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Chapter 4---Maintenance (Removal/Replacement)

Model 100 Service Manual

4-1

4.0 Maintenance

(Remove/Replace)

Contents

4.1 Introduction ................................................................................................. 4-1
4.2 Projector Covers .......................................................................................... 4-4
4.3 Air Filters .................................................................................................... 4-4
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........................................................................ 4-9
4.9 System Controller / Raster Timing Generator PCB .................................... 4-10
4.10 Video Processor PCB .................................................................................. 4-11
4.11 Deflection Processor PCB. .......................................................................... 4-12
4.12 Vertical Convergence Deflection PCB........................................................ 4-12
4.13 Horizontal Deflection PCB ......................................................................... 4-13
4.14 Video Input Cards (VICs) ........................................................................... 4-13
4.15 Regulator PCB............................................................................................. 4-13
4.16 Video Amplifier PCB.................................................................................. 4-14
4.17 CRT/ ILA® Assembly................................................................................. 4-15
4.18 Projection Lens............................................................................................ 4-17
4.19 Recommended Spares ................................................................................. 4-19

4.1 Introduction

NOTE:

Before removing the front, top or side covers 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 factory
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

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Summary of Contents for 100

Page 1: ...SERVICE MANUAL Model 100 Projector Phone 760 929 5300 Fax 760 929 5410 2310 Camino Vida Roble Carlsbad California 92009 ...

Page 2: ...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 105827 First Edition February 1999 Revision A July 1999 Copyright 1998 by Hughes JVC Technology Corporation All worldwide rights reserved This manual was produced by Hughes JVC Technology Corporation and may be revised w...

Page 3: ...oftware Updating 3 17 3 11 Graphic Enhancement Adjustment 3 21 3 12 Cleaning Lenses ILA Assemblies and Mirrors 3 22 Chapter 4 Maintenance Removal Replacement 4 1 Introduction 4 1 4 2 Projector Covers 4 4 4 3 Air Filters 4 4 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 9 4 9 System Controller Raster...

Page 4: ...del 100 Service Manual iv Chapter 5 Troubleshooting 5 1 PCB Status LEDs 5 1 5 2 Error Codes 5 5 5 3 Troubleshooting Guide 5 8 Chapter 6 Parts List 6 1 Appendix A Import Export A 1 Appendix B Glossary B 1 ...

Page 5: ...hock 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 man...

Page 6: ...r 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 enclo...

Page 7: ... 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 Volt...

Page 8: ...es supplied by the manufacturer for power and signal connections 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 4 Ensure that all vent ports are clear of obstructions K...

Page 9: ...fied 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 volt...

Page 10: ...lt 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 Screwdriver Slot Screwdriver Slot 3 16 Socket drive 7mm deep 1 4 Acronyms Used in this manual ALP...

Page 11: ... Power Supply PC Personal Computer PCB Printed Circuit Board PLL Phase Lock Loop RAM Random Access Memory REG PCB Regulator Printed Circuit Board RGB Red Green and Blue RGBHV Red Green Blue Horizontal Vertical ROM Read Only Memory SC RTG PCB System Controller Raster Timing Generator Printed Circuit Board SYNC Synchronization TTL Transistor Transistor Logic UL Underwriter Laboratories UV Ultraviole...

Page 12: ...Chapter 1 Introduction 1 4 Model 100 Service Manual ...

Page 13: ...blies and components which are grouped into the three main sections listed below Included in each of the sections is a list of the main components found in that section and a brief description of their function see Figure 4 1 for physical locations of assemblies and components The Optics Assembly Section sits toward the front of the projector It consists of an Arc Lamp Module the Illumination Path...

Page 14: ...nals 2 2 Optical System The Arc Lamp Module The Arc Lamp Module includes a 750 Watt Xenon Arc Lamp that is located directly below the Front Projector Lens in the front of the projector The Arc Lamp is driven by the Arc Lamp Power Supply which sits in the front of the projector opposite the Arc Lamp Module The Illumination Path The illumination path is a very complex optical system of condensing le...

Page 15: ...old Mirror where more IR light is removed The white light then travels out to the Secondary Condensing lens and onto the Dichroic Filters The Dichroic Filters divide the white light from the Arc Lamp into its three color components Red Green and Blue The first filter reflects the green and red light and allows the blue light to pass through the beamsplitter and continue on to the Blue Dichroic fil...

Page 16: ...Chapter 2 System Description 2 4 Model 100 Service Manual Figure 2 1 Top View of lower level of Illumination Path for the Model 100 ...

Page 17: ...ed and one is transmitted or passes through the beamsplitter Upon striking the Pre Polarizer the S electric field is reflected and is wasted the P electric field is passed through the Pre Polarizing Beamsplitter and continues on to the Main Polarizer The Main Polarizing Beamsplitter is rotated 90 from the Pre Polarizing Beamsplitter so the P electric field that was transmitted through the Pre Pola...

Page 18: ...ector above the Dichroic Filters and in front of the Electronics Module card cage The red CRT is separated and perpendicular to the green and blue CRT Two exhaust fans at the rear help cool the green and blue CRT assemblies Each CRT is sent a red green or blue image signal but they do not emit a red green or blue color as in traditional CRT projectors The CRTs are not used as a primary light sourc...

Page 19: ... ILA and travels through the 1 and 2 Combining Prisms red and green The blue polarized image light goes through the Turning Mirror and combines with the red and green light in the 2 Combining Prism to be picked up by the projection lens Figure 2 3 Overhead view of top level optical path ...

Page 20: ...ons are Zoom Lens with a 3 1 to 8 1 range 1 5 1 Fixed Range Lens with a variable offset that can be set to 50 of screen height above or below the centerline of the screen 1 1 1 Fixed Range Lens WARNING The Xenon Arc Lamp produces high intensity white ultraviolet and infrared light capable of severe eye injury Never look directly at or touch the Xenon Arc Lamp Service should be performed by Hughes ...

Page 21: ...this portion of the manual are based on an overall Electronics System block diagram and simplified block diagrams for each of the nine printed circuit assemblies The diagrams and descriptions serve two purposes first to provide the technician with an overall grasp of how the system works and how each assembly works with other assemblies in the system second to provide the technician with enough in...

Page 22: ...rrection The 5 1V Standby is on whenever AC power is connected to the projector and the circuit breaker next to AC power connection is in the On position The 24V standby power for the fans turns on when the FAN_ENA signal is received from the System Controller this turns off in 5 8 minutes if power is not turned on by the remote control or a PC All other voltages supplied by the LVPS are activated...

Page 23: ... circuitry 15V For analog circuitry 60V For Horizontal power Supply section of Horizontal Deflection PCB and Video Amplifiers PCB LV_OK Feedback signal indicating to the System Controller the status of the non standby supply working or not working NOTE a in front of signal name means active low This means the signal will enable a device such as the LVPS in LV_ENA A high 5V and low 0V The COVER_ON ...

Page 24: ... boost voltage to approximately 32KV and ignites the Xenon Arc Lamp After the Arc Lamp is lit it is maintained on by the ALPS at a constant 19 volts and 39 amps The LAMP_LIT output signal informs the System Controller if the lamp is lit or not The Arc Lamp Power Supply is shielded electrically and magnetically to prevent noise or disturbances in the CRTs or other circuitry The Cover On signal goes...

Page 25: ...oltage Power Supply HVPS is located in front of the LVPS on the left side of projector as viewed from rear This supply provides the anode focus and screen voltages required for the three CRTs in the Model 100 projector The following functions are provided by HVPS Phase locked loop circuit for synchronization to the horizontal sync Generation of anode voltages 15kV for all three CRTs RGB Generation...

Page 26: ...n of the signal The format used is such that the assembly communicated with is used as the primary heading of each output Input refers to an input to the HVPS Output refers to an output from the HVPS In each case the signals direction is noted Table 2 3 Inputs and Outputs for the HVPS Inputs LVPS 15V Power for analog circuitry 15V Power for analog circuitry 5 1V Power for digital circuitry SC RTG ...

Page 27: ...Optional Video Input Cards that can be used with the Model 100 Projector RGBHV Wide Band VIC used as a second input card Graphics Enhancer RGB VIC Four Input RGB MUX VIC used in a similar manner as a switcher HDTV VIC used for High Definition Television Quad Standard Decoder Line Doubler VIC used for NTSC PAL SECAM and other composite sources RGBHV Wide Band VIC The RGBHV Wide Band VIC has five BN...

Page 28: ...IC does not use the interrupt line of the IIC bus interface RED_VIC GRN_VIC BLU_VIC SEL_VIC RED GREEN BLUE IIC_CLK IIC_DATA 5 1V_STBY 5 1V 15V 15V B2 B4 B6 12 B8 B13 A13 A16 B16 B15 B14 H_VIC B10 V_VIC A1 GND A2 GND A3 GND IIC HORIZ VERT IIC_INT A12 Figure 2 8 RGBHV Wide Band VIC I O The RGBHV Wide Band_VIC I O This section provides a description of the inputs to and outputs from the RGB_VIC The I...

Page 29: ...izontal or composite sync signals V_VIC Vertical sync signals System Controller RTG PCB Inputs Description IIC_CLK IIC clock line Unidirectional clock line for control of synchronous data transfer over the IIC bus interface IIC_DATA IIC data line Bi directional serial line for synchronous data transfer between System Controller RTG PCB and the RGB_VIC Outputs Description IIC_INT IIC interrupt line...

Page 30: ...d so that only one is enabled at a specific time Software selects the desired input channel through the IIC bus and ensures that only one RGB VIC is enabled When one of the channels assigned to the Four Input RGB VIC is selected the SEL_VIC line to the Video Processor is enabled RED_VIC GREEN_VIC BLUE_VIC H_VIC V_VIC IIC SEL_VIC IIC_CLK IIC_DATA IIC_INT 5 1Vstby 5 1V 15V 15V 4 1 VIDEO MUX and BUFF...

Page 31: ...the inputs are color components they will be converted to RGB type signals The selection between color component input mode and RGB input mode is controlled by an input This input is controlled by the System Controller RTG PCB via the IIC serial bus interface LED indication There are two LEDs on this VIC The RGB LED is illuminated when the YPbPr_VIC is selected and is in RGB input mode The YPbPr L...

Page 32: ...s are arranged by the source destination of the signal The format used is such that the assembly communicated with is used as the primary heading of each group of signals Those signals are further subdivided into inputs and outputs Input refers to an Input to the YPbPr_VIC output refers to an output from the YPbPr_VIC Table 2 5 YPbPr VIC Signals Projector Inputs Input Description Y G Pb B Pr R Vid...

Page 33: ...coder Line Doubler VIC The Quad Standard Decoder Line Doubler VIC has two basic functions The Quad Decoder accepts C Vid and S Vid signals in four different formats PAL SECAM NTSC and 4 43NTSC and converts them to a RGBHV signal It contains one BNC input connector for C Video and two BNC connections for Luminance Y and Chrominance C for S Video The Model 100 projector does not accept sources with ...

Page 34: ...s from the System Controller Board through the Backplane Board All required adjustments for this board are provided via the IIC serial bus interface The information transferred over the IIC bus is indicated below I input to YPbPr_VIC and O output of YPbPr_VIC The selection of this VIC is accomplished through the IIC control bus which provides the SEL_VIC signal Quad Standard Decoder Line Doubler V...

Page 35: ...fer over the IIC bus interface IIC_DATA IIC data line Bi directional serial line for synchronous data transfer between SC RTG PCB and the VIC IIC_SINT IIC Interrupt Output Low Voltage Power Supply Inputs Description 5 1V 5 1V supply for use by The Quad Decoder VIC 15V 15V supply for use by the Quad Decoder VIC 15V 15V supply for use by the Quad Decoder VIC GND Ground Video Processor Board Output D...

Page 36: ...t Board PCB It also provides three primary color signals and G2 Control and DC RESTORE signals to the Video Amplifier PCBs VA PCBs The following functions are provided by the VP PCB Video signal input and multiplexing Sync signal stripping Overlay signal multiplexing Brightness and Contrast control and DC RESTORE On screen Switching Video signal gamma correction Sensitivity and Threshold signal in...

Page 37: ... 7 are arranged by the source destination of the signal The format used is such that the assembly communicated with is used as the primary heading of each group of signals Those signals are further subdivided into inputs and outputs Inputs refers to an input to the Video Processor PCB while output refers to an output from the Video Processor PCB Table 2 7 Video Processor I O signals Video Processo...

Page 38: ...lay Overlay control signal IIC DATA IIC data line Bi directional serial line for synchronous data transfer between the SCB RTG HVPS video processing and deflection processing PCBs IIC CLK IIC clock line Unidirectional clock line for control of synchronous data transfer over the IIC bus interface IICS IRQ Interrupt line Video Processor PCB BLANKING Blanking signal composed of right left top and bot...

Page 39: ...signal is received that the Video Amplifiers are functional this signal is sent to enable the HVPS Outputs Video Amplifiers Red Video Red video output 0 Volt to 1 Volt Grn Video Similar to Red Video Blue Video Similar to Red Video Restore DC Restore control signal SC RTG Grn sync Input vertical sync H sync Input Horizontal or composite sync V sync Sync on green signal that is stripped from the gre...

Page 40: ...ergence and shading maps are located on the SC RTG PCB The following functions are performed or controlled by the System Controller section of the System Controller Raster Timing Generator PCB Enables control for the Low Voltage Power Supply Arc Lamp and cooling fans Fault monitors the HVPS LVPS Arc Lamp and fans and most of the other PCBs Provides interface communication via the IIC serial bus Co...

Page 41: ...ources with the following horizontal and vertical scan frequencies Horiz 30 135 kHz Vert 50 150 Hz Selects the proper sync from the source Separate H V Comp sync and SOG Removes the serration and equalization pulses from the Composite and Sync On Green syncs Generates the back porch clamping signal Detects Non interlaced and Interlaced sources Separates horizontal and vertical syncs and provides h...

Page 42: ... three wire bus interface consists of clock line data line and interrupt line The System Controller PCB controls the IIC bus and tells the other PCB when to send and receive data over the IIC bus System Controller Raster Timing Generator Input Output This section provides a description of the inputs to and outputs from the SC RTG The I O descriptions are arranged by the source destination of the s...

Page 43: ...t has powered up HVPS HV OK High Voltage status line Low operation HVPS ALPS LAMP OK Jumpered not used LAMP LIT Signal from ALPS that the Arc Lamp is lit Video Processor V Sync Input vertical sync H Sync Input Horizontal or composite sync Grn Sync Sync on grn signal that is stripped from the green video Misc FRONT IR Input signal from Front IR Detector REAR IR Input signal from Rear IR Detector LE...

Page 44: ... Blu_Thres Blu_Sens Sensitivity correction information for Blu Real time data at 0 volt to 1 volt Grn_Sens Similar to Blu_Sens Red_Sens Similar to Blu_Sens BLANKING Blanking signal composed of right left top and bottom blanking CLAMP A negative going video clamp signal wit about 3 duty cycle Vertical Convergence Deflection X_Red Conv Red X convergence waveform The amplitude for full scale correcti...

Page 45: ...abled deflection and high disabled deflection H_F2V A DC voltage proportional to horizontal frequency CCD Camera CCD_EXP Signal to CCD Shading camera to control shutter exposure time CCD_CLK Clock pulse for CCD Shading camera CCD_ZOOM Signal to CCD Shading camera for zoom control CCD_FOCUS Signal to CCD Shading camera for focus control CCD_IRIS Signal to CCD Shading camera for aperture control Fro...

Page 46: ...n produces a voltage that is proportional to the horizontal frequency which is used by the Horizontal Deflection PCB and the phase locked loop PLL section of the RTG board This DC voltage is used to create the following frequency bands Band A from 30 kHz to 45 kHz Band B from 45 kHz to 90 kHz Band C from 90 kHz to 135 kHz These bands are outputted through the IIC interface to be used by the System...

Page 47: ...uring frequency band change period C During the period that the phase locked loop is out of lock Deflection Processor PCB The Deflection Processor PCB is the circuit board directly above the System Controller Raster Timing Generator in the Electronics Module card cage see figure 4 10 The following functions are performed by or controlled by the Deflection PCB Controls the ILA Bias and Frequency Co...

Page 48: ...Horizontal and Vertical Edge Linearity Red and Blue Horizontal Size Red and Blue Vertical Size Figure 2 15 I O diagram of Deflection Processor PCB The Deflection Processor PCB I O diagram see Figure 2 14 and the list of inputs and outputs see Table 2 9 provide information for the technician to perform module level troubleshooting ...

Page 49: ...nchronous signal for Horiz Axis V_DRIVE Square wave negative going pulse synchronized to the selected vertical sync with a pulse width of about 4 horizontal periods Outputs SC RTG IICS_IRQ Interrupt line BLANKING Blanking signal composed of right left top and bottom blanking CLAMP A negative going video clamp signal wit about 3 duty cycle V_Sync Input vertical sync H_Sync Input Horizontal or compo...

Page 50: ...n PCB is the middle circuit board above the Deflection Processor PCB and below the shorter Horizontal Deflection PCB in the Electronics Module card cage see Figure 4 10 The Vertical Convergence Deflection PCB I O diagram see Figure 2 15 and the list of inputs and outputs see Table 2 10 provide information for the technician to perform module level troubleshooting The following functions are provid...

Page 51: ...rgence Deflection PCB does not create any interrupt and the interrupt line is not used for this application Vertical Convergence Deflection Board I O This section provides a description of the inputs to and outputs from the Vertical Convergence Deflection PCB The I O descriptions are arranged by the source destination of the signal The assembly communicated with is used as the primary heading of e...

Page 52: ...ce waveform The amplitude for full scale correction is about 1 VPP Y_Red_Conv Red Y convergence waveform The amplitude for full scale correction is about 1 VPP Y_Grn_Conv Green Y convergence waveform The amplitude for full scale correction is about 1 VPP Y_Blu_Conv Blue Y convergence waveform The amplitude for full scale correction is about 1 VPP IIC_CLK IIC data line Bi directional serial line fo...

Page 53: ...oke or loose scan reverse connector This prevents the power supply section of the Horizontal Vertical Deflection Board from operating when 1 or more yoke connectors are disconnected SWEEP_OK Shuts down the video amplifiers in the event of deflection failure if DEFL_OK or H_ENABLE are not present Horizontal Deflection PCB The Horizontal Deflection PCB is the smaller circuit on the top of the Electr...

Page 54: ...ine a data line and an interrupt line The C D Board does not create any IIC interrupt The Horizontal Deflection Board I O This section describes the inputs to and outputs from the C D Board The I O descriptions are arranged by the source and destination of the signal The assembly communicated with is the primary heading of each group of signals Those signals are subdivided into inputs and outputs ...

Page 55: ...ized to the selected horizontal sync H_BAND 0 Horizontal frequency band lines H_BAND 1 Band A 00 Band B 01 Band C 11 H_ENABLE Low enabled deflection and high disabled deflection H_F2V A DC voltage proportional to horizontal frequency IIC_DATA IIC data line Bi directional serial line for synchronous data transfer between the SCB RTG and the Horizontal Deflection PCB IIC_CLK IIC clock line Unidirect...

Page 56: ... failure the SWEEP_OK signal goes high This signal goes to the Regulator PCB where it shuts down the G2 supply voltage Beamcurrent Limiting If the Contrast or G2 is adjusted too high a BEAM signal is sent to the Video Processor PCB The CRT beam current limit is 40µA If the Contrast adjustment causes a CRT beam current limit the Video Processor will reduce the Contrast If this doesn t work the Vide...

Page 57: ...s and Outputs Regulator PCB 2 7 Inputs LVPS 15V Power for analog circuitry 15V Power for analog circuitry 6 2 V CRT Filaments 60 V Video Output drive supply HVPS G2 SUPPLY G2 Supply Voltage 1 kV ARC_GND Ground G1_SUPPLY G1 Supply Voltage 75V GROUND Ground BLANKING Blanking signal composed of right left top and bottom blanking ...

Page 58: ...VA PCBs are located under the necks of each of the three CRTs The outputs from these video amplifiers connect directly to the CRTs and provide all electrical connections to the CRTs except for the anode voltages The following functions are provided by VA PCB Amplification of video signals and driving the cathode of all three CRTs Sensing the cathode beam current for all three CRTs G1 regulator for...

Page 59: ...grounds for each CRT which are used to protect against arcing of the CRT anode supply IIC Interface The Video Amplifier PCBs does not use the IIC interface All adjustments are accomplished by the control lines coming from the Video Processor Board The Video Amplifier Board I O This section provides a description of the inputs to and outputs from the Video Amplifier PCB The I O descriptions are arr...

Page 60: ...rocessor VIDEO IN Video signal in Regulator G2 CTRL Control signal to adjust G2 REG_G2 900 V to other Video Amplifier PCBs GND Ground HVPS G2 SUPPLY G2 supply voltage 1 kV ARC GND Ground Outputs Video Processor VAMP_OK VA PCB status line Low good VA PCB High Bad VA PCB This signal is called HV_ENABLE at the HVPS BEAM CRT beam current Feedback to Video Processor PCB for beam current limiting About ...

Page 61: ...d other components together either through a direct connection to a connector on the Backplane or through cables to connectors on the Backplane PCB Signals are not modified in any way by the Backplane It serves only as an interconnecting point Refer to Figure 2 20 for a general idea of how the projector wiring is interconnected through the Backplane PCB ...

Page 62: ...Chapter 2 System Description 2 50 Model 100 Service Manual Figure 2 20 Backplane Board Interface Block Diagram ...

Page 63: ...Chapter 2 System Description Model 100 Service Manual 2 51 ...

Page 64: ...t Adjustment 3 21 3 10 Cleaning Lenses CRT ILA Assemblies and Mirrors 3 22 3 1 Introduction This chapter details adjustment procedures required to maintain the Model 100 Refer to Figure 3 1 and Figure 3 2 to locate assemblies and components A tool list required to perform adjustments is in Chapter 1 CAUTION Before performing procedures in this chapter review the chapter on Safety at the beginning ...

Page 65: ...ont cover removed pull out the power interlock switch This allows power to be applied to the projector for maintainence Do not use the interlock switch to power off the projector because it maintains power to the fans to cool the Arc Lamp The power interlock switches for front cover are attached to the chassis frame ...

Page 66: ...ts 3 3Model 100 Service Manual 3 3 Figure 3 1 Major components of the Model 100 Projector Arc Lamp Arc Lamp Power Supply Front Projection Lens Igniter Assembly CRTs Electr onics M d Reg ulat Video Amplifier PCB HVPS Arc Lamp LVPS ...

Page 67: ......

Page 68: ...stment and Arc Lamp Alignment Arc Lamp Current Adjustment The Arc Lamp Current Adjustment must be performed whenever the Arc Lamp Power Supply is replaced 1 Remove the front cover 1 Apply power to the projector and allow it to operate for a minimum of 15 minutes 2 Measure the voltage across the Arc Lamp Power Supply output terminals using a DVM see Figure 3 3 CAUTION Do Not place DVM leads across ...

Page 69: ...t adjustment Figure 3 4 Zoom view of aperture on top of Arc Lamp Power Supply cover 5 Multiply the voltage by the current The result should be 750 25 watts 6 If the result is not 750 25 watts adjust the trimmer pot see Figure 3 4 until the result is 750 25 If increasing the current observe that the voltage may increase slightly 7 Wait approximately 10 minutes then recheck the current and voltage a...

Page 70: ...his bias level will be returned to when this adjustment is complete The Green value only need be recorded because Red and Blue will return to their original levels when Green is reset 6 Use the up arrow key and adjust the ILA bias for Green for maximum light output 7 Measure the light output in the center of the screen using a calibrated light meter Minolta Illuminance Meter T 1 or equivalent 8 Lo...

Page 71: ...ess than 3 1 from center to corners Each corner should be balanced evenly so that no corner is excessively brighter or darker than any other corner 16 Recheck rolloff with the light meter again Readjust recheck and readjust until a rolloff of 3 1 from screen center to screen corners is obtained 17 Loosen the 4 Phillips head retaining screws see Figure 3 6 to allow the Arc Lamp Module to move Use a...

Page 72: ...e entire range Use the Pluge Grey test pattern to perform this adjustment one color at a time The procedures below perform the ILA Back Focus for the Green lens The first procedure is for a zoom lens The second procedure is for a fixed lens To adjust the ILA Back Focus for a Zoom Lens 1 Remove all the covers seeSection 4 2 2 View the Green Channel Hide the Red and Blue Channels 3 Select Test Patte...

Page 73: ...while performing this step Figure 3 7 ILA Back Focus Adjustment 10 Repeat Steps 5 9 until the spacer balls stay in focus through the entire zoom range The spacer balls may go slightly out of focus in spots while zooming up or down but they should be in focus at the smallest and largest images 11 Tighten the 2 phillips on the Green ILA Assembly see Figure 3 7 12 Once the Green ILA is properly focus...

Page 74: ... ILA Assembly base 8 Repeat Steps 4 6 above for other Red and Blue Channels as need Be sure to hide the other 2 colors Figure 3 8 Front Projection Lens Adjust 3 4 CRT Electronic Focus The CRT Electronic Focus is factory set and will not normally need to be adjusted except after component replacement maintenance or if wide temperature variations exist between the factory and the field location View...

Page 75: ...3 colors With all colors at maximum the image on the screen should be a white screen with some colors at the edges 4 Observe the right left top and bottom of the screen Normally green is the reference to which blue and red will be matched NOTE If the green ILA has been replaced the blue or red image should be used as the reference to match green to If a red or blue border is present on either side...

Page 76: ...are for the vertical scanning jumper and CN708 and CN707 are for the convergence jumper Front Rear Jumper Setting Horizontal Scan Reverse The Horizontal Scan Reversal Jumper reverses the image projection for front or rear projection Figure 3 13 illustrates the jumpers location on the Vertical Convergence Deflection PCB NOTE When the Horizontal Scan Reversal Jumper is changed the Front Rear Converg...

Page 77: ...nsert it into CN707 Refer to Table 3 1 for other orientations NOTE The Vertical Convergence Deflection PCB does not need to be removed from the Electronics Module to change these connections 5 Replace the Electronic Module cover 6 Restart the projector 7 When changing jumpers for front or rear screen projection Centering convergence and shading must be rechecked Figure 3 10 Vertical Convergence De...

Page 78: ...for other orientations To invert the vertical image 1 Turn power off at the projector and wait for the arc lamp to cool 2 Remove the Electronics Module cover see Section 3 2 3 Verify that the vertical jumper is inserted into CN713 for upright vertical operation see Figure 3 10 and Table 3 1 Remove the connector from CN713 and insert it into CN714 NOTE The Vertical Convergence Deflection PCB does n...

Page 79: ...e 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...

Page 80: ...tings Terminal Emulation click on DEC VT 100 ANSI and 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 7 Select OK 8 Under Sett...

Page 81: ...ANSI Terminal and select OK 8 Press ESC 9 Power off the Projector 10 Cycle off the A C Main Circuit Breaker This serves to reset the software 11 Insert a small screwdriver into the Service Mode Switch Access hole on on the SC RTG PCB see Figure 3 13 Depress and hold down the Service Mode Switch While holding down the switch turn the projector A C circuit breaker on Figure 3 13 Service Mode Switch ...

Page 82: ...see the following output Command loadboot to update Boot Manager Enter 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 16 From the Windows Term...

Page 83: ...o reenter Boot Manager You should see the following displayed where y y 0 is the updated Boot Manager s version Boot Manager Ver y y 0 Service Mode Startup Copyright c 1994 1996 Hughes JVC Technology Command _ To update the System Software 21 From the Boot Manager prompt type in the command loadsys At the prompt the following should be displayed Command loadsys System software update procedure WAR...

Page 84: ... type in the sys command and press Enter The projector will now go back to the standard mode in standby ready to power up with the updated System Software 3 9 Graphic Enhancement Adjustment The optional Graphic Enhancer RGBHV VIC has a very small adjustable pot see Figure 3 14 that was designed primarily to improve the visibility of computer black text on white background such as spreadsheets This...

Page 85: ...he 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 CRT ILA Assembly The CRTand ILA should be treated as one unit The CRT has a fiber optic o...

Page 86: ... Video Amplifier PCB 4 14 4 17 CRT ILA Assembly 4 15 4 18 Projection Lens 4 17 4 19 Recommended Spares 4 19 4 1 Introduction NOTE Before removing the front top or side covers 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 factory certified technicians and engineers onl...

Page 87: ...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 optics for crazing peeling or cracking of layers or cracking If any problems are observed call the factory 800 39...

Page 88: ...moval Replacement Model 100 Service Manual 4 3 Figure 4 1 Major Components Arc Lamp Module Low Voltage Power Supply Arc Lamp Power Supply High Voltage Power Supply Electronic Module card cage CRT ILA Assembly Igniter Assembly ...

Page 89: ... 3 The front cover can also be removed without removing any other covers It also has two retaining cables It can be removed by unscrewing three Phillips head screws one on top and one on each side NOTE When the Front Cover is removed it disengages the Interlock Switch see Figure 4 2 To operate the projector with the Front Cover removed pull the Interlock Switch out 4 The top cover can be removed o...

Page 90: ...Lamp a Docking Module a light shield and an Arc Lamp cooling duct The Arc Lamp fits inside the Docking Module CAUTION It is strongly recommended that the Arc Lamp current be turned down see Section 3 1 before installing a new Arc Lamp to help prevent possible damage that could reduce the life of the new lamp WARNING Dangerous light exists in this area of the projector Before proceeding with the re...

Page 91: ...ly out 8 To replace the Arc Lamp the lamp must be removed from the Docking Module 9 Once the Docking Module is removed from the projector remove the 4 Arc Lamp Housing Phillips head clamp screws two on the top and two on the side of the Arc Lamp Housing 10 Remove and retain the Heat Sensor from the Arc Lamp NOTE The Thermal Sensor attached to the Arc Lamp must be removed from the old Arc Lamp and ...

Page 92: ...e the Arc Lamp to fail Figure 4 5 Arc Lamp Module Power Terminals Arc Lamp removed from projector 4 5 Ignitor Assembly The Igniter Assembly consists of the Igniter and the Laser Power Supply When either of these two components require replacing the Ignitor Assembly is returned and replaced as a unit The Igniter sits directly underneath the Arc Lamp Module To remove the Ignitor Assembly 1 Remove th...

Page 93: ...t be turned down see Section 3 1 before installing a new Arc Lamp to help prevent possible damage that could reduce the life of the new lamp 2 Disconnect the control cable P11 from J72 and remove the cable from the cable ties 3 Disconnect the ALPS Ouput cables from the and terminals on J74 Figure 4 7 Arc Lamp Power Supply connections 4 Disconnect the A C plug P71 from J71 Control Cable P11 A C Plu...

Page 94: ...ower Supply see Section 4 8 3 Remove the 2 Phillips head screws from the base of the LVPS 4 Slide the LVPS out slowly 5 Reach behind the LVPS and disconnect the A C cable P79 from J75 Also disconnect the control cable P07 from J76 6 Reinstall the LVPS in reverse order After the LVPS is installed recheck Timing Geometry Electronic Focus ILA Bias Sensitivity Convergence G2 and Shading Figure 4 8 Low...

Page 95: ...der from above 9 Replace the projector covers Figure 4 10 Printed Circuit Board orientation inside Electronics Module 4 9 System Controller Raster Timing Generator PCB NOTE It is strongly recommended to download Export setup data to a Laptop or PC prior to replacing the SC RTG PCB to retain data otherwise all the setup data will stay will the old SC RTG PCB see Appendix A Import Export CRT Anode l...

Page 96: ...ove To remove the System Controller Raster Timing Generator SC RTG 1 Disconnect the control cables 2 Remove the right side cover optional 3 Use a small flat head screwdriver to loosen the retaining screws 4 Grasp the D handle and pull out the SC RTG PCB 5 Reverse the order to install SC RTG PCB Figure 4 11 System Controller RTG and Video Processor PCBs 4 10 Video Processor PCB The Video Processor ...

Page 97: ...CB 1 Remove the right side cover 2 Remove the panel covering the top three circuit boards 3 Pull the PCB out about 2 inches in order to get access to the plugs and jacks 4 Remove the Horizontal Scan Reversal Jumper cable from either CN702 or CN701 This the cable that runs from the Horizontal Deflection PCB to the Vertical Convergence Deflection PCB see Figure 4 12 NOTE To remove connectors on the ...

Page 98: ...de in front of the Horizontal PCB and push the slide up 5 Grab the PCB by the edges and pull it out of the Electronics Module card cage 6 Replace the Horizontal Deflection PCB in the reverse order 4 14 Video Input Cards VICs Instructions for installing removing editing and VIC Settings are covered in Chapter 4 Section 4 11 1 of the Model 100 User s Guide 4 15 Regulator PCB The Regulator PCB is loc...

Page 99: ...tly under its respective CRT To remove a Video Amplifier PCB 1 To remove any of the Video Amplifier PCBs it will make the job easier to remove all the covers from the projector Section 4 2 To remove the Video Amplifier for the green CRT remove the Regulator PCB first Section 4 15 2 Disconnect the Video Input cable from connector CN101 3 Disconnect the G2 Output connector fron connector CN107 4 Dis...

Page 100: ...t These fiber optics are separated by a thin film of optical fluid Disassembly of the CRT ILA Assembly should not be attempted except by Hughes JVC trained technicians in a clean room environment WARNING The CRT ILA Assemblies should be handled with extreme caution If dropped they can implode and flying glass can cause severe injury to personnel Be careful not to bump or drop the CRT Place in a sa...

Page 101: ...node Lead large black connector see Figure 4 15 7 Disconnect the Deflection cable that is plugged into the Vertical Convergence Deflection PCB 8 Remove the Deflection cable from all the tie wraps 9 Disconnect the ILA Bias connector 10 Remove the 2 slotted head screws near the rear of the ILA Assembly NOTE If removing the Green CRT ILA remove the Thermistor attached to the Green ILA 11 Loosen the 2...

Page 102: ... does not fall and get damaged or damage other components in the projector 5 Replace the Projection Lens in reverse order 6 When changing from a Zoom Lens to a 1 1 Wide Angle Lens the installation is the same as the removal as stated above When changing from a Zoom or 1 1 Wide Angle to a 1 5 1 with offset or vice versa the Lens Support Bracket must be changed The appropriate Lens Support Bracket w...

Page 103: ...his offset depends on the screen image and how the screen is oriented vertically with respect to the projector Adjusting the Lens Support Bracket all the way up screws at the bottom of slots produces a 100 offset while adjusting the Bracket all the way down screws at the top of slots produces 0 offset Some offset may be necessary to compensate for a screen that is slightly higher vertically than t...

Page 104: ...ares that HJT recommends for one to four projectors Table 4 1 Recommended minimum spares PART NO DESCRIPTION QUANTITY 104515 PCA Vertical Convergence Deflection 1 104595 PCA Horizontal Deflection 1 104610 PCA Video Amplifier 1 104963 PCA Regulator 1 104510 PCA Video Processor 1 104425 PCA System Controller Raster Timing Gen 1 104520 PCA Deflection Processor 1 104413 PCA Graphics Enhancer VIC 1 104...

Page 105: ... The illustrations below indicate where various LEDs are located that indicate proper or improper operation of the System Controller Raster Timing Generator the Video Processor PCB the Deflection Processor the Vertical Convergence Deflection PCB the Horizontal Deflection PCB the Regulator and Video Amplifier PCB Figure 5 1 Location of LEDs on System Controller RTG PCB ...

Page 106: ...Chapter 5 Troubleshooting 5 2 Model 100 Service Manual Figure 5 2 Location of LEDs on the Video Processor PCB Figure 5 3 Location of LEDs on the Deflection Processor PCB ...

Page 107: ...Chapter 5 Troubleshooting Model 100 Service Manual 5 3 Figure 5 4 Location of LEDs on the Vertical Convergence Deflection PCB Figure 5 5 Location of LEDs on the Horizontal Deflection PCB ...

Page 108: ...Chapter 5 Troubleshooting 5 4 Model 100 Service Manual Figure 5 6 Location of LEDs on the Regulator and Video Amplifier PCBs ...

Page 109: ...ssor PCB IIC is noisy shorted or grounded 4 POWER ON OFF Power On Sequencing 5 FLASH MANAGER Flash Memory Data Manager software 6 VIDEO SWITCHER EXTRON or JVC Video Switcher Handler 7 ANSI OUTPUT Ansi Output Display process RS232 8 UI CHAN SRC User Interface SW for Channel SRC Data 9 VIDEO INPUT CARD VIC Card Handler 10 HARDWARE Misc HW shutters etc The error codes listed in Table 5 2 describe pro...

Page 110: ...power brown outs 3 1 Pin Timeout IIC Slave HW protocol error possible on each byte transfer Channel or Source Change Adjustment 3 2 BB Timeout IIC Slave HW protocol error 1st error possible on Read or Write Channel or Source Change Adjustment 3 3 No Slave Ack IIC Slave HW protocol error missing acknowledgement on byte transfer NOTE This error occurs if the slave is missing During Power On this err...

Page 111: ... apply to Switchers only 6 1 Sync Timeout No Header found in data stream possible baud rate error Switcher Command 6 2 No Char Repeat Expected data characters to be repeated failed Switcher Command 6 3 Invalid Format Data not in Extron or JVC Switcher format Switcher Command 7 1 Write Len Error Ansi Output to RS232 port was interrupted incomplete Any RS232 Output 8 1 VIC Slot is empty User has sel...

Page 112: ...uit Breaker User s Guide 3 6 Main Circuit Breaker fails when reset Verify input power is correct Replace defective Low Voltage Power Supply or Arc Lamp Power Supply 4 6 and 4 7 Power Interlock Switch Test switch operation If defective replace switch Projector cover not enabling interlock switch Reposition projector cover No Picture Correct channel input VIC selected Select correct channel and VIC ...

Page 113: ...he CRT ILA assembly is installed correctly 4 17 Image blurry with shadow on right edge Replace CRT ILA assembly 4 17 Characters do not appear legible Replace CRT ILA assembly 4 17 CRT focus problem is limited to one color Replace CRT ILA 4 17 Sensitivity Offset is set too high Reset Sensitivity Offset User s Guide 4 7 2 Picture Geometry Picture not centered or sized correctly Repeat the Blanking P...

Page 114: ...ast User s Guide 4 9 2 Black image is overdriven Adjust Threshold Black level and Brightness User s Guide 4 7 3 4 7 1 4 7 2 Bright Red Green or Blue area on screen limited to corners or edge Adjust ILA bias and shading User s Guide 4 5 4 8 Grey scale is Green in bright areas Subtract Green Sensitivity Offset and add Red and Blue User s Guide 4 7 2 Grey scale is Red in bright areas Subtract Red Sen...

Page 115: ...Chapter 5 Troubleshooting Model 100 Service Manual 5 11 Various Problems ...

Page 116: ...Terminal port not set up correctly Replace tether cable Select Tethered Remote and correct baud rate from menu No Response when using IR remote Intermittent operation Replace remote battery or move closer to the projector Stay in the Line of sight of the projector IR Receiver New Software won t load properly Switch position 4 on switch block on System Controller board is in incorrect position Swit...

Page 117: ...Chapter 5 Troubleshooting Model 100 Service Manual 5 13 ...

Page 118: ...tor 104425 PCA Regulator 104963 PCA Video Amplifier 104610 PCA Video Processor 104510 PCA Backplane 104604 PCA Graphics Enhancer RGB VIC Option 104413 PCA RGBHV VIC Option 102597 PCA HDTV VIC Option 103765 PCA 4 RGB Input VIC Option 103545 PCA MUX VIC Option 103668 PCA Quad Line Doubler VIC Option 105305 Power Cord USA 103253 Power Cord Europe 103939 Power Supply Arc Lamp 104450 Power Supply High ...

Page 119: ...second in digital and in Hertz in communications Bandwidth is the difference between the lowest and highest frequencies transmitted or received Wider bandwidth provides more information or picture detail capability Chrominance Abbreviated as C Color information signal or signals Cold Mirror Mirror that absorbs infrared light so that its reflection contains only cold light that does not transmit ap...

Page 120: ...r such a blue pink or aqua Hue or tint control on a display device adjusts red green balance Ignitor Provides a momentary high voltage to excite the gases in the Xenon Arc Lamp to ignite Image Light Amplifier A device that uses low intensity images to phase ILA modulate a high intensity light through a liquid crystal layer It is a key component in producing very bright high resolution images from ...

Page 121: ... of sharpness of a displayed or printed character or image the amount of detail in a picture On a display screen resolution is expressed as the number of horizontal dots columns by the number of vertical lines rows For example a 680 x 400 resolution means 680 dots across each of 400 lines Retrace The blanked out line traced by the scanning beam of a picture tube as it travels from the end of any h...

Page 122: ...es in a graphics frame Scan Rate The frequency of line scanning for a monitor or projector Synchronization Also called sync for short Working together At the same time horizontal and vertical sync signals from the signal source control the monitor s scan circuits to properly time the lines and frames of a picture Technician Remote Remote control used during Model 100 setup and adjustment Alternati...

Page 123: ...req Vertical Scan Reverses the image vertically for use with ceiling Reversal Jumper displays or mirror bounced displays Located on the Vertical Convergence Deflection PCB Vertical Synchronization The number of times per second a frame is Frequency transmitted to a video display screen Xenon Arc Lamp See Arc Lamp ...

Page 124: ...set Port A Device None or Switcher Port B Device ANSI Remember to Power Off Control P and HW RESET Push RESET button figure 5 1 in Service Manual or Circuit Breaker on rear panel after changing any configuration parameters WARNING If you use 19200 Baud your computer must have a 16550 UART installed on the Comm Port An unbuffered 8550 UART will lose data during EXPORT This data loss cannot be detec...

Page 125: ...he projector screen during the transfer Export Configuration EXPORT IN PROGRESS wait Press ESC to Abort The following message is sent at the end of the export data Export Complete STOP Host Download Now Then Press ESC END A similar message is displayed on the projector screen Export Configuration EXPORT COMPLETE STOP Host Download THEN Press ESC 6 Windows TERMINAL Select the Windows TERMINAL STOP ...

Page 126: ... Serial PORT A To Abort Stop Host Upload THEN Press ESC to Abort 6 Windows TERMINAL Transfers Send Text File 6 1 Directories set directory to desired upload directory C TEMP 6 2 File Name Type desired File Name for example import1 txt 6 3 Select OK with mouse or press Enter key upload begins 6 4 Verify TERMINAL screen shows status line at bottom Stop Pause complete bar Sending EXPORT1 TXT 6 5 Data...

Page 127: ... Old Data was Restored STOP Host SEND DATA THEN Press ESC FINALLY press ESC to exit the projector Import operation and return to the Maintenance Menu There is a 10 second pause before the screen is redrawn 9 DATA TRANSFER ERROR Example Model 100 Menu will display Import Failed Bad EXPORT File Format Old Data was Restored STOP Host SEND DATA THEN Press ESC 9 1 Windows TERMINAL FIRST press STOP to e...

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