BENQ W20000 SERVCIE MANUAL- LEVEL 2

Applicable Country & Regions:

All Regions

Product Service Manual – Level 2

Service Manual for BenQ:

Projector/W20000
<9J.0AH77.000>

Version: 00b

Date:2007/12/07

Notice:

For RO to input specific “Legal Requirement” in specific NS regarding to responsibility and liability
statements.

Please check BenQ’s eSupport web site, http://esupport.benq.com, to ensure that you have the most
recent version of this manual.

First Edition (Nov, 2007)

© Copyright BenQ Corporation 2007. All Right Reserved.

1

Content Index

Abbreviations & Acronyms……………………………………………………..……..3
About This Manual……………………………………………………..……………..4

Trademark…………………………………………………………...……………...4

Introduction……………………………………………………………………..……....4

Important Service Information………………………………………….……….....4

RoHS (2002/95/EC) Requirements – Applied to all countries require RoHS.……...4

Safety Notice…………………………....………………………....…………..…….5

Compliance Statement……………………………………………………….……..5
General Descriptions…………………………………………………………………….5
Related Service Information……………………………………………………………..5

Service Web Site…………………………………………………………………….5

Product Overview………………………………………………………………………..6

Specifications……………………………………………………………………….6

Packing……………………………………………………………………………15
Customer Acceptance……………………………………………………………..21

Disassembly/Assembly…………………………………………………………………25

Exploded View………………………………………………………………….....25

Module 1 – Total Exploded View..…………………………………………….25

Module 2 – ASSY UPPER CASE………………………………………………….27

Module 3 – ASSY LOWER CASE…….………………..……………...………..28

Disassembly/Assembly……………………………………………………………36

Level 1 Cosmetic / Appearance / Alignment Service…………………………..………36

Operational Inspection Criteria...……………..………....……………………….36

Software/Firmware Upgrade Process…………………………………………......40

Adjustment / Alignment Procedure………………………………………………54

Level 2 Circuit Board and Standard Parts Replacement……………………………….110

Block Diagram………………..………………………………………………......110

Troubleshooting………………...………………………………………………...112

Appendix 1 – Screw List / Torque…………………….……………………………...120

Appendix 2 – Code List: IR / RS232 / DDC Table…………..……………………….123

2

Abbreviations & Acronyms

A

A/D Analog to Digital

B

BenQ BenQ Corporation

D

DLP Digital Light Processing / Texas Instruments®

DMD Digital Micro mirror Device

DVI Digital Video Interface

DVI-I Digital Video Interface-Integrated

P

POM Pond of Mirrors

R

RS232 Interface Between Data terminal Equipment and

Data Communications Equipment Employing
Serial Binary Data Interchange

S

SVGA Super Video Graphics Array, A screen resolution

of 800 x 600 pixels.

SXGA Super XGA. A screen resolution of 1280x1024

pixels.

V

VGA Video Graphics Array. A screen resolution of

640x480 pixels.

X

XGA A screen resolution of 1024x768 pixels.

3

About This Manual

This manual contains information about maintenance and service of BenQ products. Use this
manual to perform diagnostics tests, troubleshoot problems, and align the BenQ product.

Important

Only trained service personnel who are familiar with this BenQ Product shall perform
service or maintenance to it. Before performing any maintenance or service, the
engineer MUST read the “Important Safety Information”

Tr a dem ar k

The following terms are trademarks of BenQ Corporation:
BenQ

Other companies, products, or service names may be the trademarks of their respective companies.

Introduction

This section contains general service information, please read through carefully. It should be stored
for easy access place.

Important Service Information

RoHS (2002/95/EC) Requirements – Applied to all countries require RoHS.

The RoHS (Restriction of Hazardous Substance in Electrical and Electronic Equipment Directive) is a
legal requirement by EU (European Union) for the global electronics industry which sold in EU and
some counties also require this requirement. Any electrical and electronics products launched in
the market after June 2006 should meet this RoHS requirements. Products launched in the market
before June 2006 are not required to compliant with RoHS parts. If the original parts are not RoHS
complaints, the replacement parts can be non ROHS complaints, but if the original parts are RoHS
compliant, the replacement parts MUST be RoHS complaints.
If the product service or maintenance require replacing any parts, please confirming the RoHS
requirement before replace them.

4

Safety Notice

1 Make sure your working environment is dry and clean, and meets all government safety

requirements.

2 Ensure that other persons are safe while you are servicing the product.
3 DO NOT perform any action that may cause a hazard to the customer or make the product

unsafe.

4 Use proper safety devices to ensure your personal safety.
5 Always use approved tools and test equipment for servicing.
6 Never assume the product’s power is disconnected from the mains power supply. Check that it is

disconnected before opening the product’s cabinet.

7 Modules containing electrical components are sensitive to electrostatic discharge (ESD). Follow

ESD safety procedures while handling these parts.

8 Some products contain more than one battery. Do not disassemble any battery, or expose it to

high temperatures such as throwing into fire or it may explode.

9 Refer to government requirements for battery recycling or disposal.

Compliance Statement

Caution: This Optical Storage Product contains a Laser device. Refer to the product specifications
and your local Laser Safety Compliance Requirements.

General Descriptions

This Service Manual contains general information. There are 2 levels of service:
Level 1: Cosmetic / Appearance / Alignment Service
Level 2: Circuit Board or Standard Parts Replacement

Related Service Information

Service Web Site

BenQ Global Service Website: http://support.benq.com/front/benqmain.asp
eSupport Website: http://esupport.benq.com/v2

5

Product Overview

Specifications:

1.0 Optical Performance

2.0 Image Quality

3.0 Mechanical Specification

4.0 Packaging

5.0 Thermal Specification

6.0 Environmental

7.0 Regulatory

8.0 Reliability

9.0 Power Requirements

10.0 Panel Specification

11.0 Compatibility

12.0 Image Interface

13.0 Control Interface

14.0 User Interface

15.0 Audio

6

1.0 Optical Performance All optical testing must be under 49”(diagonal)offset 100%and
wide at 200W lamp mode, unless other specified.

1.1 Lamp Philips lamp 200W
Minimum Typical 1.2 ANSI Brightness

(4x Spoke on, Iris full open )

1000Lumens 1200 Lumens

Minimum Typical 1.3 Brightness Uniformity

(4x Spoke on, Iris full

55% 65%

open )

1.4 Contrast Ratio
Minimum Typical 1.4.1 ANSI Contrast

150:1 300:1
Minimum Typical 1.4.2 FOFO

Contrast-Dynamic Black on

10000:1 18000:1

(4X spoke on, Full white
under iris all open /Full
black under Iris all close)

1.5 Light Leakage

1.5.1 Light Leakage out of
Active Area (except DMD
defeat)

Condition: Observer and projector at distance 3 m and the

projection image diagonal 73.5”(Wide) and 61.3(Tele)

Inspection range : 73.5” to 100” at Wide, 61.3 to 83.3 at Tele

Test pattern :Full Black pattern
Criteria: Light leakage outside active area should be < 0.3lux

1.5.2 DMD Image Quality Criteria: Follow 1080p DMD(1910-xxx7) image quality
specifications

1.5.3 Blue Edge Condition: projector @ distance 3m and the projection image
diagonal 73.5”
Test Pattern:( Iris on full white)

Criteria: Color coordinate |Δx,Δy |≦0.01 (difference between
zone A and B)

4.5 cm

7.5cm

B

A

1.6 Color Coordinates
Based on BenQ RD PR650.
EPR stage final confirm

x y

typical value

1.6.1 White .278 ± .04 .324 ± .04

1.6.2 Red .665 ± .03 .319 ± .03

1.6.3 Green .298 ± .03 .623 ± .03

1.6.4 Blue .145 ± .03 .060 ± .03

1.7 Color Uniformity x y

7

1.7.1 White ±.03 ±.03

1.7.2 Red ±.03 ±.03

1.7.3 Green ±.03 ±.03

1.7.4 Blue ±.03 ±.03

2.0 Image Quality All optical testing must be under offset 120% and wide

2.1 Throw Ratio 98” ±4% Diagonal at 4m (Wide)

2.2 Zoom Ratio >1.2:1

2.3 Distortion

2.3.1 Horizontal TV

<1.0%

Distortion

2.3.2 Vertical TV

<1.0%

Distortion

2.4 Projection Offset Vertical : +120% +10%/-5% / -80% +5%/-10%

2.5 Mechanical Focus Range

2.5.1 Visible Range 2~8 m

2.5.2 Clearly Focus Range 3~6 m(Spec. defined as item 2.7)

2.6 Focus
Test condition:

1.Viewer stand on 3m far from

Distance 3.0m 73.5”lens shift @up 120% for Focus test. (Tele @
the same Throw Distance.)

Test pattern: 区-pattern as below (Timing 1080P)

the screen)

2. Projector offset is 120%.

Criteria: Pixel clear and uniform

3. Zoom ratio is 1.2.

2.7.1 Flare and Defocus
Flare (B)

R <=3

G<=3

B<=3

2.8 Lateral Color Test pattern: pattern 34(Chroma)

Criteria: <1 pixels

3.0 Mechanical Specification
Adhere to Appendix G

3.1 Dimensions 492 x 420 x 180 mm (L x W x H)

3.2 Weight 9.6kg

3.3 Security Slot

3.4 Lens Cover

Kensington compatible slot 150N break away force

NA

3.5 Feet Four adjust feet.

4.0 Packaging

8

Defocus (A)

R<=2

G<=2

B<=2

4.1 Outside Dimensions 565 x 535 x 345mm (L x W x H)

4.2 Weight 13.5 Kg (Including Accessories, Projector)

4.3 Palletization
1070 x 1130 x 120 mm

5.0 Thermal Specification Mechanical component temperature at ambience 0~40℃

5.1 Surface held or touched for

short periods

Normal surface:
Metal < 60°C; Plastic<85°C

Bottom surface:
Metal < 55°C@25℃; Plastic<70°C@25℃

5.2 Surface which maybe

Metal < 70°C; Plastic<95°C

touched

5.3 Exhausted Air

<95°C

6.0 Environmental

6.1 Temperature

Operating

0-40°C, without condensation

Storage -20 - 60°C, without condensation
Operating 10 - 90%RH, without condensation 6.2 Humidity
Storage 10 - 90%RH, without condensation

6.3 Audible Noise Level (sea

level)

Typical Normal mode: 28dBA @ 25°C

whisper mode: 25dBA @ 25°C

Maximum Normal mode: 29dBA @ 25°C

whisper mode: 26 dBA @ 25°C

6.4 Altitude

7.0 Regulatory

Operating:
Without high altitude mode 0 ~ 35°C @ 0 ~ 1499m above sea level
With high altitude mode 0 ~ 30°C @ 1500 ~ 3000m above sea level
Non-operating:
30°C @ 0 ~ 12200m above sea level

Safety cTUVus, TUV-GS, CB Report, PSE,PSB,SASO, eK
EMC

FCC Class B, VCCI, C-Tick, CE

CE Marks Directive 73/23/EEC

Directive 89/336/EEC

ESD

8.0 Reliability

8.1 MTBF

20000 hours except for DMD chip, Color wheel, Lamp and Fan

8.2 Lamp Lifetime

9.0 Power Requirements

2000 hours (50% brightness maintenance)

Adhere to Appendix F

9.1 Power Supply (Normal) VAC 90 – 264 Auto-switch (50/60Hz), 3 Wire Grounded
Max 340W 9.2 Power Consumption

Standby

<1W, Test condition 100 ~ 240VAC

9.3 Power Connector IEC-06

10.0 Panel Specification

10.1 Type Single Chip 0.95” 12° tilt DMD (1080P) from Texas Instruments

10.2 Resolution 1920(H) x 1080(V)

10.3 Color Depth 24 Bits (16770000 colors)

11.0 Compatibility Adhere to Appendix E

11.1 PC PC Compatible VGA, SVGA, XGA

11.2 Video Signal Composite, S-Video, Y/CB/CR

11.3 HDTV DTV Y/PB/PR (480P, 1080i, 720P, 576P, 540P)

11.4 Image Inversion Floor Front, Floor Rear, Ceiling Front, Ceiling Rear

11.5 Scaling Scaling from other resolutions to native by TI+scaling chip

9

11.6 Aspect ratio ANAMORPHIC, 4x3, LETTER BOX, VIRTUAL WIDE.

11.7 DDC DDC 2B

12.0 Image Interface

12.1 RGB Input None

12.2 Composite

12.3 S-Video

12.4 Component

12.5 Progressive component

RCA x 1

S-Video x 1

RCA x 3
BNC x 5

and DTV RGBHV

12.7 Digital Video

13.0 Control Interface

HDMIx2

13.1 IR Receiver

13.1.1 Location 2 receiver, located on the front and top of this projector

13.2.2 Range 8m (front) / 5m (rear) with 30 degree horizontal Angle and 30
degree vertical angle

13.2 RS232C Input
Mini Din

13.3 USB Connector None

14.0 User Interface

14.1 Backlight None

14.2 Operator Keypad

14.3 Indicators

7 Key

Power Status LED (Green/Yellow), Lamp Status LED (Red) ,

Temp Status LED (Red)

14.4 Electric Keystone

Correction

± 12°

14.5 Onscreen Menu Should be in 8 languages (English, French, German, Italian,
Spanish, Japanese, Simplified Chinese and Traditional Chinese )

14.6 Color temperature

Color Temp 1 6500 　K (x=0.312, y=0.329)
Color Temp 2 7500 　K (x=0.296, y=0.316)
Color Temp 3 9300 　K (x=0.281, y=0.300)
Color Temp 4 None

15.0 Audio

15.1 PC Audio Input None

15.2 Speaker None

16.0 Accessories

16.1 Cables Power Cord Set (US, UK, Euro) x 1, BNC-Dsub Cable x 1,
Composite cable x 1, RCA-RCA Cable x 1, S-video Cable x 1

16.2 Printed Matter User’s manual: (English)

16.3 Remote Control IR Remote x 1, AAA Batteries x 2

16.4 User’s Manual CD Should be in 14 languages (English, French, Germany, Italian,
Spanish , Dutch , Korea, Japanese, Portuguese, Russian , Poland,
Turkey, Simplified Chinese and Traditional Chinese) x1

10

Appendix E - Electrical Specification

Table 1: Support Timings by RGBHV (Analog or Digital PC signals)

Format Resolution

720 x 350 720 x 400 70 31.469 28.322

Refresh

rate(Hz)

H.

Freq.(KHz)

Freq.(MHz)

Pixel

720 x 400

640 x 480 640 x 480

800 x 600 800 x 600

848 x 480 848 x 480 60 31.02 33.75

1024 x 768 1024 x 768

720 x 400 70 31.469 28.322

720 x 400 85 37.9 35.5

60 31.469 25.175
72 37.861 31.5
75 37.5 31.5
85 43.269 36

50 31.3 32.051
56 35.156 36
60 37.879 40
72 48.077 50
75 46.875 49.5
85 53.674 56.25

60 48.363 65
70 56.476 75
75 60.023 78.75
85 68.677 94.5

1152 x 864 1152 x 864 75 67.5 108

60 47.396 68.25

1280 x 768 1280 x 768

1280 x 960 1280 x 960

1280 x 1024 1280 x 1024

1360 x 768 1360 x 768 60 47.712 85.5

1400 x 1050 1400 x 1050

1440 x 900 1440 x 900

60 47.776 79.5
75 60.289 102.25
85 68.633 117.5

60 60 108

85 85.938 148.5

60 63.981 108
75 79.976 135
85 91.146 157.5

60 64.744 101
60 65.317 121.75
75 82.278 156
60 55.469 88.75
60 59.935 106.5

11

75 70.635 136.75
85 80.43 157

1600 x 1200 1600 x 1200 60 75 162

1680 x 1050 1680 x 1050

60 64.674 119

60 65.29 146.25

1920 x 1200 1920 x 1200 60 74.038 154

Table 2: Support Timing by HDMI-I Input

Format Resolution

Refresh

rate(Hz)

H. Freq.(KHz)

Freq.(MHz)

480/60i 720 x 487 59.94 15.734 13.5

480/60p 720 x 483 59.94 31.469 27

576/50i 720 x 576 50 15.625 14.75
576/50p 720 x 576 50 31.25 29
720/50p 1280 x 720 50 37.5 75.25
720/60p 1280 x 720 60 45 74.25

1080/50i 1920 x 1080 50 28.125/31.25 74.25/72

1080/60i 1920 x 1080 59.94 / 60 33.716/ 33.75 74.175/74.25
1080/24P 1920 x 1080 23.98 / 24 26.978/ 27 74.175/74.25
1080/48P 1920 x 1080 48 27 148.5
1080/25P 1920 x 1080 25 28.125 74.25

Pixel

1080/30P 1920 x 1080 29.97 / 30 33.716/ 33.75 74.175/74.25
1080/50P 1920 x 1080 50 56.25 148.5
1080/60P 1920 x 1080 59.94 / 60 67.433/ 67.5 148.35/148.5

Table 3: EDTV and HDTV Timing supported by component (YPBPR) and RGBHV Input

(1) RGB signals can be applied to RGBHV connectors
(2) YPBPR signals can be applied to YPBPR connectors.

Format Resolution

Refresh

rate(Hz)

H. Freq.(KHz)

Pixel

Freq.(MHz)

480/60i 720 x 487 59.94 15.734 13.5

480/60p 720 x 483 59.94 31.469 27

576/50i 720 x 576 50 15.625 14.75
576/50p 720 x 576 50 31.25 29
720/50p 1280 x 720 50 37.5 75.25
720/60p 1280 x 720 60 45 74.25

1080/50i 1920 x 1080 50 28.125/31.25

74.25/72

1080/60i 1920 x 1080 59.94 / 60 33.716/ 33.75 74.175/74.25
1080/24P 1920 x 1080 23.98 / 24 26.978/ 27 74.175/74.25
1080/48P 1920 x 1080 48 27 148.5
1080/25P 1920 x 1080 25 28.125 74.25
1080/30P 1920 x 1080 29.97 / 30 33.716/ 33.75 74.175/74.25

12

1080/50P 1920 x 1080 50 56.25 148.5
1080/60P 1920 x 1080 59.94 / 60 67.433/ 67.5 148.35/148.5

Table 4: Video, S-Video support timing is as following:

Format Resolution

Refresh

rate(Hz)

H. Freq.(KHz)

Pixel

Freq.(MHz)
NTSC 3.58 - 59.94 / 60 15.734/ 15.75 3.58
NTSC 4.43 - 59.94 / 60 15.734/ 15.75 4.43

PAL-B/G - 50 15.625 4.43

PAL M - 59.94 / 60 15.734/ 15.75 3.58

PAL N - 50 15.625 3.58

PAL 60 - 59.94 / 60 15.734/ 15.75 4.43

SECAM - 50 15.625 4.25 / 4.41

13

Appendix F. Power Supply Specification

1. Input Power Specification

Specification Description
Input Voltage Range The unit shall meet all the operating requirements with the range 90 ~ 264 VAC
Frequency Range The unit shall meet all the operating requirements with an input frequency

range 47 Hz ~ 63 Hz

Power Consumption Normal operation: 340 W (Max)

standby mode: < 1W, Test condition 100 ~ 240VAC

Regulation Efficiency 70 % (typical) measuring at 115Vac and full load

2. Output Power Requirement

The power supply can provide DC output as below：

NO. Voltage Regulation Load Current Range Ripple / Noise

1
2 +12 V

+5 V

±5 %

±10 %

0.03A ~ 3.0 A 50/100 mV

0.0 A ~ 3.5 A 120/240 mV

3. Lamp Power specifications

Specification Description
Applicable Lamp 200W, AC operation
Starting pulse from Ignitor 2.5KV(0-peak)

4. Others

Item Description
Power good signal 5V
High voltage and high temperature protection NA

14

Packing

【NOTE】The updated Service BOM is on e-Support and SPO. Please check it to order service parts.

15

16 17

CTN LBL PRINTING (For B9A-US / Taiwan)

CTN LBL PRINTING (For B9E-EU /UK)

18

CTN LBL PRINTING (For B9P- AU/JP/Korea)

19

SPEC LBL PRINTING (For B9A-US / Taiwan)

SPEC LBL PRINTING (For B9E/B9P)

20

Customer Acceptance

1.0 SCOPE

This document establishes the general workmanship standards and functional acceptance criteria

for PROJECTOR produced by Qisda.

2.0 PURPOSE

The purpose of this publication is to define a procedure for inspection of the PROJECTOR by

means of a customer acceptance test, the method of evaluation of defects and rules for

specifying acceptance levels.

3.0 APPLICATION

The "Customer Acceptance Criteria" is applicable to the inspection of the PROJECTOR,

completely packed and ready for dispatch to customers. Unless otherwise specified, the customer

acceptance inspection should be conducted at manufacturer's site.

4.0 DEFINITION

The "Customer Acceptance Criteria" is the document defining the process of examining, testing

or otherwise comparing the product with a given set of specified technical, esthetic and

workmanship requirements leading to an evaluation of the "degree of fitness for use", including

possible personal injury or property damage for the use of the product.

5.0 CLASSIFICATION OF DEFECTS

The defects are grouped into the following classes:

5.1 Critical defect

A critical defect is a defect which judgment and experience indicate that there is likely to

result in hazardous or unsafe conditions for individuals using product.

5.2 Major defect

A major defect is a defect, other than critical one, is likely to result in failure, or to reduce

materially the usability of the product for its intended purpose.

5.3 Minor defect

A minor defect is a defect that is not likely to reduce materially the usability of its intended

purpose, or is a departure from established standards having little bearing on the effective

use of operation of the product.

Note: If BenQ defect undefined failure, and it judged that is reduce the merchandisebility,

BenQ CM Inform this defect. After that parties make communication and decide how to solve.

21

6.0 EXPRESSION OF DEFECTIVES

Number of defects

Percent of defects = ------------------------------------------ X 100%

Number of products inspected

7.0 INSPECTION STANDARD

Unless otherwise specified, the inspection standard will be defined by MIL-STD-105E,

NORMAL INSPECTION LEVEL Ⅱ, SINGLE SAMPLING PLAN. Level Ⅱ is in use all the time,

inspection levels are normal, reduce and tighten.

7.1 Acceptance Quality Level

7.1.1 Critical Defect:

When a critical defect is found, this must be reported immediately upon detection, the

lot or batch shall be rejected and further shipments shall be held up pending instructions

from the responsible person in relevant department.

7.1.2 under normal sampling

Critical Defective : 0% AQL

Major Defective : 0.65% AQL

Minor Defective : 2.5% AQL

7.1.3 under special sampling

Critical Defective : 0% AQL

Major Defective : 1.0% AQL

Minor Defective : 4.0% AQL

8.0 GENERAL RULES

8.1 The inspection must be carried out by trained inspectors who have good knowledge about

the product.

8.2 The inspection must be based upon the documents concerning the completely assembled

and packed product.

8.3 When more defects appear with the same unit only the most serious defect has to be taken

into account.

22

8.4 Defects found in accessory packed with the product such as Cable, Connector, Manual, CD

and the like, and being inspected as a part of the complete product, must be included in the

evaluation.

8.5 The evaluation must be within the limits of the product specification and, for not specified

characteristics, refer to the sample machine or the judgment of BENQ QA Engineer. But any

kind of proposals or judgments must be reasonable and acceptable by both sides.

8.6 Faults must be able to be repeatedly demonstrated.

9.0 TEST CONDITIONS

9.1 Environment Condition

9.1.1 For functional inspection

Nominal voltage: 90 ~ 264 VAC, 50Hz ~ 60Hz.

Environmental illumination:

Less than 1 lux of the light on the screen shall be from any source other than the

projector.

Nominal ambient room temperature is 25±5℃

Warm up time: at least more than 5 minutes

Display mode: all measurements shall be made at standard color temperature setting,

100% white image (per ANSI IT7. 228-1997), except where noted.

9.1.2 For appearance inspection
Lighting intensity:

All appearance quality shall be inspected with the lighting condition as 500~800Lux

(natural lighting or white fluorescent light).

Inspection angle and distance to object or target:

All part inspection must be done under direct overhead lighting. Viewing angle and

distance are dependent on surface classification. In all cases, parts must be held in

such that the light reflection does not disturb the inspector's eye.

23

圖 1

Classification Area A Area B Area C
Lighting positioning Above of inspected part

Inspection position relative to part 90º 90º 90º

Inspection distance 45 cm 45 cm 45 cm

Table 1

9.1.3 Inspection interval (time)

Inspection interval is a function of surface area.
Time for visual inspection: 10sec.

10.0 TEST EQUIPMENTS

Dark room

PC

Pattern Generator: Chroma 2250 or equivalent

Minolta color analyzer (CL-100 or equivalent)

BS tuner (Sharp TU-HD1/ Panasonic TU-BHD300, or equivalent)

DVD player

Power supply (90~264 VAC) with consumption meter

Measuring tape

24

Disassembly/Assembly

Exploded View

Module 1 – Total Exploded View

25

26 27

Module 2 – ASSY UPPER CASE

Module 3 – ASSY LOWER CASE

28

Disassembly / Assembly

Operation Tool

Item

go round and
round, then pull

1

the ring zoom
and ring focus.

Picture

Ring focus

Parts

Ring zoom,
Ring focus

turn over and

2

take off the CNT
door

unlock lower

3

case screw*6

screw
driver

CNT door

CNT door

2

1

4

screw*6

3

6

5

29

unlock the
screw*2 and

4

take off the door
lamp, left case
and rear case.

screw
driver

left case

1

2

door lamp

door lamp,
left case,
rear case

rear case

unlock the
screw*9 and

5

disassembly the
IR wire and up
case

screw
driver

screw*9,
up case

Up case

30

1. unlock the
screw*3 and
take off the
cover connector

6

2. unlock the
screw*4 and
take off the EMI
shielding.

screw
driver

2

1

screw*7,

3

3

cover
connector,
EMI
shielding

2

disassembly the

7

wires

unlock the
screw*6 and

8

take off the
main B/D
module

screw
driver

3

1

2

4

screw*6 ,
main B/D
module

5

31

6

unlock the
screw*5 and

9

take off the
tunnel above .

1.unlock the
screw*2 and
take off the
lamp.

2. unlock the
screw*1 and

10

take off the lamp
wire, then
unlock the
screw*2 and
take off the lamp
box module..

screw
driver

screw
driver

screw*5 ,
tunnel
above

2

1

2

lamp wire

screw*5 ,

3

lamp,
lamp box
module

1. unlock the
inlet tunnel
screw*2 and
take off the inlet
tunnel .

2. unlock the
screw*1 and

11

take off the inlet
fan module.

3. take off the
wires, then
unlock the
screw*3 and
take off the
black tunnel .

screw
driver

fan screw

screw*6 ,
inlet
tunnel ,
inlet fan
model,
black
tunnel .

1

3

2

32

1.disassembly
the outlet fan
screw*1
and take off the
front tunnel.

2. unlock the
screw*1 and

12

take off the SW
wire, then
unlock the
engine screw*4
and take off the
optical engine
module.

screw
driver

Outlet fan screw

SW
wire

screw*6 ,
front
tunnel

1

disassembly the
screw*5 and

13

take off the
power B/D.

disassembly the
screw*3 and
take off the

14

blower module,
nozzle module
and sucker.

screw
driver

screw
driver

screw*5 ,
power B/D

1

3

screw*3,
blower

module，
nozzle

2

module,
sucker

33

1.disassembly
the C/W screw
*4 and take off
the C/W

15

module.

2.disassembly
the screw*1and
take off the C/W
module.

screw
driver

4

1

1

screw *5，
C/W
module

3

2

1.disassembly
the screw*3 and
take off the PL
shift module

16

2.disassembly
the screw*4 and
take off the PL
module.

screw
driver

1

2

4

1

screw*7，
PL shift

module.，
PL

Lens

2

module.

3

34

1.disassembly
the screw*5 and
take off the
baffle TIR and
cvreng anti dust.

2.disassembly
the screw*2 and
take off the FM

17

module .

3.disassembly
the screw*2 and
take off the ILL
module .

4.disassembly
the screw*3 and
take off the TIR
module.

screw
driver

2

1

4

screw*12，
baffle TIR

3

5

and cvreng
anti dust，

FM
module，

3

ILL
module,
TIR

5

2

module

1.take off the
wires and
unlock the
screw*3,then
take off the CE
module and TR

18

BD.

2.unlock the
screw*6，take off

the heat block
and the DMD
module

screw
driver

1

1

2

screw*9，
CE

2

module,
TR BD,
heat block,

1

DMD
module

2

35

Level 1 - Cosmetic / Appearance / Alignment Service

OPERATIONAL INSPECTION CRITERIA

1. TEST PATTERN

PATTERN

PATTERN TEST ITEM

Full white

Chessboar

d

Full Dark

Full Red

Full Green

Full Blue

ANSI Brightness、Bright Uniformity、FOFO

Contrast Ratio、CIE white coordinate、Throw

Ratio、Zoom Ratio、Distortion

ANSI Contrast

FOFO Contrast Ratio

Impurity、CIE coordinate

Impurity、CIE coordinate

Impurity、CIE coordinate

Chroma

1280x720

256/64/32

Color bar

General-1

pattern

256/32/16

Gray

DDC

check

Focus Range

Performance/ Timing check/ function check

Including S/N, model, manufacturer name,

Color and Gray Check

Gray Check

Check the DDC information,

product code.

36

2. TEST CONTENT:

Test Condition TEST ITEM Input Equipment

Chroma pattern 1280x720 Focus/ Focus range

Gray scale check

RGB-BNC Chroma

PC Mode

Timing VESA1024 / 256 gray scale

Timing ICL-406 / Gen 1 Picture quality

FULL W , R , G , B Impurity, CIE

coordinate, pixel fail

At random PC sound check Audio

CD-ROM

KEY Test Condition TEST ITEM Input Equipment

HDTV NTSC (480i)/ 480p/ PAL (576i)/

576p, HDTV (720p/ 1080i/1080p)
NTSC disk Æ

DVD

picture

Output = NTSC 3.58MHz/ 60Hz
PAL disk Æ

Output = PAL 4.43MHz / 50 Hz

HDMI NTSC 480p/ PAL (576i)/ 576p,

HDTV (720p/ 1080i/1080p)

DVI DHD control box test

DVI analog and digital signal

Picture performance YPbPr

Picture quality

Video
S-video

Picture quality

Video
S-video

Picture quality

Picture quality and
operation function

HDMI DVD player

DVI DHD control box

Chroma / BS

Tu ne r

DVD player

PC for 1080p

Chroma/ DVD
player

RGBHV NTSC (480i)/ 480p/ PAL (576i)/

576p, HDTV (720p/ 1080i/1080p)

Picture quality

RGBHV Chroma/ DVD

player

And PC signal

2. SPECIFICATION :

Item Spec. Condition Pattern

Contrast: Preset

ANSI Brightness

Minimum 936 Lumens
Typical 1170 Lumens

Brightness: Preset
5X SLR on level 10

Full white

Iris full open

Contrast: Preset
Bright Uniformity
ANSI Uniformity

Minimum 55 %
Typical 65 %

Brightness: Preset

5X SLR on level 10

Full white

Iris full open

ANSI Contrast

Minimum 400:1
Typical 500:1

Contrast: Preset

Brightness: Preset

Chessboard

Contrast: Preset

FOFO Contrast Ratio

Minimum 4400:1
Typical 5500: 1

Brightness: Preset

5X SLR on level 10

Full white and Full dark

Iris full close

37

Condition: projection
image diagonal 52”

Light Leakage
(In Active Area)

1. Full white pattern:

No see special color
spot at the corner

2. Gray 10 pattern:

No see any bright spot.
Condition: projection

Light Leakage
(Out of Active Area)

image diagonal 100”
Gray20 pattern: No light
leakage visible outside of
active area.

CIE white coordinate

CIE red coordinate

CIE green coordinate

CIE blue coordinate

Throw Ratio

x=0.291+
y=0.330+
x=0.652+0.03
y=0.335+0.03
x=0.331+0.03
y=0.627+0.03
x=0.150+0.03
y=0.060+0.03
100” ±4% Diagonal at 4 m
(Wide)

0.04

0.04

Zoom Ratio 1.15 + 3% - 1 %

Horizontal TV Distortion

Vertical TV Distortion

(W2-W1) / (W1+W2)

<1.0%
(H1+H2-2×H3)/2H2
<1.0%

Focus Range Clear focus: 2~6 m

Color and Gray Check Should be clear and bright

Defocus and Flare Don’t inspect

DMD Image Quality

See
Defect Classification

Contrast: Preset

Brightness: Preset

Contrast: Preset

Brightness: Preset

Contrast: Preset

Brightness: Preset

Contrast: Preset

Brightness: Preset

Contrast: Preset

Brightness: Preset

Contrast: Preset

Brightness: Preset

Contrast: Preset

Brightness: Preset

Contrast: Preset

Brightness: Preset

Contrast: Preset

Brightness: Preset

Contrast: Preset

Brightness: Preset

Contrast: Preset

Brightness: Preset

Brightness: Preset

Contrast: Preset

Get best focus on

screen center.

Brightness: Preset

Contrast: Preset

See

Defect

Classification

Full dark

Gray20

Full white

Full Red

Full Green

Full Blue

Full white

Full white

Full white

Full white

Chromo 84 X pattern

Chromo 256 gray
pattern

Flare and Defocus
pattern

See
Defect Classification

Item Spec. Condition Pattern

Contrast: Preset

Brightness: Preset

Timing chart refer

to C201 document

Contrast: Preset

Brightness: Preset

Chromo Test pattern

VG828 Test pattern

PC

HDTV

640X400Æ 1280X720,
Composite-Sync;
Sync-on-Green; Interlace
Mode (8514A);
NTSC (480i)/ 480p/ PAL
(625i)/ 760p, HDTV (720p/
1080i/1080p)

38

2.1 POWER CONSUMPTION:

Mode Condition Power Consumption LED Color

Standby power - < 15 W Red

Normal - < 370W Green

3. OPERATIONAL INSPECTION CRITERIA:

No Description Class

1 Noise

1.1 When power on or power off, fan or color wheel get abnormal noise. Major

1.2 When normal operation, noise exceed noise level (refer to C201 document) Major
2 Display Quality (include input: Video, S-video, YPbPr, and DVI, HDMI or

RGBHV)

2.1 Focus range out of specification Major

2.2 Focus fail (focus not clear or flare/ defocus/ lateral color out of specification) Major

2.3 Brightness & Uniformity --- out of specification. Major

2.4 Contrast ratio --- out of specification Major

2.5 Color coordinates --- out of specification. Major

2.6 Light leakage out of specification (active area or out of active area) Major

2.7 Throw ratio out of specification Major

2.8 Room ratio out of specification Major

2.9 Picture distortion out of specification Major

2.10 DMD image out of specification Major

2.11 Picture dust or other image quality out of specification Major

2.12 Gray stage check --- Missing stage Major

2.13 Video noise --- If video noise presented Major

2.14 DDC data error / incorrect Major

2.15 Mode detection error Major

2.16 OSD Malfunction Major
4 Remote control malfunction Major

Receiver range: 8 m Receiver angle: ± 30 degree (vertical and horizontal) Major

4.1

39

Software/Firmware Upgrade Process

Hardware requirement

a. RS232 cable (P/N 50.J5019.501)
b. Desktop or laptop with DB-9 connector

Software requirement

a. Developers ToolKit(DTK) produced by Silicon Optix Inc. with a download tool named

“Updater”

b. A firmware file(*.brec)

Download Procedure

a. Connect PC with projector by RS232 download cable.
b. Hold “Right” key and then turn on AC power until three LEDs lit orange to enter download

mode

c. Open “Updater”

40

d. Select “UART” in “Targets on” and then click “Search.” If PC find a link with projector, a

message “BOOT-SOI(COM:1)” will occur.

e. Select “BOOT-SOI(COM:1)”
f. Click “Browse…” to select a firmware file (*.brec) in your PC.
g. Click “Update Firmware”
h. After process bar reaching 100%, download procedure is complete.

i. Reboot projector

41

Read and Write data from Main Board

‧ Need to use service tool to read data from Main board before FW re-download.

After FW downloaded, need to write data form service tool into Main Board.

‧ To o l :

– Install W5000/W20000 service tool
– PC
– RS232 CABLE

‧ Procedure:

I. Installation:

1. Click “setup.exe” file.

2. Click “OK.”

3. Change an installation dictionary or agree default dictionary and then click the icon button.

42

4. Enter a new group name or select one from the “Existing Groups” list and then click “Continue.”

5. Click “OK” and a successful installation is completed.

II. How to Use Service Tool

(1) Read Data From Main Board:

1. Connect PC with projector by a RS232 cable (P/N 50.J5019.501).

2. Turn on projector.

3. Click “BenQ W5000&W20000” Service Tool 1.2.”

43

4. Click “Setup” first.

5. Select a folder for saving projector data and a specified COM port and then click “Save” and

“Exit.”

6. After selecting a data folder, the folder path is showed in “File Path.”

44

7. Change to “System Data” form and then click “Read System Data.”

8. ADC calibration data are uploaded first and color temperature data after.

45

9. After lamp and DLP data are uploaded, “Read System Data” is completed.

10. After completing “Read System Data,” there is a folder named “Read Data” added in the selected

folder before.

11. A file named “Scaler.dat” including adjustment data of projector is added in the “Read Data”

folder.

12. Turn off projector and then download a new firmware.

(2) Write Data From Main Board to Projector:

13. After completing firmware download, click “Retrieve System” to write back adjustment data.

46

14. ADC calibration data are written back first and color temperature data after.

15. After lamp and DLP data are written back, “Retrieve System” is completed.

47

How to enter factory menu:

Press “Up,” “Down,” “Up,” and “Down” continuously at “Information” OSD page

How to Change Model Name:

1. Turn on projector and enter factory mode (Press “Up,” “Down,” “Up” and “Down” keys

continuously on “Information” OSD page).

2. Select “Factory…” item in factory mode.

48

3. On “Factory” OSD page, select “W5000” or “W20000” at “Splash Screen” item and then exit

factory mode.

4. Reboot projector and then complete changing splash screen.

49

How to enter factory menu:

Press “Up,” “Down,” “Up,” and “Down” continuously at “Information” OSD page

How to Use RS232 Control:

Hardware requirement

1. Mini-DIN to RS232 cable for W500/W5000/W20000/SP830/SP831 (P/N 50.J5019.501)

2. Desktop or laptop with DB-9 connector

50

Physical layout of RS232 connector

a. Projector-side female connector pin definition

Pin 1 – PC RS232 TX (Projector RS232 RX)
Pin 4, 8 – GND
Pin 7 – PC RS232 RX (Projector RS232 TX)
Other Pins – floating

b. PC-side male connector pin definition

Pin 2 – PC RS232 TX
Pin 3 – PC RS232 RX
Pin 5 – GND
Other Pins -- floating

Setup for RS232 communication

a. Baud rate – 115200 bps
b. Data bits – 8 bits
c. Parity – None
d. Stop bits – 1 bit

51

Procedure of operation by HyperTerminal

Step1. Connect projector and computer via a RS232 cable
Step2. Turn on projector
Step3. Create a connection between computer and projector by HyperTerminal

a. Open “HyperTerminal”
b. Name this connection

c. Select a permitted COM port – COM1 usually

52

d. Select “115200” bps for baud rate and “None” for flow control

e. Input a valid RS232 command (refer to 6.5 RS232 command list) at terminal window

53

Adjustment / Alignment Procedure

Content

1. OPT Alignment & Assembly Procedure

1.1 Color Wheel Delay Alignment

1.2 Color Alignment procedure

1.3 Compatible DB component with DB control board

1.4 Optical test pattern

2. MD Alignment & Assembly Procedure

3. EE Alignment & Assembly Procedure

3.1 RGB Alignment Procedure

3.2 YUV Alignment Procedure

3.3 YUV 1080p Alignment Procedure

4. EMI Alignment & Assembly Procedure

5. OM Alignment & Assembly Procedure

5.1 Assembly Lamp module

5.2 Assembly CW module

5.3 Assembly LP Module

5.4 Assembly Tube Module

5.5 Assembly TIR Module

5.6 Assembly Tube Module and TIR Module on HSG

5.7 Assembly Lens on PL Slide

5.8 Assembly Lens Ring

5.9 Paste Gasket on DMD BD CVR

5.10 Assembly DB control board module

54

1. OPT Alignment & Assembly Procedure

1.1. Color Wheel Delay Alignment

Equipment:

- Battery Biased Silicon PIN Detector

- Oscilloscope

- Probe

OSD Default value:

Item Value

Brightness

Contrast

CW Delay 220

DLP Degamma Gamma 1

CW Speed 5X with BC OFF

(Choose Look1)
Procedure:
a) Coarse tune:
Probe impedance matches 50 ohm (depends on photo sensor)
Open Factory OSD, enter pure blue (Factory \Test Patterns\DLP Curtains\Blue curtain)

1. Put the detector in front of the projection lens and to decide distance.

Watch the oscilloscope and align its setup to get the stable and clear waveform. The height and

width of waveform shape are both two units (See Fig, 1).

2. under the “Blue curtain” pattern. You can use the hotkey to increase or decrease the color wheel
delay value at the same time. Software will save this value in to CW delay index automatically.

The default CW delay value is 220 and the waveform is ahead on the right of the waveform under

blue color. (No matter the waveform is square or not, let the waveform is ahead on right
first.)(See Fig. 1)

Just flat point

Then adjust CW delay value to see the waveform to be square. Stop changing the delay value when

the tilt waveform on the right side just becomes flat. (See Fig. 2). Then 32 gray ramps will be
continuous and smooth.

55

Figure1. Blue color waveform before alignment

Figure2. Blue color waveform after alignment

56

b) Fine tune:

1. After checking the waveform of the oscilloscope, check the 32-color bar (Factory \Test

Patterns\Scaler patterns\32-gray bars (Figure. 3). The gray ramps should be smooth and have no
any obvious discontinue bars. If the ramp is not smooth, use hotkey to adjust to a proper value

Figure 3

1.2. Color Alignment procedure

1.2.1. Color Alignment

Default valve(User menu)

Brightness

Component 1 50 50 50 0 0 Normal

RGBHV 50 50 50 0 0 Normal

Component 2 50 50 50 0 0 Normal

S-Video 50 50 50 0 0 Normal

Video 50 50 50 0 0 Normal

HDMI-0 IRE 50 50 50 0 0 Normal

* Black Level default is 0 IRE

* The Gamma (RED, GREEN, BLUE) offset is 512 for all color temperature.

* DB Iris function is off(full - open).

Contrast Color Tint Sharpness Te m p

* Iris is on 19 status (full - open)

* Use Gamma 2.2 for all color temperature adjustment
(A) Component 1 (YPbPr):
Equipment:

- Pattern generator (VG-828)

- Lux meter ( CL-200)

57

OSD Default value used for YPBPR color alignment

A

Y

A

A

A

Y

A

A

W

Item Value
User OSD Factory>ADC

Contrast 50 Pr Offset
Brightness 50

Offset
Color 50 Pb Offset
Tint 0 Pr Gain
Sharpness 50

Gain
Color Temperature Normal Pb Gaint

Color temperature spec: (CIE 1976 u’, v’ chromaticity)

Color temperature Lamp native Warm Normal Cool

'

27

x

y

Deviation:

　u’v ’=

u

''

+−=vu

'

12

v

''

+−=vu

2

'

( vu Δ+Δ )

364818

364818

2

'

Default 0.313 0.299 0.283

Default 0.329 0.315 0.296

Default <=0.010 <=0.010 <=0.010

The color temp of User 1~3 is the same as that of Normal

Color temperature Lamp native
Gamma-R gain 512
Gamma-G gain 512
Gamma-B gain 512
Gamma R Offset 512
Gamma G Offset 512
Gamma B Offset 512

1). Color Temperature 7500 at 80% (T1 plus)

arm
488
493
512
512
512
512

Item

Normal

486
492
512
512
512
512

Va lu e

0 IRE (Auto

7.5 IRE

uto Cal.
uto Cal. 0 IRE + 12

uto Cal.
uto Cal.
uto Cal. 0 IRE + 2
uto Cal.

Cool

483
486
512
512
512
512

1. Load all user default in factory OSD (Before Auto Cal.).

2. Set black level to 0 IRE.

3. Change pattern of pattern generator :

Timing : 480P(H:31.54 KHz,V:60.08 Hz)

Pattern : 80% gray

4. User the lux meter and adjust color temperature R gain, G gain, & B gain to meet Normal color

temperature spec (7500K).

5. Press “Exit” to save current setting into color temp “Normal” color temperature memory.

The variance of color coordinate via R,G,B gains:

x y

R ↓ x ↓
G ↓

-

-

y ↓

B ↓ x ↑ y ↑

6. Follow step 3~5 to adjust “Wa rm ” and “Cool” color temperature.

58

1.2.2. Video Color Alignment Procedure

W

Equipment:

- Pattern generator (VG-828)

- Lux meter ( CL-200)

OSD Default value used for S-video color temp alignment:

Item Value
User OSD Factory> TVP5160

>Composite & S-Video>

Contrast 50 Brightness
Brightness 50 Contrast
Color 50 Saturation

Tint 0 Hue
Sharpness 50 Sharpness
Color Temperature Normal

Color temperature spec: (CIE 1976 u’, v’ chromaticity)

Color temperature Lamp native Warm Normal Cool

'

27

x

y

Deviation:

　u’v ’=

u

''

+−=vu

'

12

v

''

+−=vu

2

'

( vu Δ+Δ )

364818

364818

2

'

Default 0.313 0.299 0.283

Default 0.329 0.315 0.296

Default <=0.010 <=0.010 <=0.010

The color temp of User 1~3 is the same as that of Normal

Color temperature Lamp native
Gamma-R gain 512
Gamma-G gain 512
Gamma-B gain 512
Gamma R Offset 512
Gamma G Offset 512
Gamma B Offset 512

arm
502
489
512
512
512
512

Item

Normal

510
492
512
512
512
512

Va lu e

0 IRE 7.5 IRE

77 63
137 138
139

128

65 84

Cool

500
477
512
512
512
512

1). Black Level Adjustment:

1. Load all user default in the factory OSD.

2. Set black level to 0 IRE.

2). Color Temperature at 80% gray

3. Change pattern of pattern generator :

Timing : NTSC(H:15.73 KHz,V:29.96 Hz)

Pattern : 80% gray

4. User the lux meter and adjust color temperature R gain, G gain, & B gain to meet Normal color

temperature spec.

5. Press “Exit” to save current setting into color temp “Normal” color temperature memory.

The variance of color coordinate via R,G,B gains:

x y

R ↓ x ↓
G ↓
B ↓ x ↑ y ↑

-

-

y ↓

6. Follow step 3~5 to adjust “War m” and “Cool” color temperature.

59

1.3 Compatible DB components with DB control board

The serial number must be the same on these two labels, and should be one-on-one, never

interchangeable. DB component must work with the same serial number label.

60

1.4. Optical testing patterns

Optical

test item

ANSI Contrast

ratio

FOFO C/R

Brightness,
Uniformity,
FOFO C/R,

White

Color

coordinate

Tes t Pat t er n

Checkerboard

Full Black (Iris off)

Full White (Iris on)

Factory OSD

Location

1. White : Full white

2. Black : Full Black

Tes t pa t tern s/

DLP Regular patterns/

ANSI C/R

Tes t pa t tern /

General inspection

patterns/

Full White (Iris off)

Tes t pa t tern /

General inspection

patterns/

Full White (Iris on)

3. Iris: Full open

4. DLP regular pattern

1.4X

2.BC look : 1

3. Lamp sync=1740

4.Black : Full Black

5.Iris: Full close

1.4X

2. BC look : 1

3. Lamp sync=1740

4.Black : Full Black

5.Iris: Full open

Test condition Code

X226X

X234X +

X258X

X252X

Red

Color

coordinate

Green

Color

coordinate

Blue

Color

coordinate

curtain

Red

Green curtain

Blue curtain

.4X

2.BC look : Disable

3. Lamp sync=1740

Tes t pa t tern s/

DLP curtains/

Red curtain

Tes t pa t tern s/
DLP curtains/
Green curtain

Tes t pa t tern s/

DLP curtains/

Blue curtain

4.Red : Red 255

5.Iris: Full Open

1.4X

2.BC look : Disable

3. Lamp sync=1740

4.Green :Green 511

5.Iris: Full Open

1. 1.4X

2.BC look : Disable

3. Lamp sync=1740

4.Blue : Blue 255

5..Iris: Full Open

X231X

X232X

X233X

61

Function

Iris Function On User OSD

Iris Function Off User OSD

CT_Red Gain

CT_Green Gain

CT_Blue Gain

set DLP gamma to 2.2

Function

Location

Factory OSD Adjust Red gain in

Factory OSD Adjust Green gain in

Factory OSD Adjust Blue gain in

User OSD set DLP gamma to 2.2 Z128W+

Test condition Code

DB function : ON

DB function : OFF

color temperature

color temperature

color temperature

X400X

X401X

Z104

Z105

Z106

0002Z

62

2. MD Alignment & Assembly Procedure

ASSY LOWER CASE
RUBBER HOOK PORON ADHESIVE AREA

SPONGE ADHESIVE LOCATION

63

Back tunnel assemble
A

Set 2 screws.

B Take case ballast direction.

C Rubber (4G.05Q22.001) stick. align below edge of hole on EMI shielding

Rubber

64

D Add 1 fabric on EMI- shielding.

Fabric W20* L40 mm

65

A RUBBER AND GASKET adhesive location
B Back tunnel assemble must touch L/C SHD as picture

C

Wire for power BD must through the back tunnel.
Assemble Wire to connector make long side close Power BD.

Long side

66

Door switch assemble to switch bracket
Take care Door switch direction.
Wire must be set on upper side.

FRONT TUNNEL SUB ASSEMBLE
A Wire for outlet fan dressing as picture.
B 8F.1A524.5R0
C Sponge (4G.05Q01.001) adhesive location.

B C

67

Two wire assemble as picture

Fan 9025 wire

Thermal sensor
wire

Fan 9025 wire

Thermal sensor
wire

68

Add tape at tunnel above as picture.

Two wire must be through SHD

69

Assemble Wire to connector make short side close DMD BD.

Short side

Long side

Assemble Wire to connector make short side close Main_BD.

70

WIRE(A) FOR INLET FAN ASSEMBLE AT LEFT SIDE OF CLIP(B)

EMI SHD MUST CONTACT M/B SHD

CHECK ADJUST FEET POSITION
TPR HAS TO TOUCH LOWER CASE.

TPR

71

Take case clip not to interfere DMD shielding.

A Blower wire
B Wire from IRIS to Main BD
Dress Wire as picture.

72

A Blower wire
B Wire from IRIS to Main BD
Dress Wire not to high to interfere EMI shielding.

73

WHEN GOODS IS PACKING, THE LENS MUST BE MIDDLE OF LENS SHIFT RANGE.

1. USE JIG TO ADJUST LENS LOCATION

2. PUSH LENS_SHIFT BUTTON TO ADJUST LENS POSITION

3. WHEN LENS_RING TOUCH SWITCH, THE WARMING LAMP LIGHTS, WHICH

MEANS LWNS POSITION IS CORRECT.

4. THEN, RELEASE LENS_SHIFT BUTTON.

WARMING LAMP

JIG

SWITCH

74

Insert clip to set blower.
Make sure there is no gap between clip and blower and clip and bkt.

75

Assemble Clip for Front fan
Two clip assemble as picture

Assemble bkt_fan and fan as picture 2

76

Assemble other two clip as picture

Use clip(4B.M2709.001 ) to fix the cable(main BD to keypad BD)

77

A CABLE from main BD to keypad BD
B Cable for lens shift

B

A

78

Earth wire alignment as picture

Fix the cable by this way (without touch H-Sink).

79

Keypad wire alignment as picture

80

AIR FILTER AND INLET TUNNEL

Switch for filter door assemble as picture

81

3. EE Alignment & Assembly Procedure

3.1 RGB Alignment

Equipment – Pattern Generator
Source – RGBHD
Alignment Procedure

a. Input test pattern with SXGA timing 1280×1024@60 Hz (H-Sync: 63.981 kHz, V-Sync: 60.02

Hz, Pixel Clock: 108 MHz)

b. Enter factory mode
c. Press “Enter” at “ADC Calibration…” line
d. Select “RGB HD” at “Select Source” line
e. Press “Enter” at “Apply Source and Port Selection” line
f. Press “Enter” at “AD9984…” line
g. Select “RGBHV Format…”
h. Press “Enter” at “Auto Calibration” line
i. Wait ADC calibration OSD unfrozen, calibration is complete.

Test Pattern

82

3.2 YUV Alignment

Equipment – Pattern Generator
Source – Component 2
Alignment Procedure

1. Input test pattern with timing HDTV 720p (H-Sync: 45 kHz, V-Sync: 60 Hz, Pixel Clock:

74.25 MHz)

2. Enter factory mode

3. Press “Enter” at “ADC Calibration…” line

4. Select “Comp 2” at “Select Source” line

5. Press “Enter” at “Apply Source and Port Selection” line

6. Press “Enter” at “AD9984…” line

7. Select “YPbPr Format…”

8. Press “Enter” at “Auto Calibration” line

9. Wait ADC calibration OSD appear again, calibration is complete.

Test Pattern

83

3.3 YUV 1080p Alignment

Equipment – Pattern Generator
Source – Component 2
Alignment Procedure

a. Input test pattern with timing HDTV 1080p (H-Sync: 67.5 kHz, V-Sync: 60 Hz, Pixel Clock:

148.5 MHz)

b. Enter factory mode
c. Press “Enter” at “ADC Calibration…” line
d. Select “Comp2” at “Select Source” line
e. Press “Enter” at “Apply Source and Port Selection” line
f. Press “Enter” at “AD9984…” line
g. Select “1080p YPbPr Format…”
h. Press “Enter” at “Auto Calibration” line
i. Wait ADC calibration OSD appear again, calibration is complete.

Test Pattern

84

4. EMI Alignment & Assembly Procedure

Item 1 EMI Solution
Description Add 2 gasket on lower case

Solution

Low Frequency power base

Gasket

W20*H20*L75 mm

Gasket

W6*H6*L43 mm

85

Item 2 EMI Solution
Description Add 4 gasket on optic engine
Solution 636 MHz

Gasket

W10*H1*L50 mm

Gasket

W6*H1*L120 mm

Gasket

W10*H1*L25 mm

86

m

Item 3 EMI Solution
Description Add 2 gasket on fan metal cover.
Solution 655 & 928MHz

Gasket

W36.5*H2*L93 mm

Gasket

W15*H10*L25 m

87

m

Item 4 EMI Solution
Description Add 1 gasket on fan metal cover.
Solution 655 & 928 MHz

gasket

W15*H17*L40 m

Item 5 EMI Solution
Description Add 1 fabric to cover rubber on PW BD metal cover.
Solution 742 MHz

Fabric

W20* L40 mm

88

Item 6 EMI Solution
Description Add 1 core
Solution 183 & 202 MHz

Core
2E.72068.011

Item 7 EMI Solution

Description Add 1 fabric
Solution 181 & 196 MHz

Fabric

W20* L40 mm

89

Item 8 EMI Solution
Description Add 1 gasket.
Solution 742 MHz

gasket.

W20*H2*L40 mm

Item 9 EMI Solution
Description Add 3 gaskets.

Solution 83 & 111 MHz

gasket.

W36.5*H2*L93 mm

gasket

W5*H2*L95 mm

4G.J0B61.001
W10*H2*L84 mm

90

Item 10 EMI Solution
Description Add 1 Gasket.
Solution 66 MHz

gasket.

W15*H18*L25 mm

Item 11 EMI Solution
Description Add 1 Gasket.

Solution 675 & 900 MHz

gasket

W15*H1*L160 mm

91

Item 12 EMI Solution
Description Fix the cable by this way.
Solution

Item 13 EMI Solution
Description Fix the LVDS cable without touch any cable and top metal cover.

Solution 928 MHz

92

Item 14 EMI Solution
Description Use clip to fix the cable by this way.
Solution 928 MHz

clip

93

Item 15 EMI Solution
Description Fix the cable by this way (without touch H-Sink).
Solution Reduce Power base

94

Item 16 EMI Solution
Description Fix the cable by this way (without touch H-Sink).
Solution Reduce Power base

95

5. OM Alignment & Assembly Procedure

5.1. Assembly Lamp module:

5.1.1 Baffle Lamp, Fin and Mesh Assembly

I. Hook “Mesh” on the Lamp Holder first and fasten the screw.(Figure 1-1).
II. Assemble “Fin Mesh” with Lamp holder fasten the screw (Figure 1-2).
III. To make sure that “Assembly of Mesh” on the Left side when you face to the Front Glass

(Figure 1-3)

Mesh

Hook on
lamp holder

Lamp Holder

Figure 1-1 Figure 1-2

Face Direction

Mesh

Figure 1-3

screw

screw

96

5.1.2 Lamp Assembly.

i. Insert Lamp into Lamp Holder and make three datum contact with the lamp. (Figure

1-4，Figure 1-5)

ii. Datum A contact Datum a, Datum B contact Datum b, Datum C contact Datum c (Figure

1-6)

Datum c

Datum C

Datum A Datum B

Datum b

Figure 1-4 Figure 1-5

Figure 1-6

Datum a

97

5.1.3 Lamp Fix

I. Hook “Clip_UP” on the Lamp Holder first. (Figure 1-7)
II. Hook “Clip_DOWN” on the Lamp Holder second. (Figure 1-8)

Clip up

Clip down

Figure 1-7 Figure 1-8

5.1.4 Lamp Box and Lamp Wire Assembly

I. Assembly one top spring and two btm springs on lamp box hooks first. (Figure 1-9)
II. Longer Lamp Wire screw on Lamp High Voltage Side. (Figure 1-10)
III. Lamp Wire Hook on Lamp Box. (Figure 1-11)
IV. Screw Lamp Wire connector on Lamp Box. (Figure 1-12)

Top Spring

High Voltage Side

Longer Lamp Wire

Figure 1-9 Figure 1-10

BTM Spring

98

Lamp Connector

Lamp Wire Hook o Lamp Box

Screw

Figure 1-12

Figure 1-11

5.1.5. Lamp Holder and Lamp Box Assembly

I. Assembly top hold of lamp holder on top hook of lamp box. (Figure 1-13)
II. Assembly btm hold of lamp holder on btm hook of lamp box. (Figure 1-14)
III. Put front glass on lamp holder, and assembly front glass clip. (Figure 1-15)

1

3

2

Front glass

Figure 1-13 Figure 1-14

99

Front Glass Clip

Figure 1-14

5.2. Assembly CW module:

5.2.1 CW Module Assembly Sequence as blow

(1) CW BKT (2) Damper CW (3) Sensor BD (4) M2 Screw (5) CW
(6) Fixed screw

1

4

6

3

2

5

Figure 2-1

100