DATA PROJECTOR VPL-ES4 VPL-EX4 -...

DATA PROJECTOR

VPL-ES4VPL-EX4REMOTE COMMANDERRM-PJ4

SERVICE MANUAL1st Edition

VPL-ES4/EX4

! WARNINGThis manual is intended for qualified service personnel only.To reduce the risk of electric shock, fire or injury, do not perform any servicing other than thatcontained in the operating instructions unless you are qualified to do so. Refer all servicing toqualified service personnel.

! WARNUNGDie Anleitung ist nur für qualifiziertes Fachpersonal bestimmt.Alle Wartungsarbeiten dürfen nur von qualifiziertem Fachpersonal ausgeführt werden. Um dieGefahr eines elektrischen Schlages, Feuergefahr und Verletzungen zu vermeiden, sind beiWartungsarbeiten strikt die Angaben in der Anleitung zu befolgen. Andere als die angegebenWartungsarbeiten dürfen nur von Personen ausgeführt werden, die eine spezielle Befähigungdazu besitzen.

! AVERTISSEMENTCe manual est destiné uniquement aux personnes compétentes en charge de l’entretien. Afinde réduire les risques de décharge électrique, d’incendie ou de blessure n’effectuer que lesréparations indiquées dans le mode d’emploi à moins d’être qualifié pour en effectuer d’autres.Pour toute réparation faire appel à une personne compétente uniquement.

CAUTIONRISK OF EXPLOSION IF BATTERY IS REPLACED BY INCORRECT TYPE.DISPOSE OF USED BATTERIES ACCORDING TO THE RULE IN REGION.

1VPL-ES4/EX4

Table of Contents

1. Service Information

1-1. Appearance Figure .......................................................... 1-1

1-2. Board Locations .............................................................. 1-1

1-3. Disassembly .................................................................... 1-2

1-3-1. Upper Case Assembly ........................................... 1-2

1-3-2. Front Case Assembly and

Sub Rear Case Assembly ...................................... 1-2

1-3-3. Main Board ............................................................ 1-3

1-3-4. Tunnel Outlet Section ............................................ 1-4

1-3-5. Main Board Bracket Section ................................. 1-4

1-3-6. Lamp Power Supply .............................................. 1-5

1-3-7. Power Board .......................................................... 1-5

1-3-8. Optics Section ....................................................... 1-6

1-3-9. Detection Switch Board ........................................ 1-7

1-3-10. DC Fan .................................................................. 1-7

1-4. Warning on Power Connection ....................................... 1-8

2. Electrical Adjustments

2-1. Initial Values of Adjustment Items ................................. 2-1

2-2. Memory Structure ........................................................... 2-5

3. Troubleshooting

3-1. Electric Troubleshooting ................................................ 3-1

3-2. Power Board Troubleshooting ........................................ 3-3

3-2-1. No Power ............................................................... 3-3

3-2-2. Failure of Turn on Lamp ....................................... 3-4

4. Spare Parts

4-1. Notes on Repair Parts ..................................................... 4-1

4-2. Exploded Views .............................................................. 4-2

4-3. Electrical Parts List ......................................................... 4-4

4-4. Packing Materials & Supplied Accessories .................... 4-4

5. Block Diagram

Overall ............................................................................ 5-1

6. Diagram

6-1. Frame Schematic Diagram ............................................. 6-1

1-1VPL-ES4/EX4

1-1. Appearance Figure

1-2. Board Locations

Section 1Service Information

Lamp power supply

Main

Power

Thermal sensor

IR sensor

Detection switch

1-2 VPL-ES4/EX4

1-3. Disassembly

1-3-1. Upper Case Assembly

1-3-2. Front Case Assembly and Sub Rear Case Assembly

Remove the upper case assembly before starting the removal work.

VPL-ES4 VPL-EX4

4 Two screws (M 3 x 6)

5 Screw (M 3)

!= Sub rear case assembly

7 Two screws (+K 3 x 12)

6 Six hexagon screws ![ Front case assembly

1 Lens cap

0 Two claws2 Main board connector (J6)

3 IR sensor board connector (J1)

Sub rear case assemblySub rear case

assembly!- Speaker harnesses

9 Remove the upper case assembly from this corner with the strong force to the extent that the upper case assembly will not be damaged.


Front case assembly

2 Four claws

4 Upper case assembly


1 Five screws (M 3 x 6)

1-3VPL-ES4/EX4

1-3-3. Main Board

Remove the front case assembly and sub rear case assembly before starting the removal work.

3 Main board

1 five screws (M 3 x 6)

2 Remove the main shield in the direction of the arrow.

J17

Note:The fan harness has been secured by the main board bracket with a fixing screw.(See section 1-3-5. mein bracket) J16

J6

J14 J20 J19 J21 J22

J23

J24

J25

J18

Lamp box assembly

When re-assembling, give an appropriate amount of extra slack of this harnesses.

Main board

Radiation sheet

Main board bracket section

Main board

Because the harnesses has the shape of flat cross-section, do not insert the harnesses with excessive force. Find out the direction in which the harnesses can be inserted easily, and then insert the harnesses.

Harnesses

Harnesses clamp section

Main shield

J22

1-4 VPL-ES4/EX4

1-3-4. Tunnel Outlet Section

Remove the front case assembly and sub rear case assembly before starting the removal work.

1-3-5. Main Board Bracket Section

Remove the main board before starting the removal work.

1 Two tapping screws (PAN 3 x 7)

2 Tunnel outlet section

J21

Main board

Main board

Lamp box assembly

J21

Harnesses clamp section

Harnesses

Because the harnesses has the shape of flat cross-section, do not insert the harnesses with excessive force. Find out the direction in which the harnesses can be inserted easily, and then insert the harnesses.

2 Three tapping screws (PAN 3 x 7)

1 Two screws (M 3 x 6)

4 Main board bracket section

3 Screw (M 4 x 6)

Power board

1-5VPL-ES4/EX4

1-3-6. Lamp Power Supply

Remove the main board bracket section before starting the removal work.

1-3-7. Power Board

Remove the main board bracket section before starting the removal work.

CN603

CN603CN701CN701Power board

Lamp power supply (P1)

2 Remove the power board in the direction of the arrow.

1 Two stand assemblies

4 Lamp

9 Lamp power supply

2 Lamp door

1 loosen screw. 3 Loosen two screws.

5 Screw (+PWH 3 x 8)

8 Connector (P1)

B

A

To the main board J16

From the Main board CN602(Red and Black wires)

6 Remove the lamp power supply connector in the direction of the arrow A.

7 Remove the lamp power supply in the direction of the arrow B.

1-6 VPL-ES4/EX4

1-3-8. Optics Section

Remove the lamp power supply and power board before starting the removal work.

2 Two claws

0 Optucs section

8 Focus/Zoom adjust assembly



5 Harness

4 Gasket 9 Four screws (+P 2.5 x 8)

!= Rotate the Focus dial counter-clockwise as shown until it is stopped.

!] Rotate the Focus/Zoom Adjust Assembly counter-clockwise until it is stopped.

!; Install the Focus/Zoom Adjust Assembly as shown.

!' After installation is completed, verify that the Optucs section can rotate from the position A to the position B smoothly.

A

B

Lower case

Focus dial

!\ Install the Optucs section in the Lower Case.

!- Rotate the Zoom dial clockwise as shown until it is stopped.

7 Dowel

A

During the assembling process, never change the gear position that is set by step ![.

Assembling Method of Optucs section and Focus/Zoom Adjust Assembly

Phase matching

![ Rotate the Focus dial counter-clockwise as shown until it is stopped.

3 Remove the lamp box assembly in the direction of the arrow A.

1-7VPL-ES4/EX4

1-3-9. Detection Switch Board

Remove the optics section before starting the removal work.

1-3-10. DC Fan

Remove the optics section before starting the removal work.

5 Tapping screw (PAN 3 x 7)

1 Tapping screw (PAN 3 x 7)

6 Detection switch board

2 Detection switch board


4 Duct lamp

CN1

CN1



2 Duct LCD assembly

4 DC fan

7 DC fan

5 harness

6 Two tapping screws (M 3 x 25)

1-8 VPL-ES4/EX4

1-4. Warning on Power Connection

Use a proper power cord for your local power supply.

The United States, Continental UK, Ireland, JapanCanada Europe Australia, New Zealand

Plug type VM0233 290B YP-12A COX-07 _1) YP332

Connector type VM0089 386A YC-13B COX-02 VM0310B YC-13

Cord type SJT SJT H05VV-F H05VV-F N13237/CO-228 VCTF

Rated Voltage/Current 10A/125V 10A/125V 10A/250V 10A/250V 10A/250V 7A/125V

Safety approval UL/CSA UL/CSA VDE VDE VDE DENAN

Cord length (max.) 4.5m (14 feet 9 inches) _

(1) Use an appropriate rating plug which is applied to local regulations.

2-1VPL-ES4/EX4

2-1.

Init

ial V

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f A

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Section 2Electrical Adjustments

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itial

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ory

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9080

8590

9075

8590

7580

9090

7575

9080

8590

9075

8590

8580

9090

6085

Brig

ht60

5055

6050

5055

6055

5060

5050

5560

5055

6050

5055

6055

5060

5050

55C

olor

5050

5068

6058

5050

5050

6860

5850

5050

5068

6058

50H

ue50

5050

5050

5050

5050

5050

5050

50S

harp

ness

6030

5050

5030

5060

4030

4040

3040

6030

4040

4030

40D

DE

Film

Film

Film

Film

Film

Film

Film

Film

Film

Film

Film

Film

Film

Film

Film

Film

Film

Film

Film

Film

Film

Gam

ma

Mod

eG

raph

ics

Gra

phic

sC

olor

Tem

pH

igh

Low

Mid

Hig

hLo

wLo

wH

igh

Hig

hM

idLo

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wM

idLo

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wM

idLo

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FO

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can

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put S

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er S

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Off

IR R

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OR

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ly

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ory

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UT

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) IN

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(C

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ter)

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SE

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IDE

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Hig

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2-2 VPL-ES4/EX4

Page Item Name Set R G BTGHST Phase Hi 0TGHST Phase Lo 109SHSH1 38TGHST Position 12DEHPF On ONDEHPF AAC ONDEHPF TAP 3DEUSC On OFF3D GammaSubCont 03D GammaSubBrt 150DELUT SW OFFDEUF SW ON

PC Hi Gain-R 128PC Hi Gain-G 128PC Hi Gain-B 128PC Hi Bias-R 0PC Hi Bias-G 0PC Hi Bias-B 0PC Lo Gain-R 128PC Lo Gain-G 70PC Lo Gain-B 100PC Lo Bias-R 0PC Lo Bias-G 0PC Lo Bias-B 0

Video Hi Gain-R 128Video Hi Gain-G 128Video Hi Gain-B 128PC Mid Bias-R 0Video Hi Bias-G 0Video Hi Bias-B 0Video Lo Gain-R 128Video Lo Gain-G 70Video Lo Gain-B 100Video Lo Bias-R 0Video Lo Bias-G 0Video Lo Bias-B 0

Color

P1-1CXD9809-page1

P1-2CXD9809-page2

P1-3CXD9809-page3

2-3VPL-ES4/EX4

PC Mid Gain-R 128PC Mid Gain-G 90PC Mid Gain-B 115PC Mid Bias-R 0PC Mid Bias-G 0PC Mid Bias-B 0Video Mid Gain-R 128Video Mid Gain-G 75Video Mid Gain-B 105Video Mid Bias-R 0Video Mid Bias-G 0Video Mid Bias-B 0

Temperature 1 Display onlyTemperature 2 Display onlyTemperature 3 N/AFanSpeed 1 Display onlyFanSpeed 2 Display onlyFanSpeed 3 Display onlyFanSpeed 4 Display onlyManualFanSpeed OFFBurn-In Cycle 0Burn-In Cycle On min 210Burn-In Cycle Off min 30Burn-In Hour 50Burn-In active OFF

Gain-R 188Gain-G 188Gain-B 188SigCen-R 35SigCen-G 35SigCen-B 35SidA-R 22SidA-G 22SidA-B 22SidB-R 85SidB-G 85SidB-B 85

P2Fan Control

P3-1CXA7005-page1

P1-4CXD9809-page4

Page Item Name Set R G BColor

2-4 VPL-ES4/EX4

Bias-R Normal 122Bias-G Normal 122Bias-B Normal 122Bias-R Flip 122Bias-G Flip 122Bias-B Flip 122Vcom-R Normal 88Vcom-G Normal 88Vcom-B Normal 88Vcom-R Flip 88Vcom-G Flip 88Vcom-B Flip 88

RGB CalibrateYUV CalibrateRGB Offset 164 222 164RGB Gain 93 105 93YUV Offset 164 222 164YUV Gain 93 105 93R Offset 164G Offset 222B Offset 164R Gain 93G Gain 105B Gain 93

Power Saving Time 10System Protect ONData ResetHard ResetROM Version Display onlyLamp Timer Display onlyOperation Timer Display onlyPrev. Lamp Timer Display onlySOG Threshold N/A

P6Error Count

All value is display only

P5

P3-2CXA7005-page2

P4ADC Calibration

Page Item Name Set R G BColor

2-5VPL-ES4/EX4

2-2. Memory Structure

Set memory Set memory Set memory

statusmemory

No.01

statusmemory

Video/SvideoNo.01 Status memory

No.02 No.02No.03

Input-A/Input-B/Component

No.03No.04 No.04No.05 No.05

No.50 No.50No.55 No.55No.56 No.56

No.101 No.101No.102 No.102

Picturememory

Video

Dynamic

picturememory

Video

Dynamic Picture memoryStandard StandardNatural NaturalGame GameLiving LivingCinema CinemaPresentation Presentation

S-Video

Dynamic

S-Video

DynamicStandard StandardNatural NaturalGame GameLiving LivingCinema CinemaPresentation Presentation

Input-A

Dynamic

Input-A


Input-B

Dynamic

Input-B


Component

Dynamic

Component


W/Bmemory

ComputerHigh

W/B memory

ComputerHigh W/B memory

Mid MidLow Low

Other thanComputer

High Other thanComputer

HighMid MidLow Low

ChannelMemory

Input-A

ChannelMemory

Input-A Channel MemoryInput-B Input-BInput-AComponent

Input-AComponent

Input-AVideo-GBR

Input-AVideo-GBR

Video VideoS-Video S-Video

CommonMemory

Wide Mode(other than computer)

CommonMemory

Wide Mode(other than computer)

Common Memory

Scan Converter(Computer only)

Scan Converter(Computer only)

Smart APA(Computer only)

Smart APA(Computer only)

Volume VolumeAuto Input Search Auto Input SearchInput-A Signal Sel. Input-A Signal Sel.Color System(Video/S-Video Only)

Color System(Video/S-Video Only)

Speaker SpeakerPower Saving Power SavingIR Receiver IR ReceiverPanel Key Lock Panel Key LockStatus StatusLanguage LanguageMenu Position Menu PositionImage Flip Image FlipBackground BackgroundLamp Mode Lamp ModeHigh Altitude High AltitudeSecurity Lock Security Lock

FLASH ROM EEPROM CPU RAM

2-6 VPL-ES4/EX4

Memory structure of this model consists of the followings.1 Set memory2 Status memory3 Picture memory4 Chroma memory5 W/B memory6 Channel memory

* The gamma memory is realized by giving offset to the Contrast and Brightness output values to thedevices in the gamma mode function.

Flow of data is described briefly. When the power plug is connected to the wall outlet for the first time(Standby state), all data that are stored in the internal ROM are written in the NVM (non-volatile memo-ry). When the POWER is turned ON, all the status memory data and other memory data that are requiredfor the present picture are selected from each memory block and expanded in the internal RAM.When any adjustment is performed at this moment, the adjustment data (user mode items) are written inthe NVM (Service/Special Service) automatically triggered by the memory operation.

The adjustment items (W/B, Device Adjust) that can be adjusted in the Service Mode or in the SpecialService Mode, are memorized in the NVM at the time when the user performs adjustment and performsthe memory operation. Note that the factory adjustment data will be lost at this moment.

3-1VPL-ES4/EX4

3-1. Electric Troubleshooting

Section 3Troubleshooting

1

No

Yes

No

No

Yes

Yes

No

Yes

No

Yes

Connect the Power

System Standby?

Power projectorLamp ON ?

System shut-downAnd cooling

No Picture ?

Picture qualityNo good ?

1. Check the LED Message and find error.2. Check lamp door, dust door.3. Check the power board out voltage 5V.4. Change main board.

1. check the Ballast power and controlsignal wire.

2. Check lamp door status.3. Check lamp status.

1. The picture is full-white pattern; pleasecheck the LCD panel connector.

2. The picture is full-black pattern; pleasecheck the LCD driver on the main board.

3. Check the system status: Is system inburn-in mode?

1. Check the LED message and find error.2. Check the Fan status or Thermal sensor

status.3. Check the lamp door or dust door.

1. The picture a little green, blue, red, please check the LCD panel connector.

2. The picture has dust, please check thelens.

3. The picture flicker, please alignmentagain.

3-2 VPL-ES4/EX4

OSD flicker ?

Color temp wrong ?

Picture has Vertical bar ?

IR remote control No good ?

Audio function isNo good ?

Please alignment V-com again.

Please alignment color temperature again.

Check the vertical bar color and find theLCD panel connector. Then check the pinof connector.

1. Please check the OSD setting2. Check the front IR board.

1. Check the OSD setting.2. Check the speak wire.

1

No

Yes

No

Yes

No

Yes

No

Yes

Yes

3-3VPL-ES4/EX4

3-2. Power Board Troubleshooting

3-2-1. No Power

Check LED circuit ofmain board.

No Power

No

Yes

F601Open?

Yes Q601(D-S) Short ?

No

No

Yes

No

Output5V DCexists ?

Voltageoutputs shut

down and builtrepeatly ?

Check if CN701 inserted properly.

Check if miss to solder any SMD type of components.

Yes

Replace Q601 and F601with new ones, and thenput power board into set.If Q601 damages again,check if other parts areshorted.

Check if 15.25V or 12Vexist. If any voltage iswrong, replace IC701 orT602 with new ones.

Check if D602 or IC602 isbroken.if yes,replace it with nowone.

Check CN701 and findout if some points are shorted to gound.

3-4 VPL-ES4/EX4

3-2-2. Failure of Turn on Lamp

Failure of turn on ballast.

No

YesCheck if the inputvoltage of ballast is

380V DCB

A LampBroken ?

Yes

No

ControlPin (SCI) is

normal ?

Yes

Replace ballast with new one.

Check main board.

Replace lamp with new one.

No

3-5VPL-ES4/EX4

B

A

No

Q602 worksnormally ?

Check ZD602, R655 and R656.

Check mian board.

No

Yes

F602 Open ?Replace F602 with new one.

Check Q701 IC604,Q604, Q603 or ZD603. And then replace broken parts.

Check if 18V exists at c-terminal

of Q603.

Yes

Yes

Check if thereis PFC_On/Off

signal.

Yes

No

No

4-1VPL-ES4/EX4

4-1. Notes on Repair Parts

1. Safety Related Components WarningwComponents marked ! are critical to safe operation.Therefore, specified parts should be used in the case ofreplacement.

[WARNHINWEIS][WARNHINWEIS][WARNHINWEIS][WARNHINWEIS][WARNHINWEIS]Les composants identifiés par la marque ! sontcritiques pour la sécurité.Ne les remplacer que par une pièce portant le numérospécifié.

2. Standardization of PartsSome repair parts supplied by Sony differ from thoseused for the unit. These are because of parts common-ality and improvement.Parts List has the present standardized repair parts.

3. Stock of PartsParts marked with “o” at SP (Supply Code) column ofthe Spare Parts list may not be stocked. Therefore, thedelivery date will be delayed.Items with no part number and no description are notstocked because they are seldom required for routineservice.

4. Units for Capacitors, Inductors and ResistorsThe following units are assumed in Schematic Dia-grams, Electrical Parts List and Exploded Viewsunless otherwise specified.

Capacitors : μFInductors : μHResistors : Ω

Section 4Spare Parts

4-2 VPL-ES4/EX4

Overall

4-2. Exploded Views

36

25

20

32

42

14 32

37

2

1

38

28

17

13

27

16

26

21

15

11

7

8 22

35

6

38

3

12

9

29

38

3838

32

30

33

38

10

38

4

32

30

32

32

+K 3x12

+K 3x12

+PWH 3x8

+PSW 4x8

+PSW 3x25

+P 2.5x8

+BVTP 3x6

VPL-ES4

VPL-EX4

38

32

24

41

34

39

4-3VPL-ES4/EX4

Overall

No. Part No. SP Description

1 ! 1-576-973-11 s FUSE, CYLINDERICAL (F602) 2 ! 1-576-233-51 s FUSE (H.B.C.) (F601) 3 ! 1-576-974-11 s THERMOSTAT 4 1-789-603-11 s DOOR DETECTION SWITCH BOARD 6 ! 9-885-114-11 s FAN, DC (AXIAL FAN UNIT)

7 ! 9-885-114-12 s FAN, DC 8 ! 1-787-496-11 s FAN, DC (DC) 9 ! 1-787-496-21 s FAN, DC (DC)10 9-885-114-05 s MOUNTED CIRCUIT BOARD, MAIN (VPL-ES4)10 9-885-114-07 s MOUNTED CIRCUIT BOARD, MAIN (VPL-EX4)

11 1-789-543-11 s MOUNTED CIRCUIT BOARD, IR SENSOR12 1-789-544-11 s MOUNTED CIRCUIT BOARD, THERMAL SENSOR13 9-885-114-04 s MOUNTED CIRCUIT BOARD, POWER14 9-885-114-06 s SPEAKER15 9-885-113-91 s LAMP DOOR

16 9-885-113-92 s DOOR, FILTER17 2-670-067-01 s MESH FILTER20 2-675-465-01 s ASSY, LAMP BOX21 9-885-113-93 s ASSY,FOOT ADJUST RUBBER22 9-885-113-94 s FOOT, ADJUST

24 9-885-113-95 s LENS CAP (VPL-ES4)24 9-885-114-08 s LENS CAP (VPL-EX4)25 9-885-114-34 s MYLAR BALLAST26 9-885-113-96 s LOWER CASE27 9-885-114-00 s ASSY, SUB REAR CASE (VPL-ES4)

27 9-885-114-33 s ASSY, SUB REAR CASE (VPL-EX4)28 9-885-113-97 s ASSY, FRONT CASE (VPL-ES4)28 9-885-114-09 s ASSY, FRONT CASE (VPL-EX4)29 9-885-113-98 s ASSY, FOCUS/ZOOM ADJUST (VPL-ES4)29 9-885-114-10 s ASSY, FOCUS/ZOOM ADJUST (VPL-EX4)

30 2-681-547-02 s SCREW, TAP PH W/FL M3*27L32 2-681-550-01 s SCREW, TAP PAN M3*7L33 2-681-552-02 s SCREW, EX-HE 4#-40X4+6 STLESS34 2-681-553-01 s SCREW, TAP PAN M2*6L35 9-885-114-32 s RUBBER PAD,ADJUST FOOT

36 9-885-113-90 s ASSY, UPPER CASE (WHITE COLOR)36 9-885-113-99 s ASSY, UPPER CASE (BLOCK COLOR) (VPL-ES4)37 4-672-839-11 s HEAD, M3 FLAT38 3-918-696-11 s SCREW (M3X6 LOCK ACE)39 2-580-621-01 s SCREW, +PWH 3X10

41 9-885-114-02 s SWITCH,TACT42 ! 1-474-023-11 s POWER SUPPLY BLOCK (BALLAST)

7-682-903-21 s SCREW, +PWH 3X8 7-682-954-01 s SCREW, +PSW 3X25 7-685-645-91 s SCREW +BVTP 3X6 7-621-262-40 s SCREW, +P 2.5X8 7-682-250-09 s SCREW, +K 3X12

7-682-961-01 s SCREW +PSW 4X8

4-4 VPL-ES4/EX4

4-3. Electrical Parts List

Ref. No. or Q’ty Part No. SP Description

1pc ! 1-576-233-51 s FUSE (H.B.C) (F601) 1pc ! 1-576-973-11 s FUSE, CYLINDERICAL (F602)

4-4. Packing Materials & SuppliedAccessories

--------------------SUPPLIED ACCESSORIES-------------------- Ref. No. or Q’ty Part No. SP Description

1pc 1-479-775-12 s REMOTE COMMANDER (RM-PJ4) 1pc 1-832-428-11 s CABLE, VGA 1pc 2-679-319-01 s BAG,CARRY 1pc 3-210-513-02 s CD MANUAL 1pc 3-100-207-01 s GUIDE QS MANUAL (JAPANESE, ENGLISH, FRENCH, SPANISH, GERMAN, ITALIAN, SIMPLIFIED CHINESE)

1pc ! ------------ s CORD SET, POWER (See 1-4. Warning on Power Connection)

5-1VPL-ES4/EX4 5-1

OverallOverall

Section 5Block Diagram

GPSIG

HCKx_R

DCK1_B

DCK1x_R

DCK1_B

HCK_R

HCK

LCDPCG

LCDENB

VST

VD

DCK1x_G

HCKx_R

HST

HCKx

VCK

DCK2_G

HCKx

CLK_B

FRP

DCK1x_G

HST

PRG

DCK1_R

CLK_G

RPSIG

DCK2x_R

VD

DCK1_G

DCK1_R

RGT

HCKx

GSIG[6:1]

DWN

HCK_G

VCK

HCK_R

HCKx_G

HCK_B

DCK2x_B

LCDVCK

LCDRGTx

PCG

HCK_G

ENB

DCK2x_B

DCK2_G

DWN

HCK

ENB

FRPPRG

DCK1x_R

PCG

LCDVST

RSIG[6:1]

VCK

HCKx_B

PCG

LCDRGT

HCK

BSIG[6:1]

VD

DCK2_B

PRG

DCK2x_G

VST

DCK2x_RDCK2_R

LCDHST

BPSIG

RGTx

HST

LCDR[11:0]

DCK1_G

DCK2_R

DWN

RGT

VCK

PRG

DCK1x_B

GVCOM

CLK_R

HST

HCK_B

FRP

DWN

HCKx_G

HCKx_B

BVCOM

LCDG[11:0]

RVCOM

ENBRGT

DCK2_B

VD

FRP

RGTx

DCK[6:1]

LCDDWN

LCDB[11:0]

ENB

PCG

DCK2x_G

DCK1x_B

VST

VST

SDA

SCL

WP

DR[9:0]

DG[9:0]

DB[9:0]

DCLKDHSDVS

SDATA

SEN

SDATA

SDATASCLK

SEN

SCLK

SEN

SCLK

SDATAiSCLKiSENi

PC-RIN1PC-GIN1PC-BIN1

HSYNC1VSYNC1

PC-RIN2PC-GIN2PC-BIN2

HSYNC2VSYNC2

R_OUTG_OUTB_OUT

HSYNCOVSYNCO

LUMA

CHROMA

CVBS

PC-RINPC-GINPC-BIN

HSYNCVSYNC

AUDIO_S

AUDIO_O_AUDIO_O

AUDIO_MUT

AUDIO_VOL1

AUDIO_VOL2

TXD

RXD

AUDIO_M

TX.DL

RX.DL

AUDIO_O+

I2C_SWFAN_SW

FG1

FG2

Fan3FG3

Fan4FG4

Fan5FG5

Fan2

AUDIO_SW

SDA

IRR5

IRF5

IRR

IRF

SCL

LED[4:1]

P15VPP12VP5V

PWR_fail

POWER_ON

LCD_SCLLCD_SDA

Dust_SW

RO

MO

En

RO

MW

En

A[0

:21

]

D[0

:15

]

LampLITLampENEco_mode

Door_SW

P15VPP12VP5V

P15VP

P5V

P15V

P5VC

P5V

P5VP1P8V

P2P5V

P3P3V

P33V

P5VCV33

P2P5V

P135V P15V

R LCDDrver R

LCD

B LCD

BLCD

Driver

LCDTiming

Generator

G LCD

G LCD

Driver

VideoProcessor

&Controller

ResetIC

EEPROM

Speaker

RS232Driver

Receiver

Fan Control EEPROM

IR Receiver

IR Receiver

S-Video

Video

INPUT A

INPUT B

MonitorOutput

Audio

Audio A/B

Audio out

RS-232RemoteControl

ThermalSensor 1

ThermalSensor 2

Analog RGBInput/Output

32.768 KHz

LEDDriver

KeypadInput

27 MHz

PowerFail DET

Dust SWDoor SW

Flashmemory

ResetIC

PowerControl

PowerSwitchBallast

Fan 1

Fan 2

Fan 3

Fan 4

Audio

Input/Output &

volumecontrol

+2.5VREG

+3.3VREG

+3.3VREG

+1.8VREG

+3.3VREG

+1.8VREG

+3.3VREG

6-1VPL-ES4/EX4 6-1

2

3

4

5

1

A B C D E F G H

Section 6Diagram

6-1. Frame Schematic Diagram

Frame Frame

CN601CN602

HALOGENLAMP

BALLAST UNIT

POWER BOARD

FAN2

FAN2

FAN1(FRONT BOTTOM)

FAN3(REAR BOTTOM)

FAN4(REAR TOP)

CN701J17

SPEAKER

J11

J22

J6 J1

J20

J19

J14

J21

J16

J23

J24

J25

J1

INPUT INPUT B

J2

INPUT INPUT A

J3

OUTPUT MONITOR

J4

VIDEO

J5

S VIDEOINPUT

INPUT

J7

RS-232CREMOTE

CN1

CN1

J18 J1

THERMALSENSORBOARD

DETECTIONSWITCHBOARD(RIGHT)

DETECTIONSWITCHBOARD(LEFT)

LCD R

IRSENSORBOARD

MAINBOARD

LCD G

LCD B

INPUTJ8

AUDIO A/B

INPUTJ9

AUDIO

OUTPUT

J10

AUDIO

VPL-ES4/EX4

SAFETY CHECK-OUT

After correcting the original service problem,perform the following safety checks beforereleasing the set to the customer :

Check the metal trim, “metallized” knobs,screws, and all other exposed metal parts for ACleakage. Check leakage as described below.

LEAKAGE TEST

The AC leakage from any exposed metal part toearth ground and from all exposed metal parts toany exposed metal part having a return tochassis, must not exceed 3.5 mA. Leakagecurrent can be measured by any one of threemethods.

1. A commercial leakage tester, such as theSimpson 229 or RCA WT-540A. Follow themanufacturers’ instructions to use theseinstruments.

2. A battery-operated AC milliammeter. TheData Precision 245 digital multimeter issuitable for this job.

3. Measuring the voltage drop across a resistorby means of a VOM or battery-operated ACvoltmeter. The “limit” indication is 5.25 V, soanalog meters must have an accurate low-voltage scale. The Simpson 250 and SanwaSH-63Trd are examples of a passive VOMthat is suitable. Nearly all battery operateddigital multimeters that have a 20 V AC rangeare suitable. (See Fig. A)

To Exposed MetalParts on Set

Fig A. Using an AC voltmeter to check AC leakage.

ACvoltmeter(5.25V)

Earth Ground

0.15 μF 1.5 kZ

English

Sony EMCS Corporation 2007DR16-1Ichinomiya Tec ©2007

VPL-ES4 (SY)

VPL-EX4 (SY) E

9-883-627-01

CoverTable of Contents1. Service Information1-1. Appearance Figure1-2. Board Locations1-3. Disassembly1-3-1. Upper Case Assembly1-3-2. Front Case Assembly and Sub Rear Case Assembly1-3-3. Main Board1-3-4. Tunnel Outlet Section1-3-5. Main Board Bracket Section1-3-6. Lamp Power Supply1-3-7. Power Board1-3-8. Optics Section1-3-9. Detection Switch Board1-3-10. DC Fan

1-4. Warning on Power Connection

2. Electrical Adjustments2-1. Initial Values of Adjustment Items2-2. Memory Structure

3. Troubleshooting3-1. Electric Troubleshooting3-2. Power Board Troubleshooting3-2-1. No Power3-2-2. Failure of Turn on Lamp

4. Spare Parts4-1. Notes on Repair Parts4-2. Exploded Views4-3. Electrical Parts List4-4. Packing Materials & SuppliedAccessories

5. Block DiagramOverall

6. Diagram6-1. Frame Schematic Diagram

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