Sony VPL-ES1 Service Manual

DATA PROJECTOR

VPL-ES1

REMOTE COMMANDER

RM-PJ2

SERVICE MANUAL 1st Edition

! WARNING

This manual is intended for qualified service personnel only. To reduce the risk of electric shock, fire or injury, do not perform any servicing other than that contained in the operating instructions unless you are qualified to do so. Refer all servicing to qualified service personnel.

! WARNUNG

Die Anleitung ist nur für qualifiziertes Fachpersonal bestimmt. Alle Wartungsarbeiten dürfen nur von qualifiziertem Fachpersonal ausgeführt werden. Um die Gefahr eines elektrischen Schlages, Feuergefahr und Verletzungen zu vermeiden, sind bei Wartungsarbeiten strikt die Angaben in der Anleitung zu befolgen. Andere als die angegeben Wartungsarbeiten dürfen nur von Personen ausgeführt werden, die eine spezielle Befähigung dazu besitzen.

! AVERTISSEMENT

Ce manual est destiné uniquement aux personnes compétentes en charge de l’entretien. Afin de réduire les risques de décharge électrique, d’incendie ou de blessure n’effectuer que les réparations indiquées dans le mode d’emploi à moins d’être qualifié pour en effectuer d’autres. Pour toute réparation faire appel à une personne compétente uniquement.

WARNING!!

AN INSULATED TRANSFORMER SHOULD BE USED DURING ANY SERVICE TO AVOID POSSIBLE SHOCK HAZARD, BECAUSE OF LIVE CHASSIS. THE CHASSIS OF THIS RECEIVER IS DIRECTLY CONNECTED TO THE AC POWER LINE.

SAFETY-RELATED COMPONENT WARNING !!

COMPONENTS IDENTIFIED BY A DIAGRAMS, EXPLODED VIEWS AND IN THE PARTS LIST ARE CRITICAL TO SAFE OPERATION. REPLACE THESE COMPONENTS WITH SONY PARTS WHOSE PART NUMBERS APPEAR AS SHOWN IN THIS MANUAL OR IN SUPPLEMENTS PUBLISHED BY SONY. CIRCUIT ADJUSTMENTS THAT ARE CRITICAL TO SAFE OPERATION ARE IDENTIFIED IN THIS MANUAL. FOLLOW THESE PROCEDURES WHENEVER CRITICAL COMPONENTS ARE REPLACED OR IMPROPER OPERATION IS SUSPECTED.

! MARK ON THE SCHEMATIC

ATTENTION!!

AFIN D’ÉVITER TOUT RISQUE D’ÉLECTROCUTION PROVENANT D’UN CHÂSSIS SOUS TENSION, UN TRANSFORMATEUR D’ISOLEMENT DOIT ETRE UTILISÉ LORS DE TOUT DÉPANNAGE. LE CHÂSSIS DE CE RÉCEPTEUR EST DIRECTEMENT RACCORDÉ Á L’ALIMENTATION SECTEUR.

ATTENTION AUX COMPOSANTS RELATIFS Á LA

LES COMPOSANTS IDENTIFIÉS PAR UNE MAPQUE LES SCHÉMAS DE PRINCIPE, LES VUES EXPLOSÉES ET LES LISTES DE PIECES SONT D’UNE IMPORTANCE CRITIQUE POUR LA SÉCURITÉ DU FONCTIONNEMENT. NE LES REMPLACER QUE PAR DES COMPOSANTS SONY DONT LE NUMÉRO DE PIÈCE EST INDIQUÉ DANS LE PRÉSENT MANUEL OU DANS DES SUPPLÉMENTS PUBLIÉS PAR SONY. LES RÉGLAGES DE CIRCUIT DONT L’IMPORTANCE EST CRITIQUE POUR LA SÉCURITÉ DU FONCTIONNEMENT SONT IDENTIFIÉS DANS LE PRÉSENT MANUEL. SUIVRE CES PROCÉDURES LORS DE CHAQUE REMPLACEMENT DE COMPOSANTS CRITIQUES, OU LORSQU’UN MAUVAIS FONCTIONNEMENT EST SUSPECTÉ.

SÉCURITÉ!!

! SUR

VPL-ES1

For the customers in the Netherlands Voor de klanten in Nederland

Hoe u de batterijen moet verwijderen, leest u in de tekst van deze handleiding.

Gooi de batterij niet weg maar lever deze in als klein chemisch afval (KCA).

Für Kunden in Deutschland

Entsorgungshinweis: Bitte werfen Sie nur entladene Batterien in die Sammelboxen beim Handel oder den Kommunen. Entladen sind Batterien in der Regel dann, wenn das Gerät abschaltet und signalisiert “Batterie leer” oder nach längerer Gebrauchsdauer der Batterien “nicht mehr einwandfrei funktioniert”. Um sicherzugehen, kleben Sie die Batteriepole z.B. mit einem Klebestreifen ab oder geben Sie die Batterien einzeln in einen Plastikbeutel.

VPL-ES1

Table of Contents

1. Service Overview

1-1. Appearance Figure ...................................................................................... 1-1

1-2. Board Locations .......................................................................................... 1-1

1-3. Disassembly ................................................................................................ 1-2

1-3-1. Top Panel Assembly .................................................................. 1-2

1-3-2. H Board ...................................................................................... 1-2

1-3-3. C Board ...................................................................................... 1-3

1-3-4. Lens Gear ................................................................................... 1-4

1-3-5. Fan Holder .................................................................................. 1-4

1-3-6. D.C. Fan (60mm) and D.C. Fan (70mm) .................................. 1-5

1-3-7. Lamp House ............................................................................... 1-5

1-3-8. Optics Block Assembly .............................................................. 1-6

1-3-9. Prism Block Assembly ...............................................................1-6

1-3-10. Incidence Polarizer (R), (G), (B) ................................................1-7

1-3-11. Side Panel Assembly-1 .............................................................. 1-8

1-3-12. Side Panel Assembly-2 .............................................................. 1-9

1-3-13. G Board .................................................................................... 1-10

1-3-14. Lamp Power Supply .................................................................1-10

1-3-15. D.C. Fan (Sirocco/For Lamp) .................................................. 1-11

1-3-16. D.C. Fan (Sirocco) ................................................................... 1-12

1-3-17. Adjuster Block Assembly ........................................................ 1-13

1-4. Warning on Power Connection ................................................................. 1-14

2. Electrical Adjustments

2-1. Preparation .................................................................................................. 2-1

2-1-1. Required Equipment ................................................................... 2-1

2-1-2. Opt Unit Adjustment .................................................................. 2-1

2-1-3. How to Enter the Factory Mode .................................................2-2

2-2. V COM Adjustment .................................................................................... 2-2

2-3. Initial Values of Adjustment Items ............................................................. 2-3

2-4. Service Know-How .....................................................................................2-8

2-4-1. When the S Prism Block Is Replaced ........................................ 2-8

2-4-2. When the C Board Is Replaced .................................................. 2-8

2-5. White Balance Adjustment ......................................................................... 2-9

2-5-1. HIGH Mode of INPUT-A .......................................................... 2-9

2-5-2. LOW Mode of INPUT-A ........................................................... 2-9

2-5-3. HIGH Mode of VIDEO .............................................................. 2-9

2-5-4. LOW Mode of VIDEO ............................................................... 2-9

2-6. Memory Structure ..................................................................................... 2-10

3. Semiconductors................................................................................. 3-1

VPL-ES1

4. Spare Parts

4-1. Notes on Repair Parts .................................................................................. 4-1

4-2. Exploded Views .......................................................................................... 4-2

4-3. Electrical Parts List ..................................................................................... 4-6

5. Block Diagrams

C ............................................................................................................................. 5-1

G, H, V, L, NR ....................................................................................................... 5-2

6. Diagrams

6-1. Frame Wiring .............................................................................................. 6-2

Frame Wiring ............................................................................................6-2

6-2. Schematic Diagrams and Board Layouts .................................................... 6-3

Schematic Diagrams

Q ................................................................................................................ 6-3

C (1/10) ..................................................................................................... 6-6

C (2/10) ..................................................................................................... 6-7

C (3/10) ..................................................................................................... 6-8

C (4/10) ..................................................................................................... 6-9

C (5/10) ................................................................................................... 6-10

C (6/10) ................................................................................................... 6-11

C (7/10) ................................................................................................... 6-12

C (8/10) ................................................................................................... 6-13

C (9/10) ................................................................................................... 6-14

C (10/10) ................................................................................................. 6-15

V .............................................................................................................. 6-14

H .............................................................................................................. 6-18

L .............................................................................................................. 6-19

NR ...........................................................................................................6-19

G (1/2) .....................................................................................................6-21

G (2/2) .....................................................................................................6-22

Board Layouts

Q ................................................................................................................ 6-3

C ................................................................................................................6-4

V .............................................................................................................. 6-14

H .............................................................................................................. 6-18

L .............................................................................................................. 6-19

NR ...........................................................................................................6-19

G .............................................................................................................. 6-20

VPL-ES1

1-1. Appearance Figure

Section 1

Service Overview

VPL-ES1 RM-PJ2

1-2. Board Locations

Lamp power supply

VPL-ES1

1-1

1-3. Disassembly

1-3-1. Top Panel Assembly

5 Flat connector assembly (CN805)

3 Three claws

6 Remove the top panel assembly

in the direction of the arrow.

C board

2 Screw (+B 3 x 6)

1-3-2. H Board

. Remove the top panel assembly. (Refer to 1-3-1.)

3 Top panel

1 Five claws

2 Two dowels

4 Ten claws

1 Five special shafts

(+BV 3 x 70)

7 Button (H)

8 H board

4 Flat connector

assembly

CN10

6 Holder (H)

1-2

5 Two claws

VPL-ES1

1-3-3. C Board

3 Four screws (+B 3 x 6)

CN904

2 Remove the fuse connector assembly

CN906

CN601

CN812

CN651

CN804

CN501

CN802

CN807

CN810

C board

5 Remove the C board in the direction of the arrow B.

Side panel shaft

1 Remove the harneses

8 Two screws

9 Bracket (C)

!- C board

CN905

4 Open the side panel assembly in the direction of the arrow A.

7 Screw (+B 3 x 6)

0 Fuse connector assembly

CN806

CN811

CN809

Side panel shaft

C board

VPL-ES1

6 Remove the C board

in the direction of the arrow C.

1-3

1-3-4. Lens Gear

. Remove the C board. (Refer to 1-3-3.)

ZOOM/FOCUS ZOOM/FOCUS

Engage the gears.

Lens gear

Lens

2 Open the side panel assembly in the direction of the arrow A.

3 Two dowels

C board

4 Remove the Iens gear

1 Screw

(+B 3 x 6)

in the direction of the arrow B.

1-3-5. Fan Holder

1 Two screws (+BVTP 3 x 10)

5 Remove the fan holder

while taking care so that it must not be caught by other parts.

4 Dowel

3 Remove the four claws

in the direction of the arrow B.

Fan holder

Side panel assembly

1-4

2 Remove the side panel assembly in the direction of the arrow A.

VPL-ES1

1-3-6. D.C. Fan (60mm) and D.C. Fan (70mm)

. Remove the fan holder. (Refer to 1-3-5.)

2 D.C. fan (70mm)

C board

5 D.C. fan (60mm)

CN810

CN811

1-3-7. Lamp House

. Remove the fan holder. (Refer to 1-3-5.)

1 Remove the harneses

4 Screw

(+BTP 3 x 10)

3 Remove the harneses

4 Two grooves

1 Two grooves

2 Two screws

(+BTP 3 x 10)

3 Lamp power supply

VPL-ES1

5 Lamp house

C board

CN807

CN810

1-5

1-3-8. Optics Block Assembly

. To remove the optics block assembly, remove the related parts beforehand.

3 Lamp house

• Remove the lamp house. (Refer to 1-3-7.)

1 C board

• Remove the C board. (Refer to 1-3-3.)

5 Two dowels

2 Fan holder

• Remove the fan holder. (Refer to 1-3-5.)

4 Four screws (+BTP 3 x 10)

6 Optics block assembly

1-3-9. Prism Block Assembly

. Remove the optics block assembly. (Refer to 1-3-8.)

3 Screw (+PTP 2 x 8)

5 Radiation polarizer (R) assembly

4 Polarizer retainer

6 Pre radiation polarizer

(G) assembly

7 Radiation polarizer (G) assembly

9 Radiation polarizer (B) assembly

8 Pre radiation polarizer (B) assembly

C board

1 Two precision screws (+B 2 x 5)

2 Prism block assembly

1-6

VPL-ES1

1-3-10. Incidence Polarizer (R), (G), (B)

. Remove the optics unit assembly. (Refer to 1-3-8.) . Remove the prism block assembly. (Refer to 1-3-9.)

1 Six screws (+BTP 3 x 10)

3 Incidence polarizer (R) assembly

2 Unit cover

4 Incidence polarizer (G) assembly

5 Incidence polarizer (B) assembly

VPL-ES1

1-7

1-3-11. Side Panel Assembly-1

2 Four screws (+B 3 x 6)

CN906

CN812

CN651

CN804

CN501

CN802

CN807

CN810

CN601

C board

4 Remove the C board in the direction of the arrow B.

Side panel shaft

1 Remove the harneses

Cover (B2)

Cover (B)

3 Open the side panel assembly in the

direction of the arrow A.

Cover (G)

C board

5 Screw (+B 3 x 6)

6 Cover (G), Sheet (G)

1-8

Sheet (G)

G board

C board

VPL-ES1

1-3-12. Side Panel Assembly-2

. Remove the C board and cover (G). (Refer to 1-3-11.)

Three claws

2 Remove the side panel assembly

in the direction of the arrow C.

Note : Remove the while taking care so that it must not be caught by other parts.

side panel assembly

Open the

in the direction of the arrow

side panel assembly

Sheet

(

speaker

Speaker assembly

)

Three claws

Sheet

CN01

(NR)

L board

CN70

9 Side panel assembly

NR board

Claw

Two claws

VPL-ES1

Speaker bracket

1-9

1-3-13. G Board

. Remove the cover (G), sheet (G). (Refer to 1-3-11)

Flat connector assembly

G board

C board

1-3-14. Lamp Power Supply

. Remove the cover (G), sheet (G). (Refer to 1-3-11) . Remove the G board. (Refer to 1-3-13.)

CN201

CN102

CN101

3 Sheet (B)

C board

1 Two screws (+BTP 3 x 10)

CN1

CN2

2 Two screws (+B 3 x 6)

Lamp power supply

1-10

VPL-ES1

1-3-15. D.C. Fan (Sirocco/For Lamp)

. Remove the side panel assembly-1,2. (Refer to 1-3-11, 12) . Remove the G board. (Refer to 1-3-13.)

5 Remove the D.C. fan (Sirocco/For lamp) in the direction of the arrow.

4 Loosen the screw.

1 Two screws

(+BTP 3 x10)

2 Fan bracket

6 D.C. fan (Sirocco/For lamp)

Fan holder

C board

3 Two dowels

VPL-ES1

1-11

1-3-16. D.C. Fan (Sirocco)

CN802

CN806

CN811

CN809

CN905

1 Remove the fuse connector assembly

2 Three screws (+BTP 3 x 10)

C board

3 Remove the fan holder in the direction of the arrow.

4 Fan holder

Dowel

7 D.C. fan (Sirocco)

1-12

5 Remove the

harneses

6 Two dowels

D.C. fan (Sirocco)

VPL-ES1

1-3-17. Adjuster Block Assembly

. To remove the adjuster block assembly, remove the related parts beforehand.

2 Fan holder

1 C board

• Remove the C board. (Refer to 1-3-3.)

4 Optics block assembly

• Remove the optics block assembly. (Refer to 1-3-8.)

• Remove the fan holder. (Refer to 1-3-5.)

3 Lamp house

• Remove the lamp house. (Refer to 1-3-7.)

7 Dowel

8 Remove the adjuster block assembly

in the direction of the arrow.

5 Three screws (+BTP 3 x 10)

9 Adjuster block assembly

6 Dowel

VPL-ES1

1-13

1-4. Warning on Power Connection

n . When a signal other than the preset signals shown above is input, the picture may not appear properly. . Memory No. 22 shows the interlace signal.

Warning on power connection

Use a proper power cord for your local power supply.

The United States, Continental Europe UK, Ireland, Japan Canada

Plug type VM0233 290B YP-12A COX-07

Connector type VM0089 386A YC-13B COX-02 VM0310B YC-13

Cord type SJT SJT H05VV-F H05VV-F N13237/CO-228 VCTF

Rated Voltage & Current 10A/125V 10A/125V 10A/250V 10A/250V 10A/250V 7A/125V

Safety approval UL/CSA UL/CSA VDE VDE VDE DENAN

Cord length (max.) 4.5m –

(1) Use an appropriate rating plug which is applied to local regulations.

Australia, New Zealand

(1) YP332

1-14

VPL-ES1

Section 2

Lens projection

Lens gear

Gear alignment portion

Lens gear

Zoom

Focus

Electrical Adjustments

2-1. Preparation

2-1-1. Required Equipment

. NTSC, PAL, SECAM component signal generator

Sony Tektronix TG2000 + AVG1 (option module) + AWVG1 (option module) or equivalent

. VG (programmable video signal generator)

VG854 or equivalent

. Illuminance meter

Allow the warm-up time of 5 minutes after the power is on before starting the following adjustments.

2-1-2. Opt Unit Adjustment

1. Let the VPL-ES1 show the ALL WHITE screen.

2. Adjust the B-channel illumination adjustment mirror so that the yellow frame must not appear in any of top, bottom, right and left of the screen.

3. Tighten the adjustment plate fixing screw using a torque screwdriver. (Torque 0.19 ±0.03 Nm)

4. Adjust the G-channel illumination adjustment mirror so that the magenta frame must not appear in any of top, bottom, right and left of the screen.

5. Tighten the adjustment plate fixing screw using a torque screwdriver. (Torque 0.19 ±0.03 Nm)

6. Adjust the R-channel illumination adjustment mirror so that the cyan frame must not appear in any of top, bottom, right and left of the screen.

7. Tighten the adjustment plate fixing screw using a torque screwdriver. (Torque 0.19 ±0.03 Nm)

8. Confirm that the illumination range error is within the allowable range of product specification.

9. Install the VPL-ES1 in the cabinet. Confirm that the illumination range error is within the allowable range of product specification after the VPL-ES1 is installed in the cabinet.

When installing the optical unit in this model, alignment of the gear tooth position is required. Perform the following steps.

Procedure

1. Rotate the lens focus and zoom in the fully clockwise positions. Lock the lens gear in the direction shown in Fig. 1.

Fig. 1

2. Align the marking position of the lens zoom gear with the protrusion of the lens gear approximately by visual observation as shown below.

Engage the gears.

VPL-ES1

Lens gear

Fig. 2 (inside view)

Lens

2-1

Confirmation

Install the side panel and confirm that the portions A and B of the dial cannot be seen from the opening of the side

panel when the ZOOM and FOCUS are moved to their very ends.

ZOOM FOCUS ZOOM FOCUS

Good No good

2-1-3. How to Enter the Factory Mode

1. Confirm that the MENU can be displayed.

2. Close the MENU.

3. Press the keys in the following order : [ENTER] → [ENTER] → [&] → [ENTER]. The message [Do you want to enter the Factory Mode? Yes : ↑ No : ↓] appears. Select [Yes : ↑].

[Supplementary information: How to Exit the Factory Mode]

Perform the step 3 KEY operation. The message [Do you want to return to the User Mode? Yes : ↑ No : ↓] appears. Select [Yes : ↑].

2-2. V COM Adjustment

1. Connect the VG to the INPUT-A connector. Connect the FLAT FIELD 100 IRE signal to the input connector. Leave the VPL-ES1 with POWER ON for 10 minutes or longer for aging.

2. Enter the Factory Mode. Enter the Device Adjust MENU, and then enter the Panel Drive Adjustment MENU.

3. Connect the SVGA, R-single color, 30 IRE, single-line ON/OFF signal to the input connector.

4. Enter the P. DRV Adjustment MENU, and then enter the VCOM R Adjustment screen.

5. Adjust the VCOM R value for minimum flicker.

6. Change the input signal to the SVGA, G-single color, 30 IRE, single-line ON/OFF signal, and connect it to the input connector.

7. Enter the P. DRV Adjustment MENU, and then enter the VCOM G Adjustment screen.

8. Adjust the VCOM G value for minimum flicker.

9. Change the input signal to the SVGA, B-single color, 30 IRE, single-line ON/OFF signal, and connect it to the input connector.

10. Enter the P. DRV Adjustment MENU, and then enter the VCOM B Adjustment screen.

11. Adjust the VCOM B value for minimum flicker.

12. Store the adjustment value in the memory.

13. Turn over the “Image flip” up side down and repeat the steps from 1 through 12.

In the Factor mode, you can close the lens shutter if you keep pressing the TILT key even though the lamp lights. If the machine is left in this state for long hours, the lens shutter may melt in the worst case. Be sure to confirm that the lens shutter is not closed when the lamp lights in the Factory mode.

2-2

VPL-ES1

MenuTitle ItemName MemoryName

Remark

Set Memory

Status

Memory

Picture Memory W/B Memory

Video

S Video Input-A Video Computer

Dynamic Standard Dynamic Standard Dynamic Standard High

Low

High

Low

PICTURE SETTING Picture Mode Standard

Adjust Picture...

Contrast 90 80 90 80 90 80

Brightness 40 50 40 50 40 50

Color 50 50 50 50 50 50

Hue 50 50 50 50 50 50

Sharpness High High Middle Middle Middle Middle

Gamma Mode ----Graphics Graphics

Color Temp. Low Low Low Low High High

Volume 30

INPUT SETTING Adjust Signal...

Dot Phase

(

H Size *

Shift *

Wide Mode Off Off Off Off Off Off

Scan Conv On On

SET SETTING Smart APA On

Auto Input Search Off

Input-A Signal Sel. Computer

Color System Auto

Power Saving Off

Illumination On

MENU SETTING Status On

Languege English

Menu Position Center

Menu Color White

2-3. Initial Values of Adjustment Items

2-3

2-4

MenuTitle ItemName MemoryName

Set Memory Status

Picture Memory W/B Memory

Video

S Video Input-A Video

Computer

Dynamic Standard Dynamic Standard Dynamic Standard High

Low

High

Low

INSTALL SETTING Tilt...

V Keystone Auto

Manual... 0

Image Flip Off

Background Blue

Lamp Mode Standard

High Altitude Off

Security Lock Off

Key Enter x 4

INFORMATION fH

(Memory No.)

(Resolution)

Lamp Timer

ROM Version

SC ROM Version

Operation Timer

Prev. Lamp Timer

W/B SETTING Gain R 155 165 150 150

G 145 120 140 140

B 130 130 150 140

Bias R 130 130 127 127

G 120 120 127 127

B 120 120 127 127

MenuTitle ItemName MemoryName

Set Memory Status

Picture Memory W/B Memory

Video

S Video Input-A Video

Computer

Dynamic Standard Dynamic Standard Dynamic Standard High

Low

High

Low

INSTALL SETTING Tilt...

V Keystone Auto

Manual... 0

Image Flip Off

Background Blue

Lamp Mode Standard

High Altitude Off

Security Lock Off

Key Enter x 4

INFORMATION fH

(Memory No.)

(Resolution)

Lamp Timer

ROM Version

SC ROM Version

Operation Timer

Prev. Lamp Timer

W/B SETTING Gain R 155 165 150 150

G 145 120 140 140

B 130 130 150 140

Bias R 130 130 127 127

G 120 120 127 127

B 120 120 127 127

Remark

Display only Display only Display only Display only Display only Display only Display only Display only

Display only

* : The “Dot Phase E, H Size, Shift H/V and Picture Mode” items in the “INPUT SETTING” menu have their respective initial values for each input signal (PRESET

MEMORY No.).

There are some adjustment items that cannot be adjusted, depending on the input signal.

VPL-ES1

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