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DLP Training 2003 SAMSUNG Copia
Transcript of DLP Training 2003 SAMSUNG Copia
DLP TRAINING
2003Samsung Product Support Department
PAGE 2
Background
Samsung introduced their new DLP technology projection televisions in 2002. DLP stands for
Digital Light Processor.
The current models (as of 04/30/03) are the:
HLM 437, HLM 4365 , HLM 507, HLM 5065, HLM617,
HLN 437, HLN 4365, HLN 507, HLN 5065, and HLN 617
DLP is quite different than conventional projection television, which uses three separate color CRT’s. These separate video signals are projected and combined on the screen. DLP, on the other hand, has no CRT’s. Instead, one high intensity lamp is used to project one image on the screen.
DLP technology was first developed by Texas Instruments.
The heart of this technology is the DMD, or
Digital Micromirror Device.
It has 922,000 tiny mirrors on one ¾ inch panel.
Each mirror represents one pixel on the screen. The maximum
resolution is 1280 x 720. Control signals are sent to each
mirror, causing them to rotate plus or minus 12 degrees.
This is how the luminance is controlled.
PAGE 3
The Chrominance is controlled by a Color Wheel.
It has six separate segments, all different colors.
This wheel spins at 9,000 RPM. Timing controls synchronize
the color wheel position and the DMD signals, resulting in the
final video signal projected to the screen.
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Light Engine Breakdown
PAGE 5
Initialization Process
1. Standby LED on Digital Board ON (5V)
2. Power on signal from keypad/remote to Digital PCB.
3. Power ON signal generated by Digital PCB> Analog PCB> PSU
4. All other voltages turn on.
5. Digital PCB tells fans to turn on.
6. Digital PCB tells DMD PCB to turn color wheel on.
7. DMD / digital PCB’S check feedback signals from fans/ color wheel.
8. If OK, Digital PCB Tells ballast to turn lamp on. LAMP ON.
9. Digital PCB then checks “lamplitz signal” from ballastfor status OK.
PAGE 6
Board DescriptionsPower Supply Board
Supplies DC Voltages:
CN 803
Ballast Drive
(380 VDC , Always ON)
PAGE 7
Digital BoardMicroprocessor (Generates Turn on Signal to power board)
Monitor LED’s
Fan Control
All Digital Video Processing
Sensor / Switch Controls
OSD / Menu
PAGE 8
Digital Board Layout
PAGE 9
Digital Board Characteristics
PAGE 10
Analog PCB Transfers Power from Power Board to Digital Board
Transfers Turn-On Command from Digital Board to Power Board.
Encompasses the majority of the Audio Circuit
Analog Video Switching / Processing
PAGE 11
Analog PCB Layout
PAGE 12
Analog PCB Characteristics
PAGE 13
DMD BoardControls Lamp Turn-On
Powers Color Wheel Motor (IC104)
Drives DMD Panel (IC117)
Sensor Controls DMD PANEL
Attaches to Light Engine
With cover removed.
PAGE 14
DMD Board Layout
CN 106
SEE BELOW
NOTES SCI : LAMP ON = SVDC , LAMP OFF = 0 V
LAMPLITZ : LAMP ON = 4VPP , LAMP OFF = 0 V
PAGE 15
Light Engine Assy’
projection lens color wheel lamp
remote sensor
illumination lenses
DMD board
fan
filtering lenses
fan ballasttemp. sensor (80 degrees C)
PAGE 16
Front LED’s
Normal Operation Indications for Front LED’s
(Stand-By Mode) Red LED = Not Lit(Power On Mode) Lamp LED = On
Will Flicker before turn on
Front LED’s
HLM 4365W / 5065W
TIMER
LAMP
TEMP.
TIMERLAMPTEMP.
ALL Other Models
PAGE 17
LED Status Chart
Lamp LED will blink for 25 seconds after powered on, before picture appears.
PAGE 18
TroubleshootingDEAD SET
Is 5V standby LED lit on digital board? Replace digital
board (see pg. 29)Check
power to analog board
CN111 (see pg. 13)
No OK
Yes
Make sure CN 304 on digital board is
connected(see pg. 9)
NG Reconnect CN 304OK
Replace keypad or digital board (see
pg. 29)
PAGE 19
Blinking Temp LED
Check Temp Sensor connector CN306 on
Digital Board
NGRe-insert connector
OK
Install jumper across Temp Sensor Terminals. Does it work?
No
Replace digital PCB (See pg. 29)
Yes
Replace temp sensor.(see pg. 16)
PAGE 20
Blinking Temp and Timer LED
Replace Digital boardAre fans running?Yes
No
Check for 7VDC fan
voltage(s) at CN315,317,320
on digital board (see pg. 10)
OKReplace fan(s)
NGOK
Replace Power
board (see pg. 34)Check CN 801 pin 15 for
5V dc turn on voltageCheck CN 801 pin 12 on power
board for 7 VDC (see pg 7) NG
OK NG
Replace Analog board
(see pg. 28)Replace Digital
board (see pg. 29)
PAGE 21
Blinking Temp, Timer & Lamp LED’s
Check or replace Lamp
PAGE 22
Reconnect CN 108 (DMD board) cable to Digital board.(see pg.15)
OK
OK
Check power to DMD board CN 106
(see pg. 15)
NGOK
Replace DMD board.
(see pg. 33)
Replace Power board
(see pg. 34)
Blinking Lamp , Temp. LED’s
Is lamp cover installed?No
Install lamp cover
Make sure lamp cover switch is activating
NG
Yes
OK
Short CN 310 on
digital board pins
( see pg. 9)
Check boss on lamp cover
NG Replace digital
board (see pg.29)
PAGE 23
Blinking Lamp LED
A blinking lamp LED is the most common failure indication. It can be caused by no lamp, no color
wheel, no fan(s), or other defective components. (refer to initialization process on pg. 6).
Do fan (s) run?
NO YES
Refer to pg. 21 Does color wheel run?
NO YES
Check Color wheel
drive signal on DMD PCB,
CN 110 pin 4 (see pg. 15)
Is lamp on?
YES NO
PAGE 24
Replace DMD PCB
(see pg. 33)NO YES See next page
Replace DMD PCB
(see pg. 33)
Replace color wheel assy’
(see pg 32)
Blinking Lamp LED (cont.)
Check 380V dc to lamp ballast (CN 1)
Measure with DC meter Does lamp come on, then shut off?
NO
PAGE 25
YESNG
Re-install lamp assy’
(see pg. 27)
Check 4 V pp at CN 107 pin 3 on
DMD PCB
(see pg. 15)
Replace Power Board
(see pg. 34)NG
Check pin 1 on CN 107
on DMD PCB for 5V dc
(see pg. 15)
OK
Replace lamp assy’ or ballast
(see pg. 27,31)
Replace DMD PCB
(see pg. 33)
NG Replace ballast
or lamp
(see pg. 27,31)
OK
NG
Disassembly / Unit Replacement
Rear Cover Removal
1. Remove (14) screws as shown.
2. Remove cover.
PAGE 26
Lamp Replacement
1. Remove lamp cover screw.
2. Remove side cover.
3. Remove two screws holding lamp assy’
4. Pull lamp assy’ out using handle.
5. Replace lamp. Re – install (2) screws.
6. Replace side cover.
7. Tighten side cover screw.
8. Go into service mode adjustments
(see pg. 35)
9. Highlight “options”
10. Select “lamp clear”
11. Press volume plus to reset lamp counter.
Note: There are two different
types of lamps. Make sure you
order for correct model (see pg. 54)
PAGE 27
Analog Board
1. Remove rear cover
(see pg. 26)
2. Remove (7) screws holding
plastic terminal panel as
shown.
3. Remove all connectors from
analog board.
4. Slide board out through rear.
PAGE 28
Digital Board Removal
1. Before replacement, go into
service mode and retrieve the
DELAY setting(see pg.36).
2. Remove rear cover (see pg. 26)
3. Remove plastic terminal panel
from analog PCB. (see pg. 28)
4. Disconnect all connectors from
PCB.
5. Remove (8) screws holding
PCB and bracket as shown.
6. Remove PCB and bracket.
7. After replacement, re-input delay setting, check lamp type, fan number,
and perform USERRESET in service mode. (see pgs. 36,43)
PAGE 29
Light Engine
1. Remove digital PCB (see pg.29)
2. Remove (1) screw as shown
3. Pull light engine assy’ out two
inches, and remove all connectors
to DMD PCB, and ballast.
4. Slide light engine assy’ out
completely.
PAGE 30
Ballast
1. Remove light engine assy’ (see pg. 30)
2. Remove all connectors to ballast.
3. Remove (4) screws attaching ballast
to light engine
4. Remove ballast PCB.
Note: There are two different types of ballast PCB’s.
The 61 inch models (617) use a ballast with GREEN PCB.
All other models use ballast with TAN PCB.
Part numbers are in service bulletin DLP03-006.
PAGE 31
Color Wheel
1. Remove light engine assy” (see pg. 30)
2. Remove (3) screw holding color wheel cover.
3. Remove cover.
4. Remove (2) connectors from
DMD PCB to color wheel.
5. Remove (3) screws holding color
wheel ass’y.
6. Remove color wheel assy’.
PAGE 32
7. Before re-assembly, blow out any dust
from the light tunnel area with compressed air,
and apply electrical tape over ends of cover.
DMD Board
1. Remove light engine. (see pg. 30)
2. Remove all connectors from DMD
PCB.
3. Remove fan assy’.
4. Remove (6) screws holding DMD
PCB as shown.
5. Perform Tilt adjustment
after replacement of
DMD PCB (see pg. 46)
PAGE 33
Power Board
1. Remove Analog PCB (see pg. 28)
2. Slide Power board out slightly.
3. Remove all connectors on power
PCB.
4. Slide out power PCB completely.
PAGE 34
Adjustment:Electronic adjustment in EPROM Adjustment:
PAGE 35
Adjustment locations:
1. DDP1010
PAGE 36
2. DNIe
fixed
fixed
PAGE 37
3. AD9883(Component/480P)
PAGE 38
4. VCP3230 (RF/S-video)
1. DDP10101. DDP10101. DDP1010
PAGE 39
4. VCP3230; (RF/S-video) continued
4. VPC3230 (480I)
PAGE 40
5.JAGADC (PC)
PAGE 41
6.FLI2300 (RF/S-video/480I)
PAGE 42
7. 3D_COMB: (all)
8. OPTION (all)
2550
PAGE 43
Adjustment Notes:
1. Item # 2 (DNIe) is MN82860 on some early versions of HLM models.
2. Item # 6 (FLI2300) is FLI2200 on some early versions of HLM models.
3. Item # 7 (3D comb) is not on some early models.
4. EER RESET should only be performed after a software upgrade.
5. DVCO is for engineering use only.
6. WB DEFSET should always be set to OFF.
PAGE 44
Mechanical Adjustment Focus adjustment:
Remove pin carefully
PAGE 45
PAGE 46
Tilt adjustment:
SERVICE BULLETINBulletin #: DLP03-002
Subject: No power, or intermittent power. Shutdown.
Background: Set will have no power intermittently, sometimes works “OK” for a few days. Shutdown intermittently.Solution: There are few different problems that cause no power or shutdown. They all listed in order to be checked. 1) Re-solder all connections on Power PCB.2) Replace resistors on Power PCB. “see figure”
2008-001050RSF801
2003-002194RS801
Part #Location
PAGE 47
SERVICE BULLETINBulletin #: DLP03-002
(Continued)
3) Replace Power PCB. See parts list for part #
4) Reseat Lamp
5) Check interlock switch on back of set.
PAGE 48
SERVICE BULLETINBulletin #: DLP03-003
Subject: Picture has 2” to 4” circler blemishes on screen. These blemishes are most noticeable in dark scenes and can be of any color.
Background: Optical engine has projection lens assembly in final stage, the lens in this assembly has become contaminated.
Solution: Replace projection lens assembly. Part # = BP67-00032A
Note: Refer to Light Engine Disassembly and Focus Lens Alignment Procedures.
PAGE 49
SERVICE BULLETINBulletin #: DLP03-004
Subject: Squealing noise comes from set, near optical engine area.
Background: When set is turned on, optical engine color wheel will have a squealing noise from the motor bearing.
Solution: Replace color wheel. Part # BP96-00250A
Remove Color WheelRemove CoverPAGE 50
SERVICE BULLETINBulletin #: DLP03-005
Subject: Poor color, overall gray scale is greenish, reddish or bluish.
Background: Set has poor black and white tracking. Black areas of picture don’t show true black.
Solution: Adjust service mode, Red, Green and Blue gains. Enter service mode:
Set-Up:
1) Apply gray scale pattern to Video 1 input.
2) Power set on, select and display gray scale pattern. Using customer menu, select picture mode. P Mode should be CUSTOM. Contrast 90. Brightness 50. Color Tone NORMAL
PAGE 51
SERVICE BULLETINBulletin #: DLP03-005
(Continued)
3) Press Mute + 1 + 8 + 2 on remote. Power set on, service menu will display.
1 DDP 1010 (all)2 DNIe (all)3 AD98834 VPC32305 JAGADC (PC)6 FLI2300 “HLM617W” only7 3D_COMB8 Option
4) Service mode control keys:
Select item.Increase or decrease item value
Volume + / - button
Move cursor to itemChannel up / down button
Menu Display (Back)Main Menu
ActionRemote button
PAGE 52
SERVICE BULLETINBulletin #: DLP03-005
(Continued)
5) Select “DNIe” mode, adjust RGB GAIN & OFFSET items for best gray scale.
Blue offset0 ~ 255128B-OFFSET
Green offset0 ~ 255128G-OFFSET
Red offset0 ~ 255128R-OFFSET
Blue gain0 ~ 255125B-GAIN
Green gain0 ~ 255125G-GAIN
Red gain0 ~ 255125R-GAIN
DescriptionRangeDefaultItem
Data will be saved automatically when set is powered off.
PAGE 53
SERVICE BULLETINBulletin #: DLP03-006
Subject: Quick reference parts list.
Background: Most repairs are done using assemblies and board level. Solution: Use quick reference parts list.
BP59-00016ABP59-00016ABP59-00016ABP59-00016ABP59-00016ARemote Control
BP96-00250ABP96-00250ABP96-00250ABP96-00250ABP96-00250AColor Wheel assy’
BP96-00087BBP96-00087ABP96-00087ABP96-00087CBP96-00087CEngine
BP96-00249ABP96-00249ABP96-00249ABP96-00249ABP96-00249ADMD PCB
BP94-00385ABP94-00502WBP94-00502WBP94-00502WBP94-00502WMain Dig. PCB
BP94-00283ABP94-00283ABP94-00283ABP94-00283ABP94-00283AMain Analog PCB
BP94-00089ABP94-00087ABP94-00087ABP94-00087ABP94-00087APower PCB
AA94-11906AAA94-11917AAA94-11906AAA94-11917AAA94-11917ASide PCB
BP47-00003AAA47-00008AAA47-00008AAA47-00008AAA47-00008ALamp Ballast
BP96-00224BBP96-00224ABP96-00224ABP96-00224ABP96-00224ALamp Assy’
BP94-00311AAA94-11912AAA94-11904AAA94-11912AAA94-11904APCB Control
BP64-00098AAA67-00172AAA67-00172AAA67-00171AAA67-00171AFresnel Screen
BP64-00099AAA67-00169AAA67-00169AAA67-00168AAA67-00168ALenticular Screen
HLM617WXHLM5065WXHLM507WXHLM4365WXHLM437WXDescription
PAGE 54
BP59-00016A
BP96-00250A
BP96-00259A
BP96-00249A
BP94-00139V
BP94-00444B
BP94-00099A
BP94-00139Y
BP47-00003A
BP96-00224B
BP94-00139T
BP64-00098A
BP64-00099A
HLM617WS
BP59-00016ABP59-00016ABP59-00016ABP59-00016ABP59-00016ARemote Control
BP96-00250ABP96-00250ABP96-00250ABP96-00250ABP96-00250AColor Wheel assy’
BP96-00087BBP96-00087ABP96-00087ABP96-00087CBP96-00087CEngine
BP96-00249ABP96-00249ABP96-00249ABP96-00249ABP96-00249ADMD PCB
BP94-00385ABP94-00385ABP94-00502WBP94-00502WBP94-00502WMain Dig. PCB
BP94-00283ABP94-00283ABP94-00283ABP94-00283ABP94-00283AMain Analog PCB
BP94-00089ABP94-00087ABP94-00087ABP94-00087ABP94-00087APower PCB
AA94-11906AAA94-11906AAA94-11906AAA94-11917AAA94-11917ASide PCB
BP47-00003AAA47-00008AAA47-00008AAA47-00008AAA47-00008ALamp Ballast
BP96-00224BBP96-00224ABP96-00224ABP96-00224ABP96-00224ALamp Assy’
BP94-00311AAA94-11904AAA94-11904AAA94-11904AAA94-11904APCB Control
BP64-00098AAA67-00172AAA67-00172AAA67-00171AAA67-00171AFresnel Screen
BP64-00099AAA67-00169AAA67-00169AAA67-00168AAA67-00168ALenticular Screen
HLN617WXHLN5065WXHLN507WXHLN4365WXHLN437WXDescription
PAGE 55
SERVICE BULLETINBulletin #: DLP03-001
Subject: No sound.
Background: No sound when using tuner or any audio input.
Solution: Check plug connectors on Analog PCB, reset connector CN103. “see figure”
PAGE 56
Tech Tip
Subject: Distortion on screen as shown
Background: If dust gets on the light tunnel, it can cause picture distortions.
Solution: Remove light engine, and color wheel cover, and bow out any dust from the ends of the light tunnel.
PAGE 57
Tech Tip 5V STANDBY DIGITAL 5V (SWITCHED) 7V (FAN VOLTAGE , SWITCHED)
Subject: LED’S on Digital board.
Background: These LED’S can assist when troubleshooting.
Solution: The LED’S are as shown.
PAGE 58
SUBJECT: Video Problem SYMPTOM: Video appears as below- screen is mostly dark, with compressed video band at top of screen; white dots on a blackish/gray background.
REPAIR: Replace DMD Module and perform tilt adjustment.
TECH TIPS PRODUCT: DLP TIP VERSION: DLP03-001 MODEL: HLM507W
SUBJECT: DLP with White Vertical Line on the Left or Right side SYMPTOM: White Vertical line on Left or Right side If a customer has the SIRTS160 and a DLP , and states they are seeing vertical line down left or right side of their TV. When hooked up to DVI or RGB input only. S O L U T I O N: The SIR - TS160 has the ability to shift the screen up to a 1 1/4" to the left or right when connected to DVI or RGB. DLP TV from Samsung with a vertical line down one side or the screen shifted over, this is USUALLY not a problem with the TV. To access adjustment menu ,use the SIR-TS160 Remote Press Menu on Remote Arrow down to Setup Highlight installation Highlight Monitor You can now adjust by following the instruction at the bottom of the screen
TECH TIPS PRODUCT: DLP – SIR-TS160 TIP VERSION: DLP03-002 MODEL: DLP and SIR-TS160
TECH TIPSPRODUCT: DLP TIP VERSION: DLP03-003 MODEL: HLM507W
SUBJECT: No video and the unit is locked. SYMPTOM: The DLP turns on normally. Within half a minute the unit locks up with the symptom of no video. DLP must be unplugged to turn it off.
REPAIR: Check the connector CN107 on the DMD Panel. Pin 1 should go high (5V) to turn the Lamp on. Pin 3 is the feedback from the Ballast PCB. You should see approximately 4Vp-p pulses if the Ballast is working properly. If these conditions are not met, physically inspect the connector and try reseating it. If the connector is OK, replace DMD Panel and perform tilt adjustment.
DMD PANEL
SYMPTOM: No picture but, audio is OK. REPAIR: Check Lamp assembly and Lamp Ballast.
TECH TIPS PRODUCT: DLP TV TIP VERSION: DLP03-004 MODEL: HLM507W
SYMPTOM: Unit is dead. REPAIR: Check the Lamp.
TECH TIPS PRODUCT: DLP TV TIP VERSION: DLP03-005 MODEL: HLM507W