Sanyo PLC-XE32 User manual

Multimedia Projector
SERVICE MANUAL
PRODUCT CODE
1 122 426 00 (LE7AC)
1 122 426 02 (LE7CC)
Original Version
REFERENCE NO. SM5110919-00
FILE NO.
Model No. PLC-XE32
Europe, U.K,
Chassis No. LE7-XE3200
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.

-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
Lamp cover switch ........................................................................... 5
Fuse........................................................................................................ 5
Warning temperature and power failure protection........... 6
Air filter care and cleaning ............................................................ 6
Security Function Notice ................................................................... 7
Lamp Replacement.............................................................................. 8
Lamp replacement........................................................................... 8
How to reset Lamp Replace Counter......................................... 8
How to check Lamp Used Time................................................... 8
Mechanical Disassembly.................................................................... 9
Optical Parts Disassembly ...............................................................14
Adjustments.........................................................................................20
Adjustments after Parts Replacement ....................................20
Optical Adjustments .........................................................................21
Contrast adjustment .....................................................................21
Integrator lens adjustment.........................................................22
Relay lens-Out adjustment .........................................................23
Electrical Adjustments......................................................................24
Service Adjustment Menu Operation .....................................24
Memory IC (IC1371) Replacement............................................24
Circuit Adjustments .......................................................................25
Test Points and Locations............................................................28
Service Adjustment Data Table .................................................29
Chassis Block Diagrams....................................................................41
Chassis over view............................................................................41
System control.................................................................................42
Power supply & protection circuit............................................43
Fan control circuit...........................................................................44
Troubleshooting .................................................................................45
Indicators and Projector Condition..........................................45
No Power ...........................................................................................46
No Picture..........................................................................................47
No Sound...........................................................................................48
Control Port Functions .....................................................................49
System Control I/O Port Functions (IC301)............................49
IIC Bus DA Converter Port Functions (IC3531) ....................50
Waveform..............................................................................................51
Cleaning.................................................................................................52
IC Block Diagrams...............................................................................53
Electrical Parts List .............................................................................56
Electrical Parts Location...............................................................57
Electrical Parts List..........................................................................58
Mechanical Parts List.........................................................................75
Cabinet Parts Location..................................................................75
Optical Parts Location...................................................................76
Mechanical Parts List.....................................................................80
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 .............................A11
Note on Soldering...........................................................................A12

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Safety Instructions
WARNING:
The chassis of this projector is isolated (COLD) from AC line by using the converter transformer. Primary side of the con-
verter 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.
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 PRO
TECTIVE 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 gener-
ates 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.

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Specifications
Mechanical Information
Projector Type Multi-media Projector
Dimensions (W x H x D) 12.99" x 3.15" x 9.33" (330 mm x 80 mm x 237 mm) (Not including adjustable
foot)
Net Weight 6.4 lbs (2.9 kg)
Foot 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 PAL, SECAM, NTSC, NTSC4.43, PAL-M, and PAL-N
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 1.65 ~ 1.81 lens with f 22.5 mm ~ 27 mm with manual zoom and focus
Throw Distance 4.6' - 43.3' (1.4m - 13.2m)
Projection Lamp 200W
Interface
Video Input Jack RCA Type x 1
Audio Input Jacks RCA Type x 2
Computer Input/S-VIDEO Analog RGB (Mini D-sub 15 pin) Terminal x 1
/Component Input Terminal
Monitor Output Terminal Analog RGB (Mini D-sub 15 pin) Terminal x 1
Component/ Computer Audio Input Jack Mini Jack (stereo) x 1
Service Port Connector Mini DIN 8 pin x 1
Audio Output Jack Mini Jack (stereo) x 1 (Variable)
Audio
Internal Audio Amp 1.0 W RMS
Built-in Speaker 1 speaker, ø1.1" (28 mm)
Power
Voltage and Power Consumption AC 200 ~ 240 V (1.6A Max. Ampere), 50/60 Hz (ContinentalEurope andTheU.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 AA or LR6 1.5 V ALKALINE TYPE x 2
Operating Range 16.4' (5 m)/±30˚
Dimensions 1.9" (W) x 0.87" (H) x 5.7" (D) (49 mm x 22 mm x 145.3 mm)
Net Weight 3.53 oz (100 g) (including batteries)
● 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.

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Fuse
A fuse is located inside of the projector. When the POWER indi-
cator 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
How to replace the fuse
1. The fuse is placed on the filter board under the main board.
Remove the cabinet top and main board.
2. Take the fuse off, 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 pro-
jector can not turn on.
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 90˚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. Remove the cabinet top.
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.
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 (SW902)
Fuse
Circuit Protections
Filter Board

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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 cool-
ing 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 pos-
sible 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)
Air filter care and cleaning
Air filters prevent dust from accumulating on the optical elements inside the projector. Should the air filters become clogged
with dust particles, it will reduce cooling fans’ effectiveness and may result in internal heat build up and adversely affect the
life of the projector. Clean the air filters following the steps below.
1. Turn off the projector, and disconnect the AC power cord from
the AC outlet.
2. Turn over the projector and remove the air filters by pulling
the latches upward.
3. Clean the air filters with a brush or rinse them softly.
4. When cleaning the air filters by rinsing, dry them well. Re-
place the air filters properly. Make sure that the air filters are
fully inserted.
CAUTION:
Do not operate the projector with the air filters removed. Dust
may accumulate on the LCD panel and the projection mirror de-
grading picture quality.
Do not put small parts into the air intake vents. It may result in
malfunction of the projector.
RECOMMENDATION:
We recommend avoiding dusty/smoky environments
when operating 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. This condition may degrade the quality of a projected image.
When the symptoms above are noticed, contact your authorized dealer or service station for proper cleaning.
Air filters

-7-
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.
Security Function Notice
Resetting procedure
1The projector is put into the state of the standby.
2Press and hold 7and 8button on the remote control unit simultaneously for more than 10 seconds.
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.
Function Description
Key lock
Locks operation of the top control or the remote control.
If the Key lock is enabled with top control lock, the projec-
tor can no longer be started.
Initial setting: Key lock function is disabled
PIN code lock
Prevents the projector from being operated by an unau-
thorized person.
Initial code: “1234”
Logo PIN code lock
Prevents an unauthorized person for changing the start-
up logo on the screen.
Initial code: “4321”

-8-
Lamp Replacement
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 below
expression,
Total lamp used time = Tnormal + Thigh x 1.5
Tnormal: used time in the Normal mode
Thigh : used time in the High mode and Auto mode.
You can check the lamp used time following to the below
procedure.
1Press and hold the ON/STAND-BY button on the remote
control unit for more than 20 seconds.
2 The projector used time and lamp used time will be dis-
played on the screen briefly as follows.
Lamp replacement
WARNING:
- For continued safety, replace with a lamp assembly of the same type.
- Allow the projector to cool for at least 45 minutes before you open the
lamp cover. The inside of the projector can become very hot.
- Do not drop the lamp module or touch the glass bulb! The glass can shatter
and cause injury.
Procedure
1Turn off the projector and disconnect the AC cord.
2Loosen 1 screw with a screwdriver and remove the lamp cover.
3 Loosen 3 screws and pull out the lamp assembly by grasping the ledges.
4Replace the lamp with a new one and tighten the 3 screws back into posi-
tion. Make sure that the lamp is set properly. Replace the lamp cover and
tighten the screw.
5Connect the AC cord to the projector and turn on.
6Reset the lamp replacement counter, see below explanation.
Note
- The projector cannot be turned-on with lamp cover removed, because
when the lamp cover is removed, the lamp cover switch is also released to
switch off the lamp circuit.
How to reset Lamp Replace Counter
1Turn the projector on, press the MENU button and the
On-Screen Menu will appear. Press the 7or 8button to
move the red frame pointer to the Setting Menu icon.
2Press the dbutton to move the red frame pointer to the
Lamp counter reset item and then press the SELECT but-
ton. Select "Reset" and press the SELECT button. The mes-
sage "Lamp replace counter Reset?" is displayed. Move
the pointer to [Yes] and then press the SELECT button.
* Refer to owner's manual for further information.
Recommendation
Should the air filter become clogged with dust particles, it
will reduce the cooling fan’s effectiveness and may result in
internal heat build up and short lamp life. We recommend
cleaning the air filter after the projection lamp is replaced.
Refer to“Air Filter Cleaning”.
Lamp
Lamp Cover Screw
Screw
Screw
Counter
Projector 525H
Lamp
High 150H
Normal 375H
Corresponding value 600H
Total lamp used time
Projector used time
ORDER REPLACEMENT LAMP
Type No. Service Parts No.
POA-LMP107 610 330 4564
WARNING : TURN OFF THE UV LAMP BEFORE OPENING THE LAMP COVER.
USE UV RADIATION EYE AND SKIN PROTECTION DURING SERVICING.
Screw

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zCabinet Top & R/C Board removal
Mechanical Disassembly
Mechanical disassembly should be made following procedures in numerical order.
Following steps show the basic procedures, therefore unnecessary step may be ig-
nored.
Caution:
The parts and screws should be placed exactly the same position as the original oth-
erwise it may cause loss of performance and product safety.
Screws Expression
(Type Diameter x Length) mm
T type M Type
(M3x8)
R/C Board
Fig.1
(M3x8)x5

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xMain Board, Filter Board removal
Mechanical Disassembly
Main board
AV Panel
(M2.5x6)x6
(T3x8)
Fig.2
Filter Board
(T3x6)x2
(M3x6)
(T3x6)
Shield Plate
(M3x6)

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Mechanical Disassembly
cPower Board, Ballast Board, Thermal Sw(SW902), Fan(FN902) removal
Fig.3
Power board
Ballast board
Isolation sheet
Ballast socket
Thermal switch
(SW902)
(M3x8)
(T3x8)x2
(T3x6)x2
(T3x8)
(T3x6)x2
(T3x8)
FN902

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Mechanical Disassembly
Fig.4
vOptical Unit, Fan(FN901) removal
Optical unit
Air Duct
FN901
(T3x8)x2
(T3x8)x2
(T3x8)x6

-13-
Mechanical Disassembly
Fig.5
bFans(FN903, FN904), Speaker, Noise Filter, MSW Board removal
Noise
Filter
Spacer
FN904
(T3x6)x4
(T3x12)x4 (Black)
(T3x8)
(T3x8)
(T3x8)x2
MSW Board
FN903
Speaker

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Optical Parts Disassembly
Before taking this procedure, remove Cabinet Top , Cabinet Front and Main Board following to the “Mechanical Disassem-
bly”.
Disassembly requires a 2.0mm hex wrench.
zIntegrator lens-in disassembly
Hooks
Integrator lens-in
Integrator Lens-In Ass'y
(M2.5x5)x2
Fig.1
* Rugged surface
(Behind)
xRelay lens disassembly
Relay lens
Relay lens Ass'y
(M2.5x5)x2
Fig.2
Spring

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Optical Pats Disassembly
cPolarized glass-in disassembly
Polarized glass
Polarized glass-in Ass'y
(M2.5x5)x1
Fig.3
Film side
LCD Panel/ Prism
Ass’y
Fig.4-1
vLCD Panel/Prism Ass’y removal
(M2.5x4)x2
(M3x10)
(Bottom side)

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#"
(
-19(
#"
(
G-LCD PANEL
Optical Parts Disassembly
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 Adjust-
ment” , “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“PROJECTOR SERVICE TOOL”. The software will
be supplied separately and can be ordered as follows;
PROJECTOR SERVICE TOOL Ver. 4.10
Service Parts No. 610 337 8787
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 projec-
tor. Check which type of LCD Panel/Prism Ass'y is used with the figure below.
When replacing the LCD Panel/Prism Ass'y, you need to take "Panel Type Check and Setting" on the Electrical Adjustment for
the replaced LCD Panel/Prism Ass'y.
The gamma-characteristics is different between L-Type and R-Type LCD Panel/Prism Ass'y.
How to check the type of LCDPanel/Prism Ass'y
Check the printed number on the flat cable of the G-LCD Panel.
L-Type LCD Panel/Prism Ass'y R-Type LCD Panel/Prism Ass'y
Fig.4-2

-17-
Optical Pats Disassembly
bPolarized glass, Pre-polarized glass removal
Polarized Glass(G)
Pre-Polarized Glass(G)
* Mount the polarized glasses as the film
attached side comes to the LCD panel
side.
(M2x2)
(M2x2)
Film
(Blue)
(Red)
(Green)
Pre-Polarized Glass(B)
Fig.5
nProjection lens removal
(M2.5x8)x4
Projection lens
Polarized Glass(B)
* Before removing the Projection Lens, it is re-
quired to remove the Optical Unit from the
cabinet bottom.
Fig.6
Optical filter (BK7)

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Optical Parts Disassembly
mOptical Unit Top removal
(M3x8)x5 Optical top
Fig.7

-19-
5
9
Fig.8
1
6
10
Optical Parts Disassembly
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.
2
3
4
88
11
,Locations and Directions
The printed part no.
comes to this side.
The printed part no.
comes to this side.
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 Relay Lens (IN)
8 Mirror (R)
9 Condenser lens (R)
10 Condenser lens (B)
11 Mirror (B)
7

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● : Adjustment necessary ❍ : Check necessary
Adjustments after Parts Replacement
Adjustments
Disassembly / Replaced Parts
LCD/
Prism Ass’y
Integrator
Lens (OUT)
Relay
Lens (OUT)
Polarized Glass
Power Board Main Board
R G B
Optical
Adjustments
Contrast Adjustment
G-Contrast adjustment ●
B-Contrast adjustment ●
Integrator lens adjustment ❍ ●
Relay lens-out adjustment ❍ ●
Electrical Adjustments
Panel type check and setting ● ●
Fan control adjustment ● ●
Pedestal adjustment [PC] ●
Gain adjustment [PC] ●
Pedestal adjustment [1080i] ●
Gain adjustment [1080i] ●
Gain adjustment [Video] ●
Black reference adjustment ●
Common center adjustment ● ●
50% white adjustment [PC] ● ●
White balance adjustment
[PC] ❍ ❍
50% white adjustment [Video] ● ●
White balance adjustment
[Video] ❍ ❍
White uniformity adjustment ❍ ❍