Toshiba TV-GEN-03 Installationsanleitung

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 picture 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

Module No. TV-GEN-03

Page 1 of 20

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. While an overlay can also be used to perform a minor alignment,

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.

TOSHIBA PJTV

Digital Convergence Alignment

Module No. TV-GEN-03

Page 2 of 20

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 Screen

Size Aspect

Ratio Picture

Size Model

Year

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

Table 1

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.

Example 1: PSOL40X1

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:

Example 2

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.

TOSHIBA PJTV

Digital Convergence Alignment

Module No. TV-GEN-03

Page 3 of 20

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

TOSHIBA PJTV

Digital Convergence Alignment

Module No. TV-GEN-03

Page 4 of 20

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.

TOSHIBA PJTV

Digital Convergence Alignment

Module No. TV-GEN-03

Page 5 of 20

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.

TOSHIBA PJTV

Digital Convergence Alignment

Module No. TV-GEN-03

Page 6 of 20

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.

ZoneScreen

Size A B C D E F G H J

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

Table 2

Zones A through J are the areas of the screen referenced by the specifications. The

zones are illustrated in Figure 4.

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.

TOSHIBA PJTV

Digital Convergence Alignment

Module No. TV-GEN-03

Page 7 of 20

Readme: Backup data should be loaded only if corruption of the original data

is suspected or if the set is severely misconverged. Minor misconvergence

issues should be corrected by performing the appropriate alignment procedure.

To load back up data:

1. Enter Service Mode as described in the appropriate Service Manual.

2. Enter convergence alignment mode by pressing the “7” key on the remote.

3. Display vertical stripes by pressing the “9” key on the remote.

4. Load the backup by pressing the “1” key on the remote.

a. The following message will appear on screen for:

ENTER: TO LOAD BACKUP DATA

EXIT: TO EXIT

5. Press the “ENTER” key on the remote, as shown in Figure 5, to load the backup

data.

a. The displayed net pattern will misconverge briefly, then return to a normal

state.

Figure 5

6. Following the alignment procedure in the service manual, make any necessary

convergence adjustments.

7. Write the new data to convergence memory by pressing the “7” key on the

remote one time.

8. Press the “Touch Focus” key on the front panel of the unit.

a. The Touch Focus pattern will scroll across the screen two times. Once

quickly, then slowly.

9. “CALIBRATION FINISHED” will display on screen and the unit will exit to service

mode.

a. The new convergence data is saved to memory and new backup data is

created.

10.Power the unit off to exit service mode.

TOSHIBA PJTV

Digital Convergence Alignment

Module No. TV-GEN-03

Page 8 of 20

Readme: Do not attempt to load backup data if the digital convergence PCB has

been replaced. Backup data in the new PCB memory is not created until

convergence has been adjusted and the CALIBRATION procedure has been

completed.

Something to think about:

It is important to know when a convergence alignment will not correct the unit problem.

If after following the correct procedure, the convergence cannot be aligned to factory

specifications, further troubleshooting is required. Table 3 lists a few of the many

possible symptoms.

Repeated Touch Focus errors

Intermittent loss of convergence

Repeated convergence drift of any color

Selected color will not adjust in either direction

Convergence crosshatch pattern will not display

Convergence crosshatch pattern is severely distorted

Touch Focus pattern is not displayed

Touch Focus pattern is severely distorted

Back up data will not load

Cannot enter Service Mode

Data cannot be saved after alignment

Table 3

Points to remember:

Familiarity and practice help the technician develop confidence in performing a digital

convergence alignment or determining the need for further troubleshooting. Having the

knowledge and necessary tools available are an important first step in the process of

gaining experience. While taking this first step, it is best to follow the alignment

instructions carefully and exactly. Back up data, if available, is a useful tool if problems

occur. It can provide a good starting point in certain cases, but it should not be viewed

as a “cure-all” for convergence problems. In most cases, only minor adjustments will be

necessary. Focus and centering adjustments will not be needed and the procedure can

begin in the GEOMETRY stage. Minor adjustments made in this way do not require

the use of back up data or an overlay kit. Simply make the needed adjustments, save

the new data accordingly, exit the service mode, and you’re outta there!

TOSHIBA PJTV

Digital Convergence Alignment

Module No. TV-GEN-03

Page 9 of 20

Appendix A

Interlaced Scan Units with 4:3 Aspect Ratio

Section 1: OPTICAL & ELECTRICAL FOCUS

1. Follow the appropriate disassembly instructions to gain access to the CRTs.

2. If the wing nuts on the lenses are pointed toward the screen, reverse the lenses

on each tube so the wing nuts are facing the back of the set. Leave the lenses in

this position after servicing. Put the screen assembly back on.

3. From the Service Mode press the 7 key on the remote control to display the

convergence crosshatch pattern.

4. Push the 100 key to turn off the red tube, and the CH RTN/ENT key to turn off

the blue tube.

5. Position a mirror for viewing the screen from the rear of the set. From the rear of

the set, loosen the wing nut on the green lens, and adjust the lens for the best

focus in the center area of the screen.

6. From the front of the set, adjust the electrical focus control for best focus in the

center of the screen.

7. Repeat the optical focus, and then tighten the wing nut.

8. Repeat the electrical focus.

9. Push the 100 key to turn on the red tube, and the 0 key to turn off the green tube.

10. Adjust the red optical and electrical focus in the same manner.

11. Push the CH RTN/ENT key to turn on the blue tube, and the 100 key to turn off

the red tube.

12. Adjust the blue optical and electrical focus in the same manner. Electrically

defocus the blue slightly, to maintain uniform brightness.

Section 2: MECHANICAL TILT ADJUSTMENT

1. With the set still in convergence mode, and the convergence overlay on the

screen, check each CRT’s tilt. If a CRT’s pattern is tilted, loosen the appropriate

yoke with a non-magnetic screwdriver. Rotate the yoke until the pattern is

aligned vertically and horizontally. Re-tighten the yoke.

2. Press the 7 key on the remote to store the convergence data.

3. After the data is stored, press the 7 key on the remote again to exit the

convergence crosshatch pattern.

4. The unit will return to service mode and display a normal picture with the letter

“S” in the upper right corner.

5. Power the unit OFF to exit service mode.

Section 3: USER CONVERGENCE AND MAGNETIC CENTERING ADJUSTMENTS

1. Disconnect any source at the Video 1 input.

2. Turn the power on.

3. Enter the user convergence screen through the customer menu.

4. Move the red vertical cross hair as far as it will go to the right. Note the location.

Move the red vertical cross hair as far as it will go to the left. Note that location.

Set the red vertical cross hair to the center of the two extremes.

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