Hughes Jvc 200 Projector Service Manual

							Chapter 3 Service Adjustments 
2. Remove the projector rear cover (Section 4.2). 
3. Verify that the jumper is plugged into JA50 and J101 for rear 
projection or J50 and J100 for front projection (See Figure 3-7). 
Change jumper if necessary. 
4. Replace the projector cover. 
5. When changing jumpers for front or rear screen projection, 
Centering, convergence and shading must be rechecked. 
3.9.2 Inverted Vertical Jumper Setting 
The Ceiling/Floor jumpers invert the image vertically for use in 
situations using mirrors or ceiling projections. Figure 3-7 illustrates \
the location of the jumpers on the Scan Reversal Board and 
indicates the proper location for ceiling or floor projection. The 
Model 200 Projector is shipped in the normal vertical projection 
position with the jumper plug inserted into J53. For an inverted 
vertical setup this jumper plug must be inserted into J53A. (Refer to 
Figure 3-7). 
To invert the vertical image: 
1. Turn power off at the projector and wait for the arc lamp to cool. 
2. Remove the projector rear cover (Section 4.2). 
3. Tilt the electronic module up (Section 3.3). 
4. Verify that the vertical jumper is inserted in the correct jacks for 
appropriate application, (see Figure 3-7).  Change jumpers if 
necessary. 
5. Replace the electronic module and rear cover. 
6. When changing jumpers for floor or ceiling screen projection, 
Centering, convergence and shading will need to be rechecked. 
3.10 Vertical and Horizontal Size Settings 
Adjust the vertical height pots and horizontal size coils when 
replacing the Horizontal/Vertical Deflection board, Scan Reversal 
board, or CRT/Yoke assembly. They may also be needed when the 
convergence adjustment procedures fail to bring the colors into 
convergence. 
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							Chapter 3---Service Adjustments 
 
  Vertical height pots. 
Figure 3-8. Horizontal/Vertical Deflection Board. 
To adjust the Vertical height (see Figure 3-8): 
Remove the rear cover (Section 4.2).  
1. Select Test Pattern 5, X-hatch. 
 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. 
2. Hide Blue and view Red and Green. 
3. 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, Section 5.5.11).  
 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.  
4. Repeat Steps 2 and 3 above for Blue while hiding Red. 
5. Recheck all Geometry and Convergence settings (see User’s 
Guide) and readjust wherever necessary. 
 
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							Chapter 3 Service Adjustments 
To adjust the horizontal size coils (see Figure 3-7): 
1. Continue to use Test Pattern 5, X-hatch. 
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, 
Section 5.5.11).  
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. 
3.11 Software Updating 
The projectors software resides in Flash Memory and is updated 
via the projectors serial Port A. To perform an update, a disk 
containing the updated Boot Software (boot.hex) and/or System 
Software (zsys.hex) and a PC with Windows 3.1 (avoid Windows 
95 at this time) 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. 
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							Chapter 3---Service Adjustments 
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 (see 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 (see Figure 
5-1) for at least 5 seconds or until Boot Manager appears on 
the terminal monitor. The Power On LED stays Red.  
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.  
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 projector software. You 
should see a file named boot.hex. Select this file and 
press the OK button to begin the upload. 
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							Chapter 3 Service Adjustments 
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. 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: _ 
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 
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							Chapter 3---Service Adjustments 
 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 
220 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 “reboot” command and press Enter. The projector will now 
restart with the updated System Software. 
3.12 Cleaning Lenses, ILA® Assemblies and Mirrors 
The projection lens is the only item that will require periodic 
cleaning. The other assemblies are covered to prevent dust from 
entering or finger smudges.  Cleaning may be needed due to 
special circumstances such as replacing the assembly or an 
adjacent assembly. Cleaning should only require removing 
excessive dust (use canned compressed 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. 
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							Chapter 3 Service Adjustments 
3-18 Model 200 Service Manual 
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 (X-Frame) and 
Polarizing Beam Splitter windows.  Normal cleaning is not required.  
Clean only if absolutely necessary using compressed air.  Do not 
wipe mirrors.  
  
						

							 Chapter 4---Maintenance (Removal/Replacement) 
4.0   Maintenance (Removal/Replacement) 
  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   Arc Lamp Power Supply..........................................................4-8 
4.6   Low Voltage Power Supply......................................................4-8 
4.7   High Voltage Power Supply.....................................................4-8 
4.8   Raster Timing, System Controller, Video Processor PCBs.....4-10 
4.9   Convergence/Deflection PCB..................................................4-11 
4.10 Horizontal/Vertical Deflection PCB..........................................4-12 
4.11 Video Input Cards (VICs).........................................................4-13 
4.12 Video Amplifier PCB................................................................4-14 
4.13 Scan Reversal PCB.................................................................4-16 
4.14 CRT/Yoke Assembly................................................................4-16 
4.15 ILA® Assembly........................................................................\
.4-18 
4.16 Relay Lens........................................................................\
.......4-19 
4.17 Projection Lens........................................................................\
4-20 
4.18 Prism Assembly.......................................................................4-21 
 
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. 
• Tools required to perform removal and replacement of 
projector components and subassemblies are listed in Chapter 
1, Introduction. 
 
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							Chapter 4---Maintenance (Removal/Replacement) 
WARNING!!! Various procedures in this 
chapter involve the removal and replacement of system 
subassemblies. Ensure that the circuit breaker on the rear 
panel of the projector 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.  
Power off: After turning power off with the remote, wait until the 
Arc Lamp cooling fans have stopped running, then toggle the 
projector circuit breaker on the rear panel to OFF and disconnect 
the power cord (allow a discharge time of at least a minute for the 
high voltage to bleed off before removing the power plug). 
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 to assemblies or components in this 
chapter, refer to Figures 4-1 and 4-11 for locations. 
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							 Chapter 
4---Maintenance 
(Removal/Replacement) Optical Shield 
Arc Lamp Air Filter and Cover 
Lamphouse Dock and Arc Lamp 
Arc Lamp Power Supply EMI Shield Lower Right Side Panel. Remove to provide access to ALPS and LVPS. 
High Voltage Power Su
pp
ly
CRT Assemblies,
 
Relay Lenses, ILA
®s, and 
Video Amplifier PCB. Tilt Card Cage up for access.
 
Card Cage containing System Controller, Raster 
Timing Generator,
Video Processor and Video Input Cards.  
Pris
m 
Assembly
 
Rollbar Shutter Motors
 
Horizontal/Vertical Deflection PCB. Convergence PCB on opposite side. 
Metal Framed Air Filter behind Grille. 
Card Cage Holding Pin 
Scan Reversal Board 
Low Voltage Power Supply 
Figure 4-1.
   Major components of the Model 200 Projector.
 
Model 200 Service Manual 
 
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