Sanyo PLC-400P User manual

F/LF

NO.

SERVtCE

MANUAL

Portab!e

LCD

Co!or

Video

Projector

Mode)

no.

PLC-400P

(Europe,As!a,Afr!ca,M.E.)

Mode)

no

PLC-400P6

(U.K.)

Mode)

no.

PLC-400PP

(Austra)ia,NewZea)and)

Contents

Safety

fnstructions'''''''''''''''''''''''''''''''''*''*

2

Principles

And

Functions

Of

The

Liquid

Crysta)

Projector

----.....'''

3

Specifications

----..---''''''''''--------------------

10

Description

of

PLC-400P/PB/PP

..........---...--...--.---

11

LampReptacement

----------------------''----''-''''15

Mochanica!

Disassemblies

16

OR)G)NAL

VERS)ON

LCD

Pane)

Replacement

----------

-"--""""""""-

21

Focus

Adjustments'''''''''''''''''''''''''''''*''''''22

Convergence

Adjustments

............"."--""".""

24

Service

0.

^

^nnp

nn

Cieaning

Methods-.""................".."..".""

25

D-^^

^LU-^UUf-UU

ServfceAdjustments

...................................

27

Ref.NO.

PLC-400PB-00

Chassis

Eioctrica)

PanE

Ust

----"..........-'''...'...."

33

PLC-400PP-00

Cabtnet&Opticai

Parts

List-""'""-""''''""'"'"'51

[CfntemaiBiock

Diagrams

'...'-..--..----'-----'----'-56

[C'Tr

Package

Outiine

Drawings.....-....---'---'--'-'-'-'

63

TroubieshootingChart

'''---''''''''--''''--'''''''''-'64

Parts

Address

List'""'"'"""'"'"'''""'"""'68

Tafte

Notice

Of

"Schematic

Diagrams"

--..-"------"-"

-----

71

Vottage

and

Wave^rme

--'---'-'''-'''''-'---'--'''''-'

73

Scnematic

Diagrams

..--'---'-'''''''''-''''---''--'-'

an

Bfock

Diagr^ns

&

+

B

Distribution

Diagrams

-------'-'-'''-----100

Component

and

Testpoint

Locations

----------'-''---'-'----104

PRODUCT

CODE

P4BA

(PLC-400P-00)

P4BB

(PLC-400PB-00)

P4BC

(PLC-400PP-00)

;

112201700

;

112201701

-

112201702

REFERENCE

NO.

SM525027

SAFETY

PRECAUTIONS

WARNING:

The

chassis

of

this

projector

is

isolated

(COLD)

from

AC

line

by

using

the

converter

transformer.

Primary

side

of

the

converter

transformer

and

tamp

power

supply

unit

circuit

!s

connected

to

the

AC

line

and

it

is

hot,

which

hot

circuit

is

identified

wtth

the

iine

in

the

schematic

diagram.

For

continued

product

safety

and

protection

of

personnel

injury,

servicing

shouid

be

made

wtth

quailed

personnel.

The

following

precautions

must

be

observed:

1.

An

isolation

transformer

shoufd

be

connected

in

the

power

!ino

between

the

receiver

and

the

AC

iine

before

any

service

is

performed

on

the

projector.

2.

Compiy

with

a)!

caution

and

safety

-

rotated

notes

provided

on

the

cabinet

back,

cabinet

bottom,

inside

the

cabinet

or

on

the

chassis.

3.

When

replacing

a

chassis

in

the

cabinet,

atways

be

certain

that

aii

the

protective

devices

are

installed

property,

such

as

control

knobs,

adjustment

covers

or

shields

and

barriers.

DO

NOT

OPERATE

THiS

PROJECTOR

WITHOUT

THE

PROTECTIVE

SHIELD

iN

POSJTiON

AND

PROPERLY

SECURED.

4.

Before

replacing

the

cabinet

cover,

thoroughly

inspect

the

inside

of

the

cabinet

to

see

that

no

strayparts

or

toots

nave

been

fefE

inside.

Before

returning

any

projector

to

the

customer,

the

service

personnef

must

perform

the

following

safety

checks

and

be

sure

that

it

is

compieteiy

safe

to

operate

without

danger

of

electrical

shock.

PRODUCT

SAFETY

NOTICE

Product

safety

should

be

considered

when

a

component

reptacement

!s

made

in

any

area

of

the

projector.

Compo-

nents

indicated

by

a

marf(

(

^

)

fn

the

parts

Mst

and

tne

schematic

diagram

designate

components

in

which

safety

can

be

of

special

significance,

it

is.

therefore,

particutariy

recommended

that

the

replacement

of

these

parts

must

be

made

by

exactly

the

same

parts-

"

SERVICE

PERSONNEL

——

WARNING

"

:

"

Eye

Damage

May

Resutt

From

Diroctiy

Viewing

The

Ught

Produced

By

The

Lamp

Used

in

This

Equtpment.

A!ways

Turn

Off

Lamp

Before

Opentng

Cover.

Uttravio)et

Radiation

Eye

Protection

Required

During

This

Servicing."

Never

turn

the

power

on

without

the

iamp

to

avoid

etectric-

shock

or

damage

of

the

devices

since

the

stabilizer

generates

high

voitages(10kV

-

15kV)

at

its

start.

Since

the

iamp

is

very

high

temperature

during

units

operation

replacement

of

the

iamp

should

be

done

at

least

one

hour

after

the

power

has

been

turned

off,

to

aitow

the

iamp

cooi

off.

—2—

[

PRINCIPLES

AND

FUNCTIONS

O^THE:L!QUtDiC^S^gi

PROJECTOR

]

1.

Fundamentat

Princip)es

of

the

Liquid

Crysta)

Projector

The

white

tight

emitted

from

the

iight

source

is

separated

into

red

(R),

green

(G)

and

biue

(B)

tight

components

by

the

dichroic

mirror.

Each

component

is

projected

onto

one

of

the

three

liquid

crystal

panefs.

The

three

crystal

iiqufd

panels

are

respoctivefy

driven

by

Ft,

G,

and

B

primary

co)or

signals.

The

R/G/B

images

are

reproduced

by

the

shutter

operation

of

these

panefs.

The

R,

G,

and

B

pictures

dispfayed

on

the

three

paneis

are

again

combined

by

the

dichroic

mirror

into

one

and

projected

onto

the

screen.

[^^]

shows

the

fundamental

phncipfes

of

the

liquid

crysta)

projector.

Uttraviotet

and

infrared

rays

are

tittered

out

by

the

UV

-

cut

fitter

and

cotd

fitter

from

the

!)ght

beams

produced

by

the

metaf

haiide

iamp

which

is

the

iight

source.

Thus

unneeded

fight

components

in

the

projected

image

are

efiminatod

and

the

liquid

crystal

panei

is

protected

from

the

iight

and

heat

of

the

famp.

The

uftravioiet

rays

harmfu!

to

the

operator

are

atso

cut

out.

The

tight

beams

now

consist

only

of

visibte

t^ght

components

which

enter

the

condenser

iens,

creating

para!!ei

iight

beams

to

prevent

tight

from

scattering,

improving

luminous

efficiency.

The

tight

beams

are

into

three

primary

cotors

(red,

green

and

btue)

by

the

dichroic

mirror.

The

dichroic

mirror

is

a

fitter

constructed

of

multiple

dielectric

layers,

each

having

a

different

refractive

index.

The

tayers

are

formed

on

g!ass

to

reflect

fight

of

a

specific

wavelength

and

transmit

others.

Each

of

the

divided

R.

G,

and

B

parafiei

tight

beams

now

enter

its

respective

liquid

crystal

pane),

where

they

are

intensity-

modulated

by

R/G/B

cotor

signats.

The

images

formed

on

R,

G

and

B

panots

are

again

combined

by

the

dichroic

mirror

end

reflected

by

the

fuii

reflection

mirror

before

being

projected

on

the

screen

by

the

projection

tens.

Projection

!eM

-

D!chro!c

m!rror

Potartztng

gtaM

^

Put)

reftectton

nthror

LiquM

^._

cryettt

panai

Met<t

hx)Me

)*mp

Lamp

Power

Source

yhe

tarn

p

power

source

smp

and

control

the

power

supply

to

We

Mmp

to

maintain

and

stabilize

the

tamp

K^tscharge,

keeptng

)Mumfhat!ort

at

a

con-

Mant^eve).__________^

(j^^tshowsthe

tamp

power

source

b)ock

diagram.

DC

and

AC

iamp

illumination

methods

are

avaiiabfe.

With

DC

illumination,

luminous

substances

are

at-

tracted

to

the

negative

electrode,

causing

discharge

to

accumulate

toward

it.

Another

drawback

is

a

greater

power

ioss

which

lessens

efficiency.

Therefore

AC

iiiumination

is

more

often

used.

The

iamp

driver

circuit

is

a

DC-

AC

converter

used

for

AC

iiiumination

of

the

iamp.

Designed

to

centre)

power

supp)y

to

the

tamp,

the

chopper

circuit

consists

of

switching

transistors,

choke

coits,

diodes,

etc.

tt

generates

intermittent

current

by

switching

the

switching

transistor

on

and

off.

The

longer

the

On

time,

does

the

supplied

power

increase,

white

the

ionger

the

Off

time,

does

the

supplied

power

!ower.

Therefore,

by

varying

the

on/off

time,

power

supply

can

be

controlled.

The

chopper

circuit

varies

the

switching

transistor

on/off

time

to

maintain

the

power

suppfy

to

the

tamp

at

a

constant

fevei.

The

high-

voitage

puise

generator

tights

the

tamp.

The

metat

hatide

tamp

emits

tight

through

arc

discharge.

To

initiate

arc

discharge,

dielectric

breakdown

must

occur

between

the

tamp

electrodes.

The

high

-

voltage

putse

generator

generates

and

applies

high

-

vottage

putses

with

peak

values

of

about

20kV

between

the

lamp's

positive

and

negative

electrodes

in

order

to

generate

g!ow

discharge.

This

in

turn

resutts

in

dielectric

break-

down

between

the

efoctrodos,

causing

a

shift

from

gtow

discharge

to

arc

discharge.

—4—

Meta)

HaHde

Lamp

The

meta)

hatide

tamp

consists

of

argon,

mercury

and

hatogen

compounds

enclosed

in

its

fuminous

tube.

j^Oshows

the

spectra!

distribution

of

this

iamp.

At

the

center

of

an

arc

discharge,

haJogen

compounds

are

dissociated

into

metai

atoms

and

haiogen

atoms,

the

meta)

being

excited

so

that

it

emits

a

metai

-

specific

spectrum.

At

the

periphery

of

the

arc

discharge,

meta!

atoms

and

haiogen

atoms

are

bonded

again.

Repeating

this

cyclic

process

causes

iight

to

be

generated.

The

meta)

haiide

tamp

features

a

higher

[uminous

efficiency

than

haiogen

and

xenon

iamps.

Depending

on

the

compounds

enclosed

in

the

tamp

tube,

different

iight

spectra

are

generated.

Thts

atso

enaMes

natura)

white

fight

to

be

produced

as

the

projector

tight

source.

Metai

haiide

tamps

are

a

mainstream

product

as

the

tight

source

of

high-

and

middle-

grade

liquid

crystal

projectors.

After

projector

turn

-

on,

2

to

3

minutes

are

required

before

the

tight

output

stabilizes.

After

the

projector

is

turned

off,

the

cooling

fan

operates

for

30

to

60

seconds

to

coot

down

the

tarnp

and

reduce

gas

pressure

inside

the

tamp.

During

this

"cooling

down"

period,

the

projector

cannot

be

turned

on.

—5

4.

Svstem

Contro)

To

ensure

correct

and

safe

tamp

illumination,

[amp

rumination

conditions

are

monitored

to

detect

abnormal

temperatures

in

the

iamp

power

source

and

to

control

the

cooiing

fan.

On

the

metai

haiide

iamp

used,

vottage

as

high

as

20kV

is

applied

at

striking

to

initiate

discharge.

Once

discharge

commences,

vott-

age

stabiles

at

about

85V.

)n

addition,

the

iamp

aiso

generates

heat,

increasing

projector

interior

temperature.

A

cooiing

fan

prevents

temperature

increases.

Cooling

fan

operation

is

con-

trolled

by

the

CPU

which

monitors

the

iamp

power

source

to

determine

iamp

illumination

conditions.

Correct

iamp

rumination

makes

the

tamp

power

source

send

an

"L"

signal

to

19

of

the

CPU

(tC801).

if

the

tamp

does

not

!ight

or

is

suddenly

extinguished,

the

"H"

signal

is

sent

to

19

of

the

CPU

(!C801).

When

the

tamp

tights

after

the

projector

is

turned

on,

the

CPU

(tC801)

starts

chocking

the

input

at

19

at

3

seconds

after

projector

turn-

on.

!f

the

"H"

signal

is

received

by

19

for

a

duration

of

1

second,

the

CPU

(tC801)

evaluates

this

indications

as

an

abnormal

condition,

turning

the

power

off

automatically

and

initiating

1

-

minute

thermal

protection.

While

in

protection

mode,

at!

set

keys

and

remote

control

keys

including

the

power

on/off

switch

witt

not

respond.

The

cooiing

fan

witi

continue

to

operate

in

protection

mode.

The

tamp

power

source

temperature

atso

rises

due

to

control

toss

of

the

chopper

(Q701)

and

tamp

driver

(Q702-

Q705).

This

makes

it

necessary

to

atso

coot

down

the

lamp

power

source

with

the

cooiing

fan,

therefore

the

tamp

power

source

temperature

is

also

monitored,

tf

the

temperature

of

power

source

heat

sink

reaches

approximately

80

°C

,

an

"H"

signat

is

sent

to

19

of

CPU

(tC801)

("L"

signal

for

normal

temperatures).

An

"H"

signal

at

19

for

a

1

second

duration

is

considered

as

abnormal.

The

projector

automatically

turns

off

and

the

1

-

minute

protection

is

initiated.

Att

set

keys

and

remote

controi

keys

wiii

not

respond

in

protection

mode,

but

the

cooling

fan

witt

continue

to

operate.

During

tamp

fighting,

the

discharge

-

induced

heat

increases

gas

pressure

inside

the

tamp.

As

gas

pres-

sure

remains

high

after

tamp

turn

-

off,

the

tamp

cannot

be

turned

on

again

immediateiy.

The

1

-

minute

protec-

tion

is

initiated

again

after

turning

off

the

tamp

(turning

off

the

projector),

disabting

ait

set

keys

and

remote

control

keys

for

that

period.

The

cooting

fan

wiit

continue

to

operate

until

the

gas

pressure

returns

to

a

satisfactory

tevet.

The

green

LED

indicates

tamp

monitor

operation

as

to)

tows:

___

^NBy^

EBMshows

tamp

monitor

flow

chart.

—6—

projector

temperature

is

monitored,

and

power

wiii

turn

off

automatically

if

the

temperature

rises

beyond

normai.

The

cooiing

fan

wi))

operate

untii

the

temper-

ature

returns

to

normat.

This

prevents

projector

compo-

nents

from

being

damaged

by

excessive

heat.

As

the

tamp

generates

heat

and

heat

waves

by

discharge,

the

temperatures

of

the

)amp

itself,

as

we))

as

the

poiarizing

g)ass,

)iquid

crysta)

pane)s

and

other

optica)

components

wiif

increase.

Fan-

induced

cooiing

is

essential.

The

temperature

of

the

iamp's

luminous

giass

surface

must

be

iower

than

approximately

950

'C

,

the

reflector

internal

surface

temperature

must

be

iower

than

350

"C

and

the

poiarizing

glass

and

liquid

crystal

pane)

surface

temperatures

tower

than

55

"C

.

Temperatures

may

exceed

these

ranges

if

the

fan

does

not

operate

or

if

the

projector

is

operated

in

poor

ventilation.

!f

the

projector

is

used

at

ambient

temper-

atures

exceeding

35

°C

,

the

above-

mentioned

temper-

atures

wiii

aiso

exceed

permissibie

ranges,

damaging

optical

components

such

as

the

poiarizing

gtass

and

tiquid

crystal

panels.

in

order

to

prevent

damage

resulting

from

excessive

heat.

temperature

sensors

are

located

at

the

peripheries

of

the

polarizing

glass

and

tiquid

crystal

pane!

to

monitor

temperatures.

The

temperature

sensor

positioned

near

the

iamp

has

an

applicable

temperature

range

of

80"

±

5

°C

with

hysteresis

of

7

"C

(sensor

activates

at

80"

±

5

^C

and

resets

at

73

"

±

5

"C

).

its

main

purpose

is

to

protect

the

tamp.

The

temperature

sensor

positioned

dose

to

the

iiquid

crystal

panets

has

an

appticabte

temperature

range

of

55

°

±

2.5

"C

with

hysteresis

of

7

'C

-

)t

moans

the

sensor

activates

at

55

°

±

2.5

°C

and

resets

at

48"

±

2.5

*C

.

its

main

purpose

is

to

protect

the

iiquid

crysta!

paneis.

Once

AC

power

is

input,

the

CPU

(tC801)

performs

an

input

chock

at

33

regardless

of

the

power

on/off

setting,

if

the

temperature

at

the

tamp

periphery

reaches

approximatety

80

*C

or

the

temperature

at

the

periphery

of

the

iiquid

crystal

paneis

reaches

approximatefy

55

°C

,

an

"L"

signai

is

generated

and

sent

to

33

of

the

CPU.

!f

the

"L"

signai

is

continuous

for

1

second,

the

CPU

sees

it

as

an

abnormal

condition,

automatically

turning

off

the

projector

and

so

turning

off

the

iamp,

and

continues

cooiing

fan

operation

untii

the

temperature

iowers.

in

this

protection

mode,

a)i

set

keys

and

remote

control

keys

do

not

respond.

The

CPU

checks

input

at

33

during

coofing

as

wo)).

The

temperature

sensor

at

the

periphery

of

the

iamp

wiii

reset

when

the

temper-

ature

goes

betow

73

°C

,

sending

an

"H"

signal,

h

similar

fashion,

the

iiquid

crystal

panei

temperature

sensor

wiii

reset

betow

48

"C

and

output

an

"H"

signal.

The

CPU

then

judges

normai

temperature

and

cuts

cooling

fan

operation.

The

red

LED

indicates

temperature

monitor

operation

as

foiiows:

shows

the

temperature

monitor

f!ow

chart.

The

iamp

wiii

require

repiacement

during

operation

at

some

point.

The

yeiiow

LED

indicator

wiii

tight

up

after

1,000

hours

of

use

and

recommend

repiacement.

Usage

time

wiii

bo

stored

in

non

-

voiatite

memory

(iC807)

by

the

CPU

(iC801).

Even

when

disconnected,

this

information

is

retained.

After

iamp

repfacement,

pressing

the

Reset

switch

at

the

bottom

of

the

projector

wiii

return

iamp

usage

time

to

0.

The

Reset

switch

activates

oniy

when

power

is

on.

When

this

switch

is

pressed,

a

"RESET"

indication

wiii

appear

onscreen.

As

the

"RESET"

indication

cannot

be

recognized

immediately

after

power

on,

the

Reset

switch

can

be

operated

oniy

after

the

iamp

has

stabilized

("A

MOMENT!"

goes

off).

Make

sure

to

confirm

"RESET."

The

Reset

switch

shouid

onfy

be

operated

at

iamp

repiacement.

For

details,

refer

to

LAMP

REPLACEMENT

procedure

—7

—8

—9

CPU

(!C80'))p*'torm<

'nput

check

tfp)n

33

(tnput

port)

onew

th<

projector

Fw

conntetwdLtO

^C

outtwt,

ftgardtMt

of

AC

power

on^dff

<Wut.

^

*

)f

$n

T''

ttanat

conttnuM

to

b^

.

;j^

'

mon!ioi^MJ

at

p!n

33

fort

MooTTt^Me^

"

CPU

a$i<ct<

an

abnortn^

oo^tMor^

^

^itf^mpwrttu

rw*

around

t^^^^^.

^

ttqu^erytta)

pNM)t

rt^^o^

^^5S^

'C

^

rMpectt^ty.thfO^fMdt^n

"L*

N)ai<)

to^jMa."

;

^:;<^

'

^-'!^^

'.

'

-

-'--^--

='

^

'

.^

^

^3rR^

trippNd,

the

'temperatuF'^^t'^E

?t^rdund

the

famp

and?!qu!d

Ofyiitta)

^

^pane!trewetretptctfvwfyt^

"^

=

^

^ttmpwraturM

ba)ow73'C^nd48'C

/

^

aend!ng

an

'H''

tight!.

^^

If

an

abnonna)

condttfon

)t

detected

^

throuoh

input

chactf

at

p)n

33^h<

CPtLi^

automtt!caHy

turn<

the

pfojecfor

offthc!

operatw*

the

coo)tng

f<n

unti)

tht

"

'

[

tamperatMre

goat

down.

?

A!!

«t

kwyw

and

remotw

contFo)

ttwya

w))t

not

respond.

TECHN)CAL

SPEC)F)CAT)ONS

"^L

Portab)e

LCD

Projector

158

mm

x

430

mm

x

385

mm

23.2

)bs

(10.5

kg)

1.3"

TFT

Active

Matrix

type

(Thin

Fi)m

Transistor)

x

3

544.410(181.470

x3)

4

coiour

system

(PAL,

SECAM,

NTSC4.43

and

NTSC)

76

cm

to

381

cm

(30

to

150

inch)

Adjustabie

100:1

550

TV

tines

f2.8

-

3.2

tens

with

53

mm

-

69

mm

Manua)

zoom

and

focus

51.8

mm

1.5m-6.0m

MetaiHatide,

195

watt

Dichroic

mirror

system

PHONO

Type

x

1

(Video,

Audio

R

and

L)

and

DiN

4

(S-Video)

x

1

PHONO

Type

x

1

PHONO

Type

x

1

(R

and

L)

Stereo

Audio

Output

Jack

x

1

and

Wired

Remote

Jack

x

1

)NT.

SP.

Monaurai,

3

watt

RMS

(T.H.D.

10%)

Up

6

220-240VAC,50/60Hz

260

Watts

5^-35^

-10^C-60^C_____

AA,

UM3

or

R06

type

x

3

Remote

Contro!

Unit,

R/C

Cabte

(1.5

m),

AC

Power

Supply

Cord,

Lens

Cover

and

Owner's

instruction

Manua)

10

Sanyo PLC-400P User manual

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