Sanyo PDG-DXL2000E User manual

Multimedia ProjectorSERVICE MANUAL
Original Version
FILE NO.
Model No. PDG-DXL2000E
U.S.A, Canada, Europe,
U.K, Asia, Brazil
Chassis No. KV2-DXL2000E00
Match the Chassis No. on the rating label on the projector
with the Chassis No. in the Service Manual.
If the Original Version Service Manual Chassis No. does
not match the projector’s, additional Service Literature is
required. You must refer to “Notices” to the Original Ser-
vice Manual prior to servicing.
PRODUCT CODE
1 122 567 00 (KV2AC) USA, Canada
1 122 567 04 (KV2EC) Brazil
1 122 566 00 (LV2AC) Asia
1 122 566 02 (LV2CC) HK
1 122 566 03 (LV2DC) Europe, UK REFERENCE NO. SM5111324-00

-2-
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
Fuse............................................................................ 5
Lamp cover switch...................................................... 5
Warning temperature and power failure protection .... 6
Maintenance.................................................................. 7
Replacing 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
Resetting procedure ................................................ 11
Standby Mode Notice .................................................. 12
Mechanical Disassembly............................................. 13
Adjustments................................................................. 22
Adjustments after parts replacement........................ 22
Note on main board replacement ............................. 22
Service adjustment menu operation ......................... 22
Circuit adjustments ................................................... 23
Service adjustment data table .................................. 26
Chassis Block Diagrams.............................................. 34
Chassis over view..................................................... 34
System control.......................................................... 35
Power supply & protection circuit ............................. 36
Fan control circuit ..................................................... 37
Troubleshooting........................................................... 38
Indicators and projector condition............................. 38
No power .................................................................. 39
No picture ................................................................. 40
No sound .................................................................. 41
Error log.................................................................... 42
Control Port Functions................................................. 43
System control (DDP, IC401) ................................... 43
IIC bus D/A converter (Fan control, IC7881) ............ 44
IC Block Diagrams....................................................... 45
Parts Location Diagrams ............................................. 50
Mechanical Parts List .................................................. 54
Electrical Parts List...................................................... 55
Diagrams & Drawings..................................................A1
Parts description and reading in schematic diagram...A2
Schematic Diagrams ...................................................A3
Printed Wiring Board Diagrams...................................A9
Pin description of diode, transistor and IC.................A13
Note on Soldering......................................................A14

-3-
Safety Instructions
Safety Precautions
Service Personnel Warning
Eye damage may result from directly viewing the light produced by the Lamp used in this equipment. Always
turn off Lamp before opening cover. The Ultraviolet radiation eye protection required during this servicing.
Never turn the power on without the lamp to avoid electric-shock or damage of the devices since the stabilizer
generates high voltages (15kV - 25kV) at its starts.
Since the lamp is very high temperature during units operation replacement of the lamp should be done at least
45 minutes after the power has been turned off, to allow the lamp cool-off.
Product Safety Notice
Product safety should be considered when a component replacement is made in any area of the projector.
Components indicated by mark ! in the parts list and the schematic diagram designate components in which
safety can be of special significance. It is, therefore, particularly recommended that the replacement of there
parts must be made by exactly the same parts.
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 per-
sonnel 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 projec-
tor.
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
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.

-4-
Specifications
This symbol on the nameplate means the product is Listed by Underwriters Labo-
ratories Inc. It is designed and manufactured to meet rigid U.L. safety standards
against risk of fire, casualty and electrical hazards.
Mechanical Information
Projector Type Multi-media Projector
Dimensions (W x H x D) 12.6" x 6.7" x 15.2" (321.0 mm x 170.0 mm x 385.0 mm) (Not including protrusions)
Net Weight 13.7 lbs (6.2 kg)
Feet Adjustment ±1.0˚
DLP Chip
Projection System 0.55" Single DLP chip, 6 segment Color Wheel
Number of Pixels 786,432 pixels (1,024 x 768 dots)
Signal Compatibility
Color System PAL, SECAM, NTSC, NTSC4.43, PAL-M, and PAL-N
SD/HDTV Signal Component: 480i, 480p, 575i, 575p, 720p and 1080i
HDMI; 480p, 575p, 720p and 1080i
Input Scanning Frequency H-sync. 15 kHz-93 kHz, V-sync. 50-120 Hz
Optical Information
Projection Image Size (Diagonal) Adjustable from 55” to 90”
Throw Distance 0.82’ - 1.43' (25.1 cm - 43.7 cm)
Projection Lens F 2.5 lens with f 4.83 mm with manual focus
Projection Lamp 275 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 Input 1 / Component Input Terminal Analog RGB (Mini D-sub 15 pin) Terminal x 1
Computer Input 2 / Monitor Output Terminal Analog RGB (Mini D-sub 15 pin) Terminal x 1 (In/Out switchable)
Computer 1/ Component Audio Input Jack Mini Jack (stereo) x 1
Computer 2 Audio Input Jack Mini Jack (stereo) x 1
Audio Output Jack Mini Jack (stereo) x 1 (Variable)
HDMI HDMI (V.1.3 with Deep Color) x 1
Control port D-sub 9 pin x 1
LAN Connection Terminal RJ-45 x 1
3D Sync Output Mini DIN 3 pin x 1
Audio
Internal Audio Amp 10 W RMS
Built-in Speaker 1 speaker, ø1.46" (37 mm)
Power
Voltage and Power Consumption AC 100–120 V (4.4 A Max. Ampere), 50/60 Hz (The U.S.A and Canada)
AC 100–240 V (4.4 - 2.3 A Max. Ampere), 50/60 Hz (For other countries)
Operating Environment
Operating Temperature 41˚F–104˚F (5 ˚C–40 ˚C)
Storage Temperature 14˚F–140˚F (-10˚C–60 ˚C)
Remote Control
Battery AAA or LR03 1.5V ALKALINE TYPE x 2
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)
Net Weight 2.37 oz (67 g) (including batteries)
Accessories
qOwner’s Manual( CD-ROM)
qQuick Reference Guide
qAC Power Cord
qRemote Control and Batteries
qVGA Cable
qPIN Code Label
lThe specifications are subject to change without notice.
lDLP chips are manufactured to the highest possible standards. A tiny fraction of pixels may be ineffective or always lit, but this is not a
malfunction.

-5-
Fuse
A fuse is located inside of the projector. When the POW-
ER indicator is not lighting, the fuse may be opened.
Check the fuse as following steps.
The fuse should be used with the type listed right;
How to replace the fuse
1. The fuse is placed on the filter board behind the opti-
cal unit. Remove the cabinet top.
2. Take the fuse off from the filter board, and replace the
new one with the specified type.
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.
Thermal switch
There is the thermal switch (SW902) inside of the projec-
tor to detect the internal temperature rising abnormally.
When the internal temperature reaches near 120˚C, the
thermal switch opens to cut off the power to the power
circuit.
The thermal switch can be reset itself automatically
when the internal temperature becomes normal.
When the internal temperature reaches near 80˚C, the
thermal switch returns automatically.
This projector provides the following circuit protections to operate in safety. If the abnormality occurs inside the pro-
jector, it will automatically turn off by operating one of the following protection circuits.
Thermal switch
(SW902)
Circuit Protections
Lamp cover switch
(SW901)
Fuse
(F601)
Fuse Part No.: 323 025 1204
TYPE 8A 250V FUSE
LITTLE FUSE INC. TYPE 215008

-6-
Circuit Protections
Indicators
WARNING TEMP.
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.
Warning temperature and power failure protection
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.
WARNING
DO NOT LEAVE THE PROJECTOR WITH THE AC POWER CORD CONNECTED UNDER AN
ABNORMAL CONDITION. IT MAY RESULT IN FIRE OR ELECTRIC SHOCK.
4Note:
- 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” and "Fan conrol circuit" in the
Chassis Block Diagram section.
When the temperature inside the projector reaches a certain level, the projector will be automatically shut down to
protect the inside of the projector and the WARNING and POWER indicators start blinking. When the projector has
cooled down enough (to its normal operating temperature), the POWER indicator stops blinking and lights red, The
projector can be turned on again by pressing the ON/STAND-BY button.
4Note:
The WARNING indicator continues to blink even after the temperature inside the projector returns to normal. When
the projector is turned on again, the WARNING indicator stops blinking.
Check items
- Remove dust around the air filter.
- 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 is blinking red.
POWER

-7-
Maintenance
1
2
Filter prevents dust from accumulating on the optical elements inside the projector. Should the filter 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, replace the filter immedi-
ately by following the steps below.
3
5
CAUTION
- Do not operate the projector with the filter re-
moved. Dust may accumulate on the optical ele-
ments degrading picture quality.
- Do not put anything into the air vents. Doing so
may result in malfunction of the projector.
- Do not wash the filter with water or any other liq-
uid matter. Otherwise the filter may be damaged.
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, or optical elements inside
the projector degrading the quality of a projected image.
When the symptoms above are noticed, clean up the lens
or other optical parts by referring to the chapter "Cleaning
the projector".
Be sure to reset the Filter counter after replacing the filter.
Press the MENU button to display the On-Screen
Menu. Use the Point ed buttons to select Setting and
then press the Point 8or SELECT button.
Use the Point ed buttons to select Filter counter and
then press the Point 8or the SELECT button. Use the
Point ed buttons to select Filter counter reset and
then press the SELECT button. Filter counter Reset?
appears. Select Yes to continue.
1
2
Resetting the filter counter
Filter counter
Filter counter
Reset? appears.
Select Yes, then
another confirmation
box appears.
Select Yes again to
reset the Filter coun-
ter.
Another confirmation dialog box appears, select Yes to
reset the Filter counter.
3
Replacing the filter
Turn off the projector, and unplug the AC power cord
from the AC outlet.
First, clean up the dust on the projector and around the
air vents.
Loosen the screw and open the lamp cover and lift the
filter out of the projector.
Reinstall the filter completely and close the lamp cover
and secure the screw.
Connect the AC power cord to the projector and turn on
the projector.
Reset the filter counter.
4
6
Lamp cover
Screw
Filter

-8-
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.
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 projector to cool for at least 45 minutes
before you open the Lamp Cover. The inside of
the projector can become very hot.
CAUTION
CAUTION
1
3
4
2
6
5
ORDER REPLACEMENT LAMP
Replacement lamp can be ordered through your dealer. When ordering a projection lamp, give the following
information to the dealer.
Replacement Lamp Type No. : POA-LMP143
Service Parts No. : 610 351 3744
Top Panel
When replacing the lamp because it has stopped illuminating, there is a possibility that the lamp may be bro-
ken. 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.
CAUTION
Lamp replacement icon
WARNING:
TURN OFF THE UV LAMP BEFORE
OPENING THE LAMP COVER
This indicator turns yellow
when the projection lamp
reaches the end of its life.
Note:
The Lamp replacement icon will not appear when the
Display function is set to Off, during Freeze, or No show.
Maintenance
Follow these steps to replace the lamp.
Turn off the projector and unplug the AC power cord. Let
the projector cool for at least 45 minutes.
Loosen the two (2) screws that secure the lamp. Lift the
lamp out of the projector by using the handle.
Replace the lamp with a new one and secure the two (2)
screws. Make sure that the lamp is set properly. Close
the lamp cover and secure the screw.
Loosen the screw and open the lamp cover.
Connect the AC power cord to the projector and turn on
the projector.
Reset the lamp counter.
See “Resetting the Lamp Counter” on the next page.
Screw
Screws
Handle
Lamp Cover
Lamp

-9-
How to check lamp used time
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 be-
low expression,
Total lamp used time (Corresponding value)
= Teco + Tnormal x 1.5
Tnormal : used time in the normal mode
Teco : used time in the eco mode
You can check the lamp used time following to the be-
low procedure.
1Press and hold the ON/STAND-BY button on the re-
mote control for more than 20 seconds.
2The projector used time and lamp used time will be
displayed on the screen briefly as follows.
Counter
Projector 500H
Lamp
Normal 200 H
Eco 300 H
Corresponding value 600 H
Total lamp used time
Projector used time
Resetting the lamp counter
Lamp counter reset
Maintenance
Be sure to reset the lamp counter after the lamp is replaced. When the lamp counter is reset, the LAMP REPLACE
indicator stops lighting and the lamp replacement icon disappears.
Note:
Do not reset the Lamp counter without implementing lamp
replacement. Be sure to reset the Lamp counter only after
replacing the lamp.
Lamp replacement
counter Reset?
appears.
Select Yes, then
another confirma-
tion box appears.
Select Yes again
to reset the Lamp
counter.
Press the MENU button to display the On-Screen
Menu. Use the Point ed buttons to select Setting
and then press the Point 8or the SELECT button.
Use the Point ed buttons to select Lamp counter
and then press the SELECT button. Use the Point ed
buttons to select Lamp counter reset and then press
SELECT button. Lamp replacement counter Reset?
appears. Select Yes to continue.
1
2
Another confirmation dialog box appears, select Yes to
reset the Lamp counter.
3

-10-
Maintenance
Cleaning the projector cabinet
Cleaning the projection window
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 sur-
face of the cabinet.
When the projector is not in use, put the projector in an ap-
propriate carrying case to protect it from dust and scratches.
CAUTION
Do not use any flammable solvents or air sprays on the pro-
jector and in its vicinity. The explosion or fire hazard may
occur even after the AC power cord is unplugged because
the temperature inside the projector is extremely high due to
the lamps. In addition, there is a risk that the internal parts
may be damaged not only by the flammable air spray but
also by the cold air.
Cleaning
Unplug the AC power cord before cleaning.
First, remove the dust with a commercially available air blow-
er. Then gently wipe the projection window surface. Use a
cleaning paper moistened with methyl alcohol (methanol).
Avoid using an excessive amount of cleaner.
Do not use abrasive cleaners, solvents, or other harsh
chemical cleaners to avoid damaging the projection win-
dow.
After long periods of use, dust and other particles will accumulate on the optical parts, mirror, color wheel, lens etc.,
causing the picture to darken or color to blur. If this occurs, remove dust and other particles using air spray. Before
taking the cleaning, turn off the projector and allow the projector to cool for more than 45 minutes. Never disas-
semble the optical unit, mirror or projection lens because those parts are aligned preciously in the factory . If do so,
the projector may have the miss-alignment in optical and reduce the optical performance.
Cleaning the Color Wheel
- The color wheel is made of thin glass. Be very careful
when handing the color wheel.
- In case of fingerprints, etc. on the surface, gently wipe
with a Cleaning Cloth for optical parts that contains a
small amount of non-abrasive camera lens cleaner to
clean the surface.
- Do not use detergents as this could cause peeling of
the color filter.
Cleaning the Reflecting Mirror
- Be careful not to touch the reflecting mirror. Touching
it directly with the hands may cause reducing the bur-
nishing.
- Do not clean other than with air.
Caution:
The optical components may have a crack or spot when
you use the air spray directly to the optical components
while they are in the state of hot. Use a commercial (inert
gas) air spray designed for cleaning camera and com-
puter equipment. Use a resin-based nozzle only. Be very
careful not to damage optical parts with the nozzle tip.