ViewSonic PJD5112 Service Manual
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ViewSonic PJD5112 Service Manual

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Service Manual

ViewSonic PJD5112
Model No. VS12618
DLP Projector
(PJD5112_SM Rev. 1a Oct.2009)
®
ViewSonic
381 Brea Canyon Road, Walnut, California 91789 USA - (800) 888-8583

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Summary of Contents for ViewSonic PJD5112

  • Page 1: Service Manual

    Service Manual ViewSonic PJD5112 Model No. VS12618 DLP Projector (PJD5112_SM Rev. 1a Oct.2009) ® ViewSonic 381 Brea Canyon Road, Walnut, California 91789 USA - (800) 888-8583...

  • Page 2: Revision History

    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.

  • Page 3: Table Of Contents

    Appendix A: RS-232 Command and Confi guration ..............51 Appendix B: IR Control Code ..................... 53 Appendix C: How to reset the Lamp Hours ................54 ViewSonic Corporation Confidential - Do Not Copy PJD5112...

  • Page 4: System Introduction

    1 System Introduction 1.1 Technical Specification ViewSonic Corporation Confidential - Do Not Copy PJD5112...

  • Page 5: Location Of Features, Controls, And I/O

    7. Filter cover 2. Elevator button 8. Speaker 3. Lens cap strap 9.Focus ring 4. Projection lens 10.Zoom ring 5. Front IR remote control sensor 11.Control panel 6. Ventilation holes (intake) 12.Lamp cover ViewSonic Corporation Confidential - Do Not Copy PJD5112...
  • Page 6 1. Connection ports 2. AC power socket 3. Kensington lock 4. Rear IR remote control sensor 5. Ventilation holes (exhaust) 6. Security bar Bottom View 1. Ceiling mount (M4*6) 2. Tilt-adjustment feet ViewSonic Corporation Confidential - Do Not Copy PJD5112...
  • Page 7 6. Enter Enter to sub-menu and confirm the menu selection. 7. Source Manually select an input source. 8. Menu/EXIT Display or exit the on-screen display menus. Power Turn the projector on or off. ViewSonic Corporation Confidential - Do Not Copy PJD5112...
  • Page 8 Control a motorized screen or similar accessory device. 9. Audio IN Connect an audio output from video equipment to this jack. 10. Audio OUT Connect to a speaker or other audio input equipment. ViewSonic Corporation Confidential - Do Not Copy PJD5112...
  • Page 9 D. Remote Control ViewSonic Corporation Confidential - Do Not Copy PJD5112...

  • Page 10: Pjd6211 Lamp Specification

    1.3 PJD5112 Lamp Specification Product Scope The product is a lamp system consisting of a short arc burner with in a reflector and electronic lamp driver. Type lamp P-VIP 180/0.8 E20.8 open type Identcode : A 599 899 Type driver...
  • Page 11 Any unusual shock or vibration to the lamp should be avoided during operation. Do not use any broken lamps. Dispose of used lamps according to your local instruction. Do not turn on the lamp while the system is opened. ViewSonic Corporation Confidential - Do Not Copy PJD5112...
  • Page 12 Use the lead below 200 C to prevent a deterioration of cladding clad of the fluorocarbon resin. The lead wire insulation clad shouldn ’t touch the reflector. Exchange the lamp that has already passed the life time immediately. ViewSonic Corporation Confidential - Do Not Copy PJD5112...

  • Page 13: Pjd6211 System Block Diagram

    1.4 PJD5112 System Block Diagram ViewSonic Corporation Confidential - Do Not Copy PJD5112...

  • Page 14: Firmware Upgraded Flow

    2 Firmware Upgraded Flow The following sections list the required software, hardware, and procedures to upgrade your ViewSonic projector firmware. WARNING During the firmware download, do not disconnect the USB cable, shut down your computer nor turn off your projector. This will corrupt the flash memory, and you may have to send in your projector to recover the flash memory.

  • Page 15: Setup Tool/Equipment

    1. After the DLP Composer ™ Lite v9.2 has been installed, choose "Install DLP Device USB Driver" under Start\All Programs\DLP Composer ™ Lite 9.2 on your computer. 2. Follow the instructions given on the screen below. Confidential - Do Not Copy ViewSonic Corporation PJD5112...
  • Page 16 Select [Edit]/ [Preferences] on the top menu bar. For [Communications], select USB as the Projector Interface. Under [USB Device Identification], verify that the USB Vendor ID and product code are Vendor 0x451 and Product 0x2000. Click [OK] to proceed. Confidential - Do Not Copy ViewSonic Corporation PJD5112...
  • Page 17 Temp LED and Lamp LED are lit up. This indicates that the projector is in the firmware download mode. 10. Click [Reset Bus] to reset and verify good USB connection. Click [Start Download]. Confidential - Do Not Copy ViewSonic Corporation PJD5112...
  • Page 18 Disconnect the USB cable and power cord from the projector. Reconnect the power cord and power on the projector. 15. Press Menu on the projector keypad, scroll down and select Factory Default. Then, select Yes and press Enter. Confidential - Do Not Copy ViewSonic Corporation PJD5112...

  • Page 19: Machine Disassembly And Replacement

    3 Machine Disassembly and Replacement 3.1 Tools Item Photo Long Nose Nipper Hex Sleeves 5mm Screw Bit(+):107 Screw Bit(+):101 Screw Bit(+):102 Anti-static wrist strap Anti-static wrist gloves ViewSonic Corporation Confidential - Do Not Copy PJD5112...

  • Page 20: Disassembly Procedure

    When you replace the projector lamp, never touch the new lamp with your bare hands. The invisible residue left by the oil on your hands may shorten the lamp life. Use lint-free gloves or finger cots are recommended. ViewSonic Corporation Confidential - Do Not Copy PJD5112...
  • Page 21 1. Flip the projector on the table. J1635-3670-00 2. Remove the screws J1635-A491-00*6 and J1635-3670-00*1 on the Bottom cover as shown. J1635-A491-00*6 Rotate the Focus Ring by forward sequence to take it off from the unit. ViewSonic Corporation Confidential - Do Not Copy PJD5112...
  • Page 22 1. Loosen the one screw to remove the safety switch. J1635-3494-00*1 2. Remove four screws to lift up the keypad board. J1635-3720-00*4 1. Remove all screws as 82035-2520-00*8 shown. J1635-3670-00*1 2. Remove the IO cover. J1635-C072-00*2 ViewSonic Corporation Confidential - Do Not Copy PJD5112...
  • Page 23 Back IR wire Remove the two Fan Modules. FAN 2 FAN 1 1. Show you what the connector should be. 2. Remove all wires. 3. Remove the Main Board. ViewSonic Corporation Confidential - Do Not Copy PJD5112...
  • Page 24 J1635-B853-0A*2 shown to remove the metal sheet of Ballast. Note: 2 wires have been Note connected to Ballast. Disconnect these 2 wires before remove the metal sheet. To Lamp To Power Board ViewSonic Corporation Confidential - Do Not Copy PJD5112...
  • Page 25 2. Remove the optical engine module. J1635-3620-0A*1 J1635-A491-00*3 Loosen the two screws and J1635-D311-00*2 remove the lamp module from optical engine. Note: Those screws and mesh are included in the Lamp module. ViewSonic Corporation Confidential - Do Not Copy PJD5112...
  • Page 26 1. Loosen the one screw and J1635-3620-0A*1 remove the Lens Housing. Lens Housing 2. Loosen the screws on the J1635-3620-0A*4 Power Board and then remove the Power module from Bottom Cover. J1635-D420-0A*1 ViewSonic Corporation Confidential - Do Not Copy PJD5112...

  • Page 27: Assembly Fan Module

    2. Paste the FAN Sponge*2 (P4R38-1530-00) on the top and bottom of it as picture shown. FAN PAD Assemble FAN1(J2394-0101-00): Paste the FAN Sponge*2 (P4R38-1530-00) on the two edges of it as picture shown. FAN Sponge*2 ViewSonic Corporation Confidential - Do Not Copy PJD5112...

  • Page 28: Disassembly Lamp Module

    8. Turn on the projector. If the lamp does not turn on after the warm-up period, try reinstalling the lamp. 9. Reset the lamp hour. Refer to the “Setting” menu. ViewSonic Corporation Confidential - Do Not Copy PJD5112...

  • Page 29: Troubleshooting And Verifying The Repair

    Move down the color bar to “ Lamp Hours” item, press the direction keypad following the actions below: Right once, left twice, right three times, left four times ; Then you will enter the Engineering Mode.) Note: This FW version is just for reference. ViewSonic Corporation Confidential - Do Not Copy PJD5112...
  • Page 30 The fan motor is cooling the lamp. Temp LED Power LED Off The lamp ignition failed. If temperature is too high, Lamp LED Solid the fans will cool the lamp. Temp LED Solid ViewSonic Corporation Confidential - Do Not Copy PJD5112...
  • Page 31 Whatever main board, ballast, IR board, power board, lamp module or optical engine are all suitable to check by swapping modules. ViewSonic Corporation Confidential - Do Not Copy PJD5112...
  • Page 32 Replace keypad Replace Check Check LED and keypad and FFC Main board Main board Check Check 7 pin Fuse Power output Replace Replace Replace fuse main board power board ViewSonic Corporation Confidential - Do Not Copy PJD5112...
  • Page 33 Main board Lamp life Main board Replace Check PWR 380V Power board output Replace Check Ballast Ballast Replace Check Main board Main board Replace Check CW Rotation while CW module power on ViewSonic Corporation Confidential - Do Not Copy PJD5112...
  • Page 34 No Signal Turn on Turn on Check Check Source Source Source Source Replace Replace Check Check Cable Cable Cable Cable Replace Replace Check Check Main board Output signal Main board Main board ViewSonic Corporation Confidential - Do Not Copy PJD5112...
  • Page 35 Input signal Wheel Index Wheel Index setting Replace Replace Check Check Main board Main board Main board Main board Replace Replace Check Check Optical Engine Optical Engine Optical Engine Optical Engine ViewSonic Corporation Confidential - Do Not Copy PJD5112...
  • Page 36 Replace Keypad Check Check Battery and FFC Battery Level Keypad and FFC Replace Replace Check Check Remote Control Main board Remote Control Main board Replace Check Replace Check Main board Main board ViewSonic Corporation Confidential - Do Not Copy PJD5112...

  • Page 37: Verifying The Repair

    I/O port Video Standard Pattern generator (Ex. Quantum data) or DVD player Test Equipment NTSC Signal format I/O port S-Video Standard Pattern generator or DVD player Test Equipment 480i Signal format I/O port ViewSonic Corporation Confidential - Do Not Copy PJD5112...
  • Page 38 2. Press Source button manually selects an input source Foot adjuster operation Foot adjuster. Test criteria Foot adjusters should stretch downward smoothly by pressing the foot Foot adjuster button adjuster buttons on the two sides ViewSonic Corporation Confidential - Do Not Copy PJD5112...
  • Page 39 Test Equipment 1024*768 60Hz Signal format 60” in diagonal length Projected image size Test criteria Test Pattern ANSI Brightness Apparent color strip, bend and streak corner on the projected image are not allowable. ViewSonic Corporation Confidential - Do Not Copy PJD5112...
  • Page 40 5. Rotate Zoom ring to tele mode (Minimum projected image) 6. Adjust focus ring to make resolution of 4 corners and center are balanced. 7. Check the characters should be recognized easily. ViewSonic Corporation Confidential - Do Not Copy PJD5112...
  • Page 41 5. Rotate Zoom ring to tele mode (Minimum projected image) 6. Adjust focus ring to make resolution of 4 corners and center are balanced. 7. Check the characters should be recognized easily. ViewSonic Corporation Confidential - Do Not Copy PJD5112...
  • Page 42 2. Plug the power cord to socket GND 30A 3sec 100m Test criteria DCW 2506V 1sec 10000uA Single Step OFF (9) Cosmetic standard for repaired projector Follow cosmetic standard for repair center. ViewSonic Corporation Confidential - Do Not Copy PJD5112...

  • Page 43: Connector Information

    5.1 Main Board Connector Description No 1 Front IR No 2 Connect to RS232 Board 5.2 The backside of Main Board No11 No10 No12 No14 No13 ViewSonic Corporation Confidential - Do Not Copy PJD5112...

  • Page 44: Ballast Board

    No 13 Back IR No 14 Keypad control 5.3 Ballast Board Connector Description No 1 Lamp power supply No 2 Ignite signal connected to Main board No 3 High Voltage Power supply ViewSonic Corporation Confidential - Do Not Copy PJD5112...

  • Page 45: Power Board

    5.4 Power Board Connector Description No 1 380V output for ballast No 2 12V output for RS232 board No 3 12V/5V output for Main board ViewSonic Corporation Confidential - Do Not Copy PJD5112...

  • Page 46: Fru (Field Replaceable Unit) List

    When working on the projector, use appropriate anti -static precautions such as anti -static mats, wrist straps and grounded work surfac es. Failure to do this can destroy static -sensitive components and make the product inoperable. ViewSonic Corporation Confidential - Do Not Copy PJD5112...

  • Page 47: Mechanical Drawing

    16.FAN2 10.RS232 Board 15.Speaker 17.FAN 1 11.DMD Board 12.Front IR 14.Ballast metal sheet of Ballast heatsink of DMD Board 18.Power Board metal sheet of IO Port 13.Back IR 20.Rear Foot 19.Bottom Cover ViewSonic Corporation Confidential - Do Not Copy PJD5112...
  • Page 48 EXPLODED PARTS LIST (PJD5112 ) ViewSonic Model Number: VS12618 Rev: 1a Item ViewSonic P/N Ref. P/N Description Q'ty C-00009804 P6L84-4500 Top Cover C-00009638 P4E34-4650-00 Lens Cover C-00009633 P4S84-4530 IO Cover C-00009630 P4R84-4520 Lamp Cover C-00009635 P4R34-4600-00 Filter Cover C-00009634 P4R34-4570-00...

  • Page 49: Packing Drawing

    6.2 Packing drawing ViewSonic Corporation Confidential - Do Not Copy PJD5112...
  • Page 50 ViewSonic Corporation Confidential - Do Not Copy PJD5112...
  • Page 51 PACKING PART LIST ( PJD5112 ) ViewSonic Model Number: VS12618 Rev: 1a Item ViewSonic P/N Ref. P/N Description Q'ty DC-00008697 P1638-5007-00 DC-00008696 P2838-5001-00 WARNING LB DC-00008692 P1638-5010-00 J4238-R815-01 SERIAL LB P4S38-5000-00 UL LB DC-00008693 P1238-R504-00 P-00009637 P4R39-7001-00 8&16 P-00009811 P6L39-6000-00...

  • Page 52: Maintenance

    If the filter cover is torn, replace it. 4. Replace the filter cover. 5. Attach the filter cover. 6. Plug the power back into the projector. ViewSonic Corporation Confidential - Do Not Copy PJD5112...

  • Page 53: Recommended Spare Parts List

    Remark 2: All revised RSPLs with newly added items or any change made should be highlighted and correlated with the ECN/ECR approved by ViewSonic Corporation. This is to eliminate repeated cross checks of each item between this version and prior versions.

  • Page 54: Appendix A: Rs-232 Command And Configuration

    Volume - BE,EF,02,06,00 20,DF 69,00,00,00,00,00 Image BE,EF,03,06,00 F2,DA 67,00,00,00,00,00 Aspect Ratio BE,EF,03,06,00 0D,DA 68,00,00,00,00,00 Factory Reset BE,EF,03,06,00 6B,DA 6E,00,00,00,00,00 Lamp Hour BE,EF,03,06,00 BA,DB 6F,00,00,00,00,00 Lamp Hour Firware Version BE,EF,03,06,00 D5,D9 70,00,00,00,00,00 Version ViewSonic Corporation Confidential - Do Not Copy PJD5112...
  • Page 55 03:Projector System Status BE,EF,03,06,00 04,D8 71,00,00,00,00,00 (Normal Mode) ViewSonic Corporation Confidential - Do Not Copy PJD5112...

  • Page 56: Appendix B: Ir Control Code

    Appendix B: IR Control Code ViewSonic Corporation Confidential - Do Not Copy PJD5112...

  • Page 57: Appendix C: How To Reset The Lamp Hours

    (1) Press “Menu” button to open the Main menu. (2) Move color bar to “setting” item and then press right button to enter sub -menu. (3) Move down the color bar to “Lamp Hours” item. ViewSonic Corporation Confidential - Do Not Copy PJD5112...
  • Page 58 (4) Press the direction keypad following the actions below to enter engineering mode : Right once, left twice, right three t imes, left four times. (5) Move down the color bar to “Lamp Reset” item. ViewSonic Corporation Confidential - Do Not Copy PJD5112...
  • Page 59 (6)Press left button to select “yes” to reset Lamp Hours . (7)Then the Lamp Hours would reset to 0 hours. ViewSonic Corporation Confidential - Do Not Copy PJD5112...
  • Page 60 C. Do you have any other opinions or suggestions regarding this service manual? Reader’s basic dada: Name: Title: Company: Add: Tel: Fax: E- mail: After completing this form, please return it to ViewSonic Quality Assurance in the USA at facsimile 1-909-839-7943. ViewSonic Corporation Confidential - Do Not Copy PJD5112...

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