Sanyo PLV-Z5 Service Manual

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Summary of Contents for Sanyo PLV-Z5

Page 1 FILE NO. SERVICE MANUAL Multimedia Projector Model No. PLV-Z5 PLV-Z5BK U.S.A., Canada,Europe, Asia, Africa,U.K. Original Version Chassis No. MC4-Z500 MC4-Z5BK00 NOTE: Match the Chassis No. on the Cabinet Bottom with the Chassis No. in the Service Manual. If the Original Version Service Manual Chassis No.
Page 2: Table Of Contents
■ Contents ■ Safety Instructions....................3 ■ Specifications ......................4 ■ Circuit Protections ....................5 ■ Maintenance and Cleaning ..................7 ■ Lamp Replacement ....................12 ■ Mechanical disassemblies..................14 ■ Optical parts disassemblies..................30 ● Optical parts location and direction ............41 ■ Adjustments After Parts Replacement ..............45 ■...
Page 3: Safety Instructions
■ Safety Instructions SAFETY PRECAUTIONS 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.
Page 4: Specifications
■ Specifications Technical Specifications Projector Type Multimedia Projector Dimensions 15.04” x 4.99” x 11.98” (382 mm x 126.8 mm x 304.3 mm) (not including raised portions) (W x H x D) Net Weight 10.2 lbs (5.0 kg) LCD Panel System 0.7”...
Page 5: Circuit Protections
■ Circuit Protections 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. ● Fuse A fuse(F601) is located inside of the projector. When the POWER indicator is not lightning, the fuse may be opened.
Page 6: Lamp Cover Switch
Circuit Protection ● Lamp cover switch LAMP COVER The lamp cover switch (SW8803) cuts off the drive sig- nal to the lamp circuit when the lamp cover is removed or not closed completely. After opening the lamp cover for replacing the lamp unit, place the lamp cover correctly otherwise the pro- jector can not turn on.
Page 7: Maintenance And Cleaning
■ Maintenance and Cleaning After long periods of use, dust and other particles will accumulate on the LCD panel, prism, mirror, polarized glass, lens, etc., causing the picture to darken or color to blur. If this occurs, clean the inside of optical unit. Remove dust and other particles using air spray.
Page 8: Cleaning The Rgb Panels
Maintenancw and Cleaning Cleaning the RGB panels Blemishes such as dust and dirt on the internal optical components of the projector tend to degrade the brightness of the screen and are likely to appear as a shadow on the screen, which can lead to deterioration of image quality.
Page 9: Bottom View
Maintenancw and Cleaning Cleaning Clean by using the Cleaning function in the Setting Menu Turn the projector on and press the MENU button to display the On-Screen Menu. Select the Setting Menu with the Point buttons. Press the Point or OK buttons to access the sub-menu items.
Page 10 Maintenancw and Cleaning Cleaning the Air Filters The air filters prevent dust from accumulating on the surface of 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 a buildup of internal heat and adversely affect the life of the projector.
Page 11 Maintenancw and Cleaning Cleaning the Projection Lens Unplug the AC power cord before cleaning. Gently wipe the projection lens with a cleaning cloth that contains a small amount of non-abrasive camera lens cleaner, or use a lens cleaning paper or a commercially available air blower to clean the lens.
Page 12: Lamp Replacement
■ Lamp Replacement When the life of the projection lamp of this projector draws Top Control This indicator lights to an end, the LAMP REPLACE indicator emits a yellow light. If this indicator lights yellow, replace the lamp with a yellow when the life of new one promptly.
Page 13: Lamp Replacement Counter
Replacement lamp can be ordered through your dealer. When ordering a projection lamp, give the following information to the dealer. ● Model No. of your projector PLV-Z5 / PLV-Z5BK ● Replacement Lamp Type No. POA-LMP94 (Service Parts No. 610 323 5998) Lamp Replacement Counter Be sure to reset the lamp replacement counter after the lamp is replaced.
Page 14: Mechanical Disassemblies
■ Mechanical disassemblies 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 Screws Expression (Type ) mm Diameter x Length...
Page 15 Mechanical disassemblies Cabinet top ass'y disassemblies. 1. Remove the 4 screws-A(T3x8). 2. Remove the Control board, remove the Control button, and Decoration inlay LED. Decoration inlay LED Cabinet top Control button Control board Fig. 2 - 15 -...
Page 16 Mechanical disassemblies Cover lens top and spacer removal. 1. Unhook the stoppers and remove the Spacer sheet top upward. 2. Unhook the stoppers and remove the Cover lens top upward. Hook Spacer sheet top Cover lens top Spacer sheet top Cover lens top Hook Fig.
Page 17 Mechanical disassemblies -2 Cabinet front ass'y disassemblies-1. 1. Remove the screw-A(M3x6). 2. Remove the screws-C(T3x8) and remove the Mounting shutter. 3. Remove the 3 screws-B(T3x8) and remove the Cover lens bottom. Cover lens bottom Mounting shutter Fig. 4-2 -3 Cabinet front ass'y disassemblies-2. 1.
Page 18 Mechanical disassemblies -4 Cabinet front ass'y disassemblies-3. 1. Remove the 3 screws-A(T3x8) and remove the Shutter rail bottom. 2. Remove the 2 screws-B(T3x8) and remove the Shutter ass'y. Cabinet front Shutter ass'y Shutter rail bottom Fig. 4-4 -5 Cabinet front ass'y disassemblies-4. 1.
Page 19 Mechanical disassemblies Main board removal. 1. Remove the 4 screws-A(M3x6), remove the Shield plate and remove the Main board. Shield plate Main board Fig. 5 -1 Lamp exhaust duct ass'y removal. 1. Remove the screw-A(M3x6), remove 2 screws-B(T3x8) and remove the Lamp exhaust duct ass'y.
Page 20 Mechanical disassemblies -2 Lamp exhaust duct ass'y disassemblies-1. 1. Remove the 4 screws-A(T3x8) and remove the Cover duct top. 2. Remove the screw-B(T3x8) and remove the Shield plate. 3. Remove the Cover duct side. Shield plate Cover duct top Cover duct side Fig.
Page 21 Mechanical disassemblies -1 Main power ass'y removal. 1. Remove the screw-A(M3x8) and disconnect the lamp connector. 2. Remove the screw-B(T3x8), remove the screw-D(T3x10) and remove the Earth bracket . Earth bracket 3. Remove the 3 screws-B(T3x8), remove the screw-C(M3x6) and remove the Main power ass'y .
Page 22 Mechanical disassemblies -3 Main power ass'y disassemblies-2. 1. Remove the 4 screws-A(M3x9.2) and remove the Fan(FN901). FN901 Fig. 7-3 -4 Main power ass'y disassemblies-3. 1. Remove the 3 screws-A(M3x6) and remove the Power board. 2. Remove the 4 screws-B(T3x8), remove the Ballast unit and remove the Holder. Power board Holder Ballast unit...
Page 23 Mechanical disassemblies Lamp duct ass'y removal. 1.Remove the screw-A(T3x8) and remove the Stopper. 2.Remove the 2 screws-B(T3x8) and remove the Lamp duct ass'y. Lamp duct ass'y Stopper Lamp duct top Lamp duct bottom Fig. 8-1 Lamp cooling Fan(FN902) ass'y removal. 1.Remove the 2 screws-A(T3x8) and remove the Lamp cooling fan(FN902) ass'y.
Page 24 Mechanical disassemblies -1 Optical base lamp ass'y removal. 1. Remove the 3 screws-A(T3x8) and remove the Optical base lamp ass'y. Optical base lamp ass'y Fig. 9-1 -2 Optical base lamp ass'y disassemblies. 1. Remove the screw-A(M3x6) and remove the thermal switch ass'y. 2.
Page 25 Mechanical disassemblies Optical unit removal. 1.Remove the screw-A(M3x6), remove the 5 screws-B(T3x10), remove the Optical unit and remove the Spacer sheet bottom. Optical unit Spacer sheet bottom Fig. 10 Filter board removal. 1.Remove the screw-C(T3x10) and remove the spacer sheet. 2.Remove the 4 screws-A(T3x8), remove the screw-B(M3x6) and remove the Filter board.
Page 26 Mechanical disassemblies Duct cover removal. 1.Remove the screws-A(T3x8), remove the screw-B(M2x4), and remove the Duct cover. Duct cover Fig. 12 LCD duct top removal. 1.Remove the 4 screws-A(T3x10) and remove the LCD duct top. LCD duct top Fig. 13 - 26 -...
Page 27 Mechanical disassemblies Fans(FN904, FN905) removal. 1.Remove the 4 screws-A(M2x11.2) and remove the Fans(FN904 and FN905). FN904 FN905 Fig. 14 LCD duct bottom removal. 1.Remove the 2 screws-A(T3x10) and remove the LCD duct bottom. LCD duct bottom Fig. 15 - 27 -...
Page 28 Mechanical disassemblies Cabinet bottom ass'y disassemblies. 1.Remove the 2 screws-A(T3x8) and remove the Lamp sw board. 2.Remove the screw-B(M2x2) and remove the Thermistor ass'y(TH902). 3.Remove the 2 screws-C(T3x8) and remove the Adjusters(R & L). Lamp sw board Thermistor ass'y Adjustor Adjustor Fig.
Page 29 Mechanical disassemblies Lamp ass'y and filters removal. 1. Loosen the screw-A and remove the Blower cover. 2. Loosen the screw-B and remove the Lamp cover. 3. Loosen the 2 screws-C and remove the Lamp ass'y. 4. Remove the Filter cover 1 and filter1. 5.
Page 30: Optical Parts Disassemblies
■ Optical parts disassemblies Lens shift panel removal. 1.Remove the screw-A(M3x6), remove the Lens shift panel and remove the Slide cover. Lens shift panel Slide cover Fig. 18 -1 Integrator lens ass'y removal. 1.Remove the 2 screws-A(M2.5x5) and remove the Integrator lens (IN) ass'y. Integrator lens(IN) ass'y Fig.
Page 31 Optical disassemblies -1 LCD panel / Prism ass'y removal. 1.Unhook the stopper and remove the Spacer. Spacer 2.Remove the screw-A(M2x3) and remove the Shield cover. 3.Remove the 4 screws-B(M2.5x5) and remove Shield cover the LCD panel/Prism ass'y. LCD panel / Prism ass'y Fig.
Page 32 Optical disassemblies -2 LCD panel / Prism ass'y disassemblies. 1.Remove the screw-A(M2x3), remove the stopper and remove the Polarized glass (OUT-R). 2.Remove the screw-B(M2x3), remove the stopper and remove the Polarized glass (OUT-G). 3.Remove the screw-C(M2x3), remove the stopper, remove the Optical filter (WV) and remove the Polarized glass (OUT-B).
Page 33 Optical disassemblies -1 Optical filter(WV-G) ass'y removal. 1.Remove the screw-A(M2x5) and remove the Optical filter(WV-G) ass'y. Optical filter (WV-G) ass'y Fig. 21-1 -2 Optical filter(WV-G) ass'y disassemblies. 1.Remove the screw-A(M2x5) and remove the Holder-A. 2.Remove the screw-B(M2x2), remove the Holder-B, remove the Holder-C and remove the Optical filter(WV-G).
Page 34 Optical disassemblies -1 Polarized glass ass'y (IN-R) removal. 1.Remove the screw-A(M2x5) and remove the Polarized glass ass'y (IN-R). Polarized glass ass'y(IN-R) Fig. 22-1 -2 Polarized glass(IN-R) removal. 1.Remove the screw-A(M2x5) and remove the Holder-A. 2.Remove the screw-B(M2x2), remove the Holder-B, remove the Holder-C and remove the Polarized glass(IN-R).
Page 35 Optical disassemblies Polarized glasses removal. 1.Remove the screw-A(M2x5) and remove the Polarized glass ass'y (IN-G). 2.Remove the screw-B(M2x5) and remove the Polarized glass ass'y (IN-B). Polarized glass ass'y(IN-G) Polarized glass ass'y(IN-B) Fig. 23-a Polarized Glass ass'y (IN-G) Polarized Glass(IN-G) Holder Hook Stopper Fig.
Page 36 Optical disassemblies Polarized Glass ass'y (IN-B) Remove the screw-A and remove the Thermistor ass'y. Push the Polarized glass upward, unhook the holder and remove the Polarized glass. (Refer to P35) Thermistor ass'y Polarized glass(IN-B) Hook Fig. 23-c Remove the Thermistor(TH901). Thermistor(TH901) Spacer Fig.
Page 37 Optical disassemblies Projection lens ass'y removal. 1.Remove the 4 screws-A(M3x6) and remove the Projection lens ass'y. Projection lens ass'y SCREW-A Fig. 24 SCREW-A Projection lens removal. 1.Remove the 4 screws-A(M2.6x6) and remove the Projection lens. 2.Remove the screw-B(M3x6) and remove the Mounting main board . Projection lens Lens shift unit Mounting main board...
Page 38 Optical disassemblies Optical base top removal. 1.Remove the 7 screws-A(T3x10) and remove the Optical base top. Optical base top Fig. 26 Lamp iris unit and Relay lens ass'y removal. 1.Remove the 2 screws-A(M2x2), remove the Shield plate and remove the Lamp iris unit. 2.Remove the screw-A(M2.5x5) and remove the Relay lens (OUT) ass'y.
Page 39 Optical disassemblies -2 Relay lens (OUT) ass'y disassemblies. 1.Remove the screw-A(M2x2), remove the Holder and remove the Relay lens (OUT). Lens holder ass'y Relay lens (OUT) Holder Fig. 27-2 -1 Condenser Lenses removal. 1.Remove the 2 stopperes and remove the Condenser lens(OUT). 2.Remove the Relay lens(in) and remove the Condenser lens(R, G, B).
Page 40 Optical disassemblies -2 PBS and Integratoe lens (OUT) removal. 1.Remove the 3 stopperes and remove the Stopper Integrator lens(OUT). 2.Remove the stopper, shield plate and remove the PBS. Shield plate Stopper Integrator lens(OUT) Stopper Fig. 28-2 -3 Mirrores removal. 1.Remove the stopperes and remove the mirrores. Stopper Dicroic Mirror(G) Dicroic Mirror(B)
Page 41: Optical Parts Location And Direction
Optical disassemblies ● Optical parts location and direction 117L 117R 113L 113R 102L 102R LAMP IRIS LAMP ASS'Y - 41 -...
Page 42 Optical disassemblies LENS, PROJECTION 102R ASS'Y, LCD PNL/PRISM --- Type 102R ASS'Y,LCD PNL/ PRISM R --- 102R-1 OPTICAL FILTER(WV-QZ) --- Type R Type 102L ASS'Y, LCD PNL/ PRISM L --- 102-2 POLARIZED GLASS(OUT/R) Type LENS, INTEGRATOR(IN) 102-3 POLARIZED GLASS(OUT/G) LENS, INTEGRATOR(OUT) UV 102-4 POLARIZED GLASS(OUT/B) LENS, CONDENSER(OUT)
Page 43 Optical disassemblies Rugged surface side Chamfer corner comes comes this side. this side. Film attached side Convex part comes this side. INTEGRATOR LENS (OUT) Flat surface side comes this side. Chamfer corner comes this side up. CONDENSER LENS (OUT) DICHROIC MIRROR Flat surface side comes this side.
Page 44 Optical disassemblies Film side The marker comes this surface side. Film side Film side Film side Reflective surface MIRROR LCD PANEl/PRISM ASS'Y Rugged surface side comes this side. Film attached side comes this side. Convex part INTEGRATOR LENS (IN) POLARIZED GLASS(G,B-IN) Film attached side comes this side.
Page 45: Adjustments After Parts Replacement
■ Adjustments After Parts Replacement ● ❍ : Adjustment necessary : Check necessary Disassembly / Replaced Parts LCD/ Optical filter Lamp Polarized glass Power Main Relay Integrator Prism Lens Lens Board Iris Board Ass’y Contrast Adjustment ❍ ● R-Contrast adjustment(Polarized glass) ❍...
Page 46: Optical Adjustment
■ Optical Adjustment Before taking optical adjustments below, remove the Cabinet Top following to the "Mechanical Disassemblies". Adjustments require a 2.0mm hex wrench, Philips Screwdriver and a slot screwdriver. When you adjust Integrator lens or Relay lens adjustment, you need to disconnect some connectors and FPC cables of LCD panels on the main board. Note: Do not disconnect connectors on the main board, because the projector can not turn on or operate properly for adjustment.
Page 47: Before Adjustment
Optical adjustment Before adjustment 1. Turn the projector on by a state of without FPC cables. 2. Integrator lens adjustment Loosen the 2 screws A and screw B. 3. Relay lens adjustment Loosen the screw C and screw D. Screws-A Integrator lens adjustment Screw-B Screw-C...
Page 48 Optical adjustment Integrator lens adjustment-1 1. Adjust the slot E to make shading appears on the right and left(magenta and cyan) of the screen as shown in figure. 2. Adjust the slot F to make shading appears on the top and bottom(cyan and magenta) of the screen as shown in figure.
Page 49 Optical adjustment 3. Adjust the boundary(edge) of the shading area to the Sharp focus. (The integrator lens rotates when the right or the left of slot-F is used.) Slot-F SLOT-B(R) Slot-F SLOT-B(L) CYAN EDGE SCREW-A Screws-A White White MAGENTA - 49 -...
Page 50: Relay Lens Adjustment
Optical adjustment 2.Relay lens adjustment 1. Adjust the slot G. It is adjusted that cyan and the magenta in the top and bottom part become the same width. 2. Adjust the slot H. It is adjusted that cyan and the magenta in the right and left part become the same width. 3.
Page 51 Optical adjustment Integrator lens adjustment-2 1. Adjust the 2 slots F to make color uniformity in white by using a slot screwdriver. (Top and bottom shading are erased.) Note; Slot F is moved in parallel by operating the right and left simultaneously. Otherwise, the integra- tor lens rotates.
Page 52 Optical adjustment 4-1. Contrast adjustment (Polarized glass-G,B) [ Before Adjustment ] - Input a 100% of black raster signal. 1. Loosen a screw on the polarized glass mounting base which you intend to adjust. 2. Adjust the slot to obtain the darkest brightness on the screen as shown in Fig. 1. 3.
Page 53 Optical adjustment 4-2. Contrast adjustment (Polarized glass-R) [ Before Adjustment ] - Input a 100% of black raster signal. 1. Loosen a screw on the polarized glass mounting base which you intend to adjust. 2. Adjust the slot to obtain the darkest brightness on the screen as shown in Fig. 2. 3.
Page 54 Optical adjustment Contrast adjustment (Optical filter WV-IN) 1. Loosen a screw on the optical filter mounting base which you intend to adjust Green. 2. Adjust the slot to obtain the uniform black on the screen as shown in Fig. 3. 3.
Page 55: Electrical Adjustment
Normal Mode "S" mark display Service mode LIGHT Service Mode INPUT DOWN LAMP CONTROL FREEZE LAMP SHOW MENU RESET POWER ON/STAND-BY Service Mode SANYO Input VIDEO SCREEN IMAGE Image Dynamic IMAGE ADJ. Group Data 1.00 MC4A TempA TempB TempC 28.62 44.75 37.75...
Page 56: Circuit Adjustment
Electrical Adjustments ● Circuit Adjustment CAUTION: The each circuit has been made by the fine adjustment at factory. Do not attempt to adjust the follow- ing adjustments except requiring the readjustments in servicing otherwise it may cause loss of perfor- mance and product safety.
Page 57 Electrical Adjustments Sub gain adjustment Panel Type Check and Setting Equipment Oscilloscope *Before setting, you need to check which type of LCD Panel is placed on the projector according to the item Input signal 16-step gray scale signal "LCD Panel/Prism ass'y removal"in the chapter "Optical Parts Disassembly"...
Page 58 Electrical Adjustments Common Center adjustment Panel Luminance adjustment [Dynamic] Input mode Computer [RGB(Analog)] Equipment luminance meter Image mode Dynamic Input mode Computer [RGB(Analog)] Image mode Dynamic Input signal 50% whole-white pattern 720p comput- er signal Input format 720p computer signal 1.
Page 59 Electrical Adjustments Electrical Adjustments ⁄0 ⁄2 Panel Luminance adjustment Panel Luminance adjustment [Pure Cinema] [Creative Cinema] Equipment luminance meter Equipment luminance meter Input mode Component_1 Input mode Component_1 Image mode Pure Cinema Image mode Creative Cinema Input format 480p component signal Input format 480p component signal 1.
Page 60: Service Adjustment Data Table
Electrical Adjustments ● Service Adjustment Data Table These initial values are the reference data written from the CPU ROM to memory IC when replaced new memory IC. The adjust- ment items indicated with “✻” are required to readjust following to the “Electrical adjustments”. Other items should be used with the initial data value.
Page 61: Electrical Adjustments
Electrical Adjustments Adjustment Item Initial Value Range Input source / Description LINE_G4 0 - 255 LINE_B0 0 - 255 LINE_B1 0 - 255 LINE_B2 0 - 255 LINE_B3 0 - 255 LINE_B4 0 - 255 GHOST_R_Pos 0 - 15 GHOST_G_Pos 0 - 15 GHOST_B_Pos 0 - 15...
Page 62 Electrical Adjustments Adjustment Item Initial Value Range Input source / Description R_DCOffset_P_1 0 - 511 R_DCOffset_P_2 0 - 511 R_DCOffset_P_11 0 - 511 R_DCOffset_P_12 0 - 511 G_DCOffset_N_Gain 0 - 255 G_DCOffset_N_1 0 - 511 G_DCOffset_N_2 0 - 511 G_DCOffset_N_11 0 - 511 G_DCOffset_N_12 0 - 511...
Page 63 Electrical Adjustments Adjustment Item Initial Value Range Input source / Description DIMMER_CTRL_LEVEL10 72/255 0 - 255 DIMMER_CTRL_LEVEL11 80/255 0 - 255 DIMMER_CTRL_LEVEL12 88/255 0 - 255 DIMMER_CTRL_LEVEL13 96/255 0 - 255 DIMMER_CTRL_LEVEL14 104/255 0 - 255 DIMMER_AVERAGE_POINT 0 - 7 DIMMER_AVERAGE_DATA 0 - 255 DIMMER_NORMAL_LV...
Page 64 Electrical Adjustments Adjustment Item Initial Value Range Input source / Description Auto Watt Max Fan3 Min 2235/2235/2415/3300 510 - 4500 Auto Watt Max Fan4 Min 2580/2580/2820/4335 510 - 6510 Auto Watt Max Fan1 Max 2490/2490/2490/2760 510 - 4500 Auto Watt Max Fan2 Max 3375/3465/3375/4530 510 - 6510 Auto Watt Max Fan3 Max...
Page 65 Electrical Adjustments Adjustment Item Initial Value Range Input source / Description Lamp IRIS Max Y 63/63/63/63/63/63/63 0 - 63 Lamp IRIS Close 0 - 63 Lamp IRIS Open 0 - 63 Lamp IRIS Ave Time 1 - 8 (Low speed / higt speed) Lamp IRIS SW 0 - 1 0:Auto, 1:Manual...
Page 66 Electrical Adjustments Adjustment Item Initial Value Range Input source / Description Group: 230 PW Input port VSBEG 0 - 15 Group: 290 Gamma L/R-View 0,20 0:Gamma for L-Panel,20: Gamma for R-Panel (Read Only) Change for R-Panel when the value is set to 20 Gamma L/R-Change Change for L-Panel when the value is set to 0 ✻...
Page 67 Electrical Adjustments Adjustment Item Initial Value Range Input source / Description DISP DOTS H BACK PORCH V BACK PORCH DISP LINE CLAMP WIDTH Group: 516 YCbCr 575p overscan TOTAL DOTS 1886 DISP DOTS 1536 H BACK PORCH V BACK PORCH DISP LINE CLAMP WIDTH...
Page 68 Electrical Adjustments Adjustment Item Initial Value Range Input source / Description Group: 533 RGB 575i overscan (Normal through/Full through) DISP DOTS H BACK PORCH V BACK PORCH DISP LINE CLAMP WIDTH Group: 536 RGB 575p overscan TOTAL DOTS DISP DOTS H BACK PORCH V BACK PORCH DISP LINE...
Page 69 Electrical Adjustments Adjustment Item Initial Value Range Input source / Description WIDTH Group: 553 SCART 575i overscan (Normal through/Full through) DISP DOTS H BACK PORCH V BACK PORCH DISP LINE CLAMP WIDTH -69-...
Page 70: Location Of Test Points
Electrical Adjustments ● Location of Test Points MAIN BOARD K78A K78B K78C K35B K3471 K35R K801 -70-...
Page 71: Waveform
■ Waveform VIDEO-IN < IC8201-(73)> Analog V-SYNC <IC8201-(99)> Digital H-SYNC <DHS> PC_16STEP-IN<IC8201-(54)> PC_16STEP-OUT<TP35G> Digital V-SYNC <DVS> Component_Y-IN <C8201-(76)> Component_Cb-IN<IC8201-(74)> Component_Cr-IN <C8201-(72)> PC_R-IN<IC8201-(58)> PC_G-IN<IC8201-(54)> PC_B-IN<C8201-(56)> R-S&H OUT<TP35R > G-S&H OUT <TP35G> B-S&H OUT <TP35B> -71-...
Page 72: Chassis Block Diagram
■ Chassis Block Diagram ● Chassis Overview DIGITAL Z5 CHASSIS OVER VIEW IC501 DIGITAL S&H BLUE IC2501 LEVEL SHIFT ANALOG IC401 IC531 IC8001 DIGITAL S&H HDMI GAMMA GREEN RECEIVER PC_H/V IC2531 LEVEL SHIFT PC_RGB SCAN IC561 IC4401 CONVERTER S&H COLOR PC_H/V MANAGER IC8201...
Page 73: Chassis Block Diagrams
Chassis Block Diagrams ● Video signal processing circuit and LCD panel driving circuit MAIN BOARD TMDS IC8001 HDMI RECEIVER SIHS/SIVS <SiI9023> TMDS D-SUB_15 Input Signal RGB(SCART) G-ON SYNC SIGE SIBE H_SYNC CV_SYNC IC801 FLASH ROM V_SYNC IC301 <S29GL064> SCAN PC_RGB PC_RGB/SCART CONVERTER, IC1391...
Page 74: System Controls
Chassis Block Diagrams ● System Controls MAIN BOARD IC8201 IC8841 FAN_CONT1 UNIT_POWER DECODER TEMP. FAN_CONT2 & A/D SENSOR FAN_CONT3 CONTROL 3.3V to 5V FAN_CONT4 CN201 PC103 54,206 IC1371 SCL0/SDA0_5V SCL0/SDA0 PHOTO BUS SW MAINON_SW COUPLER Always Available IC8001 CN203 PC101 HDMI 135,134 IC1391...
Page 75 Chassis Block Diagrams ● Description of System control circuit Power saving system control When the projector is standby mode, IC301(Main CPU) is not working and IC4801(Sub CPU) is only working for saving energy. IC4801 is working for power management at standby mode and lamp control at normal mode. (Refer to "Power supply circuit"...
Page 76: Motor Driving Circuit
Chassis Block Diagrams ● Motor driving circuit LAMP MAIN BOARD IRIS MOTOR CTL(-) DRV(+) IRIS_PWM_PW DRV(-) CTL(+) IRIS_SENS IC8701 MOTOR DRIVER <BA6287> OUT1 DRIVER IRIS_OPEN CONTROL LOGIC OUT2 IC301 IRIS_CLOSE SCAN DRIVER IRIS CONVERTER, MOTOR SYSTEM TSD : Termal Shut Down CONTROL <PW386>...
Page 77 Chassis Block Diagrams ● Description of Motor driving circuit ● Lamp iris unit MOTOR Lamp Iris Motor and Lens Iris Motor LAMP IRIS UNIT The lamp iris and the lens iris are equipped for the expansion of visible contrast level. The operation of them is varied according to "Image Level Selection"...
Page 78: Fan Control Circuit
Chassis Block Diagrams ● Fan control circuit FN901 FN902 FN903 FN904 FN905 MAIN BOARD FAN_MTR1-5 S16V_F Q6631 FAN1 FAN_CONT1 TPFAN1 Q6641 FAN2 IC6601 FAN_CONT2 TPFAN2 Q6651 FAN3 FAN_SW FAN_CONT3 TPFAN3 IC6621 Q6661 FAN4 FAN_SW FAN_CONT4 TPFAN4 Power Fail : L FAN_SW Power-On : H IC1801...
Page 79 Chassis Block Diagrams ● Description of Fan control circuit Fan control circuit The Fan drive power supplies "FAN1", "FAN2", "FAN3" and "FAN4" are generated from "S16V_F". Each power supply drives fans as follow; FAN1 ..FN901 for power and ballast exhaust FAN2 ..FN902 for lamp cooling FAN3 ..FN903 for lamp exhaust FAN4 ..FN904 and FN905 for intake and panel cooling...
Page 80: Power Supply Lines
■ Power Supply Lines ● Power supply circuit and Protection circuit FN901 FN902 FN903 FN904 FN905 MAIN BOARD FAN_MTR1-5 IC4401 S16V_F Q6631 FAN1 COLOR MANAGER FAN_CONT1 TPFAN1 Q6641 FAN2 IC6601 FAN_CONT2 TPFAN2 Q6651 FAN_SW FAN3 FAN_CONT3 TPFAN3 IC6621 Q6661 FAN4 FAN_SW FAN_CONT4 TPFAN4...
Page 81 Power Supply Lines ● Description of Power supply circuit When the projector is standby mode, IC301(Main CPU) is not working and IC4801(Sub CPU) is only working for saving energy. When the projector is connected to outlet with AC power cord and the Mains SW is switched to ON, SS5V line is supplied to to standby circuit, including IC4801.
Page 82: Troubleshooting
■ Troubleshooting ● No Power This projector provides a function which can be specified a defective area simply by indicating the LEDs on the con- trol panel. Connect the AC cord and turn the projector on and then check the LED indication. Indicators Troubleshooting WARNING...
Page 83 Troubleshooting Indicators Troubleshooting From previous page The symptom indicates that the projector detected an abnormal temperature risen inside the projector. Check the air filters and remove the object near the WARNING (red) and intake and exhaust fan openings, and wait until the POWER (red) indica- POWER indicator stops flashing, and then try to turn on the projector.
Page 84: No Picture
Troubleshooting ● No Picture Check following steps. Description of visual signal flow Sync: Description of sync signal flow No picture with all of Check signal processing stage and LCD driving stage; input sources Check RGB VID signals at test points TP35R, TP35G, TP35B. Check power supply circuit 15.5V and peripheral circuit.
Page 85 Troubleshooting From previous page No picture with Check Computer source input stage; Computer (RGB analog) Check IC8201 and peripheral circuit. input source Check sync signals <ADHS> and <ADVS>. PC_RGB signals are sent to IC8201. They are A/D-converted in IC8201 and sent to IC301. Sync: PC_HS/VS signals are sent to IC8201 via IC8271(Inverter IC) and ADHS and ADVS signals are sent to IC301.
Page 86: Control Port Functions
■ Control Port Functions ● I/O Port Table of Main CPU (IC301, PW386) Pin No. Name Function Name Function Polarity Port A7 LAMP_PWM PWM Output to Sub_CPU Port A6 IRIS_PWM PWM Output to Lamp iris Port A5 SCL2 Port A4 SDA2 Port A3 SCL1...
Page 87 Control Port Functions ● Sub CPU (IC4801, PIC16F873) Pin No. Name Function Name Function Polarity MCLR/VPP RESET RA0/AN0 LAMP_PWM APL Level Input RA1/AN1 CPU_ADCIN From lamp iris for factory usage RA2/AN2 LAMP_ERR Lamp Error Output Lamp Error = H RA3/AN3 (5V) RA4/TOCKI RA5/AN4...
Page 88: Ic Block Diagrams
■ IC Block Diagrams ● ADV7403 <Video Decoder and RGB Digitizer, IC8201> ● NJM2584 <Video Switch, IC5201> ● BA6287F <Motor Driver, IC6551, IC8701> Control Pin H = B channel output L = A channel output OPEN = A channel output -88-...
Page 89 IC Block Diagrams ● FA7701 <Switching power Supply Controller, IC6601> U V L O V R E F ON/OFF 0.3V – VREF 2.2V O S C S.C.P 1.5V – BIAS S.C.DET 2.2V 1.5V 5.5V Power Good Signal – IN– ON/OFF 0.88V –...
Page 90 IC Block Diagrams ● L3E01060 <Level Shift, IC2501, IC2531, IC2561> ● L3E06150 <Sample & Hold, > IC501, IC531, IC561 -90-...
Page 91 IC Block Diagrams ● L3E07110 <Digital Gamma, > IC401 10bit 10bit RIN[9:0] R1OUT[9:0] 10bit R2OUT[9:0] 10bit G1OUT[9:0] 10bit GIN[9:0] 10bit G2OUT[9:0] 10bit B1OUT[9:0] 10bit 10bit BIN[9:0] B2OUT[9:0] OSDRIN[1:0] OSDGIN[1:0] OSDBIN[1:0] HPLL PATTERN HRESETO GENERATOR OSDSW VRESETO DXOUT(R:G:B) CLXOUT(R:G:B) ENBX1-5(R:G:B) SCLK DYOUT(R:G:B) SDATA CLYOUT(R:G:B)
Page 92 IC Block Diagrams ● SiI9023 <HDMI Receiver, IC8001> -92-...
Page 93: Electrical Parts List
■ Electrical Parts List MC4-Z500 Product safety should be considered when a component replacement is made in any area of a projector. Components indicated by a mark in this parts list and the circuit diagram show components whose value have special significance to product safety.
Page 94 MC4-Z500 Electrical Parts List Note: Parts order must contain Chassis No., Part No., and Descriptions. ● ASSEMBLIED BOARDS R/C Board Control Board Main Board FRONT Door SW_B Board Door SW_A Board Filter Board Ballast Unit Power Unit Lamp Switch Board ●...
Page 95 MC4-Z500 Electrical Parts List Key No. Part No. Description Key No. Part No. Description 305 015 8727 TR 2SC2812-L6-TB ASSEMBLIED BOARDS 305 015 8925 TR 2SC2812-L7-TB 305 163 1615 TR 2SC2812N-L6-TB0 910 322 5709 ASSY,PWB,CTRL M4WA 305 173 9816 TR 2SC3928A1R 910 322 7178 ASSY,PWB,R/C M4WA 305 173 9915 TR 2SC3928A1S...
Page 96 MC4-Z500 Electrical Parts List Key No. Part No. Description Key No. Part No. Description 305 015 8925 TR 2SC2812-L7-TB R/C BOARD 305 163 1615 TR 2SC2812N-L6-TB0 305 173 9816 TR 2SC3928A1R 910 322 7178 ASSY,PWB,R/C M4WA 305 173 9915 TR 2SC3928A1S CAPACITOR Q1062 305 134 5928...
Page 97 MC4-Z500 Electrical Parts List Key No. Part No. Description Key No. Part No. Description Q6626 305 217 7518 TR RN1102 TE85L IC6621 309 531 6229 IC FA7701V-TE1 Q6631 305 217 6917 TR TPC6107 TE85L IC7701 309 246 9710 IC LA6358NM-TE-L Q6632 305 217 7815 TR HN1B04FE-Y TE85L...
Page 98 MC4-Z500 Electrical Parts List Key No. Part No. Description Key No. Part No. Description C2513 303 367 0410 CERAMIC 0.1U K C3434 303 409 3426 CERAMIC 0.1U K C2534 303 433 1112 CERAMIC 1U K C3436 303 397 6314 ELECT 22U M C2535 303 398 5415...
Page 99 MC4-Z500 Electrical Parts List Key No. Part No. Description Key No. Part No. Description C401 303 409 3426 CERAMIC 0.1U K C4463 303 409 3426 CERAMIC 0.1U K C402 303 409 3426 CERAMIC 0.1U K C4464 303 409 3426 CERAMIC 0.1U K C403 303 409 3426...
Page 100 MC4-Z500 Electrical Parts List Key No. Part No. Description Key No. Part No. Description C5232 303 409 3426 CERAMIC 0.1U K C577 303 433 1112 CERAMIC 1U K C5233 303 409 3426 CERAMIC 0.1U K C578 303 433 1112 CERAMIC 1U K C5234 303 409 3426...
Page 101 MC4-Z500 Electrical Parts List Key No. Part No. Description Key No. Part No. Description C8003 303 409 3426 CERAMIC 0.1U K C8134 303 383 5215 CERAMIC 4.7U K 6.3V C8004 303 276 1317 CERAMIC 1000P K 303 393 2112 CERAMIC 4.7U K 6.3V C8006...
Page 102 MC4-Z500 Electrical Parts List Key No. Part No. Description Key No. Part No. Description C8821 303 276 1317 CERAMIC 1000P K R1581 301 150 6014 MT-GLAZE 0.000 ZA 1/10W C8831 303 276 1317 CERAMIC 1000P K R1583 301 224 8814 MT-GLAZE 100 JA 1/16W C8841...
Page 103 MC4-Z500 Electrical Parts List Key No. Part No. Description Key No. Part No. Description R3424 301 226 1516 MT-GLAZE 0.000 ZA 1/16W R408 301 226 1516 MT-GLAZE 0.000 ZA 1/16W R3426 301 226 1516 MT-GLAZE 0.000 ZA 1/16W R411 301 225 1814 MT-GLAZE 47 JA 1/16W R3431...
Page 104 MC4-Z500 Electrical Parts List Key No. Part No. Description Key No. Part No. Description R4612 301 225 0718 MT-GLAZE 56K JA 1/16W R5626 301 287 2227 MT-GLAZE 22K FA 1/16W R4613 301 224 9019 MT-GLAZE 10K JA 1/16W R5627 301 294 3115 MT-GLAZE 1K FA 1/16W R4614...
Page 105 MC4-Z500 Electrical Parts List Key No. Part No. Description Key No. Part No. Description R6661 301 237 2915 MT-GLAZE 51 JA 1/16W R802 301 226 1516 MT-GLAZE 0.000 ZA 1/16W R6662 301 294 3511 MT-GLAZE 27K FA 1/16W R803 301 226 1516 MT-GLAZE 0.000 ZA 1/16W R6663...
Page 106 MC4-Z500 Electrical Parts List Key No. Part No. Description Key No. Part No. Description R8703 301 225 1210 MT-GLAZE 4.7K JA 1/16W RB402 945 036 0986 R-NETWORK 47X4 1/32W R8706 301 224 9316 MT-GLAZE 1K JA 1/16W 945 037 0831 R-NETWORK 47X4 1/16W R8707 301 225 1210...
Page 107 MC4-Z500 Electrical Parts List Key No. Part No. Description Key No. Part No. Description 945 028 0697 R-NETWORK 100X4 1/16W L3432 945 086 6662 IMPEDANCE,600 OHM P RB8001 645 049 0675 R-NETWORK 33X4 1/32W L3433 301 150 6014 MT-GLAZE 0.000 ZA 1/10W 945 049 0690 R-NETWORK 33X4 1/16W L3434...
Page 108: Remote Control
ZENER DIODE 02DZ20Y(TPH3) 910 327 3076 SPACER LNS PACKING M4WA D4800 307 163 0414 DIODE 1SS352-(TPH3) 910 330 9119 CARTON CASE-MC4A (PLV-Z5) D4851 307 254 4116 ZENER DIODE RSB6.8CS T2R 610 331 9384 CARTON CASE-MC4AA (PLV-Z5BK) D4852 307 254 4116 ZENER DIODE RSB6.8CS T2R...
Page 109: Mechanical And Optical Parts List
■ Mechanical and Optical Parts List MC4-Z500 Note: Part order must contain Model No., Chassis No., Part No., and descriptions. Give complete “Chassis No." for parts order or servicing, it is shown on the rating sheet on the cabinet bottom of the LCD projector.
Page 110 MC4-Z500 Mechanical and Optical Parts List -110-...
Page 111 MC4-Z500 Mechanical and Optical Parts List -111-...
Page 112 MC4-Z500 Mechanical and Optical Parts List -112-...
Page 113 MC4-Z500 Mechanical and Optical Parts List -113-...
Page 114 MC4-Z500 Mechanical and Optical Parts List -114-...
Page 115 MC4-Z500 Mechanical and Optical Parts List -115-...
Page 116 MC4-Z500 Mechanical and Optical Parts List -116-...
Page 117 MC4-Z500 Mechanical and Optical Parts List 102-6 102R,102L 102-6 102-5 102-2 102-4 (Red) (Green) 102-3 102R-1 102L-1 (Blue) Note: There are 2 types combination of the LCD panel/prism assembly and the optical unit, named Type-R and Type- L. Since both have no compatibility, each type should be combined with the same type, and the specific parts should be used.
Page 118 MC4-Z500 Mechanical and Optical Parts List 113R 113L Green Optical filter(wv) -118-...
Page 119 MC4-Z500 Mechanical and Optical Parts List 117R 117L BLUE GREEN -119-...
Page 120 MC4-Z500 Mechanical and Optical Parts List -120-...
Page 121 910 323 7511 STOPPER LNS INT IN D-M4WA 910 323 4459 STOPPER LNS REL-M4WA 910 323 7313 MOUNTING WV IN BASE-M4WA PLV-Z5 MC4-Z500 910 323 7337 MOUNTING WV IN TOP-M4WA 910 323 7573 STOPPER WV IN-M4WA 910 324 0016 STOPPER POL IN-M4WA...
Page 122 610 331 9742 PANEL LMP FILTER-MC4AA 610 332 0182 PANEL SHUTTER SERVICE-MC4AA OPTICAL PARTS 910 302 7648 STOPPER LID-M4JA 945 063 7415 BADGE,SANYO*26.2X5.7L26.0 645 089 8426 ASSY,LENS,PROJECTION 910 324 6216 COMPLE,FILTER-M4WC 102R 910 331 4731 ASSY,LCD PNL/PSM R-MC4A 910 325 3030...
Page 123 MC4-Z500 -123-...
Page 124 SANYO Electric Co., Ltd. (MC4A) Sep. 2006 DC 350 Printed in Japan...
Page 125 MC4-Z500 PLV-Z5BK MC4-Z5BK00 These schematic diagrams and printed wiring board drawings are part of the serv- ice manual original for chassis No. MC4-Z500,MC4-Z5BK00, models PLV-Z5,PLV- Z5BK. File with the service manual No. SM5110808-00. Note: All the information of part numbers and values indicated on these diagrams are at the beginning of production.
Page 126: Parts Description And Reading In Schematic Diagram
MC4-Z500 Parts description and reading in schematic diagram 1. The parts specification of resistors, capacitors and Resistor Reading coils are expressed in designated code. Please check Example 1/2 D J 10K B the parts description by the following code table. 2.
Page 127: Power Unit
■ Schematic Diagrams AC CORD J10ES037G K28D A2801 VA612 K8801_3 C2804 AC100-120V K601 VA613 J10EG045G R2801 C2802 U22B0080G 6.3KZ J11B7710N DVXAVB DVXAVB K8801_2 10KZ1U AC200-240V VA611 R611 C611 J10ES046G 1/16GJ47C 47ME SW601 (RED) K28D_1 1/2DJ 275GK C612 C613 1 VOUT LIVE K8801_1 S10B5930N...
Page 128 IC8171 R1001 R1002 1/16GJ10A 1/16GJ1KA TC7WBD125AFK Q1001 R0HPDOUT RN1105P IC8071 IC8081 B :2.2Kohm C8171 B-E:47Kohm 16KK0.1MN S3.3VSI TA48033AF SI-3018LSA R0PWR5V K10A R8166 R8173 J11B7450M 1/16GJ10KA D1001 1/16GJ3.3KA R8081 R8071 RSB6.8CSG L8071 1/10GZ0C L8081 1/10GZ0C S3.3VSI S1.8VSI Maximum Capacitance 1/10GZ0C 1/10GZ0C R0DDCSDA S3.3VSI S3.3VSI...
Page 129 IC801 IC8846 S29GL064A90TFIR30 S3.3VPW S3.3VPW S3.3VPW J10EG045G XC6202P502M R8821 1/16GJ560KA K8E_1 A[17] R8846 1/10GZ0C THERM1 R831 TO IC301(PW386) D8821 6.5V C8821 UDZS2.4BG TH902 KK1000MN K8E_3 A[16] C8847 THERM1_DETECT A[15] R801 R832 6.3EM473T TO IC8011(I/O) R8822 BYTE# R839 1/16GJ4.7KA K8E_G 1/16GJ10KA C8846 A[14] A[1]...
Page 130 S3.3VPW R/C_PW TO IC301(PW386) R2821 1/16GJ560A C2821 IC3401 16KK0.1MN IC2821 K4800 S3.3VFPGA MSM56V16160J TC7SZ14FU SS5V NIOS_DQ[0-15] R4800 IC4812 1/16GJ10KA TC7SET32FU D4800 C4800 1SS352G 16KK0.1MN C3401 16KK0.1MN PFAIL_HV FROM IC871 C4816 NIOS_DQ[0] DQ16 NIOS_DQ[15] PFAIL_LV 10KK1MN J10ES046G NIOS_DQ[1] NIOS_DQ[14] POWER_HV/LV DQ15 R2831 R2832 1/3GJ75...
Page 131 IC501 3.3VGA R471 FROM IC301 (PW386) IRM_RST C471 R461 1/16GJ100A SDATA SDATA C461 R462 IC841 1/16GJ100A SCLK SCLK C462 R463 1/16GJ100A C463 SHENB RESET ENBX4B R437 DIRY ENBX2B STSQ0B ENBX2G R436 1/16GZ0A DG_DIRX TO IC531 (S&H) DB[0] DB[0-9] ENBX3B STSQEB ENBX4G ENBX3G 7110_Y17...
Page 132 L3501 L3CU601PG 15V_PB 15.5V DB_ENBY2 C3509 FROM IC401 DB_ENBY1 25KK10BB (7110) DB_CLY DB_DIRX K35B DB_DY J11EA365G DB_FRP TE3501 DB_SHCLK J30B1640G DB_XFR C3501 K35B36 C515 IRM_RST 16KK0.1MN LCCOM 10KK1MN K35B35 C3502 VDDY KK0.1GQ L501 C516 L502 K35B34 L2501 1/10GZ0C 10KK1MN L3CU601PG B_DIRY DIRY 15.5V...
Page 133: Printed Wiring Board Diagrams
■ Printed Wiring Board Diagrams ! CAUTION This projector is isolated from AC line by using the internal converter transformer. Please pay attention to the following notes in servicing R/C (SIDE:A) R/C (SIDE:B) 1. Do not touch the part on hot side (primary circuit) or both parts on hot and cold sides (secondary circuit) at the same time.
Page 134 MAIN (SIDE:A) DOOR SW_A (SIDE:A) MAIN 1AA4B10C4870B_A “K8M” K8801 D4603 C4606 IC4831 R4603 L4604 D4604 IC2821 Q4605 L4603 R4611 R4622 C4611 DOOR SW_A (SIDE:B) Q4601 Q4603 IC8701 C4814 C4612 C4614 1AA4B10C55800 1st REFLOW R4612 Q8701 R8702 IC4811 R4616 R2831 C519 C8701 C2565 R2832...
Page 135 MAIN (SIDE:B) POWER DOOR SW_B LENS IRIS DOOR SW_A “CN201” “K8811” UNIT “K8801” C4832 DOOR C4607 MOTER IC4812 R2833 C4602 C4801 TE3501 2nd REFLOW C3506 1AA4B10C55800 TE3561 R2563 C2563 CTRL R2561 C2562 R2562 C2561 C4604 R4819 D2882 “K28D” D2886 L2562 “K28A”...
Page 136 FILTER (SIDE:A) LAMP BALLAST (SIDE:A) MAIN “K8P” C612 VA613 SUB1 CN201 TYPE: 215004 T4AH250V A30C5 (LIVE) 1AA4B10C4870A_A PARTS_SIDE C613 CN101 POWER SW601 C611 K601 C616 POWER “CN101” L611 “CN102” L612 C614 T103 FILTER (SIDE:B) POWER (SIDE:A) FILTER LAMP BALLAST MAIN “K6A”...
Page 137 MC4-Z500 Pin description of diode, transistor and IC Diode Diode K: Cathode A: Anode Transistor/FET Transistor/FET C: Collector D: Drain B: Base G: Gate Index E: Emitter S: Source C1 C2 C1 C2 (GND) RESET (IN) (OUT) Index Index Index Index Index Index...
Page 138: Note On Soldering
MC4-Z500 Note on soldering Do not use solder containing lead. Solder This product has been manufactured using lead-free Use solder with the metal content and composition ratio solder in order to help preserve the environment. by weight given in the table below. Do not use solders Because of this, be sure to use lead-free solder when which do not meet these conditions.

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