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Hughes JVC Projector 230 Service Manual

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    							SERVICE
    MANUAL
    Model 230 Projector
    Phone: (760) 929-5300
    Fax: (760) 929-5410
    DECLARATION OF CONFORMITY
    2310 Camino Vida Roble
    Carlsbad, California 92009 
    						
    							Model 230 Service Manualii
    PER ISO/IEC GUIDE 22 AND EN 45014
    Manufacturer
    : Hughes JVC
    2310 Camino Vida Roble
    Carlsbad, Ca 92009
    USA
    Hughes-JVC declares that this product conforms to the following Product
    Specifications (Directive/Standard):
    Safety: EN 60950
    IEC 950 (1992)
    EMC: EN 55022 (1988) / CISPR-22 (1986) Class A
    EN 50082-1 (1992) / IEC 801-2(1991)
    EN 50082-1 (1992) / IEC 801-3(1984)
    EN 50082-1 (1992) / IEC 801-4(1988)
    ANSI C63.4-1992, FCC, Part 15, Class A
    In addition, the above product complies with the requirements of the Low
    Voltage Directive 73/23 EEC and the EMC Directive 89/336/EEC.
    104809 First Edition March 1998
    © Copyright 1998 by Hughes-JVC Technology Corporation.
    All worldwide rights reserved.
    This manual was produced by Hughes-JVC Technology Corporation and may be
    revised without prior notice.
    No part of this manual may be reproduced in any form without the express
    written permission of Hughes-JVC Technology Corporation.
    ILA® 
    is a registered trademark of Hughes-JVC Technology Corporation. 
    						
    							Model 230 Service Manualiii
    Table of Contents
    Safety Information.................................................................................v
    Chapter 1  Introduction
    1.1  Safety........................................................................................................1-1
    1.2  Updates.....................................................................................................1-1
    1.3  Tool List ....................................................................................................1-1
    1.4  Acronyms Used in Manual.........................................................................1-2
    Chapter 2  Functional Description
    2.1   Introduction ..............................................................................................2-1
    2.2   Optical Section .........................................................................................2-2
    2.3   Electronics System ...................................................................................2-7
    Chapter 3  Service Adjustments
    3.1   Arc Lamp Adjustment ...............................................................................3-3
    3.2   Electronic Module Tilt-Up .........................................................................3-10
    3.3   ILA
    ® Back Focus ......................................................................................3-10
    3.4   CRT Mechanical Focus ............................................................................3-12
    3.5   CRT Rotation ...........................................................................................3-13
    3.6   CRT Electronic Focus ..............................................................................3-14
    3.7   ILA
    ® Overlap ............................................................................................3-15
    3.8   Front/Rear or Inverted Projection Jumper Settings...................................3-16
    3.9   Vertical and Horizontal Size Settings........................................................3-18
    3.10 Software Updating....................................................................................3-19
    3.11 Gamma Tracking......................................................................................3-22
    3.12 Graphic Enhancement..............................................................................3-23
    3.13 Cleaning Lenses, ILA
    ® Assemblies and Mirrors .......................................3-24
    Chapter 4  Maintenance (Removal/Replacement)
    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 Board ...............................................................................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 
    						
    							Model 230 Service Manualiv
    Chapter 5  Troubleshooting
    PCB Status LEDs ............................................................................................ 5-1
    Error Codes ................................................................................................. 5-4
    Troubleshooting Guide .................................................................................... 5-6
    Chapter 6  Parts List............................................................................ 6-1
    Appendix A Import/Export
    ...................................................A-1
    Appendix B Glossary........................................................................... B-1 
    						
    							Safety Information
    Model 230 Service Manualv
    Safety Information
    Introduction
    Read entire Safety Chapter thoroughly before performing any
    maintenance or service on the projector.  Only qualified service personnel
    should perform procedures and adjustments.
    Safety Equipment: Use safety equipment specified in the projector’s
    maintenance training and certification program.
    WARNINGS AND CAUTIONS!
    Warnings and Cautions in this manual should be read thoroughly and
    strictly adhered to. Warning and Caution definitions and symbols are as
    follows:
    WARNING SYMBOL   Warns user of a potential
    electric shock hazard in a procedure or situation that could result in
    personal injury if improperly performed.
    CAUTION SYMBOL   Warns user of a potential
    safety hazard or potential light hazard from ultraviolet, infrared or bright
    light that could cause severe eye injury or a situation that could result in
    damage to the equipment if improperly used.
    Installation Safeguards
     WARNING!!! 
    Procedures in this service manual
    require removing the projector’s covers to access internal component to
    remove, replace, service and adjust the projector. Only Hughes-JVC
    Certified Technicians are qualified to perform these procedures. Before
    removing or replacing any internal components or subassemblies, verify
    that the circuit breaker on the back panel is in the Off position and
    remove the power plug. Any adjustments performed that require covers 
    						
    							Safety Information
    Model 230 Service Manualvi
    off and power on should be performed with extreme care.  Be especially
    aware of all hazardous areas indicated by warning and caution labels.
      CAUTION! Do not use a forklift to lift the projector
    without using a safe shipping pallet. Lifting the projector without
    supporting the weight at the foot locations can cause severe damage to
    the projector.
    If there is any visible damage to the power cable, disconnect power to the
    projector until the damaged cable is replaced. Install the projector on a
    smooth, vibration-resistant level surface, or ceiling mount, in an area free
    from dust and moisture. Do not place the equipment in direct sunlight or
    near heat-radiating appliances. Smoke, steam and exposure to direct
    sunlight could adversely affect the internal components.
    If mounting the projector, use hardware that can handle a minimum of
    three (3) times the projector weight.
    Heat Safeguards
    Fans and Ventilation: The projector has multiple fans to cool the system.
    Do not block the intake or outflow of any fans.
      Heat is emitted within
    the system and must be properly dissipated to keep the system running
    correctly.  Blocking air intake or exhaust ports can lead to projector
    overheating.  Do not enclose the unit in a restricted space (refer to the
    physical access and thermal clearance illustration guidelines).
    CAUTION! Do not unplug the power cord until after the arc lamp fan
    has stopped running. This fan protects the arc lamp from overheating.
    Disconnecting power before the cooling fans have stopped running can
    shorten Arc Lamp life.
    Light Safeguards
    Dangerous high voltage, bright light, ultraviolet, and infrared
    radiation can be hazardous to personnel. Access must remain
    restricted to Hughes-JVC certified engineers and technicians.
    Ultra Violet and Infrared Light
    Protect eyes and face from ultra violet light and infrared light by using the
    following protective eyewear:
    1.  X3 (up to 375 nanometers), ANSI approved, shade goggles
    must be worn by anyone near the projector when it is lit and
    the cover is off.
    2.  X5 (375 to 700 nanometers), ANSI approved, shade goggles
    when actually working on the projector near the arc lamp
    source. 
    						
    							Safety Information
    Model 230 Service Manualvii
    WARNING, BRIGHT LIGHT!!! 
    Never look directly at the Arc Lamp, the lighted Projection Lens or
    into the lamp housing, from any distance, when the projector is on.
    Direct exposure to light of this brightness can cause severe eye
    injury.
    Dangerous levels of ultraviolet and infrared radiation, dangerous
    glare, very high temperatures (180°C to 300°C) and high internal gas
    pressure are present at the Xenon Arc Lamp. The lamp is contained
    in a protective reflector housing module and should not be operated
    outside this housing or outside of the projector. When replacement
    is needed, the arc lamp must be replaced as an entire module, as
    shown in this manual. Do not open the lamp housing or attempt to
    replace the Arc Lamp inside its module! Do not touch the Arc Lamp,
    or any connections, when the lamp is ignited or is arcing. Any
    servicing of the Arc Lamp must remain restricted to Hughes-JVC
    certified maintenance personnel.
    Electrical Safeguards
    WARNING!!! High Voltage points up to 40,000 volts are
    exposed inside the covers. Allow at least one minute for the high
    voltage to bleed off, even after power is turned off.
    Due to high voltage danger, 
    DO NOT TOUCH
    • CRT cables. These cables can cause severe shock from a
    tiny, invisible crack or hole and should never be touched while
    projector power is on.
    • CRT anodes.
    • Main power ± supply posts.
    • Arc Lamp main power ± posts
    • CRT yoke assemblies and other proximity electrical
    assemblies, components and wiring. If performing the ILA®
    Back Focus, CRT Mechanical Focus, CRT rotation, width
    adjustment, or ILA® Overlap adjustment, always use an
    High voltage access. Front and rear
    covers contain safety interlocks.
    Defeat restricted to Hughes-JVC
    certified service personnel
    ! 
    						
    							Safety Information
    Model 230 Service Manualviii
    ANSI/ASTM 10,000 volt rated glove. Periodically check the
    condition of the gloves for cracks.
    Power Supply
    The projector operates from a 220V - 240V, 20 Amp, single-phase, 50/60
    Hz AC power source. Ensure local power source matches these
    requirements before operating!
    For continued safe and reliable operation, only use cables supplied by the
    manufacturer for power and signal connections.
    Fluid Safeguards
    Certain components of the projector contain fluid. If any fluid from the
    projector contacts the skin, wash off with soap and water. If any fluid from
    the projector splashes into the eyes, rinse with cool running water.
    Ventilation and Foreign Object Retrieval
    CAUTION! Ensure the projector’s multiple fans are free from
    obstructions and operating properly. Air filters are located at vent ports on
    the cover. Air filters require periodic cleaning to ensure adequate cooling
    of the projector (
    Section 4.3). Ensure that all vent ports are clear of
    obstructions.
    Keep the inside of the projector free from foreign objects, such as
    hairpins, nails, paper, etc.  Do not attempt to retrieve any object or insert
    metal objects such as wire and screwdrivers inside the unit.  If an object
    falls inside the projector, immediately unplug the projector and call a
    Hughes-JVC certified technician to remove object. 
    						
    							Chapter 1---Introduction
    Model 230 Service Manual1-1
    1.0   Introduction
    This Service Manual is designed to be used with the Model 230 User’s
    Guide. This Service Manual provides information on the:
    •  Projector functional description;
    • Service adjustments
    •  Removal and replacement of subassemblies;
    • Troubleshooting.
    The User’s Guide covers the projector’s installation, operation, setup
    adjustments, and specifications. Together the Service Manual and User’s
    Guide provide a qualified service person with information to operate and
    maintain the projector.
    1.1 Safety
    This projector contains high voltages and high intensity light sources in its
    internal system and power supplies. Read the entire Safety Chapter at
    the front of this manual before performing any adjustments or
    maintenance.
    When performing procedures that call for the projector’s power to be on,
    always wear high voltage gloves (ANSI/ASTM 10,000 volt rated) when
    working around the CRTs, Arc Lamp or power supplies. Wear safety
    goggles (rated X5) when working anywhere near the light path from the
    Arc Lamp or the projection lens at all times.
    1.2 Updates
    Hughes-JVC will periodically provide bulletin and /or manual supplements
    to ensure the accuracy of this service manual.
    1.3 Tool List
    The following tools are required to perform service adjustments:
    All Purpose Tools=Diagonal Sidecutters, Wirestrippers, Slot
    Adjustment Screwdriver (Tweeker), Mirror/Magnet Pick-Up
    Tool, Flashlight, 6” Crescent Wrench, Needlenose pliers, 6”
    Vise Grips
    Balldriver, 1.5mm
    Balldriver, 3mm
    Balldriver, 3mm, Long
    Balldriver, 4mm
    Balldriver, 5mm, Long, T-handle
    Balldriver, 6mm
    Balldriver, 8mm 
    						
    							Chapter 1---Introduction
    1-2
    Model 230 Service Manual
    Ballpoint L-Wrench Set, 1.5-5mm
    Delrin .100 Hex Alignment Tool
    Gloves, ANSI/ASTM 10,000 volt rated, Safety
    Goggles, Safety, x3(covers on) and x5(covers off)
    Hex Ballpoint Driver, 3mm
    Hex Ballpoint Driver, 5mm
    Nutdriver, 10mm
    Nutdriver, 11mm (or 7/16”)
    Nutdriver, 5mm
    Nutdriver, 7mm
    Nutdriver, 8mm
    Screwdriver, Phillips, #1
    Screwdriver, Phillips, #2
    Screwdriver, Pozidrive, #1
    Screwdriver, Pozidrive, #2
    Screwdriver, Slot ¼”
    Screwdriver, Slot, ½”
    Screwdriver, Slot, 3/16”
    Socket, ¼” drive, 7mm-deep
    1.4 Acronyms Used in this Manual
    ALPS Arc Lamp Power Supply
    CDB Convergence/Deflection Board
    CH Channel
    CPU Central Processing Unit
    CRT Cathode Ray Tube
    EMI Electromagnetic Interference
    EPROM Erasable Programmable Read-Only Memory
    FPGA Field Programmable Gate Array
    F to V Frequency to Voltage
    G2 CRT Grid 2
    HVDB Horizontal/Vertical Deflection Board
    HDTV High Definition Television
    Hz Hertz
    HSYNC Horizontal Sync
    HVDB Horizontal/Vertical Deflection Board
    HVPS High Voltage Power Supply
    IIC Inter-Integrated Circuit
    ILA® Image Light Amplifier
    I/O Input/Output
    I/R Infrared
    kHz Kilohertz
    LED Light Emitting Diode
    LVPS Low Voltage Power Supply
    NTSC National Television Standards Committee
    PAL Phase Alternating Line
    PCB Printed Circuit Board
    PLL Phase Lock Loop
    PLUGE Picture Line-Up Generating Equipment 
    						
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