Optoma HD25 Service Manual
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Optoma HD25 Service Manual

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SERVICE MANUAL

HD25/HD25LV
Date
Revise Version
Description
2012.12.17
V1.0
Initial Issue
TSE: Mina
Check: Amy
Approved: Alick

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Summary of Contents for Optoma HD25

  • Page 1: Service Manual

    SERVICE MANUAL HD25/HD25LV Date Revise Version Description 2012.12.17 V1.0 Initial Issue TSE: Mina Check: Amy Approved: Alick...
  • Page 2 Preface This manual is applied to HD25/HD25LV projection system. The manual gives you a brief description of basic technical information to help in service and maintain the product. Your customers will appreciate the quick response time when you immediately identify problems that occur with our products. We expect your customers will appreciate the service that you offer them.
  • Page 3 HD25/HD25LV� ����ar����� L���� ����ar����� L���� Parts HD25 HD25LV MAIN BOARD 80.8RV01G002 80.8RU01G002 70.8EG32GR01 70.8RU25GR01 COLOR WHEEL 70.8RV10GR01 70.8RU24GR01 HD25/HD25LV Confidential...

  • Page 4: Table Of Contents

    �ha���er 3 Tr�uble�h�������g LED Lighting Message Main Procedure Pin Assignment �ha���er 4 Fu��c������ Te��� & Al�g���e���� Pr�cedure Test Equipment Needed Test Condition VGA Port Test Audio port Test Video port Test Component port Test HDMI Port Test 3D Test HD25/HD25LV Confidential...
  • Page 5 Run In Test Test Inspection procedure Auto Waveform and Factory Fan RPM 4-10 �ha���er 5 F�r�ware U�grade Section 1: System Firmware Upgrade Section 2: 8051 Firmware Upgrade Procedure A��e��d�x A Exploded Image A��e��d�x B Serial Number System Definition PCBA Code Definition II HD25/HD25LV Confidential...

  • Page 6: Highlight

    5000 Hours Typical @190W,50% Survival Rate Lamp ● 240W Philp E20.9 ● 0.65” S600, Dark Chip 3 DMD Chip&Number of active dots ● Number of active dots:1920x1080 For HD25 ● 6S (R63G61B56R63G61B56)&7200rpm Color wheel For HD25LV ● 6S (R81Y41G84C31W52B71)&7200rpm System controller ● TI DDP4422 ●...

  • Page 7: Compatible Mode

    640 x 480 ○ 640 x 480 ○ 640 x 480 ○ 800 x 600 56.3 ○ 800 x 600 60.3 ○ ○ SVGA 800 x 600 ○ ○ 800 x 600 ○ ○ 800 x 600 ○ ○ HD25/HD25LV Confidential...
  • Page 8 ○ SDTV 720 x 576i ○ SDTV 720 x 576p ○ SDTV 720 x 480i ○ SDTV 720 x 480p ○ Note: If the Computer Compatibility supportive signal is different from User’s Manual, please refer to User’s Manual. HD25/HD25LV Confidential...

  • Page 9: Equipment Needed & Product Overview

    * Before you start: This process is protective level II. Operators should wear electrostatic chains. * Note: - If you need to replace the main board, you have to record the lamp usage hour. - Some related contents please refer to common SM chapter 2. HD25/HD25LV Confidential...

  • Page 10: Disassemble Top Cover Module

    3. Remove the Top Cover Module. 2-1-2 Disassemble Main Board 1. Unplug 1 connector (as green square) to remove the FPC cable. 2. Unplug 8 connectors (as yellow square). 3. Unscrew 6 screws (as red circle) from the Main Board Module. FPC cable HD25/HD25LV Confidential...

  • Page 11: Main Board

    5. Unscrew 8 hex screws (as green circle) from the IO Cover. 6. Unplug 1 connector (as orange square). 7. Disassemble the Main Board Note: - Make sure cables plug into the correct ports when assembling the unit. Main Board HD25/HD25LV Confidential...
  • Page 12 System Fan Wire (3 pin) Compose of Red/Black/White Photo Sensor Wire and White wire tube (3 pin) Compose of Red/White/Black Blower Wire and White wire tube (3 pin) Compose of Black/Yellow/Red Wire and Gray wire tube (3 pin) HD25/HD25LV Confidential...
  • Page 13 Note:Please assemble the main board follow the steps as figure. 10  HD25/HD25LV Confidential...

  • Page 14: Disassemble Lens

    2. Unscrew 3 screws (as yellow circles) to disassemble lens . Note:1.Before assemble the new engine,please clean the dusty from engine base by air gun firstly . 2.Locking 3 screws into the lens after assemble the new engine.(as refer to step1) Lens Engine Base HD25/HD25LV Confidential...

  • Page 15: Rod Adjustment

    - It should not have any abnormal color at the rim of the image by estimating through the eyes. Note: - To avoid over adjusting the rod. - After the operation, please use the glue to fix the screws. HD25/HD25LV Confidential...

  • Page 16: Re-Write Lamp Hours

    4. Re-write Lamp Hours(ECO) -Select Lamp Hours(ECO) and use “left” or “right” buttons to re-write the lamp hours(ECO). 5. Choose “Exit”, press “Enter” to exit Note: left key = decrease lamp hour right key =increase lamp hour HD25/HD25LV Confidential...

  • Page 17: Repair Action

    Wheel Firmware Update Chapter 5 Chapter Color Wheel Index 4-3-1.7 Chapter OSD Reset -5.2 EDID Chapter 6 Re-write Lamp Chapter Hours Usage chapter Video port test -- Auto Waveform and Chapter Factory Fan Optical Chapter Performance 4-3-8 Measure HD25/HD25LV Confidential...

  • Page 18: Led Lighting Message

    (Green) (Red) (Red) Standby State (input power cord) Power on (Warming) Flashing Power on and Lamp lighting Power off (Cooling) Flashing Error (Lamp failed) Error Flashing Flashing (Fan failed) Error Flashing (Over Temp.) Note: Steady light No light Confidential HD25/HD25LV...

  • Page 19: Main Procedure

    - Ensure the CD in DVD is 3D format 3D Image - Ensure your standing distance is less than 6m from screen. Abnormal - Ensure the 3D function is on and execute “3D sync invert” in OSD menu. - Check main board Confidential HD25/HD25LV...

  • Page 20: Pin Assignment

    IR-P2 5.05 J11:Lamp driver J5:Photo sensor Description Voltage(V) LAMPLIT_IN 4.38 Description Voltage(V) J5- 1.14 PHOTO-IN 0.52 LAMPEN_OUT D-MODE6 PIN 3 PIN 1 PIN 3 PIN 1 PIN 3 PIN 1 PIN 1 PIN 3 PIN 1 PIN 5 HD25/HD25LV Confidential...

  • Page 21: Test Equipment Needed

    Circumstance brightness: Dark room less than 2 lux. - Product must be warmed up for 3 minutes. - Screen size: 60 inches diagonal. Zone Definition < Figure: Zone A, Zone B & Frame (as green line) Definition, Active area=Zone A+ Zone B > Confidential HD25/HD25LV...

  • Page 22: Vga Port Test

    - If there is noise on the screen, use auto or manual “frequency” function or “tracking” function to adjust the screen. - The PC mode functionally sure be workable include support format with frequency and auto detected functional will be workable. Confidential HD25/HD25LV...
  • Page 23 B. - Please refer to Pixel specification table. 5. Dark Blemish Procedure - Test equipment: video generator. - Test signal: analog 1920x1080�60Hz - Test Pattern: blue 60 Inspection item - Dark blemish check Blue 60 Confidential HD25/HD25LV...
  • Page 24 (Blur word on one of the corner after adjust- ment is acceptable. However, the word should at least be recognizable.) 7. Color Performance Procedure - Test equipment: video generator. Full screen - Test signal: 1920x1080�60Hz, 1080i 1920x1080�60Hz, 1080i �60Hz, 1080i - Test Pattern: 64 gray RGBW Confidential HD25/HD25LV...
  • Page 25 - Distances from the screen: 1.8M - Screen Size: 60 inches diagonal a. Measure setting Procedure - Please get into OSD menu, select “Lamp Setting” under “Options”, press “Enter” button, then select “Bright “mode. - Press “Power→ Left→ Left→ Menu” to get into Confidential HD25/HD25LV...
  • Page 26 ☼ Brightness Formula Full white pattern Avg. (P1~P9)*1.1m Criteria • 618 ANSI lumen (HD25) 1287 ANSI lumen (HD25LV) c. Full On/Full Off Contrast Procedure - Full white pattern & Full black pattern - Use CL100 to measure brightness values of full white pattern P5 &...

  • Page 27: Audio Port Test

    4-3-4 Component Port Test Procedure - Test equipment: DVD player - Test signal: Ycbcr/YPbPr Inspection item - HDTV performance test Inspection Distance - 1.4M ~1.6M Criteria - Check any abnormal color, line distortion or any noise on the screen. Confidential HD25/HD25LV...

  • Page 28: Hdmi Port Test

    * Cycle setting is based on the defect symptoms. ie: If it is NFF, the run-in time is 4 hours. You have to set the lamp on for 50 min. and lamp off for 10 min for 4 cycles. Confidential HD25/HD25LV...

  • Page 29: Test Inspection Procedure

    Cosmetic can not be broken Missing logo, missing prints and blurry prints are Logo unacceptable Lamp cover It should be locked in the correct place. Zoom in/out The function should work smoothly Keypad All keypad buttons must operate smoothly Confidential HD25/HD25LV...

  • Page 30: Auto Waveform And Factory Fan Rpm

    2.Wait a moment, please get into service mode then check the “Blower Factory RPM” . Note: - If the Factory FAN RPM Value doesn’t show in service mode, please repeat the step again. - Make sure the “Blower record (rpm) “is 3490- 4730. Confidential HD25/HD25LV 4-10...

  • Page 31: Section 1: System Firmware Upgrade

    Note1: we will show the hot key of fw mode and how to check FW version,the other contents please refer to common manual 5-1 . Note2: During FW upgrade procedure,please select "64KB" in "Skip Boot Loader Area". Note3: Put "11.0.2 FlashDeviceParameters” file into the folder where you setup “DLP Composer Lite 11.0.2" HD25/HD25LV Confidential...

  • Page 32: Get Into Fw Mode

    - Connect the projector with PC by USB cable. 5-1-3 Check FW version 1.Restart the unit and enter the Service Mode(Press Power --> Left -->Left --> Menu). 2.The firmware version will be shown as red circle on the screen. HD25/HD25LV Confidential...
  • Page 33 5-2-1 Equipment Needed Software : - ICP Utility (Setup, ICP Utility, v6.00.exe) - USB-to-Serial COM port Driver (PL2303_Prolific_DriverInstaller_v1417.exe) - Program file (*.TPJ) Hardware : - Projector - Power Cord (42.50115G001) - ICP FIXTUR� (SP.8JC08G001) - PC or Laptop HD25/HD25LV Confidential...

  • Page 34: Setup Procedure

    5-2-2 Setup Procedure Install ICP Utility 1.Double click "Setup,ICP Utility, v6.00.exe". 2.Click "Next". 3. Click "Next". 4. Click "Next". HD25/HD25LV Confidential...
  • Page 35 5. Click "Finish" to end ICP Utility installed. Install PL2303_Prolific_Driver 6. Double Click "PL2303_Prolific_DriverInstall er_v1417.exe" 7. Click "Next". 8. Click "Finish" to end Click "Finish" to end PL2303_Prolific_Driver installed. HD25/HD25LV Confidential...
  • Page 36 4pin cable (as the square shown). 2.Select "Start" -->"Coretronic Tools" -->"Coretronic ICP Utility V6.00" to run "ICP Utility.exe�. 3.Click "Load Proj" to open the �TPJ� file which you will upgrade MCU firmware file,then click " Update Chip" to upgrade the MCU firmware. HD25/HD25LV Confidential...
  • Page 37 5. Finish - When MCU FW upgrade process is finished, "PASS" will be shown. 6. Re-plug in power cord and power on the projector. Get into the service mode to check the MCU firmware version. HD25/HD25LV Confidential...
  • Page 38 5-3-1 Equipment Needed Software : - F�T-Pro430-Lite Setup Procedure (Setup.exe) - Program file (*.d43) Hardware : - Projector - Power Cord (42.50115G001) - MSP430 FIXTUR� (75.8KC16GR01) - PC or Laptop - USB Cable mini USB to USB (A) (42.00284G001) HD25/HD25LV Confidential...
  • Page 39 5-3-2 FET-Pro430-Lite Setup Procedure 1. Choose �Setup.exe� Program. 2. Read �License Agreement�. - Choose I accept and agree to be bound by all the terms and conditions of this License Agreement�. - Click �Next�. 3. Click �Next�. HD25/HD25LV Confidential...
  • Page 40 4. Choose installation options and click �Next�. 5. Click �Next�. 6. Click the browse button to change the downloading location to �program files�. - Select �everyone� - Click �Next�. HD25/HD25LV Confidential 5-10...
  • Page 41 7. Click �Next�. 8. The program is being installed. 9. Click �Next�. HD25/HD25LV Confidential 5-...

  • Page 42: Usb Driver Upgrade Procedure

    - Plug the VGA port of MSP430 fixture into the VGA- out port of projector and connect the PC with MSP430 fixture by mini-usb cable. 2. The window ��ardware Update Wizard� will show automatically. - Select �Install from a list or specific location(Advanced)� - Click� Next� HD25/HD25LV Confidential 5-2...
  • Page 43 - Select� LaunchPad_Driver_slac524� - Click�Ok� - Click�Next� 4. Writing system registry values. 5. Click �Finish�. Click �Finish�. Note: If the PC appear “Found New Hardware Wis zard” picture again, repeat step 2 to install USB Drivier once more. HD25/HD25LV Confidential 5-...
  • Page 44 5-3-4: MSP FW Upgrade Procedure 1. Double click �Lite F�T-Pro430�. 2. Select �Setup->Connection/Device Reset�, click �Connection/Device Reset�. 3. Select options as right photo marks. - Click � Ok� . HD25/HD25LV Confidential 5-14...
  • Page 45 4. Select �MSP430G2xx� . 5.Select �MSP430G2513� 6. Select �Open Cord File� - Choose �MSP430X.d43 �(MSP430 firmware) - Click �Open� . HD25/HD25LV Confidential 5-5...
  • Page 46 7. Select �Setup->Memory Options�, click �Memory Options� 8. Select options as right photo marks. - Click � Ok� . 9. Click �Auto Prog�. - The firmware will start to update . HD25/HD25LV Confidential 5-16...
  • Page 47 10. Get into the service mode to check the MSP430 firmware version. HD25/HD25LV Confidential 5-17...

  • Page 48: Edid Upgrade

    6-1 EDID Upgrade Procedure - The upgrade procedure for VGA and HDMI ports please refer to common service manual chapter 6. - Please use " EDID 0.81.exe" Program and Key in the serial number into the "Unit No" blank space. HD25/HD25LV Confidential...
  • Page 49 Appendix A D.C.HD25/HD25LV HD25/HD25LV Confidential...
  • Page 50 Parts Supply ASSY BOTTOM COVER MODULE HD25LV 8W SPEAKER HOLDER ASSY EX762 ASSY MAIN BOARD MODULE HD25 ASSY TOP COVER AND ZOOM RING MODULE EH1020 FOCUS RING BLACK HD200X (FOR YM40)(LGSM) ASSY LAMP COVER BLACK FOR EX615 (SERVICE) LAMP COVER BLACK EX615(LGSM) LOCK SCREW PAN MECH M3*8.5-3.5 BLACK(1018+HEAT...
  • Page 51 Assy Optical Engine Module HD25/HD25LV Confidential...
  • Page 52 ASSY ROD MODULE HD20 ASSY RELAY MODULE EW762 ASSY COLOR WHEEL MODULE FOR 8RV (SERVICE) ASSY COLOR WHEEL MODULE FOR 8PJ (SERVICE) ASSY COLOR WHEEL MODULE HD25 ASSY ENGINE BOTTOM HD20 Projection Lens TR1.5 - 1.8 (YM40Y) DMD HEATSINK AL6063 H15 S450 0.55”...
  • Page 53 Assy Color Wheel Module Item Description Parts Supply EIS CW 6S Φ42 R59G63B58R59G63B58 URD20VA6 9.4MM PCBA PHOTO SENSOR BOARD FOR EW762 PROJEC- D42 CW HOLDER COVER HD20 HD25/HD25LV Confidential...

  • Page 54: Top Cover Assembly

    Top Cover Assembly Item Description Parts Supply TOP COVER ASSYEMBLY EX762 BLACK(LGSM) KEYPAD PLATE ENTER EX612(LGSM) KEYPAD ASSY EX615 HD25/HD25LV Confidential...
  • Page 55 Keypad Assembly Item Description Parts Supply KEYPAD PLATE ENTER EX612(LGSM) KEYPAD 3M TAPE HD20 PCBA KEYPAD BD FOR SC 1080P FFC KEYPAD TO FORMATTER BD 16P P=0.5 122mm 1209S 成朋 HD25/HD25LV Confidential...
  • Page 56 Assy Bottom Cover Module Item Description Parts Supply 8FC BOTTOM COVER BLACK LN2520 EH1020-(LGSM) ADJUST FOOT P1266 YH-NUT-M2.0*2.0*4.0 8EG BOTTOM SHIELDING T=0.6MM SECURITY BAR EX525ST SECURITY BAR CAP PC MN3600H BLACK EX525ST SCREW PAN TAP M3*5 Ni EMI GASKET W5*H1.0*L155mm PD527 HD25/HD25LV Confidential...
  • Page 57 Assy LVPS Module Item Description Parts Supply POWER SUPPLY,AD-320W,INLET,200*50,DL,T-SW 230W LVPS MYLAR PC T=0.43 HD20 HD25/HD25LV Confidential...
  • Page 58 Assy Lamp Driver Holder Module item Description Parts Supply SCREW PAN MECH M3*5 Ni W.A. 2P #22 FEMALE 6KV 150C 95mm FOR LAMP DRIVER PDG-DSU30 SCREW CAP MECH M2*4 Ni LAMP DRIVER HOLDER PPS+40%GF HD20 LAMP DRIVER LAMP DRIVER PHILIPS EUC 240d HD25/HD25LV Confidential...
  • Page 59 Assy Main Board Module Item Description Parts Supply PCBA MAIN BOARD FOR HD25 PROJECTOR MAIN BOARD SHIELDING HD25LV ASSY IO COVER MODULE FOR 8PJ(SERVICE) IO COVER BLACK HD25LV SCREW PAN TAP M3*6 Ni SCREW HEX I/O #4-40 H4*L8 NI NYLOK...
  • Page 60 Assy 4520 Blower Module Item Description Parts Supply SUNON 45x20 BLOWER, F TYPE , wire length 150mm , heat-shrink length 1 BLOWER AIR TIGHT F12 H5350 BLOWER 4520 RUBBER EP7190 HD25/HD25LV Confidential...
  • Page 61 Assy 8525 Fan Shoelding Module HD25/HD25LV Confidential...
  • Page 62 LAMP BLOWER DUCT HD20 PAN SCREW M3*8 FOR YM-64 FRONT CELL & SP SCREW PAN MECH M3*6 NI THERMAL SWITCH WITH BRACKET (KLIXON YS11) HD20 100C SCREW PAN MECH M3*4 Ni TAPE 3M J350 17*60mm EMI GASKET 4*3&51mm S15E HD25/HD25LV Confidential...
  • Page 63 Assy Packing Drawing HD25/HD25LV Confidential...
  • Page 64 Item Description Parts Supply CARTON OUTSIDE BOX AB FLUTE HD25 CABLE VGA 15P 1.8M BLK EP739 PARTITION PAPER LEFT HD20 LENS CAP ASSEMBLY HD20 BLACK D.C. HD20 SPEC LABEL BLANK PD120 PE BAG HD20 AIR BAG BOTTOM HD20 AIR BAG TOP HD20 CABLE POWER CORD 1830mm SP30+IS14;BC-PU-...
  • Page 65 I. Serial Number System Definition Serial Number Format for Projector AAAAA 0001 Q = Optoma 8RV = Project code 2 = Last number of the year (ex:2012 = 2) 22 = week of the year ( ex:the twenty-second week of the year = 22)
  • Page 66 PCBA Code Definition PCBA Code for Projector XXXXXXXXXX EEEE Vendor Code Revision Date Code HD25/HD25LV Confidential...

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