ViewSonic PJ503D-1 User manual

ViewSonic PJ503D-1
Model No. VS11705
DLP Projector
(PJ503D-1_SM Rev. 1cSep. 2008)
ViewSonic 381 Brea Canyon Road, Walnut, California 91789 USA - [phone]
Service Manual

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ViewSonic Corporation Confidential - Do Not Copy PJ503D-1
Copyright
Copyright © 2008 by ViewSonic Corporation. All rights reserved. No part of this publication
may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any
language or computer language, in any form or by any means, electronic, mechanical, magnetic,
optical, chemical, manual or otherwise, without the prior written permission of ViewSonic
Corporation.
Disclaimer
ViewSonic makes no representations or warranties, either expressed or implied, with respect to
the contents hereof and specifically disclaims any warranty of merchantability or fitness for any
particular purpose. Further, ViewSonic reserves the right to revise this publication and to make
changes from time to time in the contents hereof without obligation of ViewSonic to notify any
person of such revision or changes.
Trademarks
Optiquest is a registered trademark of ViewSonic Corporation.
ViewSonic is a registered trademark of ViewSonic Corporation.
All other trademarks used within this document are the property of their respective owners.
Product disposal at end of product life
The lamp in this product contains mercury. Please dispose of in accordance with local, state or
federal laws.
Revision History
Revision SM Editing Date ECR Number Description of Changes Editor
1a 2/13/2007 Initial Release Jamie Chang
1b 3/19/2007 Revise specification section Jamie Chang
1c 9/5/2008
Revised the "Method to enter factory menu"
in page 137. Jamie Chang

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TABLE OF CONTENTS
1. Introduction 1
2. Specifications 2
3. Software/Firmware Upgrade Process 3
4. Adjustment / Alignment Procedure 18
5. Block Diagram 85
6. Troubleshooting 86
7. Schematic Diagrams 94
8. PCB Layout Diagrams 109
9. Exploded Diagrams 122
10. Recommended Spare Parts List 125
11. Appendix 126

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This section contains general service information, please read through carefully. It should be
stored for easy access place.
Important Service Information
Safety Notice
1 Make sure your working environment is dry and clean, and meets all government safety
requirements.
2 Ensure that other persons are safe while you are servicing the product.
3 DO NOT perform any action that may cause a hazard to the customer or make the product
unsafe.
4 Use proper safety devices to ensure your personal safety.
5 Always use approved tools and test equipment for servicing.
6 Never assume the product’s power is disconnected from the mains power supply. Check that
it is disconnected before opening the product’s cabinet.
7 Modules containing electrical components are sensitive to electrostatic discharge (ESD).
Follow ESD safety procedures while handling these parts.
8 Some products contain more than one battery. Do not disassemble any battery, or expose it
to high temperatures such as throwing into fire, or it may explode.
9 Refer to government requirements for battery recycling or disposal.
General Descriptions
This Service Manual contains general information. There are 2 levels of service:
Level 1: Cosmetic / Appearance / Alignment Service
Level 2: Circuit Board or Standard Parts Replacement
Level 3: Component Repair to Circuit Boards
1. Introduction

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2. Specifications
Drive system DLP
Panel size 1.4cm(0.55” type)
Liquid crystal
panel
Number of pixels 800 (H) x 600 (V)
Lamp Ushio 160W
RGB signal RGB IN
Video : Analog 0.7Vp-p(75Ωtermination)
H/V. sync. : TTL level (positive/negative)
Composite sync. : TTL level
VIDEO IN 1.0Vp-p (75Ωtermination)
S-VIDEO IN Y signal: 1.0±0.1Vp-p, (75Ωtermination)
C signal: 0.286±0.1Vp-p (NTSC burst signal, 75Ωtermination)
Y
CB/PB
VIDEO signal
COMPONENT
VIDEO
CR/PR
1.0±0.1Vp-p, 75Ωtermination (positive)
0.7±0.1Vp-p, 75Ωtermination (positive)
0.7±0.1Vp-p, 75Ωtermination (positive)
Power supply 100~240V 50~60Hz 2.5A
Power consumption 250W
Dimensions 263 (W) x 108 (H) x 218 (D) mm
Weight 2.6 kg
Temperature range Operation : 0~40°C
Storage : -20~60°C
Accessories
Remote control x1 Batteries x 2
RGB cable x 1 User’s manuals x 1
Power cords x 3 CD Wizard x 1

ViewSonic Corporation Confidential - Do Not Copy PJ503D-1
Level 1 Cosmetic / Appearance / Alignment Service
Software/Firmware Upgrade Process
How to Download Firmware
Hardware required
1. Standard USB Download cable (P/N 50.73213.501)
2. Personal computer or laptop computer
Software required
1. DDP2000 Composer lite
2. New version FW
DDP2000 Composer lite install procedure
Installation Location
The default installation directory is:
C:\Program Files\DLP Composer Lite
If you want to install to a different directory (perhaps alongside a prior release of DLP
Composer™ Lite), click the "Browse" button on the "Select Features" page..
USB Support - Installation (All Platforms)
This release includes support for a USB communications interface to DDP2000-based
projectors. The setup program includes the files needed to install USB support (for
Win98/WinMe/Win2K/WinXP only -- Win95 and WinNT are not supported).
After DLP Composer™ Lite is installed, to install the USB support, choose the "Install
DDP2000 USB Driver" icon under "DLP Composer™ Lite" in your Start menu.
USB Support - Win98/WinMe Only
Installation on Windows 98 or Windows Me may prompt "Please insert the disk labeled 'DLP
Composer Installation Directory', and then click OK". This message may be safely ignored
by clicking the OK button.
Another prompt will then appear: "The file 'windrvr6.sys' on DLP Composer Installation
Directory cannot be found". Again, click OK and the installation proceeds without further
3. Software/Firmware Upgrade Process
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problems.
USB Support - Using a projector for the first time
After installation is complete, and you plug a DDP2000-based projector into USB for the first
time, Windows will run the "New Hardware Wizard". When the wizard prompts to find the
necessary drivers, accept the recommended choice (let the system find the driver for you)
and click "Next" to complete the installation.
Note: The Windows 98/Me "New Hardware Wizard" may not automatically find the
driver. You should use the "Advanced" option, and enter the directory where the DLP
Composer™ Lite Tool Suite was installed (normally "C:\Program Files\DLP Composer
Lite"). The wizard will find the file "DDP2000.inf" and complete the installation.
USB Support - Choosing the USB interface
To select the USB communications interface, choose "Preferences" from the "Edit" menu,
click the "Communications" page and choose "USB (DDP2000 Only)". You can now use
DLP Composer™ Lite to communicate with a DDP2000-based projector via USB using the
Flash Loader tool.
Download procedure
1. Click on Flash Loader and browse the image file (new version firmware)
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2. Make sure to check “Skip Boot loader area (load all but the first 16KB)”
3. Plug power cord into projector
4. Press “UP+SOURCE+AUTO” simultaneously on keypad, the projector LAMP LED
would lite on
5. Plug in USB cable between computer and projector side
6. Press start download to begin update new firmware
7. Wait till composer lit notice upgrade completed
8. Download is completed. The factory settings should be restored.
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Visual Inspection & Cleaning
PART I Visual Inspection Criteria
1. 外觀檢驗規格/Appearance Inspection Spec.
1.1 標準檢驗環境規範 (Environment Condition)
1.1.1 光源強度(Lighting intensity)
所有外觀品質的檢驗環境亮度(白色燈管或自然光源)條件為 500- 800Lux。
All appearance quality shall be inspected with the lighting condition as 500~800Lux
(natural lighting or white fluorescent light).
1.1.2 目標或被觀察物的位置與目視距離
Inspection angle and distance to object or target
所有目標或被觀察物都要放置在投射的光源下檢測，其目視檢測的角度與距離是根據表
面位置等級加以區分。在所有檢測中，光源儘量避免其產品或零件對檢測人員眼睛造成
反射干擾。
All part inspection must be done under direct overhead lighting. Viewing angle and
distance are dependent on surface classification. In all cases, parts must be held in
such that the light reflection does not disturb the inspector's eye.
圖1
等級區分
Classification
A 區
Area A
B 區
Area B
C 區
Area C
光源位置
Lighting positioning
被觀察物正上方
Above of inspected part
目視與被觀察物位置(垂直)
Inspection position relative to part
90º 90º 90º
目視距離(參考距離)
Inspection distance
40-50 cm 40-50 cm 40-50 cm
表1
1.1.3 檢視時間
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Inspection interval (time)
檢視時間與樣品大小及檢視區域有關。
Inspection interval is a function of surface area.
檢視時間以 10 秒為限。
Time for visual inspection: 10sec.
Parts Size “A” surface “B” surface “C” surface
Time 10 sec 10 sec 10 sec
表2
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Ei i St
TABLE 1. 產品一般外觀塑膠件的黑點、雜質、凸點、砂粒缺陷檢驗標準
(General Product of plastic outlook of dot, blemish, and others spec inspection standard)
A級面
A surface
(允許數)
(Number of defect)
B級面
B surface
(允許數)
(Number of defect)
C級面
C surface
(允許數)
(Number of defect)
規格
Spec
(面積 cm2)
( Area cm2) 20*20 50*50 70*70 100*
100 20*20 50*50 70*70 100*
100 20*20 50*50 70*70 100*
100
P < 0.2 mm2
點距 Distance ≥
2cm
不計
Ignore 不計 Ignore 不計 Ignore 不計 Ignore 不計 Ignore 不計 Ignore 不計 Ignore 不計 Ignore 不計 Ignore 不計 Ignore 不計 Ignore 不計 Ignore
0.2≦P< 0.3
mm2
點距 Distance ≥
4cm
2 3 4 5 2 3 4 5 4 4 5 6
雜質
Particle
黑點
Blemish
|
異色點
0.3≦P <0.4mm2
點距 Distance ≥
4cm 0 0 0 0 2 3 4 5 3 4 5 6
P<0.1 mm2
點距 Distance ≥
2cm
不計
Ignore 不計 Ignore 不計 Ignore 不計 Ignore 不計 Ignore 不計 Ignore 不計 Ignore 不計 Ignore 不計 Ignore 不計 Ignore 不計 Ignore 不計 Ignore
0.1≦P<0.2mm2
點距 Distance ≥
4cm
4 4 5 6 5 5 6 7 6 6 7 8
0.2≦P <
0.3mm2
點距 Distance ≥
4cm
3 4 4 5 4 5 5 6 6 7 7 8
凸點
砂粒
棉絮
毛屑
Particle
|
同色點
Spot
with
same
color
0.3≦P <
0.5mm2
點距 Distance ≥
5cm
2 2 3 4 3 3 4 5 4 4 5 6
Total 4 4 5 6 5 5 6 7 6 6 7 8
備註 Note:
1. 檢測面積 A <20*20 以20*20 之規範檢驗之, 20*20≦A<50*50，以 50*50 等級檢驗之，以此類推.
Use the 20*20 criteria to the area less than 20*20; 50*50 inspection criteria to the area
20*20≦A<50*50; etc.
雜質/黑點/異色點(Particle/Blemish/Color Spot)
1.1 A、B、C級面定義請參考 6.2 級面定義。
Definition of surface A, B, C refer to 6.2
1.2 LOGO 周邊 3 cm 內不可有 0.05 mm2以上之點, (0.05 mm2以內之點不計)。
Blemish around the logo must be equal or smaller than 0.05 mm2
1.3 表面氣泡—不可有。
Bubble on the surface is to be reject.
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TABLE 2 :產品一般外觀的塑膠件檢驗標準(General Product of plastic outlook inspection standard)
NO Appearance Spec
1 縮水
Shrinkage
A區: 不可有縮水 , 以帶手套檢驗, 手摸過去不可有凹陷的感覺
A region: No Shrink. With gloves, no feeling of sink when touching the surface
B / C 區: 不能明顯看出
B/C region: not obvious
2 流痕, 咬花, 光澤
Run, Texture,
Gloss
不能有明顯的深淺不均
No obvious non-uniformity
3 接合線
Welding Line/Knit
Line
用指甲劃過不會有停頓感,並附近無明顯之光澤差異
When scratching on it, there’s no feeling of obstruction. Also, there should not
be obvious difference in gloss nearby it.
4 頂白
Ejector Mark
不可
Reject
5 Label/screws
shortage
不允許
Reject
6 缺料
Material shortage
缺料不可影向機構強度和表面
Material shortage is not allowed to impact structure strength and surface
7 色差
Chromatic
aberration
噴漆(Painting): ΔE<=2; L<=1.5 ; ΔA,B <= 0.6
銀粉漆 (Paint, aluminum).
ΔE<=2 L<=1.0; ΔA, B <= 0.6
非銀粉漆(Paint, non-aluminum)
素材(Raw material) : ΔL,A,B<=0.6 ,ΔE<=0.75
8 印刷
Printing
文字印刷不得有漏印、斷線、重影、組細不均、溢墨、印偏( 2mm )、印斜 (歪
斜＜0.5 mm )。
Printing must not have incomplete printing, break off, overlap, uneven
thickness, excessive ink, printing misalignment (2mm), printing slanting &
crooked (<0.5mm)
文字印刷顏色須確認是否正確 。
Printing color must be comparable to color chip and sample.
9 Logo of panel
sticker
文字印刷不得有漏印.斷線.重影.組細不均.溢墨.印偏( 2mm)印斜 (歪斜 ＜0.8
mm).
Printing must not have incomplete printing, break off, overlap, uneven
thickness, excessive ink, printing misalignment (2mm), printing slanting &
crooked (<0.8mm)
文字印刷顏色須確認是否正確.
Printing color must be comparable to color chip and sample.
10 刮傷
Scratch/Nicks
Side A:
(W < 0.2mm , L < 5mm): 容許 2個
Only 1 this kind of scratch is accepted
W < 0.1mm , L < 5-10mm 容許 1個
No this kind of scratch is accepted
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Side B:
W < 0.2mm , L < 5mm 容許 3個
Only less than 2 this kind of scratch is accepted
W < 0.2mm , L < 5-10mm 容許 2個
Only 1 this kind of scratch is accepted
Side C:
W < 0.3mm , L < 5mm 容許 4個
Only 4 this kind of scratch is accepted
W < 0.3mm , L < 5-10mm 容許 3個
Only 3 this kind of scratch is accepted
W < 0.3mm , L < 10-15mm 容許 2個
Only 2 this kind of scratch is accepted
Note:
1.刮傷見底材者不允許
Severe scratch which disclose the Natural
2.輕微的檫傷，用指甲劃過不會有停頓感,並附近無明顯之光澤差異，則可以
接受。
When light scratching on it, there’s no feeling of obstruction. Also, there
should not be obvious difference in gloss nearby it.
3.刮擦傷兩兩需相距 5cm 以上
Each scratch should be 5cm more far away from each other
4.A 面前蓋不允許有任何刮傷
Front case must be no any scratch

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PART II Operational Inspection Criteria
TEST CONDITIONS
Unless other prescription, the test conditions are as followings:
Nominal voltage: refer to operation manual
Environmental illumination:
Variable from 500 to 800 Lux (For appearance inspection)
Variable from 0 to 7 Lux (For functional inspection)
Temperature: 25±5℃
Visual inspection shall be done with the distance from eyes to the sample 45
cm.
Display mode: refer to operation manual
TEST EQUIPMENTS
Dark room
PC
Pattern Generator: Chroma 2327 or equivalent
Minolta color analyzer CL200 or equivalent device with accredited traceability
DVD player
Power supply (100~240 VAC) with consumption meter
Measuring tape
TEST PATTERN
PATTERN PATTERN TEST ITEM Acceptance Criteria
Full white
ANSI Brightness、
Bright Uniformity、
FOFO Contrast
Ratio、
(1) ANSI Brightness:(Normal Mode) 1050lm
(2) Uniformity: ANSI: 50% (Minimum)
(3) Contrast Ratio : 150:1 (Minimum, by ANSI
Standard Checkerboard Method), 1200:1(by All
White, All Black Method)
(4) White Point, Color :x = 0.313 ±0.04, y =
0.344 ±0.04
Full Dark
FOFO Contrast
Ratio
Contrast Ratio : 1200:1(by All White, All Black
Method)
Full Red
Impurity、CIE
coordinate
Chromaticity : Red: x =0.635 +/-0.04, y=
0.339+/-0.04

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Full Green
Impurity、CIE
coordinate
Chromaticity : Green: x =0.368 +/-0.04,
y=0.545+/-0.04
Full Blue
Impurity、CIE
coordinate
Chromaticity : Blue: x =0.147 +/-0.04, y=
0.075+/-0.04
Chromo
800x600
Focus Range
(1)Background lines should be distinguishable.
(2)“区”:Letter shape and lines should be
distinguishable.
General-1
pattern
Performance/
Timing check/
function check
(1)Phase should be stable(no flick)
(2)Whole frame should appear.
16 Gray
and Color
bar
Gray and Color
bar Check No lack or mix color
DDC check
Check the DDC
information,
Including S/N,
model,
manufacturer
name, product
code.
S/N(08-09): with numbers
Model(108-125) with numbers(ref Appendix DDC
table)
manufacturer name(08-09):5A63
product ID code (10-11): 1FC7

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PART III Inspection Criteria
IMAGE QUALITY SPECIFICATION
SEQ # TEST SCREEN ACCEPTANCE CRITERIA
1 Major Dark
Blemish
Blue 60 1. 4 visible dark blemishes are allowed in the active≦
area
2. No blemish will be >1.5” long / diameter
2 Major Light
Blemish
Gray 10 1. 4 visible light blemishes are allowed in the active≦
area
2. No blemish will be > 1.5” long / diameter
3 Reset
Boundary
Artifact
Gray 30 No rest boundary artifacts allowed
4 Eyecatchers
Border
Artifact
Any Screen 1. Eyecatcher and border artifacts are allowed
5 Projected
Images
1. Any screen
2. Gray 10
3. Any screen
4. Gray 10
5. White
6. Any screen
7. Any screen
1.No adjacent pixels
2.No bright pixels in Active Area
3.No unstable pixels in Active Area
4.≦1 bright pixel in the POM
5.≦3 dark pixels in the Active Area
6.No DMD window aperture shadowing on the Active Area
7.Minor blemishes are allowed
Notes:
1. Projected blemish numbers include the count for the shadow of the artifact in addition to the
artifact itself, so that the count usually represents a single artifact on the window.
2. During all the above table tests, projected images shall be inspected in accordance with the
conditions of inspection specified in Appendix D’s Section 3(DMD Image Quality).
3. The rejection basis for all cosmetic DMD defects (scratches, nicks, particles) will be the
projected image tests referenced in the above table.
4. Devices that meet this image quality specification but are deemed undesirable by the
customer may not be returned to T1 without prior approval by T1.
5. Screen＜Gray 10 shall not be used as a basis for rejecting a DMD for image quality.

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Gap Specification：
1.Gap between UC and FC is
0.5mm mm
mm
2.0
3.0
+
−
Step between UC and FC is
0mm mm
mm
5.0
5.0
+
−
2. Gap between LC and FC is
0.5mm mm
mm
2.0
3.0
+
−
Step between LC and FC is
0mm mm
mm
5.0
5.0
+
−
3. Gap between IR and FC is
0.2mm mm
mm
2.0
2.0
+
−
Step between IR and FC is
0mm mm
mm
3.0
3.0
+
−
4. Gap between UC and LC is
0mm mm
mm
4.0
0
+
−
Step between LC and FC is
0mm mm
mm
5.0
5.0
+
−
5.Gap between LC and Push
Button is 0.2mm mm
mm
2.0
2.0
+
−
1
3
4
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6.Gap between UC and Power
Key is 0.3mm mm
mm
2.0
2.0
+
−
7.Gap between UC and LED
Lens is 0.2mm mm
mm
2.0
2.0
+
−
Step between UC and LED
Lens is 0 mm mm
mm
3.0
3.0
+
−
8.Gap between UC and
Function Key is 0.3mm mm
mm
2.0
2.0
+
−
7
8
6

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9.Gap between UC and LC is
0mm mm
mm
4.0
0
+
−
Step between LC and FC is
0mm mm
mm
5.0
5.0
+
−
10.Gap between UC and RC is
0.4 mm mm
mm
3.0
.30
+
−
Step between UC and RC is
0mm mm
mm
3.0
3.0
+
−
11.Gap between LC and RC is
0.4 mm mm
mm
3.0
.30
+
−
Step between LC and RC is
0mm mm
mm
3.0
3.0
+
−
12.Gap between Video
Connector and RC is
1mm mm
mm
5.0
5.0
+
−
13.Gap between D-sub
Connector and RC is
1.5mm mm
mm
5.0
5.0
+
−
14.Gap between Mini-USB and
RCis0.5mm mm
mm
5.0
5.0
+
−
15.Gap between IR and RC is
0.2mm mm
mm
2.0
2.0
+
−
Step between IR and RC is
0mm mm
mm
3.0
3.0
+
−
16.Gap between Power Socket
and RC is 0.5mm mm
mm
5.0
5.0
+
−
9
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11
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17.Gap between LC and Lamp
Door is 0.3mm mm
mm
3.0
3.0
+
−
Step between LC and Lamp
Door is 0 mm mm
mm
3.0
3.0
+
−
18.Step between UC and LC is
0mm mm
mm
5.0
5.0
+
−
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