Hughes Model 230 Projector Service Manual

							Chapter 3---Service Adjustments
Model 230 Service Manual3-19
To adjust the Vertical height (
see Figure 3-14):
1.  Remove the rear cover (Section 4.2).
2.  Select the X-hatch test pattern.
 NOTE: Green is the master to which Red and Blue will be matched. The
Green height pot should not need adjustment except when the Green CRT
assembly has been replaced.
3.  Hide Blue and view Red and Green.
4.  If Red is higher than Green at the top 
and lower than Green at the bottom of
the X-hatch image, 
or If lower than Green at the top 
and higher at the bottom,
adjust Red vertical pot to correct the error.
 If Red is higher than Green at the top 
and bottom, 
or lower than Green at the
top 
and bottom, this is most likely caused by Red not being centered correctly
and can be corrected with the centering adjustment (User’s Guide, Chapter
5).
 If the Red height pot does not completely eliminate the difference in height
between Red and Green, balance the error at the top and bottom. Too much
of an error at the top or bottom makes convergence procedures harder to
accomplish.
5.  Repeat Steps 2 and 3 above for Blue while hiding Red.
6.  Recheck all Geometry and Convergence settings (
see User’s Guide) and
readjust wherever necessary.
To adjust the horizontal size coils (
see Figure 3-15):
1.  Continue to use the X-hatch test pattern.
2.  Hide Blue. View Red and Green.
3.  If Red is outside of Green on both sides, or inside of Green on both sides, use
a Delrin .100 hex alignment tool to adjust the Red horizontal size coil to
correct the error. If Red is outside of Green on one side and inside of Green
on the other side, this is most likely caused by Red not being centered
correctly and can be corrected with the centering adjustment (
User’s Guide,
Chapter 5).
If the Red horizontal size coil does not completely eliminate the size error
between Red and Green, balance the error on both sides to allow for easier
convergence.
4.  Repeat Steps 2 and 3 above for Blue while hiding Red.
5.  Recheck all Geometry and Convergence settings and readjust wherever
necessary.
6.  Replace the electronic module and rear cover.
3.10 Software Updating
The Model 230 software resides in Flash Memory and is updated via the
projectors serial Port A. To perform an update, a disk containing the updated 
						

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3-20Model 230 Service Manual
Boot Software (boot.hex) and/or System Software (zsys.hex) and a PC with
Windows 3.1 is required to perform update.
Boot Manager Software and System Software are separate products. Each may
be updated independently. The System Software will depend on a specific version
of the Boot Manager. Refer to the System Software release bulletin for Boot
Manager version dependencies.
To perform software upgrade:
1.  Verify that the projector circuit breaker is off. Use a Null Modem cable to
connect a PC to the projector’s Serial Port A.
2.  Start Windows 3.1.
3.  Click on the terminal icon from the Accessories Directory.
4.  From the Terminal menu, select Settings-Terminal Emulation and click on
DEC-VT-100(ANSI).
Select OK.
5.  Under Settings choose Terminal Preferences.
6.  Under Terminal Preferences the following selections are appropriate;
Terminal Modes=Sound, CR->CR/LF=Both off, Columns=80, Cursor=Block &
Blink, Terminal Font=Fixedsys 15, Translation=None, Show Scroll Bars=On,
Buffer Lines=100, Use Function Arrow & Control Keys for Windows=Off.
Select OK.
7.  Under Settings select Text Transfer=Standard Flow Control. Select OK.
8.  Under Settings select Communications and choose; Connector=select the PC
port being used, Baud Rate=9600 or 19200 (depending on the System
Controller Switch block Pos 4-see note below this step), Data Bits=8, Stop
Bits=1, Parity=None, Parity Check=Off, Carrier Detect=Off, Flow
Control=XON/XOFF. Select OK.
 NOTE: Switch position 4 on the switch block at the card edge of the System
Controller (
Figure 5-1) controls the baud rate for Serial Port A for the Boot
Manager and System Software. Down=9600, Up=19200. Ensure the other
SCB switches (1, 2, and 3) are in the Down position.
9.  Turn the projector circuit breaker on while depressing and holding down the
service mode switch on the SCB (Figure 5-1)
. Verify that Boot Manager
appears on the terminal monitor. The Power On LED stays Red.
Alternate for Step 9: In Power Off Standby mode, Press Control, Shift + _
(underscore), hex IF (international keyboard may vary in key placement).
10. The following should be displayed on the Windows Terminal screen (where
x.x.0 is the currently loaded Boot Manager version (e.g. 0.9.0 or 1.1.0).
 –Boot Manager Ver x.x.0 (Service Mode Startup)
 –Copyright (c) 1994 Hughes JVC Technology
 –Command: _
11. Verify that the Boot Manager version is correct. If it is necessary to update the
Boot Manager, perform the following steps. If the Boot Manager is already up
to date, skip to Step 12 to update the System Software. 
						

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Model 230 Service Manual3-21
11A. Enter the command loadboot at the prompt. You should see the
following output:
 Command: loadboot
 Boot Manager software update procedure
 ***WARNING: IMPROPER USE MAY MAKE THIS SYSTEM 
UNBOOTABLE*** (This warning relates to the Flash Memory
updating that occurs in Step 11D. Do not turn projector
power off while the Flash Memory is updating)
 Memory buffer reset to 0xff
 Begin your S-Record upload now (Esc to abort).
 11B. From the Windows Terminal Menu (normally in Accessories window),
select Transfers/Send Text File, then select List Files of Type:All Files, and
select the disk and/or directory with the Model 230 software. You should see a
file named boot.hex. Select this file and press the OK button to begin the
upload.
 11C. During upload, a progress indicator updates the number of records
received. At the completion of the upload, the system will display the following
(numerical values are for example only and depend on the  Boot Manager
version):
 S-Records processed: 823
 Upload Successful
 Address Range: 0x00000000-0x00006687
 Bytes Loaded:  26248
 ***WARNING: FLASH WILL NOW BE UPDATED***
 Press Enter to continue, Esc to abort.
 11D. The system has verified that the load module is correct and is ready to
update the Flash. Press Enter to perform the update (press Esc now to abort
the update with no changes). While the Flash memory is being updated (15-
30 seconds), DO NOT turn off the projector circuit breaker or the machine
could be made unbootable, requiring a new set of flash chips to be installed.
When the update is complete, the system will display the following:
 Reprogramming Flash Sector 0 1
Boot Manager software update successful
 Command: _
 The Boot software has been successfully updated. To restart the projector
under control of the updated boot manager, enter the reboot command while
depressing the service mode switch (Figure 5-1). The projector will now
restart with the updated boot manager software. (
NOTE: If normal software
starts, see Step 9 to reenter Boot Manager.) You should see the following
displayed, where y.y.0 is the updated Boot Managers version.
 Boot Manager Ver y.y.0 (Service Mode Startup)
Copyright (c) 1994-1996 Hughes-JVC Technology
 Command: _ 
						

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12. To update the System Software from the Boot Manager prompt:
 12A.  Type in the command “loadsys” at the prompt. The following should be
displayed:
 Command: loadsys
 System software update procedure
***WARNING: IMPROPER USE MAY MAKE THIS SYSTEM 
UNBOOTABLE*** (NOTE: This warning relates to the Flash 
Memory updating that occurs in Step 12D below. Do not 
turn projector power off while the Flash Memory is 
updating.)
 Memory buffer reset to Oxff
 Begin your S-Record upload now (Esc to abort)
 12B.  Select “Transfers/Send Text File” from the Windows Terminal Menu
(normally in Accessories window). In the “Send Text File Dialog” box, select
“List Files of Type: All Files” and select the disk and/or directory with the
Model 230 software. Select file named “zsys.hex”. Press OK to start upload.
 12C.  During upload, a progress indicator updates the number of records
received. When the upload is complete, the system will display the following
(numerical values are for example only and depend on the System Software
version):
 S-Records processed:11282
Upload Successful
Address Range: 0x00020000-0x000781cf
Bytes Loaded:360912
 ***WARNING: FLASH WILL NOW BE UPDATED***
 Press Enter to continue, Esc to abort
 12D.  At this point the system has verified that the load module is correct and
is ready to update the Flash memory. Press Enter to perform the update (Esc
will abort the update process with no changes). While the Flash is being
updated (approx 15-30 seconds), DO NOT turn off the projector circuit
breaker, this may make the machine unbootable, requiring a new set of flash
chips to be installed. When the update is complete, the system will display the
following:
 Reprogramming Flash Sector 2 3 4 5 6 7 8 9
 System software update successful
 Command: _
The software update is complete. To restart the projector, type in the “sys”
command and press Enter. The projector will now restart with the updated
System Software.
3.11 Gamma Tracking
Gamma Tracking is used mainly during factory-setup. It may be necessary when
ILA®s are replaced or when the projector has been in use for a long time. To
check if Gamma Tracking is needed, access the Grey Scale test pattern. After all 
						

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Model 230 Service Manual3-23
setup procedures are complete the Grey Scale test pattern should be grey
throughout. If the edges of the Grey Scale appear grey but the middle appears
color-tinged, this indicates that Gamma Tracking may need adjustment.
NOTE:Overall Gamma Tracking is usually best if no color is too near the extreme
(0 or 255). For example, if the middle gray level looks green and the Gamma
Tracking settings are; Red=128, Green=200, Blue=128, it is better to adjust Red
and Blue down instead of Green up.
To adjust Gamma Tracking:
1.  Select the Grey Scale test pattern.
2.  Observe the center of the Grey Scale. If the center of the test pattern shows a
red, blue or green tinge, Gamma Tracking may need to be adjusted for that
color.
 NOTE: It is also possible that two colors are dominant at the center. If the
center of the test pattern appears magenta, then red and blue are both
dominant. If the center appears cyan-tinged, green and blue are dominant. If
the center appears yellow, red and green are dominant.
3.  Select the color to adjust
4.  Make a note of the data value of the color(s) to be adjusted before making
any adjustments to gamma so that it can be returned to if adjusting gamma
does not improve the grey scale image on the screen .
5. Use the arrow keys to decrease gamma in the selected color so that the Grey
Scale looks grey throughout the pattern. Use the UP arrow key to i
ncrease the
data value for gamma in the selected color to make it less dominant!
3.12 Graphic Enhancement Adjustment
The optional Graphic Enhancer RGBHV VIC has a very small adjustable pot (see
Figure 3-15) that was designed primarily to improve the visibility of computer
black text on white background (such as spreadsheets). This pot is factory-set at
mid-range to provide an appreciable enhancement of small black text on white
background. HJT recommends this pot be left at the factory mid-range setting.
If it is absolutely necessary to adjust this pot to optimize a specific type of graphic
image, be sure to check that other sources viewed from the Graphic Enhancer
VIC are not adversely affected. This enhancement adjustment only affects
computer graphics and does not appreciably affect images from VCRs, DVDs etc.
Increasing (clockwise) sharpens the appearance of black on white text but
overadjustment will adversely affect other types of graphics. This is a fixed
adjustment and a compromise setting may be needed for best overall
performance. 
						

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3-24Model 230 Service Manual
 
Figure 3-15.   Graphic Enhancer Video Input Card.
3.13 Cleaning Lenses, ILA® Assemblies and Mirrors
The projection lens is the only item that requires periodic cleaning. Other
assemblies are covered to prevent dust entering or finger smudging. Cleaning
may be needed for special circumstances such as replacing an assembly.
Cleaning should only require removing excessive dust (use canned air such as
“Office Duster” or Aero Duster) or removing fingerprint smudges (use “Kodak
Lens paper”, or equivalent) from the projection lens. As much as possible, clean
the optics only when absolutely necessary.
Projection Lens: Use lens paper and wipe the lens clean in a vertical motion
from top to bottom. Use compressed air to blow excess dust from the lens. An
optical lens cleaning solution can also be used to remove finger smudges.
ILA® Assembly: Clean the ILA® assembly faces with compressed air only. Do
not wipe the ILA assembly faces.
CRT Faces:  Use compressed air to blow dust off and lens paper to clean face.
Relay Lens: Same as Projection Lens.
Mirrors and Polarizing Beam Splitter Windows: The Optical Shield covers the
Dichroic Mirror Assembly and Polarizing Beam Splitter windows. Normally
cleaning is not needed. Clean only if absolutely necessary using compressed air.
Do not wipe mirrors. 
						

							Chapter 4---Maintenance (Removal/Replacement)
Model 230 Service Manual4-1
4.0   Maintenance (Remove/Replace)
Contents
4.1   Introduction ..............................................................................................4-1
4.2   Projector Covers ......................................................................................4-4
4.3   Air Filters ..................................................................................................4-5
4.4   Arc Lamp Assembly .................................................................................4-5
4.5   Ignitor Assembly.......................................................................................4-7
4.6   Arc Lamp Power Supply ...........................................................................4-8
4.7   Low Voltage Power Supply.......................................................................4-9
4.8   High Voltage Power Supply ......................................................................4-10
4.9   Raster Timing, System Controller, Video Processor PCBs.......................4-12
4.10 Convergence/Deflection PCB ...................................................................4-13
4.11 Horizontal/Vertical Deflection PCB ...........................................................4-14
4.12 Video Input Cards (VICs) .........................................................................4-15
4.13 Video Amplifier PCB .................................................................................4-15
4.14 Scan Reversal PCB..................................................................................4-17
4.15 CRT/Yoke Assembly ................................................................................4-18
4.16 ILA® Assembly.........................................................................................4-19
4.17 Relay Lens ...............................................................................................4-20
4.18 Projection Lens ........................................................................................4-21
4.19 Prism Assembly .......................................................................................4-22
4.20 Recommended Spares.............................................................................4-24
4.1  Introduction
NOTE: Before removing the front or rear cover or replacing any components or
subassemblies, please review the Safety Chapter at the front of this manual.
Removal and replacement procedures in this chapter must be performed by
Hughes-JVC certified technicians and engineers only.
When performing any maintenance, protect yourself and the equipment by
following these guidelines:
•  Turn the projector off with the remote.
•  After the cooling fans have automatically stopped running, turn off the circuit
breaker.
•  Allow a discharge time of at least one minute for the high voltage to bleed off,
then unplug the power cord from the AC wall outlet.
•  Observe all Cautions and Warnings
Tools required to perform removal and replacement of projector components and
subassemblies are listed in Chapter 1, Introduction. 
						

							Chapter 4---Maintenance (Removal/Replacement)
4-2Model 230 Service Manual
 WARNING!!! Various procedures in this chapter
involve the removal and replacement of system subassemblies.
Ensure that the projector circuit breaker is turned off and the AC
power plug is removed from the AC outlet PRIOR to attempting any
of these procedures.
When performing any maintenance procedures in this chapter, follow the
guidelines below:
Left/Right Orientation: When left and right is mentioned in this chapter,
it is with reference to standing at the rear of the projector, facing the
screen.
Connectors on subassemblies and PCBs have tabs that must be
released first before pulling on the connector. The proper procedure is to
push slightly IN on the connector, then squeeze the tab, then pull the
connector out.
NOTE: While performing any maintenance procedures, check the prism
diaphragm for dryness, crazing, cracking, or possible leaking. If any
problems are observed, call HJT.
When references are made in this chapter to assemblies and
components, refer to Figures 4-1 and 4-14 for their locations. 
						

							Chapter 4---Maintenance (Removal/Replacement)Model 230 Service Manual4-3
Figure 4-1.   Major components of the Model 230 Projector. 
						

							Chapter 4---Maintenance (Removal/Replacement)
4-4Model 230 Service Manual
4.2  Projector Covers
Prior to removing either cover, review the chapter on Safety and adhere to all
warnings and cautions.
Figure 4-2   Rollbar Assembly.
To remove the front or rear covers (refer to Figure 4-2):
1.   Disconnect the projector power plug.
2.   Loosen the two pozidrive spring screws at the front of the front cover or the
rear of the rear cover.
3.   Tilt up the front or rear cover.
 CAUTION! Do not leave either cover in the tilted up
position! The covers can fall from this tilted up position and possibly damage
projector components. Remove the cover and set it aside when servicing the
projector.
4.   Release the two Latch Levers on the Rollbar assembly that hold the cover in
place. Place the ends of the Latch Levers into the holding slots.
 CAUTION! Immediately after removing the front or rear
cover, pull up the power interlock switch. This allows power to be reapplied to