Sanyo PLC-XP45 Bedienungsanleitung

Multimedia Projector

SERVICE MANUAL

PRODUCT CODE

1 122 108 00 (MA8A)

1 122 109 00 (PA8A)

1 122 109 02 (PA8C)

1 122 110 00 (MB8A)

1 122 111 00 (PB8A)

1 122 111 02 (PB8C)

Original Version

REFERENCE NO. SM5110261

FILE NO.

Model No. PLC-XP45

PLC-XP40

U.S.A., Canada,

Europe, Asia, Africa

U.K

Chassis No. MA8-XP4500

MB8-XP4000

NOTE: Match the Chassis No. on the unit’s

back cover with the Chassis No. in the

Service Manual.

If the Original Version Service

Manual Chassis No. does not match

the unit’s, additional Service

Literature is required.You must refer to

“Notices” to the Original Service

Manual prior to servicing the unit.

PLC-XP45 PLC-XP40

■Contents

■Safety instructions ________________________________________________3

■Specifications __________________________________________________ 4

■Note on Servicing ______________________________________________ 5

■Adjustments after parts replacement ________________________________ 5

■Circuit protections ______________________________________________ 6-7

● Fuse ____________________________________________________ 6

● Thermal switch ____________________________________________ 6

● Interlock switch ____________________________________________ 6

● Warning temperature and power failure protection ________________ 7

■Mechanical disassemblies ______________________________________ 8-12

■Optical parts disassemblies ____________________________________ 13-16

■LCD panel/prism ass’y replacement ________________________________ 17

■Lamp replacement ______________________________________________ 18

■Optical adjustments __________________________________________ 19-21

●Contrast adjustment ________________________________________ 19

●Condenser adjustment ______________________________________ 20

●Relay lens adjustment ______________________________________ 21

■Electric adjustments __________________________________________ 22-30

●Service adjustment menu operation____________________________ 22

●Circuit adjustments ______________________________________ 23-27

●Service adjustment data table______________________________ 28-33

●Test points and locations ____________________________________ 34

■Troubleshooting ______________________________________________ 35-40

●No power ______________________________________________ 35-36

●No picture ____________________________________________ 37-38

●No sound ________________________________________________ 39

●Lens motor problems ______________________________________ 40

■Control port functions ________________________________________ 41-45

■Waveforms __________________________________________________ 46-47

■Cleaning ______________________________________________________ 48

■IC block diagrams ____________________________________________ 49-59

■Service parts lists ____________________________________________ 60-91

●Electrical parts list ______________________________________ 60-85

●Mechanical parts list ____________________________________ 86-88

●Optical parts list ________________________________________ 89-91

Drawings & Diagrams ______________________________________ A1-A16

■Parts description and reading in schematic diagram ____________________ A2

■Circuit block diagram ____________________________________________ A3

■Power supply lines ______________________________________________ A4

■Schematic diagrams ________________________________________ A5-A12

■Printed wiring board diagrams ________________________________ A13-A15

■Pins description of ICs, transistors, diodes __________________________ A16

■Safety Instructions

WARNING:

The chassis of this projector is isolated (COLD) from AC line by using the converter transformer. Primary side of

the converter and lamp power supply unit circuit is connected to the AC line and it is hot, which hot circuit is iden-

tified with the line ( ) in the schematic diagram. For continued product safety and protection of personnel

injury, servicing should be made with qualified personnel.

The following precautions must be observed.

SAFETY PRECAUTIONS

1: An isolation transformer should be connected in the

power line between the projector and the AC line

before any service is performed on the projector.

2: Comply with all caution and safety-related notes pro-

vided on the cabinet back, cabinet bottom, inside the

cabinet or on the chassis.

3: When replacing a chassis in the cabinet, always be

certain that all the protective devices are installed

properly, such as, control knobs, adjustment covers

or shields, barriers, etc.

DO NOT OPERATE THIS PROJECTOR WITHOUT

THE PROTECTIVE SHIELD IN POSITION AND

PROPERLY SECURED.

4: Before replacing the cabinet cover, thoroughly

inspect the inside of the cabinet to see that no stray

parts or tools have been left inside.

Before returning any projector to the customer, the

service personnel must be sure it is completely safe to

operate without danger of electric shock.

SERVICE PERSONNEL WARNING

Eye damage may result from directly viewing the light produced by the Lamp used in this equipment. Always turn

off Lamp before opening cover. The Ultraviolet radiation eye protection required during this servicing.

Never turn the power on without the lamp to avoid electric-shock or damage of the devices since the stabilizer

generates high voltages(15kV - 25kV) at its starts.

Since the lamp is very high temperature during units operation replacement of the lamp should be done at least

45 minutes after the power has been turned off, to allow the lamp cool-off.

PRODUCT SAFETY NOTICE

Product safety should be considered when a component replacement is made in any area of the projector.

Components indicated by mark in the parts list and the schematic diagram designate components in which

safety can be of special significance. It is, therefore, particularly recommended that the replacement of there parts

must be made by exactly the same parts.

DO NOT ATTEMPT TO SERVICING THE

REMOTE CONTROL UNIT.

Laser Beam may be leaked out when in disassemble

the Unit. As the Laser Beam used in this Remote con-

trol unit is harmful to the eyes.

LASER RADIATION

DO NOT STARE INTO BEAM

MAX. OUTPUT: 1mW

WAVE LENGTH: 650 ±20nm

CLASS II LASER PRODUCT

This product is complied with 21 CFR

part 1040.10

CAUTION LASER RADIATION

DO NOT STARE INTO BEAM

CLASS 2 LASER PRODUCT

LASER-STRAHLING

NICHT IN DEN STRAHL BLICKEN

LASER KLASSE 2

IEC60825-1, Am. 1 1997

MAX OUTPUT ( ) : 1 mW

WAVE LENGTH ( ) : 650±20nm

■Specifications

●The specifications are subject to change without notice.

This symbol on the nameplate means the product is Listed by Underwriters

Laboratories Inc. It is designed and manufactured to meet rigid U.L. safety stan-

dards against risk of fire, casualty and electrical hazards.

Projector Type Multi-media Projector

Dimensions (W x H x D) 12.6” x 6.6” x 18.5” (319mm x 168mm x 470mm) (PLC-XP45)

12.6” x 6.6” x 16.8” (319mm x 168mm x 429.5mm) (PLC-XP40)

Net Weight 18.5 lbs (8.4 kg) (PLC-XP45), 17.4 lbs (7.9 kg) (PLC-XP40)

LCD Panel System 1.3” TFT Active Matrix type, 3 panels

Panel Resolution 1024 x 768 dots

Number of Pixels 2,359,296 (1024 x 768 x 3 panels)

Color System 6 color system (PAL, SECAM, NTSC, NTSC4.43, PAL-M and PAL-N)

High Definition TV SIgnals 480i, 480p, 575i, 575p, 720p. 1035i and 1080i

Scanning Frequency H-sync. 15 ~ 100kHz, V-sync. 50 ~ 100Hz

Projection Image Size (diagonal) Adjustable from 31” to 400”

Horizontal Resolution 800 TV lines (HDTV)

Projection Lens F 1.7 ~2.0 lens with f=48.2mm ~ 62.6mm with motor zoom and focus (PLC-XP45)

F 1.8 ~2.1 lens with f=48.4mm ~ 62.8mm with motor zoom and focus (PLC-XP40)

Throw Distance 4.6’ ~ 48.3’ (1.4m ~ 14.7m) (PLC-XP45), 4.6’ ~ 47.3’ (1.4m ~ 14.4m) (PLC-XP40)

Motorized Lens Shift Up and Down

Projection Lamp 200watts

Input 1 Jacks DVI Terminal (Digital), HDB 15-pin Terminal (Analog) and Stereo Mini Type

Jack (Audio)

Input 2 Jacks BNC Type x 5 (G or VIDEO/Y, B or Cb/Pb, R or Cr/Pr, H and V), Stereo

Mini Type Jack (Audio)

Input 3 Jacks RCA Type x 3 (VIDEO/Y, Cb/Pb, Cr/Pr), RCA Type x 2 (Audio R and L) and

DIN 4-pin (S-Video)

Other Jacks DIN 8-pin (Control port), USB port (Series B receptacle) and Wired

Remote Jack

Built-in Speakers 2 speakers Stereo (R and L), 2 watts RMS (T.H.D. 10%)

Feet Adjustment 0˚ to 10.5˚

Voltage and AC 100 ~ 120V (3.6A Max. Ampere), 50/60Hz (The U.S.A and Canada)

Power Consumption AC 200 ~ 240V (1.8A Max. Ampere), 50/60Hz (Continental Europe and The UK.)

Operating Temperature 41˚F ~ 95˚F (5˚C ~ 35˚C)

Storage Temperature 14˚F ~ 140˚F (-10˚C ~ 60˚C)

Remote Control Transmitters Wireless/Wired Remote Control, batteries AA, UM3 or R06 Type x 2

Condenser lens adjustment ❍●

Relay lens adjustment ❍●

Contrast Adjustment

R-Contrast adjustment ●

G-Contrast adjustment ●

B-Contrast adjustment ●

Output voltage adjustment ●

+16 V adjustment ●

Video center adjustment ●

PSIG adjustment ●

PC pedestal adjustment ●

Black level adjustment ●

PC gain adjustment ●

PC gamma shift adjustment ●

HDTV pedestal adjustment ●

HDTV A/D input adjustment ●

HDTV Gain adjustment ●

Video pedestal adjustment ●

Video A/D input adjustment ●

A/D offset adjustment ●

Video gain adjustment ●

Video gamma shift adjustment ●

Common center adjustment ● ●

White balance adjustment ❍ ❍

Disassembly / Replaced Parts

LCD/

Prism

Ass’y

Condenser

Lens

Polarized glass

RGB

Optical Adjustments

Electrical Adjustments

● :Adjustment necessary ❍ :Check necessary

Sub Power

Board Main Board

Relay

Lens

■Adjustments after Parts Replacement

Power

Board

-6-

●Interlock switch

The interlock switch (SW902) cuts off the AC mains power supply

when the lamp cover is removed. After opening the lamp cover for

replacing the lamp ass’y, place the lamp cover correctly otherwise

the projector can not turn on.

●Thermal switch

There is the thermal switch (SW905) inside of the projector to

prevent the internal temperature from rising abnormally. When the

internal temperature reaches near 90˚C, turn off the AC main

power supply automatically.

The thermal switch is not reset to normal automatically even if the

internal temperature becomes normal. Reset the thermal switch

following procedure.

Check the resistance between terminals of thermal switch by

using the tester. If it has high impedance, thermal switch may be

in operative.

How to reset the thermal switch

1. Loosen 2 screws and open the lamp cover.

2. Press the reset button on the thermal switch with a sharp-

pointed tool.

CAUTION:

Before press the reset button, disconnect the AC cord from the

projector.

■Circuit Protections

This projector is equipped with the following circuit protections to operate in safety. If the abnormality occurs inside

the projector, it will automatically turn off by operating one of the following protection circuits.

●Fuse

The fuse is located inside of the projector. When either the LAMP

indicator or the READY indicator is not illuminated, fuse may be

opened. Check the fuse as following steps.

It should be used the specified fuse as follows;

How to replace the fuse

1. Remove the cabinet top following to “Mechanical

Disassemblies”.

2. Remove the fuse from fuse holder.

To install the fuse, take reversed step in the above.

Fuse Part No.: 423 021 7801

TYPE T6.3AH 250V FUSE

LITTEL FUSE INC. TYPE 21506.3

Fuse Line Filter Board

Interlock switch

Thermal switch

Lamp cover

-7-

Circuit Protections

●Warning temperature and power failure protection

The TEMP WARNING indicator flashes red and the projector will automatically turn off when the internal tempera-

ture of the projector exceeds the normal temperature or when stopping cooling fans or when the internal power

supply lines are failed.

Check the following possible causes and wait until stopping the TEMP WARNING indicator flashing.

Possible causes

- Air filter is clogged with dust particles. Remove dust from the air filter by following instructions in the “Air filter

care and cleaning” below.

- Ventilation slots of the projector are blocked. In such an event, reposition the projector so that ventilation slots are

not obstructed.

- Check if projector is used at higher temperature place (Normal operating temperature is 5 to 35 ˚C or 41 to 95˚F)

If the TEMP WARNING indicator still continues to flash, there may be defects on cooling fans or power supply cir-

cuits. Please check fan operation and power supply lines referring to the “Power Supply Lines Chart”.

Air filter care and cleaning

The removable air filter prevents dust from accumulation on the surface of the projection lens and projection mirror.

Should the air filter become clogged with dust particles, it will reduce the cooling fan’s effectiveness and may result

in internal heat build up and reduce the life of the projector.

To clean up the air filters, follow the cleaning procedure

below:

1. Turn the power off, and disconnect the AC power cord

from the AC outlet.

2. Turn the projector up side down and remove an air fil-

ters by pulling the latches of them upward.

3. Clean the air filters with brush or wash out the dust and

particles.

4. Replace each air filter properly. Make sure that the air

filters are fully inserted.

CAUTION:

Do not operate the projector with the air filter removed. The

dust is stuck on the LCD panel and the mirror, and it may

spoil the fine picture image.

Do not put the small parts into the air intake vents. It may

result in the malfunction of the projector. The air filter is

small parts. Take care that children don’t eat or swallow it.

RECOMMENDATION

We recommend to avoid dusty, smoky place for operating the projector. Using in dusty place may cause the picture

of poor quality.

When using under the dusty or smoky conditions, dust may accumulate on the LCD panel and lens inside it, and

may resultantly be projected on the screen together with the picture.

When the above symptoms are noticed, please clean up the LCD panel and lens following to the “Cleaning

Method”.

Air filters

-8-

1Remove 5 screws A, 2 screws B, and loosen 2 screws

C, and then take the Cabinet Top upward off.

Note: If you want to remove the Cabinet Front-Top only,

you do not need to remove screws A.Remove 2 screws B

and Lens Front Cover.

■Mechanical Disassemblies

Mechanical disassemble should be made following procedures in numerical order.

Following steps show the basic procedures, therefore unnecessary step may be ignored.

Caution:

The parts and screws should be placed exactly the same position as the original otherwise it may cause loss of

performance and product safety.

Fig.1

1Turn the Lens Front Cover counter-clockwise and to take

it off by pulling forward as shown in Fig.2-1.

2Remove the Cabinet Front-Top, Lens Cover Holder and

Lens Cover upward off.

3Remove 2 screws Dto take the Cabinet Front off.

4Remove the RC Board and speakers on the Cabinet

Front.

Fig.2-2

Cabinet Top removal

Cabinet Front removal

Fig.2-1

Cabinet Front-Top

Lens

Front

Cover

Lens Cover Holder

Cabinet Front

Lens Cover

-9-

Mechanical Disassemblies

1Remove 7 screws to take the Main Board upward.

Fig.3

Fig.4

1Remove 2 screws A and take the Rear Panel ass’y

upward off.

2Remove 4 screws Bto take the fan (FN905) off.

3Remove 5 screws Cand 1 screw Dto take AV Board

from the Rear Panel ass’y off.

Main Board removal

AV Board & Rear Panel removal

Main Board

Rear Panel Ass’y

FN905

AV Board

-10-

Mechanical Disassemblies

1Remove 4 screws Ato take the Ballast Cover upward

off.

2Remove 2 screws Bto take the Fan (FN903) off.

3Remove the Sub Power Board and Drive Board by

pulling them upward.

Fig.5

1Remove 2 screws Aand 4 screws B(small) and pull the

Optical Unit upward off.

2Remove 4 screws Cto take the Fan (FN906) off.

3Remove 1 screws Dto take the Fan (FN904) off and 2

screws Eto take the air duct off.

Fig.6

Lamp Ballast Unit removal

Optical Unit removal

Ballast Board

FN903

Sub Power

Board

Drive Board

Ballast Cover

FN906

FN904

Optical Unit

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