SERVICE MANUAL Model Name : H57 Prepared by SI : ________________________________________ Prepared by TSE : ________________________________________ Check by : ________________________________________ Approved by : ________________________________________ Date Revise Version 2004/9/29 V1.0 Description Initial Issue Copyright September, 2004 . All Rights Reserved Document #81D-G04-01A . P/N: 36.81D01.
Preface This manual is prepared for the maintenance service for H57 Micro-portable XGA DLP Projector. Maintenance procedures described in this manual are intended to isolate faulty parts and replace them in the field. It also aims to serve as a guide in procuring replacement parts for this product. This manual is copyrighted and all rights are reserved.
Table of Contents Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Introduction 1-1 Product Highlight Optical Specification Electrical Specification Mechanical Specification Environment 1-1 1-2 1-3 1-7 1-9 Disassembly of Procedure 2-1 Disassemble Lamp Module and Elevator Foot Disassemble Top Cover, Front Cover, Keypad Board and IR Sensor Module Disassemble Main Board Module, Thermal Switch Disassemble Fan Guider Module, Wind Tunnel Module, Lamp Driver Module, LVPS and Interrupt Switch Module Dis
Chapter 6 DDC Key-in Procedure 6-1 Equipment Needed Setup Procedure DDC Key in Procedure 6-1 6-2 6-3 Appendix A 7-1 Exploded Overview 7-1 Appendix B 7-37 Serial Number System Definition Reader’s Response 7-37 7-38 iii H57
Chapter 1 Introduction This manual is applied to 0.7”*1 DMD Color Projector with digital imaging functionality based on Digital Micromirror Device (DMD) technology. It’s the mode of single panel, 250 watt long life lamp. The manual gives you a brief description of basic technical information to help in service and main taining the product. Your customers will appreciate the quick response time when you immediately identify problems that occur with our products.
1-2 Optical Specification Technology Single 0.7” 576p DDR DMD chip Resolution 1024 x 576 Brightness 1100 lumens Typical output: 850 lumens Contrast ratio 2500:1(Typical) Uniformity 85% Displayable colors 16.
Vertical scan rate 43 – 120 Hz Aspect ratio 4:3 with support for 5:4 and 1.78:1 (anamorphic DVD & HDTV) 1-3 Electrical specification Computer compatibility (analog and digital): All resolutions supported to UXGA - Use AD9888 + Silicon Image 169. Input connections - Terminal:DVI x 1 (DVI, Analog RGB, Component, HDTV) Composite Video X 1.
Power supply Universal AC 100-240V 50/60 Hz with PFC input. Used Phillip 250W Lamp. Power consumption Standby mode - < 10 Watts 110V AC Operational noise 33 dB(A) 250W in normal mode. 30 dB(A) 200 W in ECO-mode. Input signal spec Hsync Frequency 15 ~ 100 kHz Vsync Frequency 43 ~ 120 Hz Video Signal RGB (PC) Analog RGB 0.7Vp-p, 75 ohm, Separate TTL H,V Sync. Analog RGB 1Vp-p, 75 ohm, Sync. On Green signal Analog RGB 0.7Vp-p, 75 ohm, Composite TTL Sync.
Computer Compatibility (Analog) Coretronic Corporation 1-5 H57
Computer Compatibility ( Digital ) System Controller PIXELWORKS PW463 Video Compatibility Standards NTSC PAL SECAM HDTV Intelligent Zoom Control Key Pad - M (3.58 MHz), 4.43 MHz - B, D, G, H, I, M, N - B, D, G, K, K1, L - 480i/576i ; 480p/576p ; 720p ; 1080i By using “PIXELWORKS” chips to provide excellent quality zooming. 1. Power 2. Menu 3. Enter Coretronic Corporation 1-6 4. Up 5. Down 6. Right 7.
1-4 Mechanical Specification Weight Approximate 8lbs Unit dimension (W X D X H) Inner dimension 335*250*100 (mm) Projector control keypad Power/standby, Directional keys, enter, source, menu Cooling System Advanced air flow Three fans with low system acoustic noise level Temperature control circuits with adaptive voltage control fan speed Front Side Projection Zoom Lens One IR receiver window Rear Side Left Side One S-Video Input One Composite Video Input 3 RCA RGBs input AC inlet; type IEC-C14 One IR rec
Top Side Keypad LED indicators One IR Receiver Bottom One elevator foot, one fix foot and one adjustable foot One lamp cover Inlet vent Spec. and warning labels Lamp housing Lamp could be changed by customer, but should follow the user manual instruction. Replaceable Lamp should be provided by Coretronic or its authorized agencies Tilt Angle 7 degrees with elevator mechanism Keystone correction ± 16° Vertical and Horizontal Color White Materials ID housing would be plastic part.
1-5 Environment Temperature Operating Storage 5 — 35°C -20 — 60°C Operating Storage 5 — 35°C, 80% non-condensing -20 — 60°C, 80% non-condensing Maximum Humidity Acoustic noise level 33dB(A) ( Typical, 23 ± 2¢J) with wind tunnel design 33 dB(A) 250W Normal mode. 30 dB(A) 200 W in ECO-mode.
Chapter 2 Disassembly Procedure The Front Side 2-1 Step1: The Rear Side Disassemble Lamp Module and Elevator Foot Turn unit to bottom side. Remove Lamp Cover and unscrew three screws to pull out Lamp Module.
Step2: Unscrew two screws to detach the Elevator Foot from Bottom Cover.
2-2 Disassemble Top Cover, Front Cover, Keypad Board and IR Sensor Module Step1: Unscrew eight screws and then turn the unit to the top side to lift Top Cover. Step2: Unplug three wires to separate Top Cover from the main unit.
Step3: Separate Front Cover from Top Cover by pressing two tenons.
Step4: Unscrew two screws to take off IR Sensor.
Step5: Unscrew three screws and unplug the wire to remove the Keypad Board, Keypad Button and FPC. FPC Keypad Board Keypad Button Step6: Take off Top IR Sensor Module from Rear Cover and separate IR Sensor from Anti-light Mylar.
2-3 Step1: Step2: Disassemble Main Board Module and Thermal Switch Unplug nine connectors and unscrew four screws. Unscrew four hex screws from Rear Cover to remove Main Board.
Step3: Unscrew one screw to remove Thermal Switch.
2-4 Step1: Step2: Disassemble Fan Guider Module, Wind Tunnel Module, Lamp Driver Module, LVPS and Interrupt Switch Module Unscrew three screws to separate Fan Guider Module and Wind Tunnel Module from Bottom Housing. Unscrew two screws from Wind Tunnel Module to remove Fan Guider Module.
Step3: Unscrew six screws, unplug one wire and one connector to remove Lamp Driver Module.
Step4: Unsrew three screws and unplug one wire to remove LVPS.
Step5: Unscrew two screws to remove EMI Ground Plate and separate the cables.
Step6: Unscrew two screws to remove Interrupt Switch Module.
2-5 Step1: Disassemble Color Wheel Module, Axial Fan 90x25 Module, Lamp Fan 60x60x25 and Optical Engine Module Unscrew two screws to remove Color Wheel Module.
Step2: Unscrew two screws to remove Axial Fan 90x25 Module.
Step3: Unscrew two screws to remove 60x60x25 Lamp Fan. Step4: Pull two side outward to disassemble 60x60x25 Lamp Fan.
Step5: Unscrew four screws to remove Engine Module from Bottom Cover.
Step6: Tear off EMI tape to separate Wind Guider Cover Mylar from Engine Module. Wind Guider Cover Mylar Step7: Unscrew four screws to remove DMD Heatsink.
Step8: Unscrew four screws to remove Bracket Plate, Insulation Mylar, DMD Board. Bracket Plate Insulation Mylar DMD Board Step9: Separate DMD Chip from Engine Module.
Step10: Unscrew three screws to remove Focus Ring & Replace Ring.
2-6 Step1: Disassemble Blower Fan 50x20, Thermal Sensor Board, Interrupt Switch Module, Bottom Cover and Rear Cover Unscrew one screw to remove Thermal Senor Board. Thermal Senor Board Step2: Unscrew three screws to remove Blower Fan 50x20 Module.
Step3: Unscrew one screw and separate Rear Cover from Bottom Cover by pressing four tenons.
Step4: Unscrew three screws and press the tenon to remove Elevator Module.
Chapter 3 Troubleshooting 3-1 Equipment Needed - H57 Projector VESA VGA Cable/VESA DVI Cable PC (Personal Computer) with analog and digital signal output. DVD Player for Video Signal and Audio Signal.
3-2 Main Procedure 3-2.1 LED Lighting Message Warning Indicator A. When the “TEMP” indicator turns red, it indicates the projector has overheated. The projector will automatically shut itself down. B. When the “LAMP” indicator flashes red (0.5 second intervals), it indicates a problem with the lamp. C. When the “LAMP” indicator flashes red (1 second intervals), it indicates the fan failed.
3-2.2 Power Troubleshooting A. Is LED Indicator OK? Check the power cord and AC power outlet. Check if the keypad cable has been broken or not. Check if all the wires are connected well inside. Check the Ballast. Check Main Board. Check Keypad Board. B. Is Fan Working After Press Power/Standby Button? Check if the Keypad cable has been broken or not. Check if all the wires are connected well inside. Check the Thermal board. Check Main board. Check Fan. C.
3-2.3 Performance Troubleshooting (Computer Signal) A. Have Image? Ensure if the signal cable and source work as well. Check if OSD Menu shows on the screen. Check Main Board. Check DMD Board. B. Have Garbage Pattern? Ensure the Signal cable and Source work as well. Check the Main board. Check the DMD board. C. Uniformity OK? Ensure the Projection screen without dirty. Ensure the Projection lens is clean. Ensure the Uniformity is within spec. Check the Optical engine. D.
G Have Line Bar? Adjust the frequency selection in OSD Menu. Press the Menu button to check that have Line bar show on the OSD Menu. (Check the DMD chip and DMD board. If the Line bar also show on the OSD Menu) Ensure that there is no dust on the DMD Contact housing module. Re-assembly for DMD module. Check the Main board. *Note : 3-2.4 The procedure to enter engineering mode is as follows Press ”Power”, ”Up”, ”Down”, ”Right” button when the Unit under search status.
D. Is Image Flickering? Ensure the signal cable works as well. (Please check the length of cable; the signal will be reduce when the signal cable is longer than 5m) Do the “Factory Reset” of the engineering mode. (Check the Main board if the image still flicker after the factory reset.) E. Is There Line Bar Shown on The Screen? Check if the line bar appears on OSD menu. (Check DMD Board if the bar line isdisplayed on OSD menu.) (Check the Main Board if the bar line isdisplayed on OSD menu.) F.
3-2.5 3-2.6 Function Troubleshooting A. OSD Does Not Show up Check the keypad cable and ensure there isn’t something wrong with the cable. Use the remote control for the OSD function test. (Check the Keypad board and Keypad cable if the Remote control works as well) Check the Main board. B. Function Cannot Be Adjusted. Check the keypad cable and ensure there isn’t something wrong with the cable. Use the remote control for the OSD function test.
Chapter 4 Function Test and Alignment Procedure 4-1 Test Equipment - 4-2 IBM PC with XGA resolution (Color Video Signal & Pattern Generator) DVD player with component video (Y, Pb, Pr) and Multi-system (NTSC/PAL/SECAM) HDTV Tuner or Source (480i/p,576i/p,720p,1080i) Minolta CL-100 Quantum Data 802B or Chroma 2327. Test Condition - - - Circumstance Brightness 1.) Dark room less than 10 lux for functional inspection. 2.) Circumstance brightness over than 500 lux for external inspection.
4-3 Test Display Modes & Pattern 4-3.
- 4-3.2 Function Test Display Pattern - Item Digital PC Signal Test C ontent P attern S pecification R emark 1 Frequency & Tracki ng Fi ne Li ne Moi re E li mi nate vi sual wavy noi se by Rsync, Frequency or Tracki ng selecti on. Fi gure 1 2 C ontrast/B ri ghtness 16 Gray S cale / 64 RGB W scale Gray level should be di sti ngui shable and wi thout color abnormal.
Figure 2.
Coretronic Corporation 4-5 H57
- Video & Audio Signal Coretronic Corporation 4-6 H57
4-4 Inspection Procedure - Elevator Function 1. Please check and ensure the function of elevator is work as well. 2. If not, please return the unit to repair area. - Keypad Function (Including Remote Control) 1. Please check and ensure the control function of keypad is work as well. 2. If not, please return the unit to repair area. - Clock and Clock phase Test Signal:1024 x 768 @ 75Hz Test Pattern:Fine Line Moire Pattern 1. Check and see if image sharpness and focus in well performed. 2.
- Dead pixel (Dark pixel) Test Signal:1024 x 768 @ 75Hz Test Pattern:Full white pattern 1. Please check and ensure the unit is under the spec. (Pixel number should be smaller or amount to 6 pixels) 2. If not, please return the unit to repair area. - Blemish(Bright) Test Signal:1024 x 768 @ 75Hz Test Pattern:Full black and Gray 30 patterns 1. Please check and ensure the unit is under the spec. (The bright blemish should not be able to see under Gray 30 pattern) 2.
- HDTV Test Signal:HDTV signal Test Pattern:480i/p,576i/p,720p,1080i 1. Please check and ensure the unit can display the HDTV signal without color abnormal or image abnormal issue. 2. If not, please return the unit to repair area. - Reset All After final QC step, we have to erase all saved change again and restore the factory defaults. Please select and enter “Factory Reset” function of “Engineering Mode” to ensure the function is work as well.
Chapter 5 Firmware Upgrade Procedure 5-1 Equipment Needed Software : - Config.hex Flasher.hex FlashUpgrader.exe Gui.exe Pixelware.inf Romcode.hex Hardware : - 5-2 Power Cord Cable RS232 To Mini Din 3Pin PC or Laptop H57 Projector Hardware Setup Procedure 1. Connecting RS232 Cable between PC and H57 Projector.
5-3 Firmware Progarm Installation Procedure Step1. Execute the “FlashUpgrader.exe” program. Step2. 1. Click ”Choose” to get the file directory 2. Select file and open it. 3. Select the Serial port in Connection field, COM1: in COM Port field and 115200 in Baud Rate field.
Step3. Click “Flash” to start the firmware upgrade procedure and keep press the projector’s power button immediately until download “gui.hex” to 10%.
Step4. After downloading all files, enter the engineering mode to check the F/W version.
Chapter 6 DDC Key-in Procedure 6-1 Equipment Needed - PC or Laptop (OS:Windows98 or Windows Me) EDID Fixture DFP to DVI Cable Power Adapter RS-232 Cable VGA Cable Power Cord DDC Driver H57 EDID Fixture P/N:80.00001.001 DFP to DVI Cable P/N: 42.81702.001 VGA Cable P/N:42.53001.051 Power Adapter P/N: 47.53402.004 RS-232 Cable P/N: 42.55708.
6-2 Setup Procedure Step1. Step2. Step3. Step4. Step5. Connect Power Adapter with fixture. Make sure the JP1and JP5 are close and JP2 is open. Connect P2 of the fixture with VGA Port of H57 by the VGA Cable. Connect P3 of the fixture with DVI Port of H57 by the DFP to DVI cable. Turn on the power of the fixture.
6-3 DDC Key-in Procedure 6-3.1 Analog Step1. Execute “H57_EDID_B” program. OPTOMA_H57 H57 Step2. Mark sure the COM port is connected ok. Choose the “Analog” to do Analog DDC procedure.
Step3. Key-in S/N in to the blank beside Barcode, and then press “Enter” key on the keyboard to begin programming. H57 1D342TOABCD1234 081D H57 Step4. After finishing the above action, “PASS” message will appear on the screen.
6-3.2 Digital Step1. Mark sure the COM port is connected ok. Choose the “Digital” to do Digital DDC procedure. H57 081D H57 Step2. Key-in S/N in to the blank beside Barcode, and then press “Enter” key on the keyboard to begin programming.
Step3. After finishing the above action, “PASS” message will appear on the screen.
Appendix A Exploded Overview I.
Exploded Parts List of H57 Coretronic Corporation 7-2 H57
II.
Exploded Parts List of H57 Bottom Housing Module Coretronic Corporation 7-4 H57
III.
IV.
Exploded Parts List of H57 Lamp Changer Module Coretronic Corporation 7-7 H57
V.
VI.
Exploded Parts List of H57 Optical Lens Module Coretronic Corporation 7-10 H57
VII.
VIII.
IX.
Exploded Parts List of H57 Engine Base Module Coretronic Corporation 7-14 H57
X.
XI.
XII.
XIII.
XIV.
XV.
XVI.
XVII.
XVIII.
XIX.
XX.
Appendix B Serial Number System Definition Serial Number Format for Projector A BBB 1 2 Y WW C D BEMO EEEE 3 4 5 6 7 1 : O = Optoma 2 : Product code (ex: 81D = H57, 896=EP759) 3 : Y = Last number of the year (ex: 2004 - 4) 4 : Week of year 5 : Panel vendor code 6 : Electrical classification (1=110V, 2=220V, 0=universal) 7 : B = BIOS version, E = PCB board version, 8 M = Mechanical version, O = Optical version 8 : Serial code (from 0001~) EX1 : O81D429T0AAAA1001 This label “O81D429T0
*Reader’s Response* Dear Readers: Thank you for your backing our service manual up. In order to refine our content of the service manual and satisfy your requirement. We expect you can offer us some precious opinions for reference. Assessment: A. What do you think about the content after reading H57 Service Manual? U ni t Excellent Good F ai r B ad 1. Introduction 2. Disassembly Procedure 3. Troubleshooting 4. Function Test & Alignment Procedure 5. Firmware Upgrade Procedure 6.
