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Sanyo PDG-DWL2500 Service Manual

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SERVICE MANUAL

Chassis No. KG8-DWL250000
PrODuCt CODe
1 122 525 00
(KG8AC)
1 122 525 04
(KG8EC)
1 122 526 00
(LG8AC)
1 122 526 02
(LG8CC)
1 122 526 03
(LG8DC)
Multimedia Projector
Match the Chassis No. on the rating label on the projector
with the Chassis No. in the Service Manual.
I f the Original Version Service Manual Chassis No. does
not match the projector's, additional Service Literature is
required. You must refer to "Notices" to the Original Ser-
vice Manual prior to servicing.
FILE NO.
Model No. PDG-DWL2500
U .S.A, Canada, Europe,
U.K, Asia, Brazil
Original Version
SM
REFERENCE NO.
5111271-00

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Summary of Contents for Sanyo PDG-DWL2500

  • Page 1: Service Manual

    FILE NO. SERVICE MANUAL Multimedia Projector Model No. PDG-DWL2500 U .S.A, Canada, Europe, U.K, Asia, Brazil Original Version Match the Chassis No. on the rating label on the projector with the Chassis No. in the Service Manual. I f the Original Version Service Manual Chassis No. does Chassis No. KG8-DWL250000 not match the projector’s, additional Service Literature is required. You must refer to “Notices” to the Original Ser- vice Manual prior to servicing. PrODuCt CODe...

  • Page 2: Table Of Contents

    Contents SERVICE MANUAL ............1 IC Block Diagrams ............45 Contents ................ 2 Parts Location Diagrams ..........50 Safety Instructions ............3 Mechanical Parts List ..........54 Safety Precautions ............. 3 Electrical Parts List ............55 Product Safety Notice ..........3 Service Personnel Warning ........3 Diagrams & Drawings ..........A1 Specifications ..............4 Parts description and reading in schematic diagram . ..A2 Circuit Protections ............5 Schematic Diagrams ...........A3 Thermal switch ............5 Printed Wiring Board Diagrams ........A9 Fuse .

  • 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. For continued product safety and protection of per- sonnel injury, servicing should be made with qualified personnel. The following precautions must be observed. 1: An isolation transformer should be connected in the power line between the projector and the AC DO NOT OPERATE THIS PROJECTOR WITHOUT line before any service is performed on the projec- THE PROTECTIVE SHIELD IN POSITION AND PR...

  • Page 4: Specifications

    Specifications Mechanical Information Projector Type Multi-media Projector Dimensions (W x H x D) 12.6" x 6.7" x 15.2" (321.0 mm x 170.0 mm x 385.0 mm) (Not including protrusions) Net Weight 13.7 lbs (6.2 kg) Feet Adjustment -1.3˚ – +3.8˚ DLP Chip Projection System 0.65" Single DLP chip, 6 segment Color Wheel Number of Pixels 1,024,000 pixels (1,280 x 800 dots) Signal Compatibility Color System PAL, SECAM, NTSC, NTSC4.43, PAL-M, and PAL-N SD/HDTV Signal Component: 480i, 480p, 575i, 575p, 720p and 1080i HDMI; 480p, 575p, 720p and 1080i Input Scanning Frequency H-sync. 15 kHz-93 kHz, V-sync. 50-120 Hz Optical Information Projection Image Size (Diagonal) Adjustable from 60” to 110” Throw Distance 0.75’ - 1.49' (23.0 cm - 45.5 cm) Projection Lens F 2.5 lens with f 4.83 mm with manual focus Projection Lamp 275 W Interface Video Input Jack RCA Type x 1 S-Video Input Jack Mini DIN 4 pin x 1 Audio Input Jacks RCA Type x 2...

  • Page 5: Circuit Protections

    Circuit Protections This projector provides the following circuit protections to operate in safety. If the abnormality occurs inside the pro- jector, it will automatically turn off by operating one of the following protection circuits. Thermal switch Lamp cover switch There is the thermal switch (SW902) inside of the projec- The lamp cover switch (SW901) cuts off the drive signal tor to detect the internal temperature rising abnormally. to the lamp circuit when the lamp cover is removed or When the internal temperature reaches near 120˚C, the not closed completely. After opening the lamp cover for thermal switch opens to cut off the power to the power replacing the lamp ass’y, place the lamp cover correctly circuit. otherwise the projector can not turn on. The thermal switch can be reset itself automatically when the internal temperature becomes normal. When the internal temperature reaches near 80˚C, the thermal switch returns automatically. Fuse A fuse is located inside of the projector. When the POW- Fuse Part No.: 323 025 1204 ER indicator is not lighting, the fuse may be opened. tYPe 8A 250V FuSe Check the fuse as following steps.

  • 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. - I f both of the POWER and WARNING TEMP. indicators are flashing, it may detect the abnormal temperature inside the projector. Check the following possible causes and wait until the POWER indicator stops flashing, and then try to turn on the projector. - I f the WARNING TEMP. indicator lights red, it may defect the cooling fans or power supply circuits. Check fans operation and power supply lines referring to the chapter “Power supply & protection circuit” in the Chassis Block Diagram section. Possible causes - A ir filters are clogged with dust particles. Remove dust from the air filters by following instructions in the “Air filter care and cleaning” below. - V entilation slots of the projector are blocked. In such an event, reposition the projector so that ventilation slots are not obstructed. - C heck if projector is used at higher temperature place (Normal operating temperature is 5 to 40 ˚C or 41 to 104˚F) the projector is shut down and the WArNING teMP.

  • Page 7: Maintenance

    Maintenance Replacing the Filter Filter prevents dust from accumulating on the optical elements inside the projector. Should the filter become clogged with dust particles, it will reduce cooling fans’ effectiveness and may result in internal heat buildup and adversely affect the life of the projector. If a “Filter warning” icon appears on the screen, replace the filter immedi- ately by following the steps below. Lamp cover Turn off the projector, and unplug the AC power cord from the AC outlet. First, clean up the dust on the projector and around the air vents. Loosen the screw and open the lamp cover and lift the Screw filter out of the projector. Reinstall the filter completely and close the lamp cover and secure the screw.

  • Page 8: Lamp Replacement

    Maintenance Lamp Replacement When the projection lamp of the projector reaches its end top Panel of life, the Lamp replacement icon appears on the screen This indicator turns yellow and LAMP REPLACE indicator lights yellow. Replace the when the projection lamp lamp with a new one promptly. The timing when the LAMP reaches the end of its life. REPLACE indicator should light is depending on the lamp mode.

  • Page 9: Resetting The Lamp Counter

    Maintenance Resetting the Lamp Counter Be sure to reset the Lamp counter after the lamp is replaced. When the Lamp counter is reset, the LAMP REPLACE indicator stops lighting and the Lamp replacement icon disappears. Lamp counter reset Press the MENU button to display the On-Screen Menu. Use the Point ed buttons to select Setting and then press the Point 8 or the SeLeCt button. Use the Point ed buttons to select Lamp counter and then press the SeLeCt button. Use the Point ed buttons to select Lamp counter reset and then press SeLeCt button. Lamp replacement counter reset? appears. Select Yes to continue.

  • Page 10: Cleaning

    Maintenance Cleaning After long periods of use, dust and other particles will accumulate on the optical parts, mirror, color wheel, lens etc., causing the picture to darken or color to blur. If this occurs, remove dust and other particles using air spray. Before taking the cleaning, turn off the projector and allow the projector to cool for more than 45 minutes. Never disas- semble the optical unit, mirror or projection lens because those parts are aligned preciously in the factory . If do so, the projector may have the miss-alignment in optical and reduce the optical performance. Cleaning the Color Wheel Cleaning the reflecting Mirror - T he color wheel is made of thin glass. Be very careful - B e careful not to touch the reflecting mirror. Touching when handing the color wheel. it directly with the hands may cause reducing the bur- - I n case of fingerprints, etc. on the surface, gently wipe nishing. with a Cleaning Cloth for optical parts that contains a - Do not clean other than with air. small amount of non-abrasive camera lens cleaner to Caution: clean the surface.

  • Page 11: 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 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. In this case, you must reset those function first according to the resetting procedure described below and then check up on the projector. Function Description Locks operation of the side control or the remote control. If the Key lock is enabled with side control lock, the pro- Key lock jector can no longer be started. Initial setting: Key lock function is disabled Prevents the projector from being operated by an unau- thorized person. PIN code lock Initial code: “1234” Prevents an unauthorized person for changing the start- up logo on the screen. Logo PIN code lock Initial code: “4321” Resetting procedure Disconnect the AC power cord from the AC outlet.

  • Page 12: Standby Mode Notice

    Standby Mode Notice This projector provides 2 types of standby mode, Eco standby and Network standby. According to the standby mode "Eco" or "Network", several functions are restricted as shown in the table below. To change the standby mode, use the projector's menu "Setting". Network .... S upply the power to the network function even after turning off the projector. You can turn on /off the projector via network, modify network environment, and receive an e-mail about projector status while the projector is powered off. Eco .... S elect "Eco" when you do not use the projector via network. The projector's network function will stop when turning off the projector. When "Eco" is selected, several functions will be restricted. Function in the standby mode Function Network Serial command control -- * Network Function Monitor Out Audio Out Direct On *1 Effective only Power-On command. -12-...

  • Page 13: Mechanical Disassembly

    Mechanical Disassembly Mechanical disassembly should be made following procedures in numerical S crews Expression order. (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 origi- nal otherwise it may cause loss of performance and product safety. z Cabinet Top removal 1. R emove 8 screws A(M3x8) to remove the cabinet top assy upward off. Cabinet top assy Lamp cover Optical filter RC Window RC Reflector Control buttons Key sw board (T3x8)x2...
  • Page 14 Mechanical Disassembly x Optical unit Lamp and CW removal 1. Loosen 2 screws A and pull the Lamp assy upward off. 2. R emove 1 screw B(M2.5x6) to remove Temp. Sensor 2 board. 3. R emove 1 screw C(T3x12)x2 and 2 screws D (M4x8) to remove the Optical Unit upward off. (M2x8)x2 (M2x8)x1 (M2x8)x3 CW Sensor board (M2x6)x2 Color Wheel assy Color Wheel (M2x6)x2 Temp Sensor 2 board Bushes Optical unit Lamp assy Fig.2 -14-...
  • Page 15 Mechanical Disassembly c Fans (FN902, FN903, FN904) and SW901 removal 1. R emove 3 screws A(T3x8) to remove the exhaust fan assy. 2. R emove 2 screws B(M3x6) to remove the fan duct assy. Air Filter (T3x8)x2 FN902 (T3x12)x2 (T3x12)x2 FN903 (T3x8)x2 Fan duct assy Exhaust fan assy Label side SW901 (T3x32)x4 Lamp cover switch Fig.3 (T3x6)x1 (T3x8)x1 (T3x8)x1 FN904 -15-...
  • Page 16 Mechanical Disassembly v Power and FanNet Board and fan(FN905) removal 1. Remove 2 screws A(M3x8) to remove the FanNet board. 2. R emove 4 screws B(M3x8) to remove the Power box cover. 3. R emove 2 screws C(M3x8) and 1 screw D(M3x8) to remove the Power board and insula- tion sheet. 4. Remove 4 screws E(M3x8) to remove the Power box frame assy. FanNet Board Power box cover Insulation sheet Power Board Power box frame assy Fig.4 (M3x10)x3 FN905 Gasket Label side -16-...
  • Page 17 Mechanical Disassembly b Ballast Board and Thermal Switch(SW902) removal 1. Remove 2 screws A(M3x6) to remove Side lamp shield. 2. R emove 4 screws B(M3x8) to remove the Lamp house frame. 3. R emove 2 screws C(T3x8) to remove the Ballast board, remove 1 screw D(T3x8) to remove the Trigger box , remove 2 screws E(M3x6) to remove the Ballast socket. Side lamp shield SW902 Thermal switch Thermal switch (M3x10)x1 holder Lamp house frame Socket Trigger box Ballast board Fig.5 Note on mounting the thermal switch (SW902) SW902 Thermal switch Put the thermal switch on the holder and slide it in the arrow direction and then tighten the...

  • Page 18: Line Filter Board Removal

    Mechanical Disassembly n Line Filter Board removal 1. R emove 2 screw A(M3x6) to remove the Focus lever cover. 2. R emove 3 screws B(M3x8) to remove the Line filter shield. 3. R emove 4 screws C(T3x8) to remove the Line filter board and insulation sheet. Line filter shield Line filter board Insulation sheet (M2.6x6)x1 Focus lever cover Spacer sheet Fig.6 -18-...
  • Page 19 Mechanical Disassembly m Main, AV Board and Fans (FN901, FN906) removal-1 1. R emove 1 screw A(M3x6) to remove the Temp. sensor 1 board. 2. R emove 6 screws B(M3x12) to remove the Main and AV board assy. Temp sensor 1 board Main and AV board assy Fig.7 FN901 (M3x10)x2 Label side FN906 Fan Duct (M3x6)x2 (M3x28)x2 (M3x6)x2 -19-...
  • Page 20 Mechanical Disassembly , Main, AV Board and Fans (FN901, FN906) removal-2 (M3x6)x2 Shield cover (M3x6)x2 Insulation sheet AV board Main board (Hex bolt) (M3x6)x1 (T3x6)x3 (Hex bolt) x4 AV panel Speaker Bushes (T3x6)x2 (T3x8)x5 Fig.8 -20-...
  • Page 21 Mechanical Disassembly ⁄0 Note on wiring After disassembling the mechanical parts or electrical parts, the wiring cables must be placed in the original position. Especially the cable dressing indicated in the figure below, use a fixer not to touch the cable to the parts on the primary power circuit. Fix the cables connected to SW902 by using a fixer not to touch the radia- tor on the ballast board. Fix the cables by using a fixer not to touch the radiator on the ballast board. Fig.9 -21-...

  • Page 22: Adjustments

    Adjustments Adjustments after Parts Replacement : Adjustment necessary ❍ : Check necessary Disassembly / replaced Parts Optical unit Color Wheel Power Board Main Board Fan voltage adjustment Auto calibration adjustment [PC] ❍ Auto calibration adjustment [Component] ❍ Color Index Adjustment-1 Color Index Adjustment-2 Note on Main Board Replacement l Memory IC replacement (IC1431) Memory IC on the main board stores the user control value including lamp used time. When the main board is replaced with new one, the lamp used time will be reset. To keep the lamp use time, the memory IC should be...

  • Page 23: Circuit Adjustments

    Adjustments Circuit Adjustments CAUTION: T he each circuit has been made by the fine adjustment at factory. Do not attempt to adjust the following adjustments except requiring the readjustments in servicing otherwise it may cause loss of performance and product safety. Before adjustment, please turn on the projector more than ten minutes. WArNING : uSe uV rADIAtION eYe AND SKIN PrOteCtION DurING SerVICING. CAutION: to prevent suffer of uV radiation, those adjust- ments must be completed within 25 minutes. [Adjustment Condition] l Input signal Analog Computer signal .. 0 .7Vp-p/75W terminated (WXGA) Composite Video signal .
  • Page 24 Adjustments z Fan Voltages adjustment x PC Auto calibration Equipment Digital voltmeter Input mode Computer 1 (RGB) mode Input signal 16-step gray scale computer signal 1. Enter the service mode. 2. C onnect the Digital voltmeter to the test point listed 1. Enter the service mode. below. 2. S elect Group "260", No. "0" and set data value "0" to 3. A djust the voltage on each test point by changing the "1". data values of the Group - No. T he projector begins auto-calibration and then "OK" will appear on the screen.
  • Page 25 Adjustments Color Index adjustment-1 Color Index adjustment-2 Condition Dark room Condition Dark room Input mode Computer 1 (RGB) mode Input mode Computer 1 (RGB) mode Image mode Dynamic Image mode Dynamic Input signal R GBW-Ramp pattern (Internal sig- Input signal R GBW-Ramp pattern (Internal sig- nal) nal) 1. Enter the service mode. 1. Enter the service mode. 2. S elect Group "151", No. "21" and set data value to 2. S elect Group "151", No. "21" and set data value to "1". The RGBW-Ramp internal pattern is displayed on "1". The RGBW-Ramp internal pattern is displayed on the screen. the screen. 3. S elect Group "151", No. "0" and set data value to the 3. S elect Group "151", No. "0" and change data value to specified index value which is printed on the label of obtain the proper gradation color image is reproduced...

  • Page 26: Service Adjustment Data Table

    Adjustments Service Adjustment Data Table These initial values are the reference data written from the CPU ROM to memory IC when replaced new memory IC. The adjust- ment items indicated with “✻” are required to readjust following to the “Electrical adjustments”. Other items should be used with the initial data value. Group/ Item Name Function Initial Range Note Item Group 0 AD Converter (AF1000) 0 Green Offset PC / Component 512/512 0 - 4095 1 Red Offset PC / Component 512/512 0 - 4095 2 Blue Offset PC / Component...
  • Page 27 Adjustments Group/ Item Name Function Initial Range Note Item 0: Off 1: Color Ramp 2: Color Bar 3: 16 step 21 Test Pattern 4: Grid 5: Green Grid 0 - 9 6: 1-line Pattern 7: 1-dot Pattern 8: BC Calibration 9: Half Cross Group 155 CCA 0 CCA Disable...
  • Page 28 Adjustments Group/ Item Name Function Initial Range Note Item 4 Fan3 Min. Adjust (DAC) 0 - 255 5 Fan3 Max. Adjust (DAC) 0 - 255 6 Fan4 Min. Adjust (DAC) 0 - 255 7 Fan4 Max. Adjust (DAC) 0 - 255 8 Fan5 Min.
  • Page 29 Adjustments Group/ Item Name Function Initial Range Note Item Group 254 FAN Control Range Setting (Temp./Voltage) Normal Ceiling Bottom 0 Normal Fan Control Min. Temp Temp Sensor Control Start/End at Normal 20 - 100 1 Normal Fan Control Max. Temp 20 - 100 2 Normal Fan1 Min.
  • Page 30 Adjustments Group/ Item Name Function Initial Range Note Item 1 Loop Count Maximum Execution Times (OFFSET->GAIN) 1 - 30 Result of Auto-Calibration (Last Memory) 2 Auto Status 0 / 1 / 9 0: OK, 1: Adjusting, 2: Error 3 AutoWait Wait Value for each setting 1 - 20 4 CHECK -Tolelance...
  • Page 31 Adjustments Group/ Item Name Function Initial Range Note Item 8 VSBEG 0 - 255 15 Field Diff (SEP) Even/Odd Phase Compensation on HV Sync 0 - 2 16 Field (SOG) Even/Odd Phase Compensation on SOG Sync 0 - 2 Group 511 RGB Video (575i) 2 H Back Porch 0 ~ 4095 3 V Back Porch...
  • Page 32 Adjustments Group/ Item Name Function Initial Range Note Item 8 VSBEG 0 - 255 Group 526 RGB Video (1080PSF - 24) 2 H Back Porch 0 ~ 4095 3 V Back Porch 0 ~ 4095 7 Overscan 0 - 255 8 VSBEG 0 - 255 15 Field Diff (SEP)
  • Page 33 Adjustments Group/ Item Name Function Initial Range Note Item Group 551 YCrCb (1080p - 30) 2 H Back Porch 0 ~ 4095 3 V Back Porch 0 ~ 4095 7 Overscan 0 - 255 8 VSBEG 0 - 255 Group 552 YCrCb (1080p - 25) 2 H Back Porch 0 ~ 4095 3 V Back Porch...

  • Page 34: Chassis Block Diagrams

    Chassis Block Diagrams Chassis over view -34-...

  • Page 35: System Control

    Chassis Block Diagrams System control IC401 DLP DATA PROCESSOR DDP2431 -35-...

  • Page 36: Power Supply & Protection Circuit

    Chassis Block Diagrams Power supply & protection circuit -36-...

  • Page 37: Fan Control Circuit

    Chassis Block Diagrams Fan control circuit 16VF D7811 FN901 IC7811 FAN1 D7812 Q7811 D7821 FAN_CONT1 K07A FN902 K77B IC7821 FAN2 D7702 D7831 Q7821 FAN_CONT2 FN903 K77C FAN3 IC7831 D7703 D7841 Q7831 FAN_CONT3 FN904 IC7881 K77D FAN4 IC7841 <M62393> D7851 D7704 Q7841 FAN_CONT4 FN905...

  • Page 38: Troubleshooting

    Troubleshooting Indicators and Projector Condition Check the indicators for projector condition. Indicators WARNING Projector Condition POWER LAMP RE- TEMP PLACE red/green yellow blue The projector is off. (The AC power cord is unplugged.) The projector is in stand-by mode. Press the ON/STAND- BY button to turn on the projector. The projector is operating normally. green The projector is preparing for stand-by or the projection lamp is being cooled down. The projector cannot be turned on until cooling is completed and the POWER indicator stops blinking.

  • Page 39: 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. Check the power primary circuit and parts as follow; AC cord, F601 (Fuse), Line Filter board, SW902 (Thermal sw.) ....short in normal S W902 opens when the surrounding temperature of the switch exceeds 120°C. - W hen the WArNING teMP (red) and POWer (red) indicators are blinking, the symptom indicates that the projector detected an abnormal temperature risen inside the projector. Check the air filter and remove the object near the intake and exhaust fan openings, and wait until the POWER indicator stops blinking, and then try to turn on the projector. T he internal temperature is monitored by sensor ICs, IC8801 on the Temp Sensor 1 board, IC8811 on the Temp Sensor 2 board, IC8821 on the Main board.

  • Page 40: No Picture

    Troubleshooting No Picture Check following steps. No picture with all of in- put sources Check signal processing stage and DMD driving stage; C heck IC401 <DLP Data Processor>, IC2501 <DMD Power&Motor Drive>, or DMD module and peripheral cir- IC3501 <DMD Power&Reset Drive> cuits. No picture with PC1 [An- C heck IC8201 <A/D Converter> and peripheral circuit. alog rGB] input source T he R1_IN, G1_IN, B1_IN, H1_IN,V1_IN signals are applied to pins only 11, 2, 18, 81, 78.

  • Page 41: No Sound

    Troubleshooting No Sound Check following steps. Check IC5101 <Audio Selector> and Audio Input stage and peripheral Check if the audio sig- circuit. nal is observed at pins 7 and 15 of IC5101. Check 12V_AUDIO power supply. Check if the audio sig- nal is observed at pin 3 Check IC5101 and peripheral circuit. of IC001. Check Audio Output circuit or Muting circuit. The Mute signal is output from pin 137 of IC401<DLP Processor>. The Data OUT_DET signal is sent from Audio Out terminal.

  • Page 42: Error Log

    Troubleshooting Error Log This projector provides the error history log function. To Group Item Data (Error Code) check the logs, you need to enter the service mode and se- <- Latest Error ✻ lect Group No. "220" and Item No. "0" to "49". The error ✻ code is displayed on the Data column. The description of the ✻ error code is listed on the table below. ✻ * H ow to enter the service mode and select the group, item and data value, see "Service Adjustment Menu Opera- ✻...

  • Page 43: Control Port Functions

    Control Port Functions System Control (DDP, IC401) PIN NO. PORT NO. SIGNAL NAME DESCRIPTION LAMPCTRL Lamp On: H LAMPSTAT Lamp Error: H USB_DAT_PS USB_DAT_NS SCL0 IIC Bus Control Clock SDA0 IIC Bus Control Data SDA2 IIC Bus Control Data SCL2 IIC Bus Control Clock UART1_MCI_DDP Serial Control Rxd...

  • Page 44: Iic Bus D/A Converter (Fan Control, Ic7881)

    Control Port Functions IIC Bus D/A Converter (Fan Control, IC7881) ACTION PIN NO. FUNCTION NAME FUNCTION POL. Stand-by Power On Reset Input -> IIC BUS SCL -> IIC BUS SDA -> FAN_CONT5 FN905 Control Voltage (Power Box Exhaust Fan) -> 0:FAN Max ~ 255:FAN Min FAN_CONT6 FN906 Control Voltage (Color Wheel Intake Fan)

  • Page 45: Ic Block Diagrams

    IC Block Diagrams l AD8075ARU <RGB Switch, IC4001> AD8074 /AD8075 DGND Out2 +1/+2 AGND Out1 +1/+2 AGND Out0 +1/+2 l FA5550NG <P.F. Control, IC621> -45-...
  • Page 46 IC Block Diagrams l FA7701 <DC-DC Control, IC5611> U V L O V R E F 0.3V ON/OFF – VREF 2.2V O S C 5.5V S.C.P 1.5V – BIAS S.C.DET 2.2V 1.5V Power Good Signal – IN– ON/OFF 0.88V – –...
  • Page 47 IC Block Diagrams l LC87F2G08A <Sub Micom, IC4501> l LV49152V <Audio Output, IC001> -47-...
  • Page 48 IC Block Diagrams l M62393 <DAC,IC7881> l MR4010 <Power Switching, IC631> -48-...
  • Page 49 IC Block Diagrams l NJW1156 <Audio Selector,IC5101> l PIC18F67J60 <Network, IC8301> -49-...

  • Page 50: Parts Location Diagrams

    KG8-DWL250000 Parts Location Diagrams Cabinet top assembly C03-1 A6801 KEY BOARD Cabinet bottom-1 assembly A8801 TEMP SENSOR1 BOARD FN902 LP900 A9701 FANNET BOARD FN903 FN904 SW901 LAMP COVER SW A601 FN905 POWER BOARD -50-...
  • Page 51 KG8-DWL250000 Parts Location Diagrams Cabinet bottom-2 assembly A8811 TEMP SENSOR2 BOARD A602 Z602&6C LINE FILTER BOARD (SW902) SP901 A901A A901 BALLAST BOARD Cabinet bottom-3 assembly K30A1-A2 K30B1-B2 K38A1-A2 FN901 A1001 AV BOARD A401 FN906 MAIN BOARD -51-...
  • Page 52 KG8-DWL250000 Parts Location Diagrams Color Wheel A6701 CW SENSOR BOARD L01-1 * L01 provides with A6701 and L01-1. -52-...
  • Page 53 KG8-DWL250000 Parts Location Diagrams l Accessories (see accessories parts list) REMOTE CONTROL MANUALs CD-ROMs VGA CABLE AC CORD -53-...

  • Page 54: Mechanical Parts List

    KG8-DWL250000 Mechanical Parts List Note: Parts order must contain Chassis No., Part No., and Descriptions. Key No. Part No. Key No. Part No. Description Description Key No. Part No. Key No. Part No. Description Description SCREWS 411 185 8802 SCR S-TPG PAN 3X8 PACKING MATERIALS 412 079 6409 SPECIAL SCREW...

  • Page 55: Electrical Parts List

    KG8-DWL250000 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. l read Description in the parts list Read description in the Capacitor and Resistor as follows: CAPACItOr CERAMIC 100P K 50V Rated Voltage Tolerance Symbols: Less than 10pF A : Not specified B : ±0.1pF C : ±0.25pF D : ±0.5pF E : +0 -1pF F : ±1PF G : ±2pF H : +0.1 -0pF L : +0 -0.1pF R : ±0.25 -0pF S : +0-0.25pF More than 10pF A : Not specified B : ±0.1% C : ±0.25% D : ±0.5% F : ±1% G : ±2% H : ±3% J : ±5% K : ±10%...
  • Page 56 KG8-DWL250000 Electrical Parts List Key No. Part No. Description Key No. Part No. Description 305 015 8727 TR 2SC2812-L6-TB 305 015 8925 TR 2SC2812-L7-TB ASSEMBLED BOARDS 305 163 1615 TR 2SC2812N-L6-TB0 305 173 9816 TR 2SC3928A1R ! A401 610 350 0096 ASSY,PWB,MAIN KG8AC 305 173 9915 TR 2SC3928A1S...
  • Page 57 KG8-DWL250000 Electrical Parts List Key No. Part No. Description Key No. Part No. Description 305 163 1615 TR 2SC2812N-L6-TB0 305 163 1615 TR 2SC2812N-L6-TB0 305 173 9816 TR 2SC3928A1R 305 173 9816 TR 2SC3928A1R 305 173 9915 TR 2SC3928A1S 305 173 9915 TR 2SC3928A1S Q3052 305 134 5928...
  • Page 58 KG8-DWL250000 Electrical Parts List Key No. Part No. Description Key No. Part No. Description 305 173 9915 TR 2SC3928A1S 305 015 8727 TR 2SC2812-L6-TB 305 015 8925 TR 2SC2812-L7-TB Q5151 305 014 4512 TR 2SC2412K T146 R 305 163 1615 TR 2SC2812N-L6-TB0 305 014 4611 TR 2SC2412K T146 S...
  • Page 59 KG8-DWL250000 Electrical Parts List Key No. Part No. Description Key No. Part No. Description 305 015 8925 TR 2SC2812-L7-TB 305 173 9816 TR 2SC3928A1R 305 173 9915 TR 2SC3928A1S 305 163 1615 TR 2SC2812N-L6-TB0 Q6221 305 191 5814 TR 3LN01C-TB-E 305 173 9816 TR 2SC3928A1R Q6222...
  • Page 60 KG8-DWL250000 Electrical Parts List Key No. Part No. Description Key No. Part No. Description 303 409 3426 CERAMIC 0.1U K 403 478 5912 CERAMIC 1U K C007 303 396 9613 CERAMIC 1U K C1422 303 438 0219 CERAMIC 0.1U K 303 397 7618 CERAMIC 1U K...
  • Page 61 KG8-DWL250000 Electrical Parts List Key No. Part No. Description Key No. Part No. Description 303 454 1214 CERAMIC 1000P K 303 409 3426 CERAMIC 0.1U K C1451 403 455 1012 CERAMIC 1U K 303 276 1317 CERAMIC 1000P K 303 433 1112 CERAMIC 1U K C1486...
  • Page 62 KG8-DWL250000 Electrical Parts List Key No. Part No. Description Key No. Part No. Description 303 453 8610 CERAMIC 0.1U K C2522 303 383 5215 CERAMIC 4.7U K 6.3V 303 393 2112 CERAMIC 4.7U K 6.3V 303 409 3426 CERAMIC 0.1U K C2526 303 392 1215 ELECT...
  • Page 63 KG8-DWL250000 Electrical Parts List Key No. Part No. Description Key No. Part No. Description C3816 403 455 1012 CERAMIC 1U K 304 091 2609 CERAMIC 0.1U K C3513 303 367 0410 CERAMIC 0.1U K 303 433 1112 CERAMIC 1U K 303 370 1510 CERAMIC 0.1U K...
  • Page 64 KG8-DWL250000 Electrical Parts List Key No. Part No. Description Key No. Part No. Description 303 453 8917 CERAMIC 0.1U K 303 453 8610 CERAMIC 0.1U K 303 409 3426 CERAMIC 0.1U K 303 453 8610 CERAMIC 0.1U K C407 303 438 0219 CERAMIC 0.1U K 303 409 3426...
  • Page 65 KG8-DWL250000 Electrical Parts List Key No. Part No. Description Key No. Part No. Description C4701 303 438 0219 CERAMIC 0.1U K 303 370 0018 CERAMIC 10U K 6.3V 303 368 7319 CERAMIC 10U K 6.3V 303 453 8917 CERAMIC 0.1U K C4501 303 438 0219 CERAMIC...
  • Page 66 KG8-DWL250000 Electrical Parts List Key No. Part No. Description Key No. Part No. Description C5611 303 396 9613 CERAMIC 1U K 303 397 7618 CERAMIC 1U K 403 478 5912 CERAMIC 1U K 303 397 7618 CERAMIC 1U K C5102 303 396 9613 CERAMIC 1U K...
  • Page 67 KG8-DWL250000 Electrical Parts List Key No. Part No. Description Key No. Part No. Description C7802 403 455 1616 CERAMIC 10U K 303 433 1112 CERAMIC 1U K C5814 403 455 1012 CERAMIC 1U K 403 478 5813 CERAMIC 10U K 303 433 1112 CERAMIC 1U K...
  • Page 68 KG8-DWL250000 Electrical Parts List Key No. Part No. Description Key No. Part No. Description C7886 303 438 0219 CERAMIC 0.1U K 303 409 3426 CERAMIC 0.1U K C7841 303 438 0219 CERAMIC 0.1U K 303 453 8917 CERAMIC 0.1U K 303 453 8917 CERAMIC 0.1U K...
  • Page 69 KG8-DWL250000 Electrical Parts List Key No. Part No. Description Key No. Part No. Description C8072 403 455 1012 CERAMIC 1U K 303 370 0018 CERAMIC 10U K 6.3V 303 368 7319 CERAMIC 10U K 6.3V 303 433 1112 CERAMIC 1U K C8022 303 438 0219 CERAMIC...
  • Page 70 KG8-DWL250000 Electrical Parts List Key No. Part No. Description Key No. Part No. Description 303 453 8610 CERAMIC 0.1U K 303 409 3426 CERAMIC 0.1U K C8217 303 454 1917 CERAMIC 4700P K 303 409 3426 CERAMIC 0.1U K 303 379 7315 CERAMIC 4700P K C8244...
  • Page 71 KG8-DWL250000 Electrical Parts List Key No. Part No. Description Key No. Part No. Description C8371 303 358 3215 CERAMIC 10U K 6.3V 303 409 3426 CERAMIC 0.1U K C8302 303 438 0219 CERAMIC 0.1U K 303 370 0018 CERAMIC 10U K 6.3V 303 368 7319 CERAMIC...
  • Page 72 KG8-DWL250000 Electrical Parts List Key No. Part No. Description Key No. Part No. Description R2572 301 224 8913 MT-GLAZE 100K JA 1/16W R1434 301 225 1913 MT-GLAZE 68 JA 1/16W R1436 301 225 1913 MT-GLAZE 68 JA 1/16W R2573 301 226 1516 MT-GLAZE 0.000 ZA 1/16W R2574...
  • Page 73 KG8-DWL250000 Electrical Parts List Key No. Part No. Description Key No. Part No. Description R413 301 225 0312 MT-GLAZE 33 JA 1/16W R3088 301 226 1516 MT-GLAZE 0.000 ZA 1/16W R3091 301 225 1210 MT-GLAZE 4.7K JA 1/16W R414 301 226 1516 MT-GLAZE 0.000 ZA 1/16W R3092...
  • Page 74 KG8-DWL250000 Electrical Parts List Key No. Part No. Description Key No. Part No. Description R5142 301 224 9316 MT-GLAZE 1K JA 1/16W R465 301 226 1516 MT-GLAZE 0.000 ZA 1/16W R466 301 226 1516 MT-GLAZE 0.000 ZA 1/16W R5143 301 225 0213 MT-GLAZE 3.3K JA 1/16W R5144...
  • Page 75 KG8-DWL250000 Electrical Parts List Key No. Part No. Description Key No. Part No. Description R7852 301 284 3613 MT-GLAZE 16K JA 1/16W R5822 301 224 9316 MT-GLAZE 1K JA 1/16W R5823 301 224 9316 MT-GLAZE 1K JA 1/16W R7853 301 225 0510 MT-GLAZE 33K JA 1/16W R5824...
  • Page 76 KG8-DWL250000 Electrical Parts List Key No. Part No. Description Key No. Part No. Description 645 093 1048 IMPEDANCE,120 OHM P R8098 301 224 9019 MT-GLAZE 10K JA 1/16W R8099 301 224 9019 MT-GLAZE 10K JA 1/16W R8347 645 100 9340 IMPEDANCE,120 OHM P R8151 301 224 9712...
  • Page 77 KG8-DWL250000 Electrical Parts List Key No. Part No. Description Key No. Part No. Description COIL L9801 945 086 6037 IMPEDANCE,330 OHM P L001 945 041 1978 INDUCTOR,330 OHM DIODE L002 945 038 4579 INDUCTOR,33U M D2511 307 250 0716 DIODE RB060M-30-TR 945 075 1012 INDUCTOR,33U M D2512...
  • Page 78 KG8-DWL250000 Electrical Parts List Key No. Part No. Description Key No. Part No. Description D5611 307 201 2724 DIODE RB051L-40-TE25 D5621 307 223 0514 ZENER DIODE 02DZ12Y(TPH3) A1001 610 350 0072 ASSY,PWB,AV KG8AC 307 221 7119 ZENER DIODE UDZS-TE-1712B 408 063 1802 ZENER DIODE MM3Z12B CAPACITOR D5641 307 201 2724...
  • Page 79 KG8-DWL250000 Electrical Parts List Key No. Part No. Description Key No. Part No. Description L3802 945 068 8325 FILTER,EMI 20MHZ 305 173 9816 TR 2SC3928A1R L5001 945 068 8325 FILTER,EMI 20MHZ 305 173 9915 TR 2SC3928A1S L5002 945 068 8325 FILTER,EMI 20MHZ Q2816 305 014 4512...
  • Page 80 KG8-DWL250000 Electrical Parts List Key No. Part No. Description Key No. Part No. Description 307 221 7119 ZENER DIODE UDZS-TE-1712B 408 063 1802 ZENER DIODE MM3Z12B A9701 610 350 1161 ASSY,PWB,FANNET KG8AC MISCELLANEOUS CAPACITOR A2801 645 102 3773 UNIT,REMOCON RECEIVER C4751 303 438 0219 CERAMIC 0.1U K SW6801 945 026 2792...
  • Page 81 KG8-DWL250000 Electrical Parts List Key No. Part No. Description Key No. Part No. Description D7705 307 163 0414 DIODE 1SS352-(TPH3) 404 115 6306 ELECT 330U M 420V 307 149 0810 DIODE 1SS355-TE-17 C621 303 336 3510 CERAMIC 0.47U K 408 062 7201 DIODE 1SS35 403 459 8017 CERAMIC...
  • Page 82 KG8-DWL250000 Electrical Parts List Key No. Part No. Description Key No. Part No. Description R618 301 188 3313 MT-GLAZE 680K JA 1/4W D611D 645 098 1715 CORE,FERRITE R619 301 256 0718 MT-GLAZE 33 JA 1/10W D612 307 163 0414 DIODE 1SS352-(TPH3) R620 301 256 6512 MT-GLAZE...
  • Page 83 KG8-DWL250000 Electrical Parts List Key No. Part No. Description Key No. Part No. Description -83-...
  • Page 84 SANYO electric Co., Ltd. (KG8AC) July / 2010 DC 50 Printed in Japan...

  • Page 85: Diagrams & Drawings

    Diagrams & Drawings Schematic Diagrams Printed Wiring Board Drawings Model Chassis No. PDG-DWL2500 KG8-DWL250000 these schematic diagrams and printed wiring board drawings are part of the service manual original for chassis No. KG8-DWL250000 model PDG- DWL2500. File with the service manual No. SM5111271-00...

  • Page 86: Parts Description And Reading In Schematic Diagram

    KG8-DWL250000 Parts description and reading in schematic diagram 1. T he 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. S ome of transistors and diodes are indicated in mark Characteristic for the substitution of parts name. Please check the Example 6 W K 8.2 Z (Carbon fuse) parts name by the following code table. B (Non-burnable) 3. V oltages and waveforms were taken with a video color bar signal (1Vp-p at 75 ohms terminated) and Example 1/2 C K 1M...
  • Page 87 KG8-DWL250000 Pin description of diode, transistor and IC l Diode l transistor/Fet l IC...

  • Page 88: Note On Soldering

    Note on Soldering 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. when carrying out repair work, and never use solder Metal content Tin (Sn) Silver (Ag) Copper (Cu)
  • Page 89 Schematic Diagrams LP900 PROJECTION LENS A901 A901A 1AA4W30B50002 Z47A&CN2 LAMP BALLAST 1AA95BFBE1408 LAMP_DET LAMP_SW Indication of Signals / SW902A FILTER 81N83K2R0 SW902 S40B0170N Power Failure, Fan Failure Detection Signals SW902B THERMOSTAT SW - NO POWER when one of those signals detects a failure. 81N83K2R0 AC100-120V AC100-240V...
  • Page 90 K20A B4J31B01100 ;J31B06701 L2006 L2007 R2003 L2A92R2MG L2A92R2MG 1/16GJ10A K20A_7 VIDEO_EXT SC2001 R2001 R2002 L2001 VIDEO 1/16GF150A 1/16GF150A K20A_G Z30B F34DH107G R2007 0220G C2001 C2002 C2003 1/16GJ10A K20A_4 CJ330CM KK680GQ CJ330CM S_CHROMA_EXT R2004 SC2002 R2006 L2002 1/16GF150A 1/16GF150A Z30B F34DH107G R2011 0220G S-VIDEO...
  • Page 91 C3041 D3043 6.3KK10BA RB521S-30G 5VPCDDC_A D3044 DDC BUS-SW L3041 RB521S-30G R8201 D3046 L3BE331PG DDC MEMORY 1/16GZ0A UDZS6.2BG V1_IN R8202 IC6202 5VPCDDC_A 1/16GZ0A R6202 V2_IN R3041 DDC1_PCA TC74LVX4053FT IC6201 D3042 1/16GZ0A 1/16GJ4.7KA C6202 02DZ12YG R3042 R8203 DDC2_PCA 24LC21A/SNP 1/16GZ0A 16KK0.1MN 1/16GZ0A H1_IN EXT_CLK <IC401>...
  • Page 92 IC5851 TC7SH00FUP IC5852 TC74VCX32FTP P3P3V P3P3V P3P3V C5851 R5851 K401C P3P3V 1/16GZ0A 16KK0.1MN C5852 PFAIL_-5V 16KK0.1MN R443 R5856 R5858 1/16GJ33A 1/16GZ0A SSP0_CLK_DMD 1/16GJ10KA PFAIL_FAN PFAIL_P1P9V_AFE R442 R5852 SSP0_TXD_DMD PFAIL_P1P2V_HDMI 1/16GJ33A TRACECLK PM_DAT[0-15] PM_DAT[0-15] 1/16GZ0A R5854 R441 SSP0_CSZ1_DMD 1/16GZ0A 1/16GJ33A ICE_RSTZ IC1401 TDO2 P3P3V...
  • Page 93 DMD MODULE "K40A" VCC2 P3P3V C3533 16KK0.1MN C3531 16KK0.1MN C3534 16KK0.1MN C3532 16KK0.1MN K35C J10TNA00G L2546 L26B3450G R2546 DC12V P12V R2525 R2544 SN2506 C2543 1/16GD2KA 16KK0.1MN P2P5V P1P8V D2551 C2527 Q2524 SN2507 6.3EM473T 2SK3492EP R2526 VCC2 R2522 R2547 1/16GF1.6KA 1/16GD2KA VBIAS A1P8V C2522...
  • Page 94 TEMP SENSOR2 IC7881 DMD TEMP. M62393FPP Q5611 ES16V P3P3V R5612 RSQ025P03G K88H R5611 J10QF045G R5624 1/16GZ0A P3P3V D5621 1/16GJ C8841 IC8811 L5601 02DZ12YG 1/16GJ C7881 16KK0.1MN K8A_G1 R5602 C8811 16KK0.1MN R7895 K8H_1 K88H_1 P3P3V MCP9801T L3DD680PG 1/16GJ10KA 16KK0.1MN K8A_1 LAMPDC_ON L5613 R7881 1/16GJ10A...

  • Page 95: Printed Wiring Board Diagrams

    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 A/V (SIDe:A) MAIN 1. D o not touch the part on hot side (primary circuit) or both parts on hot and cold “K96B” 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. K96A A30C5 C2001 K50A...
  • Page 96 MAIN (SIDe:A) FAN NET CW SENSOR “K07A” R4702 R4701 R2857 R2852 D5611 K38C IC8821 R8821 R8822 K4501 C4502 R4533 R4531 R8823 L5611 R4528 R8824 R8826 R4523 R5818 RB4501 R4522 C8821 R4709 C7826 C7846 R2854 R4521 R2856 R4516 C2851 R4537 PWB,MAIN KG8AC IC4501 R4539 GPIO_25 1AA4B10C6720A...
  • Page 97 MAIN (SIDe:B) C7868 C7828 R4718 R2839 D2839 R2851 L4716 R2832 D2832 L4714 R4717 L4711 C7848 R2833 D2833 R2853 Q4701 R2836 D2836 R4724 R2838 D2838 D4701 R4707 R458 R1427 R4711 R1421 C1467 C5602 R4713 R4722 IC5611 R1422 R4714 C5601 R4721 R1443 C1466 Q5652 R5664...
  • Page 98 POWer (SIDe:A) POWer (SIDe:B) 1AA4B10C6820A PARTS SIDE L613 PWB,POWER KG8AC LAMP BALLAST 1AA4B10C6820A L613 A30C5 A30C5 SOLDER SIDE F631 “CN1” F631 L614 L614 Q643 Q643 R635 R635 C632 IC631 R614 C632 R614 IC631 R685 D666 IC621 D666 R685 C614 T651H1 T651H6 T651H3 C614 R643...

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