Optoma ML500 User manual

SERVICE MANUAL
Prepared: Checked: Approved:
Date Revise Version Description
2011.08.23 V1.0 Initial Issue
2011.09.5 V2.0 Modify Chapter 6 ,Chapter 3
2011.10.18
V3.0 Modify chapter 5,add new method to upgrade
multimedia FW
ML500
Copyright OCT. 2011 All Rights Reserved
Chris Amy Alick

ML500 Condential II
Preface
This manual is applied to ML500 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.
ML500 Service Manual
Copyright OCT. 2011
All Rights Reserved
Manual Version 3.0

ML500 Condential
III
Table of Content
Chapter 1 Introduction
Highlight 1-1
Compatible Mode 1-2
Chapter 2 Disassembly Process
Equipment Needed & Product Overview 2-1
Disassemble Top Cover Module and Key Pad 2-2
Disassemble LED Driver Board 2-4
Disassemble Main Board 2-5
Disassemble Fan 2-6
Disassemble Light Sensor Board 2-7
Disassemble Speaker and IR Board 2-7
Disassemble Engine Module and LED 2-8
Disassemble LVPS 2-10
Disassemble Bottom Cover Module 2-11
Re-write LED Usage Hour 2-12
Repair Action 2-13
Chapter 3 Troubleshooting
Equipment Needed 3-1
Main Procedure 3-2
No Power Troubleshooting 3-3
Power Troubleshooting 3-4
Image Troubleshooting 3-5

ML500 Condential IV
Remote Control Troubleshooting 3-9
Chapter 4 Function Test & Alignment Procedure
Test Equipment Needed 4-1
Test Conditon 4-1
I/O Port Test 4-2
Composite Port And Audio Test 4-7
S-Video Port Test 4-7
HDMI Port Test 4-7
3D test 4-8
SD Card /Mini USB/ USB ash disk test 4-8
Calibration 4-10
Run in test 4-12
Test Inspection Procedure 4-13
Chapter 5 Firmware Upgrade
Section 1: System Firmware Upgrade 5-1
Equipment Needed 5-1
DLP Composer Lite Setup Procedure 5-2
Firmware Upgrade Procedure 5-4
Section 2: Multi-Media Firmware Upgrade(USB) 5-7

ML500 Condential VI
USB Driver Upgrade Procedure 5-8
Multi-Media Firmware Upgrade 5-10
Section 3: Multi-Media Firmware Upgrade(SD Card) 5-13
Multi-Media Firmware Upgrade procedure 5-14
Section 4: 8051 Firmware Upgrade 5-17
Firmware Upgrade Procedure 5-18
Chapter 6 EDID Upgrade
EDID upgrade procedure 6-1
Appendix A Exploded Overview I
Appendix B Serial Number System Denition X
PCBA Code Denition XI

ML500 Condential 1-1
Chapter 1
Introduction
1-1 Highlight
No Item Description
1Dimensions (WxDxH) ● 220x170x41 mm
2Power Supply ● Auto-ranging: AC100V ~ 240V ± 10%, 50-60Hz
3Power consumption ●Normal mode: 120W +/- 20%.@ 110Vac
●ECO mode: 60W +/-20% @ 110Vac
4 Keystone correction ● Vertical +/-40 degree
5Throw ratio ●WXGA 1280x800 1.4 +/- 5%
6 Projection lens ● YM102
7 LED life 20,000 Hours Bright Mode @ 75W +/-10 % , B50/
L50*Note Survival Rate
8 DMD Chip ●TI” DMD , 0.45” WXGA DMD
9System controller ● TI DPP6401
10 Throw Distance 0.52m ~3.00 m (mechanical travel range)
0.91m ~ 2.40 m (optical travel range)
11 Video compatibility
Standards :
● NTSC M/J, 3.58MHz, 4.43MHz
● PAL BG/DK/I/M/N , 4.43MHz
● 480i, 480p, 576i, 576p, 720p, 1080i
12 Input signal spec
● Analog RGB signal (PC)
- Analog RGB 0.7 +/- 0.1 Vp-p, 75 ohm
- Separate TTL H,V Sync.
● Video signalVideo signal
- NTSC/PAL Composite video 1.0 +/- 0.1 Vp-p, 75ohm
● Audio signalAudio signal
- 900mVrms, 22K ohm

Condential 1-2
ML500
Compatibility Resolution V-Sync [Hz]
VGA
640 x 480 60
800x600 60
1024x768 60
1280x720 60
1280x800 60
Video
480i/480p 60
576i/576p 50
720p 50/60
1080i/1080p 50/60
HDMI
480i/480p 60
576i/576p 50
720p 50/60
1080i/1080p 50/60
No Item Description
13 Altitude&Temperature
● Operating: 0 ~ 2,500 ft, for 5°C~35°C
2,500 ft ~ 5,000 ft, for 5°C~30°C
5,000 ft ~ 10,000 ft, for 5°C~25°C
● Operating: 5 ~ 35 °C
Non-operation:-20°C ~ 60°C
1-2 Compatible Mode
●Computer Compatibility

Condential 1-3
ML500
●Compatibility: Document
Ofce Version
Microsoft® Ofce 95
Microsoft® Ofce 97
Microsoft® Ofce 2000
Microsoft® Ofce 2003
Microsoft® Ofce 2007
Microsoft® Ofce 2010
- Compatible Document Format
- Compatible Document Format
Microsoft® Ofce Application File Extension
Word .doc
.docx
Power Point .ppt
.pptx
Excel .xls
.xlsx
Adobe PDF .pdf
●Media File Support List Video
File Type Video Resolution Bit Rate Frame Rate Audio Code Remark
AVI
MKV
XVID
MPEG4
H.264
M-JPEG
WMV3
1080P 20Mbps 30fps
AC3
DTS
MPEG1/2/3
PCM
ADPCM
AAC
No support VC-
1 AP
H.264 support
less
than 4 reference
frames
TS H.264 1080P 20Mbps 30fps
AC3
AAC
MPEG1/2/3
DTS
LPCM
H.264 support
less
than 4 reference
frames
DAT
VOB
MPG
MPEG
MPEG-1 1080P 20Mbps 30fps
MPEG1/2/3
AC3
DTS
LPCM
- Video

Condential 1-4
ML500
MOV
MP4
3GP
MPEG-4
H.264
H.263
1080P 20Mbps 30fps
AAC
AMR
PCM
ADPCM
H.264 support
less
than 4 reference
frames
RM
RMVB
RV3
RV4 720P 5Mbps 30fps
Cook(RA4)
AAC(RA9)
RACP(RA10)
WMV WMV3 1080P 20Mbps 30fps WMA2
WMA3
No support VC-
1 AP
- Image
Image Type (Ext
name)
Sub Type Encode Type Max Pixels
JPEG
JPG
Baseline
YUV400 No Limit
YUV420 No Limit
YUV422 No Limit
YUV440 No Limit
YUV444 No Limit
Progressive
YUV400
Width<=10240
& Height <= 6400
YUV420
YUV422
YUV440
YUV444
BMP No Limit
- Music
Music Type (Ext name) Sample Rate (KHz) Bit Rate (Kbps)
MP1/MP2/MP3 8-48 8-320
WMA 22-48 5-320
OGG 8-48 64-320
ADPCM-WAV 8-48 32-384
PCM-WAV 8-48 128-1536
AAC 8-48 8-256
Note: If the Computer Compatibility supportive signal is different from User’s Manual,
please refer to User’s Manual.

ML500 Condential 2-1
Chapter 2
Disassemble And Repair Action
2-1 Equipment Needed & Product Overview
1. Screw Bit (+) :107
2. Hex Sleeves 5mm
3. Screw Bit (+) :102
4. Hex Sleeves 7mm
5. Tweezers
6. ML500 unit
* 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 get into service mode and
record the LED usage hour. please refer to section 2-12.

ML500 Condential 2-2
2-2 Disassemble Top Cover
Module and Key Pad
1. Unscrew 4 screws on bottom side (as
red circle)
2. Disassemble the Top Cover
(as red arrow direct).

ML500 Condential 2-3
3. Tear off the mylar
4. Separate the keypad and the Top Cover
Module.

ML500 Condential 2-4
2-3 Disassemble LED Driver
Board
1. Unscrew 2 screws (as red circle)
2. Unplug 3 connectors (as red square)
3.Push the LED Driver Board (as red
arrow direct)
4.Unplug 1 connector (as yellow square)
5. Unplug 3 connectors (as yellow circle),
disassemble LED to LED Driver Board
cable and LED Driver Board. GREEN LED
CABLE
RED LED
CABLE
BLUE LED
CABLE
LED Driver Board

ML500 Condential 2-5
2-4 Disassemble Main Board
1. Disassemble 2 hex screws on theDisassemble 2 hex screws on the
rear side(as red circle)
2. Unscrew 4 screws (as red circle)
3. Unplug 7 connectors (as red square)
4. Disassemble Main Board
Main Board

ML500 Condential 2-6
2-5 Disassemble Fan
1. Take off three Fans
Note: Care the direction about how to place
the fan (as yellow square).

ML500 Condential 2-7
2-6 Disassemble Light
Sensor Board
1. Unscrew 1 screw to disassemble Light
Sensor Board (as red circle)
2-7 Disassemble Speaker
and IR Board
1. Unscrew 2 screws to disassemble
speaker (as red circle)
2. Take off IR Board (as red square)

ML500 Condential 2-8
2-8 Disassemble Engine
Module and LED
1. Unscrew 4 screws to disassemble
Engine Module (as red circle)
2. Unscrew 4 screws on the rear side of
the Engine Module to disassemble
DMD Module and Green LED(as
yellow circle),
DMD Board

ML500 Condential 2-9
3. Disassemble the Green LED.
4. Unscrew 2 screws on the front side
of the Engine Module to disassemble
Red LED(as red circle).
ENGINE MODULE

ML500 Condential 2-10
2-9 Disassemble LVPS
1. Unscrew 6 screws (as red circle)
2. Unplug 2 cables (as red square)
to disassemble LVPS to Main Board
cable(8 pin) , LVPS to LED Driver
Board cable(10 pin) and LVPS
LVPS

ML500 Condential 2-11
2-10 Disassemble Bottom
Cover Module
1. Take off Mylar(as yellow square)
and Unscrew 1 screw (as red circle)
to disassemble Bottom Cover Module