Panasonic PT-AE700E, PT-AE700U Service Manual

PT-AE700U PT-AE700E

ORDER NO. VED0409357C0

D10

LCD Projector

PT-AE700U / PT-AE700E

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

5 5 5

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

6 6 6

PT-AE700U / PT-AE700E

3.2. Self Check Display and Contents 7

3.3. Canceling the self-check mode

4 Service Mode

4.1. Procedure to enter the service mode

4.2. Canceling the service mode

5 Flicker Adjustment Mode

5.1. Procedure to enter the adjustment mode

5.2. Adjustment Display and Contents

5.3. Canceling the flicker adjustment mode

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 S-P.C.Board

6.5. Removal of J-P.C.Board (PT-AE700E only)

6.6. Removal of B/Q-Module

6.7. Removal of P-Module

6.8. Removal of K-P.C.Board

6.9. Removal of Lamp Unit

6.10. Removal of Analysis Block and Projection Lens

6.11. Removal of LCD Block

6.12. Removal of Projection Lens

6.13. Replacement of LCD Panel

6.14. LCD Panel Discrimination

6.15. LCD Panel Combination

6.16. Replacement of Projection Polarizer

6.17. Replacement of Incidence Polarizer (R and B)

6.18. Replacement of Incidence Polarizer (G)

6.19. Replacement of PBS Array (Analysis Block)

6.20. Removal of Iris Unit

7 Measurement and Adjustments

7.1. Adjustment Procedure Flowchart

7.2. Cautions for Adjustment

9 9

9 9 9

10 11 11 11 11 12 12 13 13 13 14 14 14 15 15 16 16 17 17 18

7.3. Setting Before Adjustment

7.4. Convergence Adjustment

7.5. Lighting Area Adjustment

7.6. Software for Adjustment

7.7. Flicker Adjustment

7.8. Input Level Adjustment (RGB)

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 (1/6)

11.2. A-P.C.Board (2/6)

11.3. A-P.C.Board (3/6)

11.4. A-P.C.Board (4/6)

11.5. A-P.C.Board (5/6)

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

11.7. K-P.C.Board, S-P.C.Board, H-P.C.Board, J-P.C.Board

11.8. B-Module (1/2)

11.9. B-Module (2/2)

12 Circuit Boards

12.1. A-P.CBoard

12.2. J-P.C.Board/S-P.C.Board

13 Terminal guide of ICs and transistors 14 Exploded Views 15 Replacement Parts List

19 19 19 20 22 24 24

26 37

37 38

39 40 41 42

44 45 46 47 48 49 50 51 52

53 54

55 56 60

PT-AE700U / PT-AE700E

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.

· It is advisable to use an isolation transformer in the AC power line before the service.

· 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.

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.

· Because the high pressure lamp involves a risk of explosion, never touch the lamp wire lead during the service. (See Fig. 3)

Fig. 1

Table 1

Fig. 2

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

Fig. 3

PT-AE700U / PT-AE700E

2 Ext Option

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

· There are SELF CHECK, SERVICE MODE and FLICKER ADJ for service, etc.

2.1. Procedure to enter EXT OPTION

1. Press "MENU" button on the main unit or remote control unit to display "MENU" screen, then select "OPTION" and press "ENTER" button.

2. Select "OSD" on "OPTION" menu and press "ENTER" button 3 seconds or longer. MENU → OPTION → OSD

2.2. EXT OPTION Menu and Functions

· FREEZE MSG Switching ON/OFF "FREEZE" on-screen display

· PIC.SHIFT Switching ON/OFF the antipersistence function

−

− Shifts the picture slightly (by one dot) when every 60 minutes. (one dot shifting three times, one dot shifting three times in

− −

reverse direction, and repeats them alternately.)

· RUNTIME PRT Switching ON/OFF the shutdown when the operation time for the lamp unit is 2 000 hours or longer

· FAN CONTROL 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 "FAN CONTROL" in OPTION becomes impossible (setting FAN FULLMODE is given priority more than FAN CONTROL).

· AUTOSETUP 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

· SERVICE MODE To enter the service mode

· FLICKER ADJ To enter the flicker adjustment mode

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-AE700U / PT-AE700E

3.3. Canceling the self-check mode

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

PT-AE700U / PT-AE700E

4 Service Mode

This mode is used to display seven kinds of test patterns [Horizontal lines, Vertical lines, Dots, Crosshatch, White cross, Black cross and White (No pattern)] in the four colors (White, Red, Green and Blue).

Note:

· On the service mode, displays above patterns by each color without test equipment such as PC or SG. Use the service mode for simplified adjustments by your eyes and so on.

4.1. Procedure to enter the service mode

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

Note:

· In the service mode, pressing the up-arrow " left-arrow "

" or right-arrow " " button the color selection (White / Red / Green / Blue).

" or down-arrow " " button allows the test pattern selection and the

4.2. Canceling the service mode

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

5 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.

5.1. Procedure to enter the adjustment mode

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

Note:

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

5.2. 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 (blue)", "DESK setting (red)", "DESK setting (green)", "CEILING setting (blue)",

− −

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

−

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

− −

" and down-arrow " " buttons.

5.3. 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-AE700U / PT-AE700E

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.

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

6.1. Printed Circuit Board and Main Parts Location

Electrical Parts

Optical Parts

6.2. Removal of Upper Case

1. Remove the cap of the lens shift lever.

2. Unscrew the nut in the shift lever.

Note:

· Turn clockwise the nut to unscrew.

PT-AE700U / PT-AE700E

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

3. Turn counterclockwise the shift lever and remove it.

4. Turn the projector upside down.

5. Unscrew the 7 screws.

4. Unscrew the 7 screws and remove the connector plate.

6.4. Removal of S-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 S-P.C.Board.

6. Return the projector to the normal position.

7. Remove the upper case.

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 3 screws and remove the connector cover.

6.5. Removal of J-P.C.Board (PTAE700E only)

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

PT-AE700U / PT-AE700E

"Removal of Upper Case".

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

3. Unscrew the 3 screws and remove the J-P.C.Board.

8. Disconnect the connector P2 and remove the ballast block.

9. While sliding the ballast grounding metal, unhook the hook section and remove it.

6.6. 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 S-P.C.Board.

3. Unhook the hook section and remove the duct cover.

4. Unscrew the 1 screw and remove the ground fittings.

5. Unscrew the 1 screw and release the ballast block.

6. Unscrew the 2 screws and remove the power box with power shield plate.

7. Unscrew the 2 screws and release the lamp unit terminal.

10. Unhook the hook section of resin spacer and remove the B/Q-Module.

6.7. Removal of P-Module

1. Remove the power box according to the steps 1 through 5 in the section 6.6. "Removal of B/Q-Module".

2. Unscrew the 2 screws and remove the P-Module.

6.8. Removal of K-P.C.Board

1. Remove the A-P.C.Board block according to the steps 1 through 3 in the section 6.3. "Removal of A-P.C.Board".

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

PT-AE700U / PT-AE700E

3. Unscrew the 2 screws fixing the lamp unit and remove the lamp unit.

3. For PT-AE700E, unscrew the 2 screws and remove the JP.C.Board.

6.9. Removal of Lamp Unit

1. Turn the projector upside down.

2. Loosen the 2 screws until they idle and remove the lamp unit cover.

6.10. Removal of Analysis Block and Projection Lens

1. Remove the lamp unit according to the section 6.9.

"Removal of Lamp Unit".

2. Remove the A-P.C.Board block according to the steps 1

through 3 in the section 6.3. "Removal of A-P.C.Board".

3. Unscrew the 2 screws and release the lamp unit terminal.

4. Unscrew the 1 screw and remove the thermofuse

attachment.

5. Unscrew the 3 screws and remove the lamphouse.

PT-AE700U / PT-AE700E

6. Unscrew the 3 screws and remove the block of Analysis Block, LCD Block and Projection Lens Block.

7. Unscrew the 2 screws and remove the LCD block.

8. Unscrew the 4 screws and remove the projection lens block (with shift mechanism).

6.12. Removal of Projection Lens

1. Remove the projection lens block according to the steps 1 through 8 in the section 6.10. "Removal of Analysis Block and Projection Lens".

2. Unscrew the 4 screws and separate the projection lens and the shift mechanism.

9. Unscrew the 3 screws and remove the LCD duct and PBS fan.

6.11. Removal of LCD Block

1. Remove the A-P.C.Board block according to the steps 1 through 3 in the section 6.3. "Removal of A-P.C.Board".

2. Unscrew the 2 screws and remove the LCD block.

6.13. Replacement of LCD Panel

· The procedure is described as an example of LCD panel (B).

1. Remove the LCD block according to the section 6.11. "Removal of LCD Block".

2. Cut the 4 LCD panel installation spindles at the position A and remove the LCD panel.

3. Cut the 4 LCD panel installation spindles at the position B and remove them.

Notes:

· Work carefully not to apply external force around the spindle part by using a cutter, cutting nipper or the like for cutting the spindle.

· Adjust the height after the spindle is cut to 1 mm or less.

PT-AE700U / PT-AE700E

Note:

· Prepare a hexagon head wrench processed short.

9. Remove the LCD block again.

10. Tighten the 3 screws fixing the panel attachment.

11. Adhere the shading sheet as it was.

12. Reassemble the projector as it was.

4. Attach the base plate with 4 screws.

5. Tighten the 2 screws temporarily just until new LCD panel (with the panel attachment and panel adjuster) can be shifted by your fingers.

6.14. LCD Panel Discrimination

ID-tag seal color LCD panel

Red LCD panel (R)

Blue LCD panel (B)

(No seal) LCD panel (G)

· Since the ID-tag seal is pasted to the FPC of LCD Panl, (R), (G) or (B) can be easily identified by the color of the seal.

· Finally, identify the panel color by the part number printed on the FPC.

6. Reassemble the projector in the reverse order of disassembling, but leave the upper case and the screws fixing the A-P.C.Board block as they are removed.

7. Adjust the convergence according to the section 7.4. "Convergence Adjustment".

8. After the adjustment, while paying attention not to vary the adjusting result, tighten the 2 screws (upper) fixing the panel attachment temporarily with a hexagon head wrench.

6.15. LCD Panel Combination

· Part number is printed on the FPC of LCD Panel.

· When replacing LCD Panel, use a component which has

the same part number as the original.

PT-AE700U / PT-AE700E

LCD

panel

R L5BDAXQ00188

G L5BDAXQ00192

B L5BDAXQ00190

Combination 1 Combination 2

(L3D07H-55G01)

(L3D07H-56G01)

(L3D07H-55G01)

L5BDAXQ00191

(L3D07H-56G01)

L5BDAXQ00189

(L3D07H-55G01)

L5BDAXQ00193

(L3D07H-56G01)

6.16. Replacement of Projection Polarizer

1. Remove the LCD block according to the section 6.11.

"Removal of LCD Block".

2. Remove the projection polarizer which requires replacing.

(The projection polarizer is adhered with the adhesive tape.)

Note:

· Be careful not to damage peripheral components (prism, LCD panel, etc.).

· Use tweezers.

3. Install new projection polarizer. a. Put adhesive tape on the projection polarizer. b. Adhere the projection polarizer onthe specified position.

Notes:

· Align the projection polarizer with the guides (lower, side) of LCD block.

· Be careful not to touch the surface of projection polarizer.

· Use tweezers.

c. Press the adhesive part and secure the projection

polarizer.

6.17. Replacement of Incidence Polarizer (R and B)

1. Remove the A-P.C.Board block according to the steps 1

through 3 in the section 6.3. "Removal of A-P.C.Board".

2. Unscrew the 2 screws and release the lamp unit terminal.

3. Unscrew the 1 screw and remove the thermofuse

attachment.

4. Unscrew the 3 screws and remove the lamphouse.

5. Unscrew the 2 screws and remove the LCD block.

6. Unscrew the 2 screws and remove the analysis case

(upper) while expanding the hook of it outside.

Notes:

· Because the hook is damaged easily, be careful not to expand it excessively.

· The incidence polarizer (G) is installed in the analysis case (upper). Handle it with care.

PT-AE700U / PT-AE700E

7. Replace the incidence polarizer.

Note:

· Be careful not to touch the surface of incidence polarizer.

6.18. Replacement of Incidence Polarizer (G)

6.19. Replacement of PBS Array (Analysis Block)

1. Remove the analysis case (upper) according to the steps 1

through 6 in the section 6.17. "Replacement of Incidence Polarizer (R and B)".

Note:

· Because the hook is damaged easily, be careful not to expand it excessively.

2. Remove the PBS array .

3. Install new PBS array.

Notes:

· Be careful not to mistake the direction (inside and outside).

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

1. Remove the A-P.C.Board block according to the steps 1 through 3 in the section 6.3. "Removal of A-P.C.Board".

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

Note:

· Mark accurately as possible because the marks will be used for resetting the incidence polarizer position.

3. Unscrew the 1 screw and remove the incidence polarizer.

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

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

PT-AE700U / PT-AE700E

6.20. Removal of Iris Unit

1. Remove the analysis Block according tothe steps 1 through 7 in the section 6.10. "Removal of Analysis Block and Projection Lens".

2. Unscrew the 2 screws and remove the analysis case (upper) while expanding the hook of it outside.

Notes:

· Because the hook is damaged easily, be careful not to expand it excessively.

· The incidence polarizer (G) is installed in the analysis case (upper). Handle it with care.

3. Unscrew the 2 screwsand remove the iris unit with interlock switch.

4. Unscrew the 1 screw and remove the interlock switch.

7 Measurement and Adjustments

7.1. Adjustment Procedure Flowchart

PT-AE700U / PT-AE700E

7.2. 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.

7.3. 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.

7.4. Convergence Adjustment

extension flexible cables and 3 connector extension cables.

Note:

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

7.4.2. Preparation

1. Loosen 2 screws fixing the panel adjuster and 3 screws fixing the panel attachment, then tighten the 5 screws temporarily just until the LCD panel can be shifted by your fingers.

Note:

· See figures in the section 6.13. "Replacement of LCD Panel" for 2 screws fixing the panel adjuster and 3 screws fixing the panel attachment.

2. Reassemble the projector in the reverse order of disassembling, but leave the upper case and the screws fixing the A-P.C.Board block as they are removed.

3. Connect the service kit (extension cables).

· Each flexible cable of LCD Panels (R/G/B) - Connectors

(A1/A2/A3) on A-P.C.Board

· Ballast block [Connector (Q3) on Q-Module] - Connector

(A4) on A-P.C.Board

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

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

4. 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 AP.C.Board.

Execute this adjustment when replacing the LCD panel.

7.4.1. Tools to be used

Service Kit (Part No. TZSH07017): This kit is composed of 3

PT-AE700U / PT-AE700E

7.4.3. Adjustment Procedure

Prepare 2 pieces of thick black paper (23 mm × 100 mm) that can be shaded.

· Cover and shade LCD panels with the paper except the panel for adjustment.

7.4.3.1. When replacing single LCD panel

(R,GorB)

· The procedure is described as an example when LCD panel (B) is replaced.

1. Display the green crosshatch pattern and adjust the lens focus.

2. Display green and blue crosshatch patterns.

3. Adjust focus by shifting the panel adjuster for LCD panel (B) back and forth, then tighten the 2 screws.

4. Adjust the LCD panel (B) position so that the vertical center of blue crosshatch pattern is overlapped with the vertical center of green crosshatch pattern.

5. Adjust the LCD panel (B) position so that the horizontal center of blue crosshatch pattern is overlapped with the horizontal center of green crosshatch pattern.

6. Correct the tilt of the blue crosshatch pattern by adjusting the LCD panel (B) position.

7. Display green, red and blue crosshatch patterns and confirm the convergence. If it is necessary, fine adjust the convergence so that the red and/or blue crosshatch pattern is overlapped with green one.

8. After the adjustment, reassemble the projector according to the section 6.13. "Replacement of LCD Panel".

7.5. Lighting Area Adjustment

7.5.1. Tools to be used

Service Kit (Part No. TZSH07017): This kit is composed of 3 extension flexible cables and 3 connector extension cables.

Note:

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

7.5.2. Preparation

1. Remove the upper case and the connector cover according to the steps 1 through 2 in the section 6.3. "Removal of AP.C.Board".

2. Unscrew the 2 screws.

3. Connect the service kit (extension cables).

· Each flexible cable of LCD Panels (R/G/B) - Connectors

(A1/A2/A3) on A-P.C.Board

PT-AE700U / PT-AE700E

· Ballast block [Connector (Q3) on Q-Module] - Connector (A4) on A-P.C.Board

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

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

4. 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 AP.C.Board.

7.5.3. Adjustment Procedure

7.5.3.1. 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.

7.5.3.2. G Reflector Adjustment

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

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

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

4. Tighten the 2 screws.

7.5.3.3. R Reflector Adjustment

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

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

3. Adjust the mirror adjusting leverB position to minimize color

+ 49 hidden pages