dlp training 2003 samsung copia

DLP TRAINING

2003Samsung Product Support Department

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.

PAGE 4

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

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


(Continued)

3) Replace Power PCB. See parts list for part #

4) Reseat Lamp

5) Check interlock switch on back of set.

PAGE 48


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


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


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


(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


(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


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


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

dlp training 2003 samsung copia

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