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ROBOCOP (L64A) October 2004

DLP Training Manual. ROBOCOP (L64A) October 2004. 0. Agenda. 1. Circuit Board 1-1. Power Supply Board 1-2. Digital Board 1-3. Analog Board 1-4. DMD Board 2. Trouble Shooting 2-1. Flow chart for Malfunction 2-2. Status Table for LED

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ROBOCOP (L64A) October 2004

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  1. DLP Training Manual ROBOCOP (L64A) October 2004

  2. 0. Agenda 1. Circuit Board 1-1. Power Supply Board 1-2. Digital Board 1-3. Analog Board 1-4. DMD Board 2. Trouble Shooting 2-1. Flow chart for Malfunction 2-2. Status Table for LED 2-3. Blinking Temp LED 2-4. Blinking Temp and Timer LED 2-5. Blinking Lamp LED 2-6. Blinking Lamp and Temp LED 3. Power On Sequence 3-1. Power On Sequence 4. Optical 4-1. Back Ground 4-2. Design Concept 4-3. Realizing Method 4-4. Light Engine Breakdown 4-5. DMD 4-6. Optical Module 4-7. Color Wheel 4-8. Actuator 4-9. Lamp 4-10. Ballast 4-11. Screen 4-12. Optical Specification 4-13. Service Module 5. Mechanic 5-1. L3 JJTV Main Parts 5-2. Screen size 5-3. Mirror Size 5-4. Set Dimension

  3. 1. CIRCUIT BOARD

  4. 1-1. Power Supply Board POWER BOARD (ASSY CODE : BP94-02141B) (PCB CODE : BP41-00131D) Supplies DC Voltages:

  5. 1-2. Digital Board • Microprocessor (Generates Turn on Signal to power board) • Monitor LED’s • All Digital Video Processing • Sensor / Switch Controls • OSD / Menu • Reset Switch PAGE 8 PAGE 8

  6. - Digital Board Layout PAGE 9

  7. - Digital Board Characteristics PAGE 10

  8. 1-3. Analog Board • Distributes supply voltage from the 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 • 3D Comb Processing PAGE 11

  9. - Analog PCBLayout PAGE 12

  10. RF SWITCH POD LNA Block 2004.08.04 AIR CABLE LOOP OUT CABLE BS S/W OFF LOOP LNA SPLIT RELAY#1 AMP B+(9V) LNA S/W#1 SPLIT GND S/W#2 RELAY#2 MAIN SUB - Analog Board Block Diagram RF SWITCH (LNA) BLOCK

  11. - Analog Board Block Diagram AV Switching(TEA64XX) BLOCK

  12. - Analog Pin Assignment CN257 Supplies AV Signals to PCB DIGITAL

  13. - Analog Pin Assignment CN258 Connects Control Signals between PCB Analog and PCB Digital

  14. - Analog Pin Assignment CN270 Receives Power Signals from PCB POWER

  15. - Analog Pin Assignment CN259 Supplies Power Signals to PCB DMD 3-3-4. CN266

  16. - Analog Pin Assignment CN223 Receives AV Signals from PCB SIDE-AV

  17. - Analog Pin Assignment I/O Expander Pin Assignment IC156 IC157

  18. 1-4. DMD Board • Controls Lamp Turn-On • Powers Color Wheel Motor • Drives DMD Panel • Sensor Controls • Attached to Light Engine

  19. - DMD Block Diagram

  20. Review

  21. 2. Trouble shooting

  22. 2-1. Flow Chart for Malfunction Don’t working Yes Is the panel LED Working? See the “Status Table for LED” No Disassemble Rear Cover and Terminal Board OP1, OP2, OP3 are Lit on? Yes Check the “Control Board Ass’y” No Check the Power Connector (CN267, CN270) Yes Replace “Power PCB Ass’y”, OK? No Yes Replace “Analog PCB Ass’y”, OK? No Yes Replace “Channel PCB Ass’y”, OK? No Replace “Digital PCB Ass’y” End PAGE 19

  23. 2-2. Status Table for LED

  24. 2-3. Blinking Temp LED CN106 Check Temp Sensor connector CN106 on Actuator Board Re insert The Connector NG OK Install jumper across Temp Sensor Terminals. Does it work? Replace Actuator Board No Temperature Sensor Yes Replace Temp. Sensor

  25. 2-4. Blinking Temp and Timer LED Yes Are fans running? Replace Actuator board No NG Check for 8VDC voltage(s) at CN103,104 on Actuator Board OK Replace fan(s) NG Check CN 802 pin 8,10 on Power board for 12VB NG Replace Power Board OK Replace the Analog board

  26. 2-5. 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. Do fan(s) run? YES Does color wheel run? NO YES OK Replace color wheel assy’ Is lamp on? NG YES NO Replace DMD Board Replace DMD BOARD See next page

  27. Check 280V dc to lamp ballast (CN 1) Measure with DC meter Does lamp come on, then shut off? NO NG OK YES Replace Power Board Check 5 V pp at CN 503 pin 3 on DMD Board Re-install lamp assy’ NG Check pin 1 on CN 503 on DMD Board for 5V dc NG OK OK NG Replace ballast or lamp assy’ Replace lamp assy’ or ballast Replace DMD Board

  28. 2-6. Blinking Lamp, Temp, LED’s No Is lamp cover installed? Install lamp cover Yes Make sure lamp cover switch is activating OK NG Short CN 107 on Actuator Board Check boss on Lamp Cover CN107 NG Replace the digital board

  29. Review

  30. 3. Power On Sequence

  31. 3-1. Power On Sequence 1. Standby LED on Analog PCBON (5V) 2. Power ONsignal from Sub Front PCB to Digital PCB. 3. Power ON signal generated by Digital PCB> Analog PCB> POWER PCB

  32. 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 ballast for status OK.

  33. Review

  34. 4. Optical PAGE 18

  35. 4-1. Back Ground Background Samsung introduced their new DLP technology projection televisions in 2002. DLP stands for Digital Light Processing 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.

  36. 4-2. Design Concept 1. Display Resolution Driving Actuator X1 RESOLUTION X2 RESOLUTION

  37. 4-3. Realizing Method 1. Display Resolution Mirror movement by vibration of Piezoelectric material. Vibration distance X2 Resolution Actuator 460800 pixels -> 921600 pixels Tough to Soft line

  38. 4-4. Light Engine Breakdown LAMP MODULE (Samsung) OPTICAL MODULE (Carl-Zeiss) DMD MODULE (Samsung) 그림 보완

  39. 4-5. DMD Incident light L2 Design : HD2 Panel 1280 X 720 (921600 pixels) 0.79 L3 Design : HD3 Panel Incident light 460800 pixels Diamond Pixel

  40. 4-6. Optical Module PROJECTION LENS COLOR WHEEL LIGHT TUNNEL LOCATION OF DMD

  41. 4-7. Color Wheel <Air Bearing Type motor> Life time : over 30,000hrs On/off : over 50,000 times Good Vibration & Noise

  42. 4-8. Actuator 60Hz

  43. 4-9. Lamp Full name : High Pressure Mercury Lamp Maker : Philips Specification • Arc gap : 1.0 mm • Wattage : 100W or 120W • Life time : about 8000 hrs Optical Specification • Reflector type : E23 • Size : 95.25 +/-0.5mm • Mount to focal point : 52mm reflector burner Cover glass

  44. 4-10. Ballast Maker : Philips Type no. : EUC 120PH/11 Ignition : 20kV(Max 25kV) Size : 150 x 60 x 32mm Ambient temp. : under 65deg C.

  45. 4-11. Screen Lenticular Lens Lenticular Lens Black Stripe(BS) Black Stripe(BS) Diffusion Plate Diffusion Plate 155 155 um um High Brightness, High Brightness, High Contrast High Contrast Hard Coat Hard Coat Anti Anti - - static static 98 98 um um function function 2.0 2.0 mm mm 2.1 2.1 mm mm Fresnel Fresnel Lens Lens Lenticular Screen Lenticular Screen Maker : Toppan Good Point : 1. Good Contrast 2. No reflection of out-light. 3. Good View Angle(140 deg)

  46. 4-12. Optical Specification

  47. 4-13. Service Module DMD BOARD ASSY Problem : DOT DEFECT, VERTICAL LINE Solution : Chang the DMD Board assy.

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