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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 für qualifiziertes Fachpersonal bestimmt.
Alle Wartungsarbeiten dürfen nur von qualifiziertem Fachpersonal ausgeführt 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 dürfen nur von Personen ausgeführt werden, die eine spezielle Befähigung
dazu besitzen.

! AVERTISSEMENT
Ce manual est destiné uniquement aux personnes compétentes en charge de l’entretien. Afin
de réduire les risques de décharge électrique, d’incendie ou de blessure n’effectuer que les
réparations indiquées dans le mode d’emploi à moins d’être qualifié pour en effectuer d’autres.
Pour toute réparation faire appel à une personne compétente 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 4-3. Electrical Parts List ......................................................... 4-4
1-3-1. Upper Case Assembly ........................................... 1-2 4-4. Packing Materials & Supplied Accessories .................... 4-4
1-3-2. Front Case Assembly and
Sub Rear Case Assembly ...................................... 1-2
1-3-3. Main Board ............................................................ 1-3 5. Block Diagram
1-3-4. Tunnel Outlet Section ............................................ 1-4
1-3-5. Main Board Bracket Section ................................. 1-4 Overall ............................................................................ 5-1
1-3-6. Lamp Power Supply .............................................. 1-5
1-3-7. Power Board .......................................................... 1-5
1-3-8. Optics Section ....................................................... 1-6 6. Diagram
1-3-9. Detection Switch Board ........................................ 1-7
1-3-10. DC Fan .................................................................. 1-7
6-1. Frame Schematic Diagram ............................................. 6-1
1-4. 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. No Power ............................................................... 3-3
3-2-2. Failure of Turn on Lamp ....................................... 3-4

VPL-ES4/EX4 1
Section 1
Service Information

1-1. Appearance Figure

1-2. Board Locations

Main

Thermal sensor Detection switch Lamp power supply

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


9 Remove the upper case assembly from this corner with the
5 Screw 4 Two screws strong force to the extent that the upper case assembly will
(M 3) (M 3 x 6) not be damaged.
6 Six hexagon
screws ![ Front case assembly

2 Main board 0 Two claws


connector (J6)
1 Lens cap

7 Two screws
(+K 3 x 12)
3 IR sensor board VPL-ES4 VPL-EX4
connector (J1)

Sub rear case 8 Remove the upper case assembly from this corner with the
Sub rear case assembly strong force to the extent that the upper case assembly will
assembly not be damaged.
!- Speaker harnesses Front case assembly

1-2 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 Main shield


shield in the direction
of the arrow.

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 Harnesses
main board bracket with a fixing screw. J17
(See section 1-3-5. mein bracket) J16

3 Main board

Harnesses clamp section

Lamp box assembly


J22

When re-assembling,
give an appropriate
amount of extra slack
J14 J20 J19 J21 J22
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 2 Tunnel outlet section
excessive force. Find out the direction in
which the harnesses can be inserted easily,
and then insert the harnesses.
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)

6 Remove the lamp power supply B


connector in the direction of the
arrow A. 8 Connector (P1)
A

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

Power board CN701


CN701 CN603

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
3 Remove the lamp box assembly in the
4 Gasket 9 Four screws direction of the arrow A.
(+P 2.5 x 8)
6 Two tapping screws
(PAN 3 x 7)

5 Harness 0 Optucs section

8 Focus/Zoom adjust
assembly

Assembling Method of Optucs section and


Focus/Zoom Adjust Assembly

Phase matching !- Rotate the Zoom dial clockwise During the assembling process,
as shown until it is stopped. never change the gear position !\ Install the Optucs section
that is set by step ![. 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 Lower case


counter-clockwise as
shown until it is stopped. !' After installation is completed, verify that the Optucs
section can rotate from the position A to the position
B smoothly.
!] Rotate the Focus/Zoom Adjust Assembly
counter-clockwise until it is stopped.
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)

4 Duct lamp 6 Detection switch board

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, Continental UK, Ireland, Japan


Canada Europe 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 VDE DENAN
Cord length (max.) 4.5m (14 feet 9 inches) _
(1) Use an appropriate rating plug which is applied to local regulations.

1-8 VPL-ES4/EX4
2-1. Initial Values of Adjustment Items
MemoryName

VPL-ES4/EX4
Set
Picture Memory
Menu Memory
ItemName
Title VIDEO S VIDEO INPUT A (Component/VideoGBR) INPUT A (Computer), INPUT B (Computer)
Presen- Presen- Presen- Presen-
Dynamic Standard Natural Game Living Cinema tation Dynamic Natural Standard Game Living Cinema tation Dynamic Standard Natural Game Living Cinema tation Dynamic Natural Standard Game Living Cinema tation
Picture Mode * * * *
Adjust Picture
Contrast 90 80 85 90 90 75 85 90 75 80 90 90 75 75 90 80 85 90 90 75 85 90 85 80 90 90 60 85
Bright 60 50 55 60 50 50 55 60 55 50 60 50 50 55 60 50 55 60 50 50 55 60 55 50 60 50 50 55
Color 50 50 50 68 60 58 50 50 50 50 68 60 58 50 50 50 50 68 60 58 50
PICTURE
Hue 50 50 50 50 50 50 50 50 50 50 50 50 50 50
SETTING
Sharp ness 60 30 50 50 50 30 50 60 40 30 40 40 30 40 60 30 40 40 40 30 40
DDE Film Film Film Film Film Film Film Film Film Film Film Film Film Film Film Film Film Film Film Film Film
Gamma Mode Graphics Graphics Graphics Graphics Graphics Graphics Graphics
Color Temp High Low Mid High Low Low High High Mid Low High Low Low High High Low Mid High Low Low High High Mid High High Low Low High
Volume 30

Adjust Signal
Dot Phase 31
INPUT H Size
SETTING Shift
Wild Mode OFF OFF OFF OFF OFF ON OFF OFF OFF OFF OFF OFF ON OFF OFF OFF OFF OFF OFF ON OFF
Scan Conv ON ON ON ON ON ON ON

Smart APA On
Auto Input Search Off
Input-A Signal Sel. Auto
SET Color System Auto
SETTING Power Saving Mode Off
Front &
IR Receiver
Rear
Panel Key Lock Off

Status On
MENU Language English
SETTING Menu Position Center
Start Up Image On

V Keystone 0
Section 2

Image Flip Off


Background Blue
INSTALL
Lamp Mode Standard
SETTING
High Altitude Mode Off
Security Lock Off
Key Enter x 4
Electrical Adjustments

INFOR- All information is


MATION display only

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

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

2-1
Color
Page Item Name Set R G B
TGHST Phase Hi 0
TGHST Phase Lo 109
SHSH1 38
TGHST Position 12
P1-1 DEHPF On ON
DEHPF AAC ON
CXD9809-page1
DEHPF TAP 3
DEUSC On OFF
3D GammaSubCont 0
3D GammaSubBrt 150
DELUT SW OFF
DEUF SW ON

PC Hi Gain-R 128
PC Hi Gain-G 128
PC Hi Gain-B 128
PC Hi Bias-R 0
PC Hi Bias-G 0
P1-2 PC Hi Bias-B 0
CXD9809-page2 PC Lo Gain-R 128
PC Lo Gain-G 70
PC Lo Gain-B 100
PC Lo Bias-R 0
PC Lo Bias-G 0
PC Lo Bias-B 0

Video Hi Gain-R 128


Video Hi Gain-G 128
Video Hi Gain-B 128
PC Mid Bias-R 0
Video Hi Bias-G 0
P1-3 Video Hi Bias-B 0
CXD9809-page3 Video Lo Gain-R 128
Video Lo Gain-G 70
Video Lo Gain-B 100
Video Lo Bias-R 0
Video Lo Bias-G 0
Video Lo Bias-B 0

2-2 VPL-ES4/EX4
Color
Page Item Name Set R G B
PC Mid Gain-R 128
PC Mid Gain-G 90
PC Mid Gain-B 115
PC Mid Bias-R 0
PC Mid Bias-G 0
P1-4 PC Mid Bias-B 0
CXD9809-page4 Video Mid Gain-R 128
Video Mid Gain-G 75
Video Mid Gain-B 105
Video Mid Bias-R 0
Video Mid Bias-G 0
Video Mid Bias-B 0

Temperature 1 Display only


Temperature 2 Display only
Temperature 3 N/A
FanSpeed 1 Display only
FanSpeed 2 Display only
FanSpeed 3 Display only
P2
FanSpeed 4 Display only
Fan Control
ManualFanSpeed OFF
Burn-In Cycle 0
Burn-In Cycle On min 210
Burn-In Cycle Off min 30
Burn-In Hour 50
Burn-In active OFF

Gain-R 188
Gain-G 188
Gain-B 188
SigCen-R 35
SigCen-G 35
P3-1 SigCen-B 35
CXA7005-page1 SidA-R 22
SidA-G 22
SidA-B 22
SidB-R 85
SidB-G 85
SidB-B 85

VPL-ES4/EX4 2-3
Color
Page Item Name Set R G B
Bias-R Normal 122
Bias-G Normal 122
Bias-B Normal 122
Bias-R Flip 122
Bias-G Flip 122
P3-2 Bias-B Flip 122
CXA7005-page2 Vcom-R Normal 88
Vcom-G Normal 88
Vcom-B Normal 88
Vcom-R Flip 88
Vcom-G Flip 88
Vcom-B Flip 88

RGB Calibrate
YUV Calibrate
RGB Offset 164 222 164
RGB Gain 93 105 93
YUV Offset 164 222 164
P4 YUV Gain 93 105 93
ADC Calibration R Offset 164
G Offset 222
B Offset 164
R Gain 93
G Gain 105
B Gain 93

Power Saving Time 10


System Protect ON
Data Reset
Hard Reset
ROM Version Display only
Lamp Timer Display only
P5
Operation Timer Display only
Prev. Lamp Timer Display only
SOG Threshold N/A

P6
All value is display only
Error Count

2-4 VPL-ES4/EX4
2-2. Memory Structure

Set memory Set memory Set memory

No.01 No.01 Status memory


Video/Svideo
No.02 No.02
No.03 No.03
No.04 No.04
No.05 No.05
status status
memory memory Input-A/Input-B
No.50 No.50
/Component
No.55 No.55
No.56 No.56
No.101 No.101
No.102 No.102

Dynamic Dynamic Picture memory


Standard Standard
Natural Natural
Video Game Video Game
Living Living
Cinema Cinema
Presentation Presentation
Dynamic Dynamic
Standard Standard
Natural Natural
S-Video Game S-Video Game
Living Living
Cinema Cinema
Presentation Presentation
Dynamic Dynamic
Standard Standard
Natural Natural
Picture picture
Input-A Game Input-A Game
memory memory
Living Living
Cinema Cinema
Presentation Presentation
Dynamic Dynamic
Standard Standard
Natural Natural
Input-B Game Input-B Game
Living Living
Cinema Cinema
Presentation Presentation
Dynamic Dynamic
Standard Standard
Natural Natural
Component Game Component Game
Living Living
Cinema Cinema
Presentation Presentation

High High W/B memory


Computer Mid Computer Mid
W/B Low Low
W/B memory
memory High High
Other than Other than
Mid Mid
Computer Computer
Low Low

Input-A Input-A Channel Memory


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

Wide Mode Wide Mode


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

FLASH ROM EEPROM CPU RAM

VPL-ES4/EX4 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 memo-
ry). 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

No
System Standby? 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 No
1. check the Ballast power and control
Lamp ON ?
signal wire.
2. Check lamp door status.
3. Check lamp status.
Yes

Yes
System shut-down 1. Check the LED message and find error.
And cooling 2. Check the Fan status or Thermal sensor
status.
3. Check the lamp door or dust door.
No

Yes
No Picture ? 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.
No 3. Check the system status: Is system in
burn-in mode?

Yes
Picture quality 1. The picture a little green, blue, red,
No good ? please check the LCD panel connector.
2. The picture has dust, please check the
lens.
3. The picture flicker, please alignment
No again.

VPL-ES4/EX4 3-1
1

Yes
OSD flicker ? Please alignment V-com again.

No

Yes
Color temp wrong ? Please alignment color temperature again.

No

Picture has Yes Check the vertical bar color and find the
Vertical bar ? LCD panel connector. Then check the pin
of connector.

No

IR remote control Yes 1. Please check the OSD setting


No good ? 2. Check the front IR board.

No

Audio function is Yes


1. Check the OSD setting.
No good ? 2. Check the speak wire.

3-2 VPL-ES4/EX4
3-2. Power Board Troubleshooting

3-2-1. No Power

No Power

F601 No Check if CN701 inserted


Open? properly.

Yes

Replace Q601 and F601 Check if miss to solder


with new ones, and then any SMD type of
put power board into set. components.
Yes Q601(D-S)
If Q601 damages again, Short ?
check if other parts are
shorted.
No

Check if 15.25V or 12V Output


exist. If any voltage is Yes
5V DC
wrong, replace IC701 or exists ?
T602 with new ones.

No

Voltage Check if D602 or IC602 is


outputs shut Yes broken.
down and built if yes,replace it with now
repeatly ? one.

No

Check LED circuit of Check CN701 and find


main board. out if some points are
shorted to gound.

VPL-ES4/EX4 3-3
3-2-2. Failure of Turn on Lamp

Failure of turn on ballast.

Check if the input Yes


voltage of ballast is B
380V DC

No

Lamp Yes Replace lamp with new


A Broken ? one.

No

No Control
Check main board. Pin (SCI) is
normal ?

Yes

Replace ballast with new


one.

3-4 VPL-ES4/EX4
B

No Check if there
Check mian board. is PFC_On/Off
signal.

Yes

Check Q701 IC604,


Check if 18V No Q604, Q603 or ZD603.
exists at c-terminal And then replace broken
of Q603. parts.

Yes

Yes Replace F602 with new


F602 Open ? one.

No

Yes Q602 works


A 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 identifiés par la marque ! sont
critiques pour la sécurité.
Ne les remplacer que par une pièce portant le numéro
spécifié.

2. Standardization of Parts
Some repair parts supplied by Sony differ from those
used for the unit. These are because of parts common-
ality 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 Dia-
grams, Electrical Parts List and Exploded Views
unless otherwise specified.
Capacitors : μF
Inductors : μH
Resistors :Ω

VPL-ES4/EX4 4-1
Overall

4-2. Exploded Views

36

38 38

10

41
38
38

+PSW 4x8 32
25

9
+PWH
3x8
12
42
+PSW 3x25
20
38
6 32
32
30
1 3 32
2
13 +P 2.5x8

32

14 32

38 32
29

37
33 4
39 28
30
24
7

+K 3x12

+K 3x12
26

27 VPL-ES4

8 22 34
VPL-EX4
38 +BVTP 3x6
38

21
35

11

15
17

16

4-2 VPL-ES4/EX4
Overall

No. Part No. SP Description


1 ! 1-576-973-11 s FUSE, CYLINDERICAL (F602)
2 ! 1-576-233-51 s FUSE (H.B.C.) (F601)
3 ! 1-576-974-11 s THERMOSTAT
4 1-789-603-11 s DOOR DETECTION SWITCH BOARD
6 ! 9-885-114-11 s FAN, DC (AXIAL FAN UNIT)
7 ! 9-885-114-12 s FAN, DC
8 ! 1-787-496-11 s FAN, DC (DC)
9 ! 1-787-496-21 s FAN, DC (DC)
10 9-885-114-05 s MOUNTED CIRCUIT BOARD, MAIN (VPL-ES4)
10 9-885-114-07 s MOUNTED CIRCUIT BOARD, MAIN (VPL-EX4)
11 1-789-543-11 s MOUNTED CIRCUIT BOARD, IR SENSOR
12 1-789-544-11 s MOUNTED CIRCUIT BOARD, THERMAL SENSOR
13 9-885-114-04 s MOUNTED CIRCUIT BOARD, POWER
14 9-885-114-06 s SPEAKER
15 9-885-113-91 s LAMP DOOR
16 9-885-113-92 s DOOR, FILTER
17 2-670-067-01 s MESH FILTER
20 2-675-465-01 s ASSY, LAMP BOX
21 9-885-113-93 s ASSY,FOOT ADJUST RUBBER
22 9-885-113-94 s FOOT, ADJUST
24 9-885-113-95 s LENS CAP (VPL-ES4)
24 9-885-114-08 s LENS CAP (VPL-EX4)
25 9-885-114-34 s MYLAR BALLAST
26 9-885-113-96 s LOWER CASE
27 9-885-114-00 s ASSY, SUB REAR CASE (VPL-ES4)
27 9-885-114-33 s ASSY, SUB REAR CASE (VPL-EX4)
28 9-885-113-97 s ASSY, FRONT CASE (VPL-ES4)
28 9-885-114-09 s ASSY, FRONT CASE (VPL-EX4)
29 9-885-113-98 s ASSY, FOCUS/ZOOM ADJUST (VPL-ES4)
29 9-885-114-10 s ASSY, FOCUS/ZOOM ADJUST (VPL-EX4)
30 2-681-547-02 s SCREW, TAP PH W/FL M3*27L
32 2-681-550-01 s SCREW, TAP PAN M3*7L
33 2-681-552-02 s SCREW, EX-HE 4#-40X4+6 STLESS
34 2-681-553-01 s SCREW, TAP PAN M2*6L
35 9-885-114-32 s RUBBER PAD,ADJUST FOOT
36 9-885-113-90 s ASSY, UPPER CASE (WHITE COLOR)
36 9-885-113-99 s ASSY, UPPER CASE (BLOCK COLOR) (VPL-ES4)
37 4-672-839-11 s HEAD, M3 FLAT
38 3-918-696-11 s SCREW (M3X6 LOCK ACE)
39 2-580-621-01 s SCREW, +PWH 3X10
41 9-885-114-02 s SWITCH,TACT
42 ! 1-474-023-11 s POWER SUPPLY BLOCK (BALLAST)

7-682-903-21 s SCREW, +PWH 3X8


7-682-954-01 s SCREW, +PSW 3X25
7-685-645-91 s SCREW +BVTP 3X6
7-621-262-40 s SCREW, +P 2.5X8
7-682-250-09 s SCREW, +K 3X12
7-682-961-01 s SCREW +PSW 4X8

VPL-ES4/EX4 4-3
4-3. Electrical Parts List 4-4. Packing Materials & Supplied
Accessories
Ref. No.
or Q’ty Part No. SP Description --------------------
SUPPLIED ACCESSORIES
1pc ! 1-576-233-51 s FUSE (H.B.C) (F601) --------------------
1pc ! 1-576-973-11 s FUSE, CYLINDERICAL (F602) Ref. No.
or Q’ty Part No. SP Description
1pc 1-479-775-12 s REMOTE COMMANDER (RM-PJ4)
1pc 1-832-428-11 s CABLE, VGA
1pc 2-679-319-01 s BAG,CARRY
1pc 3-210-513-02 s CD MANUAL
1pc 3-100-207-01 s GUIDE QS MANUAL
(JAPANESE, ENGLISH, FRENCH,
SPANISH, GERMAN, ITALIAN,
SIMPLIFIED CHINESE)
1pc ! ------------ s CORD SET, POWER
(See 1-4. Warning on Power Connection)

4-4 VPL-ES4/EX4
Overall Overall

Section 5
Block Diagram
IR Receiver IRR5 IRR

DCK1_R
IRF5 IRF LCDR[11:0] DCK1x_R
IR Receiver Reset DCK2_R
IC CLK_R DCK2x_R
HCK_R
LUMA PRG HCKx_R
S-Video FRP PRG R RSIG[6:1]
CHROMA VD FRP LCD
SDA LCDRGT RGT VD Drver RVCOM R
LCDRGTx RGTx RPSIG LCD
EEPROM SCL LCDENB ENB SEN
Video CVBS LCDHST HST SCLK RGT
LCDVST VST SDATA HST
WP LCDVCK VCK ENB
LCDPCG PCG VCK
PC-RIN1 LCDDWN DWN VST
PC-GIN1 HCK HCK_R DWN
PC-BIN1 HCK HCK_G PCG
INPUT B LCD HCK HCK_B
HSYNC1 DR[9:0] HCKx HCKx_R
VSYNC1 Timing HCKx HCKx_G
Video DG[9:0] Generator HCKx HCKx_B
PC-RIN Processor DCK1_G
PC-RIN2 PC-GIN DB[9:0] LCDG[11:0] DCK1x_G
PC-GIN2 Analog RGB PC-BIN & DCK2_G
PC-BIN2 Input/Output Controller CLK_G DCK2x_G
INPUT A HSYNC HCK_G
HSYNC2 VSYNC HCKx_G
VSYNC2 DCK1_R PRG G GSIG[6:1]
DCLK DCK[6:1] DCK2_R FRP LCD
DHS DCK1_G VD
Driver GVCOM G
R_OUT DVS DCK2_G GPSIG LCD
G_OUT DCK1_B SEN
B_OUT DCK2_B SCLK RGTx
Monitor LCD_SCL SDATA HST
Output HSYNCO LCD_SDA ENB
VSYNCO VCK
DCK1x_R VST
DCK2x_R DWN
DCK1x_G PCG
DCK2x_G
DCK1x_B
Audio A/B AUDIO_S DCK2x_B

DCK1_B
AUDIO_SW LCDB[11:0] DCK1x_B
Audio DCK2_B
Audio AUDIO_M Input/Output AUDIO_MUT CLK_B DCK2x_B
HCK_B
& AUDIO_VOL1 27 MHz HCKx_B
volume PRG B BSIG[6:1]
AUDIO_O+ control AUDIO_VOL2 FRP LCD
VD Driver BVCOM B
Audio out AUDIO_O BPSIG LCD
AUDIO_O_ SENi SEN
SCLKi SCLK RGT
SDATAi SDATA HST
ENB
VCK
Speaker VST
LED[4:1] LED DWN
Driver PCG
RS-232 TX.DL RS232 TXD
Remote RX.DL Driver RXD
Control Receiver Keypad +3.3V
V33 P5VC
Input REG

P15VP
P15VP P15V P15VP
FG1 I2C_SW PWR_fail Power P12V
P12V
Power P2P5V +1.8V
FAN_SW Fail DET P5V Control REG
P5V P5VC P5V
SDA
Fan2 SCL
Fan 2 FG2 POWER_ON
P135V +3.3V P15V
REG
Fan3 Dust_SW
Fan 3 FG3 Fan Control EEPROM Dust SW
Door_SW Door SW
P1P8V +1.8V P5V
Fan4 REG
Fan 4 FG4
LampLIT Power
LampEN P5V
Fan5 Eco_mode Ballast Switch +2.5V
P2P5V
Fan 1 FG5 REG
32.768 KHz
ROMWEn

ROMOEn
D[0:15]

A[0:21]

P3P3V +3.3V
REG
Flash
Thermal Thermal memory
P33V +3.3V
Sensor 1 Sensor 2 Reset REG
IC

VPL-ES4/EX4 5-1 5-1


Frame Frame

Section 6
Diagram
J6 J1

IR
SENSOR 1
6-1. Frame Schematic Diagram BOARD

MAIN CN1
J5 BOARD DETECTION
SWITCH
INPUT S VIDEO
BOARD
(RIGHT)
J14

J4
INPUT VIDEO
CN1
DETECTION
SWITCH
BOARD
J9 (LEFT)
INPUT AUDIO
2
J18 J1
J8
THERMAL
INPUT AUDIO A/B SENSOR
BOARD

J2

J23
INPUT INPUT A
LCD R

J1 J24

INPUT INPUT B LCD G


3
J25

J3
LCD B

OUTPUT MONITOR

J21
FAN2

J10 FAN2

OUTPUT AUDIO J19

FAN3
(REAR BOTTOM)
4
J20

J7 FAN4
(REAR TOP)
REMOTE RS-232C
J22

FAN1(FRONT BOTTOM)

J11
J16

SPEAKER HALOGEN
BALLAST UNIT
LAMP

CN602
J17 CN701 CN601

POWER BOARD

VPL-ES4/EX4 6-1 6-1


A B C D E F G H
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 low-
voltage 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

AC
0.15 μF 1.5 kZ voltmeter
(5.25V)

Earth Ground

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

VPL-ES4/EX4
VPL-ES4 (SY) English
VPL-EX4 (SY) E Sony EMCS Corporation 2007DR16-1
9-883-627-01 Ichinomiya Tec ©2007