81_pdfsam_Sanyo PLV-Z5 servicemanual.pdf part of Sanyo PLV-Z5 1_pdfsam_Sanyo PLV-Z5 servicemanual.pdf, Sanyo multimedia projector service manual. Chassis no MC4-Z500 and MC4-Z5BK00. Document is split into 15 parts text manual preview

Text preview for : 81_pdfsam_Sanyo PLV-Z5 servicemanual.pdf part of Sanyo PLV-Z5 Sanyo multimedia projector service manual. Chassis no MC4-Z500 and MC4-Z5BK00. Document is split into 15 parts

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Power Supply Lines

Description of Power supply circuit
When the projector is standby mode, IC301(Main CPU) is not working and IC4801(Sub CPU) is only working for saving energy. When the projector is connected to outlet with AC power cord and the Mains SW is switched to ON, SS5V line is supplied to to standby circuit, including IC4801. IC4801 is waiting for the POWER ON/STAND-BY key input or remote control signal. When the projector is turned on, "PWR_SW" signal (Power ON:H) from pin 12 of IC4801 is sent to the UNIT_POWER, and then the switching power supply circuit starts operation. "MAINON_SW" signal (Lamp ON:H) from pin 80 of IC301 is also sent to UNIT_POWER, and then the lamp power supply circuit starts operation. The "5V_SW", "3.3V_SW", "15V_SW" and "FAN_SW" signals are also sent to the power supply circuits. Power failure protection of secondary power circuit The projector provides a protection circuit to prevent the secondary failure when the power failure, fans failure or temperature failure occurs on the projector. The power failure detection lines are connected to the main power supplies. When a failure occurs, IC301 receives the power failure detection signals "POWER_FAIL" through the power failure detection lines and "MAINON_SW" signal (Lamp OFF:L) and "PWR_SW" signal (Power OFF:L) are supplied to the UNIT_POWER to stop the power supply operation, and the lamp operation is stopped with "LAMP_SW" signal (Lamp OFF:H).

Flow chart of projector condition
(with AC power supply and Mains SW : ON) (60 sec.)

AC OFF

STAND-BY

COOLING

(Lamp : OFF)

(ON/STAND-BY KEY)

(Slide Shutter error)

WARNING

POWER ON
(Slide Shutter error, Lamp error) (Lamp : ON)

PROGRAM REPLACE MODE

(20 sec.) (with signal or any KEY)

NORMAL

SUSPEND COUNTDOWN

(Lamp : ON)

(no signal 30 sec.) (A) (with signal or any KEY) (no signal 5 min.)

SERVICE MODE

SUSPEND
(Lamp : OFF)

(60 sec.)

SUSPEND COOLING

(A) : Press MENU + INPUT KEY for 5 sec. (or press MENU KEY on R/C for 20 sec.) --> [S] mark display (for 5 sec.) --> UP + DOWN KEY or R/C SCREEN KEY for 3 sec. (Return to normal with ON/STAND-BY KEY)

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Troubleshooting
No Power
This projector provides a function which can be specified a defective area simply by indicating the LEDs on the control panel. Connect the AC cord and turn the projector on and then check the LED indication.

Indicators

Troubleshooting
POWER
red/green

WARNING
red

Does a indicator flash or light? Yes

No

The primary power supply circuit does not operate properly. Yes

Is fuse (F601) broken? No Check SS5V power supply line.
When the main power switch is ON, SS5V line is supplied to IC4801(Sub CPU).

Check Varistor (VA611). Check Power Board.

POWER (red) and WARNING (red) indicators are lighting?

Yes

The symptom indicates that the projector detected an abnormality in the cooling fan operation or in the power supply secondary circuits. Check fan operation and power supply lines, and the driving signal status.
POWER_FAIL (Error:L) signals are sent to IC301 via IC871 and IC1801, then IC301 shuts down the power supply circuit.

Check following items An abnormality occurs on the secondary power supply lines An abnormality occurs on the fan control circuits. An abnormality occurs on power starter signals.

Check power supply lines, S5V,S-5V, S16V, etc. on the Main board.
Refer to the diagram "Power Supply Lines".

Power failure detection diodes detect the fan operation stop. Check FN901/902/903/904/905 and peripheral circuit. Check connectors K8E/K8F from TH901/TH902.
Refer to the diagram "Fan control circuit".

Check power starter signals as follows:
PWR_SW signal (Power-on:H) is output from pin 12 of IC4801 and sent to the Power Board and S16V, S16V_F, S6.5V, S5V, S-5V lines are supplied. MAINON_SW signal (Power-on:H) is output from pin 80 of IC301 and sent to the Power Board and lamp ballast 375V line is supplied. 5V_SW signal (Power-on:H) is output from pin 336 of IC301 and sent to IC1581, IC8251, IC8281, Q4601, Q4603, then 12V, 3.3V_D, 3.3V_A, -5V, 6.5V lines are supplied. 3.3V_SW signal (Power-on:H) is output from pin 76 of IC301 and sent to IC3601, then 3.3V, 1.2V lines are supplied. 15V_SW signal (Power-on:H) is output from pin 79 of IC301 and sent to Q591, then 15.5V line is supplied. FAN_SW signal (Power-on:H) is output from pin 81 of IC301 and applied to the Fan power supply circuit.

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Troubleshooting

Indicators
WARNING LAMP REPLACE
red/green /orange

POWER

yellow

red

Troubleshooting
From previous page The symptom indicates that the projector detected an abnormal temperature risen inside the projector. Check the air filters and remove the object near the intake and exhaust fan openings, and wait until the POWER indicator stops flashing, and then try to turn on the projector. - The internal temperature is monitored by the sensors,
IC8841 on Main Board, TH901 and TH902. (Refer to "Fan control circuit")

Cooling

WARNING (red) and POWER (red) indicators are flashing? No

Yes

Cooling

Cooling

POWER (red) and LAMP REPLACE (yellow) indicators are flashing?

Yes

The symptom indicates that the projector detected an abnormality in the lamp driving signal. Check the lamp driving signal, Lamp Cover SW and the Thermal SW.
LAMP_SW signal (Lamp-on:L) from pin 16 of IC4801 is sent to Lamp Ballast Unit through SW8803(Lamp Cover SW) and SW902(Thermal SW). TXL signal is output from pin 17 of IC4801 and sent to Lamp ballast Unit via IC4833. (TXL signal is applied for lamp power control. Lo: Low power, Hi: High power) RXL signal (Lamp status signal) is output from Lamp Ballast Unit and sent to pin 18 of IC4801 via IC4833, then LAMP_ERR signal is output from pin 4 of IC4801 and sent to IC301 via pin 7 of IC1801.

No

-

-

If an abnormality occurred on the lamp ballast unit, RXL signal and LAMP_ERR signal become "H" and then the projector will be cooled down and to stand-by mode (POWER indicator lights red).

Lamp Cover Switch (SW8803 on Lamp SW board)
Make sure that the lamp cover is mounted correctly. If not or the lamp cover removed, the lamp does not light on for the safety. Check the lamp cover and lamp cover switch.

POWER indicator is flashing orange?
Shutter Error at 3 cases; (1) Error when turning on: Flashing orange (continuation). (2) Error when turning off: Flashing red (60sec.), flashing orange (60sec.), and then lighting red. (3) Error at normal mode: Flashing red (60sec.) and then lighting red.

Yes

Thermal Switch (SW902) ......short in normal
SW902 opens when the surrounding temperature of the switch exceeds 90°C.

The symptom indicates that the projector detected an abnormality in the slide shutter. Check the slide shutter and the door switches. Door Switches (SW8801/SW8811 on Door SW-A/B board)
Make sure that the shutter is open or close. If it is halfopen or close, the lamp does not light.

· · · lights green. · · · flashes orange.

· · · flashes green. · · · flashes yellow.

· · · lights red.

· · · flashes red.

· · · off

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Troubleshooting

No Picture Check following steps.
SG: Description of visual signal flow Sync: Description of sync signal flow

No picture with all of input sources No

Yes

Check signal processing stage and LCD driving stage;
Check RGB VID signals at test points TP35R, TP35G, TP35B. Check power supply circuit 15.5V and peripheral circuit. Check IC501, IC531, IC561, IC2501, IC2531, IC2561, IC401, IC4401, IC301 and peripheral circuits. SG: Digital RGB signals from IC8001 are sent to IC301, and the other signals are A/D converted in IC8201 and sent to IC301. They are scaled in IC301. After correcting for picture quality in IC4401 and IC401, they are sent to IC501, IC531, IC561(sampling & holding, D/A conversion). The panel driving signals are shifted the level up to 15V by IC2501, IC2531, IC2561. Sync: PW_HS/VS/CLK from IC301 to IC4401, DHS,DVS,DCLK from IC301 to IC401

No picture with COMPONENT1/2 (YCbCr) input sources

Yes

Check Component source input stage;
Check IC5201, IC8201 and peripheral circuit. Check sync signals at test points TPADHS and TPADVS. SG: Component_1/2 signals are selected in IC5201, with COMP_1/2 signal (Component_1 = Low). The selected signals are sent to IC8201. They are A/D-converted in IC8201 and sent to IC301. Sync: Y/Cb/Cr signals are sync-separated in IC8201, and ADHS and ADVS signals are sent to IC301.

No

No picture with HDMI (RGB digital) input source No

Yes

Check HDMI (RGB digital) source input stage;
Check IC8001 and peripheral circuit. Check sync signals SIHS and SIVS. Check 5VHDMI power supply line. TMDS data signals are converted to RGB digital signals in IC8001, and sent to IC301. Receiving video content encrypted with HDCP(High-bandwidth Digital Content Protection), IC8001 reads the HDCP keys and it allows the signal processing. Sync: SIHS and SIVS signals from IC8001 are sent to IC301. SG:

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Troubleshooting

From previous page

No picture with Computer (RGB analog) input source No

Yes

Check Computer source input stage;
Check IC8201 and peripheral circuit. Check sync signals and . PC_RGB signals are sent to IC8201. They are A/D-converted in IC8201 and sent to IC301. Sync: PC_HS/VS signals are sent to IC8201 via IC8271(Inverter IC) and ADHS and ADVS signals are sent to IC301. SG:

No picture with Computer (RGB SCART) input source No

Yes

Check Computer source input stage;
Check RGB SCART signals at test points TP-RIN/GIN/BIN. Check IC8201, IC5231 and peripheral circuit. Check sync signals and . SG: RGB SCART signals are A/D-converted in IC8201 and sent to IC301. Sync: SCART_CV signal at 13 pin of D-sub_15 is selected in IC5231, with S/CV_SW signal(SCART = High). The selected signal is sent to IC8201. It is sync-separated in IC8201, and ADHS and ADVS signals are sent to IC301.

No picture with SVIDEO input source No

Yes

Check AV source input stage;
Check Y/C signals at IC8201, IC5231 and peripheral circuit. Check sync signals and . SG: Y signal is selected in IC5231, with S/CV_SW signal(S-VIDEO = Low). The selected signal is sent to IC8201. S_CHROMA signal is sent to IC8201. They are A/D-converted in IC8201 and sent to IC301. Sync: Y/C signals are sync-separated in IC8201, and ADHS and ADVS signals are sent to IC301.

No picture with VIDEO input source

Yes

Check AV source input stage;
Check IC8201 and peripheral circuit. Check sync signals and . SG: Composite video signal is sent to IC8201, and sent to IC301. Sync: Composite video signal is sync-separated in IC8201, and ADHS and ADVS signals are sent to IC301.

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Control Port Functions
I/O Port Table of Main CPU (IC301, PW386)
Pin No. Name Function Name Function Polarity I/O

268 269 55 53 135 134 54 206 203 204 266 56 132 133 267 205 222 153 213 64 151 286 82 149 156 285 80 73 157 336 81 72 78 283 76 155 79 152 52 202 265 92 13 96 171 207 136 57 256 225 154 284

Port A7 Port A6 Port A5 Port A4 Port A3 Port A2 Port A1 Port A0 Port B7 Port B6 Port B5 Port B4 Port B3 Port B2 Port B1 Port B0 Port H7 Port H6 Port H5 Port H4 Port I5 Port I4 Port I3 Port I2 Port I1 Port I0 Port J5 Port J4 Port J3 Port J2 Port J1 Port J0 Port K5 Port K4 Port K3 Port K2 Port K1 Port K0 IRRCVR0 RXD TXD ROMOE ROMWE CS1 CS0 NMI RESETB EXTRSTEN IN0RO9 IN0GO9 IN0BO8 IN0GO8

LAMP_PWM IRIS_PWM SCL2 SDA2 SCL1 SDA1 SCL0 SDA0 WP11 D-CLOSE_SW PIC_POW_M NCONFIG CONF_DONE NSTATUS MICON_CLB D-OPEN_SW IRM_RST SIRST AD_RST DDC_SW DOOR_CLOSE THERM1_DET WP2 DOOR_OPEN THERM2_DET IRIS_CLOSE MAINON_SW COMP1/2_SW IRIS_OPEN 5V_SW FAN_SW S/CV_SW 3L_EN FPGA_RST 3.3V_SW EXIO_OE 15V_SW CLK_OE R/C RXD TXD ROMOE ROMWE CS1 CS0 NMI RESET EXTRSTEN HDMI2_SW R1HPDOUT PFAIL_HV DDC_SW2

PWM Output to Sub_CPU PWM Output to Lamp iris

PWM PWM

Not used

O O I/O O I/O O I/O O I/O I O O O O I O O O O O I O I O O O O O O O O O O O I I/O I/O O O I/O I/O I I/O I I O I O

Component-1/Component-2 switch

COMP1 = L ON = H ON = H S-VIDEO = L

S-VIDEO/SCART switch

ON = H ON = H IR Receiver Input 0

ROM output enable ROM write enable I/O Expander Chip Select (Input) I/O Expander Chip Select (Output) Non-maskable Interrupt Master reset External reset enable

L: external Active Low Active Low Active High Active Low H: external

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Control Port Functions

Sub CPU (IC4801, PIC16F873)
Pin No. Name Function Name Function Polarity I/O

1 2 3 4 5 6 7 9 10 11 12 13 14 15 16 17 18 21 22 23 24 25 26 27 28

MCLR/VPP RA0/AN0 RA1/AN1 RA2/AN2 RA3/AN3 RA4/TOCKI RA5/AN4 OSC1 OSC2 RC0 RC1 RC2 RC3 RC4 RC5 RC6 RC7 RB0 RB1 RB2 RB3 RB4 RB5 RB6 RB7

RESET LAMP_PWM CPU_ADCIN LAMP_ERR (5V)

APL Level Input From lamp iris for factory usage Lamp Error Output

Lamp Error = H

XTAL XTAL CPU_RESET PWR_SW PIC_POW_M SCL0_5V SDA0_5V LAMP_SW TX_LAMP RX_LAMP P_KEY_PIC RC_IN_PIC PIC_LAMP_LED PIC_READY_LED PIC_POWER_LED RB6_PIC RB7_PIC

Power ON = H Not used

I I I O O O I I O O I I I O O O I I

Lamp ON = L

Power Key Input Remote Control Input

Service Service

IIC Bus D/A Converter
IC Ref. No. Pin
1 2 3 4 6 7 8

I/O
O O O O I I -

Signal Name
FAN_CONT4 FAN_CONT3 FAN_CONT2 FAN_CONT1 SDA0_5V SCL0_5V Vcc

Function

Note

IC7841

M62334

Parallel Bus I/O Expander
IC Ref. No Pin
2 3 4 5 6 7 8 9 12 13 14 15 16 17 18 19

I/O
I I I I I I I I O O O O O O O O

Signal Name
K11 K12 K13 POWER_FAIL P-KEY_PW LAMP_ERR OPTION HDMI_SW HOT_PLUG READY_LED POWER_LED TEMP_LED LAMP_LED K03 K02 K01

Function
Key Input 1 Key Input 2 Key Input 3 Power Fail Input Power key Input Lamp Error Input Option Input HDMI

Note

IC1801 TC74LCX541

Power Fail: Low Lamp Error: High

IC1821 TC74LCX574

Key Scan Output Key Scan Output Key Scan Output

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IC Block Diagrams
ADV7403