Toshiba TV-GEN-03 User Manual

TOSHIBA AMERICA CONSUMER PRODUCTS, INC.
NATIONAL SERVICE DIVISION
1420-B TOSHIBA DR.
LEBANON, TN 37087

TECHNICAL TRAINING

TV-GEN-03
Subject: Digital Convergence Alignment

Product: PROJECTION TELEVISION, Rear CRT
Chassis: All Toshiba rear CRT projection televisions with digital convergence
Model Year: All
Models: All
Prerequisites: None

Purpose:

Upon completion of this Training Module, the technician will be able to properly
converge a Toshiba CRT-based rear projection television set. Using the correct digital
convergence alignment procedures will enable the technician to identify symptoms
requiring more in-depth troubleshooting.
These skills will help improve servicing pictu re quality issues.

Objectives:

1. While performing a convergence alignment, specify when and when not to reload
convergence backup data 100% of the time.

2. Following a written procedure, correctly reload the convergence backup data
from the DCU memory.

3. Given the TV model number and picture size, identify the correct convergence
overlay and grid 100% of the time.

4. Following a written procedure, and using the correct overlay(s), align the
convergence to factory specifications.

5. While performing a convergence alignment, identify visual symptoms which
indicate further troubleshooting is required, at least 80% of the time.

Product Specific Service Manuals:

This training is designed as an aid to the technician in servicing Toshiba products. It is not a
replacement for the appropriate service manual(s). Toshiba service manuals contain product and
model specific information and must be consulted prior to servicing any product.

Product Safety Precautions:

Product Safety Precautions are described in the Toshiba service manual(s) for products and models
covered in this training. All safety precautions and checks must be complied with before returning any
product to the customer. Servicers who defeat safety features or fail to perform safety checks may be
liable for any resulting damages and may expose themselves and others to possible injury.

 2002 Toshiba America Consumer Products, Inc.

TOSHIBA PJTV

Digital Convergence Alignment

Consider this:

Toshiba CRT based rear projection televisions allow convergence adjustments to be
made in two areas:

1. User convergence area - This area can be accessed through the customer

picture menu by using the remote control or the front panel keys.
Adjustments can only be made by remote control.

2. Service Mode convergence area – This area should only be accessed by

qualified service technicians. A remote control is required for both access
and adjustment.

Readme: Qualified technicians should always align convergence in the Service
Mode.

First things first - Overlays:

Convergence overlays are service tools available for purchase through Toshiba
National Parts or Toshiba authorized parts distributors. The overlays are recommended
as guides following a “worst-case” situation, such as a CRT or Digital Convergence Unit
(DCU) replacement. W hile an overlay can also be used to perform a minor alignmen t,
this module will assume the worst-case scenario.

Each overlay kit contains all grids relative to the screen size and aspect ratio of the unit
to be aligned. Many older 4:3 aspect ratio units have only one grid to adjust. Newer 4:3
units of the same screen size also require adjustment in High Definition (HD)
compressed mode. This mode can be accessed through the customer menu.
Widescreen (16:9 aspect ratio) units built prior to 2001 have up to six different picture
size modes that require adjustment:

1. Full/Standard/Natural

2. Wide 1

3. Wide 2

4. Wide 3

5. HD Full

6. HD Standard

Widescreen units built before the HD revolution have only picture size modes 1 through

4. Widescreen units built in 2001 and later are only adjustable in FULL mode. The

settings for all other picture size modes are calculated from the FULL mode information
by the DCU microprocessor.

The overlays come as one complete sheet and will have to be trimmed following the
included instructions. Each kit also contains step-by-step, centering, focusing, and
convergence alignment instructions. These instructions vary according to the type of
unit. Kits used for more than one type contain instructions for all types covered.

Readme: In many cases, convergence problems have been corrected by
exactly following the supplied instructions.

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Digital Convergence Alignment

When using an overlay kit, it is important to know the type of unit it is designed for use
with and the kit part number. The availability and part numbers of the overlay kits are
subject to change as screen sizes are added or discontinued. Table 1 details the
currently available overlay kit part numbers.

Part

Number

PSOL40X1 40” 16:9 All All

PSOL42W1 42” 16:9 Full 2002+

PSOL43X1 43” 4:3 All All
PSOL4801 48” 4:3 N/A All
PSOL50X1 50” 4:3 All All

PSOL50W1 50” 16:9 Full 2002+

PSOL53X1 53” 4:3 All 2002+
PSOL55X1 55” 4:3 All All
PSOL56X1 56” 16:9 All All

PSOL57W1 57” 16:9 Full 2002+

PSOL61X1 61” 4:3 All All
PSOL65X1 65” 16:9 All All
PSOL7101 71” 4:3 N/A All

Each kit part number begins with the acronym PSOL, meaning Protective Screen Over
Lay. Following the acronym are a series of alpha-numeric characters identifying the
screen size and intended unit type. In Example 1, “40” identifies the kit for use with a 40
inch screen size. “X1” indicates the kit contains all grids for any unit in that screen size.

In some cases there are models with different aspect ratios within a screen size
category. In such cases, the letter “W ” in the kit part number indicates use with wide
screen (16:9 aspect ratio) units. See Example 2 for details:

PSOL50X1 is used with any 50 inch unit with a 4:3 aspect ratio screen.
PSOL50W1 is used with any 50 inch unit with a 16:9 aspect ratio screen.

Readme: The overlay dimensions are contained in the appropriate unit Service

Manual, as shown in Figure 1. If a particular overlay kit is not available, or there
is an urgent need for a complete convergence alignment before the kit can be
delivered, strings and low-tack tape can be used to achieve the desired results.

Screen

Size

Example 1: PSOL40X1

Aspect

Ratio

Table 1

Example 2

Picture

Size

Model

Year

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Digital Convergence Alignment

Figure 1

And then… Accessing Service Mode:

Once the correct overlay is placed on the screen, the unit must be put into Service
Mode before any alignment adjustments are made. There are currently two methods of
Service Mode entry, dependant upon the model and type of set. The methods are
described as follows:

1. All digital convergence equipped units built prior to 2001 and all interlaced

scan units:

a. With the unit powered “ON”, press and release the MUTE key on the

remote control.
b. Press the MUTE key a second time and hold.
c. While holding the MUTE key, press the MENU key on the front panel.

A pale blue “S” will appear in the upper right corner of the screen, as

shown in Figure 2.
d. Press the MENU key on the front panel a second time. RCUT will

appear in the upper left corner of the screen.

Figure 2

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Digital Convergence Alignment

Readme: RCUT is a data address in the system EEPROM. The hexadecimal
data contained in the address will be shown just below it, as shown in Figure 3.

Figure 3

2. All progressive scan units built from 2001 forward:
a. With the unit powered “ON”, press and release the MUTE key on the

remote control two times.
b. Press the MUTE key a third time and hold.
c. While holding the MUTE key, press the MENU key on the front panel.

A pale blue “S” will appear in the upper right corner of the screen.
d. Press the MENU key on the front panel a second time. RCUT will

appear in the upper left corner of the screen.

Readme: Important parameters of the set can be accessed and adjusted from
Service Mode. Use caution whenever working in this area.

The rubber meets the road - Convergence Alignment:

Readme: Always allow the set to warm up for at least 15 minutes before making

any adjustments.

Convergence alignment instructions vary according to the unit type. The instructions
assume a worst-case scenario, such as replacing all three CRTs or the digital
convergence board, and the use of an overlay kit. All versions of the instructions are
included as Appendices A through C of this document.

Readme: If the set requires only minor convergence adjustments, enter the
procedure where you feel it is necessary.

1. Optical and electrical focus
a. Remove or raise the screen to gain access to the CRTs.
b. Reverse the lenses if necessary.
c. Enter the convergence alignment service mode.
d. Optically and electrically focus each CRT.

2. Mechanical tilt
a. Check each CRTs tilt.
b. Adjust if necessary.
c. Store the data.

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Digital Convergence Alignment

3. User convergence and magnetic centering
a. Disconnect any input to Video 1.
b. Enter the user convergence area.
c. Vertically and horizontally center all 3 colors in all adjustable areas.
d. Exit the user convergence area.
e. Enter the convergence alignment service mode.
f. Mechanically center all 3 colors.

i. Stretch 2 pieces of string diagonally across the screen

ii. Rotate the centering rings on each CRTs neck
g. Lock the centering rings with adhesive.
h. Exit the service mode.

4. Electrical centering
a. Use a signal generator.

i. Crosshatch pattern
b. Enter service mode.
c. Adjust HPOS to center horizontally.
d. Adjust VPOS to center vertically.

5. Green geometry
a. Enter the convergence alignment service mode.
b. Secure the appropriate overlay to the screen.
c. Adjust the green geometry to match the overlay.

i. Start in the center of the screen

ii. Work clockwise around the screen

6. Red convergence
a. Align to green.

7. Blue convergence
a. Align to green.

8. HD convergence
a. Progressive scan 4:3 units only.
b. Component video signal to HD 1 input.
c. 1080i picture on or HD image shape compressed.

9. White balance
a. Set white balance according to the appropriate Service Manual.
b. Check picture quality using a live video signal.

10. Width, height, and vertical linearity
a. Adjust if the memory IC (QA02) has been replaced.
b. Adjust if the crosshatch pattern is not reasonably close to the overlay

pattern.

Readme: The convergence alignment may not be complete at this point.
Depending on the year of production and the type of unit being adjusted, there
could be several different picture size modes that require adjustment.

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Digital Convergence Alignment

End of the line? Specifications

Once all conceivable picture size modes have been aligned, verify the convergence
meets factory specifications. The specifications listed in Table 2 reflect the maximum
allowable misconvergence, in any direction, referencing either red or blue to green.

Zone Screen

Size

40 0.5mm 3.5mm 2.5mm 3.5mm 2mm 3.5mm 2.5mm 3.5mm 2mm
42 0.5mm 3.5mm 2.5mm 3.5mm 2mm 3.5mm 2.5mm 3.5mm 2mm
43 0.5mm 3.5mm 2.5mm 3.5mm 2.5mm 3.5mm 2.5mm 3.5mm 2.5mm
48 0.5mm 4mm 3mm 4mm 3mm 4mm 3mm 4mm 3mm
50 (4:3) 0.5mm 4mm 3mm 4mm 3mm 4mm 3mm 4mm 3mm
50(16:9) 0.5mm 3.8mm 2.7mm 3.8mm 2.3mm 3.8mm 2.7mm 3.8mm 2.3mm

53 0.5mm 4.5mm 3.2mm 4.5mm 3.2mm 4.5mm 3.2mm 4.5mm 3.2mm
55 0.5mm 4.5mm 3.2mm 4.5mm 3.2mm 4.5mm 3.2mm 4.5mm 3.2mm
56 0.5mm 4.5mm 3mm 4.5mm 2.5mm 4.5mm 3mm 4.5mm 2.5mm
57 0.5mm 4.5mm 3mm 4.5mm 2.5mm 4.5mm 3mm 4.5mm 2.5mm
61 0.5mm 5mm 3.5mm 5mm 3mm 5mm 3.5mm 5mm 3mm
65 0.5mm 5mm 3.5mm 5mm 3mm 5mm 3.5mm 5mm 3mm
71 0.5mm 5mm 3.5mm 5mm 3mm 5mm 3.5mm 5mm 3mm

Zones A through J are the areas of the screen referenced by the specifications. The
zones are illustrated in Figure 4.

A B C D E F G H J

Table 2

H Q J K B

G P A L C

F N E M D

Figure 4

If the convergence cannot be aligned to factory specifications, further troubleshooting is
required.

Don’t Worry:

Beginning with the 2002 production year, HD Compatible units include a service feature
that allows a qualified technician to restore factory convergence data from a back-up
memory location.

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