Sanyo PDG-DSU30 - 2500 User manual

Chassis No. KW5-DSU3000

I

PDG-DSU30

Condential

SERVICE MANUAL Multimedia Projector Model No. PDG-DSU30

Original Version

PRODUCT CODE

1-682-348-39

REFERENCE NO. SM0946002

II

PDG-DSU30

Condential

Contents

SERVICE MANUAL�� I

Contents��II

Safety Instructions��III

Safety Precautions ��III

Product Safety Notice��III

Service Personnel Warning��III

Introduction�� 1-1

Highlight�� 1-1

Compatible Mode��1-3

Disassembly Process�� 2-1

Equipment Needed &

Product Overview��2-1

Disassemble Lamp Cover Module�� 2-2

Disassemble Lamp Module�� 2-2

Disassemble Top Cover Module�� 2-3

Disassemble Zoom Ring Module�� 2-3

Disassemble Top Shielding�� 2-4

Disassemble IO Cover��2-4

Disassemble Main Board Module�� 2-5

Disassemble Main Board Shielding�� 2-6

Disassemble Front Cover Module and

IR Sensor Board�� 2-7

Disassemble Engine Module�� 2-7

Disassemble Color Wheel Module��2-8

Disassemble DMD Chip and DMD Board�� 2-8

Disassemble Rod Module�� 2-9

Disassemble Focus Ring�� 2-9

Disassemble Fan Module and

Thermal Switch�� 2-10

Disassemble Blower Module�� 2-11

Disassemble LVPS Module�� 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 Default�� 4-1

Blower Reset�� 4-2

Test Condition�� 4-2

Test Inspection Procedure�� 4-4

PC MODE�� 4-4

Video Performance�� 4-7

Calibration�� 4-9

Optical Performance Measure�� 4-10

Others�� 4-11

Firmware Upgrade�� 5-1

Section 1: System Firmware Upgrade�� 5-1

Equipment Needed�� 5-1

DLP Composer Lite Setup Procedure�� 5-2

Firmware Upgrade Procedure�� 5-4

Section 2: 8051 Firmware

Upgrade Procedure�� 5-8

Equipment Needed�� 5-8

NLINK Setup Procedure�� 5-9

Manley USB Driver Upgrade Procedure�� 5-11

8051 Firmware Upgrade Procedure�� 5-13

Section 3: Waveform Download��5-14

�Waveform Download�� 5-14

Appendix A�� I

Exploded Image�� I

Appendix B�� II

Serial Number System Denition�� II

PCBA Code Denition�� III

III

PDG-DSU30

Condential

Safety Instructions

Service Personnel Warning

Eye damage may result from directly viewing the light produced by the Lamp used in this equipment.

Always turn off Lamp before opening cover. The Ultraviolet radiation eye protection required during

this servicing.

Never turn the power on without the lamp to avoid electric-shock or damage of the devices since the

stabilizer generates high voltages (15kV - 25kV) at its starts.

Since the lamp is very high temperature during units operation replacement of the lamp should be

done at least 45 minutes after the power has been turned off, to allow the lamp cool-off.

WARNING:

The chassis of this projector is isolated (COLD) from AC line by using the converter transformer.

Primary side of the converter and lamp power supply unit circuit is connected to the AC line and it is

hot, which hot circuit is identied with the line ( ) in the schematic diagram. For continued product

safety and protection of personnel injury, servicing should be made with qualied personnel.

The following precautions must 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 installed properly, such as,

control knobs, adjustment covers or

shields, barriers, etc.

DO NOT OPERATE THIS PROJECTOR WITHOUT

THE PROTECTIVE SHIELD IN POSITION AND PR

OPERLY SECURED.

4: Before 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.

Safety Precautions

Product Safety Notice

Product safety should be considered when a component replacement is made in any area of the

projector. Components indicated by mark ! in the parts list and the schematic diagram designate

components in which safety can be of special signicance. It is, therefore, particularly recommended

that the replacement of there parts must be made by exactly the same parts.

Condential

1-1

PDG-DSU30

Chapter 1

Introduction

No Item Description

1 Technology ● 0.55” DMD 1 chip 2xLVDS (DarkChip3) SVGA

2 Dimension (W x D x H) ● 286.3*88*192 mm (without protruding parts)

3 Weight ● < 2.31Kg

4 Power Supply

● Universal AC 100--240V ~ 50 / 60 Hz with PFC input

● 180W Lamp @ normal operation

● 160W Lamp @ eco operation

● Variance FAN speed control (Depend on temperature

variance)

5 Keystone Correction ● +/ -15 degree Vertical

6 Resolution ● Native Resolution: 800 X 600

7 Brightness ● 2500 ANSI Lumens2500 ANSI Lumens

8 Contrast ● 2200:1 (Full on/Full off)

9 Uniformity ● 80 (�BMA standard )80 (�BMA 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 initial min. Lumen output at the lamp life time.

13 Lens Offset ● 115+/-5

14 Video compatibility

● NTSC: M (3.58MHz), 4.43 MHz

● PAL: B, D, G, H, I, M, N

● SECAM: B, D, G, K, K1, L

● HDTV: 480i/p, 576i/p, 720p(50/60Hz), 1080i/p(50/60Hz)

1-1 Highlight

Condential

1-2

PDG-DSU30

No Item Description

15 Terminals

● One D-Sub 15-pin female connector for VGA input

and component video input

● One Mini DIN 4-pin for S-Video Input

● One RCA �ack for Composite Video Input

● One Min-pin RS232 port for FW update

● One D-Sub 15-pin female connector for VGA output

● One Audio in 3.5mm dia. mono mini-jack

16 System Controller ● TI DDP2431

17 Color 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 level (bi-polarity)

● Composite Sync: TTL level (bi-polarity)

● Sync-on-green: negative sync. 0.3Vp-p

● Analog Video

• Composite video 75ohm

• S-video (Y/C) 75ohm

• Component video (Y/Pb/Pr) 75ohm

Condential

PDG-DSU30

1-3

1-2 Compatible Mode

Computer Compatibility (Analog)

Compatibility Resolution V-Sync [Hz]

VGA

640x350 70

640x350 85

640x400 85

640x480 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

Condential

1-4

PDG-DSU30

Compatibility Resolution V-Sync [Hz]

UXGA 1600 x 1200 60

MAC LC 13” 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.

PDG-DSU30 Condential

2-1

Chapter 2

Disassembly Process

2-1 Equipment Needed & Product 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.

PDG-DSU30 Condential 2-2

2-3 Disassemble 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.

PDG-DSU30 Condential 2-3

2-4 Disassemble Top Cover

Module

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.

PDG-DSU30 Condential 2-4

2-6 Disassemble Top

Shielding

1. Unscrew 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

PDG-DSU30 Condential 2-5

A

B

D

EF

C

Item

Male Connector

on Main Board

The key feature Figure

A Lamp Driver Black wire tube (5 pin)

B Fan

Compose of Red/Yellow/Black

Wire (3 pin)

C Blower

Compose of Red/Black/White

Wire, white connector and Black

wire tube (3 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 refer to the table as below for

details of each connector.

PDG-DSU30 Condential 2-6

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.

PDG-DSU30 Condential 2-7

2-10 Disassemble Front

Cover Module and IR

Sensor Board

1. Unscrew 1 screw (as red circle).

2. Unfasten 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

PDG-DSU30 Condential 2-8

2-12 Disassemble Color

Wheel Module

1. Unscrew 2 screws (as red circle) to

disassemble the Color Wheel Module.

2. Unscrew 1 screw (as blue circle) to

disassemble the Photo Sensor Board

from the Color Wheel Module.

Note: - Avoid touching the glass parts 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 it.

- Pay attention to the xed position when

assembling the DMD Chip.

PDG-DSU30 Condential 2-9

2-14 Disassemble 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.

PDG-DSU30 Condential 2-10

Note: - 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

PDG-DSU30 Condential 2-11

2-16 Disassemble Blower

Module

1. Unscrew 3 screws (as red circle) to

disassemble 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

PDG-DSU30 Condential 2-12

Note: when you assemble the unit must do

actions as below:

1. Use the cable tie to pierce the rst hole of

LVPS for binding the Interlock Switch and

Lamp Driver to LVPS cable

(as blue

square)

.

2. Use clamp to x 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.

PDG-DSU30 Condential 2-13

Interlock Switch

2-19 Disassemble Interlock

Switch

1. Unscrew 1 screw (as red circle) to

disassemble the Interlock Switch.

Note: Make sure the Interlock Switch cable be

wedged llister as the picture shown.

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.

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Sanyo PDG-DSU30 - 2500 User manual

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