Sanyo PLC-SU40 Schematic
Multimedia Projector
SERVICE MANUAL
PRODUCT CODE
1 122 159 00 (MB3A)
1 122 160 00 (PB3A)
1 122 160 02 (PB3C)
1 122 159 20 (MB3AA)
Original Version
REFERENCE NO. SM5110451
FILE NO.
Model No. PLC-SU40
PLC-SU25
U.S.A., Canada,
Europe, Asia, Africa
Chassis No. MB3-SU4000
MB3-SU2500
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-
■ Contents
■ Safety Instructions ________________________________________________3
■ Specifications ____________________________________________________4
■ Adjustments after Parts Replacement ________________________________5
■ Circuit Protections ________________________________________________6
● Thermal switch ____________________________________________6
● Interlock switch ____________________________________________6
● Fuse ____________________________________________________6
● Warning temperature and power failure protection __________________7
■ Mechanical Disassemblies__________________________________________8
■ Optical Parts Disassemblies ______________________________________14
■ LCD Panel/Prism Ass’y Replacement ________________________________19
■ Lamp Replacement ______________________________________________20
■ Optical Adjustments ______________________________________________21
■ Electrical Adjustments ____________________________________________25
● Service Adjustment Menu Operation ____________________________25
● Circuit Adjustments ________________________________________26
● Test Points and Locations ____________________________________30
● Service Adjustment Data Table ________________________________31
■ Chassis Block Diagrams __________________________________________34
Chassis over view ____________________________________________34
Inputs & video signal processing stage ____________________________35
LCD panel driving stage ______________________________________36
Audio signal processing circuit __________________________________37
Motor driving circuit __________________________________________38
System controls ______________________________________________39
Power supply & protection circuit ________________________________40
■ Troubleshooting ________________________________________________42
No Power __________________________________________________42
No Picture __________________________________________________43
No Sound __________________________________________________45
Lens Motor Problems__________________________________________45
■ Control Port Functions ____________________________________________46
● System Control & I/O Port Table ______________________________46
■ Waveform ______________________________________________________48
■ Cleaning ______________________________________________________49
■ IC Block Diagrams ______________________________________________50
■ Service Parts List ____________________________________________59-87
Electrical Parts List ________________________________________59-80
Mechanical Parts List ______________________________________81-87
Drawings & Diagrams
■ Parts description and reading in schematic diagram____________________ A2
■ Schematic diagrams __________________________________________ A3-A9
■ Printed wiring board diagrams ________________________________ A11-A15
■ Pins description of ICs, transistors, diodes __________________________ A16
-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 identified 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 control 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
-4-
■ 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 standards against risk of fire, casualty and electrical hazards.
Projector Type Multi-media Projector
Dimensions (W x H x D) 13.11” x 3.52” x 9.96” (333mm x 89.5mm x 253mm)
Net Weight 9.5 lbs (4.3 kg)
LCD Panel System 0.8” TFT Active Matrix type, 3 panels
Panel Resolution 800 x 600 dots
Number of Pixels 1,440,000 (800 x 600 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 ~ 80kHz, V-sync. 50 ~ 100Hz
Projection Image Size (diagonal) Adjustable from 36” to 260”
Projection Lens F 1.9 ~ 2.1 lens with f 21.3mm ~ 25.6mm with motor zoom and focus
Throw Distance 3.6’ ~ 22.6’ (1.1m ~ 6.9m)
Projection Lamp 180watts
AV Input Jacks RCA Type x 3 (Video/Y, Cb/Pb, Cr/Pr) and Mini DIN 4 pin x 1(S-Video)
AV Audio Input Jacks RCA Type x 2
Computer Input Jacks DVI-I Terminal (Digital/Analog)
Computer Input/Monitor Output Terminal (VGA) HDB15 Terminal x 1 (This terminal is switchable)
Computer Audio Input Jack Mini Jack (stereo)
Control Port Connector Mini DIN 8 pin x 1
USB Connector USB Series B receptacle x 1
Audio Output Jacks RCA Type x 2
Internal Audio Amp. 1.0watt RMS (monaural)
Built-in Speaker 1 speaker, 1.18” x 1.57” (30mm x 40mm)
Feet Adjustment 0˚ to 15.6˚
Voltage and AC 100 ~ 120V (3.0A Max. Ampere), 50/60Hz (The U.S.A and Canada)
Power Consumption AC 200 ~ 240V (1.5A Max. Ampere), 50/60Hz (Continental Europe and the U.K)
Operating Temperature 41˚F ~ 95˚F (5˚C ~ 35˚C)
Storage Temperature 14˚F ~ 140˚F (-10˚C ~ 60˚C)
Remote Control Transmitters Wireless Remote Control, batteries AA, UM3 or R06 Type x 2
-5-
● : Adjustment necessary ❍ : Check necessary
■ Adjustments after Parts Replacement
Contrast Adjustment
R-Contrast adjustment ●
G-Contrast adjustment ●
B-Contrast adjustment ●
Condenser lens adjustment ❍●
Condenser lens-out adjustment ❍●
Relay lens-out adjustment ❍●
Fan voltage adjustment ●
Signal center adjustment ●
PSIG adjustment ●
Gain adjustment [PC] ●
Gain adjustment [Video] ●
Gain adjustment [Component] ●
Gamma gain adjustment [PC] ●
Gamma gain adjustment [AV] ●
Common center adjustment ● ●
Signal offset adjustment [PC] ●
Signal offset adjustment [AV] ●
White balance adjustment ❍ ❍
Disassembly / Replaced Parts
LCD/
Prism
Ass’y
Condenser
Lens
Polarized glass
RGB
Optical Adjustments
Electrical Adjustments
P. F .
Board
Main
Board
Condenser
Lens-Out
Relay
Lens-Out
Powe r
Board
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.
● 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.: 423 022 2102
TYPE T4.0AH 250V FUSE
LITTLE FUSE INC. TYPE 215004
-6-
● Interlock switch
The interlock switch (SW904) 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 (SW902) inside of the projector to
prevent the internal temperature rising abnormally. When the
internal temperature reaches near 100˚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. Remove cabinet top following to the “Mechanical
Disassemblies”.
2. Press the reset button on the thermal switch.
CAUTION:
Before press the reset button, make sure that the AC cord must
be disconnected from the AC outlet.
■ Circuit Protections
Thermal switch (SW902)
Reset Button
Line Filter Board
Fuse
-7-
Circuit Protections
● Warning temperature and power failure protection
The projector will be automatically turned off when the internal temperature of the projector exceeds the normal operating temperature, or the cooling fans stop, or the power supplies in the projector are failed.
- If the TEMP WARNING indicator (red) is flashing, it may detect the abnormal temperature inside the projector.
Check the following possible causes and wait until the WARNING TEMP indicator flashing stops, and then try to
turn on the projector.
- If both of the TEMP WARNING (red) and READY (green) indicators are flashing at the same time, It may defect the
cooling fans and power supply circuits. Check fan operation and power supply lines referring to the chapter “Power
supply & protection circuit” in the Chassis Block Diagram section.
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)
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. Tu rn the power off, and disconnect the AC power cord
from the AC outlet.
2. Tu rn the projector up side down and remove air filter by
pulling the latches of it upward.
3. Clean the air filter with brush or wash out the dust and
particles.
4. Replace the air filter properly. Make sure that the air fil-
ter is 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 filters are
small parts. Take care that children don’t eat or swallow it.
RECOMMENDATION
We recommend not to use the projector in dusty, smoky places. Using it in dusty place may cause the poor picture
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 filter
1 Remove 4 screws A (M3x6) to take the Cabinet Top Ass’y upward off.
2 Remove the Control Panel off from the Cabinet Top by lifting the edge of
control panel.
Fig.1
1 Remove 8 screws (M3x6) to take the Main Board upward off.
Fig.2
z Cabinet Top and Control Panel removal
x Main Board removal
A
A
A
A
Main Board
Control panel
Cabinet top
-8-
■ 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.
Screws Expression
(Type
Diameter x Length) mm
T type M Type
-9-
Mechanical Disassemblies
1 Remove 1 screw A (M4x8) to release grounding wires.
2 Pull the Rear Panel ass’y upward.
3 Remove 4 screws B (T3x6) and remove the AV Board.
4 Remove 4 screws C (T3x6) and remove the DVI Board.
5 Remove 4 screws D (T2.6x6) and remove the speaker.
6 Remove 1 screws E (T3x8) and remove the Sensor Board.
Fig.3
Fig.4
1 Remove 3 screws A (M3x4), 1 screw B (M3x8) and unhook 2 hooks C at
the both of left and right side, and the take the Front Panel ass’y off.
2 Remove 1 screw D (T3x8) to take the R/C Board off.
c AV , DVI, Temp Board and Speaker removal
v Front Panel and R/C Board removal
A
B
B
B
C
A
A
A
B
C
D
DVI board
AV board
Speaker
R/C board
B
C
C
D
D
E
Te mp board
-10-
Mechanical Disassemblies
1 Remove 1 screw A (M3x4) and remove SW902, and then remove 1 screw
B (M3x6) and disconnect the Lamp Socket.
2 Remove 2 screws C (M3x6) to take the Lamp Ballast ass’y upward off.
3 Remove 2 screws D (T2x6) to take the isolation sheet off.
4 Remove 4 screws E (T3x6) to take the lamp ballast board off.
Fig.5
1
Remove 3 screws A (M3x6) and pull the Filter Board ass’y upward.
2 Remove 1 screw B (M4x8) to take the grounding lead from the cabinet bottom.
3 Remove 4 screws C (T3x8) to take the Filter Board off.
Fig.6
b Lamp Ballast Unit removal
n Filter Board removal
B
Lamp ballast board
C
C
E
E
E
E
A
A
A
B
C
C
C
C
Filter board
D
D
Isolation sheet
A
Lamp ballast socket
SW902
-11-
Mechanical Disassemblies
1 Remove 4 screws A (M3x12) to take the Fan(FN901) off.
2 Remove 4 screws B (M3x8) to take the Fan(FN906) off.
3 Remove 3 screws C (M3x6) to take the Power Box Cover
upward off.
1 Remove 1 screw A (M3x6) to take the Lamp
Cover off.
2 Loosen 3 screws B to take the Lamp assembly by
pulling the handle.
Step to next procedure.
Fig.8-1
Fig.7
m Power Box Cover and Fans(FN901, FN906) removal
, Optical Unit removal (1)
A
A
A
A
B
BB
B
C
C
C
FN901
FN906
Power box cover
Lamp cover
Lamp ass’y
A
B
B
B
-12-
Mechanical Disassemblies
Step from previous procedure.
3 Remove 6 screws C (M3x8) to take the Optical Unit upward upward off.
To mount optical unit, mount optical unit first then mount the Lamp assembly
and Lamp Cover.
1 Remove 4 screws A (T3x6), 4 screws B (T3x8) to
take the Power Board ass’y upward off.
2 Remove 4 screws C (M3x6) to take the P. F. Board
from the Power Board.
3 Remove 3 screws D (M3x6) to take the Power
Board holder from the Cabinet Bottom.
Fig.9
. Power and P.F. Board removal
A
Power board
A
A
A
B
B
B
B
C
C
C
C
D
D
D
P. F. board
Fig.8-2
, Optical Unit removal (2)
Optical unit
C
C
C
C
C
C
-13-
1 Remove 1 screw A (M3x6) and take a Washer,
Spring and Interlock Switch lever.
2 Pull the Fan and duct ass’y upward, then remove the
2 screws B (M3x6) to take the Fan (FN905) off.
Fig.10
1 Remove 8 screws A (T3x8) and to take the Fan
Duct Top off and remove the Fans (FN902,
FN903, FN904).
2 Remove 4 screws B (M3x6) to take the Fan Duct
Bottom off from the Cabinet Bottom.
Fig.11
⁄0 Fan (FN905) removal
⁄1 Fans (FN902, FN903, FN904) removal
Interlock switch lever
A
B
B
FN905
A
A
A
A
A
A
A
B
B
B
B
FN904
FN903
FN902
Fan duct top
Mechanical Disassemblies
-14-
■ 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.
1 Remove the Front Panel following to “Front Panel Removal” on “Mechanical
Disassemblies”.
2 Remove 4 screws (M3x10) to take the Projection Lens ass’y off.
1 Remove 2 screws A (M2.5x6) and pull the Integrator Lens-In ass’y upward.
2 Remove 1 stoppers B and then take the Lens off from the holder.
Fig.1
Integrator Lens
* Lens should be placed as the
rugged surface side comes to
the holder side.
Fig.2-1
Fig.2-2
z Projection Lens removal
x Integrator Lens-In disassembly
Stopper B
A
A
-15-
Optical Pats Disassemblies
1 Remove 2 screws A (M2.5x6) and pull the Condenser Lens ass’y upward.
2 Remove 4 screws B (M2x4) to take the Lens off from the holder.
1 Remove 2 screws A (M2.5x6) and pull the Condenser Lens-Out ass’y
upward.
2 Remove 2 screws B (M2x4) to take the Lens off from the holder.
Note:
Should be place the lens as shown in the figure.
A
B
Condenser Lens
Fig.3-2
Fig.3-1
* Lens should be placed as the flat
surface side comes to the holder
side.
Holder
A
A
Fig.4-2
Fig.4-1
B
B
Holder
Condenser Lens-Out
A
c Condenser lens disassembly
v Condenser Lens-Out disassembly
B
B
B
Side View
-16-
Optical Parts Disassemblies
1 Remove 2 screws A (M2.5x6) and pull the Relay Lens-Out ass’y upward.
2 Remove 2 screws B (M2x4) to take the Lens off from the holder.
Note:
There is no mounting direction of the lens.
1 Remove each screw (M2.5x6) and pull the Polarized Glass-In ass’y
upward.
2 Unhook the stoppers and take the glass off upward.
Hooks
Polarized Glass-In
Fig.6-2
Fig.6-1
* Should be places the glass as the
film attached side comes to the
prism side.
Phase Sheet
A
Fig.5-2
Fig.5-1
B
B
Holder
Relay Lens-Out
A
b Relay Lens-Out disassembly
n Polarized Glass-In removal
-17-
Optical Parts Disassemblies
1 Remove 4 screws A (M2.5x4) and take the LCD/Prism ass’y off upward
from the optical unit.
2 Remove each screw B and take the glass off upward.
Note: The G-LCD panel has a pre-polarized glass is mounted between the
polarized glass-out (G) and LCD panel as Fig.7-2.
LCD Panel/
Prism Ass’y
Note:
Do not replace the LCD panel
separately otherwise it can
not obtain proper picture.
1 Remove 9 screws (M3x10) to take the Optical Unit Top off upward.
Fig.7-1
Fig.8
m Polarized Glass-Out/Pre-Polarized Glass removal
, Optical Unit Top removal
A
A
A
Optical Unit Top
LCD Panel/Prism
Ass’y
Fig.7-2
* Glasses should be placed as the
film attached side comes to the
LCD panel side.
LCD Panel
B
Polarized Glass-Out(G)
Pre-Polarized Glass
5
8
9
Fig.9
2
4
1
The printed marker
comes this side.
13
3
7
10
6
12
1 Mirror (W)
2 Integrator lens (OUT)
3Prism beam splitter (PBS)
4 Dichroic mirror (B)
5 Condenser lens (OUT)
6 Dichroic mirror (G)
7Relay lens (IN)
8 Mirror (R)
9 Condenser lens (R)
10 Condenser lens
11 Condenser lens (B)
12 Optical filter (UV cut)
13 Mirror (B)
Key No. Description
The printed marker
comes this side.
11
-18-
Optical Parts Disassemblies
When the optical parts in the optical unit mounting or assembling, the
parts must be mounted in the specified location and direction as
shown in figure below.
. Locations and Directions
Note: The arrows in the figure are indicated that
there are the direction of part placement.
Place each part as the printed marker on the
part comes to each arrow direction.
-19-
■ LCD Panel/Prism Ass’y Replacement
IMPORTANT NOTICE on LCD Panel/Prism Ass'y Replacement
LCD panels used for this model can not be replaced separately. Do not disassemble the LCD Panel/Prism Ass’y.
These LCD panels are installed with precision at the factory. When replacing the LCD panel, should be replaced
whole of the LCD panels and prism ass’y at once.
After replacing LCD Panel/Prism ass’y, please check the following points.
- Check that there is no color shading at the top, bottom, left or right of the screen. If there is, try to
remove the shading following to the chapter “Optical Adjustment”.
- Check the white balance. If it needs the adjustment, adjust the white balance following to the “White
Balance Adjustment” and “Common Centre Adjustment” in the chapter “Electrical Adjustment”.
- Check the white uniformity on the screen.
If you find the color shading at the some part of the screen, it needs to take the color shading adjustment. This adjustment should be performed by a computer and it also requires a special software
“Color Shading Correction”. The software will be supplied separately and can be ordered as follows;
COLOR SHADING CORRECTION Ver. 3.0
Service P
arts No. 645 056 6288
1 Remove the cabinet top and main board following to
“Mechanical Disassemblies”.
2 Remove 4 screws by using the 2.0 mm hex driver and
take the LCD Panel/Prism ass’y off upward from the
optical unit.
After replacing or installing the LCD Panel/Prism ass'y,
please make sure to obtain the best focus in both TELE
and WIDE zoom. If the focus adjustment is required,
please adjust the positioning of LCD Panel/Prism Ass’y by
following below procedure.
Mounting Procedure:
1 Loosen 4 screws A on the LCD Panel/Prism ass'y with
2.0 mm hex driver.
2 Tu rn the projector on and project the image with WIDE
zoom, and adjust the FOCUS control to obtain the best
focus.
3 Tu rn the ZOOM control to the TELE position.
4 Move the LCD Panel/Prism Ass’y backward or forward
(about 0mm ~ 0.8mm) to obtain the proper focus.
Confirm the focus at TELE and WIDE zoom.
5 Tighten 4 screws A to fix the LCD Panel/Prism ass'y.
Top View
A
A
A
A
LCD Panel/Prism Ass’y
LCD Panel/Prism Ass’y removal
Note on LCD Panel/Prism Ass’y Mounting
LCD Panel/Prism
Ass’y
Note:
Do not replace the LCD
panel separately otherwise
it can not obtain proper picture.
-20-
■ Lamp Replacement
The LAMP REPLACEMENT indicator will illuminate
when the total lamp used time reaches 2000 hours.
The total lamp used time is calculated by using the
below expression,
Total lamp used time = Teco + Tnormal (1+1/3)
Teco: used time in the Eco mode
Tnormal : used time in the Normal mode
This is to indicate that lamp replacement is required.
You can check the lamp used time following to the
below procedure.
1 Press and hold the e button on the projector for more
than 20 seconds.
2 The lamp used time in each normal mode and eco
mode and total used time are displayed on the bottom right corner of the screen briefly.
WARNING:
- For continued safety, replace with a lamp assembly of the same type.
- Allow the projector to cool for at least 45 minutes before you open the
lamp cover. The inside of the projector can become very hot.
- Do not drop the lamp module or touch the glass bulb! The glass can
shatter and cause injury.
Procedure
1 Tu rn off the projector and disconnect the AC cord. Allow the projector to
cool for at least 45 minutes.
2 Loosen 1 screws with a screwdriver and open the lamp cover.
3 Loosen 2 screws and pull out the lamp assembly by grasping the handle.
4 Replace the lamp assembly securely and tighten 2 screws.
5 Close the lamp cover and tighten 1 screw.
6 Connect the AC cord to the projector and turn on.
Note:
- Do not reset the Lamp Replace Counter, except after lamp is replaced.
- The projector can not be turned-on with lamp cover removed, because
when the lamp cover is removed, the interlock switch is also released to
switch off the mains power for safety.
7 Reset the Lamp Replace Counter, see below explanation.
1 Tu rn the projector on, and press the MENU button
and the on-screen menu will appear. Press the 7 or 8
button to move a red frame pointer to SETTING menu
icon.
2 Press the e button to move a red frame pointer to
“Lamp counter reset” and then press the SELECT
button.The message “Lamp replace counter reset?” is
displayed. Move the pointer to [Yes] and the press the
SELECT button.
3 Another confirmation dialog box appears and select
[Yes] to reset Lamp Replace Counter .
Please refer to the owners manual for further information.
Recommendation
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 short lamp life. We
recommend cleaning the air filter after the projection
lamp is replaced.
Refer to “Air Filter Cleaning”.
Total lamp used time
How to reset Lamp Replace Counter
How to check Lamp used time
Lamp cover
Lamp Assembly
Handle
ORDER REPLACEMENT LAMP
T
ype No.
Service Parts No.
POA-LMP53 610 303 5826
Lamp Age
Normal :
Eco:
0100 HOURS
0025 HOURS
0158 HOURS
-21-
■ Optical Adjustments
[Before Adjustment]
- Input a 100% of black raster signal.
[R/G/B-CONTRAST ADJUSTMENT]
1 Loosen a screw A (Fig.1-1/1-2) on the polarized glass mounting
base which you intend to adjust.
2 Turn the polarized glass mounting base as shown in Fig.1-1 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.
B-Polarized Glass
Mounting Base
R-Polarized Glass
Mounting Base
G-Polarized Glass
Mounting Base
A
A
A
Slot B
Fig.1-2
Fig.1-1
Polarized glass
mounting base
Main Board
A
Contrast 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 Condenser lens, Condenser
lens-out or Relay lens adjustment, you need to disconnect some connectors and FPC cables of LCD panels on the
main board.
Note: Do not disconnect connectors K8N, K8P and K8H on the main board, because the projector can not turn on
due to operate the power failure protection.
1 Tu rn the projector on by a state of without FPC cables.
2 Project only green light on the screen.
3 Adjust the adjustment base of condenser lens assy to make color
uniformity in green.
1) If the shading appears on the left or right of the screen as
shown in Fig.2-1, loosen 2 screws A with the 2.0mm hex driver, and adjust the slot B to make color uniformity in green by
using a slot screwdriver.
2) If the shading appears on the top or bottom of the screen as
shown in Fig.2-2, loosen 2 screws C with the 2.0mm hex driver, and adjust the slot D to make color uniformity in green by
using a slot screwdriver
4 Tighten screws A and C to fix the Condenser lens unit.
Note:
The relay lens adjustment must be carried out after completing this
adjustment.
-22-
Optical Adjustments
Condenser Lens adjustment
Fig.2-2
y
x
Moving of Slot D
Slot D
C
a
b
a
b
Moving of slot B
Fig.2-1
Slot B
A
C
y
x
Green
Green
A
-23-
Optical Adjustments
1 Tu rn the projector on by a state of without FPC cables.
2 Project green and blue lights on the screen.
3 Adjust the adjustment base of condenser lens-out assy to make
color uniformity in cyan.
1) If the shading appears on the left or right of the screen as shown
in Fig.3-1, loosen 1 screw A with the 2.0mm hex driver, and
adjust the slot B to make color uniformity in cyan by using a slot
screwdriver.
2) If the shading appears on the top or bottom of the screen as
shown in Fig.3-2, loosen 1 screw C with the 2.0mm hex driver,
and adjust the slot D to make color uniformity in cyan by using a
slot screw driver.
4 Tighten the screw A and C to fix the relay lens unit.
Fig.3-1
A
Slot B
a
b
b
Moving of slot B
a
Cyan
Fig.3-2
D
Moving of slot D
y
x
C
Condenser Lens-Out adjustment
y
x
Cyan
1 Tu rn 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 assy to make color unifor-
mity in white.
1) If the shading appears on the left or right of the screen as shown
in Fig.4-1, loosen 1 screw A with the 2.0mm hex driver, and
adjust the slot B to make color uniformity in white by using a slot
screwdriver.
2) If the shading appears on the top or bottom of the screen as
shown in Fig.4-2, loosen 1 screw C with the 2.0mm hex driver,
and adjust the slot D to make color uniformity in white by using
a slot screwdriver.
4 Tighten the screws A and C to fix the relay lens unit.
Fig.4-1
A
Slot B
a
b
b
Moving of slot B
a
White
Fig.4-2
Slot D
Moving of slot D
y
x
C
y
x
Relay lens-Out adjustment
White
-24-
Optical Adjustments
-25-
■ Electrical Adjustments
To enter the service mode
To enter the “Service Mode”, press and hold the MENU and IMAGE button on the projector at the same time for
more than 3 seconds. The service menu appears on the screen as follows.
To adjust service data
Select the adjustment item no. by pressing the e or d button, and change the data value by pressing the 7 or
8 button. Refer to the “Service Adjustment Data Table” for further description of adjustment item no. and data
value.
To exit the service mode
To exit the service mode, press the POWER ON-OFF button on the projector or remote control unit.
● Service Adjustment Menu Operation
IC351 on the main board stores the data for the service adjustments, and should not be replaced except for
the case of defective device.
If replaced, the re-adjustments are required following to
the “Electrical Adjustments”.
The data of lamp replacement counter is stored in the
IC351.
Please note that the lamp replace counter will be reset
when the memory IC (IC351) is replaced.
(Lamp replace counter can not be set to the previous
value.)
● Caution to memory IC replacement
When IC351 is replaced with new one, the CPU writes
down the default data of the service adjustments to the
replaced IC as the mentioned on the service adjustment table. As these data are not the same data as factory shipped data, it should be required to perform the
re-adjustments following to the “Electrical Adjustments”.
Please note that in this case the lamp replace counter
will be reset.
● Caution of Main Board replacement (in the case
IC351 is not defective)
When the main board is replaced, IC351 should be
replaced with the one on previous main board. After
replacement, it should be required to perform the readjustments following to the “Electrical Adjustments”.
In this case, the lamp replace counter can be kept the
value as before.
● Memory IC Replacement
Data value
Item No.
Service Mode
Computer
1 158
1.00
-26-
[Adjustment Condition]
● Input signal
Video signal .......................... 1.0Vp-p/75Ω terminated, 16 steps gray
scale (Composite video signal)
Computer signal .................... 0.7Vp-p/75Ω terminated, 16 steps gray
scale pattern (SVGA)
Component Video signal ...... 0.7Vp-p/75Ω terminated, 16 steps gray
scale (Component video signal with
480p or 1080i format)
● Picture control mode .............. “STANDARD” mode unless otherwise
noted.
Note:
* Please refer to “Service Adjustment Menu Operation” for entering the service mode and adjusting the service
data.
● Circuit Adjustments
CAUTION: The each circuit has been made by the fine adjustment at factory. Do not attempt to adjust the follow-
ing adjustments except requiring the readjustments in servicing otherwise it may cause loss of performance and product safety.
Electrical Adjustments
16 steps gray scale pattern
After replacing the Power Board, PF.C. Board, readjust
the Output voltage adjustment as follows.
1. Connect a digital voltmeter to pins 1 (+) and 3 (-) of
K6D.
2. Adjust the voltage by using VR611 as following.
AC Input Reading
230V 370V ±2V
Caution:
Be sure to connect the lamp when taking this adjustment.
Output Voltage adjustment
1. Set the lamp mode to “ECO” with the menu function.
2. Enter the service mode and select item no. “74”. Set
data value to “1”.
3. Connect a digital voltmeter to test point “TP12V1”
(+) and chassis ground (-). Select item no. “75”and
adjust the voltage to be 8.0 ±0.1Vdc by changing
the Data value.
4. Connect a digital voltmeter to test point “TP12V2”
(+) and chassis ground (-). Select item no. “76”and
adjust the voltage to be 9.0 ±0.1Vdc by changing
the Data value.
5. Select item no. “74” and set data value to “3”.
6. Connect a digital voltmeter to test point “TP12V1”
(+) and chassis ground (-). Select item no. “77”and
adjust the voltage to be 13.5 ±0.1Vdc by changing
the Data value.
7. Connect a digital voltmeter to test point “TP12V2”
(+) and chassis ground (-). Select item no. “78”and
adjust the voltage to be 13.5 ±0.1Vdc by changing
the Data value.
8. Select item no. “74” and set Data value to “0”, and
set the lamp mode to “Normal” with the menu function.
z Fan Voltage adjustment
* This adjustment is not required even if the power
board is replaced because this adjustment is carried
out before parts shipment.
White 100%
Black 100%
-27-
Electrical Adjustments
1. Receive the 16-step grey scale computer signal with
Computer [Analog RGB] mode.
2. Enter the service mode.
3. Connect a digital voltmeter to test point “TP505R”
(+) and chassis ground (-).
4. Select item no. “1 and adjust the voltage to be 7.50
±0.1Vdc by changing the Data value.
5. Connect a digital voltmeter to test point “TP503G”
(+) and chassis ground (-).
6. Select item no. “2” and adjust the voltage to be 7.50
±0.1Vdc by changing the Data value.
7. Connect a digital voltmeter to test point “TP501B”
(+) and chassis ground (-).
8. Select item no. “3” and adjust the voltage to be 7.50
±0.1Vdc by changing the Data value.
x Signal Center adjustment
1. Receive the 16-step gray scale computer signal with
Computer [Analog RGB] mode.
2. Enter the service mode.
3. Connect an oscilloscope to test point “TP3501”(+)
and chassis ground (-).
4. Select item no. “22” and adjust the amplitude “a” to be
10.0 ±0.1V by changing the Data value.
5. Select item no. “23” and adjust the amplitude “b” to be
3.8 ±0.1V by changing the Data value.
c PSIG adjustment
1. Receive the 16-step gray scale computer signal with
Computer [Analog RGB] mode.
2. Enter the service mode.
3. Connect an oscilloscope to test point “TP505R”(+)
and chassis ground (-).
4. Select item no. “4” and adjust the amplitude “a” to be
minimum by changing the Data value.
5. Connect an oscilloscope to test point “TP503G”(+)
and chassis ground (-).
6. Select item no. “5” and adjust the amplitude “a” to be
minimum by changing the Data value.
7. Connect an oscilloscope to test point “TP501B”(+)
and chassis ground (-).
8. Select item no. “6” and adjust the amplitude “a” to be
minimum by changing the Data value.
v Gain adjustment [PC]
1. Receive the 16-step gray scale composite video signal with Video [Video] mode.
2. Enter the service mode.
3. Connect an oscilloscope to test point “TP505R”(+)
and chassis ground (-).
4. Select item no. “4” and adjust the amplitude “a” to be
minimum by changing the Data value.
5. Connect an oscilloscope to test point “TP503G”(+)
and chassis ground (-).
6. Select item no. “
5” and adjust the amplitude “a” to be
minimum by changing the Data value.
7. Connect an oscilloscope to test point “TP501B”(+)
and chassis ground (-).
8. Select item no. “6” and adjust the amplitude “a” to be
minimum by changing the Data value.
b Gain adjustment [Video]
White Level
(a)
(a)
(b)
White Level
(a)
-28-
Electrical Adjustments
1. Receive the 1 dot black & white pattern computer signal with Computer [Analog RGB] mode.
2. Enter the service mode.
3. Project only red light component to the screen.
4. Select item no. “19” and change data value to obtain
the minimum flicker on the screen.
6. Project only green light component to the screen.
7. Select item no. “20 and change data value to obtain
the minimum flicker on the screen.
8. Project only blue light component to the screen.
9. Select item no. “21” and change data value to obtain
the minimum flicker on the screen.
. Common Center adjustment
1. Receive the 16-step gray scale component video signal [480i] with Video [Y,Cr,Cb] mode.
2. Enter the service mode.
3. Connect an oscilloscope to test point “TP505R”(+)
and chassis ground (-).
4. Select item no. “4” and adjust the amplitude “a” to be
minimum by changing the Data value.
5. Connect an oscilloscope to test point “TP503G”(+)
and chassis ground (-).
6. Select item no. “5” and adjust the amplitude “a” to be
minimum by changing the Data value.
7. Connect an oscilloscope to test point “TP501B”(+)
and chassis ground (-).
8. Select item no. “6” and adjust the amplitude “a” to be
minimum by changing the Data value.
n Gain adjustment [Component]
1. Receive the 16-step gray scale computer signal with
Computer [Analog RGB] mode.
2. Enter the service mode.
3. Connect an oscilloscope to test point “TP505R”(+)
and chassis ground (-).
4. Select item no. “13” and adjust the amplitude “a” to
be 4.0 ±0.1V by changing the Data value.
5. Connect an oscilloscope to test point “TP503G”(+)
and chassis ground (-).
6. Select item no. “14” and adjust the amplitude “a” to
be 4.0 ±0.1V by changing the Data value.
7. Connect an oscilloscope to test point “TP501B”(+)
and chassis ground (-).
8. Select item no. “15” and adjust the amplitude “a” to
be 4.0 ±0.1V by changing the Data value.
m Gamma Gain adjustment [PC]
1. Receive the 16-step gray scale composite video signal with Video [Video] mode.
2. Enter the service mode.
3. Connect an oscilloscope to test point “TP505R”(+)
and chassis ground (-).
4. Select item no. “13” and adjust the amplitude “a” to
be 4.0 ±0.1V by changing the Data value.
5. Connect an oscilloscope to test point “TP503G”(+)
and chassis ground (-).
6. Select item no. “14” and adjust the amplitude “a” to
be 4.0 ±0.1V by changing the Data value.
7. Connect an oscilloscope to test point “TP501B”(+)
and chassis ground (-).
8. Select item no. “15” and adjust the amplitude “a” to
be
4.0 ±0.1V by changing the Data value.
, Gamma Gain adjustment [AV]
White Level
(a)
(a)
(a)
-29-
Electrical Adjustments
1. Receive the 16-step gray scale computer signal with
Computer [Analog RGB] mode.
2. Enter the service mode.
3. Connect an oscilloscope to test point “TP503G”(+)
and chassis ground (-).
4. Select item no. “10” and adjust the amplitude “a” to
be 2.4 ±0.1V by changing the Data value.
⁄0 Signal Offset adjustment [PC]
[PC WHITE BALANCE ADJUSTMENT]
1. Receive the 16-step gray scale computer signal with
Computer [Analog RGB] mode.
2. Enter the service mode, select item no. “11” (Red) or
“12” (Blue), and change Data values respectively to
make a proper white balance.
[AV WHITE BALANCE ADJUSTMENT]
3. Receive the 16-step gray scale composite video signal with Video [Video] mode.
4. Enter the service mode, select item no. “11” (Red) or
“12” (Blue), and change Data values respectively to
make a proper white balance.
Confirm that the same white balance is obtained in
video and computer input.
⁄2 White Balance adjustment
If you find the color shading on the screen, please
adjust the white uniformity by using the proper computer and “Color Shading Correction” software supplied
separately. The software can be ordered as follows;
COLOR SHADING CORRECTION ver.. 3.0
Ser
vice Parts No. 645 056 6288
NOTE ON WHITE UNIFORMITY
ADJUSTMENT
1. Receive the 16-step gray scale composite video signal with Video [Video] mode.
2. Enter the service mode.
3. Connect an oscilloscope to test point “TP503G”(+)
and chassis ground (-).
4. Select item no. “10” and adjust the amplitude “a” to
be 2.4 ±0.1V by changing the Data value.
⁄1 Signal Offset adjustment [AV]
white level
(a)
white level
white level
(a)
white level
-30-
Electrical Adjustments
● MAIN BOARD
Test Points and Locations
K8H
K8N
P
K8
TP12R
TP12G
TP12B
TP503G
TP504G
TP6241
TP6221
TP6201
TPHS
TP501B
K5G
TPVS
TP502B
TPDVS
TPDHS
K5B
IC301
IC501
IC401
K8U
K8A
IC801
IC811
K8B
TPV3148
IC3801
IC3101
TPV3143
TP3501
IC531
K5R
TP506R
TP3531
TP505R
TP12V1
TP12V2
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