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Coretronic H57 Service Manual

Micro-portable xga dlp projector
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SERVICE MANUAL

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Copyright September, 2004 . All Rights Reserved
Model Name : H57
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Document #81D-G04-01A . P/N: 36.81D01.001
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 Coretronic H57

  • Page 1: Service Manual

    SERVICE MANUAL Model Name : H57 Prepared by SI : ________________________________________ Prepared by TSE : ________________________________________ Check by : ________________________________________ Approved by : ________________________________________ t i n Copyright September, 2004 . All Rights Reserved Document #81D-G04-01A . P/N: 36.81D01.001...
  • Page 2 Preface This manual is prepared for the maintenance service for H57 Micro-portable XGA DLP Projector. Maintenance procedures described in this manual are intended to isolate faulty parts and replace them in the field. It also aims to serve as a guide in procuring replacement parts for this product.

  • Page 3: Table Of Contents

    Table of Contents Chapter 1 Introduction Product Highlight Optical Specification Electrical Specification Mechanical Specification Environment Chapter 2 Disassembly of Procedure Disassemble Lamp Module and Elevator Foot Disassemble Top Cover, Front Cover, Keypad Board and IR Sensor Module Disassemble Main Board Module, Thermal Switch Disassemble Fan Guider Module, Wind Tunnel Module, Lamp Driver Module, LVPS and Interrupt Switch Module Disassemble Color Wheel Module, Axial Fan 90x25 Module,...
  • Page 4 Chapter 6 DDC Key-in Procedure Equipment Needed Setup Procedure DDC Key in Procedure Appendix A Exploded Overview Appendix B 7-37 Serial Number System Definition 7-37 Reader’s Response 7-38...

  • Page 5: Chapter 1 Introduction

    Auto Image.(Auto-tracking /frequency /position adjustment) Automatically saves adjustments for future use On Screen lamp life timer On-screen menu with 9 languages One DVI PC-data input ( Including Analog and Digital RGB signal ) Wireless remote controller Support HDCP function Coretronic Corporation...

  • Page 6: Optical Specification

    3000 hours in ECO-mode 2500 hours to 50% survival typical in ECO-mode Projection lens F/2.6-2.85; f22.3-26.8 : 1.2x Projection distance 1.5-10m Throw ratio 1.57~1.87 : 1distance/width ± 16° Vertical and Horizontal Keystone correction Horizontal scan rate 15 – 100 kHz Coretronic Corporation...

  • Page 7: Electrical Specification

    Red on & off : Cool down in progress Green: Projection (not abnormal) Green on & off: Warm-up in progress Warning Indicator Temp - Red: High internal temperature IR receivers Front and Top of projector. Power Switch No toggle power switch required or wanted. Coretronic Corporation...
  • Page 8 Analog RGB 0.7Vp-p, 75 ohm, Separate TTL H,V Sync. Analog RGB 1Vp-p, 75 ohm, Sync. On Green signal Analog RGB 0.7Vp-p, 75 ohm, Composite TTL Sync. Video Composite video 1Vp-p,75 ohm S-video Luminance 0.714Vp-p,75 ohm Chrominance 0.286Vp-p,75 ohm Coretronic Corporation...
  • Page 9 Computer Compatibility (Analog) Coretronic Corporation...
  • Page 10 SECAM - B, D, G, K, K1, L HDTV - 480i/576i ; 480p/576p ; 720p ; 1080i Intelligent Zoom By using “PIXELWORKS” chips to provide excellent quality zooming. Control Key Pad 1. Power 2. Menu 3. Enter 4. Up 5. Down 6. Right 7. Left Coretronic Corporation...

  • Page 11: Mechanical Specification

    One S-Video Input One Composite Video Input 3 RCA RGBs input AC inlet; type IEC-C14 One IR receiver window Kensington key lock hole One DVI-I for digital RBG & Analog RGB Left Side None. Right Side Outlet vents Coretronic Corporation...
  • Page 12 Inlet vent Spec. and warning labels Lamp housing Lamp could be changed by customer, but should follow the user manual instruction. Replaceable Lamp should be provided by Coretronic or its authorized agencies Tilt Angle 7 degrees with elevator mechanism Keystone correction ±...

  • Page 13: Environment

    30 dB(A) 200 W in ECO-mode. Follow ISO-7779 regulation sound pressure level A weighting measurement Lamp life -1500 hours typical, 50% survival rate Altitude Operating 0~2,500 ft 5°C~35°C 2,500~5,000 ft 5°C~30°C 5,000~10,000 ft 5°C~25°C Storage 40,000 ft (Max) Coretronic Corporation...

  • Page 14: Chapter 2 Disassembly Of Procedure

    Chapter 2 Disassembly Procedure The Front Side The Rear Side Disassemble Lamp Module and Elevator Foot Step1: Turn unit to bottom side. Remove Lamp Cover and unscrew three screws to pull out Lamp Module. Lamp Cover Lamp Module Coretronic Corporation...
  • Page 15 Step2: Unscrew two screws to detach the Elevator Foot from Bottom Cover. Elevator Foot Coretronic Corporation...

  • Page 16: Disassemble Top Cover, Front Cover, Keypad Board And Ir Sensor Module

    Disassemble Top Cover, Front Cover, Keypad Board and IR Sensor Module Step1: Unscrew eight screws and then turn the unit to the top side to lift Top Cover. Step2: Unplug three wires to separate Top Cover from the main unit. Coretronic Corporation...
  • Page 17 Step3: Separate Front Cover from Top Cover by pressing two tenons. Top Cover Coretronic Corporation...
  • Page 18 Step4: Unscrew two screws to take off IR Sensor. Front Cover IR sensor Module Coretronic Corporation...
  • Page 19 Unscrew three screws and unplug the wire to remove the Keypad Board, Keypad Button and FPC. Keypad Board Keypad Button Step6: Take off Top IR Sensor Module from Rear Cover and separate IR Sensor from Anti-light Mylar. Anti-light Mylar IR sensor Coretronic Corporation...

  • Page 20: Disassemble Main Board Module, Thermal Switch

    Disassemble Main Board Module and Thermal Switch Step1: Unplug nine connectors and unscrew four screws. Step2: Unscrew four hex screws from Rear Cover to remove Main Board. Main Board Module Coretronic Corporation...
  • Page 21 Step3: Unscrew one screw to remove Thermal Switch. Thermal Switch Coretronic Corporation...

  • Page 22: Disassemble Fan Guider Module, Wind Tunnel Module, Lamp Driver Module, Lvps And Interrupt Switch Module

    Lamp Driver Module, LVPS and Interrupt Switch Module Step1: Unscrew three screws to separate Fan Guider Module and Wind Tunnel Module from Bottom Housing. Step2: Unscrew two screws from Wind Tunnel Module to remove Fan Guider Module. Fan Guider Module Wind Tunnel Module Coretronic Corporation...
  • Page 23 Step3: Unscrew six screws, unplug one wire and one connector to remove Lamp Driver Module. Lamp Driver Module 2-10 Coretronic Corporation...
  • Page 24 Step4: Unsrew three screws and unplug one wire to remove LVPS. LVPS 2-11 Coretronic Corporation...
  • Page 25 Step5: Unscrew two screws to remove EMI Ground Plate and separate the cables. EMI Ground Plate LVPS Cables 2-12 Coretronic Corporation...
  • Page 26 Step6: Unscrew two screws to remove Interrupt Switch Module. Interrupt Switch Module 2-13 Coretronic Corporation...

  • Page 27: Disassemble Color Wheel Module, Axial Fan 90X25 Module

    Disassemble Color Wheel Module, Axial Fan 90x25 Module, Lamp Fan 60x60x25 and Optical Engine Module Step1: Unscrew two screws to remove Color Wheel Module. Photo Sensor Color Wheel 2-14 Coretronic Corporation...
  • Page 28 Step2: Unscrew two screws to remove Axial Fan 90x25 Module. Holder Bracket and Rubber Bottom Axial Fan 90x25 Steamtight Rubber 2-15 Coretronic Corporation...
  • Page 29 Step3: Unscrew two screws to remove 60x60x25 Lamp Fan. Step4: Pull two side outward to disassemble 60x60x25 Lamp Fan. 60x60x25 Lamp Fan Module 2-16 Coretronic Corporation...
  • Page 30 Step5: Unscrew four screws to remove Engine Module from Bottom Cover. Bottom Cover Optical Engine Module 2-17 Coretronic Corporation...
  • Page 31 Step6: Tear off EMI tape to separate Wind Guider Cover Mylar from Engine Module. Wind Guider Cover Mylar Step7: Unscrew four screws to remove DMD Heatsink. DMD Heatsink 2-18 Coretronic Corporation...
  • Page 32 Step8: Unscrew four screws to remove Bracket Plate, Insulation Mylar, DMD Board. Bracket Plate Insulation Mylar DMD Board Step9: Separate DMD Chip from Engine Module. DMD Socket DMD Chip DMD Seal rubber 2-19 Coretronic Corporation...
  • Page 33 Step10: Unscrew three screws to remove Focus Ring & Replace Ring. Focus Ring & Replace Ring Optical Engine Module 2-20 Coretronic Corporation...

  • Page 34: Disassemble Blower Fan 50*20, Thermal Sensor Board, Interrupt Switch Module, Bottom Cover And Rear Cover

    Disassemble Blower Fan 50x20, Thermal Sensor Board, Interrupt Switch Module, Bottom Cover and Rear Cover Step1: Unscrew one screw to remove Thermal Senor Board. Thermal Senor Board Step2: Unscrew three screws to remove Blower Fan 50x20 Module. Blower Fan 50x20 Module 2-21 Coretronic Corporation...
  • Page 35 Step3: Unscrew one screw and separate Rear Cover from Bottom Cover by pressing four tenons. Rear Cover Bottom Cover 2-22 Coretronic Corporation...
  • Page 36 Step4: Unscrew three screws and press the tenon to remove Elevator Module. Elevator Module 2-23 Coretronic Corporation...

  • Page 37: Chapter 3 Troubleshooting

    Chapter 3 Troubleshooting Equipment Needed H57 Projector VESA VGA Cable/VESA DVI Cable PC (Personal Computer) with analog and digital signal output. DVD Player for Video Signal and Audio Signal. H57 Remote Controller Coretronic Corporation...

  • Page 38: Main Procedure

    When the “TEMP” indicator turns red, it indicates the projector has overheated. The projector will automatically shut itself down. When the “LAMP” indicator flashes red (0.5 second intervals), it indicates a problem with the lamp. When the “LAMP” indicator flashes red (1 second intervals), it indicates the fan failed. Coretronic Corporation...

  • Page 39: Power Troubleshooting

    Check the Lamp cover assembly OK or not. Check if there is the sound of Lamp ignitor output from the unit or not. Check the Cable of Interrupt Switch. Check the DMD board. Check the Lamp module. Check the Ballast. Coretronic Corporation...
  • Page 40 Ensure if the signal cable and source work as well. Adjust the tracking selection on OSD Menu. Press the Menu button to check that have the noise issue appear on OSD Menu. (Check DMD Board if the noise also appears on OSD Menu.) Coretronic Corporation...
  • Page 41 Ensure the signal cable work 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. Ex: “Saturation”, ”Tint” and “Sharpness” setting of OSD menu. Coretronic Corporation...
  • Page 42 (Check the cable length of cable; the signal will be reduce when the signal cable is longer than 5m) Do the “Factory Reset” of the engineering mode. (Check the Main board if the image still display with noise.) Coretronic Corporation...

  • Page 43: Function Troubleshooting

    Replace the battery if there is no function. Use a well-functioning Remote controller for the function test. (Replace the Remote controller if the new Remote controller works fine with the Unit.) Check Main Board if the Unit works fine with a known good Remote controller. Coretronic Corporation...

  • Page 44: Function Test And Alignment Procedure

    Screen Size : 60 inches diagonal (wide) Each H57 should be run-in for 2 hours after repair. Before function test and alignment, each H57 should be warmed up for 5 minutes. In room temperature With cycled display colors (R,G,B,White) *Note Test Display Mode &...

  • Page 45: Test Display Modes And Pattern

    Test Display Modes & Pattern 4-3.1 Compatible Modes Analog Coretronic Corporation...

  • Page 46: Function Test Display Pattern

    Digital 4-3.2 Function Test Display Pattern PC Signal & Coretronic Corporation...
  • Page 47 Figure 2.Gray Scale Pattern Coretronic Corporation...
  • Page 48 Coretronic Corporation...
  • Page 49 Video & Audio Signal Coretronic Corporation...

  • Page 50: Inspection Procedure

    Dead pixel (Bright pixel) Test Signal:1024 x 768 @ 75Hz Test Pattern:Full black pattern Please check and ensure the unit is under the spec. (Cannot accept any bright pixel) If not, please return the unit to repair area. Coretronic Corporation...
  • Page 51 If not, please return the unit to repair area. Video Test Signal:Composite video,S-Video and Component video Test Pattern:NTSC,PAL,SECAM Please check and ensure the unit can display the video signal without color abnormal or image abnormal issue. If not, please return the unit to repair area. Coretronic Corporation...
  • Page 52 After final QC step, we have to erase all saved change again and restore the factory defaults. Please select and enter “Factory Reset” function of “Engineering Mode” to ensure the function is work as well. This action will allow you erase all end-user’s settings and restore the original factory setting. Coretronic Corporation...

  • Page 53: Firmware Upgrade Procedure

    Config.hex Flasher.hex FlashUpgrader.exe Gui.exe Pixelware.inf Romcode.hex Hardware : Power Cord Cable RS232 To Mini Din 3Pin PC or Laptop H57 Projector Hardware Setup Procedure Connecting RS232 Cable between PC and H57 Projector. RS232 Cable Mini Din 3pin Port Coretronic Corporation...

  • Page 54: Firmware Progarm Installation Procedure

    Execute the “FlashUpgrader.exe” program. Step2. 1. Click ”Choose” to get the file directory 2. Select <pwSDK.inf> file and open it. 3. Select the Serial port in Connection field, COM1: in COM Port field and 115200 in Baud Rate field. C:\Firmware\Optoma\H57 Coretronic Corporation...
  • Page 55 Step3. Click “Flash” to start the firmware upgrade procedure and keep press the projector’s power button immediately until download “gui.hex” to 10%. C:\Firmware\Optoma\H57 Flash C:\Firmware\Optoma\H57\ Coretronic Corporation...
  • Page 56 Step4. After downloading all files, enter the engineering mode to check the F/W version. (Refer to 4-1) Coretronic Corporation...

  • Page 57: H57

    PC or Laptop (OS:Windows98 or Windows Me) EDID Fixture DFP to DVI Cable Power Adapter RS-232 Cable VGA Cable Power Cord DDC Driver EDID Fixture P/N:80.00001.001 Power Adapter P/N: 47.53402.004 DFP to DVI Cable VGA Cable P/N: 42.81702.001 P/N:42.53001.051 RS-232 Cable P/N: 42.55708.001 Coretronic Corporation...

  • Page 58: Setup Procedure

    Step3. Connect P2 of the fixture with VGA Port of H57 by the VGA Cable. Step4. Connect P3 of the fixture with DVI Port of H57 by the DFP to DVI cable. Step5. Turn on the power of the fixture.

  • Page 59: Ddc Key In Procedure

    DDC Key-in Procedure 6-3.1 Analog Step1. Execute “H57_EDID_B” program. OPTOMA_H57 Step2. Mark sure the COM port is connected ok. Choose the “Analog” to do Analog DDC procedure. 081D Coretronic Corporation...
  • Page 60 Step3. Key-in S/N in to the blank beside Barcode, and then press “Enter” key on the keyboard to begin programming. 1D342TOABCD1234 081D Step4. After finishing the above action, “PASS” message will appear on the screen. 081D Coretronic Corporation...
  • Page 61 Mark sure the COM port is connected ok. Choose the “Digital” to do Digital DDC procedure. 081D Step2. Key-in S/N in to the blank beside Barcode, and then press “Enter” key on the keyboard to begin programming. 1D342TOABCD1234 081D Coretronic Corporation...
  • Page 62 Step3. After finishing the above action, “PASS” message will appear on the screen. 081D Coretronic Corporation...

  • Page 63: Appendix A

    Appendix A Exploded Overview Coretronic Corporation...
  • Page 64 Exploded Parts List of H57 Coretronic Corporation...
  • Page 65 H57 Bottom Housing Module Coretronic Corporation...
  • Page 66 Exploded Parts List of H57 Bottom Housing Module Coretronic Corporation...
  • Page 67 III. H57 Enigne Module Exploded Parts List of H57 Engine Module Coretronic Corporation...
  • Page 68 H57 Lamp Changer Module Coretronic Corporation...
  • Page 69 Exploded Parts List of H57 Lamp Changer Module Coretronic Corporation...
  • Page 70 H57 Lamp Driver Module Exploded Parts List of H57 Lamp Driver Module Coretronic Corporation...
  • Page 71 H57 Optical Lens Module Coretronic Corporation...
  • Page 72 Exploded Parts List of H57 Optical Lens Module 7-10 Coretronic Corporation...
  • Page 73 VII. H57 Front Cover Module Exploded Parts List of H57 Front Cover Module 7-11 Coretronic Corporation...
  • Page 74 VIII. H57 Back Cover Module Exploded Parts List of H57 Back Cover Module 7-12 Coretronic Corporation...
  • Page 75 H57 Engine Base Module 7-13 Coretronic Corporation...
  • Page 76 Exploded Parts List of H57 Engine Base Module 7-14 Coretronic Corporation...
  • Page 77 H57 Rod Module Exploded Parts List of H57 Rod Module 7-15 Coretronic Corporation...
  • Page 78 H57 Color Wheel Module Exploded Parts List of H57 Color Wheel Module 7-16 Coretronic Corporation...
  • Page 79 XII. H57 Elevator Foot Right Module Exploded Parts List of H57 Elevator Foot Right Module 7-17 Coretronic Corporation...
  • Page 80 XIII. H57 Elevator Foot Left Module Exploded Parts List of H57 Foot Left Module 7-18 Coretronic Corporation...
  • Page 81 XIV. H57 Main Board Module Exploded Parts List of H57 Main Board Module 7-19 Coretronic Corporation...
  • Page 82 H57 Bottom Cover Module Exploded Parts List of H57 Bottom Cover Module 7-20 Coretronic Corporation...
  • Page 83 XVI. H57 Top Cover Module Exploded Parts List of H57 Top Cover Module 7-21 Coretronic Corporation...
  • Page 84 XVII. H57 Lamp Duct Module Exploded Parts List of H57 Lamp Duct Module 7-22 Coretronic Corporation...
  • Page 85 XVIII. H57 Lamp Tip Shield Module Exploded Parts List of H57 Lamp Tip Shield Module 7-23 Coretronic Corporation...
  • Page 86 XIX. H57 Blower Fan 59X25 Module Exploded Parts List of H57 Blower Fan 59X25 Module 7-24 Coretronic Corporation...
  • Page 87 H57 Wind Tunnel & Fan Guider Cover Module Exploded Parts List of H57 Wind Tunnel & Fan Guider Cover Module 7-25 Coretronic Corporation...

  • Page 88: Appendix B

    Serial code (from 0001~) EX1 : O81D429T0AAAA1001 This label “O81D429T0AAAA1001” represents the whole serial number for H57, including Ver. 1st of BIOS and Ver. 1 of PCB Board. Both mechanical and optical ver- sion are 1st. In addition, panel vendor is T1. It’s produced on 29-week of 2004 for uni- versal area and its serial code is 1001.

  • Page 89: 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 H57 Service Manual? t n I & g i l...

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