Epson PowerLite 5000 Service Manual Download Page 1

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SM-ELP-5000

Service Manual

Epson America, Inc.

Summary of Contents for PowerLite 5000

Page 1: ...SM ELP 5000 Service Manual Epson America Inc ...

Page 2: ...ii PowerLite 5000 Service Manual ...

Page 3: ...I O cable These devices usually require a shielded cable For EPSON peripheral devices you can obtain the proper shielded cable from your dealer For non EPSON devices contact the manufacturer or dealer for assistance WARNING Only peripherals computer input output devices terminals printers etc certified to comply with the Class B limits may be attached to this projector Operation with non certified...

Page 4: ...s of failures or repair Before beginning maintenance work be sure to read and observe safety precautions and rules The contents are as follows Precautions Personal Safety Protecting the Unit from Damage Requirements for Servicers Chapter 1 Product Features Parts of the Projector System Functions Specifications etc Chapter 2 Theory of Operation Hardware Internal Connections Unit Functions etc Chapt...

Page 5: ...s on 3 ACCIDENT PREVENTION To prevent the device or its components from falling place the device on a flat stable surface before using it or working on it Be careful not to place tools or parts on the device or at your feet To prevent this product from being used while it is disassembled be sure not to leave it out during any repair work and do not place it in a location where it can be taken for ...

Page 6: ...clean room free of dust and dirt to keep the optical elements away from dirt REQUIREMENTS FOR SERVICERS Authorized servicers should have the following knowledge and skill for maintenance of the PowerLite 5000 Training in an EPSON authorized maintenance training program and authorization as a service engineer Sufficient understanding of the operations and descriptions in this service manual Basic k...

Page 7: ... 16 1 6 Interface Specifications 1 18 1 6 1 Computer In 1 2 1 18 1 6 2 Audio In 1 2 1 18 1 6 3 Audio Out 1 18 1 6 4 Monitor 1 19 1 6 5 S Video 1 19 1 6 6 Video In 1 20 1 6 7 Left and Right Audio Input 1 20 1 6 8 Mouse COM 1 2 1 21 Chapter 2 Theory of Operation 2 1 Hardware 2 1 2 1 1 Electrical System Connections 2 3 2 1 2 Optical System Connections 2 4 2 2 Power Supply Unit 2 6 2 3 Main Board 2 9 ...

Page 8: ... Removing the Rear Case Unit Assembly 3 10 3 2 5 Removing the A B Foot Adjuster 3 11 3 2 6 Removing the Switch Panel 3 12 3 2 7 Removing the Speakers 3 13 3 2 8 Removing the Main Board 3 14 3 2 9 Removing the AU Board 3 16 3 2 10 Removing the Receptor Board Assembly FI Board RI Board 3 17 3 2 11 Removing the FR Board 3 19 3 2 12 Removing the Power Supply Unit PBS Thermistor 3 20 3 2 13 Removing th...

Page 9: ...ING 4 1 Before Starting Troubleshooting Procedures 4 1 4 1 1 Tools and Accessories Required for Troubleshooting 4 1 4 1 2 Field Replacement Parts 4 1 4 2 First Action 4 2 APPENDIX A A 1 Parts List A 1 A 2 Exploded Diagrams A 4 ...

Page 10: ...ontrol You can control the projector using a hand held remote control unit that has menus for image source switching and image adjustment The remote control can also work as a wireless mouse during presentations The ELP LINK IITM software has add on features that make presentations effective Connectivity with various types of computers The projector can connect to various types of computers such a...

Page 11: ...SON PowerLite 5000 Service Manual 1 2 1 2 PARTS OF THE PROJECTOR 1 2 1 Exterior View of Main Frame Figure 1 1 Figure 1 2 Speakers Operation Indicator Lamp Indicator Handle Lock Inlet Exhaust Fan Rear Foot ...

Page 12: ...View of Main Frame Figure 1 4 Filter Cover Lamp Cover Foot Adjuster B Foot Adjuster A A Styrofoam plate is mounted under the foot at shipment Remove it when you make adjustments Right Speaker Power Supply Unit Main Board Rear Case Unit Left Speaker Projector Lens Unit ...

Page 13: ...EPSON PowerLite 5000 Service Manual 1 4 Figure 1 5 Figure 1 6 Main Board Driver Board AU Board Handle Light Guide Unit Prism Duct Driver Board Exhaust Fan Inlet Unit LV Thermistor ...

Page 14: ...EPSON PowerLite 5000 Service Manual 1 5 Figure 1 7 Figure 1 8 FR Board Foot Adjuster A Light Guide Unit Safety Switch Lamp Thermistor Lamp Power Cable RI Board AU Board ...

Page 15: ...EPSON PowerLite 5000 Service Manual 1 6 Figure 1 9 Filter Board Filter Cover Switch Inlet Unit CN Board ...

Page 16: ...Audio Port Monitor Port Serial Port Serial Mouse Cable Mouse Port COM Port Mouse Cable for PS 2 Serial Cable Main Cable Audio Cable Computer Cable Monitor Cable 1 Remote Infrared Rays 2 Menu 3 Auto 4 Video 5 Computer 6 Effects 7 Pointer 8 Right Click 9 Blank 10 Custom 11 Mute 12 Resize 13 Freeze 14 Volume 15 Power 16 Left Click Figure 1 11 ...

Page 17: ... Connecting to a Macintosh Desktop Monitor Port Video Adapter Cable Printer Port or Modem Port ADB Port Audio Port Mac Serial Cable Mac Mouse Cable Mac Desktop Video Adapter Mac Monitor Cable Computer Cable Main Cable Monitor Cable Audio Cable Figure 1 13 Note Dip switch settings change according to the machine type Refer to the following monitor adapter table for details The default setting is Ma...

Page 18: ...Port Mac Serial Cable Mac Serial Cable Main Cable Audio Cable Computer Cable Resolution Top Row A Bottom Row B VGA 3 4 5 8 13 640 480 1 2 5 8 16 832 624 2 4 5 8 19 1024 768 2 3 5 8 21 1152 870 1 2 3 4 5 8 13 Multi Res 1 2 5 8 14 Multi Res 1 2 5 3 4 8 17 Multi Res 1 2 5 3 8 4 8 21 Multi Res 1 2 5 3 8 Switch A Switch B Mac Desktop Video Adapter Figure 1 15 Table 1 1 ...

Page 19: ...ce Video Devices S Video Video In Yellow Left Audio In White Right Audio In Red Video Output Yellow Audio Output White Audio Output Red S Video Output S Video Cable Figure 1 16 1 3 4 Connecting to an Audio Source Audio Devices Audio Output Audio Input Audio Cable Figure 1 17 ...

Page 20: ...EPSON PowerLite 5000 Service Manual 1 11 1 4 MAIN COMPONENTS Main board Figure 1 18 Driver board Figure 1 19 AU board Figure 1 20 ...

Page 21: ...EPSON PowerLite 5000 Service Manual 1 12 FR board Figure 1 21 CN board Figure 1 22 Receptor boards Figure 1 23 RI board FI board ...

Page 22: ...EPSON PowerLite 5000 Service Manual 1 13 Speakers Figure 1 24 Inlet unit Figure 1 25 Filter unit Left Speaker Right Speaker Inlet Unit CN Board Figure 1 26 ...

Page 23: ...EPSON PowerLite 5000 Service Manual 1 14 Power supply unit Figure 1 27 Lamp inner housing Figure 1 28 Control panel Figure 1 29 ...

Page 24: ...EPSON PowerLite 5000 Service Manual 1 15 Optical engine Top side view Figure 1 30 Bottom side view Figure 1 31 ...

Page 25: ...ilt in speakers 2W 4Ω x 2 stereo Output for audio out Interface External speaker 3 5 mm Stereo mini jack Internal speaker output is stopped when mini jack is plugged in Output signal 0 to 500 mVrms load impedance 600Ω Left and right Audio In interface For video device Audio signal stereo from the video devices Input interface is separated into right and left Interface type RCA jack Input signal 50...

Page 26: ...ECAM 4 43 MHz Auto identification default MOUSE COM 1 2 Serial Mouse or RS 232C Auto identification Mouse or RS 232C Interface type 13 pin DIN POWER SUPPLY Input Voltage 100 120 VAC 220 240 VAC 10 50 60 Hz Power Consumption Approximately 240 W standby mode 30 W Dimensions 9 7 W x 5 5 H x 12 4 D inches 245 W x 140 H x 316 D mm 9 7 W x 6 3 H x 15 0 D inches including foot adjuster and lens 245 W x 1...

Page 27: ...on 7 Green video GND 15 SCL 8 Blue video GND 1 6 2 Audio In 1 2 Stereo mini jack with 2 circuits for detection pin The detection pin which is not required for audio input is installed for the audio out terminal Table 1 4 Pin number Signal 1 GND 2 Computer audio input L 3 Computer audio input R Others NC 1 6 3 Audio Out Stereo mini jack with two circuits for detection pins Table 1 5 Pin number Sign...

Page 28: ...ND 7 GND 8 GND 9 Reserved 10 GND 11 Reserved 12 Reserved 13 H sync Horizontal synchronization 14 V sync Vertical synchronization 15 V sync 1 6 5 S Video S terminal input Mini DIN 4 pin with a detection pin Table 1 7 Pin number Signal 1 GND 2 GND 3 Y signal input 4 C signal input 5 Input detection terminal 6 GND 4 2 3 1 5 6 5 1 10 6 15 11 Figure 1 35 Figure 1 36 ...

Page 29: ...15 mm Color yellow Table 1 8 Pin number Signal 1 GND 2 Video input Figure 1 37 1 6 7 Audio In L R RCA Gold plating only insertion part Light angle H 15 mm Color L white R red Table 1 9 Pin number Signal 3 GND 4 Audio R return 5 Audio input L 6 GND 7 Audio L return 8 Audio input R 2 1 3 6 5 8 4 7 Figure 1 38 ...

Page 30: ...2 XB DATA Encoder signal I O data signal 3 YA Encoder signal 4 YB Encoder signal 5 LEFT ID0 Left button signal Control signal 6 RIGHT ID1 Right button signal Control signal 7 NC Common Disabled 8 TxD Serial Transmitted signal 9 RxD Serial Received signal 10 DTR Serial LCP data terminal ready signal 11 DSR Serial PC data set ready signal 12 Common PC power ON signal 13 GHD Common Ground 4 8 12 1 5 ...

Page 31: ... and stores the image correction data in flash ROM MAIN BOARD Sets initial operation of the circuit and controls the computer interface Controls the sensors fans speakers and control panel POWER SUPPLY Generates DC voltages 5 V 12 V 22 V 3 3 V for the electric circuits also generates DC voltage 350 V for the light source INTAKE FAN 1 CONTROL PANEL Computer In 1 2 PROJECTOR LENS UNIT Focus Zoom Aud...

Page 32: ...og signals are converted into digital signals by the main board 2 The digital video signal is then stored in video memory SRAM on the main board Then the driver board generates signals to drive the R G B light valves 3 The R G B light valves are individual panels independent of each other They work to shut off or transmit lights from the light guide unit 4 Lights transmitted through the light valv...

Page 33: ... CONTROL PANEL CN101 CN200 CN202 CN204 RIGHT SPEAKER CN806 CN603 CN804 CN802 CN800 CN860 CN600 CN602 CN700 J302 CN805 CN803 J301 CN601 J300 CN300 LEFT SPEAKER CN250 CN900 CN100 CN800 FAN CN700 CN251 CN252 FR BOARD AU BOARD CN BOARD Monitor Computer In 2 Computer In 1 PBS Thermistor POWER SUPPLY UNIT Safety Switch Lamp Thermistor FU BOARD LAMP FC BOARD LAMP INNER HOUSING FI BOARD FILTER COVER SWITC...

Page 34: ...and the driver board These units are specified as the optical engine which is one replaceable part In addition to these five items the FC board is attached at the bottom of the light guide unit The relay board connects the FC board in the lamp inner housing to the driver board It is independent of the optical functions Lamp inner housing Light guide unit Optical head Prism unit Projection lens uni...

Page 35: ...unted for lamp inner housing detection Light Guide Unit Disperses the light from the light source uniformly using an A B lens array Ultraviolet rays are also eliminated Disperses the light in three parts R G B for the condenser lens and mirror Projector Lens Zoom 1 3 and focus adjustments Optical Head Prism Unit Consists of three light valves a polarization plate and a prism unit Each light valve ...

Page 36: ... a clamp on the power supply unit It detects the temperature If it senses overheating it shuts off the regulator output via the main board Although a functional diagram is shown below never disassemble the power supply unit at field maintenance service Figure 2 5 Functional Block Connects to CN800 on the main board DC output and power control signals Interlock Switch Power Cable for Light Source P...

Page 37: ... voltage is supplied to the main board via CN800 and power on off circuit The filter rectification circuit reduces noise on the AC line and generates DC voltage for the regulator The regulator generates the various DC voltage levels shown in the table below for the switching regulator The regulator detects the voltage output level at the 5 V line and feeds the information back to the switching cir...

Page 38: ... supply unit Heat expelled by the intake fan is blown by the exhaust fan connected to CN860 on the main board Pin assignments on CN800 main board Table 2 3 CN800 Pin No Signal 1 22 V 2 12 V 3 A GND 4 7 L GND 8 PWDS 9 BACTA 10 LPSTC 11 12 FV 12 13 3 3 V 14 15 5 V Figure 2 7 PIN 1 RED PIN 15 CN800 ...

Page 39: ...rvice The fuses listed below are soldered onto the main board and are for reference only Table 2 4 Main Board Fuses Fuse Specifications Purpose FB300 BLM41A8005 A 12 V Monitor circuit FB316 BLM41A8005 A 12 V Video input A D circuit FB317 BLM41A8005 A 12 V Computer IN 1 2 circuit FB318 BLM41A8005 A 12 V ADC for Computer IN 1 2 FB802 BLM21B201S A LPST FB806 BLM41A8005 A BACTA FB807 BLM41A8005 A PWDS...

Page 40: ...r CN803 Bus Buffer Control Lamp Thermistor CN804 PBS Thermistor CN860 12 V Regulator CN805 Connects to Driver Board IC700 Digital Video Controller RD0 7 MD0 95 IC100 CPU RDI0 7 GD0 7 SRAM MA0 19 GDI0 7 BD0 7 CN 700 RAS CAS BDI0 7 Display Timing Clock PAD0 23 IC900 Clock Delay Control PBD0 23 Computer IN1 RGB Input Line Buffer R G B D A Converter ADC J300 Gate Computer IN2 RGB Input Line Buffer J30...

Page 41: ...tal image signals are output via the gate and driver board 2 Analog RGB The analog image signals are converted by the ADC and the D A converter The data is stored in the SRAM then output for display to the video controller via the CPU Video input signals are transferred via the AU board and converted into digital signals with the A D converter They are stored in the SRAM The projector has a timer ...

Page 42: ... in maintenance service No individual parts such as the driver board may be replaced The fuses listed below are soldered onto the Driver board They are not replaceable and are listed for reference only Please refer to Section 3 1 for details Table 2 6 Driver Board Fuses Fuse Specification Purpose F250 4511 25 A 3 3 V F251 4511 25 A 12 V F252 CCP2E10 A 5 V Figure 2 10 Functional Outline The signals...

Page 43: ...ise input signals are sent through the three level filter circuit To reduce the effects of timing delays on the logic gate circuits work as trigger circuits for each signal line R G B and unify the output timing The flash ROM contains electrical correction data for the image display The display controller reads the correction data The controller uses the correction data for display timing generati...

Page 44: ... 3 3 V RPD10 17 RQD10 17 12 V 18 V G Shift Clock 1 6 Display Control Signals 12 V REGULATOR R LCCOM Timing 8CH DAC IC250 Buffer CLAMP Red CLAMP Green CLAMP Blue 18 V REGULATOR Display Timing Red Display Timing Green Display Timing Blue Control Signal Level Shifter SHIFT Clock Level shifter Red Light Valve Driver IC900 Green Light Valve Driver IC800 Blue Light Valve Driver IC700 GPD10 17 GQD10 17 B...

Page 45: ...EPSON PowerLite 5000 Service Manual 2 15 2 5 CONTROL PANEL This panel includes a board with 13 switches and is connected to CN600 on the main board Figure 2 12 ...

Page 46: ...xternal video or other device The interface connectors are shown below Figure 2 13 AU Board Circuit Block Audio Out Audio In 1 Audio In 2 Sound Controller Sound Pre Amp Amp For Internal Speaker SCL SDA SPA C0 1 SPL R OUT PUT Sound Volume 8 Level Control S Video Video In Audio In L R CN101 Connect to Main Board CN300 CN100 Reference Voltage Mode Computer 1 Computer 2 Figure 2 14 ...

Page 47: ...dio In 1 2 or from a video device via Audio In L R are input to the sound controller and amplified by the sound preamplifier Then they are output to the Audio Out interface or the built in speaker through the sound controller again The sound controller performs the audio signal output selection based on the SCL SDA serial clock data signals provided from the main board The sound volume control use...

Page 48: ...eceiver can be connected to the remote control interface J100 The receiver provides the same functions as the standard receptor board FI RI Without the receiver the remote control can be used within a limited area in the front and rear The receiver expands the range for the remote control Figure 2 15 The signals from the receptor board FI RI board and the optional remote control receiver are accep...

Page 49: ...puter through the remote The signals are transferred through the host computer s interface and you can control remote mouse controlling the host computer without its mouse FR Board Circuit Block Figure 2 16 Mouse COM1 CN100 MDA0 7 Serial to parallel For Mouse1 LEFT RIGHT CLOCK 13 PIN TXD RXD DTR DSR Mouse COM Controller Switching Mouse COM1 YA TXD Level Converter SEL SEL MDA 0 7 Serial to Parallel...

Page 50: ...o the FR board RI board signal Remote control signals go from the rear receptor to the FR board FC board signal Filter cover detection switch signals go to the main board FR board signal Mouse COM interface 1 2 signals go to the main board Figure 2 17 CN Board Connecting Block CN 201 CN 200 CN203 CN204 CN202 Connects to FR Board CN101 Connects to Main Board CN802 Connects to FI Board F Receptor Co...

Page 51: ...ards one is attached to the speaker bracket on the front face FI board and the other is on the rear case RI board You can control this device on both sides The FI and the RI are different in shape but the same in function circuit Receptor Boards and Their Circuits RI board rear FI board front Figure 2 19 FI Board Circuit RI Board Circuit Figure 2 20 Each receptor board is connected to CN203 204 on...

Page 52: ...erial signal sent to the driver board via the main board controls the display Freeze Blank 3 The serial signal sent to the AU board via the main board controls mute and audio volume Remote Control Circuit Block Figure 2 21 FR Board RI Board FI Board EEPROM Remote Control Infrared rays CN204 CN201 CN200 CN203 CN802 CN700 CN603 AU Board Driver Board CN100 CN100 Connector Board Main Board ...

Page 53: ...re 2 22 Speaker Control Circuit Block Figure 2 23 The audio input signals from computers or an audio device are first amplified by the control circuit on the AU board then output to the speakers via the main board The speakers are connected to CN601 602 on the main board The main board detects the J101 J102 J100 Sound Controller Volume Control Amplifier Circuit CN100 CN601 CN602 J103 Computer 1 Bo...

Page 54: ... The light valve block eliminates ultraviolet rays which are harmful to the light valves and makes the light intensity from the light source lamp uniform before dividing it into 3 light outputs R G B Lenses and mirrors built into the block disperse the light The illustrations below show the outside of the light valve block and an internal diagram Figure 2 24 ...

Page 55: ...green light from the light source GDM The GDM is a light filter that looks blue in visual light The GDM filter transmits only blue light from the light source Since the input light to the GDM is only blue and green light from the CDM as described above green light is reflected by the GDM and provided to condenser lens G Condenser Lens L Condenser lens L collects the light dispersed by the lens arr...

Page 56: ...s of the DC drive light source lamp 150 W 350 V the power supply connector and the fuse board FU board The lamp mounted on the base of the lower case is a user replaceable item Type ELPLP03 The average brightness of the lamp is 400 Im ANSI When the lamp is new its brightness is approx 450 Im maximum After running about 2000 hours the lamp s brightness is reduced to almost half that of a new one Th...

Page 57: ...p indicators blink alternately The controller IC600 on the main board counts the total running hours and writes the data in IC603 The lamp runs only 100 hours after the orange and the red lamp indicators start to blink alternately so you should replace the lamp as soon as possible If the lamp indicators blink alternately when you turn the projector on the lamp life is no more than 100 hours Theref...

Page 58: ... is sent to the main board via the connector CN100 When the total running time reaches 2000 hours IC600 on the main board outputs an LFUSE signal so the FC Board Signals LTPCL Light power supply control signal LPFAL Light power supply failure less than 6 V output or no current LLIFE Lamp life LFUSE FU board fuse is blown EEPROM IC603 Buffer IC618 Controller IC600 Generator X500 IC800 CN700 CN700 6...

Page 59: ...h Micro switch on the lower case Turns power off when the filter cover is open Power on is disabled Interlock switch Push switch on the power supply unit Turns power off when the lamp cover is open Power on is disabled Safety switch Thermal switch on the lamp outer housing Overheating protection for the lamp area Power is shut off if the temperature exceeds a specified limit Lamp thermistor Thermi...

Page 60: ... on the light valve and the prism degrading the displayed image The switch is installed so you cannot turn on the projector when the filter cover is open Filter cover switch Filter cover Figure 2 28 The filter cover switch signal is connected to CN802 on the main board via CN202 on the CN board In main board circuit IC100 generates the interrupt signal and outputs the power shut off signal to CN80...

Page 61: ...installed on the AC power source line and the projector cannot be turned on while the lamp cover is open Interlock switch Figure 2 29 2 13 3 Safety Switch This is the thermal switch for overheating protection installed on the lamp inner housing If an overheating condition is caused by contamination of the exhaust fan the lamp thermistor described in 2 13 4 temporarily shuts off the supply of AC po...

Page 62: ... thermistor shuts off the power on the power supply unit if the temperature rises to a certain temperature lower than the safety switch s level Lamp Thermistor Figure 2 31 The lamp thermistor is connected to CN804 on the main board If there is overheating IC600 generates an interrupt signal and shuts off power on the power supply unit via CN800 2 13 5 LV Thermistor This is the temperature detectio...

Page 63: ...rmistor installed on the side of the fan attached to the power supply unit If the environment around the power supply unit overheats because of a fan or circuit abnormality this thermistor shuts off the power The power shut off control is the same as the lamp thermistor s described in section 2 13 4 Figure 2 33 PBS Thermistor ...

Page 64: ...s to CN251 on Driver Board Connects to LV Thermistor Connects to Left Speaker CN800 CN860 PBS Thermistor CN802 CN804 Lamp Thermistor CN603 CN806 Lamp Fan Power Supply Unit Thermistor Connects to CN Board Connects to AU Board Exhaust Fan CN600 Main Board Solder Side CN300 To AU CN700 Connects to Driver Board CN Monitor Computer In2 J302 J301 Computer In1 J300 Main Board Component Side LD800 LD801 F...

Page 65: ...EEN CN900 RED Driver Board CN250 For Light Bulb Intake Fan Connects to Main Board CN805 Connects to Main Board CN700 Rear Connects to FC Board CN100 AU Board FR Board CN100 CN101 CN102 CN100 Mouse COM2 Mouse COM1 Connects to CN Board CN201 Connects to Main Board CN603 CN101 Connects to Main Board CN300 ...

Page 66: ...et White Black Power Supply Connector White Black Safety Switch F101 250V 6 3A Fast on Tab BLK WHT Figure 2 41 Connects to Front Receptor FI Board Connects to Rear Receptor RI Board Connects to Main Board CN802 CN204 CN203 CN202 CN200 Connector Board Connects to FR Board CN101 Connects to Filter Cover Switch CN201 Figure 2 40 ...

Page 67: ... the main unit 7 Clean the air filter interface and case cover with a vacuum cleaner 3 1 2 Required Tools and Accessories Prepare the tools and accessories listed in the table below Table 3 1 Required tools Name Quantity Supply Use Phillips screwdriver 2 1 Commercial Dissasembly of the case and interiors Flathead screwdriver 1 Commercial Removal of lamp cover and air filter cover Tweezers 1 Commer...

Page 68: ...with the polarization plate is aligned in the factory If the alignment is modified pixel divergence in R G B synthesizing and in the projector lens unit causes out of focus images and non uniform color Caution Do not loosen the prism unit mounting screws Light Guide Unit The components of the light guide unit are factory aligned If the alignment is modified clear images cannot be produced because ...

Page 69: ...ctrical system the driver board and the optical block consisting of the optical head light guide unit make one set At factory shipment the following correction data is stored in the flash ROM on the driver board for the specified optical engine Gamma adjustment data Flicker adjustment data Ghost contrast adjustment data Sub contrast adjustment data A special device and skilled engineer are necessa...

Page 70: ...sembling Light valves R G and B and circuit board assemblies are highly sensitive to static electricity When you remove an optical engine or circuit board place it in an anti static bag immediately When you perform the assembly or disassembly operations listed below check the unit and its surfaces for any dirt before reinstalling them If the unit is dirty clean it 1 Removing the optical engine 2 R...

Page 71: ...disassembly procedures are given in sections 3 2 1 to 3 2 26 Air Filter Frame 3 2 2 Upper Case Unit 3 2 3 FR Board 3 2 11 Foot Adjuster 3 2 5 Switch Panel 3 2 6 Left and Right Speakers 3 2 7 Filter Cover 3 2 21 CN Board 3 2 20 Inlet Unit 3 2 19 Filter Board 3 2 18 Rear Case Unit 3 2 4 AU Board 3 2 9 Lamp Thermistor 3 2 14 Main Board 3 2 8 START Lamp Inner Housing 3 2 1 Safety Switch 3 2 16 Optical...

Page 72: ...d may burn you if handled carelessly Before removing the lamp unit make sure the lamp inner housing unit has cooled down When installing the lamp unit take care not to touch the lamp s reflector with your hands to prevent the reflector from being contaminated Lamp cover Screws Figure 3 2 Screws Lamp inner housing Handle Figure 3 3 ...

Page 73: ...screws from the lamp inner housing Screw M4 7 5 F Ni P N1021771 mounting torque 4 5 kg cm 3 9 lb inch 3 Pull up the handle on the lamp inner housing and remove the lamp unit 3 2 2 Removing the Air Filter Frame Unit Figure 3 4 Remove the Air Filter Frame mounting screw from the bottom of the lower case Then lift it up Screw M4 7 5 F Ni P N1021771 mounting torque 4 5 kg cm 3 9 lb inch Screw Air Filt...

Page 74: ...ions None Handle Holder Cover Figure 3 5 Screws Figure 3 6 1 Pull the handle up 2 Remove 2 screws under the handle Screw M4 10 F ZB Bind P N1033707 mounting torque 6 0 kg cm 5 2 lb inch 3 Remove 2 upper case unit mounting screws on the right Screws M4 6 F ZB P N1034318 mounting torque 6 0 kg cm 5 2 lb inch ...

Page 75: ...ge 4 Hold the left and right sides of the upper case and lightly pull it partially up Figure 3 7 Figure 3 8 5 Disconnect the control panel cable from CN600 on the main board 6 Remove the upper case 7 Remove the handle from the lower case unit Upper case Switch panel cable ...

Page 76: ...w on the AC inlet hold plate 3 Disconnect connectors CN300 CN603 on the main board 4 Remove the cable from the RI board connector the RI board connector is mounted on the rear case unit 5 Remove the 6 hex nuts from the Computer In and Computer In2 monitor ports 6 Grasp both sides of the rear case unit then gently pull it out a short distance 7 Remove the screw holding the blue wire to the AU board...

Page 77: ...e condition 3 2 3 Foot Adjuster A Figure 3 11 1 Push down the foot pipe and hold it then fully lift up foot adjuster A 2 Remove the OP ring D from the top of foot adjuster A 3 Push down the foot pipe and remove it Foot Adjuster B Figure 3 12 E Ring Foot Adjuster A OP Ring D Foot Adjuster B ...

Page 78: ...rten it 2 Remove the E ring from foot adjuster B 3 Turn foot adjuster B completely counterclockwise to remove it 3 2 6 Removing the Control Panel Prerequisite condition 3 2 3 Figure 3 13 1 Pull down the 4 tabs from inside Then remove the control panel from the upper case Tabs Tabs Figure 3 14 ...

Page 79: ...e from CN602 on the main board Left Speaker Unit 1 Remove 2 screws mounting the left speaker unit Screw M3 4 F ZN P N1021795 mounting torque 4 0 kg cm 3 5 lb inch 2 Disconnect the speaker cable from CN601 on the main board Caution 1 The speaker unit has a permanent magnet Keep it away from electromagnetic media such as floppy disks and magnetic cards 2 When mounting a speaker align the 2 speaker h...

Page 80: ...in 12 pin 15 pin CN602 Speaker CN805 CN803 LV Thermistor CN601 Speaker Connects to Right Speaker Connects to CN251 on Driver Board Connects to LV Thermistor Connects to Left Speaker CN800 CN860 PBS Thermistor CN802 To CN361 CN804 Lamp Thermistor CN603 CN806 Lamp Fan Power Supply Unit Thermistor Under Right Speaker Connects to CN Board Connects to AU Board Exhaust Fan CN600 Main Board CN300 To AU B...

Page 81: ...unting screws from the main board Screws M3 4 F ZN Sems P N 1021795 mounting torque 4 0 kg cm 3 5 lb inch 3 Grasp the main board on the left side and disconnect the connector from the driver board Caution To avoid malfunctions caused by wire breaking or solder flaking never apply any mechanical stress to the main board ...

Page 82: ...al 3 16 3 2 9 Removing the AU Board Prerequisite conditions 3 2 3 3 2 4 Figure 3 19 1 To detach the AU board remove 4 screws from it and lift it off Screws M3 8 F ZN Bind P N1021795 mounting torque 6 0 kg cm 5 2 lb inch Screws AU Board ...

Page 83: ...ard Prerequisite conditions 3 2 3 3 2 4 RI board only FI Board Located on the speaker bracket Figure 3 20 1 Disconnect the cable connector from the FI board 2 Remove the screw mounting the FI board to the speaker bracket Screw M3 5 F ZB P N1021795 mounting torque 4 0 kg cm 3 5 lb inch FI Board Screw ...

Page 84: ...nnector from the RI board 2 Remove the screws mounting the RI board to the speaker bracket Screws M3 5 F ZB Bind P N 1033703 mounting torque 6 0 kg cm 5 2 lb inch Caution When installing the receptor board assembly align the hole in the board with the boss on the frame before tightening the screws RI board Screws ...

Page 85: ...rd shield plate from the rear case 2 To detach the remote board cover from the audio board shield plate remove 2 screws from them Screws M3 4 F ZN Bind P N 1021795 mounting torque 4 0 kg cm 3 5 lb inch 3 To separate the remote board shield plate from the FR board remove 2 screws from them Screws M3 8 F ZN P N 1021795 mounting torque 4 0 kg cm 3 5 lb inch FR Board Screws Screws ...

Page 86: ...it out 2 Remove 2 screws from the case holding plate then pull the case holding plate straight up Figure 3 25 3 To pull out the power cable connector for the lamp remove the screw and washer mounting the connector 4 Disconnect 2 wire cables connected to the safety switch 5 Disconnect the cable connector black white connected to the power supply unit Sensor Shield Plate Case Holding Plate Screws Po...

Page 87: ...que 6 0 kg cm 5 2 lb inch 7 Remove the power supply unit by lifting it straight up Caution When removing the power supply unit do not bend or damage the two bosses on the lower case unit When installing the power supply unit align the holes with the bosses The intake fan and its peripheral parts are susceptible to dust and dirt When installing the power supply unit check the fan s cleanness and cl...

Page 88: ... PBS thermistor to the power supply unit chassis 2 Separate the PBS thermistor from the cable clamp 3 Disconnect the cable from connector CN860 on the main board 3 2 14 Removing the Lamp Thermistor Prerequisite conditions 3 2 3 3 2 4 3 2 8 3 2 13 PBS Thermistor Lamp Thermistor Figure 3 27 Figure 3 28 ...

Page 89: ... Disconnect the Fast on tab terminals of the two cables connected to the safety switch 2 Remove the two mounting screws from the safety switch and detach the safety switch Screw M3 8 F ZB P Tight P N 1033691 mounting torque 6 0 kg cm 5 2 lb inch Caution When removing the Fast on terminals do not apply excess force to the terminals on the safety switch in the horizontal or vertical direction Note T...

Page 90: ... Screw M3 4 F ZN P N 1021795 mounting torque 4 0 kg cm 3 5 lb inch 2 Remove the 4 optical block mounting screws One of the screws is located on the front side of the speaker bracket Screws M5 10 F ZN Bind P N 1033704 mounting torque 6 0 kg cm 5 2 lb inch 3 Pull out the speaker bracket 4 Pull the optical engine straight up from the lower case Optical Block Except Exhaust Fan Screws Screw Speaker Br...

Page 91: ...te wire from the filter board 2 Remove the 4 mounting screws Screws M3 8 F ZN Bind P N 1021824 mounting torque 6 0 kg cm 5 2 lb inch 3 Pull up the filter board holding plate 4 Remove the cables from the cable clamp 5 Remove the filter board from the lower case Caution When installing the filter board arrange the cables in the clamp and cable guide Screws Fast on tab cable Black wire and white wire...

Page 92: ... 2 17 Figure 3 33 1 Remove 2 inlet unit mounting screws and the ground wire screw 2 Remove the cable guide cover 3 Unplug the Fast on tab cable white wire and the black wire from the filter board 4 Pull up the inlet unit from the lower case Fast on Tab Cable White Wire Screws Ground Wire Screw Cable Guide Cover Figure 3 34 ...

Page 93: ... 3 36 1 Remove the screw mounting the CN board shield plate B Screw M3 5 F ZN Bind P N 1033703 mounting torque 6 0 kg cm 5 2 lb inch 2 Disconnect the cable connectors connected to CN200 202 on the CN board 3 To detach the CN board remove the 2 screws mounting it to the projector Caution Arrange the cables in the cable guide Screw Screw CN Board ...

Page 94: ... 13 3 2 17 Figure 3 37 1 Disconnect the cable connector from the switch connected to CN202 on the CN board 2 Remove the filter cover switch pushing the latches on the lower case outward Caution Be careful not to break the latches with excessive stress When you replace the filter cover switch align the hole to the boss on the lower case Filter Cover Switch ...

Page 95: ...ervice Manual 3 29 3 2 22 Removing the FC Board Prerequisite conditions 3 2 3 3 2 4 3 2 8 3 2 13 3 2 17 Figure 3 38 1 Disconnect cable connector CN1 from the FC board 2 To detach the FC board remove the screw FC Board Screw ...

Page 96: ...sted below They need to be prepared by the user Table 4 1 Name Quantity Use Remarks Projector screen 1 To project images Tape Measure 10 ft 3 m 1 To measure the projection distance Host computer 1 To supply test patterns PC or compatible Color display 1 To manipulate and display on host computer Video equipment 1 To test video input video deck video camera etc External speaker unit 1 To test voice...

Page 97: ...r Check for any damage to the cover area Check internal cable connections except on the CN board and FR board Remove the upper case unit Check power on off and initialization No signal display Connect power cable and turn on the power Check screen display and picture quality Connect host computer video device and RGB monitor Check audio output to the internal and external speakers Check button ope...

Page 98: ...ng and zoom ring are adjustable move easily Dirt is not on the lens surface There are no cracks or other deformities The mounting screw on the air filter frame is not loose The tab on the air filter frame is not damaged Dirt is not on the air filter frame Dirt is not on the intake fan The intake fan is located under the air filter frame The 2 mounting screws on the lamp cover are not loose The tab...

Page 99: ... the main board lock type CN300 on the main board to CN101 on the AU board CN603 on the main board to CN100 on the AU board CN601 602 on the main board CN800 on the main board to power supply unit CN860 on the main board to power supply unit Light power cable connector mounting screw CN806 on the main board CN804 on the main board CN803 on the main board CN805 on the main board to CN251 on the dri...

Page 100: ...tton on the control panel Does the operation or lamp indicator light up or blink Replace the power supply unit Is the lamp cover secured to the lower case Install the lamp cover and lamp inner housing again Replace the safety switch Is the safety switch resistance almost 0 ohms Disconnect the power cable Disconnect the Fast on tab from the safety switch Measure the safety switch resistance A B Go ...

Page 101: ...ng 8 Red blinking Circuit malfunction 9 Orange and Red Lamp timer has exceeded 1900 hours 10 Red Lamp life is finished 11 Red blinking Lamp or power supply problem The following components may be causing problems in each condition Condition 1 or 8 Main board driver board optical engine power supply unit Condition 2 Main board power supply unit lamp inner housing Condition 4 Exhaust fan lamp thermi...

Page 102: ...tments shown in Table 4 3 Does a fine image appear now YES YES NO NO YES NO NO YES YES NO YES NO YES NO Replace the optical engine Display Picture Start Does the screen appear Is the light source lamp on Replace the lamp inner housing Is the light source lamp on now Replace the main board Is the light source lamp on now Replace the lamp thermistor Is the light source lamp on now Replace the power ...

Page 103: ...ty good now Is the picture quality good now Make the adjustments shown in Table 4 3 on page 4 8 Does a screen appear now Replace the optical engine YES NO YES YES YES YES YES NO YES NO YES NO NO NO NO NO NO NO NO YES YES YES Have the following devices been checked Computer In 2 Video In S Video Connect the device which has not been checked A A C Connect the CRT to the monitor interface Does a scre...

Page 104: ...ernal speaker to the Audio out Does external speaker output the sound Replace the AU board Replace the AU board Replace the main board Does the volume control work now Replace the main board Does the mute button work Does the mute button work now Reconnect CN601 602 and 603 on the main board Do the internal speakers output the sound now Replace right speaker and or left speaker Do the internal spe...

Page 105: ...ork Does the Video button work Replace the control panel Do all the buttons work Replace the main board Does the Computer button work Does the Auto button work Does the Resize button work Does the Volume button work Does the Mute button work Does the Tracking button work YES NO NO NO NO YES NO YES YES YES YES NO NO NO NO YES NO YES YES YES NO YES YES NO Go to Remote Control ...

Page 106: ... all switches except Effects 1 to 5 work correctly now Replace the main board Do all switches except Effects 1 to 5 work correctly now Replace the FR board Replace the batteries Does power ON OFF work now Replace the remote control Does power ON OFF work now Reconnect CN802 on the main board Does power ON OFF work now Replace the RI or FI board Does power ON OFF work now Replace the main board Doe...

Page 107: ... following cables Main cable Mouse cable Serial cable Does the remote control work correctly now Does the pointer button on the Remote control work correctly Are the function assignments for Effect buttons 1 to 5 available Are presentation and projector control functions available with the remote control YES YES YES YES YES YES NO NO NO NO NO NO Go to Others The ELP communication kit option is nec...

Page 108: ... be caused by dirt on the light guide unit projector lens unit and light valves on the optical head unit Check the following for defects AC input including power line transit or distortion Power supply unit Main board Cable connection failure to make connection Operating environment temperature condensation The problem may be static electricity Check that power cords to the PowerLite 5000 and inpu...

Page 109: ...on Plate 1 1 4 1032027 Foot Adjuster A Unit 1 1 5 1032032 Foot Case 1 1 6 1032036 Foot Holder 1 1 7 1032037 Foot Pipe 1 1 8 1032039 Foot Spring 1 1 9 1032580 Stop Ring D 1 10 1034249 Filter B Insulation Plate 1 11 1021824 Mounting Screw 1 12 1021795 Filter Board B Mounting Screw 1 13 2023443 Filter Cover Switch Unit 1 14 1032043 Air Frame Filter Unit 1 15 1033581 Remote Board Shield Plate B 1 16 1...

Page 110: ...D Sub Mounting Screw Hexagon 25 1032071 Upper Case Block 26 1033707 Upper Case Block Mounting Screw 27 1034318 Upper Case Block Mounting Screw 28 1032080 Control Panel 29 1034329 Control Panel Spring 30 3002147 Remote Board Assembly 31 1032368 Remote Board Shield Plate 32 1032350 Remote Board Cover 33 1021795 Filter Board B Mounting Screw 34 1034713 Remote Board Mounting Screw 35 1034319 Remote Bo...

Page 111: ...8 5005534 Lower Pad 39 5005535 Upper Pad 40 5005543 Accessory Box Big 41 5005333 Accessory Holder 42 5004108 Polyvinyl Bag 43 5003353 Soft Bag 44 4006453 Slipsheet 45 1032291 UPC Code Label 46 1032295 Caution Label A Lamp Exchange 47 1034263 Caution Label B Don t Lock 48 1034264 Caution Label C Don t Open Case 49 1034043 Caution Label D 50 1026940 Road Service Sticker 64 1033745 Serial Number Labe...

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