Ricoh Polaris-PJ1 Field Service Manual Download Page 4

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TABLE OF CONTENTS

Important Safety Notices................................................................................................................................... 1

Important Safety Notices............................................................................................................................... 1

Prevention of physical injury................................................................................................................. 1
Health safety conditions........................................................................................................................1
Observance of electrical safety standards.......................................................................................... 1

Safety and Ecological Notes for Disposal................................................................................................... 1

1. Product Information

Overview.............................................................................................................................................................5

Main Unit........................................................................................................................................................ 5
Control Panel.................................................................................................................................................. 6
Connection Ports.............................................................................................................................................7

Specifications...................................................................................................................................................... 9

General Specifications...................................................................................................................................9
Compatible Mode....................................................................................................................................... 10

2. Installation

Installation Requirements................................................................................................................................. 13

Environment/Power Requirements............................................................................................................. 13
Machine Dimensions................................................................................................................................... 13

Main Machine Installation...............................................................................................................................14

3. Replacement and Adjustment

Special Tools.................................................................................................................................................... 21
Equipment Needed..........................................................................................................................................22
Parts List.............................................................................................................................................................23

Service Parts List........................................................................................................................................... 23

Replaceable Part Hierarchy............................................................................................................................ 24
Part Replacement..............................................................................................................................................25

Lamp Cover / Lamp Module......................................................................................................................25
Top Cover Unit.............................................................................................................................................26

Top cover unit......................................................................................................................................26

Summary of Contents for Polaris-PJ1

Page 1: ...Polaris PJ1 Machine Codes Y042 Y043 Y044 Y048 Y049 Y062 Y063 Y064 Y065 Y066 Field Service Manual 1 July 2014...

Page 2: ......

Page 3: ...rified or mechanically driven components To prevent a fire or explosion keep the machine away from flammable liquids gases and aerosols Health safety conditions This machine which uses a high voltage...

Page 4: ...6 Connection Ports 7 Specifications 9 General Specifications 9 Compatible Mode 10 2 Installation Installation Requirements 13 Environment Power Requirements 13 Machine Dimensions 13 Main Machine Insta...

Page 5: ...ard 38 Focus ring 39 Thermistor 39 Color wheel 40 Optical engine Main board assembly 42 Blower Fan 42 Base Adjustable Foot 43 Required Action After Replacing Parts 45 4 Troubleshooting LED Display 47...

Page 6: ...Check points 66 OSD Reset 66 6 Update Firmware Update 67 Equipment Needed 67 Firmware Update Procedure 68 DLP composer lite setup procedure 68 Get into firmware download mode 70 USB driver update pro...

Page 7: ...1 Product Information Overview Main Unit 1 Zoom lever 2 Control panel 3 Connection ports 5...

Page 8: ...6 Speaker 7 Remote Receiver 8 Adjustable feet 9 Anti theft lock hole KensingtonTM lock 10 Lens cap 11 Lens 12 Ventilation outlet 13 Focus ring Control Panel 1 Keystone 2 Auto set 3 AV mute 4 Four dir...

Page 9: ...rts 1 S Video In terminal 2 Monitor Out terminal 3 Computer 1 In terminal 4 Computer 2 In terminal 5 AC In socket 6 HDMI Input terminal 7 Service terminal 8 PC Control terminal 9 Audio 1 In terminal 1...

Page 10: ...The interface is subject to model s specifications 1 Product Information 8...

Page 11: ...tone correction 40 degree 6 Throw ratio 1 95 2 15 D W 60 7 Projection lens YM99 8 Offset 115 5 9 Lamp life Normal mode 4500 hours Standard 190W 50 survival rate ECO mode 6000 hours Typical 160W 50 sur...

Page 12: ...emperature Operating 5 C to 40 C Non operation 10 C to 60 C 16 Altitude Temperature Operating 0 to 2 500 ft 5 C to 35 C 2 500 to 5 000 ft 5 C to 30 C 5 000 to 10 000 ft 5 C to 25 C Compatible Mode Sig...

Page 13: ...7 4 XGA 1024 x 768 60 48 4 1024 x 768 70 56 5 1024 x 768 75 60 0 1024 x 768 85 68 7 1024 x 768 120 99 0 SXGA 1152 x 864 70 63 8 1152 x 864 75 67 5 1152 x 864 85 77 1 1280 x 1024 60 64 0 1280 x 1024 72...

Page 14: ...DV G3 1024 x 768 75 60 0 WXGA 1280 x 768 60 47 8 1280 x 768 75 60 3 1280 x 720 85 68 8 1280 x 720 60 44 8 1280 x 720 120 92 9 1280 x 800 60 49 6 1280 x 900 60 59 9 WSXGA 1680 x 1050 60 65 3 1080p 60...

Page 15: ...wer Requirements Operating temperature 5 C to 40 C 41 F to 104 F Power supply 100 240VAC 10 50 60Hz Auto ranging and power factor correction Machine Dimensions With feet 314 3 x 223 6 x 101 7 mm W x D...

Page 16: ...Main Machine Installation The user must set this projector up Accessory Check No Description Q ty 1 Projector 1 2 Lens Cap 1 3 Remote Control 1 4 Power Cord 1 5 Carrying Bag 1 2 Installation 14...

Page 17: ...e bright light may hurt your eyes To reduce the risk of fire or electric shock do not expose this projector to rain or moisture Do not open or disassemble the projector as this may cause electric shoc...

Page 18: ...severe internal burns in just 2 hours and can lead to death Keep new and used batteries away from children If the battery compartment does not close securely stop using the product and keep it away fr...

Page 19: ...e the lamp when it shows warning messages Never operate this unit on AC power during a thunderstorm If you see lightning or hear thunder never touch the unit cables and or peripherals An electric surg...

Page 20: ...eak please handle with care to avoid injury and contact your sales representative for repair service Avoid any broken pieces of glass since they may cause injury In the unlikely event that the lamp ru...

Page 21: ...re cleaning Use a soft cloth moistened with mild detergent to clean the display housing Disconnect the power plug from AC outlet if the product is not being used for a long period of time Do not Block...

Page 22: ...2 Installation 20...

Page 23: ...uipped with the following tools which will be necessary in order to update the firmware and to perform adjustments that are necessary after replacing the optical engine main board assembly page 42 Opt...

Page 24: ...Equipment Needed 1 Screw bit No 2 or No 1 2 Screw bit No 0 3 Jeweler s Screwdriver 4 Hex sleeves 5 mm 5 Long nose nipper 6 Tweezers 7 Projector 3 Replacement and Adjustment 22...

Page 25: ...nel Enter key Top cover I O cover I O seal Speaker System fan Lamp cable Interlock switch LVPS LVPS cable x2 Photo sensor board Focus ring Thermistor Color wheel Optical engine Main board assembly wit...

Page 26: ...removed to access each replaceable part in the projector The parts on the first level e g Lens cap are accessible without removing any other parts The more levels down that a part is the more parts y...

Page 27: ...Part Replacement This process is protective level II Operators should wear electrostatic chains Lamp Cover Lamp Module 1 Loosen the 1 screw and then remove the lamp cover A Part Replacement 25...

Page 28: ...2 Loosen the 1 screw and unplug the 1 connector then take off the lamp module A Top Cover Unit Top cover unit 1 Remove the 6 screws from the bottom cover 3 Replacement and Adjustment 26...

Page 29: ...remove the top cover A Align the dent part of the zoom ring with the tab part on the optical engine side when attaching the top cover Keypad board IR sensor board 1 Top cover unit page 26 Top cover un...

Page 30: ...tors and separate the keypad board B and IR sensor board C and FFC cable D from the top cover A When removing the IR sensor board unfasten the 3 tenons Zoom ring 1 Top cover unit page 26 Top cover uni...

Page 31: ...1 screw and then remove the zoom ring A from the top cover B 3 Separate the bracket A and zoom ring B Control panel Top cover 1 Keypad board IR sensor board page 27 Keypad board IR sensor board Part R...

Page 32: ...2 Separate the control panel A and the top cover B Speaker 1 Top cover unit page 26 Top cover unit 2 Unplug the 1 connector to remove the speaker A 3 Replacement and Adjustment 30...

Page 33: ...cover unit 3 Remove the 3 screws and the 3 connectors and then take out the lamp housing A It is recommended to move the cable out of the way as shown by a blue circle in the following figure when rem...

Page 34: ...System fan Interlock switch 1 Lamp housing page 31 Lamp housing 2 Remove the 1 screw to separate the lamp cable A 3 Remove the 4 screws to separate the system fan A 3 Replacement and Adjustment 32...

Page 35: ...Take the fan module as the right gesture 4 Remove the 1 screw to separate the interlock switch A LVPS 1 Lamp housing page 31 Lamp housing Part Replacement 33...

Page 36: ...2 Remove the 5 screws and 3 connectors to remove the LVPS and holder A 3 Remove the 2 screws 4 Remove the 5 screws and 2 connectors to separate the LVPS A 3 Replacement and Adjustment 34...

Page 37: ...Optical System Unit If you need to replace the optical engine main board assembly you have to get into service mode and record the lamp usage hour page 62 Re write Lamp Hours Part Replacement 35...

Page 38: ...each connector Item Male Connector on Main Board Key Feature Figure A Speaker Red Black wire 2 pin B Photo sensor Red Black White wire red connector 3 pin C System fan Red Blue Black wire 3 pin D LVP...

Page 39: ...lack wire tube 5 pin F Blower fan Red White Black wire with blue wire tube 3 pin Optical system unit 1 Speaker page 30 Speaker 2 LVPS page 33 LVPS 3 Remove the 4 screws 4 Remove the 4 screws and 1 con...

Page 40: ...al 1 Optical system unit page 37 Optical system unit 2 Remove the 8 hex screws to remove IO cover with IO seal A Photo sensor board 1 Optical system unit page 37 Optical system unit 3 Replacement and...

Page 41: ...the photo sensor board A Focus ring 1 Optical system unit page 37 Optical system unit 2 Remove the 1 screw and unfasten the 2 tenons then push out the focus ring A Thermistor 1 Optical system unit pa...

Page 42: ...move the thermistor A Color wheel 1 Photo sensor board page 38 Photo sensor board 2 Thermistor page 39 Thermistor 3 Remove the 2 screws to remove the color wheel module and color wheel holder A 3 Repl...

Page 43: ...color wheel A Make sure that the color wheel A does not touch the color wheel holder when removing the color wheel A It is recommended to slide and remove the color wheel as shown by arrows in the fo...

Page 44: ...over IO seal 2 Focus ring page 39 Focus ring 3 Color wheel page 40 Color wheel 4 Remove the 2 screws to remove the heat sink A from the optical engine main board assembly B Blower Fan 1 Optical system...

Page 45: ...shown by red circles in the following figure from the blower holder to remove the blower fan A Base Adjustable Foot 1 Blower Fan page 42 Blower Fan 2 Remove the 2 screws to remove the blower holder A...

Page 46: ...3 Remove the 3 adjustable feet A from the base unit B The front adjustable foot is different in size from the rear adjustable feet 3 Replacement and Adjustment 44...

Page 47: ...v v Chapter 6 page 67 Firmware Update ADC calibration v v Chapter 5 page 60 ADC Calibration Color wheel index v v Chapter 5 page 65 Color Wheel Index OSD reset v v v Chapter 5 page 66 OSD Reset Re wr...

Page 48: ...If color appears abnormal after changing the main board do the color wheel index adjustment page 65 Color Wheel Index 3 Replacement and Adjustment 46...

Page 49: ...5 sec off 0 5 sec light Power on lamp lighting Steady light Power off Cooling down Flashing 0 5 sec off 0 5 sec light 1 Quick resume 100 sec Flashing 0 25 sec off 0 25 sec light Temperature error Ove...

Page 50: ...an failed on event Steady light Flashing Fan error Fan failed on standby Steady light Flashing Error Color wheel fail Striking lamp fail on event Steady light Flashing Error Color wheel fail Striking...

Page 51: ...k LVPS Check Main board b Fan failed Power LED flashes red Temp LED flashes red Check whether have execute Fan Calibration page 59 Fan Calibration Check System fan and Blower fan Check Main board Chec...

Page 52: ...board are assembled properly Check Main board Check DMD chip 7 Image flicker Do Reset of the OSD menu page 66 OSD Reset Ensure that the signal cables and source are work as well Check Lamp module Chec...

Page 53: ...emote controller c Check IR sensor board d Check Main board 13 Function abnormal Do Reset of the OSD Menu page 66 OSD Reset Check Main board 14 Audio abnormal For the projector has speaker Ensure that...

Page 54: ...cribed below Environment The size of screen is 60 This process should be done in a dark environment under 2 lux Procedure 1 Display a white pattern 2 Adjust the screws to readjust the image Screw A sh...

Page 55: ...Left 2 Left 2 and Menu 3 keys sequentially You can use the remote controller to enter the service mode in the same way To exit from the service mode press the Power key Service Mode Settings Here is...

Page 56: ...Factory Reset DFU Burn In Test DFU Failure Log Records the times of the failure of power on of the projector such as excessive temperature lamp failure or fan lock Analog Settings See the below table...

Page 57: ...e Offset DFU Red Gain DFU Green Gain DFU Blue Gain DFU Video Red Offset DFU Video Blue Offset DFU Reset Calibration Data DFU Optical Settings Setting Item Description Waveform ID Read only Color Wheel...

Page 58: ...e working hours of the projector in full mode page 62 Re write Lamp Hours Lamp Hours eco Use this to change the working hours of the projector in eco mode page 62 Re write Lamp Hours Start LOGO DFU AC...

Page 59: ...ory Blower RPM Read only Lamp Blower Fan Volt 1 10 Read only Lamp Blower Fan RPM Read only Temperature Degree Read only Current Lamp Voltage Read only Fan Zeta Value 1 100 DFU High Altitude DFU Lamp P...

Page 60: ...DVD player support S Video 3D source files HDMI and Video Illuminance meter Video generator Recommended Test Condition Ambient brightness Dark room less than 2 lux Product must be warmed up for 3 min...

Page 61: ...ter 3 to 5 seconds the projector will power on After the logo disappears the message Factory Fan RPM Calculation now Warning DO NOT unplug while the projector fan is still running will be shown on the...

Page 62: ...orts HDTV resolution has an independent graphics card to output the corresponding PC pattern You can download the test pattern by PC from the website as shown below Procedure Test equipment Video gene...

Page 63: ...2 Select Analog Settings 3 Execute PC Calibration 4 Select Return to Service Menu to confirm the setting Calibration 61...

Page 64: ...y you must rewrite the lamp hours Write down the lamp hours before the replacement and put back the same value after replacing the board 1 Get into service mode page 53 How to Enter the Service Mode 2...

Page 65: ...3 Select System Hours total then use the Left or Right keys to re write the System Hours 4 Select Lamp Hours DD ED then use the Left or Right keys to re write the Lamp Hours Re write Lamp Hours 63...

Page 66: ...co then use the Left or Right keys to re write the Lamp Hours Left key decrease lamp hours Right key increase lamp hours By repeatedly pressing the Enter key you can select the order of magnitude Each...

Page 67: ...e page 53 How to Enter the Service Mode 2 Select Color Wheel Index and then use the Left or Right keys to adjust the color balance of the projected image By pressing the Enter key the test pattern can...

Page 68: ...ptable Lamp cover It should be locked in the correct place Zoom in out The function should work smoothly Keypad All keypad keys must operate smoothly OSD Reset After the final QC step we have to erase...

Page 69: ...ware DLP Composer Lite 11 2 Firmware img 11 2 FlashDeviceParameters Download DLP Composer Lite 11 2 and 11 2 FlashDeviceParameters from website to update FW procedure Hardware 1 Projector 2 Power cord...

Page 70: ...r lite setup procedure 1 Execute DLP Composer Lite v Setup Program 2 Click Next 3 Read License Agreement and then choose I accept and agree to be bound by all the terms and conditions of this License...

Page 71: ...4 Click Next 5 Click Next 6 Click Next Firmware Update 69...

Page 72: ...The program is executing installing status 7 Click Finish Get into firmware download mode Set up the following procedure 1 Hold on Power button and plug in the power cord 6 Update 70...

Page 73: ...the power LED lights pink lamp and temp LED light red then release Power button as shown in the photo below USB driver update procedure 1 Execute Install DLP Device Drivers in start menu Firmware Upd...

Page 74: ...2 Select Jungo WinDriver WinVista Win7 then click install If OS is 64bit select Microsoft WinUSB 3 Click Next 6 Update 72...

Page 75: ...to the PC 1 Get into firmware download mode page 70 Get into firmware download mode 2 Connect the Projector and PC with a mini USB cable The Found New Hardware Wizard appears 3 Select No not this tim...

Page 76: ...Select Install the software automatically Recommended then click Next 5 Click Finish Firmware update procedure 1 Execute the DLP ComposerTM Lite file 2 Select the file FlashDeviceParameters 6 Update 7...

Page 77: ...3 Put FlashDeviceParameters file into the folder where you setup DLP Composer Lite 4 Click Edit and Preferences Firmware Update 75...

Page 78: ...5 Click Communications and select USB then click OK 6 Choose Flash Loader and click Browse to search the firmware file img and click Open 6 Update 76...

Page 79: ...to erase the flash memory 8 If the firmware is ready click Start Download to execute the firmware update 9 Click Yes to erase the flash memory It takes about several minutes the firmware update proces...

Page 80: ...le and power cord Check system firmware version 1 Re plug in power cord and then restart the projector 2 Get into the Service Mode page 53 How to Enter the Service Mode 3 Check the system firmware ver...

Page 81: ...MEMO 79...

Page 82: ...MEMO 80 EN...

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