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Sanyo PLC-XT20 User Manual

Sanyo PLC-XT20
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Multimedia Projector
SERVICE MANUAL
PRODUCT CODE
PLC-XT25 PLC-XT25L PLC-XT20 PLC-XT20L
1 122 248 00 1 122 248 20 1 122 320 00 1 122 320 20
1 122 255 00 1 122 255 20 1 122 321 00 1 122 321 20
1 122 255 02 1 122 255 22 1 122 321 02 1 122 321 22
Original Version
REFERENCE NO. SM5110811-00
FILE NO.
Model No. PLC-XT25
PLC-XT25L
PLC-XT20
PLC-XT20L
U.S.A, Canada,
Europe, U.K, Asia
Chassis No. MZ7-XT2500
MZ7-XT25L00
KC6-XT2000
KC6-XT20L00
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.
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.
* PLC-XT25L, PLC-XT20L---- without Projeccton Lens.

Table of Contents

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Sanyo PLC-XT20 Specifications

General IconGeneral
Projection technologyLCD
Contrast ratio (typical)1000:1
Projector native resolutionXGA (1024x768)
Resolution1024 x 768 pixels
Dimensions (WxDxH)302 x 422 x 162 mm
Display diagonal1 \
Lamp typeUHP
Lamp power300 W
Light source typeLamp
Market positioningPortable
Weight and Dimensions IconWeight and Dimensions
Weight9200 g

Summary

SERVICE MANUAL

Multimedia Projector

Service manual for the Multimedia Projector.

Safety Instructions

Safety Precautions

Important safety measures to be observed during servicing.

Product Safety Notice

Guidelines for safe component replacement emphasizing safety significance.

Service Personnel Warning

Warnings for service personnel regarding lamp and high voltage hazards.

Specifications

Product Specifications Overview

Comprehensive technical details covering mechanical, panel, signal, optical, interface, audio, power, and environment specs.

Circuit Protections

Fuse

Location and replacement procedure for the projector's fuse.

Thermostat (SW901)

Function of the thermostat for internal temperature monitoring.

Lamp cover switch (SW902)

Role of the lamp cover switch in projector operation.

Temperature sensors (TH901, TH902, IC8841)

Details on temperature sensors monitoring internal components.

Power failure and fan lock detection

Detection circuits for power failure and fan lock conditions.

Maintenance

Cleaning the Air Filter

Procedure for cleaning the projector's air filter.

Resetting the Filter Counter

Steps to reset the filter usage counter via the menu.

Lamp Replacement

Step-by-step guide for replacing the projection lamp.

Resetting the Lamp Counter

Procedure to reset the lamp replacement counter after replacement.

How to check Lamp Used Time

Method to view the total operating hours of the projection lamp.

Quick maintenance

Procedures for easily accessible maintenance tasks.

Prohibition of motor control

Function to prevent accidental operation of projector motors.

Security Function Notice

Resetting procedure

How to reset security functions like Key lock and PIN code lock.

Mechanical Disassembly

Cabinet top ass'y removal-1

Steps to remove the cabinet top assembly.

Cabinet top ass'y removal-2

Further steps for removing the cabinet top assembly.

Cabinet top ass'y removal-3

Additional steps to remove the cabinet top assembly.

Cabinet top ass'y removal-4

Final steps for removing the cabinet top assembly.

AV Panel and Side Panel removal

Procedure for removing the AV panel and side panel.

Shield plate top-A removal

Steps to remove the shield plate located at the top.

Main board ass'y removal-1

Initial steps for removing the main board assembly.

Main board ass'y removal-2

Second stage of main board assembly removal.

Main board ass'y removal-3

Third stage of main board assembly removal.

Lamp ass'y removal

Procedure for removing the lamp assembly.

Lens cover ass'y removal-1

Initial steps for removing the lens cover assembly.

Lens cover ass'y removal-2

Second stage of lens cover assembly removal.

Optical engine removal

Steps to remove the optical engine unit.

Lens cover bottom removal

Procedure for removing the bottom part of the lens cover.

AV board & Network joint board ass'y removal-1

Initial removal steps for AV and network joint boards.

AV board & Network joint board ass'y removal-2

Second removal steps for AV and network joint boards.

AV board & Network joint board ass'y removal-3

Third removal steps for AV and network joint boards.

AV board & Network joint board ass'y removal-4

Final removal steps for AV and network joint boards.

Thermostat(SW901) ass'y removal-1

Initial steps to remove the thermostat assembly.

Thermostat(SW901) ass'y removal-2

Second steps to remove the thermostat assembly.

Exhaust Fan(FN901, FN902) ass'y removal-1

Initial steps to remove the exhaust fan assembly.

Exhaust Fan(FN901, FN902) ass'y removal-2

Second steps to remove the exhaust fan assembly.

Exhaust Fan duct removal

Procedure for removing the exhaust fan duct.

Power board(Ballast) ass'y removal-1

Initial steps to remove the ballast power board assembly.

Power board(Ballast) ass'y removal-2

Second steps to remove the ballast power board assembly.

Power board ass'y removal

Procedure for removing the main power board assembly.

Power board(Filter) ass'y removal-1

Initial steps to remove the filter power board assembly.

Power board(Filter) ass'y removal-2

Second steps to remove the filter power board assembly.

Intake Fan(FN904,FN905)removal-1

Initial steps to remove the intake fan assembly.

Intake Fan(FN904,FN905)removal-2

Second steps to remove the intake fan assembly.

Intake Fan(FN904,FN905)removal-3

Third steps to remove the intake fan assembly.

Shield plate BTM removal

Procedure for removing the bottom shield plate.

Lamp cover ass'y disassemblies

Steps to disassemble the lamp cover assembly.

Lamp cover switch and R/C Front board removal

Removal of lamp cover switch and R/C front board.

Optical Parts Disassembly

Projection lens removal

Procedure for removing the projector lens.

LCD panel/Prism ass'y removal

Steps to remove the LCD panel and prism assembly.

LCD Panel Type Check

How to identify and check the type of LCD panel/prism assembly.

Polarized glass, Pre-Polarized glass removal

Procedure for removing polarized and pre-polarized glass components.

Lens mount removal

Steps to remove the lens mount.

Lens shift ass'y removal

Procedure for removing the lens shift assembly.

Condenser lens ass'y removal

Steps to remove the condenser lens assembly.

Relay lens ass'y removal

Procedure for removing the relay lens assembly.

Green Polarized glass ass'y and Optical filter ass'y removal

Removal of green polarized glass and optical filter assemblies.

Blue Polarized glass ass'y and Optical filter ass'y removal

Removal of blue polarized glass and optical filter assemblies.

Red Polarized glass ass'y and Optical filter ass'y removal

Removal of red polarized glass and optical filter assemblies.

Blue Pre-polarized glass removal

Procedure for removing the blue pre-polarized glass.

Optical base top removal-1

Initial steps for removing the optical base top.

Optical base top removal-2

Second steps for removing the optical base top.

Optical base top removal-3

Third steps for removing the optical base top.

Fan(FN903) ass'y disassemblies

Steps to disassemble the FN903 fan assembly.

Optical parts locations and directions in the Optical Unit

Diagram showing the location and orientation of optical parts.

Adjustments

Adjustments after Parts Replacement

Table detailing adjustments required after replacing optical or electrical components.

Optical Adjustments

Optical axis adjustment

Procedure for adjusting the optical axis of the projector.

Contrast adjustment (POL)

Steps to adjust the contrast using the POL component.

Contrast adjustment (WV)

Steps to adjust the contrast using the WV component.

Optical axis adjustment

Detailed steps for condenser and relay lens optical axis adjustment.

Condenser lens adjustment-1

Procedure to adjust condenser lens for shading.

Relay lens adjustment

Steps to adjust relay lens for color uniformity.

Condenser lens adjustment-2

Second stage of condenser lens adjustment for color uniformity.

Contrast adjustment (POL)

Adjusting contrast for the Green polarized glass unit.

B-Contrast adjustment (POL)

Adjusting contrast for the Blue polarized glass unit.

R-Contrast adjustment (POL)

Adjusting contrast for the Red polarized glass unit.

Contrast adjustment (WV)

Adjusting contrast for different polarized glass units using WV lever.

Electrical Adjustments

Service Adjustment Menu Operation

How to enter and navigate the service adjustment menu.

Memory IC (IC1391) Replacement

Notes and cautions regarding memory IC replacement and re-adjustments.

Circuit Adjustments

Precautions and overview for adjusting internal circuits.

Fan Voltages adjustment

Adjusting fan voltage levels via service menu.

Panel Type Check and Setting

Checking and setting the projector's LCD panel type.

PC-Gain adjustment

Adjusting PC signal gain for color uniformity.

PC-Auto Calibration adjustment

Automatic calibration for PC video signals.

Video-Auto Calibration adjustment

Automatic calibration for composite video signals.

480i-Auto Calibration adjustment

Automatic calibration for 480i component video signals.

PC-Pedestal adjustment

Adjusting pedestal level for PC signals.

Video-Gain adjustment

Adjusting composite video signal gain.

480i-Gain adjustment

Adjusting 480i component video signal gain.

Common Center adjustment

Adjusting common center for proper image alignment.

50% luminance adjustment [PC]

Adjusting PC signal luminance at 50%.

50% luminance adjustment [Video]

Adjusting video signal luminance at 50%.

White Balance adjustment [PC]

Adjusting white balance for PC signals.

White Balance adjustment [Video]

Adjusting white balance for video signals.

White Uniformity Adjustment

Adjusting white uniformity using external software.

Filter Calibration adjustment

Calibrating the filter after replacement or cleaning.

Test Points and Locations

Diagram showing locations of test points on the main board.

Service Adjustment Data Table

Table listing initial values and ranges for service adjustments.

Chassis Description

Chassis over view

Overview of the projector's main chassis components and connections.

Input & signal processing stage

Block diagram of the input and signal processing circuitry.

LCD drive stage

Block diagram illustrating the LCD panel drive circuitry.

Audio signal processing stage

Block diagram of the audio signal processing path.

Lamp control stage

Block diagram of the lamp control circuitry.

Fan control stage

Block diagram detailing the fan control system.

Motor control stage

Block diagram of the motor control system for focus, zoom, and lens shift.

Bus control stage

Block diagram illustrating the bus control system.

LED drive & RC control stage

Block diagram of LED indicators and remote control interface.

Power supply & power failure circuit

Diagram of the power supply and its failure detection circuits.

Indicators and Projector Condition

Table correlating indicator lights with projector operational status.

WARNING FILTER indicator

Explanation of the WARNING FILTER indicator and its causes.

LAMP REPLACE indicator

Explanation of the LAMP REPLACE indicator and actions to take.

Power failure detection system

Overview of the power failure detection mechanism.

Diagnosis Information of Power Failure

Information on identifying power failure causes via signals.

Power failure detection tree

Flowchart illustrating power failure detection paths and error information.

Error History Log

Function to check and log projector errors and their descriptions.

How to clear the Error History Log

Procedure to clear the projector's error history log.

Diagnosis of Power Failure with RS-232C port

Using RS-232C port for power failure diagnosis and error information retrieval.

Control Port Functions

System Control I/O Port Functions (PW190)

Pinout and description for system control I/O ports.

Parallel I/O Expander Port Functions (TE7783)

Pinout and description for parallel I/O expander ports.

IIC Bus D/A Converter Port Functions (M62334)

Pinout and description for IIC bus D/A converter ports.

Parallel Bus Input Expander Port Functions (TC74LCX541)

Pinout and description for parallel bus input expander ports.

Waveform

VIDEO signal <VIDEO>

Waveform display for the VIDEO signal.

HSYNC signal <HOUT>

Waveform display for the HSYNC signal.

VSYNC signal <VOUT>

Waveform display for the VSYNC signal.

HSYNC signal <HS1>

Waveform display for the HSYNC signal (HS1).

VSYNC signal <VS1>

Waveform display for the VSYNC signal (VS1).

R-S&H signal <TP35R>

Waveform display for the R-S&H signal.

G-S&H signal <TP35G>

Waveform display for the G-S&H signal.

B-S&H signal <TP35B>

Waveform display for the B-S&H signal.

Cleaning

Cleaning with air spray

Method for cleaning internal components using air spray.

Disassembly Cleaning

Detailed cleaning procedures requiring disassembly of optical parts.

IC Block Diagrams

AD8074/AD8075 <Amp-SW, IC4001, IC5202>

Block diagram for the AD8074/AD8075 amplifier and associated ICs.

AN5870 <Signal Switch, IC5201>

Block diagram for the AN5870 signal switch IC.

BA6287 <Motor Drive Focus, Zoom, IC5501, IC5551>

Block diagram for BA6287 motor drive ICs.

BA7078 <Sync Seperator, IC5321>

Block diagram for BA7078 sync separator IC.

FA7711V <DC-DC Controller, IC5601>

Block diagram for FA7711V DC-DC controller IC.

HIN202EIB <RS-232C Driver, IC3801>

Block diagram for HIN202EIB RS-232C driver IC.

L3E01060<Level Shift, IC2501, IC2531, IC3561>

Block diagram for L3E01060 level shift ICs.

L3E06150 <Sample&Hold, IC501, IC531, IC561>

Block diagram for L3E06150 sample & hold ICs.

L3E07110 <Digital Gamma Shift & LCD Driver, IC401>

Block diagram for L3E07110 digital gamma shift & LCD driver IC.

LM4889 <Audio Output, IC5121>

Block diagram for LM4889 audio output IC.

NJW1141 <Audio Control, IC5001>

Block diagram for NJW1141 audio control IC.

TE7783 <Parallel I/O Expander, IC1801>

Block diagram for TE7783 parallel I/O expander IC.

PW190 <Scan Converter & System Control, IC301>

Block diagram for PW190 scan converter & system control IC.

Electrical Parts List

Capacitor and Resistor Description

Explains how to read capacitor and resistor specifications and their materials.

Electrical Parts Location

Diagram showing the physical location of major electrical components on assembled boards.

Mechanical Parts List

Cabinet Parts Location

Diagram illustrating the location of cabinet parts.

Optical engine_Lens shift assembly

Exploded view of the optical engine with lens shift assembly.

Optical engine_Lens assembly

Exploded view of the optical engine with lens assembly.

Condenser lens-out assembly

Exploded view of the condenser lens assembly.

Relay lens-out assembly

Exploded view of the relay lens assembly.

LCD panel / Prism assembly

Exploded view of the LCD panel and prism assembly, noting type differences.

Polarized unit (IN)

Diagram of the polarized unit, indicating different color types and notes.

In the Optical Unit

Diagram illustrating the arrangement of optical parts within the unit.

Diagrams & Drawings

Schematic Diagrams

Reference to available schematic diagrams for various projector models.

Printed Wiring Board Drawings

Reference to available printed wiring board diagrams.

Parts description and reading in schematic diagram

Guide to understanding part specifications, types, and readings in diagrams.

Pin description of diode, transistor and IC

Illustrations of pin configurations for diodes, transistors, and ICs.

Note on Soldering

Guidelines and precautions for soldering, emphasizing lead-free practices.

Printed Wiring Board Diagrams

Layout diagrams for R/C front and network joint boards.

MAIN (SIDE:A)

Printed wiring board layout for the main board, side A.

MAIN (SIDE:B)

Printed wiring board layout for the main board, side B.

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