2007 DLP Orchid Chassis

HLT5076

HLT5676

HLT6176

2

2007 DLP Model Comparison

HLT**87HLT**89

HLS5679HLT**76seriesHLT7288HLSHLT**65HLT**75

HLSModel #s

SlimNormalUltra SlimNormalNormalSlimNormalType

LED

K880L680K780K280K280K620K220Engine Series

6LED18.515.518.515.518.5C/Wheel/LED Sensor

50/56/61K856L850/56/61K772K8K346K5, 50/56K6K2/K3Cabinet

2006 Carryover

Yes

-

1080p

Constantine

New

Yes but not replaceable

Yes

1080p

Orchid

New

Yes

Yes

720p

Sunflower

New

Yes

-

720p

Cattleya Laurel

LampLamp

1080p720p

Smooth Picture Actuator

Dynamic Black

DMD Resolution 1080p1080p720P

GalileiEinstein

NoYesYes

New2006 Carryover2006 CarryoverComments

YesYes-

3

Actuator

Light Engine

Projection Lens

Ultra Slim Light EngineTraditional Light Engine

K780 (Normal vs. Ultra Slim)

Light Engine Comparison

4

Orchid Chassis Light Path

5

Projector Cooling System

DMD-BOARD

Ultra Slim Light Engine Overhead View

6

Lamp

Color wheel

Smooth picture

Dynamic black

DMD (xHD5)

M3 mirror

Projecting Lens

Light Source

M1 mirror

M4 mirror

M2 mirror

Light-tunnel

E1 lens E2/E3 lensE4 lens

Fold mirror

L1 lens

L2 lens

Projection Module

7

Projection Light Path

8

LAMP ASSY

Wall

Engine Layout

9

Main PCB Block Diagram

10

Clear QAM tuner• A Clear-QAM tuner allows you to tune in both analog and

digital cable signals, including the HD versions of major network channels like CBS and NBC. Basically these are unencrypted digital cable channels such as the HD versions of PBS, Fox, NBC, CBS and ABC.

• Depending on the cable provider you may also be able toview other digital stations using the Clear-QAM tuner.

• Understand that cable providers are not required to carry the HD versions of broadcast channels. They are only required to carry the analog versions by law.

• Additionally just because the signal is transmitted via cable doesn't mean it is always superior to the off the air signal with an antenna.

11

S5H2201 Video Processor• Improved audio DSP, a programmable

video encoder with a dual output capability of interlaced and progressive scan

• Memory controller, – 4-channel Timers with PWM, I/O Ports, – 2-channel 8-bit ADCs, 5-channel 10-bit DACs, – 2-channel UARTs with handshake, – IIC-BUS interface, IIS-BUS interface, SIO,

USB Card Interface (WiseLink)

12

SDP62 Scaler

4CH Input• CH1, CH2 : 30Bit (RGB, YCbCr4:4:4, 601,10Bit or 8Bit)• CH3 : 24Bit (RGB,YCbCr4:4:4 each 8bit, 601 10bit)• CH4 : 20Bit (Only 601 8Bit or 10Bit)• OSD InputOutput• Digital RGB (10Bit 444) Digital YCbCr(10Bit 444)• RGB/YCbCr 10bit OUTPUT @ CLK OUT Progressive S

can• RGB/YCbCr 20bit Even/Odd) OUTPUT Interlaced Scan

13

Audio Signal Flow

L1/R1

L2/R2

SIDE-L/R

CO

MP1

L/R

CO

MP2

L/R

MAIN

-L

MAIN

-R

PC-L/R

DVI-L/R

MO

N-L/R

OU

T

X240_SR

X240_SL

X240H

_MC

LK

X240H

_LR

CL

KX

240H_SC

LK

X240H

_DA

TA A

TI_SPD

IF

I2S-DA

TA_A

MP

I2S-WS_A

MP

I2S-CLK

_AM

P

TU_SIF

HD

MI_L

RC

LK

HD

MI_SC

LK

HD

MI_D

AT

A

I2S_MC

LK

14

DMD Board Block Diagram

15

Service Adjustments• Index Delay• Actuator Gain• Focus• Tilt• V/H position• CCA (DMD <-> Digital)• Software Upgrade

16

Remove the engine by pulling it out of the cabinet.Be careful when removing the Light Engine as it may getcaught up by the upper cable of the case.

4. Disconnect the lamp door switch cable

2. Disconnect the 12P PS cable, LVDS Cable and Ballast PS Cables.

3. Disconnect the 3P cable

1. Remove the four mounting screws and the vertical bar.

Removing the Light Engine

17

Removing the Color Wheel

• Remove the lamp chimney• Remove the Ballast fan

housing• Remove the three screws

holding the C/W heat sink• The C/W gasket should

stay in place

18

5. Remove the DMD board, then transfer the current DMD mirror chip to the new DMD board

4. Remove the seven point screws, do NOT remove the screws highlighted in yellow.

2. Remove the retaining spring and the heat sink.

3. Remove the four corner screws and the shield.

1. Remove the DMD Fan and disconnect the two fan drive connectors.

Removing the DMD Board

19

OrchidChassis

Alignments

2007 DLP K780 Optical Engine _ HLT**76SX Series

20

1) Shadow Inspection and light tunnel adjustments must be performedif necessary before the geometry adjustments.- Enter Factory mode -> DDP3021 ->Test Pattern -> Select

Raster White Pattern

Test Pattern

Shadow Defect

Shadow Defect

21

Back Cover

Dust Cap

Shadow Adjustment Access

Remove the dust cap portal to view the screen from the inside

22

2) Adjust Light Tunnel1) As shown in the left picture, adjust the light

tunnel and inspect the adjust condition.

2) To remove the right side Shadow, do the

following -

- Front Screw : Turn Right (CW)

3) To remove the upper side Shadow, do the

following –

- Rear Screw : Turn Right (CW)

Adjust the Light Tunnel

23

Illumination Adjustment

24

1) Shadow Inspection- Enter Factory -> Test Pattern -> Select White Pattern

2) Make sure to inspect the left bottom and right upper corner of thescreen for shadow defect.

Test Pattern

Right upper

Left bottom

Final Inspection

25

1.Tilt Inspection – Bring up the internal tilt test patternEnter Factory mode (mute+182+Power) -> H/V Position -> Tilt Pattern

Tilt Pattern (Internal Pattern) Inspect the Tilt(with external Lionhead or Overscan pattern)

2) Tilt Specification

8 mm (.31”)7 mm (.27”)

Spec

61”*TOP Tilt : H1-H3 * BOTTOM TILT: H2-H4

50”,56”RemarkInch

Image Tilt InspectionThese adjustments muse be performed after the light tunnel adjustments and after the cabinet back is secured along with the rear cabinet braces.

26

■Top Tilt Adjustment

Screw A : Fix Engine. B : Tilt Adjustment

1) Loosen Screw A at the 2 points shown. (outside screws)

2) Use Screw B to adjust Top Tilt

-B (Right) : Rotate CW -> Image Down

-B (Left ) : Rotate CCW -> Image Up

3) Reference the overscan test pattern to determine the correct adjustment. As shown in the figure below, align the green line to the cabinet bezel. (see spec pg. 20)

Left Right

4) Fix Screw A at the 2 points shown.

A B AB

Tilt Adjustment (Top Bowing)

27

28

29

(Bottom Bowing Coarse Adjustment)First loosen the 2 screws as shown Fig #1.

If the bottom of the screen is bowing up, (In most cases)

- Insert a flat screwdriver above screw #1 as shown Fig #2.

- While applying upward force on the flat screwdriver handle (causing downward motion of screw #1 by rocking against cabinet), monitorbottom bowing on the screen and tighten screw #2 when straight.

If the bottom of the screen is bowing down,

- Insert a flat screwdriver under #1 as shown Fig #3..

- While applying downward force on the flat screwdriver handle (causing upward motion of screw #1 by rocking against cabinet), monitor bottom bowing on the screen and tighten screw #2 when straight.

1 2

Fig #1

Fig #2

Fig #3

Tilt Adjustment

30

■Bottom Bowing Fine Adjust1) Loosen Screw A at 4 points as shown.

2) Rotate Screw B to adjust Bottom Tilt

-B (Right): Rotate CW -> Image Up

-B (Left) : Rotate CCW -> Image Down

3) Refer to the monoscope pattern to determine the correct adjustment. Asshown in the figure below, align thegreen line to the cabinet bezel.

4) Fix Screw A at the 4 points as shown.

Screw A : Fix Mirror B : Tilt Adjustment

CD

A A A A

BB

Tilt Adjustment Part 2

1st : Measure inner Red box line2nd: Measure 2 end point of Red box for bottom and top side.3rd: Compare with the tilt specification

8 mm (.31”)

7 mm (.27”)

QC

61”

TOP TILT : H1-H3BOTTOM TILT: H2-H4

50”, 56”

Measuresize

Tilt Specifications

8 mm (.31”)

7 mm (.27”)

QC

61”

LEFT KEYSTONE : V1-V2RIGHT KEYSTONE : V3-V4

50”, 56”

measuresize

1st : Measure inner Red box line2nd : Measure 2 end point of Red box for right and left side.3rd : Compare with the tilt specification

Keystone Specifications

1st : Measure both 2 ends and center point (Top, Bottom or Sides)2nd: Connect both 2 ends and measure the distance to center point3rd : Compare with the tilt specification

Measure Center barrel (mm)5mm (.2”)50”

6mm (.24”)

5.5mm (.22”)

QC

61”

56”

MeasureSize

Barrel Specifications