Sanyo PLC-WM5500L Multimedia Projector Service Manual

Multimedia Projector SERVICE MANUAL Original Version REFERENCE NO. SM5111255-00 FILE NO. Model No. PLC-WM5500L PLC-WM5500 U.S.A, Canada, Europe, U.K, Asia Brazil PLC-WM5500L * Projection lens is optional. Chassis No. KK8-WM5500L00 KK8-WM550000 Match the Chassis No. on the rating label of the projector with the Chassis No. in the Service Manual. If the Original Version Service Manual Chassis No. does not match, additional Service Literature is required. You must refer to “Notices” to the Original Service Manual prior to servicing. PLC-WM5500 PLC-WM5500L 1 122 515 00 (KK8A) 1 122 515 20 (KK8AL) 1 122 515 04 (KK8E) 1 122 515 24 (KK8EL) 1 122 516 00 (LK8A) 1 122 516 20 (LK8AL) 1 122 516 02 (LK8C) 1 122 516 22 (LK8CL) 1 122 516 03 (LK8D) 1 122 516 23 (LK8DL)

-2- Contents SERVICE MANUAL ....................................................... 1 Contents ........................................................................ 2 Safety Instructions ......................................................... 3 Safety Precautions ..................................................... 3 Product Safety Notice................................................. 3 Service Personnel Warning ........................................ 3 Specifications ................................................................ 4 Circuit Protections ......................................................... 5 Fuse ............................................................................ 5 Thermal protectors (SW902) ...................................... 5 Mechanical sensor switches (SW901, SW1891) ......... 6 Temperature sensors, wind sensors........................... 7 Power failure and fan lock detection........................... 8 Maintenance .................................................................. 9 Replacing the Filter Cartridge..................................... 9 Lamp Replacement ...................................................11 How to check Lamp Used Time ............................... 12 Quick maintenance ................................................... 13 Lens Installation........................................................ 14 Using the Lens Antitheft screw ................................. 15 Cleaning ................................................................... 16 Cleaning the Projection Lens ................................... 16 Cleaning the Projector Cabinet................................. 16 Security Function Notice ............................................. 17 Mechanical Disassembly............................................. 18 Optical Parts Disassembly .......................................... 27 Adjustments................................................................. 33 Adjustments after Parts Replacement ...................... 33 Note on Main Board Replacement ........................... 33 Service Adjustment Menu Operation ....................... 34 Optical Adjustment ...................................................... 35 1. Optical axis adjustment ........................................ 36 2. Contrast adjustment ............................................. 40 Electrical Adjustments ................................................. 41 Circuit Adjustments................................................... 41 Test Points and Locations ........................................ 45 Service Adjustment Data Table ................................ 46 Troubleshooting ........................................................... 65 Chassis over view ..................................................... 65 No Power .................................................................. 66 No Power (Power supply) ......................................... 67 No Power (Power supply) ......................................... 68 No Power (Fan control)............................................. 69 No Power (Lamp control) .......................................... 70 Temperature Abnormality ......................................... 71 No Picture ................................................................. 72 No Sound.................................................................. 73 Motor control problems ............................................. 74 Bus control................................................................ 75 LED drive & RC control ........................................... 76 Indicators and Projector Condition ........................... 77 Power failure detection system ................................ 80 Diagnosis of Power Failure with RS-232C port ........ 84 Serial Control Interface............................................. 85 Control Port Functions................................................. 87 IC Block Diagrams....................................................... 90 Parts Location Diagrams ........................................... 100 Mechanical Parts List ................................................ 109 Electrical Parts List ..................................................... 111 Diagrams & Drawings.................................................. A1 Parts description and reading in schematic diagram ..A2 Schematic Diagrams ................................................... A3 Printed Wiring Board Diagrams ................................. A13 Pin description of diode, transistor and IC................. A17 Note on Soldering...................................................... A18

-3- Safety Instructions WARNING: The chassis of this projector is isolated (COLD) from AC line by using the converter transformer. Primary side of the converter and lamp power supply unit circuit is connected to the AC line and it is hot, which hot circuit is identified with the line ( ) in the schematic diagram. For continued product safety and protection of personnel injury, servicing should be made with qualified personnel. The following precautions must be observed. Safety Precautions 1: An isolation transformer should be connected in the power line between the projector and the AC line before any service is performed on the projector. 2: Comply with all caution and safety-related notes provided on the cabinet back, cabinet bottom, inside the cabinet or on the chassis. 3: When replacing a chassis in the cabinet, always be certain that all the protective devices are installed properly, such as, control knobs, adjustment covers or shields, barriers, etc. DO NOT OPERATE THIS PROJECTOR WITHOUT THE PROTECTIVE SHIELD IN POSITION AND PR OPERLY SECURED. 4: Before replacing the cabinet cover, thoroughly inspect the inside of the cabinet to see that no stray parts or tools have been left inside. Before returning any projector to the customer, the service personnel must be sure it is completely safe to operate without danger of electric shock. Service Personnel Warning Eye damage may result from directly viewing the light produced by the Lamp used in this equipment. Always turn off Lamp before opening cover. The Ultraviolet radiation eye protection required during this servicing. Never turn the power on without the lamp to avoid electric-shock or damage of the devices since the stabilizer generates high voltages (15kV - 25kV) at its starts. Since the lamp is very high temperature during units operation replacement of the lamp should be done at least 45 minutes after the power has been turned off, to allow the lamp cool-off. Product Safety Notice Product safety should be considered when a component replacement is made in any area of the projector. Components indicated by mark ! in the parts list and the schematic diagram designate components in which safety can be of special significance. It is, therefore, particularly recommended that the replacement of there parts must be made by exactly the same parts.

-4- Specifications This symbol on the nameplate means the product is Listed by Underwriters Laboratories Inc. It is designed and manufactured to meet rigid U.L. safety standards against risk of fire, casualty and electrical hazards. ● The specifications are subject to change without notice. ● LCD panels are manufactured to the highest possible standards. Even though 99.99% of the pixels are effective, a tiny fraction of the pixels (0.01% or less) may be ineffective by the characteristics of the LCD panels. Mechanical Information Projector Type Multi-media Projector Dimensions (W x H x D) PLC-WM5500L : 19.25” x 6.46” x 14.61” (489.5 mm x 164.0 mm x 371.1 mm) PLC-WM5500 : 19.25” x 6.46” x 17.12” (489.5 mm x 164.0 mm x 434.8 mm) Net Weight PLC-WM5500L : 19.6 lbs (8.9kg) PLC-WM5500 : 21.3 lbs (9.7 kg) Feet Adjustment 0˚ to 4˚ Panel Resolution LCD Panel System 0.75” TFT Active Matrix type, 3 panels Panel Resolution 1,280 x 800 dots Number of Pixels 3,072,000 (1,280 x 800 x 3 panels) Signal Compatibility Color System PAL, SECAM, NTSC, NTSC4.43, PAL-M, and PAL-N SD/HD TV Signal 480i, 480p, 575i, 575p, 720p, 1035i, 1080i and 1080p Input Scanning Frequency H-sync. 15 kHz–100 kHz, V-sync. 48 Hz–100 Hz Optical Information Projection Image Size (Diagonal) Adjustable from 40” to 400” (PLC-WM5500) Throw Distance 4.5' (1.4m) - 80.1' (24.4m) (PLC-WM5500) Projection Lens F1.7–2.3 lens with f=26.9 mm–45.4 mm with motor zoom and focus (PLC-WM5500) Projection Lamp 330 W NSHA lamp Interface Input 1 HDMI/D-sub15pin(RGB, RGB Scart) Input 2 BNC Type x 5 (G or Video/Y, B or Pb-Cb, R or Pr-Cr, H/HV and V) Input 3 RCA Type x 3 (Video/Y, Pb/Cb,Pr/Cr), Mini DIN 4 pin x 1 (S-video) Analog Out Analog RGB (Mini D-sub 15 pin) Terminal x 1 Audio Out Audio (Mini Type stereo) x 1 (Variable) Audio In 1/2 Audio (Mini Type stereo) x 1 Audio In 3 RCA Type x 2 R/C Jack Mini jack (Wired Remote) x 1 Control Port D-sub 9 pin x 1 USB Connector USB Series B x 1 Option PJ-Net Organizer Terminal x 1 LAN Connection Terminal RJ45 Audio Internal Audio Amp 7.0 W RMS Built-in Speaker 1 speaker, ø1.46" (37mm) Power Voltage and Power Consumption AC 100–120 V (5.2A Max. Ampere), 50/60 Hz (The U.S.A and Canada) AC 100-240 V (5.2-2.5A Max. Ampere), 50/60Hz (For other countries) Operating Environment Operating Temperature 41˚F–104˚F (5˚C–40˚C) Storage Temperature 14˚F–140˚F (-10˚C–60˚C) Remote Control Battery AAA or LR03 Type x 2 Operating Range 16.4’ (5 m/±30˚) Dimensions 1.8” (W) x 1.0” (H) x 5.7” (D) (45 mm x 25 mm x 145 mm) Net Weight 3.5 oz (99 g) (including batteries) Accessories Owner’s Manual (CD-ROM) Lens Cap (for PLC-WM5500) Quick Reference Guide Lens Mount Cover (for PLC-WM5500L) AC Power Cord Lens Antitheft screw * Remote Control and Batteries VGA Cable PIN Code Label

-5- 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. Circuit Protections Fuse A fuse is located inside of the projector. When the POWER indicator is not lighting, the fuse may be opened. Check the fuse as following steps. The fuse should be used with the following type; Fuse Part No. : 323 027 2605 TYPE T10AH 250V LITTEL FUSE INC. TYPE 215010 How to replace the fuse 1. The fuse is placed on the power board under the main board. Remove the cabinet top and exhaust fan assy. 2. Remove the fuse from fuse holder on the power board. Thermal protector (SW902) Thermal protectors (SW902) There are the thermal protector (SW902) inside of the projector to detect the lamp surrounding temperature rising abnormally. When the temperature reaches near 115˚C, the thermal protector cuts off the current supplied to the power supply circuit. To reset the thermal protection function, disconnect the AC cord and leave the projector at the normal surrounding temperature for about 45 minutes. The thermal protectors will automatically reset when the internal temperature becomes normal (less than 75˚C) . F601 Fuse

-6- Circuit Protections Mechanical sensor switches (SW901, SW1891) This projector provides 2 mechanical sensor switches, the one is for filter cartridge switch (SW1891) and the other one is for lamp cover switch (SW901). The filter cartridge switch detects whether the filter cartridge is installed correctly. If the filter cartridge is not installed correctly, the projector cannot turn on. In this case, the LAMP indicator is lighting and other indicators are blinking. The lamp cover switch detects whether the lamp cover is closed securely. If lamp cover is opened or not closed completely, the drive signal to the lamp circuit is cut off. After opening the lamp cover for replacing the lamp ass’y, place the lamp cover correctly otherwise the projector cannot turn on. In this case, the LAMP indicator is lighting and LAMP REPLACE indicator is blinking. Filter cartridge switch (SW1891) Lamp cover switch (SW901) Filter cartridge LED indicators

-7- The projector provides 2 temperature sensor ICs, 1 thermistor, and 1 wind sensor on the intake duct. These devices are monitoring the surrounding temperature of the lamp, panel and intake duct, and the wind sensor is monitoring airflow passed through the air filter in the intake duct. - Internal temperature sensor A (IC1692) (around the Intake duct) - Internal temperature sensor B (IC1816) (around the lamp house) - Internal temperature sensor C (IC1814) (around the panel/prism) - Wind sensor D (S901) (intake duct) Circuit Protections IC1814 on the Sensor C Board IC1692 on the Sensor A Board The projector is shut down and the WARNING TEMP. indicator is blinking red. When the temperature inside the projector reaches a certain level, the WARNING TEMP. indicator starts blinking. If the temperature rises moreover, the projector will be automatically shut down to protect the inside of the projector, and the WARNING TEMP indicator is blinking fast and the POWER indicator is blinking. When the projector has cooled down enough (to its normal operating temperature), the POWER indicator stops blinking and it can be turned on again by pressing the ON/STAND-BY button. ✔Note: • The WARNING TEMP. indicator continues to blink even after the temperature inside the projector returns to normal. When the projector is turned on again, the WARNING TEMP. indicator stops blinking. POWER indicator LED indicators Temperature sensors, wind sensors IC1816 on the Main Board (behind) S901 Wind Sensor WARNING TEMP. indicator Then check the matters below: – Did you provide appropriate space for the projector to be ventilated? Check the installing condition to see if the air vents of the projector are not blocked. – Has the projector been installed near an Air-Conditioning/ Heating Duct or Vent? Move the installation of the projector away from the duct or vent. – Is the filter clean? Replace the filter with a new one.

-8- The projector provides the detection circuits of the power failure and the fan lock. When the detection circuit detects an error at the power supply line or at the fan operation circuit, the projector will turn into the standby mode to protect the other circuits defective. Circuit Protections The projector is shut down and the LAMP indicator is lighting and other indicators are blinking. When the projector detects an abnormal condition, it will be automatically shut down to protect the inside of the projector and the LAMP indicator lights on and other indicators blink In this case, unplug the AC power cord and plug it, and then turn on the projector once again to verify operation. If the projector cannot be turned on and these indicators still lighting and blinking, it may operate the power failure protection function. Check that the filter cartridge is installed correctly. CAUTION DO NOT LEAVE THE PROJECTOR WITH THE AC POWER CORD CONNECTED UNDER AN AB- NORMAL CONDITION. IT MAY RESULT IN FIRE OR ELECTRIC SHOCK. Power failure and fan lock detection LED indicators LAMP indicator lights on and other indicators blink.

-9- Maintenance Turn off the projector, and unplug the AC power cord from the AC outlet. First, clean up the dust on the projector and around the air vents. 1 2 Press d downwards on the filter cover to release the latch and open the filter cover. 3 Put the new one back into the position and close the filter cover. Make sure that the filter cartridge is properly and fully inserted. 5 CAUTION Make sure the filter cartridge is inserted in the projector. If the filter cartridge is not inserted, the projector cannot be turned on. Make sure the filter cover is closed when using the projector. Do not put anything into the air vents. Doing so may result in malfunction of the projector. 4 Reset the filter counter and the scroll counter . See next page. 6 Replacing the Filter Cartridge Pull out the filter cartridge. When taking out the filter cartridge, put your finger on the filter cartridge’s tab and then pull. RECOMMENDATION We recommend avoiding dusty/smoky environments when operating the projector. Usage in these environments may cause a poor image quality. When using the projector under dusty or smoky conditions, dust may accumulate on a lens, liquid crystal panels, or optical elements inside the projector. Such condition may de- grade the quality of the projected image. When the symptoms above are noticed, contact your autho- rized dealer or service station for proper cleaning. ORDER REPLACEMENT FILTER CARTRIDGE Type No. POA-FIL-080 Service Parts No.: 610 346 9034 Connect the AC power cord to the projector and turn on the projector. 7 Filter prevents dust from accumulating on the optical elements inside the projector. Should the filter becomes clogged with dust particles, it will reduce cooling fans’ effectiveness and may result in internal heat buildup and adversely af- fect the life of the projector. This projector has an electrically operated filter which helps you to replace the filter easily. The projector monitors the condition of the filter at all time and replaces a filter with a new one automatically when it detects the clogging. If the projector detects that the filter is clogged and no scroll is left in the filter cartridge, a Filter cartridge replacement icon appears on the screen and the WARNING FILTER indicator on the top panel lights up. When you see this icon, replace the filter cartridge and reset the Filter counter and the Scroll counter. Filter cover Latch Filter cartridge Tab

-10- Resetting the Scroll Counter Scroll counter Resetting the Filter Counter Filter counter Be sure to reset the Filter counter after replacing the filter cartridge. Press the MENU button to display the On-Screen Menu. Use the Point ed buttons to select Setting and then press the Point 8 or the SELECT button Use the Point ed buttons to select Filter counter and then press the SELECT button. Use the Point ed buttons to select Filter counter Reset and press the SE- LECT button. Filter counter Reset? appears. Select [Yes] to continue. 1 2 Another confirmation dialog box appears, select [Yes] to reset the Filter counter. 3 Be sure to reset the Scroll counter after replacing the filter cartridge. Press the MENU button to display the On-Screen Menu. Use the Point ed buttons to select Setting and then press the Point 8 or the SELECT button Use the Point ed buttons to select Filter counter and then press the SELECT button. Use the Point ed buttons to select Scroll counter Reset and press the SE- LECT button. Scroll counter Reset? appears. Select [Yes] to continue. 1 2 Another confirmation dialog box appears, select [Yes] to reset the Scroll counter. 3 Maintenance Filter counter Reset? appears. Select Yes, then another confirmation box appears. Select Yes again to reset the Filter counter. Filter counter 150 H Timer 400 H Filter counter reset Scrolls remaining 9 Scroll(s) Scroll counter Reset Scroll counter Reset? appears. Select Yes, then another confirmation box appears. Select Yes again to reset the Scroll counter. Scroll counter Reset? Filter counter 150 H Timer 400 H Filter counter reset Scrolls remaining 9 Scroll(s) Scroll counter Reset

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Sanyo PLC-WM5500L Multimedia Projector Service Manual

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