Sanyo PDG-DSU30 - 2500 Service Manual Download Page 30 | Manualshive

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PDG-DSU30

Confidential

4-

Chapter 4

Function Test & Alignment Procedure

4-1 Test Equipment Needed

- IBM PC with HDTV resolution

- DVD player with Multi-system, equipped “Component”, “Composite”, “S-Video” and “HDMI”.

- HDTV Source (720P,1080P,1080i)

- Minolta CL-100

- Quantum Data 802B or CHROMA2327 (Color Video Signal & Pattern Generator)

4-2 Service Mode

1. Turn on the projector

2. Press “Power”, “Left”, “Left” and “Menu” buttons sequentially on remote controller to get into

service mode.

4-3 OSD Reset

After final QC step, we have to erase all saved
change again and restore the default setting:
(1) Please get into OSD menu.
(2) Execute “OSD reset” function under “Options”.

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Summary of Contents for PDG-DSU30 - 2500

Page 1: ...Chassis No KW5 DSU3000 I PDG DSU30 Confidential SERVICE MANUAL Multimedia Projector Model No PDG DSU30 Original Version PRODUCT CODE 1 682 348 39 REFERENCE NO SM0946002 ...

Page 2: ... 12 Disassemble Lamp Driver Module 2 13 Disassemble Interlock Switch 2 14 Disassemble Bottom Shielding 2 14 Disassemble Speaker 2 15 Disassemble Bottom Cover Module 2 15 Rod Adjustment 2 16 Troubleshooting 3 1 LED Lighting Message 3 1 Main Procedure 3 2 Electronic Function Block Diagram 3 5 Pin Assignment 3 6 Function Test Alignment Procedure 4 1 Test Equipment Needed 4 1 Service Mode 4 1 Factory ...

Page 3: ...be observed 1 An isolation transformer should be connected in the power line between the projector and the AC line before any service is performed on the projector 2 Comply with all caution and safety related notes provided on the cabinet back cabinet bottom inside the cabinet or on the chassis 3 When replacing a chassis in the cabinet always be certain that all the protective devices are installe...

Page 4: ...al 6 Resolution Native Resolution 800 X 600 7 Brightness 2500 ANSI Lumens 8 Contrast 2200 1 Full on Full off 9 Uniformity 80 JBMA standard 10 Throw ratio 1 95 2 15 1 distance width 2 37m 11 Projection lens F 2 41 2 55 1 10X Mechanical Zoom Lens f 21 8 24mm 60 12 Lamp life 3000 hours at typical full power mode 4000 hours at Eco mode The more than 50 of lamp population have light output 50 of initia...

Page 5: ...r Wheel 40mm diameter 6 segments R81Y41G84C31W52B71 7200 rpm 18 Lamp 180W Lamp Osram E20 8 19 Temperature Operating 5 35 C Storage 20 60 C 20 Altitude Operating 0 2 500 ft for 5 C 35 C 2 500 5 000 ft for 5 C 30 C 5 000 10 000 ft for 5 C 25 C Storage 40 000 ft 21 Input Signal Computer analog input Video Analog RGB 0 7Vp p 75ohm Sync Hsync Freq 31 35 91 1kHz Vsync Freq 56 85Hz Separate Sync H V TTL ...

Page 6: ...x480 60 640x480 72 640x480 75 640x480 85 720x400 70 720x400 85 SVGA 800x600 56 800x600 60 800x600 72 800x600 75 800x600 85 XGA 1024x768 60 1024x768 70 1024x768 75 1024x768 85 WXGA 1280x768 60 1280x768 75 1280x720 60 1280x800 60 SXGA 1152x864 60 1152x864 70 1152x864 75 1152x864 85 1280x1024 60 1280x1024 75 1280x1024 85 1280 x 960 60 SXGA 1400x1050 60 ...

Page 7: ...640x480 66 66 MAC II 13 640x480 66 68 MAC 16 832x624 74 55 MAC 19 1024x768 75 MAC 1152x870 75 06 MAC G4 640x480 60 i Mac DV 1024x768 75 i Mac DV 1152x870 75 i Mac DV 1280x960 75 Note If the Computer Compatibility supportive signal is different from User s Manual please refer to User s Manual ...

Page 8: ...duct Overview 1 Screw Bit 105 2 Screw Bit 107 3 Screw Bit 107 4 Hex Sleeves 5 mm 5 Tweezers 6 Projector Before you start This process is protective level II Operators should wear electrostatic chains Note If you need to replace the main board you have to record the lamp usage hour ...

Page 9: ... Lamp Module 1 Loosen 2 screws as red circle on the Lamp Module 2 Take off the Lamp Module 2 2 Disassemble Lamp Cover Module 1 Loosen 2 screws as red circle on the Lamp Cover 2 Disassemble the Lamp Cover Module and tear off the Aluminum foil ...

Page 10: ...1 Unscrew 2 screws as red circle from the Bottom Cover 2 Unscrew 2 screws as green circle from the IO Cover 3 Remove the Top Cover Module 2 5 Disassemble Zoom Ring Module 1 Unscrew 3 screws as red circle from the Top Cover Module 2 Remove the Zoom Ring Module ...

Page 11: ...ew 9 screws as red circle 2 Disassembled the Top Shielding Top Shielding 2 7 Disassemble IO Cover 1 Unscrew 4 hex screws as red circle 2 Unfasten 2 tenons as yellow square 3 Disassembled the IO cover Note Take care the tenons when you disassemble the unit IO Cover ...

Page 12: ...pin D Photo Sensor Compose of Red Black White Wire red connector and Black wire tube 3 pin E IR Compose of Red Black White Wire green connector and Black wire tube 3 pin F Speaker Compose of Red Black Wire and Black wire tube 2 pin 2 8 Disassemble Main Board Module 1 Unscrew 3 screws as red circle 2 Unplug the connector as green square of Color Wheel 3 Unplug 6 connectors as orange square Please r...

Page 13: ...PDG DSU30 Confidential 2 7 Unplug 1 connector as yellow square 8 Remove the Main Board 2 9 Disassemble Main Board Shielding 1 Unscrew 2 screws as red circle 2 Disassemble the Main Board Shielding ...

Page 14: ...n 2 tenons as yellow square 3 Remove the Front Cover Module 4 Unfasten 2 tenons as green square to disassemble the IR Sensor Board and IR Cover Note Take care the tenons when you disassemble the unit 2 11 Disassemble Engine Module 1 Unscrew 4 screws as yellow circle to disassemble the Engine Module IR Cover IR Sensor Board ...

Page 15: ... of color wheel 2 13 Disassemble DMD Chip and DMD Board 1 Unscrew 2 screws as red circle to disassemble the Heat Sink and DMD Module 2 Rotate the screw counterclockwise as yellow circle to disassemble the DMD Board and DMD Chip Note Avoid touching the DMD Chip when you disassemble it Found that the DMD Chip has scrapes or dirt use of a magnifying glass you may use an electrostatic ion gun to clean...

Page 16: ...semble Focus Ring 1 Unscrew 3 screws as red circle to disassemble the Focus Ring Focus Ring 2 15 Disassemble Fan Module and Thermal Switch 1 Unscrew 3 screws as red circle 2 Unscrew 1 screw as orange circle 3 Disassembled the Fan Module ...

Page 17: ...Take the Fan Module as the right gesture the wrong gesture the right gesture 4 Unscrew 4 screws as blue circle to disassemble the Fan Shielding and Fan 5 Unscrew 1 screw as green circle to disassemble the Thermal Switch Thermal Switch ...

Page 18: ...mble the Blower Module 2 Seprate the Blower and Blower Rubber 2 17 Disassemble LVPS Module 1 Unscrew 6 screws as red circle 2 Unplug 3 connectors as yellow square 3 Cut off the cable tie as green square 4 Disassemble the LVPS Module AC Inlet Bracket and LVPS to MB cable AC Inlet Bracket LVPS to MB cable ...

Page 19: ...e the cable tie to pierce the first hole of LVPS for binding the Interlock Switch and Lamp Driver to LVPS cable as blue square 2 Use clamp to fix the Lamp Driver to LVPS cable as orange square 2 18 Disassemble Lamp Driver 1 Unscrew 1 screw as red circle to disassemble the Lamp Driver Module ...

Page 20: ...crew as red circle to disassemble the Interlock Switch Note Make sure the Interlock Switch cable be wedged fillister as the picture shown Lamp Driver Lamp Driver Holder 2 Unscrew 4 screws as yellow circle 3 Unplug 3 connectors as blue square 4 Disassemble the Lamp Driver and Lamp Driver Holder ...

Page 21: ...0 Confidential 2 14 2 20 Disassemble Bottom Shielding 1 Unscrew 3 screws as red cricle to disassemble the Bottom Shielding 2 21 Disassemble Speaker 1 Unscrew 2 screws as yellow circle to disassemble the Speaker ...

Page 22: ...PDG DSU30 Confidential 2 15 2 22 Disassemble Bottom Cover Module 1 Unscrew 3 nuts as red circle to remove the rubber adjust foot ...

Page 23: ...he screen to white screen Adjust the screws by using the rod on the engine module to readjust the image screw 1 should be adjusted first and then screw 2 Adjust until the yellowish or bluish parts disappeared 3 Abnormal image inspection It should not have any abnormal color at the rim of the image by estimating through the eyes Note To avoid over adjusting the rod After the opreation please use th...

Page 24: ...Powering up Warming up Power off Cooling I It can t accept any key at this status Power off Cooling II It can accept power key to turn on the projector Flashing 0 5 sec Error Lamp failed Flashing 1 sec Error Fan lock Flashing 0 5 sec Error Over temp 3 1 LED Lighting Message Steady light Chapter 3 Troubleshooting ...

Page 25: ... pad and the air vent is not blocked Check LED Status a Lamp Failed Power LED flashing red every 1 sec Check Lamp Check Lamp Driver Check Main Board b Over Temp Power LED lights red Check Fan Check Thermal Switch Check Main Board c Fan Lock Power LED flashing red every 0 5 sec Check Fan Check Main Board 3 No Light On Ensure all connectors are securely connected and aren t broken Check Lamp Cover C...

Page 26: ...hanical Noise Check Color Wheel Check Fan Module 6 Line Bar Line Defect Check if the Main Board and the DMD Board are assembled properly Check Main Board Check DMD Board Check DMD Chip 7 Image Flicker Do OSD reset of the OSD Menu Ensure that the signal cables and source are work as well Check Lamp Driver and waveform Check Lamp Module Check Color Wheel Check Photo Sensor and clean Photo Sensor Che...

Page 27: ...sure the projection lens is clean Clean DMD Chip and Engine Module Check DMD Chip Check Engine Module 11 Garbage Image Ensure that the signal cables and source work as well Check Main Board Check DMD Board 12 Remote Control Control Panel Failed Remote Control a Check Battery b Check Remote Controller c Check Main Board Control Panel a Check Main Board 13 Function Abnormal Do OSD reset of the OSD M...

Page 28: ...PDG DSU30 Confidential 3 3 3 Electronic Function Block Diagram AC110 220V ...

Page 29: ...PDG DSU30 Confidential 3 3 4 Pin Assignment ...

Page 30: ...P 1080P 1080i Minolta CL 100 Quantum Data 802B or CHROMA2327 Color Video Signal Pattern Generator 4 2 Service Mode 1 Turn on the projector 2 Press Power Left Left and Menu buttons sequentially on remote controller to get into service mode 4 3 OSD Reset After final QC step we have to erase all saved change again and restore the default setting 1 Please get into OSD menu 2 Execute OSD reset function...

Page 31: ...than 2 lux Inspection distance 0 5m 1 0m functional inspection Screen size 60 inches diagonal After repairing each unit a Run in test is necessary refer to the below table Symptom Run in Time Normal repair 2 hours NFF 4 hours Auto shutdown 6 hours Get into Burn In Mode Cycle setting is based on the defect symptoms ie If it is NFF the run in time is 4 hours You have to set the lamp on for 50 min an...

Page 32: ...k pattern A B 1 4 Adjacent pixels White Black pattern A B 0 5 Dark blemish Blue 60 pattern A B 10 6 Bright blemish Gray 15 pattern A B 10 7 Bright dots on frame Gray 10 pattern 1 Defect specification table Figure Zone A Zone B Frame as green line Definition Active area Zone A Zone B Screen Defects While replacing DMD Chip DMD Board and Main Board Frame ...

Page 33: ... abnormal after changing Main Board Module please do Color Wheel index adjustment 4 7 PC MODE 1 Frequency and tracking boundary Procedure Test equipment video generator Test signal analog 800 x 600 60Hz Test Pattern general 1 or master Check and see if the image sharpness is well performed If not re adjust by the following steps 1 Select Frequency function to adjust the total pixel number of pixel...

Page 34: ... The PC mode functionally sure be workable include support format with frequency and auto detected functional will be workable 2 Bright Pixel Procedure Test equipment video generator Test signal analog 800 x 600 60Hz Test Pattern gray 10 Inspection item Bright pixel check Criteria Bright pixel should be no more than 1 in the active zone 1 pixel is allowed on the frame Ref Defect specification tabl...

Page 35: ...sh check Criteria The dark blemish should be no more than 10 under blue 60 pattern Ref Defect specification table 6 Focus Test Procedure Test equipment video generator Test signal analog 800 x 600 60Hz Test Pattern full screen Inspection item Focus check Criteria From screen 2 6 M via visual to check the focus look at the entire screen focus shall be clear crisp and sharp over the entire surface o...

Page 36: ...ormal It is unacceptable to have few lines flashing RGBW should all appear normal on the screen and sort from R G B W Color levels should be sufficient and normal The unidentified color levels on both left and right sides should not over 4 color levels Gray level should not have abnormal color or heavy lines If color appears abnormal please get into serv ice mode to do color wheel index adjustment...

Page 37: ...n item Audio performance test Inspection Distance 1 8M 2 8M Criteria Check the sound from speaker Plug Audio cable into Audio in port check whether Volume is normal Adjust the volume to 0 9 by using the remote controller Check the sound from speaker Check whether the mute is normal 4 S Video Procedure Test equipment DVD player Test signal S Video Inspection item Video performance test Inspection D...

Page 38: ... on the screen Horizontal and vertical position of the video should be adjustable to the screen frame Criteria If there is noise on the screen the product is considered as failure product The screen appears normal it shouldn t appear any abnormal condition such as lines and so on Check if the projection is same as monitor diplayed 2 Video Calibration Procedure Test equipment video generator Once m...

Page 39: ...med up for 5 minutes Distances from the screen 2 6 M Screen Size 60 inches diagonal 1 Test equipment Procedure Please get into OSD menu select Lamp Setting under Options press Enter button then select Bright mode Test equipment video generator Test signal analog 800 x 600 60Hz 2 Brightness Procedure Full white pattern Use CL100 to measure brightness values of P1 P9 Follow the brightness formula to...

Page 40: ...tern B5 Lux of center in full black pattern Criteria 1800 1 4 Uniformity Procedure Full white pattern Use CL100 to measure brightness values of P1 P9 see image full white Follow the Uniformity formula to calculate average values Uniformity Formula JBMA Uniformity Avg P1 P3 P7 P9 P5 Criteria 65 4 11 Others 1 Functional Inspection Power Key Power key must operate smoothly Remote Controller Check whe...

Page 41: ...gh pitch sound from cooling fan and color wheel is unacceptable 2 Check points for exterior and print pattern Check item Check point Text Pattern Missing letters pattern or blurry prints are unacceptable Exterior Dirt scrape water ripples and uneven color are unacceptable Focus ring Zoom ring Focus ring and Zoom ring should be moved smoothly Logo Missing logo missing prints and blurry prints are u...

Page 42: ... 1 Equipment Needed Software DDP 2431 RS232 DLP Composer Lite 9 2 Firmware img Library file library file has to put in PC and set right path in 5 1 3 step 4 Hardware Projector Power Cord CH4200105G011 US Type CH4200120G011 EU Type CH4200110G011 UK Type RS232 Cable CH4200272G002 PC or Laptop ...

Page 43: ...P Composer Lite Setup Procedure 1 Choose DLP Composer Lite V9 2 Setup Program 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 Click Next ...

Page 44: ...PDG DSU30 Confidential 5 5 Click Next 6 Click Next 7 The program is executing installing status 8 Click Finish ...

Page 45: ...ER button and plug in the power cord The Power LED will light red and blue Loosen POWER button Connect projector with RS232 cable to PC Note The system fan and the lamp will not operate 2 Execute the DLP ComposerTM Lite 9 2 file 3 Click Edit and Perferences RS232 cable Power cord ...

Page 46: ... the COM Port which you are using Click Configure 6 Serial Port Configuration picture will appear on the screen Make sure the settings are as below 1 In Baud Rate item select 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 4000 into Read and Write items of Timeouts in milliseconds Click ...

Page 47: ...r Click Browse to search the firmware file img Click Open 7 Select Skip Boot Loader Area select 32KB Click Reset Bus to erase the flash memory 8 If the FW is ready click Start Download to execute the firmware upgrade Click Yes 9 Proceeding Picture ...

Page 48: ...nload completed will appear on the screen Unplug RS232 cable and power cord 11 Check FW version Re plug in power cord then restart the unit and get into the Service mode to check the firmware version To get into service mode please press Power Left Left and Menu buttons sequentially on remote controller ...

Page 49: ...Procedure 5 2 1 Equipment Needed Software Setup _NLINK_en Manley USB Driver_NLINK PDG DSU 30_8051_xxx hex Hardware Projector Power Cord CH4200105G011 US Type CH4200120G011 EU Type CH4200110G011 UK Type Mini USB Cable NLINK Cable NLINK Fixture 15V PC or Laptop ...

Page 50: ...PDG DSU30 Confidential 5 5 2 2 NLINK Setup Procedure 1 Choose setup_NLINK_en exe program 2 Click Next 3 Click Next 4 Click Next ...

Page 51: ... Click Next Select the additional task that you may create a desktop icon 6 Click Install to begin installing NLINK Procedure 7 Click Finish Complete the NLINK setup 8 MCU Choose picture will appear on the screen Close the picture ...

Page 52: ...ture with PC by USB cable 2 Execute Program 1 Found New Hardware Wiszard picture will appear on the screen 2 Select Install from a list or specific location Advanced 3 Click Next 4 Select Include this location in the search then click Browse 5 Browse For Folder picture will appear on the screen 6 Select TPRP1 folder in the Manley USB Driver_N Link folder then click OK 7 Click Next 4 6 5 ...

Page 53: ...ick Continue Anyway 9 Click Finish Manley TPRP1 Protocol Emulator will appear on the picture Complete the USB Driver Upgrade Procedure Note If Found New Hardware Wiszard picture appear again repeat step 2 to install USB Drivier 7 8 9 ...

Page 54: ...on the screen select N79A901R Click OK 3 Choose 8051 file hex Manley Nlink picture will appear on the screen Ensure MCU is the one you chose in the last step as green square Click Open Select the 8051 file where you put the file in then click Open 4 Program settings Ensure NLlNK Fixture and PC are securely connected the indicator lights on green and the state is Connect as blue square Select Inter...

Page 55: ...o the service mode to check the 8051 FW version To get into service mode please press Power Left Left and Menu buttons sequentially on remote controller Section 3 Waveform Download 5 3 Waveform Download Plug in the power cord Press Power button and hold on Power button until Power LED flashes red and blue When the Power LED went off waveform download is completed ...

Page 56: ... DSU30 Confidential Note This chapter is only designed to show the exploded image of the projector For updated part numbers please refer to RSPL report Appendix A Exploded Image D C 8 3 7 5 11 6 9 2 4 10 1 ...

Page 57: ...G DSU30 5 CH758BA01G002 ASSY OSRAM LAMP DRIVER O6 MIC 180W Gen5_ Panyu E20 8 6 CH708CS14GR01 ASSY ENGINE MODULE WITH CW AND DMD PDG DSU30 SERVICE CH708CS15GR01 ASSY ENGINE MODULE PDG DSU30 SERVICE 7 CH498CS01G002 SUNON 45 20mm GB1245PKV1 8AY F TYPE BLOWER SHRINK TUBE 8 CH518CS03G012 FRONT COVER FOR IR PC MN3600H BLACK 9 CH518CS04G001 IO COVER PC MN3600H BLACK PDG DSU30 10 CH518CS05G001 LAMP COVER ...

Page 58: ...III Item P N Description 1 CH528EH05G001 RUBBER ADJUST FOOT 2 CH498CQ01G001 SPEAKER 2W 16OHM DAB128 90mm 3 CH758AA04G001 BUY ASSY INTERLOCK SWITCH 4 CH758CS01GP01 ASSY 180W LVPS FOR PDG DSU30 ASSY BOTTOM COVER MODULE 3 2 1 4 ...

Page 59: ...PDG DSU30 Confidential IV ASSY ENGINE MODULE 2 1 4 3 ...

Page 60: ...dential Item P N Description 1 CH808CP02G001 PCBA DMD BOARD 2 CH708CS17GR01 DMD MODULE SVGA FOR SANYO PDG DSU30 SERVICE 3 CH808EG04G001 PCBA PHOTO SENSOR BOARD 4 CH708CS16GR01 ASSY COLOR WHEEL MODULE PDG DSU30 SERVICE ...

Page 61: ...PDG DSU30 Confidential VI ASSY FRONT COVER MODULE Item P N Description 1 CH518CS03G012 FRONT COVER FOR IR PC MN3600H BLACK 2 CH808CP05G001 PCBA IR SENSOR BD 1 2 ...

Page 62: ...fidential VII ASSY FAN MODULE Item P N Description 1 CH498CP02G002 SUNON 70 70 20mm AXIAL FAN KDE1207PKV1 MS B3001 AF GN SHRINK TUBE 2 CH438CS17G001 THERMAL SWITCH WITH BRACKET KLIXON YS11 100C WIRE LENGTH 130MM 1 2 ...

Page 63: ...PDG DSU30 Confidential VIII ASSY PACKING DRAWING 7 4 5 3 8 6 9 2 1 ...

Page 64: ...RD 1 8M SP 023 IS 14 EUROPE DIS WARN ING LABEL CH4200110G011 CABLE POWER CORD 1 8M SP 60 IS 14 UK DIS WARNING LABEL 3 CH568EH02G001 PACKING TOP AIR BAG 240 1050MM 4 CH568EH01G001 PACKING BOTTOM AIR BAG 480 600MM 5 CH5152109G005 PE BAG 450 350 0 07 6 CH558EH02G001 PARTITION PAPER 7 CH558EH01G011 CARTON AB FLUTE 18KG 395 165 314MM PDG DSU30 8 CH758FL03G001 8FL LENS CAP MODULE 9 CH3552302G091 LABEL C...

Page 65: ...jector 5 9 9 01001 1 2 3 1 9 Last number of the manufacture year ex 2009 9 2 9 Month ex 9 September 3 01001 Production number 5 digits It starts from 01001 99999 EX 59601001 This label 59901001 represents the serial number for PDG DSU30 It is produced on September of 2009 Its serial code is 01001 ...

Page 66: ...PDG DSU30 Confidential II II PCBA Code Definition PCBA Code for Projector A B XXXXXXXXXXX C XXX EEEE 1 2 3 4 5 6 1 ID 2 Vendor Code 3 P N 4 Revision 5 Date Code 6 S N ...

Page 67: ...PRODUCT CODE 1 682 348 39 SANYO Electric Co Ltd Printed In Japan ...

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