FILE NO. SERVICE MANUAL Multimedia Projector Model No. PLC-XE45 U.S.A. Canada Europe, U.K original Version NotE: Match the Chassis No. on the unit's back cover with the Chassis No. in the Service Manual. If the original Version Service Manual Chassis No. KJ7-XE4500 Chassis No.
Dispose of used batteries according to the manufacture’s instructions. Replace Battery With SANYO Electric Co., Ltd., Part No. 945 081 87 or 945 088 6837 Only. Use of Another Battery May Present A Risk Of Fire or Explosion.
Specifications Mechanical Information Projector Type Multi-media Projector Dimensions (W x H x D) 12.6" x 5.83" x 11.5" (320mm x 148mm x 292mm) (Not including adjustable feet) Net Weight 7 .3 lbs (3.3kgs) Feet Adjustment 0˚ to 10.0˚ Panel Resolution LCD Panel System 0.6" TFT Active Matrix type, 3 panels Panel Resolution 1,024 x 768 dots Number of Pixels 2,359,296 (1,024 x 768 x 3 panels) Signal Compatibility Color System PAL, SECAM, NTSC, NTSC4.43, PAL-M, PAL-N High Definition TV Signal 480i, 480p, 575i, 575p, 720p, 1035i, and 1080i Scanning Frequency H-sync. 15 ~ 100 KHz, V-sync. 50 ~ 100 Hz Optical Information Projection Image Size (Diagonal) Adjustable from 60" to 80" Projection Lens F 1.85 lens with f 8.1 mm ~ 27 mm with manual focus Throw Distance 2.40’ - 3.22’ (0.73m - 0.98m) Projection Lamp 200W Interface Video Input Jack RCA Type x 1 S-Video Input Jack Mini DIN 4 pin x 1...
Circuit Protections This projector provides the following circuit protections to operate in safety. If the abnormality occurs inside the pro- jector, it will automatically turn off by operating one of the following protection circuits. Thermal switch There is the thermal switch (SW90) inside of the projector to detect the internal temperature rising abnormally.
Circuit Protections Warning temperature and power failure protection The projector will be automatically turned off when the internal temperature of the projector is abnormally high, or the cooling fans stop spinning, or the power supplies in the projector are failed. - If the WARNING indicator is flashing, it may detect the abnormal temperature inside the projector.
Security Function Notice Security Function Disable This projector provides security functions such as "PIN code lock" and "Logo PIN code lock". When the projector has set these security function on, you are required to enter correct PIN code to use the projector. If you do not know the correct PIN code to the projector, the projector can no longer be operated or started.
Lamp Replacement Lamp replacement oRdER REPLACEMENt LAMP Type No. Service Parts No. WARNING: POA-LMP106 610 33 3855 - For continued safety, replace with a lamp assembly of the same type. - Allow the projector to cool for at least 45 minutes before you open the Screw Lamp Cover lamp cover.
Mechanical Disassembly Mechanical disassembly should be made following procedures in numerical or- Screws Expression der. (Type ) mm Diameter x Length Following steps show the basic procedures, therefore unnecessary step may T type M Type be ignored. Caution: The parts and screws should be placed exactly the same position as the original otherwise it may cause loss of performance and product safety.
Page 10
Mechanical disassembly Main Board, Rear Panel, Fan(FN905), SP901 removal (M.5x6)x Grounding (M.5x6)x8 (M4x5) lead Rear panel FN905 (T3x8) Main board SP901 Fig.2 -10-...
Optical Parts Disassembly Before taking this procedure, remove Cabinet Top , Cabinet Front and Main Board following to the “Mechanical Disassembly”. Disassembly requires a .0mm hex wrench. Projection lens removal (M3x8)x4 Fixing tape Projection lens Fig.1 Note on replaceing the Projection Lens - When the Projection Lens is replaced with the new one, make sure that the fixing tape must be removed as the figuer.
Page 15
optical Pats disassembly Relay lens disassembly (M.5x5)x Relay lens Ass'y (Mx3) Relay lens Fig.3 Polarized glass-in disassembly (M.5x5)x1 Polarized glass-in Ass'y Film side Polarized glass Fig.4 -15-...
Page 16
optical Parts disassembly LCD Panel/Prism Ass’y removal LCD Panel/ (M.5x4)x Prism Ass’y (M3x10) (Bottom side) Fig.5 IMPoRtANt NotICE on LCd Panel/Prism Ass'y Replacement LCD panels used for this model can not be replaced separately. Do not disassemble the LCD Panel/Prism Ass’y. These LCD panels are installed with precision at the factory.
Panel Type Check There are types of LCD/Prism Ass'y for this model. Either L-Type or R-Type LCD /Prism Ass'y is used on the projec- tor. Check which type of LCD/Prism Ass'y is used with the figure below. When replacing the LCD/Prism Ass'y, you need to take "Panel Type Check and Setting" on the Electrical Adjustment for the replaced LCD/Prism Ass'y.
Page 18
optical Parts disassembly Polarized glass, Pre-polarized glass removal (Mx) (Mx) (Green) Pre-Polarized Glass(G) Polarized Glass(G) (Red) (Mx4) (Mx) Pre-Polarized Glass(B) Film (Blue) Polarized Glass(R) Fig.6 Polarized Glass(B) * Mount the polarized glasses as the film attached side comes to the LCD Film panel side.
optical Parts disassembly Locations and Directions Parts Name When mounting or assembling the optical parts in the Integrator lens (OUT) optical unit, the parts must be mounted in the specified Prism beam splitter (PBS) location and direction as shown in figure below. Condenser lens (OUT) Dichroic mirror (B) Dichroic mirror (G) Condenser lens (G) Mirror (R) Condenser lens (R)
Optical Adjustments Before taking optical adjustments below, remove the Cabinet Top following to the “Mechanical Disassembly”. Adjustments require a .0mm hex wrench and a slot screwdriver. When you adjust Integrator lens or Relay lens adjustment, you need to disconnect FPC cables of LCD panels on the main board. Optical adjustment requires a .0mm hex wrench and a slot screwdriver.
optical Adjustments Integrator lens adjustment Turn the projector on by a state of without FPC cables. Project all of lights on the screen. Adjust the adjustment base of integrator lens assy to make color uniformity in white. 1) If the shading appears on the left or right of the screen as White shown in Fig.2-1, loosen 1 screw , and adjust the slot...
Page 23
optical Adjustments Relay lens-Out adjustment Turn the projector on by a state of without FPC cables. Project all of lights on the screen. Adjust the adjustment base of relay lens assy to make color unifor- mity in white. If the shading appears on the left or right of the screen as shown in Fig.3, loosen 1 screw , and adjust the slot to make color...
Electrical Adjustments Service Adjustment Menu Operation to enter the service mode To enter the “Service Mode”, press and hold the MENU button on the remote control for more than 0 seconds. The service menu appears on the screen as follows. to adjust service data Select the adjustment group no.
Electrical Adjustments Circuit Adjustments CAUTION: The each circuit has been made by the fine adjustment at factory. Do not attempt to adjust the fol- lowing adjustments except requiring the readjustments in servicing otherwise it may cause loss of performance and product safety. Before taking these adjustments, turn the projector for more than 10 minutes to stabilize the operation.
Page 26
Electrical Adjustments Pedestal adjustment [PC] Pedestal adjustment [1080i] 1. Receive the 16-step grey scale computer signal with 1. Receive the 16-step grey scale component signal Computer1 [RGB] mode. with Computer1 [Component1080i] mode. . Enter the service mode. . Enter the service mode. tP_G1 tP_G1 3.
Electrical Adjustments m Gain adjustment [Video] ⁄0 50% White adjustment [Video] 1. Receive the 16-step grey scale composite signal with 1. Receive the 16-step grey scale composite video sig- Video [Video] mode. nal with Video [Video] mode. . Enter the service mode. .
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 adjustment items indicated with “✻” are required to readjust fol- lowing to the “Electrical adjustments”. Other items should be used with the initial data value.
Page 34
Link with Group 10 - No 17 R-ENBX1IN L3E01060 0-255 G-ENBX1IN L3E01060 0-255 B-ENBX1IN L3E01060 0-255 Group 100 OPTION (Lamp Time, Service Port etc) RS232C Baudrate PW186 0 : 19200bps 1: 9600bps PJLink Enable 0:Disable 1:Enable PW Debug Command Enable PW186 0:Disable 1:Enable(Sanyo Serial Command Disable)(Not memorized) Device Refresh Disable PW186 0:Enable 1:Disable(Not memorized) Projector Time Reset PW186 0-20 Resets Projector time when the value is set to 10. Lamp Warning Time (HIGH) PW186 1500 0-10000 Normal lamp warning time Lamp Warning Time (NORMAL) PW186 3000 0-10000 Eco lamp warning time Lamp life test enable PW186 0:Disable 1:Enable For safety test purpose...
Page 36
Electrical Adjustments Item No. NAME Device Range Description Component Video HDTV 480p 480i NTSC NOR_TEMP_FAN2_MIN 0-255 FAN2 Control start temp.at High NOR_TEMP_FAN2_MAX 0-255 FAN2 Control end temp. at High NOR_VALU_FAN1_MIN 0-255 FAN1 Control Min at High (0:0V, 255:25.5V) NOR_VALU_FAN1_MAX 0-255 FAN1 Control Max at High NOR_VALU_FAN2_MIN 0-255 FAN2 Control Min at High NOR_VALU_FAN2_MAX 0-255 FAN2 Control Max at High ECO_TEMP_FAN1_MIN 0-255 FAN1 Control start temp.at Normal ECO_TEMP_FAN1_MAX 0-255 FAN1 Control end temp. at Normal ECOTEMP_FAN2_MIN 0-255 FAN2 Control start temp.at Normal ECO_TEMP_FAN2_MAX 0-255 FAN2 Control end temp. at Normal...
Page 37
Electrical Adjustments Item No. NAME Device Range Description Component Video HDTV 480p 480i NTSC GAIN target PW186 0 - 255 Target for White Level Adj. GAIN torelance PW186 1 - 255 Allowence Range for White Level Adj Offset Area Average [ Red ] PW186 0 - 255 Read Only Offset Area Average [ Green ] PW186 0 - 255 Read Only Offset Area Average [ Blue ] PW186 0 - 255 Read Only Gain Area Average [ Red ] PW186 0 - 255 Read Only Gain Area Average [ Green ] PW186 0 - 255 Read Only Gain Area Average [ Blue ] PW186 0 - 255 Read Only...
Page 38
Electrical Adjustments Item No. NAME Device Range Description Component Video HDTV 480p 480i NTSC Horz Back Porch (HPOS) PW186 Horizontal Back Porch Vert Back Porch (VPOS) PW186 Vertical Back Porch Disp Line (VRES) PW186 Vertical Resolution Group 522 OverScan HDTV 575i Disp Dots (HRES) PW186 Horizontal Resolution Horz Back Porch (HPOS) PW186 Horizontal Back Porch Vert Back Porch (VPOS) PW186 Vertical Back Porch Disp Line (VRES) PW186 Vertical Resolution Group 524 OverScan HDTV 480p Total Dots(HTOTAL) AD9883 1317 AD9883 PLL Div Disp Dots (HRES)
Page 39
Electrical Adjustments Item No. NAME Device Range Description Component Video HDTV 480p 480i NTSC Clamp Pos AD9883 AD9883 Clamp Placement Clamp Width AD9883 AD9883 Clamp Duration Group 544 OverScan RGB 480p Total Dots(HTOTAL) AD9883 1200 AD9883 PLL Div Disp Dots (HRES) PW186 Horizontal Resolution Horz Back Porch (HPOS) PW186 Horizontal Back Porch Vert Back Porch (VPOS) PW186 Vertical Back Porch Disp Line (VRES) PW186 Vertical Resolution Clamp Pos AD9883 AD9883 Clamp Placement Clamp Width AD9883 AD9883 Clamp Duration...
Troubleshooting Indicators and Projector Condition Check the indicators for projector condition. Indicators LAMP Projector Condition WARNING PoWER REPLACE red/green yellow The projector is off. (The AC power cord is unplugged.) The projector is preparing for stand-by or the projection lamp is being cooled down.
troubleshooting No Power This projector provides a function which can be specified a defective area simply by indicating the LEDs. Connect the AC cord and press the Power button once and then check the LED indication. - When all of LEd indicators are not lighting, the symptom indicates that the primary power supply circuit does not operate properly.
troubleshooting No Picture Check following steps. No picture with all of input sources Check signal processing stage and LCD driving stage; Check RGB S&H signals at test points TP_B1, TP_G1, TP_R1. Check power supply circuit 15.5V and peripheral circuit. Check ICs IC501, IC531, IC561, IC501, IC531, IC561, IC401, IC301 and peripheral circuits.
troubleshooting No Sound Check following steps. Check if the audio sig- nal is observed at pins Check IC5001 and peripheral circuit. 10 and 21 of IC5001. Check 5V_AUDIO, 9V power supply. Check if the audio sig- Check IC5031 and peripheral circuit. nal is observed at pins 5 Check the Mute signal at pin 1 of IC5031.
Control Port Functions System Control I/O Port Functions (IC301) PIN No. PIN NAME PORT SIGNAL DESCRIPTION IN0RO5 SCL1_3 IIC bus PWM_120HZ Ballast Drive Power-On: H IN0RO3 SCL0 IIC bus IN0GO7 ON_3.3V 3.3V Drive On: H IN0GO5 ON_15V 15V Drive On: H IN0BO3 PANEL_OPT Panel Optioin H: XGA, L:SVGA IN0GO9 FAN_K8N Fan Drive On: H IN0RO6 IIC bus IN0BO4 CARD_IN IN0RO2 SDA0 IIC bus...
Waveform CVBS <tCV> HSYNC signal <tGHS> VSYNC signal <tVGS> HSYNC signal <tdHS> VSYNC signal <tdVS> R-S&H signal <tP_R1> G-S&H signal <tP_G1> B-S&H signal <tP_B1> -50-...
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.
KJ7-XE4500 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.
KJ7-XE4500 Mechanical Parts List Mechanical Parts List Note: Parts order must contain Chassis No., Part No., and descriptions. Key No. Part No. description Key No. Part No. description CABINET PARTS L12 945 078 0845 PRISM(PBS) C01 910 323 1779 ASSY,STAND LEG-MT5A L13 945 087 1178 POLARIZED GLASS(IN/G) L14 945 083 3886 POLARIZED GLASS(IN/B) 910 330 9362 ASSY,STAND-KT6AC...
PLC-XE45 KJ7-XE4500 these schematic diagrams and printed wiring board drawings are part of the service manual original for chassis No. KJ7-XE4500 model PLC-XE45. File with the service manual No. SM5110937-00. Note: All the information of part numbers and values indicated on these diagrams are at the beginning of production.
KJ7-XE4500 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 91
KJ7-XE4500 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 C C1 C ● IC ● IC (GND) RESET (IN)
KJ7-XE4500 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 which do not meet these conditions.
Page 101
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 R/C (SIdE:A) R/C (SIdE:B) sides (secondary circuit) at the same time.
Page 104
LINE FILtER (SIdE:A) ALARM-B (SIdE:A) ALARM-A “K8703” 1AA4B10C5310B_A A SIDE LF901 POWER “K6C” A30C5 K8751 1AA4B10C5690B A SIDE SW8751 SW8752 SW8754 SW8753 F601B F601A T6.3AH 250V F601 TYPE: 21506.3 L601 SW901 K690 POWER “K6K” ALARM-B (SIdE:B) LINE FILtER (SIdE:B) 1AA4B10C5690B B SIDE A30C5 SW8754...