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Troubleshooting
Disassembly / Assembly
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PowerLite® S1, S1+ Service Manual, Section Two: Troubleshooting Disassembly / Assembly
Epson PowerLite S1 Series
Copyright Notice
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the written permission of Epson America, Inc. Copyright © 2005 Epson America, Inc. 3840 Kilroy Airport Way Long Beach, CA 90806-2469
Trademark Information
EPSON, Epson PowerLite, and ESC/P are registered trademarks of SEIKO EPSON CORPORATION. Epson Connection is a service mark of Epson America, Inc. General Notice: Other product names used herein are for identification purposes only and may be trademarks of their respective companies. EPSON disclaims any and all rights in those marks.
FCC Compliance Statement
For American Users
This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio and television reception. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause interference to radio and television reception, which can be determined by turning the equipment on and off, the user is encouraged to try to correct the interface by one or more of the following measures: Reorient or relocate the receiving antenna. Increase the separation between the equipment and receiver. Connect the equipment into an outlet on a circuit different from that to which the receiver is connected. Consult the dealer or an experienced radio/television technician for help.
Warning
The connection of a non-shielded equipment interface cable to this equipment will invalidate the FCC Certification of this device and may cause interference levels that exceed the limits established by the FCC for this equipment. It is the responsibility of the user to obtain and use a shielded equipment interface cable with this device. If this equipment has more than one interface connector, do not leave cables connected to unused interfaces. Changes or modifications not expressly approved by the manufacturer could void the user's authority to operate the equipment.
Preface
ii
Copyright Notice
Epson PowerLite S1 Series
For Canadian Users
This Class B digital apparatus meets all requirements of the Canadian Interface-Causing Equipment Regulations. Cet appareil numérique de classe B respecte toutes les exigences du Règlement sur le matériel brouilleur du Canada.
Precautions
Precautionary notations throughout the text are categorized relative to personal injury (WARNING), and damage to equipment (CAUTION).
W A R N IN G
Signals a precaution which, if ignored, could result in personal injury. Great caution should be exercised in performing procedures preceded by WARNING headings
C A U T IO N
Signals a precaution which, if ignored, could result in damage to equipment.
General Precautions
The precautionary measures itemized below should always be observed when performing repair and maintenance on this product.
W A R N IN G
Always disconnect the product from the power source and any peripheral devices before performing any maintenance or repair procedures. No work should be performed on the unit by persons unfamiliar with basic safety measures as dictated for all electronics technicians in their line of work. When performing testing as dictated within this manual, do not connect the unit to a power source until instructed to do so. When the power supply cable must be connected, use extreme caution in working on power supply and other electronic components. When disassembling or assembling a product, make sure to wear gloves to avoid injury from metal parts with sharp edges.
Preface
iii
Precautions
Epson PowerLite S1 Series
C A U T IO N
Repairs on Epson product should be performed only by an Epson Certified repair technician. Make certain that the source voltage is the same as the rated voltage, listed on the serial number/rating plate. If the Epson product has a primary AC rating different from available power source, do not connect it to the power source. Always verify that the Epson product has been disconnected from the power source before disconnecting any cables, or removing or replacing printed circuit boards and/or individual chips. In order to protect sensitive microprocessors and circuitry, use static discharge equipment, such as anti-static wrist straps, when accessing internal components. Do not replace malfunctioning components with components that are not manufactured by Epson. If second source IC or other components that have not been approved are used, they could cause damage to the Epson product, or could void the warranty offered by Epson.
About This Manual
This manual describes basic functions, theory of electrical and mechanical operations, maintenance, and repair procedures for the projector. The instructions and procedures included herein are intended for experienced repair technicians, and attention should be given to the precautions on the preceding page. Manual Configuration This manual consists of the two chapters highlighted below. Chapter 1. Product Specifications Describes the features and basic specifications of the product. Chapter 2. Theory of Operation Describes the electrical and mechanical basic operating principles of the product. Chapter 3. Troubleshooting Describes step-by-step procedures for troubleshooting. Chapter 4. Disassembly/Assembly Describes step-by-step procedures for disassembling and assembling the product. Chapter 5. After Service (AS) Menu Explains how to access the servicer-exclusive menus.
Preface
iv
About This Manual
Epson PowerLite S1 Series
Additional Symbols Used in this Manual Various symbols are used throughout this manual either to provide additional information on a specific topic or to warn of possible danger present during a procedure or an action. Be aware of all symbols when they are used, and always read CAUTION, and WARNING messages. Indicates a product reassembly procedure, practice or condition that must be executed in accordance with the specified standards to maintain the product's quality.
C H E C K P O IN T
May indicate an operating or maintenance procedure, practice or condition that is necessary to accomplish a task efficiently. It may also provide additional information that is related to a specific subject, or comment on the results achieved through a previous action.
Preface
v
About This Manual
Epson PowerLite S1 Series
Service memo Make notes of important technical information from Support Bulletins. For the latest Support Bulletins, go to www.epsonsinsider.com.
Preface
vi
About This Manual
Epson PowerLite S1 Series
Table of Contents
Chapter 3 Troubleshooting
Before Troubleshooting...........................................................................................................42 Troubleshooting Tools and Equipment .............................................................................42 Field Replacement Parts ...................................................................................................42 Safety Instructions...................................................................................................................43 Maintaining Operator Safety .............................................................................................43 Maintaining the Projector in Good Condition.....................................................................43 Safety Testing ...................................................................................................................44 Requirements for Service Technicians .............................................................................46 Start-up Sequence Troubleshooting .......................................................................................47 Detailed Troubleshooting ........................................................................................................50 Exterior Examination .........................................................................................................50 Image Display and Quality ................................................................................................52 Audio Output .....................................................................................................................53 Control Panel ....................................................................................................................53 Remote Control Operation ................................................................................................54 Internal Cable Check.........................................................................................................55 Miscellaneous ...................................................................................................................56
Chapter 4 Disassembly / Assembly
Overview .................................................................................................................................58 Precautions .......................................................................................................................58 Tools and Equipment ........................................................................................................60 Projector-Specific Service Precautions .............................................................................60 Projector Disassembly and Assembly.....................................................................................62 Removing the Lens Cap Unit ............................................................................................63 Removing the Lamp Inner Unit .........................................................................................64 Removing the Air Filter......................................................................................................65 Removing the Foot Units...................................................................................................65 Removing the Remote Control Holder ..............................................................................66 Removing the Upper Case................................................................................................67 Removing the Speaker......................................................................................................69 Removing the Switch (SW) Board Assembly ....................................................................71 Removing the Lamp Shield Plate......................................................................................72 Removing the Main (MA) Shield Plate ..............................................................................73 Removing the Main (MA) Board, IF Panel and IF Label ...................................................73 Removing the Main Board Fixing Plate.............................................................................77 Removing the IF Board Assembly.....................................................................................78 Removing the Exhaust Fan Assembly ..............................................................................79 Disassembling the Exhaust Fan Assy...............................................................................80 Removing the RC Board Assembly...................................................................................81 Left MA Frame, Lower Shield Plate Removal ...................................................................82 Removing the Power Supply / Ballast Assembly ..............................................................82
Table of Contents vii
Epson PowerLite S1 Series Removing the Ballast Assembly........................................................................................84 Removing the Power Supply Fan......................................................................................86 Removing the Optical Engine............................................................................................88 Removing the Focus Ring.................................................................................................89 Removing the Projection Lens Unit...................................................................................90 Removing the Intake Fan (Fan 100) .................................................................................91 Removing the Intake Duct and Right MA Frame...............................................................92 Removing the Lamp Cover Detection Switch....................................................................93 Removing the Handle........................................................................................................94 Removing the Rubber Foot ...............................................................................................95
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Chapter 3 Troubleshooting
Epson PowerLite S1 Series
3.1 Before Troubleshooting
If you have replaced parts or components as part of a repair procedure, always be sure to re-check whether any parts previously replaced are themselves operating correctly. Determine whether the problem is the result of a malfunctioning replacement part, an incorrectly installed part, or a loose cable. Follow all troubleshooting instructions and procedures as written. Follow the procedures given in Chapter 4 - Disassembly and Assembly - when replacing any projector parts or components. If you find problems when checking the operation of the projector, always check the external cable connections before proceeding to other checks. After the projector has been unplugged and cooled, check the internal cable connections. In order to confirm proper operation, use AC power from a known, clean source and use a power cable in good condition.
3.1.1 Troubleshooting Tools and Equipment
Check that the following tools are on hand before you begin troubleshooting. Table 3-1. Troubleshooting Tools and Equipment
Name Quantity. Application
Projection screen Tape measure (10 ft.) Host computer Video equipment Multimeter External speaker Heat-resistant tape General tools
1 1 1 1 1 1 1 foot 1 set
Projecting images Measuring projection distances Transmitting audio and image data Transmitting audio and image data Measuring resistance values and voltages (AC/DC) Testing audio output (with audio cable connector) Attaching parts Tools and equipment listed in Chapter 4 Section 4.1.
3.1.2 Field Replacement Parts
C A U T IO N
The Optical Engine and MA Board are configured and adjusted together at the factory. They are only available as a matched pair, and must always be replaced together when either the Optical Engine or MA Board has a failure. Many of the components that comprise a service unit have each been adjusted in relation to each other. Therefore, when replacing parts during troubleshooting or repair, do not disassemble service units in order to harvest and use constituent components. This is especially critical for the components in the optical engine (Light Guide Unit, Prism Unit and Light Valves) and the MA Board. Perform safety tests after replacing any parts. See Section 3.2.3 on page 44.
C H E C K P O IN T
Troubleshooting
42
Before Troubleshooting
Epson PowerLite S1 Series
3.2 Safety Instructions
3.2.1 Maintaining Operator Safety
Prevent Electric Shocks Turn off the power switch and disconnect the power cord from the AC outlet before performing any disassembly and assembly work on this projector. If power needs to be supplied to the projector while the cover is removed (such as when making adjustments), remove all metallic objects such as wristwatches, shirt cuff buttons, rings and tie pins which may pose the danger of coming into contact with the projector. Prevent Injury Projector components such as the Lamp Inner Housing and the area around it will remain hot after the power has been turned off, even when the cool-down period is compete. If removing the cover in order to carry out procedures while power is being supplied to the projector, be careful not to touch the intake and exhaust fans. Always wear gloves when disassembling and reassembling the projector in order to avoid injury from metallic parts with sharp edges. Do not look directly into the projector's lens while power is being supplied to the projector, otherwise injury to the eyes may occur. Prevent Accidents Place the projector on a stable, level surface when carrying out any repair or adjustment work. Do not place any tools or projector components on top of or underneath the projector. Always use the supplied Epson power cord to connect the projector to an AC outlet, and make sure that the AC outlet is properly grounded.
3.2.2 Maintaining the Projector in Good Condition
Preventing Static Electrical Damage When disassembling and assembling the projector, always use a grounding strap and a grounding mat. When replacing electrical circuit components such as circuit boards and optical engine, touch the staticproof bag containing the new parts against a metallic section of the projector before removing the component from the static-proof bag. During disassembly, temporarily store any electrical circuit parts you have removed in static-proof bags. Use of Genuine Parts When replacing the structural components inside the projector, including the Lamp Inner Housing, use only replacement parts supplied by Epson and listed in the projector's Parts List. Use the power cord and video interface cable provided with the projector.
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Safety Instructions
Epson PowerLite S1 Series
3.2.3 Safety Testing
Perform the following tests after you repair the projector. Insulation resistance test Illumination check Insulation resistance test
1. Set the range selection switch to 500 V.
W A R N IN G
High voltage (500 V) is 2. Connect the black lead wire to the ground terminal. present. Make sure the pro3. Connect the red lead wire to the line terminal. jector is turned off and unplugged. Do not touch the 4. Connect the black lead wire (crocodile clip) to c in order to measure the insulation resistance (1) probe during testing.
5. 6.
Ground terminal
Line terminal Display
7. 8.
9.
(between a and c) in the diagram below. Next, insert the probe of the red lead wire into a. Set the measure switch to LOCK, and then measure the insulation resistance for 1 minute. Check that the insulation resistance after 1 minute is 10 M or more. Next, measure the insulation resistance at (2) (between b and c) in the diagram below in the same way as for (1). Check that the insulation resistance at (2) after 1 minute is 10 M or more.
Projector AC inlet
Measure Switch
a
Power supply lines
Range Selection Switch
b
(1)
(2)
Exposed metal on the projector
c
VGA (Computer) connector
Troubleshooting
44
Safety Instructions
Epson PowerLite S1 Series
Illumination safety check Connect a Computer or Video signal to the projector and check the illumination for at least 5 minutes. Verify that there is no abnormal odor or smoke. Additional safety checks and precautions Check that the connectors at both ends of the power cord are not dirty or bent, and clean them if they are dirty. Visually inspect the power cord. Replace the power cord if there is any noticeable discoloration. When you connect cables inside the projector, push the cables into the connectors as far as they will go and make sure that the cables are fully seated in the connectors. If the connector is a locking connector, make sure the connector is unlocked before attempting to seat the cable. To prevent problems caused by dirt getting into the optical system, always disassemble and assemble the projector in an area which is free from floating dust. When disconnecting the cables connected to CN400 and CN600 of the MA Board, remember to release the connector locks. To release the connector lock, push up both ends of the connector simultaneously with tweezers or small pliers.
CN600 (underneath) CN400
Enlarged view
Locked
Unlocked
Release the connector locks before you disconnect the three light valve cables from their connectors.
Locked
connector lock
Unlocked
Troubleshooting
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Safety Instructions
Epson PowerLite S1 Series
3.2.4 Requirements for Service Technicians
Service technicians who perform repair work on the PowerLite S1/S1+ must possess the following knowledge and abilities. They must have read and fully understood the contents of this Service Manual. They must have a fundamental knowledge of working with electronics including, but not limited to: industry standard safety procedures, general operations of electrical circuitry, and static electricity precautions.
Troubleshooting
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Safety Instructions
Epson PowerLite S1 Series
3.3 Start-up Sequence Troubleshooting
C H E C K P O IN T
Always check the Epson Insider web site for the latest Support Bulletins for this product. Support Bulletins provide up-to-date supplemental information on how to troubleshoot and repair the product. Go to http://www.epsoninsider.com.
The following troubleshooting steps can be used with most Epson video projectors: 1. Plug the projector into AC power and listen for the power supply fan. 1.1 The power supply fan runs constantly while the projector is plugged into a live AC outlet. If the fan can be heard running, then the power supply in the projector is probably working properly (with very few exceptions). 1.2 If the fan does not begin to run when the projector is plugged in, check and replace the Power Supply. See Section 4.2.18 on page 82. Immediately after plugging the projector into AC power, the P Power Status indicator LED will briefly flash in an amber color, then will turn solid (constant) amber. Once the P Power Status LED is solid amber, the projector has checked main board functions and loaded its basic instruction set from ROM. In general, the main board is functional at this point and is not likely to be a cause of failure in the projector. If the Fan is running but the P Power Status LED does not light or does not stop flashing, the MA Board and Optical Engine need to be replaced. See Section 4.2.11 on page 73 and Section 4.2.21 on page 88. Once the Power Status LED is amber and not blinking, the projector is in sleep mode - it has performed power on diagnostics. The projector is ready to be powered on with the [Power] button on the remote control or the control panel of the projector. This will activate the power-on sequence from the ROM instructions.
2. Observe the P Power Status LED. 2.1
2.2
2.3
3. Press the [Power] button and listen for intake and exhaust fans. The intake and exhaust fans start operating in high speed mode as soon as a power on request is made. This means the power on process has started properly. 4. Observe the P Power Status indicator. If the power status indicator is blinking green, the projector is warming up and trying to strike the lamp. 4.1 If the projector can be switched on with the Control Panel, but not the Remote Control, the Remote Control batteries need to be replaced. 4.2 Conversely, if the Remote Control powers on the projector, but the Control Panel does not, there is a problem with the Control Panel on the main unit. Try reconnecting the SW (Switch) Cable, or replace the SW Board Assembly. See Section 4.2.8 on page 71. If the Fans do not pick up speed when power is turned on, there is either a malfunction of one or more fans, or a malfunction of the MA Board. Observe the Status LEDs. A properly functioning MA Board can indicate a fan error on the Status LEDs: the mo Lamp Temperature indicator LED will flash red at 1 second intervals, and the P Power Status indicator will remain solid amber. If a fan error is indicated, check or replace the fans. See Section 4.2.14 on page 79, Section 4.2.20 on page 86 and Section 4.2.24 on page 91. 4.4 If the fans are slow and no error is indicated by the LEDs, replace the MA Board and Optical Engine.
47 Start-up Sequence Troubleshooting
4.3
Troubleshooting
Epson PowerLite S1 Series
5. Watch for light output. If there is no light output after approximately 40 seconds, observe the mo Lamp Temperature indicator. See the table below for error indication definitions and take the appropriate remedial steps in the order provided. Table 3-2. Power and Lamp Temperature Status LED
Indicator Status Projector Status Likely Fault and Remedy
Flashing orange Flashing orange
High-speed cooling in progress Lamp problem
· Clean the air inlet, air vent and air filter. · Install the projector in a place that has good ventilation so that the air inlet and air output are unobstructed. 1. Check that the lamp cover is closed. 2. If the lamp is broken, replace it. 3. If the lamp is not broken, reinstall the lamp and check whether it turns on. 4. Replace the MA board and Optical Engine. 1. Replace any fans that are not working. 2. Replace the thermistor. 3. Replace the MA board and Optical Engine. 1. Let the projector cool down. Leave the projector plugged in and allow the fans to run. 2. Once cooled and turned off, check all fans for obstruction. 3. Replace the MA Board and Optical Engine. LED Board fault. Reconnect or replace the LED Board.
Lit orange Flashing red (0.5 second interval)
Lit orange Flashing red (1 second interval) Lit orange Lit red
Fan problem, Sensor problem, or other internal problem High temperature problem
All extinguished
Operating normally.
6. If the mo Lamp Temperature indicator is flashing red in 0.5-second intervals, a Lamp or Lamp Cover Switch error is indicated. 6.1 6.2 Check the Lamp Cover and Lamp Cover Switch. If the Lamp is broken, replace it. If it is not broken, reinstall it. If the Lamp Cover Switch is broken, replace it. See Section 4.2.26 on page 93.
7. If the mo Lamp Temperature Indicator is lit solid red, then there is a lamp failure, lamp switch error (Lamp Cover Switch, Lamp Thermistor), or Ballast failure. Check and replace those components. 7.1 See Chapter 2, Section 2.9.1 on page 35 for an overview of the switches and their locations. 7.2 For Lamp Thermistor removal, see Section 4.2.15 on page 80. For Lamp Cover Switch removal, see Section 4.2.26 on page 93.
48 Start-up Sequence Troubleshooting
Troubleshooting
Epson PowerLite S1 Series
7.3
To replace the Ballast, see Section 4.2.18 on page 82 and Section 4.2.19 on page 84.
8. If there is light output, look for video output. If there is no video output, check the video source selection on the projector, the cables connected to the video source and the video source itself. 8.1 If the wrong video source is selected on the projector, change it to the correct input selection. 8.2 If there still is no video output, test the video source by connecting it to another output device. If there is a problem with the video source, no output will be seen on any display device regardless of cables or settings used. If there is a problem with the cable, the video source should fail with all display devices that use that cable type. If the video source works with another display device there is a problem with the video input ports of the projector. Check and replace the I/F Board (Section 4.2.13 on page 78), and if there is still no video output, replace the MA Board and Optical Engine (Section 4.2.11 on page 73 and Section 4.2.21 on page 88).
8.3 8.4
Troubleshooting
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Start-up Sequence Troubleshooting
Epson PowerLite S1 Series
3.4 Detailed Troubleshooting
The table below provides additional troubleshooting procedures if the above process is unsuccessful in determining the problem. Check the nature of the problem using the following table, and then proceed to the corresponding section in the following pages. Always be alert for abnormal noise, image problems, unusual odors and smoke while following troubleshooting procedures. Table 3-3. Troubleshooting Quick Check and Detailed References
Troubleshooting Area Quick Check Detailed Troubleshooting Reference
Exterior Examination Image Display and Quality
Audio Output
Control Panel
Examine the unit for any external abnormalities, such as drop damage or case discoloration. Before checking the image quality: 1. Adjust the projector's front feet as appropriate for the projection position and distance. 2. Adjust the image using the Focus Ring. 3. Press the Auto button to optimize the display. Use the Source and Enter buttons to change the input source. Check the source quality of the Computer/Component Video, S-Video, and Video signals. Use a second display device to verify the image source quality. Check for audio output from each of the input sources. Use a second display device to verify the audio from the source device. Test the operation of each button on the control panel.
Section 3.4.1 on page 50. Section 3.4.2 on page 52.
Section 3.4.3 on page 53 Section 3.4.4 on page 53 Section 3.4.5 on page 54 Section 3.4.6 on page 55 Section 3.4.7 on page 56
Remote Control Oper- Test the operation of each button on the remote control. ation Internal Cable Check Remove the upper case and check the cable connections on the MA board. Reconnect any loose cables. Miscellaneous Troubleshooting suggestions for abnormal noise, overheating, abnormal odor or smoke, and the Power Supply.
3.4.1 Exterior Examination
1. Upper Case 1.1 There should be no damage, deformation or cracking due to external force, such as being dropped. 1.2 1.3 1.4 The Upper Case should be installed correctly. To reinstall it, see Section 4.2.6 on page 67. The remote signal receivers should be clean and free from tape, etc. Air vents should be clean and clear of obstruction
Troubleshooting
50
Detailed Troubleshooting
Epson PowerLite S1 Series
2. Control Panel 2.1 No buttons should be stuck down. 3. Projection Lens Unit 3.1 The Focus Ring and Zoom Ring should turn smoothly. To reinstall or replace it, see Section 4.2.22 on page 89. 3.2 The Lens should be clean and free from damage. 4. IF Panel 4.1 The Remote Control IR signal receiver should be clean and free of foreign materials such as tape. 4.2 There should be no damage, deformation or cracking due to external force. To replace it, see Section 4.2.11 on page 73.
5. Lower Case 5.1 There should be no damage, deformation or cracking due to external force. Replacing the lower case requires nearly complete disassembly. Start with Section 4.2 on page 62. 6. Air Filter 6.1 The Air Filter should be installed correctly. 6.2 Remove the Air Filter from the lower case to check that it is clean. Replace it if necessary. See Section 4.2.3 on page 65.
7. Lamp Cover Unit 7.1 Lamp Cover should be securely attached to lower case. See Section 4.2.2 on page 64. 7.2 Lamp Cover Detection Switch latch should be free from damage. Remove the lamp cover to check. To replace or reinstall the Lamp Cover Detection Switch, see Section 4.2.26 on page 93.
8. Lamp Inner Unit 8.1 The plastic frame should be free from deformation, damage or discoloration from heat. Remove the Lamp Inner Unit to check. See Section 4.2.2 on page 64. 8.2 The cable from the Lamp Inner Unit to the Ballast should be free from discoloration. To replace the Lamp Inner Unit, see Section 4.2.2 on page 64. To replace the Ballast, see Section 4.2.18 on page 82 and Section 4.2.19 on page 84. The glass surface of the Lamp should be clean. Clean the Lamp with isopropyl alcohol to remove contaminants such as fingerprints.
8.3
9. Adjustable Foot Unit 9.1 Check that the projection height can be adjusted with the Foot Unit. To replace the Foot Unit, see Section 4.2.4 on page 65. 10. Interface connectors 10.1 The connectors and terminals should not be bent or discolored, and should be free from contamination, corrosion, etc. To replace the Interface Board, see section Section 4.2.11 on page 73. 11. AC Inlet 11.1 The AC connector should not be discolored. 11.2 The AC source socket should be free from damage. To replace the Power Supply, see Section 4.2.18 on page 82.
Troubleshooting 51 Detailed Troubleshooting
Epson PowerLite S1 Series
3.4.2 Image Display and Quality
C H E C K P O IN T
The image quality can be affected by condensation or by a dirty lens. If condensation forms, the problem will correct itself naturally if the projector is left to stand for a while. Clean a dirty lens with isopropyl alcohol.
1. Press the [Power] button and wait approximately 40 seconds for an image to appear. "NO SIGNAL" should appear in the bottom left of the screen. 1.1 If the lamp does not turn on, replace the Lamp Inner Unit. See Section 4.2.2 on page 64. 1.2 1.3 If the lamp will still not turn on, check the Lamp Thermistor, and if necessary, replace it. See Section 4.2.15 on page 80. If the lamp still does not light, try replacing the following in this order:
Ballast Power Supply MA Board and Optical Engine 2. With the lamp lit and nothing connected to the input connectors, the projector should display the words "NO SIGNAL" on the screen. 2.1 If not, replace the MA Board and Optical Engine. 3. If the image appears, but is poor quality, do the following in the order below: 3.1 Adjust the height of the Front Foot. 3.2 3.3 3.4 3.5 Use the [Keystone] buttons to remove the angle distortion. Adjust the focus using the Focus Ring. Clean the projection lens. If the image cannot be corrected using the above, replace the Optical Engine and MA Board.
4. Next, test the computer and video inputs. Connect a host computer to the Computer/Component Video connectors and look for an image to be displayed. (Some computers, especially laptops, may require activation of an external or secondary video output - usually by pressing a function-key combination.) 4.1 Press the [Source] button to change the display to Computer. 4.2 If there is no image on the screen, disconnect the video cable from the projector and connect the cable to another display device, such as a monitor, to verify that the problem is not with the source computer.
4.3 If the image displays on the monitor, but will not display on the projector, reconnect the projector to the computer and replace the following in the order below, checking for a projected image at each stage: Computer video cable I/F Board MA Board and Optical Engine 5. Check the image quality. If it needs improving, and you've made all the adjustments in 3.1 through 3.4 above, take the following steps: 5.1 Press the [Auto] button. 5.2 Press the [Menu] button, and select the Video menu. From the Video menu, adjust the Brightness and Contrast.
52 Detailed Troubleshooting
Troubleshooting
Epson PowerLite S1 Series
5.3
If the image quality still cannot be improved, replace the Optical Engine and MA Board.
6. Test the Video and S-Video by connecting a video source to each, and repeat all steps in 4 and 5 for each. 7. Test the Monitor Out function. Connect a monitor to the Monitor Out connector on the projector. 7.1 If the projected image is not displayed on the monitor, replace the following in the order below, checking the results at each step: Replace the monitor cable Replace the monitor Replace the projector's IF Board Replace the MA Board and Optical Engine
3.4.3 Audio Output
1. Connect a source computer's audio-out to the projector's audio input connector, and test for sound output from the projector's internal speaker. 1.1 1.2 1.3 If there is no sound, first check that the [AV Mute] button is not muting the sound, and that the volume is not turned completely down. If there is still no sound, connect another speaker device, such as headphones or external speakers, to the host computer audio to verify that the fault is not with the source computer If the projector's speaker appears to be at fault, open the upper case and reconnect the speaker cable to CN1701 on the MA Board. See Figure 3-1 on page 55 for a diagram of connectors on the MA Board. If reconnecting the cable does not solve the problem, replace the speaker. Replace the IF Board if there is no sound from the new speaker. If there is still no sound, replace the MA Board and Optical Engine.
1.4 1.5 1.6
2. Once the speaker is working, test the volume adjustment, tone adjustment and [AV Mute] function correctly. If not, replace the following in the order below, checking the results at each step: IF Board MA Board and Optical Engine 3. Repeat steps 1 and 2 for Video and S-Video source equipment. Remember to independently verify the functionality of the source equipment by connecting it to other display devices capable of sound output. Also remember to press the [Source] button on the projector to select the appropriate test source. 4. Connect external speakers to the projector's audio output connector. If no sound is output, replace the IF Board.
3.4.4 Control Panel
1. Test the following buttons on the Control Panel: 1.1 1.2 1.3 The [Power] button should turn the projector on and off. The [Menu] button should cause the menu to be displayed by the projector. The [Source] button should switch between Computer/Component Video, S-Video and Video input sources.
Troubleshooting
53
Detailed Troubleshooting
Epson PowerLite S1 Series
1.4 1.5 1.6
The [Esc] button should, depending on where you are in a menu, either cancel the current function, or return one level up to the previous menu much like a "back" key. The [Enter] key should select a menu item. The [Keystone] buttons should adjust the image vertical display angle distortion.
2. If any of these keys fail to work, check and replace the following in the order below, checking functionality at each stage: 2.1 Reconnect the SW Board Cable to CN400 on the MA Board. Remember that CN400 is a locking connector, and be sure that it is seated firmly in the connector before re-locking it. Check that the other end of the cable is connected properly to the SW Board (Control Panel). See Section 4.2.8 on page 71. 2.2 2.3 Replace the SW Board. Replace the MA Board and Optical Engine
3.4.5 Remote Control Operation
1. Check the functionality of all buttons on the infra-red (IR) Remote Control. If the buttons do not operate normally, check and replace the following in the order below. Check functionality at each stage before proceeding to the next. 1.1 First, verify that the projector operates normally using the on-board Control Panel. 1.2 1.3 1.4 1.5 1.6 Check that the Remote Control is being operated with a clear line-of-sight to the projector, and within the specified range of 20 ft. Test both front and rear IR sensors on the projector. Check whether functionality returns if the Remote Control is operated very close to the projector. Replace the batteries in the Remote Control and repeat steps 1.2 and 1.3. Replace the Remote Control and recheck. Check the remote control with another projector to verify that it operates normally. Test whether there is any difference in functionality between the Front IR sensor and the Rear IR sensor. Check the cable connections for each. If the cable connections appear to be OK, replace the sensors:
The Front IR sensor is on the RC Board, connected by cable to CN603 on the MA Board. See Section 4.2.16 on page 81. The Rear IR sensor is on the IF Board Assembly, which is connected by cable to CN600 on the MA Board. Connector CN600 is on the underside of the MA Board, so removal of the MA Board will be necessary to check the connection or replace the IF Board Assembly. See Section 4.2.11 on page 73 through Section 4.2.13 on page 78. 2. If the above repairs do not solve the problem, replace the MA Board and Optical Engine.
Troubleshooting
54
Detailed Troubleshooting
Epson PowerLite S1 Series
3.4.6 Internal Cable Check
Check connections at the following locations:
C A U T IO N
Turn off the power and disconnect the power cable before you begin the following connector checks.
CN1600
CN1701
CN603
CN1400
CN704 CN1500 CN601 CN702 CN701 CN1800 CN400 CN602 CN600 (Underneath)
Figure 3-1. Main (MA) Board Connector Locations Table 3-4. MA Board Connector Description (Clockwise from lower-left)
MA Board connector Connects to: MA Board connector Connects to:
CN600 CN400 CN702 CN1500 CN1600 CN1701 CN603
Troubleshooting
I/F Board (incl. Rear IR Sensor) Control Panel Intake Fan (Fan100) Green Light Valve Red Light Valve Speaker RC Board (Front IR Sensor)
55
CN1400 CN704 CN601 CN701 CN1800 CN602
Blue Light Valve Exhaust Fan (Fan80) Lamp Cover Detection Switch Lamp Thermistor Power Supply Unit Ballast
Detailed Troubleshooting
Epson PowerLite S1 Series
3.4.7 Miscellaneous
1. Abnormal noise 1.1 Check for foreign objects around the Exhaust Fan, Intake Fan and Power Supply Fan. 1.2 Check whether the noise is being generated by the Power Supply (e.g. pulse transformer vibration, etc.) or Ballast, and replace them if necessary.
2. Projector overheating 2.1 Check and replace the Air Filter. 2.2 2.1 2.2 3.1 3.2 Check the Exhaust Fan, Intake Fan and Power Supply Fan. Clean or replace as necessary. Check and replace the Lamp Thermistor or Safety Switch. If none of the above fix the overheating problem, replace the Optical Engine and MA Board. Check cables for charring or discoloration. First, correct the cause of the overheating problem, and then replace all discolored or damaged cables. Burning dust causes abnormal odors, so be sure the air filter is clean and undamaged, and make sure the Intake Duct is clean. Check for excessive heat.
3. Smoke or abnormal odor
4. Power Supply Problems 4.1 Determine whether the problem is being caused by components inside the power supply unit, or whether it is being caused by some external factor. To determine this, check factors such as output voltage, internal temperature, appearance of components, odors and smoke. 4.2 If the cause is judged to be an internal problem, replace the power supply unit. If the newlyreplaced power supply unit also has a problem and the symptoms are the same as before, then the cause of the problem is probably some external factor. Eliminate the external factor that is causing the problem. If the power supply unit is recoverable but is not working properly, for example if high temperatures are causing the thermostat to shut down the power supply, or if the overcurrent protection circuit has tripped, then there is no need to replace the power supply unit. If the power supply unit is not recoverable and is not working properly, for example if an overcurrent has repeatedly blown the fuse, replace the power supply unit. If there is a problem with the power supply fan, the power supply will shut down after several minutes of operation, and the LED indicators will switch off. If that happens, replace the power supply unit.
4.3
4.4 4.5
Troubleshooting
56
Detailed Troubleshooting
CHAPTER 4 DISASSEMBLY / ASSEMBLY
Epson PowerLite S1 Series
4.1 Overview
This chapter describes the procedures for disassembling and assembling the main components of the PowerLite S1/S1+ projector. Unless otherwise specified, reassembly is the reverse of the disassembly procedure. Read the precautions described in the next section before starting.
4.1.1 Precautions
Some procedures require specific precautions that must be followed, and those will be noted throughout this chapter. Note the following precaution definitions: WARNING
W A R N IN G
Procedures which, if not strictly observed, could result in personal injury are described under the heading WARNING.
CAUTION
C A U T IO N
CAUTION
signals a precaution which, if ignored, could result in damage to equipment.
REASSEMBLY If assembly needs special attention or the procedure is different from the reversed disassembly procedure, the correct procedure is described under the heading REASSEMBLY.
CHECK POINT
C H E C K P O IN T
Important tips for procedures are described under the heading CHECK POINT.
The precautions in the two lists below, WARNING and CAUTION, must always be followed during disassembly and assembly. Before starting the disassembly work on this product, read and follow these precautions.
Disassembly / Assembly
58
Precautions
Epson PowerLite S1 Series
W A R N IN G
No work should be performed on the unit by persons unfamiliar with basic safety measures as dictated for all electronics technicians in their line of work. Remove any metallic objects such as wristwatches, shirt cuff buttons, rings and tie pins which may pose a danger of coming into contact with the projector. Always wear gloves when disassembling and reassembling the projector. Disconnect the power cord from both the projector and the electrical outlet. If you need to work on the projector with power applied, strictly follow the instructions in this manual. When the power supply cable must be connected, use extreme caution in working on the power supply and other electronic components. Repairs on Epson product should only be performed by an Epson certified repair technician. Turn off the power for both the projector and the host computer before disconnecting or connecting them. Once all power has been turned off, disconnect any interface cables that are still connected. Prior to disassembly, use a vacuum cleaner to clean the air filter, interface panel, fan ducts and outer case. Use only recommended tools for disassembly and assembly of the projector. Always verify that the product has been unplugged from the AC power source before disconnecting, removing, or replacing any cables or printed circuit boards. Use static discharge equipment such as anti-static wrist straps when accessing internal components to protect sensitive electronic components and circuitry. Do not use second source ICs or other components not approved by Epson. They could cause damage to the Epson product and void the Epson warranty.
C A U T IO N
Disassembly / Assembly
59
Precautions
Epson PowerLite S1 Series
4.1.2 Tools and Equipment
The tools and equipment in the following table will be needed. All are commercially available, and should be made ready beforehand. Table 4-1. Tools Needed
Name Application
Phillips screwdriver No. 0 Phillips screwdriver No. 2, 8 inches (20 cm) long Hexagonal box screwdriver (5 mm) Tweezers Brush Vacuum cleaner Lens cleaner, isopropyl alcohol Air blower Gloves Grounding strap Heat-resistant tape, 1 foot length
Disassembling the Focus ring Disassembling the outer case and inner components Removing the computer interface Unlocking cable connectors Cleaning away dust Cleaning away dust Cleaning the projection lens Cleaning the light valves and fans Protection from sharp edges Protection from static electricity Securing cables
4.1.3 Projector-Specific Service Precautions
C H E C K P O IN T
The Optical Engine and Main (MA) Board are paired together as a single service part. Neither is available separately. For service that requires the replacement of either the MA Board or the Optical Engine, both components must be replaced together. The component parts of the Optical Engine require mechanical installation positions to be adjusted in relation to each other. In addition, the control circuit also has its own unique characteristics, such as display signal output drivers, that differ from projector to projector. There are also unique differences in each optical system mechanism, such as in the light valves. In order to obtain the optimum display, it is necessary to eliminate these differences in electrical and mechanical characteristics as well as to make mechanical adjustments. The various correction values are set at the time of shipment from the factory and are stored in ROM on the MA Board. Always replace the Optical Engine and MA Board together as a matched pair. Do not disassemble the Optical Engine. Do not replace the component parts of the Optical Engine with parts from other Optical Engines.
Disassembly / Assembly
60
Tools and Equipment
Epson PowerLite S1 Series
Points to Note When Working Detailed points to note are given in each section, so be sure to read each section thoroughly before beginning the disassembly procedure. Below are several general points which should be noted. When you disassemble the projector, the dust in and around parts such as the fans and air filter may get transferred to other parts such as the light valves. This is likely to have an adverse effect on the quality of projected images. Accordingly, check whether any of the fans, ducts or filter parts are dusty or dirty, and use a vacuum cleaner to clean them first before carrying out disassembly work. The Optical Engine and the circuit boards are very sensitive to static electricity. Store them inside staticproof bags once they have been removed from the projector. When you perform any of the following operations, check that there is no dust or dirt on these components or on any lens or glass surfaces before installation. If any such contamination is found, clean it off using isopropyl alcohol. · Optical engine removal · Lamp inner unit removal · Air filter removal The speaker unit contains a permanent magnet, so keep it away from any storage media such as floppy disks and magnetic cards. The Optical Engine is very sensitive to vibration and shocks, so handle it with care. Do not disassemble any components (such as the power supply unit) which do not have express disassembly procedures described in this Service Manual.
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61
Projector-Specific Service Precautions
Epson PowerLite S1 Series
4.2 Projector Disassembly and Assembly
The general disassembly procedure for the PowerLite S1/S1+ projectors is illustrated below. Sections 4.2.1 to 4.2.28 provide detailed instructions, and are linked below. Except where indicated separately, reassembly should be carried out by following the disassembly procedures in reverse.
PROJECTOR
LAMP LID AND LAMP ASSEMBLY 4.2.2 page 64
AIR FILTER 4.2.3 page 65
UPPER CASE 4.2.6 page 67
REMOTE CONTROL 4.2.5 page 66
LENS CAP UNIT 4.2.1 page 63
FOOT UNIT 4.2.4 page 65 SW BOARD ASSY. 4.2.8 page 71
SPEAKER 4.2.7 page 69
MA SHIELD PLATE 4.2.10 page 73
LAMP SHIELD PLATE 4.2.9 page 72 POWER SUPPLY ASSY. 4.2.18 page 82
EXHAUST FAN ASSY. 4.2.14 page 79 LAMP THERMISTOR 4.2.15 page 80 INNER EXHAUST DUCT 4.2.15 page 80 FAN 80 4.2.15 page 80 OUTER EXHAUST DUCT 4.2.15 page 80
MA BOARD, IF PANEL, IF LABEL 4.2.11 page 73 MA FIXING PLATE 4.2.12 page 77 IF BOARD ASSY. 4.2.13 page 78
OPTICAL ENGINE 4.2.21 page 88
LEFT MA FRAME 4.2.17 page 82
BALLAST ASSY. 4.2.19 page 84 POWER SUPPLY FAN 4.2.20 page 86
LOWER SHIELD PLATE 4.2.17 page 82 FOCUS RING 4.2.22 page 89 PROJECTION LENS 4.2.23 page 90
REMOTE CONTROL BOARD ASSY. 4.2.16 page 81
INTAKE DUCT AND RIGHT MA FRAME 4.2.25 page 92 RUBBER FOOT 4.2.28 page 95 LOWER CASE
FAN 100 4.2.24 page 91
LAMP COVER DETECTION SWITCH 4.2.26 page 93
HANDLE 4.2.27 page 94
Figure 4-1. S1/S1+ Projector Disassembly Flowchart
Disassembly / Assembly
62
Projector-Specific Service Precautions
Epson PowerLite S1 Series
4.2.1 Removing the Lens Cap Unit
Remove the Lens Cap and disconnect the tether from the case.
Lens Cap Unit Tether
Figure 4-2. Removing the Lens Cap Unit
Disassembly / Assembly
63
Removing the Lens Cap Unit
Epson PowerLite S1 Series
4.2.2 Removing the Lamp Inner Unit
W A R N IN G
The lamp is very hot immediately after use. Be extremely careful when removing the Lamp Inner Unit. Let the lamp cool a minimum of 30 minutes before beginning the removal procedure. If the lamp breaks, handle the shards carefully to avoid injury. In the unlikely event that the bulb has ruptured, small glass fragments may be present and should be removed with caution.
While releasing the catches of the Lamp Lid, lift it in the direction of the arrow. Loosen the two screws that secure the Lamp Inner Unit, and remove it.
Lamp Lid Lamp Inner Unit
Figure 4-3. Removing the Lamp Inner Unit
C A U T IO N
Do not touch the glass surface of the lamp, and keep the lamp as clean as possible. Clean off fingerprints and other contamination using isopropyl alcohol.
When installing the Lamp Inner Unit, check that it is fitted securely onto the guide pins.
Guide Pins
Figure 4-4. Lamp Inner Unit Guide Pins
Disassembly / Assembly
64
Removing the Lamp Inner Unit
Epson PowerLite S1 Series
4.2.3 Removing the Air Filter
While releasing the catch of the Air Filter Lid, lift it in the direction of the arrow. Remove the Air Filter Lid and Air Filter.
Lid, Air Filter Air Filter
Figure 4-5. Removing the Air Filter
4.2.4 Removing the Foot Units
1. Extend the legs of the Foot Unit as far as they will go. 2. Press a screwdriver into the small slot beside the Foot Unit and pry the Foot Unit out of the projector Lower Case.
Foot Unit
Figure 4-6. Removing the Foot Units
Disassembly / Assembly
65
Removing the Air Filter
Epson PowerLite S1 Series
4.2.5 Removing the Remote Control Holder
1. Open the Remote Control Holder and remove Remote Control.
Holder, Remote Control
Remote Control
Figure 4-7. Removing the Remote Control 2. Squeeze the top and bottom of the Remote Control Holder together near the hinge to disengage the hinge pins, and remove the Remote Control Holder.
Holder, Remote Control
Figure 4-8. Removing the Remote Control Holder
Disassembly / Assembly
66
Removing the Remote Control Holder
Epson PowerLite S1 Series
4.2.6 Removing the Upper Case
1. Remove the 6 (C.B.P-Tite, 4x10, F/ZN) screws and the (C.B., 3x6, F/ZB) screw that secure the Upper Case.
C.B. Screw, 3x8, F/ZB
Figure 4-9. Removing the Upper Case 2. Carefully lift open the front of the Upper Case, and take note of the two cables connected to the Upper Case.
Case, Upper
Speaker Cable
SW Cable (Control panel cable)
Figure 4-10. Opening the Upper Case
Disassembly / Assembly
67
Removing the Upper Case
Epson PowerLite S1 Series
3. Disconnect the Speaker Cable from connector CN1701 on the MA (Main) Board. 4. Unlock connector CN400 on the MA Board and disconnect the Switch (SW) Cable (Control Panel Cable).
CN1701
CN400
Locked
Unlocked
Figure 4-11. Disconnecting the Upper Case Cables
Disassembly / Assembly
68
Removing the Upper Case
Epson PowerLite S1 Series
4.2.7 Removing the Speaker
Remove the two (C.C.P-Tite, 3x6, F/ZN) screws that secure the Speaker to the Upper Case, and remove the Speaker and Speaker Spring.
Speaker
Spring, Speaker
Case, Upper
Figure 4-12. Removing the Speaker
Disassembly / Assembly
69
Removing the Speaker
Epson PowerLite S1 Series
When installing the Speaker, make sure that the lead wire runs in the direction shown in Figure 4-13. Install the Speaker Spring so that it is in contact with the Shield Plate of the Upper Case.
Figure 4-13. Installing the Speaker
Disassembly / Assembly
70
Removing the Speaker
Epson PowerLite S1 Series
4.2.8 Removing the Switch (SW) Board Assembly
1. Unlock the connector and disconnect the Switch (SW) Cable. 2. Remove the 4 (C.C.P-Tite, 3x6, F/ZN) screws that secure the SW Board Assembly. 3. Remove the Switch (SW) Button, LED Lens, and SW Panel.
Spring, SW Board
Spring, SW Board SW Board Connector Button, SW Cable, SW
LED Lens
Panel, SW
Figure 4-14. Removing the Switch (SW) Board Assembly
Disassembly / Assembly
71
Removing the Switch (SW) Board Assembly
Epson PowerLite S1 Series
When reinstalling the SW Board, replace the screws in the hole positions shown in Figure 4-14. Bend and route the SW Cable as shown in Figure 4-15.
Figure 4-15. Switch (SW) Cable Routing
4.2.9 Removing the Lamp Shield Plate
Remove the 2 (C.O., 3x5, F/ZN) screws that secure the Lamp Shield Plate, and remove it.
Shield Plate, Lamp
Figure 4-16. Removing the Lamp Shield Plate
Disassembly / Assembly 72 Removing the Lamp Shield Plate
Epson PowerLite S1 Series
4.2.10 Removing the MA Shield Plate
Remove the 7 (C.O., 3x5, F/ZN) screws that secure the MA Shield Plate, and remove the MA Shield Plate.
Shield Plate, MA
Figure 4-17. Removing the MA Shield Plate
4.2.11 Removing the MA Board, IF Panel and IF Label
1. Release the locks for the R, G and B Light Valve Cable connectors.
Light Valve G Connector Locked
Unlocked
Light Valve B Connector
Light Valve R Connector
Figure 4-18. Unlocking the Light Valve Cable Connectors
Disassembly / Assembly
73
Removing the MA Shield Plate
Epson PowerLite S1 Series
When connecting the cables to the R/G/B light valve connectors, insert the cables squarely as far as they will go, as shown in Figure 4-19.
Figure 4-19. Light Valve Cable Connection
.
2. Disconnect the R, G and B Light Valve cables and the seven remaining MA Board cables. Note: The cables for connectors CN1701 and CN400 were disconnected earlier in Section 4.2.6 on page 67. Connector CN600 is on the underside of the MA Board and will be disconnected in the next section. All three of these are indicated by blue arrows below.
CN1600 CN1701 CN603 CN1400
CN704 CN1500 CN601 CN702 CN701 CN1800 CN400 CN602 CN600 (Underneath)
Figure 4-20. Disconnecting the MA Board and Light Valve Cables
Disassembly / Assembly
74
Removing the MA Board, IF Panel and IF Label
Epson PowerLite S1 Series
When reinstalling the front IR sensor's Remote Control (RC) Cable, secure it to the Left MA Frame with heat-resistant tape as shown in Figure 4-21.
RC Cable
Heat-resistant tape
Figure 4-21. Reinstalling the RC Cable When wiring the Exhaust Fan Cable and Lamp Thermistor Cable, run the Lamp Thermistor Cable under the projection of the Exhaust Fan and twist it twice with the Exhaust Fan Cable as shown in Figure 4-22.
LAMP Thermistor Cable
Exhaust Fan Cable
Figure 4-22. Routing the Exhaust Fan and Lamp Thermistor Cables
Disassembly / Assembly
75
Removing the MA Board, IF Panel and IF Label
Epson PowerLite S1 Series
3. Remove the 2 (C.B., 3x6, F/ZB) screws that secure the IF Panel and the (C.B, P-Tite, 3x10, F/ZN) screw that secures the MA Fixing Plate, and remove the MA Board.
Panel, IF
MA Board
Figure 4-23. Removing the MA Board 4. Remove the (C.B., 3x6, F/ZB) screw that secures the IF Panel, and remove the IF Panel and the IF Label.
MA Board
Panel, IF
Label, IF
Figure 4-24. Removing the IF Panel and Label
Disassembly / Assembly
76
Removing the MA Board, IF Panel and IF Label
Epson PowerLite S1 Series
4.2.12 Removing the Main Board Fixing Plate
1. Unlock connector CN600 on the Main Board and connector CN3002 on the IF Board Assembly, and then remove the IF Assembly Cable.
IF Assembly Cable Solid White Side Blue Side IF Board Assembly
CN600
CN3002 MA Board
Figure 4-25. Disconnecting the IF Board Assembly from the MA Board Install the IF Board Assembly Cable with the solid white surface facing upward as shown below. When reinstalling the cable, secure it to the IF Board Assembly and connector with heat-resistant tape as shown in Figure 4-26.
Heat-Resistant Tape IF Assembly Cable Solid White Surface
MA Board
Figure 4-26. Installing the IF Board and Cable
Disassembly / Assembly
77
Removing the Main Board Fixing Plate
Epson PowerLite S1 Series
2. Remove the 4 (HSH 4-40) screws and 2 (C.B. 3x10, F/ZB) screws from the MA Fixing Plate, then remove the plate from the MA Board.
Edge Guards
MA Board
Fixing Plate, MA
Figure 4-27. Removing the MA Fixing Plate
4.2.13 Removing the IF Board Assembly
Remove the (C.B.P.-Tite, 3x10, F/ZB) screw, the 2 (HSH 4-40) screws, and the (C.O., 3x5, F/ZN) screw that secure the IF Board Assembly, and remove the IF Board Assembly.
IF Board Assembly Fixing Plate, MA
Figure 4-28. Removing the IF Board Assembly
Disassembly / Assembly
78
Removing the IF Board Assembly
Epson PowerLite S1 Series
4.2.14 Removing the Exhaust Fan Assembly
Remove the 3 (C.B.P-Tite, 3x10, F/ZB) screws from the Exhaust Fan Assembly, and remove the Exhaust Fan Assembly.
Exhaust Fan Assembly
Figure 4-29. Removing the Exhaust Fan Assembly
Disassembly / Assembly
79
Removing the Exhaust Fan Assembly
Epson PowerLite S1 Series
4.2.15 Disassembling the Exhaust Fan Assy.
Remove the 2 (C.B.P-Tite, 4x35, F/ZN) screws that secure Fan 80, and then remove the Lamp Thermistor, Inner Exhaust Duct, Fan 80, and Outer Exhaust Duct.
Duct, Exhaust Outer
Fan 80 Duct, Exhaust, Inner
Lamp Thermistor
Figure 4-30. Removing the Lamp Thermistor, Fan 80, and Exhaust Ducts
Disassembly / Assembly
80
Disassembling the Exhaust Fan Assy.
Epson PowerLite S1 Series
4.2.16 Removing the RC Board Assembly
1. Remove the (C.(O), 3x5, F/ZN) screw that secures the Remote Control (RC) Board Assembly, and remove the RC Board Assembly. 2. Disconnect the RC Board Cable from the RC Board Assembly.
Cable, RC Board
Printed Circuit Board Assy: RC-R1
Figure 4-31. Removing the RC Board Assembly
Disassembly / Assembly
81
Removing the RC Board Assembly
Epson PowerLite S1 Series
4.2.17 Left MA Frame, Lower Shield Plate Removal
1. Remove the 2 (C.B.P-Tite, 3x10, F/ZN) screws that secure the Left MA Frame. 2. Remove the Lower Shield Plate.
Shield Plate, Lower
Frame, MA Left
Figure 4-32. Removing the Left MA Frame and Lower Shield Plate
4.2.18 Removing the Power Supply / Ballast Assembly
1. Remove the 3 (C.C.P-Tite, 3x8) screws that secure the Ballast Output Cable and Thermostat.
Ballast Output Connector
Ferrite Core
Ballast Output Cable
Thermostat
3 C.C.P. 3x8 Screws
AC Inlet
Figure 4-33. Removing the Ballast Output Cable and Thermostat
Disassembly / Assembly 82 Left MA Frame, Lower Shield Plate Removal
Epson PowerLite S1 Series
C A U T IO N
When reconnecting the Ballast Output Cable, pay attention to the connector orientation.
When installing the AC Inlet, pull the AC wires out of the Power Supply and loop them to the left as shown in the blue circle in Figure 4-33.
2. Remove the 4 (C.B.P-TITE, 3x10, F/ZB) screws that secure the Power Supply/Ballast Assembly, and remove the Power Supply/Ballast Assembly.
Power Supply / Ballast Assembly
Figure 4-34. Removing the Power Supply/Ballast Assembly
Disassembly / Assembly
83
Removing the Power Supply / Ballast Assembly
Epson PowerLite S1 Series
4.2.19 Removing the Ballast Assembly
Disconnect the cable that is connected to the Power Supply Assembly and Ballast Assembly, and separate the two assemblies.
Power Supply Assembly (100 V or 200 V)
Ballast Input Cable Ballast Assembly
Figure 4-35. Removing the Ballast Assembly from the Power Supply Assembly
Disassembly / Assembly
84
Removing the Ballast Assembly
Epson PowerLite S1 Series
When reconnecting the Power Supply Assembly and Ballast Assembly with the Ballast Input Cable, route the cable so that the ferrite core is located under the Power Supply Fan.
.
Power Supply Fan
Ferrite Core
Figure 4-36. Routing of the Ballast Input Cable When reinstalling the Ballast Assembly, route the SCI cable as shown in Figure 4-37.
Ballast Assembly
SCI Cable
Figure 4-37. Routing the SCI Cable
Disassembly / Assembly 85 Removing the Ballast Assembly
Epson PowerLite S1 Series
4.2.20 Removing the Power Supply Fan
1. Remove the 4 (C.B., 3x8, F/ZB) screws that secure the Power Supply Assembly Case, and disconnect the Power Supply Fan Cable from the Power Supply Assembly.
C.B. 3x8 Screws
Power Supply Fan
Power Supply Fan Cable Power Supply Fan Connector
Figure 4-38. Disconnecting the Power Supply Fan Cable
Disassembly / Assembly
86
Removing the Power Supply Fan
Epson PowerLite S1 Series
2. Remove the 2 (C.P.B-Tite, 5x10, F/ZN) screws that secure the Power Supply Fan, and remove it.
Power Supply Fan
Figure 4-39. Removing the Power Supply Fan When routing the Power Supply Fan Cable, secure it in two places with heatresistant tape as shown in Figure 4-40.
Heat-Resistant Tape
Figure 4-40. Routing the Power Supply Fan Cable
Disassembly / Assembly
87
Removing the Power Supply Fan
Epson PowerLite S1 Series
4.2.21 Removing the Optical Engine
C A U T IO N
Make sure that you remove only the correct 4 screws so as not to disassemble the Optical Engine.
1. Remove the 4 (C.B.P-Tite, 3x10, F/ZB) screws that secure the Optical Engine to the projector. 2. Lift the Optical Engine straight up to remove it.
Screw Screw Screw
Optical Engine
Screw
Figure 4-41. Removing the Optical Engine
Disassembly / Assembly
88
Removing the Optical Engine
Epson PowerLite S1 Series
When reinstalling the Optical Engine, pay attention to the cable routing.
Optical Engine Fan 100 Cable Frame, MA Right
Projection Lens Unit
Lamp Cover Detection Switch
Figure 4-42. Cable Routing, Optical Engine Installation
4.2.22 Removing the Focus Ring
Use a No. 0 Phillips screwdriver to remove the 3 (6008240) screws that secure the Focus Ring, and remove the ring from the Projection Lens.
Optical Engine
Tab
Projection Lens Unit Focus Ring
Figure 4-43. Removing the Focus Ring
Disassembly / Assembly
89
Removing the Focus Ring
Epson PowerLite S1 Series
When installing the Focus Ring, make sure that the tab on the outside of the Focus Ring is facing upward. See Figure 4-43.
4.2.23 Removing the Projection Lens Unit
Remove the 4 (C.P. S-P1, 3x10, F/ZN) screws that secure the Projection Lens, and remove the Lens from the Optical Engine.
Optical Engine
Projection Lens Unit
Figure 4-44. Removing the Projection Lens Unit
Disassembly / Assembly
90
Removing the P