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Sanyo PLC-XL45 Service Manual

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SERVICE MANUAL

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. does not match the unit's, addi-
tional Service Literature is required. You must
refer to "Notices" to the Original Service Manual
prior to servicing the unit.
PRodUCt CodE
1 122 373 00
(KZ6AC)
1 122 374 00
(LZ6AC)
1 122 374 02
(LZ6CC)
Multimedia Projector
FILE NO.
Model No. PLC-XL45
U.S.A. Canada
Europe, U.K
original Version
Chassis No. KZ6-XL4500
REFERENCE NO.
SM
5110900-00

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Summary of Contents for Sanyo PLC-XL45

  • Page 1: Service Manual

    FILE NO. SERVICE MANUAL Multimedia Projector Model No. PLC-XL45 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. KZ6-XL4500 Chassis No.

  • Page 2: Table Of Contents

    Contents Safety Instructions ............3 IC Block Diagrams ............51 SAFETY PRECAUTIONS ........... 3 Electrical Parts List ............57 PRODUCT SAFETY NOTICE ........3 Electrical Parts Location ........... 58 SERVICE PERSONNEL WARNING ......3 Mechanical Parts List ..........79 Specifications ..............4 Cabinet Parts Location ..........

  • 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 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.

  • Page 4: Specifications

    Specifications Mechanical Information Projector Type Multi-media Projector Dimensions (W x H x D) 10.50" x 4.86" x 9.58" (320mm x 148mm x 292mm) (Not including adjustable feet) Net Weight 7 .1 lbs (3.2kgs) 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 KHz~ 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 2.49’ - 3.38’ (0.76m - 1.03m) Projection Lamp 200W Interface Video Input Jack RCA Type x 1 S-Video Input Jack Mini DIN 4 pin x 1...

  • Page 5: Circuit Protections

    Circuit Protections This projector provides the following circuit protections to operate in safety. If the abnormality occurs inside the projec- tor, 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.

  • Page 6: Warning Temperature And Power Failure Protection

    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.

  • Page 7: Security Function Notice

    Security Function Notice This projector provides security functions such as "Key lock", "PIN code lock" and "Logo PIN code lock". When the pro- jector 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.

  • Page 8: Lamp Replacement

    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.

  • Page 9: Mechanical Disassembly

    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 lead (M.5x6)x8 (M4x5) Rear panel FN905 (T3x8) Main board SP901 Fig.2 -10-...
  • Page 11 Mechanical disassembly Power, Line Filte, Ballast Board, Thermal Sw(SW902), Fan(FN906) removal Isolation sheet Power board (T3x6)x4 (T3x6) (T3x6) (T3x6)x (T3x6)x4 (T3x6) Thermal switch (SW90) Line Filter board (T3x6) (M3x8) Ballast board FN906 Ballast socket FN906 (T3x6)(Black) (T3x6)(Black) Fig.3 -11-...
  • Page 12 Mechanical disassembly Optical Unit, Fans(FN903, FN904), Noise Filter removal (T3x8)x6 (T3x1)x Optical unit (T3x6) (T3x10)x4 (T3x6)x (T3x6)x3 FN904 (T3x8) Noise filter FN903 Fig.4 -1-...

  • Page 13: Optical Parts Disassembly

    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 14 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 -14-...
  • Page 15 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.

  • Page 16: Panel Type Check

    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 17 optical Parts disassembly Polarized glass, Pre-polarized glass removal (Mx) (Mx) (Green) Pre-Polarized Glass(G) (Red) Polarized Glass(G) (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.

  • Page 18: Locations And Directions

    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)

  • Page 19: Adjustments

    Adjustments Adjustments after Parts Replacement ● : Adjustment necessary ❍ : Check necessary Disassembly / Replaced Parts Polarized glass Integrator Relay Power LCD/ Main Board Prism Ass’y Lens (OUT) Lens (OUT) Board Contrast Adjustment R-Contrast adjustment ● G-Contrast adjustment ● B-Contrast adjustment ● Integrator lens adjustment ❍ ●...

  • Page 20: Optical Adjustments

    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.

  • Page 21: Integrator Lens Adjustment

    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 22 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 White in Fig.3, loosen 1 screw , and adjust the slot...

  • Page 23: Electrical Adjustments

    Electrical Adjustments Service Adjustment Menu Operation to enter the service mode To enter the “Service Mode”, press and hold the MENU and INPUt buttons on the projector at the same time for more than 3 seconds. The service menu appears on the screen as follows. to adjust service data Select the adjustment group no.

  • Page 24: Circuit Adjustments

    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 perfor- mance and product safety. [Adjustment Condition] 16 steps gray scale pattern ●...
  • Page 25 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.

  • Page 26: Common Center Adjustment

    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. .

  • Page 27: Test Points And Locations

    Electrical Adjustments Test Points and Locations MAIN BoARd -7-...

  • Page 28: 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. 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 29 Electrical Adjustments Item No. NAME Device Range Description Component Video HDTV 480p 480i NTSC CRDLY uPD64012 PHBDL uPD64012 PHRDL uPD64012 CBOFS uPD64012 CROFS uPD64012 FRCENY uPD64012 FRCENC uPD64012 DLYCTL uPD64012 OUTBITW uPD64012 CLKOINV uPD64012 RDOSEL uPD64012 SQCBCR uPD64012 ACTVH uPD64012 HPOSI uPD64012 HSPOS uPD64012...
  • Page 30 Electrical Adjustments Item No. NAME Device Range Description Component Video HDTV 480p 480i NTSC VIDEO S-VIDEO YCBCR SCART NTSC / PAL NSTC / PAL 480i / 575i 480i / 575i SBCNT uPD64012 109 / 111 104 / 106 108 / 108 102 / 102 SBCLRU uPD64012 SBCLRV uPD64012 YCONR uPD64012 CCONR uPD64012 YCORB uPD64012 YCOREN uPD64012 YCORH uPD64012 CCORB uPD64012...
  • Page 31 Electrical Adjustments Item No. NAME Device Range Description Component Video HDTV 480p 480i NTSC B-BasePos L3E07110 0-15 RGB-Ajust L3E07110 RGB-AdjLv L3E07110 0-1023 LineR0 L3E07110 0-255 LineR1 L3E07110 0-255 LineR2 L3E07110 0-255 LineR3 L3E07110 0-255 LineR4 L3E07110 0-255 LineG0 L3E07110 0-255 LineG1 L3E07110 0-255 LineG2...
  • Page 32 Electrical Adjustments Item No. NAME Device Range Description Component Video HDTV 480p 480i NTSC R-DCOffset-N6 L3E07110 Normal:0/Ceiling:0 0-511 R-DCOffset-N7 L3E07110 Normal:0/Ceiling:0 0-511 R-DCOffset-N8 L3E07110 Normal:0/Ceiling:0 0-511 R-DCOffset-N9 L3E07110 Normal:0/Ceiling:0 0-511 R-DCOffset-N10 L3E07110 Normal:0/Ceiling:0 0-511 R-DCOffset-N11 L3E07110 Normal:0/Ceiling:0 0-511 R-DCOffset-N12 L3E07110 Normal:0/Ceiling:0 0-511 G-DCOffset-NGain L3E07110...
  • Page 33 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 (NORMAL) PW186 1000 0-10000 Normal lamp warning time Lamp Warning Time (ECO) PW186 2000 0-10000 Eco lamp warning time Lamp life test enable PW186 0:Disable 1:Enable For safety test purpose...
  • Page 34 Electrical Adjustments Item No. NAME Device Range Description Component Video HDTV 480p 480i NTSC DIMMER_CTRL_LEVEL3 PW186 0-255 DIMMER_CTRL_LEVEL4 PW186 0-255 DIMMER_CTRL_LEVEL5 PW186 0-255 DIMMER_CTRL_LEVEL6 PW186 0-255 DIMMER_CTRL_LEVEL7 PW186 0-255 DIMMER_CTRL_LEVEL8 PW186 0-255 DIMMER_CTRL_LEVEL9 PW186 0-255 DIMMER_CTRL_LEVEL10 PW186 0-255 DIMMER_CTRL_LEVEL11 PW186 0-255 DIMMER_CTRL_LEVEL12 PW186 0-255...
  • Page 35 Item No. NAME Device Range Description Component Video HDTV 480p 480i NTSC NOR_TEMP_FAN2_MIN 0-255 FAN2 Control start temp.at Normal NOR_TEMP_FAN2_MAX 0-255 FAN2 Control end temp. at Normal NOR_VALU_FAN1_MIN 0-255 FAN1 Control Min at Nromal (0:0V, 255:25.5V) NOR_VALU_FAN1_MAX 0-255 FAN1 Control Max at Normal NOR_VALU_FAN2_MIN 0-255 FAN2 Control Min at Normal NOR_VALU_FAN2_MAX 0-255 FAN2 Control Max at Normal ECO_TEMP_FAN1_MIN 0-255 FAN1 Control start temp.at Eco ECO_TEMP_FAN1_MAX 0-255 FAN1 Control end temp. at Eco ECOTEMP_FAN2_MIN 0-255 FAN2 Control start temp.at Eco ECO_TEMP_FAN2_MAX 0-255 FAN2 Control end temp. at Eco ECO_VALU_FAN1_MIN 0-255...
  • Page 36 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 Image LevelUpdate [ OFFSET ]...
  • Page 37 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) PW186 1050...
  • Page 38 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 Group 546 OverScan RGB 575p...

  • Page 39: Chassis Block Diagrams

    Chassis Block Diagrams Chassis over view -39-...

  • Page 40: System Control

    Chassis Block diagrams System control IC891 INVERTER <MH74LVC> MONIT_OUT IC3571 <M62334> IC301 IC1801 SYSTEM CONTROL I/O EXPANDER -40-...

  • Page 41: Power Supply & Protection Circuit

    Chassis Block diagrams Power supply & protection circuit IC631 POWER OSC. <STR-Z2156> IC621 P.F.CONTROL <FA5502> PWM_120HZ FAN_ERR IC301 SYSTEM CONTROL -41-...

  • Page 42: Fan Control Circuit

    Chassis Block diagrams Fan control circuit TPFANA Q7812 FN904 S15.5V FANA D3621 D3613 Q7811 FN903 IC7811 D3622 Q7813 FN906 D3624 TPFANB D5621 Q7862 FN901 FANB D3623 FN902 D3614 Q7861 IC7861 D3626 FN905 Q7864 D3627 Q3601 POWER_FAIL P_FAIL P_Fail: H FAN_ERR Power Error: On SIGNAL/MODE POWER-ON...

  • Page 43: Troubleshooting

    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.

  • Page 44: No Power

    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.

  • Page 45: No Picture

    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.

  • Page 46: No Sound

    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.

  • Page 47: Control Port Functions

    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...

  • Page 48: I/O Expander Port Functions (Ic1801)

    Control Port Functions I/O Expander Port Functions (IC1801) PIN NO . NAME FUNCTION ACTION S_SW Scart switch H: Scart WAKEUP WAKEUP RESET L - H: Reset XTAL IN XTAL OUT DDC_SW2 READY_LED Ready LED Drive H: On S/CV_SW S-Video/Video Switch H: Composite Video-in SC_SW SCART In Switch H: Scart In RESET_N USB_VBUS AIN1 Option Switch AIN2 Option Switch AIN3 Option Switch AIN4 Option Switch AIN5 Option Switch AIN6...

  • Page 49: Waveform

    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> -49-...

  • Page 50: Cleaning

    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 51: Ic Block Diagrams

    IC Block Diagrams ● Ad9883 <A/d, IC8201> CLAMP oUtA CLAMP oUtA CLAMP oUtA MIdSCV HSYNC dtACK SYNC CoASt PRoCESSING HSoUt ANd CLoCK CLAMP VSoUt GENERAtIoN SoGoUt FILt BYPASS SERIAL REGIStER Ad9883A PoWER MANAGEMENt ● AN5870 <RGB,SYNC-SW, IC5201> -51-...
  • Page 52 IC Block diagrams ● BA7078 <Sync Separator, IC5301> ● BA9743<ddC Control, IC5651> -5-...
  • Page 53 IC Block diagrams ● FA5502 <P.F. Control, IC621> ● L3E01060 <LEVEL SHIFt, IC2501, IC2531, IC2561> -53-...
  • Page 54 IC Block diagrams ● L3E06150 <d/A S&H, IC501, IC531, IC561> ● L3E07110 <LCd driver & Gamma Correction IC401> -54-...
  • Page 55 IC Block diagrams ● M62334 <d/A, IC3571> ● NJW1141 <Audio Control, IC5001> -55-...
  • Page 56 IC Block diagrams ● StR-Z2156A <Power Switching, IC631> ● uPd64012 <Video decoder, IC101> -56-...

  • Page 57: Electrical Parts List

    KZ6-XL4500 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 58: Electrical Parts Location

    KZ6-XL4500 Electrical Parts List Electrical Parts Location ● Assemblied Boards Main Board Power Board Line Filter Board A901 Ballast Board R/C Board ● oUt oF CIRCUIt BoARd LF901 Noise Filter FN904 Cooling Fan(G) FN905 Cooling Fan(PBS) SP901 Speaker FN903 Cooling Fan(B) FN901 FN906 Cooling Fan(Main)
  • Page 59 KZ6-XL4500 Electrical Parts List Key No. Part No. Description Key No. Part No. Description Q643 305 217 6600 TR 2SK3934 Q651 305 014 4512 TR 2SC2412K T146 R ASSEMBLED BOARDS 305 014 4611 TR 2SC2412K T146 S 305 015 8727 TR 2SC2812-L6-TB 610 334 8797 ASSY,PWB,POWER KZ6AC 305 015 8925 TR 2SC2812-L7-TB 610 334 8889 ASSY,PWB,LINE FILTER KZ6AC 305 163 1615 TR 2SC2812N-L6-TB0 610 334 8810 ASSY,PWB,MAIN KZ6AC 305 173 9816 TR 2SC3928A1R 305 173 9915 TR 2SC3928A1S 610 334 8773 ASSY,PWB,R/C KZ6AC Q661...
  • Page 60 KZ6-XL4500 Electrical Parts List Key No. Part No. Description Key No. Part No. Description C655 303 164 0217 CERAMIC 0.1U Z R658 301 150 6212 MT-GLAZE 1K JA 1/10W C656 303 345 9619 CERAMIC 0.47U K R659 301 150 6212 MT-GLAZE 1K JA 1/10W C657 303 157 6417 CERAMIC 330P K R660 301 162 3711 MT-GLAZE 4.7K JA 1/10W C658 303 157 6417 CERAMIC...
  • Page 61 KZ6-XL4500 Electrical Parts List Key No. Part No. Description Key No. Part No. Description 305 014 4611 TR 2SC2412K T146 S C 602 304 079 5608 MT-POLYEST 0.47U M 275V 305 015 8727 TR 2SC2812-L6-TB 304 094 2002 MT-POLYEST 0.47U K 275V 305 015 8925 TR 2SC2812-L7-TB RESISTOR 305 163 1615 TR 2SC2812N-L6-TB0 R 601 301 287 9018 MT-GLAZE 470K JA 305 173 9816 TR 2SC3928A1R R 602 301 287 9018 MT-GLAZE...
  • Page 62 KZ6-XL4500 Electrical Parts List Key No. Part No. Description Key No. Part No. Description 305 014 4611 TR 2SC2412K T146 S 305 163 1615 TR 2SC2812N-L6-TB0 305 015 8727 TR 2SC2812-L6-TB 305 173 9816 TR 2SC3928A1R 305 015 8925 TR 2SC2812-L7-TB 305 173 9915 TR 2SC3928A1S Q5031 305 014 4512 TR 2SC2412K T146 R 305 163 1615 TR 2SC2812N-L6-TB0 305 014 4611 TR 2SC2412K T146 S 305 173 9816 TR 2SC3928A1R 305 015 8727 TR 2SC2812-L6-TB 305 173 9915 TR 2SC3928A1S Q5203 305 014 4512 TR 2SC2412K T146 R 305 015 8925...
  • Page 63 KZ6-XL4500 Electrical Parts List Key No. Part No. Description Key No. Part No. Description Q6841 305 014 4512 TR 2SC2412K T146 R 305 163 1615 TR 2SC2812N-L6-TB0 305 014 4611 TR 2SC2412K T146 S 305 173 9816 TR 2SC3928A1R 305 015 8727 TR 2SC2812-L6-TB 305 173 9915 TR 2SC3928A1S Q5284 305 014 4512 TR 2SC2412K T146 R 305 015 8925 TR 2SC2812-L7-TB 305 014 4611 TR 2SC2412K T146 S 305 163 1615 TR 2SC2812N-L6-TB0 305 015 8727 TR 2SC2812-L6-TB 305 173 9816 TR 2SC3928A1R 305 173 9915 TR 2SC3928A1S 305 015 8925...
  • Page 64 KZ6-XL4500 Electrical Parts List Key No. Part No. Description Key No. Part No. Description C141 403 461 3710 CERAMIC 0.1U Z IC3571 309 431 4424 IC M62334FP-DF5Q 303 454 0514 CERAMIC 0.1U Z IC3801 309 565 9613 IC SP232AEN-L IC4011 310 358 1506 IC TC74HC4053AFT(EL) 303 343 3718 CERAMIC 0.1U Z IC4071 310 348 7501 IC TC7WT241FU(TE12L) C142 403 461 3710 CERAMIC 0.1U Z IC4891 309 404 7213 IC TC7SET00FU-(TE85L)
  • Page 65 KZ6-XL4500 Electrical Parts List Key No. Part No. Description Key No. Part No. Description 303 343 3718 CERAMIC 0.1U Z C164 403 461 3710 CERAMIC 0.1U Z C1821 403 461 3710 CERAMIC 0.1U Z 303 454 0514 CERAMIC 0.1U Z 303 454 0514 CERAMIC 0.1U Z 303 343 3718 CERAMIC 0.1U Z C165 403 461 3710 CERAMIC 0.1U Z 303 343 3718 CERAMIC 0.1U Z 303 454 0514 CERAMIC...
  • Page 66 KZ6-XL4500 Electrical Parts List Key No. Part No. Description Key No. Part No. Description 303 343 3718 CERAMIC 0.1U Z 303 373 5218 CERAMIC 1U Z 6.3V C311 403 461 3710 CERAMIC 0.1U Z C2543 303 396 9613 CERAMIC 1U K 303 454 0514 CERAMIC 0.1U Z C2544 303 391 5511 ELECT 10U M 303 175 7212 ELECT 10U M 303 343 3718 CERAMIC 0.1U Z C2564...
  • Page 67 KZ6-XL4500 Electrical Parts List Key No. Part No. Description Key No. Part No. Description C413 303 453 8016 CERAMIC 1U Z 6.3V C3532 303 396 9613 CERAMIC 1U K 303 454 1313 CERAMIC 1U Z 6.3V C3533 303 391 5115 ELECT 100U M 303 373 5218 CERAMIC 1U Z 6.3V 303 296 9515 ELECT 100U M C3534 303 396 9613 CERAMIC 1U K C414...
  • Page 68 KZ6-XL4500 Electrical Parts List Key No. Part No. Description Key No. Part No. Description C5081 303 379 6714 CERAMIC 10U K C5002 303 454 0613 CERAMIC 0.01U K C5083 303 394 1312 ELECT 100U M 6.3V C5003 303 454 0613 CERAMIC 0.01U K 303 387 4917 ELECT 100U M 6.3V C5004 303 453 8917 CERAMIC 0.1U K 303 453 8610 CERAMIC 0.1U K C5084...
  • Page 69 KZ6-XL4500 Electrical Parts List Key No. Part No. Description Key No. Part No. Description C5609 303 391 5115 ELECT 100U M C5311 303 453 6319 CERAMIC 100P J 303 296 9515 ELECT 100U M 303 454 0910 CERAMIC 100P J C561 303 453 8016 CERAMIC 1U Z 6.3V 303 294 6110 CERAMIC 100P J C5312 303 323 8818 CERAMIC 2.2U Z 303 454 1313 CERAMIC 1U Z...
  • Page 70 KZ6-XL4500 Electrical Parts List Key No. Part No. Description Key No. Part No. Description C7868 303 454 1917 CERAMIC 4700P K 303 454 0514 CERAMIC 0.1U Z C7871 303 381 5316 ELECT 100U M 303 343 3718 CERAMIC 0.1U Z C7872 303 381 5316 ELECT 100U M C5687 303 394 1312 ELECT 100U M 6.3V 303 387 4917 ELECT 100U M 6.3V 303 369 3211 ELECT...
  • Page 71 KZ6-XL4500 Electrical Parts List Key No. Part No. Description Key No. Part No. Description C8272 403 461 3710 CERAMIC 0.1U Z R1042 301 224 8814 MT-GLAZE 100 JA 1/16W 303 454 0514 CERAMIC 0.1U Z R1043 301 226 1516 MT-GLAZE 0.000 ZA 1/16W 303 343 3718 CERAMIC 0.1U Z R1044 301 224 9019 MT-GLAZE 10K JA 1/16W C8273 403 461 3710 CERAMIC 0.1U Z...
  • Page 72 KZ6-XL4500 Electrical Parts List Key No. Part No. Description Key No. Part No. Description R1832 301 224 9019 MT-GLAZE 10K JA 1/16W R3051 301 224 8913 MT-GLAZE 100K JA 1/16W R3052 301 224 8814 MT-GLAZE 100 JA 1/16W R1833 301 224 8814 MT-GLAZE 100 JA 1/16W R1834 301 224 9019 MT-GLAZE 10K JA 1/16W R3053 301 224 8913 MT-GLAZE 100K JA 1/16W...
  • Page 73 KZ6-XL4500 Electrical Parts List Key No. Part No. Description Key No. Part No. Description R5038 301 224 9019 MT-GLAZE 10K JA 1/16W R3804 301 225 0213 MT-GLAZE 3.3K JA 1/16W R5039 301 229 7218 MT-GLAZE 18K JA 1/16W R3806 301 224 9019 MT-GLAZE 10K JA 1/16W R5041 301 224 9316 MT-GLAZE 1K JA 1/16W R381 301 224 9019 MT-GLAZE 10K JA 1/16W...
  • Page 74 KZ6-XL4500 Electrical Parts List Key No. Part No. Description Key No. Part No. Description R5286 301 225 1319 MT-GLAZE 470 JA 1/16W R5698 301 224 9316 MT-GLAZE 1K JA 1/16W R5699 301 287 2029 MT-GLAZE 100K FA 1/16W R5287 301 225 1319 MT-GLAZE 470 JA 1/16W R5288 301 224 9019 MT-GLAZE 10K JA 1/16W R570 301 294 3115 MT-GLAZE 1K FA 1/16W...
  • Page 75 KZ6-XL4500 Electrical Parts List Key No. Part No. Description Key No. Part No. Description 945 037 0824 R-NETWORK 22X4 1/16W R7866 301 237 2915 MT-GLAZE 51 JA 1/16W RB104 945 034 5051 R-NETWORK 22X4 1/32W R7868 301 276 3010 MT-GLAZE 75K JA 1/16W 945 037 0824 R-NETWORK 22X4 1/16W R7869 301 224 8913 MT-GLAZE 100K JA 1/16W R7871 301 225 0114 MT-GLAZE 27K JA 1/16W...
  • Page 76 KZ6-XL4500 Electrical Parts List Key No. Part No. Description Key No. Part No. Description L1071 945 068 8349 FILTER,EMI 400MHZ D3051 307 163 0414 DIODE 1SS352-(TPH3) L108 301 037 5017 MT-GLAZE 0.000 ZA 1/10W 307 149 0810 DIODE 1SS355-TE-17 L1081 945 068 8332 FILTER,EMI 200MHZ D3501 307 163 0414 DIODE 1SS352-(TPH3) L109 301 037 5017 MT-GLAZE 0.000 ZA 1/10W 307 149 0810 DIODE 1SS355-TE-17 L1091 945 068 8332 FILTER,EMI 200MHZ...
  • Page 77 KZ6-XL4500 Electrical Parts List Key No. Part No. Description Key No. Part No. Description 307 209 1214 ZD UDZS-TE-176.2B SC5602 945 076 3503 SURGE-ABSORBER D6803 307 223 1115 ZENER DIODE 02DZ6.2Y(TPH3 SC5603 945 076 3503 SURGE-ABSORBER 307 209 1214 ZD UDZS-TE-176.2B SC5607 945 076 3503 SURGE-ABSORBER D6804 307 223 1115 ZENER DIODE 02DZ6.2Y(TPH3 SC5608 945 076 3503 SURGE-ABSORBER 307 209 1214 ZD UDZS-TE-176.2B SC5691 945 076 3503 SURGE-ABSORBER D6831 307 209 7414...
  • Page 78 KZ6-XL4500 Electrical Parts List Key No. Part No. Description Key No. Part No. Description 945 054 1149 CORD,POWER-3.138MK MISCELLANEOUS 610 332 3299 STRAP COMP-LK6AC 945 073 4855 CABLE,INTERFACE VGA -78-...

  • Page 79: Mechanical Parts List

    KZ6-XL4500 Mechanical Parts List Cabinet Parts Location C03-b C3-a -79-...

  • Page 80: Optical Parts Location

    KZ6-XL4500 Mechanical Parts List Optical Parts Location Integrator Lens-In (Integrator-In) Relay Lens-Out (Relay-out) -80-...
  • Page 81 KZ6-XL4500 Mechanical Parts List Polarized Glass-In (Polarized-in-R) (Polarized-in-G) (Polarized-in-B) Projection Lens (Projection) -81-...
  • Page 82 KZ6-XL4500 Mechanical Parts List Prism/LCD Panel Assy (Red) (Green) L01-d L01-b L01-e (Blue) L01-a L01-c (Prism/LCD panel Ass'y) -8-...
  • Page 83 KZ6-XL4500 Mechanical Parts List In the Optical Unit -83-...

  • Page 84: Mechanical Parts List

    KZ6-XL4500 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 L15 945 077 8347 POLARIZED GLASS(IN/R) C01 910 323 1779 ASSY,STAND LEG-MT5A L16 945 085 0043 DICHROIC MIRROR (B) L17 945 078 0784 DAICHROIC MIRROR(G) 910 330 9362...
  • Page 85 KZ6-XL4500 Mechanical Parts List -85-...
  • Page 86 SANYo Electric Co., Ltd. (KZ6AC) Dec. 007 DC 350 Printed in Japan...

  • Page 87: Diagrams & Drawings

    PLC-XL45 KZ6-XL4500 these schematic diagrams and printed wiring board drawings are part of the service manual original for chassis No. KZ6-XL4500 model PLC-XL45. File with the service manual No. SM5110900-00 Note: All the information of part numbers and values indicated on these diagrams are at the beginning of production.

  • Page 88: Parts Description And Reading In Schematic Diagram

    KZ6-XL4500 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 89 KZ6-XL4500 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)

  • Page 90: Note On Sordering

    KZ6-XL4500 Note on Sordering 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 91 Schematic Diagrams LINE FILTER AC CORD POWER FACTOR CORRECTION POWER C613 AC100-120V C611 400GK LF901 1000KK AC200-240V 1000NH U20B30103 ;400GK1DV C601 C602 (LIVE) J10B1010N F601 VA601 275GK 275GK (LIVE) 6.3A250VTC J10EM024N 0.47VBB 0.47VBB DVXAVB007 DB611 ;275GM0.47VB K6A_1A K6A_1B ;275GM0.47VB K6B_1B K6B_1A K6C_1A K6C_1B...
  • Page 92 R5239 R5238 1/10GJ 1/3GZ0 C5223 C5221 6.3EM IC5201 16KK10BB 2203T C5222 C5219 ;6.3EM220WD 10KK1MN AN5870SB 16KZ1FA F_GND PC1/PC2-SW F_GND F_GND F_GND L1002 RIN1 SC1001 F34DG407G R5201 C5201 R1001 1/16GJ100A 16KZ 2.2FA 1/3GJ75 R5233 K10A 1/16GJ BJ11B0381N F_GND F_GND F_GND R1002 F_GND RIN2 ROUT...
  • Page 93 IC301 SCAN CONVERTER & SYSTEM CONTROL FAN_A R1881 1/16GZ0A R1883 FAN_B R1885 TVPEN R1882 VPEN (TO IC301 IN1PEN R4) F_GND R1884 TVFLD R1880 1/16GZ0A VFIELD (TO IC301 IN1FIELD Y3) F_GND TVBLK VBLK (TO IC301 IN1VBI Y4) TVSYNC (TO IC301 IN1VS AB2(VVS)) C1822 THSYNC 25KZ...
  • Page 94 IC801 S3.3V_PW S29GL032 S3.3V_PW A[17] R831 TICE A[16] R801 R832 R839 A[15] BYTE 1/16GJ3.3KA TEICE 1/16GJ10KA A[14] A[1] J30B1640G A[13] D[15] F_GND DQ15/A-1 A[12] D[7] D[0] D[8] F_GND A[11] D[14] D[1] D[9] DQ14 A[10] D[6] D[2] D[10] A[9] D[13] D[3] D[11] DQ13 R802...
  • Page 95 IC2501 B-LEVEL SHIFT IC501 B-S&H R438 1/16GZ0A R472 1/16GZ0A FROM IC301 (PW186) IRM_RST C471 6.3KZ1MNF RB480 ;6.3KZ1AX R1JA1014G F_GND ;6.3KZ1AY SDATA FROM IC301 SCLK F_GND F_GND R436 R437 1/16GZ0A F_GND DB[0-9] DIRXG TO IC531 (S&H) RB483 DB[0] R1JA4704G DB[1] ENBX1G DB[2] DB[3] DXOUTG...
  • Page 96 DIRXB 15.5VL C3508 FRPB C3509 R3535 16EM 16EM FROM IC401 F34DF222G SHCLKB 2201V 2201V 15.5V C525 XFRB C3507 R3505 Q3502 25KK P_FAIL 1/16GJ 2SA1203Y D3501 1.5KA F_GND R3507 1SS355 L501 1/16GJ 1/10GZ0.0 R3510 1/16GJ 4.7KA F_GND 3.3V 15.5VL 10KA Q3501 ON_15V R501 TP_B1...
  • Page 97 EXHAUST EXHAUST EXHAUST SIDE FRONT SIDE G/R-PNL B-PNL LAMP POWER FN901 FN906 FN902 FN904 FN903 FN905 60X25mm 52X15mm 60X15mm J10EG035G J10EG035G J10EG035G J10EG036G J10EG035G J10EG035G K6L_3 K6M_3 K6K_3 K8P_3 K6J_3 K8N_3 FB3627 F_GND FB3626 F_GND FB3624 F_GND FB3623 F_GND F_GND F_GND L26B3470G L26B3470G...
  • Page 98 NO DATA SCH_KZ6AC...
  • Page 99 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 100 MAIN (SIdE:A) LAMP BALLAST FN906 UNIT K8A_4 K8A_10 A SIDE (1st Reflow) D4812 D6833 D6844 K8A_3 D6832 R9882 C9882 R6836 R9883 R6837 R6831 R6832 D6831 IC9882 PB10 TDVS TDHS KT6AC R5622 R6838 1LG4B10W0030A A30C5 X1331 IC8831 THSYNC TVBLK TVSYNC IC891 SC308 L561 TVFLD...
  • Page 101 MAIN (SIdE:B) POWER “K6R” IC5621 R5611 L401 Q5692 C5623 SC5608 L5691 C5705 C5600 C5621 L5600 SC5607 R5702 D5622 D5623 D5624 C479 IC1371 R5697 R5672 R5671 IC5691 C5609 R3626 IC1471 C2013 (2nd Reflow) D3626 FN90 B SIDE Q5693 C5658 R2018 FB3622 C1371 1LG4B10W0030A R355...
  • Page 102 LINE FILtER (SIdE:A) 1AA4B10C5310B_A A SIDE LF901 POWER “K6C” F601B F601A T6.3AH 250V F601 TYPE: 21506.3 L601 SW901 K690 POWER “K6K” LINE FILtER (SIdE:B) R602 F601B F601A B SIDE SW901 PCB_KZ6AC...

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