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FILE NO. SERVICE MANUAL Multimedia Projector Model No. PLC-XP57L U.S.A., Canada, Europe, Asia, Africa, Original Version (Projection lens is optional.) Chassis No. KE6-XP57L00 NOTE: Match the Chassis No. on the unit’s back cover with the Chassis No. in the Service Manual.
Safety Instructions SAFETY PRECAUTIONS WARNING: The chassis of this projector is isolated (COLD) from AC line by using the converter transformer. Primary side of the converter and lamp power supply unit circuit is connected to the AC line and it is hot, which hot circuit is iden- tified with the line ( ) in the schematic diagram.
Specifications Projector Type Multi-media Projector Dimensions 12.6” x 6.6” x 16.8” (319 mm x 168 mm x 429.5 mm) (W x H x D) Net Weight 17.4 lbs (7.9 kg) LCD Panel System 1.3” TFT Active Matrix type, 3 panels Panel Resolution 1024 x 768 dots Number of Pixels...
Circuit Protections This projector is equipped with 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 The fuse is located inside of the projector. When either the LAMP indicator or the READY indicator is not illuminated, fuse may be opened.
Circuit Protections ● Warning temperature and power failure protection The WARNING TEMP. indicator flashes red and the projector will automatically turn off when the internal tempera- ture of the projector exceeds the normal temperature or when stopping cooling fans or when the internal power sup- ply lines are failed.
Mechanical Disassemblies Mechanical 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 otherwise it may cause loss of performance and product safety.
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Mechanical Disassemblies Main Board removal Remove 6 screws to take the Main Board upward. Main Board Fig.3 AV, I/F Board & Rear Panel removal FN905 Remove 1 screw and take the Rear Panel ass’y upward off. Remove 4 screws to take the fan (FN905) off. Remove 5 screws and 1 screw to take AV Board...
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Mechanical Disassemblies Lamp Ballast Unit removal FN904 Remove 4 screws to take the Ballast Cover upward off. Ballast Cover Remove 3 screws to take the Fan (FN904) and the Fan mounting base off. Remove 2 screws to take the Fan (FN904) off from the Fan mounting base.
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Mechanical Disassemblies Prism Base removal Remove 2 screws to take the Prism Base ass’y upward off. Remove 2 screws to take the Lens Shift Motor and Sensor SW Holder from the Base. Prism Base Ass’y Motor and Sensor Holder Fig.7 Power Board removal Remove 3 screws to take the Power Board off.
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Mechanical Disassemblies Filter Board & Interlock SW & Thermal SW removal Remove 1 screw to take Interlock Switch(SW902). Remove 2 screws to take Filter Board Holder and remove 2 screws to take Filter Board from the Holder. Remove 1 screw to take Thermal Switch(SW905).
Optical Parts Disassemblies Before taking this procedure, remove Cabinet Top and Main Board following to the “Mechanical Disassemblies”. Disassembly requires a 2.0mm or 2.5mm hex wrench and a slot screwdriver. Projection Lens removal Shift the Projection lens to the low end by the LENS SHIFT function. Remove Cabinet Front-Top following to the chapter “Mechanical Disassemblies”.
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Optical Pats Disassemblies Polarized Glass-In removal Remove each hex screw and pull the Polarized Glass-In ass’y upward. Remove each hex screw and pull the Optical Filter (HCP) ass'y upward. Remove the stoppers and take the polarized glasses and optical filters off upward.
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Optical Pats Disassemblies Polarized Glass-Out removal Remove 4 hex screws and take the LCD/Prism ass’y off upward. Remove 3 screws and take the Glass Holder, and then pull the polarized Glass-Out upwards off. These glasses are mounted for R, G and B LCD panels respectively.
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Optical Pats Disassemblies Optical Unit Top removal Remove 7 screws to take the Optical Unit Top off upward. Fig.5 Condenser Lens disassembly Remove 2 hex screws and take the Condenser Lens ass’y. Release 4 hooks to take the Lens off from the holder. * Lens should be placed as the flat surface side comes to the holder...
Optical Parts Disassemblies Locations and Directions Key No. Description When the optical parts in the optical unit mounting or assembling, the Condenser lens (R) parts must be mounted in the specified location and direction as Condenser lens shown in figure below. Condenser lens Mirror (B) Dichroic mirror (B...
LCD Panel/Prism Ass’y Replacement 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. When replacing the LCD panel, should be replaced whole of the LCD panels and prism ass’y at once.
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LCD Panel/Prism Ass'y Replacement Note on LCD Panel/Prism Ass’y There are 2 types combination of the LCD panel/prism assembly and the optical unit, named Type-R and Type-L. Since both have no compatibility, each type should be com- bined with the same type, and the specific parts should be used.
Lamp Replacement WARNING: ORDER REPLACEMENT LAMP - For continued safety, replace with a lamp assembly of the same type. Type No. Service Parts No. - Allow the projector to cool for at least 45 minutes before you open the POA-LMP101 610 328 7362 lamp cover.
Optical Adjustments Before taking optical adjustments below, remove the Cabinet Top and Main Board following to the “Mechanical Disassemblies” Adjustments require a 2.0mm hex wrench and a slot screwdriver. Note: Do not disconnect connectors K8L, K8X, K8D, K8G and K8E on the main board, because the projector can not turn on due to operate the power failure protection.
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Optical Adjustments Condenser Lens adjustment Turn the projector on by a state of without FPC cables. Adjust the adjustment base of condenser lens ass’y 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 2 screws with the 2.0mm hex driv-...
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Optical Adjustments Relay lens-Out adjustment Turn the projector on by a state of without FPC cables. Adjust the adjustment base of relay lens ass’y to make color unifor- mity in white. 1) If the cyan bar appears on the left or right of the screen as shown in Fig.4-1, loosen 1 screw with the 2.0mm hex driver, and White...
Electrical Adjustments Service Adjustment Menu Operation To enter the service mode To enter the “Service Mode”, press and hold the MENU and IMAGE button on the projector at the same time for more than 3 seconds, or press and hold the MENU button on the remote control unit for more than 20 seconds. The service menu appears on the screen as follows.
Electrical Adjustments Circuit Adjustments CAUTION: The each circuit has been made by the fine adjustment at factory. Do not attempt to adjust the follow- ing adjustments except requiring the readjustments in servicing otherwise it may cause loss of per- formance and product safety. WARNING : USE UV RADIATION EYE CAUTION: To prevent suffer of UV radia- AND SKIN PROTECTION...
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Electrical Adjustments Fan Voltage adjustment PSIG adjustment 1. Enter the service mode. 1. Receive the 16-step gray scale computer signal with 2. Connect a digital multimeter to test point “ ” (+) and Input 1 [RGB(Analog)] mode. chassis ground (-). (as shown below) 2.
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Electrical Adjustments PC Input adjustment Common Center adjustment 1. Receive the 16-step gray scale computer signal with 1. Receive the 16-step gray scale computer signal with Input 1 [RGB(Analog)] mode. Input 1 [RGB(Analog)] mode. 2. Enter the service mode. 2. Enter the service mode. 3.
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Electrical Adjustments ⁄2 AV Gamma-shift adjustment NOTE ON WHITE UNIFORMITY 1. Receive the 100% whole-white composite video sig- ADJUSTMENT nal with Input 3 [Video] mode. 2. Enter the service mode. If you find the color shading on the screen, please 3.
Electrical Adjustments Service Adjustment Data Table These initial values are the reference data written from the CPU ROM to memory IC when replaced new memory IC. The adjust- ment items indicated with “✻” are required to readjust following to the “Electrical adjustments”. Other items should be used with the initial data value.
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Electrical Adjustments Group No. Adjustment Item Initial Value Range Input source / Description Lamp Go Out Lamp Go Out 0: Disable / 1: Enable Lamp Replace Display Display when lamp replace time 0 / 1 0: Disable / 1: Enable RC KEY Disable RC KEY Front/Rear Disable 0 / 1 / 2 / 3...
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Electrical Adjustments Group No. Adjustment Item Initial Value Range Input source / Description Real G_GAM_BRT -4096 ~ 4095 Differential data of white balance adjustment at Real mode Real B_GAM_BRT -4096 ~ 4095 Real R_GAM_BRT -4096 ~ 4095 Real G_BRT_CTRL -128 ~ 127 Differential data of white-white level adjustment at Real mode Real B_BRT_CTRL -128 ~ 127...
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Electrical Adjustments Group No. Adjustment Item Initial Value Range Input source / Description Total Dots 0 ~ 3000 Read only Disp Dots 0 ~ 3000 H Back Porch 0 ~ 3000 V Back Porch 0 ~ 3000 Disp Line 0 ~ 1500 Not used VSBEG 0 ~ 15...
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Electrical Adjustments Group No. Adjustment Item Initial Value Range Input source / Description Total Dots 1980 0 ~ 3000 Read only Disp Dots 1250 0 ~ 3000 H Back Porch 0 ~ 3000 V Back Porch 0 ~ 3000 Disp Line 0 ~ 1500 Not used VSBEG...
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Electrical Adjustments Group No. Adjustment Item Initial Value Range Input source / Description Total Dots 1980 0 ~ 3000 Read only Disp Dots 1250 0 ~ 3000 H Back Porch 0 ~ 3000 V Back Porch 0 ~ 3000 Disp Line 0 ~ 1500 Not used VSBEG...
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Electrical Adjustments Group No. Adjustment Item Initial Value Range Input source / Description Total Dots 2200 0 ~ 3000 Disp Dots 1874 0 ~ 3000 H Back Porch 0 ~ 3000 V Back Porch 0 ~ 3000 Disp Line 1050 0 ~ 1500 Not used VSBEG...
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Electrical Adjustments Group No. Adjustment Item Initial Value Range Input source / Description Alpha Brightness /120/120/120/120 /120/120/120 120/120/120/120 Alpha Color /120/120/120/120 /120/120/120 10/10/10/10 Alpha Tint /10/10/10/10 /10/10/10 10/10/10/10 Alpha Sharpness /10/10/10/10 /10/10/10 Auto Calibration Execute Calibration 0 ~ 1 Execute Auto Calibration when the value changes. Loop Count 1 ~ 30 Maximum Loop with OFFSET -->...
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Electrical Adjustments Group No. Adjustment Item Initial Value Range Input source / Description 2:2pull down setting 22Film Mode Sensitivity 1 ~ 5 Film Detection Sensitivity <FILMSTVT22> 22Film Mode Threshold Low 0 ~ 32767 <FILMTHRD22A> 22Film Mode Threshold High 0 ~ 32767 <FILMTHRD22B>...
Chassis Description LED indication and projector condition Check the indicators for projector condition. Indicators Projector Condition LAMP WARNING READY LAMP REPLACE TEMP. green yellow ● ● ● ● The projector is OFF. (The AC power cord is unplugged.) The projector is ready to be turned on with the POWER ON- ✽...
Chassis Description Power failure detection system Detection of Power failure The projector provides a protection circuit to prevent the secondary failure when the power failure, fans failure or tem- perature failure occurs on the projector. The power failure detection lines "MAIN_6V_PF", "MAIN_-5V_PF", etc. are connected to the main power supplies.
Chassis Description Diagnosis of power failure with RS-232C port This projector provides a function to get the error information of the projector by using the RS-232C serial port for the power failure diagnosis. The further error information of the power failure and fan failure can be found out by using this function. Diagnosis procedure Connect a RS-232C serial cross cable to SERIAL PORT IN on the projector and serial port on the PC.
Chassis Description Error history log The projector provides the error history log function. To check the logs, you need to enter the service mode and select Group No. "91" and Item No. "0" to "49". The error code is displayed on the Data column. The description of the error code is listed on the table below.
Control Port Functions ● System Control & I/O Port Table (IC801, HD6417727F) Pin No. Function Name Function Polarity 1.9V Power for RTC(1.9V) (Not used) X'TAL for built-in RTC (Open) 1.9V X'TAL for built-in RTC (Vcc) Power for RTC(0V) Clock mode setting [Default:L] L fixed Clock mode setting [Default:L] L fixed...
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Control Port Functions Pin No. Function Name Function Polarity Address Bus Address Bus Address Bus Address Bus Address Bus Address Bus Address Bus Power for Input/Output(0V) Address Bus 3.3V Power for Input/Output(3.3V) Address Bus Address Bus Address Bus Address Bus Address Bus Address Bus Address Bus...
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Control Port Functions Pin No. Function Name Function Polarity Power (0V) PW_RESET Reset for PW Reset with L>H>L 1.9V Power (1.9V) PW_SEL PIXEL 232C Selection SH:H, PW:L EXP_RESET I/O Expander Reset Signal Reset: H RESET_GAM Reset for Digital Gamma IC TDO [for ICE] Test Data output (Not used)
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Control Port Functions Pin No. Function Name Function Polarity NET_SW Switch On/Off for PJ-Net Power L:On, H: Off Power for Inout/Output(0V) FPGA_CLB Initialize for circuit H after config. 3.3V Power for Inout/Output(3.3V) SYS SW_CPU Bus Switch IC_RESET_CPU Power Control peripheral ICs LAMP_SWIN Lamp Drive H: On, L: Off...
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Control Port Functions ● Parallel I/O Expander (IC4801, TIC81592GP) Pin No. Function Name Function Polarity S3.3V Clock input (14.7456MHz) XOUT Open S3.3V Data Bus 7 Data Bus 6 Data Bus 5 Data Bus 4 Data Bus 3 Data Bus 2 Data Bus 1 Data Bus 0 Address 5...
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Control Port Functions Pin No. Function Name Function Polarity M/A_PF Power Fail Detection M/A L: Error FAN_PF Power Fail Detection FAN L: Error SWF_1.2V_PF Power Fail Detection SWF_1.2V L: Error SWF_2.5.V_PF Power Fail Detection SWF_2.5V L: Error VDEC_1.8V_PF Power Fail Detection VDEC_1.8V L: Error FPGA_1.5V_PF Power Fail Detection FPGA_1.5V...
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Control Port Functions ● I/O Port Table (IC301, PW388B) Pin No. Name Function Name Function Polarity Port A7 PW_SCL_DDC_D Port A6 PW_SDA_DDC_D Port A5 PW_SCL_3V Port A4 PW_SDA_3V Port A3 PW_SCL_EEP Port A2 PW_SDA_EEP Port A1 PW_SCL_DDC_A Port A0 PW_SDA_DDC_A Port B7 SC_SEM_DPRAM H fixed...
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.
KE6-XP57L00 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.
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KE6-XP57L00 Electrical Parts List Note: Parts order must contain Chassis No., Part No., and Descriptions. ● OUT OF CIRCUIT BOARD RC Front Board Sensor1 Board FN901 Intake Fan FN904 Cooling Fan Drive Board Power Board Sub Power Main Board Board Lamp Ballast FN902 Board...
KE6-XP57L00 Optical Parts List Key No. Part No. Description Key No. Part No. Description OPTICAL PARTS TYPE-R 610 328 6488 ASSY,LCD PNL/PRISM R-KE6A 645 041 3711 ASSY,PRISM(PBS) (Including Key No. 71-a to e) 645 051 9420 ASSY,PRISM(PBS) 71-a 645 085 8017 POLARIZED GLASS(OUT/R) 71-b 645 085 8024...
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KE6-XP57L00 Optical Parts List Note: Parts order must contain Chassis No., Optical Unit Type-L or Type-R, Part No., and Descriptions. NOTE: There are 2 types combination of the LCD panel/prism assembly and the optical unit, named Type-R and Type-L. Since both have no compatibility, each type should be combined with the same type, and the specific parts should be used.
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KE6-XP57L00 Optical Parts List CAUTION: Part must be placed in specified direction when replacing the optical parts. Please see “Optical Parts Disassemblies” for further instructions. -103-...
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SANYO Electric Co., Ltd. (KE6AL) JUN. 2006 BB 400 Printed in Japan...
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PLC-XP57L KE6-XP57L00 These schematic diagrams and printed wiring board drawings are part of the serv- ice manual original for chassis No. KE6-XP57L00, model PLC-XP57L. File with the service manual No. SM5110792-00. Note: All the information of part numbers and values indicated on these diagrams are at the beginning of production.
■ Parts description and reading in schematic diagram KE6-XP57L00 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.
■ Schematic Diagrams CAUTION Fuse of the specified parts number must be used. DRIVE Unauthorized substitutions may result in fire or accident. IC1631 IC1632 R1644 1/10GJ TDA7056AT TDA7056AT 560KC POWER C1636 K911P K911S 16EM K16N 2205D J11MC J11MB J10EP041G 020N 020N SP901 FILTER...
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LENS SUB POWER SUB POWER SUB POWER SUB POWER SHIFT CONTROL SENSOR 1 DRIVE TEMP-SENSOR "K66F" "K66E" "K66D" "K66H" "K68A" "K16I" "K9C" "K16R" K47A R1826 TO:SH3 JTAG 1/16GZ0A J10EG135G J11B4050G J10EP131G J10EG105G SH_SDA_S5V J10EP041G J10EP121G C1813 R1827 IC1816 25KZ J10EG065G 1/16GZ0A 0.1MNF J10EG095G...
■ Printed Wiring Board Diagrams ! CAUTION RC FRONT (SIDE:A) RC FRONT (SIDE:B) 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 1AA4B10C4460C JAPAN sides (secondary circuit) at the same time.
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MAIN (SIDE:A) LENS SHIFT CONNECT RC FRONT “K28A” SUB POWER “K66E” SUB POWER “K66D” CONTROL “K68A” “K9C” C2591 C2589 K47A K25R C2588 C2586 TP563 C4808 R4854 R4853 TP561 RB561 RB562 R4851 R561 R4848 FAN2 FAN1 R501 R4846 R4843 TP_VOL R502 RB1561 B-LCD PANEL C566...
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LAMP BALLAST MAIN (SIDE:B) SUB POWER “CJ2” “K66F” SENSOR1 “K16I” R2584 DRIVE “K16R” R2583 IC2581 R5855 R5869 R5847 R5894 R5802 C5804 RB4701 L563 RB4702 C4705 R5851 Q1861 R1563 C7881 R9824 SUB POWER R2501 R874 C2503 C507 R875 R869 R4757 R876 R872 R4756 R2567...