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Casio XJ-450 Service Manual & Parts List

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XJ-450
MAR. 2004
INDEX
Ver.7 : Feb. 2006
R

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  Summary of Contents for Casio XJ-450

  • Page 1 (without price) XJ-450 MAR. 2004 INDEX Ver.7 : Feb. 2006...
  • Page 2: Table Of Contents

    CONTENTS 1. SPECIFICATIONS ..........................1 2. BLOCK DIAGRAM 2-1. CONSTRUCTION OF WHOLE UNIT .................... 2 2-2. PROTECTION CIRCUIT 1......................3 2-3. PROTECTION CIRCUIT 2......................4 3. BASIC PRINCIPLE 3-1. DATA PROJECTOR ........................5 3-2. DISPLAYED PIXEL ........................6 3-3. BASIC STRUCTURE ........................7 4.
  • Page 3: Specifications

    1. Specifications Projection System DLP (DMD, single panel) Size 0.7inch XGA (1024 × 768) Number of Pixels Projection Lens Auto, optical zoom (×2); auto focus F = 2.0 to 2.8 f = 20 to 40mm Light Source 250W high-pressure mercury lamp RGB mini D-Sub 15-pin ×...
  • Page 4: Block Diagram

    2. Block Diagram 2-1. Construction of Whole Unit — 2 —...
  • Page 5: Protection Circuit 1

    2-2. Protection Circuit 1 — 3 —...
  • Page 6: Protection Circuit 2

    2-3. Protection Circuit 2 — 4 —...
  • Page 7: Basic Principle

    3. Basic Principle 3-1. Data projector DLP single panel metho DLP single panel method color wheel lamp condenser lens lens Total reflection mirror projection lens — 5 —...
  • Page 8: Displayed Pixel

    3-2. Displayed pixel One mirror makes up one pixel. Clear image with high contrast Light source 3 DMD Micro mirror device (side) Projection lens Light absorber 3 pixel image onto the screen Bright, because the open area ratio is high —...
  • Page 9: Basic Structure

    3-3. Basic structure — 7 —...
  • Page 10: Repair Precautions

    All the replaced parts will be collected. Note: Make sure to specify the lot No. details of defects and approximate days (months) of use. • Send the collected units to: Casio Techno Co.,Ltd. Overseas Service Division Market Quality Control Department. — 8 —...
  • Page 11 (2) Precautions and actions during the assembly and repair of the projector Actions Precautions Projector Be careful of high heat. Make sure to open the projector after turning the power off, unplugging the AC power cord from the wall outlet and waiting to allow for the projector to sufficiently cool down.
  • Page 12: Password

    5. Password XJ-450 has a password function that prevents unauthorized persons from operating the projector. (1) Details 1 The password can be input using the remote controller only. If the remote controller is lost, the password cannot be input. 2 The initial factory default password is as follows;...
  • Page 13: Disassembly And Assembly

    6. Disassembly and Assembly Note: Place a soft cloth or a cushion underneath the projector when disassembling and assembling as the surface (especially upper and front sides) can be easily damaged. Since there are many types of screws, record the positions and types when removing the screws. Refer to the following list for the specifications of screws described in ( ) in the procedures below.
  • Page 14 Screws (S2) Remove three screws (S2). 4 First unhook the lower hook toward this side, and then remove the front panel by unhooking the upper hooks. Hooks Note: After removing the front panel, pay utmost attention in handling the lens area. The surface of the transparent acrylic plate in the AF (auto focus) area next to the lens (on the right in the figure) is especially delicate.
  • Page 15 Removing the upper case 1 Remove the pin which prevents the upper case from loosening. 2 Remove three screws (S2) on the back and then remove four screws (S2) on the underside. Screws (S2) Screws (S2) — 13 —...
  • Page 16 3 Remove the upper case from the main unit. 4 Remove the FPC from the two connectors on the lower side of the main PCB. This removes the upper case. Removing the main PCB 1 Remove the side panel in advance in order to be able to remove the PCB easily. Remove one screw (S3) and then the side panel.
  • Page 17 2 Remove 14 screws out of 15 on the surface side of the main PCB. Note: There is no protrusion to grasp in the connector CN430. Remove everything else but the connector CN430 first. CN430 1 CN580 2 CN581 3 CN560 4 CN570 5 CN530 CN430...
  • Page 18 Removing the fan duct Screws (S4) 1 Remove three screws (S4). 2 Remove the aluminum foil. Note: The aluminum foil is adhered. Once peeled off, it cannot be reused. Replace it with new foil when assembling. Also note that the foil should be fixed together with screws (S4).
  • Page 19: Removing The Lamp Cover

    Removing the power unit 1 Remove two screws (S6) in the connector B. Note: Remove the connectors connecting from the power PCB to other places in advance. Cut the cable tie binding cables by a nipper etc. Remove the back connector while pushing its tab. 2 Remove two screws (S7) and then one hexagon nut.
  • Page 20 Removing the OPM unit 1 Remove three screws (S9) and then the OPM unit. Note: There is a place where FPC and connectors are located closely with one another. Pay good attention not to damage them. FPC and connectors Screws (S9) Note: There is a wing for the encoder between the zoom and the focus.
  • Page 21 Removing the fan unit 1 Remove three screws (S10). Note: A rubber spacer, which is a very small part, is attached to the screw. Be careful not to lose it. Screw (S10) Screws (S10) 2 This removes the fan unit. Note: The cushion around the fan frame cannot be reused.
  • Page 22 Removing the lamp shield C (silver plate with a thermister which monitors the temperature in the lamp house attached in the lower case) 1 Remove two screws (S3). Screws (S3) Note: Make sure to fix the lamp shield in the correct direction. The thermister should be fixed in the lamp.
  • Page 23 3 Remove two screws (S3) in the filter unit. Screws (S3) 4 Remove the remaining screw (S2) in the back panel. Screw (S2) 5 The back panel can be removed together with the filter unit. 6 Remove one screw (S12), and then the terminal panel for audio.
  • Page 24 7 Remove one screw (S13) in the ground. Note: Be careful with the wiring of the ground cable when reassembling. Screw (S13) 8 While holding the hooks in the inlet from both sides, unhook them from the back panel. Hooks 9 Remove one screw (S3) and then the noise prevention panel.
  • Page 25 Removing the tilt unit 1 Remove three screws (S2) and then the tilt unit. v Disassembling the OPM unit v IMPORTANT: Try not to touch the distance sensor as much as possible. It is made of acrylic part and can be easily damaged.
  • Page 26 To confirm the ranks OPM units are ranked. Those with stickers with alphabets B, C and D are ranked B, C and D respectively. Those with no sticker attached are ranked E. rank v Precautions when replacing the transparent acrylic plate in the AF area v Effect on the precision by fingerprints, scratches and dusts on the acrylic plate Note: Foreign particles and fingerprints attached on the acrylic plate may cause deviance in the detected angle of keystone correction.
  • Page 27 Acrylic plate 2 Remove two screws (S18) fixing the transparent acrylic plate, which will remove the acrylic plate itself. 3 Fix a new acrylic plate with two screws. 4 Make sure to peel off the surface protection seal (Do not forget to do so.) The acrylic plate is resistant to scratches to some extent since its surface is applied with hard coat.
  • Page 28: Diagnostic Program

    7. Diagnostic Program 1. To boot the diagnostic program 1-1 Insert the AC cord into the projector and wait until only the power LED lights amber. 1-2 Turn the power key of the remote controller or the projector to boot the user flow. 1-3 Press the Input key for more than 3 seconds while pressing both the Esc and Menu keys to boot the diagnostic program.
  • Page 29 1 Index Delay: The Index Delay of CW is adjusted as shown below. (1) The gradation display of RGB appears and the following menu is displayed in the upper part of the display. (2) Use the keys to focus the Min Index Delay. Use the keys to change the Index Delay value.
  • Page 30 3-2 Function Test 2 Select “2 Function Test 2” of the Main Menu. The following menu is displayed. Function Test 2 MENU Select the test item. 1 USB: Connect the projector to the PC and press the Enter key. A buzzer sounds if connected correctly. If not, the following message is displayed.
  • Page 31 3-3 Special Functions Select “4 Special Functions” of the main menu. The following Special Function menu is displayed. Special Function menu * Select the test item. 1 Aging : This test is not performed. 2 Zoom Focus Aging: This test is not performed. 3 Get Lamp Time: The accumulated use hours of the lamp is displayed.
  • Page 32 3-4 Initializing Select “5 Initializing” of the main menu. The following menu is displayed Initializing menu. 1 Initializing ALL: Initializing all is performed. The following confirmation OSD is displayed. Pressing the Enter key performs the initialization of all. After initialization, the display returns to the initializing menu. This “Initializing All”...
  • Page 33: Data Backup

    © We don't assume all responsibility for the problem and the trouble which occurred when this software was used. Use it in the responsibility of each person of the user. © This software can be reprinted and distributed to only the employee of CASIO Computer Co.,Ltd. and those persons concerned. Environment ©...
  • Page 34 2 Plug in the special adapter to the Projector. Note: If the AC power cord of the projector is plugged in without performing the above, a host PC can't find the USB device driver (Refer to the figure on page 34 for the details). 3 Turn on a power supply of the projector after a host PC and the projector are connected with a USB cable.
  • Page 35 After about 10 seconds , Power indicator is lighting orange and other indicators are light off. 3 Transits a projector in the Backup Mode by pushing the following three keypads.† XJ-450 : [ESC] [Menu] [Auto] keypads (more than 3 seconds) Projector's indicators are following status.
  • Page 36 4 Execute "XjBackup.exe" after a projector transits in the Backup Mode. 5 Menu bar and Tool bar Menu bar and Tool bar can operate the following. Main menu Sub menu Tool bar icon Description File Create a new Backup archive file ( *.xbk ). Open Open an existing Backup archive file ( *.xbk ).
  • Page 37 6 Product information group box Note: Select the product model name and type the serial number before getting or writing backup information. Item Description Select the product model name in combo box items. The product model name selected in combo box must be same as the product connected Model Name with USB cable.
  • Page 38 Firmware Information * Version and code sum of Main CPU. * Version and code sum of Sub CPU. * Version and code sum of OPM (Optical Module) . (only XJ-450) This category is system internal error information. System Error Logs We can get and show the internal error logs as same as its showed in diagnostic mode B.
  • Page 39 How to get the backup information Getting method of the backup information is two ways. A Getting an each backup item (example : Getting Sub CPU code sum information) 1 Select a category item which contain a backup item which want to be get. (example : [Firmware Informations]) Firmware information list is showed in right side of view.
  • Page 40 B Getting all backup items collectively 1 Select [Get All Backup Datas] in the menu bar. (As same as button in the tool bar) [Get All Backup Datas] dialog is showed. 2 Check in each check box of backup item which want to be get. All check box is checked if push [Select All] button , and all check box is checked off if push [Deselect All] button.
  • Page 41 5 When click [Cancel] button , backup item data which complete to get is showed in each list. How to write the backup information Writing method of the backup information is two ways. A Writing an each backup item (example : Writing lamp on time information) 1 Select a category item which contain a backup item which want to write.
  • Page 42 3 We write a backup item in a projector when you click button. 4 The following dialog is showed if writing is completed. Note: Internal writing process need about 5 seconds after setting a backup item. Don't plug out AC cable of a projector during about 5 seconds after this dialog is showed. B Writing all backup items collectively 1 Select [Set All Backup Datas] in the menu bar.
  • Page 43 Save and open the backup information file All backup items can be saved archive file. And an existing archive file can be also opened. Operate [New] or [Open] or [Save] or [Save As] in [File] menu bar according to the purpose. File extension of this software is [*.xbk].
  • Page 44: Adjustment

    9. Adjustment CW Index Delay Adjustment 1. Boot the diagnostic program. 2. Adjust the delay value while checking the projected image ( , Align with the minimum and maximum values at which colors change, and then proceed to the next item. 3.
  • Page 45: Troubleshooting

    10. Troubleshooting CONTENTS 1. Cover malfunction ..............................43 Detail Then the lamp cover is open ........................ 43 2. FAN malfunction ..............................43 Detail Malfunction of FAN ..........................44 3. High Temperature malfunction ..........................44 Detail (1) When the thermister is at high temperature ..................44 Detail (2) Lamp is off.
  • Page 46 Buzzer Recovery A few seconds Unplug and plug the AC power cord (reset). Detail Code Malfunction of FAN (FAN is running although it has been ordered to stop.) (FAN stopped although it has been ordered to run.) 4. Internal malfunction Recovery LED status (1) Unplug and plug the AC power cord (reset).
  • Page 47 Code Code Related to AD converter Detail (7) When the color wheel is stopped while the lamp is lit. I2C error (no response) Recovery Unplug and plug the AC power cord (reset). Code 8* Color wheel stopped Detail (4) 9* Color wheel stopped Error in the peripheral device of SUB CPU Recovery Unplug and plug the AC power cord (reset).
  • Page 48 Buzzer Detail A few seconds When the lamp time reaches more than 2000 hours Detail Recovery EEPROM error of CPU Unplug and plug the AC power cord (reset) and clear the accumulated lamp time Code LED status (2) POWER Amber flashing (one-second interval) / during cool 5.
  • Page 49: Exploded View

    11. Exploded View — 47 —...
  • Page 50 — 48 —...
  • Page 51 128 136 117 118 — 49 —...
  • Page 52: Parts List

    12. Parts List Item Part Code Part Name Specification Applicable Q'ty Price Code COMPONENTS 1014 8937 LAMP ASSY RJA512337*001 TK Common 1014 8935 CASE ASSY/FRONT RJA512341*001 TK Common 1014 9012 LENS COVER UNIT RJA512900*001TK Common 1014 8936 TILT FOOT ASSY RJA512347*001 TK Common 1014 7132...
  • Page 53 Item Part Code Part Name Specification Applicable Q'ty Price Code LOWER CASE ASSY 1014 7094 CASE/LOWER RJA512272-001V01 Common 1014 8981 PCB ASSY/MAIN/G791-1 RJA512345*001 TK Except China/Taiwan 1021 3428 PCB ASSY/MAIN/G791-1 RJA512345*002 TK Only China/Taiwan 1014 8984 PCB ASSY/G791-3 RJA512421*001 TK Common 1014 8987 PCB ASSY/G791-7...
  • Page 54 Item Part Code Part Name Specification Applicable Q'ty Price Code LAMP HOUSE ASSY 1014 7158 HOUSING/LAMP RJA512427-001V01 Common 1014 7159 SWITCH SUBASSY/COVER RJA512201*001V01 Common 1014 6070 BUSH/B RJA512309-001V02 Common 1015 3768 FAL3F12LLSG Common 1013 8056 TAPE/C RJA512185-001V01 Common 1015 4610 TAPE/C RJA513256-001V01 Common...
  • Page 55 Item Part Code Part Name Specification Applicable Q'ty Price Code CASE LABEL 1016 0426 LABEL/REAR/A RJA513321-001V01 Common 1016 0435 LABEL/CASE/A RJA513532-001V01 Common 1016 0427 LABEL/CASE/B RJA513322-001V01 Japan USA/Canada/Europe/ 1016 0428 LABEL/CASE/B RJA513322-002V01 UK/Australia Taiwan/Singapore/ 1016 0429 LABEL/CASE/B RJA513322-003V01 Hong Kong/China 1016 0430 LABEL/CASE/B RJA513322-004V01...
  • Page 56: Schematic Diagrams

    13. Schematic Diagrams Main PCB 1/7 (PW-BLOCK) — 54 —...
  • Page 57 Main PCB 2/7 (VGA-INTERFACE) — 55 —...
  • Page 58 Main PCB 3/7 (VIDEO-BLOCK) — 56 —...
  • Page 59 Main PCB 4/7 (MEMORY, CONNECTOR BLOCK) — 57 —...
  • Page 60 Main PCB 5/7 (DMD-INTERFACE) — 58 —...
  • Page 61 Main PCB 6/7 (SUB CPU BLOCK) — 59 —...
  • Page 62 Main PCB 7/7 (IP00C782 BLOCK) — 60 —...
  • Page 63 Jack PCB (PWB-G790-C-3) Infrared PCB (PWB-G790-C-4) Connector PCB (PWB-G790-C-7) — 61 —...
  • Page 64 Key PCB 1/2 (PWB-G790-C-5) — 62 —...
  • Page 65 Key PCB 2/2 (PWB-G790-C-6) — 63 —...
  • Page 66 Ver. 5 : July. 2005 Correction of pages 47 Ver. 6 : Aug. 2005 Correction of pages 47, 48, 50 and 52 Ver. 7 : Feb. 2006 Correction of page 51 CASIO COMPUTER CO.,LTD. Overseas Service Division 6-2, Hon-machi 1-Chome Shibuya-ku, Tokyo 151-8543, Japan...