Sanyo PLC-XL45 User Manual

FILE NO.

SERVICE MANUAL

Multimedia Projector

Model No. PLC-XL45

U.S.A. Canada Europe, U.K

Original Version

NOTE: Match the Chassis No. on the unit's back cover

with the Chassis No. in the Service Manual.

If the Original Versi on Service Manua l Chassis No. does not match the unit’s, addi-

tional Service Literature is required. You must refer to “Notices” to the Original Service Manual prior to servicing the unit.

PRODUCT CODE 1 122 373 00 (KZ6AC)

1 122 374 00 (LZ6AC) 1 122 374 02 (LZ6CC)

Chassis No. KZ6-XL4500

REFERENCE NO. SM5110900-00

Contents

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

SAFETY PRECAUTIONS ........................................... 3

PRODUCT SAFETY NOTICE .................................... 3

SERVICE PERSONNEL WARNING ..........................

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

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

Thermal switch ........................................................... 5

Lamp cover switch ...................................................... 5

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

Warning temperature and power failure protection .... 6

Air ﬁlter care and cleaning .......................................... 6

Security Function Notice ................................................ 7

Lamp Replacement .......................................................8

Lamp replacement ...................................................... 8

How to reset Lamp Replace Counter ......................... 8

How to check Lamp used time ................................... 8

Mechanical Disassembly ............................................... 9

Optical Parts Disassembly ........................................... 13

Panel Type Check .................................................... 16

Adjustments ................................................................. 19

Adjustments after Parts Replacement ...................... 19

Electrical Adjustments ................................................. 23

Service Adjustment Menu Operation ........................ 23

Memory IC (IC1371) Replacement ........................... 23

Circuit Adjustments ................................................... 24

Test Points and Locations ........................................ 27

Service Adjustment Data Table ................................ 28

Chassis Block Diagrams .............................................. 39

Chassis over view ..................................................... 39

System control .......................................................... 40

Power supply & protection circuit ............................. 41

Fan control circuit ..................................................... 42

Troubleshooting ........................................................... 43

Indicators and Projector Condition ........................... 43

No Power .................................................................. 44

No Picture ................................................................. 45

No Sound .................................................................. 46

Control Port Functions ................................................. 47

System Control I/O Port Functions (IC301) .............. 47

I/O Expander Port Functions (IC1801) .................... 48

IIC Bus DA Converter Port Functions (IC3571) ....... 48

Waveform .................................................................... 49

Cleaning ......................................................................50

Projection Lens Cleaning .......................................... 50

IC Block Diagrams ....................................................... 51

Electrical Parts List ...................................................... 57

Electrical Parts Location ........................................... 58

Mechanical Parts List ..................................................79

Cabinet Parts Location ............................................. 79

Optical Parts Location .............................................. 80

Mechanical Parts List ............................................... 84

Diagrams & Drawings ..................................................A1

Parts description and reading in schematic diagram ...A2

Schematic Diagrams ...................................................A3

Printed Wiring Board Diagrams .................................A11

Pin description of diode, transistor and IC .................A15

Note on Sordering .....................................................A16

-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.

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.

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

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) 10.50" x 4.86" x 9.58" (320mm x 148mm x 292mm) (Not including adjustable feet)

Net Weight 7.1 lbs (3.2kgs)

Feet Adjustment 0˚ to 10.0˚

Panel Resolution

LCD Panel System 0.6" TFT Active Matrix type, 3 panels

Panel Resolution 1,024 x 768 dots

Number of Pixels 2,359,296 (1,024 x 768 x 3 panels)

Signal Compatibility

Color System

High Definition TV Signal 480i, 480p, 575i, 575p, 720p, 1035i, and 1080i

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

Optical Information

Projection Image Size (Diagonal) Adjustable from 60" to 80"

Projection Lens F 1.85 lens with f 8.1 mm ~ 27 mm with manual focus

Throw Distance 2.49’ - 3.38’ (0.76m - 1.03m)

Projection Lamp 200W

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

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 Anlaog RGB (Mini D-sub 15 pin) Terminal X 1

Computer Input 2 / Monitor Output Terminal

Computer/ Component Audio Input Jack

Service Port Connector Mini DIN 8 pin x 1

USB Connector USB Series B receptacle x 1

Audio Output Jack Mini Jack (stereo) x 1 (Variable)

Anlaog RGB (Mini D-sub 15 pin) Terminal X 1 (In / Out switchable)

Mini Jack (stereo) x 1

Audio

Internal Audio Amp 1.0W RMS

Built-in Speaker 1 speaker, ø1.1" (28mm)

Power

Voltage and Power Consumption AC 100 ~ 120 V (3.2A Max. Ampere), 50 / 60 Hz (The U.S.A and Canada)

AC 200 ~ 240 V (1.6A Max. Ampere), 50 / 60 Hz (Continental Europe and The U.K.)

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 AA or LR6 1.5V ALKALINE TYPE x 2

Operating Range 16.4’ (5m) / ±30˚

Dimensions 1.9”(W) x 0.87”(H) x 5.7”(D) (49mm x 22mm x 145.3mm)

Net Weight 3.53 oz (100 g) (including batteries)

Antitheft Alarm

Battery CR2 3V LITHIUM BATTERY x 1

● 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 105˚C, the thermal switch opens to stop the operation of the power supply circuit. The thermal switch cannot be reset itself automatically even if the internal temperature becomes normal. Reset the thermal switch following to the below procedure.

How to reset the thermal switch

1. Remove the cabinet top, cabinet front and main board and then remove the power box top cover.

2. Press the reset button on the thermal switch in the power box.

CAUTION:

Before press the reset button, make sure that the AC cord must be disconnected from the AC outlet.

Thermal switch (SW902)

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

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

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

Fuse cover

Fuse

How to replace the fuse

1. Remove the lamp cover and fuse cover as shown in ﬁgure.

2. Take the fuse out from the aperture, and replace the new one with the speciﬁed type.

-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.

- If the WARNING indicator is ﬂashing, it may detect the abnormal temperature inside the projector. Check the following possible causes and wait until the WARNING indicator stops ﬂashing, and then try to turn on the projector.

- 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” in the Chassis Block Diagram section.

Possible causes

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

Air ﬁlters prevent dust from accumulating on the optical elements inside the projector. Should the air ﬁlters become clogged with dust particles, it will reduce cooling fans’ effectiveness and may result in internal heat build up and adversely affect the life of the projector. Clean the air ﬁlters following the steps below.

1. Turn off the projector, and disconnect the AC power cord

from the AC outlet.

2. Turn over the projector and remove the air ﬁlters by pulling

the latches upward.

3. Clean the air ﬁlters with a brush or rinse them softly.

4. When cleaning the air ﬁlters by rinsing, dry them well. Re-

place the air ﬁlters properly. Make sure that the air ﬁlters are fully inserted.

Air filters

CAUTION:

Do not operate the projector with the air ﬁlters removed. Dust may accumulate on the LCD panel 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.

RECOMMENDATION:

We recommend avoiding dusty/smoky environments when operating 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 elements inside the projector. This condition may degrade the quality of a projected image. When the symptoms above are noticed, contact your authorized dealer or service station for proper cleaning.

-6-

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 top control or the remote control.

Key lock

PIN code lock

Logo PIN code lock

If the Key lock is enabled with top 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 start-up 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 on the projector, connect the AC power cord into an AC outlet again. Keep

pressing the SELECT button until the POWER indicator lights continuously.

This is complete the resetting of the security function. The PIN code lock and Logo PIN code lock are 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.

-7-

Lamp Replacement

Counter Projector 525H Lamp Normal 150H Eco 375H Corresponding value 675H

Lamp replacement

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 Turn off the projector and disconnect the AC cord. 2 Remove 1 screw with a screwdriver and remove the lamp cover. 3 Loosen 2 screws and pull out the lamp assembly by grasping the

handle.

4 Replace the lamp with a new one and tighten the 2 screws back into

position. Make sure that the lamp is set properly. Replace the lamp

cover and tighten the screw. 5 Connect the AC cord to the projector and turn on. 6 Reset the lamp replacement counter, see below explanation.

Note

- The projector cannot be turned-on with lamp cover removed, because

when the lamp cover is removed, the lamp cover switch is also released to switch off the lamp circuit.

ORDER REPLACEMENT LAMP

Type No. Service Parts No. POA-LMP106 610 332 3855

Lamp Cover

Lamp

Screw

Handle

WARNING : TURN OFF THE UV LAMP BEFORE OPENING. USE UV RADIATION EYE AND SKIN PROTECTION DURING SERVICING.

How to reset Lamp Replace Counter

1 Turn the projector on, press the MENU button and the

On-Screen Menu will appear. Press the 7 or 8 but- ton to move the red frame pointer to the Setting Menu

icon.

2 Press the d button to move the red frame pointer to

the Lamp counter reset item and then press the SELECT button. Select "Reset" and press the SELECT

button. The message "Lamp replace counter Reset?" is displayed. Move the pointer to [Yes] and then press the SELECT button.

* Refer to owner's manual for further information.

How to check Lamp used time

The LAMP REPLACE indicator will light yellow when the total lamp used time (Corresponding value) reaches 3000 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 = Teco + Tnormal x 2

Teco: used time in the Eco mode Tnormal : used time in the Normal mode

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

1 Press and hold the ON-OFF button for more than 20

seconds.

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”.

2 The projector used time and lamp used time will be

displayed on the screen brieﬂy as follows.

Projector used time

Total lamp used time

-8-

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 Cabinet Top & Fans (FN901, FN902), R/C Board removal

(M3x8)x5

Cabinet top

Screws Expression (Type Diameter x Length) mm

T type M Type

LED spacer

(M3x8)x2

(T3x6)

R/C board

(T3x6)

FN902

FN901

Side grille

Fig.1

-9-

Mechanical Disassembly

x Main Board, Rear Panel, Fan(FN905), SP901 removal

Grounding lead

(M4x5)

(M2.5x6)x8

(M2.5x6)x2

Rear panel

FN905

Main board

(T3x8)

SP901

-10-

Fig.2

Mechanical Disassembly

c Power, Line Filte, Ballast Board, Thermal Sw(SW902), Fan(FN906) removal

Isolation sheet

Power board

(T3x6)x4

(T3x6)

(T3x6)x4

Ballast board

FN906

(T3x6)

(T3x6)x2

Thermal switch (SW902)

Line Filter board

(M3x8)

Ballast socket

(T3x6)(Black)

-11-

(T3x6)(Black)

Fig.3

Mechanical Disassembly

v Optical Unit, Fans(FN903, FN904), Noise Filter removal

(T3x8)x6

(T3x12)x2

Optical unit

(T3x8)

(T3x6)

(T3x10)x4

(T3x6)x2

(T3x6)x3

FN904

Noise filter

FN903

-12-

Fig.4

Optical Parts Disassembly

Before taking this procedure, remove Cabinet Top , Cabinet Front and Main Board following to the “Mechanical Disassembly”. Disassembly requires a 2.0mm hex wrench.

z Projection lens removal

(M3x8)x4

Fixing tape

Projection lens

Fig.1

Note on replaceing the Projection Lens

- When the Projection Lens is replaced with the new one, make sure that the ﬁxing tape must be removed as the ﬁguer.

x Integrator lens-in disassembly

(M2.5x5)x2

Integrator Lens-In Ass'y

Hooks

Fig.2

Integrator lens-in

* Rugged surface

(Behind)

-13-

Optical Pats Disassembly

c Relay lens disassembly

(M2.5x5)x2

Relay lens Ass'y

(M2x3)

Relay lens

Fig.3

v Polarized glass-in disassembly

(M2.5x5)x1

Polarized glass-in Ass'y

Film side

Polarized glass

Fig.4

-14-

Optical Parts Disassembly

b LCD Panel/Prism Ass’y removal

(M2.5x4)x2

(M3x10)

(Bottom side)

LCD Panel/ Prism Ass’y

Fig.5

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” , “Gamma 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. 4.00

Service Parts No. 645 075 9611

-15-

Panel Type Check

L3P06X-65G00

1-B-1234A1

-65G00

L3P06X-66G000

1-B-1234A1

-66G00

There are 2 types of LCD/Prism Ass'y for this model. Either L-Type or R-Type LCD /Prism Ass'y is used on the projector. Check which type of LCD/Prism Ass'y is used with the ﬁgure below. When replacing the LCD/Prism Ass'y, you need to take "Panel Type Check and Setting" on the Electrical Adjustment for the replaced LCD/Prism Ass'y. The gamma-characteristics is different between L-Type and R-Type LCD /Prism Ass'y.

How to check the type of LCD/Prism Ass'y

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

L-Type LCD/Prism Ass'y R-Type LCD/Prism Ass'y

G-LCD PANEL

-16-

Optical Parts Disassembly

n Polarized glass, Pre-polarized glass removal

Polarized Glass(R)

(Red)

(M2x4)

(M2x2)

Film

(Green)

Polarized Glass(B)

(M2x2)

Pre-Polarized Glass(G)

Polarized Glass(G)

(M2x2)

Pre-Polarized Glass(B)

Film

(Blue)

Fig.6

* Mount the polarized glasses as the

ﬁlm attached side comes to the LCD panel side.

m Optical Unit Top removal

Optical top cover

(M3x8)x4

(M3x8)x2

Optical top cover-A

Fig.7

-17-

Optical Parts Disassembly

, 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 Integrator lens (OUT) 2 Prism beam splitter (PBS) 3 Condenser lens (OUT) 4 Dichroic mirror (B) 5 Dichroic mirror (G) 6 Condenser lens (G) 7 Mirror (R) 8 Condenser lens (R) 9 Condenser lens (B) 10 Mirror (B)

The arrows in the figure indicate the mount direction of the part for the replacement. Check the number on the arrows and mount each part according to its note; A: The printed part no. comes to this side. B: Rugged surface comes to this side.

Place the lens as the leddes come up side.

slit

Fig.8

-18-

Adjustments

Adjustments after Parts Replacement

● : Adjustment necessary ❍ : Check necessary

Disassembly / Replaced Parts

LCD/

Prism Ass’y

Co ntrast A dj ustment

R- Contrast a djustment ●

G- Contrast a djustment ●

B- Contrast a djustment ●

In tegrato r lens ad ju st ment ❍ ●

Optical Adjustments

Re lay lens-out adjustment ❍ ●

Pane l type check and se tt in g ● ●

Fan co nt ro l adjustment ● ●

Ped estal ad ju st me nt [ PC ] ●

Integrator

Lens (OUT)

Relay

Lens (OUT)

Polarized glass

R G B

Power Board

Main Board

Ga in a dj us tm en t [PC]

Ped estal ad ju st me nt [ 10 80 i] ●

Ga in a dj us tm en t [108 0i ] ●

Ga in a dj us tm en t [Vid eo ] ●

Co mmon c en te r adjust me nt ● ●

50% w hi te adjustment [PC] ● ●

Wh ite ba la nc e adjust me nt [PC] ❍ ❍

Electrical Adjustments

50% w hi te adjustment [Video] ● ●

Wh ite ba la nc e adjust me nt [Video] ❍ ❍

Wh ite un ifor mi ty a dj us tm en t ❍ ❍

●

-19-

Optical Adjustments

Before taking optical adjustments below, remove the Cabinet Top following to the “Mechanical Disassembly”. Adjustments require a 2.0mm hex wrench and a slot screwdriver. When you adjust Integrator lens or Relay lens adjustment, you need to disconnect FPC cables of LCD panels on the main board. Optical adjustment requires a 2.0mm hex wrench and a slot screwdriver. Note: Do not disconnect connectors on the main board, because the projector cannot turn on due to operate the

power failure protection.

WARNING : USE UV RADIATION EYE AND SKIN

PROTECTION DURING SERVICING

CAUTION: To prevent suffer of UV radiation, those adjustment

must be completed within 25 minutes.

Contrast adjustment

[Before Adjustment]

- Input a 100% of black raster signal.

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.

Polarized glass

mounting base

Repeat steps 1 to 3 for remaining polarized glasses.

Main Board

Fig.1-1

R-Polarized Glass Mounting Base

B-Polarized Glass Mounting Base

-20-

G-Polarized Glass Mounting Base

Fig.1-2

Optical Adjustments

Integrator lens 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 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 A , 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.2-2, loosen 2 screws C, and adjust the slots D to make color uniformity in white by using a slot screwdriver

4 Tighten screws A and C to fix the Integrator lens unit.

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

White

Fig.2-1

Moving of slot B

White

Slot D

Slot B

Slot D

-21-

Fig.2-2

Moving of Slot D

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 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 A, and adjust the slot B to make color uniformity in white by using a slot screwdriver.

4 Tighten the screws A to fix the relay lens unit.

White

Fig.3

Moving of slot B

Slot B

-22-

Service Mode Input Video Group No. Data 0 0 32 Ver. 1 .00

Electrical Adjustments

OFF

POWER

KEYSTONE

INPUT

WARNING

LAMP REPLACE

LUME

+ VO

UME

SELECT

Service Adjustment Menu Operation

To enter the service mode

To enter the “Service Mode”, press and hold the MENU and INPUT buttons 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 group no. by pressing the MENU (+) or KEYSTONE (-) button, 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 POWER ON-OFF button on the projector or remote control unit.

Group No.

Item No.

Data value

Memory IC (IC1371) Replacement

Memory IC 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 Memory IC. Please note that the lamp replace counter will be reset when the memory IC is replaced. (Lamp replace counter cannot be set to the previous value.)

● Caution to memory IC replacement

When memory IC 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 memory IC is not defective)

When the main board is replaced, memory IC should be replaced with the one on previous main board. After replacement, it should be required to perform the re-adjustments following to the “Electrical Adjustments”. In this case, the lamp replace counter can be kept the value as before.

-23-

White 100%

Black 100%

Electrical Adjustments

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.

[Adjustment Condition]

● Input signal

Video signal ......................... 1.0Vp-p/75

scale (Composite video signal)

Computer signal .................... 0.7Vp-p/75W terminated, 16 steps gray

scale pattern

Component Video signal....... 0.7Vp-p/75W terminated, 16 steps gray

scale (Component video signal with 480p, 575p, 720p 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.

Output Voltage adjustment

After replacing the Power 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 380V ±2V

Caution: Be sure to connect the lamp when taking this adjustment.

* This adjustment is not required even if the power

board is replaced because this adjustment is carried out before parts shipment.

W terminated, 16 steps gray

z Panel Type Check and Setting

1. Enter the service mode.

2. Panel Type Check Select group no. “

value as follows; Data value: 0 For L-Type of LCD Panel Data value: 20 For R-Type of LCD panel

3. Panel Type Setting Select group no. “

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 according to your selection.

* Refer to the item "LCD Panel/Prism Ass'y removal"

for the panel type check.

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.

16 steps gray scale pattern

290”, item no. “0”. Check the data

290”, item no. “1” and change data

WARNING : USE UV RADIATION EYE

AND SKIN PROTECTION DURING SERVICING

x Fan Control adjustment

1. Enter the service mode.

2. Connect a digital voltmeter to test point “

(+) and chassis ground (-). Select group no. “111”, item no. “94” and change data value to adjust voltage to be 5.2 ±0.1V.

3. Connect a digital voltmeter to test point “TPFANB” (+) and chassis ground (-). Select item no. “96” and change data value to adjust voltage to be 6.3 ±0.1V.

-24-

TPFANA”

Electrical Adjustments

Pedestal Lebel

Black Lebel

Pedestal Lebel

Black Lebel

(a)

White Level

(a)

White Level

c Pedestal adjustment [PC]

1. Receive the 16-step grey scale computer signal with Computer1 [RGB] mode.

2. Enter the service mode.

3. Connect an oscilloscope to test point “TP_G1” (+) and chassis ground (-).

4. Select group no. “0”, item no. “0” and change data value to adjust the pedestal level and black level to be the same level.

5. Connect an oscilloscope to test point “TP_R1” (+) and chassis ground (-).

6. Select item no. “1” and change data value to adjust the pedestal level and black level to be the same level.

7. Connect an oscilloscope to test point “TP_B1” (+) and chassis ground (-).

8. Select item no. “2” and change data value to adjust the pedestal level and black level to be the same level.

b Pedestal adjustment [1080i]

1. Receive the 16-step grey scale component signal with Computer1 [Component1080i] mode.

2. Enter the service mode.

3. Connect an oscilloscope to test point “TP_G1” (+) and chassis ground (-).

4. Select group no. “0”, item no. “0” and change data value to adjust the pedestal level and black level to be the same level.

5. Connect an oscilloscope to test point “TP_R1” (+) and chassis ground (-).

6. Select group no. “0”, item no. “1” and change data value to adjust the pedestal level and black level to be the same level.

7. Connect an oscilloscope to test point “TP_B1” (+) and chassis ground (-).

8. Select group no. “0”, item no. “2” and change data value to adjust the pedestal level and black level to be the same level.

v Gain adjustment [PC]

1. Receive the 16-step grey scale computer signal with Computer1 [RGB] mode.

2. Enter the service mode.

3. Connect an oscilloscope to test point “TP_G1” (+) and chassis ground (-).

4. Select group no. “0”, item no. “3” and adjust the amplitude “a” to be minimum by changing the Data value.

5. Connect an oscilloscope to test point “TP_R1” (+) and chassis ground (-).

6. Select item no. “4” and adjust the amplitude “a” to be

minimum by changing the Data value.

7. Connect an oscilloscope to test point “TP_B1” (+) and chassis ground (-).

8. Select item no. “5” and adjust the amplitude “a” to be

minimum by changing the Data value.

n Gain adjustment [1080i]

1. Receive the 16-step grey scale component signal with Computer1 [Component1080i] mode.

2. Enter the service mode.

3. Connect an oscilloscope to test point “TP_G1” (+) and chassis ground (-).

4. Select group no. “103”, item no. “0” and adjust the amplitude “a” to be minimum by changing the Data value.

-25-

Electrical Adjustments

(a)

white level

(a)

White Level

(a)

white level

m Gain adjustment [Video]

1. Receive the 16-step grey scale composite signal with Video [Video] mode.

2. Enter the service mode.

3. Connect an oscilloscope to test point “TP_G1” (+) and chassis ground (-).

4. Select group no. “103”, item no. “0” and adjust the amplitude “a” to be minimum by changing the Data value.

, Common Center adjustment

1. Receive the 50%-Whole Gray computer signal with Computer1 [RGB] mode.

2. Enter the service mode.

3. Select group no. “9”, item no. “92” and change data value to “2” to reduce the panel frequency.

4. Project only green light component to the screen.

5. Select group no. “10”, item no. “1” and change data value to obtain the minimum flicker on the screen.

6. Project only red light component to the screen.

7. Select item no. “0” 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. “2 and change data value to obtain the minimum flicker on the screen.

10. Select group no. “9”, item no. “92” and change data value to “0” to reset the panel frequency.

⁄0 50% White adjustment [Video]

1. Receive the 16-step grey scale composite video signal with Video [Video] mode.

2. Enter the service mode.

3. Connect an oscilloscope to test point “TP_G1” (+) and chassis ground (-).

4. Select group no. “9”, item no. “7” and change data value to adjust amplitude “a” to be 1.6 ±0.1V.

⁄1 White Balance adjustment [PC]

1. Receive the 16-step gray scale computer signal with Computer1 [RGB] mode.

2. Enter the service mode, select group no. “

9” item

no. “6” (Red) or “8” (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 [Video]

1. Receive the 16-step grey scale composite video signal with Video [Video] mode.

2. Enter the service mode, select group no. “ no. “6” (Red) or “8” (Blue), and change Data values respectively to make a proper white balance.

9” item

. 50% White adjustment [PC]

1. Receive the 16-step grey scale computer signal with Computer1 [RGB] mode.

2. Enter the service mode.

3. Connect an oscilloscope to test point “TP_G1” (+) and chassis ground (-).

4. Select group no. “9”, item no. “7” and change data value to adjust amplitude “a” to be 1.6 ±0.1V.

Confirm that the same white balance is obtained in video and computer input.

Note On White Uniformity 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. 4.00

Service Parts No. 645 075 9611

-26-

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Electrical Adjustments

Test Points and Locations

MAIN BOARD

-27-

Electrical Adjustments

Service Adjustment Data Table

These initial values are the reference data written from the CPU ROM to memory IC when replaced new memory IC. The adjustment items indicated with “✻” are required to readjust following to the “Electrical adjustments”. Other items should be used with the initial data value.

Item No. NAME Device

Group 0 AD9883

0 ADC G-OFFSET AD9883 55 55

1 ADC R-OFFSET AD9883 55 55

2 ADC B-OFFSET AD9883 55 55

3 ADC G-GAIN AD9883 70 128

4 ADC R-GAIN AD9883 70 128

5 ADC B-GAIN AD9883 70 128

10 VCO 0 Thresh MAX AD9883 32 32 32 Maximum frequency to select VCO 0

11 VCO 1 Thresh MAX AD9883 58 Maximum frequency to select VCO 1

12 VCO 2 Thresh MAX AD9883 110 Maximum frequency to select VCO 2

20 CPC 0 Thresh MAX (VCO 0) AD9883 0 Maximum frequency to select CPC0 at VCO 0

21 CPC 1 Thresh MAX (VCO 0) AD9883 0 Maximum frequency to select CPC1 at VCO 0

22 CPC 2 Thresh MAX (VCO 0) AD9883 15 Maximum frequency to select CPC2 at VCO 0

23 CPC 3 Thresh MAX (VCO 0) AD9883 18 Maximum frequency to select CPC3 at VCO 0

24 CPC 4 Thresh MAX (VCO 0) AD9883 23 Maximum frequency to select CPC4 at VCO 0

25 CPC 5 Thresh MAX (VCO 0) AD9883 32 Maximum frequency to select CPC5 at VCO 0

26 CPC 6 Thresh MAX (VCO 0) AD9883 255 Maximum frequency to select CPC6 at VCO 0

30 CPC 0 Thresh MAX (VCO 1) AD9883 0 Maximum frequency to select CPC0 at VCO 1

31 CPC 1 Thresh MAX (VCO 1) AD9883 0 Maximum frequency to select CPC1 at VCO 1

32 CPC 2 Thresh MAX (VCO 1) AD9883 0 Maximum frequency to select CPC2 at VCO 1

33 CPC 3 Thresh MAX (VCO 1) AD9883 0 Maximum frequency to select CPC3 at VCO 1

34 CPC 4 Thresh MAX (VCO 1) AD9883 0 Maximum frequency to select CPC4 at VCO 1

35 CPC 5 Thresh MAX (VCO 1) AD9883 48 Maximum frequency to select CPC5 at VCO 1

36 CPC 6 Thresh MAX (VCO 1) AD9883 65 Maximum frequency to select CPC6 at VCO 1

40 CPC 0 Thresh MAX (VCO 2) AD9883 0 Maximum frequency to select CPC0 at VCO 2

41 CPC 1 Thresh MAX (VCO 2) AD9883 0 Maximum frequency to select CPC1 at VCO 2

42 CPC 2 Thresh MAX (VCO 2) AD9883 0 Maximum frequency to select CPC2 at VCO 2

43 CPC 3 Thresh MAX (VCO 2) AD9883 0 Maximum frequency to select CPC3 at VCO 2

44 CPC 4 Thresh MAX (VCO 2) AD9883 0 Maximum frequency to select CPC4 at VCO 2

45 CPC 5 Thresh MAX (VCO 2) AD9883 75 Maximum frequency to select CPC5 at VCO 2

46 CPC 6 Thresh MAX (VCO 2) AD9883 95 Maximum frequency to select CPC6 at VCO 2

50 CPC 0 Thresh MAX (VCO 3) AD9883 0 Maximum frequency to select CPC0 at VCO 3

51 CPC 1 Thresh MAX (VCO 3) AD9883 0 Maximum frequency to select CPC1 at VCO 3

52 CPC 2 Thresh MAX (VCO 3) AD9883 0 Maximum frequency to select CPC2 at VCO 3

53 CPC 3 Thresh MAX (VCO 3) AD9883 0 Maximum frequency to select CPC3 at VCO 3

54 CPC 4 Thresh MAX (VCO 3) AD9883 0 Maximum frequency to select CPC4 at VCO 3

55 CPC 5 Thresh MAX (VCO 3) AD9883 0 Maximum frequency to select CPC5 at VCO 3

56 CPC 6 Thresh MAX (VCO 3) AD9883 140 Maximum frequency to select CPC6 at VCO 3

60 PRECOAST (PC) AD9883 3

61 POSTCOAST(PC) AD9883 3

62 PRECOAST (PC Video) AD9883 10

63 POSTCOAST(PC Video) AD9883 4

64 PRECOAST (Component) AD9883 10 Maximum frequency to select CPC6 at VCO 3

65 POSTCOAST(Component) AD9883 4 Maximum frequency to select CPC7 at VCO 3

70 FREQ OFFSET AD9882 0 Offset at DCLK more than 82MHz for AD9882

Group 1

UPD64012

7 IMODE uPD64012 0

8 RGB_MIX uPD64012 2

9 AUTOCLR uPD64012 1

10 SIGDETLV uPD64012 1

11 SIGON uPD64012 1

12 SIGOFF uPD64012 0

13 TV50F uPD64012 0

14 TV60F uPD64012 0

15 SETINT uPD64012 1

16 SETPRG uPD64012 0

17 COLORM uPD64012 0

18 KILOFFT uPD64012 0

19 UNLINC uPD64012 0

20 DETOUT uPD64012 3

21 DETTIM uPD64012 3

22 CLKVA uPD64012 1

23 CLKKLL uPD64012 40

24 CODDEN uPD64012 0

XGA

Component Video

HDTV 480p 480i NTSC PAL

Range Description

PC/AV 30KHz/AV 15KHz

　✻ Pedestal Adj.(PC),(1080i) 　✻ Pedestal Adj.(PC),(1080i) 　✻ Pedestal Adj.(PC),(1080i) 　✻ Gain Adj.(PC),(1080i) 　✻ Gain Adj.(PC),(1080i) 　✻ Gain Adj.(PC),(1080i)

-28-

Electrical Adjustments

Item No. NAME Device

25 CRDLY uPD64012 1

26 PHBDL uPD64012 0

27 PHRDL uPD64012 0

28 CBOFS uPD64012 0

29 CROFS uPD64012 0

30 FRCENY uPD64012 0

31 FRCENC uPD64012 0

32 DLYCTL uPD64012 8

33 OUTBITW uPD64012 0

34 CLKOINV uPD64012 1

35 RDOSEL uPD64012 0

36 SQCBCR uPD64012 0

37 ACTVH uPD64012 128

38 HPOSI uPD64012 128

39 HSPOS uPD64012 132

40 HSWID uPD64012 64

41 FSTAV uPD64012 0

42 VSPOS uPD64012 64

43 VSWID uPD64012 2

44 VBKFAL uPD64012 260

45 VBKRIS uPD64012 16

46 INBKENA uPD64012 0

47 YBLK uPD64012 0

48 SYNCSEL uPD64012 1

49 VDSEL uPD64012 1

50 HSPOL uPD64012 1

51 VSPOL uPD64012 1

52 FIELDPOL uPD64012 1

53 INHBKST uPD64012 715

54 INHBKEN uPD64012 853

55 INVBLKST uPD64012 260

56 INVBLKEN uPD64012 16

57 FLDTHR uPD64012 0

58 FILDIV uPD64012 0

59 TSRTCNV uPD64012 1

60 R_GAIN uPD64012 22 22 22 10

61 G_GAIN uPD64012 22 22 22 17

62 B_GAIN uPD64012 22 22 22 10

63 FLTSEL uPD64012 0

64 PEDIIRS2 uPD64012 0

65 SBCNT2 uPD64012 32

66 CBGAIN uPD64012 32

67 CRGAIN uPD64012 32

68 YGCAUTO uPD64012 0

69 YGCVAL uPD64012 42/45 42/45 45/45 45/45

70 YGCOFF uPD64012 0

71 YGCMVS uPD64012 0

72 YPGAINS uPD64012 2

73 YGCAVAL uPD64012 9

74 MAXIIRS uPD64012 0

75 PEDIIRS uPD64012 0

76 YGCMODE1 uPD64012 0

77 YGCMODE2 uPD64012 0

78 YGCIIRS uPD64012 1

79 YCSV uPD64012 0

80 YCOMA uPD64012 2

81 YCOMB uPD64012 2

82 YCSHY uPD64012 0

83 YCSHC uPD64012 0

84 COBPFOFF uPD64012 0

85 YCSCOF uPD64012 4

86 YCSSY uPD64012 0

87 VLTYPE uPD64012 1

88 YCSSC uPD64012 0

89 VAPONV uPD64012 0

90 VAPG uPD64012 4

91 VAPI uPD64012 16

92 PALCFIL uPD64012 0

93 YCSY2F uPD64012 3

94 TRF uPD64012 0

95 TRGAIN uPD64012 0

96 TRPAL uPD64012 0

97 APCGAIN uPD64012 1

98 ACCGAIN uPD64012 1

99 ACCLIM uPD64012 8

100 STNTSCM uPD64012 0

101 STPALD uPD64012 0

VIDEO

NTSC/PAL

S-VIDEO

NTSC/PAL

XGA

Component Video

HDTV 480p 480i NTSC PAL

YCBCR

480i/575i

Range Description

SCART

480i/575i

-29-

Electrical Adjustments

Item No. NAME Device

102 SBCNT uPD64012 109 / 111 104 / 106 108 / 108 102 / 102

103 SBCLRU uPD64012 128 128 128 141

104 SBCLRV uPD64012 128 128 128 141

105 YCONR uPD64012 0

106 CCONR uPD64012 0

107 YCORB uPD64012 0

108 YCOREN uPD64012 1

109 YCORH uPD64012 0

110 CCORB uPD64012 0

111 CCOREN uPD64012 0

112 LTIGAIN uPD64012 0

113 CTIGAIN uPD64012 0

114 LTITAP uPD64012 2

115 LTICORE uPD64012 3

116 CTITAP uPD64012 2

117 CTICORE uPD64012 3

118 SHPGAIN uPD64012 176

119 SHPCHAR uPD64012 2

120 SHPCORE uPD64012 0

121 BRIGHT uPD64012 512

122 OFRY uPD64012 32

123 COLORG uPD64012 128

124 HUE uPD64012 114

125 CONT uPD64012 128

126 APLWID uPD64012 0

127 APLCOE uPD64012 5

128 DCREGAIN uPD64012 8

129 BLENGAIN uPD64012 16

130 ABLENST uPD64012 0

131 BLEXST uPD64012 0

132 GAMGAIN uPD64012 0

133 AGAMGAIN uPD64012 0

134 GAMST uPD64012 255

135 BLENCTL uPD64012 0

136 YGACTL uPD64012 0

137 ACLSEN uPD64012 0

138 ACLST uPD64012 255

139 YVBCTL uPD64012 1

140 CRLPF uPD64012 1

141 CBLPF uPD64012 1

142 KILLV uPD64012 8

143 KILLVCTL uPD64012 9

144 VLIM uPD64012 0

145 VDCOR uPD64012 0

146 LPFTHR uPD64012 SCART: 0 COMPOSET/SVIDEO:0

147 ADCLK uPD64012 SCART: 3 COMOSITE/SVIDEO:2

Group 9 PANEL CONTROL

0 R-SubGain L3E07110 512/524/472/535/512/524/472/535 1-1023

1 G-SubGain L3E07110 512/524/472/472/512/524/472/472 1-1023

2 B-SubGain L3E07110 512/524/472/472/512/524/472/472 1-1023

3 R-SubBright L3E07110 0/0/24/16/0/0/24/16 1-1023

4 G-SubBright L3E07110 0/0/24/16/0/0/24/16 1-1023

5 B-SubBright L3E07110 0/0/24/16/0/0/24/16 1-1023

6 R-GammaShift L3E07110 0/0/0/0 1-1023

7 G-GammaShift L3E07110 0/0/0/0 1-1023

8 B-GammaShift L3E07110 0/0/0/0 1-1023

9 R_ReferH L3E07110 Normal:1000/Ceiling:1000 1-1023

10 R_ReferL L3E07110 Normal:304/Ceiling:304 1-1023

11 G_ReferH L3E07110 Normal:1000/Ceiling:1000 1-1023 When adjusting G, the value of R and B changes together

12 G_ReferL L3E07110 Normal:304/Ceiling:304 1-1023 When adjusting G, the value of R and B changes together

13 B_ReferH L3E07110 Normal:1000/Ceiling:1000 1-1023

14 B_ReferL L3E07110 Nor mal:304/Ceiling:304 1-1023

15 DXOUTR L3E07110 237 1-1023

16 DXOUTG L3E07110 237 1-1023

17 DXOUTB L3E07110 237 1-1023

18 H_Change_Pos L3E07110 3 0-256

19 SH_Base L3E07110 273 0-4095

20 NRG_Pos L3E07110 62 0-128

21 NRG_Width L3E07110 53 0-255

22 OSD_Pos L3E07110 2 0-3

23 OSD_Ptn L3E07110 0 0-7

24 GammaCtrl L3E07110 1 0-1

25 REF_GatePos L3E07110 5 0-1023

26 REF_GateDur L3E07110 204 0-1023

27 R-BasePos L3E07110 8 0-15

28 G-BasePos L3E07110 8 0-15 When adjusting G, the value of R and B changes together

VIDEO S-VIDEO YCBCR SCART

NTSC / PAL NSTC / PAL 480i / 575i 480i / 575i

XGA

Component Video

HDTV 480p 480i NTSC PAL

Range Description

PCStandard/PCDynamic/PCReal/PCBlackBoard/

AVStandard/AVDnamic/AVCinema/AVBlackBoard

PC/DVI/HDCP/VIDEO　✻ White Balance Adj.(PC),(Video)

When adjusting G, the value of R and B changes together ✻ 50%-White Adj.(PC),(Video) PC/DVI/HDCP/VIDEO　✻ White Balance Adj.(PC),(Video)

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