SERVICE MANUAL - e-ASP
Contents
1. BA NEJ az 24 22 usg 12212 2 2230x TI ESTE i ZBESEESZEE 2 Please click Read noi 4 5 skt 15 asas ZEEASZRE L LE u 3 EDID Analog information will show prom the result mt a ow D AJ 5 weer LEJ t ht w fe oF 16064 68 46 66 m 1 77 168 14 ee m 76 76 79 Ph 79 76 IC mumia 74707470 9 A 14 18 3 32 33 m 26 79 76 P 18 76 03 Pa 13 84 68 V w 51 14 75 4 Ma GA GA GA I AA GA T Digital ML500 Confidential 6 5 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 Barcode mat limit Me l AAA AC Wite teleri mm Pert Message ML500 25 2 2858525527 Confidential 66 Appendix A Explode Image DC ML500 ML500 Confidential ASSY ENGINE MODULE FOR 70 8LK04GRO1 500 SERVICE V 75 8LK02G001 BLK TOP COVER MODULE2. 189 b Ag guid soejday 0 95 pe jos s uq 14 ou 41 8g eui 5820 0 6 8 1 844 pue RAB pieoq 1 131 8JNSEGLU i O as 188 01 as 6 zs _ 8 we 2 nar 9 peroauuco saa 1 meemnsexew Bunoousa qnoJ JBM J 3 5 Image Performance Troubleshooting 3 5 ML500 Confidential UO jou si pue BU euBis jeubis ejnsug 2 uaals _ eu uo abeu Jd BU 5900 UBBJIS BUJ ua MOUs 54 seoc peog ON ON uc UB y 2200 ajnpow 141 84 TELWOJ 008 TI ui EF IE LL sell BLI LIELUGU 4 PL pang 101 51 jndjno apne S i BEE ey poney ndino 5j HJOM ndino apne sj peog eu hos EUGIS
3. PCBA FRONT IR SENSOR BOARD FOR 80 8KU05G001 1339 PROJECTOR 75 8LK01G001 BLK BOTTOM COVER MODULE 51 8KU08G002 5 MYLAR PLED W500 51 8LK01G001 KEY BUTTON MODULE 51 8MA06H011 FOCUS RING ABS FOR ML500 52 8KU02G001 FAN RUBBER BLACK K330 52 81 02 001 ML500 SPONGE 125 15 0 95mm a 61 8MA02H001 SPEAKER BRACKET SECC PLED W500 PCBA MAIN BD FOR ML500 80 8LK01G002 PROJECTOR PCBA LED DRIVER BD LT3743 TYPE FOR K330 PROJECTOR 75 8KU01GP03 ASSY YGE 120 LVPS FOR K330 LED 500lm DELTA 35X35X15 AXIAL FAN 49 8KU11G001 LENGTH 120mm 49 8FS01G001 DELTA 35 15 AXIAL FAN 49 8KU01G001 SPEAKER MINI 2W 4ohm 100mm K330 6 EN ML500 Confidential 789 LIGHT SENSOR BOARD 85 1A622G040 SCREW PAN MECH M2 4 BLACK PCBA LIGHT SENSOR BD FOR K330 85 1A121G040 SCREW PAN MECH M1 7 4 5001 Condena ENGINE MODULE 1 1 e m LE 5 ASSY ENGINE MODULE FOR ML500 10 81 4 SERVICE 200000 RONEM C1 S LAM 60 T7 1 D14 2 Ka COLLIMATOR 1 COVER C1NEW A PC 20 GF 7 23 8KU15G002 4 Die Config D52 y 400LM Luminus 61 8KU02H001 5 FIXPHOLD SECC K330 ML500 Confidential 0M 61 8KU03H001 5 CLAMP SUS K330 61 8KU04H001 HEAT PIPE MODULE GREEN C1N EW K330 PT54 RED LED Standard Die Config D52 61 8KU05H002 HEAT PIPE MODULE RED C1N EW K330
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5. 10 23 8KU15G003 PT54 BLUE LED Standard Die Config D52 400LM Luminus 11 52 8KU10G001 Projection Lens ENG 052 12 51 8MA06H011 FOCUS RING ABS FOR ML500 DMD 1140x910 PIXEL 0 45 WXGA DDR Type is Series 310 DMD 14 80 8KU02G001 DMD BOARD FOR K330 PROJECTOR ADJUST FOOT 52 8FS02H001 ADJUST FOOT K11 DEE 86 00122G015 NUT HEX M2 0 0 4P 1 15 Ni DER ML500 Confidential VE Assy Packing Drawing V ML500 Confidential 0 wano WTO X H 53mm FOR 51 00069G001 PACKING STRAP 13 5MM 1500M 0 7MM 500MM 1500M 0 02MM ML500 Confidential VIII 2 5854604601 COVER PALLET 120 t00om FOR COMPAQ _ m sexus puBaeRrooraiackka _ Wa 42 00200G005 CABLE VGA 15P 1 8M BLK EP739 45 8LK01G001 REMOTE CONTROL FOR ML500 PE BAG ZIPPER 240 170 0 04 88 FOR 53 8LK01G001 ML500 36 8LK01G001 QUICK START CARD MULTILINGUAL nm WARRANTY CARD US FOR OPTOMA 1 INSTRUCTION CARD OPTOMA BEFORE iced DC Appendix B Serial Number System Definition Serial Number Format for Projector Q 8LK 1 17 0001 1 2 3 4 5 6 7 1 Q Optoma 2 8LK Project Code ML500 3 0 Last number of the manufacture year ex 2011 1 4 17 week of the manufacture year ex the seventeenth week of the year 17 5 AAAAA n
6. 2 Criteria there is noise on the screen the product is considered as failure product If there is noise on the screen use auto or manual frequency function or tracking function to adjust the screen The PC mode functionally sure be workable include support format with frequency and auto detected functional will be workable 2 Bright Pixel Procedure Test equipment video generator Test signal 1280 800 60Hz Test Pattern Full black Inspection item Bright pixel check Fill Black Criteria Adjacent pixels are unacceptable f there is blemish on full black pattern please use gray 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 4 3 Criteria Adjacent pixels are unacceptable Please refer to Pixel specification table 4 Bright Blemish Procedure Test equipment video generator Test signal 1280 800 60Hz Test Pattern Gray 10 Inspection item Bright blemish check Criteria Please refer to Pixel specification table Gray 10 5 Dark Blemish Procedure Test equipment video generator 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 u
7. 4 The success information will show on Update Make F ul Za CU SDE ace umagar 1211 SCTEEN Very SeleciDrver Linux 150 110525 bn Patlp we ML500 Confidential 5 11 5 Restart the unit and enter the service mode to check the Multi Media firmware version System Hours LED Hours LED Hours low Factory Fan RPM ML500 Confidential 5 12 Section3 Multimedia FW Upgrade SD Card 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 Iranscena pi GB ML500 Confidential 5 13 5 3 2 Multi Media Firmware Upgrade Procedure 1 Rename multimedia software file name to 5 ACTUPGRADE BIN 2 Copy the file to SD card by PC 3 Insert SD card to projector Optoma 4 Choose Setup ML500 Confidential 5 14 5 Choose System 6 Choose Firmware Upgrade Choose Yes to process FW Upgrade ML500 Confidential 5 15 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 System Hours LED Hows LED Hours
8. Level 3 8V as green square Select Internel RC 11 0592MHz as M pm uC cinck ts for Watendog None e Code DataFlash Port 1 3 and 5 reset to quasi e 3 Port reset to w state 21 Brownout Level 3 8V Addr Len Sep green square Enable Clock Fiter Date Time internet RC 11 0592342 None 95 Move Disabled None Click Erase Write W to execute 8051 FW upgrade as red circle ML500 Confidential 5 18 5 4 3 Check 8051 FW version 1 Restart the unit and enter the Service Mode Press Power gt Left gt Left gt Menu 2 The firmware version will be shown as red circle on the screen System Hours LED Hours LED Hours low Factory Fan RPM Factory Reset ML500 Confidential 5 19 Chapter 6 EDID Upgrade 6 1 EDID Introduction Extended Display Identification Data is a VESA standard data format that contains basic information about a display device and its capabilities including vendor information maximum image size color characteristics factory pre set timings frequency range limits and character strings for the monitor name and serial number The information is stored in the display and is used to communicate with the system through a Display Data Channel DDC which sites between the display device and the PC graphics adapter The system uses this informa
9. Source 480P 720P 1080i 1080P Minolta CL 200 Quantum Data 8028 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 lt Figure Zone A amp Frame as green line Definition gt ML500 Confidential 4 3 I O Port Test 4 3 1 VGA Port Test Note When doing function test get in to service mode choose lenstop press enter adjust the lens to the highest state and then adjust Zoom and Focus to guarantee the image maximum and clearest then start 1251 1 Frequency and Tracking Boundary Procedure Test equipment video generator Test signal 1280 800 60Hz Test Pattern Master Check and see if the image sharpness is well performed If not re adjust by the following steps 1 Select Frequency function to adjust the total pixel number of pixel clock in one line period 2 Select Tracking function and use right or left arrow key to adjust the value to minimize video flicker AE Adjust Resync or Frequency Tracking H Position 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 4
10. Supply e Auto ranging AC100V 240V 10 50 60Hz eNormal mode 120W 20 110Vac Power consumption mode 60W 20 110 Keystone correction e Vertical 40 degree WXGA 1280x800 1 4 5 Projection lens e YM102 7 LED life 20 000 Hours Bright Mode 75W 10 B50 L50 Note Survival Rate DMD Chip DMD 0 45 WXGA System controller e DPP6401 0 52m 3 00 m mechanical travel range Dimensions WxDxH e 220 170 41 mm Throw Distance 0 91m 2 40 m optical travel range Standards e NTSC 3 58MHz 4 43MHz e PAL BG DK I M N 4 43MHz e 480i 480 576i 576p 720p 1080 e Analog RGB signal PC Analog RGB 0 7 0 1 Vp p 75 ohm Separate TTL H V Sync Input signal spec e Video signal NTSC PAL Composite video 1 0 0 1 Vp p 5ohm e Audio signal 900mVrms 22K ohm Video compatibility ML500 Confidential 1 1 e Operating 0 2 500 ft for 5 C 35 C 2 500 ft 5 000 ft for 5 C 30 C 5 000 ft 10 000 ft for 5 C 25 C 13 Altitude amp Temperature e Operating 5 35 C Non operation 20 C 60 C 1 2 Compatible Mode e Computer Compatibility 800x600 640 x 480 VGA 1024x768 1280 720 4600 2 1280 800 4801 480 Widze 576i 576p 50 720p 50 60 1080i 1080p 50 60 480i 480p 60 ____ 576i 576p HDMI 720p 50 60 1080i 1080p 50 60 ML500 Con
11. alick lin Desktop Manle Don t search will choose the driver to install Choose this option to select the device driver from a list windows does not guarantee that the driver you choose will be the best match for your hardware ML500 Confidential 5 8 Found New Hardware Wizard 3 rows e b u tto n to ch OOS Please choose your search and installation options cy t O O for the best driver in these locations Use the check boxes below to limit or expand the default search which includes local paths and removable media The best driver found will be installed C Search removable media floppy CD ROM 14 JJ S e e ct O K Include this location in the search C Documents and Settings alex wang Desktop 4M _ click Next Browse For Folder Select the Folder that contains drivers for your hardware indows does not guarantee that are Desktop 3 My Documents My Network Places Hardware Installation The software you nstaling for this hardware 4 Click Continue Anyway Actions USB Device with Windows AP Tell me why this testing is important Continuing your installation of this software may impair or destabilize the correct operation of your system either immediately or in the future Microsoft strongly recommends that you stop this installation now and contact the har
12. low Factory Fan RPM Factory Reset ML500 Confidential 5 16 Section 4 8051 FW Upgrade 5 4 1 Equipment Needed Software N79A901R USB Setup NLINK_en Manley USB Driver NLINK 8051 Hardware Projector Power cord 42 50115G001 USB Cable mini USB to USB A 42 00284 5001 NLINK Fixture PC or Laptop ML500 Confidential 5 17 5 4 2 8051 Firmware Upgrade Procedure 1 Set up Plug in USB cable into the projector and link to the USB portofa PC Connect VGA Port of projector with NLINK Fixture Connect NLINK Fixture with PC by USB cable 2 Execute 8051 FW Program Double click NLINK V1 2 to execute NLINK program 3 Choose the right type of MCU Cancel MCU Choose picture will appear on the screen select N79A901R Click 4 Program settings Ensure NLINK Fixture and PC are TET _sm securely connected the indicator lights ta Code DataFlash ia 0000 02 OB 7B 00 7A 00 79 64 22 22 02 13 B4 EA FF z yd on green and the state is Connect ns 3 0020 40 05 22 02 OE C6 30 86 04 77 03 80 02 77 04 12 0030 16 E 22 02 09 DO 2 00 92 10 22 02 1 BB 01 0040 06 89 82 83 EO 22 50 02 7 22 BB FE 02 22 as blue square 0050 99 82 83 E4 93 22 88 01 ES 82 29 FS 82 ES Select Brownout
13. pue suaj ayy o yos asn EMO 5020 MO 5120 S 3 ML500 Confidential diuo QW ai a2e day peog JO 828 09 panos aul 5 2184 peog AU 808 0988 au 9 1 868 08 01 4919 pug 158 3 JL ON WOM peog pubis abeu BU pug ajqga Bl u asiou 8181 8 5 eJnsu3 PJEGQ asejday j Agjdsip au aues GU ui desy Jed aui a4 S 584 3 8 ML500 Confidential 3 6 Remote Control Troubleshooting Jarno SBA J8jeJ pue UOJDUNY peog ayy sI pe pos 2 uejqoud au 5 _ owe JO 2 O uonounj 2 aowa au SI Gowa 2 jouda ayoway 3 9 ML500 Confidential Chapter 4 Function Test 8 Alignment Procedure 4 1 Test Equipment Needed DVD player with Multi system equipped Component S Video Composite and HDMI HDTV
14. Projector by VGA Cable System Hours LED Hours LED Hours low Factory Fan Factory Reset Burn im Failure Log R nal n Sel tins Optical Settings Thermal Settings Other Settings Sento Calibration Read SNID ML500 Confidential 4 11 Connect LED Calibration Fixture and CL200 by CL200 RS232 Cable Connect LED Calibration Fixture and Computer by USB Cable Must be on the center of the screen Power on the projector and get into Service Mode Press LED Calibration Setting Press LED Calibration to start calibration and success will appear in right blank 4 G Sensor Calibration To keep the balance of screen after replacing main board the G System Hours LED Hours LED Hours low Procedure Please put the Projector on a horizontal surface Factory Fan RPM Sensor calibration is needed Factory Reset Please press Power Left Left and Burn In Test Failure Log Menu buttons sequentially to get into Service Mode a LED Calibration Settings Optical Settings Press G Sensor Calibration for correction Other Settings G Sensor Calibration _ 4 5 Run In Test 29 35 Circumstance brightness Normal environment Screen size No concern Display mode ECO mode After repairing each unit it should be Run in refer to th
15. SERVICE MANUAL ML500 2011 08 23 V1 0 Initial Issue 2011 09 5 V2 0 Modify Chapter 6 Chapter 3 2011 10 18 V3 0 Modity chapter add new method to upgrade multimedia FW Copyright OCT 2011 All Rights Reserved Prepared Chris Checked Amy Approved Alick 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 We expect your customers will appreciate the service that you offer them This manual is for technicians and people who have an electronic background Please send the product back to the distributor for repairing and do not attempt to do anything that is complex or is not mentioned in the troubleshooting Notice The information found in this manual is subject to change without prior notice Any subsequent changes made to the data herein will be incorporated in future edition ML500 Service Manual Copyright OCT 2011 All Rights Reserved Manual Version 3 0 ML500 Confidential Table of Content Chapter 1 Introduction Highlight 1 1 Compatible Mode 1 2 Chapter 2 Disassembly Process Equipment Needed 8 Product Overview 2 1 Disassemble Top Cover Module and Key Pad 2 2 Disassemble LED Driver Board 2 4 Disassemble Main Board 2 5 Disassemble Fan 2 6 Disassembl
16. Test pattern 64 gray RGBW After finishing ADC adjustment check 64 gray 64 gray RGBW RGBW pattern Inspection item Color saturation Criteria 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 10 2 Fan Calibration To store the value of fan in main board after replacing main board blower or upgrading the firmware the Fan calibration is needed Procedure Hold on Menu button then plug in Power Power LED will flash red and blue Release Menu button once Power LED flashes red blue only The Projector will power on After about 30s get into Service Mode to check the fan speed has been recorded 3 LED Calibration Note After replacing main board Engine Module if the color abnormal you can do the LED calibration 1 Procedure Press Power gt left gt left gt Menu to get into Service Mode Select LED Calibration Setting Enter in LED Calibration Settings and select Reset Calibration Data 2 If the color appears abnormal please execute below procedure 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
17. ance ls image OK troubleshooting Yes D Remote control troubleshooting Is remote control OK ML500 Confidential 3 2 3 3 No Power Ttoubleshooting No power 4 Troubleshooting Js tti power cord connected securely al the unit and the power source 7 Properly connect power cord at unit No and AG power source tes fhe power source Supply AC valtage 100V 240V measure main board J1 Pin 1 2 825V7 a Sy ML500 Confidential 3 3 3 4 Power Troubleshooting o Uan enumuan peog 7 gp pun SI JUBLUUOJIAUB BUJ Guns you ale sapna DUE Jojoa jg SMOUE OSH 16 1005 aur 99 8 Luld Zr ON 101 Ad LsjqaJd S 8jn38x3 ML500 Confidential gt 7 s v 9 w B s 20 usar 4 UpaAJos peog 971 wajqcud s 131
18. ction 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 ML500 Confidential 5 1 5 1 2 DLP Composer Lite Setup Procedure gs 1 Choose DLP Composer Lite V10 5 Setup DLP Composer Lite 10 5 5 Program DLP Lite 10 5 Setup Welcome to the DLP Composer TM Lite 10 5 Installation Wizard It is strongly recommended that you exit all Windows programs before running this setup program 2 1 N b gt Click Cancel to quit the setup program then close any programs ext u tto n vou have running Click Next to continue the installation WARNING This program is protected by copyright law and international treaties Unauthorized reproduction or distribution of this program or any portion of it may result in severe civil and criminal penalties and will be prosecuted to the maximum extent possible under law ie DLP omposer TM Lite Setup Licence Agreement You must agree wih the license aqreement below to proceed 3 Read License Agreement Agreement for which the icenses or government approvals are required 116 Entre Agreement The terms and conditions of thes Agreement merge and supersede all pro
19. dware vendor for software that has passed Windows Logo testing has not passed Windows Logo testing to verify its compatibaity Continue Anyway STOP Installation Found New Hardware Wizard Completing the Found New Hardware Wizard The wizard has frushed instaling the software tor 5 Click Finish to end the ci USB Device installation Cick Fresh to close the wead ML500 Confidential 5 9 5 2 3 Multi Media Firmware Upgrade Procedure 1 Open tools file ow d Mew Faves uM O xm Execute Actions MP Update exe ms JEZ F Actor ta B AM ACM Erish 1 03 Ere dh m n perry Firraroni p 11 Ershad ActionsMPUpdate_v1 10 1 MassProduc 2 Click Firmware Make firmware Config Ziami2wAQCALSDKicaseMmagesttwinage_l2lLl Select the FW upgrade file bin Update Click Open Read Serial Number Qj weltrend 1 yusan MLS00_AM8201_B01_110525 5 File ML500_AM8201_BO1 2110525 Files of type BIN FW Y PartDownload pn SelectDriver Linux update _Fimmae z Download PartUpdate ML500 Confidential 5 10 lionsMPUpdaie v1 10 3 Click Download VMLSOO AMG2U 801 110525 bn
20. e button and navigate to the directory where you put the library file ii ii N Communications 5 Click Communications select USB ete e NNI CE gt COH USS Draps jJ bevel Lurra es 6 Choose Flash Loader Click Browse to search the firmware file Click Open ML500 Confidential 5 9 7 Selete the item skip Boot Loader Area Select 32KB Click Reset Bus to erase the flash memory 8 If the firmware is ready click start download to process the firmware upgrade 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 LI W w im Em System Hours LED Hours LED Hours low Factory Fan RPM Burn In Test Failure Log Analog Settings LED Calibration Settings Optical Settings Thermal Settings Other Settings Sensor Calibration Exit ML500 Confidential 5 6 Section 2 Multimedia FW Upgrade USB 5 2 1 Equipment Needed Software Firmware Bin Tools Hardware Projector Power cord 42 53506G002 USB Cable male to male 42 0028JG001 PC or Lapto
21. e Light Sensor Board 2 7 Disassemble Speaker and IR Board 2 7 Disassemble Engine Module and LED 2 8 Disassemble LVPS 2 10 Disassemble Bottom Gover Module 2 11 Re write LED Usage Hour 2 12 Repair Action 2 13 Chapter 3 Troubleshooting Equipment Needed 3 1 Main Procedure 3 2 No Power Troubleshooting 3 3 Power Troubleshooting 3 4 Image Troubleshooting 3 5 ML500 Confidential Remote Control Troubleshooting 3 9 Chapter 4 Function Test 8 Alignment Procedure Test Equipment Needed 4 1 Test Conditon 4 1 I O Port Test 4 2 Composite Port And Audio Test 4 7 S Video Port 4 7 HDMI Port Test 4 7 3D test 4 8 SD Card Mini USB USB flash disk test 4 8 Calibration 4 10 Run in test 4 12 Test Inspection Procedure 4 13 Chapter 5 Firmware Upgrade Section 1 System Firmware Upgrade 5 1 Equipment Needed 5 1 DLP Composer Lite Setup Procedure 5 2 Firmware Upgrade Procedure 5 4 Section 2 Multi Media Firmware Upgrade USB 5 7 ML500 Confidential IV USB Driver Upgrade Procedure 5 8 Multi Media Firmware Upgrade 5 10 Section 3 Multi Media Firmware Upgrade SD 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 6 1 Appendix A Exploded Overview Appendix B Serial Number System Definition X PCBA Code Definition XI ML500 Confidential VI Chapter 1 Introduction 1 1 Highlight Power
22. e below table Normal repair 2 hours Auto shut down ML500 Confidential 4 12 Get into Burn In Mode Cycle setting is based on the defect symptoms ie If it is NFF the run in time is 4 hours You have to set the LED on for 60 min and LED off for 15 min for 4 cycles Note Please make sure that the hot exhaust airflows from projectors can flow towards the aisle Press power gt Left gt Left gt menu to get into service mode Choose Burn In Test enter LED On Press right key to adjust the time 60 LED Off Press right key to adjust the time 15 Set burn in cycle Press right key to adjust the cycle After setting up the time choose Get into Burn In Mode and press enter 4 6 Test Inspection Procedure 1 Check Points Firmware version All firmware version must be the lastest version TB implementation Related TB must be implement Cosmetic Cosmetic can not be broken Missing logo missing prints and blurry prints are Logo unacceptable The function should work smoothly Keypad All keypad buttons must operate smoothly ML500 Confidential 4 13 2 050 Reset 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 14 Chapter 5 Firmware Upgrade Se
23. e screen 4 3 4 HDMI Port Test Procedure Test Signal 720 10801 Test Pattern Any Pattern Equipment DVD Player with HDMI output Display type must be set to 16 9 Inspection item HDMI Test ML500 Confidential 4 7 Inspection Distance 0 8 1 0 Criteria Ensure the image and sound are well performed and the color should not discolor 4 3 5 3D Test Procedure Test equipment PC with 3D display card DLP 3D goggles and 3D player software or DVD player Test signal 3D Format movie for PC HQFS format CD for DVD Inspection item 3D test with 120Hz VGA port for PC test with 480i Video for DVD Inspection Distance 5 Criteria The image should not appear noise flicker 4 3 6 SD Card Mini USB USB flash disk Test 1 50 Card Test Procedure 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 gt Photo play the test pattern in WhiteBlack_640x480 SD Card GrayStep16_640x480 ML500 Confidential 4 8 Press gt button on remote controller when the image is at WhiteBlack test pattern Get into service mode ColorBar_640x480 2 USB flash disk Test Procedure Test equipment USB flash disk include video file Test Pattern video file Turn on the projector and plug USB flash disk into the project
24. fidential 1 2 e Compatibility Document Compatible Document Format Microsoft Office 95 Microsoft Office 97 Microsoft Office 2000 Microsoft Office 2007 Microsoft Office 2010 Compatible Document Format docx pptx XISX Adobe PDF pdf AC3 No support DTS 1AP MPEG1 2 3 H 264 support 20Mbps PCM less ADPCM than 4 reference AAC frames Microsoft Office 2003 e Media File Support List Video Video AC3 AAC e 20Mbps MPEG1 2 3 than 4 reference DIS frames LPCM MPEG1 2 3 20Mbps E LPCM ML500 Confidential 1 3 w p MP4 1080P 20Mbps 30fps than 4 reference 3GP frames Cook RA4 RA E 720P 5Mbps 30fps AAC RA9 RACP RA10 WMA2 No support VC Image YUV400 Baseline JPEG JPG YUV400 YUV420 Width lt 10240 Progressive YUV422 amp Height lt 6400 YUV440 YUV444 BP Neumt Music Note If the Computer Compatibility supportive signal is different from User s Manual please refer to User s Manual ML500 Confidential 1 4 Chapter 2 Disassemble And Repair Action 2 1 Equipment Needed 8 Product Overview 1 Screw Bit 107 2 Hex Sleeves 5mm 3 Screw Bit 102 4 Hex Sleeves 7mm 5 Tweezers 6 ML500 unit Before you start This process is protective level Il 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
25. ircle 2 7 Disassemble Speaker and IR Board 1 Unscrew 2 screws to disassemble speaker as red circle 2 lake off IR Board as red square m gt ML500 Confidential 2 7 2 8 Disassemble Engine Module and LED 1 Unscrew 4 screws to disassemble Engine Module as red circle T III nn mmm 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 2 8 3 Disassemble the Green LED Noc tae PRO Z SZARY O KOSZ SALMON gt 4 Pes gt P m 7 i 4 Unscrew 2 screws on the front side of the Engine Module to disassemble Red LED as red circle 144 a NGI MODULE ML500 Confidential 2 9 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 ML500 Confidential 2 10 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 2 11 Re write LED Usage Hour 1 Get into service mode Press power left left menu t
26. lue it means the projector has got into EDID FW mode ML500 Confidential 6 3 6 4 EDID Key In Procedure 1 Execute EDID Program 1 Click on EDID to execute EDID program 2 Process 1 Check the COM port is 1 Select the COM port which you are using 2 Click the Model button 3 Choose the source file ini and then open it 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 button ML500 Confidential 6 4 4 Please change the cable to HDMI will be 4 shown on the screen Please press OK button 5 Finish 9 1 OK will be shown on the screen ma 1 ie FE AE WW dA TT FF GAM ta EG Gi dh bh BA x his PRK OBS SB du Wb JE d dS Lh PS FE REA 1a A 8 5 4 EO I PE TE ret ee ZE H ba Gi GA 10 GA ti Ha a In E RF KA NG B Gub GA WS PE KA EF Fert m ob mm TU Tm PE Wu dd n FB Fk mh ai 18 SF LA AF dd AT FR FT Bp 15 AT LE Wa PR WE dh Tr amp TP Fa wa mi d WD 6 Read EDID Analog information 1 In the Read item select Analog and s Trans rm
27. nder blue 60 pattern Please refer to Pixel specification table ML500 Confidential 4 4 Pixel specification Black pattern 1 Bright pixel dots 1 0 0 Bright blemish Gray 10 pattern A 0 A 0 lt 1 0 tern m i ai z m Dac EI M 6 Focus Test Procedure Test equipment video generator E ES mm eem E Bu 4 Test signal 1280 800 60Hz z z z E 4 i i m mm Pa 1 IM EFA L u F PI m m 5 4 1 r Hi MER H Test Pattern Full screen A Full Screen Inspection item Focus check Criteria From screen 1 0M via visual to check the focus look at the entire screen focus shall be clear crisp and sharp over the entire surface of the display pattern Blur word on one of the corner after adjustment is z acceptable 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 be adjudicated as NG ML500 Confidential 4 5 7 Color Performance Procedure Test equipment video generator Test signal 480p 720p 1080p Test Pattern Master 64 gray RGBW or 32GRAYS Plea
28. o get into service mode 2 Choose Other Settings As the red square 3 Choose System Hours Adjust to re write the usage hour back to previous 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 2 12 Repair Action v Vv chapters Section v v V gt write LED Chapter 2 11 Usage Hour Optical perfermance V Chapter 4 3 1 Measure ML500 Confidential 2 13 Chapter 3 Troubleshooting 3 1 LED Lighting Message Power Plug ON gt OFF gt 1 second gt ON Power button ON Firmware download Power button ON 0 5 second H ON 0 5 second L OFF flashing O Power off Cooling state Power button OFF Cooling com pleted Standby Mode O Thermal sensor error OSD shows Projector Overheated O Fan lock error OSD shows red Fan Fail Will automatically turn off soon O O 2 2 2 2 2 ML500 Confidential 3 1 3 2 Main Procedure Connect power cord analog or digital signal cable properly Does the power LED light power troubleshooting Yes Tum an the projector Does the lamp ignite B Power troubleshooting Yes Image perform
29. omposer TM Lite 10 5 Setup Select Features Please select which features you would like to install Compose te Tool Suite I OLP Composer Lite Tool Suit Feature Description DLP Composer Lite Tool Suite This feature will be installed on the local hard drive This feature requires 24KB on your hard drive Current location C Program Files DLP Composer Lite 10 54 Browse Disk Cost Reset Cancel See F ie DLP Composer TM Lite 10 5 Setup Ready to Install the Application 6 Click Next 7 Click Finish 8 Restart the computer Click Next to begin installation Click the Back button to reenter the installation information or click Cancel to exit the wizard Cancel 2 DLP Composer TM Lite 10 5 Beta Setup DLP Composer TM Lite 10 5 Beta2 has been successfully inst Click the Finish button to exit this installation ML500 Confidential 5 3 5 1 3 Firmware Upgrade Procedure 1 Set up Hold on Power and menu and plug in 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 amp PC 2 Execute the DLP Compose file 3 Click edit and perferences p DLP Lite ML500 Confidential 5 4 4 Click Library Click the brows
30. or Select USB gt Video then play video file in USB flash disk 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 3 Mini USB Test Procedure Test equipment Mini USB Test Pattern video file Turn on the projector and plug Mini USB cable into the projector Select menu gt mini USB gt 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 4 9 4 4 Calibration 1 PC Calibration To adjust the white black value of VGA signal after replacing main board or upgrading firmware the PC calibration is needed Procedure Test equipment video generator Once Main Board or FW is changed PC Calibration should be done as well White Black 1 Test signal analog 1280 800 60Hz 2 Test Pattern White up Black down Note 1 Calibration pattern should be in full screen mode 2 Please press Power Left Left and Menu buttons sequentially to get into Service Mode 3 Choose Analog Settings press Menu button to access PC Calibration for correction When the message Success appears it means PC Calibration is OK Choose Exit to leave the Service Mode Check pattern Test signal 1280 800 60Hz
31. ot defined 6 C Manufacture factory CPC 7 0001 Serial Code Q8LKO17AAAAACOO01 This label 981 117 0001 represents the serial number for ML500 It is produced at CPC on seventeenth of 2011 Its serial code is 0001 ML500 Confidential _ ll PCBA Code Definition PCBA Code for Projector A B XXX XXXXXXXXX CC XXX EEEE W ID Vendor Code Firmware Version P N MB Version Date Code O 69 S N TT PU sw Godenia X
32. p Note After upgrade the multimedia FW the files of the projector will be cleared ML500 Confidential 5 2 2 USB Driver Upgrade Procedure 1 Setup Hold on Power and menu and plug in Power Cord to get into FW Download Mode Once Power LED lights pink then release Power and menu button Plug in USB cable into the projector and link to the USB portofa 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 Found New Hardware Wizard welcome to the Found New Hardware wizard This wizard helps you install software for Actions USB Device If your hardware came with an installation CD or floppy disk insert it now What do you want the wizard to do nstall the software automatically Recommended tall fron a list or specific location Advanced Click Next to centinue Ce Found New Hardware Wizard Please choose your search and installation options 5 Search for the best driver in these locations Use the check boxes below to limit or expand the default search which includes local paths and removable media The best driver found will be installed Search removable media floppy CD ROM Inklude this location in the search T Documents and Settings
33. please refer to section 2 12 ML500 Confidential 2 1 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 cA FM ML500 Confidential 2 2 3 Tear off the mylar 4 Separate the keypad and the Top Cover Module ML500 Confidential 2 3 2 3 Disassemble LED Driver Board 1 Unscrew 2 screws as red circle 2 Unplug 3 connectors as red square 3 Push the LED Driver Board as red arrow direct 4 Unplug 1 connector as yellow square 5 Unplug 3 connectors as yellow circle disassemble LED to LED Driver Board cable and LED Driver Board GREEN LED CABLE RED LED CABLE BLUE LED CABLE LED Driver Board ML500 Confidential 2 4 2 4 Disassemble Main Board 1 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 2 5 2 5 Disassemble Fan 1 Take off three Fans Note Care the direction about how to place the tan as yellow square ML500 Confidential 2 6 2 6 Disassemble Light Sensor Board 1 Unscrew 1 screw to disassemble Light Sensor Board as red c
34. r and contemporaneous agreements understandings negotanons and discusmon Choose pt a nd ag bou nd concermng the matter hereof No amendments or modhhcanons to thes Agreement shall be effective unless m wning and mgned by the authonzed representatives of both parter These terms and conditons will prevail notwithstanding any different conflicting or additonal terms and conditons that may appear on any purchase order acknowledgment or by all the te rms and conditions of this other writing not expressly incorporated into this Agreement Licensee hereby warrants and represents that all authorizations and other applicable consents required empowenng you to enter into this Agreement have been obtaned License Agreement and to be bound by el he terms condone ort License Agam Ol do not accept the terms and conditions Click Next i DLP Composer TM Lite 10 5 Setup Readme Information The following information describes this installation DLP Composer Lite Release 10 5 2 CI Next Installation Location The default installation directory is C Program Files DLP Composer Lite 10 5 To install in a different directory click the Browse button on the Select Features page Drivers Included The DLP Composer installation includes device drivers for Cancel ML500 Confidential 5 2 4 5 Click Next ie DLP C
35. se get into service mode Master Use 720p amp 1080p signal master pattern to do HDTV test Color should not discolor to purple and blue Inspection item Check if each color level is well functioned Color saturation Criteria Screen appears normal It should not have any Rd abnormal condition such as lines appear on the screen and so on Color appears normal is unacceptable to have few lines flashing 32GHAYS RGBW should all appear normal on the screen and sort from R G B W Color levels should be sufficient and normal 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 f color appears abnormal please get into service mode to do LED Calibration ML500 Confidential 4 6 4 3 2 Composite Port And Audio Test Procedure Test equipment DVD player Test signal CVBS Inspection item Video performance test Inspection Distance 0 8 1 0 Criteria Check any abnormal color line distortion or any noise on the screen Check if the sound from speaker Check if Volume and Mute functions are normal 4 3 3 S Video Port Test Procedure Test equipment DVD player Test signal S Video Inspection item Video performance test Inspection Distance 0 8 1 0 Criteria Check any abnormal color line distortion or any noise on th
36. tion 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 6 1 6 2 Equipment Needed Software EDID Program Generic V0 81 EDID File ini Hardware Projector Generic Fixture 80 00001 001 for EDID Key in Power Cord RS 232 9 Pin Cable pin to 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 6 2 6 3 Setup Procedure 1 Connect all ports 1 Connect P1 of Fixture with COM Port of PC Laptop by RS232 Cable 2 Connect P2 of Fixture with VGA port of Projector by VGA Cable 3 Connect P3 of Fixture with DVI port and connect oS PASA 4 1 1 p EL Pa SA ON Sq HDMI port of Projector I 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 2 When the Power LED flashes blue release the power button 3 When the Power LED flash alternates red with b
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