Download VPL-ES4/VPL-EX4 Service Manual
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DATA PROJECTOR VPL-ES4 VPL-EX4 REMOTE COMMANDER RM-PJ4 SERVICE MANUAL 1st Edition ! WARNING This manual is intended for qualified service personnel only. To reduce the risk of electric shock, fire or injury, do not perform any servicing other than that contained in the operating instructions unless you are qualified to do so. Refer all servicing to qualified service personnel. ! WARNUNG Die Anleitung ist nur für qualifiziertes Fachpersonal bestimmt. Alle Wartungsarbeiten dürfen nur von qualifiziertem Fachpersonal ausgeführt werden. Um die Gefahr eines elektrischen Schlages, Feuergefahr und Verletzungen zu vermeiden, sind bei Wartungsarbeiten strikt die Angaben in der Anleitung zu befolgen. Andere als die angegeben Wartungsarbeiten dürfen nur von Personen ausgeführt werden, die eine spezielle Befähigung dazu besitzen. ! AVERTISSEMENT Ce manual est destiné uniquement aux personnes compétentes en charge de l’entretien. Afin de réduire les risques de décharge électrique, d’incendie ou de blessure n’effectuer que les réparations indiquées dans le mode d’emploi à moins d’être qualifié pour en effectuer d’autres. Pour toute réparation faire appel à une personne compétente uniquement. CAUTION RISK OF EXPLOSION IF BATTERY IS REPLACED BY INCORRECT TYPE. DISPOSE OF USED BATTERIES ACCORDING TO THE RULE IN REGION. VPL-ES4/EX4 Table of Contents 1. Service Information 4. Spare Parts 1-1. Appearance Figure .......................................................... 1-1 4-1. Notes on Repair Parts ..................................................... 4-1 1-2. Board Locations .............................................................. 1-1 4-2. Exploded Views .............................................................. 4-2 1-3. Disassembly .................................................................... 1-2 1-3-1. Upper Case Assembly ........................................... 1-2 4-3. Electrical Parts List ......................................................... 4-4 4-4. Packing Materials & Supplied Accessories .................... 4-4 1-3-2. Front Case Assembly and Sub Rear Case Assembly ...................................... 1-2 1-3-3. 1-3-4. Main Board ............................................................ 1-3 Tunnel Outlet Section ............................................ 1-4 1-3-5. 1-3-6. Main Board Bracket Section ................................. 1-4 Lamp Power Supply .............................................. 1-5 1-3-7. 1-3-8. Power Board .......................................................... 1-5 Optics Section ....................................................... 1-6 1-3-9. 1-3-10. Detection Switch Board ........................................ 1-7 DC Fan .................................................................. 1-7 1-4. 5. Block Diagram Overall ............................................................................ 5-1 6. Diagram 6-1. Frame Schematic Diagram ............................................. 6-1 Warning on Power Connection ....................................... 1-8 2. Electrical Adjustments 2-1. Initial Values of Adjustment Items ................................. 2-1 2-2. Memory Structure ........................................................... 2-5 3. Troubleshooting 3-1. Electric Troubleshooting ................................................ 3-1 3-2. Power Board Troubleshooting ........................................ 3-3 3-2-1. 3-2-2. VPL-ES4/EX4 No Power ............................................................... 3-3 Failure of Turn on Lamp ....................................... 3-4 1 Section 1 Service Information 1-1. Appearance Figure 1-2. Board Locations Main Thermal sensor Lamp power supply Detection switch IR sensor Power VPL-ES4/EX4 1-1 1-3. Disassembly 1-3-1. Upper Case Assembly 2 Four claws 4 Upper case assembly 3 Remove the upper case assembly from this corner with the strong force to the extent that the upper case assembly will not be damaged. 1 Five screws (M 3 x 6) 1-3-2. Front Case Assembly and Sub Rear Case Assembly Remove the upper case assembly before starting the removal work. != Sub rear case assembly 5 Screw (M 3) 6 Six hexagon screws 4 Two screws (M 3 x 6) 9 Remove the upper case assembly from this corner with the strong force to the extent that the upper case assembly will not be damaged. ![ Front case assembly 2 Main board connector (J6) 0 Two claws 1 Lens cap 7 Two screws (+K 3 x 12) Sub rear case assembly !- Speaker harnesses 1-2 3 IR sensor board connector (J1) Sub rear case assembly VPL-ES4 VPL-EX4 8 Remove the upper case assembly from this corner with the strong force to the extent that the upper case assembly will not be damaged. Front case assembly VPL-ES4/EX4 1-3-3. Main Board Remove the front case assembly and sub rear case assembly before starting the removal work. 1 five screws (M 3 x 6) Main board bracket section 2 Remove the main shield in the direction of the arrow. Main shield Because the harnesses has the shape of flat cross-section, do not insert the harnesses with excessive force. Find out the direction in which the harnesses can be inserted easily, and then insert the harnesses. Note: The fan harness has been secured by the main board bracket with a fixing screw. (See section 1-3-5. mein bracket) Harnesses J17 J16 3 Main board Harnesses clamp section Lamp box assembly J22 J14 J20 J19 J21 J22 When re-assembling, give an appropriate amount of extra slack of this harnesses. J25 Main board J24 Radiation sheet J18 J23 J6 Main board VPL-ES4/EX4 1-3 1-3-4. Tunnel Outlet Section Remove the front case assembly and sub rear case assembly before starting the removal work. 1 Two tapping screws (PAN 3 x 7) Lamp box assembly J21 J21 Main board Main board Because the harnesses has the shape of flat cross-section, do not insert the harnesses with excessive force. Find out the direction in which the harnesses can be inserted easily, and then insert the harnesses. 2 Tunnel outlet section Harnesses Harnesses clamp section 1-3-5. Main Board Bracket Section Remove the main board before starting the removal work. 2 Three tapping screws (PAN 3 x 7) 1 Two screws (M 3 x 6) Power board 4 Main board bracket section 3 Screw (M 4 x 6) 1-4 VPL-ES4/EX4 1-3-6. Lamp Power Supply Remove the main board bracket section before starting the removal work. 9 Lamp power supply To the main board J16 5 Screw (+PWH 3 x 8) B 6 Remove the lamp power supply connector in the direction of the arrow A. A 8 Connector (P1) 7 Remove the lamp power supply in the direction of the arrow B. From the Main board CN602 (Red and Black wires) 4 Lamp 1 loosen screw. 3 Loosen two screws. 2 Lamp door 1-3-7. Power Board Remove the main board bracket section before starting the removal work. 1 Two stand assemblies CN701 CN603 Power board CN701 CN603 Lamp power supply (P1) 2 Remove the power board in the direction of the arrow. VPL-ES4/EX4 1-5 1-3-8. Optics Section Remove the lamp power supply and power board before starting the removal work. 1 Two tapping screws (PAN 3 x 7) 7 Dowel 2 Two claws A 4 Gasket 6 Two tapping screws (PAN 3 x 7) 3 Remove the lamp box assembly in the 9 Four screws direction of the arrow A. (+P 2.5 x 8) 0 Optucs section 5 Harness 8 Focus/Zoom adjust assembly Assembling Method of Optucs section and Focus/Zoom Adjust Assembly Phase matching !- Rotate the Zoom dial clockwise as shown until it is stopped. During the assembling process, never change the gear position that is set by step ![. !\ Install the Optucs section in the Lower Case. != Rotate the Focus dial counter-clockwise as shown until it is stopped. Focus dial !; Install the Focus/Zoom Adjust Assembly as shown. ![ Rotate the Focus dial counter-clockwise as shown until it is stopped. !] Rotate the Focus/Zoom Adjust Assembly counter-clockwise until it is stopped. Lower case !' After installation is completed, verify that the Optucs section can rotate from the position A to the position B smoothly. A B 1-6 VPL-ES4/EX4 1-3-9. Detection Switch Board Remove the optics section before starting the removal work. 3 Two tapping screws (PAN 3 x 7) 5 Tapping screw (PAN 3 x 7) 6 Detection switch board 4 Duct lamp 1 Tapping screw (PAN 3 x 7) CN1 CN1 2 Detection switch board 1-3-10. DC Fan Remove the optics section before starting the removal work. 1 Two tapping screws (PAN 3 x 7) 2 Duct LCD assembly 6 Two tapping screws (M 3 x 25) 3 Two tapping screws (PAN 3 x 10) 5 harness 4 DC fan 7 DC fan VPL-ES4/EX4 1-7 1-4. Warning on Power Connection Use a proper power cord for your local power supply. The United States, Canada Continental Europe UK, Ireland, Australia, New Zealand Plug type VM0233 290B YP-12A COX-07 _1) YP332 Connector type VM0089 386A YC-13B COX-02 VM0310B YC-13 Cord type SJT SJT H05VV-F H05VV-F N13237/CO-228 VCTF Rated Voltage/Current 10A/125V 10A/125V 10A/250V 10A/250V 10A/250V 7A/125V Safety approval UL/CSA UL/CSA VDE VDE DENAN Cord length (max.) 4.5m (14 feet 9 inches) VDE Japan _ (1) Use an appropriate rating plug which is applied to local regulations. 1-8 VPL-ES4/EX4 VPL-ES4/EX4 0 Off Blue Standard Off Off Enter x 4 V Keystone Image Flip Background INSTALL Lamp Mode SETTING High Altitude Mode Security Lock Key All information is display only S VIDEO Picture Memory INPUT A (Component/VideoGBR) OFF Low High OFF 80 50 50 50 30 Film 90 60 50 50 60 Film * OFF Mid 85 55 50 50 50 Film OFF High 90 60 68 50 50 Film OFF Low 90 50 60 50 50 Film ON Low 75 50 58 50 30 Film OFF High 85 55 50 50 50 Film OFF High 90 60 50 50 60 Film OFF Mid 75 55 50 50 40 Film OFF Low 80 50 50 50 30 Film * OFF High 90 60 68 50 40 Film OFF Low 90 50 60 50 40 Film ON Low 75 50 58 50 30 Film OFF High 75 55 50 50 40 Film OFF OFF Low 30 Film 60 Film High 80 50 50 90 60 50 * OFF Mid 40 Film 85 55 50 OFF High 40 Film 90 60 68 n There are some adjustment items that cannot be adjusted, depending on the input signal. OFF Low 40 Film 90 50 60 ON Low 30 Film 75 50 58 OFF High 40 Film 85 55 50 85 55 80 50 * Standard 90 60 Game 90 50 Living 60 50 Cinema 85 55 Presentation ON ON ON ON ON ON ON Graphics Graphics Graphics Graphics Graphics Graphics Graphics Mid High Low High Low High High 90 60 Natural INPUT A (Computer), INPUT B (Computer) PresenPresenPresenDynamic Standard Natural Game Living Cinema tation Dynamic Natural Standard Game Living Cinema tation Dynamic Standard Natural Game Living Cinema tation Dynamic VIDEO MemoryName * The “Picture Mode” items in the “PICTURE SETTING” menu have their respective initial values for each input signal (PRESET MEMORY No.). INFORMATION On English Center On Panel Key Lock IR Receiver Status MENU Language SETTING Menu Position Start Up Image 31 30 On Off Auto Auto Off Front & Rear Off Dot Phase H Size Shift Wild Mode Scan Conv Adjust Signal Volume Contrast Bright Color Hue Sharp ness DDE Gamma Mode Color Temp Picture Mode Adjust Picture ItemName Set Memory Smart APA Auto Input Search Input-A Signal Sel. SET Color System SETTING Power Saving Mode INPUT SETTING PICTURE SETTING Menu Title 2-1. Initial Values of Adjustment Items Section 2 Electrical Adjustments 2-1 Page P1-1 CXD9809-page1 Item Name TGHST Phase Hi TGHST Phase Lo SHSH1 TGHST Position DEHPF On DEHPF AAC DEHPF TAP DEUSC On 3D GammaSubCont 3D GammaSubBrt DELUT SW DEUF SW Set 0 109 38 12 ON ON 3 OFF 0 150 OFF ON P1-2 CXD9809-page2 PC Hi Gain-R PC Hi Gain-G PC Hi Gain-B PC Hi Bias-R PC Hi Bias-G PC Hi Bias-B PC Lo Gain-R PC Lo Gain-G PC Lo Gain-B PC Lo Bias-R PC Lo Bias-G PC Lo Bias-B 128 128 128 0 0 0 128 70 100 0 0 0 P1-3 CXD9809-page3 Video Hi Gain-R Video Hi Gain-G Video Hi Gain-B PC Mid Bias-R Video Hi Bias-G Video Hi Bias-B Video Lo Gain-R Video Lo Gain-G Video Lo Gain-B Video Lo Bias-R Video Lo Bias-G Video Lo Bias-B 128 128 128 0 0 0 128 70 100 0 0 0 2-2 R Color G B VPL-ES4/EX4 Page P1-4 CXD9809-page4 P2 Fan Control P3-1 CXA7005-page1 VPL-ES4/EX4 Item Name PC Mid Gain-R PC Mid Gain-G PC Mid Gain-B PC Mid Bias-R PC Mid Bias-G PC Mid Bias-B Video Mid Gain-R Video Mid Gain-G Video Mid Gain-B Video Mid Bias-R Video Mid Bias-G Video Mid Bias-B Temperature 1 Temperature 2 Temperature 3 FanSpeed 1 FanSpeed 2 FanSpeed 3 FanSpeed 4 ManualFanSpeed Burn-In Cycle Burn-In Cycle On min Burn-In Cycle Off min Burn-In Hour Burn-In active Gain-R Gain-G Gain-B SigCen-R SigCen-G SigCen-B SidA-R SidA-G SidA-B SidB-R SidB-G SidB-B Set 128 90 115 0 0 0 128 75 105 0 0 0 R Color G B Display only Display only N/A Display only Display only Display only Display only OFF 0 210 30 50 OFF 188 188 188 35 35 35 22 22 22 85 85 85 2-3 Page P3-2 CXA7005-page2 P4 ADC Calibration P5 P6 Error Count 2-4 Item Name Bias-R Normal Bias-G Normal Bias-B Normal Bias-R Flip Bias-G Flip Bias-B Flip Vcom-R Normal Vcom-G Normal Vcom-B Normal Vcom-R Flip Vcom-G Flip Vcom-B Flip RGB Calibrate YUV Calibrate RGB Offset RGB Gain YUV Offset YUV Gain R Offset G Offset B Offset R Gain G Gain B Gain Power Saving Time System Protect Data Reset Hard Reset ROM Version Lamp Timer Operation Timer Prev. Lamp Timer SOG Threshold Set 122 122 122 122 122 122 88 88 88 88 88 88 R 164 93 164 93 Color G 222 105 222 105 B 164 93 164 93 164 222 164 93 105 93 10 ON Display only Display only Display only Display only N/A All value is display only VPL-ES4/EX4 2-2. Memory Structure Set memory status memory Set memory No.01 No.02 No.03 No.04 No.05 S-Video Picture memory Input-A Input-B Component Computer W/B memory Other than Computer Channel Memory Input-A Input-B Input-A Component Input-A Video-GBR Video S-Video Common Memory Wide Mode (other than computer) Scan Converter (Computer only) Smart APA (Computer only) Volume Auto Input Search Input-A Signal Sel. Color System (Video/S-Video Only) Speaker Power Saving IR Receiver Panel Key Lock Status Language Menu Position Image Flip Background Lamp Mode High Altitude Security Lock FLASH ROM VPL-ES4/EX4 No.01 No.02 No.03 No.04 No.05 Video/Svideo status memory No.50 No.55 No.56 No.101 No.102 Video Set memory Dynamic Standard Natural Game Living Cinema Presentation Dynamic Standard Natural Game Living Cinema Presentation Dynamic Standard Natural Game Living Cinema Presentation Dynamic Standard Natural Game Living Cinema Presentation Dynamic Standard Natural Game Living Cinema Presentation High Mid Low High Mid Low Input-A/Input-B /Component Video S-Video picture memory Input-A Input-B Component Computer W/B memory Other than Computer Channel Memory Input-A Input-B Input-A Component Input-A Video-GBR Video S-Video Common Memory Wide Mode (other than computer) Scan Converter (Computer only) Smart APA (Computer only) Volume Auto Input Search Input-A Signal Sel. Color System (Video/S-Video Only) Speaker Power Saving IR Receiver Panel Key Lock Status Language Menu Position Image Flip Background Lamp Mode High Altitude Security Lock EEPROM Status memory No.50 No.55 No.56 No.101 No.102 Dynamic Standard Natural Game Living Cinema Presentation Dynamic Standard Natural Game Living Cinema Presentation Dynamic Standard Natural Game Living Cinema Presentation Dynamic Standard Natural Game Living Cinema Presentation Dynamic Standard Natural Game Living Cinema Presentation Picture memory High Mid Low High Mid Low W/B memory Channel Memory Common Memory CPU RAM 2-5 Memory structure of this model consists of the followings. 1 Set memory 2 Status memory 3 Picture memory 4 Chroma memory 5 W/B memory 6 Channel memory * The gamma memory is realized by giving offset to the Contrast and Brightness output values to the devices in the gamma mode function. Flow of data is described briefly. When the power plug is connected to the wall outlet for the first time (Standby state), all data that are stored in the internal ROM are written in the NVM (non-volatile memory). When the POWER is turned ON, all the status memory data and other memory data that are required for the present picture are selected from each memory block and expanded in the internal RAM. When any adjustment is performed at this moment, the adjustment data (user mode items) are written in the NVM (Service/Special Service) automatically triggered by the memory operation. The adjustment items (W/B, Device Adjust) that can be adjusted in the Service Mode or in the Special Service Mode, are memorized in the NVM at the time when the user performs adjustment and performs the memory operation. Note that the factory adjustment data will be lost at this moment. 2-6 VPL-ES4/EX4 Section 3 Troubleshooting 3-1. Electric Troubleshooting Connect the Power System Standby? No 1. Check the LED Message and find error. 2. Check lamp door, dust door. 3. Check the power board out voltage 5V. 4. Change main board. Yes Power projector Lamp ON ? No 1. check the Ballast power and control signal wire. 2. Check lamp door status. 3. Check lamp status. Yes System shut-down And cooling Yes 1. Check the LED message and find error. 2. Check the Fan status or Thermal sensor status. 3. Check the lamp door or dust door. No Yes 1. The picture is full-white pattern; please check the LCD panel connector. 2. The picture is full-black pattern; please check the LCD driver on the main board. 3. Check the system status: Is system in burn-in mode? No Picture ? No Picture quality No good ? No Yes 1. The picture a little green, blue, red, please check the LCD panel connector. 2. The picture has dust, please check the lens. 3. The picture flicker, please alignment again. 1 VPL-ES4/EX4 3-1 1 OSD flicker ? Yes Please alignment V-com again. No Color temp wrong ? Yes Please alignment color temperature again. No Picture has Vertical bar ? Yes Check the vertical bar color and find the LCD panel connector. Then check the pin of connector. Yes 1. Please check the OSD setting 2. Check the front IR board. No IR remote control No good ? No Audio function is No good ? 3-2 Yes 1. Check the OSD setting. 2. Check the speak wire. VPL-ES4/EX4 3-2. Power Board Troubleshooting 3-2-1. No Power No Power F601 Open? No Check if CN701 inserted properly. Yes Replace Q601 and F601 with new ones, and then put power board into set. If Q601 damages again, check if other parts are shorted. Yes Check if miss to solder any SMD type of components. Q601(D-S) Short ? No Check if 15.25V or 12V exist. If any voltage is wrong, replace IC701 or T602 with new ones. Yes Output 5V DC exists ? No Voltage outputs shut down and built repeatly ? Yes Check if D602 or IC602 is broken. if yes,replace it with now one. No Check LED circuit of main board. VPL-ES4/EX4 Check CN701 and find out if some points are shorted to gound. 3-3 3-2-2. Failure of Turn on Lamp Failure of turn on ballast. Check if the input voltage of ballast is 380V DC Yes B No Lamp Broken ? A Yes Replace lamp with new one. No Check main board. No Control Pin (SCI) is normal ? Yes Replace ballast with new one. 3-4 VPL-ES4/EX4 B No Check mian board. Check if there is PFC_On/Off signal. Yes Check if 18V exists at c-terminal of Q603. No Check Q701 IC604, Q604, Q603 or ZD603. And then replace broken parts. Yes F602 Open ? Yes Replace F602 with new one. No A Yes Q602 works normally ? No Check ZD602, R655 and R656. VPL-ES4/EX4 3-5 Section 4 Spare Parts 4-1. Notes on Repair Parts 1. Safety Related Components Warning w Components marked ! are critical to safe operation. Therefore, specified parts should be used in the case of replacement. [WARNHINWEIS] Les composants identifiés par la marque ! sont critiques pour la sécurité. Ne les remplacer que par une pièce portant le numéro spécifié. 2. Standardization of Parts Some repair parts supplied by Sony differ from those used for the unit. These are because of parts commonality and improvement. Parts List has the present standardized repair parts. 3. Stock of Parts Parts marked with “o” at SP (Supply Code) column of the Spare Parts list may not be stocked. Therefore, the delivery date will be delayed. Items with no part number and no description are not stocked because they are seldom required for routine service. 4. Units for Capacitors, Inductors and Resistors The following units are assumed in Schematic Diagrams, Electrical Parts List and Exploded Views unless otherwise specified. Capacitors : μF Inductors : μH Resistors :Ω VPL-ES4/EX4 4-1 Overall 4-2. Exploded Views 36 38 38 10 41 38 38 32 +PSW 4x8 25 9 +PWH 3x8 12 42 +PSW 3x25 20 38 6 32 32 30 3 1 32 2 13 +P 2.5x8 32 14 32 32 38 33 37 29 4 39 28 30 24 7 +K 3x12 26 +K 3x12 27 VPL-ES4 8 34 22 VPL-EX4 38 +BVTP 3x6 38 21 35 11 15 17 16 4-2 VPL-ES4/EX4 Overall No. Part No. 1 2 3 4 6 ! ! ! 7 8 9 10 10 ! ! ! SP Description 1-576-973-11 1-576-233-51 1-576-974-11 1-789-603-11 9-885-114-11 s s s s s FUSE, CYLINDERICAL (F602) FUSE (H.B.C.) (F601) THERMOSTAT DOOR DETECTION SWITCH BOARD FAN, DC (AXIAL FAN UNIT) 9-885-114-12 1-787-496-11 1-787-496-21 9-885-114-05 9-885-114-07 s s s s s FAN, DC FAN, DC FAN, DC MOUNTED MOUNTED 11 12 13 14 15 1-789-543-11 1-789-544-11 9-885-114-04 9-885-114-06 9-885-113-91 s s s s s MOUNTED CIRCUIT BOARD, IR SENSOR MOUNTED CIRCUIT BOARD, THERMAL SENSOR MOUNTED CIRCUIT BOARD, POWER SPEAKER LAMP DOOR 16 17 20 21 22 9-885-113-92 2-670-067-01 2-675-465-01 9-885-113-93 9-885-113-94 s s s s s DOOR, FILTER MESH FILTER ASSY, LAMP BOX ASSY,FOOT ADJUST RUBBER FOOT, ADJUST 24 24 25 26 27 9-885-113-95 9-885-114-08 9-885-114-34 9-885-113-96 9-885-114-00 s s s s s LENS CAP (VPL-ES4) LENS CAP (VPL-EX4) MYLAR BALLAST LOWER CASE ASSY, SUB REAR CASE (VPL-ES4) 27 28 28 29 29 9-885-114-33 9-885-113-97 9-885-114-09 9-885-113-98 9-885-114-10 s s s s s ASSY, ASSY, ASSY, ASSY, ASSY, 30 32 33 34 35 2-681-547-02 2-681-550-01 2-681-552-02 2-681-553-01 9-885-114-32 s s s s s SCREW, SCREW, SCREW, SCREW, RUBBER 36 36 37 38 39 9-885-113-90 9-885-113-99 4-672-839-11 3-918-696-11 2-580-621-01 s s s s s ASSY, UPPER CASE (WHITE COLOR) ASSY, UPPER CASE (BLOCK COLOR) (VPL-ES4) HEAD, M3 FLAT SCREW (M3X6 LOCK ACE) SCREW, +PWH 3X10 41 42 ! ! (DC) (DC) CIRCUIT BOARD, MAIN (VPL-ES4) CIRCUIT BOARD, MAIN (VPL-EX4) SUB REAR CASE (VPL-EX4) FRONT CASE (VPL-ES4) FRONT CASE (VPL-EX4) FOCUS/ZOOM ADJUST (VPL-ES4) FOCUS/ZOOM ADJUST (VPL-EX4) TAP PH W/FL M3*27L TAP PAN M3*7L EX-HE 4#-40X4+6 STLESS TAP PAN M2*6L PAD,ADJUST FOOT 9-885-114-02 s SWITCH,TACT 1-474-023-11 s POWER SUPPLY BLOCK (BALLAST) 7-682-903-21 7-682-954-01 7-685-645-91 7-621-262-40 7-682-250-09 s s s s s SCREW, +PWH 3X8 SCREW, +PSW 3X25 SCREW +BVTP 3X6 SCREW, +P 2.5X8 SCREW, +K 3X12 7-682-961-01 s SCREW +PSW 4X8 VPL-ES4/EX4 4-3 4-3. Electrical Parts List Ref. No. or Q’ty Part No. 1pc 1pc ! ! SP Description 1-576-233-51 s FUSE (H.B.C) (F601) 1-576-973-11 s FUSE, CYLINDERICAL (F602) 4-4. Packing Materials & Supplied Accessories -------------------SUPPLIED ACCESSORIES -------------------Ref. No. or Q’ty Part No. SP Description 1pc 1pc 1pc 1pc 1pc 1pc 4-4 1-479-775-12 1-832-428-11 2-679-319-01 3-210-513-02 3-100-207-01 ! s s s s s REMOTE COMMANDER (RM-PJ4) CABLE, VGA BAG,CARRY CD MANUAL GUIDE QS MANUAL (JAPANESE, ENGLISH, FRENCH, SPANISH, GERMAN, ITALIAN, SIMPLIFIED CHINESE) ------------ s CORD SET, POWER (See 1-4. Warning on Power Connection) VPL-ES4/EX4 Overall Overall Section 5 Block Diagram IR Receiver IRR5 IRR IRF5 IRF IR Receiver CLK_R LUMA S-Video CHROMA SDA EEPROM Video SCL CVBS WP PC-RIN1 PC-GIN1 PC-BIN1 INPUT B INPUT A Analog RGB Input/Output HSYNC2 VSYNC2 Video Processor & Controller PC-RIN PC-GIN PC-BIN DG[9:0] Audio A/B Audio R LCD Drver RSIG[6:1] SEN SCLK SDATA RGT HST ENB VCK VST DWN PCG DCK1_G DCK1x_G DCK2_G DCK2x_G HCK_G HCKx_G CLK_G DCK1_R DCK2_R DCK1_G DCK2_G DCK1_B DCK2_B DCK[6:1] DCLK DHS DVS PRG FRP VD G LCD Driver GSIG[6:1] RGTx HST ENB VCK VST DWN PCG DCK1x_R DCK2x_R DCK1x_G DCK2x_G DCK1x_B DCK2x_B Audio Input/Output & volume control AUDIO_SW LCDB[11:0] AUDIO_MUT CLK_B 27 MHz AUDIO_VOL1 PRG FRP VD AUDIO_VOL2 AUDIO_O AUDIO_O_ SENi SCLKi SDATAi B LCD Driver DCK1_B DCK1x_B DCK2_B DCK2x_B HCK_B HCKx_B BSIG[6:1] LED[4:1] RGT HST ENB VCK VST DWN PCG RS232 Driver Receiver FG1 Fan 2 Fan 3 Fan 4 Fan4 FG4 Fan 1 Fan5 FG5 Keypad Input I2C_SW FAN_SW SDA SCL Fan2 FG2 Fan3 FG3 RXD P5VC P15VP P12V P5V P15VP P12V P5V P15V Power Control P5VC P135V +3.3V REG P15V P1P8V +1.8V REG P5V P2P5V +2.5V REG P3P3V +3.3V REG P33V +3.3V REG P15VP P2P5V P5V POWER_ON Fan Control Dust_SW EEPROM Dust SW Door SW Door_SW LampLIT LampEN Eco_mode Thermal Thermal Sensor 1 Sensor 2 A[0:21] D[0:15] 32.768 KHz VPL-ES4/EX4 Power Fail DET PWR_fail +3.3V REG V33 Ballast Power Switch ROMOEn RX.DL LED Driver TXD ROMWEn TX.DL B LCD BVCOM BPSIG SEN SCLK SDATA Speaker RS-232 Remote Control G LCD GVCOM GPSIG SEN SCLK SDATA LCD_SCL LCD_SDA R LCD RVCOM RPSIG LCDG[11:0] AUDIO_S AUDIO_M PRG FRP VD RGT RGTx ENB HST VST VCK PCG DWN HCK_R HCK_G HCK_B HCKx_R HCKx_G HCKx_B HSYNC VSYNC HSYNCO VSYNCO AUDIO_O+ Audio out PRG FRP VD LCDRGT LCDRGTx LCDENB LCDHST LCDVST LCDVCK LCDPCG LCDDWN HCK HCK HCK HCKx HCKx HCKx DB[9:0] R_OUT G_OUT B_OUT Monitor Output LCD Timing Generator DR[9:0] HSYNC1 VSYNC1 PC-RIN2 PC-GIN2 PC-BIN2 DCK1_R DCK1x_R DCK2_R DCK2x_R HCK_R HCKx_R LCDR[11:0] Reset IC Flash memory Reset IC 5-1 5-1 P5V +1.8V REG Frame Frame Section 6 Diagram J6 J1 IR SENSOR BOARD 6-1. Frame Schematic Diagram J5 MAIN BOARD CN1 DETECTION SWITCH BOARD (RIGHT) S VIDEO INPUT 1 J14 J4 VIDEO INPUT CN1 DETECTION SWITCH BOARD (LEFT) J9 AUDIO INPUT 2 J18 J8 THERMAL SENSOR BOARD AUDIO A/B INPUT J1 J2 J23 INPUT INPUT A LCD R J1 INPUT J24 LCD G INPUT B 3 J25 J3 LCD B MONITOR OUTPUT J21 FAN2 J10 OUTPUT FAN2 J19 AUDIO FAN3 (REAR BOTTOM) 4 J20 J7 REMOTE FAN4 (REAR TOP) RS-232C J22 FAN1(FRONT BOTTOM) J11 J16 SPEAKER HALOGEN LAMP BALLAST UNIT 5 J17 CN602 CN701 CN601 POWER BOARD 6-1 VPL-ES4/EX4 A B C D 6-1 E F G H SAFETY CHECK-OUT After correcting the original service problem, perform the following safety checks before releasing the set to the customer : Check the metal trim, “metallized” knobs, screws, and all other exposed metal parts for AC leakage. Check leakage as described below. LEAKAGE TEST The AC leakage from any exposed metal part to earth ground and from all exposed metal parts to any exposed metal part having a return to chassis, must not exceed 3.5 mA. Leakage current can be measured by any one of three methods. 1. A commercial leakage tester, such as the Simpson 229 or RCA WT-540A. Follow the manufacturers’ instructions to use these instruments. 2. A battery-operated AC milliammeter. The Data Precision 245 digital multimeter is suitable for this job. 3. Measuring the voltage drop across a resistor by means of a VOM or battery-operated AC voltmeter. The “limit” indication is 5.25 V, so analog meters must have an accurate lowvoltage scale. The Simpson 250 and Sanwa SH-63Trd are examples of a passive VOM that is suitable. Nearly all battery operated digital multimeters that have a 20 V AC range are suitable. (See Fig. A) To Exposed Metal Parts on Set 0.15 μF 1.5 kZ AC voltmeter (5.25V) Earth Ground Fig A. Using an AC voltmeter to check AC leakage. VPL-ES4/EX4 VPL-ES4 (SY) VPL-EX4 (SY) E 9-883-627-01 Sony EMCS Corporation Ichinomiya Tec English 2007DR16-1 ©2007