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Sanyo PDG-DSU20N Service Manual

Multimedia projector
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See also: Owner's Manual

SERVICE MANUAL

Product code
1 122 418 00
(KA7A)
1 122 419 00
(LA7A)
1 122 419 02
(LA7C)
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-dSu20N
U.S.A, Canada,
PdG-dSu20e
Europe, Asia
PdG-dSu20B
U.K.
original Version
chassis No. KA7-dSu20N00
LA7-dSu20e00
LA7-dSu20B00
REFERENCE NO.
SM
5110884-00

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Summary of Contents for Sanyo PDG-DSU20N

  • Page 1: Service Manual

    FILE NO. SERVICE MANUAL Multimedia Projector Model No. PdG-dSu20N U.S.A, Canada, PdG-dSu20e Europe, Asia PdG-dSu20B U.K. original Version chassis No. KA7-dSu20N00 LA7-dSu20e00 LA7-dSu20B00 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 Note the current topic. Alert you any damage that might result form doing or not Warning doing specific actions.

  • Page 4: Table Of Contents

    Table of Contents System Introduction ....................... 1 Technical Specification ......................1 1.1. Lamp Specification......................2 1.2. System Block Diagram.......................4 1.3. Firmware Upgraded Flow....................... 5 Setup Tool/Equipment ......................5 2.1. Upgrading Procedure ......................5 2.2. Machine Disassembly and Replacement ................10 Tools ............................10 3.1. Disassembly Procedure ....................11 3.2.

  • Page 5: System Introduction

    1. System Introduction 1.1. Technical Specification PDG-DSU20 Display Type DLP Single Panel Projector Resolution(Pixels) 800 x 600 Lens Manual Zoom (1.1x) Lamp 180W Projection Type Front, Rear, Ceiling Input Source D-Sub 15 pin, S-Video, Composite Video, YPbPr, Audio in(Stereo phone jack), USB Video Compatibility NTSC-M, 4.43 PAL-60, M, N...

  • Page 6: Lamp Specification

    1.2. 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 22. PDG-SU20...
  • 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: System Block Diagram

    1.3. System Block Diagram PDG-SU20...

  • 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 5. When the installation is finished, click [Finish] and reboot the PC. (A shortcut to DLP Composer (TM) Lite is created on the desktop.) PDG-SU20...
  • 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 ™ Lite is installed, to install the USB support, choose the "Install DDP2000 USB Driver"...
  • 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-SU20...

  • 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-SU20...

  • 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-SU20...
  • Page 18 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 Black IR 7 pin for Power 1.Remove all screws on the Ballast module Note: screws S05 is connect ground 2.
  • Page 19 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-SU20...
  • Page 20 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-SU20...
  • Page 21 Step Figure Description Loose the screws and remove the DMD Hsink Loose the screws and remove the mainboard and DMD PDG-SU20...
  • Page 22 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-SU20...
  • Page 23 Step Figure Description 1.Remove Speaker 2.Loosen the screw and remove front IR Remove the foot stand PDG-SU20...
  • Page 24 Step Figure Description Remove led lens and Top cover Loosen the screws and Remove the Top cover holder PDG-SU20...
  • Page 25 Step Figure Description Remove the foot stand PDG-SU20...

  • Page 26: Disassembly Lamp Module

    3.3. Disassembly Lamp Module Step Figure Description Loosen the screw on the Top cover Remove the lamp cover. Loosen the three screws of lamp module Pull the lamp module out by lamp handle. Insert the new lamp module into the projector and tighten the screws.

  • Page 27: Disassembly The Optical Engine (Lens&Color Wheel)

    3.4. 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-SU20...
  • Page 28 Remove the screws M3x6x2 Remove Color wheel module PDG-SU20...

  • Page 29: 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 30 Lamp LED Green Solid Temperature is too high. The lamp will turn Temp LED Flash off. The fan motor is cooling the lamp. Lamp LED Amber Solid The lamp ignition failed. If temperature is too Temp LED high, the fans wi11 be cooling the lamp. Flash : 2Hz (3) Confirm cable connection well.
  • Page 31 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 32 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 33: 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 34 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 35 Operation Function Troubleshoo 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-SU20...

  • Page 36: 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 37 (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 38 (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) Test Equipment Standard Pattern generator (Ex. Quantum data) Signal format 800*600 60Hz 60” in diagonal length Projected image size Test Pattern Test criteria...
  • Page 39 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 Test Equipment Standard Pattern generator (Ex. Quantum data)&DVD player Signal format 480i No apparent color deviation on the projected image Criteria...
  • Page 40 (4) Resolution I/O port SVGA 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 41 (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 42: 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 1 No 2 No 3 Connector Description No 1 Speaker No 2 Front IR No 3...

  • Page 43: 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-SU20...

  • Page 44: 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-SU20...

  • Page 45: The Backside Of Main Board

    5.4. The backside of Main Board NO 8 NO 7 NO 6 NO 5 Connector Description No 5 Connect to I/O board(100PIN) No 6 Connect to Power board(7PIN) No 7 Ballast Control No 8 PDG-SU20...

  • Page 46: Ballast Board

    5.5. Ballast Board No 3 No 1 No 2 Connector Description No 1 Lamp power supply No 2 Ignite signal connected to Mainboard No 3 Power supply PDG-SU20...

  • Page 47: Power Board

    5.6. Power board No 4 No 3 No 1 No 2 Connector Description No 1 7-pin control No 2 Safety switch No 3 380V output No 4 AC Input PDG-SU20...

  • Page 48: 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 49: Mechanical Drawing

    6.1. Mechanical Drawing PDG-SU20...

  • Page 50: Optical Parts Location

    6.2. Optical Parts Location PDG-SU20...
  • Page 51 PDG-SU20...
  • Page 52 PDG-SU20...

  • Page 53: Accessory

    6.3. Accessory Key No. Description 645 095 7567 REMOTE CONTROLLER 6.4. Board/Module Key No. Description 610 337 1764 COMPL,OPTICAL LMP O180W-KA7A 645 095 7581 OPTICAL ENGINE MODULE 645 095 7598 MAIN BOARD MODULE 645 095 7154 I/O PCB 645 095 7161 BALLAST MODULE 645 095 7178 POWER MODULE...

  • Page 54: Fans

    6.6. Fans Key No. Description 645 095 7796 FAN 70X70 645 095 7789 FAN 80X80 645 095 7802 SMALL FAN(OPTICAL ENGINE) 6.7. Speaker Key No. Description 645 095 7390 SPEAKER_PB28KC04-9-7JS1_V 6.8. Wire Key No. Description 645 095 7406 WIRE CON-MOTOR(TEMP.SENSO 645 095 7413 WIRE CON-CON.(BACK IR,CLR 645 095 7420...

  • Page 55: 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 56: Appendix C: Connection Definition

    Appendix C: Connection Definition 13-1. VGA IN 13-2. 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-SU20...

  • Page 57: Appendix D: More Details For Main Board Measurement

    Appendix D: More details for main board measurement 1. Signal of DAD2000: -26V +26V PDG-SU20...
  • Page 58 2. Ballast Feedback Signal: PDG-SU20...
  • Page 60 SANYo electric co., Ltd. (KA7A) Sep. 2007 DC 350 Printed in Japan...

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