CASTOR Y057 Quick start guide

Castor-PJ1
Machine Codes: Y057
Field Service Manual
August, 2014

Important Safety Notices
Safety Instructions
The service technician is required to read and follow the “Safety Precautions” and “Important Safety
Notice” in this service manual.
• This service information is designed for experienced repair technicians only and is not designed for
use by the general public. It dose not contain warnings or cautions to advise non-technical
individuals of potential dangers in attempting to service a product. Products powered by electricity
should be serviced or repaired only by experienced professional technicians. Any attempt to
service or repair the product or products dealt with in this service information by anyone else could
result in serious injury or death.
• Use UV Radiation eye and skin protection during servicing.
• Precaution
• If using of this projector at high altitudes, “High Altitude” to “ON” for 1,000 to 3,000m.
(Refer to “PROJECTOR SETUP menu” in Operating Instructions.)
Failure to observe this may cause malfunctions. Never use this projector at an altitude of 3,000m
or higher. Using this projector at high altitude, consult your dealer or Authorized Service Center
about preparations.
• About lead free solder (PbF)
• This projector is using the P.C.Board which applies lead free solder.
Use lead free solder in servicing from the standpoint of antipollution for the global environment.
• Lead free solder: Sn-Ag-Cu (tin, silver and copper) has a higher melting point (approx.
217°C) than standard solder Typically the melting point is 30 to 40°C higher. When
servicing, use a high temperature soldering iron with temperature limitation function and set it
to 370 ± 10°C.
• Be precautious about lead free solder. Sn-Ag-Cu (tin, silver and copper) will tend to splash
when heated too high (approx. 600°C or higher).
• Use lead free solder for the P.C.Board (specified on it as “PbF”) which uses lead free solder.
(When you unavoidably use lead solder, use lead solder after removing lead free solder. Or
be sure to heat the lead free solder until it melts completely, before applying lead solder.)
• After solder to double layered P.C Boards, check the component side for excess solder which
may flow onto the opposite side.
IMPORTANT SAFETY NOTICE
1

There are special parts used in the projector which are important for safety. These parts are shaded on
the schematic diagram. It is essential that these critical parts should be replaced with manufacturer’s
specified parts to prevent shock, fire, or other hazards. Do not modify the original design without
permission of Ricoh Company Ltd.
• This equipment has been tested and found to comply with the limits for a Class B digital device,
pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection
against harmful interference in a residential installation.
• This equipment generates, uses and can radiate radio frequency energy and, if not installed and
used in accordance with the instructions,
• may cause harmful interference to radio communications. However, there is no guarantee that
interference will not occur in a particular installation.
• If this equipment dose cause harmful interference to radio or television reception, which can be
determined by turning the equipment
• off and on, The user is encouraged to try to correct the interference by one or more of the following
measures.
• - Reorient or relocate the receiving antenna.
• - Increase the separation between the equipment and receiver.
• - Connect the equipment into an outlet on a circuit different from that to which the receiver is
connected.
• - Consult the dealer or an experienced radio/TV technician for help.
• Any unauthorized changes or modifications to this equipment will void the user’s authority to
operate this device.
Safety and Ecological Notes for Disposal
Dispose of replaced parts in accordance with local regulations.
2

TABLE OF CONTENTS
Important Safety Notices................................................................................................................................... 1
Safety Instructions...........................................................................................................................................1
Safety and Ecological Notes for Disposal................................................................................................... 2
1. Product Information
Specifications...................................................................................................................................................... 5
List of General Specifications........................................................................................................................ 5
Compatibility Modes......................................................................................................................................6
2. Replacement and Adjustment
Equipment Needed & Product Overview......................................................................................................... 9
Disassembly & Assembly Process................................................................................................................... 10
Disassemble Filter and Focus Ring..............................................................................................................10
Disassemble Lamp Module.........................................................................................................................11
Disassemble Top Cover Module................................................................................................................ 13
Disassemble IR Sensor and IR Sensor Board.............................................................................................14
Disassemble Main Board Module and Shielding.....................................................................................16
Disassemble Speaker Module and Filter Holder...................................................................................... 20
Disassemble Engine Module.......................................................................................................................21
Disassemble System Fan Module...............................................................................................................22
Disassemble Blower.....................................................................................................................................25
Disassemble LVPS Module..........................................................................................................................25
Disassemble Ballast Module and Interrupter Switch.................................................................................27
Disassemble Bottom Shielding and IO Cover Module.............................................................................29
Repair Action................................................................................................................................................31
OSD Reset............................................................................................................................................31
Waveform Download and Fan Calibration......................................................................................32
Color Wheel Index Adjustment..........................................................................................................32
3. Troubleshooting
LED Lighting Message......................................................................................................................................35
Troubleshooting Guide.................................................................................................................................... 36
Main Procedure........................................................................................................................................... 36
NO Power Troubleshooting........................................................................................................................37
Power Troubleshooting................................................................................................................................38
Image Troubleshooting 1............................................................................................................................ 39
3

Image Troubleshooting 2............................................................................................................................ 40
Image Troubleshooting 3............................................................................................................................ 41
Image Troubleshooting 4............................................................................................................................ 42
Remote Control Troubleshooting................................................................................................................ 43
Audio Troubleshooting................................................................................................................................ 44
Pin Assignment..................................................................................................................................................45
J1: 8Pin POWER From LVPS........................................................................................................................45
J2: Front IR.................................................................................................................................................... 46
J10: Blower.................................................................................................................................................. 46
J11: CW to MB............................................................................................................................................46
J12: Ballast................................................................................................................................................... 47
J13: Photo Sensor........................................................................................................................................ 47
J15: Speaker................................................................................................................................................ 48
J23: System Fan........................................................................................................................................... 48
Service Menu Explanation.............................................................................................................................. 49
Get into Service Mode................................................................................................................................ 49
4. Firmware Update
SYS Firmware Upgrade Procedure................................................................................................................ 53
Equipment Needed......................................................................................................................................53
DLP Composer Lite Setup Procedure..........................................................................................................53
Firmware Upgrade Procedure....................................................................................................................56
4

1. Product Information
Specifications
List of General Specifications
Item Specification
Consumption Power 240W (ECO mode) / 295W (Full mode)
Weight 2.9kg
Dimensions (WxHxD) 220 x 288 x 100 mm (with protruding parts)
Environmental Considerations
Operational Temperatures : 41° to 95°F (5° to 35°C) 20% to
80% humidity (non-condensing)
Storage Temperatures : -4° to 140°F (-20° to 60°C) 20% to
80% humidity (non-condensing)
Projection System Single DLP® 0.55” chip
Resolution 1024 × 768 pixels (XGA)
Lens F#2.8 f=7.26mm
Lamp High-pressure mercury lamp (240W)
Lamp Life 3500hours typical (Full Mode) / 5000 hours typical (ECO1/
ECO2 Mode) / 10000hours typical (Auto Mode)
Projection screen size 40 - 200 inch
Projection distance 0.51 - 2.54m (Focus range)
Speaker 8W (Mono)
Connection terminal,
Computer In terminal× 2 Mini D sub 15 pin RGB / Y/PB / PR (dual use)
Monitor Out terminal Mini D sub 15 pin
HDMI terminal HDMI
Video terminal RCA Pin Jack
5

Item Specification
PC Control terminal D sub 9 pin Female (RS-232C compliant)
Audio In terminal × 2 3.5mm diameter mini-jack (1) Computer 1 or Computer 2 (2)
Video
Audio Out terminal 3.5mm diameter mini-jack
Compatibility Modes
Computer/ Video/ HDMI/ Mac Compatibility
Signal Resolution Refresh Rate (Hz) Video Analog HDMI Mac
NTSC 720 x 480 60 O - - -
PAL/SECAM 720 x 576 50 O - - -
VGA
640 x 480 60 - O O O
640 x 480 67 - O - -
640 x 480 72.8 - O - O
640 x 480 85 - O - O
SVGA
800 x 600 56.3 - O - -
800 x 600 60.3 - O O O
800 x 600 72.2 - O O O
800 x 600 85.1 - O O O
800 x 600 120 - O O -
XGA
1024 x 768 60 - O O O
1024 x 768 70.1 - O O O
1024 x 768 75 - O O O
1024 x 768 85 - O O O
1024 x 768 120 - O O -
WSVGA 1024 x 600 60 - - O O
1. Product Information
6

HDTV (720p)
1280 x 720 50 O O O -
1280 x 720 60 O O O O
1280 x 720 120 - O O -
WXGA
1280 x 768 60 - O O O
1280 x 768 75 - O O O
1280 x 768 85 - O O O
1280 x 800 60 - O O O
1366 x 768 60 - O O -
WXGA+ 1440 x 900 60 - O O -
SXGA
1280 x 1024 60 - O O O
1280 x 1024 75 - O O O
1280 x 1024 85 - O O -
SXGA+ 1400 x 1050 60 - O O -
UXGA 1600 x1200 60 - O O -
HDTV (1080p)
1920 x 1080 24 O O O -
1920 x 1080 30 - - O -
1920 x 1080 50 O O O -
1920 x 1080 60 O O O O
HDTV (1080i)
1920 x 1080 50 O - O -
1920 x 1080 60 O - O -
WUXGA 1920 x 1200 60 (*1) - O O O
SDTV (576i) 768 x 576 50 O - O -
SDTV (576p) 768 x 576 50 O - O -
SDTV (480i) 640 x 480 60 O - O -
SDTV (480p) 640 x 480 60 O - O -
Specifications
7

• Please note that using resolutions other than native 1024 x 768 (native resolution of this model)
may result in some loss of image clarity.
• (*1) 1920 x1200 @60Hz only support RB (reduced blanking).
• 120Hz input signals may be dependent on graphics cards support.
1. Product Information
8

2. Replacement and Adjustment
Equipment Needed & Product Overview
1. Screw Bit (+): 105
2. Screw Bit (+): 107
3. Screw Bit (-): 107
4. Hex Sleeves 5 mm
5. Long Nose Nipper
6. Tweezers
7. Projector
* Before you start: This process is protective level 2. Operators should wear electrostatic chains.
9

Disassembly & Assembly Process
Disassemble Filter and Focus Ring
1. Separate the Lens Cap and projector (as blue square).
2. Pull down the tenon (as red square) to disassemble the Left Filter.
3. Pull down the tenon (as yellow square) to disassemble the Right Filter.
4. Disassembled the Left Filter [A] and the Right Filter [B].
2. Replacement and Adjustment
10

5. Please rotate the Focus Ring outward so as to take out the focus ring easily.
6. Pull out the Focus Ring.
• When you assemble the Focus Ring, ensure the 3 card slot (as green square) placed in the 3
double-screw bolt (as red circle) properly, and the Focus Ring can be well adjusted.
Disassemble Lamp Module
1. Loosen 1 screw (as red circle) on the Lamp Cover.
Disassembly & Assembly Process
11

2. Disassembled the Lamp Cover.
3. Loosen 2 screws (as yellow circle) on the Lamp Module.
4. Take off the Lamp Module.
2. Replacement and Adjustment
12

Disassemble Top Cover Module
1. Unscrew 2 screws (as red circle) from the Top Cover and unscrew 8 screws (as green
circle) from the Bottom Cover.
2. Pull upward the Top Cover Module.
3. Unplug connector (as blue square), then remove the Top Cover Module.
Disassembly & Assembly Process
13

4. Disassemble the Top Cover Module.
Disassemble IR Sensor and IR Sensor Board
1. Unscrew 2 screws (as red circle) and tear off the Tape (as yellow square) to disassemble
the IR Sensor Module.
2. Replacement and Adjustment
14

2. Tear off the Mylar (as blue square).
3. Separate the IR Holder and IR Sensor Board.
4. Tear off the Tape (as red square) to disassemble the IR Sensor Board.
Disassembly & Assembly Process
15

5. Tear off the Sponge and Mylar (as red square).
Disassemble Main Board Module and Shielding
1. Tear off the Tape (as blue square) and unscrew 4 screws (as red circle).
2. Unscrew 8 hex screws (as green circle) and screw (as yellow circle).
2. Replacement and Adjustment
16

3. Unplug 3 connectors (as red square) and 1 connector (as yellow square) of Blower.
4. Unplug connector (as green square) of Color Wheel.
• Correctly SYS FAN Cable as the below arrow.
Disassembly & Assembly Process
17

5. Unplug 2 connectors (as purple square).
• Please refer to the table as below for details about each connector.
Item Male Connector on
Main Board The key feature Figure
A System Fan Compose of Red/Blue/Black
wire (3 pin)
B Blower Compose of Red/White/Black
wire (3 pin)
C Photo Sensor
Compose of Red/ Black/White
wire, Red Connector and Black
wire tube (3 pin)
D Speaker Compose of Black/Red wire and
Black wire tube (2 pin)
2. Replacement and Adjustment
18