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Sanyo PDG-DSU21N Service Manual

Multimedia projector
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SERVICE MANUAL

Product code
1 122 418 20
(KA7AA)
1 122 419 20
(LA7AA)
1 122 419 22
(LA7CA)
Multimedia Projector
Match the Chassis No. on the unit's back cover with the
Chassis No. in the Service Manual.
If the Original Version Service Manual Chassis No. does
not match the unit's, additional Service Literature is re-
quired. You must refer to "Notices" to the Original Service
Manual prior to servicing the unit.
FILE NO.
Model No. PdG-dSu21N
U.S.A, Canada,
PdG-dSu21e
Europe, Asia
PdG-dSu21B
U.K.
original Version
chassis No. KA7-dSu21N00
LA7-dSu21e00
LA7-dSu21B00
REFERENCE NO.
SM
5110976-00

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Summary of Contents for Sanyo PDG-DSU21N

  • Page 1: Service Manual

    FILE NO. SERVICE MANUAL Multimedia Projector Model No. PdG-dSu21N U.S.A, Canada, PdG-dSu21e Europe, Asia PdG-dSu21B U.K. original Version chassis No. KA7-dSu21N00 LA7-dSu21e00 LA7-dSu21B00 Match the Chassis No. on the unit's back cover with the Chassis No. in the Service Manual.

  • Page 2: Safety Instructions

    Safety Instructions Safety Precautions WARNING: The chassis of this projector is isolated (COLD) from AC line by using the converter transformer. Primary side of the converter and lamp power supply unit circuit is connected to the AC line and it is hot, which hot circuit is identified with the line ( ) in the schematic diagram.
  • Page 3 Conventions The following conventions are used in this manual Screen Messages Denote actual messages that appear on screen. Give bits and pieces of additional information related to the Note current topic. Alert you any damage that might result form doing or not doing Warning specific actions.

  • Page 4: Table Of Contents

    Table of Contents System Introduction......................1 Technical Specification ..................1 Lamp Specification....................2 DSU21 System Block Diagram ................4 Firmware Upgraded Flow ..................... 5 Setup Tool/Equipment .................... 5 Upgrading Procedure ..................... 6 Machine Disassembly and Replacement ................10 Tools........................10 Disassembly Procedure ..................11 Disassembly the Optical engine(Lens&Color Wheel)...........

  • Page 5: System Introduction

    1. System Introduction 1.1. Technical Specification PDG-DSU21 Display Type DLP Single Panel Projector Resolution(Pixels) 800 x 600 Lens Manual Zoom (1.1x) Input Source D-Sub 15 pin, S-video, composite video, USB, AUDIO IN (stereo phone jack), RS-232C Lamp 180W Projection Type Front, Rear, Ceiling Video Compatibility NTSC3.58, NTSC4.43...

  • Page 6: Lamp Specification

    Lamp Specification Product Type: Short arc mercury lamp with reflector. Initial Characteristics Note: More information about lamp replacement procedure, resetting lamp timer and lamp part number, please check the page 23. PDG-DSU21...
  • Page 7 Attention for handling ♦ Do not touch the lamp until it has cooled completely, because the lamp is very hot during operation and immediately after turned off. ♦ The lamp has to be fixed firmly to the base or socket. ♦...

  • Page 8: Dsu21 System Block Diagram

    1.2. DSU21 System Block Diagram PDG-DSU21...

  • Page 9: Firmware Upgraded Flow

    2. Firmware Upgraded Flow This chapter provides the information regarding relevant equipments and upgrading procedure for firmware upgrade. Note: Please check the firmware and composer version before any firmware upgrade procedures. During firmware download period, please do not shut down PC or projector, this will cause flash memory’s damage.

  • Page 10: Upgrading Procedure

    2.1. Upgrading Procedure Installing [DLP Composer (TM) Lite] 1. Double-click [DLP Composer Lite Vx.x Setup.exe]. 2. Installation starts. Click [Next] to continue the installation process. 3. On the [License Agreement] screen, move the scroll bar on the right to the bottom, select [I accept and agree to be bound by all the terms and conditions of this License Agreement], and click Next to continue the installation process.
  • Page 11 USB Support - Installation (All Platforms) This release includes support for a USB communications interface to DDP2000-based projectors. The setup program includes the files needed to install USB support (for Windows 98/Me/2000/XP only -- Win95, WinNT and Windows Vista are not supported). After DLP Composer ™...
  • Page 12 4. Click [USB Device Identification]. 5. Set the items on the [Vendor 0x451, Product 0x2000 ]. 6. Click [OK] 7. Move the cursor to [Flash Loader] on the Project window of [DLP Composer Lite]. (The [Flash Loader] screen will appear.) 8.
  • Page 13 12. Wait for the Completion of Burning and then remove Power Cord and Burning Cord Note: In case, the device manager can’t recognize the DDP2000 as blow, please disable this device. This will not affect upgrade procedure. PDG-DSU21...

  • Page 14: 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 PDG-DSU21...

  • Page 15: Disassembly Procedure

    3.2. Disassembly Procedure Warning ♦ Put on the Static Electricity Ring when starting for repair. ♦ Repair Environment suggest in Clean-room class 10000. Do not remove Optical Engine or DMD panel outside the clean room. Please return the optical engine to supplier if your repair condition can not meet the requirement.
  • Page 16 Step Figure Description Press the power button to shutdown the projector and disconnect the power cord. If the lamp is hot, please do not start any procedure until the projector lamp cools down. Flip the projector and remove the lens cover. 1.Remove the screws S01 x5 on the back cover as shown.
  • Page 17 Step Figure Description 3. Remove the Top Cover 4. Remove the screwsS03 x2 on the I/O cover 1.Remove the Key 2.Remove the screws S04x2 on the I/O board 3.Remove the IO board PDG-DSU21...
  • Page 18 Step Figure Description Note Add one more key holder under the KEY. Detail procedure as left. Part of the key holder is Once button can directly sticking out and situated at touch the metal spring the screw on the I/O board ,to prevent incorrect installation of keypad PDG-DSU21...
  • Page 19 Step Figure Description 1.Show you what the 5pin for Ballast O/E Fan Lamp Fan Right Fan connector should be. 2.Remove all the wires Speaker Front IR 7 pin for Power Black IR 1.Remove all screws on the Ballast module Note: screws S05 is connect ground 2.
  • Page 20 Step Figure Description 1. Remove the I/O cover 2. Remove the FAN Module(M04&M05) Note 1.Remove the screws S06 On the optical engine 2. Remove the optical engine PDG-DSU21...
  • Page 21 Step Figure Description Remove the Lamp house Loosen screws and remove the lamp module from optical engine. Note: Those screws and mesh are included in the Lamp module. PDG-DSU21...
  • Page 22 Step Figure Description Loose the screws and remove the DMD Hsink Loose the screws and remove the mainboard and DMD PDG-DSU21...
  • Page 23 Step Figure Description Note Note: 2 wires still have connection under mainboard. Disconnect these two wires before remove mainboard. Loosen screws and remove the Power module from Bottom cover C4 (Back Cover) PDG-DSU21...
  • Page 24 Step Figure Description 1.Remove Speaker 2.Loosen the screw and remove front IR Remove the foot stand PDG-DSU21...
  • Page 25 Step Figure Description Remove led lens and Top cover Loosen the screws and Remove the Top cover holder PDG-DSU21...
  • Page 26 Step Figure Description Remove the foot stand PDG-DSU21...

  • Page 27: Disassembly Lamp Module

    Disassembly Lamp Module Step Figure Description Turn off the projector. If the projector is installed in a ceiling mount, remove it from the mount. Unplug the power cord Loosen the screw in the side of the lamp cover and slide forward and remove the cover.

  • Page 28: Disassembly The Optical Engine(Lens&Color Wheel)

    3.3. Disassembly the Optical engine(Lens&Color Wheel) Step Figure Description Disassembly the Lens Remove the Lens screws Take the Lensr off. Disassembly the Color Wheel Remove the screws( M3x5)x4 Remove Color Wheel project cover PDG-DSU21...
  • Page 29 Remove the screws M3x6x2 Remove Color wheel module PDG-DSU21...

  • Page 30: Troubleshooting And Verifying The Repair

    4. Troubleshooting and Verifying the Repair This chapter provides technicians with electronic background how to maintain the product. Moreover, you can get the appropriate operation to solve some complicated problems of component repairing and professional problems. 4.1. Troubleshooting Warning Do not directly look into the lens to avoid eyesight damages. The projector is equipped with ventilation holes (intake) and ventilation holes (exhaust).
  • Page 31 (3) Confirm cable connection well. Note: Swapping modules that may be defective with others known to be good is generally an ideal way to find the module responsible for the problem. A failure symptom is rarely caused by more than one module, so you will not usually need to replace more than one to correct a particular failure.
  • Page 32 Power Source Troubleshooting: No Power Source Fan failure after after turning on turning on Replace AC Reconnect fan Check fan Check AC socket and socket connection connector Replace safety Replace fan Check Check switch or reinstall Safety Switch Replace power Replace Check 7PIN power Check...
  • Page 33 Fail to light up No Volume Refer to LED Replace Check LED Check indicator and follow Speaker indication indicative actions Speaker Replace Replace Check Check Lamp Module Lamp life I/Oboard I/Oboard Replace Replace Check Check Power board Power board Mainboard Mainboard 380V output Replace...

  • Page 34: Video Signal Troubleshooting

    Video Signal Troubleshooting Computer Video No Signal No Signal Turn on Turn on Check Check Source Source Source Source Replace Replace Check Check Cable Cable Cable Cable Replace Replace I/O Check monitor Check I/Oboard Board in signal I/O Board Replace Check Replace Check u5...
  • Page 35 Image abnormal Color abnormal Adjust Check input cable Power on again and Input signal and signal setting reset OSD Adjust Adjust Color Check Color Check input cable and Input signal Wheel Index Wheel Index signal setting Replace Replace Check Check Mainboard Mainboard Mainboard...
  • Page 36 Operation Function Troubleshooting Remote Control Button Failure Failure Replace Replace Check Check Battery I/Oboard Battery Level I/Oboard Replace Replace Check Check Remote Control Mainboard Remote Control Mainboard Replace Check Replace Check I/Oboard I/Oboard Replace Check Mainboard Mainboard PDG-DSU21...

  • Page 37: Verifying The Repair

    4.2. Verifying the Repair After repairing projector (Dissembling and assembling projector), Repair center should verify the quality of repaired unit. (1) Signal test (Each I/O can function normally) Connect all connector to the jacks one after the other to check whether each channel can project normally I/O port Monitor In (VGA)
  • Page 38 (2) Operation test Buttons operation Button description Test criteria Power button 1. Mechanical motion (Up & Down) should be free from getting stuck when pressing the button 2. Press “power” button and projector will switch on Menu 1. Mechanical motion (Up & Down) should be free from getting stuck when pressing the button.
  • Page 39 (3) Image Quality Projected image size: 60 inches (diagonal length) Zoom ring: Adjust zoom ring to wide (Maximum projection size) SVGA I/O port Monitor In (SVGA) Standard Pattern generator (Ex. Quantum data) Test Equipment Signal format 800*600 60Hz Projected image size 60”...
  • Page 40 Gray 10 Blemish, stain are not allowable on the projected screen Full darkness Light leak in the non-effective area. Should be less than 0.7 lux(<0.7lux) S-Video I/O port S-Video Standard Pattern generator (Ex. Quantum data)&DVD player Test Equipment Signal format 480i No apparent color deviation on the projected image Criteria...
  • Page 41 (4) Resolution SVGA I/O port Test Equipment 1. Rotate Zoom ring to wide mode (Maximum projected image) Test Method 2. Fix projector to set diagonal length of projected image to 60”. 3. Adjust focus ring to make resolution of 4 corners and center are balanced.
  • Page 42 (7) Safety test equipments Safety test Test items Test Equipment Safety analyzer Test method 1. Clamp the metal shell of SVGA connector 2. Plug the power cord to socket Test criteria GND 30A 3sec 100mΩ DCW 2506V 1sec 10000uA Single Step OFF (8) Cosmetic standard for repaired projector Follow cosmetic standard for repair center.

  • Page 43: Connector Information

    5. Connector Information This section provides each connector location on boards and function of each board. They will be useful for your detecting the defective boards. 5.1. I/O Board No 2 No 1 No 3 Connector Description No 1 Speaker No 2 Front IR No 3...

  • Page 44: The Backside Of I/O Board

    5.2. The backside of I/O Board NO 4 Connector Description No 4 Connect to Main board(100PIN) PDG-DSU21...

  • Page 45: Main Board

    5.3. Main Board NO 1 NO 2 NO 3 NO 4 Connector Description No 1 Color Wheel Sensor No 2 Color Wheel control No 3 No 4 PDG-DSU21...

  • Page 46: The Backside Of Main Board

    5.4. The backside of Main Board NO 5 NO 8 NO 7 NO 6 Connector Description No 5 Connect to I/O board(100PIN) No 6 Connect to Power board(7PIN) No 7 Ballast Control No 8 PDG-DSU21...

  • Page 47: Ballast Board

    5.5 Ballast Board No 1 No 3 No 2 Connector Description No 1 Lamp power supply No 2 Ignite signal connected to Mainboard No 3 Power supply PDG-DSU21...

  • Page 48: Power Board

    5.6 Power board No 3 No 4 No 2 No 1 Connector Description No 1 7-pin control No 2 Safety switch No 3 380V output No 4 AC Input PDG-DSU21...

  • Page 49: Fru (Field Replaceable Unit) List

    6. FRU (Field Replaceable Unit) List Introduction This section is a list of all the FRU removal. Following the FRU table of contents is an enlarged view of the entire projector, which shows the primary FRUs in the projector. When working on the projector, use appropriate anti-static precautions such as anti-static mats, wrist straps and grounded work surfaces.

  • Page 50: Mechanical Drawing

    6.1 Mechanical Drawing PDG-DSU21...

  • Page 51: Optical Parts Location

    6.2 Optical Parts Location PDG-DSU21...
  • Page 52 PDG-DSU21...
  • Page 53 PDG-DSU21...

  • Page 54: Accessory

    6.3 Accessory&Packing Key No. Description 645 096 2523 REMOTE CONTROL 645 098 1319 OWNERS MANUAL(US,EU,UK) 645 098 1326 QUICK SETUP GUIDE(US,EU,U 645 098 1333 OWNERS MANUAL(CHN) 645 096 8747 VGA-15P CABLE AC CORD 645 098 1258 POWER CORD(JAPAN) AC CORD 645 096 8709 POWER CORD(CHINA) AC CORD...

  • Page 55: Fans

    645 095 7253 FRONT FOOT STAND 645 095 7260 FRONT FOOT RUBBER 645 095 7277 IR COVER 645 095 7284 LENS COVER 645 095 7291 FRONT FOOT 645 095 7307 ZOOM-RING 645 098 1449 FOCUS-RING 645 095 7321 REAR FOOT 645 098 1456 KEY ASSY 645 098 1463...

  • Page 56: Appendix A: Ansi Lumen Measuring

    Appendix A: ANSI Lumen Measuring Chroma 7600 Video Pattern Generator values Set diaphragm to wide size Projection test chart to 60 inches (projection distance 2m) and measurement 9 points Measuring equation: Brightness = [(Y1+Y2+...+Y9)/9] × Projection ratio DVI Pattern: 102 Appendix B: Service Level Definition Level 1 : Cosmetic Parts ;...

  • Page 57: Appendix C: Connection Definition

    Appendix C: Connection Definition 1). VGA IN 2). USB DEFINITION DEFINITION R/Pr USB- B/Pb USB+ Ground Ground Ground Ground Ground Ground Ground Ground Ground WC-A EDIDA-SDA Hsync Vsync EDIDA-SCL PDG-DSU21...

  • Page 58: Appendix D: More Details For Main Board Measurement

    Appendix D: More details for main board measurement 1. Signal of DAD2000: -26V +26V PDG-DSU21...
  • Page 59 2. Ballast Feedback Signal: PDG-DSU21...
  • Page 60 SANYo electric co., Ltd. (KA7AA) May 2008 DC 300 Printed in Japan...

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