BenQ Mainstream MP611 Product Service Manual Download Page 130

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130

Chapter 5 Error Count Messages Definition

Error Count

Definition

Specification

LAMP FAIL COUNT

LAMP OFF

DETECT LAMPLIT

LAMP FAN ERROR COUNT

LAMP FAN SPEED ERROR

SPEED OVER ± 20%

BALLAST FAN ERROR COUNT

BALLAST FAN SPEED ERROR

SPEED OVER ± 20%

BLOWER ERROR COUNT

BLOWER FAN SPEED ERROR

SPEED OVER ± 20%

DIODE1 ERROR COUNT

LAMP BOX SENSOR ERROR

DETECT DIODE1

DIODE2 ERROR COUNT

FRONT SENSOR ERROR

DETECT DIODE2

DIODE3 ERROR COUNT

MCU WATCHDOG RESET

DETECT WTD

LAMP BOX SENSOR OVER

TEMPERATURE COUNT

LAMP BOX TEMPERATURE ERROR

TEMPERATURE OVER 65

℃

FRONT SENSOR OVER

TEMPERATURE COUNT

N/A

FAN IC I2C ERROR

N/A

Level 3 - Component Repair to Curcuit Boards

Theory of Circuit Operation

Chapter 1 System Operation Theory

1.1 Overview

The Projector system consists of display function, cooling function, lighting function, safety protection function, and User

interface control function and power control function. An ARM processor embedded in the DDP ASIC is used to execute

system firmware. The ARM processor serves as the master controller of the projector and provides the link between the

display screen and end-user controls such as a keypad and IR remote control. These inputs can be processed in the ARM

Summary of Contents for Mainstream MP611

Page 1: ...000 Notice For RO to input specific Legal Requirement in specific NS regarding to responsibility and liability statements Please check BenQ s eSupport web site http esupport benq com to ensure that you have the most recent version of this manual First Edition August 2006 Copyright BenQ Corporation 2006 All Right Reserved ...

Page 2: ...DISASSEMBLY ASSEMBLY 64 LEVEL 1 COSMETIC APPEARANCE ALIGNMENT SERVICE 64 APPEARANCE 68 SOFTWARE FIRMWARE UPGRADE PROCESS 72 ADJUSTMENT ALIGNMENT PROCEDURE 76 LEVEL 2 CIRCUIT BOARD AND STANDARD PARTS REPLACEMENT 125 TROUBLESHOOTING 125 LEVEL 3 COMPONENT REPAIR TO CURCUIT BOARDS 130 THEORY OF CIRCUIT OPERATION 130 CIRCUIT SCHEMATICS 149 PCB ARTWORK 152 APPENDIX 1 SCREW LIST TORQUE 161 APPENDIX 2 COD...

Page 3: ...rated P POM Pond of Mirrors R RS232 Interface Between Data Terminal Equipment and Data Communications Equipment Employing Serial Binary Data Interchange S SVGA Super Video Graphics Array A screen resolution of 800 x 600 pixels SXGA Super XGA A screen resolution of 1280x1024 pixels V VGA Video Graphics Array A screen resolution of 640 x 480 resolution X XGA A screen resolution of 1024 x 768 pixels ...

Page 4: ...uct Important Only trained service personnel who are familiar with this BenQ Product shall perform service or maintenance to it Before performing any maintenance or service the engineer MUST read the Important Safety Information Trademark The following terms are trademarks of BenQ Corporation BenQ Other companies products or service names may be the trademarks of their respective companies ...

Page 5: ...HS complaints If the product service or maintenance require replacing any parts please confirming the RoHS requirement before replace them Safety Notice 1 Make sure your working environment is dry and clean and meets all government safety requirements 2 Ensure that other persons are safe while you are servicing the product 3 DO NOT perform any action that may cause a hazard to the customer or make...

Page 6: ...6 Compliance Statement 1 Caution This Optical Storage Product contains a Laser device Refer to the product specifications and your local Laser Safety Compliance Requirements ...

Page 7: ...Level 1 Cosmetic Appearance Alignment Service Level 2 Circuit Board or Standard Parts Replacement Level 3 Component Repair to Circuit Boards Related Service Information BenQ Global Service Website http support benq com front benqmain asp eSupport Website http bqpgsr benq corp com customize asplogin asp ...

Page 8: ...in Active Area 0 5 lux compared to center point within 60 Diagonal at 2 2m Wide image size Note This light leakage in Active area is only described as the spot light with obvious shape It is not included the uniformity difference of the projector for black pattern 1 4 2 Light Leakage out of Active Area 0 5 lux between of 54 Diagonal at 2m Tele image size and 60 Diagonal at 2 2m Wide image size 1 5...

Page 9: ... as flare 2 6 3 Focus unbalance Adjust focus from near to far until one corner clear difference less than 70 cm Center of 49 diagonal area All other area R G 2 3 1 G B 2 3 1 2 7 Lateral Color R B 1 1 2 8 Image Quality 2 8 1 DMD Image Quality See Appendix D 2 8 2 Image Imperfection See Appendix D Blemish 2 8 3 Image Shadow or Blur Procedure 1 53 Diagonal at 2m Wide image size 2 Default preset mode ...

Page 10: ... 5 Kg Including Accessories Projector 4 3 Palletization A type 24 B type 36 by Air 2016 40 container or 1008 20 container by sea 5 0 Thermal Specification Mechanical component temperature at ambience 0 40 5 1 Surface held or touched for short periods Normal surface Metal 60 C Plastic 85 C Bottom surface 25 C Metal 55 C Plastic 70 C Metal Plastic 5 2 Surface which may be touched 70 C 95 C 5 3 Exhau...

Page 11: ...is one sweep 30 min minimum per orientation total of 90 min 6 7 Vibration Random 5 100 Hz 0dB Oct 0 015 g2 Hz 100 200 Hz 6dB Oct N A 200Hz N A 0 0038 g2 Hz Equivalent to 1 47 Grms All primary axis 20 min per orientation total 60min Safety cCSAus TUV GS CCC CB Report PSE GOST R PSB SASO EMC FCC Class B requirements C Tick VCCI MIC CE Marks Directive 73 23 EEC Directive 89 336 EEC 7 0 Regulatory ESD...

Page 12: ...HD VD CS TTL Level 12 2 Video Input RCA jack Yellow Video amplitude 1 0 Vp p Impedance 75Ω 12 3 S Video Input 4 pin Mini Din Female Y Luminance amplitude 1 0 Vp p Impedance75Ω C Chroma amplitude 0 268 Vp p Impedance75Ω 12 4 YPbPr Input 15 pin D Sub Female x 1 Y Luminance amplitude1 0 Vp p Impedance 75Ω PbPr CbCr Chroma amplitude 0 7 Vp p Impedance 75Ω 12 5 Analog RGB Output 15 pin D Sub Female x 1...

Page 13: ...in a light proof room where the only source of illumination is the projector Less than 1 lux of the light on the screen shall be from any source other than the projector 3 All measurements shall be made on flat screens that do not provide any advantage to the performance of the unit 4 All measurements shall be made at standard color temperature setting 100 white image per ANSI IT7 228 1997 except ...

Page 14: ...L1 L3 L7 L9 L5 A4 ANSI CONTRAST ANSI Contrast Average lux value of the white rectangles Average lux value of the black rectangles Contrast Ratio shall be determined from illuminance values obtained from a black and white chessboard pattern consisting of 16 equal rectangles The white rectangles shall be at 100 gray and the black rectangles at 0 gray Illuminance measurements shall be made at the cen...

Page 15: ...2xW3 2W1 x100 W1 image width at image bottom W2 image width at image top W3 image width at the half image height H1 image height at image left H2 image height at image right H3 image height at half image Note 1 Keystone and Vertical TV Distortion are recommended for Front Projection Display 2 Vertical and Horizontal TV Distortion are recommended for Rear Projection Display A9 THROW RATIO Throw rat...

Page 16: ...the screen that is entirely the measured color under default brightness and contrast settings A14 COLOR UNIFORMITY Color Uniformity is the maximum color difference x y between any two points out of L1 L13 A15 ANSI COLOR UNIFORMITY ANSI Color Uniformity u v u 1 u 0 2 v 1 v 0 2 1 2 u 0 v 0 the average color of L1 L13 u 1 v 1 the spot with maximum deviation from u 0 v 0 A16 PROJECTION OFFSET Projecti...

Page 17: ...o measure Lateral Color for whole screen with Pattern 5 and record the maximum number a Example if 0 6 pixel lateral color A19 Lamp Lifetime Test Procedure 50 lamp brightness maintenance under 3 5hr ON 0 5hr OFF cycling test 1 5 pixels Grid of 1 5 pixels Flare Defocus 1 Pixel Center of G B with defocus only no count of flare G B Defocus of Blue Flare of Blue About 0 6 pixels ...

Page 18: ...18 Pattern 1 Please contact BenQ RD for file with correct resolution Pattern 2 Please contact BenQ RD for file with correct resolution ...

Page 19: ...19 Pattern 3 Please contact BenQ RD for file with correct resolution Pattern 4 Please contact BenQ RD for file with correct resolution Pattern 5 Please contact BenQ RD for file with correct resolution ...

Page 20: ...20 Chart 1 Example of Pixel Testing Pattern 60 screen size Please contact BenQ RD for file with correct size ...

Page 21: ...slight flare is defined as flare with very faint brightness compares to Normal Flare in Line Please refer to the drawing below A21 Blur and Shadow description Blur looks deep blue color and has edge obviously Shadow looks slightly gray If image has shadow but without blur it will pass image shadow and blur definition 80 Normal Flare Slight flare Pixel Shadow ...

Page 22: ...st Specification Package Drop Drop test with packing gross weight and falling height relationship Gross Weight Falling Height cm spec Kg C3 C4 C5 MP Remark 0 0 W 4 5 106 106 4 5 W 11 0 106 91 11 0 W 20 5 91 76 20 5 W 34 0 76 61 34 0 W 45 5 61 46 45 5 W 79 4 46 31 Test Orientation 1 corner 3 edges 6 Faces After drop test no abnormality on function appearance Package Vibration Test condition 1 Sine ...

Page 23: ...st Temperature Humidity Operating Test condition 0 40 10 90 no condensation Test procedure 25 90 2hrs 40 90 6hrs 0 6hrs 40 10 6hrs 25 90 2hrs 2 Cy cles Storage High Temperature Humidity Non operating with package Test condition 20 C 60 C 10 90 R H 1 Storage high temperature humidity exposure test 25 60 1hrs 60 90 24hrs 25 60 1hrs 2 Storage transportation test 25 60 1hrs 20 24hrs 25 60 1hrs 60 90 2...

Page 24: ...50 for details B3 Failure Criteria The product is expected to perform to its full potential without loss of function performance critical parametric changes and other undesirable anomalies over the applied boundaries of this specification The following product failure is not allowed within the boundaries defined in this specification 1 Failure including permanent damage critical paramedics changes...

Page 25: ...ting shall be performed serially within each set Set 1 2 units Set 2 2 units Set 3 Dynamics Atmospherics Safety EMC 1 Package Vibration Temperature Humidity Operating EMC 2 Package Drop Storage High Temperature Humidity Non operating ESD 3 Un Package Vibration Altitude Operating Surge 4 Un Package Shock Start Safety 5 Bench Drop ...

Page 26: ...urfaces and calculated the noise value by log average 5 Background noise 19dBA Exhausted Air Test Procedure Ⅱ Exhausted Air 95 oC measurement position shown as follows S h a p e o f f a n o u t l e t T h e e d g e o f o u t l e t A i r F l o w F i n d t h e m a x i m u m t e m p e r a t u r e a n d p o s i t i o n Position of measurement Ⅲ Temperature of System Level Before measurement temperature...

Page 27: ...e and measurement position as following Spec Maximum Area Define metal plastic Maybe touch All surface 70 95 Touch for short period only Key pad Adjustment foot lens side surface 60 85 Bottom Lamp cover 55 70 Outlet Mesh surface 70 95 ...

Page 28: ...age illumination path 2 2 Dark pixel A single pixel or mirror that is stuck in the OFF position and is visibly darker than the surrounding pixels 2 3 Bright pixel A single pixel or mirror that is stuck in the ON position and is visibly brighter than the surrounding pixels 2 4 Unstable pixel A single pixel or mirror that does not operate in sequence with parameters loaded into memory The unstable p...

Page 29: ...s short light parallel lines outside of the Pond of Mirrors POM 2 9 2 Exposed Metal 2 Exposed Metal 2 is due to a shift in positioning of either the die or the window aperture which may allow light to be reflected off of the layer of metal 2 that is below the super structure mirrors This defect is located outside of the POM 2 9 3 Reflective Edge Reflective Edge is light that may reflect from the e...

Page 30: ...must be adjusted to match the degamma table being used in order to generate an equivalent gray level on the test screen image 3 ACCEPTANCE REQUIREMENTS 3 1 Conditions of Acceptance All DMD image quality defects must be determined under the following projected image test conditions a Test Set degamma shall be linear b Test Set brightness and contrast settings shall be set to nominal c The diagonal ...

Page 31: ... 6 No DMD window aperture shadowing on the Active Area 7 Minor blemishes are allowed Notes 1 Projected blemish numbers include the count for the shadow of the window artifact in addition to the artifact itself 2 During all Table 1 tests projected images shall be inspected in accordance with the conditions of inspection specified in Section 3 3 The rejection basis for all cosmetic DMD defects scrat...

Page 32: ...32 Figure 1 Major Blemish Two Zone Screen Non Critical Zone Critical Zone center 25 ...

Page 33: ...00 37 500 31 500 640 x 480 VGA_85 85 008 43 269 36 000 SVGA_60 60 317 37 879 40 000 SVGA_72 72 188 48 077 50 000 SVGA_75 75 000 46 875 49 500 800 x 600 SVGA_85 85 061 53 674 56 250 XGA_60 60 004 48 363 65 000 XGA_70 70 069 56 476 75 000 XGA_75 75 029 60 023 78 750 1024 x 768 XGA_85 84 997 68 667 94 500 1280 x 1024 SXGA3_60 60 020 63 981 108 000 1280 x 768 SXGA_60 60 09 47 77 80 768 1280 x 800 SXGA...

Page 34: ... 720p 750p 60Hz 45 00 60 00 720p 750p 50Hz 37 50 50 00 1080i 1125i 60Hz 33 75 60 00 1080i 1125i 50Hz 28 13 50 00 Video S Video support timing is as following Video mode fh kHz fv Hz fsc MHz NTSC 15 73 60 3 58 PAL 15 63 50 4 43 SECAM 15 63 50 4 25 or 4 41 PAL M 15 73 60 3 58 PAL N 15 63 50 3 58 PAL 60 15 73 60 4 43 NTSC4 43 15 73 60 4 43 ...

Page 35: ...lt HDATA Frequency 31 82 K Hz Impedance 1 K ohm Amplitude low level 0 0 8 volt Amplitude high level 2 5 5 Volt VDATA Frequency 48 85 Hz Amplitude low level 0 0 8 volt SDADATA Amplitude high level 2 5 5 Volt Amplitude low level 0 0 8 volt SCLDATA Amplitude high level 2 5 5 Volt RXD Amplitude 25 25 Volt TXD Amplitude 25 25 Volt Amplitude total video sync 1 Volts peak to peak Amplitude video 0 7 Volt...

Page 36: ...ocol 1 5 6 10 11 15 Pi n Definition Pi n Definitio n Pin Definiti on Pi n Definition 1 Red video 2 Green Video 3 Blue Video 4 NC 5 NC 6 Red Video Return 7 Green Video Return 8 Blue Video Return 9 NC 10 Sync Retu rn 11 Monitor ID bit 0 12 Bi direction al data SDA 13 Horizontal Sync 14 Vertical Sync 15 Data clock SCL Video Component Input Composite input 1 ...

Page 37: ...efinition 1 Composite video input S Video input Pin Description 1 GND 2 GND 3 Luminance 4 Chroma Control Port Pin Description Pin Description 1 DSR 2 CTS 3 RD 4 GND 5 RTS 6 NC 7 TX 8 NC 2 4 1 3 8 7 6 5 4 3 2 1 ...

Page 38: ...emote Control Keys Description Detailed description refer to SW Specification IR Key Name Detailed Description Power Use this button to turn your Data Projector on and off standby mode Source To select input sources as Computer YPbPr Video S Video Menu 1 OSD pop up 2 Move next item 4 1 Move next page 2 OSD increment move next sub item 3 1 Move previous page 2 OSD decrement move previous sub item 5...

Page 39: ...pported Detailed description refer to SW Specification Functionality Data Computer Video S Video YPbPr YCbCr Volume YES YES YES Mute YES YES YES Preset Mode YES YES YES Brightness YES YES YES Contrast YES YES YES Color NO YES YES Tint NO YES YES Sharpness NO YES NO Color Temp YES YES YES H Position YES NO YES V Position YES NO YES H Phase YES NO YES H Size YES NO YES Keystone YES YES YES Language ...

Page 40: ... Message indicator Detailed description refer to SW Specification Message Occasion PC Composite Video S Video Analog YPbPr Searching The system does not detect the signal Out of range The signal is over the specification Lamp Warning The Power Will Turn Off After 4000 Hours Lamp Hour is over 3000 hours Change The Lamp The Power Will Turn Off After 4000 Hours Lamp Hour is over 3950 hours Change The...

Page 41: ...ge 50 Hz 60 Hz Power Consumption Normal operation 285 W Max standby mode 5W Regulation Efficiency 80 typical measuring at 115Vac and full load 2 Output Power Requirement The power supply can provide DC output as below NO Voltage Regulation Load Current Range Ripple Noise 1 5 V 5 0 06A 2 A 100 mV 2 2 5 V 5 0 3 A 2 A 100 mV 3 12 V 10 0 04 A 1A 300 mV 3 Lamp Power specifications Specification Descrip...

Page 42: ... 90 of its rating High voltage and high temperature protection To avoid user from the dangerous of HV and high temperature when front door of lamp case is opened whether intentionally or accidentally the power should be disconnected immediately When the door is closed again the igniter restart sequence should be compliant to that is described previously ...

Page 43: ...43 Packing ...

Page 44: ...44 ...

Page 45: ...ng or otherwise comparing the product with a given set of specified technical esthetic and workmanship requirements leading to an evaluation of the degree of fitness for use including possible personal injury or property damage for the use of the product 5 3 5 CLASSIFICATION OF DEFECTS The defects are grouped into the following classes 5 3 5 1 Critical defect A critical defect is a defect which ju...

Page 46: ...his must be reported immediately upon detection the lot or batch shall be rejected and further shipments shall be held up pending instructions from the responsible person in relevant department 5 3 7 1 2 under normal sampling Critical Defective 0 AQL Major Defective 0 65 AQL Minor Defective 2 5 AQL 5 3 7 1 3 under special sampling Critical Defective 0 AQL Major Defective 1 0 AQL Minor Defective 4 ...

Page 47: ... manual Environmental illumination Variable from 300 to 700 Lux For appearance inspection Variable from 0 to 7 Lux For functional inspection Temperature 25 5 Warm up time at least more than 10 minutes Visual inspection shall be done with the distance from eyes to the sample 50 cm Display mode refer to operation manual 5 3 10 TEST EQUIPMENTS Dark room PC Pattern Generator Chroma 2327 Minolta color ...

Page 48: ...earance quality shall be inspected with the lighting condition as 500 800Lux natural lighting or white fluorescent light 5 3 11 1 1 1 2 Inspection angle and distance to object or target All part inspection must be done under direct overhead lighting Viewing angle and distance are dependent on surface classification In all cases parts must be held in such that the light reflection does not disturb ...

Page 49: ... 70 70 100 100 20 20 50 50 70 70 100 100 20 20 50 50 70 70 100 100 P 0 1 mm2 Distance 2cm Ignore Ignore Ignore Ignore Ignore Ignore Ignore Ignore Ignore Ignore Ignore Ignore P 0 2mm2 Distance 4cm 2 3 4 5 2 3 4 5 4 4 5 6 Particle Blemish Color spot 0 2 P 0 3mm2 Distance 4cm 0 0 0 0 2 3 4 5 3 4 5 6 P 0 1 mm2 Distance 2cm Ignore Ignore Ignore Ignore Ignore Ignore Ignore Ignore Ignore Ignore Ignore Ig...

Page 50: ... is not allowed to impact structure strength and surface 7 Chromatic aberration Painting ΔE 2 L 1 5 Δ A B 0 6 Paint aluminum ΔE 2 L 1 0 Δ A B 0 6 Paint non aluminum Raw material ΔL A B 0 6 ΔE 0 75 8 Printing Printing must not have incomplete printing break off overlap uneven thickness excessive ink printing misalignment 1mm printing slanting crooked 0 3mm Printing color must be comparable to color...

Page 51: ...2mm L 3mm Only 3 this kind of scratch is accepted W 0 2mm L 3 5mm Only 2 this kind of scratch is accepted Note Severe scratch which disclose the Natural Each scratch should be 5cm more far away from each other ...

Page 52: ...0 15 0 2 0 1 mm Cap between LENS and Ring FC 1 5 0 1 0 1 mm Cap between UC and FC 0 1 0 3 0 1 mm Cap between PUSH BTN and LC 0 3 0 2 0 2 mm Step between FC and UC 0 0 3 0 3 mm Cap between LED LENS and UC 0 1 0 2 0 1 mm Cap between KEYFUN and UC 0 1 0 2 0 1 mm Cap between Door and LC step between Door and LC Gap 0 6mm step 0 8mm 1 2 Packing and marking Item Description Class 1 Inner packing materia...

Page 53: ... rugged illegible printing Minor 7 LED sink over 1 mm Minor 8 Label screws shortage or missing Major 9 Wrong logo of panel sticker Major 10 Wrong spec label printing Major 11 Label on product wrong or missing Major 1 5 AC power and signal cable Item Description Class 1 AC power or connector not correct or damaged not safe Critical 2 AC power or connector not correct or damaged but safe Major 3 Sig...

Page 54: ...ned on EMI Minor 7 Cold soldering loose connections Electrical Major 8 Wires and mechanical structure do not meet UL CSA or TUV Critical 9 Wrong parts broken component not safe Critical 10 Component burn Critical 5 3 12 PART II OPERATIONAL INSPECTION CRITERIA 5 3 12 1 TEST PATTERN PATTERN PATTERN TEST ITEM Full white ANSI Brightness Bright Uniformity FOFO Contrast Ratio CIE white coordinate Throw ...

Page 55: ...ay Gray Check DDC check Check the DDC information Including S N model manufacturer name product code 5 3 12 2 TEST CONTENT Test Condition TEST ITEM Input Equipment Chroma pattern 1024x768 800x600 Focus Focus range Timing VESA1024 256 gray scale Gray scale check Timing ICL 406 Gen 1 Picture quality PC Mode FULL W R G B Impurity CIE coordinate pixel fail D SUB Chroma ...

Page 56: ...et Chessboard FOFO Contrast Ratio Minimum1200 1 Contrast Preset Brightness Preset Full white and Full dark Light Leakage In Active Area 0 5 lux compared to center point within 60 Diagonal at 2 2m wide image size Contrast Preset Brightness Preset Full dark Light Leakage Out of Active Area 0 5 lux between of 54 Diagonal at 2m Tele image size and 60 Diagonal at 2 2m wide image size Contrast Preset Br...

Page 57: ...ld be clear and bright Brightness Preset Contrast Preset Chromo 256 gray pattern DMD Image Quality See Defect Classification See Defect Classification See Defect Classification Item Spec Condition Pattern PC 640X400Æ 800X600 compressed 1280X1024 Composite Sync Sync on Green Interlace Mode 8514A Contrast Preset Brightness Preset Chromo Test pattern Video NTSC NTSC4 43 PAL In cluding PAL M PAL n SEC...

Page 58: ...or 2 6 Light leakage out of specification active area or out of active area Major 2 7 Throw ratio out of specification Major 2 8 Room ratio out of specification Major 2 9 Picture distortion out of specification Major 2 10 DMD image out of specification Major 2 11 Picture dust or other image quality out of specification Major 2 12 Gray stage check Missing stage Major 2 13 Video noise If video noise...

Page 59: ...e Area 1 bright pixel in the SOM 4 dark pixels 6 minor blemishes No DMD window aperture shadowing on the Active Area Notes 1 Projected blemish numbers include the count for the shadow of the artifact in addition to the artifact itself so that the count usually represents a single artifact on the window 2 No blemish shall be more than 5 inches long or have a total area of more than 5 square inches ...

Page 60: ... Criteria Broken Deformed Print mistake Carton Cushion damaged No allow No label Invert label Broken No allow Dirt Not clear Word out of shape Word can be read Mistake No allow Label Position Be attached on right position Solder Appearance Can t see the abnormal color shape hurt dirt fused goods etc If it is necessary please prepare sample Missing No Loose No Screw Screw stripe damaged Can be scre...

Page 61: ...61 Disassembly Assembly Exploded View ...

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Page 64: ...64 Disassembly Assembly ...

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Page 68: ...68 Level 1 Cosmetic Appearance Alignment Service Appearance ...

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Page 72: ...Composer Lite If you want to install to a different directory perhaps alongside a prior release of DLP Composer Lite click the Browse button on the Select Features page USB Support Installation All Platforms This release includes support for a USB communications interface to DDP2000 based projectors The setup program includes the files needed to install USB support for Win98 WinMe Win2K WinXP only...

Page 73: ...ardware Wizard When the wizard prompts to find the necessary drivers accept the recommended choice let the system find the driver for you and click Next to complete the installation Note The Windows 98 Me New Hardware Wizard may not automatically find the driver You should use the Advanced option and enter the directory where the DLP Composer Lite Tool Suite was installed normally C Program Files ...

Page 74: ... Make sure to check Skip Boot loader area load all but the first 16KB 3 Plug power cord into projector 4 Press UP SOURCE AUTO simultaneously on keypad the projector LAMP LED would lite on 5 Plug in USB cable between computer and projector side 6 Press start download to begin update new firmware ...

Page 75: ...ice upgrade completed 2 Download is completed The factory settings should be restored How to enter Factory mode 1 Press up key until lamp information appear 2 Press Source key and Blank key simultaneously then enter the Factory area ...

Page 76: ...Watch DMD chip Label Example 9477000 0234B 2 Switch the DIP switch on DMD board according to the red character on the DMD chip 2 Color Wheel Delay Alignment Equipment Battery Biased Silicon PIN Detector Oscilloscope Vertical scale set to 10mV Probe Procedure 1 Probe impedance matches 50 ohm ...

Page 77: ...the oscilloscope and notice the square waveform 6 Use the and key to increment or decrement the color wheel delay value 7 No matter the waveform is square or not let the waveform was lagged first see picture 1 8 Then increment or decrement the value to let the waveform just to be square see picture 2 3 sRGB Mode alignment procedure Overfill adjustment And Burn In setting ...

Page 78: ...78 Overfill adjustment As the picture below adjust light pipe to keep overfill image center ...

Page 79: ...79 Burn In setting Burn In On Minute 210 Burn In Off Minute 30 4 Formatter board check procedure Equipment Pattern ...

Page 80: ...tter board 5 DMD Panel Alignment Equipment Pattern Generator Procedure 1 Connect power Video signal into projector 2 Light on projector 3 Change pattern generator to full white pattern 4 Watch the image if any pixel lost 5 Change pattern to full black 6 Watch the image if any pixel lost 7 Change pattern from full black to full white 8 Watch the image if any pixel can not return 9 Change pattern fr...

Page 81: ...p with Lamp holder and alight screw holes with holder first Figure 1 1 ٛ II Assemble assembly of Fin_Mesh on Baffle first and fasten the screw Figure 1 2 ٛ III Hook Mesh on the Lamp Holder first and fasten the screw Figure 1 3 ٛIV To make sure that Assembly of Fin_Mesh on the left side when you face to the Baffle Figure 1 4 ...

Page 82: ...e 1 4 1 2 Front Glass Assembly i Front Glass UV coated surface marked must face to Lamp Figure 1 5 ii F G must be placed on datum surfaces well Figure 1 6 iii To make sure F G Clip hooked well with Lamp Sleeve Figure 1 7 ...

Page 83: ...p Figure1 8 ii Hook Clip_UP on the Lamp Holder first Figure 1 9 iii Hook Clip_DOWN on the Lamp Holder second Figure 1 10 iv Check assembly again and make sure the three datum contact with the lamp v Assemble Lamp Wire to Lamp vi Assemble Lamp_Plate on the Holder and fasten the screw Figure 1 11 ...

Page 84: ...84 ...

Page 85: ...he Lamp Wire arrangement have to look like the picture as blow Figure 1 12 13 I The under wire go through the wire saddle directly II The upper Wire have to detour the wall of Lamp_Plate first then go through wire saddle Figure1 13 ...

Page 86: ...nsert CW Shield to BKT LINK Lamp and fasten screw Figure 2 1 2 2 Figure 2 1 Figure 2 2 3 Assembly CW Module 2 1 CW Module Assembly Sequence as blow Fig3 1 ٛ 1 BKT CW 2 Damper CW 3 CW 4 Fixed screw 5 CVR CW ٛ 6 M2 Screw 7 Sensor Board 8 M2 Screw ...

Page 87: ...87 Fig3 1 Fig3 2 4 Assembly LP Module 4 1 LP must datum well with BKT_LP show as Figure 4 1 4 2 Referring to Figure 4 2 there must be visible clearance between BKT_LP and LP opening after assembly ...

Page 88: ...420nm at least 100mW cm2 wavelength for 20 seconds ix After curing the height of UV glue should not exceed BKT_LP for more than 0 6mm Figure 4 3 4 5 Assembly LP Module to HSG DMD ٛ i Assembly two Overfill adjustment screw 8F 1A752 8R0 to HSG DMD Figure4 4 Adjustment criteria refer to item 4 6 ٛ ii Insert CLIP of BKT_LP into the hole ٛ iii Placed LP Module on LP datum and adjustment screw well show...

Page 89: ...wo hook places to make sure that Baffle_LP touches BKT_LP well don t push the middle place of Baffle_LP ٛ 4 6 Overfill Adjustment LP Module Overfill Adjustment Criteria For Overfill Re adjustment 1 Those 2 Adjustment Screws must be released closely to the Pre assembly positions first defined in 4 6 i 2 Follow adjustment steps shown in Item 4 6 ii ...

Page 90: ...90 Figure 4 6 Figure 4 9 ...

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Page 93: ...M1 must be face to inside Fig 5 1 ٛ II Insert the CLIP of FM1 into the hole on the HSG ILL and make sure CLIP of FM1 hook on the HSG ILL well Fig 5 2 ٛ 5 2 CM Assembly ٛ III Assemble CM to HSG ILL and to make CM contact three datums on the HSG ILL well Fig 5 3 ٛ IV Assemble CLIP of CM to the HSG ILL Fig 5 4 ...

Page 94: ...94 ٛ V To check and make sure CLIP of CM hook the HSG ILL very Well Fig 5 5 Fig 5 1 Fig 5 2 Fig 5 3 Fig 5 4 ...

Page 95: ...nd HSG DMD Assembly 6 1 Placed AL on the HSG DMD The raised surface of AL shall toward DMD direction Fig 6 1 6 2 Assemble HSG ILL Module to HSG DMD and cover over on AL Fig 6 2 Figure 6 1 Figure 6 2 7 HSINK DMD SOCKET Assembly ...

Page 96: ... and the other is Long hole Fig 7 1 II The circle of Baffle_DMD have to match with the circle on HSG DMD and the Long hole is the same Fig 7 2 7 2 As shown in Figure 6 3 i Pre fastening Sequence 1 2 3 4 ii Fastening Sequence 2 1 4 3 iii Screw Torque must be confirmed to be 6 kg cm ...

Page 97: ...97 Figure 7 3 8 PL Module Assembly 1 Assemble PL to HSG DMD and fasten screw to fix PL first Fig 8 1 2 Assemble Ring Zoom second and fasten screw Fig 8 2 3 Insert Ring Focus third Fig 8 3 Figure 8 1 ...

Page 98: ...ICAL ENGINE Assembly I Assemble CW Module to HSG DMD Figure9 1 9 2 II Assemble BKT Link Lamp Shield CW to HSG DMD and fasten the screw Figure9 3 9 4 III Assemble Lamp Module to HSG DMD Figure9 5 9 6 Figure9 1 Figure 9 2 ...

Page 99: ...99 BKT Link Lamp Shield CW Figure9 3 Figure9 4 ...

Page 100: ...ent Pattern generator Chroma 2250 OSD Default value Item Value Cal R Offset 127 Cal G Offset 127 Cal B Offset 127 Cal R Gain 127 Cal G Gain 127 Cal B Gain 127 YPbPr R Offset 122 YPbPr B Offset 122 AutoKeystone Cal TiltRatio Flat 0 TiltRatio Flat 0 ...

Page 101: ... As Figure1 A near white color 240 240 240 and a near black color 16 16 16 5 Light on projector 6 Set user OSD values to default 7 Enter factory mode 8 Set Factory values to default 9 Press Calbration RGB to let the black level to just distinguish and the light output of white level to just max 10 Check the 32 levels of gray All steps must appear ...

Page 102: ...ffset 127 Cal G Offset 127 Cal B Offset 127 Cal R Gain 127 Cal G Gain 127 Cal B Gain 127 YPbPr R Offset 122 YPbPr B Offset 122 AutoKeystone Cal TiltRatio Flat 0 TiltRatio Flat 0 Procedure 1 Connect power YpbPr cable into projector 2 Change Timing and pattern of pattern generator Timing 480i Pattern As Figure2 ...

Page 103: ...y mode 5 Adjust Factory values to default 6 Press Calibration YpbPr to calibrate the mid level offset 9 How to change Model name Equipment PC and RS232 cable Procedure 1 Plug in power core and RS232 cable 2 use RS232 command to set model name command format please refer below ...

Page 104: ...104 3 Example ...

Page 105: ...105 10 Mechanical Assembly Concerns ...

Page 106: ...g wire is come out from the middle opening area of the BKT L frame see figure 1 1 Figure 1 2 is the final assembly of this wire 3D J2C13 001 BKT L frame Grounding wire with EMI cord Figure 1 2 Grounding wire alignment II 2 Speaker wire alignment ...

Page 107: ...Lower case rib and Lower case boss before assembling Main board see figure 2 1 After assembling main board put speaker wire between Lower case rib and BKT L frame see figure 2 2 Figure 2 1 Speaker wire alignment I 3D J2C13 001 BKT L frame ...

Page 108: ...ssed above Thermal breaker wire and keep the redundant wire above lamp box Blower wire and CW sensor wire are constrained by the Wire saddle clips too They are assembled after CW FPR wire see figure 3 2 4 Thermal breaker wire and blower wire alignment After put CW sensor CW FPC and blower wires in the wire saddle clips put thermal breaker wire in ...

Page 109: ...ly see figure 4 2 The wire has to keep straight between blower and clip 2 and leave redundant wire between clip 2 and connector Figure 4 2 Old blower 2C J10102 031 wire length 170mm wire alignment New Blower part number 2C J10102 051 the wire goes above the blower itself and be constrained by clip no 1 and 2 see figure 4 3 The wire has to keep straight between blower and clip 2 and leave redundant...

Page 110: ...00mm wire alignment NOTE Please check thermal breaker wire is connected to power board indeed before assembling BKT L frame 5 Fan 8025 wire assembly concern After assembling BKT U frame connect fan connector to Main board before put Fan body in Lower case ...

Page 111: ... 5 1 Fan 8025 assembly concern before Figure 5 2 Fan 8025 assembly concern after 6 Front IR wire assembly concern Make sure IR wire is aligned between Optical engine housing and Lower case see figure 6 1 IR wire ...

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Page 113: ...113 11 Power Assembly Concerns 1 Power board component add GP glue 1 1 CY604 CY605 add glue ...

Page 114: ...114 1 2 CY625 CY612 add glue ...

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Page 116: ...116 1 3 C651 R651 add glue 2 SW2 solder by operator ...

Page 117: ...117 3 Power board top side check list 3 1 C601 and HS1 can t be touched each other 3 2 TR601 and HS1 can t be touched each other ...

Page 118: ...118 4 Process Q602 12 EMI Parts Assembly Concerns z All contact fact with conduct fabric isn t any paint or non conduct article Item Frequenc Solution ...

Page 119: ...119 1 180MHz 300MHz 1 1 Add three springs on the plate 1 2 1 2 Add one spring on the plate 2 300MHZ 420MHZ 2 Add two springs on the plate ...

Page 120: ...120 3 640MHZ 3 Add a Gasket on the lamp box 4 720MHZ 4 Add a Gasket on the DMD Board to Engine ...

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Page 123: ...123 9 180MHz 9 add gasket 4G J0C38 001 between iron plate and DMD Board 10 180MHz 10 add grounding wire of IR wire 5K J2J01 001 on the optical engine ...

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Page 125: ...ampen wire Lamp wire and Ballast wire 2 Check C W and wire connection 3 Check Main board 4 Check Lamp 5 Check Ballast 1 Check Input Cable 2 Check OSD Source set up 3 Check Main board 1 Check OSD Lamp Hours 2 Check Lamp Door 3 Check Lamp still light or not 4 Check Fan still spin or not 5 Check Thermal status 1 Check Remote module battery 2 Check Remote module 3 Check IR Reciver on Main board 4 Chec...

Page 126: ...e Edge 1 Refer to Item 2 1 attached below 2 Change CM 3 Change SUB HSG 8 Blue Purple Border 1 Refer to Item 2 1 attached below 2 Change CM 3 Change SUB HSG 9 Focus 1 Change Projection Lens 2 Check PL datum and DMD parallel 10 Dust Clean DMD 11 Horizontal Vertical Strips 1 Check connector between chipBD and MainBD 2 Re install DMD with chipBD 3 Check if any pin of C Spring is missing damaged or dir...

Page 127: ...zontal Adjustment Screw firstly then Vertical Adjustment Screw b Refer to Figure 2 1 Fig 2 1 II Re assemble LP module include LP LP Baffle LP clip 2 Overfill Vertical Adjustment Screw 1 Overfill Horizontal Adjustment Screw ...

Page 128: ...128 Chapter 3 Power Supply Trouble Shooting Guide 1 2 ...

Page 129: ...esired speed R R R Thermal Sensor 1 open error the remote diode has an open circuit condition DMD sensor R R G Thermal Sensor 2 open error the remote diode has an open circuit condition R R O Thermal Sensor 3 open error the remote diode has an open circuit condition G R R Thermal Sensor 1 short error the remote diode has an short circuit condition DMD sensor G R G Thermal Sensor 2 short error the ...

Page 130: ...BOX TEMPERATURE ERROR TEMPERATURE OVER 65 FRONT SENSOR OVER TEMPERATURE COUNT N A N A FAN IC I2C ERROR N A N A Level 3 Component Repair to Curcuit Boards Theory of Circuit Operation Chapter 1 System Operation Theory 1 1 Overview The Projector system consists of display function cooling function lighting function safety protection function and User interface control function and power control funct...

Page 131: ... power status lamp status and temperature status 3 IR remote function There are two IR receivers one is at the front side and the other one is at back side The receiver sensor has 3 legs pin1 is output pin2 is ground and pin3 is VCC 5V The output pin is pulled high and will sink to low when it receives infrared signal coming from remote controller MCU will decode the signal and execute related pro...

Page 132: ... reset itself and start to send the formatting data to DMD chip At the mean time MCU reset the cooling circuit and let it working Then the whole system is warming up 20 Turn Off function User can touch Power key or use remote controller to turn off the projector When MCU receives the command it will start the power down sequence DDP ASIC will be reset off and then Lamp enable signal will be turn o...

Page 133: ...ature sensor built in the system MCU will do polling the temperature status If the system temperature is over heat MCU will shut down the whole system Chapter 2 DLP Operation Theory 2 1 Overview The DLP is the abbreviation of Digital Light Processing technology The DLP consists of DMD data formatting Color light sequencing processing and the core component DMD chip Please sees figure 4 DMD data fo...

Page 134: ... modulation concept DMD data formatting circuit DMD chip Color Light sequence module Image Display output Light Source Color Sequence for DMD Figure 4 DMD image display concept Image Color Phase Synchronization Feedback ...

Page 135: ...try establish the 3 voltage levels that comprise the reset waveform The DDP ASIC supplies the timing information to the DAD1000 via the STROBE signal and controls which of the 16 individual reset signals will be output via the SR16ADDR 3 0 lines The SR16SEL 1 0 signals select the correct voltage level bias offset or reset for the current transition 3 The RAM is used with the DDP ASIC for bit plane...

Page 136: ...electronic alignment of the color wheel The CWINDEX signal is generated by color wheel sensor board that was attached around the motor hub 3 Light source control and synchronization circuit provides a lamp enable LAMPEN signal to control the projector lamp and ballast The LAMPEN is used for on off control as well as synchronization of AC lamps The LAMPLITZ signal shall be asserted to the DDP ASIC ...

Page 137: ...ger inverter and is fed to ADC device PC DDC signal will link to an EEPROM built on main board The EDID function setting data please refer to C212 Software Specification Component signal is plugged in by a VGA to RCA convert cable This signal will be also converted to digital data by ADC device Please refer figure 2 ADC device consists of Analog interface Sync processing and Digital interface The ...

Page 138: ...signal processing It is an integrated device that consists of A D interface Sync processing Luma Chroma decoding and processing and Digital output interface Please see Figure 9 3 4 Audio Signal Processing The PC Audio signal input to source board There is an audio amplifier built on it It supplies the mute control and volume control The output audio power is 2 watts Digital YUV 16 bits output Figu...

Page 139: ...ot spot points are Lamp Tip Lamp Burner DMD Heat sink and Lamp Box There are three fans blower fan main fan 1 and main fan 2 for driving airflow to cool down the system and hot spot point temperature Figure 10 Fan Control DC DC board BLOCK DIAGRAM Fan Control DC DC Board DC DC To PFC board REAR FAN DRIVER BLOWER FAN DRIVER To Main board B VCC V12 VDD 2V5 To Main board To Rear Fan To Blower Fan To ...

Page 140: ...meter interface MCU access fan driver device by I2C interface Thermal sensor interface is analog small sensitive signal The temperature measurement principle is calculating the biasing current of diode to figure out the temperature parameter of the diode Chapter 5 Power Supply Circuit Operation Theory 5 1 Overview The power supply unit includes EMI board PFC board DC DC board built on Fan board an...

Page 141: ...3 5V 1 4A 4 12V 0 5A 5 3 EMI filter EMI components include common choke L606 L603 X Capacitor C602 C603 Y Capacitor C604 C605 and differential choke L604 and discharge resistor R651A R651B This circuit designed to inhibit electric and magnetic interference for meet FCC class B and CISPR class B standard requirements 5 4 Bridge rectifier and filter ...

Page 142: ...142 Bridge converts the AC input into DC output and the CAP is AC filter ...

Page 143: ...he the boost converter This using a switching technique boost the recdtified input voltage to a regulated DC output voltage Vo The boost converter consists of a boost inductor L a controlled power switch Q a catch diode D an output capacitor Co and a PFC controller PFC s goal id to shape the input current in a sinsoidal fashion in phase with the input sinusoidal voltage ...

Page 144: ...11 VCC 10 VC 9 CT 15 IDET 16 C613 68P K C612 0 1U M D601 SF10L60U 3 1 R609 2 05K F D613 RB160L 40 A K D612 RB160L 40 A K Q601 SPW20N60C3 D G S C625 4700P M D611 27V 1 2 R631 20K L605 800U C608 220P t TR601 NTC 5OHM 2 1 C620 10U 50V 1 2 C611 0 01U K D614 BAV99 A J K C616 0 47U K R611 27K C601 220U 450V 1 2 R612 10K C615 0 33U K C619 0 1U M R613 47 20VPFC R614 10K C621 0 1U M R621 33K R622 169K F R6...

Page 145: ...o current error amplifier to connect compensation network 3 VDET Multiplier input input of multiplier to detect sinusoidal waveform 4 OVP overvoltage protection inpution overvoltage protection circuit 5 VFB voltage error amplifier output It s connect compensation network 6 VIN Inverting input to voltage erroramplifier It s detect PFC output voltage 7 GND Ground 8 OUT output output for direct drivi...

Page 146: ... D 2W 39K ES1D 630V 0 01U P6KE200A 380V To IC651 pin 7 Drain TO D703 In a flyback converter operated in the discontinuous mode the energy stored in the flyback transformer must be zero at the beginning and end of each switching period During the on time energy is stored in the transformer and energy taken from the transformer when the switching transistor turn off the stored energy is all delivere...

Page 147: ...2 C654 IC651 6 8 50V 0 1U 20K 47U 25V EL TOP247Y From T651 From IC652 The Power module IC is TOP247Y The function of each pins described as follow pin 1 Control pin pin 5 Frequency pin pin 2 Line sense pin pin 6 NA pin 3 External current limit pin pin 7 Drain pin pin 4 Source pin ...

Page 148: ...le feedback circuit of 12V It used IC750 for voltage regulation and IC652 for primary secondary isolation The output voltage will be controlled by IC750 pin 1 feedback the duty cycle of MOSFET will be decided to control the output voltage 5 9 Secondary rectifier and filter D703 C709 T651 2 5V GND Since the transformer T651 acts as a storing energy inductance Diode D703 is rectifier and capacitor C...

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Page 161: ...3 GEAR FIXBLOCK 1 BKT MB LC 3 POWER LC 2 LAMP BOX LC 2 BALLAST LC 3 3 8F VA564 8R0 TAP DELTA PH 8 NI 6 7 BLOWER LC 2 UC LC 4 4 8F VA564 100 TAP DELTA PH 10 NI 5 8 ENGINE LC 3 MB MB SHIELDING 5 MB BRACKET ENGINE 1 5 8F 1G524 6R0 MACH PAN 6 NI 4 5 BKT BLOWER NOZZLE 1 M3 6 8F 1A524 8R0 MACH PAN 8 NI 4 5 ASSY DOOR 2 4 40 7 8F 00480 120 MACH HEX 8 NI 3 5 MB REAR COVER 4 M4 8 8F 00010 161 MACH PAN 8 NI ...

Page 162: ...162 Appendix 2 Code List IR RS232 1 IR Code CUSTOMER CODE DATA CODE FUNCTION 2 RS232 command format 1 ...

Page 163: ...0x04 0x00 0x34 0x12 0x06 0x00 0x64 Horizontal position Read Horizontal position 0x07 0x14 0x00 0x05 0x00 0x34 0x00 0x00 0x12 0x06 0x65 Write Vertical position shift up 0x06 0x14 0x00 0x04 0x00 0x34 0x12 0x07 0x00 0x65 Vertical position Vertical position shift down 0x06 0x14 0x00 0x04 0x00 0x34 0x12 0x07 0x01 0x66 Read read Vertical position 0x07 0x14 0x00 0x05 0x00 0x34 0x00 0x00 0x12 0x07 0x66 co...

Page 164: ...0 0x04 0x00 0x34 0x13 0x01 0x07 0x67 Input source YPbPr2 W100 0x06 0x14 0x00 0x04 0x00 0x34 0x13 0x01 0x08 0x68 Input source YCbCr2 W100 0x06 0x14 0x00 0x04 0x00 0x34 0x13 0x01 0x09 0x69 Read Source 0x07 0x14 0x00 0x05 0x00 0x34 0x00 0x00 0x13 0x01 0x61 Write Source scan on 0x06 0x14 0x00 0x04 0x00 0x34 0x13 0x02 0x01 0x62 Source scan Source scan off 0x06 0x14 0x00 0x04 0x00 0x34 0x13 0x02 0x00 0x...

Page 165: ... 0x10 0x71 Read Write Language Reset Lamp usuage hour 0x07 0x14 0x00 0x05 0x00 0x34 0x00 0x00 0x15 0x00 0x62 0x06 0x14 0x00 0x03 0x00 0x34 0x15 0x01 0x61 0x07 0x14 0x00 0x05 0x00 0x34 0x00 0x00 0x15 0x01 0x63 Lamp Time error status Read read Lamp usuage hour 0x07 0x14 0x00 0x05 0x00 0x34 0x00 0x00 0x15 0x02 0x64 3 RS232 command format 2 CMD ACTION ASCII Power on pow on off pow off tatus on off coo...

Page 166: ...k Blank status blank Keystone Vertical Decrease keyst Increase keyst Keystone status keyst Preset mode Preset mode presentation PC appmod preset preset mode brightness appmod bright preset mode srgb appmod srgb Preset mode gaming appmod game Preset mode video appmod video preset mode movie appmod mov Preset mode cinema appmod cine Preset mode game appmod game Preset modephoto appmod phot Preset mo...

Page 167: ...ecrese Volume vol Volume vol Language English lang eng FRE Français lang fre Deutsch lang ger Italiano lang ita Español lang spa lang pro 繁體中文 lang cht 简体中文 lang chs 日本語 lang jap korean 한국어 lang kor swidish lang swd dutch lang dut turkish lang turk czech lang czech portugese lang portug thai lang thai polish lang pol Language lang Lamp Time Reset Lamp usuage hour ltim rst Lamp usuage hour ltim Err...

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