Sanyo PLC XU350 CPP2930
FILE NO.
SERVICE MANUAL
Multimedia Projector
Model No. PLC-XU350
PLC-XU300
U.S.A, Canada,
Europe, U.K, Asia
Original Version
PRODUCT CODE
PLC-XU350 PLC-XU300
1 122 471 00 (KF5AC) 1 122 461 00 (KA5AC)
1 122 472 00 (LF5AC) 1 122 462 00 (LA5AC)
1 122 472 02 (LF5CC) 1 122 462 02 (LA5CC)
Chassis No. KF5-XU35000
KA5-XU30000
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.
REFERENCE NO. SM5111050-00
Contents
SERVICE MANUAL ........................................................ 1
Contents ........................................................................ 2
Safety Instructions ......................................................... 3
Safety Precautions ...................................................... 3
Product Safety Notice ................................................. 3
Service Personnel Warning ......................................... 3
Specifications ................................................................4
Circuit Protections ......................................................... 5
Thermal switch ...........................................................5
Lamp cover switch ...................................................... 5
Fuse ............................................................................ 5
Warning temperature and power failure protection .... 6
Maintenance .................................................................. 7
Cleaning the Air Filter ................................................. 7
Resetting the Filter Counter........................................ 7
Attaching the Lens Cover ............................................ 8
Cleaning the Projection Lens ...................................... 8
Cleaning the Projector Cabinet ...................................8
Lamp Replacement .......................................................9
Lamp replacement ...................................................... 9
How to check Lamp Used Time ................................ 10
Warning Message on the non-standard lamp used .. 10
Security Function Notice ..............................................11
Resetting procedure ..................................................11
Mechanical Disassembly ............................................. 12
Cabinet Top, Front, R/C Board removal ..................... 12
Main Board, AV Panel and Fan removal .................... 13
Speaker(SP901), Fan (FN901),Lamp Unit(LP900) and
Optical Unit removal ................................................. 14
Power Board removal ................................................ 15
Mounting Duct, Fan(FN903, FN904, FN905) and Filter
Board removal ........................................................... 16
Optical Parts Disassembly ........................................... 17
Adjustments ................................................................ 23
Adjustments after Parts Replacement ...................... 23
Optical Adjustments .................................................... 24
Contrast adjustment .................................................24
Integrator lens adjustment ....................................... 25
Relay lens-Out adjustment ....................................... 26
Electrical Adjustments ................................................. 27
Service Adjustment Menu Operation .......................27
Memory IC (IC1371) Replacement ...........................27
Circuit Adjustments ..................................................28
Test Points and Locations ......................................... 33
Service Adjustment Data Table ................................. 34
Chassis Block Diagrams .............................................. 51
Chassis over view ..................................................... 51
System control .......................................................... 52
Lamp control ............................................................. 53
Audio circuit .............................................................. 54
Power supply & protection circuit ............................. 55
Fan control circuit ..................................................... 56
Troubleshooting ........................................................... 57
Indicators and Projector Condition ............................ 57
No Power .................................................................. 58
No Picture ................................................................. 59
No Sound .................................................................. 60
Control Port Functions ................................................. 61
Scaler I/O Port Functions (PW190) ............................ 61
Waveform .................................................................... 62
Electrical Parts List ...................................................... 69
Electrical Parts Location ............................................ 70
Electrical Parts List ................................................... 71
Mechanical Parts List ................................................... 88
Cabinet Parts Location .............................................. 88
Optical Parts Location ............................................... 89
Mechanical Parts List ................................................ 93
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 Soldering ...................................................... 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, adjust-
ment covers or shields, barriers, etc.
DO NOT OPERATE THIS PROJECTOR WITHOUT T
HE PROTECTIVE SHIELD IN POSITION AND PROP
ERLY 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) 12.80" x 3.27" x 9.12" (326mm X 83.1mm X 231.6mm ) (Not including protrusions)
Net Weight 5.52 lbs (2.5 kg)5.52 lbs (2.5 kg)
Feet Adjustment 0˚ to 12˚
Panel Resolution
LCD Panel System 0.63" 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 40” to 300”
Throw Distance 4.6' ~ 41.7' (1.4 m ~ 12.7 m)4.6' ~ 41.7' (1.4 m ~ 12.7 m)
Projection Lens F 1.60 ~ 1.76 lens with f 22.3 mm ~ 26.8 mm with manual zoom and focusF 1.60 ~ 1.76 lens with f 22.3 mm ~ 26.8 mm with manual zoom and focus
Projection Lamp 225 W
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 1/Computer 2 Audio Input Jacks Mini Jack (stereo) x 2
Computer In 1/Component Input Terminal Mini D-sub 15 pin x 1
Computer In 2/Monitor Output Terminal Mini D-sub 15 pin x 1
Control Port Connector D-sub 9 pin x 1
Audio Output Jack Mini Jack (stereo) x 1 (variable)
LAN Connection Terminal 100 Base-TX (100Mbps)/10 Base-T (10Mbps), RJ45
Audio
Internal Audio Amp 1.0 W RMS
Built-in Speaker 1 speaker, ø1.1"(28 mm)
Power
Voltage and Power Consumption AC 100–120 V (3.7A Max. Ampere), 50/60 Hz (The U.S.A and Canada)
AC 200–240 V (2.0A 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 AAA or LR03 1.5V ALKALINE TYPE x 2Battery AAA or LR03 1.5V ALKALINE TYPE x 2
Operating Range 16.4' (5 m)/�30˚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)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)Net Weight 2.37 oz (67 g) (including batteries)
PAL, SECAM, NTSC, NTSC4.43, PAL-M, and PAL-N
●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 100˚C, the thermal switch opens to stop
the operation of the power supply circuit.
The thermal switch can be reset itself automatically when the internal temperature becomes normal.
When the internal temperature reaches near 70˚C, the thermal
switch returns automatically.
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;
Lamp cover switch
(SW901)
Fuse
Fuse Part No.: 323 021 7804
TYPE T6.3AH 250V FUSE
LITTLE FUSE INC. TYPE 21506.3
How to replace the fuse
1. The fuse is placed on the filter board under the main board. Remove the cabinet top and the main board.
2. Take the fuse off, 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)
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. If the
projector cannot be turned on and the WARNING indicator
still lights red, unplug the AC power cord and contact the
service station.
CAUTION
DO NOT LEAVE THE PROJECTOR WITH THE
AC POWER CORD CONNECTED UNDER AN
ABNORMAL CONDITION. IT MAY RESULT IN FIRE
OR ELECTRIC SHOCK.
Top Control
WARNI NG emi t a
red light
-6-
Maintenance
Cleaning the Air Filter
Filter prevents dust from accumulating on the optical elements inside the projector. Should the filters 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, clean the filters
immediately. Clean the filters by following the steps below.
Turn off the projector, and unplug the AC power cord
1
from the AC outlet.
Turn the projector over and remove the filters.
2
Clean the filters softly by using a brush.
3
Replace the filters properly. Make sure that the filters
4
are fully inserted to the projector.
Filters
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.
✔Note:
When reinserting this
filter, be sure that the
slit part is facing the
outer side.
Filter Base
Air Filter
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
elements 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.
Resetting the Filter Counter
Be sure to reset the Filter counter after cleaning or replacing
the filters.
Press the MENU button to display the On-Screen
1
Menu. Use the Point buttons to select Setting and
then press the Point or SELECT button.
Use the Point buttons to select Filter counter and
2
then press the SELECT button. Use the Point buttons
to select Filter counter reset and then press SELECT
button. Filter counter Reset? appears. Select Yes to
continue.
Another confirmation dialog box appears, select Yes to
3
reset the Filter counter.
Filter counter
Filter counter ,
Reset? appears.
Select Yes,
then another
confirmation box
appears.
Select Yes again
to reset the Filter
counter.
-7-
Maintenance
Attaching the Lens Cover
When moving the projector or while it is not in use, replace
the lens cap.
Thread the string through the hole on the lens cap and
1
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
2
top of the projector and pull at it.
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.
-8-
Lamp Replacement
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
Unplug the AC power cord. Let the projector cool for at least 45
1
minutes.
Loosen the screw and open the lamp cover.
2
Loosen the three (3) screws that secure the lamp. Lift the lamp
3
out of the projector by using the handles.
Replace the lamp with a new one and secure the three (3)
4
screws. Make sure that the lamp is set properly. Push the
lamp cover and secure the screw.
Connect the AC power cord to the projector and turn on the
5
projector.
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. POA-LMP131
Service Parts No. 610 343 2069
Lamp Cover
Screw
Lamp
Screw
Screw
Handles
Screw
WARNING : TURN OFF THE UV LAMP BEFORE OPENING THE LAMP COVER.
USE UV RADIATION EYE AND SKIN PROTECTION DURING SERVICING.
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
CAUTION
When replacing the lamp because it has stopped illuminating, there is a possibility that the lamp may be
broken.
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.
-9 -
Lamp Replacement
Counter
Projector 450H
Lamp
Normal 200H
Eco 250H
Corresponding value 500H
Counter
Projector 450H
Lamp
Normal
Eco
Corresponding value
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”.
How to check Lamp Used Time
The LAMP REPLACE indicator will light yellow when
the total lamp used time (Corresponding value) reaches
2,500 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 1.25
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/STAND-BY button on the pro-
jector for more than 20 seconds.
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
Note:
When non-standard lamp is used, lamp used time
should not appear.
Warning Message on the non-standard lamp used
If the non-standard lamp is used, the warning and confirmation messages will appear on the screen every startup.
Some of the functions are limited when the non-standard lamp is used in spite of the warning.
Since the lamp is not standard,
projector failed to read lamp data.
Continue to use this lamp?
Yes
No
-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 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.
-11-
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, Front, R/C Board removal
1. Loose screw A (M3x8 ) to remove the Lamp Cover.
2. Remove 5 screws B (M3x8 ) to remove the Cabinet Top.
3. Remove the Control Buttons and Dec Inlay LED.
4. Remove 3 screws C (M3x6) and screws D (T3x8 ) to remove the Cabinet Front.
5. Remove screw E (T3x6 ) to remove the R/C Board.
6. Remove 2 screws F (T3x6) ti remove the Dec Lens.
Cabinet top
B
Screws Expression
(Type Diameter x Length) mm
T type M Type
Lamp Cover
A (M3x8)
C
D
B
Control Buttons
Dec Inlay LED
R/C Board
E (T3X6)
C
F
F (T3X6)x2
Dec Lens
B
B
B (M3x8)x5
C (M3X6)x3
Cabinet Front
D
D (T3X8)x3
Fig.1
-12-
Mechanical Disassembly
x Main Board, AV Panel and Fan removal
1. Remove 5 screws A (M2.5x6) and 2 screws B (M4x4) to remove the Main Board.
2. Release the hooks to remove the AV Panel and remove 3 screws C (T3x6) to remove
the AV Board.
3. Remove 3 screws D (T3X8) to remove the fans (FN902 and FN906).
B
C (T3x6)x3
C
C
AV Panel
Main Board
A
A (M2.5x6)x5
A
A
B (M4x4)x2
AV Board
A
Hooks
D (T3x8)x3
D
D
SW901
Fan (FN902)
Fan (FN906)
-13-
Fig.2
Mechanical Disassembly
c Speaker(SP901), Fan (FN901),Lamp Unit(LP900) and Optical Unit removal
1. Remove the 2 screws A (T3x8) to remove the speaker holder and the
Speaker (SP901).
2. Remove 2 screws B (T3x8) and screw C (T3x12) to remove the fan
(FN901).
3. Remove the lamp shield-top. Remove 3 screws D(M3x7) to remove the
Lamp unit (LP900).
4. Remove the 2 screws E (T3x6) to remove the CONNECT ID board.
5. Remove the screw F (T3x8) to disconnect the Ballast socket.
6. Remove 5 screws G (T3x8) and 3 screws H(T3x8) to remove the Optical
Unit and the Lamp holder.
Lamp shield-top
Optical Unit
G (T3x8)X5
Lamp
(LP900)
G
G
D (M3x7)X3
G
H
G
D
D
A (T3x8)X2
Ballast socket
F (T3x8)
G
H
H(T3x8)X3
E
E (T3x6)x2
CONNECT ID
board
B
Speaker
(SP901)
A
Spacer
Speaker holder
B (T3x8)X2
C (T3x12)
-14-
Lamp holder
Fan (FN901)
Fig.3
Mechanical Disassembly
v Power Board removal
1. Remove 3 screws A (T3x8), screw B (M3x8) and 3 screws C (M4x4) to
remove the power board shield.
2. Remove the 2 screws D (T3x8) to remove the Ballast board.
3. Remove the power board holder. Loose the hooks to remove the Power
board.
C (M4x4)x3
Ballast board
Power board
holder
C
D (T3x8)x2
B(M3x8)
C
A
A (T3x8)x3
A
Power board
shield
D
Hooks
Thermal switch
(SW902)
Hooks
Power board
Power board
holder
Fig.4
-15-
Mechanical Disassembly
b Mounting Duct, Fan(FN903, FN904, FN905) and Filter Board removal
1. Remove screw A (M4x4) , 2 screws B (T3x12) and 4screws C (T3x6) to remove the Mounting duct top,
Mounting duct bottom and fan (FN904).
2. Remove 2 screws D ( T3x12) to remove the fans (FN903 and FN905).
3. Remove screw E (T3x8) and screw F (M3X8) to remove the Left side shield.
4. Remove 2 screws G (T3x8) to remove the filter board.
5. Remove the Air filters.
B (T3x12)x2
E (T3x8)
Left side shield
F (M3x8)
Filter Board
Mounting duct
top
FN903
G (T3x8) x2
C
D(T3x12)x2
FN905
G
C T(3x6)x4
C
C
D
A
Mounting duct
bottom
B
A M4x4)
FN904
Filter Board spacer sheet
Air filter
Air filter
Air filter base
Fig.5
-16-
Optical Parts Disassembly
Before taking this procedure, remove Cabinet Top , Main Board and the Network board following to the “Mechanical
Disassembly”.
Disassembly requires a 2.0mm hex wrench.
z Projection lens disassembly
Note: The optical unit should be removed from the cabinet bottom before re-
moving the projection lens.
Optical unit
(M2.5x6)x4
x Integrator lens-in disassembly
M(2.5x6)
(M3x14)x2
Integrator Lens-In Ass'y
Projection lens
Prism Beam Splitter
(PBS)
Integrator lens-out
* Rugged surface
(Rear)
Fig.1
Integrator lens-in
* Rugged surface
(Front)
Fig.2
-17-
Optical Parts Disassembly
cLCD Panel/Prism Ass’y removal
(M3x10)
(Bottom side)
LCD Panel/
Prism Ass’y
Fig.3-1
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 Center 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
-18-
Optical Parts Disassembly
L3P06X-86G20
a03CA142I8
-86G20
L3P06X-85G20
a00ca146I8
-85G20
Panel Type Check
There are 2 types of LCD Panel/Prism Ass'y for this model. Either L-Type or R-Type LCD Panel/Prism Ass'y is used on
the projector. Check which type of LCD Panel/Prism Ass'y is used with the figure below.
When replacing the LCD Panel/Prism Ass'y, you need to take "Panel Type Check and Setting" on the Electrical Adjustment for the replaced LCD Panel/Prism Ass'y.
The gamma-characteristics is different between L-Type and R-Type LCD Panel/Prism Ass'y.
How to check the type of LCDPanel/Prism Ass'y
Check the printed number on the flat cable of the G-LCD Panel.
L-Type LCD Panel/Prism Ass'y R-Type LCD Panel/Prism Ass'y
G-LCD PANEL
-19-
Fig.3-2
Optical Parts Disassembly
v Polarized glass-in disassembly
(M2.5x6)x1
Polarized glass-in Ass'y
Polarized glass
Fig.4
b Polarized glass, Pre-polarized glass removal
* Mount the polarized glasses as the film
attached side faces the LCD panel side.
(Red)
(M2x4)
Pre-Polarized Glass(R)
Polarized Glass(R)
(Green)
(M2x4)
Pre-Polarized Glass(G)
Polarized Glass(G)
* Note:
There is no Pre-Polarized Glass(R) for
KA5-XU30000.
-20-
Polarized Glass(B)
(M2x4)
(Blue)
Film
Pre-Polarized Glass(B)
Fig.5
Optical Parts Disassembly
n Optical unit top removal
Optical top
M(2.5x6)
m Relay lens disassembly
Relay lens Ass'y
Fig.6
Fig.7
Relay lens
-21-
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.
1
No. Parts Name
1 Integrator lens (IN)
2 Integrator lens (OUT)
3 Prism beam splitter (PBS)
4 Condenser lens (OUT)
5 Dichroic mirror (B)
6 Dichroic mirror (G)
7 Condenser lens (G)
8 Mirror (R)
9 Relay lens (IN)
10 Condenser lens (R)
11 Condenser lens (B)
12 Mirror (B)
For KF5-XU35000,
the rugged surface
is facing this side.
For KA5-XU30000,
the rugged surface
is opposite to this
side.
2
3
4
P o i n t m a r k e r i s
printed on this side
up
5
Point m a r k e r is
printed on this side
up
6
7
9
Rugged surface is
facing this side.
Film attached side
is facing this side.
12
11
10
8
8
Fig.8
-22-
Adjustments
Adjustments after Parts Replacement
LCD/
Prism Ass’y
Adjustments
Contrast Adjustment
Optical
G-Contrast adjustment
❍ ●
● : Adjustment necessary ❍: Check necessary
Disassembly / Replaced Parts
Integrator
Lens (OUT)
Relay
Lens (OUT)
Polarized Glass
Power Board Main Board
G
Integrator lens adjustment
Relay lens-out adjustment
Fan control adjustment
Reference voltage adjusment
Panel type check and setting
Auto calibration adjustment [PC]
Electrical Adjustments
Auto cali bration adj ustment
[Component]
Auto calibration adjustment
[Video]
Common center adjustment
50% white adjustment [PC]
White balance adjustment [PC]
50% white adjustment [Video]
Whi te ba lance adju stmen t
[Video]
White uniformity adjustment
Keystone offset adjustment
❍ ●
❍
● ●
● ●
● ●
❍ ❍
● ●
❍ ❍
❍ ❍
●
● ●
●
●
●
●
●
-23-
Optical Adjustments
A
Slot B
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 PRO-
TECTION 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) 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 hex screwdriver.
3 Tighten the screw A to fix the polarized glass mounting base.
Polarized glass
mounting base
Fig.1
-24-
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.
a
A
White
a
b
b
Slot B
Fig.2-1
Moving of slot B
x
White
y
Slot D
x
y
C
-25-
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 by using a hex screwdriver, and adjust the
slot B to make color uniformity in white by using a slot screwdriver.
4 Tighten the screw A to fix the relay lens unit.
b
White
a
Fig.3
Moving of slot B
A
Slot B
b
a
-26-
Service Mode
Input Computer 1
Group No. Data
0
0 +179
Ver. R 0.00 KF5AC
Electrical Adjustments
Service Adjustment Menu Operation
To enter the service mode
To enter the “Service Mode”, press and hold the MENU and SELECT button 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 (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.
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”.
●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.
-27-
Electrical Adjustments
White 100%
Black 100%
W
Y C
G
M
R
B
BLK
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 adjustments
must be completed within 25 minutes.
[Adjustment Condition]
● Input signal
Video signal ........................
1.0Vp-p/75W terminated, 16 steps gray scale
(Composite video signal)
Component Video signal ...... 1.0Vp-p/75W terminated, 8 color 100% color
bar or 16 step gray scale (Component video
signal)
Computer signal ................... 0.7Vp-p/75W terminated, 16 steps gray scale
pattern
● Image control mode ......... “STANDARD” mode unless otherwise not-
ed.
Note:
* Please refer to “Service Adjustment Menu Operation” for entering the
service mode and adjusting the service data.
16 steps gray scale pattern
8 color 100% color bar
White 100%
Black 100%
-28-
Electrical Adjustments
㪛㩷㪲㪭㫇㫇㪴
Output Voltage adjustment
After replacing the Power Board readjust the Output
voltage adjustment as follows.
1. Connect a digital voltmeter to RED WIRE (+) and
BLACK WIRE (-).
2. Adjust the voltage by using VR621 as following.
AC Input Reading
230V 374V �1V
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.
2. Fan Control adjustment
1. Enter the service mode.
2. Connect a digital voltmeter to test point “TPFANA”
(+) and chassis ground (-). Select group no. “250”,
item no. “0” and change data value to adjust voltage
to be 5.0 ±0.1V.
3. Connect a digital voltmeter to test point “TPFANA”
(+) and chassis ground (-). Select item no. “1” and
change data value to adjust voltage to be 13.5
±0.1V.
4. Connect a digital voltmeter to test point “TPFANB”
(+) and chassis ground (-). Select item no. “2” and
change data value to adjust voltage to be 4.5 ±0.1V.
5. Connect a digital voltmeter to test point “TPFANB”
(+) and chassis ground (-). Select item no. “3”
and change data value to adjust voltage to be 13.5
±0.1V.
6. Connect a digital voltmeter to test point “TPFANC”
(+) and chassis ground (-). Select item no. “4” and
change data value to adjust voltage to be 5.0 ±0.1V.
7. Connect a digital voltmeter to test point “TPFANC” (+)
and chassis ground (-). Select item no. “5” and change
data value to adjust voltage to be 13.5 ±0.1V.
1. Panel Type Check and Setting
* Before setting, you need to check which type of LCD
panel is placed on the projector according to the item
"LCD Panel/Prism Ass'y removal" in the chapter "Optical
Parts Disassembly".
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
3. Panel Type 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-characteris-
tics changes according to your selection.
Note:
Be ca reful 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.
3 .Reference Voltage Adjustment
1. Enter the service mode.
2. Receive the 16-step grey scale computer signal
with Computer 1 [RGB] mode.
3. Select group no. “101”, item no. “12” to ad-
just the voltage of TP_VMIDG to be 7.00
±0.01V.
4. Select group no. “101”, item no. “14” to adjust
the voltage of TP35G to make the amplitude
“D[Vpp]” to be 10.00 ±0.05V.
-29-
Electrical Adjustments
(a)
White Level
Pedestal Lebel
Black Lebel
Pedestal Lebel
Black Lebel
(a)
White Level
4. Auto Calibration adjustment [PC]
1. Enter the service mode.
2. Receive the 16-step grey scale computer signal with
Computer1 [RGB] mode.
3. To start the auto-calibration for PC adjustment, select
group no. “260”, item no. “0” and then change data
value from “0” to “1”. After the auto-calibration completed, "OK" will appear on the screen.
Below adjustments are performed when the above
auto calibration is failed.
Pedestal adjustment [PC]
1. Enter the service mode.
2. Receive the 16-step grey scale computer signal with
Computer1 [RGB] mode.
3. Connect an oscilloscope to test point “TP35G” (+)
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 “TP35R” (+)
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 “TP35B” (+) 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.
5. Auto Calibration adjustment [Component]
1. Enter the service mode.
2. Receive the 8 color 100% color bar 480i-component
signal with Computer2 [Component] mode.
3. To start the auto-calibration for Component adjust-
ment, select group no. “260”, item no. “0” and then
change data value from “0” to “1”. After the auto-calibration completed, "OK" will appear on the screen.
Below adjustments are performed when the above
auto calibration is failed.
Pedestal adjustment [Component]
1. Enter the service mode.
2. Receive the 16-step grey scale 480i-component signal
with Computer2 [Component] mode.
3. Connect an oscilloscope to test point “TP35G” (+)
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 “TP35R” (+)
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 “TP35B” (+)
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.
Gain adjustment [PC]
1. Enter the service mode.
2. Receive the 16-step grey scale computer signal with
Computer1 [RGB] mode.
3. Connect an oscilloscope to test point “TP35G” (+)
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 “TP35R” (+)
and chassis ground (-).
6. Select group no. “0”, item no. “4” and adjust the amplitude “a” to be minimum by changing the Data value.
7. Connect an oscilloscope to test point “TP35B” (+) and
chassis ground (-).
8. Select group no. “0”, item no. “5” and adjust the amplitude “a” to be minimum by changing the Data value.
Gain adjustment [Component]
1. Enter the service mode.
2. Receive the 16-step grey scale 480i-component signal
with Computer2 [Component] mode.
3. Connect an oscilloscope to test point “TP35G” (+)
and chassis ground (-).
4. Select group no. “0”, item no. “3” and adjust the amplitude “a” to be minimum by changing the Data value.
-30-
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