Sanyo PLC-XP57L Bedienungsanleitung

Multimedia Projector

SERVICE MANUAL

PRODUCT CODE

1 122 340 20 (KE6AL)

1 122 341 20 (LE6AL)

1 122 341 22 (LE6CL)

Original Version

REFERENCE NO. SM5110792-00

FILE NO.

Model No. PLC-XP57L

U.S.A., Canada,

Europe, Asia, Africa,

(Projection lens is optional.)

Chassis No. KE6-XP57L00

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.

RoHS

• This product does not contain any hazardous sub-

stances prohibited by the RoHS Directive. (You will

ﬁnd “RSF” mark near the rating plate on the RoHS

compliant product.)

!WARNING

• You are requested to use RoHS compliant parts for

maintenance or repair.

• You are requested to use lead-free solder.

- 2 -

Contents

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Circuit Protections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Mechanical Disassemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Optical Parts Disassemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

LCD Panel/Prism Ass’y Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Lamp Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Adjustments after Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Optical Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Electrical Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Service Adjustment Menu Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Circuit Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Test Points and Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Service Adjustment Data Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Chassis Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Chassis block diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

LED indication and projector condition . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Power failure detection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Power failure detection tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Diagnosis of power failure with RS-232C port . . . . . . . . . . . . . . . . . . . . .50

Error history log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Control Port Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

IC Block Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Electrical Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

Mechanical Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

Optical Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

Drawings & Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-A17

Parts description and reading in schematic diagram . . . . . . . . . . . . . . . . . . . . . A2

Schematic diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-A10

Printed wiring board diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-A16

Pins description of ICs, transistors, diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . A17

- 3 -

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 (about 8kV) 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.

- 4 -

Specifications

Owner’s Manual (CD-ROM)

Quick Reference Guide

AC Power Cord

Wireless/Wired Remote Control Transmitter and Batteries

VGA Cable

USB Cable

Control Cable for Serial Port

Lens Attachment

Lens Replacement And Installation Manual

PIN Code Label

Multi-media Projector

Accessories

●Specifications are subject to change without notice.

●LCD panels are manufactured to the highest possible standards. Even though 99.99% of the pixels are

effective, a tiny fraction of the pixels (0.01% or less) may be ineffective by the characteristics of the LCD

panels.

●Each projector has its own characteristics.

When projecting with several projectors on the same screen or side by side, you may recognize different

white balance and color uniformity on each projector.

1.3” TFT Active Matrix type, 3 panels

17.4 lbs (7.9 kg)

12.6” x 6.6” x 16.8” (319 mm x 168 mm x 429.5 mm)

1024 x 768 dots

2,359,296 (1024 x 768 x 3 panels)

PAL, SECAM, NTSC, NTSC4.43, PAL-M, and PAL-N

Up and Down

800 TV lines (HDTV)

41 ˚F ~ 95 ˚F (5 ˚C ~ 35 ˚C)

14 ˚F ~ 140 ˚F (-10 ˚C ~ 60 ˚C)

Projector Type

Net Weight

Dimensions (W x H x D)

Panel Resolution

Number of Pixels

Color System

Scanning Frequency

Horizontal Resolution

Operating Temperature

Storage Temperature

LCD Panel System

300 watt type

Projection Lamp

Power Source : AA or LR6 ALKALINE Type x 2

Operating Range : 16.4’ (5 m) / ± 30˚

Dimensions : 2.0” x 1.4” x 7.6” (50 mm x 36 mm x 193 mm)

Net Weight : 0.35 lbs (160 g) (including batteries)

Laser Pointer : Class II Laser (Max. Output: 1mW/Wave length: 650±20nm)

Remote Control Transmitter

480i, 480p, 575i, 575p, 720p, 1035i, and 1080i

High Definition TV Signal

H-sync. 15 kHz ~ 100 kHz, V-sync. 48 ~ 100 Hz

Motorized Lens Shift

DVI Terminal (Digital) HDCP Compatible, HDB 15-pin Terminal (Analog)

and Stereo Mini Type Jack (Audio)

Input 1 Jacks

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

Stereo Mini Type Jack (Audio)

Input 2 Jacks

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

and DIN 4-pin (S-Video)

Input 3 Jacks

DIN 8-pin (Control port), USB port (Series B receptacle), Wired Remote Jack

and PJ-Net Organizer Connector

Other Jacks

AC 100 ~ 120 V (5.7 A Max. Ampere), 50/60 Hz (The U.S.A and Canada)

AC 200 ~ 240 V (2.7 A Max. Ampere), 50/60 Hz

(Continental Europe and The U.K.)

Voltage and Power

Consumption

INT. SP. Stereo (R and L), 3 watt RMS (T.H.D. 10%)

Built-in Speakers

0˚ to 10.5˚

Feet Adjustment

- 5 -

●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 pre-

vent 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.: 323 025 1204

TYPE T8AH 250V FUSE

LITTEL FUSE INC. TYPE 215008

Interlock switch

Thermal switch

Lamp cover

Fuse Filter Board

- 6 -

Circuit Protections

●Warning temperature and power failure protection

The WARNING TEMP. 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 sup-

ply 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 WARNING TEMP. 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 the air filters

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 fil-

ters 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

- 7 -

Mechanical Disassemblies

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 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

- 8 -

Mechanical Disassemblies

1Remove 6 screws to take the Main Board upward.

Fig.3

Fig.4

1Remove 1 screw 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.

4Remove 2 screws Eand grounding leads and then pull

up the I/F Board and Holder assy from the bottom cabi-

net.

5Remove 4 screws Fto take the I/F Board.

Main Board removal

AV, I/F Board & Rear Panel removal

Main Board

Rear Panel Ass’y

FN905

AV Board

I/F Board

FEE

- 9 -

Mechanical Disassemblies

1Remove 4 screws Ato take the Ballast Cover upward

off.

2Remove 3 screws Bto take the Fan (FN904) and the

Fan mounting base off.

3Remove 2 screws Cto take the Fan (FN904) off from

the Fan mounting base.

4Remove the Sub Power Board and Drive Board by

pulling them upward.

Fig.5

Lamp Ballast Unit removal

Ballast Board

FN904

Sub Power

Board

Drive Board

Ballast Cover

1Remove 1 screw Aand then remove the holder.

2Remove 2 screws Band 4 screws C(small) and pull the

Optical Unit upward off.

3Remove 4 screws Dto take the Fan (FN906) off.

4Remove 1 screws Eto take the Fan (FN903) off and 2

screws Fto take the air duct off.

5Remove 3 screws Gto take the Fan (FN907) off.

Fig.6

Optical Unit removal

FN906

FN903

Optical Unit

FN907

- 10 -

1Remove 2 screws Ato take the Prism Base ass’y

upward off.

2Remove 2 screws Bto take the Lens Shift Motor and

Sensor SW Holder from the Base.

Mechanical Disassemblies

1Remove 3 screws Ato take the Power Board off.

2Remove 4 screws Bto take Holder off from the cabinet

bottom.

Fig.8

Fig.7

Prism Base removal

Power Board removal

Prism Base Ass’y

Motor and

Sensor Holder

Power Board

Holder

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