Optoma ES520 Instruction manual

Delta Elec. Inc. ES520 & EX530 ver.02
Company Confidential Optoma___________________ Delta________________
1 2008/09/17
DATA PROJECTOR
ES520 (DP-2512) & EX530 (DP-3511)
SERVICE MANUAL (ver.00)

Delta Elec. Inc. ES520 & EX530 ver.02
Company Confidential Optoma___________________ Delta________________
2 2008/09/17
DLP DIGITAL PROJECTOR
Model Name: ES520 & EX530
Revision Description Date
Ver.00 Primarily 03/07/2008
Ver.01 Revisedthesparepartlist 05/28/2008
Ver.02 Revisedthesparepartlist,changethemainboardPNto5600600785 09/17/2008

Delta Elec. Inc. ES520 & EX530 ver.02
Company Confidential Optoma___________________ Delta________________
3 2008/09/17
CONTENTS
1.COMPLIANCE OF SAFE REPAIR.........................................................................................5
1-1.Caution During Disassembling And Assembling.............................................................5
1-2.Lamp..............................................................................................................................5
1-3.Lens................................................................................................................................5
1-4.Eye Safety Warnings......................................................................................................6
2.SPECIFICATIONS.................................................................................................................7
2-1.Summary Specifications................................................................................................. 7
2-2.DMD Specifications........................................................................................................ 8
2-3.Color Wheel................................................................................................................... 8
2-4.Lamp..............................................................................................................................8
2-5.Input/output connectors…………………………………………………………………….…8
2-6.I/O Ports Illustration........................................................................................................9
2-7.Remote Control Parts...................................................................................................10
2-8.Key Pad-Top view and LEDs…………………………………………………...………….. 12
2-9.Optical Adjustment & Image Size (ES 520)…….………………………………………....13
2-10. Optical Adjustment & Image Size (EX 530)………………………………………….….14
2-11.BLOCK DIAGRAM..................................................................................................... 16
2-12. Wire diagram………………………………………………………………………………..17
3.TROUBLE SHOOTING....................................................................................................... 18
4.DISASSEMBLY AND ASSEMBLY (ES 520)....................................................................... 25
.. DISASSEMBLY AND ASSEMBLY (EX 530)....................................................................... 41
5.Flash Upgrade Flow............................................................................................................ 58
5-1.Projector USB Drivers Installation Guide…………………………………………………..58
Appendix-A How to clear the USB enumeration registry?............................................67
Appendix-B Projector USB status on Windows Device Manager………………………69
5-2.DLP Projector Flash-Tool (firmware) User Guide…………………….……….…………..70
5-3.Start with Flash-Tool………………………………………………………………………....71
5-4.Starting and Shutting down the Projector……………………………………………….....76
5-5.Setting an Access Password (Security Lock)………………………………….…………..77
5-6.SETUP / Advanced………………………………………………………………………..…81
5-7.Security Timer………………………………………………………………………………...82
5-8.Options Menu…………………………………………………………………………………83
5-9.OPTIONS / Advanced…………………………….………………………………………….84

Delta Elec. Inc. ES520 & EX530 ver.02
Company Confidential Optoma___________________ Delta________________
4 2008/09/17
6. Calibration…………………………….………………………………………….………………..85
7. Color Border Adjustment………………………………………………………………………...91
8. Projection Lamp…………………………………………………………………………………..92
9. Cleaning…………………………………………………………………………………………...95
10.SERVICE NOTE............................................................................................................... 96
10-1.Service Note Description........................................................................................... 96
10-2.Power & READY LED Blink Code Message.............................................................. 97
10-3.Factory Preset Display Modes................................................................................... 98
11.Spare Part List ................................................................................................................ 100

Delta Elec. Inc. ES520 & EX530 ver.02
Company Confidential Optoma___________________ Delta________________
5 2008/09/17
1. COMPLIANCE OF SAFE REPAIR
Be sure to read this Service Manual before providing services. In the projector, full
consideration is taken to ensure safety for fire, electric shock, injury, harmful radiation, and
substance. Therefore, observe the notice described in this Service Manual so that safety is
kept when providing services. Moreover, be sure to observe the notice described in the
Instruction Manual.
Pay attention to the following items during service inspection.
1-1 Cautions during disassembling and assembling
1. This equipment contains parts under high voltage. When making repairs, etc.
Be sure to pull out the power plug beforehand to insure safety.
2. Parts may be very hot immediately after use.
Make sure the equipment has cooled off sufficiently before carrying out repairs.
3. Make sure that parts and screws and wiring, etc. are returned to their original positions.
Tube, tape and other insulation materials have been used for safety reasons.
The internal wiring has been designed to avoid direct contact with hot parts or parts under
high voltage when using clamps or other tools.
4. The parts used in this device have special safety features such as flame-resistance and
anti-voltage properties. When replacing parts, always use parts supplied from the factory.
5. After finishing operations make sure that all parts and wires have been returned to their
original position and that there has been no deterioration of the area around the location that
was worked on.
6. Be sure to use a grounding strap (wrist band) during repair and inspection.
1-2 Lamp
During current conduction, the lamp is in the high-temperature state. In this case, pay
careful attention because a high voltage is used. When replacing a lamp, replace it after
confirming that the lamp has gotten cold sufficiently.
1-3 Lens
Do not look into a lens during projection. This damages your eyes.

Delta Elec. Inc. ES520 & EX530 ver.02
Company Confidential Optoma___________________ Delta________________
6 2008/09/17
1-4 Eye Safety Warnings
1.Avoid staring directlyinto the projector’s beam of light at all times.
2.Minimize standing facing into the beam. Keep your back to the beam as much as
possible.
3.Using a stick or laser pointer is recommended to avoid the need for the presenter
to enter the beam.
4.Ensure that projectors are located out of the line of sight from the screen to the
audience; this ensures that, when presenters look at the audience, they do not also
have to stare at the projector lamp.
5.The best way to achieve this is by ceiling-mounting the projector rather than placing it
on floor or table top.
6.When projector is used in a classroom, adequately supervise students when they are
asked to point out something on the screen.
7.In order to minimize the lamp power needed, use room blinds to reduce ambient light
levels.

Delta Elec. Inc. ES520 & EX530 ver.02
Company Confidential Optoma___________________ Delta________________
7 2008/09/17
2. SPECIFICATIONS
2-1. Summary Specifications
Model ES520 (DP-2512) EX530 (DP-3511)
Display type TIDMDTypeA,12° 0.55inches,SVGADarkChip1
TIDMDTypeA,12° 0.55inches,XGADarkChip2
Resolution SVGA 800X600 Native (4:3) XGA 1024x768 Native (4:3)
Color Brilliant Color
Projection distance 1.5 meters ~ 10 meters 1.0 meters ~ 10 meters
Projection screen size
36” to 243” (overdrive to 300”) 23” to 255” (overdrive to 300”)
Projection lens Manual focus Manual focus / Manual zoom
Thro 1.15:1
Vertical keystone
correction +/- 15 degrees ; +/- 30 vertical stepping in OSD
Projection methods Front / Rear-Desktop & Front / Rear-Ceiling
Data compatibility IBM PC or compatibles
(VGA, SVGA, XGA, SXGA, UXGA), Mac
SDTV/EDTV/ HDTV 480i/576i, 480p/576p, 720p, 1080i
Video compatibility NTSC/NTSC 4.43, PAL/PAL-M/PAL-N,SECAM
H-Sync 15, 30 – 91.4 KHz
V-Sync 43 - 87 Hz
Safety certification
FCC (class B), UL/CUL, ICES-003(Class B), CE, TUV-GS, CB report, CCC, EK, PSB
Operation temperature
5°~ 35°C
Dimensions / Weight 280 mm (W) x 80 mm (H) x 205 mm (D) / 5.6lb (2.5kg)
AC Input AC Universal 110 ~ 240 @50~60Hz , Typical @110 VAC (100~240)/±10%
Power consumption Typical 230W (standard mode); Typical 200W (ECO mode)
Stand By
< 5 watts @ 110Vac
Lamp E20.6 / 180W
Audio speaker 1W / 8 ohm mono speaker
PC VGA in (Compatible with HDTV component YPbPr / SCART)
Composite video (RCA X 1)
Video
S-Video (DIN)
Audio Input: R / L (RCA X 2) , Out: Mini-Jack X 1
Security Kensington lock

Delta Elec. Inc. ES520 & EX530 ver.02
Company Confidential Optoma___________________ Delta________________
8 2008/09/17
2-2.DMD Specifications
Unit Min. Max.
Typical Notes
DMD type (ES520) TI 0.55" SVGA 12 deg LVDS Type A
Dark chip 1
Number of Columns (ES520) Pixel
800
Number of Rows (ES520) Pixel
600
DMD type (EX530) TI 0.55" XGA 12 deg LVDS Type A Dark chip 2
Number of Columns (EX530) Pixel
1024
Number of Rows (EX530) Pixel
768
Panel Operating Temp. ℃10 65
Ambient Temp ℃25
2-3.Color Wheel
Spec. Unit Min. Max.
Typical Notes
Color Segment RYGWB 82/29/80/91/78 (44mm)
2-4. Lamp
Description
Vendor OSRAM
Type E20.6 180W
Standard Mode , 3000 Hours Standard @ 180W, 50% Survival Rate
Lamp Life ECO Mode , 4000 Hours Typical @ 150W, 50% Survival Rate
Normal: 180W±3%@Vo from 50V to 120V
Lamp Power ECO: 150W±3%@Vo from 50V to 120V
2-5. Input/output connectors
VGA in (Compatible with HDTV component YPbPr / SCART)
PC USB (Service Only)
Composite video (RCAx1)
Video S-Video (Mini-DIN)
RS232 DB9
Audio Input: R / L (RCA X 2) , Out: Mini-Jack X 1
Security Kensington slot

Delta Elec. Inc. ES520 & EX530 ver.02
Company Confidential Optoma___________________ Delta________________
9 2008/09/17
2-6. I/O Ports Illustration about Projector
Note:
If your video equipment has both S-VIDEO and RCAjacks (composite video) connect to the
S-VIDEO connector. S-VIDEO provides a better quality signal

Delta Elec. Inc. ES520 & EX530 ver.02
Company Confidential Optoma___________________ Delta________________
10 2008/09/17
2-7. Remote Control Parts
Important:
1. Avoid using the projector with bright fluorescent lighting turned on. Certain high-frequency
fluorescent lights can disrupt remote control operation.
2. Be sure nothing obstructs the path between the remote control and the projector. If the path
between the remote control and the projector is obstructed, you can bounce the signal off
certain reflective surfaces such as projector screens.
3. The buttons and keys on the projector have the same functions as the corresponding
buttons on the remote control. This user’s manual describes the functions based on the remote
control.

Delta Elec. Inc. ES520 & EX530 ver.02
Company Confidential Optoma___________________ Delta________________
11 2008/09/17
Remote Control Operating Range
The remote control uses infrared transmission to control the projector. It is not necessary to
point the remote directly at the projector. Provided you are not holding the remote
perpendicular to the sides or the rear of the projector, the remote will function well within a
radius of about 10 meters (33 feet) and 30 degrees above or below the projector level.

Delta Elec. Inc. ES520 & EX530 ver.02
Company Confidential Optoma___________________ Delta________________
12 2008/09/17
2-8. Key Pad -- Top view and LEDs

Delta Elec. Inc. ES520 & EX530 ver.02
Company Confidential Optoma___________________ Delta________________
13 2008/09/17
2-9. Optical Adjustment & Image Size (ES 520)
Adjusting the Focus (Fixed Zoom Series)
The Fixed Zoom Series’ lens is fixed and does not provide a zoom function.
To focus the image, rotate the focus ring until the image is clear.
The projector will focus at distances from 4.9 to 40 feet (1.5 to 12.2 meters).
Adjusting Projection Image Size

Delta Elec. Inc. ES520 & EX530 ver.02
Company Confidential Optoma___________________ Delta________________
14 2008/09/17
2-10. Optical Adjustment & Image Size (EX 530)
Adjusting the Zoom / Focus (Zoom Series)
You may turn the zoom ring to zoom in or out.
To focus the image, rotate the focus ring until the image is clear.
The projector will focus at distances from 4.9 to 40 feet (1.5 to 12.2 meters).
Adjusting Projection Image Size

Delta Elec. Inc. ES520 & EX530 ver.02
Company Confidential Optoma___________________ Delta________________
15 2008/09/17

Delta Elec. Inc. ES520 & EX530 ver.02
Company Confidential Optoma___________________ Delta________________
16 2008/09/17
2-11. Block Diagram

Delta Elec. Inc. ES520 & EX530 ver.02
Company Confidential Optoma___________________ Delta________________
17 2008/09/17
2-12. Wire diagram

Delta Elec. Inc. ES520 & EX530 ver.02
Company Confidential Optoma___________________ Delta________________
18 2008/09/17
3. TROUBLE SHOOTING
By checking operations during normal usage time, it is possible to carry out judgments on
malfunction to a certain extent. Carry out the following checks before disassembling the
equipment.
Waiting
Power On
No
No
Yes
Yes
Connect the power cord
POWER: Light
READY : Light
Standy-by-ready
POWER
:
7
Blinks
Over Temp LED
:
ON
• Cable of Power Supply Unit and thermostatAss’y.
•
Check the connection of Power Supply (CON900 to CN201)
• Power Supply Unit malfunction
• Check keypad connection
•Lamp Cover A’ssy is not attached
•Switch (CN343) is open
•Connector (CN342) disconnected.
•Thermal sensor PWB Ass’y check.
Yes
Press
“
power key
”
POWER: Light
READY : OFF
Power ON
No
POWER:8 Blinks
•DMD chip error.
•DMD Board PWB Ass’y check.
Yes
Yes
Yes
Yes
No
No
No
No
No

Delta Elec. Inc. ES520 & EX530 ver.02
Company Confidential Optoma___________________ Delta________________
19 2008/09/17
Yes
Yes
Yes
Yes
No
LAMP：
：：
：3 Blinks
LAMP：
：：
：2
Blinks
POWER
:
4
Blinks
POWER: 6 Blinks
POWER: 7
Blinks
• Connector CN340 of Fan disconnected
• Power fan malfunction
•Thermal Break Sensor error
•Thermal Break Sensor disconnected.
• Connector CN341 of Fan disconnected
• Blower fan malfunction
•Lamp Cover is not attached.
•Switch (CN343) is open malfunction
Yes
POWER:
9
Blinks
Lamp does not light：
No lighting operation sound (ignition sound) exists.
• Flexible cable of Color Wheel Ass’y is disconnected
(CN373) or
broken.
• Color Wheel Ass’y malfunction (does not rotate).
• Main BoardAss’y malfunction (Color Wheel Ass’y does not rotate).
•Power Supply Unit malfunction.
• Index board malfunction (color wheel turns fast).
• C/W sensor PWBAss’y (CN7) / MB PWB (CN503) is disconnected
or broken.
POWER:5 Blink
Lamp does not light：
lighting operation sound (ignition sound)
exists.
• Main Board and Ballast BoardAss’y malfunction
• Ballast Connector (CJ4) or LVPS unit (CJ1) or
MB(CN572)disconnected
• Lamp failure (Lamp is broken, damaged, or burst)
The lamp is ON
Turn the
power ON
Image
Display
No
No
No
No
Yes
No
• Connector CN344 of Fan disconnected
• Lamp fan malfunction
LAMP：
：：
：1
Blinks
Yes
No
No
No
No
No

Delta Elec. Inc. ES520 & EX530 ver.02
Company Confidential Optoma___________________ Delta________________
20 2008/09/17
Confirmation with none-signal state
Yes
No
No
No
Yes
No
Yes
Projector logo
screen display
Yes
• CW Sensor Board Ass’y malfunction
• Main Board Ass’y malfunction
•
DMD Set malfunction
Still dark after the
lamp is on for more
than 1min
• Lamp deterioration (malfunction/usage time)
• Power Supply Unit malfunction
(No change occurs even after lamp replacement.)
• DMD Set malfunction
(No change occurs even after lamp replacement.)
Menu display
• Remote controller set malfunction, Low battery,
and outside operation rang
• Main Board Ass’y malfunction
• Connector (CN374) 、 (CN8 of IR PWB) disconnected
• IR PWB Ass’y malfunction
• Check the pattern generator setting is wrong
• Main Board Ass’y malfunction
• DMD Set malfunction
• Setting on PC side(external output settin
g, resolution, etc.)
• Cable malfunction (disconnection and pins broken)
• Connector (CN304) disconnected
• Speaker Ass’y malfunction
• Main Board Ass’y malfunction
Check the
projection
Screen
I
mage
display
normally
Input each signal
Speaker work
normally
Image
Display
No
Yes
Yes
Yes
No
No
No
No
No