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Hughes JVC Projector 230 Sc Service Manual

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    							Chapter 3---Service Adjustments
    Model 230 Service Manual3-19
    To adjust the Vertical height (
    see Figure 3-14):
    1.  Remove the rear cover (Section 4.2).
    2.  Select the X-hatch test pattern.
     NOTE: Green is the master to which Red and Blue will be matched. The
    Green height pot should not need adjustment except when the Green CRT
    assembly has been replaced.
    3.  Hide Blue and view Red and Green.
    4.  If Red is higher than Green at the top 
    and lower than Green at the bottom of
    the X-hatch image, 
    or If lower than Green at the top 
    and higher at the bottom,
    adjust Red vertical pot to correct the error.
     If Red is higher than Green at the top 
    and bottom, 
    or lower than Green at the
    top 
    and bottom, this is most likely caused by Red not being centered correctly
    and can be corrected with the centering adjustment (User’s Guide, Chapter
    5).
     If the Red height pot does not completely eliminate the difference in height
    between Red and Green, balance the error at the top and bottom. Too much
    of an error at the top or bottom makes convergence procedures harder to
    accomplish.
    5.  Repeat Steps 2 and 3 above for Blue while hiding Red.
    6.  Recheck all Geometry and Convergence settings (
    see User’s Guide) and
    readjust wherever necessary.
    To adjust the horizontal size coils (
    see Figure 3-15):
    1.  Continue to use the X-hatch test pattern.
    2.  Hide Blue. View Red and Green.
    3.  If Red is outside of Green on both sides, or inside of Green on both sides, use
    a Delrin .100 hex alignment tool to adjust the Red horizontal size coil to
    correct the error. If Red is outside of Green on one side and inside of Green
    on the other side, this is most likely caused by Red not being centered
    correctly and can be corrected with the centering adjustment (
    User’s Guide,
    Chapter 5).
    If the Red horizontal size coil does not completely eliminate the size error
    between Red and Green, balance the error on both sides to allow for easier
    convergence.
    4.  Repeat Steps 2 and 3 above for Blue while hiding Red.
    5.  Recheck all Geometry and Convergence settings and readjust wherever
    necessary.
    6.  Replace the electronic module and rear cover.
    3.10 Software Updating
    The Model 230 software resides in Flash Memory and is updated via the
    projectors serial Port A. To perform an update, a disk containing the updated 
    						
    							Chapter 3 Service Adjustments
    3-20Model 230 Service Manual
    Boot Software (boot.hex) and/or System Software (zsys.hex) and a PC with
    Windows 3.1 is required to perform update.
    Boot Manager Software and System Software are separate products. Each may
    be updated independently. The System Software will depend on a specific version
    of the Boot Manager. Refer to the System Software release bulletin for Boot
    Manager version dependencies.
    To perform software upgrade:
    1.  Verify that the projector circuit breaker is off. Use a Null Modem cable to
    connect a PC to the projector’s Serial Port A.
    2.  Start Windows 3.1.
    3.  Click on the terminal icon from the Accessories Directory.
    4.  From the Terminal menu, select Settings-Terminal Emulation and click on
    DEC-VT-100(ANSI).
    Select OK.
    5.  Under Settings choose Terminal Preferences.
    6.  Under Terminal Preferences the following selections are appropriate;
    Terminal Modes=Sound, CR->CR/LF=Both off, Columns=80, Cursor=Block &
    Blink, Terminal Font=Fixedsys 15, Translation=None, Show Scroll Bars=On,
    Buffer Lines=100, Use Function Arrow & Control Keys for Windows=Off.
    Select OK.
    7.  Under Settings select Text Transfer=Standard Flow Control. Select OK.
    8.  Under Settings select Communications and choose; Connector=select the PC
    port being used, Baud Rate=9600 or 19200 (depending on the System
    Controller Switch block Pos 4-see note below this step), Data Bits=8, Stop
    Bits=1, Parity=None, Parity Check=Off, Carrier Detect=Off, Flow
    Control=XON/XOFF. Select OK.
     NOTE: Switch position 4 on the switch block at the card edge of the System
    Controller (
    Figure 5-1) controls the baud rate for Serial Port A for the Boot
    Manager and System Software. Down=9600, Up=19200. Ensure the other
    SCB switches (1, 2, and 3) are in the Down position.
    9.  Turn the projector circuit breaker on while depressing and holding down the
    service mode switch on the SCB (Figure 5-1)
    . Verify that Boot Manager
    appears on the terminal monitor. The Power On LED stays Red.
    Alternate for Step 9: In Power Off Standby mode, Press Control, Shift + _
    (underscore), hex IF (international keyboard may vary in key placement).
    10. The following should be displayed on the Windows Terminal screen (where
    x.x.0 is the currently loaded Boot Manager version (e.g. 0.9.0 or 1.1.0).
     –Boot Manager Ver x.x.0 (Service Mode Startup)
     –Copyright (c) 1994 Hughes JVC Technology
     –Command: _
    11. Verify that the Boot Manager version is correct. If it is necessary to update the
    Boot Manager, perform the following steps. If the Boot Manager is already up
    to date, skip to Step 12 to update the System Software. 
    						
    							Chapter 3---Service Adjustments
    Model 230 Service Manual3-21
    11A. Enter the command loadboot at the prompt. You should see the
    following output:
     Command: loadboot
     Boot Manager software update procedure
     ***WARNING: IMPROPER USE MAY MAKE THIS SYSTEM 
    UNBOOTABLE*** (This warning relates to the Flash Memory
    updating that occurs in Step 11D. Do not turn projector
    power off while the Flash Memory is updating)
     Memory buffer reset to 0xff
     Begin your S-Record upload now (Esc to abort).
     11B. From the Windows Terminal Menu (normally in Accessories window),
    select Transfers/Send Text File, then select List Files of Type:All Files, and
    select the disk and/or directory with the Model 230 software. You should see a
    file named boot.hex. Select this file and press the OK button to begin the
    upload.
     11C. During upload, a progress indicator updates the number of records
    received. At the completion of the upload, the system will display the following
    (numerical values are for example only and depend on the  Boot Manager
    version):
     S-Records processed: 823
     Upload Successful
     Address Range: 0x00000000-0x00006687
     Bytes Loaded:  26248
     ***WARNING: FLASH WILL NOW BE UPDATED***
     Press Enter to continue, Esc to abort.
     11D. The system has verified that the load module is correct and is ready to
    update the Flash. Press Enter to perform the update (press Esc now to abort
    the update with no changes). While the Flash memory is being updated (15-
    30 seconds), DO NOT turn off the projector circuit breaker or the machine
    could be made unbootable, requiring a new set of flash chips to be installed.
    When the update is complete, the system will display the following:
     Reprogramming Flash Sector 0 1
    Boot Manager software update successful
     Command: _
     The Boot software has been successfully updated. To restart the projector
    under control of the updated boot manager, enter the reboot command while
    depressing the service mode switch (Figure 5-1). The projector will now
    restart with the updated boot manager software. (
    NOTE: If normal software
    starts, see Step 9 to reenter Boot Manager.) You should see the following
    displayed, where y.y.0 is the updated Boot Managers version.
     Boot Manager Ver y.y.0 (Service Mode Startup)
    Copyright (c) 1994-1996 Hughes-JVC Technology
     Command: _ 
    						
    							Chapter 3 Service Adjustments
    3-22Model 230 Service Manual
    12. To update the System Software from the Boot Manager prompt:
     12A.  Type in the command “loadsys” at the prompt. The following should be
    displayed:
     Command: loadsys
     System software update procedure
    ***WARNING: IMPROPER USE MAY MAKE THIS SYSTEM 
    UNBOOTABLE*** (NOTE: This warning relates to the Flash 
    Memory updating that occurs in Step 12D below. Do not 
    turn projector power off while the Flash Memory is 
    updating.)
     Memory buffer reset to Oxff
     Begin your S-Record upload now (Esc to abort)
     12B.  Select “Transfers/Send Text File” from the Windows Terminal Menu
    (normally in Accessories window). In the “Send Text File Dialog” box, select
    “List Files of Type: All Files” and select the disk and/or directory with the
    Model 230 software. Select file named “zsys.hex”. Press OK to start upload.
     12C.  During upload, a progress indicator updates the number of records
    received. When the upload is complete, the system will display the following
    (numerical values are for example only and depend on the System Software
    version):
     S-Records processed:11282
    Upload Successful
    Address Range: 0x00020000-0x000781cf
    Bytes Loaded:360912
     ***WARNING: FLASH WILL NOW BE UPDATED***
     Press Enter to continue, Esc to abort
     12D.  At this point the system has verified that the load module is correct and
    is ready to update the Flash memory. Press Enter to perform the update (Esc
    will abort the update process with no changes). While the Flash is being
    updated (approx 15-30 seconds), DO NOT turn off the projector circuit
    breaker, this may make the machine unbootable, requiring a new set of flash
    chips to be installed. When the update is complete, the system will display the
    following:
     Reprogramming Flash Sector 2 3 4 5 6 7 8 9
     System software update successful
     Command: _
    The software update is complete. To restart the projector, type in the “sys”
    command and press Enter. The projector will now restart with the updated
    System Software.
    3.11 Gamma Tracking
    Gamma Tracking is used mainly during factory-setup. It may be necessary when
    ILA®s are replaced or when the projector has been in use for a long time. To
    check if Gamma Tracking is needed, access the Grey Scale test pattern. After all 
    						
    							Chapter 3---Service Adjustments
    Model 230 Service Manual3-23
    setup procedures are complete the Grey Scale test pattern should be grey
    throughout. If the edges of the Grey Scale appear grey but the middle appears
    color-tinged, this indicates that Gamma Tracking may need adjustment.
    NOTE:Overall Gamma Tracking is usually best if no color is too near the extreme
    (0 or 255). For example, if the middle gray level looks green and the Gamma
    Tracking settings are; Red=128, Green=200, Blue=128, it is better to adjust Red
    and Blue down instead of Green up.
    To adjust Gamma Tracking:
    1.  Select the Grey Scale test pattern.
    2.  Observe the center of the Grey Scale. If the center of the test pattern shows a
    red, blue or green tinge, Gamma Tracking may need to be adjusted for that
    color.
     NOTE: It is also possible that two colors are dominant at the center. If the
    center of the test pattern appears magenta, then red and blue are both
    dominant. If the center appears cyan-tinged, green and blue are dominant. If
    the center appears yellow, red and green are dominant.
    3.  Select the color to adjust
    4.  Make a note of the data value of the color(s) to be adjusted before making
    any adjustments to gamma so that it can be returned to if adjusting gamma
    does not improve the grey scale image on the screen .
    5. Use the arrow keys to decrease gamma in the selected color so that the Grey
    Scale looks grey throughout the pattern. Use the UP arrow key to i
    ncrease the
    data value for gamma in the selected color to make it less dominant!
    3.12 Graphic Enhancement Adjustment
    The optional Graphic Enhancer RGBHV VIC has a very small adjustable pot (see
    Figure 3-15) that was designed primarily to improve the visibility of computer
    black text on white background (such as spreadsheets). This pot is factory-set at
    mid-range to provide an appreciable enhancement of small black text on white
    background. HJT recommends this pot be left at the factory mid-range setting.
    If it is absolutely necessary to adjust this pot to optimize a specific type of graphic
    image, be sure to check that other sources viewed from the Graphic Enhancer
    VIC are not adversely affected. This enhancement adjustment only affects
    computer graphics and does not appreciably affect images from VCRs, DVDs etc.
    Increasing (clockwise) sharpens the appearance of black on white text but
    overadjustment will adversely affect other types of graphics. This is a fixed
    adjustment and a compromise setting may be needed for best overall
    performance. 
    						
    							Chapter 3 Service Adjustments
    3-24Model 230 Service Manual
     
    Figure 3-15.   Graphic Enhancer Video Input Card.
    3.13 Cleaning Lenses, ILA® Assemblies and Mirrors
    The projection lens is the only item that requires periodic cleaning. Other
    assemblies are covered to prevent dust entering or finger smudging. Cleaning
    may be needed for special circumstances such as replacing an assembly.
    Cleaning should only require removing excessive dust (use canned air such as
    “Office Duster” or Aero Duster) or removing fingerprint smudges (use “Kodak
    Lens paper”, or equivalent) from the projection lens. As much as possible, clean
    the optics only when absolutely necessary.
    Projection Lens: Use lens paper and wipe the lens clean in a vertical motion
    from top to bottom. Use compressed air to blow excess dust from the lens. An
    optical lens cleaning solution can also be used to remove finger smudges.
    ILA® Assembly: Clean the ILA® assembly faces with compressed air only. Do
    not wipe the ILA assembly faces.
    CRT Faces:  Use compressed air to blow dust off and lens paper to clean face.
    Relay Lens: Same as Projection Lens.
    Mirrors and Polarizing Beam Splitter Windows: The Optical Shield covers the
    Dichroic Mirror Assembly and Polarizing Beam Splitter windows. Normally
    cleaning is not needed. Clean only if absolutely necessary using compressed air.
    Do not wipe mirrors. 
    						
    							Chapter 4---Maintenance (Removal/Replacement)
    Model 230 Service Manual4-1
    4.0   Maintenance (Remove/Replace)
    Contents
    4.1   Introduction ..............................................................................................4-1
    4.2   Projector Covers ......................................................................................4-4
    4.3   Air Filters ..................................................................................................4-5
    4.4   Arc Lamp Assembly .................................................................................4-5
    4.5   Ignitor Assembly.......................................................................................4-7
    4.6   Arc Lamp Power Supply ...........................................................................4-8
    4.7   Low Voltage Power Supply.......................................................................4-9
    4.8   High Voltage Power Supply ......................................................................4-10
    4.9   Raster Timing, System Controller, Video Processor PCBs.......................4-12
    4.10 Convergence/Deflection PCB ...................................................................4-13
    4.11 Horizontal/Vertical Deflection PCB ...........................................................4-14
    4.12 Video Input Cards (VICs) .........................................................................4-15
    4.13 Video Amplifier PCB .................................................................................4-15
    4.14 Scan Reversal PCB..................................................................................4-17
    4.15 CRT/Yoke Assembly ................................................................................4-18
    4.16 ILA® Assembly.........................................................................................4-19
    4.17 Relay Lens ...............................................................................................4-20
    4.18 Projection Lens ........................................................................................4-21
    4.19 Prism Assembly .......................................................................................4-22
    4.20 Recommended Spares.............................................................................4-24
    4.1  Introduction
    NOTE: Before removing the front or rear cover or replacing any components or
    subassemblies, please review the Safety Chapter at the front of this manual.
    Removal and replacement procedures in this chapter must be performed by
    Hughes-JVC certified technicians and engineers only.
    When performing any maintenance, protect yourself and the equipment by
    following these guidelines:
    •  Turn the projector off with the remote.
    •  After the cooling fans have automatically stopped running, turn off the circuit
    breaker.
    •  Allow a discharge time of at least one minute for the high voltage to bleed off,
    then unplug the power cord from the AC wall outlet.
    •  Observe all Cautions and Warnings
    Tools required to perform removal and replacement of projector components and
    subassemblies are listed in Chapter 1, Introduction. 
    						
    							Chapter 4---Maintenance (Removal/Replacement)
    4-2Model 230 Service Manual
     WARNING!!! Various procedures in this chapter
    involve the removal and replacement of system subassemblies.
    Ensure that the projector circuit breaker is turned off and the AC
    power plug is removed from the AC outlet PRIOR to attempting any
    of these procedures.
    When performing any maintenance procedures in this chapter, follow the
    guidelines below:
    Left/Right Orientation: When left and right is mentioned in this chapter,
    it is with reference to standing at the rear of the projector, facing the
    screen.
    Connectors on subassemblies and PCBs have tabs that must be
    released first before pulling on the connector. The proper procedure is to
    push slightly IN on the connector, then squeeze the tab, then pull the
    connector out.
    NOTE: While performing any maintenance procedures, check the prism
    diaphragm for dryness, crazing, cracking, or possible leaking. If any
    problems are observed, call HJT.
    When references are made in this chapter to assemblies and
    components, refer to Figures 4-1 and 4-14 for their locations. 
    						
    							Chapter 4---Maintenance (Removal/Replacement)Model 230 Service Manual4-3
    Figure 4-1.   Major components of the Model 230 Projector. 
    						
    							Chapter 4---Maintenance (Removal/Replacement)
    4-4Model 230 Service Manual
    4.2  Projector Covers
    Prior to removing either cover, review the chapter on Safety and adhere to all
    warnings and cautions.
    Figure 4-2   Rollbar Assembly.
    To remove the front or rear covers (refer to Figure 4-2):
    1.   Disconnect the projector power plug.
    2.   Loosen the two pozidrive spring screws at the front of the front cover or the
    rear of the rear cover.
    3.   Tilt up the front or rear cover.
     CAUTION! Do not leave either cover in the tilted up
    position! The covers can fall from this tilted up position and possibly damage
    projector components. Remove the cover and set it aside when servicing the
    projector.
    4.   Release the two Latch Levers on the Rollbar assembly that hold the cover in
    place. Place the ends of the Latch Levers into the holding slots.
     CAUTION! Immediately after removing the front or rear
    cover, pull up the power interlock switch. This allows power to be reapplied to 
    						
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