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Sanyo PDG-DSU30 Service Manual

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SERVICE MANUAL

Multimedia Projector
Model No. PDG-DSU30
Original Version
Chassis No. KW5-DSU3000
PRODUCT CODE
REFERENCE NO. SM0946002
1-682-348-39
PDG-DSU30
Confidential
I

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  • Page 1: Service Manual

    SERVICE MANUAL Multimedia Projector Model No. PDG-DSU30 Original Version Chassis No. KW5-DSU3000 PRODUCT CODE REFERENCE NO. SM0946002 1-682-348-39 PDG-DSU30 Confidential...

  • Page 2: Table Of Contents

    PCBA Code Definition ������������ ����������������������������������������� Disassemble Interlock Switch 2-14 ������������������������ Disassemble Bottom Shielding 2-14 ��������������������� Disassemble Speaker 2-15 ����������������������������������� Disassemble Bottom Cover Module 2-15 ������������� Rod Adjustment 2-16 ������������������������������������������������ Troubleshooting ����������������������������������������������� LED Lighting Message �������������������������������������� Main Procedure ������������������������������������������������ PDG-DSU30 Confidential...

  • Page 3: Safety Instructions

    (15kV - 25kV) at its starts. Since the lamp is very high temperature during units operation replacement of the lamp should be done at least 45 minutes after the power has been turned off, to allow the lamp cool-off. PDG-DSU30 Confidential...

  • Page 4: Introduction

    Lumen output at the lamp life time. Lens Offset ● 115��+/-5�� ● NTSC: M (3.58MHz), 4.43 MHz ● PAL: B, D, G, H, I, M, N Video compatibility ● SECAM: B, D, G, K, K1, L ● HDTV: 480i/p, 576i/p, 720p(50/60Hz), 1080i/p(50/60Hz) Confidential PDG-DSU30...
  • Page 5 • Vsync Freq. 56~85Hz Input Signal ● Separate Sync :(H V) TTL level (bi-polarity) ● Composite Sync: TTL level (bi-polarity) ● Sync-on-green: negative sync. 0.3Vp-p ● Analog Video • Composite video 75ohm • S-video (Y/C) 75ohm • Component video (Y/Pb/Pr) 75ohm Confidential PDG-DSU30...

  • Page 6: Compatible Mode

    V-Sync [Hz] 640x350 640x350 640x400 640x480 640x480 640x480 640x480 720x400 720x400 800x600 800x600 SVGA 800x600 800x600 800x600 1024x768 1024x768 1024x768 1024x768 1280x768 1280x768 WXGA 1280x720 1280x800 1152x864 1152x864 1152x864 1152x864 SXGA 1280x1024 1280x1024 1280x1024 1280 x 960 SXGA+ 1400x1050 Confidential PDG-DSU30...
  • Page 7 74.55 MAC 19” 1024x768 1152x870 75.06 MAC G4 640x480 i Mac DV 1024x768 i Mac DV 1152x870 i Mac DV 1280x960 Note: If the Computer Compatibility supportive signal is different from User's Manual, please refer to User's Manual. Confidential PDG-DSU30...

  • Page 8: Disassembly Process

    5. Tweezers 6. Projector * Before you start: This process is protective level II. Operators should wear electrostatic chains. * Note: - If you need to replace the main board, you have to record the lamp usage hour. PDG-DSU30 Confidential...

  • Page 9: Disassemble Lamp Cover Module

    1. Loosen 2 screws (as red circle) on the Lamp Cover. 2. Disassemble the Lamp Cover Module and tear off the Aluminum foil. 2-3 Disassemble Lamp Module 1. Loosen 2 screws (as red circle) on the Lamp Module. 2. Take off the Lamp Module. PDG-DSU30 Confidential...

  • Page 10: Disassemble Top Cover Module

    2. Unscrew 2 screws (as green circle) from the IO Cover . 3. Remove the Top Cover Module. 2-5 Disassemble Zoom Ring Module 1. Unscrew 3 screws (as red circle) from the Top Cover Module. 2. Remove the Zoom Ring Module. PDG-DSU30 Confidential...

  • Page 11: Disassemble Top Shielding

    Top Shielding 2-7 Disassemble IO Cover 1. Unscrew 4 hex screws (as red circle). 2. Unfasten 2 tenons (as yellow square). 3. Disassembled the IO cover. Note: - Take care the tenons when you disassemble the unit. IO Cover PDG-DSU30 Confidential...

  • Page 12: Disassemble Main Board Module

    (3 pin) Compose of Red/Black/White Photo Sensor Wire, red connector and Black wire tube (3 pin) Compose of Red/Black/White Wire, green connector and Black wire tube (3 pin) Compose of Red/Black Wire and Speaker Black wire tube (2 pin) PDG-DSU30 Confidential...

  • Page 13: Disassemble Main Board Shielding

    7. Unplug 1 connector (as yellow square). 8. Remove the Main Board. 2-9 Disassemble Main Board Shielding 1. Unscrew 2 screws (as red circle). 2. Disassemble the Main Board Shielding. PDG-DSU30 Confidential...

  • Page 14: Disassemble Front Cover Module And Ir Sensor Board

    IR Sensor Board and IR Cover. Note: - Take care the tenons when you disassemble the unit. IR Sensor Board IR Cover 2-11 Disassemble Engine Module 1. Unscrew 4 screws (as yellow circle) to disassemble the Engine Module. PDG-DSU30 Confidential...

  • Page 15: Disassemble Color Wheel Module

    - Found that the DMD Chip has scrapes or dirt use of a magnifying glass, you may use an electrostatic ion gun to clean it. - Pay attention to the fixed position when assembling the DMD Chip. PDG-DSU30 Confidential...

  • Page 16: Disassemble Focus Ring

    1. Unscrew 3 screws (as red circle) to disassemble the Focus Ring. Focus Ring 2-15 Disassemble Fan Module and Thermal Switch . Unscrew 3 screws (as red circle). 2. Unscrew 1 screw (as orange circle). 3. Disassembled the Fan Module. PDG-DSU30 Confidential...
  • Page 17 4. Unscrew 4 screws (as blue circle) to disassemble the Fan Shielding and Fan. 5. Unscrew 1 screw (as green circle) to disassemble the Thermal Switch. Thermal Switch Note: - Take the Fan Module as the right gesture. the right gesture the wrong gesture PDG-DSU30 Confidential 2-0...

  • Page 18: Disassemble Blower Module

    1. Unscrew 6 screws (as red circle). 2. Unplug 3 connectors (as yellow square). 3. Cut off the cable tie (as green square). 4. Disassemble the LVPS Module, AC Inlet Bracket and LVPS to MB cable. AC Inlet Bracket LVPS to MB cable PDG-DSU30 Confidential 2-...

  • Page 19: Disassemble Lamp Driver Module

    Lamp Driver to LVPS cable square) 2. Use clamp to fix the Lamp Driver to LVPS (as orange square) cable 2-18 Disassemble Lamp Driver 1. Unscrew 1 screw (as red circle) to disassemble the Lamp Driver Module. PDG-DSU30 Confidential 2-2...

  • Page 20: Disassemble Interlock Switch

    Lamp Driver Lamp Driver Holder 2-19 Disassemble Interlock Switch 1. Unscrew 1 screw (as red circle) to disassemble the Interlock Switch. Note: Make sure the Interlock Switch cable be wedged fillister as the picture shown. Interlock Switch PDG-DSU30 Confidential 2-3...

  • Page 21: Disassemble Bottom Shielding

    2-20 Disassemble Bottom Shielding 1. Unscrew 3 screws (as red cricle) to disassemble the Bottom Shielding. 2-21 Disassemble Speaker 1. Unscrew 2 screws (as yellow circle) to disassemble the Speaker. PDG-DSU30 Confidential 2-...

  • Page 22: Disassemble Bottom Cover Module

    2-22 Disassemble Bottom Cover Module 1. Unscrew 3 nuts (as red circle) to remove the rubber adjust foot. PDG-DSU30 Confidential 2-15...

  • Page 23: Rod Adjustment

    - It should not have any abnormal color at the rim of the image by estimating through the eyes. Z type driver Note: - To avoid over adjusting the rod. - After the opreation, please use the glue to fix the screws. PDG-DSU30 Confidential 2-...

  • Page 24: Troubleshooting

    Power off (Cooling-II: It can accept Flashing (0.5 sec) power key to turn on the projector) Error (Lamp failed) Flashing (1 sec) Error (Fan lock) Flashing (0.5 sec) Error (Over temp.) Steady light PDG-DSU30 Confidential...

  • Page 25: Main Procedure

    - Ensure all connectors are securely connected and aren’t broken - Check Lamp Cover - Check Interrupt Switch - Check Lamp Driver No Light On - Check LVPS - Check Main Board - Check Color Wheel - Check Photo Sensor Board PDG-DSU30 Confidential...
  • Page 26 - Do “OSD reset” of the OSD Menu OSD reset” of the OSD Menu ” of the OSD Menu - Adjust Color Wheel Index Color Abnormal - Check Main Board - Check DMD Board - Check Color Wheel PDG-DSU30 Confidential...
  • Page 27 - Check DMD Board - Ensure that the signal cables and source are work as well - Ensure that your Projector is not in “Mute” mode Audio Abnormal - Check the interior Speaker of the projector - Check Main Board PDG-DSU30 Confidential...

  • Page 28: Electronic Function Block Diagram

    3-3 Electronic Function Block Diagram PDG-DSU30 Confidential...

  • Page 29: Pin Assignment

    3-4 Pin Assignment PDG-DSU30 Confidential...

  • Page 30: Function Test & Alignment Procedure

    2. Press “Power”, “Left”, “Left” and “Menu” buttons sequentially on remote controller to get into service mode. 4-3 OSD Reset After final QC step, we have to erase all saved change again and restore the default setting: (1) Please get into OSD menu. (2) Execute “OSD reset” function under “Options”. PDG-DSU30 Confidential...

  • Page 31: Test Condition

    Press right key to adjust the time (50) Lamp Off Press right key to adjust the time (10) Set burn in cycle Press right key to adjust the cycle After setting up the time, choose “Get into Burn-In Mode” and press enter PDG-DSU30 Confidential...

  • Page 32: Defect Specification Table

    Gray 10 pattern A+B≤1 Dark pixel White pattern A+B≤6 Unstable pixel White&Black pattern A+B≤1 Adjacent pixels White&Black pattern A+B=0 Dark blemish Blue 60 pattern A+B≤10 Bright blemish Gray 15 pattern A+B≤10 Bright dots on frame Gray 10 pattern PDG-DSU30 Confidential...

  • Page 33: Test Inspection Procedure

    - If not, re-adjust by the following steps: (1) Select “Frequency” function to adjust the total pixel number of pixel clock in one line period. (2) Select “Tracking” function and use right or left arrow key to adjust the value to minimize video flicker. Master PDG-DSU30 Confidential...
  • Page 34 - Test Pattern: full white Inspection item - Dead pixels check. - White pattern (IRE=100) Criteria - The dark pixel can accept no more than 6 dark pixels. Full white - Adjacent pixels are unacceptable. - Ref. Defect specification table PDG-DSU30 Confidential...
  • Page 35 Full screen pattern. (Blur word on one of the corner after adjustment is acceptable. However, the word should at least be recognizable.) 7. Color Performance Procedure - Test equipment: video generator. PDG-DSU30 Confidential...

  • Page 36: Video Performance

    1. CVBS Procedure - Test equipment: DVD player - Test signal: CVBS Inspection item - Video performance test Inspection Distance - 1.8M ~2.8M Criteria - Check any abnormal color, line distortion or any noise on the screen. Motion video PDG-DSU30 Confidential...
  • Page 37 - Test equipment: DVD player - Test signal: S-Video Inspection item - Video performance test Inspection Distance - 1.8M ~2.8M 1.8M ~2.8M Criteria - Check any abnormal color, line distortion or any noise on the screen. - Check the sound from speaker. PDG-DSU30 Confidential...

  • Page 38: Calibration

    (1) Test signal: 480i (2) Test Pattern: SMPTE BAR - Note SMPTE BAR (1) Calibration pattern should be in full screen mode. (2) Please refer to 4-2 Guide to get into Service Mode select ‘‘ADC/DEC color’’, and choose “Video Calibration”. PDG-DSU30 Confidential...

  • Page 39: Optical Performance Measure

    - Full white pattern - Use CL100 to measure brightness values of P1~P9. - Follow the brightness formula to calculate brightness values. ☼ Brightness Formula Avg. (P1~P9)*1.1m Avg. (P1~P9)*1.1m Full white pattern Criteria • 1100 ANSI lumen PDG-DSU30 Confidential 4-0...

  • Page 40: Others

    Full white pattern X100% P5 Criteria • 65% 4-11 Others 1. Functional Inspection Power Key - Power key must operate smoothly. Remote Controller - Check whether the remote controller can work normal, “Menu”, “Left” and “Right” buttons work smoothly. PDG-DSU30 Confidential 4-...
  • Page 41 All plastic parts can not be broken and damaged. All safety and warning labels should be visible, Safety or warning label including all contents. All interface connectors should be complete and Connector workable. Adjust foot Adjust foot should be adjusted smoothly. PDG-DSU30 Confidential 4-12...

  • Page 42: Firmware Upgrade

    - Library file (library file has to put in PC and set right path in 5-1-3 step 4) Hardware: - Projector - Power Cord: CH4200105G011 (US Type) CH4200120G011 (EU Type) CH4200110G011 (UK Type) - RS232 Cable: CH4200272G002 - PC or Laptop PDG-DSU30 Confidential...

  • Page 43: Dlp Composer Lite Setup Procedure

    1. Choose "DLP Composer Lite V9.2 Setup" Program. 2. Click "Next". 3. Read "License Agreement". - Choose "I accept and agree to be bound by all the terms and conditions of this License Agreement". - Click "Next". 4. Click "Next". PDG-DSU30 Confidential...
  • Page 44 5. Click "Next". 6. Click "Next". 7. The program is executing "installing" status. 8. Click "Finish". PDG-DSU30 Confidential...

  • Page 45: Firmware Upgrade Procedure

    - The Power LED will light red and blue. - Loosen "POWER" button. - Connect projector with RS232 cable to PC. Note: - The system fan and the lamp will not operate. 2. Execute the "DLP Composer Lite 9.2" file. 3. Click "Edit" and "Perferences". PDG-DSU30 Confidential...
  • Page 46 (3) In “Stop Bits” item, select “1”. (4) In “Parity” item, select “None”. (5) In “RTS” item, select “Enable”. (6) In “CTS” item, select “Disable”. (7) Key in “4000” into “Read” and “Write” items of “Timeouts (in milliseconds)”. - Click “OK”. 7. Click “OK”. PDG-DSU30 Confidential...
  • Page 47 - Click "Open". 7. Select "Skip Boot Loader Area". (select "32KB"). - Click "Reset Bus" to erase the flash memory. 8. If the FW is ready, click "Start Download" to execute the firmware upgrade. - Click "Yes". 9. Proceeding Picture. PDG-DSU30 Confidential...
  • Page 48 11. Check FW version. - Re-plug in power cord, then restart the unit and get into the Service mode to check the firmware version. (To get into service mode, please press "Power", "Left", "Left" and "Menu" buttons sequentially on remote controller.) PDG-DSU30 Confidential...

  • Page 49: Section 2: 8051 Firmware Upgrade Procedure

    - Setup _NLINK_en - Manley USB Driver_NLINK - PDG-DSU 30_8051_xxx.hex Hardware: - Projector - Power Cord: CH4200105G011 (US Type) CH4200120G011 (EU Type) CH4200110G011 (UK Type) - Mini USB Cable - NLINK Cable - NLINK Fixture (15V) - PC or Laptop PDG-DSU30 Confidential...

  • Page 50: Nlink Setup Procedure

    5-2-2 NLINK Setup Procedure 1. Choose "setup_NLINK_en.exe" program. 2. Click "Next". 3. Click "Next". 4. Click "Next". PDG-DSU30 Confidential...
  • Page 51 - Select the additional task that you may create a desktop icon. 6. Click "Install" to begin installing NLINK Procedure. 7. Click "Finish". - Complete the NLINK setup. 8. "MCU Choose" picture will appear on the screen. - Close the picture. PDG-DSU30 Confidential 5-0...

  • Page 52: Manley Usb Driver Upgrade Procedure

    (4) Select "Include this location in the search", then click "Browse". (5) "Browse For Folder" picture will appear on the screen. (6) Select "TPRP1" folder in the "Manley USB Driver_N-Link" folder, then click "OK". (7) Click "Next". PDG-DSU30 Confidential 5-...
  • Page 53 (8) Click "Continue Anyway". (9) Click "Finish". - "Manley TPRP1-Protocol Emulator" will appear on the picture. - Complete the USB Driver Upgrade Procedure. Note: - If "Found New Hardware Wiszard" picture appear again, repeat step 2 to install USB Drivier. PDG-DSU30 Confidential 5-12...

  • Page 54: 8051 Firmware Upgrade Procedure

    - Ensure NLlNK Fixture and PC are securely connected: the indicator lights on green, and the state is "Connect" (as blue square). - Select "Internel RC(11.0592MHz)" (as green square). - Click "Erase/Write(W)" to execute 8051 FW upgrade. PDG-DSU30 Confidential 5-3...

  • Page 55: Section 3: Waveform Download

    Section 3: Waveform Download 5-3 Waveform Download - Plug in the power cord. - Press “Power” button and hold on “Power” button until Power LED flashes red and blue. - When the Power LED went off, waveform download is completed. PDG-DSU30 Confidential 5-14...

  • Page 56: Exploded Image

    Appendix A (Exploded Image) Note: This chapter is only designed to show the exploded image of the projector. For updated part numbers, please refer to RSPL report. D.C. PDG-DSU30 Confidential...
  • Page 57 AF.GN, SHRINK TUBE CHSP8CS01GC01 LAMP MODULE FOR PROJECTOR PDG-DSU30 ASSY OSRAM LAMP DRIVER O6 MIC 180W(Gen5_ CH758BA01G002 Panyu+E20.8) ASSY ENGNE MODULE WTH CW AND DMD PDG-DSU30 CH708CS14GR01 (SERVICE) CH708CS15GR01 ASSY ENGINE MODULE PDG-DSU30(SERVICE) SUNON 45*20mm GB1245PKV1-8AY, F TYPE BLOWER, SHRINK...
  • Page 58 ASSY BOTTOM COVER MODULE Item Description CH528EH05G001 RUBBER ADJUST FOOT CH498CQ01G001 SPEAKER 2W 16OHM DAB128 90mm CH758AA04G001 BUY ASSY NTERLOCK SWTCH CH758CS01GP01 ASSY 180W LVPS FOR PDG-DSU30 PDG-DSU30 Confidential...
  • Page 59 ASSY ENGINE MODULE PDG-DSU30 Confidential...
  • Page 60 Item Description CH808CP02G001 PCBA DMD BOARD CH708CS17GR01 DMD MODULE SVGA FOR SANYO PDG-DSU30(SERVICE) CH808EG04G001 PCBA PHOTO SENSOR BOARD CH708CS16GR01 ASSY COLOR WHEEL MODULE PDG-DSU30(SERVICE) PDG-DSU30 Confidential...
  • Page 61 ASSY FRONT COVER MODULE Item Description CH518CS03G012 FRONT COVER FOR IR PC MN3600H BLACK CH808CP05G001 PCBA R SENSOR BD PDG-DSU30 Confidential...
  • Page 62 ASSY FAN MODULE Item Description SUNON 70*70*20mm AXIAL FAN, KDE1207PKV1.MS.B3001. CH498CP02G002 AF.GN, SHRINK TUBE THERMAL SWITCH WITH BRACKET (KLIXON YS11) 100C WIRE CH438CS17G001 LENGTH=130MM PDG-DSU30 Confidential...
  • Page 63 ASSY PACKING DRAWING PDG-DSU30 Confidential V...
  • Page 64 Item Description CH458CS01G001 Name Card Type Remote Controller for SANYO PDG-DSU30 CABLE POWER CORD 1.8M SP-305A/IS-14 US DIS-WARNING CH4200105G011 LABEL CABLE POWER CORD 1.8M SP-023/IS-14 EUROPE DIS-WARN- CH4200120G011 NG LABEL CABLE POWER CORD 1.8M SP-60/IS-14 UK DIS-WARNING CH4200110G011 LABEL CH568EH02G001...

  • Page 65: Serial Number System Definition

    9 = Month (ex:9 = September) 01001 = Production number (5 digits), It starts from “01001” ~“99999” EX: 59601001 This label "59901001" represents the serial number for PDG-DSU30. It is produced on September of 2009. Its serial code is 01001. PDG-DSU30 Confidential...

  • Page 66: Pcba Code Definition

    II. PCBA Code Definition PCBA Code for Projector XXXXXXXXXXX EEEE Vendor Code Revision Date Code PDG-DSU30 Confidential...
  • Page 67 PRODUCT CODE SANYO Electric Co., Ltd. 1-682-348-39 Printed In Japan...

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