VPL-ES4/VPL-EX4 Service Manual
Contents
1. 4 2 Electrical Parts Dil unse 4 4 4 4 Packing Materials amp Supplied Accessories 4 4 5 Block Diagram A A Spa nakaiayayaiyaysaawaaqa 5 1 6 Diagram 6 1 Frame Schematic Diagram 6 1 Section 1 Service Information 1 1 Appearance Figure SSS QS SS Lf p A SN A 1 2 Board Locations Main Lamp power supply Thermal sensor Detection switch A 2 gt lt Wa W IR sensor Power 1 1 VPL ES4 EX4 1 3 1 3 1 Disassembly Upper Case Assembly 2 Four claws pr 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 D 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 Bene 9 Remove the upper case assembly from this corner with the 5 4 Two screws strong force to the extent that the upper case assembly will M 3 x6 not be damaged 43 Front case assembly Six EL Two claws Screws 2 Main board connector J6 G r D Lens cap l ee all a aici we mr2. 3 Two tapping screws PAN 3 x 7 5 Tapping screw PAN 3 x 7 Duct lamp H 6 Detection switch board 1 Tapping screw 2 PAN3x7 T as 2 Detection switch board al n cx E A a Rn 4 7 bs Yv FIL IL R al L UL ll 1 3 10 DC Fan Remove the optics section before starting the removal work Two tapping screws PAN 3x 7 2 Duct LCD assembly 6 Two tapping screws M 3 x 25 Em 5 harness 3 Two tapping screws PAN 3 x 10 iT 4 DC fan A 7 DC fan g iZ B 2 ih UNA EL re nl h GU er V 1 i SS SS Et lt VPL ES4 EX4 1 7 1 4 Warning on Power Connection Use a proper power cord for your local power supply The United States Continental UK Ireland Japan Canada Europe Australia New Zealand Plug type VMO233 2908 YP 42A_ YP332 Connector type VM0089 386A YC 13B COX 02 VM0310B YC 13 See FEH were Rated Voltage Current 10A 125V 10A 125V 10A 250V 10A 250V 10A 250V 7A 125V Cord length max 4 5m 14 feet 9 inches 1 Use an appropriate rating plug which is applied to local regulations 1 8 VPL ES4 EX4 Section 2 Electrical Adjustments TeustIs
3. Fig A Using an AC voltmeter to check AC leakage VPL ES4 SY English VPL EX4 SY E sony EMCS Corporation 2007DR16 1 9 883 627 01 Ichinomiya Tec 2007
4. LCDR a 24 LCD G 5 LCD B 1 11 FAN2 FAN2 9 FAN3 REAR BOTTOM FAN4 REAR TOP FAN1 FRONT BOTTOM HALOGEN LAMP CN602 I CN601 POWER BOARD VPL ES4 EX4 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 Acommercial leakage tester such as the Simpson 229 or RCA WT 540A Follow the manufacturers instructions to use these instruments A battery operated AC milliammeter The Data Precision 245 digital multimeter is suitable for this job 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 low voltage 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 AC voltmeter 5 25V Earth Ground
5. Computer only Computer only Cominan weenie Only Speaker u H EEPROM Status memory W B memory Channel Memory Common Memory CPU RAM 2 5 Memory structure of this model consists of the followings Set memory Status memory Picture memory Chroma memory W B memory ON BW NY ra 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 memo ry 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 3 1 Electric Troubleshooting Connect the Power No System Stan
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8. 701L 1 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 D Two tapping screws PAN 3 7 R 2 Two claws 3 Remove the lamp box assembly in the 9 Four screws direction of the arrow 9 P 2 5 x 8 4 Gasket zen 6 Two tapping screws PAN 3 x 7 gt x 5 Harness Optucs section Focus Zoom adjust assembly 2 Y AN GES zem Assembling Method of Optucs section and Focus Zoom Adjust Assembly Phase matching 17 Rotate the Zoom dial clockwise During the assembling process as shown until it is stopped never change the gear position 9 Install the Optucs section that is set by step 3 in the Lower Case 12 Rotate the Focus dial counter clockwise as shown until it is stopped Focus dial Adjust Assembly as shown m Install the Focus Zoom 43 Rotate the Focus dial Lower case counter clockwise as shown until it is stopped 2 After installation is completed verify that the Optucs section can rotate from the position A to the position smoothly Rotate the Focus Zoom Adjust Assembly counter clockwise until it is stopped 9 1 6 VPL ES4 EX4 1 3 9 Detection Switch Board Remove the optics section before starting the removal work
9. 885 114 33 2 895 113 97 9 885 114 09 9 805 113 98 9 005 114 10 2 681 547 02 2 b551 550 01 2 001 904 04 001 593 01 9 885 114 32 2555s 113990 2 895 113 39 4 612 859 11 3 910 696 11 2 5005025 01 9 885 114 02 1 474 023 11 1 002 715 21 1 682 954 01 7 685 645 91 1 621 262 40 1 682 250 09 1 082 961 01 VPL ES4 EX4 SP Description FUSE CYLINDERICAL F602 FUSE H B C F601 THERMOSTAT DOOR DETECTION SWITCH BOARD FAN DC AXIAL FAN UNIT FAN DC FAN DC DC FAN DC DC MOUNTED CIRCUIT BOARD MAIN VPL ES4 MOUNTED CIRCUIT BOARD MAIN VPL EXA MOUNTED CIRCUIT BOARD IR SENSOR MOUNTED CIRCUIT BOARD THERMAL SENSOR MOUNTED CIRCUIT BOARD POWER SPEAKER LAMP DOOR DOOR FILTER MESH FILTER ASSY LAMP BOX ASSY FOOT ADJUST RUBBER FOOT ADJUST LENS CAP VPL ES4 LENS CAP VPL EX4 MYLAR BALLAST LOWER CASE ASSY SUB REAR CASE VPL ES4 ASSY SUB REAR CASE VPL EX4 ASSY FRONT CASE VPL ES4 ASSY FRONT CASE VPL EX4 ASSY FOCUS ZOOM ADJUST VPL ES4 ASSY FOCUS ZOOM ADJUST VPL EX4 SCREW TAP PH W FL M3 27L SCREW PAN M3 7L SCREW EX HE 4 40X4 6 STLESS SCREW TAP PAN M2 6L RUBBER PAD ADJUST FOOT ASSY UPPER CASE WHITE COLOR ASSY UPPER CASE BLOCK COLOR VPL ES4 HEAD M3 FLAT SCREW M3X6 LOCK ACE SCREW PWH 3X10 SWITCH TACT POWER SUPPLY BLOCK BALLAST SCREW PWH 3X8 SCREW PSW 3X25 SCREW BVTP 3X6 SC
10. REW P 2 5X8 SCREW K 3X12 SCREW PSW 4X8 Overall 4 3 4 3 Electrical Parts List 4 4 Packing Materials amp Supplied Accessories Ref No or Q ty Part No SP Description Ipc 1 576 233 51 s FUSE H B C 860 PE NT 1 576 973 11 s FUSE CYLINDERICAL F602 EN or Q ty Part No SP Description Ipc 1 479 775 12 5 REMOTE COMMANDER RM PJA Ipc 1 832 428 11 s CABLE VGA Ipc 2 679 319 01 s BAG CARRY Ipc 3 210 513 02 s CD MANUAL 5 1 6 3 100 207 01 s GUIDE QS MANUAL JAPANESE ENGLISH FRENCH SPANISH GERMAN ITALIAN SIMPLIFIED CHINESE lpc S CORD SET POWER See 1 4 Warning on Power Connection 4 4 VPL ES4 EX4 Overall Overall Section 5 Block Diagram IR Receiver IRR5 p IRR DCK1 R IRF5 gt IRF LCDR 11 0 IR Receiver LUMA S Video a N CHROMA N SDA LCDRGT R LCDRGTx EEPROM LCDRGT LCD Video CVBS LCDHST LCDVST WP PC RIN1 HSYNC1 DRI9 0 VSVNCI HCKx G Video Generator HCKx_B PC RIN DCK1_G PC RIN2 EC GIN LODGI1 O DOKIX G PC GIN2 Analog RGB PC BIN DCK2_G PC BIN2 Input Output Controller DCK2x_G INP
11. SONY DATA PROJECTOR VPL ES4 VPL EX4 REMOTE COMMANDER RM PJ4 SERVICE MANUAL 1st Edition ABS VE Y EXENTOS BERN Wiehe NK PRT MUR BEER ERTS ERB IK IX AHEHKORNAZENBOET 192570 PEARL TASEVIERNEDATER lt S FAV A 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 A WARNUNG Die Anleitung ist nur f r qualifiziertes Fachpersonal bestimmt Alle Wartungsarbeiten d rfen nur von qualifiziertem Fachpersonal ausgef hrt 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 d rfen nur von Personen ausgef hrt werden die eine spezielle Bef higung dazu besitzen A AVERTISSEMENT Ce manual est destin uniquement aux personnes comp tentes en charge de l entretien Afin de r duire les risques de d charge lectrique d incendie ou de blessure n effectuer que les r parations indiqu es dans le mode d emploi moins d tre qualifi pour en effectuer d autres Pour toute r paration faire appel une personne comp tente uniquement zus 974 7 SSW L 166 WADIEMNAD ARABI Ho 2
12. TE 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 l l Appe san Fever 1 1 1 2 Board Locations cocinados 1 1 I IG 1 2 1 3 1 Upper Case Assembly 1 2 1 3 2 Front Case Assembly and Sub Rear C ase Assembly 1 2 1 3 3 Main 1 3 1 3 4 Tunnel Outlet Seelen san 1 4 1 3 5 Main Board Bracket Section 1 4 1 3 6 Lamp Power Supply 1 5 1 3 7 e 1 5 1 3 8 PUES SE LION 1 6 1 3 9 Detection Switch Board 1 7 DC A ee 1 7 1 4 Warning on Power Connection 1 8 2 Electrical Adjustments 2 1 Initial Values of Adjustment Items 2 2 2 O A 2 5 3 Troubleshooting 3 1 Electric Telleren DR ERE ra 3 1 3 2 Power Board Troubleshooting 3 3 3 2 1 Plo e ici 3 3 3 2 2 Failure of Turn on Lamp 3 4 VPL ES4 EX4 4 Spare Parts 4 1 Notes on Repair Parts 4 1 4 2 Exploded Views
13. UT A HSYNC HCK_G HSYNC2 VSYNC HCKx_G VSYNC2 PRG G GSIGI6 1 Driver GVCOM G GPSIG LCD Monitor LCD_SCL SDATA HST HSYNCO LCD_SDA ENB Output VSYNCO Audio A B AUDIO_S And AUDIO SW udio me AUDIO_VOL1 27 MHz AUDIO_O control AUDIO_VOL2 B Audio out AUDIO O AUDIO O SEN LCD SCLKi BGT HST LED 4 1 OWN PCG RS 232 TX DL RS232 TD Driver Remote RX DL Driver RXD Control Receiver Keypad 3 3V yp V33 lt lt I lt P5VC Input REG P15VP d FG1 GC SW PWR fail Power 0 P15V lt lt lt P15VP P2P5V 1 8V N Fail DET P5V P5VC lt lt P5V REG V N Fan2 T 56 Fan 2 FG2 POWER_ON Nu A P135V lt lt a lt P15V N Fan3 Dust_SW Fan 3 FG3 Fan Control EEPROM Dust SW ik 2 Door SW Door SW 7x Fan4 P1P8V lt lt lt P5V Fan 4 FG4 EM ru Power Lamp P5V ow ans Eco_mode P2PSV lt lt 32 768 KHz 5 A PaP3V lt lt II Thermal Thermal memory P33V lt lt Sensor 1 Sensor2 ROMWEn ROMOEn VPL ES4 EX4 5 1 5 1 6 1 Frame Schematic Diagram VPL ES4 EX4 A Section 6 Diagram MAIN BOARD I J2 4 I J gell J 3 J10 J7 I 11 SPEAKER I l kur D Frame I 5 I 6 1 c m Frame IR SENSOR BOARD CN1 DETECTION SWITCH BOARD RIGHT d 4 CN1 DETECTION SWITCH BOARD LEFT ei 8 THERMAL SENSOR BOARD I N
14. dby Yes Power projector No Lamp ON Yes Yes System shut down And cooling No Yes No Yes Picture quality No good No VPL ES4 EX4 Section 3 Troubleshooting Check the LED Message and find error Check lamp door dust door Check the power board out voltage 5V Change main board check the Ballast power and control signal wire Check lamp door status Check lamp status Check the LED message and find error Check the Fan status or Thermal sensor status Check the lamp door or dust door The picture is full white pattern please check the LCD panel connector The picture is full black pattern please check the LCD driver on the main board Check the system status Is system in burn in mode The picture a little green blue red please check the LCD panel connector The picture has dust please check the lens The picture flicker please alignment again 3 1 3 2 No No Picture has Yes Check the vertical bar color and find the Vertical bar LCD panel connector Then check the pin of connector No IR remote control 1 Please check the OSD setting No good 2 Check the front IR board Audio function is No good 1 Check the OSD setting 2 Check the speak wire VPL ES4 EX4 3 2 Power Board Troubleshooting 3 2 1 No Power Replace Q601 and F601 with new ones and then put powe
15. efore specified parts should be used in the case of replacement WARNHINWEIS Les composants identifi s par la marque A sont critiques pour la s curit Ne les remplacer que par une pi ce portant le num ro sp cifi 2 Standardization of Parts Some repair parts supplied by Sony differ from those used for the unit These are because of parts common ality 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 Dia grams Electrical Parts List and Exploded Views unless otherwise specified Capacitors UF Inductors UH Resistors po VPL ES4 EX4 Overall 4 2 Exploded Views He HI 0 K 3x12 an K 3x12 4 2 VPL ES4 EX4 Pee E BBB Part No 1 576 973 11 15810 222 21 1 576 974 11 1 789 603 11 9 885 1 14 11 9 085 114 12 1 187 496 11 1 787 496 21 9 805 114 05 9 885 114 07 1 789 543 11 1 789 544 11 9 885 114 04 9 885 114 06 E 11 E ER 2 610 067 01 2 615 465 01 2 595 113593 9 895 113 94 2 005 112 95 9 885 114 08 9 885 114 34 2 895 113 90 9 885 114 00 9
16. ol re MILI ui LEE a d AL 4 JA priest Ar Ek U am Ly 7 Two screws K 3x 12 3 IR sensor board VPL ES4 VPL EX4 connector J1 Zeh Sub rear case Remove the upper case assembly from this corner with the Sub rear case gt assembly strong force to the extent that the upper case assembly will assembly not be damaged Front case assembly VPL ES4 EX4 1 Speaker harnesses 1 2 1 3 3 Main Board Remove the front case assembly and sub rear case assembly before starting the removal work D five screws T M 3 x 6 Main board bracket section Pr 2 Remove the main shield in the direction SY of the arrow Main shield AA SP 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 Y y X O Harnesses clamp section 3 Main board Lamp box assembly When re assembling give an appropriate amount of extra slack J14 J20 J19 J21 J22 of this harnesses J25 Main board J24 Radiation sheet J18 J6 Main board VPL ES4 EX4 1 3 1 3 4 Tunnel Outlet Section Remove the front case assembly and sub
17. r board into set If Q601 damages again check if other parts are shorted Check if 15 25V or 12V exist If any voltage is wrong replace IC701 or T602 with new ones VPL ES4 EX4 Yes Q601 D S Short No Output 5V DC exists Yes No Voltage outputs shut down and built repeatly Yes No Check LED circuit of main board Check if CN701 inserted properly Check if miss to solder any SMD type of components Check if D602 or IC602 is broken if yes replace it with now one 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 No Lamp Yes Broken No Control Pin SCI is normal No Check main board Yes Replace ballast with new one 3 4 Replace lamp with new one VPL ES4 EX4 Check if there is On Off signal Check mian board Check if 18V exists at c terminal of Q603 No Yes Yes F602 Open No Q602 works normally No Check ZD602 R655 and R656 VPL ES4 EX4 Check 0701 IC604 Q604 Q603 or ZD603 And then replace broken parts Replace F602 with new one Section 4 Spare Parts 4 1 Notes on Repair Parts 1 Safety Related Components Warning Components marked A are critical to safe operation Ther
18. rear case assembly before starting the removal work D Two tapping screws dii PAN 3 x 7 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 Harnesses Sl E lt gt NT lt p 2 E 1 Se gt TIE NAAA qe DS d i nv t gt i 8 rane B a gr J A E x 7 L EAS da y 5 fr MTOR 47 C E Laj haf CEIF D _ _ Harnesses clamp section 1 3 5 Main Board Bracket Section Remove the main board before starting the removal work 4 Power board 2 Three tapping screws PAN 3 x 7 ____ 0 Two screws T M 3 x 6 pe Main board bracket section Ln el w ee 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 3x8 6 Remove the lamp power supply connector in the direction of the arrow A Connector P1 7 Remove the lamp power supply in the direction of the arrow From the Main board CN602 Red and Black wires 2 Lamp door 1 3 7 Power Board Remove the main board bracket section before starting the removal work 1 Two stand assemblies Power board CN
19. s B VPL ES4 EX4 PC PC PC PC PC P1 4 CXD9809 page4 P2 Fan Control P3 1 7005 1 VPL ES4 EX4 PC Mid Bias B Video Mid Gain R Video Mid Gain G Video Mid Bias B Temperature 1 Display only Mid Bias G Temperature 2 Display only Temperaue3 2 NA Display onl Burn InCycle 2 3 temName Se R s P3 2 CXA7005 page2 P4 ADC Calibration Color NENNEN Bias GNormal 122 TI Bias BNormal 122 Bias R Fip 122 Bias GFip 122 Bias BFip 122 Vcom R Normal 88 VcomG Normal 88 Vcom B Normal 88 Vcom RFlip 88 VcomGFlip 88 VcomBFlip 12980 RGB Calibrate ILL YUV Calibrate RGBOfset _ 14 22 164 99 105 X 98 YUVOfset LL 14 22 164 98 105 _ 98 DataReset 1 Hard Reset 0 SOG Threshold P6 2 4 VPL ES4 EX4 2 2 Memory Structure Video S Video Picture Input A u L Input B Component Other than Computer Channel Component Video GBR other than computer Computer only Computer only Common Only Speaker mu FLASH ROM VPL ES4 EX4 Video Svideo ____ 03 05 mine anbauen 5 S Video T Input A memory Input B Component Computer W B memory Other than Computer Channel Component Video GBR other than computer
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