Casio XJ-450 Troubleshooting guide

R
XJ-450
MAR. 2004
(without price)
Ver.7 : Feb. 2006

CONTENTS
1. SPECIFICATIONS................................................................................................................................ 1
2. BLOCK DIAGRAM
2-1. CONSTRUCTION OF WHOLE UNIT ............................................................................................ 2
2-2. PROTECTION CIRCUIT 1............................................................................................................. 3
2-3. PROTECTION CIRCUIT 2............................................................................................................. 4
3. BASIC PRINCIPLE
3-1. DATA PROJECTOR ..................................................................................................................... 5
3-2. DISPLAYED PIXEL....................................................................................................................... 6
3-3. BASIC STRUCTURE .................................................................................................................... 7
4. REPAIR PRECAUTIONS ..................................................................................................................... 8
5. PASSWORD....................................................................................................................................... 10
6. DISASSEMBLY AND ASSEMBLY .................................................................................................... 11
7. DIAGNOSTIC PROGRAM.................................................................................................................. 26
8. DATA BACKUP.................................................................................................................................. 31
9. ADJUSTMENT ................................................................................................................................... 42
10. TROUBLESHOOTING ....................................................................................................................... 43
11. EXPLODED VIEW .............................................................................................................................. 47
12. PARTS LIST ....................................................................................................................................... 50
13. SCHEMATIC DIAGRAMS .................................................................................................................. 54

— 1 —
1. Specifications
Projection System DLP (DMD, single panel)
DMD Size 0.7inch
Number of Pixels XGA (1024 ×768)
Projection Lens Auto, optical zoom (×2); auto focus
F = 2.0 to 2.8 f = 20 to 40mm
Light Source 250W high-pressure mercury lamp
RGB input terminal RGB mini D-Sub 15-pin ×1
(Also used as component signal input terminal.)
VIDEO input terminal RCA pin jack ×1
S-VIDEO input terminal Mini DIN4-pin ×1
Audio input terminal Stereo mini jack ×1
Audio output 1W monaural
USB port USB TYPE B
Environment Operating Temperature: 5 to 35°C (41 to 95°F)
Operating Humidity: 20 to 80% (non-condensation)
Power Requirements 100-240V AC, 50/60Hz
Dimensions 278(W) ×64(H) ×197(D) mm (excluding projections)
(10.9 ×2.5 ×7.8 inch)
Weight Approximately 2.4kg (5.3 lbs)
Display Languages A Model: English, French, German, Italian, Spanish,
Swedish, Korean, Japanese
B Model: English, Spanish, Chinese (Simplified),
Chinese (Traditional), Japanese
* Specifications are subject to change without notice.

— 2 —
2. Block Diagram
2-1. Construction of Whole Unit
128Mbit
RD-RAM
PW265
MAIN CPU
DDP1000
DMD Controller
THC7216
SAA7115
A/D Converter
Sub CPU
POWER SUPPLY
330W 13V
5V
3.3V
Lamp
250W
UHE
To PWB-GY791-1
DMD PCB GY791-2
Color Wheel
AF/Zoom Motor
Optical Module
TPA0172
FAN
FAN
Thermistor
Lamp
SW
Control
DMD
USB
LED
CPU
AF Sensor
EEPROM
I-Chip
keystone
Audio
RGB
S-Video
Video
MAIN PCB-GY791-1
Video Decoder
FLASH
ROM
12 0.7inch
XGA DDR
108MHz DDR
10x10x10bit RGB
FLASH
ROM
Motor
Driver
DAD1000
DMD driver
DMD
IR
KEY

—3 —
2-2. Protection Circuit 1
13V
5V
3.3V
KEY
PW265
MAIN CPU
Sub CPU
Display Controller
DDP1000
DAD
CW
DMD Controller
FAN
Thermistor
Detects abnormal condition
Detects abnormal condition
Temperature
Surplus voltage
Surplus current
Thermostat
Monitors runaway
User
2Requests lighting
1ON Key
Monitors
runaway 3Requests
lighting
Detects abnormal condition Detects abnormal condition
4Permits lighting 6Lighting signal
5Lamp output 250W
Detects abnormal condition Detects abnormal condition
Detection SW Detects abnormal
condition
AF/Zoom Motor
POWER SUPPLY
330W
Lamp

—4 —
2-3. Protection Circuit 2
Lamp
Exterior case (magnesium alloy) Fireproof enclosure / Protection ground
Power unit (330W) Circuit which detects that the lamp is on Excess current, excess voltage, excess heat protection
Thremostat Lens
DMD
Thermistor
Lamp cover detect SW
Color wheel Motor
Detects rotation
Motor (for ZOOM) Detects rotation Motor (for AF) Detects rotation
Control circuit (Secondary circuit) Counts hours for which the lamp has been lit Temperature monitoring Detects different abnormal conditions
Cooling FAN Detects rotation
Th
Th
Th
Th
Th Th
Th
Blast wall

—5 —
3. Basic Principle
3-1. Data projector DLP single panel metho
lamp
projection lens
lens
DMD
color wheel
condenser lens
Total reflection mirror
DLP single panel method

—6 —
3-2. Displayed pixel
One mirror makes up one pixel.
Clear image with high contrast
Bright, because the open area ratio is high
Light source
3 DMDTM Micro mirror device (side)
Light absorber Projection lens
3 pixel image onto the
screen

—7 —
3-3. Basic structure

— 8 —
4. Repair Precautions
(1) Record /collection defective parts
쮿Record
• OPM unit
1Record the serial number.
• Lamp (only during the warranty period)
1Used hours (if not known precisely, approximate hours of use)
2Lot No.
• Power source / Main PCB / Sub PCB
1Lot No.
쮿Collection
• All the replaced parts will be collected.
Note: Make sure to specify the lot No. details of defects and approximate days (months) of use.
• Send the collected units to:
Casio Techno Co.,Ltd.
Overseas Service Division Market Quality Control Department.
쮿Basic Precautions
1Before repairing, record the information below.
Lamp time, Unit Time, ERROR code (total of ten)
2When replacing the main PCB, input the lamp time and unit time again (to correctly figure out used hours of
the lamp or the OPM unit).
3If the projector does not boot normally and the lamp time and the unit time are not known, check with the
user about the approximate hours (Especially if the lamp time is set to 0, "replace lamp" message will not
appear at a correct timing.)
Even the approximate hours are not known by the user, input from 50 to 100 hours as the estimate.
4When replacing the lamp with a new one, input 0 as the lamp time. When replacing the OPM unit or main
PCB with new ones, leave the unit time as it is.
5Custom logo is not cleared by "Initialize ALL". It has to be initialized in the Custom logo menu.
6When replacing the main PCB whose custom logo is set by the user, the custom logo cannot be transferred.
Tell the user that the custom logo has to be set again.

— 9 —
(3) Operation when returning the projector
1Initialize by the diagnostic program (the projector is initialized to the factory default.). *1
2Set the operating hours of the lamp.
3Set other necessary items (such as language).
*1 Items not to be initialized
1Operating hours of the projector
2Custom logo settings
*1 Keep a note of such contents as that should at least be saved when returning the projector to the user, and
input it again later.
쮿Other precautions
얖The remote controller works in the distance of more than 7 meters, which may affect other nearby projectors.
Perform the diagnostic test by the keys of the projector itself, and not by the remote controller.
얖When the lamp is exploded, the broken glasses are scattered inside the projector. Clean the inside of the
projector by a vacuum cleaner.
Collect mercury drops (if any) by a dropper or piece of packing tape, put them into a glass bottle and dispose
of them according to the local regulations.
As part of the evaluation we exploded a lamp, but found no mercury drops (the amount of mercury inside the
lamp is 10 mg to 50 mg.).
얖The lamp emits strong light and produces high heat while it is on. Do not look directly into or touch the light
source. Doing so creates the risk of eye damage or burn injury.
Projector
Lamp
Mercury
Ultraviolet ray
Precautions
Be careful of high heat.
Be careful of high heat.
Do not look at the lamp by the naked eye when it is on.
Do not point the lamp light directly to the skin.
Do not cover the lamp with combustible materials.
Do not touch the lamp ball, reflector or explosion-proof
glass by bare hands (wear a pair of gloves.).
Be careful of vaporized mercury when the lamp is
exploded.
Be careful of projected light.
Actions
Make sure to open the projector after turning the power off, unplugging the AC
power cord from the wall outlet and waiting to allow for the projector to sufficiently
cool down.
Do not touch the area of the exhaust vent which is quite hot while the projector
is running. Doing so creates the risk of burn injury.
When replacing the lamp, make sure to turn the power off, unplug theAC power
cord from the wall outlet and wait for about 30 minutes to allow for the projector
cool down (wear a pair of gloves.).
Never look at the lamp by the naked eye when it is on. Doing so creates the risk
of eye damage.
Never point the lamp light directly to the skin. Doing so creates the risk of skin
irritation.
Do not near the lamp to or cover it with combustible materials. Doing so creates
the risk of fire.
Do not touch the lamp ball, reflector or explosion-proof glass by bare hands.
Doing so may cause damages to them or shorten their lives. When the explosion-
proof glass becomes dirty, wipe it off with a clean cloth moistened in alcohol.
When fingerprints are attached to the lamp ball and the reflector, dispose of them.
In case the lamp is exploded while it is on, leave the area to prevent from
breathing the mercury vapor and ventilate it for more than 30 minutes. Failure
to do so may cause inhalation of leaked mercury and damage to the health.
Wait to allow for the lamp to sufficiently cool down, collect the remaining mercury
by a dropper or piece of packing tape, and put it into such container as a glass
bottle. Dispose of the collected mercury according to the local regulations. In
case of having inhaled the mercury vapor, consult a physician.
Do not look directly into the lens while the projector is running. Strong light and
hazardous ultraviolet ray create the risk of eye damage.
(2) Precautions and actions during the assembly and repair of the projector

— 10 —
5. Password
쮿XJ-450 has a password function that prevents unauthorized persons from operating the
projector.
(1) Details
1The password can be input using the remote controller only.
If the remote controller is lost, the password cannot be input.
2The initial factory default password is as follows;
[AF/AK][PAGEUP][PAGEDOWN][왖][왔][왗][왘][MENU]
3Setting and changing the password can only be done in [Option Settings 1] [Power On Password] of the
Setup Menu.
4The password cannot be changed unless the initial factory default password is input correctly once.
5While the password is set in [Option Settings 1] of the Setup Menu, the password input dialog box appears
every time the power is turned on. It will not disappear unless the correct password is entered by the remote
controller. (Normal operation can be performed even when the dialog box appears).
(2) Resetting the password (CONFIDENTIAL!)
Note: MAKE SURE NOT to let users reset the password themselves or to tell them how to do so. Even
when users inquire about how to reset the password, do not inform them about it. Make sure to
reset the password inside CASIO.
There are two ways of resetting the password as described below;
1Use the [initializing] menu in the diagnostic program to return the password to the initial factory default.
(Note that by initializing the password, the lamp time and other settings will also be cleared. Make sure to
record such information before initializing the password and set it again afterwards.)
2Use the setting backup tool to transfer the password to PC and reset the password. (Refer to “8. Data
Backup” section in the service manual for details.)

— 11 —
6. Disassembly and Assembly
 Removing the lower case of the main unit 
 Removing the lamp unit and the front panel
1Remove two screws (S1) and then the cover on the underside.
Note: Place a soft cloth or a cushion underneath the projector when disassembling and assembling as the
surface (especially upper and front sides) can be easily damaged.
Since there are many types of screws, record the positions and types when removing the screws.
Refer to the following list for the specifications of screws described in ( ) in the procedures below.
NO Parts Name Specification Size NO Parts Name Specification Size
S1 LAMP-SCREW-G790 RJA511931-001 S2 H5-SCREW-A-G790 RJA512301-001
S3 BIND-SCREW S-BDMA-2X4NI 2x4mm S4 FLAT-SCREW-A-G408 A44793-17
S5 PAN-SCREW-A-G791 RJA512967-001 S6 BIND-TAP-SCREW S-BDBO-2.3X6ZC 2.3x6mm
S7 PAN-SCREW S-PAMA-2. 6X35ZC 2.6x3.5mm S8 - -
S9 PAN-SCREW S-PASEMA-3X6ZC 3x6mm S10 F-S-SCREW-G790 RJA512805-001
S11 BIND-SCREW S-BDMA-3X6NI 3x6mm S12 BIND-SCREW S-BDMA-2X4NI 2x4mm
S13 PAN-DSEMS-SCREW S-PADLMA-4X6ZC 4x6mm S14 HS-SCREW-A-G791 RJA512436-001
S15 FLUSH-SCREW S-FLMA-2X4ZC 2x4mm S16 H5-SCREW-A-G791 RJA512301-004
S17 BIND-SCREW S-BDMA-2X5ZC 2x5mm
Screws (S1)
2Remove three screws (S1), lift the handle slowly and then remove the lamp unit.

— 12 —
3Remove three screws (S2). Screws (S2)
Hooks
4First unhook the lower hook toward this side, and then remove the front panel by unhooking the upper hooks.
Note: After removing the front panel, pay utmost attention in handling the lens area.
The surface of the transparent acrylic plate in the AF (auto focus) area next to the lens (on the right
in the figure) is especially delicate. Never touch it directly to avoid sensor malfunction.
Refer to “Precautions when replacing the transparent acrylic plate in the AF area” on page 25 for
details.

— 13 —
2Remove three screws (S2) on the back and then remove four screws (S2) on the underside.
Screws (S2) Screws (S2)
Removing the upper case
1Remove the pin which prevents the upper case from loosening.
Pin

— 14 —
Screw (S3)
Removing the main PCB
1Remove the side panel in advance in order to be able to remove the PCB easily.
Remove one screw (S3) and then the side panel.
3Remove the upper case from the main unit.
4Remove the FPC from the two connectors on the lower side of the main PCB.
This removes the upper case.

— 15 —
4Remove two hexagon nuts in the monitor output terminal on the
back of the main unit, and then remove the main PCB from the
main unit.
Note: The main PCB is connected by the PCB of the OPM unit
on the lower rear side and the connector. To remove the
main PCB easily, lift it upward while tilting it to the left and
right.
5Remove the connector CN430 which was not removed in the
step 2.
Note: Hold the whole connector and then remove it slowly.
This removes the main PCB.
CN430
3
6
7
4
5
21
0
8
A
9
1CN580 2CN581
3CN560 4CN570
5CN530 6CN430
7CN316 8CN630
9CN615 0CN420
ACN410
Height adjustment spacer
Screws (S4)
Screws (S3)
Screw (S5)
2Remove 14 screws out of 15 on the surface side of the main
PCB.
Note: There is no protrusion to grasp in the connector
CN430. Remove everything else but the connector
CN430 first.
3Remove four screws (S3), two screws (S4) and one screw (S5).
Note: Be careful not to lose the height adjustment spacer after remove the screw (S5).

— 16 —
쮿Removing the fan duct
1Remove three screws (S4).
2Remove the aluminum foil.
Note: The aluminum foil is adhered. Once peeled off, it cannot
be reused. Replace it with new foil when assembling.
Also note that the foil should be fixed together with
screws (S4).
3Remove three screws (S4), and then remove the aluminum plate inside the lamp house on the underside by
sliding it toward this side.
Screws (S4)
Screws (S4)
4Remove the fan duct.

— 17 —
Removing the lamp cover
1Remove the FPC.
2Remove four screws (S3) (S8).
Screws (S8) is a little longer.
Note: Be careful not to let it come in contact with the coil in the PCB.
Pull it up carefully since it is assembled to the PCB of the OPM unit.
This removes the lamp cover.
FPC Screw (S8)
Screws (S3)
Hexagon nutScrews (S7)
Cable tie
Screws (S6)
Back connector
Connector B
Removing the power unit
1Remove two screws (S6) in the connector B.
Note: Remove the connectors connecting from the power PCB to other places in advance.
Cut the cable tie binding cables by a nipper etc. Remove the back connector while pushing its tab.
2Remove two screws (S7) and then one hexagon nut.
3This removes the power unit.
Coil

— 18 —
Removing the OPM unit
1Remove three screws (S9) and then the OPM unit.
Note: There is a place where FPC and connectors are located closely with one another. Pay good attention
not to damage them.
Screws (S9)
FPC and connectors
Note: There is a wing for the encoder between the zoom and the focus.
Bending this wing may touch the reader part and cause noise.
Do not hold this wing part even though there is enough space for a finger to put in.
Do not hold this part by a
finger.