Hughes-JVC Technology Corporation
2310 Camino Vida Roble
Carlsbad, CA. 92009-1416
102802 First Edition July 1994
102802 Rev A December 1994
102802 Rev B August 1995
Confidential and proprietary inf or mation.
© Copyright 1994 by Hughes-JVC Technology Corporation.
All worldwide rights reserved.
No part of this manual may be reproduced in any form without the express written
permission of Hughes-JVC Technology Corporation. The contents of this Supplement
may be revised without prior notice.
ILA™ is a trademark of Hughes-JVC Technology Corporation.
This Supplement was produced by Hughes-JVC Technology Corporation.
The Series 300 Projector Warranty provisions are provided in a separate document.
Model 335 Supplement 2
Table of Contents
General Information................................................................................4
1.0 Safety Precautions...........................................................................4
2.0 External Arc Lamp Power Supply....................................................6
3.0 Brightness Level Checks..................................................................7
4.0 Electronics Module Removal and Replacement..............................11
5.0 Lamphouse/Ignitor Removal and Replacement...............................13
Model 335 Supplement 3
General Information
The Series 300 Operator’s Manual and Service Manual provide
information on installation, checkout and maintenance for all
Series 300 projectors including the Model 335. There ar e som e
distinct areas with reference to the Model 335, mainly due to the
larger Xenon Arc Lamp, that require additional information and
procedures. Focusing on these distinct areas and special
procedures is the purpose of this supplement.
The areas discussed in this supplement are:
1.0 Safety precautions: Any necessary safety precautions that
are characteristic to the Model 335 Projector that were not
referred to in the Series 300 O per at or’s Manual or Service
Manual.
2.0 External Arc Lamp Power Supply: Provides the additional
power required for the larg er 2500 watt Xenon Arc Lamp.
NOTE: Model 335 Projectors with serial numbers 351100 or
higher will not require an external power supply. The additional
current required by the larger ar c lam p is supplied by the system
power supply itself. Refer to the Ser ies 300 Ser vice Manual.
3.0 Brightness Level Checks: Additional procedures requir ed
for adjustments that m ay be necessary on the arc lamp and
external power supply if low brightness levels are encountered.
4.0 Electronics Module Removal and Replacement: A separ at e
procedure is included for the Model 335 for the r emoval and
replacement of the Electronics m odule.
5.0 Lamphouse and Ignitor Removal and Replacement: A
separate procedure is included for the Model 335 for the removal
and replacement of the Lamphouse Assembly or Ignitor Assembly.
1.0 Safety Precautions
All safety precautions mentioned in the Series 300 Oper ator’s
Manual are applicable and should be reviewed prior to operating
or adjusting the Model 335.
Model 335 Supplement 4
WARNING!!!
The Squirrel Cage (see BLOWER in Figure 1) Blower located next
to the Xenon Arc Lamp Assembly is not covered by a grill. Use
extreme caution near this blower when performing any
adjustments or maintenance that r equire the projector cover to be
off with power on.
WARNING!!!
High voltage exists on the Ignitor Board Assembly at the front, left
of the projector. Be car eful when reaching over this area when the
Arc Lamp is operating. Wear proper safet y clothing to avoid shock
hazard. Also wear safety goggles to protect your eyes f r om
Ultraviolet and Infrared exposure.
CAUTION!!!
To avoid possible overheating, be sure to allow at least six inches
of clearance on both sides of the External Ar c Lamp Power
Supply.
Model 335 Supplement 5
2.0 External Arc Lamp Power Supply
NOTE: This section applies only to those Model 335 projectors
that use the external power supply. Projectors with serial numbers
351100 or higher do not require t he exter nal power supply. Refer
to the Series 300 Service Manual for these units.
CAUTION!!!
The external power supply can be placed on its side in the upright
position or laid flat on its back sur face. W or king with this power
supply in the upright position is a personal safet y hazard. T he
power supply can tip over and cause physical injury to anyone
nearby. For this reason, the pow er suppl y should always be on
its FLAT SURFACE, not
The External Arc Lamp Power Supply provides the additional
power necessary to operate the larger 2500 watt Xenon Arc Lamp
that is used in the Model 335 Projector. The External Ar c Lam p
Power Supply and all required cables are shipped with the Model
335 Projector. The external power supply operates f r om a 200240 VAC, 30 amp, 50/60 Hz source and can be used with a single
or three phase power source.
on its side!
Power is applied to the unit by a circuit breaker located on one
side next to a 16 amp, 600 volt fuse that protect s t he power
supply. Another circuit breaker (on anot her side of the power
supply) applies power to the Xenon Arc Lamp in the projector.
Two access openings (covered by plastic caps about an inch in
diameter) are located on the top of the power supply near the
nameplate. The cap furthest from the nameplate can be removed
to access the Current Adjust Pot, whenever it is necessary to
increase the Xenon Lamp current (see the pr ocedur e shown
below under “Brightness Level Checks”). The other access
opening is not used.
The smaller power cord, that plugs int o t he side of the External
Arc Lamp Power Supply, supplies all the voltages for the projector
electronics. The larger cable, t hat plugs into the connector at the
rear of the projector , pr ovides the power for the 2500 watt Xenon
Arc Lamp.
The installation and operation of the Exter nal Arc Lamp Power
Supply consists only of connecting the two power cables to the
power source and the projector and activating both circuit
breakers to the ON position. The red lamp near the large circuit
breaker will light to indicate power on.
Very little maintenance is required on the Exter nal Ar c Lamp
Power Supply. The ventilation inlet and outlet grills should be
cleaned on a regular basis to insure good air flow. The blower
motors are permanently lubricated.
Model 335 Supplement 6
CAUTION!!!
If the 16 amp, 600 volt fuse becom es defective and must be
replaced, use an exact replacement and, to avoid possible electric
shock, wait at least 15 minutes aft er t urning power off (f or
discharging) before replacing the fuse.
CAUTION!!!
ALLOW ADEQUATE CLEARANCE!
The fan inside the External Arc Lamp Power Supply helps keep
the unit cool. Be sure to allow at least six inches of clearance on
both sides to prevent overheating of the unit .
3.0 Brightness Level Checks
If the projector has a low brig ht ness level the items below should
be checked and adjusted, if necessary:
WARNING!!!
The following procedures require the removal of the projector
covers and should be performed by Hughes-JVC Cert ified
Maintenance Technicians only. Prior to removing covers, review
the chapter on Safety in the Series 300 Service Manual and the
Safety information in t his supplem ent.
Model 335 Supplement 7
WARNING!!!
The Squirrel Cage blower (see Figure 1) , next t o t he Arc Lamp
Assembly, is not covered by a grill. Use extreme caution near this
blower when performing any adjustments or maintenance that
require the projector cover to be removed with power on.
WARNING!!!High voltage exists on the Ignitor Boar d
Assembly at the front, left of the projector. Be careful when
reaching over this area when the Arc Lamp is operating. Wear
proper safety clothing to avoid shock hazard. Also wear safety
goggles to protect your eyes f r om Ultraviolet and Infrared
exposure.
1. The Xenon Arc Lamp may have moved within the reflector. To
check this, look at the anode shadow on the blue dichroic mirror
(the blue dichroic mirror is the f ir st mirror after the condensing
lens). Verify that the anode shadow (small, dar k oval inside the
light circle) is a uniform oval that is no more than 1/2 inch or no
less than 1/4 inch in diameter. If the oval looks non-uniform or has
a flare coming from one side, adjust the X-Y plates on the back of
the lamphouse (see Figure 1). Use a standar d Phillips scr ewdriver
and loosen the two top screws on the pivot holes and slide the
plates on their pivots until the shadow looks unifor m . While
viewing Test Pattern 6 (Static Flat Field) t he uniformity on the
screen should become more centered also.
2. Adjust the Z-axis of the Xenon Ar c Lamp. (This procedure will
probably be required if the lamp has been in use for a long time.)
Use a 9/64 inch hexhead balldriver and rotate the screwhead
located on the black ball on the rear of the lamphouse (see Figure
1). Only a turn or two should be required. Obser ve the scr een or
use a light meter to verify proper br ightness (refer to st ep 8 below
for details on how to measure the screen brig ht ness). Be sure to
maintain proper Roll-Of f (refer t o NOTE ON ROLL-OFF below
Step 3).
Model 335 Supplement 8
Figure 1. Model 335 Xenon Arc Lamp Housing Assembly (Lamphouse)
3. Verify that the condensing (collimating) lens assembly has not
moved (see Figure 2-2 in the Series 300 Operator’s Manual).
Check to see if the assembly is loose. It should be unmovable in
any direction. The barrel of the lens assembly should be no more
than 1 1/2 inches (usually much closer) from t he blue dichroic
mirror. If it needs t o be moved closer, first loosen the 3mm set
screw located at the top of the mounting ring that the barrel sets
in, then move the lens closer to the blue dichroic mirr or. This will
increase the center brightness but t he r oll- off may not be
acceptable if the barrel is moved too far forward. Roll-off is the
gradual difference in br ightness on the screen from the cent er to
the edges.
NOTE ON ROLL-OFF: In these illumination optics (arc lamp and
condensing lens) adjustments, be careful to maintain proper rolloff. It is possible t o get very high brightness values at the screen
center at the expense of proper roll-off. Try to keep the ratio
between center brightness and edge bright ness at no m ore than
2:1 (e.g. if t he cent er brightness is 20 foot-candles, t he edge
brightness should be at least
10 foot-candles). Use a light meter
to determine if the roll- off is appropriate.
Model 335 Supplement 9
WARNING!!!
High voltages exist inside the External Arc Lamp Power Supply.
Remove only the small plastic access cover to adjust the lamp
current when necessary. No other access covers or panels
should be removed by anyone other than an authorized Strong
International dealer. There ar e no user ser viceable component s in
this unit.
4. Verify that the power supply current is set high enough. The
current to the lamp is factory-set at 90 amps. Use a current probe
(similar to Amprobe Model AC/DC 1000) to check t he current on
the positive wire going into the Xenon Arc Lamp housing (see
Figure 1). Clamp the probe (CAUTION! Do not have the current
probe around the wire when the projector is being powered
up or damage to the probe will result) around the positive wire-
the positive wire will provide a more accurate reading. If this value
is low, increase it (see CAUTION below) with the current adjust
pot on the External Arc Lamp Power Supply or the System Power
Supply (refer to the NOT ES in Sect ion 4. 4.B and 4.5 and Figure
4-4 in the Series 300 Service Manual). This adjustment screw is
located under a plastic protective cover about an inch in diameter
on the top of the External Arc Lamp Power Supply (under the cap
furthest fr om the nameplate). Be sure to maintain pr oper Roll- Off
(refer to NOTE ON ROLL-OFF below Step 3).
CAUTION!!!
Make adjustments in very small increments to insure lamp
integrity (lamp overheating could occur if current is abruptly
increased). Do not increase the external power supply current
beyond 100 amps or damage to the equipment could occur .
5. Whenever the Sensitivity Offsets are reset it affects the
brightness level. Refer to t he Ser ies 300 O per ator’s Manual,
Section 4.12, for inf ormation on how to correctly set the Sensitivity
Offsets.
Model 335 Supplement 10
6. If none of the previous procedur es cur e the problem of low
brightness, it may be time to replace t he Xenon Arc Lamp. Low
brightness could be caused by a lamp with over 1200 hours of use
or one that has been turned on and off many times. If either of
these is the case, the Lamphouse Assembly must be returned t o
be relamped. Do not remove the Xenon Arc Lamp from the
lamphouse-return the entire unit.
7. Verify that the cold mirror , condensing lens, and UV filter are
all free from stains and cr acks.
8. The Model 335 should always be able to achieve a minimum of
3000 lumens of brightness level. Use a light meter, after the
above adjustments are completed, to measure the foot-candles of
light output at the screen and multiply this number by the area of
the screen in square feet. As an example, if the screen area is 15
x 20 =300 square feet and the light out put on the light meter
measures 11 foot-candles, the br ightness level in lumens equals
300 x 11=3300 lumens.
4.0 Electronics Module Removal and Replacement
The Electronics Module is the entire assembly to the rear of the
Arc Lamp and optics assemblies. It consists of the System Power
Supply, High Voltage Power Supply, Main PCB Card Cage, and
CRT Housing Assembly. Refer t o Figure 2-2 in the Series 300
Operator’s Manual (the CRT Housing Assembly is next to the
High Voltage Power Supply and is not shown in Figure 2-2).
To remove and replace the Electronics Module:
1. Unplug the projector.
2. Free the power cord from the electronics m odule by rem oving
the cable clamp(s) on the right side base of the electronics
module.
3. On the left side of t he car d cage, detach the power supply
jumper cable from P/J81.
4. At the rear of the pr oj ector, remove the three fan housing
screws (located under the rear lip of the proj ect or baseplate) and
remove the fan housing. Carefully, loosen and move the attached
wires aside.
5. On the left side of t he car d cage, unplug connectors P82 and
P83 from the back plane and move the wiring harness out of the
way (separate these wires from others to free them if necessary).
Model 335 Supplement 11
6. On the right side of t he System Power Supply, at t he input
power terminal block, mark and detach t he three wires supplying
power to the arc lamp housing’s squirrel cage blower. ( Be sur e t o
label the three wires carefully so they can be reconnected
correctly.) Move that cable out of the way.
7. Back all CRTs into the CRT assem bly by turning the focus rod
screws, at the rear of the CRT assembly (see Figure 6-4 in the
Series 300 Operator’s Manual) all the way to the stops. Be careful
not to jam the focus rod screws by turning t hem too tightly into
their stops.
8. At the base of the electronics m odule r em ove the hex screw at
each corner (four screws).
9. Make sure that all control and input cables are disconnected
from the back of the card cage, then tilt the card cage back.
10. Remove the two hex screws in the base of the electronics
module under the card cage.
11. Tilt the card cage forward.
12. Remove the electronics module (two people) by grasping t he
handles at the rear and the lip under the system power supply in
the front. When removing, be caref ul not t o bump t he CRT
cooling bellows (see Figure 4-8 in t he Servi ce Manual). The
bellows will not be covered under warranty if damaged in this
procedure! The easiest way to remove the module is to tip the
entire electronics module back until the System Power Supply
clears the arc lamp housing, then lift the module up and back.
13. Replace the module in the reverse order. When replacing the
module, make sure that the m odule base plate is tight against the
two front alignment pins and the one left-side alignment pin prior
to tightening the hex screws.
14. After the module is replaced, perform a CRT mechanical
focus adjustment, as shown in Section 6.8 of the Series 300
Operator’s Manual.
Model 335 Supplement 12
5.0 Lamphouse/Ignitor Removal and Replacement
5.1 Lamphouse
The Xenon Arc Lamp Lamphouse must be removed as a
complete unit. Do not remove the arc lamp separately!
To remove the Xenon Arc Lamp Lamphouse:
1. Turn power off and unplug t he pr ojector. Do not attempt to
remove or replace the Lamphouse without first removing
power by turning power off with the remote (or PC terminal)
and the circuit breaker on the side of the System Power
Supply and unplugging the projector from the AC wall outlet.
2. Disconnect the high voltage leads f r om the Ignitor (the two
wires shown at the right in Figure 1). NOTE: DO NO T REMOVE
THE CABLES FROM THE ARC LAMP-LEAVE BOTH CABLES
ATTACHED TO PREVENT MISALIGNING THE ARC LAMP
INTERIOR COMPONENTS.
3. Disconnect the fan connector on the left side of the
Lamphouse.
4. Disconnect the squirrel cage blower connector on the right side
of the Lamphouse.
5. Remove the two hex bolts on the right rear of the Lamphouse
slide.
6. Carefully slide the Lamphouse out f r om the right side of the
projector.
Replace the Lamphouse in the reverse order.
Model 335 Supplement 13
5.2 Ignitor
HEX SCREW
IGNITOR
MOUNTING
BOARD
NEGATIVE
POSITIVE
IN
HIGH VOLTAGE
TRANSFORMER
LASER
POWER
SUPPLY
POSITIVE
OUT
Figure 2. Ignitor Assembly.
The Ignitor Assembly consists of a Laser Power Supply, a High
Voltage Transform er and the associated wiring.
To remove the Ignitor Assembly:
1. Turn power off and unplug t he pr ojector.
2. Remove the front and rear covers.
3. Clearly label and remove the four (4) cables connected t o t he
Ignitor Assembly.
4. Remove the three (3) hex screws that attach the Ig nit or
Mounting Board to the projector. NOTE: The larger washer
must be replaced to the hex screw at the left, front of the
Ignitor Mounting Board to allow space for t he ot her component
that is connected there.
Model 335 Supplement 14
5. Carefully remove the Ignit or Assembly, being cautious not to
lose the spacers that are under the board holes. When
replacing the Ignitor Assembly, it will be easier to keep the
spacers stationary by placing a small amount of super glue
under them prior to replacing t he Ignitor Mounting Board.
Replace the Ignitor Assembly in reverse order. When replacing
the cables, make sure the negat ive cables go on first and that the
positive cable to the front of t he Ignitor Assembly is placed “over”
them-otherwise the point where they cross over each other will get
in the way of the fan when the front cover is replaced.
Model 335 Supplement 15
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