Sony VPL-ES7 User manual

DATA PROJECTOR
VPL-ES7
VPL-EX7
VPL-EX7IN
VPL-EX70
REMOTE COMMANDER
RM-PJ6
SERVICE MANUAL
1st Edition (Revised 2)

VPL-ES7
!警告
このマニュアルは，サービス専用です。
お客様が，このマニュアルに記載された設置や保守，点検，修理などを行うと感電や火災，
人身事故につながることがあります。
危険をさけるため，サービストレーニングを受けた技術者のみご使用ください。
!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.
警告
万一，異常が起きた際に，お客様が電源を切ることが
できるように，設置の際には，機器近くの固定配線内
に専用遮断装置を設けるか，機器使用中に，容易に抜
き差しできるコンセントに電源プラグを接続してくだ
さい。
WARNING
When installing the unit, incorporate a readily accessible
disconnect device in the fixed wiring, or connect the
power cord to a socket-outlet which must be provided
near the unit and easily accessible, so that the user can
turn off the power in case a fault should occur.
WARNUNG
Beim Einbau des Geräts ist daher im Festkabel ein
leicht zugänglicher Unterbrecher einzufügen, oder
das Netzkabel mußmit einer in der Nähe des Geräts
befindlichen, leicht zugänglichen Wandsteckdose
verbunden werden, damit sich bei einer
Funktionsstörung die Stromversorgung zum Gerät
jederzeit unterbrechen läßt.
For kundene i Norge
Dette utstyret kan kobles til et IT-strømfordelingssystem.

VPL-ES7 1 (P)
CAUTION
Danger of explosion if battery is incorrectly replaced.
Replace only with the same or equivalent type rec-
ommended by the manufacturer.
When you dispose of the battery, you must obey the
law in the relative area or country.
ATTENTION
Il y a danger d’explosion s’il y a remplacement incor-
rect de la batterie. Remplacer uniquement avec
une batterie du même type ou d’un type équivalent
recommandé par le constructeur.
Lorsque vous mettez la batterie au rebut, vous devez
respecter la législation en vigueur dans le pays ou la
région où vous vous trouvez.
VORSICHT
Explosionsgefahr bei Verwendung falscher Batterien.
Batterien nur durch den vom Hersteller empfohlenen
oder einen gleichwertigen Typ ersetzen.
Wenn Sie die Batterie entsorgen, müssen Sie die
Gesetze der jeweiligen Region und des jeweiligen
Landes befolgen.
FÖRSIKTIGHET!
Fara för explosion vid felaktigt placerat batteri.
Byt endast mot samma eller likvärdig typ av batteri,
enligt tillverkarens rekommendationer.
När du kasserar batteriet ska du följa rådande lagar
för regionen eller landet.
PAS PÅ
Fare for eksplosion, hvis batteriet ikke udskiftes
korrekt.
Udskift kun med et batteri af samme eller tilsvarende
type, som er anbefalet af fabrikanten.
Når du bortskaffer batteriet, skal du følge
lovgivningen i det pågældende område eller land.
HUOMIO
Räjähdysvaara, jos akku vaihdetaan virheellisesti.
Vaihda vain samanlaiseen tai vastaavantyyppiseen,
valmistajan suosittelemaan akkuun.
Noudata akun hävittämisessä oman maasi tai
alueesi lakeja.
FORSIKTIG
Eksplosjonsfare hvis feil type batteri settes i.
Bytt ut kun med samme type eller tilsvarende
anbefalt av produsenten.
Kasser batteriet i henhold til gjeldende avfallsregler.
注意
指定以外の電池に交換すると，破裂する危険があります。
必ず指定の電池に交換してください。
使用済みの電池は，国または地域の法令に従って
処理してください。

1
VPL-ES7
Table of Contents
1. Service Overview
1-1. Appearance Figure .......................................................... 1-1
1-2. Board Location................................................................ 1-1
1-3. Disassembly .................................................................... 1-2
1-3-1. Upper Case Assembly............................................ 1-2
1-3-2. Rear Case Pack Assembly...................................... 1-3
1-3-3. Main Board ............................................................ 1-3
1-3-4. Power Board and Thermal Sensor Board .............. 1-4
1-3-5. Front Case Assembly and IR Sensor Board...........1-5
1-3-6. Fan (Exhaust)-1...................................................... 1-5
1-3-7. Fan (Exhaust)-2...................................................... 1-6
1-3-8. Optional Unit Assembly ........................................ 1-7
1-3-9. Lamp Power Supply...............................................1-8
1-3-10. Fan ......................................................................... 1-9
1-4. 3D GAMMA Service Tool Application Software ......... 1-10
1-5. Indicator ........................................................................ 1-10
1-6. Circuit Description ........................................................ 1-11
1-7. Replacing Fuse .............................................................. 1-13
1-8. Connecting/Disconnecting the Flexible Card Wire.......1-14
1-9. Lead-free Solder............................................................ 1-14
2. Electrical Adjustments
2-1. Preparation ...................................................................... 2-1
2-1-1. Required Equipment .............................................. 2-1
2-1-2. How to Enter the Service Mode............................. 2-1
2-2. Adjustment of Main Board When it is Replaced ........... 2-1
2-2-1. Save the Optical Data and Replacement................2-1
2-3. EEPROM Replacement................................................... 2-2
2-4. ADC Calibration ............................................................ 2-2
2-4-1. RGB Alignment Procedure .................................... 2-2
2-4-2. YUV Alignment Procedure ................................... 2-3
2-5. V COM Adjustment ........................................................ 2-4
2-6. White Balance Adjustment.............................................. 2-6
2-6-1. HIGH Mode of PC ................................................ 2-6
2-6-2. MIDDLE Mode of PC .......................................... 2-6
2-6-3. LOW Mode of PC .................................................2-7
2-6-4. HIGH Mode of VIDEO ......................................... 2-7
2-6-5. MIDDLE Mode of VIDEO....................................2-8
2-6-6. LOW Mode of VIDEO ..........................................2-8
2-7. Others .............................................................................. 2-9
2-7-1. Note When Replacing the Main Board..................2-9
2-7-2. Status Information................................................ 2-10
2-7-3. ADC Calibration Value........................................ 2-10
2-8. Memory Structure ......................................................... 2-11
2-9. Initial Values of Adjustment Items ................................ 2-13
3. Troubleshooting
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 Diagrams
Overall (VPL-ES7).......................................................... 5-1
Overall (VPL-EX70) ....................................................... 5-2
Overall (VPL-EX7) ......................................................... 5-3
Overall (VPL-EX7IN)..................................................... 5-4
6. Schematic Diagrams
Frame Wiring (VPL-ES7) ............................................... 6-1
Frame Wiring (VPL-EX70)............................................. 6-2
Frame Wiring (VPL-EX7)............................................... 6-3
Frame Wiring (VPL-EX7IN) .......................................... 6-4

1-1
VPL-ES7
Section 1
Service Overview
1-1. Appearance Figure
1-2. Board Location
Main
Door detection switch
Thermal sensor
Door detection switch
IR sensor
Power
Lamp power supply

1-2 VPL-ES7
1-3. Disassembly
1-3-1. Upper Case Assembly
 Upper case assembly
 Screw
(+P M3 x 6)
Loosen screw.

Lamp door
 Two claws
 Remove the filter
door in the direction
of the arrow  .



Front Side
of Unit
These portions are fragile.
Be very careful not to
damage them.
 Five screws
(+P M3 x 6)
 Screw
(+P M3 x 6)


Caution :
If the spacings in the top and bottom are not equal, go to “Assembling
method of optical unit assembly and Focus/Zoom adjust assembly”.
(Refer to section 1-3-8. Steps 9 to 14.)
Upon completion of the upper
case assembly attachment,
check to see that the spacing
in the top is equal to the
spacing in the bottom.
Zoom adjust gear knob
 Press here strongly.
 Remove the Upper case assembly
in the direction of the arrow.
Caution :
Remove the upper case assembly from this corner.
When attaching the upper case assembly, attach it while
aligning with the lower case pack assembly
starting from this corner.
 Disengage the claws at
the 17 locations respectively.
Upper case assembly
Lower case pack
assembly
Front Side
of Unit






Lower case pack
assembly

1-3
VPL-ES7
1-3-2. Rear Case Pack Assembly
Main board
J11
 Speaker harness
 Rear case pack assembly, etc.
 Six hexagon
screws
 Two screws
(+K 3 x 12)
 Two screws
(+PWH 3 x 6)
 Rear case pack assembly
 Speaker
VPL-EX7
Rear Side
of Unit
Rear Side
of Unit
Route the speaker harness
under the MB bracket.
 Two screws (+K 3 x 12)
 Two screws (+K 3 x 12)
 Eight hexagon screws
 Rear case pack assembly
VPL-ES7
VPL-EX7IN
 Four hexagon screws
Rear case pack assembly
 Rear case pack assembly
 Two screws (+K 3 x 12)
 Eight hexagon screws
VPL-EX70
 Rear case pack assembly
1-3-3. Main Board
 Two screws
(+PWH 3 x 6)
 Three screws
(+PWH 3 x 6)
 Shield
Shield
 Main board
Rear case pack assembly,
etc.
 Remove the
twelve connectors.
J17 J16
J26
J21
J20
J14
J23
J24 J22
J6
J19
J18
Main board
(Refer to section 1-3-2, steps 1 to 4.)
J11

1-4 VPL-ES7
1-3-4. Power Board and Thermal Sensor Board
 Screw
(+PSW M4 x 6)
 Five tapping screws
(PAN M3 x 7)
Tapping screw
(PAN M3 x 7)
 MB bracket

Thermal sensor board
Power board
 Remove the three connectors.
Lamp nozzle assembly
Fuse (H.B.C.)
(F601)
Miniature fuse-links (F602)
CN603
CN605
CN701
 Dowel
Power board
Power board
Lamp nozzle assembly
 Remove the fan in the
direction of the arrow.
J1
Mai n board
(Refer to section 1-3-3, steps 2 to 6.)
Fan
Lamp nozzle assembly
Be careful that the harnesses must not override on
top of this port or must not be pinched by this portion.
Check to see that the seven connectors are
protruding from the MB bracket.
Caution :
When attaching the MB bracket, bind the four harnesses into the shape
of “U” and attaching them to the MB bracket.
Door detection
switch board

1-5
VPL-ES7
1-3-5. Front Case Assembly and IR Sensor Board
 Four claws
 IR sensor board
 Sheet
 Tapping screw
(PAN M3 x 7)
 Lens cap
 Front case assembly
J7
 Logo
1-3-6. Fan (Exhaust)-1
Front case assembly
 MB bracket
 Power board
(Refer to section 1-3-5.)
(Refer to section 1-3-1, steps 2 to 4.)
 Lamp door
Caution :
Because the harness has the shape of flat
cross-section, do not insert the harness into the
harness clamp section with excessive force.
Find out the direction in which the harness can
be inserted easily, and then insert the harness.
Harness
Harness clamp section
(Refer to section 1-3-4, steps 2 to 8.)
 Screw
(+PWH 3 x 6)
 Loosen two screws.
 Lamp connector
assembly
 Door detection switch
harness
 Lamp assembly
Lamp box assembly
Good
No good

1-6 VPL-ES7
1-3-7. Fan (Exhaust)-2

 Door detection switch board
 Lamp box assembly
 Remove the protrusion in the
direction of the arrow  .
 Remove the door detection switch
harness in the direction of the arrow  .
 Remove the fan harness in the direction of the arrow  .
 Two tapping screws
(PAN M3 x 7)
 Tapping screw
(PAN M3 x 7)
 Fan (Exhaust)
80*25 AD0812HB/HB
CN1
Door detection
switch board


Lamp box assembly
Caution :
When attaching the lamp box assembly, insert the door detection
switch harness into the groove of the lower case pack assembly.
Caution :
Two exhaust fans are the two different fans having the difference
characteristics. Be careful not to make mistake in choosing the
desired fan by confirming the indication on the fans.
Lower case pack
assembly
protrusion

HB mark is
indicated.
UB mark is
indicated.

1-7
VPL-ES7
1-3-8. Optional Unit Assembly
Caution :
When attaching the lamp nozzle assembly, route that harnesses
in between the lamp nozzle assembly and optical unit assembly.
Assembling method of optical unit assembly and
Focus/Zoom adjust gears assembly
 Rotate the zoom adjust gear in the
counter-clockwise direction by one
tooth. Then, engage these gears
with the corresponding lens gears.
 Lens: Rotate the Focus/Zoom gears in
the counter-clockwise direction as far
as it can be rotated.
 Attach the Focus/Zoom Adjust assembly into the two
dowels of the lower case pack assembly after rotating the
Focus/Zoom Adjust assembly as far as it can be rotated
in the direction of clockwise direction.
Two dowels
Lower case pack assembly
 Fix the Focus/Zoom Adjust assembly
tentatively with the screw.
 Attach the other screw while fixing
the gear position.
 Tighten the screw finally that has
been tightened tentatively.
Focus adjust gear
Lens: Focus/Zoom gears
Zoom adjust gear
 Lamp box assembly
(Refer to section 1-3-6, steps 5 to 9) and
(refer to section 1-3-7, steps 1,2, 4 to 6.)
 Lamp nozzle assembly
L amp nozzle assembly
Lamp connector
assembly
CON thermal
145MM wire
 Two tapping screws
(PAN M3 x 7)
 Three tapping screws
(PAN M3 x 7)
 Two tapping screws
(PAN M3 x 7)
 Focus/Zoom adjust
assembly
 Optical unit
assembly
 Tapping screw
(PH W/FLA M3 x 10L PT ZN)
Thermal sensor harness,
Fan harness
Door detection
switch harness

1-8 VPL-ES7
1-3-9. Lamp Power Supply
 Fan (Exhaust)
80*25 AD0812HB/HB
(Refer to section 1-3-8, steps 2 to 8.)
 Lamp box assembly
 Lamp nozzle assembly
 Focus/Zoom adjust
assembly
 Optical unit assembly
(Refer to section 1-3-6, steps 5 to 9) and
(refer to section 1-3-7, steps 1 to 6.)
Route the harness

through the hole of
this sheet.
Caution :
When re-assembling the machine,
route the respective harnesses and
wires at the specified locations as shown.




Lamp power supply
Door detection switch board
Route the Lamp connector
assembly
 between them.
 Two tapping screws
(PAN M3 x 7)
 Remove the lamp power supply
in the direction of the arrow  .
 Claw  Door detection
switch board
 Two harnesses
Door detection
switch board
CN1
X1





Lamp power supply
 Lamp power supply
 Lamp connector
assembly
 Mylar ballast
Mylar ballast

1-9
VPL-ES7
1-3-10. Fan
 Tapping screw
(PAN M3 x 7)
 Washer
 Two tapping screws
(PAN M3 x 7)
 Two tapping screws
(PH W/FLA M3 x 10L PT ZN)
 Fan
75*75*30 145MM AB7512UB

Fan
70*70*25 240MM AB07012UB
Prism duct
 Harness
 Tapping screw
(PH W/FL M3 x 35 NI D-PT)
Thermal sensor board
(Refer to section 1-3-6, steps 5 to 9) and
(refer to section 1-3-7, steps 1,2, 4 to 6.) (Refer to section 1-3-8, steps 2 to 8.)
 Lamp box assembly
 Lamp nozzle assembly
 Focus/Zoom adjust
assembly
 Optical unit assembly
 Dowel
Prism duct
Prism duct

Dowel

1-10 VPL-ES7
1-4. 3D GAMMA Service Tool Application Software
Feature:
The Ernie Service Tool is the application software for performing the tasks such as reading out and writ-
ing of the 3D GAMMA data on the projector that is connected to a PC via a communication function.
The Ernie Service Tool has the following features.
.It can read 3D GAMMA data from a set and save it in a file.
.It can write 3D GAMMA data in a PC into a set.
When the optical unit is replaced, write 3D GAMMA data recorded on the CD-ROM, which is supplied
together with the optical unit, into a set using the application software.
.VPL-ES7 set has not RS-232C terminal, use the QUICK ACCESS Assy.
.Remove the rubber cap on the upper left of the rear side of the unit.
1-5. Indicator
The error status of the this units are indicated by the type of flashing of indicator. The top cover has the
ON/STANDBY indicator and the LAMP/COVER indicator. Various error contents are indicated by the
type of flashing of indicator. For details of the types of indicator flashing and the error statuses, refer to
the list shown below.
ON/STANDBY Indicator (Red flashing)
LAMP/COVER Indicator (Orange flashing)
J12
Set
Main board CN
CN 5P
CN J8
5pin
Dsub
9pin
(Parts No. A-1568-125-A)
RS-232C
Straight
cable
PC
QUICK ACCESS Assy
QUICK ACCESS
Assy
ON
Flash Frequency
Temperature Error
Error Name
Fan Error
Power Error
The temperature of the equipment is high.
Status
Each fan dose not work normally.
The power is not turned on correctly.
2 Times
4 Times
6 Times
OFF
ON
OFF
ON
OFF
Cover Error
Lamp Error
Flash FrequencyError Name Status
The lamp or filter cover is opened.
The UHP lamp is not lighting.
2 Times
3 Times
ON
OFF
ON
OFF

1-11
VPL-ES7
1-6. Circuit Description
Main Board:
Video input block*1
The video input has two channels: Composite video and S-Video. The 2-channel inputs are sent directly to
the video processor, and converted to the digital data by the built-in AD converter of the video processor.
PC input block
There are two channels: Input A and Input B, one of which is selected with the toggle switch. The selected
output is input to the video processor and the video buffer. At the video processor, the signal is converted
to the digital data by the built-in AD converter. The signal input to the video buffer is output as a monitor
out.
To Input A, PC signals, component signals, and video GBR signals can be input. To Input B, only PC
signals can be input. (VPL-EX7IN can input only PC signals.)
Audio input block*1
Stereo mini jack input. The L/R input is synthesized internally into a monaural signal. The signal is syn-
thesized by a resistance, so the output level varies between the case where only one channel is input and
the case where both channels are input. The standard is prescribed under the condition where only one
channel is input.
Monitor output block (PC)
The signals input to Input A and Input B are output. The signal of the channel that is selected with the
input toggle switch is output. No output is made if Video or S-Video is selected.
Monitor output block (Audio)*1
The signal input to the audio input is output. This output is variable with the volume control. If a cable is
connected to this connector, the output from the built-in speaker stops.
Video processor & System control block
PW-190 made by Pixelworks Inc. is used. This IC performs pixel number conversion, aspect conversion,
and OSD addition to the input signals. This IC also controls brightness, sharpness, chroma, and hue.
In addition, the built-in CPU controls the system.
Control target: Control panel, OSD display, lamp cover switch, filter door switch, LED control, serial
control
LCD timing generator (DSD) block
The IC for LCD panel made by Sony is used. This IC generates the timing for driving the LCD panel.
This uses the method that inverts the driving direction for each frame. In addition to timing generation,
this IC performs white balance adjustment, gamma adjustment, and color shading adjustment.
LCD driver block
The drive IC for LCD panel made by Sony is used. This drives the LCD panel in a 12-phase drive method
at the timing generated by the timing generator IC. The GBR and the circuit for three channels are
equipped.
*1: Not valid for VPL-EX7IN.

1-12 VPL-ES7
FAN control, Thermal sensor block
The IC with the built-in FAN control and thermal sensor function is used.
.FAN control
This detects the FG of the FAN, and controls the number of rotations. The number of rotations is set in
accordance with the internal temperature.
.Thermal sensor
The thermal sensor is placed at the lower part of the power board, and the internal temperature is mea-
sured.
Ballast drive block
This drives the ballast in synchronization with the input signal. The synchronous circuit is formed by the
microprocessor.
When the lamp mode is standard, ballast is driven in synchronization with the frequency 1.5 times higher
than that of the input signal. When the lamp mode is high, the ballast is driven in synchronization with the
input signal.
RS232C block
This is used to connect the PW-190 via the RS232C driver/receiver IC. Because the number of serial ports
is limited on the PW-190, the RS232C and network cannot be used at the same time. The RS232C block
is equipped with the circuit that switches them.
Sensor Board:
The sensor boards include the thermal sensor board, lamp cover switch board, filter door switch board,
and IR sensor board.
Power Board:
This supplies the lamp power and the system power. For the system power, +15.25 V, +12 V, and +5 V
are output, and the circuit power is generated on the main board.

1-13
VPL-ES7
1-7. Replacing Fuse
w
The fuse is essential parts for safe operation.
Replace the components with Sony parts whose part numbers appear in the manual published by Sony. If
the components are replaced with any parts other than the specified ones, this may cause a fire or electric
shock.
c
If the fuse is replaced while the main power is kept on, this may cause electric shock.
Before replacing the fuse, not only turn off the POWER switch but also disconnect the AC power cord
that is connected to the AC IN connector.
This unit is equipped with fuses.
The fuses blow if an excessive current flows due to abnormality inside the equipment. If fuses blow, turn
off the main power of the equipment once, and inspect inside of the equipment and remove the cause of
excessive current. After that, replace the fuses. (Refer to Section 1-3-4.)
Board Ref. No. (Address) Part No./Name
POWER F601 !1-576-233-51 Fuse 6.3 A, 250 V
F602 !1-576-973-11 Fuse 2 A, 600 V
Fuse (H.B.C.)
(F601)
Miniature fuse-links (F602)
Power board

1-14 VPL-ES7
1-8. Connecting/Disconnecting the Flexible Card Wire
m
.Be very careful not to fold the flexible card wire. Life of flexible card wire will be significantly short-
ened if it is folded.
.The flexible card wire has the conduction side and the insulation side. If the conduction side and the
insulation side are connected in the wrong direction, the circuit will not function.
.Insert the flexible card wire straight.
.Ensure that the conduction surface of the flexible card wire is not contaminated.
Disconnecting
Life portions A of the connector to unlock, and disconnect the flexible card wire.
Connecting
1. Insert the flexible card wire firmly as far as it will go, with the conduction side up.
2. Push portions A of the connector to lock.
1-9. Lead-free Solder
Boards requiring use of lead-free solder are printed with a lead free mark (LF) indicating the solder
contains no lead.
(Caution: Some printed circuit boards may not come printed with the lead free mark due to their particular
size.)
: LEAD FREE MARK
m
.Be sure to use the lead-free solder for the printed circuit board printed with the lead free mark.
.The lead-free solder melts at a temperature about 40 dC higher than the ordinary solder, therefore, it is
recommended to use the soldering iron having a temperature regulator.
.The ordinary soldering iron can be used but the iron tip has to be applied to the solder joint for a slightly
longer time. The printed pattern (copper foil) may peel away if the heated tip is applied for too long, so
be careful.
Connector
Disconnecting Connecting
Conduction
side
Portion A
Portion A
Flexible card wire
Connector Flexible card wire