Panasonic PT-AE3000E, PT-AE3000U Service Manual

PT-AE3000U PT-AE3000E

ORDER NO. VED0810389C0

D10

LCD Projector

PT-AE3000U / PT-AE3000E

CONTENTS

Page Page

1 Safety Precautions 5

1.1. General Guidelines

1.2. Leakage Current Check

1.3. UV Precaution and UHM Lamp Precautions

2 Ext Option

2.1. Procedure to enter EXT OPTION

2.2. EXT OPTION Menu and Functions

2.3. Canceling EXT OPTION

3 Self-Check Mode

3.1. Procedure to enter the self-check mode

3.2. Self Check Display and Contents

3.3. Canceling the self-check mode

4 Flicker Adjustment Mode

4.1. Procedure to enter the adjustment mode

4.2. Adjustment Display and Contents

4.3. Canceling the flicker adjustment mode

5 Using the SERIAL Connector

5.1. Connection

5.2. Pin Layout and Signal Names for SERIAL Connector

5.3. Communication Settings

5.4. Basic Format

5.5. Control / Query Commands

5.6. Communication Cable Specifications

6 Disassembly Instructions

6.1. Printed Circuit Board and Main Parts Location

6.2. Removal of Upper Case

6.3. Removal of A-P.C.Board

6.4. Removal of K1- and K3- P.C.Boards Block

6.5. Removal of R-P.C.Board

6.6. Removal of S-P.C.Board

6.7. Removal of V-P.C.Board

6.8. Removal of B/Q-Module

6.9. Removal of P-Module

6.10. Removal of Lamp Unit

6.11. Removal of Analysis Block and LCD Block / Shift Mechanism / Projection Lens

6.12. Replacement of Incidence Polarizer

6.13. Replacement of PBS Array (Analysis Block)

6.14. Removal of Iris Unit

7 Measurement and Adjustments

5 5 5

6 6 6

7 7 8

8 8 8

9 9

9 10 10 12

14 15 15 16 16 17 17 17 18 19

19 20 20 21

7.1. Cautions for Adjustment

7.2. Setting Before Adjustment

7.3. Lighting Area Adjustment

7.4. Software for Adjustment

7.5. Flicker Adjustment

7.6. Input Level Adjustment (RGB)

7.7. Serial Number Setup

7.8. Sensor Correction

8 Troubleshooting 9 Interconnection Block Diagram

9.1. Interconnection Block Diagram (1/2)

9.2. Interconnection Block Diagram (2/2)

10 Block Diagram

10.1. Power Supply

10.2. Signal Processing (1/3)

10.3. Signal Processing (2/3)

10.4. Signal Processing (3/3)

11 Schematic Diagram

11.1. A-P.C.Board (1/9)

11.2. A-P.C.Board (2/9)

11.3. A-P.C.Board (3/9)

11.4. A-P.C.Board (4/9)

11.5. A-P.C.Board (5/9)

11.6. A-P.C.Board (6/9)

11.7. A-P.C.Board (7/9)

11.8. A-P.C.Board (8/9)

11.9. A-P.C.Board (9/9)

11.10. K1-P.C.Board, K2-P.C.Board, K3-P.C.Board

11.11. S-P.C.Board, R-P.C.Board, V-P.C.Board, H-P.C.Board

11.12. B-Module (1/2)

11.13. B-Module (2/2)

12 C irc uit Boards

12.1. A-P.C.Board (Foil Side)

12.2. A-P.C.Board (Component Side)

12.3. V-P.C.Board

13 Ex ploded View s 14 Replacement Parts List

22 22 22 24 27 28 29 29

31 41

41 42

43 44 45 46

48 49 50 51 52 53 54 55 56 57 58 59 60

61 62 63

65 69

1 Safety Precautions

1.1. General Guidelines

· For continued safety, no modification of any circuit must be

attempted.

· Unplug the power cord from the power outlet before

disassembling this projector.

· Use correctly the supplied power cord and must ground it.

· It is advisable to use an isolation transformer in the AC

power line before the service.

· Be careful not to touch the rotation part (cooling fan, etc.) of

this projector when you service with the upper case removed and the power supply turned ON.

· Observe the original lead dress during the service. If a short

circuit is found, replace all the parts overheated or damaged by the short circuit.

· After the service, all the protective devices such as

insulation barriers, insulation papers, shields, and isolation R-C combinations must be properly installed.

· After the service, check the leakage current to prevent the

customer from getting an electric shock.

1.2. Leakage Current Check

1. Prepare the measuring circuit as shown in Fig.1. Be sure to use a voltmeter having the performance

described in Table 1.

PT-AE3000U / PT-AE3000E

Fig. 2

2. Assemble the circuit as shown in Fig. 2. Plug the power cord in a power outlet.

3. Connect M1 to T1 according to Fig. 2 and measure the voltage.

4. Change the connection of M1 from T1 to T2 and measure the voltage again.

5. The voltmeter must read 0.375 V or lower in both of steps 3 and 4. This means that the current must be 0.75 mA or less.

6. If the reading is out of the above standard, the projector must be repaired and rechecked before returning to the customer because of a possibility of an electric shock.

1.3. UV Precaution and UHM Lamp

Precautions

· Be sure to unplug the power cord from the power outlet when replacing the lamp.

· Because the lamp reaches a very high temperature during its operation, wait until it cools completely when replacing the Lamp Unit.

· The lamp emits small amounts of UV-radiation, avoid directeye contact with the light.

· The lamp unit has high internal pressure. If improperly handled, explosion might result.

· Because the high pressure lamp involves a risk of failure, never touch the lamp wire lead during the service. (See Fig.

Fig. 1

Table 1

Fig.3

PT-AE3000U / PT-AE3000E

2 Ext Option

This projector has EXT OPTION in addition to standard on-screen menus.

· There are SELF CHECK and FLICKER ADJUST for service, etc.

2.1. Procedure to enter EXT OPTION

1. When the projector is power ON, press "POWER" button on the main unit or remote control unit to display "POWER OFF" confirmation screen.

2. Press the right-arrow "

3. On the main unit or remote control unit, press the buttons in order of up-arrow " down-arrow "

(When the "ENTER" button is pressed, "EXT OPTION" menu is displayed.)

" and "ENTER".

2.2. EXT OPTION Menu and Functions

" button to select "CANCEL" in the "POWER OFF" confirmation screen.

", down-arrow " ", up-arrow " ",

· FAN FULLMODE Setting the cooling fan motor rotation speed

−

− Switching ON "FAN FULLMODE", the rotation level of the fan becomes high-speed rotation (fixed). Moreover, when "FAN

− −

FULLMODE" is ON, changing "HIGH ALTITUDE MODE" in OPTION menu becomes impossible (setting FAN FULLMODE is given priority more than HIGH ALTITUDE MODE).

· AUTO SETUP Setting AUTO SETUP mode

−

− NORMAL: To set the normal mode (the dot clock is adjusted strictly)

− −

−

− SPECIAL: To set the special mode (the dot clock is adjusted roughly)

− −

* Do not change the initial setting (NORMAL).

· SELF CHECK To enter the self-check mode

· FLICKER ADJ To enter the flicker adjustment mode

· OS Setting of the reflection noise reduction filter when a component signal (except 525i, 625i, 1125/60p and 1125/50p) is inputted.

Usually set it to ON. * Do not change the initial setting (ON).

· HPLL When non-standard signal of VIDEO/S-VIDEO is inputted (VTR, VHD, etc.), horizontal synchronization might be disordered

according to connected equipment. In this case, set HPLL to OFF.

2.3. Canceling EXT OPTION

Press "MENU" button on the main unit or remote control unit.

3 Self-Check Mode

This mode is used to narrow down the location of the failure.

3.1. Procedure to enter the self-check mode

Select "SELF CHECK" on "EXT OPTION" menu and press "ENTER" button on the main unit or remote control unit.

3.2. Self Check Display and Contents

PT-AE3000U / PT-AE3000E

3.3. Canceling the self-check mode

Press "MENU" button on the main unit or remote control unit.

4 Flicker Adjustment Mode

If replacing the optical parts (LCD Panel / LCD block) or A-P.C.Board of this projector, enter the flicker adjustment mode and minimize the flicker.

4.1. Procedure to enter the adjustment mode

Select "FLICKER ADJUST" on "EXT OPTION" menu and press "ENTER" button on the main unit or remote control unit.

Note:

"DESK setting (red)" is displayed when entering the adjustment mode.

4.2. Adjustment Display and Contents

· Setting value is increased and decreased with the right-arrow " " and left-arrow " " buttons.

": Decrease, " ": Increase

−

− Adjust the setting value to minimize the flicker on the screen.

− −

−

− Execute the adjustment by 6 patterns below.

− −

· The pattern (adjustment display) is switched with the up-arrow "

": Forward direction, " ": Reverse direction

−

− There are 6 patterns of "DESK setting (red)", "DESK setting (blue)", "DESK setting (green)", "CEILING setting (red)",

− −

"CEILING setting (blue)" and "CEILING setting (green)".

−

− The setting value is saved into this projector when the pattern is switched.

− −

" and down-arrow " " buttons.

4.3. Canceling the flicker adjustment mode

Press "MENU" button on the main unit or remote control unit.

Note:

When "MENU" button is pressed, the setting value at that time is saved into this projector and the adjustment mode is canceled.

PT-AE3000U / PT-AE3000E

5 Using the SERIAL Connector

The serial connector which is on the back connector panel of the projector conforms to RS-232C standard. This projector can be controlled by a PC which is connected as shown in "5.1. Connection".

For controlling this projector by a PC, requires communication software on the market, and inputs control commands according to communication settings and basic format below.

5.1. Connection

Note:

Use a proper communication cable which is suitable for the PC to connect SERIAL connector and the PC.

5.2. Pin Layout and Signal Names for SERIAL Connector

Pin No Signal Name Contents

1 --- NC 2 TXD Transmit data 3 RXD Receive data 4 --- NC 5 GND Ground 6 --- NC 7 CTS Connected internally 8 RTS 9 --- NC

5.3. Communication Settings

Signal Level Contents Description

Sync. method Asynchronous Synchronizes every 1 character (8 bits)

Baud rate Conforms to 9 600 bps Data transfer speed

Parity RS-232C None Error detection method

Character length standard 8bits Number of bit composing 1 character

Stop bit 1bit Uses stop bit when asynchronous method X parameter Not used S parameter Not used

PT-AE3000U / PT-AE3000E

5.4. Basic Format

The data sent from the PC to the projector is transmitted in the format shown below.

Notes:

· If sending multiple commands, check that a call back has been received from the projector for 1 command before sending

the next command.

· When a command which does not require parameters is sent, the colon (:) is not required.

5.5. Control / Query Commands

Control Commands

Query Commands

PT-AE3000U / PT-AE3000E

Parameters

[Example]

Setting to which the power is turned off in 90 minutes, using SLEEP command by a PC

· When a command which does not require parameters is sent, the colon (:) is not required.

PT-AE3000U / PT-AE3000E

5.6. Communication Cable Specifications

PT-AE3000U / PT-AE3000E

6 Disassembly Instructions

Warning:

· Be sure to unplug the power cord from the power outlet before disassembling this projector.

Caution:

· While turning over a printed circuit board, be sure to put a insulating material under it to prevent a short circuit.

· Printed circuit boards and wires must not be pulled forcibly, but be handled carefully.

· Connectors also must be handled carefully.

· When reassembling, replace used adhesive tape with new one (Do not re-use used tape).

· After repairing this projector, be sure to put back the wires and connectors to the original condition.

· Service or repair the product according to service information on the service manual, etc. so that a fire, injury or electric

shock caused by an improper repair may not occur.

1. Do not modify equipments, components and materials when attempting to service or repair.

2. Do not repair nor connect wires even in case of a part of the disconnection when the wiring unit is supplied as a replacement parts, replace the wiring unit (complete).

3. For a fasten terminal (push-in type terminal), pull out or insert straightly without twisting it.

4. When the fuse has blown, do not turn on the power supply replacing only the fuse because the secondary disaster of fumes, fire or other hazards is expected. Turn on the power supply after doing the confirmation and measures of defective causes (structure and circuit, etc.).

5. After the service or the repair is completed, confirm the operation of the product is normal.

6. Do handling and safekeeping carefully because the user setup information remains in the projector.

PT-AE3000U / PT-AE3000E

6.1. Printed Circuit Board and Main Parts Location

Electrical Parts

Optical Parts

6.2. Removal of Upper Case

1. Lift the rear side of the top panel and disconnect the top panel Open/Close hook, then open the top panel.

PT-AE3000U / PT-AE3000E

6.3. Removal of A-P.C.Board

1. Remove the upper case according to the section 6.2. "Removal of Upper Case".

2. Unscrew the 2 screws and remove the A-P.C.Board block.

2. While pressing hooks of the 2 top panel fastening devices, remove the top panel.

3. Unscrew the 2 screws and remove the connector cover.

4. Unscrew the 11 screws and remove the A-P.C.Board.

3. Loosen the 3 screws until they idle.

4. Slide the lamp lock button to release, and remove the lamp unit block (with lamp unit cover).

5. Unscrew the 8 screws and remove the upper case.

PT-AE3000U / PT-AE3000E

6.4. Removal of K1- and K3P.C.Boards Block

1. Remove the upper case according to the section 6.2.

"Removal of Upper Case".

2. Unscrew the 2 screws and remove the A-P.C.Board block.

6. Unscrew the 1 screw and remove the intake air duct 1.

3. Unscrew the 1 screw and release the grounding terminal.

4. Unscrew the 4 screws and remove Analysis Block and the

block of LCD Block / Shift Mechanism / Projection Lens.

5. Unscrew the 4 screws and remove the intake air duct 2.

7. Unscrew the 3 screws and remove the K1- and K3P.C.Boards block.

6.5. Removal of R-P.C.Board

1. Remove the upper case according to the section 6.2. "Removal of Upper Case".

2. Unscrew the 2 screws and remove the V-P.C.Board.

3. Unscrew the 1 screw and remove the P.C.Board attachment fittings with R-P.C.Board.

Note:

· R-P.C.Board is secured. Be careful not to apply

excessive force.

4. Unscrew the 1 screw and remove the R-P.C.Board.

PT-AE3000U / PT-AE3000E

6.7. Removal of V-P.C.Board

1. Remove the upper case according to the section 6.2. "Removal of Upper Case".

2. Unscrew the 2 screws and remove the V-P.C.Board.

6.6. Removal of S-P.C.Board

1. Remove the upper case according to the section 6.2. "Removal of Upper Case".

2. Unscrew the 1 screw and release the grounding terminal.

3. Unscrew the 1 screw and remove the operation button block.

4. Unscrew the 2 screws and remove the S-P.C.Board.

6.8. Removal of B/Q-Module

1. Remove the upper case according to the section 6.2. "Removal of Upper Case".

2. Unscrew the 2 screws and remove the A-P.C.Board block.

3. Unscrew the 2 screws and remove the V-P.C.Board.

PT-AE3000U / PT-AE3000E

4. Unscrew the 1 screw and remove the P.C.Board attachment fittings with R-P.C.Board.

Note:

· R-P.C.Board is secured. Be careful not to apply

excessive force.

5. Unscrew the 1 screw and release the grounding terminal.

6. Unscrew the 1 screw and release the grounding terminal.

7. Unscrew the 4 screws and remove the block of Analysis Block, LCD Block, Shift Mechanism and Projection Lens.

11. Unscrew the 1 screw and separate the B/Q-Module block and P-Module block.

12. Unscrew the 2 screws.

13. While pressing to shut each hook of the 2 resinous stands, remove the B/Q-Module.

8. Unscrew the 2 screws and remove the exhaust fan.

9. Unscrew the 1 screw and release the lamp unit terminal.

10. Unscrew the 3 screws and remove the power block (B/QModule and P-Module).

6.9. Removal of P-Module

1. Remove the P-Module block according to the steps 1 through 11 in the section 6.8. "Removal of B/Q-Module".

2. Unscrew the 2 screws.

3. While pressing to shut each hook of the 2 resinous stands, remove the P-Module.

PT-AE3000U / PT-AE3000E

6.10. Removal of Lamp Unit

1. Lift the rear side of the top panel and disconnect the top panel Open/Close hook, then open the top panel.

Note:

· When installing the lamp unit in the main unit, place

it in a specified position and press the connector side and the opposite side of the lamp unit (arrow positions shown in the figure below), and confirm the lamp unit is inserted securely. Then, tighten the 3 screws fixing the lamp unit cover.

2. Loosen the 3 screws until they idle.

3. Slide the lamp lock button to release, and remove the lamp unit block (with lamp unit cover).

6.11. Removal of Analysis Block and LCD Block / Shift Mechanism / Projection Lens

1. Remove the upper case according to the section 6.2.

"Removal of Upper Case".

2. Unscrew the 2 screws and remove the A-P.C.Board block.

PT-AE3000U / PT-AE3000E

3. Unscrew the 1 screw and release the grounding terminal.

4. Unscrew the 4 screws and remove Analysis Block and the block of LCD Block / Shift Mechanism / Projection Lens.

"Removal of Upper Case".

2. Unscrew the 2 screws and remove the A-P.C.Board block.

3. Mark positions of the incidence polarizer (G).

Note:

· Mark accurately as possible because the marks will

be used for resetting the incidence polarizer position.

4. Unscrew the 1 screw and remove the incidence polarizer (G).

5. Attach a new incidence polarizer and align it with the mark.

6. Tighten the 1 screw with care not to move the incidence polarizer position.

5. Unscrew the 2 screws and separate Analysis Block and the block of LCD Block / Shift Mechanism / Projection Lens.

Note:

· There is not enough space between the analysis

block and LCD block. Be careful not to damage nor dirty precision components (LCD panel, incidence polarizer, etc.) when removing.

6.12. Replacement of Incidence

Polarizer

The procedure is described as an example of incidence polarizer (G).

1. Remove the upper case according to the section 6.2.

6.13. Replacement of PBS Array (Analysis Block)

1. Remove the upper case according to the section 6.2.

"Removal of Upper Case".

2. Unscrew the 2 screws and remove the A-P.C.Board block.

3. Unscrew the 4 screws and remove the analysis case

(upper).

Note:

· The incidence polarizer is installed in the analysis

case (upper). Be careful not to shift the installation position nor damage it.

4. Remove the PBS array.

5. Install new PBS array.

Note:

· Be careful not to mistake the direction

(inside/outside, upper/lower).

· Be careful not to touch the surface of PBS array.

PT-AE3000U / PT-AE3000E

6.14. Removal of Iris Unit

1. Remove the Analysis Block and the block of LCD Block / Shift Mechanism / Projection Lens according to the steps 1 through 4 in the section 6.11. "Removal of Analysis Block and LCD Block / Shift Mechanism / Projection Lens".

2. Unscrew the 4 screws and remove the analysis case (upper).

Note:

· The incidence polarizer is installed in the analysis

case (upper). Be careful not to shift the installation position nor damage it.

3. Unscrew the 1 screw and remove the integrator hold spring.

4. Unscrew the 2 screws and remove the iris unit .

PT-AE3000U / PT-AE3000E

7 Measurement and Adjustments

When the following components in this projector are replaced, adjustments are required. Adjust each item according to the table below.

7.1. Cautions for Adjustment

· Never turn off the MAIN POWER switch until every fan completely stops.

· To maintain and ensure safety, always use the designated components for replacement parts.

· If removing any clamps, lead wires or connectors, always place them back in their proper locations.

· Be careful not to damage the lead wires or components when using a soldering iron or similar tool.

7.2. Setting Before Adjustment

· Set up the projector to obtain the projection distance below.

· Turn the zoom ring of the projector to obtain the largest size of the picture.

7.3. Lighting Area Adjustment

7.3.1. Tools to be used

Service Kit (Part No. TZSH07027): This kit is composed of 3 extension flexible cables and 5 connector extension cables.

Note:

· Consult your dealer or Authorized Service Center for the service kit.

7.3.2. Preparation

1. Remove the upper case according to the section 6.2. "Removal of Upper Case".

2. Install the lamp unit block (with lamp unit cover) and tighten the 3 screws fixing the lamp unit cover.

3. Unscrew the 2 screws fixing the A-P.C.Board.

PT-AE3000U / PT-AE3000E

4. Connect the service kit (extension cables).

· Each flexible cable of LCD Panels (R/G/B) - Connectors (A1/A2/A3) on A-P.C.Board

· Intake fan connector - Connector (A15) on A-P.C.Board

· Power fan connector - Connector (A16) on A-P.C.Board

· PBS fan connector - Connector (A18) on A-P.C.Board

· Thermosensor (Intake air) connector - Connector (A7) on A-P.C.Board

· H-P.C.Board connector - Connector (A23) on A-P.C.Board

5. Covering with an insulator (cloth or the like) to prevent a short circuit, set the A-P.C.Board block on the main unit.

Note:

· Handle with care not to apply external force to connecting parts which connect the main unit and A-P.C.Board.

7.3.3. Adjustment Procedure

7.3.3.1. Outline

When the lighting area is off from the adjustment and color unevenness appears, adjust the lighting area into correct position.

Symptom Measure Magenta unevenness G Reflector Adjustment Cyan unevenness R Reflector Adjustment Yellow unevenness B Reflector Adjustment

· Shifting the mirror adjusting lever horizontally, adjust color unevenness on the screen upper/lower sides.

· Twisting the mirror adjusting lever, adjust color unevenness on the screen right/left sides.

PT-AE3000U / PT-AE3000E

7.3.3.2. G Reflector Adjustment

1. Turn on the power and display 100 % white pattern on the screen.

2. Loosen the 1 screw fixing the mirror adjusting lever A just until the lever can be shifted.

3. Adjust the mirror adjusting lever A position to minimize color unevenness on the screen by shifting the lever in arrow directions.

4. Tighten the 1 screw.

7.3.3.3. R Reflector Adjustment

1. Turn on the power and display 100 % white pattern on the screen.

2. Loosen the 1 screw fixing the mirror adjusting lever B just until the lever can be shifted.

3. Adjust the mirror adjusting lever B position to minimize color unevenness on the screen by shifting the lever in arrow directions.

4. Tighten the 1 screw.

7.3.3.4. B Reflector Adjustment

1. Turn on the power and display 100 % white pattern on the screen.

2. Loosen the 1 screw fixing the mirror adjusting lever C just until the lever can be shifted.

3. Adjust the mirror adjusting lever C position to minimize color unevenness on the screen by shifting the lever in arrow directions.

4. Tighten the 1 screw.

7.4. Software for Adjustment

7.4.1. Outline

· This projector needs computer-aided adjustments.

· After the software adjustments, this projector must be turned off and on again to memorize the settings.

· Connect the cable between the projector and a PC as shown below.

· Updating the software will change the version number.

7.4.2. Operating Procedure

1. Run software program by the keyboard entry.

Note:

· Use the software program as below.

Adjustment Tool [AE3000]

2. The first menu is Port selection menu.

3. Adjust the projector by selecting the necessary item from the menu in each stage.

PT-AE3000U / PT-AE3000E

7.4.3. Port Selection Menu

Select the port name of PC which connects with the projector, then click [Data] or [Adjustment] button.

7.4.3.1. Explanation of Buttons

Data:

Displays the data setting menu.

Adjustment:

Displays the adjustment menu.

Exit:

Exits this application.

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