infocus LP815-820_ServiceManual

LP815/LP820 PDF service manual We designed this service manual for use on a computer. We suggest that you save it on your hard drive

and make a short cut to it from the desktop.

What is the difference between the LP815 and the LP820?

The two models have identical specifications, with the following exceptions:

♦ The LP815 has 2,800 maximum lumens, while the LP820 has 3,200 maximum lumens in high power

mode and 2,500 maximum lumens in low power mode. The LP815 does not have the low power/high

power option.

♦ The audible noise level of the LP815 is 34 dB, while the noise level of the LP820 is 38db in high

power mode and 34 dB in low power mode.

The two models are diagnosed and repaired identically. Only two part numbers differ between the two,

and each has its own system software.

The part number differences are listed below.

Part LP815 part number LP820 part number

Controller ECA 510-0909-xx 510-1755-xx

Label kit 802-0054-xx Various *

* The LP820 offers separate brand, certification, I/O and top labels. The LP815 combines the four labels into a kit.

Using the manual

The bookmarks that appear on the side of the screen help you navigate to each topic in the manual. You

can use them to quickly go from a troubleshooting topic to instructions to remove a specific part.

The manual is arranged in the order you can use to diagnose and then repair the projector. The four main

sections of the service manual are:

Troubleshooting— In this section, you will find troubleshooting flowcharts for a variety of symptoms. The

flowcharts lead you through power and image diagnostics, as well as audio, keypad and remote issues.

There is also a controller and power supply voltage diagram.

Parts Removal and Replacement—instructions to remove and replace each FRU in the projector. We’ve

also included a Removable Parts Hierarchy you can use to see what parts must be removed to access

each FRU in the projector. You can also refer to the Exploded View in the Parts Lists.

Performing Functional Tests—You use these tests to ensure that the projector is ready to return to the

customer after you have repaired it.

Parts Lists—In this section are the exploded view, the replaceable parts list and the kit contents lists. For

specifications, software updates and instructions, and current field communications, see your online ASC

Resource Center.

LP815/LP820 Service Manual

Troubleshooting

You use the Troubleshooting section to diagnose problems with the projector. In this section, you will find

troubleshooting flowcharts for a variety of symptoms. Each flowchart leads you through a series of steps

that will ultimately result in a solution. The solutions begin with the most simple and progress to the most

complex.

On the left, select the section you want.

Power problems, including lamp issues, partial power up, shutdown and no power

Image problems, including no image, bad color, dim image and other picture distortions

Keypad problems

Remote problems

Audio problems

In addition to the troubleshooting trees, you will also find a controller voltage diagram.


Power Problems The LP815/LP820 communicates its status via an LED and an LCD located on the keypad. When this

status LED is green, you know that the projector is working properly. When the status LED is solid red or

flashing red, you know there are lamp, power or startup problems. The frequency with which the status

indicator blinks red indicates one of several error codes. These error codes provide crucial information

about projector malfunctions. The LCD panel provides text messages related to the error messages.

Below is a table that shows the meaning the various LED states.

NOTE We strongly suggest that you follow the entire power diagnosis sequence.

LED Status

LED flashes green The projector is starting up after the Power button was pressed, or the projector is shutting down after the Power button was pressed.

LED is solid green The projector is ready to light the lamp when the Power button is pressed. Or the lamp is lit and the projector is operating properly.

LED flashes red once The lamp will not strike after five tries (2 1/2 minutes).

LED flashes red two times The lamp has more than 2,000 hours of use. Requires replacement. Projector shuts down.

LED flashes red three times Lamp failure. Projector shuts down.

LED flashes red four times One or more fans not operating. Projector shuts down.

LED flashes red five times High temperature condition. Projector shuts down.

LED is solid red Undiagnosed error. Projector shuts down


Power Diagnostics, Part 1

Plug the projector into a good powersource with a known good power cord.

Replace thepower supply

No, thefans

started butthe LED

did not light

Yes

Replace controller ECA

Replacepower supply

No Voltages OK?

Solid green

This is thenormalcondition.

Do the fansrun briefly andthe LED light?

No, thefans

did notstart andthe LEDdid notlight.

Red

Go to PowerDiagnostics, part 2

Go to ErrorCodes

This is the normal condition.

LED lightgreen or red?

Confirm that unit is goodby starting again.

Confirm that unit isgood by starting again.

Power Diagnostics, part 1

Solve theproblem?

Yes

Yes

No

Replace keypad ECA

NoteA solid greenLED means theprojector is eitherwaiting for acommand or isoperatingnormally.

A flashing greenLED means theprojector is eitherattempting to lightthe lamp or isshutting down.

Check the voltages at thecontroller/power supply

connector.

Confirm that thekeypad cable is

plugged in.


Power Diagnostics, Part 2

Press the Power button on the keypad

Did the lamp lightand the LED turn

solid green?

Go to Error Codes

Is the LEDflashinggreen?

No, theLED

remainssolid green.

Press the Powerbutton again.

The LED continues flashinggreen until the lamp lights.

Yes

Yes

The Startup tone sounds.The fans spin up, then slow.

The color wheel spins up.

This assumes you have plugged thepower cord in and that the LED issolid green. If not, go back to Part 1.

The LED remains solid greenafter pressing the Power buttontwice. The lamp does not light.

Replace keypad ECA

Repeat process to confirmthe problem fixed.

Run the projector long enough toensure that the problem is solved.If the lamp goes out and the LED

turns red, go to error codes.

No. The lamp doesnot light, and the

LEDbegins blinking red.

The lamp attempts to strike five times at30-second intervals. After 2 1/2 minutes,the projector no longer tries to strike the

lamp and the LED begins flashing red.

Power Diagnostics, part 2

NoteA solid greenLED means theprojector is eitherwaiting for acommand or isoperatingnormally.

A flashing greenLED means theprojector is eitherattempting to lightthe lamp or isshutting down.

Replace controller ECA

Solve theproblem?

NoYes


Error Codes

Interpret red LED behavior

Flashing

Is the LED steady orflashing?

Steady

An internal error occurredthat the projector cannot

identify.Diagnose the error.See Solid Red LED.

What is theflashing pattern?

Red LED flasheshave 2-second

intervals betweenseries of flashes. For

example, the LEDmay flash 4 times,then pause for 2

seconds, then flash4 times again.

Power Diagnostics, Error Codes

5 flashesThe projector detects

high internaltemperature.

Diagnose thermalproblems.

OnOff

4 flashesA fan failed.

Check the fans.

OnOff

3 flashesThe projector detectedan internal error andshutdown the lamp.

Diagnose lampshutdown.

OnOff

2 flashesThe lamp timer registerslamp use of 2000 hours

or more.Replace the lamp.

OnOff

1 flashThe lamp failed to strike

after five attempts.Diagnose lamp strike

failure.

OnOff

LAMP WON'T STRIKE

Keypad LCD messages

REPLACE LAMP LAMP FAILURE

FAN FAILURE SHUTDOWN...10 OVER TEMP CONDITION

OVER TEMP CONDITION SHUTDOWNFAN FAILURE SHUTDOWN...1

RETRYING WAIT...

Repeats


LED flashes repeated red single-flash sequence

The lamp won't strike after five attempts. The statusLED flashes a repeated red single-flash sequence.

Verify the repair byrestarting the PowerDiagnosis process.

Ensure that the lampdoor is present and shut.

Voltages goodat power supply/

controllerconnector?

No

Replace the lampmodule.

Yes

Ensure that the safety switch cable isconnected to the power supply. Also, ohm

out the interlock switch and the thermalswitch to make sure they are good. If not,

replace the safety switch assembly.

Replace theballast.

Replace controllerECA

Replace powersupply.

Yes

Ensure that the lamp controlcable is connected to the

controller ECA and the ballast.

Can you hearthe safety switchopen and close?

NoReplace safety

switch.

Verify the repair byrestarting the PowerDiagnosis process.

Solve theproblem?

No

Yes

LAMP WON'T STRIKE

LCD Message

RETRYING WAIT...

Repeats


LED flashes repeated red three-flash sequence

The lamp was operating but shut down. Fans arerunning. The status LED flashes a repeated

red three-flash sequence.

Reinstall the lamp,ensuring that it isproperly seated.

Solve theproblem?

No

Replace the ballast. If the projector fails to start properly,you may see the status LED flash arepeated red single-flash sequenceindicating that the lamp won't strike.See LED flashes a repeated redsingle-flash sequence.

Replace the lamp.

Solve theproblem?

No

Yes

Run the projector longenough to ensure that the

problem is solved.Yes

Repeat the diagnosticprocess to ensure thatthe problem is solved.

NoteIf the projector isoperated in a hot

environment,especially at highaltitudes, the unitmay overheat andshut down when

the thermal switchopens. The only

solution for this isto let the projector

cool down. TheLP650 should not

be used whereambient

temperatures areover 95º F (35º C).

LAMP FAILURE

LCD Message


LED flashes repeated red five-flash sequence

It is very rare that a thermal switch opens under too little heat.Check the thermal switch. Power up the projector with the top off. Letthe projector run until it shuts down. Measure the resistance at theswitch. If the resistance is infinity (open), the thermal switch is bad.

Projector shuts down after detecting high temperaturecondition. LED flashes in repeated five-flash sequence.

Replace the controller ECA.

Substitute a good power supplyand run projector long enough to

know if that is the problem.

Yes

This is a thermal problem. If a fanisn't running it causes a power upproblem because fans have asensor line that prevents theprojector from properly starting up.

Is the thermalswitch good?

Replace the safety switch.

The problem is almostalways a power supply orcontroller board with athermal breakdownproblem.

No

The safety switchassembly includesa thermal switch..

Solve theproblem?

No

Run the projector long enough toconfirm the problem issolved.Repeat the diagnosis process.

Yes

NoteIf the projector isoperated in a hot

environment, especiallyat high altitudes, the

unit may overheat andshut down when the

thermal switch opens.The only solution for this

is to let the projectorcool down. The LP650

should not be usedwhere ambient

temperatures are over95º F (35º C).

Ensure that the dust filteris not clogged.

OVER TEMP CONDITION

LCD Messages

OVER TEMP CONDITION SHUTDOWN


LED is solid red

Replace the power supply.

LED solid red.Fans may or may not be running.

Powersupply

voltages good?(except lamp

enable)

No


Yes

Replace the optical engine.

To confirm that theproblem is solved, restart

the diagnosis process.


Check fan operation

You can do a visual check on the fans. Remove the top case and power the projector up using the remote

control. Use the illustrations below to verify that a fan or blower is operating. If you identify a fan that does

not work, plug a known good fan into the connector on the controller ECA. If the good fan does not

operate, the problem is likely in the controller ECA.

Go to the next page.


Image Problems

Dim imageSee Dim Image

at left.

Bad or missing tint or colorMissing logo, VGA, composite

video, or S-videoDistorted image, noisy, rolling,

torn, frozen, 'plaid', repeated, orshifted image.

See Bad Colors at left.

No image at all.Vertical or horizontal

lines.Sparkley picture.Clusters of dark

pixels.See No Image at

left.

The image is not correct.The projector starts and runs normally.

The menus are accessible. The lamp is lit.

Flash the projectorwith the latest software.

Confirm that all imageadjustments are set to

the factory defaults.

Select Factory Resetfrom theSettings>Service menu.

Confirm that the cablesand the source signals

are good.

If in doubt, feed thesignal to a goodprojector.

What is theproblem?


No image

No image.

Vertical lines. Horizontal lines.

Sparkly picture. Clusters of dark pixels.

Replace the controller ECA

Is the imagecorrect?

No

Replace the optical engine

Bad colors

Bad or missing tint or color.

Missing startup screen, VGA, composite video or S-video.

Distorted image, excess noise, rolling image, torn image, frozen image, 'plaid' image,repeated single image, or shifted image.

Make sure cables are good.

Is the imagecorrect?

No



Dim image

Dim image

Substitute knowngood lamp

Replace the lamp.Is the imagebrighter?

Yes

Substitute a known goodcontroller ECA.

Replace the controller ECA.Is the imagebrighter?

Yes

No

Replace the optical engine.

The lamp takes about 90seconds to achieve full

brightness.

No


Keypad Problems

There are IR lenses on the frontand both sides of the projector.Make sure you try the remotethrough at least two lenses. If oneor more IR receivers do not work,go to Remote problems.

Keypad does not respond to key presses

Does theremote control

work?No Replace the controller ECA.YesReplace the keypad ECA


Remote Control Problems

Infrared remote problem

Does theremote work?

No

Use known good batteries in the remote.

Replace the remote.

Does theremote work?

No

Aim the remote at each of the IR receivers on theprojector. There are IR receivers on three sides of theprojector: the front, right and left sides. Issue a remote

command to each receiver.

No


Responds to the rightand left IR receivers,but not the front IR

receiver

Replace thefront IR ECA

Does not respond toany receivers, or

responds the frontreceiver but not the

right and/or leftreceviers.

Check the IRcable


Audio Problems

No audio or sound is scratchy or distorted.

Replace the speakers

But note:A shorted speaker can damage the stereo

audio amp on the controller ECA.Run the projector with audio for 30

minutes.If the problem returns, replace both thecontroller ECA and the top case if the

resistance across either speaker coil nolonger measures approximately 16 ohms.

Is theresound?

Yes

No

Is there soundfrom bothspeakers?

No,onlyone


Yes

Problem solved.

Make sure the speaker cable isconnected to the controller ECA.


Controller and Power Supply Voltages


Parts Removal and Replacement

Removable Parts Hierarchy The flow chart below shows what parts must be removed to access each FRU in the projector. The parts

on the first level (the lamp door, for example) are accessible without removing any other parts. The more

levels down a part is, the more parts you need to remove.

Lamp door

Start

Filter door

Keypad ECA

Focus andzoom rings

Rear Bezel

IR ECA

Lamphousing

Bottom case(Remove all FRUsto replace case)

Speakers

Ballast

Lamp module

OpticalEngine

Top case

Elevatorbutton

Power supply

ControllerECA

Safety switchcable

Lamp blower& bracket

LCD cover

Top cover

Keypad

LCD blower

Lamphousing air

guide

Engineblower &bracket

Handle

Power supplyfan Elevator foot

& actuator

Leveling foot& shaft

Front IRwindow

R & L IRwindows

Controller/power supply

cable


Lamp Module The lamp module (SP-LAMP-012) fits inside the projector, and is protected by the lamp door (505-1641-xx). You access the lamp from the bottom of the projector. Once you remove the lamp door, you

have access to the dust filter (420104).

Lamp module Lamp door Dust filter

Lamp door

♦ Loosen the two captive screws that fasten the lamp door to the projector. Then lift the door off.

Lamp module

♦ Loosen the three captive screws that fasten the lamp module to the projector. Then lift the module out

of the projector using the built in handle.


Dust filter removal and cleaning

1 Lift the tab that secures the filter door to the projector. Then remove the filter.

2 Use a vacuum to remove the dust from the inside and outside of the filter.

Assembly Notes

♦ If you install a new lamp, you need to reset the lamp counter.

1. Turn the projector on.

2. Press and hold the Volume + and Volume - keys for 10 seconds.

The LED will turn from red to green, and the lamp ignites.

You can also reset the lamp counter in the projector menu. Go to Main Menu > Settings >

Service > Lamp Reset.

3. To verify that the lamp timer is reset, select About on the Main menu. The lamp hours are

listed in the About box.


Rear Bezel The rear bezel (505-1596-xx) covers the back of the projector. It fits over lips on the top case and the

bottom case, helping to keep the case halves secure. It fastens to the projector with seven screws.

When you replace the rear bezel, you need to adhere a new brand label to the bezel.. Order part number 020-1823-xx for the LP820 or the label kit (802-0054-xx) for the LP815.

The I/O panel label (020-1822-xx) is included with a new rear bezel. The I/O panel label is available as a separate part for the LP820 and is included in the label kit (802-0054-xx) for the LP815.

♦ Remove the eight black M3.5x7 Plastite screws that fasten the rear bezel to the bottom case and the

controller ECA. Two screws are located in the center of each rubber foot on the ends of the bezel. Six

screws are located on the I/O panel. Then remove the bezel.


Assembly notes

♦ Tighten the M3x7 screws to 7 in/lbs (.8 Nm).

♦ If you are installing a new rear bezel, adhere a rear brand label to the bezel.


Top Case The top case (505-1584-xx) covers the top half of the projector. Once you remove the top case, you

have access to the replaceable parts inside the projector, and you can measure controller ECA voltages.

NOTE The top case has a number of replaceable parts fastened to it. If you are installing a new top case, the parts must be removed from the old case and fastened to the new one. See step 7 below.

1 Remove the rear bezel.

2 Place the projector upside down on the work surface.

3 Use a T10 Torx driver to remove the two M3x5 screws that fasten the top case to the bottom

case. The screws are located in recesses near the handle.

4 Place the projector right side up on the work surface.

5 Press the locking tabs on both sides of the top case, then lift the top case up. The tabs are

located at the center of each side.

NOTE There are cables inside the top case that are still attached.


6 Swing the top case forward so you can disconnect the keypad cable and the speaker cable from

the controller ECA.

7 Do one of the following:

Set the top case aside and proceed to the next part.

—Or—

If you are replacing top case or a part inside the top case, go to Top Case Contents.

Assembly Notes

♦ If you are installing a new top case, make sure you replace all the removable parts in the top case.

See Top Case Contents for information.

♦ Plug the keypad and speaker cables into their connectors on the controller ECA.

♦ To install the bottom case, first engage the tab in the front, then swing the top case downward. Press

the each side down to engage the locking tabs together until the case snaps into place.

♦ Torque the screws to 7 in-lb (.8 Nm).


Top Case Contents

Once you remove the top case, you have access to the replaceable parts inside the projector.

The parts below are fastened to the top case, and may be removed once the top case is off of the

projector. If you are replacing the top case with a new one, these parts must be removed and installed on

the new top case. Each of these parts is available separately.

♦ Speakers (412-0004-xx; includes two speakers cabled together)

♦ Speaker bracket (330-0999-xx; one for each speaker)

♦ Keypad/LCD ECA (510-1808-xx)

♦ Keypad cable (330-0999-xx; part of the Cable Kit [410480])

♦ Keypad (505-1624-xx)

♦ LCD cover (part of Hardware Kit [410483])

♦ Right and left IR windows (part of the IR window kit [410484])

♦ Top cover (505-1585-xx)

♦ LP820 Top label (20-1591-xx)

♦ LP815 top label available in the Label Kit (802-0054-xx)

♦ Elevator button (part of the Adjustable Feet Kit [410482])

Speakers

The speaker set is wired to a common connector. Both speakers must be replaced at the same time.


1 Remove the three M3.5x6 Plastite screws that fasten the speaker bracket and speaker to the top

case.

2 Remove the bracket from the speaker.

3 Repeat the steps above for the other speaker.

4 Lift the two speakers out of the case.

Keypad/LCD ECA, keypad, keypad cable and LCD cover

Keypad/LCD ECA Keypad Keypad cable LCD cover

1 Use a T10 Torx driver to remove the eight M3.5x6 Plastite screws that fasten the ECA to the top

case.


2 Lift the side of the ECA closest to the rear of the top case up so that the tabs that secure the

opposite side disengage from the edge of the ECA.

3 If you are replacing either the keypad cable or the keypad/LCD ECA, unplug the keypad cable

from its connector on the keypad/LCD ECA.

4 Once you remove the keypad/LCD ECA, you can remove the keypad from its position in the top

case.

5 To remove the LCD cover, lift one of the tabs, then pull the cover out of its hole in the top case.


Right and left IR windows

The IR windows are keyed so they fit only one way. The right and left windows are not interchangeable.

1 On the inside of the top case, press the two hooked tabs on the IR window to disengage the

window from the top cover.

2 Remove the window from the outside the case.

Top Cover

The top cover snaps onto the outside of the top case. The top label adheres to indented area near the

speaker grill.

1 On the inside of the top case, press the two hooked tabs adjacent to the keypad inward so that

they disengage the top cover.


2 Remove the top cover from the outside.

NOTE To replace the top cover, engage the three tabs at the front. Then align the tabs in the

center and rear, and press down. The top cover should snap into place.

Elevator button

The elevator button is part of the Adjustable Feet Kit. It mounts inside the top case and, when pressed,

engages the elevator actuator in the bottom case. Click here for information about replacing the other

elevator parts.

♦ On the inside of the top case, use a bladed screwdriver to disengage the tab on the elevator button

shaft from the top case. Then extract the button from the outside of the case.


Focus and Zoom Rings The focus ring and zoom ring mount on the lens barrel. Each ring turns independently to adjust the

focus and zoom settings. The two rings are available in the Zoom and Focus Ring Kit (340-1031-xx).

You only need to remove the focus and zoom rings when you are replacing the optical engine or if one of

the rings is broken.

Focus ring Zoom ring

1 Remove the rear bezel and top case.

2 While holding the focus ring stationary, rotate the zoom ring counterclockwise until the alignment

pins on the lens barrel disengage the slots on the zoom ring.


3 Push the zoom ring inward to expose the focus ring. Use a small bladed screwdriver to gently

disengage the pin on the lens barrel from its alignment hole in the focus ring.

4 Repeat the process for the next pin and alignment hole. Then pull the focus and zoom rings off of

the lens barrel.

Assembly notes

♦ When the focus and zoom rings are properly aligned, the words, "Focus" and "Zoom" should appear

aligned on top when the rings are turned counterclockwise until they stop. See the illustration below.

♦ To install the rings, slide the zoom ring onto the lens barrel first. Then slide the focus ring on and

snap the three tabs over the three matching alignment pins on the lens barrel. Then slide the zoom

ring forward and turn it clockwise to lock it in place. Make sure that both rings turn easily and

independently.


Front IR ECA and Window The IR ECA (510-1814-xx) and the front IR window (available in the IR Window Kit [410484]) mount to

the bottom case adjacent to the projection lens. The IR cable (available in the Cable Kit [410480]) connects the IR ECA to the controller ECA.

Front IR window IR ECA IR cable

1 Remove the rear bezel and the top case.

2 Unplug the IR cable from the IR ECA.

3 To remove the IR ECA, remove the M3.5x7 Plastite screw that fastens it to the bottom case.


4 To remove the IR window, from the inside of the bottom case, press the tabs on the window

inward. Then remove the window from the outside of the bottom case.

Assembly notes

♦ Insert the IR window into its hole from the inside of the bottom case. Then snap it into place.

♦ The IR ECA is keyed so that it fits only one way.


Ballast The ballast (525-0074-xx) provides high voltage to the lamp. It mounts to the bottom case at the front of

the projector. To remove the ballast, you also remove the handle and front vent, which are part of the

Mounting Parts Kit (410483).

Ballast Handle and front vent

NOTE Most of the illustrations below show the controller ECA removed. It is not necessary to remove the controller to access the ballast.

1 Remove the rear bezel and the top case.

2 Lift the handle and front vent out of the bottom case.

3 Disconnect the power supply/ballast cable from the ballast.

4 Disconnect the lamp blower, LCD blower and ballast control cables from the controller ECA.


5 Disconnect the lamp power cable from the lamp connector inside the lamp housing. It snaps into

place, so you may need to use a small screwdriver to remove the connector. Remove the cable

from the two cable clips on the lamp housing air guide and the cable clip adjacent to the ballast.


6 Remove the three M3.5x25 Plastite screws that fasten the ballast to the bottom case. Then lift the

ballast out of the bottom case.

7 If you are replacing the ballast, disconnect the ballast control cable from its connector on the

ballast.

8 Remove the ballast from the bottom case.


Assembly notes

♦ Connect the power supply/ballast and ballast control cables to the ballast before installing it in the

bottom case.

♦ Place the ballast into the bottom case so that the alignment pin in the bottom case fits into fits into the

hole in the ballast at the rear corner nearest the projection lens.

♦ Torque the screws to 7 in-lb (.8 Nm)

♦ Reconnect the other cables to the controller ECA. Make sure to route the lamp power cable through

its guides.

♦ Reconnect the lamp power cable to the lamp house air guide. Note that the connector is keyed so

that it fits only one way. The connector should snap into place.

♦ To replace the handle and front vent, align the tabs on the front of the handle with the slots in the

bottom case. Then lower the handle into place, making sure the alignment pin in the bottom case fits

into the hole on the side of the handle.


Engine Blower and Bracket

The engine blower and bracket (505-1623-xx) consists of a blower and a bracket. Both fasten to the bottom case adjacent to the projection lens.


2 Remove the M3x7 Plastite screw that fastens the blower and bracket to the bottom case.


3 Lift the blower and bracket out of the bottom case.

Assembly Note

♦ When you install the engine blower, make sure the alignment pin in the bottom case fits into the hole

near the blower duct. Then torque the M3x7 screw to 7 in/lb (.8 Nm).


Leveling Foot The leveling foot allows the user to adjust the horizontal image position by tilting the projector slightly to

the left or to the right. The foot includes a threaded shaft, which moves up and down as the foot is turned

clockwise or counterclockwise. The leveling foot and the shaft are part of the Adjustable Feet Kit (410482). The parts are not available separately.

Leveling foot, shaft and rubber insert

You can replace the leveling foot without disassembling the projector. To replace the shaft, you must

partially disassemble the unit.

Leveling foot

1 Turn the projector upside down on the work surface.

2 Use a small screwdriver to pry the rubber insert out of the hole on the bottom of the plastic

leveling foot.

3 Use a T10 driver to remove the M3x5 Plastite screw that fastens the leveling foot to the shaft.

Then pull the foot off the shaft.

When you install the foot, note that it is keyed, and fits on the shaft only one way.


Leveling foot shaft

1 Remove the leveling foot as shown above.


3 Unscrew the shaft from the inside of the projector. You can use your fingers to do this.


Controller ECA The controller ECA (LP820: 510-1755-xx; LP815: 510-1923-xx) is located beneath the top case on top

of the optical engine. It provides all control functions and processes the data and video signals. The

controller connects directly to the formatter ECA and power supply with connectors on its bottom.

NOTE Each optical engine includes a matched NV RAM chip, which plugs into the controller ECA. The NV RAM chip allows precise calibration of picture quality. When you replace an engine, you must remove the old NV RAM chip from the controller and install the new one. Likewise, when you replace the controller ECA, you must remove the chip from the old ECA and install it on the new one. See step 7 below.


2 Unplug the three ribbon cables at the center of the controller ECA. Each cable plugs into a ZIF

connector on the top of the controller ECA.

CAUTION The connectors are extremely delicate. A broken tab or connector requires replacing the controller ECA.


3 Unplug the cables from their connectors as shown below.

4 Use a T10 Torx driver to remove the five M3x5 Torx screws and three M3.5x7 black Plastite

screws that fasten the controller ECA to the optical engine.


5 Use a T10 Torx driver to remove the M3x5 Torx screw that fastens the I/O EMI shield to the

power supply.

6 Lift the controller off of the engine.

7 If you are replacing the controller ECA, do the following:

1. Remove the NV RAM chip and install it on the new controller. See NV RAM Chip for

instructions.

2. Remove the left IR gasket (available in the Cable Kit [410480]) from the controller. Note

the orientation of the gasket. You will install it on the new controller.

Assembly Notes

♦ If you are installing a new controller ECA, make sure to install the NV RAM chip from the old

controller. See step 7 above.

♦ Install the left IR gasket.

♦ Align the two holes on the ECA with the alignment pins on the optical engine (circled below). Make

sure the two connectors align properly before pressing the controller


♦ Make sure to connect all cables shown in step 3 above.

♦ Torque all screws to 7 in/lb (8 Nm).

♦ If necessary, flash the projector with the latest software.


NV RAM Chip The NV RAM chip plugs into a socket on the controller ECA. Each NV RAM chip is set up to maximize

the image reproduction for a specific optical engine. A unique chip ships with each new optical engine.

Thus, when an engine is replaced, the NV RAM chip installed on the controller ECA must be removed

and replaced with the chip that came with the new engine. Likewise, when you replace the controller

ECA, you need to remove the chip from the old controller and install it on the new one.

The NV RAM chip is not available as a separate replaceable part.

The procedure assumes that the controller ECA is already removed from the projector.

Remove the NV RAM chip

1 Turn the controller upside down on the work surface.

NOTE The controller ECA in the LP815/LP820 differs slightly from the controller ECA shown

below. The NV RAM chip is located near the I/O panel adjacent to the left IR window. Its

appearance is identical to the chip shown in these illustrations.


2 Use an IC puller or a small flat bladed screwdriver to remove the chip from its base on the

controller.

Install the NV RAM chip

1 Align the chip so that the eight pins align with the eight holes on the base. Then press the chip

into place.


CAUTION The pins on the NV RAM chip are delicate. Make sure that the pins are straight and that they align with the corresponding holes in the socket. Press straight down, making sure that you do not bend the pins while inserting them into the socket.


Controller/power supply Cable The controller/power supply cable runs between the power supply and controller ECA. It provides

power to the controller. The controller/power supply cable is available in the Cable Kit (410480).

The cable you are working with is color coded instead of white. Otherwise it is identical.

1 Remove the following items:

Rear bezel

Top case

Controller ECA

Power supply fan

2 Remove the two M3x7 Plastite screws that fasten the power supply to the bottom case.

3 Lift the power supply away from the optical engine enough to access the controller/power supply

cable. Then disconnect the cable from the power supply.

4 Lift the cable out of the bottom case. Note the cable routing.


Assembly Notes

♦ Plug the cable into the power supply, then fasten the power supply to the bottom case. Note that the

power supply ECA fits into four aligning tabs in the bottom case. Tighten the screws to 7 in/lb (.8 Nm).

♦ Route the cable bundle through the bottom case, making sure that it runs below the power supply fan

and will not be pinched when the projector is reassembled.


Power Supply Fan The power supply fan (526-0173-xx) blows outside air onto the power supply. It fits into a cavity in the

bottom case adjacent to the power supply and optical engine.

The power supply fan uses a rubber gasket to help dampen fan sound. The rubber gasket is available in

the Screw and Mounting Details Kit (410481).

To access the power supply fan, you must remove the power supply cover, which is part of the

Mounting Parts Kit (410483).


Rear bezel

Top case

Controller ECA


2 Remove the power supply cover. To do this, disengage the locking tab on the end of the power

supply cover adjacent to the lamp housing. Lift the end of the cover while sliding it toward the

power supply fan.

3 Lift the power supply fan out of the bottom case.

4 If you are replacing the power supply fan with a new one, remove the rubber gasket.

Assembly Notes

♦ Install the rubber gasket on the new fan so that the cable fits through the slot on the top of the gasket.

See the illustrations above.

♦ To install the fan in the bottom case, slide the bottom of the fan into the slots in the bottom case.

When the fan is installed correctly, the word, "UP" is on top, and the label on the fan faces inward.


Safety Switch Cable The safety switch cable (211-0243-xx) includes the lamp door interlock switch and the thermal switch. It

is replaced as an assembly. The individual switches are not available separately.

1 Remove the following parts:

Rear bezel

Top case

Controller ECA

Lamp housing air guide

When you remove the lamp housing air guide, you also detach the thermal switch from the top of

the lamp housing.

2 Remove the safety switch cable from the cable clip in the bottom case adjacent to the leveling

foot.

3 Remove the two screws that fasten the power supply to the bottom case. Then lift the power

supply out of the way so that you can access the interlock switch. Note that cables still attach to

the power supply.


4 Remove the interlock switch from its housing in the bottom case. To do this, use a small

screwdriver to pull back the retainer on the housing, then lift the switch out of the housing.

5 Unplug the safety switch cable from its connector on the power supply.

Assembly Notes

♦ When replacing the interlock switch make sure to orient the switch in proper direction. See the

illustration in step 4.

♦ When you reinstall the power supply, note that the ECA inside the unit fits into slots in the bottom

case. Make sure that the cables are routed cleanly in the cavity between the power supply and optical

engine.

♦ Replace the safety switch cable in the cable clip adjacent to the leveling foot before you install the

lamp housing air guide. See the illustration in step 2.


Lamp Blower and LCD Blower The lamp blower (505-1622-xx) includes a mounting bracket and blower. The assembly fastens to the

bottom case adjacent to the lamp housing, with ducting connecting the blower to the housing.

Once the lamp blower and bracket are removed, you have access to the LCD blower (526-0181-xx). Three rubber feet mount on the bottom of the LCD blower, keeping it in place and dampening noise

while the blower operates. The three feet are available in the Screw & Mounting Details Kit (410481).


Rear bezel

Top case

Controller ECA

Ballast

2 Remove the M3.5x25 Plastite screw that fastens the mounting bracket to the bottom case. Then

remove the power supply/ballast cable from the cable clip on the corner of the mounting bracket.


3 Lift the assembly out, working the lip on the end of the blower duct past the hole in the lamp

housing.

4 Lift the LCD blower out of the bottom case.

5 If you are replacing the LCD blower, remove the three rubber feet from the blower.


Assembly Notes

♦ If you are installing a new LCD blower, install the three rubber feet on the new blower. Then install the

blower in the bottom case. Make sure the blower duct fits into the hole in the bottom case, and that

the rubber feet fit inside the guides in the bottom case.

♦ To install the lamp blower and bracket, first insert the duct into its hole on the side of the optical

engine. Then align the base of the bracket so that the three posts in the bottom case fit inside the

matching screw holes on the bracket. Route the power supply/ballast cable through the slot in the

blower bracket.

♦ Secure the bracket with the M3.5x25 screw.


Optical engine The optical engine (410488) mounts to the bottom case below the controller ECA.

NOTE Each optical engine includes a matched NV RAM chip, which plugs into the controller ECA. The NV RAM chip allows precise calibration of picture quality. When you replace an engine, you must remove the old NV RAM chip from the controller and install the new one.


Lamp and lamp door

Rear bezel

Top case

Controller ECA

Power supply fan

Ballast

Lamp and LCD blowers


2 Remove the five M3.5x10 Plastite screws that fasten the engine to the bottom case. Then lift the

engine out.

3 If you are replacing the optical engine, do the following:

1. Remove the lamp housing from the optical engine.


2. Remove the NV RAM chip from the controller ECA. Make sure you return the chip with

the engine.

Assembly Notes

♦ If you are installing a new optical engine, install the matched NV RAM chip on the controller ECA. Go

to NV RAM chip.

♦ Before installing the engine, make sure the power supply/ballast cable is routed through the rubber

cable clips in the bottom case.


Power Supply The power supply (510-1741-xx) is located adjacent behind the optical engine. The power supply

converts 100-240 VAC supply voltage to various low voltage DC levels required internally by the

projector. The power supply interfaces with the ballast to control lamp strike and operation.

The power supply shown below has the white controller/power supply cable attached to it. The cable is

not included with the power supply. It is available in the Cable Kit (510-1741-xx). The power supply/ballast cable (not shown) is also available in the cable kit.

1 Remove the following parts:

Lamp and lamp door

Rear bezel

Top case

Controller ECA

Power supply fan

Ballast

Lamp and LCD blowers


Optical engine

2 Remove the two M3x8 Plastite screws that fasten the power supply to the bottom case.

3 Remove the power supply/ballast cable from the two rubber cable clips (available in the Hardware

Kit [410481]). Then lift the power supply out of the bottom case.


Assembly Notes

♦ Make sure to route the power supply/ballast cable through the rubber cable clips.

♦ The ECA on the power supply fits into slots on the bottom case. The slots help align the power supply

and keep it in place.


Lamp Housing The lamp housing (410487) encloses the lamp module. It fastens to the optical engine. You must

remove the optical engine to access the lamp housing.

1 Remove the optical engine.

2 Remove the two M3x5 screws on the top of the lamp housing.

3 Turn the engine/lamp housing assembly upside down on the work surface.

4 On the bottom of the lamp housing, lift the tab off of the locking pin, then swing the lamp housing

off of the engine.


Assembly Notes

♦ Slide the top of the lamp housing into place first. Next press the bottom on until the alignment pin on

the optical engine engages the hole in the tab on the lamp housing. Then fasten the lamp housing to

the engine with the two screws.


Elevator Foot and Actuator The elevator assembly includes the elevator foot, actuator, button, and spring. These parts are

included in the Adjustable Feet Kit (410482) The foot, actuator and spring are located in the bottom

case beneath the projection lens.

The elevator button fastens inside the top case. To replace the button, you need only to remove the top

case. See Top Case Contents for instructions on replacing the button.

Follow the procedure below to replace the rest of the elevator parts.

1 Remove the Optical engine.

2 Use a needle nosed pliers to remove the spring on the elevator actuator.

3 Lift the actuator out of the bottom case.


4 Use a small bladed screwdriver to release the retainer on the elevator foot. Then remove the foot

from the outside of the bottom case.

Assembly Note

♦ Install the elevator foot first. Then place the actuator over the elevator housing. The actuator fits into

guides in bottom case. When installed correctly, the actuator should move back and forth smoothly.


Bottom Case The bottom case (505-1586-xx) covers the bottom half of the projector. To replace the bottom case,

remove the pieces listed below and install them in the new bottom case.

When you replace the bottom case, it is important that you remove the LCD air guide from the bottom

case and install it on the new case. See below for instructions. The LCD air guide is included in the

Mounting Parts Kit (410483), and is not available separately.

When you replace the bottom case, you need to transfer the serial number label from the old case to the

new case. You also need to adhere a new generic bottom label (LP820: 020-1821-xx; LP815: in the Label Kit—510-1923-xx ) (below left) and a certification label (020-1903-xx; LP815: in the Label Kit—510-1923-xx) (below right) to the bottom case. Note that the certification label fits into a matching space

in the bottom label.


Lamp, lamp door, filter door

Rear bezel

Top case

IR ECA & front IR window

Controller ECA

Ballast and handle


Lamp & LCD blowers

Power supply fan

Engine blower & bracket


Leveling foot

Optical engine (leave the lamp housing and lamp attached)

Power supply

Elevator actuator & foot

2 Remove the serial number label from the old bottom case. You can use a hair drier or heat gun to

soften the label if needed.

3 Remove the two M3x7 Plastite screws that fasten the LCD air guide to the bottom case. Then

remove the air guide.


Assembly Notes

♦ Adhere a new certification label and certification label to the bottom case. Replace the serial number

label from the old bottom case.

♦ Make sure you install the LCD air guide in the new bottom case.


Performing functional tests

You perform the functional tests after you’ve repaired the projector to make sure all components of the

projector operate properly. You can also perform the functional tests if you’re having trouble determining

what is wrong with the projector. For additional help in diagnosing trouble with the projector, see

Troubleshooting.

Required equipment

Equipment Notes

Composite video DVD player with S-video capability

Make sure the video player has an S-video Out port and cables. The player should also have a Composite video output port (RCA). InFocus strongly suggests you use a DVD player to test the video quality. DVD players reproduce colors better and project sharper images. The least preferable is a VCR. If you must use a VCR, make sure you use a commercially produced recording, not one recorded from a broadcast source. The VCR must include an S-video connector in addition to a composite connector.

Commercially produced video to test S-video, composite video, and audio.

You'll need the video in DVD, laser disc, or videocassette format. For ASCs located in the US and Canada, InFocus suggests you use Digital Video Essentials (DVD International, 2003). This DVD is encoded for Region 1.

Audio & Video cables Use the AV cable that came with the projector. You also need the optional S-video cable.

Computer cables VESA cable, M1 cable

RGB test screens in a PowerPoint presentation

We recommend that you Use the Test Patterns on the InFocus website to check image quality.

PC with digital video and sound card

The sound card should have either a 3.5mm stereo audio jack. The computer must have a CD-ROM and a standard VESA connector for analog output.

Remote control Ensure that the remote has fresh AA batteries.

Projection screen Use a flat screen, not a curved one.

Before beginning

Make sure the work surface where you perform the functional tests is level and clean. Place the projector

on a soft surface (such as an anti-static mat) when running the tests.


Connect the following to the I/O panel on the projector:

♦ Video player through Composite Video, S-video, and Component connectors. Also connect the sound

cable to the video source and projector.

♦ Computer and video through the M1 and VESA connectors

Perform the following tests

Test Verification

Power Up Connect AC power, and turn the unit on.

Verify that the proper splash (logo) screen appears. If the incorrect logo screen appears, you must install the proper brand system software. The logo screen is automatically installed when you do this. Verify image quality.

Cosmetics and mechanicals Adjust the projector so that the image is square. Make sure the lens is at a 90° angle to the wall.

Verify that the elevator and leveling foot are functional. Verify that the focus and zoom rings operate properly. Verify cosmetics.

Video sources On the keypad, press the Video button to cycle through the video sources.

Verify that the video automatically synchronizes from all sources, including HDTV. If it doesn't, press the Video button on the keypad. Verify there is no distortion, noise or other abnormalities. Verify that the audio plays clearly.

Audio from video source Verify that the audio is clear with no distortion.

Software Version / Keystone / Reset All

1. Press and hold the Keystone up and Keystone down button on the keypad.

2. Press the Menu button, then navigate to About.

3. Navigate to Main > Settings > Service. Select Factory Reset.

Verify that the keystone adjustment works properly. Verify software version in the About box. Verify the keys are not sticky.


The next step is to observe 3 computer images. These will confirm that the computer input works properly, and will test image quality. On the keypad, press the Computer button to select Computer.

Image #1: Focus Test Image

1. Turn off any local light.

2. Turn the zoom ring to make the smallest image.

3. Focus the image so the middle icon is clearly focused.

4. Focus the image on the 4 green squares.

5. After focusing on the green squares on the middle icon, turn the zoom ring to make the largest image, then repeat the focus tests.

Verify that all four corner icons have clear resolution Verify that the white space is visible on all 5 bar/line icon areas (between green). Verify that the image focuses through the full zoom range. Verify that the image remains in focus when the Image Shift knob is turned.

Image #2: Color Ramp Project the Color Ramp image.

Verify there are no missing parts of the ramp. Verify that the bars are not flashing. Verify that the transitions from light to dark are smooth and gradual.


Image #4: SMPTE133 Project the SMPTE133 image.

Verify that there are no noise, tint, duplicating columns, or other general image abnormalities present

Power Down After all tests are complete, turn the power off and disconnect all cables. Attach the lens cap.

Verify unit is powered off before disconnecting cables.


Parts Lists

Exploded View For part numbers, see Replaceable Parts List on the left.


Replaceable Parts List Below is a list of replaceable parts (FRUs) for the LP815/LP820. It includes the part name as used in this

service guide, as well as the part name as listed in the parts pricing list database. The names often differ.

NOTE Before you order a part, make sure that you confirm the correct part number in the online parts list for this product. The parts pricing list is available in your ASC Resource Center.

Part name in service guide Part name in parts pricing list Part number

Top label LABEL, TOP, INFOCUS 020-1591-xx

Certification label LABEL BOTTOM, CERTIFICATION, INFOCUS, NJORD

020-1903-xx

InFocus brand label LABEL REAR LOGO, INFOCUS, NJORD

020-1823-xx

I/O label LABEL REAR, GENERIC, NJORD 020-1822-xx

Bottom label LABEL BOTTOM, INFOCUS, NJORD 020-1821-xx

Cable kit CABLE KIT, NJORD, LP820 410480

Screw & mounting details kit SCREW AND MOUNTING DETAILS KIT, NJORD, LP820

410481

Adjustable feet kit ADJUSTABLE FEET KIT, NJORD, LP820

410482

Mounting parts kit MOUNTING PARTS/BRACKET KIT, NJORD, LP820

410483

IR window kit IR GLASS KIT, NJORD, LP820 410484

Optical engine ENGINE LP820 WITH XGA MLA PANELS INCL. NVRAM

410488

Speaker set S/A, LOUDSPEAKER SETS, NJORD YD50-9-6 WITH CABLES

412-0004-xx

Top case S/A TOP, NJORD 505-1584-xx

Top cover S/A TOP COVER, NJORD 505-1585-xx

Bottom case S/A BOTTOM NJORD 505-1586-xx

Rear bezel S/A REAR COVER COMPLETE, NJORD 505-1596-xx

Lamp housing air guide S/A AIR GUIDE LAMPHOUSE COMPLETE, NJORD

505-1600-xx

Lamp blower & bracket S/A HOLDER LCD FAN COMPLETE, NJORD

505-1622-xx


Part name in service guide Part name in parts pricing list Part number

Engine blower & bracket S/A HOLDER PBS FAN COMPLETE, NJORD

505-1623-xx

Keypad S/A KEYPAD, NJORD 505-1624-xx

Lamp housing S/A LAMP HOUSE COMPLETE, NJORD 505-1709-xx

Power supply fan S/A, FAN AXIAL COMPLETE, POWER, 60X25, NJORD

505-1710-xx

Power supply ECA, P/S, POWER, LP820 510-1741-xx

Controller ECA (LP820) ECA, NJORD MAIN BOARD EXCL. NVRAM

510-1755-xx

Controller ECA (LP815) ECA, NJORD MAIN BOARD EXCL. NVRAM

510-1923-xx

Keypad LCD ECA ECA, KEYB/LCD NJORD (LP820) 510-1808-xx

Front IR ECA ECA, NJORD IR-BOARD 510-1814-xx

Ballast 250W POWER PACK LAMP,C13HB/NJORD

525-0061-xx

LCD blower S/A FAN BLOWER,LCD,TYF209 NJORD 526-0181-xx

Label kit (LP815) Includes top, certification, I/O and brand labels.

LABEL KIT, LP815 802-0054-xx


Screw and Mounting Details Kit

Screw and mounting details kit (410481)

Part Name Quantity

Rubber foot (rear) 1

Rubber foot for LCD blower 3

Power supply fan rubber holder 1

Rubber IR shield 1

Bottom gasket 1

LCD air guide 1

Speaker bracket 1

Lens cover shroud 2

Front fan cable plug 2

I/O shield 1

Elevator foot spring 1

Elevator actuator spring 1

Right blower mount 1

M3x8 black Torx Pan screw w/washer 1

M4x8 PC screw 1

M3x7 Torx Plastite screw 17

M3x5 Torx screw 10

M3x5 Plastite Torx screw 16

M3.5x10 Plastite Torx screw 5

M3.5x25 Torx Plastite screw 3

M4x7.5 black Torx screw 5


Cable Kit

LP815/LP820 cable kit (410480)

Part Name Quantity

Keypad cable 1

Lamp control cable 1

Power supply / ballast cable 1

Safety switch cable 1

IR cable 1

Adjustable Feet Kit

LP815/LP820 adjustable feet kit (410482)

Part Name Quantity

Elevator spring 1

Elevator button 1

Elevator shaft 1

Elevator activator 1

Leveling foot shaft 1

Leveling foot 1

Leveling foot insert 1

Mounting Parts Kit

LP815/LP820 mounting parts kit (410483)

Part Name Quantity

LCD protective cover 1

Handle 1

LCD air guide 1

Power supply cover 1

Front vent 1


IR Window Kit

IR window kit (410484)

Part Name Quantity

Front IR window 1

Left IR window 1

Right IR window 1

Focus and Zoom Ring Kit

Focus and zoom ring kit (410485)

Part Name Quantity

Focus ring 1

Zoom ring 1

infocus LP815-820_ServiceManual

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