Sony VPL-ES4 User manual

DATA PROJECTOR
VPL-ES4
VPL-EX4
REMOTE COMMANDER
RM-PJ4
SERVICE MANUAL
1st Edition

VPL-ES4/EX4
!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-ES4/EX4
Table of Contents
1. Service Information
1-1. Appearance Figure ..........................................................1-1
1-2. Board Locations ..............................................................1-1
1-3. Disassembly .................................................................... 1-2
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. Lamp Power Supply ..............................................1-5
1-3-7. Power Board ..........................................................1-5
1-3-8. Optics Section ....................................................... 1-6
1-3-9. Detection Switch Board ........................................ 1-7
1-3-10. 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-ES4/EX4
1-1. Appearance Figure
1-2. Board Locations
Section 1
Service Information
Lamp power supply
Main
Power
Thermal sensor
IR sensor
Detection switch

1-2 VPL-ES4/EX4
1-3. Disassembly
1-3-1. Upper Case Assembly
1-3-2. Front Case Assembly and Sub Rear Case Assembly
Remove the upper case assembly before starting the removal work.
VPL-ES4 VPL-EX4
4 Two screws
(M 3 x 6)
5S crew
(M 3)
!=
Sub rear case assembly
7 Two screws
(+K 3 x 12)
6 Six hexagon
screws ![
Front case assembly
1 Lens cap
0 Two claws
2 Main board
connector (J6)
3 IR sensor board
connector (J1)
Sub rear case
assembly
Sub rear case
assembly
!-
Speaker harnesses
9 Remove the upper case assembly from this corner with the
strong force to the extent that the upper case assembly will
not be damaged.
8 Remove the upper case assembly from this corner with the
strong force to the extent that the upper case assembly will
not be damaged.
Front case assembly
2 Four claws
4Upper case assembly
3 Remove the upper case assembly from this corner with the
strong force to the extent that the upper case assembly will
not be damaged.
1 Five screws (M 3 x 6)

1-3
VPL-ES4/EX4
1-3-3. Main Board
Remove the front case assembly and sub rear case assembly before starting the removal work.
3 Main board
1 five screws
(M 3 x 6)
2 Remove the main
shield in the direction
of the arrow.
J17
Note:
The fan harness has been secured by the
main board bracket with a fixing screw.
(See section 1-3-5. mein bracket) J16
J6
J14 J20 J19 J21 J22
J23
J24
J25
J18
Lamp box assembly
When re-assembling,
give an appropriate
amount of extra slack
of this harnesses.
Main board
Radiation sheet
Main board bracket section
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
Main shield
J22

1-4 VPL-ES4/EX4
1-3-4. Tunnel Outlet Section
Remove the front case assembly and sub rear case assembly before starting the removal work.
1-3-5. Main Board Bracket Section
Remove the main board before starting the removal work.
1 Two tapping screws
(PAN 3 x 7)
2 Tunnel outlet section
J21
Main board
Main board
Lamp box
assembly
J21
Harnesses clamp section
Harnesses
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.
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-ES4/EX4
1-3-6. Lamp Power Supply
Remove the main board bracket section before starting the removal work.
1-3-7. Power Board
Remove the main board bracket section before starting the removal work.
CN603
CN603
CN701
CN701
Power board
Lamp power supply (P1)
2 Remove the power board in
the direction of the arrow.
1Two stand assemblies
4 Lamp
9 Lamp power supply
2 Lamp door
1 loosen screw.
3 Loosen two screws.
5Screw
(+PWH 3 x 8)
8 Connector (P1)
B
A
To the main board J16
From the Main board CN602
(Red and Black wires)
6 Remove the lamp power supply
connector in the direction of the
arrow A .
7 Remove the lamp power supply in the
direction of the arrow B .

1-6 VPL-ES4/EX4
1-3-8. Optics Section
Remove the lamp power supply and power board before starting the removal work.
2 Two claws
0 Optucs section
8 Focus/Zoom adjust
assembly
1 Two tapping screws
(PAN 3 x 7)
6 Two tapping screws
(PAN 3 x 7)
5Harness
4
Gasket
9 Four screws
(+P 2.5 x 8)
!= Rotate the Focus dial
counter-clockwise as
shown until it is stopped.
!] Rotate the Focus/Zoom Adjust Assembly
counter-clockwise until it is stopped.
!;
Install the Focus/Zoom
Adjust Assembly as shown.
!' After installation is completed, verify that the Optucs
section can rotate from the position
A to the position
B smoothly.
A
B
Lower case
Focus dial
!\ Install the Optucs section
in the Lower Case.
!-
Rotate the Zoom dial clockwise
as shown until it is stopped.
7 Dowel
A
During the assembling process,
never change the gear position
that is set by step ![.
Assembling Method of Optucs section and
Focus/Zoom Adjust Assembly
Phase matching
![
Rotate the Focus dial
counter-clockwise as
shown until it is stopped.
3 Remove the lamp box assembly in the
direction of the arrow
A .

1-7
VPL-ES4/EX4
1-3-9. Detection Switch Board
Remove the optics section before starting the removal work.
1-3-10. DC Fan
Remove the optics section before starting the removal work.
5 Tapping screw
(PAN 3 x 7)
1 Tapping screw
(PAN 3 x 7)
6 Detection switch board
2 Detection switch board
3 Two tapping screws
(PAN 3 x 7)
4 Duct lamp
CN1
CN1
1 Two tapping screws
(PAN 3 x 7)
3 Two tapping screws
(PAN 3 x 10)
2 Duct LCD assembly
4DC fan
7DC fan
5harness
6
Two tapping screws
(M 3 x 25)

1-8 VPL-ES4/EX4
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-ES4/EX4
2-1. Initial Values of Adjustment Items
Section 2
Electrical Adjustments
*The “Picture Mode” items in the “PICTURE SETTING” menu have their respective initial values for each input signal (PRESET MEMORY No.).
n
There are some adjustment items that cannot be adjusted, depending on the input signal.
Set
Memory
Dynamic Standard Natural Game Living Cinema
Presen-
tation Dynamic Natural Standard Game Living Cinema
Presen-
tation Dynamic Standard Natural Game Living Cinema
Presen-
tation Dynamic Natural Standard Game Living Cinema
Presen-
tation
Picture Mode * * * *
Adjust Picture
Contrast 90 80 85 90 90 75 85 90 75 80 90 90 75 75 90 80 85 90 90 75 85 90 85 80 90 90 60 85
Bright 60 50 55 60 50 50 55 60 55 50 60 50 50 55 60 50 55 60 50 50 55 60 55 50 60 50 50 55
Color 50 50 50 68 60 58 50 50 50 50 68 60 58 50 50 50 50 68 60 58 50
Hue 50 50 50 50 50 50 50 50 50 50 50 50 50 50
Sharp ness 60 30 50 50 50 30 50 60 40 30 40 40 30 40 60 30 40 40 40 30 40
DDE Film Film Film Film Film Film Film Film Film Film Film Film Film Film Film Film Film Film Film Film Film
Gamma Mode Graphics Graphics
Color Temp High Low Mid High Low Low High High Mid Low Low Low Low Mid Low Low Mid Low Low
Volume 30
Adjust Signal
Dot Phase 31
H Size
Shift
Wild Mode OFF OFF OFF OFF OFF ON OFF OFF OFF OFF OFF OFF ON OFF OFF OFF OFF OFF OFF ON OFF
Scan Conv ON ON ON ON ON ON ON
Smart APA On
Auto Input Search Off
Input-A Signal Sel. Auto
Color System Auto
Power Saving Mode Off
IR Receiver Front &
Rear
Panel Key Lock Off
Status On
Language English
Menu Position Center
Start Up Image On
V Keystone 0
Image Flip Off
Background Blue
Lamp Mode Standard
High Altitude Mode Off
Security Lock Off
Key Enter x 4
INFOR-
MATION
All information is
display only
Picture Memory
INPUT
SETTING
SET
SETTING
MENU
SETTING
INSTALL
SETTING
VIDEO INPUT A (Component/VideoGBR) INPUT A (Computer), INPUT B (Computer)
PICTURE
SETTING
S VIDEO
Menu
Title ItemName
MemoryName
High High High High High High High High High
Graphics Graphics Graphics Graphics Graphics

2-2 VPL-ES4/EX4
Page Item Name Set R G B
TGHST Phase Hi 0
TGHST Phase Lo 109
SHSH1 38
TGHST Position 12
DEHPF On ON
DEHPF AAC ON
DEHPF TAP 3
DEUSC On OFF
3D GammaSubCont 0
3D GammaSubBrt 150
DELUT SW OFF
DEUF SW ON
PC Hi Gain-R 128
PC Hi Gain-G 128
PC Hi Gain-B 128
PC Hi Bias-R 0
PC Hi Bias-G 0
PC Hi Bias-B 0
PC Lo Gain-R 128
PC Lo Gain-G 70
PC Lo Gain-B 100
PC Lo Bias-R 0
PC Lo Bias-G 0
PC Lo Bias-B 0
Video Hi Gain-R 128
Video Hi Gain-G 128
Video Hi Gain-B 128
PC Mid Bias-R 0
Video Hi Bias-G 0
Video Hi Bias-B 0
Video Lo Gain-R 128
Video Lo Gain-G 70
Video Lo Gain-B 100
Video Lo Bias-R 0
Video Lo Bias-G 0
Video Lo Bias-B 0
Color
P1-1
CXD9809-page1
P1-2
CXD9809-page2
P1-3
CXD9809-page3

2-3
VPL-ES4/EX4
PC Mid Gain-R 128
PC Mid Gain-G 90
PC Mid Gain-B 115
PC Mid Bias-R 0
PC Mid Bias-G 0
PC Mid Bias-B 0
Video Mid Gain-R 128
Video Mid Gain-G 75
Video Mid Gain-B 105
Video Mid Bias-R 0
Video Mid Bias-G 0
Video Mid Bias-B 0
Temperature 1 Display only
Temperature 2 Display only
Temperature 3 N/A
FanSpeed 1 Display only
FanSpeed 2 Display only
FanSpeed 3 Display only
FanSpeed 4 Display only
ManualFanSpeed OFF
Burn-In Cycle 0
Burn-In Cycle On min 210
Burn-In Cycle Off min 30
Burn-In Hour 50
Burn-In active OFF
Gain-R 188
Gain-G 188
Gain-B 188
SigCen-R 35
SigCen-G 35
SigCen-B 35
SidA-R 22
SidA-G 22
SidA-B 22
SidB-R 85
SidB-G 85
SidB-B 85
P2
Fan Control
P3-1
CXA7005-page1
P1-4
CXD9809-page4
Page Item Name Set R G B
Color

2-4 VPL-ES4/EX4
Bias-R Normal 122
Bias-G Normal 122
Bias-B Normal 122
Bias-R Flip 122
Bias-G Flip 122
Bias-B Flip 122
Vcom-R Normal 88
Vcom-G Normal 88
Vcom-B Normal 88
Vcom-R Flip 88
Vcom-G Flip 88
Vcom-B Flip 88
RGB Calibrate
YUV Calibrate
RGB Offset 164 222 164
RGB Gain 93 105 93
YUV Offset 164 222 164
YUV Gain 93 105 93
R Offset 164
G Offset 222
B Offset 164
R Gain 93
G Gain 105
B Gain 93
Power Saving Time 10
System Protect ON
Data Reset
Hard Reset
ROM Version Display only
Lamp Timer Display only
Operation Timer Display only
Prev. Lamp Timer Display only
SOG Threshold N/A
P6
Error Count All value is display only
P5
P3-2
CXA7005-page2
P4
ADC Calibration
Page Item Name Set R G B
Color

2-5
VPL-ES4/EX4
2-2. Memory Structure
Set memory Set memory Set memory
status
memory
No.01
status
memory
Video/Svideo No.01 Status memory
No.02 No.02
No.03
Input-A/Input-B
/Component
No.03
No.04 No.04
No.05 No.05
No.50 No.50
No.55 No.55
No.56 No.56
No.101 No.101
No.102 No.102
Picture
memory
Video
Dynamic
picture
memory
Video
Dynamic Picture memory
Standard Standard
Natural Natural
Game Game
Living Living
Cinema Cinema
Presentation Presentation
S-Video
Dynamic
S-Video
Dynamic
Standard Standard
Natural Natural
Game Game
Living Living
Cinema Cinema
Presentation Presentation
Input-A
Dynamic
Input-A
Dynamic
Standard Standard
Natural Natural
Game Game
Living Living
Cinema Cinema
Presentation Presentation
Input-B
Dynamic
Input-B
Dynamic
Standard Standard
Natural Natural
Game Game
Living Living
Cinema Cinema
Presentation Presentation
Component
Dynamic
Component
Dynamic
Standard Standard
Natural Natural
Game Game
Living Living
Cinema Cinema
Presentation Presentation
W/B
memory
Computer
High
W/B memory
Computer
High W/B memory
Mid Mid
Low Low
Other than
Computer
High Other than
Computer
High
Mid Mid
Low Low
Channel
Memory
Input-A
Channel
Memory
Input-A Channel Memory
Input-B Input-B
Input-A
Component
Input-A
Component
Input-A
Video-GBR
Input-A
Video-GBR
Video Video
S-Video S-Video
Common
Memory
Wide Mode
(other than computer)
Common
Memory
Wide Mode
(other than computer) Common Memory
Scan Converter
(Computer only)
Scan Converter
(Computer only)
Smart APA
(Computer only)
Smart APA
(Computer only)
Volume Volume
Auto Input Search Auto Input Search
Input-A Signal Sel. Input-A Signal Sel.
Color System
(Video/S-Video Only)
Color System
(Video/S-Video Only)
Speaker Speaker
Power Saving Power Saving
IR Receiver IR Receiver
Panel Key Lock Panel Key Lock
Status Status
Language Language
Menu Position Menu Position
Image Flip Image Flip
Background Background
Lamp Mode Lamp Mode
High Altitude High Altitude
Security Lock Security Lock
FLASH ROM EEPROM CPU RAM

2-6 VPL-ES4/EX4
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
*The gamma memory is realized by giving offset to the Contrast and Brightness output values to the
devices in the gamma mode function.
Flow of data is described briefly. 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 memo-
ry). 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-ES4/EX4
3-1. Electric Troubleshooting
Section 3
Troubleshooting
1
No
Yes
No
No
Yes
Yes
No
Yes
No
Yes
Connect the Power
System Standby?
Power projector
Lamp ON ?
System shut-down
And cooling
No Picture ?
Picture quality
No good ?
1. Check the LED Message and find error.
2. Check lamp door, dust door.
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 status.
3. Check lamp status.
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.
3. Check the system status: Is system in
burn-in mode?
1. Check the LED message and find error.
2. Check the Fan status or Thermal sensor
status.
3. Check the lamp door or dust door.
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-ES4/EX4
OSD flicker ?
Color temp wrong ?
Picture has
Vertical bar ?
IR remote control
No good ?
Audio function is
No good ?
Please alignment V-com again.
Please alignment color temperature again.
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. Check the OSD setting.
2. Check the speak wire.
1
No
Yes
No
Yes
No
Yes
No
Yes
Yes