Optoma ML300 Service Manual Download

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SERVICE MANUAL

Prepared:Cherry Checked:Amy Approved: Alick

Date

Revise Version

Description

2012.01.12

V1.0

Initial Issue

2012.05.23

V2.0

Add Engine Adjustment in chapter 2-10
Modify Pixel specification in chapter 4-3
Modify LED Calibration in chapter 4-4
Add Wavie Items in chapter 4-5

ML300

Summary of Contents for ML300

Page 1: ...evise Version Description 2012 01 12 V1 0 Initial Issue 2012 05 23 V2 0 Add Engine Adjustment in chapter 2 10 Modify Pixel specification in chapter 4 3 Modify LED Calibration in chapter 4 4 Add Wavie Items in chapter 4 5 ML300 Copyright May 2012 All Rights Reserved ...

Page 2: ...stomers 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 repairing and do not attempt to do anything that is complex or is not mentioned in the troubleshooting Notice The information found in this manual is subject to change without prior notice Any subsequent changes made...

Page 3: ...le Top Cover Module 2 2 Disassemble Daughter Board and Keypad Board 2 3 Disassemble LED Cable 2 5 Disassemble Focus Ring 2 5 Disassemble Fan 2 7 Separate Engine Module and Main board 2 8 Disassemble Engine Module and LED 2 10 Disassemble Bottom Cover Module 2 13 Engine Adjustment 2 14 Repair Action 2 15 Chapter 3 Troubleshooting LED Lighting Message 3 1 Main Procedure 3 2 ...

Page 4: ... Run In Test 4 12 Test Inspection Procedure 4 13 Chapter 5 Firmware Upgrade Section 1 System Firmware Upgrade 5 1 Equipment Needed 5 1 Check FW version 5 2 Section 2 PIC Firmware Upgrade 5 3 Equipment Needed 5 3 PIC Firmware Upgrade 5 4 Section 3 MST7286 Firmware Upgrade 5 7 Equipment Needed 5 7 USB Driver Upgrade Procedure 5 8 MST7286 Firmware Upgrade Procedure 5 10 Section 4 SSD1938 FW Upgrade 5...

Page 5: ...Confidential ML300 IV Chapter 6 EDID Upgrade EDID upgrade 6 1 Appendix A Exploaded Overview I Appendix B Serial Number System Definition I PCBA Code Definition II ...

Page 6: ...or 5 C 35 C 2 500 ft 5 000 ft for 5 C 30 C 5 000 ft 10 000 ft for 5 C 25 C 10 DMD TI DMD 0 45 WXGA DMD 11 Power Consumption Full Mode 93W 10 110VAC Standby Mode 0 5W 12 LED Power Bright Mode 54W 10 PC Mode 48W 20 Cinema Mode 37 W 20 Photo Mode 43W 20 13 Video compatibility NTSC M J 3 58MHz 4 43MHz PAL BG DK I M N 4 43MHz 480i 480p 576i 576p 720p 1080i follow section 8 4 timing table 14 Terminal VG...

Page 7: ...DMI 480i 480P 60Hz 576i 576P 50Hz 720P 50Hz 60Hz 1080i 50Hz 60Hz Compatibility Multimedia Format Video File format Video format MAX resolution Profile AVI MOV MP4 3GP MKV H 264 1280x800 30fps BP MP HP AVI 3GP mov wmv MPEG4 1280x800 30fps SP ASP AVI MOV MP4 3GP xvid 1280x800 30fps HD FLV Sorenson Spark 1280x800 30fps Spark WMV VC 1 1280x800 30fps SP MP AP AVI mov MJPEG 1280x800 30fps Baseline Note ...

Page 8: ...e extension BMP bmp JPG JPEG jpg jpeg Audio AAC MP3 PCM ADPCM WMA Microsoft Office Viewer Word document PDF Powerpoint Excel txt Note If the Computer Compatibility supportive signal is different from User s Manual please refer to User s Manual ...

Page 9: ...Chapter 2 Disassemble And Repair Action 2 1 Equipment Needed Product Overview 1 Screw Bit No 00 2 Hex Sleeves 5mm 3 ML300 unit Before you start This process is protective level II Operators should wear electrostatic chains ...

Page 10: ...2 2 Disassemble Top Cover Module 1 Take off 7 rubbers on bottom side as yellow circles and then unscrew 7 screws under the rubbers 2 Unplug the keypad cable and FPC cable as yellow circles 3 Disassemble the Top Cover module ...

Page 11: ...onfidential 2 ML300 2 3 Disassemble Daughter Board and Keypad Board 1 Unscrew 4 screws from the daughter board as yellow circles 2 Unscrew 4 screws from the keypad board as yellow circles Daughter Board ...

Page 12: ...Confidential 2 ML300 3 Separate the keypad and the Top Cover Module 4 Disassemble the IO cover from the top cover Keypad ...

Page 13: ...1 Unplug 4 connectors to disassemble LED cable as yellow circles 2 5 Disassemble Focus Ring 1 Tear off the mylar from the focus ring as yellow square and unscrew 2 screws under the mylar as yellow circles GREEN LED CABLE RED LED CABLE BLUE LED CABLE ...

Page 14: ...Confidential 2 ML300 2 Tear off the rubber from the bottom cover 3 Unscrew 1 screws to disassemble the focus ring as yellow square Focus Ring ...

Page 15: ...Confidential 2 ML300 2 6 Disassemble Fan 1 Take off three Fans Note Care the direction about how to place the fan as yellow square Tear off the mylar from the fans ...

Page 16: ...te Engine Module and Main board 1 Unscrew 5 screws from the Main board as yellow squares 2 Unscrew 2 screws as yellow squares 3 Unplug the speaker from the main board as yellow squares and take off the rubber from the speaker Speaker ...

Page 17: ...tial 2 ML300 4 Unscrew 3 screws from the Main board to separate main board and engine module as yellow circles 5 Unplug the keypad cable and FPC cable from main board as yellow circles Main Board Engine Module ...

Page 18: ...ule and LED 1 Unscrew 4 screws to disassemble heat sink and DMD board as yellow circles 2 Separate heat sink and DMD board from engine module 3 Separate DMD chip and DMD chip rubber from engine module DMD chip rubber Heat sink DMD board Engine DMD chip ...

Page 19: ...Confidential 2 11 ML300 4 Unscrew 8 screws to disassemble 2 heat sink 5 Disassemble the green and red LED from the engine module Green LED Red LED ...

Page 20: ...Confidential 2 12 ML300 6 Unscrew 2 screws to disassemble heat sink and blue LED as yellow circles Blue LED Heat sink ...

Page 21: ...Confidential 2 13 ML300 2 9 Disassemble Bottom Cover Module 1 Unscrew 1 screw and tear off 4 rubbers on the back of bottom cover to disassemble bottom cover Module ...

Page 22: ...ol to get into service mode then seclect Test pattern Change the screen to white screen Loosen the 2 screws slightly on the engine module then use Pliers or other tools to knock the green square to readjust the image until the image is normal 3 Abnormal image inspection It should not have any abnormal color at the rim of the image by estimating through the eyes Note To avoid over adjusting the mir...

Page 23: ...are Description page Main Board Engine Module Fan Firmware Version Update V V Chapter 5 Reset LED Calibration V Chapter 4 4 PC Calibration V V V Chapter 4 4 Auto Keystone Calibration V Chapter 4 4 EDID V Chapter 6 OSD Reset V V Chapter 4 6 2 11 Repair Action ...

Page 24: ...ential 3 Chapter 3 Troubleshooting 3 1 LED Lighting Message For Projector Message LED Indicator Button Standby mode Flashing 2 second On 1 second Off orange Fan lock error Flashing Red Over temperature Flashing Red ...

Page 25: ...ignal Cable and Source work If you connect multiple sources at the same time use the Source button on the control panel to switch Ensure all connectors are securely connected and aren t broken Ensure all Multimedia Format Supported detail in chapter 1 3 by the projector Check FPC cable between Daughter Board and Main Board Check Daughter Board Check Main Board Check DMD Chip Check Engine Module 5 ...

Page 26: ...et Check R G B LED Board Check Engine Module 11 Garbage Image Ensure that the signal cables and source work well Check Daughter Board Check Main Board 12 Remote Control Failed Check Battery Check Remote Controller Check Keypad Board Check Main Board 13 Function Abnormal Do Factory Reset of the OSD Menu Check Daughter Board Check Main Board 14 Audio Abnormal Ensure that the signal cables and source...

Page 27: ...omponent S Video Composite and HDMI HDTV Source 480P 720P 1080i 1080P Minolta CL 200 Quantum Data 802B or CHROMA2327 Color Video Signal Pattern Generator 4 2 Test Condition Circumstance brightness Dark room less than 2 0 lux Inspection distance 0 8M 1M functional inspection Screen size 30 inches diagonal Zone Definition Figure Zone A as green line Definition ...

Page 28: ... the image sharpness is well performed Inspection item Check if there is noise on the screen Horizontal and vertical position of the video should be adjustable to the screen frame Criteria If there is noise on the screen the product is considered as failure product The PC mode functionally sure be workable include support format with frequency and auto detected functional will be workable General ...

Page 29: ... white Inspection item Dark pixels check Criteria Please refer to Pixel specification table 4 Bright Blemish Procedure Test equipment video generator Test signal 1280 800 60Hz Test Pattern Gray 10 Inspection item Bright blemish check Criteria Please refer to Pixel specification table 5 Dark Blemish Procedure Test equipment video generator Test signal 1280 800 60Hz Test Pattern Blue 60 Inspection i...

Page 30: ... on one of thecorner after adjustment is acceptable However the word should at least be recognizable Unbalance After adjust the lens if the diagonal or adjacent two grids vague it will be regarded as NG Full Screen Order Symptom Pattern Criteria 1 Bright pixel dots Gray 10 pattern A 0 2 Dark pixel dots White pattern A 4 3 Bright blemish Any pattern Blemishes are allowed 4 Dark Blemish Any pattern ...

Page 31: ... normal on the screen and sort from R G B W Color levels should be sufficient and normal The uni dentified color levels on both left and right sides should not over 4 color levels Gray level should not have abnormal color or heavy lines If color appears abnormal please get into serice mode to do color wheel index adjustment 4 3 2 AV Input Port And Audio Out Port Procedure Test equipment DVD player...

Page 32: ...olor can not discolor 4 3 4 Micro SD Card USB flash disk Micro USB Test 1 Micro SD Card Test Procedure Test equipment SD Card include test pattern Test Pattern photo video or audio Turn on the projector and plug SD Card into the projector Press Home button and O of remote controller to play the files Get into service mode Inspection item Color saturation Criteria The color should appear normal and...

Page 33: ...y and the voice sounds normal 3 Micro USB Test Procedure Test equipment Micro USB Test Pattern PC file Turn on the projector and plug Micro USB cable into the projector USB connected OSD will appear automatically Select USB Display as red square the PC information will be shown Select Data Transfer as yellow square then select O to confirm transfer The screen turns black after 60 seconds for power...

Page 34: ...me Down Zoom of remote controller to get into Service Mode 3 Choose PC Calibration for correction When the message Success appears it means PC Calibration is OK Choose Exit to leave the Service Mode Check pattern Test signal 1280 800 60Hz Test pattern 64 gray RGBW After finishing PC adjustment check 64 gray RGBW pattern Inspection item Color saturation Criteria There should not have any lack of RG...

Page 35: ...lease put the Projector on a horizontal surface Press Up Home Down Zoom buttons of remote controller sequentially to get into Service Mode Press VGA of remote controller then select Auto Keystone Calibration Press Auto Keystone Calibration for correction Check pattern Test signal 1280 800 60Hz Test pattern General 1 General 1 ...

Page 36: ...to start calibration and Fail will appear in right blank it means it has return to default value Note System Firmware C04 will phase in this function 2 Put the CL200 on the center of the screen Connect LED Calibration Fixture and Projector by VGA Cable Connect LED Calibration Fixture and CL200 by CL200 RS232 Cable 42 89509 001 Connect LED Calibration Fixture and Computer by USB Cable Power on the ...

Page 37: ... NB test c This issue only happened on 1280x800 mode of special pattern if user occasionally found noise we can guide him her to change to 1280x768 or 1280x720 mode 2 Uneven image quality in Line morie pattern from Chroma signal generator normal uneven line morie comparison This is a design limitation and it only found in Line morie pattern No Issue Description Root Cause 1 VGA ripple Design limit...

Page 38: ...the defect symptoms ie If it is NFF the run in time is 4 hours You have to set the LED on for 60min and LED off for 15 min for 2 cycles Note Please make sure that the hot exhaust airflows from projectors can flow towards the aisle Press Up Home Down Zoom of remote controller Choose Burn In Test enter Lamp On Min Press right key to adjust the time 60 Lamp Off Min Press right key to adjust the time ...

Page 39: ...missing prints and blurry prints are 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 2 OSD Reset 1 After final QC step we have to erase all saved change again and restore the OSD default setting The following actions will allow you to erase all end users settings and restore the default s...

Page 40: ...ary library 10 5 Hardware Projector Adapter 47 8LU01G001 Power cord 42 0010AG002 Cable USB micro B M to USB A M 1000MM 42 0028DG001 PC or Laptop Remote control 45 8LU01G001 Note1 We will show the hot key of FW mode and how to check FW version the other contents please refer to common manual Note2 During FW upgrade procedure please select 32KB in Skip Boot Loader Area ...

Page 41: ...tor light orange all the time press Power button of remote control the projector will flash blue in a moment When the LED indicator of the projector have no light on this projector has been got into firmware mode Insert Micro USB cable to ML300 PC 5 1 3 Check FW version 1 Restart the unit and enter the Service Mode Press Up Home Down Zoom of remote control 2 The firmware version will be shows as r...

Page 42: ...eeded Software ML300_Pic FW_All_Ver XX Hex PICGA002 Downloader Hardware Adapter 47 8LU01G001 Power cord 42 0010AG002 VGA Cable 42 00200G004 RS232 Cable DSUB F 9 DIN M 6 42 89509 001 USB Cable mini USB to USB A 42 00284G001 Debug Board 80 8KT11G001 Projector PC or Laptop ...

Page 43: ...ture and PC Plug in the VGA cable to VGA port of fixture and ML300 Plug in the USB cable to VGA port of fixture and PC Note The position of fixture s pin as right picture shown Press Power plug in the power cord until the LED Indicator flash orange release the power button 2 Execute the PICGA002 Downloader file ...

Page 44: ...Confidential 5 ML300 3 Select the COM Port which you are using 4 Select 19200 5 Click LOAD to search the PIC FW file 6 Click SEND 7 Click OK ...

Page 45: ... upgrade procedure will run automatically 9 Click OK then close the window 5 2 3 Check FW version 1 Restart the unit and enter the Service Mode Press Up Home Down Zoom of remote control 2 The firmware version will be shows as red square ...

Page 46: ...rmware Upgrade Procedure 5 3 1 Equipment Needed Software ML300 MST7286 FW file BIN Mstar Tool exe Hardware Projector Adapter 47 8LU01G001 Power cord 42 0010AG002 Debug Board 75 8GA01GR01 USB cable 42 00281G102 VGA Cable 42 00200G004 Monitor PC ...

Page 47: ...C by USB cable Note The VGA cable is special the PN is 42 00200G004 The position of fixture s pin as right picture shown 2 Insert another side of the VGA cable and power cable into projector 2 Execute Program 1 Found New Hardware Wizard picture will appear on the screen 2 Select Install from a list or specific location Advanced 3 Click Next ...

Page 48: ...n the search then click Browse 5 Browse For Folder picture will appear on the screen 6 Select FTC100103 MSTAR folder then click OK 7 Click Finish Note If the PC appear Found New Hardware Wizard picture again repeat step 2 to install USB Drivier once more ...

Page 49: ...Procedure 1 Press power button and power on the projector Enter into the Service Mode Up Home Down Zoom then select Debug switch select MST7286 2 Unzip the Mstar Tool zip and double click ISP_Tool V4 4 5 0 exe 3 Select Read to search the FW file Select Open ...

Page 50: ...Confidential 5 11 ML300 4 Select Device and double click MX25L8005 5 Select Connect Make sure the device type is MX25L8005 Click OK ...

Page 51: ...Confidential 5 12 ML300 5 Select Auto Cancel ReConnect Select Run to Start Download 6 When download finished the green character Pass will show ...

Page 52: ...Confidential 5 13 ML300 5 3 3 Check FW version 1 Restart the unit and enter the Service Mode Press Up Home Down Zoom of remote control 2 The firmware version will be shows as red square ...

Page 53: ...Confidential 5 14 ML300 Section 4 SSD1938 FW Upgrade 5 4 1 Equipment Needed Software Upgrade zip Hardware Projector Power cord PC or Laptop Adapter micro SD Card ...

Page 54: ...idential 5 15 ML300 5 4 2 SSD1938 Firmware Upgrade Procedure 1 Unzip the file and copy the file to micro SD Card by PC 2 Insert SD card to projector 3 Turn on the projector then select Setup 4 Select System ...

Page 55: ...o process the firmware upgrade 8 Firmware upgrade procedure image will appear as the right picture shown Note 1 Do not touch any buttons or turn off the projector while upgrading is in progress Otherwise this may damage the projector 2 Do not remove the microSD card until the upgrade is complete ...

Page 56: ...rs update is complete Press and hold the Power button for 6 seconds to turn off the projector 5 4 3 Check FW version 1 Restart the unit and enter the Service Mode Press Up Home Down Zoom of remote control 2 The firmware version will be shows as red square ...

Page 57: ...r 6 EDID Upgrade 6 1 Projector EDID Upgrade Procedure The upgrade procedure for VGA and HDMI ports please refer to common manual chapter 6 Please use EDID 0 67exe Program and Key in the serial number into the Unit No blank space ...

Page 58: ...ML300 Confidential Appendix A D C Exploded Image 4 ...

Page 59: ...i NYLOK 4 75 8LU01G001 BUY ASSY IO COVER ML300 V 5 23 8KW15G001 PT39 RED LED Standard Die Config D51 220LM Luminus V 6 23 8KW15G002 PT39 GREEN LED Standard Die Config D51 220LM Luminus V 7 23 8KW15G003 PT39 BLUE LED Standard Die Config D51 220LM Luminus V 8 80 8LU02G001 PCBA DMD BD FOR ML300 PROJECTOR V 9 48 8KU01G001 DMD 1140x910 PIXEL 0 45 WXGA DDR Type Series 310 DMD TI V ...

Page 60: ...ML300 Confidential III Assy Top Cover Module 6 5 8 9 7 ...

Page 61: ...E ML300 3 75 8LU02G002 BUY ASSY BOTTOM COVER ML300 V 4 51 8LU07G001 KEYPAD P R ML300 5 52 8LU05G001 PORON FOR TOP COVER ML300 6 75 8LU01G001 BUY ASSY IO COVER ML300 V 7 80 8LU03G001 PCBA KEYPAD BD FOR ML300 PROJECTOR V 8 80 8LU06G001 PCBA DAUGHTER BD FOR ML300 PROJECTOR V 9 85 1A522G060 SCREW PAN MECH M2 6 Ni NYLOK 10 85 3A522G030 SCREW CAP MECH M2 3 Ni NYLOK ...

Page 62: ...ML300 Confidential Assy Bottom Cover Module Assy Bottom Cover Module 19 20 ...

Page 63: ...BER SPEAKER SILICONE RUBBER ARES 9 52 8LU04G001 SPONGE FOR AXIAL FAN ML300 10 52 8LU05G001 PORON FOR TOP COVER ML300 11 52 8LU06G001 PORON FOR HEAT PIPE ML300 12 70 8LU08GR01 ASSY ENGINE MODULE 8LU SERVICE V 13 75 8LU02G002 BUY ASSY BOTTOM COVER ML300 V 14 80 8LU01G001 PCBA MAIN BOARD FOR ML300 PROJECTOR V 15 85 005AGG408 SCREW HEX I O 4 40 H4 L8 NI NYLOK 16 85 1A522G040 SCREW PAN MECH M2 4 Ni NYL...

Page 64: ...ML300 Confidential VII Assy Packing Drawing ...

Page 65: ...AG011 PACKING TAPE 72MM FOR OPTOMA 8 51 00037G001 TRANSPARENT TAPE 2 4cm 9 51 00069G001 PACKING STRAP 13 5MM 1500M 0 7MM GREEN 10 51 00070GC01 PE STRETCH FILM 500MM 1500M 0 02MM GREEN FOR CPC 11 51 00174G002 PE BAG 380 310 0 07mm FOR OPTOMA 12 51 86848G001 3 INCH 100m WHITE ADHESIVE 13 55 83R03G002 L TYPE PAPER 1190x1000x1350 EP747 14 55 87202GC01 BOTTOM PAPER COVER PLATE 1230 15 55 8LU02G001 UNIT...

Page 66: ...D 0 5M SP305B IS034 US PK 301 V 26 42 00200G005 CABLE VGA 15P 1 8M BLK EP739 V 27 45 8LU01G001 REMOTE CONTROL FOR ML300 V 28 51 80135G002 PE BAG ZIPPER 240 170 0 04 8 FOR OPTOMA 29 53 8LU01G001 SOFT BAG ML300 V 30 36 8LU01G001 QUICK START CARD MULTILINGUAL ML300 31 36 00024G021 WARRANTY CARD US FOR OPTOMA 1 YEAR W O BATTERY 32 36 00040G011 INSTRUCTION CARD OPTOMA BEFORE RETURN FOR PICO 33 42 00233...

Page 67: ...7 1 Q Optoma 2 8LU Project code 3 0 Last number of the manufacture year ex 2011 0 4 08 week of the manufacture year ex the eighth week of the year 08 5 AAAAA Not Defined 6 C Manufacture factory CPC 7 0001 Serial Code EX Q8LU008AAAAC0001 This label represents the serial number for ML300 It is produced for USA at CPC on eight week of 2011 ...

Page 68: ...ML300 Confidential XI 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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