Optoma H77 Service Manual
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Optoma H77 Service Manual

Optoma H77 Service Manual

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SERVICE MANUAL

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Copyright April, 2004 . All Rights Reserved
Document #81E-G04-01A . P/N: 36.81E03.001
Prepared by SI :
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Prepared by TSE :
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Check by :
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Approved by :
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Summary of Contents for Optoma H77

  • Page 1: Service Manual

    SERVICE MANUAL Model Name : H77 Prepared by SI : ________________________________________ Prepared by TSE : ________________________________________ Check by : ________________________________________ Approved by : ________________________________________ t i n Copyright April, 2004 . All Rights Reserved Document #81E-G04-01A . P/N: 36.81E03.001...
  • Page 2 Preface This manual is applied to H77 0.79” DMD SXGA Home Theater Projector with digital imaging functional- ity based on Digital Micro-mirror Device (DMD) technology. It’s the mode of single Panel, 250 watt Philips UHP lamp and 1280(H) x 720(V) resolution. The manual gives you a brief description of basic technical information to help in service and maintaining the product.

  • Page 3: Table Of Contents

    Table of Contents Chapter 1 Introduction Product Highlights Mechanical Specifications Electrical Specifications Optical Specifications Environmental Specifications Chapter 2 Disassembly Procedure Tools Needed Removing Lamp Module Removing I/O Panel, Top Cover and Keypad Board Removing Thermal Board, Main Board, Connector Board and Power Module Removing Fan Module(92x25mm), Lamp Ballast, Power Board and DMD Board Removing DMD Chip, Front Panel Module...
  • Page 4 Chapter 6 DDC Key-in Procedure Equipment Needed Setup Procedure DDC Key-in Procedure Appendix A Exploded Overview Appendix B Serial Number System Definition 7-19 Reader’s Response 7-20...

  • Page 5: Chapter 1 Introduction

    Chapter 1 Introduction Product Highlights One HD2 2.5G 0.79" DMD projection system with 540 ANSI lumens (Minimim Engineering spec. condition : Spoke on), 80% uniformity minimum (ANSI)( con- dition offset = 0 %) Contrast (Full on/Full off) : 2500 : 1 (Typical), 2200:1 (Minimum Engineering spec.) ( Meter : Minolta T10 ) 250 - Watt Philips UHP Lamp.

  • Page 6: Mechanical Specifications

    Mechanical Specifications Dimensions (WxHxD) 16.9(W) x 12.0 (D) x 5.3 (H) inches (430 x 305 x 135mm) Weight < 17.1 lbs. (7.8 Kg) Cooling System Advanced Air Flow Three fans with system acoustic noise level : 53 dB(A)(Typical) Temperature control circuits with adaptive voltage control fan speed Max touch temperature follows UL60950 regulation Color...
  • Page 7 Video Compatibility Standards : NTSC - M, 4.43 MHz - B, D, G, H, I SECAM - B, G, H, K, K1, L HDTV - 480i, 480p, 576i, 576p, 720p, 1080i TV Lines - 500 lines Keystone Vertical : +/- 16 degree (Desk-projector angle) Horizontal : +/- 7 degree (Screen-projector angle) Control Key Pad 9 keys...
  • Page 8 IR Remote Controller 22 Keys c i t t i x t i x i t p c i t i t p c i t i t p c i t i t p c i t...

  • Page 9: Optical Specifications

    Optical Specifications Projection Lens f = 28.3 ~ 38.2mm, F/3.4, 1.35X Manual Zoom Lens. Projection Image Size 30” to 280” Diagonal (Wide) Throw Distance 3.28 ft to 32.80 ft / 1.0m to 10m (Wide). Throw Ratio 1.6 ~ 2.16 (Projection Distance / Image Width) Tolerance Throw ratio <= + / - 5% Lens shift <= + / - 5%...
  • Page 10 Lamp Life 1500 hours min., 50% survial rate (Normal mode) 3000 hours min., 50% survial rate (Eco mode) Altitude Operating 0~2,500 ft 5 C~35 2,500~5,000 ft 5 C~30 5,000~10,000 ft 5 C~25 Storage 40,000 ft MTBF Operating more than 12,000 hours (90% confidence level)

  • Page 11: Disassembly Procedure

    Chapter 2 Disassembly Procedure Tools Needed Screw Bit (+) : 107 Screw Bit (+) : 102 Hex Sleeves 5mm (TOP) Ball-end hex-key 3mm Long Nose Nipper Angle Cutting Nipper...

  • Page 12: Removing Lamp Module

    Removing Lamp Module Unscrew one screw and push the Lamp Cover. Note : Be careful that Lamp Cover has the tenon inside. Loosen 3 screws to remove Lamp Module.

  • Page 13: Removing I/O Panel, Top Cover And Keypad Board

    Removing I/O Panel, Top Cover and Keypad Board Unscrew 4 hex screws to remove I/O Panel. Unscrew 11 screws, and then open Top Cover and unplug one FPC cable to remove Top Cover.
  • Page 14 Unscrew 10 screws to remove Keypad Board, Keypad and Lens Shift Gear Module. Keypad Board Keypad Lens Shift Gear Module Unscrew 8 screws to remove brackets.

  • Page 15: Removing Thermal Board, Main Board, Connector Board And Power Module

    Removing Thermal Board, Main Board, Connector Board and Power Module Unscrew 2 screws and unplug 8 wires to remove Thermal Board. Unscrew 9 screws(a stand off shoulder & spring) on the Main Board, unscrew 4 screws on Connector Board and remove them. Connector Board Unscrew 8 screws and unplug 4 wires to remove Power Module.
  • Page 16 Unscrew 4 screws to remove Lamp Housing Holder. Lamp Housing Holder Remove the power panel Unscrew 3 screws to remove I/O Bracket Module.

  • Page 17: Removing Fan Module(92X25Mm), Lamp Ballast, Power Board And Dmd Board

    Removing Fan Module(92x25mm), Lamp Ballast , Power Board and DMD Board Unscrew 4 screws to remove Fan Module(92x25mm). Remove Ballast Module, then separate Lamp Ballast and Power Bracket. Lamp Ballast Power Bracket Unscrew 2 screws to remove Power Board from Power Bracket.
  • Page 18 Unscrew 4 screws to remove DMD Heatsink. Unscrew 4 screws to remove DMD Board and unplug the cable of Color Wheel. Unscrew 3 screws to remove Formatter Board Shielding.

  • Page 19: Removing Dmd Chip, Front Panel Module And Fan Module(50X15Mm)

    Removing DMD Chip, Front Panel Module and Fan Module(50x15mm) Unscrew 3 screws to remove DMD Chip. Unscrew 3 screws to remove Front Panel Module. Front Panel Module Unscrew 3 screws to remove Fan Module(50x15mm).

  • Page 20: Removing Air Duct Module, Engine Module And Fan Module

    Removing Air Duct Module, Engine Module and Fan Module Unscrew all screws to remove Air Duct Module. Unscrew all screws to remove Engine Module. Turn over and then unscrew 4 screws to remove Engine Base Plate and Fan Module (59x25mm). Fan Module (59x25mm) Engine Base Plate 2-10...
  • Page 21 Unscrew 3 screws to separate Engine and Lamp Housing Module. Short Medium Long Notice : Thermal Switch is fixed by Engine’s screw. 2-11...

  • Page 22: Chapter 3 Troubleshooting

    Chapter 3 Troubleshooting Equipment Needed • H77 Projector • DVI to VGA Cable, Power Cord • PC (Personal Computer) • Video Input (DVD Player & HDTV) • Screw Drivers Main Procedure Start Connect Power cord, analog or digital signal, then turn power on A.
  • Page 23 Continue Is Remote D. Remote Control Control OK? Troubleshooting E. Video Signal Is Video OK? Troubleshooting No Fault Found...
  • Page 24 3-2.1 A. Power Troubleshooting Start Check power Is LED Reassembly Lamp Cover cord & indicator Lamp assembly OK? input power Cover voltage Change Supply Power Supply Power Module Source Change Change Fan Is Fan working? Thermal Change Module Board Front-End Board Change Change...
  • Page 25 3-2.2 B. Image Performance Troubleshooting Start Change Change Have image? Front-End DMD Module Board Change Change Have garbage Front-End DMD Module pattern? Board Change Uniformity OK? Engine Module Change Color Adjust Change Optical Is color OK? Front-End Procedure Engine Module Board * Note 1 Dot defect isn’t...
  • Page 26 3-2.3 C. Function Troubleshooting Start Change Is Remote Does OSD Is KeyPad Front-End Controller show up? Board OK? Board Change Change Key Pad Board Remote Control Can function Change be adjusted? Front-End Board No Fault Found...
  • Page 27 3-2.4 D. Remote Control Troubleshooting Start Does the Remote Function work? Replace the battery Change Remote Control Change Front-End Board 3-2.5 E. Video Signal Troubleshooting A. Have Image ? ? ? ? Ensure the signal cable and source work as well. Check that OSD menu can show on the screen.
  • Page 28 C. Is Color OK ? ? ? ? Do the “Factory Reset” of the engineering mode. Ensure the signal cable works as well. Check the color temperature setting of OSD menu. (Check the main board if the setting of color temperature is under default) Check the color setting of OSD menu.
  • Page 29 H77 Projector Signal Test According to the signal of Lamp, Temp and Power LED to decide the function error as follows : Turn on the power and press the Power LED button, Power LED signal on but lamp can’t be lit up.

  • Page 30: Chapter 4 Function Test And Alignment Procedure

    Chapter 4 Function Test & Alignment Procedure Product Test Equipment IBM PC with XGA resolution (Color Video Signal & Pattern Generator) DVD player with component video(Y, Pb, Pr) and Multi-system(NTSC / PAL / SECAM) HDTV Tuner or Source (480i, 480p, 720p, 1080i) Minolta CL-100 Test Condition Circumstance Brightness :...

  • Page 31: Compatible Modes

    Test Display Modes & Pattern 4-4.1 Compatible Modes Analog : i l i Digital : i l i...

  • Page 32: Function Test Display Pattern

    4-4.2 Function Test Display Pattern PC Signal : c i f i l E e s i & e r i o i t i t s a r t g i r r o l . l a e t i r o l r o l e t i...
  • Page 33 Figure 1. Fine Line Moire Figure 2. 32 Gray Scale Figure 3. 64 RGBW Scale Figure 4. Red Pattern Figure 5. Green Pattern Figure 6. Blue Pattern...
  • Page 34 Figure 7. Full White Figure 8. Full Black Figure 9. Gary 30 Pattern Figure 10. Blue 60 Pattern Figure 11. Text Pattern Figure 12. Boundary Frame...

  • Page 35: Inspection Procedure

    Video & Audio Signal : c i f r o l . l a e t i i t c r o l . l a r o l . l a r o l . l a Inspection Procedure How to enter the service mode? Press the “RESYNC”...
  • Page 36 Clock and Clock phase : Test Signal : 1024*768 @ 75Hz Test Pattern : Fine Line Moire Pattern Check and see if image sharpness and focus are well performed. If not, readjust by following steps. Enter “Advanced picture” of “Adjust picture” selection, and then select “Frequency” function to adjust the total pixel number of pixel clock in one line period.
  • Page 37 Blemish (Bright) : Test Signal : 1024 x 768 @ 75Hz Test Pattern : Full black and Gray 30 patterns Please check and ensure the unit is within the spec. (The bright blemish should not be seen under Gray 30 pattern) If out of spec, please return the unit to repair area.
  • Page 38 HDTV : Test Signal : HDTV signal Test Pattern : 480i, 480p, 720p, 1080i Please check and ensure the unit can display the HDTV signal without color abnormal or image abnormal issue. If not, please return the unit to repair area. Machine Reset : After final QC step, we have to erase all saved change again and restore the factory defaults.

  • Page 39: Firmware Upgrade Procedure

    Firmware Upgrade Procedure Equipment Needed Software : – FlashUpgrader.EXE – pwSDK.inf – Bootcode.hex – Flasher.hex – Gui.hex – Config.hex – RomCode.hex Hardware : – H77 Projector RS-232 to RS-232 9 Pin female connector cable. (Figure 1) Figure 1 Pin Assignment...

  • Page 40: Setup Procedure

    Setup Procedure The 9 pins female RS-232 cable connect to the COM port of PC and H77.

  • Page 41: Firmware Upgrade Procedure

    Firmware Upgrade Procedure Execute “FlashUpgrader.exe”. The window of FlashUpgrader shows up. Click “Choose” to get the file directory.
  • Page 42 Select <pwSDK.inf> file and open it. Select the serial port which is connected with the unit. Select baud rate to 115200, don’t use other baud rate. Click “Flash” button to start the firmware upgrade.
  • Page 43 6. Turn on the Power Switch of H77 and then start to run the next procedure. H77 is under upgrading Firmware as follows. (Download the file : RomCode.hex) H77 is under upgrading Firmware as follows. (Download the file : configdata.hex) After all files are downloaded, enter the service mode to check the F/W version.

  • Page 44: Ddc Key-In Procedure

    Chapter 6 DDC Key-in Procedure 6-1 Equipment Needed Hardware : EDID Fixture DFP to DVI cable Power Cord Power Adapter RS-232 Cable H77 Unit DDC Driver EDID Fixture RS232 Cable Power Adapter DFP to DVI cable...

  • Page 45: Setup Procedure

    Make sure the JP1 and JP5 are close and JP2 is open. Connect P1 of the fixture with COM1 port of PC by RS-232 cable. ( Figure 1) Connect P3 of fixture with DVI port of H77 by the DFP to DVI cable. Turn on the power of the fixture. Power...

  • Page 46: H77

    DDC Key-in Procedure Run H77 DDC program in PC. Note : The DDC program file use on win98/ME only. Make sure the COM port is link OK. Note : Don’t modify the other setting.
  • Page 47 Key-in S/N into the blank beside Bar Code, and then press “Enter” key on the key- board to begin programming. A81E429T0AAAA1001 After finishing the above action, “PASS” message will appear on the screen. 1001 2004...

  • Page 48: Exploded Overview

    Appendix A Exploded Overview...
  • Page 49 Exploded Parts List...
  • Page 50 Exploded Parts List t i P &...
  • Page 51 Exploded Parts List...
  • Page 52 Exploded Parts List...
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  • Page 54 Exploded Parts List...
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  • Page 56 Exploded Parts List t i P...
  • Page 57 Exploded Parts List 7-10...
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  • Page 62 Exploded Parts List 7-15...
  • Page 63 Exploded Parts List 7-16...
  • Page 64 Exploded Parts List 7-17...
  • Page 65 Exploded Parts List 7-18...

  • Page 66: Serial Number System Definition

    Serial code (from 0001~) EX : A81E429T0AAAA1001 This label “A81E429T0AAAA1001” represents the whole serial number for H77, including Ver. 1st of BIOS and Ver. 1 of PCB Board. Both mechanical and optical version are 1st. In addition, panel vendor is T1. It’s produced on 29-week of 2004 for universal area and its serial code is 1001.

  • Page 67: Reader’S Response

    Thank you for your backing our service manual up. In order to refine our content of the service manual and satisfy your requirement. We expect you can offer us some precious opinions for reference. Assessment: What do you think about the content after reading H77 Service Manual? t i n e l l...

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