DLP

TRAINING
2003
Samsung Product Support Department
Background
Samsung introduced their new DLP technology projection
televisions in 2002. DLP stands for
Digital Light Processor.
The current models (as of 04/30/03) are the:
HLM 437, HLM 4365 , HLM 507, HLM 5065, HLM617,
HLN 437, HLN 4365, HLN 507, HLN 5065, and HLN 617

DLP is quite different than conventional projection

television, which uses three separate color CRT’s. These
separate video signals are projected and combined on the
screen. DLP, on the other hand, has no CRT’s. Instead, one
high intensity lamp is used to project one image on the
screen.
PAGE 2
DLP technology was first developed by Texas Instruments.
The heart of this technology is the DMD, or
Digital Micromirror Device.
It has 922,000 tiny mirrors on one ¾ inch panel.

Each mirror represents one pixel on the screen. The maximum

resolution is 1280 x 720. Control signals are sent to each
mirror, causing them to rotate plus or minus 12 degrees.
This is how the luminance is controlled.
PAGE 3
The Chrominance is controlled by a Color Wheel.
It has six separate segments, all different colors.

This wheel spins at 9,000 RPM. Timing controls synchronize

the color wheel position and the DMD signals, resulting in the
final video signal projected to the screen.

PAGE 4
Light Engine Breakdown

PAGE 5
Initialization Process
1. Standby LED on Digital Board ON (5V)
2. Power on signal from keypad/remote to Digital PCB.
3. Power ON signal generated by Digital PCB> Analog PCB> PSU
4. All other voltages turn on.
5. Digital PCB tells fans to turn on.
6. Digital PCB tells DMD PCB to turn color wheel on.
7. DMD / digital PCB’S check feedback signals from
fans/ color wheel.

8. If OK, Digital PCB Tells ballast to turn lamp on. LAMP ON.

9. Digital PCB then checks “lamplitz signal” from ballast

for status OK.

PAGE 6
 Board Descriptions
Power Supply Board

Supplies DC Voltages:

CN 803
Ballast Drive
(380 VDC , Always ON)

PAGE 7
 Digital Board
Microprocessor (Generates Turn on Signal to power board)
Monitor LED’s
Fan Control
All Digital Video Processing
Sensor / Switch Controls
OSD / Menu

PAGE 8
Digital Board Layout

PAGE 9
Digital Board Characteristics

PAGE 10
 Analog PCB
Transfers Power from Power Board to Digital Board
Transfers Turn-On Command from Digital Board to Power
Board.
Encompasses the majority of the Audio Circuit
Analog Video Switching / Processing

PAGE 11
Analog PCB Layout

PAGE 12
Analog PCB Characteristics

PAGE 13
 DMD Board
Controls Lamp Turn-On
Powers Color Wheel Motor (IC104)
Drives DMD Panel (IC117)
Sensor Controls DMD PANEL

Attaches to Light Engine

With cover removed.

PAGE 14
 DMD Board Layout

CN 106

SEE BELOW

NOTES SCI : LAMP ON = SVDC , LAMP OFF = 0 V

LAMPLITZ : LAMP ON = 4VPP , LAMP OFF = 0 V

PAGE 15
 Light Engine Assy’

projection lens color wheel lamp

remote sensor
illumination lenses
DMD board
fan
filtering lenses
fan ballast
temp. sensor (80 degrees C)
PAGE 16
 Front LED’s
Front LED’s
TIMER

LAMP
Normal Operation Indications for Front LED’s
TEMP.

(Stand-By Mode) Red LED = Not Lit

(Power On Mode) Lamp LED = On
HLM 4365W / 5065W

Will Flicker before turn on

TIMER
LAMP
TEMP.

ALL Other Models

PAGE 17
LED Status Chart

Lamp LED will blink for 25 seconds after powered on, before
picture appears.

PAGE 18
 Troubleshooting
DEAD SET

Is 5V standby LED
lit on digital board? Check Replace digital
No power to OK
board (see pg. 29)
analog
Yes board
CN111 (see
Make sure CN 304 pg. 13)
on digital board is
connected
(see pg. 9)
NG Reconnect CN 304
OK

Replace keypad or
digital board (see
pg. 29)

PAGE 19
 Blinking Temp LED

Check Temp Sensor NG

connector CN306 on Re-insert connector
Digital Board

OK

Install jumper across No

Temp Sensor
Terminals. Does it Replace digital PCB (See pg. 29)
work?

Yes

Replace temp sensor.

(see pg. 16)

PAGE 20
 Blinking Temp and Timer LED

Are fans running? Replace Digital board

Yes
No

Check for 7VDC fan OK

voltage(s) at CN315,317,320 Replace fan(s)

on digital board (see pg. 10)

NG
OK
Check CN 801 pin 15 for Replace Power
Check CN 801 pin 12 on power
board for 7 VDC (see pg 7) 5V dc turn on voltage board (see pg. 34)
NG
OK NG

Replace Analog board Replace Digital

(see pg. 28) board (see pg. 29)

PAGE 21
 Blinking Temp, Timer & Lamp LED’s

Check or replace Lamp

OK

Reconnect CN 108 (DMD board)

cable to Digital board.(see pg.15)

OK

Check power to DMD board CN 106

(see pg. 15)

OK NG

Replace DMD board. Replace Power board

(see pg. 33) (see pg. 34)

PAGE 22
 Blinking Lamp , Temp. LED’s

Is lamp cover installed? Install lamp cover

No
Yes

Make sure lamp cover

switch is activating

OK
NG

Short CN 310 on Check boss on lamp cover

digital board pins
( see pg. 9)

NG Replace digital
board (see pg.29)

PAGE 23
 Blinking Lamp LED
A blinking lamp LED is the most common failure indication. It can be caused by no lamp, no color
wheel, no fan(s), or other defective components. (refer to initialization process on pg. 6).

Do fan (s) run?

NO YES

Refer to pg. 21 Does color wheel run?

NO YES

Check Color wheel Is lamp on?

drive signal on DMD PCB,
YES NO
CN 110 pin 4 (see pg. 15)
Replace DMD PCB
NO YES See next page
(see pg. 33)
Replace DMD PCB Replace color wheel assy’
(see pg. 33) (see pg 32)
PAGE 24
 Blinking Lamp LED (cont.)

Check 380V dc to lamp ballast (CN 1) Does lamp come

Measure with DC meter on, then shut off?
NO
NG YES

Re-install lamp assy’ Check 4 V pp at

Replace Power Board CN 107 pin 3 on
(see pg. 27)
(see pg. 34) DMD PCB
NG (see pg. 15)
Check pin 1 on CN 107
NG
on DMD PCB for 5V dc
OK
(see pg. 15)

OK
NG Replace ballast
Replace lamp assy’ or ballast Replace DMD PCB or lamp
(see pg. 27,31) (see pg. 33) (see pg. 27,31)

PAGE 25
 Disassembly / Unit Replacement

Rear Cover Removal

1. Remove (14) screws as shown.
2. Remove cover.

PAGE 26
Lamp Replacement
1. Remove lamp cover screw.
2. Remove side cover.
3. Remove two screws holding lamp
assy’
4. Pull lamp assy’ out using handle.
5. Replace lamp. Re – install (2)
screws.
6. Replace side cover.
7. Tighten side cover screw.
8. Go into service mode adjustments
(see pg. 35)
9. Highlight “options” Note: There are two different
types of lamps. Make sure you
10. Select “lamp clear”
order for correct model (see pg. 54)
11. Press volume plus to reset lamp
counter.
PAGE 27
Analog Board

1. Remove rear cover

(see pg. 26)
2. Remove (7) screws holding
plastic terminal panel as
shown.
3. Remove all connectors from
analog board.
4. Slide board out through rear.

PAGE 28
Digital Board Removal
1. Before replacement, go into
service mode and retrieve the
DELAY setting(see pg.36).
2. Remove rear cover (see pg. 26)
3. Remove plastic terminal panel
from analog PCB. (see pg. 28)
4. Disconnect all connectors from
PCB.
5. Remove (8) screws holding
PCB and bracket as shown.
6. Remove PCB and bracket.
7. After replacement, re-input delay setting, check lamp type, fan number,
and perform USERRESET in service mode. (see pgs. 36,43)
PAGE 29
Light Engine

1. Remove digital PCB (see pg.29)

2. Remove (1) screw as shown
3. Pull light engine assy’ out two
inches, and remove all connectors
to DMD PCB, and ballast.
4. Slide light engine assy’ out
completely.

PAGE 30
Ballast
1. Remove light engine assy’ (see pg. 30)
2. Remove all connectors to ballast.
3. Remove (4) screws attaching ballast
to light engine
4. Remove ballast PCB.

Note: There are two different types of ballast PCB’s.

The 61 inch models (617) use a ballast with GREEN PCB.
All other models use ballast with TAN PCB.
Part numbers are in service bulletin DLP03-006.

PAGE 31
Color Wheel
1. Remove light engine assy” (see pg. 30)
2. Remove (3) screw holding color wheel cover.
3. Remove cover.
4. Remove (2) connectors from
DMD PCB to color wheel.
5. Remove (3) screws holding color
wheel ass’y.
6. Remove color wheel assy’.

7. Before re-assembly, blow out any dust

from the light tunnel area with compressed air,
and apply electrical tape over ends of cover. PAGE 32
DMD Board
1. Remove light engine. (see pg. 30)
2. Remove all connectors from DMD
PCB.
3. Remove fan assy’.
4. Remove (6) screws holding DMD
PCB as shown.
5. Perform Tilt adjustment
after replacement of
DMD PCB (see pg. 46)

PAGE 33
Power Board
1. Remove Analog PCB (see pg. 28)
2. Slide Power board out slightly.
3. Remove all connectors on power
PCB.
4. Slide out power PCB completely.

PAGE 34
 Adjustment:
Electronic adjustment in EPROM Adjustment:

PAGE 35
Adjustment locations:
1. DDP1010

PAGE 36
 2. DNIe

fixed

fixed

PAGE 37
3. AD9883(Component/480P)

PAGE 38
4. VCP3230 (RF/S-video)

1. DDP1010

PAGE 39
4. VCP3230; (RF/S-video) continued

4. VPC3230 (480I)

PAGE 40
5.JAGADC (PC)

PAGE 41
6.FLI2300 (RF/S-video/480I)

PAGE 42
7. 3D_COMB: (all)

8. OPTION (all)

2550

PAGE 43
 Adjustment Notes:

1. Item # 2 (DNIe) is MN82860 on some early versions of HLM models.

2. Item # 6 (FLI2300) is FLI2200 on some early versions of HLM models.
3. Item # 7 (3D comb) is not on some early models.
4. EER RESET should only be performed after a software upgrade.
5. DVCO is for engineering use only.
6. WB DEFSET should always be set to OFF.

PAGE 44
 Mechanical Adjustment
Focus adjustment:

Remove pin carefully

PAGE 45
Tilt adjustment:

PAGE 46
 SERVICE BULLETIN
Bulletin #: DLP03-002
Subject: No power, or intermittent power. Shutdown.
Background: Set will have no power intermittently, sometimes works
“OK” for a few days. Shutdown intermittently.
Solution: There are few different problems that cause no power or
shutdown. They all listed in order to be checked.
1) Re-solder all
connections on Power
PCB.
2) Replace resistors on
Power PCB. “see figure”
Location Part #

RS801 2003-002194

RSF801 2008-001050

PAGE 47
 SERVICE BULLETIN
Bulletin #: DLP03-002
(Continued)

3) Replace Power PCB. See parts list for part #

4) Reseat Lamp

5) Check interlock switch on back of set.

PAGE 48
 SERVICE BULLETIN
Bulletin #: DLP03-003
Subject: Picture has 2” to 4” circler blemishes
on screen. These blemishes are most
noticeable in dark scenes and can be of any
color.
Background: Optical engine has projection lens assembly in final
stage, the lens in this assembly has become contaminated.

Solution: Replace projection lens

assembly. Part # = BP67-00032A

Note: Refer to Light Engine

Disassembly and Focus Lens
Alignment Procedures.

PAGE 49
 SERVICE BULLETIN
Bulletin #: DLP03-004
Subject: Squealing noise comes from set, near optical engine area.

Background: When set is turned on, optical engine color wheel will
have a squealing noise from the motor bearing.

Solution: Replace color wheel. Part # BP96-00250A

Remove Cover Remove Color Wheel

PAGE 50
 SERVICE BULLETIN
Bulletin #: DLP03-005
Subject: Poor color, overall gray scale is greenish, reddish or bluish.

Background: Set has poor black and white tracking. Black areas of
picture don’t show true black.

Solution: Adjust service mode, Red, Green and Blue gains. Enter
service mode:
Set-Up:
1) Apply gray scale pattern to Video 1 input.

2) Power set on, select and display gray scale pattern. Using
customer menu, select picture mode. P Mode should be
CUSTOM. Contrast 90. Brightness 50. Color Tone NORMAL

PAGE 51
 SERVICE BULLETIN
Bulletin #: DLP03-005
(Continued)
3) Press Mute + 1 + 8 + 2 on 1 DDP 1010 (all)
remote. Power set on, service 2
3
DNIe (all)
AD9883
menu will display. 4 VPC3230
5 JAGADC (PC)
6 FLI2300 “HLM617W” only
7 3D_COMB
8 Option

4) Service mode control keys:

Remote button Action

Main Menu Menu Display (Back)

Channel up / down button Move cursor to item

Volume + / - button Select item.

Increase or decrease item value

PAGE 52
 SERVICE BULLETIN
Bulletin #: DLP03-005
(Continued)
5) Select “DNIe” mode, adjust RGB GAIN &
OFFSET items for best gray scale.

Item Default Range Description

R-GAIN 125 0 ~ 255 Red gain

G-GAIN 125 0 ~ 255 Green gain
B-GAIN 125 0 ~ 255 Blue gain
R-OFFSET 128 0 ~ 255 Red offset
G-OFFSET 128 0 ~ 255 Green offset
B-OFFSET 128 0 ~ 255 Blue offset

Data will be saved automatically when set is powered off.

PAGE 53
 SERVICE BULLETIN
Bulletin #: DLP03-006
Subject: Quick reference parts list.
Background: Most repairs are done using assemblies and board level.
Solution: Use quick reference parts list.
Description HLM437WX HLM4365WX HLM507WX HLM5065WX HLM617WX
Lenticular Screen AA67-00168A AA67-00168A AA67-00169A AA67-00169A BP64-00099A

Fresnel Screen AA67-00171A AA67-00171A AA67-00172A AA67-00172A BP64-00098A

PCB Control AA94-11904A AA94-11912A AA94-11904A AA94-11912A BP94-00311A

Lamp Assy’ BP96-00224A BP96-00224A BP96-00224A BP96-00224A BP96-00224B

Lamp Ballast AA47-00008A AA47-00008A AA47-00008A AA47-00008A BP47-00003A

Side PCB AA94-11917A AA94-11917A AA94-11906A AA94-11917A AA94-11906A

Power PCB BP94-00087A BP94-00087A BP94-00087A BP94-00087A BP94-00089A

Main Analog PCB BP94-00283A BP94-00283A BP94-00283A BP94-00283A BP94-00283A

Main Dig. PCB BP94-00502W BP94-00502W BP94-00502W BP94-00502W BP94-00385A

DMD PCB BP96-00249A BP96-00249A BP96-00249A BP96-00249A BP96-00249A

Engine BP96-00087C BP96-00087C BP96-00087A BP96-00087A BP96-00087B

Color Wheel assy’ BP96-00250A BP96-00250A BP96-00250A BP96-00250A BP96-00250A

Remote Control BP59-00016A BP59-00016A BP59-00016A BP59-00016A BP59-00016A

PAGE 54
Description HLM617WS HLN437WX HLN4365WX HLN507WX HLN5065WX HLN617WX

Lenticular Screen BP64-00099A AA67-00168A AA67-00168A AA67-00169A AA67-00169A BP64-00099A

Fresnel Screen BP64-00098A AA67-00171A AA67-00171A AA67-00172A AA67-00172A BP64-00098A

PCB Control BP94-00139T AA94-11904A AA94-11904A AA94-11904A AA94-11904A BP94-00311A

Lamp Assy’ BP96-00224B BP96-00224A BP96-00224A BP96-00224A BP96-00224A BP96-00224B

Lamp Ballast BP47-00003A AA47-00008A AA47-00008A AA47-00008A AA47-00008A BP47-00003A

Side PCB BP94-00139Y AA94-11917A AA94-11917A AA94-11906A AA94-11906A AA94-11906A

Power PCB BP94-00099A BP94-00087A BP94-00087A BP94-00087A BP94-00087A BP94-00089A

Main Analog PCB BP94-00444B BP94-00283A BP94-00283A BP94-00283A BP94-00283A BP94-00283A

Main Dig. PCB BP94-00139V BP94-00502W BP94-00502W BP94-00502W BP94-00385A BP94-00385A

DMD PCB BP96-00249A BP96-00249A BP96-00249A BP96-00249A BP96-00249A BP96-00249A

Engine BP96-00259A BP96-00087C BP96-00087C BP96-00087A BP96-00087A BP96-00087B

Color Wheel assy’ BP96-00250A BP96-00250A BP96-00250A BP96-00250A BP96-00250A BP96-00250A

Remote Control BP59-00016A BP59-00016A BP59-00016A BP59-00016A BP59-00016A BP59-00016A

PAGE 55
 SERVICE BULLETIN
Bulletin #: DLP03-001

Subject: No sound.

Background: No sound
when using tuner or any
audio input.

Solution: Check plug

connectors on Analog
PCB, reset connector
CN103. “see figure”

PAGE 56
 Tech Tip

Subject: Distortion
on screen as shown

Background: If dust gets on

the light tunnel, it can
cause picture distortions.

Solution: Remove light

engine, and color wheel
cover, and bow out any
dust from the ends of the
light tunnel.

PAGE 57
 Tech Tip 5V STANDBY DIGITAL 5V (SWITCHED) 7V (FAN VOLTAGE ,
SWITCHED)

Subject: LED’S on
Digital board.

Background: These LED’S

can assist when
troubleshooting.

Solution: The LED’S are as

shown.

PAGE 58
 TECH TIPS
PRODUCT: DLP
TIP VERSION: DLP03-001
MODEL: HLM507W

SUBJECT: Video Problem

SYMPTOM: Video appears as below- screen is mostly dark, with compressed video
band at top of screen; white dots on a blackish/gray background.

REPAIR: Replace DMD Module and perform tilt adjustment.

 TECH TIPS
PRODUCT: DLP – SIR-TS160
TIP VERSION: DLP03-002
MODEL: DLP and SIR-TS160

SUBJECT: DLP with White Vertical Line on the Left or Right side

SYMPTOM: White Vertical line on Left or Right side

If a customer has the SIRTS160 and a DLP , and states they are seeing vertical line down left or right side of their TV. When hooked up to DVI or
RGB input only.

S O L U T I O N:
The SIR - TS160 has the ability to shift the screen up to a 1 1/4" to the left or right when connected to DVI or RGB.
DLP TV from Samsung with a vertical line down one side or the screen shifted over, this is USUALLY not a problem with the TV.

To access adjustment menu ,use the SIR-TS160 Remote

Press Menu on Remote
Arrow down to Setup
Highlight installation
Highlight Monitor
You can now adjust by following the instruction at the bottom of the screen
 TECH TIPS
PRODUCT: DLP
TIP VERSION: DLP03-003
MODEL: HLM507W

SUBJECT: No video and the unit is locked.

SYMPTOM: The DLP turns on normally. Within half a minute the unit locks up with the symptom of no video. DLP
must be unplugged to turn it off.

REPAIR: Check the connector CN107 on the DMD Panel. Pin 1 should go high (5V) to turn the Lamp on. Pin 3 is the
feedback from the Ballast PCB. You should see approximately 4Vp-p pulses if the Ballast is working properly.

If these conditions are not met, physically inspect the connector and try reseating it. If the connector is OK, replace
DMD Panel and perform tilt adjustment.

DMD PANEL
 TECH TIPS
PRODUCT: DLP TV
TIP VERSION: DLP03-004
MODEL: HLM507W

SYMPTOM: No picture but, audio is OK.

REPAIR: Check Lamp assembly and Lamp Ballast.

 TECH TIPS
PRODUCT: DLP TV
TIP VERSION: DLP03-005
MODEL: HLM507W

SYMPTOM: Unit is dead.

REPAIR: Check the Lamp.