LVPS Replacement Instruction Sheet INTRODUCTION Use the following instructions when replacing the Astec Low Voltage Power Supply (LVPS) in CP2000-ZX (116-001101-03/04, 116-001113-01, 116-001124-01) or CP2000-M/MR (119-001101-02, 119-001101-03) projectors. KIT REQUIRED 003-120488-01 LVPS Service Kit (includes low voltage power supply, AC harness for ZX (001-111092-01), AC harness for M/MR (001-110858-01), DC harness (001-111081-01), 1/8 plastic slot driver, instructions) TOOLS REQUIRED CP2000-ZX: Phillips #3, #2 (long stem) 1/8 plastic slot driver (for LVPS POT adjustments in CP2000-ZX projectors) CP2000-M: Phillips#1, #2 (long stem, and 4 ) SAFETY AND WARNING GUIDELINES HIGH VOLTAGES MAY BE EXPOSED: Always power down and disconnect power sources prior to servicing. Once the projector is powered down, allow the cooling fans to automatically turn OFF before disconnecting from AC and opening the projector. Depending on your projector model this can take 10-15 minutes. QUALIFIED SERVICE TECHNICIANS REQUIRED: All module replacement procedures must be performed by qualified service technicians. NON-INSULATED DANGEROUS VOLTAGES MAY BE EXPOSED: Always disconnect from AC prior to disassembly. OBSERVE ALL ELECTROSTATIC PRECAUTIONS: Use a grounded wrist strap when handling electronic assemblies. Never operate the projector (or the fans) without all the covers installed. LVPS Replacement Instruction Sheet 1 of 11
INSTRUCTIONS FOR CP2000-ZX 1. Ensure power to the projector is OFF. 2. At the wall breaker, set the main AC circuit breaker to OFF. 3. Remove the LVPS/Ballast cover (Figure 1): a. Loosen the 3 captive screws securing the cover to the chassis. b. Lift the cover enough to clear the tabs at the bottom and remove. Figure 1 4. Remove the EMI shield (Figure 2): a. Loosen the 2 screws securing the shield to the frame. Remove shield to access harness connections to the LVPS. Figure 2 2 of 11 LVPS Replacement Instruction Sheet
5. Disconnect the DC harness (P1) from the Motherboard. (Figure 3) Figure 3 6. Disconnect the signal connection from the AC end of the LVPS, and the three signal harnesses (+3.3V, +5V and +12V) from the DC end. (Figure 4) 7. Remove the AC relay cover. 8. Disconnect the four AC harnesses from the AC relay (4, #2 Phillips screws). (Figure 5) 9. Disconnect ground. Figure 4 Figure 5 LVPS Replacement Instruction Sheet 3 of 11
10. Remove 4, #3 Phillips screws securing the LVPS module to the vertical plate. (Figure 6) Figure 6 11. Before installing the new LVPS, remove the AC harness and connect the loose AC harness labeled P/N 001-111092-01 from the kit. This AC harness is specific for CP2000-ZX. 12. Continue replacing the LVPS by following instructions in reverse. Refer to the Interconnect drawing provided with your projector when reconnecting harnesses. Pay particular attention to the connection of the +3.3V and the +12V signal harnesses. These are critical connections that if not done correctly can lead to LVPS damage. To adjust LVPS voltage rails: Use the non-conductive plastic slot driver provided in the service kit when adjusting the LVPS voltage rails on the CP2000-ZX LVPS. LVPS rail adjustment must be performed by qualified service technician. 1. Remove the LVPS/ballast side cover. 2. Adjust POT s to 3.366 +/-0.003v and 5.110v +/-0.003v. Observe the CDP to see the adjustment value of the rails. Figure 7 4 of 11 LVPS Replacement Instruction Sheet
FOR CP2000-M 1. Ensure power to the projector is OFF. 2. Remove top lid. (Figure 8) 3. Remove the 13 screws securing the high security cover. Remove cover (Figure 9) Figure 8 Figure 9 4. If your projector is manufactured early 2009, continue with Steps 5-9. If your projector is manufactured late July 2009, continue with Step 10. These units have longer LVDS cables which allow the connections to the FFIB to remain intact. LVPS Replacement Instruction Sheet 5 of 11
5. Remove the 4 screws securing the small plate on top of the cardcage. Remove the plate. (Figure 10) Figure 10 6. Disconnect power harnesses J7, J8 and J9 from the FPGA Formatter Interface Board (FFIB). Note: The FFIB is located in the top slot of the cardcage. 7. Remove clips securing power harnesses. (Figure 11) 8. Disconnect the 6 LVDS harnesses from the FFIB. 9. Disconnect the CDP power harness. Figure 11 6 of 11 LVPS Replacement Instruction Sheet
10. Remove the intake duct (Figure 12): a. Remove 3 screws from the corners of the intake duct. b. Remove the duct by pulling it up and out. Figure 12 11. Remove the air filter cover (Figure 13): a. Loosen the 2 captive screws at the bottom of the filter cover. b. Pull the cover up and remove. Figure 13 12. Loosen 2 thumbscrews on the cardcage. (Figure 14) Figure 14 LVPS Replacement Instruction Sheet 7 of 11
13. Remove 6, #1 Phillips screws on the cardcage front plate. (Figure 15) 14. Slide the cardcage out a few centimeters, then re-tighten the 2 thumbscrews on the cardcage (Figure 14) to prevent the cardcage from sliding all the way out. Figure 15 15. Disconnect DC power P1 and P35 on the Motherboard. 16. Disconnect the inline connection to the voltage adjustment harness. 17. Disconnect the signal connection from the AC end of the LVPS, and the two signal harnesses (+3.3V,+5V) from the DC end. (Figure 16) Figure 16 18. Using a long stem #2 Phillips screwdriver, loosen the 2 thumbscrews on each side of the LVPS (behind the cardcage). 19. Open the rear lamp door. 8 of 11 LVPS Replacement Instruction Sheet
20. Remove the exhaust panel (Figure 17): a. Remove 2 screws from each corner of the panel. b. Using a 4mm Allen key, remove 5 socket head cap screws along the bottom edge of the panel. c. Pull the skin forward and out. Figure 17 21. Disconnect the two harnesses (brown -SW1 and blue - SW2) from the AC selector switch. (Figure 18) Figure 18 22. Remove the 10mm nut from the GRN terminal and disconnect. (Figure 19) Figure 19 LVPS Replacement Instruction Sheet 9 of 11
23. Disconnect the lamp exhaust thermal harness. (Figure 20) 24. Remove 3 screws from the lamp exhaust duct. Remove duct. 25. Remove 2 screws and loosen the thumbscrew from the liquid cooling module. Pull the liquid cooling module up slightly and slide it out enough to gain access to the LVPS plate cover. (Figure 21) Figure 20 Figure 21 10 of 11 LVPS Replacement Instruction Sheet
26. Using a long stem #2 Phillips screwdriver, remove 2 screws and PEM nut from the LVPS plate cover. Remove cover. Using caution not to catch any harnesses on the opposite end, slowly pull the LVPS out of the compartment. (Figure 22) Figure 22 27. Remove 4 screws from the LVPS cover. 28. When replacing, repeat instructions in reverse. Refer to the Interconnect drawing provided with your projector when reconnecting harnesses. NOTE: The AC harness for the CP2000-M already comes connected to the LVPS. It is labeled 001-110858-01. To adjust LVPS voltage rails: LVPS rail adjustment must be performed by qualified service technician. 1. Remove the air filter cover (and filter). 2. Adjust POT s to 3.366 +/-0.003v and 5.110v +/-0.003. Observe the CDP to see the adjustment value of the rails. (Figure 23) Figure 23 LVPS Replacement Instruction Sheet 11 of 11