Sanyo PLV-Z2000 Service Manual
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Sanyo PLV-Z2000 Service Manual

Multimedia projector
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See also: Owner's Manual

SERVICE MANUAL

original Version
Multimedia Projector
PRodUCt CodE :
1 122 400 00
PLV-Z2000
MD4A
1 122 401 00
PLV-Z2000
PD4A
1 122 401 02
PLV-Z2000
PD4C
U.S.A., Canada
Europe, Asia, Africa
U.K.
FILE NO.
PLV-Z2000
ModEL No.
U.S.A., Canada, Europe,
U.K. Asia, Africa
Chassis No.
Md4-Z200000
NotE: Match the Chassis No. on the rating
sheet on the cabinet with the Chassis
No. in the Service Manual.
If the original Version Service
Manual Chassis No. does not
match the unites, additional Service
Literature is required. You must refer
to "Notices" to the Original Service
Manual prior to servicing the unit.
REFERENCE NO.
SM5110894-
00

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Summary of Contents for Sanyo PLV-Z2000

  • Page 1: Service Manual

    FILE NO. SERVICE MANUAL PLV-Z2000 ModEL No. original Version U.S.A., Canada, Europe, U.K. Asia, Africa Multimedia Projector Chassis No. Md4-Z200000 NotE: Match the Chassis No. on the rating sheet on the cabinet with the Chassis No. in the Service Manual.

  • Page 2: Table Of Contents

    ■ Contents ■ Safety Instructions ............................3 ■ Specifications ..............................4 ■ Circuit Protections ............................5 ■ Maintenance and Cleaning........................7 ■ Lamp Replacement..........................13 ■ Mechanical disassemblies ........................16 ■ Optical parts disassemblies ........................33 ● Optical parts location and direction ..................42 ■...

  • 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 con- verter 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 (W x H x d) 15.75” x 5.75” x 13.62” (400 mm x 146 mm x 346 mm) (not including raised portions) Net Weight 16.1 lbs (7.3 kg ) LCd Panel System 0.74”...

  • 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 Fuse (F601) POWER indicator is not lightning, the fuse may be opened.

  • Page 6: Lamp Cover Switch

    Circuit Protection Lamp cover switch ● The lamp cover switch (SW8803) 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 unit, Lamp cover switch place the lamp cover correctly otherwise the projector 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

    Maintenance 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. This projector is equipped with the RGB panel cleaning holes on the bottom for cleaning of the internal parts (such as optical components) of the projector.

  • Page 9: Bottom View

    Maintenance and Cleaning Clean by using the Cleaning function in the Setting Menu Cleaning 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 submenu items.

  • Page 10: Warning Indicator

    Maintenance and Cleaning Warning Indicator The WARNING indicator shows the state of the function that protects the projector. Check the state of the WARNING indicator and the POWER indicator to take proper maintenance. the projector is shut down and the WARNING indicator is blinking red. When the temperature inside the projector reaches a certain level, the toP CoNtRoL projector is automatically shut down to protect its inside.

  • Page 11: Cleaning The Air Filters

    Maintenance 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 12: Resetting The Filter Counter

    Maintenance and Cleaning Resetting the Filter Counter Be sure to reset the Filter counter after cleaning or replacing the air filter. Filter counter Turn the projector on and press the MENU button to display the On-Screen Menu. Select the Setting Menu with the Point buttons.

  • Page 13: Lamp Replacement

    Screws oRdER REPLACEMENt LAMP 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-Z2000 ● Replacement Lamp type No.: PoA-LMP114 ● (Service Parts No. 610 336 5404)

  • Page 14: Lamp Replacement Counter

    Lamp Replacement Lamp Replacement Counter Be sure to reset the lamp replacement counter after the lamp is replaced. When the lamp replacement counter is reset, the LAMP REPLACE indicator stops lighting. Lamp counter reset Turn the projector on and press the MENU button to display the On-Screen Menu.
  • Page 15 Lamp Replacement How to check lamp used time Lamp Counter display Projector used time The LAMP REPLACE indicator will light when the total Counter lamp used time reaches 3,000 hours. This is to indicate Projector 475H that lamp replacement is required. Lamp Normal 100H...

  • Page 16: 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 other- Screws Expression wise it may cause lose of performance and product safety.
  • Page 17 Mechanical disassemblies Lamp cover ass'y removal. 1. Loosen the screw-A and remove the Lamp cover ass'y. 2. Remove the 2 screws-B(T3X8) and remove the shield plate. Lamp cover ass'y Shield plate Lamp cover - 17 -...
  • Page 18 Mechanical disassemblies Filter removal. 1. Remove the Filter cover and Filter. Filter Filter cover AV panel removal. 1. Remove the 2 screws-A(M3x8), remove the screw-B(T3x8) and remove the AV panel. AV panel - 18 -...
  • Page 19 Mechanical disassemblies Main PWB shield plata(top) removal. 1. Remove the10 screws-A(M3x6) and remove the Shield plate (Main board-top) . Shield plate (Main board toP) Main PWB removal. 1. Remove the 3 screws (M3x6), remove the Main board and remove the Shield plate (Main board-BTM). Main board Shield plate (Main board BtM)
  • Page 20 Mechanical disassemblies Cover lens top removal. 1. Remove the Cover lens top upward. Cover lens top Cabinet front ass'y removal. 1. Remove the 2 screws (T3x8) and remove the Cabinet front ass'y forward. Cabinet front ass'y - 20 -...
  • Page 21 Mechanical disassemblies 1 Cabinet front ass'y disassembly. 1. Remove the 2 screws-A(T3x8) and remove the Mounting front. 2. Remove the 2 screws-B(T3x8), remove the screw-C(M3x6), and remove the Cover lens bottom. Mounting front Cover lens bottom 2 Cabinet front ass'y disassembly. 1.
  • Page 22 Mechanical disassemblies 3 Cabinet front ass'y disassembly. 1. Remove the 2 screws-A (T3x8) and remove Shutter rail top unit. 2. Remove the 2 screws-B (T3x8) and remove the Shutter motor. Shutter motor Shutter rail top unit 4 Cabinet front ass'y disassembly. 1.
  • Page 23 Mechanical disassemblies 5 Cabinet front ass'y disassembly. 1. Remove the 3 screws-A (M2.5x6) and remove the Gear. 2. Remove the 2 screws-B (M2.5x6) and remove the Shutter panel. 3. Remove the 2 screws-C (M2.5x6) and remove the 2 spacers. Gear Spacer Shutter panel Spacer...
  • Page 24 Mechanical disassemblies 1 Lamp unit removal. 1. Loosen the 2 screws-A and remove the Lamp unit. 2. Remove the screw-B (T3x8) and remove the Main board holder. Main board holder Lamp unit 2 Lamp connector removal. 1. Remove the 2 screws(T3X6) and remove the Lamp connector. Lamp connector Ballast Cable Caution:...
  • Page 25 Mechanical disassemblies 3 Fan(FN902) removal. 1. Remove the 2 screws-A (T3x8) and remove the Fan unit. 2. Remove the 2screws-B (M3x8) and remove the Fan(FN902). Fan unit Fan(FN902) - 25 -...
  • Page 26 Mechanical disassemblies 4 Lamp unit holder removal. 1. Remove the 2 screws-A (T3x8) and remove the Lamp unit holder. 2. Remove the screwB (T3x8) and remove the Lamp cover switch(SW8803) board. 3. Remove the 2screws-C (T3x8), remove the Spacer, remove the Cap and remove the Thermal switch(SW902). Lamp unit holder Lamp cover switch(SW8803) board Spacer...
  • Page 27 Mechanical disassemblies optical removal. 1. Remove the 5 screws (T3x10) and remove the Optical unit. optical unit 1 Cover duct EXH removal. 1. Remove the 2 screws (T3x8) and remove the Cover duct EXH. Cover duct EXH - 27 -...
  • Page 28 Mechanical disassemblies 2 Exhaust Fan (FN901, FN903) removal. 1. Remove the 3 screws-A (T3x8) and remove the Exhaust fan unit. 2. Remove the 8 screws-B (M3x28) and remove the Exhaust fan FN901, FN903. Exhaust fan unit FN901 FN903 - 28 -...
  • Page 29 Mechanical disassemblies Power unit removal. 1. Remove the 6 screws-A (M3x6) and remove the Power & Ballast unit. 1. Remove the screw-B (M3x6) and remove the Power & Ballast unit. Power & Ballast unit Ballast unit Power unit - 29 -...
  • Page 30 Mechanical disassemblies Filter board unit removal. 1. Remove the 2 screws (M3x6) and remove the Filter unit. Filter board unit Spacer Filter board - 30 -...
  • Page 31 Mechanical disassemblies duct unit removal. 1. Remove the 7 screws (T3x8) and remove the Duct panel top. 2. Remove the Spacer and remove the Themistor(TH902). 3. Remove the FN904 and FN905. 4. Remove the Duct panel bottom. Spacer themistor(tH902) duct panel top duct panel bottom FN905 FN904...
  • Page 32 Mechanical disassemblies Cabinet bottom unit desassemblies. 1. Remove the 6 screws-A (T3x8) and remove the Shield cabinet bottom. 2. Remove the 2 screws-B (T3x8) and remove the Adjustor. 3. Remove the 3 nuts. Shield cabinet bottom Adjustor Nuts Adjustor - 32 -...

  • Page 33: Optical Parts Disassemblies

    ■ optical disassemblies optical unit Lens shift panel remonal. 1. Remove the screw (M3x6), remove the Lens shift panel and remove the Slide cover. 2. Remove the Spacer sheet. Lens shift panel Slide cover Spacer sheet - 33 -...
  • Page 34 Optical disassemblies Integrator lens (IN) ass'y removal. 1. Remove the 2 screws-A (M2.5x5) and remove the Integrator lens (IN) ass'y. 2. Remove the 2 screws-B (M2x2), remove the Holder-A, remove the Holder-B and remove the Integrator lens (IN). Integrator lens (IN) ass'y Holder-B Integrator lens (IN) Holder-A...
  • Page 35 Optical disassemblies LCd panel / prism ass'y removal. 1. Remove the 4 screws-A (M2.5x4) and remove the LCD panel / prism ass'y. LCd panel / prism ass'y Panel type Check There are 2 types combination of the LCD Panel/Prism Ass'y and the optical unit, named Type-L and Type-R.Since both have no compatibility, each type should be combined with the same type, and the specificparts should be used.
  • Page 36 Optical disassemblies LCd panel / prism ass'y disassemblies. 1. Remove the 3 screws (M2x2), remove the 3 Stopper and remove the Polarized glasses(R,G,B). stopper stopper stopper Polarized glass (oUt/G) Polarized glass (oUt/B) Polarized glass (oUt/R) Note; Do not replace the LCD panel separately otherwise it can not obtain proper picture. Do not touch the prism, the LCD panel and electrode of flexible cable.
  • Page 37 Optical disassemblies Polarized glasses removal. 1. Remove the 3 screws-A (M2.5x5) and remove the 3 Holders (R,G,B). 2. Remove the 3 screws-B (M2.5x6) and remove the 3 Stoppers (R,G,B). 3. Remove the 3 Optical filter ass'y and remove the 3 Polarized glass (IN) ass'y (R,G,B). optical filter Holder Polarized glass (IN)
  • Page 38 Optical disassemblies Lamp iris unit removal. 1. Remove the 2 screws-A (T3x10) and remove the Stopper. 2. Remove the 2 screws-B (T2x6), remove the Shield plate iris and remove the Lamp iris unit. 3. Remove the Integrator lens (OUT), PBS, Shield plate PBS and Condensor lens (OUT). Shield plate iris Shield plate PBS Lamp iris unit...
  • Page 39 Optical disassemblies Relay lens ass'y removal. 1. Remove the Optical base top (unhook). 2. Remove the screw-A (M2.5x5) and remove the Relay lens ass'y. 3. Remove the screw-B (M3x6) and remove the Shield plate (Lens shift). 4. Remove the 2 screws-C (M2x2), remove the Holder and remove the Relay lens (OUT). optical base top Relay lens ass'y Shield plate...
  • Page 40 Optical disassemblies Lens shift unit removal. 1. Remove the 4 screws (M3x6) and remove the Lens shift unit. Lens shift unit Projection lens removal. 1. Remove the 4 screws (M2.6x6) and remove the Projection lens. Projection lens - 40 -...
  • Page 41 Optical disassemblies Condensor lenses removal. Mirrores removal. - 41 -...

  • Page 42: Optical Parts Location And Direction

    ● optical parts location and direction 113R/L 114R/L 102R/L 115R/L LAMP IRIS LAMP ASS'Y - 42 -...
  • Page 43 Optical parts location and direction LENS, PROJECTION 102R ASS'Y,LCD PNL/ PRISM R --- Type 102L ASS'Y, LCD PNL/ PRISM L --- Type LENS, INTEGRATOR(IN) LENS, INTEGRATOR(OUT) UV LENS, CONDENSER(OUT) LENS, CONDENSER(G) LENS, CONDENSER(B) LENS, CONDENSER(R) LENS, RELAY(OUT) MIRROR(B) MIRROR(R) OPTICAL FILTER(R) 113R OPTICAL FILTER(HPO)87--- Type R 113L...
  • Page 44 Optical parts location and direction Rugged surface side Chamfer corner comes comes this side. this side. Film attached side comes Convex part this side. INtEGRAtoR LENS (oUt) Flat surface side comes Chamfer corner comes this side up. this side. CoNdENSER LENS (oUt) dICHRoIC MIRRoR Flat surface side comes this side.
  • Page 45 Optical parts location and direction Film side the marker comes this surface side. Film side Film side Reflective surface MIRRoR LCd PANEl/PRISM ASS'Y Rugged surface side the marker comes this up side. comes this side. Film attached side comes Convex part this side.

  • Page 46: Adjustments After Parts Replacement

    ■ Adjustments After Parts Replacement : Adjustment necessary : Check necessary ● ❍ Disassembly / Replaced Parts Polarized glass Optical filter Lamp Power Main LCD/ Relay Integrator (IN/OUT) Prism Ass’y Lens Lens Board Iris Board Contrast Adjustment R-Contrast adjustment(Polarized glass) ❍...

  • Page 47: 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 48: Before Adjustment

    Optical Adjustments ■ Before adjustment Relay lens adjustment 1. Remove the cabinet top, filter cover, filter and AV panel following to "Mechanical Disassemblies". 2. Filter is installed again. 3. It adjusts it from the rear side as shown in figure. AV panel Filter cover Filter...
  • Page 49 Optical Adjustments Integrator lens adjustment 1. Remove the cabinet top, and shield plate (Main board top) following to "Mechanical Disassemblies". Adjustment area Contrast adjustment (Polarized glass (IN), optical filter) 1. Remove the cabinet top, and shield plate (Main board top) following to "Mechanical Disassemblies". Adjustment area dEtAIL - 49 -...

  • Page 50: Integrator Lens Adjustment

    Optical Adjustments 1. Integrator lens adjustment-1 1. Turn the projector on. Input the white raster signal (100% of white raster signal). 2. Loosen the 2 screws-A and screw-B 3. Adjust the slot E to make shading appears on the right and left(magenta and cyan) of the screen as shown in figure.
  • Page 51 Optical Adjustments 5. 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 - 51 -...

  • Page 52: Relay Lens Adjustment

    Optical Adjustments 2. Relay lens adjustment 1. Turn the projector on. Input the white raster signal (100% of white raster signal). 2. Loosen the screw-C and screw-d 3. Adjust the slot G. It is adjusted that cyan and the magenta in the top and bottom part become the same width. 4.
  • Page 53 Optical Adjustments 3. 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 integrator lens rotates.
  • Page 54 Optical Adjustments 4. Contrast adjustment (Polarized glass and optical filter) [ Before Adjustment ] - Input a 100% of black raster signal. 1. Loosen a screw on the optical base which you intend to adjust. 2. Adjust the slot to obtain the darkest brightness on the screen. (Polarized glass adjustment.) 3.

  • Page 55: Electrical Adjustment

    . Remote Control MENU Normal Mode "S" mark display Service mode Service Mode INPUT DOWN POWER ON/STAND-BY Service Mode SANYO Input VIDEO Image Natural Group Data Ver. 1.00 MD4A - 55 -...

  • 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 following adjustments except requiring the readjustments in servicing otherwise it may cause loss of performance and product safety.
  • Page 57 Electrical Adjustments 3. Lamp Iris adjustment 6. Component (480i) input adjustment Equipment Input signal 480i (Y, Cb, Cr) colour bar Input mode (Component1) After replacing or repairing the LAMP IRIS, this re-adjust- Input image Natural ment is needed. 1. Enter the service mode. 1.

  • Page 58: Common Center Adjustment

    Electrical Adjustments 9. Component (1080i) input adjustment 11. Colour Correction Input signal 1080i (Y, Cb, Cr) colour bar Input signal Internal Signal Input mode (Component1) Input image Natural Using the proper computer and “Projector Service Tool” software supplied separately. 1. Enter the service mode. After the all steps adusted, check the colour shading.

  • Page 59: 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. Adjustment Item Initial Value Range Input source / Description Group: 0 ADConverter (PW392) SOGTH 2/2/4 0 - 15...

  • Page 60: Electrical Adjustments

    Electrical Adjustments Adjustment Item Initial Value Range Input source / Description Group: 55 LTI / CTI Video Enhancement Enable 0 - 1 0x1AC7 DLTI Gain 0 - 15 0x1AC0 DLTI Frequency 0 - 3 0x1AC0 Bypass Anti-Alias Filter 0 - 1 0x1AC0 Lower DCTI Frequency 0 - 1...
  • Page 61 Electrical Adjustments Adjustment Item Initial Value Range Input source / Description SH_Pos 1638 0 - 4095 SH_Pos_R 0 - 12 SH_Pos_G 0 - 12 SH_Pos_B 0 - 12 NRG_Pos 0 - 127 NRG_Width 0 - 255 FRP_Pos 0 - 255 OSD_Pos 0 - 31 OSD_Ptn...
  • Page 62 Electrical Adjustments Adjustment Item Initial Value Range Input source / Description DCOffset_R_12 0 - 2047 Normal 0 - 2047 R/L Reverse DCOffset_R_13 0 - 2047 Normal 0 - 2047 R/L Reverse DCOffset_R_14 0 - 2047 Normal 2032 0 - 2047 R/L Reverse DCOffset_R_15 0 - 2047...
  • Page 63 Electrical Adjustments Adjustment Item Initial Value Range Input source / Description DCOffset_B_04 0 - 2047 Normal 0 - 2047 R/L Reverse DCOffset_B_05 0 - 2047 Normal 0 - 2047 R/L Reverse DCOffset_B_06 0 - 2047 Normal 2032 0 - 2047 R/L Reverse DCOffset_B_07 0 - 2047...
  • Page 64 Electrical Adjustments Adjustment Item Initial Value Range Input source / Description Group:200 Option Logo Select 0 - 2 0 : Menu 1 : No Brand 2 : For China Logo RS232C Baudrate 0 - 2 0 : 19200bps 1: 9600bps 2: 115200bps PW Debug Command Enable 0 - 1 0 : Disable...
  • Page 65 Electrical Adjustments No. Adjustment Item Initial Value Range Input source / Description Group:230 DOOR CONTROL First 200 0 - 2000 Unit : ms Low time 0 -2000 Unit : ms High time 100 0 - 2000 Unit : ms After arrival 500 0 - 2000 Unit : ms Limit 50 (=5000ms) 0 - 200 Open count 0 - 30000 Close count 0 - 30000 reset open counter 0 - 1 reset close counter 0 - 1 Exhibition 0 - 1 Demo Time 22 (=2200ms) 0 - 200 Blink time 2 (60sec) 0 - 10 Lamp start timing 0 - 1...
  • Page 66 Electrical Adjustments Adjustment Item Initial Value Range Input source / Description Eco Fan4 Min 1710/1710/1920 510 - 6510 Eco Fan5 Min 945/945/1050 510 - 6510 Eco Fan1 Max 1140/1140/1200 510 - 4500 Eco Fan2 Max 1485/1485/2010 510 - 6510 Eco Fan3 Max 1665/1665/1800 510 - 4500 Eco Fan4 Max...
  • Page 67 Electrical Adjustments Adjustment Item Initial Value Range Input source / Description AutoWait 1 - 20 Wait value CHECK - Tolerance 1 - 255 Offset Final check Tolerance Time out wait 1 - 255 Wait time (sec) Group:261 AUTO CALIBRATION (RGB) OFFSET AREA H START 0 - 1000 Black Level H...
  • Page 68 Electrical Adjustments Adjustment Item Initial Value Range Input source / Description H Back Porch 0 - 4095 V Back Porch 0 - 4095 Disp Line 0 - 4095 Group : 521 YCbCr (575i) Total Dots 0 - 4095 Disp Dots 0 - 4095 H Back Porch 0 - 4095...
  • Page 69 Electrical Adjustments Adjustment Item Initial Value Range Input source / Description H Back Porch 0 - 4095 V Back Porch 0 - 4095 Disp Line 0 - 4095 Group : 544 RGB Video (720P - 60) Total Dots 1657 0 - 4095 Disp Dots 1280 0 - 4095...
  • Page 70 Electrical Adjustments Adjustment Item Initial Value Range Input source / Description Creative Cinema : VT_AXIS_IS_V 0 - 1 Creative Cinema : VT_USED_R 0 - 100 x 0.01 Creative Cinema : VT_USED_G 0 - 100 x 0.01 Creative Cinema : VT_USED_B 0 - 100 x 0.01 Pure Cinema...

  • Page 71: Location Of Test Points

    Electrical Adjustments Location of Test Points ● MAIN BOARD TP_FAN2 K4801 TP_FAN3 TP_FAN1 IC4801 K78A TE6601 K78B K78C IC4401 IC501 IC561 TP_FAN4 K78D IC301 K78E K35G TP_FAN5 IC531 -71- -71-...

  • Page 72: Chassis Block Diagram

    ■ Chassis Block Diagram ● Chassis Overview Z2000 CHASSIS OVER VIEW DIGITAL IC501 DIGITAL S&H ANALOG IC401 IC531 IC8001 DIGITAL S&H HDMI GAMMA GREEN RECEIVER PC_H/V PC_RGB SCAN IC561 IC4401 CONVERTER S&H COLOR BLUE PC_H/V MANAGER Y,Cb,Cr SCART_CV Y,Cb,Cr Y,Cb,Cr IC3401 SDRAM FOR JAPAN...

  • Page 73: Video Signal Processing Circuit And Lcd Panel Driving Circuit

    Chassis Block Diagrams ● Video signal processing circuit and LCD panel driving circuit MAIN BOARD TMDS IC8001 HDMI RECEIVER <SII9125> SIHS/SIVS TMDS D-SUB_15 Input Signal RGB(SCART) G-ON SYNC ADHS SIOUTR,G,B ADVS H_SYNC CV_SYNC IC801 FLASH ROM V_SYNC <S29GL064> PC_RGB PC_RGB/SCART IC301 IC1391 PC_HS...

  • Page 74: Chassis Block Diagrams

    Chassis Block Diagrams ● System Controls MAIN BOARD IC8841 UNIT_POWER TEMP. SENSOR PC103 CN201 444,355 PHOTO SCL0/SDA0_3.3V SCL0/SDA0 IC301 COUPLER MAINON_SW Always Available IC8001 PC101 IC4801 POWER_ON_SW HDMI PHOTO 154,41 CN101 RECEIVER SCL1/SDA1 COUPLER Always Available 153,258 IC1391 EEPROM SW902 THERMAL SW FAN_CONT0 CTL(-)
  • Page 75 Chassis Block Diagrams ● Description of System control circuit Remote control R/C signal is sent to pin 292 of IC301(Main CPU) and also sent to pin 20 of IC4801(Sub CPU). Thermal switch There is the thermal switch (SW902) above the lamp holder to prevent the internal abnormal temperature rising. If the internal temperature reaches near 100°C, the switch will be opened and the lamp operation will be stopped.

  • Page 76: Motor Driving Circuit

    Chassis Block Diagrams ● Motor driving circuit LAMP MAIN BOARD IRIS MOTOR CTL(-) PW_PWM0 DRV(+) DRV(-) CTL(+) IC301 SCAN CONVERTER, SYSTEM CONTROL <PW386> IC6551 MOTOR DRIVER <BA6287> OUT1 DRIVER DOOR_OPEN CONTROL LOGIC OUT2 DOOR_CLOSE DRIVER DOOR MOTOR DOOR SW_2 BOARD 3.3V= DOOR SW8811 CLOSE...
  • 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 FN901 FN902 FN903 FN904 FN905 ● Fan control circuit MAIN BOARD FAN_MTR1-5 S16V_F Q7821 FAN1 FAN_CONT0 TPFAN1 Q7831 FAN2 IC7801 FAN_CONT1 TPFAN2 Q7841 FAN3 FAN_SW FAN_CONT2 TPFAN3 IC7802 Q7851 FAN4 FAN_SW FAN_CONT3 TPFAN4 FAN5 IC7861 TPFAN5 PW_PWM4 FAN_SW Power-On : H FAN_CONT0...
  • Page 79 Chassis Block Diagrams ● Description of Fan control circuit Fan control circuit The Fan drive power supplies "FAN1", "FAN2", "FAN3", "FAN4" and "FAN5" 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 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 Q7821 FAN1 COLOR MANAGER FAN_CONT0 TPFAN1 Q7831 FAN2 IC7801 FAN_CONT1 TPFAN2 PW_PWM4 Q7841 FAN3 FAN_SW FAN_CONT2 TPFAN3 IC7802 Q7851 FAN4 FAN_SW FAN_CONT4...
  • 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 ener- When the projector is connected to outlet with AC power cord and the Mains SW is switched to ON, SS3.3V line is supplied to to standby circuit, including IC4801.

  • Page 82: Troubleshooting

    ■ Troubleshooting ● Flow chart of projector condition (with AC power supply and Mains SW : ON) (90 sec.) AC OFF STAND-BY COOLING (Lamp : OFF) <RECOVER> (ON/STAND-BY KEY) (Slide Shutter error) <ACCIDENT> WARNING POWER ON (Slide Shutter error, Lamp error) (Lamp : ON) (20 sec.) <ACCIDENT>...

  • Page 83: No Power

    Troubleshooting ● No Power This projector provides a function which can be specified a defective area simply by indicating the LEDs on the control panel. Connect the AC cord and turn the projector on and then check the LED indication. Indicators Troubleshooting POWER...
  • Page 84 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 intake and WARNING (red) and exhaust fan openings, and wait until the POWER indica- POWER (red) indicators tor stops flashing, and then try to turn on the projector.

  • Page 85: No Picture

    Troubleshooting ● No Picture Check following steps. Description of visual signal flow Sync: Description of sync signal flow No p i c t u re w i t h a l l o f Check signal processing stage and LCD driving stage; input sources Check power supply circuit 15.5V and peripheral circuit.
  • Page 86 Troubleshooting From previous page Check Computer source input stage; No picture with Computer (RGB analog) input source Check IC301 and peripheral circuit. Check sync signals <PC_V> and <PC_H>. PC_RGB signals are sent to IC301. Sync: PC_HS/VS signals are sent to IC301. Check Computer source input stage;...

  • Page 87: Control Port Functions

    ■ Control Port Functions ● I/O Port Table of Main CPU (IC301, PW392) Pin No. Name Function Name Function Polarity SIDEN SIEVNODO SICLK SIAHS SIHS SIVS SYNC_SEL1 DOOR_OPEN_SENS DOOR_CLOSE_SENS SYNC_SEL2 STANDBY_LED WARNING_LED POWER_LED LAMP_LED DOOR_OPN DOOR_CLS BALLAST_ON_SW (BALLAST_ON_SW_FPGA TO : IC4401) MAIN_ON_SW 15V_SW 1.8V_SW...
  • Page 88 Control Port Functions ● I/O Port Table of Main CPU (IC301, PW392)_CONTINUE Pin No. Name Function Name Function Polarity PFAIL_DCT2 FROM : POWER_FAIL 1.0VGA_DETECT S1.2V_DETECT THERM1 FROM : EXT. TEMP SENSOR1 THERM2 FROM : EXT. TEMP SENSOR2 IC301_ADC7 CPU_ADC_IN PW_DHS PW_DVS PW_DCLK PW_DEN...

  • Page 89: Service Parts List

    Electrical Parts List 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. It is particularly recommended that only parts specified on the following parts list be used for components replacement pointed out by the mark.
  • Page 90 Electrical Parts List ● Assembled Board A901 A8803 Ballast unit Lamp switch board A902 Power unit A100 Main board A8801 Door switch1 board A601 Filter board Front A8802 Door switch2 board A101 R/C board ● Out of Circuit Board Thermal Switch (SW902) Thermistor (TH901) FAN (FN903) Thermistor (TH902)
  • Page 91 MD4-Z200000 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description 305 163 1615 TR 2SC2812N-L6-TB0 ASSMBLIED BOARDS 305 173 9816 TR 2SC3928A1R 305 173 9915 TR 2SC3928A1S 610 335 4170 ASSY,PWB,MAIN MD4A Q1243 305 014 4512 TR 2SC2412K T146 R 610 335 4149 ASSY,PWB,R/C MD4A...
  • Page 92 MD4-Z200000 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description 305 014 4611 TR 2SC2412K T146 S IC1362 309 439 8919 IC TC7WH125FU 305 015 8727 TR 2SC2812-L6-TB IC1391 310 538 4907 IC 24LC64T-I/SNG 305 015 8925 TR 2SC2812-L7-TB IC1401 310 362 6504...
  • Page 93 MD4-Z200000 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description C1071 303 409 3426 CERAMIC 0.1U K C1536 303 433 1112 CERAMIC 1U K C1081 303 409 3426 CERAMIC 0.1U K C1537 303 397 5713 ELECT 100U M C1082 303 409 3426...
  • Page 94 MD4-Z200000 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description C2548 403 455 1418 CERAMIC 2.2U K C324 303 433 1112 CERAMIC 1U K C2549 403 455 1418 CERAMIC 2.2U K C326 303 409 3426 CERAMIC 0.1U K C2551 403 455 1418...
  • Page 95 MD4-Z200000 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description C371 303 409 3426 CERAMIC 0.1U K C4429 303 409 3426 CERAMIC 0.1U K C372 303 358 3215 CERAMIC 10U K 6.3V C4431 303 409 3426 CERAMIC 0.1U K 303 368 7319...
  • Page 96 MD4-Z200000 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description C474 303 409 3426 CERAMIC 0.1U K C5613 303 347 5510 POS-SOLID 470U M C478 303 409 3426 CERAMIC 0.1U K C562 303 409 3426 CERAMIC 0.1U K C479 303 409 3426...
  • Page 97 MD4-Z200000 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description C6553 303 409 3426 CERAMIC 0.1U K C7853 303 409 3426 CERAMIC 0.1U K C6554 303 409 3426 CERAMIC 0.1U K C7861 303 342 3313 CERAMIC 0.1U K C6627 303 342 3313...
  • Page 98 MD4-Z200000 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description C8058 303 276 1317 CERAMIC 1000P K C881 303 433 1112 CERAMIC 1U K C8059 303 276 1317 CERAMIC 1000P K C8821 303 409 3426 CERAMIC 0.1U K C8061 303 409 3426...
  • Page 99 MD4-Z200000 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description R1200 301 263 7420 MT-GLAZE 75 JA 1/16W R3003 301 260 4115 MT-GLAZE 75 JA 1/3W R1245 301 256 0015 MT-GLAZE 120 JA 1/10W R3004 301 260 4115 MT-GLAZE 75 JA 1/3W...
  • Page 100 MD4-Z200000 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description R3471 301 226 1516 MT-GLAZE 0.000 ZA 1/16W R4041 301 225 8110 MT-GLAZE 10 JA 1/16W R3472 301 226 1516 MT-GLAZE 0.000 ZA 1/16W R4042 301 225 8110 MT-GLAZE 10 JA 1/16W R3473...
  • Page 101 MD4-Z200000 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description R468 301 225 1814 MT-GLAZE 47 JA 1/16W R5646 301 150 6014 MT-GLAZE 0.000 ZA 1/10W R469 301 225 1814 MT-GLAZE 47 JA 1/16W R5651 301 225 8516 MT-GLAZE 1.8K JA 1/16W R471...
  • Page 102 MD4-Z200000 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description R6557 301 225 1210 MT-GLAZE 4.7K JA 1/16W R7803 301 298 6518 MT-GLAZE 3.3K FA 1/16W R6559 301 225 8110 MT-GLAZE 10 JA 1/16W R7804 301 294 3016 MT-GLAZE 10K FA 1/16W R6628...
  • Page 103 MD4-Z200000 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description R7884 301 224 9316 MT-GLAZE 1K JA 1/16W R8212 301 226 1516 MT-GLAZE 0.000 ZA 1/16W R7886 301 224 9019 MT-GLAZE 10K JA 1/16W R8213 301 226 1516 MT-GLAZE 0.000 ZA 1/16W R7887...
  • Page 104 MD4-Z200000 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description R9716 401 350 1014 MT-GLAZE 51 DA 1/10W RB403 945 036 3529 R-NETWORK 0X4 1/32W R9717 401 350 1014 MT-GLAZE 51 DA 1/10W 945 037 0817 R-NETWORK 0X4 1/16W R9718 301 226 1516...
  • Page 105 MD4-Z200000 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description 945 037 0831 R-NETWORK 47X4 1/16W RB472 945 036 0986 R-NETWORK 47X4 1/32W RB4427 945 036 0986 R-NETWORK 47X4 1/32W 945 037 0831 R-NETWORK 47X4 1/16W 945 037 0831 R-NETWORK 47X4 1/16W RB473...
  • Page 106 MD4-Z200000 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description L1532 945 086 6662 IMPEDANCE,600 OHM P L5632 945 086 6648 IMPEDANCE,220 OHM P L1533 945 001 5923 INDUCTOR,2.2U M L5641 945 086 6662 IMPEDANCE,600 OHM P L1534 945 001 5923 INDUCTOR,2.2U M...
  • Page 107 MD4-Z200000 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description D1081 307 205 5216 DIODE RB521S-30-TE61 D8081 307 254 2716 DIODE CMS16 D1082 307 223 1115 ZENER DIODE 02DZ6.2Y(TPH3 D8091 307 254 2716 DIODE CMS16 D1083 307 205 5216 DIODE RB521S-30-TE61 D8101...
  • Page 108 MD4-Z200000 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description ! C616 304 073 4508 CERAMIC 2200P K 250V RESISTOR ! R611 301 008 8620 CARBON 220K JA 1/2W ! VARIABLE RESISTOR VA611 308 061 5607 VARISTOR ENE471D-14A-S6 COIL L611...
  • Page 109 MD4-Z200000 Mechanical Parts List Cabinet Parts - 109 - - 109 -...
  • Page 110 MD4-Z200000 Mechanical Parts List Front Panel Assembly - 110 - - 110 -...

  • Page 111: Mechanical And Optical Parts List

    MD4-Z200000 Mechanical Parts List Optical unit Integrator Lens (IN) - 111 - - 111 -...
  • Page 112 MD4-Z200000 Mechanical Parts List Relay Lens (IN) LCD panel / Prism Assembly 102-2 102-3 102-1 102R 102L - 112 - - 112 -...
  • Page 113 MD4-Z200000 Mechanical Parts List Polarized grass / Optical filter 47R/47L 113R/113L 115R/115L 114R/114L 48R/48L 49R/49L - 113 - - 113 -...
  • Page 114 MD4-Z200000 Mechanical Parts List - 114 - - 114 -...
  • Page 115 645 095 4269 OPTICAL FILTER (HPO)87 610 336 5381 SPACER SHEET LNS-MD4A 114R 645 095 4245 OPTICAL FILTER (HPO)90 945 080 8792 BADGE,SANYO*26.2X5.7L26.0 115L 645 095 4238 OPTICAL FILTER (HPO)90 115R 645 095 4252 OPTICAL FILTER (HPO)87 610 336 7552...
  • Page 116 MD4-Z200000 Mechanical / Optical Parts List Key. No. Part No. Description Key. No. Part No. Description PACKING MATERIALS 610 336 5657 CARTON CASE -MD4A 610 336 5848 CASE ACCESSORY-MD4A 610 336 5725 CUSHION LENS-MD4A 610 336 5671 CUSHION-MD4A 645 095 7765 POLY BAG-0750X0600*NC ACCESSORIES OWNER'S MANUAL...
  • Page 117 - 117 -...
  • Page 118 - 118 - - 118 -...
  • Page 119 - 119 - - 119 -...
  • Page 120 SM5110894-00 (PLV-Z2000) Nov. 2007 DC 350 Printed in japan...
  • Page 121 PLV-Z2000 MD4_Z200000 These schematic diagrams and printed wiring board drawings are part of the service manual original for chassis No. MD4_Z200000 models PLV-Z2000. File with the service manual No. SM5110894-00 Note: All the information of part numbers and values indicated on these diagrams are at the beginning of production.

  • Page 122: Parts Description And Reading In Schematic Diagram

    MD4_Z200000 Parts description and reading in schematic diagram 1. The parts specification of resistors, capacitors and coils Resistor Reading are expressed in designated code. Please check the parts Example 1/2 D J 10K B description by the following code table. 2.

  • Page 123: Schematic Diagrams

    Schematic Diagrams SS3.3V K2801 J10EG045G A2801 L2801 K8K_1 L3CU601PG U22B0080G K8K_2 1 VOUT J10EG045G R2801 C2802 DOOR SWITCH1 1/16GJ100A 10KK1MN LINE FILTER 2 VCC R2802 1/16GJ47A K8K_G 3 GND C2801 AC CORD F601B J10EG036G KK470MN R/C PREAmp. J20B K601 (RED) 0040N K8801_3 AC100-120V...
  • Page 124 R1002 R1001 1/16GJ1KA 1/16GJ10A HDMIHPD1 B :2.2Kohm B-E:47Kohm S3.3VSI SDA1 Q1001 R1HPDOUT RN1105P IC8121 SCL1 R1003 QXXAVC247P K10A D1001 1/16GJ TPH1DCT C8121 J11B7450M RSB6.8CSG R1DDCSDA 3.3KA D1002 HDMI1DCT 16KK0.1MN RSB6.8CSG 1 %%oOE1 R1DDCSCL K10A_19 D1003 Q1002 R8121 5VHDMI1 %%oOE2 S3.3VSI IC301 K10A_18 RSB6.8CSG...
  • Page 125 R1301 1/16GD1.2KA S2.6VPW S2.6VPW S1.3VREF S2.6VPW IC5681 IC1301 IC1321 S3.3V R5681 R1302 XC6202P502MP L5681 QXXAVC926M 1/16GD1.2KA QXXAVC926M 1/10GZ0C R839 L3CU601PG 5VTMP 6.5V 5VTMP C1303 C1323 16KK0.1MN 16KK0.1MN FPGA_FLASH C5683 16KK0.1MN MD[8] MD[7] MD[24] MD[23] DQ15 DQ15 PW_ICE C5682 S3.3VPW C1304 C1324 C5681 D871...
  • Page 126 SS3.3V IC4802 QXXAVB449P J10EG045G C4803 R4811 16KK0.1MN R2831 R2832 L2831 1/10GZ0C 1/16GJ100A RC_VOUT 1/3GJ47 1/3GJ47 K8J_1 WIRELESS_REMOTE K8J_2 R2833 R/C RECEIVER 1/16GJ100A K8J_3 IC4801 SS3.3V IC4804 QXXAVC920P TC7SH04FUP R4808 ;74LVC1G04GWP 1/16GZ0A TPPIC_1 RA2/AN2/VREF- RA1/AN1 KEY_SW TPIRISOP SS3.3V TPPIC_2 RA3/AN3/VREF+ RA0/AN0 R4807 1/16GJ100A POWER_SW...
  • Page 127 K1400 3.3VGA R1401 1/16GJ1KA FPGA_SCLK FPGA_SCS From IC301 I/O SERIAL_EN FPGA_SCSR IC1401 FPGA_SCSG SERIAL_EN_ICE FPGA_SCSB QXXAVB618P FPGA_SDATA C1401 16KK0.1MN TPF_SCLK PANEL_IC_SCLK FPGA_SCLK R1411 PANEL_IC_SCS PANEL_IC_SCSR FPGA_SCS TPF_SCS 1/16GJ22A PANEL_IC_SCLK R1412 PANEL_IC_SCSG TPF_SCSR 1/16GJ22A PANEL_IC_SCSB FPGA_SCSR PANEL_IC_SCS R1413 PANEL_IC_SDATA FROM IC4401 TPF_SCSG 1/16GJ22A R1419...
  • Page 128 3.3VPNL C3501 6.3EM221V C3506 TPR1OUT5 25KK0.1GQ K35R 15.5V J11B8800G C3504 25EM103T C3507 25KK0.1GQ TP_CLK1R VREF1 VREF2 C522 VREF3 16KK0.1MN VREF4 VREF5 C1524 C517 KK1000MN CVDD CLKIN2 VREF6 VREF7 CVSS CLKIN1 CLKR1 VREF8 VREF9 R1OUT[11] R1OUT[11] D0IN11 PANEL_IC_RESET R1OUT[10] R1OUT[10] D0IN10 DX_R DY_R IC7631...

  • Page 129: 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 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 130 MAIN (SIDE : A) POWER “CN201” C2853 D2866 D2863 C2852 D2864 L4602 Q2854 Q2856 R2851 Q2853 R2852 L4601 L7821 L7831 L7841 R2853 D2851 Q2857 C2857 R2862 R2863 D2867 C2851 L4603 L4612 R2832 R2831 R2861 L4604 D7821 D7831 TPF_SCSR C7602 TPF_SCLK L4606 TPF_SCS R2864 D2853 TPF_SCSG R2866...
  • Page 131 MAIN (SIDE : B) R/C DOOR SW_2 DOOR SW_1 DOOR “K28D” “K8811” “K8801” MOTER BLUE RED R7839 D2868 D2869 D2871 TP_FAN1 C7833 Q7832 R7821 R7829 LAMP REPLACE WARNING TEMP READY TP_FAN3 TP_FAN2 C7823 K4801 TE4654 TPLE_PWR TPLEWARN R4822 R7849 TPLELAMP TPLESTBY TPSS3.3V Q7841 Q7831 Q7821 TE401 C7843 Q7842...
  • Page 132 LAMP BALLAST (SIDE : A) POWER (SIDE : A) LAMP BALLAST “CN101” FILTER “K6A” CN102 CN101 LAMP CN102 POWER “CN102” CN201 CN201 MAIN MAIN “K8P” “K8A” LAMP SW (SIDE : A) LAMP SW (SIDE : B) R/C (SIDE : A) R/C (SIDE : B) K8803 MAIN A30C5 1AA4B10C5980D “K8Q” MAIN “K8J” SW8803 PARTS_SIDE R2801 C2801 C2802 A12 PCB_MD4A...
  • Page 133 MD4_Z200000 Pin description of diode, transistor and IC ● Diode ● Transistor/FET ● IC...

  • Page 134: Note On Soldering

    Note on Soldering Do not use solder containing lead. Solder This product has been manufactured using lead-free solder Use solder with the metal content and composition ratio 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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