Optoma DV11 Serveice Manual
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Optoma DV11 Serveice Manual

Optoma DV11 Serveice Manual

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SERVICE MANUAL

Date
Revise Version
2007.03.28
2007.07.02
2007.08.10
2009.03.05
Copyright March, 2009. All Rights Reserved P/N: 36.85E05G001
SI :
DV11 / DVD100 / U2 / U3
V1.0
V2.0
V3.0
V4.0
TSE:
Description
Initial Issue
Edit 2-24, 4-4, 4-6, 4-10, 5-1, 5-3 and 5-4
Edit 5-4, 6-4, Appendix B. Add 5-5 and 5-6
Add DV11 extended models: DVD100, U2, U3
(modify 2-25 of Chapter 2 and Chapter 3)
Check:
Approved:

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  • Page 1: Service Manual

    SERVICE MANUAL DV11 / DVD100 / U2 / U3 Date Revise Version Description 2007.03.28 V1.0 Initial Issue 2007.07.02 V2.0 Edit 2-24, 4-4, 4-6, 4-10, 5-1, 5-3 and 5-4 2007.08.10 V3.0 Edit 5-4, 6-4, Appendix B. Add 5-5 and 5-6 Add DV11 extended models: DVD100, U2, U3 2009.03.05...
  • Page 2 DV11 / DVD100 / U2 / U3 Comparison List Parts DV11 DVD100 TOP COVER MODULE 75.85E16G001 75.85E16G011 75.85E22G001 70.85E36GR01 (USA) MAIN BD MODULE 70.85E40GR01 70.85E39GR01 70.85E40GR01 (EMEA) 51.85E14G002 (USA) LAMP COVER 51.85E14G001 51.85E14G001 (EMEA) REAR COVER MODULE 75.85E09G001 75.85E23G001 DV11 / DVD100 / U2 / U3...
  • Page 3 The information found in this manual is subject to change without prior notice. Any subsequent changes made to the data herein will be incorporated in future edition. Service Manual DV11 / DVD100 / U2 / U3 Copyright March, 2009 All Rights Reserved Manual Version 4.0 DV11 / DVD100 / U2 / U3 Confidential...

  • Page 4: Table Of Contents

    Disassemble Bottom Cover Module 2-12 Disassemble Engine Module 2-12 Disassemble Bottom Base Plate Module 2-13 Disassemble Engine & Color Wheel 2-13 Disassemble Zoom Ring & Focus Ring 2-14 Disassemble DMD Chip 2-15 DV11 / DVD100 / U2 / U3 Confidential...
  • Page 5 DVD Funcation Check Optical Performance Measure Others 4-11 Chapter 5 Firmware Upgrade Equipment Needed DLP Composer Lite Setup Procedure USB Driver Upgrade Procedure Firmware Upgrade Procedure DVD Region Code DVD Code Installation Procedure DV11 / DVD100 / U2 / U3 Confidential...
  • Page 6 Chapter 6 EDID Upgrade EDID Introduction Equipment Needed Setup Procedure EDID Key-In Procedure Appendix A Recommended Spare Parts Appendix B Serial Number System Definition PCBA Code Definition DV11 / DVD100 / U2 / U3 Confidential...

  • Page 7: Chapter 1 Introduction

    � �� 15.0� � 1�.78 mm��� ��2.8��� 1.1X. ● 180�att P��oenix �am�. �am� li�e 1500 ��ours based on 180Watt Phoenix Lamp. Lamp life 1500 hours based on Lamp life P��oenix DC lam� s�e�ifi�ation System controller ● �I DDP2000 TI DDP2000 DV11 / DVD100 / U2 / U3 Confidential...

  • Page 8: Compatible Mode

    ● ��eratin��� 5���C �� 35���C ��eratin��� 5���C �� 35���C Temperature (Satisfied en�ineerin� s�e�ifi�ation & �un�tions) ● Stora�e�� �10���C �� �0���C Stora�e�� �10���C �� �0���C 1-2 Compatible Mode Analog Compatibility Resolution ��Syn� [����] ��Syn� [K����] 640x350 31.46 640x400 31.46 640x480 37.86 640x480 37.5 640x480 43.26 720x400 31.46 720x400 37.92 DV11 / DVD100 / U2 / U3 Confidential...
  • Page 9 1280x1024 64.31 640x480 31.4 640x480 37.41 640x480 37.5 640x480 43.26 800x600 35.15 800x600 37.81 800x600 48.13 MAC (G4) 800x600 46.87 800x600 53.67 1024x768 48.27 1024x768 56.47 1024x768 60.2 1024x768 68.67 1152x870 68.76 DV11 / DVD100 / U2 / U3 Confidential...

  • Page 10: Disassembly Process

    * Note: - If you need to replace the main board, you have to get into service mode and record the lamp usage hour. please refer to section 2-25. - As the process of DVD100 / U2 / U3 disassembling is the same as DV11, we take DV11 for example here.

  • Page 11: Disassemble Lamp Cover

    2-2 Disassemble Lamp Cover 1. Unscrew 1 screw on the lamp cover 2-3 Disassemble Lamp Module 1. Unscrew 2 screws on the lamp module DV11 / DVD100 / U2 / U3 Confidential...

  • Page 12: Disassemble Top Cover Module

    - Hold the CNNT plug when pulling the FPC cable is strongly recommended. Pulling the cable directly from the unit will cause the cable damages. - Make sure cables are plug in the correct ports when assembling the unit. DV11 / DVD100 / U2 / U3 Confidential...

  • Page 13: Disassemble Keypad Board

    1. unscrew 4 screws on the keypad Note: - Make sure cables plug into the correct ports when assembling the unit. 2-6 Disassemble Speaker Module 1. Unscrew 4 screws on the speaker DV11 / DVD100 / U2 / U3 Confidential...

  • Page 14: Disassemble Front&Back Cover Module

    2-7 Disassemble Front&Back Cover Module 1. Unscrew 2 screws and take out the back cover 2-8 Disassemble EMI Front Cover 1. Unscrew 3 screws on the EMI front cover DV11 / DVD100 / U2 / U3 Confidential...

  • Page 15: Disassemble Dvd Module

    Module 1. Unscrew 4 screws on the system Note: - Use two fingers to pull out the cover - Refer to the image on the bottom right corner to unplug the cables DV11 / DVD100 / U2 / U3 Confidential...
  • Page 16 Note: - Make sure cables plug into the correct ports when assembling the unit. - When you disassemble the FPC cable, you should use two figures to parallel pull out the hook. DV11 / DVD100 / U2 / U3 Confidential...

  • Page 17: Disassemble Mb Module

    Note: - Each cable should be plug into the correct ports. - Avoid cables interrupt with system fan when organizing the cables. (see images) - Use an electrostatic ion gun to puff the main board connector DV11 / DVD100 / U2 / U3 Confidential...

  • Page 18: Disassemble Air Cut Module

    1. Unscrew 3 screws and take out the air cut module 2-12 Disassemble System Fan Module 1. Unscrew 3 screws on the fan module 2. Unscrew 4 screws on the system fan DV11 / DVD100 / U2 / U3 Confidential...

  • Page 19: Disassemble Lamp Driver Module

    1. Unscrew 2 screws and take out the lamp line 2. Unscrew 2 screws to take out the lamp driver from bottom cover 3. Unscrew 4 screws to separate the lamp driver and lamp driver holder DV11 / DVD100 / U2 / U3 Confidential 2-10...

  • Page 20: Disassemble Lvps Module

    2-14 Disassemble LVPS Module 1. Unscrew 5 screws on the LVPS 2-15 Disassemble Power Bracket 1. Unscrew 5 screws DV11 / DVD100 / U2 / U3 Confidential 2-11...

  • Page 21: Disassemble Bottom Cover Module

    2-16 Disassemble Bottom Cover Module 1. Unscrew 1 screw on the bottom base 2-17 Disassemble Engine Module 1. Unscrew 4 screws on the engine module DV11 / DVD100 / U2 / U3 Confidential 2-12...

  • Page 22: Disassemble Bottom Base Plate Module

    1. Unscrew 3 screws on the blower fan 2. Unscrew 2 screws on the limit switch 2-19 Disassemble Engine & color wheel 1. Unscrew 1 screw on the thermal switch 2. Unscrew 1 screw on the color wheel DV11 / DVD100 / U2 / U3 Confidential 2-13...

  • Page 23: Disassemble Zoom Ring & Focus Ring

    3. Unscrew 1 screw on the photo sensor board Note: - The manner of holding a color wheel (see image) 2-20 Disassemble Zoom Ring & Focus Ring 1. Unscrew 3 screws on the focus ring 2. �ns�re� 2 s�re�s on t��e ���oom rin� DV11 / DVD100 / U2 / U3 Confidential 2-14...

  • Page 24: Disassemble Dmd Chip

    - To double check and see if the pin is out of shape. DV11 / DVD100 / U2 / U3 Confidential 2-15...

  • Page 25: Rod Module

    2-23 Bottom Cover Module & Elevator 1. Unscrew 2 screws on the elevator 2. When disassembling the springs, please refer to the bottom images. DV11 / DVD100 / U2 / U3 Confidential 2-16...

  • Page 26: 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 adjusting, add green glue to fasten DV11 / DVD100 / U2 / U3 Confidential 2-17...

  • Page 27: Re-Write Lamp Usage Hour

    2. � se "u�" or "do�n" ��ey to sele�t "Exit"��� t��en use "left" or "right" key to re-write the lamp hour back to previous lamp usage hour. 3. Press "�nter" to exit t��e ser�i�e mode. Note: left key = decrease lamp hour right key =increase lamp hour DV11 / DVD100 / U2 / U3 Confidential 2-18...

  • Page 28: Chapter 3 Troubleshooting

    Power LED Temp LED Lamp LED Message (Green) (Blue) (Red) (Red) Standby State Flashing (input power cord) Normal Mode Cooling Flashing Error (Lamp failed) Error Flashing (Fan failed) Error (Over Temp.) Light on Light off DV11 / DVD100 / U2 / U3 Confidential...

  • Page 29: Main Procedure

    - Check Photo Sensor Auto Shut Down b. Temp LED lights red - Check Thermal Sensor - Check Thermal Switch - Check Fan c. Temp LED flashing red - Check Fan - Check Main Board DV11 / DVD100 / U2 / U3 Confidential...
  • Page 30 - Check DMD Chip � Do ��eset (All data)” o� t��e �SD �enu - Ensure that the signal cables and source are work as well Image Flicker - Check Lamp Module - Check Color Wheel- Check DMD Board - Check Main Board DV11 / DVD100 / U2 / U3 Confidential...
  • Page 31 Remote Controller c.IR receiver Remote Control/ d.Check Main Board Control Panel Failed - Control Panel a.Check FPC b.Check keypad c.Check Main Board � Do ��eset (All data)” o� t��e �SD �enu Function Abnormal - Check Main Board - Check DMD Board DV11 / DVD100 / U2 / U3 Confidential...
  • Page 32 - Check if the disk is scratched. - Check if the anti-static protection of DVD Loader Module is unsoldered. Disk cannot be read - Check if the region code is correct or not. - Check DVD Loader Module. DV11 / DVD100 / U2 / U3 Confidential...

  • Page 33: Function Test & Alignment Procedure

    4-3 OSD Reset 1. A �ter final QC ste���� �e ��a�e to erase all sa�ed ���an�e a�ain and resotre t��e �SD 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) �o exe�ute "�eset" �un�tion. DV11 / DVD100 / U2 / U3 Confidential...

  • Page 34: Test Condition

    Set burn in cycle Press right key to adjust the cycle After setting up the time, choose Burn-In mode and hit enter Screen Defects (While replacing DMD Chip, DMD BD and MB) < �i�ure�� Zone A &B Definition > DV11 / DVD100 / U2 / U3 Confidential...

  • Page 35: Test Inspection Procedure

    - Eliminate visual wavy noise by Rsync, Fre- Inspection item quency or Tracking selection. Master - Check if there is noise on the screen. � � ori���ontal and �erti�al �osition o� t��e �ideo should be adjustable to the screen frame. DV11 / DVD100 / U2 / U3 Confidential...
  • Page 36 - Test Pattern: blue 60 Inspection item - Dark blemish check.(dirty) Criteria - The bright blemish is unacceptable when it ap- pears on blue 60 pattern. Blue 60 � � e�. De�e�t s�e�ifi�ation table Note�� ���e de�e�t �riteria �ollo�s �I s�e�ifi�ation. DV11 / DVD100 / U2 / U3 Confidential...
  • Page 37 (Blur word on one of the corner after adjustment is acceptable. However, the �ord s��ould at least be re�o�ni���able.) MEME Sony DV11 / DVD100 / U2 / U3 Confidential...
  • Page 38 SMPTE RP-133 - Grey level should not have abnormal color or heavy lines. - The PC mode functionally sure be workable include support format with frequency and auto detected functional will be workable DV11 / DVD100 / U2 / U3 Confidential...

  • Page 39: Video Performance

    - Check any abnormal color, line distortion or any Motion video noise on the screen. - Check the sound from speakers. 2. S-Video Procedure - Test equipment: DVD player - Test signal: S-Video DV11 / DVD100 / U2 / U3 Confidential...

  • Page 40: Dvd Funcation Check

    - Check the sound from speakers. � C��e��� ��olume” is normal � C��e��� ��ute” is normal 4-9 DVD Function Check Material - DVD Procedure - Put DVD into DV11 � P ress "�lay" and ���e��� i� t��e dis�lay ima�e is normal - Check DVD keypad function (FWD, REW, S��P��� �olume ��� ) logo DV11 / DVD100 / U2 / U3 Confidential...

  • Page 41: Optical Performance Measure

    - Use CL100 to measure brightness values of P1�P13. - Follow the brightness formula to calculate brightness values. ☼ Bri���tness � ormula Full white pattern A��. (P1�P2�P3�...�P9) x 1.1 Criteria �� 495 Lumens �� 495 Lumens 495 Lumens DV11 / DVD100 / U2 / U3 Confidential...

  • Page 42: Others

    ANSI �ni�ormity �� A��. (P1��� P3��� P7��� P9) x 100� Criteria • 75 � 4-9 Others 1. Functional Inspection Keypad button - All keypad buttons must operate smoothly. General - All OSD functions must be DV11 / DVD100 / U2 / U3 Confidential 4-10...
  • Page 43 Focus ring Focus ring is functioning smoothly. missing logo, missing prints and blurry prints are Logo unacceptable screw All s�re� sure be fixed and in ri���t ty�e. DV11 / DVD100 / U2 / U3 Confidential 4-11...
  • Page 44 All plastic parts can not be broken and Plastic parts damaged. Safety or warning All safety and warning label should be visible, label including all contents. All interface connectors should be complete and Connector workable. DV11 / DVD100 / U2 / U3 Confidential 4-12...

  • Page 45: Firmware Upgrade

    - Power code - USB Cable - PC or Laptop Note: The FW Upgrade procedure for DVD100 / U2 / U3 is the same as DV11, we take DV11 for example here. DV11 / DVD100 / U2 / U3 Confidential...

  • Page 46: Dlp Composer Lite Setup Procedure

    5-2 DLP Composer Lite Setup Procedure 1. C ��oose �D�P Com�oser �ite ��.0 Setu�” Program. 2. Cli��� �Next” buttom 3. � ead ��i�ense A�reement.” � C ��oose �I aa�e�t and a�ree to be bound by all the terms and conditions of this �i�ense A�reement.” �.. Cli��� �Next.” DV11 / DVD100 / U2 / U3 Confidential...
  • Page 47 5. Cli��� �Next.” �. Cli��� �Next.” 7. Writing system registry values 8. Cli��� ��inis��.” DV11 / DVD100 / U2 / U3 Confidential...

  • Page 48: Usb Driver Upgrade Procedure

    Note: The system fan and the light will not operated. 2. Execute Program � ��en t��e �D�P Com�oser �ite ��.0” folder. � Sele�t and double �li��� �usbu�date.�md”. Note: “DLP Composer” must be closed first. 3. Press any key to continue and wait for about 1 minute. 4. Update Successfully. � Cli��� ��K”. DV11 / DVD100 / U2 / U3 Confidential...
  • Page 49 � � i���t �li��� ��y Com�uter” on t��e des��to�. � S ele�t �Pro�erties” on t��e �o�u� menu to laun��� t��e �system �ro�erties” �indo�. � C ��oose ��ard�are” and t��en �li��� �De�ice �an�er”. Cli��� ��un�o” to ensure � DDP 2000” and ��indri�er” are �ro�erly installed. I� not��� repeat the above steps. Note: If you have installed the USB driver, there is no need to perform this action. DV11 / DVD100 / U2 / U3 Confidential...

  • Page 50: Firmware Upgrade Procedure

    ��” 2. �xe�ute t��e �D�P Com�ose file. 3. Cli��� �edit” and ��er�eren�es.” �. Cli��� ��ibrary.” - The library path located in the default installation directory. - C:\Program Files\DLP Composer Lit 6.0 Note: If not, press “Browse” to select the right path. DV11 / DVD100 / U2 / U3 Confidential...
  • Page 51 5. Sele�t ��dit\�re�eren�es\Communi�ations” � ���oose ��SB.” Cli��� ��K.” C��oose ��las�� �oader.” � C li��� �Bro�se” to sear��� t��e firm�are file. 7. S elete t��e item �s��i� Boot �oader Area (select 16KB) � C li��� ��eset Bus” to erase t��e flas�� memory 8. I � t��e firm�are is ready��� �li��� �start do�nload” to �ro�ess t��e firm�are upgrade. � Cli��� ��es” to erase t��e flas�� memory. DV11 / DVD100 / U2 / U3 Confidential...
  • Page 52 - Unplug USB cable and power cord and replug in power cable. 10. Restart the unit and get into the service mode to ���e��� t��e firm�are �ersion. (To get into service mode, please refer to Chapter 4 Funcation Test and Alignment Procedure.) DV11 / DVD100 / U2 / U3 Confidential...

  • Page 53: Dvd Region Code

    6. Region 6 - China 5-6 DVD Code Installation Procedure 1. Turn on DV11 unit and wait until the right image shows on the screen (signal source is from DVD loader) 2. Put the DVD code CD into DVD loader. The CD will be running automatically.
  • Page 54 3. Please wait until the installation process finis��. ���e CD �ill e�e�t automati�ally 4. Press the number buttons, 1 to 4, on the remote control to check if the DVD code is correct or not DV11 / DVD100 / U2 / U3 Confidential 5-10...

  • Page 55: Edid Upgrade

    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 DVD100 / U2 / U3 is the same as DV11, we take DV11 for example here.
  • Page 56 - EDID Program (Generic V0.51) - EDID File (*.ini) Hardware - Projector � Generi� �ixture (80.00001.001) �or �DID Key�in (�ixture�� �P3 must be �losed) - Power code x 2 - RS-232 Cable (pin to pin, F-M) - Monitor - PC - VGA cable � Po�er ada�ter �or fixture (�7.57702G001) DV11 / DVD100 / U2 / U3 Confidential...
  • Page 57 1. Cli��� on "�DID" to exe�ute �DID �ro�ram 2. Choose model a. in the port selection bar, please choose the port that you use. ie: if you use "C��1��� " ���oose C��1 in t��e �ort selection. b. �li��� on "�odel." c. Select VGA in write source DV11 / DVD100 / U2 / U3 Confidential...
  • Page 58 6. Read EDID information � I n t��e "read item��� " sele�t "analo�" and "trans" � Press "read" to ���e��� t��e serial number Note: If EDID upgrade failed, push the reset button on the EDID board and re-proceed step 3 to step 5 in section 6-4. DV11 / DVD100 / U2 / U3 Confidential...
  • Page 59 Description Photo 11.009F0G005 CNN� � 1��P ��� 0.55" SVGA LGA 43.85E01G001 THERMAL SWITCH K�IX�N 125 D�G� 48.859DMGD13 D�D 800*�00 PIX�� DD� FTP 0.55 49.82Y02G001 SUSON 4520 BLOWER R �9.83�01G001 70x20 SYSTEM FAN, SU- NON GM1207 51.85E14G001 (DV11) �A�P C���� ��I�IN PC(MN-3600H) 51.85E14G001 (DVD100/U2/U3) DV11 / DVD100 / U2 / U3 Confidential...
  • Page 60 ASSY ROD MODULE 70.82G16GR01 EP7190 (RMA) 70.85E28GR01 ASSY COLOR WHEEL MODULE FOR DV11(RMA) 70.85E29GR01 ASSY ENGINE MODULE DV11 (RMA) ASSY FOCUS RING MOD- 70.85E35GR01 ULE DV11 (RMA) 75.85E01G001 BUY ASSY SPEAKER ��D��� �IB�X DV11 / DVD100 / U2 / U3 Confidential...
  • Page 61 DRIVER KDRM08 75.85E09G001 (DV11) BUY ASSY REAR COVER MODULE 75.85E23G001 (DVD100/U2/U3) 75.85E08G001 BUY ASSY FRONT COVER DV11 75.85E11G001 BUY ASSY BOTTOM COV- ER MODULE DV11 75.85E13G001 BUY ASSY INTERRUPT- ER SWITCH DV11 DV11 / DVD100 / U2 / U3 Confidential...
  • Page 62 BUY ASSY TOP COVER MODULE 75.85E16G011 (DVD100) 75.85E22G001 (U2/U3) 75.85E18G001 ASSY HITACHI LAMP DRIVER 180W 75.85S15G001 BUY ASSY CEILING MOUNT MODULE HD70 80.82G06G001 PCBA PHOTO SENSOR BOARD EP719 Active 80.85E01G001 PCBA DMD BD FOR DV11 DV11 / DVD100 / U2 / U3 Confidential...
  • Page 63 80.85E03G001 PCBA KEYPAD BD FOR DV11 80.85E04G001 PCBA CONNECTOR BD FOR DV11 80.85E05G001 PCBA FRONT IR SENSOR BD DV11 80.85E06G001 PCBA TOP IR SENSOR BD DV11 SP.85E01GC01 LAMP CHANGER MOD- ULE DV11 DV11 / DVD100 / U2 / U3 Confidential...
  • Page 64 Item Latest Description Photo 35.82001G111 �AB�� CA���N 3"*3" B�ANK P�885 36.85E04G001 USER'S MANUAL FOR USA/ASIA 45.85E01G001 REMOTE CONTROL DV11 42.86502G101 ADAPTER D-SUB TRANS- FORM RCA 42.87205G201 CABLE COMPOSITE VIDEO 35.52302G091 LABEL CARTON 108*92 BLANK DV11 / DVD100 / U2 / U3 Confidential...
  • Page 65 Item Latest Description Photo 35.00040G001 LABEL 30mm,GREEN 35.00041G001 LABEL 35mm,YELLO 35.00042G001 "��AGI��" �AP� 60mm*50Y*0.05mm 56.85E01G001 CUSHION DV11 55.85E01G001 CARTON OPTOMA LOGO DV11 35.85E01G001 SPEC LABEL 104*65 DV11 DV11 / DVD100 / U2 / U3 Confidential...
  • Page 66 Item Latest Description Photo 35.85E03G001 LICENCE LABEL 70*50 DV11 DV11 / DVD100 / U2 / U3 Confidential VIII...
  • Page 67 C = Manufacture factory (TW or CPC) 0001 = Serial code �X�� Q85�71�AAAAAC0001 This label represents the serial number for DV11. It is produced for USA at CPC on fourteenth week of 2007. Its serial code is 0001. DV11 / DVD100 / U2 / U3 Confidential...
  • Page 68 II. PCBA Code Definition PCBA Code for Projector XXXXXXXXXX EEEE Vendor Code Revision Date Code DV11 / DVD100 / U2 / U3 Confidential...

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