SERVICE MANUAL ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Date Revise Version Description 2009.05.14 V1.0 Initial Issue 2009.11.10 V2.0 Add EX531/CB2800 2010.03.12 V3.0 Add ES526L/EX536L Add DS316L 2010.07.02 V4.0 Add Burn-in environment setting in Chapter 4 Copyright July. 2010. All Rights Reserved. Prepare : Check: Approve:...
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Preface This manual is applied to ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L 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.
Item Description �4 System Controller ● DDP243� ASIC Controller with Brilliant Color ● For ES526 • VGA-in: D-sub �5 pin x � D-sub �5 pin x � • Composite: RCA x � RCA x � • S-�ideo: Mini-DI� 4 pin x �...
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75.06 68.68 MAC G4 640 x 480 3�.35 �024 x 768 i Mac DV ��52 x 870 68.49 �280 x 960 Note: If the Computer Compatibility supportive signal is different from User's Manual, please refer to User's Manual. Confidential ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L...
* 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. - As the disassembly process of EX536/ES526/EX531/CB2800/ES526L/EX536L/DS316L is the same, we take ES526 for example here.
1. Unfasten 2 screws (as red circle) on the Lamp Cover. 2. Disassemble the Lamp Cover Module. 2-3 Disassemble Lamp Module 1. Unfasten 2 screws (as red circle) on the Lamp Module. 2. Take off the Lamp Module. ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential...
Main Board and Keypad Board Module, then unplug it from Keypad Board Module. - Avoid damaging by pulling keypad FPC cable. - Make sure the FPC cable plug into the correct ports when assembling it. ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential...
2. Tear off mylar from the Keypad Board Module. 3. Separate the Keypads from the Top Cover Module. 2-6 Disassemble Zoom Ring 1. Unscrew 3 screws (as red circle) from the Top Cover Module. 2. Remove the Zoom Ring. Zoom Ring ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential...
1. Unscrew 3 screws (as red circle). 2. Tear off the black mylar (as green square). 3. Unplug 1 connector (as orange square) to remove the FPC cable. 4. Unplug 1 connector (as blue square) of Color Wheel. FPC cable ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential...
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Compose of Red/Yellow/Black Wire (3 pin) Compose of Red/Black/White Photo Sensor Wire and Black wire tube (3 pin) Compose of Red/Black/White Wire and Gray wire tube (3 pin) Compose of Red/Black Wire and Speaker Black wire tube (2 pin) ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential...
IR Sensor Board Note: - Take care of the tenons when you disassemble the unit. IR Sensor Board IR Cover 2-11 Disassemble Engine Module 1. Unscrew 4 screws (as yellow circle) to disassemble the Engine Module. ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential...
- Found that the DMD Chip has scrapes or dirt use of a magnifying glass, you may use an electrostatic ion gun to clean it. - Pay attention to the fixed position when assembling the DMD Chip. ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential...
- Ensure left edge of Rod Module contact with the Engine base’s blocks. - Rod Spring must hook in the position as picture B shown. 2-15 Disassemble Focus Ring 1. Unscrew 3 screws (as red circle) to disassemble the Focus Ring. Focus Ring ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential 2-10...
1. Unscrew 3 screws (as red circle) to disassemble the Fan Module. 2. Unscrew 4 screws (as blue circle) to separate Fan and Fan Shielding. 3. Unscrew 1 screw (as yellow circle) to disassemble the Fan Duct. Fan Duct Fan and Fan Shielding ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential 2-11...
3. Disassemble the IO Cover. 4. Unscrew 1 screw (as blue circle) to disassemble the Security Bar and Security Bar Cap from the IO Cover. Note: - Take care of the tenons (as green square) when you disassemble the IO Cover. ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential 2-13...
- Change the screen to "white screen". - Adjust the screws by using the rod on the engine module to readjust the image. ("screw 1" should be adjusted first, and then "screw 2". Adjust until the yellowish or bluish parts disappeared.) ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential 2-16...
"Exit", then use "left" or "right" buttons to re-write the lamp hour back to previous lamp usage hour. 3. Press "Enter" to exit the service mode. Note: left key = decrease lamp hour right key =increase lamp hour ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential 2-17...
- Check Main Board - Ensure all connectors are securely connected and aren’t broken - Check Lamp Module - Check Lamp Driver No Light On - Check LVPS - Check Main Board - Check Color Wheel - Check Photo Sensor Board ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential...
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- Check Photo Sensor and clean Photo Sensor - Check DMD Board - Check Main Board - Do “Reset (All data)” of the OSD Menu - Adjust Color Wheel Index Color Abnormal - Check Main Board - Check DMD Board - Check Color Wheel ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential...
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- Ensure that the signal cables and source are work as well - Ensure that your Projector is not in “Mute” mode Audio Abnormal - Check the interior Speaker of the projector - Check the exterior Speaker that you are using - Check Main Board ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential...
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(3) The message “Enter New Security Code” appears. Input a 4-digits code (letters and/or numbers) that you define. (4) To confirm, key in the password again. The “Security Code change successfully” appear on the screen. Forgetting Password (administrator Password) ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential...
1. After final QC step, we have to erase all saved change again and restore the OSD default setting. The following actions will allow you to erase all end-users' settings and restore the default setting: (1) Please get into OSD menu. (2) To execute "Reset" function. ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential...
< Figure: Zone A, Zone B, Zone C & Frame (as green line) Definition, Active area=Zone A + Zone B > Defect specification table For EX536/EX536L Order Symptom Pattern Criteria Bright pixel ( dots) Gray 10 pattern A+B=0 Dark pixel(dots) White pattern A+B≤4 Unstable pixel (dots) Any pattern A+B=0 Adjacent dark pixel (dots) Any pattern A+B=0 ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential...
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Gray 10 pattern (diameter <1/2 inch) A+B≤2 Dark blemish (Dirty) Blue 60 pattern (diameter <1/2 inch) Bright dot on frame Gray 10 pattern ≤1 For ES526/CB2800/ES526L/DS316L Order Symptom Pattern Criteria Bright pixel ( dots) Any pattern A+B=0 Dark pixel(dots) Any pattern A+B≤3...
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Press right key to adjust the time (50) Lamp Off (Min) Press right key to adjust the time (10) Set Burning cycle Press right key to adjust the cycle After setting up the time, choose ''Enter to Burn In'' and press "enter" button. ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential...
Note: - When getting into function test, adjust the zoom ring and focus ring to guarantee the image maximum and clearest, then start to test. - Test signal: analog 800 x 600 @60Hz (for ES526/CB2800/ES526L/DS316L) analog 1024 x 768 @60Hz (for EX536/EX531/EX536L) - We take ES526 for example here.
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- Test pattern: Black pattern - Check if the light leaks. * Light leak on reflective edge, eye-catcher, bond wires and exposed metal. Full black Inspection item - Light leak check. Criteria - The pattern cannot accept the color level of the ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential...
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- It is acceptable when it has 3 dead pixels on any pattern, the picture frame should not appear yellow, shadow, light blue, and other nonperforming. - Adjacent pixel with each other is unacceptable. - Ref. Defect specification table Note: The defect criteria follows TI specification. ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential...
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Full screen sharp over the entire surface of the display pattern. (Blur word on one of the corner after adjustment is acceptable. However, the word should at least be recognizable.) ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential...
- Test equipment: DVD player - Test signal: CVBS Inspection item - Video performance test Inspection Distance - 1.8 M ~2.5 M Criteria - Check any abnormal color, line distortion or any noise on the screen. Motion video ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential...
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- Check any abnormal color, line distortion or any noise on the screen. - Check the sound from speakers. - Check if "freeze" is normal. 4. Audio Test (not for CB2800/ES526L/EX536L) Procedure - Test equipment: DVD Player - Test signal: CVBS - Test signal: CVBS ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential 4-10...
- Screen Size: 60 inches diagonal 1. Test equipment Procedure - Connect VGA IN port of ES526/CB2800/ES526L (VGA1-IN/SCART port of EX536/EX531/EX536L) with VGA port of Chroma by VGA cable, press "Menu" button, get into OSD mode, the settings are as below: - "Display mode"...
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- Use CL100 to measure brightness values of P1~P9 (see image: full white). - Follow the Uniformity formula to calculate average values. ☼ Uniformity Formula JBMA Uniformity = Avg. (P1, P3, P7, P9)/P5 X100% Criteria ● 70% ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential 4-12...
It should be locked in the correct place. Plastic Parts All plastic parts can not be broken and damaged. Safety or warning All safety and warning labels should be visible, including all label contents. Connector All interface connectors should be complete and workable. ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential 4-13...
- Firmware - Library file (Library v7.1 0330) Hardware: - Projector - Power cord: 42.50115G001 - RS232 cable: 42.83618G001 - PC or Laptop Note: The FW upgrade procedure for EX536/ES526/EX531/CB2800/ES526L/EX536L/DS316L is the same,we take ES526 as an example here. ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential...
1. Choose "DLP Composer Lite V7.1 Setup" Program. 2. Click "Next". 3. Read "License Agreement". - Choose "I accept and agree to be bound by all the terms and conditions of this License Agreement". - Click "Next". 4. Click "Next". ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential...
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5. Click "Next". 6. Click "Next". 7. The program is executing "installing" status. 8. Click "Finish". ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential...
Lamp LED will light on red. - Loosen the "POWER" button. - Connect projector with PC by RS232 cable. Note: The system fan and the lamp will not operated. 2. Execute the "DLP Composer Lite 7.1" file. 3. Click "Edit" and "Perferences". ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential...
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(3) In "Stop Bits" item, select "1". (4) In "Parity" item, select "None". (5) In "RTS" item, select "Enable". (6) In "CTS" item, select "Disable". (7) Key in "4000" into "Read" and "Write" items of "Timeouts (in milliseconds)". - Click "OK". 7. Click "OK". ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential...
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- Click "Open". 9. Select "Skip Boot Loader Area". (select "32KB"). - Click "Reset Bus" to erase the flash memory. 10. If the FW is ready, click "Start Download" to execute the firmware upgrade. - Click "Yes". 11. Proceeding Picture. ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential...
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13. Check FW version. - Re-plug in power cable, then restart the unit and get into the Service mode to check the firmware version. (To get into Service mode, please press "Power", "Left", "Left" and "Menu" buttons sequentially.) ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential...
- xxx_8051_xx.hex Hardware: - Projector - Power cord: 42.50115G001 - NLINK Fixture: SP.8CS02G001(include Mini USB cable) - PC or Laptop Note: The 8051 FW upgrade procedure for EX536/ES526/CB2800/EX531/ES526L/EX536L/ DS316L is the same, we take ES526 as an example here. ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential...
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5. Click "Next". - Select the additional task that you may create a desktop icon. 6. Click "Install" to begin installing NLINK Procedure. 7. Click "Finish". - Complete the NLINK setup. ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential 5-10...
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(3) Then click "Next". (4) Select "Include this location in the search", then click "Browse". (5) "Browse For Folder" picture will appear on the screen. (6) Select "TPRP1" folder in the "Manley USB Driver_N-Link" folder, then click "OK". ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential 5-11...
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(9) Click "Finish". - "Manley TPRP1-Protocol Emulator" will appear on the picture. - Complete the USB Driver Upgrade Procedure. Note: If the PC appear "Found New Hardware Wiszard" picture again, repeat step 2 to install USB Drivier once more. ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential 5-12...
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- Confirm the settings are as green square, such as: "The uC clock is for Watchdog...", "Port 1~3 and 5 reset to quasi ...", "Port reset to high state", "Brownout Level 3.8V", "Enable Clock Filter", "Internel RC (11.0592MHZ)", "MovC Inhibit Disabled". ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential 5-13...
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- In "Security" item, select "None". - In "Code" item, select "Keep...". - Checking the "CheckSum" item 322E. - Click "Erase/Write(W)" to execute 8051 FW upgrade. 6. Finish - When 8051 FW upgrade process is finished, "Write Chip success" will be shown. ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential 5-14...
Note: - If a display device has digital input ports, like DVI or HDMI, but without EDID in its main board, the display device will show no image while the input source is digital signal. - The EDID Upgrade procedure for ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L is the same, we take ES526 for example here.(EX536/EX531/EX536L have VGA1-IN and VGA2-IN/SCART ports) ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L...
VGA Cable. Adapter RS232 Cable (3) Plug Power Adapter to JP1 of fixture. (4) Power on fixture. (5) Plug Power Cord to projector. Note: You must confirm that the JP3 is closed Power Port in all procedure. VGA Port ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential...
(1) Select the COM Port which you are using. (2) Click "Model". (3) Select the source file (*.ini). (4) Click "Open". (5) Key in the Serial Number into the Barcode blank space. (6) In "Write Source Select" item, select "VGA1". (7) Click "Program". ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential...
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4. When the EDID program is completed, a message "OK" will appear on the screen. 5. Read EDID "VGA" information - In "Read item", select "Analog" and "Trans", then click the "Read". 6. EDID informations will show the result. ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential...
Appendix A (Exploded Image) Note: This chapter is only designed to show the exploded image of the projector. For updated part numbers, please refer to RSPL report. D.C. ES526 ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential...
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LAMP DRIVER HOLDER PPS BLACK PDG- 51.8CS11G001 DSU30 70.8EH06G001 ASSY ENGINE MODULE ES526 85.0A123G050 SCREW P/F MECH M3*5 Ni ASSY IO COVER MODULE FOR ES526 (SERV- 70.8EH13GR01 CE) 35.8EH01G001 IO LABEL ES526 85.1A323G080 SCREW PAN MECH M3*8 BLACK “GREEN” 41.89Z02G001 HDMI CONNECTOR GASKET L15*W10*H1 85.005AGG308...
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CABLE TIE PG-YJ-80 51.8CS03G011 FRONT COVER PC MN3600H ES526 70.8EH04G001 ASSY IO COVER MODULE ES526 51.8CS16G001 MB SHIELDING MYLAR PDG-DSU30 ASSY LAMP COVER MODULE FOR ES526 70.8EH17GR01 (SERVICE) 51.8CS05G001 LAMP COVER PC MN3600H BLACK PDG-DSU30 52.8CS05G001 MB SHIELDING AIR THIGHT PDG-DSU30 85.1A526G060...
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ASSY TOP COVER MODULE ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential...
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ZOOM RING HOLDER PC MN3600H BLACK 51.8CS12G001 PDG-DSU30 51.8CS08G001 ZOOM RING PC MN3600H BLACK PDG-DSU30 70.8EH11GR01 ASSY ENTER KEY PC OF ES526 (SERVICE) 51.8EH05G001 ENTER KEY PC MN3600H ES526 51.8EH02G001 LED LENS PC-121 ES526 51.8EH06G001 4WAY KEY PC MN3600H ES526 51.8EH03G001...
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SUNON, KDE1207PKV1-A 70*70*20mm AXIAL 49.88T01G001 85.1A123G060 SCREW PAN MECH M3*6 NI 61.8EH01G001 FAN SHIELDING SECC 0.6T ES526 85.1F123G260 SCREW PAN MECH E/SF M3*26 Ni 61.8EH03G001 ONE FAN DUCT AL ALLOY ES526 51.8EH08G001 ONE FAN DUCT CAP PPS+GF40% ES526 ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential...
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Item Description Parts Supply 70.8EH14GR01 ASSY ENGINE MODULE FOR ES526 (SERVICE) 23.8CP01G002 FPL62 PROJECTION LENS 70.8CP15G001 ASSY RELAY MODULE Z15 23.8AH20G001 CONDENSER1 FOR A15W 85.1A526G060 SCREW PAN MECH M2.6*6 Ni NYLOK 80.8CP02G001 PCBA DMD BOARD FOR X1161 ASSY ROD MODULE FOR ES526/EX536 70.8EH18GR01...
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ASSY COLOR WHEEL MODULE Z15 Item Description Parts Supply ASSY COLOR WHEEL MODULE FOR ES526 70.8EH15GR01 (SERVICE) 61.8CP03G001 CW BRACKET SECC X1161 80.8EG04G001 PCBA PHOTO SENSOR BOARD FOR HD20 COLOR WHEEL YO 6SCW 23.8BA19G001 R85Y37G90C28W42B78 FOR P1166/1266 85.1A126G040 SCREW PAN MECH M2.6*4 Ni TAPE 3M J350 10*5mm FOR COLOR WHEEL 51.82Y29G001...
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A.K. ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential X...
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LENS CAP MODULE PDG-DSU30 51.52109G003 PE BAG 450*350*0.07 FOR OPTOMA 55.8EH02G001 PARTITION PAPER ES526 56.8EH01G001 PACKING BOTTOM AIR BAG 480*600MM ES526 56.8EH02G001 PACKING TOP AIR BAG 240*1050MM ES526 42.00200G002 CABLE VGA 15P 1.8M BLK EP739 CABLE POWER CORD 1.8M SP-023/IS-14 42.00120G001...
= 15) AAAAA = not-defined C = Manufacture factory (CPC) 0001 = Serial Code EX: Q8EH915AAAAAC0001 This label "Q8EH915AAAAAC0001" represents the serial number for ES526. It is produced at CPC on fifteenth of 2009. Its serial code is 0001. ES526/EX536/EX531/CB2800/ES526L/EX536L/DS316L Confidential...