Optoma HD72 Serivce Manual
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Optoma HD72 Serivce Manual

0.65” dark chip 2 dmd projection system
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SERVICE MANUAL

Date
Version
2006/02/27
V2.0
Model Name : HD72
Prepared by SI :
Prepared by TSE :
________________________________________
Checked by :
Approved by :
________________________________________
Initial Issue
Copyright February, 2006 . All Rights Reserved
P/N#36.83F01.001 . Document#83F-G04-01A
________________________________________
________________________________________
Description

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Summary of Contents for Optoma HD72

  • Page 1: Service Manual

    SERVICE MANUAL Model Name : HD72 Prepared by SI : ________________________________________ Prepared by TSE : ________________________________________ Checked by : ________________________________________ Approved by : ________________________________________ Date Version Description 2006/02/27 V2.0 Initial Issue Copyright February, 2006 . All Rights Reserved P/N#36.83F01.001 . Document#83F-G04-01A...
  • Page 2 Preface This manual is applied to HD72 0.65” Dark Chip 2 DMD 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

    Chapter 4 Function Test and Alignment Procedure Test Equipment Needed Service Mode Test Condition Inspection Procedure Chapter 5 Firmware Upgrade Procedure Equipment Needed Firmware Upgrade Mode Installation Procedure Firmware Upgrade Procedure Chapter 6 EDID Upgrade Procedure EDID Introduction Equipment Needed HD72...
  • Page 4 Setup Procedure EDID Key-In Procedure Appendix Appendix A Exploded Overview Appendix B 7-28 I . Serial Number System Definition 7-28 II. PCBA Code Definition 7-29 Reader’s Response 7-30 HD72...

  • Page 5: Chapter 1 Introduction

    Input signal spec. - PC Signal - Hsync Frequency 31.5 ~ 100 kHz - Vsync Frequency 56 ~ 85 Hz - Video Signal RGB (PC) - Analog RGB 0.7 Vp-p, 75 ohm - Separate TTL H, V Sync Composite TTL Sync. HD72...
  • Page 6 - Ceiling Mount - new ceiling mount with the pole centred above the lens - Carry case - HDMI to DVI adaptor Full Printed manual - EMEA & USA : English, French, German, Spanish and Portuguese - ASIA : English, Traditional Chinese, Japanese, Korean and Simplified Chinese, HD72...
  • Page 7 Polish, Norwegian,(No/DK), Russian, Finnish, Traditonal Chinese, Simplified Chinese, Japanese, Korean Color Wheel - 7 segment colour wheel GRBWGRB (G56R62B47W30G56R62B47). Noise - 29 dB (A) Quick shut down - 30 seconds Input connectors - DVI-I, HDMI, 3xRCA component, Composite, S-Video HD72...

  • Page 8: Computer Compatible

    800 x 600 800 x 600 800 x 600 800 x 600 1024 x 768 1024 x 768 1024 x 768 1024 x 768 1024 x 768 WXGA 1280 x 768 1280 x 768 1280 x 768 1280 x 768 HD72...
  • Page 9 1280 x 1024 1280 x 1024 1280 x 1024 1280 x 1024 1280 x 1024 SXGA+ 1400 x 1050 1400 x 1050 1400 x 1050 1400 x 1050 1400 x 1050 1152 x 870 75.06 MAC G4 640 x 480 HD72...

  • Page 10: Equipment Needed

    Chapter 2 Disassembly Process 2-1 Equipment Needed Item Photo Item Photo Screw Bit Hex Sleeves (+) :107 Sleeves Tweezers HD72...

  • Page 11: 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 HD72...
  • Page 12 Procedure Photo Unscrew 5 screws and un- plug FPC Wire to remove Top Cover Note : There is a tennon in each side, please press left and right side cover to separate top cover easier. Top Cover HD72...
  • Page 13 Top Shielding Module Note : There are four ten- nons, before separate the top shield, please press them (Green square in right picture). Top Shielding Module Unscrew 1 screw to remove Keypad Board Keypad Board HD72...
  • Page 14 Procedure Photo Remove Keypad Button directly. Keypad Button Remove IR receiver, Mylar and lens from Top Cover directly. IR Receiver HD72...

  • Page 15: 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 2 hex screws and 2 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 HD72...
  • Page 16 Procedure Photo Unscrew 3 screws to re- move Air Duct Module. Air Duct Module Unscrew 5 screws and unplug 7 connectors to re- move Main Board Main Board HD72...
  • Page 17 Procedure Photo Remove Main Board Mylar from Main Board Main Board Mylar Unscrew 5 screws (red circle) and unplug 3 con- nectors (green square) to remove Lamp Driver and Lamp Driver Holder. Lamp Driver Lamp Driver Holder HD72...
  • Page 18 Procedure Photo Unscrew 5 screws to re- move LVPS Shielding Module. Unplug 3 connectors to remove LVPS HD72...
  • Page 19 Procedure Photo Unscrew 2 screws to re- move Axial Fan Module. Axial Fan module HD72 2-10...

  • Page 20: Disassemble Engine Module, Dmd Chip, Dmd Board, Color Wheel And Photo Sensor Board

    Color Wheel and Photo Sensor Board. Procedure Photo Unscrew 2 screws to re- move Wire 2P#22 220C. Wire 2P#22 220C Unscrew 7 screws to re- move Engine Module and remove Upper Lens Sup- porrer directly. Upper Lens Supporter Engine Module HD72 2-11...
  • Page 21 Procedure Photo Unscrew 4 screws to re- move Heatsink and 2 Springs. Unscrew 4 hex screws to remove DMD Board and DMD Chip. DMD Board & DMD Chip HD72 2-12...
  • Page 22 Procedure Photo Unscrew 2 screws to re- move Color Wheel and Photo Sensor Board. Color Wheel & Photo Sensor Board HD72 2-13...

  • Page 23: Disassemble Focus Ring, Dmd Fan, Speaker, Blower Fan And Elevator Module

    2-5 Disassemble Focus Ring, DMD Fan, Speaker, Blower Fan and Elevator Module Procedure Photo Unscrew 3 screws to sepa- rate Replace Ring from Focus Ring. Focus Ring Remove DMD Fan directly. DMD Fan & Speaker HD72 2-14...
  • Page 24 Procedure Photo Unscrew 1 screw to remove thermal switch. Unscrew 3 screws to re- move and separate Power Shielding Module. HD72 2-15...
  • Page 25 Unscrew 2 screws to re- move Interrupt Switch Module. Interrupt Switch Module Unscrew 1 screw to remove PCBA Thermal Sensor BD. Thermal Sensor BD Unscrew 1 screw and 1 hex spacer to remove Bottom Base and Down Less Sup- portor. HD72 2-16...
  • Page 26 Procedure Photo Unscrew 2 screws to re- move Front Shielding Mod- ule. Front Shielding Module HD72 2-17...

  • Page 27: Chapter 3 Troubleshooting

    - Check Main Board Video, S-Video and Component at - Check DMD Board - Check Color Wheel the same time, the third source will not be searched due to the original - Check DMD Chip design. - Check Engine Module HD72...
  • Page 28 - 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 HD72...
  • Page 29 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 HD72...

  • Page 30: Test Equipment Needed

    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. HD72...

  • Page 31: Test Condition

    - Circumstance Brightness : Dark room less than 10 lux. - Inspection Distance : 1.5m~3m for functional inspection - Screen Size : 60 inches diagonal (wide) - After repairing each HD72, the unit should be burn-in (Refer to the table below). Symptom Burn-in Time...
  • Page 32 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. HD72...
  • Page 33 Gray 10 accepted if the problem appear with Gary 10 pat- tern Blemish The dark blem- - Test Pattern : (Dark) ish cannot be Blue 60 accepted if the problem appear with Blue 60 pat- tern. HD72...
  • Page 34 Step Specification Procedure Photo FW version Ensure FW is the - In Service Mode Latest version. - FW must be the latest version EDID Ensure the EDID - Read EDID data is available via DVI-analog, DVI-Digital and HDMI port. HD72...

  • Page 35: Chapter 5 Firmware Upgrade Procedure

    Chapter 5 Firmware Upgrade Procedure Equipment Needed Software : (DDP 2000- USB) - DLP Composer (Version 6.0) - Firmware (HD72 *.img) - Library files Hardware : Item Photo Item Photo Projector USB Cable (HD72) PC or Lap- Power Cord Firmware Upgrade Mode: Before doing firmware upgrade, please get into firmware mode first.

  • Page 36: 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. HD72...
  • Page 37 Step Procedure Photo Next 1. Choose “All” icon. 2. Click “Next” button. Next Click “Next” button. Process- The program is execut- ing “Initializing” status. HD72...

  • Page 38: Usb Driver Upgrade Procedure

    Projector & 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. HD72...
  • Page 39 “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 HD72...

  • Page 40: Firmware Upgrade Procedure

    2. The library path located in the default installation directory is C:\Program Files\ DLP Composer Lite 6.0\CCA_Library\ 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 HD72...
  • Page 41 Step Procedure Photo 1. Choose “Flash Loader” 2. Click “Browse” to search the firmware file. (HD72) 3. Select the item “Skip Boot Loader Area 4. Select 64KB).” 5. Click “Reset Bus” to erase the flash memory. (Note: If the error mes- sage “cannot open USB...
  • Page 42 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.) HD72...

  • Page 43: Edid Introduction

    - EDID Program (Generic V0.51) - EDID Table (*.ini) Hardware: - V3 Fixture for EDID Key-in (Fixture: JP3 must be closed) Item Photo Item Photo Power VGA-DVI Adapter for Cable Fixture Generic DVI Cable Fixture RS232 Power Cord Cable HDMI-DVI Projector Adapter (HD72) HD72...

  • Page 44: Setup Procedure

    Photo One additional monitor (for checking the pro- gram execution) Setup Procedure Note: HD72 includes VGA, DVI and HDMI function, please burn in EDID for each function. Step Procedure Photo C o n n e c t 1. Power Adapter to Fixture JP1 All Ports 2.
  • Page 45 2. Click “Program”. Change - “Please change the Cable Cable to to VGA” message is shown on the screen. - Connect the port P2 of fixture to the DVI port of HD72 by VGA-DVI Cable - Click “OK” HD72...
  • Page 46 - “Please change the Cable Cable to to Digital” message is Digital shown on the screen. - Connect Port P3 of fixture to DVI Port of HD72 by DVI Cable. - Click “OK” When the EDID program is Finished completed, the message, “OK”, will appear on the...
  • Page 47 2. Click on “Read” to read EDID information. 3. The “EDID Informations” will show the result. 4. Click “Reset” to do the next unit or “Exit” to close the EDID program. Note: Please make sure the EDID of DVI and HDMI has burned in. HD72...

  • Page 48: Appendix

    Appendix A Exploded Overview 1. HD72 Unit HD72...
  • Page 49 YM10 ZOOM RING PC+ABS MB1700 HD72 51.83F11G001 LAMP COVER PC HD72 51.83F30G001 DMD HEATSINK MYLAR FOR THERMAL GS 0.43t HD72 51.83F31G001 LAMP LIGHT CUT MYLAR FRPP 0.43t HD72 61.00018G002 LOCK SCREW PAN MECH M3*8.5-3.5 BLACK 70.83F01G001 ASSY TOP COVER MODULE HD72 FOR OPTOMA DCDI 70.83F02G001 ASSY BOTTOM COVER MODULE HD72 75.83F11G001...
  • Page 50 ASSY TOP COVER MODULE HD72 HD72...
  • Page 51 Item Part NO Description 42.83F04G001 CABLE FFC 14P PITCH=1.0mm HD72 51.83F01G001 TOP COVER PC MN3600 HD72 FOR OPTOMA EXCLUDE 51.83F07G001 KEYPAD BUTTON PC HD72 51.83F08G001 IR FRONT MOUNT PC HD72 51.83F26G001 FRONT IR MYLAR 0.2t HD72 51.83F29G001 KEYPAD LED LENS HOLDER PC HD72 75.83F09G001...
  • Page 52 ASSY BOTTOM COVER MODULE Item Part NO Description 51.83F12G001 FRONT LOWER PANEL PC MN3600 HD72 75.83F03G001 BUY ASSY BOTTOM COVER MODULE HD72 75.83F05G001 BUY ASSY FRONT SIDE SHIELDING HD72 85.WA123.080 SCREW PAN TAP M3*8 Ni 80.83F06G001 PCBA THERMAL SENSOR BD H72...
  • Page 53 ASSY LAMP MODULE H72 HD72...
  • Page 54 LAMP INSULATOR AL 2300MPX 61.83F08G001 LAMP HOLDR Mg AZ91D HD72 61.83J08G001 LAMP LIGHT CUT AL 0.6t PD527 61.83F10G001 LAMP MESH OUT OSRAM SUS301 t=0.1 HD72 61.83F11G001 LAMP ANTIGLASS LAMP SUS301 t=0.25 HD72 61.83F12G001 LAMP CLAMP SUS301 t=0.3 HD72 61.87125G001 LAMP HADNLER SUS304 61.88506G001...
  • Page 55 ASSY PCB MAIN BD MODULE HD72 Item Part NO Description 80.83F02G002 PCBA MAIN BD ENTEK FOR HD72 USA 51.83F23G001 MB UP INSULATOR MYLAR FRPP 0.43t HD72 51.83F24G001 MB DOWN INSULATOR MYLAR FRPP 0.43t HD72 51.83F32G001 M/B DOWN INSULATOR I/O MYLAR FRPP 0.43t...
  • Page 56 ASSY POWER MODULE HD72 Item Part NO Description 70.83F07G001 ASSY LAMP DRIVER MODULE HD72 70.83F08G001 ASSY LVPS MODULE H72 75.83F08G001 BUY ASSY POWER SHIELDING MODULE HD72 85.1C224G050 SCREW PAN MECH M4*5 COLOR W/TOOTH WASHER 85.1F123G060 SCREW PAN MECH W/SF M3*6 Ni GREEN HD72...
  • Page 57 ASSY LAMP DRIVER MODULE HD72 Item Part NO Description 51.83F20G001 LAMPDRIVER HOLDER PC MN3600 HD72 85.1F123G060 SCREW PAN MECH W/SF M3*6 Ni GREEN 42.80S03G001 W.A. 5P #28 210mm LVPS TO MB TDP-T90 75.83J01G001 ASSY OSRAM LAMPDRIVER 230W 76.83F01G001 ASSY LAMP DRIVER(OSRAM)) TO LAMP W.A.
  • Page 58 ASSY LVPS MODULE HD72 Item Part NO Description 70.83F09G001 ASSY SUB LVPS MODULE HD72 75.83F07G001 BUY ASSY LVPS SHIELDING MODULE HD72 85.1F123G060 SCREW PAN MECH W/SF M3*6 Ni GREEN 51.00001G001 CABLE TIE PG-YJ-80 HD72 7-11...
  • Page 59 ASSY SUB LVPS MODULE HD72 Item Part NO Description 75.83F12G001 ASSY LVPS TIGERPOWER 200W H72 42.80S07G001 W.A. 14P 190mm LVPS TO M/B TDP-T90 ‘’ 42.81R09G001 W.A. 2P #20 220mm LVPS/BALLAST DV10 42.81R13G001 W.A. #28 2P LIMITE SWITCH EXTENTION CABLE 115mm DV10 43.83F17G001...
  • Page 60 ASSY ENGINE & BOTTOM BASE MODULE HD72 Item Part NO Description 41.83F16G001 GASKET Glue/W*10 H*10 L*40 41.83F20G001 GASKET Glue/W*10 H*20 L*35 61.81R06G001 M/B STAND BRACKET AL 5052 t=1.0 & STEEL HS DV10 70.83F11G001 ASSY ENGINE MODULE HD72 70.83F18G001 ASSY BOTTOM BASE MODULE H72 85.1F123G060...
  • Page 61 ASSY ENGINE MODULE HD72 HD72 7-14...
  • Page 62 61.80J48G002 DMD HEATSINK BACKER PLATE A6061 739 61.88608G001 DMD HEATSINK SPRING PLATE SUS301 0.4t Ivy10X 61.88611G001 DMD SCREW Ivy10X 70.83F12G001 ASSY SUB ENGINE MODULE HD72 80.83F01G001 PCBA DMD BD WXGA FOR H72 85.1A523G040 SCREW PAN MECH M3*4 NYLOK HD72 7-15...
  • Page 63 ASSY SUB ENGINE MODULE HD72 HD72 7-16...
  • Page 64 ASSY OPTICAL LENS MODULE HD72 70.83F14G001 ASSY COLOR WHEEL MODULE HD72 70.83F15G001 ASSY ROD MODULE HD72 70.83F16G001 PRE ASSY ENGINE BASE MODULE HD72 70.80N19.001 PRE ASSY ENGINE BOTTOM MODULE EP739 85.1A326G060 SCREW PAN HEAD MECH M2.6*6 BLACK 85.1A526G060 SCREW PAN MECH M2.6*6 Ni NYLOK 85.1A626G040...
  • Page 65 ASSY OPTICAL LENS MODULE Item Part NO Description 23.83F01G002 YM10 PROJECTION ZOOM LENS WITH MASK FOR 739 series,F/2.5~F/2.8 51.83F06G001 YM10 FOCUS RING PC+ABS MB1700 HD72 85.WA321G040 SCREW PAN TAP M1.7*4 BLACK HD72 7-18...
  • Page 66 CW HOLDER 739 SECC 1.2t 52.83615G001 COLOR WHEEL DISC RUBBER, EzPro755 61.83628G002 COLOR WHEEL SHOULDER SCREW NICKEL M2*4.8 FILLIST 80.83F07G001 PCBA PHOTO SENSOR BD HD72 85.1A626G040 SCREW PAN MECH M2.6*4 BLACK NYLOK 51.80J38G002 MYLAR CW SUPPORT 739 FRPP 0.125t HD72 7-19...
  • Page 67 ASSY ROD MODULE HD72 Item Part NO Description 61.80J04G001 ROD HOLDER 739 SUS301 0.2t 23.83F17G001 INTEGRATION ROD OF H72 SERIES HD72 7-20...
  • Page 68 PRE ASSY ENGINE BASE HD72 7-21...
  • Page 69 REFLECTION MIRROR2 OF DP739 SERIAL 23.80S10G001 UV/IR FILTER OF DP739 SERIES 61.80J02G001 UVIR HOLDER 739 SUS301 0.3t 51.80W34G001 ENGINE BASE MIRROR2 TAPE 3M-J350 2300MP 51.81542G001 TAPE 3M J350 17*15mm 61.83F17G001 BLOWER DUCT AL HD72 85.5A126G040 SCREW BINDING MECH M2.6*4 Ni HD72 7-22...
  • Page 70 PRE ASSY ENGINE BOTTOM MODULE HD72 Item Part NO Description 23.80J02G001 REFLECTION MIRROR1 OF DP739 SERIAL ‘’ 51.80J01G001 ENGINE BOTTOM 739 BMC 52.80J05G002 PORON RELAY 739 SILICONE RUBBER 52.80J25G002 PORON CONDENSOR 739 SILICONE RUBBER 61.80J06G001 SPRING MIRROR1 739 SUS301 0.25t...
  • Page 71 ASSY BOTTOM BASE MODULE HD72 HD72 7-24...
  • Page 72 Part NO Description 51.83F03G001 IO COVER PC MN3600 HD72 51.83F04G001 VENT PANEL RIGHT PC HD72 61.81R01G011 BOTTOM BASE Mg ALLOY AZ91D HD72 61.87340G001 STAND OFF M3*4L D8.0 2100MP 70.83F19G001 ASSY BLOWER FAN MODULE HD72 75.83F10G001 ASSY INTERRUPTER SWITCH HD72 85.1F123G060...
  • Page 73 ASSY BLOWER FAN MODULE Item Part NO Description 49.83F02G001 SUNON 50*20 LAMP BLOWER H72 52.87306G001 RUBBER BLOWER FAN FRAME 2100MP 52.80S14G001 BLOWER PAD F12 76*5.0*t1.6 TDP-T90 HD72 7-26...
  • Page 74 ASSY AXIAL FAN MODULE HD72 Item Part NO Description 41.83F02G001 GASKET/H*8 W*8 L*74 41.83F17G001 GASKET/W*15 H*2.5 L*74 49.83F01G001 AVC 7020 AXIAL FAN 52.80N06G001 SPONGE FOR BLOWER DUCT BF1000 t=3.3mm EP739 52.80W01G001 RUBBER FOR FAN7020 2300MPX 51.82G29G001 WIRE MOUNTS FW-4D-MKW EP719 61.80N07G001...

  • Page 75: Appendix B

    EX : A83F548T0AAAA1001 This label “A83F548T0AAAA1001” represents the whole serial number for HD72,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 48s-week of 2005 for universal area and its serial code is 1001.

  • Page 76: Pcba Code Definition

    PCBA Code Definition PCBA Code for Projector XXXXXXXXXX C XXX EEEE C: M/B B: DMD/ B Vendor Code Revision Date Code HD72 7-29...

  • Page 77: 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 HD72 Service Manual? Unit Excellent Good Fair 1.

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