Optoma EX542 User manual

SERVICE MANUAL
SI : TSE: Check: Approved:
Date Revise Version Description
2009.07.08 V1.0 Initial Issue
2009.10.13 V2.0 Add EX540/EX762
2009.12.16 V3.0 Add EX540I/EX542I
2010.02.07
V4.0 Add ES523ST/EW533ST;
Modify “Defect specication table” in Chapter 4;
EX542/EX612/EX615/EX540/EX762/EX540I/EX542I/
ES523ST/EW533ST
Copyright Feb, 2010. All Rights Reserved. P/N: 36.8FJ01G001

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Condential I
Preface
This manual is applied to EX542/EX612/EX615/EX540/EX762/EX540I/EX542I/ES523ST/
EW533ST 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.
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.
EX542/EX612/EX615/EX540/EX762/EX540I/EX542I/ES523ST/EW533ST Service Manual
Copyright Feb. 2010
All Rights Reserved
Manual Version 4.0

Condential
EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST II
EX542/EX612/EX615/EX540/EX762/EX540I/EX542I /ES523ST/
EW533ST Comparison List
Parts EX540 EX542 EX540I EX542I EW533ST ES523ST EX615 EX612 EX762
USER’S
GUIDE 36.8FB01G001 36.8EF01G001 36.8FR01G001 36.8HA01G001 36.8EF01G001 36.8FK01G001 36.8FB01G001
LAMP
DRIVER
MODULE
70.8FJ05GR01 70.8EF38GR01 70.8FB21GR01
LVPS 75.8CT02G001 75.8CT01G001 75.8FB01GP01
BLOWER 49.8CS01G002 49.8EF04G001 49.8FB01G001
OPTICAL
ENGINE
MODULE
70.8FJ06GR01 70.8FJ30GR01 70.8HA18GR01 70.8GZ16GR01 70.8EF40GR01 70.8FK03GR01 70.8FB22GR01
MAIN
BOARD
MODULE
70.8FR05GR01 70.8FJ03GR01 70.8FR24GR01 70.8FJ27GR01 80.8HA01G001 80.8GZ01G001 70.8EF43GR01 80.8FK01G001 70.8FB24GR01
DMD CHIP 48.8EZ01G001 48.8CQ01G001 48.8EZ01G001 48.8CQ01G003 48.8EJ01G001 48.8EH01G001 48.8CQ01G001 48.8CQ01G003
FAN 49.88T01G001 49.8EF03G001
THERMAL
SWITH 43.8EF17G001 43.8EG17G001 43.8FB17G001
IO COVER
MODULE 70.8FJ04GR01 70.8FJ28GR01 70.8HA20GR01 70.8GZ17GR01 70.8EF44GR01 70.8FK02GR01 70.8EF44GR01
SPEAKER 49.8EF01G001 49.8GZ01G001 49.87K01G201 49.8EM01G011
DAUGHTER
BOARD 80.8EF06G002 80.8GZ06G001 80.8EF06G003 80.8EF06G002
LAN
MODULE
BOARD
80.8EF07G001 NA 80.8EF07G001
REMOTE
CONTROL 45.8EF01G001 45.8GZ01G001 45.8EF02G001 45.8EF01G001
COLOR
WHEEL
MODULE
70.8EF41GR01 70.8FJ29GR01 70.8FB23GR01 70.8EF41GR01 70.8FB23GR01

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Condential III
Table of Content
Chapter 1 Introduction
Highlight 1-1
Compatible Mode 1-3
Chapter 2 Disassembly Process
Equipment Needed & Product Overview 2-1
Disassemble Lamp Cover Module 2-2
Disassemble Lamp Module 2-2
Disassemble Focus Ring 2-3
Disassemble Top Cover Module 2-3
Disassemble Keypad Board Module and Zoom Ring 2-4
Disassemble Top Shielding 2-5
Disassemble Main Board Module 2-5
Disassemble Daughter Board and Lan Module Board 2-8
Disassemble Engine Module 2-9
Disassemble Color Wheel Module 2-9
Disassemble DMD Chip and DMD Board 2-10
Disassemble Rod Module 2-10
Disassemble System Fan Module and Thermal Switch 2-11
Disassemble Speakers 2-12
Disassemble Blower 2-13
Disassemble Front IR Module 2-14
Disassemble LVPS Module and Interlock Switch 2-14
Disassemble Lamp Driver Module 2-15
Disassemble Security Bar Cap 2-15
Disassemble Bottom Shielding 2-16

Condential
EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST IV
Disassemble IO Cover 2-17
Rod Adjustment 2-18
Re-write Lamp Usage Hour 2-19
Chapter 3 Troubleshooting
LED Lighting Message 3-1
Main Procedure 3-2
Chapter 4 Function Test & Alignment Procedure
Test Equipment Needed 4-1
Service Mode 4-1
OSD Reset 4-1
Test Condition 4-2
Test Inspection Procedure 4-4
PC MODE 4-5
Video Performance 4-8
ADC Calibration 4-11
Optical Performance Measure 4-13
Network Function Test
( For EX542/EX615/EX540/EX762/EX540I/EX542I) 4-15
Others 4-18
Chapter 5 Firmware Upgrade
Section 1: System Firmware Upgrade
(For EX540/EX542/EX612/EX615/EX762/EX540I/EX542I) 5-1
Equipment Needed 5-1
DLP Composer Lite Setup Procedure 5-2
Setup Procedure 5-4

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Condential V
USB Driver Upgrade Procedure 5-4
Firmware Upgrade Procedure 5-5
Section 2: System Firmware Upgrade
(For ES523ST/EW533ST) 5-8
DLP Composer Lite Setup Procedure 5-9
Setup Procedure 5-9
Firmware Upgrade Procedure 5-9
Section 3: 8051 Firmware Upgrade Procedure 5-13
Equipment Needed 5-13
NLINK Setup Procedure 5-14
Manley USB Driver Upgrade Procedure 5-16
8051 Firmware Upgrade Prodedure 5-18
Section 4: Network Firmware Upgrade Procedure
( For EX542/EX615/EX540/EX762/EX540I/EX542I) 5-20
Equipment Needed 5-20
Write Down Projector IP 5-21
Network Setting 5-22
PC Hardware Link 5-23
Chapter 6 EDID Upgrade
EDID Introduction 6-1
Equipment Needed
(For EX542/EX615/EX540/EX762/EX540I/EX542I) 6-2
Setup Procedure (VGA)
(For EX542/EX615/EX540/EX762/EX540I/EX542I) 6-3
EDID Key-In Procedure (VGA-1 & VGA-2)
(For EX542/EX615/EX540/EX762/EX540I/EX542I) 6-3

Condential
EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST VI
Equipment Needed (for ES523ST/EW533ST) 6-6
Setup Procedure (VGA) (for ES523ST/EW533ST) 6-7
EDID Key-In Procedure (for ES523ST/EW533ST) 6-7n Procedure (for ES523ST/EW533ST) 6-7(for ES523ST/EW533ST) 6-7
Setup Procedure (HDMI)
(For EX542/EX615/EX540/EX762/EX540I/EX542I) 6-10
EDID Key-In Procedure (HDMI)
(For EX542/EX615/EX540/EX762/EX540I/EX542I) 6-10
Appendix A
Exploded Image I
Appendix B
Serial Number System Denition I
PCBA Code Denition II

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST  1-1
Chapter 1
Introduction
No  
1

EX542/EX612/EX615/EX762/EX542I/EX540/EX540I)
       ES523ST)
        
2
 
3

EX542/EX612/EX615/EX540/EX540I/EX542I)
EX762)

4 
5
    
6

EX542/EX612/EX615

    
7















1-1 Highlight

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST  1-2
No  
 
EX612/EX615)




 

EX540I/EX542I)



10 












11 

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I)
   
12 




EX540/EX542/EX612/EX615/EX762/EX540I/EX542I)


13 

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I)
       
14 




15 




EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST  1-3
No  
16  

17 


EX540/EX542/EX612/EX615/EX762/EX540I/EX542I)


EX540/EX542/EX612/EX615/EX762/EX540I/EX542I)



          
  



/EX540I/EX542I))


)

EX540/EX762/EX540I/EX542I)



  

 
EX540/EX542/EX612/EX615/EX762










EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST 
1-4
1-2 Compatible Mode
Computer Compatibility (Analog)
   

 70 
  
  
 60 
 72 
 75 
  
 70 
  

 56 
 60 
 72 
 75 
  

 60 
 70 
 75 60
  
  60 

 60 
 70 
 75 
  
 60 
 75 
  
 60 
  60 
  60 
  60 75
   
   35
  75 

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST  1-5
   
  75 
  75 
  60 
  75 60
  75 
  75 75
Computer Compatibility (Digital)
   

 70 
  
  
 60 
 72 
 75 
  
 70 
  

 56 
 60 
 72 
 75 
  

 60 
 70 
 75 60
  
   
 60 

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST  1-6
   

 60 
 70 
 75 
  
 60 
 75 
  
  60 
  60 75
Note: If the Computer Compatibility supportive signal is different from User's Manual, please refer
to User's Manual.

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST 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.
- The disassembly process for EX542/EX612/EX615/EX540/EX762/EX540I/EX542I/
ES523ST/EW533ST is the same , we take EX615 as an example here.

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Condential 2-2
2-3 Disassemble Lamp
Module
1. Loosen 2 screws (as red circle) on the
Lamp Module.
2. Take off the Lamp Module.
2-2 Disassemble Lamp
Cover Module
1. Loosen 2 screws (as red circle) on the
Lamp Cover.
2. Disassemble the Lamp Cover Module.

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Condential 2-3
2-4 Disassemble Focus Ring
1. Rotate the Focus Ring clockwise until
you cannot rotate any more (as red
arrow direction).
2. Pull out the Focus Ring.
Note: - When you assemble the Focus Ring,
ensure the 3 card slot (as green square)
placed in the 3 double-screw bolt (as
yellow circle) properly, and the Focus
Ring can be well adjusted.
2-5 Disassemble Top Cover
Module
1. Unscrew 2 screws (as red circle) from the
Bottom Cover.
2. Press two sides of the projector as the
blue arrows point.
3. Remove the Top Cover Module.

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Condential 2-4
Note: - When you remove the Top Cover,
take care the connector (as yellow
square) of FPC cable which connect
Main Board and Keypad Board Module,
then unplug it from Keypad Board
Module.
- Avoid damaging by pulling keypad FPC
cable.
- Make sure the FPC cable plug into the
correct ports when assembling it.
2-6 Disassemble Keypad
Board Module and Zoom
Ring
1. Unscrew 4 screws (as blue circle) to
disassemble the Keypad Board Module
from the Top Cover Module.
2. Separate the Keypad from the Top
Cover Module.
3. Unscrew 3 screws (as red circle) to
disassemble the Zoom Ring.
Zoom Ring
Keypad
Keypad Board

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Condential 2-5
2-8 Disassemble Main Board
Module
1. Unplug 1 connector (as green square) to
remove the FPC cable.
2. Unplug 8 connectors (as yellow square).
3. Unscrew 5 screws (as red circle) from
the Main Board Module.
2-7 Disassemble Top
Shielding
1. Tear off 2 EMI tapes (as green square).
2. Unscrew 12 screws (as red circle).
3. Disassemble the Top Shielding.
Top Shielding
FPC cable

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Condential 2-6
4. Unscrew 1 screw (as blue circle) from
the IO Cover.
5. Unscrew 8 hex screws (as green circle)
from the IO Cover.
6. Unplug 1 connector (as orange square).
7. Separate the Main Board Module
and Main Board Shielding.
Note: - Make sure cables plug into the correct
ports when assembling the unit.
Main Board Shielding

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Condential 2-7
Please refer to the table as below for
details of each connector.
AG F E D C B
Item Male Connector
on Main Board The key feature Figure
A & G Speaker Compose of Red/Black Wire and
Black wire tube (2 pin)
B Lamp Driver Black wire tube (5 pin)
CSystem Fan Compose of Red/Yellow/Black
Wire (3 pin)
DPhoto Sensor Compose of Red/Black/White
Wire and Black wire tube (3 pin)
EBlower Compose of Black/Yellow/Red
Wire and Blue wire tube (3 pin)
FIR Compose of Black/Yellow/Red
Wire and Gray wire tube (3 pin)