Mitsubishi Electric XD221U User manual

2009
CAUTION
Before servicing this chassis, it is important that the service person reads the “PRODUCT SAFETY NOTICE” in this service
manual.
SPECIFICATIONS
Copyright © 2009 Mitsubishi Electric Corporation All Rights Reserved.
MODEL
XD221U/
XD221U -G
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
Rated power supply : 100-240 V AC, 50/60 Hz
Rated input : 2.7A
Display technology : 0.55 inch Single chip
Digital Micromirror Device (DMD)
Pixels : 1,024x768= 786,432 pixels
Colors : 16,770,000 colors
Projection lens : F2.5-2.7, f=19.9-23.9 mm
Light source lamp :180 W
Picture Size : 40-300 inch, aspect ratio rate 4:3
PC compatibility : 640 x 400 (Expand) -1,024 x 768 (Real) -
1,280 x 1,024 (Compress)
Sync on Green available
Video compatibility : NTSC / NTSC 4.43 / PAL (including PAL-M, N)
/ SECAM / PAL-60 / Component Video
(DVD/HDTV) (480i/p, 576i/p, 720p, 1080i)
Speaker : 10W mono round type
•
•
•
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•
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•
•
•
•
S-Video input : Luminance signal: 1.0 Vp-p
   75Ω(negativesync)
  Chromasignal:0.286Vp-p75Ω
(burst signal)
Video input :1.0Vp-P75Ω(negativesync)
Audio input :350mVrms,10kΩormore
Analog RGB input :RGB:0.7Vp-p75Ω(negativesync)
YPbPr/YCbCr: Y-> 1.0 Vp-p (negative sync)
PbPr/CbCr-> 0.7 Vp-p
HD/CS: TTL level(positive or negative)
VD: TTL level(positive or negative)
Control connector : Serial terminal(RS-232C) (Mini-Din)
Outside dimensions : 302 x 104 x 236mm (width x height x depth)
Weight : Approx. 3.2kg
Temperature, humidity : +41°F (+5°C) - +95°F (+35°C), 30-90%
(performance guaranteed)
• Weight and dimensions shown are approximate.
•Designandspecicationsaresubjecttochangewithoutnotice.
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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identication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
Mark position

- 3 -
– FILE “COVERPGE” –
SPECIFICATIONS................................................................................................................................................. 1
NOTES FOR SERVICING RoHS-COMPLIANT PRODUCTS ............................................................................... 2
CONTENTS........................................................................................................................................................... 3
– FILE “EXPOSED” –
TRADE MARK, REGISTERED TRADEMARK...................................................................................................... 1
PRODUCT SAFETY NOTICE ............................................................................................................................... 1
SAFETY PRECAUTIONS...................................................................................................................................... 2
PRECAUTIONS FOR RESOLDERING................................................................................................................. 3
EXPOSED VIEW................................................................................................................................................... 4
DLP ASSY........................................................................................................................................................ 4
Optical unit....................................................................................................................................................... 6
DISASSEMBLY ..................................................................................................................................................... 8
LABEL POSITION ................................................................................................................................................. 18
PACKING............................................................................................................................................................... 19
– FILE “MAINTENA” –
REPLACING THE LAMP....................................................................................................................................... 1
MAINTENANCE .................................................................................................................................................... 3
ENGINEERING MODE.......................................................................................................................................... 4
LIFE TIME OF THE CONSUMABLE PARTS ........................................................................................................ 6
DEFECT STANDARD OF DMD PIXEL (REFERENCE)........................................................................................ 6
DOWNLOAD OF THE FIRMWARE....................................................................................................................... 7
– FILE “PCCONTRL” –
Controllingtheprojectorusingapersonalcomputer............................................................................................. 1
– FILE “DIAGNO” –
DIAGNOSIS INFORMATION................................................................................................................................. 1
SPECIFICATION OF RGB SIGNALS IN EACH COMPUTER MODE OF THE PROJECTOR.............................. 2
– FILE “DIAGFLOW” –
TROUBLESHOOTING .......................................................................................................................................... 1
Power source 1................................................................................................................................................ 1
Power source 2................................................................................................................................................ 2
Video signal 1 .................................................................................................................................................. 3
Video signal 2 .................................................................................................................................................. 4
Operation function ........................................................................................................................................... 5
– FILE “PARTSLST” –
PARTS LIST .......................................................................................................................................................... 1
EXPOSED VIEW ............................................................................................................................................. 2
PACKING ......................................................................................................................................................... 4
ELECTRICAL PARTS AND OTHERS.............................................................................................................. 5
– FILE “SCHEMATC” –
BLOCK DIAGRAM................................................................................................................................................. 1
CONTENTS

- 1 -
DLP™ (Digital Light Processing) and DMD (Digital Micromirror Device) are trademarks of Texas Instruments Incorporated.
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 identied in this ser-
vice manual. Electrical components having such features are identied 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 met-
al part (screwheads, 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 4 megohm. 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
AC 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 megohm. Any resistance be-
low 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 gure 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 milliampere.
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

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12
5
6
OPTICAL UNIT
8
11
14
9
7
10
3
4
12
13
EXPOSED VIEW
Fig.1-1
DLP ASSY

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Table 1-1
Parts list : See page 2 of PARTS LIST
Item No. Part name
1 LAMP COVER
2 IO COVER
3 TOP COVER
4 MAIN PCB ASSY
5 AUDIO PCB ASSY
6 SPEAKER
7 LAMP POWER UNIT
8 IR(F) PCB ASSY
9 FAN MOTOR (POWER)
10 FAN MOTOR (EXHAUST)
11 POWER PCB ASSY
12 BOTTOM COVER
13 ADJUSTER
14 KEY PCB ASSY

- 6 -
Optical unit
2
1
3
45
6
7
8
Fig.1-2

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Item No. Part name
1 DMD-CHIP
2 DMD PCB ASSY
3 LENS UNIT
4 COLOR WHEEL PCB ASSY
5 COLOR WHEEL
6 LIGHT PIPE
7 FAN MOTOR (LAMP)
8 LAMP CONNECTOR
Table 1-2
Parts list : See page 3 of PARTS LIST

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DISASSEMBLY
1Unscrew the 8 screws (a) from
the bottom cover.
(a)
(a)

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2Unscrew the 6 screws (a) and
unscrew the 3 screws (b) ,then
take off the IO COVER.
3Remove the cover of the screw
fixing the lamp cover with a
fingernail.
Remove the screw (a) and
slide the lamp cover for
removal.
(a)
(b)
(b)
(a)
Cover of the screw fixing the lamp cover
Lamp cover

- 10 -
4Make sure zoom ring and
focus ring back inside.
Then take the top cover off
gently.
Note: Please disconnect the
FFC cable connected with
MAIN PCB ASSY first before
take the top cover off.
5Unscrew the 5 screws and then
remove main top shield.
Top cover
Unscrew sequence : E - D - C - B - A
C B A E
D
Main top shield

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Note
1.Show you what the connector
should be.
2.Disconnect all lines gently.
6Remove the MAIN PCB
ASSY.
/#+02%$#55;
MAIN PCB ASSY

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7
Remove the two fan motor.
8Unscrew 1 screw (a) and
1 screw(b).
Then take out the lamp
power unit.
Unscrew 2 screw (c).
Then take out the AUDIO
PCB ASSY.
Fan motor(exhaust)
Fan motor(power)
Lamp power unit
(a)
(b)
(c)
(c)

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9
Unscrew the 6 screws.
screws.
Then take out the optical
unit gently.
10 Unscrew the 4 screws(a),
disconnect (b) and (c)
then take off POWER PCB
ASSY.
Optical unit
Unscrew sequence D - C - B - A
(D) (B) (C) (A)
(F)
(E)
POWER PCB ASSY
(a)
(a)
(b)
(c)
(a) (a)

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11
Take off the power board
holder.
12 Unscrew 2 screw (a).
Then take off the lighting
wire module.
Power board holder
Lighting wire module
(a)
(a)

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13
Unscrew the 4 screws (a)
take off grille.
14 Unscrew the 2 screws (a)
take off lens holder.
(a)
Grille
(a)
(a)
(a)
(a)
Lens holder
(a)

- 16 -
15
Unscrew the 2 screws (a)
take off speaker module
and (b).
16 Unscrew 1 screw (a) and
take off the IR(F)PCB ASSY.
(b)
Speaker
(a)
IR(F)PCB ASSY (a)

- 17 -
17
Remove adjuster from the
bottom cover.
Bottom cover
Adjuster