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DATA PROJECTOR

VPL-ES4
VPL-EX4
REMOTE COMMANDER

RM-PJ4

SERVICE MANUAL
1st Edition

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

! WARNUNG
Die Anleitung ist nur fr qualifiziertes Fachpersonal bestimmt.
Alle Wartungsarbeiten drfen nur von qualifiziertem Fachpersonal ausgefhrt werden. Um die
Gefahr eines elektrischen Schlages, Feuergefahr und Verletzungen zu vermeiden, sind bei
Wartungsarbeiten strikt die Angaben in der Anleitung zu befolgen. Andere als die angegeben
Wartungsarbeiten drfen nur von Personen ausgefhrt werden, die eine spezielle Befhigung
dazu besitzen.

! AVERTISSEMENT
Ce manual est destin uniquement aux personnes comptentes en charge de lentretien. Afin
de rduire les risques de dcharge lectrique, dincendie ou de blessure neffectuer que les
rparations indiques dans le mode demploi moins dtre qualifi pour en effectuer dautres.
Pour toute rparation faire appel une personne comptente uniquement.

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

VPL-ES4/EX4

Table of Contents
1. Service Information

4. Spare Parts

1-1.

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

4-1.

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

1-2.

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

4-2.

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

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


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

4-3.

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

4-4.

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

1-3-2.

Front Case Assembly and


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

1-3-3.
1-3-4.

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


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

1-3-5.
1-3-6.

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


Lamp Power Supply .............................................. 1-5

1-3-7.
1-3-8.

Power Board .......................................................... 1-5


Optics Section ....................................................... 1-6

1-3-9.
1-3-10.

Detection Switch Board ........................................ 1-7


DC Fan .................................................................. 1-7

1-4.

5. Block Diagram
Overall ............................................................................ 5-1

6. Diagram
6-1.

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

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

2. Electrical Adjustments
2-1.

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

2-2.

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

3. Troubleshooting
3-1.

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

3-2.

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

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

VPL-ES4/EX4

No Power ............................................................... 3-3


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

Section 1
Service Information
1-1. Appearance Figure

1-2. Board Locations

Main
Thermal sensor

Lamp power supply

Detection switch

IR sensor
Power

VPL-ES4/EX4

1-1

1-3. Disassembly
1-3-1.

Upper Case Assembly


2 Four claws

4 Upper case assembly

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

1 Five screws (M 3 x 6)

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


Remove the upper case assembly before starting the removal work.
!= Sub rear case assembly
5 Screw
(M 3)
6 Six hexagon
screws

4 Two screws
(M 3 x 6)

9 Remove the upper case assembly from this corner with the
strong force to the extent that the upper case assembly will
not be damaged.
![ Front case assembly
2 Main board
connector (J6)

0 Two claws
1 Lens cap

7 Two screws
(+K 3 x 12)

Sub rear case


assembly
!- Speaker harnesses

1-2

3 IR sensor board
connector (J1)
Sub rear case
assembly

VPL-ES4 VPL-EX4

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

Front case assembly

VPL-ES4/EX4

1-3-3. Main Board


Remove the front case assembly and sub rear case assembly before starting the removal work.
1 five screws
(M 3 x 6)

Main board bracket section

2 Remove the main


shield in the direction
of the arrow.

Main shield

Because the harnesses has the shape of flat


cross-section, do not insert the harnesses with
excessive force. Find out the direction in
which the harnesses can be inserted easily,
and then insert the harnesses.
Note:
The fan harness has been secured by the
main board bracket with a fixing screw.
(See section 1-3-5. mein bracket)

Harnesses
J17
J16

3 Main board
Harnesses clamp section

Lamp box assembly


J22

J14 J20

J19 J21 J22

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

J25
Main board
J24
Radiation sheet
J18

J23
J6

Main board

VPL-ES4/EX4

1-3

1-3-4. Tunnel Outlet Section


Remove the front case assembly and sub rear case assembly before starting the removal work.
1 Two tapping screws
(PAN 3 x 7)

Lamp box
assembly

J21

J21
Main board
Main board
Because the harnesses has the shape of flat
cross-section, do not insert the harnesses with
excessive force. Find out the direction in
which the harnesses can be inserted easily,
and then insert the harnesses.

2 Tunnel outlet section

Harnesses

Harnesses clamp section

1-3-5. Main Board Bracket Section


Remove the main board before starting the removal work.
2 Three tapping screws
(PAN 3 x 7)

1 Two screws
(M 3 x 6)

Power board

4 Main board bracket section

3 Screw
(M 4 x 6)

1-4

VPL-ES4/EX4

1-3-6. Lamp Power Supply


Remove the main board bracket section before starting the removal work.
9 Lamp power supply
To the main board J16
5 Screw
(+PWH 3 x 8)
B

6 Remove the lamp power supply


connector in the direction of the
arrow A.
A

8 Connector (P1)
7 Remove the lamp power supply in the
direction of the arrow B.

From the Main board CN602


(Red and Black wires)

4 Lamp
1 loosen screw.

3 Loosen two screws.

2 Lamp door

1-3-7. Power Board


Remove the main board bracket section before starting the removal work.
1 Two stand assemblies

CN701

CN603

Power board

CN701

CN603

Lamp power supply (P1)

2 Remove the power board in


the direction of the arrow.

VPL-ES4/EX4

1-5

1-3-8. Optics Section


Remove the lamp power supply and power board before starting the removal work.
1 Two tapping screws
(PAN 3 x 7)

7 Dowel
2 Two claws
A
4 Gasket
6 Two tapping screws
(PAN 3 x 7)

3 Remove the lamp box assembly in the


9 Four screws direction of the arrow A.
(+P 2.5 x 8)

0 Optucs section

5 Harness

8 Focus/Zoom adjust
assembly

Assembling Method of Optucs section and


Focus/Zoom Adjust Assembly
Phase matching

!- Rotate the Zoom dial clockwise


as shown until it is stopped.

During the assembling process,


never change the gear position
that is set by step ![.

!\ Install the Optucs section


in the Lower Case.

!= Rotate the Focus dial


counter-clockwise as
shown until it is stopped.

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

![ Rotate the Focus dial


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

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

1-6

VPL-ES4/EX4

1-3-9. Detection Switch Board


Remove the optics section before starting the removal work.
3 Two tapping screws
(PAN 3 x 7)
5 Tapping screw
(PAN 3 x 7)
6 Detection switch board

4 Duct lamp

1 Tapping screw
(PAN 3 x 7)

CN1

CN1
2 Detection switch board

1-3-10. DC Fan
Remove the optics section before starting the removal work.

1 Two tapping screws


(PAN 3 x 7)

2 Duct LCD assembly

6 Two tapping screws


(M 3 x 25)
3 Two tapping screws
(PAN 3 x 10)
5 harness
4 DC fan
7 DC fan

VPL-ES4/EX4

1-7

1-4. Warning on Power Connection


Use a proper power cord for your local power supply.
The United States,
Canada

Continental
Europe

UK, Ireland,
Australia, New Zealand

Plug type

VM0233

290B

YP-12A

COX-07

_1)

YP332

Connector type

VM0089

386A

YC-13B

COX-02

VM0310B

YC-13

Cord type

SJT

SJT

H05VV-F

H05VV-F

N13237/CO-228

VCTF

Rated Voltage/Current

10A/125V

10A/125V

10A/250V

10A/250V 10A/250V

7A/125V

Safety approval

UL/CSA

UL/CSA

VDE

VDE

DENAN

Cord length (max.)

4.5m (14 feet 9 inches)

VDE

Japan

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

1-8

VPL-ES4/EX4

VPL-ES4/EX4

0
Off
Blue
Standard
Off
Off
Enter x 4

V Keystone
Image Flip
Background
INSTALL
Lamp Mode
SETTING
High Altitude Mode
Security Lock
Key

All information is
display only

S VIDEO

Picture Memory
INPUT A (Component/VideoGBR)

OFF

Low

High

OFF

80
50
50
50
30
Film

90
60
50
50
60
Film

OFF

Mid

85
55
50
50
50
Film

OFF

High

90
60
68
50
50
Film

OFF

Low

90
50
60
50
50
Film

ON

Low

75
50
58
50
30
Film

OFF

High

85
55
50
50
50
Film

OFF

High

90
60
50
50
60
Film

OFF

Mid

75
55
50
50
40
Film

OFF

Low

80
50
50
50
30
Film

OFF

High

90
60
68
50
40
Film

OFF

Low

90
50
60
50
40
Film

ON

Low

75
50
58
50
30
Film

OFF

High

75
55
50
50
40
Film

OFF
OFF

Low

30
Film

60
Film
High

80
50
50

90
60
50

OFF

Mid

40
Film

85
55
50

OFF

High

40
Film

90
60
68

n
There are some adjustment items that cannot be adjusted, depending on the input signal.

OFF

Low

40
Film

90
50
60

ON

Low

30
Film

75
50
58

OFF

High

40
Film

85
55
50
85
55
80
50

Standard

90
60

Game

90
50

Living

60
50

Cinema

85
55

Presentation

ON

ON

ON

ON

ON

ON

ON

Graphics Graphics Graphics Graphics Graphics Graphics Graphics


Mid
High
Low
High
Low
High
High

90
60

Natural

INPUT A (Computer), INPUT B (Computer)

PresenPresenPresenDynamic Standard Natural Game Living Cinema tation Dynamic Natural Standard Game Living Cinema tation Dynamic Standard Natural Game Living Cinema tation Dynamic

VIDEO

MemoryName

* The Picture Mode items in the PICTURE SETTING menu have their respective initial values for each input signal (PRESET MEMORY No.).

INFORMATION

On
English
Center
On

Panel Key Lock

IR Receiver

Status
MENU Language
SETTING Menu Position
Start Up Image

31

30

On
Off
Auto
Auto
Off
Front &
Rear
Off

Dot Phase
H Size
Shift
Wild Mode
Scan Conv

Adjust Signal

Volume

Contrast
Bright
Color
Hue
Sharp ness
DDE
Gamma Mode
Color Temp

Picture Mode
Adjust Picture

ItemName

Set
Memory

Smart APA
Auto Input Search
Input-A Signal Sel.
SET
Color System
SETTING Power Saving Mode

INPUT
SETTING

PICTURE
SETTING

Menu
Title

2-1. Initial Values of Adjustment Items

Section 2
Electrical Adjustments

2-1

Page

P1-1
CXD9809-page1

Item Name
TGHST Phase Hi
TGHST Phase Lo
SHSH1
TGHST Position
DEHPF On
DEHPF AAC
DEHPF TAP
DEUSC On
3D GammaSubCont
3D GammaSubBrt
DELUT SW
DEUF SW

Set
0
109
38
12
ON
ON
3
OFF
0
150
OFF
ON

P1-2
CXD9809-page2

PC Hi Gain-R
PC Hi Gain-G
PC Hi Gain-B
PC Hi Bias-R
PC Hi Bias-G
PC Hi Bias-B
PC Lo Gain-R
PC Lo Gain-G
PC Lo Gain-B
PC Lo Bias-R
PC Lo Bias-G
PC Lo Bias-B

128
128
128
0
0
0
128
70
100
0
0
0

P1-3
CXD9809-page3

Video Hi Gain-R
Video Hi Gain-G
Video Hi Gain-B
PC Mid Bias-R
Video Hi Bias-G
Video Hi Bias-B
Video Lo Gain-R
Video Lo Gain-G
Video Lo Gain-B
Video Lo Bias-R
Video Lo Bias-G
Video Lo Bias-B

128
128
128
0
0
0
128
70
100
0
0
0

2-2

Color
G

VPL-ES4/EX4

Page

P1-4
CXD9809-page4

P2
Fan Control

P3-1
CXA7005-page1

VPL-ES4/EX4

Item Name
PC Mid Gain-R
PC Mid Gain-G
PC Mid Gain-B
PC Mid Bias-R
PC Mid Bias-G
PC Mid Bias-B
Video Mid Gain-R
Video Mid Gain-G
Video Mid Gain-B
Video Mid Bias-R
Video Mid Bias-G
Video Mid Bias-B
Temperature 1
Temperature 2
Temperature 3
FanSpeed 1
FanSpeed 2
FanSpeed 3
FanSpeed 4
ManualFanSpeed
Burn-In Cycle
Burn-In Cycle On min
Burn-In Cycle Off min
Burn-In Hour
Burn-In active
Gain-R
Gain-G
Gain-B
SigCen-R
SigCen-G
SigCen-B
SidA-R
SidA-G
SidA-B
SidB-R
SidB-G
SidB-B

Set
128
90
115
0
0
0
128
75
105
0
0
0

Color
G

Display only
Display only
N/A
Display only
Display only
Display only
Display only
OFF
0
210
30
50
OFF
188
188
188
35
35
35
22
22
22
85
85
85

2-3

Page

P3-2
CXA7005-page2

P4
ADC Calibration

P5

P6
Error Count

2-4

Item Name
Bias-R Normal
Bias-G Normal
Bias-B Normal
Bias-R Flip
Bias-G Flip
Bias-B Flip
Vcom-R Normal
Vcom-G Normal
Vcom-B Normal
Vcom-R Flip
Vcom-G Flip
Vcom-B Flip
RGB Calibrate
YUV Calibrate
RGB Offset
RGB Gain
YUV Offset
YUV Gain
R Offset
G Offset
B Offset
R Gain
G Gain
B Gain
Power Saving Time
System Protect
Data Reset
Hard Reset
ROM Version
Lamp Timer
Operation Timer
Prev. Lamp Timer
SOG Threshold

Set
122
122
122
122
122
122
88
88
88
88
88
88

164
93
164
93

Color
G

222
105
222
105

164
93
164
93

164
222
164
93
105
93
10
ON

Display only
Display only
Display only
Display only
N/A

All value is display only

VPL-ES4/EX4

2-2. Memory Structure


Set memory

status
memory

Set memory
No.01
No.02
No.03
No.04
No.05

S-Video

Picture
memory

Input-A

Input-B

Component

Computer
W/B
memory

Other than
Computer

Channel
Memory

Input-A
Input-B
Input-A
Component
Input-A
Video-GBR
Video
S-Video

Common
Memory

Wide Mode
(other than computer)
Scan Converter
(Computer only)
Smart APA
(Computer only)
Volume
Auto Input Search
Input-A Signal Sel.
Color System
(Video/S-Video Only)
Speaker
Power Saving
IR Receiver
Panel Key Lock
Status
Language
Menu Position
Image Flip
Background
Lamp Mode
High Altitude
Security Lock
FLASH ROM

VPL-ES4/EX4

No.01
No.02
No.03
No.04
No.05

Video/Svideo

status
memory

No.50
No.55
No.56
No.101
No.102

Video

Set memory

Dynamic
Standard
Natural
Game
Living
Cinema
Presentation
Dynamic
Standard
Natural
Game
Living
Cinema
Presentation
Dynamic
Standard
Natural
Game
Living
Cinema
Presentation
Dynamic
Standard
Natural
Game
Living
Cinema
Presentation
Dynamic
Standard
Natural
Game
Living
Cinema
Presentation
High
Mid
Low
High
Mid
Low

Input-A/Input-B
/Component

Video

S-Video

picture
memory

Input-A

Input-B

Component

Computer
W/B memory
Other than
Computer

Channel
Memory

Input-A
Input-B
Input-A
Component
Input-A
Video-GBR
Video
S-Video

Common
Memory

Wide Mode
(other than computer)
Scan Converter
(Computer only)
Smart APA
(Computer only)
Volume
Auto Input Search
Input-A Signal Sel.
Color System
(Video/S-Video Only)
Speaker
Power Saving
IR Receiver
Panel Key Lock
Status
Language
Menu Position
Image Flip
Background
Lamp Mode
High Altitude
Security Lock
EEPROM

Status memory

No.50
No.55
No.56
No.101
No.102
Dynamic
Standard
Natural
Game
Living
Cinema
Presentation
Dynamic
Standard
Natural
Game
Living
Cinema
Presentation
Dynamic
Standard
Natural
Game
Living
Cinema
Presentation
Dynamic
Standard
Natural
Game
Living
Cinema
Presentation
Dynamic
Standard
Natural
Game
Living
Cinema
Presentation

Picture memory

High
Mid
Low
High
Mid
Low

W/B memory

Channel Memory

Common Memory

CPU RAM

2-5

Memory structure of this model consists of the followings.


1 Set memory
2 Status memory
3 Picture memory
4 Chroma memory
5 W/B memory
6 Channel memory
* The gamma memory is realized by giving offset to the Contrast and Brightness output values to the
devices in the gamma mode function.
Flow of data is described briefly. When the power plug is connected to the wall outlet for the first time
(Standby state), all data that are stored in the internal ROM are written in the NVM (non-volatile memory). When the POWER is turned ON, all the status memory data and other memory data that are required
for the present picture are selected from each memory block and expanded in the internal RAM.
When any adjustment is performed at this moment, the adjustment data (user mode items) are written in
the NVM (Service/Special Service) automatically triggered by the memory operation.
The adjustment items (W/B, Device Adjust) that can be adjusted in the Service Mode or in the Special
Service Mode, are memorized in the NVM at the time when the user performs adjustment and performs
the memory operation. Note that the factory adjustment data will be lost at this moment.

2-6

VPL-ES4/EX4

Section 3
Troubleshooting
3-1. Electric Troubleshooting

Connect the Power

System Standby?

No

1. Check the LED Message and find error.


2. Check lamp door, dust door.
3. Check the power board out voltage 5V.
4. Change main board.

Yes

Power projector
Lamp ON ?

No

1. check the Ballast power and control


signal wire.
2. Check lamp door status.
3. Check lamp status.

Yes

System shut-down
And cooling

Yes
1. Check the LED message and find error.
2. Check the Fan status or Thermal sensor
status.
3. Check the lamp door or dust door.

No

Yes
1. The picture is full-white pattern; please
check the LCD panel connector.
2. The picture is full-black pattern; please
check the LCD driver on the main board.
3. Check the system status: Is system in
burn-in mode?

No Picture ?

No

Picture quality
No good ?

No

Yes

1. The picture a little green, blue, red,


please check the LCD panel connector.
2. The picture has dust, please check the
lens.
3. The picture flicker, please alignment
again.

VPL-ES4/EX4

3-1

OSD flicker ?

Yes

Please alignment V-com again.

No

Color temp wrong ?

Yes

Please alignment color temperature again.

No

Picture has
Vertical bar ?

Yes

Check the vertical bar color and find the


LCD panel connector. Then check the pin
of connector.

Yes

1. Please check the OSD setting


2. Check the front IR board.

No

IR remote control
No good ?

No

Audio function is
No good ?

3-2

Yes

1. Check the OSD setting.


2. Check the speak wire.

VPL-ES4/EX4

3-2. Power Board Troubleshooting


3-2-1.

No Power

No Power

F601
Open?

No

Check if CN701 inserted


properly.

Yes

Replace Q601 and F601


with new ones, and then
put power board into set.
If Q601 damages again,
check if other parts are
shorted.

Yes

Check if miss to solder


any SMD type of
components.

Q601(D-S)
Short ?

No

Check if 15.25V or 12V


exist. If any voltage is
wrong, replace IC701 or
T602 with new ones.

Yes

Output
5V DC
exists ?

No

Voltage
outputs shut
down and built
repeatly ?

Yes

Check if D602 or IC602 is


broken.
if yes,replace it with now
one.

No

Check LED circuit of


main board.

VPL-ES4/EX4

Check CN701 and find


out if some points are
shorted to gound.

3-3

3-2-2.

Failure of Turn on Lamp

Failure of turn on ballast.

Check if the input


voltage of ballast is
380V DC

Yes

No

Lamp
Broken ?

Yes

Replace lamp with new


one.

No

Check main board.

No

Control
Pin (SCI) is
normal ?
Yes

Replace ballast with new


one.

3-4

VPL-ES4/EX4

No

Check mian board.

Check if there
is PFC_On/Off
signal.
Yes

Check if 18V
exists at c-terminal
of Q603.

No

Check Q701 IC604,


Q604, Q603 or ZD603.
And then replace broken
parts.

Yes

F602 Open ?

Yes

Replace F602 with new


one.

No

Yes

Q602 works
normally ?

No

Check ZD602, R655 and


R656.

VPL-ES4/EX4

3-5

Section 4
Spare Parts
4-1. Notes on Repair Parts
1. Safety Related Components Warning
w
Components marked ! are critical to safe operation.
Therefore, specified parts should be used in the case of
replacement.
[WARNHINWEIS]
Les composants identifis par la marque ! sont
critiques pour la scurit.
Ne les remplacer que par une pice portant le numro
spcifi.
2. Standardization of Parts
Some repair parts supplied by Sony differ from those
used for the unit. These are because of parts commonality and improvement.
Parts List has the present standardized repair parts.
3. Stock of Parts
Parts marked with o at SP (Supply Code) column of
the Spare Parts list may not be stocked. Therefore, the
delivery date will be delayed.
Items with no part number and no description are not
stocked because they are seldom required for routine
service.
4. Units for Capacitors, Inductors and Resistors
The following units are assumed in Schematic Diagrams, Electrical Parts List and Exploded Views
unless otherwise specified.
Capacitors
: F
Inductors
: H
Resistors
:

VPL-ES4/EX4

4-1

Overall
4-2. Exploded Views

36
38

38

10
41
38
38
32

+PSW 4x8

25
9

+PWH
3x8

12

42

+PSW 3x25

20

38
6

32

32

30
3

32

2
13

+P 2.5x8

32
14

32

32

38

33

37

29

4
39

28

30
24
7
+K 3x12

26

+K 3x12

27

VPL-ES4

34

22

VPL-EX4

38

+BVTP 3x6

38

21

35
11
15

17
16

4-2

VPL-ES4/EX4

Overall
No.

Part No.

1
2
3
4
6

!
!
!

7
8
9
10
10

!
!
!

SP Description

1-576-973-11
1-576-233-51
1-576-974-11
1-789-603-11
9-885-114-11

s
s
s
s
s

FUSE, CYLINDERICAL (F602)


FUSE (H.B.C.) (F601)
THERMOSTAT
DOOR DETECTION SWITCH BOARD
FAN, DC (AXIAL FAN UNIT)

9-885-114-12
1-787-496-11
1-787-496-21
9-885-114-05
9-885-114-07

s
s
s
s
s

FAN, DC
FAN, DC
FAN, DC
MOUNTED
MOUNTED

11
12
13
14
15

1-789-543-11
1-789-544-11
9-885-114-04
9-885-114-06
9-885-113-91

s
s
s
s
s

MOUNTED CIRCUIT BOARD, IR SENSOR


MOUNTED CIRCUIT BOARD, THERMAL SENSOR
MOUNTED CIRCUIT BOARD, POWER
SPEAKER
LAMP DOOR

16
17
20
21
22

9-885-113-92
2-670-067-01
2-675-465-01
9-885-113-93
9-885-113-94

s
s
s
s
s

DOOR, FILTER
MESH FILTER
ASSY, LAMP BOX
ASSY,FOOT ADJUST RUBBER
FOOT, ADJUST

24
24
25
26
27

9-885-113-95
9-885-114-08
9-885-114-34
9-885-113-96
9-885-114-00

s
s
s
s
s

LENS CAP (VPL-ES4)


LENS CAP (VPL-EX4)
MYLAR BALLAST
LOWER CASE
ASSY, SUB REAR CASE (VPL-ES4)

27
28
28
29
29

9-885-114-33
9-885-113-97
9-885-114-09
9-885-113-98
9-885-114-10

s
s
s
s
s

ASSY,
ASSY,
ASSY,
ASSY,
ASSY,

30
32
33
34
35

2-681-547-02
2-681-550-01
2-681-552-02
2-681-553-01
9-885-114-32

s
s
s
s
s

SCREW,
SCREW,
SCREW,
SCREW,
RUBBER

36
36
37
38
39

9-885-113-90
9-885-113-99
4-672-839-11
3-918-696-11
2-580-621-01

s
s
s
s
s

ASSY, UPPER CASE (WHITE COLOR)


ASSY, UPPER CASE (BLOCK COLOR) (VPL-ES4)
HEAD, M3 FLAT
SCREW (M3X6 LOCK ACE)
SCREW, +PWH 3X10

41
42

(DC)
(DC)
CIRCUIT BOARD, MAIN (VPL-ES4)
CIRCUIT BOARD, MAIN (VPL-EX4)

SUB REAR CASE (VPL-EX4)


FRONT CASE (VPL-ES4)
FRONT CASE (VPL-EX4)
FOCUS/ZOOM ADJUST (VPL-ES4)
FOCUS/ZOOM ADJUST (VPL-EX4)
TAP PH W/FL M3*27L
TAP PAN M3*7L
EX-HE 4#-40X4+6 STLESS
TAP PAN M2*6L
PAD,ADJUST FOOT

9-885-114-02 s SWITCH,TACT
1-474-023-11 s POWER SUPPLY BLOCK (BALLAST)
7-682-903-21
7-682-954-01
7-685-645-91
7-621-262-40
7-682-250-09

s
s
s
s
s

SCREW, +PWH 3X8


SCREW, +PSW 3X25
SCREW +BVTP 3X6
SCREW, +P 2.5X8
SCREW, +K 3X12

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

VPL-ES4/EX4

4-3

4-3. Electrical Parts List


Ref. No.
or Qty Part No.
1pc
1pc

!
!

SP Description

1-576-233-51 s FUSE (H.B.C) (F601)


1-576-973-11 s FUSE, CYLINDERICAL (F602)

4-4. Packing Materials & Supplied


Accessories
-------------------SUPPLIED ACCESSORIES
-------------------Ref. No.
or Qty Part No.
SP Description
1pc
1pc
1pc
1pc
1pc

1pc

4-4

1-479-775-12
1-832-428-11
2-679-319-01
3-210-513-02
3-100-207-01

s
s
s
s
s

REMOTE COMMANDER (RM-PJ4)


CABLE, VGA
BAG,CARRY
CD MANUAL
GUIDE QS MANUAL
(JAPANESE, ENGLISH, FRENCH,
SPANISH, GERMAN, ITALIAN,
SIMPLIFIED CHINESE)

------------ s CORD SET, POWER


(See 1-4. Warning on Power Connection)

VPL-ES4/EX4

Overall

Overall

Section 5
Block Diagram
IR Receiver

IRR5

IRR

IRF5

IRF

IR Receiver

CLK_R

LUMA

S-Video

CHROMA
SDA

EEPROM
Video

SCL

CVBS
WP
PC-RIN1
PC-GIN1
PC-BIN1

INPUT B

INPUT A

Analog RGB
Input/Output

HSYNC2
VSYNC2

Video
Processor
&
Controller

PC-RIN
PC-GIN
PC-BIN

DG[9:0]

Audio A/B

Audio

R
LCD
Drver

RSIG[6:1]

SEN
SCLK
SDATA

RGT
HST
ENB
VCK
VST
DWN
PCG

DCK1_G
DCK1x_G
DCK2_G
DCK2x_G
HCK_G
HCKx_G

CLK_G
DCK1_R
DCK2_R
DCK1_G
DCK2_G
DCK1_B
DCK2_B

DCK[6:1]

DCLK
DHS
DVS

PRG
FRP
VD

G
LCD
Driver

GSIG[6:1]

RGTx
HST
ENB
VCK
VST
DWN
PCG

DCK1x_R
DCK2x_R
DCK1x_G
DCK2x_G
DCK1x_B
DCK2x_B

Audio
Input/Output
&
volume
control

AUDIO_SW

LCDB[11:0]

AUDIO_MUT

CLK_B

27 MHz

AUDIO_VOL1

PRG
FRP
VD

AUDIO_VOL2

AUDIO_O
AUDIO_O_

SENi
SCLKi
SDATAi

B
LCD
Driver

DCK1_B
DCK1x_B
DCK2_B
DCK2x_B
HCK_B
HCKx_B
BSIG[6:1]

LED[4:1]

RGT
HST
ENB
VCK
VST
DWN
PCG

RS232
Driver
Receiver

FG1

Fan 2
Fan 3
Fan 4

Fan4
FG4

Fan 1

Fan5
FG5

Keypad
Input
I2C_SW
FAN_SW
SDA
SCL

Fan2
FG2
Fan3
FG3

RXD
P5VC

P15VP
P12V
P5V

P15VP
P12V
P5V

P15V

Power
Control

P5VC

P135V

+3.3V
REG

P15V

P1P8V

+1.8V
REG

P5V

P2P5V

+2.5V
REG

P3P3V

+3.3V
REG

P33V

+3.3V
REG

P15VP
P2P5V
P5V

POWER_ON

Fan Control

Dust_SW

EEPROM

Dust SW
Door SW

Door_SW

LampLIT
LampEN
Eco_mode

Thermal Thermal
Sensor 1 Sensor 2

A[0:21]

D[0:15]

32.768 KHz

VPL-ES4/EX4

Power
Fail DET

PWR_fail

+3.3V
REG

V33

Ballast

Power
Switch

ROMOEn

RX.DL

LED
Driver

TXD

ROMWEn

TX.DL

B
LCD

BVCOM
BPSIG

SEN
SCLK
SDATA

Speaker
RS-232
Remote
Control

G
LCD

GVCOM
GPSIG

SEN
SCLK
SDATA

LCD_SCL
LCD_SDA

R
LCD

RVCOM
RPSIG

LCDG[11:0]

AUDIO_S

AUDIO_M

PRG
FRP
VD

RGT
RGTx
ENB
HST
VST
VCK
PCG
DWN
HCK_R
HCK_G
HCK_B
HCKx_R
HCKx_G
HCKx_B

HSYNC
VSYNC

HSYNCO
VSYNCO

AUDIO_O+

Audio out

PRG
FRP
VD
LCDRGT
LCDRGTx
LCDENB
LCDHST
LCDVST
LCDVCK
LCDPCG
LCDDWN
HCK
HCK
HCK
HCKx
HCKx
HCKx

DB[9:0]

R_OUT
G_OUT
B_OUT

Monitor
Output

LCD
Timing
Generator

DR[9:0]

HSYNC1
VSYNC1
PC-RIN2
PC-GIN2
PC-BIN2

DCK1_R
DCK1x_R
DCK2_R
DCK2x_R
HCK_R
HCKx_R

LCDR[11:0]

Reset
IC

Flash
memory
Reset
IC

5-1

5-1

P5V

+1.8V
REG

Frame

Frame

Section 6
Diagram
J6

J1
IR
SENSOR
BOARD

6-1. Frame Schematic Diagram


J5

MAIN
BOARD

CN1
DETECTION
SWITCH
BOARD
(RIGHT)

S VIDEO

INPUT

J14
J4
VIDEO

INPUT

CN1
DETECTION
SWITCH
BOARD
(LEFT)

J9
AUDIO

INPUT

2
J18
J8

THERMAL
SENSOR
BOARD

AUDIO A/B

INPUT

J1

J2
J23
INPUT

INPUT A
LCD R

J1
INPUT

J24
LCD G

INPUT B

J25
J3

LCD B

MONITOR

OUTPUT

J21

FAN2

J10
OUTPUT

FAN2
J19

AUDIO

FAN3
(REAR BOTTOM)

J20
J7
REMOTE

FAN4
(REAR TOP)

RS-232C

J22
FAN1(FRONT BOTTOM)

J11

J16

SPEAKER

HALOGEN
LAMP

BALLAST UNIT

J17

CN602

CN701

CN601

POWER BOARD

6-1

VPL-ES4/EX4

6-1
E

SAFETY CHECK-OUT
After correcting the original service problem,
perform the following safety checks before
releasing the set to the customer :
Check the metal trim, metallized knobs,
screws, and all other exposed metal parts for AC
leakage. Check leakage as described below.
LEAKAGE TEST
The AC leakage from any exposed metal part to
earth ground and from all exposed metal parts to
any exposed metal part having a return to
chassis, must not exceed 3.5 mA. Leakage
current can be measured by any one of three
methods.
1. A commercial leakage tester, such as the
Simpson 229 or RCA WT-540A. Follow the
manufacturers instructions to use these
instruments.
2. A battery-operated AC milliammeter. The
Data Precision 245 digital multimeter is
suitable for this job.
3. Measuring the voltage drop across a resistor
by means of a VOM or battery-operated AC
voltmeter. The limit indication is 5.25 V, so
analog meters must have an accurate lowvoltage scale. The Simpson 250 and Sanwa
SH-63Trd are examples of a passive VOM
that is suitable. Nearly all battery operated
digital multimeters that have a 20 V AC range
are suitable. (See Fig. A)

To Exposed Metal
Parts on Set

0.15 F

1.5 kZ

AC
voltmeter
(5.25V)

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

VPL-ES4/EX4

VPL-ES4 (SY)
VPL-EX4 (SY) E
9-883-627-01

Sony EMCS Corporation


Ichinomiya Tec

English
2007DR16-1
2007