ViewSonic VS10400 PJ402D, PJ402D Service Manual

Service Manual

ViewSonic



381 Brea Canyon Road, Walnut, California 91789 USA - (800) 888-8583

Portable DLP Projector

ViewSonic PJ402D

(PJ402D_SM Rev. 1a June 2005)

Model No. VS10400

Copyright

¤

2005 by ViewSonic Corporation. All rights reserved. No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any language or computer language, in any form or by any means, electronic, mechanical, magnetic, optical, chemical, manual or otherwise, without the prior written permission of ViewSonic Corporation.

Disclaimer

ViewSonic makes no representations or warranties, either expressed or implied, with respect to the contents hereof and specifically disclaims any warranty of merchantability or fitness for any particular purpose. Further, ViewSonic reserves the right to revise this publication and to make changes from time to time in the contents hereof without obligation of ViewSonic to notify any person of such revision or changes.

Trademarks

ViewSonic is a registered trademark of ViewSonic Corporation. All other trademarks used within this document are the property of their respective owners.

Optiquest is a registered trademark of ViewSonic Corporation.

Revision History

ECR Number

Description of Changes

EditorRevision SM Editing Date

1a

Initial Release

06/14/05

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N. Huang

TABLE OF CONTENTS

1. Precautions and Safety Notices

1

2

3. Firmware Update

4. Machine Disassembly and Replacement

5. Troubleshooting

6. Connector Information

7. FRU (Field Replaceable Unit) List

8. Recommended Spare Parts List

2. System Introduction

10 12

25

35

45

49

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1. Precautions and Safety Notices

1. When replacing the lamp, use care to avoid burns to your fingers. The lamp becomes very hot during operation.

2. Never touch the lamp with your fingers as body oil transferred to the lamp can damage the lamp’s useful life.

3. Never drop the lamp or jar it in any manner. This may cause the lamp to burst.

4. This projector is provided with a high voltage circuit for the lamp. Do not touch any electric part or component after the projector has been turned on and is operating. Doing so could induce a severe shock causing injury or death.

5. Do not touch the exhaust fan, nor block its air flow, during operation, as the fan is hot.

6. The LCD module assembly can be easily damaged during service. If replacing the LCD Lens/Prism assembly, do not hold the FPC of the LCD module assembly.

7. Use only the cables which are included with the projector, or are specified in this manual.

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Technical Specification

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2. System Introduction

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Lamp Specification

1.Product Scope

The product is a lamp system consisting of a short arc burner within a reflector, and an electric la mp driver.

La mp type P-VIP 200/1.0 E 17.5 identcode A390 425 0004 Driver type PT VIP 3AC/380 O3 identcode A392 891 0027

2. Product Specifications : P-VIP 200/1.0 E 17.5 lamp

2.1 Dimensions and weight

Lamp see lamp drawing

Reflector type elliptical Cable and conne ctor on r eque st Lamp weight < 70g

2.2 Marking on the la mp

Position of marking On ceramic cap on the ba ck side of refle ctor Manufacturer OSRAM Type no. P-VIP 200/1.0 E 17.5 Country of origin Germa ny

2.3 Operating a nd me asurement conditions

Ballast type Test conditions stable at 200W with OSRAM PT VIP 3 AC/380 O3 ballast

Rated lamp wattage 200W

Bu rner positi on 0 deg ree to +20 deg ree ( 0 degre e opti cal a xis ho rizon tal)

Burning position

horizontal

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2.4 Temperature

La mp burner Mo f oil , back < 350 degree C La mp burner Mo wire < 350 degree C La mp burner Mo f oil, front < 350 degree C Burner bulb (top) temperature 860 degree C - 960 degree C (measured with pyrometer)

Validation of max. permissible temperatures by reference thermocouple measure ment ba sed on a referece lamp housing .

2.5 Rise time

Rise time to 80% of the stabilized luminous output is < 90% sec .

Extensive cooling of the bulb during lamp run-up pha se has to be avoided .

2.6 Hot restrike

If the unit has been off for more than 60 sec. the la mp must restrike . ( Ignition voltage 5kV +/- 3kV)

2.7 Light output

Ballast type Test conditions on electronic power supply

OSRAM PT VIP 3 AC/380 o3 stable at 200W

Stabilization time 5 min.

Luminous flux (initial values) typ. : 6300 lm @ 5.0 x 3.8 mm rect. aperture

min. : 5800 lm @ 5.0 x 3.8 mm rect. aperture

Color coordinates typ. x : 0.290 +/- 0.020

typ. y : 0.290 +/- 0.020

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2.8 Lamp drawing

1. The la mp be comes high temperature after turning off the proje ctor with the power button. If you touch the la mp, you may scald your finger . When you re pla ce the la mp, wait for at least 45 minutes for the lamp to cool down.

2. Do not touch the la mp glass at any ti me. The lamp may explode due to improper handling, including the touching of the lamp glass.

3. La mp lifetime may dif fer from lamp to lamp and according to the environment of use. There is no guarantee of the same lifetime for e a ch lamp. Some la mps may fail or terminate their lifetime in a shorter period of ti me tha n other si milar lamps.

4. A lamp may explode as a result of vibration, shock or degradation as a re sult of hours of use a s its lifetime draws to an end. Risk of explosion may differ according to the environment or conditions in which the projector a nd lamp are being used.

5. W e ar protective glove s and eyeglasses when fixing or deta ching the lamp.

6. Fa ster on-off-cycle s will damage the lamp a nd reduce lamp life. Wait at least for 5 minutes to turn off the projector after powering on.

7. Do not operate the lamp in proximity to pa per, cloth, or other combustible material nor cover it with such materials. Otherwise it could cause a fire.

2.9 Instructions for use

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8. Do not operate the lamp in an atmosphere containing a n inflammable substance, such a s thinner . Otherwise it could cause a f ire or explosion.

9. Thoroughly ventilate the area or the room when operating the la mp in a n oxygen atmosphere (in the air). If ozone is inhaled, it could cause heada ches, nause a, dizziness, etc.

10. The inorganic mercury is involved in the lamp. If the lamp bursts, the mercury in side the la mp will go out of the projector. Leave the area immediately if the lamp shatters while being operated and ventilate the are a for at least 30 minutes in order to avoid the inhalation of mercury fumes. Otherwise it could be harmful to user’s health.

1 1. Dispose of the used lamp according to local regulations.

12. Ensure that screws are tightened properly. Screws not tightened fully may result in injury or a ccidents.

13. Since the la mp is made of glass, do not drop the unit and do not scratch the glass.

14. Do not reuse the old la mp. This could cause the lamp to explode.

15. Be sure to turn off the projector a nd unplug the AC power cord bef ore repla cing the lamp.

16. Do not use the proje ctor with the la mp cover re moved.

Disposal : For disposal of spent lamps, always consult federal, state, local and provincial hazardous wa ste disposal rule s a nd regulations to en sure proper disposal.

Caution : This lamp emits ultra violet (UV) radiation and operate s at high pressure. This la mp may only be used in enclosed f ixtures that comply with UL1572. Due to the high luminous eff icacy, the UV ra di ation which the lamp emits and the high pre ssure within the lamp, P-VIPâ lamps may only be operated within enclosed, purpose-built housings.

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System Block Diagram

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Optics-Conceptual Drawing

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Upgrading Procedure

This cha pter provides the equi pment needed, setup a nd upgra ding procedure f or Firmware upgrade.

Setup Tool / Equipment

1. Computer

2. USB Cable (see right picture)

3. Power Coard

1. Connect Downloa d Cable to proje ctor

2. Open burning progra mma (DLP Composer Lite)

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3. Firmware Upgrade

3. Press Power and Menu button together a nd conne ct the power cord into the

projector . Tha n release these 2 bottoms .

4. Click the Start Download button a nd then start to burning of program .

5. Completion of Burning than re move Power Cord a nd Burning Cord .

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This section provides disassembly procedures for PD-S600 DLP Projector. Before you begin any of these procedure s, be sure to turn of f the power, computer system, and other attached devices; then disconnect the power cable from the electronically outlet. Moreover, when you disa ssemble the projector , be sure to put the screws in a safe pla ce a nd separate them a ccording to grouping.

T ool Needed

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4. Machine Disassembly and Replacement

General Information

Before You Begin

Before proceeding with the disa ssembly procedure, ma ke sure that you do the f ollowing:

1. Turn of f the power to the system a nd all peripherals.

2. Unplug the AC ada pter a nd all power a nd signal ca bles from the syste m.

3. Wear Anti-static wrist strap.

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1. Loosen two screws of La mp Cover

2. Remove La mp Cover

3. Loosen two screws of La mp Module .

4. Grasp the la mp ha ndle a nd pull out La mp Module

p.s Related notice of replace lamp pls refer to the Lamp Spe cification section .

Disassemble Lamp Module

Note:Un plug all the cord before disa ddembling the Proje ctor .

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1. Turn over the Proje ctor .

2. Remove four 4 screws of bottom cover.

3. Remove the front cover set.

Disassemble FroŠ Top Cover

1. Remove the 4 screws of ba ck cover.

2. Life up top cover directly (Be careful there is a internal wire connect with the main board)

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P1643-0021

Disassemble Front Fan

1. Then life up the fan set dire ctly .

02595-0014-00

01635-361 *7

1. Remove the all screws of top cover.

2. Life up all components include key pad , spea ker , front IR board .

Disassemble Key Pad , Speaker & Front IR Board

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1. Remove the five screws of main board .

2. Un plug all wires on the board (Main Board PIN location of connectors pls refer to Cha pter 5 )

3. Remove the Main Board.

Disassemble Main Board

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Disassemble IO Cover and Video Baord

1. Unscrew two screws of the IO cover .

2. Separate all parts individually .

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Disassemble Ballast Module

1. Un plug all wires on Balla st Module (Ballast Board PIN location of connectors pls refer to Cha pter 5 )

2. Unscrew f our screws on Balla st Module.

3. Remove the Balla st Module.

01635-366 *2

01635-361 *2

P1643-0016

Un screw than life up the IR board

01635-A44-N *4

P1647-9000

P1638-152

P1635-055

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Disassemble Optical Engine

1. Unplug the wire in side.

2.. Un screw four screws on Optical Engine.

3. Then remove the Engine Module.

4. Be careful don’t let the Engine go down due to the heavy machine.

P1638-102

P0335-101 *3

P1643-0020

P1635-600

Unscrew three screws tha n re move the fa n .

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Disassemble Power Outlet Set

1. Remove the screw from the bottom of power wires a nd unplug the connector.

2. Then lift up the power outlet set.

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1. Unplug all the wire s on the board (Power Board PIN location of connectors pls refer to Chapter 5 )

2. Unscrew f ive screws on Power Board.

3. Then remove Power Board.

Disassemble Power Board

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Disassemble Foot Screw Assembly

1. Push buttom let foot screw a ssembly fall of f.

2. Use nipper or tweezers carfully to press the head of foot screw .

3. Then foot screw assembly drop out by itself .

82135-351

82134-465

82134-464-99

P1634-466

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Ballast exploded overview

Exploded overview

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This chapter provides technicians and people who have an electronic background a primary description about maintaining the product. Moreover, you can get the appropriate operation to solve some complicated problems of component repairing and professional problems.

The Troubleshooing se ction focus on below items:

1. Video Signal T rouble shooting

2. Operation Function Troubleshooing

3. Power Source T roubleshooting

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5. Troubleshooting

Video Signal

Computer No Signal

Check Source

Turn on Source

Check

Cable

Replace Cable

Computer

Mode

Input

Change to Computer Mode

Change Main Board

NG

Video

No Signal

Check Source

Turn on Source

Check

Cable

Replace Cable

Video Mode

Input

Change to Video Mode

OK

NG

OK

NG

OK

Change Main Board

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Fail to light up

Check

Lamp

Look up user manual ,a nd follow indicative action

Check

Fan

Replace Lamp

Check

LED indication

Repla ce Fan

OK

NG

Connect C/W cable completely

NG

Check

C/W wire loose or

not

OK

Repla ce Ballast

NG

Check Balla st

OK

Repla ce Main Board

NG

Check

Main Board

Check

Optical Engine

Replace Optical Engine

OK

NG

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Color Missing On Screen

C/W Sensor

Cable

Connector

Check C/W Sensor Cable Connector become loose or not

Check

Cable

Replace Cable

Check Main

Board

Change Main Board

NG

OK

NG

Change Optical Engine

No Volume

Check

Speaker

Connector

Speaker Connector Become loose

Check

Speaker

Replace Speaker

Check

keypad

Replace keypad

OK

NG

Check

Top cover’s cable

Replace cable or connect the cable back

OK

NG

Check

source and mute

function

Input the correct source to Projector

OK

NG

Check

Main

Board

Repla ce Main

OK

NG

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Operation Function:

Remote Control Failure

Check

Battery

Level

Repla ce Battery

Check

Remote

Control

Repla ce Remote Control

Check

IR Board or IR cable

Replace IR Board or IR cable

Main

Board Fail

OK

NG

OK

NG

Button Failure

Check Button

Repla ce Button

Check

Keypad

Replace Keypad

Replace Main Board

OK

NG

Check

Top cover’s cable

OK

NG

Replace cable or connect the cable back

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No Power Source After Turning On

Check

Power Cord

Check

Top Cover (keypad

cable...)

Repla ce keypad cable...

Check Power

Board

Replace M ain Board

OK

NG

OK

NG

Replace Power Board

NG

Check

Main

Board

Power Source:

Fan failure After Turning On

Check

Fan

Connector

Fan Connector Become loose

Check

Inner

Wires

Replace Inner Wires

Check

Fan

Replace Fan

Check

Main

Board

Replace Main Board

OK

NG

OK

NG

OK

Replace Power Baord

Repla ce Power Cord

Check

La mp Cover

Switch

Replace Lamp Cover or Reassembly

NG

Check Power

Board wire

OK

Repla ce Power Board wire

NG

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Test Condition

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Test Display Modes and Patterns

Compatible Modes

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Function Test Display Pattern

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Full Black Pattern (Figure 3) Full White Pattern (Figure 4)

Gray Pattern (Figure 7) Boundary Frame (Figure 8)

Black and White Word Pattern (Figure 5) 256RGB Pattern (Figure 6)

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Main Board

Summarize

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Introduction

This section provides ea ch conne ctor location on boards, signal and function of each board. They will be useful for your detecting the defective boards.

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6. Connector Information

The Locations of Connectors

CN3 , CN4 , Cn5 : FAN

J1 :Balla st Control

CN1 , CN7 : IR

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CN2 : Keypad Control

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CON2 : Video

CON3 : S-Video

J3 , J15 : Video & S-Videop IN

J2 :Thermal

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J7 : Phone jack Stereo-R

CON1 : D_SUB

J8 : Color Wheel

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JP1 : USB

J9 : Power Supply

JP3 : CW Index

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JP4 : FirmWare Debug

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Power Board

Summarize

The Locations of Connectors

CN101 : AC Inout

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CN201 : +380V Output

CN301 :DC Output

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Ballast Board

Summarize

The Locations of Connectors

CN3 : 380V

CN1 : Lamp Signal

CN2 : 380V

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This cha pter give s you FRU ( Field Re placeable Unit ) listing in global conf iguration of S600. Refer to this chapter whenever ordering for parts to repair or for RMA ( Return Merchandise Authorization ). Plea se note that WHEN OR DERING FRU PARTS, you should check the most up-to-date information available on your regional web or cha nnel. For whatever re a son s a part number change is ma de, it will not be noted on the printed Service Guide. For Premier AUTHORIZED SERVICE PROVIDERS, Premier office may have a DIFFERENT part number code from those given in the FRU list of this printed Service Guide. You MUST use the local FRU list provided by your regional Premier off ice to order FRU parts for re pair a nd service of customer machines.

NOTE : To scrap or to return the defective parts, you should follow the local government

ordinance or regulation s on how to dispose it properly, or follow the rules set by your regional Premier office on how to return it.

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7. FRU (Field Replaceable Unit) List

.oN otohP emaNtraP N/P

1draoBniaM1000-7461P

2draoBtsallaB0009-7461P

3draoBrewoP1008-7461P

4dapyeK6000-4861P

5draoBRItnorF1006-7461P

6draoBRIkcaB1005-7461P

7draoBlamrehT0003-7461P

8revocpo 000-4861P

9revocmottoB99-154-4361P

01revoctnorF99-254-4361P

FRU List

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.oN otohP emaNtraP N/P

11revocRItnorF99-164-4361P

21revocOI99-564-4361P

31ylbmessawercstooF2100-3461P

41enignElacitpO2000-3461P

51eludoMpmaL4100-3461P

611xNAF0200-3461P

712XNAF1200-3461P

81rekaepS00-6100-31420

91elbacCFF00-4100-59520

02W/CP4eriW00-7100-59520

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.oN otohP emaNtraP N/P

12F/RIP3eriW00-6100-59520

22B/RIP3eriW00-7200-59520

32TSBP5eriW00-5100-59520

42pmaLP4-P2eriW00-5200-59520

52V083P2eriW00-9100-59520

62

P2+01-P21eriW

DBRWP

00-4100-59520

72tekcoSCAP2eriW00-8200-59520

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Rev: 1a

Serial No. Prefix: PD4

Item ViewSonic P/N Ref. P/N Q'ty

MOQ

1

AC POWER CORD A-00003061

According to POI

2

LAMP MODULE RLC-001

P1684-0001 1 1

3

REMOTE CONTROLLE

R

A-00003062

82143-4000 1 1

4

MAIN BOARD B-00003063

P1684-0000 1 1

5

OSRAM BALLAST B-00003064

P1684-0005 1 1

6

PD-S600 IR PCB/F B-00003065

P1647-6001 1 1

7

PD-S600 IR PCB/

R

B-00003066

P1647-5001 1 1

8

PD-S600 KEYPAD+METAL DOME B-00003067

P1684-0006 1 1

9

PD-S600 PFC, POWE

R

B-00003068

P1684-0007 1 1

10

PD-S600 THERMAL PCB B-00003069

P1647-3000 1 1

11

BACK IR COVE

R

C-00003070

P1634-462 1 1

12

BOTTOM COVER C-00003071

P1684-0004 1 1

13

FRONT COVE

R

C-00003072

P1684-0002 1 1

14

FRONT IR COVE

R

C-00003073

P1634-461 1 1

15

IO COVE

R

C-00003074

P1634-465 1 1

16

LAMP COVER + ISOLATO

R

C-00003075

P1643-0013 1 1

17

LENS COVE

R

C-00003076

P1634-458 1 1

18

TOP COVER (include keystroke , bac

k

IR cover ,side cover) C-00003077

P1684-0003 1 1

19

AUDIO CABLE CB-00003078

Accordin

g

to POI

20

FFC CABLE 0.5P 28P CB-00003079

02595-0014-00 1 1

21

S-VIDEO CABLE CB-00003080

02547-1007 1

22

VGA (D-SUB) to HDTV(RCA) CABLE CB-00003081

Accordin

g

to POI

23

VGA CABLE CB-00003082

Accordin

g

to POI 1

24

WIRE CON-CON 12P-10+2P PWR B

D

CB-00003083

02595-0014-00 1 1

25

WIRE CON-CON 2P 380V CB-00003084

02595-0019-00 1 1

26

WIRE CON-CON 2P AC SOCKE

T

CB-00003085

02595-0028-00 1 1

27

WIRE CON-CON 2P-4P LAM

P

CB-00003086

02595-0025-00 1 100

28

WIRE CON-CON 3P IR/

F

CB-00003087

02595-0016-00 1 1

29

WIRE CON-CON 3P IR/

R

CB-00003088

02595-0027-00 1 1

30

WIRE CON-CON 4P C/

W

CB-00003089

02595-0017-00 1 1

31

WIRE CON-CON 5P BS

T

CB-00003090

02595-0015-00 1 1

32

CD ROM DC-00003091

P1639-A001-00 1 1

33

Instruction manual DC-00003092

P1639-406-VIE 1 1

34

OPTICAL ENGINE (include Fan) E-00003093

P1684-0008 1 1

35

SPEAKER E-00003094

02413-0016-00 1 1

36

CU FOOT SCRE

W

M-SCW-0824-6923

01635-B77 17 1

37

S: M1.7*2 B

L

M-SCW-0824-6913

01635-366 56 1

38

S: M3*10*A2 B

L

HW-00003095

P0335-101 25 1

39

S: M3*18*A2 N

I

HW-00003096

01635-A44-N 15 1

40

S: M3*28.5*E1.2 B

L

HW-00003097

01635-C98-N 16 1

41

S: M3*6*A2 B

L

HW-00003098

01635-C01 12 1

42

S: M3*6*D2 B

L

HW-00003099

82035-251 8 1

43

S: M4*6*A3 N

I

M-SCW-0824-6918

01635-A08 3 1

44

S: T3*5*A3 B

L

HW-00003100

01635-353 18 1

45

S: T3*8*A2 N

I

M-SCW-0824-6917

01635-A01 3 1

46

S: T4*10*A2.5 N

I

M-SCW-0824-6910

01635-361 48 1

47

SHD-PWR-BD-PD-S600 HW-00003105

P1635-052 1 1

48

WSC:8*4.3*1FE/NI S-GT

Y

M-SCW-0824-6916

01635-705 3 1

49

FAN (OE) FAL3F12LLSC Ass

y

M-00003101

P1643-0020 1 1

50

FAN MODULE_PD-S600 M-00003102

P1643-0021 1 1

51

MESH M-00003103

P1638-156 1 1

52

MYLAR-POWER-BD-PD-S60

0

M-00003104

P1638-150 1 1

53

UV/IR FILTE

R

M-00003106

P1636-764 1 1

RECOMMENDED SPARE PARTS LIST (PJ402D-1)

Description

Accessories:

PC Board Assembly:

ViewSonic Model Number: VS10400-1W

Documentation:

Electronics:

Cabinets:

Cables:

Hardware:

Miscellaneous:

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8. Recommended Spare Parts List

Item ViewSonic P/N Ref. P/N Q'ty MOQ

Description

54

CABLE BA

G

P-00003107

04039-184 1 1

55

EPE P-00003108

04039-544 2 1

56

OUTER CARTON P-00003109

P1639-6003-00 1 1

57

PAD P-00003110

P1639-690 1 1

58

PE BAG P-00003111

04039-145 1 1

59

POUCH P-00003112

P1639-306-VIE 1 1

60

FOOT ASSEMBLY PL-00003113

P1643-0012 1 1

61

FUNCTION KEYSTROKE PL-00003114

P1634-460 1 1

62

KEYSTROKE PL-00003115

P1634-459 1 1

Packing Material:

Plastics:

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*Readers Response*

Dear Readers:

Thank you in advance for your feedback on our Service Manual, which allows continuous improvement

of our products. We would appreciate your completion of the Assessment Matrix below, for return to

ViewSonic Corporation.

Assessment

Readers basic data:

After completing this form, please return it to ViewSonic Quality Assurance

metI tnellecxE dooG riaF daB

.1

.2

.3

tinU riaF daB

in the USA at facsimile

1-909-839-7943.

You may also e-mail any suggestions to the Director, Quality Systems & Processes

(marc.maupin@viewsonic.com)

dooGtnellecxE

Precautions and Safety Notices

1.

5.

4.

3.

Service Manual Content

Service Manual Layout

The form and listing

Name: Title: Company:

Add.: Tel: E-mail:

Fax:

C. Do you have any other opinions or suggestions regarding this service manual?

Firmware Update

Machine Disassembly and Replacement

Troubleshooting

6. Connector Information

FRU (Field Replaceable Unit) List

7.

8. Recommended Spare Parts List

2. System Introduction

A. What do you think about the content of this Service Manual?

B. Are you satisfied with this Service Manual?

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