Hughes Model 230 Projector Service Manual

							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