Sony VPL-CS5A User manual

DATA PROJECTOR
VPL-CS5A
VPL-CS6
VPL-CX6
VPL-EX1
REMOTE CONTROLLER
RM-PJ2
RM-PJM12
SERVICE MANUAL
1st Edition

VPL-CS5A/CS6/CX6/EX1
!WARNING
This manual is intended for qualified service personnel only.
To reduce the risk of electric shock, fire or injury, do not perform any servicing other than that
contained in the operating instructions unless you are qualified to do so. Refer all servicing to
qualified service personnel.
!WARNUNG
Die Anleitung ist nur für qualifiziertes Fachpersonal bestimmt.
Alle Wartungsarbeiten dürfen nur von qualifiziertem Fachpersonal ausgeführt werden. Um die
Gefahr eines elektrischen Schlages, Feuergefahr und Verletzungen zu vermeiden, sind bei
Wartungsarbeiten strikt die Angaben in der Anleitung zu befolgen.Andere als die angegeben
Wartungsarbeiten dürfen nur von Personen ausgeführt werden, die eine spezielle Befähigung
dazu besitzen.
!AVERTISSEMENT
Ce manual est destiné uniquement aux personnes compétentes en charge de l’entretien.Afin
de réduire les risques de décharge électrique, d’incendie ou de blessure n’effectuer que les
réparations indiquées dans le mode d’emploi à moins d’être qualifié pour en effectuer d’autres.
Pour toute réparation faire appel à une personne compétente uniquement.
WARNING!!
AN INSULATED TRANSFORMER SHOULD BE USED DURING
ANY SERVICE TO AVOID POSSIBLE SHOCK HAZARD, BE-
CAUSE OF LIVE CHASSIS.
THE CHASSIS OFTHIS RECEIVER IS DIRECTLY CONNECTED
TOTHE AC POWER LINE.
SAFETY-RELATED COMPONENT WARNING !!
COMPONENTS IDENTIFIED BYA !!
!!
!MARKONTHESCHEMATIC
DIAGRAMS, EXPLODEDVIEWS AND INTHE PARTS LIST ARE
CRITICAL TO SAFE OPERATION. REPLACE THESE COMPO-
NENTSWITH SONY PARTSWHOSE PART NUMBERS APPEAR
AS SHOWN IN THIS MANUAL OR IN SUPPLEMENTS PUB-
LISHED BY SONY.
ATTENTION!!
AFIN D’ÉVITER TOUT RISQUE D’ÉLECTROCUTION
PROVENANT D’UN CHÂSSIS SOUS TENSION, UN
TRANSFORMATEUR D’ISOLEMENT DOITETRE UTILISÉLORS
DETOUT DÉPANNAGE.
LE CHÂSSIS DE CE RÉCEPTEUR EST DIRECTEMENT
RACCORDÉ Á L’ALIMENTATION SECTEUR.
ATTENTION AUX COMPOSANTS RELATIFS Á LA
SÉCURITÉ!!
LES COMPOSANTS IDENTIFIÉS PAR UNE MAPQUE !!
!!
!SUR
LES SCHÉMAS DE PRINCIPE,LESVUES EXPLOSÉES ET LES
LISTES DE PIECES SONT D’UNE IMPORTANCE CRITIQUE
POUR LA SÉCURITÉ DU FONCTIONNEMENT. NE LES
REMPLACER QUE PAR DES COMPOSANTS SONY DONT LE
NUMÉRODEPIÈCEESTINDIQUÉDANSLE PRÉSENTMANUEL
OU DANS DES SUPPLÉMENTS PUBLIÉS PAR SONY.

VPL-CS5A/CS6/CX6/EX1
For the customers in the Netherlands
Voor de klanten in Nederland
Hoe u de batterijen moet verwijderen, leest u in de tekst
van deze handleiding.
Gooi de batterij niet weg maar lever deze in als klein
chemisch afval (KCA).
Für Kunden in Deutschland
Entsorgungshinweis: Bitte werfen Sie nur entladene
Batterien in die Sammelboxen beim Handel oder den
Kommunen.Entladen sind Batterien in der Regel dann,
wenn das Gerät abschaltet und signalisiert “Batterie
leer”oder nach längerer Gebrauchsdauer der Batterien
“nicht mehr einwandfrei funktioniert”. Um
sicherzugehen, kleben Sie die Batteriepole z.B.mit
einem Klebestreifen ab oder geben Sie die Batterien
einzeln in einen Plastikbeutel.
1 (P)

1
VPL-CS5A/CS6/CX6/EX1
Table of Contents
1. Service Overview
1-1. Appearance Figure ......................................................................................1-1
1-2. Board Locations ..........................................................................................1-1
1-3. Disassembly ................................................................................................1-2
1-3-1. Top Panel Assy Removal ...........................................................1-2
1-3-2. Side Panel Assy and L, NR, H2, Q Boards Removal ................1-2
1-3-3. Power Block (Lamp) Removal...................................................1-3
1-3-4. DC Fan Removal........................................................................1-3
1-3-5. Lens Gear Removal ....................................................................1-4
1-3-6. Speaker Assy and DC Fan (Sirocco) Removal ..........................1-4
1-3-7. C Board Removal .......................................................................1-5
1-3-8. MSC and MS (VPL-CX6) Boards Removal ..............................1-5
1-3-9. GA and GB Boards Removal .....................................................1-6
1-3-10. Opt Unit Assy and Lamp Assy Removal ...................................1-7
1-3-11. PS Con Aperture (VPL-EX1) and S In-polarizer (R), (G), (B)
Removal .....................................................................................1-7
1-3-12. Projection Lens Assy, Lamp Duct Assy and
U Board Removal.......................................................................1-8
1-3-13. S Prism Block Assy and
S Out-pre-polarizer (R), (G), (B) Removal ................................1-9
1-3-14. DC Fan (Sirocco) and V Board Removal ................................1-10
1-3-15. S Board Removal .....................................................................1-11
1-3-16. Extension Board and Extension Connectors ............................1-12
1-3-17. Extension Board and Extension Connectors Connection.........1-13
1-3-18. Warning on Power Connection ................................................1-14
2. Electrical Adjustments
2-1. Preparation ..................................................................................................2-1
2-1-1. Required Equipment...................................................................2-1
2-1-2. Opt Unit Adjustment ..................................................................2-1
2-1-3. How to Enter the Factory Mode .................................................2-2
2-2. V COM Adjustment ....................................................................................2-2
2-3. Initial Values of Adjustment Items .............................................................2-3
2-4. Service Know-How ...................................................................................2-11
2-4-1. When the S Prism Block Is Replaced ......................................2-11
2-4-2. When the C Board Is Replaced ................................................2-11
2-4-3. When the Adjuster Assy Is Returned
by the Emergency Mode ..........................................................2-11
2-5. White Balance Adjustment .......................................................................2-12
2-5-1. HIGH Mode of INPUT-A ........................................................2-12
2-5-2. LOW Mode of INPUT-A .........................................................2-12
2-5-3. HIGH Mode of VIDEO............................................................2-12
2-5-4. LOW Mode of VIDEO.............................................................2-12
2-6. Memory Structure .....................................................................................2-13

2VPL-CS5A/CS6/CX6/EX1
3. Semiconductors................................................................................. 3-1
4. Spare Parts
4-1. Notes on Repair Parts..................................................................................4-1
4-2. Exploded Views ..........................................................................................4-2
4-3. Electrical Parts List ...................................................................................4-10
5. Block Diagrams
Overall ....................................................................................................................5-1
C (1/4), Q................................................................................................................5-2
C (2/4).....................................................................................................................5-3
C (3/4), H1, H2, L, V, U, NR .................................................................................5-4
C (4/4).....................................................................................................................5-5
MS, MSC ................................................................................................................5-6
GA, GB...................................................................................................................5-7
6. Diagrams
6-1. Frame Schematic Diagrams ........................................................................6-2
Frame (1/2) ...............................................................................................6-2
Frame (2/2) ...............................................................................................6-3
6-2. Schematic Diagrams and Board Layouts ....................................................6-4
Schematic Diagrams
Q................................................................................................................6-4
C (1/10) .....................................................................................................6-6
C (2/10) .....................................................................................................6-7
C (3/10) .....................................................................................................6-8
C (4/10) .....................................................................................................6-9
C (5/10) ...................................................................................................6-10
C (6/10) ...................................................................................................6-11
C (7/10) ...................................................................................................6-12
C (8/10) ...................................................................................................6-13
C (9/10) ...................................................................................................6-14
C (10/10) .................................................................................................6-15
V..............................................................................................................6-14
U..............................................................................................................6-14
S ..............................................................................................................6-15
H1............................................................................................................6-20
H2............................................................................................................6-21
L ..............................................................................................................6-22
NR ...........................................................................................................6-22

3
VPL-CS5A/CS6/CX6/EX1
MSC (1/2) ...............................................................................................6-23
MSC (2/2) ...............................................................................................6-24
MS (1/3) ..................................................................................................6-26
MS (2/3) ..................................................................................................6-27
MS (3/3) ..................................................................................................6-28
GA...........................................................................................................6-30
GB ...........................................................................................................6-33
Board Layouts
Q................................................................................................................6-5
C ..............................................................................................................6-16
S ..............................................................................................................6-16
U..............................................................................................................6-16
V..............................................................................................................6-17
H1............................................................................................................6-20
H2............................................................................................................6-21
L ..............................................................................................................6-22
NR ...........................................................................................................6-22
MSC ........................................................................................................6-25
MS...........................................................................................................6-29
GA...........................................................................................................6-31
GB ...........................................................................................................6-34

1-1
VPL-CS5A/CS6/CX6/EX1
Section 1
Service Overview
1-2. Board Locations
C
H1 NR
H2
MSC
MS
(VPL-CX6 )
V
U
Q
Power block (lamp)
GB
GA
L
S
1-1. Appearance Figure

1-2 VPL-CS5A/CS6/CX6/EX1
1Six shafts
4H1 board
3Button (H1) assy
5Top panel assy
2Two screws
(+B 3 x6)
1-3. Disassembly
1-3-1. Top Panel Assy Removal
1-3-2. Side Panel Assy and L, NR, H2, Q Boards Removal
7Button (H2)
2Two screws
(+B 3 x6)
6Screw
(+B 3 x6)
9Screw
(+B 3 x6)
3Side panel assy
8H2 board
1Connector cover
!- Q board
0Video sleeve
4L board
5NR board
CN914
CN915
CN201

1-3
VPL-CS5A/CS6/CX6/EX1
1-3-3. Power Block (Lamp) Removal
3Holder (LPS2)
4Holder (LPS1)
5Sheet (LPS)
6Power block (Lamp)
1Two screws
(+PTPWH 3 x10)
CN1
CN1
CN907
2Two screws
(+B 3 x6)
1-3-4. DC Fan Removal
2Four screws
(+B 3 x20)
CN908
C board
CN909
3Fan holder (EX2)
5Two DC fans
4Two masks
1Screw
(+B 3 x6)

1-4 VPL-CS5A/CS6/CX6/EX1
1-3-5. Lens Gear Removal
2Lens gear
1Two screws
(+BTP 3 x12)
1-3-6. Speaker Assy and DC Fan (Sirocco) Removal
1Two screws
(+B 3 x6)
5Two screws
(+B 3 x6)
6Screw
(+B 3 x6)
3Two screws
(+BTP 3 x12)
9Speaker assy
7Speaker holder
8Speaker bracket
CN1102
CN912
4DC fan (Sirocco)
2Fan (RE) holder

1-5
VPL-CS5A/CS6/CX6/EX1
1-3-7. C Board Removal
1Three screws
(+B 3 x6)
Flat connector assy
2C board
CN904 CN202 (VPL-CX6)
CN907
CN913
CN1101
CN901
CN911
CN910
CN914
CN912
CN909
CN908
CN1102
CN903
CN202
CN904
*1: CN601
*2: CN602
*1: CN701
*2: CN702
*1: CN501
*2: CN502
*1: Indicates the VPL-CX6/EX1.
*2: Indicates the VPL-CS5A/CS6.
1-3-8. MSC and MS (VPL-CX6) Boards Removal
To remove the MS (VPL-CX6) board, remove the C board beforehand.
2MSC board
4MS board
CN1303
CN1301
CN1002
CN1001
(VPL-CX6)
Flat connector assy
(12P) Flat connector assy
(50P)
3Two screws
(+B 3 x6)
1Screw
(+B 3 x6)

1-6 VPL-CS5A/CS6/CX6/EX1
CN3301
CN3501
CN3201
CN2001CN2002
Flat connector assy
(24P)
7GB board
5GA board
6Holder GB
1Two screws
(+B 3 x6)
3Screw
(+B 3 x6)
2Screw
(+B 3 x6)
4Holder (GA),
Shield (GA)
1-3-9. GA and GB Boards Removal
To remove the GA and GB boards, remove the C board beforehand.

1-7
VPL-CS5A/CS6/CX6/EX1
1-3-10.Opt Unit Assy and Lamp Assy Removal
To remove the opt unit assy and lamp assy, remove C board and the DC fan beforehand.
4Four screws
(+P M4x12)
5Opt unit assy
1Two screws
(+PWHTP 3 x10)
6Lamp house,
Lamp top cover
2Connector
(Lamp)
7Lamp assy
3Two screws
(+B 3 x6)
Opt unit assy
Note :Do not disassemble the opt unit unless
specified by the above views.
!- S In-polarizer (B)
assy 4Lens-1 fly eye
Note when installing:
(For theVPL-EX1, the protruded portion
should be installed in the Lens-2 fly eye side.)
(For theVPL-CS6/CX6/CS5A, the protruded portion
should be installed in the UV-cut pre-filter side.)
5P/S assy
0S In-polarizer (R)
assy
9S In-polarizer (G)
assy
6PS con aperture
(VPL-EX1)
7Lens-2 fly eye
3UV-cut pre-filter
2Unit cover (B), Six cushions
Opt unit assy
1Two screws
(+B 2 x6)
8Three screws
(+B 2 x6)
1-3-11.PS Con Aperture (VPL-EX1) and S In-polarizer (R), (G), (B) Removal

1-8 VPL-CS5A/CS6/CX6/EX1
1-3-12.Projection Lens Assy, Lamp Duct Assy and U Board Removal
To remove the projection lens assy, lamp duct assy and U board, remove the C board, opt unit assy and lamp assy
beforehand.
5Lamp duct assy
3Projection lens assy
1Four screws
(+B 4 x12)
2Four screws
(+BSW M3 x8)
4Two screws
(+B 3 x6)
6Screw
(+B 3 x6)
7Holder U
8U board

1-9
VPL-CS5A/CS6/CX6/EX1
0S Out-pre-polarizer (G)
7S Out-pre-polarizer (B)
9Fastener (OP)
6Fastener (OP)
!- S Prism block assy
4S Out-pre-polarizer (R)
3Fastener (OP)
1Two screws
(+PS 3 x6)
8Screw
(+PTP 2 x5)
5Screw
(+PTP 2 x5)
2Screw
(+PTP 2 x5)
1-3-13.S Prism Block Assy and S Out-pre-polarizer (R), (G), (B) Removal
n
Do not touch the flexible cable, glass surface of S prism and especially the conductor surface of flexible cables.

1-10 VPL-CS5A/CS6/CX6/EX1
1-3-14.DC Fan (Sirocco) and V Board Removal
To remove the DC fan (sirocco) and V board, remove the C board, opt unit assy, lamp assy and
S prism block assy beforehand.
2Prism duct
8DC fan (sirocco)
7Two screws
(+BTB 3 x12)
1Two screws
(+B 3 x6)
3Screw (+B 3 x6)
6DC fan (sirocco)
9Fan holder (IN)
4V board
5Two screws
(+BTP 3 x12)

1-11
VPL-CS5A/CS6/CX6/EX1
4 Two screws
(+P 2 x 4)
6Adjuster shaft
9S board
3
Four screws
(+P 2 x 2.2)
8
Two screws
(+P 2 x 4)
7Adjuster frame assy
5Remove the adjuster holder
in the direction of the arrow.
CN1
VR shaft
1Adjuster section
2Remove the
binding band
1-3-15.S Board Removal
To remove the S board, remove the C board, opt unit Assy, lamp assy, S prism block assy and
DC fan (sirocco) beforehand.

1-12 VPL-CS5A/CS6/CX6/EX1
X kit assy
(A-1603-729-A)
3 Five ZH connectors assy (3P)
5 ZH connector assy (5P)
1 VH connector assy (3P)
4 SR connector assy (4P)
6 SR connector assy (7P)
7 SR connector assy (14P)
2 Flat connector assy (24P)
8 Three flat connectors assy (32P)
(VPL-CX6/EX1)
9 Three flat connectors assy (24P)
(VPL-CS5A/CS6)
0 SR connector assy (12P)
!- SR connector assy (5P)
!; X1 board
!\ X5 board
!= Three X2 boards
(VPL-CX6/EX1)
!] X4 board
![ Three X3 boards
(VPL-CS5A/CS6)
The numbers encircled by round corresponds to those of section 1-3-17.
1-3-16.Extension Board and Extension Connectors