Sony VPL-ES3 User manual

DATA PROJECTOR
VPL-ES3
REMOTE COMMANDER
RM-PJ4
SERVICE MANUAL
1st Edition

VPL-ES3
!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.
CAUTION
RISK OF EXPLOSION IF BATTERY IS REPLACED BY INCORRECT TYPE.
DISPOSE OF USED BATTERIES ACCORDING TO THE RULE IN REGION.

1
VPL-ES3
Table of Contents
1. Service Information
1-1. Appearance Figure .......................................................... 1-1
1-2. Board Locations .............................................................. 1-1
1-3. Disassembly .................................................................... 1-1
1-3-1. Upper Case Assembly ........................................... 1-2
1-3-2. Front Case Assembly and
Sub Rear Case Assembly ...................................... 1-2
1-3-3. Main Board ............................................................ 1-3
1-3-4. Tunnel Outlet Section ............................................1-4
1-3-5. Main Board Bracket Section ................................. 1-4
1-3-6. Power Board and Lamp Power Supply ................. 1-5
1-3-7. Optics Section ....................................................... 1-6
1-3-8. DC Fan .................................................................. 1-7
1-4. Warning on Power Connection ....................................... 1-8
2. Electrical Adjustments
2-1. Initial Values of Adjustment Items ................................. 2-1
2-2. Memory Structure ........................................................... 2-5
3. Troubleshooting
3-1. Electric Troubleshooting ................................................ 3-1
3-2. Power Board Troubleshooting ........................................ 3-3
3-2-1. No Power ............................................................... 3-3
3-2-2. Failure of Turn on Lamp ....................................... 3-4
4. Spare Parts
4-1. Notes on Repair Parts ..................................................... 4-1
4-2. Exploded Views .............................................................. 4-2
4-3. Electrical Parts List ......................................................... 4-4
4-4. Packing Materials & Supplied Accessories .................... 4-4
5. Block Diagram
Overall ............................................................................ 5-1
6. Diagram
6-1. Frame Schematic Diagram ............................................. 6-1

1-1
VPL-ES3
1-1. Appearance Figure
1-2. Board Locations
Section 1
Service Information
Lamp power supply
Main
Power Detection switch
IR sensor
Thermal sennsor

1-2 VPL-ES3
1-3. Disassembly
1-3-1. Upper Case Assembly
3 Four claws
4Upper Case assembly
Remove the Upper Case from this corner with the
strong force to the extent that the Upper Case will
not be damaged.
1 Filter door
2 Five screws
(M 3 x 6)
1-3-2. Front Case Assembly and Sub Rear Case Assembly
7 Two screws
(M 3 x 6)
6Flat head
s
crew (M 3)
9 Sub rear case assembly
4 Two screws
(+K 3 x 12)
5 Six hexagon
screws
0 Front case assembly
1 Lens cap
8 Two claws
J6
J11
Main board
3Shield
2 Two screws
(M 3 x 6)

1-3
VPL-ES3
1-3-3. Main Board
3 Main shield
2 Joystick key
4 Main board
1 Three screws
(M 3 x 6)
J19
J12
J13 J17 J24 J16 J18
J20
J21
J22
J14
Because the harnesses has the shape of flat
cross-section, do not insert the harnesses with
excessive force. Find out the direction in
which the harnesses can be inserted easily,
and then insert the harnesses.
Harnesses
Lamp box assembly
Main board
Harnesses clamp section
When re-assembling,
give an appropriate
amount of extra slack
of this harnesses.

1-4 VPL-ES3
1-3-4. Tunnel Outlet Section
J16
Main board
1 Two tapping screws
(PAN 3 x 7)
2 Tunnel outlet section
J16
Main board
Because the harnesses has the shape of flat
cross-section, do not insert the harnesses with
excessive force. Find out the direction in
which the harnesses can be inserted easily,
and then insert the harnesses.
Harnesses
Harnesses clamp section
Lamp box
assembly
When re-assembling,
give an appropriate
amount of extra slack
of this harnesses.
1-3-5. Main Board Bracket Section
Remove the Main board before starting the removal work
2 Three tapping screws
(PAN 3 x 7)
1 Two screws
(M 3 x 6)
4 Main board bracket section
3S crew
(M 4 x 6)
Power board

1-5
VPL-ES3
1-3-6. Power Board and Lamp Power Supply
Remove the Tunnel Outlet unit before starting the removal work.
n
In older to remove the connector that is connected to the lamp power supply block, remove the lamp
power supply first. Then, remove the connector after the lamp power supply block is raise up. Do not give
an excessive force to the harness.
7 Lamp
9 Cushion
0 Lamp power supply
1Two stands assembly
2 Power board
8 Lamp power
supply
connector
5 Lamp door
4 loosen screw.
6 Loosen two screws.
3Screw
(+PWH 3 x 8)
CN603
To the main board J12
From the Main board CN602
(Red and Black wires)

1-6 VPL-ES3
1-3-7. Optics Section
2 Lamp box assembly
6Optics section
1 Rotate the Zoom dial clockwise
as shown until it is stopped.
4 Focus/Zoom adjust
assembly
1 Two tapping screws
(PAN 3 x 7)
3 Two tapping screws
(PAN 3 x 7)
5 Four screws
(+P 2.5 x 8)
2 Rotate the Focus dial
counter-clockwise as
shown until it is stopped.
3 Rotate the Focus dial
counter-clockwise as
shown until it is stopped.
5
Install the Optics section
in the Lower Case.
During the assembling process,
never change the gear position
that is set by step
3 .
4
Rotate the Focus/Zoom Adjust Assembly
counter-clockwise until it is stopped.
6
Install the Focus/Zoom
Adjust Assembly as shown.
7After installation is completed, verify that the Optics
section can rotate from the position A to the position
B smoothly.
A
B
Lower case
Assembling Method of Optics section and
Focus/Zoom Adjust Assembly
Phase matching
Focus dial

1-7
VPL-ES3
1-3-8. DC Fan
1 Two tapping screws
(PAN 3 x 7)
3 Two tapping screws
(+PWH 3 x 10)
2 Duct LCD assembly
8 Duct lamp
4DC fan
6DC fan
5
Two tapping screws
(M 3 x 25)
7 Two tapping screws
(PAN 3 x 7)

1-8 VPL-ES3
1-4. Warning on Power Connection
Use a proper power cord for your local power supply.
The United States, Continental UK, Ireland, Japan
Canada Europe Australia, New Zealand
Plug type VM0233 290B YP-12A COX-07 _1) YP332
Connector type VM0089 386A YC-13B COX-02 VM0310B YC-13
Cord type SJT SJT H05VV-F H05VV-F N13237/CO-228 VCTF
Rated Voltage/Current 10A/125V 10A/125V 10A/250V 10A/250V 10A/250V 7A/125V
Safety approval UL/CSA UL/CSA VDE VDE VDE DENAN
Cord length (max.) 4.5m (14 feet 9 inches) _
(1) Use an appropriate rating plug which is applied to local regulations.

2-1
VPL-ES3
2-1. Initial Values of Adjustment Items
Section 2
Electrical Adjustments
ItemName MemoryName
Re-
marks
Set
Memory
Status
Memory
Picture Memory
Video S Video Input-A (Computer) Input-A (Component,VideoGBR)
Dynamic Standard Game Living Cinema
Presentation
Dynamic Standard Game Living Cinema
Presentation
Dynamic Standard Game Living Cinema
Presentation
Dynamic
Standard
Game Living Cinema Presentation
Picture Mode *
Adjust
Picture...
Contrast 90 80 90 90 75 85 90 80 90 90 75 75 90 80 90 90 60 85 90 80 90 90 75 85
Brightness 60 50 60 50 50 55 60 50 60 50 50 55 60 50 60 50 50 55 60 50 60 50 50 55
Color 50 50 65 60 58 50 50 50 65 60 55 50 - - - - - - 50 50 65 60 50 55
Hue 50 50 50 50 50 50 50 50 50 50 50 50
Sharpness 60 30 50 50 30 50 60 30 40 40 30 40 - - - - - - 60 30 40 40 30 40
Gamma
Mode
- - - - - - - - - - - - Graphics Graphics
Graphics Graphics Graphics
Graphics - - - - - -
Color
Temp. High Low High Low Low High High Low High Low Low High High High High Low Low High High Low High Low Low High
Volume 30
INPUT
SETTING
Adjust
Signal...
Dot Phase
15 (*)
H Size *
Shift *
Wide Mode Off Off Off Off On Off Off Off Off Off On Off - - - - - - Off Off Off Off On Off
Scan Conv On On On On On On - - - - - -
Smart APA On
Auto Input
Search
Off
Color System Auto
Input-A
Signal Sel.
Component
Power Saving Off
IR Receiver Front & Rear
Panel Key Lock Off
Status On
Languege English
Menu Position Center
V Keystone 0
Image Flip Off
Background Blue
Lamp Mode Standard
High Altitude
Mode
Off
Security Lock Off
Key Enter x 4
fH Display only
Display only
Display only
Display only
Display only
fV
(Memory No.)
(Resolution)
Lamp Timer
Menu
Title
INFOR-
MATION
PICTURE
SETTING
MENU
SETTING
INSTALL
SETTING
SET
SETTING
*The “Dot Phase E, H Size, Shift H/V and Picture Mode” items in the “INPUT SETTING” menu have their respective initial values for each input signal (PRESET MEMORY No.).
*PICTURE SETTING" The "Picture Mode" item that exists in the menu is also similar.
n
There are some adjustment items that cannot be adjusted, depending on the input signal.

2-2 VPL-ES3
Page ItemName MemoryName
Re-
marks
Set Color CH
RGB Video Computer Component
VideoGBR
Page1 TGHST Phase Hi 0
TGHST Phase Lo 109
SHSH1 38
TGHST Position 12
DEHPF On Off On Off
DEHPF AAC Off Off Off
DEHPF TAP 1 1 1
DEUSC On On On On
3D GAMMASubCont 0
3D GAMMASubBrt 150
Page2 USC_GAIN_R 128
USC_GAIN_G 128
USC_GAIN_B 128
USC_BIAS_R 0
USC_BIAS_G 0
USC_BIAS_B 0
USC_GAIN_R 128
USC_GAIN_G 70
USC_GAIN_B 100
USC_BIAS_R 0
USC_BIAS_G 0
USC_BIAS_B 0
USC_GAIN_R 128
USC_GAIN_G 80
USC_GAIN_B 120
USC_BIAS_R 0
USC_BIAS_G 0
USC_BIAS_B 0
USC_GAIN_R 128
USC_GAIN_G 70
USC_GAIN_B 100
USC_BIAS_R 0
USC_BIAS_G 0
USC_BIAS_B 0
DELUT SW ON
DEUF SW Off
ROM Version Display only
Display only
Display only
Display only
LAMP TIMER
OPERATION TIMER
PREV.LAMp TIMER
PC COLOR
TEMP Hi
PC COLOR
TEMP Lo
VIDEO COLOR
TEMP Hi
VIDEO COLOR
TEMP Lo

2-3
VPL-ES3
Page ItemName MemoryName
Re-
marks
Set Color CH
RGB Video Computer Component
VideoGBR
Page3 GainR 163
GainG 163
GainB 163
BiasR_NORMAL 102
BiasG_NORMAL 102
BiasB_NORMAL 102
BiasR_FLIP 128
BiasG_FLIP 128
BiasB_FLIP 128
Page4 SigCenR 33
SigCenG 33
SigCenB 33
SidA_R 21
SidA_G 20
SidA_B 20
SidB_R 83
SidB_G 85
SidB_B 84
Page5 VcomR_NORMAL 88
VcomG_NORMAL 88
VcomB_NORMAL 88
VcomR_FLIP 88
VcomG_FLIP 88
VcomB_FLIP 88
Page6 ADC Offset RGB 70 70 70
ADC Gain RGB 130 130 130
PbPr R Offset 123
PbPr R Offset 63
PbPr R Offset 120
PbPr R Gain 23
PbPr G Gain 63
PbPr B Gain 30
Page7 Test-Pattern 2 Off
PW filter RGB_320T_1.PWF RGB_320T_3.PWF RGB_320T_1.PWF
Color Space REC601_YCBCR RGB REC601_YCBCR
Interpolation 1-Field 1-Field 1-Field
Gray Value 128
Blue Value 128

2-4 VPL-ES3
Page ItemName MemoryName
Re-
marks
Set Color CH
R G B Video Computer Component
VideoGBR
Page8 TemperatureSensor1 Display only
Display only
Display only
Display only
Display only
Display only
Display only
Display only
TemperatureSensor2
TemperatureSensor3
FanSpeed1
FanSpeed2
FanSpeed3
FanSpeed4
FanSpeed5
ManualFanSpeed Off
System Protect On
Page9 RS232 Debug Info 1
RS232 Debug Info 2
RS232 Debug Info 3
RS232 Debug
Test Strin
g
SogThreshold 25
Page10 Uniformity R 123
Uniformity G 63
Uniformity B 120
Burn-In Cycle 0
Burn-In Cycle
On Time 210
Burn-In Cycle
Off Time 30
Burn-In Hour 50
Burn-In Lamp Mode Low
Burn-In Off

2-5
VPL-ES3
No.01
No.02
No.03
No.04
No.05
...
Status
Memory
No.50
No.01
No.02
No.03
No.04
No.05
...
Status
Memory
Input-A /
Componet
Preset
No.50
Dynamic Dynamic
Standard Standard
Game Game
Living Living
Cinema Cinema
Video
Presentation
Video
Presentation
Dynamic Dynamic
Standard Standard
Game Game
Living Living
Cinema Cinema
S Video
Presentation
S Video
Presentation
Dynamic Dynamic
Standard Standard
Game Game
Living Living
Cinema Cinema
Picture
Memory
Input-A
Presentation
Picture
Memory
Input-A
Presentation
NT358 /443/BW60
PAL/ PAL- M/ N/
SECA M/ BW50
15k RGB
Component(15k )
HDTV(YP bPr)
Chroma
Memory
NT358 /443/BW60
PAL/ PAL- M/ N/
SECAM /BW50
15k RGB
Component(15k )
HDTV(YP bPr)
Chroma
Memory
High
Computer
Low
High
W/B
Memory Others
Low
High
Computer
Low
High
W/B
Memory Others
Low
Video
S Video
Input- A RGB
Channel
Memory
Input-A Component
Video
S Video
Input-A RGB
Channel
Memory
Input-A Component
Image Flip
Memory
Image Flip
Memory
CPU ROM
CPU RA M
Initialize Active memory cop y
Memory
Low
W/B
Memory
High
Set Memory Set Memory Set Memory
Status Memory
Chroma Memory
Channel Memory
Image Flip Memory
External NVM
Double speed Component Double speed Component
HDTV(GBR)includ.double-speed HDTV(GBR)includ.double-speed
Up/Down inversionis impossible
Up/Down inversionis possible
Up/Down inversionis impossible
Up/Down inversionis possible
Picture Memory
2-2. Memory Structure

2-6 VPL-ES3
Memory structure of this model consists of the followings.
1 Set memory
2 Status memory
3 Picture memory
4 Chroma memory
5 W/B memory
6 Channel memory
7 Image Flip memory
*The gamma memory is realized by giving offset to the Contrast and Brightness output values to the
devices in the gamma mode function.
When the power plug is connected to the wall outlet for the first time (Standby state), all data that are
stored in the internal ROM are written in the NVM (non-volatile memory). When the POWER is turned
ON, all the status memory data and other memory data that are required for the present picture are
selected from each memory block and expanded in the internal RAM.
When any adjustment is performed at this moment, the adjustment data (user mode items) are written in
the NVM (Service/Special Service) automatically triggered by the memory operation.
The adjustment items (W/B, Device Adjust) that can be adjusted in the Service Mode or in the Special
Service Mode, are memorized in the NVM at the time when the user performs adjustment and performs
the memory operation. Note that the factory adjustment data will be lost at this moment.

3-1
VPL-ES3
3-1. Electric Troubleshooting
Section 3
Troubleshooting
1
No
Ye s
No
No
Ye s
Ye s
No
Ye s
No
Ye s
Connect the Power
Power LED OK
Power ON
Lamp ON ?
System shut-down
And cooling
No Picture ?
Picture quality
No good ?
1. Check Power
2. Check lamp cover LED, lamp door,
dust filter switch.
3. Check the power board out voltage 5V.
4. Change main board.
1. check the Ballast power and control
signal wire
2. Check lamp door switch.
3. Check power board output voltage 15V
and 12V.
1. Check the LED message table and find
the error.
2. If the error code is lamp cover shine,
please check the lamp.
3. If the error code is lamp cover flash,
please check the door switch.
4. If the error code is temp/fan, please
check the fan status and thermal sensor.
1. The picture is full-white pattern; please
check the LCD panel connector.
2. The picture is full-black pattern; please
check the LCD driver on the main board.
1. The picture a little green, blue, red,
please check the LCD panel connector.
2. The picture has dust, please check the
lens.
3. The picture flicker, please alignment
again.

3-2 VPL-ES3
OSD flicker ?
Color temp wrong ?
Picture has
Vertical bar ?
IR remote control
No good ?
Audio function is
No good ?
Please alignment V-com again.
1. Please alignment gain again.
2. Only in YPbPr, please alignment offset.
Check the vertical bar color and find the
LCD panel connector. Then check the pin
of connector.
1. Please check the OSD setting
2. Check the front IR board.
1. P1. Check the OSD setting.
2. Check the speak wire.
1
No
Ye s
No
Ye s
No
Ye s
No
Ye s
Ye s