Optoma PK-102 Serivce Manual
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Optoma PK-102 Serivce Manual

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SERVICE MANUAL

Date
Revise Version
2009.05.26
2009.08.05
2009.11.24
2010.01.28
Copyright Jan. 2010. All Rights Reserved P/N: 36.8BU05G001
SI
PK-102
V1.0
Update Engineering Spec. in Chapter 1;
V2.0
Modify GM7020 FW and SD Files Upgrade
Procedure in Ch5-2;
Add tear off 3M Tape in Ch2-5;
V3.0
Add ACCO PK-102
Modify "Defect specification table" in Chapter 4;
V4.0
Add picture in Chapter 5;
Mina
TSE:
Description
Initial Issue
Check:
Approved:

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Summary of Contents for Optoma PK-102

  • Page 1: Service Manual

    Modify GM7020 FW and SD Files Upgrade Procedure in Ch5-2; Add tear off 3M Tape in Ch2-5; 2009.11.24 V3.0 Add ACCO PK-102 Modify “Defect specification table” in Chapter 4; 2010.01.28 V4.0 Add picture in Chapter 5; Copyright Jan. 2010. All Rights Reserved P/N: 36.8BU05G001...
  • Page 2 Preface This manual is applied to PK-102 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: Table Of Contents

    Disassemble Engine Module and DMD Board Chapter 3 Troubleshooting Equipment Needed Main Procedure Power Troubleshoting Image Performance Troubleshooting Audio Troubleshooting Battery Troubleshooting Chapter 4 Function Test & Alignment Procedure Test Equipment Needed Service Mode Factory Reset Test Condition Test Inspection Procedure PK-102 Confidential...
  • Page 4 Section 2: GM7020 Firmware and SD Files Upgrade Equipment Needed Setup Procedure GM7020 Firmware Upgrade Procedure SD Files Upgrade Procedure 5-13 Chapter 6 EDID Upgrade EDID Introduction Equipment Needed Setup Procedure EDID Key-In Procedure (VGA Interface) Appendix A Exploded Image Appendix B PCBA Code Definition PK-102 Confidential...

  • Page 5: Chapter 1 Introduction

    ● 5 �, �GA display mode �for AC adapter, but not include AC adaptor’s power consumption�� ● 6 �, Playback mode �for AC adapter, but not include AC Power Consumption adaptor’s power consumption�� ● Off mode current < 0.5mA ● USB host mode support 150mA 5� PK-102 Confidential...
  • Page 6 ● PAL: B, D, G, �, I, M, N ● System controller: T���16�TI�FPGA�� Main Controller ● Media controller : GM7020 ● Internal storage: Micro SD size: 4Gbytes ● �ideo: MPEG4�ISO�IEC 144��6-2�� Q�GA video decoder Multimedia Format ��ID simple profile L0�L3 standard. ● Photo: JPEG, BMP PK-102 Confidential...

  • Page 7: Compatible Mode

    1-2 Compatible Mode Computer compatibility Compatibility Resolution �-Sync [�z] �-Sync [K�z] �GA 640×4�0 31.5 S�GA �00×600 37.�� PK-102 Confidential...

  • Page 8: Equipment Needed & Product Overview

    2. Screw Bit (+): No.00 3. Screw Bit (-) : 1.4mm 4. Tweezers (Wide flat-head tweezers) 5. PK-102 unit * Before you start: This process is protective level II. Operators should wear electrostatic chains. Set the screwdriver's torque to 0.5-0.6 kgf-cm.

  • Page 9: Disassemble Battery Cover And Battery Module

    1. Disassembly the Battery Cover Module (as red arrow direct). 2. Remove the Battery. 2-3 Disassemble Bottom Cover Module 1. Tear off the rubber (as blue circle). 2. Unscrew 5 screws from the Bottom Cover (as red circle). PK-102 Confidential...

  • Page 10: Disassemble Lens And Focus Ring

    2-4 Disassemble Lens and Focus Ring 1. Disassemble the Lens Deco and Deco Inner (as yellow square). 2. Unscrew 1 screw (as red circle) to disassemble the Focus Ring. PK-102 Confidential...

  • Page 11: Disassemble Engine Module And Main Board Module

    - After sticking the changed graphite plate on the top cover, please press lightly to avoid it warping. 3. Disassemble mylar from the speaker (as blue square). 4. Disassemble the power switch (as yellow circle). PK-102 Confidential...
  • Page 12 6. Turn the Engine Module and Main Board Module to backside and unplug 1 connector (as red square). 7. Separate the Engine Module and the Main Board Module. 8. Tear off the 3M tape from the Main Board Module (as blue square). PK-102 Confidential...

  • Page 13: Equipment Needed

    Chapter 3 Troubleshooting 3-1 Equipment Needed 1. Projector 2. DVD player 3. Screw drivers 4. Power adapter 5. Voltage test meter PK-102 Confidential...

  • Page 14: Main Procedure

    3-2 Main Procedure PK-102 Confidential...

  • Page 15: Power Troubleshoting

    3-3 Power Troubleshoting (Battery) PK-102 Confidential...
  • Page 16 3-3 Power Troubleshooting (Power Adapter) PK-102 Confidential...

  • Page 17: Image Performance Troubleshooting

    3-4 Image Performance Troubleshooting PK-102 Confidential...
  • Page 18 3-4 Image Performance Troubleshooting PK-102 Confidential...

  • Page 19: Audio Troubleshooting

    3-5 Audio Troubleshooting PK-102 Confidential...

  • Page 20: Battery Troubleshooting

    3-6 Battery Troubleshooting PK-102 Confidential...

  • Page 21: Function Test&Alignment Procedure

    - Minolta CL-100 - Quantum Data 802B or CHROMA2327 (Color Video Signal & Pattern Generator) - Remote control (P/N: 45.89Z01G001 only for PK-102 test using) - PK-102 universal to VGA cable (P/N: 42.00206G001-B) - Mini JACK-M to 3*RCA-F R/W/Y cable (P/N: 42.00235G001-B) - PK-102 universal to USB cable (P/N: 42.00288G001-B)

  • Page 22: Test Condition

    - Screen size: 20 inches diagonal - Connect the power adapter to "dc in" port of the projector - After repairing PK-102, the unit should be run-in (refer to the below table) PK-102, the unit should be run-in (refer to the below table)

  • Page 23: Test Inspection Procedure

    - When the projector in standby mode, check whether the LED indicator - When the projector in standby mode, check whether the LED indicator flashing orange. - Press the ‘‘Power’’ button, check whether the projector can turn on or off normally. PK-102 Confidential...

  • Page 24: Pc Mode

    - Bright pixel check. Note: Frame dimension under operative zone1 inch. Criteria - The number of the bright pixels should be less or equal to 1 pixels. - Ref. below table Gray 10 Note: The defect criteria follows TI specification. PK-102 Confidential...
  • Page 25 - In the charging procedure, check whether the green LED is lighting and the charging is complete. - Unplug the power adapter, turn on the projector to check if the discharging is normal. PK-102 Confidential...

  • Page 26: Video Performance

    - 0.8 M ~1.0 M Criteria - Check the sound from speaker - Press ‘‘Up’’ button of the projector to modulate the volume to 20, then press “down“ button to modulate the volume to 18, check whether the volume is normal. PK-102 Confidential...

  • Page 27: Sd Card Test

    - Please get into bright mode, focus should be clear, the display format is 3:2. - Press ‘‘VGA->Select->Down->Down’’ on remote control, then press ‘‘Left’’ or ‘‘Right’’ to select full white and full black pattern, then start signal test. PK-102 Confidential...
  • Page 28 Procedure - Full white pattern - Use CL100 to measure brightness values of P1~P9 (see image: full white). - Follow the Uniformity formula to calculate average values. ☼ Uniformity Formula ANSI Uniformity = Avg.(P1,P3,P7,P9)/P5×100% Criteria • 50 % PK-102 Confidential...

  • Page 29: Others

    Buttons stuck buttons are unacceptable. Focus Ring Focus ring is functioning smoothly. Logo missing logo, missing prints and blurry prints are unacceptable Screw All screws sure be fixed and in right type. PK-102 Confidential...

  • Page 30: Firmware Upgrade

    Section 1: System Firmware Upgrade 5-1 Equipment Needed Software : - PK-102_FW_All_XX.bin Hardware : - Projector (PK-102) - Monitor - PC - Power cord & Power adapter for generic fixture: (P/N: 42.00147G001 & 47.8CR02G001) - Generic Fixture for FW Upgrade - FPC - Cable RS-232 9P (F) to 9P (F) (P/N:42.85H02G001)

  • Page 31: Setup Procedure

    2 are ''on'' state , the switch of 3 and 4 are ''off'' state; As the red square 2, the switch of 1, 2, 3, 4 are all ''on'' state. Note2: Plug in the power, then the LED will flashing red. PK-102 Confidential...

  • Page 32: Firmware Upgrade Procedure

    5-3 Firmware Upgrade Procedure Procedure 1. Firmware Upgrade Precedure (1) Select ''Programs->Accessories ->Communications->Hyper Terminal''. (2) Key in ''download''. (3) Select '' (4) Click ''OK''. (5) In the "Connect using" item, please choose the port which you are using. PK-102 Confidential...
  • Page 33 (10) Click ''OK''. (11) Select " ". (12) Select "Setting". (13) Select "Terminal Keys" in "Function, arrow, and ctrl keys as" item. (14) Select "Ctrl+H" in "Backspace key sends" item. (11) (15) Select "ASKII Setup...". (12) (13) (14) (15) PK-102 Confidential...
  • Page 34 (18) Click "OK". (19) Press "Power" button of the projector. (20) Press ''Reset'' button on the fixture, then the message ''Change to Xmodem mode'' will show on the screen. (16) (21) Select ''Transfer->Send File...''. (17) (18) (19) (20) (22) PK-102 Confidential...
  • Page 35 (24) Select the file ''PK-102_FW_All_XX.bin''. (24) (25) Click ''Open''. (26) Select ''Xmodem''. (25) (27) Click ''Send''. (28) Firmware upgrade will take about 30 seconds. (29) ''Programming finish'' information will show out when firmware upgrade procedure is completed. (27) (28) (29) PK-102 Confidential...
  • Page 36 2. Check Firmware Version - Select ''VGA->Down->Down->Select'' on remote control to check Firmware Version. PK-102 Confidential...

  • Page 37: Section 2: Gm7020 Firmware And Sd Files Upgrade

    Section 2: GM7020 Firmware and SD Files Upgrade 5-4 Equipment Needed Software : - PK-102_GM7020 FW_All_XX.bin - PK-102_SD FILES Hardware : - Projector (PK-102) - Monitor - PC - Universal to USB Cable (P/N: 42.00288G001) - Power adapter for projector (P/N: 47.8BU11G001 & 47.8BU12G001) PK-102...

  • Page 38: Setup Procedure

    5-5 Setup Procedure 1. Connect Power adapter to P1 Port of the projector. 5-6 GM7020 Firmware Upgrade Procedure Procedure Enter Down 1. Turn on the projector, press "Down->Down" key on the projector, select "Setting". PK-102 Confidential...
  • Page 39 4. Remove the cursor on "F/W Upgrade Off", then press "Enter" key, change "F/W Upgrade Off" to "F/W Upgrade On" state. 5. Connect PC and VGA/USB IN by USB cable, then the projection picture will disappear, the USB information will appear on PC. PK-102 Confidential 5-10...
  • Page 40 "PK102",another one named "Local Disk". 8. Double click "Local Disk (H:)"Disk, and then delete all of the files. Note: "Local Disk (H:)" represent the location of projector SD card's document. 9. Double click the Folder "PK-102_GM7020 FW_All_xx" PK-102 Confidential 5-11...
  • Page 41 (10) 11. Paste "res" and "Image.bin" to Disk "Local Disk (H:)". GM7020 firmware upgrade complete. Note: Delete the primary documents first. Do not cover them directly. (12) 12. Press "Up->Down->Up->Down->Enter" on the projector to check firmware version. PK-102 Confidential 5-12...

  • Page 42: Sd Files Upgrade Procedure

    Double click Disk �PK102 (G:)�, and then delete all of the files. 2. Double click the Folder "PK102_SD FILES". Double click the Folder "PK102_SD FILES". Then Select Folders "Optoma Video Encoder", "Users Manual", "Photo" and "Video", copy them next. 3. Paste �Users Manual�,�Photo� and �Video�...

  • Page 43: Edid Upgrade

    The information is stored in the display and is used to communicate with the system through a Display Data Channel (DDC), which sites between the display device and the PC graphics adapter. The system uses this information for configuration purposes, so the monitor and system can work together. PK-102 Confidential...

  • Page 44: Equipment Needed

    - Generic Fixture :80.00001.001 for EDID Key-in (Fixture: JP3 must be closed) - Power adapter for projector (P/N: 47.8BU11G001&47.8BU12G001) - Monitor - PC - Universal to VGA Cable (P/N: 42.00206G001) - RS-232 Cable (pin to pin, F-M): 42.83618G001 - Power adapter 2 for fixture: 47.57702G001 PK-102 Confidential...

  • Page 45: Setup Procedure

    1. Click on "EDID" to execute EDID program. EDID program. program. program. 2. Choose model (1) In the port selection bar, please choose the port which you are using. (2) Click on "Model''. (3) Choose the source file ''PK-102_EDID_All_XX.ini''. (4) Click ''Open''. PK-102 Confidential...
  • Page 46 Analog” is shown on the screen, click “OK” button. 5. When the EDID program is completed, a message "OK" will appear on the screen. 6. Select ''Trans'' in the read item, and then click ''Read'' button, EDID informations will show the result. PK-102 Confidential...
  • Page 47 9. Use the tweezers to lift the SD card shielding, disassemble the SD card. 2-6 Disassemble Engine Module and DMD Board 1. Unscrew 2 screws on the DMD Board (as red circle). 2. Separate the Engine Module and the DMD Board. PK-102 Confidential...

  • Page 48: Exploded Image

    RSPL report. D.C. For PK-102 Parts Supply Item Description 52.8BU02G001 FRONT RUBBER FOOT SILICON PK-101 70.8BU13G001 TOP COVER MODULE PK-102 70.8BU14G001 BOTTOM COVER MODULE PK-102 70.8BU18G001 BATTERY COVER MODULE PK-102 85.4A12AG060 SCREW FLAT MACHINE M1.4*6.0 P=0.3 85.4A12AG100 SCREW FLAT MACHINE M1.4*10.0 P=0.3...
  • Page 49 Assy Top Cover Module For PK-102 PK-102 Confidential...
  • Page 50 Hm 0.8mm 52.8BU10G001 TOP GRAPHITE PLATE BUY ADD POWER BUTTON TOP COVER MODULE 75.8BU02G012 PK-102 70.8BU15G001 MB ENGINE AND MYLAR MODULE PK-102 FOCUS RING STEP SCREW NICKEL M2 WITH NY- 61.8BU02G001 LOK PK-101 85.1A52AG030 SCREW PAN MACHINE M1.4*3.0 P=0.3 70.8BU21GR01 ASSY TOP COVER MODULE FOR PK-102(SERVICE) 61.D0124G001...
  • Page 51 Assy Bottom Cover Module For PK-102 Item Description Parts Supply OPTICAL ENGINE BOTTOM THERMAL PAD GR-Hm 52.8BU05G001 0.8mm ASSY BOTTOM COVER MODULE FOR PK-102- 70.8BU22GR01 (SERVICE) 52.8BU09G001 BOTTOM GRAPHITE PLATE 75.8BU03G011 BUY ASSY BOTTOM COVER MODULE PK-102 51.8BU12G001 BATTERY PULL TAPE PK-101 51.8BU17G001...
  • Page 52 Assy Main Board Module For PK-102 Parts Supply Item Description 80.8BUT1G073 PCBA MAIN BD PK-102 REV:D ASSY PCBA MAIN BD MODULE FOR PK-102- 70.8BU19GR01 (SERVICE) 51.81542G001 TAPE 3M J350 17*15mm MICROSD CARD SDSDQ-4096 4GB CLASS-2 80.8BU08G001 “Sandisk” 49.8BU01G022 SPEAKER 1W 8OHM LB15100083-C201 #28 PK-102...
  • Page 53 Parts Supply Item Description ASSY PROJECTOR LIGHT ENGINE PK-101- 70.8BU20GR01 (SERVICE) 75.8BU01G001 0.17” DMD PICO PROJECTOR LIGHT ENGINE 80.8BUT2G074 PCBA DMD CONNECTOR BD ENTEK PK-102 REV:E 85.1A52AG030 SCREW PAN MACHINE M1.4*3.0 P=0.3 3M DOUBLE-SIDED TAPE(L10*W5*T0.2MM)FOR PK- 51.8BU30G001 101 ENGINE PK-102 Confidential...
  • Page 54 Assy Battery Cover Module For PK-102 Parts Supply Item Description ASSY BATTERY COVER MODULE FOR PK-102- 70.8BU23GR01 (SERVICE) 51.8BU02G011 BATTERY COVER PK-102 52.8BU03G001 REAR RUBBER FOOT SILICON PK-101 PK-102 Confidential...
  • Page 55 D.P. For PK-102(Packing Procedure Drawing) PK-102 Confidential VIII...
  • Page 56 CABLE 2.5MM MINI JACK-M TO 3.5MM MINI JACK-M 42.00266G002 1000mm WITH VOLUME CONTROL-WHITE-IPOD 42.00294G001 CABLE AV ADAPTER DEXIM FOR IPOD WHITE 47.8BU12G001 AC ADAPTOR PLUG USA TYPE PHIHONG PK-102 47.8BU11G001 AC ADPTR 100-240VAC IN 5V 2A OUT FOR PHIHONG 53.8BU01G001 SOFT BAG PK-101 36.00024G011 WARRANTY CARD US FOR OPTOMA PICO, 1 YEAR 42.00206G001...
  • Page 57 C = Manufacture factory (TW or CPC) 0001 = Serial code EX: Q8BU918AAAAAC0001 This label represents the serial number for PK-102. It is produced for USA at CPC on eighteen week of 2009. Its serial code is 0001. PK-102 Confidential...

  • Page 58: Pcba Code Definition

    PCBA Code Definition PCBA Code for Projector XXXXXXXXXX EEEE Vendor Code Revision Date Code PK-102 Confidential...

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