Optoma EP735 User manual

SERVICE MANUAL
EzPro735
EzPro735
This manual is prepared for the maintenance service for EP735 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. This product may not, in
whole or in part, be copied, photocopied, translated or reduced to any electronic or machine
readable form without prior written consent except for copies retained by the purchaser for
backup purpose.
This manual includes system overview, major system assembly, components’
description, and the “Troubleshooting” making explanations on how to detect errors. It also
includes a flow chart for checking or correcting faults.
No warranty or representation, either expressed or implied, is made with respect
to this documentation, its quality, performance, merchantability or fitness for
particular purpose.
No event that the vendor will be liable for direct, indirect, special, incidental or
consequential damages arising out of the user or inability to use this product or
documentation.
✍NOTICE :
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
further edition.
Copyright 2001, July
AllRightsReserved
Manual Version 1.0
Doc.#834-G04-01A
P/N : 36.83403.001
Preface

SERVICE MANUAL
EzPro735
EzPro735
4TABLE OF CONTENTS 3
1. Introduction 1-1
1-1 Product Features 1-2
1-2 Technical Specification 1-3
2. Fundamental Principle 2-1
2-1 BlockDiagram 2-2
2-2 Optics 2-6
3. Mechanical Construction 3-1
3-1 Package Overview 3-2
3-2 Exploded Overview 3-4
3-3 Recommendation Spare Parts List 3-10
4. Procedure of Disassembly 4-1
4-1 Disassemble Top Cover and Speaker 4-2
4-2 Disassemble Main Board and DC-DC Module 4-3
4-3 Disassemble Engine, Formatter Board and Thermal Board 4-5
4-4 Disassemble Ballast Module 4-8
4-5 Disassemble Fan Modules 4-9
4-6 Disassemble Lamp Module 4-11
4-7 Disassemble Base Housing 4-13
5. The Function of Boards 5-1
5-1 Main Board 5-2
5-2 Formatter Board 5-10
5-3 IR Board 5-16
5-4 DC-DC Power 5-17
5-5 Thermal Board 5-19
5-6 Ballast 5-24

SERVICE MANUAL
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EzPro735
6. Specifications 6-1
6-1 Lamp Specifications 6-2
6-2 DMD Specifications 6-4
6-3 ScreenDefects 6-7
6-4 DC-DC Specifications 6-9
6-5 LampDriver Specifications 6-10
7. Troubleshooting Procedure 7-1
7-1 EquipmentNeeded 7-2
7-2 Main Procedure 7-2
8. Function Test and Alignment Procedure 8-1
8-1 EquipmentNeeded 8-2
8-2 Test Condition 8-2
8-3 Test Display Modes and Pattern 8-3
8-4 Inspection Procedure 8-7
9. Firmware Upgrading Procedure 9-1
9-1 EquipmentNeeded 9-2
9-2 Setup Procdure 9-2
9-3 Upgrading Procdure 9-3
10. DDC Key-In Procedure 10-1
10-1 EquipmentNeeded 10-2
10-2 Setup Procdure 10-2
10-3 Upgrading Procdure 10-3
11. Appendix 11-1
11-1 SerialNumber Format 11-2

SERVICE MANUAL 1 - 1
EzPro735
EzPro735
Chapter 1
This manual is applied to EP735 0.7”*1 DMD XGA Micro Portable
Projector with digital imaging functionality based on Digital Micromirror
Device (DMD) technology. It’s the mode of single panel, 130 watt Compact
P-VIP lamp and 1024*768 resolution. The manual gives you a brief
description of basic technical information to help in service and maintaining
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. 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.
INTRODUCTION

SERVICE MANUAL 1 - 2
EzPro735
EzPro735
1-1 Product Highlights
uOne panel 0.7” DMDprojection system with 820 ANSI lumens (Average),
75% uniformity (Min.)
u130-Watt Compact P-VIP Lamp (user replaceable)
uHigh efficiency cooling system with system acoustic noise level 38dBA(Average)
uLight weight less than 3.4 lbs
uManual focus projection zoom lens
uTrue 1024*768 resolution, True colors
uWith up, down, left, and right screen reverse
uBuilt-in full screenNTSC/PAL/SECAM video capability with S-video/composite/
component and HDTV terminals
uSXGA/XGA/SVGA/VGA/MAC/PC98/FM Towns compatibility with XGA
compression/pan
uAuto image re-sizing to 1024*768 full screen
uAuto detection of computer signal input
uAuto image. (Auto-tracking/frequency/position adjustment)
uPowerful enlarge and freeze function
uAutomatically saves adjustments for furture use
uOn-screen menu with 9 languages
uOn-screen lamp life timer
uOneDVI PC-data input (IncludingAnalog andDigital RGAsignal)
uBuilt-in one speaker with 2-Watt amplifier
uSelf protect (15 seconds) timer for hot re-strike of compact P-VIP lamp
uWireless remote controller/mouse
uAdaptive voltage control fan speed

SERVICE MANUAL 1 - 3
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EzPro735
1-2 Technical Specification
1-2.1 Optical Features
Technology Digital Light Processing™ (DLP™) technology
by Texas Instruments
Resolution 1024*768 XGA, True color
Brightness 820ANSI Lumens (Average)
700ANSI Lumens (Minimum)
Contrast Ratio 300:1 (Full White and Black)
Uniformity 50% (ANSI standard)
60% (3*3)
75% (Japan standard)
Displayable Color 16.7 Milion colors
ColorTemperature 6500oK~9000oK
Projection Lens f =28.51~34.21mm, F/2.2~2.4
ZoomFactor 1.2X , Manual
Projection Screen Size Adjustable from 20.5” to 246” Diagonal
Throw Distance 1.0m to 12m

SERVICE MANUAL 1 - 4
EzPro735
EzPro735
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ThrowRatio 2.17~2.94(ProjectionDistance/Image Width)
Horizontal Scan Rate 15~100 kHz
Vertical Refresh Rate 43~120 Hz
Pixel Frequency 140 MHz
Aspect Ratio 4:3, 16:9 (wide screen) compatible
VideoCompatibility Standards : NTSC (M, 4.43 MHz)
PAL ( B,D,G, H, I, M, N )
SECAM (B, D, G, K, K1, L)
HDTV ( 1080i , 720P , 480i/P )
TV Lines : 500 lines
PowerSupply UniversalAC 100-240V,AC 50/60Hz with PFC input (SRAM)
130W for 130W Compact V-VIP Lamp @ normal operation
Variance FAN speed control (Depend on temperature variant)
Audio One 8-Ohm, 2W, internal speaker
3-Watt amplifier
Input sensitivity 0.3Vrms.
1-2.2 Electrical Features

SERVICE MANUAL 1 - 5
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EzPro735
Dimension (W x H xD) 8.86*6.93*2.0” / 225*176*52mm
Keystone Correction ± 16 degrees
Weight Approx. 3.46 lbs (1.572 Kg)
LampDoorProtection Lamp Power Supply shut off automatically when door open
1-2.3 Mechnical Features
Temperature Operating : 10°C~40°C / 50°F~104°F
Storage : -20°C~60°C / -4°F~140°F
Humidity Operating : 10°C~40°C, 80%RH (Max.), non-condensing
Storage : -20°C~60°C, 80%RH (Max.), non-condensing
Acoustic Noise Level 38dBA (Average, under 25oC)
Less than 40dBA(Minimum)
Lamp Life 1,000 hours Min. 70% survival rate
1,500 hours typical, 50% survival rate
Altitude Operating : 10,000 ft
Storage : 40,000 ft
MTBF Operating : more than 10,000 hours (80% confidence level)
1-2.4 Environmental Features
Regulation FCC Part 15 Class B
CE --- Class B
VCC --- Class B
UL
CUL
TUV —GS
1-2.5 Regulation Features

SERVICE MANUAL 2 - 1
EzPro735
EzPro735
Chapter 2
FUNDAMENTAL PRINCIPLE
This section provides the conceptual drawing about optics of projector.
You can realize optical projection system through the following diagram and
the integral part of configuration, too.

SERVICE MANUAL 2 - 2
EzPro735
EzPro735
2-1 Block Diagram
Speaker
D-subOutput
IR Receiver
S-Video
Video
Audio
DVI
Mouse
Input
Main
Board
DMD
Board
DMD
DC toDC
Inter Lock Switch
Thermal
Board
Fan
Ballast
Thermal
Switch
Sensor
Board
Projection Lens
Mirror
Condenser
Hollow Rod
Color Wheel
UV-IRL3
Lamp
Condenser
Keypad
Board
Mirror

SERVICE MANUAL 2 - 3
EzPro735
EzPro735
2-1.1 Main Board Block Diagram
GVS
GHS
GCOAST
GCLK
GBLKSPL
GRE(0..7)
GRO(0..7)
GGE(0..7)
GGO(0..7)
GBE(0..7)
GBO(0..7)
GCLK
GVS
GHS
GFBK
GRE(0..7)
GGE(0..7)
GBE(0..7)
Switch
GFBK
DE
SCL
SDA
DE
SCL
SDA
Y(0..7)
UV(0..7)
Speaker±
GCOAST
GCLK
GBLKSPL
GFBK
GRE(0..7)
GRO(0..7)
GGE(0..7)
GGO(0..7)
GBE(0..7)
GBO(0..7)
DRE(0..7)
GGE(0..7)
DBE(0..7)
TEMPER
SCL
SDA
TXD
RXD
Switch
Y(0..7)
UV(0..7)
Standby RESET 7SEC KEY(1..7) DCLK MCLK
Standby
RESET
7SEC
KEY(1..7)
DCLK
MCLK
BOOTWE
A(0..5)
VPPEN
D(0..5)
ROMOEN
ROMWEN
DRE(0..7)
GGE(0..7)
DBE(0..7)
TEMPER
SCL
SDA
TXD
RXD
PWRGOOD
IR-ONOFF
LAMPEN
-RESET
BOOTWE A(0..5) VPPEN D(0..5) ROMOEN ROMWEN
-RESET PWRGOOD IR-ONOFF LAMPEN
Memory
Image Processor
ADC
Digital Receiver
Video
Audio Speaker
DMDModule
MIS
GHS
GVS

SERVICE MANUAL 2 - 4
EzPro735
EzPro735
2-1.2 Thermal Board Block Diagram
THERMALBOARDInterface +12V*1
+5V*2
+3.3V*2
GND
LAMPEN (RESETZ)
CWINDEX
LAMPLIT
Power on/off (only 5V, 15V)
3P Connector
3P Connector*3
2P Connector
4P Connector*2
14P Connector
PHOTO
SENSOR
FAN1-13
THERMAL
SWITCH
THERMAL
SENSOR
DC TODC POWER SUPPLY
+15VSBY
+5VSBY
+3.3VSBY
LAMPLIT_IN 30P Connector
to Formatter Board
LAMPEN_OUT

SERVICE MANUAL 2 - 5
EzPro735
EzPro735
2-1.3 Formatter Board Block Diagram
Customer Interface Connector
CONTROL
FPGA
CONFIG/
SEQUENCE
PROM
MICRO
CONTROLLER
ALLEGRO
MOTOR
CONTROL
VCC2,VOFFSET,VBIAS
VERSETGENERATION
COLOR
WHEEL
DRIVE
DATAPATH
FORMATTER
DPF2A
CLOCK
OSC
VSYNCZ
HSYNCZ
ACTDATA
SYNCVAL
TFIELD
FPGA CLK
DPF2A CONTROL
LAMP CONTROL&STATUS
COLOR WHEEL INDEX
OLACT
INPUTCLK
FLASH
PROGRAMMING
HEADER
HITACHI
DOWNLOAD
HEADER
CLKIN
IIC BUS
VSYNCZ, RESETZ
CWRSTZ
DMD CONTROL
MEMORY CONTROL B
MEMORY ADDRESS B (12)
MEMORYADDRESS A (12)
MEMORY CONTROL A
DMD CONTROL
PBUS2
BIAS/RESET CONTROL
BIAS BIN
VOLTAGE ENABLES
+5V+12V
U504
U6
U13
COLOR
WHEEL
CONTROL
COLOR WHEEL STATUS
U2
SDRAM
ASDRAM
B
FPGA CLK
DMDCLK
SDRAM CLK
DMDDATA(0..63) DATA (0..63)
DMD
0.7”XGA
MBIASRST(16)
VRESET
VBIAS
VCC2(ASIC)
VOFFSET
VCC2 (DMD)
RESETASIC
ADDRESS(19)
DATA(8)

SERVICE MANUAL 2 - 6
EzPro735
EzPro735
3
10
2-2 Optics
2-2.1 Conceptual Drawing
1. OSRAM Elliptical Reflector 6. Condenser Lens 2
UHPLamp 120W 7. Enhance Mirror
2. UV-IR Filter 8. Field Lens
3. Color Wheel 9. Projection Zoom Lens
4. Hollw Integratin Rod 10. DMDModule
5. Condenser Lens 1

SERVICE MANUAL 2 - 7
EzPro735
EzPro735
2-2.2 Basic Functions
◆Elliptical Reflector The light source.
UHP Lamp 120W
◆UV-IR Filter Filtering UV-IR out.
◆Color Wheel Separating the light beam into and produce
R.G.B colors.
◆Hollow Making the light beam uniform.
Integration Rod
◆Condenser Lens Condensing the light beam.
◆Enhance Mirror Folding optical path.
◆Projection Zoom Lens Projecting image on the screen
◆DMD Module Displaying component.

SERVICE MANUAL 3 - 1
EzPro735
EzPro735
Chapter 3
MECHANICAL CONSTRUCTION
This section provides the package and exploded overview, replaceable
parts list and recommendatiom parts list for the portable projector. You can
place an order for correct parts in the recommendation parts list.

SERVICE MANUAL 3 - 2
EzPro735
EzPro735
3-1 ackage Overview

SERVICE MANUAL 3 - 3
EzPro735
EzPro735
3-1.1 Replacement Parts List
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SERVICE MANUAL 3 - 4
EzPro735
EzPro735
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in blue color is deleted.

SERVICE MANUAL 3 - 5
EzPro735
EzPro735
3-2 Exploded Drawing