Epson Powerlite Projector 5000xb,7000xb Service 3i2036

Service Manual

Epson America, Inc.

SM-ELP51/71

PowerLite 5000XB/7000XB Service Manual

EPSON PowerLite 5000XB/7000XB Service Manual

INTRODUCTION This Service Manual describes hardware information necessary for field service and troubleshooting of the PowerLite 5000XB/7000XB Multimedia Projector. Manual updates will be supplied in service bulletins.

HOW TO USE THIS SERVICE MANUAL The manual covers topics that may be required for field maintenance so you can use it for diagnosis of failures or repair. Before beginning maintenance work, be sure to read and observe safety precautions and rules. The contents are as follows: Introduction

Personal Safety, Protecting the Unit from Damage, Requirements for Maintenance

Chapter 1

Product Features (Parts of the Projector, System Functions, Specifications, and Other Features)

Chapter 2

Theory of Operation (Hardware, Internal Connections, Unit Functions)

Chapter 3

Disassembly and Assembly (Assembly Process for Main Unit and Remote Control)

Chapter 4

Troubleshooting

iv


PRECAUTIONS

OPERATOR SAFETY PROTECTION FROM ELECTRIC SHOCK • Before performing any repair work on the product, be sure to turn off the power switch and remove the power cable from the electrical outlet. • Whenever it is necessary to turn the power on after opening the case or cover (for example, during the adjustment process) be sure to take off any metallic materials such as a watch, cuff links, rings, or tie pin, which may touch the metallic part of the product, creating a danger of electric shock. PROTECTION FROM INJURY • Be sure not to touch the lamp and its surroundings after the power is turned off. They may be hot. Also, be sure not to touch the light source and its surroundings during adjustments while power is turned on. • Make sure to use gloves to protect your hands from sharp edges during assembly and disassembly. • To protect your eyes, do not look into the light source or lens while the light is on. ACCIDENT PREVENTION • To prevent the device or its components from falling, place the device on a flat, stable surface before using it or working on it. Be careful not to place tools or parts on the device or at your feet. • To prevent this product from being used while it is disassembled, be sure not to leave it out during any repair work, and do not place it in a location where it can be taken for use by mistake. • Be sure to use the attached power cable to supply power to the product.

PRODUCT SAFETY ELECTROSTATIC DISCHARGE • Whenever performing repair work on the product, be sure to wear a wristband and use an electrostatic mat for grounding. When replacing any electric components (boards and optical engine), touch the electrostatic plastic bag containing the component to a metallic part of the product before taking the component out of the plastic bag.

v


RESTRICTIONS FOR PARTS REPLACEMENT • Use only authorized or EPSON-supplied parts for replacement of mechanical components including the lamp inner housing, fuse, air filter, etc. • Use only the power cable and interface cables supplied with the product. OTHER PRECAUTIONS • Visually check for damage or dirt on the power connectors and cable. If dirty, clean it, and if bent or damaged, replace the cable to prevent firing by the flush over phenomenon. • When connecting the internal connector cables or interface cables, be sure to plug them into the connector fully, until they are attached to the connector edge. • Be sure to remove the connector lock before removing the FPC cable for the light bulb. Unlock the connector lock by pulling up both ends simultaneously with tweezers. • Whenever removing parts or repairing the product, work in a clean room, free of dust and dirt, to keep the optical elements away from dirt.

REQUIREMENTS FOR SERVICERS Authorized servicers should have the following knowledge and skill for maintenance of the PowerLite 5000XB/7000XB: • Training in an EPSON-authorized maintenance training program and authorization as a service engineer. • Sufficient understanding of the operations and descriptions in this service manual. • Basic knowledge of electricity (safety operations, circuit diagrams, static electricity, etc.).

FURTHER INFORMATION For questions on PowerLite 5000XB/7000XB maintenance, including service parts or document contents, the address below. Any technical information about changes will be released as necessary in the service bulletins. EPSON AMERICA, INC. 20770 Madrona Avenue Torrance, CA 90503 (310) 782-0770

vi


Contents Chapter 1 Product Features 1.1 PRODUCT FEATURES........................................................................................... 1-1 1.2 PARTS OF THE PROJECTOR ............................................................................... 1-3 Exterior View of Main Frame ............................................................................... 1-3 Interior View of Main Frame................................................................................. 1-4 Exterior View of Remote Control ......................................................................... 1-8 1.3 CONNECTIONS ....................................................................................................... 1-9 Connecting to a PC.............................................................................................. 1-9 Connecting to a Macintosh .................................................................................. 1-10 Connecting to a Video Source ............................................................................. 1-11 Connecting to an Audio Source ........................................................................... 1-12 1.4 MAIN COMPONENTS .............................................................................................. 1-13 Main Board (PowerLite 5000XB) ......................................................................... 1-13 Main Board (PowerLite 7000XB) ......................................................................... 1-13 Driver Board (PowerLite 5000XB) ....................................................................... 1-14 Driver Board (PowerLite 7000XB) ....................................................................... 1-14 AU Board ............................................................................................................. 1-15 Remote Board...................................................................................................... 1-15 CN Board ............................................................................................................. 1-15 Receptor Board (RI/FI) ........................................................................................ 1-16 Speaker ............................................................................................................... 1-16 Inlet Unit............................................................................................................... 1-16 Filter Unit ............................................................................................................. 1-17 Power Supply Unit ............................................................................................... 1-17 Lamp Inner Housing ............................................................................................ 1-17 Optical Engine ..................................................................................................... 1-18 Switch ........................................................................................................ 1-19 1.5 SPECIFICATIONS.................................................................................................... 1-20 1.6 INTERFACE SPECIFICATIONS .............................................................................. 1-23 Computer In 1/2 ................................................................................................... 1-23 Audio In 1/2.......................................................................................................... 1-24 Audio Out............................................................................................................. 1-24 Monitor................................................................................................................. 1-25 S-Video ................................................................................................................ 1-25 Video-In ............................................................................................................... 1-26 Audio In L/R ......................................................................................................... 1-26 Mouse / Com 1/2 ................................................................................................. 1-27 Multi-mouse, 13-pin Jack..................................................................................... 1-27 vii


Chapter 2 Theory of Operation 2.1 HARDWARE............................................................................................................ 2-1 Description of the Projection Process.................................................................. 2-2 Electrical System Connections ............................................................................ 2-2 Optical System Connections (Optical Engine) ..................................................... 2-5 Inside View of the Light Guide Unit...................................................................... 2-6 2.2 POWER SUPPLY UNIT........................................................................................... 2-7 Function Block ..................................................................................................... 2-8 Functional Outline................................................................................................ 2-8 Pin Assignments on CN800 (801) Main Board .................................................... 2-10 2.3 MAIN BOARD .......................................................................................................... 2-11 2.4 DRIVER BOARD ..................................................................................................... 2-15 2.5 CONTROL .................................................................................................. 2-18 2.6 AU BOARD .............................................................................................................. 2-19 2.7 REMOTE BOARD.................................................................................................... 2-21 2.8 CN BOARD.............................................................................................................. 2-23 2.9 RECEPTOR BOARD (FI/RI BOARD) ...................................................................... 2-25 2.10 SPEAKERS UNIT .................................................................................................. 2-27 2.11 LIGHT GUIDE UNIT .............................................................................................. 2-28 2.12 LAMP INNER HOUSING ....................................................................................... 2-30 2.13 SENSOR/SWITCH ................................................................................................. 2-33 Filter Cover Switch............................................................................................... 2-34 Interlock Switch.................................................................................................... 2-35 Lamp Thermistor.................................................................................................. 2-36 LV Thermistor ...................................................................................................... 2-37 PBS Thermistor ................................................................................................... 2-38

Chapter 3 Disassembly and Assembly 3.1 Disassembly and Assembly Procedures .................................................................. 3-1 Preparatory Procedures....................................................................................... 3-1 Required Tools and Accessories ......................................................................... 3-1 Limitations of Disassembly (Optical Engine Handling) ........................................ 3-2 Cautions for Field Maintenance ........................................................................... 3-3 Precautions.......................................................................................................... 3-3 3.2 Disassembling and Assembling the Projector Main Unit .......................................... 3-4 3.2.1 Removing the Lamp Inner Housing ............................................................ 3-5 3.2.2 Removing the Air Filter Frame Unit............................................................. 3-6 3.2.3 Removing the Upper Case Unit and Handle............................................... 3-7 3.2.4 Removing the Switch ........................................................................ 3-9 3.2.5 Removing the Right and Left Speakers ...................................................... 3-10 3.2.6 Removing the Main Board .......................................................................... 3-11

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3.2.7 Removing the Driver Board Assembly ........................................................ 3-14 3.2.8 Removing the Lamp Thermistor ................................................................. 3-17 3.2.9 Removing the Optical Engine ..................................................................... 3-18 3.2.10 Removing the Rear Case Unit Assembly.................................................. 3-20 3.2.11 Removing the Receptor Board Assembly (FI Board / RI Board)............... 3-21 3.2.12 Removing the AU Board ........................................................................... 3-22 3.2.13 Removing the Remote Board ................................................................... 3-24 3.2.14 Removing the Power Supply Unit / Power Supply Thermistor.................. 3-25 3.2.15 Removing the Safety Switch from the Power Supply................................ 3-28 3.2.16 Removing the Filter Board ........................................................................ 3-29 3.2.17 Removing the A/C Power Inlet Unit .......................................................... 3-30 3.2.18 Removing the CN Board........................................................................... 3-31 3.2.19 Removing the Air Filter Frame Unit Switch (Filter Cover Switch) ............. 3-32 3.2.20 Removing the Foot Adjuster A/B and FA Housing.................................... 3-33 3.2.21 Removing the FC Board (Cable Assembly F)........................................... 3-35 3.2.22 Removing the Cooling Fan / Exhaust Fan ............................................... 3-36

Chapter 4 Troubleshooting 4.1 Before Starting Troubleshooting Procedures............................................................ 4-1 Tools and Accessories Required for Troubleshooting ......................................... 4-1 Field Replacement Parts ..................................................................................... 4-1 4.2 Start .......................................................................................................................... 4-2 Exterior View........................................................................................................ 4-3 Internal Cable Connections ................................................................................. 4-4 Display/Picture..................................................................................................... 4-7 Audio Output........................................................................................................ 4-9 Control ....................................................................................................... 4-10 Remote Control.................................................................................................... 4-11 Mouse/COM......................................................................................................... 4-12 Others .................................................................................................................. 4-13

Appendix A A.1 Parts List ................................................................................................................. A-1

ix


1.1 PRODUCT FEATURES The PowerLite 5000XB/7000XB multimedia projector is a portable, easy-to-use presentation device with SVGA/XGA resolution. It projects enhanced color images from personal computers and from video equipment such as VCRs, camcorders, and digital cameras.

Features •

Lightweight, Compact, Portable The PowerLite 5000XB/7000XB weighs only 14.1 lb. (6.4 kg) / 14.5 lb. (6.6 kg). An optional carrying case is available for transporting the projector.

•

Bright and Clear Images The high performance zoom lens, new bright lamp (750/650 lm. ANSI), and optical block provide a wide image of 21" to 300" (1.2 to 12.3 m). An optional brightness screen provides clear images, even with bright ambient light.

•

High Resolution Full Color (16770 Thousand Colors) Three TN liquid crystal s (R, G, and B) of 480,000 / 786,432 pixels an SVGA resolution of 800 x 600 / 1024 x 768. The grid between pixels in the liquid crystal is thinner than that of conventional projectors, providing sharp contrast.

•

Remote Control You can control the projector using a hand-held remote control unit that has menus for image source switching and image adjustment. The remote control can also work as a wireless mouse during presentations. The ELP LINK IITM software has add-on features that make presentations effective.

•

Connectivity with Various Types of Computers The projector can connect to various types of computers, such as IBM-compatible PCs, laptops, and Macintosh computers. It also differentiates NTSC, PAL, or SECAM video signals in composite video or S-Video format.

•

Advanced Image Real-Time Resizer The projector features a new, patented SizeWiseTM chip that s SVGA, VGA and XGA output. No matter what type of output is used, the result is a full-size video image of outstanding clarity.

1-1


•

Automatic Video Tracking A totally new AVTSSTM (Automatic Video Tracking and Synchronization) feature provides automatic setup of images from the computer with a touch of the AUTO button for quick and easy projection of images.

•

Theft-proof An optional KensingtonTM lock is available.

1-2


1.2 PARTS OF THE PROJECTOR Note: The following drawings and photographs are of the PowerLite 5000XB, except where indicated.

Exterior View of Main Frame

Figure 1-1

Speakers Rear Infrared Receptor

Operation Indicator Lamp Indicator

Exhaust Fan Handle

Lock Inlet Rear Foot

Figure 1-2

1-3


A Styrofoam plate is mounted under the foot at shipment. Remove it when you make adjustments.

Filter Cover

Foot Adjuster A

Foot Adjuster B

Lamp Cover

Figure 1-3

Interior View of Main Frame Right Speaker

Main Board

Power Supply Unit

Projector Lens Unit

Left Speaker

Figure 1-4

1-4

Rear Case Unit


AU Board

Main Board

Driver Board

Light Guide Unit

Figure 1-5 LV Thermistor

Prism Duct

Driver Board Exhaust Fan

Inlet Unit

Figure 1-6

1-5

EPSON PowerLite 5000XB/7000XB Service Manual RI board

AU board

FR board FR board Figure 1-7 Foot Adjuster A

Lamp Thermistor

Lamp Power Cable

Light Guide Unit Figure 1-8

1-6

Safety Switch


Air Filter Frame

Filter Board

Filter Cover Switch

CN Board

Inlet Unit

Figure 1-9

Figure 1-10 Inside View of PowerLite 7000XB

1-7


Exterior View of Remote Control

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Remote Infrared Emitter

Figure 1-11

1-8

Remote Infrared Ray Menu Button Auto Button Video Button Computer Button Effects Button Pointer Button Right Click Button Blank Button Custom Button Mute Button Resize Button Freeze Button Volume Button Power Button Left Click Button


1.3 CONNECTIONS Connecting to a PC Desktop Audio Port Monitor Port Mouse Cable for Serial Serial Port Mouse Port Com Port

Monitor Cable

Mouse Cable for PS/2 Serial Cable

Computer Cable Main Cable

Audio Cable

Figure 1-12

Laptop Audio Port Monitor Port Mouse Cable for Serial Serial Port Mouse Port Com Port Mouse Cable for PS/2 Serial Cable

Monitor Cable Main Cable

Figure 1-13

1-9

Audio Cable


Connecting to a Macintosh Desktop Monitor Port Printer Port or modem Port ADB Port

Video Cable Adapter Mac Desktop Adapter

Mac Monitor Adapter

Audio Port Monitor Cable

MAC Serial Cable Mouse Cable for Mac

Computer Cable Main Cable

Audio Cable

Figure 1-14

* Attached Accessory Note: Dip switch settings vary according to the machine type. Refer to the following monitor adapter table for details. (The default setting is Mac 13" mode.)

Table 1-1 Switch A

Resolution

Top Row (A)

Bottom Row (B)

VGA

3, 4, 5

8

13" 640 × 480

1, 2, 5

8

16" 832 × 624

2, 4, 5

8

19" 1024 × 768

2, 3, 5

8

21" 1152 × 870

1, 2, 3, 4, 5

8

13" Multi Res.

1, 2, 5

8

14" Multi Res.

1, 2, 5

3, 4, 8

17" Multi Res.

1, 2, 5

3, 8/4, 8

21" Multi Res.

1, 2, 5

3,8

Switch B

Mac Desktop Video Adapter

Figure 1-15

1-10


Power Book

Monitor Port Printer Port or Modem Port

Video Cable Adapter

Mac Desktop Adapter

ADB Port Audio Port Mac Serial Cable Mac Mouse Cable

Computer Cable Audio Cable

Main Cable

Figure 1-16

Connecting to a Video Source

S-Video

Video Output (Yellow)

S-Video Output

Audio Output (White) Audio Output (Red) S-Video Cable

Figure 1-17

1-11

Video In (Yellow)

Audio In L Audio In R (White) (Red)


Connecting to an Audio Source

External Audio Devices

Audio In

Audio Out

Audio Cable

Figure 1-18

1-12


1.4 MAIN COMPONENTS Main Board (PowerLite 5000XB)

Figure 1-19

Main Board (PowerLite 7000XB)

Figure 1-20

1-13


Driver Board (PowerLite 5000XB)

Figure 1-21

Driver Board (PowerLite 7000XB)

Figure 1-22

1-14


AU Board

Figure 1-23

Remote Board

Figure 1-24

CN Board

Figure 1-25

1-15


Receptor Board (RI/FI) Rl

Fl

Figure 1-26

Speaker Left Speaker

Right Speaker

Figure 1-27

Inlet Unit

Inlet Unit

Figure 1-28

1-16


Filter Unit

Figure 1-29

Power Supply Unit

Figure 1-30

Lamp Inner Housing

Figure 1-31

1-17


Optical Engine Top Side View

Figure 1-32

Bottom Side View

Figure 1-33

1-18


Switch

Figure 1-34

1-19


1.5 SPECIFICATIONS Table 1-2 Optical Features Transparency type poly-silicon TFT color liquid crystal display with three s (R/G/B) Optical method Diachronic mirror separation and prism combination methods Projection image size Minimum 23 inches to maximum 300 inches (0.6 m to 7 m) Projection distance (PowerLite 5000XB) 3.94 feet to 40.35 feet (1.2 m to 12.3 m) (PowerLite 7000XB) 3.28 feet to 32.80 feet (1.0 m to 10.0 m) Resolution (PowerLite 5000XB) 800 x 600 dots; 1,440,000 pixels (480,000 x 3) (PowerLite 7000XB) 1024 x 768 dots; 2,359,296 pixels (786,432 x 3) Projection lens (PowerLite 5000XB) Zoom lens F2.5 - 2.9 (45-59 mm) (PowerLite 7000XB) Zoom lens F2.5 - 2.9 (45-59 mm) Focus adjustment Manual Zooming adjustment Manual (1:1.3) Light Source (PowerLite 5000XB) 150 W Life (lamp inner housing) UHE (type ELPLP04) 2000 hours Light source (PowerLite 7000XB) 150 W Life (lamp inner housing) UHE (type ELPLP04) 2000 hours Average luminance (PowerLite 5000XB) 750 lumens (ANSI) (PowerLite 7000XB) 650 lumens (ANSI) Display method

1-20


Audio Features Internal speakers Built-in speakers (2W-4Ω) x 2 (stereo) Output for Audio Out interface External speaker 3.5 mm stereo minijack internal speaker output is stopped when mini-jack is plugged in. Output signal: 0 to 500 mVrms Load impedance: 600Ω Left and right Audio In interface Audio signal (stereo) from the video (For video device ) devices. Input interface is separated into right and left. Interface type: RCA jack Input signal: 500 mVrms Audio In 1 interface Host computer 1 audio input (stereo) (For Computer In 1) Interface type: 3.5 mm stereo mini-jack Input signal: 500 mVrms/47KΩ Audio In 2 interface Host computer 1 audio input (stereo) (For Computer In 2) Interface type: 3.5 mm stereo mini-jack Input signal: 500 mVrms/47KΩ Remote Control Wireless remote control Controls the projector operating mode and the host computer. The signal is detected by an internal receptor board. Control range: Within 33 feet (10 m) and 30 degrees of the projector receptor Video Input/Output Computer In 1 interface Host computer 1 RGB output Computer In 2 interface Interface type: HD-15-pin (DDC1/2B compatible) S-video interface Input signal: Luminous 0.714 Vp-p, Chrominous 0.28 Vp-p. Interface type: Min-DIN 4-pin S-Video is prior to composite video Video In interface Input signal: 1,0 Vp-p, sync, negative (Composite video interface) Interface type: RCA jack (yellow) TV signal type: NTSC 3.58 MHz PAL 4.43 MHz SECAM 4.43 MHz Auto identification (default) Mouse/Com 1/2 Serial mouse or RS-232C Auto identification (Mouse or RS-232C) Interface type: 13-pin DIN

1-21


Power Supply Input voltage 100 – 120 VAC /220 – 240 VAC± 10% (50/60 Hz) Power consumption (PowerLite 5000XB) Approximately 240 W (standby mode: 38 W) (PowerLite 7000XB) Approximately 260 W (standby mode: 38 W) Dimensions W 9.65 inches (245 mm) D 14.96 inches (380 mm) H 6.26 inches (159 mm) Weight (PowerLite 5000XB) Approximately 14.5 lb. (6.6 kg) (PowerLite 7000XB) Approximately 14.7 lb. (6.7 kg) Environment Operational/ storage temperature +39°F ~ 104°F/ +14°F ~ 140°F (+5°C ~ +40°C/ -10°C ~ +60°C) (non condensing) Operational/ storage humidity 20% ~ 80% / 10% ~ 90% (non condensing) Operational/ storage altitude 10,000 feet (3048 m) / 20,000 feet (6096 m)

1-22


1.6 INTERFACE SPECIFICATIONS

Figure 1-35

Computer In 1/2 Computer video input D-SUB 15 (HD) 5

1

10

6

15

11

Figure 1-36

Table 1-3 Pin 1 2 3 4 5 6 7 8

Terminal Red video Green video Blue video Monitor (ID bit 2) GND Red video GND Green video GND Blue video GND

Pin 9 10 11 12 13 14 15

1-23

Terminal +5V Synchronous GND Monitor (ID bit 0) SDA Horizontal synchronization Vertical synchronization SCL


Audio In 1/2 Stereo mini jack with 2 circuits for detection pin (The detection pin, which is not required for audio input, is installed for the audio out terminal.)

1 5

Table 1-4 Pin number 1 2 3 Others

Signal GND Computer audio input L Computer audio input R NC

Figure 1-37

Audio Out Stereo mini jack with two circuits for detection pins

Figure 1-38

Table 1-5 Pin number 1 2 3 4 5 Others

1-24

Signal GND Audio output L Audio output R GND Detection of line-out jack insertion NC


Monitor 5

Table 1-6 Pin 1 2 3 4 5 6 7 8 9 10 11 12 13

1

10

6

15

11

Figure 1-39

Signal R Out G Out B Out Reserved GND GND GND GND Reserved GND Reserved Reserved H sync

14

V sync

15

V sync

Function Red video Green video Blue video

Horizontal synchronization Vertical synchronization

S-Video S-terminal input Mini DIN 4-pin with a detection pin

4

3

2

1

6

5

Table 1-7 Pin Signal 1 GND 2 GND 3 Y signal input 4 C signal input 5 Input detection terminal 6 GND

Figure 1-40

1-25


Video-In RCA gold plating (only insertion part), light angle H=15 mm Color: yellow

2

Table 1-8 Pin number 1 2

Signal GND Video input

1

Figure 1-41

Audio In L/R RCA gold plating (only insertion part), light angle H = 15 mm Color: L = white R = red 3, 6 4, 7 5, 8

Figure 1-42

Table 1-9 Pin 3 4 5 6 7 8

Signal GND Audio R return Audio input L GND Audio L return Audio input R

1-26


Mouse / Com 1/2

Figure 1-43

Multi-mouse, 13-pin Jack 4

1

8

5

12

9

13

Figure 1-44

Tables 1-10 and 1-11 show the pin assignments and the signals transmitted to different mice, respectively. Table 1-10 Pin Signal 1 XA/CLK/ADB 2 3 4 5 6 7 8 9 10 11 12 13

XB/DATA YA YB LEFT/ID0 RIGHT/ID1 NC TxD RxD DTR DSR GHD

Type

Common Serial Serial Serial Serial Common Common

Functions Encoder signal/I/O data signal/synchronous clock signal Encoder signal/I/O data signal Encoder signal Encoder signal Left button signal/control signal Right button signal/control signal Disabled Transmitted signal Received signal L data terminal ready signal PC data set ready signal PC power ON signal Ground

1-27


Table 1-11 Pin 1 2 3 4 5 6 7 8 9 10 11 12 13

PS/2 Mouse XA XB Reserved Reserved LEFT Reserved Reserved Reserved Reserved Reserved Reserved PCV (+5 V) GND

98 Mouse XA XB YA YB LEFT RIGHT Reserved Reserved Reserved Reserved Reserved PCV (+5 V) GND

Mac Mouse XA Reserved Reserved Reserved Reserved LEFT Reserved Reserved Reserved Reserved Reserved PCV (+5 V) GND

1-28

Serial Mouse Reserved Reserved TXD READY GND GND GND Reserved Reserved Reserved Reserved Reserved GND

PC Serial/ Mac Serial Reserved Reserved Reserved Reserved Reserved Reserved Reserved TXD RXD DTR DSR Reserved GND


2.1 HARDWARE Most of the repair actions that can be performed on the PowerLite 5000XB/7000XB concern the optical and electrical systems of the projector. The following diagram shows the relationship between the optical and electrical systems of the projector. The lower level (below the broken line in the figure) shows the optical system, and the upper level shows the electrical system.

POWER SUPPLY: Generates DC voltages (+5 V, +12 V, +22 V, +3.3 V) for the electric circuits; also generates DC voltage (65 V) for the light source.

MAIN BOARD: Sets initial operation of the circuit and controls the computer interface. Controls the sensors, fans, speakers, and control .

CONTROL

INTAKE FAN

Computer In 1/2

EXHAUST FAN

LAMP INNER HOUSING 150 W 65 V max (light source)

DRIVER BOARD: Generates R/G/B video signals, outputs to the light valves, and stores the image correction data in *3 flash ROM.

LIGHT GUIDE UNIT: Divide the light into 3 (R/G/B) by lens, filter, and mirror

Figure 2-1

Notes: *1 The intake fan cools the R/G/B light valves (LCD ). *2 The exhaust fan removes hot air around the light source. *3 The driver board contains a DC-DC board and a sub board.

2-1

Audio In 1/2 Audio Out S-Video Video Audio In L/R

CN BOARD FR BOARD

Mouse/ COM 1/2

*1

OPTICAL UNIT: (polarization plate / light valves R/G/B)

*2

AU BOARD: Audio In / Out, Video In

PRISM R/G/B composite

PROJECTOR LENS UNIT: Focus/Zoom


Description of the Projection Process 1. The digital or analog R/G/B signal is provided by a computer (1 or 2) to the main board. Analog signals (S-video or video signals) are sent to the main board through the AU board. (Analog signals are converted into digital signals by the main board.) 2. The digital video signal is then stored in video memory (SRAM) on the main board. Then the driver board generates signals to drive the R/G/B light valves. 3. The R/G/B light valves are individual s, independent of each other. They work to shut off or transmit lights from the light guide unit. 4. Lights transmitted through the light valves are combined by a prism and projected through the lens unit.

Electrical System Connections Electrical units of the PowerLite 5000XB are physically connected to the main board as shown in the following diagram (next page):

2-2


Mouse/COM2

Mouse/COM1

CN100

CN102 Remote

Audio In 1 Audio In 2 Audio Out S-Video Video In Audio In L Audio In R

Remote Board

J100

CN101

AU BOARD CN100

CN201

CN BOARD

SWITCH

FI BOARD

CN203

CN101 CN200

CN202 CN204 FILTER COVER SWITCH

RIGHT SPEAKER

CN802 CN800 CN860

RI BOARD

CN804

CN603

Exhaust Fan CN806

CN600

CN602

CN700

CN805

Monitor

J302

CN803 CN601

MAIN BOARD

LEFT SPEAKER

J301

Computer In 2

J300

Computer In 1

CN300

CN250 CN900 Red Light Valve

DRIVER BOARD

CN100 PBS Thermistor

Green

CN800 FAN

Blue LV Thermistor

POWER SUPPLY UNIT

CN700 CN251

CN252 Safety Switch Lamp Thermistor

Cooling Fan FC BOARD

(for light valve)

FU

LAMP

BOARD LAMP INNER HOUSING

Figure 2-2 2-3


Electrical units of the PowerLite 7000XB are physically connected to the main board as shown in the following diagram: Mouse/COM2

Mouse/COM1

CN100

CN102 J100

Audio In 1 Audio In 2 Audio Out S-Video Video In Audio In L Audio In R

FR BOARD CN101

AU BOARD CN100

CN201

CN BOARD

CONTROL

FI BOARD

CN203

CN101 CN200

CN202 CN204 FILTER COVER SWITCH

RIGHT SPEAKER

RI BOARD CN603

CN800 CN852 CN801 CN851

Exhaust Fan CN831

CN600

CN602

CN700

CN830

Monitor

CN202

CN850 CN601

MAIN BOARD

LEFT SPEAKER

CN201

Computer In 2

CN200

Computer In 1

CN203

DC-DC Converter CN104 CN800 Red Light Valve

CN100

DRIVER BOARD

CN103

PBS Thermistor

Green

CN560 FAN

Blue LV Thermistor

POWER SUPPLY UNIT

CN900 CN101

CN102 Safety Switch Lamp Thermistor

Cooling Fan FC BOARD

(for light valve)

FU

LAMP

BOARD LAMP INNER HOUSING

Figure 2-3

2-4


Optical System Connections (Optical Engine) The optical system consists of 5 blocks: the lamp inner housing, light guide unit, optical head/prism unit, and projector lens unit (which are shown below) and the driver board. These units comprise the optical engine, which is a single replaceable part. In addition to the optical engine, an FC board is attached at the bottom of the light guide unit. The relay board connects the FC board in the lamp inner housing to the driver board, and is independent of the optical functions.

Lamp Inner Housing Mounting Position

Optical Head/Prism Unit Light Guide Unit

FC Board

Figure 2-4

2-5

Projector Lens Unit


Inside View of the Light Guide Unit

Figure 2-5

Caution: Do not disassemble the optical engine or subject it to shock or mechanical stress, as pixel divergence may occur. The alignment is adjusted in the factory and specific electrical corrections are made on the driver board for each optical engine. Table 2-1 Unit Name Lamp inner housing Light guide unit

Projector lens Optical head/prism unit

Function and Remarks Includes one metal halide lamp as a light source. The FC board is mounted for lamp inner housing detection. Disperses the light from the light source uniformly using an A/B lens array. (Ultraviolet rays are also eliminated.) Disperses the light in three parts (R/G/B), for the condenser lens and mirror. Zoom (*1.3) and focus adjustments Consists of three light valves, a polarization plate, and a prism unit. Each light valve controls the shutter of pixels with six levels. The prism unit creates R/G/B optical signals and transfers them to the projector lens unit.

Caution: The optical engines of the PowerLite 5000XB and the PowerLite 7000XB are not interchangeable.

2-6


2.2 POWER SUPPLY UNIT The power supply unit includes a DC regulator, intake fan, and interlock switch for the lamp cover. The projector uses AC input to generate voltages for the control circuit (+3.3v, +5v, +12v, +22v) and for the light source lamp from AC input (+350V for 5000XB, +65V for 7000XB). The PBS thermistor is installed on the side of the power supply intake fan and is attached by a clamp on the power supply unit. If the power supply overheats, the PBS thermistor shuts off the regulator output via the main board. Caution: •

Never disassemble the power supply unit.

•

Do not interchange the power supply units for the PowerLite 5000 and PowerLite 5000XB (or the PowerLite 7000 and PowerLite 7000XB)—they are different and are not compatible.

•

The lamps from the PowerLite 5000 and the PowerLite 7000 have different connector wiring and are not interchangeable.

Connects to CN800 on the main board (DC output and power control signals)

Interlock Switch

Power Cable for Light Source PBS Thermistor Intake Fan

Figure 2-6

2-7


Function Block INTERLOCK SW

SAFTY SW N/C

N/C

FILTER/ RECTIFIER

REGULATOR

AC IN

MAIN BOARD

C N 8 6 0

CN851 for 7000XB CN801 for 7000XB

INHALE FAN

PBS Thermistor

BALLAST

AC Voltage +5V

CN800 +22V +12V +3.3V

Figure 2-7

An interlock switch is included for safety. The interlock switch shuts off the supply of AC power if the lamp cover at the bottom of the main chassis is open. The safety switch input signal stops power output to the light source lamp if the projector detects overheating. The safety switch is mounted on the light guide unit attached to the lamp inner housing.

Functional Outline •

The interlock switch at the bottom of the main chassis shuts off power when the lamp cover is opened. It is normally in the ON position.

•

The power supply is connected to CN800 / CN801 on the main board. The following items are also connected to CN800 / CN801: DC output (+3.3/+5/+12/+22V) PWDS signal for the power down detection Lamp power on/off control signal (LPSTC) Power on/off signal (BACT) Caution: If the AC power cable is still connected after the power is shut off, +3.3 V background voltage is supplied to the main board via CN800 / CN801 and to the power on/off circuit.

2-8


•

The filter/rectification circuit reduces noise on the AC line and generates DC voltage for the regulator.

•

The regulator generates the various DC voltage levels shown in the table below for the switching regulator. The regulator detects the voltage output level at the +5 V line and feeds the information back to the switching circuit to maintain a stable output level regardless of load variations. Not every output level is subject to adjustment.

Table 2-2 Output Specifications Power Source +5 V +3.3 V +12 V +12 FV Output voltage ±5 ±5 ±5 12.0-13.8 V accuracy (%) Ripple (mV p-p) 200 100 100 400 Ripple/ Spike(mV p-p) 200 100 100 400 Output current Min (A) 1.0 0.3 0.2 0.05 Rated (A) 2.4 2.0 1.0 1.5 Peak (A) 2.0 Overvoltage protection +7 V +4.6 V +16 V Overcurrent protection Transient* Distortion Distortion Transient* Use Logic Logic Analog Fan/Audio circuit circuit circuit Circuit * Protection is the transient detection type, it is recoverable with power on. •

+22 V 19.0-24.0 V 400 400 0.0 0.3 +30 V Transient* Light valves

The intake fan removes the heat generated in the power supply unit. Heat expelled by the intake fan is blown by the exhaust fan, connected to CN860 / CN831 on the main board.

2-9


Pin Assignments on CN800 (801) Main Board

PIN 15

CN800

PIN 1 (Red)

Table 2-3 CN800 (801) Pin No. 1,2 3,4 5 6 7 8 9,10,11,12,13 14 15

Figure 2-8

2-10

Signal +5V +3.3V +12V F L PST BACT PWDS L GND +12V +22V


2.3 MAIN BOARD The main board consists of the U, P-ROM, video memory (SRAM), digital video controller, and circuits to control the control , computer input interface, monitor output, speakers, power management, and other components. The main board controls everything except video signal generation. The main board is available as a unit for service.

Figure 2-9 PowerLite 5000XB Main Board


2-11


Main Board Circuit Block (Parts for PowerLite 5000XB) Connect to Power

Connect to

Supply Unit

AU Board

CN800

CN603

DC Input +5V +3.3V +12V

CN601

Connect to Speaker L

CN602

Connect to Speaker R Connect to CN Board

LED Indicator

CN802

Power Control • Power ON/OFF • Lamp power

IC600 Power management

• Back up power

Audio control

control

Connect to

Connect to

Exhaust Fan

Switch

CN806

CN600

+12V Switching circuit

IC601

Indicator driver

A 0 •

+22V

•

7

A D 8

17

EEPROM CN803

LV Thermistor

CN804

Lamp Thermistor

CN860

PBS Thermistor

Bus buffer/ Control

RD0• 7

XD0• 7

IC700 Digital Video Controller

GD0• 7 CN 700

XA0• 7

+12V Regulator

CN805

Connect to Driver Board

RDI0• 7

BD0• 7

GDI0• 7

Display timing

BDI0• 7

MD0• 95

IC100 U

MA0• 19 RAS/CAS

Clock IC900

PAD0• 23 PBD0• 23

Clock/delay control

Computer In1

J300

Computer In2

J301

Monitor

J302

RGB Input

RGB Input Digital RGB Output

AU Board

ADC

Line Buffer

R/G/B Gate

D/A Converter

Line Buffer ADC Driver D/A Converter

Connect to

•

22

M A C 8

Timing

Video Input (Analog) CN300

IC316 OSC

Figure 2-11 2-12

A/D Converter

PDA0• 15

SRAM


Functional Outline The circuit functions of the PowerLite 5000XB and PowerLite 7000XB main boards are similar, except for video control. This section explains PowerLite 5000XB main board functions. •

IC600 and related circuits are backed up with +3.3 V, which is provided by the power supply. (If the AC cable is connected to the AC source, the power supply provides +3.3 V for backup bias even if the projector is turned off.)

•

When the power is turned on, IC600 on the main board generates a reset signal and initializes the circuit. The U reads the program from flash ROM and writes it into SRAM. Then the U sets functions based on the program and projects the image.

•

Three thermistors (LV Thermistor / Lamp Thermistor / PBS Thermistor) detect temperature. If the temperature exceeds a predefined level, the thermistors send an interrupt signal to IC600 and shut off the power supply.

•

Signals, either analog or digital, from Computer In 1/2 are converted into analog signals first, then converted to digital signals again by ADC. This display data is written into the video memory (SRAM).

•

Analog output signals are transmitted in differently for anaput and digital input. 1. Digital RGB: The digital image signals are output via the gate and driver board. 2. Analog RGB: The analog image signals are converted by the ADC and the D/A converter.

•

The data is stored in the SRAM, then output to the video controller for display via the U. The video controller generates the display control timing and sends the information to the driver board.

•

Video input signals (S-Video / Video In) are transferred via the AU board and converted into digital signals by the A/D converter. They are stored in the SRAM.

•

The projector has an EEPROM and timer circuit that control the operating time of the light source bulb (lamp inner housing). Its operation is described in the following table.

2-13


Table 2-4 Light source state When the operating time of the light source bulb (lamp inner housing) exceeds 1900 hours.

Lamp monitor state The lamp monitor continues to flash red and orange for 5 minutes after it is turned on. (The light source stays on.) When the operating time of the light source bulb (lamp The lamp monitor is red. inner housing) exceeds 2000 hours. When the light source bulb (lamp inner housing) runs The lamp monitor is red. out before its expected end of life.

If you observe the conditions above, replace the light source bulb (lamp inner housing), then turn on the switch. The fuse in the lamp melts and shorts out, so that lamp timer is reset automatically. Note: If any of the three thermistors in the temperature detection circuit detects a specified temperature, the circuit interrupts the U, then shuts off the power supply regulation.

2-14


2.4 DRIVER BOARD The driver board has two functions: one is converting the R/G/B display signal from the main board into six states of analog signals (light valve driver signals) and the other is controlling the display image by referencing electrical correction data. In maintenance service, the entire optical engine must be replaced. No individual parts, such as the driver board, may be replaced..

Figure 2-12 PowerLite 5000XB Driver Board


2-15


Functional Outline Circuit function is almost the same with PowerLite 5000XB and PowerLite 7000XB driver boards except light valve control. Thus, this section explains PowerLite 5000XB driver board functions. •

The signals RD 0~7, GD 0~7, and BD 0~7 are output from the main board. They are first converted into analog signals by the digital to analog converter before being output to the driver circuit for the light valves.

•

Timing signals output from the display controller are converted into signals for the light valves (LCDs) by the D/A converter and LCCOM circuit before they are output.

•

The filter/gate circuit is designed to reduce noise influence on the display driver circuit. To reduce impulse noise, input signals are sent through the three-level filter circuit. To reduce the effects of timing delays on the logic, gate circuits work as trigger circuits for each signal line (R/G/B) and unify the output timing.

•

The flash ROM contains electrical correction data for the image display. The display controller reads the correction data. The controller uses the correction data for display timing generation, brightness/contrast/chroma, and density control.

•

Light valve driver circuits convert the input analog signals to LCD driver signals.

2-16


Circuit Block Diagram of Driver Board (PowerLite 5000XB)

RD0-7 GD0-7 C N 1 0 0

IC100 Display Controller

IC250 Buffer

BD0-7

RPD10-17/RQD1017

CLAMP (Red)

GPD10-17/GQD1017

CLAMP (Green)

BPD10-17/BQD1017

SCL / SDA

CLAMP (Blue)

IC300 Flash ROM

+22 V

+18 V REGULATOR +18 V

+12 V

Display Timing (Red) F251 4511.25 A

+12V REGULATOR

+12 V

+5 V +5V REGULATOR

F252C2E10 A

Display Timing (Green) +5 V

+3.3 V F250 4511.25 A

Display Timing (Blue)

+3.3 V REGULATOR

+3.3 V

Display Control Signals

SHIFT Clock Level Shifter

Filter/Gate

Control Signal Level Shifter R

G

B

Shift clock 1-6 8CH DAC

LCCOM (Timing) R

G

B

Red Light Valve Driver (IC700)

Green Light Valve Driver (IC800)

CN900

CN800

Figure 2-14

2-17

Blue Light Valve Driver (IC700) CN700


2.5 CONTROL The control includes a board with 13 switches, and is connected to CN600 on the main board.

Figure 2-15

2-18


2.6 AU BOARD The AU board includes an audio control circuit and interface connectors that receive audio signals from a host computer or external video or other device. The interface connectors are shown below. Audio In 1 (for Computer In 1)

S-Video In (superimpose video)

Audio In 1 (for Computer In 1)

Video In

Audio In

Audio Out

Audio Out

Figure 2-16

2-19


AU Board Circuit Block

Audio Out Computer 1 Audio In 1

Amp (For Internal Speaker)

Sound Pre-Amp

Sound Controller

Computer 2 Audio In 2

CN100 Reference Mode Connects to Main Board CN603

Voltage SCL/SDA

Sound Volume (8 Level Control)

SPA C0/1

SPL/R OUT PUT

CN101

Audio In L

S Video R

Video In

Connects to Main Board CN300

Figure 2-17

The only circuits that the interface signal lines for S-Video and Video are noise filter circuits; therefore, they output signals to the main board through the connector CN101. Audio input signals from computer 1/2 (via Audio In 1/2) or from a video device (via Audio In L/R) are input to the sound controller and amplified by the sound pre-amplifier. Then they are output to the Audio Out interface or the built-in speaker through the sound controller again. The sound controller performs the audio-signal output selection based on the SCL/SDA (serial data/clock) signals provided by the main board. The sound volume control uses 8 levels (mute ~ max.) based on the signals (SPAC 0/1) from the main board.

2-20


2.7 REMOTE BOARD The REMOTE board is used for connecting the remote control receiver to a mouse or serial interface of a host computer. The controller has an 8-bit U and mouse / serial switching circuit installed on the board. CN100 (Mouse/COM1) and CN102 (Mouse/COM2) are multi-mouse connectors. If the ELP communication kit option 2 is installed on the host computer and cables are connected to it, you can control the computer with the remote control. The controller on the REMOTE board automatically determines the circuit operation mode (Mouse or COM) to apply the proper circuit. The optional remote control receiver can be connected to the remote control interface (J100). The receiver provides the same functions as the standard receptor board (FI/RI). Without the receiver, the remote control can be used within a limited area in the front and rear. The receiver expands the range for the remote control.

Figure 2-18

The signals from the receptor board (FI/RI board) and the optional remote control receiver are accepted by the remote (IC101). The infrared signals received from the remote control are output under OR conditions to the main board through CN101 and the connector board. If a host computer with the ELP communication kit 2 option is connected to the interface, the relay circuit is switched depending on each operation. This enables the switch data transmission to the host computer and remote mouse operation by the remote control. The ELP communication kit 2 option also enables the remote control to draw lines and patterns on the screen.

2-21


The relay circuit (IC111 or IC116C) is switched to be able to accept the mouse encoder signal and the button signal. Then the signals based on the Tracking +/- button operation are output to a host computer through the remote. The signals are transferred through the host computer’s interface, thus you can control the host computer without its mouse. Refer to the appendix for detailed data. The following figure shows the Remote board circuit block: Mouse/COM1 (CN100)

MDA0~7

LEFT/RIGHT/CLOCK

Serial to Parallel (For Mouse1)

13-PIN TXD/RXD/DTR/DSR YA/TXD Switching (Mouse/COM1)

Mouse/COM Controller

Level Converter

SEL SEL

MDA 0~7

TXD/RXD/DTR/DSR

Serial to Parallel (For Mouse2)

YA/TXD

Switching (Mouse/COM2)

CN101

13-PIN

Mouse/COM2 (CN102)


COM1/COM2 Level Converter

Figure 2-19

2-22


2.8 CN BOARD The CN board is the relay board for the cable connector. It has five connectors. The signals below are transferred to the main board through this board. •

FI board signal: Remote control signals go from the front receptor to the FR board.

•

RI board signal: Remote control signals go from the rear receptor to the FR board.

•

FC board signal: Filter cover detection switch signals go to the main board.

•

FR board signal: Mouse/COM interface 1/2 signals go to the main board.

Figure 2-20

2-23


The following figure shows the CN board connecting block.

Connects to Remote Board CN101


Connects to Remote Board CN101


CN203

CN 201

CN 200

CN204

Connects to RI Board (R receptor)

CN202

Connects to Filter Cover Switch

CN203

CN 201

CN 200

Connects to FI Board (F receptor)

Connects to FI Board (F receptor)

CN204

Connects to RI Board (R receptor)

CN202

Connects to Filter Cover Switch

Figure 2-21

The signals from the receptor board (FI board/RI board) are first sent to the FR board and are used for wireless mouse control (controlling the host computer via the remote control). The signals from the filter cover switch are sent to the main board. If the filter cover is open, power cannot be supplied. The signals for controlling serial operations and the receptor board signals are sent from the FR board to the CN board.

2-24


2.9 RECEPTOR BOARD (FI/RI BOARD) This board detects infrared signals. This unit consists of two receptor boards: one is attached to the speaker bracket on the front face (FI board), and the other is on the rear case (RI board). You can control this device through the boards on both sides. The FI and the RI are different in shape, but the same in function (circuit). F I board (front)

R I bo ard (rear)

Figure 2-22

361FI R300 47

CN300 S38-PH-K 1

2

2 2 3 3

1

VCC

GND

4

2

VOUT

GND

3

1

CHIP

3 3

2 F

2

1 1 2 2

1

IC400 GP1U102X

R400 47

CN400 B38-PH-K-S

1 1 C300 0.1U 16V

361RI

IC300 GP1U102X

C400 0.1U 16V

1

VCC

GND

4

2

VOUT

GND

3

1 CHIP 2 F

Figure 2-23 Fl Board Circuit

Figure 2-24 RI Board Circuit

Each receptor board is connected to CN203/204 on the connector board. Each board’s output signal (serial data) is connected to CN802 on the main board via CN200 after wired OR is applied. 1. The main board operates the power and the start-up menus, using serial data received from the remote control (button switches and pointers). 2. The serial signal sent to the driver board via the main board controls the display (Freeze/blank). 3. The serial signal sent to the AU board via the main board controls mute and audio volume.

2-25


The following figure shows the remote control circuit block.

Connector Board CN204

CN201

Main Board FR Board

CN802

RI Board

EEPROM

Remote Control CN200

FI Board Infrared Rays

CN700

CN603

CN203 CN100 Driver Board

Figure 2-25

2-26

CN100 AU Board


2.10 SPEAKERS UNIT Inside the case are two upward-facing speakers (4 Ω -2W). Audio signals from the computer or AV devices are output through these speakers. If an external speaker is connected to the Audio Out terminal (the rear face), the built-in speakers are disabled. Right Speaker

Left Speaker

Figure 2-26 Computer 1 Board Audio In

Computer 2 Audio In

Audio Audio In L/R

J101

J102

AU Board

CN100

Sound Controller Volume Control Amplifier Circuit

CN603

CN601

Main Board

CN602

EXT.SP

J100

Right Speaker

J103

Left Speaker

Audio Out

Figure 2-27

The audio input signals from computers or an audio device are first amplified by the control circuit on the AU board, then output to the speakers via the main board. The speakers are connected to CN601/602 on the main board. The main board detects the presence of an external speaker and uses the built-in speakers if there is no external speaker.

2-27


2.11 LIGHT GUIDE UNIT FOR REREFENCE ONLY—DO NOT DISASSEMBLE THE LIGHT GUIDE UNIT The light valve block eliminates ultraviolet rays, which are harmful to the light valves, and makes the light intensity from the light source lamp uniform before dividing it into 3 light outputs (R/G/B). Lenses and mirrors built in the block disperse the light. The following drawings show the light valve block.

Figure 2-28 Lens Array A

Lens Array B

Condenser Lens L

Mirror L

GDM

CDM Condenser Lens G Lens Array Adjusting Springs

Mirror R Lens Adjusting Screw

Mirror B

Condenser Lens R Mirror C Lens Adjusting Screw

Condenser Lens D

Figure 2-29

2-28

Condenser Lens E

Condenser Lens B


•

Lens Arrays A and B After dispersion of the light from the light source lamp by lens arrays A and B, the brightness is roughly uniform. A UV filter coats the surface of the multi-lens array to eliminate ultraviolet rays. The light dispersed through the lens arrays A and B is further dispersed through the PBS to make the light intensity uniform.

•

CDM The CDM is a light filter that looks red in visual light. The CDM (A) filter transmits only red light and reflects blue and green light from the light source.

•

GDM The GDM is a light filter that looks blue in visual light. The GDM filter transmits only blue light and reflects the green light provided by the CDM.

•

Condenser Lens L Condenser lens L collects the light dispersed by the lens arrays A and B to prevent reduction and provide light to mirror L in the next stage.

•

Condenser Lens R/G/B Collects the light dispersed into the polarization plate on the optical head.

•

Mirror R/C Unit and Lens Adjusting Screw Reflects light to the condenser lens E/B. The reflection angle can be adjusted with the lens adjusting screw.

•

Mirror B Reflects the light to condenser lens E.

•

Lens Array Adjusting Screw Used for adjusting the A/B lens array position to obtain the best uniformity of source light.

2-29


2.12 LAMP INNER HOUSING The lamp inner housing consists of the DC drive light source lamp (150 W), the power supply connector, and the fuse board (FU board). The lamp mounted on the base of the lower case is a -replaceable item (type: ELPLP04). The average brightness of the lamp is 650 (7000XB) / 750 (5000XB) Im (ANSI). The fuse board (FU board) determines whether the lamp inner housing is installed, and controls the lamp life (2000 hours). The power supply connector receives 350 VDC from the power supply unit. Its lead wire is connected to the lamp.

Light Source Lamp

Power Supply Connector Upper Face

FU Board

Figure 2-30

Figure 2-31

2-30


Light Source Lamp The standard lamp life is 2000 hours. If you notice reduced lamp brightness, replace the lamp inner housing even if you have used the projector for less than 2000 hours. The total running time of the light source lamp is written in the EEPROM (IC603: ST24W04FM6TR) on the main board. If the lamp is nearing or has reached the end of its life, IC600 (M37732S4BFP) outputs signals to control the following: •

When the total running time has reached 1900 hours (1900~2000), the orange and red lamp indicators blink alternately. The controller (IC600) on the main board counts the total running hours and has written the running data in IC603. The lamp runs only 100 hours after the orange and the red lamp indicators start to blink alternately, so you should replace the lamp as soon as possible. (If the lamp indicators blink alternately when you turn the projector on, the lamp life is no more than 100 hours. Therefore, the lamp life may be suddenly terminated.)

•

When the total running time has reached 2000 hours, the lamp is turned off. Then the cooling down operation starts (the orange lamp indicator blinks). Afterward, the lamp will not run until you replace it with a new one. You cannot replace it with a used inner housing because the fuse on the FU board is blown when you start the lamp, which prevents a used housing from being recognized as a new unit.

2-31


Lamp Indicator

EEPROM (IC603)

Buffer (IC618)

Controller (IC600)

Generator (X500)

Main Board

+5 VDC

CN800

Power Supply Unit

BACT LPST

IC800 LPCTL LPFAL LLIFE

DC65V Regulator 33

LFUSE

CN700 Lamp Inner Housing

CN700

+5V_A

Lamp LSTAT

FU Board

~

CN250 1

2

Driver Board

Figure 2-32

2-32

Signals: LTPCL: Light power supply control signal LPFAL: Light power supply failure LLIFE: Lamp life LFUSE: FU board fuse is blown


2.13 SENSOR/SWITCH The following table lists devices installed in the projector for safe operation and prevention of malfunctions. Table 2-5 Name Filter cover switch

Location/Type Micro switch on the lower case

Interlock switch

Push-switch on the power supply unit

Lamp thermistor

Thermistor on the lamp outer housing

LV thermistor

Thermistor on the prism duct

PBS thermistor

Thermistor on the side of the power supply unit

2-33

Function/Use Turns power off when the filter cover is open. (Power on is disabled.) Turns power off when the lamp cover is open. (Power on is disabled.) Overheating protection for the lamp area. Power is shut off if the temperature exceeds a specified limit. Overheating protection for the light bulb. Power is shut off when the temperature exceeds a specified limit. Overheating protection for power supply unit. Power is shut off when the temperature exceeds a specified limit.


Filter Cover Switch This switch is installed in the lower case and locks with the tab of the filter cover. With the filter cover open, the intake fan draws in external air to cool down the light valve. This allows dust to get on the light valve and the prism, degrading the displayed image. The switch is installed so you cannot turn on the projector when the filter cover is open.

Filter Cover Switch

Filter Cover

Figure 2-33

The filter cover switch is connected to CN802 (800) on the main board via CN202 on the CN board. In main board circuit, IC100 generates the interrupt signal and outputs the power shut off signal to CN800 (801), so all regulation of operations of the power supply unit are stopped.

2-34


Interlock Switch This switch is installed on the side of the power supply unit and locks with the tab on the lamp cover. If you turned on the projector with the lamp cover open, the light source lamp (lamp inner housing) would run and generate high heat. To protect you from burns, the interlock switch is installed on the AC power source line and the projector cannot be turned on while the lamp cover is open. Interlock switch

Figure 2-34

Interlock switch

Figure 2-35

2-35


Lamp Thermistor This is the temperature detection thermistor installed on the lamp outer housing. To protect the light source lamp from overheating, this thermistor shuts off the power on the power supply unit if the temperature rises to a certain temperature (lower than the safety switch level). Lamp Thermistor

Figure 2-36

The lamp thermistor is connected to CN804 (851) on the main board. If there is overheating, IC600 generates an interrupt signal and shuts off power in the power supply unit via CN800 (801).

2-36


LV Thermistor This is the temperature detection thermistor installed on top of the light valve. If cooling is not sufficient because of intake fan failure (installed at the bottom of the light valve) or filter contamination (installed at the top of the light valve), the power is shut off to protect the light valves from overheating. The light valve (liquid crystal ) has poor thermal stability. The power shut off control is the same as that of the lamp thermistor, described in the previous section. LV Thermistor

Figure 2-37

2-37


PBS Thermistor This is the temperature detection thermistor installed on the side of the fan (attached to the power supply unit). If the environment around the power supply unit overheats because of a fan or circuit abnormality, this thermistor shuts off the power. The power shut off control is the same as that of the lamp thermistor. PBS Thermistor

Figure 2-38

2-38


3.1 DISASSEMBLY AND ASSEMBLY PROCEDURES This section explains how to disassemble the PowerLite 5000XB/7000XB. The reassembly procedure is the reverse of the disassembly procedure.

Preparatory Procedures 1. Remove any ring, wristwatch, cuff buttons, or other metal accessories that are likely to come into with the equipment. 2. Wear gloves. 3. Wear a wristband and ground it. Place a ground mat under the unit. 4. Turn off the main unit and the host computer. 5. Unplug the power cord from the main unit and service outlet. (Even if the power is off, back-up bias is regulated and supplied to the circuit board when the power cord is connected to the service outlet.) 6. Disconnect the interface cable from the main unit. 7. Clean the air filter, interface, and case cover with a vacuum cleaner.

Required Tools and Accessories Prepare the tools and accessories listed in the table below: Table 3-1 Name Phillips screwdriver 2 Flathead screwdriver Tweezers

Quantity 1 1 1

Supply Market Market Market

Brush Vacuum cleaner Paper wiper Air blower Gloves Wrist band, ground mat

1 1 Some 1 1 1

Market Market Market Market Market Market

3-1

Use To dissasemble the case and interiors Removal of lamp cover and air filter cover To unlock the FPC connnector on the DR board To brush off the dust around fan To clean the fan and filter To clean the projector lens To clean the fan and filter To avoid cuts To avoid electrostatic effects


Limitations of Disassembly (Optical Engine Handling) Although the disassembly of the projector is detailed in section 3.2, the optical engine is one replaceable part. (Treat as one replaceable part in field maintenance.) • • • • •

Optical head unit Prism unit Light guide unit Projection lens unit Driver board

Note: • Do not disassemble the optical engine or replace any unit in the optical engine. •

Do not exchange any unit of the optical engine for the matching unit in another optical engine.

Caution: Do not disassemble the light guide unit. If you remove the upper guide cover from the unit, the alignment of lenses or mirrors may be changed or dust may stick to the unit. Since the PowerLite 5000XB/7000XB requires precise adjustment, it cannot be adjusted in the field.

3-2


Cautions for Field Maintenance Observe the following procedures when you repair the projector. Otherwise, display quality is not guaranteed. Note: Violating any of the following points voids the manufacturer’s warranty, and EPSON repair service will no longer be available. •

Do not disassemble the optical block or loosen any screws.

•

If either the optical block or the driver board requires replacement, replace them as a set. Also, when you send them back for repair, send them back as a set (optical engine).

Precautions The following precautions are for the individual assembly and disassembly procedures. Read them carefully before starting the assembly or disassembly procedure. A set of general precautions is given below. •

As you disassemble the main unit, dust that has collected on the internal fans and air filters is likely to migrate and contaminate light valves R, G, and B (the heart of the display mechanism), deteriorating the display quality. To prevent this from occurring, check for dust inside of the main unit and, if necessary, clean it with a vacuum cleaner before reassembling. Light valves R, G, and B and circuit board assemblies are highly sensitive to static electricity. When you remove an optical engine or circuit board, place it in an antistatic bag immediately.

•

When you perform the assembly or disassembly operations listed below, check the unit and its surfaces for any dirt before reinstalling. If the unit is dirty, clean it. – – –

Removing the optical engine Removing the lamp inner housing Removing the air filter frame

•

The speaker unit incorporates a permanent magnet. Keep it away from electromagnetic media such as floppy disks and magnetic cards.

•

Handle the optical engine (projector lens and light guide unit) with care. They are highly susceptible to vibration and shock.

•

Do not try to disassemble any part that is not covered in this manual (for example, the optical engine or power supply unit).

3-3


3.2 DISASSEMBLING AND ASSEMBLING THE PROJECTOR MAIN UNIT The flowchart for disassembling the projector main unit is shown below. Note: • Since the PowerLite 5000XB and PowerLite 7000XB are disassembled in the same manner, only one procedure is shown. •

Since you can reassemble the dismantled projector parts by reversing the order of disassembly, no assembly procedures are provided. START Lamp inner housing (3.2.1)

Air filter frame (3.2.2) Switch (3.2.4)

Upper case unit (3.2.3) Speaker (L/R) (3.2.5)

Main board (3.2.6)

A

Lamp thermistor (3.2.8) Safety switch (3.2.15) Driver board (3.2.7)

A

Optical engine (3.2.9)

Receptor BD(RI/FI board) (3.2.11)

Rear case unit (3.2.10)

A

AU board (3.2.12) Power supply unit/ PBS thermistor (3.2.14)

Filter board (3.2.16)

Figure 3-1

Inlet unit (3.2.17)

FR board (3.2.13)

CN board (3.2.18)

FC board (3.2.21)

Filter cover (3.2.19)

Foot adjuster (3.2.20)

Cooling/exhaust fan (3.2.22 ) 3-4


3.2.1 Removing the Lamp Inner Housing Prerequisite conditions: None Warning: • The lamp unit is very hot during use and immediately after, and may burn you if handled carelessly. Before removing the lamp unit, make sure the lamp inner housing unit has cooled. •

When installing the lamp unit, take care not to touch the lamp’s reflector with your hands to prevent the reflector from being contaminated. Lamp Cover

Screws

Figure 3-2

Screws

Lamp Housing

Handle

Figure 3-3

3-5


1. Remove the lamp cover mounting screws from the bottom of the lower case. Screws: -M4*7.5 F/Ni: P/N1021771 (mounting torque: 4.5 kg. cm = 3.9 lb. inch) 2. Remove 2 mounting screws from the lamp inner housing. Screws: -M4*7.5 F/Ni: P/N1021771 (mounting torque: 4.5 kg. cm = 3.9 lb. inch) 3. Pull up the handle on the lamp inner housing and remove the lamp unit. Caution: Do not touch the lamp’s reflector when you install the lamp unit, as touching it will contaminate it and degrade lamp performance.

3.2.2 Removing the Air Filter Frame Unit Prerequisite conditions: None Air Filter

Screw

Figure 3-4

1. Remove the air filter frame unit mounting screw from the bottom of lower case. Screw: -M4×7.5 F/Ni: P/N1021771 (mounting torque: 4.5 kg. cm = 3.9 lb. inch) 2. Lift cover.

3-6


3.2.3 Removing the Upper Case Unit and Handle Prerequisite conditions: None. Handle

Screws

Figure 3-5 Screws

Figure 3-6

1. Pull the handle up. 2. Remove 2 left upper case unit screws (under the handle). Screws: +M4*6 F/ZB Bind: P/N1034318 (mounting torque: 6.5 kg. cm = 5.6 lb. inch) 3. Remove 2 upper case unit mounting screws from the right side. Screws: +M4*10 F/ZB: P/N1033707 (mounting torque: 6.5 kg. cm = 5.6 lb. inch) 4. Hold the left and right sides of the upper case unit and lightly pull it partially up.

3-7


Warning: The switch cable is very short. Slowly lift the upper case until it is just high enough to disconnect the switch cable. Upper Case

Figure 3-7

5. Unlock the connector (CN600) on the main board, then disconnect the switch cable. 6. Remove the upper case. 7. Remove the handle from the lower case unit. Switch Cable

Figure 3-8

3-8

CN600


3.2.4 Removing the Switch Prerequisite condition: 3.2.3 Tab (A)

Offset Tape A*

Offset Tape B*

Switch Spring

* Marked with square area are sealed with tape.

Tab (B)

Figure 3-9

1. Pull down the four tabs from inside, then detach the tape seals. 2. Remove the switch . Switch

Switch spring

Figure 3-10

Caution: When re-installing the switch , be sure to replace the spring in the upper case.

3-9


3.2.5 Removing the Right and Left Speakers Prerequisite condition: 3.2.3 Screws

Screws

Left Speaker Unit

Right Speaker Unit

Speaker Cables

Figure 3-11

Right Speaker 1. Remove 2 screws mounting the right speaker unit. Screws: +M3*4 F/ZN: P/N1021795 (mounting torque: 4.5 kg. cm = 3.9 lb. inch) 2. Disconnect the speaker cable from CN602 on the main board. Left Speaker 1. Remove 2 screws mounting the left speaker unit. Screws: +M3*4 F/ZN: P/N1021795 (mounting torque: 4.5 kg. cm = 3.9 lb. inch) 2. Disconnect the speaker cable from CN601 on the main board. Caution: • The speaker unit has a permanent magnet. Keep it away from electromagnetic media such as floppy disks and magnetic cards. •

When mounting a speaker, align the 2 speaker holes with those of the frame, then secure them with same tightening torque.

•

Do not detach the speaker cushions.

3-10


3.2.6 Removing the Main Board Prerequisite condition: 3.2.3 Screws

PowerLite 5000XB:

Hex Stud Screws

Screws

Screws


PBS Thermistor

Power Supply Unit

Thermistor (Under t he Speaker R)

Connect to CN board

15pin CN860 Connect to Speaker R Connect to CN251 on Driver Board Connect to LV Thermistor

CN800

CN602 (Speaker R)

Connect to AU Board

Exhaust Fan

12pin

15pin

CN802 (To361CN)

CN603 (To361AU)

CN804 (Lamp Thermistor)

CN806

CN600

CN805 (To361DR) CN803 (LV Thermistor)

PowerLite 5000XB Main Board (P/N 3002081)

CN601 (Speaker L) Connect to Speaker L

CN300 (To361AU)

Figure 3-13 PowerLite 5000XB Connector Locations 3-11


1. Remove the 9 mounting screws securing the main board and the shield plate (the shield plate covers main board—see figure 3-21 for photograph). Screws: +M3*4 F/ZN P/N 1021795 (mounting torque: 4.5 kg. cm = 3.9 lb. inch) 2. Disconnect all cable connectors on the main board. 3. Remove the 6 hexagonal screws that attach the interface connectors to the rear case. Screws: Hex stud: P/N1032134 (mounting torque: 4.5 kg. cm = 3.9 lb. inch) 4. Grasp the main board on the left side and disconnect the connector from the driver board. Caution: To avoid malfunctions caused by wire breaking or solder flaking, never apply any mechanical stress to the main board. PowerLite 7000XB:

Screws

Hex Stud Screws

Screws

Screws

Figure 3-14

Figure 3-15 PowerLite 7000XB Main Board (Present and Removed)

3-12


PBS Thermistor

Power Supply Unit

Thermistor (Under t he Speaker R)

Connect to CN board

Connect to AU Board

12pin 15pin CN852 Connect to Speaker R Connect to CN251 on Driver Board Connect to LV Thermistor

CN801

CN602 (Speaker R)

15pin

CN800 (To361CN)

Exhaust Fan

CN831

CN603 (To361AU)

CN851 (Lamp Thermistor)

CN600

CN830 (To361DR) CN850 (LV Thermistor)

PowerLite 7000XB Main Board (P/N 3002081)

CN601 (Speaker L) Connect to Speaker L

CN203 (To361AU)

Figure 3-16 PowerLite 7000XB Connector Locations

1. Remove the 9 mounting screws securing the main board and the shield plate (the shield plate covers main board—see figure 3-21 for photograph). Screws: +M3*4 F/ZN P/N 1021795 (mounting torque: 4.5 kg. cm = 3.9 lb. inch) 2. Disconnect all cable connectors on the main board. 3. Remove the 6 hexagonal screws that attach the interface connectors to the main board. Screws: Hex stud: P/N1032134 (mounting torque: 4.5 kg. cm = 3.9 lb. inch) 4. Grasp the main board on the left side and disconnect the connector from the driver board. Caution: To avoid malfunctions caused by wire breaking or solder flaking, never apply any mechanical stress to the main board.

3-13


3.2.7 Removing the Driver Board Assembly Prerequisite: 3.2.3/3.2.6 PowerLite 5000XB: CN251

CN252

CN250

CN700

CN800

CN900

Hex Stud Screw


For Light Bulb Cooling Fan

Rear CN252

PowerLite 5000XB Driver Board

CN251 CN700 (Blue)

CN800 (Green)

Connect to Main Board CN700

CN100

CN900 (Red) CN250

Connect to FC Board

Figure 3-18 PowerLite 5000XB Driver Board 3-14



1. Remove the five hexagonal stud screws that attach the driver board and shield plate. Screws: hexagonal screw: P/N1032134 (mounting torque: 6.0 kg. cm = 5.2 lb. inch) 2. Disconnect the cables from the driver board. 3. Pull straight up on the driver board. Caution: Before disconnecting the FPC cable from the connectors, gently pull straight up on each connector to unlock it. PowerLite 7000XB: CN700

CN800

CN900

CN100

Hex Stud Screws

Hex Stud Screws

CN102


3-15


For Light Bulb Cooling Fan

Rear CN102

PowerLite 7000XB Driver Board


CN101 CN900 (Blue)

CN800 (Green)


CN103

CN700 (Red) CN100

Connect to FC Board

Figure 3-20 PowerLite 7000XB Driver Board Connectors

1. Remove the five hexagonal stud screws that attach the driver board and shield plate. Screws: hexagonal screw: P/N1032134 (mounting torque: 6.0 kg. cm = 5.2 lb. inch) 2. Disconnect the cables from the driver board. 3. Pull straight up on the driver board. Caution: Before disconnecting the FPC cable from the connectors, gently pull straight up on each connector to unlock it.

3-16


3.2.8 Removing the Lamp Thermistor Prerequisite conditions: 3.2.3/3.2.6 (Shield Plate) 1. Remove the remaining screws on the case securing plate, then pull the plate straight up. Screw: +M3*4 FZN: P/N1021795 (mounting torque: 4.5 kg. cm. = 3.9 lb. inch) Screws

Case Securing Plate

Shield Plate

Figure 3-21

2. Remove the 2 screws that secure the lamp thermistor to the light guide unit. Screw +M3*8 F/ZB: P/N1033691 (mounting torque 6.0 kg. cm. = 5.2 lb. inch) Screws

Lamp Thermistor

Figure 3-22

3-17


3.2.9 Removing the Optical Engine Prerequisite conditions: 3.2.3/3.2.6/3.2.7(left)/3.2.8

Screw

Screw (Speaker Bracket)

Screws

Figure 3-23 Power Connector Mounting Screws Lamp Power Connector

Figure 3-24

3-18


1. Remove the screw mounting the speaker bracket to the optical head chassis. Screw: +M3*4 F/ZN: P/N1021795 (mounting torque: 4.0 kg. cm = 3.5 lb. inch) 2. Remove 4 optical block-mounting screws. (One of the screws is located on the front side of the speaker bracket.) Screws: +M5*10 F/ZN Bind: P/N1033704 (mounting torque: 6.0 kg. cm = 5.2 lb. inch) 3. Remove the 2 lamp power connector mounting screws and remove the lamp power connector from the optical head. 4. Pull out the speaker bracket. 5. Remove the cable from the RI sensor board (attached to the rear case). 6. Pull rear case gently away from optical block. 7. Grasp the lens unit and the optical engine rear fan, then pull the optical engine straight up from the lower case.

Figure 3-25

3-19


3.2.10 Removing the Rear Case Unit Assembly Prerequisite conditions: 3.2.3/3.2.6/3.2.7/3.2.9 Screws

Screws

Ground Wire

Screw with Ground Wire

Figure 3-26

Figure 3-27

1. Remove the 3 screws that connect the rear case to the bottom of lower case. Screws: +M3*8 F/ZN Bind: P/N1033691 (mounting torque: 4.5 kg. cm = 3.9 lb. inch) 2. Remove the 4 screws that attach the AU board. Screws: +M3*6 F/ZB: P/N1021795 (mounting torque: 4.5 kg. cm = 3.9 lb. inch) 3. Remove the cable from the RI board connector. (The RI board connector is mounted on the rear case unit.) 4. Grasp both sides of the rear case unit, then pull out. Caution: When installing the case unit assembly, be sure to attach the ground wire to the screw shown above.

3-20


3.2.11 Removing the Receptor Board Assembly (FI Board / RI Board) Prerequisite conditions: 3.2.3 FI Board (located on the speaker bracket) Screw

FI Board

Cable Connector

Figure 3-28

1. Disconnect the cable connector from the FI board. 2. Remove the screw mounting the FI board to the speaker bracket. Screw: +M3*5 F/ZN: P/N1021795 (mounting torque: 4.5 kg. cm = 3.9 lb. inch) RI Board (located on the rear cover) Screws

RI Board

Figure 3-29

3-21


1. Disconnect the cable connector on the RI board. 2. Remove the two screws securing the RI board to the rear cover. Screw: +M3*5 F/ZN Bind: P/N1033703 (mounting torque: 6.5 kg. cm = 5.6 lb. inch) Caution: When installing the receptor board assembly, align the hole on the board with the boss on the frame before tightening the screw.

3.2.12 Removing the AU Board Prerequisite conditions: 3.2.3/3.2.6/3.2.7/3.2.9 1. Remove the screw on the AC inlet bracket. Screw: +cupM3*6 F/ZN: P/N1021795 (mounting torque: 4.5 kg. cm. = 3.9 lb. inch)

A/C Inlet Bracket

Screw

Figure 3-1 Figure 3-30

3-22


2. Remove the two mouse/COM screws that attach the cover and the AU shield plate. Screw: +M3*4 FZN Bind: P/N1021795 (mounting torque: 4.0 kg. cm. = 3.5 lb. inch) RCA Jack Plate Screws Screw

RI Board

Mouse/COM Screws

Figure 3-31

Figure 3-32

3. Remove the RCA jack plate screws and detach the jack plate. 4. Remove the AU shield plate with the AU board. (The AU shield plate is glued to the AU Board.)

3-23


3.2.13 Removing the Remote Board Prerequisite conditions: 3.2.3/3.2.6/3.2.7/3.2.9/3.2.10/3.2.12 FR board Interface Connector Securing Screws

Screws

Figure 3-33

Remote Board Shield Plate

Figure 3-34

1. Slowly slide the FR board out of the rear case to disconnect FR board from the CN board, then completely remove the FR board. 2. Remove four screws securing the COM1/COM2 interface connector. Screw: +M3*4 F/ZN Bind: P/N1021795 (mounting torque: 4.0 kg. cm = 3.5 lb. inch) 3. To separate the remote board shield plate from the FR board, remove two screws on it. Screw: +M3*8 F/ZN : P/N1021824 (mounting torque: 4.0 kg. cm = 3.5 lb. inch)

3-24


3.2.14 Removing the Power Supply Unit / Power Supply Thermistor Prerequisite conditions: 3.2.3/3.2.4/3.2.6/3.2.7 Power Supply Unit:

Screws

Case Securing Plate

Sensor Shield Plate

Figure 3-35

1. Remove the four screws on the sensor shield plate, then pull out it. Screw: +M3*4 F/ZN: P/N1021795 (mounting torque: 4.5 kg. cm = 3.9 lb. inch) Lamp Power Connector Mounting Screws Lamp Power Connector

Figure 3-36

3-25


2. Remove the lamp power connector mounting screws, then remove the lamp power connector. 3. Disconnect the cable connector (black / white) connected to the power supply unit. 4. Remove five screws fixing the power supply unit to the lower case. Screw (4P.C.S.): M3*8 F/ZN Bind: P/N1021824 (mounting torque: 6.5 kg. cm = 5.6 lb. inch) Screw (1P.C.S.): M3*12 F/ZB Bind: P/N1033692 (mounting torque: 6.5 kg. cm = 5.6 lb. inch) 5. Remove the power supply unit, lifting it straight up. Screws

M3*12

Screws

Note: Screws are located on the bottom of power supply unit, thus screws are not shown on this figure.

Cable Connector (Black and White)

. Figure 3-37

Caution: • When removing the power supply unit, do not bend or damage the two bosses on the lower case unit. •

When installing the power supply unit, align the power supply unit positioning holes with the bosses. The intake fan and its peripheral parts are susceptible to dust and dirt. When installing the power supply unit, check the fan's cleanliness and clean it if necessary.

3-26


Power Supply Thermistor:

PBS Thermistor

Figure 3-38

1. Slide the PBS thermistor out from the thermistor retaining clamp. 2. Disconnect PBS thermistor cable from main board.

3-27


3.2.15 Removing the Safety Switch from the Power Supply Prerequisite conditions: 3.2.3/3.2.4/3.2.6/3.2.7/3.2.14

Power Connectors (4)

Safety Switch

Figure 3-39

1. Disconnect the power connectors from the safety switch. 2. Remove the 2 mounting screws from the safety switch and detach the safety switch Screws: +M3*8 F/ZB: P-Tight P/N1033691 (mounting torque: 6.0 kg. cm = 5.2 lb. inch) Caution: When removing the connectors from the safety switch, do not apply excess force to the connectors on the safety switch in the horizontal or vertical direction.

3-28


3.2.16 Removing the Filter Board Prerequisite conditions: 3.2.3/3.2.6/3.2.7/3.2.9

Cable Clamps

Lower Filter Board

Screws

CN6

Figure 3-40

1. Unplug the black and white cable from the upper filter board (not shown). 2. Remove the 4 mounting screws. Screws: +M3*8 F/ZN Bind: P/N1021824 (mounting torque: 6.0 kg. cm = 5.2 lb. inch) 3. Remove the upper and lower filter boards. Caution: The upper and lower filter boards are connected by soldered wires. Use caution when removing the boards. 4. Remove safety switch cable. 5. Remove the filter board from lower case. 6. Remove lamp thermistor (see 3.2.8). Caution: When installing the filter board, arrange the cables in the cable guide.

3-29


3.2.17 Removing the A/C Power Inlet Unit Prerequisite conditions: 3.2.3/3.2.6/3.2.7/3.2.9

Screws


Figure 3-41

1. Remove three inlet unit fixing screws. Screw:+M3*8 F/ZN P-Tight: P/N1021824 (mounting torque: 6.5 kg. cm = 5.6 lb. inch) 2. Unplug the cable connector CN6 on the filter board. 3. Remove remaining remote board shield plate screws, then remove the remote shield plate. 4. Pull up the inlet unit from the lower case. Cable

Figure 3-42

3-30


3.2.18 Removing the CN Board. Prerequisite conditions: 3.2.3/3.2.6/3.2.7/3.2.9/3.2.10/3.2.11/3.2.13 Screws


CN Board

Figure 3-43

Screws

Figure 3-44

1. Remove the screw fixing the remote board shield plate. Screw (1): +M3*8 F/ZN Bind: P/N1021824 (mounting torque: 6.5 kg. cm = 5.6 lb. inch) Screw (1): +M3*4 F/ZN: P/N1021795 (mounting torque: 6.5 kg. cm = 5.6 lb. inch) 2. Disconnect the cable connectors connected to CN200/202 on the CN board. 3. To detach the CN board, remove the two screws securing it. 4. Pull out the cable connector connected to CN204 from the three cable clamps. 5. Pull out the cable connector connected to CN203 from 2 cable clamps. Caution: Arrange the cables in the cable guide when reassembling the unit.

3-31


3.2.19 Removing the Air Filter Frame Unit Switch (Filter Cover Switch) Prerequisite conditions: 3.2.3/3.2.6/3.2.7/3.2.9/3.2.10/3.2.11/3.2.13

Filter Cover Switch

Figure 3-45

1. Disconnect the cable connector from to the switch connected to CN202 on the CN board. 2. Remove the filter cover switch, pushing the latches on the lower case outward. Caution: Be careful not to break the latches with excessive stress. When you replace the filter cover switch, align the hole to the boss on the lower case.

3-32


3.2.20 Removing the Foot Adjuster A/B and FA Housing Prerequisite conditions: 3.2.3/3.2.14 (Housing Only) Foot Adjuster A: OP Ring

Foot Adjuster A

Figure 3-46

1. Push down the foot pipe and hold it, then fully lift up the foot adjuster A. 2. Remove the OP ring D on the top of foot adjuster A. 3. Remove foot pipe, then unscrew the three screws securing the foot adjuster housing and remove the housing.

3-33


Foot Adjuster B: E Ring

Foot Adjuster B

Figure 3-47

Figure 3-48

1. Fully turn clockwise the foot adjuster B in order to shorten it. 2. Remove the E ring on the foot adjuster B. 3. Fully turn the foot adjuster B counterclockwise to remove it.

3-34


3.2.21 Removing the FC Board (Cable Assembly F) Prerequisite conditions: 3.2.3/3.2.6/3.2.7/3.2.9/3.2.10/3.2.11/3.2.13

FC Board

Screw

Figure 3-49

1. Disconnect cable connector CN1 from the FC board. 2. To detach the FC board, remove the screw holding it. Screw: +M3*8 F/ZB: P-Tight P/N1033691 (mounting torque: 6.0 kg. cm = 5.2 lb. inch)

3-35


3.2.22 Removing the Cooling Fan / Exhaust Fan Caution: This section is included for reference purpose only. Do not disassemble the exhaust fans as part of normal maintenance or repair. (This caution does not apply to removing the cooling and exhaust fans for cleaning purposes.) Prerequisite conditions: 3.2.3/3.2.6/3.2.7/3.2.9/3.2.10/3.2.11/3.2.13

Cooling Fan: Cooling Fan Fixing Screws

Figure 3-50

1. Remove two cooling fan fixing screws and remove the cooling fan. Screw: +M4*20 F/ZN S2W1: P/N1033711 (mounting torque: 6.0 kg. cm = 5.2 lb. inch) Caution: When installing the cooling fan, place it so that the label side faces down (on the aluminum die-cast side) and that its cable is oriented as shown in the photo. Clean the cooling fan until it is free of dust and dirt.

3-36


Exhaust Fan: Screws

Figure 3-51

Cable Connector

Figure 3-52

1. Disconnect the cable connector CN806 on the main board. 2. Remove two fixing screws on the exhaust fan. Screw: +M4*35 F/ZB: P Tight P/N1033696 (mounting torque: 6.0 kg. cm = 5.2 lb. inch) 3. Remove the exhaust fan. Caution: • When installing the exhaust fan, be careful to orient it correctly. Installing the fan in the reverse orientation may result in a device failure or extended cooling time because of an overheat condition. Make sure that the label on the fan faces outward. •

The exhaust fan unit and its peripherals are susceptible to dust and dirt. When installing the exhaust fan unit, check its cleanliness and clean it if necessary.

3-37


3-38


4.1 BEFORE STARTING TROUBLESHOOTING PROCEDURES •

Whenever you replace a unit or block for maintenance, double-check the replaced unit or block to make sure it is defective (not inoperable due to a poor cable connection or other problem).

•

If you have questions while examining the flowchart, check the items in question during the troubleshooting procedure.

•

Refer to the instructions in Chapter 3, “Disassembly and Assembly,” when replacing a component unit.

•

Before making a functional check, be sure to check connections.

Tools and Accessories Required for Troubleshooting The tools and accessories required for troubleshooting (including fault isolation) are listed below. Table 4-1 Name

Quantity

Use/Remarks

Projector screen

1

To project images

Tape measure 10 ft (3 m)

1

To measure the projection distance

Host computer

1

To supply test patterns (PC or compatible)

Color display

1

Video equipment

1

External speaker unit

1

To manipulate and display on host computer To test video input (for example, video deck, video camera) To test voice output (with audio cable terminals)

Multimeter

1

To measure resistance and voltage (AC/DC)

Tool set

1 set

Tools and accessories listed in Section 3.1

Field Replacement Parts For parts to be replaced during troubleshooting, such as boards, cases, plates, and screws, refer to the parts list in the appendix of this manual. The optical engine (light guide unit, optical head unit, projector lens unit, prism unit and driver board) is one maintenance unit. Do not separate any units from the optical engine.

4-1


4.2 START Follow the flowcharts in this chapter when troubleshooting problems and proceed to the pertinent detailed flowchart (given on the subsequent pages).

Start

•

Visually check the exterior. (Check for any damage to the cover area.)

•

Check internal cable connections except on the CN board and FR board. (Remove the upper case unit.)

•

Check power on/off and initialization (No signal display). (Connect power cable and turn on the power.)

•

Check screen display and picture quality. (Connect host computer, video device, and RBG monitor.)

Audio Out

•

Check audio output to the internal and external speakers.

Switch

•

Check button operations on the switch .

Remote Control

•

Check button operations on the remote control.

•

Check ELP communication functions from the remote control. (ELP communication kit option is necessary.)

•

Check for noise, overheating, and other problems.

External View

Internal Cable Connectors

Power ON/OFF

Display/Picture Quality

Mouse/COM Interface Control

Others

Figure 4-1

4-2


Exterior View Start

Note: Before proceeding, turn off the power and disconnect the power cable. Then check the following: • •

Upper Case Unit

•

There are no cracks or other deformities. The upper case is secured to the lower case with screws. (Refer to 3.2.3.) Dirt is not on the front or rear receptor windows of the upper case. Buttons move smoothly. The switch is mounted on the upper case with 4 tabs.

Switch

• •

Rear Case Unit

•

There are no cracks or other deformities.

• •

The focus ring and zoom ring are adjustable (move gently). Dirt is not on the lens surface.

•

There are no cracks or deformities.

• • •

The mounting screw on the air filter frame is not damaged. Dirt is not on the air filter frame. Dirt is not on the intake fan. (The intake fan is located under the air filter frame.)

• •

The 2 mounting screws on the lamp cover are not loose. The tab on the lamp cover is not damaged.

• •

The lamp inner housing frame or power cable connector is not damaged or discolored. The reflector and surroundings are not damaged or dirty.

•

Foot adjusters A and B should move smoothly.

• •

The interface connector is not damaged or discolored. (Rust may cause discoloration.) The socket is not damaged or dirty.

• •

The connector terminal is not discolored. The socket is not damaged or dirty.

Projector Lens Unit

Lower Case Unit

Air Filter Frame

Lamp Cover

Lamp Inner Housing

Foot Adjusters A and B

Interface Connectors

AC Inlet

Attach the air filter frame, lamp inner housing and lamp cover.

Figure 4-2

4-3


Caution: Before following this flowchart, turn off the power and then disconnect the power cable.

Internal Cable Connections Start

Remove upper case unit.

Note: Part numbers for the PowerLite 7000XB are given in parentheses.

Switch

•

CN600 on the main board (lock type)

•

CN300 (203) on the main board to CN101 on the AU board

•

CN603 on the main board to CN100 on the AU board

•

CN601/602 on the main board

Exhaust Fan

•

CN800 (801) on the main board to power supply unit

Lamp Thermistor

•

CN860 (851) on the main board to power supply unit

LV Thermistor

•

Light power cable connector mounting screw

•

CN806 (831) on the main board

•


•


•

Cable connection CN400 on the RI board and CN300 on the FI board

Disconnect main board.

•

CN805 (830) on the main board to CN251 (101) on the driver board

FC Board to Driver Board

•

CN700 on the main board to CN100 (103) on the driver board

•


•

CN250 (100) on the driver board

•

CN252 (102) on the driver board

•

CN700/800/900 on the driver board (lock type)

AU Board

Left and Right Speakers

Power Supply Unit

RI Board / FI Board

Driver Board to Main Board

CN Board to Main Board

Intake Fan Light Valves R/G/B

Attach the main board. Attach upper case unit.

Figure 4-3

4-4


Power ON/OFF Disconnect all interface cables and the projector lens cover. Then connect the power cable. Start

B

Press the Power button on the control .

Does the exhaust fan work? YES

YES

Does the operation or lamp indicator light up or blink?

Press the Power button on the remote control.

YES

NO Is AC power applied to the power supply unit connector? NO Is the lamp cover secured to the lower case?

Refer to the table on next page according to the lamp indication.

NO Replace the main board.

NO Now does the operation or lamp indicator light up or blink?

Go to Display/ Picture.

NO Replace the exhaust fan.

Does the exhaust fan work now?

NO

Do the operation and lamp indicators display the first 3 conditions described in the table on the next page?

YES

YES

NO

Make sure CN600 is connected. Then replace the control .

Replace the power supply unit.

Install the lamp cover and lamp inner housing again.

YES Press the Power button on the control . Does the operation or NO lamp indicator light up or blink?

Press the Power button on the YES control . Does the operation or lamp indicator light up or blink? NO YES Press the Power button on the control . Does the operation or NO lamp indicator light up or blink?

YES

• Disconnect the power cable. • Disconnect the Fast-on tab from the safety switch. • Measure the safety switch resistance. Is the safety switch NO resistance almost 0 ohms?

B

AC Measurement Point

Replace the safety switch.

YES

A Go to Start

Caution: Measure the resistance when the safety switch has cooled down.

Figure 4-4

4-5


Continued from previous page. Table 4-2 A

Condition 1 2

Replace the power cable.

Is AC power applied to the power supply unit connector?

3 4 YES

Replace the filter board.

NO

Operation Indicator Orange Green

Meaning System initialization Warm up operation

Green Orange

Operating Cool down operation

Orange

OFF

OFF Red or orangeblinking Red-blinking

Standby (Cool down complete) Power off Overheating

6 7

NO

Is AC power applied to the power supply unit connector?

5

Lamp Indicator OFF Greenblinking Green Orangeblinking OFF

YES

8 9

Orange and Red Red Redblinking

10 11

Replace the inlet unit.

Circuit malfunction Lamp timer has exceeded 1900 hours Lamp life is finished Lamp or power supply problem

The following components may be causing problems in each condition: Condition 1 or 8

Main board, driver board (optical engine), power supply unit

Condition 2

Main board, power supply unit, lamp inner housing

Condition 4

Exhaust fan, lamp thermistor

Condition 6

(Power-on problem). AC input, power supply unit (including the interlock switch), main board, safety switch, filter board, inlet unit

Condition 7

(Sometimes occurs during operation.) Air filter frame (dirt), exhaust fan, power supply unit, main board, thermistor (LV/PBS/lamp)

Condition 9 or 10

Lamp inner housing, main board, FC board

Condition 11

Power supply unit, lamp inner housing

Go to start

Figure 4-5

4-6


Display/Picture

Start

Does the screen appear? NO Is the light source lamp on?

YES

Does a “NO SIGNAL” message appear?

YES

NO

YES

Does a “NO SIGNAL” message appear now?

YES

Replace the optical engine.

NO

Table 4–3

NO Replace the lamp thermistor.

Is the light source lamp on now?

Computer In 1/2

Video In/ S-Video

• • • •

• • • • •

Brightness Contrast Synchronization Tracking

Brightness Contrast Saturation Tint Mode

YES

Does the menu screen appear?

Does a fine image appear now?

NO

YES



YES

NO

Replace the power supply unit. Is the light source lamp on now?

NO

YES Make the adjustments shown in Table 4-3.

Replace the main board.

Is the light source lamp on now?

Press the menu button on the control or remote control.

NO

YES

YES

YES Go to next page.

NO


NO Replace the lamp inner housing. Is the light source lamp on now?

Does a fine image appear by adjusting the focus and zoom rings?

Make the adjustments shown in Table 4-3. YES


NO

NO



Figure 4-6

4-7

YES


Continued from previous page.

A C NO Is the picture quality good?

Connect the host computer to the Computer In 1 interface.

Connect the CRT to the monitor interface.

YES YES

Does a screen appear?

YES

NO Change the video mode by pressing the computer or video button.

Have the following devices been checked? • Computer In 2 • Video In • S-Video

Does a screen appear on the CRT? YES

NO Replace the monitor cable.

YES NO YES Connect the device which has not been checked.

Does a screen appear on the CRT now? NO

Does a screen appear now?

Replace the CRT monitor.

A

Replace the computer VGA cable. Does a screen appear now?

Does a screen appear on the CRT now?

YES

NO NO Replace the main board.

Does a screen appear now?

YES

Is the picture quality good now?

B NO


Press the auto button.

YES Go to Audio Output

NO Make the adjustments shown in Table 4–3 on page 4–8.

Replace the optical engine. Is the picture quality good now? YES NO

B Figure 4-7

4-8

C

YES


Audio Output

Start

A

Does the volume control work?

Connect the audio cable to the Audio In 1 interface.

YES

NO Replace the AU board.

Have the following audio interfaces been checked? 1. Audio In 2 2. Audio In L/R

YES

NO Do the internal speakers output the sound?

YES

NO

NO

YES

NO

Does the mute button work?

YES

A

NO

Replace right speaker and/or left speaker.

Do the internal speakers output the sound now?

Connect the audio cable to the interfaces listed above.


Reconnect CN601, 602, and 603 on the main board. Do the internal speakers output the sound now?

Does the volume control work YES now?

Connect the external speaker to the Audio out.

Replace the AU board.

YES Does the Mute button work now?

NO

YES

Does external speaker output the sound? NO

NO



Replace the main board. Do the internal speakers output the sound now?

YES Go to Switch


Figure 4-8

4-9

YES


Control Start

Does the Power button work? YES Does the Menu button work?

NO

NO

YES Does the Video button work?

YES Does the Computer button work?

YES Does the Auto button work? YES

NO

NO

Does the Enter button work?

YES NO

Replace the switch .

YES

Do all the buttons work?

Go to Remote Control. Replace the main board.

NO

NO

YES Does the Tracking +/- button work?

NO

NO NO

YES Does the Mute button work?

NO

YES

Does the Resize button work? YES Does the Volume button work?

Does the Sync +/- button work?

NO

YES

Figure 4-9

4-10


Remote Control Start

YES Does power ON/OFF work?

Do all switches except Effects 1 to 5 work correctly?

NO Replace the batteries.

YES

Does the remote control work at a 33 foot (10 m) distance?

YES

NO NO

Replace the remote control.

Replace the batteries. Does power ON/OFF work now?

YES

YES Do all switches except Effects 1 to 5 work correctly now?

NO

Does the remote control work at a 33 foot (10 m) distance now?



YES

NO YES Does power ON/OFF work now?

Do all switches except Effects 1 to 5 work correctly now? NO

NO Reconnect CN802(800) on the main board. Does power ON/OFF work now?

YES

Replace the Remote board. YES


Replace the RI or FI board.

YES


Does power ON/OFF work now?

Does the remote control work at a 33 foot (10 m) distance now? NO

NO

Does power ON/OFF work now?

Replace the RI or FI board.

YES

NO Replace the CN board.

Figure 4-10

4-11

YES

Go to Mouse/ COM.


Mouse/COM

Note: The ELP communication kit option II is necessary. If the option is not installed, ignore the following flowchart.

Start

Does the Pointer button on the remote control work correctly?

NO

Replace the following cables: • Main cable • Mouse cable • Serial cable

NO

Does the remote control work correctly now?

Install the ELP link program in the host computer again.

YES

Are the function assignments for Effect buttons 1 to 5 available?

YES Are presentation and projector control functions available with the remote control?

YES

NO


NO

YES

NO

Replace the remote board. YES


YES


Go to Others

Figure 4-11

4-12

NO


Others

Start

YES Is there a noise problem?

Check the following for defects: • Intake fan and exhaust fan on the power supply unit • Power supply unit (vibration noise from the pulse transformer)

NO

Is there an overheating problem?

YES

NO

Is there an image display problem?

Check the following for defects: • Thermistor (LV/PBS/Lamp) • Exhaust fan, intake fan • Air filter frame (dirt)

YES Check the following for defects: • Optical engine (The problem may be caused by dirt on the light guide unit, projector lens unit, and light valves on the optical head unit.)

NO YES Is the problem not easily identifiable or is reproducibility low?

Check the following for defects: • AC input (including power line transit or distortion) • Power supply unit • Main board • Cable connection (failure to make connection) • Operating environment (temperature, condensation) The problem may be static electricity. Check that power cords to the projector and input devices are grounded properly.

Figure 4-12

4-13


4-14


A.1 PARTS LIST For a parts price list for the PowerLite 5000XB, order Epson part number PL-ELP5100. For a parts price list for the PowerLite 7000XB, order Epson part number PL-ELP7100.

A-1

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