RGB rebuild, moving to pro case

[michelrietveld]

Saturday july 30th, drove to Edison with a hobby rgb projector build into a wooden case.



Items used:
The setup, seen from scanhead, red, green and blue.
1W Blue 445nm created by Edison
Quad 800mW 660nm Red created by Edison
300 mW 532nm Green LaserWave
2 x dichro's for reflecting red and green
1 x Front surface mirror for reflecting blue
DT40Kpro scanners
Several power supplies
PT-Itrust ilda board
2 x Fan

The new case will look like this:


First we disconnected all components from the old case, sad feeling since you dissassemle a working setup

Then we took out the base plate from the new projector for preparing the setup.
The new projector will use the ilda board from Rob so i have to change the wiring for the drivers and scanners since it uses different connectors then the pt-itrust board.

For power connector we will use a Neutrik powerconnector, first time i use it, there will be a key switch and a power connector. Only item missing since moving to the Neutrik is the combination with a fuse so i will have to add this by drilling another hole in the back plate. The fuse i am planning to use will be 3AT (3Amps and type slow).

Have to do some shopping this afternoon for the power connector, fuse holder and fuse and the wires for the power cables internally.

Will also have to decide what type/kind of connectors to use to connect the wires to the Neutrik and if i will connect the wires directly to the power supplies or use also some kind of connector.

For detirmining the layout we put tape on the base plate so we could draw on it where the holes should be drilled.
Keep in mind that this case has profiles that connect the top to the front/rear and bottom that take up some space.
Also keep in mind, and we did not think about this when we put the items in place, that you will add a window in front of the scanhead so keep some distance to the front. Hopefully the 1mm non-reflective glass will still fit otherwise we have to change the mount for the scanhead.




Then we positioned the power supplies and the drivers on the bottom side of the plate.



and the lasers on the other side


also the scanner drivers found a place and the ilda board fet holes were marked.

Then a lot of drilling and tapping (if this is the correct word)
At the end of the evening the baseplate was prepared and i went home with all my components and the cabling adventure can begin.
Big thanks to Edison for all his patience and efforts, the case is very well designed, as you will see it can be set up so you have plenty of room and keeping the lasers and optics separated from the power and drivers.
Perhaps we will add a divider for the optic section too but that is looking forward too far for now.

Will update this post as i move on.
http://www.photonlexicon.com/forums/...proved-version.

Michel

[hobbybob]

Wow, excellent. Really cool seeing you will be housing all the stuff in a nice projector case !
Still i have warm memories to the waser. It was a cool box, and only gets better now.
Well done, will definately track your progress. Excellent work guys !

I will start building my greens to green/blue somewhere this week and will post a blog as well.
You will somehow recognize the case used in that build since it was one of the first Edison made ;-)

[michelrietveld]

Well yesterday i went shopping, got the needed wires, fuse holder, for the moment will use the wired one instead of drilling a hole for a fuse holder and a power buton.

First wired all the power lines, the ilda board has a relais (relay??) to turn of the power to the lasers so i used two power lines, one to the ilda board and then to the powers supplies for green, red and blue, green and red are on the same by the way. And i directly connected the power to the galvo power supply since this also powers the ilda board itself.

Then i installed the red laser since it has a flexmod attached to it instead of a separate driver.

When this was done i connected the cables for the green and blue and put the plate into the case.

After that placing the green and blue and that is where i finished yesterday.

[dnar]

Nice, thanks for the photos.

[norty303]

I think I really need to rebuild my 2 1.5W RGB's into a pair of those cases....

*rummages*

Damn, I must've lost that £500 in my pocket...

[michelrietveld]

Sigh, big sigh, installed the scan head, connected everything and thought, before mounting the dichro's, lets test drive first.

1) find power connector block with on/off switch to keep safe distance (i know i did a great job but better safe than sorry)
2) insert and turn the key
3) turn on the power button
4) turn on the switch on the extension block

power light turns on on the power connector on the rear, good sign.
waiting, ilda board has 30 sec timer so can take a while, waiting some more, counting to 30, counting slower, nothing....

hmmm, volt meter, 220 from the neutric, check
220 inside in the power connector, ok
220 to the power supply for the ilda board, nothing.
checking cables, looks good, oh wait, the power button has 4 connectors, used the wrong ones.
Ok, corrected that.

test run 2
power =on
key=turned
safety power=on
ilda board red operation led lights up = good
counting to 30, slower counting to 30, nothing........ ????
called rob stanwax, should be locking mechanism, 1 interlock key switch, check, 2, interlock and start button on 9-pin (dummy), check, 3 attached ilda cable with dac (oh, is that needed)

connected dac
repeat procedure

we have liftoff !!!!!

testrun using easylase test program, all looks fine except that the retuned blue does show too much light, will contact Edison about it.

Now i will place and align the dichro's.

Me so happy !!!

Michel

[michelrietveld]

Created little movie from the video, easier to watch.

http://www.youtube.com/watch?v=8bcfWpmiHoo

Michel

[hivelaser]

What did you use to make the video? Btw congrats looks great.

[edison]

Great to see the works!!! I,m happy that i could help. It was a long day but definitively worth it.

Nice case where did you bought it?


No just kidding. The Next build in one of these case will be the one from rizard I will start with the build this weekend.

[hobbybob]

LOL readin the build thread, really cool.

The ILDA cable needing to be present at least means that the board works. Pull it out while operating and the whole stuff should turn down.

I wanted to see the video, but Youtube keeps telling me the video is not available in your country hahahah Since i am now in Germany ;-)
Am curious to find out.
Way to go man, projector looks fine.
If you can point me in the right direction or can change the Youtube to play in Germany as well (did you add some copyrighted music under it ?) that would be appreciated.