Optoma EX612 User manual

SERVICE MANUAL
Prepare: 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
2010.01.30 V4.0 Add ES523ST/EW533ST;
Modify “Defect specication table” in Chapter 4;
2010.05.20 V5.0 Delete EX540/EX762/EX540I/EX542I/ES523ST/EW533STEX540/EX762/EX540I/EX542I/ES523ST/EW533ST
2011.05.04 V6.0 Add EW615i
2011.09.03 V7.0 Add EW612i/ EX615i
EX612/EX615/EW615i/EX612i/ EX615i
Copyright Sep, 2011. All Rights Reserved
Cherry Amy

EX612/EX615/EW615i/EX612i/EX615iEX615i Condential I
Preface
This manual is applied to EX612/EX615/EW615i/EX612i/EX615i 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.
EX612/EX615/EW615i/EX612i/EX615i Service Manual
Copyright Sep. 2011
All Rights Reserved
Manual Version 7.0

Condential
EX612/EX615/EW615i/EX612i/EX615iEX615i II
EX612/EX615/EW615i/EX612i/ EX615i Comparison ListEX615i Comparison ListComparison List
Parts EX615 EX612 EX612i EW615i EX615i
USER’S
GUIDE 36.8EF01G001 36.8FK01G001 36.8NN01G001 36.8MP01G001
OPTICAL
ENGINE
MODULE
70.8EF40GR01 70.8FK03GR01 70.8MP01GR01 70.8NA39GR01
MAIN BOARD
MODULE 70.8EF43GR01 80.8FK01G001 80.8NN01G001 80.8MP01G001 70.8NA38GR01
IO COVER
MODULE 70.8EF44GR01 70.8FK02GR01 70.8EF44GR01 70.8NA37GR01
DMD CHIP 48.8CQ01G003 48.8EJ01G001 48.8CQ01G003
ROD
MODULE 70.8EF42GR01 70.8LM15GR01 70.8EF42GR01
COLOR
WHEEL
MODULE
70.8EF41GR01 70.8FB23GR01
LAN BOARD 80.8EF07G001 NA 80.8MP07G002
LAMP SP.8EG01GC01 SP.8MP01GC01 SP.8EG01GC01

EX612/EX615/EW615i/EX612i/EX615iEX615i 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
EX612/EX615/EW615i/EX612i/EX615iEX615i 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
Defect specication table 4-3
Test Inspection Procedure 4-3
Factory Fan RPM Reset 4-4
PC MODE 4-5
Video Performance 4-8
ADC Calibration 4-11
Optical Performance Measure 4-13
Network Function Test(For EX615/EW615i) 4-15
Others 4-18

EX612/EX615/EW615i/EX612i/EX615iEX615i Condential V
Chapter 5 Firmware Upgrade
Section 1: System Firmware Upgrade 5-1
Equipment Needed 5-1
DLP Composer Lite Setup Procedure 5-2
Setup Procedure 5-4
USB Driver Upgrade Procedure 5-4
Firmware Upgrade Procedure 5-5
Section 2: 8051 Firmware Upgrade Procedure 5-6
Equipment Needed 5-6
NLINK Setup Procedure 5-9
Manley USB Driver Upgrade Procedure 5-11
8051 Firmware Upgrade Prodedure 5-13
Section 3: Network Firmware Upgrade Procedure
(For EX615/EW615i) 5-15
Equipment Needed 5-15
Write Down Projector IP 5-16
Network Setting 5-17
PC Hardware Link 5-18

Condential
EX612/EX615/EW615i/EX612i/EX615iEX615i VI
Chapter 6 EDID Upgrade
EDID Introduction 6-1
Equipment Needed 6-2
Setup Procedure(VGA) 6-3
EDID Key-In Procedure(VGA-1 & VGA-2) 6-3
Setup Procedure(HDMI)(For EX615/EW615i) 6-6Setup Procedure(HDMI)(For EX615/EW615i) 6-6
EDID Key-In Procedure (HDMI)(For EX615/EW615i) 6-6
Appendix A
Exploded Image I
Appendix B
Serial Number System Denition I
PCBA Code Denition II

Condential 1-1
EX612/EX615/EW615i/EX612i/EX615iEX615i
Chapter 1
Introduction
No Item Description
1Technology
● 0.55” XGA 2xLVDS SERIES 450 DMD DC3 (For EX615/EX612/
EX612i/EX615i)
● 0.65” WXGA 2xLVDS SERIES 450 DMD DC3(For EW615i) 0.65” WXGA 2xLVDS SERIES 450 DMD DC3(For EW615i)
2Dimension
(W x D x H) ● 324 x 234 x 97 mm
3 Weight ● 6.3-6.4 lbs
4 Power Supply ● Auto-ranging: 100V~ 240V ± 10%, 50~ 60Hz
5Keystone
Correction ● �/-40 degree (TI spec.)�/-40 degree (TI spec.)
6Resolution
● Native Resolution: 1024 x 768(For EX615/EX612/EX612i/EX612i/
EX615i))
● Native Resolution: 1280 x 800(For EW615i)
7 Power consumption ● Full Mode:(Typ)298W,(Max)328W @ac 110V
● ECO Mode:(Typ)247W,(Max)272W @ac 110V
8 Throw ratio
● 1.95 ~ 2.15 @60”(For EX615/EX612/EX612i)
● 1.28~1.536:1 @60” (For EW615i)1.28~1.536:1 @60” (For EW615i)(For EW615i)
● 1.6~1.92(D/W) @ 60” (For EX615i)1.6~1.92(D/W) @ 60” (For EX615i)(For EX615i) EX615i)EX615i)
9 Projection lens ● YM09X/FPL30, F# 2.41~ 2.55 @60”, f= 21.8 ~ 24 mm @60”
10 Lamp life ● 2500 Hours, 50% Survival Rate (Standard-Mode)
● 4000 Hours, 50% Survival Rate (ECO-Mode)
11 Offset ● 115% ± 5%
12 Video compatibility
● NTSC: NTSC M 3.58 MHz, 4.43 MHz
● PAL: PAL B/D/G/H/I/M/N, 4.43 MHz
● SECAM: SECAM B/D/G/K/K1/L, 4.25/4.4 MHz
● Component: 480i/p, 576i/p, 720p (50/60Hz), 1080i/p (50/60Hz)
● HDTV: 720p(50/60Hz), 1080i(50/60Hz),1080P(24/50/60Hz) (ForHDTV: 720p(50/60Hz), 1080i(50/60Hz),1080P(24/50/60Hz) (For
EW615i/EX615i)/EX615i))
13 Aspect ratio
● 4:3, 16:9 I, 16:9 II, NATIVE, AUTO (For EX615/EX612/EX612i/X615/EX612/EX612i/
EX615i ))
● 4:3, 16:9 or 16:10, LBX, Native, Auto(For EW615i)
14 Lamp ● 230 W OSRAM Lamp E20.8 elliptic
15 Color Wheel
● 5 Segments; RGBYW; Filter Diameter 40 mm
● R76Y32G78W98B76
● 2x,7200 RPM
1-1 Highlight

Condential 1-2
EX612/EX615/EW615i/EX612i/EX615iEX615i
No Item Description
16 System Controller ● DDP2430
17 Input Connections
● VGA-in: VGA in 1 (wireless dongle, YPbPr)
VGA in 2 (SCART, YPbPr)
● Composite: RCA x 1
● S-video: Mini-DIN 4 pin x 1
● Audio-in (Green coded port):
• Audio-in 1 only (Daughter Board) (for EX612//EX612i)/EX612i))
• Audio-in 1, 2, 3 (Daughter Board) (for EX615/EW615i)
● HDMI: HDMI v1.3 (HDCP) (for EX615/EW615i/EX615i)(for EX615/EW615i/EX615i)
● Audio-in connectivity grouping (for EX615/EW615i)(for EX615/EW615i)
• VGA-in1 -> Audio in1
• VGA-in2 -> Audio in2
• Composite/S-Vidoe -> Audio in3
18 Temperature ● Operating ( Full-power-mode): 5~ 40 °C
● Non-operation (storage): -10°C~ 60°C
19 Altitude
● Operating:Operating:
0 ~ 2,500 ft, for 5°C~ 40°C
2500 ft ~ 5,000 ft, for 5°C~ 35°C
5,000 ft ~ 10,000 ft, for 5°C~ 30°C

Condential 1-3
EX612/EX615/EW615i/EX612i/EX615iEX615i
1-2 Compatible Mode
Computer Compatibility (Analog)
Compatibility Resolution V-Sync [Hz] H-Sync [KHz]
VGA
640 x 350 70 31.5
640 x 350 85 37.9
640 x 400 85 37.9
640 x 480 60 31.5
640 x 480 72 37.9
640 x 480 75 37.5
640 x 480 85 43.3
720 x 400 70 31.5
720 x 400 85 37.9
SVGA
800 x 600 56 35.2
800 x 600 60 37.9
800 x 600 72 48.1
800 x 600 75 46.9
800 x 600 85 53.7
XGA
1024 x 768 60 48.4
1024 x 768 70 56.5
1024 x 768 75 60
1024 x 768 85 68.7
WXGA 1280 x 768 60 47.8
SXGA
1152 x 864 60 53.5
1152 x 864 70 63.8
1152 x 864 75 67.5
1152 x 864 85 77.1
1280 x 1024 60 63.98
1280 x 1024 75 79.98
1280 x 1024 85 91.1
1280 x 960 60 60.0
WXGA 1280 x 800 60 49.68
SXGA� 1400 x 1050 60 63.98
UXGA 1600 x 1200 60 75
MAC LC 13” 640 x 480 66.66 34.98

Condential
EX612/EX615/EW615i/EX612i/EX615iEX615i
1-4
Compatibility Resolution V-Sync [Hz] H-Sync [KHz]
MAC II 13” 640 x 480 66.68 35
MAC 16” 832 x 624 75 49.725
MAC 19” 1024 x 768 75 60.24
MAC 1152 x 870 75 68.68
MAC G4 640 x 480 60 31.35
i Mac DV 1024 x 768 75 60
i Mac DV 1152 x 870 75 68.49
i Mac DV 1280 x 960 75 75
Computer Compatibility (Digital)
Compatibility Resolution V-Sync [Hz] H-Sync [KHz]
VGA
640 x 350 70 31.5
640 x 350 85 37.9
640 x 400 85 37.9
640 x 480 60 31.5
640 x 480 72 37.9
640 x 480 75 37.5
640 x 480 85 43.3
720 x 400 70 31.5
720 x 400 85 37.9
SVGA
800 x 600 56 35.2
800 x 600 60 37.9
800 x 600 72 48.1
800 x 600 75 46.9
800 x 600 85 53.7
XGA
1024 x 768 60 48.4
1024 x 768 70 56.5
1024 x 768 75 60
1024 x 768 85 68.7
WXGA 1280 x 768 60, 75, 85 47.8
1280 x 800 60 49.64

Condential
EX612/EX615/EW615i/EX612i/EX615iEX615i 1-5
Compatibility Resolution V-Sync [Hz] H-Sync [KHz]
SXGA
1152 x 864 60 53.5
1152 x 864 70 63.8
1152 x 864 75 67.5
1152 x 864 85 77.1
1280 x 1024 60 63.98
1280 x 1024 75 79.98
1280 x 1024 85 91.1
SXGA� 1400 x 1050 60 63.98
UXGA 1600 x 1200 60 75
Note: If the Computer Compatibility supportive signal is different from User's Manual, please refer
to User's Manual.

Condential 2-1
EX612/EX615/EW615i/EX612i/EX615iEX615i
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 EX612/EX615/EW615i/EX612i/EX615i is the same,we ta�eEX612i/EX615i is the same,we ta�eis the same,we ta�e
EX615 as an example here.

Condential 2-2
EX612/EX615/EW615i/EX612i/EX615iEX615i
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.

Condential 2-3
EX612/EX615/EW615i/EX612i/EX615iEX615i
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.

Condential 2-4
EX612/EX615/EW615i/EX612i/EX615iEX615i
Note: - When you remove the Top Cover,
ta�e 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 �eypad FPC
cable.
- Ma�e 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

Condential 2-5
EX612/EX615/EW615i/EX612i/EX615iEX615i
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

Condential 2-6
EX612/EX615/EW615i/EX612i/EX615iEX615i
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: - Ma�e sure cables plug into the correct
ports when assembling the unit.
Main Board Shielding

Condential 2-7
EX612/EX615/EW615i/EX612i/EX615iEX615i
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)
F IR Compose of Black/Yellow/Red
Wire and Gray wire tube (3 pin)

Condential 2-8
EX612/EX615/EW615i/EX612i/EX615iEX615i
2-9 Disassemble Daughter
Board and Lan Module
Board
1. Unscrew 2 screws (as green circle) to
disassemble the Daughter Board.
2. Unscrew 1 screw (as red circle) to
disassemble the Lan Module Board.
3. Unscrew 3 hex screws (as yellow circle)
from the Main Board Module.
Note: EX612/EX612i has not Lan Module
Board,so disassemble Lan Module
Board is for EX615/EW615i/EX615i.
Daughter Board Lan Module Board