Optoma EX631 Service Manual
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Optoma EX631 Service Manual

Projection system
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OPTOMA
EX631/EW631 Projector

Service Manual

100% Recycled Paper
Date: 2012/03/20

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Summary of Contents for Optoma EX631

  • Page 1: Service Manual

    OPTOMA EX631/EW631 Projector Service Manual 100% Recycled Paper Date: 2012/03/20...
  • Page 2 Update History Date of issue Published by Version Desc. 2012/03/20 Ciom New version released.

  • Page 3: Safety Instructions

    ■ Safety Instructions SAFETY PRECAUTIONS WARNING: The chassis of this projector is isolated (COLD) from AC line by using the converter transformer. Primary side of the converter and lamp power supply unit circuit is connected to the AC line and it is hot, which hot circuit is iden- tified with the line ( ) in the schematic diagram.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS System Introduction ......................1 1.1 Technical Specification......................1 1.2 System Block Diagram......................3 Firmware Upgraded Flow ....................4 2.1 Setup Tool/Equipment ......................5 2.2 Upgrading Procedure......................5 Machine Disassembly and Replacement ................. 16 3.1 Tools ........................... 16 3.2 Disassembly Procedure ......................

  • Page 5: System Introduction

    1 System Introduction 1.1 Technical Specification CONTENT Item EX631 EW631 Display Type Single 0.55” DLP panel Single 0.65” DLP panel Native Resolution: Native Resolution: Resolution(Pixels) XGA, 1024x768 WXGA, 1280x800 Maximum Resolution: UXGA, 1600x1200@60Hz 1.1x 1.2x Zoom Range(Ratio) Lamp 240W Screen size 30”~300”...
  • Page 6 Attention for handing Do not touch the lamp until it has cooled completely, because the lamp is very hot  during operation and immediately after turned off. The lamp has to be fixed firmly to the base or socket.  Turn off the power supply during maintenance.

  • Page 7: System Block Diagram

    1.2 System Block Diagram...

  • Page 8: Firmware Upgraded Flow

    2 Firmware Upgraded Flow This provides the information regarding relevant equipments and upgrading procedure for firmware upgrade. Purpose: Flash Loader vX.X.exe flash loader is for upgrading image file to projector and is be designed to execute on Windows 2000/Windows XP/Windows Vista/Win 7. Note: Please check the firmware version before any firmware upgrade procedures.

  • Page 9: Setup Tool/Equipment

    2.1 Setup Tool/Equipment  Computer  Power Cord  USB Cable 2.2 Upgrading Procedure 1) Upgrading the Firmware on the Unit To update the firmware on your projector, you first need to install the Firmware Update Utility software DPL Composer Lite v10.3.x on your PC. Open Windows Explorer, locate the DLP Composer Lite v10.3.x Setup, and then double-click the icon to launch installation procedure, and follow the on-screen instructions to finish the installation procedure.
  • Page 10 Once you have read the License Agreement and agree, select the I Agree radio button , then click Next >. In the box of Readme Information, after read click Next>...
  • Page 11 Select which features you would like to install, and then click Next> Click Next to begin installation...
  • Page 12 You’ll see a progress bar as the DLP Composer is installed Once the installation is complete, select Finish The DLP Composer Icon will appear on desktop of WindowsTM after successful installation.
  • Page 13 2) Install DLP Processor USB Driver 1. If DLP Composer Lite does not be installed yet, please follow the description of section DLP Composer Lite Installation to install it first. 2. Please click the ”Install DLP Processor USB Driver” (as below graphic) to install USB Driver. During installation, the installer will show a DOS screen.
  • Page 14 3) Upgrade the firmware on the projector To update firmware, you need a USB type A to USB type B cable (available at any electronics store). Don’t connect the cable until these instructions tell you to do so. IMPORTANT! While the firmware is being downloaded to the projector, do not shut down the computer or projector or disconnect the USB cable.
  • Page 15 7. Change the USB Device Identification of DLP Composer Lite to be Vendor: 0x451, Product: 0x2000.
  • Page 16 8. Click DLP Composer Lite\Flash Loader, and change Flash Image File to be C:\dev\Library\. Comment:...
  • Page 17 9. Select the Skip Boot Loader Area check box, when you do not want to overwrite boot loader of projector, as picture 1 (recommend). Otherwise, do not select the Skip Boot Loader Area check box, when you want to overwrite the boot loader, as picture 2. Picture 1: Skip boot loader Picture 2: Overwrite boot loader...
  • Page 18 10. Press to start download firmware into projector. 11. Projector will turn on automatically when FW update is finished ("Download complete" will appear). Press "MENU" or "4-direction" navigator button to turn off the projector (NOTE: "Power" button does not function at this point). Cooling process (fans spinning) will then start. Unplug the power cord when the cooling process is complete;...
  • Page 19 12. Plug in the power cord, press "Power" button to turn on the projector. The projector will function as usual...

  • Page 20: Machine Disassembly And Replacement

    3 Machine Disassembly and Replacement 3.1 Tools Item Photo Hex Sleeves 5mm Screw Bit(+):107 Screw Bit(+):101 Screw Bit(+):102 Anti-static wrist strap Anti-static wrist gloves...

  • Page 21: Disassembly Procedure

    3.2 Disassembly Procedure Warning Put on the Static Electricity Ring when starting for repair.  Repair Environment suggest in Clean-room class 10000. Do not remove Optical  Engine or DMD panel outside the clean room. Please return the optical engine to supplier if your repair condition can not meet the requirement.
  • Page 22 Step Figure Description Shown you the projector. Rotate the focus ring left and remove it. 1. Unscrew the screw on the side of the lamp cover. Screw 2. Sliding the lamp cover forward, and lifting the lamp cover off. Sliding the lamp cover rightward, and lifting the lamp cover off...
  • Page 23 Step Figure Description Disconnect the lamp connecter as shown. Flip the projector on the table. Removing screws x 7on the bottom cover as show. Screws x 7...
  • Page 24 Step Figure Description Lifting the top cover off upward gently, disconnect the front IR wire and the safety switch wire then remove the top cover. Disconnect the two wires and remove the ballast module. Remove the screws*5 on the main board Screws*5...
  • Page 25 Step Figure Description Black Screw*1 Screws x 8 Removing the screws on the back cover as shown Black Screws x 3 Show you the main board and the connectors. Disconnect all wires connected on the main board and tear the yellow adhesive tape off remove Speaker 2 the 2 speakers then remove...
  • Page 26 Step Figure Description Tear the yellow adhesive tape off and take out of the EMI shielding , then remove the metal plate. Metal plate EMI shielding Unscrew the 3 screws and remove the Optical Engine (With lamp). Screws x 3...
  • Page 27 Step Figure Description Unscrew the 3 screws then remove Fin outlet. Screws x 3 Fan2 Remove the 2 Fan module. Fan 1 Fan 2 2 Fan module Removing the 2 screws and take off the Fan3 module. Fan 3 Screws x 2...
  • Page 28 Step Figure Description Unscrew the 5 screws and remove the ballast mylar and power board. Screws x 5 Remove the power mylar . Power Mylar Remove the power holder Power Holder...

  • Page 29: Troubleshooting And Verifying The Repair

    Troubleshooting and Verifying the Repair This chapter provides technicians with electronic background how to maintain the product. Moreover, you can get the appropriate operation to solve some complicated problems of component repairing and professional problems. 4.1 Troubleshooting Warning  Do not directly look into the lens to avoid eyesight damages. ...
  • Page 30 Note: Swapping modules that may be defective with others known to be good is generally an ideal way to find the module responsible for the problem. A failure symptom is rarely caused by more than one module, so you will not usually need to replace more than one to correct a particular failure.
  • Page 31 Fail to light up No Volume Refer to LED Replace button Check LED indicator and Check button indication follow indicative actions Replace Replace Check Check Lamp Module Speaker Lamp Speaker Replace Replace Check Check Mainboard Mainboard Mainboard Mainboard Replace Check Ballast Ballast Replace Check Power...

  • Page 32: Video Signal Troubleshooting

    Video Signal Troubleshooting Computer Video No Signal No Signal Turn on Turn on Check Check Source Source Source Source Replace Replace Check Check Cable Cable Cable Cable Replace Replace Check Check monitor Mainboard Mainboard Mainboard out signal...
  • Page 33 Image abnormal Color abnormal Adjust Power on again Check input cable Input signal and reset OSD and signal setting Adjust Adjust Color Check input cable Check Color Input signal Wheel Index and signal setting Wheel Index Replace Replace Check Check Mainboard Mainboard Mainboard...
  • Page 34 Operation Function Troubleshooting Button Failure Remote Control Failure Replace button Replace Check Check Battery Level button Battery Replace Replace Check Check Remote Control Remote Control Mainboard Mainboard Replace Check Replace Check Mainboard Mainboard...

  • Page 35: Verifying The Repair

    I/O port VGA In (XGA/WXGA) Test Equipment Standard Pattern generator (Ex. Quantum data) Signal format EX631: 1024*768 60Hz EW631: 1280*800 60Hz I/O port Audio input Test Equipment Connect audio input to audio output from video equipment Signal format...
  • Page 36 (2) Operation test Buttons operation Button description Test criteria Power button 1. Touch “power” button and projector will switch on, and in standby mode the LED should solid. 2. Touch the “power” button (Up & Down) should be sensitive 3. The LED indicator lighteness and uniformity normally MENU/EXIT 1.
  • Page 37 Zoom ring: Adjust zoom ring to wide (Maximum projection size) I/O port Monitor In (XGA/WXGA) Test Equipment Standard Pattern generator (Ex. Quantum data) Signal format EX631: 1024*768 60Hz EW631: 1280*800 60Hz Projected image size 60” in diagonal length TOP SMPTE133 • Use to confirm overall image quality.
  • Page 38 BLUE 120 • Use for dark blemish and ghost inspection. • Confirm there are no more than four blemishes darker than Blue 120. • No blemish greater than one inch or 25mm in length/diameter is allowed. • Confirm there is no ghosting. •...
  • Page 39 WHITE • Use for lumens and uniformity measurements, banding adjustment and inspection of dark (stuck OFF) pixels, minor blemishes. • Confirm there are no more than six total of light and dark blemishes • Confirm no blemish is greater than five inches in length/diameter. •...
  • Page 40 Set UUT to Film gamma when using this image • Distance from edge of image to Gray 245 band is 20 pixels. • No banding appearing beyond the outer rectangle is allowed. • No banding appearing darker than the Gray 245 band is allowed. ...
  • Page 41 Audio I/O port Audio Test Equipment Speaker &DVD player Signal format NTSC Criteria The audio out is normal Video I/O port Video Test Equipment Standard Pattern generator (Ex. Quantum data)&DVD player Signal format NTSC Criteria No apparent color deviation on the projected image S-Video I/O port S-Video...
  • Page 42 (6) Brightness measurements Test items Brightness measurements Test Equipment Chroma automatic system (The alternative is CL-200) Test method Measure 9 points Criteria Marketing spec 20% off (7) Safety test equipments Test items Safety test Test Equipment Safety analyzer Test method 1.

  • Page 43: Connector Information

    5 Connector Information This section provides each connector location on boards and function of each board. They will be useful for your detecting the defective boards. 5.1 Main Board No 05 No 04 No 07 No 06 No 02 No 08 No 03 No 01 Connector...

  • Page 44: The Backside Of Mainboard

    The backside of mainboard No 02 No 01 No 04 No 03 No 05 Connector Description No 1 Connect to DMD Board No 2 Fan2 No 3 Color Wheel Sensor No 4 Connect to Power Board No 5 Ballast control...

  • Page 45: Ballast Board

    5.3 Ballast Board No 2 No 1 Connector Description No 1 Lamp power supply No 2 Ignite signal connected to Mainboard No 3 Power supply 5.4 Power board No 3 No 1 No 2 Connector Description No 1 AC Input No 2 Ballast Power Supply No 3...

  • Page 46: Fru (Field Replaceable Unit) List

    6 FRU (Field Replaceable Unit) List Introduction This section is a list of all the FRU removal. Following the FRU table of contents is an enlarged view of the entire projector, which shows the primary FRUs in the projector. When working on the projector, use appropriate anti-static precautions such as anti-static mats, wrist straps and grounded work surfaces.

  • Page 47: Mechanical Drawing

    6.1 Mechanical Drawing...

  • Page 48: Board/Module

    6.2 Board/Module Key No. Description MAIN_BOARD_EX631 PE884-7100 MAIN_BOARD_EW631 PE984-7100 PE884-8100 POWER_ASY BALLAST_EX631 PE884-9000 BALLAST_EW631 PE984-9000 PE884-7500 FIR_DIP_PCB_ASY 6.3 Case/Cover/Bracket Assembly Key No. Description PE884-4540 LAMP-COVER_ASY PE884-4500 TOP-COVER_ASY PA834-4540-99 KEY_ASY PE884-4510 BOTTOM-COVER_ASY 6.4 Optical Device Key No. Description OPTICAL ENGINE WITHOUT LAMP_EX631 PE884-2200 OPTICAL ENGINE WITHOUT LAMP_EW631 PE984-2200...

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Ew631

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