Sanyo PLV-Z5 Bedienungsanleitung

Multimedia Projector

SERVICE MANUAL

PRODUCT CODE

PLV-Z5 PLV-Z5BK

1 122 365 00 (MC4A) 1 122 365 20 (MC4AA)

1 122 366 00 (PC4A) 1 122 366 20 (PC4AA)

1 122 366 02 (PC4C) 1 122 366 22 (PC4CA)

Original Version

REFERENCE NO. SM5110808-00

FILE NO.

Model No. PLV-Z5

PLV-Z5BK

U.S.A., Canada,Europe,

Asia, Africa,U.K.

Chassis No. MC4-Z500

MC4-Z5BK00

NOTE: Match the Chassis No. on the Cabinet

Bottom 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

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

■Specifications ........................................................................................................4

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

■Maintenance and Cleaning ....................................................................................7

■Lamp Replacement ..............................................................................................12

■Mechanical disassemblies....................................................................................14

■Optical parts disassemblies..................................................................................30

●Optical parts location and direction ............................................................41

■Adjustments After Parts Replacement ................................................................45

■Optical Adjustment ..............................................................................................46

■Electrical Adjustment............................................................................................55

●Service Adjustment Menu Operation ..........................................................55

●Circuit Adjustment ......................................................................................56

●Service Adjustment Data Table ..................................................................60

●Location of Test Points................................................................................70

■Waveform ............................................................................................................71

■Chassis Block Diagram ........................................................................................72

■Power Supply Lines..............................................................................................80

■Troubleshooting....................................................................................................82

●No Power ....................................................................................................82

●No Picture ..................................................................................................84

■Control Port Functions..........................................................................................86

■IC Block Diagrams................................................................................................88

■Service Parts List ................................................................................................93

●Electrical Parts List ....................................................................................93

●Mechanical and Optical Parts List ..........................................................109

Drawings & Diagrams .................................................................................. A1-A14

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

■Schematic diagrams...................................................................................... A3-A8

■Printed wiring board diagrams .................................................................... A9-A12

■Pins description of ICs, transistors, diodes ...................................................... A13

■Note on soldering.............................................................................................. A14

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

identified with the line ( ) in the schematic diagram. For continued product safety and protection of person-

nel 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

provided 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, adjust-

ment 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 - 20kV) 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.

■Safety Instructions

- 3 -

0.7” wide TFT Active Matrix type, 3 panels

Multimedia Projector

10.2 lbs (5.0 kg)

15.04” x 4.99” x 11.98” (382 mm x 126.8 mm x 304.3 mm)

(not including raised portions)

1280 x 720 dots

2,764,800 (1280 x 720 x 3 panels)

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

H-sync. 15 ~ 80 KHz, V-sync. 50 ~ 100 Hz

Adjustable from 40” to 300”

41 ˚F ~ 95 ˚F (5 ˚C ~ 35 ˚C)

14 ˚F ~ 140 ˚F (-10 ˚C ~ 60 ˚C)

Owner’s Manual (CD-ROM)

Quick Reference Guide

AC Power Cord

Remote Control and Batteries

Air Blower

Projector Type

Net Weight

Dimensions (W x H x D)

Panel Resolution

Number of Pixels

Color System

Scanning Frequency

Projection Image size (Diagonal)

Operating Temperature

Storage Temperature

Accessories

LCD Panel System

●The specifications are subject to change without notice.

F 2.0 ~ 3.0 lens with f 21.3 mm ~ 42.6 mm with manual zoom and focus

3.9’ ~ 30.2’ (1.2 m ~ 9.2 m)

145 W

RCA Type x 1 (Video), RCA Type x 3 (Y, Pb/Cb, Pr/Cr) x 2 and Mini DIN 4 pin x 1 (S-video)

Projection Lens

Throw Distance

Projection Lamp

Video Input Jacks

(VGA) HDB 15 Terminal x 1

Computer Input Terminal

HDMI terminal 19 pin x 2

HDMI Input Terminal

0˚ to 7.7˚

Feet Adjustment

Power Source : AA or LR06 1.5V ALKALINE Type x 2

Operating Range : 16.4’ (5 m) / ± 30˚

Dimensions : 1.57” x 0.96” x 5.12” (40 mm x 24.4 mm x 130 mm)

Net Weight : 3.6 oz (102 g) (including batteries)

Remote Control

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

High Definition TV Signal

AC 100 ~ 120 V (2.4 A Max. Ampere), 50/60 Hz

(The U.S.A. and Canada)

AC 200 ~ 240 V (1.3 A Max. Ampere), 50/60 Hz

(Continental Europe and The U.K.)

Voltage and

Power Consumption

●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.

Technical Specifications

Mini DIN 8 pin x 1

Service Port Connector

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 standards against risk of

fire, casualty and electrical hazards.

The CE Mark is a Directive conformity mark of the European Community (EC).

Pixelworks ICs used.

- 4 -

■Specifications

- 5 -

■Circuit Protections

This projector provides 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.

A fuse(F601) is located inside of the projector. When

the POWER indicator is not lightning, the fuse may be

opened. Check the fuse as following steps.

The fuse should be used with the following type;

●Fuse

●Thermal switch

Fuse Part No. : 323 022 2105

TYPE T4.0AH 250V FUSE

LITTEL FUSE INC. TYPE 215004

How to replace the fuse

1. Remove the cabinet top and main board following to

"Mechanical Disassemblies".

2. Remove the fuse from fuse holder on the Filter

Board.

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

There is the thermal switch (SW902) inside of the pro-

jector to prevent the internal temperature rising abnor-

mally. When the internal temperature reaches near

90°C, the thermal switch cuts off the drive signal to the

lamp circuit automatically. The thermal switch is not

reset to normal automatically, even if the internal tem-

perature becomes normal. Reset the thermal switch fol-

lowing procedure.

Check the resistance between terminals of thermal

switch by using a tester. If it has high impedance, ther-

mal switch may be open.

How to reset the thermal switch

1. Remove the cabinet top ass'y following to

"Mechanical Disassemblies".

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

sharp-pointed tool.

CAUTION:

Before press the reset button, make sure that the AC

cord must be disconnected from the AC outlet.

Press

Thermal switch

(SW902)

Fuse (F601)

●Warning temperature and power failure protection

The projector will be automatically turned off when the internal temperature of the projector is abnormally high, or

the cooling fans stop spinning, or the power supplies in the projector are failed.

- If the WARNING indicator is flashing, it may detect the abnormal temperature inside the projector. Check the fol-

lowing possible causes and wait until the WARNING indicator stops flashing, and then try to turn on the projec-

tor.

- If the WARNING indicator lights red, it may defect the cooling fans or power supply circuits. Check fans opera-

tion and power supply lines referring to the chapter “Power supply & protection circuit” in the power Supply Lines

section.

Possible causes

- Air filters are clogged with dust particles. Remove dust from the air filters.

- 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)

- 6 -

LAMP COVER SWITCH

(SW8803)

LAMP COVER

The lamp cover switch (SW8803) cuts off the drive sig-

nal to the lamp circuit when the lamp cover is removed

or not closed completely.

After opening the lamp cover for replacing the lamp

unit, place the lamp cover correctly otherwise the pro-

jector can not turn on.

The projector provides 2 door switches against an acci-

dent of the automatic slide shutter.

The door switch-A(SW8801) turns ON when the slide

shutter is opened.

The door switch-B(SW8811) turns ON when the slide

shutter is closed.

If the slide shutter stops half-open after turning on, the

POWER indicator will blink orange and the projector

goes to stand-by mode after cooling. In this case,

press the POWER ON/STAND-BY button again.

If the slide shutter is closed during operation, the pro-

jector is automatically turned off for safety.

In this case, be sure to check the position of the slide

shutter. After opening or closing the slide shutter man-

ually, press the POWER ON/STAND-BY button and the

projector turns on.

●Door switches for automatic slide shutter

Slide shutter

Door switch-A

Door switch-B

●Lamp cover switch

Circuit Protection

- 7 -

■Maintenance and Cleaning

After long periods of use, dust and other particles will accumulate on the LCD panel, prism, mirror, polarized

glass, lens, etc., causing the picture to darken or color to blur. If this occurs, clean the inside of optical unit.

Remove dust and other particles using air spray. If dirt cannot be removed by air spray, disassemble and clean

the optical unit.

● Cleaning with air spray

1. Remove the cabinet top following to "Mechanical Disassemblies".

2. Clean up the LCD panel and polarized glass by using the air spray from the cabinet top opening.

Caution:

Use a commercial (inert gas) air spray designed for

cleaning camera and computer equipment. Use a

resin-based nozzle only. Be vary careful not to damage optical parts with the nozzle tip. Never use any kind of

cleanser on the unit. Also, never use abrasive materials on the unit as this may cause irreparable damage.

● Disassembly Cleaning

Disassembly cleaning method should only be performed when the unit is considerable dirty and cannot be suffi-

ciently cleaned by air spraying alone.

Be sure to readjust the optical system after performing disassembly cleaning.

1. Remove the cabinet top and main units following to "Mechanical Disassemblies".

2. Remove the optical base top following to"Optical Unit Disassemblies". If the LCD panel needs cleaning,

remove the LCD panel unit following to "LCD panel/Prism ass'y replacement".

3. Clean the optical parts with a soft cloth. Clean extremely dirty areas using a cloth moistened with alcohol.

Caution:

The surface of the optical components consists of multiple dielectric layers with varying degrees of refraction.

Never use organic solvents (thinner, etc.) or any kind of cleanser on these components.

Since the LCD panel is equipped with an electronic circuit, never use any liquids (water, etc.) to clean the unit.

Use of liquid may cause the unit to malfunction.

- 8 -

Cleaning the RGB panels

Blemishes such as dust and dirt on the internal optical components of the projector tend to degrade the

brightness of the screen and are likely to appear as a shadow on the screen, which can lead to deterioration of

image quality.

This projector is equipped with the RGB panel cleaning holes on the bottom for cleaning of the internal parts

(such as optical components) of the projector. When you use the projector for a lengthy period of time or a

shadow of dust appears on the projected screen, clean the inside of the projector.

Using the supplied air blower and with the Cleaning function in the Setting Menu, you can remove the dusts from

the projector.

CAUTION IN USING THE AIR BLOWER AND THE NOZZLE

●Turn the projector over when using the blower.

●Use only the supplied air blower and nozzle to keep the projector from being out of oder or

damaged. We could not guarantee the malfunction or breakage caused by other tools.

● Never use a commercially available compressed air duster. It causes the interior of the projector to

malfunction with release of cold liquid propellant.

● Put the projector on a soft cloth to prevent scratching the surface.

●Open the hole cover only when you clean the inside of the projector.

●Do not look into the holes. A strong light could damage your eyes. (Do not look into the Air intake

vent and Exhaust vent, either.)

●Use the blower and nozzle only to clean the projector. Do not attempt to use them for other

purposes. Do not use the blower and nozzle against persons (particularly to eyes, mouth or ear, and

so on). Be especially careful to ensure that children do not put the blower and nozzle into their

mouth and swallow them.

●Do not attempt to pull the nozzle out of the blower. If the nozzle happened to be pulled out, put it

back into the blower immediately.

●Do not use the blower supplied with this projector (model: Z5/Z5BK) to clean the other models: Z4,

Z3, and Z1X.

In the unlikely event that something goes wrong (smoke, a strange sound, an abnormal odor, and such) while you

are cleaning, turn off and unplug the projector immediately, then call the dealer where you purchased the

projector or service center.

✔Note:

•Dust might not be removed completely with these steps. In that case, contact the dealer where you pur-

chased the projector or service center.

If the nozzle is pulled out ....

The nozzle has the stopper. Put the stopper-side of the nozzle into

the blower. Put the nozzle firmly into the blower until the stopper

becomes invisible.

When putting the nozzle into the blower, hold near the stopper so

that it will not break.

Make sure not to attempt to pull the nozzle out of the blower.

Stopper

Hold near the stopper

of the nozzle.

Put the nozzle in

until the stopper

becomes invisible.

Put this end of the

nozzle into the

blower.

CAUTION

PROHIBITED

Maintenancw and Cleaning

- 9 -

Turn the projector on and press the MENU button to display

the On-Screen Menu. Select the Setting Menu with the

Point ed buttons. Press the Point 8or OK buttons to

access the sub-menu items.

Put the blower’s nozzle into a hole.

Blow air into the projector with the blower watching the

position of the dust from the screen.

Set the projector back into the right position, then press any

button on the top control or on remote control to quit the

Cleaning function.

Clean by using the Cleaning function in the Setting Menu

Select Cleaning and then press the OK or Point 8buttons.

The screen is blacked out temporarily.

Turn the projector over. Loosen the screw that secures the

hole cover, and then open the hole cover.

When cleaning is done, pull the blower out of the hole and

replace the hole cover and secure it with the screw.

Loosen the screw that

secures the hole

cover.

The nozzle will go no

further than a certain

point when it is put

into the hole. Do not

attempt to push the

nozzle in further, or it

could break and is

stuck inside of the

projector.

*Do not open the hole cover except when you clean the inside of the projector to

prevent foreign matters from getting into the projector. If it is open especially while

operating the projector, the optical parts could damage.

Which hole to put the nozzle in?

When you look at the screen:

●When a red spot (dust) is showed up, put the nozzle into

the R panel cleaning holes.

●When a green spot (dust) is showed up, put the nozzle

into the G panel cleaning holes.

●When a blue spot (dust) is showed up, put the nozzle into

the B panel cleaning holes.

Wave the nozzle back and forth inside of the projector.

(Do not attempt to bend the nozzle.)

Use only the supplied blower and nozzle.

Do not use a commercially available

compressed air duster. It causes the interior of

the projector to malfunction with release of cold liquid

propellant. We could not guarantee the malfunction of

breakage by using other tools.

Cleaning

Select Cleaning in the

Setting Menu.

Green

Red

Blue

LCD Panel

BOTTOM VIEW

Maintenancw and Cleaning

- 10 -

The air filters prevent dust from accumulating on the surface of the optical elements inside the projector. Should the

air filters become clogged with dust particles, it will reduce cooling fans’ effectiveness and may result in a buildup of

internal heat and adversely affect the life of the projector. Clean the air filters by following the steps below.

CAUTION

Do not operate the projector with the air filters

removed. Dust may accumulate on the LCD panel

degrading the picture quality of the projection mirror.

Do not put anything into the air intake vents. It may

result in malfunction of the projector.

RECOMMENDATION

We recommend avoiding dusty/smoky environments when

operating the projector. Usage in these environment may

cause a poor image quality.

When using the projector under dusty or smoky conditions, dust

may accumulate on a lens, LCD panels, or optical elements

inside the projector degrading the quality of a projected image.

When the symptoms above are noticed, contact your authorized

dealer or service station for proper cleaning.

Cleaning the Air Filters

Air Filter 2

(Intake Vent)

Air Filter 1

(Intake Vent)

Press the latch and release it. Take off the filter covers.

Do not try to pull the delicate filter part.

Remove dust and dirt with a soft brush or a vacuum

cleaner. Be careful not to damage the air filters and do

not clean them with water.

When the Air Filter 1 gets dusty and dirty, replace it

with a new one. For ordering the replacement filter,

contact your sales dealer.

Put the air filters back into the position and close the

filter covers. Do not push the delicate filter part. Make

sure that the air filters are properly and fully inserted.

Cleaning the Air Filter 1 and 2

Pull out the air filters.

When taking out the Air Filter 2, put your finger on the

air filters tab and pull.

Pull out the air filters.

Press the latch and take

off the filter covers.

Put your finger on the

air filter’s tab and

pull.

Latch

Arrows

When putting back this air fil-

ter, make sure that the arrows

on the filter are facing towards

the projector.

Arrow

Maintenancw and Cleaning

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