Sanyo PDG-DSU21B, Service Manual

Page 1: ...anada PDG DSU21E Europe Asia PDG DSU21B U K Chassis No KA7 DSU21N00 LA7 DSU21E00 LA7 DSU21B00 Match the Chassis No on the unit s back cover with the Chassis No in the Service Manual If the Original Version Service Manual Chassis No does not match the unit s additional Service Literature is re quired You must refer to Notices to the Original Service Manual prior to servicing the unit ...

Page 2: ...e replacing the cabinet cover thoroughly inspect the inside of the cabinet to see that no stray parts or tools have been left inside Before returning any projector to the customer the service personnel must be sure it is completely safe to operate without danger of electric shock Service Personnel Warning Eye damage may result from directly viewing the light produced by the Lamp used in this equip...

Page 3: ...ve bits and pieces of additional information related to the current topic Warning Alert you any damage that might result form doing or not doing specific actions Caution Give precautionary measures to avoid possible hardware or software problems Important Remind you doing specific actions relevant to the accomplishment of procedures ...

Page 4: ... 1 Troubleshooting 26 4 2 Verifying the Repair 33 5 Connector Information 39 5 1 I O Board 39 5 2 The backside of I O Board 40 5 3 Main Board 41 5 4 The backside of Main Board 42 5 5 Ballast Board 43 5 6 Power board 44 6 FRU Field Replaceable Unit List 45 6 1 Mechanical Drawing 46 6 2 Optical Parts Location 47 6 3 Accessory 50 6 4 Board Module 50 6 5 Case Cover Bracket Assembly 50 6 6 Fans 50 6 7 ...

Page 5: ...60 M N SECAM HDTV 480i p 576i p 720p 1080i Scanning Frequency Horizontal Frequency 31 79 KHz Vertical Frequency 50 85 Hz Digital Keystone Correction Vertical 15 degree Integrated Speaker 2W x 1 Environment Operating Temperature 5 C to 35 C Humidity 30 85 No condensation Storage Temperature 20 C to 60 C 40 F 140 F Humidity 30 85 No condensation Power Requirement AC100 240 V 50 60 Hz Power Consumpti...

Page 6: ...amp Specification Product Type Short arc mercury lamp with reflector Initial Characteristics Note More information about lamp replacement procedure resetting lamp timer and lamp part number please check the page 23 ...

Page 7: ...g operation the lamp is under extremely high pressure Please manage provision at the customer s product to prevent fragments of bulb and mercury from flowing out of it If the lamp bursts in case of an emergency the sound will be occurred Lamp operation should be with the specified lamp driver and the system ONLY Do not look at the lamp directly during operations Do not expose your skin directly We...

Page 8: ...PDG DSU21 4 1 2 DSU21 System Block Diagram ...

Page 9: ...pgrade Note Please check the firmware and composer version before any firmware upgrade procedures During firmware download period please do not shut down PC or projector this will cause flash memory s damage And need to return the unit to manufacturer for flash memory recovery Setup Tool Equipment Computer USB Cable See the picture Power Cord ...

Page 10: ...ve the scroll bar on the right to the bottom select I accept and agree to be bound by all the terms and conditions of this License Agreement and click Next to continue the installation process 4 On the Select Installation Type screen select ALL and click Next to continue the installation process 5 When the installation is finished click Finish and reboot the PC A shortcut to DLP Composer TM Lite i...

Page 11: ...is installed to install the USB support choose the Install DDP2000 USB Driver icon under DLP Composer Lite in your Start menu Follow the instruction on the screen to press any key and wait for the installation done And copy the file FlashDeviceParameters txt into the C Program Files DLP Composer Lite X X Operating procedure 1 Connect the Projector and PC via USB cable 2 Double click DLP Composer T...

Page 12: ...x img is for download 9 Make sure Skip Boot Loader Area is with a check 10 Press Menu and Power buttons constantly and then give power supply switch power on Power LED and Lamp LED will become amber That indicates the projector is in the download mode At this moment you can release these two buttons 11 Click Start Download When the dialog box is displayed click Yes Put checkmark next to Skip Boot ...

Page 13: ...2 Wait for the Completion of Burning and then remove Power Cord and Burning Cord Note In case the device manager can t recognize the DDP2000 as blow please disable this device This will not affect upgrade procedure ...

Page 14: ...PDG DSU21 10 3 Machine Disassembly and Replacement 3 1 Tools Item Photo Long Nose Nipper Hex Sleeves 5mm Screw Bit 107 Screw Bit 101 Screw Bit 102 Anti static wrist strap Anti static wrist gloves ...

Page 15: ...ewing or unscrewing screws please keep the screwdriver straight Keeping screwdriver inclined will damage the screw holes Please turn off the power before replacing any parts Please wait for the projector lamp cooling down and turn off the power before changing it Never touch or hit the lamp module when replacing the lamp When you replace the projector lamp never touch the new lamp with your bare h...

Page 16: ...the projector and disconnect the power cord If the lamp is hot please do not start any procedure until the projector lamp cools down Flip the projector and remove the lens cover 2 1 Remove the screws S01 x5 on the back cover as shown 2 Remove the screwsS02 x2 on the top cover ...

Page 17: ...PDG DSU21 13 Step Figure Description 3 3 Remove the Top Cover 4 Remove the screwsS03 x2 on the I O cover 4 1 Remove the Key 2 Remove the screws S04x2 on the I O board 3 Remove the IO board ...

Page 18: ...ote Add one more key holder under the KEY Detail procedure as left Part of the key holder is sticking out and situated at the screw on the I O board to prevent incorrect installation of keypad Once button can directly touch the metal spring ...

Page 19: ... the connector should be 2 Remove all the wires 6 1 Remove all screws on the Ballast module Note screws S05 is connect ground 2 Remove the one screw S07 and safety switch 5pin for Ballast O E Fan Lamp Fan Right Fan Speaker Front IR 7 pin for Power Black IR ...

Page 20: ...PDG DSU21 16 Step Figure Description 7 1 Remove the I O cover 2 Remove the FAN Module M04 M05 Note 1 Remove the screws S06 On the optical engine 2 Remove the optical engine ...

Page 21: ...PDG DSU21 17 Step Figure Description 8 Remove the Lamp house 9 Loosen screws and remove the lamp module from optical engine Note Those screws and mesh are included in the Lamp module ...

Page 22: ...PDG DSU21 18 Step Figure Description 10 Loose the screws and remove the DMD Hsink 11 Loose the screws and remove the mainboard and DMD ...

Page 23: ... 19 Step Figure Description Note Note 2 wires still have connection under mainboard Disconnect these two wires before remove mainboard 12 Loosen screws and remove the Power module from Bottom cover C4 Back Cover ...

Page 24: ...PDG DSU21 20 Step Figure Description 13 1 Remove Speaker 2 Loosen the screw and remove front IR 14 Remove the foot stand ...

Page 25: ...PDG DSU21 21 Step Figure Description 15 Remove led lens and Top cover 16 Loosen the screws and Remove the Top cover holder ...

Page 26: ...PDG DSU21 22 Step Figure Description 17 Remove the foot stand ...

Page 27: ... slide forward and remove the cover 2 z Loosen the three screws of lamp module z Pull the lamp module out by lamp handle z Insert the new lamp module into the projector and tighten the screws z Replace the lamp cover and tighten the screws z Reset the lamp timer Press MENU go to Main MENU SETTING LAMP COUNTER RESET YES and press MENU Note Turn on the projector If the lamp does not turn on after th...

Page 28: ...mbly the Optical engine Lens Color Wheel Step Figure Description 1 Disassembly the Lens z Remove the Lens screws z Take the Lensr off 2 Disassembly the Color Wheel z Remove the screws M3x5 x4 z Remove Color Wheel project cover ...

Page 29: ...PDG DSU21 25 3 z Remove the screws M3x6x2 z Remove Color wheel module ...

Page 30: ...Lamp LED Temp LED Green Green Solid Flash The projector system has some problems with its fan so the projector cannot start up Lamp LED Temp LED Green Green Solid Solid The lamp is in good condition and is projecting at maximum brightness Lamp LED Temp LED Amber Green Solid Solid The lamp has reached its end of life and must be changed soon The lamp will continue to operate until it fails Change t...

Page 31: ...y an ideal way to find the module responsible for the problem A failure symptom is rarely caused by more than one module so you will not usually need to replace more than one to correct a particular failure Whatever main board ballast IR board power board lamp module or optical engine are all suitable to check by swapping modules ...

Page 32: ...ocket Replace safety switch or reinstall Replace power wire Replace power board Replace mainboard OK OK OK OK NG NG NG NG Check 9 pin Power output Check Safety Switch Check AC socket and connector Check 7PIN power wire Fan failure after turning on Reconnect fan Replace fan Replace Mainboard NG NG NG OK OK Check Mainboard Check Fan Check fan connection Pin1 5VS Pin2 GND Pin3 5VS Pin4 TP40 function ...

Page 33: ...Ballast Replace Mainboard OK OK OK OK OK NG NG NG NG NG Check Mainboard Check Ballast Check Lamp life Check LED indication Check Power board 380V output Replace Optical Engine NG Check CW Rotation while power on No Volume Replace Speaker Replace I Oboard NG NG OK Check I Oboard Check Speaker Replace Mainboard Check Mainboard OK NG ...

Page 34: ...Cable Replace I Oboard Replace Mainboard OK OK OK NG NG NG NG Check u5 Output signal Check Cable Check Source Check monitor in signal Video No Signal Turn on Source Replace Cable Replace I O Board NG NG NG OK OK Check Cable Check Source Check I O Board Replace Mainboard Check Mainboard ...

Page 35: ...ptical Engine Check input cable and signal setting Power on again and reset OSD Check Mainboard Color abnormal Adjust Input signal Adjust Color Wheel Index Replace Mainboard NG NG NG OK OK Check Mainboard Check Color Wheel Index Check input cable and signal setting Replace Optical Engine OK NG Check Optical Engine ...

Page 36: ...place Battery Replace Remote Control Replace IR Replace I Oboard OK OK OK NG NG NG NG Check I Oboard Check Remote Control Check Battery Level Check IR Button Failure Replace I Oboard Replace Mainboard NG NG OK Check Mainboard Check I Oboard Check Mainboard Replace Mainboard ...

Page 37: ...mat 800 600 60Hz I O port Video Test Equipment Standard Pattern generator Ex Quantum data or DVD player Signal format NTSC I O port S Video Test Equipment Standard Pattern generator or DVD player Signal format 480i I O port USB Test Equipment PC and Remote controller Test method 1 Connect PC laptop VGA output to projector Set PC laptop output signal to projector 2 Connect projector USB to PC Press...

Page 38: ...ake adjustments Source 1 Mechanical motion Up Down should be free from getting stuck when pressing the button 2 Press Source button manually selects an input source Resync 1 Mechanical motion Up Down should be free from getting stuck when pressing the button 2 Press Resync button automatically adjusts frequency and phase Foot adjuster operation Foot adjuster Test criteria Foot adjuster button Foot...

Page 39: ...Test Pattern Test criteria Full white Apparent color strip bend and streak corner on the projected image are not allowable 256 level RGB 256 level of RGB color should be distinguishable at least Red color scales should be For each RGB 256 levels Noise or color deviation in R G and B single level respectively are acceptable 16 gray level 16 level of gray level color should be distinguishable When G...

Page 40: ... than 0 7 lux 0 7lux S Video I O port S Video Test Equipment Standard Pattern generator Ex Quantum data DVD player Signal format 480i Criteria No apparent color deviation on the projected image Video I O port Video Test Equipment Standard Pattern generator Ex Quantum data DVD player Criteria No apparent color deviation on the projected image ...

Page 41: ...mage 6 Adjust focus ring to make resolution of 4 corners and center are balanced 7 Check the characters should be recognized easily 5 Front and Rear infrared sensor Device Front and Rear infrared Test Equipment Remote controller Test method 1 Cover front sensor and operate remote controller to test rear sensor 2 Cover rear sensor and operate remote controller to test front sensor 6 Brightness meas...

Page 42: ...quipment Safety analyzer Test method 1 Clamp the metal shell of SVGA connector 2 Plug the power cord to socket Test criteria GND 30A 3sec 100mΩ DCW 2506V 1sec 10000uA Single Step OFF 8 Cosmetic standard for repaired projector Follow cosmetic standard for repair center ...

Page 43: ...on This section provides each connector location on boards and function of each board They will be useful for your detecting the defective boards 5 1 I O Board Connector Description No 1 Speaker No 2 Front IR No 3 Back IR No 1 No 2 No 3 ...

Page 44: ...PDG DSU21 40 5 2 The backside of I O Board Connector Description No 4 Connect to Main board 100PIN NO 4 ...

Page 45: ...PDG DSU21 41 5 3 Main Board Connector Description No 1 Color Wheel Sensor No 2 Color Wheel control No 3 FAN No 4 FAN NO 1 NO 2 NO 3 NO 4 ...

Page 46: ...PDG DSU21 42 5 4 The backside of Main Board Connector Description No 5 Connect to I O board 100PIN No 6 Connect to Power board 7PIN No 7 Ballast Control No 8 FAN NO 5 NO 6 NO 7 NO 8 ...

Page 47: ...PDG DSU21 43 5 5 Ballast Board Connector Description No 1 Lamp power supply No 2 Ignite signal connected to Mainboard No 3 Power supply No 1 No 2 No 3 ...

Page 48: ...PDG DSU21 44 5 6 Power board Connector Description No 1 7 pin control No 2 Safety switch No 3 380V output No 4 AC Input No 1 No 3 No 4 No 2 ...

Page 49: ...e of contents is an enlarged view of the entire projector which shows the primary FRUs in the projector When working on the projector use appropriate anti static precautions such as anti static mats wrist straps and grounded work surfaces Failure to do this can destroy static sensitive components and make the product inoperable ...

Page 50: ...PDG DSU21 46 6 1 Mechanical Drawing ...

Page 51: ...PDG DSU21 47 6 2 Optical Parts Location ...

Page 52: ...PDG DSU21 48 ...

Page 53: ...PDG DSU21 49 ...

Page 54: ..._ EUROPE PKG 645 098 1296 CARTON UK PKG 645 098 1272 CARTON CHINA PKG 645 096 8778 CUSHION RIGHT PKG 645 096 8761 CUSHION LEFT PKG 645 098 1302 PE BAG GLOBAL 6 4 Board Module Key No P N Description M01 610 337 1764 COMPL OPTICAL LMP O180W KA7A M02 645 098 1357 OPTICAL ENGINE MOD W M B M03 645 098 1364 MAIN BOARD MODULE M04 645 098 1371 I O PCB M05 645 098 1388 BALLAST MODULE M06 645 098 1395 POWER...

Page 55: ...iption F01 645 098 1470 FAN1 L 50MM F02 645 098 1487 FAN2 L 50MM F03 645 098 1494 FAN3 L 140MM 6 7 Speaker 6 8 Wire Key No P N Description W01 645 095 7406 WIRE CON MOTOR TEMP SENSO W02 645 095 7413 WIRE CON CON BACK IR CLR W03 645 095 7420 WIRE CON CON BALAST M B W04 645 098 1517 WIRE PWR M B W05 645 098 1524 WIRE FRONT IR W06 645 098 1531 WIRE SAFETY SW W07 645 098 1548 WIRE BALLAST LAMP W08 645...

Page 56: ... Definition Level 1 Cosmetic Parts Easy To Repair Lamp Module Lens Cap assy Level 2 Module Replacement Top Case assy Low Case assy Housing R Vent Housing L Vent assy Ring Zoom Lens Deco CVR Lamp Door Power assy Ballast Board assy Video Board Driver Board Keypad assy FAN assy Speaker assy IR sensor assy thermal sensor Level 3 Board Level Repair or RTV Optical Engine DMD Panel Color Wheel lens light...

Page 57: ...n Definition 1 VGA IN 2 USB PIN DEFINITION 1 R Pr 2 G Y 3 B Pb 4 Ground 5 Ground 6 Ground 7 Ground 8 Ground 9 VCC 10 Ground 11 WC A 12 EDIDA SDA 13 Hsync 14 Vsync 15 EDIDA SCL PIN DEFINITION 1 EOT 2 USB 3 USB 4 Ground 5 Ground 6 Ground ...

Page 58: ...PDG DSU21 54 z Appendix D More details for main board measurement 1 Signal of DAD2000 26V 26V ...

Page 59: ...PDG DSU21 55 2 Ballast Feedback Signal ...

Page 60: ... KA7AA May 2008 DC 300 Printed in Japan SANYO Electric Co Ltd ...