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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

LP815 part number

LP820 part number

Controller ECA

510-0909-xx

510-1755-xx

Label kit

802-0054-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 Replacementinstructions to remove and replace each FRU in the projector. Weve
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 TestsYou use these tests to ensure that the projector is ready to return to the
customer after you have repaired it.
Parts ListsIn 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.

LED is solid green

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.

LED flashes red once

The lamp will not strike after five tries (2 1/2 minutes).

LED flashes red two times

The lamp has more than 2,000 hours of use. Requires replacement.
Projector shuts down.

LED flashes red three times

Lamp failure. Projector shuts down.

LED flashes red four times

One or more fans not operating. Projector shuts down.

LED flashes red five times

High temperature condition. Projector shuts down.

LED is solid red

Undiagnosed error. Projector shuts down

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.

Replace the
power supply

No, the
fans
did not
start and
the LED
did not
light.

Do the fans
run briefly and
the LED light?

Confirm that unit is


good by starting again.

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.

Yes

LED light
green or red?
Note
A solid green
LED means the
projector is either
waiting for a
command or is
operating
normally.

Solid green

Go to Power
Diagnostics, part 2

A flashing green
LED means the
projector is either
attempting to light
the lamp or is
shutting down.

This is the
normal
condition.

Red

No

Voltages OK?

Replace
power supply

Yes

Go to Error
Codes

Replace controller ECA

Solve the
problem?

Yes
Confirm that unit is good
by starting again.

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.

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.

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 LED remains solid green


after pressing the Power button
twice. The lamp does not light.

Yes
The LED continues flashing
green until the lamp lights.

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?

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.

LP815/LP820 Service Manual

Solve the
problem?
Yes

No
Replace controller ECA

Repeat process to confirm


the problem fixed.

Error Codes
Power Diagnostics, Error Codes
Interpret red LED behavior

Is the LED steady or


flashing?
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.

An internal error occurred


that the projector cannot
identify.
Diagnose the error.
See Solid Red LED.

On
Off

What is the
flashing pattern?

On
Off

On
Off

1 flash
The lamp failed to strike
after five attempts.
Diagnose lamp strike
failure.

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 WON'T STRIKE

REPLACE LAMP

LAMP FAILURE

RETRYING WAIT...

Repeats
Keypad LCD messages

On
Off

On
Off
4 flashes
A fan failed.
Check the fans.

FAN FAILURE SHUTDOWN...10

FAN FAILURE SHUTDOWN...1

LP815/LP820 Service Manual

5 flashes
The projector detects
high internal
temperature.
Diagnose thermal
problems.
OVER TEMP CONDITION
OVER TEMP CONDITION SHUTDOWN

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

Ensure that the lamp


door is present and shut.

LAMP WON'T STRIKE

RETRYING WAIT...
Repeats

Can you hear


the safety switch
open and close?

No

Replace safety
switch.

Verify the repair by


restarting the Power
Diagnosis process.

Yes
Replace the lamp
module.

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

Yes

Replace the
ballast.

Solve the
problem?

No
Verify the repair by
restarting the Power
Diagnosis process.

LP815/LP820 Service Manual

Replace controller
ECA

LED flashes repeated red three-flash sequence


LCD Message

The lamp was operating but shut down. Fans are


running. The status LED flashes a repeated
red three-flash sequence.

LAMP FAILURE

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 95 F (35 C).

Replace the ballast.

Reinstall the lamp,


ensuring that it is
properly seated.

Solve the
problem?

Run the projector long


enough to ensure that the
problem is solved.

No
Replace the lamp.

No

Solve the
problem?

Yes
Repeat the diagnostic
process to ensure that
the problem is solved.

LP815/LP820 Service Manual

Yes

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.

LED flashes repeated red five-flash sequence


Projector shuts down after detecting high temperature
condition. LED flashes in repeated five-flash sequence.

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
95 F (35 C).

Is the thermal
switch good?

No

The safety switch


assembly includes
a thermal switch..

Replace the safety switch.

Yes
Substitute a good power supply
and run projector long enough to
know if that is the problem.

Solve the
problem?

No

Yes
Run the projector long enough to
confirm the problem issolved.
Repeat the diagnosis process.

LP815/LP820 Service Manual

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.

The problem is almost


always a power supply or
controller board with a
thermal breakdown
problem.
Replace the controller ECA.

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.

Confirm that all image


adjustments are set to
the factory defaults.

If in doubt, feed the


signal to a good
projector.

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.

LP815/LP820 Service Manual

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.

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?

Yes

Replace the lamp.

No
Substitute a known good
controller ECA.

Is the image
brighter?

Yes

No
Replace the optical engine.

LP815/LP820 Service Manual

Replace the controller ECA.

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.

LP815/LP820 Service Manual

Responds to the right


and left IR receivers,
but not the front IR
receiver

Check the IR
cable

Replace the
front IR ECA

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

Yes

Is there sound
from both
speakers?

Yes
Problem solved.

LP815/LP820 Service Manual

Replace the controller ECA.

Replace the speakers

No,
only
one

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.

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

IR ECA

Elevator
button

Front IR
window

Focus and
zoom rings

Top cover
LCD cover

Bottom case
(Remove all FRUs
to replace case)
LCD blower

R & L IR
windows

Handle

LP815/LP820 Service Manual

Power supply
Lamp blower
& bracket

Engine
blower &
bracket

Leveling foot
& shaft

Ballast

Controller
ECA

Optical
Engine
Lamp
housing

Power supply
fan

Lamp
housing air
guide

Safety switch
cable

Controller/
power supply
cable

Elevator foot
& actuator

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

Dust filter

Lamp door

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.

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

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.

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

Swing the top case forward so you can disconnect the keypad cable and the speaker cable from
the controller ECA.

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

Remove the three M3.5x6 Plastite screws that fasten the speaker bracket and speaker to the top
case.

Remove the bracket from the speaker.

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

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.

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.

Once you remove the keypad/LCD ECA, you can remove the keypad from its position in the top
case.

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.

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.

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

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

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

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.

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

IR ECA

IR cable

Remove the rear bezel and the top case.

Unplug the IR cable from the IR ECA.

To remove the IR ECA, remove the M3.5x7 Plastite screw that fastens it to the bottom case.

LP815/LP820 Service Manual

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

Remove the rear bezel and the top case.

Lift the handle and front vent out of the bottom case.

Disconnect the power supply/ballast cable from the ballast.

Disconnect the lamp blower, LCD blower and ballast control cables from the controller ECA.

LP815/LP820 Service Manual

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

Remove the three M3.5x25 Plastite screws that fasten the ballast to the bottom case. Then lift the
ballast out of the bottom case.

If you are replacing the ballast, disconnect the ballast control cable from its connector on the
ballast.

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.

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

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

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.

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

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

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

Unplug the cables from their connectors as shown below.

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

Use a T10 Torx driver to remove the M3x5 Torx screw that fastens the I/O EMI shield to the
power supply.

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

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.

Remove the following items:


Rear bezel
Top case
Controller ECA
Power supply fan

Remove the two M3x7 Plastite screws that fasten the power supply to the bottom case.

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.

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).

Remove the following items:


Rear bezel
Top case
Controller ECA

LP815/LP820 Service Manual

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.

Lift the power supply fan out of the bottom case.

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.

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.

Remove the safety switch cable from the cable clip in the bottom case adjacent to the leveling
foot.

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

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.

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).

Remove the following items:


Rear bezel
Top case
Controller ECA
Ballast

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

Lift the assembly out, working the lip on the end of the blower duct past the hole in the lamp
housing.

Lift the LCD blower out of the bottom case.

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

Remove the five M3.5x10 Plastite screws that fasten the engine to the bottom case. Then lift the
engine out.

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.

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

Remove the two M3x8 Plastite screws that fasten the power supply to the bottom case.

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.

Remove the optical engine.

Remove the two M3x5 screws on the top of the lamp housing.

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

Remove the Optical engine.

Use a needle nosed pliers to remove the spring on the elevator actuator.

Lift the actuator out of the bottom case.

LP815/LP820 Service Manual

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 Kit510-1923-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.

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.

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 youve repaired the projector to make sure all components of the
projector operate properly. You can also perform the functional tests if youre 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.

Audio & Video cables

Use the AV cable that came with the projector. You also need the
optional S-video cable.

Computer cables

VESA cable, M1 cable

RGB test screens in a


PowerPoint presentation

We recommend that you Use the Test Patterns on the InFocus


website to check image quality.

PC with digital video and sound


card

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.

Remote control

Ensure that the remote has fresh AA batteries.

Projection screen

Use a flat screen, not a curved one.

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

Verification

Power Up
Connect AC power, and turn
the unit on.

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.

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.

Audio from video source

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.

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.

Image #2: Color Ramp


Project the Color Ramp
image.

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.

LP815/LP820 Service Manual

Verify unit is powered off before disconnecting cables.

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

Part name in parts pricing list

Part number

Top label

LABEL, TOP, INFOCUS

020-1591-xx

Certification label

LABEL BOTTOM, CERTIFICATION,


INFOCUS, NJORD

020-1903-xx

InFocus brand label

LABEL REAR LOGO, INFOCUS,


NJORD

020-1823-xx

I/O label

LABEL REAR, GENERIC, NJORD

020-1822-xx

Bottom label

LABEL BOTTOM, INFOCUS, NJORD

020-1821-xx

Cable kit

CABLE KIT, NJORD, LP820

410480

Screw & mounting details kit

SCREW AND MOUNTING DETAILS


KIT, NJORD, LP820

410481

Adjustable feet kit

ADJUSTABLE FEET KIT, NJORD,


LP820

410482

Mounting parts kit

MOUNTING PARTS/BRACKET KIT,


NJORD, LP820

410483

IR window kit

IR GLASS KIT, NJORD, LP820

410484

Optical engine

ENGINE LP820 WITH XGA MLA


PANELS INCL. NVRAM

410488

Speaker set

S/A, LOUDSPEAKER SETS, NJORD


YD50-9-6 WITH CABLES

412-0004-xx

Top case

S/A TOP, NJORD

505-1584-xx

Top cover

S/A TOP COVER, NJORD

505-1585-xx

Bottom case

S/A BOTTOM NJORD

505-1586-xx

Rear bezel

S/A REAR COVER COMPLETE, NJORD 505-1596-xx

Lamp housing air guide

S/A AIR GUIDE LAMPHOUSE


COMPLETE, NJORD

505-1600-xx

Lamp blower & bracket

S/A HOLDER LCD FAN COMPLETE,


NJORD

505-1622-xx

LP815/LP820 Service Manual

Part name in service guide

Part name in parts pricing list

Part number

Engine blower & bracket

S/A HOLDER PBS FAN COMPLETE,


NJORD

505-1623-xx

Keypad

S/A KEYPAD, NJORD

505-1624-xx

Lamp housing

S/A LAMP HOUSE COMPLETE, NJORD 505-1709-xx

Power supply fan

S/A, FAN AXIAL COMPLETE, POWER,


60X25, NJORD

505-1710-xx

Power supply

ECA, P/S, POWER, LP820

510-1741-xx

Controller ECA (LP820)

ECA, NJORD MAIN BOARD EXCL.


NVRAM

510-1755-xx

Controller ECA (LP815)

ECA, NJORD MAIN BOARD EXCL.


NVRAM

510-1923-xx

Keypad LCD ECA

ECA, KEYB/LCD NJORD (LP820)

510-1808-xx

Front IR ECA

ECA, NJORD IR-BOARD

510-1814-xx

Ballast

250W POWER PACK


LAMP,C13HB/NJORD

525-0061-xx

LCD blower

S/A FAN BLOWER,LCD,TYF209 NJORD 526-0181-xx

Label kit (LP815)


Includes top, certification, I/O and brand
labels.

LABEL KIT, LP815

LP815/LP820 Service Manual

802-0054-xx

Screw and Mounting Details Kit


Screw and mounting details kit (410481)
Part Name

Quantity

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

17

M3x5 Torx screw

10

M3x5 Plastite Torx screw

16

M3.5x10 Plastite Torx screw

M3.5x25 Torx Plastite screw

M4x7.5 black Torx screw

LP815/LP820 Service Manual

Cable Kit
LP815/LP820 cable kit (410480)
Part Name

Quantity

Keypad cable

Lamp control cable

Power supply / ballast cable

Safety switch cable

IR cable

Adjustable Feet Kit


LP815/LP820 adjustable feet kit (410482)
Part Name

Quantity

Elevator spring

Elevator button

Elevator shaft

Elevator activator

Leveling foot shaft

Leveling foot

Leveling foot insert

Mounting Parts Kit


LP815/LP820 mounting parts kit (410483)
Part Name

Quantity

LCD protective cover

Handle

LCD air guide

Power supply cover

Front vent

LP815/LP820 Service Manual

IR Window Kit
IR window kit (410484)
Part Name

Quantity

Front IR window

Left IR window

Right IR window

Focus and Zoom Ring Kit


Focus and zoom ring kit (410485)
Part Name

Quantity

Focus ring

Zoom ring

LP815/LP820 Service Manual