Sony VPL-GH10 Optical Unit Replacement

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Rev 3 – 29 Apr 2015 TPD 19551

CAE SONY Projector VPL-GH10

Optical Block Replacement Procedure

CAE Inc. Confidential and/or Proprietary Information – see title page

Contact Information

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Disclaimer

The information contained herein does not claim to provide for every possible contingency met in connection with the maintenance or operation of the training device. It is the user's responsibility to determine the usage of this information in conjunction with national, local and organizational health and safety codes, regulations, laws and practices (“Laws”). The procedures described herein under no circumstances may substitute the applicable Laws.

All maintenance and operating actions shall be undertaken by qualified personnel with the skills and knowledge relating to maintenance of the training device. Qualified personnel shall be trained and authorized, but not limited to, safely energize, de-energize, ground, lockout/tagout circuits and equipment, and clear faults in accordance with applicable Laws.

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SONY Projector VPL-GH10

Record of Amendments


Rev 3 – 29 Apr 2015 Page i



Revision No. Date Description of Changes

- 03 Nov 2014 Initial Release.

1 18 Dec 2014 File name updated and steps added from the service manual.

2 17 Mar 2015 New part list and power supply installation steps.

3 29 Apr 2015 Updated the settings table and added sticker picture position


Table of Contents

Table of Contents

Rev 3 – 29 Apr 2015 Page iii


Table of Contents

1. Introduction ............................................................................................................................. 7 1.1 Objectives ........................................................................................................................7 1.2 List of Tools .....................................................................................................................8

2. GH10 Firmware Verification .................................................................................................. 9 3. GH10 Optical Block Change Procedure ............................................................................... 11

3.1 Data Save .......................................................................................................................12 3.2 Manual Data Reading ....................................................................................................15 3.3 Optical Block Removal ..................................................................................................17

3.3.1 Lens Types ............................................................................................................ 19 3.3.2 Detailed Removal Steps ........................................................................................ 20

3.4 Lamp Power Supply Removal .......................................................................................26

3.5 Projector Rebuild ...........................................................................................................29

3.6 Data Upload ...................................................................................................................31 3.6.1 NVM Selection ..................................................................................................... 33

3.7 Manual Data Modification .............................................................................................35 3.8 Projector Settings Update ..............................................................................................37

4. Conclusion ............................................................................................................................ 39


List of Figures

List of Figures

Rev 3 – 29 Apr 2015 Page v


List of Figures

Figure 1-1 Typical Optical Block ............................................................................................. 7 Figure 1-2 Parts List ................................................................................................................. 8 Figure 2-1 GH10 Projector ....................................................................................................... 9 Figure 2-2 Information Page ................................................................................................... 10 Figure 3-1 Flash Upgrader Settings ........................................................................................ 11

Figure 3-2 QuickAccess Window ........................................................................................... 12 Figure 3-3 Save Selection Chart ............................................................................................. 13 Figure 3-4 NVM SAVE section ............................................................................................. 13 Figure 3-5 Press Browse, Enter Info....................................................................................... 14 Figure 3-6 Selecting COM Port, Baud Rate ........................................................................... 14

Figure 3-7 Excerpt – Service Manual (1 of 2) ........................................................................ 17

Figure 3-8 Excerpt – Service Manual (2 of 2) ........................................................................ 18

Figure 3-9 SONY Lens (Do not remove) ............................................................................... 19 Figure 3-10 CNL (To be transferred to new optical block) ...................................................... 19 Figure 3-11 Vertical Locking Mechanism ................................................................................ 20 Figure 3-12 Spring Kit Locking Mechanism ............................................................................ 20

Figure 3-13 Horizontal Locking Mechanism ........................................................................... 21 Figure 3-14 Flaring Clamp ....................................................................................................... 21

Figure 3-15 Flaring Clamp – Zoom View ................................................................................ 22 Figure 3-16 Information Page ................................................................................................... 22 Figure 3-17 Guide Pin Locations .............................................................................................. 23

Figure 3-18 Removing CA and CA Board (1 of 2) .................................................................. 23 Figure 3-19 Removing CA and CA Board (2 of 2) .................................................................. 24

Figure 3-20 Removing Board and Holder ................................................................................ 24 Figure 3-21 Removing Optics Attachment ............................................................................... 25

Figure 3-22 Removing Pads ..................................................................................................... 25 Figure 3-23 Removing Fans ..................................................................................................... 25 Figure 3-24 Excerpt – Service Manual ..................................................................................... 26

Figure 3-25 Power Supply Cover Removal .............................................................................. 27 Figure 3-26 Removing Power Supply Connectors ................................................................... 27

Figure 3-27 Removing Connectors From QA Board ............................................................... 27 Figure 3-28 Screw Removal ..................................................................................................... 28 Figure 3-29 Lamp Power Supply Screws ................................................................................. 28

Figure 3-30 Removing Lamp Power Supply ............................................................................ 28 Figure 3-31 Heat Sink Removal ............................................................................................... 29

Figure 3-32 Horizontal Locking Mechanism ........................................................................... 30 Figure 3-33 QuickAccess Window ........................................................................................... 31

Figure 3-34 LOAD Selection Chart .......................................................................................... 31 Figure 3-35 Browse, Enter Name ............................................................................................. 32 Figure 3-36 Selecting COM port, Baud Rate ........................................................................... 32 Figure 3-37 Select Part, deselect Verify ................................................................................... 33 Figure 3-38 Browse, Select....................................................................................................... 33 Figure 3-39 Answer Yes To Continue Push ............................................................................. 34


List of Figures Rev 3 – 29 Apr 201 Page vi


Figure 3-40 When STBY LED Turns Red, Remove AC Power .............................................. 34

Figure 3-41 Settings Table (1 of 2 ............................................................................................ 37

Figure 3-42 Settings Table (2 of 2)........................................................................................... 38 Figure 4-1 Information Page ................................................................................................... 39 Figure 4-2 Suggested Sticker Location................................................................................... 39


Introduction

Introduction

Rev 3 – 29 Apr 2015 Page 7


1. Introduction

This procedure will guide you through the steps to replace the VPL-GH10 optical

block and lamp power supply. It will provide all the instructions on how to remove

and install the optical block, lamp power supply and identify all the needed software

and data to be updated during the process.

The received unit can come with FIRMWARE 9.02, 9.04, 9.06 or higher

installed.

The unit can come as GH10/0 (firmware 9.02 or 9.04) or GH10/1 (Firmware

9.06 and higher).

The unit can come with a Custom Navitar Lens (CNL) or a SONY lens.

1.1 Objectives

This manual documents the following procedures:

Replacing SONY VPL-GH10 optical block and lamp power supply.

Replacing the radiation pads, fans and fan cushions.

Updating data into the projector reflecting the optical block change.

Identify CNL vs SONY projector lenses.

Figure 1-1 shows the projector equipment that will be used in the optical block

replacement procedure. Figure 1-2 lists the individual components found in the

optical block assembly.

Figure 1-1 Typical Optical Block


Introduction Rev 3 – 29 Apr 201 Page 8


MA527304.01.2.258 Optical Block Assembly Parts List

PS418699.19.5.842 Parts List

Figure 1-2 Parts List

1.2 List of Tools

The following tools are needed to complete these tasks.

1) Allen Key 2.5 mm (SONY lens)

2) Allen Key 0.9mm (CNL lens)

3) Philips screw driver #2

4) Computer with serial port or EDGE port cable (USB to serial)

5) RS232 crossover cable

6) QUICKACCESS and FLASHUPGRADER software

7) New optical block (MA527304.01.2.258)

8) CD-ROM with specific optical block information

9) CNL Product Manual, Maintenance and Operation

10) SONY GH10 Service Manual


GH10 Firmware Verification

GH10 Firmware Verification

Rev 3 – 29 Apr 2015 Page 9


2. GH10 Firmware Verification

The following procedure is used to verify the projector's firmware version. To update

the optical block, the projector must have FIRMWARE 9.02, 9.04, 9.06 or higher

installed.

1) Turn ON the GH10 projector.

2) Verify the Firmware revision (must be in service mode).

a. Using the joystick (or the enter button in Figure 2-1), PRESS in sequence

ENTER-ENTER-LEFT-ENTER.

b. Answer Yes to enter Service mode

c. PRESS the MENU button

Figure 2-1 GH10 Projector


GH10 Firmware Verification Rev 3 – 29 Apr 201 Page 10


d. Select INFORMATION from the menu. See Figure 2-2.

e. Document the SC ROM Version, NVM Version, Sub ROM Version, and

IP ROM Version numbers.

Figure 2-2 Information Page


GH10 Optical Block Change Procedure


Rev 3 – 29 Apr 2015 Page 11


3. GH10 Optical Block Change Procedure

For systems with firmware revision 9.02, 9.04 and 9.06, update the firmware to

revision 9.07 by performing the following steps:

1) Make sure the files, from the SONY supplied CD are in the same folder as the

QUICKACCESS and FLASHUPGRADER software.

2) Turn projector OFF. Projector is in STANBY mode (Do not remove power.).

3) Connect the RS232 cable to the unit.

4) Verify the serial port # and baud rate via Windows Device Manager.

5) Start FLASHUPGRADER software and make sure the proper settings are in

place as shown in Figure 3-1.

Figure 3-1 Flash Upgrader Settings


GH10 Optical Block Change Procedure Rev 3 – 29 Apr 201 Page 12


6) Confirm selection of NOTIFY ON COMPLETION, RESET TARGET AFTER

DOWNLOAD and FLASH mode.

7) See Figure 3-1 and proceed as follows:

Select the CHOOSE button and select PW0P907a.inf file.

Confirm proper settings in COM PORT and BAUD RATE section. COM

port number is specific to the system. Confirm with the device manager.

Select EXT_232C_PW1 button.

Press FLASH.

NOTE: Always quit FLASHUPGRADER after each use.

NOTE: It can happen that the transfer stops at around 4%, CLOSE and

repeat the procedure. You may have to cycle power on the

projector.

8) Turn projector ON and verify the Firmware revision. Refer back to GH10

Firmware Verification, paragraph 2.

3.1 Data Save

1) Turn projector ON.


3) Start QUICKACCESS and select model VPL-GH10.

Figure 3-2 QuickAccess Window




Rev 3 – 29 Apr 2015 Page 13


4) Select SAVE and select proper 3dgm/lut function, see Figure 3-3.

3dgm/lut function in pull down section File name

3DGamma 3DG_xxxxxxx.csv

LookUpTable LUT_ xxxxxxx.csv

DDC NOT NEEDED

ABGamma ABG_ xxxxxxx.csv

LCK LCK xxxxxxx.csv

OGMTable OGM_ xxxxxxx.csv

CSMatrixTable CSMatrix_ xxxxxxx.csv

NVM NVM_xxxxxxx.csv (see Figure 3-4) (Select SAVE_ALL)

NOTE: xxxxxxx represents the projector serial number.

Figure 3-3 Save Selection Chart

NOTE: It is necessary to record the serial number of the projector should you need

to revert back. Each optical block has files associated with it and cannot be

mixed. For the Non Volatile Memory (NVM) section the selection is as

follows:

Figure 3-4 NVM SAVE section




5) Press BROWSE and type a name with the file associated in the function (refer

to SAVE SELECTION CHART, see Figure 3-3. Create a directory for each

optical block for clarity.

Figure 3-5 Press Browse, Enter Info

6) Select the proper COM port and baud rate (38400) and press NEXT to proceed.

Figure 3-6 Selecting COM Port, Baud Rate

7) Once completed, QUICKACCESS software will automatically quit.

8) Repeat steps 3) to 7), using the next proposed file from the SAVE SELECTION

CHART (see Figure 3-3).




Rev 3 – 29 Apr 2015 Page 15


3.2 Manual Data Reading

The following procedure is used to document the device settings.

NOTE: The information to proceed can also be found in the GH10 Service

Manual, section 1-5-3 to 1-5-5.

Proceed as follows:


2) Make sure the projector is in SERVICE MODE (Refer back to GH10 Firmware

Verification, paragraph 2.).

3) Select MENU on the projector.

4) Select DEVICE option and select OTHER for the IRIS data reading.

a. Press the down arrow to

b. 02 IRIS/OPEN REG menu and read value _____________________

c. 03 IRIS/CLOSE REG menu and read value _____________________

d. Press enter to go back to DEVICE menu.

5) From DEVICE menu, select PANEL DRIVER for the driver gain data reading


b. 01 P.DRV/GAIN R menu and read value _____________________

c. 02 P.DRV/GAIN G menu and read value _____________________

d. 03 P.DRV/GAIN B menu and read value _____________________

e. Press enter to go back to DEVICE menu.

6) From DEVICE menu, select DISPLAY ENGINE


b. 06 DE/R REG H menu and read value _____________________

c. 07 DE/R REG V and read value _____________________

d. 08 DE /B REG H and read value _____________________

e. 09 DE/B REG V and read value _____________________

f. Press enter to go back to DEVICE menu.




7) From DEVICE menu, select OTHER for the LENS SHIFT data reading.


b. 13 LENS SHIFT/H CENTER menu and read value _______________

c. 14 LENS SHIFT/V CENTER menu and read value _______________

d. 15 LENS SHIFT/V TOP menu and read value _______________

e. 16 LENS SHIFT/V BOTTOM menu and read value ______________

f. 17 LENS SHIFT/ RIGHT menu and read value _______________

g. 18 LENS SHIFT/LEFT menu and read value _______________

h. Press enter to go back to DEVICE menu.




Rev 3 – 29 Apr 2015 Page 17


3.3 Optical Block Removal

Remove lamp, covers, filter and optical block as per Service Manual section 1-3-1 to

1-3-9, 1-3-12 and 1-3-14 to 1-3-15.

NOTE: Two screws at the front of the projector are intentionally missing.

Figure 3-7 Excerpt – Service Manual (1 of 2)




Figure 3-8 Excerpt – Service Manual (2 of 2)




Rev 3 – 29 Apr 2015 Page 19


3.3.1 Lens Types

The following figures show the different types of GH10 lens available.

Figure 3-9 SONY Lens (Do not remove)

Figure 3-10 CNL (To be transferred to new optical block)




3.3.2 Detailed Removal Steps

1) Remove Vertical locking mechanism on SONY LENS or CNL. See Figure

3-11.

NOTE: Two types of locking mechanism are available, a vertical locking

or a spring kit mechanism (see Figure 3-12). You do not need to

remove the Spring Kit mechanism.

Figure 3-11 Vertical Locking Mechanism

Figure 3-12 Spring Kit Locking Mechanism




Rev 3 – 29 Apr 2015 Page 21


2) Remove Horizontal locking mechanism on SONY LENS or CNL and put

aside.

Figure 3-13 Horizontal Locking Mechanism

3) Remove FLARING CLAMP on CNL projectors and put aside.

NOTE: Release the two set screws first.

Figure 3-14 Flaring Clamp




Figure 3-15 Flaring Clamp – Zoom View

4) Remove CNL lens.

NOTE: Hold the lens while removing the four screws.





Rev 3 – 29 Apr 2015 Page 23


Figure 3-17 Guide Pin Locations

5) Remove CA and CB board.

Figure 3-18 Removing CA and CA Board (1 of 2)




Figure 3-19 Removing CA and CA Board (2 of 2)

6) Disconnect panel from the board. Remove the board and holder from the

optical block.

Figure 3-20 Removing Board and Holder




Rev 3 – 29 Apr 2015 Page 25


7) Remove optics attachment.

Figure 3-21 Removing Optics Attachment

8) Remove PADS (record location).

Figure 3-22 Removing Pads

9) Remove the three fans.

Figure 3-23 Removing Fans




3.4 Lamp Power Supply Removal

Remove power supply cover to ease access, harnesses and lamp power supply as per

Service Manual section 1-3-13.

Figure 3-24 Excerpt – Service Manual




Rev 3 – 29 Apr 2015 Page 27


1) Remove power supply cover 2 screws (careful with the retaining clip).

Figure 3-25 Power Supply Cover Removal

2) Remove power supply connectors.

Figure 3-26 Removing Power Supply Connectors

3) Remove connectors from the QA board and red cable retaining clip.

Figure 3-27 Removing Connectors From QA Board




4) Remove 4 screws retaining plastic power supply cage (G holder). Also, remove

qty 1 screw retaining the metallic support.

Figure 3-28 Screw Removal

5) Remove the assembly and lamp power supply screws (qty 2) + connectors (qty 3).

Figure 3-29 Lamp Power Supply Screws

6) Remove lamp power supply. Remove heat sink retaining clamp

Figure 3-30 Removing Lamp Power Supply




Rev 3 – 29 Apr 2015 Page 29


7) Carefully remove the heat sink protecting the sheet integrity. Install new power

supply and rebuild in the opposite order.

Figure 3-31 Heat Sink Removal

3.5 Projector Rebuild

1) Replace FANS (ensure proper orientation).

2) Replace heat sink pads.

3) Install the optical block spacer and the horizontal lock mechanism (see

Figure 3-32).

4) Reassemble all boards.

5) Refer to the CNL Product Manual, Maintenance and Operation. In the

projector replacement section and perform to the CNL installation

procedures.

6) Install new optical block inside projector.

7) Reassemble projector as per Sony Service Manual.




Figure 3-32 Horizontal Locking Mechanism




Rev 3 – 29 Apr 2015 Page 31


3.6 Data Upload

The Data Upload procedure is similar to the Data Save procedure (paragraph 3.1)

with NVM procedures. Ensure s/n of optical block and the files from CD are the same



3) Start QUICKACCESS and select model VPL-GH10.

Figure 3-33 QuickAccess Window

4) Select LOAD and select proper 3dgm/lut function, see Figure 3-34.

3dgm/lut function in pull down section File name 3DGamma GH10_3DG_xxxxxxx.csv *

LookUpTable GH10_LUT_ xxxxxxx.csv * DDC NOT NEEDED

ABGamma GH10_ABG_ xxxxxxx.csv * LCK GH10_LCK xxxxxxx.csv *

OGMTable GH10_OGM_ xxxxxxx.csv * CSMatrixTable GH10_CSMatrix_ xxxxxxx.csv *

NVM USE the NVM Selection in paragraph 3.6.1. NEVER USE CD supplied version

NOTE: xxxxxxx represents the optical block identifier number (different for each optical block).

* Files are located on the CD provided with the associated optical block.

Figure 3-34 LOAD Selection Chart




5) Press BROWSE and type a name with the file associated in the function (refer

to LOAD SELECTION CHART, Figure 3-34.

Figure 3-35 Browse, Enter Name

6) Select the proper COM port and baud rate (38400) and press NEXT to proceed.

Figure 3-36 Selecting COM port, Baud Rate

7) Once completed, QUICKACCESS software will automatically quit.

8) Repeat steps 3) to 7), using the next proposed file from the LOAD SELECTION

CHART (see Figure 3-34).




Rev 3 – 29 Apr 2015 Page 33


3.6.1 NVM Selection

The NVM is loaded with a file not supplied on the CD (DO NOT use the NVM file

from the TRAINING or optical block CD)

The file to be used is called nvm_qh9v0102aPatch.csv. It will be supplied on your

computer or you can get it from the STEP 1 article KBID 11063

When the NVM selection is done, select PART and remove the VERIFY selection.

Figure 3-37 Select Part, deselect Verify

1) Select Browse and select nvm_qh9v0102aPatch.csv.

Figure 3-38 Browse, Select




2) Answer YES to PUSH the new data.

Figure 3-39 Answer Yes To Continue Push

3) Once completed, you will be asked to turn OFF the projector. When the

STANBY LED turns RED, remove the AC power.

Figure 3-40 When STBY LED Turns Red, Remove AC Power




Rev 3 – 29 Apr 2015 Page 35


3.7 Manual Data Modification

The .txt files listed below are available on the SONY CD provided with the optical

block.

NOTE: The information to proceed can also be found in the GH10 Service Manual,

section 1-5-3 TO 1-5-5.


2) Make sure the projector is in SERVICE MODE.

3) Select MENU on the projector.

4) Select DEVICE option and select OTHER for the IRIS data change (value

found in IRIS ADJ_VALUE.TXT from the SONY CD).

a. 01 IRIS/ADJ menu set value to 1.

b. 02 IRIS/OPEN REG menu set value as per IRIS ADJ_VALUE.TXT.

c. 03 IRIS/CLOSE REG menu set value as per IRIS ADJ_VALUE.TXT.

d. Go to 01 IRID/ADJ menu and set value to 0.

e. Back to DEVICE menu and select SAVE TO MEMORY.

5) From DEVICE menu, select PANEL DRIVER for the driver gain data change

(value found in GH10_BGAIN.TXT from the SONY CD).

a. Go to 03 P.DRV/GAIN B menu and set value as per GH10_BGAIN.TXT.

b. Back to DEVICE menu and select SAVE TO MEMORY.

6) From DEVICE menu, select DISPLAY ENGINE

a. Go to 06 DE/R REG H menu and set value as per GH10_BGAIN.TXT.

b. 07 DE/R REG V and set value as per GH10_BGAIN.TXT.

c. 08 DE /B REG H and set value as per GH10_BGAIN.TXT.

d. 09 DE/B REG V and set value as per GH10_BGAIN.TXT.

e. Back to DEVICE menu and select SAVE TO MEMORY.

7) From DEVICE menu, select OTHER for the LENS SHIFT data change (value

found in GH10_LENZ_SHIFTDATE_X.TXT).

a. Go to 13 LENS SHIFT/H CENTER menu and set value as per

GH10_LENZ_SHIFTDATE_.TXT.

b. 14 LENS SHIFT/V CENTER menu and set value as per

GH10_LENZ_SHIFTDATE_X.TXT.

c. 15 LENS SHIFT/V TOP menu and set value as per





d. 16 LENS SHIFT/V BOTTOM menu and set value as per


e. 17 LENS SHIFT/ RIGHT menu and set value as per


f. 18 LENS SHIFT/LEFT menu and set value as per


g. Back to DEVICE menu and select SAVE TO MEMORY.




Rev 3 – 29 Apr 2015 Page 37


3.8 Projector Settings Update

1) Select MENU.

2) Verify each field to match the following table. Please note the new cooling

settings.

Figure 3-41 Settings Table (1 of 2




Figure 3-42 Settings Table (2 of 2)


Conclusion

Conclusion

Rev 3 – 29 Apr 2015 Page 39


4. Conclusion

At the end of the process, access the Information menu (refer to paragraph 2, GH10

Firmware Verification). The projector should display the information as shown

below.


1) Using the LENS menu, one is able to FOCUS, ZOOM IN AND OUT, LENS

SHIFT up/down and left/right (ensure no locking mechanism is in place).

2) This update is complete; connect the projector to a computer with DVI

connection to display a full HD 1920x1080 image.

3) For CNL projectors, please verify that the BFL is optimal using the CNL

Product Manual, Maintenance and Operation (Typically in projector

replacement section, typically paragraph 2.3.4.2.3).

4) Once everything is completed, please affix the supplied sticker indicating the

180W power supply modification at the location indicated in Figure 4-2.

Figure 4-2 Suggested Sticker Location

Documents

Sony VPL-GH10 Optical Unit Replacement