KDL 55 Ex 500

Training Manual
KDL-55EX500
Models: AZ1K Chassis
KDL-55EX500
KDL-55EX501
KDL-60EX500
Triage and Troubleshooting Guide

Course: CTV-65
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Table of Contents
Section 1 - AZ1K Chassis Models Overview ..................... 3 Normal Operation .............................................................. 12
AZ1K Chassis Models Covered....................................... 5 Failure Symptoms .............................................................. 12
Model Introduction ........................................................... 5 No Power/Dead Set (No RED Standby LED) .............. 12
AV Input & Output Descriptions ....................................... 5 55” Power Supply System Block Diagram ..................... 14
RF Input ............................................................................... 5 G5E-Board Connector Diagram .................................... 15
Composite Video & Audio Inputs ......................................... 5 60” Power Supply System Block Diagram ..................... 16
Component/Composite Video & Audio Inputs...................... 6 G8S-Board Connector Diagram .................................... 17
HDMI/DVI Video Input and DVI Video ................................. 6 Protection Mode Symptom Troubleshooting.................. 18
PC Video & Audio Input (and DVI Audio) ............................. 6 Failure Symptoms .............................................................. 18
USB 2.0 Side Connection - Photos & Music ........................ 6 2X Blink - Main Power Error ........................................ 18
Audio Outputs .................................................................. 7 3X Blink- Audio Error ................................................... 18
Fixed Analog Audio Output .................................................. 7 4X Blink - Balancer Failure (55” Model Only) .............. 19
Digital Audio Output (Optical) .............................................. 7 5X Blink - TCON & HFR Failure .................................. 19
55” Model Overall PCB Block Diagram ........................... 8 6X Blink - Backlight System Failure (60” Models) ........ 19
60” Models Overall PCB Block Diagram.......................... 9 6X Blink - Backlight System Failure (55” Models) ........ 19
PCB and Component Descriptions ................................ 10 7X Blink - Temperature Failure .................................... 20
A-Board ............................................................................. 10 55” Model Protection Mode System Block Diagram ...... 21
G5E-Board (55") or G8S-Board (60") ................................ 10 60” Model Protection Mode System Block Diagram ...... 22
D1-Board (55") ................................................................... 10 All Models Power Board Protection Circuits Block
Backlight Inverter Board (60") ............................................ 10 Diagram ......................................................................... 23
HRK-Board ........................................................................ 10 Video Symptom Troubleshooting ................................... 24
Switch Unit ......................................................................... 10 Normal Operation .............................................................. 24
LCD Panel Assembly ..........................................................11 Troubleshooting ................................................................. 24
Missing or Distorted Video (Individual Inputs) ................... 24
Section 2 - Troubleshooting Procedures ......................... 12
Missing Video (All Inputs) .................................................. 25
Power Symptom Troubleshooting.................................. 12
Skewing LVDS Connector Troubleshooting Method .... 25
CTV-65 i

Table of Contents
Distorted Video (All Inputs) ................................................ 25 Flowchart ....................................................................... 35

WIDE Mode Button (Aspect Ratio) Troubleshooting Protection Mode 6X(55”) & 7X Troubleshooting
Method ................................................................... 25
Flowchart ....................................................................... 36
Unique Main Video Board (A-Board) or
Video Troubleshooting Flowchart .................................. 37
LVDS Cable Effects ..................................................... 26
Audio Troubleshooting Flowchart .................................. 38
Unique TCON/HFR Board Effects ............................... 27
Unique LCD Panel Assembly Effects ........................... 27 Appendix............................................................................. 39
Common Main Video Board (A-Board) and LCD Panel Distortion Pictures ....................................... 39
LCD Panel Assembly Effects ....................................... 27 TCON/HFR Board Distortion Pictures ........................... 40
Video System Block Diagram ........................................ 28 TCON/HFR Board Distortion Pictures Continued .......... 41
Audio Symptom Troubleshooting................................... 29 Video Board Distortion Pictures ..................................... 42
Normal Operation .............................................................. 29 Video Board Distortion Pictures Continued ................... 43
Failure Symptoms .............................................................. 29
Missing or Distorted Main Speaker Audio - All Inputs .. 29
Missing or Distorted Main Speaker Audio - Individual
Inputs ..................................................................... 29
Audio System Block Diagram ........................................ 30
Section 3 - Service Mode .................................................. 31

Service Mode Access .................................................... 31
Section 4 - Triage & Troubleshooting Flowcharts .......... 32

Triage Flowchart ............................................................ 32
Power-ON Troubleshooting Flowchart........................... 33
Protection Mode 2X, 3X, & 4X Troubleshooting
Flowchart ....................................................................... 34
Protection Mode 5X & 6X(60”) Troubleshooting
CTV-65 ii

Section 1 - AZ1K Chassis Models Overview
TCON/HFR
Board
D1-Board
Balancer
Board LVDS Cable
G5E-Board
A-Board
Switch Unit
Speaker HRK-Board
Speaker
55" Model
55” OVERALL PCB LOCATION DIAGRAM FIGURE

1-1
CTV-65 3

AZ1K Chassis Models Overview
TV Rear View
Inverter
Inverter
G8S-Board
Switch
Unit
TCON A-Board
Speaker Speaker
HRK-Board
60” OVERALL PCB LOCATION DIAGRAM

FIGURE 1-2
CTV-65 4

AZ1K Chassis Models Covered AV Input & Output Descriptions

KDL-55EX500
KDL-55EX501
USB
KDL-60EX500
Model Introduction Composite
All models contain a Full High-Definition 1920 X 1080 resolution panel.

The backlight is produced using a Cold Cathode Fluorescent Lamp HDMI
Input
(CCFL) light system for all models. All models have the Advanced
Contrast Enhancer (ACE) feature and Dynamic Backlighting. The Dynamic HDMI
Input
Contrast Ratio (DCR) for all models is 150,000:1. All models contain the
BRAVIA Engine™ 2 digital video processor for superior resolution. Plus,
7 HD inputs (4 HDMI™, 2 component and 1 PC) are provided to connect Component/Composite
all of your HD devices including PLAYSTATION®3, Blu-ray Disc™ player Input
and laptop or desktop. Component Input
The BRAVIA Engine 2 fully digital video processor uses a collection of PC Input
PC & DVI Audio Input
unique Sony technologies to significantly reduce noise, enhance overall RF Input
HDMI/DVI
image detail, and optimize contrast so every scene produces sharp, Digital Audio Input
Output
vibrant, life-like images and color. (Optical) HDMI
Analog Audio Input
The EX500 series models contain the Motionflow™ 120Hz frame rate Output
(FIXED)
technology which enhances sharpness and delivers smooth motion for

fast-action sports and movies.
Sony® HDTVs exceed Energy Star 3.0 requirements. In addition, they
incorporate advanced power saving features such as Light Sensor®
RF Input
technology that adjusts backlight intensity based on ambient room lighting This is a 75 ohm connection for either terrestrial NTSC and ATSC (8VSB)
conditions and Dynamic Backlight Control that adjusts backlight intensity or cable QAM64 and QAM256 signals.
based on the brightness of the image on the screen.
Composite Video & Audio Inputs
Yellow Jack - Composite Video Input
Red & White Jacks - Right & Left Audio Input
NOTE: The second composite input is shared with one of the component
inputs. Reference the description of the component inputs for details on
activating the composite input.
CTV-65 5

Component/Composite Video & Audio Inputs HDMI/DVI Video Input and DVI Video
Red, Blue, & Green Jacks - Component Video Inputs Both the HDMI and DVI formats contain digital video. In the case of the
Red & White Jacks - Right & Left Audio Input HDMI format the audio is also digital and is part of the video and audio
NOTE: Composite video can be applied to the component input label data stream over the single HDMI connection. In contrast, the DVI format
“VIDEO IN”. The yellow composite video connector is connected to contains only digital video in its data stream. The audio is sent over a
the green component connector. The audio is connected to the same separate Stereo Mini Jack audio connection. Furthermore, a DVI to HDMI
component audio inputs. adapter is required to connect the DVI connector to the HDMI connector.
IMPORTANT: For automatic signal detection make sure the User Menu The EX500 series models contain the BRAVIA® Sync™ feature (or HDMI
item is set to “AUTO. “ Reference the below for the specific menu item. CEC). With this feature external devices with HDMI CEC capabilities can
The input can also locked to Video 1 (composite) or Component 1 be operated and controlled using only the TV remote controller. Devices
(component) signal. However, the input will only process the chosen such as, Blu-ray Disc™ players, Surround Sound Systems, Handycam®
signal type. If the other signal type is connected the picture will be lost or camcorders, and Cybershot® digital still cameras can all be controlled
black & white. over the HDMI connection.
PC Video & Audio Input (and DVI Audio)

All EX models have a Personal Computer Input (PC-IN), which connects
directly to the PC 15 pin DIN connector (HD15 connector). Once connected
the TV functions as a video monitor and audio output (separate Stereo
Mini Plug) for the PC audio. There is a complete table of PC Input Signal
Select the appropriate input Compatibility in the Owners Manual for each model.
for the input signal type.
Auto – Auto Detection The Stereo Mini Plug is also used for a DVI audio connection at HDMI 1
Video 1 – Composite
Component 1 - Component video input. The DVI video is connected through an adapter to HDMI 1
input and the DVI audio to connected to the Stereo Mini Jack.
USB 2.0 Side Connection - Photos & Music

Connect a camera, USB-Enabled MP3 player, or USB storage device
directly to this side USB input to view JPG photos and MPEG1 & MPEG2
videos on the screen or listen to MP3 music files.
This USB connection is also used for TV Software updates using a USB
drive device.
CTV-65 6

Audio Outputs
Fixed Analog Audio Output
This audio output can be used to listen to the TV audio through an external
AV stereo system. The audio level at the output is set to a fixed level and
cannot be turned off or adjusted.
Digital Audio Output (Optical)

Connects to the optical audio input of any digital audio equipment that is
PCM/Dolby digital compatible. The following table shows the audio inputs
and the audio format which are present at the Optical Audio Output per
input format.
Audio Input Source Optical Output
Digital Tuner 5.1 (ATSC) 5.1 Dolby
HDMI 5.1 5.1 Dolby
All Analog Audio Inputs 2CH PCM
Analog Tuner (NTSC) 2CH PCM
SACD Format (HDMI) No Output
DVD Audio Format (HDMI) No Output
CTV-65 7

55” Model Overall PCB Block Diagram
Switch Unit A-Board
 Power Key Keys
 Function Keys
HRK-Board
 LEDs SIRCS
 IR Sensor
 Ambient Light Level Sensor Optical Digital Audio Output
RF Input
Analog Audio Output
1 Composite Input
 TV Microprocessor
 MT5388 Processor : R
2 Component Inputs Video Processing
(Composite can be applied to Component 1)
HDMI Processing L
HDCP Processing
1 PC Input *High Frame Rate (120HZ)
IP (Image Processor) Standard Frame Rate (60Hz)
Scan Converter (Scalar)
4 HDMI Inputs  ATSC/NTSC Tuner LCD Panel Assembly
 Temperature Sensor
USB 2.0  Audio Output Amplifier LVDS
TCON/HFR Board
Power
LCD Panel
G5E-Board
Control LCD PANEL

Power
AC
Input Power
 Main Power Supply
 Standby Power Supply
 AC Relay D1-Board Control B
A
Control L
HV Drive A CCFL
Power  Backlight High- N
Backlight System
Voltage Circuits Power C
E 55” OVERALL PCB
R
BLOCK DIAGRAM
FIGURE 1-3
CTV-65 8

60” Models Overall PCB Block Diagram
Switch Unit A-Board
Keys
 Power Key
 Function Keys
HRK-Board
Power/
 LEDs SIRCS
 IR Sensor Optical Digital Audio Output
 Ambient Light Level Sensor
RF Input Analog Audio Output
 TV Microprocessor
1 Composite Input
 MT5388:
Video Processing R
2 Component Inputs HDMI Processing
(Composite can be applied to Component 1) HDCP Processing L
IP (Image Processor)
1 PC Input Scan Converter (Scalar) *High Frame Rate (120HZ)
 HDMI Switcher LCD Panel Assembly
3 HDMI Inputs  ATSC/NTSC Tuner
 Temperature Sensor
 Audio Output Amplifier LVDS
1 USB 2.0
TCON/HFR
Power
LCD Panel
G8S-Board
Control LCD PANEL
Power
AC
Input Power
 Main Power Supply

 Standby Power Supply
Control & 24V
 AC Relay Inverter Board HV CCFL
Backlight System
60” OVERALL PCB

24V HV BLOCK DIAGRAM
Inverter Board
FIGURE 1-4
CTV-65 9

PCB and Component Descriptions D1-Board (55")

Reference Figures 1-3 The D1-Board develops the high-volatge that drives the CCFL backlight
system. It takes the 400V from the Main Power supply PFC circuit on
A-Board the G5E-Board and develops approximately 2KVrms to initially ignite the
lamps and 1KVrms to drive the backlight Cold-Cathode-Fluorescent Lamps
The circuits located on the A-Board perform all Video and Audio processing (CCFL) in normal operation. The backlight ON and Dimmer functions are
functions. It also contains all the microprocessor control circuits. The also performed on the D1-Board.
following circuits are included on this board.
• TV Microprocessor Backlight Inverter Board (60")
• MT5388 Processor There are two (right and left) Inverter boards in the 60” models.
- Video Signal Processing NOTE: The Inverter boards are not available as separate parts. If a
- HDMI Signal Processing Inverter board is found to be defective the complete LCD Panel assembly
- Scan Converter must be replaced.
- HDCP Processing The 24V developed in the Main Power Supply on the G8S-Board powers
the Backlight Inverter Boards. The Inverter Board takes that 24V and
• Audio Amplifier develops approximately 2KVrms to initially ignite the lamps and 1KVrms
• Temperature Sensor to drive the backlight Cold-Cathode-Fluorescent Lamps (CCFL) in normal
operation.
G5E-Board (55") or G8S-Board (60")
Except for some regulator circuits on the A-Board, the G2LE-Board or HRK-Board
G2HE-Board is the power supply system board for the 32” and 40” models, • Function LEDs`
which includes the following components and circuits. • IR Sensor
• Main Power Supply • Ambient Light Level Sensor
• 12V
• AU12V (Audio Amp) Switch Unit
• 24V (Backlight Inverter) (60”) • Power Key
• Standby Power Supply • Function Keys
• 3.3V for standby circuits
• Power Factor Control Circuit (PFC)
CTV-65 10

LCD Panel Assembly

The LCD Panel Assembly includes the LCD Panel, TCON/HFR Board ,
and CCFL Backlight system.
The LCD Panel contains the actual liquid crystals, color filters, and
polarizers. The liquid crystals are manipulated by the applied voltage to
pass a specific amount of light - from the backlight- depending on the level
of voltage applied.
The TCON performs all the control, timing, charge, and discharge functions
driving the operation of the LCD Panel. The HFR (High Frame Rate)
section performs the 60Hz to 120Hz frame refresh rate conversion.
A replacement LCD Panel assembly from parts will include the following
items.
55” Models:
1) LCD Panel and Backlighting Components
2) TCON/HFR Board
3) Balancer Board
60” Models:
1) LCD Panel and Backlighting Components
2) TCON/HFR Board
3) Inverter Boards
CTV-65 11

Section 2 - Troubleshooting Procedures
Power Symptom Troubleshooting Failure Symptoms

Reference Figures 2-1, 2-2, 2-3, and 2-4
Normal Operation
Reference Figure 2-1 and 2-2 No Power/Dead Set (No RED Standby LED)
110VAC is applied directly to the G5E-Board or G8S-Board. It can be In a dead set condition there will be No RED Standby LED illumination in
measured at CN6102 or CN1 respectively. In the standby mode the AC the Standby Mode (TV plugged into an active AC Outlet).
power passes through the main fuse F6101 or F101. The AC power passes The following bullet list gives the possible failures for a “No Power/Dead
through R6118 or R106 (Inrush resistors), and D6001 and is applied to Set” condition.
the Main DC/DC Converter IC6301 and the Standby DC/DC Converter
• Loss of AC Power (Dead AC Wall Outlet)
IC6103 on the G5E-Board. IC6301 is not active in the standby mode.
However, IC6103 is active in standby mode and outputs STBY 3.3Vdc • Loss of AC-OFF-DET
as long as AC power is applied to the TV and the RED Standby LED is • Loss of Standby 3.3Vdc
illuminated on the front panel. The Standby 3.3Vdc is supplied to the TV-
• Loss of REG12V
Microprocessor, Switch Unit (Power Key), and HRK-Board (IR Sensor) in
the standby mode. The G8S-Board has three separate power supplies for • Loss of Power-On
the 24V, 12V, and Standby 3.3V supplies. However, the basic operation • Defective Main Microprocessor
is the same as the G5E-Board. Only the Standby 3.3V is active in the
The first step in troubleshooting a “No Power/Dead Set” condition is to
Standby mode.
confirm that 110ACV power from an active AC wall outlet is applied to the
Once a ON command is received form the remote controller or the power G5E-Board or G8S-Board. AC power is applied to, and can be measured
button on the Switch Unit the TV-Microprocessor outputs the Power-ON at CN6102 on the G5E-Board and at CN1 on the G8S-Board.
signal. The Power-On signal is applied to the G5E-Board or G8S-Board.
Next, check for the presence of the AC-OFF-DET voltage at CN6201/pin 2
On the power supply board the Power-On signal switches the 19V from
or CN2/pin 2. If the AC-OFF-DET circuit is working properly 3V should be
the standby power supply to activate the PFC and Main Power supply
measured. If the 3V is not present replace the G5E-Board or G8S-Board.
IC6301. One relay click is heard at power-on. The relay engages to bypass
If the 3V is present, then the Standby Power supply, Main power supply,
the inrush resistors R6118 or R106 during the ON state.
or Main microprocessor is defective. Further troubleshooting is necessary
The main power supply IC6301 (Z501, 60”) is now active and outputting all to determine the defective component.
secondary supplies. The 12Vdc secondary is the supply voltage for all the
After confirming the AC power and AC-OFF-DET, check for a defective
voltage regulators on the A-Board. The AU12V is the supply voltage for
Standby 3.3Vdc power supply. Check for the 3.3V secondary voltage at
the audio output amplifier. The 60” model’s power supply (Z301) will also
CN6201/pin 1 or CN2/pin 1. As long as AC power is applied to the TV
output 24V which is the supply voltage for the backlight inverter boards.
the Standby power supply should be active and outputting 3.3Vdc. If the
The D1-Board in the 55” model will develop and output the backlight high- 3.3V is not present then Standby power supply is defective. Replacing the
voltage (1KV) to the Balancer board and the CCFL backlights. power supply board will fix the problem.
If the Standby 3.3V is okay, the next step is to check the REG12V from
CTV-65 12

the Main Power supply. A loss of the REG12V will cause a “Dead Set”
condition on these models. Check for the 12V at CN6201/pin 9 on the
G5E-Board or CN2/pin 9. If the 12V is missing replace the power supply
board.
Finally, a “Dead Set” condition can be caused by a defective microprocessor
IC400. The microprocessor outputs the Power-On signal which activates
the switch circuit on the power supply board and passes the 19V from
the Standby power supply to active the Relay, PFC, and Main Power
Supply circuits. If the Power-On signal is not output after receiving the
Power-ON command the power supply board circuits remain inactive and
a “Dead Set” condition exists. The Power-On signal can be checked at
CN6201/pin 3 or CN2/pin 3. It should measure approximately 3.3Vdc If
the measurement is 0Vdc after pressing the power button then the TV
microprocessor is defective. Replace the A-Board. If the power-on voltage
is 3V after pressing the power button then the switch circuit on the power
supply board is defective. Replace the power supply board.
CTV-65 13

55” Power Supply System Block Diagram
D1-Board CN6704
LCD Panel
HV Assembly
1.1KV (~2KV Strike Voltage) CCFL
CN6705
Backlight Inverter High Voltage Circuits HV Balancer Board Backlights
CN6702
FB
LD
CN6703 CN6600 12V
2 3 6 4 LCD
2 3 6 4
G5E-Board A-Board PANEL
CN6401 CN6301 400V CN6201 CN201
DIM BL- 12V F1
ON AU12V IC8151
IC6301 4 4 LCD
Audio Output Amp
R6118 Main Panel
Power
D6301 R6350 PS6402 LVDS
CN6102 F6101 L6301 Supply IC8301
D6309 0.1ohm Cable
& Line Out Amp TCON/
PFC HFR
12V LVDS 12V
Q6303 14 10 8
IC266 5V
RY6102 To CN4152
5V Reg
AC VSense Tuner
Input
D6302 PFC_OUT 12V IC231 5V
R6314 R6315 9 9 To USB
AC_DET 5V Reg
To Optical Out
AC_DET IC232 IC267
1V Reg 3V Reg
VCC
To Micro
ON/OFF IC268 IC269
1.25V Reg 1V Reg
19V PS6401
CN6403
12V To Micro To Micro
2 To DDR
12V TCON 12V
Q6403 2
A-Board
Switch 3V 15 15 TCON ON
Circuit
3V Power ON
IC6104 PH6301 3 3
R6153
10ohm 19V
IC6103
Standby IC400
STBY 3.3V MT5388
3.3V 1 1
Power
Supply
3V AC-OFF-DET
2 2
CN6201 CN201
55” POWER SUPPLY SYSTEM DIAGRAM
FIGURE 2-1
CTV-65 14

G5E-Board Connector Diagram
7 - LD
6 – 12V
5 - Ground
5 – 400V 4 – BL-ER
4 – NC 3 – BL-ON
3 – Ground 2 – Dimmer
2 – NC 1 – H-Symc
1 – 12V
CN6401
CN6301 6 – Ground
5 - Ground
CN6403 4 – Ground
3 – TCON 12V
2 – TCON 12V
1 – REG12V
15 – TCON -ON
HV 14 – TCON 12V
13 – NC
12 – DIMMER
CN6201 11 – BL-ON
D1-Board G5E-Board 10 – BL-ERR
9 – REG12V
8 – REG12V
7 – Ground
HV 6 – Ground
IC6103
5 – Ground
4 – AU12V
3 – POWER-ON (3V)
2 – AC-OFF-DET (3V)
AC Relay 1 – STBY 3.3V
5 – 400V 7 - LD
4 – NC 6 – 12V
3 – Ground 5 - Ground
2 – NC 4 – BL-ER
1 – 12V 3 – BL-ON F6001
2 – Dimmer
1 – H-Symc
CN6003
AC Input
G5E-BOARD & D1-BOARD CONNECTOR DIAGAM

FIGURE 2-2
CTV-65 15

60” Power Supply System Block Diagram
G8S-Board CN4 Backlight HV
24V HV Inverter
3
Board
CCFL
Z301
24V 24V Backlight HV Backlights
3 HV Inverter
Power
Supply Board
CN5 LCD Panel Assembly
LCD
A-Board
PANEL
CN2 CN201
AU12V F1
IC8151
R106 4 4 LCD
Audio Output Amp
Panel
RC101
RC102 L201 RC201 LVDS
CN1 F101 RL101 L202 IC8301
RC202 Cable
Line Out Amp TCON/
12V LVDS 12V HFR
14 10 8
Z251 IC266 5V
From To CN4152
PFC 5V Reg
AC Q751 Tuner
Input Z501
12V 12V IC231 5V
9 9 To USB
Power 5V Reg
To Optical Out
Supply
IC232 IC267
12V 1V Reg 3V Reg
To Micro
Power IC268 IC269
ON F751 1.25V Reg 1V Reg
CN3
Panel 12V To Micro To Micro
1
To DDR
12V TCON 12V
Q751 2
To CN2 A-Board
3V 15 15 TCON ON
Q208
19V Switch 3V Power ON
PH201 3 3
Circuit
Z401 IC400
Standby STBY 3.3V
1 1 MT5388
3.3V
Power
Supply
3V AC-OFF-DET
PH202 2 2
CN2 CN201
60” POWER SUPPLY SYSTEM DIAGRAM
FIGURE 2-3
CTV-65 16

G8S-Board Connector Diagram
1 – UNREG24V
2 – UNREG24V
3 – UNREG24V
4 – UNREG24V
5 – UNREG24V
6 – Ground
7 – Ground
8 – Ground
9 – Ground
10 – Ground
1 – REG12V
2 – TCON12V
3 – TCON12V
1 – UNREG24V CN4 CN3
4 – Ground
2 – UNREG24V 5 – Ground
3 – UNREG24V 6 – Ground
4 – UNREG24V
5 – UNREG24V
6 – Ground 15 – TCON-ON
7 – Ground CN5 14 – TCON 12V
8 – Ground 13 – NC
9 – Ground F751 CN2 12 – DIMMER
10 – Ground 11 – BL-ON
11 – BL-ERR 10 – BL-ERR
12 – BL-ON 9 – REG12V
13 – NC G8S-Board 8 – REG12V
14 - Dimmer 7 – Ground
Z401
6 – Ground
5 – Ground
4 – AU12V
3 – POWER -ON (3V)
Z301 Z501 2 – AC-OFF-DET (3V)
1 – STBY 3.3V
RY101
F101
CN1
AC Input
G8S-BOARD CONNECTOR DIAGAM

FIGURE 2-4
CTV-65 17

Protection Mode Symptom Troubleshooting • Excessive PFC Temperature (OTP)

Reference Figures 2-5, 2.6, and 2-7 *Low Voltage Protection (LVP)
The KDL-55EX500, KDL-55EX501, and KDL-60EX500 include the *Over Voltage Protection (OVP)
following protection mode blink patterns (or self-diagnostics). A loss or excessive condition of the AU12Vdc secondary voltage from the
main power supply will cause a 2X blink pattern on the Standby-LED. The
Possible Error
Protect Description Blink Pattern 12Vdc can be checked at CN6201/pin 9 or CN2/pin 9.
Location
If the measurement is 0V or rises above 12Vdc (approaches 15V) before
G5E, G8S-Brd, or A-
Main Power Error 2 the TV shuts down then the G5E-Board or G8S-Board is defective.
Brd
A-Brd or G5E, G8S- If approximately 12Vdc is present and remains below 12Vdc before
Audio Error 3 shutdown then the A-Board is defective.
Brd
LCD Panel, A-Brd, D1- An excessive 24Vdc (60” Model) secondary voltage from the power supply
Balancer Error (55”) 4 Z301 will also cause a 2X blink pattern on the Standby-LED. The 24Vdc
Brd, or G5E-Brd
TCON/HFR Brd or A- can be measured at CN4/pin 3 or CN5/pin3 on the G8S-Board before the
TCON Error 5 TV shuts down. If the voltage rises above the 24V level (approaches 27)
Brd
before the TV shuts down then the power supply is defective, replace the
TCON/HFR Brd or A- G8S-Board to fix the problem.
HFR Error 5
Brd
Finally, there are PFC protection circuits on the power supply board that
G8S-Board,D1-Brd,
Backlight Error 6 when activated will cause a 2X blink protection mode (reference Figure 2-
LCD Panel,or A-Board
7). The PFC circuit is monitor for both over-voltage and over-temperature.
Temperature Error 7 Ventilation or A-Board Therefore, if the AU12V and 24V circuits checkout okay, there could still
NOTE: All red protection mode LED blink patterns occur using the be a problem on the power supply board in the PFC circuit causing the 2X
Standby-LED at the lower left front of the TV. blink. Replace the G5E-Board or G8S-Board to fix this condition.
Failure Symptoms 3X Blink- Audio Error

The Audio error can occur due one of the following error conditions.
2X Blink - Main Power Error • Shorted or Damaged Speaker Connections
A 2X protection mode blink pattern can be activated due one of the • Defective Audio Amplifier (A-Board)
following defects on the G5E-Board or G8S-Board..
• Loss of AU12V (Open F1 on A-Board)
• Loss of AU12V (LVP)*
The first thing to check when a 3X blink protection mode occurs is the
• Excessive AU12V Level (OVP)* physical condition of the speakers and speaker connections. The speakers
• Excessive 24V Level (OVP) (60” Model) should measure 8 ohms. Shorted speakers or connections can cause a
3X blink protection mode.
• Excessive PFC Voltage (OVP)
CTV-65 18

If the speakers and connections check okay, then the defective component • Defective TV Microprocessor
is on the A-Board. Either a open F1 or defective audio amplifier will cause • Defective 24V Power Supply
a 3X blink protection mode. In either case, replace the A-Board to fix this
condition. When troubleshooting a 6X backlight system failure it is key to notice if
the backlights illuminate before the TV shuts off. The following list shows
the possible backlight status and blink pattern and the possible failed
4X Blink - Balancer Failure (55” Model Only) components.
In most cases, a 4X protection mode indicates a defective lamp or lamps. 1) Momentary Backlight and 6X
A defective panel can be confirmed by checking the LD protection voltage
a) Defective Lamp (Part of LCD Panel Assb)
level at CN6702/pin 5. In normal operation LD should be 12V. If the voltage
goes low then replace the LCD panel to fix this condition. If the voltage b) Defective Backlight Inverter Brd (Part of LCD Panel Assb)
is 12V then there could be a problem on the A-Board or D1-Board. First 2) No Backlight and 6X
replace the D1-Board then the A-Board.
a) Defective TV Microprocessor
5X Blink - TCON & HFR Failure b) Defective 24V Power Supply
The 5X blink protection mode indicates a communications error between c) Defective Backlight Inverter Brd (Part of LCD Panel Assb)
the TCON/HFR board and the MT5388 microprocessor on the A-Board. IMPORTANT: If there is no backlight before the TV shuts off and
First replace the TCON/HFR Board if the 5X protection mode blink pattern activates a 6X, than check the “Backlight ON” signal from the TV
occurs. If the TCON/HFR Board does not repair the problem then replace microprocessor and the 24V power supply from the G8S-Board.If the
the A-Board. “Backlight ON” and 24V power supply are okay than the Backlight
Inverter board has failed and the LCD Panel Assembly must be
6X Blink - Backlight System Failure (60” Models) replaced.
NOTE: All models will make three attempts to power up before a 6X 6X Blink - Backlight System Failure (55” Models)
error is activated. The SONY logo (Backlight) will display on the screen
and the tones (with Volume up) will be heard three times. After the The 55” models have both a 4X and 6X blink protection mode. The 4X
third attempt the TV will turn off and the Standby LED will blink a 6X blink will, in most cases, be caused by a defective lamp (Reference 4X
protection mode. Blink description).
In most cases, if the backlight momentarily illuminates and the TV The visual symptom for a 6X Blink error for the 55” model will be “No
shuts off and a 6X is activated than one or more of the backlight lamps Backlight Illumination” before shutdown. Because all the Backlight HV
are defective. The LCD Panel assembly panel must be replaced for a Inverter circuits are located on the D1-Board, a 6X blink protection
defective lamp. mode will be fixed, in most cases, by replacing the D1-Board. If the D1-
If a 6X blink pattern is activated than a defect has occurred in one of the Board does not repair the problem replace the A-Board. The BL-ON
following areas. and Dimmer signals come from the microprocessor on the A-Board.
A shorted or open BL-ON signal will cause this 6X condition. Also a
• Defective Panel Lamp(s) shorted Dimmer will cause this 6X condition.
• Defective Backlight Inverter Board
CTV-65 19

7X Blink - Temperature Failure In either case the A-Board must be replaced to fix the problem.
These models do not display a temperature warning OSD dialogue box
before shutting-off and going into a 7X Standby-LED blink pattern. It
will just shut-off and activate a 7X without any usually warning on the
screen.
The main objective when a 7X blink pattern occurs is to determine which
of the following possible defects is causing the excessive temperature
condition.
• Excessive Ambient Room Temperature
• Dust or Debris Blocking the TV Ventilation Apertures
• Defective Temperature Sensor IC4305 or MT5388
microprocessor (A-Board)
The first step is to notice how long it takes the TV to shut-off and trigger a
7X blink protection mode.
If the TV has an actual excessive temperature condition it will take a
considerable period of time to shut-off and indicate a 7X blink protection
mode. This is because it will take time for the TV to heat up and for the
temperature sensor to detect the excessive temperature and shut the TV
off
If the TV takes a considerable period of time to shut-off check the following
items:
• The TV should not be located too close to any heating
elements.
• The TV should have at least 4 inches of clearance around all
sides to ensure adequate ventilation.
• Check that all vented areas on the TV are clear of all Dust and
Debris.
If the TV shuts-off immediately (Not an Actual Excessive Temperature
Condition) after Power-ON then one of the following components has
failed.
• Main Microprocessor IC3002 (A-Board)
• Temperature Sensor IC3502 (A-Board)
CTV-65 20

55” Model Protection Mode System Block Diagram
G5E-Board A-Board
AC
CN6102 CN6201 CN201
Input
Main 12V Interface
3V
RECT 8 9 DC_Detect
PS Circuit
RECT & 2X
PFC Dimmer
12 IC400
BL_ON MTK5388
11
BL_ERR
10
3.3V
STBY 1 1 Standby 3.3V
PS
3V
SW 3 3 Power ON
CN6401
Dimmer 2
BL_ON 3
BL_ERR 4 BL_ERR
CN6301 IC4305 4X & 6X
Temp
Sensor Temp_ERR
Protection Circuit
Q8153, Q8155
70C 7X
D1-Board CN6600 Q8158, Q8160, Audio_ERR
400V
Q8156 3X
CN6703
IC8151
Dimmer 1V to 3V
12 Audio
BL_ON 3V
11 Amp
BL_ERR 0V
10
CN8151
LCD Panel Assb
CN8152
CN6704 CN4152
B
CN6705 TCON
A
HV L SDA (I2C)
Backlight Inverter TCON_ERR
High Voltage A 5X
BL* HFR
Circuits HV N HFR_ERR
C 5X
FB E
2
R
LD
5
12V
CN6702
*BL - Backlight
55” PROTECTION CIRCUITS DIAGRAM

FIGURE 2-5
CTV-65 21

60” Model Protection Mode System Block Diagram
G8S-Board A-Board
AC
Input CN1 CN2 CN201
12V AU12V Interface
Fuse RECT 8 9 DC_Detect
PS Circuit
2X
1V to 3V Dimmer
13 13
3V BL_ON
12 12
0V BL_ERR IC400
11 11 MTK5388
3
24V 24V
3
PS
CN5
3
CN4 Backlight_ERR
IC4305 6X
Temp
Sensor Temp_ERR
LCD Panel Assb Protection Circuit 70C
Q8153, Q8155 7X
Q8158, Q8160, Audio_ERR
HV Inverter Board HV Inverter Board
Q8156 3X
24V 24V IC8151
Dimmer
Audio
BL_ON
BL_ERR Amp
CN8151
CN8152
CN4152
Backlight Backlight
Inverter Inverter
High HV HV LCD TCON SDA (I2C)
High BL TCON_ERR
Voltage Panel -HFR
Voltage 5X
Corcuits Corcuits HFR_ERR
5X
60” PROTECTION CIRCUITS DIAGRAM

FIGURE 2-6
CTV-65 22

All Models Power Board Protection Circuits Block Diagram
G5E-Board (55") 60" Model ONLY

CN6102 (55") G8S-Board (60") CN4
CN1 (60") CN5
3 To Inverter Board
Reg 24V
REC 3 To Inverter Board
AC
Reg 12V
PFC Power 9 To A-Board
Input
OVP Supply
& PFC
REC Circuits
30V 15V G5E-Board &
Zener Zener G8S-Board
OTP 24V 12V Protection
OVP OVP circuits will
PFC
cause a 2X
OTP
blink pattern
Latch Circuit
19V Switch Circuit 3V 3 Power-ON

Pulls CN2 (60") From A-Board
Power_ON CN6201 (55")
Low
OVP – Over Voltage Protection

OTP – Over Temperature Protection
PROTECTION CIRCUITS DIAGRAM

FIGURE 2-7
CTV-65 23

Video Symptom Troubleshooting Video Anomaly:

Reference Figure 1-8 • Poor Detail
• Moving Video Distortion (e.g. Bars)
Normal Operation • Static H/V Lines (Any Color)
All video processing is performed by IC400 (MT5388) on the A-Board. • Static Missing Pixels (Any Color)
The RF input is first processed by the RF Tuner and is then applied to
• Static Bars (Solid Black or White, Transparent Color)
IC400. Both the ATSC and NTSC signal are processed by IC400. All four
HDMI inputs are first applied to a HDMI switch circuit (IC6601). The switch • White Balance
circuit applies the selected input to IC400. IC6601 also contains the EDID • Gamma
(Extended Display Identification Data), which is part of the HDMI hand-
The main objective when troubleshooting one of the previously listed
shake process.
symptoms is to determine if the defect exists in the following sections of
All other inputs (Composite, Component, PC, and USB) are connected the TV system.
directly to IC400 inputs.
• LCD Panel Assembly
The USER, White Balance, and Gamma data is stored in IC4302.
• TCON/HFR Board
Both the USER Menu and Service Mode screen are generated by, and
output from IC400. • A-Board
IMPORTANT:
Missing or Distorted Video (Individual Inputs)
1) Confirm the TV has the most recent Software Version installed.
Go to the User Menu for the present TV software revision and The primary objective is to locate the defective component through
the ASC web site for the most recent software version. activating each individual video input and checking for any abnormal
symptoms on the screen. If the video distortion appears only in one or
2) Before proceeding with the following video troubleshooting two video inputs then the next step is to eliminate the possibility of a
procedures it is assumed that the TV is turning on with the defective or improperly connected external device such as, a STB, DVR
Green Power-LED illuminated, Backlight is illuminated or DVD player. The quickest way to troubleshooting the external devices
(brightened raster), and the Audio is present. is to swap the suspect device with a known good device at the input in
question.
Troubleshooting If the external device or connections are defective then the TV is okay
When a video problem occurs you will experience one of the two following and the external device and connections need to be serviced. If the
symptoms. external devices and their connections are okay, then the next step is to
Input Status: troubleshoot the problem by accessing and displaying each video input.
• Missing or Distorted Video (Individual Inputs) The rationale behind this troubleshooting method is that each of these
video inputs takes an altogether or somewhat different path through the
• Missing or Distorted Video (All Inputs) video processing system. This fact enables you to determine the defect,
CTV-65 24

in some cases, down to the component level, and in almost all cases, 2) Check for TCON 12V at CN4152/pins 4 - 10 & CN6151/pin 2
down to at least the board level. For example, if the distortion appears in a) No 12V. Check connections between A-Board & Panel
a HDMI input but not in any other inputs (e.g. composite or component)
then most likely the HDMI Switcher (IC6601) is causing the distortion. b) 12V Present. Go to Step 3
The reason for this conclusion is because the HDMI signals are the only 3) Check LVDS Cable Video Signal Levels at CN4152
signals to pass through IC6601 before being applied to IC400. All other a) LVDS Video Signal(s) Low or Missing. Replace A-Board
input signals bypass IC6601. The composite and component signals go
directly to the video processor IC400. b) LVDS Video Signal(s) Okay. Replace TCON/HFR Board
Although all the individual input circuits are located on a single board (A-
Board), the previously described troubleshooting procedure can still serve
Skewing LVDS Connector Troubleshooting Method
as a reliable confirmation of a defective component on the A-Board before It maybe difficult or impossible to check the LVDS signal while in the field.
replacing the board. Therefore, a quick and somewhat reliable method of checking the TCON/
HFR operation is to skew the LVDS connector out of the its mount at the
The same deductive reasoning can be applied when troubleshooting
TCON/HFR Board. When performing this method it is important to keep
video defects using the other video inputs shown on the flowchart (Section
the 12V end of the connector connected while dislodging the LVDS video
4). This method simply involves knowing the path the input signal must
connections. Therefore, find the 12V using a voltmeter. The 12V is usually
take through the video processing system to reach the display. With this
on one end of the connector (usually left-side on bottom mount or top on
knowledge you can effectively divide the video system into distinct areas,
side mount connect).
and therefore, isolate the defect.
When skewing the connector if color flashing occurs on the screen then
the TCON/HFR Board is most likely okay and the A-Board is defective. If
Missing Video (All Inputs) the is no video reaction on the screen while skewing the connector then
If the video is completely missing you will first use the User Menu (On- the TCON/HFR Board is defective.
Screen-Display - OSD) in an attempt to isolate the defect to the A-Board
or the TCON/HFR Board.
Distorted Video (All Inputs)
If the OSD can be displayed then the TCON/HFR Board is okay, and
The following paragraphs describe the unique and common effects the LCD
you can safely assume the defect exists on the A-Board. However, if the
Panel Assembly, TCON/HFR Board, and A-Board have on the displayed
OSD cannot be displayed you need to do further troubleshooting because
video concerning possible distortions. Knowing how each component
either IC400 on the A-Board is not sending the OSD or the TCON/HFR
affects the displayed video can be very helpful in troubleshooting a
Board is not able to process the OSD and display it on the LCD Panel.
distorted video condition.
If the OSD cannot be displayed then the LVDS signal levels must be
NOTES: Reference Appendix for picture examples of unique distortions
checked to reliably determine whether the A-Board or the TCON/HFR
for the LCD Panel, TCON/HFR Board, and the A-Board
Board is defective.
1) Check for USER Menu OSD Display WIDE Mode Button (Aspect Ratio) Troubleshooting Method
a) USER Menu Displays. Replace A-Board A quick test to determine if the A-Board, TCON/HFR, or LCD Panel is
b) USER Menu Does Not Display. Go to Step 2 causing the distortion is to change the panel aspect ratio (or picture size).
CTV-65 25

The aspect ratio can be easily changed using the “WIDE” key on the • Color Distortion - A color distortion can be caused by a
remote controller. If the distortion follows the video then the A-Board is defective IC400 or LVDS cable. The individual color signals
causing the distortion. If the distortion remains stationary after changing are spread out over the LVDS twist pair wires. For example,
the aspect ratio then the LCD Panel assembly is causing the distortion. the Red signal may be broken up into three components and
sent over three different LVDS twisted pairs. Therefore, this
WIDE Mode distortion will display as a poor reproduction of a particular
Button
color not an overall loss of one color. Use a Red, Green, and
Blue raster generator to confirm a poor reproduction of a
WIDE Mode single color.
Function
• Loss of a Single Color - A loss of a single color can only be
caused by a defective MT5388 (IC400). Use a Red, Green,
and Blue raster generator to confirm a complete loss of a
single color.
• RF Signal Distortion - A weak video signal from the antenna
or cable connection can cause RF video distortions. The signal
strength of the Digital Signals can be checked in the USER
menu. Go to the Product Support and Signal Diagnostic item to
check signal strength and errors. NOTE: This is only for digital
channels. No information will display for analog channels. The
Unique Main Video Board (A-Board) or LVDS Cable Effects SNR should be in the range of 25db to 30db and there should
be zero Errors.
A video distortion that has soft edges and/or is moving through the video
is most likely caused by a defect in the video processing circuitry. All video
processing circuitry is located on the A-Board. Therefore, replace the A- Signal Diagnostics
Board if the video distortion has soft edges and/or is moving through the
video on the screen. Macro-Blocking (digital picture breakup) is a good
example of this type of distortion. Be careful though, macro-blocking can
also be caused by a weak RF signal when the TV is in the tuner mode.
• Poor Picture Detail - Loss of overall picture detail. A loss Product Support
of information on the LVDS lines from IC400 will cause poor

overall picture detail.
• Abnormal Picture Size or Geometry- The video signal scaler
circuit is located on the main video board A-Board. Therefore, Signal Diagnostics
if either the picture size or geometry is abnormal the A-Board Screen
is defective. Only the A-Board can cause such a distortion.
CTV-65 26

Unique TCON/HFR Board Effects • 2” Vertical Solid White or Black Bar- The bar will be
• 2” Vertical Transparent Colored Bar- The bar will be approximately 2" because this is the area that is controlled
approximately 2" because this is the area that is controlled by a single drive IC that is located across the top of the LCD
by a single drive IC that is located across the top of the LCD Panel assembly.
Panel assembly. • Horizontal Bar- Any horizontal bar of any color will be caused
• Video Timing - The Video Timing distortion may appear as a by a defective LCD Panel assembly
double image or ghosting type distortion.
Common Main Video Board (A-Board) and LCD Panel
• Loss of Half Screen Video - Half the screen will have live
Assembly Effects
video and the other half will be a white raster.
• White Balance (WB) Irregularity - A WB irregularity will
• Half or Full Screen Video Distortion - In this case, the key
show up as an overall poor reproduction of white. A white
distinguishing factor is the presence of undistorted video
raster can be used to determine if a WB or gamma irregularity
behind the color distortion. The distortion is basically an
has occurred. WB will cover the complete picture, where as,
overlay (transparent color half-screen or bar) in front of the
gamma will be in specific zones or specific color areas in the
good video coming from the A-Board.
picture. WB adjustment data is stored in the EEPROM IC4302
• White or Colored Blooming - The bloomings may come on the A-Board. The WB data stored in IC4302 is set to the
down from the top of the screen and vary in size. middle value of the data span. The TCON/HFR Board also
• GAMMA Irregularity - A GAMMA distortion will appear contains WB data, which is specifically set for the associated
as a overall brightness problem or a localized area color LCD Panel.
distortion. • GAMMA Irregularity - Gamma Correction affects the overall
picture brightness level and individual color (RGB) brightness
Unique LCD Panel Assembly Effects levels. Gamma adjustment data is stored in the EEPROM
• Line(s) of Pixels (Fixed Position) - Poor physical connection IC4702 The TCON/HFR Board also contains GAMMA
(or bonding) between the LCD Panel and the flex cables will data, which is specifically set for the associated LCD Panel.
cause a loss of line(s) of pixels. The pixel drive lines can be The data may become corrupted causing irregular gamma
open (no drive) or shorted (drive all the time). Depending on adjustment. Therefore, a gamma distortion can show up as a
the type of failure the line(s) or pixel(s) will be black, white, or color brightness irregularity in specific zones or specific color
colored (red, green, or blue). These lines and pixels will also areas in the picture, as well as an irregularity in overall picture
be very sharp in detail. brightness.
• Random Line(s) of Pixels (Random Movement) - The

TCON board controls the charging and timing of the pixels.
If the TCON Board is partially defective random lines and/or
pixels will be seen flashing across the screen. These lines
and pixels will be very sharp in detail, like a specific line of
pixels are randomly turned off and on.
CTV-65 27

Video System Block Diagram
A-Board User Menu Service Mode
TM701
RF Input NTSC/ATSC IC4302
Tuner NAND FLASH
Video 1 (Component & Composite) User Data
White Balance
GAMMA
Video 2 (Composite / S-Video)
Video 3 (Component)
LVDS Cable LCD Panel Assembly
CN4152
PC Input
1 LCD Panel
/
HDMI IN 1 IC400 49 TCON/ LCD
MTK5388 Panel
4 HFR
HDMI IN 2
IC6601
LVDS 12V /
HDMI (HDCP) 10
Switch
HDMI IN 3
(EDID)
CCFL
HDMI IN 4 Backlight
TCON 12V 12V System
USB 2.0 From Power

Supply Board
IC303
Sub
Micro
VIDEO SYSTEM
FIGURE 2-8
CTV-65 28

Audio Symptom Troubleshooting Missing or Distorted Main Speaker Audio - All Inputs
Reference Figure 2-9
In this case, the most likely defective is the A-Board. Before you replace
the A-Board perform the following test procedures to confirm the actual
Normal Operation defective component.
The HDMI digital audio signal is first applied to the HDMI Receiver/Switch 1) Check for audio at the Analog FIX or DIGITAL Audio Outputs
IC6601 and then to the MT5388 on the A-Board.
a) No or Distorted Audio (Replace A-Board)
The RF input is first applied to the Tuner and then to the IC400. The Tuner
outputs the ATSC and NTSC signals as an IF signal to IC400. b) Audio Present & Undistorted. Go to Step 2
All other audio inputs are applied directly to IC400. The MT5388 IC400. 2) Check for AU12V at CN201/pin 1 on A-Board
outputs the audio signal as a SPDIF signal for the Optical output. The a) No AU12V - Check connections between the Power Supply
FIXED analog audio output passes through an amplifier IC8301 and then board and the A-Board
is applied to CN8301. b) AU12V Present replace A-Board
The main speaker audio comes from IC400 and passes through amplifier
IC8151 and then to CN8151 and CN8152 speaker connections.. Missing or Distorted Main Speaker Audio - Individual Inputs
The AU12V from the G5E, or G8S-Board is the power supply for the audio If only one or a select number of input sources are experiencing a problem,
output amplifier IC8151. then the individual inputs must be checked separately. The external
IMPORTANT: devices and their associated cables connected to the faulty input should
be checked first.
• Confirm the TV has the most recent Software Version
installed. Go to the User Menu for the present TV software Substitute a known good device and cable on the suspected faulty input.
revision and the ASC web site for the most recent software Connect the device and cable at separate times to determine if the device
version. or cable is causing the problem. Replace the device or cabling if found to
be defective. However, if the external device and cables are okay, then
the next step is to replace the common board or module associated with
Failure Symptoms that particular input source.
The first step when a “Missing or Distorted Audio” defect occurs is to
For example, consider the symptom of all HDMI inputs are faulty. Logically
determine if audio is missing or distorted on all audio input sources or
the only device that could cause this symptom is the HDMI switcher
only on one or a select number of audio input sources.
IC6601 on the A-Board. In this case, replace the A-Board.
Input Status:
• Missing or Distorted Audio on All Inputs
• Missing or Distorted Audio on Individual Inputs
CTV-65 29

Audio System Block Diagram
A-Board
HDMI IN 1 IC6601
HDMI IN 2 HDMI
Digital I2S
Receiver/
HDMI IN 3 Audio
Switch
(EDID) CN8302
HDMI IN 4 SPDIF
Digital Audio
Output (Optical)
TM701
IF
RF Input NTSC/ATSC
Tuner IC400 CN8301
LR Audio IC8301 FIXED Analog
MTK5388
Amp Audio Output
USB 2.0
(HDCP)
LR Audio
Video 1 (Component & Composite)
LR Audio
Video 2 (Composite/S-Video)
LR Audio CN8151
Video 3 (Component)
LR Audio L
PC IN IC8151
LR Audio
LR Audio Output
Audio IN (DVI) Amplifier
R
G5E-Board (55")
G8S-Board (60") CN8152
CN6201 (55")
CN2 (60") CN201
AC F1
AU12V 1 1
PS6402 (55")
No Fuse (60")
AUDIO SYSTEM
FIGURE 2-9
CTV-65 30

Section 3 - Service Mode
Service Mode Access
Service Mode Access
Display > 5 > Volume + > Power
Reset Self Check, Press 8 > 0 keys
Panel operation time by hour (max 99999 )

(Reset Panel operation Time , Press 7 > 0 keys )
Boot count (max 99999 )
Total operation time by hour (max 99999 )
SERVICE MODE
FIGURE 3-1
CTV-65 31

Section 4 - Triage & Troubleshooting Flowcharts
Triage Flowchart
A Triage Flowchart A
(AZ1K 55", 60" Models)
Start
Triage
Is Go to GO TO
RED No “No Standby LED” Power-ON
“Standby” LED Triage Sheet Troubleshooting
ON? Replacement Parts Flowchart B
Yes
Is Go to GO TO
“Standby” LED Yes “Protect Blink Code” Protection Mode
Flashing Triage Sheet Troubleshooting
Red? Suggested Parts Flowcharts C1, 2, 3
No
Is Go to GO TO
Video Missing Yes “Video” Missing or Distorted
or Distorted Triage Sheet Video Troubleshooting
? Suggested Parts Flowchart D
No
Is Go to GO TO
Audio Missing or Yes “Audio” Missing or Distorted
Distorted Triage Sheet Audio Troubleshooting
? Suggested Parts Flowchart E
No
No Problem
Found
Unit Fully
Operational
CTV-65 32

Triage & Troubleshooting Flowcharts
Power-ON Troubleshooting Flowchart
Power-ON Troubleshooting Flowchart B
(AZ1K 55", 60" Models) Check STBY 3.3V
at CN6201/pin 1 CN2 - 60"
(In STBY Mode)
NOTE: Confirm all connections
B between circuit boards before replacing
Is voltage Replace
Unit will Not No
3.3V G5E-Board or
Power-ON Present? G8S-Board
(All Models)
Yes
Press
Check Power_ON
TV & Remote at CN6201/pin 3 CN2 - 60"
POWER (In STBY Mode)
Button
Confirm Remote
Control Operation
Is voltage
No Replace
3.3V
Is What is the “Power” Glows Present? A-Board
“Standby” LED Yes State of the Steady Green
illuminated “Power” & “Standby”
Yes
RED? LEDs?
Cycle AC power while
Check SW_12V checking for 12V.
No “Standby” Red LED at CN6201/pin 9
(In STBY Mode)) Unplug and Plug AC
Blink Pattern
Power Cord .
Confirm Unit is CN2 - 60"
Initial Power -ON OK
securely plugged into GO TO
Troubleshoot Video,
an active AC Outlet FlowCharts C1, 2, 3
Backlight, Panel, or Audio
Protection Modes
OK Problem Is voltage No
12V
Present?
Is
No Repair AC Outlet or
110VAC Present Yes
Replace AC-Power Cord
at CN6102?
Check Replace
CN1 - 60" AC_OFF_DET G5E-Board or
at CN6201/pin 2 G8S-Board
Yes
CN2 - 46"
Check Main Fuse
F6101
(0 ohms) Is voltage
F101 - 60" No
3V
Present?
Yes Replace
Is Fuse Yes
G5E-Board or
Open?
G8S-Board
Replace
No A-Board
CTV-65 33

Protection Mode 2X, 3X, & 4X Troubleshooting Flowchart
NOTES:
1) All Red Blink patterns will occur on the Front Panel
Protection Mode Troubleshooting
C1
Red “Standby” LED Flowchart C 1 (AZ1K 55" & 60" Models)
2) All voltage are measured prior to unit shutdown
3) Confirm all connections between circuit boards Unit Shuts OFF
before replacing RED LED
Blinking
2X Blink Pattern 3X Blink Pattern 4X Blink Pattern

AU12V LVP & SW12V OVP Audio Balancer
Check Check LD
Check AU12V at Speakers & Volatge
CN6201/pin 4 Connections CN6403/pin 7
*Before Shutdown CN2 - 60"
Is voltage 0V
Do Replace
Is voltage Replace 0V or 12V
12V
Present?
No
G5E-Board or
G8S-Board
Speakers
Measure
No ■ Replace Present?
LCD Panel
Speaker(s)
8 ohms
? 12V
Yes
Yes
Check SW12V at Replace
CN6201/pin 9 G5E-Board or
CN2 - 60" Replace
*Before Shutdown G8S-Board
A-Board
(>) Greater Than
(~) Approximately (Does
not exceed) Is
>12V Replace
Voltage Is Problem No Replace
G5E-Board or
~12V or >12V Solved? A-Board
G8S-Board
?
Yes
~12V
Problem
Replace Sloved
A-Board
CTV-65 34

Protection Mode 5X & 6X(60”) Troubleshooting Flowchart

NOTES:
1) All Red Blink patterns will occur on the Front Panel
Protection Mode Troubleshooting
C2
Blinking
Check 24V at
CN4/pin 3
*Before Shutdown
6X Blink Pattern
5X Blink Pattern
(No Backlight)
TCON/HFR Error Is
60" Models
voltage No Replace
24V Before
G8S-Board
Is “SONY” logo Shutdown
Check LVDS connection
Displayed and Is ?
between
LCD Panel (TCON) & A Brds Tones Heard? Backlight ON No Yes
Before Shut
Down? Check Backlight-ON
signak at
Yes CN2/pin 11
Is
No Repair *Before Shutdown
connection
Connection Replace
OK?
LCD Panel
Is
Yes Assembly
voltage
No Check for
3V Before Open or Short
Check TCON 12V supply Shutdown
CN6403/pins 1 & 2 CN3 - 46"
Is ?
Issue No Replace Yes Replace
Resolved A-Board
A-Board
? Check Dimmer signal at
Is 12V CN2/pin 12
Yes Replace Yes
Present *Before Shutdown
TCON/HFR Brd
?
Issue
No Resolved
Is
Is voltage
Check for
Replace Issue No Replace 1V to 3V Before Short
G5E-Board or Resolved A-Board Shutdown
G8S-Board ? ?
Yes Replace
A-Board
Issue
Resolved Replace
LCD Panel
Assembly
CTV-65 35

Protection Mode 6X(55”) & 7X Troubleshooting Flowchart
NOTES:
1) All Red Blink patterns will occur on the Front Panel Protection Mode Troubleshooting
C3
Blinking
Temperature Threshold
6X Blink Pattern Ambient 80°C
(No Backlight) 7X Blink Pattern
Check 390V connection
CN6301 on (G5E-Brd) to Temperature Error
55" Models
CN6601 (D1-Brd)
Check HV at Does
D1-Brd Output Is Yes unit Shut-Down
Yes Immediately after
*Before Shutdown Connection Replace
Power ON
Okay D1-Board
?
?
No
Is No
voltage Clear unit ventilation areas
No and confirm adequate local
HV Before Repair
Shutdown room temperature
Connection
?
Yes
Does unit still No Issue

Check Backlight-ON Check Dimmer signal at shutdown (7X)? Resolved
signak at CN6201/pin 12
CN201/pin 11 *Before Shutdown
*Before Shutdown
Yes
Is Is Replace
voltage
No voltage A-Board
Check for No Check for
3V Before Open or Short 1V to 3V Before
Shutdown Short
Shutdown
? ?
Yes Replace
Yes Replace
A-Board A-Board
Replace
G5E-Board
CTV-65 36

Video Troubleshooting Flowchart
D Video Troubleshooting
Flowchart D (AZ1K 55" & 60" Models)
Missing or
Distorted Video
NOTE : Confirm all connections
between circuit boards before replacing
All Video Inputs :
Composite Is Check External Device Is
Component Video Missing or No and Connections External Device Yes Replace
HDMI Distorted on All Swap Devices and & connection OK A-Board
PC IN Inputs ? connections ?
ATSC/NTSC (Tuner)
USB Yes No
Repair External
Is Device
Video Missing Distorted
or Distorted
?
Is
Missing Distortion
Present in No Replace
User Menu A-Board
Is No OSD
Go To Flowchart
Backlight ON ?
C2 or C3
?
Yes
Yes
Sharp Horizontal
or Vertical Lines Is
Can Single Pixels Replace
No Check LVDS cable
User Menu be Yes Replace or Complete Line LVDS Cable
for Physical Damage
Displayed A-Board of Pixels If Damaged
? missing? Cable OK
No Yes Perform WIDE Mode Test
(Reference TM for Dertails)
Or check LVDS cable Video & Skew (or Rock) the LVDS Replace
Clock Signal Levels at connector from its socket
LCD Panel
CN4152/pins 1 - 49 using an at the TCON/HFR Brd.
Oscilloscope . (Reference TM for Details)
Does
Distortion follow
TM – Training Manual Yes
picture size Replace
Are when changing A-Board
Flashes WIDE mode
Yes Replace
of color ?
displayed
A-Board
? No
No
Replace
Replace TCON/HFR Board
TCON/HFR Board
CTV-65 37

Audio Troubleshooting Flowchart
Audio Troubleshooting
E
Flowchart E (AZ1K 55" & 60" Models)
NOTE: Confirm all connections between
Missing or Distorted Audio circuit boards before replacing
(Speaker Outputs )
All Video Inputs :

Composite
Component Is Audio Check External Device Is
No and Connections External Device Yes Replace
HDMI Missing or Distorted Swap Devices and & connection OK A-Board
PC IN on All Inputs ? connections ?
ATSC/NTSC (Tuner)
USB
Yes No
Repair External
Check
Device
Fix Audio Output
Is Audio No Replace
Present? A-Board
Yes
Check
Check Speaker Resistance at
Voltage from Power Supply CN8301 & CN8302
CN2 - 60"
at CN6201/pin 4 (across Speakers)
& Connections
No Replace
Is 12V
G5E-Board or 8 ohms
Present? No Replace
G8S-Board &
Connections Speaker(s)
Yes OK?
Yes
Replace
A-Board
CTV-65 38

Appendix
LCD Panel Distortion Pictures
The following distortions and anomalies where fixed by replacing the LCD Panel.
2' Solid Black Bar Distortion Timing Distortion
Double Image Distortion Ghosting Distortion
2" Solid White Bar Distortion Sharp Lines & Missing Pixels
CTV-65 39

Appendix
TCON/HFR Board Distortion Pictures
The following distortions and anomalies where fixed by replacing the TCON/HFR Board.
Large Blooming Distortion Two Small Blooming Distortions
GAMMA Type Distortion 2" Transparent Colored Bar Distortion
Complete Washout Distortion 2" Transparent Colored bar Distortion
CTV-65 40

Appendix
TCON/HFR Board Distortion Pictures Continued

The following distortions and anomalies where fixed by replacing the TCON/HFR Board.
2" White Bar w/ Random Colored Lines Exact Half-Screen Distortion
Complete Washout w/ Colored Lines
CTV-65 41

Appendix
Video Board Distortion Pictures

The following distortions and anomalies where fixed by replacing the Video Board.
Green Carpet Raster Multi-Colored Carpet Raster
Text Bleed Lines Random Size Vertical Bars
Overall Red Tinting Solarization
CTV-65 42

Appendix
Video Board Distortion Pictures Continued
The following distortions and anomalies where fixed by replacing the Video Board.
Partial Washout w/ Random Video Bar Overall Blue Tinting w/ Soft Vertical Lines
Green Raster Overall Green Tinting w/ Video Ghosting
Overall Red Tinting
CTV-65 43

and i.Link are trademarks of Sony Electronics
2007 Sony Electronics, Inc.

EMCSA - A Service Company
16530 Via Esprillo
San Diego, CA 92127
CTV650310 Reproduction in whole or part without written permission is prohibited. All rights reserved 03/30/10

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Training Manual

Triage and Troubleshooting Guide

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Distorted Video (All Inputs) ................................................ 25 Flowchart ....................................................................... 35

Section 3 - Service Mode .................................................. 31

Section 4 - Triage & Troubleshooting Flowcharts .......... 32

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55” OVERALL PCB LOCATION DIAGRAM FIGURE

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60” OVERALL PCB LOCATION DIAGRAM

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AZ1K Chassis Models Covered AV Input & Output Descriptions

Model Introduction Composite

All models contain a Full High-Deﬁnition 1920 X 1080 resolution panel.

and laptop or desktop. Component Input

technology which enhances sharpness and delivers smooth motion for

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PC Video & Audio Input (and DVI Audio)

USB 2.0 Side Connection - Photos & Music

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Digital Audio Output (Optical)

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Control LCD PANEL

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RF Input Analog Audio Output

 Main Power Supply

60” OVERALL PCB

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PCB and Component Descriptions D1-Board (55")

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LCD Panel Assembly

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Power Symptom Troubleshooting Failure Symptoms

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G5E-BOARD & D1-BOARD CONNECTOR DIAGAM

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G8S-BOARD CONNECTOR DIAGAM

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Protection Mode Symptom Troubleshooting • Excessive PFC Temperature (OTP)

Failure Symptoms 3X Blink- Audio Error

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5X Blink - TCON & HFR Failure b) Defective 24V Power Supply

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55” PROTECTION CIRCUITS DIAGRAM

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60” PROTECTION CIRCUITS DIAGRAM

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G5E-Board (55") 60" Model ONLY

19V Switch Circuit 3V 3 Power-ON

OVP – Over Voltage Protection

PROTECTION CIRCUITS DIAGRAM

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Video Symptom Troubleshooting Video Anomaly:

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of information on the LVDS lines from IC400 will cause poor

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• Random Line(s) of Pixels (Random Movement) - The