Sony VPL-ES4, VPL-EX4 Service Manual

DATA PROJECTOR

VPL-ES4
VPL-EX4

REMOTE COMMANDER

RM-PJ4

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.

CAUTION

RISK OF EXPLOSION IF BATTERY IS REPLACED BY INCORRECT TYPE.
DISPOSE OF USED BATTERIES ACCORDING TO THE RULE IN REGION.

VPL-ES4/EX4

Table of Contents

1. Service Information

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

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

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

1-3-1. Upper Case Assembly ........................................... 1-2

1-3-2. Front Case Assembly and

Sub Rear Case Assembly ......................................1-2

1-3-3. Main Board ............................................................ 1-3

1-3-4. Tunnel Outlet Section ............................................ 1-4

1-3-5. Main Board Bracket Section ................................. 1-4

1-3-6. Lamp Power Supply ..............................................1-5

1-3-7. Power Board ..........................................................1-5

1-3-8. Optics Section ....................................................... 1-6

1-3-9. Detection Switch Board ........................................ 1-7

1-3-10. DC Fan .................................................................. 1-7

1-4. Warning on Power Connection ....................................... 1-8

2. Electrical Adjustments

4. Spare Parts

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

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

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

4-4. Packing Materials & Supplied Accessories ....................4-4

5. Block Diagram

Overall ............................................................................ 5-1

6. Diagram

6-1. Frame Schematic Diagram ............................................. 6-1

2-1. Initial Values of Adjustment Items ................................. 2-1

2-2. Memory Structure ...........................................................2-5

3. Troubleshooting

3-1. Electric Troubleshooting ................................................ 3-1

3-2. Power Board Troubleshooting ........................................3-3

3-2-1. No Power ...............................................................3-3

3-2-2. Failure of Turn on Lamp ....................................... 3-4

VPL-ES4/EX4

1

1-1. Appearance Figure

Section 1

Service Information

1-2. Board Locations

Thermal sensor

Detection switch

IR sensor

Main

Lamp power supply

Power

VPL-ES4/EX4

1-1

1-3. Disassembly

1-3-1. Upper Case Assembly

2

Four claws

4 Upper case assembly

3

Remove the upper case assembly from this corner with the
strong force to the extent that the upper case assembly will
not be damaged.

1

Five screws (M 3 x 6)

1-3-2. Front Case Assembly and Sub Rear Case Assembly

Remove the upper case assembly before starting the removal work.

!=

5 S

(M 3)

6

Six

hexagon

screws

7

Two screws

(+K 3 x 12)

Sub rear case assembly

4

crew

Two screws

(M 3 x 6)

9

Remove the upper case assembly from this corner with the
strong force to the extent that the upper case assembly will
not be damaged.

2

Main board

connector (J6)

0

Two claws

3

IR sensor board

connector (J1)

Front case assembly

![

1

VPL-ES4 VPL-EX4

Lens cap

Speaker harnesses

!-

1-2

Sub rear case
assembly

Sub rear case

assembly

Front case assembly

8

Remove the upper case assembly from this corner with the
strong force to the extent that the upper case assembly will
not be damaged.

VPL-ES4/EX4

1-3-3. Main Board

Remove the front case assembly and sub rear case assembly before starting the removal work.

1

five screws

(M 3 x 6)

2

Remove the main
shield in the direction
of the arrow.

Note:
The fan harness has been secured by the
main board bracket with a fixing screw.
(See section 1-3-5. mein bracket)

J17

J16

Main board bracket section

Because the harnesses has the shape of flat
cross-section, do not insert the harnesses with
excessive force. Find out the direction in
which the harnesses can be inserted easily,
and then insert the harnesses.

Main shield

Harnesses

3

Main board

Radiation sheet

Main board

J22

Main board

J18

Harnesses clamp section

J14 J20 J19 J21 J22

J25

J24

J23

Lamp box assembly

When re-assembling,
give an appropriate
amount of extra slack
of this harnesses.

J6

VPL-ES4/EX4

1-3

1-3-4. Tunnel Outlet Section

Remove the front case assembly and sub rear case assembly before starting the removal work.

1

Two tapping screws

(PAN 3 x 7)

Lamp box
assembly

J21

Main board

Main board

Because the harnesses has the shape of flat
cross-section, do not insert the harnesses with
excessive force. Find out the direction in
which the harnesses can be inserted easily,
and then insert the harnesses.

Harnesses

J21

2

Tunnel outlet section

Harnesses clamp section

1-3-5. Main Board Bracket Section

Remove the main board before starting the removal work.

2

Three tapping screws

(PAN 3 x 7)

Power board

3 S

crew

(M 4 x 6)

1

Two screws

(M 3 x 6)

4

Main board bracket section

1-4

VPL-ES4/EX4

1-3-6. Lamp Power Supply

4

Lamp

9

Lamp power supply

2

Lamp door

1

loosen screw.

3

Loosen two screws.

5 Screw
(+PWH 3 x 8)

8

Connector (P1)

B

A

To the main board J16

From the Main board CN602

(Red and Black wires)

6

Remove the lamp power supply
connector in the direction of the
arrow A.

7

Remove the lamp power supply in the

direction of the arrow B.

Remove the main board bracket section before starting the removal work.

1-3-7. Power Board

Remove the main board bracket section before starting the removal work.

VPL-ES4/EX4

2

Remove the power board in

the direction of the arrow.

1 Two

stand assemblies

CN701

CN603

Power board

CN603

Lamp power supply (P1)

CN701

1-5

1-3-8. Optics Section

Remove the lamp power supply and power board before starting the removal work.

1

Two tapping screws

(PAN 3 x 7)

7

Dowel

2

Two claws

4

Gasket

6

Two tapping screws

(PAN 3 x 7)

5 Harness

8

Focus/Zoom adjust

assembly

Assembling Method of Optucs section and
Focus/Zoom Adjust Assembly

Phase matching

Rotate the Zoom dial clockwise

!-

as shown until it is stopped.

!= Rotate the Focus dial

counter-clockwise as
shown until it is stopped.

A

9

Four screws

(+P 2.5 x 8)

0

During the assembling process,
never change the gear position
that is set by step ![.

3

Remove the lamp box assembly in the

direction of the arrow

Optucs section

A

.

!\ Install the Optucs section

in the Lower Case.

Focus dial

Rotate the Focus dial

![

counter-clockwise as
shown until it is stopped.

!] Rotate the Focus/Zoom Adjust Assembly

counter-clockwise until it is stopped.

1-6

!;

Install the Focus/Zoom

Adjust Assembly as shown.

!' After installation is completed, verify that the Optucs

section can rotate from the position

B

smoothly.

A

B

Lower case

A

to the position

VPL-ES4/EX4

1-3-9. Detection Switch Board

Remove the optics section before starting the removal work.

3

Two tapping screws

(PAN 3 x 7)

4

Duct lamp

1

Tapping screw

(PAN 3 x 7)

CN1

2

Detection switch board

CN1

5

Tapping screw

(PAN 3 x 7)

6

Detection switch board

1-3-10. DC Fan

Remove the optics section before starting the removal work.

6

Two tapping screws

(M 3 x 25)

5 harness

7 DC fan

1

Two tapping screws

(PAN 3 x 7)

2

Duct

LCD assembly

3

Two tapping screws

(PAN 3 x 10)

4 DC fan

VPL-ES4/EX4

1-7

1-4. Warning on Power Connection

Use a proper power cord for your local power supply.

The United States, Continental UK, Ireland, Japan
Canada Europe Australia, New Zealand

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 (14 feet 9 inches) _

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

1)

YP332

1-8

VPL-ES4/EX4

Set

Memory

Dynamic Standard N

atural

Game Living Cinema

Presen-

tation Dynamic N

atural

Standard Game Living Cinema

Presen-

tation Dynamic Standard N

atural

Game Living Cinema

Presen-

tation Dynamic N

atural

Standard Game Living Cinema

Presen-

tation

Picture Mode * * * *

Adjust Picture

Contrast

90 80 85 90 90 75 85 90 75 80 90 90 75 75 90 80 85 90 90 75 85 90 85 80 90 90 60 85

Bright

60 50 55 60 50 50 55 60 55 50 60 50 50 55 60 50 55 60 50 50 55 60 55 50 60 50 50 55

Color

50 50 50 68 60 58 50 50 50 50 68 60 58 50 50 50 50 68 60 58 50

Hue

50 50 50 50 50 50 50 50 50 50 50 50 50 50

Sharp

ness 60 30 50 50 50 30 50 60 40 30 40 40 30 40 60 30 40 40 40 30 40

DDE

Film Film Film Film Film Film Film Film Film Film Film Film Film Film Film Film Film Film Film Film Film

Gamma Mode

Graphics Graphics

Color Temp

High Low Mid High Low Low High High Mid Low Low Low Low Mid Low Low Mid Low Low

Volume

30

Adjust Signal

Dot Phase 31

H Size

Shift

W

ild Mode OFF OFF OFF OFF OFF ON OFF OFF OFF OFF OFF OFF ON OFF OFF OFF OFF OFF OFF ON OFF

Scan Conv ON ON ON ON ON ON ON

Smart APA On

Auto Input Search Off

Input-A Signal Sel. Auto

Color System Auto

Power Saving Mode Off

IR Receiver

Front &

Rear

Panel Key Lock Off

Status On

Language English

Menu Position Center

Start Up Image On

V Keystone 0

Image Flip Off

Background Blue

Lamp Mode Standard

High Altitude Mode Off

Security Lock Off

Key Enter x 4

INFOR-

MATION

All information is

display only

Picture Memory

INPUT

SETTING

SET

SETTING

MENU

SETTING

INSTALL

SETTING

VIDEO INPUT A (

Component

/VideoGBR)

INPUT A (

Computer

)

, INPUT B (Computer)

PICTURE

SETTING

S VIDEO

Menu

Title

ItemName

MemoryName

High High High High High High High High High

Graphics Graphics Graphics Graphics Graphics

Section 2

Electrical Adjustments

Y No.).

2-1. Initial Values of Adjustment Items

VPL-ES4/EX4

* The “Picture Mode” items in the “PICTURE SETTING” menu have their respective initial values for each input signal (PRESET MEMOR

n

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

2-1

Color

Page Item Name Set R G B

TGHST Phase Hi 0
TGHST Phase Lo 109

SHSH1 38
TGHST Position 12

P1-1

CXD9809-page1

DEHPF On ON
DEHPF AAC ON
DEHPF TAP 3
DEUSC On OFF
3D GammaSubCont 0
3D GammaSubBrt 150
DELUT SW OFF
DEUF SW ON

PC Hi Gain-R 128
PC Hi Gain-G 128
PC Hi Gain-B 128
PC Hi Bias-R 0
PC Hi Bias-G 0

P1-2

CXD9809-page2

PC Hi Bias-B 0
PC Lo Gain-R 128
PC Lo Gain-G 70
PC Lo Gain-B 100
PC Lo Bias-R 0
PC Lo Bias-G 0
PC Lo Bias-B 0

P1-3

CXD9809-page3

2-2

Video Hi Gain-R 128
Video Hi Gain-G 128
Video Hi Gain-B 128
PC Mid Bias-R 0
Video Hi Bias-G 0
Video Hi Bias-B 0
Video Lo Gain-R 128
Video Lo Gain-G 70
Video Lo Gain-B 100
Video Lo Bias-R 0
Video Lo Bias-G 0
Video Lo Bias-B 0

VPL-ES4/EX4

Color

Page Item Name Set R G B

PC Mid Gain-R 128
PC Mid Gain-G 90
PC Mid Gain-B 115
PC Mid Bias-R 0
PC Mid Bias-G 0

P1-4

CXD9809-page4

PC Mid Bias-B 0
Video Mid Gain-R 128
Video Mid Gain-G 75
Video Mid Gain-B 105
Video Mid Bias-R 0
Video Mid Bias-G 0
Video Mid Bias-B 0

Temperature 1 Display only
Temperature 2 Display only
Temperature 3 N/A
FanSpeed 1 Display only
FanSpeed 2 Display only

P2

Fan Control

FanSpeed 3 Display only
FanSpeed 4 Display only
ManualFanSpeed OFF
Burn-In Cycle 0
Burn-In Cycle On min 210
Burn-In Cycle Off min 30
Burn-In Hour 50
Burn-In active OFF

P3-1

CXA7005-page1

VPL-ES4/EX4

Gain-R 188
Gain-G 188
Gain-B 188
SigCen-R 35
SigCen-G 35
SigCen-B 35
SidA-R 22
SidA-G 22
SidA-B 22
SidB-R 85
SidB-G 85
SidB-B 85

2-3

Color

Page Item Name Set R G B

Bias-R Normal 122
Bias-G Normal 122
Bias-B Normal 122
Bias-R Flip 122
Bias-G Flip 122

P3-2

CXA7005-page2

Bias-B Flip 122
Vcom-R Normal 88
Vcom-G Normal 88
Vcom-B Normal 88
Vcom-R Flip 88
Vcom-G Flip 88
Vcom-B Flip 88

RGB Calibrate
YUV Calibrate
RGB Offset 164 222 164
RGB Gain 93 105 93
YUV Offset 164 222 164

P4

ADC Calibration

YUV Gain 93 105 93
R Offset 164
G Offset 222
B Offset 164
R Gain 93
G Gain 105
B Gain 93

Error Count

2-4

P5

P6

Power Saving Time 10
System Protect ON
Data Reset
Hard Reset
ROM Version Display only
Lamp Timer Display only
Operation Timer Display only
Prev. Lamp Timer Display only
SOG Threshold N/A

All value is display only

VPL-ES4/EX4

2-2. Memory Structure

Set memory Set memory Set memory

No.01
No.02 No.02
No.03
No.04 No.04

status

memory

Picture

memory

W/B

memory

Channel
Memory

Common

Memory

No.05 No.05

No.50 No.50
No.55 No.55

No.56 No.56
No.101 No.101
No.102 No.102

Video

S-Video

Input-A

Input-B

Component

Computer

Other than

Computer

Input-A
Input-B Input-B
Input-A
Component
Input-A
Video-GBR
Video Video
S-Video S-Video

Wide Mode
(other than computer)
Scan Converter
(Computer only)
Smart APA
(Computer only)
Volume Volume
Auto Input Search Auto Input Search
Input-A Signal Sel. Input-A Signal Sel.
Color System
(Video/S-Video Only)
Speaker Speaker
Power Saving Power Saving
IR Receiver IR Receiver
Panel Key Lock Panel Key Lock
Status Status
Language Language
Menu Position Menu Position
Image Flip Image Flip
Background Background
Lamp Mode Lamp Mode
High Altitude High Altitude
Security Lock Security Lock

FLASH ROM EEPROM

Video/Svideo

status

memory

Dynamic
Standard Standard
Natural Natural
Game Game
Living Living
Cinema Cinema
Presentation Presentation
Dynamic
Standard Standard
Natural Natural
Game Game
Living Living
Cinema Cinema
Presentation Presentation
Dynamic
Standard Standard
Natural Natural
Game Game
Living Living
Cinema Cinema
Presentation Presentation
Dynamic
Standard Standard
Natural Natural
Game Game
Living Living
Cinema Cinema
Presentation Presentation
Dynamic
Standard Standard
Natural Natural
Game Game
Living Living
Cinema Cinema
Presentation Presentation

High
Mid Mid
Low Low
High
Mid Mid
Low Low

picture

memory

W/B memory

Channel
Memory

Common

Memory

Input-A/Input-B
/Component

Video

S-Video

Input-A

Input-B

Component

Computer

Other than

Computer

Input-A Channel Memory

Input-A
Component
Input-A
Video-GBR

Wide Mode
(other than computer)
Scan Converter
(Computer only)
Smart APA
(Computer only)

Color System
(Video/S-Video Only)

No.01 Status memory

No.03

Dynamic

Dynamic

Dynamic

Dynamic

Dynamic

High

High

Picture memory

W/B memory

Common Memory

CPU RAM

VPL-ES4/EX4

2-5

Memory structure of this model consists of the followings.
1 Set memory
2 Status memory
3 Picture memory
4 Chroma memory
5 W/B memory
6 Channel memory

* The gamma memory is realized by giving offset to the Contrast and Brightness output values to the

devices in the gamma mode function.

Flow of data is described briefly. When the power plug is connected to the wall outlet for the first time
(Standby state), all data that are stored in the internal ROM are written in the NVM (non-volatile memo­ry). When the POWER is turned ON, all the status memory data and other memory data that are required
for the present picture are selected from each memory block and expanded in the internal RAM.
When any adjustment is performed at this moment, the adjustment data (user mode items) are written in
the NVM (Service/Special Service) automatically triggered by the memory operation.

The adjustment items (W/B, Device Adjust) that can be adjusted in the Service Mode or in the Special
Service Mode, are memorized in the NVM at the time when the user performs adjustment and performs
the memory operation. Note that the factory adjustment data will be lost at this moment.

2-6

VPL-ES4/EX4

3-1. Electric Troubleshooting

Connect the Power

Section 3

Troubleshooting

System Standby?

Yes

Power projector
Lamp ON ?

Yes

System shut-down
And cooling

No

No Picture ?

No

No

No

Yes

Yes

1. Check the LED Message and find error.

2. Check lamp door, dust door.

3. Check the power board out voltage 5V.

4. Change main board.

1. check the Ballast power and control
signal wire.

2. Check lamp door status.

3. Check lamp status.

1. Check the LED message and find error.

2. Check the Fan status or Thermal sensor
status.

3. Check the lamp door or dust door.

1. The picture is full-white pattern; please
check the LCD panel connector.

2. The picture is full-black pattern; please
check the LCD driver on the main board.

3. Check the system status: Is system in
burn-in mode?

VPL-ES4/EX4

Picture quality
No good ?

No

1

Yes

1. The picture a little green, blue, red,
please check the LCD panel connector.

2. The picture has dust, please check the
lens.

3. The picture flicker, please alignment
again.

3-1

1

OSD flicker ?

No

Color temp wrong ?

No

Picture has
Vertical bar ?

No

IR remote control
No good ?

Yes

Yes

Yes

Yes

Please alignment V-com again.

Please alignment color temperature again.

Check the vertical bar color and find the
LCD panel connector. Then check the pin
of connector.

1. Please check the OSD setting

2. Check the front IR board.

No

Audio function is
No good ?

Yes

1. Check the OSD setting.

2. Check the speak wire.

3-2

VPL-ES4/EX4

3-2. Power Board Troubleshooting

3-2-1. No Power

No Power

Replace Q601 and F601
with new ones, and then
put power board into set.
If Q601 damages again,
check if other parts are
shorted.

Check if 15.25V or 12V
exist. If any voltage is
wrong, replace IC701 or
T602 with new ones.

Yes

Yes

F601

Open?

Yes

Q601(D-S)

Short ?

No

Output
5V DC

exists ?

No

Voltage

outputs shut

down and built

repeatly ?

No

Yes

Check if CN701 inserted
properly.

Check if miss to solder
any SMD type of
components.

Check if D602 or IC602 is
broken.
if yes,replace it with now
one.

VPL-ES4/EX4

No

Check LED circuit of
main board.

Check CN701 and find
out if some points are
shorted to gound.

3-3

3-2-2. Failure of Turn on Lamp

Failure of turn on ballast.

Check main board.

A

Check if the input

voltage of ballast is

380V DC

No

Lamp

Broken ?

No

No

Control

Pin (SCI) is

normal ?

Yes

Replace ballast with new
one.

Yes

Yes

B

Replace lamp with new
one.

3-4

VPL-ES4/EX4

B

Check mian board.

A

No

exists at c-terminal

Yes

Check if there

is PFC_On/Off

signal.

Yes

Check if 18V

of Q603.

Yes

F602 Open ?

No

Q602 works

normally ?

No

Yes

Check Q701 IC604,
Q604, Q603 or ZD603.
And then replace broken
parts.

Replace F602 with new
one.

VPL-ES4/EX4

No

Check ZD602, R655 and
R656.

3-5

4-1. Notes on Repair Parts

1. Safety Related Components Warning

w

Components marked ! are critical to safe operation.
Therefore, specified parts should be used in the case of
replacement.

[WARNHINWEIS][WARNHINWEIS]

[WARNHINWEIS]

[WARNHINWEIS][WARNHINWEIS]

Les composants identifiés par la marque ! sont
critiques pour la sécurité.
Ne les remplacer que par une pièce portant le numéro
spécifié.

2. Standardization of Parts

Some repair parts supplied by Sony differ from those
used for the unit. These are because of parts common­ality and improvement.
Parts List has the present standardized repair parts.

Section 4

Spare Parts

3. Stock of Parts

Parts marked with “o” at SP (Supply Code) column of
the Spare Parts list may not be stocked. Therefore, the
delivery date will be delayed.
Items with no part number and no description are not
stocked because they are seldom required for routine
service.

4. Units for Capacitors, Inductors and Resistors

The following units are assumed in Schematic Dia­grams, Electrical Parts List and Exploded Views
unless otherwise specified.

Capacitors : μF
Inductors : μH
Resistors : Ω

VPL-ES4/EX4

4-1

Overall

4-2. Exploded Views

10

38

38

36

38

41

38

33

+PSW 4x8

32

25

9

12

+PSW 3x25

+PWH
3x8

42

20

38

32

6

32

30

1

3

32

2

13

+P 2.5x8

32

14

37

32

38

32

29

4

39

28

30

24

7

+K 3x12

+K 3x12

4-2

27

17

26

21

VPL-ES4

8

38

22

38

34

VPL-EX4

+BVTP 3x6

35

11

15

16

VPL-ES4/EX4

No. Part No. SP Description

1 ! 1-576-973-11 s FUSE, CYLINDERICAL (F602)
2 ! 1-576-233-51 s FUSE (H.B.C.) (F601)
3 ! 1-576-974-11 s THERMOSTAT
4 1-789-603-11 s DOOR DETECTION SWITCH BOARD
6 ! 9-885-114-11 s FAN, DC (AXIAL FAN UNIT)

7 ! 9-885-114-12 s FAN, DC
8 ! 1-787-496-11 s FAN, DC (DC)
9 ! 1-787-496-21 s FAN, DC (DC)
10 9-885-114-05 s MOUNTED CIRCUIT BOARD, MAIN (VPL-ES4)
10 9-885-114-07 s MOUNTED CIRCUIT BOARD, MAIN (VPL-EX4)

11 1-789-543-11 s MOUNTED CIRCUIT BOARD, IR SENSOR
12 1-789-544-11 s MOUNTED CIRCUIT BOARD, THERMAL SENSOR
13 9-885-114-04 s MOUNTED CIRCUIT BOARD, POWER
14 9-885-114-06 s SPEAKER
15 9-885-113-91 s LAMP DOOR

16 9-885-113-92 s DOOR, FILTER
17 2-670-067-01 s MESH FILTER
20 2-675-465-01 s ASSY, LAMP BOX
21 9-885-113-93 s ASSY,FOOT ADJUST RUBBER
22 9-885-113-94 s FOOT, ADJUST

24 9-885-113-95 s LENS CAP (VPL-ES4)
24 9-885-114-08 s LENS CAP (VPL-EX4)
25 9-885-114-34 s MYLAR BALLAST
26 9-885-113-96 s LOWER CASE
27 9-885-114-00 s ASSY, SUB REAR CASE (VPL-ES4)

Overall

27 9-885-114-33 s ASSY, SUB REAR CASE (VPL-EX4)
28 9-885-113-97 s ASSY, FRONT CASE (VPL-ES4)
28 9-885-114-09 s ASSY, FRONT CASE (VPL-EX4)
29 9-885-113-98 s ASSY, FOCUS/ZOOM ADJUST (VPL-ES4)
29 9-885-114-10 s ASSY, FOCUS/ZOOM ADJUST (VPL-EX4)

30 2-681-547-02 s SCREW, TAP PH W/FL M3*27L
32 2-681-550-01 s SCREW, TAP PAN M3*7L
33 2-681-552-02 s SCREW, EX-HE 4#-40X4+6 STLESS
34 2-681-553-01 s SCREW, TAP PAN M2*6L
35 9-885-114-32 s RUBBER PAD,ADJUST FOOT

36 9-885-113-90 s ASSY, UPPER CASE (WHITE COLOR)
36 9-885-113-99 s ASSY, UPPER CASE (BLOCK COLOR) (VPL-ES4)
37 4-672-839-11 s HEAD, M3 FLAT
38 3-918-696-11 s SCREW (M3X6 LOCK ACE)
39 2-580-621-01 s SCREW, +PWH 3X10

41 9-885-114-02 s SWITCH,TACT
42 ! 1-474-023-11 s POWER SUPPLY BLOCK (BALLAST)

7-682-903-21 s SCREW, +PWH 3X8
7-682-954-01 s SCREW, +PSW 3X25
7-685-645-91 s SCREW +BVTP 3X6
7-621-262-40 s SCREW, +P 2.5X8
7-682-250-09 s SCREW, +K 3X12

7-682-961-01 s SCREW +PSW 4X8

VPL-ES4/EX4

4-3

4-3. Electrical Parts List

Ref. No.
or Q’ty Part No. SP Description

1pc ! 1-576-233-51 s FUSE (H.B.C) (F601)
1pc ! 1-576-973-11 s FUSE, CYLINDERICAL (F602)

4-4. Packing Materials & Supplied

-------------------­SUPPLIED ACCESSORIES

-------------------­ Ref. No.
or Q’ty Part No. SP Description

1pc 1-479-775-12 s REMOTE COMMANDER (RM-PJ4)
1pc 1-832-428-11 s CABLE, VGA
1pc 2-679-319-01 s BAG,CARRY
1pc 3-210-513-02 s CD MANUAL
1pc 3-100-207-01 s GUIDE QS MANUAL
(JAPANESE, ENGLISH, FRENCH,
SPANISH, GERMAN, ITALIAN,
SIMPLIFIED CHINESE)

1pc ! ------------ s CORD SET, POWER
(See 1-4. Warning on Power Connection)

Accessories

4-4

VPL-ES4/EX4

Section 5

GPSIG

HCKx_R

DCK1_B

DCK1x_R

DCK1_B

HCK_R

HCK

LCDPCG

LCDENB

VST

VD

DCK1x_G

HCKx_R

HST

HCKx

VCK

DCK2_G

HCKx

CLK_B

FRP

DCK1x_G

HST

PRG

DCK1_R

CLK_G

RPSIG

DCK2x_R

VD

DCK1_G

DCK1_R

RGT

HCKx

GSIG[6:1]

DWN

HCK_G

VCK

HCK_R

HCKx_G

HCK_B

DCK2x_B

LCDVCK

LCDRGTx

PCG

HCK_G

ENB

DCK2x_B

DCK2_G

DWN

HCK

ENB

FRP

PRG

DCK1x_R

PCG

LCDVST

RSIG[6:1]

VCK

HCKx_B

PCG

LCDRGT

HCK

BSIG[6:1]

VD

DCK2_B

PRG

DCK2x_G

VST

DCK2x_R

DCK2_R

LCDHST

BPSIG

RGTx

HST

LCDR[11:0]

DCK1_G

DCK2_R

DWN

RGT

VCK

PRG

DCK1x_B

GVCOM

CLK_R

HST

HCK_B

FRP

DWN

HCKx_G

HCKx_B

BVCOM

LCDG[11:0]

RVCOM

ENB

RGT

DCK2_B

VD

FRP

RGTx

DCK[6:1]

LCDDWN

LCDB[11:0]

ENB

PCG

DCK2x_G

DCK1x_B

VST

VST

SDA

SCL

WP

DR[9:0]

DG[9:0]

DB[9:0]

DCLK

DHS

DVS

SDATA

SEN

SDATA

SDATA

SCLK

SEN

SCLK

SEN

SCLK

SDATAi

SCLKi

SENi

PC-RIN1
PC-GIN1
PC-BIN1

HSYNC1
VSYNC1

PC-RIN2
PC-GIN2
PC-BIN2

HSYNC2
VSYNC2

R_OUT
G_OUT
B_OUT

HSYNCO
VSYNCO

LUMA

CHROMA

CVBS

PC-RIN
PC-GIN
PC-BIN

HSYNC
VSYNC

AUDIO_S

AUDIO_O_

AUDIO_O

AUDIO_MUT

AUDIO_VOL1

AUDIO_VOL2

TXD

RXD

AUDIO_M

TX.DL

RX.DL

AUDIO_O+

I2C_SW
FAN_SW

FG1

FG2

Fan3
FG3

Fan4
FG4

Fan5
FG5

Fan2

AUDIO_SW

SDA

IRR5

IRF5

IRR

IRF

SCL

LED[4:1]

P15VP
P12V
P5V

PWR_fail

POWER_ON

LCD_SCL
LCD_SDA

Dust_SW

ROMOEn

ROMWEn

A[0:21]

D[0:15]

LampLIT
LampEN
Eco_mode

Door_SW

P15VP
P12V
P5V

P15VP

P5V

P15V

P5VC

P5V

P5V

P1P8V

P2P5V

P3P3V

P33V

P5VC

V33

P2P5V

P135V

P15V

R

LCD

Drver

R

LCD

B

LCD

B

LCD

Driver

LCD

Timing

Generator

G

LCD

G

LCD

Driver

Video

Processor

&

Controller

Reset

IC

EEPROM

Speaker

RS232

Driver

Receiver

Fan Control

EEPROM

IR Receiver

IR Receiver

S-Video

Video

INPUT A

INPUT B

Monitor
Output

Audio

Audio A/B

Audio out

RS-232
Remote
Control

Thermal

Sensor 1

Thermal

Sensor 2

Analog RGB
Input/Output

32.768 KHz

LED

Driver

Keypad

Input

27 MHz

Power

Fail DET

Dust SW
Door SW

Flash

memory

Reset

IC

Power

Control

Power
Switch

Ballast

Fan 1

Fan 2

Fan 3

Fan 4

Audio

Input/Output

&
volume
control

+2.5V

REG

+3.3V

REG

+3.3V

REG

+1.8V

REG

+3.3V

REG

+1.8V

REG

+3.3V

REG

Block Diagram

OverallOverall

VPL-ES4/EX4

5-1

5-1

Section 6

CN601

CN602

HALOGEN

LAMP

BALLAST UNIT

POWER BOARD

FAN2

FAN2

FAN1(FRONT BOTTOM)

FAN3
(REAR BOTTOM)

FAN4
(REAR TOP)

CN701J17

SPEAKER

J11

J22

J6

J1

J20

J19

J14

J21

J16

J23

J24

J25

J1

INPUT

INPUT B

J2

INPUT

INPUT A

J3

OUTPUT

MONITOR

J4

VIDEO

J5

S VIDEO

INPUT

INPUT

J7

RS-232CREMOTE

CN1

CN1

J18

J1

THERMAL

SENSOR

BOARD

DETECTION

SWITCH

BOARD

(RIGHT)

DETECTION

SWITCH

BOARD

(LEFT)

LCD R

IR

SENSOR

BOARD

MAIN

BOARD

LCD G

LCD B

INPUT

J8

AUDIO A/B

INPUT

J9

AUDIO

OUTPUT

J10

AUDIO

Diagram

Frame Frame

6-1. Frame Schematic Diagram

1

2

3

4

5

VPL-ES4/EX4

6-1

6-1

A BCDEFGH

SAFETY CHECK-OUT

After correcting the original service problem,
perform the following safety checks before
releasing the set to the customer :

Check the metal trim, “metallized” knobs,
screws, and all other exposed metal parts for AC
leakage. Check leakage as described below.

LEAKAGE TEST

The AC leakage from any exposed metal part to
earth ground and from all exposed metal parts to
any exposed metal part having a return to
chassis, must not exceed 3.5 mA. Leakage
current can be measured by any one of three
methods.

1. A commercial leakage tester, such as the
Simpson 229 or RCA WT-540A. Follow the
manufacturers’ instructions to use these
instruments.

2. A battery-operated AC milliammeter. The
Data Precision 245 digital multimeter is
suitable for this job.

3. Measuring the voltage drop across a resistor
by means of a VOM or battery-operated AC
voltmeter. The “limit” indication is 5.25 V, so
analog meters must have an accurate low­voltage scale. The Simpson 250 and Sanwa
SH-63Trd are examples of a passive VOM
that is suitable. Nearly all battery operated
digital multimeters that have a 20 V AC range
are suitable. (See Fig. A)

VPL-ES4/EX4

To Exposed Metal
Parts on Set

0.15 μF 1.5 k

Fig A. Using an AC voltmeter to check AC leakage.

Z

Earth Ground

AC
voltmeter
(5.25V)

VPL-ES4 (SY)

VPL-EX4 (SY) E

9-883-627-01

English

Sony EMCS Corporation 2007DR16-1

Ichinomiya Tec ©2007