Sanyo Xp 55 Manual

							Multimedia ProjectorSERVICE MANUAL  
PRODUCT CODE 
1 122 185 00
(MR3A)
1 122 185 20(MR3AL)
1 122 186 00(PR3A)
1 122 186 20 (PR3AL)
1 122 186 02 (PR3C)
1 122 186 22(PR3CL)
Original Version
REFERENCE NO. SM5110500
FILE NO.
Model No. PLC-XP55
PLC-XP55L
U.S.A., Canada,
Europe, Asia, Africa
Chassis No. MR3-XP5500
MR3-XP55L00
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, additional Service
Literature is required. You must refer
to “Notices” to the Original Service
Manual prior to servicing the unit.
PLC-XP55
Note:
Model PLC-XP55L does not provide projection lens. 
						

							2
■Contents
■Safety instructions ________________________________________________3
■Specifications __________________________________________________ 4
■Note on Servicing  ______________________________________________ 5
■Adjustments after parts replacement ________________________________ 5
■Circuit protections ______________________________________________ 6-7
● Fuse ____________________________________________________ 6
● Thermal switch ____________________________________________ 6
● Interlock switch ____________________________________________ 6
● Warning temperature and power failure protection ________________ 7
■Mechanical disassemblies ______________________________________ 8-12
■Optical parts disassemblies ____________________________________ 13-16
■LCD panel/prism ass’y replacement ________________________________ 17
■Lamp replacement ______________________________________________ 18
■Optical adjustments __________________________________________ 19-21
●Contrast adjustment ________________________________________ 19
●Condenser adjustment ______________________________________ 20
●Relay lens adjustment ______________________________________ 21
■Electric adjustments __________________________________________ 22-40
●Service adjustment menu operation ____________________________ 22
●Circuit adjustments ______________________________________ 23-27
●Service adjustment data table ______________________________ 28-39
●Test points and locations ____________________________________ 40
■Circuit block diagrams ________________________________________ 41-45
■Power supply lines ______________________________________________ 46
■Troubleshooting ______________________________________________ 47-51
●No power ______________________________________________ 47-48
●No picture ________________________________________________ 49
●No sound ________________________________________________ 50
●Lens motor problems ______________________________________ 51
■Control port functions__________________________________________ 52-56
■Waveforms ____________________________________________________ 57
■Cleaning ______________________________________________________ 58
■IC block diagrams ____________________________________________ 59-70
■Service parts lists ____________________________________________ 71-113
●Electrical parts list ______________________________________ 71-107
●Mechanical parts list __________________________________ 108-110
●Optical parts list ______________________________________ 111-113
Drawings & Diagrams______________________________________ A1-A17
■Parts description and reading in schematic diagram ____________________ A2
■Schematic diagrams ________________________________________ A3-A10
■Printed wiring board diagrams ________________________________ A11-A16
■Pins description of ICs, transistors, diodes __________________________ A17 
						

							3
■Safety Instructions
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. For continued product safety and protection of personnel
injury, servicing should be made with qualified personnel.
The following precautions must be observed.
SAFETY PRECAUTIONS
1: An isolation transformer should be connected in the
power line between the projector and the AC line
before any service is performed on the projector.
2: Comply with all caution and safety-related notes pro-
vided on the cabinet back, cabinet bottom, inside the
cabinet or on the chassis.               
3: When replacing a chassis in the cabinet, always be
certain that all the protective devices are installed
properly, such as, control knobs, adjustment covers
or shields, barriers, etc.DO NOT OPERATE THIS PROJECTOR WITHOUT
THE PROTECTIVE SHIELD IN POSITION AND
PROPERLY SECURED.
4: Before replacing the cabinet cover, thoroughly
inspect the inside of the cabinet to see that no stray
parts or tools have been left inside.
Before returning any projector to the customer, the
service personnel must be sure it is completely safe to
operate without danger of electric shock.
SERVICE PERSONNEL WARNING
Eye damage may result from directly viewing the light produced by the Lamp used in this equipment. Always turn
off Lamp before opening cover. The Ultraviolet radiation eye protection required during this servicing.
Never turn the power on without the lamp to avoid electric-shock or damage of the devices since the stabilizer
generates high voltages(15kV - 25kV) at its starts.
Since the lamp is very high temperature during units operation replacement of the lamp should be done at least
45 minutes after the power has been turned off, to allow the lamp cool-off.
PRODUCT SAFETY NOTICE
Product safety should be considered when a component replacement is made in any area of the projector.
Components indicated by mark  in the parts list and the schematic diagram designate components in which
safety can be of special significance. It is, therefore, particularly recommended that the replacement of there parts
must be made by exactly the same parts.
DO NOT ATTEMPT TO SERVICING THE
REMO
TECONTROLUNIT.
Laser Beam may be leaked out when in disassemble
the Unit. As the Laser Beam used in this Remote con-
trol unit is harmful to the eyes.
LASER RADIATION
DO NOT STARE INTO BEAM
MAX. OUTPUT: 1mW
WAVE LENGTH: 650±20nm
CLASS 
IILASER PRODUCT
This product is complied with 21 CFR
part 1040.10
CAUTION 
						

							4
■Specifications
●The specifications are subject to change without notice.
This symbol on the nameplate means the product is Listed by Underwriters
Laboratories Inc. It is designed and manufactured to meet rigid U.L. safety stan-
dards against risk of fire, casualty and electrical hazards.
Projector Type Multi-media Projector
Dimensions (W x H x D)12.6” x 6.6” x 18.5” (319mm x 168mm x 470mm) 
Net Weight 20.3 lbs (9.2 kg) (PLC-XP55), 
17.4 lbs (7.9 kg) (PLC-XP55L)
LCD Panel System 1.3” TFT Active Matrix type, 3 panels
Panel Resolution 1024 x 768 dots
Number of Pixels 2,359,296 (1024 x 768 x 3 panels)
Color System PAL, SECAM, NTSC, NTSC4.43, PAL-M and PAL-N
High Definition TV SIgnals 480i, 480p, 575i, 575p, 720p, 1035i and 1080i
Scanning Frequency H-sync. 15 ~ 100kHz, V-sync. 50 ~ 100Hz
Projection LensF 1.7 ~2.0 lens with f=48.2mm ~ 62.6mm  motor zoom and focus (PLC-XP55)
Throw Distance4.6’ ~ 48.3’ (1.4m ~ 14.7m)  (PLC-XP55)
Motorized Lens Shift Up and Down
Projection Image Size (Diagonal) Adjustable from 31” to 400”
Horizontal Resolution 800 TV lines (HDTV)
Projection Lamp 300 watt type 
Input 1/Monitor Output Jacks DVI Terminal (Digital) HDCP Compatible, HDB 15-pin Terminal (Analog)
and Stereo Mini Type Jack (Audio)
Input 2 Jacks BNC Type x 5 (G or VIDEO/Y, B or Cb/Pb, R or Cr/Pr, H and V),
Stereo Mini Type Jack (Audio)
Input 3 Jacks RCA Type x 3 (VIDEO/Y, Cb/Pb, Cr/Pr), RCA Type x 2 (Audio R and L)
and DIN 4-pin (S-Video)
Other Jacks DIN 8-pin (Control port), USB port (Series B receptacle),                   Wired
Remote Jack and PJ-Net Organizer Connector
Built-in Speakers INT. SP. Stereo (R and L), 2 watts RMS (T.H.D. 10%)
Feet Adjustment 0˚ to 10.5˚
Voltage and AC 100 ~ 120V (5.0A Max. Ampere), 50/60Hz (The U.S.A and Canada)
Power Consumption AC 200 ~ 240V (2.5A Max. Ampere), 50/60Hz (Continental Europe and The U.K.)
Operating Temperature 41 ˚F ~ 95 ˚F (5˚C ~ 35˚C)
Storage Temperature 14 ˚F ~ 140 ˚F (-10˚C ~ 60˚C)
Remote Control Transmitters Wireless/Wired Remote Control, batteries AA, UM3 or R06 Type x 2
The CE Mark is a Directive conformity mark of the European Community (EC). 
						

							5
● : Adjustment  necessary ❍ : Check necessary
■Adjustments after Parts Replacement
Condenser lens adjustment❍●
Relay lens adjustment❍●
Contrast Adjustment
R-Contrast adjustment●
G-Contrast adjustment●
B-Contrast adjustment●
Output voltage adjustment●
+16 V adjustment●
Fan output voltage adjustment●●
Video center adjustment●
PSIG adjustment●
PC pedestal adjustment●
PC gain adjustment●
PC gamma gain adjustment●
PC black level adjustment●
Video A/D reference voltage top & bottom adj.●
Video pedestal adjustment●
Video gain adjustment●
Video black level adjustment●
Component pedestal adjustment●
Component A/D reference voltage top adjustment●
Component gain adjustment●
RGB pedestal adjustment●
RGB A/D reference voltage top adjustment●
RGB gain adjustment●
Common center adjustment●●
PC white balance adjustment❍❍
Video white balance adjustment❍❍
Disassembly / Replaced Parts
LCD/
Prism
Ass’yCondenser
LensPolarized glass
RGB
Optical Adjustments
Electrical Adjustments
Sub
Power
BoardMain
BoardRelay
LensPower
Board 
						

							-6-
●Interlock switch
The interlock switch (SW902) cuts off the AC mains power supply
when the lamp cover is removed. After opening the lamp cover
for replacing the lamp ass’y, place the lamp cover correctly other-
wise the projector can not turn on.
●Thermal switch
There is the thermal switch (SW905) inside of the projector to
prevent the internal temperature from rising abnormally. When
the internal temperature reaches near 90˚C, turn off the AC main
power supply automatically.
The thermal switch is not reset to normal automatically even if
the internal temperature becomes normal. Reset the thermal
switch following procedure.
Check the resistance between terminals of thermal switch by
using the tester. If it has high impedance, thermal switch may be
in operative.
How to reset the thermal switch
1.
Loosen 2 screws and open the lamp cover.
2.Press the reset button on the thermal switch with a sharp-
pointed tool.
CAUTION:
Before press the reset button, disconnect the AC cord from the
projector.
■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. Check the fuse as following steps.
It should be used the specified fuse as follows;
How to replace the fuse
1.
Remove the cabinet top following to “Mechanical
Disassemblies”.
2.Remove the fuse from fuse holder.
To install the fuse, take reversed step in the above.
Fuse Part No.: 423 025 1201 
TYPE T8AH 250V FUSE
LITTEL FUSE INC. TYPE 215008
FuseLine Filter Board
Interlock switch
Thermal switch 
Lamp cover 
						

							-7- Circuit Protections
●Warning temperature and power failure protection
The TEMP WARNING 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
supply lines are failed.
Check the following possible causes and wait until stopping the TEMP WARNING indicator flashing.
Possible causes
- Air filter is clogged with dust particles. Remove dust from the air filter by following instructions in the “Air filter
care and cleaning” below.
- Ventilation slots of the projector are blocked. In such an event, reposition the projector so that ventilation slots
are not obstructed.
- Check if projector is used at higher temperature place (Normal operating temperature is 5 to 35 ˚C or 41 to 95˚F)
If the TEMP WARNING indicator still continues to flash, there may be defects on cooling fans or power supply cir-
cuits. Please check fan operation and power supply lines referring to the “Power Supply Lines Chart”.
Air filter care and cleaning
The removable air filter prevents dust from accumulation on the surface of the projection lens and projection mir-
ror. Should the air filter become clogged with dust particles, it will reduce the cooling fan’s effectiveness and may
result in internal heat build up and reduce the life of the projector.
To clean up the air filters, follow the cleaning procedure
below:
1.Turn the power off, and disconnect the AC power cord
from the AC outlet.
2.Turn the projector up side down and remove an air fil-
ters by pulling the latches of them upward.
3.Clean the air filters with brush or wash out the dust and
particles.
4.Replace each air filter properly. Make sure that the air
filters are fully inserted.
CAUTION:
Do not operate the projector with the air filter removed.
The dust is stuck on the LCD panel and the mirror, and it
may spoil the fine picture image.
Do not put the small parts into the air intake vents. It may
result in the malfunction of the projector. The air filter is
small parts. Take care that children don’t eat or swallow it.
RECOMMENDATION
We recommend to avoid dusty, smoky place for operating the projector. Using in dusty place may cause the pic-
ture of poor quality.
When using under the dusty or smoky conditions, dust may accumulate on the LCD panel and lens inside it, and
may resultantly be projected on the screen together with the picture.
When the above symptoms are noticed, please clean up the LCD panel and lens following to the “Cleaning
Method”.
Air filters 
						

							-8-
1Remove 5 screws A, 2 screws B, and loosen 2 screws
C, and thentake the Cabinet Top upward off.
Note: If you want to remove the Cabinet Front-Top only,
you do not need to remove screws 
A. Remove 2 screws
Band Lens Front Cover.
■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.
Fig.1
1Turn the Lens Front Cover counter-clockwise and to
take it off by pulling forward as shown in Fig.2-1.
2Remove the Cabinet Front-Top, Lens Cover Holder and
Lens Cover upward off.
3Remove 2 screws Dto take the Cabinet Front off.
4Remove the RC Board and speakers on the Cabinet
Front.
Fig.2-2
Cabinet Top removal1
Cabinet Front removal2
UP
Fig.2-1
CB AA A
A
B A
D
D
Cabinet Front-Top
Lens
Front
Cover
Lens Cover Holder
Cabinet Front
Lens Cover
C 
						

							-9- Mechanical Disassemblies
1Remove 6 screws to take the Main Board upward.
Fig.3
Fig.4
1Remove 1 screw A and take the Rear Panel ass’y
upward off.
2Remove 4 screws Bto take the fan (FN905) off.
3Remove 5 screws Cand 1 screw Dto take AV Board
from the Rear Panel ass’y off.
4Remove 2 screws Eand grounding leads and then pull
up the I/F Board and Holder assy from the bottom cabi-
net.
5Remove 4 screws Fto take the I/F Board.
Main Board removal3
AV,I/F Board & Rear Panel removal4
Main Board
AB B
B
B
C
D
Rear Panel Ass’y
FN905
AV Board
I/F Board
FF FFEE 
						

							-10- Mechanical Disassemblies
1Remove 4 screws Ato take the Ballast Cover upward
off.
2Remove 3 screws Bto take the Fan (FN904) and the
Fan mounting base off.
3Remove 2 screws Cto take the Fan (FN904)  off from
the Fan mounting base.
4Remove the Sub Power Board and Drive Board by
pulling them upward.
Fig.5 Lamp Ballast Unit removal
5
A
Ballast Board
FN904
Sub Power
Board
Drive Board
AA
A
CC
Ballast Cover
1Remove 1 screw Aand then remove the holder.
2Remove 2 screws Band 4 screws C(small)and pull the
Optical Unit upward off.
3Remove 4 screws Dto take the Fan (FN908) off.
4Remove 1 screws Eto take the Fan (FN903) off and 2
screws 
Fto take the air duct off.
5Remove 3 screws Gto take the Fan (FN907) off.
Fig.6 Optical Unit removal
6
FN908
FN903
Optical Unit
B
BC
C
C
C D
DDE
FF
A
FN907
G
GGB
B
B