Optoma EX556 Serivce Manual
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Optoma EX556 Serivce Manual

Optoma EX556 Serivce Manual

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SERVICE MANUAL

EX556/ES556/EW556/ES555/EX555
Date
Revise Version
Description
2012.05.20
V1.0
Initial Issue
TSE: Mina
Check: Alick
Approved: Alick

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Summary of Contents for Optoma EX556

  • Page 1: Service Manual

    SERVICE MANUAL EX556/ES556/EW556/ES555/EX555 Date Revise Version Description 2012.05.20 V1.0 Initial Issue TSE: Mina Check: Alick Approved: Alick...

  • Page 2: Ex556/Es556/Ew556/Es555/Ex555 Confidential

    Preface This manual is applied to EX556/ES556/EW556/ES555/EX555 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. We expect your customers will appreciate the service that you offer them.

  • Page 3: Ex556/Es556/Ew556/Es555/Ex555 Confidential

    Comparison List EX556/ES556/EW556/ES555/EX555 ES555 ES556 EX556 EX555 EW556 Main Board 80.8PJ01G012 80.8PJ01G002 80.8PL01G002 80.8PL01G012 80.8PM01G002 DMD Chip 48.8EH01G001 48.8CQ01G003 48.8EJ01G001 IO Cover 70.8PJ21GR01 70.8PJ18GR01 70.8PL09GR01 70.8PM10GR01 Engine Module 70.8PJ17GR01 70.8PM09GR01 EX556/ES556/EW556/ES555/EX555 Confidential...

  • Page 4: Table Of Contents

    Chapter 4 Function Test & Alignment Procedure Test Equipment Needed Test Condition S-Video and Audion Port Test(not for ES555) Video port Test Component port Test HDMI Port Test HDMI Port Test(3D Test ) 3D Test Run In Test EX556/ES556/EW556/ES555/EX555 Confidential...
  • Page 5 Test Inspection procedure Factory Fan RPM 4-10 Chapter 5 Firmware Upgrade Section 1: System Firmware Upgrade Section 2: 8051 Firmware Upgrade Procedure Appendix A Exploded Image Appendix B Serial Number System Definition PCBA Code Definition II EX556/ES556/EW556/ES555/EX555 Confidential...

  • Page 6: Chapter 1 Introduction

    ● Normal:TYP 239W MAX 263W @110 Power Consumption ● ECO:TYP 200W MAX 220W@110 Keystone correction ● +/- 40 degree is the scaler spec ● 1.95~2.15(D/W) (For ES555/ES556/EX555/EX556) Throw ratio ● 1.55~1.7(D/W) (For EW556) ● YM09X/FPL65(For ES555/ES556) Projection lens ● YM09X/FPL30(For EX555/EX556) ●...
  • Page 7 Item Description For ES556/EX556/EW556 ● VGA-in x 2(support SCART/YPbPr) ● HDMIv1.3(with HDCP support) x 1 ● Composite Video x 1 ● S-Video (Mini DIN) x 1 ● Audio input (phone Jack) x 1 For ES555 Input signal spec ● VGA-in x 1(support SCART/YPbPr) ●...

  • Page 8: Compatible Mode

    1-2 Compatible Mode Computer Compatibility ES555/ES556/EX555/EX556 V-Sync Compatibility Resolution H-Sync [KHz] Analog/Digital [Hz] NTSC 15.734 － － 15.625 － － 640 x 350 31.5 640 x 350 37.9 720 x 350 31.5 640 x 400 31.5 PAL/SECAM 640 x 400 37.9...
  • Page 9 1280 x 768 47.4 WXGA 1280 x 768 WXGA 1280 x 768 WXGA 1280 x 768 WXGA-800 1280 x 800 SXGA 1280 x 1024 SXGA 1280 x 1024 SXGA 1280 x 1024 91.1 SXGA+ 1400 x 1050 UXGA 1600 x1200 Confidential EX556/ES556/EW556/ES555/EX555...
  • Page 10 1920 x 1080p 1920 x 1080p 1920 x 1080p 1280 x 720 1280 x 720p 1280 x 720p 720 x 576 31.3 720 x 576i 720 x 576p SDTV 720 x 480 31.5 720 x 480i 720 x 480p Confidential EX556/ES556/EW556/ES555/EX555...
  • Page 11 1024 x 768 48.4 1024 x 768 56.5 70.1 1024 x 768 1024 x 768 1152 x 870 HD720 1280 x 720 WXGA-800 1280 x 800 SXGA 1280 x 1024 1366x768 1400x900 55.935 SXGA+ 1400 x 1050 1680 x 1050 Confidential EX556/ES556/EW556/ES555/EX555...
  • Page 12 1280 x 720 1280 x 720p 1280 x 720p 720 x 576i 720 x 576p SDTV 720 x 480i 720 x 480p Note: If the Computer Compatibility supportive signal is different from User’s Manual, please refer to User’s Manual. Confidential EX556/ES556/EW556/ES555/EX555...

  • Page 13: Disassembly Process

    * 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. - Some related contents please refer to common SM chapter 2. Confidential EX556/ES556/EW556/ES555/EX555...

  • Page 14: Disassemble Lamp Module

    2-2-1 Disassemble Lamp Module 1. Unfasten 1 screw (as red circle) on the front Cover. 2. Push the Lamp Cover (as blue arrow). 3.Then open the lamp cover, unfasten 2 screws(as red circle). 4.Take off the Lamp Module. Confidential EX556/ES556/EW556/ES555/EX555...

  • Page 15: Disassemble Focus Ring

    (as yellow circle) properly, and the Focus Ring can be well adjusted. 2-2-3 Disassemble Top Cover Module 1. Unscrew 2 screws (as red circle) from the top cover. 2. Unscrew 8 screws(as red circle) from bottom cover. Confidential EX556/ES556/EW556/ES555/EX555...

  • Page 16: Disassemble Lamp Cover

    4. Unplug 1 connector (as blue square),then remove the Top Cover Module. 2-2-4 Disassemble Lamp Cover 1.Unscrew 2 screws (as red circle) to disassemble the IR sensor and IR sensor board. 2. Unscrew 2 screws (as blue circle) to disassemble the Zoom Ring. Confidential EX556/ES556/EW556/ES555/EX555...
  • Page 17 3.Then remove the lamp cover from the top cover. 2-2-5 Disassemble Main Board 1. Tear off the tape (as blue square). 2.Unscrew 4 screws (as red circle). 3. Unplug 4 connector (as green square). Confidential EX556/ES556/EW556/ES555/EX555...

  • Page 18: Disassemble Main Board

    4. Unscrew 9 screws (as blue circle). 5. Unplug 1 connector (as yellow square). 6. Disassemble Main Board. Confidential EX556/ES556/EW556/ES555/EX555...
  • Page 19 Yellow/Red Wire and Black tube(3 pin) Compose of Black/ White/Red Wire, Red Photo Sensor BD Connector and Black tube(3 pin) Compose of Black/ System Fan Blue/Red Wire, White Connector (3 pin) Black wire tube (5 Lamp driver pin) Confidential EX556/ES556/EW556/ES555/EX555...

  • Page 20: 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 the operation, please use the glue to fix the screws. Confidential EX556/ES556/EW556/ES555/EX555...

  • Page 21: Re-Write Lamp Hours

    5.Re-write Lamp Hours(Image Care) Select Lamp Hours(Image Care) and use “ left” or “right” buttons to re-write the lamp hours(ECO). 6. Choose “Exit”, press “Enter” to exit Note: left key = decrease lamp hour right key =increase lamp hour Confidential EX556/ES556/EW556/ES555/EX555...

  • Page 22: Repair Action

    Firmware Update chapter 5 Color Wheel Chapter Index 4-3-1.7 Chapter OSD Reset -5.2 EDID Chapter 6 Re-write Lamp Chapter 2-4 Hours Usage chapter Video port test -- Factory Fan RPM Chapter 4-7 Optical Chapter Performance -- Measure Confidential 2-10 EX556/ES556/EW556/ES555/EX555...

  • Page 23: Chapter 3 Troubleshooting

    (input power cord) Power on (Warming) Flashing Power on and Lamp lighting Power off (Cooling) Flashing Quick Resume Flashing (100 secs) Error Flashing (Lamp failed) Error Flashing Flashing (Fan failed) Error Flashing (Over Temp.) Note: Steady light No light EX556/ES556/EW556/ES555/EX555 Confidential...

  • Page 24: Main Procedure

    PC can support 3D format. 3D Image - Ensure your standing distance is less than 6m from screen. Abnormal - Ensure the 3D function is on and execute “3D sync invert” in OSD menu. - Check main board. Confidential EX556/ES556/EW556/ES555/EX555...

  • Page 25: Function Test & Alignment Procedure

    - Quantum Data 802B or CHROMA2327 (Color Video Signal & Pattern Generator) 4-2 Test Condition Circumstance brightness: Dark room less than 2 lux. - Product must be warmed up for 3 minutes. - Screen size: 60 inches diagonal. Zone Definition < Figure: Zone A(as green line) Definition > Confidential EX556/ES556/EW556/ES555/EX555...

  • Page 26: Vga Port Test

    4-3 I/O Port Test 4-3-1 VGA Port Test Note: ES556/ES555 the native resolution of test signal is 800x600@60HZ. EX556/EX555 the native resolution of test signal is 1024x768@60HZ. EW556 the native resolution of test signal is 1280x800@60HZ. we take ES556 for example here.
  • Page 27 - The bright blemish should be no more than 2 Gray 10 under gray 10 pattern. - Ref. Defect specification table 5. Dark Blemish Procedure - Test equipment: video generator. - Test signal: analog 800x600�60Hz - Test Pattern: blue 60 Blue 60 Confidential EX556/ES556/EW556/ES555/EX555...
  • Page 28 Inspection item - Dark blemish check Criteria - The bright blemish should be no more than 2 under blue 60 pattern. Pixel specification ES556/ES555/EX556/EX555 Order Symptom Pattern Criteria Bright pixel ( dots) Gray 10 pattern Dark pixel(dots) White pattern A≤4...
  • Page 29 8. Optical Performance Inspection Condition - Environment luminance: 2 Lux - Product must be warmed up for 5 minutes - Distances from the screen: 2.4M(For ES556/ES555/EX556/EX555) 2.0M(For EW556) - Screen Size: 60 inches diagonal Confidential EX556/ES556/EW556/ES555/EX555...
  • Page 30 Note: P5 = Lux of center in full white pattern B5 = Lux of center in full black pattern Criteria • 6000:1 d. Uniformity Full white pattern Procedure - Full white pattern - Use CL100 to measure brightness values of Confidential EX556/ES556/EW556/ES555/EX555...

  • Page 31: S-Video And Audion Port Test(Not For Es555)

    - Check any abnormal color, line distortion or any noise on the screen. - Check the sound from speaker. 4-3-4 Component Port Test Procedure - Test equipment: DVD player - Test signal: Ycbcr/YPbPr Inspection item - HDTV performance test Confidential EX556/ES556/EW556/ES555/EX555...

  • Page 32: Hdmi Port Test

    2. PC with 3D Graphic card - Test signal: 1080p�24Hz �24Hz(for 3D movie) 720p�60HZ(for 3D game) Inspection item - 3D test Inspection Distance - 3~5 M Criteria - The image should not appear noise, flicker shadow, shocking, abnormal color. Confidential EX556/ES556/EW556/ES555/EX555...

  • Page 33: Run In Test

    Cosmetic can not be broken Missing logo, missing prints and blurry prints are Logo unacceptable Lamp cover It should be locked in the correct place. Zoom in/out The function should work smoothly Keypad All keypad buttons must operate smoothly Confidential EX556/ES556/EW556/ES555/EX555...
  • Page 34 “Fan Menu” ,then enter it to check to check the “Blower Factory RPM” . Note: - If the Factory FAN RPM Value doesn’t show in service mode, please repeat the step again. - Make sure the “Blower record (rpm) “is 2000-3400. Confidential EX556/ES556/EW556/ES555/EX555 4-10...

  • Page 35: Firmware Upgrade

    - Cable USB-A to USB-B(42.87304G001) - PC or Laptop Note: 1.The FW upgrade procedure for EX556/ES556/EW556/ES555/EX555 is the same,we take ES556 as an example here. 2.we will show the hot key of service mode and how to check FW version,the other contents please refer to common service manual 5-1 .

  • Page 36: Get Into Fw Mode

    - Restart the unit and get into the Service Mode(Press Power --> Left --> Left --> Menu). - The firmware version will be shown as red circle on the screen. Note: Another contents please refer to common service manual 5-Section 1. EX556/ES556/EW556/ES555/EX555 Confidential...
  • Page 37 Section 2: 8051 Firmware Upgrade Procedure 5-2-1 Equipment Needed Software : - ICP Programmer(Coretronic ICP Programmer,v5.41.exe) - USB-to-Serial COM port Driver (PL2303_Prolific_DriverInstaller_v110.exe) - Program file (*.TPJ) Hardware : - Projector - Power Cord - ICP FIXTURE (SP.8JC08G001) - PC or Laptop EX556/ES556/EW556/ES555/EX555 Confidential...

  • Page 38: Setup Procedure

    5-2-2 Setup Procedure Install ICP Utility 1.Double Click" the Coretronic ICP Programmer, v5.41 (Production Line)",then double click PC-site AP. 2. Double click "Setup,Coretronic ICP Programmer, v5.41.exe". 3. Click "Next". 4. Click "Next". 4. Click "Next". EX556/ES556/EW556/ES555/EX555 Confidential...
  • Page 39 6. Click "Finish" to end Coretronic ICP Programmer installed. Install PL2303_Prolific_Driver 7.Double Click" the Coretronic ICP Programmer, v5.41(Production Line)",then double click Driver,then double Click "PL23 03_Prolific_Driver Installer_v110.exe" 8. Click "Next". 9. Click "Finish" to end Click "Finish" to end PL2303_Prolific_Driver installed. EX556/ES556/EW556/ES555/EX555 Confidential...
  • Page 40 VGA-IN Port of projector and PC by ICP Fixture. 2. Select "Start" -->"Coretronic Tools" -->"Coretronic ICP Programmer V5.41" to run "Coretronic ICP Programmer.exe”. 3. Click “Load Proj” to open the “TPJ” file which you will upgrade 8051 firmware file. EX556/ES556/EW556/ES555/EX555 Confidential...
  • Page 41 4. Click “ Update Chip” to upgrade the 8051 firmware. 5. Finish - When 8051 FW upgrade process is finished, "PASS" will be shown. 6. Re-plug in power cord and Power on the projector. Get into the service mode to check the 8051 firmware version. EX556/ES556/EW556/ES555/EX555 Confidential...

  • Page 42: Edid Upgrade

    6-1 EDID Upgrade Procedure - The upgrade procedure for VGA and HDMI ports please refer to common service manual chapter 6. - Please use " EDID 0.81.exe" Program and Key in the serial number into the "Unit No" blank space. Confidential EX556/ES556/EW556/ES555/EX555...
  • Page 43 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. Confidential EX556/ES556/EW556/ES555/EX555...
  • Page 44 ASSY PHILIPS ONE FAN LAMP MODULE ES555 70.8PJ05G00 ASSY ENGINE MODULE ES556 FOCUS RING PC MN3600H PANTONE BLACK 5.8PCG0 GEN .5 70.8PJ03G00 ASSY I/O COVER ES556 6.8EG4G00 EMISPRINGHD0 4.83F6G00 GASKET 全背膠 /W*0 H*0 L*40 4.87Y03G00 EMI GASKET W3*H6*L35 Confidential EX556/ES556/EW556/ES555/EX555...
  • Page 45 Assy Main Board EX556/ES556/EW556/ES555/EX555 Confidential...
  • Page 46 Description Supply 80.8PJ0G0 PCBA MAIN BOARD FOR ES555. [PROJECTOR] 80.8PM0G00 PCBA MAIN BOARD FOR EW556. [PROJECTOR] 80.8PL0G00 PCBA MAIN BOARD FOR EX556. [PROJECTOR] 80.8PL0G0 PCBA MAIN BOARD FOR EX556. [PROJECTOR] 80.8PJ0G00 PCBA MAIN BOARD FOR ES556. [PROJECTOR] 5.8PJ06G00 M/B MYLAR ES556 6.8PC06G00 M/B BOTTOM SHIELDING SECC 0.6t GEN 1.5...
  • Page 47 Assy Engine Module EX556/ES556/EW556/ES555/EX555 Confidential...
  • Page 48 ASSY ENGINE BOTTOM COVER Z5 85.A56G060 SCREW PAN MECH M2.6*6 Ni NYLOK 70.8FP08G00 ASSY RELAY MODULE M40HD 3.8AH0G0 YO CONDENSER  FOR A5W 6.8EF03G00 CONDENSER LIGHT STOP EX65 3.8AH0G0 YO CONDENSER  FOR A5W 5.8CPG00 DMD PORON+MYLAR FOR Z5/X5Z ENGINE Confidential EX556/ES556/EW556/ES555/EX555...
  • Page 49 ASSY IO COVER MODULE FOR 8PL(SERVICE) 70.8PM0GR0 ASSY IO COVER MODULE FOR 8PM(SERVICE) ASSY IO COVER MODULE FOR 8PJ(SERVICE) 70.8PJ8GR0 70.8PJGR0 ASSY IO COVER MODULE FOR 8PJ(SERVICE) BACK COVER PC LN50A PANTONE BLACK 5.8PC03G00 C GEN .5 35.8PJ0G00 I/O LABEL ES556 EX556/ES556/EW556/ES555/EX555 Confidential...
  • Page 50 Assy Top Cover Module Confidential EX556/ES556/EW556/ES555/EX555...
  • Page 51 ZOOMRING TEFLON 0.3T 3M 947 GEN .5 ZOOM RING PC MN3600H PANTONE BLACK GEN 5.8PC09G0 5.8PC0G00 IR HOLDER MYLAR GK-7 GEN .5 5.8PC06G00 IR HOLDER PC MN3600H BLACK GEN .5 80.8PJ05G00 PCBA IR SENSOR BD FOR ES556 [PROJECTOR] 85.WA3G080 SCREW PAN TAP M3*8 Ni EX556/ES556/EW556/ES555/EX555 Confidential...
  • Page 52 COLOR WHEEL DISC RUBBER, EzPro755 6.8CP03G0 CW BRACKET SECC FOR Z5 NEW LOW COST 40MM,6SEG R81Y41G84C31W52B71 3.8JP9G00 Y41,3X,FD20VA 5.8HH7G00 PHOTO SENSOR BD SPACER UF65 PCBA PHOTO SENSOR BOARD FOR ES56X 80.8LP04G00 PROJECOR 85.A6G080 SCREW PAN MECH M2.6*8 Ni Confidential EX556/ES556/EW556/ES555/EX555...
  • Page 53 Assy Bottom Cover Module EX556/ES556/EW556/ES555/EX555 Confidential...
  • Page 54 ASSY PHILIPS LAMP DRIVER MODULE 90W 70.8PJ6GR0 FOR 8PJ(SERVICE) 70.8PJ06G00 ASSY LAMP DRIVER MODULE ES556 POWER SUPPLY, AD-254W, AC INLET, 75.8PC0G00 180*50, DL, HS-C SUNON MF75251V1-Q000-G99; 7525 axial 49.8PJ0G0 fan; ROHS2.0 49.8PJ0G00 SPEAKER 2W 4Ohm 90mm ASSY INTERRUPTER SWITCH P560 75.87U0G00 L=80MM Confidential EX556/ES556/EW556/ES555/EX555...
  • Page 55 EX556/ES556/EW556/ES555/EX555 Confidential...
  • Page 56 S.P. INFRARED REMOTE CONTROL FOR ES/ SP.8PJ0GC0 EX/EW556 “Laser” INFRARED REMOTE CONTROL ES/EX/EW556 45.8PM0G00 “Laser” 55.8PJ0G00 OUTSIDE CARTON B FLUTE ES555 QUICK START CARD MULTILINGUAL EW556 36.8PM0G00 SERIES USER’S GUIDE MULTILINGUAL (CD) EW556 36.8PM0G00 SERIES WARRANTY CARD USA FOR OPTOMA, 3 36.0004G04 YEARS Confidential EX556/ES556/EW556/ES555/EX555...
  • Page 57 I. Serial Number System Definition Serial Number Format for Projector AAAAA C 0001 Q = Optoma 8PJ = Project Code 2 = Last number of the manufacture year (ex:2012= 2) 15 = week of the manufacture year (ex:the fifteenth week of the...
  • Page 58 II. PCBA Code Definition PCBA Code for Projector XXXXXXXXXX EEEE Vendor Code Revision Date Code EX556/ES556/EW556/ES555/EX555 Confidential...

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