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Sanyo PDG-DWL100 Service Manual

Multimedia projector
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Download this manual See also: Owner's Manual, Command Manual
SERVICE MANUAL
Multimedia Projector
Model No. PDG-DWL100
Original Version
Chassis No. KY5-DWL10000
PRODUCT CODE
1 682 347 82
REFERENCE NO. SM0946001
PDG-DWL100 Confidential
I

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Summary of Contents for Sanyo PDG-DWL100

  • Page 1 SERVICE MANUAL Multimedia Projector Model No. PDG-DWL100 Original Version Chassis No. KY5-DWL10000 PRODUCT CODE 1 682 347 82 REFERENCE NO. SM0946001 PDG-DWL100 Confidential...

  • Page 2: Table Of Contents

    2-16 Appendix A ������������������������ ��������������������������������������������������������������� Disassemble Bottom Shielding 2-16 Exploded Image ��������������������� ������������������������������������������������������ Disassemble IO Cover and Appendix B �������������������������������������������������������������� Bottom Cover Module 2-17 Serial Number System Definition ������������������������������������ ����������������������� Rod Adjustment 2-18 PCBA Code Definition ������������������������������������������������ ����������������������������������������� PDG-DWL100 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-DWL100 Confidential...

  • Page 4: Introduction

    Lumen output at the lamp life time) Lens Offset ● 115%+/-5% ● NTSC: 3.58/4.43 ● PAL: B/D/G/H/I/M/N Video compatibility ● SECAM: B/D/G/K/K1/L ● HDTV: 480i, 480p, 576i, 576p,720p, 1080i, 1080p 480i, 480p, 576i, 576p,720p, 1080i, 1080p Confidential PDG-DWL100...
  • Page 5 • Composite video 1Vp-p, 75 ohm Composite video 1Vp-p, 75 ohm • S-video Luminance 0.714Vp-p, 75 ohm S-video Luminance 0.714Vp-p, 75 ohm • Chrominance 0.286Vp-p, 75 ohm Chrominance 0.286Vp-p, 75 ohm • Component Video 1Vp-p, 75 ohm Component Video 1Vp-p, 75 ohm Confidential PDG-DWL100...

  • Page 6: Compatible Mode

    1600 x 1200 75.00 640 x 480 66.6(67) 34.93 800x600 37.90 Power Mac G4 1024x768 48.40 1152x870 68.68 640x480 31.35 640x480 66.6(67) 34.93 PowerBook G4 800x600 37.90 1024x768 48.40 1152x870 68.68 i Mac DV(G3) 1024 x 768 60.00 Confidential PDG-DWL100...
  • Page 7 1280x960 59.7 SXGA+ 1400x1050 63.98 UXGA 1600x1200 75.00 640x480 66.6(67) 34.93 800x600 37.9 Power Mac G4 1024x768 48.4 1152x870 68.68 640x480 31.35 640x480 66.6(67) 34.93 PowerBook G4 800x600 37.9 1024x768 48.4 1152x870 68.68 i Mac DV(G3) 1024x768 60.00 Confidential PDG-DWL100...
  • Page 8 576p (PAL) 720x576 720p (NTSC) 1280x720 720p (PAL) 1280x720 1080i (NTSC) 1920x1080 1080i (PAL) 1920x1080 1080p (NTSC) 1920x1080 1080p (PAL) 1920x1080 Note: If the Computer Compatibility supportive signal is different from User's Manual, please refer to User's Manual. Confidential PDG-DWL100...

  • Page 9: 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-DWL100 Confidential...

  • Page 10: Disassemble Filter

    3. Disassembled the left filter and the right filter. The left filter The right filter 2-3 Disassemble Lamp Cover Module 1. Loosen 2 screws (as red circle) on the Lamp Cover. 2. Disassembled the Lamp Cover Module. PDG-DWL100 Confidential...

  • Page 11: Disassemble Lamp Module

    1. Loosen 2 screws (as red circle) on the Lamp Module. 2. Pull out the Lamp Module. 2-5 Disassemble Top Cover Module, Front Cover and Lens Cover 1. Unscrew 4 screws (as red circle) from the Bottom Cover. PDG-DWL100 Confidential...
  • Page 12 (as picture A shown). - Make sure the FPC cable plug into the correct ports when assembling it. 3. Disassembled the Lens Cover, Front Cover and Top Cover Module. PDG-DWL100 Confidential...

  • Page 13: Disassemble Keypad Board Module

    2. Separate mylar, keypad board and keypad. 3. Tear off 2 EMI gaskets (as green square). Keypad 2-7 Disassemble Zoom Ring Module 1. Unscrew 3 screws (as red circle) from the Top Cover Module. 2. Remove the Zoom Ring Module. Zoom Ring Module PDG-DWL100 Confidential...

  • Page 14: Disassemble Top Shielding And Fpc Cable

    4. Unplug 1 connector (as green square) to disassemble the FPC cable. Top Shielding FPC Cable 2-9 Disassemble Main Board Module 1. Unscrew 2 screws (as blue circle). 2. Unscrew 6 hex screws (as green circle). 3. Unscrew 2 screws (as red circle). PDG-DWL100 Confidential...
  • Page 15 Wire and Black wire tube (3 pin) Compose of Red/White/Black Blower Wire and Blue wire tube (3 pin) Compose of Red/Black/Yellow Wire (3 pin) Compose of Red/Black Wire and Speaker Black wire tube (2 pin) Lamp Driver Black wire tube (5 pin) PDG-DWL100 Confidential...

  • Page 16: Disassemble Lan Board Module

    5. Unplug 1 connector (as orange square) . Disassembled the Main Board Module. 2-10 Disassemble Lan Board Module 1. Unscrew 1 screw (as green circle) to disassemble the Lan Board Module. PDG-DWL100 Confidential...

  • Page 17: Disassemble Main Board Shielding

    (as red square). 3. Tear off two black rubbers (as green square). 2-11 Disassemble Main Board Shielding 1. Unscrew 3 screws (as red circle) to disassemble the main board shielding. 2. Disassembled the Main Board Shielding. PDG-DWL100 Confidential...

  • Page 18: Disassemble Speaker

    2. Tear off the black mylar (as yellow square). 3. Separate the speaker rubber and speaker. 2-13 Disassemble Engine Module 1. Unscrew 6 screws (as red circle) to disassemble the Engine Module. 2. Remove the Engine Module. PDG-DWL100 Confidential 2-10...

  • Page 19: Disassemble Color Wheel Module And Photo Sensor Board

    - 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-DWL100 Confidential 2-11...

  • Page 20: Disassemble Rod Module

    3. Unplug 1 connector (as yellow square). 4. Unplug 2 connectors (as blue square) to take off the LVPS Module and the AC Inlet Bracket. 5. Unplug 1 connector (as red square). 6. Disassembled the LVPS. AC Inlet Bracket LVPS PDG-DWL100 Confidential 2-12...

  • Page 21: Disassemble Thermal Switch

    Thermal Switch. 2. Disassembled the Thermal Switch. 2-19 Disassemble Fan Module 1. Unscrew 4 screws (as red circle) to disassemble the Fan Module. 2. Unscrew 4 screws (as blue circle) to separate the Fan and Fan Shielding. PDG-DWL100 Confidential 2-1...

  • Page 22: Disassemble Blower Module

    Note: - Take the Fan Module as the right gesture. Fan Shielding The right gesture The wrong gesture 2-20 Disassemble Blower Module 1. Unscrew 3 screws (as red circle) to disassemble the Blower Module. 2. Seprate the Blower and Blower Rubber. PDG-DWL100 Confidential 2-1...

  • Page 23: Disassemble Lamp Driver Module

    Lamp Driver Module. 2. Unscrew 4 screws (as green circle). 3. Unplug 3 connectors (as yellow square). 4. Separate the Lamp Driver Holder and Lamp Driver . 5. Disassembled the cables. Lamp Driver Lamp Driver Holder PDG-DWL100 Confidential 2-15...

  • Page 24: Disassemble Interlock Switch

    2-22 Disassemble Interlock Switch 1. Unscrew 1 screw to disassemble the Interlock Switch. 2. Disassembled the Interlock Switch. 2-23 Disassemble Bottom Shielding 1. Unscrew 3 screws to disassemble the Bottom Shielding. 2. Disassembled the Bottom Shielding. Bottom Shielding PDG-DWL100 Confidential 2-1...

  • Page 25: Disassemble Io Cover And Bottom Cover Module

    2-24 Disassemble IO Cover and Bottom Cover Module 1. Unscrew 3 screws (as red circle). 2. Separate the IO Cover and Bottom Cover Module. PDG-DWL100 Confidential 2-17...

  • Page 26: Rod Adjustment

    Note: - To avoid over adjusting the rod. - After the opreation, please use the glue to fix the screws. - Please use Z type driver to adjust Rod screw 1. PDG-DWL100 Confidential 2-1...

  • Page 27: Led Lighting Message

    Power off (Cooling-II: It can Flashing accept power key to turn on the projector) Error (Lamp failed) Error Flashing (Fan lock) Error (Over temp.) Steady light When LED light on after 5 sec., go to standby mode. No light PDG-DWL100 Confidential...

  • Page 28: Main Procedure

    Over Temp.: Power LED (lights red), Temp LED (lights red) Auto Shut Down - Clean air filters - Check Fan - Check Thermal Switch - Check Main Board c. Fan Lock: Power LED (lights red), Temp LED (Flashes red) - Check Fan - Check Main Board PDG-DWL100 Confidential...
  • Page 29 - Check Color Wheel Mechanical Noise - Check Fan Module - Check if the Main Board and the DMD Board are assembled properly - Check Main Board Line Bar/Line Defect - Check DMD Board - Check DMD Chip PDG-DWL100 Confidential...
  • Page 30 - Clean DMD Chip and Engine Module (Out of spec.) - Check DMD Chip - Check Engine Module - Ensure that the signal cables and source work as well - Check Main Board Garbage Image - Check DMD Board PDG-DWL100 Confidential...
  • Page 31 (2) Get into service mode (please refer to 4-2 for details) Forget Password (3) Select “factory reset”. click “enter” button. (4) The “security settings” in OSD menu will change to “OFF” and user can use the default password (1234) to set new password . PDG-DWL100 Confidential...

  • Page 32: Electronic Function Block Diagram

    3-3 Electronic Function Block Diagram PDG-DWL100 Confidential...

  • Page 33: Pin Assignment

    3-4 Pin Assignment PDG-DWL100 Confidential...

  • Page 34: Function Test & Alignment Procedure

    (1) Please get into OSD menu. (2) Execute “Factory Default” function under “Setting”. 2. Lan Card Reset (1) Get into Service mode. (2) Select “Lan Card Reset”, click “Enter” to restore all lan card setup to its factory default settings. PDG-DWL100 Confidential...

  • Page 35: 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-DWL100 Confidential...

  • Page 36: Defect Specification Table

    White pattern A+B≤6 Unstable pixel White&Black pattern A+B≤1 Adjacent pixels White&Black pattern A+B=0 A+B≤10 Dark blemish Blue 60 pattern (diameter <1 inch) A+B≤10 Bright blemish Gray 15 pattern (diameter <1 inch) Bright dots on frame Gray 10 pattern PDG-DWL100 Confidential...

  • Page 37: Test Inspection Procedure

    (2) Select “Tracking” function and use right or left arrow key to adjust the value to minimize video flicker. - Adjust Resync or Frequency/Tracking/H. Position/V. Position to the inner screen. Master Inspection item - Eliminate visual wavy noise by Resync, Frequency or Tracking selection. PDG-DWL100 Confidential...
  • Page 38 - The dark pixel is unacceptable in Zone A under full white pattern; other area can accept no more than 6 dark pixels. - Adjacent pixels are unacceptable. - Ref. Defect specification table Full white Note: The defect criteria follows TI specification. PDG-DWL100 Confidential...
  • Page 39 (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. - Test signal: 1280 x 800@75Hz, 1080P PDG-DWL100 Confidential...

  • Page 40: Video Performance

    1. CV�S Procedure - Test equipment: DVD player - Test signal: CVBS Inspection item - Video performance test Inspection Distance - 0.5M ~1.0M Criteria - Check any abnormal color, line distortion or any noise on the screen. Motion video PDG-DWL100 Confidential...
  • Page 41 - Plug Audio cable into Audio Out port, check whether the outboard speaker’s “Volume” is normal. - Adjust the volume to “0→ 9” by using the remote controller. - Check the sound from speaker. - Check whether the “mute” is normal. PDG-DWL100 Confidential...

  • Page 42: Pc Calibration

    - If there is noise on the screen, the product is considered as failure product. - The screen appears normal, it shouldn’t appear any abnormal condition, such as lines and so on. - Check if the projection is same as monitor diplayed. PDG-DWL100 Confidential...

  • Page 43: Optical Performance Measure

    - Follow Contrast formula to calculate contrast values. ☼ Contrast Formula Full black pattern P5/B5 Note: P5 = Lux of center in full white pattern B5 = Lux of center in full black pattern PDG-DWL100 Confidential 4-10...
  • Page 44 - Select “RS232 Mode”, then select “Network”. (2) Select “Network”, press “Enter” button. “Network”, press “Enter” button. Network”, press “Enter” button. ”, press “Enter” button. , press “Enter” button. “Enter” button. Enter” button. ” button. button. PDG-DWL100 Confidential 4-11...
  • Page 45 - Key in the IP address: 192.168.0.100. - Key in the Subnet mask: 255.255.255.0. (5) The image C will appear on the screen, please wait a moment. (6) The image D will appear on the screen, please wait a moment. PDG-DWL100 Confidential 4-12...
  • Page 46 (3) Modify the IP address to 192.168.0.99, and modify Subnet mask to 255.255.255.0. Note: - The HOST ID (192.168.0.XXX) of PC IP address must be different from the projector IP address written down in step 1 of 4-11-1. (4) Click “OK”. PDG-DWL100 Confidential 4-13...

  • Page 47: Others

    Factory Default - The factory settings (with appropriate centering, size, geometry distortion, etc.) shall be displayed upon “Recall” is selected from OSD. PDG-DWL100 Confidential 4-14...
  • Page 48 It should be locked in the correct place. Plastic Parts All plastic parts can not be broken and damaged. Safety or warning All safety and warning labels should be visible, label including all contents. All interface connectors should be complete and Connector workable. PDG-DWL100 Confidential 4-15...

  • Page 49: 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 (DSUB(F) 9 – DIN(M) 8) - PC or Laptop PDG-DWL100 Confidential...

  • Page 50: Dlp Composer Lite Setup Procedure

    1. Choose "DLP Composer Lite V8.3 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-DWL100 Confidential...
  • Page 51 "Browse" button to change the Browse" button to change the " button to change the button to change the downloading location to “program files”, then click "Next". click "Next". 6. Click "Next". 7. The program is executing "installing" status. 8. Click "Finish". PDG-DWL100 Confidential...

  • Page 52: Firmware Upgrade Procedure

    - Loosen the two buttons. Menu button - Connect projector with PC by RS232 cable. Note: The system fan and the lamp will not operated. RS232 port 2. Execute the "DLP Composer Lite 8.3" file. Power port 3. Click "Edit" and "Perferences". PDG-DWL100 Confidential...
  • Page 53 (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 "6000" into "Read" and "Write" items of "Timeouts (in milliseconds)". - Click "OK". 7. Click "OK". PDG-DWL100 Confidential...
  • Page 54 9. Select "Complete Image Download", then select "Skip Boot Loader Area". (select "32KB"). - Click "Reset Bus" to erase the flash memory. 10. If the FW is ready, click "Start Download" to execute the firmware upgrade. - Click "Yes". 11. Proceeding Picture. PDG-DWL100 Confidential...
  • Page 55 13. Check FW version. - Re-plug in power cable, then restart the unit and get into the Service mode to check the firmware version. (To get into Service mode, please press "Power", "Enter", "Enter" and "Menu" buttons sequentially.) PDG-DWL100 Confidential...

  • Page 56: Section 2: 8051 Firmware Upgrade Procedure

    - Setup _NLINK_en - Manley USB Driver_NLINK - PDG-DWL 100_8051_xxx.hex Hardware: - Projector - Power Cord: CH4200105G011 (US Type) CH4200120G011 (EU Type) CH4200110G011 (UK Type) - Mini USB Cable - NLINK Cable - NLINK Fixture - PC or Laptop PDG-DWL100 Confidential...

  • Page 57: 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-DWL100 Confidential...
  • Page 58 - 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-DWL100 Confidential 5-10...

  • Page 59: Upgrade Procedure

    (3) Click "Next". (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". PDG-DWL100 Confidential 5-11...
  • Page 60 (7) Click "Next". (8) Click "Continue Anyway". (9) Click "Browse". (10) Select the file "slabser.sys", then open (10) PDG-DWL100 Confidential 5-12...
  • Page 61 Note: - When we execute NLINK program, the Power LED flashes orange and Fixture LED flashes red. 2. Choose the right type of MCU - "MCU Choose" picture will appear on the screen, select "W79E804". - Click "OK". PDG-DWL100 Confidential 5-13...
  • Page 62 (as red square). 6. Check 8051 FW version - Turn on the unit and get into the service mode to check the 8051 FW version. (To get into Service mode, please press "Power", "Enter", "Enter" and "Menu" buttons sequentially.) PDG-DWL100 Confidential 5-14...
  • Page 63 Section 3: Network Firmware Upgrade Procedure 5-3-1 Equipment Needed Software: - PDG-DWL 100_LAN Module FW_xxx.bin (*.bin) Hardware: - Projector - Power Cord: CH4200105G011 (US Type) CH4200120G011 (EU Type) CH4200110G011 (UK Type) - LAN Cable - PC PDG-DWL100 Confidential 5-15...

  • Page 64: Pc Hardware Link

    "IP address/tgi/fu.tgi". - Click "Continue". 4. "Firmware Update" image will appear on the screen. - Click "Browse" button to select the Network FW file (*.bin) which you saved. - Click "Open". 5. Click "Update" to start updating. PDG-DWL100 Confidential 5-1...
  • Page 65 6. Firmware Upgrade procedure. 7. Click "Re Login". 8. Firmware upgrade procedure completes. - The projector Network FW version will appear. PDG-DWL100 Confidential 5-1...

  • Page 66: Section 4: Lamp Driver Waveform Download

    - After several seconds, the Temp LED and Lamp LED will light red, then loosen "Input" and "Enter" buttons. Enter button - After 5 seconds, the Temp LED and Lamp LED will flash red. - Waveform Download is completed. PDG-DWL100 Confidential 5-18...

  • Page 67: 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-DWL100 PDG-DWL100 Confidential...
  • Page 68 CH708EL07GR01 ASSY ENGNE MODULE PDG-DWL100(SERVCE) ASSY COLOR WHEEL MODULE PDG-DXL100/ PDG-DWL100 PDG-DWL100 CH708EM16GR01 (SERVCE) ASSY ENGNE MODULE WTH CW AND DMD PDG-DWL100 CH708EL09GR01 (SERVCE) CH438EM17G001 THERMAL SWITCH WITH BRACKET (KLIXON YS11) 105deg. C CH758EL02G001 BUY ASSY TOP COVER MODULE PDG-DWL100...
  • Page 69 Description CH498EM02G001 SUNON 45x20 BLOWER, F TYPE CH758AA04G001 BUY ASSY NTERLOCK SWTCH ASSY MATRTEK CT-320 LVPS FOR PDG-DXL100/PDG-DWL100 CH758EM01GP03 (RELAY TYPE) SPEAKER 8W 8-OHM WTH GND WRE PDG-DWL100/ PDG- CH498EM01G002 DXL100 CH758EL01G001 PHILIPS Euc 225 dW/C31(225W) for PDG-DWL100/PDG-DXL100 PDG-DWL100 Confidential...
  • Page 70 ASSY BOTTOM COVER MODULE Item Description CH5289601G041 ADJUST REAR FOOT RUBBER PDG-DXL100/ PDG-DWL100 CH5289601G003 ADJUST FOOT RUBBER 65 DEGREE PDG-DWL100 Confidential...
  • Page 71 ASSY COLOR WHEEL MODULE Item Description CH808BY04G001 PCBA PHOTO SENSOR BOARD PDG-DWL100 Confidential...
  • Page 72 ASSY ENGINE MODULE Item Description CH708EL10GR01 DMD MODULE WXGA FOR SANYO PDG-DWL100(SERVCE) CH808EL02G001 PCBA DMD BOARD FOR PDG-DWL100/PDG-DXL100 PDG-DWL100 Confidential...
  • Page 73 ASSY TOP COVER MODULE Item Description CH758EM02G001 BUY ASSY KEYPAD MODULE PDG-DXL100/ PDG-DWL100 CH4283C06G001 CABLE FFC 16P P=0.5 200mm KAYPAD TO M/B CH808EM03G001 PCBA Keypad BD FOR SANYO PDG-DXL100/ PDG-DWL100 PDG-DWL100 Confidential...
  • Page 74 ASSY MB MODULE Item Description CH808EL07G001 PCBA LAN MODULE BOARD FOR Sanyo PDG-DWL100 CH808EL01G001 PCBA MAN BD FOR SANYO WXGA_ST PDG-DWL100 Confidential V...
  • Page 75 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 CH568EM03G001 PACKNG EPE BAG 420*500MM PDG-DXL100/ PDG-DWL100 CH368EL01G001 USER’S GUDE MULTLNGUAL SANYO DWL100 CH3589504G001 LABEL CARTON 108*92 BLANK PDG-DWL100 Confidential...

  • Page 76: Serial Number System Definition

    6 = Month (ex:6 = June) 01002 = Production number (5 digits), It starts from “01001” ~“99999” EX: 59601002 This label "59601002" represents the serial number for PDG-DWL100. It is produced on June of 2009. Its serial code is 01002. PDG-DWL100 Confidential...

  • Page 77: Pcba Code Definition

    II. PCBA Code Definition PCBA Code for Projector XXXXXXXXXXX EEEE Vendor Code Revision Date Code PDG-DWL100 Confidential...
  • Page 78 PRODUCT CODE SANYO Electric Co., Ltd. 1 682 347 82 Printed In Japan...

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