Data Projector

EMP-7700

EMP-7700

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Chapter 1 Product general

1.1. PRODUCT GENERAL ............................................................................ 1-2 1.2. PART NAME ........................................................................................... 1-3 1.2.1. Outside View of Main Frame ........................................................... 1-3 1.2.2. Inside view of main frame................................................................ 1-6 1.2.3. Outside View of Remote Controller ................................................. 1-7 1.3. SPECIFICATIONS .................................................................................. 1-8 1.3.1. Main unit specifications ................................................................... 1-8 1.3.2. Accessory specification ................................................................... 1-9 1.4. INTERFACE SPECIFICATION ............................................................. 1-11 1.4.1. Computer 1 Analog (The picture input of analogue RGB from Computer)...................... 1-11 1.4.2. Computer 1 Digital (Digital RGB video input from computer) interface.......................... 1-12 1.4.3. Audio 1 (The voice input from computer) ...................................... 1-13 1.4.4. Audio Out ...................................................................................... 1-13 1.4.5. Monitor Out.................................................................................... 1-13 1.4.6. S-Video.......................................................................................... 1-13 1.4.7. Video In / Audio L/R ...................................................................... 1-14 1.4.8. Mouse / Com 1/2 ........................................................................... 1-14 1.4.9. Remote.......................................................................................... 1-15 1.4.10. Control (RS-232C)....................................................................... 1-15

Chapter 2 Theory of operation

2.1. Hardware Configulation .......................................................................... 2-2 2.1.1. Process Outline ............................................................................... 2-3 2.1.2. Electrical System............................................................................. 2-4 2.1.3. Optical System Connections (Optical Engine) ................................ 2-4 2.2. Safety switch.......................................................................................... 2-6 2.3. Power Supply Unit .................................................................................. 2-7 2.3.1. Power supply unit circuit block ........................................................ 2-7 2.4. Ballast unit ............................................................................................ 2-10 2.5. Main Board Assy Unit ........................................................................... 2-12 2.6. Driver Board Assy ................................................................................. 2-18 2.7. IF Units.................................................................................................. 2-21 2.8. RC Receptor Board Assembly .............................................................. 2-24 2.9. Speaker Unit ......................................................................................... 2-25 2.10. Light Guide Unit .................................................................................. 2-26 2.11. Lamp Inner Housing............................................................................ 2-28 2.12. Sensor / Switch ................................................................................... 2-32 2.12.1. Lamp cover sensor switch........................................................... 2-33 2.12.2. Safety Switch............................................................................... 2-34 2.12.3. Thermistor and temperature sensor operation ............................ 2-34 2.13. Fan Operation ..................................................................................... 2-36 2.14. LED indicator ...................................................................................... 2-39 2.15. Operation Panel (Upper Case Unit) .................................................... 2-40

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Chapter 3 Disassembly and assembly

3.1. DISASSEMBLY AND ASSEMBLY PROCEDURES .............................. 3-2 3.2. DISASSEMBLING THE MAIN UNIT ....................................................... 3-5 3.2.1. Disassembly flow chart.................................................................... 3-5 3.2.2. Lamp Cover Unit ............................................................................. 3-6 3.2.3. Lamp Inner Housing ........................................................................ 3-7 3.2.4. Upper Case Unit.............................................................................. 3-8 3.2.5. Main Board Assembly Unit / Speaker Unit ...................................... 3-9 3.2.6. Front Case..................................................................................... 3-10 3.2.7. Middle case L unit ......................................................................... 3-10 3.2.8. Middle case L2 unit ....................................................................... 3-11 3.2.9. IF unit/Ballast unit.......................................................................... 3-12 3.2.10. Thermistor LAMP ........................................................................ 3-14 3.2.11. Safety Switch............................................................................... 3-14 3.2.12. Optical Engine ............................................................................. 3-15 3.2.13. Auxiliary Duct Unit / Lamp Fan Unit ............................................ 3-15 3.2.14. Intake Fan/Exhaust Fan .............................................................. 3-16 3.2.15. Projection Lens assembly ........................................................... 3-17 3.2.16. Replacing the attachment lens .................................................... 3-18 3.2.17. Middle case R unit....................................................................... 3-19 3.2.18. Exhaust duct unit......................................................................... 3-20 3.2.19. Power supply unit ........................................................................ 3-20 3.2.20. Lower case unit ........................................................................... 3-21 3.2.21. Foot unit ...................................................................................... 3-21

Chapter 4 Troubleshooting
4.1. Before Starting Troubleshooting Procedures.......................................... 4-2 4.1.1. Tools and Accessories Required for Troubleshooting..................... 4-2 4.1.2. Field Replacement Parts ................................................................. 4-2 4.2. Entry........................................................................................................ 4-3

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INTRODUCTION
This Service Manual contains hardware information which is necessary for smooth field servicing of the ELP-7700 XGA data projector. Information on main technological changes are provided in the Technical Information releases, and so you should use them to update this manual periodically.

HOW TO USE THE SERVICE MANUAL

Since the service manual describes the topics which may be required in the field maintenance, you may utilize this for repair or diagnosis of failures. The contents are as following. Before you start the maintenance service, read every safety precautions and observe safety precautions and observe safety rules. precautions : SAFETY,MAINTENANCE,PERSON chapter 1 : GENERAL (PART NAME, CONNECTION, SPECIFICATION, etc...) chapter 2 : THEORY OF OPERATION (HARDWARE CONFIGURATION, FUNCTION OF UNITS, etc...) chapter 3 : DISASSEMBLE & ASSEMBLE (DISASSEMBLY PROCESS FOR MAIN UNIT) chapter 4 : TROUBLE SHOOTING PARTS LIST, EXPLODED DIAGRAM

VCCI RADIO FREQUENCY INTERFERENCE SELF RESTRICTION

This product is the type 1 information equipment and uses radio frequency energy and fully complies with the limits for the specifications in the computer information equipment radio interference regulation (VCCI rules). If not installed and used properly manufacturer's instructions, may cause interference to radio and television reception.

TRADEMARK
IBM and DOS/V are the trademark or the registered trademark of International Business Machines Corporation. Macintosh and Power Book are the registered trademarks of Apple Computer Inc. Windows is the trademark of Microsoft Corporation. EPSON is the trademark of SEIKO EPSON CORPORATION.

NOTICES
1.This document should not be reproduced in whole or in part without the written permission of SEIKO EPSON CORPORATION. 2.Any of description in this document is the subject to change without notice in future. 3.The information and specification in this document are the most up-to-date at the time of publication. However, we are unable to guarantee the accuracy of printed material after the date of publication. In case of any mistake or lack of description, please kindly notify us to correct. 4.Any influence by utilizing the document may be out of our responsibility regardless the item 3 above. 2000 SEIKO EPSON CORPORATION

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Record of Revisions
History REV.A REV.B Issued Date 2000.9.1 2000.10.18

Alternation

Memo Random
Free area to memorize any important technical information here.

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PRECAUTIONS
1. MAINTAIN THE SAFETY OF OPERATORS
(1). PROTECTION FROM ELECTRIC SHOCK *Whenever doing any repair work on the product, be sure to turn off the power and remove the electric power cable from the electrical outlet. * Whenever inevitably turning the power on to the product opening the case or cover (repair process) be sure to take off any metallic materials such as a watch, cuffs, rings, and tie pins which may touch the metallic part of the product and dangerous of electric shock. (2). PROTECTION FROM ACCIDENTAL INJURYOBSTACLES * Be sure not to touch the lamp inner housing and its circumstances after the power is turned off, they may be heated up even after the cooling down process was ended. Also make sure not to touch the fan during the operation of repair as turning the power on. * Make sure to protect your hands by gloves from sharp edges during assembly and disassembly. * Do not look into the lens while the lights is on. Protect eyes from being damaged. (3). PROTECTION FROM ACCIDENTS * Any operation should be done while the device placed on a flat and stable place to prevent the device or parts from being dropped. Be careful not to place tools and parts on the device or at your feet. * Whenever doing any repair work on the product, be sure to away from a place for foreigner come across in order to prevent the product from being used in incomplete condition or accidental near miss. Be sure not to leave the product during any repair work. * Be sure to use attached power cable when you supply the power to the product.

2. SAFETY MAINTENANCE
(1). ELECTROSTATIC DISCHARGE * Whenever doing any repair work on the product, be sure to wear the wrist band and the electrostatic mat with grounding. When replacing any electric components (Boards and Optical engine), it is recommended to touch the electrostatic plastic bag of the component to the metallic part of the product once before take the component out from the plastic bag. (2). LIMITATION OF PARTS * Use only authorized or supplied parts from EPSON for the replacement of mechanical parts including the lamp inner housing, air filter and so on. * Use only the power cable and the interface cables attached with the product. (3). Others * Visually check the distortion or dirt at the connectors of the power cable. If dirty, clean off, and if distorted, replace the cable in order to avoid firing by the flush over phenomenon. * When plug the internal connector cables or the interface cables, be sure to fully plug into the connectors until it stack to the connector edge. * When remove the FPC cable be sure to remove the connector lock in advance. When remove the cable on the CN/003/1800 of the Main board assembly unit or CN700~702 of the Driver Board Assy, the connector lock should be unlocked by pulling up the both end of connector lock simultaneously with tweezers. * Whenever doing removal of parts or repair work on the product, make sure that the work is done in a clean room, free of dust and dirt in order to keep the optical element away from dirt.

3. OTHERS
*The hardware of the RS-042UG is basically the same as that of the RS-042 except some components. Consequently, this manual basically describes the hardware of the RS-042. Differences between these two units are explained in this manual as comments. * Any questions on the EMP-9000/8000LCP maintenance including supply of the service parts

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or contents of the document would like to be contacted to the below address. Any technical information about amendments is occasionally available as the service bulletin. SEIKO EPSON CORPORATION 4897 SHIMAUCHI, MATSUMOTO-SHI, NAGANO-KEN 390-8640 JAPAN ATTN: Visual Device Customer Support Group

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Chapter 1 Product general

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1.1. PRODUCT GENERAL

EMP-7700 MULTIMEDIA PROJECTOR designed as the new model of projector is the brightly with new optical engine to project enhanced color images from the personal computers CRT and any one of video equipment such as video tape deck, video camcorders or digital camera.

FEATURE OF EMP-7700
Bright and clear Flexible projection image size The big caliber zoom lens, and the new type of high brightness lamp (class No.1) and the optical block(220W uHra high efficiency lamp) enable to achieve a wide projection image from 30" to 300" (projection distance : 1.07 to 11.35 m). EMP-7700 : 3000ANSI lm High resolution full color (16770 thousands colors) EMP-7700(XGA): 3(R,G.and) of TN liguid crystal panels of 786.432 pixel supply approximatly 2.3 million (1024x768x3) dots. The signal to VGA~UXGA is able to be projected full screen with the adoption of Epson original image compression technology DAR (Digital Active Resizing). Standard attachment of remote controller The projector can be controlled using a handheld remote control unit, with menus being provided for Image source switching and Image adjustment. The remote control can also be used as a wireless mouse to control mouse operations on the computer screen during presentations. The EMP LINK V software that combines as a standard accessory of product. Connectivity with various computers The advanced data signal determination function Standard attachments of interface cables and adapters enables EMP-7700 to connect with various computers such as IBM-compatible PCs and laptops, Macintosh. Almost all of the video signals are available for this. Keystone collection by digital processing and optical lens shift. Contract a upper /lower part of image with smoothing function. The projector for supporting of miscellaneous computer (DOS/V, Mac, PC98) output. No matter what type of output is used, the result is video image of outstanding clarity. Simple Maintenance The maintenance easy. Number of image adjustment process is not required. Celing mount (option part)
Table 0-1The projector can be fixed to the celing.

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1.2. PART NAME

1.2.1. Outside View of Main Frame
Operation Panel Upper Case

Remote control receiver Lens cover

Foot adjust lever Front foot

Lower Case

Figure1-1 Front side view

Video buton Menu buton Computer buton Esc buton Help buton

Power buton Tracking buton

Sync buton A/V Mute buton

Resize buton

Shift buton

Volume buton

Figure1-2 Operation panel

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Computer1 (Digital) Computer 1 Signal Select switch Computer1 (Analog)

Monitor Out BNC S-Video Audio (Computer1) Composite Video Audio Out L-Audio-R

Mouse1

Remote Control(RS-232C)

Mouse2

Figure1-3 Interface panel

Operation panel

Power inlet

Figure1-4 Main projector unit (left side)

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Remote control receiver

Lamp case

Foot Rubber

Figure1-5 Main projector unit (back)

Handle

Figure1-6 Main projector unit (right side)

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1.2.2. Inside view of main frame

Switch board Projection panel

RC receptor Speaker L

Speaker R

IF unit

Main board assy unit

Safety switch

Thermistor, Lamp

RC receptor board assembly Lamp cover sensor switch

Figure1-7

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1.2.3. Outside View of Remote Controller

(Front)

(Back)

Inside of cover

Figure1-8 Remote controller

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1.3. SPECIFICATIONS
1.3.1. Main unit specifications
Table 1-1
OPTICAL FEATURES Display method Optical method Projection image size Projection distance Liquid crystal screen /Drive system Pixels Focal Lens Focus adjustment Zooming adjustment Keystone correction ratio Light Source Life(Lamp inner housing) SPECIFICATIONS Transparency type poly-silicon TFT color liquid crystal display (R/G/B three panels) Dichroic mirror separation and prism combine method 28 inch ~ maximum 300 inch (Wide angle), 21 inch ~ 230 inch (Tele angle) 1.07m~11.35m Poly-cilicon TFT (MLA built in) 1.3inch (Diagonal) EMP-7700 :Full lines, 12phase block series EMP-7700 :786432x3 (1024x768x3) Manual Zoom lens F1.7-2.3 (49~63 mm) Manual Manual(1:Approx1.3)/E zom by remote control(1:Approx4) 10(Upper) :0(Lower) ~ 5:5 optical axis discharge lamp A.C. drive UHE (Ultra High Efficiency Lamp) lamp 200W Life 1,500 hours (Light 50% or the survival rate 50%) EMP-7700 :3000ANSHm Typ.85% Dynamic speaker(3W-8) x 2 speaker 3D stereo sound: 50~18000Hz, S/N 85db External speaker 3.5mm Stereo mini-jack Internal speaker output is stopped when mini-jack is plugged. Output signal:0 to 500mvrms land imperdance:600 Audio signal(stereo) from the video devices. Input interface is separated with R(Right) and L(Left). Interface type:RCA jack Input signal:500mvVrms / 47K Computer 1 Audio input (stereo) Interface type:3.5mm Stereo mini-jack Input signal: 500mVrms/47K

Brightness AUDIO FEATURES Average brightness uniformity Output for internal speaker Audio out Interface

Audio interface (L/R) x2 (S Video /Video )

Audio (Computer 1)

Audio 2(L/R) interface REMOTE CONTROL Wireless remote controller

Remote interface

For controlling EMP-7700 operating mode and controlling host computer from EMP-7700. Signal is detected with internal receptor board. Control range: Within 10 m and 30 degree (Left / Right), 15 degree (upper /Lower) wide from receptor . For conect to optional remote control receiver (EMPST02) Interface type : 3.5mm Stereo mini-jack (The function of Receptor board is stopped when mini-jack is plugged) Host computer RGB output (0.7Vp-p 75/ Mac 0.714Vp-p 75)

VIDEO INPUT/OUTPUT Computer 1 interface Analog (input) Computer 1 interface Digital (input)

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Table 1-1
Conputer2 RGB/Component video input This terminal is work as RGB Video and compornent Video interface (R/cr/Pr, G/Y, B/Cb/Pb, H/CStnc, input terminal as well, I can switch on OSD menu. (Default VSync) :RGB) Input signa :Analog RGB Standard level (0.7Vp-p, 75,Negative synchronous0.3V) Interface Typ :BNC Jack Monitor OUT interface (output) EMP-7700 RGB output Interface type: HD-15pin(DDC1/2B correspondence) S-Video Interface Input signal: Luminous 0.714Vp-p,Chrominous 0.28Vp-p. Interface type: Min-DIN 4pin S-Video is prior to composite video. Video IN Interface Input signal: 1.0Vp-p,sync.negative 75 (Composite video interface) Interface type: RCA jack (yellow) TV signal type: NTSC carrier frequency :3.58MHz(4.43MHz) PAL carrier frequency :4.43MHz(3.58MHz) SECAM carrier frequency :4.43MHz Auto identification(Default) MOUSE Serial Mouse USB Mouse PS/2 Mouse ADB POWER SUPPLY Input Voltage Power Consumption Dimensions Weight Mechanical Function Foot Adjuster Tilt Angle Theft-proof Nut for celling ENVIRONMENT Operational/storage temperature Operational/storage humidity Operational/storage Altitude Mouse/Com1, Mouse/Com2 Auto identification (Mouse) Interface type: DIN 13pin Control RS-232C D-sub9 AC100-120V /220-240V10% (50/60Hz) Approx. 360 W (Standby :6w) Conform to energy star program. 278 mm (W) x 153 mm (H)x 401 mm (D) (Include lens and foot) Approx. 6.9 kg Quick-release and fine adjustment machanism. 0~+12 Arranges holds to install Kensington Lock on lower case. For of muts are prepaired onthe Bottom case to fix a product to celling. +5C~+40C / -10C~ +60C (non condensing) 20%~ 80% / 10%~ 90% (non condensing) 3048m / 6096m

1.3.2. Accessory specification

Remote Control Design Dimension Weight Number of Button Pointer Battery Battery Life Transmission Directivity Stick type 165 x 48 x 35 mm 70g (except battery) 24 (operating button 22 + mouse button 2) Malti-polarized switch methode Alkaline LR6 <AA> x2 Over 3 months (1 hour use per day) Right / Left:20 Upper / Lower:20

Power cord 3.0m <10ft>.Prepares it with ground for each sales branches. Computer cable Mini D-Sub15pin type : 1.8m <6ft>, HDsub-15pin type. 5 BNC type : 1.8m <6ft>, Conversion from HDsub-15pin to BNC.

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Audio cable 1.8m <6ft>, 3.5mm stereo mini type. Video/Audio cable 1.8m <6ft>, RCA plug type, 3cables.(yellow) 1cable 1.8m <6ft>, RCA plug type, 3cables.(red,white) 2cable Mouse cable set PS/2 Mouse cable set,1.8M<6FT>, Mini DIN 10pin - Mini DIN 6pin, x1 USB Mouse cable set,1.8M<6FT>, Mini DIN 10pin - USB 4pin, x1 Battery Simple 3 Alkaline LR6 <AA> x2.

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1.4. INTERFACE SPECIFICATION

Figure1-9

1.4.1. Computer 1 Analog (The picture input of analogue RGB from Computer)
HD D-SUB 15

5 10 15

1 6 11

Pin 1 2 3 4 5 6 7 8

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

Pin 9(None) 10 11 12 13 14 15

Terminal (Pin is not exist) Synchronous GND Monitor (ID bit 0) SDA Horizontal synchronization Vertical synchronization SCL

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1.4.2. Computer 1 Digital (Digital RGB video input from computer) interface

1 9 17

8 16 24

Pin 1 2 3 4 5 6 7 8 9 10 11 12 Data 2Data 2+ GND Reserved Reserved DDC Clock DDC Data No Connect Data 1Data 1+ GND Reserved

Terminal 13 14 15 16 17 18 19 20 21 22 23 24

Pin Reserved +5V Power GND Hot Plug Det Data 0Data 0+ GND Reserved Reserved GND Clock+ Clock-

Terminal

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1.4.3. Audio 1 (The voice input from computer)

3.5mm Stereo mini jack
6 5 4 3 2 7 8 9 1

1 pin: GND 2 pin: Computer audio input L 3 pin: Computer audio input R The other pins: NC

1.4.4. Audio Out

3.5mm Stereo mini jack

1,6~9 pin: GND 2 pin: Audio output L 3 pin: Audio output R 5 pin: Detection of Line-out jack insertion The other pins: NC

1.4.5. Monitor Out

5 10 15 1 6 11

Pin 1 2 3 4 5 6 7 8

Signal R Out G Out B Out Reserved GND GND GND GND

Function Red video Green video Blue video

Pin 9 10 11 12 13 14 15

Signal Reserved GND Reserved Reserved H sync V sync V sync

Function

Horizontal sync. Vertial sync.

1.4.6. S-Video
S-terminal input Mini DIN 4-pin
1,2,6 pin: GND 3 pin: Y signal input 4 pin: C signal input 5 pin: Input detection terminal
5

4 2

3 1

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1.4.7. Video In / Audio L/R

RCA Gold plating (only insertion part), Light angle H=15mm, Color: yellow

Video in
2

Audio L
3 4 5

Audio R
6 7 8

1 pin: GND 2 pin: Video input 3 pin: GND 4 pin: Audio R return 5 pin: Audio input L 6 pin: GND 7 pin: Audio L return 8 pin: Audio input R

1.4.8. Mouse / Com 1/2

Multi-mouse jack 10-pin jack
1 3 6 9 4 7 10 2 5 8

Signal meanings are different according to the operation mode.

Pin PS/2 Mouse Reserved GND Reserved Reserved Reserved GND Reserved Reserved DATA CLK USB Mouse Reserved GND DD+ Reserved Reserved Reserved Reserved Reserved Reserved ADB Mouse +5V GND Reserved Reserved GND Reserved Reserved Reserved Reserved ADB Serial Mouse DTR GND Reserved Reserved GND GND RTS RD Reserved Reserved Serial (Cross) Mouse Reserved TD RD DSR GND DTR Reserved Reserved Reserved Reserved

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1.4.9. Remote 3.5mm Stereo mini-jack

6 5 4 3 2 7 8 9 1

1,6 pin: GND 2 pin: Repeater detection / Signal 5 pin: LED lanp

1.4.10. Control (RS-232C)

PIN
5 9 1 6

Signal CD RD(Received data) TD(Transmitted data) DTR GND DSR RTS(Request to send) CTS(Clear to send) RI

1 2 3 4 5 6 7 8 9

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Chapter 2 Theory of operation

EMP-7700

2.1. Hardware Configulation

The hardware of EMP-7700 is distinguished in the optical system and the electrical system. The lower level beyond the breaking line in the Figure2-1 show the optical system, and the upper level shows the electrical system. (Dotted line inside is the optical system.)

Figure2-1 Hardware block diagram

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2.1.1. Process Outline

1. The video signal is provided to the main board Assy uniy from the IF unit. (Analog signal should be once changed into digital signal by the Main board Assy uint.) 2. Video signal (digital) is once stored in the video memory (SRAM) on the Main board Assy unit, then the Driver board Assy generates signals to drive the light valves R/G/B. 3. The light valves R/G/B are individual panels each others. They work to shut or transmit the lights from the light guide unit. 4. The lights transmitted through the light valves will be combined the prism and projected through the projection lens unit. 5. The audio signal is sent from the IF unit to the AU block of the main board assembly and is output from the right and left speakers. Circut process block
IF unit Display signal Audio signal Speaker R Speaker L AU block Display control Main board Assy unit Digital Analog A/D Converter Display Memory Driver board Assembly Display Correction

LCD Driver

R G B Light Valves R/G/B

Figure2-2

Optical Process block

Light Valves R Lamp inner Housing (Light Source)

Projection Lens

Light Valves G

Light Valves B Prism (R/G/B sinthesize) Balast Unit Driver board Assy

Figure2-3

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2.1.2. Electrical System

Electrical units of EMP-7700 are physically connected mainly to the Main board Assy unit as shown figure 2-1. The function outline of each circuit system unit is shown below table. Unit name 1. Main board Assy unit function outline Power (DC voltage generation) ON/OFF, The ballast power supply (for light source lamp) On/Off, Circuit reset, Air cooling fan control, The temperature detection (protect overheat condition), Store the display data, The display control (resizing etc.), Display data and timing signals generation, condition lamp (LED indicator) display, Audio signal control, Remote controller /operation panel control, Mouse control, Relay the DC power supply hook up, PC interface connector, Audio control 2. Driver-board Assy Display compensation data preservation, Read out the dis(optical engine) play data, Digital to analog coversion (D/A), Light valve (liquid crystal panel) drive signal generation, Bias generation for the light valve 3. IF unit Display data input/output, Interface connector, Audio input/ output interface connector, BNC interface connector, Mouse/ Com interface connector. 4. RC receptor board Assembly Infrared ray signal receiving of the remote controller, Serial (The front/the back) data transmission 5. Operation panel Switch (the matrix) signal generation

2.1.3. Optical System Connections (Optical Engine)

The optical systems consists of 5 blocks (Intake fan, Exhaust fan,Light guide unit, Optical head (Light valve R/G/B)/Prism unit, and Projection lens unit) as shown next page. These units and Driver board Assy are specified as Optical engine and it is one replaceable part.

Lamp inner Housing installing location

Optical Head/ Prism unit

Projection Lens Unit

Figure2-4 Optical block

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Inside view of light guide unit

Figure2-5 Inside of light guide unit

Lamp inner housing

Projection lens unit

Figure2-6

Figure2-7

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! Caution: Take care not to cause any shock or mechanical stress to the optical engine and also not to disassemble it. Otherwise, the pixel divergence may occur. The alignment adjustment for each other is applied in the factory, and also electrical correction is applied with Driver board Assy according to the each optical engine. Therefor do not separate or exchange the each unit to the others.
Table 2-1Unit function
UNIT NAME LAMP INNER HOUSING (Type :ELPLP12) Optical engine Light guide unit Optical head unit FUNCTION & REMARKS Include one Discharge Lamp (UHE 200W)as a light source. FUSE board is mounted for new lamp UNIT detection. The light guide unit disperses the light from the light source via a multi-lens in order to provide uniform illumination. In addition, an UV filter removes any harmful ultraviolet light from the LCD. After this light is polarized, it is then split into R/G/B3 spectrums. The optical head unit consists of three light valves and a prism unit. Each light valve controls the pixel shutter in 256 steps. The prism unit synthesizes the R/G/B signals and sends them to the projector lens unit. Manual zooming and focus adjustment, the image is projected.

PROJECTION LENS UNIT

! Caution: The intake fan,light guide unit,optical head,prism unit,projection lens unit and driver board assembly are treated as a single unit which is termed the optical engine.(The parts other than the intake fan and the projection lens unit are not designated as serviceable parts.The optical engine should be serviced as a single unit.)

2.2. Safety switch

The safety switch is a thermal switch which isolates the power supply in the event of overheating.
Safety Switch

Figure2-8

The safety switch (thermistor) is installed to the lamp inner housing (lamp unit mount) of the optical engine. The safety switch isolates the AC power supply if the temperature rises above a certain level (to prevent overheating). Safety switch : Overheat condition is presented around the lamp inner housing area, (The N/C type) it shutdown the AC power.

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2.3. Power Supply Unit

The power supply unit function is divided by 2, one is from the EMI filter circuit to the sub power supply (Primary) and another is the main power supply (Secondary). The sub power supply is actuated always, nonexistent the relation to the power ON/OFF. The main power supply department actuation is contorolled by the power supply control signal (PWON) that is output from the main board Assy unit.
DC Output/Input cable (connected to Main board Assy unit)

Power Supply Fan Power Supply connector for Ballast

AC input Connector

Figure2-9

2.3.1. Power supply unit circuit block

This is a unit which consists of the EMI filter circuit, safety circuit (thermostat), power supply cooling fan sub power supply circuit and smoothing/control block.

Figure2-10

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(1). Outline of function AC input circuit department: Include AC input connector, thermostat and EMI filter circuit. The AC voltage is supplied via the filter unit and safety switch, when the power cable is connected. Safety circuit department: Include the thermostat on the AC input circuit. The thermostat cut off the AC power when it becomes overheat condition. Ballast power supply circuit department: It is the circuit that generates the power supply (DC300~400V) for the lamp inner housing according to the power ON/OFF control signal of the main board Assy unit. The output cable is connected to the ballast unit. The primary regulator circuit: The DC voltage is generated by rectifying and stabilizing the AC power supply. This DC voltage are supplied to the sub power supply circuit and ballast power supply circuit. Regulate the DC voltage that is generated with primary regulator circuit with DC-DC switching regulator then produce the various bios as shown in the next table. This DC-DC switching circuit has feedback function with +7V output and reducing the fluctuation of output. (Adjustment of individual output voltage is not possible.) Power Supply fan: The heat that occurred with the power supply unit is radiated. The fan bios (+12V) is supplied from CN201 of the power supply unit. The sub power supply circuit (+3.3R): Always+3.3V be output irrespective of the ON/OFF of the power supply if the AC voltage is supplied. (It is used to the power ON control circuit on the main board Assy unit.) The circuit power supply output is as next it showed it.

(2). Input / output specification

Table 2-2 AC input (CN103 N/L)
AC Input Input voltage frequency AC100~240V 50 / 60Hz Rating AC85~276V 48~62Hz Tolerance

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Table 2-3 Bllast output

Pin No. 1 2 Signal name HGNT (+) Ballast out put (+) BAHV(-) Ballast out put (-)
Ballast Output

WHT

BLK

Figure2-11

Voltage/Signal arrange of DC output (CN201/202/203/204) connector department is shown below.

Figure2-12

DC output (CN201/202/203/204)
Pin No. 14 13 12 11 10 9 8 7 6 5 4 3 2 1 Signal name +12T +5VT +3.3T +3.3T +3.3T +3.3R +3.3R +3.3R +11 +7 +18 -7 +13 FANCTL Direction Remarks Pin No. 28 27 26 25 24 23 22 21 20 19 18 17 16 15 Signal name +5VT +5VT GND GND GND GND GND GND GND GND GND GND GND PWON Direction Remarks Sub power supply Sub power supply

Sub power supply Sub power supply Sub power supply Sub power supply Sub power supply Main power supply Main power supply Main power supply Main power supply Main power supply Main power supply Main power supply Main power supply Fan control

Main power supply ON/OFF

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2.4. Ballast unit

it is the unit that regulates again the DC power supply (DC220-410V/0.8A) for the ballast that is supplied from the power supply unit to generates the AC power supply (AC45-200V) for the UHE lamp.

Figure2-13

Circuit
UHP Lampdriver CB1-1 4BYM56 Power input 50 F 450V 0.5s/a W

Fuse 4 AF 220IF Mains input

L1 Stabiliser R1 C1 C2 Control L2 Commu tator Ignlter L1 Lamp Lamp output

Mains filter gnd

Mains Isolation CB1-3

10n 470 E

CB2-1

CB2-2 CB2-3

+5V 4k7

ECI-Input

Flag-output

Figure2-14

(1). Process outline The sub power supply : The voltage for control circuit (+15V/+20V) inside the ballast unit is generated. Switching circuit : Doing the switch actuation for the regulation again according to the output signal (BACT) of the main board Assy unit. (The BACT signal is doing the ON/OFF of the ballast output.) Doing the modification (the adjustment of the output voltage) of the switching duty according to the feedback signal from the detection circuit. Regulator circuit : The voltage for the lamp of AC45~200V is generated.

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Detection circuit

: Monitoring the regulator circuit and genarates the feedback signal of the output voltage stabilization and detects of output current. When the lamp inner housing becomes consume, the LPST signal is transmitted to the main board Assy unit.

(2) Input/output specification

Voltage Input output 220~410VDC AC45~200V Rating power 260W (max) 3W (At the time of the standby) 220W4%

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2.5. Main Board Assy Unit

The Main board Assy unit controls the center of the product. It consists of CPU, ROM, (Flash ROM / EE-PROM) video memory, display controller, resizing, and circuits for operation panel control, temperature sensor circuit, ballast power supply control receptor board interface control and etc... The Main board Assy unit controls everything except to generate the display signal and audio output. The Main board Assy unit is available as a unit for the service parts., Outside View and connection of the Main board Assy unit for EMP-9000 are shown below.

Figure2-15

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PC In 1

MA Board

Digital RGB

YUV-RGB TA1270
Video SW Digitizer Resizing operation

Digital RGB
LCD Drive Block

DR Board

Digital I/F TFP401 GAUGE2 ET7040 ET6060 DEC Driver Color uniformity Correction Gamma Correction PLL/ADC (3ch) CXA3516

12.5MHz

SEIKO EPSON
PW364D
Sync. SW

PC In 1

Analog RGB

PC Out

RGB Timing E 2 PROM 256Kb

Sync.signal Processor TA1318 EV 9803 DATA swap Sync.signal Processor BA7078

Syncronizer

YCrCb

Digitizing controll Frame buffer controll Resizing controll Digital- Gamma correction PC mode detection Keystone correction

ET1030 Level Shifter

BNC In I2 C

Video amp. AD8185 I-P Genesis gmVLX1A

I2 C I2 C

RGB

L/V CN LCD Drive Block L/V CN

(1). Main board Assy unit circuit block

Video In SAA7114H

Digital Chroma

Driver CPU EV****

LCCOM

FAN1

CVBS

C O N N E C T O R

Y/C I 2C FROM 8Mb

SRAM
1Mb 1Mb
MBM29DL800 (Fujitsu)

EMP-7700

Figure2-16 Main board circuit block

IF Board
MBM29DL800 (Fujitsu)

E 2 PROM 16K b

SRAM

FROM 8Mb

Serial DAC

L/V CN

2-13
Audio Controller
TDA7464 Address / Data

TV Audio in

Stereo X 2

Stereo

PC1 Audio in IM2 Audio in

Stereo

AUDIO Selector

LCD Drive Block

Audio out
Stereo Line Out Power Save

FAN Driver Locked Det.

SP
TDA8542AT

L
Remote INT MUTE

Power Amp. FR30

Main CPU
FAN2
Thermistor

SP

(L/H) Multi Mouse CPU Multi Mouse CPU

Serial (control)

RS-232C Driver

FAN3 FAN4
3.3 ,7,12,12F,18,-7V
LED 1 LED 2 LED 3 Power Supply /Ballast Cntl IR Remote 1
RC Board
Lamp Fail Ballast Cntl Fan Cntl

PC mouse 1

EV9905AA Address decode Bus control I/O port PDEN control

3.3 , 5,12 for IM2

CONNECTOR BOARD

PC mouse 2

FUSE BOARD
Ballast SW Board

New component Always on

Revision:A

Wired Remote

IR Decode

Lamp
IR Remote 2
AC In

off during standby

EMP-7700

(2). Function outline Projector control Controls the driver board, video board and IF (audio) board. Digitalization of input video signal Converts the video signals which are input from the PC/video to digital signals. Conversion of input video signal resolution using a digital filter Converts the resolution of the video signals which are input from the PC/video by means of a digital filter. Conversion of transmitted IF to digital video signals in accordance with digital video standards Allows digital video signals which conform to DVI standards to be received. Frequency conversion for input video signals Converts the frequency of video signals which are input from a PC/video to create LCD drive video signals. Display of sub video signal within the main video signal as a PIP (Picture in Picture) image Converts the resolution of the video sub-carrier signal which is part of the main video signal which is input from the PC/Video and displays it as a PIP image with the size you select. 3D-Y/C separation and digital NR (Noise Reduction) control for video signals (NTSC signals) Applies 3D-Y/C separation and digital NR (Noise Reduction) control to composite video signals in NTSC format. On-screen display function Displays menus and ELP links which are contained in the input video signal as overlay images. DDC control Responds to DDC queries from the connected computer. Remote control Receives and decodes remote control signals and uses these signals to control peripheral circuits. Mouse control Converts pointer information within the remote control signals into mouse signals for PS/ 2, ADB, 98 bus and serial mouse signals and sends them to the connected computer. Lamp control Controls the ballast and controls the lamp illumination. LED control Controls the various power supply, temperature and lamp indicators. Cooling control Measures the temperature and uses this temperature to control the fan operation. Power supply control Controls the power supply in order to reduce power consumption. PC serial interface function Uses the RS-232C interface to for projector control, uploading and downloading between the projector and the computer using ESC/VP . (Digitizer block) 3D-Y/C separation & digital NR block (both main/sub screens) *3-dimensional separation of composite video signals in NTSC format into Y signals and C signals *Digital elimination of interference from S terminal (Y/C) video signals in NTSC format (Main device: TC90A28F 3D Y/C Comb Filter [Toshiba]) Digital chroma decoder block (for PIP sub-screen) Converts composite/Y/C analog video signals in NTSC/PAL/SECAM format into digital luminance signals (Y, U, V) for displaying in the sub-screen.

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(Main device: SAA7114 Digital Video Decoder [Phillips]) IP conversion block (for PIP sub-screen) *Conversion of the digital video signal obtained from the digital chroma decoder for displaying in the sub-screen. *Resolution conversion for the sub-screen signal. (Main device: gmVLX1A IP converter [GENESIS]) Analog color difference - RGB conversion block (for main screen) *Converts Y/Cr/Cb and Y/Pr/Pb video signals into analog RGB signals which are HDTV compatible. *Carries out sharpness, tint, brightness, correction, contrast and gain correction. (Main device: TA1316N analog video decoder [Toshiba]) Analog-digital conversion block (for main screen) *Converts analog RGB video signals from computer (RGB) and video deck (RGB) sources into digital signals (RGB8:8:8) for displaying in the main screen. *Adjusts the brightness and contrast. *Carries out dual line sampling and frame half sampling control. *Includes a PLL function for generating sampling frequencies which correspond to the various video signals. (SYNC adjustment) *Enables adjustment of the sampling phase of the sampling frequency. (SYNC adjustment) (Main device: CXA3516R Video ADC [Sony]) DVI converter block (for main screen) *Receives transmitted digital video signals which conform to the DVI standard and converts them to digital signals. (Main device: SiL161 DVI converter [SII]) Sync signal separation block (for computer image signals)Separates the composite sync signals and sync on-screen signals which are contained in the computer image signals into H/V sync signals. (Main device: BA7078AF Sync Separator [ROHM]) Sync signal separation block (for video deck image signals) *Receives the V/H sync signals, Y/Cr/Cb signals and HDTV-compatible signals which have been separated from video image signals and selects the H/V sync signal component. *Cancels Macrovision-compatible copyguard for sync separation. (Main device: TA1318N Sync Separator [Toshiba]) (Video overlay display block) Has a built-in frame memory, CPU, assignment control and I/O. Converts the position and size/resolution of the input digital video signals in real time and overlays them inside the operating menu display screen. Enables digital filtering of the digital image signals which are input as desired by means of a programmed internal FIR filter (80 or 160 taps). Analyzes the frequency characteristics of the digital image signals which are input and digitally resizes the signals to the desired size. (Example: Digitally enlarges and reduces the video signals with various frequencies and resolutions in NTSC, PAL, SECAM, VGA, SVGA, XGA, SXGA and UXGA formats and converts them to the LCD resolution. Displays the sub-screen inside the main screen as a PIP (Picture in Picture). (Main device: PW364 overlay processor (Frequency conversion FIFO block) Converts the digital video signals (48 bits) which are output from the video overlay display to the upper frequency which matches the LCD driver specifications to generate the video signal.

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(Main device: EV9811AA 48-bit asynchronous FIFO [GAFIFO48: Seiko Epson]) (PC video signal output block) Amplifies and outputs the analog RGB signals which are input from a computer to the PC out terminal. (Main device: AD8185ARU Video Amplifier [ANALOG DEVICES]) (DDC block) Responds to DDC queries from the connected computer. (Main device: 24LCS21T/PCB2421T EEPROM) (Control block) Performs projector control, remote control unit control, mouse control, cooling control, lamp control, LED control and computer serial interface control. Main devices Main CPU:MB91101PFV-G-BND-R Decoder IC: EV9807AA (3). Outline of operation When the power supply is turned on, the reset signal for the I/O controller (IC1108) on the main board assembly unit is canceled. The settings for all components are made in accordance with the program which is stored in the flash ROM, and the projector changes to standby mode (waiting for the lamp unit to turn on [project]) The Computer In input signal (digital) is first converted by the video amplifier circuit into an analog signal, and then it is converted back into a digital signal by the ADC. The Monitor Out output signal is the input signal from the Computer 1 terminal which has passed through the video amplifier circuit. In order to display the picture, the received data is first stored in the frame buffer of the resizing block where it is resized. The resized data is then output to the driver board assembly along with a synchronizing signal. The video input signal (S-Video/Video) is converted into a digital signal by the digital chroma processor, and is then stored in the frame buffer. The I/O controller (IC1108) outputs four scanning signals to represent operations carried out at the operating panel. When an operating panel switch is pressed, a scanning signal passes through the switch contact and then passes through the return signal line. The I/O controller controls the operation the various projector components based on the return signal. (Example: When the Power switch is pressed, the I/O controller outputs a "BACTA" signal to the ballast power supply [lamp power supply].) A +5 V voltage is supplied to the RC receptor board assembly. When the RC receptor board assembly detects a remote control signal, the data in serial format is received by the IR decoder (IC1507), and the I/O controller uses this to control the operation of the various components. (This is the same as the repeater (Remote) I/F signal (serial format) which is supplied from the IF panel unit.) The projector includes a timer circuit which regulates the usage time for the light source lamp (the lamp life) and an EEPROM circuit which operate as shown in the table below.
Table 2-4 Lamp inner housing timer control
Lamp inner housing when the operating time of the light source lamp exceeds 1,400 hours. When the lamp inner housing run out before its life. Lamp indicator state The projection screen continues to flash the message(Exchange Lamp) in red for 30 seconds after it is turned or and the lamp indicator blink in orange. The lamp indicator blink in red.

If the above occurs, the light source lamp needs to be replaced. After replacing the light source lamp, press the POWER switch to turn the lamp on. The lamp timer inside the EEPROM will then be reset automatically.

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The two thermistor circuits (PBS thermistor and LAMP thermistor) detect the temperatures of the respective parts of the projector. The CPU monitors the thermistor signals once every 100 ms, and controls the fan and the power supply lamp based on the temperature state. There are five temperature sensors which are mounted on the main board assembly in order to prevent overheating. If the detected temperature rises above a certain level, the temperature detection circuit applies an interrupt to the CPU, which causes the temperature warning indicator to illuminate, and also changes the fan speed (low speed--high speed) and stops the supply of ballast power to the light source lamp. The mouse interface is provided so that the accessory remote control can be used as a wireless remote control for a connected computer.

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2.6. Driver Board Assy

The Driver board Assy has two functions, one is for converting the R/G/B display signal from the Main board Assy unit into analog signals (12 states(EMP-7700) ) (light valve driver signals) and another is for controlling the display image by electrical correction data. The Driver board Assy is a parts of a optical engine, and it is not the object of service parts. Outside View of the Driver board Assy are shown below. ! Caution: Below is a diagram of the driver board assembly.

Driver Board

Figure2-17 Driver board Assy

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DIRYIN,NRGIN RCLXIN,RDXIN,RCLYIN,RDYIN,RENBX[2:1]IN,RDIRXIN,RNRS1C GCLXIN,GDXIN,GCLYIN,GDYIN,GENBX[2:1]IN,GDIRXIN,GNRS1C

SN74LVC04APW
DLCK2[A,B,C] BUFFER DCLK2[R1,G1,B1]

SEIKO EPSON
L/V Connector ET1030F0A
Level shifter

MA I/F Connector ET6060D0A

Controller EV9812RB RG1[9:0] GG1[9:0] BG1[9:0] ET7040K0A BC1[9:0] GC1[9:0]
DEC DRIVER DEC DRIVER

CLK HSYNC VSYNC RVID[16:11] RC1[9:0] RVID[26:21]

Circuit block diagram of Driver board Assy

RD0[7:0] GD0[7:0] BD0[7:0]

L/V Connector
Level shifter
DEC DRIVER

AT25256N GVID[16:11]

EMP-7700

Figure2-18

2-19
M62367GP D/A
NRSH,NRSL LCCOM[A,B,C]

EEPROM

EP_CS,EP_SKEP_DI,EP_DO

D[9:0] A0,WR

DEC DRIVER

GVID[26:21]

SCL

CPU

CS1,RD1

L/V Connector

SDA

MB90P653AFPV

ADRESS:70

DDAN

OPAMP
DEC DRIVER DEC DRIVER

Reference voltage +9.5V +7.0V

BVID[16:11]

Regulator

+5V_D (S/H)

DI,DO CLK,LD

BVID[26:21]

Regulator

+5V_C (CPU,ET7021) +2.8V

Regulator Regulator

BA10324AFV OPAMP

VREFHI,VMID NRS1A,NRS1B RLCCOM,GLCCOM,BLCCOM BA10324AFV

Regulator

+15V_A (S/H)

+18V

Regulator

+15.5V (VDDX,VDDY)

+3.3V

Revision:A

Power Supply

+3.3V_D (CPU,EV9812RB)

EMP-7700

Process outline of Driver Board Assy The CPU (IC900) read the data stored in EE-PROM (correction parameter), and regulate operation mode of the correction circuit (IC200/300). The display data output from the Main board Assy unit are once the signal timing is combined by the bus data changer (IC100) before output to the correction circuit. The timing signals and analog video signals output from the correction circuit are done electric correction by DAC for best display quality before output. The RGB video bias circuit generate standard voltage for video amplifier circuit based on control signal output from driver circuit. Each shift register generates the display data of 24 bit from 4 analog signals. The LCCOM circuit generate standard voltage for the light valve driver (LCD) based on three display voltage control (R/G/B) output from the correction circuit DAC.

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2.7. IF Units
The IF unit has 10 interface connectors and audio controllers.The audio signals are selected by the IC200 (Audio Controller) at the input interface, and are then output to the main board assembly.

CN101 CN100 CN201 CN202 J301 J201 J202

CN302

CN300

J300

Figure2-19

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Circuit Block

CN301

J201 (PC AUDIO 1 IN) Audio 1 Level converter 0~+9V

IC200 Audio Serector

CN202 (PC AUDIO 2 IN) L-Audio2-R

CN201 (S AUDIO) L-Audio-R L-OUT/ R-OUT

J202 (AUDIO OUT) Audio out Amplifier circuit

+12V 12

Connected to main board assembly unit CN1800

CN201 (VIDEO AUDIO) Video L-Audio-R

SCL5/SDA5/ AJ-DET/ CN1EN/DDCCLK/ +5V/-5V

CN100 (S-VIDEO) S-Video AU-DETECT J301 Mouse/Com1

J300 Mouse/Com2 CN302 Remote

Figure2-20

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EMP-7700

Function of the audio controller 1. The audio controller perform the selection of the input source, volume, tone quality, surround on/off, and surround control. 2. It sends the signal to the CPU on the main board ASSY unit when detects the jack connection to Audio Out interface. 3. It controls mute of an audio amplifier (When detect the Audio Out connection). (Amp mute is valid only for internal speaker.) 4. The tone adjustment is performed by "BASS" "TREBLE". The adjustment step is a center6 step. (Initial value is :center0) 5. The volume adjustment is performed by "AMP VOL" and "LINE OUT VOL". The adjustment step is 32 steps. (Initial value is :step15) 6. Voice mute is performed when "MUTE" key was pushed.

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EMP-7700

2.8. RC Receptor Board Assembly

This assembly is equipped with an element which detects (receives) the infrared signals from the remote control unit. The RC receptor board assembly is installed to the switch board (at the front) and to the exhaust duct unit bracket (at the rear). The receptor board assembly is shown in Figure 2-23.
Switch board RC receptor

RC receptor board assembly

Figure2-21 Receptor board assembly

The receptor board assembly signal is being jointed the cable to CN1006 (the front)/CN1002 (the rear) of the main board ASSY unit and the output signals and Repeater input signal (the serial data) from both receptor board assemblies are an information retrieval decoder and be converted to 16 bit parallel data. 1. The Main board Assy unit performs the power ON/OFF operation and the starting up menus, utilizing the serial data received from the remote controller (button switches and pointers). 2. The serial signal send to the Driver board Assy via the Main board Assy unit performs the display control (Freeze / Blank/etc.). 3. The serial signal send to the Main board via the Main board Assy unit performs the audio volume control. Circuit block
Main board Assy unit IR decoder (IC1507)

Remote controller

RC Receptor board Assembly

CN1006 CN1001

Address, I/O Bus controller (IC1108)

Receiver

IF unit CN302 CN301 CN1800

CPU (IC1101)

SDA/SCK Driver board Assy

Figure2-22

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2.9. Speaker Unit

Two speaker brackets at the left and right of the switch board. (8-3W) are equipped inside the upper case unit, faced upward. The audio input signal from a host computer or AV devices connected to this device can be output in stereo through the units. If an external speaker is connected (with the hEMP of an accessory audio cable) to the Audio Out terminal on theIF unit, the built-in speakers are disabled.

Speaker R

Speaker L

Figure2-23 Speaker unit

Figure2-24 Speaker control circuit block

The audio input from the computer or some other audio source is amplified at the AU block of the main board assembly, and is then output to the speakers. If the main board assembly unit detects that if source is connected to the external speaker (Audio Out) terminal, and controls whether the audio signal is output to the internal speakers or to external speakers (Audio Out).

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EMP-7700

2.10. Light Guide Unit

The light guide unit eliminates ultraviolet rays which are harmful to the light valve and uniforms the intensity of divided the light from the lamp inner housing before dividing it into 3 light outputs (R/G/B). There are lenses and mirrors for dispersing the light a mirror and lens built in the block. The below photograph show the appearance and the internal block of the light guide unit (Do not disassemble the light guide unit in the field maintenance).

Lens Array B PBS lens

UV Filter

Lens Array A Mirror

GDM CDM Mirror Condenser Lens R/G

Condenser LensB

Mirror

Mirror

Condenser lens B adjusting Screw

PBS adjusting Screw

Polarization plate B

Polarization plate G

Polarization plate R

Figure2-25 Light guide unit

(1). Lens Array Lens Array A/B Dispersion of the light from the lamp inner housing by the Lens Array lens array A/B roughly uniform the brightness. The UV filter coated on the surface of the multi-lens array eliminates ultraviolet rays to reduce the light valves deterioration. The light dispersed through the Lens Array A/B is reuniformed with PBS lens. (2). CDM

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CDM is a light filter looks red in the visual light. The CDM filter transmit only the red light and reflect blue and green lights from the light source. (3). GDM GDM is a light filter looks blue in the visual light. The GDM filter transmit only the blue light from the light source. Since the input light to the GDM is only blue and green lights by the CDM as described above, green light is reflected by the GDM and provided to the light valve G. (4). Condenser Lens The condenser lens collects the light and provide to the next process. (5). Condenser Lens R/G/B To collect the lights dispersed into each polarization plate. (6). Adjusting screws Adjusting the PBS lens position to obtain the best uniformity of source light.

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EMP-7700

2.11. Lamp Inner Housing

This unit includes the light source lamp (200 W) and the ballast power supply connector. The lamp is secure to the rear of the projector by three screws, and the lamp is a user replaceable item. The light source lamp las a luminance of 1700 lm, but the luminance becomes lower over time as the lamp is used. The maximum degree of luminance is obtained when the lamp is first being used, but after approximately 1,500 hours of usage time, the luminance will drop to between 50%--70% of this. The ballast power supply connector is used to supply power for driving the lamp to the ballast unit. The lead wires are connected to the lamp.

Light source lamp

Connector for ballast power supply

Figure2-26

1. The light source lamp The brightness of the light source lamp reduces in proportion to its running hours as mentioned above. In this device the standard lamp life is 1,500 hours. If you notice the lamp brightness reduces, we recommend you to replace the lamp inner housing even before 1,500 hours. The total running hour of the light source lamp is written in EEPROM (IC1107) on the Main board Assy unit. If the lamp is reaching or has reached the end of its life, CPU (IC1101) outputs some signals to control the following. (1). When the cumulative usage time reaches 1,400 hours, the lamp indicator flashes with an orange color. If the indicator starts flashing orange, it means that the lam has reached the end of its useful life, and it should be replaced as soon as possible. If the lamp is used after the cumulative usage time reaches 1,400 hours, the message "Please replace the projector lamp" will flash on the screen. (2). After the new lamp has been installed, be sure to initialize the lamp usage time by following the procedure given below. Press the HELP button for 5 seconds or more. After the help menu is displayed, the lamp usage time initialization screen will be displayed. Select "Yes". Press the ENTER button

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EMP-7700

The 2-27 shows the control circuit.

PWON Power supply Unit FANCL CN1001 Ballast unit BACTA LPSTC CN1003 Ballast power supply LSTAT I/O Decorder (IC1001) CN1000 Lamp inner housing FUSE board Lamp CN2 1 CN3 2 Driver board +5V LSTAT CN100 CPU (IC1101) EE-PROM(IC1107) Main board Assy unit

CN3 FC board

Figure2-27 Lamp inner housing control

2. Fuse board The lamp inner housing is installed to distinguish a new one (placed and havent started up) from an old one. This is the board with rated 100mA fuse, a new one has a fuse circuit. The terminal sections placed on the both ends of this board touch the FC board installed on the back of the light guide unit. The cable of the FC board is connected to the connector CN2 on the Driver board Asembly, so the signal from FC board is sent to the Main board Assy unit via the connector CN100 on the Driver board asssembly. When it is new or changed to a new one, LSTAT signal to I/O decoder on the Main board Assy unit becomes high. (+5VA on the Driver board assembly pulls up LSTAT signal line through the FC board and the fuse on the FUSE board.) When LSTAT shows high, CPU is reset the lamp total hour in EEPROM (IC1107) to zero. After word, I/O decoder on the Main board Assy unit output low level, and connects LSTAT signal line to the ground through a resistance. Consequently, the fuse on the FUSE board is blown, the lamp total hour in EEPROM (IC1107) will not be reset, the running hour is integrated every power ON operation.

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EMP-7700

3. Lamp information control

Table 2-5 Lamp information
Lamp indicator Lamp running hours Exceed 1,400 hours Blink in orange Screen display etc. Ensure with information of MENU display. After the power on, Clear the Exchange lamp message EE-PROM with appear on the screen. lamp replacement. Lamp goes off. Increment by one. Ensure with information of MENU display. Keep total running Ensure with information of hours with EMP-7500. MENU display. Keep exchange times. Ensure with information of MENU display. EE-PROM Keep total running hours with lamp.

Out of order (Lamp off) Number of turn on times Lamp total running hours with EMP-5500 Lamp exchange times

Blink in red

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4. Lamp on sequence

START

Power ON

N Y
Overheat or Sensor error

Terminate the following lamp on sequence

N
Rotate the fan

Wait 500ms

Lamp on
(LPCTL signal on)

Ballast power supply start

Wait 4Sec

LPSTC signal (Lamp abnormal) OFF

Lamp on? Y
Driver board Assy initialize

Lamp off
(LPCTL signal off)

Three times? Main board Assy unit initialize

N Y
Lamp off Error handling Wait 30sec

END
Figure2-28 Lamp on sequence

*Filter eliminate ultraviolet rays from light, then output to the light bulb block. If this filter

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2.12. Sensor / Switch

For users safety and safety operation of this projector (for prevention from malfunction), the following devices listed the 2-6 are installed in it.
Table 2-6 Sensor/switch
Name Lamp cover sensor switch Safety switch LAMP thermistor Location/Type Function/Use Pushbutton switch on middle case AC power off, in opening the lamp reinforcement plate cover unit. On the lamp outer housing Overheat protection for lamp inner (Thermal switch ) housing area. (AC power off.) On the lamp outer housing Overheat protection for light source lamp area.

Safety switch

Lamp cover sensor switch

LAMP Thermistor

Figure2-29 Sensor/Switch

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2.12.1. Lamp cover sensor switch

When the lamp cover is removed, the lamp cover sensor witch turns off.

Lamp cover sensor switch

Figure2-30

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2.12.2. Safety Switch

This is the thermal switch for overheat protection installed on the lamp outer housing. If overheat condition is caused by the contamination of the exhaust fan, normally the thermistors (PBS/LAMP) temporarily shuts off the supply of ballast power to protect it from overheat. The safety switch is installed, considering the thermistors trouble in overheat condition.
LAMP Thermistor Safety Switch

Figure2-31 Safety switch

To the safety switch the cable with fasten tab is connected from interlock switch. When the temperature increase to certain degrees, every regulating operations of the power supply unit are stopped. (AC power is shut off and this switch runs once, you can not start up the power, before the temperature decrease to certain degrees.) In this case, you must also consider the thermistor trouble or the Main board Assy unit trouble.

2.12.3. Thermistor and temperature sensor operation

CPU on the Main board Assy unit detects the temperature (resistance) with three thermistors and five temperature sensors in each 100ms. Five of temperature sensors are placed on the Main board Assy Unit and detect the temperature of major circuit. three of thermistors are placed in the main body and mainly detect the temperature of optical block area. CPU judge the following state according to the measurment result then change the fan operation or shut down the power.
Shut down Thermistor Temperature sensor Arround LH Arround L/V Arround CXA3516 Arround PW364D Arround LH 60 47 64 64 65 Medium- MediumHigh low high 74 75 77 44 60 60 61 49 63 63 63 50 66 66 66 Warning 78 55 71 71 70 80 57 73 73 73 6 3 2 2 2

! Caution: The stop setting values equal the operation setting values less the value in the xxx column. However, there is no stop setting value for high-temperature abnormalities.

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Temperature detection result are notified to the operation with temperature indicator..
Table 2-7 Temperature indication
Condition Normal temperature Warning temperature Abnormal temperature Temperature indicator Off Blink in orange Red Light in red Blink in red Meaning Operating in the normal condition Projection will stop if the temperature increase more. Over heat condition(stop the display) Malfunction with fan, thermistor, temperature detection circuit and etc..

*Result of condition affect to the fan operations. Refer to the paragraph 2.13 for details. *Refer to the paragraph 2.14 for detail of temperature indicator. (1). PBS/Lamp thermistor Two thermistors are combined with connector and treat as one parts. Lamp thermistor is mounted with screw on the lamp outer housing (closed to safety switch) and detect the temperature of lamp area.

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2.13. Fan Operation

Four of fans are laid on in this main body. These fan exhaust the warm air and prevent the circuit malfunction or damage which will cause over heat condition. (Mainly lamp inner housing and power supply unit produce the heat and increase the temperature.)

Power supply unit fan

Figure2-32 Exhaust fan

Figure2-33 Power supply unit fan

Lamp fan

Figure2-34 Intake fan

Figure2-35Lamp fan

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(1). Control block diagram of fan

Main board Assy unit Power Supply unit 13V 2.5A Regurator (12V_F) CN 1400 Lamp Fan

Regurator IC1400 FCTL00

CN1800

Controller IC1108

FCTL01 CN 1401 Regurator IC1401 CN 1002 Exhaust Fan Intake Fan

FCTL20 FCTL21

FRS0 CPU IC1101 FRS1 FRS2

Figure2-36 Fan control block

Intake Fan
FCTL01 FCTL00 FRS1 FRS0 1: Slow (10.0V) 1: Run 1: Run 1: Run 0: Fast (12.0V) 0: Stop 0: Stop 0: Stop

Exhaust Fan
FCTL23,22,21 FCTL20 FRS2 001: Slow 010: Midium-Slow 100: Midium-Fast 000: Fast 1: Run 1: Run (8.0V) (9.0V) (10.0V) (11.0V) 0: Stop 0: Stop

Lamp Fan
FANCL 1: Slow 0: Fast

! Caution: Low-Speed operation occurs only during standby (except when a temperature warning has occurred) and when there is a problem with fan operation.
(2). Out Line of function Each fan has three lead wires, one of these used for status feed back that fan is running or not. CPU on the Main board Assy unit always observe the fan operations by monitoring feed back signals. If the feed back signal condition is different from expected, CPU judge as fan abnormal condition then turns on temperature indicator in red and turn off lamp with ballast power off. Fan drive bias for intake fan and exhaust fan are regulated at the driver circuit (consist from regulator and transistor circuit) according to the fan control signal from CPU on the Main board Assy unit. (Intake fan has three state :stop /slow /fast, Exhaust fan has five state :stop / slow /midium-slow /midium-fast /fast) Power supply fans is provided drive bias which produced on the power supply unit.

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(3). Fan operation Stand by: Turn on the fan regurator then drive the intake fan1/2 and exhaust fan with slow mode when the thermistor detect the temperature of Slow level or temperature sensor detect the level of midium-low. Stop the intake fan1/2 and Exhaust fan then shut down the fan regulator when the thermistor detect the below of Slow level or temperature sensor detect the below of midiunlow. Lamp on: Befor 0.5 second, start up the intake fan and exhaust fan for lamp on. After the lamp on, both fan operation are controlledaccoording to the thermistor and temperature sensor. (Refer to the paragraph 2.14 for detail) Cool down After the lamp Fast condition until the thermistor and temperature sensor detect the below level of Slow.

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2.14. LED indicator

Three of indicators are mounted on the Switch assembly board unit and indicate the machine operation status. You can see these indication at slit on the upper case unit.

Operation indicator

Lamp indicator

Temperature indicator

Figure2-37 Indicator

Table 2-8 Indicator operation

Operation indicator Orange Green Red ON Blink 1 ON Blink 1 OFF ON Blink 1 Blink 1 ON Blink 1 Blink 1 OFF OFF OFF ON Blink 1 Blink 1 OFF OFF OFF OFF OFF Blink 1 Blink 1 OFF OFF Blink 1 OFF OFF Blink 1 OFF OFF OFF OFF OFF Blink 1 OFF OFF OFF Lamp indicator Orange Green Red OFF OFF OFF OFF OFF OFF Blink 1 Blink 1 Blink 1 Blink 1 Blink 1 Blink 1 OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF Blink 1 Blink 1 Blink 1 Blink 1 Blink 1 Blink 1 ON Blink 1 Blink 2 OFF OFF OFF OFF OFF OFF Temperature indicator Orange Green Red OFF OFF OFF OFF OFF OFF OFF OFF OFF Blink 1 Blink 1 Blink 1 OFF OFF OFF Blink 1 Blink 1 Blink 1 OFF OFF OFF OFF OFF OFF Blink 1 OFF OFF OFF Blink 1 Blink 1 Blink 1 OFF OFF OFF Blink 1 Blink 1 Blink 1 ON Blink 1 Blink 2 Meanings Standby mode(Sleep mode) Lamp warm-up Lamp on Cool down mode Bas error (Circuit malfunction) Warning for lamp life (during lamp on) Warning for lamp life (during warm-up) Warning for lamp life (during cool down) Warning for lamp life and overheat (during lamp on) Warning for lamp life and overheat (during warm-up) Warning for lamp life and overheat (during cool down) Lamp life Lamp or ballast power defect Lamp fuse defect Overheat operation (Lamp on) Overheat operation (Warm-up) Overheat operation (Cool down) Overheat Fan defect Sensor defect

*1 second 50%duty.

Blink2:2 second 50%duty.

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2.15. Operation Panel (Upper Case Unit)

The operation panel has 15 switches, and is connected between connector CN100 on the switch board and connector CN1006 on the main board assembly unit.

Figure2-38 Operation Panel

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Chapter 3 Disassembly and assembly

EMP-7700

3.1. DISASSEMBLY AND ASSEMBLY PROCEDURES

This section explains how to disassemble the EMP-7700. The reassembly procedure is the exact reverse of the disassembly procedure. (1). Preparatory Procedure 1. Remove any ring, wrist watch, cuff buttons, or other metal accessories that are likely to get in contact with the equipment. 2. Wear gloves. 3. Wear a wrist band and ground it. Place a ground mat. 4. Turn off the power of EMP-9000/8000LCP and the host computer. 5. Unplug the power cord from the main unitLCP and service outlet. 6. Disconnect the interface cable from the main unitLCP . 7. Clean the air filter, interface and case cover with a vacuum cleaner. (2). Required tools and accessories Prepare the tools and accessories listed in the table below.
Table 3-1 : Tool requirement
Name Phillips screwdriver 2 (-)Phillips screwdriver Tweezers Brush Vacuum cleaner Paper wiper Air blower Glove Wrist band,Groung map Driver Six corner (5mm) Driver Six corner (5.5mm) Torx screwdriver (H10) Q.t.y 1 1 1 1 1 Some 1 1 1 1 1 1 Supply Market Market Market Market Market Market Market Market Market Marker Marker Marker Use Dissasemble the case and interiors Remove lamp cover and air filter cover Unlock the FPC connnector on D.R board Burush off the dust around fan Clean the fan and filter Clean the projection lens Clean the fan and filter. Avoide finger injury Avoide electro ststic influence For the D-Sub fixed screw Removing the spacer Removing the upper case unit

(3). Limitation of disassembly (Optical engine handling) The disassembly of the mechanical section is detailed in paragraph 3.2. The optical engine is one replaceable part. When you order the maintenance parts or request our repair service, perform works by the units listed in the folowing table.
Table 3-2
1 2 3 4 Optical head unit Prism unit Light guide unit Driver board Assy These units are specified as Optical engine. (Treat as one replaceable part in the field maintenance.)

* Do not disassemble the Optical engine. * Do not individually replace any of the components which make up the optical engine except for the projection lens unit. The optical components listed in the next page are required the mechanical alignment or electrical correction in the control circuit. (writing the image adjustment data)

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Mechanical adjustments for optical engine.

1. Optical Head Unit The alignment (height/left and right/concurrent) of the polarization plates (include R/G/B light valves) is applied in the factory. If the alignment is modified, clear color image will not be made, because of the color divergence. ! Caution: Do not apply any mechanical stress and also not loosen the screws. 2. Prism Unit To synthesize the light output from each polarization plate (include R/G/B light valves), the alignment (concurrent to the polarization plate) of the prism unit is applied in our factory. If the alignment is modified, clear image will not be made, because of the pixel divergence to R/G/B synthesizing and projection lens unit, being out of focus and color uniformity. ! Caution: Do not loosen the prism unit fixing screws. 3. Light guide unit The alignment of the light guide unit on the optical head unit is applied (gap and concurrent to the polarization plate) in our factory. If the alignment is modified, clear image will not be made, because of being out of the brightness uniformity on the display screen (brightness or chroma is not uniform on the screen.) In consideration of the alignment of the lens array and the mirrors, and also their combinations, the factory setting is applied to the light guide unit to support the best display performance. (If the alignment is modified or the location is changed, there comes distortion on the display screen, therefore clear image will nit be made.) ! Caution: Do not disassemble the light guide unit. If you remove the upper guide cover from the unit, the alignment of lenses or mirrors may be unintentionally changed and also dust may stick to the unit. Since Optical engine on the EMP-7700 requires very precise adjustment, it can not be adjusted in the field.

Electrical corrections(DR board)

Some parts in the mechanical section of the optical system require some mechanical adjustments mentioned above. In the control circuit (Driver Board Assembly), the output driver for the display signal is slightly different from the output driver of other device (Driver Board Assembly) in individuality. The mechanical section itself of the optical system (e.g. light valves) must be electrically corrected. Therefore to obtain the best image, not only the mechanical adjustment but the electric correction is required. For this reason some correction values are written to Flash ROM of the Driver Board Assembly on factory shipping. For matching the optical system and electrical system, the electric correction is necessary. Consequently, the driver board and the optical block (consists of optical head / light guide unit) make one set. At the factory shipment, following correction data are stored in the Flash ROM on the Driver Board Assembly according to the specified optical engine. Gamma adjustment data Flicker adjustment data Ghost contrast adjustment data Sub contrast adjustment data ! Caution: For the writing correction values, an expensive, special device and also skillful engineer are necessary, therefore it can not adjust in the field.

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(4). Caution for field maintenance Observe the following procedure, when you repair. Otherwise, display quality is not guaranteed, and also EPSON repair service is not available. 1. Do not disassemble the block. (Do not loosen any screws.) 2. If either the optical block or the Driver Board Assembly becomes wrong, replace them in set. And when you send back them to us for repair, send back them in set (by optical engine). 3. The optical block and the Driver Board Assembly make the optical engine set, so never change its combination (e.g. use only the driver board1 for the other repair parts). (5). Precautions Precautions given to the individual assembly and disassembly procedures. Read them carefully before starting the assembly or disassembly procedure. A set of general precautions are given below. As you disassemble the main unit, dust that is sticked to the internal fans and air filters is likely to migrate and contaminate the light valves R, G, and B which are the heart of the display mechanism, thus deteriorating the display quality. Accordingly, before reassembling, check the dust inside of the main unit and, if necessary, clean them with a vacuum cleaner. The light valves R, G, and B and circuit board assemblies are highly sensitive to static electricity. When you remove a optical engine or circuit board ,place it in an antistatic bag immediately. When you perform the assembly or disassembly operations listed below, check the pertinent unit and its surfaces for any dirt before reinstalling them. If the unit is found dirty, clean it. 1. Removing the optical engine. 2. Removing the lamp inner housing. The speaker unit incorporates a permanent magnet. Keep it away from electromagnetic media such as floppy disks and magnetic cards. Handle the optical engine(projection lens and light guide units) with care as they are highly susceptible to vibration and shock. Do not try to disassemble any part (e.g., power supply unit) that is not covered in this manual.

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3.2. DISASSEMBLING THE MAIN UNIT

The flowchart for disassembling the main unit is shown below. You can take same disassembling procedure for EMP-7700. Since you can reassemble the dismantled parts in the reverse order of disassembly, unless specifically specified, this manual contains no reassembly procedure. Detailed descriptions of the disassembly procedures are given in subsections 3.2.1 through 3.2.20

3.2.1. Disassembly flow chart

Start

Lamp cover unit

(P3-6)

Upper cace unit Speaker unit

(P3-8) (P3-9) (P3-9) Front case (P3-10) (P3-17)

Key top Speakers Lamp inner housing (P3-7)

Main board assembly

Middle case L1 unit Middle case L2 unit IF unit

(P3-10) (P3-11)

Projection lens Focus ring Zoom ring

(P3-12)

Ballast unit (P3-12)

Thermistor lamp (P3-14) Optical engine (P3-15)

Safety switch (P3-14)

Exhaust fan (P3-16) Lower duct Duct sponge A Duct sponge B

Intake fan guard (P3-16) Intake fan (P3-16)

RC receptor board assembly (P3-15) Auxiliary duct unit/ Lamp fan unit (P3-15)

Middle case R unit (P3-19) Exhaust duct unit Power supply unit Lower case unit (P3-21)

Handle (P3-20) (P3-20) Foot unit (P3-21)

Figure3-1 : Disassembly flow chart

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3.2.2. Lamp Cover Unit

1. Loosen the lamp cover unit screw, and then remove the lamp cover unit from the rear of the main unit.

Screw

Lamp cover

Figure3-2

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3.2.3. Lamp Inner Housing

1. Loosen the two fixing screws. 2. Hold the lever and remove the lamp inner housing.

Lamp inner housing

Screw

Figure3-3

! Caution: Pay attention to handling because the Lamp might be superheating Immediately after lamp is used. When installing the Lamp Inner Housing, take care not to touch the lamps reflector with a hand (to prevent the reflector flom being contaminated).

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3.2.4. Upper Case Unit

1. Remove four screws fixing the Upper Case Unit then open the Upper Case Unit to direction of the arrow.

Upper case unit

Figure3-4

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3.2.5. Main Board Assembly Unit / Speaker Unit

1. Disconnect the cables from the speaker unit and the main board assembly unit. 2. Remove the speaker unit from the projector. 3. Remove the IF panel from the main board reinforcing plate. 4. Remove the six main board fixing screws (+, Capco, 3x6, F/Zn). 5. Disconnect all cables which are connected to the main board. 6. Remove the main board assembly unit.

Key top

Speaker Main board assembly unit Speaker unit IF panel

Figure3-5

! Caution: Refer to page.2-13 about cable splicing figure of Main Board Assy Unit.

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3.2.6. Front Case

1. Remove the stopper bracket. 2. Disengage the tabs at the left and right of the front case from the middle case L and R.

Tab

Tab Stopper bracket

Figure3-6

3.2.7. Middle case L unit

1. Remove the two screws (+, Capco, 3x6, F/Zn) which are securing the IF unit and the middle case L1 unit. 2. Remove the two screws (+, Capco, 3x6, F/Zn) which are securing the middle case L1 unit. 3. Remove the middle case L1 unit from the lower case.

Figure3-7

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3.2.8. Middle case L2 unit

1. Remove the two screws (+, Capco, 3x6, F/Zn) which are securing the IF unit and the middle case L2 unit. 2. Remove the screw (+, Capco, 3x6, F/Zn) which is securing the middle case L2 unit, and then remove the middle case L2 unit from the lower case.

Middle case L2 unit

Figure3-8

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3.2.9. IF unit/Ballast unit

1. Disconnect the cable which is connected to the driver board assembly at the top of the optical engine. 2. Disconnect the cable which connects the power supply and the ballast unit. 3. Remove the lamp connector presser. Remove the connector from the lamp inner housing and take it out of the lower case.
Lamp connector presser

Figure3-9

4. Remove the two screws (+, binding, P tight, 3x8, F/Zn) which are securing the IF unit and the ballast unit, and then the ballast unit can be removed.

Ballast unit

IF unit

Figure3-10

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5. Remove fourteen screws fixing the IF Fixing Plate, and remove the BNC Reinforcement Plate on the IF Fixing Plate.
Screw CBP-tite M3x8 Screw (+Capco, 3x6, F/Zn)

Screw (HSH)

Figure3-11

Figure3-12

6. Separate IF Fixing Plate and IF Circuit Assy. ! Caution: When installing the IF unit, refer to 2.7 and confirm cable is wired correctly.

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3.2.10. Thermistor LAMP

1. Remove a screw(Screw, CBP-tite M3x8) fixing the Thermistor OA/LAMP , then detach the Thermistor LAMP on the Optical Engine.

Figure3-13

3.2.11. Safety Switch

1. Disconnect two wire cables conneced to the Safety Switch. 2. Remove two screws(Screw, CP(S-P1) M3x6) fixing the Safety switch, then detach the Safety Switch on the Optical Engine.

Figure3-14

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3.2.12. Optical Engine

1. Disconnect the cable. 2. Remove five screws fixing the Optical Engine, then detach the Optical Engine on the Lower Case Unit.

Figure3-15

3.2.13. Auxiliary Duct Unit / Lamp Fan Unit

1. Remove the two screws which are securing the auxiliary duct unit, and the remove the auxiliary duct unit from the optical engine. 2. Remove the two screws which are securing the lamp fan unit, and then remove the lamp fan unit from the optical engine 3. Remove the screw (+, binding, P-tite, 3x8, F/Zn) which is securing the RC receptor board assembly, and then remove the RC receptor board assembly from the optical engine.

Auxiliary duct unit

RC receptor board

Lamp fan unit

Figure3-16

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3.2.14. Intake Fan/Exhaust Fan

1. Remove the intake fan and exhaust fan guards which are at the bottom of the optical engine. The guards are secured by two screws (+, binding, 4x30, F/Zn).

Figure3-17

2. Remove the exhaust fan which is at the bottom of the optical engine. The exhaust fan is secured by three screws (+, standard, Sems S2W1, 4x22, F/Zn)

Figure3-18

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3.2.15. Projection Lens assembly

1. Remove four screws(Screw, HSH M4x8) fixing the Projection Lens by using exclusive use 4 corner wrench then take out Projection Lens from Optical Engine.

Figure3-19

2. Remove the Zoom / Focus Ling from the Projection Lens. Each is fixed three screws(Screw, CPB-tite Mini M2x4).

Zoom Ling

Focus Ling

Figure3-20

! Caution: Take care not to touch the lens surface of the Projection Lens with a hand (to prevent their surface from being contaminated). When installing the Projection Lens, take care Screw and label becomes the upper side.

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3.2.16. Replacing the attachment lens

Attachment lens removal While pressing the attachment lens lever, turn the attachment lens in the direction of the arrow. When the attachment lens cannot be turned any further, pull it forward. When removing the attachment lens, turn it gently to the left and right to make removal easier.

Figure3-21

Attachment lens installation Align the notch on the attachment lens with the notch in the lens holder. Then turn the lens in the direction of the arrow until it cannot be tuned any further.

Figure3-22

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3.2.17. Middle case R unit

1. Remove the two screws (+, Capco, 3x6, F/Zn) which are securing the IF unit and the ballast unit, and then the ballast unit can be removed..

Middle case R unit

Figure3-23

2. When the handle shaft is removed, the handle can then be removed from middle case R.
Handle cover

Handle shaft

Handle

Middle case R

Figure3-24

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3.2.18. Exhaust duct unit

1. Remove the RC receptor board assembly from the exhaust duct unit. The RC receptor board assembly is secured by one screw (+, binding, P tight, 3x8, F/Zn). 2. Remove the four screws (+, Capco, 3x6, F/Zn), and then remove the exhaust duct from the lower case.

Figure3-25

3.2.19. Power supply unit

1. Remove the five screws (+, Capco, 3x6, F/Zn) and the screw (+, standard pan-head, sems B, 4x6, F/Ni) for securing the ground, and the two hexagonal head screws, and then remove the power supply unit from the lower case.

Figure3-26

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3.2.20. Lower case unit

Air filter

Foot cushion

Lower case

Figure3-27

3.2.21. Foot unit

Screw

Front cushion unit

Front levers R & L

Figure3-28

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Chapter 4 Troubleshooting

EMP-7700

4.1. Before Starting Troubleshooting Procedures

1. Whenever you replace a unit or block for maintenance purposes, double-check the replaced unit or block is defective (to determine whether the problem was due to a poor cable connection). 2. If you find questions you want to check while examining the flowchart, be sure to check those items during the troubleshooting procedure. 3. Refer to the instructions given in Chapter 3, "Disassembly and Assembly," when replacing a component unit. 4. Before making a functional check, be sure to check for proper connection.

4.1.1. Tools and Accessories Required for Troubleshooting

The tools and accessories required for troubleshooting (including fault isolation) are listed below. They need to be prepared by the user.
Table 4-1
Name Screen Rule (3 m) Host computer Color display monitor Video equipment External speaker unit Multi-meter Tool set Quantity 1 1 1 1 1 1 1 1 set Use/Remarks To project images To measure the projection distance To supply test patterns (PC or compatible) To manipulate and display on host computer To test video input (video deck, video camera, etc.) To test voice output (with audio cable terminals) To measure resistance and voltage (AC/DC) Tools and accessories listed in Section 3.1

4.1.2. Field Replacement Parts

The parts that need be replaced during troubleshooting , such as board, cases, plates, and screws, refer to the parts list listed in an appendix of this manual. Optical engine (consist from Light guide unit, Optical head unit, Projection lens unit, Prism unit and Driver board Assembly) is the one maintenance unit. Do not separate any unit from optical engine. ! Caution: This chapter omits Main board Assy Unit with MA Board for space.

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4.2. Entry
Follow the flowchart shown below when starting troubleshooting EMP-7700 problems and proceed to the pertinent detailed flowchart (given on the next and subsequent pates).
Start

Outside view

Visual check for outside view. (Check out the any damage on the cover area.)

Internal cable connectors

Ensure internal cable connections. Remove the upper case unit. (Reconnect the cable if necessary)

Power ON/OFF

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

Display/Picture quality

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

Audio out

Ensure audio output to the internal speaker and external speaker. (Connect external speaker)

Operation panel

Ensure button operations on the Operation panel.

Remote controller

Ensure button operations on the remote controller. (Front /Rear)

Mouse/Com interface control

Ensure link set functions from remote controller. (Link set option is necessary.)

Others

Others (Noise, Over heat, etc.)

Figure4-1

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Outside view
Turn off the power then remove power and interface cables.
Start

Upper case unit

Any transformation or crack are not presented. Upper case unit is secured to the lower case with screws.(Refer to 3.2.3) Button switches should move in smoothly. Operator panel is fixed on the upper case with four tabs. Any transformation or crack are not presented. Rear case unit is secured to the upper case unit and lower case unit. Dirt condition is not presented on it air duct. Focus ring and zoom ring are adjustable.(move it in easily) Dirt condition is not presented on the lens surface. Has the part been damaged,bent or cracked from having been dropped?

Key top

Lamp case unit

Projection lens unit

Front case Has the part been damaged,bent or cracked from having been dropped? Is the RC receptor cover dirty or coverd with some other object(such as tape)? Has the part been damaged,bent or cracked from having been dropped? Middle case L2 unit Has the part been demaged,bent or cracked from having been dropped? Is the RC receptor cover dirty or coverd with some other object(such as tape)? Any transformation or crack are not presented. Lower cover unit Air filter frame is looked on the lower case unit. Tab on the Air filter frame is not transformed. Dirt condition is not presented on the Air filter frame. Dirt condition is not presented on the cooling fan.(cooling fan is located under the Air filter frame. Two of fixing screw on the Lamp cover are not loosen. Tab on the Lamp cover is not transformed. Any transformation or discoloration are not presented on the Lamp inner housing frame and power cable connector. Any damage or dirt condition is not presented on glass surface. Discoloration are not presented on the FC board. Foot lever A/B should move in smoothly. Foot Unit Any transformation or discoloration are not presented on the interface connector.(rust may cause discoloration.) Any damage or dirt condition is not presented on the socket. Discoloration is not presented on the connector terminal. Any damage or dirt condition is not presented on the socket.

Middle case L1 unit

Middle case R unit

Air filter

Handle

Lamp cover unit/ Lamp inner housing

Interface connectors

AC inlet

Attach the Lamp inner housing and Lamp cover unit.

Figure4-2

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Internal cable connections

Before taking following flow, turn off the power then disconnect power cable.

Start

Switch Assembly

CN1006 on the MA board.(lock type) CN1006 on the MA board to CN100 on the MA board. CN1800 on the MA board to CN301 on the IF unit. CN1804 on the MA board to CN303 on the IF unit.(lock type) CN1801/1802 on the MA board.

MA Board Assembly

Speaker Land R

Power supply unit / Ballast Unit

CN1004 on the MA board to CN on the Power supply unit B. CN201 on the DR board to CP501 on the Ballast unit A. Power supply unit to CP1 on the Ballast unit.

Lamp cover removal Driver board CN200 Lamp cover sensorswitch.

Lamp cover sensor switch

Thermistor Lamp

CN1010 on the MA board

Middle case R unit removal CN1001 on the MA board

RC receptor board(rear)

Exhaust fan

CN1402 on the MA board

Lamp fan

CN1400 on the MA board

Intake fan

CN1401 on the MA board(Intake fan)

IF unit

CN301 on the IF unit to CN1800 on the MA board.

Attach the upper case unit

Attach the Lamp cover unit

Figure4-3

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Power ON / OFF Start

Does AC input voltage is correct? Yes AC power is applied on the interlock switch. Yes Remove the power cable. Unplug the fast-on tab on the safety switch. Measure the safety switch resistance.

Press Power button on the Operation panel.

Replace AC power

No Go to start

Operation indicator becomes lights in green? Yes

No Press Power button by the Remote controller .

Safety switch resistance is nearly zero ohm? Yes Replace power supply unit A No

No

Does Intake fan move? No

Operation indicator No becomes lights in green? Yes

Yes Does power supply unit A/B fan move? Yes No Replace Vacuum fan Filter unit A

Fixed? Yes Go to start

Does exhaust fan move? Yes

No

Go to start Replace MA board

Replace applicable power supply unit. Dose Exhaust fan move? Yes Replace Exhaust fan

Replace MA board

Replace Safety switch

Go to start

Go to start

Dose Exhaust fan move? Yes Press Power switch on the switch panel pushes down 30 second.

No

A
Figure4-4

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A B

Does the light source lamp is turned on? Yes

No

Lamp indicator become No lights or blink in red?

Temperature indicator becomes blink in orange?

Yes

Replace these thermistor one piece each 1.LAMP

Replace lamp Operation indicator become lights Green? Yes Operation indicator becomes blink in red? Yes No No

Lamp indicator is it turn No off. Yes Cleaning the fan (Intake fan, Power supply fan, Exhaust fan) Fixed? No Yes Fixed? No Replace MA board. Yes

Lamp and temperature No indicators are off?

A
Yes

B
Replace MA board.

Lamp indicator become No blink in orange? Yes Press power button (Off) Warning for lamp life.

Operation indicator becomes blink in orange? Yes

No

Temp indicator becomes No blink Orange? Yes Replace MA board. Overheat condition (Turn off the power and cool down enough) Fan or thermistors problem. Replace the following unit. 1.MA board 2. LAMP thermistor

Wait 60 sec

Operation indicator becomes lights in orange? Yes

No Cool down

Operation indicator goes off? Yes Normal and Go to next page.

Operation, Lamp, Temperature

Figure4-5

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Display / Pictuer quality

Start

Does screen appear? NO Lamp indicator becomes blink in red? NO Replace Lamp inner housing.

YES

Does NO SIGNAL message appear on the screen? NO Replace MA board.

YES

Does fine image appear by adjusting focus and zoom ring. NO Press Menu button on the switch panel or remote controller.

YES Go to next page.

NO

Does NO SIGNAL message appear on the screen? NO Replace Optical engine.

YES

Does light source lamp on? YES NO Lamp indicator becomes lights or blink in red? YES Replace the following thermistors. 1.PBS 2.LV 3.LAMP

NO

Does Menu screen appear? YES Take the adjustment shown in the table 1. YES Does fine image appear? NO Replace MA board.

Does light source lamp on? YES NO Replace MA board.

Computer In 1/2 Brightness Contrast Synchroniz ation Tracking Color

Video In/ S-Video Brightness Contrast Saturation Tint Sharpness

Does fine image appear? NO Take the adjustment shown in the table 1. Does fine image appear? NO Replace optical engine.

YES

YES

Does light source lamp on? NO YES

Reconnect the cable connector on the CN1003(MA board) to Ballast unit. YES Does light source lamp on? NO Replace Ballast unit A.

! Caution: Even the picture quality defectiveness that originates from condensation or dirt of lens is conceivable. In case of condensation, it becomes normal naturally if it leaves for a while.

Figure4-6

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Continued from page 4-7

A C
Connect host computer to the Computer In interface. YES Does following devices are checked? Does screen appear? NO NO Change the video mode by pressing source button. YES Connect the proper device which are not checked. Does screen appear? NO Replace Main board. Does screen appear on the CRT? NO Replace monitor cable. YES YES Video In S-Video In YES Does screen appear on the CRT? NO Replace MA board. YES Does picture quality is good? NO Connect the CRT to the Computer Out interface.

A
Does screen appear? NO Replace computer cable. YES Does screen appear? NO YES

Does screen appear on the CRT? NO Replace CRT monitor.

YES

B
NO Take the adjustment shown in the table 1(page 4-7).

Go to Audio out

Replace optical engine. Does picture quality is good? NO YES

B
Figure4-7

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Audio out
Start

A
YES

Does Mute button works? Connect the audio cable to the Audio In interface. NO Replace MA board. Does internal speaker R/L output the sound? NO Re-connect the CN201/202 on the MA board. Does internal speaker R/L output the sound? NO Replace speaker R/L. YES Connect the audio cable to the Audio In L/R interface. YES Does A/V devices are checked? NO

YES

Does internal speaker R/L output the sound? NO Replace MA board

YES

Connect the external speaker to the Audio out. Does external speaker output the sound? NO Replace MA board. YES

Does volume control works? NO Replace MA board.

YES

Go to Operator panel.

Figure4-8

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Operator panel
Start

Does power button works? YES Does menu button works? YES Does computer button works?

NO

NO

NO

Does Sync +/- button works?

NO

YES Does Help button works? NO

YES Does Enter button works? NO Reconnect cable connector on the CN502 of MA board.

YES Does Resize button works? YES Does Volume button works? YES Does AV Mute button works? YES Does Tracking +/- button works? YES Does Video button Works? YES Does ESC button works? YES Does Key stone button works? YES Does Shift +Volume button works? NO NO NO NO NO NO NO NO

YES

Does all button works?

NO

Replace Operation Speakers.panel. Go to Remote controller. NO

Does all button works?

YES

Replace MA board.

Figure4-9

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Remote controller
Start

Does power ON/OFF are available? NO Replace batteries.

Does all switches are works correctly?

Does Remote controller works with 10m distance of the front and the rear?

Go to others

Exchange remote controller.

Replace batteries.

Does power ON/OFF are available? NO Exchange Remote controller. Does power ON/OFF are available? Re-connect RC receptor cable. Does power ON/OFF are available? NO Replace RC receptor.

Does all switches are works correctly?

Does remote controller works with 10m distance of the front and the rear?

Replace MA board.
Replace the RC receptor board (rear). Replace the speaker unit (front).

Does remote controller works with 10m distance of the front YES and the rear?

NO
Replace Remote controller.

Does power ON/OFF are available? NO Replace MA board.

YES

Does power ON/OFF are available? Replace RC receptor cable.

Figure4-10

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Others
Start

Noise problem? NO

YES

Suspect following defects. Exhaust fan, inhale fan and fan on the power supply unit. Power supply unit (Vibration noise from pulse transformer)

Overheat problem? NO

YES

Suspect following defects. Thermistor (LV, LAMP, PBS) or safety switch. Exhaust fan, Inhale fan, Power supply unit fan. Air filter (Dirt condition)

Image display problem? NO

YES

Suspect following defects. Optical engine (May cause with dirt condition on the light guide unit, projection lens unit and light valve on the optical head unit.)

Low reproduced problem?

YES

Suspect following defects. AC input(Include power line transit or distortion) Power supply unit MA board Cable connection (fail to make condition.)

Figure4-11

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Index
A
Accessory specification 1-9 Function outline 2-14 Process Outline 2-16 Main unit specifications 1-8

B
Ballast unit Circuit Block 2-10 Input/output specification 2-11 Process outline 2-10

O
Operation Panel 2-40 Optical system block 2-2

P
Power Supply Unit 2-7 Circuit block 2-7 Outline of function 2-8 Process Outline Circut process block 2-3 Optical Process block 2-3 Projection image size 1-2 Protection From Accidental Injuryobstacles 0-3 Accidents 0-3 Electric Shock 0-3

D
Disassembly flow chart 3-5 Driver Board Assembly Circuit block 2-19 Process outline 2-20

E
Electrical System Connections 2-4 function 2-6

F
Fan Operation 2-36 Filter unit 2-6

R
RC Receptor Board Assembly 2-24 Record of Revisions 0-2 Remote Controller 1-7 Resolution 1-2

I
IF Panel Units 2-21 Circuit Block 2-22 Inquiry tip 0-4 Inside view of main frame 1-6 Interface Specification 1-11

S
Sensor / Switch 2-32 Interlock Switch 2-33 Safety Switch 2-34 Thermistor and temperature sensor 2-34 Speaker Unit 2-25

L
Lamp Inner Housing 2-28 Circuit block 2-29 Lamp on sequence 2-31 LED indicator 2-39 Light Guide Unit 2-26

T
Tools and accessories For Disassembly and assembly 3-2 For Troubleshooting 4-2 Trademark 0-1

M
Main Board Assy Unit Circuit block 2-13

V
VCCI rules 0-1

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