Nacho Family Service Manual UPDATES 07-February-2005: Light Tunnel (315-0053-xx) added as a replaceable part in service manual. 26-October-2004: Color wheel assembly (525-0139-xx) added as a replaceable part in service manual. The Nacho family of projectors includes the ASK Proxima C170 and the InFocus LP600. Using the manual The bookmarks that appear on the side of the screen help you navigate to each topic in the manual.
Table of Contents Nacho Family Service Manual ................................................................................................................. 1 Table of Contents...................................................................................................................................... 2 Troubleshooting........................................................................................................................................ 3 Power and Start-up Problems .............
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 and Start-up Problems The projector communicates its status via an LED 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.
Power Diagnostics, part 1 Plug the projector into a good power source with a known good power cord. Check the lamp door. Check the interlock switch. (page 24) No, the LED and the Power button did not light. Does the LED light a steady green and is the Power button illuminated? Confirm that the keypad flex cable is plugged in. (page 31) Go to Power Diagnostics, part 2 A solid green LED means the projector is either waiting for a command or is operating normally.
Power Diagnostics, part 2 Press the Power button on the keypad. The power cord must be plugged in and the LED must be solid green. If not, go back to Part 1. Does the startup tone sound? No Confirm that the speaker cables are connected to the keypad ECA on the inside of the top enclosure (page 31) Check the LED status Solve the problem? Is the LED flashing green? No, the LED Is flashing red. Go to Error Codes on page 7. No Measure the resistance across the speaker terminal.
Power Diagnostics, Error Codes Is the LED steady or flashing? Flashing Steady Red LED flashes have approx. 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. On Off An internal error occurred that the projector cannot identify. Diagnose the error. (page 11) What is the flashing pattern? On Off On Off 1 flash The lamp failed to strike after five attempts. Diagnose lamp strike failure.
LED flashes single red The lamp won't strike after five attempts. The status LED flashes a repeated red single-flash sequence. Ensure that the lamp is good. Is the lamp door closed? Close the door properly and restart diagnostics No LCD Message Lamp did not strike Yes Open the lamp door. Check the interlock switch. (page 24) Retrying, wait... Repeats Interlock switch good? No Replace the exhaust fan assembly (includes the interlock switch).
LED repeats 3 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 shutoff 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 projector should not be used where ambient temperatures are over 95º F (35º C).
LED repeats 5 flash sequence Projector shuts down after detecting high temperature condition. LED flashes in repeated five-flash sequence. LCD Messages Verify that the two exhaust fans are operating. These fans are not sensed. (page 20) High temperature shutdown Are both fans turning? No Remove the top case (page 31), then check the fan voltages (page 21). If the voltages are good, replace the exhaust fan assembly (page 37). If the voltages are bad, replace the controller ECA.
LED is solid red LED solid red. Fans may or may not be running. Replace the power supply. (page 52) No Power supply voltages good? (except lamp enable) (page 15) Yes Reseat color wheel cable. No Is the color wheel spinning? Yes If color wheel does not spin, replace the color wheel assembly. (page 40) Does the color wheel start and the lamp light? Replace the controller ECA. (page 44) No Replace the controller ECA.
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. Make sure the signal is good. 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.
Keypad Problems LCD Problems Nacho Family Service Manual 13
Remote Problems 44) 44) Nacho Family Service Manual 14
Check Controller ECA and I/O Voltages 1 Remove the top case. 2 Plug the projector into a power source. You can measure ‘non-power state’ voltages on the controller ECA when the projector is not powered up. 3 Use the remote control to power up the projector. NOTE If you don’t have a remote control, you can plug the keypad cable into its connector on the controller ECA, and use the power button on the keypad. 4 Use measurement equipment to check the controller ECA for voltages.
5 Check the voltages on the I/O ECA.
Adjust Image Banding Image banding can appear on the top, bottom, right or left sides of the projected image. Banding occurs when a portion of the picture that is normally masked appears on the screen. This occasionally happens during shipping or handling. This model allows adjustments for banding on any side of the image. Banding examples are circled in the images below. NOTE If this adjustment does not resolve the issue, the issue may lie with the light tunnel.
4 To adjust banding on the top or bottom of the image, use a T6 driver to turn the adjustment screw in the hole shown below. Turn clockwise or counterclockwise until the top and bottom of the image are even. 5 To adjust banding on the right or left side of the image, use the T6 driver to turn the adjustment screw in the hole shown below. Note that you must insert the driver at an angle to engage the screw head. Turn clockwise or counterclockwise until the top and bottom of the image are even.
Check the Thermal Switch The thermal switch is designed to open when the temperature inside the projector gets too high. When the switch opens, the power supply shuts down, turning the projector off. When the projector shuts down after operating for a few minutes or when the lamp fails to strike after repeated attempts at startup, check the thermal switch. 1 Power up the projector. 2 Let the projector run until it shuts down. 3 Remove the top enclosure (page 31).
Check fan operation Exhaust fans The two exhaust fans are not three wire fans. Thus, if either or both stops working, the four-flash red LED error code will not appear. It is more likely that the projector will overheat or will be noisier. The noise level would rise when one exhaust fan stopped working and the other ran at high speed to compensate. The projector may not shut down and the fan error may not appear if the single exhaust fan can keep the temperature below the critical level.
Checking fan voltages Checking fan voltages allows you to determine whether the fan or the ECA to which it connects is faulty. 1 Remove the top enclosure (page 31). 2 Plug the projector into a power source. 3 Measure the voltage at pin one at both fans and the blower at both power down and power up states. The voltage for both exhaust fans and the lamp blower should be ~5VDC when the lamp is off, and ~11VDC when the lamp is on. Additionally, pin two on the lamp blower should read 1.
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.
Exploded View Nacho Family Service Manual 23
Lamp and Lamp Door The lamp door fits over the lamp cavity on the bottom of the projector. It includes a tab that closes the interlock switch when the door is shut. The projection lamp consists of a metal housing, an enclosed reflector assembly and an arc tube. CAUTION The lamp module gets very hot during operation. Allow the lamp to cool for 60 minutes before handling it. 1 Use your fingers or a small bladed screwdriver to release the locking tabs on the lamp door. Then remove the door.
2 Release the locking tab on the top of the lamp power connector, then unplug the cable from its connector in the lamp cavity. 3 Loosen the captive screw on the lamp module. 4 Release the handle from its catch, then lift the lamp out of the projector. Assembly Note ♦ The projector will not power up if the lamp and lamp door are not installed.
Focus ring The focus ring snaps onto projection lens barrel. The focus ring includes a trim ring that snaps onto the front of the focus ring. You need to remove the focus ring only when it needs to be replaced or when you replace the optical engine with a new one. Focus ring Focus ring trim 1 Grasp the ring and pull it firmly away from the projector. 2 If necessary, remove the trim ring from the focus ring. To do this, carefully pry the two pieces apart.
Assembly Notes ♦ If you removed the trim from the focus ring, make sure to align the parts correctly before snapping them together. The two parts fit together only one way. ♦ Align the three pins on the lens barrel with the three slots on the inside of the focus ring, then press the focus ring into place. Make sure it turns evenly and smoothly after installation.
Front bezel The front bezel snaps onto the front of the projector. It includes the brand name. The front IR window snaps to the front bezel. 1 Carefully place the projector on its end so that the projection lens faces upward. 2 Use a T10 Torx driver to remove the silver M3x25 Plastite screw from the recess in the front corner opposite the projection lens. NOTE You may need to work the screw out of the hole by using a magnetized driver.
4 If you are replacing the front bezel with a new one, remove the front IR window and install it on the new one. Assembly Notes ♦ If you are installing a new front bezel, make sure to install the front IR window first. ♦ To install the front bezel, fully insert the two tabs on the end of the bezel nearest the projection lens into the two matching holes in projector case. Make sure the bezel fits flush with the projector case.
♦ To install the other end of the bezel, slightly flex the bezel so that you can insert the two tabs into the matching holes in the projector case. ♦ Install the M3x25 screw in the bottom case. Torque it 4 in-lb (.42 Nm).
Top Enclosure The top enclosure covers the top half of the projector. Once you remove the top enclosure, you have access to a number of parts inside the projector. The top enclosure includes the keypad, the LCD/keypad ECA, the speaker and the elevator button. These parts are not available separately. When you replace the top enclosure, adhere a new brand label to the top. 1 Remove the front bezel (page 28). 2 Carefully place the projector on its end so that the projection lens faces upward.
5 Lift the front of the top enclosure so that you can unplug the keypad cable from its ZIF connector on the controller ECA.
Assembly notes ♦ Connect the keypad cable to the controller first. ♦ Insert the five alignment tabs on the rear of the top enclosure into the matching holes in the bottom enclosure. Then swing the top closed ♦ Make sure the front of the top enclosure mates properly with the bottom. The two parts should fit flush.
Exhaust and Intake Bezels The intake bezel fits on the projection lens side of the projector. The exhaust bezel fits on the opposite side, adjacent to the exhaust fan assembly. An identical, clear IR window fits into each bezel. All three parts are replaceable. Intake bezel Exhaust bezel IR window The bezels are not fastened to the bottom case. They secured in place when the top and bottom enclosures are fastened together. 1 Remove the top enclosure (page 31).
Assembly Notes ♦ When you replace the exhaust bezel, note how the front and rear of the bezel interlock with the bottom case.
♦ The rear of the intake bezel also features a tab that fits over a boss in the bottom enclosure.
Exhaust Fan Assembly The exhaust fan assembly is comprised of 60mm and 80mm exhaust fans, the front and side IR assembly, the safety cable, and a bracket. The assembly is located on the side of the projector adjacent to the lamp. The parts are not available separately. 3 Remove the following parts: Front bezel (page 28) Top enclosure (page 31) Exhaust bezel (page 34) 4 Unplug the exhaust fan cables and the IR cable from their connectors on the controller ECA.
5 Unplug the safety cable from its connector on the power supply. You access the connector through a hole in the chassis. Remove the cable from the cable guide in the metal chassis. 6 Lift the exhaust fan assembly out of the projector. There are no fasteners to remove.
Assembly Notes ♦ When you install the exhaust fan assembly, make sure the front and rear of the fan bracket fits properly in the bottom enclosure. ♦ Plug the safety cable connector in first. Use a needle nosed pliers or screwdriver to ensure that the connector fully engages. ♦ Make sure the cables route through the guide on the metal chassis.
Color Wheel Assembly The color wheel assembly includes the color wheel, the color wheel ECA and the color wheel bracket. You can remove and replace the assembly without removing the controller or the engine.
2 Unplug the color wheel ribbon cable, the front blower cable from the controller ECA. Unplug the color wheel ECA cable from the color wheel ECA. Move the lamp blower and color wheel ECA cables out of the way. 3 Remove the M3x8 screw that fastens the cable clip and color wheel bracket to the engine casting. Note that the clip keeps the color wheel ribbon cable in place. When you remove the screw, the color wheel assembly will be loose.
4 Lift the color wheel assembly out of the projector. Take care not to scratch the glass wheel as you lift. Assembly Notes ♦ When you install the color wheel assembly, make sure the alignment pin on the engine fits into the matching hole in the color wheel bracket.
♦ Start the M3x8 screw and cable clip, then insert the ribbon cable before tightening the screw. Torque the screw to 6 in-lbs (.67 Nm). ♦ Plug the three cables in once the color wheel assembly is secure.
Controller ECA and I/O ECA The controller ECA and the I/O ECA are fastened to the top of the metal chassis. The two boards are connected to each other with the I/O-controller cable. The controller ECA connects to the power supply via a direct connection on the bottom of the board. Each board has its own I/O EMI shield. All five parts are replaceable. Controller ECA I/O ECA I/O-controller ECA I/O EMI shields WARNING Be sure to take proper ESD precautions while working near the driver ECA.
Controller ECA 1 Unplug the color wheel cable, the color wheel sync cable and the lamp blower cable from their connectors on the controller ECA. 2 Unplug the I/O-controller cable from its ZIF connector on the controller ECA. 3 Use a T10 driver to remove the four M3x8 machine screws that secure the controller ECA to the chassis. The screw locations are noted in the illustration in step 1.
4 Lift the controller by the two corners shown below. As you remove the controller, the controller/power supply connector and the controller/DMD connector disengage. 5 If you are replacing the controller or the controller EMI shield, separate the shield and the controller. The shield fastens to the controller with four jack screws.
Assembly Notes ♦ Note the location of the power supply and DMD connectors before installing the controller ECA. Firmly press the controller into place. Make sure the pins on the controller match the receptacle on the power supply. ♦ Torque the M3x8 screws to 6 in-lbs (.67 Nm).
I/O ECA 1 Unplug the I/O-controller cable from its ZIF connector on the I/O ECA. See step 2 above for details. 2 Unplug the two exhaust fan cables and the IR cable from the I/O ECA. 3 Use a T10 driver to remove the two M3x8 machine screws that fasten the board to the chassis. 4 If you are replacing the I/O ECA or the I/O EMI shield, separate the two parts. The shield fastens to the board with two jack screws.
Power Supply and Chassis The power supply fastens to the metal chassis. The plastic power supply insulator fits between the chassis and power supply. The three parts are available separately. Power supply ECA Chassis Power supply insulator Remove the power supply assembly 1 Remove the following items: Focus ring (page 26) Front bezel (page 28) Top enclosure (page 31) Controller and I/O ECAs (page 44) 2 Lift the exhaust fan assembly out of the bottom case.
4 Lift the chassis and power supply out of the bottom. 5 If you need to replace any of the assembly components, go the next step. Otherwise, place the assembly aside and continue to the next procedure. 6 Remove the lamp power cable connector from its mount in the chassis. To do this, pinch the locking tabs on the connector with one hand, then withdraw the connector with the other.
8 To separate the power supply and chassis, pinch the locking tabs on the plastic standoff located in middle of the AC plug side of the ECA. Then lift the power supply off of the chassis. 9 If you need to replace either the chassis or the power supply insulator, remove the plastic standoff from the chassis. Assembly notes ♦ Make sure to fasten the power supply ground cable to the chassis. ♦ Torque all screws to 6 in-lbs (.67 Nm).
Optical Engine The optical engine includes all components in the light path except the lamp. Once you remove the engine, you can remove the zoom ring and the lamp blower. These two parts and the color wheel sync cable that fastens to the color wheel ECA are available separately.
2 Remove the three M3x10 Plastite screws that fasten the engine to the bottom case. 3 Lift the engine out of the enclosure. 4 If you removed the engine to access another part, put the engine aside and continue to that procedure. Otherwise, continue to the next step. 5 To remove the zoom ring, use a small Phillips screwdriver to remove the two M1.7x5 Phillips screws that fasten the zoom ring to the projection lens.
6 To remove the lamp blower, remove the two M3x30 Phillips screws with washers that fasten the blower to the engine assembly. 7 If you are replacing the engine, unplug the color wheel sync cable from its connector on the color wheel ECA. Assembly Notes ♦ Torque the M1.7x5 screws that fasten the zoom ring to the lens to 2 in-lb (.2 Nm). ♦ Torque the two M3x30 screws that fasten the lamp blower to the engine to 6 in-lb (.67 Nm).
Bottom Enclosure The bottom enclosure encloses the bottom half of the projector. The bottom case includes the elevator assembly, the leveling foot When you replace a bottom enclosure, adhere a new certification label and a new bottom model label to it.
2 Remove the curved metal air deflector from the old bottom enclosure and install it on the new one. The air deflector is located adjacent to the lamp blower and elevator. Tighten the M3x8 Plastite screw to 4 in-lb (.42 Nm) with a T10 driver. 3 Remove the Serial Number label from the old bottom enclosure. You may need to use a heat gun to soften the glue. 4 Adhere a new certification label and model label to the new bottom case.
5 Adhere the old Serial Number label to the new certification label. 6 Install the parts you removed in the reverse order.
Light Tunnel The light tunnel is comprised of four pieces of mirrored glass that are glued together to form a box with two open ends. The light tunnel focuses the light between the color wheel and the DMD. An issue with the light tunnel is indicated when image banding appears on the right and/or left sides of the image. Usually, this means that the glue that adheres the sides of the light tunnel has deteriorated and the sides have slipped out of alignment.
1 Remove the following parts: Front bezel (page 28) Top enclosure (page 31) Controller ECA (page 44) Color Wheel Assembly (page 40) 2 Use a T6 driver to remove the two M2x3 screws that fasten the tunnel clip to the engine. Then lift the clip out of the projector with a tweezers.
3 Lift the light tunnel out of the projector. 4 To install the light tunnel, place it on the engine casting so that the end farthest from the color wheel meets the lip on the edge of the engine casting. Note that the wide sides of the light tunnel are on the top and bottom.
Nacho Family Service Manual 61
5 Slide the clip over the light tunnel so that two of the tabs press against the top of the tunnel and two press against the side. The two alignment pins in the engine fit into two matching holes on the clip. Once you get the clip in place, you must hold it down with your finger until you get the screws threaded. 6 After you reassemble the projector, confirm that the sides of the image do not show banding. If you need to adjust the edges of the image, see the Nacho Family Service Manual.
Parts Lists Illustrated Replaceable Parts List Below is a list of replaceable parts (FRUs). 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 the projector you are working on.
Part Illustration Part name in service guide Part name in parts pricing list Part number I/O EMI shield Shield ,I/O, LP600 330-1106-xx Side IR window Window, IR, side, LP600 340-1318-xx Front IR window Window, IR, front, LP600 340-1320-xx Exhaust fan assembly S/A, fan bracket 505-1856-xx Fastener kit Nacho fastener kit 505-1860-xx Bottom enclosure S/A bottom, LP600 505-1862-xx S/A bezel vent, exhaust 505-1864-xx (Includes 60mm fan, 70mm fan, fan bracket, front and side IR assembly, s
Part Illustration Nacho Family Service Manual Part name in service guide Part name in parts pricing list Part number Intake bezel S/A bezel vent, intake 505-1865-xx Front bezel S/A bezel trim 505-1866-xx Power supply Power Supply Assy Nacho 510-1842-xx Controller ECA ECA, Cntrllr, Nacho 510-2083-xx I/O ECA ECA, Nacho I/O 510-1850-xx Color wheel assembly SA, colorwheel, Nacho, Service 525-0139-xx Optical engine Assy, engine, LP600 530-0179-xx 65
Part Illustration Part name in service guide Top enclosure Part name in parts pricing list Part number S/A, Enclosure, Top 505-1852-xx Zoom ring S/A ring, zoom 505-1863-xx Lamp blower S/A, blower, lamp, with wire 526-0197-xx (Includes keypad, keypad/LCD ECA, speaker, heat shield, LCD EMI shield, elevator button and spring, rear IR window) Nacho Family Service Manual 66
Illustrated User Replaceable Parts List Below is a list of replaceable parts (URPs). 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 the projector you are working on.
Labels Below is a list of labels available for this projector, as well as illustrations showing the label locations.
