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Optoma EW615i Service Manual Download Page 91

Confidential

VIII

EX612/EX615/EW615i/EX612i/EX615i

EX615i

ASSY MAIN BOARD MODULE

Summary of Contents for EW615i

Page 1: ...62 2009 12 16 V3 0 Add EX540I EX542I 2010 01 30 V4 0 Add ES523ST EW533ST Modify Defect specification table in Chapter 4 2010 05 20 V5 0 Delete EX540 EX762 EX540I EX542I ES523ST EW533ST 2011 05 04 V6 0...

Page 2: ...pect your customers will appreciate the service that you offer them This manual is for technicians and people who have an electronic background Please send the product back to the distributor for repa...

Page 3: ...8EF40GR01 70 8FK03GR01 70 8MP01GR01 70 8NA39GR01 MAIN BOARD MODULE 70 8EF43GR01 80 8FK01G001 80 8NN01G001 80 8MP01G001 70 8NA38GR01 IO COVER MODULE 70 8EF44GR01 70 8FK02GR01 70 8EF44GR01 70 8NA37GR01...

Page 4: ...om Ring 2 4 Disassemble Top Shielding 2 5 Disassemble Main Board Module 2 5 Disassemble Daughter Board and Lan Module Board 2 8 Disassemble Engine Module 2 9 Disassemble Color Wheel Module 2 9 Disasse...

Page 5: ...1 Main Procedure 3 2 Chapter 4 Function Test Alignment Procedure Test Equipment Needed 4 1 Service Mode 4 1 OSD Reset 4 1 Test Condition 4 2 Defect specification table 4 3 Test Inspection Procedure 4...

Page 6: ...B Driver Upgrade Procedure 5 4 Firmware Upgrade Procedure 5 5 Section 2 8051 Firmware Upgrade Procedure 5 6 Equipment Needed 5 6 NLINK Setup Procedure 5 9 Manley USB Driver Upgrade Procedure 5 11 8051...

Page 7: ...duction 6 1 Equipment Needed 6 2 Setup Procedure VGA 6 3 EDID Key In Procedure VGA 1 VGA 2 6 3 Setup Procedure HDMI For EX615 EW615i 6 6 EDID Key In Procedure HDMI For EX615 EW615i 6 6 Appendix A Expl...

Page 8: ...Throw ratio 1 95 2 15 60 For EX615 EX612 EX612i 1 28 1 536 1 60 For EW615i 1 6 1 92 D W 60 For EX615i 9 Projection lens YM09X FPL30 F 2 41 2 55 60 f 21 8 24 mm 60 10 Lamp life 2500 Hours 50 Survival...

Page 9: ...port Audio in 1 only Daughter Board for EX612 EX612i Audio in 1 2 3 Daughter Board for EX615 EW615i HDMI HDMI v1 3 HDCP for EX615 EW615i EX615i Audio in connectivity grouping for EX615 EW615i VGA in1...

Page 10: ...31 5 720 x 400 85 37 9 SVGA 800 x 600 56 35 2 800 x 600 60 37 9 800 x 600 72 48 1 800 x 600 75 46 9 800 x 600 85 53 7 XGA 1024 x 768 60 48 4 1024 x 768 70 56 5 1024 x 768 75 60 1024 x 768 85 68 7 WXG...

Page 11: ...c DV 1280 x 960 75 75 Computer Compatibility Digital Compatibility Resolution V Sync Hz H Sync KHz VGA 640 x 350 70 31 5 640 x 350 85 37 9 640 x 400 85 37 9 640 x 480 60 31 5 640 x 480 72 37 9 640 x 4...

Page 12: ...1152 x 864 60 53 5 1152 x 864 70 63 8 1152 x 864 75 67 5 1152 x 864 85 77 1 1280 x 1024 60 63 98 1280 x 1024 75 79 98 1280 x 1024 85 91 1 SXGA 1400 x 1050 60 63 98 UXGA 1600 x 1200 60 75 Note If the C...

Page 13: ...07 3 Screw Bit 107 4 Hex Sleeves 5 mm 5 Tweezers 6 Projector Before you start This process is protective level II Operators should wear electrostatic chains Note If you need to replace the Main Board...

Page 14: ...12i EX615i 2 3 Disassemble Lamp Module 1 Loosen 2 screws as red circle on the Lamp Module 2 Take off the Lamp Module 2 2 Disassemble Lamp Cover Module 1 Loosen 2 screws as red circle on the Lamp Cover...

Page 15: ...ut the Focus Ring Note When you assemble the Focus Ring ensure the 3 card slot as green square placed in the 3 double screw bolt as yellow circle properly and the Focus Ring can be well adjusted 2 5 D...

Page 16: ...oard Module Avoid damaging by pulling keypad FPC cable Make sure the FPC cable plug into the correct ports when assembling it 2 6 Disassemble Keypad Board Module and Zoom Ring 1 Unscrew 4 screws as bl...

Page 17: ...or as green square to remove the FPC cable 2 Unplug 8 connectors as yellow square 3 Unscrew 5 screws as red circle from the Main Board Module 2 7 Disassemble Top Shielding 1 Tear off 2 EMI tapes as gr...

Page 18: ...circle from the IO Cover 5 Unscrew 8 hex screws as green circle from the IO Cover 6 Unplug 1 connector as orange square 7 Separate the Main Board Module and Main Board Shielding Note Make sure cables...

Page 19: ...feature Figure A G Speaker Compose of Red Black Wire and Black wire tube 2 pin B Lamp Driver Black wire tube 5 pin C System Fan Compose of Red Yellow Black Wire 3 pin D Photo Sensor Compose of Red Bla...

Page 20: ...as green circle to disassemble the Daughter Board 2 Unscrew 1 screw as red circle to disassemble the Lan Module Board 3 Unscrew 3 hex screws as yellow circle from the Main Board Module Note EX612 EX61...

Page 21: ...yellow circle to disassemble the Engine Module 2 11 Disassemble Color Wheel Module 1 Unscrew 2 screws as red circle to disassemble the Color Wheel Module 2 Unscrew 1 hex screw as green circle 3 Unscr...

Page 22: ...you may use an electrostatic ion gun to clean it Pay attention to the fixed position when assembling the DMD Chip 2 13 Disassemble Rod Module 1 Unscrew 2 screws as green circle to take off the Rod Sp...

Page 23: ...Switch 1 Tear off the black tape as yellow square 2 Unscrew 4 screws as red circle to disassemble the System Fan Module 3 Unscrew 1 screw as blue circle and unplug 1 connector as green square to disa...

Page 24: ...2 12 EX612 EX615 EW615i EX612i EX615i 2 15 Disassemble Speakers 1 Unscrew 4 screws as yellow circle to disassemble the two Speakers the wrong gesture the right gesture Note Take the Fan Module as the...

Page 25: ...12 EX615 EW615i 2 16 Disassemble Blower 1 Unscrew 2 screws as red circle to disassemble the Blower Module 2 Separate Blower and Blower Rubber 2 Unscrew 4 screws as red circle to separate the Speaker H...

Page 26: ...circle 2 Unplug 1 connector as blue square 3 Disassemble the LVPS Module the AC Inlet Bracket and Mylar 4 Unscrew 1 screw as green circle AC Inlet Bracket 2 17 Disassemble Front IR Module 1 Unscrew 1...

Page 27: ...2 connectors as green square 6 Disassemble the Interlock Switch and the cable from the LVPS Module 2 19 Disassemble Lamp Driver Module 1 Unscrew 1 screw as red circle to disassemble the Lamp Driver Mo...

Page 28: ...EX615 EW615i EX612i EX615i 3 Separate the Lamp Driver Module and Lamp Driver Holder 2 20 Disassemble Security Bar Cap 1 Unscrew 1 screw as red circle to disassemble the Security Bar Cap and Security...

Page 29: ...X612 EX615 EW615i EX612i EX615i 2 22 Disassemble IO Cover 1 Unfasten 2 tenons as green square 2 Remove the IO Cover 2 21 Disassemble Bottom Shielding 1 Unscrew 2 screws as red cricle to disassemble th...

Page 30: ...white screen Adjust the screws by using the rod on the engine module to readjust the image screw 1 should be adjusted first and then screw 2 Adjust until the yellowish or bluish parts disappeared 3 Ab...

Page 31: ...en use left or right buttons to re write the Projection Hours 3 Re write Lamp Hours Normal Use up or down buttons to select Lamp Hours Normal then use left or right buttons to re write the Lamp Hours...

Page 32: ...d Lamp LED Red Standby State Input power cord Amber Power on Warming Flashing Green Power on and Lamp lighting Green Power off Cooling Flashing Green Error Lamp failed Flashing Amber Red Error Fan fai...

Page 33: ...Board 2 Auto Shut Down Check LED status a Lamp Fail ON STANDBY LED flashes amber Lamp LED lights red Check Lamp Check Lamp Driver Check Main Board Check Color Wheel Check Photo Sensor Check whether W...

Page 34: ...Board 4 No Image Ensure the Signal Cable and Source work If you connect multiple sources at the same time use the Source button switch Ensure all connectors are securely connected and aren t broken C...

Page 35: ...of the OSD Menu Adjust Color Wheel Index Check Main Board Check DMD Board Check Color Wheel 9 Poor Uniformity Shadow Ensure the projection screen without dirt Ensure the projection lens is clean Ensu...

Page 36: ...t in Mute mode Check the interior Speakers of the projector Check the exterior Speaker that you are using Check Main Board Check Daughter Board 15 Network Fail For EX615 EW615i EX615 i Ensure you have...

Page 37: ...ter Security Code appears Please Input the Current Security Code 8642 by Remote Control then press Enter 2 Press Menu button select Setup Change Password then press Enter button The message Enter Secu...

Page 38: ...inds of Service Mode use different ways to get into each Service Mode 1 Turn on the projector 2 1 Press Power Left Left and Menu buttons sequentially to get into Service Mode 1 2 Press Power Up Down a...

Page 39: ...ion Active area Zone A Zone B Defect specification table 12 5 cm 12 5 cm Zone B Frame Zone C For EX615 EX612 EX612i EX615i Order Symptom Pattern Criteria 1 Bright pixel dots Gray 10 pattern A B 0 2 Da...

Page 40: ...0 min for 4 cycles Press Power Left Left Menu to get into service mode 1 Choose Burn In Test enter Lamp On Mins Press right key to adjust the time 50 Lamp Off Mins Press right key to adjust the time 1...

Page 41: ...15 EX615i EW615i Blower Version Update v v v Color Wheel Index v v ADC Calibration RGB Video Calibration v Reset lamp hour v OSD Reset v v EDID v Re write Lamp Hour Usage v Rod adjustment v Factory RP...

Page 42: ...tor after about 30 seconds press Power Left Left and Menu button sequentially to get into service mode1 press right key to change the Factory RPM Save status to On The Current Blower RPM will be saved...

Page 43: ...al pixel number of pixel clock in one line period 2 Select Tracking function and use right or left arrow key to adjust the value to minimize video flicker Adjust Resync or Frequency Tracking H Positio...

Page 44: ...re in 4 4 Test Condition for Frame and Active area Note The defect criteria follows TI specification 3 Dark pixel Procedure Test equipment video generator Test signal analog 1024x768 60Hz Test Pattern...

Page 45: ...Inspection item Dark blemish check Criteria The dark blemish should be less or equal to 4 under blue 60 pattern Note The defect criteria follows TI specification 6 Focus test Procedure Test equipment...

Page 46: ...ondition such as lines appear on the screen and so on Color appears normal It is unacceptable to have few lines flashing RGBW should all appear normal on the screen and sort from R G B W Color levels...

Page 47: ...2 5 M Criteria Check any abnormal color line distortion or any noise on the screen Check the sound from speakers Check whether freeze and mute are normal Press V Keystone on remote controller check w...

Page 48: ...e Test equipment DVD Player Test signal CVBS Inspection item Audio performance test Inspection Distance 1 8 M 2 5 M Criteria Check the sound from speakers Plug Audio cable into Audio in 1 port check w...

Page 49: ...te 1 Calibration pattern should be in full screen mode 2 Please refer to 4 2 Guide to get into service mode 1 and choose ADC calibration 3 Choose and get into Video Calibration press Enter button to e...

Page 50: ...ss appears it means RGB Calibration is OK Choose Menu or Exit to leave service mode 1 Check pattern Test signal 1024 x 768 60Hz Test pattern 64 grey RGBW After finishing RGB adjustment check 64 gray R...

Page 51: ...Distances from the screen 1 95 M Screen Size 60 inches diagonal 1 Test equipment Procedure Press Power Left Left Menu to get into service mode 1 Select Spoke Test 2 Brightness Procedure Full white pa...

Page 52: ...Contrast formula to calculate contrast values Contrast Formula P5 B5 Note P5 center of white image B5 the center of black image Criteria 1600 1 4 Uniformity Procedure Full white pattern Use CL100 to m...

Page 53: ...o select SETUP Use down button to remove the light mark to RS232 then press Enter button to select Network press Enter button 2 Select Network press Enter button 3 Remove the light mark to DHCP then p...

Page 54: ...s 2 Select Internet protocol TCP IP then click Properties 3 Modify the IP address to 192 168 0 101 and modify Subnet mask to 255 255 255 0 Note The HOST ID 192 168 0 XXX of PC IP address must be diffe...

Page 55: ...the Projector with LAN Cable 2 Execute Internet Explorer 3 Visit the IP address http 192 168 0 100 Key in User Name Administrator and Password administrator click Login to get into Projector Web Serve...

Page 56: ...DDC1 DDC2B operation of the projector and to verify Plug Play function Acoustic High pitch sound from cooling fan and color wheel is unacceptable 2 Check points for exterior and print pattern Check i...

Page 57: ...ade 5 1 1 Equipment Needed Software DDP 2430 USB DLP Composer Lite 9 2 Firmware img Library file Library 9 2 Hardware Projector Power Cord 42 50115G001 Mini USB Cable 42 00286G101 PC or Laptop Note Th...

Page 58: ...i 5 1 2 DLP Composer Lite Setup Procedure 1 Choose DLP Composer Lite V9 2 Setup Program 2 Click Next 3 Read License Agreement Choose I accept and agree to be bound by all the terms and conditions of t...

Page 59: ...Confidential 5 EX612 EX615 EW615i EX612i EX615i 5 Click Next 6 Click Next 7 The program is executing installing status 8 Click Finish...

Page 60: ...r with USB cable Note The system fan and the lamp will not operate 5 1 4 USB Driver Upgrade Procedure 1 Execute Program 1 Connect projector with PC by USB cable 2 Found New Hardware Wiszard picture wi...

Page 61: ...he USB driver there is no need to perform this action 5 1 5 Firmware Upgrade Procedure 1 Execute the DLP ComposerTM Lite 9 2 file 2 Click Edit and Perferences 3 Click Library Click the Browse and navi...

Page 62: ...ick Communications Select USB Click OK 5 Choose Flash Loader Click Browse to search the firmware file img Click Open 6 Select Skip Boot Loader Area select 32KB Click Reset Bus to erase the flash memor...

Page 63: ...he firmware upgrade process is finished Download completed will appear on the screen The projector will automatically turn on Unplug USB cable 10 Check FW version Get into the service mode to check th...

Page 64: ...oftware DDP 2430 USB EX612 EX615 EW615i Setup _NLINK_en Manley USB Driver_NLINK EX612 EX615 EW615i_8051_xxx hex Hardware Projector Power Cord 42 50115G001 Mini USB Cable NLINK Cable 2 NLINK Fixture PC...

Page 65: ...Confidential 5 EX612 EX615 EW615i EX612i EX615i 5 2 2 NLINK Setup Procedure 1 Choose setup_NLINK_en exe program 2 Click Next 3 Click Next 4 Click Next...

Page 66: ...2i EX615i 5 Click Next Select the additional task that you may create a desktop icon 6 Click Install to begin installing NLINK Procedure 7 Click Finish Complete the NLINK setup 8 MCU Choose picture wi...

Page 67: ...h NLINK Fixture Connect NLINK Fixture with PC by USB cable 2 Execute Program 1 Found New Hardware Wiszard picture will appear on the screen 2 Select Install from a list or specific location Advanced 3...

Page 68: ...7 Click Next 8 Click Continue Anyway 9 Click Finish Manley TPRP1 Protocol Emulator will appear on the picture Complete the USB Driver Upgrade Procedure Note If Found New Hardware Wiszard picture appea...

Page 69: ...will appear on the screen select W79E804 Click OK 3 Choose 8051 file hex Manley Nlink picture will appear on the screen Ensure MCU is the one you chose in the last step as green square Click Open Sel...

Page 70: ...When 8051 FW upgrade process is finished Write Chip success will be shown 6 Check 8051 FW version Turn on the unit and get into the service mode to check the 8051 FW version To get into service mode...

Page 71: ...15 EW615i EX612i EX615i Section 3 Network Firmware Upgrade Procedure for EX615 EW615i EX615i 5 3 1 Equipment Needed Software EX615 EW615i EX615i_LAN Module FW_xxx bin bin Hardware Projector Power Cord...

Page 72: ...utton to select SETUP Use down button to remove the light mark to RS232 then press Enter button to select Network press Enter button 3 Select Network press Enter button 4 Remove the light mark to DHCP...

Page 73: ...perties 2 Select Internet protocol TCP IP then click Properties 3 Modify the IP address to 192 168 0 101 and modify Subnet mask to 255 255 255 0 Note The HOST ID 192 168 0 XXX of PC IP address must be...

Page 74: ...92 168 0 100 tgi fu tgi to get into Firmware Update screen Note The format of address is IP address tgi fu tgi Click Continue 3 Firmware Update image will appear on the screen Click Browse button to s...

Page 75: ...Confidential 5 19 EX612 EX615 EW615i EX612i EX615i 5 Click Re Login 6 Firmware upgrade procedure completes The projector Network FW version will appear...

Page 76: ...and serial number The information is stored in the display and is used to communicate with the system through a Display Data Channel DDC which sites between the display device and the PC graphics adap...

Page 77: ...ini Hardware Projector Power Cord for Projector 42 53506G002 VGA Cable 42 87305G102 HDMI M to DVI F Adapter 42 82B13G001 DVI Cable 42 83N06G001 Generic Fixture 80 00001 001 for EDID Key in Fixture JP3...

Page 78: ...le 1 3 Connect P4 of fixture with VGA 2 Port of projector by VGA Cable 2 4 Plug Power Adapter to JP1 of fixture 5 Power on fixture 6 Plug Power Cord to projector Note You must confirm that the JP3 is...

Page 79: ...Click Model 3 Select the EDID file ini 4 Click Open 5 Key in the Serial Number into the Barcode blank space 6 In Write Source Select item select VGA A and VGA B 7 Click Program 3 Change the cable to...

Page 80: ...e message Please change the cable to VGA B appears on the screen click OK 5 When the EDID program is completed a message OK will appear on the screen 6 Read EDID VGA A VGA B information In Read item s...

Page 81: ...ure with HDMI Port of projector by DVI Cable 3 Plug Power Adapter to JP1 of fixture 4 Power on fixture 5 Plug Power Cord to projector Note You must confirm that the JP3 is closed in all procedure 6 6...

Page 82: ...using 2 Click Model 3 Select the EDID file ini 4 Click Open 5 Key in the Serial Number into the Barcode blank space 6 In Write Source Select item select HDMI 7 Click Program 3 Change the cable to HDMI...

Page 83: ...5 EW615i EX612i EX615i 4 When the EDID program is completed a message OK will appear on the screen 5 Read EDID HDMI information In Read item select Digital and Trans then click the Read 6 EDID informa...

Page 84: ...idential EX612 EX615 EW615i EX612i EX615i Note This chapter is only designed to show the exploded image of the projector For updated part numbers please refer to RSPL report Appendix A Exploded Image...

Page 85: ...CK EX615 SERVICE V 6 51 8EG03G011 LAMP COVER BLACK EX615 7 61 00018G002 LOCK SCREW PAN MECH M3 8 5 3 5 BLACK 8 SP 8EG01GC01 LAMP MODULE FOR PROJECTOR EX615 EX612 V 9 41 83M06G001 EMI TAPE W30 L70mm 10...

Page 86: ...Confidential III EX612 EX615 EW615i EX612i EX615i 5 4 3 2 7 1 6 Assy TOP COVER MODULE...

Page 87: ...F01G002 TOP COVER ASSEMBLY EX615 V 2 51 8EG14G011 KEYPAD PLATE ENTER EX612 3 80 8EF03G001 PCBA KEY PAD BOARD FOR EX615 V 4 85 1A123G050 SCREW PAN MECH M3 5 Ni 5 85 1A123G050 SCREW PAN MECH M3 5 Ni 6 8...

Page 88: ...Confidential EX612 EX615 EW615i EX612i EX615i 2 3 4 5 13 18 12 16 10 14 15 9 7 8 6 1 11 ASSY BOTTOM COVER MODULE...

Page 89: ...K 230W LVPS FOR HORUS V 8 85 1C224G051 SCREW PAN MECH M4 5 COLOR W TOOTH WASHER Cr3 9 61 87340G001 STAND OFF M3 4L D8 0 2100MP 10 51 8EG20G001 230W LVPS MYLAR PC T 0 43 HD20 11 70 8EG14G001 ASSY 4520...

Page 90: ...FOR EX615 V 3 80 8EF07G001 PCBA LAN MODULE BD FOR EX615 V 4 61 00080G001 STAND OFF H 6 0 M2 M3 L6 Sn EP910 5 85 1A122G040 SCREW PAN MECH M2 4 Ni 6 86 0A123G024 HEX NUT M3 5 5 0 5P L2 4 Ni 7 85 1A123G0...

Page 91: ...Confidential VIII EX612 EX615 EW615i EX612i EX615i ASSY MAIN BOARD MODULE...

Page 92: ...R MODULE FOR EX615 SERVICE V 3 51 8EG10G011 IO COVER EX612 4 41 86R01G001 ADUIO I O PORT EMI GASKET W13 H1 L13mm diameter 6 5mm 5 85 005AGG408 SCREW HEX I O 4 40 H4 L8 NI NYLOK 6 85 1A123G050 SCREW PA...

Page 93: ...Confidential EX612 EX615 EW615i EX612i EX615i ASSY OPTICAL ENGINE MODULE...

Page 94: ...TI 1076 603cB V 9 52 8CP01G011 DMD RUBBER EX615 10 52 8CP02G001 DMD BOARD RUBBER X1161 11 85 4A826G118 STEP SCREW FOR TYPEX DMD M2 6 11 8mm X15 12 52 8CP04G001 S450 0 55 XGA SVGA DMD thermal pad FUJIP...

Page 95: ...SERVICE V 1 61 8CP03G001 CW BRACKET SECC X1161 2 80 8EF04G001 PCBA PHOTO SENSOR BOARD FOR EX615 V 3 23 8EF19G101 YO 5S R76Y32G78W98B76 CW WITH FTZS MO TOR 4 85 1A126G040 SCREW PAN MECH M2 6 4 Ni 5 51...

Page 96: ...5 EW615i EX612i EX615i ASSY BlOWER MODULE Item P N Description Parts Supply 1 49 8EF04G001 SUNON 45 20mm GB1245PKVX 8 F TYPE BLOWER EX612 EX615 V 2 52 89T01G001 BLOWER AIR TIGHT F12 H5350 3 52 82G08G0...

Page 97: ...V 2 61 8EG05G001 8525 FAN SHIELDING HD20 3 61 8EG11G001 LAMP BLOWER DUCT HD20 4 85 1A123G080 PAN SCREW M3 8 FOR YM 64 FRONT CELL SP 5 85 1A123G060 SCREW PAN MECH M3 6 NI 6 43 8EG17G001 THERMAL SWITCH...

Page 98: ...Confidential XV EX612 EX615 EW615i EX612i EX615i A K...

Page 99: ...4 EUR GREEN 11 42 00200G005 CABLE VGA 15P 1 8M BLK EP739 12 45 8EF01G001 REMOTE CONTROL OF Z15II WITH LASER V 13 57 00001G001 PACK SIO2 DRIER 20g 14 51 00027G003 PE BAG ZIPPER 33cm 25cm SIZE GREEN FOR...

Page 100: ...5 6 7 1 Q Optoma 2 8EF Project Code 3 9 Last number of the manufacture year ex 2009 9 4 15 week of the manufacture year ex the fifteenth week of the year 15 5 AAAAA not defined 6 C Manufacture factory...

Page 101: ...Confidential II EX612 EX615 EW615i EX612i EX615i II PCBA Code Definition PCBA Code for Projector A B XXXXXXXXXX C XXX EEEE 1 2 3 4 5 6 1 ID 2 Vendor Code 3 P N 4 Revision 5 Date Code 6 S N...

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