Optoma ES520 DP-2512, ES520, EX530, DP-3511, DP-2512 Schematic

Delta Elec. Inc. ES520 & EX530 ver.02

DATA PROJECTOR

ES520

(DP-2512)

& EX530

SERVICE MANUAL

(ver.00)

(DP-3511)

Company Confidential Optoma___________________ Delta________________ 1

2008/09/17

Delta Elec. Inc. ES520 & EX530 ver.02

DLP DIGITAL PROJECTOR

Model Name: ES520 & EX530

Revision Description Date

Ver.00 Primarily 03/07/2008 Ver.01 Revised the spare part list 05/28/2008

Ver.02 Revised the spare part list, change the main board PN to 5600600785 09/17/2008

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2008/09/17

Delta Elec. Inc. ES520 & EX530 ver.02

CONTENTS

1.COMPLIANCE OF SAFE REPAIR.........................................................................................5

1-1.Caution During Disassembling And Assembling.............................................................5

1-2.Lamp.............................................................................................................................. 5

1-3.Lens................................................................................................................................5

1-4.Eye Safety Warnings......................................................................................................6

2.SPECIFICATIONS.................................................................................................................7

2-1.Summary Specifications................................................................................................. 7

2-2.DMD Specifications........................................................................................................ 8

2-3.Color Wheel................................................................................................................... 8

2-4.Lamp.............................................................................................................................. 8

2-5.Input/output connectors…………………………………………………………………….…8

2-6.I/O Ports Illustration........................................................................................................9

2-7.Remote Control Parts...................................................................................................10

2-8.Key Pad-Top view and LEDs…………………………………………………...………….. 12

2-9.Optical Adjustment & Image Size (ES 520)…….………………………………………....13

2-10. Optical Adjustment & Image Size (EX 530)………………………………………….….14

2-11.BLOCK DIAGRAM..................................................................................................... 16

2-12. Wire diagram………………………………………………………………………………..17

3.TROUBLE SHOOTING....................................................................................................... 18

4.DISASSEMBLY AND ASSEMBLY (ES 520)....................................................................... 25

.. DISASSEMBLY AND ASSEMBLY (EX 530)....................................................................... 41

5.Flash Upgrade Flow............................................................................................................ 58

5-1.Projector USB Drivers Installation Guide…………………………………………………..58

Appendix-A How to clear the USB enumeration registry?............................................67

Appendix-B Projector USB status on Windows Device Manager………………………69 5-2.DLP Projector Flash-Tool (firmware) User Guide…………………….……….…………..70

5-3.Start with Flash-Tool………………………………………………………………………....71

5-4.Starting and Shutting down the Projector……………………………………………….....76

5-5.Setting an Access Password (Security Lock)………………………………….…………..77 5-6.SETUP / Advanced………………………………………………………………………..…81 5-7.Security Timer………………………………………………………………………………...82 5-8.Options Menu…………………………………………………………………………………83 5-9.OPTIONS / Advanced…………………………….………………………………………….84

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Delta Elec. Inc. ES520 & EX530 ver.02

6. Calibration…………………………….………………………………………….………………..85

7. Color Border Adjustment………………………………………………………………………...91

8. Projection Lamp…………………………………………………………………………………..92

9. Cleaning…………………………………………………………………………………………...95

10.SERVICE NOTE............................................................................................................... 96

10-1.Service Note Description........................................................................................... 96

10-2.Power & READY LED Blink Code Message.............................................................. 97

10-3.Factory Preset Display Modes................................................................................... 98

11.Spare Part List ................................................................................................................ 100

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2008/09/17

Delta Elec. Inc. ES520 & EX530 ver.02

1. COMPLIANCE OF SAFE REPAIR

Be sure to read this Service Manual before providing services. In the projector, full consideration is taken to ensure safety for fire, electric shock, injury, harmful radiation, and substance. Therefore, observe the notice described in this Service Manual so that safety is kept when providing services. Moreover, be sure to observe the notice described in the Instruction Manual. Pay attention to the following items during service inspection.

1-1 Cautions during disassembling and assembling

1. This equipment contains parts under high voltage. When making repairs, etc. Be sure to pull out the power plug beforehand to insure safety.

2. Parts may be very hot immediately after use. Make sure the equipment has cooled off sufficiently before carrying out repairs.

3. Make sure that parts and screws and wiring, etc. are returned to their original positions. Tube, tape and other insulation materials have been used for safety reasons. The internal wiring has been designed to avoid direct contact with hot parts or parts under high voltage when using clamps or other tools.

4. The parts used in this device have special safety features such as flame-resistance and anti-voltage properties. When replacing parts, always use parts supplied from the factory.

5. After finishing operations make sure that all parts and wires have been returned to their original position and that there has been no deterioration of the area around the location that was worked on.

6. Be sure to use a grounding strap (wrist band) during repair and inspection.

1-2 Lamp

During current conduction, the lamp is in the high-temperature state. In this case, pay careful attention because a high voltage is used. When replacing a lamp, replace it after confirming that the lamp has gotten cold sufficiently.

1-3 Lens

Do not look into a lens during projection. This damages your eyes.

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Delta Elec. Inc. ES520 & EX530 ver.02

1-4 Eye Safety Warnings

Avoid staring directly into the projector’s beam of light at all times.

Minimize standing facing into the beam. Keep your back to the beam as much as

possible.

3.Using a stick or laser pointer is recommended to avoid the need for the presenter to enter the beam.

4.Ensure that projectors are located out of the line of sight from the screen to the

audience; this ensures that, when presenters look at the audience, they do not also have to stare at the projector lamp.

5.The best way to achieve this is by ceiling-mounting the projector rather than placing it

floor

or table top.

6.When projector is used in a classroom, adequately supervise students when they are asked to point out something on the screen.

7.In order to minimize the lamp power needed, use room blinds to reduce ambient light

levels.

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Delta Elec. Inc. ES520 & EX530 ver.02

2. SPECIFICATIONS

2-1. Summary Specifications

Model ES520 (DP-2512) EX530 (DP-3511)

Display type Resolution SVGA 800X600 Native (4:3) XGA 1024x768 Native (4:3) Color Brilliant Color Projection distance 1.5 meters ~ 10 meters 1.0 meters ~ 10 meters Projection screen size Projection lens Thro 1.15:1 Vertical keystone

correction Projection methods Front / Rear-Desktop & Front / Rear-Ceiling

Data compatibility

SDTV/EDTV/ HDTV Video compatibility NTSC/NTSC 4.43, PAL/PAL-M/PAL-N,SECAM H-Sync 15, 30 – 91.4 KHz

TI DMD Type A,12° 0.55inches, SVGA Dark Chip 1 TI DMD Type A,12° 0.55inches, XGA Dark Chip 2

36” to 243” (overdrive to 300”) 23” to 255” (overdrive to 300”)

Manual focus Manual focus / Manual zoom

+/- 15 degrees ; +/- 30 vertical stepping in OSD

IBM PC or compatibles

(VGA, SVGA, XGA, SXGA, UXGA), Mac

480i/576i, 480p/576p, 720p, 1080i

V-Sync 43 - 87 Hz Safety certification

Operation temperature

Dimensions / Weight AC Input Power consumption Stand By Lamp Audio speaker PC

Video

Audio Security

FCC (class B), UL/CUL, ICES-003(Class B), CE, TUV-GS, CB report, CCC, EK, PSB

5° ~ 35°C

280 mm (W) x 80 mm (H) x 205 mm (D) / 5.6lb (2.5kg)

AC Universal 110 ~ 240 @50~60Hz , Typical @110 VAC (100~240)/±10%

Typical 230W (standard mode); Typical 200W (ECO mode)

< 5 watts @ 110Vac

E20.6 / 180W

1W / 8 ohm mono speaker

VGA in (Compatible with HDTV component YPbPr / SCART)

Composite video (RCA X 1)

S-Video (DIN)

Input: R / L (RCA X 2) , Out: Mini-Jack X 1

Kensington lock

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Delta Elec. Inc. ES520 & EX530 ver.02

2-2.DMD Specifications

Unit Min. Max. Typical Notes

DMD type (ES520) TI 0.55" SVGA 12 deg LVDS Type A Dark chip 1 Number of Columns (ES520) Pixel 800 Number of Rows (ES520) Pixel 600

DMD type (EX530) Number of Columns (EX530) Pixel 1024 Number of Rows (EX530) Pixel 768

Panel Operating Temp. Ambient Temp

℃ ℃

10 65 25

TI 0.55" XGA 12 deg LVDS

Type A

2-3.Color Wheel

Spec. Color Segment

Unit Min. Max. Typical Notes RYGWB 82/29/80/91/78 (44mm)

2-4. Lamp

Vendor Type

Lamp Life

Lamp Power

Description

OSRAM E20.6 180W

Standard Mode , 3000 Hours Standard @ 180W, 50% Survival Rate

ECO Mode , 4000 Hours Typical @ 150W, 50% Survival Rate Normal: 180W±3%@Vo from 50V to 120V ECO: 150W±3%@Vo from 50V to 120V

Dark chip 2

2-5. Input/output connectors

VGA in (Compatible with HDTV component YPbPr / SCART) USB (Service Only) Composite video (RCAx1)

Video

S-Video (Mini-DIN) RS232 DB9 Audio Input: R / L (RCA X 2) , Out: Mini-Jack X 1 Security Kensington slot

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Delta Elec. Inc. ES520 & EX530 ver.02

2-6. I/O Ports Illustration about Projector

Note:

If your video equipment has both S-VIDEO and RCA jacks (composite video) connect to the S-VIDEO connector. S-VIDEO provides a better quality signal

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2008/09/17

Delta Elec. Inc. ES520 & EX530 ver.02

2-7. Remote Control Parts

Important:

1. Avoid using the projector with bright fluorescent lighting turned on. Certain high-frequency

fluorescent lights can disrupt remote control operation.

2. Be sure nothing obstructs the path between the remote control and the projector. If the path between the remote control and the projector is obstructed, you can bounce the signal off certain reflective surfaces such as projector screens.

3. The buttons and keys on the projector have the same functions as the corresponding buttons on the remote control. This user’s manual describes the functions based on the remote control.

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2008/09/17

Delta Elec. Inc. ES520 & EX530 ver.02

Remote Control Operating Range

The remote control uses infrared transmission to control the projector. It is not necessary to point the remote directly at the projector. Provided you are not holding the remote perpendicular to the sides or the rear of the projector, the remote will function well within a radius of about 10 meters (33 feet) and 30 degrees above or below the projector level.

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2008/09/17

Delta Elec. Inc. ES520 & EX530 ver.02

2-8. Key Pad -- Top view and LEDs

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2008/09/17

Delta Elec. Inc. ES520 & EX530 ver.02

2-9. Optical Adjustment & Image Size (ES 520)

Adjusting the Focus (Fixed Zoom Series)

The Fixed Zoom Series’ lens is

fixed

and does not provide a zoom function. To focus the image, rotate the focus ring until the image is clear. The projector will focus at distances from 4.9 to 40 feet (1.5 to 12.2 meters).

Adjusting Projection Image Size

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Delta Elec. Inc. ES520 & EX530 ver.02

2-10. Optical Adjustment & Image Size (EX 530)

Adjusting the Zoom / Focus (Zoom Series)

You may turn the zoom ring to zoom in or out. To focus the image, rotate the focus ring until the image is clear. The projector will focus at distances from 4.9 to 40 feet (1.5 to 12.2 meters).

Adjusting Projection Image Size

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Delta Elec. Inc. ES520 & EX530 ver.02

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2008/09/17

Delta Elec. Inc. ES520 & EX530 ver.02

2-11. Block Diagram

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Delta Elec. Inc. ES520 & EX530 ver.02

2-12. Wire diagram

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Delta Elec. Inc. ES520 & EX530 ver.02

Waiting

POWER

: 7 Blinks

Over Temp LED

•

Press

“

power key

”

Power ON

3. TROUBLE SHOOTING

By checking operations during normal usage time, it is possible to carry out judgments on malfunction to a certain extent. Carry out the following checks before disassembling the equipment.

Yes

Connect the power cord

Yes

POWER: Light READY : Light

Standy-by-ready

Yes

POWER: Light

READY : OFF

Yes

• Cable of Power Supply Unit and thermostat Ass’y. Check the connection of Power Supply (CON900 to CN201)

• Power Supply Unit malfunction

• Check keypad connection

•Lamp Cover A’ssy is not attached

•Switch (CN343) is open

•Connector (CN342) disconnected.

•Thermal sensor PWB Ass’y check.

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POWER:8 Blinks

Yes

Power On

Yes

•DMD chip error.

•DMD Board PWB Ass’y check.

2008/09/17

Delta Elec. Inc. ES520 & EX530 ver.02

Blinks

POWER

: 4 Blinks

Blinks

POWER:

9 Blinks

No lighting operation sound (ignition sound) exists.

(CN373) or

lighting operation sound (ignition sound)

Turn the

Image

Blinks

Yes

power ON

Yes

The lamp is ON

•Thermal Break Sensor error

Yes

•Thermal Break Sensor disconnected.

POWER: 5 Blink

Yes

Lamp does not light exists.

• Main Board and Ballast Board Ass’y malfunction Ballast Connector (CJ4) or LVPS unit (CJ1) or

•

MB(CN572)disconnected

• Lamp failure (Lamp is broken, damaged, or burst)

：

LAMP

：：：：

• Connector CN344 of Fan disconnected

• Lamp fan malfunction

POWER: 6 Blinks

Yes

LAMP

：：：：

LAMP

3 Blinks

：：：：

• Connector CN340 of Fan disconnected

• Power fan malfunction

• Connector CN341 of Fan disconnected

• Blower fan malfunction

POWER: 7

Yes

•Lamp Cover is not attached.

•Switch (CN343) is open malfunction

Display

Yes

Lamp does not light

• Flexible cable of Color Wheel Ass’y is disconnected broken.

• Color Wheel Ass’y malfunction (does not rotate).

• Main Board Ass’y malfunction (Color Wheel Ass’y does not rotate).

• Power Supply Unit malfunction.

• Index board malfunction (color wheel turns fast).

• C/W sensor PWB Ass’y (CN7) / MB PWB (CN503) is disconnected

or broken.

：

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2008/09/17

Delta Elec. Inc. ES520 & EX530 ver.02

Projector logo

screen display

• DMD Set malfunction

Still dark after the

than 1min

g, resolution, etc.)

Check the

mage

display

Speaker work

normally

Image

Display

Confirmation with none-signal state

Yes

lamp is on for more

Menu display

Yes

Input each signal

Yes

• CW Sensor Board Ass’y malfunction

• Main Board Ass’y malfunction

• Lamp deterioration (malfunction/usage time)

• Power Supply Unit malfunction (No change occurs even after lamp replacement.)

• DMD Set malfunction (No change occurs even after lamp replacement.)

• Remote controller set malfunction, Low battery,

and outside operation rang

• Main Board Ass’y malfunction

• Connector (CN374)、(CN8 of IR PWB) disconnected

• IR PWB Ass’y malfunction

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Yes

normally

Yes

projection

Screen

• Check the pattern generator setting is wrong

• Main Board Ass’y malfunction

• DMD Set malfunction

• Setting on PC side(external output settin

• Cable malfunction (disconnection and pins broken)

• Connector (CN304) disconnected

• Speaker Ass’y malfunction

• Main Board Ass’y malfunction

2008/09/17

Delta Elec. Inc. ES520 & EX530 ver.02

Check the

Check using all black/white screens with

Are abnormalities

Does the lamp

oper

ation?

Over Temp LED:

Light again?

System OK

• Temperature protector operated due to the increase in

• Temperature protector operated due to blocked suction and

projection

Screen

Yes

PC connection

Yes

noticeable on

projection screen?

go off during

Yes

• Black lines on screen (horizontal and vertical)

Yes

→ DMD Set malfunction

• Missing pixels (Missing white: 1 or more, missing black: 5 or more, or sequence missing pixels)

→ DMD Set malfunction

• Shadows on screen

→

Dirt on DMD/projection lens surface

• Bluish shadows on corners of screen (during white screen

display)

→

Shifted optical axis of Lens Base Unit

Is LAMP

Normal operation

Yes

• Lamp malfunction

• Power Supply Unit malfunction

temperature based on operating environment exhaust holes or dirty fan

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Delta Elec. Inc. ES520 & EX530 ver.02

Common problems and solutions

These guidelines provide tips to deal with problems you may encounter while using the projector. If the problem remains unsolved, contact your dealer for assistance.

Often after time spent troubleshooting, the problem is traced to something as simple as a loose connection. Check the following before proceeding to the problem-specific solutions.

• Use some other electrical device to confirm that the electrical outlet is working. Ensure the projector is turned on.

•

• Ensure all connections are securely attached.

Ensure the attached device is turned on.

•

• Ensure a connected PC is not in suspending mode.

Ensure a connected notebook computer is configured for an external display. (This is usually done by pressing an Fn-key combination on the notebook.)

Image Problems

Problem: No image appears on the screen

1. Verify the settings on your notebook or desktop PC.

2. Turn off all equipment and power up again in the correct order.

Problem: The image is blurred

1. Adjust the Focus on the projector.

2. Press the Re-sync button on the remote control or projector.

3. Ensure the projector-to-screen distance is within the 10-meter (33-feet) specified range.

4. Check that the projector lens is clean.

Problem: The image is wider at the top or bottom (trapezoid effect)

1. Position the projector so it is as perpendicular to the screen as possible.

2. Use the Keystone button on the remote control or projector to correct the problem.

Problem: The image is reversed

Check the Projection setting on the Setup menu of the OSD.

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Problem: The image is streaked

1. Set the Frequency and Phase settings on the Computer menu of the OSD to the default settings.

2. To ensure the problem is not caused by a connected PC’s video card, connect to another computer.

Problem: The image is flat with no contrast

Adjust the Contrast setting on the Image menu of the OSD.

Problem: The color of the projected image does not match the source image.

Adjust the Color Temperature and Gamma settings on the Image menu of the OSD.

Lamp Problems

Problem: There is no light from the projector

1. Check that the power cable is securely connected.

2. Ensure the power source is good by testing with another electrical device.

3. Restart the projector in the correct order and check that the Power LED is still green.

4. If you have replaced the lamp recently, try resetting the lamp connections.

5. Replace the lamp module.

6. Put the old lamp back in the projector and have the projector serviced.

Problem: The lamp goes off

1. Power surges can cause the lamp to turn off. Re-plug power cord. When the Ready LED is on, press the power button.

2. Replace the lamp module.

3. Put the old lamp back in the projector and have the projector serviced.

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Delta Elec. Inc. ES520 & EX530 ver.02

Remote Control Problems

Problem: The projector does not respond to the remote control

1. Direct the remote control towards remote sensor on the projector.

2. Ensure the path between remote and sensor is not obstructed.

3. Turn off any fluorescent lights in the room.

4. Check the battery polarity.

5. Replace the batteries.

6. Turn off other Infrared-enabled devices in the vicinity.

7. Have the remote control serviced.

Audio Problems

Problem: There is no sound

1. Adjust the volume on the remote control.

2. Adjust the volume of the audio source.

3. Check the audio cable connection.

4. Test the source audio output with other speakers.

5. Have the projector serviced.

Problem: The sound is distorted

1. Check the audio cable connection.

2. Test the source audio output with other speakers.

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2008/09/17

Delta Elec. Inc. ES520 & EX530 ver.02

a. ES520 (DP-2512)

Removing the Lamp Cover and Lamp Module

4.DISASSEMBLY AND ASSEMBLY

Look the full set projector. Look at the IO side.

Look at the case of top side. Look at the keypad of top side.

Loose these two screws. Remove and take out the lamp cover.

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Delta Elec. Inc. ES520 & EX530 ver.02

Removing the Lamp Cover and Lamp Module

Remove the lamp cover. Loose two screws and take out (S01).

Remove the lamp modules. Look the bottom case.

Look the Lamp #1.

Look the Lamp #2.

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Delta Elec. Inc. ES520 & EX530 ver.02

Removing the Lamp Module and Top Cover

Look the Lamp #3. Look the Lamp #4.

Remove the five screws. Look these five screws (

S02)

Remove the two screws.

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Remove the two screws.

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Delta Elec. Inc. ES520 & EX530 ver.02

Removing the Top Cover and Keypad Board

Look these four screws (

S03)

Remove the FFC cable and take off the top case.

. Look at the top case.

Keypad board / FCC cable / Screw review.

Review the four screw (

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S04).

Remove the 7+3 piece screws.

2008/09/17

Delta Elec. Inc. ES520 & EX530 ver.02

piece screws.

Review the 7

Removing the Main Board Plant & Main Board

(S05)+3(S06)

Remove the Main Board Plant.

(two kinds S05 & S06).

Remove the Main Board. Remove the four hexagonal screws.

Review four hexagonal screws (S07).

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Delta Elec. Inc. ES520 & EX530 ver.02

check these right positions connection

area of these connectors and

check these right positions connection

CN300 SPK

Mono

Main Board Review

Careful area of these connectors and

when you recover main board again.

CN341 Blower Fan

CN343 Lock-SW

CN340 Power Fan

CN344 Lamp Fan

Careful

when you recover main board again.

Main Board Review #Top side

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2008/09/17

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