Optoma EP747 Service Manual
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Optoma EP747 Service Manual

Optoma EP747 Service Manual

Projection system
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SERVICE MANUAL

Date
Revise Version
2005/12/13
Model Name : EP747
V1.0
Initial Issue
Copyright December, 2005 . All Rights Reserved
Prepared by SI :
________________________________________
Prepared by TSE :
________________________________________
Checked by :
________________________________________
Approved by :
________________________________________
Description

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  • Page 1: Service Manual

    SERVICE MANUAL Model Name : EP747 Prepared by SI : ________________________________________ Prepared by TSE : ________________________________________ Checked by : ________________________________________ Approved by : ________________________________________ Date Revise Version Description 2005/12/13 V1.0 Initial Issue Copyright December, 2005 . All Rights Reserved...
  • Page 2 Preface This manual is applied to EP747 0.7” DMD XGA digital projection system. It’s the mode of single Panel, 180 Watt Compact P-VIP Lamp and 1024(H) x 768(V) resolution. The manual gives you a brief descrip- tion of basic technical information to help in service and maintaining the product.

  • Page 3: Table Of Contents

    Disassemble Focus Ring, DMD Fan, Speaker, Blower Fan and Elevator Module 2-14 Chapter 3 Troubleshooting Equipment Needed Main Procedure Chapter 4 Function Test and Alignment Procedure Test Equipment Needed Service Mode Test Condition Inspection Procedure Chapter 5 Firmware Upgrade Procedure Equipment Needed Installation Procedure Firmware Upgrade Procedure EP747...
  • Page 4 Chapter 6 EDID Key-in Procedure Equipment Needed Setup Procedure DDC Key-in Procedure Appendix A Exploded Overview Appendix B 7-17 PCBA Code Definition 7-17 Appendix C 7-18 Serial Number System Definition 7-18 Reader’ s Response 7-19 EP747...

  • Page 5: Chapter 1 Introduction

    NTSC/PAL/SECAM video capability with composite and S- Video HDTV video (480i/p, 576i/p, 720p, 1080i) with 480i/576i/1080i deinterlacing Electrical Spec Photocatalysis (O2air) Technology VGA with Audio 1 (could by fixed) 1 audio outRS232/mini connector (not D-Sub9) DVI-I (connector) (accept DVI-Dsignal) with HDCP EP747...

  • Page 6: Mechanical Specification

    - High Altitude fan setting for user setting Tilt Angle 7 degrees with elevator mechanism 1-3 Optical Specification Item Description Single 0.7” 12D DDR DMD XGA Resolution Native 4:3, 1024*768 resolution 2040 lumens (Minimum) Brightness 2550 lumens (Typical) EP747...

  • Page 7: Environment

    37 dB(A) 230W Normal mode. Acoustic 32 dB(A) 180 W ECO-mode. noise level Follow ISO-7779 regulation sound pressure level A weighting measurement -2000 hours typical, 50% survival rate (Full power Mode) Lamp life -4000 hours min, 50% survival rate (Eco Mode) EP747...
  • Page 8 Item Description - Operating 0~2,500 ft 5°C~35°C 2,500~5,000 ft 5°C~30°C Altitude 5,000~10,000 ft 5°C~25°C - Storage 40,000 ft (Max) MTBF 12000 HRs EP747...

  • Page 9: Compatible Mode

    MAC LC 13” 640x480 66.66 34.98 MAC II 13” 640x480 66.68 MAC 16” 832x624 74.55 49.725 MAC 19” 1024x768 60.24 1152x870 75.06 68.68 MAC G4 640x480 31.35 I Mac DV 1024x768 I Mac DV 1152x870 68.49 I Mac DV 1280x960 EP747...
  • Page 10 640x400 37.9 640x480 31.5 640x480 37.9 640x480 37.5 640x480 43.3 720x400 31.5 720x400 37.9 SVGA 800x600 35.2 800x600 37.9 800x600 48.1 800x600 46.9 800x600 53.7 1024x768 48.4 1024x768 56.5 1024x768 60.0 1024x768 68.7 SXGA 1280x1024 63.98 SXGA+ 1400x1050 63.98 EP747...

  • Page 11: Equipment Needed

    Chapter 2 Disassembly Process 2-1 Equipment Needed Item Photo Item Photo Screw Bit Hex Sleeves (+) :107 Sleeves Tweezers EP747...

  • Page 12: Disassemble Lamp, Top Cover, Keypad Board And Ir Receiver

    2-2 Disassemble Lamp, Top Cover, Keypad Board and IR Receiver Procedure Photo Unscrew 1 screw to remove Lamp Cover Unscrew 2 screws to re- move Lamp Module Lamp EP747...
  • Page 13 Procedure Photo Unscrew 5 screws and unplug FPC Wire to remove Top Cover Top Cover FPC Wire EP747...
  • Page 14 Procedure Photo Unscrew 4 screws to re- move Top Shielding Module Top Shielding Module Unscrew 1 screw to remove Keypad Board Keypad Board EP747...
  • Page 15 Procedure Photo Remove Keypad Button directly. Notice: please turn Keypad But- ton at 45 angle 45 angle Keypad Button Remove IR receiver, Mylar and lens from Top Cover directly. IR Receiver EP747...

  • Page 16: Disassemble I/O Cover, Main Board, Lamp Driver, Lvps And Axial Fan Module

    2-3 Disassemble I/O Cover, Main Board, Lamp Driver, LVPS and Axial Fan Module Procedure Photo Unscrew 8 hex screws to remove I/O Cover and I/O Shielding Moudle. I/O Cover I/O Shileding Module Remove Light Cut Mylar. I/O Shileding Module EP747...
  • Page 17 Procedure Photo Unscrew 3 screws to re- move Air Duct Module. Air Duct Module Remove Isolator Mylar directly. Isolator Mylar EP747...
  • Page 18 Procedure Photo Unscrew 5 screws and unplug 9 connectors to re- move Main Board Main Board Remove Main Board Mylar from Main Board. Main Board Mylar EP747...
  • Page 19 Photo Unscrew 5 screws and unplug 3 connectors to remove Lamp Driver, Lamp Driver Holder and Lamp Driver Mylar. Lamp Driver Lamp Driver Lamp Driver Maylar Holder Unscrew 5 screws to re- move LVPS Shielding Module. LVPS Shielding Module EP747...
  • Page 20 Procedure Photo Unplug 3 connectors to remove LVPS. Take off Maylar directly. Mylar Unscrew 2 screws to re- move Axial Fan Module. Axial Fan module EP747 2-10...

  • Page 21: Disassemble Engine Module, Dmd Chip, Dmd Board, Color Wheel And Photo Sensor Board

    2-4 Disassemble Engine Module, DMD Chip, DMD Board, Color Wheel and Photo Sensor Board. Procedure Photo Unscrew 2 screws to re- move Wire 2P#22 220C. Wire 2P#22 220C Unscrew 1 screw to remove Blower Duct. Blower Duct EP747 2-11...
  • Page 22 Upper Lens Supporter. Upper Lens Supporter Engine Module Unscrew 4 screws to re- move Heatsink and 2 Springs. Heatsink & 2 Springs Unscrew 4 hex screws to remove DMD Board and DMD Chip. DMD Board & DMD Chip EP747 2-12...
  • Page 23 Procedure Photo Unscrew 2 screws to re- move Color Wheel and Photo Sensor Board. Color Wheel & Photo Sensor Board EP747 2-13...

  • Page 24: Disassemble Focus Ring, Dmd Fan, Speaker, Blower Fan And Elevator Module

    3 ten- ons to separate Replace Ring from Focus Ring. Replace Ring & Focus Ring Unscrew 2 screws to re- move DMD Fan and Speak- er modulen from Buttom Module. DMD Fan & Speaker EP747 2-14...
  • Page 25 Procedure Photo Unscrew 4 screws to break down DMD Fan and Speak- EP747 2-15...
  • Page 26 Procedure Photo Unscrew 3 screws to re- move Power Shielding Module. Power Shielding Module Unscrew 3 screws to re- move Blower Fan. Blower Fan Unscrew 2 screws to re- move Interrupt Switch Module. Interrupt Switch Module EP747 2-16...
  • Page 27 Procedure Photo Unscrew 3 screws to re- move Bottom Base and Down Less Supporter. Bottom Base & Down Less Supporter Take off Elevator Foot di- rectly. EP747 2-17...
  • Page 28 Procedure Photo Unscrew 2 screws to re- move Front Shielding Mod- ule. Front Shielding Module Turn Bottom Cover to the obverse side and use a tweezers to loose the tenon to remove Elevator Module. Elevator Module EP747 2-18...

  • Page 29: Chapter 3 Troubleshooting

    (If you connect multiple sources at the same time, use the “Source” button on the control panel to swtich) - Ensure all connectors are securely connected and aren’t broken - Check Main Board - Check DMD Board - Check Color Wheel - Check DMD Chip - Check Engine Module EP747...
  • Page 30 - Ensure the Projection Lens is clean - Clean DMD Chip and Engine Module - Check DMD Chip - Check Engine Module Garbage Image - Ensure the Signal Cable and Source work - Check Main Board - Check DMD Board EP747...
  • Page 31 Check Battery Failed b. Check Remote Control c. IR Receiver - Control Panel a. Check FPC b. Check Keypad c. Check Main Board Function Abnormal - Do “Reset” of the OSD Menu - Check Main Board - Check DMD Board EP747...

  • Page 32: Function Test And Alignment Procedure

    After final QC step, we have to erase all saved change again and Reset restore the factory defaults. The following actions will allow you to erase all end-users’ settings and restore the original setting: 1. Please enter Menu. 2. Use OSD to reset. EP747...

  • Page 33: Test Condition

    - Circumstance Brightness : Dark room less than 0.5 lux. - Inspection Distance : 1.5m~3m for functional inspection - Screen Size : 60 inches diagonal (wide) - After repairing each EP747, the unit should be burn-in (Refer to the table below). Symptom Burn-in Time...
  • Page 34 ICON Pattern & 64 GRAYS RGBW - Please check and Color ensure if each color is Performance normal and distin- guishable. - If not, please adjust color index of the Engineering Mode. - Fix OSD to re-sync or track Frenquency. EP747...
  • Page 35 *Note Light Leak age is brighter - The unit cannot accept than Gray 10 the leakage is brighter pattern than Gray 10 Pattern Note: Light leak on reflective edge, eyecatcher, bond wires and exposed metal. EP747...
  • Page 36 Service Mode. Choose “Menu” to leave the Service Mode after all. R, G, Each R, G, B - Test Pattern : R, B and color should be G, B and White White normal without Color Color color abnormal Perfor- issue. mance EP747...
  • Page 37 - Test Pattern : (Bright) cannot be accept- Gray 30 ed if the problem appear with Gary 30 pattern Blemish The dark blemish - Test Pattern : (Dark) cannot be accept- Blue 60 ed if the problem appear with Blue 60 pattern. EP747...

  • Page 38: Equipment Needed

    Firmware Upgrade Equipment Needed Software : (DDP 2000- USB) - DLP Composer - Firmware (EP747) Hardware : Item Photo Item Photo Projector USB Cable (EP747) PC or Lap- Power Cord EP747...

  • Page 39: Installation Procedure

    Next Click “Next” button. Next 1. Reading the “License Agreement” rules. 2. Choose “I accept and agree to be bound by all the terms and conditions of this License Agreement” icon. 3. Click “Next” button. Next Click “Next” button. EP747...
  • Page 40 Step Procedure Photo Next 1. Choose “All” icon. 2. Click “Next” button. Next Click “Next” button. Process- The program is execut- ing “Initializing” status. EP747...

  • Page 41: Usb Driver Upgrade Procedure

    Execute Execute the C:\Program Program files\DLP Composer\us- bupdata.cmd (Note: The “DLP Com- poser” program must be closed first.) Type any Press any key to contin- key to ue. Then, wait for about continue 1 minute. EP747...
  • Page 42 “System Properties” window. 3. Choose “Hardware” and then click “Device Manager”. Ensure Click “Jungo” to ensure Device Manager “DDP2000” “DDP2000” and “Win- & “Win- driver” are properly Driver” are installed. If not, repeart properly Step 1~5. installed EP747...

  • Page 43: Chapter 5 Firmware Upgrade Procedure

    2. The library path located in the default installation directory is C:\Program Files\ DLP Composer. If not, press “Browse” to select the right path. 1. Select “Edit\Prefer ences\Communi cations” and choose “USB”. 2. Click “OK”. Vendor: 0x451 Product: 0x2000 EP747...
  • Page 44 Step Procedure Photo 1. Choose “Flash Loader” 2. Click “Browse” to search the firmware file. (EP747) 3. Select the item “Skip Boot Loader Area (load all but the first 16KB).” 4. Click “Reset Bus” to erase the flash memory. (Note: If the error mes- sage “cannot open USB...
  • Page 45 2. Unplug USB Cable and Power Cord. Re-plug in Power Cable. Check Restart the unit and Firmware enter the Service Mode to check the Firmware Version. (For entering Service Mode, please refer to Chapter 4 Function Test and Alignment Proce- dure.) EP747...

  • Page 46: Edid Upgrade

    - EDID Program (Generic V0.51) - EDID Table (*.ini) Hardware: - Generic Fixture for EDID Key-in (Fixture: JP3 must be closed) Item Photo Item Photo RS-232 Power Cable Adapter for (F - M) Fixture Generic DVI Cable Fixture VGA Cable Power Cord EP747...

  • Page 47: Chapter 6 Edid Key-In Procedure

    Item Photo Item Photo One additional monitor (for checking the pro- gram execution) Projector (EP747) Setup Procedure Step Procedure Photo Adapter To Digital Port C o n n e c t 1. Power Adapter to Fixture JP1 All Ports 2. Fixture P1 to PC COM1 Port 3.
  • Page 48 Cable to Digital” mes- Digital sage is shown on the screen, then click “OK”. (Note: “RUN” mes- sage will appear on the screen.) Finished When the EDID program is completed, the mes- sage, “OK”, will appear on the screen. EP747...
  • Page 49 “Read”, if the code in the Serial Blank is scrambled, please make a check in “Trans”.) 4. Click “Reset” to do the next unit or “Exit” to close the EDID program. Note Both Analog and Digi- tal are needed to be checked. EP747...

  • Page 50: Appendix A

    Appendix A Exploded Overview EP747 UNIT EP747...
  • Page 51 ASSY BOTTOM COVER MODULE EP747 70.83R05G001 ASSY PCB MAIN BD MODULE EP747 70.83R06G001 ASSY POWER MODULE EP747 70.83R10G001 ASSY ENGINE & BOTTOM BASE MODULE EP747 70.83R20G001 ASSY SIDE SHIELDING MODULE EP747 75.83F01G001 BUY ASSY AIRDUCT MODULE HD72 85.005AG.408 SCREW HEX I/O #4-40 H4xL8 Ni NYLOK 85.1F123.060...
  • Page 52 SUB ENGINE MODULE EP747...
  • Page 53 ASSY OPTICAL LENS MODULE EP747 70.83R14G001 ASSY COLOR WHEEL MODULE EP747 70.83R15G001 ASSY ROD MODULE EP747 70.83R16G001 PRE ASSY ENGINE BASE MODULE EP747 70.83R17G001 PRE ASSY ENGINE BASE MODULE EP747 75.80W15.002 BUY ASSY ZOOM RING STOP EMI MODULE 2300MP 85.1A326.060 SCREW PAN HEAD MECH M2.6x6 BLACK...
  • Page 54 DMD HEATSINK BACKER PLATE A6061 739 61.88605G001 DMD HEATSINK A1070 Ivy10X 61.88608G001 DMD HEATSINK SPRING PLATE SUS301 0.4t Ivy10X 61.88611G001 DMD SCREW Ivy10X 70.83R12G001 ASSY SUB ENGINE MODULE EP747 80.83R02G001 PCBA DMD BD FOR EP747 85.1A523G040 SCREW PAN MECH M3*4 NYLOK EP747...
  • Page 55 IV. TOP COVER MODULE Exploded Parts List Item PART_NO Description 42.83F04G001 CABLE FFC 14P PITCH=1.0mm HD72 51.83F01G011 TOP COVER PC+ABS EP747 51.83F07G011 KEYPAD BUTTOM PC EP747 51.83F08G011 IR FRONT LENS EP747 51.83F26G001 FRONT IR MYLAR 0.2t HD72 51.83F29G001 KEYPAD LED LENS HOLDER PC HD72 75.83F09G001...
  • Page 56 ENGINE AND BOTTOM BASE MODULE Exploded Parts List Item PART_NO Description 41.83F04G001 GASKET h%%204%%160/(L*125,W*7,H*2) 61.83R05G001 DOWN LENS SUPPORTER SECC t=0.8mm EP747 61.83R06G001 UP LENS SUPPORTER SECC t=0.6mm EP747 70.82G11G001 ASSY LAMP CHANGE PLATE MODULE EP7190 70.83F18G001 ASSY BOTTOM BASE MODULE H72 85.1A123G050 SCREW PAN MECH M3x5 Ni 85.1A126.050...
  • Page 57 VI. BOTTOM COVER MODULE Exploded Parts List Item PART_NO Description 51.83F12G011 FRONT LOWER PANEL PC+ABS EP747 75.83F05G001 BUY ASSY FRONT SIDE SHIELDING HD72 75.83R03G001 BUY ASSY BOTTOM COVER MODULE EP747 85.WA123.080 .SCREW PAN TAP M3*8 Ni EP747...
  • Page 58 PART NO Description 51.83R08G001 POWER SHIELDING FORMAX MYLAR EP747 70.83R09G001 ASSY SUB LVPS MODULE EP747 75.83R05G001 BUY ASSY LVPS SHIELDING MODULE EP747 75.83R06G001 BUY ASSY POWER SHIELDING MODULE EP747 SCREW PAN MECH M4*5 COLOR W/TOOTH 85.1C224.050 WASHER 85.1F123.060 SCREW PAN MECH W/SF M3x6 Ni...
  • Page 59 Exploded Parts List Item PART NO Description 49.83J03G001 MISC 45x10 DMD BLOWER, SUNON B1245PFV1-8A, R TYPE 49.83R01G001 SPEAKER 4ohm 3W 90mm EP747 52.83R01G001 SIDE SPEAKER SPONGE EP747 61.83R04G002 SIDE SHIELDING AL 5052 t=0.8mm EP747 85.1A123.060 SCREW PAN MECH M3x6 Ni 7-10 EP747...
  • Page 60 51.80J38G002 MYLAR CW SUPPORT 739 FRPP 0.125t 52.83615.001 COLOR WHEEL DISC RUBBER , EzPro755 61.80J08G002 CW HOLDER 739 SECC 1.2t 61.83628G001 COLOR WHEEL SHOULDER SCREW , EzPro755 80.80N04.001 PCBA PHOTO SENSOR BD EP739 85.1A626G040 SCREW PAN MECH M2.6x4 BLACK NYLOK 7-11 EP747...
  • Page 61 61.80J39G001 OFF LIGHT PLATE AL VULCAN-1 61.83F17G001 BLOWER DUCT AL H72 85.1A326.060 SCREW PAN HEAD MECH M2.6x6 BLACK 85.1A626G040 SCREW PAN MECH M2.6x4 BLACK NYLOK 85.5A126G040 SCREW BINDING MECH M2.6x4 Ni 87.FL030G008 WASHER FLAT 7*3.1*0.8t PC PINGOOD WS-1M 7-12 EP747...
  • Page 62 XI. I/O COVER FAN MODULE Exploded Parts List Item PART NO Description 35.83R01G001 IO LABEL PC 8B35 EP747 51.83R02G001 IO COVER EP747 75.83R04G001 BUY ASSY IO COVER MODULE EP747 7-13 EP747...
  • Page 63 XII. POWER MODULE Exploded Parts List Item PART NO Description 51.83R10G001 LAMP DRIVER HOLDER MYLAR FORMAX EP747 70.83R07G001 ASSY LAMP DRIVER MODULE EP747 70.83R08G001 ASSY LVPS MODULE EP747 85.1F123.060 SCREW PAN MECH W/SF M3x6 Ni 7-14 EP747...
  • Page 64 XIII. SUB LVPS MODULE Exploded Parts List Item PART NO Description 75.80J02G001 ASSY INTERRUPTER SWITCH 42.83R01G001 W.A. 16P 170mm LVPS TO M/B EP747 42.89602.001 W.A. 3P #20 180mm LAMP DRIVER TO LAMP EP759 75.83M01G002 ASSY LITEON LVPS 2400MP 7-15 EP747...
  • Page 65 XIV. MAIN BOARD MODULE Exploded Parts List Item PART NO Description 51.83F23G001 MB UP INSULATOR MYLAR FRPP 0.43t H72 51.83R09G001 MB DOWN INSULATOR MYLAR Frpp 0.43t EP747 80.83R01G001 PCBA MAIN BD FOR EP747 7-16 EP747...
  • Page 66 XV. OPTICAL LENS MODULE Exploded Parts List Item PART NO Description 23.89601G001 YM06 1.2X XGA ZOOM PROJECTION LENS 75.83R07G001 BUY ASSY FORCUS RING MODULE EP747 85.YA121G040 SCREW FLAT HEAD TAP M1.7*4 Ni 7-17 EP747...
  • Page 67 PART NO Description 42.80S03G001 W.A. 5P #28 210mm LVPS TO MB TDP-T90 51.83F20G001 LAMPDRIVER HOLDER PC+ABS MN3600 HD72 75.83J01G001 ASSY OSRAM LAMPDRIVER 230W 76.83F01G001 ASSY LAMP DRIVER(OSRAM)) TO LAMP W.A. HD72 85.1F123.060 SCREW PAN MECH W/SF M3x6 Ni 7-18 EP747...
  • Page 68 XVII. ENGINE BASE MODULE Exploded Parts List Item PART NO Description 23.80J02G001 REFLECTION MIRROR1 OF DP739 SERIAL '' 51.80J01G001 ENGINE BOTTOM 739 BMC 52.80J05G002 PORON RELAY 739 SILICONE RUBBER 61.80J06G001 SPRING MIRROR1 739 SUS301 0.25t 7-19 EP747...
  • Page 69 XVIII. ROD MODULE Exploded Parts List Item PART NO Description 23.83L17G001 INTEGRATION ROD FOR 739 XGA GLASS RELAY SERIES 57.81501.001 UV GLUE 6-628-GEL DYMAX 61.83J10G001 ROD HOLDER SUS301 0.2t PD527 7-20 EP747...

  • Page 70: Appendix B

    Appendix B I. PCBA Code Definition PCBA Code for Projector A B XXXXXXXXXX C XXX EEEE C: M/B B: DMD/ B Vendor Code Revision Date Code 7-21 EP747...

  • Page 71: Appendix C

    Serial code (from 0001~) EX : A83R529T0AAAA1001 This label “A83R529T0AAAA1001” represents the whole serial number for EP747, including Ver. 1st of BIOS and Ver. 1 of PCB Board. Both mechanical and optical version are 1st. In addition, panel vendor is TI. It’s produced on 29s-week of 2005 for universal area and its serial code is 1001.

  • Page 72: 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 EP747 Service Manual? Unit Excellent Good Fair 1.

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