Optoma ES529 Instruction manual

SERVICE MANUAL
Prepare : Check: Approve:
Date Revise Version Description
2011.02.12 V1.0 Initial Issue
Mina Amy

ES529/EX539/EW539 Condential I
Preface
This manual is applied to ES529/EX539/EW539 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 not mentioned in the troubleshooting.
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 future edition.
ES529/EX539/EW539 Service Manual
Copyright Feb. 2011
All Rights Reserved
Manual Version 1.0

ES529/EX539/EW539 Condential
ES529/EX539/EW539 Comparison List
Parts ES529 EX539 EW539
Engine Module 70.8LH05GR01 70.8LE10GR01 70.8LJ08GR01
DMD 48.8EH01G001 48.8CQ01G003 48.8EJ01G001
Main BD 80.8LH01G001 80.8LE01G001 80.8LJ01G001
IO COVER 70.8LH03GR01 70.8LJ07GR01
TOP COVER 75.8EH01G091 75.8EH01G001

III
Table of Content
Chapter 1 Introduction
Highlight 1-1
Chapter 2 Disassembly Process
Equipment Needed & Product Overview 2-1
Repair notice 2-2
Rod Adjustment 2-3
Re-write Lamp Usage Hour 2-4
Chapter 3 Troubleshooting
LED Lighting Message For Projector 3-1
Main Procedure 3-2
Chapter 4 Function Test & Alignment Procedure
Service Mode Instruction 4-1
Factory Fan RPM Reset 4-1
Test Condition 4-2
Test Inspection Procedure 4-3
PC MODE 4-3
Calibration 4-6
Optical Performance 4-7
Chapter 5 Firmware Upgrade
Section 1: System Firmware Upgrade 5-1
Equipment Needed 5-1

ES529/EX539/EW539 Condential IV
Get into FW mode 5-2
Check FW version 5-2
Section 2: 8051 FW Upgrade (USB) 5-3
Equipment Needed 5-3
8051 Firmware Upgrade Procedure 5-4
Check 8051 FW version 5-5
Chapter 6 EDID Upgrade
EDID Upgrade Procedure 6-1
Appendix A Exploded Image I
Appendix B
Serial Number Denition I
PCBA Code Denition II

ES529/EX539/EW539 Condential 1-1
Chapter 1
Introduction
1-1 Highlight
No Item Description
1Dimensions (WxDxH) ● 286x192x97mm
2Power Supply ● 100V-240V±10% 50-60Hz
3Power Consumption
● Normal: TYP 250W Max 275W @110V AC
● ECO: TYP 200W Max 220W @110V AC
● Standby mode < 1W @110V AC
4 Keystone correction ● +/-40 degree is the scaler spec.
● +/-20 degree is for system angle of V-keystone
5Throw ratio ● 1.95~2.15 (D/W)(ES529/EX539)
● 1.55~1.7(D/W)(EW539)
6 Projection lens
● YM09X/FPL62(ES529)
● YM09X/FPL30(EX539)
● YM31Z(EW539)
7 Lamp life
Normal Mode:
● 3000 Hours Standard @ 200W, 50% Survival Rate
ECO Mode:
● 6000 Hours Typical @ 160W, 50% Survival Rate
8 Lamp ● 200W Lamp (Osram E20.8)
9DMD Chip&Number of
active dots
● 0.55” SVGA, S450, Dark Chip 3(ES529)
0.55” XGA, S450, Dark Chip 3(EX539)
0.65” WXGA, S450, Dark Chip 3(EW539)
● Number of active dots: 800x600 (ES529)
1024x768(EX539)
1280x800(EW539)
10 Color wheel ● 6 segments (R81Y41G84C31W52B71)
11 System controller ● TI DDP 2431
12 Video compatibility
● NTSC: M/J,3.58MHz, 4.43MHz
● PAL: B, D, G, H, I, M, N, 4.43MHz
● SECAM: B, D, G, K, K1, L,4.25/4.4MHZ
● SDTV: 480i/p, 576i/p
● HDTV: 720p(50/60Hz), 1080i/p(50/60Hz)

ES529/EX539/EW539 Condential 1-2
No Item Description
13 Input signal spec
● VGA-in x1 (support SCART/YPbPr)
● S-Video(Mini DIN) x1
● Audio input(Mini Jack) x1
● Composite Video x1
● HDMI v1.3(with HDCP support)
14 Altitude&Temperature
● Operating: 0~2,500 ft 5°C~35°C
2,500~5,000 ft 5°C~30°C
5,000~10,000 ft 5°C~25°C
1-2 Compatible Mode
Computer Compatibility
Compatibility Resolution
Analog/Digital
ES529/
EX539 EW539
V-Sync(Hz) H-Sync(KHz)
VGA
640x350 70 31.5 V V
640x350 85 37.90 V V
640x400 70 31.50 V
640x400 85 37.90 V V
640x480 60 31.5 V V
640x480 67 -V V
640x480 72 37.90 V V
640x480 75 37.50 V V
640x480 85 43.30 V
720x350 70 31.50 V
720x400 70 31.50 V V
720x400 85 37.90 V V
720x576 50 -V
720x576 60 -V
SVGA
800x600 56 35.20 V V
800x600 60 37.90 V V
800x600 72 48.10 V V
800x600 75 46.90 V V
800x600 80 -V
800x600 85 53.70 V
800x600 120 -V

ES529/EX539/EW539 Condential 1-3
Compatibility Resolution
Analog/Digital
ES529/
EX539 EW539
V-Sync(Hz) H-Sync(KHz)
XGA
1024x576 50 -V
1024x576 60 -V
1024x768 60 48.40 V V
1024x768 70 56.50 V V
1024x768 72 57.70 V -
1024x768 75 60.00 V V
1024x768 85 68.70 V
1024x768 120 -V
1152 × 864 60 -V
1152 × 864 70 -V
1152 × 864 75 -V
1152 × 864 85 -V
1152 × 870 75 -V V
HD 1280x720 50 -V V
HD 1280x720 60 45.00 V V
HD 1280x720 75 -V V
HD 1280x720 85 -V V
HD 1280x720 120 -V
WXGA 1280 x 768 60 47.40 V
WXGA 1280 x 768 70 -V
WXGA 1280 x 768 75 -V
WXGA 1280 x 768 85 -V
WXGA-800 1280 x 800 60 -V V
SXGA 1280x1024 60 64.00 V V
SXGA 1280x1024 75 80.00 V V
SXGA 1280x1024 85 91.10 V V
1366x768 60 -V
1400x900 60 55.94 V
SXGA+ 1400x1050 60 -V
UXGA 1600x1200 60 75.00 V V
1600x1050 60 -V
HDTV 1920x1080 30 33.80 V V
HDTV 1920x1080 25 28.10 V
MAC LC 13’’ 640x480 66.66 34.98

ES529/EX539/EW539 Condential 1-4
Compatibility Resolution V-Sync(Hz) H-Sync(KHz)
MAC LC13” 640 x 480 66.68 34.98
MAC II 13” 640 x 480 66.66 34.98
MAC 16” 832x624 74.55 49.73
MAC 19” 1024X768 75 60.24
MAC 1152X870 75.06 68.68
MAC G4 640X480 60 31.35
i MAC DV 1024X768 75 60.00
i MAC DV 1152X870 75 68.49
Note: If the Computer Compatibility supportive signal is different from User’s Manual,
please refer to User’s Manual.

ES529/EX529/EW539 Condential 2-1
Chapter 2
Disassembly Process
2-1 Equipment Needed & Product Overview
1. Screw Bit (+): 105
2. Screw Bit (+): 107
3. Screw Bit (-): 107
4. Hex Sleeves: 5 mm
5. Tweezers
6. Projector
* Before you start: This process is protective level II. Operators should wear electrostatic chains.
* Note: - If you need to replace the main board, you have to record the lamp usage hour.
- Some related contents please refer to common SM chapter 2.

ES529/EX539/EW539 Condential 2-2
2-2 Repair notice
Item Male Connector
on Main Board The key feature Figure
ALamp Driver Black wire tube (5 pin)
B Fan Compose of Black/Yellow/Red Wire (3
pin) and green connector
CBlower Compose of Red/White/Black Wire (3
pin) and blue wire tube
D Photo Sensor
Compose of Red/Black/White Wire (3
pin) and red connector
EIR Compose of Red/Black/White Wire and
Gray wire tube (3 pin)
FSpeaker Compose of Red/Black Wire and Black
wire tube (2 pin)
Disassemble Main Board
Please refer to the below table details of
each connector on Main Board.
A
B
C
D
E
F

ES529/EX539/EW539 Condential 2-3
2-3 Rod Adjustment
1. Environment Adjustment
- The distance between the engine and
the screen is 2.4M (ES529/EX539) or
2.0M(EW539).
- This process should be done at a dark
environment (under 10 Lux).
2. Procedure Adjustment
- Change the screen to "white screen".
- Adjust the screws by using the rod
on the engine module to readjust the
image.
("screw 1" should be adjusted rst, and
then "screw 2". Adjust until the yellowish
or bluish parts disappeared.)
3. Abnormal image inspection
- It should not have any abnormal color
at the rim of the image by estimating
through the eyes.
Note: - To avoid over adjusting the rod.
- After the operation, please use the glue
to x the screws.
1
2

ES529/EX539/EW539 Condential 2-4
2-4 Re-write Lamp Usage
Hour
1. Get into service mode
- Press “Power”, “Left”, “Left” and “Menu”
buttons sequentially to get into service
mode.
2.Use “up” or “down” buttons to select “ Exit”,
then use “left” or “right” buttons to re-write
the lamp hour back to previous lamp usage
hour.
Note: left key = decrease lamp hour
right key =increase lamp hour

ES529/EX539/EW539 Condential 3-1
Chapter 3
Trobleshooting
Message Power LED
(Amber)
Power LED
(Green)
Temp LED
(Red)
Lamp LED
(Red)
Standby State
(input power cord) o o o
Power on (warming) oFlashing
Green o
o
Lamp lighting o o o
Power off (Cooling) oFlashing
Green o o
Error
(Over Temp.)
Flashing
Amber o o
Error
(Fan failed)
Flashing
Amber oFlashing o
Error
(Lamp failed)
Flashing
Amber o o
No light
Steady light
3-1 LED Lighting Message

ES529/EX539/EW539 Condential 3-2
3-2 Main Procedure
The other troubleshooting procedures please refer to common service manual
3-1(Main Procedure).
No Symptom Procedure
1Auto Shut Down
- Check LED Status
a. Lamp Fail Power LED (ashes amber) Lamp LED (lightsLamp Fail Power LED (ashes amber) Lamp LED (lightsPower LED (ashes amber) Lamp LED (lights
red)
- Check Lamp
- Check Lamp Driver
- Check Main Board
b. Over Temp. Power LED (ashes amber) Temp LED (lightsOver Temp. Power LED (ashes amber) Temp LED (lightsPower LED (ashes amber) Temp LED (lightsashes amber) Temp LED (lights Temp LED (lights
red)
- Check Fan
- Check Main Board
c. Fan Fail Power LED (ashes amber) Temp LED (FlashesFan Fail Power LED (ashes amber) Temp LED (FlashesPower LED (ashes amber) Temp LED (Flashesashes amber) Temp LED (Flashes Temp LED (Flashes
red)
- Check Fan
- Check Main Board
23D Image Abnormal
- Ensure the using 3D glasses is good and you must face the
projection.
- Ensure the CD in DVD is HQFS format or the graphic card
from PC can support 3D format.
- Ensure your standing distance is less than 6m from screen.
- Ensure the 3D function is on and execute “3D sync invert” in
OSD menu.
- Check main board.

ES529/EX539/EW539 Condential 3-3
No Symptom Procedure
3
Forgetting Password
(administrator
Password)
- If you forget the Password please do the following steps to get
the Universal Password
(1) When you turn on the projector the message “Enter
Security Code” appears. Please Input the “Current Security
Code 8642” by Remote Control then press “Enter”.
(2) Press “Menu” button select “Setup” “Change Password”
then press” Enter” button. The message “Enter Security
Code” appears again repeat step (1).
(3) The message “Enter New Security Code” appears. Input a
4-digits code (letters and/or numbers) that you dene.
(4) To conrm key in the password again. The “Security Code
change successfully” appear on the screen.
(1)
(3)
(2)

ES529/EX529/EW539 Condential 4-1
Chapter 4
Function Test & Alignment Procedure
4-1 Service Mode Instruction (This section
links to common service manual 4-2 Service
Mode)
1. Turn on the projector.
2. Press Power --> Left --> Left --> Menu on Keypad or Remote
controller.
3. Service mode will be shown. After conrming the conguration,
press "Exit" to exit.
4-2 Factory Fan RPM Reset
After replace main board,blower or upgrade system FW, you need to
do:
1. Plug in the power cord, hold on “Menu” button then press
“Power” button, when the power LED lighted orange, Temp
LED and Lamp LED lighted red about one second, loosen
“Menu” button.
2. After several minutes, you can check the fan RPM as red circle
a. Please get into Service Mode.
b. Select “RD menu”, then press “Enter”, Fan detail information
will be shown.
Note: If the factory fan Value doesn’t show in service mode,please
repeat the step 1,2 again.

ES529/EX539/EW539 Condential 4-2
4-3 Test Condition(This section links to commonThis section links to common
service manual 4-4 Test Condition)
Defect specication table
For ES529/EX539
Order Symptom Pattern Criteria
1Bright pixel ( dots) Gray10 pattern A+B=0
2Dark pixel(dots) White pattern A+B≤4
3Unstable pixel (dots) Any pattern A+B=0
4Adjacent dark pixel (dots) Any pattern A+B=0
5Dark blemish (Dirty) Blue 60 pattern A+B≤2
(diameter <1/2 inch)
6 Bright blemish (Dirty) Gray10 pattern A+B≤2
(diameter <1/2 inch)
7Bright dots on frame Gray10 pattern ≤1
For EW539
Order Symptom Pattern Criteria
1Bright pixel ( dots) Gray 10 pattern A+B=0
2Dark pixel(dots) White pattern A+B≤7
3Unstable pixel (dots) Any pattern A+B=0
4Adjacent dark pixel (dots) Any pattern A+B=0
5Dark blemish (Dirty) Blue 60 pattern A+B≤4
(diameter <1 inch)
6 Bright blemish (Dirty) Gray 10 pattern A+B≤4
(diameter <1 inch)
7Bright dots on frame Gray 10 pattern ≤1

Condential 4-3
ES529/EX539/EW539
4-4 Test Inspection Procedure
Update
Change Parts
Main
Board FW Color wheel
Lamp
module
Engine
module
Rod
module Blower
Version Update V V
Color Wheel Index V V
Lamp reset V
ADC Calibration V V
OSD Reset V V
Re-write Lamp Hour
Usage V
EDID V
ROD Adjustment V V
Factory Fan RPM
Reset V V V
4-5 PC MODE
Note:EX539 the native resolution of test signal is 1024x768@60HZ.
ES529 the native resolution of test signal is 800x600@60HZ.
EW539 the native resolution of test signal is 1280x800@60HZ.
We take EX539 for example here.
The other contents please refer to common service manual 4-6 PC MODE.

ES529/EX539/EW539 Condential 4-4
1.Bright pixel
Procedure - Test equipment: video generator.
- Test signal: analog 1024x768@60Hz.
- Test Pattern: Gray10 pattern
Inspection item - Bright pixel check.
Criteria - Bright pixel is unacceptable under gray10 pattern
Please refer to the gure in 4-4 Test Condition
for Frame and Active area.
Note: The defect criteria follows TI specication.
2. Dark pixel
Procedure - Test equipment: video generator.
- Test signal: analog 1024x768@60Hz.
- Test Pattern: White pattern
Inspection item - Dark pixels check.
- White pattern
- Adjacent dark pixel.
Criteria - The number of the dark pixels should be less or
equal to 4 pixels.
- Adjacent pixel with each other is unacceptable.
Note: The defect criteria follows TI specication.
Gray 10
White