Sanyo PLC-EF10EA User manual

Multimedia Projector
SERVICE MANUAL
PRODUCT CODE
(P6VAA) PLC-EF10EA: 1 122 058 30
(P6VAM) PLC-EF10EAL: 1 122 058 40
(P6VCA) PLC-EF10BA: 1 122 058 32
Original Version
REFERENCE NO. SM5110008
FILE NO.
Model No. PLC-EF10EA
PLC-EF10EAL
(Europe, Asia, Africa,
M.E.)
PLC-EF10BA
(U.K.)
PLC-EF10EAL: Projection lens optional model.
Give complete “Service Ref. No.” for parts
order or servicing, it is shown on the rating
sheet on the projector.
Service Ref. No.: PLC-EF10EA-00
PLC-EF10EAL-00
PLC-EF10BA-00

Multimedia Projector
SERVICE MANUAL
PRODUCT CODE
(P6VAA) PLC-EF10EA: 1 122 058 30
(P6VAM) PLC-EF10EAL: 1 122 058 40
(P6VCA) PLC-EF10BA: 1 122 058 32
Original Version
REFERENCE NO. SM5110008
FILE NO.
Model No. PLC-EF10EA
PLC-EF10EAL
(Europe, Asia, Africa,
M.E.)
PLC-EF10BA
(U.K.)
PLC-EF10EAL: Projection lens optional model.
Give complete “Service Ref. No.” for parts
order or servicing, it is shown on the rating
sheet on the projector.
Service Ref. No.: PLC-EF10EA-00
PLC-EF10EAL-00
PLC-EF10BA-00

2
■Contents
■Safety instructions ________________________________________________3
■Specifications __________________________________________________ 4
■Adjustments after parts replacement ________________________________ 5
■Circuit protections ______________________________________________ 6-7
Fuse ______________________________________________________ 6
Thermal switch ______________________________________________ 6
Warning temperature and power failure protection____________________ 7
■Mechanical disassemblies ______________________________________ 8-15
■Optical unit disassemblies______________________________________ 16-19
■Lamp replacement ______________________________________________ 20
■LCD panel replacement __________________________________________ 21
■Electric adjustments __________________________________________ 22-28
●Service adjustment menu operation____________________________ 22
●Service adjustment data table______________________________ 23-28
●Circuit adjustments ______________________________________ 29-34
■Optical adjustments __________________________________________ 35-40
●Focus adjustment ______________________________________ 35-36
●Convergence adjustment ____________________________________ 37
●Contrast adjustment ________________________________________ 38
●Integrator lens adjustment __________________________________ 39
●Relay lens adjustment ______________________________________ 40
■Troubleshooting ______________________________________________ 41-45
●No Power______________________________________________ 41-43
●No Picture________________________________________________ 44
●No Sound ________________________________________________ 45
■CPU (IC801) port functions ____________________________________ 46-50
■Waveforms __________________________________________________ 51-52
■Cleaning ______________________________________________________ 53
■IC block diagrams ____________________________________________ 54-65
■Pins description of ICs, transistors, diodes____________________________ 66
■Parts description in schematic diagram ______________________________ 67
■Service parts lists __________________________________________ 68-103
●Electrical parts list ______________________________________ 68-108
●Mechanical parts list __________________________________ 101-108
■Circuit block diagram ____________________________________________ A1
■Power supply lines ______________________________________________ A2
■Schematic diagrams ________________________________________ A3-A10
■Printed wiring board diagrams ________________________________ A11-A15

3
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 iden-
tified with the line ( ) in the schematic diagram. For continued product safety and protection of personnel
injury, servicing should be made with qualified personnel.
The following precautions must be observed.
■Safety Instructions
SAFETY PRECAUTIONS
1: An isolation transformer should be connected in the
power line between the projector and the AC line
before any service is performed on the projector.
2: Comply with all caution and safety-related notes pro-
vided on the cabinet back, cabinet bottom, inside the
cabinet or on the chassis.
3: When replacing a chassis in the cabinet, always be
certain that all the protective devices are installed
properly, such as, control knobs, adjustment covers
or shields, barriers, etc.
DO NOT OPERATE THIS PROJECTOR WITHOUT
THE PROTECTIVE SHIELD IN POSITION AND
PROPERLY SECURED.
4: Before replacing the cabinet cover, thoroughly
inspect the inside of the cabinet to see that no stray
parts or tools have been left inside.
Before returning any projector to the customer, the
service personnel must be sure it is completely safe to
operate without danger of electric shock.
SERVICE PERSONNEL WARNING
Eye damage may result from directly viewing the light produced by the Lamp used in this equipment. Always turn
off Lamp before opening cover. The Ultraviolet radiation eye protection required during this servicing.
Never turn the power on without the lamp to avoid electric-shock or damage of the devices since the stabilizer
generates high voltages(15kV - 25kV) at its starts.
Since the lamp is very high temperature during units operation replacement of the lamp should be done at least
45 minutes after the power has been turned off, to allow the lamp cool-off.
PRODUCT SAFETY NOTICE
Product safety should be considered when a component replacement is made in any area of the projector.
Components indicated by mark in the parts list and the schematic diagram designate components in which
safety can be of special significance.It is, therefore, particularly recommended that the replacement of there parts
must be made by exactly the same parts.
DO NOT ATTEMPT TO SERVICING THE
REMOTE CONTROL UNIT.
Laser Beam may be leaked out when in disassemble
the Unit. As the Laser Beam used in this Remote con-
trol unit is harmful to the eyes.
LASER RADIATION
DO NOT STARE INTO BEAM
MAX. OUTPUT: 1mW
WAVE LENGTH: 660 ±20nm
CLASS II LASER PRODUCT
This product is complied with 21 CFR
part 1040.10
CAUTION LASER RADIATION
DO NOT STARE INTO BEAM
CLASS 2 LASER PRODUCT
LASER-STRAHLING
NICHT IN DEN STRAHL BLICKEN
LASER KLASSE 2
IEC60825-1, Am. 1 1997
MAX OUTPUT ( ) : 1 mW
WAVE LENGTH ( ) : 660±20nm

4
Projector Type Multi-media Projector
Dimensions (W x H x D) 390mm x 245mm x 585mm
Net Weight 17.8kg
LCD Panel System 1.8” TFT Active Matrix type x 3 panels
Number of Pixels 3,932,160 {1,310,720 (1280 x 1024) x 3}
Color System 6 color system (PAL, SECAM, NTSC, NTSC4.43, PAL-M and PAL-N)
Scanning Frequency H-sync. 15 ~ 100kHz, V-sync. 50 ~ 120Hz
Projection Image Size (diagonal) Adjustable from 40” to 600”
Horizontal Resolution 800 TV lines
Projection Lens F2.0 ~ 2.3 lens with f75.7mm ~ 97.5mm Motor zoom and focus
Motor Lens Shift ± 760mm on 100” screen
Throw Distance 1.5m ~ 24.6m
Projection Lamp 440watt type
AV Input Jacks BNC Type {Video/Y, C/Cb (B-Y), Cr (R-Y)} x 2 sets,
Phono Type (Audio R and L) x 2 sets and DIN 4 pin (S-Video) x 2 sets
Video Monitor Output Jack BNC Type {Video/Y, C/Cb (B-Y), Cr (R-Y)} x 1 set,
and DIN 4 pin (S-Video) x 1 set
Audio Monitor Output Jack Phono Type (R and L) x 1 set
Computer Input 1 Jack MDR20-pin Terminal (Digital), HDB15-pin Terminal (Analog), Multi-pole 12
pin (Control port) and USB port
Computer Input 2 Jack BNC Type (R, G, B, H and V), Multi-pole 12-pin (Control port) and USB port
Computer Audio Input Jack Phono Type (R and L) x 2 set
Computer Output Jack HDB15-pin Terminal
Computer Audio Output Jack RCA Type (R and L) x 1 set
Other Jacks Wired Remote Control Jack and Serial port (DB 9)
Built-in Speaker INT. SP. Stereo (R and L), 3watt RMS (T.H.D. 10%)
Image Elevation Adjustment Up to 4˚
Voltage 200 ~ 240V AC, 50/60Hz
Power Consumption 3.6A (Max. Ampere)
Operating Temperature 5˚C ~ 35˚C
Storage Temperature -10˚C ~ 60˚C
Remote Control Transmitters Wireless Remote Control with Laser Beam (Class II Laser)
Max. Output 1mW/Wave length 660 ±20nm, batteries (2) AA,UM3 or R06 type.
Wireless/Wired Remote Control, batteries (2) AA, UM3 or R06 type.
■Specifications

5
■Adjustments after Parts Replacement
Focus Adjustment
R-Focus adjustment ●
G-Focus adjustment ●
B-Focus adjustment ●
Convergence Adjustment
R-Convergence adjustment ●●
B-Convergence adjustment ●●
Integrator Lens Adjustment ●
Relay Lens Adjustment ●
Contrast Adjustment
R-Contrast adjustment ●
G-Contrast adjustment ●
B-Contrast adjustment ●
Output Voltage Adjustment ❍
+6V Adjustment ❍
+15V Adjustment ❍
+12V Adjustment ❍
DVCO Adjustment ●
DC Adjustment
R-DC adjustment ●
G-DC adjustment ●
B-DC adjustment ●
PSIG Adjustment ●
Pedestal Adjustment-[CG] ●
R-Pedestal adjustment ●
G-Pedestal adjustment ●
B-Pedestal adjustment ●
Gain Adjustment-[CG]
R-Gain adjustment ●
G-Gain adjustment ●
B-Gain adjustment ●
Pedestal Adjustment-[AV]
R-Pedestal adjustment ●
G-Pedestal adjustment ●
B-Pedestal adjustment ●
Gain Adjustment-[AV]
R-Gain adjustment ●
G-Gain adjustment ●
B-Gain adjustment ●
Video Adjustment-[CG]
R-Video adjustment ●
G-Video adjustment ●
B-Video adjustment ●
Video Adjustment-[AV]
R-Video adjustment ●
G-Video adjustment ●
B-Video adjustment ●
Common Center Adjustment
R-Common center adjustment ● ●
G-Common center adjustment ● ●
B-Common center adjustment ● ●
Offset Adjustment-[AV]
R-Offset adjustment ●
G-Offset adjustment ●
B-Offset adjustment ●
Offset Adjustment-[CG]
R-Offset adjustment ●
G-Offset adjustment ●
B-Offset adjustment ●
White Balance Adjustment-[CG] ●●● ●
White Balance Adjustment-[AV] ●●● ●
White Uniformity Adjustment ❍❍❍ ❍
Disassembly / Replaced Part
LCD Panel
RGB
Integrator
lens Relay
Lens Polarized glass
RGB Main
Board
Optical AdjustmentsElectrical Adjustments
● : Adjustment necessary ❍ : Check necessary
Power
Board Sub
Power
Board

-6-
■Circuit Protections
This projector is equipped with the following circuit protections to operate in safety. If the abnormality occurs inside
the projector, it will automatically turn off by operating one of the following protection circuits.
Fuse
The fuse is located inside the projector. When the Mains switch on the rear panel is turned on and the lamp indica-
tor does not illuminate, fuse may be open. Remove the AV board ass’y by following below and check the fuse.
It should be used the specified fuse as follows;
How to replace the fuse
1. Remove 4 screws and pull out the AV Jack board ass’y.
2. Insert slot screwdriver into a globe of the fuse holder, then push and turn the screwdriver in the arrow direction.
To install the fuse, take reversed step in the above.
Fuse Part No.: 423 025 1201
TYPE T8.0AH 250V FUSE
LITTLE FUSE INC.TYPE 215008

-7-
Circuit Protections
Warning temperature and power failure protection
The TEMP WARNING indicator flashes red and the projector will automatically turn off when the internal tempera-
ture of the projector exceeds the normal temperature or when stopping cooling fans or when the internal power sup-
ply lines are failed.
Check the following possible causes and wait until stopping the TEMP WARNING indicator flashing.
Possible causes
- Air filter is clogged with dust particles. Remove dust from the air filter by following instructions in the “Air filter care
and cleaning” below.
- Ventilation slots of the projector are blocked. In such an event, reposition the projector so that ventilation slots are
not obstructed.
- Check if projector is used at higher temperature place (Normal operating temperature is 5 to 35 ˚C)
If the TEMP WARNING indicator still continues to flash, there may be defects on cooling fans or power supply cir-
cuits. Please check fan operation and power supply lines referring to the “Power Supply Lines Chart”.
Air Filter care and cleaning
The removable air filter prevents dust from accumulation on the surface of
the projection lens and projection mirror. Should be the air filter become
clogged with dust particles, it will reduce the cooling fan’s effectiveness
and may result in internal heat build up and reduce the life of the projector.
To clean up the air filter, follow the cleaning procedure below:
1. Turn the MAINS ON/OFF switch to OFF, and disconnect the AC power
code from the AC outlet.
2. Remove the air filter cover.
Press the cover latch sideway and lift the cover.
3. Remove the air filter and sponge from the filter cover.
4. Clean the air filter with a vacuum cleaner.
5. Replace the air filter and sponge. Make sure that air filter cover is fully
inserted.
CAUTION:
Do not clean with water. Doing so may damage the air filter.
Do not operate the projector with air filter removed.
RECOMMENDATION
We recommend to avoid dusty, smoky place for operating the projector.
Using in dusty place may cause the picture of poor quality.
When using under the dusty or smoky conditions, dust may accumulate on
the LCD panel and lens inside it, and may resultantly be projected on the
screen together with the picture.
When the above symptoms are noticed, please clean up the LCD panel
and lens following to the “Cleaning Method”.
Air filter cover
Air filter cover
Sponge
Air filter

-8-
The cover top is fixed by the 2 locked levers(A). When removing the top
cover, turn the lock lever to the released position as shown in Fig.1-3.
The pen-type light and thin flat tool (like cutter knife) will be required to
release the lock.
1) Confirm the position of the lock lever with the pen-light. Release the lock
lever by sliding it laterally by using at the edge of the tool as shown in
Fig.1-1.
2) Release the other lock lever in the same way.
3) Lift the cover top to the upward by the tool as shown in Fig.1-2.
4) After lifting it, hold the cover top and pull it to the backward.
Note:
Be careful not to damage the cabinet finish when
removing it.
1. COVER TOP REMOVAL
■Mechanical Disassemblies
Mechanical disassemble should be made following procedures in numerical order.
Following steps show the basic procedures, therefore unnecessary step may be ignored.
Caution:
The parts and screws should be placed exactly the same position as the original otherwise it may cause loss of per-
formance and product safety.
Fig.1-2
Fig.1-3
Locked Released
Fig.1-1
AA
Cover Top
Lock Lever

-9-
Mechanical Disassemblies
1) Remove 4 screws (A) on the cabinet front.
2) Push down the part B of the cabinet front by finger (slight bent cabinet
downward) and remove the engagement of it. See Fig.2-1.The front and
top cabinets are engaged with 4 hooks at the top and 3 hooks at the lower
part. See Fig.2-4 on next page for location of the hooks. Release those
hooks when separate the both cabinets.
2. CABINET FRONT REMOVAL
3) Pull the lower side of the cabinet front forward and remove it as shown in
Fig.2-2.
Lower part is engaged with the 3 hooks. Push the cabinet front downward
slightly and pull the lower forward.
Fig.2-1
Fig.2-2
A
A
A
A
B
B
Front Cabinet
Cabinet Top
Front Cabinet
Cabinet Top

-10-
Mechanical Disassemblies
1) Front and top cabinets are engaged with 4 hooks at the
upper side and 3 hooks at lower side. See Fig.2-4. First
engage the upper side at each end of the cabinet front
with the cabinet top.
Then, push the lower of the cabinet in the direction of the
arrow and engage the lower part of cabinet front with the
lower part of cabinet top. See Fig.2-4.
It is not enough to engage the upper side of the cabinet
front with the upper side of the top cabinet. Follow the
next steps for engaging them completely.
2) See Fig.2-3. Slightly push the cabinet front backward
and pushing arrow points of the cabinet top until each
hooks are fitted.
Push the arrow point in the order if the number. Space
should not be obtained between the cabinet front and
the cabinet top. Engage both cabinets until no space
observed between both cabinets.
* CABINET FRONT MOUNTING
Fig.2-3
Fig.2-4
1
4
3
2

-11-
Mechanical Disassemblies
1) Loose 2 screws (A) on side of the cabinet and remove the lamp cover.
3. LAMP COVER and CABINET TOP REMOVAL
2) Remove 7 screws (B) and pull the cabinet top upward.
1) Disconnect the connectors and FPC on the main board.
2) Remove 8 screws and pull the main board upward.
4. MAIN BOARD REMOVAL
Lamp Cover
A
B
A
B
B
B
BB
B
Cabinet Top
Fig.4
Fig.3-2
Fig.3-1

-12-
Mechanical Disassemblies
1) Pull out the AV Jack board ass’y upward and remove a screw (A).
2) Remove 4 screws (B) and then take out AV Jack board ass’y.
3) Remove 6 screws (C) and 4 screws (D), then remove the AV Jack board.
6. AV JACK BOARD REMOVAL
1) Remove 2 screws (A) and disconnect the lamp socket.
2) Remove 4 screws (B) and pull the lamp ballast unit upward.
3) Release 4 hooks (C) on the shield box and remove
the shield cover.
4) Pull out the lamp ballast unit by sliding it to the
upward.
5) Remove 2 screws (D) and remove the FAN
(FN905).
6) Remove 2 screws (E) and remove video
board.
5. LAMP BALLAST, VIDEO BOARD and FAN(FN905) REMOVAL
AA
B
B
B
BC
C
C
C
D
D
C
D
B
A
B
B
B
Shield Cover
FN905
Lamp
Ballast
Board
AV Jack Board
Fig.6
Fig.5
EEVideo Board

-13-
Mechanical Disassemblies
1) Remove 2 screws (A) and remove the FAN(FN903).
2) Remove 4 screws (B) and remove the duct cover.
3) Remove 2 screws (C) and remove the Sub Power board.
4) Remove 4 screws (D) and remove the shield box.
5) Release 4 hooks (E) on the shield box and remove the shield box cover.
6) Remove the Power unit by sliding it to the upward.
7) Remove 2 screws (F) and remove the FAN(FN904).
7. POWER, SUB POWER BOARD and FAN(FN903, FN904)
REMOVAL
A
Power Board
ABBB
B
C
CD
D
D
D
E
E
EE
FF
Sub Power Board
FN903
Duct
Cover
FN904
Shield Box Cover
Fig.7

-14-
Mechanical Disassemblies
1) Remove a screw (A) and remove the
ground wire.
2) Pull out the Interface Panel ass’y by slid-
ing it upward.
3) Remove 6 screws (B) and 5 screws (C),
then remove the Interface board.
8. INTERFACE BOARD REMOVAL
Remove 4 screws and the pull out the Mains Switch Ass’y.
9. MAINS SWITCH ASS’Y REMOVAL
A
B
C
Interface Board
Mains Switch Ass’y
B
B
B
B
B
Fig.9
Fig.8

-15-
Mechanical Disassemblies
1) Remove 5 screws (A) and remove the Mother board.
2) Remove 4 screws (B) and remove the
Filter board.
3) Remove a screw (C) and remove the RC2
board.
11. MOTHER, FILTER and RC2 BOARD REMOVAL
1) Remove 9 screws (A) and pull out the Optical Unit Ass’y upward.
2) Remove 4 screws (B) and remove the Lamp Box.
3) Remove 4 screws (C) and then pull out the Duct Cover and
FAN (FN902).
4) Remove 4 screws (D) and remove the Duct In Cover.
5) Remove 6 screws (E) and remove FAN (FN901,
FN906, FN907).
6) Remove 2 screws (F) and remove the Interlock Switch
(SW902).
7) Remove 2 screws (G) and remove the Net Unit.
10. OPTICAL UNIT and FAN (FN901, FN902,
FN906,FN907) REMOVAL
AC
G
E
F
D
B
FN902
Duct
Cover
Interlock Switch
Duct In Cover
FN901
FN907
FN906
Net Board
C
C
C
B
B
B
AA
A
AA
AA
A
EE
B
A
C
A
A
A
A
BB
B
Mother Board
Filter Board
RC2 Board
Fig.10
Fig.11

-16-
Remove 4 screws (Hexial screws) and remove the Projector Lens.
1. PROJECTOR LENS REMOVAL
Remove 4 screws and remove the Lens Holder ass’y.
2. LENS HOLDER ASS’Y REMOVAL
Projector Lens
Lens Holder Ass’y
Fig.2
Fig.1
■Optical Unit Disassemblies
Remove the Cabinet Front , Lamp Cover, Cabinet Top and Main Unit by following to steps 2 to 4 of “Mechanical
Disassemblies”, before proceeding these disassemblies.
Spacer

-17-
1) Remove 2 screws (A) and pull out the Integrator Lens ass’y upward.
2) Remove 2 screws (B) and pull out the Relay Lens ass’y upward.
3) Remove 3 screws (C) and pull out the Polarized Glass ass’y upward.
3. INTEGRATOR, RELAY LENS and POLARIZED GLASS
REMOVAL
Remove 9 screws and then pull out the Optical Unit Top upward.
4. OPTICAL UNIT TOP REMOVAL
A
Integrator Lens Ass’y
A
B
B
C
C
C
Relay Lens Ass’y
Polarized Glass (B) Ass’y
Polarized Glass (G) Ass’y
Polarized Glass (R) Ass’y
Fig.3
Fig.4
Optical Unit Disassemblies

-18-
Optical Unit Disassemblies
When the optical parts mounting or assembling, the parts must be mounted
in the specified location and direction. Please refer to the figure below and
“Mounting direction of optical parts” on next page.
1 Prism
2 Optical filter UV/IR
3 Integrator lens
4 Prism (Polarized Beam Splitter)
5 Condenser lens (IN)
6 Mirror (W)
7 Dichroic mirror (B)
8 Dichroic mirror (G)
9 Optical filter
10 Mirror (B)
11 Condenser lens
12 Polarized glass (IN/R)
13 Polarized glass (IN/G)
14 Polarized glass (IN/B)
15 Relay lens (IN)
16 Mirror (R)
17 Relay lens (OUT)
No. Part name No. Part name
1
3
2
4 5
6
7
13
15
14
8
12
17
11
16
Parts Name and Locations
11
16
15 Printed marker
comes this side
Fig.5
Printed marker
comes this side Printed marker
comes this side
Printed marker
comes this side
10
9

-19-
Optical Unit Disassemblies
Lighting
source
Top view
Slit
Side View
Polarized Beam Splitter
●Mirror (Ref.No.6, 10, 16) mounting direction
Mount the mirror with coating side(mirror side) inside.
●Optical filter (Ref No. 2) mounting direction
Mount the optical filter as the printed marker (Lot No.) comes left side view-
ing from the lighting source side.
●Polarized glass (Ref No. 12, 13, 14) mounting direction
Mount the Polarized glass as the face which the polarized sheet is attached
to prism side.
●Lens mounting
Lens (Ref.No. 11) must be mounted as shown in Fig.5.
Lens (Ref.No. 5, 15, 17) has no mounting direction.
●Dichroic Mirror (Ref No. 7, 8) mounting
Dichroic mirrors must be mounted as shown in Fig.5.
Integrator lens
Integrator lens
Bottom side
Printed marker comes this side
Printed marker comes this side
The optical parts must be mounted in specified direction otherwise the pic-
ture image will not reproduce correctly.
●Integrator lens (Ref No. 3) mounting direction
Mount the Integrator lens as shown in Fig.5 and Fig.6.
●Polarized beam splitter (Ref No. 4) mounting direction
Mount the Polarized beam splitter as shown in Fig.5 and Fig.6.
Note:The marking comes upper right corner viewing from the projected side
and the marking comes lower right corner viewing from the lighting
source side.
Mounting direction of optical parts
Fig.6