Hughes JVC 100 User manual

SERVICE
MANUAL
Model 100 Projector
Phone: [phone]
Fax: [phone]
2310 Camino Vida Roble
Carlsbad, California 92009

Model 100 Service Manual
ii
DECLARATION OF CONFORMITY
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.
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 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 100 Service Manual iii
Table of Contents
Safety Information...............................................................................v
Chapter 1 Introduction
1.1 Safety...............................................................................................1-1
1.2 Updates............................................................................................1-1
1.3 Tool List..........................................................................................1-2
1.4 Acronyms Used in this Manual......................................................1-2
Chapter 2 Functional Description
2.1 Introduction....................................................................................2-1
2.2 Optical Section...............................................................................2-2
2.3 Electronics System.........................................................................2-9
Chapter 3 Service Adjustments
3.1 Introduction....................................................................................3-1
3.2 Arc Lamp Adjustment....................................................................3-5
3.2 ILA®Back Focus............................................................................3-9
3.3 CRT Electronic Focus....................................................................3-11
3.4 ILA®Overlap..................................................................................3-12
3.5 Front/Rear or Inverted Projection Jumper Settings........................3-13
3.8 Horizontal Size Settings.................................................................3-15
3.9 Software 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 Timing Generator................................4-10
4.10 Video Processor PCBs ...................................................................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 ..........................................................................4-13
4.15 Regulator PCB................................................................................4-13
4.16 Video Amplifier PCBs...................................................................4-14
4.17 CRT/ILA®Assembly.....................................................................4-15
4.18 Projection Lens...............................................................................4-17
4.19 Recommended Spares....................................................................4-19

Model 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

Safety Information
Model 100 Service Manual v
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

Safety Information
vi Model 100 Service Manual
performed that require covers 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 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:

Safety Information
Model 100 Service Manual vii
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.
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 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, Overlap
High voltage access. The front cover
contains a safety interlock. Defeat
restricted to certified service
personnel!

Safety Information
viii Model 100 Service Manual
adjustment, always use an ANSI/ASTM 10,000 volt rated glove.
Periodically check the condition of the gloves for cracks.
Power Supply
The Model 100 projector operates from a 90V - 264V, 20 Amp, single-phase,
50/60 Hz AC power source. Verify that local power source matches these
requirements before operating! Installation should be performed by an
electrician with current knowledge of electrical codes in the country of use.
For continued safe and reliable operation, only use cables 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.
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 certified technician to remove object.

Chapter 1---Introduction
Model 100 Service Manual 1-1
1.0 Introduction
Contents
1.1 Safety........................................................................................................1-1
1.2 Updates.....................................................................................................1-1
1.3 Tool List...................................................................................................1-2
1.4 Acronyms Used in this manual ................................................................1-2
This Service Manual is designed to be used with the Model 100 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 Service Bulletins and /or manual
supplements to ensure the accuracy of this service manual.

Chapter 1---Introduction
1-2 Model 100 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
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
DP PCB Deflection Processor Printed Circuit Board
EMI Electromagnetic Interference
EPROM Erasable Programmable Read-Only Memory
FPGA Field Programmable Gate Array
F to V Frequency to Voltage
G1CRT Grid 1

Chapter 1---Introduction
Model 100 Service Manual 1-3
G2CRT Grid 2
HD PCB Horizontal Deflection Printed Circuit Board
Hz Hertz
HSYNC Horizontal Sync
VCD PCB Vertical Convergence Deflection Printed Circuit 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
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 Ultraviolet
VA PCB Video Amplifier Printed Circuit Board
VCO Voltage Controlled Oscillator
VIC Video Input Card
VIN Video Input
VP PCB Video Processor Printed Circuit Board
VSYNC Vertical Sync

Chapter 1---Introduction
1-4 Model 100 Service Manual

Chapter 2---System Description
Model 100 Service Manual 2-1
2.0 System Description
Contents
2.1 Introduction.................................................................................................. 2-1
2.2 Optical System .............................................................................................2-2
The Arc Lamp Module...............................................................................2-2
The Illumination Path................................................................................. 2-2
CRT \ ILA®Module................................................................................... 2-6
Front Projection Lens................................................................................. 2-8
2.3 Electronics System.......................................................................................2-9
General Description.................................................................................... 2-9
Power Supplies...........................................................................................2-10
Video Input Cards (VIC)............................................................................2-15
Video Processor PCB.................................................................................2-24
System Controller/ Raster Timing Generator PCB....................................2-28
Deflection Processor PCB..........................................................................2-35
Vertical Convergence Deflection PCB.......................................................2-38
Horizontal Deflection PCB ........................................................................2-41
Regulator for three CRTs...........................................................................2-44
Video Amplifier PCBs............................................................................... 2-46
Backplane PCB ..........................................................................................2-49
2.1 Introduction
The Model 100 Projector consists of assemblies 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, the CRT/ILA®
Modules and the Front Lens. The Arc Lamp Module provides the 750
Watt high intensity light source for the projected image. The illumination
path consists of optics that filter, polarize, separate the beam into red,
green, and blue light and direct it to the ILA®and then to the Front Lens
Assembly. The ILA®\CRT Modules supply the image and modulate the
light to create the projected image. The Front Lens sends the image to the
screen.

Chapter 2---System Description
2-2 Model 100 Service Manual
!The Power Supply Section consists of three power supplies: the Arc Lamp
Power Supply, the Low Voltage Power Supply and the High Voltage
Power Supply. The Arc Lamp Power Supply supplies constant adjustable
current to the arc lamp. The High Voltage Power Supply drives the CRTs
with anode voltage, G2voltage, the focus voltage and the G1voltage. The
Low Voltage Power Supply provides the standby voltages and bias voltage
for all the digital and analog circuits. It also supplies the CRT filament
voltage and some supply voltages for the Horizontal Deflection PCB, and
the Video Amp PCBs.
!The Projector Electronics Section is located mainly in the back half of the
projector. It consists of the Electronics Module that houses 6 of the
electronics printed circuit boards used in the projector, and their associated
cabling. It also contains the Backplane PCB which is used to electrically
interconnect the printed circuit boards, power supplies and other units in
the projector, the Video Amp PCBs and Regulator PCB, and the Video
Input Cards that interface with different kinds of input signals.
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 lenses and
integrator lenses, reflective steering mirrors and Dichroic Filters, polarizing
optics, beamsplitters and combining prisms (see Figure 2-1 for physical layout).
The illumination path actually consists of two sections: the light path and the
image path. The light path begins with a light source, the Arc Lamp, then passes
through Primary Condensing Lens and is reflected off the #1IR Filter/Cold Mirror
where the infrared heat radiation is filtered out.
CAUTION! The term "cold mirror" is used because the
mirror passes infrared light and its reflection contains only "cold' light that
does not transmit appreciable heat. As a result of the absorption of
infrared heat radiation, "cold" mirrors can get very hot.
From the #1 Cold Mirror the high intensity light passes through the Secondary
Focusing Lens, a UV Filter and into the Integrator, which consists of two “fly’s
eye” integrating lenses. The Primary Condensing Lens collects all the light from

Chapter 2---System Description
Model 100 Service Manual 2-3
the Arc Lamp and begins to bend the light rays into a straight path. The Secondary
Focusing Lens works with the Primary Condensing Lens to collimate or
“straighten” the light path before it enters the Integrator. The UV Filter filters out
unwanted ultravioltet light.
After leaving the UV Filter the light passes through the Integrator. The function of
the Integrator is to spread out the beam so that it will have a more uniform
distribution of light across the face of the ILA®. This will result in a more
uniform image on the screen. After leaving the Integrator the white light is
reflected off the #2 IR Filter/Cold 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 filter. The red and green light travel on to a second Dichroic Filter
where the red light is separated from the green light. The Blue Dichroic Filter
Mirror reflects the blue light into a Feedthru Beamsplitter. The red light is also
reflected from a Dichroic Filter into a Feedthru Steering Mirror and the green light
is transmitted through the beamsplitter into its respective Feedthru Beamsplitter.
All three light beams are reflected up into the Polarizing Beam Splitter.

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.

Chapter 2---System Description
Model 100 Service Manual 2-5
The Polarizing Beam Splitter (PBS) actually consists of a Pre-Polarizer and a
main Polarizer. The process of polarizing light is discussed in the following
paragraph.
Light can be viewed as having two electromagnetic components: a S-electric field
and a P-electric field. These fields are perpendicular to each other. When
unpolarized light travels through a polarizing beamsplitter one of these fields is
reflected 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-Polarizer
becomes the S-electric field and is reflected by the Main Polarizer. The reflected
polarized light, either red, green or blue, leaves the PBS and goes directly into the
ILA®device.
Figure 2-2 Side view of a Feedthru Beamsplitter and the Polarizing
Beamsplitter (PBS).

Chapter 2---System Description
2-6 Model 100 Service Manual
The polarized light from each of the PBS’s enters the ILA® and is rotated and
modulated with the image signal. The amount the polarized light is rotated is
controlled by the ILA®bias and the amount of CRT light hitting the input side of
the ILA®, and translates directly to the brightness of the image on the screen.
The image light from each of the ILA®s is then sent back through the Main
Polarizer portion of the PBS. The polarized blue image light continues on to a
Turning Prism where it is reflected into the 2P Combining Prism. The red and
green light come from their respective PBSs and are combined in the1P
Combining Prism. From the 1P Combining Prism, the red and green image light
go into the 2P Combining Prism to combine with the blue image light, where the
RGB image light goes through the Front Projection Lens and out onto the screen.
This completes the Illumination Path.
CAUTION! The alignment of system optical components is
critical. Replacement of individual mirrors or prisms requires removing the
projector cover and must be performed only by Hughes-JVC Certified
technicians. Consult the factory before removing or aligning any mirrors or
prisms.
CRT \ ILA®Module
The three CRT/ILA®assemblies are located in the main body of the projector
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 source.
The light output to the screen is the function of the Arc Lamp, ILA®bias, and
CRT output. The purpose of the CRT is to generate an image and to control the
amount of modulation the ILA®assemblies introduce on the light coming from
the Arc Lamp. The Red, Green, and Blue image signals are routed to the CRTs
from the Video Amplifier Board through the CRT socket connectors. The CRT
image passes through a thin fiber-optic coating on the CRT face and another fiber-
optic on the back surface of the ILA®. There is a thin layer of optical fluid
between the two fiber optic coatings. The input and output sides of the ILA®
assembly are isolated from each other electrically and optically but are coupled
electrostatically.
At the same time the image is received at the input side of the ILA®, the output
side of the ILA®is receiving high intensity polarized light from the arc lamp
through the PBS. This high intensity polarized light is modulated by the image
from the CRT and the light polarization is rotated (90°at 100% CRT output) by
the liquid crystal on the output side of the ILA®. The light is then reflected back

Chapter 2---System Description
Model 100 Service Manual 2-7
from the output side of the 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.

Chapter 2---System Description
2-8 Model 100 Service Manual
Front Projection Lens
The Front Projection Lens picks up the high intensity image from the 2P
Combining Prism and transmits it to the projector screen. The Front Lens options
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-JVC certified technicians only.