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Model Name: PB6240 Marketing Description :

BenQ PB6240
C3-323 Alignment & Assembly Concerns

Revision 1

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Subject: C3-323 Alignment & Assembly Part No.: 99.J0Y77.B52 Rev.: 1

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Model Name: PB6240 Marketing Description :

Catalog:
Chapter 1 DMD Bias Voltage Alignment
Chapter 2 Color Wheel Delay Alignment
Chapter 3 ADC Alignment
Chapter 4 YUV Alignment
Chapter 5 Image Performance Check
Chapter 6 DMD Performance Check
Chapter 7 sRGB Alignment
Chapter 8 Optical Engine Alignment
Chapter 9 Mechanism Assembly Concerns
Chapter 10 EMI Assembly Concerns
Chapter 11 Download Procedure

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Chapter 1
DMD Bias Voltage Alignment
Equipment:
- None
Procedure:
1. Watch DMD chip Label (Example: 9477000 0234B)
2. Switch the DIP switch on DMD board according to the red character on the DMD chip
3. See Figure 1
BINSEL1 BINSEL0 DMD Bin Direction

0 0 B

0 1 C

1 0 D
H1
4 1
3 2 1 1 E
6240019001

Figure 1

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Chapter 2
Color Wheel Delay Alignment
Equipment:
- Battery Biased Silicon PIN Detector
- Oscilloscope (Vertical scale set to 10mV)
- Probe
PB6240 CW delay alignment procedure
Step Process Tool
Oscilloscope, photo
1 Put the photo sensor 30~50 cm in front of projector.
sensor。

Show Blue pattern, and check the photo sensor output waveform by
2 oscilloscope. Check the square pulse’s edge, is flat or not? Please see
Figure 2. (A) If it is flat, go to step 4. (B) If it is not flat, go to step 3.

Adjust CW delay value to let left edge getting a peak. And then adjust the
3
CW delay value, increase it till the left edge is flat. Then stop action.

Show Green pattern, and check the waveform. See Figure 3.

(a) It is flat. Go to step 5。
4
(b) It is not. Right side gets a peak. Go to Blue pattern, decrease the CW
delay value till left side of waveform getting a little peak.
Show Red pattern, and check the waveform. See Figure 4.
(a) If it is flat, then go to step 6.
5
(b) If it gets a peak at right edge, then go back to show Blue pattern.
Decrease the CW delay value till the left edge getting a little peak.
6 Record CW delay value.

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Figure 2 Figure 3

Figure 4

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Chapter 3
ADC Alignment
Equipment:
- Pattern generator (Chroma-2250)
OSD Default value:
Item Value
Cal R Offset 127
Cal G Offset 127
Cal B Offset 127
Cal R Gain 127
Cal G Gain 127
Cal B Gain 127
YPbPr R Offset 127
YPbPr B Offset 127

Procedure:
Gray Level:
1. Connect power, D-sub, into projector.
2. Change Timing and pattern of pattern generator:
3. Timing: 1024*768 @60Hz (XGA) for PB6210 and 800*600@60 for PB6110
4. Pattern: As Figure 5 {A near white color (240,240,240) and a near black color(16,16,16), the area
of white is 101/200, black is 99/200}
5. Light on projector
6. Set user OSD values to default.
7. Enter factory mode.
8. Set Factory values to default.
9. Press “Calibration RGB” to let the black level to just distinguish, and the light output of white
level to just max.
10. Check the 32 levels of gray. All steps must appear.

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Figure 5

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Chapter 4
YUV Alignment
Equipment:
- Pattern generator (VG-828)
OSD Default value:
Item Value
Cal R Offset 127
Cal G Offset 127
Cal B Offset 127
Cal R Gain 127
Cal G Gain 127
Cal B Gain 127
YPbPr R Offset 127
YPbPr B Offset 127
Procedure:
1. Connect power, YpbPr cable, into projector.
2. Change Timing and pattern of pattern generator:
Timing: 480i
Pattern: As Figure 6
3. Light on projector
4. Adjust user OSD values to default.
5. Enter factory mode.
6. Adjust Factory values to default.
7. Press “Calibration Yapp” to calibrate the mid level offset.

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Figure 6

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Chapter 5 Image Performance Check

Equipment: Pattern generator
Procedure:
1. Connect power, D-sub, into projector.
2. Light on projector.
3. Testing below patterns and resolution is 1024*768@60Hz (XGA); 800*600@60Hz (SVGA)
(1) General-1 pattern. (Pattern 1)
(2) 32 grays pattern. (Pattern 48)
(3) White pattern. (Pattern 41)
(4) SMPTE pattern. (Pattern 5)
4. The formatter board would be note fail if above three image-quality is not good.
5. Test the connection between formatter board to keypad board and IR board.
6. The formatter board would be note fail if there are some wires is broken in formatter board.

Chapter 6 DMD Performance Check

Equipment: Pattern Generator
Procedure:
1. Connect power, Video signal into projector.
2. Light on projector
3. Change pattern generator to full white pattern.
4. Watch the image if any pixel lost
5. Change pattern to full black.
6. Watch the image if any pixel lost
7. Change pattern from full black to full white.
8. Watch the image if any pixel can not return
9. Change pattern from full black to full white.
10. Watch the image if any pixel can not return
11. If above 8 step has some pixel lost or can not return, it’s DMD chip has pixel defect
12. Change to the Slid Line pattern
13. Watch the image if any pixel lost
14. If above step has some pixel lost, its conductive socket has defect or assembly loosed.

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Model Name: PB6240 Marketing Description :

Chapter 7
sRGB Mode alignment procedure

Confirm CW delay adjustment OK

Confirm ADC adjustment OK

Choose sRGB Mode in PC source

Input W(128,128,128) by pattern generator

Read Wx, Wy

Set CSC table

If ‘NO’
Read Wx,Wy until Wx(0.313+/-6,0.329+/-10)

If ‘NO’ If ‘Yes’

Input W(255,255,255) by pattern generator

Read Wx, wy

Read Wx,Wy until Wx(0.313+/-6,0.329+/-6)

If ‘Yes’

OK

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Chapter 8
Optical Engine Alignment & Assembly Concerns
n FM Module:
(1) FM holder 3 clips should be actually mounted. See Figure 7.
(2) FM frame’s pivot should be tightened. Torque is 2~3 kg*cm. See Figure 8.

Figure 7 Figure 8

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n SL/AL Tube Module:

(1) LP should be leaned against on datum. Note the datum near SL should be correct leaned at
right side. See Figure9 & Figure 12.
(2) LP baffle’s hook should be actually hooked with LP holder. And the LP baffle should be
mounted flatly on LP. See Figure 10.
(3) SL/AL tube mounting, SL more protruding side should be put to face with LP. AL more
protruding side should be put back on LP. See Figure 11.

Figure 9 Figure 10
凸面
凸面

AL SL

Figure 11 Figure 12

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n CM Assembly:
(1) CM clip top hook should be actually mounted inside. See Figure 13
(2) CM is leaned against at the left datum surface and right datum surface of optical engine. Note the
contacted surface has no gap. See Figure 14.

勾子

Figure 13

Figure 14
n Lamp Module:
(1) Lamp is leaned against with the left datum and bottom datum of Lamp holder. After assembling check
the datum surface (left side datum*1 & bottom side datum*2). See Figure 15.
(2) Check up side clip and bottom side clip. Does it clip the lamp tightly? And check the lamp datum
surface should have no gap. See Figure 16.

Figure 15 Figure 16

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n CW Module:
(1) Figure 17 Bracket diagram consists of one BKT, two Cushions.

BKT

Cushions

Figure 17

(2) Figure 18 Put Rubber pins into BKT holes.

Damper

Figure 18

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(3)Rubber assemble diagram. See Figure19. Mount with CW.

CW

Flat touching with BKT

Figure 19

(4) See Figure 20. Pre screw 3 screws to CW. And then screw tightly these three screws sequentially.
Note: Rubber should not be extruded too much to cause bulge.

Easy extruding
too much

Figure 20

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(5) Figure 21 Final assemble diagram. Check the screw will protrude out CW motor for a little distance,
and this is correct.

Figure 21

n Optical Engine Assembly Procedure

(1) Mount CM on DMD housing, and check it is leaned perfectly.
(2) Mount FM Module on DMD housing, note the FM positional pin should be plug into the DMD
housing.
(3) Mount AL/SL Tube Module on Optical engine.
(4) Mount CW Module on optical engine. Rotate CW lightly to make sure CW don’t interfere with
LP baffle.
(5) Mount DMD baffle, DMD, DMD SKT, chip board, backer, and Heat sink on optical engine. Note
the spring screw should be screwed sequentially, and check all parts are mounted flat.
(6) At last mount the projection lens, FM off-light shield, CW shield and put on Engine cover.

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Optical Alignment Procedure:

Step Process Tool
1 Use 1.0 mm thickness Gauge for assembly the Tube. Gauge 1.0 mm
Look into the tube form the LP to SL, AL side. Watch the image of
2
DMD. The overfill image will be clearly seen.
If bottom of picture is near to right blue edge, the overfill left down
3
side and down side will just touch the LP’s edge.
Pre-adjust Overfill form LP image. First step adjust 1 click from
bottom side (rotate wrench for 60°). Then adjust 2 clicks on left
4
side (rotate wrench for 120°). The Overfill image inside LP will be
as figure 1.
5 Mount optical engine into projection jig. Projection Jig
First adjust FM up and down, in order to let blue edge occur on
6 Hexagonal screw driver
bottom side. Note half click distance is ok.
a. Adjust FM left and right, in order to let blue edge occur at right
7 side or left side. Finally stop at middle point from right or left.
B. If left or rights clicks are over 2, go to Step 9.
a. No blue edge, go to Step10.
8 b. Has blue edge, adjust Tube out for two clicks. Back to Step 6,
adjust FM.
If left or right clicks are over two, put Tube in for one click. Back to
9
Step 6, adjust FM.
10 Add glue to mount Tube and FM.

Figure 22

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Model Name: PB6240 Marketing Description :

Chapter 9
Mechanism Assembly Concerns
n Wire Dressing Concerns

THERMAL SENSOR wire is

This myler hole is no
plug in CONNECTOR directly,
need for wire dressing.
don’t care the LAMP BOX ditch.

FIG 23 AC Socket & Safety Switch

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Rear fan wire goes through the hole.

FIG24

Put the wire into ditch. Compress the

wire hook flat on top of engine.

FIG 25

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Press wire down away from lens in order

to prevent interference with lens.

FIG 26

Keep the wire flat, no bulge up. For

sure engine assemble is not interfered
with the wire.

FIG 27

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Clip the core here.

The wire should not press down the

metal claw.
FIG 28

The wire should be mounted below the

HEATSINK.

FIG 29

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Add a wire clip here to prevent wire interfering

with lens. Note: REWORK this wire clip should
be changed new.

Add the tape on the pillar.

FIG 30

Put the BALLAST control wire behind

the POWER MODULE wire.

FIG 31

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For sure the metal sheet is

assembled behind IR SENSOR.

FIG 32

SPONGE is leaned against with

front edge and right edge.

FIG 33

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Model Name: PB6240 Marketing Description :

Wire clip is mounted against the

FIG 34 nick of MYLAR.

Wire through the clip.

FIG 35
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SPONGE is mounted against the

nick of Myler.

FIG 36

SPONGE is mounted against the

CHIP BD edge. FIG 37

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Model Name: PB6240 Marketing Description :

Chapter 10
EMI Assembly Concerns
Model:PB6240 Page : of
Stage :LP2 Doc No.:
Test Engineer :Rodney Lin
Test Mode: 1280X1024@60Hz Test Date :04/19/2005
EMI Lab :QTK LAB

n EMI ISSUE:
Part number and mounting position
47.J9418.001 1.Connecter & grounding (l*w*t) 20mm x 10 mm x 1mm
47.J9417.001 2.ENG & M/B SHD(lower) (l*w*t) 20mm x 10 mm x 12mm
3.Heatsink & M/B SHD(lower) (l*w*t) 20mm x 10 mm x
47.J9417.001 12mm
47.J8112.001 4.M/B & M/B SHD(lower) (l*w*t) 8mm x 8 mm x 3mm
34.J9317.001 6.ENG & standoff clip 34.J9317.001 *1pcs
34.J9317.001 7.Keypad & M/B SHD(upper) 34.J9317.001 *1pcs
47.J8111.001 Gasket 50*14*14
Notice:
(1) Blower module’s BKT should be touched with GASKET
(2) CON module’s BKT should be touched with GASKET
(3) ENG Cover’s GASKET should be mounted at figure 3 position
(4) LENS should mount with CLIP, CLIP should touch aluminum pillar

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Model Name: PB6240 Marketing Description :

Item Problem Solution

1 53MHz 1.Add three Gasket
720MHz
600MHz

2 360MHz 3.Add two Gasket

720MHz
600MHz
840MHz

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3 54MHz 4.Add Shielding

62MHz

4 120MHz 5.Add one spring on shielding

240MHz

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5 480MHz 6.Add shielding on up cover

300MHz
720MHz

6 360MHz 7.Add two Gaskets

720MHz

840MHz 8.Add shielding on up cover

7 960MHz
720MHz

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9.Keypad wire shielding and Grounding

8 756MHz

9 120MHz 11.Power wire shielding

240MHz

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10.Power wires shielding and Grounding

10 720MHz
840MHz

11 420MHz 11. Add aluminum tape.

660MHz

12
120MHz 12. Add a Gasket.

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Model Name: PB6240 Marketing Description :

Chapter 11
DDP2000 based Projectors Download Procedure
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

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Model Name: PB6240 Marketing Description :

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 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.

34
Form No: BQY0-0B-003-32(031205)
q Product System (PS)

Subject: C3-323 Alignment & Assembly Part No.: 99.J0Y77.B52 Rev.: 1

Concerns
Doc. No. 99.J0Y77.B52-C3-323-001

Project Code: 9J.J0Y77.001 Component Part. No.: NA Page 35 of 37

Model Name: PB6240 Marketing Description :

35
Form No: BQY0-0B-003-32(031205)
q Product System (PS)

Subject: C3-323 Alignment & Assembly Part No.: 99.J0Y77.B52 Rev.: 1

Concerns
Doc. No. 99.J0Y77.B52-C3-323-001

Project Code: 9J.J0Y77.001 Component Part. No.: NA Page 36 of 37

Model Name: PB6240 Marketing Description :

Download procedure
1. Click on Flash Loader and browse the image file (new version firmware)

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

36
Form No: BQY0-0B-003-32(031205)
q Product System (PS)

Subject: C3-323 Alignment & Assembly Part No.: 99.J0Y77.B52 Rev.: 1

Concerns
Doc. No. 99.J0Y77.B52-C3-323-001

Project Code: 9J.J0Y77.001 Component Part. No.: NA Page 37 of 37

Model Name: PB6240 Marketing Description :

7. Wait till composer lit notice upgrade completed

8. Download is completed. The factory settings should be restored.

Verification
Check the version number

37
Form No: BQY0-0B-003-32(031205)