Sanyo PLC-XU87,PLC-XU8 Service Manual
FILE NO.
SERVICE MANUAL
Multimedia Projector
Model No. PLC-XU87
U.S.A, Canada,
Europe, U.K, Asia
Original Version
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.
!
RoHS
K
• This product does not contain any hazardous substances prohibited by the RoHS Directive. (You will
find “RSF” mark near the rating plate on the RoHS
compliant product.)
PRODUCT CODE
1 122 369 00 (KW6AC)
1 122 370 00 (LW6AC)
1 122 370 02 (LW6CC)
Chassis No. KW6-XU8700
! WARNING
• You are requested to use RoHS compliant parts for
maintenance or repair.
• You are requested to use lead-free solder.
REFERENCE NO. SM5110832-00
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 Filter ...................................................... 7
Resetting the Filter Counter ........................................ 7
Lamp Replacement .................................................... 8
Resetting the Lamp Counter ....................................... 9
How to check Lamp Used Time .................................. 9
Cleaning ................................................................... 10
Security Function Notice.............................................. 11
Security Function Disable ......................................... 11
Mechanical Disassembly ............................................. 12
Optical Parts Disassembly ........................................... 16
Adjustments ................................................................. 22
Adjustments after Parts Replacement ...................... 22
Optical Adjustments ..................................................... 23
Contrast adjustment.................................................. 23
Integrator lens adjustment ........................................ 24
Relay lens-Out adjustment ....................................... 25
Electrical Adjustments ................................................. 26
Service Adjustment Menu Operation ........................ 26
Memory IC (IC1391) Replacement ........................... 26
Circuit Adjustments ................................................... 27
Test Points and Locations ......................................... 31
Service Adjustment Data Table ................................. 32
Chassis Block Diagrams .............................................. 45
Chassis over view ..................................................... 45
System control .......................................................... 46
Lamp control ............................................................. 47
Audio circuit .............................................................. 48
Power supply & protection circuit .............................. 49
Fan control circuit ..................................................... 50
IIC bus control circuit ................................................ 51
Network (MCI) circuit ................................................52
Troubleshooting ........................................................... 53
Indicators and Projector Condition ........................... 53
No Power .................................................................. 54
No Picture ................................................................. 55
No Sound .................................................................. 56
Control Port Functions ................................................. 57
Scaler I/O Port Functions (PW190) .......................... 57
IIC Bus D/A Converter Port Functions (M62334) ...... 58
I/O Expander Port Functions (TE7783) ................... 59
Waveform .................................................................... 60
IC Block Diagrams ....................................................... 61
Electrical Parts List ...................................................... 69
Electrical Parts Location ........................................... 70
Electrical Parts List ................................................... 71
Mechanical Parts List ..................................................98
Cabinet Parts Location ............................................. 98
Optical Parts Location .............................................. 99
Mechanical Parts List ............................................. 103
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, 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.
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.
-3-
Specifications
Mechanical Information
Projector Type Multi-media Projector
Dimensions (W x H x D) 11.6" x 2.74" x 8.23" (294.5mm x 69.5mm x 209mm) (Not including adjustable feet)
Net Weight 5.7 lbs (2.6kgs)
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 ~ 100 KHz, V-sync. 50 ~ 100 Hz
Optical Information
Projection Image Size (Diagonal) Adjustable from 40" to 300"
Projection Lens F 1.6 ~ 2.5 lens with f 17.7 mm ~ 28.3 mm with manual zoom and focus
Throw Distance 3.6’ - 43.0’ (1.1m - 13.1m)
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 / DVI-I Input Terminal DVI-I 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 A Connector x 1 / USB Series B connector x 1
Audio Output Jack Mini Jack (stereo) x 1 (Variable)
LAN Connection Terminal 100 Base-TX (100Mbps) / 10 Base-T (10Mbps)
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 AAA, UM-04 or LR03 type x 2
Operating Range 16.4’ (5m) / ±30˚
Dimensions 1.8”(W) x 1.0”(H) x 5.7”(D) (45mm x 25mm x 145mm)
Net Weight 3.5 oz (99 g) (including batteries)
Laser Pointer Class II Laser (Max. Output: 1mW/Wave langth: 640-660nm)
●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. Insert the sharp tool like a screwdriver into a hole on the cabinet
from the cabinet bottom.
2. Press the reset button on the thermal switch with the screwdriver.
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 off, and replace the new one with the specified type.
-5-
ON
OFF
POWER
KEYST
ONE
I
NPUT
WARNING
LAMP REPLACE
MENU
VOL
UME
+
VO
L
UME
SELECT
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)
WARNING
lights red
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, it may
defect the cooling fans or power supply circuits.
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
-6-
Maintenance
Cleaning the Filter
Filter prevents dust from accumulating on the optical elements inside the projector. Should the filter becomes
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 filter immediately.
Clean the filter 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 by pulling
2
the latches upward.
Filter warning icon appears on the screen at a
set time.
Gently clean the filter by using a brush or rinse it softly.
3
When rinsing the filter, dry it well. Replace the filter prop-
4
erly. Make sure that the filter is fully inserted to the projector.
CAUTION
Do not operate the projector with the filter removed.
Dust may accumulate on the optical elements degrading picture quality.
Do not put anything into the air vents. Doing so may
result in malfunction of the projector.
RECOMMENDATION
We recommend avoiding dusty/smoky environments when
you operate the projector. Usage in these environments may
cause poor image quality.
When using the projector under dusty or smoky conditions, dust
may accumulate on a lens, LCD panels, or optical 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.
Air filters
Resetting the Filter Counter
Be sure to reset the Filter counter after cleaning or replacing the filter.
Press the MENU button to display the On-Screen Menu.
1
Use the Point 7 8 buttons to move the red frame pointer
to the Setting Menu icon.
Use the Point ed buttons to move the red frame pointer
2
to Filter counter and then press the SELECT button. A
dialog box appears showing the total accumulated time
of the filter use, a timer setting option, and the reset option. Select Reset and the “Filter counter Reset?” appears. Select [Yes] to continue.
Another confirmation dialog box appears, select [Yes] to
3
reset the Filter counter.
Filter counter
Select Reset and the “Filter
counter Reset?” appears.
Select [Yes],
then another
confirmation
box appears.
-7-
ON
OF
F
POWER
AU
TO
SET UP
I
NPUT
WARNING
LAMP REPLACE
MENU
VOL
+
VO
SELECT
Maintenance
Lamp Replacement
When the projection lamp of the projector reaches its end of life,
the Lamp replacement icon appears on the screen and LAMP
REPLACE indicator lights yellow. Replace the lamp with a new
one promptly. The timing when the LAMP REPLACE indicator
should light is depending on the lamp mode.
WARNING:
TURN OFF THE UV LAMP BEFORE OPENING THE LAMP COVER
LAMP REPLACE
indicator
Top Control
Lamp replacement icon
✔Note:
• The Lamp replacement icon will not appear when
the Display function is set to “Off”, during “Freeze”,
or “No show”.
CAUTION
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.
Follow these steps to replace the lamp.
Turn off the projector and unplug the AC power cord. Let
1
the projector cool for at least 45 minutes.
Remove 1 screw with a screwdriver and remove the
2
lamp cover.
Loosen 2 screws and pull out the lamp assembly by
3
grasping the handle.
Replace the lamp with a new one and secure the two (2)
4
screws. Make sure that the lamp is set properly. Close
the lamp cover and tighten the screw.
Connect the AC power cord to the projector and turn on
5
the projector.
Reset the lamp counter.
6
See “Resetting the Lamp Counter” on the next page.
CAUTION
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.
Lamp Cover
Lamp
Screw
Screw
Screw
Handle
ORDER REPLACEMENT LAMP
Type No. Service Parts No.
POA-LMP106 610 332 3855
-8-
Maintenance
Counter
Projector 525H
Lamp
Normal 150H
Eco 375H
Corresponding value 675H
Resetting the Lamp Counter
Be sure to reset the Lamp counter after the lamp is replaced. When the Lamp counter is reset, the LAMP REPLACE indicator stops lighting.
Press the MENU button to display the On-Screen Menu.
1
Use the Point 7 8 buttons to move the red framed
pointer to the Setting Menu icon.
Use the Point ed buttons to move the red framed point-
2
er to Lamp counter and then press the SELECT button.
A dialog box appears showing the total accumulated time
of the lamp usage and the reset option. Select Reset and
the “Lamp replacement counter Reset?” appears. Select
[Yes] to continue.
Another confirmation dialog box appears, select [Yes] to
3
reset the Lamp counter.
✔Note:
• Do not reset the Lamp counter without implementing lamp
replacement. Be sure to reset the Lamp counter only after
replacing the lamp.
How to check Lamp Used Time
Lamp counter
Select Reset and the “Lamp
replacement counter Reset?
” appears.
Select [Yes],
then another
confirmation
box appears.
Select [Yes] again to reset the
Lamp counter.
The LAMP REPLACE indicator will light yellow when the total lamp used time (Corresponding value) reaches 3,000
hours. This is to indicate that lamp replacement is required.
The total lamp used time is calculated by using the below expression,
Total lamp used time (Corresponding value) = Teco + Tnormal x 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 on the projector 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
-9-
Maintenance
Cleaning
After long periods of use, dust and other particles will accumulate on the LCD panel, prism, mirror, polarized glass,
lens, etc., causing the picture to darken or color to blur. If this occurs, clean the inside of optical unit.
Remove dust and other particles using air spray. If dirt cannot be removed by air spray, disassemble and clean the
optical unit.
Cleaning with air spray
1. Remove the cabinet top following to “Mechanical Disassemblies”.
2. Clean up the LCD panel and polarizing plate by using
the air spray from the cabinet top opening.
Caution:
Use a commercial (inert gas) air spray designed for
cleaning camera and computer equipment. Use a resinbased nozzle only. Be vary careful not to damage optical
parts with the nozzle tip. Never use any kind of cleanser
on the unit. Also, never use abrasive materials on the
unit as this may cause irreparable damage.
Disassembly Cleaning
Disassembly cleaning method should only be performed
when the unit is considerable dirty and cannot be sufficiently cleaned by air spraying alone.
Be sure to readjust the optical system after performing disassembly cleaning.
1. Remove the cabinet top and main units following to
“Mechanical Disassemblies”.
2. Remove the optical base top following to “Optical Unit
Disassemblies”.
3. Clean the optical parts with a soft cloth. Clean extremely dirty areas using a cloth moistened with alcohol.
Caution:
The surface of the optical components consists of multiple dielectric layers with varying degrees of refraction.
Never use organic solvents (thinner, etc.) or any kind of
cleanser on these components.
Since the LCD panel is equipped with an electronic circuit, never use any liquids (water, etc.) to clean the unit.
Use of liquid may cause the unit to malfunction.
-10-
Security Function Notice
Security Function Disable
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 and captured image 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 & Fans (FN901, FN902) removal
(M3x8)x5
Cabinet top
Screws Expression
(Type Diameter x Length) mm
T type M Type
Control buttons
(T3x6)
FN901
(T3x6)
Side grille
FN902
Fig.1
-12-
Mechanical Disassembly
x Cabinet Front, R/C Board, Main Board,
Fans(FN905,FN906), SP901 removal
(M2.5x6)x2
(M2.5x6)
Main board
R/C board
(M2.5x6)
Grounding
lead
(T3x6)
(M4x5)
(M2.5x6)x7
Rear panel
FN905
(T3x8)
SP901
(M3x8)
Cabinet front
(M3x8)
(M2.5x6)
FN906
Fig.2
-13-
Mechanical Disassembly
c Power, Sub-Power, Line Filter Board, Ballast Board, Ther-
mal Sw(SW902) removal
Isolation sheet
(T3x6)x4
Ballast board
Power board
(T3x6)
(T3x6)
(T3x6)x2
(T3x6)x4
Thermal switch
(SW902)
(T3x6)
(T3x6)
Line Filter board
(M3x8)
Ballast socket
(T3x6)(Black)
(T3x6)(Black)
-14-
Mechanical Disassembly
v Optical Unit, MCI Board, Fans(FN903, FN904), Noise Fil-
ter removal
(T3x8)x6
(T3x6)x4
Optical unit
MCI board Ass'y
(T3x8)
FN904
(T3x10)x4
(T3x6)x3
Fig.4-1
(T3x6)
(T3x6)x2
Noise filter
FN903
Fig.4-2
-15-
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
(M2.5x8)x4
Projection lens
x Integrator lens-in disassembly
(M2.5x5)x2
Integrator Lens-In Ass'y
Spacer
Fig.1
Hooks
Fig.2
Integrator lens-in
* Rugged surface
(Behind)
-16-
Optical Parts Disassembly
c Relay lens disassembly
(M2.5x5)x2
Relay lens Ass'y
(M2x3)
Relay lens
Fig.3
v Polarized glass-in disassembly
Polarized glass-in Ass'y
(M2.5x5)x1
Film side
Polarized glass
Fig.4
-17-
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
-18-
Optical Parts Disassembly
L3P06X-65G00
1-B-1234A1
-65G00
L3P06X-66G000
1-B-1234A1
-66G00
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/Prism Ass'y R-Type LCD/Prism Ass'y
G-LCD PANEL
Fig.5-2
Fig.5-2
-19-
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
-20-
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 (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.
2
3
slit
B
A
4
10
9
A
5
6
8
8
7
7
Fig.8
-21-
Adjustments
Adjustments after Parts Replacement
LCD/
Prism Ass’y
Optical Adjustments
Contrast Adjustment
●: Adjustment necessary ❍: Check necessary
Disassembly / Replaced Parts
Integrator
Lens (OUT)
Relay
Lens (OUT)
Polarized Glass
Power Board Main Board
R G B
R-Contrast adjustment
G-Contrast adjustment
B-Contrast adjustment
Integrator lens adjustment
Relay lens-out adjustment
Fan control adjustment
Panel type check and setting
Auto calibration adjustment [PC]
Electrical Adjustments
Auto calibration adjustment [Component]
Auto calibration adjustment [Video]
Common center adjustment
50% white adjustment [PC]
White balance adjustment [PC]
50% white adjustment [Video]
White balance adjustment [Video]
White uniformity adjustment
●
●
●
❍ ●
❍ ●
● ●
● ●
●
●
●
● ●
● ●
❍ ❍
● ●
❍ ❍
❍ ❍
Keystone offset adjustment
●
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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 adjustments 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.
Repeat steps 1 to 3 for remaining polarized glasses.
Main Board
A
Polarized glass
mounting base
Fig.1-1
R-Polarized Glass
Mounting Base
A
B-Polarized Glass
Mounting Base
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A
G-Polarized Glass
Mounting Base
A
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.
a
White
b
A
A
a
b
Fig.2-1
Moving of slot B
White
x
y
x
y
Slot D
Slot B
C
Slot D
Fig.2-2
Moving of Slot D
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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.
b
White
a
A
Fig.3
Moving of slot B
Slot B
a
b
-25-
Service Mode
Input Video
Group No. Data
0 0 32
Ver. 1 .00
Electrical Adjustments
ON
OF
F
POWER
AU
TO
SET UP
I
NPUT
WARNING
LAMP REPLACE
MENU
VO
L
UME
+
VO
L
UME
SELECT
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 (IC1391) 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.
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Electrical Adjustments
White 100%
Black 100%
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.
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 .......................
Component Video signal ...... 0.7Vp-p/75W terminated, 16 steps gray scale
Computer signal ................... 0.7Vp-p/75W terminated, 16 steps gray scale
● Image 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 2 (-) 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.
1.0Vp-p/75W terminated, 16 steps gray scale
(Composite video signal)
(Component video signal)
pattern
z Fan Control adjustment
1. Eenter 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. Select item no. “1” and change data value to adjust
voltage to be 13.5 ±0.1V.
5. Connect a digital voltmeter to test point “TPFANB” (+)
and chassis ground (-). Select item no. “2” and change
data value to adjust voltage to be 5.0 ±0.1V.
6. Select item no. “3” and change data value to adjust
voltage to be 13.5 ±0.1V.
16 steps gray scale pattern
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Electrical Adjustments
Pedestal Lebel
Black Lebel
(a)
White Level
Pedestal Lebel
Black Lebel
x Panel Type Check and Setting
* Before setting, you need to check which type of LCD pan-
el is placed on the projector according to the item "LCD
Panel/Prism 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-characteristics changes ac-
cording to your selection.
c Auto Calibration adjustment [PC]
1. Enter the service mode.
2. Receive the 16-step grey scale computer signal with
Computer2 [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-calbration 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
Computer2 [RGB] mode.
3. Connect an oscilloscope to test point “TP35G” (+) and
chassis ground (-).
4. Select group no. “0”, item no. “0” and change data val-
ue 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
Computer2 [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.
v Auto Calibration adjustment [Component]
1. Enter the service mode.
2. Receive the 16-step grey scale 480i-component sig-
nal 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-calbration 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.
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Electrical Adjustments
(a)
White Level
(a)
white level
white level
(a)
White Level
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.
n Common Center adjustment
1. Enter the service mode.
2. Receive the 50%-Whole Gray computer signal with
Computer2 [RGB] mode.
3. Select group no. “100”, 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. “101”, 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. “100”, item no. “92” and change
data value to “0” to reset the panel frequency.
b Auto Calibration adjustment [Video]
1. Enter the service mode.
2. Receive the 16-step grey scale composite video sig-
nal with Video [Video] 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-calbration completed, "OK" will appear on the screen.
below adjustment is performed when the above auto
calibration is failed.
Gain adjustment [Video]
1. Enter the service mode.
2. Receive the 16-step grey scale composite video signal
with Video [Video] 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.
m 50% White adjustment [PC]
1. Enter the service mode.
2. Receive the 16-step grey scale computer signal with
Computer2 [RGB] mode.
3. Connect an oscilloscope to test point “TP35G” (+)
and chassis ground (-).
4. Select group no. “100”, item no. “6” and change data
value to adjust amplitude “a” to be 1.6 ±0.1V.
, White Balance adjustment [PC]
1. Enter the service mode,
2. Receive the 16-step gray scale computer signal with
Computer2 [RGB] mode.
3. Select group no. “100” 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.
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Electrical Adjustments
(a)
white level
white level
.50% White adjustment [Video]
1. Enter the service mode.
2. Receive the 16-step grey scale composite video sig-
nal with Video[Video] mode.
3. Connect an oscilloscope to test point “TP35G” (+)
and chassis ground (-).
4. Select group no. “100”, item no. “6” and change data
value to adjust amplitude “a” to be 1.6 ±0.1V.
⁄0 White Balance adjustment [Video]
1. Enter the service mode.
2. Receive the 16-step grey scale composite video sig-
nal with Video[Video] mode.
3. Select group no. “100” item no. “7” (Red) or “8” (Blue),
and change Data values respectively to make a proper white balance.
⁄1 Keystone Offset adjustment
After replacing the G-sensor circuit (IC3851, IC1802
and peripheral circuit), readjust the Keystone Offset
adjustment as follows.
1. Put the projector on a horizontal place with the
adjustable feet being minimum range and then enter
the service mode.
2. Select group no. “102”, item no. “3” and set data
value from “0” to “5”.
3. By pressing the SELECT button, the Keystone
Offset adjustment will start.
4. When it has completed, the "OK" message will
appear on the screen.
5. By pressing any button on the projector or the
remote control, the "OK" message will disappear.
(Data value of Group no. “102”, item no. “3” will be
back from “5” to “0” for initial value.)
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
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