Sanyo PLV-70 User manual

Multimedia Projector
SERVICE MANUAL
PRODUCT CODE
1 122 130 00 (M4LA)
1 122 131 00 (P4LA)
Original Version
REFERENCE NO. SM5110361
FILE NO.
Model No. PLV-70
U.S.A., Canada,
Europe, Asia, Africa
Chassis No. M4L-7000
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, additional Service
Literature is required.You must refer to
“Notices” to the Original Service
Manual prior to servicing the unit.

-2-
■Contents
■Safety instructions ________________________________________________3
■Specifications __________________________________________________ 4
■Adjustments after parts replacement ________________________________ 5
■Circuit protections ______________________________________________ 6-7
● Fuse ____________________________________________________ 6
● Thermal switch ____________________________________________ 6
● Interlock switch ____________________________________________ 6
● Warning temperature and power failure protection ________________ 7
■Mechanical disassemblies ______________________________________ 8-12
■Optical parts disassemblies ____________________________________ 13-16
■LCD panel/prism ass’y replacement ________________________________ 17
■Lamp replacement ______________________________________________ 18
■Optical adjustments __________________________________________ 19-21
●Contrast adjustment ________________________________________ 19
●Condenser adjustment ______________________________________ 20
●Relay lens adjustment ______________________________________ 21
■Electric adjustments __________________________________________ 22-30
●Service adjustment menu operation____________________________ 22
●Circuit adjustments ______________________________________ 23-27
●Service adjustment data table______________________________ 28-40
●Test points and locations ____________________________________ 41
■Troubleshooting ______________________________________________ 42-47
●No power ______________________________________________ 42-43
●No picture ____________________________________________ 44-45
●No sound ________________________________________________ 46
●Lens motor problems ______________________________________ 47
■Control port functions ________________________________________ 48-52
■Waveforms __________________________________________________ 53-54
■Cleaning ______________________________________________________ 55
■IC block diagrams ____________________________________________ 56-67
■Service parts lists __________________________________________ 68-102
●Electrical parts list ______________________________________ 68-95
●Mechanical parts list ____________________________________ 96-98
●Optical parts list________________________________________ 99-102
Drawings & Diagrams ______________________________________ A1-A16
■Parts description and reading in schematic diagram ____________________ A2
■Circuit block diagram ____________________________________________ A3
■Power supply lines ______________________________________________ A4
■Schematic diagrams ________________________________________ A5-A12
■Printed wiring board diagrams ________________________________ A13-A15
■Pins description of ICs, transistors, diodes __________________________ A16

-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 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 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.

-4-
■Specifications
●The specifications are subject to change without notice.
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.
Projector Type Multi-media Projector
Dimensions (W x H x D) 12.6” x 6.6” x 16.8” (319mm x 168mm x 429.5mm)
Net Weight 17.4 lbs (7.9 kg)
LCD Panel System 1.21” TFT Active Matrix type, 3 panels
Panel Resolution 1366 x 768 dots
Number of Pixels 3,147,264 (1366 x 768 x 3 panels)
Color System 6 color system (PAL, SECAM, NTSC, NTSC4.43, PAL-M and PAL-N)
High Definition TV SIgnals 480i, 480p, 575i, 575p, 720p. 1035i and 1080i
Scanning Frequency H-sync. 15 ~ 100kHz, V-sync. 50 ~ 100Hz
Projection Image Size (diagonal) Adjustable from 31” to 400”
Horizontal Resolution 800 TV lines (HDTV)
Projection Lens F 1.8 ~2.1 lens with f=48.4mm ~ 62.8mm with motor zoom and focus
Throw Distance 4.6’ ~ 48.3’ (1.4m ~ 14.7m) (PLC-XP45), 4.6’ ~ 47.3’ (1.4m ~ 14.4m) (PLC-XP40)
Motorized Lens Shift Up and Down
Projection Lamp 200 watts
Input 1 Jacks DVI Terminal (Digital), HDB 15-pin Terminal (Analog) and Stereo Mini Type
Jack (Audio)
Input 2 Jacks BNC Type x 5 (G or VIDEO/Y, B or Cb/Pb, R or Cr/Pr, H and V), Stereo
Mini Type Jack (Audio)
Input 3 Jacks RCA Type x 3 (VIDEO/Y, Cb/Pb, Cr/Pr), RCA Type x 2 (Audio R and L) and
DIN 4-pin (S-Video)
Other Jacks DIN 8-pin (Control port), Wired Remote Jack and Network Board
Connector Jack
Built-in Speakers 2 speakers Stereo (R and L), 2 watts RMS (T.H.D. 10%)
Feet Adjustment 0˚ to 10.5˚
Voltage and AC 100 ~ 120V (3.6A Max. Ampere), 50/60Hz (The U.S.A and Canada)
Power Consumption AC 200 ~ 240V (1.8A Max. Ampere), 50/60Hz (Continental Europe and the U.K)
Operating Temperature 41 ˚F ~ 95 ˚F (5˚C ~ 35˚C)
Storage Temperature 14 ˚F ~ 140 ˚F (-10˚C ~ 60˚C)
Remote Control Transmitters Wireless/Wired Remote Control, batteries AA, UM3 or R06 Type x 2

-5-
Condenser lens adjustment ❍●
Relay lens adjustment ❍●
Contrast Adjustment
R-Contrast adjustment ●
G-Contrast adjustment ●
B-Contrast adjustment ●
Output voltage adjustment ●
+16 V adjustment ●
Video center adjustment ●
NRS adjustment ●
PC pedestal adjustment ●
PC gain adjustment ●
Black level adjustment ●
PC gamma shift adjustment ●
A/D reference adjustment ●
AV pedestal adjustment ●
A/D input adjustment ●
Video pedestal adjustment ●
Video gain adjustment ●
HDTV pedestal adjustment ●
HDTV Gain adjustment ●
Video gamma shift adjustment ●
Common center adjustment ● ●
White balance adjustment ❍ ❍
Disassembly / Replaced Parts
LCD/
Prism
Ass’y
Condenser
Lens
Polarized glass
RGB
Optical Adjustments
Electrical Adjustments
● : Adjustment necessary ❍ : Check necessary
Sub Power
Board Main Board
Relay
Lens
■Adjustments after Parts Replacement
Power
Board

-6-
●Interlock switch
The interlock switch (SW902) cuts off the AC mains power supply
when the lamp cover is removed. 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 (SW905) inside of the projector to
prevent the internal temperature from rising abnormally. When the
internal temperature reaches near 90˚C, turn off the AC main
power supply automatically.
The thermal switch is not reset to normal automatically even if the
internal temperature becomes normal. Reset the thermal switch
following procedure.
Check the resistance between terminals of thermal switch by
using the tester. If it has high impedance, thermal switch may be
in operative.
How to reset the thermal switch
1. Loosen 2 screws and open the lamp cover.
2. Press the reset button on the thermal switch with a sharp-
pointed tool.
CAUTION:
Before press the reset button, disconnect the AC cord from the
projector.
■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 of the projector. When either the LAMP
indicator or the READY indicator is not illuminated, fuse may be
opened. Check the fuse as following steps.
It should be used the specified fuse as follows;
How to replace the fuse
1. Remove the cabinet top following to “Mechanical
Disassemblies”.
2. Remove the fuse from fuse holder.
To install the fuse, take reversed step in the above.
Fuse Part No.: 423 025 1201
TYPE T8AH 250V FUSE
LITTEL FUSE INC. TYPE 215008
Fuse Line Filter Board
Interlock switch
Thermal switch
Lamp cover

-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
supply 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 or 41 to 95˚F)
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 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 filters, follow the cleaning procedure
below:
1. Turn the power off, and disconnect the AC power cord
from the AC outlet.
2. Turn the projector up side down and remove an air fil-
ters by pulling the latches of them upward.
3. Clean the air filters with brush or wash out the dust and
particles.
4. Replace each air filter properly. Make sure that the air
filters are fully inserted.
CAUTION:
Do not operate the projector with the air filter removed. The
dust is stuck on the LCD panel and the mirror, and it may
spoil the fine picture image.
Do not put the small parts into the air intake vents. It may
result in the malfunction of the projector. The air filter is
small parts. Take care that children don’t eat or swallow it.
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 filters

-8-
1Remove 5 screws A, 2 screws B, and loosen 2 screws
C, and then take the Cabinet Top upward off.
Note: If you want to remove the Cabinet Front-Top only,
you do not need to remove screws A. Remove 2 screws B
and Lens Front Cover.
■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
performance and product safety.
Fig.1
1Turn the Lens Front Cover counter-clockwise and to take
it off by pulling forward as shown in Fig.2-1.
2Remove the Cabinet Front-Top, Lens Cover Holder and
Lens Cover upward off.
3Remove 2 screws Dto take the Cabinet Front off.
4Remove the RC Board and speakers on the Cabinet
Front.
Fig.2-2
Cabinet Top removal
1
Cabinet Front removal
2
UP
Fig.2-1
C
B
A
A
A
A
B
A
D
D
Cabinet Front-Top
Lens
Front
Cover
Lens Cover Holder
Cabinet Front
Lens Cover
C

-9-
Mechanical Disassemblies
1Remove 7 screws to take the Main Board upward.
Fig.3
Fig.4
1Remove 1 screw A and take the Rear Panel ass’y
upward off.
2Remove 4 screws Bto take the fan (FN905) off.
3Remove 5 screws Cand 1 screw Dto take AV Board
from the Rear Panel ass’y off.
4Remove 2 screws Eand grounding leads and then pull
up the I/F Board and Holder assy from the bottom cabi-
net.
5Remove 4 screws Fto take the I/F Board.
Main Board removal
3
AV, I/F Board & Rear Panel removal
4
Main Board
A
B
B
B
B
C
D
Rear Panel Ass’y
FN905
AV Board
I/F Board
F
F
F
FEE

-10-
Mechanical Disassemblies
1Remove 4 screws Ato take the Ballast Cover upward
off.
2Remove 2 screws Bto take the Fan (FN903) off.
3Remove the Sub Power Board and Drive Board by
pulling them upward.
Fig.5
Lamp Ballast Unit removal
5
A
Ballast Board
FN903
Sub Power
Board
Drive Board
A
AA
B
B
Ballast Cover
1Remove 2 screws Aand 4 screws B(small) and pull the
Optical Unit upward off.
2Remove 4 screws Cto take the Fan (FN906) off.
3Remove 1 screws Dto take the Fan (FN904) off and 2
screws Eto take the air duct off.
Fig.6
Optical Unit removal
6
FN906
FN904
Optical Unit
A
A
BB
BB
C
C
C
D
E
E