Sanyo PLC-XW55A User manual

Multimedia Projector
SERVICE MANUAL
PRODUCT CODE
PLC-XW50A PLC-XW55A
1 122 356 20 (KP6AD) 1 122 358 20 (KR6AD)
1 122 357 20 (LP6AD) 1 122 359 20 (LR6AD)
1 122 357 22 (LP6CD) 1 122 359 22 (LR6CD)
Original Version
REFERENCE NO. SM5110860-00
FILE NO.
Model No. PLC-XW55A
PLC-XW50A
U.S.A, Canada,
Europe, U.K, Asia
Chassis No. KR6-XW55A00
KP6-XW50A00
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 re-
quired. You must refer to “Notices” to the Original Service
Manual prior to servicing the unit.

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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 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.

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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) 12.99" x 3.15" x 9.33" (330 mm x 80 mm x 237 mm) (Not including adjustable feet)
Net Weight 6.4 lbs (2.9 kgs)
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 40" to 300"
Projection Lens F 1.7 lens with f 20.06 mm with manual focus
Throw Distance 4.3’ - 32.6’ (1.31 m - 9.9 m)
Projection Lamp 200W
Interface
Video Input Jack RCA Type x 1
Audio Input Jacks RCA Type x 2
Computer/Component/S-Viideo Input Terminal Anlaog RGB (Mini D-sub 15 pin) Terminal x 1
Monitor Output Terminal Anlaog RGB (Mini D-sub 15 pin) Terminal x 1
Computer/ Component 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 1.0W RMS
Built-in Speaker 1 speaker, ø1.1" (28mm)
Power
Voltage and Power Consumption AC 100 ~ 120 V (3.2A Max. Ampere), 50 / 60 Hz (The U.S.A and Canada)
AC 200 ~ 240 V (1.6A 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)
● The specifications are subject to change without notice.
● LCDpanels 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 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. The fuse is placed on the filter board under the main board. Re-
move 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 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.
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 projec-
tor, 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
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-
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”

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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 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/STAND-BY button on the pro-
jector 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
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
position. 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 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
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-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 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)
Control
Buttons
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

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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 Disas-
sembly”.
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 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
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 projector. 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 Adjust-
ment 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

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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
required to remove the Optical Unit from
the cabinet bottom.
Fig.6

-18-
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 opti-
cal unit, the parts must be mounted in the specified loca-
tion and direction as shown in figure below.
2
3
4
88
11
,Locations and Directions
Direction of Integrator lens-out
PLC-XW55A
Rugged surface is facing to the PBS side.
PLC-XW50A
Rugged surface is facing to the lamp side.
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 ❍ ❍