Optoma HD33 Service Manual
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Optoma HD33 Service Manual

Projection system
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SERVICE MANUAL

HD33
Date
Revise Version
Description
2011.08.17
V1.0
Initial Issue
Copyright Aug. 2011. All Rights Reserved
Amy
Prepared:
Check:
Approved:
Mina

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Summary of Contents for Optoma HD33

  • Page 1: Service Manual

    SERVICE MANUAL HD33 Date Revise Version Description 2011.08.17 V1.0 Initial Issue Copyright Aug. 2011. All Rights Reserved Prepared: Check: Approved: Mina...
  • Page 2 Preface This manual is applied to HD33 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: Table Of Contents

    Function Test & Alignment Procedure Test Equipment Needed Test Condition I/O Port Test Run In Test Test Inspection Procedure ADC Calibration 4-10 Restore Blower Speed 4-11 Chapter 5 Firmware Upgrade Section 1: Pixelworks for FW Upgrade (USB) Equipment Needed HD33 Confidential...
  • Page 4 Firmware Upgrade Procedure Section 3: 8051 FW Upgrade Equipment Needed 8051 Firmware Upgrade Procedure 5-10 Check 8051 FW version 5-11 Chapter 6 EDID Upgrade EDID Upgrade Procedure Appendix A Exploded Image Appendix B Serial Number Definition PCBA Code Definition HD33 Confidential...

  • Page 5: Chapter 1 Introduction

    ● HDTV: 720p(50/60Hz), 1080i(50/60Hz),1080p(24/50/ 60Hz) ●3D Timing: HDMI1.4A/1.3 ● VGA (D-Sub 15pin) x1 Input signal spec ● HDMI x 2 (Version1.4A) ● YPbPr ( 3 RCA ) x 1 ● Operating: 0~2,500 ft 5°C~35°C Altitude&Temperature 2,500~5,000 ft 5°C~30°C 5,000~10,000 ft 5°C~25°C Confidential HD33...

  • Page 6: Compatible Mode

    ○ ○ 1152 x 864 ○ ○ HD720 1280 x 720 ○ ○ HD720 1280 x 720 ○ ○ HD720 1280 x 720 ○ ○ WXGA 1280 x 768 47.4 ○ ○ WXGA 1280 x 768 ○ ○ Confidential HD33...
  • Page 7 ○ ○ SDTV 720 x 480 31.5 － － 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. Confidential HD33...

  • Page 8: Disassembly Process

    * 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. HD33 Confidential...

  • Page 9: Repair Notice

    2. Press two sides of the projector and push them as the blue arrow. 3. Remove the Top Cover Module. 2-1-2 Disassemble Main Board 1. Unscrew 11 screws (as red circle). 2. Unplug 9 connector (as green square). HD33 Confidential...
  • Page 10 3. Unscrew 6 screws (as blue circle). 4. Unplug 1 connector (as yellow square). 5. Disassemble Main Board,Scaler Board and Main Board Shielding. Formatter BD Main BD HD33 Confidential...
  • Page 11 Yellow/Red Wire and Gray tube(3 pin) Compose of Black/ White/Red Wire, Red Photo Sensor BD Connector and Black tube(3 pin) Compose of Black/ White/Red Wire, Lamp Blower White Connector (3 pin) Black wire tube (5 Lamp driver pin) HD33 Confidential...
  • Page 12 Black wire tube (8 Main Board pin) 2-1-3 Disassemble System Fan Module . Unscrew 4 screws (as red circle) to disassemble the System Fan Module. Note: You should disassemble the System Fan Module first before the Engine Module disassembly. HD33 Confidential...

  • Page 13: 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. HD33 Confidential...

  • Page 14: Re-Write Lamp Usage Hour

    - Use “up” or “down” buttons to select “ Factory reset”,then use “left” or “right” buttons to re-write the lamp hour(ECO). 4. Choose “Exit”, press “Enter” to exit Note: left key = decrease lamp hour right key =increase lamp hour HD33 Confidential...

  • Page 15: Repair Action

    Firmware Update Color Wheel Chapter Index 4-3-1.7 OSD Reset Chapter 4-5.2 Video Chapter Calibration Chapter Calibration EDID Chapter 6 Re-write Lamp Chapter 2-3 Hours Usage Video chapter -3-2 Performance Restore Blower Chapter 4-7 Speed Optical Chapter Performance -3- Measure HD33 Confidential...

  • Page 16: Chapter 3 Troubleshooting

    (Red) (Orange) Standby State (input power cord) Power on (Warming) Flashing Power on and Lamp lighting Power off (Cooling) Flashing Error Flashing (Lamp failed) Error Flashing Flashing (Fan failed) Error Flashing (Over Temp.) Note: Steady light No light HD33 Confidential...

  • Page 17: Main Procedure

    PC can support 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. HD33 Confidential...

  • Page 18: Function Test & Alignment Procedure

    Circumstance brightness: Dark room less than 2 lux. - Product must be warmed up for 3 minutes. - Screen size: 60 inches diagonal. Zone Definition Frame < Figure: Zone A, Zone B & Frame (as green line) Definition, Active area=Zone A+ Zone B > Confidential HD33...

  • Page 19: Vga Port Test

    4-3 I/O Port Test 4-3-1 VGA Port Test Note:HD33 the native resolution of test signal is 1920 x 1080@60HZ. 1. Frequency and tracking boundary Procedure - Test equipment: video generator. - Test signal: analog 1�20 x 1080�60Hz - Test Pattern: general-1 or master...
  • Page 20 10 pattern in zone A and no more than 4 bright blemish in zone B. - Ref. Defect specification table 5. Dark Blemish Procedure - Test equipment: video generator. - Test signal: analog 1�20 x 1080�60Hz Blue 60 Confidential HD33...
  • Page 21 (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. - Test signal: 1�20 x 1080�60Hz, 1080i �60Hz, 1080i - Test Pattern: Master, 64 gray RGBW Master Confidential HD33...

  • Page 22: Optical Performance

    Procedure - Please get into OSD menu, select “Lamp Setting” under “Options”, press “Enter” button, then select “Bright” of “Bright mode”. - Press “Power off→ Left→ Left→ UP” to get into service mode. - Test equipment:Select “Spoke Test” Confidential HD33...
  • Page 23 B5 = Lux of center in full black pattern Criteria • 1300:1 d. Uniformity Procedure - Full white pattern - Use CL100 to measure brightness values of P1~P� (see image: full white). - Follow the Uniformity formula to calculate Full white pattern Confidential HD33...

  • Page 24: Video Port Test

    - Test signal: 720p, 1080p, 1080i Inspection item - HDMI performance test. Inspection Distance - 1.4 M ~1.5 M. Criteria - Ensure the image is well performed and the color can not discolor. - Check whether "mute" is normal. Confidential HD33...

  • Page 25: Run In 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 HD33...

  • Page 26: Test Inspection Procedure

    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 enter OSD menu. (2) Choose "SetUp" and then execute "Reset" function Confidential HD33 4-�...

  • Page 27: Adc Calibration

    Adjustment”, and choose “YUV Calibration”. Inspection item - Color saturations Criteria - There should not have any lack of SMPTE BAR.Color levels should be sufficient and normal. - There is not any abnormal lines on the image. Confidential HD33 4-10...

  • Page 28: Restore Blower Speed

    “Blower Factory RPM” (as Picture A shown). Note: - If the Factory FAN RPM Value doesn’t show in service mode, please repeat the step again. - Make sure the “� Blower Factory RPM�� is 4204-4836. Picture A Confidential HD33 4-...

  • Page 29: Firmware Upgrade

    Chapter 5 Firmware Upgrade Section 1: PW980 for FW Upgrade (USB) 5-1-1 Equipment Needed Software: (PW980) - HD33_PW980 FW_xxx Hardware: - Projector - Power Cord: 42.50115G001 - USB Cable mini USB to USB (A) (42.00284G001) - PC or Laptop HD33 Confidential...

  • Page 30: Setup Procedure

    1.Click on the “Found New Hardware Wizard”. - Select “Install from a list or special location (Advanced)”. - Click “Next”. 2.Select “Search for the best driver in these locations.” - Choose “Include this location in the search”. - Click “Browse”. HD33 Confidential...
  • Page 31 3. Select the "Windowns-Side usb driver" then click "OK". 4.Wait for several seconds. 5.Click “Finish”. Note: - If “Found New Hardware Wiszard” picture appear again, repeat step 2 to install USB Drivier. HD33 Confidential...

  • Page 32: Firmware Upgrade Procedure

    5-1-4 Firmware Upgrade Procedure 1. Double click the folder ''HD33_PW980 FW_xxx''. 2. Execute "PW980 FlashUpgrader.exe" 3. - Select "HD33.inf" for Flash File. - Select "USB 2.0" for Connection - Select"Notify On Completion" and "Reset Target After Download". - Double click the "u-boot.bin"...
  • Page 33 5. When “uImage” downloads compeletly, “Downloading :root.cramfs” will running automatically. 6. When message "Flash Completed" appears, click "OK". 7. Press “Power off”, “Left”, “Left” and “Up” button to get into service mode to check firmware version. HD33 Confidential...

  • Page 34: Equipment Needed

    Section 2: PA131 for FW Upgrade (RS232) 5-2-1 Equipment Needed Software: (PA131) - HD33_PA131 FW_xxx Hardware: - Projector - Power Cord: 42.50115G001 - RS232 Cable 9PIN to 9PIN: 42.85H02G001 - PC or Laptop HD33 Confidential...

  • Page 35: Firmware Upgrade Procedure

    - Select “Serial” for Connection. - Select the COM Port which you are using. - Select “38400” for Baud Rate. - Select"Notify On Completion" and "Reset Target After Download". - Choose “PA131.inf” for Flash File. - Click “Flash” button,then press “Power” button. HD33 Confidential...
  • Page 36 7. When “FlasherBoot.hex” downloads completely, “Downloading Appcode.hex” will running automatically. 8. When message “Flash Completed” appears, click “OK”. 9. Press “Power off”, “Left”, “Left” and “Up"button on remote controller to get into service mode to check firmware version. HD33 Confidential...

  • Page 37: Section 3: 8051 Fw Upgrade

    Section 3: 8051 FW Upgrade 5-3-1 Equipment Needed Software: (N79A901R-USB) - Setup _NLINK_en - Manley USB Driver_NLINK - xxx_8051_xx.hex Hardware: - Projector - Power cord: 42.50115G001 - USB Cable mini USB to USB (A) (42.00284G001) - NLINK Fixture - PC or Laptop HD33 Confidential...

  • Page 38: 8051 Firmware Upgrade Procedure

    “Connect” (as blue square). - Select “Brownout Level 3.8V” (as green square). - Select “Internel RC(22.1184MHz)” (as green square). - Click “Erase" then press"Write(W)” to execute 8051 Note: Another contents please refer to common service manual 5-Section 4. HD33 Confidential 5-0...

  • Page 39: Check 8051 Fw Version

    5-3-3 Check 8051 FW version 1. Restart the unit and enter the Service Mode (Press Power off --> Left --> Left--> up). 2. The firmware version will be shown as red circle on the screen. HD33 Confidential 5-...

  • Page 40: 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. HD33 Confidential...

  • Page 41: Appendix A Exploded Image

    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. HD33 Confidential...
  • Page 42 6.8EG4G00 EMISPRINGHD0 85.A6G040 SCREWPANMECHM2.6*4Ni SUNON855AXIALFANLOWROTATINGSPEED 49.8KZ0G0 WITHLINELENGTH50MM/RoHS.0 85.0A33G030 SCREWP/FMECHM3*L3BLACK 85.3A6G060 NEWSCREWM=.6D=.48-.58L=6 .0束尾2 .0MM 6.8KZ08G00 MAINBOARDTOPSHEETMETAL0.3T 6.8KZ0G00 SIDEMESHHD33 85.0A3G040 SCREWP/FMECHM3*4Ni 5.0000G00 CABLETIEPG-YJ-80 5.854G00 TAPE3MJ35017*30mm 70.8KZ06G00 TOPCOVERASSEMBLYWHITE 85.A3G080 PANSCREWM3*8FORYM-64FRONTCELL&SP 70.8KZ0G00 ASSYORSAME0.880WLAMPMODULEHD33 70.8KZ9GR0 ASSY LAMP COVER MODULE 8KZ WHITE(SERVICE) 5.8KZ04G00 WHITELAMPCOVERHD33 HD33 Confidential...
  • Page 43 Parts Item Description Supply 6.0006G00 LOCKSCREWPANMECHM3*8.5-3.5Ni 5.8KZ4G00 LEFTVENTHD33 5.8KZ8G00 TOPIRMYLARBLACK 5.8KZ0G00 TOPPROTECTIVEFILMHD33 6.8KZ03G00 DUAL855FANSHIELDINGHD33 70.8KZ0G00 FOCUSRINGASSEMBLYWHITE 5.8KZ08G00 FANSHIELDINGTOPSPONGEHD33 HD33 Confidential...
  • Page 44 Assy Main Board Confidential HD33...
  • Page 45 Parts Item Description Supply 80.8KZ06G00 PCBAFORMATTERBOARDFORHD33PROJECT 80.8KZ0G00 PCBAMAINBOARDFORHD33PROJECTOR 6.00074G00 HEXSCREWL=18.4M3-M3Ni5100MP 85.F3G060 SCREWPANMECHW/SFM3*6NiGREEN 5.8KZ04G00 FORMATTERLIGHTLEAKSPONGE 5.8KZ05G00 SCALARBDLIGHTLEAKSPONGE 5.8KZ5G00 MAINBDBOTTOMMYLAR HD33 Confidential...
  • Page 46 Assy Engine Module Confidential HD33...
  • Page 47 70.8EGG00 ASSYENGINEBOTTOMHD0 3.8CV0G00 PROJECTIONLENSYM40 6.8EG0G0 DMDHEATSINKAL6063HD33 5.8CG4G00 THERMALPAD/XR-Hj18.5x14.5x0.5mm 6.8FC0G00 DMDLIGHTMASKEH00 6.886G00 DMDSCREWIvy10X 5.000G00 DMDSCREWWASHERA39 48.8EG0G00 DMD90*080PIXEL0.65"080PxLVDSDCTYPEA .009F0G007 CNNTF03PFOR70PLGADMDSOCKETPE0033- 03040-0;FOXCO 5.8540G00 TAPE3MJ35017*60mm 3.8AH0G00 CONDENSERFORA5W 3.8AH0G00 CONDENSERFORA5W 5.8EG34G00 DMDINSULATIONSLICEHD0 6.8AH08G00 DMDPLATEALA606M409WX 6.8GV0G00 RODCOVERA15WEW330e 6.8EG8G00 RODSPRINGSUS30HD0 5.80J0G00 DMDANTIDUSTRUBBER739SILICONERUBBER 80.8KZ0G00 PCBADMDBOARDFORHD33PROJECTOR 85.A56G060 SCREWPANMECHM2.6*6NiNYLOK HD33 Confidential...
  • Page 48 Parts Item PN Description Supply 6.8AH3G00 DMDHEATSINKSPRINGSUS304M409WX 6.8597G00 DMDSHOULDERSCREWSB 6.8EG5G00 STEPSCREWMx4FORYM40LENS 6.8KZ05G00 DMDBOARDBRACKETHD33 5.8EG33G00 3MTAPEA5WENGINEBASEHD0 5.8KZ07G00 ENGINETOPSPONGEHD33 6.8KZ03G00 DUAL855FANSHIELDINGHD33 70.8KZ0G00 FOCUSRINGASSEMBLYWHITE 5.8KZ08G00 FANSHIELDINGTOPSPONGEHD33 Confidential HD33...
  • Page 49 Assy IO Cover Module Parts Item Description Supply ASSY IO COVER MODULE 8KZ 70.8KZ8GR0 WHITE(SERVICE) 75.8KZ0G00 IOCOVERASSYWHITEHD33 80.8KZ03G00 PCBAPOWERLEDBDFORHD33PROJECTOR 85.0A3G040 SCREWP/FMECHM3*4Ni 35.8KZ0G00 REARIOLABELHD33WHITE 4.005E0G00 WIREPOWERBOARDTOMAINBOARD50MM HD33 Confidential...
  • Page 50 Assy Top Cover Module Parts Item Description Supply 75.8KZ0G00 TOPCOVERWHITEHD33 5.8EG09G00 ZOOMRINGHD0 5.8KZ9G00 ZOOMRINGTEFLONHD33 85.A3G050 SCREWPANMECHM3*5Ni 5.8KZG00 ZOOMRINGCOVERBLACK Confidential HD33...
  • Page 51 Assy Lamp Module HD33 Confidential...
  • Page 52 LAMPCLAMPTOPP66 6.8BA07G00 LAMPCLAMPBOTTOMP66 6.8KZ06G00 LAMPHOLDERMESHOUTLETHD33 6.8KZG00 LAMPLIGHTCUTHD33 6.8KZG00 LAMPBLOWERDUCTHD33 6.8EE8H00 LAMPDUCTBACKFOILALADC-H7530 6.8EE9H00 LAMPDUCTCAPH7530 5.8KZ0G00 LAMPLIGHTCUTRUBBERHD33 6.0008G003 LOCKSCREWPANMECHM3*8.5- 3.5BLACK(08+HEATTREATMENT) 6.80L06G00 UVIRSPRINGPLATESUS3080L 6.86808G00 LAMPCHANGERHANDLESUS3041.6dDP725F ORCPC 3.88N0G00 UV-IR24*25*2mm(5*5mmcut)_AddDotinkmark- Oerlikon 4.0043GG00 W.A.P#MALE6KV0 0度 C140mmFORLAMPVP22 85.0A6G040 SCREWDOUBLEFLATMECHM2.6*4Ni 85.A66G040 SCREWPANMECHM.6*4BLACKNYLOK 85.A66G050 SCREWPANMECHM.6*5BLACKNYLOK 85.3AG040 SCREWCAPMECHM2*4Ni Confidential HD33...
  • Page 53 Assy Color Wheel Module Parts Item Description Supply ASSYCOLORWHEELMODULE8KZR6G64B54R6 70.8KZ6GR0 G64B54(SERVICE) 3.8EG9G03 ASSYCOLORWHEELMODULEHD33 6.8EG06G00 D4COLORWHEELHOLDERHD0 6.8EG07G00 D4CWHOLDERCOVERHD0 5.8365G00 COLORWHEELDISCRUBBER,EzPro755 6.8368G00 COLORWHEELSHOULDERSCREW,EzPro755 5.8Y9G00 PCBAPHOTOSENSORBOARDFORHD0 PCBAPHOTOSENSORBOARDFORES56XPROJE 80.8LP04G00 PHOTOSENSORCOVERHOLDERPCLN- 5.8HH08G00 50AUF65 54.8HH0G00 PHOTOSENSORCOVERGLASSUF65 85.A56G060 SCREWPANMECHM2.6*6NiNYLOK HD33 Confidential...
  • Page 54 Assy Bottom Cover Module Confidential HD33...
  • Page 55 Parts Item Description Supply 5.8KZ0G00 WHITE BOTTOM COVER HD33 70.8EG4G00 ASSY FRONTIR MODULE HD0 DELTA45*10mm/WIRE LENGTH 180mm 49.8JF0G00 BLOWER 5.8KZ3G00 450 BLOWER DUCT HD33 85.A6G060 SCREW PAN MECH M2.6*6Ni 85.A6G040 SCREW PAN MECH M2.6*4Ni 6.8KZ0G00 BOTTOM SHIELDING HD33 85.A3G050 SCREW PAN MECH M3*5Ni 4.83J0G00...
  • Page 56 Confidential HD33...
  • Page 57 CABLE POWER CORD 1830mmSP30+IS14;BC- SP.870GC0 PUPIXY0 4.505G00 CABLE POWER CORD .8M SP30+IS4 US CABLEPOWERCORD1830mmSP30+IS14;BC- SP.80N03GC0 PUPIXY0 35.800G AK LABEL 3”*3” BLANK 36.0004G00 WARRANTYCARDUSFORLPPSERIES,YEAR 36.8KZ0G00 USER’SGUIDEMULTILINGUAL(CD)HD33 INSTRUCTIONCARD(OPTOMA)- 36.00040G0 BEFORERETURNFORPICO 45.8KZ0G00 REMOTECONTROLFORHD33PROJECTOR SP.8KZ0GC0 REMOTECONTROLFORHD33 46.80S0G0 BATTERY#7.5VNOVACELL PEBAGZIPPER33cm*25cmSIZEGREENFOROP 5.0007G003 TOMA AK.8KZ0GC0A A.K.HD33FORAMERICA HD33...

  • Page 58: Serial Number Definition I

    = 15) AAAAA = not-defined C = Manufacture factory 0001 = Serial Code EX: Q8KZ115AAAAAC0001 This label "Q8KZ115AAAAAC0001" represents the serial number for HD33. It is produced at CPC on fifteenth of 2011. Its serial code is 0001. HD33 Confidential...

  • Page 59: Pcba Code Definition

    II. PCBA Code Definition PCBA Code for Projector XXXXXXXXXX EEEE Vendor Code Revision Date Code HD33 Confidential...

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