Sanyo PLC-XP45,PLC-XP40 Service Manual
Multimedia Projector
SERVICE MANUAL
PRODUCT CODE
1 122 108 00
(MA8A)
1 122 109 00 (PA8A)
1 122 109 02 (PA8C)
1 122 110 00 (MB8A)
1 122 111 00 (PB8A)
1 122 111 02 (PB8C)
Original Version
REFERENCE NO. SM5110261
FILE NO.
Model No. PLC-XP45
PLC-XP40
U.S.A., Canada,
Europe, Asia, Africa
U.K
Chassis No. MA8-XP4500
MB8-XP4000
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.
PLC-XP45
PLC-XP40
2
■ Contents
■ Safety instructions ________________________________________________3
■ Specifications __________________________________________________ 4
■ Note on Servicing ______________________________________________ 5
■ Adjustments after parts replacement ________________________________ 5
■ Circuit protections ______________________________________________ 6-7
● Fuse ____________________________________________________ 6
● Thermal switch ____________________________________________ 6
● Interlock switch ____________________________________________ 6
● Warning temperature and power failure protection ________________ 7
■ Mechanical disassemblies ______________________________________ 8-12
■ Optical parts disassemblies ____________________________________ 13-16
■ LCD panel/prism ass’y replacement ________________________________ 17
■ Lamp replacement ______________________________________________ 18
■ Optical adjustments __________________________________________ 19-21
● Contrast adjustment ________________________________________ 19
● Condenser adjustment ______________________________________ 20
● Relay lens adjustment ______________________________________ 21
■ Electric adjustments __________________________________________ 22-30
● Service adjustment menu operation ____________________________ 22
● Circuit adjustments ______________________________________ 23-27
● Service adjustment data table ______________________________ 28-33
● Test points and locations ____________________________________ 34
■ Troubleshooting ______________________________________________ 35-40
● No power ______________________________________________ 35-36
● No picture ____________________________________________ 37-38
● No sound ________________________________________________ 39
● Lens motor problems ______________________________________ 40
■ Control port functions ________________________________________ 41-45
■ Waveforms __________________________________________________ 46-47
■ Cleaning ______________________________________________________ 48
■ IC block diagrams ____________________________________________ 49-59
■ Service parts lists ____________________________________________ 60-91
● Electrical parts list ______________________________________ 60-85
● Mechanical parts list ____________________________________ 86-88
● Optical parts list ________________________________________ 89-91
Drawings & Diagrams ______________________________________ A1-A16
■ Parts description and reading in schematic diagram____________________ A2
■ Circuit block diagram ____________________________________________ A3
■ Power supply lines ______________________________________________ A4
■ Schematic diagrams ________________________________________ A5-A12
■ Printed wiring board diagrams ________________________________ A13-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) 12.6” x 6.6” x 18.5” (319mm x 168mm x 470mm) (PLC-XP45)
12.6” x 6.6” x 16.8” (319mm x 168mm x 429.5mm) (PLC-XP40)
Net Weight 18.5 lbs (8.4 kg) (PLC-XP45), 17.4 lbs (7.9 kg) (PLC-XP40)
LCD Panel System 1.3” TFT Active Matrix type, 3 panels
Panel Resolution 1024 x 768 dots
Number of Pixels 2,359,296 (1024 x 768 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 ~ 100kHz, V-sync. 50 ~ 100Hz
Projection Image Size (diagonal) Adjustable from 31” to 400”
Horizontal Resolution 800 TV lines (HDTV)
Projection Lens F 1.7 ~2.0 lens with f=48.2mm ~ 62.6mm with motor zoom and focus (PLC-XP45)
F 1.8 ~2.1 lens with f=48.4mm ~ 62.8mm with motor zoom and focus (PLC-XP40)
Throw Distance 4.6’ ~ 48.3’ (1.4m ~ 14.7m) (PLC-XP45), 4.6’ ~ 47.3’ (1.4m ~ 14.4m) (PLC-XP40)
Motorized Lens Shift Up and Down
Projection Lamp 200watts
Input 1 Jacks DVI Terminal (Digital), HDB 15-pin Terminal (Analog) and Stereo Mini Type
Jack (Audio)
Input 2 Jacks BNC Type x 5 (G or VIDEO/Y, B or Cb/Pb, R or Cr/Pr, H and V), Stereo
Mini Type Jack (Audio)
Input 3 Jacks RCA Type x 3 (VIDEO/Y, Cb/Pb, Cr/Pr), RCA Type x 2 (Audio R and L) and
DIN 4-pin (S-Video)
Other Jacks DIN 8-pin (Control port), USB port (Series B receptacle) and Wired
Remote Jack
Built-in Speakers 2 speakers Stereo (R and L), 2 watts RMS (T.H.D. 10%)
Feet Adjustment 0˚ to 10.5˚
Voltage and AC 100 ~ 120V (3.6A Max. Ampere), 50/60Hz (The U.S.A and Canada)
Power Consumption AC 200 ~ 240V (1.8A Max. Ampere), 50/60Hz (Continental Europe and The UK.)
Operating Temperature 41˚F ~ 95˚F (5˚C ~ 35˚C)
Storage Temperature 14˚F ~ 140˚F (-10˚C ~ 60˚C)
Remote Control Transmitters Wireless/Wired Remote Control, batteries AA, UM3 or R06 Type x 2
5
Condenser lens adjustment ❍●
Relay lens adjustment ❍●
Contrast Adjustment
R-Contrast adjustment ●
G-Contrast adjustment ●
B-Contrast adjustment ●
Output voltage adjustment ●
+16 V adjustment ●
Video center adjustment ●
PSIG adjustment ●
PC pedestal adjustment ●
Black level adjustment ●
PC gain adjustment ●
PC gamma shift adjustment ●
HDTV pedestal adjustment ●
HDTV A/D input adjustment ●
HDTV Gain adjustment ●
Video pedestal adjustment ●
Video A/D input adjustment ●
A/D offset adjustment ●
Video gain adjustment ●
Video gamma shift adjustment ●
Common center adjustment ● ●
White balance adjustment ❍ ❍
Disassembly / Replaced Parts
LCD/
Prism
Ass’y
Condenser
Lens
Polarized glass
RGB
Optical Adjustments
Electrical Adjustments
● : Adjustment necessary ❍ : Check necessary
Sub Power
Board
Main Board
Relay
Lens
■ Adjustments after Parts Replacement
Powe r
Board
-6-
● Interlock switch
The interlock switch (SW902) 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 (SW905) inside of the projector to
prevent the internal temperature from rising abnormally. When the
internal temperature reaches near 90˚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.
Loosen 2 screws and open the lamp cover.
2. Press the reset button on the thermal switch with a sharp-
pointed tool.
CAUTION:
Before press the reset button, disconnect the AC cord from the
projector.
■ Circuit Protections
This projector is equipped with 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.: 423 021 7801
TYPE T6.3AH 250V FUSE
LITTEL FUSE INC. TYPE 21506.3
Fuse
Line Filter Board
Interlock switch
Thermal switch
Lamp cover
-7-
Circuit Protections
● Warning temperature and power failure protection
The TEMP WARNING indicator flashes red and the projector will automatically turn off when the internal temperature of the projector exceeds the normal temperature or when stopping cooling fans or when the internal power
supply lines are failed.
Check the following possible causes and wait until stopping the TEMP WARNING indicator flashing.
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)
If the TEMP WARNING indicator still continues to flash, there may be defects on cooling fans or power supply circuits. Please check fan operation and power supply lines referring to the “Power Supply Lines Chart”.
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 an air fil-
ters by pulling the latches of them upward.
3. Clean the air filters with brush or wash out the dust and
particles.
4. Replace each air filter properly. Make sure that the air
filters are 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 filter is
small parts. Take care that children don’t eat or swallow it.
RECOMMENDATION
We recommend to avoid dusty, smoky place for operating the projector. Using in dusty place may cause the picture
of poor 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 filters
-8-
1 Remove 5 screws A, 2 screws B, and loosen 2 screws
C, and then take the Cabinet Top upward off.
Note: If you want to remove the Cabinet Front-Top only,
you do not need to remove screws A. Remove 2 screws B
and Lens Front Cover.
■ 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.
Fig.1
1 Tu rn the Lens Front Cover counter-clockwise and to take
it off by pulling forward as shown in Fig.2-1.
2 Remove the Cabinet Front-Top, Lens Cover Holder and
Lens Cover upward off.
3 Remove 2 screws D to take the Cabinet Front off.
4 Remove the RC Board and speakers on the Cabinet
Front.
Fig.2
-2
Cabinet Top removal
1
Cabinet Front removal
2
UP
Fig.2-1
C
B
A
A
A
A
B
A
D
D
Cabinet Front-Top
Lens
Front
Cover
Lens Cover Holder
Cabinet Front
Lens Cover
C
-9-
Mechanical Disassemblies
1 Remove 7 screws to take the Main Board upward.
Fig.3
Fig.4
1 Remove 2 screws A and take the Rear Panel ass’y
upward off.
2 Remove 4 screws B to take the fan (FN905) off.
3 Remove 5 screws C and 1 screw D to take AV Board
from the Rear Panel ass’y off.
Main Board removal
3
AV Board & Rear Panel removal
4
A
Main Board
A
B
B
B
B
C
D
Rear Panel Ass’y
FN905
AV Board
-10-
Mechanical Disassemblies
1 Remove 4 screws A to take the Ballast Cover upward
off.
2 Remove 2 screws B to take the Fan (FN903) off.
3 Remove the Sub Power Board and Drive Board by
pulling them upward.
Fig.5
1
Remove 2 screws A and 4 screws B(small)
and pull the
Optical Unit upward off.
2 Remove 4 screws C to take the Fan (FN906) off.
3 Remove 1 screws D to take the Fan (FN904) off and 2
screws E to take the air duct off.
Fig.6
Lamp Ballast Unit removal
5
Optical Unit removal
6
A
Ballast Board
FN903
Sub Power
Board
Drive Board
A
A
A
B
B
Ballast Cover
FN906
FN904
Optical Unit
A
A
B
B
B
B
C
C
C
D
E
E
-11-
1 Remove 2 screws A to take the Prism Base ass’y
upward off.
2 Remove 2 screws B to take the Lens Shift Motor and
Sensor SW Holder from the Base.
Mechanical Disassemblies
1 Remove 3 screws A to take the Power Board off.
2 Remove 4 screws B to take Holder off from the cabinet
bottom.
Fig.8
Fig.7
Prism Base removal
7
Power Board removal
8
Prism Base Ass’y
Motor and
Sensor Holder
B
B
A
A
Power Board
Power Board
Holder
B
B
A
A
B
B
A
1 Remove 1 screw A to take Interlock Switch(SW905).
2 Remove 2 screws B to take Filter Board Holder and
remove 2 screws C to take Filter Board from the Holder.
3 Remove 1 screw D to take Thermal Switch(SW902).
-12-
Mechanical Disassemblies
1 Remove 4 screws A to take Air-duct Top off.
2 Remove 1 screw B (small) and 1 screw C (big) to take
Duct Cover-A.
3 Remove 2 screws D to take Fan (FN901) off.
4 Remove 2 screws E (small) and 2 screws F (big) to take
Air-duct-A and Fan (FN902) off.
Fig.10
Fans (FN901, FN902) removal
10
Fig.9
Line Filter Board & Interlock SW & Thermal
SW removal
9
D
Interlock Switch
(SW905)
Filter Board
C
C
A
B
B
Holder
Thermal Switch
(SW902)
A
A
AA
B
C
D
D
E
E
F
F
F
Duct
Cover
-A
FN901
FN902
Air-duct-A
Air-duct
To p
Duct
Cover-B
-13-
1 Remove Cabinet Front-Top following to the chapter “Mechanical
Disassemblies”.
2 Loosen 2 screws A with 2.5mm hex wrench.
3 Unhook 2 hooks B on the both side of the lens and remove the
Projection Lens ass’y off.
Fig.1
■ Optical Parts Disassemblies
Before taking this procedure, remove Cabinet Top and Main Board following to the “Mechanical Disassemblies”.
Disassembly requires a 2.0mm or 2.5mm hex wrench and a slot screwdriver.
Projection Lens removal
Fig.1-2
1 Remove each hex screw and pull the Polarized Glass-In ass’y upward.
2 Remove a stopper and take the glass off upward.
Polarized Glass-In removal
Fig.2-1
Fig.2-2
A
A
B
B
Stopper
polarized glass
* Should be placed the glass as the
printed marker comes to the
upper left corner.
Phase Sheet
Part No. is printed on
upper side.
-14-
1 Remove 4 hex screws A and take the LCD/Prism ass’y off upward.
2 Remove 3 screws B and take the Glass Holder, and then pull the polarized
Glass-Out upwards off.
Note:
To avoid the CG and focus alignments slipping off, please be careful to handle the LCD/Prism ass'y.
LCD Panel/Prism Ass’y
* Should be placed the glass as the
sheet attached side comes to the
LCD panel side.
Note:
Do not replace the LCD panel
separately otherwise it can
not obtain proper picture.
Fig.4-1
Polarized Glass-Out removal
A
A
A
Optical Pats Disassemblies
1 Remove 2 hex screws A and pull the Relay Lens ass’y upward.
2 Remove 2 screws B to take the Lens off from the holder.
Note:
There is no mounting direction of the lens.
A
Fig.3-2
Fig.3-1
B
B
Holder
Relay Lens
A
Relay Lens disassembly
Fig.4-2
B
B
B
Polarized GlassOut
Phase Sheet
-15-
Optical Parts Disassemblies
1 Remove 7 screws to take the Optical Unit Top off upward.
Optical Unit Top removal
1 Remove 2 hex screws A and take the Condenser Lens ass’y.
2 Release 4 hooks B to take the Lens off from the holder.
A
Fig.6-2
Fig.6-
1
B
Holder
Condenser Lens
A
Condenser Lens disassembly
* Should be placed the
lens as the flat surface
side comes to the
holder side.
Condenser Lens
Fig.5
-16-
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.
14
12
8
Fig.7
3
14
1
2
4
9
Locations and Directions
13
6
1 Condenser lens (R)
2 Condenser lens
3 Condenser lens
4 Mirror (B)
5 Optical filter (UV cut)
6 Dichroic mirror (B
7 Dichroic mirror (G)
8 Mirror (W)
9 Condenser lens (IN)
10 PBS (prism beam splitter)
11 Integrator lens (OUT)
12 Integrator lens (IN)
13 Relay lens (IN)
14 Mirror (R)
Key No. Description
7
10
11
5
The printed marker
comes this side.
The printed marker
comes this side.
Place the lens as the both
rugged surface sides face
each other.
-17-
■ LCD Panel/Prism Ass’y Replacement
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.
LCD Panel/Prism
Ass’y
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 the 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.
T
op View
A
A
A
A
LCD Panel/Prism Ass’y
Note:
Do not replace the LCD
panel separately otherwise
it can not obtain proper picture.
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 adjustments.
- Check the “Condenser Lens Adjustment” and “Relay Lens Adjustment” following to chapter “Optical
Adjustment”.
- Check the “White Balance Adjustment” and “Common Centre Adjustment” following to chapter
“Electrical Adjustment”.
- Check the white uniformity on the screen.
If you find the color shading, 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 SOFTWARE
Service Parts No. 645 051 2308
LCD Panel/Prism Ass’y removal
Note on LCD Panel/Prism Ass’y Mounting
-18-
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 2 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 2 screws.
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.
■ Lamp Replacement
1 Tu rn the projector on, and press the MENU button
and the on-screen menu will appear. Press the POINT
LEFT/RIGHT buttons to move a red frame pointer to
SETTING menu icon.
2 Press the POINT DOWN 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”.
The LAMP REPLACEMENT indicator will illuminate
when the Lamp Replace Counter reaches 1000
hours. This is to indicate that lamp replacement is
required.
You can check the lamp replace counter following to
below procedure.
1 Press and hold the pointer UP on the projector for
more than 20 seconds.
2 The Lamp replace Counter service menu appears
on the screen briefly. For example, when the value
of data indicates “123”, the accumulated operation
time is 123 hours.
Lamp cover
Lamp replace counter data
ORDER REPLACEMENT LAMP
T
ype No.
Service Parts No.
POA-LMP38 610 293 5868
How to reset Lamp Replace Counter
How to check Lamp Replace Counter
Screws
Handle
Lamp Assembly
Service Mode
Input 1
Group No. Data
10 0 123
Ver. 1.00 .00
-19-
[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 Tu rn 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
Fig.1-2
Fig.1-1
Polarized glass
mounting base
■ Optical Adjustments
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.
Note: Do not disconnect connectors K8L, K8X, K8D, K8G and K8E on the main board, because the projector can
not turn on due to operate the power failure protection.
-20-
Optical Adjustments
Fig.2-2
1 Tu rn the projector on by a state of without FPC cables.
2 Adjust the adjustment base of condenser lens ass’y 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 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 1 screw C with the 2.0mm hex driver,
and adjust the slot D to make color uniformity in green by using
a slot screwdriver
3 Tighten screws A and C to fix the Condenser lens unit.
Note:
The relay lens adjustment must be carried out after completing this
adjustment.
y
x
Moving of Slot D
Slot D
a
b
a
b
Moving of slot B
Fig.2-1
Slot B
A
C
y
x
White
White
Condenser Lens adjustment
A
-21-
1 Tu rn the projector on by a state of without FPC cables.
2 Adjust the adjustment base of relay lens ass’y to make color unifor-
mity in white.
1) If the cyan bar 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 cyan bar appears on the top or bottom of the screen as
shown in Fig.4-2, loosen 2 screws C with the 2.0mm hex driver,
and adjust the screw D to make color uniformity in white by using
a slot screwdriver.
3 Tighten the screws A and C to fix the relay lens unit.
Fig.4-1
A
Slot B
a
b
a
Moving of slot B
b
White
Fig.4-2
Screw D
Moving of slot D
y
x
C
Optical Adjustments
y
x
Relay lens-Out adjustment
White
C
Cyan
Cyan
-22-
■ 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 group no. by pressing the MENU button, and select the adjustment item no. by pressing the
pointer UP or DOWN button, and change the data value by pressing the VOLUME – or VOLUME + 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.
● Service Adjustment Menu Operation
IC808 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, it should be performed the re-adjustments
following to the “Electrical Adjustments”.
The data of lamp replacement monitor timer is stored
in the IC808.
Please note that the lamp replace counter is reset
when the memory IC (IC808) is replaced.
(Lamp replace counter can not be set to the previous
value.)
● Caution to memory IC replacement
When IC808 is replaced with new one, the CPU writes
down the default data of the service adjustments to the
replaced IC, refer to the service adjustment table. As
these data are not the same data as factory shipped
data, it should be required to perform the re-adjust-
ments following to the “Electrical Adjustments”.
Please note that the lamp replace counter is reset.
● Caution of Main Board replacement (in the case
IC808 is not defective)
When the main board is replaced, IC808 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
v
alue as before.
● Memory IC Replacement
Group No.
Data value
Item No.
Service Mode
Input 1
Group No. Data
0032
Ver. 1.00 .00
[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 (XGA)
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 to the service mode and adjusting the service
data.
-23-
After replacing the Power Board readjust the Output
voltage adjustment as follows.
1. Connect a digital voltmeter to pin 1 (+) of K6A and
chassis ground (-).
2. Adjust the voltage by using VR601 on the power
board as following.
AC Input Reading
230V 370 ±2Vdc
or 120V 340 ±2Vdc
Caution:
Be sure to connect the lamp when taking this adjustment.
● 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
Output Voltage adjustment
1. Receive the 16-step gray scale video signal with
Input 3 [VIDEO] mode.
2. Connect a digital voltmeter to pin 3 (+) of CN6A and
chassis ground (-).
3. Adjust the voltage to be 15.8 ±0.1Vdc by using
VR681 on the power board.
+16V adjustment
1. Receive the 16-step gray scale computer signal with
Input 1 [COMPUTER] mode.
2. Enter the service mode.
3. Connect a digital voltmeter to test point “TP531”(+)
and chassis ground (-).
4. Select group no. “5”, item no. “1” and change data
value to adjust the voltage to be 7.30 ±0.1Vdc.
5. Connect a digital voltmeter to test point “TP501”(+)
and chassis ground (-).
6. Select item no. “0” and change data value to adjust
the voltage to be 7.30 ±0.1Vdc.
7. Connect a digital voltmeter to test point “TP561”(+)
and chassis ground (-).
8. Select item no. “2” and change data value to adjust
the voltage to be 7.30 ±0.1Vdc.
Video Center adjustment
16 steps gray scale pattern
White 100%
Black 100%
-24-
Electrical Adjustments
1. Receive the 16-step gray scale computer signal with
Input 1 [COMPUTER] mode.
2. Enter the service mode.
3. Connect an oscilloscope to test point “TP531” (+) and
chassis ground (-).
4. Select group no. “5”, item no. “16” and change data
value to adjust the pedestal level and black level to be
the same level.
5. Connect an oscilloscope to test point “TP501” (+) and
chassis ground (-).
6. Select item no. “15” and change data value to adjust
the pedestal level and black level to be the same
level.
7. Connect an oscilloscope to test point “TP561” (+) and
chassis ground (-).
8. Select item no. “17” and change data value to adjust
the pedestal level and black level to be the same
level.
PC Pedestal adjustment
1. Receive the a6-step gray scale computer signal with
Input 1 [COMPUTER] mode.
2. Enter the service mode.
3. Connect an oscilloscope to test point “2551” (+) and
chassis ground (-).
4. Select group no. “5”, item no. “6” and change data
value to adjust amplitude “a” to be 3.8 ±0.1V.
5. Select item no. “8” and change data value to adjust
amplitude “b” to be 3.1 ±0.1V.
PSIG adjustment
1. Receive the 16-step gray scale computer signal with
Input 1 [COMPUTER] mode.
2. Enter the service mode.
3. Connect an oscilloscope to test point “TP531” (+)
and chassis ground (-).
4. Select group no. “5”, item no. “4” and change data
value to adjust amplitude “a” to be 10.0 ±0.1V.
5. Connect an oscilloscope to test point “TP501”(+)
and chassis ground (-).
6. Select item no. “3” and change data value to adjust
amplitude “a” to be 10.0 ±0.1V.
7. Connect an oscilloscope to test point “TP561”(+)
and chassis ground (-).
8. Select item no. “5” and change data value to adjust
amplitude “a” to be 10.0 ±0.1V.
Black Level adjustment
1. Receive the 16-step gray scale computer signal with
Input 1 [COMPUTER] mode.
2. Enter the service mode.
3. Connect an oscilloscope to test point “TP531”(+)
and chassis ground (-).
4. Select group no. “4”, item no. “4” and set data value
to “600”, and then decrease data to adjust waveform
“a” to be minimum amplitude.
5. Connect an oscilloscope to test point “TP501”(+)
and chassis ground (-).
6. Select item no. “5” and set data value to “600”, and
then decrease data to adjust waveform “a” to be minimum amplitude.
7. Connect an oscilloscope to test point “TP561”(+)
and chassis ground (-).
8. Select item no. “3” and set data value to “580”, and
then decrease data to adjust waveform “a” to be minimum amplitude.
PC Gain adjustment
black level
(a)
Pedestal Lebel = Black Lebel
(b)
black level
White Level
(a)
(a)
-25-
Electrical Adjustments
1. Receive the 16-step gray scale computer signal with
Input 1 [COMPUTER] mode.
2. Enter the service mode.
3. Select group no. “4”, item no. “6” and change data
value to reproduce the proper gray scale picture on
the screen.
PC Gamma Shift adjustment
[480p-PEDESTAL ADJUSTMENT]
1. Receive the 16-step gray scale component signal
[480p] with Input 3 [COMPONENT] mode.
2. Enter the service mode.
3. Connect an oscilloscope to test point “TP21G”(+)
and chassis ground (-).
4. Select group no. “3”, item no. “1” and change data
value to adjust the pedestal level and black level to be
the same level.
5. Connect an oscilloscope to test point “TP21B”(+)
and chassis ground (-).
6. Select group no. “5”, item no. “14” and change data
value to adjust the pedestal level and black level to be
the same level.
7. Connect an oscilloscope to test point “TP21R”(+)
and chassis ground (-).
8. Select item no. “13 and change data value to adjust
the pedestal level and black level to be the same
level.
[1080i-PEDESTAL ADJUSTMENT]
1. Receive the 16-step gray scale component signal
[1080i] with Input 3 [COMPONENT] mode.
2. Enter the service mode.
3. Connect an oscilloscope to test point “TP21G”(+)
and chassis ground (-).
4. Select group no. “3”, item no. “1” and change data
value to adjust the pedestal level and black level to be
the same level.
5. Connect an oscilloscope to test point “TP21B”(+)
and chassis ground (-).
6. Select item no. “14” and change data value to adjust
the pedestal level and black level to be the same
level.
7. Connect an oscilloscope to test point “TP21R”(+)
and chassis ground (-).
HDTV Pedestal adjustment
8. Select item no. “13 and change data value to adjust
the pedestal level and black level to be the same
level.
[480p-A/D INPUT ADJUSTMENT]
1. Receive the 16-step gray scale component signal
[480p] with Input 3 [COMPONENT] mode.
2. Enter the service mode.
3. Connect an oscilloscope to test point “TP21G”(+)
and chassis ground (-).
4. Select group no. “3”, item no. “0” and change data
value to adjust amplitude “a” to be 0.9 ±0.1V.
5. Connect an oscilloscope to test point “TP21B”(+)
and chassis ground (-).
6. Select item no. “4” and change data value to adjust
amplitude “a” to be 0.9 ±0.1V.
7. Connect an oscilloscope to test point “TP21R”(+)
and chassis ground (-).
8. Select item no. “2 and change data value to adjust
amplitude “a” to be 0.9 ±0.1V.
[1080i-A/D INPUT ADJUSTMENT]
1. Receive the 16-step gray scale component signal
[1080i] with Input 3 [COMPONENT] mode.
2. Enter the service mode.
3. Connect an oscilloscope to test point “TP21G”(+)
and chassis ground (-).
4. Select group no. “
3”, item no. “0” and change data
value to adjust amplitude “a” to be 0.9 ±0.1V.
5. Connect an oscilloscope to test point “TP21B”(+)
and chassis ground (-).
6. Select item no. “4” and change data value to adjust
amplitude “a” to be 0.9 ±0.1V.
7. Connect an oscilloscope to test point “TP21R”(+)
and chassis ground (-).
8. Select item no. “2 and change data value to adjust
amplitude “a” to be 0.9 ±0.1V.
Note: This adjustment should be done after HDTV
Pedestal adjustment.
HDTV A/D Input adjustment
(a)
Pedestal Lebel = Black Lebel
(a)
-26-
Electrical Adjustments
1. Receive the 16-step gray scale component signal
[1080i] with Input 3 [COMPONENT] mode.
2. Enter the service mode.
3. Connect an oscilloscope to test point “TP531”(+)
and chassis ground (-).
4. Select group no. “4”, item no. “4” and set data value
to “600”, and then decrease data to adjust waveform
“a” to be minimum amplitude.
5. Connect an oscilloscope to test point “TP501”(+)
and chassis ground (-).
6. Select item no. “5” and set data value to “600”, and
then decrease data to adjust waveform “a” to be minimum amplitude.
7. Connect an oscilloscope to test point “TP561”(+)
and chassis ground (-).
8. Select item no. “
3” and set data value to “600”, and
then decrease data to adjust waveform “a” to be minimum amplitude.
HDTV Gain adjustment
1. Receive the 16-step gray scale video signal with
Input 3 [VIDEO] mode.
2. Enter the service mode.
3. Connect an oscilloscope to test point “TP4151G”(+)
and chassis ground (-).
4. Select group no. “3”, item no. “1” and change data
value to adjust the pedestal level and black level to be
the same level.
5. Connect an oscilloscope to test point “TP4151B”(+)
and chassis ground (-).
6. Select group no. “5”, item no. “14” and change data
value to adjust the pedestal level and black level to be
the same level.
7. Connect an oscilloscope to test point “TP4151R”(+)
and chassis ground (-).
8. Select item no. “13 and change data value to adjust
the pedestal level and black level to be the same
level.
VIDEO Pedestal adjustment
1. Receive the 16-step gray scale video signal with
Input 3 [VIDEO] mode.
2. Enter the service mode.
3. Connect an oscilloscope to test point “TP4151G”(+)
and chassis ground (-).
4. Select group no. “3”, item no. “0” and change data
value to adjust amplitude “a” to be 0.8 ±0.1V.
5. Connect an oscilloscope to test point “TP4151B”(+)
and chassis ground (-).
6. Select item no. “4” and change data value to adjust
amplitude “a” to be 0.8 ±0.1V.
7. Connect an oscilloscope to test point “TP4151R”(+)
and chassis ground (-).
8. Select item no. “2 and change data value to adjust
amplitude “a” to be 0.8 ±0.1V.
Note: This adjustment should be done after VIDEO
Pedestal adjustment.
VIDEO A/D Input adjustment
White Level
(a)
Pedestal Lebel = Black Lebel
(a)
-27-
1. Receive the 16-step gray scale video signal with
Input 3 [VIDEO] mode.
2. Enter the service mode.
3. Connect an oscilloscope to test point “TP531” (+) and
chassis ground (-).
4. Select group no. “6”, item no. “11” and change data
value to adjust the pedestal level and black level to be
the same level.
5. Connect an oscilloscope to test point “TP501” (+) and
chassis ground (-).
6. Select item no. “12” and change data value to adjust
the pedestal level and black level to be the same
level.
7. Connect an oscilloscope to test point “TP561” (+) and
chassis ground (-).
8. Select item no. “10 and change data value to adjust
the pedestal level and black level to be the same
level.
1. Receive the 16-step gray scale computer signal with
Input 1 [COMPUTER] mode.
2. Enter the service mode.
3. Project only green light component to the screen.
4. Select group no. “5”, item no. “11” and change data
value to obtain the minimum flicker on the screen.
5. Project only blue light component to the screen.
6. Select item no. “12” and change data value to obtain
the minimum flicker on the screen.
7. Project only red light component to the screen.
8. Select item no. “10” and change data value to obtain
the minimum flicker on the screen.
A/D Offset adjustment
Common Center adjustment
[PC WHITE BALANCE ADJUSTMENT]
1. Receive the 16-step gray scale computer signal with
Input 1 [COMPUTER] mode.
2. Enter the service mode.
3. Select group no. “4”, item no. “7” (Red) or “8”(Blue),
and change data values respectively to make a proper white balance.
[AV WHITE BALANCE ADJUSTMENT]
4. Receive the 16-step gray scale video signal with
Input 3 [VIDEO] mode.
5. Enter the service mode.
6. Select group no. “4”, item no. “7” (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.
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 SOFTWARE
Ser
vice Parts No. 645 051 2308
NOTE ON WHITE UNIFORMITY
ADJUSTMENT
1. Receive the 16-step gray scale video signal with Input
3 [VIDEO] mode.
2. Enter the service mode.
3. Connect an oscilloscope to test point “TP531”(+)
and chassis ground (-).
4. Select group no. “4”, item no. “4” and set data value
to “600”, and then decrease data to adjust waveform
“a” to be minimum amplitude.
5. Connect an oscilloscope to test point “TP501”(+)
and chassis ground (-).
6. Select item no. “5” and set data value to “600”, and
then decrease data to adjust waveform “a” to be minimum amplitude.
7. Connect an oscilloscope to test point “TP561”(+)
and chassis ground (-).
8. Select item no. “3” and set data value to “580”, and
then decrease data to adjust waveform “a” to be minimum amplitude.
Video Gain adjustment
1. Receive the 16-step gray scale video signal with
Input 3 [VIDEO] mode.
2. Enter the service mode.
3. Select group no. “4”, item no. “6” and change data
value to reproduce the proper gray scale picture on
the screen.
Video Gamma Shift adjustment
Pedestal Lebel = Black Lebel
White Level
(a)
-28-
Group: 0 TC90A26
0Y-EQ_GAIN 3 0 ~ 3
1Y-EQ_N_C_LIM 3 0 ~ 3
2V-ENH_GAIN 4 0 ~ 7
3 V_ENH_CORING 2 0 ~ 3
4 NTSC443_SW 1 0 ~ 1 Input signal setting 0:NTSC4.43 1:PAL60 (Only effective for NTSC4.43 signal inputs)
Group: 1 uPD64082
0 NRMD 0 0 ~ 3
1 HDP 4 0 ~ 7
2 CDL 4 0 ~ 7
3DYCOR 4 0 ~ 15
4DYGAIN 15 0 ~ 15
5 DCCOR 2 0 ~ 15
6 DCGAIN 13 0 ~ 15
7 YNRK 0 0 or 1
8 YNRINV 0 0 or 1
9 YNRLIM 0 0 ~ 3
10 CNRK 0 0 or 1
11 CNRINV 0 0 or 1
12 CNRLIM 0 0 ~ 3
13 VAPGAIN 2 0 ~ 15
14 VAPINV 2 0 ~ 15
15 YPFT 3 0 ~ 3
16 YPFG 9 0 ~ 15
17 V1PSEL 3 0 ~ 3
18 VEGSEL 3 0 ~ 3
19 CC3N 0 0 or 1
20 SELD2FH 1 0 or 1
21 SELDFL 1 0 or 1
22 YHCOR 0 0 ~ 3
23 HPLLFS 1 0 or 1
24 PLLFG 1 0 or 1
25 KILR 3 0 ~ 15
26 HSSL 12 0 ~ 15
27 VSSL 3 0 ~ 15
28 BGPS 7 0 ~ 15
29 BGPW 3 0 ~ 15
Group: 2 TB1274
0 TINT 32 0 ~ 63
1 SHP_EQ 2 0 ~ 3
2 SHP_FO 2 0 ~ 3
3 SHP_GAIN 8/8/8/8/8/8/8 0 ~ 15 VideoNT/ PAL,PALM,PALN/SECAM,BW60,BW50/ NT443/ PAL60/ S-Video/YCbCr
4 Y_OUT_LEVEL 31/32/32/32/32 0 ~ 63 VideoNT/ NT443/ PAL,PALM,PALN/ PAL60/ SECAM,BW
0.7V 32/32/32/32/32/32 S-VideoNT,BW/ NT443/ PAL,PALM,PALN/ PAL60/ SECAM/ YCbCr
5 C_OUT_LEVEL 12/12/15/15/22 0 ~ 63 VideoNT/ NT443/ PAL,PALM,PALN/ PAL60/ SECAM,BW
0.6V 12/12/15/15/22/18/20 S-VideoNT,BW/ NT443/ PAL,PALM,PALN/ PAL60/ SECAM/480i/575i
6 Y_DELAY 5/5/4/4/4 0 ~ 15 Video NT,BW60/ PAL,PALM,PALN,BW50/ SECAM/NT443/PAL60
4/4/3/3/4 S-Video NT,BW60/PAL,PALM,PALN,BW50/ SECAM/ NT443/ PAL60
7 COL_SYS - -
8X’TAL - -
9 NOISE_DET - - Read Only
10 V_FREQ - -
11 Vert. Std - -
12 CID - -
13 VSIG - -
14 MVM 0 0 or 1
15 AFC_GAIN 1 0 ~ 3
Group: 3 CXA2101
0 PICTURE 15/25/25 0 ~ 63 NT,PAL,SECAM,NT443,PALM,PALN,480i,575i/ 480p,575p/ 1080i,1035i,720p ✻ A/D Input adjustment [G]
1 BRIGHT 50/50/50 0 ~ 63 NT,PAL,SECAM,NT443,PALM,PALN,480i,575i/ 480p,575p/ 1080i,1035i,720p ✻ Pedestal adjustment [G]
2 R_DRIVE 31/31/31 0 ~ 63 NT,NT443,PAL,PALM,PALN,480i,575i/ 480p,575p/ 1080i,1035i,720p ✻ A/D Input adjustment [R]
3 G_DRIVE 31 0 ~ 63
4 B_DRIVE 31/31/31 0 ~ 63 NT,NT443,PAL,PALM,PALN,480i,575i/ 480p,575p/ 1080i,1035i,720p ✻ A/D Input adjustment [B]
No. Adjustment Item Initial Value Range Input source / Description
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.
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