Optoma ML500 Service Manual
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Optoma ML500 Service Manual

Projection system
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SERVICE MANUAL

Date
2011.08.23
2011.09.5
2011.10.18
Prepared:
Chris
Revise Version
V1.0
V2.0
V3.0
Copyright OCT. 2011 All Rights Reserved
Checked:
ML500
Description
Initial Issue
Modify Chapter 6 ,Chapter 3
Modify chapter 5,add new method to upgrade
multimedia FW
Amy
Approved:
Alick

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Summary of Contents for Optoma ML500

  • Page 1: Service Manual

    SERVICE MANUAL ML500 Date Revise Version Description 2011.08.23 V1.0 Initial Issue 2011.09.5 V2.0 Modify Chapter 6 ,Chapter 3 Modify chapter 5,add new method to upgrade 2011.10.18 V3.0 multimedia FW Copyright OCT. 2011 All Rights Reserved Prepared: Checked: Approved: Alick Chris...
  • Page 2 Preface This manual is applied to ML500 projection system. The manual gives you a brief description of basic technical information to help in service and maintain the product. Your customers will appreciate the quick response time when you immediately identify problems that occur with our products.

  • Page 3: Table Of Contents

    Disassemble Speaker and IR Board Disassemble Engine Module and LED Disassemble LVPS 2-10 Disassemble Bottom Cover Module 2-11 Re-write LED Usage Hour 2-12 Repair Action 2-13 Chapter 3 Troubleshooting Equipment Needed Main Procedure No Power Troubleshooting Power Troubleshooting Image Troubleshooting Confidential ML500...
  • Page 4 SD Card /Mini USB/ USB flash disk test Calibration 4-10 Run in test 4-12 Test Inspection Procedure 4-13 Chapter 5 Firmware Upgrade Section 1: System Firmware Upgrade Equipment Needed DLP Composer Lite Setup Procedure Firmware Upgrade Procedure Section 2: Multi-Media Firmware Upgrade(USB) Confidential ML500...
  • Page 5 Section 3: Multi-Media Firmware Upgrade(SD Card) 5-13 Multi-Media Firmware Upgrade procedure 5-14 Section 4: 8051 Firmware Upgrade 5-17 Firmware Upgrade Procedure 5-18 Chapter 6 EDID Upgrade EDID upgrade procedure Appendix A Exploded Overview Serial Number System Definition Appendix B PCBA Code Definition Confidential ML500...

  • Page 6: Chapter 1 Introduction

    - Analog RGB 0.7 +/- 0.1 Vp-p, 75 ohm - Separate TTL H,V Sync. Input signal spec ● Video signal Video signal - NTSC/PAL Composite video 1.0 +/- 0.1 Vp-p, 75ohm ● Audio signal Audio signal - 900mVrms, 22K ohm Confidential ML500...

  • Page 7: Compatible Mode

    ● Operating: 5 ~ 35 °C Non-operation:-20°C ~ 60°C 1-2 Compatible Mode ● Computer Compatibility Compatibility Resolution V-Sync [Hz] 640 x 480 800x600 1024x768 1280x720 1280x800 480i/480p 576i/576p Video 720p 50/60 1080i/1080p 50/60 480i/480p 576i/576p HDMI 720p 50/60 1080i/1080p 50/60 Confidential ML500...
  • Page 8 1 AP MPEG4 MPEG1/2/3 H.264 support H.264 1080P 20Mbps 30fps less M-JPEG ADPCM than 4 reference WMV3 frames H.264 support less H.264 1080P 20Mbps 30fps MPEG1/2/3 than 4 reference frames LPCM MPEG1/2/3 MPEG-1 1080P 20Mbps 30fps MPEG LPCM Confidential ML500...
  • Page 9 Sample Rate (KHz) Bit Rate (Kbps) MP1/MP2/MP3 8-48 8-320 22-48 5-320 8-48 64-320 ADPCM-WAV 8-48 32-384 PCM-WAV 8-48 128-1536 8-48 8-256 Note: If the Computer Compatibility supportive signal is different from User’s Manual, please refer to User’s Manual. Confidential ML500...

  • Page 10: Equipment Needed & Product Overview

    3. Screw Bit (+) :102 4. Hex Sleeves 7mm 5. Tweezers 6. ML500 unit * Before you start: This process is protective level II. Operators should wear electrostatic chains. * Note: If you need to replace the main board, you have to get into service mode and record the LED usage hour.

  • Page 11: Disassemble Top Cover Module And Key Pad

    2-2 Disassemble Top Cover Module and Key Pad 1. Unscrew 4 screws on bottom side (as red circle) 2. Disassemble the Top Cover (as red arrow direct). ML500 Confidential...
  • Page 12 3. Tear off the mylar 4. Separate the keypad and the Top Cover Module. ML500 Confidential...

  • Page 13: Disassemble Led Driver Board

    4.Unplug 1 connector (as yellow square) 5. Unplug 3 connectors (as yellow circle), disassemble LED to LED Driver Board GREEN LED cable and LED Driver Board. CABLE RED LED CABLE BLUE LED CABLE LED Driver Board ML500 Confidential...

  • Page 14: Disassemble Main Board

    2-4 Disassemble Main Board 1. Disassemble 2 hex screws on the Disassemble 2 hex screws on the rear side(as red circle) 2. Unscrew 4 screws (as red circle) 3. Unplug 7 connectors (as red square) 4. Disassemble Main Board Main Board ML500 Confidential...

  • Page 15: Disassemble Fan

    2-5 Disassemble Fan 1. Take off three Fans Note: Care the direction about how to place the fan (as yellow square). ML500 Confidential...

  • Page 16: Disassemble Light Sensor Board

    Sensor Board 1. Unscrew 1 screw to disassemble Light Sensor Board (as red circle) 2-7 Disassemble Speaker and IR Board 1. Unscrew 2 screws to disassemble speaker (as red circle) 2. Take off IR Board (as red square) ML500 Confidential...

  • Page 17: Disassemble Engine Module And Led

    2-8 Disassemble Engine Module and LED 1. Unscrew 4 screws to disassemble Engine Module (as red circle) 2. Unscrew 4 screws on the rear side of the Engine Module to disassemble DMD Module and Green LED(as yellow circle), DMD Board ML500 Confidential...
  • Page 18 3. Disassemble the Green LED. 4. Unscrew 2 screws on the front side of the Engine Module to disassemble Red LED(as red circle). ENGINE MODULE ML500 Confidential...

  • Page 19: Disassemble Lvps

    2-9 Disassemble LVPS 1. Unscrew 6 screws (as red circle) 2. Unplug 2 cables (as red square) to disassemble LVPS to Main Board cable(8 pin) , LVPS to LED Driver Board cable(10 pin) and LVPS LVPS ML500 Confidential 2-10...

  • Page 20: Disassemble Bottom Cover Module

    2-10 Disassemble Bottom Cover Module 1. Take off Mylar(as yellow square) and Unscrew 1 screw (as red circle) to disassemble Bottom Cover Module ML500 Confidential 2-11...

  • Page 21: Re-Write Led Usage Hour

    4. Choose "LED Hours Adjust" to re-write the usage hour back to previous usage 5. Choose "Return to Service Menu" 6. Choose Exit Note: left key = decrease LED hour right key =increase LED hour ML500 Confidential 2-12...

  • Page 22: Repair Action

    Chapter 4-3-7 OSD Reset Chapter 4-7 Chapter 6 EDID Chapter 2-11 Re-write LED Usage Hour USB Port Test Chapter 4-3-7 Chapter 4-3-1 Optical perfermance Measure LED calibration Chapter 4-3-7 G sensor calibration Chapter 4-3-7 Chapter 4-3-7 Fan calibration ML500 Confidential 2-13...

  • Page 23: Chapter 3 Troubleshooting

    0.5 second H(ON), 0.5 second Power off, Cooling state L(OFF) flashing Power button OFF: Cooling com- pleted; Standby Mode Thermal sensor error, OSD shows “Projector Overheated” Fan lock error, OSD shows red “Fan Fail, Will automatically turn off soon” ML500 Confidential...

  • Page 24: Main Procedure

    3-2 Main Procedure ML500 Confidential...

  • Page 25: No Power Troubleshooting

    3-3 No Power Ttoubleshooting pin 2 pin 1 pin 8 ML500 Confidential...

  • Page 26: Power Troubleshooting

    3-4 Power Troubleshooting J8 pin1 J7 pin1 J9 pin1 pin8 ML500 Confidential...

  • Page 27: Image Performance Troubleshooting

    3-5 Image Performance Troubleshooting ML500 Confidential...
  • Page 28 ML500 Confidential...

  • Page 29: Ml500 Confidential

    ML500 Confidential...
  • Page 30 ML500 Confidential...

  • Page 31: Remote Control Troubleshooting

    3-6 Remote Control Troubleshooting ML500 Confidential...

  • Page 32: Function Test & Alignment Procedure

    - Quantum Data 802B or CHROMA2327 (Color Video Signal & Pattern Generator) 4-2 Test Condition - Circumstance brightness: Dark room less than 2.0 lux - Product must be warmed up for 3 minutes. - Screen size: 30 inches Zone Definition < Figure: Zone A&Frame (as green line) Definition > ML500 Confidential...

  • Page 33: I/O Port Test

    V. Position to the inner screen. Inspection item - Eliminate visual wavy noise by Resync, Frequency or Tracking selection. - Check if there is noise on the screen. - Horizontal and vertical position of the video should be adjustable to the screen frame. ML500 Confidential...
  • Page 34 10 pattern to judge it. - Please refer to Pixel specification table. 3. Dark Pixel Procedure - Test equipment: video generator - Test signal: 1280*800@60Hz - Test Pattern: Full white Inspection item - Dark pixels check Full white ML500 Confidential...
  • Page 35 - Test signal: 1280*800@60Hz - Test Pattern: Blue 60 Inspection item - Dark blemish check. Criteria - The dark blemish should be no more than 10 Blue 60 under blue 60 pattern. - Please refer to Pixel specification table. ML500 Confidential...
  • Page 36 However, the word should at least be recognizable.) Note:After adiust the focus , if the screen appear as picture A will be regarded as OK .Otherwise , if the screen appear as picture B will B NG”Poor” be adjudicated as NG. ML500 Confidential...
  • Page 37 (The unidentified color levels on both left and right sides should not over 4 color levels.) - Gray level should not have abnormal color or heavy lines. - If color appears abnormal, please get into service mode to do LED Calibration. ML500 Confidential...

  • Page 38: Composite Port And Audio Test

    4-3-4 HDMI Port Test Procedure - Test Signal : 720p,1080i - Test Pattern : Any Pattern - Equipment: DVD Player with HDMI output - Display type must be set to 16:9 Inspection item - HDMI Test ML500 Confidential...

  • Page 39: Test

    - Test equipment: SD Card (include test pattern) - Test Pattern: WhiteBlack ,Graystep16, ColorBar - Turn on the projector and plug SD Card into the projector. - Select “SD”-->”Photo”, play the test pattern in WhiteBlack_640x480 SD Card. GrayStep16_640x480 ML500 Confidential...
  • Page 40 - Turn on the projector and plug Mini USB cable into the projector. - Select “menu”-->”mini USB”-->”USB display” Inspection item - Check any abnormal color, any noise on the screen. - Check the sound from speaker. Criteria - The video is played smoothly and the voice sounds normal. ML500 Confidential...

  • Page 41: Calibration

    - There should not have any lack of RGBW. The color should appear normal and sort in right order. - Color levels should be sufficient and normal. (the unidentified color levels on both left and right sides should not over 8 color levels.) ML500 Confidential 4-0...
  • Page 42 - Put the CL200 on the center of the screen which - Put the CL200 on the center of the screen which is about 0.8~1.0m far away from projector - Connect LED Calibration Fixture and Projector by VGA Cable. ML500 Confidential 4-...

  • Page 43: Run In Test

    - Screen size: No concern - Display mode: ECO mode After repairing each unit, it should be Run-in (refer to the below table). Symptom Run-in Time Normal repair 2 hours 4 hours Auto shut down 6 hours ML500 Confidential 4-12...

  • Page 44: Test Inspection Procedure

    TB implementation Related TB must be implement Cosmetic Cosmetic can not be broken Missing logo, missing prints and blurry prints are Logo unacceptable Zoom in/out The function should work smoothly Keypad All keypad buttons must operate smoothly ML500 Confidential 4-13...
  • Page 45 After final QC step, we have to erase all saved change again and restore the OSD default setting. The following actions will allow you to erase all end-users' settings and restore the default setting: (1) Please get into OSD menu. (2) To execute "Reset" function. ML500 Confidential 4-4...

  • Page 46: Firmware Upgrade

    Section 1: System Firmware Upgrade 5-1-1 Equipment Needed Software : (DDP6401-USB) - DLP Composer Lite v10.5 - Firmware (*.img) - library (ML500 library) Hardware : - Projector - Power Cord - USB Cable mini USB to USB (A) (42.00284G001) - PC or Laptop...

  • Page 47: Setup Procedure

    1. Choose "DLP Composer Lite V10.5 Setup" Program. 2. Click Next button. 3. Read License Agreement. - Choose" I accept and agree to be bound by all the terms and conditions of this License Agreement". - Click Next. 4. Click "Next". Confidential ML500...
  • Page 48 5. Click Next. 6. Click Next. 7. Click Finish. 8. Restart the computer. Confidential ML500...

  • Page 49: Firmware Upgrade Procedure

    Power Cord to get into FW Download Mode. - Once Power LED show pink light,this time for FW upgrade mode. - Insert Mini-USB Cable (USB A to Mini B) to ML500&PC 2. Execute the DLP Compose file. 3. Click "edit" and "perferences". Confidential ML500...
  • Page 50 - Click the “browse” button and navigate to the directory where you put the library file 5. Click "Communications ",then select "USB" 6. Choose "Flash Loader". - Click "Browse" to search the firmware file (*.img). - Click "Open" Confidential ML500...
  • Page 51 - Click “Yes” to erase the flash memory. 9.When firmware upgrade process is finished, “Download Complete” will appear. 10.Re-plug in power cord and Power on the projector. Get into the service mode (power--left--left--menu) to check the firmware version. Confidential ML500...
  • Page 52 5-2-1 Equipment Needed Software : - Firmware (*.Bin) - Tools Hardware : - Projector - Power cord (42.53506G002) USB Cable (male to male)(42.0028JG001) - PC or Laptop Note:After upgrade the multimedia FW, the files of the projector will be cleared. Confidential ML500...

  • Page 53: Usb Driver Upgrade Procedure

    USB port of a PC. 2. Execute Program 1) Found new hardware wiszard will appear on the screen. - Select “Install from a list or specific location (Advanced)” - Then click Next. 2) Select “Include this location in the search” Confidential ML500...
  • Page 54 3) Click "Browse" button to choose "tools". - Select “OK”. - Then click Next. 4) Click "Continue Anyway". 5) Click "Finish" to end the installation. Confidential ML500...

  • Page 55: Multi-Media Firmware Upgrade

    5-2-3 Multi-Media Firmware Upgrade Procedure 1. - Open "tools" file, - Execute “Actions MP Update.exe”. 2. - Click "Firmware", - Select the FW upgrade file(*.bin), - Click "Open". Confidential ML500 5-0...
  • Page 56 3. Click “Download.” 4. The success information will show on screen. Confidential ML500 5-...
  • Page 57 5. Restart the unit and enter the service mode to check the Multi-Media firmware version. Confidential 5-12 ML500...
  • Page 58 5-3-1 Equipment Needed Software : - Firmware (*.Bin) - Tools Hardware : - Projector - Power cord (42.53506G002) - PC or Laptop Card Reader SD Card Note:After upgrade the multimedia FW, the files of the projector will be cleared. Confidential ML500 5-...

  • Page 59: Multi-Media Firmware Upgrade Procedure

    5-3-2 Multi-Media Firmware Upgrade Procedure 1.Rename multimedia software file name to “ ACTUPGRADE.BIN”. 2.Copy the file to SD card by PC. 3.Insert SD card to projector. 4.Choose "Setup" Confidential 5-14 ML500...
  • Page 60 5.Choose "System" 6.Choose"Firmware Upgrade" 7.Choose "Yes" to process FW Upgrade . Confidential ML500 5-5...
  • Page 61 8.Firmware upgrade procedure image will appear as the right picture shown. 9.Restart the unit and enter the service mode to check the Multi-Media firmware version. Confidential ML500 5-...
  • Page 62 5-4-1 Equipment Needed Software: (N79A901R-USB) - Setup _NLINK_en - Manley USB Driver_NLINK - xxx_8051_xx.hex Hardware: - Projector - Power cord: 42.50115G001 - USB Cable mini USB to USB (A) (42.00284 G001) - NLINK Fixture - PC or Laptop Confidential ML500 5-...

  • Page 63: Firmware Upgrade Procedure

    “Connect” (as blue square). - Select “Brownout Level 3.8V” (as green square). - Select “Internel RC(11.0592MHz)” (as green square). - Click “Erase/Write(W)” to execute 8051 FW upgrade (as red circle). Confidential 5-18 ML500...

  • Page 64: Check 8051 Fw Version

    5-4-3 Check 8051 FW version 1. Restart the unit and enter the Service Mode (Press Power --> Left --> Left--> Menu). 2. The firmware version will be shown as red circle on the screen. Confidential ML500 5-...

  • Page 65: Edid Upgrade

    The system uses this information for configuration purposes, so the monitor and system can work together. Note: If a display device has digital input ports, like DVI or HDMI, but without EDID in its main board, the display device will show no image while the input source is digital signal. ML500 Confidential...
  • Page 66 - Generic Fixture (80.00001.001) for EDID Key-in - Power Cord - RS-232 9 Pin Cable (pin to pin, F-M) (42.83C07G001) - Monitor - PC - VGA cable (42.87305G102) - Power adapter (47.57803G001) and power cord (42.53506G002) for fixture - HDMI to DVI Cable(42.00256G001) ML500 Confidential...
  • Page 67 (3) Connect P3 of Fixture with DVI port ,and connect HDMI port of Projector. (4) Plug Power Adapter to Power CNN. (5) Plug power cord to ML500 unit. 2. EDID Firmware Mode (1) Hold the “Power” button to plug Power Cord to Power Port HDMI Port VGA Port ML500 unit.
  • Page 68 3. Process (1) Key in the serial number into the barcode blank space. (2) Click "Program" button. (3) - "Please change the cable to VGA" will be shown on the screen. - Please press "Ok" button. ML500 Confidential...
  • Page 69 - Please press "OK" button. 5. Finish (1) "OK" will be shown on the screen. 6. Read EDID "Analog" information (1) In the Read item,select "Analog" and "Trans". (2) Please click "Read" . (3) EDID “Analog” information will show the result. ML500 Confidential...
  • Page 70 7. Read EDID "Digital"information (1) In the Read item,select "Digital" and "Trans". (2) Please click "Read" . (3) EDID “Digital” information will show the result. ML500 Confidential...
  • Page 71 Appendix A (Explode Image) DC. ML500 ML500 Confidential...
  • Page 72 80.8KU05G001 K330 PROJECTOR 75.8LK01G001 8LK BOTTOM COVER MODULE 51.8KU08G002 LVPS MYLAR PLED-W500 51.8LK01G001 8LK KEY BUTTON MODULE 51.8MA06H011 FOCUS RING ABS FOR ML500 52.8KU02G001 FAN RUBBER BLACK K330 ML500 SPONGE 125*15*0.95mm 52.8LK02G001 61.8MA02H001 SPEAKER BRACKET SECC PLED-W500 PCBA MAIN BD FOR ML500 80.8LK01G002...
  • Page 73 LIGHT SENSOR BOARD ITEM DECRIPTION Supply 85.1A622G040 SCREW PAN MECH M2*4 BLACK NYLOK PCBA LIGHT SENSOR BD FOR K330 80.8KU04G001 PROJECTOR 85.1A121G040 SCREW PAN MECH M1.7*4 Ni ML500 Confidential...
  • Page 74 ENGINE MODULE ML500 Confidential...
  • Page 75 HEAT PIPE MODULE RED C1NEW K330 PT54,BLUE LED,Standard Die Config,D52 23.8KU15G003 400LM,Luminus 52.8KU10G001 RUBBER Projection Lens ENG D52 51.8MA06H011 FOCUS RING ABS FOR ML500 DMD 1140x910 PIXEL 0.45” WXGA DDR Type 48.8KU01G001 Series 310 DMD “TI” 80.8KU02G001 PCBA DMD BOARD FOR K330 PROJECTOR ML500 Confidential...
  • Page 76 ADJUST FOOT ITEM DECRIPTION Supply 52.8FS02H001 ADJUST FOOT K11 86.00122G015 NUT HEX M2.0*0.4P L15 Ni ML500 Confidential...
  • Page 77 Assy Packing Drawing ML500 Confidential...
  • Page 78 55.83R03G002 L TYPE PAPER 1190x1000x1350 EP747 55.87202GC01 BOTTOM PAPER COVER PLATE 1230* 55.8LK01G001 UNIT BOX ML500 55.8LK02G001 CARDBOARD ML500 55.8LK03G001 CARTON OUTSIDE BOX AB FLUTE ML500 55.8LK04G001 PAPER PARTITION ML500 56.8LK01G001 AIR BAG ML500 57.00001G001 PACK SIO2 DRIER 20g ML500 Confidential...
  • Page 79 AK.8LK01G00A A.K.ML500 35.82001G111 AK LABEL 3”*3” BLANK CABLE POWER CORD 1.8M SP30+IS14 42.50115G001 42.00200G005 CABLE VGA 15P 1.8M BLK EP739 45.8LK01G001 REMOTE CONTROL FOR ML500 PE BAG ZIPPER 240*170*0.04 #8 FOR 51.80135G002 OPTOMA 53.8LK01G001 SOFT BAG ML500 36.8LK01G001 QUICK START CARD MULTILINGUAL WARRANTY CARD US FOR OPTOMA, 1 36.00024G021...
  • Page 80 = 17) AAAAA = not-defined C = Manufacture factory (CPC) 0001 = Serial Code EX: Q8LK017AAAAAC0001 This label "Q8LK117AAAAAC0001" represents the serial number for ML500. It is produced at CPC on seventeenth of 2011. Its serial code is 0001. ML500 Confidential...
  • Page 81 PCBA Code Definition PCBA Code for Projector XXXXXXXXX EEEE Vendor Code Firmware Version MB Version Date Code ML500 Confidential...

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