Optoma EX542 Service Manual
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Optoma EX542 Service Manual

Projection system
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SERVICE MANUAL

EX542/EX612/EX615/EX540/EX762/EX540I/EX542I/
Date
2009.07.08
2009.10.13
2009.12.16
2010.02.07
Copyright Feb, 2010. All Rights Reserved. P/N: 36.8FJ01G001
SI :
ES523ST/EW533ST
Revise Version
V1.0
V2.0
V3.0
V4.0
TSE:
Description
Initial Issue
Add EX540/EX762
Add EX540I/EX542I
Add ES523ST/EW533ST;
Modify "Defect specification table" in Chapter 4;
Check:
Approved:

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Summary of Contents for Optoma EX542

  • Page 1: Service Manual

    SERVICE MANUAL EX542/EX612/EX615/EX540/EX762/EX540I/EX542I/ ES523ST/EW533ST Date Revise Version Description 2009.07.08 V1.0 Initial Issue 2009.10.13 V2.0 Add EX540/EX762 2009.12.16 V3.0 Add EX540I/EX542I Add ES523ST/EW533ST; 2010.02.07 V4.0 Modify “Defect specification table” in Chapter 4; Copyright Feb, 2010. All Rights Reserved. P/N: 36.8FJ01G001 SI :...
  • Page 2 Preface This manual is applied to EX542/EX612/EX615/EX540/EX762/EX540I/EX542I/ES523ST/ EW533ST 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.
  • Page 3 EX542/EX612/EX615/EX540/EX762/EX540I/EX542I /ES523ST/ EW533ST Comparison List Parts EX540 EX542 EX540I EX542I EW533ST ES523ST EX615 EX612 EX762 USER’S 36.8FB01G001 36.8EF01G001 36.8FR01G001 36.8HA01G001 36.8EF01G001 36.8FK01G001 36.8FB01G001 GUIDE LAMP DRIVER 70.8FJ05GR01 70.8EF38GR01 70.8FB21GR01 MODULE LVPS 75.8CT02G001 75.8CT01G001 75.8FB01GP01 BLOWER 49.8CS01G002 49.8EF04G001 49.8FB01G001 OPTICAL ENGINE 70.8FJ06GR01...

  • Page 4: Table Of Contents

    Disassemble System Fan Module and Thermal Switch 2-11 Disassemble Speakers 2-12 Disassemble Blower 2-13 Disassemble Front IR Module 2-14 Disassemble LVPS Module and Interlock Switch 2-14 Disassemble Lamp Driver Module 2-15 Disassemble Security Bar Cap 2-15 Disassemble Bottom Shielding 2-16 EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...
  • Page 5 Test Condition Test Inspection Procedure PC MODE Video Performance ADC Calibration 4-11 Optical Performance Measure 4-13 Network Function Test ( For EX542/EX615/EX540/EX762/EX540I/EX542I) 4-15 Others 4-18 Chapter 5 Firmware Upgrade Section 1: System Firmware Upgrade (For EX540/EX542/EX612/EX615/EX762/EX540I/EX542I) Equipment Needed DLP Composer Lite Setup Procedure...
  • Page 6 5-13 NLINK Setup Procedure 5-14 Manley USB Driver Upgrade Procedure 5-16 8051 Firmware Upgrade Prodedure 5-18 Section 4: Network Firmware Upgrade Procedure ( For EX542/EX615/EX540/EX762/EX540I/EX542I) 5-20 Equipment Needed 5-20 Write Down Projector IP 5-21 Network Setting 5-22 PC Hardware Link...
  • Page 7 Equipment Needed (for ES523ST/EW533ST) Setup Procedure (VGA) (for ES523ST/EW533ST) EDID Key-In Procedure (for ES523ST/EW533ST) n Procedure (for ES523ST/EW533ST) (for ES523ST/EW533ST) Setup Procedure (HDMI) (For EX542/EX615/EX540/EX762/EX540I/EX542I) 6-10 EDID Key-In Procedure (HDMI) (For EX542/EX615/EX540/EX762/EX540I/EX542I) 6-10 Appendix A Exploded Image Appendix B Serial Number System Definition...

  • Page 8: Introduction

    Keystone ● �/-40 degree (TI spec.�� �/-40 degree (TI spec.�� Correction ● Native Resolution: 1024 x 7�8 (�or �or EX542/EX612/EX615/EX7�2/EX542I/ EX540/EX540I�� Resolution ● Native Resolution: 800x�00 (�or ES523ST�� ● Native Resolution: 1280x800 (�or E�533ST�� 1280x800 (�or E�533ST�� (�or E�533ST�� ● Full Mode:(Typ��338���(Max��372� @ac 110V ●...
  • Page 9 4:3�� 1�:9�� 1�:10�� Native�� Auto (�or ES523ST/E�533ST�� (�or ES523ST/E�533ST�� ● 180 � OSRAM Lamp E20.8 elliptic (�or EX540/ EX542/EX540I/ EX542I/ ES523ST/E�533ST�� Lamp ● 230 � OSRAM Lamp E20.8 elliptic (�or EX�15/EX�12�� ● 280 � OSRAM Lamp E20.8 elliptic (�or EX7�2��...
  • Page 10 Item Description ● DDP2430(�or EX540/EX542/EX�15/EX�12�� System Controller ● DDP2431(�or EX7�2 �or EX540I/EX542I/ ES523ST/E�533ST�� ● VGA-in: VGA in 1 (wireless dongle�� YPbPr�� VGA in 2 (SCART�� YPbPr�� (�or �or EX540/EX542/EX612/EX615/EX762/EX540I/EX542I) ● VGA-in: VGA-in x 1 (RGB�� (�or ES523ST/E�533ST�� ● Composite: RCA x 1 (�or...

  • Page 11: Compatible Mode

    1280 x 9�0 �0.0 �XGA 1280 x 800 49.�8 SXGA� 1400 x 1050 �3.98 UXGA 1�00 x 1200 MAC LC 13” �40 x 480 ��.�� 34.98 MAC II 13” �40 x 480 ��.�8 MAC 1�” 832 x �24 49.725 EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...
  • Page 12 800 x �00 48.1 800 x �00 4�.9 800 x �00 53.7 1024 x 7�8 48.4 1024 x 7�8 5�.5 1024 x 7�8 1024 x 7�8 �8.7 1280 x 7�8 �0�� 75�� 85 47.8 �XGA 1280 x 800 49.�4 EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...
  • Page 13 1280 x 1024 �3.98 1280 x 1024 79.98 1280 x 1024 91.1 SXGA� 1400 x 1050 �3.98 UXGA 1�00 x 1200 Note: If the Computer Compatibility supportive signal is different from User's Manual, please refer to User's Manual. EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...

  • Page 14: 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. - The disassembly process for EX542/EX612/EX615/EX540/EX762/EX540I/EX542I/ ES523ST/EW533ST is the same , we take EX615 as an example here.

  • Page 15: Disassemble Lamp Cover Module

    1. Loosen 2 screws (as red circle) on the Lamp Cover. 2. Disassemble the Lamp Cover Module. 2-3 Disassemble Lamp Module 1. Loosen 2 screws (as red circle) on the Lamp Module. 2. Take off the Lamp Module. EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...

  • Page 16: Disassemble Focus Ring

    Ring can be well adjusted. 2-5 Disassemble Top Cover Module 1. Unscrew 2 screws (as red circle) from the Bottom Cover. 2. Press two sides of the projector as the blue arrows point. 3. Remove the Top Cover Module. EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...

  • Page 17: Disassemble Keypad Board Module And Zoom Ring

    1. Unscrew 4 screws (as blue circle) to disassemble the Keypad Board Module from the Top Cover Module. 2. Separate the Keypad from the Top Cover Module. 3. Unscrew 3 screws (as red circle) to disassemble the Zoom Ring. Keypad Board Keypad Zoom Ring EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...

  • Page 18: Disassemble Top Shielding

    2-8 Disassemble Main Board Module 1. Unplug 1 connector (as green square) to remove the FPC cable. 2. Unplug 8 connectors (as yellow square). 3. Unscrew 5 screws (as red circle) from the Main Board Module. FPC cable EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...
  • Page 19 IO Cover. 6. Unplug 1 connector (as orange square). 7. Separate the Main Board Module and Main Board Shielding. Note: - Make sure cables plug into the correct ports when assembling the unit. Main Board Shielding EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...
  • Page 20 System Fan Wire (3 pin) Compose of Red/Black/White Photo Sensor Wire and Black wire tube (3 pin) Compose of Black/Yellow/Red Blower Wire and Blue wire tube (3 pin) Compose of Black/Yellow/Red Wire and Gray wire tube (3 pin) EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...

  • Page 21: Disassemble Daughter Board And Lan Module Board

    1. Unscrew 2 screws (as green circle) to disassemble the Daughter Board. 2. Unscrew 1 screw (as red circle) to disassemble the Lan Module Board. Daughter Board Lan Module Board 3. Unscrew 3 hex screws (as yellow circle) from the Main Board Module. EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...

  • Page 22: Disassemble Engine Module

    Color Wheel Module. 2. Unscrew 1 hex screw (as green circle). 3. Unscrew 1 screw (as blue circle) to disassemble the Photo Sensor Board from the Color Wheel Module. Note: - Avoid touching the glass parts of color wheel. EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...

  • Page 23: Disassemble Dmd Chip And Dmd Board

    - Please notice the Rod Module’s direction when you assemble it (as picture A shown). - Ensure left edge of Rod Module contact with the Engine base’s blocks. - Rod Spring must hook in the position as picture B shown. EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 2-10...

  • Page 24: Disassemble System Fan Module And Thermal Switch

    System Fan Module. 3. Unscrew 1 screw (as blue circle) and unplug 1 connector (as green square) to disassemble the Thermal Switch. Thermal Switch 4. Unscrew 4 screws (as green circle) to separate Fan and Fan Shielding. Fan Shielding EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 2-11...

  • Page 25: Disassemble Speakers

    Note: - Take the Fan Module as the right gesture. the wrong gesture the right gesture 2-15 Disassemble Speakers 1. Unscrew 4 screws (as yellow circle) to disassemble the two Speakers. EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 2-12...

  • Page 26: Disassemble Blower

    2. Unscrew 4 screws (as red circle) to separate the Speaker Holder and Speaker. (Same procedure for the other Speaker) 2-16 Disassemble Blower 1. Unscrew 2 screws (as red circle) to disassemble the Blower Module. 2. Separate Blower and Blower Rubber. EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 2-13...

  • Page 27: Disassemble Front Ir Module

    Module and Interlock Switch 1. Unscrew 6 screws (as yellow circle). 2. Unplug 1 connector (as blue square). 3. Disassemble the LVPS Module, the AC Inlet Bracket and Mylar. 4. Unscrew 1 screw (as green circle). AC Inlet Bracket EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 2-14...

  • Page 28: Disassemble Lamp Driver Module

    6. Disassemble the Interlock Switch and the cable from the LVPS Module. Interlock Switch 2-19 Disassemble Lamp Driver Module 1. Unscrew 1 screw (as red circle) to disassemble the Lamp Driver Module. 2. Unplug 3 connectors (as yellow square). EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 2-15...

  • Page 29: Disassemble Security Bar Cap

    3. Separate the Lamp Driver Module and Lamp Driver Holder. Lamp Driver Holder 2-20 Disassemble Security Bar Cap 1. Unscrew 1 screw (as red circle) to disassemble the Security Bar Cap and Security Bar. EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 2-16...

  • Page 30: Disassemble Bottom Shielding

    2-21 Disassemble Bottom Shielding 1. Unscrew 2 screws (as red cricle) to disassemble the Bottom Shielding. 2-22 Disassemble IO Cover 1. Unfasten 2 tenons (as green square). 2. Remove the IO Cover. EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 2-17...

  • Page 31: Rod Adjustment

    Z type driver Note: - To avoid over adjusting the rod. - After the opreation, please use the glue to fix the screws. - Please use Z type driver to adjust Rod screw 1. EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 2-18...

  • Page 32: Re-Write Lamp Usage Hour

    "Lamp Hours (Normal)". 4. Exit Service Mode - Use "up" or "down" buttons to select "Exit", then press "Enter" to exit the Service Mode. Note: left key = decrease lamp hour right key =increase lamp hour EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 2-1...

  • Page 33: Led Lighting Message

    Power on (Warming) (Green) Power on and Lamp lighting (Green) Flashing Power off (Cooling) (Green) Error Flashing (Lamp failed) (Amber) (Red) Error Flashing Flashing (Fan failed) (Amber) (Red) Error Flashing (Over Temp.) (Amber) (Red) Note: Steady light No light EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...

  • Page 34: Main Procedure

    Temp LED (lights red) - Check Thermal Switch - Check Fan - Check Main Board c. Fan Fail: ON/STANDBY LED (flashes amber); ON/STANDBY LED (flashes amber); LED (flashes amber); Temp LED (Flashes red) - Check Fan - Check Main Board EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...
  • Page 35 - Check Color Wheel Mechanical Noise - Check Fan Module - Check whether the Main Board and the DMD Board are assembled properly - Check Main Board Line Bar/Line Defect - Check DMD Board - Check DMD Chip EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...
  • Page 36 - Clean DMD Chip and Engine Module (Out of spec.) - Check DMD Chip - Check Engine Module - Ensure that the signal cables and source work as well Garbage Image - Check Main Board - Check DMD Board EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...
  • Page 37 - Check Daughter Board - Ensure you have set up the right IP address and the Network Fail (for connection is OK (Network green LED should light up) EX542/EX615/ EX540/EX762/ - Check Lan Module Board EX540I/EX542I) - Check Main Board EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...
  • Page 38 - Ensure the using 3D glasses is good and you must face the projection. 3D Image Abnormal - Ensure the signal source is 3D format. (for EX762/EX540I/ - Ensure the 3D function of projector OSD is on and 3D sync EX542I/ES523ST/ EW533ST) invert is on. - Check main board. EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...

  • Page 39: Function Test & Alignment Procedure

    - Minolta CL-100 - Quantum Data 802B or CHROMA2327 (Color Video Signal & Pattern Generator) 4-2 Service Mode - EX542/EX612/EX615/EX540/EX762/EX540I/EX542I/ES523ST/EW533ST have two kinds of Service Mode, use different ways to get into each Service Mode: 1. Turn on the projector 2.

  • Page 40: Test Condition

    After setting up the time, choose ''Enter to Burn-In'' and press Enter button Screen Defects (While replacing DMD Chip, DMD Board and Main Board) 12.5 cm Frame Zone C Zone B 12.5 cm < Figure: Zone A, Zone B & Frame(as green line) Definition, Active area=Zone A+ Zone B > EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...

  • Page 41: Defect Specification Table

    Blue 60 pattern (diameter <1/2 inch) A+B≤2 Bright blemish (Dirty) Gray 10 pattern (diameter <1/2 inch) Bright dots on frame Gray 10 pattern ≤1 For EX542/EX612/EX615/EX540/EX540I Order Symptom Pattern Criteria Bright pixel ( dots) Any pattern A+B=0 Dark pixel(dots) Any pattern A+B≤4...

  • Page 42: Test Inspection Procedure

    OSD Reset EDID Re-write Lamp Hour Usage Rod adjustment Factory RPM Save Note: - If Color appears abnormal after changing Main Board/Color Wheel Module, please do Color Wheel index adjustment. - After changing parts, check the information above. EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...

  • Page 43: Pc Mode

    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 1024 x 768 (for EX542/EX612/EX615/EX762/EX542I/EX540/EX540I) analog 800 x 600 @60Hz (for ES523ST))
  • Page 44 - White pattern (IRE=100) - Adjacent dark pixel. White pattern Criteria - The number of the dead pixels should be less or equal to 4 pixels. - Adjacent pixel with each other is unacceptable. Note: The defect criteria follows TI specification. EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...
  • Page 45 Full screen of the display pattern.(Blur word on one of the corner after adjustment is acceptable. However, the word should at least be recognizable.) EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...

  • Page 46: Video Performance

    - If color appears abnormal, please get into ser- vice mode 1 to do color wheel index adjustment. 4-8 Video Performance 1. CVBS Procedure - Test equipment: DVD player - Test signal: CVBS Inspection item - Video performance test Motion video EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...
  • Page 47 - Check any abnormal color, line distortion or any noise on the screen. - Check the sound from speakers. - Check whether "freeze" and "mute" are normal. - Press "V Keystone" on remote controller, check whether keystone function is normal. EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...
  • Page 48 - Adjust the volume to "5→ 10" by using the remote controller. - Check the sound from speakers. - Check whether the "mute" is normal. Note: EX542/EX615/EX540/EX762/EX540I/ EX542I have 3 Audio. In ports for different input signals. To test each Audio In port, make sure input its correspondent signal.

  • Page 49: Adc Calibration

    - There should not have any lack of SMPTE BAR. - The screen appears normal, it shouldn’t appear any abnormal condition, such as lines and so on. - It is unacceptable that the color appears abnormal and flashing. EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 4-11...
  • Page 50 - The color should appear normal and sort in right order, it is unacceptable that the color appears abnormal and flashing. - Color levels should be sufficient and normal. (the unidentified color levels on both left and right sides should not over 8 color levels.) EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 4-12...

  • Page 51: Optical Performance Measure

    - Use CL100 to measure brightness values of P1~P9. - Follow the brightness formula to calculate brightness values. ☼ Brightness Formula Avg. (P1~P9)*1.1m Criteria • 1000 ANSI lumen (for EX542/EX540/EX540I/EX542I/ES523ST/ EW533ST) • 1400 ANSI lumen (for EX612/EX615/EX762) EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 4-13...
  • Page 52 ☼ Contrast Formula P5/B5 Full black pattern Note: P5=center of white image B5 = the center of black image. Criteria • 1600:1 (for EX540/EX542/EX612/EX615/ EX762/EX540I/EX542I) • 1750:1 (for ES523ST/EW533ST) • 1750:1 (for ES523ST/EW533ST) 1750:1 (for ES523ST/EW533ST) ES523ST/EW533ST) 4. Uniformity...

  • Page 53: Network Function Test ( For Ex542/Ex615/Ex540/Ex762/Ex540I/Ex542I)

    4-11 Network Function Test For EX540/EX542/EX615/EX762/EX540I/EX542I 1. Write Down Projector IP (1) Turn on the Projector, then press "Menu" button to get into OSD Mode. - Use "right" button to select "SETUP". - Use "down" button to remove the light mark to "RS232", then press "Enter"...
  • Page 54 Subnet mask to 255.255.255.0. Note: - The HOST ID (192.168.0.XXX) of PC IP address must be different from the projector IP address written down in step 1 of 4-10. (4) Click "OK". (5) Click "Close" to quit the setting screen. EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 4-16...
  • Page 55 (3) Visit the IP address: "http://192.168.0.100/". - Key in "User Name: Administrator" and "Password: administrator", click "Login" to get into Projector Web Server. (4) Projector information will be shown on the screen. - Please check whether each item's function is OK. EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 4-17...

  • Page 56: Others

    It should be locked in the correct place. Plastic Parts All plastic parts can not be broken and damaged. All safety and warning labels should be visible, Safety or warning label including all contents. All interface connectors should be complete and Connector workable. EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 4-18...

  • Page 57: Firmware Upgrade

    - Library file (library file has to put in PC and set right path in 5-1-5 step 3) Hardware: - Projector - Power Cord: 42.50115G001 - Mini USB Cable: 42.00286G101 - PC or Laptop Note: The FW upgrade procedure for EX612/EX615/EX542/EX540/EX762/EX540I/EX542I is the same ,we take EX542 as an example here. EX540EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...

  • Page 58: Setup Procedure

    1. Choose "DLP Composer Lite V9.2 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". EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...
  • Page 59 5. Click "Next". 6. Click "Next". 7. The program is executing "installing" status. 8. Click "Finish". EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...

  • Page 60: Setup Procedure

    1. Execute Program (1) Connect projector with PC by USB cable. (2) "Found New Hardware Wiszard" picture will appear on the screen. (3) Select "Install the software automatically (Recommended)". (4) Click "Next". (5) Searching picture, please wait for several seconds. EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...

  • Page 61: Firmware Upgrade Procedure

    (6) Click "Finish", then the USB driver has been installed successfully. Note: - If you have installed the USB driver, there is no need to perform this action. 5-1-5 Firmware Upgrade Procedure 1. Execute the "DLP Composer Lite 9.2" file. 2. Click "Edit" and "Perferences". EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...
  • Page 62 - Select "USB". - Click "OK". 5. Choose "Flash Loader". - Click "Browse" to search the firmware file (*.img). - Click "Open". 6. Select "Skip Boot Loader Area". (select "32KB"). - Click "Reset Bus" to erase the flash memory. EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...
  • Page 63 - The projector will automatically turn on. - Unplug USB cable. 10. Check FW version. - Get into the service mode to check the firmware version. (To get into service mode, please press "Power", "Left", "Left" and "Menu" buttons sequentially.) EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...
  • Page 64 - Library file (library file has to put in PC and set right path in 5-1-5 step 3) Hardware: - Projector - Power Cord: 42.50115G001 - RS232 Cable: 42.00272G002 - PC or Laptop Note: The FW upgrade procedure for EW533ST is the same ,we take ES523ST as an example here. EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...

  • Page 65: Dlp Composer Lite Setup Procedure

    - Hold the "Menu" then press "Power" button about 5 seconds then release these two buttons. Note: - The system fan and the lamp will not operate. RS232 port 5-2-4 Firmware Upgrade Procedure 1. Execute the "DLP Composer Lite 9.2" file. EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...
  • Page 66 5. “Serial Port Configuration” picture will appear on the screen. - Make sure the settings are as below: (1) In “Baud Rate” item, select “115200”. (2) In “Data Bits” item, select “8”. (3) In “Stop Bits” item, select “1”. EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 5-10...
  • Page 67 - Click “OK”. 6. Click “OK”. 7. Choose "Flash Loader". - Click "Browse" to search the firmware file (*.img). - Click "Open". 8. Select "Skip Boot Loader Area". (select "32KB"). - Click "Reset Bus" to erase the flash memory. EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 5-11...
  • Page 68 - The projector will automatically turn on. 12. Check FW version. - Get into the service mode to check the firmware version. (To get into service mode, please press "Power", "Left", "Left" and "Menu" buttons sequentially.) EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 5-12...

  • Page 69: Section 3: 8051 Firmware Upgrade Procedure

    - Power Cord: 42.50115G001 - Mini USB Cable - NLINK Cable 2 - NLINK Fixture - PC or Laptop Note: - The 8051 FW upgrade procedure for EX615/EX612/EX542/EX540/EX762/EX540I/EX542I/ ES523ST/EW533ST is the same, we take EX542 as an example here. EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 5-13...

  • Page 70: Nlink Setup Procedure

    5-3-2 NLINK Setup Procedure 1. Choose "setup_NLINK_en.exe" program. 2. Click "Next". 3. Click "Next". 4. Click "Next". EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 5-14...
  • Page 71 - 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. 8. "MCU Choose" picture will appear on the screen. - Close the picture. EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 5-15...

  • Page 72: Manley Usb Driver Upgrade Procedure

    (3) 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". EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 5-16...
  • Page 73 (8) Click "Continue Anyway". (9) Click "Finish". - "Manley TPRP1-Protocol Emulator" will appear on the picture. - Complete the USB Driver Upgrade Procedure. Note: - If "Found New Hardware Wiszard" picture appear again, repeat step 2 to install USB Drivier. EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 5-17...

  • Page 74: Firmware Upgrade

    - Ensure NLlNK Fixture and PC are securely connected: the indicator lights on green, and the state is "Connect" (as blue square). - Select "4MHz-20MHz Crystal" (as green square). - Click "Erase/Write(W)" to execute 8051 FW upgrade. EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 5-18...
  • Page 75 6. Check 8051 FW version - Turn on the unit and get into the service mode to check the 8051 FW version. (To get into service mode, please press "Power", "Left", "Left" and "Menu" buttons sequentially.) EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 5-19...

  • Page 76: Equipment Needed

    5-4-1 Equipment Needed Software: - EX542_LAN Module FW_xxx.bin (*.bin) Hardware: - Projector - Power Cord: 42.50115G001 - LAN Cable - PC Note:The Network FW Upgrade Procedure for EX615/EX542/EX540/EX762/EX540I/EX542I is the same,we take EX542 as an example here. EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 5-20...

  • Page 77: Write Down Projector Ip

    "Enter" button to select "Off", press "Enter" button. - The IP address will be shown on screen. - Write down the IP address: 192.168.0.100. - Ensure the IP address, Subnet Mask, Gateway and DNS are right as the the picture 4 shown. EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 5-21...

  • Page 78: Network Setting

    Subnet mask to 255.255.255.0. Note: - The HOST ID (192.168.0.XXX) of PC IP address must be different from the projector IP address written down in step 4 of 5-3-2. 4. Click "OK". 5. Click "Close" to quit the setting screen. EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 5-22...

  • Page 79: Pc Hardware Link

    - Click "Continue". 3. "Firmware Update" image will appear on the screen. - Click "Browse" button to select the Network FW file (*.bin) which you saved. - Click "Open". - Click "Update" to start updating. 4. Firmware Upgrade procedure. EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 5-23...
  • Page 80 5. Click "Re Login". 6. Firmware upgrade procedure completes. - The projector Network FW version will appear. EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 5-24...

  • Page 81: Edid Introduction

    Board, the display device will show no image while the input source is digital signal. - The EDID Upgrade procedure for EX615/EX612/EX542/EX540/EX762/EX540I/EX542I is the same, we take EX542 as an example here. - The EDID Upgrade procedure for ES523ST/EW533ST is the same, we take ES523ST as an example here.
  • Page 82 - HDMI(M) to DVI(F) Adapter (42.82B13G001) - DVI Cable (42.83N06G001) - Generic Fixture (80.00001.001) for EDID Key-in (Fixture: JP3 must be closed) - RS-232 9 Pin Cable (pin to pin, F-M) (42.83C07G001) - Power Adapter (47.57803G001) - Monitor - PC EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...
  • Page 83 VGA-2 Port Power Port Note: -You must confirm that the JP3 is closed in all procedure. 6-� EDID Key-In Procedure �VGA-1 & VGA-2� ��or E���2�E�61��E����� E��62�E����I�E���2I� 1. Execute EDID Program - Double click "EDID" to execute EDID program. EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...
  • Page 84 (6) In "Write Source Select" item, select "VGA-A" and "VGA-B". (7) Click "Program". �3� ��� ��� ��� �6� 3. Change the cable to VGA-A - When the message "Please change the cable to VGA-A" appears on the screen, click "OK". EX540/EX542/EX612/EX615/EX762EX540I/EX542I/ES523ST/EW533ST Confidential...
  • Page 85 5. When the EDID program is completed, a message "OK" will appear on the screen. 6. Read EDID "VGA-A&VGA-B" information - In "Read item", select "Analog" and "Trans", then click the "Read". 7. EDID information will show the result. EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...
  • Page 86 - Power Cord for Projector (42.53506G002) - VGA Cable (42.87305G102) - Generic Fixture (80.00001.001) for EDID Key-in (Fixture: JP3 must be closed) - RS-232 9 Pin Cable (pin to pin, F-M) (42.83C07G001) - Power Adapter (47.57803G001) - Monitor - PC EX540/EX542/EX612/EX615/EX762EX540I/EX542I/ES523ST/EW533ST Confidential...
  • Page 87 (6) Plug Power Cord to projector. VGA-IN Port Note: -You must confirm that the JP3 is closed in all procedure. Power Port 6-� EDID Key-In Procedure �VGA-1 & VGA-2� ��or ES�23ST�EW�33ST� 1. Execute EDID Program - Double click "EDID" to execute EDID program. EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...
  • Page 88 (6) In "Write Source Select" item, select "VGA". (7) Click "Program". �3� ��� ��� ��� �6� 3. Change the cable to VGA - When the message "Please change the cable to VGA" appears on the screen, click "OK". EX540/EX542/EX612/EX615/EX762EX540I/EX542I/ES523ST/EW533ST Confidential...
  • Page 89 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 information will show the result. EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...
  • Page 90 (5) Plug Power Cord to projector. HDMI Port Note: You must confirm that the JP3 is closed in all procedure. Power Port 6-9 EDID Key-In Procedure �HDMI� ��or E���2�E�61��E����� E��62�E����I�E���2I� 1. Execute EDID Program - Double click "EDID" to execute EDID program. EX540/EX542/EX612/EX615/EX762EX540I/EX542I/ES523ST/EW533ST Confidential 6-10...
  • Page 91 (6) In "Write Source Select" item, select "HDMI". (7) Click "Program". �3� ��� ��� ��� �6� 3. Change the cable to HDMI - When the message "Please change the cable to HDMI" appears on the screen, click "OK". EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 6-11...
  • Page 92 4. When the EDID program is completed, a message "OK" will appear on the screen. 5. Read EDID "HDMI" information - In "Read item", select "Digital" and "Trans", then click the "Read". 6. EDID information will show the result. EX540/EX542/EX612/EX615/EX762EX540I/EX542I/ES523ST/EW533ST Confidential 6-12...
  • Page 93 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. EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...
  • Page 94 ASSY LAMP COVER BLACK EX615 (SERVICE) 51.8EG03G011 LAMP COVER BLACK EX615 61.00018G002 LOCK SCREW PAN MECH M3*8.5-3.5 BLACK SP.8EF01GC01 LAMP MODULE FOR PROJECTOR EX542 SP.8EG01GC01 LAMP MODULE FOR PROJECTOR EX615/EX612 41.83M06G001 EMI TAPE W30*L70mm 85.1A123G050 SCREW PAN MECH M3*5 Ni 85.00823G080...
  • Page 95 Assy TOP COVER MODULE EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...
  • Page 96 TOP COVER ASSEMBLY EX615 51.8EG14G011 KEYPAD PLATE ENTER EX612 80.8EF03G001 PCBA KEY PAD BOARD FOR EX615 85.1A123G050 SCREW PAN MECH M3*5 Ni 85.1A123G050 SCREW PAN MECH M3*5 Ni 85.41BA6G060 FLAT SCERW M2.6*6 Flat Thickness1.1mm 51.8EG11G001 ZOOM RING DUST COVER HD20 EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...
  • Page 97 ASSY BOTTOM COVER MODULE EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...
  • Page 98 Parts Supply ASSY BOTTOM COVER MODULE FOR EX615 70.8EF37GR01 (SERVICE) 51.8EG01G011 BOTTOM COVER MN3600H BLACK EX612 ASSY OSRAM LAMP DRIVER 230W FOR EX542 70.8EJ01GR01 (SERVICE) ASSY OSRAM LAMP DRIVER 230W FOR EX615 70.8EF38GR01 (SERVICE) ASSY OSRAM LAMP DRIVER O3 MID 230W 75.8BW01G002...
  • Page 99 ASSY MAIN BOARD AND IO BOARD MODULE Item Description Parts Supply 70.8EF09G001 IO BOARD ASSEMBLE EX612 ASSY PCBA MAIN BOARD FOR EX542 70.8EJ03GR01 (SERVICE) 80.8FK01G001 PCBA MAIN BD FOR EX612 ASSY PCBA MAIN BOARD FOR EX615 70.8EF43GR01 (SERVICE) 80.8EF01G003 PCBA MAIN BD FOR EX615 80.8EF07G001...
  • Page 100 ASSY MAIN BOARD MODULE EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential VIII...
  • Page 101 Item Description Parts Supply 70.8EF26G001 MAIN BOARD IO BOARD ASSY EX612 61.8EG02G011 MAIN BOARD SHIELDING EX612 ASSY IO COVER MODULE FOR EX542 70.8EJ04GR01 (SERVICE) ASSY IO COVER MODULE FOR EX612 70.8FK02GR01 (SERVICE) ASSY IO COVER MODULE FOR EX615 70.8EF44GR01 (SERVICE) 51.8EG10G011...

  • Page 102: Ex540/Ex542/Ex612/Ex615/Ex762/Ex540I/Ex542I/Es523St/Ew533St Confidential

    ASSY OPTICAL ENGINE MODULE EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...
  • Page 103 Item Description Parts Supply 23.8BA01G001 PROJECTION LENS YM25 70.8EG18G001 ASSY RELAY MODULE HD20 ASSY OPTICAL ENGINE MODULE EX542 70.8EJ02GR01 (SERVICE) ASSY OPTICAL ENGINE MODULE EX612 70.8FK03GR01 (SERVICE) ASSY OPTICAL ENGINE MODULE EX615 70.8EF40GR01 (SERVICE) 23.8AH20G011 YO CONDENSER 1 FOR A15W 85.1A526G060...
  • Page 104 PCBA PHOTO SENSOR BOARD FOR EX615 YO 5S R76Y32G78W98B76 CW (WITH FTZS MO- 23.8EF19G101 TOR) 85.1A126G040 SCREW PAN MECH M2.6*4 Ni TAPE 3M J350 10*5mm FOR COLOR WHEEL 51.82Y29G001 DP715 52.83615G001 COLOR WHEEL DISC RUBBER, EzPro755 61.83628G001 COLOR WHEEL SHOULDER SCREW,EzPro755 EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...
  • Page 105 ASSY BlOWER MODULE Item Description Parts Supply SUNON 45*20mm GB1245PKVX-8 F-TYPE 49.8EF04G001 BLOWER (EX542) SUNON 45*20mm GB1245PKVX-8 F-TYPE 49.8EF04G001 BLOWER (EX612/EX615) 52.89T01G001 BLOWER AIR TIGHT F12 H5350 52.82G08G001 BLOWER 4520 RUBBER EP7190 EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential XIII...
  • Page 106 85.1A123G080 PAN SCREW M3*8 FOR YM-64 FRONT CELL&SP 85.1A123G060 SCREW PAN MECH M3*6 NI THERMAL SWITCH WITH BRACKET (KLIXON 43.8EF17G001 YS11) EX542 85C (EX542) THERMAL SWITCH WITH BRACKET (KLIXON 43.8EG17G001 YS11) HD20 100C (EX612/EX615) 85.1A123G040 SCREW PAN MECH M3*4 Ni 51.81540G001...
  • Page 107 A.K. EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...
  • Page 108 36.8EF02G001 EX542/EX612/EX615 USER’S GUIDE MULTILINGUAL (CD) OPTOMA 36.8FK01G001 EX612 USER’S GUIDE MULTILINGUAL (CD) OPTOMA 36.8EF01G001 EX542/EX615 WARRANTY CARD 3 YEARS, USA FOR OPTOMA 36.00012G002 LPP SERIES EXTENDED WARRANTY ; REGISTRATION 36.00018G001 FORM,USA FOR LPP SERIES 46.80S01G101 BATTERY #7 1.5V NOVACELL 51.00200G001...
  • Page 109 AAAAA = not-defined C = Manufacture factory (TW or China) 0001 = Serial Code EX: Q8FJ915AAAAAC0001 This label "Q8FJ915AAAAAC0001" represents the serial number for EX542. It is produced at CPC on ffifteenth of 2009. Its serial code is 0001. EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...
  • Page 110 II. PCBA Code Definition PCBA Code for Projector XXXXXXXXXX EEEE Vendor Code Revision Date Code EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential...

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