Optomaex 615

SERVICE MANUAL
EX542/EX612/EX615/EX540/EX762/EX540I/EX542I/
ES523ST/EW533ST
Date Revise Version Description
2009.07.08 V1.0 Initial Issue
2009.10.13 V2.0 Add EX540/EX762
2009.12.16 V3.0 Add EX540I/EX542I
Add ES523ST/EW533ST;
2010.02.07 V4.0
Modify “Defect specification table” in Chapter 4;
Copyright Feb, 2010. All Rights Reserved. P/N: 36.8FJ01G001
SI : TSE: Check: Approved:

Preface
This manual is applied to EX542/EX612/EX615/EX540/EX762/EX540I/EX542I/ES523ST/
EW533ST projection system. The manual gives you a brief description of basic technical
information to help in service and maintain the product.
Your customers will appreciate the quick response time when you immediately identify
problems that occur with our products. We expect your customers will appreciate the
service that you offer them.
This manual is for technicians and people who have an electronic background. Please
send the product back to the distributor for repairing and do not attempt to do anything that
is complex or is not mentioned in the troubleshooting.

Notice: The information found in this manual is subject to change without prior notice. Any
subsequent changes made to the data herein will be incorporated in future edition.

EX542/EX612/EX615/EX540/EX762/EX540I/EX542I/ES523ST/EW533ST Service Manual
Copyright Feb. 2010
All Rights Reserved
Manual Version 4.0
EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential I
EX542/EX612/EX615/EX540/EX762/EX540I/EX542I /ES523ST/
EW533ST Comparison List
Parts EX540 EX542 EX540I EX542I EW533ST ES523ST EX615 EX612 EX762
USER’S
36.8FB01G001 36.8EF01G001 36.8FR01G001 36.8HA01G001 36.8EF01G001 36.8FK01G001 36.8FB01G001
GUIDE
LAMP
DRIVER 70.8FJ05GR01 70.8EF38GR01 70.8FB21GR01
MODULE
LVPS 75.8CT02G001 75.8CT01G001 75.8FB01GP01
BLOWER 49.8CS01G002 49.8EF04G001 49.8FB01G001
OPTICAL
ENGINE 70.8FJ06GR01 70.8FJ30GR01 70.8HA18GR01 70.8GZ16GR01 70.8EF40GR01 70.8FK03GR01 70.8FB22GR01
MODULE
MAIN
BOARD 70.8FR05GR01 70.8FJ03GR01 70.8FR24GR01 70.8FJ27GR01 80.8HA01G001 80.8GZ01G001 70.8EF43GR01 80.8FK01G001 70.8FB24GR01
MODULE
DMD CHIP 48.8EZ01G001 48.8CQ01G001 48.8EZ01G001 48.8CQ01G003 48.8EJ01G001 48.8EH01G001 48.8CQ01G001 48.8CQ01G003
FAN 49.88T01G001 49.8EF03G001
THERMAL
43.8EF17G001 43.8EG17G001 43.8FB17G001
SWITH
IO COVER
70.8FJ04GR01 70.8FJ28GR01 70.8HA20GR01 70.8GZ17GR01 70.8EF44GR01 70.8FK02GR01 70.8EF44GR01
MODULE
SPEAKER 49.8EF01G001 49.8GZ01G001 49.87K01G201 49.8EM01G011
DAUGHTER
80.8EF06G002 80.8GZ06G001 80.8EF06G003 80.8EF06G002
BOARD
LAN
MODULE 80.8EF07G001 NA 80.8EF07G001
BOARD
REMOTE
45.8EF01G001 45.8GZ01G001 45.8EF02G001 45.8EF01G001
CONTROL
COLOR
WHEEL 70.8EF41GR01 70.8FJ29GR01 70.8FB23GR01 70.8EF41GR01 70.8FB23GR01
MODULE
EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential II
Table of Content
Chapter 1 Introduction
Highlight 1-1
Compatible Mode 1-3
Chapter 2 Disassembly Process

Equipment Needed & Product Overview 2-1
Disassemble Lamp Cover Module 2-2
Disassemble Lamp Module 2-2
Disassemble Focus Ring 2-3
Disassemble Top Cover Module 2-3
Disassemble Keypad Board Module and Zoom Ring 2-4
Disassemble Top Shielding 2-5
Disassemble Main Board Module 2-5
Disassemble Daughter Board and Lan Module Board 2-8
Disassemble Engine Module 2-9
Disassemble Color Wheel Module 2-9
Disassemble DMD Chip and DMD Board 2-10
Disassemble Rod Module 2-10
Disassemble System Fan Module and Thermal Switch 2-11
Disassemble Speakers 2-12
Disassemble Blower 2-13
Disassemble Front IR Module 2-14
Disassemble LVPS Module and Interlock Switch 2-14
Disassemble Lamp Driver Module 2-15
Disassemble Security Bar Cap 2-15
Disassemble Bottom Shielding 2-16
EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential III

Disassemble IO Cover 2-17
Rod Adjustment 2-18
Re-write Lamp Usage Hour 2-19
Chapter 3 Troubleshooting
LED Lighting Message 3-1
Main Procedure 3-2
Chapter 4 Function Test & Alignment Procedure

Test Equipment Needed 4-1
Service Mode 4-1
OSD Reset 4-1
Test Condition 4-2
Test Inspection Procedure 4-4
PC MODE 4-5
Video Performance 4-8
ADC Calibration 4-11
Optical Performance Measure 4-13
Network Function Test
( For EX542/EX615/EX540/EX762/EX540I/EX542I) 4-15
Others 4-18
Chapter 5 Firmware Upgrade

Section 1: System Firmware Upgrade
(For EX540/EX542/EX612/EX615/EX762/EX540I/EX542I) 5-1
Equipment Needed 5-1
DLP Composer Lite Setup Procedure 5-2
Setup Procedure 5-4
EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential IV
USB Driver Upgrade Procedure 5-4
Firmware Upgrade Procedure 5-5

(For ES523ST/EW533ST) 5-8
DLP Composer Lite Setup Procedure 5-9
Setup Procedure 5-9
Firmware Upgrade Procedure 5-9
Section 3: 8051 Firmware Upgrade Procedure 5-13

NLINK Setup Procedure 5-14
Manley USB Driver Upgrade Procedure 5-16
8051 Firmware Upgrade Prodedure 5-18
Section 4: Network Firmware Upgrade Procedure

( For EX542/EX615/EX540/EX762/EX540I/EX542I) 5-20
Write Down Projector IP 5-21
Network Setting 5-22
PC Hardware Link 5-23
Chapter 6 EDID Upgrade

EDID Introduction 6-1
Equipment Needed
(For EX542/EX615/EX540/EX762/EX540I/EX542I) 6-2
Setup Procedure (VGA)
EDID Key-In Procedure (VGA-1 & VGA-2)
EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential V
Equipment Needed (for ES523ST/EW533ST) 6-6
Setup Procedure (VGA) (for ES523ST/EW533ST) 6-7
EDID Key-I��
n Procedure ��
(for ES523ST/EW533ST) 6-7
Setup Procedure (HDMI)

EDID Key-In Procedure (HDMI)
Appendix A
Exploded Image I
Appendix B
Serial Number System Definition I
PCBA Code Definition II
EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential VI
Chapter 1
Introduction
1-1 Highlight
No Item Description
● 0.55” XGA 2xLVDS SERIES 450 DMD DC3
(��
for EX542/EX612/EX615/EX762/EX542I/EX540/EX540I)
1 Technology
● 0.55”
��
SVGA, ��
S450, ��
Dark ��
Chip 3 (for ��
ES523ST)�
● 0.65”
�� WXGA,
��
S450, ��
Dark ��
Chip 3 (��
for EW533ST)
Dimension
2 ● 324 x 234 x 97 mm
(W x D x H)
● 6.3-6.4 lbs
(for EX542/EX612/EX615/EX540/EX540I/EX542I)
3 Weight
● <6.7 lbs (for EX762)
● 6.5 lbs (for ES523ST/EW533ST)
4 Power Supply ● Auto-ranging: 100V~ 240V ± 10%, 50~ 60Hz
Keystone
5 ● +/-40
��
degree (TI spec.)
Correction
● Native Resolution: 1024 x 768
(��
for EX542/EX612/EX615/EX762/EX542I/ EX540/EX540I)
6 Resolution
● Native Resolution: 800x600 (for ES523ST)
● Native Resolution: ��
1280x800��
(for EW533ST)
● Full Mode:(Typ)338W,(Max)372W @ac 110V
● ECO mode:(Typ)285W,(Max)314W @ac 110V
(for EX762)
● ECO Mode:(Typ)212W,(Max)233W @ac 110V
(for EX540/EX542)
7 Power consumption (for EX615/EX612)
(for EX540I/EX542I)
● Full Mode: (Typ) 230W, (Max) 255W @ 110VAC
● ECO Mode:(Typ) 212W, (Max) 233W @ 110VAC
(for ES523ST/EW533ST)
EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 1-1

No Item Description
● 1.95~ 2.15 @60”(Distance/Width) (for EX612/EX615)
● 1.6~ 1.92 @60”(Distance/Width)
8 Throw ratio (for EX540/EX542/EX762/EX540I/EX542I)
● 0.72 (Distance/Width) (for EW533ST)
● 0.9 (Distance/Width) (for ES523ST)
● YM25, F# 2.4~ 2.66, f= 18.2~ 21.8 mm @60”
(for EX542/EX762/EX540/EX540I/EX542I)
9 Projection lens ● YM09X/FPL30, F# 2.41~ 2.55 @60”, f= 21.8 ~ 24 mm @60”
(for EX612/EX615)
● YM43, F# 2.55, f= 10.19 mm (for ES523ST/ EW533ST)
● 2000 Hours, 50% Survival Rate (Standard-Mode)
(for EX540/EX542/EX762)
● 2500 Hours, 50% Survival Rate (Standard-Mode)
(for EX615/EX612)
● 3000 Hours,50% Survival Rate(Standard-Mode)
(for EX540I/EX542I/ ES523ST/EW533ST)
10 Lamp life
● 4000 Hours, 50% Survival Rate (ECO-Mode)
(for EX542/EX540/EX615/EX612)
● 3000 Hours, 50% Survival Rate (ECO-Mode)
(for EX762)
● 4500 Hours,50% Survival Rate(ECO-Mode)
(for EX540I/EX542I/ ES523ST/EW533ST)
● 115% ± 5%
11 Offset (for EX540/EX542/EX612/EX615/EX762/EX540I/EX542I)
● 112.4%±5%
��
(��
for ES523ST/EW533ST)
● NTSC: NTSC M 3.58 MHz, 4.43 MHz
● PAL: PAL B/D/G/H/I/M/N, 4.43 MHz
● SECAM: SECAM B/D/G/K/K1/L, 4.25/4.4 MHz
12 Video compatibility ● Component: 480i/p, 576i/p, 720p (50/60Hz), 1080i/p (50/60Hz)
(for EX540/EX542/EX612/EX615/EX762/EX540I/EX542I)
● Component: 480i/p, 576i/p, 720p(50/60Hz), 1080i(50/60Hz),
1080P(50/60Hz) (for ES523ST/EW533ST)
● 4:3, 16:9 I, 16:9 II, NATIVE, AUTO
13 Aspect ratio (for
�� EX540/EX542/EX612/EX615/EX762/EX540I/EX542I)
● 4:3,
�� 16:9,
�� 16:10,
�� Native,
�� Auto
��
(for
��
ES523ST/EW533ST)
● 180 W OSRAM Lamp E20.8 elliptic
(for EX540/ EX542/EX540I/ EX542I/ ES523ST/EW533ST)
14 Lamp
● 230 W OSRAM Lamp E20.8 elliptic (for EX615/EX612)
● 280 W OSRAM Lamp E20.8 elliptic (for EX762)
● 5 Segments; RGBYW; Filter Diameter 40 mm
15 Color Wheel ● R76Y32G78W98B76
● 2x, 7200 RPM

No Item Description
● DDP2430(for EX540/EX542/EX615/EX612)
16 System Controller
● DDP2431(for EX762 for EX540I/EX542I/ ES523ST/EW533ST)
● VGA-in: VGA in 1 (wireless dongle, YPbPr)
VGA in 2 (SCART, YPbPr)
(��
for EX540/EX542/EX612/EX615/EX762/EX540I/EX542I)
● VGA-in: VGA-in x 1 (RGB) (for ES523ST/EW533ST)
● Composite: RCA x 1
(��
for EX540/EX542/EX612/EX615/EX762/EX540I/EX542I)
● Composite video: Composite Video x 1
(for ES523ST/ EW533ST)
● S-video: Mini-DIN 4 pin x 1
● RCA
��
Audio in: RCA Audio in x 2 (R ��& ��
L)
(for
��
ES523ST/ EW533ST)
17 Input Connections ● Audio-in (Green coded port):
• Audio-in 1 only (Daughter Board) (for EX612)
• Audio-in 1, 2, 3 (Daughter Board)
(for EX542/EX615/EX540/EX762��
/EX540I/EX542I�)
● HDMI: HDMI v1.3 (HDCP)
(for EX542/EX615/EX540/EX762��
/EX540I/EX542I/ES523ST/
EW533ST�)
● Audio-in connectivity grouping
(for EX542/EX615/��
EX540/EX762/EX540I/EX542I)
• VGA-in1 -> Audio in1
• VGA-in2 -> Audio in2
• Composite/S-Vidoe -> Audio in3
● Operating ( Full-power-mode): 5~ 40 °C
18 Temperature
● Non-operation (storage): -10°C~ 60°C
● For
�� EX540/EX542/EX612/EX615/EX762/EX540I/EX542I:
• Operating:
��
0 ~ 2,500 ft, for 5°C~ 40°C
2500 ft ~ 5,000 ft, for 5°C~ 35°C
5,000 ft ~ 10,000 ft, for 5°C~ 30°C
19 Altitude
● For ES523ST/ EW533ST:
• Operating:
0 ~ 2,500 ft, for 5°C~ 40°C
2500 ft ~ 5,000 ft, for 5°C~ 30°C
5,000 ft ~ 10,000 ft, for 5°C~ 25°C

1-2 Compatible Mode
Computer Compatibility (Analog)

Compatibility Resolution V-Sync [Hz] H-Sync [KHz]
640 x 350 70 31.5
640 x 350 85 37.9
640 x 400 85 37.9
640 x 480 60 31.5
VGA 640 x 480 72 37.9
640 x 480 75 37.5
640 x 480 85 43.3
720 x 400 70 31.5
720 x 400 85 37.9
800 x 600 56 35.2
800 x 600 60 37.9
SVGA 800 x 600 72 48.1
800 x 600 75 46.9
800 x 600 85 53.7
1024 x 768 60 48.4
1024 x 768 70 56.5
XGA
1024 x 768 75 60
1024 x 768 85 68.7
WXGA 1280 x 768 60 47.8
1152 x 864 60 53.5
1152 x 864 70 63.8
1152 x 864 75 67.5
1152 x 864 85 77.1
SXGA
1280 x 1024 60 63.98
1280 x 1024 75 79.98
1280 x 1024 85 91.1
1280 x 960 60 60.0
WXGA 1280 x 800 60 49.68
SXGA+ 1400 x 1050 60 63.98
UXGA 1600 x 1200 60 75
MAC LC 13” 640 x 480 66.66 34.98
MAC II 13” 640 x 480 66.68 35
MAC 16” 832 x 624 75 49.725

MAC 19” 1024 x 768 75 60.24
MAC 1152 x 870 75 68.68
MAC G4 640 x 480 60 31.35
i Mac DV 1024 x 768 75 60
i Mac DV 1152 x 870 75 68.49
i Mac DV 1280 x 960 75 75
Computer Compatibility (Digital)

640 x 350 70 31.5
640 x 350 85 37.9
640 x 400 85 37.9
640 x 480 60 31.5
VGA 640 x 480 72 37.9
640 x 480 75 37.5
640 x 480 85 43.3
720 x 400 70 31.5
720 x 400 85 37.9
800 x 600 56 35.2
800 x 600 60 37.9
SVGA 800 x 600 72 48.1
800 x 600 75 46.9
800 x 600 85 53.7
1024 x 768 60 48.4
1024 x 768 70 56.5
XGA
1024 x 768 75 60
1024 x 768 85 68.7
1280 x 768 60, 75, 85 47.8
WXGA
1280 x 800 60 49.64

1152 x 864 60 53.5
1152 x 864 70 63.8
1152 x 864 75 67.5
SXGA 1152 x 864 85 77.1
1280 x 1024 60 63.98
1280 x 1024 75 79.98
1280 x 1024 85 91.1
SXGA+ 1400 x 1050 60 63.98
UXGA 1600 x 1200 60 75
Note: If the Computer Compatibility supportive signal is different from User's Manual, please refer
to User's Manual.

Chapter 2
Disassembly Process
2-1 Equipment Needed & Product Overview
1. Screw Bit (+): 105
2. Screw Bit (+): 107
3. Screw Bit (-): 107
4. Hex Sleeves 5 mm
5. Tweezers
6. Projector
* Before you start: This process is protective level II. Operators should wear electrostatic chains.
* Note: - If you need to replace the Main Board, you have to record the Lamp Usage Hour.
- The disassembly process for EX542/EX612/EX615/EX540/EX762/EX540I/EX542I/
ES523ST/EW533ST is the same , we take EX615 as an example here.
EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 2-

2-2 Disassemble Lamp
Cover Module
1. Loosen 2 screws (as red circle) on the
Lamp Cover.
2. Disassemble the Lamp Cover Module.

Module
1. Loosen 2 screws (as red circle) on the
Lamp Module.
2. Take off the Lamp Module.

2-4 Disassemble Focus Ring
1. Rotate the Focus Ring clockwise until
you cannot rotate any more (as red
arrow direction).
2. Pull out the Focus Ring.
Note: - When you assemble the Focus Ring,

ensure the 3 card slot (as green square)
placed in the 3 double-screw bolt (as
yellow circle) properly, and the Focus
Ring can be well adjusted.
2-5 Disassemble Top Cover

Module
1. Unscrew 2 screws (as red circle) from the
Bottom Cover.
2. Press two sides of the projector as the
blue arrows point.
3. Remove the Top Cover Module.

Note: - When you remove the Top Cover,
take care the connector (as yellow
square) of FPC cable which connect
Main Board and Keypad Board Module,
then unplug it from Keypad Board
Module.
- Avoid damaging by pulling keypad FPC
cable.
- Make sure the FPC cable plug into the
correct ports when assembling it.
2-6 Disassemble Keypad

Board Module and Zoom
Ring
1. Unscrew 4 screws (as blue circle) to
disassemble the Keypad Board Module
from the Top Cover Module.
2. Separate the Keypad from the Top
Cover Module.
3. Unscrew 3 screws (as red circle) to
disassemble the Zoom Ring.
Keypad Board Keypad
Zoom Ring

2-7 Disassemble Top
Shielding
1. Tear off 2 EMI tapes (as green square).
2. Unscrew 12 screws (as red circle).
3. Disassemble the Top Shielding.
Top Shielding
2-8 Disassemble Main Board

Module
1. Unplug 1 connector (as green square) to

remove the FPC cable.
2. Unplug 8 connectors (as yellow square).
3. Unscrew 5 screws (as red circle) from
the Main Board Module.
FPC cable

4. Unscrew 1 screw (as blue circle) from
the IO Cover.
5. Unscrew 8 hex screws (as green circle)
from the IO Cover.
6. Unplug 1 connector (as orange square).
7. Separate the Main Board Module

and Main Board Shielding.
Note: - Make sure cables plug into the correct
ports when assembling the unit.
Main Board Shielding

Please refer to the table as below for
details of each connector.
G F E D CB A
Male Connector
Item The key feature Figure
on Main Board
Compose of Red/Black Wire and

A&G Speaker
Black wire tube (2 pin)
B Lamp Driver Black wire tube (5 pin)
Compose of Red/Yellow/Black
C System Fan
Wire (3 pin)
Compose of Red/Black/White
D Photo Sensor
Wire and Black wire tube (3 pin)
Compose of Black/Yellow/Red
E Blower
Wire and Blue wire tube (3 pin)
Compose of Black/Yellow/Red
F IR
Wire and Gray wire tube (3 pin)

2-9 Disassemble Daughter
Board and Lan Module
Board
1. Unscrew 2 screws (as green circle) to

disassemble the Daughter Board.
2. Unscrew 1 screw (as red circle) to
disassemble the Lan Module Board.
Daughter Board Lan Module Board
3. Unscrew 3 hex screws (as yellow circle)

from the Main Board Module.

2-10 Disassemble Engine
Module
1. Tear off the black mylar (as green square).

2. Unscrew 4 screws (as yellow circle) to
disassemble the Engine Module.
2-11 Disassemble Color

Wheel Module

disassemble the Color Wheel Module.
2. Unscrew 1 hex screw (as green circle).
3. Unscrew 1 screw (as blue circle) to
disassemble the Photo Sensor Board
from the Color Wheel Module.
Note: - Avoid touching the glass parts of color

wheel.

2-12 Disassemble DMD Chip
and DMD Board
disassemble the Heat Sink and DMD
Module.
2. Rotate the screw (as yellow circle)
clockwise to disassemble the DMD
Board and DMD Chip.
Note: - Avoid touching the DMD Chip when you

disassemble it.
-F
ound that the DMD Chip has scrapes
or dirt use of a magnifying glass, you
may use an electrostatic ion gun to
clean it.
- Pay attention to the fixed position when
assembling the DMD Chip.
2-13 Disassemble Rod

Module

take off the Rod Spring.
2. Unscrew 1 screw (as yellow circle) to
take off the Rod Cover.
3. Remove the Rod.
Note: - Avoid touching the Rod when you
disassemble or assemble it.
- Please notice the Rod Module’s direction Rod spring Rod cover
when you assemble it (as picture A shown). Rod
- Ensure left edge of Rod Module contact
A B
with the Engine base’s blocks.
- Rod Spring must hook in the position as
picture B shown.

2-14 Disassemble System
Fan Module and
Thermal Switch
1. Tear off the black tape (as yellow square).

disassemble the System Fan Module.
3. Unscrew 1 screw (as blue circle) and
unplug 1 connector (as green square) to
disassemble the Thermal Switch.
Thermal Switch
separate Fan and Fan Shielding.
Fan Shielding

Note: - Take the Fan Module as the right
gesture.
the right gesture the wrong gesture
2-15 Disassemble Speakers
1. Unscrew 4 screws (as yellow circle) to

disassemble the two Speakers.

separate the Speaker Holder and
Speaker.
(Same procedure for the other Speaker)
2-16 Disassemble Blower

disassemble the Blower Module.
2. Separate Blower and Blower Rubber.

2-17 Disassemble Front IR
Module

disassemble the Front IR Module.
2. Unfasten 2 tenons (as yellow square) to
separate the IR Board and IR Holder.
2-18 Disassemble LVPS

Module and Interlock
Switch
1. Unscrew 6 screws (as yellow circle).

2. Unplug 1 connector (as blue square).
3. Disassemble the LVPS Module,
the AC Inlet Bracket and Mylar.
4. Unscrew 1 screw (as green circle).
AC Inlet Bracket

5. Unplug 2 connectors (as green square).
6. Disassemble the Interlock Switch and the
cable from the LVPS Module.
Interlock Switch

Driver Module
disassemble the Lamp Driver Module.
2. Unplug 3 connectors (as yellow square).

3. Separate the Lamp Driver Module
and Lamp Driver Holder.
Lamp Driver Holder
2-20 Disassemble Security

Bar Cap
disassemble the Security Bar Cap and
Security Bar.

2-21 Disassemble Bottom
Shielding
1. Unscrew 2 screws (as red cricle) to
disassemble the Bottom Shielding.
2-22 Disassemble IO Cover

1. Unfasten 2 tenons (as green square).
2. Remove the IO Cover.

2-23 Rod Adjustment
1. Environment Adjustment
- The distance between the engine and
the screen is 1.95 M.
- This process should be done at a dark
environment (under 10 Lux).
2. Procedure Adjustment
- Change the screen to "white screen".
- Adjust the screws by using the rod
on the engine module to readjust the
image.
("screw 1" should be adjusted first, and Screw 2
then "screw 2". Adjust until the yellowish
or bluish parts disappeared.) Screw 1
3. Abnormal image inspection

- It should not have any abnormal color
at the rim of the image by estimating
through the eyes.
Z type driver
Note: - To avoid over adjusting the rod.
- After the opreation, please use the glue
to fix the screws.
- Please use Z type driver to adjust Rod
screw 1.

2-24 Re-write Lamp Usage
Hour
1. Get into Service Mode
- Press "Power", "Left", "Left" and "Menu"
buttons sequentially to get into Service
Mode.
2. Re-write Lamp Hours (Normal)
- Use "up" or "down" buttons to select
"Lamp Hours (Normal)", then use "left"
or "right" buttons to re-write the Lamp
Hours.
3. Re-write Lamp Hours (ECO)
- The way of re-write "Lamp Hours (ECO)"
is the same as "Lamp Hours (Normal)".
4. Exit Service Mode
- Use "up" or "down" buttons to select
"Exit", then press "Enter" to exit the
Service Mode.
Note: left key = decrease lamp hour

right key =increase lamp hour

Chapter 3
Trobleshooting
3-1 LED Lighting Message
ON/STANDBY LED Temp LED Lamp LED

Message
(Amber/Green) (Red) (Red)
Standby State
(Input power cord)
(Amber)
Flashing
Power on (Warming)
(Green)
Power on and Lamp

lighting
(Green)
Flashing
Power off (Cooling)
(Green)
Error Flashing
(Lamp failed) (Amber)
(Red)
Error Flashing Flashing

(Fan failed) (Amber) (Red)
Error Flashing
(Over Temp.) (Amber)
(Red)
Note: Steady light No light

3-2 Main Procedure
No Symptom Procedure
- Ensure the Power Cord and AC Power Outlet are securely con-
nected
- Ensure all connectors are securely connected and aren’t broken
1 No Power
- Check LVPS
- Check Lamp Driver
- Check Main Board
- Check LED status
a. Lamp Fail: ON/STANDBY LED (flashes amber);
Lamp LED (lights red)
- Check Lamp
- Check Lamp Driver
- Check Main Board
- Check Color Wheel
- Check Photo Sensor
- Check whether Wireless status of OSD Menu is on
2 Auto Shut Down (conncet VGA1- IN port with VGA source)
b. Over Temp.: ��
ON/STANDBY��
LED (flashes amber);
Temp LED (lights red)
- Check Thermal Switch
- Check Fan
- Check Main Board
c. Fan Fail: ON/STANDBY��
��
LED (flashes amber);
Temp LED (Flashes red)
- Check Fan
- Check Main Board

- Check Lamp Cover, Interrupt Switch
- Check Lamp Module
- Check Lamp Driver
3 No Light On
- Check LVPS
- Check Main Board
- Check Color Wheel
- Check Photo Sensor Board
- Ensure the Signal Cable and Source work
(If you connect multiple sources at the same time, use the
"Source" button switch)
- Check Main Board
4 No Image
- Check DMD Board
- Check DMD Chip
- Check Color Wheel
- Check Engine Module
- Check Color Wheel
5 Mechanical Noise
- Check Fan Module
- Check whether the Main Board and the DMD Board are
assembled properly
6 Line Bar/Line Defect - Check Main Board

- Check DMD Board
- Check DMD Chip

- Do "Reset (All data)" of the OSD Menu
- Ensure that the signal cables and source are work as well
- Check Lamp Driver and waveform
- Check Lamp Module
7 Image Flicker
- Check Color Wheel
- Check Photo Sensor and clean Photo Sensor
- Check DMD Board
- Check Main Board
- Adjust Color Wheel Index
8 Color Abnormal - Check Main Board
- Check DMD Board
- Check Color Wheel
- Ensure the projection screen without dirt
- Ensure the projection lens is clean
Poor Uniformity/
9 - Ensure the Brightness is within spec.
Shadow
- Check rod alignment
- Ensure the projection screen without dirt
- Ensure the projection lens is clean
Dead Pixel/Dust
10 - Clean DMD Chip and Engine Module
(Out of spec.)
- Check DMD Chip
- Ensure that the signal cables and source work as well
11 Garbage Image - Check Main Board
- Check DMD Board

- Remote Controller
a. Check Battery
b. Check Remote Controller
c. Check IR Sensor Board
Remote
12 Controller/Control d. Check Main Board
Panel Failed
- Control Panel
a. Check FPC
b. Check Keypad
c. Check Main Board
Function
13 - Check Main Board
Abnormal
- Check DMD Board
- Ensure that the signal cables and source are work as well
- Ensure that your Projector is not in “Mute” mode
- Check the interior Speakers of the projector
14 Audio Abnormal
- Check the exterior Speaker that you are using
- Check Main Board
- Check Daughter Board
- Ensure you have set up the right IP address and the
Network Fail (for connection is OK (Network green LED should light up)
EX542/EX615/
15
EX540/EX762/ - Check Lan Module Board
EX540I/EX542I)
- Check Main Board

- If you forget the Password, please do the following steps to get
the Universal Password:
(1) When you turn on the projector, the message "Enter
Security Code" appears. Please Input the "Current Security
Code 8642" by Remote Control, then press "Enter".
(2) Press "Menu" button, select "Setup", "Change Password",
then press "Enter" button. The message "Enter Security
Code" appears again, repeat step (1).
(3) The message "Enter New Security Code" appears. Input a
4-digits code (letters and/or numbers) that you define.
(4) To confirm, key in the password again. The "Security Code
change successfully" appear on the screen.
(1) (2)
Forgetting
Password
16
(Administrator
Password)
(3)
- Ensure the using 3D glasses is good and you must face the
projection.
3D Image Abnormal
(for EX762/EX540I/ - Ensure the signal source is 3D format.
17 - Ensure the 3D function of projector OSD is on and 3D sync
EX542I/ES523ST/
EW533ST) invert is on.
- Check main board.

Chapter 4
Function Test & Alignment Procedure

4-1 Test Equipment Needed
- IBM PC with XGA resolution
- DVD player with Multi-system, equipped “Component”, “S-Video”,“Composite” and
"HDMI".
- HDTV Source (720P,1080P,1080i)
- Minolta CL-100
- Quantum Data 802B or CHROMA2327 (Color Video Signal & Pattern Generator)
4-2 Service Mode

- EX542/EX612/EX615/EX540/EX762/EX540I/EX542I/ES523ST/EW533ST have two kinds of
Service Mode, use different ways to get into each Service Mode:
1. Turn on the projector
2. (1) Press "Power", "Left", "Left" and "Menu" buttons sequentially to get into Service Mode 1.
(2) Press "Power", "Up", "Down" and "Menu" button sequentially to get into Service Mode 2.
(3) Select "Exit" to leave the Service Mode after confirming the configuration.
4-3 OSD Reset

- After final QC step, we have to erase all saved change again and restore the OSD default setting.
The following actions will allow you to erase all end-users' settings and restore the default setting:
1. Please get into OSD menu.
2. Execute "Reset" function.

4-4 Test Condition
- Circumstance brightness: Dark room less than 10.0 lux.
- Inspection distance: 1.8 m~2.5 m functional inspection.
- Screen size: 60 inches diagonal.
- After repairing each unit, a Run-in test is necessary (refer to the below table).
Symptom Run-in Time

Normal repair 2 hours
NFF 4 hours
Auto shutdown 6 hours
- Get into Burn-In Mode

* Cycle setting is based on the defect symptoms. ie: If it is NFF, the run-in time is 4 hours. You have
to set the lamp on for 50 min. and lamp off for 10 min for 4 cycles.
Press Power > Left > Left > Menu to get into service mode 1
Choose Burn-In Test > enter
Lamp On (Mins) Press right key to adjust the time (50)
Lamp Off (Mins) Press right key to adjust the time (10)
Burn in cycle Press right key to adjust the cycle
After setting up the time, choose ''Enter to Burn-In'' and press Enter button
Screen Defects (While replacing DMD Chip, DMD Board and Main Board)
12.5 cm
Zone B Frame Zone C

12.5 cm
< Figure: Zone A, Zone B & Frame(as green line) Definition, Active area=Zone A+ Zone B >

4-5 Defect specification table
For EX762/EX542I/ES523ST
Order Symptom Pattern Criteria
1 Bright pixel ( dots) Gray 10 pattern A+B=0
2 Dark pixel(dots) White pattern A+B≤4
3 Unstable pixel (dots) Any pattern A+B=0
4 Adjacent dark pixel (dots) Any pattern A+B=0
A+B≤2
5 Dark blemish (Dirty) Blue 60 pattern
(diameter <1/2 inch)
A+B≤2
6 Bright blemish (Dirty) Gray 10 pattern
(diameter <1/2 inch)
7 Bright dots on frame Gray 10 pattern ≤1
For EX542/EX612/EX615/EX540/EX540I
1 Bright pixel ( dots) Any pattern A+B=0
2 Dark pixel(dots) Any pattern A+B≤4
A+B≤4
(diameter <1 inch)
A+B≤4
(diameter <1 inch)
7 Bright dots on frame Any pattern ≤1

For EW533ST
1 Bright pixel ( dots) Gray 10 pattern A+B=0
2 Dark pixel(dots) White pattern A+B≤7
A+B≤4
(diameter <1 inch)
A+B≤4
(diameter <1 inch)
7 Bright dots on frame Gray 10 pattern ≤1
4-6 Test Inspection Procedure
Change parts
Update Main Color Lamp Engine Lan
Firmware Blower
Board Wheel Module Module Module
Version Update v v v
Color Wheel Index v v
ADC
Calibration (RGB/ v
Video Calibration)
Reset lamp hour v
OSD Reset v v
EDID v
Re-write Lamp
v
Hour Usage
Rod adjustment v
Factory RPM
v v
Save
Note: - If Color appears abnormal after changing Main Board/Color Wheel Module, please do Color
Wheel index adjustment.
- After changing parts, check the information above.

4-7 PC MODE
Note: - When getting into function test, adjust the zoom ring and focus ring to guarantee the image
maximum and clearest, then start to test.
- Test signal: analog 1024 x 768 (for EX542/EX612/EX615/EX762/EX542I/EX540/EX540I)
analog 800 x 600 @60Hz (for ES523ST))
analog 1280 x 800 @60HZ (for EW533ST)
- The defect specification for EX762/EX542I/ES523ST is the same, we take EX762 for
example here, others model please refer to 4-5 for details.
1. Frequency and tracking boundary

Procedure - Test equipment: video generator
- Test signal: analog 1024 x 768@60Hz
- Test Pattern: General-1 or Master
- Check and see if the image sharpness
is well performed.
- If not, re-adjust by the following steps:
(1) Select "Frequency" function to adjust General-1
the total pixel number of pixel clock in

one line period.
(2) Select "Tracking" function and use
right or left arrow key to adjust the
value to minimize video flicker.
- Adjust Resync or Frequency/Tracking/H.
Position/V. Position to the inner screen.
Inspection item - Eliminate visual wavy noise by Resync, Master
Frequency or Tracking selection.

- Check if there is noise on the screen.
- Horizontal and vertical position of the video
should be adjustable to the screen frame.
Criteria - If there is noise on the screen, the product
is considered as failure product.
- If there is noise on the screen, use auto or
manual “frequency” function or “tracking”
function to adjust the screen.

- The PC mode functionally sure be workable
include support format with frequency and auto
detected functional will be workable.

2.Bright pixel
Procedure - Test equipment: video generator.
- Test signal: analog 1024x768@60Hz.
- Test Pattern: Gray 10
Inspection item - Bright pixel check.
Criteria - Bright pixel is unacceptable under gray 10
pattern. Gray 10
Please refer to the figure in 4-4 Test Condition
for Frame and Active area.
Note: The defect criteria follows TI specification.
3. Dark pixel
- Test signal: analog 1024x768@60Hz.
- Test Pattern: White pattern
Inspection item - Dark pixels check.
- White pattern (IRE=100)
- Adjacent dark pixel.
White pattern
Criteria - The number of the dead pixels should be less or
equal to 4 pixels.
- Adjacent pixel with each other is unacceptable.
Note: The defect criteria follows TI specification.

4. Bright Blemish
- Test signal: 1024x768 @60Hz
- Test Pattern: Gray 10
Inspection item - Bright blemish check
Criteria - The bright blemish should be less or
equal to 2 under gray 10 pattern.
- Ref. Defect specification table Gray 10
5. Dark Blemish
- Test signal: 1024x768 @60Hz
- Test Pattern: Blue 60
Inspection item - Dark blemish check
Criteria - The dark blemish should be less or
equal to 2 under blue 60 pattern.
- Ref. Defect specification table
Blue 60
6. Focus test
- Test signal: analog 1024 x 768@60Hz
- Test Pattern: full screen or MEME Sony
I nspection item - Focus check
Criteria -From screen 2.38 Mvia visual to check the
focus, look at the entire screen, focus shall be
clear, crisp, and sharp over the entire surface Full screen
of the display pattern.(Blur word on one of the
corner after adjustment is acceptable. However,
the word should at least be recognizable.)

7. Color performance
- Test signal: 720p, 1080i, 1080p
- Test Pattern: Master, 64 gray RGBW or
SMPTE bar Master
* Please refer to 4-2 to get into service mode 1.
Use 720p & 1080p signal, master pattern to do
HDTV test. Color cannot discolor to purple and
blue.
Inspection item - Check if each color level is well-functioned.
- Color saturation
Criteria - Screen appears normal. It should not have any
abnormal condition, such as lines appear on the
screen and so on. 64 gray RGBW
- Color appears normal.

- It is unacceptable to have few lines flashing.
- RGBW should all appear normal on the screen
and sort from R-G-B-W.
- Color levels should be sufficient and normal.
(The unidentified color levels on both left and
right sides should not over 4 color levels.)
- Gray level should not have abnormal color or SMPTE BAR
heavy lines.
- If color appears abnormal, please get into ser-
vice mode 1 to do color wheel index adjustment.
4-8 Video Performance
1. CVBS
Procedure - Test equipment: DVD player
- Test signal: CVBS
Inspection item - Video performance test
Motion video

Inspection Distance - 1.8 M ~2.5 M
Criteria - Check any abnormal color, line distortion or any
noise on the screen.
- Check the sound from speakers.
- Check whether "freeze" and "mute" are normal.
- Press "V Keystone" on remote controller, check
whether keystone function is normal.
2. S-Video
Procedure - Test equipment: DVD player
- Test signal: S-Video
Inspection item - Video performance test

3. HDTV/Component
Procedure - Test equipment:DVD player
- Test signal:Ycbcr/YPbPr
Inspection item - HDTV performance test

4. HDMI Test (not for EX612)
Procedure - Test equipment: DVD Player with HDMI output.
- Test signal: 720p, 1080p, 1080i
Inspection item - HDMI performance test.
Inspection Distance - 1.8 M ~2.5 M.
Criteria - Ensure the image is well performed and the
color can not discolor.
- Check whether "mute" is normal.
5. Audio Test
Procedure - Test equipment: DVD Player
- Test signal: CVBS
Inspection item - Audio performance test
Criteria - Check the sound from speakers
- Plug Audio cable into Audio in 1 port, check
whether "Volume" is normal.
- Plug Audio cable into Audio Out port, check
whether the outboard speaker’s “Volume” is
normal.
- Adjust the volume to "5→ 10" by using the
remote controller.
- Check whether the "mute" is normal.
Note: EX542/EX615/EX540/EX762/EX540I/
EX542I have 3 Audio.
In ports for different input signals. To test each
Audio In port, make sure input its correspondent
signal.

6. 3D Test
Procedure - Test equipment: DVD Player
- Test signal: 1280X720@120Hz (HQFS format CD)
Inspection item - 3D test
Inspection Distance - < 6M
Criteria - The image should not appear noise, flicker,
4-9 ADC Calibration
1. Video Calibration
��
- Once Main Board is changed, video calibration
should be done as well.
(1) Test signal: 480i
(2) Test Pattern: SMPTE BAR
- Note
SMPTE BAR
(1) Calibration pattern should be in full screen mode.
(2) Please refer to 4-2 Guide to get into service
mode 1 and choose "ADC calibration".
(3) Choose and get into "Video Calibration", press
"Enter" button to execute "Video Calibration". When
the message "Success" appears, it means "Video
Calibration" is OK. Choose "Menu" or "Exit" to
leave service mode 1.
Check pattern - Test signal: 576p, 720p, 1080i Master
- Test pattern: Master

* After finishing Video adjustment, check Master
pattern.
Inspection item - Color saturation
Criteria - There should not have any lack of SMPTE BAR.
- The screen appears normal, it shouldn’t appear
any abnormal condition, such as lines and so on.
- It is unacceptable that the color appears
abnormal and flashing.

2. RGB Calibration
��
- Once Main Board is changed, RGB calibration
should be done as well.
(1) Test signal: 1024 x 768@60Hz
(2) Test Pattern: White/Black
- Note
(1) C
alibration pattern should be in full screen White/Black
mode.
(2) P
lease refer to 4-2 Guide to get into service
mode 1 and choose "RGB calibration".
(3) C
hoose and get into "Video Calibration",
press "Enter" button to execute "RGB Calibra-
tion". When the message "Success" appears,
it means "RGB Calibration" is OK. Choose
"Menu" or "Exit" to leave service mode 1.
Check pattern - Test signal: 1024 x 768@60Hz
- Test pattern: 64 grey RGBW
* After finishing RGB adjustment, check 64 gray
RGBW pattern.
Inspection item - Color saturation
Criteria - There should not have any lack of 64 gray
RGBW pattern. 64 gray RGBW
- The screen appears normal, it shouldn’t appear

any abnormal condition, such as lines and so on.
- The color should appear normal and sort in right
order, it is unacceptable that the color appears
abnormal and flashing.
- Color levels should be sufficient and normal.
(the unidentified color levels on both left and
right sides should not over 8 color levels.)

4-10 Optical Performance Measure
Inspection Condition
- Environment luminance: 10.0 Lux
- Product must be warmed up for 5 minutes
- Distances from the screen: 1.95 M
- Screen Size: 60 inches diagonal
1. Test equipment
Procedure - Press "Power→ Left→ Left→ Menu" to get
into service mode 1.
- Select "Spoke Test"
2. Brightness
Procedure - Full white pattern
- Use CL100 to measure brightness values
of P1~P9.
- Follow the brightness formula to calculate
brightness values.
☼ Brightness Formula
Avg. (P1~P9)*1.1m2
Criteria • 1000 ANSI lumen
(for EX542/EX540/EX540I/EX542I/ES523ST/
EW533ST)
• 1400 ANSI lumen (for EX612/EX615/EX762)

3. Full On/Full Off Contrast
Procedure - Full white pattern & Full black pattern
- Use CL100 to measure brightness values of full
white pattern P5 & full black pattern B5
- Follow Contrast formula to calculate contrast
values.
☼ Contrast Formula

P5/B5 Full black pattern
Note: P
5=center of white image
B5 = the center of black image.
Criteria • 1600:1 (for EX540/EX542/EX612/EX615/
EX762/EX540I/EX542I)
��
• 1750:1
��
(for ��
ES523ST/EW533ST)
4. Uniformity
Procedure - Full white pattern
- Use CL100 to measure brightness values of
P1~P9 (see image: Full white).
- Follow the Uniformity formula to calculate
average values.
☼ Uniformity Formula

JBMA Uniformity = Avg. (P1, P3, P7, P9)/
Full white pattern
P5X100%
Criteria • 70%

4-11 Network Function Test
For EX540/EX542/EX615/EX762/EX540I/EX542I
1. Write Down Projector IP
(1) Turn on the Projector, then press "Menu" button to
get into OSD Mode.
- Use "right" button to select "SETUP".
- Use "down" button to remove the light

mark to "RS232", then press "Enter" button to select
"Network", press "Enter" button.
(2) Select "Network", press "Enter" button.
(3) Remove the light mark to "DHCP", then press "Enter"

button to select "Off", press "Enter" button.
- The IP address will be shown on screen.
- Write down the IP address: 192.168.0.100.
- Ensure the IP address, Subnet Mask, Gateway

and DNS are right as the the picture shown.

2. Network Setting
(1) Open the "Local area connection", choose "properties".
(2) Select "Internet protocol (TCP/IP)", then click

"Properties".
(3) Modify the IP address to 192.168.0.101, and modify

Subnet mask to 255.255.255.0.
Note: - The HOST ID (192.168.0.XXX) of PC

IP address must be different from the
projector IP address written down in
step 1 of 4-10.
(4) Click "OK".
(5) Click "Close" to quit the setting screen.

3. Read Projector Information
(1) Connect the PC and the Projector with LAN Cable.
(2) Execute "Internet Explorer".

542
(3) Visit the IP address: "http://192.168.0.100/".
- Key in "User Name: Administrator" and "Password:

administrator", click "Login" to get into Projector
Web Server.
(4) Projector information will be shown on the screen.
- Please check whether each item's function is OK.
542

4-12 Others
1. Function Inspection
Keypad button - All keypad buttons must operate smoothly.
General - All OSD functions must be checked for functionality. When OSD
menu is displayed, there shall be no visible peaking, ringing,
streaking, or smearing artifacts on the screen.
Factory Default - The factory settings (with appropriate centering, size, geometry
distortion, etc.) shall be displayed upon “Recall” is selected from
OSD.
Display Size - All preset modes shall expand to full screen size using OSD
Horizontal and Vertical Size controls.
Display Data Channel (DDC) - The purpose of the DDC test is to verify the DDC1/DDC2B
operation of the projector and to verify Plug & Play function.
Acoustic -H
igh pitch sound from cooling fan and color wheel is
unacceptable.
2. Check points for exterior and print pattern

Check item Check point
Missing letters & pattern or blurry prints are
Text & Pattern
unacceptable.
Dirt, scrape, water ripples and uneven color are
Exterior
unacceptable.
Focus ring&Zoom ring Focus ring&Zoom ring is functioning smoothly.
Missing logo, missing prints and blurry prints are
Logo
unacceptable
Screw All screws sure be fixed and in right type.
Pedestal Well-functioned
Lamp Cover It should be locked in the correct place.
Plastic Parts All plastic parts can not be broken and damaged.
All safety and warning labels should be visible,
Safety or warning label
including all contents.
All interface connectors should be complete and
Connector
workable.

Chapter 5
Firmware Upgrade
(For EX540/EX542/EX612/EX615/EX762/EX540I/EX542I)
5-1-1 Equipment Needed
Software: (DDP 2430-USB/EX540/EX542/EX612/EX615;

DDP 2431-USB/EX762/EX540I/EX542I)
- DLP Composer Lite 9.2
- Firmware (*.img)
- Library file (library file has to put in PC and set right path in 5-1-5 step 3)
Hardware:
- Projector
- Power Cord: 42.50115G001
- Mini USB Cable: 42.00286G101
- PC or Laptop
Note: The FW upgrade procedure for EX612/EX615/EX542/EX540/EX762/EX540I/EX542I is the

same ,we take EX542 as an example here.
EX540EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 5-

5-1-2 DLP Composer Lite
Setup Procedure
1. Choose "DLP Composer Lite V9.2 Setup"
Program.
2. Click "Next".
3. Read "License Agreement".

-C
hoose "I accept and agree to be bound
by all the terms and conditions of this
License Agreement".
- Click "Next".
4. Click "Next".

5. Click "Next".
6. Click "Next".
7. The program is executing "installing"

status.
8. Click "Finish".

5-1-3 Setup Procedure
1. Set up
- Hold on "MENU" and "POWER" buttons
and plug in the power cord.
- The ON/STANDBY LED will be flashing
green.
- Release "MENU" and "POWER" buttons.
-C
onnect projector with USB cable.
Note: - The system fan and the lamp will not
operate.
USB port
5-1-4 USB Driver Upgrade (2)

Procedure
1. Execute Program
(1) Connect projector with PC by USB
cable. (3)
(2) "Found New Hardware Wiszard" picture

will appear on the screen. (4)
(3) Select "Install the software automatically

(Recommended)".
(4) Click "Next".
(5) Searching picture, please wait for
several seconds.

(6) Click "Finish", then the USB driver has
been installed successfully.
Note: - If you have installed the USB driver, there

is no need to perform this action.
(6)
5-1-5 Firmware Upgrade Procedure

1. Execute the "DLP ComposerTM Lite 9.2" file.
2. Click "Edit" and "Perferences".

3. Click "Library".
-C
lick the "Browse" and navigate to
the directory where you put the DLP
Composer installation files in.
- Click "Library v9.2" folder.
- Click "OK".
4. Click "Communications".
- Select "USB".
- Click "OK".
5. Choose "Flash Loader".

-C
lick "Browse" to search the firmware file
(*.img).
- Click "Open".
6. Select "Skip Boot Loader Area".

(select "32KB").
- Click "Reset Bus" to erase the flash
memory.

7. If the FW is ready, click "Start Download" to
execute the firmware upgrade.
- Click "Yes".
8. Proceeding Picture.
9. It takes about several minutes, the

firmware upgrade process is finished,
"Download completed" will appear on the
screen.
- The projector will automatically turn on.
-U
nplug USB cable.
10. Check FW version.

- Get into the service mode to check the
firmware version.
( To get into service mode, please press
"Power", "Left", "Left" and "Menu" buttons
sequentially.)

(For ES523ST/EW533ST)
Software: DDP 2431-RS232

- DLP Composer Lite 9.2
- Firmware (*.img)
- Library file (library file has to put in PC and set right path in 5-1-5 step 3)
Hardware:
- Projector
- Power Cord: 42.50115G001
- RS232 Cable: 42.00272G002
- PC or Laptop
Note: The FW upgrade procedure for EW533ST is the same ,we take ES523ST as an example
here.

5-2-2 DLP Composer Lite Setup
Procedure
Note: "DLP Composer Lite V9.2 Setup" Program refer
to 5-1-2 for details.
5-2-3 Setup Procedure

1. Set up
- Plug in Power and RS232 cable in the PC, the ON/
STANDBY LED will display green.
- Hold the "Menu" then press "Power" button about 5
seconds then release these two buttons.
Note: - The system fan and the lamp will not operate.
RS232 port
5-2-4 Firmware Upgrade Procedure

1. Execute the "DLP ComposerTM Lite 9.2" file.

2. Click "Edit" and "Perferences".
3. Click "Library".
-C
lick the "Browse" and navigate to the directory
where you put the DLP Composer installation files
in.
- Click "ES523ST Library" folder.
- Click "OK".
4. Click "Communications".
- Select "Serial Port".
- Choose "COM1".
- Click "OK".
5. “Serial Port Configuration” picture will appear on the

screen.
- Make sure the settings are as below:
(1) In “Baud Rate” item, select “115200”.
(2) In “Data Bits” item, select “8”.
(3) In “Stop Bits” item, select “1”.

(4) In “Parity” item, select “None”.
(5) In “RTS” item, select “Disable”.
(6) In “CTS” item, select “Disable”.
(7) Key in “2000” into “Read” and “Write” items of “
Timeouts (in milliseconds)”.
- Click “OK”.
6. Click “OK”.
7. Choose "Flash Loader".

-C
lick "Browse" to search the firmware file (*.img).
- Click "Open".
8. Select "Skip Boot Loader Area".

(select "32KB").
- Click "Reset Bus" to erase the flash
memory.

9. If the FW is ready, click "Start Download" to execute
the firmware upgrade.
- Click "Yes".
10. Proceeding Picture.
11. It takes about several minutes, the

firmware upgrade process is finished, "Download
completed" will appear on the screen.
- The projector will automatically turn on.
12. Check FW version.

- Get into the service mode to check the
firmware version.
( To get into service mode, please press "Power", "Left",
"Left" and "Menu" buttons sequentially.)

Section 3: 8051 Firmware Upgrade Procedure
Software: (DDP 2430-USB/EX540/EX542/EX612/EX615;

DDP 2431-USB/EX762/EX540I/EX542I/ES523ST/EW533ST)
- Setup _NLINK_en
- Manley USB Driver_NLINK
- EX542/EX612/EX615_8051_xxx.hex
- EX540_8051_xxx.hex
- EX762_8051_xxx.hex
- EX540I/EX542I_8051_xxx.hex
- ES523ST/EW533ST_8051_xxx.hex
Hardware:
- Projector
- Power Cord: 42.50115G001
- Mini USB Cable
- NLINK Cable 2
- NLINK Fixture
- PC or Laptop
Note: - The 8051 FW upgrade procedure for EX615/EX612/EX542/EX540/EX762/EX540I/EX542I/
ES523ST/EW533ST is the same, we take EX542 as an example here.

5-3-2 NLINK Setup Procedure
1. Choose "setup_NLINK_en.exe" program.
2. Click "Next".
3. Click "Next".
4. Click "Next".

5. Click "Next".
- Select the additional task that you may
create a desktop icon.
6. Click "Install" to begin installing NLINK

Procedure.
7. Click "Finish".
- Complete the NLINK setup.
8. "MCU Choose" picture will appear on the

screen.
- Close the picture.

5-3-3 Manley USB Driver
Upgrade Procedure
1. Set up
VGA-1 Port
- Plug in the power cord, the power
LED will light on red.
- Connect VGA-1 Port of projector with
NLINK Fixture.
- Connect NLINK Fixture with PC by
USB cable. (1)
2. Execute Program
(1) "Found New Hardware Wiszard" picture
will appear on the screen. (2)
(3)
(2) Select "Install from a list or specific

location (Advanced)".
(3) Click "Next".

(4)
(4) Select "Include this location in the

search", then click "Browse".
(5) "Browse For Folder" picture will appear

on the screen.
(6) Select "TPRP1" folder in the "Manley (5)

USB Driver_N-Link" folder, then click
"OK".
(6)

(7) Click "Next".
(8) Click "Continue Anyway".
(9) Click "Finish".

- "Manley TPRP1-Protocol Emulator" (7)
will appear on the picture.
- Complete the USB Driver Upgrade
Procedure.
Note: - If "Found New Hardware Wiszard" picture

appear again, repeat step 2 to install USB
Drivier.
(8)
(9)

5-3-4 8051 Firmware Upgrade
Procedure
1. Execute 8051 FW Program
- Double click "NLINK V1.2" to execute
NLINK program.
Note: - When we execute NLINK program, the
power LED and Fixture LED flash red.
2. Choose the right type of MCU

- "MCU Choose" picture will appear on the
screen, select "W79E804".
- Click "OK".
3. Choose 8051 file (*.hex)

- "Manley Nlink" picture will appear on the
screen.
- Ensure "MCU" is the one you chose in the
last step (as green square).
- Click "Open".
- Select the 8051 file where you put the file
in, then click "Open".
4. Program settings
- Ensure NLlNK Fixture and PC are
securely connected: the indicator lights on
green, and the state is "Connect" (as
blue square).
- Select "4MHz-20MHz Crystal" (as green
square).
- Click "Erase/Write(W)" to execute 8051
FW upgrade.

5. Finish
- When 8051 FW upgrade process is
finished, "Write Chip success" will be
shown.
6. Check 8051 FW version

- Turn on the unit and get into the service
mode to check the 8051 FW version.
(To get into service mode, please press
"Power", "Left", "Left" and "Menu" buttons
sequentially.)

Section 4: Network Firmware Upgrade Procedure
(for EX542/EX615/EX540/EX762/EX540I/EX542I)
Software:
- EX542_LAN Module FW_xxx.bin (*.bin)
Hardware:
- Projector
- Power Cord: 42.50115G001
- LAN Cable
- PC
Note:The Network FW Upgrade Procedure for EX615/EX542/EX540/EX762/EX540I/EX542I is the

same,we take EX542 as an example here.

5-4-2 Write Down Projector IP
1. Plug in power cord to the projector and

plug in LAN cable to the PC.
2. Turn on the projector, then press "Menu"

button to get into OSD menu.
- Use "right" button to select "SETUP". 2
- Use "down" button to remove the light
mark to "RS232", then press "Enter"
button to select "Network", press "Enter"
button.
3. Select "Network", press "Enter" button. 3
4. Remove the light mark to "DHCP", then

press "Enter" button to select "Off", press
"Enter" button.
- The IP address will be shown on screen.
4
- Write down the IP address: 192.168.0.100.
- Ensure the IP address, Subnet Mask,
Gateway and DNS are right as the the
picture 4 shown.

5-4-3 Network Setting
1. Double click the "Local area connection",

choose "Properties".
2. Select "Internet protocol (TCP/IP)", then

click "Properties".
3. Modify the IP address to 192.168.0.101,

and modify Subnet mask to 255.255.255.0.
Note: - The HOST ID (192.168.0.XXX) of PC
IP address must be different from the
projector IP address written down in
step 4 of 5-3-2.
4. Click "OK".
5. Click "Close" to quit the setting screen.

5-4-4 PC Hardware Link
1. Execute "Internet Explorer".
2. Visit "http:// 192.168.0.100/tgi/fu.tgi" to get

into Firmware Update screen.
Note: - The format of address is "IP address/tgi/fu.tgi".
- Click "Continue".
3. "Firmware Update" image will appear on the

screen.
- Click "Browse" button to select the Network
FW file (*.bin) which you saved.
- Click "Open".
- Click "Update" to start updating.
4. Firmware Upgrade procedure.

5. Click "Re Login".
6. Firmware upgrade procedure completes.

- The projector Network FW version will
appear.
542

Chapter 6
EDID Upgrade
6-1 EDID Introduction
Extended Display Identification Data is a VESA standard data format that contains basic
information about a display device and its capabilities, including vendor information,
maximum image size, color characteristics, factory pre-set timings, frequency range limits,
and character strings for the monitor name and serial number.
The information is stored in the display and is used to communicate with the system
through a Display Data Channel (DDC), which sites between the display device and the
PC graphics adapter. The system uses this information for configuration purposes, so the
monitor and system can work together.
Note: - If a display device has digital input ports, like DVI or HDMI, but without EDID in its Main
Board, the display device will show no image while the input source is digital signal.
- The EDID Upgrade procedure for EX615/EX612/EX542/EX540/EX762/EX540I/EX542I is
the same, we take EX542 as an example here.
- The EDID Upgrade procedure for ES523ST/EW533ST is the same, we take ES523ST as
an example here.

6-2 Equipment Needed
(for
��
EX542/EX615/EX540/EX762/EX540I/EX542I)
Software
- EDID Program
- EDID File (*.ini)
Hardware
- Projector
- Power Cord for Projector (42.53506G002)
- VGA Cable (42.87305G102)
- HDMI(M) to DVI(F) Adapter (42.82B13G001)
- DVI Cable (42.83N06G001)
- Generic Fixture (80.00001.001) for EDID Key-in (Fixture: JP3 must be closed)
- RS-232 9 Pin Cable (pin to pin, F-M) (42.83C07G001)
- Power Adapter (47.57803G001)
- Monitor
- PC

6-3 Setup Procedure (VGA)
(for
��
EX542/EX615/EX540/ RS232 Cable Adapter
P1 JP1
1. Connect all ports
JP3
(1) Connect P1 of fixture with COM Port of P3 P4
PC/Laptop by RS232 Cable.
(2) Connect P3 of fixture with VGA-1 Port
of projector by VGA Cable 1. VGA Cable 1 VGA Cable 2
(3) Connect P4 of fixture with VGA-2 Port
of projector by VGA Cable 2.
(4) Plug Power Adapter to JP1 of fixture.
(5) Power on fixture.
(6) Plug Power Cord to projector. VGA-1 Port
VGA-2 Port
Note: -You must confirm that the JP3 is closed in Power Port
all procedure.
6-4 EDID Key-In Procedure

(VGA-1 & VGA-2)
(for EX542/EX615/EX540/
1. Execute EDID Program
- Double click "EDID" to execute EDID
program.

2. Process
(1) Select the COM Port which you are
(2)
using.
(2) Click "Model".
(3) Select the EDID file (*.ini).
(1)
(4) Click "Open".
(5) Key in the Serial Number into the
Barcode blank space.
(6) In "Write Source Select" item, select
"VGA-A" and "VGA-B".
(7) Click "Program".
(3)
(4)
(5)
(7)
(6)
3. Change the cable to VGA-A

- When the message "Please change the
cable to VGA-A" appears on the screen,
click "OK".
EX540/EX542/EX612/EX615/EX762EX540I/EX542I/ES523ST/EW533ST Confidential 6-

4. Change the cable to VGA-B
cable to VGA-B" appears on the screen,
click "OK".
5. When the EDID program is completed, a

message "OK" will appear on the screen.
6. Read EDID "VGA-A&VGA-B" information

- In "Read item", select "Analog" and
"Trans", then click the "Read".
7. EDID information will show the result.

6-5 Equipment Needed
Software
- EDID Program
- EDID File (*.ini)
Hardware
- Projector
- Power Cord for Projector (42.53506G002)
- VGA Cable (42.87305G102)
- Generic Fixture (80.00001.001) for EDID Key-in (Fixture: JP3 must be closed)
- RS-232 9 Pin Cable (pin to pin, F-M) (42.83C07G001)
- Power Adapter (47.57803G001)
- Monitor
- PC

6-6 Setup Procedure (VGA)
(for ES523ST/EW533ST) RS232 Cable Adapter
P1 JP1
(1) Connect P1 of fixture with COM Port of
PC/Laptop by RS232 Cable. JP3
(2) Connect P3 of fixture with VGA-IN Port P3

of projector by VGA Cable. VGA Cable

(6) Plug Power Cord to projector.
Note: -You must confirm that the JP3 is closed in VGA-IN Port
all procedure.
Power Port
6-7 EDID Key-In Procedure

(VGA-1 & VGA-2)
program.

2. Process
using. (2)
(2) Click "Model".

(3) Select the EDID file (*.ini). (1)
(4) Click "Open".

"VGA".
(7) Click "Program". (3)
(4)
(5)
(7)
(6)
3. Change the cable to VGA

cable to VGA" appears on the screen,
click "OK".

5. Read EDID "VGA" information

- In "Read item", select "Analog" and
"Trans", then click the "Read".

6-8 Setup Procedure (HDMI)
(for EX542/EX615/EX540/
EX762/EX540I/EX542I) RS232 Cable Adapter
P1 JP1
(1) Connect P1 of fixture with COM Port of JP3
PC/Laptop by RS232 Cable.
P5
(2) Connect P5 of fixture with HDMI Port of
projector by DVI Cable.
DVIDVI
Cable
Cable
(5) Plug Power Cord to projector.
Note: You must confirm that the JP3 is closed in HDMI Port
all procedure.
Power Port
6-9 EDID Key-In Procedure (HDMI)

(for EX542/EX615/EX540/
program.
EX540/EX542/EX612/EX615/EX762EX540I/EX542I/ES523ST/EW533ST Confidential 6-10

2. Process
(2)
using.
(2) Click "Model".
(3) Select the EDID file (*.ini).
(1)
(4) Click "Open".
"HDMI".
(7) Click "Program".
(3)
(4)
(5)
(7)
(6)
3. Change the cable to HDMI

- When the message "Please change the cable
to HDMI" appears on the screen, click "OK".

5. Read EDID "HDMI" information

- In "Read item", select "Digital" and "Trans",
then click the "Read".
EX540/EX542/EX612/EX615/EX762EX540I/EX542I/ES523ST/EW533ST Confidential 6-12

Appendix A (Exploded Image)
Note: This chapter is only designed to show the exploded image of the projector. For updated part
numbers, please refer to RSPL report.
D.C.
EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential
Item P/N Description Parts Supply
1 70.8EF11G001 EX612 ASSY BOTTOM HOUSING MODULE
2 70.8EF01G001 ASSY OPTICAL ENGINE MODULE EX612
3 70.8EF08G001 MAIN BOARD ASSEMBLY EX612
TOP COVER AND ZOOM RINGASSYEMBLY
4 70.8EF06G001
EX612
5 51.8EF02G001 FOCUS RING EX612 (FOR YM09)
70.8EF45GR01 ASSY LAMP COVER BLACK EX615 (SERVICE) V
6 51.8EG03G011 LAMP COVER BLACK EX615
7 61.00018G002 LOCK SCREW PAN MECH M3*8.5-3.5 BLACK
8 SP.8EF01GC01 LAMP MODULE FOR PROJECTOR EX542 V
8 SP.8EG01GC01 LAMP MODULE FOR PROJECTOR EX615/EX612 V
9 41.83M06G001 EMI TAPE W30*L70mm
10 85.1A123G050 SCREW PAN MECH M3*5 Ni
11 85.00823G080 HEX SCREW M3*H8*L5.3,BRASS
12 61.8EG03G001 TOP SHIELDING HD20
13 85.0A122G030 SCREW DOUBLE FLAT MECH M2*3Ni
14 85.1A323G080 SCREW PAN MECH M3*8 BLACK “GREEN”
15 85.1A526G060 SCREW PAN MECH M2.6*6 Ni NYLOK
16 70.8EG17G001 ASSY 8525 FAN SHIELDING MODULE HD20
17 85.1A123G060 SCREW PAN MECH M3*6 NI
Assy TOP COVER MODULE
7 6
3
2
EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential III

1 75.8EF01G002 TOP COVER ASSEMBLY EX615 V
2 51.8EG14G011 KEYPAD PLATE ENTER EX612
3 80.8EF03G001 PCBA KEY PAD BOARD FOR EX615 V
6 85.41BA6G060 FLAT SCERW M2.6*6 Flat Thickness1.1mm
7 51.8EG11G001 ZOOM RING DUST COVER HD20
EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential IV
ASSY BOTTOM COVER MODULE
5
4 18
3
2
12
13
9
7
16
6
11
10
14 15
ASSY BOTTOM COVER MODULE FOR EX615
70.8EF37GR01 V
(SERVICE)
1 51.8EG01G011 BOTTOM COVER MN3600H BLACK EX612
ASSY OSRAM LAMP DRIVER 230W FOR EX542
70.8EJ01GR01 V
(SERVICE)
ASSY OSRAM LAMP DRIVER 230W FOR EX615
70.8EF38GR01 V
(SERVICE)
ASSY OSRAM LAMP DRIVER O3 MID 230W
2 75.8BW01G002
(Gen5_Panyu+E20.8)
3 75.8AA04G001 BUY ASSY INTERLOCK SWITCH 1409X
LIMIT SWITCH HOLDER PC MN3600H BLACK
4 51.89W18G001
TDP-SP1
5 85.WA126G060 SCREW PAN HEAD TAP M2.6*6
6 61.88T19G001 AC INLET BRACKET FOR X1160E
ASSY MATRITEK 180/200W LVPS FOR HORUS
7 75.8CT02G001 V
(EX542)
7 75.8CT01G001 ASSY MATRITEK 230W LVPS FOR HORUS V
SCREW PAN MECH M4*5 COLOR W/TOOTH
8 85.1C224G051
WASHER Cr3+
9 61.87340G001 STAND OFF M3*4L D8.0 2100MP
10 51.8EG20G001 230W LVPS MYLAR PC T=0.43 HD20
11 70.8EG14G001 ASSY 4520 BLOWER MODULE HD20
12 70.8EF10G001 EX612 2W SPEAKER HOLDER ASSY
13 85.WA123G060 SCREW PAN TAP M3*6 Ni
14 51.8EG05G001 IR FRONT BOTTOM HOLDER MN3600H BLACK
15 80.87Z04G001 PCBA IR SENSOR BD HD80
16 85.1F123G060 SCREW PAN MECH W/SF M3*6 Ni GREEN
W.A. 16P 90mm LVPS TO MAIN BD UL1007
17 42.00451G011
P1266
18 85.1F123G060 SCREW PAN MECH W/SF M3*6 Ni GREEN
CABLE W.A. 2P #20 160mm LAPS TO BALLAST
19 42.81G01G001
PD120
20 51.8EG27G001 REAR SPEAK MYLAR HD20
21 51.8EF06G001 AIR STOP MYLAR EX615
22 51.8EG31G001 FRON LEFT LIGHT LEAK MYLAR HD20
EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential VI
ASSY MAIN BOARD AND IO BOARD MODULE
10

1 70.8EF09G001 IO BOARD ASSEMBLE EX612
ASSY PCBA MAIN BOARD FOR EX542
70.8EJ03GR01 V
(SERVICE)
80.8FK01G001 PCBA MAIN BD FOR EX612 V
ASSY PCBA MAIN BOARD FOR EX615
70.8EF43GR01 V
(SERVICE)
2 80.8EF01G003 PCBA MAIN BD FOR EX615
3 80.8EF07G001 PCBA LAN MODULE BD FOR EX615/EX542 V
4 61.00080G001 STAND OFF H=6.0 M2/M3*L6 Sn EP910
6 86.0A123G024 HEX NUT M3*5.5*0.5P L2.4 Ni
8 61.83N19G001 HEX SPACER M3 H=17mm L=5mm AL PD726
9 80.8EF06G003 PCBA DAUGHTER BD FOR EX612 V
9 80.8EF06G002 PCBA DAUGHTER BOARD FOR EX615/EX542 V
EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential VII

ASSY MAIN BOARD MODULE
EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential VIII

1 70.8EF26G001 MAIN BOARD IO BOARD ASSY EX612
2 61.8EG02G011 MAIN BOARD SHIELDING EX612
ASSY IO COVER MODULE FOR EX542
70.8EJ04GR01 V
(SERVICE)
70.8FK02GR01 V
(SERVICE)
70.8EF44GR01 V
(SERVICE)
3 51.8EG10G011 IO COVER EX612
ADUIO I/O PORT EMI GASKET W13*H1*L13mm
4 41.86R01G001
diameter 6.5mm
5 85.005AGG408 SCREW HEX I/O #4-40 H4*L8 NI NYLOK
7 51.8EF04G001 MAIN BOARD MYLAR EX542
8 52.8EF02G001 MAIN BOARD SPONGE EX615
9 52.8EF04G001 MAIN BOARD SPONGE 20mm EX615
EMI GASKET (S-VIDEO & S-VIDEO)
10 41.85Y04G002
W18*H0.35*L17 mm
EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential IX
ASSY OPTICAL ENGINE MODULE
1 23.8BA01G001 PROJECTION LENS YM25
2 70.8EG18G001 ASSY RELAY MODULE HD20
ASSY OPTICAL ENGINE MODULE EX542
70.8EJ02GR01 V
(SERVICE)
70.8FK03GR01 V
(SERVICE)
70.8EF40GR01 V
(SERVICE)
3 23.8AH20G011 YO CONDENSER 1 FOR A15W
4 85.1A526G060 SCREW PAN MECH M2.6*6 Ni NYLOK
5 80.8EF02G001 PCBA DMD BD FOR X15-II XGA V
70.8EF42GR01 ASSY ROD MODULE EX615 (SERVICE) V
6 70.8EF36G001 ASSY ROD MODULE EX615
7 70.8CP10G001 ASSY ENGINE BOTTOM COVER Z15
0.55” XGA 2xLVDS SERIES 450 DMD -8 TI 1076-
8 48.8CQ01G001 V
603cB
9 52.8CP01G011 DMD RUBBER EX615
10 52.8CP02G001 DMD BOARD RUBBER X1161
STEP SCREW FOR TYPEX DMD M2.6*11.8mm,
11 85.4A826G118
X15
S450 0.55” XGA/SVGA DMD thermal pad, FUJIPO-
12 52.8CP04G001
LY, Sarcon XR-HE, 18.4x12.5x0.5 mm
13 70.8CP11G001 ASSY ENGINE BASE Z15
14 61.8EF02G001 DMD HEATSINK AL6063 EX615
15 70.8EF03G001 ASSY COLOR WHEEL MODULE EX612
16 61.8EF03G001 CONDENSER LIGHT STOP EX615
17 23.8AH20G012 YO CONDENSER 2 FOR A15W
18 61.88N13G002 ROD COVER NEW SUS301 X15
19 61.88N12G001 ROD SPRING SUS301,X15
20 85.WA321G040 SCREW PAN TAP M1.7*4 BLACK
21 85.00823G080 HEX SCREW M3*H8*L5.3,BRASS
22 41.83C01G001 EMI GASKET W13*H15*L40
23 41.8BV01G001 EMI GASKET W6*H13*L40
24 61.8EF01G001 DMD MASK EX615
EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential XI
ASSY COLOR WHEEL MODULE

ASSY COLOR WHEEL MODULE EX615
70.8EF41GR01 V
(SERVICE)
1 61.8CP03G001 CW BRACKET SECC X1161
2 80.8EF04G001 PCBA PHOTO SENSOR BOARD FOR EX615 V
YO 5S R76Y32G78W98B76 CW (WITH FTZS MO-
3 23.8EF19G101
TOR)
4 85.1A126G040 SCREW PAN MECH M2.6*4 Ni
TAPE 3M J350 10*5mm FOR COLOR WHEEL
5 51.82Y29G001
DP715
6 52.83615G001 COLOR WHEEL DISC RUBBER, EzPro755
7 61.83628G001 COLOR WHEEL SHOULDER SCREW,EzPro755
EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential XII

ASSY BlOWER MODULE

SUNON 45*20mm GB1245PKVX-8 F-TYPE
1 49.8EF04G001 V
BLOWER (EX542)
SUNON 45*20mm GB1245PKVX-8 F-TYPE
1 49.8EF04G001 V
BLOWER (EX612/EX615)
2 52.89T01G001 BLOWER AIR TIGHT F12 H5350
3 52.82G08G001 BLOWER 4520 RUBBER EP7190
EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential XIII

ASSY FAN SHIELDING MODULE
9
6
1
4
5

SUNON, KDE1207PKV1-A 70*70*20mm AXIAL
1 49.88T01G001 V
FAN (EX542)
SUNON KDE1285PTV1 AXIAL FAN-LOW COST
1 49.8EF03G001 V
(EX612/EX615)
2 61.8EG05G001 8525 FAN SHIELDING HD20
3 61.8EG11G001 LAMP BLOWER DUCT HD20
4 85.1A123G080 PAN SCREW M3*8 FOR YM-64 FRONT CELL&SP
5 85.1A123G060 SCREW PAN MECH M3*6 NI
THERMAL SWITCH WITH BRACKET (KLIXON
6 43.8EF17G001 V
YS11) EX542 85C (EX542)
THERMAL SWITCH WITH BRACKET (KLIXON
6 43.8EG17G001 V
YS11) HD20 100C (EX612/EX615)
8 51.81540G001 TAPE 3M J350 17*60mm
9 41.8EF01G001 EMI GASKET W5*H4*L80m
EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential XIV

A.K.
EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential XV
1 55.8EG01G011 CARTON OUTSIDE BOX AB FLUTE EX615 V
2 55.8EG02G001 PARTITION PAPER RIGHT HD20
3 55.8EG03G001 PARTITION PAPER LEFT HD20
4 70.8EG01G001 LENS CAP ASSEMBLY HD20
5 DC.8EF01G001 D.C. EX615
6 35.86301G001 SPEC LABEL BLANK PD120
7 51.00093G002 PE BAG 400*520*0.07mm FOR OPTOMA
8 56.8EG01G001 AIR BAG BOTTOM HD20
9 56.8EG02G001 AIR BAG TOP HD20
CABLE POWER CORD 1830mm SP-023+IS14
10 42.50112G001
EUR. GREEN
11 42.00200G005 CABLE VGA 15P 1.8M BLK EP739
REMOTE CONTROLER OF EX612 WITHOUT
45.8EF02G001 V
LASER
12 45.8EF01G001 REMOTE CONTROL OF Z15II WITH LASER V
13 57.00001G001 PACK SIO2 DRIER 20g
PE BAG ZIPPER 33cm*25cm SIZE GREEN FOR
14 51.00027G003
OPTOMA
QUICK START CARD MULTILINGUAL OPTOMA
15 36.8EF02G001
EX542/EX612/EX615
USER’S GUIDE MULTILINGUAL (CD) OPTOMA
36.8FK01G001 V
EX612
USER’S GUIDE MULTILINGUAL (CD) OPTOMA
16 36.8EF01G001 V
EX542/EX615
WARRANTY CARD 3 YEARS, USA FOR OPTOMA
17 36.00012G002
LPP SERIES
EXTENDED WARRANTY ; REGISTRATION
18 36.00018G001
FORM,USA FOR LPP SERIES
19 46.80S01G101 BATTERY #7 1.5V NOVACELL
20 51.00200G001 HANDLE BAR 2. PE HD70
21 51.00201G001 HANDLE BAR 1.PE HD70
22 35.82001G111 AK LABEL 3”*3” BLANK
23 35.00040G001 LABEL 30mm,GREEN
24 35.52302G091 LABEL CARTON 108*92 BLANK
EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential XVI

Appendix B
I. Serial Number System Definition
Serial Number Format for Projector (take EX542 as example)
Q 8FJ 9 15 AAAAA C 0001
1 2 3 4 5 6 7

1 : Q = Optoma
2 : 8FJ = Project Code
3 : 9 = Last number of the manufacture year (ex: 2009 = 9)
4 : 15 = week of the manufacture year (ex: the fifteenth week of the

year = 15)
5 : AAAAA = not-defined
6 : C = Manufacture factory (TW or China)
7 : 0001 = Serial Code
EX: Q8FJ915AAAAAC0001
This label "Q8FJ915AAAAAC0001" represents the serial number for EX542. It is produced
at CPC on ffifteenth of 2009. Its serial code is 0001.
II. PCBA Code Definition
PCBA Code for Projector
A B XXXXXXXXXX C XXX EEEE
1 2 3 4 5 6

1 : ID
2 : Vendor Code
3 : P/N
4 : Revision
5 : Date Code
6 : S/N

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SERVICE MANUAL

Date Revise Version Description

2009.07.08 V1.0 Initial Issue

2009.10.13 V2.0 Add EX540/EX762

2009.12.16 V3.0 Add EX540I/EX542I

Copyright Feb, 2010. All Rights Reserved. P/N: 36.8FJ01G001

SI : TSE: Check: Approved:

LVPS 75.8CT02G001 75.8CT01G001 75.8FB01GP01

BLOWER 49.8CS01G002 49.8EF04G001 49.8FB01G001

FAN 49.88T01G001 49.8EF03G001

SPEAKER 49.8EF01G001 49.8GZ01G001 49.87K01G201 49.8EM01G011

Chapter 2 Disassembly Process

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential III

Chapter 4 Function Test & Alignment Procedure

Chapter 5 Firmware Upgrade

Section 2: System Firmware Upgrade

Section 3: 8051 Firmware Upgrade Procedure 5-13

Section 4: Network Firmware Upgrade Procedure

Chapter 6 EDID Upgrade

Setup Procedure (HDMI)

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 1-1

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 1-2

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 1-3

Computer Compatibility (Analog)

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 1-4

Computer Compatibility (Digital)

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 1-5

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 1-6

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 2-

2-3 Disassemble Lamp

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 2-

Note: - When you assemble the Focus Ring,

2-5 Disassemble Top Cover

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 2-

2-6 Disassemble Keypad

Keypad Board Keypad

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 2-

2-8 Disassemble Main Board

1. Unplug 1 connector (as green square) to

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 2-

7. Separate the Main Board Module

Main Board Shielding

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 2-

Compose of Red/Black Wire and

B Lamp Driver Black wire tube (5 pin)

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 2-

1. Unscrew 2 screws (as green circle) to

Daughter Board Lan Module Board

3. Unscrew 3 hex screws (as yellow circle)

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 2-

1. Tear off the black mylar (as green square).

2-11 Disassemble Color

1. Unscrew 2 screws (as red circle) to

Note: - Avoid touching the glass parts of color

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 2-

Note: - Avoid touching the DMD Chip when you

2-13 Disassemble Rod

1. Unscrew 2 screws (as green circle) to

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 2-10

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 2-

2-3 Disassemble Lamp

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 2-

2-5 Disassemble Top Cover

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 2-

2-6 Disassemble Keypad

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 2-

2-8 Disassemble Main Board

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 2-

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 2-

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 2-

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 2-

2-11 Disassemble Color

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 2-

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 3-

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 3-

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 3-

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 3-

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 3-

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 3-

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 4-

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 4-

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 4-

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 4-

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 4-

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 4-

EX540/EX542/EX612/EX615/EX762/EX540I/EX542I/ES523ST/EW533ST Confidential 4-