Toshiba P503DL User Manual

SERVICE MANUAL

DATA WALL PROJECTION UNIT

CONTENTS

P503DL

1

SAFETY PRECAUTIONS FOR USER·············································· 3
PRECAUTIONS FOR USE AND MAINTENANCE ···························· 8
GENERAL DESCRIPTIONS ····························································· 9

FEATURES ·················································································· 9
P503DL DIMENSIONS ······························································10

·······································································································
FUNCTION of I/O PANEL····························································11
FUNCTION of POWER PANEL ····················································11
POWER SWITCH AND POWER INDICATOR·····························12
SPECIFICATIONS ·······································································13
ACCEPTABLE SIGNAL TYPE ·····················································14
ACCEPTABLE RGB INPUT SIGNAL TIMING······························15
CONNECTION AT A MULTI-PROJECTION SYSTEM··················16

DISASSEMBLE ·················································································19

1. HOW TO REP LACE THE LAMP··············································19

2. Air Filter····················································································20

3. Cabinet Disassemble ·····························································20

4. Location of Key Components and Function Module ·················21

5. Wiring between Function Unit··················································22

6. Light Engine Block···································································23

ADJUSTMENT··················································································23

1. DLP ENGINE adjustment·························································23

LENS FOCUS adjustment························································23
ENGINE MOUNT adjustment preparation································24

2. ENGINE MOUNT adjustment ·················································25

3. ELECTRONICS ADJUSTMENT OR SETTING························27

3-1. Input Signal selection·························································28
3-2. Adjust Mode········································································28
3-3. Saving adjustments····························································28
3-4. Adjustment parameters·······················································28
3-5. Internal Test Pattern ···························································28
3-6. White Balance adjustment··················································28
3-7. Gain and Off- Set·································································28
3-8. Clock frequency adjustment and phase adjustment···········29
3-9. Image position adjustment ··················································29
3-10. Screen Mode Selection····················································29
3-11. On-Screen-Display, OSD··················································29
3-12. Video Enhancer································································30
3-13. Picture in Picture ······························································30
3-14. Image orientation······························································30
3-15. Status Indication·······························································30
3-16. Factory Reset STD key ····················································30
3-17. Color Mix adjustment························································30

4. Multiple Screen Wall system (example)···································30

5. ID Assignment (example)·························································30

5-1. Clearing I.D. ·······································································30
5-2. Setting I.D.··········································································30

5-3. Selecting I.D.······································································31

6. Magnification············································································31

7. Function in Special mode···········································31
7-1. Auto-Adjust On-Off················································31
7-2. Picture in Picture ···················································31
7-3. OSD color ·····························································31
7-4. Power On delay····················································31
7-5. Firmware Version ··················································31
7-6. Lamp Timer History···············································32
7-7. Current Lamp Timer indication ······························32
7-8. Lamp Timer Reset·················································32

8. Function in Service mode···········································32
8-1. OSD Mute·····························································32
8-2. Screen Mode Lock················································32
8-3. Picture Smoothing Filter········································32

Electric Circuit Explanation·················································32

1. RGB/Control PCB ······················································33

2. DMD Driver PCB························································33

3. Power Supply PCB ····················································33

4. Lamp Ballast PCB······················································33

5. RS232C Control PCB·················································33

6. Video PCB································································· 33

APPENDIX

1. P503DL control board LED status································34
Overall Block Diagram ················································35

2. Control via RS- 232C -Command Protocol List ·············36

3. Trouble shooting hints··················································39

4. PARTS LIST ·································································40

·························································································

·························································································

2

SAFETY PRECAUTION

WARNING: Service should not be attempted by anyone unfamiliar with the necessary precautions on this
projector. The following are the necessary precautions to be observed before servicing this chassis.

1. An isolation Transformer should be connected in the power line between the projector and the AC line
before any service is performed on the projector.

2. When replacing a chassis in the cabinet, always be certain that all the protective devices are put back in
place, such as; non-metallic control knobs, insulating covers, shields, isolation resistor-capacitor network
etc.

3. Before returning the set to the customer, always perform an AC leakage current check on the exposed
metallic parts of the cabinet, such as terminals, screwheads, metal overlays, control shafts etc. to be sure
the set is safe to operate without danger of electrical shock. Plug the AC line cord directly into a AC outlet
(do not use a line isolation transformer during this check). Use an AC voltmeter having 5000-ohm per volt
or more sensitivity in the following manner: Connect a 1500-ohm 10W resistor, paralleled by a 0.15-MFD,
AC type capacitor, between a known good earth ground (water pipe, conduit, etc.) and the
exposed metallic parts, one at a time. Measure the AC
voltage across the combination of 1500-ohm resistor
and 0.15-MFD capacitor. Reverse the AC plug at the
AC outlet and repeat AC voltage measurements for
each exposed metallic part. Voltage measured must
not exceed 5.25V(rms). This corresponds to

3.5mA(AC). Any value exceeding this limit constitutes
a potential shock hazard and must be corrected
immediately.

Good earth ground
such as a water
pipe, conduit, etc.

AC VOLTMETER

0.15MFD
Place this probe on

each exposed
metallic part.

1500 ohm
10 watt

PRODUCT SAFETY NOTICE

Many electrical and mechanical parts in this chassis have special safety-related characteristics. These
characteristics are often passed unnoticed by a visual inspection and the protection afforded by them cannot
necessarily be obtained by using replacement components rated for higher voltage, wattage, etc.
Replacement parts which have these special safety characteristics are identified in this manual and its
supplements; electrical components having such features are identified by the international hazard symbols
on the schematic diagram and the parts list.
Before replacing any of these components, read the parts list in this manual carefully. The use of substitute
replacement parts which do not have the same safety characteristics as specified in the parts list may create
shock, fire or other hazards.

ULTRAVIOLET DANGER IN SERVICE MODE

Eye damage may result from directly viewing the light produced by the lamp used in this product. Always turn
off lamp before opening this cover. Ultraviolet radiation eye protection required during servicing.

3

SAFETY PRECAUTIONS FOR USER

WARNING

On the product and in the operation manual, precautions are presented to use this equipment safely, in
order to protect you and other persons from injury and to protect from property damage.
Indications and symbols for such precautions are as shown below.

WARNING

Wrong operation or incorrect handling by ignoring this notice may result in

Wrong operation or incorrect handling by ignoring this notice may result in
death or serious injury of users and third parties.

serious injury of users, third parties and damage to property.

First things to be observed

When installing or move the equipment:

Installation or transportation of this equipment shall be entrusted to vendors qualified by " Toshiba
Lightning and Technology ".
Installation and transportation by parties other than qualified dealers may result in injury or damage of the
equipment. Also, improper power connection may result in fire disasters.
For installation notes, please refer to the section entitled "Items to be confirmed with a qualified dealer
before installation".

Items to be observed upon use of this equipment

For abnormality or trouble

WARNING

If during operation the unit emits smoke or odor, cut off the power circuit breaker immediately and
disconnect the power plug from the outlet.
After confirming smoke has stopped, contact your dealer for repair.
If you should continue using the equipment, fire or electric shocks may result.

When no image appears on the screen, cut off the power circuit breaker immediately and disconnect the
power plug from the outlet.
If you should continue using the equipment, fire or electric shocks may result. Contact your dealer for
repair.

If water or a foreign matter should get into the equipment, cut off the power circuit breaker immediately
and disconnect the power plug from the outlet.
If you should continue using the equipment, fire or electric shocks may result. Contact your dealer for
repair.

If the equipment should fall down or the cabinet is broken, cut off the power circuit breaker immediately
and disconnect the power plug from the outlet.
If you should continue using the equipm ent, fire or electric shocks may result. Contact your dealer for
repair.

4

Equipment Use

SAFETY PRECAUTIONS FOR USER

WARNING

Do not remove the rear cabinet cover, as there are high-voltage parts in the unit. Touching components
inside may result in electric shocks.
End user should not repair or reconstruct the equipment.
Never attempt to do so, otherwise fire disaster or electric shocks may result. For repair, contact your dealer.
Do not damage, break, modify, bend forcibly, tug, t wist, bundle, place heavy weights on or heat the power

cable.
If the equipment is used with damaged power cable, fire disaster or electric shocks may result.
If the cable is damaged, contact your dealer for repair.
Do not insert or drop metals, liquids or combustible materials into the equipment through the vent holes,
etc. Fire disaster or electric shocks may result.
Do not place items on the equipment. These may fall from the unit, resulting in injury or other damage.
Do not obstruct any of the ventilation holes. Should metals or liquids get into the equipment, fire or electric
shocks may result.
Do not humidify the atmosphere around the unit. Do not place a humidifier near or under the unit.
High humidity may cause fire or electric shocks. Also, the screen may be degraded and broken, resulting in
injury.

CAUTION

When disconnecting the power plug, do not pull the power cable.
Make sure to hold the plug to disconnect. If you pull the cable, the cable may be damaged, causing fire or
electric shocks.

Do not connect/disconnect the power plug with wet hands. It may cause electric shocks.
Do not step on the equipment, or place heavy items on it.

This may cause the unit to fall possibly causing injury or damage, which may also cause fire or electric
shocks.

When leaving the equipment out of use for a long time, make sure to disconnect the power plug from the
outlet for safety.

When the power supply is turned off by the controller and the equipment is placed in “stand-by” mode,
electricity is still consumed and parts of the circuitry are still “live”.

If the equipment is not to be used for extended periods, shut off the power by main power switch and isolate
from the main power supply to avoid any unexpected problems, which may cause fire or other damage.

Do not block the vent ports of the equipment, or obstruct airflow around the equipment.
When the vent ports are blocked, temperature inside will rise and cause fire disaster. For example, avoid
using the equipment under the following conditions.

(1) Cover the equipment with a cloth or curtain.
(2) Place packages around the equipment or stand things against the equipment.
(3) Operating the equipment in an enclosed cabinet, without adequate ventilation.
(4) Operating the equipment in a manner or environment outside the published specifications.

Do not expose the equipment to oily smoke or steam, or use the equipment in dusty atmosphere.
Do not expose the equipment to wind and rain. This may cause damage to the unit, which can result in
electric shocks or other injury.
The screen may drop or fall down due to wind, excessive vibration etc. and cause injury or damage.

5

For servicing, maintenance and inspection

SAFETY PRECAUTIONS FOR USER

WARNING

If dust or dirt is visible on the blades or the blade clamping face of the power plug, clean the plug or blade
clamping face before connection. Otherwise, fire may occur due to lowering of insulation of the power plug.

CAUTION

Make a maintenance contract with the dealer and entrust the dealer with periodical inspection and
adjustment.
If the equipment is left for long time without cleaning, dust inside the equipment may build up and the unit
may malfunction, possibly causing fire, electric shocks or other third party damage.
Servicing of the equipment must only be performed after disconnecting the power plug from the outlet.
Otherwise electric shocks resulting in death or injury may occur.
Pay attention to all connection cables. Injury may occur by being caught by or stumbling on the cables.
In addition, the equipment may fall down, resulting in injury or damage.

Items to be confirmed with the qualified dealer before installation

WARNING

This equipment has been designed exclusively for indoor use. Do not use the equipment
outdoors; fire or electric shocks may result.
Do not install the equipment on or in unstable locations. The equipment may drop or fall down, resulting in
injury.

When mounting the equipment on a wall or other vertical surface, ensure that all fixings are secure and that
the surface the equipment is being fastened to, is perpendicular and capable of supporting the additional
lord.
When mounting the equipment from a ceiling or other overhead horizontal surface, ensure that all fixings
are secure and able to support the load. Also ensure that the horizontal surface can support the additional
load and that any fixings used do not cause a trip or other safety hazard.

Confirm that the installation procedure are undertaken with sufficient allowance and consideration for the
total weight/load of all the units installed in the event of outside influences such as earthquakes, explosions
or other factors.

Always ensure that installation does not cause or create a safety hazard by being placed too low, so that a
passer-by can hit the unit with their head or other body part by accident.
If the installation is unstable, the equipment may drop or fall down, resulting in injury.
Do not install the equipment at places exposed to direct sunshine, or where temperature rises, such as a
place near heater, etc.

If the temperature inside the equipment rises, fire may result.
Do not use the equipment in places with high humidity, such as a bathroom or a place nea r a humidifier.
It may cause fire or electric shocks. Also, the screen may become broken, resulting in injury.

Do not use the equipment with power voltages other than the one indicated on the equipment.
otherwise, fire or electric shocks may result.

Ma ke sure to install a circuit breaker in the power supply line exclusively for the equipment.
otherwise, fire may occur because the power supply cannot be cut off immediately when trouble or
abnormality occurs in the equipment.
The socket-outlet shall be installed near the equipment and shall be easily accessible.

6

SAFETY PRECAUTIONS FOR USER

Make sure to provide ground line from the ground terminal of the power plug.
Otherwise, electric shocks may result.

Always calculate the total loading of any installed equipment and ensure that the power supply, (sockets or
other outlets) are suitable for the installation. Failure to do so may cause fire or electric shocks due to
overload.

Do not place or store anything on the equipment. If metals, liquid or other objects should get inside the
equipment, fire or electric shocks may result. Also, any heavy items placed on the top of the units may fall
down, resulting in injury or damage.

Secure the equipment to the building. The wall to be attached needs to have strong and rigid construction.
A high position projection system may topple during an earthquake. Human life and property may sustain
great damage if a system topples. Prevent toppling and accidents. Following offers some examples of how to
avoid topplin g. Use the most appropriate one for the installation conditions.

CAUTION

Do not block the vent ports of the equipment, or obstruct
airflow around the equipment.

When the vent ports are blocked, temperature inside cube
will rise and cause fire disaster. For example, do not use
the equipment in the following conditions.

(1) Install the equipment in places with poor ventilation.
(2) Place the equipment facing up, sideways, or upside -down.
(3) Place the equipment on a carpet or bedding.
(4) Cover the equipment with a cloth or curtain.
(5) Place packages around the equipment or lean/place items

against the equipment.

(6) Placing the equipment on a table, unstable base or directly

against a wall. Rear access is required for periodic
maintenance or inspection.

(7) Do not place the equipment where it may be exposed to

dust, oily smoke or steam such as a cooking area, etc..

(8) Do not place the equipment where it may be exposed to

wind and rain.
The screen may drop or fall down due to wind and cause
injury. Or rain may result in fire or electric shocks.

7

PRECAUTIONS FOR USE AND MAINTENANCE

Request to User

Plastic Screen

The P503DL screen is made of a plastic material and can be easily scratched. During manufacture and
packing, every care is taken to ensure that no hard objects that could scratch or otherwise cause damage are
allowed to touch the screen when opening the carton box and taking out the product. Please exercise
caution, when unpacking the unit to prevent the packing material or other items from scratching and
rubbing the screen to avoid (i) damage to the screen and (ii) generation of static electricity which may attract
dust particles onto the screen.

Precautions on Use

Connection of a grounded cable

Ground the projection unit in order to prevent electric shock with 3-core power cable. There is greater danger
of electric shock when multi projection units are used without ground wire connected.

Condensation

When room temperature rises rapidly (or the Dat a Display projection unit is moved from a cold place to a
hot place), condensation may form on the lens, causing picture distortion or color fade-out. In such case, wait
for a while (with keeping power ON) until the condensation clears.

About cooling fan and color wheel motor

The axial cooling fan and also color wheel motor in the projection unit should be considered a consumable
item and need to be replaced after about one or two years of use or whenever noise or other symptoms of
breakdown are apparent. Contact your dealer for the replacement work.

** Air filter equipped at air intake needs periodical cleaning. A clogged air filter will result in temperature

build up inside the P503DL cabinet. Possibly in excess of stated operating specification, th is may lead to

malfunction or reduced equipment life.

Maintenance

Do not use solvent or paint thinner
If these are used, coating layer may peel off or deteriorate. If rubber or plastic comes into contact with the
projection unit for a long time, the projection unit may be stained.

Care of the screen

After switching the power supply off, gently wipe the screen with a soft cotton cloth. Since the screen
surface is easily scratched, this may also build up an electronic static charge. Do not rub it with a hard
object; the screen may be easily damaged. Never use a chemical duster.

Care of the cabinet

After switching the power supply off, wipe gently with soft cloth.
When using a chemical duster, follow the maker's precautions.

Care of the air filter

The air intake filter should be regarded as a consumable and changed on periodic bases, depending on the
operating conditions. If or when the filter becomes clogged (by oily smoke etc) replacement of the filter is
recommended.
For a temporally remedy, the filter may be cleaned by an oil removal cleaner, detergent used in a kitchen
or a diluted vinegar solution.

8

GENERAL DESCRIPTIONS

FEATURES

l Digital Light Processing TM (DLP TM) by Texas Instruments
P503DL is a projection unit using the Texas Instruments’ Digital Mirror Device (DMD) TM optical element.

The DLP TM, Digital Light Processing TM engine is constructed with the DMD chip, with XGA resolution.

l Input capability

From PC video output card, SVGA signal is best suitable but some others are also compatible.
Incoming PC signal timing should be followed the VESA standard.
SVGA signal is reproduced on screen without having any scaling function.
The other frequencies are converted to XGA resolution inside the cube. See note 1.
In case of SXGA resolution such as 1280x1024, an original aspect ration of 5:4 is changed to DLP aspect
ratio of 4:3 so that picture may have different shape in this resolution.

l Internal magnification

A multi -screen system can be formed easily with an internal magnification up to x6 magnification.

l Superior image quality

* Native resolution of XGA, 1024 x 768 pixels
* No burn-in unlike projection tube
* High Contrast image by 12 -degree mirror flip Double Data Rate DMD chip

l Easy installation and maintenance

* Convergence free between colors
* Steady geometric alignment
* Engine installed at factory

l Easy replacement 10,000/6000 H (Survival rate of 50%) UHP 100/120W selectable lamp power,

See note 2

l Low power consumption

100W UHP lamp is used for light source, ballast power selection of 100W/120W is possible.

Total power consumption is less than 200W.

l Highly reliable control system

Projection system can be controlled with a PC via RS232C cable. Also most of the

control/adjustment is possible to do with optional wired remote control, CT-90000.

RS232C IN/OUT are equipped to send command and also for communication between cubes.

l Mechanical function

Screen escutcheon can be removed from front. The mullion size is 1.0mm. When adjacent cube

is attached, total mullion size becomes 2.5mm including gap in between.

Note 1: This does not mean that all the signals are accepted. For acceptable signals, refer to the later page in

Note 2: The lamp is expected to last more than 8000H, with the recent information, it will be more than 10000H, with

Acceptable Signal Type and also Acceptable RGB input Signal Timing.

survival rate of 50% at 100W power selection, however, the actual life of each lamp varies depending on
conditions of use. For warranty and exchange of lamp, please check with your dealer/distributor.

9

P503DL DIMENSIONS

Size: mm (inch)
Front Rear

[? ? ]

0.5 (0.02)

1016 (40.0)

0.5 (0.02)

0.5 (0.02)0.5 (0.02)

762 (30.0)

Side

550 (21.7)

[? ? ]

Top

[? ? ]

1050 (41.3)

550 (21.7)

[? ? ]

10

FUNCTION OF I/O PANEL

(7)

(6)

(5)

(10)

(11)

(1) (2) (3) (4)

OUT IN RGB 2 RGB 1DIGITAL SIGNAL LINK RGB INPUT

POWER FAN LAMP REMOTE

OUT

CONTROL RS-232C

VIDEO

(8)

(9)

INOUT

IN

No. Name Function Remarks

1 DVI Digital Output DVI Link (switched) Output Digital pins of DVI connector
2 DVI Digital Input DVI Input (Link or PC) Digital pins of DVI connector
3 RGB-2 Inp ut terminal RGB-HV signal Input D-sub HD 15 -pin (female)

4 RGB-1 Input terminal RGB-HV signal D-sub HD 15 -pin (female)
5 Power Indicator Power status indication Green/Red two colors LED
6 Fan Indicator Fan status indication Green LED
7 Lamp Indicator Fan status indication Green LED
8 RS232C Output RS232C Communication D-sub 9- pin (male)
8 RS232C Input RS232C Communication D-sub 9-pin (female)
9 Remote control Input jack Wired remote control 3.5mm stereo Mini Jack

10 Video Output Composite Video thru- Output BNC connector

11 Video Input Composite Video Input BNC connector

Note: Video signal: not fully compatible
Basic model does not include Video input terminal since the moving picture displayed with this

unit may not have full compatibility and picture will not display all the pictures supplied, it may
appear as missing field, picture lacks smooth movement

11

FUNCTION OF POWER PANEL

No.

1

2

3

Note 1: The AC outlet supplies un- switched power source to a

second unit in a multi-projection system.

Do not use it for any other purpose. Serial connection

using this power outlet must be maximum of four units

including the 1st unit.

Note 2: The plug type of the projection unit power cable may not

AC INLET

AC100~ 240 50/60Hz
AC100~ 240 50/60Hz

match the AC outlet. When power is to be supplied

to another unit from this AC outlet, please purchase

necessary power cable.

AC OUT INLET

UNSWITCHED 8A MAX

Note 3: About Power Supply cord

The Power Supply cord must be in accordance with

the applicable standards.
A three-core cord, one for ground, must be used.

POWER

The power cord must be at least 1.0mm2 and H05VV-F.

Name Function Remarks
Power Switch Turn ON and OFF main power ON/OFF

AC Inlet AC 100-240V, 50/60Hz input 3P plug
AC Outlet AC outlet, un -switched, max 8A 3P socket

POWER SWITCH AND POWER INDICATOR

AC power source is turned-on/off with the Power Switch. When the Power Switch is turned-on, the Power
Lamp LED Indicator lights in green, Fan indicator by green and some periods later, green at Lamp when
lamp is ON and the projection unit enters active state.

It takes about 30 seconds typically till an image is shown after Power Switch is turned -on.
In the active state, it is possible to power on/off with an external controller. When power is turned-off with
an external controller, the Power Indicator LED lights in red color and a projection unit enters standby
state.

Interval from turn-off to turn-on shall be more than 30 seconds. If the interval is not enough, the lamp
may not strike, longer the wait time, lamp life risk becomes less. If the user continues to repeat this
short wait re-strike, it may shorten the life of the lamp.

The power/lamp/fan indicators also indicate failure information of the projection unit by blinking light.

The later page at appendix list shows the lamp status.

( 2)

( 3)

ON

(1 )

OFF

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SPECIFICATIONS

Model name P503DL
Type 50- inch rear projection unit
Acceptable signals Refer to page 13 and page 14.
Image device 1 chip XGA Digital Mirror Device
Light source 100W/120W switch selectable UHP lamp
Resolution 1024 x 768 dots (Include part hidden with screen frame)
Brightness 500cd/m2 (Typ.) by 120W operation
Screen Fresnel sheet (internal), Lenticular sheet (external)
Screen frame 1 mm average (2.5mm between cubes when two are attached)
Viewing Angle Horizontal: Min. 150 degrees, Vertical: Min. 60 degrees
Operating temperature 5 -35 ? (41-95 F)
Operating humidity 30-70 % (Relative humidity non-condensing)
Power requirement AC100-240V, 50/60Hz, 200W (200VA)
Dimens ions 1016 (W) x 1050 (H) x 550 (D) mm (40.0 x 41.3 x 21.7 inch)

Weight about 63kg (139 lbs)
Accessories Owner’s Manual, Assembly screws

Video Input Terminal Video Composite Input: BNC
Level Video Input: 1.0Vp-p composite video, PAL/NTSC
DVI Input DVI signal from PC or Link, No HDCP compatible

RGB Inputs Terminal RGB input: HD D-sub 15pin (female) connector

Level R/G/B signal: 0.7Vp-p (75-ohm termination)
H.SYNC / V.SYNC signals: TTL

External control System: RS-232C, Terminal: D- sub 9pin (female) connector x 1
Speed: 1200, 2400, 4800, 9600 baud
Communication Link System: RS-232C, Terminal: D -sub 9pin connector x 2 for IN and OUT

Remote Control Terminal 3.5mm terminal for optional CT-90000 Remote Controller
The DVI i nput is compatible for PC signal but for 1080i HDCP.
DVI connector and RS232C cables are included as accessories. RS232C cable is common type and if

cubes are assembled more than 10 sets, RS232C communication error may become obvious by means of
its standard, length limitation. In such case, using better and thicker wire may extend the cable length
or possibly use buffered splitter and separate the wiring into two or more branch will result better
communication.

DVI output signal is possible to make link for any selected input but this DVI output comes after its
frequency converted digital output, having several frames of signal delay. Thus quick movement
such as moving video may result signal delay added by each cubes and picture may not match while
moving image displayed.

The specifications and design of this product are subject to change without notice.

(R)

Double Data Rate type

13