Mitsubishi Electric DLP XD8100U User manual

2012
CAUTION
Before servicing this chassis, it is important that the service person reads the “SAFETY PRECAUTIONS” and “PRODUCT
SAFETY NOTICE” in this service manual.
Copyright © 2012 Mitsubishi Electric Corporation All Rights Reserved.
MODEL
XD8100U/
XD8100LU/
XD8100U(BL)
These models are RoHS-compliant.
Provide servicing referring to “NOTES
FOR SERVICING RoHS-COMPLIANT
PRODUCTS” described in the service
manual.
Pb Solder, Pb Joints, Pb PCA
This product uses lead-free solder
on the circuit boards. For repairing
circuit boards, see "Precautions for
resoldering" in this Service Manual.
DLP™ PROJECTOR
DL23 CHASSIS

- 2 -
NOTES FOR SERVICING RoHS-COMPLIANT PRODUCTS
Follow the notes and instructions below when servicing RoHS-compliant
products.
1. For RoHS-compliant products, be sure to use RoHS-compliant service parts.
2. Check the presence of <G> marking on the rating plate to distinguish RoHS-
compliant product from non-RoHS-compliant product.
<G> marking
With <G> marking: RoHS-compliant product
Without <G> marking: Non-RoHS-compliant product
<Sample>
3. Labels of RoHS-compliant service parts bear <G> marking for identification purpose.
<Sample>
4. Don’t use non-RoHS-compliant parts with RoHS-compliant products.
5. Service parts for RoHS-compliant products are listed in the parts catalog contained
in the service manual.
Parts Name
Model Name
Parts No.
E05R
Mark position
8.7A
XD8100U
850C180A10
Mark position

- 3 -
SPECIFICATIONS
• Rated Voltage
•
Power Consumption
• Display Technology
• Projection Lens
•
Light Source Lamp
• Image Size
(projection distance)
• Computer Signal
• Video Signal
• Component Signal
• S-Video Input
• Video Input
• Component Video Input
• Analog Input
•
Digital Input (DVI)
•
Digital Input (HDMI)
• Control Terminal/
Others
• Dimensions
(not including protrusion)
• Weight
• Operating temperatures
: AC 100 to 240V ; 50/60Hz,
: 8.7A , 860W
During standby
AC 100-120V:
2W (when STANDBY MODE is STANDARD)
0.2W (when STANDBY MODE is LOW)
AC 220-240V:
2W (when STANDBY MODE is STANDARD)
0.3W (when STANDBY MODE is LOW)
: 0.7-inch single chip DMD
Pixel 1,024 × 768 = 786,432 pixels
: F 2.0 - 2.4 f = 24.5 - 33.1 mm
: 330 W
× 2
: 40 to 300 inch
(projection distance ; 1.4 to 10.6 m)*1
: Maximum resolution ; 1,920 × 1,200 dots
Panel resolution ; 1,024 × 768 dots
: NTSC/PAL/SECAM/4.43NTSC/PAL-M/PAL-N/PAL-60
: 480i,480p,576i,576p,720p,1080i,1080p
Panel resolution ; 1,024 × 768 dots
:
Luminance signal ; 1.0 V(p-p) 75Ω(negative sync)
Chrominance signals ; 0.286 V(p-p) 75Ω(burst signal)
: 1.0 V(p-p) 75 Ω(negative sync)
: YCBCR;
Y ; 1.0 V(p-p) 75 Ω(negative sync)
C
BCR ;0.7 V(p-p) 75 Ω
: RGB ;
0.7 V(p-p) 75 Ω(negative sync)
: YCBCR;
Y ; 1.0 V(p-p) (negative sync)
C
BCR ;0.7 V(p-p)
: HD/CS ;
TTL level ( negative or positive polarity)
: VD ; TTL level (negative or positive polarity)
: DVI-D interface (TMDS single link) with HDCP
: HDMI interface (TMDS single link)
: SERIAL IN/OUT (D-SUB 9-pin male)
RS-232C standards,
LAN (RJ-45),
REMOTE 1 IN (D-SUB 9-pin female),
REMOTE2 IN/OUT (Stereo mini jack (ø3.5))
: 490 (W) × 201 (H) × 421 (D) mm
(projector only)
490 (W) × 201 (H) × 506 (D) mm
(including the terminal cover)
: 16.0 kg (projector only)*1
: 16.5 kg (including the terminal cover)
*1
: +41°F (+5°C) to +104°F (+40°C)
( Standard altitude mode: Floor
installation/ceiling installation)
+41°F (+5°C) to +95°F (+35°C)
(Other than above.)
*1: For XD8100U only.
• Weight and dimensions shown are approximate.
• Design and specifications are subject to change without notice.

- 4 -
CONTENTS
– FILE “COVERPGE” –
NOTES FOR SERVICING RoHS-COMPLIANT PRODUCTS ............................................................................... 2
SPECIFICATIONS................................................................................................................................................. 3
CONTENTS........................................................................................................................................................... 4
– FILE “EXPOSED” –
TRADE MARK, REGISTERED TRADEMARK...................................................................................................... 1
PRODUCT SAFETY NOTICE ............................................................................................................................... 1
SAFETY PRECAUTIONS...................................................................................................................................... 2
PRECAUTIONS FOR RESOLDERING................................................................................................................. 3
PCB LOCATION .................................................................................................................................................... 4
EXPOSED VIEW................................................................................................................................................... 6
DLP ASSY........................................................................................................................................................ 6
Chassis ASSY 1............................................................................................................................................... 8
Chassis ASSY 2............................................................................................................................................... 10
Chassis ASSY 3............................................................................................................................................... 12
Chassis ASSY 4............................................................................................................................................... 14
Main terminal ASSY......................................................................................................................................... 16
Filter ASSY....................................................................................................................................................... 17
Optical unit 1.................................................................................................................................................... 19
Optical unit 2.................................................................................................................................................... 21
DISASSEMBLY ..................................................................................................................................................... 22
1. Removal of the lens ASSY, zoom, focus motor ASSY ................................................................................. 22
2. Removal of the color wheel ASSY ............................................................................................................... 23
3. Removal of the ACF SENSOR PCB ASSY.................................................................................................. 23
4. Removal of the exhaust fan ASSY (front) .................................................................................................... 24
5. Removal of the lamp fan 1........................................................................................................................... 25
6. Removal of the lamp fan 3........................................................................................................................... 25
7. Removal of the MOTOR PCB ASSY............................................................................................................ 26
8. Removal of the IRF PCB ASSY ................................................................................................................... 26
9. Removal of the drive motor ASSY, ACF MOTOR PCB ASSY...................................................................... 26
10.Removal of the exhaust fan (rear) .............................................................................................................. 27
11.Removal of the IRR PCB ASSY.................................................................................................................. 27
12.Removal of the KEY PCB ASSY................................................................................................................. 28
13.Removal of the main terminal ASSY........................................................................................................... 28
14.Removal of the MAIN PCB ASSY............................................................................................................... 29
15.Removal of the TERMINAL PCB ASSY...................................................................................................... 29
16.Removal of the power fan........................................................................................................................... 29
17.Removal of the FORMATTER PCB ASSY.................................................................................................. 30
18.Removal of the DRCT OFF PCB ASSY...................................................................................................... 31
19.Removal of the DMD fan ............................................................................................................................ 31
20.Removal of the POWER PCB ASSY .......................................................................................................... 32
21.Removal of the lamp power unit ................................................................................................................. 32
22.Removal of the PFC PCB ASSY................................................................................................................. 33
23.Removal of the optical unit ......................................................................................................................... 34
24.Removal of the CW fan............................................................................................................................... 35
25.Removal of the lamp fan 2.......................................................................................................................... 36
26.Removal of the lamp fan 4.......................................................................................................................... 36
27.Removal of the light pipe ASSY.................................................................................................................. 37
28.Removal of the DMD PCB ASSY................................................................................................................ 38
29.Removal of the DMD chip........................................................................................................................... 38
30.Removal of the lens shift motor ASSY........................................................................................................ 39
31.Removal of the shift sensor ASSY.............................................................................................................. 39
32.Removal of the shutter ASSY, shutter motor ASSY .................................................................................... 40
33.Removal of the flat mirror ASSY ................................................................................................................. 40
LEAD DRESS........................................................................................................................................................ 41
PACKING............................................................................................................................................................... 46
– FILE “MAINTENA” –
LAMP REPLACEMENT......................................................................................................................................... 1
MAINTENANCE .................................................................................................................................................... 4
AUTOMATIC CLEANING FILTER ......................................................................................................................... 5
RESET OF THE THERMAL PROTECTOR........................................................................................................... 7
SERVICE COMMANDS ........................................................................................................................................ 8
Display the operation status screen................................................................................................................. 8
Reset to the factory settings ............................................................................................................................ 8
Reset the lamp operating time......................................................................................................................... 8
LIFE TIME OF THE CONSUMABLE PARTS ........................................................................................................ 9
DEFECT STANDARD OF DMD PIXEL (REFERENCE)........................................................................................ 9
FUNCTION MENU (SETTING MENU ONLY FOR SERVICE) .............................................................................. 10
REPLACEMENT OF THE MAIN PCB ASSY......................................................................................................... 11

- 5 -
REPLACEMENT OF THE TERMINAL PCB ASSY................................................................................................ 12
DOWNLOAD OF THE FIRMWARE....................................................................................................................... 13
DOWNLOAD OF LAN MICROCOMPUTER SOFTWARE .................................................................................... 14
– FILE “ELCTADJ” –
ELECTRICAL ADJUSTMENTS ............................................................................................................................. 1
Necessary Equipment and Connecting ........................................................................................................... 1
Test Signal ....................................................................................................................................................... 1
Adjustment with Microsoft®Windows®95/98/Me/XP Operating System......................................................... 2
Adjustment Procedures ................................................................................................................................... 3
DMD BIAS VOLTAGE ADJUSTMENT................................................................................................................... 5
– FILE “DIAGNO” –
DIAGNOSIS INFORMATION................................................................................................................................. 1
DIAGNOSTIC SOFTWARE,TO READ WARNING HISTORY(PCGC8 Ver.2)....................................................... 4
SPECIFICATION OF RGB SIGNALS IN EACH COMPUTER MODE OF THE PROJECTOR.............................. 7
– FILE “DIAGFLOW” –
DIAGNOSIS FLOW CHART.................................................................................................................................. 1
Image system .................................................................................................................................................. 1
Power source system 1 ................................................................................................................................... 2
Power source system 2 ................................................................................................................................... 3
Power source system 3 ................................................................................................................................... 4
– FILE “PCCONTRL” –
Controlling the projector using a personal computer............................................................................................. 1
– FILE “PARTSLST” –
PARTS LIST .......................................................................................................................................................... 1
PCB LOCATION .............................................................................................................................................. 2
EXPOSED VIEW ............................................................................................................................................. 3
DLP ASSY.................................................................................................................................................. 3
Chassis ASSY 1 ......................................................................................................................................... 3
Chassis ASSY 2 ......................................................................................................................................... 3
Chassis ASSY 3 ......................................................................................................................................... 4
Chassis ASSY 4 ......................................................................................................................................... 4
Main terminal ASSY ................................................................................................................................... 5
Filter ASSY................................................................................................................................................. 5
Optical unit 1 .............................................................................................................................................. 6
Optical unit 2 .............................................................................................................................................. 6
PACKING......................................................................................................................................................... 7
ELECTRICAL PARTS AND OTHERS.............................................................................................................. 8
– FILE “SCHEMATC” –
IC BLOCK DIAGRAMS
SCHEMATIC DIAGRAMS
PRINTED CIRCUIT BOARD PARTS LAYOUT

- 1 -
Microsoft Windows 95/98/Me/XP are either registered trademarks or trademarks of Microsoft Corporation in the United States
and/or other countries.
Other brand or product names are trademarks or registered trademarks of their respective holders.
TRADEMARK, REGISTERED TRADEMARK
Many electrical and mechanical parts in the projector have special safety related characteristics. These characteristics are often
not evident from visual inspection nor can the protection afforded by them necessarily be obtained by using replacement compo-
nents rated for higher voltage, etc. Replacement parts which have these special safety characteristics are identified in this ser-
vice manual. Electrical components having such features are identified by shading on the schematic diagram and the parts list
of this service manual and by the supplementary sheet for this chassis to be issued subsequently.
PRODUCT SAFETY NOTICE

- 2 -
Europe, other than USA
NOTICE: Observe all cautions and safety related notes located inside the cabinet and on the chassis.
Warning
1. An isolation transformer should be used between the projector and the AC supply point before any test/service is performed
on a LIVE chassis projector.
2. Operation of this projector outside the cabinet or with the cover removed, involves a shock hazard from the projector power
supplies. Work on the projector should not be attempted by anyone who is not thoroughly familiar with precautions neces-
sary when working on high voltage equipment.
3. When service is required, observe the original lead dressing. Extra precaution should be given to assure correct lead dress-
ing in the high voltage area. Where a short-circuit has occurred, replace those components that indicate evidence of over-
heating.
Leakage current cold check
Before returning the projector to the customer, it is recommended that leakage current be measured according to the following
methods.
With the AC plug removed from the AC source, place a jumper across the two AC plug prongs. Turn the projector AC switch
on. Using an 500 V D.C. Insulation Tester, connect one lead to the jumpered AC plug and touch the other lead to each exposed
metal part (screwheads, etc.), particularly any exposed metal part having a return path to the chassis. Exposed metal parts hav-
ing a return path to the chassis should have a minimum resistance reading of 4 MΩ. Any resistance below this value indicates
an abnormality which requires corrective action.
V
S1
S2
GH
(grounding)
open
Grounding supply conductor B
Insulating table
Projector
A
AC milliammeter
Figure
A
C 100 to 240V
North america
NOTICE: Observe all cautions and safety related notes located inside the cabinet and on the chassis.
Warning
1. Operation of this projector outside the cabinet or with the cover removed presents a shock hazard from the projector power
supplies.
2. When a short-circuit has occurred, replace those components that indicate evidence of overheating.
3. Grounding circuit continuity is vital for safe operation of equipment. Do not remove ground connection while the power cord
is still connected to the supply. Disconnect supply before servicing.
Leakage current check
Before returning the projector to the customer, it is recommended that leakage current be measured according to the follow-
ing methods.
1. Cold check
With the AC plug removed from the AC 100 to 240 V, place a jumper across the two AC plug prongs. Turn the projector AC
switch on. Using an ohm-meter, connect one lead to the AC plug and touch the other lead to each exposed metal part (metal
cabinet, screwheads, metal overlays, etc.), particularly any exposed metal part having a return path to the chassis. Exposed
metal parts having a return path to the chassis should have a minimum resistance reading of 1 MΩ. Any resistance below
this value indicates an abnormality which requires corrective action. Exposed metal parts not having a return path to the
chassis will indicate an open circuit.
2. Hot check
Use the circuit in figure to perform this test.
(1) With switch S1 open, connect the projector to the measuring circuit. Immediately after connection, measure the leakage
current using both positions of switch S2, and with the switching devices in the projector in all of their operating positions.
(2) Switch S1 is then closed, energizing the projector. Immediately after closing the switch, measure the leakage current us-
ing both positions of switch S2, and with the switching devices in the projector in all of their operating positions. Current
measurements of items (1) and (2) are to be repeated after the projector has reached thermal stabilization. The leakage
current must not be more than 0.5 mA.
SAFETY PRECAUTIONS

- 3 -
Lead-free solder is handled in a different way from eutectic solder. See below for details.
How to distinguish circuit boards using lead-free solder from those using
eutectic solder
Circuit boards using lead-free solder
A mark of Solder, Joints, PCA or LFS (for limited marking space) is printed near the board assembly number on
the component side.
Circuit boards using eutectic solder
Circuit boards using eutectic solder are divided into two groups.
- Boards having no mark of Solder, Joints, PCA or LFS (for limited marking space) near the board assembly
number.
- Boards having a mark of Solder, Joints, PCA or LFS (for limited marking space) that is painted out by a felt-
pen near the board assembly number.
* Only when there is a limited marking space on the board, Solder may be indicated as S, Joints as J, and
PCA as P.
* Circuit boards using lead-free solder and those using eutectic solder may be used together in the same product.
Instructions for resoldering
- For circuit boards using lead-free solder, use lead-free solder.
- For circuit boards using eutectic solder, use eutectic solder.
- Separate the soldering iron for lead-free solder from that for eutectic solder completely for use.
(It is prohibited to use a same soldering iron for lead-free solder and eutectic solder.)
- For lead-free solder, it is advisable to use a soldering iron of at least 40 W because lead-free solder has a melting point ap-
prox. 35°C higher than that of eutectic solder as conventionally used. For wire solder, use M705ESC made by Senju Metal
Industry Co., Ltd.
- To remove solder, you can use desoldering wires for eutectic solder as conventionally used.
PRECAUTIONS FOR RESOLDERING

- 4 -
PCB LOCATION
Fig.1
1
2
7
5
8
3
4
6910
11
12
13 14

- 5 -
Parts list : See page 2 of PARTS LIST
Item No. Part name
1 MAIN PCB ASSY
2 TERMINAL PCB ASSY
3 KEY PCB ASSY
4 FORMATTER PCB ASSY
5 POWER PCB ASSY
6 MOTOR PCB ASSY
7 IRR PCB ASSY
8 IRF PCB ASSY
9 DRCT OFF PCB ASSY
10 PFC PCB ASSY
11 LAMP POWER UNIT
12 DMD PCB ASSY
13 ACF MOTOR PCB ASSY
14 ACF SENSOR PCB ASSY
Table 1

- 6 -
EXPOSED VIEW
Fig.2-1
5
3
Fx1
Hx2
7
2
Dx2
Cx3
8
Ex1
Gx1
1
Ax1
46
Kx2
Jx1
Bx1
9
DLP ASSY

- 7 -
Part name Number of screw
1.Lens cap None
2.Lens ring None
3.Top case ASSY Cx3, Dx2, Ex1, Fx1, Gx1
4.CW cover unit Bx1
5.Top cover ASSY Ax1
6.Terminal cover Hx2
7.Filter cover unit Jx1
8.Lamp cover unit Kx2
9.Top ASSY
Table 2-1
Parts list : See page 3 of PARTS LIST

- 8 -
Chassis ASSY 1
Fig.2-2
1
Ax10
Bx2
Cx2
4
5
Fx5
Gx2
Hx2
6
8
9
2
Kx5
Lx3
3Dx2
7
Jx1
Ex2

- 9 -
Part name Number of screw
1.Main top shield Ax10
2.Main terminal ASSY Bx2, Cx2
3.Radiator plate Dx2, Ex2
4.FORMATTER PCB ASSY Fx5
5.CW plate 2 Gx2
6.CW plate 1 Hx2
7.Micro switch unit Jx1
8.Terminal board ASSY Kx5
9.KEY PCB ASSY Lx3
Table 2-2
Parts list : See page 3 of PARTS LIST

- 10 -
1
Ax5
4
5
6
8
7
Bx2
Cx4
Dx2
Ex4
Hx2
11
2
3
10
9
Hx2
Fx1
Gx2
Chassis ASSY 2
Fig.2-3

- 11 -
Part name Number of screw
1.Main shield bottom Ax5
2.lamp power duct None
3.Lamp power unit None
4.POWER PCB ASSY Bx2
5.Power shield Cx4
6.PFC duct None
7.Power shield R Dx2
8.PFC PCB ASSY Ex4, Fx1,Gx2
9.Triger holder T None
10.Triger holder B None
11.CNT AC support Hx2
Table 2-3
Parts list : See page 3 of PARTS LIST

- 12 -
Chassis ASSY 3
Fig.2-4
1
Ax2
3
5
4
6
7
8
9
Cx2
Dx2
Ex1
Fx2
Hx4
1
Jx3
Kx2
Lx1
2
Mx1
10
13
12
16
17
Bx1
Gx2
14
11
15

- 13 -
Part name Number of screw
1.EX duct FT Ax2
2.Exhaust fan (front) None
3.EX duct FB None
4.EX duct F Bx1
5.EX duct RT Cx2
6.Exhaust fan (rear) None
7.EX duct RB None
8.Side panel L Dx2
9.IRR PCB ASSY Ex1
10.Fan holder Fx2
11.Power fan None
12.Fan holder Gx2
13.Side panel R Hx4
14.MOTOR PCB ASSY Jx3
15.Lens shield Kx2
16.Filter ASSY Lx1
17.Screw side holder Mx1
Table 2-4
Parts list : See page 4 of PARTS LIST

- 14 -
5
Ax6
4
Bx2
Cx3
Dx4
2
11
7
17
14
16
1
6
8
9
10
12
13
15
19
18
Bx2
Ex3
Fx3
Gx2
Hx1
Jx2 Lx3
Kx3
Mx2
3
Chassis ASSY 4
Fig.2-5

- 15 -
Part name Number of screw
1.Optical unit Ax6
2.Thermostat Bx2
3.Sensor plate None
4.Holder cover unit LP Cx3
5.Optical base plate Dx4
6.HP duct T Ex3
7.HP duct B Fx3
8.DMD fan None
9.ENT duct Gx2
10.IRF PCB ASSY Hx1
11.DRCT OFF PCB ASSY Jx2
12.Holder power off None
13.Power shield F Kx3
14.CW duct T Lx3
15.CW duct C None
16.CW duct B None
17.CW fan Mx2
18.Adjustment foot None
19.Bottom case ASSY None
Table 2-5
Parts list : See page 4 of PARTS LIST