Samsung PCJ522RX/XAA, PCJ522RX/XAC, PCJ612RX/XAC, PCJ612RX/XAA Service Manual

PROJECTION TV RECEIVER

Chassis : P51A Model: PCJ522RX/XAA

PCJ612RX/XAA PCJ522RX/XAC PCJ612RX/XAC

PROJECTION TV RECEIVER C O N T E N T S

Precautions

Reference Information

Specifications

Alignment and Adjustments

Troubleshooting

Exploded View and Parts List

Electrical Parts List

Block Diagrams

Wiring Diagram

Schematic Diagrams

10.

ELECTRONICS

Printed in Korea

3P51A-5201

1. Precautions

1-1 Safety Precautions

1. Be sure that all of the built-in protective devices are replaced. Restore any missing protective shields.

2. When reinstalling the chassis and its assemblies, be sure to restore all protective devices, including: nonmetallic control knobs and compartment covers.

3. Make sure that there are no cabinet openings through which people—particularly children—might insert fingers and contact dangerous voltages. Such openings include the spacing between the picture tube and the cabinet mask, excessively wide cabinet

ventilation slots, and improperly fitted back

covers.

If the measured resistance is less than 1.0 megohm or greater than 5.2 megohms, an abnormality exists that must be corrected before the unit is returned to the customer.

4. Leakage Current Hot Check (Figure 1-1): Warning: Do not use an isolation transformer during this test. Use a leakagecurrent tester or a metering system that complies with American National Standards Institute (ANIS C101.1, Leakage Current for Appliances), and Underwriters Laboratories (UL Publication UL1410, 59.7).

5. With the unit completely reassembled, plug the AC line cord directly into the power outlet. With the unit’s AC switch first in the ON position and then OFF, measure the current between a known earth ground (metal water pipe, conduit, etc.) and all exposed metal parts, including: antennas, handle brackets, metal cabinets, screwheads and control shafts. The current measured should not exceed 0.5 milliamp. Reverse the powerplug prongs in the AC outlet and repeat the test.

Fig. 1-1 AC Leakage Test

6. Antenna Cold Check: With the unit’s AC plug disconnected from the AC source, connect an electrical jumper across the two AC prongs. Connect one lead of the ohmmeter to an AC prong. Connect the other lead to the coaxial connector.

7. X-ray Limits: The picture tube is especially designed to prohibit X-ray emissions. To ensure continued X-ray protection, replace the picture tube only with one that is the same type as the original. Carefully reinstall the picture tube shields and mounting hardware; these also provide X-ray protection.

8. High Voltage Limits: High voltage must be measured each time servicing is done on the B+, horizontal deflection or high voltage circuits. Correct operation of the X-ray protection circuits must be reconfirmed whenever they are serviced.

(X-ray protection circuits also may be called

“horizontal disable” or “hold-down”.)

Heed the high voltage limits. These include the X–ray Protection Specifications Label, and the Product Safety and X-ray Warning Note on the service data schematic.

Precautions

Samsung Electronics 1-1

Follow these safety, servicing and ESD precautions to prevent damage and protect against potential hazards such as electrical shock and X-rays.

1-1 Safety Precautions (Continued)

9. High voltage is maintained within specified limits by close-tolerance, safety-related components and adjustments. If the high voltage exceeds the specified limits, check each of the special components.

10. Design Alteration Warning: Never alter or add to the mechanical or electrical design of this unit. Example: Do not add auxiliary audio or video connectors. Such alterations might create a safety hazard. Also, any design changes or additions will void the manufacturer’s warranty.

11. Hot Chassis Warning: Some TV receiver chassis are electrically connected directly to one conductor of the AC power cord. If an isolation transformer is not used, these units may be safely serviced only if the AC power plug is inserted so that the chassis is connected to the ground side of the AC source.

To confirm that the AC power plug is inserted correctly, do the following: Using an AC voltmeter, measure the voltage between the chassis and a known earth ground. If the reading is greater than 1.0V, remove the AC power plug, reverse its polarity and reinsert. Re-measure the voltage between the chassis and ground.

12. Some TV chassis are designed to operate with 85 volts AC between chassis and ground, regardless of the AC plug polarity. These units can be safely serviced only if an isolation transformer inserted between the receiver and the power source.

13. Some TV chassis have a secondary ground system in addition to the main chassis ground. This secondary ground system is not isolated from the AC power line. The two ground systems are electrically separated by insulating material that must not be defeated or altered.

14. Components, parts and wiring that appear to have overheated or that are otherwise damaged should be replaced with parts that meet the original specifications. Always determine the cause of damage or overheating, and correct any potential hazards.

15. Observe the original lead dress, especially near the following areas: Antenna wiring, sharp edges, and especially the AC and high voltage power supplies. Always inspect for pinched, out-of-place, or frayed wiring. Do not change the spacing between components and the printed circuit board. Check the AC power cord for damage. Make sure that leads and components do not touch thermally hot parts.

16. Picture Tube Implosion Warning: The picture tube in this receiver employs “integral implosion” protection. To ensure continued implosion protection, make sure that the replacement picture tube is the same as the original.

17. Do not remove, install or handle the picture tube without first putting on shatterproof goggles equipped with side shields. Never handle the picture tube by its neck. Some “in-line” picture tubes are equipped with a permanently attached deflection yoke; do not try to remove such “permanently attached” yokes from the picture tube.

18. Product Safety Notice: Some electrical and mechanical parts have special safety-related characteristics which might not be obvious from visual inspection. These safety features and the protection they give might be lost if the replacement component differs from the original—even if the replacement is rated for higher voltage, wattage, etc.

Components that are critical for safety are indicated in the circuit diagram by shading, ( ) or ( ).

Use replacement components that have the same ratings, especially for flame resistance and dielectric strength specifications. Areplacement part that does not have the same safety characteristics as the original might create shock, fire or other hazards.

Precautions

1-2 Samsung Electronics

1-2 Servicing Precautions

1. Servicing precautions are printed on the cabinet. Follow them.

2. Always unplug the unit’s AC power cord from the AC power source before attempting to: (a) Remove or reinstall any component or assembly, (b) Disconnect an electrical plug or connector, (c) Connect a test component in parallel with an electrolytic capacitor.

3. Some components are raised above the printed circuit board for safety. An insulation tube or tape is sometimes used. The internal wiring is sometimes clamped to prevent contact with thermally hot components. Reinstall all such elements to their original position.

4. After servicing, always check that the screws, components and wiring have been correctly reinstalled. Make sure that the portion around the serviced part has not been damaged.

5. Check the insulation between the blades of the AC plug and accessible conductive parts (examples: metal panels, input terminals and earphone jacks).

6. Insulation Checking Procedure: Disconnect the power cord from the AC source and turn the power switch ON. Connect an insulation resistance meter (500V) to the blades of the AC plug.

The insulation resistance between each blade of the AC plug and accessible conductive parts (see above) should be greater than 1 megohm.

7. Never defeat any of the B+ voltage interlocks. Do not apply AC power to the unit (or any of its assemblies) unless all solid-state heat sinks are correctly installed.

8. Always connect a test instrument’s ground lead to the instrument chassis ground before connecting the positive lead; always remove the instrument’s ground lead last.

9. When some parts inside the optical engine (except lamp) are damaged, replace the whole optical engine.

Precautions

Samsung Electronics 1-3

Warning 1 : First read the “Safety Precautions” section of this manual. If some unforeseen circumstance creates a

conflict between the servicing and safety precautions, always follow the safety precautions.

Warning 2 : An electrolytic capacitor installed with the wrong polarity might explode.

1-3 Precautions for Electrostatically Sensitive Devices (ESDs)

1. Some semiconductor (“solid state”) devices are easily damaged by static electricity. Such components are called Electrostatically Sensitive Devices (ESDs); examples include integrated circuits and some field-effect transistors. The following techniques will reduce the occurrence of component damage caused by static electricity.

2. Immediately before handling any semicon ductor components or assemblies, drain the electrostatic charge from your body by touching a known earth ground. Alternatively, wear a discharging wrist-strap device. (Be sure to remove it prior to applying power— this is an electric shock precaution.)

3. After removing an ESD-equipped assembly, place it on a conductive surface such as aluminum foil to prevent accumulation of electrostatic charge.

4. Do not use freon-propelled chemicals. These can generate electrical charges that damage ESDs.

5. Use only a grounded-tip soldering iron when soldering or unsoldering ESDs.

6. Use only an anti-static solder removal device. Many solder removal devices are not rated as “anti-static”; these can accumulate sufficient electrical charge to damage ESDs.

7. Do not remove a replacement ESD from its protective package until you are ready to install it. Most replacement ESDs are packaged with leads that are electrically shorted together by conductive foam, aluminum foil or other conductive materials.

8. Immediately before removing the protective material from the leads of a replacement ESD, touch the protective material to the chassis or circuit assembly into which the device will be installed.

9. Minimize body motions when handling unpackaged replacement ESDs. Motions such as brushing clothes together, or lifting a foot from a carpeted floor can generate enough static electricity to damage an ESD.

Precautions

1-4 Samsung Electronics

Reference Information

Samsung Electronics 2-1

2. Reference Information

2-1 Tables of Abbreviations and Acronyms

A Ah Å dB dBm

°C °F °K F G GHz g H Hz h ips kWh kg kHz kΩ km km/h kV kVA kW I MHz

Ampere Ampere-hour Angstrom Decibel Decibel Referenced to One Milliwatt Degree Celsius Degree Fahrenheit degree Kelvin Farad Gauss Gigahertz Gram Henry Hertz Hour Inches Per Second Kilowatt-hour Kilogram Kilohertz Kilohm Kilometer Kilometer Per Hour Kilovolt Kilovolt-ampere Kilowatt Liter Megahertz

MV MW MΩ m µA µF µH µm µs µW mA mg mH mI mm ms mV nF

Ω

pF Ib rpm rps s V VA W Wh

Megavolt Megawatt Megohm Meter Microampere Microfarad Microhenry Micrometer Microsecond Microwatt Milliampere Milligram Millihenry Milliliter Millimeter Millisecond Millivolt Nanofarad Ohm Picofarad Pound Revolutions Per Minute Revolutions Per Second Second (Time) Volt Volt-ampere Watt Watt-hour

Table 2-1 Abbreviations

Reference Information

2-2 Samsung Electronics

Table 2-2 Table of Acronyms

ABL AC ACC AF AFC AFT AGC AM ANSI APC APC A/V AVC BAL BPF B-Y CATV CB CCD CCTV Ch CRT CW DC DVM EIA ESD ESD FBP FBT FF FM FS GND G-Y H HF HI-FI IC IC IF

Automatic Brightness Limiter Alternating Current Automatic Chroma Control Audio Frequency Automatic Frequency Control Automatic Fine Tuning Automatic Gain Control Amplitude Modulation American National Standards Institute Automatic Phase Control Automatic Picture Control Audio-Video Automatic Volume Control Balance Bandpass Filter Blue-Y Community Antenna Television (Cable TV) Citizens Band Charge Coupled Device Closed Circuit Television Channel Cathode Ray Tube Continuous Wave Direct Current Digital Volt Meter Electronics Industries Association Electrostatic Discharge Electrostatically Sensitive Device Feedback Pulse Flyback Transformer Flip-Flop Frequency Modulation Fail Safe Ground Green-Y High High-Frequency High Fidelity Inductance-Capacitance Integrated Circuit Intermediate Frequency

I/O L L LED LF MOSFET MTS NAB NEC NTSC OSD PCB PLL PWM QIF R RC RF R-Y SAP SAW SIF SMPS S/N SW TP TTL TV UHF UL UV VCD VCO VCXO VHF VIF VR VTR VTVM TR

Input/output Left Low Light Emitting Diode Low Frequency Metal-Oxide-Semiconductor-Field-Effect-Tr Multi-channel Television Sound National Association of Broadcasters National Electric Code National Television Systems Committee On Screen Display Printed Circuit Board Phase-Locked Loop Pulse Width Modulation Quadrature Intermediate Frequency Right Resistor & Capacitor Radio Frequency Red-Y Second Audio Program Surface Acoustic Wave(Filter) Sound Intermediate Frequency Switching Mode Power Supply Signal/Noise Switch Test Point Transistor Transistor Logic Television Ultra High Frequency Underwriters Laboratories Ultraviolet Variable-Capacitance Diode Voltage Controlled Oscillator Voltage Controlled Crystal Oscillator Very High Frequency Video Intermediate Frequency Variable Resistor Video Tape Recorder Vacuum Tube Voltmeter Transistor

IC665 TDA7265

IC904 KS24C04 ICS801 TNY253P ICS802 PC123

IC601 TDA7429S

IC602 KA4558

IC905 PCF8574P

ICV01 TA8851BN

ICV02,ICV03 HCF4053BE

ICP01 TDA8601

ICP02 TDA9160A

ICP03 SDA9288X

IC101 TDA9850

IC101 LA7565B

IC471 TL494CN

IC491 74HC123P

ICZ104,ICZ103 STK392-010

IC301 LA7845

IC801 STR-F6656

IC802 SVD001

IC804 SE110N

IC806 PS2561

IC501,IC531,IC561 TDA6111Q

IC01 UPD6488

ICI02 CXA1686M

ICC03 CXD2043Q

4 5

Block NameNo. IC Location IC Name

Table 2 - 3 IC Line - Up

Reference Information

Samsung Electronics 2-3

2-2 IC Line Up

MAIN

TERMINAL BOARD

PIP

MTS MODULE IF MODULE

HV MODULE

CONVERGENCE

SUB

CRT

2D-COMB

Reference Information

2-4 Samsung Electronics

Block NameNo. IC Location IC Name

Table 2 - 3 IC Line - Up (Continued)

CHROMA

IC201 CXA2095S IC202 TDA9177 IC203 MC14577BP

IC204, IC205 BCF4053B

Reference Information

Samsung Electronics 2-5

2-3 MICOM IIC BUS LINE -UP

2-6 Samsung Electronics

MEMO

Specifications

Samsung Electronics 3-1

3. Specifications

Broadcasting System Scanning System

Tuning Range

Antenna Impedance

Intermediate Frequency

Sound Output

Rated Voltage

W/B Coordinates

High Voltage

FUSE

Power Consumption

NTSC Interlace Scanning VHF : CH2 ~ CH13 UHF : CH14 ~ CH69 Cable : CH1, CH14 ~ 125 75 ohm Unbalanced Video : 45.75 MHz Sound : 42.25 MHz Chrominance Subcarrier : 42.17 MHz STD : 15W FULL MAX : 20 W 120V / 60 Hz Hx : 292 ± 3 Hy : 270 ± 3 Y : 3.0 ± 0.2 Lx : 278 ± 5 Ly : 246 ± 5 Y : 0.13 ± 0.02 29 KV 250V/6.3A CODE NO : 3601-000300 230W

3-2 Samsung Electronics

MEMO

Alignment and Adjustments

4.Alignment and Adjustments

4-1 When entering the service mode:

1. Turn on the TV, and then select “STANDARD”on the picture adjustment mode.

2. Turn off the TV (STAND-BY).

3. Enter the service mode by pressing the remote control keys in the following sequence :

MUTE →1→8→2→Power On

Note : If necessary, re-do steps 1~3.

Initial display when the service mode is switched.

FACTORY

GEOMETRIC PICTURE SOUND PIP OPTION READ RESET

1. When a RF signal is received

MAIN MENU MENU DISPLAY

CH UP/DOWN Select item by moving cursor

VOL UP/DOWN Decrease or increase the adjustment values

2. Service Mode Control Keys

Samsung Electronics 4-1

Alignment and Adjustments

4-2 Samsung Electronics

GEOMETRIC

VS 32 V-SHIFT HLC 8 PIN-LO-CORR VA 32 V-SIZE VAS 40 V-ASPECT-SIZE VCP 0 V-COMP VSR 25 V-SCROLL VLN 5 V-LIN VUV 0 V-UP-LIN VSC 3 V-S-CORR VLV 0 V-LO-LIN HS 0 H-SHIFT VJS 0 V-JUMP-SW HPC 17 PIN-AMP VZS 0 V-ZOOM-SW HA 20 H-SIZE VRP 3 VBLKW HPP 8 PIN-PHASE VBS 3 V-BLK-SW HAA 7 V-ANGLE HBS 0 H-BLK-SW HAB 5 V-BOW HLB 15 H-LEFT-BLK HUC 8 PIN-UP-CORR HRB 15 H-RIGHT-BLK

PICTURE

DCT 1 GC 8 DPI 1 BC 8 AS 1 GAM 2 DCL 1 AFC 2 ABL 1 TOC 1 POV 3 SSP 40 SFO 1 AMS 1 TA 1 FHS 0 SCT 5 CFS 0 SBT 8 SC 40 SCR 4 LWC 32 STT 11 COR 45 GA 32 BA 32

SOUND

STEREO 9 ALIGN1 27 SAP 9 ALIGN2 25 LEVEL 9 ALIGN3 4

PIP

CONTRAST 10 HUE 32 POS-HOR 137 POS-VER 34

OPTION

BYTE O : 91 BYTE 1 : 00

4-1-1 Factory Data

ITEM

INITIAL VALUE FUNCTION

ITEM

INITIAL VALUE FUNCTION

Alignment and Adjustments

Samsung Electronics 4-3

4-2 Screen Change (When adjusting I2C Bus Geometric items)

PIN PHASE

10 V BOW

5 V ANGLE

PIN AMP

2 V LINEARITY

6 V SIZE

3 H SIZE

9 H SHIFT

7 V - S - CORRECTION

1 V SHIFT

Alignment and Adjustments

4-4 Samsung Electronics

4-3 Beam Alignment

PRECAUTION

1. Input a crosshatch and dot pattern.

2. Select the “STANDARD” video mode.

3. Warm up the TV for at least 10 minutes.

4. Connect an audio oscillator to the pin jig between GT401~GT402 (located on the deflection PCB) and GND.

5. Determine the ZERO-magnet area (using the beam-alignment CY)

6. Check the squarewave at the point where the focus is misaligned (Use an audio oscillator).

ADJUSTMENT

1. Cover the Red and Blue lenses.

2. Adjust the Green lens as shown in the figures below

3. Adjust the G-Focus until any light around the core disappears.

4. Cover the Green and Blue lenses.

5. Adjust the Red lens using the same method as with the Green lens.

6. Note: The Blue lens is not adjusted because its focus varies little (VM-coil is installed).

7. After the adjustments are completed, disconnect the jig pin connector.

(Creation of CPM Zero Magnet)

(Creation of the 2-pole/4-pole zero magnets)

G-FOCUS

CORE

(Varying G-Focus Pack)

Varying the 2-pole of VM

(Positioning the Core in the Center)

Varying the 4-pole of VM

CORE

G-FOCUS

(When VM 2-Pole Adjustment is completed)

(Adjust until the light around the core becomes a circle)

Alignment and Adjustments

Samsung Electronics 4-5

4-4 Other Adjustments

4-4-1 Screen Adjustment

1. Warm up the TV for at least 30 minutes.

2. Turn to the Video Mode (No Signal) using a remote-control.

3. Connect an oscilloscope to RK,GK,BK.

4. Adjust the VR (VR501, VR531, VR561) screen so that RK, GK, BK pulse is 20Vp-p each. (Turn the R,G,B VR screen fully counterclockwise in the area of each flyback line.)

4-4-2 White Balance Adjustment

1. Select the “STANDARD” video mode.

2. Input 100% white pattern.

3. In the stand-by mode, press the remote-control keys in the following sequence: Mute → 1 → 8 → 2 → Power ON

4. Warm up the TV for at least 30 minutes.

5. Input a 10-step signal.

6. R-cut off, B-cut off, and G-cut off by pressing the Volume +/- keys.

7. Adjust the low light with viewing the dark side of the screen.

8. Select R-drive, G-drive, and B-drive by pressing the Volume +/- keys.

9. Adjust the high light with viewing the light side of the screen.

10. If necessary, redo adjustments 6~9.

11. Press the Menu key to exit.

4-4-3 Sub-Brightness Adjustment

1. Input a sub-brightness adjustment signal. (TOSHIBA PATTERN)

2. In the stand-by mode, press the remote-control keys in the following sequence : Mute - 1 - 8 - 2 - Power ON

3. Select SBT by pressing the Volume +/- keys.

4. Adjust so that the 7th step on the right side of the screen is not seen (Use the Volume +/keys).

5. Press the Menu key to exit.

4-4-4 High Voltage (31KV) Check

PRECAUTION

1. Input a lion head pattern.

2. Select “STANDARD” video mode.

3. Warm up the TV for at least 10 minutes.

4. Use a 1000:1 probe.

ADJUSTMENT

1. Connect the (+) terminal of the 1000:1 probe to the high voltage distributor and the (-) terminal to GND (located on the deflection board).

2. Adjust VR471 (located on the deflection board) so that the digital meter indicates DC 31V ± 0.1V.

Alignment and Adjustments

4-6 Samsung Electronics

4-4-5 F.S. (Fail Safe) Circuit Check

Note : The F.S. Circuit check must be performed

after servicing.

1. Turn on the TV.

2. Select the “STANDARD” video mode.

3. Short GT18, GT17 (located on the Convergence PCB). Then, both sound and picture disappear. (Note: Even if the shorted terminals are removed, both sound and picture do not appear. This proves the F.S. circuit is working. )

4. To restore both sound and picture, turn off the TV and reset it after about 30 seconds.

4-4-6 Static Focus Adjustment

PRECAUTION

1. Select the “STANDARD” video mode.

2. Input a crosshatch pattern.

3. Cover the lenses that are not being adjusted.

4. Connect a convergence jig and read data.

5. Adjust the lens for best focus. (See Fig, 4-1, next page)

STATIC FOCUS (CONTINUED)

Vary the focus pack VR (Red, Blue) on the front cabinet. Adjust the TV for best possible focus around the center of the crosshatch pattern, without losing overall screen balance. Figure Crosshatch Pattern Examine these points together.

4-4-7 Lens Focus Adjustment

PRECAUTIONS

1. Do this adjustment after the static focus adjustment and the tilt adjustment.

2. Select the “STANDARD” video mode. (Contrast:64, Brightness:32)

3. Input a crosshatch pattern.

ADJUSTMENT

1. Loosen the lens screws.

2. Cover the two lenses that are not being adjusted.

3. Adjust the lens, observing the color aberration vertically and horizontally within 3 blocks of the center of the crosshatch pattern.

4. When the lens is turned clockwise, the color aberration will change as follows:

Lens Color Aberration Change R Orange - Crimson G Blue - Red B Purple - Green

5. Green lens adjustment: Set the lens at the point where Blue just changes to Red. If the color aberration is irregular throughout the picture screen, adjust the lens to show Red color aberration (approximately 1~3 mm area) within a 3-block grid around the horizontal center-line. If the color aberration is irregular, adjust the lens as shown in the diagram below. (Accurate alignment of Green is important for overall color quality.)

6. Red lens adjustment Set the Red lens at the point where Orange becomes Crimson.

7. Blue lens adjustment Set the Blue lens at the point where Purple becomes Green.

RED ABERRATION

BLUE ABERRATION

L1, L2 < P

Fig. 4-1 Crosshatch Pattern.

Fig. 4-2 Color Aberration

Examine these points together

Alignment and Adjustments

Samsung Electronics 4-7

4-4-8 Horizontal Dynamic Focus Adjustment

PRECAUTION

1. Input a crosshatch pattern.

2. Select the “STANDARD” video mode.

3. Warm up the set for at least 10 minutes.

ADJUSTMENT

1. Cover the Red and Blue lenses.

2. Adjust VR491 (located on the convergence PCB, H-Parabola).

3. Balance the left and right sides of the dynamic focus lines.

4-5 Screen-Jig

0.3

2.5

0.3 11

0.3

22.7

0.3

22.7

0.3 11

0.3

2.5

0.3 2

26.4 26.2

26.2 26.4

(FRONT MASK)

0.3 0.3 0.3

Unit : cm

Alignment and Adjustments

4-8 Samsung Electronics

4-6 Remote Control for Servicing (Convergence Mode)

Fine Adjustment Button

Factory Data Select Button Last Data Save Button

Half Adjustment Button

G-Mute B-Mute

H/V Direction Select Button

Save Button

Line Shift

R-Select

R-Mute

Exit Button

Move Course Reverse

Move Course Forward

G-Select B-Select

Convergence Picture

Move Button

Test/Noraml

Convergence data Increase, decrease button

Convergence Data Zero Button

+ 51 hidden pages

Samsung PCJ522RX/XAA, PCJ522RX/XAC, PCJ612RX/XAC, PCJ612RX/XAA Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual