Optoma DV20 Instruction manual

SERVICE MANUAL
Prepared: Check: Approved:
Date Revise Version Description
2010.11.25
V1.0 Initial Issue
DV20
Copyright Nov 2010. All Rights Reserved

DV20 Condential
I
Preface
This manual is applied to DV20 projection system. The manual gives you a brief
description of basic technical information to help in service and maintain the product.Your
customers will appreciate the quick response time when you immediately identify problems
that occur with our products. We expect your customers will appreciate the service that you
offer them.
This manual is for technicians and people who have an electronic background. Please
send the product back to the distributor for repairing and do not attempt to do anything that
is complex or is not mentioned in the troubleshooting.
Note: The information found in this manual is subject to change without prior notice. Any
subsequent changes made to the data herein will be incorporated in future edition.
DV20 Service Manual
Copyright Nov 2010
All Rights Reserved
Manual Version 1.0

DV20 Condential II
Table of Content
Chapter 1 Introduction
Highlight 1-1
Compatible Mode 1-2
Chapter 2 Disassembly Process
Equipment Needed & Product Overview 2-1
Disassemble Top Cover Module 2-2
Disassemble Speaker and Fan 2-4
Disassemble Main Board 2-4
Disassemble Audio Board and Format Board 2-5
Disassemble Engine Module 2-5
Chapter 3 Troubleshooting
Main Procedure 3-1
Chapter 4 Function Test & Alignment Procedure
Test Equipment Needed 4-1
Service Mode 4-1
System Reset 4-1
Test Condition 4-2
Test Inspection Procedure 4-3
Power and Led indicator 4-3
PC Mode 4-4
Video Performance 4-6
i-pod and iphone function test 4-7
Optical Performance Measure 4-7

DV20 Condential III
Others 4-9
Chapter 5 Firmware Upgrade
Equipment Needed 5-1
Firmware Upgrade Procedure 5-2
Chapter 6 EDID Upgrade
EDID introduction 6-1
Appendix A
Exploded Image I
Appendix B
   SerialNumberSystemDenition     XII
   PCBACodeDenition      XIII

DV20  1-1
Chapter 1
Introduction
No  
1        

2    
3 
      
       

   ""
7         

8



9
       


10          
11     
12        
13 




 



1-1 Highlight

DV20  1-2
1-2 Compatible Mode
Computer compatibility
Compatibility  V-Sync[Hz]

 
 
 
 
 

 
 
 

 
 
 
 

DV20 Condential 2-1
Chapter 2
Disassembly Process
2-1 Equipment Needed & Product Overview
1. Screw Bit (+): No.00
2. Screw Bit (+) :107
3. Screw Bit (-) :107
4. Hex Sleeves 5mm
5. DV20 Unit
* Before you start: This process is protective level II. Operators should wear electrostatic chains.

DV20 Condential 2-2
2-2 Disassemble Top Cover
Module
1. Unscrew 8 screws.(As red circles)
2. Unplug 3 cables.(As yellow squares)
3. Unplug the M/B to DOCK Board Cable
and M/B to Touchpad Board Cable.
M/B to DOCK Board Cable M/B to Touchpad Board Cable

DV20 Condential 2-3
4. Unscrew 2 screws(as blue circles) to
disassemble the touchpad holder,keypad
board and touchpad cover.
Touchpad Holder
Keypad Board
Touchpad Cover
5. Unscrew 4 screws and disassemble the
DOCK board.(As green circles)
6. Unscrew 1 screw and disassemble the
DOCK Spring.(As yellow circle)
DOCK Board

DV20 Condential 2-4
2-3 Disassemble Speaker
and Fan
1. Tear off the Mylar.(As red square)
2. Unscrew 4 screws(as red circles)
3. Unplug one cable and take out the
Speaker.(As yellow circle)
4. Unscrew 3 screws and take out the fan
and fan duct.
Note:The fan cable should be stuffed into
the gap when assemble the fan.
Fan Duct
Fan
Fan Cable
2-4 Disassemble Main Board
1. Unplug 4 cables.
a) 40P M/B TO FORMAT/B Cable
b) 20P M/B TO FORMAT/B Cable
c) 20P M/B to Audio/B Cable
d) 50MM M/B to Audio/B Cable
2. Unscrew 7 screws and then take out the
main board.(As red circles)
ab
cd

DV20 Condential 2-5
2-5 Disassemble Audio
Board and Format Board
1. Unscrew 4 screws and then take out the
audio board.(As red circles)
2. Unplug the 50 Pin FPC cable and
unscrew 5 screws and then take out the
format board.(As yellow square and blue
circles)
2-6 Disassemble Engine
Module
1. Unscrew 2 screws and one hex screw,
then take out the Engine Module.(As red
circles)
2. Unscrew 3 screws(As yellow circles) and
then pull out the focus ring as red arrow
direct.

DV20 Condential 2-6
4.Unscrew 2 screws and disassemble the
50 Pin FPC cable.(As red squares)
5.Unscrew 2 screws, disassemble the
engine holder and DMD chip.(As yellow
squares)
The disassemble process is over.
3. Unscrew 8 screws(as blue circles) and
disassemble 3 heatsinks.

DV20 Condential 3-1
Chapter 3
Trobleshooting
3-1 Main Procedure
No Symptom Procedure
1No Power
- Ensure the Power Cord and AC Power Outlet are securely con-
nected
- Ensure all connectors are securely connected and aren’t broken
- Check Format Board
- Check Main Board
- Check 40 Pin M/B to Format BD cable
- Check 20 Pin M/B to Format BD cableM/B to Format BD cable
2Auto Shut Down
- Check Fan
- Check Format Board
- Check Main Board
3No Light On
- Ensure all connectors are securely connected and aren’t broken
- Check Fan
- Check Format Board
- Check Main Board
- Check Engine Module
4 No Image
- Ensure the Signal Cable and Source work
(If you connect multiple sources at the same time, use the
"Source" button switch)
- Ensure all connectors are securely connected and aren’t broken
- Check Format Board
- Check Main Board
- Check 50 Pin FPC cable
- Check Engine Module
5 Mechanical Noise - Check Fan Module

DV20 Condential 3-2
No Symptom Procedure
6Line Bar/Line Defect
- Check whether the Main Board and the FPC Cable are
assembled properly
- Check Format Board
- Check Main Board
- Check 50 Pin FPC cable50 Pin FPC cable
- Check DMD Chip
7Image Flicker
- Ensure that the signal cables and source are work as well
- Check 50 Pin FPC cable
- Check Format Board
- Check Main Board
- Check Engine Module
8Color Abnormal
- Do "Auto Color" of the Service Menu
- Check Format Board
- Check Main Board
- Check 50 Pin FPC cable50 Pin FPC cable
- Check Engine ModuleEngine Module
9Poor Uniformity/
Shadow
- Ensure the projection screen without dirt
- Ensure the projection lens is clean
- Ensure the Brightness is within spec.
- Check Engine Module
10 Dead Pixel/Dust
(Out of spec.)
- Ensure the projection screen without dirt
- Ensure the projection lens is clean
- Clean DMD Chip and Engine Module
- Check DMD Chip
- Check Engine Module
- Check 50 Pin FPC cable
11 Garbage Image
- Ensure that the signal cables and source work as well
- Check Format Board
- Check Main Board
- Check Engine ModuleEngine Module

DV20 Condential 3-3
No Symptom Procedure
12
Remote
Controller/Control
Panel Failed
- Remote Controller
a. Check Battery
b. Check Remote Controller
- Control Panel
a. Check Touchpad Cable
b. Check Touchpad Board
c. Check Main Board
13
i-pad and iphone-
Function
Abnormal
- Ensure the i-pod & iphone and projector are securely connected
- Check DOCK Board
- Check DOCK Board to Main Board Cable
- Check Main Board
14 Audio Abnormal
- Ensure that the signal cables and source are working well
- Ensure that your Projector is not in “Mute” mode
- Check the interior Speakers of the projector
- Check the exterior Speaker that you are using
- Check Main Board
- Check Audio Board

DV20 Condential 4-1
Chapter 4
Function Test&Alignment Procedure
4-1 Test Equipment Needed
- DVD player with Multi-system (NTSC/PAL)
- Minolta CL-100
- Quantum Data 802B or CHROMA2327 (Color Video Signal & Pattern Generator)
- Remote control (P/N: 45.8GA01G001)
- iPod or i-Phone
4-2 Service Mode
1. Turn on the projector
2. Do the following actions sequentially to get into service mode
- Press "Menu -> Up -> Up -> Up -> Enter -> Menu"
- Service mode will be shown
- After conrming the conguration, choose "menu" to exit.
Note: The projector image will turn to black and all the LED indicator will extinguish if the projector
can not serach signal after 15 seconds.Please touch the keypad to awake it.
4-3 System Reset
After nal QC step, we have to erase all saved change.
The following actions will allow you to erase all
end-users’ settings and restore the default setting:
- Connect the VGA signal and then get into service mode.
- Choose “image” and then choose “Auto Color”,the “PASS“
will show after press Enter.Then choose “System Reset“,the
“Finish“ will show after press Enter.

DV20 Condential 4-2
4-4 Test Condition
4-4-1 Normal Test Condition
- Circumstance brightness: Dark room less than 2.0 lux
- Screen size: 20 inches
Screen Defects
Defect specication table
Order Symptom Pattern Criteria
1Dark pixel (dots) White pattern A+B≤4
2Unstable pixel (dots) Any pattern A+B=1
3 Adjacent pixel (dots) Any pattern A+B=0
4Bright pixel (dots) Gray 10 pattern A+B=0
5 Bright dot on frame Gray 10 pattern ≤1
Frame
< Figure: Zone A, Zone B & Frame (as green line) Denition, Active area=Zone A+ Zone B >

DV20 Condential 4-3
4-4-2 Burn-In Test
- Temperature: 15°C~35°C
- Circumstance brightness: Normal environment
- Screen size: No concern
- Display mode: ECO mode
After repairing DV20, it should be Burn-in (refer to the below table).
Symptom Burn-in Time
Normal repair 2 hours
NFF 4 hours
Auto shutdown 6 hours
- Get into Burn-In Mode
* Cycle setting is based on the defect symptoms. ie: If it is NFF, the burn-in time is 4 hours. You
have to set the lamp on for 50 min. and lamp off for 10 min for 4 cycles.
Note: Please make sure that the hot exhaust airows from projectors can ow towards the aisle.
Get into Service Mode (as above step 4-2)
Choose Burn In > enter
Lamp On (Min) Press right key to adjust the time (50)
Lamp Off (Min) Press right key to adjust the time (10)
Set Burning cycle Press right key to adjust the cycle
After setting up the time, choose ''Enter into Burn In Mode'' and press "Menu" button.
4-5 Test Inspection Procedure
- After changing parts, check the information below
Update Change parts
Main Board Module Engine Firmware
Version Update V V
Factory Reset V V
EDID V
Duty Selection V V

DV20 Condential 4-4
4-6 PC Mode
1. Bright Pixel
Note: Link Chroma VGA port to the VGA port of the projector
by VGA cable.
Procedure - Test equipment: video generator.
- Test signal: analog 1280x800@60Hz.
- Test Pattern: gray 10
Inspection item - Bright pixel check
Criteria - Bright pixel is unacceptable.
- No more than 1 bright pixel in the POM.
- Adjacent with each other is unacceptable.
2. Dark Pixel
Procedure - Test equipment: video generator.
- Test signal: Analog 1280x800@60Hz.
- Test Pattern: full white
Inspection item - Dark pixels check.
Criteria - The number of the dead pixels should be less or
equal to 4 pixels.
- Adjacent dark with each other is unacceptable.
Full white
Gray 10

DV20 Condential 4-5
3. Color performance
Procedure - Test equipment: Chroma 2327
- Test signal: Analog 1024x768@60HZ
- Test Pattern: 64 gray RGBW,master pattern
- Use test signal to do the test.
Color cannot discolor to purple and blue.
Inspection item - Check if each color level is well-functioned.
- Color saturations
Criteria - Screen appears normal. It should not have any
abnormal condition, such as lines appear on the
screen and so on.
- Color appears normal.
- RGBW should all appear normal on the screen
and sort from R-G-B-W.
- Color levels should be sufcient and normal.
64 gray RGBW
Master pattern