Text preview for : LP815-820_ServiceManual.pdf part of Infocus LP815 LP820 Official service manual. Faultfinding, disassembly, photos of innards. No schematics.
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LP815/LP820 PDF service manual
We designed this service manual for use on a computer. We suggest that you save it on your hard drive and make a short cut to it from the desktop. What is the difference between the LP815 and the LP820? The two models have identical specifications, with the following exceptions: The LP815 has 2,800 maximum lumens, while the LP820 has 3,200 maximum lumens in high power mode and 2,500 maximum lumens in low power mode. The LP815 does not have the low power/high power option. The audible noise level of the LP815 is 34 dB, while the noise level of the LP820 is 38db in high power mode and 34 dB in low power mode. The two models are diagnosed and repaired identically. Only two part numbers differ between the two, and each has its own system software. The part number differences are listed below. Part Controller ECA Label kit LP815 part number 510-0909-xx 802-0054-xx LP820 part number 510-1755-xx Various *
* The LP820 offers separate brand, certification, I/O and top labels. The LP815 combines the four labels into a kit. Using the manual The bookmarks that appear on the side of the screen help you navigate to each topic in the manual. You can use them to quickly go from a troubleshooting topic to instructions to remove a specific part. The manual is arranged in the order you can use to diagnose and then repair the projector. The four main sections of the service manual are: Troubleshooting-- In this section, you will find troubleshooting flowcharts for a variety of symptoms. The flowcharts lead you through power and image diagnostics, as well as audio, keypad and remote issues. There is also a controller and power supply voltage diagram. Parts Removal and Replacement--instructions to remove and replace each FRU in the projector. We've also included a Removable Parts Hierarchy you can use to see what parts must be removed to access each FRU in the projector. You can also refer to the Exploded View in the Parts Lists. Performing Functional Tests--You use these tests to ensure that the projector is ready to return to the customer after you have repaired it. Parts Lists--In this section are the exploded view, the replaceable parts list and the kit contents lists. For specifications, software updates and instructions, and current field communications, see your online ASC Resource Center.
Troubleshooting
You use the Troubleshooting section to diagnose problems with the projector. In this section, you will find troubleshooting flowcharts for a variety of symptoms. Each flowchart leads you through a series of steps that will ultimately result in a solution. The solutions begin with the most simple and progress to the most complex. On the left, select the section you want. Power problems, including lamp issues, partial power up, shutdown and no power Image problems, including no image, bad color, dim image and other picture distortions Keypad problems Remote problems Audio problems In addition to the troubleshooting trees, you will also find a controller voltage diagram.
LP815/LP820 Service Manual
Power Problems
The LP815/LP820 communicates its status via an LED and an LCD located on the keypad. When this status LED is green, you know that the projector is working properly. When the status LED is solid red or flashing red, you know there are lamp, power or startup problems. The frequency with which the status indicator blinks red indicates one of several error codes. These error codes provide crucial information about projector malfunctions. The LCD panel provides text messages related to the error messages. Below is a table that shows the meaning the various LED states. NOTE We strongly suggest that you follow the entire power diagnosis sequence. LED Status LED flashes green The projector is starting up after the Power button was pressed, or the projector is shutting down after the Power button was pressed. The projector is ready to light the lamp when the Power button is pressed. Or the lamp is lit and the projector is operating properly. The lamp will not strike after five tries (2 1/2 minutes). The lamp has more than 2,000 hours of use. Requires replacement. Projector shuts down. Lamp failure. Projector shuts down. One or more fans not operating. Projector shuts down. High temperature condition. Projector shuts down. Undiagnosed error. Projector shuts down
LED is solid green LED flashes red once LED flashes red two times LED flashes red three times LED flashes red four times LED flashes red five times LED is solid red
LP815/LP820 Service Manual
Power Diagnostics, Part 1
Power Diagnostics, part 1 Plug the projector into a good power source with a known good power cord. No, the fans did not start and the LED did not light. This is the normal condition. No, the fans Confirm that the started but keypad cable is the LED plugged in. did not light Check the voltages at the controller/power supply connector.
Replace the power supply
Do the fans run briefly and the LED light?
Confirm that unit is good by starting again.
Yes
LED light green or red? Note A solid green LED means the projector is either waiting for a command or is operating normally. A flashing green LED means the projector is either attempting to light the lamp or is shutting down. No Solid green Red Replace power supply Voltages OK?
Yes
Go to Power Diagnostics, part 2 This is the normal condition.
Go to Error Codes
Replace controller ECA
Yes Confirm that unit is good by starting again.
Solve the problem?
No
Replace keypad ECA
LP815/LP820 Service Manual
Power Diagnostics, Part 2
Note A solid green LED means the projector is either waiting for a command or is operating normally. A flashing green LED means the projector is either attempting to light the lamp or is shutting down. Power Diagnostics, part 2 Press the Power button on the keypad This assumes you have plugged the power cord in and that the LED is solid green. If not, go back to Part 1.
The Startup tone sounds. The fans spin up, then slow. The color wheel spins up.
Is the LED flashing green?
No, the LED remains solid green.
Press the Power button again.
The lamp attempts to strike five times at 30-second intervals. After 2 1/2 minutes, the projector no longer tries to strike the lamp and the LED begins flashing red.
Yes The LED continues flashing green until the lamp lights.
The LED remains solid green after pressing the Power button twice. The lamp does not light.
Replace keypad ECA No. The lamp does not light, and the LED begins blinking red. Go to Error Codes Did the lamp light and the LED turn solid green?
Solve the problem? Yes
Yes Run the projector long enough to ensure that the problem is solved. If the lamp goes out and the LED turns red, go to error codes.
No Replace controller ECA
Repeat process to confirm the problem fixed.
LP815/LP820 Service Manual
Error Codes
Power Diagnostics, Error Codes Interpret red LED behavior
Is the LED steady or flashing? Steady Red LED flashes have 2-second intervals between series of flashes. For example, the LED may flash 4 times, then pause for 2 seconds, then flash 4 times again. Flashing
An internal error occurred that the projector cannot identify. Diagnose the error. See Solid Red LED.
What is the flashing pattern?
On Off 1 flash The lamp failed to strike after five attempts. Diagnose lamp strike failure.
LAMP WON'T STRIKE
On Off 2 flashes The lamp timer registers lamp use of 2000 hours or more. Replace the lamp.
3 flashes The projector detected an internal error and shutdown the lamp. Diagnose lamp shutdown.
LAMP FAILURE
On Off
REPLACE LAMP
RETRYING WAIT...
Repeats
Keypad LCD messages
On Off 4 flashes A fan failed. Check the fans.
On Off
5 flashes The projector detects high internal temperature. Diagnose thermal problems. OVER TEMP CONDITION OVER TEMP CONDITION SHUTDOWN
FAN FAILURE SHUTDOWN...10
FAN FAILURE SHUTDOWN...1
LP815/LP820 Service Manual
LED flashes repeated red single-flash sequence
The lamp won't strike after five attempts. The status LED flashes a repeated red single-flash sequence. LCD Message LAMP WON'T STRIKE
Ensure that the lamp door is present and shut.
RETRYING WAIT... Repeats Can you hear the safety switch open and close? Replace safety switch.
No
Yes Replace the lamp module.
Verify the repair by restarting the Power Diagnosis process.
Ensure that the lamp control cable is connected to the controller ECA and the ballast.
Ensure that the safety switch cable is connected to the power supply. Also, ohm out the interlock switch and the thermal switch to make sure they are good. If not, replace the safety switch assembly.
Replace power supply.
No
Voltages good at power supply/ controller connector?
Yes
Replace the ballast.
Yes
Solve the problem?
No Verify the repair by restarting the Power Diagnosis process. Replace controller ECA
LP815/LP820 Service Manual
LED flashes repeated red three-flash sequence
LCD Message LAMP FAILURE The lamp was operating but shut down. Fans are running. The status LED flashes a repeated red three-flash sequence.
Note If the projector is operated in a hot environment, especially at high altitudes, the unit may overheat and shut down when the thermal switch opens. The only solution for this is to let the projector cool down. The LP650 should not be used where ambient temperatures are over 95º F (35º C).
Reinstall the lamp, ensuring that it is properly seated.
Solve the problem?
Yes
Run the projector long enough to ensure that the problem is solved.
No Replace the lamp.
Replace the ballast.
No
Solve the problem?
Yes Repeat the diagnostic process to ensure that the problem is solved.
If the projector fails to start properly, you may see the status LED flash a repeated red single-flash sequence indicating that the lamp won't strike. See LED flashes a repeated red single-flash sequence.
LP815/LP820 Service Manual
LED flashes repeated red five-flash sequence
Projector shuts down after detecting high temperature condition. LED flashes in repeated five-flash sequence. This is a thermal problem. If a fan isn't running it causes a power up problem because fans have a sensor line that prevents the projector from properly starting up.
LCD Messages
OVER TEMP CONDITION
OVER TEMP CONDITION SHUTDOWN
Ensure that the dust filter is not clogged.
It is very rare that a thermal switch opens under too little heat. Check the thermal switch. Power up the projector with the top off. Let the projector run until it shuts down. Measure the resistance at the switch. If the resistance is infinity (open), the thermal switch is bad.
Note If the projector is operated in a hot environment, especially at high altitudes, the unit may overheat and shut down when the thermal switch opens. The only solution for this is to let the projector cool down. The LP650 should not be used where ambient temperatures are over 95º F (35º C).
The safety switch assembly includes a thermal switch..
Is the thermal switch good?
No
Replace the safety switch.
Yes Substitute a good power supply and run projector long enough to know if that is the problem.
The problem is almost always a power supply or controller board with a thermal breakdown problem. Replace the controller ECA.
Solve the problem?
No
Yes Run the projector long enough to confirm the problem issolved. Repeat the diagnosis process.
LP815/LP820 Service Manual
LED is solid red
LED solid red. Fans may or may not be running.
Replace the power supply.
No
Power supply voltages good? (except lamp enable)
Yes Replace the controller ECA.
Replace the optical engine.
To confirm that the problem is solved, restart the diagnosis process.
LP815/LP820 Service Manual
Check fan operation You can do a visual check on the fans. Remove the top case and power the projector up using the remote control. Use the illustrations below to verify that a fan or blower is operating. If you identify a fan that does not work, plug a known good fan into the connector on the controller ECA. If the good fan does not operate, the problem is likely in the controller ECA.
Go to the next page.
LP815/LP820 Service Manual
LP815/LP820 Service Manual
Image Problems
The image is not correct. The projector starts and runs normally. The menus are accessible. The lamp is lit.
Confirm that the cables and the source signals are good.
If in doubt, feed the signal to a good projector.
Confirm that all image adjustments are set to the factory defaults.
Select Factory Reset from the Settings>Service menu.
Flash the projector with the latest software.
What is the problem?
No image at all. Vertical or horizontal lines. Sparkley picture. Clusters of dark pixels. See No Image at left.
Bad or missing tint or color Missing logo, VGA, composite video, or S-video Distorted image, noisy, rolling, torn, frozen, 'plaid', repeated, or shifted image. See Bad Colors at left.
Dim image See Dim Image at left.
LP815/LP820 Service Manual
No image
No image. Vertical lines. Horizontal lines. Sparkly picture. Clusters of dark pixels.
Replace the controller ECA
Is the image correct?
No Replace the optical engine
Bad colors
Bad or missing tint or color. Missing startup screen, VGA, composite video or S-video. Distorted image, excess noise, rolling image, torn image, frozen image, 'plaid' image, repeated single image, or shifted image.
Make sure cables are good.
Is the image correct?
No Replace the controller ECA.
LP815/LP820 Service Manual
Dim image
Dim image
The lamp takes about 90 seconds to achieve full brightness.
Substitute known good lamp
Is the image brighter? No
Yes
Replace the lamp.
Substitute a known good controller ECA.
Is the image brighter? No
Yes
Replace the controller ECA.
Replace the optical engine.
LP815/LP820 Service Manual
Keypad Problems
Keypad does not respond to key presses
Replace the keypad ECA
Yes
Does the remote control work?
No
Replace the controller ECA.
There are IR lenses on the front and both sides of the projector. Make sure you try the remote through at least two lenses. If one or more IR receivers do not work, go to Remote problems.
LP815/LP820 Service Manual
Remote Control Problems
Infrared remote problem
Use known good batteries in the remote.
Does the remote work?
No Replace the remote.
Does the remote work?
No Aim the remote at each of the IR receivers on the projector. There are IR receivers on three sides of the projector: the front, right and left sides. Issue a remote command to each receiver.
Does not respond to any receivers, or responds the front receiver but not the right and/or left receviers. No Replace the controller ECA.
Responds to the right and left IR receivers, but not the front IR receiver
Check the IR cable
Replace the front IR ECA
LP815/LP820 Service Manual
Audio Problems
No audio or sound is scratchy or distorted.
Make sure the speaker cable is connected to the controller ECA. Is there sound?
No
Replace the controller ECA.
Yes
Replace the speakers But note: A shorted speaker can damage the stereo audio amp on the controller ECA. Run the projector with audio for 30 minutes. If the problem returns, replace both the controller ECA and the top case if the resistance across either speaker coil no longer measures approximately 16 ohms.
Is there sound from both speakers?
No, only one
Yes Problem solved.
LP815/LP820 Service Manual
Controller and Power Supply Voltages
LP815/LP820 Service Manual
Parts Removal and Replacement
Removable Parts Hierarchy
The flow chart below shows what parts must be removed to access each FRU in the projector. The parts on the first level (the lamp door, for example) are accessible without removing any other parts. The more levels down a part is, the more parts you need to remove.
Start Lamp module Lamp door Filter door Rear Bezel
Top case Keypad Speakers Keypad ECA Top cover LCD cover IR ECA Elevator button
Front IR window
Focus and zoom rings LCD blower
Bottom case (Remove all FRUs to replace case)
R & L IR windows
Handle
Ballast Lamp blower & bracket Controller ECA Optical Engine
Power supply
Engine blower & bracket
Lamp housing
Leveling foot & shaft
Power supply fan
Lamp housing air guide
Elevator foot & actuator
Safety switch cable
Controller/ power supply cable
LP815/LP820 Service Manual
Lamp Module
The lamp module (SP-LAMP-012) fits inside the projector, and is protected by the lamp door (5051641-xx). You access the lamp from the bottom of the projector. Once you remove the lamp door, you have access to the dust filter (420104).
Lamp module Lamp door
Lamp door
Dust filter
Loosen the two captive screws that fasten the lamp door to the projector. Then lift the door off.
Lamp module Loosen the three captive screws that fasten the lamp module to the projector. Then lift the module out of the projector using the built in handle.
LP815/LP820 Service Manual
Dust filter removal and cleaning 1 Lift the tab that secures the filter door to the projector. Then remove the filter.
2
Use a vacuum to remove the dust from the inside and outside of the filter.
Assembly Notes If you install a new lamp, you need to reset the lamp counter. 1. Turn the projector on. 2. Press and hold the Volume + and Volume - keys for 10 seconds. The LED will turn from red to green, and the lamp ignites. You can also reset the lamp counter in the projector menu. Go to Main Menu > Settings > Service > Lamp Reset. 3. To verify that the lamp timer is reset, select About on the Main menu. The lamp hours are listed in the About box.
LP815/LP820 Service Manual
Rear Bezel
The rear bezel (505-1596-xx) covers the back of the projector. It fits over lips on the top case and the bottom case, helping to keep the case halves secure. It fastens to the projector with seven screws.
When you replace the rear bezel, you need to adhere a new brand label to the bezel.. Order part number 020-1823-xx for the LP820 or the label kit (802-0054-xx) for the LP815.
The I/O panel label (020-1822-xx) is included with a new rear bezel. The I/O panel label is available as a separate part for the LP820 and is included in the label kit (802-0054-xx) for the LP815. Remove the eight black M3.5x7 Plastite screws that fasten the rear bezel to the bottom case and the controller ECA. Two screws are located in the center of each rubber foot on the ends of the bezel. Six screws are located on the I/O panel. Then remove the bezel.
LP815/LP820 Service Manual
Assembly notes Tighten the M3x7 screws to 7 in/lbs (.8 Nm). If you are installing a new rear bezel, adhere a rear brand label to the bezel.
LP815/LP820 Service Manual
Top Case
The top case (505-1584-xx) covers the top half of the projector. Once you remove the top case, you have access to the replaceable parts inside the projector, and you can measure controller ECA voltages.
NOTE The top case has a number of replaceable parts fastened to it. If you are installing a new top case, the parts must be removed from the old case and fastened to the new one. See step 7 below. 1 2 3 Remove the rear bezel. Place the projector upside down on the work surface. Use a T10 Torx driver to remove the two M3x5 screws that fasten the top case to the bottom case. The screws are located in recesses near the handle.
4 5
Place the projector right side up on the work surface. Press the locking tabs on both sides of the top case, then lift the top case up. The tabs are located at the center of each side.
NOTE There are cables inside the top case that are still attached.
LP815/LP820 Service Manual
6
Swing the top case forward so you can disconnect the keypad cable and the speaker cable from the controller ECA.
7
Do one of the following: Set the top case aside and proceed to the next part. --Or-- If you are replacing top case or a part inside the top case, go to Top Case Contents.
Assembly Notes If you are installing a new top case, make sure you replace all the removable parts in the top case. See Top Case Contents for information. Plug the keypad and speaker cables into their connectors on the controller ECA. To install the bottom case, first engage the tab in the front, then swing the top case downward. Press the each side down to engage the locking tabs together until the case snaps into place. Torque the screws to 7 in-lb (.8 Nm).
LP815/LP820 Service Manual
Top Case Contents
Once you remove the top case, you have access to the replaceable parts inside the projector. The parts below are fastened to the top case, and may be removed once the top case is off of the projector. If you are replacing the top case with a new one, these parts must be removed and installed on the new top case. Each of these parts is available separately. Speakers (412-0004-xx; includes two speakers cabled together) Speaker bracket (330-0999-xx; one for each speaker) Keypad/LCD ECA (510-1808-xx) Keypad cable (330-0999-xx; part of the Cable Kit [410480]) Keypad (505-1624-xx) LCD cover (part of Hardware Kit [410483]) Right and left IR windows (part of the IR window kit [410484]) Top cover (505-1585-xx) LP820 Top label (20-1591-xx) LP815 top label available in the Label Kit (802-0054-xx) Elevator button (part of the Adjustable Feet Kit [410482])
Speakers The speaker set is wired to a common connector. Both speakers must be replaced at the same time.
LP815/LP820 Service Manual
1
Remove the three M3.5x6 Plastite screws that fasten the speaker bracket and speaker to the top case.
2
Remove the bracket from the speaker.
3 4
Repeat the steps above for the other speaker. Lift the two speakers out of the case.
Keypad/LCD ECA, keypad, keypad cable and LCD cover
Keypad/LCD ECA 1
Keypad
Keypad cable
LCD cover
Use a T10 Torx driver to remove the eight M3.5x6 Plastite screws that fasten the ECA to the top case.
LP815/LP820 Service Manual
2
Lift the side of the ECA closest to the rear of the top case up so that the tabs that secure the opposite side disengage from the edge of the ECA.
3
If you are replacing either the keypad cable or the keypad/LCD ECA, unplug the keypad cable from its connector on the keypad/LCD ECA.
4
Once you remove the keypad/LCD ECA, you can remove the keypad from its position in the top case.
5
To remove the LCD cover, lift one of the tabs, then pull the cover out of its hole in the top case.
LP815/LP820 Service Manual
Right and left IR windows
The IR windows are keyed so they fit only one way. The right and left windows are not interchangeable. 1 On the inside of the top case, press the two hooked tabs on the IR window to disengage the window from the top cover.
2
Remove the window from the outside the case.
Top Cover The top cover snaps onto the outside of the top case. The top label adheres to indented area near the speaker grill.
1
On the inside of the top case, press the two hooked tabs adjacent to the keypad inward so that they disengage the top cover.
LP815/LP820 Service Manual
2
Remove the top cover from the outside.
NOTE To replace the top cover, engage the three tabs at the front. Then align the tabs in the center and rear, and press down. The top cover should snap into place. Elevator button The elevator button is part of the Adjustable Feet Kit. It mounts inside the top case and, when pressed, engages the elevator actuator in the bottom case. Click here for information about replacing the other elevator parts.
On the inside of the top case, use a bladed screwdriver to disengage the tab on the elevator button shaft from the top case. Then extract the button from the outside of the case.
LP815/LP820 Service Manual
Focus and Zoom Rings
The focus ring and zoom ring mount on the lens barrel. Each ring turns independently to adjust the focus and zoom settings. The two rings are available in the Zoom and Focus Ring Kit (340-1031-xx). You only need to remove the focus and zoom rings when you are replacing the optical engine or if one of the rings is broken.
Focus ring 1 2
Zoom ring
Remove the rear bezel and top case. While holding the focus ring stationary, rotate the zoom ring counterclockwise until the alignment pins on the lens barrel disengage the slots on the zoom ring.
LP815/LP820 Service Manual
3
Push the zoom ring inward to expose the focus ring. Use a small bladed screwdriver to gently disengage the pin on the lens barrel from its alignment hole in the focus ring.
4
Repeat the process for the next pin and alignment hole. Then pull the focus and zoom rings off of the lens barrel.
Assembly notes When the focus and zoom rings are properly aligned, the words, "Focus" and "Zoom" should appear aligned on top when the rings are turned counterclockwise until they stop. See the illustration below.
To install the rings, slide the zoom ring onto the lens barrel first. Then slide the focus ring on and snap the three tabs over the three matching alignment pins on the lens barrel. Then slide the zoom ring forward and turn it clockwise to lock it in place. Make sure that both rings turn easily and independently.
LP815/LP820 Service Manual
Front IR ECA and Window
The IR ECA (510-1814-xx) and the front IR window (available in the IR Window Kit [410484]) mount to the bottom case adjacent to the projection lens. The IR cable (available in the Cable Kit [410480]) connects the IR ECA to the controller ECA.
Front IR window 1 2
IR ECA
IR cable
Remove the rear bezel and the top case. Unplug the IR cable from the IR ECA.
3
To remove the IR ECA, remove the M3.5x7 Plastite screw that fastens it to the bottom case.
LP815/LP820 Service Manual
4
To remove the IR window, from the inside of the bottom case, press the tabs on the window inward. Then remove the window from the outside of the bottom case.
Assembly notes Insert the IR window into its hole from the inside of the bottom case. Then snap it into place. The IR ECA is keyed so that it fits only one way.
LP815/LP820 Service Manual
Ballast
The ballast (525-0074-xx) provides high voltage to the lamp. It mounts to the bottom case at the front of the projector. To remove the ballast, you also remove the handle and front vent, which are part of the Mounting Parts Kit (410483).
Ballast
Handle and front vent
NOTE Most of the illustrations below show the controller ECA removed. It is not necessary to remove the controller to access the ballast. 1 2 Remove the rear bezel and the top case. Lift the handle and front vent out of the bottom case.
3
Disconnect the power supply/ballast cable from the ballast.
4
Disconnect the lamp blower, LCD blower and ballast control cables from the controller ECA.
LP815/LP820 Service Manual
5
Disconnect the lamp power cable from the lamp connector inside the lamp housing. It snaps into place, so you may need to use a small screwdriver to remove the connector. Remove the cable from the two cable clips on the lamp housing air guide and the cable clip adjacent to the ballast.
LP815/LP820 Service Manual
6
Remove the three M3.5x25 Plastite screws that fasten the ballast to the bottom case. Then lift the ballast out of the bottom case.
7
If you are replacing the ballast, disconnect the ballast control cable from its connector on the ballast.
8
Remove the ballast from the bottom case.
LP815/LP820 Service Manual
Assembly notes Connect the power supply/ballast and ballast control cables to the ballast before installing it in the bottom case. Place the ballast into the bottom case so that the alignment pin in the bottom case fits into fits into the hole in the ballast at the rear corner nearest the projection lens.
Torque the screws to 7 in-lb (.8 Nm) Reconnect the other cables to the controller ECA. Make sure to route the lamp power cable through its guides.
Reconnect the lamp power cable to the lamp house air guide. Note that the connector is keyed so that it fits only one way. The connector should snap into place.
To replace the handle and front vent, align the tabs on the front of the handle with the slots in the bottom case. Then lower the handle into place, making sure the alignment pin in the bottom case fits into the hole on the side of the handle.
LP815/LP820 Service Manual
Engine Blower and Bracket
The engine blower and bracket (505-1623-xx) consists of a blower and a bracket. Both fasten to the bottom case adjacent to the projection lens.
1 2
Remove the rear bezel and top case. Remove the M3x7 Plastite screw that fastens the blower and bracket to the bottom case.
LP815/LP820 Service Manual
3
Lift the blower and bracket out of the bottom case.
Assembly Note When you install the engine blower, make sure the alignment pin in the bottom case fits into the hole near the blower duct. Then torque the M3x7 screw to 7 in/lb (.8 Nm).
LP815/LP820 Service Manual
Leveling Foot
The leveling foot allows the user to adjust the horizontal image position by tilting the projector slightly to the left or to the right. The foot includes a threaded shaft, which moves up and down as the foot is turned clockwise or counterclockwise. The leveling foot and the shaft are part of the Adjustable Feet Kit (410482). The parts are not available separately.
Leveling foot, shaft and rubber insert You can replace the leveling foot without disassembling the projector. To replace the shaft, you must partially disassemble the unit. Leveling foot 1 2 Turn the projector upside down on the work surface. Use a small screwdriver to pry the rubber insert out of the hole on the bottom of the plastic leveling foot. 3 Use a T10 driver to remove the M3x5 Plastite screw that fastens the leveling foot to the shaft. Then pull the foot off the shaft.
When you install the foot, note that it is keyed, and fits on the shaft only one way.
LP815/LP820 Service Manual
Leveling foot shaft 1 2 3 Remove the leveling foot as shown above. Remove the rear bezel and top case. Unscrew the shaft from the inside of the projector. You can use your fingers to do this.
LP815/LP820 Service Manual
Controller ECA
The controller ECA (LP820: 510-1755-xx; LP815: 510-1923-xx) is located beneath the top case on top of the optical engine. It provides all control functions and processes the data and video signals. The controller connects directly to the formatter ECA and power supply with connectors on its bottom.
NOTE Each optical engine includes a matched NV RAM chip, which plugs into the controller ECA. The NV RAM chip allows precise calibration of picture quality. When you replace an engine, you must remove the old NV RAM chip from the controller and install the new one. Likewise, when you replace the controller ECA, you must remove the chip from the old ECA and install it on the new one. See step 7 below. 1 2 Remove the rear bezel and top case. Unplug the three ribbon cables at the center of the controller ECA. Each cable plugs into a ZIF connector on the top of the controller ECA.
CAUTION The connectors are extremely delicate. A broken tab or connector requires replacing the controller ECA.
LP815/LP820 Service Manual
3
Unplug the cables from their connectors as shown below.
4
Use a T10 Torx driver to remove the five M3x5 Torx screws and three M3.5x7 black Plastite screws that fasten the controller ECA to the optical engine.
LP815/LP820 Service Manual
5
Use a T10 Torx driver to remove the M3x5 Torx screw that fastens the I/O EMI shield to the power supply.
6 7
Lift the controller off of the engine. If you are replacing the controller ECA, do the following: 1. Remove the NV RAM chip and install it on the new controller. See NV RAM Chip for instructions. 2. Remove the left IR gasket (available in the Cable Kit [410480]) from the controller. Note the orientation of the gasket. You will install it on the new controller.
Assembly Notes If you are installing a new controller ECA, make sure to install the NV RAM chip from the old controller. See step 7 above. Install the left IR gasket. Align the two holes on the ECA with the alignment pins on the optical engine (circled below). Make sure the two connectors align properly before pressing the controller
LP815/LP820 Service Manual
Make sure to connect all cables shown in step 3 above. Torque all screws to 7 in/lb (8 Nm). If necessary, flash the projector with the latest software.
LP815/LP820 Service Manual
NV RAM Chip
The NV RAM chip plugs into a socket on the controller ECA. Each NV RAM chip is set up to maximize the image reproduction for a specific optical engine. A unique chip ships with each new optical engine. Thus, when an engine is replaced, the NV RAM chip installed on the controller ECA must be removed and replaced with the chip that came with the new engine. Likewise, when you replace the controller ECA, you need to remove the chip from the old controller and install it on the new one. The NV RAM chip is not available as a separate replaceable part. The procedure assumes that the controller ECA is already removed from the projector. Remove the NV RAM chip 1 Turn the controller upside down on the work surface.
NOTE The controller ECA in the LP815/LP820 differs slightly from the controller ECA shown below. The NV RAM chip is located near the I/O panel adjacent to the left IR window. Its appearance is identical to the chip shown in these illustrations.
LP815/LP820 Service Manual
2
Use an IC puller or a small flat bladed screwdriver to remove the chip from its base on the controller.
Install the NV RAM chip 1 Align the chip so that the eight pins align with the eight holes on the base. Then press the chip into place.
LP815/LP820 Service Manual
CAUTION The pins on the NV RAM chip are delicate. Make sure that the pins are straight and that they align with the corresponding holes in the socket. Press straight down, making sure that you do not bend the pins while inserting them into the socket.
LP815/LP820 Service Manual
Controller/power supply Cable
The controller/power supply cable runs between the power supply and controller ECA. It provides power to the controller. The controller/power supply cable is available in the Cable Kit (410480). The cable you are working with is color coded instead of white. Otherwise it is identical.
1
Remove the following items: Rear bezel Top case Controller ECA Power supply fan
2
Remove the two M3x7 Plastite screws that fasten the power supply to the bottom case.
3
Lift the power supply away from the optical engine enough to access the controller/power supply cable. Then disconnect the cable from the power supply.
4
Lift the cable out of the bottom case. Note the cable routing.
LP815/LP820 Service Manual
Assembly Notes Plug the cable into the power supply, then fasten the power supply to the bottom case. Note that the power supply ECA fits into four aligning tabs in the bottom case. Tighten the screws to 7 in/lb (.8 Nm). Route the cable bundle through the bottom case, making sure that it runs below the power supply fan and will not be pinched when the projector is reassembled.
LP815/LP820 Service Manual
Power Supply Fan
The power supply fan (526-0173-xx) blows outside air onto the power supply. It fits into a cavity in the bottom case adjacent to the power supply and optical engine.
The power supply fan uses a rubber gasket to help dampen fan sound. The rubber gasket is available in the Screw and Mounting Details Kit (410481).
To access the power supply fan, you must remove the power supply cover, which is part of the Mounting Parts Kit (410483).
1
Remove the following items: Rear bezel Top case Controller ECA
LP815/LP820 Service Manual
2
Remove the power supply cover. To do this, disengage the locking tab on the end of the power supply cover adjacent to the lamp housing. Lift the end of the cover while sliding it toward the power supply fan.
3
Lift the power supply fan out of the bottom case.
4
If you are replacing the power supply fan with a new one, remove the rubber gasket.
Assembly Notes Install the rubber gasket on the new fan so that the cable fits through the slot on the top of the gasket. See the illustrations above. To install the fan in the bottom case, slide the bottom of the fan into the slots in the bottom case. When the fan is installed correctly, the word, "UP" is on top, and the label on the fan faces inward.
LP815/LP820 Service Manual
Safety Switch Cable
The safety switch cable (211-0243-xx) includes the lamp door interlock switch and the thermal switch. It is replaced as an assembly. The individual switches are not available separately.
1
Remove the following parts: Rear bezel Top case Controller ECA Lamp housing air guide When you remove the lamp housing air guide, you also detach the thermal switch from the top of the lamp housing.
2
Remove the safety switch cable from the cable clip in the bottom case adjacent to the leveling foot.
3
Remove the two screws that fasten the power supply to the bottom case. Then lift the power supply out of the way so that you can access the interlock switch. Note that cables still attach to the power supply.
LP815/LP820 Service Manual
4
Remove the interlock switch from its housing in the bottom case. To do this, use a small screwdriver to pull back the retainer on the housing, then lift the switch out of the housing.
5
Unplug the safety switch cable from its connector on the power supply.
Assembly Notes When replacing the interlock switch make sure to orient the switch in proper direction. See the illustration in step 4. When you reinstall the power supply, note that the ECA inside the unit fits into slots in the bottom case. Make sure that the cables are routed cleanly in the cavity between the power supply and optical engine. Replace the safety switch cable in the cable clip adjacent to the leveling foot before you install the lamp housing air guide. See the illustration in step 2.
LP815/LP820 Service Manual
Lamp Blower and LCD Blower
The lamp blower (505-1622-xx) includes a mounting bracket and blower. The assembly fastens to the bottom case adjacent to the lamp housing, with ducting connecting the blower to the housing.
Once the lamp blower and bracket are removed, you have access to the LCD blower (526-0181-xx). Three rubber feet mount on the bottom of the LCD blower, keeping it in place and dampening noise while the blower operates. The three feet are available in the Screw & Mounting Details Kit (410481).
1
Remove the following items: Rear bezel Top case Controller ECA Ballast
2
Remove the M3.5x25 Plastite screw that fastens the mounting bracket to the bottom case. Then remove the power supply/ballast cable from the cable clip on the corner of the mounting bracket.
LP815/LP820 Service Manual
3
Lift the assembly out, working the lip on the end of the blower duct past the hole in the lamp housing.
4
Lift the LCD blower out of the bottom case.
5
If you are replacing the LCD blower, remove the three rubber feet from the blower.
LP815/LP820 Service Manual
Assembly Notes If you are installing a new LCD blower, install the three rubber feet on the new blower. Then install the blower in the bottom case. Make sure the blower duct fits into the hole in the bottom case, and that the rubber feet fit inside the guides in the bottom case. To install the lamp blower and bracket, first insert the duct into its hole on the side of the optical engine. Then align the base of the bracket so that the three posts in the bottom case fit inside the matching screw holes on the bracket. Route the power supply/ballast cable through the slot in the blower bracket.
Secure the bracket with the M3.5x25 screw.
LP815/LP820 Service Manual
Optical engine
The optical engine (410488) mounts to the bottom case below the controller ECA.
NOTE Each optical engine includes a matched NV RAM chip, which plugs into the controller ECA. The NV RAM chip allows precise calibration of picture quality. When you replace an engine, you must remove the old NV RAM chip from the controller and install the new one. 1 Remove the following items: Lamp and lamp door Rear bezel Top case Controller ECA Power supply fan Ballast Lamp and LCD blowers Lamp housing air guide 2 Remove the five M3.5x10 Plastite screws that fasten the engine to the bottom case. Then lift the engine out.
3
If you are replacing the optical engine, do the following: 1. Remove the lamp housing from the optical engine.
LP815/LP820 Service Manual
2. Remove the NV RAM chip from the controller ECA. Make sure you return the chip with the engine. Assembly Notes If you are installing a new optical engine, install the matched NV RAM chip on the controller ECA. Go to NV RAM chip. Before installing the engine, make sure the power supply/ballast cable is routed through the rubber cable clips in the bottom case.
LP815/LP820 Service Manual
Power Supply
The power supply (510-1741-xx) is located adjacent behind the optical engine. The power supply converts 100-240 VAC supply voltage to various low voltage DC levels required internally by the projector. The power supply interfaces with the ballast to control lamp strike and operation. The power supply shown below has the white controller/power supply cable attached to it. The cable is not included with the power supply. It is available in the Cable Kit (510-1741-xx). The power supply/ballast cable (not shown) is also available in the cable kit.
1
Remove the following parts: Lamp and lamp door Rear bezel Top case Controller ECA Power supply fan Ballast Lamp and LCD blowers Lamp housing air guide Optical engine
2
Remove the two M3x8 Plastite screws that fasten the power supply to the bottom case.
3
Remove the power supply/ballast cable from the two rubber cable clips (available in the Hardware Kit [410481]). Then lift the power supply out of the bottom case.
LP815/LP820 Service Manual
Assembly Notes Make sure to route the power supply/ballast cable through the rubber cable clips. The ECA on the power supply fits into slots on the bottom case. The slots help align the power supply and keep it in place.
LP815/LP820 Service Manual
Lamp Housing
The lamp housing (410487) encloses the lamp module. It fastens to the optical engine. You must remove the optical engine to access the lamp housing.
1 2
Remove the optical engine. Remove the two M3x5 screws on the top of the lamp housing.
3 4
Turn the engine/lamp housing assembly upside down on the work surface. On the bottom of the lamp housing, lift the tab off of the locking pin, then swing the lamp housing off of the engine.
LP815/LP820 Service Manual
Assembly Notes Slide the top of the lamp housing into place first. Next press the bottom on until the alignment pin on the optical engine engages the hole in the tab on the lamp housing. Then fasten the lamp housing to the engine with the two screws.
LP815/LP820 Service Manual
Elevator Foot and Actuator
The elevator assembly includes the elevator foot, actuator, button, and spring. These parts are included in the Adjustable Feet Kit (410482) The foot, actuator and spring are located in the bottom case beneath the projection lens.
The elevator button fastens inside the top case. To replace the button, you need only to remove the top case. See Top Case Contents for instructions on replacing the button. Follow the procedure below to replace the rest of the elevator parts. 1 2 Remove the Optical engine. Use a needle nosed pliers to remove the spring on the elevator actuator.
3
Lift the actuator out of the bottom case.
LP815/LP820 Service Manual
4
Use a small bladed screwdriver to release the retainer on the elevator foot. Then remove the foot from the outside of the bottom case.
Assembly Note Install the elevator foot first. Then place the actuator over the elevator housing. The actuator fits into guides in bottom case. When installed correctly, the actuator should move back and forth smoothly.
LP815/LP820 Service Manual
Bottom Case
The bottom case (505-1586-xx) covers the bottom half of the projector. To replace the bottom case, remove the pieces listed below and install them in the new bottom case.
When you replace the bottom case, it is important that you remove the LCD air guide from the bottom case and install it on the new case. See below for instructions. The LCD air guide is included in the Mounting Parts Kit (410483), and is not available separately.
When you replace the bottom case, you need to transfer the serial number label from the old case to the new case. You also need to adhere a new generic bottom label (LP820: 020-1821-xx; LP815: in the Label Kit--510-1923-xx ) (below left) and a certification label (020-1903-xx; LP815: in the Label Kit-- 510-1923-xx) (below right) to the bottom case. Note that the certification label fits into a matching space in the bottom label.
1
Remove the following items: Lamp, lamp door, filter door Rear bezel Top case IR ECA & front IR window Controller ECA Ballast and handle
LP815/LP820 Service Manual
Lamp & LCD blowers Power supply fan Engine blower & bracket Lamp housing air guide Leveling foot Optical engine (leave the lamp housing and lamp attached) Power supply Elevator actuator & foot 2 Remove the serial number label from the old bottom case. You can use a hair drier or heat gun to soften the label if needed. 3 Remove the two M3x7 Plastite screws that fasten the LCD air guide to the bottom case. Then remove the air guide.
LP815/LP820 Service Manual
Assembly Notes Adhere a new certification label and certification label to the bottom case. Replace the serial number label from the old bottom case.
Make sure you install the LCD air guide in the new bottom case.
LP815/LP820 Service Manual
Performing functional tests
You perform the functional tests after you've repaired the projector to make sure all components of the projector operate properly. You can also perform the functional tests if you're having trouble determining what is wrong with the projector. For additional help in diagnosing trouble with the projector, see Troubleshooting. Required equipment Equipment Notes
Composite video DVD player with Make sure the video player has an S-video Out port and cables. The S-video capability player should also have a Composite video output port (RCA). InFocus strongly suggests you use a DVD player to test the video quality. DVD players reproduce colors better and project sharper images. The least preferable is a VCR. If you must use a VCR, make sure you use a commercially produced recording, not one recorded from a broadcast source. The VCR must include an S-video connector in addition to a composite connector. Commercially produced video to test S-video, composite video, and audio. You'll need the video in DVD, laser disc, or videocassette format. For ASCs located in the US and Canada, InFocus suggests you use Digital Video Essentials (DVD International, 2003). This DVD is encoded for Region 1. Use the AV cable that came with the projector. You also need the optional S-video cable. VESA cable, M1 cable We recommend that you Use the Test Patterns on the InFocus website to check image quality. The sound card should have either a 3.5mm stereo audio jack. The computer must have a CD-ROM and a standard VESA connector for analog output. Ensure that the remote has fresh AA batteries. Use a flat screen, not a curved one.
Audio & Video cables
Computer cables RGB test screens in a PowerPoint presentation PC with digital video and sound card
Remote control Projection screen
Before beginning Make sure the work surface where you perform the functional tests is level and clean. Place the projector on a soft surface (such as an anti-static mat) when running the tests.
LP815/LP820 Service Manual
Connect the following to the I/O panel on the projector: Video player through Composite Video, S-video, and Component connectors. Also connect the sound cable to the video source and projector. Computer and video through the M1 and VESA connectors
Perform the following tests Test Power Up Connect AC power, and turn the unit on. Verification Verify that the proper splash (logo) screen appears. If the incorrect logo screen appears, you must install the proper brand system software. The logo screen is automatically installed when you do this. Verify image quality.
Cosmetics and mechanicals Verify that the elevator and leveling foot are functional. Adjust the projector so that the Verify that the focus and zoom rings operate properly. image is square. Make sure Verify cosmetics. the lens is at a 90° angle to the wall. Video sources On the keypad, press the Video button to cycle through the video sources. Audio from video source Verify that the video automatically synchronizes from all sources, including HDTV. If it doesn't, press the Video button on the keypad. Verify there is no distortion, noise or other abnormalities. Verify that the audio plays clearly. Verify that the audio is clear with no distortion.
Software Version / Keystone / Reset All 1. Press and hold the Keystone up and Verify that the keystone adjustment works properly. Keystone down button on the keypad. Verify software version in the About box. 2. Press the Menu button, then navigate to About. 3. Navigate to Main > Settings > Service. Select Factory Reset. Verify the keys are not sticky.
LP815/LP820 Service Manual
The next step is to observe 3 computer images. These will confirm that the computer input works properly, and will test image quality. On the keypad, press the Computer button to select Computer. Image #1: Focus Test Image 1. Turn off any local light. 2. Turn the zoom ring to make the smallest image. 3. Focus the image so the middle icon is clearly focused. 4. Focus the image on the 4 green squares. 5. After focusing on the green squares on the middle icon, turn the zoom ring to make the largest image, then repeat the focus tests. Image #2: Color Ramp Project the Color Ramp image.
Verify that all four corner icons have clear resolution Verify that the white space is visible on all 5 bar/line icon areas (between green). Verify that the image focuses through the full zoom range. Verify that the image remains in focus when the Image Shift knob is turned.
Verify there are no missing parts of the ramp. Verify that the bars are not flashing. Verify that the transitions from light to dark are smooth and gradual.
LP815/LP820 Service Manual
Image #4: SMPTE133 Project the SMPTE133 image.
Verify that there are no noise, tint, duplicating columns, or other general image abnormalities present Power Down After all tests are complete, turn the power off and disconnect all cables. Attach the lens cap. Verify unit is powered off before disconnecting cables.
LP815/LP820 Service Manual
Parts Lists
Exploded View
For part numbers, see Replaceable Parts List on the left.
LP815/LP820 Service Manual
Replaceable Parts List
Below is a list of replaceable parts (FRUs) for the LP815/LP820. It includes the part name as used in this service guide, as well as the part name as listed in the parts pricing list database. The names often differ.
NOTE Before you order a part, make sure that you confirm the correct part number in the online parts list for this product. The parts pricing list is available in your ASC Resource Center.
Part name in service guide Top label Certification label
Part name in parts pricing list LABEL, TOP, INFOCUS LABEL BOTTOM, CERTIFICATION, INFOCUS, NJORD LABEL REAR LOGO, INFOCUS, NJORD LABEL REAR, GENERIC, NJORD LABEL BOTTOM, INFOCUS, NJORD CABLE KIT, NJORD, LP820 SCREW AND MOUNTING DETAILS KIT, NJORD, LP820 ADJUSTABLE FEET KIT, NJORD, LP820 MOUNTING PARTS/BRACKET KIT, NJORD, LP820 IR GLASS KIT, NJORD, LP820 ENGINE LP820 WITH XGA MLA PANELS INCL. NVRAM S/A, LOUDSPEAKER SETS, NJORD YD50-9-6 WITH CABLES S/A TOP, NJORD S/A TOP COVER, NJORD S/A BOTTOM NJORD
Part number 020-1591-xx 020-1903-xx
InFocus brand label
020-1823-xx
I/O label Bottom label Cable kit Screw & mounting details kit
020-1822-xx 020-1821-xx 410480 410481
Adjustable feet kit
410482
Mounting parts kit
410483
IR window kit Optical engine
410484 410488
Speaker set
412-0004-xx
Top case Top cover Bottom case Rear bezel Lamp housing air guide
505-1584-xx 505-1585-xx 505-1586-xx
S/A REAR COVER COMPLETE, NJORD 505-1596-xx S/A AIR GUIDE LAMPHOUSE COMPLETE, NJORD S/A HOLDER LCD FAN COMPLETE, NJORD 505-1600-xx
Lamp blower & bracket
505-1622-xx
LP815/LP820 Service Manual
Part name in service guide Engine blower & bracket
Part name in parts pricing list S/A HOLDER PBS FAN COMPLETE, NJORD S/A KEYPAD, NJORD
Part number 505-1623-xx
Keypad Lamp housing Power supply fan
505-1624-xx
S/A LAMP HOUSE COMPLETE, NJORD 505-1709-xx S/A, FAN AXIAL COMPLETE, POWER, 60X25, NJORD ECA, P/S, POWER, LP820 ECA, NJORD MAIN BOARD EXCL. NVRAM ECA, NJORD MAIN BOARD EXCL. NVRAM ECA, KEYB/LCD NJORD (LP820) ECA, NJORD IR-BOARD 250W POWER PACK LAMP,C13HB/NJORD 505-1710-xx
Power supply Controller ECA (LP820)
510-1741-xx 510-1755-xx
Controller ECA (LP815)
510-1923-xx
Keypad LCD ECA Front IR ECA Ballast
510-1808-xx 510-1814-xx 525-0061-xx
LCD blower Label kit (LP815) Includes top, certification, I/O and brand labels.
S/A FAN BLOWER,LCD,TYF209 NJORD 526-0181-xx LABEL KIT, LP815 802-0054-xx
LP815/LP820 Service Manual
Screw and Mounting Details Kit
Screw and mounting details kit (410481) Part Name Rubber foot (rear) Rubber foot for LCD blower Power supply fan rubber holder Rubber IR shield Bottom gasket LCD air guide Speaker bracket Lens cover shroud Front fan cable plug I/O shield Elevator foot spring Elevator actuator spring Right blower mount M3x8 black Torx Pan screw w/washer M4x8 PC screw M3x7 Torx Plastite screw M3x5 Torx screw M3x5 Plastite Torx screw M3.5x10 Plastite Torx screw M3.5x25 Torx Plastite screw M4x7.5 black Torx screw Quantity 1 3 1 1 1 1 1 2 2 1 1 1 1 1 1 17 10 16 5 3 5
LP815/LP820 Service Manual
Cable Kit
LP815/LP820 cable kit (410480) Part Name Keypad cable Lamp control cable Power supply / ballast cable Safety switch cable IR cable Quantity 1 1 1 1 1
Adjustable Feet Kit
LP815/LP820 adjustable feet kit (410482) Part Name Elevator spring Elevator button Elevator shaft Elevator activator Leveling foot shaft Leveling foot Leveling foot insert Quantity 1 1 1 1 1 1 1
Mounting Parts Kit
LP815/LP820 mounting parts kit (410483) Part Name LCD protective cover Handle LCD air guide Power supply cover Front vent Quantity 1 1 1 1 1
LP815/LP820 Service Manual
IR Window Kit
IR window kit (410484) Part Name Front IR window Left IR window Right IR window Quantity 1 1 1
Focus and Zoom Ring Kit
Focus and zoom ring kit (410485) Part Name Focus ring Zoom ring Quantity 1 1
LP815/LP820 Service Manual