Page 1: Service Manual
FILE NO. SERVICE MANUAL Model No. PLC-XL50A Multimedia Projector U.S.A, Canada, Europe,U.K, Africa, Asia original Version Chassis No. KM3-XL50A00 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 the projector's, additional Service Literature is required.
Page 2: Table Of Contents
Contents SERVICE MANUAL ................. 1 Troubleshooting .................7 Contents .................... Indicators and Projector Condition ..........7 Safety Instructions ................3 No Power ...................73 Specifications ..................4 No Picture ..................74 Circuit Protections ................5 No Sound ...................75 Fuse......................5 Control Port Functions ..............76 Lamp cover switch ................
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 con- verter 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
technical Specifications Mechanical Information Projector Type Multi-media Projector Dimensions (W x H x D) 14.7” x 7.75” x 19.49” (374 mm x 196.8 mm x 495 mm) (Not including Rear leg) Net Weight 15,9 lbs (7. kg) Feet Adjustment 0˚ to 1.0˚ Panel Resolution LCD Panel System 0.8”...
Page 5: Circuit Protections
■ Curcuit Protections 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. Fuse A fuse is located inside of the projector. When the POWER indicator is not lightning, the fuse may be opened.
Page 6: Lamp Cover Switch
Circuit Protects Lamp cover switch Lamp cover switch (SW901) The lamp cover switch (SW901) cuts off the drive signal to the lamp circuit when the lamp cover is removed or not closed com- pletely. After opening the lamp cover for replacing the lamp ass’y, place the lamp cover correctly otherwise the projector can not turn on.
Page 7: Warning Temperature And Power Failure Protection
Circuit Protects 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 cool- ing fans stop spinning, or the power supplies in the projector are failed. - If the WARNING TEMP.
Page 8: Maintenance And Cleaning
■ Maintenance and Cleaning Cleaning the Air Filter The air filter prevents dust from accumulating on the surface of the optical elements inside the projector. Should the air filter become clogged with dust particles, it will reduce cooling fans’ effectiveness and may result in a buildup of internal heat and adversely affects the life of the projector.
Page 9: Cleaning The Projection Window
Maintenance and Cleaning Cleaning the Projection Window CAUtIoN This projector is equipped with a projection window. Do not rub the projection window with a hard fiber cloth or hit it with a something hard to prevent the projection window from scratching. Do not use a chemical cleaner (liquid and solid) to avoid deteriorating the projection window. Unplug the AC power cord before cleaning.
Page 10: Cleaning
Maintenance and 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 11: Lamp Replacement
REPLACEMENt LAMP Replacement lamp can be ordered through your dealer. When ordering a projection lamp, give the following information to the dealer. Model No. of your projector : PLC-XL50A ● Replacement Lamp type No. : PoA-LMP139 ●...
Page 12: Lamp Replacement Counter
Lamp Replacement Lamp Replacement Counter Be sure to reset the Lamp replacement counter after the lamp is replaced. When the Lamp replacement counter is reset, the LAMP REPLACE indicator stops lighting. Turn the projector on and press the MENU button to display the On-Screen Menu.
Page 13: How To Check Lamp Used Time
Lamp Replacement How to check Lamp Used time The LAMP REPLACE indicator will light yellow when the total lamp used time (Corresponding value) reaches 3,000 hours. This is to indicate that lamp replacement is required. The total lamp used time is calculated by using the below expression, Total lamp used time (Corresponding value) = eco + ( normal x 1.5)
Page 14: Security Function Notice And Standby Mode Notice
■ Security Function Notice and Standby mode Notice Security Function disable This projector provides security functions such as "Key lock", "PIN code lock" and "Logo PIN code lock". When the projector has set these security function on, you are required to enter correct PIN code to use the projector. If you do not know the correct PIN code to the projector, the projector can no longer be operated or started.
Page 15: Mechanical Disassemblies
■ Mechanical disassemblies 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 other- Screws Expression wise it may cause lose of performance and product safety.
Page 16 Mechanical disassemblies . Remove the DEC Legs. DEC Leg 3. Remove the screws-B (M3x35). 4. Remove the Stand Legs and Cap Stand Legs. DEC Leg Stand Leg Stand Plate Stand Leg Cap Stand Leg Cap Stand Leg Lamp Unit and Alarm Battery removal.
Page 17 Mechanical disassemblies Cabinet top ass'y removal. 1. Remove the 9 screws-A(M3x8) and remove the Cabinet top ass'y. . Remove the screw-B(T3x8), remove the R/C board, R/C pipe and remove the Decoration R/C. 3. Remove the Control board and Control Button. 4.
Page 18 Mechanical disassemblies Main Board ass'y removal. 1. Remove the 3 screws-A(M.5x6), screw-B(T3x8), screw-C(M4x6) and remove the Main board ass'y. Main board ass'y Hook Press this part - 18 -...
Page 19 Mechanical disassemblies Main board ass'y . Remove the screws-D(M.5x6). 3. Remove the 3 screws-E(T3x6) and AV panel. 4. Remove the 4 nuts-F and Holder AV. AV board Main board Holder AV AV Panel - 19 -...
Page 20 Mechanical disassemblies Exhaust Fan ass'y removal. 1. Remove the exhaust Fan ass'y(FN903, FN904) upward. . Remove the screws-A(T3x8), remove the stopper exhaust Fan and remove the FN903, FN904. Exhaust Fan ass'y Mounting exhaust duct FN904 Exhaust Fan ass'y Stopper exhaust fan FN903 - 0 -...
Page 21 Mechanical disassemblies Power supply ass'y removal. 1. Remove the screw-A(M3x8) and remove the Lamp connector. . Remove the screw-B(M.5x6) and shield plate. 3. Remove the screws-C(T3x8), remove the screw-D(T3x8) and remove the Power Supply ass'y. Power supply ass'y Shield plate Lamp connector - 1 -...
Page 22 Mechanical disassemblies Power supply ass'y disassemble. Insulation sheet -A Insulation sheet -B M.5x6 T3x6 Power supply ass'y Power board T3x6 Spacer sheet -A T3x6 T3x6 Ballast unit Holder - -...
Page 23 Mechanical disassemblies optical unit removal. 1. Remove the 5 screws-A(T3x8) and remove the Optical unit. Optical unit - 3 -...
Page 24 Mechanical disassemblies Line filter board removal. 1. Remove the 3 screws-A(T3x8) and remove the Line filter board ass'y. . Remove the Shield plate. Shield plate Line filter board ass'y Holder Line filter board M3x6 M3x6 Line filter board ass'y InsulatIion sheet AC-A InsulatIion sheet AC-B...
Page 25 Mechanical disassemblies Lamp Cover Switch removal. 1. Remove the screws-A(T3x8), remove the Spacer sheet, remove the Holder-SW and remove the Thermal Switch (SW90) . Remove the screw-B(T3x8) and remove the Lamp cover switch (SW901). Spacer sheet Holder -SW Thermal SW(SW90) Lamp cover SW(SW901) - 5 -...
Page 26 Mechanical disassemblies duct ass'y removal. 1. Remove the 6 screws-A(T3x30), remove the screw-B(T3x8) and remove the Duct ass'y. . Remove the screw-C(T3x8) and remove the Duct-top. 3. Remove the Fans(FN901, FN90, FN905) and Temp board. Duct ass'y Duct top Duct ass'y FN90 FN901 FN905...
Page 27 Mechanical disassemblies Speaker unit removal. 1. Remove the screws-A (T3x1) and remove the speaker unit. Speaker unit M3x4 M3x4 Speaker Damper Damper Holder Spacer - 7 -...
Page 28: Optical Disassemblies
■ optical disassemblies optical unit Projection lens removal. 1. Remove the 4 screws (M4x1), remove the shield plate and remove the projection lens. Shield plate Projection lens - 8 -...
Page 29 Optical disassemblies LCd panel/prism ass'y removal. 1. Remove the 4 screws-A (M.5x8) and remove the LCD panel/prism unit. . Remove the screws-B (M.5x4), remove the screw-C (M3x10) and remove the LCD panel/prism ass'y. LCD panel/prism unit LCD panel/prism ass'y Damper Mounting prism Damper...
Page 30 Optical disassemblies R-type LCd Panel/Prism Ass'y L-type LCd Panel/Prism Ass'y There are types of LCD Panel/Prism Ass'y for this model. Either L-Type or R-Type LCD Panel/Prism Ass'y is used on the projec- tor. Check which type of LCD Panel/Prism Ass'y is used with the figure below. When replacing the LCD Panel/Prism Ass'y, you need to take "Panel Type Check and Setting"...
Page 31 Optical disassemblies Integrator Lens ass'y and Relay Lens ass'y removal. 1. Remove the screws-A (M.5x5) and remove the Integrator Lens ass'y. . Remove the screws-B (M.5x5), remove the Relay Lens ass'y. Relay lens ass'y Integrator lens ass'y Relay lens ass'y Spring Relay lens Integrator lens ass'y...
Page 32 Optical disassemblies Polarized grass ass'y removal. 1. Remove the screw-A (M.5x5) and remove the Polarized grass ass'y (R, G, B). Polarized grass ass'y Polarized grass ass'y Polarized grass-IN Film sheet Hooks - 3 -...
Page 33 Optical disassemblies optical base top removal. 1. Remove the Optical base top-B. . Remove the screws (T3x8) and remove the Optical base top-A. Optical base top-B Optical base top-A Hook - 33 -...
Page 34: Optical Parts Location And Direction
■ Optical Parts Location and direction Parts Name INTEGRATOR LENS (OUT) CONDENSER LENS (OUT) NC CONDENSER LENS (G) CONDENSER LENS (B) CONDENSER LENS (R) RELAY LENS (IN) MIRROR (B) MIRROR (R) PRISM (PBS) DICHROIC MIRROR (B) DICHROIC MIRROR (G) Rugged surface Print marker this top side.
Page 35: Adjustments
■ Adjustments Adjustments after Parts Replacement : Adjustment necessary : Check necessary ● ❍ Disassembly / Replaced Parts Polarized Glass LCD/ Projection Integrator Relay Power Main Prism lens Lens (IN) Lens (OUT) Board Board Ass’y Contrast Adjustment R-Contrast adjustment ● G-Contrast adjustment ●...
Page 36: Optical Adjustments
■ Optical Adjustments Before taking optical adjustments below, remove the Cabinet Top following to the “Mechanical Disassembly”. Adjustments require a 2.0mm 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 2.0mm hex wrench and a slot screwdriver.
Page 37: 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 unifor- mity in white. 1) If the shading appears on the left or right of the screen as shown in White Fig.2-1 , loosen 1 screw...
Page 38: Relay Lens-Out Adjustment
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 uniformity in white. Fig.3 If the shading appears on the left or right of the screen as shown in loosen 1 screw , and adjust the slot to make color uniformity in white...
Page 39: Projection Lens Focus Adjustment
Optical Adjustments Projection lens focus adjustment Projection lens [ Before Adjustment ] The projector is set from the screen to 8 cm. The hole of the focus ring is set to the position of figure by operating the focus lever. (Screen size 78") Input a cross pattern.
Page 40 Optical Adjustments Loosen the 4 screws-A (A1, A2, A3, A4). Right and left focus under the screen is adjusted by using slot B. (Pre-adjustment) The screws-A1, A2 are lightly tightened and temporary is fixed. Focus on the entire screen is adjusted. Tighten the 4 screws-A (A1, A2, A3, A4).
Page 41: Electrical Adjustments
Refer to the “Service Adjustment Data Table” for further description of adjustment group no., item no. and data value. To exit the service mode ON/STAND-BY button To exit the service mode, press the ON / STAND-BY button MENU button Service Mode SANYO Input Video Group Data Ver. R 1.00 KM3AB Group No.
Page 42: Circuit Adjustments
Service Adjustment Circuit Adjustments CAUTION: The each circuit has been made by the fine adjustment at factory. Do not attempt to adjust the following adjust- ments except requiring the readjustments in servicing otherwise it may cause loss of performance and product safety.
Page 43: Fan Control Adjustment
Service Adjustment 1. Fan Control adjustment 3. Auto Calibration adjustment [PC] 1. Enter the service mode. 1. Enter the service mode. TPFANA Com- 2. Connect a digital voltmeter to test point “ ” (+) and 2. Receive the 16-step grey scale computer signal with puter1 [RGB] mode.
Page 44 Service Adjustment Gain adjustment [PC] 5. Auto Calibration adjustment [Component] 1. Enter the service mode. Com- 1. Enter the service mode. 2. Receive the 16-step grey scale computer signal with Video puter1 [RGB] 2. Receive the Color Bar 480i-component signal with mode.
Page 45: Common Center Adjustment
Service Adjustment 6. Common Center adjustment 9. 50% White adjustment [Video] 1. Enter the service mode. 1. Enter the service mode. 2. Receive the 50%-Whole Gray computer signal with 2. Receive the 16-step grey scale composite video signal Video[Video] Computer1 [RGB] mode. with mode.
Page 46: Note On White Uniformity Adjustment
Service Adjustment 11. Gamma Correction adjustment [PC] This adjustment must use the service tool. Adjust the gamma correction by using the proper computer and "PROJECTOR SERVICE TOOL" software supplied sepa- rately. 12. Gamma Correction adjustment [Video] This adjustment must use the service tool. Adjust the gamma correction by using the proper computer and "PROJECTOR SERVICE TOOL"...
Page 47: Test Points And Locations
Service Adjustment Test Points and Locations MAIN BOARD ONLY IC561 IC501 K35G IC1802 IC801 K7301 K401A - 47 -...
Page 48: Service Adjustment Data Table
Service Adjustment 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 following to the “Electrical adjustments”. Other items should be used with the initial data value.
Page 49 Service Adjustment Group/ Item Name Function Initial Range Note Item 162 PreCoast YCbCr 1080i 60Hz 0 - 63 163 PostCoast YCbCr 1080i 60Hz 0 - 63 164 PreCoast YCbCr 1080i 50Hz 0 - 63 165 PostCoast YCbCr 1080i 50Hz 0 - 63 166 PreCoast YCbCr 1035i 0 - 63 167 PostCoast YCbCr 1035i...
Page 50 Service Adjustment Group/ Item Name Function Initial Range Note Item 3 Noise Region 2 <NSREGIONY2> / <NSREGIONUV2> 0 - 1023 4 Noise Gain Level <NSFILTERY**> / <NSFILTERUV**> 0 - 255 Group 47 Noise Reduction (Time) Effective only for N.R L1 0 Noise Pixel Range <NSRANGEY>...
Page 51 Service Adjustment Group/ Item Name Function Initial Range Note Item PCStandard/PCDynamic/PCReal/PC- ColorBoard/PCBlackBoard/AVStandard/ 2048/2096/1860/1860/1860/2048 2 B-SubGain 0-4095 AVDynamic/AVCinema/AVcolorBoard/ /2096/1860/1860/1860 AVBlackBoard Center=2048 PCStandard/PCDynamic/PCReal/PC- ColorBoard/PCBlackBoard/AVStandard/ 2048/2048/2088/2088/2088/2048 3 G-SubBright 0-4095 AVDynamic/AVCinema/AVcolorBoard/ /2048/2088/2088/2088 AVBlackBoard Center=2048 PCStandard/PCDynamic/PCReal/PC- ColorBoard/PCBlackBoard/AVStandard/ 2048/2048/2088/2088/2088/2048 4 R-SubBright 0-4095 AVDynamic/AVCinema/AVcolorBoard/ /2048/2088/2088/2088 AVBlackBoard Center=2048 PCStandard/PCDynamic/PCReal/PC- 2048/2048/2088/2088/2088/2048 ColorBoard/PCBlackBoard/AVStandard/...
Page 52 Service Adjustment Group/ Item Name Function Initial Range Note Item 56 GhostB-Cent 0-2047 (MIN<-->MAX Cyclic Operation) 57 GhostB-Start 0-255 58 GhostB-End 0-255 59 BlockR1 0-2047 (MIN<-->MAX Cyclic Operation) 60 BlockG1 0-2047 (MIN<-->MAX Cyclic Operation) 61 BlockB1 0-2047 (MIN<-->MAX Cyclic Operation) 62 BlockR2 0-2047 (MIN<-->MAX Cyclic Operation) 63 BlockG2...
Page 53 Service Adjustment Group/ Item Name Function Initial Range Note Item 125 G-DCOffset-N9 0-2047 (MIN<-->MAX Cyclic Operation) 126 G-DCOffset-N10 0-2047 (MIN<-->MAX Cyclic Operation) 127 G-DCOffset-N11 0-2047 (MIN<-->MAX Cyclic Operation) 128 G-DCOffset-N12 2008 0-2047 (MIN<-->MAX Cyclic Operation) 129 B-DCOffset-NGain 0-2047 (MIN<-->MAX Cyclic Operation) 130 B-DCOffset-N1 0-2047 (MIN<-->MAX Cyclic Operation) 131 B-DCOffset-N2...
Page 54 Service Adjustment Group/ Item Name Function Initial Range Note Item 194 G_V_INPUT_STEP_0 0-1023 (MIN<-->MAX Cyclic Operation) 195 G_V_INPUT_STEP_512 0-1023 (MIN<-->MAX Cyclic Operation) 196 G_V_INPUT_STEP_1024 0-1023 (MIN<-->MAX Cyclic Operation) 197 G_V_INPUT_STEP_1536 0-1023 (MIN<-->MAX Cyclic Operation) 198 G_V_INPUT_STEP_2048 0-1023 (MIN<-->MAX Cyclic Operation) 199 G_V_INPUT_STEP_2560 0-1023 (MIN<-->MAX Cyclic Operation) 200 G_V_INPUT_STEP_3072...
Page 55 Service Adjustment Group/ Item Name Function Initial Range Note Item 3 Shipping Setting 0 - 20 Default set when the value is set to 10 4 CABLE SW Long Cable 0 - 1 0: Disable, 1: Enable 0:Disable (Serial Command Eanble) 5 PW Debug Command Enable 0 - 1 1: Enable (PW Debug Mode)
Page 56 Service Adjustment Group/ Item Name Function Initial Range Note Item 8 Table Table etting Group 205 Spread Spectrum 0 Enable Spread ON/OFF 0 - 1 0 : ON 1 : OFF 1 Modulation Frequency Modulation ratio 1 - 500 x 100Hz 2 Spread ratio 0 -300 (Set value 100 --->...
Page 57 Service Adjustment Group/ Item Name Function Initial Range Note Item Group 250 FAN Cntorol 0 FAN1 MIN ADJUST (DAC) 0 - 255 1 FAN1 MAX ADJUST (DAC) 0 - 255 DAC Output for Fan 2 FAN2 MIN ADJUST (DAC) Adjust the tolerance of DAC and Fan 0 - 255 Volage.
Page 58 Service Adjustment Group/ Item Name Function Initial Range Note Item Group 254 Fan Control Range Setting (Temp./Fan Voltage) Normal Ceiling Down 0 Not used 1 Not used Down 2 Not used 3 Not used 4 Not used 5 Not used Normal Celling 6 Not used...
Page 59 Service Adjustment Group/ Item Name Function Initial Range Note Item Group 256 Fan Lamp Voltage Down Setting Current Lamp Voltage (0.1V)(Read 0 Lamp Voltage 0-255 only) Threshold to judge Lamp Voltage 1 Lamp Vol Threshold 30-90 Down ( V×10) 2 Fan1 Speed Gain 0-255 3 Fan2 Speed Gain 0-255...
Page 60 Service Adjustment Group/ Item Name Function Initial Range Note Item 8 CB - GAIN AREA H START 0 - 1000 9 CB - GAIN AREA V START 0 - 1000 10 CR - GAIN AREA H START 0 - 1000 11 CR - GAIN AREA V START 0 - 1000 12 Image AREA H WIDTH...
Page 61 Service Adjustment Group/ Item Name Function Initial Range Note Item 3 V Back Porch 0 ~ 4095 4 Disp Line 0 ~ 4095 Group 511 SCART (575i) 0 Total Dots Read only 1 Disp Dots 0 ~ 4095 2 H Back Porch 0 ~ 4095 3 V Back Porch 0 ~ 4095...
Page 62 Service Adjustment Group/ Item Name Function Initial Range Note Item 2 H Back Porch 0 ~ 4095 3 V Back Porch 0 ~ 4095 4 Disp Line 1012 0 ~ 4095 Group 540 RGB Video (480i) 0 Total Dots 0 ~ 4095 1 Disp Dots 0 ~ 4095 2 H Back Porch...
Page 63 Service Adjustment Group/ Item Name Function Initial Range Note Item 1 Disp Dots 1868 0 ~ 4095 2 H Back Porch 0 ~ 4095 3 V Back Porch 0 ~ 4095 4 Disp Line 1012 0 ~ 4095 Group 550 RGB Video (1080P - 50) 0 Total Dots 2640 0 ~ 4095...
Page 64: Chassis Block Diagram
Chassis Block Diagrams Chassis over view 18,17,16 28,29,135 DHS,DVS,DCLK POWER_SW_MCU MCU_STAT PW_EX_UART 124,368 EX_PW_UART IRRCVR0 331,161 IC5301 SYNC SEP. <BA7078> IC5041 AUDIO OUTPIT IC5201 <TDA7056AT> PC1/PC2-SW <AN5870> IC5001 AUDIO CONTROL <NJW1141> IC4011 IC4001 AUDIO - 64 -...
Page 65: System Control
Chassis Block Diagrams System control IC891 INVERTER <MH74LVC> IC3501 <M62334> IC301 SCALER <PW190> - 65 -...
Page 66: Lamp Control
Chassis Block Diagrams Lamp control - 66 -...
Page 67: Audio Circuit
Chassis Block Diagrams Audio circuit - 67 -...
Page 68: Power Supply & Protection Circuit
Chassis Block Diagrams Power supply & protection circuit IC631 BLAST_AC FAN_ERR IC301 SCALER <PW190> - 68 -...
Page 69: Eco Standby (Sub Cpu)
Chassis Block Diagrams Service Adjustment Eco-Standby (Sub -CPU) POWER BOARD KEY SW BOARD KEY3 POWER_SW_MCU_A IC301 MCU_STAT MCU_FILTER_LED MCU_POWER_LED IC301 PW190 PW_MASTER_SD0 IC4501 MCU_READY_LED SUB-CPU MCU_LAMP_LED MCU_TEMP._LED Control MASTER_SDI Port IC6942 MCU_EX_UART CPU_EX_UART MASTER_SCK IC3801 IC6961 EX_MCU_UART EX_CPU_UART IC891 RC_MCU ON_DC MAIN S16V...
Page 70: Fan Control Circuit
Service Adjustment Chassis Block Diagrams Fan control circuit TPFANA FN901 S16V FAN_A D3622 D3621 FN902 IC7811 D3624 Q7813 TPFANB FN903 FAN_B D3627 FN904 D3626 IC7841 D3629 Q7864 Q3601 P_FAIL P_FAIL P_Fail: H Power Error: On FAN_ERR TPFANC FN905 FAN_C D3632 D3631 IC7871 Q7841...
Page 71: Iic Bus Control Circuit
Chassis Block Diagrams IIC bus control circuit - 71 -...
Page 72: Troubleshooting
■ Troubleshooting Indicators and Projector Condition Check the indicators for projector condition. Indicators WARNING WARNING LAMP Projector Condition POWER TEMP. FILTER REPLACE red/green yellow orange 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 73: 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 74: 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 TP35B, TP35G, TP35R1. Check power supply circuit 15.5V and peripheral circuit. Check ICs IC501, IC531, IC561, IC2501, IC2531, IC2561, IC401, IC301 and peripheral circuits.
Page 75: No Sound
Troubleshooting No Sound Check following steps. Check if the audio signal Check IC5001 and peripheral circuit. is observed at pins 10 and Check 9V_AUDIO, 16V power supply. 21 of IC5001. Check if the audio signal Check IC5041, 9V_AUDIO and peripheral circuit. is observed at pins 5 and Check the Mute signal at pin 7 of IC5041.
Page 76: Control Port Functions
Control Port Functions Scaler I/O Port Functions (PW190) PIN NO. PORT NO. SIGNAL NAME DESCRIPTION DDC_SW2 DDC Mode Switch OFF :L DDC_SW1 DDC Mode Switch OFF :L PC1/PC2_SW PC1/PC2 Switch PC1 : L ON_5VA 5V Power On/Off ON: H MUTE Audio Mute ON : H SCS_PW 3wirw Chip Select...
Page 77 Control port functions Scaler I/O Port Functions (PW190) (Continue) PIN NO. PORT NO. SIGNAL NAME DESCRIPTION BLAST_AC Power Control , Power ON : H CABLE_SW Long Cable Switch Output, Long Cable ON : H LAMPDC_ON Lamp Control, Power ON : H S_SW S-Video Input Switch WAKEUP...
Page 78: Ic Block Diagrams
IC Block Diagrams ● AN5870 <Signal Switch, IC5201> ● BA7078 <Sync Separator, IC5301> - 78 -...
Page 79 IC Block disgrams ● FA5502 <P.F. Control, IC601> ● HIN202EIB <RS-232C Driver, IC3801> - 79 -...
Page 80 IC Block disgrams ● L3E06150 <D/A, S/H-LCD Driver, IC501, IC531, IC561> ● L3E07110 <LCD Driver & Gamma Correction, IC401> - 80 -...
Page 81 IC Block disgrams ● L3E01060 <Level Shift, IC2501, IC2531, IC2561> ● M62334 <DAC, IC3501> - 81 -...
Page 82 IC Block disgrams ● NJW1141 <Audio Control, IC5001> ● PW190 <Scaler, IC301> - 82 -...
Page 83: Electrical Parts List
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 84: Electrical Parts Location
Elecrical Parts Location ● Assemblied Board A601 A2901 POWER BOARD R/C BOARD A6801 KEY SW BOARD A901 BALLAST UNIT A690 A2001 LAMP COVER SW BOARD AV BOARD A4831 A602 TEMP BOARD LINE FILTER BOARD A1001 MAIN BOARD ● Out of Circuit Board SW902 FN904 (Thermal Switch)
Page 85: Electrical Parts List
KM3-XL50A00 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description 305 173 9816 TR 2SC3928A1R 305 173 9915 TR 2SC3928A1S ASSEMBLED BOARDS Q1875 305 014 4512 TR 2SC2412K T146 R A1001 610 346 7108 ASSY,PWB,MAIN KM3AB 305 014 4611 TR 2SC2412K T146 S A2001 610 346 7115 ASSY,PWB,AV KM3AB...
Page 86 KM3-XL50A00 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description 305 173 9915 TR 2SC3928A1S 305 014 4611 TR 2SC2412K T146 S 305 015 8727 TR 2SC2812-L6-TB Q4548 305 134 5928 TR 2SA1037AK-T146-R 305 147 2218 TR 2SA1037AK-S-T146 305 015 8925 TR 2SC2812-L7-TB...
Page 87 KM3-XL50A00 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description 305 173 9915 TR 2SC3928A1S 305 173 9618 TR 2SA1235A1E 305 173 9717 TR 2SA1235A1F Q5701 305 217 5019 TR RN1117 TE85L Q5702 305 217 5019 TR RN1117 TE85L 405 220 3115 TR ISA1235AC1E...
Page 88 KM3-XL50A00 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description IC6961 309 439 8919 IC TC7WH125FU 305 173 9915 TR 2SC3928A1S Q7871 305 014 4512 TR 2SC2412K T146 R IC6962 309 439 8919 IC TC7WH125FU 305 014 4611 TR 2SC2412K T146 S IC7201 410 631 4504...
Page 89 KM3-XL50A00 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description C1875 303 438 0219 CERAMIC 0.1U K C1402 303 394 1312 ELECT 100U M 6.3V 303 427 9315 ELECT 100U M 6.3V 303 409 3426 CERAMIC 0.1U K C1876 303 383 5215...
Page 90 KM3-XL50A00 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description C333 303 438 0219 CERAMIC 0.1U K C2568 303 396 9613 CERAMIC 1U K 303 397 7618 CERAMIC 1U K 303 409 3426 CERAMIC 0.1U K C334 303 438 0219 CERAMIC...
Page 91 KM3-XL50A00 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description C3692 303 438 0219 CERAMIC 0.1U K C3534 303 438 0219 CERAMIC 0.1U K 303 409 3426 CERAMIC 0.1U K 303 409 3426 CERAMIC 0.1U K C3694 303 438 0219 CERAMIC...
Page 92 KM3-XL50A00 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description C445 303 438 0219 CERAMIC 0.1U K C411 303 438 0219 CERAMIC 0.1U K 303 409 3426 CERAMIC 0.1U K 303 409 3426 CERAMIC 0.1U K C446 303 438 0219 CERAMIC...
Page 93 KM3-XL50A00 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description C511 303 342 3313 CERAMIC 0.1U K C465 303 438 0219 CERAMIC 0.1U K 303 409 3426 CERAMIC 0.1U K C512 303 276 1317 CERAMIC 1000P K C513 303 342 3313 CERAMIC...
Page 94 KM3-XL50A00 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description 303 368 7319 CERAMIC 10U K 6.3V C532 303 342 3313 CERAMIC 0.1U K C533 303 342 3313 CERAMIC 0.1U K C5623 303 438 0219 CERAMIC 0.1U K 303 409 3426 CERAMIC...
Page 95 KM3-XL50A00 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description 303 409 3426 CERAMIC 0.1U K C6813 303 342 3313 CERAMIC 0.1U K C6814 303 342 3313 CERAMIC 0.1U K C7270 303 438 0219 CERAMIC 0.1U K 303 409 3426 CERAMIC 0.1U K...
Page 96 KM3-XL50A00 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description R1356 301 294 2613 MT-GLAZE 4.7K FA 1/16W 303 409 3426 CERAMIC 0.1U K C801 303 438 0219 CERAMIC 0.1U K R1361 301 037 5017 MT-GLAZE 0.000 ZA 1/10W R1362 301 224 9217...
Page 97 KM3-XL50A00 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description R347 301 226 1516 MT-GLAZE 0.000 ZA 1/16W R2071 301 224 8913 MT-GLAZE 100K JA 1/16W R2072 301 224 8913 MT-GLAZE 100K JA 1/16W R348 301 225 8110 MT-GLAZE 10 JA 1/16W R349...
Page 98 KM3-XL50A00 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description R4524 301 224 9712 MT-GLAZE 22 JA 1/16W R382 301 263 7420 MT-GLAZE 75 JA 1/16W R389 301 225 0817 MT-GLAZE 68K JA 1/16W R4526 301 224 9712 MT-GLAZE 22 JA 1/16W R4528...
Page 99 KM3-XL50A00 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description R542 301 224 8814 MT-GLAZE 100 JA 1/16W R5046 301 234 9917 MT-GLAZE 6.8K JA 1/16W R5047 301 225 0510 MT-GLAZE 33K JA 1/16W R543 301 224 8814 MT-GLAZE 100 JA 1/16W R551...
Page 100 KM3-XL50A00 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description R7284 301 226 1516 MT-GLAZE 0.000 ZA 1/16W R6858 301 225 1616 MT-GLAZE 390 JA 1/16W R6859 301 225 1616 MT-GLAZE 390 JA 1/16W R7286 301 226 1516 MT-GLAZE 0.000 ZA 1/16W R7287...
Page 101 KM3-XL50A00 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description 945 037 0831 R-NETWORK 47X4 1/16W R808 301 224 9019 MT-GLAZE 10K JA 1/16W R809 301 225 8516 MT-GLAZE 1.8K JA 1/16W RB418 945 036 0986 R-NETWORK 47X4 1/32W 945 037 0831 R-NETWORK 47X4 1/16W...
Page 102 KM3-XL50A00 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description L306 301 150 6014 MT-GLAZE 0.000 ZA 1/10W D2891 307 223 1115 ZENER DIODE 02DZ6.2Y(TPH3 L307 301 150 6014 MT-GLAZE 0.000 ZA 1/10W 307 209 1214 ZD UDZS-TE-176.2B L308 301 150 6014...
Page 103 KM3-XL50A00 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description K30A 645 089 7696 SOCKET,D-SUB 15P L2021 945 086 7461 FILTER,EMI 100MHZ 952 001 8601 SOCKET,D-SUB 15P L2031 945 086 7461 FILTER,EMI 100MHZ K30B 645 089 7702 SOCKET,D-SUB 15P L2051 945 068 8325...
Page 104 KM3-XL50A00 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description A6801 610 347 0313 ASSY,PWB,KEY SW. KM3AB 305 015 8925 TR 2SC2812-L7-TB 305 163 1615 TR 2SC2812N-L6-TB0 CAPACITOR 305 173 9816 TR 2SC3928A1R 305 173 9915 TR 2SC3928A1S C6801 303 438 0219...
Page 105 KM3-XL50A00 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description RESISTOR DIODE R611 401 353 0311 MT-GLAZE 430K JA 1/3W D611 307 225 4401 DIODE FMX-G26S R612 401 353 0212 MT-GLAZE 360K JA 1/3W D612 307 163 0414 DIODE 1SS352-(TPH3) R613 301 256 6314...
Page 106: Mechanical Parts List
Mechanical Parts Location S3 S3 - 106 -...
Page 107 Mechanical Parts Location...
Page 108: Optical Parts Location
Optical Parts Location L10-1 Polarized Grass Red: L02-R Green: L02-G Blue: L02-B...
Page 109 Optical Parts Location Relay Lens Out Integrator Lens In...
Page 110 Optical Parts Location In the Optical Unit - 110 -...
Page 111: Mechanical Parts List
KM3-XL50A00 Mechanical Parts List Key. No. Part No. Description Key. No. Part No. Description CABINET PARTS OPTICAL PARTS DIRECTORY 610 347 8326 CABINET TOP-KM3AB 610 346 4237 ASSY,PNL/PSM-KM3AA 610 347 5318 CABINET BOTTOM-KM3AB L02-R 645 089 3476 POLARIZED GLASS(IN/R) 610 336 2595 CAP FOCUS LEVER-KM3A L02-G 645 101 1909...
Page 112 SM5111155-00 (PLC-XL50A) Oct. 2009 DC 200 Printed in Japan SANYO Electric Co., Ltd.
Page 113: Diagrams & Drawings
PLC-XL50A KM3-XL50A00 These schematic diagrams and printed wiring board drawings are part of the service manual original for chassis No. KM3-XL50A00 models PLC-XL50A. File with the service manual No. SM5111155-00 Note: All the information of part numbers and values indicated on these diagrams are at the beginning of production.
Page 114: Parts Description And Reading In Schematic Diagram
KM3-XL50A00 Parts description and reading in schematic diagram 1. The parts specification of resistors, capacitors and coils Resistor Reading are expressed in designated code. Please check the parts Example 1/2 D J 10K B description by the following code table. 2.
Page 115: Schematic Diagrams
MIRROR LENS Schematic Diagrams ES3.3V POWER D6804 P-RIGHT SW6803 S10B3530G POWER FACTOR CORRECTION SW803_1 R6806 1/16GJ15KA P-LEFT SW6804 S10B3530G SW804_1 R6807 1/16GJ6.8KA KEYSTONE P-DOWN (TERMOSTAT_SW) C611 SW6800 SW6806 SW902 D611 S10B3530G S10B3530G 1000KK1000NH L612 FMX-G26S SW801_0 R6808 SW806_1 L613 S10B5470N (LIVE) K6C_1B K6C_1A...
Page 116 L1001 SC1001 R1001 F34DG407G 1/3GJ75 R1_IN R1002 D6201 1/16GJ100A RB521S-30G L1011 SC1011 R1011 F34DG407G 1/3GJ75 L6201 G1_IN L26B3470G 5VPC_A 5VPCDDC_A IC6201 D6202 ;6.3KK10MB R1012 RB521S-30G 24LC21A/SNP 1/16GJ C6203 100A K30A 6.3KK10BA SC1021 L1021 J11B8382N F34DG407G R1021 1/3GJ75 B1_IN K30A_1 TEST 5VPCDDC_A ;16KK0.11B R1022...
Page 117 IC1351 TA48S00AFP S3.3V_PW S3.3V_PW A[17] R839 S3.3V_PW A[16] S3.3V_PW R1352 TP_ICE R1353 A[15] R801 R1351 BYTE# J30B1640G TEICE 1/16GJ 1/16GF3.9KA 1/16GJ10KA 1/10GZ0.0 10KA A[14] A[1] J30B1640G PW_ICE R1354 C1352 C1353 1/16GF3.9KA A[13] D[15] 10KK11B DQ15/A-1 6.3KK10BA ;10KK1MN A[12] D[7] D[0] D[8] C1351 R1356...
Page 118 IC7261 TA48S00AFP D3633 1SS352G P_FAIL R7262 3.3V_A R7261 3.3V_A 1/16GJ IC7201 1/10GZ0.0 10KA R7263 IC1411 1/16GF3.9KA C7263 10KK2.2GQ BD7820FPP R7264 EP2C5F256C8N 1/16GF3.9KA 3.3V_FPGA C7262 6.3KK10BA IC1401 ;6.3KK10MB R7266 R7267 1/16GF4.7KA 1/10GZ0.0 TA48S00AFP 3.3V_A 3.3V_FPGA C7264 C7266 C7202 C7223 6.3EM471V 16KK0.1MN R1411 D3634 1/10GZ0.0...
Page 119 3.3V_SH_B R504 R527 DRB_DIRX TPSHCLKB R503 J30B1640G 1/16GJ10KA FROM IC401 DB_FRP FROM IC401(7111) DG_ENBY2 C3508 (7111) R3509 DB_SHCLK 25EM 1/10GZ0.0 DG_ENBY1 473T DB_XFR 15V_PB 15.5V_PNL C515 CLYOUT C510 16KK0.1MN C3509 C516 ;16KK0.11B DRGB_DY 25KK1GQ L521 K35B L501 L26B3470G C3500 3.3V_SH_B 16KK0.1MN L26B3470G 25EM...
Page 120 D6831 LAMP REPLACE(Y) D6832 TEMP WARNING(R) D6833 STAND-BY (RED ON) LAMP ON (GREEN ON) ES5V D6846 FILTER WARNING (ORANGE) D3612 1SS352G P_FAIL TE5001 R6863 R6857 J30B1640G R5649 1/16GZ0A 1/16GJ R6858 R5654 D6831 390A C5653 1/16GJ 1/16GJ L26B4110G 30KA SMLE12Y8WG 390A D6844 9V_AUDIO R5651...
Page 121: Printed Wiring Board Diagrams
Printed Wiring Board Diagrams ■ ! CAUTION This projector is isolated from AC line by using the internal converter transformer. AV (SIDE : A) Please pay attention to the following notes in servicing 1. D o not touch the part on hot side (primary circuit) or both parts on hot and cold sides (secondary circuit) at the same time. 2. Do not shorten the circuit between hot and cold sides. 3. T he grounding lead must be connected to the ground of the same circuit when measuring of voltages and waveforms.
Page 122 R/C (SIDE : A) MAIN (SIDE : A) LAMP BALLAST SPEAKER “CN2” KEY SW "K6801A" C6814 D6833 K29D C6816 Q3694 Q5684 R3614 C5613 SCREW2 R8749 R8747 R8757 R8758 R4861 Q8701 Q8702 D6841 R5696 Q5651 C9882 D5651 C3611 R6841 D2892 R3616 D6832 R3611 R/C (SIDE : B)
Page 123 MAIN (SIDE : B) POWER “K6R” R3696 C3694 C4808 C5617 C5615 Q9881 C5623 Q4801 L5601 C5618 C5616 R5622 C3692 C9647 R3697 C5602 FB609 R9881 R9624 R9882 R9621 R9657 Q3642 R9661 R9622 R9659 C9603 R5620 C5621 R9629 R9658 C8707 SCREW5 K20C R6863 Q2091 R2093 C5651 R2094 R9641...
Page 124 POWER (SIDE : A) POWER (SIDE : B) C661 C664 SCB6 C665 C665 L611 A30C5 C672 C672 T651 C613 C613 T651 MAIN DB611 D665 “K8R” DB611 D665 A30C5 DB611H DB611H PC671 Q612 Q611 D611 PC661 Q611 D611 Q612 PC663 IC621 Q611H Q611H C651 C612 C611 C612 C611 R685 R614...
Page 125: Pin Description Of Diode, Transistor And Ic
KM3-XL50A00 Pin description of diode, transistor and IC ● Diode ● Transistor/FET ● IC...
Page 126: Note On Soldering
Note on Soldering Do not use solder containing lead. Solder This product has been manufactured using lead-free solder Use solder with the metal content and composition ratio 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 when which do not meet these conditions.

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