Service Manual Epson America, Inc.
PowerLite 5000 Service Manual ii
VCCI COMPLIANCE STATEMENT This equipment has been tested and found to comply with the limits for Type 1 information equipment, which uses radio-frequency energy and fully complies with the specifications limiting computer information equipment in radio interference regulations (VCCI rules). If not installed and used properly according to the manufacturer's instructions, this device may cause interference to radio and television reception.
INTRODUCTION This Service Manual describes hardware information necessary for field service and troubleshooting of the PowerLite 5000 Multimedia Projector. Manual updates will be supplied in service bulletins. HOW TO USE THIS SERVICE MANUAL The manual covers topics which may be required for field maintenance so you can use it for diagnosis of failures or repair. Before beginning maintenance work, be sure to read and observe safety precautions and rules.
PRECAUTIONS OPERATOR SAFETY 1. PROTECTION FROM ELECTRIC SHOCK • Before performing any repair work on the product, be sure to turn off the power switch and remove the power cable from the electrical outlet. • Whenever it is necessary to turn the power on after opening the case or cover (for example, during the adjustment process) be sure to take off any metallic materials such as a watch, cuff links, rings, or tie pin, which may touch the metallic part of the product, creating a danger of electric shock. 2.
3. OTHER PRECAUTIONS • Visually check for damage or dirt on the power connectors and cable. If dirty, clean it, and if bent or damaged, replace the cable to prevent firing by the flush over phenomenon. • When connecting the internal connector cables or interface cables, be sure to plug them into the connector fully, until they are attached to the connector edge. • Be sure to remove the connector lock before removing the FPC cable for the light bulb.
Contents Chapter 1 Product Features 1.1 Product Features .........................................................................................1-1 1.2 Parts of the Projector ..................................................................................1-2 1.2.1 Exterior View of Main Frame..............................................................1-2 1.2.2 Interior View of Main Frame ...............................................................1-3 1.2.3 Exterior View of Remote Control ...........
2.13.1 Filter Cover Switch...........................................................................2-30 2.13.2 Interlock Switch................................................................................2-31 2.13.3 Safety Switch ...................................................................................2-31 2.13.4 Lamp Thermistor..............................................................................2-32 2.13.5 LV Thermistor ...............................................................
CHAPTER 4 TROUBLESHOOTING 4.1 Before Starting Troubleshooting Procedures ...............................................4-1 4.1.1 Tools and Accessories Required for Troubleshooting ........................4-1 4.1.2 Field Replacement Parts....................................................................4-1 4.2 First Action ..................................................................................................4-2 APPENDIX A A.1 Parts List ........................................................
EPSON PowerLite 5000 Service Manual 1.1 PRODUCT FEATURES The PowerLite 5000 multimedia projector is a portable, easy-to-use presentation device with an SVGA resolution. It projects enhanced color images from personal computers and from video equipment such as VCRs, camcorders, and digital cameras. Features ❐ Light weight, compact, portable The new structure minimizes the projector to page size with a weight of only 14.1 lb (6.4 kg). An optional carrying case is available for transporting the projector.
EPSON PowerLite 5000 Service Manual 1.2 PARTS OF THE PROJECTOR 1.2.
EPSON PowerLite 5000 Service Manual A Styrofoam plate is mounted under the foot at shipment. Filter Cover Remove it when you make adjustments. Foot Adjuster A Foot Adjuster B Lamp Cover Figure 1-3 1.2.
EPSON PowerLite 5000 Service Manual Main Board Handle Driver Board AU Board Light Guide Unit Figure 1-5 LV Thermistor Prism Duct Driver Board Exhaust Fan Inlet Unit Figure 1-6 1-4
EPSON PowerLite 5000 Service Manual RI Board AU Board FR Board Figure 1-7 Foot Adjuster A Lamp Thermistor Light Guide Unit Figure 1-8 1-5 Safety Switch Lamp Power Cable
EPSON PowerLite 5000 Service Manual Filter Board Filter Cover Switch CN Board Figure 1-9 1-6 Inlet Unit
EPSON PowerLite 5000 Service Manual 1.2.3 Exterior View of Remote Control 1 Remote Infrared Rays 2 Menu 3 Auto 4 Video 5 Computer 6 Effects 7 Pointer 8 Right Click 9 Blank 10 Custom 11 Mute 12 Resize 13 Freeze 14 Volume 15 Power 16 Left Click Figure 1-10 1.3 CONNECTIONS 1.3.
EPSON PowerLite 5000 Service Manual Laptop Audio Port Monitor Port Serial Mouse Cable Serial Port Mouse Port COM Port PS/2 Mouse Cable Serial Cable Monitor Cable Main Cable Audio Cable Figure 1-12 1.3.
EPSON PowerLite 5000 Service Manual Table 1-1 Switch A Resolution Switch B Top Row (A) Bottom Row (B) VGA 3, 4, 5 8 13” 640 × 480 1, 2, 5 8 Mac Desktop 16” 832 × 624 2, 4, 5 8 Video Adapter 19” 1024 × 768 2, 3, 5 8 21” 1152 × 870 1, 2, 3, 4, 5 8 13” Multi Res. 1, 2, 5 8 14” Multi Res. 1, 2, 5 3, 4, 8 17” Multi Res. 1, 2, 5 3, 8/4, 8 21” Multi Res.
EPSON PowerLite 5000 Service Manual 1.3.3 Connecting to a Video Source Video Devices S-Video Video Output (Yellow) Video In (Yellow) Left Audio In (White) S-Video Output Audio Output (White) Audio Output (Red) S-Video Cable Figure 1-16 1.3.
EPSON PowerLite 5000 Service Manual 1.
EPSON PowerLite 5000 Service Manual FR board Figure 1-21 CN board Figure 1-22 Receptor boards RI board FI board Figure 1-23 1-12
EPSON PowerLite 5000 Service Manual Speakers Left Speaker Right Speaker Figure 1-24 Inlet unit CN Board Figure 1-25 Filter unit Figure 1-26 1-13 Inlet Unit
EPSON PowerLite 5000 Service Manual Power supply unit Figure 1-27 Lamp inner housing Figure 1-28 Control panel Figure 1-29 1-14
EPSON PowerLite 5000 Service Manual Optical engine Top side view Figure 1-30 Bottom side view Figure 1-31 1-15
EPSON PowerLite 5000 Service Manual 1.5 SPECIFICATIONS Table 1-2 OPTICAL FEATURES Display method Transparency type poly-silicon TFT color liquid crystal display with three panels (R/G/B) Optical method Diachronic mirror separation and prism combination methods Minimum 21 inches to maximum 300 inches (0.6 m to 7 m) 3.94 feet to 40.35 feet (1.2 m to 12.3 m) 800 x 600 dots; 1,440,000 pixels (480,000 x 3) Zoom lens F2.5 - 2.9 (55-77 mm) Manual Manual (1:1.
EPSON PowerLite 5000 Service Manual VIDEO INPUT/OUTPUT Computer In 1 interface Computer In 2 interface S-Video Interface Video IN Interface (Composite video interface) Host computer 1 RGB output Interface type: HD-15-pin (DDC1/2B compatible) Input signal: Luminous 0.714 Vp-p, Chrominous 0.28 Vp-p. Interface type: Min-DIN 4-pin S-Video is prior to composite video.p. Input signal: 1,0 Vp-p, sync, negative Interface type: RCA jack (yellow) TV signal type: NTSC 3.58 MHz PAL 4.43 MHz SECAM 4.
EPSON PowerLite 5000 Service Manual 1.6 INTERFACE SPECIFICATIONS 1.6.1 Computer In 1/2 Computer video input D-SUB 15 (HD) 5 1 10 6 15 11 Figure 1-32 Table 1-3 Pin 1 2 3 4 5 6 7 8 Terminal Red video Green video Blue video Monitor (ID bit 2) GND Red video GND Green video GND Blue video GND Pin 9 10 11 12 13 14 15 Terminal +5V Synchronous GND Monitor (ID bit 0) SDA Horizontal synchronization Vertical synchronization SCL 1.6.
EPSON PowerLite 5000 Service Manual 1.6.4 Monitor 5 1 10 6 15 Table 1-6 Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 11 Figure 1-35 Signal R Out G Out B Out Reserved GND GND GND GND Reserved GND Reserved Reserved H sync V sync V sync Function Red video Green video Blue video Horizontal synchronization Vertical synchronization 1.6.
EPSON PowerLite 5000 Service Manual 1.6.6 Video-In RCA gold plating (only insertion part), Light angle H=15 mm Color: yellow 2 1 Table 1-8 Pin number 1 2 Signal GND Video input Figure 1-37 1.6.
EPSON PowerLite 5000 Service Manual 1.6.
EPSON PowerLite 5000 Service Manual 2.1 HARDWARE The optical and electrical systems are the major areas of projector hardware. The lower level (below the broken line in the figure) shows the optical system, and the upper level shows the electrical system. POWER SUPPLY: Generates DC voltages (+5 V, +12 V, +22 V, +3.3 V) for the electric circuits; also generates DC voltage (350 V) for the light source.
EPSON PowerLite 5000 Service Manual Description of the Projection Process 1. The digital or analog R/G/B signal is provided from a computer (1 or 2) to the main board. Analog signals (S-Video or Video signals) are sent to the main board through the AU board. (Analog signals are converted into digital signals by the main board.) 2. The digital video signal is then stored in video memory (SRAM) on the main board. Then the driver board generates signals to drive the R/G/B light valves. 3.
EPSON PowerLite 5000 Service Manual 2.1.1 Electrical System Connections Electrical units are physically connected to the main board as shown below.
EPSON PowerLite 5000 Service Manual 2.1.2 Optical System Connections (Optical Engine) The optical system consists of 5 blocks: the lamp inner housing, light guide unit, optical head/prism unit, and projector lens unit, which are shown below, and the driver board. These units are specified as the optical engine, which is one replaceable part. In addition to these five items, the FC board is attached at the bottom of the light guide unit.
EPSON PowerLite 5000 Service Manual Inside View of the Light Guide Unit Figure 2-4 Caution: Do not cause any shock or mechanical stress to the optical engine or disassemble it. Otherwise, pixel divergence may occur. The alignment is adjusted in the factory, and specific electrical correction is made on the driver board for each optical engine.
EPSON PowerLite 5000 Service Manual 2.2 POWER SUPPLY UNIT The power supply unit includes a DC regulator, intake fan, and interlock switch for the lamp cover. This unit generates the voltages for the control circuit (+3.3 V, +5 V, +12 V, +22 V) and for the light source lamp (+350 V) from AC input. The PBS thermistor is installed on the side of the power supply intake fan and is retained with a clamp on the power supply unit. It detects the temperature.
EPSON PowerLite 5000 Service Manual • • An interlock switch is included for safety. The interlock switch shuts off the supply of AC power if the lamp cover at the bottom of the main chassis is open. The safety switch input signal stops power output to the light source lamp if the projector detects overheating. The safety switch is mounted on the light guide unit attached to the lamp inner housing.
EPSON PowerLite 5000 Service Manual • The intake fan removes the heat generated in the power supply unit. Heat expelled by the intake fan is blown by the exhaust fan, connected to CN860 on the main board. Pin assignments on CN800 (main board) Table 2-3 CN800 Pin. No Signal 1 2 3 4-7 8 9 10 11 12,13 14,15 PIN 15 +22 V +12 V A GND L GND PWDS BACTA LPSTC +12 FV +3.
EPSON PowerLite 5000 Service Manual 2.3 MAIN BOARD The main board consists of the CPU, P-ROM, video memory (SRAM), digital video controller, and circuits to control the control panel, computer input interface, monitor output, speakers, power management, etc. The main board controls everything except video signal generation. The main board is available as a unit for service. The fuses listed below are soldered onto the main board and are for reference only.
EPSON PowerLite 5000 Service Manual Main Board Circuit Block Connects to Connects to Power Supply AU Board CN800 CN603 DC Input +5 V CN602 Connects to Right Speaker • • +22 V Connects to Control Panel Connects to CN Board LED Indicator Power Control • Connects to Exhaust Fan CN802 IC600 Power Power ON/OFF Management Lamp power Audio Control Backup Power Indicator Driver CN806 CN600 +12 V Switching Circuit IC601 A 0 Control A D 8 7 ~ +12 V Connects to Left Speaker ~ +3
EPSON PowerLite 5000 Service Manual Functional Outline • • • • • • • • IC600 and related circuits are backed up with +3.3 V which is provided from the power supply. (If the AC cable is connected to the AC source, power supply provides the +3.3 V for back-up bias even if RS-361 is turned off.) When the power is turned on, IC600 on the main board generates the reset signal and initializes the circuit. The CPU reads the program from flash ROM and writes it into SRAM.
EPSON PowerLite 5000 Service Manual 2.4 DRIVER BOARD The driver board has two functions: one is converting the R/G/B display signal from the main board into six states of analog signals (light valve driver signals) and the other is controlling the display image by referencing electrical correction data. The entire optical engine must be replaced in maintenance service. No individual parts, such as the driver board, may be replaced. The fuses listed below are soldered onto the Driver board.
EPSON PowerLite 5000 Service Manual • the driver circuit for the light valves. Timing signals output from the display controller are converted into signals for the light valves (LCDs) by the D/A converter and LCCOM circuit before they are output. • The filter/gate circuit is designed to reduce noise influence on the display driver circuit. To reduce impulse noise, input signals are sent through the three-level filter circuit.
EPSON PowerLite 5000 Service Manual Circuit Block Diagram of the Driver Board RPD10-17/RQD10-17 RD0-7 GD0-7 CLAMP (Red) IC100 IC250 Display Buffer BD0-7 GPD10-17/GQD10-17 Controller CLAMP (Green) C N BPD10-17/BQD10-17 SCL / SDA CLAMP (Blue) 1 IC300 0 Flash ROM 0 +22V +18 V REGULATOR +12 V F251 4511.25 A +18 V +12 V REGULATOR Display Timing (Red) +12 V +5 V +5 V REGULATOR F252CCP2E10 A Display Timing (Green) +5 V +3.3 V F250 4511.25 A +3.
EPSON PowerLite 5000 Service Manual 2.5 CONTROL PANEL This panel includes a board with 13 switches, and is connected to CN600 on the main board.
EPSON PowerLite 5000 Service Manual 2.6 AU BOARD The AU board includes an audio control circuit and interface connectors that receive audio signals from a host computer or external video or other device. The interface connectors are shown below. Figure 2-13 AU Board Circuit Block Audio Out Computer 1 Amp. Audio In 1 Sound Pre. Sound Computer 2 (For Internal Speaker) Amp.
EPSON PowerLite 5000 Service Manual The only circuits that the interface signal lines for S-Video and Video In have are noise filter circuits, therefore they output signals to the main board through the connector CN101. Audio input signals from computer 1/2 (via Audio In 1/2) or from a video device (via Audio In L/R) are input to the sound controller and amplified by the sound preamplifier. Then they are output to the “Audio Out” interface or the built-in speaker through the sound controller again.
EPSON PowerLite 5000 Service Manual 2.7 FR BOARD The FR board is used for connecting the remote control receiver and a mouse or serial interface of a host computer. The control has an 8-bit CPU and mouse / serial switching circuit installed on the board. CN100 (Mouse / COM1) and CN102 (Mouse / COM2) are multi-mouse connectors. If the ELP communication kit is installed on the host computer and cables are connected to it, you can control the computer with the remote control.
EPSON PowerLite 5000 Service Manual The ELP communication kit 2 option also enables the remote control to draw lines and patterns on the screen. The relay circuit (IC111 or IC116C) is switched to be able to accept the mouse encoder signal and the button signal. Then the signals based on “ Tracking +/- button” operation are output to a host computer through the remote.
EPSON PowerLite 5000 Service Manual 2.8 CN BOARD The CN board is the relay board for the cable connector. It has five connectors. The signals below are transferred to the main board through this board. *FI board signal: Remote control signals go from the front receptor to the FR board. *RI board signal: Remote control signals go from the rear receptor to the FR board. *FC board signal: Filter cover detection switch signals go to the main board.
EPSON PowerLite 5000 Service Manual The signals from the receptor board (FI board/RI board) are sent to the FR board and are used for wireless mouse control (controlling the host computer via the remote control). The signals from the filter cover switch are sent to the main board. If the filter cover is open, power cannot be supplied. The signals for controlling serial operations and the receptor board signals are sent from the FR board to the CN board. 2.
EPSON PowerLite 5000 Service Manual 1. The main board operates the power and the start-up menus, using serial data received from the remote control (button switches and pointers). 2. The serial signal sent to the driver board via the main board controls the display (Freeze/Blank). 3. The serial signal sent to the AU board via the main board controls mute and audio volume.
EPSON PowerLite 5000 Service Manual 2.10 SPEAKER UNIT Inside the upper case are two, upward-facing speakers. Audio signals from the computer or AV devices are output through these speakers. If an external speaker is connected to the Audio Out terminal, the built-in speakers are disabled.
EPSON PowerLite 5000 Service Manual presence of an external speaker and uses the built-in speakers if there is no external speaker. 2.11 LIGHT GUIDE BLOCK The light valve block eliminates ultraviolet rays, which are harmful to the light valves, and makes the light intensity from the light source lamp uniform before dividing it into 3 light outputs (R/G/B). Lenses and mirrors built into the block disperse the light. The illustrations below show the outside of the light valve block and an internal diagram.
EPSON PowerLite 5000 Service Manual Lens Array A Lens Array B Condenser Lens L Mirror L GDM CDM Condenser Lens G Lens Array Mirror R Adjusting Springs Lens Adjusting Screw Mirror B Condenser Lens R Mirror C Lens Adjusting Screw Condenser Lens E Condenser Lens B Condenser Lens D Figure 2-25 • Lens Arrays A and B After dispersion of the light from the light source lamp by lens arrays A and B, the brightness is roughly uniform.
EPSON PowerLite 5000 Service Manual • Condenser Lens R/G/B Collects the lights dispersed into the polarization plate on the optical head. • Mirror R/C Unit and Lens Adjusting Screw Reflects light to condenser lens E/B. The reflection angle can be adjusted with the lens adjusting screw. • Mirror B Reflects the light to condenser lens E. • Lens Array Adjusting Screw Used for adjusting the A/B lens array position to obtain the best uniformity of source light. 2.
EPSON PowerLite 5000 Service Manual Light source lamp The standard lamp life is 2000 hours. If you notice reduced lamp brightness, replace the lamp inner housing even if you have used the projector for less than 2000 hours. The total running time of the light source lamp is written in the EEPROM (IC603: ST24W04FM6TR) on the main board.
EPSON PowerLite 5000 Service Manual Control Circuit Diagram Lamp Indicator EEPROM Buffer Controller Generator (IC603) (IC618) (IC600) (X500) Main Board +5 VDC CN800 Power Supply Unit IC800 LPCTL BACT LPST LPFAL LLIFE 65 VDC Regulator LFUSE 33 FC Board CN700 Lamp Inner Housing CN700 +5 V_A Signals: LTPCL: Light power supply control signal Lamp LSTAT (less than 6 V output or no current) CN250 1 LPFAL: Light power supply failure 2 Driver Board LLIFE: Lamp life LFUSE: FU board fuse
EPSON PowerLite 5000 Service Manual fuse on this board is connected to the ground through a resistance (88 Ω). Consequently, the fuse is blown and the LLIFE signal is switched from HIGH to LOW. When LLIFE becomes LOW, IC600 switches LPCTL to HIGH and shuts down the lamp power (65 VDC) from the power supply unit. When the power is shut off, and LPST (LPFAL) becomes HIGH, IC600 detects power off in the lamp and starts the cooling down sequence. 2.
EPSON PowerLite 5000 Service Manual 2.13.1 Filter Cover Switch This switch is installed in the lower case and locks with the tab of the filter cover. With the filter cover open, the intake fan absorbs external air to cool down the light valve. This allows dust get on the light valve and the prism, degrading the displayed image. The switch is installed so you cannot turn on the projector when the filter cover is open.
EPSON PowerLite 5000 Service Manual 2.13.2 Interlock Switch This switch is installed on the side of the power supply unit and locks with a tab on the lamp cover. If you turned on the projector with the lamp cover open, the light source lamp (lamp inner housing) would run and generate high heat. To protect you from burns, the interlock switch is installed on the AC power source line and the projector cannot be turned on while the lamp cover is open. Interlock switch Figure 2-29 2.13.
EPSON PowerLite 5000 Service Manual The power supply unit cable is connected with a fastening tab to the safety switch. When the temperature rises to a certain temperature, all regulating operations of the power supply unit are stopped and power is shut off. Once this switch runs, you cannot start the power until the temperature falls to a certain temperature. In this case, you must also consider the lamp thermistor or the main board may be defective. 2.13.
EPSON PowerLite 5000 Service Manual LV Thermistor Figure 2-32 2.13.6 PBS Thermistor This is the temperature detection thermistor installed on the side of the fan (attached to the power supply unit). If the environment around the power supply unit overheats because of a fan or circuit abnormality, this thermistor shuts off the power. The power shut off control is the same as the lamp thermistor’s described in section 2.13.4.
EPSON PowerLite 5000 Service Manual 2.
EPSON PowerLite 5000 Service Manual FR Board AU Board Connects CN101 to CN Board Connects to CN100 CN102 CN101 CN201 Main Board CN100 CN300 Connects to Main Board CN603 Figure 2-37 For Light Bulb Intake Fan Connects to Main Board Rear CN805 CN252 CN251 CN700 (BLUE) Front Driver Board CN800 (GREEN) Connects to Main Board CN100 Mouse/COM2 CN700 CN900 (RED) CN250 Connects to FC Board Figure 2-38 2-35 Mouse/COM1
EPSON PowerLite 5000 Service Manual Connects to Connects to Rear Filter Connects to Main Receptor (RI Board) Cover Switch Board CN802 Connects to Front Receptor (FI Board) CN200 CN204 CN202 CN203 Connector Board CN201 Connects to FR Board CN101 Figure 2-40 To Regulation Circuit Power Supply Connector Safety Switch WHT AC InIet White BLK Fast-on Tab White Black F101 250V/6.3A Black Connects to the Inlet Hold Plate with Green/Yellow Wire.
EPSON PowerLite 5000 Service Manual 3.1 Disassembly and Assembly Procedures This section explains how to disassemble the projector. The reassembly procedure is the exact reverse of the disassembly procedure. 3.1.1 Preparatory Procedures 1) Remove any ring, wrist watch, cuff buttons, or other metal accessories that are likely to come into contact with the equipment. 2) Wear gloves. 3) Wear a wrist band and ground it. Place a ground mat under the unit. 4) Turn off the main unit and the host computer.
EPSON PowerLite 5000 Service Manual These units are specified as the optical engine. (Treat as one replaceable part in field maintenance.) Optical head unit À Prism unit Á Light guide unit  Projector lens unit à Driver board Ä Note: Do not disassemble the optical engine or replace any unit in the optical engine. 3.1.4 Mechanical Adjustments Optical Head Unit The polarization plates (R/G/B) are factory-aligned. Do not apply any mechanical stress to the polarization plate, and do not loosen the screws.
EPSON PowerLite 5000 Service Manual Projector Lens Unit The projector lens unit is aligned (position and mounting torque) in the factory. If the alignment is modified, pixel divergence will occur, creating unclear images. Electrical Corrections: Driver Board Some parts in the mechanical section of the optical system require adjustments as mentioned above. In the control circuit (driver board), the output driver for the display signal is slightly different from the output driver of other devices.
EPSON PowerLite 5000 Service Manual 3.1.6 Precautions These precautions are for the individual assembly and disassembly procedures. Read them carefully before starting an assembly or disassembly procedure. A set of general precautions is given below. As you disassemble the main unit, dust that has collected on the internal fans and air filters is likely to migrate and contaminate light valves R, G, and B (the heart of the display mechanism), deteriorating the display quality.
EPSON PowerLite 5000 Service Manual 3.2 Disassembling and Assembling the Projector Main Unit The flowchart for disassembling the projector main unit is shown below. You can reassemble dismantled projector parts by reversing the order of disassembly. Therefore unless specified, this manual contains no assembly procedures. Detailed descriptions of disassembly procedures are given in sections 3.2.1 to 3.2.26. START Lamp Inner Housing (3.2.1) Air Filter Frame (3.2.2) Upper Case Unit (3.2.
EPSON PowerLite 5000 Service Manual Removing the Lamp Inner Housing WARNING: The lamp unit is very hot immediately after use and may burn you if handled carelessly. Before removing the lamp unit, make sure the lamp inner housing unit has cooled down. When installing the lamp unit, take care not to touch the lamp's reflector with your hands (to prevent the reflector from being contaminated).
EPSON PowerLite 5000 Service Manual 1. Remove the lamp cover mounting screws from the bottom of the lower case. Screw: -M4*7.5 F/Ni: P/N1021771 (mounting torque: 4.5 kg. cm = 3.9 lb. inch) 2. Remove the two mounting screws from the lamp inner housing. Screw: -M4*7.5 F/Ni: P/N1021771 (mounting torque: 4.5 kg. cm = 3.9 lb. inch) 3. Pull up the handle on the lamp inner housing and remove the lamp unit. 3.2.
EPSON PowerLite 5000 Service Manual 3.2.3 Removing the Upper Case Unit and Handle Prerequisite conditions: None. Handle Holder Cover Figure 3-5 Screws Figure 3-6 1. Pull the handle up. 2. Remove 2 screws under the handle. Screw: +M4×10 F/ZB Bind: P/N1033707 (mounting torque: 6.0 kg. cm = 5.2 lb. inch) 3. Remove 2 upper case unit mounting screws on the right. Screws: +M4×6 F/ZB: P/N1034318 (mounting torque: 6.0 kg. cm = 5.2 lb.
EPSON PowerLite 5000 Service Manual (Continued from the previous page) 4. Hold the left and right sides of the upper case and lightly pull it partially up. Upper case Figure 3-7 Switch panel cable Figure 3-8 5. Disconnect the control panel cable from CN600 on the main board. 6. Remove the upper case. 7. Remove the handle from the lower case unit.
EPSON PowerLite 5000 Service Manual 3.2.4 Removing the Rear Case Unit Assembly Prerequisite condition: 3.2.3 Screw CN300 Screws Screws Figure 3-9 CN603 Figure 3-10 1. Remove 3 screws mounting the rear case to the bottom of the lower case. Screws: +M3×8 F/ZB: P/N 1033691 (mounting torque: 6.0 kg. cm = 5.2 lb. inch) 2. Remove 3 screws mounting the main board to the audio board shield plate, and the screw on the AC inlet hold plate. 3. Disconnect connectors CN300/CN603 on the main board. 4.
EPSON PowerLite 5000 Service Manual 3.2.5 Removing the A/B Foot Adjuster Prerequisite condition: 3.2.3 Foot Adjuster A Foot Adjuster A OP Ring D Figure 3-11 1. Push down the foot pipe and hold it; then fully lift up foot adjuster A. 2. Remove the OP ring D from the top of foot adjuster A. 3. Push down the foot pipe and remove it.
EPSON PowerLite 5000 Service Manual 1. Turn foot adjuster B completely clockwise to shorten it. 2. Remove the E ring from foot adjuster B. 3. Turn foot adjuster B completely counterclockwise to remove it. 3.2.6 Removing the Control Panel Prerequisite condition: 3.2.3 Tabs Tabs Figure 3-13 1. Pull down the 4 tabs from inside. Then remove the control panel from the upper case.
EPSON PowerLite 5000 Service Manual 3.2.7 Removing the Right and Left Speakers Prerequisite condition: 3.2.3 Screws Screws Left Speaker Right Speaker Figure 3-15 Right Speaker 1. Remove 2 screws mounting the right speaker unit. Screws: +M3×4 F/ZN: P/N1021795 (mounting torque: 4.0 kg. cm = 3.5 lb. inch) 2. Disconnect the speaker cable from CN602 on the main board. Left Speaker Unit 1. Remove 2 screws mounting the left speaker unit. Screw: +M3×4 F/ZN: P/N1021795 (mounting torque: 4.0 kg. cm = 3.5 lb.
EPSON PowerLite 5000 Service Manual 3.2.8 Removing the Main Board Prerequisite conditions: 3.2.3/3.2.4 Figure 3-16 1. Disconnect all cable connectors from the main board. (Refer to Figure 3-10.
EPSON PowerLite 5000 Service Manual (Continued from the previous page) Screw Screws Screws Figure 3-18 2. Remove 5 mounting screws from the main board. Screws: +M3×4 F/ZN Sems P/N 1021795 (mounting torque: 4.0 kg. cm = 3.5 lb. inch) 3. Grasp the main board on the left side and disconnect the connector from the driver board. Caution: To avoid malfunctions caused by wire breaking or solder flaking, never apply any mechanical stress to the main board.
EPSON PowerLite 5000 Service Manual 3.2.9 Removing the AU Board Prerequisite conditions: 3.2.3/3.2.4 Screws AU Board Figure 3-19 1. To detach the AU board, remove 4 screws from it and lift it off. Screws: +M3×8 F/ZN Bind: P/N1021795 (mounting torque: 6.0 kg. cm = 5.2 lb.
EPSON PowerLite 5000 Service Manual 3.2.10 Removing the Receptor Board Assembly (FI Board / RI Board) Prerequisite conditions: 3.2.3/3.2.4/(RI board only) FI Board (Located on the speaker bracket) Screw FI Board Figure 3-20 1. Disconnect the cable connector from the FI board. 2. Remove the screw mounting the FI board to the speaker bracket. Screw: +M3×5 F/ZB: P/N1021795 (mounting torque: 4.0 kg. cm = 3.5 lb.
EPSON PowerLite 5000 Service Manual RI Board (Located on the rear cover) Screws RI board Figure 3-21 1. Disconnect the cable connector from the RI board. 2. Remove the screws mounting the RI board to the speaker bracket. Screws: +M3×5 F/ZB Bind: P/N 1033703 (mounting torque: 6.0 kg. cm = 5.2 lb. inch) Caution: When installing the receptor board assembly, align the hole in the board with the boss on the frame before tightening the screws.
EPSON PowerLite 5000 Service Manual 3.2.11 Removing the FR Board Prerequisite conditions: 3.2.3/3.2.4/3.2.9 FR Board Screws Screws Figure 3-22 Figure 3-23 1. Pull out the FR board with the audio board shield plate from the rear case. 2. To detach the remote board cover from the audio board shield plate, remove 2 screws from them. Screws: +M3×4 F/ZN Bind: P/N 1021795 (mounting torque: 4.0 kg. cm = 3.5 lb. inch) 3. To separate the remote board shield plate from the FR board, remove 2 screws from them.
EPSON PowerLite 5000 Service Manual 3.2.12 Removing the Power Supply Unit / PBS Thermistor Prerequisite conditions: 3.2.3/3.2.4/3.2.8/3.2.7 (right speaker) Power Supply Unit Screws Case Holding Plate Sensor Shield Plate Figure 3-24 1. Remove the screw from the sensor shield plate, then pull it out. 2. Remove 2 screws from the case holding plate, then pull the case holding plate straight up. Power Cables Cable Connector Screw Safety Switch Figure 3-25 3.
EPSON PowerLite 5000 Service Manual Caution: When removing the screws, do not let them drop inside the power supply unit. Screws Screw Screws The screws are located on the bottom of the power supply unit and are not visible in the figure. Figure 3-26 6. Remove 5 screws mounting the power supply unit to the lower case. Screws (4P.C.S.): M3×8 F/ZN Bind: P/N1021824 (mounting torque: 6.0 kg. cm = 5.2 lb. inch) Screws (1P.C.S.): M3×12 F/ZB Bind: P/N1033692 (mounting torque: 6.0 kg. cm = 5.2 lb. inch) 7.
EPSON PowerLite 5000 Service Manual PBS Thermistor PBS Thermistor Figure 3-27 1. Remove the cable clamp screw mounting the PBS thermistor to the power supply unit chassis. 2. Separate the PBS thermistor from the cable clamp. 3. Disconnect the cable from connector CN860 on the main board. 3.2.14 Removing the Lamp Thermistor Prerequisite conditions: 3.2.3/3.2.4/3.2.8/3.2.
EPSON PowerLite 5000 Service Manual 1. Remove the screw mounting the lamp thermistor to the light guide unit. Screw: +M3×8 F/ZB: P/N 1033691 (mounting torque: 6.0 kg. cm = 5.2 lb. inch) 2. Disconnect the cable from connector CN804 on the main board. 3.2.16 Removing the Safety Switch Prerequisite conditions: 3.2.3/3.2.4/3.2.8/3.2.13 Fast-on Tabs Screws Figure 3-29 1. Disconnect the Fast-on tab terminals of the two cables connected to the safety switch. 2.
EPSON PowerLite 5000 Service Manual 3.2.17 Removing the Optical Engine Prerequisite conditions: 3.2.3/3.2.4/3.2.8/3.2.13/3.2.7 (left) Screw (Speaker Bracket) Screws Screws Figure 3-30 1. Remove the screw mounting the speaker bracket to the optical head chassis. Screw: +M3×4 F/ZN: P/N 1021795 (mounting torque: 4.0 kg. cm = 3.5 lb. inch) 2. Remove the 4 optical block-mounting screws. (One of the screws is located on the front side of the speaker bracket.
EPSON PowerLite 5000 Service Manual 3.2.18 Removing the Filter Board Prerequisite conditions: 3.2.3/3.2.4/3.2.8/3.2.12/3.2.13/3.2.17 Screws Fast-on tab cable (Black wire and white wire) Figure 3-32 1. Unplug the Fast-on tab cable (black wire and white wire) from the filter board. 2. Remove the 4 mounting screws. Screws: +M3×8 F/ZN Bind: P/N 1021824 (mounting torque: 6.0 kg. cm = 5.2 lb. inch) 3. Pull up the filter board holding plate. 4. Remove the cables from the cable clamp. 5.
EPSON PowerLite 5000 Service Manual 3.2.19 Removing the Inlet Unit Prerequisite conditions: 3.2.3/3.2.4/3.2.8/3.2.13/3.2.17 Ground Wire Screw Screws Figure 3-33 1. Remove 2 inlet unit mounting screws and the ground wire screw. 2. Remove the cable guide cover. 3. Unplug the Fast-on tab cable (white wire) and the black wire from the filter board. 4. Pull up the inlet unit from the lower case.
EPSON PowerLite 5000 Service Manual 3.2.20 Removing the CN Board Prerequisite conditions: 3.2.3/3.2.4/3.2.8/3.2.13/3.2.17 Screw CN Board Figure 3-35 Figure 3-36 1. Remove the screw mounting the CN board shield plate B. Screw: +M3×5 F/ZN Bind: P/N 1033703 (mounting torque: 6.0 kg. cm = 5.2 lb. inch) 2. Disconnect the cable connectors connected to CN200/202 on the CN board. 3. To detach the CN board, remove the 2 screws mounting it to the projector. Caution: Arrange the cables in the cable guide.
EPSON PowerLite 5000 Service Manual 3.2.21 Removing the Air Filter Flame Unit Switch (Filter Cover Switch) Prerequisite conditions: 3.2.3/3.2.4/3.2.8/3.2.13/3.2.17 Filter Cover Switch Figure 3-37 1. Disconnect the cable connector from the switch connected to CN202 on the CN board. 2. Remove the filter cover switch, pushing the latches on the lower case outward. Caution: Be careful not to break the latches with excessive stress.
EPSON PowerLite 5000 Service Manual 3.2.22 Removing the FC Board Prerequisite conditions: 3.2.3/3.2.4/3.2.8/3.2.13/3.2.17 FC Board Screw Figure 3-38 1. Disconnect cable connector CN1 from the FC board. 2. To detach the FC board, remove the screw.
EPSON PowerLite 5000 Service Manual 4.1 Before Starting Troubleshooting Procedures 1. Whenever you replace a unit or block for maintenance, double-check the replaced unit or block to make sure it is defective (not inoperable due to a poor cable connection or other problem). 2. If you have questions while examining the flowchart, check the items in question during the troubleshooting procedure. 3. Refer to the instructions in Chapter 3, "Disassembly and Assembly," when replacing a component unit. 4.
EPSON PowerLite 5000 Service Manual 4.2 Before Starting Troubleshooting Procedures Follow the flowchart shown below when troubleshooting projector problems and proceed to the pertinent detailed flowchart (given on the next and subsequent pages). Start External View • Visually check the exterior. (Check for any damage to the cover area.) Internal Cable Connectors • Check internal cable connections except on the CN board and FR board. (Remove the upper case unit.
EPSON PowerLite 5000 Service Manual External View Turn off the power and remove power and interface cables. Then check the following: Start • • Upper Case Unit Control Panel • Projector Lens Unit • • Lower Case Unit • Lamp Cover The upper case is secured to the lower case with screws. (Refer to 3.2.3.) • • • Rear Case Unit Air Filter Frame There are no cracks or other deformities. • • • • • • • Dirt is not on the front or rear receptor windows of the upper case. Buttons move smoothly.
EPSON PowerLite 5000 Service Manual Internal cable connections Start Remove upper Note: Before following this flowchart, turn off the power and then disconnect the power cable. case unit Control Panel • AU Board • • Left and Right Speakers • Power Supply Unit • • • CN600 on the main board (lock type). CN300 on the main board to CN101 on the AU board. CN603 on the main board to CN100 on the AU board. CN601/602 on the main board. CN800 on the main board to power supply unit.
EPSON PowerLite 5000 Service Manual Power ON/OFF Disconnect all interface cables and the projector lens cover. Then connect the power cable. B Start YES Does the exhaust fan work? Press the power button on the control panel. NO YES Does the operation or lamp indicator light up or blink? YES Now does the exhaust fan work? NO NO Press the power button on the remote control. YES NO Is the lamp cover secured to NO the lower case? YES • Disconnect the power cable.
EPSON PowerLite 5000 Service Manual Continued from page 4-5 Lamp indication table Condition A Lamp Operation indicator indicator OFF Orange System initialization. Green- Green Warm up operation. 1 2 Replace the power cable. Is AC power applied to the power supply unit connector? blinking 3 Green Green Operating. 4 Orange- Orange Cool down operation. Standby. YES blinking 5 OFF Orange 6 OFF OFF (Cool down complete) NO Replace the Filter board.
EPSON PowerLite 5000 Service Manual Display/Picture Start Does the screen appear? YES NO Is the light source lamp on? YES NO Replace the lamp inner housing. Is the light source lamp on now? Does a “NO SIGNAL” message appear? NO Replace the main board. Does a “NO SIGNAL” message appear now? YES YES Does a fine image appear by YES Go to adjusting the focus and zoom next page. rings? NO Press the menu button on the control panel or remote control. YES NO Replace the optical engine.
EPSON PowerLite 5000 Service Manual Continued from page 4-7 A C Connect the host computer to the Computer In 1 interface. Is the picture quality good? NO Connect the CRT to the monitor interface. YES Does a screen appear? YES NO Change the video mode by pressing the computer or video button. Does a screen appear now? Have the following devices been checked? • Computer In 2 • Video In • S-Video Does a screen appear on the CRT? YES YES NO Replace the monitor cable.
EPSON PowerLite 5000 Service Manual Audio Output Start A Does the volume control work? Connect the audio cable to the Audio In 1 interface. YES NO Replace the AU board. Do the internal speakers output the sound? YES YES NO Connect the audio cable to the interfaces listed above. Does the mute button work? YES NO Replace the AU board. YES NO Replace the AU board. Do the internal speakers output the sound now? YES A NO Replace right speaker and/or left speaker.
EPSON PowerLite 5000 Service Manual Control Panel Start Does the Power button work? NO YES Does the Menu button work? NO YES Does the Video button work? NO YES Does the Computer button work? YES Does the Auto button work? Does the Sync +/- button work? YES Does the Enter button work? NO YES NO Replace the control panel. Do all the buttons work? NO Go to Remote Control.
EPSON PowerLite 5000 Service Manual Remote Control Start Does power ON/OFF work? YES NO Replace the batteries. Does power ON/OFF work now? YES Do all switches except Effects 1 to 5 work correctly now? YES Do all switches except Effects 1 to 5 work correctly now? NO Replace the FR board. YES YES NO Replace the main board. Does power ON/OFF work now? YES NO Replace the CN board. Figure 4-10 4-11 YES Go to Mouse/ COM.
EPSON PowerLite 5000 Service Manual Mouse/COM The ELP communication kit option is necessary. If the option is not installed, ignore the following flowchart. Start Does the pointer button on the Remote control work NO correctly? YES Are the function assignments for Effect buttons 1 to 5 available? Replace the following cables: • Main cable • Mouse cable • Serial cable Install the ELP link program in the host computer again.
EPSON PowerLite 5000 Service Manual Others Start Is there a noise problem? YES Check the following for defects: • Intake fan and exhaust fan on the power supply unit.
EPSON PowerLite 5000 Service Manual A.1 Parts List The following table shows the parts that are available for the projector*. Appendix B of this manual, which contains the schematic diagrams for the projector, is available separately. (The part number is listed in the table below.
EPSON PowerLite 5000 Service Manual 15-2 15-3 15-4 15-5 16 17 18 19 20 20-1 20-10 20-11 20-12 20-2 20-5 20-6 20-7 20-8 20-9 21 22 25 26 27 28 29 30 31 32 33 34 35 36 8 9 2 2-1-13 2-19 23 24 4 5 6 7 51 52 53 54 55 56 57 2023192 1021795 1034025 1034398 1021795 1021795 3001779 1021795 1032053 1032054 1033583 3001779 1033703 3002195 1032057 1021824 1021795 1021824 1032367 1033691 1032134 1032071 1033707 1034318 1032080 1034329 3002147 1032368 1032350 1021795 1034713 1034319 1033584 1033646 1034261 1034024 103
EPSON PowerLite 5000 Service Manual 58 59 61 62 63 64 65 66 67 37 38 39 40 41 42 43 44 45 46 47 48 49 50 64 65 66 * 2022956 2024268 2023367 2023368 2023369 2023370 2023642 2023643 2024409 5005532 5005534 5005535 5005543 5005333 5004108 5003353 4006453 1032291 1032295 1034263 1034264 1034043 1026940 1033745 1034757 1034758 Audio Cable (3.
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