Sanyo PLC-WL2500A, PLC-WL2503A Instruction Manual

FILE NO.

Multimedia ProjectorSERVICE MANUAL

Model No. PLC-WL2500A PLC-WL2503A

U.S.A, Canada, Europe,

U.K, Asia, Brazil

Original Version

PLC-WL2500A

* Model PLC-WL2503A has an interactive module on the cabinet front. The illustrations in this manual are used for the model PLC-WL2500A.

Match the Chassis No. on the rating label on the projector with the Chassis No. in the Service Manual.

Chassis No. KJ8-WL2500A00 KJ8-WL2503A00

PRODUCT CODE PLC-WL2500A PLC-WL2503A 1 122 509 60 (KJ8AG) 1 122 509 80 (KJ8AH)

1 122 510 60 (LJ8AG) 1 122 510 80 (LJ8AH) 1 122 510 62 (LJ8CG) 1 122 510 82 (LJ8CH) 1 122 510 63 (LJ8DG) 1 122 510 83 (LJ8DH) 1 122 509 64 (KJ8EG) 1 122 509 84 (KJ8EH)

If the Original Version Service Manual Chassis No. does not match the projector’s, additional Service Literature is required. You must refer to “Notices” to the Original Service Manual prior to servicing.

PLC-WL2503A

REFERENCE NO. SM5111348-00

SERVICE MANUAL ....................................................... 1

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

Safety Instructions .........................................................

Safety Precautions ......................................................

Product Safety Notice .................................................

Service Personnel Warning ........................................

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

Circuit Protections .........................................................

Thermal switch ...........................................................

Fuse ............................................................................ 5

Lamp cover switch ......................................................

Warning temperature and power failure protection .....

Maintenance .................................................................. 7

Replacing the filters ....................................................

Resetting the filter counter ..........................................

Lamp replacement ......................................................

Resetting the lamp counter .........................................

How to check lamp used time .....................................

Attaching the lens cover ...........................................

Cleaning the projector ..............................................

Cleaning the projection lens .....................................

Cleaning the projector cabinet ..................................

Security Function Notice

Standby Mode Notice ..................................................

Mechanical Disassembly .............................................

Optical Parts Disassembly ...........................................

Adjustments ................................................................. 25

Adjustments after parts replacement ........................

Note on main board replacement .............................

Optical Adjustments .....................................................

Contrast adjustment

Condenser lens (OUT) adjustment ...........................

Relay lens (OUT) adjustment ...................................

Electrical Adjustments .................................................

Service adjustment menu operation .........................

Circuit adjustments ...................................................

Test points and locations ..........................................

Service adjustment data ..........................................

Chassis Block Diagrams ..............................................

Chassis over view .....................................................

System control ..........................................................

Power supply & protection circuit ..............................

Fan control circuit .....................................................

.............................................. 11

.................................................. 26

10 10 10 10

12 13 19

25 25 26

27 28 29 29 29 33 34 48 48 49 50 51

Troubleshooting ........................................................... 52

Indicators and rojector condition ...............................

No power ..................................................................

No picture .................................................................

No sound ..................................................................

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

Scaler I/O port functions (PW190) ............................

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

Parts Location Diagrams .............................................

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

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

Diagrams & Drawings ..................................................

Parts description and reading in schematic diagram ...

Schematic Diagrams ...................................................

Printed Wiring Board Diagrams ...................................

Pin description of diode, transistor and IC .................

Note on Soldering ......................................................

52 53 54 55 56 56 57 61 68 70

A1 A2 A3

A9 A11 A12

-2-

Safety Instructions

Safety Precautions

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.

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.

DO NOT OPERATE THIS PROJECTOR WITHOUT THE PROTECTIVE SHIELD IN POSITION AND PR OPERLY SECURED.

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, adjustment covers or shields, barriers, etc.

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.

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.

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.

-3-

Specifications

Mechanical Information

Projector Type Multi-media Projector Dimensions (W x H x D) 13.78 x 5.10" x 15.03" ( 350.0mm x 129.4mm x 381.9mm ) (Not including protrusions) Net Weight PLC-WL2500A:10.1 lbs (4.6kg) , PLC-WL2503A:10.3lbs (4.7Kg) Feet Adjustment 0˚ to 10˚

Panel Resolution

LCD Panel System 0.59" TFT Active Matrix type, 3 panels Panel Resolution 1,280 x 800 dots Number of Pixels 3,072,000 (1,280 x 800 x 3 panels)

Signal Compatibility

Color System SD/HDTV Signal 480i, 480p, 575i, 575p, 720p, 1035i, and 1080i Input Scanning Frequency H-sync. 15 kHz-100 kHz, V-sync. 50-100 Hz

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

Optical Information

Projection Image Size (Diagonal) Adjustable from 60” to 110” Throw Distance 2.09’ - 3.94' (0.64 m - 1.20 m) Projection Lens F 1.8 lens with f 6.68 mm with manual focus Projection Lamp 230W

Interface

Video Input Jack RCA Type x 1 S-Video Input Jack Mini DIN 4 pin x 1 Audio Input Jacks RCA Type x 2 Computer Input 1 / Component Input Terminal Computer Input 2 / Monitor Output Terminal Computer/ Component Audio Input Jack Control port D-sub 9 pin x 1 Audio Output Jack Mini Jack (stereo) x 1 (Variable) LAN Connection Terminal RJ-45 HDMI x 1

Analog RGB (Mini D-sub 15 pin) Terminal x 1

Analog RGB (Mini D-sub 15 pin) Terminal x 1 (In/Out switchable) Mini Jack (stereo) x 1

Audio

Internal Audio Amp 10.0 W RMS Built-in Speaker 1 speaker, 1.46" (37mm)

Power

Voltage and Power Consumption AC 100–120 V (3.9 A Max. Ampere), 50/60 Hz (The U.S.A and Canada) AC 100-240 V (3.9 - 2.2 A Max. Ampere), 50/60Hz (For other countries)

Operating Environment

Operating Temperature 41˚F–95˚F (5 ˚C–35 ˚C) Storage Temperature 14˚F–140˚F (-10˚C–60 ˚C)

Remote Control

Battery AAA or LR03 1.5V ALKALINE TYPE x 2 Operating Range 16.4' (5 m)/±30˚ Dimensions 2.0" (W) x 0.7" (H) x 4.3" (D) (52 mm x 18 mm x 110 mm) Net Weight 2.37 oz (67 g) (including batteries)

Accessories

Owner’s Manual (CD-ROM), Quick Reference Guide, AC Power Cord, Remote Control and Batteries VGA Cable, PIN Code Label, Lens Cover, Safety Manual

Only PLC-WL2503A : CD-ROM (ED Interactive CD), IR Light Pen, IR Pointer, Cable, USB

● The 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.

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.

-4-

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.

Thermal switch

There is the thermal switch (SW902) inside of the projector to detect the internal temperature rising abnormally. When the internal temperature reaches near 85˚C, the thermal switch opens to cut off the power to the power circuit.

The thermal switch can be reset itself automatically when the internal temperature becomes normal.

When the internal temperature reaches near 55˚C, the thermal switch returns automatically.

Fuse

A fuse is located inside of the projector. When the POWER indicator is not lighting, the fuse may be opened. Check the fuse as following steps. The fuse should be used with the type listed right;

How to replace the fuse

1. The fuse is placed on the filter board behind the main board. Remove the cabinet top, AV panel and main board.

2. Take the fuse off, and replace the new one with the specified type.

Lamp cover switch

The lamp cover switch (SW901) cuts off the drive signal to the lamp circuit when the lamp cover is removed or not closed completely. After opening the lamp cover for replacing the lamp ass’y, place the lamp cover correctly otherwise the projector can not turn on.

Fuse Part No.: 323 021 7804 TYPE T6.3AH 250V FUSE LITTEL FUSE INC. TYPE 21506.3

Fuse Part No, : 423 034 4101 TYPE T6.3AH 250V FUSE Hollyland Co, Ltd. TYPE 50CT063H

Thermal switch

(SW902)

Lamp cover switch

(SW901)

Fuse (F601)

-5-

Circuit Protections

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.

LED indicator

WARNING emit a red light

The projector is shut down and the WARNING indicator is blinking red.

When the temperature inside the projector reaches a certain level, the projector will be automatically shut down to protect the inside of the projector and the WARNING and POWER indicators start blinking. When the projector has cooled down enough (to its normal operating temperature), the POWER indicator stops blinking and lights red, The projector can be turned on again by pressing the ON/STAND-BY button.

4Note:

The WARNING indicator continues to blink even after the temperature inside the projector returns to normal. When the projector is turned on again, the WARNING indicator stops blinking.

Check items

- Remove dust around the air filter.

- 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)

The projector is shut down and the WARNING indicator lights red.

When the projector detects an abnormal condition, it is automatically shut down to protect the inside of the projector and the WARNING indicator lights red. In this case, unplug the AC power cord and reconnect it, and then turn the projector on once again to verify operation.

4Note:

- If the WARNING indicator lights red, it may defect the cooling fans or power supply circuits. Check fans operation and power supply lines referring to the chapter “Power supply & protection circuit” and "Fan conrol circuit" in the Chassis Block Diagram section.

WARNING

DO NOT LEAVE THE PROJECTOR WITH THE AC POWER CORD CONNECTED UNDER AN ABNORMAL CONDITION. IT MAY RESULT IN FIRE OR ELECTRIC SHOCK.

-6-

Maintenance

Replacing the filters

Filter prevents dust from accumulating on the optical elements inside the projector. Should the filter become clogged with dust particles, it will reduce cooling fans’ effectiveness and may result in internal heat buildup and adversely affect the life of the projector. If a “Filter warning” icon appears on the screen, replace the filter cartridge immediately by following the steps below.

Turn off the projector, and unplug the AC power cord

from the AC outlet. First, clean up the dust on the projector and around the

air vents. Press and hold any part of the red circle, and press 7

leftwards on the filter cover to release the latch and open the filter cover.

Pull out the filter cartridge. When taking out the filter car-

tridge, put your fingers on the filter tab and then pull.

Put the new one back into the position and close the

filter cover. Ensure that the area with “TOP” mark is in an upward direction.

Connect the AC power cord to the projector and turn on

the projector.

Reset the filter counter.

CAUTION

Do not operate the projector with the filters removed. Dust may accumulate on the optical elements degrading picture quality. Do not put anything into the air vents. Doing so may result in malfunction of the projector.

RECOMMENDATION

We recommend avoiding dusty/smoky environments when you operate the projector. Usage in these environments may cause poor image quality. When using the projector under dusty or smoky conditions, dust may accumulate on a lens, LCD panels, or optical ele ments 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.

Latch

Filter counter

Filter cover

TOP mark

Pull out and remove.

Resetting the filter counter

Be sure to reset the filter counter after replacing the filters.

Press the MENU button to display the On-Screen

Menu. Use the Point ed buttons to select Setting and then press the Point 8 or SELECT button.

Use the Point ed buttons to select Filter counter and

then press the Point 8 or the SELECT button. Use the Point ed buttons to select Filter counter Reset and then press the SELECT button. Filter counter Reset? appears. Select Yes to continue.

Another confirmation dialog box appears, select Yes to

reset the filter counter.

-7-

Filter counter Reset? appears.

Select Yes, then another confirmation box appears.

Select Yes again to reset the filter coun ter.

Maintenance

Lamp replacement

When the projection lamp of the projector reaches its end of life, the Lamp replacement icon appears on the screen and LAMP REPLACE indicator lights yellow. Replace the lamp with a new one promptly. The timing when the LAMP REPLACE indicator should light is depending on the lamp mode.

WARNING:

TURN OFF THE UV LAMP BEFORE OPENING THE LAMP COVER

Top Panel

This indicator turns yellow when the projection lamp

reaches the end of its life.

Lamp replacement icon

Note: The lamp replacement icon will not appear when the display function is set to Off, during Freeze, or No show.

CAUTION

When replacing the lamp because it has stopped illuminating, there is a possibility that the lamp may be bro ken. If replacing the lamp of a projector which has been installed on the ceiling, you should always assume that the lamp is broken, and you should stand to the side of the lamp cover, not underneath it. Remove the lamp cover gently. Small pieces of glass may fall out when the lamp cover is opened. If pieces of glass get into your eyes or mouth, seek medical advice immediately.

CAUTION

Allow a projector to cool for at least 45 minutes before you open the lamp cover. The inside of the projector can become very hot.

For continued safety, replace with a lamp of the same type. Do not drop a lamp or touch a glass bulb! The glass can shatter and may cause injury.

CAUTION

Follow these steps to replace the lamp.

Turn off the projector and unplug the AC power cord. Let

the projector cool for at least 45 minutes.

Loosen the screw and open the lamp cover.

Loosen the three (3) screws that secure the lamp. Lift

the lamp out of the projector by using the handle.

Replace the lamp with a new one and secure the three

(3) screws. Make sure that the lamp is set properly. Close the lamp cover and secure the screw.

Connect the AC power cord to the projector and turn on

the projector.

Reset the lamp counter.

See “Resetting the lamp counter” on the next page.

Lamp cover

Screw

Screws

Lamp

Handles

ORDER REPLACEMENT LAMP

Replacement lamp can be ordered through your dealer. When ordering a projection lamp, give the following information to the dealer.

Replacement Lamp Type No. : POA-LMP141 Service Parts No. : 610 349 0847

-8-

Counter Projector 500H Lamp Normal 300 H Eco 200 H Corresponding value 600 H

Maintenance

Resetting the lamp counter

Be sure to reset the lamp counter after the lamp is replaced. When the lamp counter is reset, the LAMP REPLACE indicator stops lighting and the lamp replacement icon disappears.

Press the MENU button to display the On-Screen

Menu. Use the Point ed buttons to select Setting and then press the Point 8 or the SELECT button.

Use the Point ed buttons to select Lamp counter

and then press the SELECT button. Use the Point ed buttons to select Lamp counter reset and then press SELECT button. Lamp replacement counter Reset? appears. Select Yes to continue.

Another confirmation dialog box appears, select Yes to

reset the lamp counter.

Note: Do not reset the lamp counter without implementing lamp replacement. Be sure to reset the lamp counter only after replacing the lamp.

Lamp counter reset

Lamp replacement counter Reset? appears.

Select Yes, then another confirmation box appears.

Select Yes again to reset the lamp counter.

How to check lamp used time

The LAMP REPLACE indicator will light yellow when the total lamp used time (Corresponding value) reaches 4,000 hours. This is to indicate that lamp replacement is required. The total lamp used time is calculated by using the below expression, Total lamp used time (Corresponding value) = Teco + Tnormal x 1.33

Tnormal : used time in the normal mode Teco : used time in the eco mode

Projector used time

Total lamp used time

You can check the lamp used time following to the below procedure.

1 Press and hold the ON/STAND-BY button on the re-

mote control for more than 20 seconds.

2 The projector used time and lamp used time will be

displayed on the screen briefly as follows.

-9-

Maintenance

Attaching the lens cover

When moving the projector or while it is not in use, replace the lens cover.

Thread the string through the hole on the lens cover

and then tie a knot in the string to secure it in place.

To pass the other end of the string into the hole on

the top of the projector and pull at it.

Cleaning the projector

Cleaning the projection lens

Unplug the AC power cord before cleaning.

Gently wipe the projection lens with a cleaning cloth that contains a small amount of non-abrasive camera lens cleaner, or use a lens cleaning paper or commercially available air blower to clean the lens.

Avoid using an excessive amount of cleaner. Abrasive cleaners, solvents, or other harsh chemicals might scratch the surface of the lens.

Cleaning the projector cabinet

Unplug the AC power cord before cleaning.

Gently wipe the projector body with a soft dry cleaning cloth. When the cabinet is heavily soiled, use a small amount of mild detergent and finish with a soft dry cleaning cloth. Avoid using an excessive amount of cleaner. Abrasive cleaners, solvents, or other harsh chemicals might scratch the surface of the cabinet.

When the projector is not in use, put the projector in an appropriate carrying case to protect it from dust and scratches.

CAUTION Do not use any flammable solvents or air sprays on the projector and in its vicinity. The explosion or fire hazard may occur even after the AC power cord is unplugged because the temperature inside the projector is extremely high due to the lamps. In addition, there is a risk that the internal parts may be damaged not only by the flammable air spray but also by the cold air.

-10-

Security Function Notice

This projector provides security functions such as "Key lock", "PIN code lock" and "Logo PIN code lock". When the projector has set these security function on, you are required to enter correct PIN code to use the projector. If you do not know the correct PIN code to the projector, the projector can no longer be operated or started. In this case, you must reset those function first according to the resetting procedure described below and then check up on the projector.

Function Description

Locks operation of the side control or the remote control.

Key lock

PIN code lock

Logo PIN code lock

If the Key lock is enabled with side control lock, the projector can no longer be started.

Initial setting: Key lock function is disabled

Prevents the projector from being operated by an unauthorized person.

Initial code: “1234”

Prevents an unauthorized person for changing the startup logo on the screen.

Initial code: “4321”

Resetting procedure

1 Disconnect the AC power cord from the AC outlet. 2 As pressing the SELECT button, connect the AC power cord into an AC outlet again.

3 Keep pressing the SELECT button and then press the ON/STAND-BY button. 4 Release the ON/STAND-BY button first and then release the SELECT button.

- The PIN code lock and Logo PIN code lock will be reset as the initial PIN code at the factory and the Key lock function is disabled.

Please refer to the owner's manual for further information of the security functions.

-11-

Standby Mode Notice

This projector provides 2 types of standby mode, Eco standby and Network standby. According to the standby mode "Eco" or "Network", several functions are restricted as shown in the table below. To change the standby mode, use the projector's menu "Setting".

Network ............ Supply the power to the network function even after turning off the projector. You can turn on /off

the projector via network, modify network environment, and receive an e-mail about projector status while the projector is powered off.

Eco ................... Select "Eco" when you do not use the projector via network. The projector's network function will stop

when turning off the projector.

When "Eco" is selected, several functions will be restricted.

Function in the standby mode

Function Eco Network

Serial command control --

Network function --

Monitor out --

Audio out -- --

Direct on

-12-

Mechanical Disassembly

Mechanical disassembly 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.

z Filter cartridge removal

1. Press and hold the part indicated with the arrow, and press 7 leftwards

on the filter cover to release the latch and open the filter cover.

2. Pull out the filter cartridge.

Screws expression (Type Diameter x Length) mm

T type M Type

Filter cartridge

Filter cover

Fig.1

Note: Do not disassemble the filter cartridge to clean up or replace the parts inside of the filter cartridge. When replacing the filter cartridge, replace whole the filter cartridge with new one to maintain the projector's performance.

-13-

Mechanical Disassembly

x AV panel and cabinet top removal

1. Remove 5 screws A(M3x8) to remove the AV panel.

2. Remove 3 screws B(T3x8), 1 screw C(T3x8), 2 screws D(M3x8) and 1 screw E(T3x8) and 1 screw F(T3x8) to remove the cabinet top assy.

3. Loosen 1 screw G and remove the lamp cover in the arrow direction.

4. Remove 2 screws H(T3x8) to remove the shield plate.

Lamp cover

Cabinet top

Shield plate

AV panel

(Located on the center of the cabinet bottom.)

Fig.2

-14-

Mechanical Disassembly

c Main, filter boards and lamp removal

1. Remove 2 screws A(M4x6), 2 screws B(T3x8), 2 screws C(M2.5x8) and remove the main board upward.

2. Remove 2 screws D(M4x6) and 2 screws E(T3x8) and remove the filter shield top.

3. Remove 1 screw F(M3x6) and 2 screws G(T3x8) and remove the filter board upward off.

4. Loosen 3 screws H and pull the lamp upward off.

Lamp

Main board

D D

Filter shield top

G G

Isolation sheet

Filter board

-15-

Fig.3

Mechanical Disassembly

v Power, ballast boards and fans (FN906, FN907) removal

1. Remove 3 screws A(T3x8) to remove the fans (FN906, FN907) assy.

2. Remove 1 screw B(T3x8) to remove the lamp socket. Remove 3 screws C(T3x8) to remove the lamp cover bottom. Unhook the ballast cable from the cabinet bottom.

3. Remove 2 screws D(M4x6) and 3 screws E(T3x8). Disconnect the connectors "CN1" on the ballast board and "K6C" on the power board. Remove the power box top upward off.

4. Remove 3 screws F(T3x8) to remove the power board.

Lamp socket

Lamp cover

bottom

C C

FN906

FN907

Power box top

Power board

Isolation sheet

Fig.4

Isolation sheet

Ballast board

-16-

Mechanical Disassembly

b Optical unit and duct assembly removal

1. Remove 2 screws A(T3x8) to remove the main board holder.

2. Remove 2 screws B(T3x12) and 5 screws C(T3x8) and remove the optical unit upward off.

3. Remove 9 screws D(T3x8) and remove the duct assembly upward off.

Main board holder

SW901

Lamp cover

switch

T3x12

Duct assy

T3x8

Temp sensor A board

Optical unit

Fig.5

Panel duct

bottom

FN904

FN903

T3x30

FN902 FN901

T3x12

T3x30

-17-

Mechanical Disassembly

n Fan (FN905), SW902, temp sensor C, R/C front board removal

1. Remove 2 screws A(T3x8) to remove the duct assy. Remove fan (FN905) and temp sensor C board.

2. Remove 1 screw B(T3x8) to remove the thermal switch holder and thermal switch (SW902).

3. Remove 2 screws C(T3x8) to remove the lens holder. Pull the R/C front board upward off.

T3x8

Temp sensor

C board

T3x30 T3x30

T3x12

Speaker box

SW902

Bushes

FN905

T3x12

Lens holder

R/C front board

SW902

Fig.6

-18-

Optical Parts Disassembly

Before taking this procedure, remove AV panel, cabinet top and main board following to the “Mechanical disassembly”. Disassembly requires a 2.0mm hex wrench and a screwdriver.

z Projection lens removal

(T3x8)x2

Note: The main board holder should be removed from the

cabinet bottom before removing the projection lens.

Projection lens

x Integrator lens (OUT) & PBS removal

Main board holder

(M3x8)x4

Fig.1

Lens holder top

Lens assy

(M2.5x6)x1

(M3x14)x2

Fig.2

PBS marker

* Rugged surface

is facing to PBS.

PBS

Light mask PBS

Integrator(OUT)

Light mask Int

* Rugged sur

Integrator(IN)

face is facing to the lamp.

-19-

Optical Parts Disassembly

c Condenser lens (OUT) removal

(M2.5x6)x2

Fig.3

v Polarized glasses removal

Polarized glass(IN/B)

(M2.5x6)x3

Condenser Lens(OUT)

Polarized glass(IN/G)

Polarized glass(IN/R)

(M2.5x6)

* Polarized glass is not re-

moved from the mounting base.

Fig.4

-20-

Optical Parts Disassembly

b LCD panel/prism assy removal

Loosen 1 screw A and then pull the panel/prism assy upward off.

LCD panel/prism assy

Fig.5-1

*Note on handling the LCD panel/prism assy

LCD panel, polarized glasses are very sensitive parts. Never touch or wipe the surface. When removing the dust on the surface, use a commercial (inert gas) air spray to remove them.

-21-

Optical Parts Disassembly

L3D05X-86G10

a01J6336L9

-86G10

L3D05X-85G10

a01J6336L9

-85G10

Panel type check

There are 2 types of LCD panel/prism assy for this model. Either L-type or R-type LCD panel/prism assy is used on the projector. Check which type of LCD panel/prism assy is used with the figure below. When replacing the LCD panel/prism assy, you need to take "Panel type check and setting" on the electrical adjust ment for the replaced LCD panel/prism assy. The gamma-characteristics is different between L-type and R-type LCD panel/prism assy.

How to check the type of LCD panel/prism assy

Check the printed number on the flat cable of the G-LCD panel.

L-type LCD panel/prism assy R-type LCD panel/prism assy

G-LCD panel

Fig.5-2

IMPORTANT NOTICE on LCD panel/prism assy replacement

LCD panels used for this model can not be replaced separately. Do not disassemble the LCD panel/prism assy. 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 assy at once. When replacing the LCD panel/prism assy, take the optical and electrical adjustments following to the chapter "Adjustment".

-22-

Optical Parts Disassembly

n Optical unit top removal

Optical unit top

Unhook 6 hooks to remove the optical unit top.

Fig.6

m Relay lens(OUT) assy removal

(M2.5x5)

Relay lens(OUT)

Fig.7

-23-

Optical Parts Disassembly

m Locations and directions

When mounting or assembling the optical parts in the optical unit, the parts must be mounted in the specified location and direction as shown in figure below.

No. Parts Name

1 Dichroic mirror (B) 2 Dichroic mirror (G) 3 Condenser lens (G) 4 Relay lens (IN) 5 Mirror (R) 6 Condenser lens (R) 7 Condenser lens (B) 8 Mirror (B)

Marker comes this side up

Marker

-24-

Fig.8

Adjustments

Adjustments after parts replacement

LCD/

Prism assy

Condenser

lens (OUT)

● : Adjustment necessary ❍ : Check necessary

Disassembly / Replaced parts

Relay

lens (OUT)

Polarized glass

R G B

Power

board

Main board

Optical

adj.

Contrast adjustment

Condenser lens (OUT) adjustment

Relay lens (OUT) adjustment

❍ ●

Fan voltage adjustment

Panel type check and setting

Electrical adjustments

Auto calibration adjustment [PC]

● ●

Auto calibration adjustment [Component]

Auto calibration adjustment [Video]

Common voltage adjustment

50% white adjustment [PC]

50% white adjustment [Video]

White balance adjustment [PC]

White balance adjustment [Video]

Color shading correction adjustment *

* To adjust this item, the Projector Service Tool v. 4.20 software is needed. Refer to the owner's manual for this software for the

further details.

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Note on main board replacement

Take the following setting and replacement when the main board is replaced.

- Shipment data setting (Color shading correction, gamma correction)

- Memory IC replacement

● Shipment data setting

This projector stores "Color shading correction data" and "Gamma correction data" in the flash memory (IC801) on the main board. Those shipping data have been setup according to the optical characteristics of the mounted LCD panels preciously in the factory. When replacing the main board, you need to read out the those setting data stored in the memory IC on the previous main board and write down them into the memory IC on the new main board. By this way, the projector enables to reproduce the picture which has properly adjusted color shading correction, gamma correction. For further details, refer to the operation manual of the software [PROJECTOR SERVICE TOOL v4.20].

PROJECTOR SERVICE TOOL CD-ROM v4.20 SERVICE CODE: 610 343 5596

● Memory IC replacement (IC1371)

Memory IC (IC1371) on the main board stores the user control value including lamp used time. When the main board is replaced with new one, the lamp used time will be reset. To keep the lamp use time, the memory IC should be replaced with the one on previous main board.

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Optical Adjustments

Before taking optical adjustments below, remove the AV panel and cabinet top following to the “Mechanical disassembly”.

Optical adjustment requires a 2.0mm hex wrench and a slot screwdriver.

WARNING : USE UV RADIATION EYE AND SKIN PROTEC-

TION DURING SERVICING

CAUTION: To prevent suffer of UV radiation, those adjust-

ment must be completed within 25 minutes.

Contrast adjustment

[Before adjustment]

- Input a 100% of black raster signal.

1 Loosen a screw A (Fig.1) on the polarized glass

mounting base which you intend to adjust.

2 Adjust the slot B to obtain the darkest brightness on

the screen by using a slot screwdriver.

3 Tighten the screw A to fix the polarized glass mount-

ing base.

Repeat steps 1 to 3 for remaining polarized glasses.

- This adjustment should be taken in order of G-panel, R-panel and B-panel.

- This adjustment should be taken in the darkest room to adjust preciously.

Fig.1

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Optical Adjustments

Condenser lens (OUT) 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 condenser lens (OUT) assy to make

color uniformity in white.

1) If the shading appears on the left or right of the screen as shown

in Fig.2-1, loosen 1 screw C , and adjust the slot D 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.2-2, loosen 2 screws E, and adjust the slots F to make color uniformity in white by using a slot screwdriver.

4 Tighten screws C and E to fix the condenser lens (OUT) assy.

Note: The relay lens adjustment must be carried out after completing this adjustment.

White

Fig.2-1

Moving of slot D

White

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Fig.2-2

Moving of slot F

Optical Adjustments

Relay lens (OUT) 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 relay lens (OUT) assy to make color unifor-

mity in white.

If the shading appears on the left or right of the screen as shown in Fig.3,

loosen 1 screw G by using a hex screwdriver, and adjust the slot H to make color uniformity in white by using a slot screwdriver.

4 Tighten the screw G to fix the relay lens (OUT) assy.

White

Fig.3

Moving of slot H

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Electrical Adjustments

Service Mode Input Computer 1 Group No. Data

0 +179

Ver.

1.00

White 100%

White 0%

W Y C G M R B BK

White 100%

White 0%

Service adjustment menu operation

To enter the service mode

To enter the “Service mode”, press and hold the MENU button on the remote control for more than 20 seconds. The service menu appears on the screen as follows.

To adjust service data

Select the adjustment group no. by pressing the MENU button (increase) or SELECT button (decrease), and select the adjustment item no. by pressing the pointer 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 group no., item no. and data value.

To exit the service mode

To exit the service mode, press the ON/STAND-BY button on the remote

Group No.

Item No.

Data value

Firmware version

control.

Circuit adjustments

CAUTION: The each circuit has been made by the fine adjustment at factory. Do not attempt to adjust the following

adjustments except requiring the readjustments in servicing otherwise it may cause loss of performance and product safety. Before adjustment, please turn on the projector more than ten minutes.

WARNING : USE UV RADIATION EYE AND SKIN

PROTECTION DURING SERVICING.

CAUTION: To prevent suffer of UV radiation, those adjust ments must be completed within 25 minutes.

[Adjustment condition]

● Input signal

Analog computer signal .....

Composite video signal ........ 1.0Vp-p/75W terminated (NTSC / PAL)

Component video signal ...... 1.0Vp-p/75W terminated (480i)

0.7Vp-p/75W terminated (XGA)

16 steps gray scale pattern

● Picture contorol mode ......Standard mode unless otherwise noted.

● Lamp control .................... Normal mode unless otherwise noted.

Note:

* Please refer to “Service adjustment menu operation” for entering the service mode and adjusting the service data.

8 color 100% color bar

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Electrical Adjustments

z Fan voltage adjustment

Equipment Digital voltmeter

1. Enter the service mode.

2. Adjust the voltage on each test point by changing the data values of the Group - No.

Group No. Test Point Adjustment value

250 - 0 TPFANA 4.5 ±0.1Vdc 250 - 1 TPFANA 13.5 ±0.1Vdc 250 - 2 TPFANB 5.0 ±0.1Vdc 250 - 3 TPFANB 13.5 ±0.1Vdc 250 - 4 TPFANC 5.0 ±0.1Vdc 250 - 5 TPFANC 13.5 ±0.1Vdc

x Panel type check and setting

* Before setting, you need to check which type of LCD pan-

el is placed on the projector according to the item "LCD panel/prism assy removal" in the chapter "Optical parts disassembly".

c PC auto calibration

Input mode Computer 1 (RGB) Input signal XGA computer signal Input pattern 16-step gray scale

1. Enter the service mode.

Select Group "260", No. "0" and set data value "0" to "1".

The projector begins auto-calibration and then "OK"

will appear on the screen.

Component auto calibration

Input mode Computer 1 (Component) Input signal 480i componennt signal Input parttern 8 color signal

1. Enter the service mode.

Select Group "260", No. "0" and set data value "0" to "1".

The projector begins auto-calibration and then "OK"

will appear on the screen.

1. Enter the service mode.

2. Panel type check

Select group no. "290", item no. "0". Check the data

value as follows; Data value: 0 For L-type of LCD panel Data value: 20 For R-type of LCD panel If the mounted LCD panel type and set panel mode

are differ, take the step below.

3. Panel type mode setting

Select group no. "290", item no. "1" and change data

value from 10 to 0 or 20 depending on your LCD panel

type. When the data value reaches 0 or 20, it returns

to 10 quickly. The gamma-characteristics changes ac-

cording to your selection.

Note:

Be careful to take this adjustment. The value of gamma adjustment data will be reset and cannot be restored if you change the mode of LCD panel type

b Video auto calibration

Input mode Video Input signal Composite video signal Input pattern 16-step gray scale

1. Enter the service mode.

Select Group "260", No. "0" and set data value "0" to "1".

After the auto-calibration completed, "OK" will appear

on the screen.

Adjustments item no. [3] to [5] are carried out at the spare parts shipment in the factory, therefore they are not required when the main board is replaced with new one.

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