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SP7205 Service Manual

35

Lamp Door and Lamp Module

The lamp door fits over the lamp cavity in the projector. It includes a tab that closes the interlock switch

when the door is shut.

The lamp module consists of a metal housing and enclosed reflector assembly and arc tube. A blower on

the side of the lamp module provides cooling air to the arc tube and reflector inside of the housing.

CAUTION

The lamp module gets very hot during operation. Allow the lamp to cool for 30 minutes before

handling it. The lamp module gets very hot during operation. Allow the lamp to cool for 30 minutes

before handling it.

1

Place the projector upside down on a soft work surface.

2

To remove the lamp door, loosen the two captive screws that secure it to the projector.

3

To remove the lamp, loosen the captive screw that secures it in the projector, swing the bail on

the top of the lamp module up from its storage position, and then pull the module out of the

projector.

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Summary of Contents for ScreenPlay 7205

Page 1: ...ScreenPlay 7205 Service Guide ...

Page 2: ...30 Handle 31 I O EMI Shield 32 Keypad 33 Lamp Door and Lamp Module 35 Outer Handle 37 Power Supply 39 Rear IR Receiver 42 Rear Bezel 43 Safety Switch 45 Top Case 47 Troubleshooting 49 Power and Start up Problems 50 Image Problems 58 Keypad Problems 59 Remote Problems 60 Audio Problems 61 Block Diagram 62 Check Controller Voltages 63 Power Up with Top Case Removed to Check Fans and Voltages 64 Chec...

Page 3: ...rmful interference to radio communications Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense WARNING Changes or modifications made to this equipment not expressly approved by Toshiba or parties authorized by Toshiba could void the user s authority to operate the equipment ...

Page 4: ...le operation of the product and to protect it from overheating and these openings must not be blocked or covered The openings should never be blocked by placing the product on a bed sofa rug or other similar surface This product should not be placed in a built in installation such as a bookcase or rack unless proper ventilation is provided or the manufacturer s instructions have been adhered to IM...

Page 5: ...e are other parts you must remove to access the part you want you should go to those removal instructions NOTE You can also see a flow chart of FRU removal FRU Hierarchy on page 6 shows a chart of which parts must be removed to access any FRU in the projector Generally the replacement procedure is the reverse of the removal process Sometimes you will find special instructions under Assembly Notes ...

Page 6: ... flow chart below shows what parts must be removed to access each FRU in the projector The parts on the first level the lamp door for example are accessible without removing any other parts The more levels down a part is the more parts you need to remove ...

Page 7: ...ruments as well as cause personal injury 1 Remove the following items Lamp module page 35 Outer handle page 37 Rear bezel page 42 Top case page 47 Controller ECA page 14 2 Remove the two M3x6 Torx screws from the lamp connector retainer on the front of the chassis 3 Unplug the ballast power supply cable from X1 and the lamp control cable from the connector on the ballast Squeeze the latch on the s...

Page 8: ...ly Notes Plug in the power supply ballast cable and the lamp control cables to their connectors on the ballast Position the bottom of the ballast in the slots in the chassis Make sure the two screw holes in the ballast align with the threaded standoffs on the wall of the chassis Install and torque the two M3x8 Torx screws to 6 in lbs 68 Nm ...

Page 9: ... bezel page 42 Top case page 47 Inner handle and front vent page 31 Controller ECA page 14 Fan assembly page 26 Chassis page 11 Optical engine page 24 Side IR receivers and lenses page 42 Rubber feet page 45 Leveling foot page 37 2 Remove the serial number label from the certification label To do this carefully use a heat gun or hair drier to soften the adhesive on the back of the label then peel ...

Page 10: ...erial number box Adhere one of the old rubber feet to the foot at the rear of the bottom case Adhere the other rubber foot to the center of the leveling foot knob Use new rubber feet if the adhesive was damaged when you removed the old ones from the old bottom case Replace the parts in the bottom case reversing the order you used to remove them ...

Page 11: ...er lamp connector retainer and safety switch fasten to the chassis The ballast power supply insulator provides electrical insulation between the chassis and components inside it 1 Remove the following items Lamp module page 35 Outer handle page 37 Rear bezel page 42 Top case page 47 Controller ECA page 14 Rear IR receiver page 42 2 Remove the four M3x8 Torx screws that fasten the chassis to the bo...

Page 12: ...side of the chassis above the power supply ground terminal 4 Remove the two M3x6 Torx screws from the lamp connector retainer on the front of the chassis The lamp connector and lamp connector retainer remove with the chassis 5 Lift the chassis from the bottom case ...

Page 13: ... chassis so that the holes in the bottom of the insulator align with the ballast mounting slots and power supply standoffs that protrude from the floor of the chassis Then press the insulator over the ballast mounting standoffs on the front of the chassis WARNING The insulator must always be installed between the ballast and power supply and the chassis Inspect the gasket closely whenever the ball...

Page 14: ...mely fragile If it breaks the glass shards are sharp and can cut your fingers When working with the color wheel take care not to scrape it against the metal portions of the optical engine Handle the color wheel only by the motor Do not touch the glass with your fingers Ccontamination from oil on the fingers can cause hot spots on the color wheel which could lead to breakage 8 Remove the optical en...

Page 15: ...nce you remove the screw all that is holding the color wheel to the engine are two alignment pins that insert into two matching holes on the color wheel bracket 13 Remove the color wheel from the engine To do this grasp the metal heatsink and carefully pry the bracket away from the engine with a small bladed screwdriver ...

Page 16: ... Handle the new color wheel only by the heatsink and bracket Do not touch the glass or flex the color wheel Bearing damage could occur Torque the color wheel and color wheel shroud screws to 6 in lbs 67 Nm InFocus recommends that you use a calibrated driver to avoid stripping the threads in the aluminum engine Connect the color wheel cable to the color wheel ECA before you install the engine in th...

Page 17: ...ge www infocus com service sp7205 asc resources asp 1 Connect the projector and computer Display the computer image The projector must be five feet from the projection screen 2 Open the Color Ramp screen in Microsoft Paint or similar application Display it full screen 3 Observe the screen in a dark room If the three colors do not smoothly progress from black to color the color wheel index must be ...

Page 18: ...e the Hidden Service menu to adjust the color wheel index To enter the Hidden Service menu do the following a Use the Director remote control to navigate to Main Settings Service b On the Service menu select Service Code to display the password box c Immediately press the following keys in order on the remote control i Source 1 ii Source 3 iii Source iv Overscan v Contrast vi Contrast If the Hidde...

Page 19: ...s an illustration showing the sequence of keys to press on the remote 5 On the Hidden Service menu select Color Wheel Index The color wheel index slider bar appears to the right of the menu Both appear on top of the color ramp screen ...

Page 20: ... to adjust the color uniformity on the color ramp screen 7 When you finish press the Menu button to close the Hidden Service menu and accept the changes NOTE As long as the projector remains powered up you do not need to re enter the password to open the Hidden Service menu ...

Page 21: ... new I O shield over the input and output ports WARNING Be sure to take proper ESD precautions while working near the controller ECA It can be easily damaged by static electricity ECAs damaged by static electricity require replacement 1 Remove the following items Outer handle page 37 Rear bezel page 42 Top case page 47 2 Unplug the two fan cables the front rear and two side IR receiver cables the ...

Page 22: ...tom of the connector to release it 4 Remove the seven M3x8 Torx screws that fasten the controller ECA to the chassis 5 Lift the controller ECA over the optical engine to release the DMD controller connector 6 Lift the controller out of the projector WARNING Make sure to store the controller ECA in a static safe container ...

Page 23: ...ews to 6 in lbs 68 Nm Plug in the controller power supply cable Make sure the cable is clear of the fan blades Secure cables around the fans in their retainers to prevent cable damage or fan blade blockage Plug in the two fan cables the front rear and two side IR receiver cables the photodiode cable the color wheel ribbon cable and the light tunnel heater cable See page 67 if you need help with th...

Page 24: ... DMD Color wheel provides colors for the DMD to use in image production Light tunnel conducts focused light from the lamp module to the DMD Light tunnel heater maintains a stable light tunnel temperature preventing unwanted expansion and contraction that degrades the image Photodiode reads color wheel rotation to maintain proper synchronization with the DMD and allow accurate image color reproduct...

Page 25: ...ket 4 Grasp the engine around the projection lens barrel Then lift the engine up out of the case 5 Place the engine on a static free surface or in an ESD protected container Assembly Note Make sure the engine aligns with the holes in the mounting bracket Torque all five of the M3x8 Torx screws to 6 in lbs 68 Nm ...

Page 26: ...mbly Notes Make sure bottom and sides of the fan bracket engage the slots in the bottom case and the front vent The fan bracket fits into the bottom case only one way Plug the cable from the fan nearest the lamp into connector J506 on the controller ECA The cable from the fan nearest the power supply plugs into connector J517 on the controller ECA Plug the cable from the left IR receiver into conn...

Page 27: ...ner slots inside the zoom ring engage alignment pins on the outside of the lens Three retainer tabs on the zoom ring engage holes on the lens barrel 1 Place the projector right side up on a soft work surface 2 Grasp the focus ring and pull it off of the lens barrel The retainer slots disengage the pins on the lens 3 Stand the projector on its rear side and insert a small flat blade screwdriver int...

Page 28: ...205 Service Manual 28 4 Gently pull forward on the zoom ring and repeat step 3 for the other two retainer tabs 5 When you release all 3 retainer tabs grasp the zoom ring and pull it off of the lens barrel ...

Page 29: ...d fit snugly against the collar inside the zoom ring Rotate the zoom ring to ensure that the tabs properly engage the holes Align the three slots on the focus ring with the three alignment pins on the end of the lens barrel Press the focus ring into place Rotate the focus ring to ensure that the slots properly engage the alignment pins Place the lens cap over the focus ring ...

Page 30: ...from the remote control 1 Remove the following items Outer handle page 37 Rear bezel page 42 Top case page 47 2 Unplug the front IR receiver cable it from J500 on the controller ECA 3 Slide the front IR receiver upward and out of the alignment slots in the inner handle Assembly Notes Route the cable to the left of the front IR receiver ECA and through the saddle at the top of the inner handle Make...

Page 31: ...e 37 Rear bezel page 42 Top case page 47 Front IR receiver page 30 2 Lift the handle from the side of the projector opposite the lens Swing the handle upward slightly then lift it from the bottom case Assembly Notes Position the front vent in the slots in the bottom case Make sure that it fits properly and that the side of the fan bracket rests in the vertical slot along the back of the vent ...

Page 32: ...op case page 47 2 Remove the six 4 40 jack screws and the two Phillips screws that fasten the EMI shield to connectors on the controller ECA 3 Carefully pull the I O EMI shield off of the connectors Take care not to bend the shield or the fingers as you work the shield off Assembly Notes Make sure the fingers on the shield contact the connectors Torque the jackscrews to 2 in lbs 226 Nm Lightly snu...

Page 33: ...ilable separately 1 Remove the following items Rear bezel page 42 Outer handle page 37 Top case page 47 2 Place the top case face down on a soft work surface 3 Remove the eight M3x6 Plastite Torx screws that fasten the keypad to the top case Then lift the keypad ECA out of the recess in the top case 4 Gently lift the rubberized key set out of the top case ...

Page 34: ... set fit only one way in the top case Make sure that the alignment holes in the keypad ECA fit over the pins in the top case Make sure that the collar on each key fits flush against its hole in the top case Torque the eight M3x6 Plastite Torx screws to 4 in lbs 452 Nm ...

Page 35: ... the housing CAUTION The lamp module gets very hot during operation Allow the lamp to cool for 30 minutes before handling it The lamp module gets very hot during operation Allow the lamp to cool for 30 minutes before handling it 1 Place the projector upside down on a soft work surface 2 To remove the lamp door loosen the two captive screws that secure it to the projector 3 To remove the lamp loose...

Page 36: ...ush in the door opening it is probably because the bail is not completely folded down You must replace the lamp door for the projector to operate If you installed a new lamp module follow the directions below to reset the lamp timer a Power up the projector b Hold down the two Brightness buttons on the projector keypad for 10 seconds c After you reset the lamp timer read the timer value to make su...

Page 37: ...ector and hold the outer handle in place The outer handle contains the front IR lens The lens snaps into the recess in the outer handle A new outer handle does not include a front IR lens 1 Insert a small flat blade screwdriver behind the edge of the outer handle near the lens 2 Gently pry the edge of the outer handle away from the projector CAUTION Don t pry against the focus ring or lens 3 Pull ...

Page 38: ...m its slot on the outer handle Assembly Notes Align the two tabs on the front IR lens with the slots on the outer handle Press the lens into place to secure it Position the outer handle against the front of the projector so that the pins align with the holes in the top and bottom case tabs Then press the outer handle into place against the front of the projector ...

Page 39: ... also interfaces with the controller ECA through the power supply controller ECA cable to provide DC power and exchange control signals 1 Remove the following items Outer handle page 37 Rear bezel page 42 Top case page 47 Controller ECA page 14 2 Unplug the safety switch cable from J3 on the power supply Then unplug the power supply controller ECA cable from P1 the ballast power supply cable from ...

Page 40: ...he side of the chassis 4 Use a Torx T 10 screwdriver to remove the seven M3x8 screws that fasten the power supply to the chassis 5 Lift the forward side of the power supply to allow the AC line connector to pass through the hole in the chassis Then lift the power supply away from the chassis ...

Page 41: ...o 6 in lbs 68 Nm Connect the ground terminal to the chassis Torque the M3x8 Torx screw to 6 in lbs 68 Nm Connect the safety switch cable to J3 on the power supply Then connect the power supply controller ECA cable to P1 the ballast power supply cable to J1 and the lamp control cable to J4 on the power supply Make sure that you route the safety switch cable through the eye at the front left side of...

Page 42: ...le page 37 Rear bezel page 42 Top case page 47 Fan assembly page 26 2 Unplug the rear IR receiver cable from J518 on the controller ECA 3 Remove the two M3x8 Torx screws that fasten the rear IR receiver to the chassis Assembly Notes Route the cable to the inside of the rear IR receiver ECA Make sure that the rear IR receiver aligns with the hole in the chassis Torque the two M3x8 Torx screws to 6 ...

Page 43: ...inside of the rear bezel If you replace the rear bezel you need a replacement I O panel label You cannot remove the label from the rear bezel A new rear bezel does not include a rear IR lens or security plate 1 Remove the two M3x8 Torx screws from the rear bezel 2 Pull the rear bezel away from the projector 3 To replace the rear IR lens press on one of the tabs on the lens to disengage it from the...

Page 44: ...SP7205 Service Manual 44 Assembly Notes When you install a new rear bezel affix the new I O panel label to the outside of the bezel Torque the two M3x8 Torx screws to 6 in lbs 68 Nm ...

Page 45: ...e the M3x6 Torx Plastite screw that fastens the thermal switch to the lamp connector retainer 3 Remove the two M2x8 Torx screws that fasten the safety switch to the chassis Then remove the safety switch cable from the eye on the chassis 4 Remove the safety switch from the chassis Assembly Notes To install the safety switch orient it so that the lever actuator faces away from the mounting tab on th...

Page 46: ...7205 Service Manual 46 Torque the M3x6 Torx Plastite screw to 3 in lbs 34 Nm After you install the safety switch route the cable through the eye on the chassis Connect the cable to J3 on the power supply ...

Page 47: ...remove the top case you also have access to the elevator button A new top case contains two speakers You cannot remove the speakers from the top case 1 Remove the following items Rear bezel page 42 Outer handle page 37 2 Place the projector right side up on the bench and then remove the two black M3x8 Torx screws from the bottom case 3 Slowly lift the top case away from the projector Avoid stress ...

Page 48: ...is use a small flat blade screwdriver to depress the retainer tab on the side of the elevator button Then slide the button out of the top case Assembly Notes If you re replacing the top case with a new one install the elevator button Adhere a new nameplate to the top case in the recess near the handle Connect the keypad lamp blower contact ECA cable the speaker cable and the keypad cable Make sure...

Page 49: ...you through a series of steps that will ultimately result in a solution The solutions begin with the most simple and progress to the most complex What do you want help solving Power problems including lamp issues partial power up shutdown and no power page 50 Image problems including no image bad color dim image and other picture distortions page 58 Keypad problems page 59 Remote problems page 60 ...

Page 50: ...w the entire power diagnosis sequence page 51 LED Status LED flashes green The projector is starting up after the Power button was pressed or the projector is shutting down after the Power button was pressed LED is solid green The projector is ready to light the lamp when the Power button is pressed Or the lamp is lit and the projector is operating properly LED flashes red once The lamp will not s...

Page 51: ... did not light Red Go to Power Diagnostics part 2 page 52 Go to Error Codes page 53 This is the normal condition LED light green or red Confirm that unit is good by starting again Confirm that unit is good by starting again Solve the problem Yes Yes No Replace keypad ECA page 33 Note A solid green LED means the projector is either waiting for a command or is operating normally A flashing green LED...

Page 52: ...ssing the Power button twice The lamp does not light Replace keypad ECA page 33 Repeat process to confirm the problem fixed Run the projector long enough to ensure that the problem is solved If the lamp goes out and the LED turns red go to error codes page 53 No The lamp does not light and the LED begins blinking red The lamp attempts to strike five times at 30 second intervals After 2 1 2 minutes...

Page 53: ...s the flashing pattern Red LED flashes have 2 second intervals between series of flashes For example the LED may flash 4 times the pause for 2 seconds the flash 4 times again 5 flashes The projector detects high internal temperature Diagnose thermal problems page 56 On Off 4 flashes A fan failed Check the fans page 64 On Off On Off 2 flashes The lamp timer registers lamp use of 2000 hours or more ...

Page 54: ...age 35 Yes Ensure that the safety switch cable is connected to the power supply Also ohm out the interlock switch and the thermal switch to make sure they are good If not replace the safety switch assembly page 69 Replace the ballast page 7 Replace controller ECA page 21 Replace power supply page 39 Yes Ensure that the color wheel cable is connected to the controller ECA page 67 Can you hear the s...

Page 55: ...ng that the lamp won t strike Go to page 54 to solve failure to strike problems The top of the lamp module includes three contacts that must align with three matching contacts inside the projector To ensure contact two alignment pins on the lamp engage two holes in the lamp cavity Make sure the pins engage the holes If the lamp is improperly installed the lamp door will probably not seat properly ...

Page 56: ...r ECA page 21 Substitute a good power supply and run projector long enough to know if that is the problem page 39 Yes This is a thermal problem If a fan isn t running it causes a power up problem because fans have a sensor line that prevents the projector from properly starting up Is the thermal switch good Replace the safety switch page 45 The problem is almost always a power supply or controller...

Page 57: ...ace the controller ECA page 21 Reseat color wheel cable page 67 If color wheel does not spin replace the color wheel assembly page 14 Yes No Does the color wheel start and the lamp light Replace the controller ECA page 21 To confirm that the problem is solved restart the diagnosis process page 51 Yes No When you press the Power button you should hear the brief high pitched sound of the color wheel...

Page 58: ...n frozen plaid repeated or shifted image Flash the projector with the latest software Confirm that all image adjustments are set to the factory defaults Select Factory Reset from the Settings Service menu Confirm that the cables and the source signals are good If in doubt feed the signal to a good projector What is the problem Dim image Replace the lamp page 35 Replace the optical engine page 24 R...

Page 59: ... the projector Make sure you try the remote through at least two lenses If one or more IR receivers do not work go to Remote problems page 56 Keypad does not respond to key presses Does the remote control work No Replace the controller ECA page 21 Yes Replace the keypad ECA page 33 ...

Page 60: ...h of the IR receivers on the projector There are IR receivers on all four sides of the projector Issue a remote command to each receiver Does the projector respond to the command from any of the IR receivers No Replace the controller ECA page 21 Yes Replace the malfunctioning IR receiver s Front IR receiver page 30 Right or left IR receiver replace bottom case page 9 Rear IR receiver page 42 ...

Page 61: ...ECA Run the projector with audio for 30 minutes If the problem returns replace both the controller ECA and the top case if the resistance across either speaker coil no longer measures approximately 16 ohms Is there sound Yes No Is there sound from both speakers No only one Replace the controller ECA page 21 Yes Problem solved Make sure the speaker cable is connected to the controller ECA ...

Page 62: ...SP7205 Service Manual 62 Block Diagram ...

Page 63: ...SP7205 Service Manual 63 Check Controller Voltages To check voltages you need to power up the projector with the top case removed See page 64 for instructions on how to do this ...

Page 64: ...he top case from the projector Once the top case is removed you can power up the projector and check internal voltages or verify whether the fans operate 1 Remove the following items Top case page 47 NOTE The lamp and the lamp door must be in place to start the projector with the top case removed 2 Remove the lamp blower contact ECA from the top case ...

Page 65: ...s point the remote at any side of the projector and press Power If you do not have a remote connect the keypad cable to the controller ECA and power up the projector using the keypad CAUTION When you start the projector there is voltage present on the controller ECA and power supply Be very careful where you probe and where you touch 6 Do one or all of the following Check controller ECA voltages p...

Page 66: ...is bad unplug the connector for the suspect unit then plug in a known good fan or blower 9 If the lamp blower fails to operate replace the lamp module page 35 10 If one of the fans fails to operate remove the fan assembly and replace the defective fan page 26 ...

Page 67: ...speed If you don t hear the sound or if you are not sure you can do a visual check to confirm the color wheel operation If the color wheel is not spinning the first item to check is the color wheel cable connection and reseat it if necessary To check color wheel operation and reseat the cable do the following 1 Power up the projector with the top off page 64 NOTE The lamp and the lamp door must be...

Page 68: ...nual 68 3 If the color wheel is not spinning check and reseat the color wheel cable connection To reseat the cable open the ZIF connector and pull the cable out Re insert the cable fully and then close the ZIF connector ...

Page 69: ...own after operating for a few minutes or when the lamp fails to strike after repeated attempts at startup you need to check the thermal switch operation First power up the projector with the top off page 64 Let the projector run until it shuts down Measure the resistance at the switch If the resistance is infinity Ω replace the safety switch assembly which includes the thermal switch Go to remove ...

Page 70: ... Parts Exploded View NOTE The exploded view below shows the available parts for the SP7200 The parts in the SP7205 look identical however not every part is available as an FRU Be sure to check the parts list to confirm a specific part is available ...

Page 71: ...xploded View NOTE The exploded view below shows the available parts for the SP7200 The parts in the SP7205 look identical however not every part is available as an FRU Be sure to check the parts list to confirm a specific part is available ...

Page 72: ...990 xx Window IR rear Chassis 505 1236 xx S A system chassis Lamp Door 505 1380 xx S A elastomer keypad Outer Handle 505 1473 xx S A handle outer Focus Ring 505 1474 xx S A focus ring Fan Assembly 505 1479 xx S A fans bracket Handle 505 1481 xx S A handle Bottom Case 505 1486 xx S A enclosure lower Rear Bezel 505 1487 xx S A enclosure rear Top Case 505 1810 xx S A enclosure upper Zoom Ring 505 182...

Page 73: ...8 Torx T 10 23 Power supply controller ECA chassis M2x8 Torx T 10 5 Safety switch to chassis M4x10 Torx T 10 Conepoint 3 Top and bottom cases M3x10 Torx T 10 10 Lamp connector retainer to chassis M3x8 Torx T 10 black 10 Rear bezel M3x8 Torx T 10 Plastite 5 Leveling foot knob to leveling foot shaft M4x10 slotted black 2 Lamp door to bottom case Leveling foot shaft M8x29 5 ...

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