Barco DP3000- Failure to Turn lamp on

[Nalini Laveti]

Hello All-

We have BARCO series 1 projector DP3000. It is running great, until recently stopped in middle of the show, getting "failure to turn on lamp". The bulb have decent 600 hrs left, and power supply working good aswell. I pulled out the history logs.. here are below. Can someone pls assist me to get back the projector running ? is it coolant issue?

4113=20230122145539 - main.cpp - main - starting application (version 1.13.214)
4114=20230122145539 - main.cpp - Init - 3 lamp power supplies detected
4115=20230122145540 - Command.cpp - WriteProjectorOn - request (port = internal) = set power on
4116=20230122145541 - Command.cpp - DetectWaterFlow - detect water flow...
4117=20230122145541 - I2c.cpp - Write - node = 0, data = 0x18 0x00
4118=20230122145541 - I2c.cpp - Read - node = 0, data = 0x18 0x03
4119=20230122145541 - I2c.cpp - Write - node = 0, data = 0x18 0x03
4120=20230122145541 - I2c.cpp - Read - node = 0, data = 0x18 0x22
4121=20230122145541 - I2c.cpp - Write - node = 0, data = 0x18 0x04
4122=20230122145541 - I2c.cpp - Read - node = 0, data = 0x18 0x22
4123=20230122145541 - I2c.cpp - Write - node = 0, data = 0x18 0x05
4124=20230122145541 - I2c.cpp - Read - node = 0, data = 0x18 0x21
4125=20230122145541 - I2c.cpp - Write - node = 3, data = 0x16 0x02 0x81
4126=20230122145541 - I2c.cpp - Write - node = 3, data = 0x16 0x03 0x81
4127=20230122145541 - I2c.cpp - Write - node = 3, data = 0x16 0x04 0x81
4128=20230122145611 - I2c.cpp - Write - node = 0, data = 0x18 0x03
4129=20230122145611 - I2c.cpp - Read - node = 0, data = 0x18 0x3b
4130=20230122145611 - I2c.cpp - Write - node = 0, data = 0x18 0x04
4131=20230122145611 - I2c.cpp - Read - node = 0, data = 0x18 0x3b
4132=20230122145611 - I2c.cpp - Write - node = 0, data = 0x18 0x05
4133=20230122145611 - I2c.cpp - Read - node = 0, data = 0x18 0x3a
4134=20230122145611 - I2c.cpp - Write - node = 3, data = 0x16 0x02 0x80
4135=20230122145611 - I2c.cpp - Write - node = 3, data = 0x16 0x03 0x80
4136=20230122145611 - I2c.cpp - Write - node = 3, data = 0x16 0x04 0x80
4137=20230122145611 - Command.cpp - DetectWaterFlow - detect water flow indicates no water flow
4138=20230122145621 - Command.cpp - WriteProjectorOn - no acsar2 detected
4139=20230122145624 - Command.cpp - SynchronizeDate - synchronize date to 20230122145636
4140=20230122145604 - Command.cpp - ReadLens - command (port = internal) - execute lens file '.init'
4141=20230122145604 - Command.cpp - DebugLens - lenspositions (file = ".active", z = +0, f = +0, v = +0, h = +0)
4142=20230122145604 - Command.cpp - DebugLens - lenspositions (file = ".init", z = -6445, f = +22560, v = -34012, h = +4294935376)
4143=20230122145605 - Command.cpp - WriteShutter - request (port = internal) = set dowser closed
4144=20230122145605 - Command.cpp - InitDciSecurity - ti interface board type 0x05 detected
4145=20230122145605 - Command.cpp - WriteMark - log mark - 0000003d9db9 - 0
4146=20230122145805 - Command.cpp - SynchronizeDate - synchronize date to 20230122145842
4147=20230122151019 - Command.cpp - WriteToLog - logon-praveen-screens8-default
4148=20230122151023 - Command.cpp - WriteLampStatus - request (port = 192.168.206.129:43680:26) - set lamp on
4149=20230122151023 - Command.cpp - WriteLampStatus - water-flow switch indicates no water-flow
4150=20230122151026 - Command.cpp - WriteLampStatus - request (port = 192.168.206.129:43680:26) - set lamp on
4151=20230122151026 - Command.cpp - WriteLampStatus - water-flow switch indicates no water-flow
4152=20230122151030 - Command.cpp - WriteLampStatus - request (port = 192.168.206.129:43680:26) - set lamp on
4153=20230122151030 - Command.cpp - WriteLampStatus - water-flow switch indicates no water-flow
4154=20230122151034 - Command.cpp - WriteLampStatus - request (port = 192.168.206.129:43680:26) - set lamp on
4155=20230122151034 - Command.cpp - WriteLampStatus - water-flow switch indicates no water-flow
4156=20230122151038 - Command.cpp - WriteLampStatus - request (port = 192.168.206.129:43680:26) - set lamp on
4157=20230122151038 - Command.cpp - WriteLampStatus - water-flow switch indicates no water-flow
4158=20230122151042 - Command.cpp - WriteLampStatus - request (port = 192.168.206.129:43680:26) - set lamp on
4159=20230122151042 - Command.cpp - WriteLampStatus - water-flow switch indicates no water-flow
4160=20230122151045 - Command.cpp - WriteShutter - request (port = 192.168.206.129:43680:26) = set dowser open
4161=20230122151046 - Command.cpp - WriteShutter - request (port = 192.168.206.129:43680:26) = set dowser open
4162=20230122151051 - Command.cpp - WriteLampStatus - request (port = 192.168.206.129:43680:26) - set lamp on
4163=20230122151051 - Command.cpp - WriteLampStatus - water-flow switch indicates no water-flow
4164=20230122151150 - Command.cpp - WriteLampStatus - request (port = 192.168.206.129:43680:26) - set lamp on
4165=20230122151150 - Command.cpp - WriteLampStatus - water-flow switch indicates no water-flow
4166=20230122151152 - Command.cpp - WriteLampStatus - request (port = 192.168.206.129:43680:26) - set lamp on
4167=20230122151152 - Command.cpp - WriteLampStatus - water-flow switch indicates no water-flow

[Frank Cox]

I'm not a tech and I don't have or know anything about Barco projectors, but your problem is this: "WriteLampStatus - water-flow switch indicates no water-flow"

The coolant pump failed, the coolant has leaked out to a point that it's too low to function, or there's a blockage in the line.

[Steve Guttag]

It can also be a failed or stuck water flow meter. If one of the rubber hoses lets any debris into the stream...it will stick an impeller.

When was the last time you flushed the cooling lines? Have you verified that cooling pump is working?

[Leo Enticknap]

Sorry to be the bringer of bad news, but welcome to a world of pain; otherwise known as having to f*** with a Barco Series 1 pressurized liquid cooling system. And the DP3000 is even worse than the 1500 and the 2000, thanks to the amount of disassembly around the lamphouse needed to get at the pump. The positioning of the pump is almost up there with NEC levels of sadism.

Agreed with both Frank and Steve: it could be a failed pump, or UV damage to those brown squishy hoses causing them to discharge crud into the liquid stream. The one piece of good news is that the model of pump is the same as for Series 2 projectors, so they are still available from Cinionic.

As well as a new pump, coolant, and possibly new hoses (if you do replace any hoses, I would suggest using braided, transparent, UV-resistant stuff: that will enable you to confirm visually that coolant is flowing and that there are no air bubbles in the circuit), you will need some Series 1 quick release hose couplings, a large syringe, and a bicycle pump with an attachment for the Schrader valve on the pressure vessel. Replacing any component in the cooling system requires draining, refilling, and repressurizing it afterwards. This is a nasty, messy, and time consuming job, and I am truly thankful that I no longer have any Series 1 Barcos to look after for my regular customers. Without wanting to sound condescending, I would suggest outsourcing this job to a tech unless you are masochistically inclined.

[Nalini Laveti]

Thank you Frank, Steve and Leo- It's almost more than 2 years we haven't cleaned the cooling system. Seems I need to do cleanup and replace with the coolant and re-pressure it. Do you recommend any techs in ohio ?

[Dave Macaulay]

The DP3000 cooling system is sometimes troublesome. Along with the rest of it...
I've had the "lamp off for low flow" on several occasions. Yes the cooling plumbing is complicated and weird. I don't know the root cause but doing a coolant flush and then an extended air removal - letting it circulate through a bottle (in and out hoses into a half full coolant bottle) for 30 minutes or more has somehow "fixed" them. With closing and opening the valve a few times during this.
You don't need to pressurize the system. The pressurizer rarely has a problem if you decide to pressurize, but if it takes less than 80ml or so to get to pressure the pressurizer should be calibrated.
Barco designed the projector to work upside down (why??), hence the sealed and pressurized cooling system. Barco techs have told me not to bother with pressurizing S1 units. There is no pressure sensor that would cause trouble. The "cavitation" argument is pure BS: the same pump is in S2 projectors with no pressurization.
I always run air removal for an extended time.
In my experience, doing the pressurizing is not difficult - it does get splashy if the hose pops off the syringe though - but pressure is almost always gone after 6 months and there's absolutely no sign of the missing 90ml or so used in the pressurization. Waste of time and effort.

[Marco Giustini]

I believe the S1 were based on existing non cinema products which could be installed upside down - hence the cooling design was inherited with the first D-Cinema series.

[Leo Enticknap]

I was also told by Barco techs that there is no need to add any pressure, as long as you aren't actually hanging the projector upside down. Personally, I have tended to pump it up such that the manometer reading is just "off the floor," so to speak, as a way of checking for leaks; but not to the 1 bar specified in the service manual.

[Ioannis Syrogiannis]

I only once came upon an upside-down series 2 Barco, a C model. The feet were placed on the top, where the screw holes for rigging are. The installer had to do the trick, so there was access to the elca box and lamp, since the other way around, those would be blocked.
I didn't get a picture, so I don't remember what was on the other side. But it was a pain in the ass to work with.

[Nalini Laveti]

It can also be a failed or stuck water flow meter. If one of the rubber hoses lets any debris into the stream...it will stick an impeller.

When was the last time you flushed the cooling lines? Have you verified that cooling pump is working?

Yes. I have a flow indicator on the pump and can see that coolant is definitely circulating with good flow volume. The projector will no longer detect coolant flow. I believe something wrong with sensor. How can we fix the sensor? or bypass it?

[Leo Enticknap]

Looking at the service manual, it seems that there is actually no water flow switch: just a jumper on the backplane to where one would be connected if there was one.

DP3000_waterflow.png

Maybe check and reseat that jumper?

I find it ironic that the easiest and quickest thing to check when confronted by that error is what they recommend doing last!

[Nalini Laveti]

Thank you for Leo for the the details, However we are not to able find the location of the Jumper. Can you share the service manual? or show how to get access into that jumper board.

[Leo Enticknap]

From memory, that location is towards the top, facing the non-operator side. You may have to pull the light engine to get at it - can't remember. I'm afraid that the DP3000 is by far in a way the most difficult Barco digital cinema projector to work inside.

The manual is something like 150MB, so I can't just email it to you. Will try to figure out a way of getting it to you in the few days (slammed with service calls at the moment), or you could email techsupport.us {at} cinionic.com, and they could probably give you a link.

[Marcel Birgelen]

AFAIK a DP3000 doesn't have a flow switch. The DP100 had one, that could be easily bypassed by just closing the contact. If the DP3000 complains specifically about a flow switch not triggering, then most likely the bridging connection on the Power Board thingamabob is bad or one of your power rails on that board has failed.

[Leo Enticknap]

Yes - per the service manual screenshot above, there is a connector on the board for one, but it comes from the factory jumpered. It's entirely possible, IMHO, that the jumper could have been damaged by many years of UV exposure from the lamp. Definitely worth pulling that jumper, checking its continuity with a multimeter, and reseating.