SERVICE MANUAL EW536/HD66/DW318 Date Revise Version Description 2010.04.30 V1.0 Initial Issue Copyright Apr. 2010. All Rights Reserved. P/N: 36.8FF03G001 Prepare : Check: Approve:...
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Preface This manual is applied to EW536/HD66/DW318 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.
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EW536/HD66/DW318 Comparison List Parts DW318 EW536 HD66 REMOTE CONTROLLER 45.8FF01G001 45.8FF01G002 REMOTE CONTROLLER 45.8FF01G011 (FOR CHINA) BOTTOM COVER 70.8EH12GR01 70.8FF20GR01 MODULE IO COVER MODULE 70.8FF16GR01 70.8FF21GR01 TOP COVER MODULE 75.8EH01G011 75.8EH01G031 LAMP COVER 70.8EH17GR01 70.8FF22GR01 PCBA MAIN BOARD 80.8FF01G001 80.8FF01G011 SOFT CARRY BAG 53.8EH01G101...
● Composite: RCA x 1 Input Connections ● S-video: Mini-DIN 4 pin x 1 ● Audio-in: (Green coded port) Mini Jack x 1 ● HDMI x 1 (with HDCP support) System Controller ● DDP2431 ASIC Controller with Brilliant Color EW536/HD66/DW318 Confidential...
640 x 480 37.5 720 x 400 31.5 720 x 400 37.9 800 x 600 35.2 800 x 600 37.9 SVGA 800 x 600 48.1 800 x 600 46.9 1024 x 768 48.4 1024 x 768 56.5 1024 x 768 EW536/HD66/DW318 Confidential...
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75.06 68.68 MAC G4 640 x 480 31.35 1024 x 768 i Mac DV 1152 x 870 68.49 1280 x 960 Note: If the Computer Compatibility supportive signal is different from User' Manual, please refer to User' Manual. EW536/HD66/DW318 Confidential...
* 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 disassembliy process of EW536/HD66/DW318 is the same,we take EW536 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. EW536/HD66/DW318 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. EW536/HD66/DW318 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 EW536/HD66/DW318 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 EW536/HD66/DW318 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) EW536/HD66/DW318 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. EW536/HD66/DW318 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. EW536/HD66/DW318 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 EW536/HD66/DW318 Confidential 2-10...
Fan and Fan Shielding. 3. Unscrew 1 screw (as yellow circle) to disassemble the Fan Duct. Fan and Fan Shielding Fan Duct Note: - Take the Fan Module as the right gesture. the right gesture the wrong gesture EW536/HD66/DW318 Confidential 2-11...
IO Cover. 2-19 Disassemble Interlock Switch 1. Unscrew 1 screw (as red circle) to disassemble the Interlock Switch. Note: Make sure the Interlock Switch cable be wedged fillister as the picture shown. Interlock Switch EW536/HD66/DW318 Confidential 2-13...
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. EW536/HD66/DW318 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 EW536/HD66/DW318 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 EW536/HD66/DW318 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 EW536/HD66/DW318 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 EW536/HD66/DW318 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) EW536/HD66/DW318 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. EW536/HD66/DW318 Confidential...
Screen Defects (While replacing DMD Chip, DMD Board , Main Board) 12.5 cm Frame Zone B Zone C 12.5 cm < Figure: Zone A, Zone B, Zone C & Frame (as green line) Definition, Active area=Zone A + Zone B > EW536/HD66/DW318 Confidential...
Reset lamp hour OSD Reset EDID Re-write Lamp Hour Usage Rod adjustment Note: - If Color appears abnormal after changing Main Board Module, please do Color Wheel index adjustment. - After changing parts, check the information above table. EW536/HD66/DW318 Confidential...
- Test signal: analog 1280 x 800 @60Hz - We take EW536 for example here. - Connect VGA IN port of Projector with VGA port of Chroma and connect VGA Out port of Projector with VGA port of Monitor by VGA cable, check if the Projected image and the LCD image are the same.
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B. Gray 10 - Ref. Defect specification table 4. Dark pixel Procedure - Test equipment: video generator - Test signal: analog 1280 x 800 @60Hz - Test pattern: White pattern Inspection item - Dark pixels check. Full White EW536/HD66/DW318 Confidential...
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- Test equipment: video generator - Test signal: analog 1280 x 800 @60Hz - Test pattern: Full screen Inspection item - Focus check Criteria - From screen 2.4 M via visual to check the focus, look Full screen EW536/HD66/DW318 Confidential...
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- If color appears abnormal, please get into service mode to do Color Wheel Index adjustment. SMPTEbar - The PC mode functionally sure be workable include support format with frequency and auto detected func- tional will be workable. EW536/HD66/DW318 Confidential...
Check if "freeze" and "mute" are normal. - Press "V Keystone" on remote controller, check if keystone function is normal. 3. HDTV/ Component Procedure - Test equipment: DVD player - Test signal: Ycbcr/YPbPr Inspection item - HDTV performance test EW536/HD66/DW318 Confidential...
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-Test equipment: DVD Player with HDMI output. -Test signal: digital 1280 x 800@60Hz Inspection item - HDMI performance test. Inspection Distance - 1.8 M ~2.5 M Criteria - Ensure if the image is well performed and the color can not discolor. EW536/HD66/DW318 Confidential...
"Contrast" is "60", and the "Format" is "4:3". - Please do the Optical Performance Measure. 2. Brightness Procedure - Full white pattern - Use CL100 to measure brightness values of P1~P9. - Follow the brightness formula to calculate EW536/HD66/DW318 Confidential 4-10...
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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% EW536/HD66/DW318 Confidential 4-11...
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. EW536/HD66/DW318 Confidential 4-12...
- Library file (library file has to put in PC and set right path in 5-3 step 4) Hardware: - Projector - Power cord: 42.50115G001 - RS232 cable: 42.83618G001 - PC or Laptop Note: The FW upgrade procedure for EW536/HD66/DW318 is the same, we take EW536 as an example here. EW536/HD66/DW318 Confidential...
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". EW536/HD66/DW318 Confidential...
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5. Click "Next". 6. Click "Next". 7. The program is executing "installing" status. 8. Click "Finish". EW536/HD66/DW318 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 9.2" file. 3. Click "Edit" and "Perferences". EW536/HD66/DW318 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". EW536/HD66/DW318 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. EW536/HD66/DW318 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.) EW536/HD66/DW318 Confidential...
- xxx_8051_xx.hex Hardware: - Projector - Power cord: 42.50115G001 - USB cable: 42.00286G101 - NLINK Fixture - PC or Laptop Note: The 8051 FW upgrade procedure for EW536/HD66/DW318 is the same, we take EW536 as an example here. EW536/HD66/DW318 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. EW536/HD66/DW318 Confidential 5-10...
(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". EW536/HD66/DW318 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. EW536/HD66/DW318 Confidential 5-12...
- “Manley Nlink” picture will appear on the screen. - Ensure “MCU” is the one you chose in the last step (as green square). - Click “Open”. - Select the 8051 file where you put the file in, then click “Open”. EW536/HD66/DW318 Confidential 5-13...
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Chip success" will be shown. 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.) EW536/HD66/DW318 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 EW536/HD66/DW318 is the same,we take EW536 for example here.
- Power Cord for Projector (42.53506G002) - VGA Cable (42.87305G102) - RS-232 9 Pin Cable (pin to pin, F-M) (42.83C07G001) - HDMI to DVI adapter(For EW536/HD66/HD67): 42.82B13G001 - Generic Fixture (80.00001.001) for EDID Key-in (Fixture: JP3 must be closed) - Power Adapter (47.57803G001) - DVI cable: 42.83N06G001...
- Connect P3 of fixture to Projector digital port (HDMI) - Power on fixture HDMI VGA Port Note: JP3 is closed in all procedure. Power Port 6-4 EDID Key-In Procedure 1. Execute EDID Program - Double click "EDID" to execute EDID EW536/HD66/DW318 Confidential...
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(5) Key in the Serial Number into the Barcode blank space. (6) In "Write Source Select" item, select "VGA1","HDMI". (7) Click "Program". 3. Change the cable to VGA1 - When the message "Please change the cable to VGA1" appear on the screen, click "OK". EW536/HD66/DW318 Confidential...
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- In "Read item", select "Analog" and "Trans", then click the "Read". 7. EDID informations will show the result. 8. Read EDID "HDMI" information - In "Read item", select "Digital" and "Trans", then click the "Read". 9. EDID informations will show the result. EW536/HD66/DW318 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. EW536 EW536/HD66/DW318 Confidential...
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LAMP COVER PC MN3600H BLACK PDG-DSU30 52.8CS05G002 MB SHIELDING AIR THIGHT JK-1105 PDG-DSU30 85.1A526G060 SCREW PAN MECH M2.6*6 Ni NYLOK 61.8CS05G021 MAIN BD SHIELDING SECC 0.6T EW536 61.8CS04G001 TOP SHIELDING SECC 0.4T PDG-DSU30 LOCK SCREW PAN MECH M3*8.5-3.5 61.00018G003 BLACK(1018+HEAT TREATMENT) 80.8FF01G001...
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ASSY TOP COVER MODULE EW536/HD66/DW318 Confidential...
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FFC KEYPAD TO FORMATTER BD 16P P=0.5 42.00304G001 122mm HD80 51.8CS13G001 TOP COVER MYLAR PDG-DSU30 75.8EH01G011 TOP COVER MODULE EW536 85.1A123G050 SCREW PAN MECH M3*5 Ni 85.3A126G040 SCREW CAP HEAD D7.0 MECH M2.6*4 Ni ZOOM RING HOLDER PC MN3600H BLACK 51.8CS12G002...
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SUNON 70*70*20mm AXIAL FAN, KDE1207PKV1. 49.8CP02G002 MS.B3001.AF.GN, SHRINK TUBE 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 EW536/HD66/DW318 Confidential...
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CONDENSER1 FOR A15W 85.1A323G080 SCREW PAN MECH M3*8 BLACK “GREEN” 80.8EH02G001 PCBA DMD BOARD FOR ES526 70.8FF19GR01 ASSY ROD MODULE FOR EW536 (SERVICE) 70.8FF03G001 ASSY ROD MODULE EW536 70.8CP10G001 ASSY ENGINE BOTTOM COVER Z15 0.65’’ WXGA 2xLVDS SERIES 450 DMD -8 TI 48.8EJ01G001...
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PCBA PHOTO SENSOR BOARD FOR HD20 YO 6S HE3 CW R81Y41G84C31W52B71, URD20 23.8BA19G001 MOTOR 85.1A126G040 SCREW PAN MECH M2.6*4 Ni TAPE 3M J350 10*5mm FOR COLOR WHEEL 51.82Y29G001 DP715 52.83615G011 COLOR WHEEL DISC RUBBER, EzPro755 61.83628G001 COLOR WHEEL SHOULDER SCREW EW536/HD66/DW318 Confidential...
AAAAA = not-defined C = Manufacture factory (TW or China) 0001 = Serial Code EX: Q8EH915AAAAAC0001 This label "Q8FF941AAAAAC0001" represents the serial number for EW536. It is produced at CPC on forty-one of 2009. Its serial code is 0001. EW536/HD66/DW318 Confidential...
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