Data Projector
Service Manual
EMP-S4
EMP-S4
INTRODUCTION
This Service Manual describes the hardware information necessary for troubleshooting and
field service of the EMP-S4 DATA PROJECTOR.
Before starting service on this unit, always check the EPSON website for additional up-to date
service information provided in Technical Information Bulletins.
HOW TO USE THE SERVICE MANUAL
Before you start the maintenance service, read the SAFETY INSTRUCTIONS carefully.
The contents are as follows:
• Safety Instructions: Operator Safety, Maintaining the projector in good condition
• Chapter 1: PRODUCT SPECIFICATION (Part name, System function,
Specification, etc.)
• Chapter 2: THEORY OF OPERATION (Hardware, Internal connection,
Function of units, etc.)
• Chapter 3: TROUBLE SHOOTING
• Chapter 4: DISASSEMBLY & ASSEMBLY (Procedures to disassemble the
main unit)
• Chapter 5: APPENDIX (AS (After Service) menu)
VCCI RADIO FREQUENCY INTERFERENCE SELF RESTRICTION
This product is Type 1 information equipment and uses radio frequency energy. It fully complies with the rules of the Voluntary Control Council for Interference by Information Technology Equipment (VCCI). Accordingly, if this product is used in a residential area or place
situated close to residential area, it may interfere with reception of televisions or radios in the
neighborhood. Follow the instruction manual to avoid mishandling of this product.
TRADEMARK
EPSON is a trademark of SEIKO EPSON CORPORATION.
NOTICES
• This document should not be reproduced in whole or in part without the written permission
of SEIKO EPSON CORPORATION.
• Any information in this document is subject to change without prior notice.
• The information and specifications in this document are the most up-to-date at the time of
publication. However, we are unable to guarantee the accuracy of printed material after the
date of publication. In case of any mistake or lack of description, please kindly notify us.
• Any influence by utilizing the document may be out of our responsibility regardless the
item 3 above.
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PRECAUTIONS
Some procedures require specific precautions that must be followed, and those will be noted
throughout this manual. Note the following precaution definitions:
WARNING
W A R N I N G
Procedures which, if not strictly observed, could result in personal injury are
described under the heading WARNING
CAUTION
C A U T I O N
CAUTION signals a precaution which, if ignored, could result in damage to equip-
ment.
REASSEMBLY
If assembly needs special attention or the procedure is different from the reversed
disassembly procedure, the correct procedure is described under the heading
REASSEMBLY.
CHECK POINT
C H E C K
P O I N T
Important tips for procedures are described under the heading CHECK POINT.
2006 SEIKO EPSON CORPORATION
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Manual Revision History
History Date Detail of change
Rev.A 2006.4.10
First Release
Rev.B 2006.5.9 Change in P.4-10.
Service memo
Make a note here of important technical information from Technical Information bulletins.
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SAFETY INSTRUCTIONS
1. MAINTAINING OPERATOR SAFETY
1. PREVENTING ELECTRIC SHOCKS
• Turn off the power switch and disconnect the power cord from the AC outlet before car-
rying out any disassembly and assembly work on this projector.
• If power needs to be supplied to the projector while the cover is removed (such as when
making adjustments), take off any metallic objects such as wristwatches, shirt cuff buttons, rings and tie pins which may pose the danger of coming into contact with the projector.
2. PREVENTING INJURY
• Do not touch the lamp assy and the area around it with bare hands immediately after
turning the power off, or even after cool-down period is completed since the lamp and
the area around it may still remain hot.
• When removing the cover in order to carry out adjustments while power is being sup-
plied to the projector, be careful not to touch the fans (intake and exhaust).
• Always wear gloves when disassembling and reassembling the projector in order to
avoid injury from metallic parts with sharp edges.
• Do not look directly into the projector's lens while power is being supplied to the projec-
tor, otherwise your eyes may be injured.
3. PREVENTING ACCIDENTS
• Place the projector on a stable, level surface when carrying out any repair or adjustment
work, to prevent the projector and its components from slipping and falling down. Furthermore, do not place any tools or projector components on top of or underneath the
projector.
• Avoid working on the projector in places where other people might receive injuries from
touching the projector while it is in a state of disassembly. Furthermore, do not leave the
projector unattended in the workplace at such times.
• When turning on the projector's power, always use the accessory power cord to connect
the projector to the power supply, and always make sure that the power supply is properly grounded.
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2. MAINTAINING THE PROJECTOR IN GOOD CONDITION
1. PREVENTING STATIC ELECTRICAL DAMAGE
• When disassembling and assembling the projector, always use a grounding strap and a
grounding mat. Furthermore, when replacing electrical circuit components (such as circuit boards and optical engine), bring the static-proof bag containing the new parts into
contact with a metallic section of the projector before taking out the component from the
static-proof bag.
2. USE OF GENUINE PARTS
• When replacing the structural components inside the projector (including the lamp assy),
use only replacement parts supplied by EPSON and listed in the projector's Parts List.
• Use the accessory power cord and interface cable provided with the projector.
3. SAFETY TESTING
The following tests should be carried out on repair parts used in the LCP.
Note:These are simplified tests that can be carried out at a repair centre that is not
equipped with full safety testing equipment.
Test items
1). Insulation resistance test
2). Ground continuity check
3). Illumination check
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Testing procedure
Carry out testing in the order given below.
EMP-S4
Repair EndInsulation resistance test Ground continuity check
Safety inspections
Testing methods
1). Insulation resistance test
• Testing apparatus: Insulation ohmmeter (Rating: 500 V/100 MΩ)
Check Item Tool Standard
Insulation resistance check Insulation ohmmeter
• Insulation ohmmeter settings
1. Set the range selection switch to 500 V.
Ground terminal Line terminal
Display
2. Connect the black lead wire to the ground terminal.
3. Connect the red lead wire to the line terminal.
4. Connect the black lead wire (crocodile clip) to c in
order to measure the insulation resistance (1) (between
a and c) in the diagram below.
5. Next, insert the probe of the red lead wire into a.
6. Set the measure switch to LOCK, and then measure the
insulation resistance after 1 minute.
7. Check that the insulation resistance after 1 minute is
10 MΩ or more.
8. Next, measure the insulation resistance at (2) (between
b and c) in the diagram below in the same way as for
(1).
9. Check that the insulation resistanc e at (2) a fter 1 minut e
is 10 MΩ or more.
Illumination check
Insulation resistance
should be 10 MΩ or
more.
! Caution
Because high voltage (500 V) is present,
do not touch the probe during testing.
Measure switch
a
Power supply lines
b
Range selection
switch
Projector AC inlet
(1) (2)
c
Computer IN connector
Exposed metal part of projector
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2). Ground continuity check
• Testing apparatus: Multimeter (with sensitivity down to 0.1 Ω)
Check Item Tool Standard
Ground continuity check Multimeter
• Multimeter settings
Display
1. Turn on the power switch.
2. Set the range selection switch to Ω.
3. Connect the black lead wire to the COM terminal.
4. Connect the red lead wire to the V/Ω/Hz terminal.
5. Check that the resistance at (1) in the diagram below is
0.5 Ω or less.
DC/AC, SW
Should be no resistance
(0.5 Ω or less)
a
Range selec-
tion switch
Power supply
lines
b
(1)
Terminals
Projector AC inlet
c
V, Ω, HzCOM
Computer IN connector
Exposed metal part of projector
3). Illumination check
• Test conditions: Input a PC or video signal to the projector and check the illumination for about 5 minutes.
• Evaluation: Projector should operate normally with no smoke or fire.
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Other
• Check that the connectors at both ends of the power cord are not dirty or bent, and clean
them if they are dirty. Furthermore, if there is any noticeable discoloration on the power
cord, it should be replaced.
• When connecting the connector cables and interface cables inside the projector, make
sure that the cable connectors are pushed on as far as they will go.
• To prevent problems caused by dirt getting into the optical system, always disassemble
and assemble the projector in an area which is free from floating dust.
• When disconnecting the FPC cable from the CN502 of the MA board assembly, release
the connector locks. To release the connector lock, push up both ends of the connector
simultaneously with tweezers.
CN502
Enlarged view of CN502
Locked
Unlocked
• When disconnecting the three FPC cables for the light valves from their connectors,
release the connector locks first.
Locked Unlocked
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3. NECESSARY REQUIREMENTS FOR SERVICE TECHNICIANS
Service technicians who carry out repairs and servicing work on the EMP-S4 must possess the
following knowledge and abilities:
• The service technician must have read and fully understood the contents of the User's
Guide, especially projector operation.
• The service technician must have a fundamental knowledge of working with electricity,
including safety procedures, knowledge regarding electrical circuits, and knowledge
regarding static electricity.
4. Others
• Any questions regarding repairs and service to this projector (such as supply of parts and
the contents of this Service Manual) should be directed to EPSON at the address below.
Furthermore, information regarding matters such as technical changes to the projector
are released when necessary in the form of Technical Information bulletins, and these
should be referred to also.
SEIKO EPSON CORPORATION
ADDRESS 4897 OH-AZA, SHIMAUCHI, MATSUMOTO-SHI,
NAGANO-KEN, 390-8640 JAPAN
TEL. 81-263-48-2946
FAX. 81-263-48-5680
SECTION VI.CS Quality Assurance Department
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Chapter 1 Product Specifications
1.1 Product Features .....................................................................................1-2
1.1.1 Features of the Projector...............................................................1-2
1.2 Components, Connectors and Switches..................................................1-4
1.2.1 External Components....................................................................1-4
1.2.2 Internal Components.....................................................................1-6
1.2.3 Remote Control.............................................................................1-7
1.3 Specifications...........................................................................................1-8
1.4 Interface Specifications..........................................................................1-10
1.4.1 Computer Port.............................................................................1-10
1.4.2 USB Interface..............................................................................1-11
1.4.3 S-Video Interface.........................................................................1-11
1.4.4 CVBS Input Interface/Audio Input Interface ................................1-12
1.5 External Views.......................................................................................1-13
Chapter 2 Theory of Operation
2.1 Hardware Overview .................................................................................2-2
2.1.1 Component Connection Diagram..................................................2-3
2.1.2 Control Circuitry.............................................................................2-4
2.2 Optical Engine..........................................................................................2-5
2.2.1 Lamp Assy.....................................................................................2 -7
2.3 MA Board.................................................................................................2-8
2.3.1 External View of MA Board ...........................................................2-8
2.3.2 Overview of Operation...................................................................2-9
2.4 Interface Connectors..............................................................................2-10
2.5 Power Supply Ballast Unit......................................................................2-11
2.5.1 Power Supply Circuit Block Diagram...........................................2-11
2.5.2 Overview of Operation.................................................................2-12
2.5.3 Connector CN2000 Pin Layout....................................................2-13
2.6 RC Board Assembly...............................................................................2-14
2.7 Speaker..................................................................................................2-15
2.8 Temperature Control..............................................................................2-16
2.8.1 Sensors and Switches .................................................................2-16
2.8.2 Fan Operation .............................................................................2-18
2.9 LED Indicators .......................................................................................2-21
Chapter 3 Troubleshooting
3.1 Before Carrying Out Troubleshooting......................................................3-2
3.1.1 Troubleshooting Tools and Equipment..........................................3-2
3.1.2 Field Replacement Parts...............................................................3-2
3.2 Overview..................................................................................................3-3
3.2.1 Exterior Check...............................................................................3-4
3.2.2 Internal Cable Check.....................................................................3-5
3.2.3 Power Supply On/Off.....................................................................3-6
3.2.4 Image Display and Quality ............................................................3-8
3.2.5 Audio Output ...............................................................................3-10
3.2.6 Control Panel...............................................................................3-11
3.2.7 Remote Control Operation ..........................................................3-12
3.2.8 A/V mute slide.............................................................................3-13
3.2.9 Other ...........................................................................................3-14
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Chapter 4 Disassembly/Assembly
4.1 Overview..................................................................................................4-2
4.1.1 Precautions ...................................................................................4-2
4.1.2 Tools and Equipment ....................................................................4-4
4.1.3 Projector-Specific Service Precautions.........................................4-5
4.2 Projector Disassembly and Assembly......................................................4-6
4.2.1 Removing the Model Name Plate..................................................4-9
4.2.2 Removing the Lamp Lid Assy and ELPLP36 Spare Lamp............4-9
4.2.3 Removing the Rear Foot/Rubber Foot..........................................4-9
4.2.4 Removing the Front Foot Unit.....................................................4-10
4.2.5 Removing the Air Filter Frame and Air Filter A............................4-10
4.2.6 Removing the Upper Case..........................................................4-11
4.2.7 Removing the RC filter, SW Light Shade Sheet B,
SW Board Assy,SW Cable Au, SW Button, and LED Lens ........4-13
4.2.8 Removing the Cover Lens Holder, Cover Lens Unit,
Cover Lens Sheet, Cover Lens Frame, Photo Interrupter,
Cover Lens Guide, Lamp Lid Latch Springand and SW Cable....4-16
4.2.9 Removing the MA Board Assy. ...................................................4-19
4.2.10 Removing the IF Case Set, RC Filter,
and SW Light Shade Sheet B ......................................................4-23
4.2.11 Removing the MA Plate...............................................................4-24
4.2.12 Removing the Optical Engine......................................................4-25
4.2.13 Removing the Focus Ring...........................................................4-25
4.2.14 Projection Lens ............................................................................4-26
4.2.15 Removing the RC Board Assy, RC Cable B, Safety Switch,
Intake Duct, Intake Fan, and Intake Fan Sheet............................4-27
4.2.16 Removing the Lamp Duct and Lamp Fan B ................................4-29
4.2.17 Removing the Exhaust Fan Set, Outer Exhaust Duct, and
Exhaust Fan B..............................................................................4-30
4.2.18 Removing the TH Board Assy, Cable RCR FIF,
Lamp Lid Detection Switch, and Inner Exhaust Duct..................4-32
4.2.19 Removing the Power Supply Fan B and Power Supply Assy .....4-33
4.2.20 Removing the Lamp Shield Plate, Power Supply Filter, and
Lower Case..................................................................................4-34
Chapter 5 Appendix
5.1 AS (After Service) Menu..........................................................................5-2
5.1.1 How To Display the AS (After Service) Menu ...............................5-2
5.1.2 Initializing (Resetting) the AS Menu Values..................................5-3
5.1.3 Software DIP Switches..................................................................5-4
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Chapter 1 Product Specifications
EMP-S4
1.1 Product Features
The EMP-S4 is a B4-sized portable projector that is the smallest and lightest in its class. It
offers high-quality color images allowing you to enlarge and project from personal computers,
video equipment (VCRs, video cameras, video disc players, etc.).
1.1.1 Features of the Projector
Compact and lightweight
• B4-sized dimensions: 247 mm x 327 mm x 99 mm (D x W x H)
• 2.6kg weight
Brilliant, attractive images
The Projector employs a high-luminance lamp assembly (170W) and an optical block that
allows the S4 to project images at a brightness of up to 1800 lm.
Full-color, high-resolution capabilities
The projector has three transparent LCD panels (R, G and B), each with 480,000 pixels which
can project images at resolution of up to 800 x 600 dots (approximately 1.677 billion pixels).
Quiet operation
Operating noise at low brightness is only 30 dB.
Brief cool-down period (Instant-Off function)
Cool-down is completed in just a few seconds when turning the projector power off.
Easy to Operate
The accessory remote control can be used for operations such as Freeze, E-Zoom, Effect,
A/V Mute, User's Logo Capturing and Resize functions.
Direct Power-ON
The projector is automatically turned on when an AC connector is plugged in.
Password Protect function
Activating the Password Protection Function prevents unauthorized persons from using the
projector.
Vertical keystone correction
This function allows users to correct vertical image distortion easily.
Color mode function
The images can be projected at the optimum image quality for the projecting environment by
selecting the image source and environment mode from one of seven preset settings.
• Photo
• Presentation
• Theatre
• Game
• sRGB
• Black Board
• Sports
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Automatic Incoming Signal Detection Function
The Search button on the remote control and the Source Search button on the control panel allow
the user to switch between images from different pieces of equipment connected to the projector each time either one of the two buttons is pressed. While the projector is detecting a source,
it displays the Search in Progress screen to show the user which source being detected.
Instant-Off Function
This lets the user to turn the projector off quickly by reducing the cool-down period. When the
Power button on the remote control or the control panel is pressed, the lamp is turned off and
then the end of power-off process is indicated by two beeps. The fans stops soon after the beep
regardless of the internal temperature.
Fan Speed Switch Function
When using the projector at high altitude (higher than 1,500 meters above sea-level), the fan
speed should be increased to cool the projector efficiently and extend the lamp life since air
density is low at high altitude. Select High for the Fan Speed in the Extended Menu to increase the
fan speed.
Image Shift Function
This allows the user to adjust the image position without moving the projector. The image
retains its original aspect ratio after it is moved. This function is useful when it is difficult to
set the projector straight in front of the screen.
After correcting keystone distortion and adjusting the zoom, a screen to select the image position is displayed. The user can select one of nine image position settings on the screen.
Lens-Shutter Function
Users can interrupt or restart the projection by opening and closing the A/V mute slide of the
main unit front. Closing the slide when the projector is not in use protects the lens from dirt
and scratches. During projection, closing the A/V mute slide turns off both the audio and
image while keeping the power and the lamp on.
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1.2 Components, Connectors and Switches
1.2.1 External Components
Lamp cover
Security lock ( )
Control panel
Focus ring
Remote control
light-receiving area
Air exhaust vent
Air intake vent
Foot adjust lever
A/V mute slide
Front adjustable foot
Figure 1-1. Main Unit Front
Foot adjust lever Front adjustable foot
Air filter
(air intake vent)
Ceiling mount
attachment points
(3 points)
Figure 1-2. Main Unit Bottom
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Computer port
Monitor Out port
Power inlet
Rear adjustable foot
[Menu] button
Displays and closes the configuration menu.
[Power] button
Turns the projector power on or of f.
Indicators
The colour of the
indicators and
whether they are
flashing or lit shows
the state of this
projector.
S-Video port
Video port
USB port
Remote control light-receiving area
Speaker
Audio input
Figure 1-3. Input and Output Connectors
[Enter] button
Automatically adjusts analogue RGB images from
computers and RGB video images to the optimum
images.
If a configuration menu or help screen is displayed, it
accepts and enters the current selection.
[Esc] button
Stops the current function.
Displays the previous screen or menu
while viewing a configuration menu.
[Help] button
Displays and closes the help, which
shows solutions if a problem occurs.
[Wide] [Tele] button
Adjusts the image size. If a configuration menu
[Source Search] button
The input source is automatically searched for in the
following order, and the input image from the connected
equipment is projected.
Computer port
S-Video port
Video port
[] []button
Press to correct keystone distortion.
If a configuration menu or help screen is displayed, it
selects menu items and setting values.
or help screen is displayed, it selects menu
items and setting values.
Figure 1-4. Control Panel
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1.2.2 Internal Components
EMP-S4
Control Panel
Cover Lens Frame Assy.
Lamp Assy.
TH Board
Lamp lid detection switch
Speaker
Upper case unit
MA Board
Optical Engine
IF unit
Safety Switch
Exhaust Fan
Power Supply Fan
Lamp Fan
Power Supply Unit
Intake Fan 1
Intake Fan 2
Figure 1-5. Major Internal Components
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1.2.3 Remote Control
[E-Zoom] button( ) ( )
() Enlarges parts of images without changing
the size of the projection area.
() Reduces the part of images that have been
enlarged using the ( ) button.
[Page down][Page up] buttons
When using the remote control as a wireless
mouse, press these buttons to scroll back and
forth through pages in a PowerPoint file.
[Enter] button
Accepts a menu or help item or displays the
next screen or menu when viewing a configuration menu or help menu.
Acts as a mouse left-click when using the
wireless mouse function.
[A/V Mute] button
The audio and video are turned on or off
each time the button is pressed.
[Pointer] button
Press to indicate part of an image being projected as part of a presentation.
[Computer] button
[S-Video] button
[Video] button
Switches to images from the corresponding
port.
[Auto] button
Automatically adjusts and optimises analogue
RGB computer video signals.
Numeric buttons
Use these buttons to enter a password when
using Password Protect.
EMP-S4
Remote control light-emitting area
Outputs remote control signals.
[Power] button
Turns the projector power on and off .
[] button
When a configuration menu or help menu
is displayed, the button selects menu items
and setting values.
When the wireless mouse function is activated, tilting this button moves the pointer
in the direction of tilt.
[Esc] button
Stops the current function.
Displays the previous screen or menu
while viewing a configuration menu.
Acts as a mouse right-click when using the
wireless mouse function.
[Freeze] button
Images are paused or unpaused each time
the button is pressed.
[Num] button
This is used when entering and changing
passwords.
[Menu] button
Displays and closes the configuration menu.
[Help] button
Each time this button is pressed, it displays
and hides the online help menu that can
assist you if you have a problem.
[Volume] buttons
Adjusts the sound volume.
[Search] button
The next input source is searched for automatically in the following order and the image input from the connected equipment is projected each time this button is pressed.
Computer port
S-Video port
Video port
[Color Mode] button
Changes the colour mode. When you press the button, the
colour modes change in the following order.
[Resize] button
When Component videog, Composite videog or S-Videog signals are being projected, the Aspect ratio changes each time
this button is pressed.
Figure 1-6. Remote Control
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1.3 Specifications
Projection System RGB Liquid Crystal Shutter Projection
Projection Method Front/Rear/Ceiling Mount
Size 0.5 inches with MLA
Driving Method Poly-silicon TFT Active Matrix
LCD
Specifications of
main parts
Projection lens
Lamp
Optical System Dichroic Mirror Separation & Prism combine Method
Screen Size (Projected Distance)
High Brightness
Brightness
Low Brightness
Contrast
Brightness Uniformity 85 % (Typ.)
Color Reproduction Full-Color (16.77 million colors)
Sound Output 1W Monaural
Color Mode
Effective Scanning
Frequency Range
(Analog)
Adjustment
Function
PC Photo, Presentation, Theatre, Game, sRGB, Black Board
Video Sports, Presentation, Theatre, Game, sRGB, Black Board
Pixel Clock 13.5 MHz to 162 MHz
Horizontal 15 MHz to 92 KHz
Vertical 50 MHz to 85 Hz
Projector/Remote Control
Tilt Angle 0 to 10degrees
Keystone
Correction
Pixel Number 480000 dots (800 x 600) x 3
Native Resolution SVGA
Aspect Ratio 4 : 3
Pixel Arrangement Stripe
Type
F-number 1.4
Focal Length 16.6 mm
Zoom Ratio 1.0 to 1.35
Offset 9.6 : 1
Type 170W
Life
PC
Component Video
Power zoom/Manual focus
2000 h (High Brightness)
3000 h (Low Brightness)
30 to 300 inch (1.19 to 12.12 m) (Zoom: Tele)
30 to 300 inch (0.87 to 8.97 m) (Zoom: Wide)
1800 ANSI lumens
(Color Mode: Game, Zoom: Wide)
1500 ANSI lumens
Color Mode: Game, Zoom: Wide)
500 : 1
Color Mode: Game, High Brightness)
Keystone/Brightness/Contrast/Tint/Saturation/Sound/
Input signal etc.
Vertical: -30 to +30 degrees
Vertical: -20 to +20 degrees Assuming the aspect ratio is 16 : 9.
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Display
Performance
Input Signal
Analog RGB I/O
Input T erminal
Output Signal Signal Type Not analog-RGB standard level
Video Output Terminal Mini D-sub 15 pin x 1 (Black)
Display Performance
Input Signal
Video I/O
Input T erminal
Control I/O USB I/O I/O Terminal
Operating Temperature 5 °C to 35 °C [41 °F to 95 °F]
Operating altitude 0 to 2286 m (0 to 7500 ft)
Cool-down period A few seconds (Instant-Off)
Start-up period About 4 seconds
Power Supply Voltage 100-240 VAC ± 10%, 50/60 Hz
Power
Consumption
Dimension
W eight Approximately 5.7 lb/2.6 Kg
Fan Noise
Accessories
Lamp ON 250W
Stand-by 5.0 W
Exclude Projection lens & Feet 247(D) x 327 (W) x 87 (H) mm
Maximum Dimension 247 (D) x 327 (W) x 99 (H) mm
High Brightness 36 dB
Low Brightness 30 dB
Power Cable 1.8 m
Computer Cable 1.8 m, Mini D-sub 15 pin - Mini D-sub 15 pin
Remote Control attached
Battery AAA battery x 2
Password Protect sticker attached
Soft Carrying Case attached
Native 800 x 600 dots
Signal Type Separ ate signal
Video Signal Analog (0.7 V p-p, 75 Ω/ Mac 0.714 Vp-p, 75 Ω)
Sync. Signal
Audio Signal 500 mVrms/47 KΩ
Video Mini D-sub 15 pin x 1 (Blue)
Audio RCA x 2 (Whie/Red)
Video Standard NTSC/NTSC4.43/PAL/M-PAL/N-PAL/PAL60/SECAM
Video Signal
Audio Signal 500 mVrms/47 KΩ
Video
Audio RCA x 2 (Whie/Red)
Separate (positive & negative, bi-polarity 2-5 Vpp)
Composite (positive & negative, bi-polarity 2-5 Vpp)
Sync-on-green (negative, 0.3 Vpp)
NTSC: 560 lines, PAL: 560 lines
Depending on observation of the multi-burst pattern)
Composite Video (1.0 Vpp/Sync.negative 75 Ω)
S-Video (Luminous 0.714 Vpp, Chrominous 0.286 Vpp, 75 Ω)
Component Video (Analog Y level 0.7 V 75 Ω/CrCb level ±
0.35 V 75 Ω/Sync., negative 0.3 V or 3-state ± 0.3 V on Y)
Video-RGB (0.7 Vp-p, 75 Ω/Mac 0.714 Vpp, 75 Ω)
Composite Video: RCA (Yellow) x 1
S-Video: Mini DIN
Component Video: Mini D-sub 15 pin (Blue)
(in common with Analog RGB connector)
Video-RGB: Mini D-su b 15 pin (Blue)
(in common with Analog RGB connector)
USB connector series B x 1
(for control of the mouse and keyboard)
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1.4 Interface Specifications
1.4.1 Computer Port
Mini D-sub, 15 pin (input)
CN102
7513S-15G2-08
11
6
1
15
10
5
EMP-S4
Figure 1-7.
Pin No. Signal Name Pin No. Signal Name
1R9(No pin)
2 G 10 GND
3B11GND
4 GND 12 SDA
5 GND 13 H Sync
6 GND 14 V Sync
7 GND 15 SCL
8 GND
Mini D-sub, 15 pin (output)
CN103
7513S-15G2
11
6
1
15
10
5
Pin No. Signal Name Pin No. Signal Name
1 OUT A 9 T.P
2 OUT B 10 GND
3 OUT C 11 T.P
4 T.P 12 T.P
5 GND 13 H Sync
6 GND 14 V Sync
7 GND 15 T.P
8 GND
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1.4.2 USB Interface
USB-Type B
CN503
UBB-4R-D14C
21
34
65
GND
1.4.3 S-Video Interface
EMP-S4
Pin No. Signal Name
1VBUS
2D3D+
4 GND
5 GND
6 GND
Mini DIN4 pin
CN100
TCS7708-012020
6
Pin No. Signal Name
1 GND
4
3
12
5
GND
2 GND
3 Y signal input
4 C signal input
5DET
6 GND
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1.4.4 CVBS Input Interface/Audio Input Interface
RCA pin jack x 3
J101
YKC21-4098N
Pin No. Signal Name
1CVBS
2 GND
3L
4 GND
5R
6 GND
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1.5 External Views
EMP-S4
Unit: mm
Figure 1-8. External Dimens io ns
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Figure 1-9. External Dimens io ns
Unit: Inch
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Chapter 2 Theory of Operation
EMP-S4
2.1 Hardware Overview
The hardware for the EMP-S4 can basically be divided into two sections: the optical engine
and the circuit system. This section of the manual describes functions of the major hardware
components.
The components and unit in the dotted frame shown in the diagram below make up an optical
engine and MA Board Kit, which is provided as one part.
*1: The Intake Fan cools the R, G and B light
valves (LCD panels).
170
Figure 2-1.
*2: The Exhaust Fan and the Lamp Fan mainly
exhaust heat from the Lamp Assy.
*3: During repair work, the section enclosed by the
dotted lines should be handled as a single unit.
Overview of Display Operation
1. The MA Board receives RGB/Component signals from the Computer port. Video signals or
S-Video signals are provided to the MA Board from the CVBS input or S-Video port. Analog signals are converted to digital signals at the MA board.
2. The digital display signals are temporarily stored in video memory on the MA board.
3. The R, G and B light valves control the amount of light that passes through the valves.
4. The light that passes through the light valves is combined by the prism and projected as an
image through the projection lens unit.
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2.1.1 Component Connection Diagram
The connectors for the components and Main (MA) board are shown in the following diagram.
Photo
Interrupter
Lamp Fan
CN708
CN704 CN705 CN300 CN502
CN1500
CN1300
CN1400
CN102CN103
CN504 CN500
CN100 CN101
CN2000
CN706 CN501 CN707 CN701
CN503CN1800
Figure 2-2. MA Board Connectors
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MONI TOR O UT TE ST
CONE CTOR
USB
TP
15
(TI )
RCA-
RCA-
VI
Audio
Bu
ffe
Buzze r
Video AMP
EL830 2
2.1.2 Control Circuitry
The control circuits are illustrated in the following block diagram.
CONECTOR
MONITOR OUT TEST
Newly added part
DD5
GAUGE5S
Driver ASIC
DD5
DD5
NRS
AMP
Thermister
Thermister
FAN Driver
Circuit
Power Supply
POWER SUPPLY LAMP Ballast
AC
PANEL DRIVER B LOCK
(SST)
16Mbit
SST36VF 1602E
FLASH ROM
ADC
Main CPU
Frame Memory
Image Processor
Resizing
Frame Rate Conversion
OSD
Video Decoder
Color Space Conversion
PW190
( Pixelworks )
LED
KEY
MATRIX
4W
( ROHM)
BR24C21F
EL8302
DDC EEPROM
Video AMP
r
ffe
Monitor Out
Bu
DDC
RGB
YUV
Sync
DDC
RGB
YUV
DSUB15
Sync
DSUB15
PC
Y/C
RCA
CVBS
DEO
VI
DIN4
Vol Control,Mute
-B
USB
Audio
2
A015
(TI)
TP
Buzzer
2.8W
L
R
RCA-
RCA-
IR
HU MA N I/F
PC/VIDEO I/F
Figure 2-3. Control Circuit Block Diagram
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2.2 Optical Engine
The optical system consists of four components: the Lamp Assys., the Light Guide Unit, the
Panel-on-Prism (POP) Unit, and the projection lens. These four components together are called
the Optical Engine.
Light Valve (B)
Optical Engine
Light Valve (G)
Projection lens (focus)
POP Unit
Light Valve (R)
Light Guide Unit
Figure 2-4. Optical Engine
Figure 2-5. Optical Engine Functional Diagram
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EMP-S4
C H E C K
P O I N T
The Lamp Assy., Light Guide Unit, POP Unit, and Projection Lens together
make up the Optical Engine. These components are assembled and adjusted
together at the factory, and are not available as separate service parts.
note: The Lamp and Projection Lens can be enacted with AS parts.
C A U T I O N
Do not subject the optical system components to physical shocks or strong
vibration.
Do not disassemble the Light Guide Unit. Disassembly will cause color
distortion, even if reassembled very carefully.
The Optical Engine and MA Board are figured and adjusted together at the
factory. They are only available as a matched pair, and must always be
replaced together when either the Optical Engine or MA Board has a failure.
Table 2-1.
Component Name Function/Other
Lamp Assy. An 170W discharge lamp is the light source.
The Light Guide Unit disperses the light from the light source via
lens arrays A and B in order to provide uniform illumination. In
Light Guide Unit
addition, a UV filter protects the LCDs from harmful ultraviolet
light. After this light is polarized, it is then split into 3 spectrums
(R, G and B).
POP Unit and Projection lens
The Panel-on-Prism (POP) Unit, which incorporates the Light
Valves, controls the intensity of the distributed components of the
RGB light. The prism unit then integrates the RGB light and
sends it through the projection lens.
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EMP-S4
2.2.1 Lamp Assy.
The Lamp Assy. is comprised of the Lamp (170W) and Ballast Power Supply Connector. The
Ballast Power Supply Connector is used to supply the AC voltage from the ballast unit for
driving the lamp. The lead wires are connected to the lamp.
The lamp is fastened to the bottom of the projector body with 2 screws. The lamp is a
consumable part, and is to be replaced as the luminance of the Lamp Assy. declines over time
as the lamp is used. Maximum luminance is obtained when a new lamp is first installed. After
approximately 1,900 hours at high brightness or 2,900 hours at low brightness, the luminance
will drop by approximately 50%.
Ballast Power Supply Connector
Figure 2-6.
The Lamp may be replaced at any time. Replace the Lamp Assy. before the full 1900-hour
period (at high brightness) or 2900-hour period (at low brightness) has been reached if it seems
that the luminance of the lamp is unacceptable during actual use.
The cumulative operating time for the Lamp Assy. is stored in IC104 (I/F Controller) on the
MA board. When the lamp is replaced, the lamp timer should be reset using the Reset Lamp
Timer function in the Reset menu. Check the Lamp Time in the About menu to confirm that
the timer has been correctly reset.
IC104
CN2000CN500
Figure 2-7. Lam p Assy. Control Circuit
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2.3 MA Board
The MA board processes the core circuit controls for the projector , including interface control,
operation panel control, temperature sensor circuit and fan control, ballast power supply
control and the Infrared RC board interface.
The MA board also contains an imaging processor (PW465), EEPROM, digitizers (ADC and
video decoder), and SRAM memory.
2.3.1 External View of MA Board
Figure 2-8. MA Board Top
Figure 2-9. MA Board Bottom
* The MA Board and the Optical Engine must always be replaced together.
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2.3.2 Overview of Operation
Digitalization control of the picture signal
Converts the analog RGB image signals input from Computer/Component Video port from
analog to digital form.
Frequency transformation control
Transforms the picture signal into the appropriate signals to drive the R, G and B LCD panels.
On screen display
Displays the menu and other information overlaid onto the input picture signal.
Remote control
Receives and decodes IR signals from the remote control and supplies control signals to
various MA board circuits.
Mouse control
Converts pointer information contained within the remote control signals into mouse signals in
PS/2 and USB serial format to send them to the computer.
Lamp control
Controls the ballast and lamp illumination.
LED control
Controls the display characteristics of the LEDs that indicate the power, temperature and
operational status of the projector.
Cooling control
Measures temperature and controls the speed of the fan.
Power supply control
Controls low-power consumption, sleep and stand-by modes.
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EMP-S4
2.4 Interface Connectors
The MA board includes interface connectors for external devices such as video equipment.
The MA board is equipped with the following connectors.
Computer port
Monitor Out port
Computer/
Component Video (Output)
Computer/
Component Video (Intput)
S-Video
S-Video port
Video port Audio input
Figure 2-10. IF Board External Connectors
CN103
IC104
PW190
CN102
A/D Converter
+
Chroma
CN100
USB port
Remote control
light-receiving area
USB TypeB
Audio input/CVBS input
CN503
CN101
IC501
IC1800
Figure 2-11. MA Board Block Diagram
IC1801
Speaker
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A
A
2.5 Power Supply Ballast Unit
The Power Supply Ballast Unit contains the power supply/ballast section, power supply filter
and the AC cord socket. The power supply/ballast section re-regulates the DC power supply
that comes from the AC inlet and power supply filter in order to generate the AC power supply
170W for the lamps.
AC Inlet
Figure 2-12. Power Supply Ballast Unit
2.5.1 Power Supply Circuit Block Diagram
C Input
C100-240V
Ballast output
250W
DC output
to CN2000
on MA board
EMI Filter
Secondary Power Supply
EMI Filter
The First Power Supply
Smoothing/Control circuits
Figure 2-13. Power Supply Circuit Block Diagram
Fuse: Protects the power supply and internal circuitry from overcurrent on
the AC supply line.
EMI filter circuit: Eliminates interference from the AC power supply input.
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EMP-S4
2.5.2 Overview of Operation
The output cable of the power supply unit is connected to CN2000 on the MA board. It allows
the following voltages and signals to be transmitted.
• DC output
• The power supply On/Off signal (PWON)
C A U T I O N
Background power is still supplied to the MA board through CN2000
connector as long as the power cord is connected to the projector, even if the
[Power] switch is turned off.
The EMI filter/regulator circuit eliminates interference (noise) from the AC
line and generates the DC voltage for the regulators.
The DC voltages shown in the tables below are generated by a Switching
Regulator. No fluctuations in output potential occur as a result of load
fluctuations, and the individual output voltages cannot be adjusted.
Output voltage
Signal
name
+13 +13.8
+18 +1.8
Ballast
Output
Voltage
+5 +5 V ±5 % 100 200
+7 +7.2 V
380 VDC
Output
voltage
accuracy
+0.8 V/-
-0.4 V
+15 V ~
+13.5 V
+16 V ~
+23 V
360-400
VDC
Ripple
(mVpp)
100 200 0 A 0 A 0 .5 A -
200 300 0 A 0.2 A 1.5 A -
400 400 0 A 0.2 A 0.45 A -
25 Vpp 25 Vpp
Table 2-2.
Ripple/
Spike
(mVpp)
Output current Protection circuit
Standby
mode
20 mA to
220 mA
(0.1) (0.1) 250 W
Min Typ
20 mA 3.5 A -
Over-
voltage
410 V Shutoff
Over-
current
Shutoff
Shutoff
Shutoff
Shutoff
Load capac-
ity (Reference) (µF)
100
200
100+470
47
The power supply fan reduces the internal heat in the power supply unit. The heated air
discharged from the power supply unit is then exhausted with the exhaust fan connected to
CN706 on the MA board.
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EMP-S4
2.5.3 Connector CN2000 Pin Layout
1
Figure 2-14.
12
Power Supply Connector (connected to CN2000 on the MA board) Pinout Definition
Pin No. Signal name
1 PFCON
2 +5 V_T
3 GND
4 +5 V_T
5 +5 V_T
6 +7 V
7 GND
8 +13 V
9 GND
10 +18 V
11 GND
12 NC
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EMP-S4
2.6 RC Board Assembly
The Remote Control (RC) board is equipped with sensors that detect (receive) infrared signals
transmitted from the remote control. The two RC IR sensors are mounted on the front and rear
of the projector.
Front IR Receiver Sensor
RC Board
Figure 2-15. RC Receiver Sensor
Rear IR Receiver Sensor
The output signals (serial data) received by the sensors are sent to IC104 on the MA board. The
MA board uses the serial data received from the remote control button switches to control the
power ON/OFF status, menu start, and control the display (temporary stop, blank, etc.).
The remote control function is illustrated in Figure 2-16.
Figure 2-16. Remote Control Circuit Block Diagram
CN300
IC300
CN104
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EMP-S4
A
r
2.7 Speaker
The projector has a single 1 W built-in speaker that is at the rear of the projector.
It can be used for monaural output of the sound that is input to the projector from a host
computer or video source.
The signal from the computer or video source is amplified by the audio control circuits on the
AV board and then output to the built-in speaker through connector CN1800.
Speaker
Figure 2-17. Speaker
The following diagram illustrates the circuits that control the speaker.
udio input port
CN101 CN1800 Speake
Figure 2-18. Speaker Control Circuit Block Diagram
IC1800
Audio Amp
Volum up/down
Mute
IC104
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EMP-S4
2.8 Temperature Control
2.8.1 Sensors and Switches
This projector is equipped with the devices shown in the table below in order to protect the
safety of the operator and maintain general safety with regard to the projector itself by
preventing abnormalities in operation.
Table 2-3.
Sensor/Switch Location Function
Interrupts AC power when the
Lamp lid detection switch On the Exhaust Duct Inner
TH board On the Exhaust Duct Inner
Safety Switch
On the side of the Exhaust
Duct Inner
lamp lid is opened. Power cannot
be turned on until the lid is closed.
Prevents overheating around the
Lamp Assy. Turns the lamp off
when a temperature rises above a
certain level.
Prevents overheating around the
Lamp Assy. Interrupts the AC
power when a temperature rises
above a certain level.
Lamp Lid Detection Switch
This switch is located on the Inner Exhaust Duct and connected to the lamp lid latch on the
inside base of the projector, and prevents current from going to the lamp if the lamp lid is open.
This lid is opened only when the operator is replacing the Lamp Assy. The switch is provided
in order to prevent the danger of burns that could occur if the lamp turned on accidentally.
The lamp lid detection switch is connected to CN900 on the MA board. When the lamp lid
opens, IC501 (IFCPU) detects the lamp lid open signal and sends the Lamp OFF signal to turn
off the lamp.
Lamp Lid Detection Switch
Figure 2-19. Lamp Lid Detection Switch
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EMP-S4
TH Board
The TH Board is attached to the Inner Exhaust Duct to detect the temperature of the lamp
section. To prevent damage to the surrounding components from overheating, the power save
controller on the MA board first provides a warning indication through the temperature
indicator LED, and stops the output of the ballast when the temperature rises above a given
level.
TH Board
Figure 2-20. TH Board
Safety Switch
This is a backup overheating prevention switch mounted on the side of the Inner Exhaust Duct.
If overheating occurs around the Lamp Assy . due to problems with the exhaust fan, the lamp is
normally turned off by the TH Board to prevent overheating. The Safety Switch is provided as
a backup in case the TH Board and temperature detection circuit fail simultaneously . When the
temperature rises above a given level, the safety switch interrupts AC power to stop all regular
operations. Once the safety switch is activated, power cannot be switched on again until the
temperature falls below the given level.
Safety Switch
Figure 2-21. Safety Switch
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EMP-S4
Thermistor and Temperature Sensor Operation
Analog/Digital converters in IC104 on the MA board detect the temperatures of the Optical
Engine and Power Supply sections by means of the two Lamp Thermistors at intervals of 1
second. Based on the measurement results, the CPU controls fan operations and power supply
shutdown operations as necessary.
Table 2-4. Temperature Sensors
Condition Warning Indicator Meaning
Normal temperature Off Normal operation in progress
Warning temperature Flashes orange
If temperature rises any higher, projection
stops.
Abnormal temperature Steady red Overheating (no projection)
Internal error Flashes red
Problem with fans, thermistors or temperature detection circuit
See Section 2.8.2 for more information on fan operation, and Section 2.9 for more information
on the LED status indicators.
2.8.2 Fan Operation
There are five cooling fans inside the projector. These fans discharge heated air produced by
the Lamp Assy., power supply unit, and ballast unit.
Intake fan 1 Intake fan 2
Lamp Fan
Figure 2-22. Fan Locations
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Exhaust FanPower Supply Fan
PW190
PW190
-05L
EMP-S4
-05L
DAC0
DAC1
DAC2
DAC3
Intake Fan 1
PE2
PE3
PE4
PE5
FANDET0
FANAJST1
FANON1
Intake Fan 2
FANDET1
Exhaust Fan
FANAJST2
FANON2
FANDET2
Power
Supply Fan
FANAJST3
FANON3
FANDET3
Lamp Fan
FANAJST4
FANON4
FANDET4
PC3
PC4
PC5
PC6
PC7
Figure 2-23. Fan Control Circuit Block
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EMP-S4
Operation Control
The MA board is connected to the Lamp Thermistor . The driver CPU controls the operation of
the five fans, Intake fan 1, Intake fan 2, Exhaust fan, Power Supply fan and Lamp Fan, based
on the temperatures detected by the thermistor.
The signals output by IC1102, the driver CPU on the MA board, are used to change the output
from the fan drive regulator circuit on the MA board in order to control Intake and Exhaust
fans. The feedback signals from the fans are used by the CPU to monitor the fan operation
(stopped or running) for any abnormalities. If the feedback signal indicates a condition that the
CPU does not expect, the CPU determines that there is an abnormality in the operation of the
fan and immediately turns off the lamp and causes the warning indicator to light red.
Fan Operation
Standby Mode
Intake Fan (LV/G FAN): Operates at a constant speed from power-on.
Power Supply Fan
Intake Fan (LV/R FAN): The rotating speed is adjusted according to preset
temperatures detected by the thermistor.
Exhaust Fan: Turns on the power supply fan and starts to operate at low
speed when the thermistor detects temperatures higher than
a given level, and stops when the temperature becomes
lower than the level.
Lamp Fan: The rotating speed is adjusted according to preset
temperatures detected by the thermistor.
When the Lamp is ON
The Intake, Exhaust, and Lamp Fans start to operate at low speed 0.5 second before turning
the lamp on. After the lamp turns on, the fan operates at high speed or low speed based on the
temperatures detected by the thermistor.
During Cool-down
When the lamp is turned off, the fans operate for a few seconds to cool the projector.
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EMP-S4
2.9 LED Indicators
The SW board has three LEDs that indicate the operating status of the projector.
The status indicators are located on the upper case unit.
Temp indicator
Lamp indicator
Power indicator
Figure 2-24. Status Indicator LEDs Location
The following tables show what the indicators mean and how to remedy any problem
indicated.
Power indicator lights red: Abnormal
On Blink Off
Indicator Status Projector Status Problem and Remedy
Power
Red
Red
Internal error
Stop using the projector, disconnect the power cable
from the electrical outlet, and contact your dealer or
the nearest address provided in the "International
Power
Red
Fan related error
Red
Sensor error
Warranty Conditions" section of the Safety
Instructions/
World-Wide Warranty Terms booklet.
Stop using the projector, disconnect the power cable
from the electrical outlet, and contact your dealer or the
nearest address provided in the "International Warranty
Red
Conditions" section of the Safety Instructions/WorldWide Warranty Terms booklet.
Power
Red
Red
Internal
temperature
error
(overheating)
The lamp will turn off automatically and projection will
stop. Wait for about 5 minutes. After about 5 minutes
the projector will switch to standby mode, so check the
following two points.
• Check that the air filter and air exhaust vent are
clear, and that the projector is no t positioned
a wall.
• If the air filters are blocked, clean or replace them.
If this does not solve the problem and the projector
continues to overheat or the indicators continue to
show a problem when the power is turned on, stop
using the projector, disconnect the power cable
from the wall outlet, and contact your dealer or the
nearest address provided in the "International
Warranty Conditions" section of the Safety
Instructions/World-Wide Warranty Terms booklet.
After checking, press the
[Power]
button to turn the
power back on.
against
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EMP-S4
Indicator Status Projector Status Problem and Remedy
Power
Red
Lamp problem
Red
Lamp timer
failure
Lamp cover is
open
Check that the lamp is not cracked and that the air filter
and air intake vent are clear.
• Remove the lamp and check if it is cracked.
• Clean the air filter and the air intake vent.
• If it is not cracked
Replace the lamp and turn on the power.
If error still occurs
Replace it with a new lamp and turn on the power.
If error still occurs
Stop using the projector, disconnect the power
cable from the wall outlet, and contact your dealer
or the nearest address provided in the
"International Warranty Conditions" section of the
Safety Instructions/World-Wide Warranty Terms
booklet.
• If it is cracked
Contact your dealer or the nearest address
provided in the "International Warranty
Conditions" section of the Safety Instructions/
World-Wide Warranty Terms booklet. (You cannot
continue projecting until the lamp is replaced).
Check that the lamp cover and the lamp are securely
installed.
If the lamp cover or the lamp is not securely installed,
the lamp does not switch on.
When using above an altitude of about 1500m, make
sure you set the "High Altitude Mode" to "On".
Lamp or Temp indicator flashes orange: Warning
On Blink Off
Indicator Status Projector Status Problem and Remedy
Power
Orange
Red
High-speed
cooling in
progress
This is not an abnormality, but if the temperature rises
too high again, projection will stop automatically.
• Check that the air filters and air exhaust vent are
clear and that they are not up against a surface such
as a wall.
• If the air filters are clogged, clean or replace them.
Power
Orange
Lamp
replacement
notification
Replace the lamp with a new one.
If you continue to use the lamp after it has passed the
replacement period, the possibility that the lamp may
break will increase. Replace the lamp with a new one
as soon as possible. The Power indicator status will
vary depending on the projector status at the time.
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Chapter 3 Troubleshooting
EMP-S4
3.1 Before Carrying Out Troubleshooting
• If repairs involving the replacement of parts or components have been carried out, always
be sure to re-check whether the replacement parts themselves are operating correctly or not
in order to determine whether the problem is the result of something such as a loose connector.
• All instructions and procedures listed in troubleshooting flowcharts should be carried out as
given.
• Follow the procedures given in Chapter 4 Disassembly and Assembly when replacing any
of the projector components.
• When checking the operation of the projector, always check that the connectors are connected securely before proceeding to other checks.
• In order to confirm proper operation, use AC power from a normal source and use the correct cable type.
3.1.1 Troubleshooting Tools and Equipment
The following tools and equipment will be required in order to carry out troubleshooting, and
so you should check that they are on hand.
Table 3-1.
Name Quantity Application/Other
Projection screen
Tape measure (3 m)
Host computer
USB mouse
Video equipment
Multi meter
1
1
1
1
1
1
Projecting images
Measuring projection distances
Transmitting audio and image data
Checking the operation of the mouse
Transmitting audio and image data
Measuring resistance values and voltages (AC/DC)
Double-sided tape Short length Attaching parts
General tools 1 set Tools and equipment listed in Section 4.1.2
3.1.2 Field Replacement Parts
Many of the components that comprise a service unit have each been adjusted in relation to
each other. Therefore, when replacing parts during troubleshooting or repair, do not disassemble service units in order to harvest and use constituent components. This is especially critical
for the components in the optical engine (Light Guide Unit, Prism Unit and Light Valves) and
the MA Board.
Carry out the safety tests after parts replacement is completed.
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EMP-S4
3.2 Overview
Check the nature of the problem using the following flow diagram, and then proceed to the
corresponding flow chart (on the following pages).
START
Exterior Check
Internal Cable Check
Power Supply On/Off
Image Display and Quality
Check for any external abnormalities, such as a damaged case.
Remove the Upper Case unit and check the cable connectors on the MA Board.
Reconnect any loose cables as required.
Connect the power cord and turn on the power. Check the initial operations until the
NO SIGNAL message appears, and then check the power off operation.
1). After power is turned on, the Power indicator flashes green and projection starts.
2). After about 30 seconds, the operation indicator lights green, and projection starts at
maximum brightness.
Carry out the following three steps.
1). Check and adjust the projector's Front Feet as appropriate for the projection
position and distance.
2). Adjust the image using the Focus Ring.
3). Press the [Auto] button to optimize the display.
Display input/output and image quality. Use the [Source] and [Enter] buttons to
change input.
Check the quality of input and output signals from Computer/Component Video,
S-Video and CVBS sources.
Audio Output
A/V mute slide
Control Panel
Remote Control
USB Mouse
Other
Check that there are audio inputs from Computer/Component Video, S-Video and
CVBS. Also check the operation of the [AV Mute] button.
Slide the cover and check if it slides properly. Close the cover during the projection and
check if the audio and image turn off.
Test the operation of each button on the control panel.
Test the operation of each button on the remote control.
USB mouse operations using USB interface.
Examine the unit for abnormal noise, image problems, unusual odors, and smoke.
SEIKO EPSON Revision:B
3-3
3.2.1 Exterior Check
START
EMP-S4
Upper Case Unit
Cover Lens Holder
Control Panel
Projection Lens Unit
Lower Case
Air Filter
There should be no damage, deformation or cracking due to external force.
The Lower Case should be installed correctly.
The remote signal receiver should be
The Cover Lens Holder should be correctly installed.
The Upper Case should be correctly installed.
No buttons should be stuck down.
The Focus Ring should turn smoothly.
The Lens should be clean and free from damage.
There should be no damage, deformation or cracking due to external
The vent hole should be clean and free from any foreign materials.
The Air Filter should be installed correctly.
Remove the Air Filter from the Lower Case to check that it is clean
The Intake Fan inside the Air Filter frame should be clean and free from foreign
materials.
clean and free from foreign materials.
forces.
Lamp Lid Unit
Lamp Assy
Adjustable Front Foot Unit
Interface Connectors
AC Inlet
Air Filter/Lamp Assy
Installation
The Lamp Lid
The Lamp Lid Detection Switch latch should be free from damage.
The plastic frame should be free from any deformation, damage or discoloration
from heat. Remove the lamp inner unit to check.
The lamp connector should be free from discoloration.
The white glass surface
Can the projection height be adjusted with the Foot Unit?
The connectors and terminals should not be bent or discolored.
The connectors and terminals should be free from foreign materials.
The AC connectors should not be discolored.
The AC source socket should be free from damage.
should be securely attached to the Lower Case.
of the lamp should be clean.
SEIKO EPSON Revision:B
3-4
EMP-S4
)
3.2.2 Internal Cable Check
Turn off the power and disconnect the power cable before you begin the following connector
checks. See Figure 2-2 on page 2-3 for the location of the MA Board connectors.
START
Upper Case Unit
Removal
Control Panel
Photo Interrupter
Exhaust Fan
LAMP Themistor
RC Board
Intake Fan 1, 2
Light Valve R/G/B
Power Supply Ballast Unit
Power Supply Fan
Lamp Lid Detection
Switch
MA Board CN502 (Lock-type connector)
MA Board CN504
MA Board CN706
MA Board CN701
MA Board CN300
MA Board CN704, CN705
MA Board CN1300/CN1400/CN1500 (Lock-type connector
MA Board CN2000, CN500
MA Board CN707
MA Board CN501
Lamp Fan
MA Board Removal
Speaker
MA Board Installation
Upper Case Unit
Installation
SEIKO EPSON Revision:B
MA Board CN708
MA Board CN1800
3-5
3.2.3 Power Supply On/Off
START
Power cord connection.
EMP-S4
Is the indicator lit orange?
Ye s
Press the [Power] button on
the control panel. Does the
indicator flash green?
Ye s
No
No
Replace the Power Supply
Ballast Unit.
Press the [Power] button
on the remote control.
Does the indicator
flash green?
Ye s
Reconnect or replace the
control panel.
To START
No
Replace tha Optical Engine
and the MA Board.
To START
Does the indicator
flash green?
Ye s
No
Refer to "2.9 LED Indicators" on page 2-21.
A
(To next page)
SEIKO EPSON Revision:B
3-6
(Continued from previous page)
A
EMP-S4
Is the lamp turned on?
Ye s
Press the [Power] button
to turn the power off.
Does the indicator
flash orange?
Ye s
Does the indicator
light orange after it flashes
for approx. 2 seconds?
Ye s
Image Display and Quality
No
No
No
Replace the Optical Engine
and MA Board.
Replace the Optical Engine
and MA Board.
Replace the Optical Engine
and MA Board.
Remedy For Power Supply Problems
1. Determine whether the problem is being caused by components inside the power supply
unit, or whether it is being caused by some external factor. To determine this, check factors
such as output voltage, internal temperature, appearance of components, odors and smoke.
2. If the cause is judged to be an internal problem, replace the power supply unit. If the newlyreplaced power supply unit also has a problem and the symptoms are the same as before,
then the cause of the problem is probably some external factor . Eliminate the external factor
that is causing the problem.
3. If the power supply unit is recoverable but is not working properly, for example if high temperatures are causing the thermostat to shut down the power supply, or if the overcurrent
protection circuit has tripped, then there is no need to replace the power supply unit.
4. If the power supply unit is not recoverable and is not working properly, for example if an
overcurrent has repeatedly blown the fuse, replace the power supply unit.
SEIKO EPSON Revision:B
3-7
3.2.4 Image Display and Quality
EMP-S4
C A U T I O N
The image quality can also be affected by condensation or by a dirty lens.
If condensation forms, the problem will correct itself naturally if the projector
is left to stand for a while.
START
Press the [Power] button
to turn the power on.
Does an image appear on
the screen?
No
Is the lamp turned on?
No
Replace the Lamp Assy.
Ye s
Ye s
Does "NO SIGNAL"
appear in the bottom-left
of the screen?
No
Replace the Optical
Engine and MA Board.
Ye s
Does the image appear
clearer?
No
Clean the Projection Lens.
Does the image appear
clearer?
No
Clean the areas around
the Light Valves.
Ye s
Ye s
Is the lamp turned on?
No
Replace the Optical
Engine and MA Board.
Ye s
1. Adjust the height using
the front adjustable foot.
2. Press the [Wide] or
[Tele] button to adjust
the projection size.
3. Press the or
button to correct
distortion.
4. Check the projection
position on the
[Image Shift] adjustment
screen.
5. Adjust the focus with the
Focus Ring.
Does the image appear
clearer?
No
Replace the Optical
Engine and MA Board.
Ye s
B
(To next page)
SEIKO EPSON Revision:B
3-8
(Continued from previous page)
B
EMP-S4
C
Connect the host
computer to the Computer
connectors and display
an image.
Does an image appear
on the screen?
No
Press the [Source] button
to change the display to
Computer.
Does an image appear
on the screen?
No
Ye s
Ye s
Is the image quality good?
No
1. Press the [Menu]
button.
2. Select the "Image"
menu.
3. Adjust the brightness
and contrast.
Is the image quality good?
No
Replace the Optical
Engine and MA Board.
Ye s
Ye s
Connect external devices
to all the interfaces.
No
Connect a source to the
interface to be checked.
C
Audio Output
Ye s
Replace the computer
cable.
Does an image appear
on the screen?
No
Replace the Optical
Engine and MA Board.
Ye s
SEIKO EPSON Revision:B
3-9
3.2.5 Audio Output
START
EMP-S4
Connect the audio input connector and
host computer. Press the [Source]
button to select the corresponding input
source, and output sound from the
internal speaker.
Is sound output from the built-in
speaker?
No
Reconnect CN1800 on the MA board.
Is sound output from the built-in
speaker?
No
Ye s
Ye s
Can the volume be adjusted?
No
Replace the Optical Engine and
MA Board.
Can the audio output be started
and stopped using the [AV Mute]
button?
No
Replace the Optical Engine and
MA Board.
Control Panel
Ye s
Ye s
Replace the audio cable.
No
Is sound output from the built-in
speaker?
No
Replace the speaker unit.
Is sound output from the built-in
speaker?
No
Replace the Optical Engine and
MA Board.
Ye s
Ye s
SEIKO EPSON Revision:B
3-10
3.2.6 Control Panel
START
EMP-S4
Does pressing the [Power] button turn
the power on and off?
Ye s
Does pressing the [Menu] button display
the menu?
Ye s
Does pressing the [Source] button switch
the input source?
Ye s
Does pressing the [Help] button show the
explanation display?
Ye s
Does pressing the [Enter] button change the
menu item?
Ye s
Does pressing the or buttons
correct keystone distortion?
Ye s
No
No
No
No
No
No
Does pressing the [TELE] or [WIDE] buttons
change the image size?
Ye s
No
Ye s
Ye s
Reconnect CN502 on the
MA board.
Do all switches function
normally?
No
Replace the control panel.
Do all switches function
normally?
No
Replace the Optical Engine
and MA Board.
Remote Control Operation
SEIKO EPSON Revision:B
3-11
3.2.7 Remote Control Operation
START
EMP-S4
Can the power be turned
on and off using the
remote control?
No
Replace the
remote control battery.
Can the power be turned
on and off using the
remote control?
No
Replace the remote
control.
Can the power be turned
on and off using the
remote control?
No
Replace the Optical
Engine and MA Board.
Ye s
Ye s
Ye s
Do all buttons operate
normally?
No
Replace the remote
control.
Do all buttons operate
normally?
No
Replace the Optical
Engine and MA Board.
Ye s
Ye s
Does the remote control
work 20 ft. (6 m) away
from the front or rear of
the projector?
No
Replace the remote
control battery.
Does the remote control
work 20 ft. (6 m) away
from the front or rear of
the projector?
No
Replace the remote
control.
Does the remote control
work 20 ft. (6 m) away
from the front or rear of
the projector?
No
Replace the Optical
Engine and MA Board.
Ye s
Ye s
Ye s
A/V mute slide
SEIKO EPSON Revision:B
3-12
3.2.8 A/V mute slide
EMP-S4
START
Does opening/closing the A/V mute slide
activate or deactivate A/V Mute?
No
Replace the Photo Interrupter cable.
Does opening/closing the A/V mute slide
activate or deactivate A/V Mute?
No
Replace the Photo Interrupter.
Does opening/closing the A/V mute slide
activate or deactivate A/V Mute?
No
Ye s
Ye s
Ye s
Replace the Optical Engine and MA Board.
Other
SEIKO EPSON Revision:B
3-13
3.2.9 Other
START
EMP-S4
Is the projector making
abnormal noise?
No
Is the projector overheating?
No
Are there any image
problems?
No
Is there any abnormal
odor or smoke?
Ye s
Check for any objects around the Exhaust Fan, Intake Fan and Power Supply Fan.
The cause might be a malfunction of the power supply unit (pulse transformer
vibration, etc.).
Ye s
Malfunction of the Lamp Thermistor or Safety Switch.
Malfunctioning or dirty Exhaust Fan, Intake Fan or Power Supply Fan. Clean
or replace as necessary.
Dirty air filter.
Malfunction of the Optical Engine.
Ye s
Malfunction of Optical Engine
Malfunctioning or dirty Light Guide Unit (lenses, mirrors, etc.).
Dirty Projection Lens.
Malfunctioning or dirty Light Valve. Replace the Optical Engine and MA Board.
Ye s
Charring of cables due to excessive heat. Replace any damaged cables and
resolve the overheating problem.
Dust burning due to heat. Make sure the air filter is not damaged, and check for
excessive heat.
SEIKO EPSON Revision:B
3-14
Chapter 4 Disassembly/Assembly
EMP-S4
4.1 Overview
This chapter describes the procedures for disassembling and assembling the main components
of the EMP-S4 projector. Unless otherwise specified, reassembly is the reverse of the disassembly procedure. Read the precautions described in the next section before starting.
4.1.1 Precautions
Some procedures require specific precautions that must be followed, and those will be noted
throughout this chapter. Note the following precaution definitions:
WARNING
W A R N I N G
Procedures which, if not strictly observed, could result in personal injury are
described under the heading WARNING
CAUTION
C A U T I O N
CAUTION signals a precaution which, if ignored, could result in damage to
equip-ment.
REASSEMBLY
If assembly needs special attention or the procedure is different from the reversed
disassembly procedure, the correct procedure is described under the heading
REASSEMBLY.
CHECK POINT
C H E C K
P O I N T
Important tips for procedures are described under the heading CHECK POINT.
The precautions in the two lists below, WARNING and CAUTION, must always be followed
during disassembly and assembly. Before starting the disassembly work on this product, read
and follow these precautions.
SEIKO EPSON Revision:B
4-2
EMP-S4
W A R N I N G
C A U T I O N
No work should be performed on the unit by persons unfamiliar with basic
safety measures as dictated for all electronics technicians in their line of work.
Remove any metallic objects such as wristwatches, shirt cuff buttons, rings
and tie pins which may pose a danger of coming into contact with the
projector.
Always wear gloves when disassembling and reassembling the projector.
Disconnect the power cord from both the projector and the electrical outlet.
If you need to work on the projector with power applied, strictly follow the
instructions in this manual. When the power supply cable must be connected,
use extreme caution in working on the power supply and other electronic
components.
Repairs on Epson product should only be performed by an Epson certified
repair technician.
Turn off the power for both the projector and the host computer before
disconnecting or connecting them.
Once all power has been turned off, disconnect any interface cables that are
still connected.
Use a vacuum cleaner to clean the air filter, interface panel and outer case.
Use only recommended tools for disassembly, assembly or adjustment of the
projector.
Always verify that the product has been unplugged from the AC power source
before disconnecting, removing, or replacing any cables or printed circuit
boards.
Use static discharge equipment such as anti-static wrist straps when accessing
internal components to protect sensitive electronic components and circuitry.
Do not use second source ICs or other components not approved by Epson.
They could cause damage to the Epson product or could void the Epson
warranty.
SEIKO EPSON Revision:B
4-3
EMP-S4
4.1.2 Tools and Equipment
The tools and equipment in the following table will be needed. All are commercially available,
and should be made ready beforehand.
Table 4-1. Tools Needed
Name Application
Phillips screwdriver No. 0 Disassembling the Focus ring
Phillips screwdriver No. 2 (20 cm)
Flathead screwdriver
Disassembling the outer case and inner
components
Disassembling the rear foot and the
front foot
Flathead precision screwdriver Removing the front foot
Hexagonal box screwdriver (5 mm) Removing the computer interface
Brush Cleaning away dust
Vacuum cleaner Cleaning away dust
Lens cleaner Cleaning the projection lens
Air blower Cleaning the light valves and fans
Gloves Protection against sharp edges
Antislip and static protection
Grounding strap Anti-static protection
Heat-resistant tape Securing cables
Farst drying iubricant *1 Lever Zoom/Focus
*1 Recommendation Properties
Appearance : light milky white liquid
Specific gravity : 1.5-1.7
Flash point [ ℃] : non-flammable
Boiling point [ ℃] : 50-100
Major component : fluorocarbon type inactive liquid
Solubility in water : Nil
GWP : 500
ODP : 0
ex, Sankei Kagaku Co.,Ltd. SANKOL CFD-931Z (http//www.sankeikagaku.co.jp/)
Please inquire of EMPTechSupport mailbox when there is an uncertain point.
SEIKO EPSON Revision:B
4-4
EMP-S4
4.1.3 Projector-Specific Service Precautions
C H E C K
P O I N T
The Optical Engine and Main (MA) Board are paired together as a single service
part. Neither is available separately. For service that requires the replacement of
either the MA Board or the Optical Engine, both components must be replaced
together.
The component parts of the Optical Engine require mechanical installation
positions to be adjusted in relation to each other. In addition, the control circuit
also has its own unique characteristics, such as display signal output drivers, that
differ from projector to projector. There are also unique differences in each
optical system mechanism, such as in the light valves.
In order to obtain the optimum display, it is necessary to eliminate these
differences in electrical and mechanical characteristics as well as to make
mechanical adjustments. The various correction values are set at the time of
shipment from the factory and are stored in ROM on the MA Board.
Always replace the Optical Engine and MA Board together as a matched pair.
Do not disassemble the Optical Engine.
Do not replace the component parts of the Optical Engine with parts from
other Optical Engines.
Points to Note When Working
Detailed points to note are given in each section, so be sure to read each section thoroughly
before beginning the disassembly procedure. Below are several general points which should be
noted.
• When the projector is disassembled, the dust in and around parts such as the fans and air fil-
ter may get transferred to other parts such as the R, G and B light valves which are the central part of the display mechanism. This may have an adverse effect on the quality of
projected images. Accordingly, check whether any of the parts are dusty or dirty, and use a
vacuum cleaner to clean them first before carrying out disassembly work.
• The Optical Engine and the circuit boards are very sensitive to static electricity. Place them
inside static-proof bags once they have been removed from the projector.
• When carrying out any of the following operations, check that there is no dust or dirt on the
respective components or on any lens and glass surfaces before installation. If any such contamination is found, clean it off using isopropyl alcohol.
• Optical engine removal
• Lamp inner unit removal
• Air filter removal
• The speaker unit contains a permanent magnet, so keep it away from any storage media
such as floppy disks and magnetic cards.
• The Optical Engine is very sensitive to vibration and shocks, so handle it with care.
• Do not disassemble any components (such as the power supply unit) which do not have
express disassembly procedures described in this Service Manual.
SEIKO EPSON Revision:B
4-5
EMP-S4
4.2 Projector Disassembly and Assembly
The general disassembly procedure for the EMP-S4 projectors is illustrated below. Except
where indicated separately, all reassembly should be carried out by following the disassembly
procedures in reverse. Detailed disassembly procedures for each component are given in Sections 4.2.1 to 4.2.20,
links to which are given in the flowchart below.
Projector
HOLDER,COVER LENS
(4.2.8)
COVER,LENS UNIT
(4.2.8)
FRAME,COVER LENS
(4.2.8)
GUIDE,COVER LENS
(4.2.8)
SPRING,LAT CH,LID LAMP
(4.2.8)
SHEET,SHADING,SW;B
(4.2.7)
PRINTED CIRCUIT BOARD
ASSEMBLY;SW_R2
(4.2.7)
CABLE,SW;Au
(4.2.7)
BUTTON,SW
(4.2.7)
LENS,LED
(4.2.7)
SHEET,COVER LENS
(4.2.8)
PHOTO INTERRUPTER
(4.2.8)
CABLE,SW
(4.2.8)
LID ASSY.,LAMP
(4.2.2)
ELPLP36 Spare Lamp
(4.2.2)
SET,CASE,UPPER;E
(4.2.6)
MA Board Assy.
(4.2.9)
Optical Engine and MAB set
(4.2.12)
Safety Switch
(4.2.15)
DUCT, INTAKE
(4.2.15)
FAN,INTAKE
(4.2.15)
SHEET,INTAKE FAN
(4.2.15)
DUCT,LAMP
(4.2.16)
FAN,LAMP;B
(4.2.16)
MODEL NAME PLATE ;
Power Lite S4
(4.2.1)
FOOT UNIT,FRONT
(4.2.4)
EMI,SUPPRESSOR
(4.2.9)
PRINTED CIRCUIT BOARD
ASSEMBLY;RC_R1
(4.2.15)
Cable RC ; B
(4.2.15)
Exhaust Fan Set
(4.2.17)
DUCT,EXHAUST,OUTER
(4.2.17)
FAN,EXHAUST;B
(4.2.17)
PRINTED CIRCUIT BOARD
ASSEMBLY;TH_R1
(4.2.18)
CABLE RCR;FIF
(4.2.18)
Lamp Cover Detection Switch
(4.2.18)
DUCT,EXHAUST,INNER
(4.2.18)
FAN,POWER SUPPLYB
(2406GL-B49)
(4.2.19)
POWER SUPPLY ASSY.
(4.2.19)
SHIELD PLATE,LAMP
(4.2.20)
FILTER,POWER SUPPLY
(4.2.20)
CASE, LOWER
(4.2.20)
FOOT,REAR
(4.2.3)
FOOT RUBBER
(4.2.3)
FILTER,RC
(4.2.7)
SET,CASE,IF
(4.2.10)
SHEET,SHADING,SW;B
(4.2.10)
FOCUS,RING
(4.2.13)
PROJECTION LENS
(4.2.14)
FRAME,AIR FILTER
(4.2.5)
AIR FILTER;A
(4.2.5)
FILTER,RC
(4.2.10)
PLATE,MA
(4.2.11)
C H E C K
P O I N T
Part names indicated in the above flow and used in this chapter are simplified
names. See the “Part Names given in the SPI” table on the next page to know
their corresponding official names.
Figure 4-1.
SEIKO EPSON Revision:B
4-6
EMP-S4
The table below shows the part names used in this chapter and their official names given in the
After Service Part List in the SPI (Service Part Information).
Table 4-2. Part Names given in the SPI
Official Name used in SPI Names used this Chapter
MODEL NAME PLATE;PowerLiteS4 EMP-S4 Model Name Plate
Optical Engine and MAB set Optical Engine
LAMP UNIT FOR AS
CASE, LOWER Lower Case
FILTER,POWER SUPPLY Power Supply Filter
FRAME,AIR FILTER Air Filter Frame
AIR FILTER;A Air Filter, A
FOOT UNIT,FRONT Front Foot Unit
FOOT,REAR Rear Foot
FOOT RUBBER Rubber Foot
SHIELD PLATE,LAMP Lamp Shield Plate
PRINTED CIRCUIT BOARD ASSEMBLY;RC_R1 RC Board Assy.
Cable RC ; B RC Cable, B
FAN,LAMP;B Lamp Fan, B
DUCT,LAMP Lamp Duct
DUCT, INTAKE Intake Duct
FAN,INTAKE Intake Fan
SHEET,INTAKE FAN Intake Fan Sheet
POWER SUPPLY ASSY. Power Supply Assy.
FAN,POWER SUPPLYB(2406GL-B49) Power Supply Fan, B
DUCT,EXHAUST,INNER Inner Exhaust Duct
DUCT,EXHAUST,OUTER Outer Exhaust Duct
FAN,EXHAUST;B Exhaust Fan, B
PRINTED CIRCUIT BOARD ASSEMBLY;TH_R1 TH Board Assy.
CABLE RCR;FIF Cable RCR, FIF
Lamp Cover Detection Switch Lamp Lid Detection Switch
PROJECTION LENS Projection Lens
FOCUS,RING Focus Ring
PLATE,MA MA Plate
EMI,SUPPRESSOR EMI Control Sheet
SET,CASE,IF IF Case Set
FILTER,RC RC Filter
SHEET,SHADING,SW;B SW Light Shade Sheet, B
CASE,UPPER;E Upper Case , E
PHOTO INTERRUPTER Photo Interrupter
CABLE,SW SW Cable
FRAME,COVER LENS Cover Lens Frame
GUIDE,COVER LENS Cover Lens Guide
SPRING,LATCH,LID LAMP Lamp Lid Latch Spring
COVER,LENS UNIT Lens Unit Cover
SHEET,COVER LENS Cover Lens Sheet
HOLDER,COVER LENS Cover Lens Holder
BUTTON,SW SW Button
SEIKO EPSON Revision:B
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EMP-S4
Table 4-2. Part Names given in the SPI
Official Name used in SPI Names used this Chapter
LENS,LED LED Lens
PRINTED CIRCUIT BOARD ASSEMBLY;SW_R2 SW Board Assy.
CABLE,SW;Au SW Cable, Au
LID ASSY.,LAMP Lamp Lid Assy.
SEIKO EPSON Revision:B
4-8
EMP-S4
4.2.1 Removing the Model Name Plate
Remove the EMP-S4 Model Name Plate.
4.2.2 Removing the Lamp Lid Assy and LAMP UNIT FOR AS
1. Remove the screw that secures the Lamp Lid Assy, and remove the Lamp Lid Assy.
2. Remove the two screws that secure the LAMP UNIT FOR AS, and remove the LAMP
UNIT FOR AS.
LAMP UNIT FOR AS
Lamp Lid Assy.
Figure 4-2.
4.2.3 Removing the Rear Foot/Rubber Foot
1. Pull and rotate the Rear Foot to remove the Rear Foot.
2. Press a screwdriver or similar tool into the small slot beside the Rear Foot and pry the
Rubber Foot out of the projector Lower Case Unit.
Rubber Foot
Rear Foot
Figure 4-3.
SEIKO EPSON Revision:B
4-9
EMP-S4
4.2.4 Removing the Front Foot Unit
1. Press a screwdriver or similar tool into the small slot beside the Front Foot Unit, and take
out the Front Foot Unit.
Front Foot Unit
Figure 4-4.
4.2.5 Removing the Air Filter Frame and Air Filter A
1. Slide the Air Filter Frame in the direction of the arrow with your fingers, and remove the
Air Filter Frame.
2. Remove the Air Filter A from the Air Filter Frame.
Air Filter, A
Air Filter Frame
Figure 4-5.
SEIKO EPSON Revision:B
4-10
EMP-S4
4.2.6 Removing the Upper Case
1. Remove the 7 (C.B.P-TITE, 3x10, F/ZB-3C) screws that secure the Upper Case Unit.
Figure 4-6.
2. Carefully lift the front of the Upper Case taking care not to pull the two cables connected to
the Upper Case.
Upper Case
CN502
Figure 4-7.
SEIKO EPSON Revision:B
4-11
EMP-S4
3. Unlock connector CN502 on the MA Board and disconnect the Control Panel Cable and
SW cable.
CN502
Locked
CN502
Unlocked
Figure 4-8.
SEIKO EPSON Revision:B
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EMP-S4
4.2.7 Removing the RC filter, SW Light Shade Sheet B, SW Board Assy, SW
Cable Au, SW Button, and LED Lens
1. Detach the RC Filter from the Upper Case.
2. Remove the SW Light Shade Sheet B from the SW Board Assy.
3. Remove the 4 (C.C.P-TITE, 3x6, F/ZN-3C) screws to remove the SW Board Assy.
4. Unlock connector H179 and disconnect the SW Cable Au.
5. Remove the SW Button.
6. Remove the LED Lens.
SW Light Shade Sheet, B
SW Cable, Au
SW Board Assy.
SW Button
RC Filter
LED Lens
Figure 4-9.
SEIKO EPSON Revision:B
4-13
EMP-S4
C A U T I O N
After connecting the SW Cable Au, aslant to fold and secure it with a piece of
heat resistant tape as shown in Figure 4-10. Make sure that the fold is kept 1
cm away from the SW Board Assy.
PRINTED CIRCUIT BOARD
ASSEMBLY; SW_R1
1cm
cable sw , Au
Figure 4-10.
Heat-Resistant Tape
After connecting the SW Cable, be sure to secure the cable with a piece of
heat-resistant tape as shown in Figure 4-11.
Heat-Resistant Tape
cable sw
Figure 4-11.
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C A U T I O N
The SW Cable and the SW Cable Au should be routed as shown in Figure 4-
12.
cable sw, Au
cable sw
Figure 4-12.
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4.2.8 Removing the Cover Lens Holder, Cover Lens Unit, Cover Lens Sheet,
Cover Lens Frame, Photo Interrupter, Cover Lens Guide, Lamp Lid Latch
Springand and SW Cable.
1. Remove a (C.C.P-TITE SCREW, 3x8, F/ZN-3C) screw that secures the Cover Lens Unit,
and remove the Cover Lens Holder and the Lens Cover from the Upper Case E.
2. Remove the Cover Lens Sheet from the Cover Lens Frame.
Cover Lens Sheet
Lens Cover
Cover Lens Holder
Figure 4-13.
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3. Remove the 2 (C.C.P-TITE SCREW, 3x8, F/ZN-3C) screws that secure the Cover Lens
Frame, and remove the Cover Lens Frame from the Upper Case E.
4. Remove the Photo Interrupterthe, the Cover Lens Guide and the Lamp Lid Latch Spring
from the Cover Lens Frame.
5. Disconnect the SW Cable from the Photo Interrupter.
Lamp Lid Latch Spring
SW Cable
Photo Interrupter
Cover Lens Guide
Cover Lens Frame
Figure 4-14.
C A U T I O N
Apply the proper amount of lubricant to the surface indicated by gray shading.
*Be sure to apply the
lubricant not only when
replacing parts but also
when the Cover Lens does
not slide smoothly. For
details, refer to 4.1.2 Tools
and Equipment
Figure 4-15.
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EMP-S4
C A U T I O N
After replacing the Photo Interrupter, always perform operation check as
described below.
1). Turn the projector on leaving the Cover Lens open.
2). After confirming that the blue image (default) is displpayed, close the
Cover Lens as shown in Figure 4-16.
If the image turns balck, there is no problem with the parts or the
connection.
Figure 4-16.
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4.2.9 Removing the MA Board Assy.
1. Unlock the connectors of the Light Valve R/G/B connection cables.
Light Valve R
Locked
Light Valve B
Unlocked
Light Valve G
Figure 4-17.
2. Disconnect the Light Valve R/G/B connection cables and 10 cable connectors that are
connected to the MA Board.
CN708
CN704
CN705
Light valve connectors
CN300
CN500
CN2000
CN706
CN501
CN707
CN701
Figure 4-18.
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3. Remove the EMI Control Sheet from the MA Board Assy.
4. Remove the (C.C., 3x6, F/ZN-3C) screw to remove the MA Board Assy.
EMI Control Sheet
MA Board Assy.
C A U T I O N
Figure 4-19.
When installing the MA Board Assy, pay attention to the followings.
1). Fix both the RC Cable B and the Intake Fan Cable with two pieces of
heat-resistant tape as shown in Figure 4-20.
Intake Fan Cable RC Cable; B
Figure 4-20.
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C A U T I O N
2). Route the Power Supply Fan Cable as shown in Figure 4-21, and press into
the cable under the MA Board as far as it will go.
Power Supply Fan Cable
Figure 4-21.
3). Route the cable of the Intake Fan as shown in Figure 4-22.
Intake Fan Cable
Figure 4-22.
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C A U T I O N
4). Route the power cord as shown in Figure 4-23, and secure the cable with a
heat-resistant tape. Gently squeeze the Power Supply Ballast Cable into the
Power Supply Unit.
Heat-Resistant Tape
Power Cord Power Supply Ballast Cable
Figure 4-23.
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4.2.10 Removing the IF Case Set, RC Filter, and SW Light Shade Sheet B
1. Remove the SW Light Shade Sheet B from the IF Case Set.
2. Remove the 2 (C.B.P-TITE, 3x10, F/ZB-3C) screws that secure the IF Case Set, disconnect
the Speaker Cable from connector CN1800 on the MA Board, and remove the IF Case Set
from the MA Board Assy.
3. Remove the Remote Control (RC) Filter from the IF Case Set.
RC Filter
IF Case Set
Speaker Cable
MA Borad Assy.
CN1800
SW Light Shade Sheet, B
Figure 4-24.
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4.2.11 Removing the MA Plate
1. Remove the 2 (C.B.P-TITE, 3x10, F/ZB-3C) screws that secure the RCA connector, and the
4 (1/4-40x1/4, H.H., F/NI, O) screws that secure D-sub 15 Pin connectors.
2. Remove the 2 (C.C., 3x6, F/ZN-3C) screws that secure the MA Plate to the MA Board, and
remove the MA Plate from the MA Board Assy.
MA Board Assy.
MA Plate
Figure 4-25.
1/4-40x1/4, H.H., F/NI, O Screws
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EMP-S4
4.2.12 Removing the Optical Engine
1. Remove the four (C.B.P-TITE SCREW, 3x10, F/ZB-3C) screws that secure the Optical
Engine to the projector, and remove the Optical Engine.
Screw
Screw
Screw
Screw
Figure 4-26.
4.2.13 Removing the Focus Ring
1. Remove the three (C.P.TYPE1 B-TITET -A. S CREW, 2x6, F/ZB-3C) screws that secure the
Focus Ring, and remove the Focus Ring from the Projection Lens.
Optical Engine
Focus Ring
Figure 4-27.
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4.2.14 Projection Lens
1. Remove the four (C.P.(S-P1)SCREW,3x10,F/ZN-3C) screws that secure the Projection
Lens, and remove the Projection Lens from the Optical Engine.
2. Remove the (H.N.-3, F/ZN-3C) screw nut from the Optical Engine.
Optical Engine
Projection Lens
Figure 4-28.
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EMP-S4
4.2.15 Removing the RC Board Assy, RC Cable B, Safety Switch,
Intake Duct, Intake Fan, and Intake Fan Sheet
1. Remove the RC Board Assy, and disconnect the RC Cable B from the RC Board Assy.
2. Remove the (C.C.P-TITE, 3x8, F/ZN-3C) screw that secures the Safety Switch, and remove
the Safety Switch from the Inner Exhaust Duct.
3. Remove the 5 (C.B.P-TITE, 3x10, F/ZB-3C) screws that secure the Intake Duct to remove
it.
4. Remove the four (C.B.P-TITE SCREW , 3x12, F/ZN-3C) screws that secure the Intake Fan,
and remove the Intake Fan.
5. Remove the Intake Fan Sheet from the Intake Fan.
Intake Fan Sheet
RC Board Assy.
Intake Duct
Intake Fan
Intake Fan
Intake Fan Sheet
Safety Switch
RC Cable, B
Figure 4-29.
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EMP-S4
C A U T I O N
Route the AC Inlet Cable as shown in the figure below, and secure the ferrite
core on the tab of the Lower Case.
Ferrite core
Figure 4-30.
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4.2.16 Removing the Lamp Duct and Lamp Fan B
1. Remove the two (C.B.P-TITE SCREW , 3x10, F/ZB-3C) screws that secure the Lamp Duct,
and remove the Lamp Duct.
2. Remove the Lamp Fan B from the Lower Case.
Lamp Duct
Lamp Fan, B
Figure 4-31.
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EMP-S4
4.2.17 Removing the Exhaust Fan Set, Outer Exhaust Duct, and
Exhaust Fan B
1. Remove the (C.B.P-TITE, 3x10, F/ZB-3C) screw that secures the Exhaust Fan Set and
remove it.
Exhaust Fan Set
C A U T I O N
Figure 4-32.
When installing the cable of both the Lamp Lid Detection Switch and the
Exhaust Fan, route them as shown in Figure 4-33.
Lamp Lid Detection Switch Cable Exhaust Fan Cable
Figure 4-33.
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EMP-S4
C A U T I O N
When installing the Ballast Cable, route the cable and move the ferrite core
into the position as shown in Figure 4-34.
Ballast Cable Ferrite Core
Figure 4-34.
2. Remove the two (C.B.P-TITE SCREW , 3x30, F/ZN-3C) screws that secure the Exhaust Fan
B, and remove the Outer Exhaust Duct from the Exhaust Fan Set.
Outer Exhaust Duct
Exhaust Fan, B
Figure 4-35.
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EMP-S4
4.2.18 Removing the TH Board Assy, Cable RCR FIF, Lamp Lid Detection
Switch, and Inner Exhaust Duct
1. Remove the (C.C.P-TITE, 2x12, F/ZN-3C) screw that secure the Lamp Lid Detection
Switch, and remove the Lamp Lid Detection Switch from the Inner Exhaust Duct.
2. Remove the (C.C.P-TITE, 3x8, F/ZN-3C) screw that secures the TH Board Assy (Printed
Circuit Board Assy, TH_S2), and remove the TH Board Assy from the Inner Exhaust Duct.
3. Remove the Cable RCR FIF from the TH Board Assy.
4. Remove the (C.C.P-TITE, 3x8, F/ZN-3C) screw that secures the Lamp Connector, and
remove the Lamp Connector from the Inner Exhaust Duct.
5. Remove the 2 (C.B.P-TITE, 3x10, F/ZB-3C) screws to remove the Inner Exhaust Duct.
Cable RCR, FIF
Lamp Connector
Lamp Lid
Detection Switch
Inner Exhaust Duct
TH Board Assy.
Figure 4-36.
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4.2.19 Removing the Power Supply Fan B and Power Supply Assy
1. Remove the two (C.P.(S-P2)SCREW , 3x20, F/ZN-3C) screws that secure the Power Supply
Fan B, and remove the Power Supply Fan B from the Power Supply Assy.
Power Supply Fan, B
Figure 4-37.
2. Remove the heat-resistant tape that secures the Power Supply Cable.
3. Remove the 4 (C.B.P-TITE, 3x10, F/ZB-3C) screws that secure the Power Supply Assy and
remove the Power Supply Assy. Extra caution is required as one of the screws is located
underneath the Insulation Plate Ballast.
Isulation
Plate Ballast
Power Supply Assy.
Figure 4-38.
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4.2.20 Removing the Lamp Shield Plate, Power Supply Filter, and
Lower Case
1. Remove the Lamp Shield Plate from the Lower Case.
Lamp Shield Plate
Power Supply Filter
Lower Case
Figure 4-39.
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Chapter 5 Appendix
EMP-S4
Computer
Input Signal
: ---- (---- )
Frequency
: H 0.000kHz / V 0.000Hz
Sync Polarity
: H -------- / V --------
Sync Mode
: ----
Detected Comp Mode
: XXXXXXXXXXXXXXX
Total Operation Time
: 0H
Lamp Op. Time (C)
: 0H
(H/M/L)
: 0H / 0H / 0H
Lamp Replacement
: 0Times
Lamp ON/LampOFF
: 0Times / 0Times
Cool Down Completed
: 0Times
Fatal Error
: T 0 L 0 I 0
Destination
: XXXXXXXX
Engine Type
: XXXXXXX
P
XXXXXXXXXXXXXXX
O
------------------
J XXXXXXXXXXXXXXX
C A U T I O N
The contents of this chapter are for use only by Epson Authorized Servicers, and
are not to be disclosed to others without the express written consent of Epson.
5.1 AS (After Service) Menu
The AS (After Service) menu provides information and settings that are not displayed on the
standard menu.
5.1.1 How To Display the AS (After Service) Menu
Press the Menu button on either the remote control or the projector's control panel for at least 7
seconds. Within 4 seconds after pressing the Menu key, hit these buttons in order shown below
to display AS menu.
Esc → Esc → Tele → Wide
When the video source is PC type, Component type, the following screen appears.
Computer
Input Signal
Frequency
Sync Polarity
Sync Mode
Detected Comp Mode
Total Operation Time
Lamp Op. Time (C)
(H/M/L)
Lamp Replacement
Lamp ON/LampOFF
Cool Down Completed
Fatal Error
Destination
Engine Type
P
O
J XXXXXXXXXXXXXXX
XXXXXXXXXXXXXXX
------------------
: ---- (---- )
: H 0.000kHz / V 0.000Hz
: H -------- / V -------: ---: XXXXXXXXXXXXXXX
: 0H
: 0H
: 0H / 0H / 0H
: 0Times
: 0Times / 0Times
: 0Times
: T 0 L 0 I 0
: XXXXXXXX
: XXXXXXX
• Fatal Error: Abnormal termination
counter
Displays the number of times of each
of the following abnormal terminations.
T: Temperature problem
L: Lamp problem
I: Internal problem
(Same as for S-Video and Video)
The last four digits show the PW
firmware version.
The last four digits show the Y43
firmware version.
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Computer
Video Signal
: ---- (No Signal )
Total Operation Time
: 0H
Lamp Op. Time (C)
: 0H
(H/M/L)
: 0H / 0H / 0H
Lamp Replacement
: 0Times
Lamp ON/LampOFF
: 0Times
Cool Down Completed
: 0Times
Fatal Error
: T 0 L 0 I 0
Destination
: XXXXXXXX
Engine Type
: XXXXXXX
P
XXXXXXXXXXXXXXX
O
------------------
J
XXXXXXXXXXXXXXX
When the video source is Video type, the following screen is displayed.
Computer
Video Signal
Total Operation Time
Lamp Op. Time (C)
(H/M/L)
Lamp Replacement
Lamp ON/LampOFF
Cool Down Completed
Fatal Error
Destination
Engine Type
P
O
J
5.1.2 Initializing (Resetting) the AS Menu Values
There are two levels of initialization that can be used to reset the projector usage history values
stored in EEPROM.
1. Clearing the Basic Lamp Information
While the AS menu is being displayed, simultaneously press the [Source] and [] keys for
10 seconds.
XXXXXXXXXXXXXXX
-----------------XXXXXXXXXXXXXXX
: ---- (No Signal )
: 0H
: 0H
: 0H / 0H / 0H
: 0Times
: 0Times
: 0Times
: T 0 L 0 I 0
: XXXXXXXX
: XXXXXXX
The last four digits show the PW
firmware version.
The last four digits show the Y43
firmware version.
2. Clearing All the Lamp Information
While the AS menu is being displayed, simultaneously press the
10 seconds.
Total Operation Time No Change Reset to 0H
Lamp Operation Time Reset to 0H Reset to 0H
Lamp ON Reset to 1 Reset to 1
Lamp OFF Reset to 0 Reset to 0
Lamp Replacement
Fatal Error (3 items) No Change Reset to 0
SEIKO EPSON Revision:B
Item
Clearing the Lamp Informa-
tion
Add 1 to the
current value
5-3
[Source] and [] keys for
Clearing All the Lamp
Information
Reset to 0
EMP-S4
5.1.3 Software DIP Switches
Some software DIP-switch settings are only accessible from the AS menu. To display the DIPSW Setting Menu, do the following operation.
1. Press Menu button on the remote control for at least 5 seconds.
2. Within 4 seconds after releasing the Menu button, hit these buttons in order shown below.
Esc → Esc → Tele → Wide
The following sub-menu is displayed.
Switch On or Off, as necessary
DIP-SW
No
BIT Function
Default
Setting
Setting Value Note
SW1 0 (reserved) - - -
0: ↑, ↓,
1 Select USB key code 1
1: PageUp,
PageDown
2 (reserved) - - 3 (reserved) - - 4 (reserved) - - 5 (reserved) - - -
Volume gauge display
6
1 0: OFF, 1: ON -
ON/OFF
7 (reserved) - - -
-
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