SANYO PLV65WHD1 User Manual
FILE NO.
SERVICE MANUAL
LCD Projection TV
REFERENCE NO. SM5110797-00
PRODUCT CODE :
PLV-55WHD1 M8LA 1 122 293 00
PLV-65WHD1 M8PA 1 122 364 00
Original Version
MODEL NO. PLV-55WHD1
PLV-65WHD1
U.S.A.
Chassis No. M8L-55WHD100
M8P-65WHD100
NOTE: Match the Chassis No. on the rating
sheet on the cabinet with the
Chassis No. in the Service Manual.
If the Original Version Service
Manual Chassis No. does not
match the unites, additional
Service Literature is required. You
must refer to “Notices” to the
Original Service Manual prior to
servicing the unit.
Give complete “CHASSIS NO." for parts order
or servicing, it is shown on the rating sheet on
the cabinet of the LCD Projection TV.
■ Contents .................................................................................................................2
■ Safety Instructions..................................................................................................3
■ Specifications .........................................................................................................4
■ Circuit Protections ..................................................................................................5
■ Installation ..............................................................................................................7
■ Cleaning ...............................................................................................................10
■ Lamp Replacement ..............................................................................................12
■ Mechanical Disassemblies...................................................................................15
■ Optical Parts Location and Direction....................................................................54
■ Adjustments after Parts Replacement .................................................................58
■ Optical Adjustments .............................................................................................59
■ Electrical Adjustments..........................................................................................72
● Service Adjustment Menu Operation ..........................................................72
● Circuit Adjustments .....................................................................................73
● Service Adjustment Data Table...................................................................77
● Test Points Location ...................................................................................84
■ Chassis Block Diagrams ......................................................................................85
■ Power Supply Lines..............................................................................................94
■ Troubleshooting ....................................................................................................95
■ Control Port Functions .........................................................................................98
■ Waveforms..........................................................................................................100
■ IC Block Diagrams .............................................................................................101
■ Service Parts List ...............................................................................................106
■ Mechanical and Optical Parts List ............................................................106
■ Electrical Parts List ...................................................................................123
■ Appendix ............................................................................................................148
● Quick Reference of Chassis Disassemblies .............................................148
--------------------------------------------------------------------------------------------------------------------
Drawings & Diagrams .......................................................................... A1 - A15
■ Parts description and reading in schematic diagram .......................................... A2
■ Schematic Diagrams ....................................................................................A3 - A8
■ Printed Wiring Board Diagrams ................................................................ A9 - A14
■ Pins description of ICs, transistors, diodes ...................................................... A15
Note: "PTV" may be used as an abbreviation for LCD Projection TV in this manual.
- 2 -
■ Contents
WARNING:
The chassis of this LCD projection TV 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 per-
sonnel 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 LCD projection TV and the
AC line before any service is performed on the LCD projection TV.
2: Comply with all caution and safety-related notes provided on the cabinet top, 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 LCD projection TV WITHOUT THE PROTECTIVE SHIELD IN POSITION AND
PROPERLY SECURED.
4: Before replacing the cabinet, thoroughly inspect the inside of the cabinet to see that no stray parts or
tools have been left inside.
Before returning any LCD projection TV 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 LCD projec-
tion TV. 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
the parts must be made by exactly the same parts.
Caution:
The parts and screws should be placed exactly the same position as the original otherwise it may cause lose of
performance and product safety.
The wiring method of the leads should be returned exactly the same state as the original otherwise it may cause
lose of performance and product safety.
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 is 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 at its starts.
Since the lamp is very high temperature during units operation. Replacement of the lamp should be done at
least 30 minutes after the power has been turned off, to allow the lamp cool-off.
CAUTION
RISK OF EXPLOSION IF BATTERY IS REPLACED BY AN INCORRECT TYPE.
DISPOSE OF USED BATTERIES ACCORDING TO THE INSTRUCTIONS.
- 3 -
■ Safety Instructions
● 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.
Technical Specifications
- 4 -
Screen Size (Measured Diagonally):
PLV-55WHD1: 55-inches/PLV-65WHD1: 65-inches
LCD Panel System:
0.7” wide TFT Active Matrix type, 3 panels
Panel Resolution:
1280 x 720 dots
Number of Pixels:
2,764,800 (1280 x 720 x 3 panels)
Signal Compatibility:
NTSC; 480i, 480p, 1080i, 720p
Scanning Format:
720p (All Signals are Converted to 720p)
RF Antenna Input:
Analog—UHF/VHF/CATV 75 ohm
Digital—75 ohm
Jacks and Connectors:
Video 1 Input: Composite Video/S-Video
and Audio L/R
Video 2 Input: Component (Y/Pb/Pr) with
Audio L/R Input
Video 3 Input: Component (Y/Pb/Pr) with
Audio L/R Input
Digital Audio Output: Dolby® Digital (Optical)
Analog Audio Output:Audio L/R (Fixed)
HDMI Input: 19-pin connector
(Picture/Sound with HDCP)
Woofer Output: RCA Type
Service Jack: D-Sub (HDB 9)
Sound:
Two Speakers, size: 5.0” x 3.0” (128 x 77 mm)
Amplifier:
Built-in with 15.0 W/ch
Power Requirement:
Source: AC 120 V, 60 Hz
AC Power Consumption (average):
PLV-55WHD1: 120 V, 2.8 A
PLV-65WHD1: 120 V, 2.8 A
Size and Weight (approximately):
PLV-55WHD1
Width: 50.9” (1294 mm)
Height: 34.0” (864 mm)
Depth: 15.6” (397 mm)
Weight: 86.4 lbs (39.2 kg)
PLV-65WHD1
Width: 60.6” (1538 mm)
Height: 40.0” (1016 mm)
Depth: 18.4” (468 mm)
Weight: 106.0 lbs (48.1 kg)
Environmental Considerations:
Operating Temperature: 41˚F–95˚F (5˚C–35˚C)
Storage Temperature: 14˚F–140˚F (-10˚C–60˚C)
Remote Control:
Battery : 1.5 V AAA Alkaline type x 2
Operating Range:16.4’ (5 m)/±30
Dimensions: 7.72” (L) x2.15” (W) x 0.83” (H)
(196 mm x 54.7 mm x 21.0 mm)
Net Weight: 2.96 oz (84 g)
(without batteries)
Accessories:
Owner’s Manual
AC Power Cord
Remote Control
Specifications are subject to change without notice.
■ Specifications
This LCD Projection TV provides the following circuit protections to operate in safety. If the abnormality occurs
inside the LCD Projection TV, it will automatically turn off by operating one of the following protection circuits.
A fuse(F601) is located inside of the LCD Projection TV.
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
● Thermal switch
Fuse Part No. : 323 022 2105
TYPE T4.0AH 250V FUSE
LITTEL FUSE INC. TYPE 215004
How to replace the fuse
1. Unplug the AC power cord.
2. Remove the cabinet bottom cover following to
"Mechanical Disassemblies".
3. Remove the fuse from fuse holder on the Power Board.
To install the fuse, take reversed step in the above.
There is the thermal switch (SW902) inside of the LCD
Projection TV to prevent the internal temperature rising
abnormally. When the internal temperature reaches near
95°C, the thermal switch cuts off the drive signal to the
lamp circuit 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 a tester. If it has high impedance, thermal switch
may be in open.
How to reset the thermal switch
1. Remove the optical / chassis unit following to
"Mechanical Disassemblies".
2. Press the reset button on the thermal switch.
CAUTION:
Before press the reset button, make sure that the AC cord
must be disconnected from the AC outlet.
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■ Circuit Protections
Fuse
(F601)
Thermal switch
(SW902)
Press
● Lamp cover switch
The lamp cover switch (SW1861) cuts off the drive signal to the lamp circuit when the lamp cover is removed or no
close completely.
After opening the lamp cover for replacing the lamp unit, place the lamp cover correctly otherwise the LCD
Projection TV can not be turned on.
● Warning indicator
The LCD Projection TV is shut down and the WARNING indicator is flashing red
When the temperature inside the LCD Projection TV exceeds the normal temperature, it is automatically shut down
to protect the LCD Projection TV. The POWER indicator flashes red and the LCD Projection TV is being cooled
down. When the temperature inside the LCD Projection TV returns to normal, the POWER indicator is turned off
and the LCD Projection TV can be turned on. When the LCD Projection TV is turned on again, the WARNING indi-
cator stops flashing.
Check the items listed below;
> Installation and air circulation
> Temperature abnormality with temperature sensors
The LCD Projection TV is shut down and the WARNING indicator lights red
When the LCD Projection TV detects an abnormal condition, it is automatically shut down to protect the LCD
Projection TV and the WARNING indicator lights red. In this case, unplug the AC power cord and plug it, and then
turn the LCD Projection TV on again to verify operation. If the LCD Projection TV is turned off again or fails to be
turned on, the internal check and repair will be required.
Check the items listed below;
> Power failure protection circuit
> Temperature abnormality with temperature sensors and thermal switch
> Lamp cover switch
Circuit Protections
- 6 -
LAMP COVER SWITCH
(SW1861)
LAMP COVER
The openings in the cabinet are provided for ventilation. To
ensure reliable operation of the product and protect it from
overheating, these openings must not be blocked or
covered.
● Ta ke appropriate space on the top, sides and rear of the
LCD Projection TV
cabinet for allowing air circulation and
cooling the
LCD Projection TV
. Minimum distance should
be taken. If the
LCD Projection TV
is to be built into a
compartment or similarly enclosed, the minimum
distances must be maintained. Do not cover the
ventilation slot on the
LCD Projection TV
. Heat build-up
can reduce the service life of your
LCD Projection TV
, and
can also be dangerous.
Air Circulation
Throughout the installation process, handling by more
than two people is recommended.
RECOMMENDATION
BE SURE TO USE OR PLACE THE LCD
PROJECTION TV IN THE TEMPERATURE
INDICATED BELOW:
Place the LCD Projection TV on flat places or with an exclusive
LCD Projection TV stand. Placing on uneven places may cause
picture tilt or distortion.
Do not place the LCD Projection TV under direct sunlight. This may
have a damaging effect on picture quality and the screen surface
of the LCD Projection TV.
41°F ~ 95°F (5°C ~ 35°C)
14°F ~ 140°F (-10°C ~ 60°C)
Operating Temperature
Storage Temperature
Placing and Settling the LCD Projection TV
CAUTION;
When placing the LCD Projection TV, the spaces
for ventilation must be maintained.
SIDE and TOP REAR
- 7 -
■ Installation
4" (10cm)
8"
(20cm)
8"
(20cm)
4"
(10cm)
This LCD Projection TV is equipped with cooling fans for protec-
tion from overheating. Pay attention to following to ensure proper
ventilation and avoid a possible risk of fire and malfunction.
- Do not cover vent slots.
Obstructions may block cooling air.
Hot air is exhausted from the exhaust vent.
When using or installing the LCD Projection TV, the following pre-
cautions should be taken.
– Do not put any flammable objects near the vent.
– Do not touch a peripheral part of the exhaust vent, especially
screws and metallic part. This area will become hot while the
LCD Projection TV is being used.
COOLING FANS
Cooling fans are provided to cool the LCD Projection TV. The fans'
running speed is changed according to the temperature inside the
LCD Projection TV. When the LCD Projection TV is cooled down
enough, the fans will stop running.
Caution;
Caution;
Air intake vents and exhaust vents
BACK OF CABINET
Installation
- 8 -
Air intake vents
Exhaust vents (Hot air exhaust)
Caution;
When placing on a LCD Projection TV stand, take the measures against
prevention of fall for safety.
Placing on the TV stand
Attach the LCD Projection TV stand.
Stand attachment hole
(3 holes at bottom of cabinet)
Note; Follow to installation manual of a LCD Projection TV stand.
(PLV-5565STD)
Installing the LCD Projection TV for safety.
When Installing the LCD Projection TV, secure the LCD
Projection TV on the stand. If not, the LCD Projection TV may
fall down and accident can result.
Place the LCD Projection TV on the proper position of the
stand. There are 3 holes on the top panel of the stand. Use
the 3 screws (included with the stand) to fix the LCD
Projection TV.
Installation
- 9 -
Screw
- 10 -
Care for Using the LCD Projection TV
When using the LCD Projection TV, the following
precautions should be taken. Otherwise, the screen can
be damaged:
●
Do not push or hit the screen surface.
●
Do not write, paint, or affix anything on the screen.
●
Do not put anything on the LCD Projection TV.
●
Never touch the projection screen directly with hands.
NOTE:
Black dots or bright points of light (red, green, or blue) may appear
on the screen. This is a characteristic of the LCD panels, not a
malfunction of the LCD Projection TV.
Do not push or hit
the screen.
Be sure to disconnect the AC Power cord from the AC outlet
before cleaning the LCD Projection TV.
●
Gently wipe the screen and the cabinet with a soft dry clean
cloth.
●
When it is heavily soiled, wipe the screen and the cabinet
with a soft cloth dampened with warm water and finish with a
soft, dry clean cloth.
CAUTION;
Do not use benzene, thinner, or any volatile
substances to clean the LCD Projection TV. These
chemicals may cause damage to the product.
● Cleaning the LCD Projection TV
■ Cleaning
Cleaning
- 11 -
Cleaning Procedure
(When no good, progress to next step.)
1. Clean surface of optical parts using air spray.
2. Wipe the dry cleaning with wiping cloth and the wiper.
3. Soak a few medicines in the cloth as follows and wipe up them lightly. After that, always wipe the dry cleaning
cloth.
Disassembly Cleaning
Disassembly cleaning method should only be performed when the unit is considerable dirty and cannot be sufficient-
ly cleaned by air spraying alone.
Be sure to readjust the optical system after performing disassembly cleaning.
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 liquid (water,etc.) to clean the unit.
Use of liquid may cause the unit to malfunction.
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 inside of the optical unit.
Remove dust or other particles using air spray. If dirt cannot be removed by air spray, disassemble and clean the opti-
cal unit.
Caution:
Use a commercial (inert gas) air spray designed for cleaning camera and computer equipment.
Use a resin-based nozzle only. Be very 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.
● Optical parts care and cleaning
Screen handling precaution;
1. Wear gloves when handling the screen to prevent fingerprints (also, protection of hand).
2. Do not use force when handling the screen so that edges will not brake or crack.
3. Be careful in handling at the process of disassemblies, because scratch or scrub wound makes transparency
decrease easily.
4. Keep the screen in a dust free environment, because dust may accumurate on the screen by static electricity.
5. Do not stand a screen obliquely for long time.
6. Use thinned synthetic detergent for cleaning, because of the weakness against solvent. Wipe gently with soft
cloth.
7. The screen has laminated Lenticular lens and the Fresnel lens. As scrubbed wound on lens is occured by vibra-
tion, so avoid too much vibration after lamination of Lenticular lens and Fresnel lens.
- 12 -
When the life of the projection lamp of this LCD Projection TV
draws to an end, the LAMP REPLACE indicator will become
yellow. If this indicator turns to yellow, replace the lamp with a
new one promptly.
G
This indicator becomes yellow
when the life of the projection
lamp draws to an end.
Front Panel
Tu rn off the LCD Projection TV and disconnect the AC plug. Allow
the LCD Projection TV to cool for at least 30 minutes.
Loosen a screw that secure the Lamp Cover with a screwdriver
and remove the Lamp Cover.
1
3
Loosen 2 screws that secure the lamp with a screwdriver and
pull out the Lamp by holding the holes on both sides.
4
Replace the Lamp with a new one and put it back and tighten 2
screws. Make sure that the Lamp is correctly secured into the
Lamp compartment.
5
Press the latches on both side of the front cover and pull the front
cover forward to remove.
2
Connect the AC Power Cord to the Power Cord Connector and
turn on the LCD Projection TV.
Follow these steps to replace the lamp assembly.
Put the Lamp Cover back and tighten the screw, and then replace
the front cover.
6
Reset the Lamp replace counter.
See “Lamp Replace Counter” on the next page .
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.
Allow a LCD Projection TV to cool, for at least 30
minutes before you open the Lamp cover. The inside of
the LCD Projection TV can become very hot.
CAUTIONCAUTION
Loosen the screw
Lamp Cover
CAUTION
When installing the new Lamp into the Lamp compartment, make sure
the Lamp socket is securely plugged into the compartment socket.
Improper or loosen socket connection may cause arc discharge resulting fire hazard.
7
8
Part (a)
Part (a)
Loosen the screw
Loosen the screw
LAMP
With pressing
the button, pull
the front cover
forward.
Press the latch
on both side.
Hold here and pull out the lamp.
(There are holes inside)
■ Lamp Replacement
LAMP
REPLACE
WARNIN
Lamp Replacement
- 13 -
The LAMP REPLACE indicator will light yellow when
the total lamp used time reaches 7,980 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 1.14 -(✽)
T
eco : used time in LAMP MODE "Low"
Tnormal : used time in LAMP MODE "High" & "Mid"
You can check the lamp replace counter following to
below procedure.
1 Press and hold INFO button on the remote control
and then press CH(+) button on the side control.
2 The LCD Projection TV used time and lamp used
time will be displayed on the screen briefly.
Total lamp used time
● How to check Lamp Used Time
LCD Projection TV used time
(✽) The specifications are subject to change without
notice.
Be sure to reset the lamp counter after the lamp is
replaced. When the lamp counter is reset, the LAMP
REPLACE indicator will be turned off.
1
Press the MENU key to display the Main menu.
2
Use the CURSOR ed keys to highlight (green)
Lamp Counter Reset. Press ENTER.
3
Use the CURSOR d key to select Ye s . Press
ENTER.
4
Press the EXIT key to return to normal TV viewing.
Lamp Replace Counter
NOTE:
● Do not reset Lamp replace counter without implementation of
lamp replacement. Be sure to reset the Lamp replace counter only after replacing the lamp.
● The lamp counter cannot be reset even if you press the
RESET key on the remote control.
Lamp counter reset?
Use this feature only after replacing the lamp in your PTV.
Coun t e r
To t a lTime 0022
No rma l A 00 10
Eco B 0012
Ak+B 0023
3
H
0
H
3
H
7
H
Lamp Replacement
- 14 -
This LCD Projection TV uses a high-pressure lamp which must be handled carefully and properly. Improper handling
may result in accidents, injury, or create a fire hazard.
● Lamp lifetime may differ from lamp to lamp and according to the environment of use. There is no guarantee of the
same lifetime for each lamp. Some lamps may fail or terminate their lifetime in a shorter period of time than other
similar lamps.
● If the LCD Projection TV indicates that the lamp should be replaced, i.e., if the LAMP REPLACE indicator lights up,
replace the lamp with a new one IMMEDIATELY after the LCD Projection TV has cooled down.
( Follow carefully the instructions in the Lamp Replacement section of this manual.) Continuous use of the lamp
with the LAMP REPLACE indicator lighted may increase the risk of lamp explosion.
● A Lamp may explode as a result of vibration, shock or degradation as a result of hours of use as its lifetime draws
to an end. Risk of explosion may differ according to the environment or conditions in which the LCD Projection TV
and lamp are being used.
IF A LAMP EXPLODES, THE FOLLOWING SAFETY PRECAUTIONS SHOULD BE TAKEN.
If a lamp explodes, disconnect the LCD Projection TV’s AC plug from the AC outlet immediately. Contact an authorized service station for a checkup of the unit and replacement of the lamp. Additionally, check carefully to ensure that
there are no broken shards or pieces of glass around the LCD Projection TV or coming out from the cooling air circulation holes. Any broken shards found should be cleaned up carefully. No one should check the inside of the LCD
Projection TV except those who are authorized trained technicians and who are familiar with LCD Projection TV service. Inappropriate attempts to service the unit by anyone, especially those who are not appropriately trained to do so,
may result in an accident or injury caused by pieces of broken glass.
ORDER REPLACEMENT LAMP
Replacement lamp can be ordered through your dealer. When ordering a projection lamp, give the following
information to the dealer.
● Model No. of your LCD Projection TV : PLV-55WHD1 / PLV-65WHD1
● Replacement Lamp Type No. : POA-LMP96
(Service Parts No. 610 322 7382)
1
Cabinet bottom cover removal.
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 lose of performance and product safety.
The wiring method of the leads and ferrite cores should be returned exactly the
same state as the original, otherwise it may cause lose of performance and prod-
uct safety.
Fig. 1
1. Remove the 10 screws-A(T4x14) and remove the Cabinet bottom cover.
- 15 -
Cabinet bottom cover
■ Mechanical Disassemblies
Screws Expression
(Type
Diameter x Length) mm
T type M Type
Ta pping screw Machine screw
A
A
A
A
A
A
A
A
A
A
2
Holder bracket back removal.
1. Remove the 4 screws-A(m3x8) and removw the Rear AV panel.
2. Remove the 7 screws-B(T4x12), remove the 2 screws-C(M3x6), remove the 2 screws
D(M3x8) and remove the Holder bracket back.
Fig. 2
- 16 -
Mechanical disassemblies
Rear AV panel
Holder bracket back
A
A
A
A
B
B
C
C
B
B
B
D
D
B
B
Fig. 3-b
3
Front cover removal.
1. Remove the Front cover of the LCD projection TV.
(Press the latches on both side of the front cover and pull the front cover forward to remove.)
Fig. 3-a
Press the latch on both side.
Front cover
Front cover
With pressing the button,
pull the front cover.
- 17 -
Mechanical disassemblies
Latch-L
Latch-R
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