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M4J-Z100
Service Manual
67 pgs5.21 Mb0

Sanyo M4J-Z100, PLV-Z1 Service Manual

PRODUCT CODE
1 122 115 00 PLV-Z1 (M4JA)
1 122 116 00 PLV-Z1 (P4JA)
1 122 116 02 PLV-Z1 (P4JC)
REFERENCE NO. SM5110416-00
CONTENTS
Pages
TECHNICAL SPECIFICATIONS ------------------------------------------------------------- 2
Multimedia Projector
SERVICE MANUAL
FILE NO.
Model No. PLV-Z1
(U.S.A., Canada, Europe
Asia, Africa, U.K. )
ORIGINAL VERSION Chassis No. M4J-Z100
(PLV-Z1)
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.
-2-
■ Technical Specifications
0.7" Wide TFT Active Matrix type, 3 panels
Multi-media Projector
7.5lbs (3.4 kg)
13.11" x 4.27" x 9.70" (333mm x 108.5mm x 246.5mm)
(not including Adjustable Feet)
964 x 544 dots
1,555,200 (964 x 544 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 30” to 200”
41 ˚F ~ 95 ˚F (5 ˚C ~ 35 ˚C)
14 ˚F ~ 140 ˚F (-10 ˚C ~ 60 ˚C)
Owner’s Manual AC Power Cord Remote Control and Batteries Video Cable
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 2.03 ~ 2.34 lens with f 21.2 mm ~ 25.4 mm with manual zoom and focus
3.6’ ~ 19.7’ (1.1 m ~ 6.0 m)
130 W
RCA Type x 4 (Video, Y, Pb/Cb, Pr/Cr) 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
0˚ to 11.8˚
Feet Adjustment
Power Source : AA, UM3 or R06 Type x 2 Operating Range : 16.4’ (5m) / ±30˚ Dimensions : 1.85” x 1.18” x 6.26” (47mm x 30mm x 159mm) Net Weight : 4.4oz (125g) (including batteries)
Remote Control
480i, 480p, 575i, 575p, 720p, 1035i, 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 (1.2 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
-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.
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 cabi-
net or on the chassis.
3: When replacing a chassis in the cabinet, always be certain that all the protective devices are installed proper-
ly, 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.
■ SAFETY PRECAUTIONS
■ 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 the parts must be made by exactly the same parts.
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 is 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(20~25kV) 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.
■ SERVICE PERSONNEL WARNING
-4-
■ Lamp Replacemant
■
Lamp Replacement
When the life of the projection lamp draws to an end, the LAMP REPLACE indicator lights yellow. When this indicator lights yellow, replace the projection lamp with a new one promptly.
ORDER REPLACEMENT LAMP
Replacement Lamp can be ordered through your dealer. When ordering a Projection Lamp, give the following information to the dealer.
● Model No. of your projector : PLV-Z1 / PLV-Z1BL
● Replacement Lamp Type No. : POA-LMP54
(Service Parts No. 610 302 5933)
FOR CONTINUED SAFETY, REPLACE WITH A LAMP ASSEMBLY OF THE SAME TYPE. DO NOT DROP A LAMP ASSEMBLY OR TOUCH A GLASS BULB! THE GLASS CAN SHATTER AND MAY CAUSE INJURY.
ALLOW A PROJECTOR TO COOL, FOR AT LEAST 45 MINUTES BEFORE YOU OPEN LAMP COVER. THE INSIDE OF A PROJECTOR CAN BECOME VERY HOT.
ARNING
TEMP
REPLACECE
EREADY
LAMP
ON-OFF
CAUTION
Follow these steps to replace the lamp assembly.
LAMP ASSEMBLY
HANDLE
LAMP COVER
This indicator lights yellow when the life of the projection lamp draws to an end. Replace the Projection Lamp with a new one.
SCREW
SCREW
SCREW
TOP CONTROL
1. Turn off the projector and disconnect AC plug. Allow the projector
to be cooled for at least 45 minutes.
2. To remove the Lamp cover, remove the screw with a screwdriver.
3. Remove 2 screws with a screwdriver and pull out the Lamp assem-
bly by grasping the handle.
4. Replace the Lamp assembly with a new one and tighten 2 screws
back into position. Make sure that the Lamp assembly is set prop­erly. Replace the Lamp cover and tighten the screw.
5. Connect the AC Power Cord to the projector and turn on the projec-
tor.
6. Reset the Lamp Replace Counter.
Refer to “Lamp Replace Counter” on the next page .
NOTE : Do not reset the Lamp Replace Counter when the
Projection lamp is not replaced.
LAMP
REPLA
WARNING
TEMP
.
ON-OFF
R
-5-
■
Lamp Replacement
Be sure to reset the Lamp Replace Counter after the Lamp assembly is replaced. After the Lamp Replace Counter is reset, the LAMP REPLACE indicator stops lighting.
NOTE : Do not reset the Lamp Replace Counter before the Projection lamp is replaced.
This projector uses a high-pressure lamp which must be handled carefully and properly. Improper
handling may result in accidents, injury, or create a fire hazard.
● Lamp lifetime may differ from lamp to lamp and according to the environment of use. There is no
guarantee of the same lifetime for each lamp. Some lamps may fail or terminate their lifetime in a shorter period of time than other similar lamps.
● If the projector indicates that the lamp should be replaced, i.e., if the LAMP REPLACE INDICATOR
lights up, replace the lamp with a new one IMMEDIATELY after the projector has cooled down. ( Follow carefully the instructions in the Lamp Replacement section of this manual. ) Continuous use of the lamp with the LAMP REPLACE INDICATOR lighted may increase the risk of lamp explosion.
● A Lamp may explode as a result of vibration, shock or degradation as a result of hours of use as its
lifetime draws to an end. Risk of explosion may differ according to the environment or conditions in which the projector and lamp are being used.
IF A LAMP EXPLODES, THE FOLLOWING SAFETY PRECAUTIONS SHOULD BE TAKEN.
If a lamp explodes, disconnect the projector’s AC plug from the AC outlet immediately. Contact an
authorized service station for a checkup of the unit and replacement of the lamp. Additionally, check
carefully to ensure that there are no broken shards or pieces of glass around the projector or coming out
from the cooling air circulation holes. Any broken shards found should be cleaned up carefully. No one
should check the inside of the projector except those who are authorized trained technicians and who are
familiar with projector service. Inappropriate attempts to service the unit by anyone, especially those who
are not appropriately trained to do so, may result in an accident or injury caused by pieces of broken
glass.
LAMP HANDLING PRECAUTIONS
Setting menu
Select "Yes" to reset.
■
Lamp Replacement Counter
1. Turn on the projector and press the MENU button. The main
menu appears. Select the Setting menu with the POINT UP/DOWN button, and then press the POINT RIGHT button to enter the sub-menu.
2. Choose the Lamp counter reset with the POINT UP/DOWN
button, and then press the SELECT button.
3. The message “Lamp replace counter reset?” is displayed.
Select "Yes" with the SELECT button, and the other confirma­tion display appears. Select "Yes" with the SELECT button to reset.
The LAMP REPLACE indicator stops lighting after the Lamp Replace Counter is reset.
-6-
■ Indicators and Projector Condition
LAMP
The projector is OFF.
READY
The projector is READY to be turned on.
WARNING TEMP.
Indicator Projector Condition
LAMP REPLACE
Check the Indicators for projector condition.
The projector is ON.
Red Light
Dim Light
Green Light
Off
The projector is OFF. (The MAIN ON/OFF switch is off, AC Power Cord is disconnected, or the front cover is closed.)
Red Flashing
Off
The temperature inside the projector is abnormally high. Flashing stops when the temperature returns to normal. The projector cannot be turned on until the indicator goes off.
The projector is operating normally.
Yellow Light
Off
The projection lamp needs to be replaced.
The projector is operating normally.
Off
The MAIN ON/OFF switch is off or AC Power Cord is disconnected.
The projector is in the Power management mode.
Green Flashing
■
Indicators and Projector Condition
-7-
■ Temp. Indicator and Cleaning
■
Warning Temp. Indicator
Follow these steps to clean the projection lens.
The WARNING TEMP. indicator flashes red when an internal temperature of the projector exceeds the normal temperature. The indicator stops flashing when the temperature of the projector returns to normal. When the WARNING TEMP. indicator continues to flash, check the items listed below.
AIR FILTER
The removable Air filter prevents dust from accumulating on the surface of the projection lens and projection mirror. Should the Air filter become clogged with dust particles, it will reduce the cooling fans’ effectiveness and may result in internal heat build up and adversely affect the life of the projector. Clean the Air filter by following the steps below.
CAUTION
Do not operate the projector with the Air filter removed. Dust may accumulate on the LCD panels and the projection mirror degrading picture quality. Do not put small parts into the Air intake vents. It may result in malfunction of the projector.
Operating Environment
We recommend avoiding dusty/smoky environments when operating a projector.
When using under dusty or smoky conditions, dust may accumulate on the lens, liquid crystal panels, or optical elements inside the projector. This condition may degrade the quality of a projected image and the life of the projector. When the above symptoms are noticed, contact your authorized dealer or service station for proper cleaning.
LATCH
ARNING
TEMP
LAMP
REPLACECE
EREADY
LAMP
ON-OFF
Warning Temp. indicator
TOP CONTROL
■
Air Filter Care and Cleaning
■
Cleaning the Projection Lens
1. Ventilation slots of the projector may be blocked. In such an event,
reposition the projector so that the Ventilation slots cannot be obstructed.
2. The Air filter may be clogged with dust particles. Clean the Air filter
by following the section "Air Filter Care and Cleaning" below.
3. If the WARNING TEMP. indicator remains on after performing the
above checks, the Cooling fans or the internal circuits may be mal­functioning. Contact service personnel from an authorized dealer or a service station.
1. Turn off the projector, and disconnect AC Power Cord from the AC
outlet.
2. Turn over the projector and remove the Air filter by pulling the latch
upward.
3. Clean the Air filter with a brush or wash out dust and particles.
4. Replace the Air filter properly. Make sure that it is fully inserted.
1. Apply a non-abrasive camera lens cleaner to a soft, dry cleaning cloth. Avoid using an excessive amount of cleaner.
Abrasive cleaners, solvents or other harsh chemicals might scratch a surface.
2. Lightly wipe the Projection lens with a cleaning cloth.
3. When the projector is not in use, close the front cover.
LAMP
REPLA
WARNING
TEMP
.
ON-OFF
R
-8-
■ Dimensions
■
Dimensions
ARNING TEMP
LAMP
LAMP
ON-OFF
SELECT
Unit : inch (mm)
13.11 (333)
9.70 (246.5)
4.27 (108.5)
11.8˚ (Max.)
LAMP
REPLACE
WARNING
TEMP
READY
.
LAMP
ON-OFF
MENU
SELECT
INPUT
-9-
■ Protections
This projector is equipped with the following protections to operate in safety. If the abnormality occurs inside the projector, it will turn off the projector by operating one of the following protections.
■
FUSE FOR CIRCUIT PROTECTION
The fuse is located on the ass'y-filter. When either the LAMP indicator or the READY indicator is not illuminated, fuse may be opened. Check the fuse as following steps.
1. Remove the ass'y-filter following to “Mechanical Disassemblies”.
2. Remove the fuse from fuse holder.
3. Check the resistance of fuse by using the tester.
To install the fuse, take reversed step in the above.
It should be used the specified fuse as parts list.
■
OVERHEATING PROTECTION
(The temperature monitor system )
The temperature monitor system is provided to prevents damage of component parts inside the pro­jector from overheat. Two protection systems are provided. Each system operating as follows.
■ Temperature monitor -1 :
When this function operates, warning-temperature-indica­tor flashes. And cooling fan continues operating until it becomes a normal temperature. If it continue to flush and flash does not stopped, disconnect the AC cord and inves­tigate the cause of overheating.
■ Temperature monitor -2 :
(thermostat switch SW902) This function (thermostat switch SW902) will not operate, while the temperature monitor -1 is operating normally. If it has operated, it needs to be reset manually. Disconnect the AC cord first and investigate the cause of overheating. After servicing, reset the thermostat switch (SW902) as shown in a figure.
Fuse
Ass’y Filter
SW902
-10-
■ Mechanical Disassemblies
1. CABINET - TOP REMOVAL
1. Remove six screws to take the Cabinet Top upward off.
2. MAIN BOARD AND THERMAL BARRIER PLATE REMOVAL
1. Remove six screws A to take the Main Board upward
off.
2. Remove the screw B to take the termal barrier plate
upward off.
Fig. 1
Fig. 2
A
A
A
A
A
A
B
Main Board
Thermal Barrier Plate
3. CABINET - FRONT REMOVAL
1. Open the door.
2. Remove the screw to take the Cabinet Front off.
Fig. 3
Cabinet Top
Cabinet Front
Door
-11-
■ Mechanical Disassemblies
4. DOOR REMOVAL
1. Remove two screws to take the Door off.
5. DOOR LEG AND DOOR SWITCH BOARD REMOVAL
1. Remove the screw to take each leg off.
2. Pull the Door Switch Board out.
Fig. 4
Door
Door
Door Switch Board
Door Leg
Fig. 5
6. AV BOARD REMOVAL
1. Remove three screws to take the AV Board upward off.
AV Board
Fig. 6
-12-
■ Mechanical Disassemblies
7. LAMP BALLAST UNIT REMOVAL
1. Remove four screws A to take the Lamp Ballast Cover
upward off.
2. Remove the screw B to disconnect the Lamp Ballast
Socket.
3. Remove five screws C to take the Lamp Ballast Unit off.
Lamp Ballast Unit
Fig. 7
A
A
A
A
B
C
C
C
C
C
Lamp Ballast Cover
8. POWER UNIT, R/C BOARD, AND FANS REMOVAL
1. Remove five screws A to take the Power Unit upward
off.
2. Remove three screws B to take the Power Unit Ass’y
upward off.
3. Remove two screws C to take the Fan (FAN904) off.
4. Remove two screws D to take the Fan (FAN903) off.
Fig. 8
A
Power Unit
R/C
A
A
A
A
B
B
B
C
C
D
D
Power Unit Ass’y
FAN904
FAN903
Note:
The transparent plates are fixed between the Lamp Ballast Unit and the Power Unit to
control the flow of air by the fans. After servicing, fix them to previous position.
-13-
■ Mechanical Disassemblies
9. OPTICAL UNIT, LAMP ASS’Y, AND FAN REMOVAL
1. Remove the screw A to take the Lamp Cover and the
Lamp Ass’s off.
2. Remove six screws B to take the Optical Unit upward
off.
3. Remove three screws C to take the Fan (FAN905) off.
Fig. 9
B
Optical Unit
B
B
B
B
B
A
C
C
C
Lamp Ass’y
Lamp Cover
FAN905
10. FILTER BOARD REMOVAL
1. Remove two screws A to take the Filter Cover upward
off.
2. Remove five screws B to take the Filter Board off.
Fig. 10
A
A
B
B
BB
B
Filter Board
Filter Cover
-14-
■ Mechanical Disassemblies
11. FANS REMOVAL
1. Remove seven screws A to take the Fan Cover and
Fan (FN902) off.
2. Remove two screws B to take the Fian (FN901) off.
Fig. 11
A
Fan Cover
A
A
A
A
A
A
B
B
FAN901
FAN902
-15-
■ Optical Parts Disassemblies
Before Taking this procedure, remove Cabinet Top and Main board following to the “Mechanical Disassemblies”. Disassembly requires a 2.0mm hex wrench and a screwdriver.
1.
PROJECTION LENS REMOVAL
1. Remove the Cabinet Front following to “CABINET ­FRONT REMOVAL” on “Mechanical Disassemblies”.
2. Remove four screws to take the Projection Lens with Cushion Ring off.
Fig. 1
Projection Lens
Cushion Ring
2. INTEGRATOR LENS REMOVAL
1. Remove two screws and pull the Integrator Lens Ass’y upward.
2. Remove the Stopper and bend four hooks and then take the Lens off from the Holder.
Integrator Lens
Stopper
Lens Holder
Fig. 2
Integrator Lens Ass’y
Note:
Should be placed the lens as the rugged surface side of it comes to the holder side.
-16-
■ Optical Parts Disassemblies
3. RELAY LENS REMOVAL
1. Remove two screws A and pull the Relay Lens Ass’y
upward.
2. Remove two screws B to take the Lens off from the
Holder.
Relay Lens
Relay Lens Ass’y
Fig. 3
A
B
A
B
4. POLARIZED GLASS-IN REMOVAL
1. Remove each screw and pull the Polarized Glass-In Ass’y upward.
2. Unhook the stoppers and take the glass off upward.
Polarized Grass Ass’y
Polarized
Grass-In
Phase Sheet
Hooks
Note:
Should be placed the giass as the film attached side come to the prism side.
Fig. 4
-17-
■ Optical Parts Disassemblies
5. POLARIZED GLASS-OUT REMOVAL
1. Remove four screw A and take the LCD Panel/Prism
Ass’y upward from the Optical Unit.
2. Remove each screw B and take the glass off upward.
LCD Panel/Prism Ass’y
Note:
1. Do not replace the LCD panel separately otherwise
it can not obtain proper picture
2. Should be replaced the glass as the film attached
side comes to the LCD panel side.
Fig. 5
Polarized
Grass-Out
LCD Panel
Note 2
A
A
A
A
B
6. OPTICAL UNIT TOP REMOVAL
1. Remove eight screws to take the Optical Unit Top off upward.
Fig. 6
-18-
■ Optical Parts Disassemblies
7. LOCATIONS IN OPTICAL UNIT
When mounting or assembling the optical parts in the optical unit, the parts must be mounted specified location as shown in figure below.
1 Mirror (B) X2 2 Optical Filter (UV Cut) 3 Condenser Lens (B) 4 Condenser Lens (G) 5 Condenser Lens (R) 6 Optical Filter (R, G) 7 Relay Lens (In) 8Dichroic Mirror (G)
9Dichroic Mirror (R) 10 Mirror (R) 11 Condensor Lens (Out) 12 Prism Beam Splitter (PBS) 13 Integrator Lens (Out)
Key No. Description
1
1
2
3
4
5
6
7
8
9
11
10
12
13
-19-
■ Optical Adjustment
Before taking optical adjustments below, remove the Cabinet Top and Main Board following to the “Mechanical Disassemblies” Adjustments require a 2.0mm hex wrench and a slot screwdriver. When you adjust Integrator lens or Relay lens adjustment, you need to disconnect some connectors and FPC cables of LCD panels on the main board. Note:
1. Do not disconnect connectors K56M, K56N, K48K, K8E, K8H, K66A, K66B, K66C, K66D and K66F on the main board, because the projector can not turn on or operate properly for adjustment.
2. In case of adjusting without the cabinet top, the setting for Fan Control is needed specially as shown below. (Refer to “Electrical Adjustment” to enter the service mode and adjust.) After servicing, set to previous data.
Adjustment Item: No. 51 Adjustment Data: “0” (With Cabinet Top) ➞ “1” (Without Cabinet Top)
[Before Adjustment]
- Input a 100% of black raster signal.
[R/G/B-CONTRAST ADJUSTMENT]
1. Loosen a screw A on the polarized glass mounting base which
you intend to adjust.
2. Turn the polarized glass mounting base as shown in Fig. 1 to obtain the darkest brightness on the screen.
3. Tighten the screw A to fix the polarized glass mounting base.
Repeat steps 1 to 3 for remaining polarized glasses.
Slot B
Polarized Glass Mounting Base
A
1. CONTRAST ADJUSTMENT
Fig. 1
B-Polarized Grass
Mounting Base
A
G-Polarized Grass
Mounting Base
A
R-Polarized Grass
Mounting Base
A
Fig. 2
-20-
■ Optical Adjustment
1. Turn the projector on by a state of without FPC cables.
2. Project all of lights on the screen.
3. Adjust the adjustment base of integrator lens ass’y to make color uniformity in white.
2. INTEGRATOR ADJUSTMENT
Fig. 3
1. Turn the projector on by a state of without FPC cables.
2. Project all of lights on the screen.
3. Adjust the adjustment base of relay lens ass’y to make color uniformity in white.
3. RELAY ADJUSTMENT
Fig. 4
-21-
■ Electrical Adjustment
■ SERVICE ADJUSTMENT MENU OPERATION
■ To enter service mode
To enter service mode press the "MENU" and "IINPUT"
buttons on the projector simultaneously and hold for 2
seconds. As shown in a figure, a service mode display
appears on a screen.
■ Adjustment
Adjust service data using the following control buttons.
1. "POINT UP" ------- An item number increases.
2. "POINT DOWN" -- An item number decreases.
3. "POINT RIGHT" -- An adjustment value increases.
4. "POINT LEFT" ---- An adjustment value decreases.
■ To exit service mode
Press the "POWER on/off" button only once on the projec-
tor or remote control unit to quit the service mode.
■ LOCATION OF TEST POINT
ASSY PWB MAIN
Normal Mode Service Mode
"MENU" "INPUT"
"POWER ON/OFF"
Service Mode
Computer
13710
Service Mode
Computer
13710
"Point Up / Down"
"Point Left / Right"
Adjustment item Adjustment deta value
TPB1
TPR1
TPG1
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