SERVICE MANUAL
Date Revise Version Description
2010.4.14 V1.0 Initial Issue
2011.11.18 V2.0
According to the customer whole enginge module requirement to revise service manual,the contents as following:
1.Cancel charpter 2-13(Disassemble color wheel mod-ule).
2.Cancel charpter 2-14(Disassemble DMD chip and DMD board).
3.Cancel No.5,6,7,19,20 parts and modify No.18 part number in appendix A
2011.12.1 V3.0
According to the customer requirement to add contents as following:
1.Add charpter 2-13(Disassemble color wheel module). 2.Add charpter 2-14(Disassemble DMD chip and DMD board).
Preface
This manual is applied to BS275/BX275 projection system. The manual gives you a brief
description of basic technical information to help in service and maintain the product.
Your customers will appreciate the quick response time when you immediately identify
problems that occur with our products. We expect your customers will appreciate the
service that you offer them.
This manual is for technicians and people who have an electronic background. Please
send the product back to the distributor for repairing and do not attempt to do anything
that is complex or is not mentioned in the troubleshooting.
Notice:
The information found in this manual is subject to change without prior notice. Any
subsequent changes made to the data herein will be incorporated in future edition.
BS275/BX275 Service Manual
Copyright March., 2012.
All Rights Reserved
Manual Version 5.0
BS275/BX275 Comparison List
PARTS
BS275
BX275
Main BD
80.8HC01G003
80.8HF01G003
Top Cover
51.8HC01G001
51.8HC01G011
DMD
48.8EH01G001
48.8CQ01G003
Engine
70.8HC13GR01
70.8HF05GR01
Table of Content
Chapter 1 Introduction
Highlight
1-1
Compatible Mode 1-4
Product Overview 1-6
Remote control battery installation 1-12
Chapter 2 Disassembly Process
Equipment Needed & Product Overview
2-1
Disassemble Lamp Cover Module
2-2
Disassemble Lamp Module
2-2
Disassemble Top Cover Module 2-3
Disassemble Zoom Ring Module 2-3
Disassemble Keypad Board Module
2-4
Disassemble Top Shielding
2-4
Disassemble IO Cover
2-5
Disassemble Main Board Module
2-5
Disassemble Main Board Shielding 2-6
Disassemble Front Cover Module and IR Sensor Board 2-8
Disassemble Engine Module 2-8
Disassemble Color Wheel Module
2-9
Disassemble DMD Chip and DMD Board
2-9
Disassemble Focus Ring 2-10
Disassemble Fan Module and Thermal Switch
2-10
Disassemble Blower Module
2-12
Disassemble Interlock Switch 2-14
Disassemble Bottom Shielding
2-15
Disassemble Speaker
2-15
Disassemble Bottom Cover Module 2-16
Rod Adjustment
2-17
Re-write Lamp Usage Hour 2-19
Chapter 3 Troubleshooting
LED Lighting Message 3-1
Main Procedure 3-2
Chapter 4 Function Test & Alignment Procedure
Test Equipment Needed
4-1
Service Mode
4-1
OSD Reset
4-1
Factory Fan RPM Reset 4-2
Test Condition 4-2
Test Inspection Procedure 4-4
PC MODE
4-5
Video Performance
4-8
Calibration
4-10
Optical Performance Measure 4-12
NLINK Setup Procedure 5-9
Manley USB Driver Upgrade Procedure
5-10
8051 Firmware Upgrade Procedure
5-13
Chapter 6 EDID Upgrade
EDID Introduction
6-1
Equipment Needed 6-2
Setup Procedure (VGA)
6-3
EDID Key-In Procedure
6-4
Appendix A Exploded Image
I
Appendix B
Serial Number Definition
I
PCBA Code Definition
II
Appendix C
Chapter 1
Introduction
1-1 Highlight
No Item Description
1 Technology ● 0.55” DMD 1 chip 2xLVDS (DarkChip3) S450 2 Dimension (W x D x H) ● 286.3*88.2*192 mm (without protruding parts)
3 Weight ● < 2.31Kg
4 Power Supply
● Universal AC 100--240V ~ 50 / 60 Hz with PFC input ● 180W Lamp @ normal operation
● 160W Lamp @ eco operation
● Variance FAN speed control (Depend on temperature variance)
5 Keystone Correction ● +/ -15 degree Vertical
6 Resolution ● Native Resolution: 800 X 600 7 Brightness ● 2250 ANSI Lumens ( Typical )
● 2000 ANSI Lumens ( Minimum ) 8 Contrast ● 2200:1 (Full on/Full off)
9 Uniformity ● 80% Typical (JBMA standard ) ● 65% Minimum (JBMA standard ) 10 Throw ratio ● 1.95 ~ 2.15:1 distance/width @2.37m 11 Projection lens ● F# 2.41-2.55, 1.10X Mechanical Zoom Lens.
f=21.8-24mm @ 60”
12 Lamp life
● 3000 hours at typical full power mode. ● 4000 hours at Eco mode
(The more than 50% of lamp population have light out put>50% of initial min. Lumen output at the lamp life time.
No Item Description
15 Terminals
● One D-Sub 15-pin female connector for VGA input and component video input
● One Mini DIN 4-pin for S-Video Input ● One RCA Jack for Composite Video Input ● One Min-pin RS232 port for FW update
● One D-Sub 15-pin female connector for VGA output ● One Audio in 3.5mm mini-jack
16 System Controller ● TI DDP2431
17 Color Wheel ● 40mm diameter, 6 segments (R81Y41G84C31W52B71) & 7200 rpm
18 Lamp ● 180W Lamp (Osram E20.8)
19 Temperature ● Operating: 5 ~ 35°C ● Storage: -20 ~ 60°C 20 Altitude ● Operating: 0~2,500 ft, for 5°C~35°C 2,500~5,000 ft, for 5°C~30°C 5,000~10,000 ft, for 5°C~25°C ● Storage 40,000 ft 21 Input Signal
● Computer analog input ● Video
● Analog RGB 0.7Vp-p, 75ohm ● Sync
• Hsync Freq. 31.35~91.1kHz • Vsync Freq. 56~85Hz
● Separate Sync: (HV) TTL level (bi-polarity) ● Composite Sync: TTL level (bi-polarity) ● Sync-on-green: negative sync. 0.3Vp-p ● Analog Video
• Composite video 75ohm • S-video (Y/C) 75ohm
No Item Description 22 Projection Distance ● 1.2~12m
23 Projection Screen Size ● Adjustable from 27.46” to 302.8” (Focus range)(Diagonal)
24 Color Wheel ● UL/ cUL, FCC B, TUV-GS & CB report, CE, C-Tick, CCC, KC, Gost-R, NOM, SASO 25 Audio speaker ● Built-in one 2W speaker
1-2 Compatible Mode
Computer Compatibility (Analog)
Compatibility Resolution V-Sync [Hz]
VGA 640x350 70 640x350 85 640x400 85 640x480 60 640x480 72 640x480 75 640x480 85 720x400 70 720x400 85 SVGA 800x600 56 800x600 60 800x600 72 800x600 75 800x600 85 XGA 1024x768 60 1024x768 70 1024x768 75 1024x768 85 WXGA 1280x768 60 1280x768 75 1280x720 60 1280x800 60 SXGA 1152x864 60 1152x864 70 1152x864 75 1152x864 85 1280x1024 60 1280x1024 75 1280x1024 85 1280 x 960 60 SXGA+ 1400x1050 60
Compatibility Resolution V-Sync [Hz] UXGA 1600 x 1200 60 MAC LC 13” 640x480 66.66 MAC II 13” 640x480 66.68 MAC 16” 832x624 74.55 MAC 19” 1024x768 75 MAC 1152x870 75.06 MAC G4 640x480 60 i Mac DV 1024x768 75 i Mac DV 1152x870 75 i Mac DV 1280x960 75
Note: If the Computer Compatibility supportive signal is different from User's Manual, please refer to User's Manual.
1-3 Product Overview
Projector Outlook
Front /Upper side
Item
Description
Item
Description
1 Control Panel 6 Focus Ring
2 Remote Sensor 7 Ventilation (outlet)
3 Zoom Ring 8 Lens
Rear side
Item
Description
Item
Description
1 RGB IN Connector 5 RGB OUT Connector
2 S-VIDEO Connector 6 AUDIO-IN Jack
3 VIDEO Connector 7 AC IN
Control Panel
Item
Function
Description
1 POWER Power On/Off the Projector 2 POWER LED Indicate the projector’s status. 3 LAMP LED Indicate the projector’s lamp status.
4 TEMP LED Indicate the projector’s temperature status..
5 KEYSTONE Adjust the image to compensate for distortion caused by tilting the projector.
6 Four Directional
Select Keys Use to select items or make adjustments to your selection. 7 SOURCE Press “SOURCE” to select an input signal.
8 MENU Press “Menu” to launch the on-screen display (OSD) menu. To exit OSD, Press “Menu” again. 9 VOLUME Adjust to increase / decrease the volume.
Item
Function
Description
1 Infraredtransmitter Sends signals to the projector.
2 DIS-MODE Select the Image mode from Presentation,Bright, Movie, SRGB, Blackboard,Classroom, User1 and User2.
3 POWER Turning the Projector On/Off
4 COMPUTER Press “COMPUTER” to choose RGB IN connector.
5 FREEZE Pause the screen image. Press again to resume the screen image. 7 ENTER Confirm your section of items in sub menu operation.
8 SOURCE Press “SOURCE” to choose RGB, Component, S-Video and Composite sources.
9 MENU Press “MENU” to launch the Onscreendisplay (OSD), back to the top level of OSD for the OSD main menu operation
10 KEYSTONE - Adjust the image to compensate for distortion caused by tilting the projector.
11 AV-MUTE Momentarily turn off/on the audio and video.
12 RESET Return the adjustments and settings to the factory default val-ues. (except for lamp counter)
13 VIDEO 1
(S-VIDEO) Press “VIDEO 1” to choose S-VIDEO connector.
14 VIDEO 2
(VIDEO) Press “VIDEO 2” to choose VIDEO connector.
15 KEYSTONE + Adjust the image to compensate for distortion caused by tilting the projector.
16 D.ZOOM Zoom out or Zoom in the projector display.
17 Four Directional Select Keys Use to select items or make adjustments to your selection.
18 RE-SYNC Automatically synchronize the projector to the input source.
1-4 Remote control battery installation
- Press firmly and slide the battery cover off.
- Install new battery (CR2025 type battery)into the compartment.Ensure
that the side with a “+”
- Install new battery into the compartment.
Chapter 2
Disassembly Process
2-1 Equipment Needed & Product Overview
1. Screw Bit (+): 105
2. Screw Bit (+): 107
3. Screw Bit (-): 107
4. Hex Sleeves 5 mm
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.
2-2 Disassemble Lamp
Cover Module
1. Loosen 2 screws (as red circle) on the
Lamp Cover.
2. Disassemble the Lamp Cover Module
and tear off the Aluminum foil.
2-3 Disassemble Lamp
Module
1. Loosen 2 screws (as red circle) on the
Lamp Module.
2-4 Disassemble Top Cover
Module
1. Unscrew 2 screws (as red circle) from the
Bottom Cover.
2. Unscrew 2 screws (as green circle) from
the IO Cover .
3. Remove the Top Cover Module.
Note:When you disassemble the top
cover, please pay attention to the
tenons(as yellow square).
2-5 Disassemble Zoom Ring
Module
1. Unscrew 7 screws (as red circle) from
the Top Cover Module.
2-7 Disassemble Top
Shielding
1. Unscrew 9 screws (as red circle).
2. Disassembled the Top Shielding.
2-6 Disassemble Keypad
Board Module
1. Unscrew 4 screws (as red circle) to
disassemble Keypad Board Module.
2. Tear off 2 EMI gaskets from Keypad
Board Module.
3. Separate Keypad Button from Top Cover
Module.
2-8 Disassemble IO Cover
1. Unscrew 4 hex screws (as red circle).
2. Unfasten 2 tenons (as yellow square).
. Disassembled the IO cover.
Note:Take care the tenons when you
disassemble the unit.
2-9 Disassemble Main Board
Module
1. Unscrew 3 screws (as red circle).
2. Unplug 1 connector (as green square)
of Color Wheel.
Item Male Connector on Main Board The key feature Figure
A Lamp Driver Black wire tube (5 pin)
B Fan Compose of Red/Yellow/Black Wire (3 pin)
C Blower Compose of Red/Black/White Wire, white connector and Black wire tube (3 pin)
D Photo Sensor Compose of Red/Black/White Wire, red connector and Black wire tube (3 pin)
E IR Compose of Red/Black/White Wire, green connector and Black wire tube (3 pin)
F Speaker Compose of Red/Black Wire and Black wire tube (2 pin)
F E D C B A
Please refer to the table as below for
details of each connector.
4. Unplug 1 connector (as yellow square).
5. Remove the Main Board.
2-10 Disassemble Main
Board Shielding
1. Unscrew 2 screws (as red circle).
2. Disassemble the Main Board Shielding.
2-11 Disassemble Front
Cover Module and IR
Sensor Board
1. Unscrew 1 screw (as red circle).
2. Unfasten 2 tenons (as green square).
3. Remove the Front Cover Module.
4. Unfasten 2 tenons (as green square) to
disassemble the IR Sensor Board and IR
Cover.
Note: - Take care the tenons when you disassemble the unit.
IR Cover IR Sensor Board
2-12 Disassemble Engine
Module
1. Unscrew 4 screws (as yellow circle) to
disassemble the Engine Module.
2-13 Disassemble Color
Wheel Module
1. Unscrew 2 screws (as red circle) to
disassemble the Color Wheel Module.
2. Unscrew 1 screw (as blue circle) to
disassemble the Photo Sensor Board
from the Color Wheel Module.
Note: - Avoid touching the glass parts of color wheel.
2-14 Disassemble DMD Chip
and DMD Board
1. Unscrew 2 screws (as red circle) to
disassemble the Heat Sink and DMD
Module.
2. Rotate the screw counterclockwise (as
yellow circle) to disassemble the DMD
2-15 Disassemble Focus
Ring
1. Unscrew 3 screws (as red circle) to
disassemble the Focus Ring.
Focus Ring
2-16 Disassemble Fan
Module and Thermal
Switch
. Unscrew 3 screws (as red circle).
2. Unscrew 1 screw (as orange circle).
Note: - Take the Fan Module as the right gesture.
the wrong gesture the right gesture
4. Unscrew 4 screws (as blue circle) to
disassemble the Fan Shielding and Fan.
5. Unscrew 1 screw (as green circle) to
disassemble the Thermal Switch.
2-17 Disassemble Blower
Module
1. Unscrew 3 screws (as red circle) to
disassemble the Blower Module.
2. Seprate the Blower and Blower Rubber.
2-18 Disassemble LVPS
Module
1. Unscrew 6 screws (as red circle).
2. Unplug 3 connectors (as yellow square).
3. Cut off the cable tie (as green square).
4. Disassemble the LVPS Module, AC
Inlet Bracket and LVPS to MB cable.
Note: when you assemble the unit must do actions as below:
1. Use the cable tie to pierce the first hole of LVPS for binding the Interlock Switch and Lamp Driver to LVPS cable
(as blue
square)
.2. Use clamp to fix the Lamp Driver to LVPS cable
(as orange square)
.2-19 Disassemble Lamp
Driver
1. Unscrew 1 screw (as red circle) to
disassemble the Lamp Driver Module.
2-20 Disassemble Interlock
Switch
1. Unscrew 1 screw (as red circle) to
disassemble the Interlock Switch.
Note: Make sure the Interlock Switch cable be wedged fillister as the picture shown.
Lamp Driver Lamp Driver Holder
2. Unscrew 4 screws (as yellow circle).
3. Unplug 3 connectors (as blue square).
4. Disassemble the Lamp Driver and Lamp
Driver Holder.
2-21 Disassemble Bottom
Shielding
1. Unscrew 3 screws (as red cricle) to
disassemble the Bottom Shielding.
2-22 Disassemble Speaker
1. Unscrew 2 screws (as yellow circle) to
disassemble the Speaker.
2-23 Disassemble Bottom
Cover Module
1. Unscrew 3 nuts (as red circle) to
remove the rubber adjust foot.
2-24 Rod Adjustment
1. Environment Adjustment
- The distance between the engine and
the screen is 2.4 M.
- This process should be done at a dark
environment (under 2 Lux).
2. Procedure Adjustment
- Change the screen to "white screen".
- Adjust the screws by using the rod
on the engine module to readjust the
image.
("screw 1" should be adjusted first, and
then "screw 2". Adjust until the yellowish
or bluish parts disappeared.)
3. Abnormal image inspection
- It should not have any abnormal color
at the rim of the image by estimating
through the eyes.
Note:To avoid over adjusting the rod. After the operation, please use the glue to fix the screws.
please refer to the blow table for rod
Z type driver
Screw1
Screw2
Adjustment
Part Screw direction
Screen State
Description
Initial state State after adjusting
Right/Left screw1
Right(tighten direction)
When the right color band appeared,rotate scew1 clockwise,then the color band disap-peared.
Lift(loosen direc-tion
When the left color band appeared,rotate scew1 anti-clockwise,then the color band disappeared.
Up/Down screw2
Right(tighten direction)
When the bottom color band appeared,rotate scew2 clockwise,then the color band disap-peared.
Lift(loosen direc-tion
When the top color band appeared,rotate scew2 anti-clockwise,then the color band disappeared.
2-25 Re-write Lamp Usage
Hour
1.Press "Menu",when "OSD" is displayed.
- Use “Left” or “Right” key to select
"OPTIONS" .
- Use "UP" or "DOWN" key to select
"Lamp settings",then press"OK".
- Use"UP" or "DOWN" key to select
"Eco Mode".
- Use“Left” or “Right” key to select
"on"or"off",then press "OK".
2. Get into service mode.
-
Press Power --> Left --> Left --> Menu
to get into service mode.
- Use “Down” key to select “Exit"
- Use “Left” or “Right” key to re-write the
Normal Lamp hour or Eco Lamp hour.
Note:"Eco Mode" status is"on",you can Re- write Eco Lamp Hour.
"Eco Mode"status is"off",you can Re-write Normal Lamp Hour.
3. Choose “Exit”, press “OK” to exit service
mode.
Chapter 3
Troubleshooting
3-1 LED Lighting Message
Message Power-LED LED
Green Amber LAMP(Red) TEMP(Red)
Standby
(Input power cable)
O
Normal (Power on)
O
Powering up
(Warming up) Flashing
O
Power off
(Cooling-I: It can’t accept
any key at this status) Flashing
O
Power off (Cooling-II: It can accept power key to turn on
the projector)
O
FlashingError (Lamp failed)
O
O
O
Error (Fan lock)
O
O
O
Flashing3-2 Equipment Needed
1. Projector
2. PC (Personal computer)
3. DVD player
4. Screw drivers
5. VGA cable, power cord, S-video cable,Video-cable, audio cable,
6. Voltage test meter
Chapter 4
Function Test & Alignment Procedure
4-1 Test Equipment Needed
- IBM PC with HDTV resolution
- DVD player with Multi-system, equipped “Component”, “Composite”, “S-Video” and “HDMI”. - HDTV Source (720P, 1080P, 1080i)
- Minolta CL-100
- Quantum Data 802B or CHROMA2327 (Color Video Signal & Pattern Generator)
4-2 Service Mode
1. Turn on the projector
2. Press “Power”, “Left”, “Left” and “Menu” buttons sequentially on keypad to get into service mode.
4-3 OSD Reset
After final QC step, we have to erase all saved change again and restore the default setting: (1) Please get into OSD menu.
(2) Execute “OSD reset” function under “Options”.
4-4 Factory Fan RPM Reset
After replace main board, fan or upgrade system FW, you need to do: Picture A 1. Plug in the power cord, hold on "left" button then press "power"
button, when the power LED lighted green, Temp LED and Lamp LED lighted red about one second, loosen "left" button.
2. After the “Logo” disappeared, Picture A will be shown.
3. After several minutes, you can check the fan RPM as red circle. a.Please get into Service Mode (refer to 4-2)
b.Select “Thermal Settings”, then press “OK”, Fan detail information will be shown.
Note: 1.The steps must be finished in 50 seconds after powering on projector.
2. If the factory fan Value don’t show in service mode,please repeat the step 1,2 again.
4-5 Test Condition
- Circumstance brightness: Dark room less than 2 lux.
- Inspection distance: 0.5m~1.0m functional inspection.
- Screen size: 60 inches diagonal.
- After repairing each unit, a Run-in test is necessary (refer to the below table).
Symptom Run-in Time
Normal repair 2 hours
NFF 4 hours
Auto shutdown 6 hours
Get into Burn-In Mode
* Cycle setting is based on the defect symptoms. ie: If it is NFF, the run-in time is 4 hours. You have to set the lamp on for 50 min. and lamp off for 10 min for 4 cycles.
Press power > Left > Left > Menu buttons sequentially on remote controller to get into service mode
Choose Burn-In Test > enter
Defect specification table
< Figure: Zone A, Zone B & Frame(as green line) Definition, Active area=Zone A+ Zone B >
Screen Defects (While replacing DMD Chip, DMD Board and Main Board)
Frame
Order Symptom Pattern Criteria
Bright pixel (dots) Gray 10 pattern A+B≤1
2 Dark pixel (dots) White pattern A+B ≤ 6
4-6 Test Inspection Procedure
Update
Main
Change Parts
Board
FW
wheel
Color
module
Lamp
module
Engine
module Fan
Rod
FW Version Update
(refer to chapter 5)
V
V
Color Wheel Index
(refer to chapter 4-9)
V
V
Lamp counter reset
(refer to chapter 2-25)
V
PC Calibration
(refer to chapter 4-9)
V
V
Video Calibration
(refer to chapter 4-9)
V
V
OSD Reset
(refer to chapter 4-3)
V
V
Re-write Lamp Hour
Usage
(refer to chapter 2-25)
V
EDID
(refer to chapter 6)
V
ROD Adjustment(refer
to chapter 2-24)
V
V
Factory Fan RPM
Reset
(refer to chapter 4-4)
V
V
V
Note: - If Color appears abnormal after changing Main Board Module, please do Color
Wheel index adjustment.
4-7 PC MODE
For BS275, the native resolution of test signal is 800x600@60HZ. BX275, the native resolution of test signal is 1024x768@60HZ
- We take BS275 for example here.
1. Frequency and tracking boundary
Procedure - Test equipment: video generator. - Test signal: analog 800 x 600@60Hz - Test Pattern: general-1 or master
- Check and see if the image sharpness is well performed.
- If not, re-adjust by the following steps:
(1) Select “Frequency” function to adjust the total pixel number of pixel clock in one line period. (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.
Inspection item - Eliminate visual wavy noise by Resync, Frequency or Tracking selection.
- Check if there is noise on the screen.
- Horizontal and vertical position of the video should be adjustable to the screen frame.
Criteria - If there is noise on the screen, the product is con-sidered as failure product.
- If there is noise on the screen, use auto or manual “frequency” function or “tracking” function to adjust
Master General-1
2. Bright Pixel
Procedure - Test equipment: video generator. - Test signal: analog 800 x 600@60Hz - Test Pattern: gray 10
Inspection item - Bright pixel check.
Criteria - Bright pixel should be no more than 1 in the active zone; 1 pixel is allowed on the frame.
- Ref. Defect specification table
3. Dark Pixel
Procedure - Test equipment: video generator. - Test signal: analog 800 x 600@60Hz - Test Pattern: full white
Inspection item - Dead pixels check. - White pattern (IRE=100)
Criteria - The dark pixel can accept no more than 6 dark pixels. - Adjacent pixels are unacceptable.
- Ref. Defect specification table
4. Bright Blemish
Procedure - Test equipment: video generator. - Test signal: analog 800 x 600@60Hz - Test Pattern: gray 15
Inspection item - Bright blemish check.
Criteria - The bright blemish should be no more than 10 under gray 15 pattern.
- Ref. Defect specification table
5. Dark Blemish
Full white Gray 10
Inspection item - Dark blemish check
Criteria - The dark blemish should be no more than 10 under blue 60 pattern.
- Ref. Defect specification table
6. Focus Test
Procedure - Test equipment: video generator. - Test signal: analog 800 x 600@60Hz - Test Pattern: full screen
Inspection item - Focus check
Criteria - From screen 2.6 M via visual to check the focus, look at the entire screen, focus shall be clear, crisp, and sharp over the entire surface of the display pattern. (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: 800 x 600@60Hz, 1080i - Test Pattern: Master, 64 gray RGBW
* Please Use 800 x 600@60Hz signal & 64 gray RGBW pattern and 1080i signal & master pat-tern to do color performance test. Color can not discolor to purple and blue.
Inspection item - Check if each color level is well-functioned.
Blue 60
Full screen
(The unidentified color levels on both left and right sides should not over 4 color levels.) - Gray level should not have abnormal color or
heavy lines.
- If color appears abnormal, please get into ser-vice mode to do color wheel index adjustment.
4-8 Video Performance
1. CVBS
Procedure - Test equipment: DVD player - Test signal: CVBS
Inspection item - Video performance test Inspection Distance - 1.8M ~2.8M
Criteria - Check any abnormal color, line distortion or any noise on the screen.
2. HDTV/ Component
Procedure - Test equipment: DVD player - Test signal: Ycbcr/YPbPr Inspection item - HDTV performance test Inspection Distance - 1.8M ~2.8M
Criteria - Check any abnormal color, line distortion or any noise on the screen.
3. Audio Test
Procedure - Test equipment: DVD Player - Test signal: CVBS
Inspection item - Audio performance test
Criteria - Check the sound from speaker
- Plug Audio cable into Audio in port, check whether “Volume” is normal.
- Adjust the volume to “0→ 9” by using the remote con troller.
- Check the sound from speaker. - Check whether the “mute” is normal.
4. S-Video
Procedure - Test equipment: DVD player - Test signal: S-Video
Inspection item - Video performance test Inspection Distance - 1.8M ~2.8M
Criteria - Check any abnormal color, line distortion or any noise on the screen.
- Check the sound from speaker.
5. 3D Test
Procedure - Test equipment: DVD Player
- Test signal:HQFS format CD Inspection item - 3D testInspection Distance - < 6M
Criteria The image should not appear noise, flicker, shadow, shocking, abnormal color.
4-9 Calibration
1. Color Wheel Index Adjust
Check pattern - Test signal: 800*600@60Hz - Test pattern: 64 gray RGBW Procedure - Test equipment: video generator
- Please press "Power", "Left", "Left" and "Menu" buttons sequentially to get into Service Mode.
- Adjust "Color Wheel Index" to correct the test patten.
Inspection item - Color saturation
Criteria - There should not have any lack of RGBW. - Color levels should be sufficient and normal.
note: Color Wheel Index should be adjusted when
the test pattern appears flashing,abnormal color,missing color.
1. PC Calibration
Procedure - Test equipment: video generator
- Once Main Board is changed, PC calibration should be done as well.
(1) Test signal: 800 x 600@60Hz (2) Test Pattern: White/Black
- Note
(1) Calibration pattern should be in full screen mode.
(2) Please refer to 4-2 Guide to get into service mode, then get into “ADC/DEC color”, and choose “PC Calibration”.
Inspection item - Check if there is lines on the screen. - Check if there is noise on the screen.
- Horizontal and vertical position of the video should
be adjustable to the screen frame. SMPTE BAR
any abnormal condition, such as lines and so on. - Check if the projection is same as monitor diplayed.
2. Video Calibration
Procedure - Test equipment: video generator.
- Once main board is changed, Video calibration should be done as well.
(1) Test signal: 480i
(2) Test Pattern: SMPTE BAR - Note
(1) Calibration pattern should be in full screen mode.
(2) Please refer to 4-2 Guide to get into Service Mode select ‘‘ADC/DEC color’’, and choose “Video Calibration”.
Inspection item - Color sturations
Criteria - There should not have any lack of SMPTE BAR.Color levels should be sufficient and normal.
4-10 Optical Performance Measure
Inspection Condition
- Environment luminance: 2 Lux
- Product must be warmed up for 5 minutes - Distances from the screen: 2.4 M
- Screen Size: 60 inches diagonal
1. Test equipment
Procedure - Please get into OSD menu, select “Lamp Setting” under “Options”, press “Enter” but ton, then select “Bright” mode.
- Test equipment: video generator.
- Test signal: analog 800 x 600@60Hz
2. Brightness
Procedure - Full white pattern
- Use CL100 to measure brightness values of P1~P9.
- Follow the brightness formula to calculate brightness values.
☼ Brightness Formula
Avg. (P1~P9)*1.1m2
Criteria • 1100 ANSI lumen
Full black pattern
Full white pattern
X100% full white pattern P5 & full black pattern B5 (see image: full white)
- Follow Contrast formula to calculate contrast values.
☼ Contrast Formula
P5/B5
Note: P5 = Lux of center in full white pattern B5 = Lux of center in full black pattern
Criteria • 1800:1
4. Uniformity
Procedure - Full white pattern
- Use CL100 to measure brightness values of P1~P9 (see image: full white).
- Follow the Uniformity formula to calculate average values.
☼ Uniformity Formula
JBMA Uniformity = Avg. (P1, P3, P7, P9) P5
Criteria • 65%
4-11 Others
1. Functional Inspection
Factory Default - The factory settings (with appropriate centering, size, geometry distortion, etc.) shall be dis-played upon “Recall” is selected from OSD.
Display Size - All preset modes shall expand to full screen size using OSD Horizontal and Vertical Size controls.
Display Data Channel (DDC) - The purpose of the DDC test is to verify the DDC1/DDC2B operation of the projector and to verify Plug & Play function.
Acoustic - High pitch sound from cooling fan and color wheel is unacceptable.
2. Check points for exterior and print pattern
Check item Check point
Text & Pattern Missing letters & pattern or blurry prints are unacceptable.
Exterior Dirt, scrape, water ripples and uneven color are unacceptable.
Focus ring/ Zoom ring Focus ring and Zoom ring should be moved smoothly.
Logo Missing logo, missing prints and blurry prints are unacceptable Screw All screws sure be fixed and in right type.
Pedestal Well-functioned
Lamp Cover It should be locked in the correct place.
Plastic Parts All plastic parts can not be broken and damaged. Safety or warning label All safety and warning labels should be visible, including all contents. Connector All interface connectors should be complete and workable.
Chapter 5
Firmware Upgrade
Section 1: System Firmware Upgrade
5-1-1 Equipment Needed
Software: (DDP2431-RS232)
- DLP Composer Lite 9.2
- Firmware (*.img)
- 1510X library
Hardware:
- Projector
- Power Cord (42.50115G001)
- RS232 Cable 9PIN to 3PIN (42.83618G001)
- PC or Laptop
5-1-2 DLP Composer Lite
Setup Procedure
1. Choose "DLP Composer Lite V9.2 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".
5. Click "Next".
6. Click "Next".
7. The program is executing "installing"
status.
5-1-3 Get into FW mode
1. Get into Firmware mode
Hold on “POWER” button and plug in the power cord.
- The LED will light red and amber.
- Loosen “POWER” button.
- Connect projector with RS232 cable to PC.
Note: - The system fan and the lamp will not
operate.
2. Execute the "DLP Composer
TMLite 9.2" file.
4. Click "Library".
- Click the "Browse" and navigate to
the directory where you put the DLP
Composer files in.
- Click "1510X Library" folder.
- Click "OK".
5. Click “Communications”.
- Select “Serial Port”.
- Select the COM Port which you are using.
- Click “Configure”.
6. “Serial Port Configuration” picture will
appear on the screen.
- Make sure the settings are as below:
(1) In “Baud Rate” item, select “115200”.
(2) In “Data Bits” item, select “8”.
(3) In “Stop Bits” item, select “1”.
(4) In “Parity” item, select “None”.
6. Choose "Flash Loader".
- Click "Browse" to search the firmware file
(*.img).
- Click "Open".
7. Select "Skip Boot Loader Area".
(select "32KB").
- Click "Reset Bus" to erase the flash
memory.
8. If the FW is ready, click "Start Download" to
execute the firmware upgrade.
- Click "Yes".
10. It takes about several minutes, the
firmware upgrade process is finished,
"Download completed" will appear on the
screen.
- Unplug RS232 cable and power cord.
11. Check FW version.
- Re-plug in power cord, then restart the
unit and get into the Service mode to
check the firmware version.
(To get into service mode, please press "Power", "Left", "Left" and "Menu" buttons sequentially on remote controller.)
Section 2: 8051 FW Upgrade
5-2-1 Equipment Needed
Software: (N79A901R-USB)
- Setup _NLINK_en
- Manley USB Driver_NLINK (for N79A901R)
- XXX_8051_XXX.hex
Hardware:
- Projector
- Power cord: 42.50115G001
- USB Cable mini USB to USB (A) (42.00284G001)
- NLINK Fixture
5-2-2 NLINK Setup Procedure
1. Choose "setup_NLINK_en.exe" program.
2. Click "Next".
3. Click "Next".
5. Click "Next".
- 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.
5-2-3 Manley USB Driver
Upgrade Procedure
1. Set-up
- Plug in the power cord, the power LED will light on red.
- Connect RGB-IN Port of projector with NLINK Fixture .
- Connect NLINK Fixture with PC by USB cable.
2. Execute Program
(1) "Found New Hardware Wiszard" picture
will appear on the screen.
(2) Select "Install from a list or specific
location (Advanced)".
(3) Click "Next".
(4) Select "Include this location in the
search", then click "Browse".
(1)
(3) (2)
(7) Click "Next".
(8) Click "Continue Anyway".
(9) Click "Finish".
- "Manley TPRP1-Protocol Emulator"
will appear on the picture.
- Complete the USB Driver Upgrade
Procedure.
Note: - If "Found New Hardware Wiszard" picture appear again, repeat step 2 to install USB Drivier.
(7)
(8)
5-2-4 8051 Firmware Upgrade
Procedure
1. Execute 8051 FW Program
- Double click "NLINK V1.2" to execute
NLINK program.
Note: - When we execute NLINK program, the power LED and Fixture LED flash red.
2. Choose the right type of MCU
- "MCU Choose" picture will appear on the
screen, select "N79A901R".
- Click "OK".
3. Choose 8051 file (*.hex)
- "Manley Nlink" picture will appear on the
screen.
- Ensure "MCU" is the one you chose in the
last step (as green square).
- Click "Open".
- Select the 8051 file where you put the file
in, then click "Open".
5. Finish
- When 8051 FW upgrade process is
finished, "Write Chip success" will be shown.
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", "Left", "Left" and "Menu" buttons sequentially on remote controller.)
Chapter 6
EDID Upgrade
6-1 EDID Introduction
Extended Display Identification Data is a VESA standard data format that contains basic
information about a display device and its capabilities, including vendor information,
maximum image size, color characteristics, factory pre-set timings, frequency range limits,
and character strings for the monitor name and serial number.
The information is stored in the display and is used to communicate with the system
through a Display Data Channel (DDC), which sites between the display device and the
PC graphics adapter. The system uses this information for configuration purposes, so the
monitor and system can work together.
Note: - If a display device has digital input ports, like DVI or HDMI, but without EDID in its Main Board, the display device will show no image while the input source is digital signal. - The EDID Upgrade procedure for BS275 is the same as BX275, we take BS275 for example here.
6-2 Equipment Needed
Software
- EDID Program
- EDID File (*.ini)
Hardware
- Projector
- Power Cord for Projector (42.50115G001)
- VGA Cable (42.87305G102)
- Generic Fixture (80.00001.001) for EDID Key-in (Fixture: JP3 must be closed)
- RS-232 9 Pin Cable (pin to pin, F-M) (42.83C07G001)
- Power Adapter (42.50115G001)
- Monitor
6-3 Setup Procedure (VGA)
1. Connect all ports
(1) Connect P1 of fixture with COM Port of
PC/Laptop by RS232 Cable.
(2) Connect P3 of fixture with RGB-IN Port
of projector by VGA Cable.
(3) Plug Power Adapter to JP1 of fixture.
(5) Power on fixture.
(6) Plug Power Cord to projector.
Note: -You must confirm that the JP3 is closed in all procedure.
6-4 EDID Key-In Procedure
1. Execute EDID Program
- Double click "EDID" to execute EDID
program.
JP3 Adapter RS232 Cable VGA Cable JP1 P1 P32. Process
(1) Select the COM Port which you are
using.
(2) Click "Model".
(3) Select the EDID file (*.ini).
(4) Click "Open".
(5) Key in the Serial Number into the
Barcode blank space.
(6) In "Write Source Select" item, select
"VGA".
(7) Click "Program".
3. Change the cable to VGA
- When the message "Please change the
cable to VGA" appears on the screen,
click "OK".
(1) (2) (3) (4) (5) (6) (7)4. When the EDID program is completed, a
message "OK" will appear on the screen.
5. Read EDID "VGA" information
- In "Read item", select "Analog" and
"Trans", then click the "Read".
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.
22 21 20 19 18 17 16 15 14 13 10 7 6 5 4 2 3 8 9 1 24 23 29 28 30 27 25 26 5 31 32 33
Item P/N LG P/N Description BX275 BS275
5.8HC0G00 COV05290 TOP COVER MN600H BLACK BS275 v
5.8HC0G0 COV0500 TOP COVER MN600H BLACK BX275 v
2 80.8CP05G00 COV08690 PCBA IR SENSOR BD FOR X6 v v
5.8CS0G02 COV05280 FRONT COVER FOR IR PC MN600H BLACK ES526 v v 4 49.8CP02G00 COV05250 SUNON 70*70*20mm AXIAL FAN, SHRINK TUBE, WIRE
LENGTH 55mm
v v
5 80.8LP04G00 COV087002 PCBA PHOTO SENSOR BOARD FOR ES526X PROJECOR v v 6 70.8HC09GR0 COV0550 ASSY COLOR WHEEL MODULE BS275, BX275(SERVICE) v v
7 70.8HC0GR0 COV08820 ASSY ROD MODULE BS275, BX275(SERVICE) v v
8 49.8CS0G002 COV05260 SUNON 45*20mm GB245PKV-8AY, F TYPE BLOWER v v 9 70.8CQ4GR0 COV08640 ASSY LAMP DRIVER MODULE X26 D (SERVICE) v v
0 49.8CQ0G00 COV0860 SPEAKER 2W 6OHM DAB28 90mm X26 v v
SP.8HF0GC0 COV0890 LAMP MODULE FOR PROJECTOR Z5-XGA/Z5-SVGA v v 2 70.8HC2GR0 COV08900 ASSY LAMP COVER MODULE BS275, BX275(SERVICE) v v
52.8EH05G00 COV050 RUBBER ADJUST FOOT ES526 v v
4 5.8CS02G00 COV05270 BOTTOM COVER PC MN600H BLACK PDG-DSU0 v v
5 75.8AA04G00 COV08660 BUY ASSY INTERLOCK SWITCH 409X v v
6 75.8CP0GP0 COV08670 LVPS 80W X6 STB<W CT-258C v v
7 70.8HCGR0 COV08860 ASSY IO COVER MODULE BS275, BX275(SERVICE) v v 8 70.8HCGR0 COV0502 WHOLE ASSY ENGINE MODULE 800*600 8HC(SERVICE) v
70.8HF05GR0 COV050 WHOLE ASSY ENGINE MODULE 024*768 8HF(SERVICE) v
9 80.8CP02G00 COV08680 PCBA DMD BOARD FOR X6 v v
20 48.8CQ0G00 COV08740 0.55" XGA 2xLVDS SERIES 450 DMD -8 TI 8060-60cB v
48.8EH0G00 COV08750 0.55" SVGA 2xLVDS SERIES 450 DMD -8 TI 8060-60cB v 2 80.8HC0G00 COV087301 PCBA MAIN BD FOR LGE BS275 NEW PHOTO SENSOR v
80.8HF0G00 COV087102 PCBA MAIN BD FOR LGE BX275 NEW PHOTO SENSOR v
22 42.0004G00 COV0860 FFC KEYPAD TO FORMATTER BD 6P P=0.5 22mm HD80 v v 2 80.8HC0G00 COV08720 PCBA KEYPAD BD FOR LGE Z5-SVGA PROJECTOR v v
24 52.8HC0G00 COV0520 KEYPAD RUBBER FOR BS275, BX275 v v
25 42.505G00 COV08620 CABLE POWER CORD .8M SP0+IS4 US v v
42.000G0 COV08580 CABLE POWER CORD .8M SP-62/IS-4 UK DIS-WARNING LABEL
v v
42.0020G0 COV08590 CABLE POWER CORD .8M SP-02/IS-4 EUROPE DIS-WARNING LABEL
Appendix B
I. Serial Number System Definition
Serial Number Format for Projecto
Y MM RR CC SSSSS
1 2
3 4 5
1:
Y = YEAR(Last digit of Year) (ex:2010 = 0)
2:
MM =Month(Jan = 01,Feb =02,...Dec=12)
3:
RR =Site code for each production factory (For Coretronic:CT)
4:
CC =Code is self-produced by coding program.
5:
SSSSSS = Serial code (00001~09999)
EX:
This label "003CTCC00001” represents the serial number for LG. It is produced in China
Coretronic on March, 2010. Its serial code is 00001.
II. PCBA Code Definition
PCBA Code for Projector
A B XXXXXXXXXX
C XXX
EEEE
1 2
3
4
5
6
1
:
ID
2
:
Vendor Code
3
:
P/N
4
:
Revision
5
:
Date Code
6
:
S/N
Appendix C
New photo sensor board Reworking SOP
Note:
1.This procedure only for reworking old photo sensor(80.8EG04G002) to improve auto
shutdown, image flicker issue
2. The new photo sensor(80.8LP04G001) board must match with new main board
The PN of new main board of BS275 is 80.8HC01G003
The PN of new main board of BX275 is 80.8HF01G003
3. For main board rework, refer to chapter 2 (2-1~2-9)for details
1. Parts Required
Coretronic P/N LG P/N Description Quantity
80.8LP04G001 COV30387002 PCBA PHOTO SENSOR BOARD
85.1A126G080 COV31453101 SCREW PAN MECH M2.6*8 NI
51.8HH17G001 COV31453201 PHOTO SENSOR BD SPACER
