus and create a hazard to the user. Any design alterations

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

damage resulting therefrom.

4. Observe original lead dress. Always inspect in all areas for pinched, out-of-face, or frayed wiring. Do not change spacing

between components, and between components and the printed-circuit board. Check AC power cord for damage. Take extra

care to assure correct lead dress in the following areas:

a) near sharp edges

b) near thermally hot parts - be sure that leads and components do not touch thermally hot parts

c) the AC supply

d) high voltage

5. Components, parts, and/or wiring that appear to have overheated or are otherwise damaged should be replaced with compo-

nents, parts, or wiring that meet original speciﬁcations. Additionally, determine the cause of overheating and/or damage and, if

necessary, take corrective action to remove any potential safety hazard.

6. PRODUCT SAFETY NOTICE - Many electrical and mechanical parts have special safety-related characteristics some of which

are often not evident from visual inspection, nor can the protection they give necessarily be obtained by replacing them with

components rated for higher voltage, wattage, etc. Use of a substitute replacement that does not have the same safety charac-

teristics as the recommended replacement part in BARCO service data parts list might create shock, ﬁre, and/or other hazards.

Product Safety is under review continuously and new instructions are issued whenever appropriate. For the latest information,

always consult the appropriate current BARCO service literature.

4R5906015 ULC-30A 01/02/2018

1. Safety

7. Do not spray chemicals on or near the chiller or any of its assemblies.

8. Electrostatically Sensitive (ES) Devices. Some semiconductor (solid state) devices can be damaged easily by static electricity.

Such components commonly are called Electrostatically Sensitive (ES) Devices. Examples of typical ES devices are integrated

circuits and some ﬁeld-effect transistors and semiconductor "chip" components. The following techniques should be used to

help reduce the incidence of component damage caused by static electricity:

a) Immediately before handling any semiconductor-equipped assembly, drain off any electrostatic charge on your body by

touching a known earth ground. Wear a commercially available high impedance discharging wrist strap device.

b) After removing an electrical assembly equipped with ES devices, place the assembly on a static dissipative surface such as

a 3M No 8210 table mat, to prevent electrostatic charge buildup or exposure of the assembly.

c) Do not use freon-propelled chemicals. These can generate electrical charges sufﬁcient to damage ES devices.

d) Do not remove a replacement ES device from its protective package until immediately before you are ready to install it

(Most replacement ES devices are packaged with leads electrically shorted together by conductive foam, aluminium foil or

comparable conductive material).

e) Immediately before removing the protective material from the leads of a replacement ES device, touch the protective material

to the chassis or circuit assembly into which the device will be installed. CAUTION: Be sure no power is applied to the chassis

or circuit, and observe all other safety precautions.

f) Minimize bodily motions when handling unpacked replacement ES devices (Otherwise harmless motion such as the brush-

ing together of your clothes fabric or the lifting of your foot from a carpeted ﬂoor can generate static electricity sufﬁcient to

damage an ES device).

R5906015 ULC-30A 01/02/2018 5

1. Safety

6R5906015 ULC-30A 01/02/2018

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