Beruflich Dokumente
Kultur Dokumente
KDL40XBR9
KDL40Z5100 KDL40XBR9
KDL46Z5100 KDL46XBR9
KDL52Z5100 KDL52XBR9
Course : CTV-57
Table of Contents
Chapter 1 Introduction ..................................................... 1
Overview.......................................................................... 1
Features .......................................................................... 1
No Video ............................................................................ 15
Video Distortions................................................................ 15
Troubleshooting Flowchart ................................................ 15
HDMI.................................................................................. 18
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Troubleshooting ............................................................. 18
Chapter 5 - Power Supply and Protection ....................... 20
Overview........................................................................ 20
Power Supply ................................................................ 20
40-inch Models .................................................................. 20
46 and 52-inch Models ...................................................... 20
Protection ...................................................................... 23
i
52-inch Backlighting........................................................... 32
Troubleshooting .................................................................
Inverter Failures .....................................................................
Balancer Errors ......................................................................
CTV-45
ii
Chapter 1 Introduction
Overview
240HZ Motionow
The EX-2M chassis is one of several designs for the 2009 model line of
Sony Bravia LCD televisions. Several models will be released during the
rst half of 2009. This training manual will cover the rst batch of models
and will include the following:
KDL40Z5100
KDL46Z5100
KDL52Z5100
KDL40XBR9
KDL46XBR9
KDL52XBR9
The chassis design revolves around the video processing circuits located
on the BU board. The key difference between models is determined by
the size of the LCD panel and its manufacturing source. This manual will
describe the new circuit features and individually describe the models
based on these differences.
Features
Several new features are introduced in the EXM chassis model lineup
along with some carryovers from the previous year.
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The customer has the option of changing the settings of the Motion
Enhancement and Motion Compensation circuits to smooth the judder
inherent with 24-frame lm-based content or can choose keep the judder
for a lm-like experience.
Chapter 1 - Introdcution
This feature was available in selected 2008 models and allowed the
viewing of JPEG formatted pictures and playback of MP3 audio les. The
media content has been expanded this year to allow playback of MPEG2
format video content.
By monitoring the overall level of the video signal, the backlights are
dynamically controlled and reduced during low light level scenes to
enhance the contrast ratio.
HDMI 1.3
This port allows for the hookup of optional devices that provide an
interface with portable digital media products such as MP3 players and
video cameras.
xvYCC
The previous color bandwidth limitations applied for compatibility with
analog signals are no longer present with digital signals. This allows for
1.8 times more colors.
Deep Color
The previous HDMI specications limited the RGB sample level to 24-bit.
Deep Color expands this up to 48-bit giving the ability to generate a color
depth of 2.8 trillion levels.
Bravia Sync
By utilizing the CEC feature of HDMI 1.3, this feature allows the customer
to easily control the various Sony devices within their home entertainment
system provided that all of the other devices have this feature included.
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BU Board
Essentially the brains of the system, this board contains all of the input
sources for video and audio information along with an on-board ATSC/
NTSC combination tuner. It also contains all of the video and audio
switching and processing circuits. The front-end (FE) microprocessor is
contained within IC7000 and is responsible for all handling of the various
video resolutions that are input to the television along with the generation
of OSD graphics for the user menu. It also serves as the ATSC decoder
for the MPEG2 video and Digital Dolby audio content. The third function
is to process the various video formats and resolutions to insure that all
are scaled to the native resolution of the LCD panel. All video sources exit
the BU board as 10-bit RGB 1920 X 1080 at 60HZ refresh rate.
All audio processing is performed on the BU board. This includes switching,
A/D conversion of analog sources, equalization and amplication to drive
the speakers
The TV Micro IC3002 is located on the BU board. It is responsible for
control of the television via the user interfaces. Monitoring of key circuits
and voltages is also performed to provide protection of the unit and shut
it down if necessary along with providing diagnostics codes to assist in
determining the cause a failure.
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The BU board used in these models is specically congured for the panel
types and sizes used. Note that all input sources are directly connected to
the BU board. The past use of separate boards for input switching, tuner,
ATSC decoder and side video inputs has all been incorporated onto this
single board.
Power Supply
Models using the 40-inch LCD panel contain a G6N power supply whereas
the 46 and 52-inch models use a G7N power supply circuit.
Inverters
The inverters provide high voltage to the uorescent lamps via a oating
ground differential AC voltage. The 40 and 46-inch panels use the D1N
and D2N. The 52-inch panels use the same layout except the inverter
boards are known as the D3N and D4N.
Switch Unit
Known as the H1 board in previous models, this board contains the
power, channel up/down, volume up/down and menu control buttons. It is
located on the lower right side of the television as viewed from the front.
HL5 Board
Used exclusively in the XBR9 models, this board contains the POWER/
STANDBY, PICTURE OFF/TIMER and HD SIGNAL LEDs. It also contains
the IR receiver and photo sensor for ambient room light detection.
Board Layouts
Figures 2-2 through 2-7 illustrate the circuit board locations for each model.
The Z5100 and XBR9 models are very similar with the exception of the
speaker layout and LED and IR receiver boards. These illustrations are
also useful to properly dress the wire harnesses when major component
replacements are performed.
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RF
VIDEO 1
VIDEO 3
COMPOSITE/
COMPONENT 1
COMPONENT 2
COMPOSITE 2
HDMI 1
A/V DECODER
VIDEO PROCESS
VIDEO SWITCH
AUDIO PROCESS
AUDIO AMP
TV MICRO
DVI AUDIO
HDMI 2
HDMI 3
HDMI 4
240 HZ
HFR
TCON
PC HD15
OPTICAL OUT
LCD PANEL
USB 1.1
DIGITAL
MEDIA PORT
ETHERNET
BU
SONY
LOGO
MODULE
SWITCH
UNIT
LED & IR
RECIVER
(XBR9)
HL5
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LED
(Z5100)
HL3
IR
RECEIVER
(Z5100)
HSN
INVERTER
INVERTER
D1N (40/46")
D3N (52")
D2N (40/46")
D4N (52")
POWER SUPPLY
AC IN
FIGURE 2-1
OVERALL BLOCK DIAGRAM
G6N (40")
G7N (46/52")
D1N
D2N
TCON
BU
G6N
SWITCH
UNIT
HL3
HSN
40Z5100 BOARD
FIGURE LOCATIONS
2-2
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D1N
D2N
TCON
RIGHT
TWEETER
BU
LEFT
TWEETER
G6N
SWITCH
UNIT
HL5
RIGHT
SPEAKER
HOUSING
LEFT
SPEAKER
HOUSING
FIGURE 2-3
KDL40XBR9 BOARD LAYOUT
40XBR9 BOARD LOCATIONS
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D1N
TCON
D2N
BU
G7N
SWITCH
UNIT
HL3
HSN
FIGURE 2-4
KDL46Z5100 BOARD LAYOUT
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D1N
TCON
D2N
RIGHT
TWEETER
LEFT
TWEETER
BU
G7N
SWITCH
UNIT
HL5
RIGHT
SPEAKER
HOUSING
LEFT
SPEAKER
HOUSING
FIGURE 2-5
KDL46XBR9 BOARD LAYOUT
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D3N
TCON
D4N
BALANCER
BU
G7N
SWITCH
UNIT
HL3
HSN
FIGURE 2-6
KDL52Z5100 BOARD LAYOUT
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10
LEFT
TWEETER
RIGHT
TWEETER
D3N
TCON
D4N
BALANCER
BU
G7N
SWITCH
UNIT
HL5
LEFT
SPEAKER
HOUSING
RIGHT
SPEAKER
HOUSING
FIGURE 2-7
KDL52XBR9 BOARD LAYOUT
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11
Analog Signals
All analog signals are directly selected by IC7000. By monitoring the
selected input and its sync frequency, IC7000 will process the video
accordingly so that resolution is always 1920 X 1080p upon exiting the
BU board. The signal format is 10-bit RGB converted to LVDS format.
HDMI Inputs
HDMI input selection is performed by IC5000 and sends the selected input
to IC7000. Unlike previous designs, there are no external EDID ICs for
each of the inputs. EDID information is now contained within IC5000.
USB1.1 (DMEX)
This USB input is labeled DMEX (Digital Media Extender) on the rear of
the unit. If the customer chooses to purchase optional Bravia Link devices,
such as DVD Link, this port will provide 2-way communication with that
device and links with the customer GUI interface. This port is also used to
input software upgrades to the television via USB storage devices.
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12
PC Input
Analog RGB input from a PC can be connected to the HD15 connector.
The video process circuits will support conventional resolutions from
640 X 480 VGA up to 1920 X 1080 HD. EDID information for the PC HD
material is also contained within IC5101
LCD Panel
The LCD panel receives the 10-bit RGB video data from the BU board via
a Low Voltage Differential Signaling (LVDS) cable. IC7000 contains the
LVDS transmitter within and transmits a video resolution of 1920 X 1080
60HZ to TCON board. The TCON board contains a frame-rate quadrupling
circuit for a net refresh rate of 240HZ.
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13
ATSC IF
TUNER
RF
NTSC CV
NTSC
AUDIO
TO DSP
D1_DET
COMPOSITE 1
COMPONENT 1
1920 X1080
60HZ
D1_PR_DET
IC7000
AMD
COMPOSITE 2
SIDE INPUT
240HZ
HFR
COMPONENT 2
HDMI 1
SIDE
INPUT
HDMI 2
HDMI 3
HDMI 4
IC5000
HDMI
SWITCH
EQ AND
EDID
TCON
LCD PANEL
DIGITAL MEDIA
PORT
PC HD15
IC5101
EDID
USB 1.1
ETHERNET
USB 2.0
SIDE INPUT
PHYSICAL
INTERFACE
PHYSICAL
INTERFACE
BU
FIGURE 3-1
OVERALL VIDEO PROCESS BLOCK DIAGRAM
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14
Troubleshooting
Video Distortions
Since virtually all of the video inputs and most of the video processing is
located on the BU board, failures causing a loss of video or distortions
in the picture need to be isolated to the BU board or the LCD panel.
The combining of all video processing circuitry into 2 major components
makes the troubleshooting approach to seem rather simplistic and in most
cases it will be just so.
This is, by far, the most difcult failure to troubleshoot due to the many
sources that can cause it. Noise emanating from the power supply, outside
interferences, video process failures and even mechanical problems in
the LCD panel can cause video distortion.
No Video
If a total loss of video occurs (including OSD graphics) the most likely
course of action is to bring a replacement BU board to the service location
since the unit is serviced at board-level only. It is unlikely that a loss of
voltage from the power supply is the cause since these voltages are
monitored and the unit will likely experience a protection shutdown event
rather than a no video condition. Although a failure of the backlights to
turn on would certainly cause a no video condition, this too would cause
the unit to shut down and indicate a failure via the self diagnostics feature.
If the replacement BU board does not resolve the issue, the LCD panel is
the only other likely culprit.
The presence of OSD graphics with a no video condition certainly
eliminates the LCD panel as the cause and the BU board will almost
certainly x the problem.
The up-side to display devices is that they are the most valuable tool in
determining the source of the problem so long as one knows the basic
theory of how they function. The Appendix section of this training manual
contains a section on basic troubleshooting of LCD panel televisions. The
primary objective when diagnosing no video or distortions in the video is
to eliminate the LCD panel as the cause. Replacement of the LCD panel
requires special authorization and, in some instances, will not be allowed
due to economical reasons.
Troubleshooting Flowchart
Due to the reduced number of circuit boards used in this chassis,
troubleshooting video problems must focus on whether the problem lies
on the BU board or the LCD panel. In a no video symptom the owchart
asks if the backlights are lit. Hypothetically, the backlights must light or the
unit will shut down and blink a balancer or inverter error but there have
been cases in previous chassis designs where the backlights do not light
and the unit did not enter the protect mode. The troubleshooting owchart
in Figure 3-2 will provide some guidance in diagnosing a video problem.
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15
IC7000 HEARTBEAT
LED
FIGURE 3-2
BU BOARD HEARTBEAT LED
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16
All inputs?
Yes
Distortion
stationary ?
Video Failure
Distorted
Symentrical ?
BU Board
No
Active video
anywhere on
screen?
If no 6X or 13X
BU Board
Yes
OSD graphics
present ?
Yes
TCON or
LCD Panel
No
None
Backlights
turning on ?
BU Board
Yes
No
No video or
distorted
video?
No
No
BU Board
Yes
Yes
TCON or
LCD Panel
BU Board
No
Heartbeat
LED on BU
board flashing ?
No
BU Board
Yes
Unplug LVDS
connector at
TCON while unit
is running . This
may need to be
done more than
once
Any flashes
seen on
screen?
No
TCON
(LCD Panel )
BU IC7000
HEARTBEAT LED
Yes
BU Board
FIGURE 3-3
VIDEO TROUBLESHOOTING FLOWCHART
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17
USB 2.0
MP3 audio les can be input to the USB side jack. The USB device is
detected and a list of the available audio les can be viewed in the XMB
graphics menu. The audio can be listened to via the television speakers
or and external amplier hooked up to the L/R analog outputs or optical
output jack.
HDMI
The 4 HDMI inputs are selected by HDMI switch and equalizer IC5000.
The serial audio data is received by IC7000 where it is converted to I2S
format. The I2S digital audio data is transmitted via the bus to IC2003.
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Ethernet (DLNA)
MP3 audio les may be read from a DLNA compliant computer on the
home network.
Optical Output
IC2003 outputs the SPDIF format signal for use by the optical output
transmitter. Included in Figure 4-1 is a truth table for the optical output.
The only time 5.1 channel audio is available from a tuner source is when a
digital ATSC source is received and 5.1 channel audio is being transmitted.
This includes terrestrial 8VSB and QAM from cable systems. If a DVD
player is connected via HDMI and the DVD output is set to 5.1, the output
from the optical jack will also be in 5.1 channel audio. Previous years of
Sony models did not pass the 5.1 channel audio from a DVD player and
down-converted it to 2-channel PCM. All analog sources are output as 48
KHZ 2CH PCM. The only time audio is not output is when digital audio is
input via the HDMI connectors from a SACD or DVD-Audio disc.
Troubleshooting
Since all circuitry involving audio processing and amplication is located
on the BU board, troubleshooting audio problems consists of determining
whether the failure affects all inputs or it is input specic. Failures affecting
all inputs would require changing the BU board whereas input specic
problems would require eliminating the input device as the source.
18
HDMI 4
AUDIO SOURCE
IC5000
HDMI
SWITCH &
EQ
DIGITAL TUNER
IC7000
AMD
USB2.0
ETHERNET
ATSC/NTSC
TUNER
OPTICAL OUTPUT
2CH PCM
2CH PCM
NO OUTPUT
NO OUTPUT
USB2.0
2CH PCM
ETHERNET
2CH PCM
DIGITAL
ANALOG
I2S
I2S
COMPOSITE 1
COMPONENT 1
COMPOSITE 2
COMPONENT 2
PC
IC2003
AUDIO SW
DSP
PWM
IC2201
CLASS D
AUDIO AMP
SPDIF
OPTICAL OUT
DVI
DIGITAL
MEDIA PORT
DMP
AUDIO
IC2301
LINE OUT
AMP
BU
FIGURE 4-1
AUDIO PROCESS CIRCUITS
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19
Power Supply
40-inch Models
A block diagram of the power and protection circuits is shown in Figure
5-1. Once AC power is applied current ows through R6022 to provide AC
power to bridge rectier D6000. This supplies a continuous 160VDC and
is only used by the standby power supply.
The G6N board has areas of protection monitoring which includes PFC
over-temperature and various over and under-voltage monitoring (not
shown). The activation of any these protect lines will pull down and latch
the power on command entering pin1 of CN6100. The REG12V line is
monitored by TV micro IC3002 on the BU board so any time a protection
circuit is activated on the G6N board the unit will shut down with a 2-blink
diagnostics error.
When the unit is power on, the main relay RY6000 is engaged by the
power-on command to Q6300. PRI_VCC is now applied to the main
relay and PFC circuit. The closing of the main relay shunts R6300 and
activates the PFC circuit and main switching supply. The PFC voltage is
now approximately 390VDC.
The main switching supply is now active, providing REG12V and AUDIO
15V to operate the television. Note that the switched PRI_VCC from
Q6300 is also applied to CN6500 and CN6501 for the inverter circuits.
CTV-57
20
D6000
RECT
1
2
3
PFC
1
2
3
1
2
3
4
5
6
7
R6022
Q6300
PRI_VCC
CN6600
CN6501
PRI_VCC
PFC GND
PFC OUT
PFC OUT
PFC GND
PRI_VCC
CN6500
PRI_VCC
PFC GND
PFC OUT
TO D2N
BOARD
INVERTER
CN6702
CN6103
H_SYNC
DIMMER
BACKLIGHT_ON
INV_ERR
GND
12V
BALANCER_ERR
H_SYNC
DIMMER
BACKLIGHT_ON
INV_ERR
GND
REG12V
BALANCER_ERR
D1N
RY6000
12X
AC IN
STANDBY
SWITCHING
SUPPLY
1
2
3
4
5
6
1~4
5~8
MAIN
SWITCHING
SUPPLY
11~13
8~9
6, 7
4, 5
3
2
1
CN6102
CN1002
BALANCER_ERR
GND
INV_ERR
BACKLIGHT_ON
DIMMER
HSYNC
CN6101
REG12V
REG12V_GND
CN6100
REG12V
REG12V_GND
UNREG_15_GND
UNREG_15V
STBY3.3V
AC_OFF_DET
POWER_ON
BALANCER_ERR
GND
INV_ERR
BACKLIGHT_ON
DIMMER
HSYNC
TO
TCON
CN1003
REG12V
REG12V_GND
UNREG_15_GND
UNREG_15V
STBY3.3V
AC_OFF_DET
POWER_ON
G6N
14X
HFR ERR
TCON ERR
FROM
TCON
NOT USED
6X
10X
IC7000
AMD
8X
SPKR
PROT
IC3002
TV MICRO
2X
3X
REG 5V
OVP
LVP
7X
IC3007
TEMP
SENSE
BU
FIGURE 5-1
40 POWER SUPPLY AND PROTECTION BLOCK DIAGRAM
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21
D6501
RECT
1
2
3
PFC
1
2
3
R6117
Q6305
PRI_VCC
1
2
3
4
5
6
7
CN6600
CN6501
PFC OUT
PFC GND
PRI_VCC
PRI_VCC
PFC GND
PFC OUT
CN6502
PRI_VCC
PFC GND
PFC OUT
TO D2N (46")
TO D4N (50")
INVERTER
CN6201
CN6702
H_SYNC
DIMMER
BACKLIGHT_ON
INV_ERR
GND
REG12V
BALANCER_ERR
H_SYNC
DIMMER
BACKLIGHT_ON
INV_ERR
GND
12V
BALANCER_ERR
D1N (46")
D3N (52")
RY6101
12X
AC IN
STANDBY
SWITCHING
SUPPLY
1
2
3
4
5
6
1~4
5~8
MAIN
SWITCHING
SUPPLY
11~13
8~9
6, 7
4, 5
3
2
1
CN6204
CN1002
BALANCER_ERR
GND
INV_ERR
BACKLIGHT_ON
DIMMER
HSYNC
BALANCER_ERR
GND
INV_ERR
BACKLIGHT_ON
DIMMER
HSYNC
CN6203
REG12V
REG12V_GND
CN6202
REG12V
REG12V_GND
UNREG_15_GND
UNREG_15V
STBY3.3V
AC_OFF_DET
POWER_ON
TO
TCON
CN1003
REG12V
REG12V_GND
UNREG_15_GND
UNREG_15V
STBY3.3V
AC_OFF_DET
POWER_ON
G7N
14X
HFR ERR
TCON ERR
FROM
TCON
IC7000
AMD
8X
SPKR
PROT
IC3002
TV MICRO
2X
3X
REG 5V
OVP
LVP
7X
IC3007
TEMP
SENSE
BU
FIGURE 5-2
46/52 POWER SUPPLY AND PROTECTION BLOCK DIAGRAM
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22
Protection
Diagnostics History
Referring once again to Figure 5-1, the protection circuits will be covered.
All protection monitoring that will generate diagnostics codes is performed
on the BU board and detected by TV micro IC3002. The protections circuits
will be described by the number of blink codes.
2X Main Power: The REG12V line from the power supply is monitored
directly by IC3002 via a resistor/divider network (not shown).
3X DC_ALERT1: The switched REG5V generated on the BU board is
monitored for over and under-voltage conditions.
6X Backlight: One or both of the inverters has failed. In the 40 and 46inch models, a failed backlight lamp will also generate this error.
7X Temperature: IC3007 on the BU board is a digital thermometer and
will notify IC3002 once a maximum acceptable temperature inside the
television cabinet has been reached.
8X Audio Protect: DC voltage has been detected on one or both of the
speaker output lines. This circuit is designed to protect the speakers from
damage.
10X DTT Watchdog Timer: Communications from the AMD IC7000 have
stopped.
Troubleshooting Flowcharts
12X HFR (High Frame Rate) Error: The frame quadrupling circuit on the
TCON has failed.
The troubleshooting owcharts found in Figures 5-4 and 5-5 will assist in
determining what component is the likely cause of no power or protect
shutdown.
13X Balancer: Available only on the 52-inch models, one or more open
backlight lamps has been detected.
14X TCON Error: The timing control IC located on the TCON is not
communicating with IC7000.
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23
SELF CHECK
PAGE 1
DIAGNOSTICS
BLINK
CODE
002
003
012
006
007
008
009
010
005
013
EVENT
COUNT
MAIN POWER
DC ALERT1
HFR ERR
INV ERR
TEMP ERR
AUD PROT
FAN ERR
DTT WDT
DC ALERT3
BALANCER
000
000
000
004
000
000
000
000
000
004
TOGGLE PAGES
WITH 1 AND 4' KEY
ON REMOTE
DETECTED EVENTS
HIGHLIGHTED IN RED
00007
00046
00005
SELF CHECK
DIAGNOSTICS
PAGE 2
000
FIGURE 5-3
SELF DIAGNOSTICS PAGES
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24
No Power
REMOVE AC POWER
FOR AT LEAST 30
SECONDS AND REAPPLY. DOES MAIN
RELAY CLICK?
Yes
Replace
G6N board (40")
G7N board (46/52")
No
3.3VDC
CN6100 -3 G6N
CN6202 -3 G7N?
No
Replace
G6N board (40")
G7N board (46/52")
Yes
3.3VDC at turn on
CN6100 -1 G6N
CN6202 -1 G7N?
No
Replace
BU board
Yes
Replace
G6N board (40")
G7N board (46/52")
FIGURE 5-4
NO POWER TROUBLESHOOTING FLOWCHART
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25
Immediately ?
Shutdown
Red Standby
LED Flashing
7X
Temperature
No
Yes
Yes
BU Board
No
2X
MAIN POWER
Yes
G6N (40")
G7N (46/52")
8X
Speaker
Protect
Yes
BU Board
No
No
3X
DC ALERT
Yes
BU Board
No
Yes
BU Board
No
No
6X
BACKLIGHT
11X
Yes
Go To Panel Error
Troubleshooting
Flowchart
12X or 14X
Yes
TCON on LCD
PANEL
No
No
13X
Balancer
Yes
LCD Panel
FIGURE 5-5
PROTECT MODE TROUBLESHOOTING FLOWCHART
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26
CN6550
HV
CN6600
CN6103
CN6501
1. PRI 12V
2. PRI GND (HOT)
3. PFC 390V
CN6500
1. PRI 12V
2. PRI GND (HOT)
3. PFC 390V
CN6005
CN6102
1. BALANCER ERROR
2. GND
3. INV ERR
4. BACKLIGHT ON
5. DIMMER
6. H SYNC
CN6903
1. SLAVE FAIL
2. PWM
3. LD
4. HV SENSE 2
5. SS
6. FB
7. DUTY
8. ENABLE
8. GND
9. SYNC
10. REG 12V
CN6101
1~4. REG 12
5~8. REG 12 GND
CN6100
1. POWER ON
2. AC OFF DET
3. STBY 3.3
4, 5. UNREG 15V
6, 7. UNREG GND
8~10 REG 12V GND
11~13 REG 12V
CN6850
HV
CN6800
CN6102
CN3002
CN7800
CN1003
CN2201
FIGURE 5-6
40 TEST POINTS
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27
CN6702
1. H SYNC
2. DIMMER
3. BACKLIGHT ON
4. INV ERR
5. GND
6. 12V
7. BALANCER ERROR
CN6850
HV
CN6703
CN6800
CN6600
CN6501
1. PRI 12V
2. PRI GND (HOT)
3. PFC 390V
CN6502
1. PRI 12V
2. PRI GND (HOT)
3. PFC 390V
CN6201
CN6203
1~4. REG 12
5~8. REG 12 GND
CN6202
1. POWER ON
2. AC OFF DET
3. STBY 3.3
4, 5. UNREG 15V
6, 7. UNREG GND
8~10 REG 12V GND
11~13 REG 12V
CN6903
1. SLAVE FAIL
2. PWM
3. LD
4. HV SENSE 2
5. SS
6. FB
7. DUTY
8. ENABLE
8. GND
9. SYNC
10. REG 12V
CN6102
CN3002
CN7800
CN1003
CN2201
CN6104
CN6204
1. BALANCER_ERR
2. GND
3. INV_ERR
4. BACKLIGHT_ON
5. DIMMER
6. H SYNC
FIGURE 5-7
46 TEST POINTS
CTV-57
28
CN6650
HV
CN6702
1. H SYNC
2. DIMMER
3. BACKLIGHT ON
4. INV ERR
5. GND
6. 12V
7. BALANCER ERROR
CN6850
HV
CN6703
CN6701
1. 12V
4, 5 GND
6, 7 LD
CN6800
CN6600
CN6201
CN6501
1. PRI 12V
2. PRI GND (HOT)
3. PFC 390V
CN6502
1. PRI 12V
2. PRI GND (HOT)
3. PFC 390V
CN6203
1~4. REG 12
5~8. REG 12 GND
CN6202
1. POWER ON
2. AC OFF DET
3. STBY 3.3
4, 5. UNREG 15V
6, 7. UNREG GND
8~10 REG 12V GND
11~13 REG 12V
CN6104
CN6903
1. SLAVE FAIL
2. PWM
3. LD
4. HV SENSE 2
5. SS
6. FB
7. DUTY
8. ENABLE
8. GND
9. SYNC
10. REG 12V
CN6102
CN3002
CN7800
CN1003
CN2201
CN6204
1. BALANCER_ERR
2. GND
3. INV_ERR
4. BACKLIGHT_ON
5. DIMMER
6. H SYNC
FIGURE 5-8
52 TEST POINTS
CTV-57
29
40-inch Backlighting
Figure 6-1 illustrates a block diagram of the circuits used to control and
operate the backlights for the KDL40Z5100 and KDL40XBR9. This panel
size uses a G6N power supply to generate a 390V PFC voltage along with
a PRI_VCC of approximately 12VDC which supplies operating voltage to
the D1N and D2N inverter circuits. Both of these voltages are referenced
to hot ground.
The use of left and right inverter circuits creates a oating ground AC circuit
to supply differential AC voltage to both ends of the lamps. This helps to
insure steady brightness across the length of each lamp. The D1N board
serves as the master (containing the oscillator and drive circuits) while the
D2N board is the slave having only the inverter switching circuits. This is
how the 2 inverters remain locked out of phase.
Inverters
Once the circuits on the D1N board are operating, control of the D2N board
is also achieved. Both inverter circuits operate out of phase to supply a
45KHZ AC sine wave at approximately 800VRMS per side. Both inverter
circuits contain protection circuits to monitor over-voltage and over-current
conditions. If a problem occurs on one or both of the inverters an inverter
failure high will be generated and is easily measured at pin 3 of CN6102
on the G6N board. This will cause the unit to shut down and blink the
POWER/STBY LED on the front bezel to blink in groups of 6.
The 40-inch panels do not utilize and external balancer circuit that was
found in the previous years of models. Models that used a balancer circuit
had the ability to monitor for an open lamp condition and shut the unit down
with a 13-blink error code. If one or more of the uorescent backlights fails
to light, the resulting loss of load will cause an overvoltage condition in the
inverter circuit and the unit will shut down with a 6 blink error code just as
if the inverter had failed.
Power-on Sequence
TV micro IC 3002 on the BU board sends a power on command to pin 1
of CN6100 on the G6N board to turn on the main relay, PFC and main
switching relay. The necessary operating voltages are now generated for
the televisions circuits.
CTV-57
30
LCD PANEL
INVERTER
OSC /
DRV
CN6600
1 PRI_VCC
3 HOT GND
5 PFC 390 V
CN6102
1
2
3
4
5
6
CN6703
CN6600
CN6702
CN6500
CN6501
CN6153
PFC
800VRMS
INV
FAIL
INV
FAIL
INVERTER
CN6950
D1N
CN6800
D2N
CN6102
1
2
3
4
5
6
BALANCER_ERR
GROUND
INVERTER_ERR
BACKLIGHT ON
DIMMER
H_SYNC
POWER ON
CN6100
G6N
CN1003
IC3002
TV
MICRO
CN1002
BU
FIGURE 6-1
40 PANEL BACKLIGHT DIAGRAM
CTV-57
31
46-inch Backlighting
Figure 6-2 illustrates the backlighting circuits for the KDL46Z5100 and
KDL46XBR9. The only difference is the use of a G7N power supply to
handle the larger current requirements of the larger panel. The operation
of the circuit is the same as the design for the 40-inch models except the
connector numbers are different for the G7N board.
The part numbers for the D1N and D2N boards are also different due to
their larger current capacity.
52-inch Backlighting
Figure 6-3 illustrates the block diagram of the backlight circuits for the
KDL52Z5100 and KDL52XBR9. The operation is the same as previously
described with the following differences:
The inverter boards used are the D3N and D4N. Once again, they are
basically the same in operation as the D1N and D2N found in the 40
and 46-inch models. The same G7N power supply found in the 46-inch
models is also used.
A single, external balancer circuit is used to distribute the high voltage,
maintain even current draw amongst the parallel connected lamps and
to monitor for an open lamp. The D3 board provides a 12VDC operating
voltage for the balancer circuit along with monitoring for an open lamp
via the LD line at pin 6 and 7 of CN6701. This LD line is normally high
(12VDC) and goes low if an open lamp is detected. An inverter located on
the D3N board will reverse this logic line and it becomes a balancer error
line that is normally low. An open lamp condition will cause this line to go
high and the unit will shut down with a 13-blink error code.
CTV-57
32
LCD PANEL
INVERTER
OSC /
DRV
CN6600
1 PRI_VCC
3 HOT GND
5 PFC 390 V
CN6204
1 BALANCER_ERR (NOT USED)
2 GROUND
3 INV_ERR (NORM LOW)
4 BACKLIGHT_ON (3.3V ON)
5 DIMMER (PWM)
6 REG_12V
CN6703
CN6600
CN6702
CN6501
CN6502
CN6153
PFC
800VRMS
INV
FAIL
INV
FAIL
INVERTER
CN6950
D1N
CN6800
D2N
CN6204
1
2
3
4
5
6
BALANCER_ERR
GROUND
INVERTER_ERR
BACKLIGHT ON
DIMMER
H_SYNC
POWER ON
CN6202
G6N
CN1003
IC3002
TV
MICRO
CN1002
BU
FIGURE 6-2
46 PANEL BACKLIGHT DIAGRAM
CTV-57
33
BALANCER
CN3
INVERTER
CN6701
12V
GND
LD
CN6600
1 PR__VCC
3 HOT GND
5 PFC 390V
CN6204
1 BALANCER_ERR (NORM LOW)
2 GROUND
3 INV_ERR (NORM LOW)
4 BACKLIGHT_ON (3.3V ON)
5 DIMMER (PWM)
6 H SYNC
CN6702
CN6501
CN6502
CN6201
INV
FAIL
INVERTER
CN6950
CN6703
CN6600
PFC
800VRMS
INV
FAIL
OSC/
DRV
1
4,5
6,7
LCD PANEL
D3N
CN6800
D4N
CN6204
1
2
3
4
5
6
BALANCER_ERR
GROUND
INVERTER_ERR
BACKLIGHT ON
DIMMER
H_SYNC
POWER ON
CN6202
G7N
CN1003
IC3002
TV
MICRO
CN1002
BU
FIGURE 6-3
BACKLIGHT
DIAGRAM
EX2M 52" 52
LCDPANEL
BACKLIGHT
CONTROL
AND MONITORING
CTV-57
34
PANEL ERROR
BACKLIGHT 6X
BALANCER 13X
Backlights Light
At turn-on?
Even lighting
across screen?
Yes
No
LCD Panel
13X
6X
No
LCD Panel
Left Side
Right Side
Yes
No
6X OR 13X*?
*52" only
Yes
Yes
No
FIGURE 6-4
BACKLIGHT TROUBLESHOOTING FLOWCHART
CTV-57
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Chapter 7 Appendix
LCD Panel Troubleshooting
When a customer calls and is complaining of poor picture quality,
colored lines, or no picture at all, it is very important that the technician
rule out the LCD panel assembly as the cause. Technicians should be
using the triage system found on the ASC Portal site and in the back of the
training manuals to assist on which parts should be brought to the location
to service the unit. LCD panels are not suggested to be brought to the
service location based on the customers description of the problem. They
are expensive to ship and prone to damage. The technician must diagnose
the unit and obtain special authorization before the panel can be replaced.
In certain cases it may be determined that it is not economically feasible
to replace an LCD panel for a particular model and that replacement of
the unit would be the best option.
The purpose of this article is to assist the technician in determining if
the LCD panel is defective as efciently as possible. In many cases,
failures of the physical aspects of the panel (panel glass damage, tab
bonding issues) are easily recognized. Failures of the TCON board (which
is considered part of the panel) can sometimes lead the technician to
erroneously change a video process board and have wasted time only to
nd out that panel is the cause of the failure.
CTV-57
Figure 7-1 illustrates a typical LCD panel and the associated video
processing circuits as found in the WAX3 chassis. The various formats
and resolutions of video signals are processed on the BU1 board. All video
signals exit the video processor in the native resolution of the LCD panel.
In this design, the resolution is for a 1280 by 768 at 60HZ refresh rate
panel. 48 horizontal lines are discarded to match up to the 720p resolution
of the ATSC specications so the video will exit as 720p.
The LCD panel used in this model processes 8-bit RGB video data. Before
the video information can be sent to the TCON board it must be converted
to a format that allows for practical and noise-free transmission. The large
number of parallel lines to transmit the 8-bit RGB data would need to be
sent on differential lines for noise reduction. This would require 48 lines
just for the video. The TCON circuit also requires B+, ground connections,
a communications bus, sync, and a clocking line transmitted differentially
so we can see that up to 100 lines would be required. The practical way
to transmit this information is to convert the parallel video data to a serial
stream and this is accomplished by the Low-Voltage Differential Signaling
(LVDS) transmitter.
The LVDS transmitter contains a circuit to serialize the parallel data. The
parallel video information along with sync and clocking data are transmitted
via twisted line pairs. Depending on the logic level, current is sent along
one or the other of the twisted pair of wires. The receiving end of the wires
is loaded with a resistor (usually around 100 to 120 ohms). The receiver
detects the polarity of the voltage drop across the resistor to determine
the logic level. The current level swings in the wire are about 3ma with a
voltage differential of around 350mv. This allows for transmission of the
video signal with minimal EMI.
The LVDS receiver on the TCON board converts the serialized data back
to parallel. This data is processed by the timing control IC to allocate the
RGB data into serial streams for processing by the LCD panel. The LCD
panel contains shift registers and drivers for all of the rows and columns
of pixels on the panel. The drivers are mounted on exible circuit boards
and bonded to the top and side of the panel. Without this arrangement the
TCON would require an IC and connectors to transmit on 4,560 lines!
36
Chapter 7 - Appendix
Panel Failures
The key to good troubleshooting when video quality issues are involved
is the understanding what type of distortions cannot be generated by the
panel. The loss of an entire color is highly unlikely. The LVDS transmitter
does not handle the RGB data as groups. The data (along with sync and
clock) is distributed among 6 separate transmission lines for an 8-bit
panel. A 10-bit panel uses 12 transmission lines. If one of these lines
fails the result is random, multiple colored lines appearing on the screen.
Distortions caused by the panel will be stationary and, in almost all cases,
will consist of a single line or multiple lines in a repetitive pattern. Any
distortion that is not stationary (ying color spots, loss of detail, etc.) is
being generated by the video process circuits on the B board.
Electrical Failures
There are multiple drive ICs located along the top and side of the panel
to de-multiplex the data for all of the rows and columns of pixels. If one
of these ICs fails there will be a cluster of missing information on the
screen. The second photo in Figure 7-2 contains an illustration of a panel
with such a failure.
Although the TCON board is considered part of the LCD panel, we will
focus on the panel itself and discuss TCON failures separately since it
generates symptoms that are quite distinguishable from panel issues.
Panel failures fall into 2 different categories: Physical and electrical.
Physical Failures
The most obvious failure is physical damage to the panel. This can appear
as a small cluster of damaged pixels or a complete shattering of the panel
glass. Another physical failure may appear as a single or several lines
running vertically or horizontally across the screen. The lines may be
brightly lit or dark. This is caused by a failure of the exible printed circuit
where it is bonded to the panel edge. This is known as a tab bond issue.
Do not confuse this with multiple vertical lines across the screen that are of
the same color. This is electrical and usually caused by the TCON board.
Figure 8-5 illustrates some examples of tab bonding issues.
SOURCE DRIVERS
VIDEO
PROCESS
TIMING
CONTROL
LVDS
TRANSMITTER
LVDS
RECEIVER
PANEL B+
BU1
TCON
LCD PANEL
GATE
DRIVERS
FIGURE 7-1
LCD PANEL DRIVE
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Chapter 7 - Appendix
FIGURE 7-2
LCD PANEL FAILURES
CTV-57
38
Chapter 7 - Appendix
TCON Failures
Failures of the TCON circuit can cause a variety of symptoms varying
from evenly spaced multiple vertical lines of the same color, xed random
patterns, colored blotches, or the complete loss of video. A complete
failure of the TCON is difcult to determine since there is nothing on the
display to help troubleshoot and has the same symptoms as a complete
video process failure on the B board. A procedure to help in diagnosing
this failure will be covered shortly.
Figure 7-3 contains several photos of symptoms caused by a failure on
the TCON board. Note the xed and symmetrical lines in the rst 3 photos.
This is a classic timing IC failure on the TCON board. The fourth photo
is interesting. Another task performed on the TCON board is gamma
correction. The correction is performed in dened zones across the entire
panel. The data is stored in an on-board EEPROM. If this data is corrupted
for whatever reason, one or more of the zones will exhibit a severe white
balance issue.
FIGURE 7-3
SAMPLES OF TCON FAILURES
CTV-57
39
Chapter 7 - Appendix
Troubleshooting a Dead TCON
This is a tough one. Fortunately, most of the 2007 Sony models now monitor
the TCON for communications and will shut down with a diagnostics
indication. In units that do not have this feature you will experience
the same symptom as a complete video process failure (no on-screen
graphics, no video, but audio is OK). Based on data gathered from our
panel refurbishing group, about 10 to 15% of TCON failures cause a no
video condition.
If a customer complains of no video from any source you will be asked to
bring a B board to the location since that is the most likely component to
x the problem. What if you install the board and still have no video? Did
you receive a defective B board? Did you overlook any other symptoms?
Make sure you have audio. This is critical. There have been numerous
issues of technicians troubleshooting older models in which the ATI
decoder IC for digital channels is located on a separate board (QM or QBox). When this decoder fails, it kills all video and audio. The technician
changed several parts based on a no video condition and did not bother
to check for the presence of audio. If it is veried that audio is present, the
following procedure can help isolate a defective TCON in most cases.
Warning: Do not attempt to check for data or voltages on the LVDS
connector at the TCON. This advice has been circulating around and is not
recommended. In Figure 7-4 a picture of the LVDS connector is shown. In
order to take a reading from one of the pins, you must insert your probe
between a narrow area that is shielded and at ground potential. Several
of the pins contain B+ for the TCON and panel. It is very easy to short
one of these pins to ground and if it is a B+ line it is guaranteed you will
be replacing a B board whether or not it was the original cause of the
problem. The LVDS connector is shown in Figure 8-7.
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RELEASE TABS
FIGURE 7-4
LVDS CONNECTOR
40
Chapter 7 - Appendix
If the TCON is receiving B+ and functioning properly, the timing circuits
are waiting for RGB data to allocate to the proper pixel. When a video
processor failure occurs, there is simply no data being sent to the TCON
and it does exactly what it is supposed to do: Keep all of the pixels dark.
One trick that works rather well is to partially disconnect the LVDS connector
from the TCON board while the unit is running. Do this very carefully!
Both sides of the connector have release tabs that must be squeezed
inward to release the connector. This was performed over 30 times to the
same television without any damage to the connector or electrical circuits.
Release the connector and carefully pull it partially out of the socket being
careful not to pull one side out much further than the other. Too much
skewing can damage the connector and possibly cause a short on the B+
line. The idea is to remove some of the LVDS data entering the TCON.
If the TCON is functioning the loss of data will cause the timer circuits to
generate random patterns. These patterns may appear as a brief colored
horizontal bar or continuously active random lines covering the entire
screen. The type of response you get will depend on the panel design
and how much LVDS data you have removed. Sometimes a momentary
line will ash on the screen, other times the screen will ll with random
patterns. If you dont see any response, try plugging the connector back
in and pulling it out one more time watching the screen very closely for
any reaction. Figure 7-5 illustrates 2 different types of patterns generated
by the same unit.
If you are able to generate any response on the screen, the TCON is
most likely OK. A TCON that has completely failed (causing a no video
condition) will not produce any pixel lighting on the screen.
FIGURE 7-5
SAMPLE REACTIONS TO LVDS LOOSENING
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