Epson EMP-822 Service Manual
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Epson EMP-822 Service Manual

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EMP-822/EMP-83
EMP-X5/EMP-S5

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Summary of Contents for Epson EMP-822

  • Page 1 Data Projector Service Manual EMP-822/EMP-83 EMP-X5/EMP-S5...
  • Page 2 Other company or product names used herein are for identification purpose only and may be trademarks or registered trademarks of their respective owners. EPSON disclaims any and all rights in those marks.

  • Page 3: Revision History

    EMP-822/EMP-83/EMP-X5/EMP-S5 REVISION HISTORY After first release of this manual, the parts and mechanism may be subject to change for improvement of their performance and the manual may be revised. Be sure to always keep this manual up to date. History...
  • Page 4 EMP-822/EMP-83/EMP-X5/EMP-S5 IMPORTANT PRECAUTIONS IN SAFETY AND MAINTENANCE PERFORMANCE Here describes the important points to keep in mind in repair and maintenance performance. Symbols To prevent injury to the repair technicians and to protect the devices, the categorized safety instructions are provided in this manual with the symbols below. Be sure to read and under- stand their meanings before proceeding to the next section.

  • Page 5: Safety Instructions

    EMP-822/EMP-83/EMP-X5/EMP-S5 Safety Instructions The precautionary measures itemized below should be fully understood when performing repair and maintenance procedures. When disassembling/assembling, be sure to turn off the power switch and pull out the power cable from the projector beforehand. Never touch the current-carrying part or high temperature section during a test oper- ation, signal measurement or any other situations that is necessary to perform the repair/maintenance work with the power turned on and the cover removed.
  • Page 6 EMP-822/EMP-83/EMP-X5/EMP-S5 Never use or replace with any service parts that is not specified by EPSON. Be sure to perform the repair/maintenance work on the even and stable work bench to prevent the product from dropping down or mal-operation due to the improper setting of the product.

  • Page 7: Table Of Contents

    3.3.8 Lens Shutter’s Operation Check ..........3-20 3.3.9 Switch Board’s Operation Check..........3-21 3.3.10 RC & Projector’s Operation Check..........3-22 3.3.11 Wired LAN’s Operation Check (EMP-822/EMP-83 only) .... 3-23 Chapter 4 Disassembly/Assembly 4.1 Overview ....................4-2 4.1.1 Precautions ................... 4-2 4.1.2...
  • Page 8 Removing the Inner EX Duct A/Intake Fan/RC Board Assy..4-43 4.5.2 Removing the PS Ballast Assy............ 4-47 4.5.3 Removing the Lamp Fan/Speaker Unit (EMP-822/EMP83 only) 4-50 4.5.4 Removing the Lower Case ............4-51 Chapter 5 Appendix 5.1 AS (After Service) Menu ................5-2 5.1.1...

  • Page 9: Chapter 1 Product Specifications

    Chapter 1 Product Specifications...

  • Page 10: Product Features

    EMP-822/EMP-83/EMP-X5/EMP-S5 1.1 Product Features The EMP-822/EMP-83/EMP-X5/EMP-S5 is a portable data projector in a compact body and with the following features. 1.1.1 Features of the Projector EMP-822/EMP-83/EMP-X5/EMP-S5 Common Features The A/V mute slide makes it easy to project and store The A/V mute slide simplifies stopping and resuming projection. You can stop/resume projection simply by closing/opening the A/V mute slide.

  • Page 11: Specifications

    EMP-822/EMP-83/EMP-X5/EMP-S5 1.2 Specifications MODEL EMP-S5 EMP-X5 EMP-83 EMP-822 Specification Size 0.55-inch 0.63-inch 0.63-inch of main parts without MLA without MLA with MLA Pixel number 480,000 dots 786,432 dots (800 x 600) x 3 (1024 x 768) x 3 Native Resolution...

  • Page 12: External Views

    EMP-822/EMP-83/EMP-X5/EMP-S5 1.3 External Views EMP-822/83 28 35.9 78.4 175.1 23.7 83.2 69.5 M4x9-3 144.5 37.7 158.8 Unit: mm Figure 1-1. External Dimensions (EMP-822/83) (mm) SEIKO EPSON Revision:A...
  • Page 13 EMP-822/EMP-83/EMP-X5/EMP-S5 1.1 1.41 3.09 6.89 0.93 12.87 3.28 9.53 2.74 2.17 M4x9-3 6.14 4.29 5.69 1.48 6.25 Unit: inch Figure 1-2. External Dimensions (EMP-822/83) (inch) SEIKO EPSON Revision:A...
  • Page 14 EMP-822/EMP-83/EMP-X5/EMP-S5 EMP-X5/S5 37.5 173.5 24.5 83.2 69.5 M4x9-3 144.5 37.7 158.8 Unit: mm Figure 1-3. External Dimensions (EMP-X5/S5) (mm) SEIKO EPSON Revision:A...
  • Page 15 EMP-822/EMP-83/EMP-X5/EMP-S5 5.43 1.48 6.83 0.96 12.87 3.28 9.53 2.74 2.17 M4x9-3 6.14 4.29 5.69 1.48 6.25 Unit: inch Figure 1-4. External Dimensions (EMP-S5/X5) (inch) SEIKO EPSON Revision:A...

  • Page 16: Dimensions For Ceiling Mount

    EMP-822/EMP-83/EMP-X5/EMP-S5 1.4 Dimensions for Ceiling Mount EMP-822/83 26.5 100.5 141.5 133.2 83.2 86.3 157.5 Unit: mm Figure 1-5. Dimensions for Ceiling Mount (EMP-822/83) (mm) SEIKO EPSON Revision:A...
  • Page 17 EMP-822/EMP-83/EMP-X5/EMP-S5 0.04 1.04 3.15 3.96 5.57 7.87 5.24 4.84 3.28 Unit: inch Figure 1-6. Dimensions for Ceiling Mount (EMP-822/83) (inch) SEIKO EPSON Revision:A...
  • Page 18 EMP-822/EMP-83/EMP-X5/EMP-S5 EMP-X5/S5 0.9 26.5 100.5 141.5 133.2 86.5 157.5 Unit: mm Figure 1-7. Dimensions for Ceiling Mount (EMP-X5/S5) (mm) SEIKO EPSON 1-10 Revision:A...
  • Page 19 EMP-822/EMP-83/EMP-X5/EMP-S5 0.04 1.04 3.15 3.96 5.57 7.87 5.24 4.84 3.27 3.41 Unit: inch Figure 1-8. Dimensions for Ceiling Mount (EMP-X5/S5) (inch) SEIKO EPSON 1-11 Revision:A...

  • Page 20: Chapter 2 Theory Of Operation

    Chapter 2 Theory of Operation...

  • Page 21: Internal Components

    EMP-822/EMP-83/EMP-X5/EMP-S5 2.1 Internal Components The main components that make up the projector are shown in the figure below. EMP-X5/EMP-S5 Upper Case Control Panel (Switch Board) EMP-S5 MA Board Assy. Lamp Unit Optical Engine TH Board Exhaust Fan (Lamp Thermistor) Safety Switch...

  • Page 22: Hardware Overview

    EMP-822/EMP-83/EMP-X5/EMP-S5 2.2 Hardware Overview The hardware of this projector consists of the optical block and the electrical circuit components. The overview of the hardware and functions is shown below. Lamp Lid Detection Switch Wired LAN EMP-822/83 EMP-X5/S5 Audio In/Out MA Board...

  • Page 23: Electrical Circuit Components

    EMP-822/EMP-83/EMP-X5/EMP-S5 2.2.1 Electrical Circuit Components The components and their functions are explained below. Component name Function The circuit board that controls the whole system and functions of the projector. The main functions are listed below. • Digitally processes the input data from the external devices.
  • Page 24 EMP-822/EMP-83/EMP-X5/EMP-S5 Component name Function EMP-X5 has an auto keystone correction function. It uses a mechanical device to measure the amount of protrusion of the Front Foot to detect the tilting level Sensors Foot Detection of the projector. The device detects only four predetermined points. If the auto correction does not adjust the distortion enough, you can make further correc- tion manually.

  • Page 25: Optical Engine

    3 spectrums (R, G and B). Multi Lens Alley Diffuses the light from the lamp to provide uniform illumination. Light Guide (EMP-822 only) Unit Polarizes the light and remove the U/V component harmful to the Polarizer (PBS) L/V.

  • Page 26: Temperature Control

    EMP-822/EMP-83/EMP-X5/EMP-S5 2.3 Temperature Control The internal temperature of this projector is monitored by the sensors (the Lamp thermistor, L/ V thermistor) in order to protect the projector from internal overheat, which may cause unsafe state or damage to the projector. The fans’ revolutions are controlled according to the detected temperature data.

  • Page 27: Chapter 3 Troubleshooting

    Chapter 3 Troubleshooting...

  • Page 28: Before Carrying Out Troubleshooting

    EMP-822/EMP-83/EMP-X5/EMP-S5 3.1 Before Carrying Out Troubleshooting • If repairs involving the replacement of parts or components have been carried out, always be sure to re-check whether the replacement parts themselves are operating correctly or not in order to determine whether the problem is the result of something such as a loose connec- tor.

  • Page 29: Basic Information On Troubleshooting

    EMP-822/EMP-83/EMP-X5/EMP-S5 3.2 Basic Information on Troubleshooting This section describes basic information needed when executing the troubleshooting. 3.2.1 LED Indicators The control panel has three LEDs that indicate the operating status of the projector. Power indicator Lamp indicator Temp indicator Figure 3-1 LED Indicators The following tables show what the indicators mean and how to remedy any problem indicated.
  • Page 30 EMP-822/EMP-83/EMP-X5/EMP-S5 Table 3-2. LED Indicator Status (Error) Projector Indicator Status Problem and Remedy Status [Status] Abnormality is detected from any of the fans or the sensors mounted on the projector. (Fan’s abnormality: irregular revolution/disconnection, Sensor’s abnormality: irregular value detected/disconnection) [Remedy] Fan Error Check the connections between the fans/sensors and the MA board.
  • Page 31 EMP-822/EMP-83/EMP-X5/EMP-S5 Lamp or Temp indicator flashes orange: Warning Blink Varies according to the projector status Table 3-3. LED Indicator Status (Warning) Projector Indicator Status Problem and Remedy Status (This is not an abnormality. However, if the temperature rises too high again, projection stops automatically.)

  • Page 32: Troubleshooting From The Error Code

    EMP-822/EMP-83/EMP-X5/EMP-S5 3.2.2 Troubleshooting from the Error Code START ★ Checking Error Code Check the Error Code from AS menu. (5.1 "AS (After Service) Menu" (p. (If the image cannot be projected, connect PC to the service ter- minal and check the code from the AS menu.) Repair or replace the failed parts.
  • Page 33 EMP-822/EMP-83/EMP-X5/EMP-S5 Error Status Cause Point to be checked Remedy (Part to be improved/Reference) (AS menu) If not appropriate, correct the connection. • MA Board Assy. Connection status (p. 26) • TH Board Assy. (p. 35) Inappropriate connec- If damaged, replace the cable/board including tion of connectors Connecter’s terminal sta-...
  • Page 34 EMP-822/EMP-83/EMP-X5/EMP-S5 Error Status Cause Point to be checked Remedy (Part to be improved/Reference) (AS menu) Internal Abnormality of the error RAM (RA) Menu’s operation Replace the Optical Engine and MAB set. Abnormality of the • MA Board Assy. (p. 26) •...

  • Page 35: Cable Connection And Projector's Status

    EMP-822/EMP-83/EMP-X5/EMP-S5 3.2.3 Cable Connection and Projector’s Status The projector’s status when disconnection occurs somewhere is described below. When some irregular status is seen, refer to the following table and check the doubted connec- tors are securely connected. If there is a disconnection or a loose connection, connect it firmly.
  • Page 36 Exhaust Fan period of cooling. But the error message continues to be on. CN805 P/S Fan CN806 Lamp Fan Connection (EMP-822/83 only) Status IF board Connected to The power can turn on and the projection starts normally. But CN3003 Speaker Unit no sound is output from the speaker even if the audio input is applied.

  • Page 37: Troubleshooting

    Check the operation and the function of each button of Remote Control. Wired LAN's Operation Check Wired LAN Check the operation between the projector (EMP-822/EMP-83 only) and the computer on the wired LAN. Flowchart 3-1 Basic Checking Flowchart SEIKO EPSON 3-11...

  • Page 38: Abnormality Check

    EMP-822/EMP-83/EMP-X5/EMP-S5 3.3.2 Abnormality Check START Any abnormal noises? Check the fans for any foreign objects around them. The cause might be a malfunction of the power supply unit (pulse transformer vibration, etc.). Overheated? Check the thermistors and Safety Switch for malfunction.

  • Page 39: Exterior Check

    EMP-822/EMP-83/EMP-X5/EMP-S5 3.3.3 Exterior Check START Any damage/deformation/cracking due to external forces? Fixed to Lower Case correctly? Upper Case Any foreign object/dirt on IR receiver? Any foreign object/dirt on the vents? Fixed to Upper Case correctly? Lens Shutter Work smoothly? Fixed to Upper Case correctly?

  • Page 40: Connection Check

    EMP-822/EMP-83/EMP-X5/EMP-S5 3.3.4 Connection Check Before starting the checking work, be sure to turn off the power and detach the AC cable. (refer to 3.2.3 "Cable Connection and Projector’s Status" (p. Start Remove Upper Case Switch Board MA board CN702 (Lock-type connector)
  • Page 41 P/S Fan MA board CN805 Lamp Lid MA board CN700 Detection SW Lamp Fan MA board CN806 (EMP-X5/EMP-S5's case (EMP-822/EMP-83's case) Speaker Unit IF board CN3003 Speaker MA board CN501 Install Upper Case Flowchart 3-5 Connection Check (2) SEIKO EPSON...

  • Page 42: Power On/Off & Initialization Check

    EMP-822/EMP-83/EMP-X5/EMP-S5 3.3.5 Power ON/OFF & Initialization Check Start Connect AC cable 1.When pressing [Power] button on Switch Board, does indicator flash green, then light green? 2.Does the lamp illuminate? 3.Does indicator flash orange for approx. 2 seconds, then light orange? 1.

  • Page 43: Image Display & Quality Check

    EMP-822/EMP-83/EMP-X5/EMP-S5 3.3.6 Image Display & Quality Check The image quality can also be affected by condensation or by a dirty lens. If condensation forms, the problem will correct itself naturally if the projector is left to stand for a while.
  • Page 44 EMP-822/EMP-83/EMP-X5/EMP-S5 From previous page 1. Clean Projection Is the image vivid? Lens. 2. Clean the periphery Connect PC to the of L/V. computer terminal, and project an image. If the image is not vivid enough, apply the remedy from the top (1). If it does not work, go on to the next remedy.

  • Page 45: Audio I/O's Check

    If it doesnot work, go on to the next remedy. For more information, refer to 4.5.3 "Removing the Lamp Fan/Speaker Unit (EMP-822/EMP83 only)" (p. 50) 4.4.2.2. "Removing the Speaker. (EMP-X5/EMP-S5 only)" (p. 34)/4.4.2 "Removing the Optical Engine and MAB set(1) (MA Board Assy.) /IF Case" (p. 26) 4.4.5 "Removing the Optical Engine and MAB set (2) (Optical Engine)"...

  • Page 46: Lens Shutter's Operation Check

    EMP-822/EMP-83/EMP-X5/EMP-S5 3.3.8 Lens Shutter’s Operation Check Start 1. Reconnect MA board CN704 correctly. Does AV Mute function start/stop, when closing/opening the shutter? 2. Replace Shutter Switch. 3. Replace Optical Engine and MAB set. If theAV Mute does not work correctly, apply the remedy from the top (1).

  • Page 47: Switch Board's Operation Check

    EMP-822/EMP-83/EMP-X5/EMP-S5 3.3.9 Switch Board’s Operation Check Start 1. Does pressing [Power] button turn the power on/off? 2. Does pressing [Menu] button display the menu window? 3. Does pressing [Source Search] button change input sources? 4. Does pressing [Help] button display the help window? 5.

  • Page 48: Rc & Projector's Operation Check

    3. Is the control effective approx. 6m away from the front/back of the projector? 1. Select [Remote Receiver] from the menu, set all the receivers active. (EMP-822/83 only) 2. Replace the batteries of the controller. 3. Replace the controller. 4. Replace the RC Board.

  • Page 49: Wired Lan's Operation Check (Emp-822/Emp-83 Only)

    4.4.2 "Removing the Optical Engine and MAB set(1) (MA Board Assy.) /IF Case" (p. 26) 4.4.5 "Removing the Optical Engine and MAB set (2) (Optical Engine)" (p. 39). Flowchart 3-13 Wireless/Wired LAN’s Operation Check (EMP-822/EMP-83 only) SEIKO EPSON 3-23 Revision:A...

  • Page 50: Chapter 4 Disassembly/Assembly

    Chapter 4 Disassembly/Assembly...

  • Page 51: Overview

    EMP-822/EMP-83/EMP-X5/EMP-S5 4.1 Overview This chapter describes the procedures for disassembling and assembling the main components of the EMP-822/EMP-83/EMP-X5/EMP-S5 projector. Unless otherwise specified, reassembly is the reverse of the disassembly procedure. Read the precautions described in the next section before starting.

  • Page 52: Precautions Which Must Be Taken When Servicing

    EMP-822/EMP-83/EMP-X5/EMP-S5 4.1.2 Precautions which must be taken when servicing The precautions given below must be always observed whenever you disassemble/reassemble the projector to maintain the quality. In addition, make sure to observe the WARNING and CAUTION precautions given in each section which describe disassemble/reassemble procedure of each unit or component in this chapter.

  • Page 53: Safety Check After Servicing

    EMP-822/EMP-83/EMP-X5/EMP-S5 4.1.4 Safety Check after Servicing Definition “Unsafe state” is the state of a part that may cause or contain the risk of the following: • personal injuries • damages to the property • abnormal heat generation • smoking • fire •...
  • Page 54 EMP-822/EMP-83/EMP-X5/EMP-S5 4. Method to check the Safety Control Points Insulation resistance test Testing procedure Carry out testing in the order given below. Repair Insulation resistance test Illumination check Safety inspections Testing methods • Testing apparatus: Insulation ohmmeter (Rating: 500 V/100 MΩ)
  • Page 55 EMP-822/EMP-83/EMP-X5/EMP-S5 • Checking labels Check that each caution labels are placed in the positions shown in the figure below. * When replacing parts with caution labels attached, make sure to stick the label to the replaced parts. THE CAUTION NOT TO...

  • Page 56: Tools And Equipment

    EMP-822/EMP-83/EMP-X5/EMP-S5 4.1.5 Tools and Equipment The table below lists the tools and equipment required for servicing the projector. All are commercially available, and should be made ready beforehand. Table 4-1. Name Qty. Application Disassembling the focus ring and the zoom Phillips screwdriver No.

  • Page 57: Precautions For Optical Engine And Main (Ma) Board

    EMP-822/EMP-83/EMP-X5/EMP-S5 4.1.6 Precautions for Optical Engine and Main (MA) Board The Optical Engine and MA Board are paired together as a single service part. Neither is available separately. For servicing that requires the replacement either of the MA Board or the Optical Engine, both components must be replaced together.

  • Page 58: Projector Disassembly And Assembly

    EMP-822/EMP-83/EMP-X5/EMP-S5 4.2 Projector Disassembly and Assembly The general disassembly procedure for the EMP-822/EMP-83/EMP-X5/EMP-S5 projectors is illustrated below. Except where indicated separately, all reassembly should be carried out by following the disassembly procedures in reverse. Detailed disassembly procedures for each component are given in Sections 4.3 Removing Exterior Parts/Components...
  • Page 59 Front Case case,front;AJ Front Foot Unit FOOT UNIT,FRONT IF Case CASE,IF;G IF Label label if ;J PRINTED CIRCUIT BOARD ASSEM- IF Board Assy.(EMP-822/83 only) BLY;IF_R1 Inner Exhaust Dust A DUCT,EXHAUST,INNER;A42 Inner EX Dust B DUCT,EXHAUST,INNER;B Intake Duct DUCT,INTAKE Intake Fan...
  • Page 60 Shutter Sheet sheet,shutter Shutter Spring SPRING,SHUTTER Shutter Switch SWITCH,SHUTTER Speaker Spring Spring Speaker Speaker(EMP-X/S5 only) Speaker Speaker Unit(EMP-822/83 only) Speaker Unit SW Shading Sheet SHEET,SHADING,SW;B PRINTED CIRCUIT BOARD ASSEM- Switch Board Assy. BLY;SW_R2 PRINTED CIRCUIT BOARD ASSEM- TH Board Assy. BLY;TH_R1...

  • Page 61: Removing Exterior Parts/Components

    EMP-822/EMP-83/EMP-X5/EMP-S5 4.3 Removing Exterior Parts/Components 4.3.1 Removing the AS Lamp Unit This part is designated as the Safety Device. When removing/replacing the part for repair, be sure to refer to the following section. According to the instructions in it, handle the part and perform the procedure after servicing.

  • Page 62: Removing The Air Filter Assy

    EMP-822/EMP-83/EMP-X5/EMP-S5 4.3.2 Removing the Air Filter Assy. 1. Pull the tab of the Air Filter Assy. outward with your finger, and remove the Air Filter Frame. Air Filter Assy. Figure 4-4. SEIKO EPSON 4-13 Revision:A...

  • Page 63: Removing The Front Foot Unit/Rear Foot/Rubber Foot

    EMP-822/EMP-83/EMP-X5/EMP-S5 4.3.3 Removing the Front Foot Unit/Rear Foot/Rubber Foot Removing the Front Foot Unit 1).Press a Tweezers or similar tool into the small slot beside the Front Foot Unit, and take out the Front Foot Unit. Front Foot Unit Figure 4-5.

  • Page 64: Removing The Upper Case Unit

    EMP-822/EMP-83/EMP-X5/EMP-S5 4.3.4 Removing the Upper Case Unit 1. Remove the eight screws (C.B.P-TITE SCREW,3X10,F/ZB-3C) that secure the Upper Case Unit from the bottom. Figure 4-7. Be careful, as there are 2 cables connected to the Upper Case Unit. 2. Lift the Upper Case Unit carefully.
  • Page 65 EMP-822/EMP-83/EMP-X5/EMP-S5 When connecting the cable to CN702, be sure to lock the connector. 3. Disconnect the Shutter Switch cable from the connector CN704 on the MA Board, and unlock the connector CN702 and disconnect the Switch Board cable. CN704 CN702...
  • Page 66 EMP-822/EMP-83/EMP-X5/EMP-S5 4.3.4.1. Removing the Switch Board Assy. 1. Remove the four screw (C.C.P-TITE SCREW,3X8,F/ZN-3C) that secure the Switch Board Assy., and remove the Switch Board Assy. from the Upper Case Unit. 2. Remove the following parts from the Upper Case Unit.
  • Page 67 EMP-822/EMP-83/EMP-X5/EMP-S5 When reassembling the SW Board Assy., be careful of the following. • On the central part of the SW Board, fold the cable of the SW Board Assy., and heat-resistant tape secure it with a • Route the cable of the Shutter Switch as shown in the figure below, and fix it with heat-resistant tape fixing the SW Board Assy.
  • Page 68 EMP-822/EMP-83/EMP-X5/EMP-S5 4.3.4.2. Removing the Shutter Switch 1. Remove the screw (C.B.P-TITE SCREW,3X8,F/ZN-3C) that secures the Shutter Frame, and remove the Shutter Frame from the Upper Case Unit carefully not to lose the Shutter Spring and the Shutter Ball. When carrying out the following steps, be careful not to lose the Shutter Ball, and the Shutter Spring.
  • Page 69 Shutter Switch Figure 4-13. Correct assembly of the Shutter Switch Stick the Shutter Sheet to the Shutter A in the position shown in the figure below. EMP-822/83’s case Shutter A Shutter Sheet EMP-X5/S5’s case Shutter A Shutter Sheet Figure 4-14.
  • Page 70 After replacing the Shutter A and the Shutter Frame, or when the sliding action of the shutter become awkward, apply grease in the size of a grain of rice to the positions indicated in the figure below. (EMP-822/83’s case) ejection pin marks...
  • Page 71 EMP-822/EMP-83/EMP-X5/EMP-S5 After replacing the Shutter A and the Shutter Frame, or when the sliding action of the shutter become awkward, apply grease in the size of a grain of rice to the positions indicated in the figure below.(EMP-X5/S5’s case) ejection pin marks...
  • Page 72 EMP-822/EMP-83/EMP-X5/EMP-S5 When reassembling the Shutter Spring and the Shutter Ball, assemble in the order of the following. 1). Keep the Shutter A open. 2). Put the Shutter Ball into the hole of the Shutter Frame. 3). Move the Shutter Ball to the direction of the arrow, then squeeze and insert the Shutter Spring to the hole of the Shutter Frame.
  • Page 73 EMP-822/EMP-83/EMP-X5/EMP-S5 4.3.4.3. Removing the Front Case/Rear Case 1. Remove the four screws (C.C.P-TITE SCREW,3X8,F/ZN-3C) that secure the Front Case and the Rear Case, and remove the Rear Case from the Front Case. 2. Remove the screw (C.C.P-TITE SCREW,3X8,F/ZN-3C) that secures the Plate Nut, and remove the Plate Nut from the Rear Case.

  • Page 74: Removing The Engine/Boards

    EMP-822/EMP-83/EMP-X5/EMP-S5 4.4 Removing the Engine/Boards 4.4.1 Removing the Foot Detection Assy. (EMP-X5 only) 1).Disconnect the cable of the Foot Detection Assy. from the connector CN705 on the MA Board. 2). Remove the two screws (C.B.P-TITE SCREW,3X10,F/ZB-3C) that secure the Foot Detection Assy., and remove the Foot Detection Assy.

  • Page 75: Removing The Optical Engine And Mab Set(1) (Ma Board Assy If Case

    EMP-822/EMP-83/EMP-X5/EMP-S5 4.4.2 Removing the Optical Engine and MAB set(1) (MA Board Assy.) /IF Case 1).Unlock the connectors of the Light Valve R/G/B connection cables. Light Valve R Locked Light Valve B Unlocked Light Valve G Figure 4-20. When connecting the R/G/B Light Valve cables, be sure to insert the R/G/B Light Valve cables securely into the connectors to the end.
  • Page 76 EMP-822/EMP-83/EMP-X5/EMP-S5 2).Disconnect all the following cables that are connected to the MA Board from the board. • CN1400/CN1500/CN1600: Light Valve R/G/B connection cables • CN1700: Power Cable • CN700: Lamp Lid Detection Switch • CN701: SCI Cable • (* CN702): Switch Board cable •...
  • Page 77 EMP-822/EMP-83/EMP-X5/EMP-S5 Removing the Optical Engine and MAB set (1) (MA Board Assy.) /IF Case (EMP-822/EMP-83’s case) Be careful when lifting the IF Board Assy., as the Speaker Unit Cable is connected to connector CN3003. 1).Remove the three screws (one C.C.SCREW,3X6,F/ZN-3C, and two C.B.P-TITE SCREW,3X10,F/ZB-3C) that secures the MA Board Assy., and lift it up.
  • Page 78 EMP-822/EMP-83/EMP-X5/EMP-S5 Removing the Optical Engine and MAB set (1) (MA Board Assy.) /IF Case (EMP-X5/EMP-S5’s case) 1).Remove the three screws (one C.C.SCREW,3X6,F/ZN-3C, and two C.B.P-TITE SCREW,3X10,F/ZB-3C) that secure the MA Board Assy., and the screw (C.B.P-TITE SCREW,3X10,F/ZB-3C) that secure the IF Case, and remove the MA Board Assy.
  • Page 79 EMP-822/EMP-83/EMP-X5/EMP-S5 When connecting the connectors to the MA Board Assy., route the cables as shown below. Figure 4-24. Connector Connector Lamp Lid Detection SW RC Board Lamp Fan Intake Fan2 Speaker PS Ballast Assy.(SCI) Intake Fan1 SEIKO EPSON 4-30 Revision:A...
  • Page 80 EMP-822/EMP-83/EMP-X5/EMP-S5 • (1)’s Routing 1).Route the cable of the Lamp Lid Detection Switch under the MA Plate, and through the slit shown in the figure below in the direction of the arrow. 2).Connect to CN700 on the MA Board Assy.
  • Page 81 EMP-822/EMP-83/EMP-X5/EMP-S5 • (5)’s Routing 1). Secure the RC Board Cable to the Intake Fan1 with a heat-resistant tape, then route it twice around the Intake Duct, and connect the connector. Intake Duct RC Board Cable Intake Fan1 Figure 4-27. • (6), (7)’s Routing 1).
  • Page 82 EMP-822/EMP-83/EMP-X5/EMP-S5 4.4.2.1. Removing the IF Board Assy. (EMP-822/EMP-83 only) 1. Remove the following screws and remove the MA Plate, the MA Shield and the IF Board Assy. • D sub15pin fastening screws (1/4-40X1/4,H.H.,F/NI,O SCREW): x 8 • S-terminal/RCA terminal fastening screws (C.B.P-TITE SCREW,3X10,F/ZB-3C): x 2 •...
  • Page 83 EMP-822/EMP-83/EMP-X5/EMP-S5 4.4.2.2. Removing the Speaker. (EMP-X5/EMP-S5 only) 1. Remove the two screws (C.P.TYPE2 P-TITESCREW,1.7X6,F/ZB-3C) that secure the Speaker and remove the Speaker from the IF Case. IF Case Speaker Figure 4-30. SEIKO EPSON 4-34 Revision:A...

  • Page 84: Removing The Lamp Lid Detection Switch/Th Board Assy

    EMP-822/EMP-83/EMP-X5/EMP-S5 4.4.3 Removing the Lamp Lid Detection Switch/TH Board Assy. Removing the Lamp Lid Detection Switch This part is designated as the Safety Device. When removing/replacing the part for repair, be sure to refer to the following section. According to the instructions in it, handle the part and perform the procedure after servicing.
  • Page 85 EMP-822/EMP-83/EMP-X5/EMP-S5 Check the following, when installing the Lamp Lid Detection Switch. • The contact has no deformation. • The distance between two contact points must be 0.3mm and more. Lamp Lid Detection Switch 0.3mm and more Figure 4-32. Correct status of the Lamp Lid Detection Switch When installing the Lamp Lid Detection Switch, connect the cable of the Lamp Lid Detection Switch in the order described below.

  • Page 86: Removing The Ex Fan/Inner Ex Duct B

    EMP-822/EMP-83/EMP-X5/EMP-S5 4.4.4 Removing the EX Fan/Inner EX Duct B 1. Remove the three screws (C.B.P-TITE SCREW,3X10,F/ZB-3C) that secure the Inner EX Duct B, and remove the Inner EX Duct B together with the EX Fan. 2. Remove the two screws (C.B.P-TITE SCREW,3X10,F/ZB-3C) that secure the EX Fan, and remove the EX Fan from the Inner EX Duct B.
  • Page 87 EMP-822/EMP-83/EMP-X5/EMP-S5 Route the cable of the Ex Fan to the ditch of the Inner EX Duct B. Ex Fan Cable Inner EX Duct B Figure 4-35. When installing the Inner EX Duct B, split the Lamp Connector Cable into two, and route the cables to the protrusion of Inner EX Duct B as shown in the figure below.

  • Page 88: Removing The Optical Engine And Mab Set (2) (Optical Engine)

    EMP-822/EMP-83/EMP-X5/EMP-S5 4.4.5 Removing the Optical Engine and MAB set (2) (Optical Engine) 1. Remove the four screws (C.B.P-TITE SCREW,3X10,F/ZB-3C) that secure the Optical Engine, and remove the Optical Engine. Optical Engine Figure 4-37. SEIKO EPSON 4-39 Revision:A...
  • Page 89 EMP-822/EMP-83/EMP-X5/EMP-S5 Components of the Optical Engine and MAB set EMP-822/83 EMP-X5/S5 Optical Engine OPTICAL ENGINE OPTICAL ENGINE PRINTED CIRCUIT BOARD PRINTED CIRCUIT BOARD MA Board Assy. ASSEMBLY;MA_R1 ASSEMBLY;MA_S2 MA Plate PLATE,MA PLATE,MA MA Shield SHIELD,MA SHIELD,MA Screw C.C.SCREW,3X6,F/ZN-3C C.C.SCREW,3X6,F/ZN-3C PRINTED CIRCUIT BOARD IF Board Assy.
  • Page 90 EMP-822/EMP-83/EMP-X5/EMP-S5 4.4.5.1. Removing the Focus Ring/Zoom Ring Removing the Focus Ring/Zoom Ring (EMP-822/EMP-83/EMP-X5’s case) 1. Remove the four screws (C.P.(S-P1)SCREW,3X10,F/ZN-3C) and the four nuts (H.N.- 3,F/ZN-3C) that secure the PROJECTION LENS, and the PROJECTION LENS. 2. Remove the two screws (C.P.TYPE1 B-TITET-A.SCREW,2X6,F/ZB-3C) that secure the Focus Ring, and remove the Focus Ring.
  • Page 91 EMP-822/EMP-83/EMP-X5/EMP-S5 Removing the Focus Ring (EMP-S5’s case) 1. Remove the four screws (C.P.(S-P1)SCREW,3X10,F/ZN-3C) and the four nuts (H.N.- 3,F/ZN-3C) that secure the PROJECTION LENS, and the PROJECTION LENS. 2. Remove the two screws (C.P.TYPE1 B-TITET-A.SCREW,2X6,F/ZB-3C) that secure the Focus Ring, and remove the Focus Ring.

  • Page 92: Removing Other Main Parts

    EMP-822/EMP-83/EMP-X5/EMP-S5 4.5 Removing Other Main Parts 4.5.1 Removing the Inner EX Duct A/Intake Fan/RC Board Assy. Removing the Inner EX Duct A 1).Remove the two screws (C.B.P-TITE SCREW,3X10,F/ZB-3C) that secure the Inner Exhaust Duct A, and remove the Inner Exhaust Duct A.
  • Page 93 EMP-822/EMP-83/EMP-X5/EMP-S5 Before installing the Intake Fan, attach the Intake Fan Sheet to the fan. Make sure to align the arc of the sheet with the arc of the fan where the fan cable comes out. Intake Fan Intake Fan Sheet Figure 4-41.
  • Page 94 EMP-822/EMP-83/EMP-X5/EMP-S5 Lamp Fan Intake Duct. • Route the cable of the under the Intake Duct Lamp Fan Figure 4-43. When installing the Inner Exhaust Duct A, check the following. • The Lamp Connector is secured to the notch of the Inner Exhaust Duct A.
  • Page 95 EMP-822/EMP-83/EMP-X5/EMP-S5 Safety Switch, • After installing the pull the Protection Tube in the direction of the arrow, and make sure that the cable of the Safety Switch is covered with the Protection Tube. Safety Switch Protection Tube Figure 4-45. SEIKO EPSON...

  • Page 96: Removing The Ps Ballast Assy

    EMP-822/EMP-83/EMP-X5/EMP-S5 4.5.2 Removing the PS Ballast Assy. Removing the PS Ballast Assy. This part is designated as the Safety Device. When removing/replacing the part for repair, be sure to refer to the following section. According to the instructions in it, handle the part and perform the procedure after servicing.
  • Page 97 • The tube part of the AC Inlet is not crossing over the Lamp Duct. (To prevent the AC Cable from being caught between the IF Board Assy. and the Lamp Duct, when the MA Board Assy. is installed.)(EMP-822/83 only) Lamp Duct...
  • Page 98 EMP-822/EMP-83/EMP-X5/EMP-S5 • The Ferrite Core is set so that the AC Cable is facing the Lamp Fan side. AC Cable Ferrite Core Lamp Fan Figure 4-49. • The Lamp Connector Cable in the figure below are routed to the two ditches of the PS Ballast Assy.

  • Page 99: Removing The Lamp Fan/Speaker Unit (Emp-822/Emp83 Only)

    EMP-822/EMP-83/EMP-X5/EMP-S5 4.5.3 Removing the Lamp Fan/Speaker Unit (EMP-822/EMP83 only) Removing the Lamp Fan 1).Remove the two screws (C.B.P-TITE SCREW,3X10,F/ZB-3C) that secure the Lamp Duct, and remove the Lamp Duct and the Lamp Fan from the Lower Case. Removing the Speaker Unit 1).Remove the three screws (C.B.P-TITE SCREW,3X10,F/ZB-3C) that secure the Speaker...

  • Page 100: Removing The Lower Case

    EMP-822/EMP-83/EMP-X5/EMP-S5 4.5.4 Removing the Lower Case 1. Remove the following parts from the Lower Case. • Lower Case Seal • Filter,RC • Lamp Shield B 2. Remove the screw (C.B.P-TITE SCREW,3X10,F/ZB-3C) that secures the Lamp Shield, and remove the Lamp Shield from the Lower Case.
  • Page 101 EMP-822/EMP-83/EMP-X5/EMP-S5 When installing the EMI Sheet, stick it to the position described below. EMI Sheet stick position Figure 4-53. When installing the Lamp Shield, secure the PS Air Filter under it. PS Air Filter Lamp Shield Figure 4-54. SEIKO EPSON...
  • Page 102 Chapter 5 Appendix...

  • Page 103: As (After Service) Menu

    EMP-822/EMP-83/EMP-X5/EMP-S5 The contents of this chapter are for use only by Epson Authorized Services, and C A U T I O N are not to be disclosed to others without the express written consent of Epson. 5.1 AS (After Service) Menu This menu provides information and settings that are not displayed on the standard menu.
  • Page 104 EMP-822/EMP-83/EMP-X5/EMP-S5 S-Video/ Video’s case. (Page 1) Source XXXXXXXXXXXXXX XXXXXXXXXXXXXX Video Signal Video Signal : ----------- : ----------- Total Operation Time Total Operation Time : 0H : 0H Lamp Op. Time (C) Lamp Op. Time (C) : 0H/ 0H : 0H/ 0H...
  • Page 105 EMP-822/EMP-83/EMP-X5/EMP-S5 Error Log Window (Page 2) While the AS menu is displayed, the Error Log Window can be displayed by pressing the button. To go back to the AS menu, press the button. [Right] [Left] CD TOT (h CD TOT (h:m:s) LOT (h:m:s) POT (h:m:s) ST...

  • Page 106: Initializing (Resetting) The As Menu Values

    EMP-822/EMP-83/EMP-X5/EMP-S5 Item Contents Representation Internal overheat Fan error Thermistor error Lamp burnt out Lighting failure Internal error (RAM) Internal error (ROM) 2-digit number (00-99) Internal error (I2S) Error Count Over 99: “99” (times) Internal error (DR) (Not cleared to “0.”)

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