NOTE: THIS PROCEDURE DOES NOT APPLY TO RCA CHASSIS MODEL ITC222. FOR THAT MODEL CLICK HERE.
When the picture on your projection TV looks like 3D, the image bows in on all sides and red/green/blue are separated you have bad convergence ICs. They are located on the mainboard attached to a large aluminum heat sink. The heat sink could be shiny or black depending on the manufacturer. They are generally located near the rear of the High Voltage/Power supply board. The ICs are shaped like a trapezoid. I have a picture of one at the end of this tip. It is for identification purposes only, your actual part number may be different. Make sure you get the correct units.
Once you have located the ICs and heat sink look at the numbers printed on the ICs. The numbers on them should be of the form STK392-XXX. Note the number and go to http://www.encompass.com
and order two. One is for horizontal and one is for vertical. You should also go to http://www.mcmelectronics.com
and if you do not already own one order a good solder iron (40 watts with conical tip, temp control would be helpful), solder wick, heat sink compound, solder puller and solder.
You will need good soldering equipment and skills. Do not apply too much heat to the connections on the underside of the board or the lands will come off causing bigger problems. The secret to soldering/desoldering is to have a hot iron and concentrate on one part at a time. Keep good contact with the piece being soldered/unsoldered.
In addition you must have a clean tip to do a good job and get the soldering done in the shortest period of time. Use a good tip cleaner (looks like a kitchen scrubber) which can be purchased at the site I mentioned or a substitute you may have, steel wool or a damp cloth. All work about the same, the important part is that the tip is kept clean.
Sometimes you need to remove the heat sink to install the IC's leads due to the number, and difficulty, of getting them in the proper holes. This usually requires removing several screws from the bottom of the board or unsoldering the hold down tabs and possibly straigtening them to get them through the holes in the circuit board depending on your particular model. The ICs can be removed from the heat sinks by removing two hold down screws and prying them loose from the heat sink. This can sometimes take quite a bit of pressure.
Another problem to watch out for is bridging of the leads when resoldering the IC into the board. Before powering up the unit make absolutely certain that no leads have been soldered together or "bridged". Correct any issues. You do not need a large amount of solder on the leads. A nice round smooth connection is best. Look at some of the other solder joints to see what a good solder joint should look like.
If your eyes are like mine it would pay to purchase a pair of magnifying binoculars from the same site you can get the equipment from, http://www.mcmelectronics.com
After replacing the ICs check all the resistors and microfuses in the area of the convergence ICs for opens. The fuses will look like resistors but no color code.
Remove the old ICs from the board and install the new ones. Be careful not to get the units too hot when installing the new ones. The heat sink compound goes on the back of the ICs in a thin coat to aid heat disapation. Don't over do it! Also clean all the old heat sink compound off the heat sink.
Once the ICs have been replaced and the unit is up and running you will need to set the convergence to align the beams. You should be familiar with this, if not the procedure should be outlined in your operations manual. If you lost your manual go to http://www.retrevo.com
to get a new one for free.
If this was the only problem your unit should now look fine. While you have it apart you should clean the lenses and the mirror with a soft lint free cloth and window cleaner (no ammonia). Always spray the cloth, never spray inside the TV.
If the lines still will not converge you have a bad digital control box. Detailed intructions for removal and replacement of the digital box are located at my tip http://www.fixya.com/support/r4273935-replace_digital_convergence_box
Example of a convergence IC. Your part # may be different.
Thanks for using FixYa.