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CASTOR Y057, Field Service Manual

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CASTOR Y057 Field Service Manual Download Page 33

4.

Disassemble is completed.

Repair Action

Update

Change Parts

Main

Board

Firmware

Lamp

Module

Ballast

Blower

Color

Wheel

Version Update

V

V

Reset Lamp Hour

V

OSD Reset

V

V

Waveform Download and

Fan Calibration

V

V

V

V

Color Wheel Index

Adjustment

V

V

V

• After changing parts, please execute the related items as table show above.

OSD Reset

After final QC step, we have to erase all saved change again and restore the OSD default setting. The
following actions will allow you to erase all end-users' settings and restore the default settings:

1.

Please enter OSD menu.

2.

Choose "Settings" and then execute "Reset" function.

Disassembly & Assembly Process

31

Summary of Contents for Y057

Page 1: ...Castor PJ1 Machine Codes Y057 Field Service Manual August 2014 ...

Page 2: ......

Page 3: ...projector at an altitude of 3 000m or higher Using this projector at high altitude consult your dealer or Authorized Service Center about preparations About lead free solder PbF This projector is using the P C Board which applies lead free solder Use lead free solder in servicing from the standpoint of antipollution for the global environment Lead free solder Sn Ag Cu tin silver and copper has a h...

Page 4: ...ith the instructions may cause harmful interference to radio communications However there is no guarantee that interference will not occur in a particular installation If this equipment dose cause harmful interference to radio or television reception which can be determined by turning the equipment off and on The user is encouraged to try to correct the interference by one or more of the following...

Page 5: ...R Sensor and IR Sensor Board 14 Disassemble Main Board Module and Shielding 16 Disassemble Speaker Module and Filter Holder 20 Disassemble Engine Module 21 Disassemble System Fan Module 22 Disassemble Blower 25 Disassemble LVPS Module 25 Disassemble Ballast Module and Interrupter Switch 27 Disassemble Bottom Shielding and IO Cover Module 29 Repair Action 31 OSD Reset 31 Waveform Download and Fan C...

Page 6: ...ssignment 45 J1 8Pin POWER From LVPS 45 J2 Front IR 46 J10 Blower 46 J11 CW to MB 46 J12 Ballast 47 J13 Photo Sensor 47 J15 Speaker 48 J23 System Fan 48 Service Menu Explanation 49 Get into Service Mode 49 4 Firmware Update SYS Firmware Upgrade Procedure 53 Equipment Needed 53 DLP Composer Lite Setup Procedure 53 Firmware Upgrade Procedure 56 4 ...

Page 7: ...140 F 20 to 60 C 20 to 80 humidity non condensing Projection System Single DLP 0 55 chip Resolution 1024 768 pixels XGA Lens F 2 8 f 7 26mm Lamp High pressure mercury lamp 240W Lamp Life 3500hours typical Full Mode 5000 hours typical ECO1 ECO2 Mode 10000hours typical Auto Mode Projection screen size 40 200 inch Projection distance 0 51 2 54m Focus range Speaker 8W Mono Connection terminal Computer...

Page 8: ... Compatibility Signal Resolution Refresh Rate Hz Video Analog HDMI Mac NTSC 720 x 480 60 O PAL SECAM 720 x 576 50 O VGA 640 x 480 60 O O O 640 x 480 67 O 640 x 480 72 8 O O 640 x 480 85 O O SVGA 800 x 600 56 3 O 800 x 600 60 3 O O O 800 x 600 72 2 O O O 800 x 600 85 1 O O O 800 x 600 120 O O XGA 1024 x 768 60 O O O 1024 x 768 70 1 O O O 1024 x 768 75 O O O 1024 x 768 85 O O O 1024 x 768 120 O O WS...

Page 9: ...1280 x 1024 60 O O O 1280 x 1024 75 O O O 1280 x 1024 85 O O SXGA 1400 x 1050 60 O O UXGA 1600 x1200 60 O O HDTV 1080p 1920 x 1080 24 O O O 1920 x 1080 30 O 1920 x 1080 50 O O O 1920 x 1080 60 O O O O HDTV 1080i 1920 x 1080 50 O O 1920 x 1080 60 O O WUXGA 1920 x 1200 60 1 O O O SDTV 576i 768 x 576 50 O O SDTV 576p 768 x 576 50 O O SDTV 480i 640 x 480 60 O O SDTV 480p 640 x 480 60 O O Specification...

Page 10: ...ther than native 1024 x 768 native resolution of this model may result in some loss of image clarity 1 1920 x1200 60Hz only support RB reduced blanking 120Hz input signals may be dependent on graphics cards support 1 Product Information 8 ...

Page 11: ...pment Needed Product Overview 1 Screw Bit 105 2 Screw Bit 107 3 Screw Bit 107 4 Hex Sleeves 5 mm 5 Long Nose Nipper 6 Tweezers 7 Projector Before you start This process is protective level 2 Operators should wear electrostatic chains 9 ...

Page 12: ...ate the Lens Cap and projector as blue square 2 Pull down the tenon as red square to disassemble the Left Filter 3 Pull down the tenon as yellow square to disassemble the Right Filter 4 Disassembled the Left Filter A and the Right Filter B 2 Replacement and Adjustment 10 ...

Page 13: ...t the Focus Ring When you assemble the Focus Ring ensure the 3 card slot as green square placed in the 3 double screw bolt as red circle properly and the Focus Ring can be well adjusted Disassemble Lamp Module 1 Loosen 1 screw as red circle on the Lamp Cover Disassembly Assembly Process 11 ...

Page 14: ...2 Disassembled the Lamp Cover 3 Loosen 2 screws as yellow circle on the Lamp Module 4 Take off the Lamp Module 2 Replacement and Adjustment 12 ...

Page 15: ...ew 2 screws as red circle from the Top Cover and unscrew 8 screws as green circle from the Bottom Cover 2 Pull upward the Top Cover Module 3 Unplug connector as blue square then remove the Top Cover Module Disassembly Assembly Process 13 ...

Page 16: ...semble the Top Cover Module Disassemble IR Sensor and IR Sensor Board 1 Unscrew 2 screws as red circle and tear off the Tape as yellow square to disassemble the IR Sensor Module 2 Replacement and Adjustment 14 ...

Page 17: ...2 Tear off the Mylar as blue square 3 Separate the IR Holder and IR Sensor Board 4 Tear off the Tape as red square to disassemble the IR Sensor Board Disassembly Assembly Process 15 ...

Page 18: ...lar as red square Disassemble Main Board Module and Shielding 1 Tear off the Tape as blue square and unscrew 4 screws as red circle 2 Unscrew 8 hex screws as green circle and screw as yellow circle 2 Replacement and Adjustment 16 ...

Page 19: ... Unplug 3 connectors as red square and 1 connector as yellow square of Blower 4 Unplug connector as green square of Color Wheel Correctly SYS FAN Cable as the below arrow Disassembly Assembly Process 17 ...

Page 20: ...nector on Main Board The key feature Figure A System Fan Compose of Red Blue Black wire 3 pin B Blower Compose of Red White Black wire 3 pin C Photo Sensor Compose of Red Black White wire Red Connector and Black wire tube 3 pin D Speaker Compose of Black Red wire and Black wire tube 2 pin 2 Replacement and Adjustment 18 ...

Page 21: ...6 Disassemble Main Board Module 7 Unscrew 3 screws as green circle to disassemble the Shielding Disassembly Assembly Process 19 ...

Page 22: ...Speaker Module and Filter Holder 1 Unscrew 2 screws as yellow circle to disassemble the Speaker Module 2 Separate the Speaker and Rubber 3 Separate the Filter Holder as yellow square 2 Replacement and Adjustment 20 ...

Page 23: ...and right filter B Disassemble Engine Module 1 Unscrew 4 screws as yellow circle to disassemble the Engine Module 2 Unscrew 2 screws as red circle to disassemble the Color Wheel Module Disassembly Assembly Process 21 ...

Page 24: ...cle to disassemble the Photo Sensor Board 4 Unscrew screw as red circle to disassemble C W Module and C W Holder Plate Disassemble System Fan Module 1 Unplug the Thermal Fuse connector as blue square 2 Replacement and Adjustment 22 ...

Page 25: ...2 Unscrew 5 screws as red circle to disassemble System Fan Module 3 Unscrew 4 screws as green circle to separate System Fan and Fan Shielding Disassembly Assembly Process 23 ...

Page 26: ...4 Unscrew 2 screws as blue circle to disassemble Thermal Fuse 5 Separate Thermal Fuse and Thermal Fuse Holder Take the Fan Module as the right gesture 2 Replacement and Adjustment 24 ...

Page 27: ...sassemble the Blower Module 2 Separate the Blower and Blower Rubber Disassemble LVPS Module 1 Unscrew 7 screws as red circle to disassemble the LVPS Module Two screws for AC inlet One screw for ground cable Four screws for LVPS Disassembly Assembly Process 25 ...

Page 28: ...2 Unplug 3 connectors as green square 3 Remove the Cable and the AC Inlet Bracket from LVPS Module 2 Replacement and Adjustment 26 ...

Page 29: ...Disassemble Ballast Module and Interrupter Switch 1 Disassemble the Ballast Module as yellow square 2 Unscrew screw as red circle to disassemble the Interrupter Switch Disassembly Assembly Process 27 ...

Page 30: ...3 Take the Interrupter Switch as green square 4 Unplug 3 connectors as red square 5 Unscrew 4 screws as green circle 6 Separate Ballast and Ballast Holder 2 Replacement and Adjustment 28 ...

Page 31: ...w as red circle separate Ballast Holder and Ballast 2P Cable Disassemble Bottom Shielding and IO Cover Module 1 Take off the Bottom Shielding and Mylar and unscrew 3 screws as red circle Disassembly Assembly Process 29 ...

Page 32: ...e Bottom cover Module and IO Cover Module 3 Tear off Mylar as blue square and Sponge as red square Pull out the Security Bar as yellow square Unscrew 2 hex screws as green circle 2 Replacement and Adjustment 30 ...

Page 33: ...lor Wheel Index Adjustment V V V After changing parts please execute the related items as table show above OSD Reset After final QC step we have to erase all saved change again and restore the OSD default setting The following actions will allow you to erase all end users settings and restore the default settings 1 Please enter OSD menu 2 Choose Settings and then execute Reset function Disassembly...

Page 34: ...by pressing the buttons sequentially as follows Power Left Left Menu 6 Select Factory Fan RPM on the service menu and press Menu button The picture as shown below will appear Check that the value of Factory RPM is within the range Color Wheel Index Adjustment After replacing main board optical engine or upgrading firmware the Color Wheel Index Adjustment should be done Color wheel index adjustment...

Page 35: ...ndex Adjustment mode 4 Choose Color Wheel Index press Menu button to enter the Color Wheel Index Adjustment 5 Adjust the color and gradation of the pattern correctly on the screen by pressing the Left or Right button Disassembly Assembly Process 33 ...

Page 36: ...2 Replacement and Adjustment 34 ...

Page 37: ...ge LAMP Red TEMP Red STANDBY LED Red Green Standby Normal Power ON Cooling state Flashing 0 5 Sec Power up Flashing 0 5 Sec Firmware Download Over Temp Fan lock Flashing 0 5 Sec Lamp Fail Color Wheel Fail Flashing 0 5 Sec Steady light No light 35 ...

Page 38: ...Troubleshooting Guide Main Procedure 3 Troubleshooting 36 ...

Page 39: ...NO Power Troubleshooting Troubleshooting Guide 37 ...

Page 40: ...Power Troubleshooting 3 Troubleshooting 38 ...

Page 41: ...Image Troubleshooting 1 Troubleshooting Guide 39 ...

Page 42: ...Image Troubleshooting 2 3 Troubleshooting 40 ...

Page 43: ...Image Troubleshooting 3 Troubleshooting Guide 41 ...

Page 44: ...Image Troubleshooting 4 3 Troubleshooting 42 ...

Page 45: ...Remote Control Troubleshooting Troubleshooting Guide 43 ...

Page 46: ...Audio Troubleshooting 3 Troubleshooting 44 ...

Page 47: ...tage V 1 12 V 12 25 V 5 2 12 V 12 25 V 5 3 12 V 12 25 V 5 4 5 V 5 V 5 5 GND 0 V 6 GND 0 V 7 GND 0 V 8 PFC_ON Signal High 3 3 V Low 0 V 9 GND 0 V 10 GND 0 V 11 GND 0 V 12 GND 0 V 13 GND 0 V 14 12 V 12 25 V 5 15 12 V 12 25 V 5 16 12 V 12 25 V 5 Pin Assignment 45 ...

Page 48: ...iption Voltage V 1 5 VSBY 5 V 5 2 GND 0 V 3 IR_8051_F_1 Signal High 5 V Low 0 V J10 Blower PIN Description Voltage V 1 FAN_V2 4 5 V to 12 25 V 2 FAN_LOCK Signal High 3 3 V Low 0 V 3 GND 0 V J11 CW to MB 3 Troubleshooting 46 ...

Page 49: ...l High 12 25 V Low 6 5 V 4 CWY1 Signal High 12 25 V Low 6 5 V J12 Ballast PIN Description Voltage V 1 LAMPLIT_IN Signal High 5 V Low 4 V 2 GND 0 V 3 5 V 5 V 5 4 LAMPEN_OUT Signal High 5 V Low 2 5 V 5 LAMP_TXD4 Signal High 5 V Low 2 5 V J13 Photo Sensor PIN Description Voltage V 1 P5 V 5 V 5 Pin Assignment 47 ...

Page 50: ... to 0 V 3 GND 0 V J15 Speaker PIN Description Voltage V 1 RON_1 Signal 0 V to 12 5 V 2 ROP_1 Signal 0 V to 12 55 V J23 System Fan PIN Description Voltage V 1 FAN1_V1 4 5 V to 12 25 V 2 FAN1_LOCK Signal High 3 3 V Low 0 V 3 GND 0 V 3 Troubleshooting 48 ...

Page 51: ...ower Left Left Menu buttons sequentially on remote controller or on the top panel to get into service mode Item Description Explanation For Service 1 MCU M01 Shows the present MCU FW version V 2 PJ K360 Indicate the model name V Service Menu Explanation 49 ...

Page 52: ...the fan lock times V 12 Lamp Fail Counts the lamp ignite fail times V 13 CW Fail Counts the color wheel times V 14 Spoke Test To select some test pattern for simple test V 15 Burn in Test Choose this option and press enter key getting into Burn in Test menu V 16 Color Wheel Index Choose CW index to adjust color wheel index V 17 ADC Calibration To adjust the white and black signal level V 18 SNID R...

Page 53: ...ation For Service 23 Factory Fan RPM Shows the FAN rotate value V 24 Factory Reset Resets the projector s value V 25 Internal Bus Log Records the I2C bus error status 26 Exit Leaves Service Menu V Service Menu Explanation 51 ...

Page 54: ...3 Troubleshooting 52 ...

Page 55: ...e Equipment Needed Software DLP Composer Lite 11 1 1 Firmware img 11 1 1 FlashDeviceParameters Hardware Projector Power Cord RS232 Cable 9P F TO 9P M PC or Laptop DLP Composer Lite Setup Procedure 1 Choose DLP Composer Lite V11 1 1 Setup Program 53 ...

Page 56: ...2 Click Next 3 Read License Agreement Choose I accept and agree to be bound by all the terms and conditions of this License Agreement Click Next 4 Firmware Update 54 ...

Page 57: ...4 Click Next 5 Click Next 6 Click Next SYS Firmware Upgrade Procedure 55 ...

Page 58: ...Set up Hold on Power button and plug in the power cord Until Power will light orange Temp and Lamp LED will light red loosen Power button Connect projector with RS232 cable to PC 2 Execute the DLP ComposerTM Lite 11 1 1 file 4 Firmware Update 56 ...

Page 59: ...eviceParameters Put FlashDeviceParameters file into the folder where you setup DLP Composer Lite 11 1 1 4 Click Edit and Preferences 5 Click Communications Select Serial Port then click Configure Select the COM Port which you are using SYS Firmware Upgrade Procedure 57 ...

Page 60: ...115200 2 In Data Bits item select 8 3 In Stop Bits item select 1 4 In Parity item select None 5 In RTS item select Enable 6 In CTS item select Disable 7 Key in 2000 into Read and Write items of Timeouts in milliseconds Click OK 7 Choose Flash Loader Click Browse to search the firmware file img Click Open 4 Firmware Update 58 ...

Page 61: ...skip Boot Loader Area Select 32KB Click Reset Bus to erase the flash memory 9 If the FW is ready click Start Download to execute the firmware upgrade Click Yes to erase the flash memory SYS Firmware Upgrade Procedure 59 ...

Page 62: ...ocess is finished Download Complete will appear 11 Check SYS FW version Re plug in power cord and Power on the projector Get into the service mode Power Left Left Menu to check the system firmware version 4 Firmware Update 60 EN ...

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