Sanyo PLC-XL40 User manual

Multimedia Projector
SERVICE MANUAL
PRODUCT CODE
1 122 371 00 (KY6A)
1 122 372 00 (LY6A)
1 122 372 02 (LY6C)
Original Version
REFERENCE NO. SM5110816-00
FILE NO.
Model No. PLC-XL40
U.S.A. Canada
Europe, U.K
Chassis No. KY6-XL4000
NOTE: 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, addi-
tional Service Literature is required. You must
refer to “Notices” to the Original Service Manual
prior to servicing the unit.
K
!RoHS
• This product does not contain any hazardous sub-
stances prohibited by the RoHS Directive. (You will
find “RSF” mark near the rating plate on the RoHS
compliant product.)
!WARNING
• You are requested to use RoHS compliant parts for
maintenance or repair.
• You are requested to use lead-free solder.

-2-
Contents
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
Anititheft Alarm Function Disable ............................... 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
Panel Type Check ..................................................... 17
Adjustments................................................................. 20
Adjustments after Parts Replacement ...................... 20
Electrical Adjustments ................................................. 24
Service Adjustment Menu Operation........................ 24
Memory IC (IC1371) Replacement........................... 24
Circuit Adjustments................................................... 25
Test Points and Locations......................................... 29
Service Adjustment Data Table................................. 30
Chassis Block Diagrams.............................................. 40
Chassis over view..................................................... 40
System control.......................................................... 41
Power supply & protection circuit.............................. 42
Fan control circuit ..................................................... 43
Troubleshooting ........................................................... 44
Indicators and Projector Condition ........................... 44
No Power .................................................................. 45
No Picture................................................................. 46
No Sound.................................................................. 47
Control Port Functions................................................. 48
System Control I/O Port Functions (IC301) .............. 48
I/O Expander Port Functions (IC1801) .................... 49
IIC Bus DA Converter Port Functions (IC3531) ....... 49
Waveform .................................................................... 50
Cleaning ...................................................................... 51
Projection Lens Cleaning.......................................... 51
IC Block Diagrams....................................................... 52
Electrical Parts List...................................................... 58
Electrical Parts Location ........................................... 59
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.................A13
Note on Sordering .....................................................A14

-3-
Safety Instructions
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 person-
nel 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 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.
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.

-4-
Specifications
This symbol on the nameplate means the product is Listed by Underwriters
Laboratories Inc. It is designed and manufactured to meet rigid U.L. safety stan-
dards against risk of fire, casualty and electrical hazards.
Mechanical Information
Projector Type Multi-media Projector
Dimensions (W x H x D) 10.50" x 4.86" x 9.58" (320mm x 148mm x 292mm) (Not including adjustable feet)
Net Weight 7.3 lbs (3.3kgs)
Feet Adjustment 0˚ to 10.0˚
Panel Resolution
LCD Panel System 0.6" TFT Active Matrix type, 3 panels
Panel Resolution 1,024 x 768 dots
Number of Pixels 2,359,296 (1,024 x 768 x 3 panels)
Signal Compatibility
Color System PAL, SECAM, NTSC, NTSC4.43, PAL-M, 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 60" to 80"
Projection Lens F 1.85 lens with f 8.1 mm ~ 27 mm with manual focus
Throw Distance 2.49’ - 3.38’ (0.76m - 1.03m)
Projection Lamp 200W
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 Anlaog RGB (Mini D-sub 15 pin) Terminal X 1
Computer Input 2 / Monitor Output Terminal Anlaog RGB (Mini D-sub 15 pin) Terminal X 1 (In / Out switchable)
Computer/ Component Audio Input Jack Mini Jack (stereo) x 1
Service Port Connector Mini DIN 8 pin x 1
USB Connector USB Series B receptacle x 1
Audio Output Jack Mini Jack (stereo) x 1 (Variable)
Audio
Internal Audio Amp 1.0W RMS
Built-in Speaker 1 speaker, ø1.1" (28mm)
Power
Voltage and Power Consumption AC 100 ~ 120 V (2.9A Max. Ampere), 50 / 60 Hz (The U.S.A and Canada)
AC 200 ~ 240 V (1.4A Max. Ampere), 50 / 60 Hz (Continental Europe and The U.K.)
Operating Environment
Operating Temperature 41 ˚F ~ 95 ˚F (5 ˚C ~ 35 ˚C)
Storage Temperature 14 ˚F ~ 140 ˚F (-10˚C ~ 60 ˚C)
Remote Control
Battery AA or LR6 1.5V ALKALINE TYPE x 2
Operating Range 16.4’ (5m) / ±30˚
Dimensions 1.9”(W) x 0.87”(H) x 5.7”(D) (49mm x 22mm x 145.3mm)
Net Weight 3.53 oz (100 g) (including batteries)
Antitheft Alarm
Battery CR2 3V LITHIUM BATTERY x 1
● 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.

-5-
Fuse
A fuse is located inside of the projector. When the POWER indicator
is not lightning, the fuse may be opened. Check the fuse as follow-
ing 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. Remove the lamp cover and fuse cover as shown in figure.
2. Take the fuse out from the aperture, 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 projector to detect
the internal temperature rising abnormally. When the internal tem-
perature reaches near 105˚C, the thermal switch opens to stop the
operation of the power supply circuit.
The thermal switch cannot be reset itself automatically even if the
internal temperature becomes normal. Reset the thermal switch fol-
lowing to the below procedure.
How to reset the thermal switch
1. Remove the cabinet top, cabinet front and main board and then
remove the power box top cover.
2. Press the reset button on the thermal switch in the power box.
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 projec-
tor, it will automatically turn off by operating one of the following protection circuits.
Thermal switch (SW902)
Fuse
Circuit Protections
Fuse cover

-6-
Circuit Protections
Warning temperature and power failure protection
The projector will be automatically turned off when the internal temperature of the projector is abnormally high, or the
cooling fans stop spinning, or the power supplies in the projector are failed.
- If the WARNING indicator is flashing, it may detect the abnormal temperature inside the projector. Check the follow-
ing possible causes and wait until the WARNING indicator stops flashing, and then try to turn on the projector.
- If the WARNING indicator lights red, it may defect the cooling fans or power supply circuits. Check fans operation
and power supply lines referring to the chapter “Power supply & protection circuit” in the Chassis Block Diagram
section.
Possible causes
- Air filters are clogged with dust particles. Remove dust from the air filters by following instructions in the “Air filter
care and cleaning” below.
- Ventilation slots of the projector are blocked. In such an event, reposition the projector so that ventilation slots are
not obstructed.
- Check if projector is used at higher temperature place (Normal operating temperature is 5 to 35 ˚C or 41 to 95˚F)
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 ad-
versely 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 degrading 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-
Anititheft Alarm Function Disable
This projector provides an Antitheft alarm function which
works when detecting a vibration to protect the projector
from a suspicious person.
Release the alarm setting
Press the Fbutton and input the four-digit PIN code
within 10 seconds. (default PIN code "1111") When the
alarm is released, you will hear high-pitched confirma-
tion sound.
When inputting an incorrect PIN code, you will hear low-
pitched sound. If you input incorrect PIN codes 3 times,
the alarm will start ringing.
If you forget the PIN code to release the alarm setting,
press and hold the button 3 and F button at the same
time for more than 3 seconds.
Side Control
F button button 1, 2, 3
This projector provides security functions such as "Key lock", "PIN code lock" and "Logo PIN code lock".When the pro-
jector 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
1Disconnect the AC power cord from the AC outlet.
2As pressing the SELECT button on the projector, connect the AC power cord into an AC outlet again. Keep
pressing the SELECT button until the POWER indicator lights continuously.
This is complete the resetting of the security function. The PIN code lock and Logo PIN code lock are reset as
the initial PIN code at the factory and the Key lock function is disabled.
Please refer to the owner's manual for further information of the security functions.
Function Description
Key lock
Locks operation of the top control or the remote con-
trol.
If the Key lock is enabled with top control lock, the pro-
jector can no longer be started.
Initial setting: Key lock function is disabled
PIN code lock
Prevents the projector from being operated by an un-
authorized 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
3000 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 = Teco + Tnormal x 1.5
Teco: used time in the Eco mode
Tnormal : used time in the Normal mode
You can check the lamp used time following to the below
procedure.
1Press and hold the ON-OFF button for more than 20
seconds.
2 The projector used time and lamp used time will be
displayed 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
1 Turn off the projector and disconnect the AC cord.
2 Remove 1 screw with a screwdriver and remove the lamp cover.
3 Loosen 2 screws and pull out the lamp assembly by grasping the
handle.
4 Replace the lamp with a new one and tighten the 2 screws back into
position. Make sure that the lamp is set properly. Replace the lamp
cover and tighten the screw.
5 Connect the AC cord to the projector and turn on.
6 Reset 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 re-
leased 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 8but-
ton 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 SE-
LECT button. Select "Reset" and press the SELECT
button. The message "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 re-
sult in internal heat build up and short lamp life. We rec-
ommend cleaning the air filter after the projection lamp
is replaced.
Refer to “Air Filter Cleaning”.
Lamp
Lamp Cover Screw
Screw
Handle
Screw
Counter
Projector 525H
Lamp
Normal 150H
Eco 375H
Corresponding value 600H
Total lamp used time
Projector used time
ORDER REPLACEMENT LAMP
Type No. Service Parts No.
POA-LMP90 610 323 0726
WARNING : TURN OFF THE UV LAMP BEFORE OPENING.
USE UV RADIATION EYE AND SKIN PROTECTION DURING SERVICEING.

-9-
zCabinet Top & Fans (FN901, FN902), R/C Board removal
Mechanical Disassembly
Mechanical disassembly should be made following procedures in numerical or-
der.
Following steps show the basic procedures, therefore unnecessary step may
be ignored.
Caution:
The parts and screws should be placed exactly the same position as the original
otherwise it may cause loss of performance and product safety.
Screws Expression
(Type Diameter x Length) mm
T type M Type
(M3x8)x5
Cabinet top
Side grille
FN901
FN902
(T3x6)
Fig.1
(T3x6)
R/C board
(T3x6)
LED spacer
(M3x8)x2

-10-
xMain Board, Rear Panel, Fan(FN905), SP901 removal
Mechanical Disassembly
Main board
Rear panel
FN905
SP901
(M2.5x6)x8
(M4x5)
(T3x8)
Fig.2
Grounding
lead
(M2.5x6)x2

-11-
FN906
Mechanical Disassembly
cPower, Line Filte, Ballast Board,Thermal Sw(SW902), Fan(FN906) removal
Fig.3
Power board
Ballast board
Isolation sheet
Ballast socket
Thermal switch
(SW902)
(T3x6)x4
(T3x6)
(T3x6)x2
(T3x6)
(T3x6)x4
Line Filter board
(M3x8)
(T3x6)(Black)
(T3x6)
(T3x6)
(T3x6)(Black)

-12-
Mechanical Disassembly
Fig.4
vOptical Unit, Fans(FN903, FN904), Noise Filter removal
Noise filter
Optical unit
FN904
FN903
(T3x8)
(T3x6)x3
(T3x10)x4
(T3x6)
(T3x6)x2
(T3x8)x6
(T3x12)x2

-13-
Mechanical Disassembly
Fig.5
bAlarm-A and Alarm-B board removal
Alarm-B Board
(M3x8)
(T3x6)x4
Alarm-A Board
Battery
Battery cover Switch cover
(M3x8)
(T3x6)
LED Spacer
(T3x6)

-14-
Optical Parts Disassembly
Before taking this procedure, remove Cabinet Top , Cabinet Front and Main Board following to the “Mechanical
Disassembly”.
Disassembly requires a 2.0mm hex wrench.
Fig.1
zProjection lens removal
xIntegrator lens-in disassembly
Hooks
Integrator lens-in
Integrator Lens-In Ass'y
(M3x8)x4
(M2.5x5)x2
Fig.2
Projection lens
* Rugged surface
(Behind)
Note on replaceing the Projection Lens
- When the Projection Lens is replaced with the new
one, make sure that the fixing tape must be removed
as the figuer.
Fixing tape

-15-
Optical Pats Disassembly
cRelay lens disassembly
Relay lens
Relay lens Ass'y
(M2.5x5)x2
(M2x3)
vPolarized glass-in disassembly
Polarized glass
Polarized glass-in Ass'y
(M2.5x5)x1
Fig.3
Fig.4
Film side

-16-
LCD Panel/
Prism Ass’y
Fig.5
bLCD Panel/Prism Ass’y removal
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 Ad-
justment” , “Gamma Adjustment” and “Common Centre Adjustment” in the chapter “Electrical Adjustment”.
- Check the white uniformity on the screen.
If you find the color shading at the some part of the screen, it needs to take the color shading adjustment. This
adjustment should be performed by a computer and it also requires a special software “Color Shading Correction”.
The software will be supplied separately and can be ordered as follows;
COLOR SHADING CORRECTION Ver. 4.00
Service Parts No. 645 075 9611
(M2.5x4)x2
(M3x10)
(Bottom side)

-17-
Panel Type Check
There are 2 types of LCD/Prism Ass'y for this model. Either L-Type or R-Type LCD /Prism Ass'y is used on the projec-
tor. Check which type of LCD/Prism Ass'y is used with the figure below.
When replacing the LCD/Prism Ass'y, you need to take "Panel Type Check and Setting" on the Electrical Adjustment
for the replaced LCD/Prism Ass'y.
The gamma-characteristics is different between L-Type and R-Type LCD /Prism Ass'y.
How to check the type of LCD/Prism Ass'y
Check the printed number on the flat cable of the G-LCD Panel.
L3P06X-55G20
1-B-1234A1
-55G20
L3P06X-56G20
1-B-1234A1
-56G20
L-Type LCD/Prism Ass'y R-Type LCD/Prism Ass'y
G-LCD PANEL

-18-
Optical Parts Disassembly
Fig.6
mOptical Unit Top removal
(M3x8)x4
(M3x8)x2
Optical top cover
Optical top cover-A
Fig.7
nPolarized glass, Pre-polarized glass removal
Polarized Glass(G)
Pre-Polarized Glass(G)
Polarized Glass(R)
* Mount the polarized glasses as the
film attached side comes to the LCD
panel side.
Polarized
Glass(B)
(M2x2) (M2x2)
(M2x2)
Film
(Blue)
(Red)
(Green)
Pre-Polarized Glass(B)
Film
(M2x4)

-19-
5
8
Fig.8
1
6
No. Parts Name
1 Integrator lens (OUT)
2 Prism beam splitter (PBS)
3 Condenser lens (OUT)
4 Dichroic mirror (B)
5 Dichroic mirror (G)
6 Condenser lens (G)
7 Mirror (R)
8 Condenser lens (R)
9 Condenser lens (B)
10 Mirror (B)
9
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.
The arrows in the figure indicate the mount direction
of the part for the replacement. Check the number on
the arrows and mount each part according to its note;
A: The printed part no. comes to this side.
B: Rugged surface comes to this side.
2
3
4
77
10
,Locations and Directions
A
A
B
slit
Place the lens
as the leddes
come up side.

-20-
Adjustments
 ●: Adjustment necessary ❍: Check necessary
Contrast Adjustment
R-Contrast adjustment ●
G-Contrast adjustment ●
B-Contrast adjustment ●
Integrator lens adjustment ❍●
Relay lens-out adjustment ❍●
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 ❍       ❍  
Disassembly / Replaced Parts
LCD/
Prism Ass’y
Integrator
Lens (OUT)
Polarized glass
R G B
Optical Adjustments
Electrical Adjustments
Main Board
Relay
Lens (OUT)
Power
Board
Adjustments after Parts Replacement
Turning On the Projector
If the PIN code is set on the projector, you cannot use the projector. The PIN code can be reset to the factory default
setting (1234) according to the following procedure.
When you reset the PIN code, the Logo PIN code and key lock will be reset, as well.
1. Connect the AC power cord from the AC outlet. The projector is in the standby mode.
2. Press and hold the 7and 8button on the remote control at the same time for more than 20 seconds.
3. Turn the projector on with the ON-OFF button, enter the PIN code "1234" (the factory default setting).
Please refer to the owners manual for further information.