2007 DLP Orchid Chassis

HLT5076
HLT5676
HLT6176

2007 DLP Model Comparison

720p

1080p

Lamp

Lamp

LED

Einstein

Cattleya

Galilei

Sunflower

Orchid

Constantine

Laurel

Engine Series

K220

K620

K280

K280

K780

L680

K880

Type

Normal

Slim

Normal

Normal

Ultra Slim

Normal

Slim

Cabinet

K2/K3

46K5, 50/56K6

K3

72K8

50/56/61K7

56L8

50/56/61K8

DMD Resolution

720P

720p

1080p

720p

1080p

1080p

1080p

C/Wheel/LED
Sensor

18.5

15.5

18.5

15.5

18.5

LED

Dynamic Black

Yes

Yes

Yes

Yes

Smooth Picture
Actuator

Yes

Yes

Yes

Yes

Yes but not

replaceable

Yes

No

Comments

2006 Carryover

New

2006 Carryover

New

New

2006 Carryover

New

Model #s

HLS

HLT**65
HLT**75

HLS

HLT7288

HLT**76series

HLS5679

HLT**87
HLT**89 2

Light Engine Comparison

K780 (Normal vs. Ultra Slim)

Traditional
Light Engine

Ultra Slim Light Engine

Projection
Lens
Light Engine

Actuator

Orchid Chassis Light Path

Ultra Slim Light Engine Overhead View

Projector

Cooling
System

DMD-BOARD
5

Projection Module
M4 mirror

M3 mirror

Projecting
Lens
M2
mirror

L2 lens

Smooth
picture
L1 lens

Dynamic
black

Light Source
DMD (xHD5)
Light-tunnel
M1 mirror
Lamp

Fold mirror
E4 lens
E1 lens
Color wheel

E2/E3 lens

Projection Light Path

Engine Layout

LAM
P

A SS

Wall
8

Main PCB Block Diagram

Clear QAM tuner

A Clear-QAM tuner allows you to tune in both analog and
digital cable signals, including the HD versions of major netw
ork channels like CBS and NBC. Basically these are
unencrypted digital cable channels such as the HD versions
of PBS, Fox, NBC, CBS and ABC.
Depending on the cable provider you may also be able to
view other digital stations using the Clear-QAM tuner.
Understand that cable providers are not required to carry the
HD versions of broadcast channels. They are only required
to carry the analog versions by law.
Additionally just because the signal is transmitted via cable
doesn't mean it is always superior to the off the air signal with
an antenna.
10

S5H2201 Video Processor

Improved audio DSP, a programmable
video encoder with a dual output
capability of interlaced and progressive
scan
Memory controller,
4-channel Timers with PWM, I/O Ports,
2-channel 8-bit ADCs, 5-channel 10-bit DACs,
2-channel UARTs with handshake,
IIC-BUS interface, IIS-BUS interface, SIO,
USB Card Interface (WiseLink)
11

SDP62 Scaler
4CH Input
CH1, CH2 : 30Bit (RGB, YCbCr4:4:4, 601,10Bit or 8Bit)
CH3 : 24Bit (RGB,YCbCr4:4:4 each 8bit, 601 10bit)
CH4 : 20Bit (Only 601 8Bit or 10Bit)
OSD Input
Output
Digital RGB (10Bit 444) Digital YCbCr(10Bit 444)
RGB/YCbCr 10bit OUTPUT @ CLK OUT Progressive
S
can
RGB/YCbCr 20bit Even/Odd) OUTPUT Interlaced Scan

12

Audio Signal Flow

ATI_SPDIF

X240H_DATA
X240H_SCLK
X240H_LRCLK
X240H_MCLK

HDMI_DATA
HDMI_SCLK
HDMI_LRCLK

I2S_MCLK
I2S-CLK_AMP
I2S-WS_AMP
I2S-DATA_AMP

X240_SL
X240_SR

MAIN-R
MAIN-L

DVI-L/R
PC-L/R

COMP2 L/R

COMP1 L/R

L1/R1

L2/R2

SIDE-L/R

MON-L/ROUT

TU_SIF

13

DMD Board Block Diagram

14

Service Adjustments

Index Delay
Actuator Gain
Focus
Tilt
V/H position
CCA (DMD <-> Digital)
Software Upgrade

15

Removing the Light Engine

1. Remove the four m
ounting screws and
the vertical bar.

2. Disconnect the 1
2P PS cable, LVDS
Cable and Ballast
PS Cables.

3. Disconnect the 3P
cable

4. Disconnect the
lamp door switch
cable

Remove the engine by pulling it out of the cabinet.

Be careful when removing the Light Engine as it may get
caught up by the upper cable of the case.

16

Removing the Color Wheel

Remove the lamp chimney
Remove the Ballast fan
housing
Remove the three screws
holding the C/W heat sink
The C/W gasket should
stay in place

17

Removing the DMD Board

1. Remove the DMD
Fan and disconnect the
two fan drive
connectors.

2. Remove the
retaining spring and
the heat sink.

3. Remove the four

corner screws and the
shield.

4. Remove the
seven point screws,
do NOT remove the
screws highlighted
in yellow.

5. Remove the DMD board, then transfer the current DMD mirror chip to the new DMD board

18

2007 DLP K780 Optical Engine _ HLT**76SX Series

Orchid
Chassis
Alignments

19

Shadow Defect
1) Shadow Inspection and light tunnel adjustments must be performed
if necessary before the geometry adjustments.
- Enter Factory mode -> DDP3021 ->Test Pattern -> Select
Raster White Pattern

Shadow Defect

Test Pattern

20

Shadow Adjustment Access

Dust Cap

Back Cover

Remove the dust cap portal to view the screen from the inside
21

Adjust the Light Tunnel

2) Adjust Light Tunnel
1) As shown in the left picture, adjust the light
tunnel and inspect the adjust condition.
2) To remove the right side Shadow, do the
following - Front Screw : Turn Right (CW)

3) To remove the upper side Shadow, do the

following
- Rear Screw : Turn Right (CW)

22

Illumination Adjustment

23

Final Inspection
1) Shadow Inspection
- Enter Factory -> Test Pattern -> Select White Pattern
2) Make sure to inspect the left bottom and right upper corner of the
screen for shadow defect.

Right upper

Left bottom

Test Pattern

24

Image Tilt Inspection

These adjustments muse be performed after the light tunnel adjustments and after the
cabinet back is secured along with the rear cabinet braces.
1.Tilt Inspection Bring up the internal tilt test pattern
Enter Factory mode (mute+182+Power) -> H/V Position -> Tilt Pattern

Tilt Pattern (Internal Pattern)

Inspect the Tilt

(with external Lionhead or Overscan pattern)

2) Tilt Specification
Inch

Spec

50,56

7 mm (.27)

61

8 mm (.31)

Remark

*TOP Tilt : H1-H3

* BOTTOM TILT: H2-H4

25

Tilt Adjustment (Top Bowing)

1) Loosen Screw A at the 2 points shown.
(outside screws)

Top Tilt Adjustment

2) Use Screw B to adjust Top Tilt

-B (Right) : Rotate CW -> Image Down
-B (Left ) : Rotate CCW -> Image Up
3) Reference the overscan test pattern to
determine the correct adjustment. As
shown in the figure below, align the
green line to the cabinet bezel. (see spec
pg. 20)

Left

A B
Screw A : Fix Engine.

Right

B A
B : Tilt Adjustment

4) Fix Screw A at the 2 points shown.

26

27

28

Tilt Adjustment
(Bottom Bowing Coarse Adjustment)
First loosen the 2 screws as shown Fig #1.
If the bottom of the screen is bowing up, (In most cases)
- Insert a flat screwdriver above screw #1 as shown Fig #2.
1

- While applying upward force on the flat screwdriver handle (causing

downward motion of screw #1 by rocking against cabinet), monitor
bottom bowing on the screen and tighten screw #2 when straight.
If the bottom of the screen is bowing down,
- Insert a flat screwdriver under #1 as shown Fig #3..
- While applying downward force on the flat screwdriver handle
(causing upward motion of screw #1 by rocking against cabinet),
monitor bottom bowing on the screen and tighten screw #2 when
straight.

Fig #1

Fig #2

Fig #3

29

Tilt Adjustment Part 2

Bottom

Bowing Fine Adjust

A
A
A

1) Loosen Screw A at 4 points as shown.

2) Rotate Screw B to adjust Bottom Tilt

-B (Right): Rotate CW -> Image Up

-B (Left) : Rotate CCW -> Image Down

C
D

3) Refer to the monoscope pattern to

determine the correct adjustment. As
shown in the figure below, align the
green line to the cabinet bezel.

Screw A : Fix Mirror

B : Tilt Adjustment
4) Fix Screw A at the 4 points as shown.
30

Tilt Specifications
1st : Measure inner Red box line
2nd: Measure 2 end point of Red box for bottom and top side.
3rd: Compare with the tilt specification

size

QC

50, 56

7 mm (.27)

61

8 mm (.31)

Measure
TOP TILT : H1-H3
BOTTOM TILT: H2-H4

Keystone Specifications
1st : Measure inner Red box line
2nd : Measure 2 end point of Red box for right and left side.
3rd : Compare with the tilt specification

size

QC

50, 56

7 mm (.27)

61

8 mm (.31)

measure
LEFT KEYSTONE : V1-V2
RIGHT KEYSTONE : V3-V4

Barrel Specifications
1st : Measure both 2 ends and center point (Top, Bottom or Sides)
2nd: Connect both 2 ends and measure the distance to center point
3rd : Compare with the tilt specification

Size

QC

50

5mm (.2)

56

5.5mm (.22)

61

6mm (.24)

Measure
Measure Center barrel (mm)