LCD PROJECTORS FILE NO.

PBS LCD Projectors

PLC5600 series
PLC8800 series

TRAINING MANUAL
Contents
WARNING !.......................................... 5
Safety Notice ! ...................................... 5
Service Personnel Warning ................... 5
PBS LCD Projectors ............................. 7
New XGA panels and drive circuits ..... 7
Polarised Beam Splitter (PBS) system.. 9
Simplified Block diagram ................... 10
Block Diagram Description ................ 11
A/D and Memory system .................... 12
PC ID and TIMING Control ............... 12
Computer Signal Path ......................... 13
AV Signal Path .................................... 13
Picture Image Control ......................... 13
Mouse and Serial interface ................. 13
Power Supply ...................................... 14
Regulation ........................................... 14
Active Filter ........................................ 15
Protection ............................................ 15
Power supply protection circuit .......... 15
POWER SUPPLY INTERCONNECTIONS ................... 16
Power Switch-on circuits .................... 17
Lamp Circuit ....................................... 17
Temperature monitor .......................... 17
Power Fail Rail ................................... 18
Remote control.................................... 19
Firmware upgrade ............................... 20
Service Position .................................. 21
New service mode............................... 21
Adjustments ........................................ 21
PBS adjustments ................................. 22
Parts Position ...................................... 23
Cable & wire positions ....................... 24
And now it's broken ............................ 25
3 PBS - LCD Projectors Training Manual
Index
A/D and Memory system .................... 12
Active Filter ........................................ 15
Adjustments ........................................ 21
And now it's broken ............................ 25
AV signal Path..................................... 13
Block Diagram Description ................ 11
Cable & wire positions ....................... 24
Computer Signal Path ......................... 13
Firmware upgrade ............................... 20
Lamp Circuit ....................................... 17
Mouse and Serial interface ................. 13
New service mode ............................... 21
New XGA panels and drive circuits ..... 7
Parts position....................................... 23
PBS adjustments ................................. 22
PC ID and TIMING Control ............... 12
Picture Image Control ......................... 13
Polarised Beam Splitter (PBS) system .. 9
PBS LCD Projectors ............................. 7
Power Fail Rail ................................... 18
Power Supply ...................................... 14
POWER SUPPLY INTERCONNECTIONS ................. 16
Power supply protection circuit .......... 15
Power Switch-on circuits .................... 17
Protection ............................................ 15
Regulation ........................................... 14
Remote control.................................... 19
Safety Notice ! ...................................... 5
Service Personnel Warning ................... 5
Service Position .................................. 21
Simplified Block diagram ................... 10
Temperature monitor .......................... 17
WARNING ............................................ 5
 WARNING

Safety Notice

Service Personnel Warning

Never turn the power on without the lamp installed. Electric shock and/or
damage may occur since the lamp circuitry produces 10kV to 15kV during the
startup phase.

Since the lamp is at a very high temperature during its operation, it is recom-
mended that the replacement of the lamp occur at least one hour after the
lamps has been turned off.

N E V E R , N E V E R u s e A I R S P R AY f o r c l e a n i n g t h e o p t i c s
while the power is turned ON.

Many of these sprays contain highly inflammable gas. The very high tempera-tureof
the lamp and optics can cause fire or an explosion.
It is recommended to use ONLY compressor air for cleaning.

Eye damage may result from directly viewing the light produced by the lamp in this
equipment. Ultraviolet radiation eye protection required during servicing.

5 PBS - LCD Projectors Training Manual

 POLARIZED BEAM SPLITTER LCD PROJECTORS
PLC5600 & PLC8800 series

New XGA panels and drive circuits

The display area of the XGA panel is made-up from a 1024x768 TFT matrix.
Each horizontal line is split-up in series of 12 pixels.
This is twice the number used in VGA and SVGA models.
Videosignals are input as VIDEO1 - VIDEO12. (VIDEO1 - VIDEO6 on SVGA models)
Three pairs of S/H LCD drive IC's (IC501/1501, IC531/1531, IC561/1561) IC are used.
The panel has a build-in function to display images up/down (DIR Y) and/or
left/right (DIR X) inverted.
On this panels the COMMON or PSIG signal is called NRS (Noise Reduction Signal).
Control signals to the panels are level-shifted in specific IC's type LA4105. (IC2501 etc)
RGB interfaces are similar to SVGA PLC5500 series. (IC401/1401)

Polarized
Beam
Spiltter

Fig 1

7 PBS - LCD Projectors Training Manual

Polarised Beam Splitter (PBS) system

The modulation of light passing through a LCD panel is possible by twisting the polarisation of
the light. In standard LCD projectors the panel is sandwiched between two Polarizing Filters.
The light going into the panel is only the P wave. Normal light from the lamp has P and S waves.
The input polarizing filter blocks the S wave. This means that about 50% of the amount of light
is lost. By using a P wave-only light source, the luminosity can be almost doubled.
In the PBS system the light from the lamp is converted in P wave-only light.
This is possible by a special optical lens system where all S waves are twisted 90 degrees,
leaving the lens as P waves.
The efficiency is almost a double light output.
By using this PBS system one can reduce the lamppower and maintain the same light output.
In such way it is possible to save on power consumption, lamp temperature and thus cooling.
Furthermore the new XGA models use the new UHP lamp. This lamp has a very high pressure
bulb, 100-120 Hp compared to 20-42 Hp for a standard metal-halide lamp.
The power of the lamp could be reduced to 120 Watt.

P wave P wave P wave P wave P wave P wave

Integrator
12x18 Half wave plate
shift S > P
PBS
Polarized
Beam S wave S wave
Splitter

Integrator
9x12
Normal Lamp Light

Fig 2

9 PBS - LCD Projectors Training Manual

Simplified Block diagram

C
D
L
S/H
A
D
/ FILTER

C P U
T M
R A M

MEC CTL
SYNC
P

S
/
D
A
/
W

C
H
T
S

I
VIDEO
P

S
N

U
T
I

Fig 3

PBS - LCD Projectors Training Manual 10

Block Diagram Description

Input Panel
Two 15 pin standard VGA inputs, one buffered 15 pin monitor output.
RCA style composite video input, SVHS input.
Connectors for audio, two mouse connectors, serial control input etc.

Video Decoder
Processor IC for converting PAL/SECAM/NTSC signals into RGB.
System Switch controlled by the CPU, switches to the proper input :
Video (AV) or Computer Graphics (CG).

A/D, Memory
Analog-to-Digital conversion and three one-field memories.
This circuit converts the analog RGB signals to a digital representation.
The parallel data is converted into a serial format
Each field is written into a serial memory.

Scan Conversion Filter, Mixer and Digital-to-Analog conversion.

This circuit, together with the memory provides conversion between the
input standard and the LCD panel configuration.

LCD Interface
Convert the RGB video signals to an appropriate LCD video drive signal.

S/H
Sample and Hold circuit. Prepares the RGB signal to a twelve channel LCD video signal.

TIMING & PC-ID

PC identifier, Timing and Scan conversion controller.

CPU
Central Processing Unit. Controls all actions in the projector. The program ROM is a rewritable
Flash memory. Upgrading can be done via the serial port 2. See page 20.

Active Filter
Electronic correction for PHI factor of the AC mains power drain.

Power Supply
Switching power supply and protection circuits.

Lamp Ballast
Includes the lamp ignistion circuit and supplies and controls the necessary power to the lamp.
Protected internally against overtemperature.

11 PBS - LCD Projectors Training Manual

A/D and Memory system

The memory circuit uses two times 3 channels : R1/R2, G1/G2, B1/B2.
By using specific IC's the number of discrete components could be reduced.
The field memories are of the serial type. Information is traveling like serial data, reduring the
number of wires.
Video rotation is not used on PLC8800 series, even if the original IC's (IC2411-2413) are still
present on the circuit board.

PC ID and TIMING Control

The PC ID system has been greatly enhanced.

PLC8800 has three automatic adjustments, the auto adjustment by look-up table, the hybrid
adjustment by digital and analogue method and the full digital adjustment.
In the auto adjustment by look-up table, a counter circuit with a 60 Mhz oscillator counts the
horizontal frequency and another counter circuit counts the vertical line number.
By the vertical line number, the CPU looks into groups, VGA, SVGA, XGA etc., and checks if
there is the counted horizontal frequency in the selected group of vertical line number.
If the CPU finds both values in the look-up table, the gate array is given the related data.
If the CPU cannot find the counted horizontal frequency and the vertical line number in the
look-up table, the CPU uses the hybrid adjustment by digital and analogue method.
The CPU takes the most close horizontal frequency and vertical line number, controls the gate
array and makes analogue synchronisation.
In the full digital adjustment, the CPU detects the right and the left edge on the PC signal and
identifies the total dot number. It makes the horizontal synchronisation by using the identified
total dot number and makes the vertical synchronisation by the counted vertical line number.
The CPU can also adjust the horizontal and vertical position by the value of the detected edges.
A similar method is used for the auto FINE SYNC adjustment.

Notes

PBS - LCD Projectors Training Manual 12

Computer Signal Path

RGB signals from the 15p VGA plug are routed through the computer-1 / computer-2 switches
IC2102 and the AV/CG switches IC2103.
At the same time these RGB and the sync signals are buffered (IC2104) and sent back to the
monitor OUT socket. Here is a copy available of the CG input signal and can be fed to a CRT
monitor or to another projector.
Pins 12 and 15 on the 15p VGA plug are routed directly to the monitor OUT plug.
These pins are the VIDEO ID bits. Some video cards sense these pins at BOOT time to find out
what monitor is connected to the computer.
If left open, it may happen that the computer starts up in B/W mode.
To avoid this situation, an external monitor (colour) or a special dummy plug must be connected,
shorting pin 12 to ground.
There are three (RGB) identical memory circuits.
We follow here the Red path :
The analog R signal is A/D converted in IC204 and send via a parallel to serial converter to a
serial VRAM IC2301 / IC2301. The signal is going to the Digital filter IC301, all picture transla-
tions are performed in this circuit.
The output is a 2 times 8 bit signal RA and RB.
IC1301 and IC1302 are three colour D/A converters, the outputs are R1/R2, G1/G2 and B1/B2.
R1 is used for the odd pixels (1-11) and R2 is used for the even pixels (2-12).
The twelve videosignals are input to the RGB interface driver IC's IC1401 and IC401.
After Sample and Hold in IC501 / IC151 the 12 signals are input to the LCD panels.

AV signal Path

The XGA series has a new video subsystem. The video decoder is build around a CX2076AQ
(IC101). Luminance / Chroma separation is with a COMB filter IC4101. This results in an excel-
lent video resolution. Secam processing is in IC102. RGB adjustments are via the SDA/SCL bus.

Picture Image Control

The CPU controls via another serial bus, DAC1, DAC2, DAC3, the D/A converter IC2401.
The analog output of IC801 controls the gain and sub-brightness of both RGB interface
drivers IC401,1401.

Mouse and Serial interface

This series has two sets of serial ports. The projectors can emulate a mouse signal and replaces
the PC's (or MAC) mouse. Port number two can also be used as a serial input for remote control
of projector functions and for the update of the flash memory's firmware. See page 20.

13 PBS - LCD Projectors Training Manual

Power Supply

Main Oscillation part

The main part of the power supply is made around converter transformer T601 and power transis-
tor Q602. Basically these form a Ringing Choke self-excited converter. See fig 4.

+B

Q602
Q13
T601 +B
PC01

Q602
Vout drive

I LED

Q12
Fig 4 Fig 5

Regulation
Feedback from the output is supplied to optocoupler PC01 via voltage reference IC631.
When the output voltage increases, the current through the LED increases and the resistance of its
output transistor decreases.
Transistor Q13's collector current increases and drives Q12 into saturation. See fig 5.
This shorts the drive to the base of Q602 to ground, and thus decreases the power output.
PC02 is controlled by the secondary protection circuit. Current through the LED of PC02 trig-
gers the internal thyristor with as a result that Q16 shorts the drive to Q602. See fig 6.

+ DC IN

R626

R627

D08
R39 R29
R27
Q13 Q602

Q12
R33

PC01

- DC IN

R31 D634
+ 5 V
R36

R51
C646
D11
D09

IC631
C21 R34

Fig 6

PBS - LCD Projectors Training Manual 14

Active Filter

Because of the high non-resistive load of the lamp circuit, a POWER CORRECTION FACTOR
(PHI-factor) circuit is inserted between the rectifier and the power supply circuits and lamp
ballast.
Basically, IC01 senses the relation between the current (R607/R608) and the voltage to the load.
It outputs a switching pulse to make corrections on the current via Q601. PTH601 is in series
with the whole circuit, thyristor DS601 is initially OFF. A delayed part of the secondary voltage
is used to trigger DS601, shorting out rush-in resistor PTH601, protecting the circuit from
too-high rush-in currents.
Temperature in the power supply is sensed by TSW601 and TSW602, shutting down IC01
if it becomes too high.

Protection

On the secondary side there is a multipurpose protection circuit. See fig 7.

Q18 : This is an overvoltage protection on the +S5 Volt line.
When the voltage on the +S5 Volt line increases zenerdiode D24 conducts, Q18 conducts, the
LED of PC02 triggers the internal thyristor, stopping the power supply.
Q17 : The base of Q17 is held high via diode D22 or D19 and D21.
The emitter is held high via diodes D16 or D27, the transistor is non-conducting. When a short
arrives on +S5 or +S15, Q17 conducts and shuts down the power supply via PC02.
An overvoltage on +S5V or +S15 makes Q17 conduct via D26 and D21 or D22.
Q662 : This transistor senses the presence of supply voltage to the fan. If for some reason the
supply voltage to the fan goes to zero, Q662 conducts, and PC02 will shut down the power
supply. The base of Q662 is kept high by one of the diodes D664.

+ S15V
+ S 5V
D17

D16

D27
D13

D23

D22

D19

D24
D24

D21

D18

PC02
D26

Q18

Q17
Fig 7

Q662 + 5 V switched
D664
READY
D663
+ 12V
FAN
FAN

Power supply protection circuit

15 PBS - LCD Projectors Training Manual

 AF PS
220 V
AC SUB
MOTOR
POWER LENS
DRIVE
BOARD
POWER
SUPPLY
BOARD

S P

PBS - LCD Projectors Training Manual

W F

16
+ 5V

BALLAST

LAMP

CPU
Power fail
- 5V

MAIN BOARD

Fig 8
POWER SUPPLY INTERCONNECTIONS
Power Switch-on circuits
During Stand-by only -5 and +S5V is available.
This is the supply for the syscon circuits and for the loop-through video and computer buffers.

Lamp Circuit
Supply to the lamp circuit is 400 Vdc.
The power is switched on by thyristor D5602 via optocouplers PC691 and PC03.
The lamp ballast on this chassis is non-serviceable, when a defect occurs it must be replaced.
No circuit diagram is available.

Temperature monitor
Projector temperature is monitored, and power will turn off automatically if the temperature
rises beyond normal. The cooling fan will operate until the temperature returns to normal.
This prevents projector components from being damaged by excessive heat.
As the lamp generates heat and heat waves by discharge, the temperature of the lamp itself, as
well as the polarizing glass, liquid crystal panels and other optical components will increase.
Fan-induced cooling is essential.
The temperature of the lamp's luminous glass surface must be lower than approximately 950°C,
the reflector internal surface temperature must be lower than 350°C and the polarizing glass and
liquid crystal panel surface temperatures must be lower than 55°C.
Temperatures may exceed these ranges if the fan does not operate or if the projector is operated
in poor ventilation. If the projector is used at ambient temperatures exceeding 35°C, the above-
mentioned temperatures will also exceed permissible ranges, damaging optical components such
as the polarizing glass and liquid crystal panels.
In order to prevent damage resulting from excessive heat, a temperature sensors is located at the
peripheries of the polarizing glass and liquid crystal panels.
The thermal switch positioned near the lamp housing under the main board, is set to open at
100°C. This switch opens the AC mains supply. Its main purpose is to protect the lamp.
When this switch triggers it must be reset mechanically by pushing a button.

17 PBS - LCD Projectors Training Manual

Power Fail Rail
Pin 94 of CPU IC801 is the POWER FAIL detect input. This input is connected to some of the
power supply rails via diodes. See figure. If any of these rails go to "low", pin 94 is also pulled
down. Then the CPU detects a failure in the circuit, (shorted capacitor, IC etc), and puts the unit
in STAND-BY mode. This takes about three seconds. When the set switches to standby, 3 sec-
onds after switching ON, usually the power fail line is active. In case of power supply failure, it
will be difficult to find out what diode and what circuit pulls the power fail input down. One can
remove the AUDIO amp and MOTOR drive sub-board, this eliminates the possibility of defects
on that board. The sub-power board must be connected all times, the LCD panels can be discon-
nected and the main board put in front of the lens. Keep connectors K8C, K8D and K8E con-
nected to the main board. This enables you to switch on the projector, test the ballast and the
lamp. When disconnecting the main board and the ballast, the projector cannot switch on, only the
+S5V (standby 5V) can be tested.
+ 5V

D661

FN901

FN902 Q801
D662

FN903

- 5V

SUB Power AV Assy

D666 D191

9V

+ 9V

M & A Assy

D003

IC001

D006

IC002

D1602

IC1601

D1612

IC102

pin 94
Fig 9
IC801

PBS - LCD Projectors Training Manual 18

REMOTE CONTROL C00 POWER ON

C01 POWER OFF

RS232 Port Communications
C02 POWER OFF

C05 MODE COMPUTER 1

1. Protocol
Baudrate : 19200 C06 MODE COMPUTER 2
Databits :8 C07 MODE AV1
Stopbit :1
C08 MODE AV2
Parity : None
C09 VOLUME +

2. Command format C0A VOLUME -

- The commands are send as ASCII caracters, COB SOUND MUTE ON
terminated by an <ENTER>.
C0C SOUND MUTE OFF
- To send the command "VOLUME +" type the
keyboard characters C Ø 9 followed by an ENTER. C0D VIDEO MUTE ON

The Ø is a keyboard zero, not the letter "O". C0E VIDEO MUTE OFF
The projector then sends an aknowledge. See fig 10. C1C MENU ON

C1D MENU OFF

3. Command list
See table. C1E DISPLAY CLEAR

C1F NORMAL

C3A POINTER RIGHT

C3B POINTER LEFT

C3C POINTER UP

C3D POINTER DOWN

C3F ENTER

C42 SYSTEM

C43 FREEZE ON

C44 FREEZE OFF

C49 FINE SYNC +

C4D FINE SYNC -

C80 ZOOM

C87 FOCUS

Fig 10

19 PBS - LCD Projectors Training Manual

INSTRUCTIONS FOR FIRMWARE UPGRADE

A. Installation of control software (works only on Windows95)

1. Insert disk 1, select and open "Setup.exe"
2. Insert disk 2 when requested
3. Click OK
4. Click setup icon
5. OK and finish

B. Installation of firmware version data files

1. Insert data disk
2. Open "Setup.bat"
3. Finish and close file

C. Com Port settings

- Transfer speed = 19200
- Data bit = 8
- Stopbit = 1
- Echo = OFF
- Parity = NON
- Port = Com1
- Flow control = N/A

D. Version Upgrade
1. There are two executables in the directory "c:\Program Files\DT-term1"
- Dttrm1.1.exe for upgrading from Ver. 1 to Ver. 1.7
- Dttrmsp1.exe for upgrading from other versions (Ver. 1.2 - Ver. 1.6) to Ver. 1.7
2. Select the correct program and launch it
3. Turn on the projector. (mains and lamp switch)
4. Connect the original PLC5605 or PLC8805 serial mouse cable to serial port 2
5. Open "Data Erase" and select "Prog Erase"
- 4 leds turn ON
6. Turn the projector OFF with the mains switch
7. Wait for 5 seconds and turn the projector on with the mains switch
8. Open "File" and select "Prog send"
- SVGA13th.mot for PLC5605 series
- XGA932th.mot for PLC8805 series
9. Click the appropriate file
- Start writing .... "Data writing, please wait ..."
- The upload takes around 20 minutes
10. When finished appears : "Job finished"
11. Click "OK" to end

IMPORTANT NOTE : Check the current version before erasing !

PBS - LCD Projectors Training Manual 20

Service Position

The AV board can be removed and plugged on top of the main board, this allows service on both
sides of the AV board while the projector is fully working.
When disconnecting the three LCD panels, the mainboard can be removed while staying con-
nected to the power supply. This position is also needed for adjusting the PBS.
In that case no picture is needed, only light passing through the optics.
The thermal switch SW905 has to be unscrewed from the optical engine and left connected to
the mainboard, otherwise the power supply will not start.

Fig 11

New service mode

Service mode can be invoked by pressing the "MENU" and "NORMAL" buttons together for 3
seconds. Return to normal mode by pressing the "POWER ON/OFF" button.
The "FINE SYNC" buttons change the adjustment item, the "VOLUME" buttons change the
adjustment data.

Adjustments

There are no basic differencies with the adjustments of the 5500 series.
Note that the service manual advises to use the CH1+CH2inv to adjust the two videochannels to
the same amplitude.

Warning
The coating of the projector's inside is conductive !
Watch out for wires or PCB's touching the cabinet !

21 PBS - LCD Projectors Training Manual

PBS adjustments

The position of Polarized Beam Splitter prism has to be adjusted in relation to the integrator
lens. (see photo). This adjustment allows to obtain a smooth and equal white screen.
Adjustment is possible in both Vertical (screws A) and Horizontal (slide B) direction. See fig 12.
The horizontal slide (B) is still accessible through a hole in the main board.
When the PBS prism is not correctly adjusted some dark area will apear on top/bottom or on the
left/right. See fig 13. Adjustment can be done with the LCD panels disconnected.

Fig 12

Fig 13

PBS - LCD Projectors Training Manual 22

PARTS POSITIONS

Fig 14

Fig 15

23 PBS - LCD Projectors Training Manual

CABLE & WIRE POSITIONS

Fig 16

Fig 17

PBS - LCD Projectors Training Manual 24

And now it's broken ....

Before opening the cabinet consider safety procedures.

Power failures
Many different protections are build in. The power supply has two working states :
Stand-by and normal working condition. During stand-by mode the "powerfail" is not active.
In stand-by mode two voltages are generated : +S5V and -5V. Regulation is on +S5V by IC631.
Overvoltage protection of +S5V is by Q18/D24/PC02. Please note that the protection by PC02 is
via a thyristor, after triggering, the power supply can only be restarted after a full powerdown.

When switching ON the set, the other operating voltages are switched on by Q631/633/636/638.
The lamp ballast power is switched on by DS602 via PC691 and the lamp is switched on via pin1
of connector K6F.
The three fans must start running, failure to run is passed to the powerfail rail by Q661.
The lamp "lighted condition" is detected via pin3 of connector K6F.
Various protections work via Q17 and associated components. The presence of -5V is detected by
Q801 via the powerfail line. An active powerfail (LOW) is detected by the CPU and the
powersupply is shut down to stand-by. This takes about 3 seconds.
(If the problem is via powerfail, the set goes to stand-by about 3 seconds after switching ON)

Observation of the behaviour of the set during the first seconds is interesting :
1. Does stand-by works ? +S5V and -5V present, both red and green LED's on ?
2. Does the 3 fans start to run after switch on ?
3. Does the lamp goes on ?
4. If the projector goes off after 3 seconds, investigate on powerfail.
5. Measure the powersupply
connector K8C :
pin 7 : +S5V
pin 5 : powerfail (High = OK)
connector K8D :
pin 1 : -5V (there is the possibility of rupture in R645)
6. The M&A board can be unplugged (only audio amp and lens motor drive) eliminating
powerfail from this board.
7. The LCD panels can be unplugged and the mainboard put in front of the lens.
8. Check the other power lines :
connector K8D :
pin 1 : -5V
pin 3 : 17V
pin 5 : 9V
pin 7 : 9V
connector K8E :
pin 2 : 5V
pin 5 : 15V
pin10 : 5V
9. The power supply board can be tested outside the projector, only dureing stand-by mode.
10. The coating of the projector's inside is conductive !
Watch out for wires or PCB's touching the cabinet !

25 PBS - LCD Projectors Training Manual

 Prepared by j bellemans Technical Advisor SANYO Antwerpen

©
SANYO Version 1.0 july '98 (this document is also available as a PDF file)
PBS - LCD Projectors Training Manual 26