Optoma ES522 Instruction manual

Delta Elec. Inc. ES522 & EX532
Company Confidential Optoma___________________ Delta________________
1
2009/06/30
DATA PROJECTOR
ES522 (DP-2400) & EX532 (DP-3400)
SERVICE MANUAL

Delta Elec. Inc. ES522 & EX532
Company Confidential Optoma___________________ Delta________________
2
2009/06/30
CONTENTS
1.COMPLIANCE OF SAFE REPAIR.........................................................................................4
1-1.Caution During Disassembling And Assembling.............................................................4
1-2.Lamp.............................................................................................................................. 4
1-3.Lens................................................................................................................................4
1-4.Eye Safety Warnings......................................................................................................5
2.SPECIFICATIONS.................................................................................................................6
2-1.Summary Specifications................................................................................................. 6
2-2.DMD Specifications........................................................................................................ 7
2-3.Color Wheel................................................................................................................... 7
2-4.Lamp.............................................................................................................................. 7
2-5.Input/output connectors…………………………………………………………………….…7
2-6.Main Unit View………………………………………………………………………………....8
2-7.I/O Ports Illustration........................................................................................................9
2-8.Remote Control Parts...................................................................................................10
2-9.Key Pad-Top view and LEDs…………………………………………………...………….. 12
2-10.Optical Adjustment & Image Size (ES 520)…….…………………………………..…....13
2-11. Optical Adjustment & Image Size (EX 532)………………………………………….….14
2-12.BLOCK DIAGRAM..................................................................................................... 16
2-13. Wire diagram………………………………………………………………………………..17
3.TROUBLE SHOOTING....................................................................................................... 18
4.DISASSEMBLY AND ASSEMBLY (ES 520)....................................................................... 26
.DISASSEMBLY AND ASSEMBLY (EX 532)....................................................................... 43
5.Flash Upgrade Flow............................................................................................................ 61
5-1.Projector USB Drivers Installation Guide…………………………………………………..61
Appendix-A How to clear the USB enumeration registry?............................................70
Appendix-B Projector USB status on Windows Device Manager………………………72
5-2.DLP Projector Flash-Tool (firmware) User Guide…………………….……….…………..73
5-3.Start with Flash-Tool………………………………………………………………………....74
5-4.Starting and Shutting down the Projector……………………………………………….....79
5-5.Setting an Access Password (Security Lock)………………………………….…………..80
5-6.SETUP / Advanced…………………………………………………………………...…...…83
5-7.Security Timer………………………………………………………………………………...84
5-8.Options Menu…………………………………………………………………………………85

Delta Elec. Inc. ES522 & EX532
Company Confidential Optoma___________________ Delta________________
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2009/06/30
5-9.OPTIONS / Advanced…………………………….………………………………………….86
6. Calibration…………………………….………………………………………….………………..87
7. Color Border Adjustment………………………………………………………………………...93
8. Projection Lamp…………………………………………………………………………………..94
9. Cleaning…………………………………………………………………………………………...97
10.SERVICE NOTE............................................................................................................... 98
10-1.Service Note Description........................................................................................... 98
10-2.Power & READY LED Blink Code Message...............................................................99
10-3.Factory Preset Display Modes..................................................................................100
11. RS-232 Command……………………………………………………………………………..102
12. EDID………………………………………………………………………………………….....106
13. Spare Part List ...............................................................................................................122
Update History
No. Description Date
1 Primarily 05/20/2009
Update the photos on the cover of service manual (p1)
Lamp spec update to ‘E20.8’ (P6,7)
Add EX532 VGA2 port from VGA2/SCART/YPbPr (p7)
Add VGA Out (p7)
Change Keypad diagram (p12)
2
FW upgrade program suitable is for DDP2000/2230/2430/2431 (p61,73)
06/30/2009

Delta Elec. Inc. ES522 & EX532
Company Confidential Optoma___________________ Delta________________
4
2009/06/30
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. ES522 & EX532
Company Confidential Optoma___________________ Delta________________
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2009/06/30
1-4 Eye Safety Warnings
1.Avoid staring directly into 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. ES522 & EX532
Company Confidential Optoma___________________ Delta________________
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2009/06/30
2. SPECIFICATIONS
2-1. Summary Specifications
Model ES522 (DP-2400) EX532 (DP-3400)
Display type TI DMD Type A,LVDS,12° 0.55inches TI DMD Type A,LVDS,12° 0.55inches
Resolution SVGA 800X600 Native (4:3) XGA 1024x768 Native (4:3)
Color Brilliant Color
Projection distance 1.25 meters ~ 8.15 meters 1.35 meters ~ 11.75 meters
Projection screen size 30” to 200” 30” to 300”
Projection lens Manual focus Manual focus / Manual zoom
Throw ratio 2 1.93 ~ 2.16
Vertical keystone
correction +/- 15 degrees (depend on input signal)
Projection methods Front / Rear-Desktop & Front / Rear-Ceiling
Data compatibility IBMPCorcompatibles
(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 < 1 watts @ 110Vac / 60Hz
Lamp E20.8 / 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. ES522 & EX532
Company Confidential Optoma ______________________ Delta____________
7 2009/06/30
2-2.DMD Specifications
Unit Min. Max. Typical Notes
DMD type (ES522) TI 0.55" SVGA 12 deg LVDS Type A
Number of Columns (ES522) Pixel 800
Number of Rows (ES522) Pixel 600
DMD type (EX532) TI 0.55" XGA 12 deg LVDS Type A
Number of Columns (EX532) Pixel 1024
Number of Rows (EX532) 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 E20.8 180W
Standard Mode , 3000 Hours Standard @ 180W, 50% Survival Rate
Lamp Life
ECO Mode , 4000 Hours Typical @ 160W, 50% Survival Rate
Normal: 180W±3%@Vo from 50V to 120V
Lamp Power ECO:
160W±3%@Vo from 50V to 120V
2-5. Input/output connectors
V
GA1 in (Compatible with component YPbPr / SCART)
V
GA2 in (Compatible with component YPbPr / SCART) – EX532 only
V
GA Out
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. ES522 & EX532
Company Confidential Optoma ______________________ Delta____________
8 2009/06/30
2-6. Main Unit View
1. Control Panel 8. Front IR Receiver
2. Zoom (EX532 only) 9. Rear IR Receiver
3. Focus 10. Kensington™ Lock
4. Lens 11. Tilt-Adjustment Foot
5. Lens CAP 12. Input/Output Connections
6. Elevator foot 13. Power Socket
7. Elevator button

Delta Elec. Inc. ES522 & EX532
Company Confidential Optoma ______________________ Delta____________
9 2009/06/30
2-7. I/O Ports Illustration about Projector
1．Composite Video Input
2. Audio Input L/R RCA Connectors
3. VGA 2/ SCART/ YPbPr Connector (EX532 only)
4. VGA 1/ SCART/ YPbPr Connector
5. VGA Out (EX532 only)
6. Rear IR receiver
7. KensingtonTM - Lock Port
8. Audio Out 3.5mm Jack
9. RS-232 Connector
10. Mini USB Connector (for remote mouse function)
11. Power Socket
12. S-Video Connector
Note:
If your video equipment has both S-VIDEO and RCA jacks (composite video) connect to the
S-VIDEO connector. S-VIDEO provides a better quality signal

Delta Elec. Inc. ES522 & EX532
Company Confidential Optoma ______________________ Delta____________
10 2009/06/30
2-8. 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. ES522 & EX532
Company Confidential Optoma ______________________ Delta____________
11 2009/06/30
1. Indicator LED
2. Power On/Off
3. Laser Pointer
4. Page Up
5. Mouse Right Click
6. Four Directional
Select Keys
7. Re-Sync
8. Page Down
9. Volume +/-
10. Menu
11. Zoom
12. AV mute
13. Video Source
14. VGA Source
15. Freeze
16. S-Video Source
17. Contrast
18. Brightness
19. Number Buttons
(for password input)
20. Keystone +/-
21. Source
22. Enter/Help
23. Mouse Left Click
24. PC/Mouse control
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. ES522 & EX532
Company Confidential Optoma ______________________ Delta____________
12 2009/06/30
2-9. Key Pad -- Top view and LEDs

Delta Elec. Inc. ES522 & EX532
Company Confidential Optoma ______________________ Delta____________
13 2009/06/30
2-10. Optical Adjustment & Image Size (ES522)
Adjusting the Focus
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. ES522 & EX532
Company Confidential Optoma ______________________ Delta____________
14 2009/06/30
2-11. Optical Adjustment & Image Size (EX532)
Adjusting the Zoom / Focus
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 3.28 to 38.7 feet (1.0 to 11.8 meters).
Adjusting Projection Image Size

Delta Elec. Inc. ES522 & EX532
Company Confidential Optoma ______________________ Delta____________
15 2009/06/30
Max. 25.5”
(64.8cm) 86.7” (220.2cm) 140.2” (356.2cm) 196.3” (498.7cm) 255” (647.6cm) 300.8” (764.2cm)
Screen
(Diagonal) Min. 22.8”
(57.9cm) 77.5” (196.8cm) 125.3” (318.3cm) 175.4” (445.6cm) 227.8” (578.7cm) 268.8” (682.9cm)
Max
(WxH).
20.4” x 15.3”
51.8 x 38.9cm
69.4” x 52.0”
176.2 x 132.1cm
112.1” x 84.1”
285 x 213.7cm
157.1” x 117.8”
399 x 299.2cm
204” x 153”
518.1 x 388.6cm
240.7” x 180.5”
611.4 x 458.5cm
Screen
Size Min.
(WxH)
18.2” x 13.7”
46.3 x 34.7cm
62” x 45.5”
157.4 x 118.1cm
100.2” x 75.2”
254.6 x 191cm
140.3” x 105.3”
356.5 x 267.4cm
182.3” x 136.7”
463 x 347cm
215.1” x 161.3”
546.3 x 409.7cm
Max. 2.1” (5.4cm) 7.2” (18.5cm) 11.8”
(29.9cm) 16.5” (41.9cm) 21.4” (54.4cm) 25.2” (64.2cm)
Hd
Min. 1.9” (4.9cm) 6.5” (16.5cm) 10.5”
(26.7cm) 14.7” (37.4cm) 19.1” (48.6cm) 22.6” (57.4cm)
Distance 3.28” (1.0m) 11.2” (3.4m) 18.0” (5.5m) 25.3” (7.7m) 32.8” (10.0m) 38.7” (1.0m)

Delta Elec. Inc. ES522 & EX532
Company Confidential Optoma ______________________ Delta____________
16 2009/06/30
2-12. Block Diagram

Delta Elec. Inc. ES522 & EX532
Company Confidential Optoma ______________________ Delta____________
17 2009/06/30
SPEAKER
KEY BOARD IO BOARD BALLAST POWER WOARD
AC IN
INDEX BOARD
COLOR WHEEL
VGA IN
P7O7
P800
P804
P900 P704
P708
P803
TH--BREAK
P8002
BLOWER FAN
P802
LOCK SWICH
P8003
POWER FAN
LAMP FAN
DMD BOARD
P801
P8001
IR BOARD
2-13. Wire diagram
ES522
EX532
DMD BOARD SPEAKER COLOR WHEEL
INDEX BOARD
TH--BREAK
IR BOARD
BLOWER FAN
LOCK SWICH
POWER FAN
LAMP FAN
AC IN
POWER BOARDBALLASTIO BOARDKEY BOARD
P900 P704 P708
P803 P801
P8002
P802
P803
P8001P707
P800
P804
VGA2 IN
VGA1 IN
VGA OUT

Delta Elec. Inc. ES522 & EX532
Company Confidential Optoma ______________________ Delta____________
18 2009/06/30
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.
Connect the power cord
• Power Supply Unit malfunction
• Check the connection of Power Supply (Power BD CN201 to MB P301)
• Check keypad connection
• Check voltage (12v, 5v, 3.3v, 1.8v,…etc) on Main Board.
< Stand-by >
Power: Flashing Green
Light
Temp : OFF
Lamp : OFF
Yes
< System error >
Power: Flashing Green
Light 4
Temp: OFF
Lamp: Flashing Red
Light 4
• Thermal break sensor is open.
• Connector (P803) on Main Board disconnected.
< Power supply error >
Power: OFF
Temp: OFF
Lamp: OFF
Yes
Yes
No
No

Delta Elec. Inc. ES522 & EX532
Company Confidential Optoma ______________________ Delta____________
19 2009/06/30
Yes
No
Waiting
Power On
< DMD error >
Power: Flashing Green
Light 8
Temp: OFF
Lam
p
: OFF
Yes
• DMD chip error.
• Check DMD Board PWB Ass’y .
No
• Lamp Cover A’ssy is not attached
• Connector (P802) on Main Board disconnected.
< System error >
Power: Flashing Green
Light 7
Temp: OFF
Lamp: OFF

Delta Elec. Inc. ES522 & EX532
Company Confidential Optoma___________________ Delta________________
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2009/06/30
Turn the
power ON
Image
Display
< Powering up >
Power: Flashing Green
Temp: OFF
Lamp: OFF
Ignition sound doesn’t exist.
• Power Board Ass’y malfunction (CN102 doesn’t output 370 V)
• Ballast Connector (CJ4) or LVPS unit (CJ1) disconnected
• Main Board (P707) disconnected
• Main Board or Ballast Ass’y malfunction
Ignition sound exists.
• Lamp failure (Lamp is broken, damaged, or burst)
• System Change a new Lamp
< Lamp error >
Power: OFF
Temp: OFF
Lamp: Static Red
< Normal operation >
Power: Flashing Green
Temp: OFF
Lamp: OFF
• Flexible cable of Color Wheel Ass’y is disconnected (P708) or broken.
• Index Board (CN7) / Main Board (P704) is disconnected
• Index Board malfunction
• Color Wheel Ass’y malfunction (doesn’t rotate).
• Main Board Ass’y malfunction (Color Wheel Ass’y doesn’t rotate).
< Color Wheel error >
Power: Flashing Green
Light 9
Temp: OFF
Lamp: OFF
Yes
Yes
No
No
No