Training Manual

KDL-40EX500

Models: AZ1K Chassis

KDL-32EX301 KDL-32EX500 KDL-46EX400
KDL-32EX400 KDL-40EX500 KDL-46EX500
KDL-40EX400 KDL-40EX501 KDL-46EX501
KDL-40EX401

Triage and Troubleshooting Guide

Course: CTV-61
 Table of Contents
Section 1 - AZ1K Chassis Models Overview ..................... 3
AZ1K Chassis Models Covered....................................... 5
Model Introduction ........................................................... 5
AV Input & Output Descriptions ....................................... 5
RF Input ............................................................................... 5
Composite Video & Audio Inputs ......................................... 5
Component/Composite Video & Audio Inputs...................... 6
HDMI/DVI Video Input and DVI Video ................................. 6
PC Video & Audio Input (and DVI Audio) ............................. 6
USB 2.0 Side Connection - Photos & Music ........................ 6
Audio Outputs .................................................................. 7
Fixed Analog Audio Output .................................................. 7
Digital Audio Output (Optical) .............................................. 7
32’” & 40” Models Overall PCB Block Diagram ............... 8
46” Models Overall PCB Block Diagram.......................... 9
PCB and Component Descriptions ................................ 10
A-Board ............................................................................. 10
G2LE-Board (32") or G2HE-Board (40")............................ 10
GD2-Board (46") ................................................................ 10
Backlight Inverter Board (32" & 40") .................................. 10
H2-Board ........................................................................... 10
Switch Unit ......................................................................... 10
LCD Panel Assembly ..........................................................11
Section 2 - Troubleshooting Procedures ......................... 12
Power Symptom Troubleshooting.................................. 12
CTV-61
Normal Operation .............................................................. 12
Failure Symptoms .............................................................. 12
No Power/Dead Set (No RED Standby LED) .............. 12
32” & 40” Power Supply System Block Diagram ........... 14
G2LE-Board & G2HE-Board Connector Diagram ......... 15
46” Power Supply System Block Diagram ..................... 16
GD2-Board Connector Diagram .................................... 17
Protection Mode Symptom Troubleshooting.................. 18
Failure Symptoms .............................................................. 18
2X Blink - Main Power Error ........................................ 18
3X Blink- Audio Error ................................................... 18
4X Blink - Balancer Failure (46” Models ONLY) .......... 19
5X Blink - TCON & HFR Failure .................................. 19
6X Blink - Backlight System Failure (32” & 40” Models)19
6X Blink - Backlight System Failure (46” Models) ........ 19
7X Blink - Temperature Failure .................................... 20
32” & 40” Models Protection Mode System Block Diagram
21
46” Models Protection Mode System Block Diagram .... 22
All Models Power Board Protection Circuits Block Dia-
gram........................................................................... 23
Video Symptom Troubleshooting ................................... 24
Normal Operation .............................................................. 24
Troubleshooting ................................................................. 24
Missing or Distorted Video (Individual Inputs) ................... 24
Missing Video (All Inputs) .................................................. 25
i
 Table of Contents

Skewing LVDS Connector Troubleshooting Method .... 25 chart ........................................................................... 35

Distorted Video (All Inputs) ................................................ 25 Protection Mode 6X(46”) & 7X Troubleshooting Flowchart
WIDE Mode Button (Aspect Ratio) Troubleshooting 36
Method ................................................................... 25 Video Troubleshooting Flowchart .................................. 37
Unique Main Video Board (A-Board) or LVDS Cable Ef- Audio Troubleshooting Flowchart .................................. 38
fects ....................................................................... 26
Unique TCON/HFR Board Effects ............................... 27 Appendix............................................................................. 39
Unique LCD Panel Assembly Effects ........................... 27 LCD Panel Distortion Pictures ....................................... 39
Common Main Video Board (A-Board) and LCD Panel TCON/HFR Board Distortion Pictures ........................... 40
Assembly Effects ................................................... 27
TCON/HFR Board Distortion Pictures Continued .......... 41
Video System Block Diagram ........................................ 28 Video Board Distortion Pictures ..................................... 42
Audio Symptom Troubleshooting................................... 29 Video Board Distortion Pictures Continued ................... 43
Normal Operation .............................................................. 29
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(32”, 40”) Troubleshooting Flow-

CTV-61 ii
 Section 1 - AZ1K Chassis Models Overview

TCON
Board

G2LE-Board (32")
LVDS Cable
G2HE-Board (40")
Backlight
Inverter
Board

A-Board

Switch Unit

H2-Board

32" & 40" Models

32” & 40” OVERALL PCB LOCATION DIAGRAM

FIGURE 1-1
CTV-61 3
 AZ1K Chassis Models Overview

TCON
Board

Balancer
Board LVDS Cable

GD2-Board

A-Board

Switch Unit

H2-Board

46" Models

46” OVERALL PCB LOCATION DIAGRAM

FIGURE 1-2
CTV-61 4
 AZ1K Chassis Models Overview

AZ1K Chassis Models Covered AV Input & Output Descriptions

KDL-32EX301 KDL-32EX500 KDL-46EX400
KDL-32EX400 KDL-32EX501 KDL-46EX500
USB
KDL-40EX400 KDL-40EX500 KDL-46EX501
KDL-40EX401 KDL-40EX501
Composite

Model Introduction
All models, except the KDL-32EX301, contain a Full High-Definition HDMI
Input

1920 X 1080 resolution panel. The KDL-32EX301 contains a 1280 X HDMI

720 resolution panel. The backlight is produced using a Cold Cathode Input

Fluorescent Lamp (CCFL) light system for all models. All models have the
Advanced Contrast Enhancer (ACE) feature and Dynamic Backlighting.
The Dynamic Contrast Ratio (DCR) for the 400 series is 140,000:1 and Component/Composite
Input
for the 500 series it is 2150,00:1. All models contain the BRAVIA Engine™
2 digital video processor for superior resolution. Plus, 7 HD inputs (4 Component Input

HDMI™, 2 component and 1 PC) are provided to connect all of your HD PC Input
PC & DVI Audio Input
devices including PLAYSTATION®3, Blu-ray Disc™ player and laptop or RF Input
HDMI/DVI
desktop. Digital Audio Input
Output
The BRAVIA Engine 2 fully digital video processor uses a collection of (Optical)
Analog Audio
HDMI
Input

unique Sony technologies to significantly reduce noise, enhance overall Output

(FIXED)

image detail, and optimize contrast so every scene produces sharp,

vibrant, life-like images and color.
The EX500 series models contain the Motionflow™ 120Hz frame rate
technology which enhances sharpness and delivers smooth motion for
RF Input
fast-action sports and movies. The EX300 and EX400 series models This is a 75 ohm connection for either terrestrial NTSC and ATSC (8VSB)
contain the standard 60Hz frame rate. or cable QAM64 and QAM256 signals.
Sony® HDTVs exceed Energy Star 3.0 requirements. In addition, they
incorporate advanced power saving features such as Light Sensor® Composite Video & Audio Inputs
technology that adjusts backlight intensity based on ambient room lighting Yellow Jack - Composite Video Input
conditions and Dynamic Backlight Control that adjusts backlight intensity Red & White Jacks - Right & Left Audio Input
based on the brightness of the image on the screen. 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-61 5

Component/Composite Video & Audio Inputs
Red, Blue, & Green Jacks - Component Video Inputs
Red & White Jacks - Right & Left Audio Input
NOTE: Composite video can be applied to the component input label
“VIDEO IN”. The yellow composite video connector is connected to
the green component connector. The audio is connected to the same
component audio inputs.
IMPORTANT: For automatic signal detection make sure the User Menu
item is set to “AUTO. “ Reference the below for the specific menu item.
The input can also locked to Video 1 (composite) or Component 1
(component) signal. However, the input will only process the chosen
signal type. If the other signal type is connected the picture will be lost or
black & white.
Select the appropriate input
for the input signal type.
Auto – Auto Detection
Video 1 – Composite
Component 1 - Component
CTV-61
AZ1K Chassis Models Overview
HDMI/DVI Video Input and DVI Video
Both the HDMI and DVI formats contain digital video. In the case of the
HDMI format the audio is also digital and is part of the video and audio
data stream over the single HDMI connection. In contrast, the DVI format
contains only digital video in its data stream. The audio is sent over a
separate Stereo Mini Jack audio connection. Furthermore, a DVI to HDMI
adapter is required to connect the DVI connector to the HDMI connector.
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
Compatibility in the Owners Manual for each model.
The Stereo Mini Plug is also used for a DVI audio connection at HDMI 1
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.
6
 AZ1K Chassis Models Overview

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-61 7
 AZ1K Chassis Models Overview
32’” & 40” Models Overall PCB Block Diagram

Switch Unit A-Board

Keys
 Power Key
 Function Keys

H2-Board
Power/
 LEDs SIRCS
 IR Sensor Optical Digital Audio Output

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
G2LE-Board (32")
G2HE-Board (40")
Control LCD PANEL
Power
AC
Input Power
 Main Power Supply
 Standby Power Supply
Backlight Inverter Board
Control  CCFL Backlight HV Inverter
Circuits Power/Drive CCFL
 Backlight System Error Backlight System
Power
Circuits 32” & 40” OVERALL PCB
BLOCK DIAGRAM
FIGURE 1-3

CTV-61 8
 AZ1K Chassis Models Overview
46” Models Overall PCB Block Diagram
Switch Unit A-Board
Keys
 Power Key
 Function Keys

H2-Board
Power/
 LEDs SIRCS
 IR Sensor Optical Digital Audio Output

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
GD2-Board

Control LCD PANEL

Power
AC  Main Power Supply
Input  Standby Power Supply Power
 AC Relay
 Backlight HV Inverter
Circuits
Control
Power/Drive CCFL
Backlight System
Balancer Board
HV 46” OVERALL PCB
HV BLOCK DIAGRAM
FIGURE 1-4

CTV-61 9
 AZ1K Chassis Models Overview

PCB and Component Descriptions GD2-Board (46")

Reference Figures 1-3 Except for some regulator circuits on the A-Board, the GD2-Board is
the power supply system board for the 46” models, which includes the
A-Board following components and circuits.

The circuits located on the A-Board perform all Video and Audio processing • Main Power Supply
functions. It also contains all the microprocessor control circuits. The o 12V
following circuits are included on this board. o AU12V (Audio Amp)
• TV Microprocessor • Standby Power Supply
• MT5388 Processor o 3.3V for standby circuits
- Video Signal Processing • Backlight High Voltage Inverter Power Supply
- HDMI Signal Processing • Main/Inrush AC Input Relay
- Scan Converter • Power Factor Control Circuit (PFC)
- HDCP Processing
• Audio Amplifier Backlight Inverter Board (32" & 40")
• Temperature Sensor The 24V developed in the Main Power Supply on the G2LE-Board or
G2HE-Board powers the Backlight Inverter Board. The Inverter Board
G2LE-Board (32") or G2HE-Board (40") takes that 24V and develops approximately 2KVrms to initially ignite
the lamps and 1KVrms to drive the backlight Cold-Cathode-Fluorescent
Except for some regulator circuits on the A-Board, the G2LE-Board or Lamps (CCFL) in normal operation.
G2HE-Board is the power supply system board for the 32” and 40” models,
which includes the following components and circuits.
H2-Board
• Main Power Supply
• IR Sensor
• 12V
• AU12V (Audio Amp) Switch Unit
• 24V (Backlight Inverter) • Power Key
• Standby Power Supply • Function Keys
• 3.3V for standby circuits
• Power Factor Control Circuit (PFC)

CTV-61 10
 AZ1K Chassis Models Overview

LCD Panel Assembly

The LCD Panel Assembly includes the LCD Panel, TCON Board (300 &
400 series models), TCON/HFR Board (500 series models), 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.
32” & 40” Models:
1) LCD Panel and Backlighting Components
2) TCON/HFR Board
3) Inverter Board
46” Models:
1) LCD Panel and Backlighting Components
2) TCON/HFR Board
3) Balancer Board

CTV-61 11
 Section 2 - Troubleshooting Procedures
Power Symptom Troubleshooting
Normal Operation
Reference Figure 2-1 and 2-2
110VAC is applied to the G2LE-Board, G2HE-Board, or GD2-Board it can
be measured at CN6101 or CN6003. In the standby mode the AC power
passes through the main fuse F6101 or F6001. The is no main relay on
the G2LE & G2HE-Board so the AC power is applied directly to the Main
& Standby Power supply. The GD2-Board does have a Main AC Relay.
The AC power passes through R6003 (Inrush resistor), and D6001 and
is applied to the Main DC/DC Converter IC6501 and the Standby DC/DC
Converter IC6201. IC6501 is not active in the standby mode. However,
IC6201 is active in standby mode and outputs STBY 3.3Vdc as long as
AC power is applied to the TV. The Standby 3.3Vdc is supplied to the TV-
Microprocessor, Switch Unit (Power Key), and HSR-Board (IR Sensor) in
the standby mode.
Once a ON command is received form the remote controller or the power
button on the Switch Unit the TV-Microprocessor outputs the Power-ON
signal. The Power-On signal is applied to the G2LE-Board, G2LE-Board,
or GD2-Board. On the power supply board the Power-On signal switches
the 19V from the standby power supply to activate the PFC and Main
Power supply IC6501. No relay click will be heard on the 32” or 40” models
because there is not a main relay. However, on the 46” models there is a
main relay and one relay click is heard at power-on. The relay engages to
bypass the inrush resistor R6003 during the ON state.
The main power supply IC6501 is now active and outputting all secondary
supplies. The 12Vdc secondary is the supply voltage for all the voltage
regulators on the A-Board. The AU12V is the supply voltage for the audio
output amplifier. The 32” and 40” models power supply will also output
24V which is the supply voltage for the backlight inverter board.
The GD2-Board in the 46” models will develop and output the backlight
high-voltage (1KV) to the Balancer board and the CCFL backlights.
CTV-61
Failure Symptoms
Reference Figures 2-1, 2-2, 2-3, and 2-4
No Power/Dead Set (No RED Standby LED)
In a dead set condition there will be No RED Standby LED illumination in
the Standby Mode (TV plugged into an active AC Outlet).
The following bullet list gives the possible failures for a “No Power/Dead
Set” condition.
• Loss of AC Power
• Loss of AC-OFF-DET
• Loss of Standby 3.3Vdc
• Loss of REG12V
• Loss of Power-On
• Defective Main Microprocessor
The first step in troubleshooting a “No Power/Dead Set” condition is to
confirm that 110ACV power from an active AC outlet is applied to the
G2LE-Board, G2LE-Baord, or GD2-Board. AC power is applied to, and
can be measured at CN6101 on the G2BE-Board or G2CE-Board and at
CN6003 on the GD2-Board.
Next, check for the presence of the AC-OFF-DET voltage at CN6401/pin 2
or CN6150/pin 2. If the AC-OFF-DET circuit is working properly 3V should
be measured. If the 3V is not present replace the G2BE-Board, G2CE-
Board, or GD2-Board. If the 3V in not present either the main fuse or the
main power supply IC6501 is defective. In either case, replace the power
supply board.
After confirming the AC power and AC-OFF-DET, check for a defective
Standby 3.3Vdc power supply IC6201. To confirm a defective IC6201
check the 3.3V secondary voltage at CN6401/pin 1 or CN6150/pin 1.
As long as AC power is applied to the TV IC6201 should be active and
outputting 3.3Vdc. If the 3.3V is not present then IC6201 is defective.
Replacing the power supply board will fix the problem.
12
 AZ1K Chassis Models Overview

Finally, a “Dead Set” condition can be caused by a defective microprocessor

IC400. The microprocessor outputs the Power-On signal which activates
the switch Q6301 and IC6301 on the power supply board and passes
the 19V from the Standby power supply to active the relay (46” models),
PFC, and Main Power Supply IC6501. 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 CN6401/pin 3 or CN6150/pin 3. It should measure
approximately 3.3Vdc If the measurement is 0Vdc before shut-off the TV
microprocessor is defective. Replace the A-Board. If the power-on voltage
is 3V before shutdown then the switch circuit on the power supply board
is defective. Replace the power supply board.

CTV-61 13
 AZ1K Chassis Models Overview
32” & 40” Power Supply System Block Diagram
G2LE-Board (32") CN6402 LCD Panel
G2HE-Board (40") Backlight Assembly
24V
3 HV Inverter 1.1KV (~2KV Strike Voltage) CCFL
Board
Backlights

IC6301 LCD
A-Board
Main PANEL
Power CN6401 CN201
Supply F1
& AU12V IC8151
4 4 LCD
PFC Audio Output Amp
Panel
D6301 R6342 LVDS
CN6101 F6101 TH6301 L6302 PS6402 IC8301
D6308 0.1ohm Q6302 Line Out Amp
Cable
Q6303
TCON/
12V LVDS 12V HFR
Q6304 14 10 8
IC266 5V
From To CN201
VSense 5V Reg
AC Q6403 Tuner
Input
D6302 PFC_OUT 12V 5V
HFR on
9 9 IC231
R6302 L6303 To USB EX500
AC_DET 5V Reg
To Optical Out Series
AC_DET IC232 IC267 Only
1V Reg 3V Reg
VCC
PS6401
To Micro
ON/OFF IC268 IC269
1.25V Reg 1V Reg
19V
CN6403
12V Panel 12V To Micro To Micro
1
To DDR
12V TCON 12V
Q6403 2

Switch
To CN6401 A-Board
3V 15 15 TCON ON
Circuit
Q6101 3V Power ON
PH6103 3 3
Q6102 EX500 Series ONLY
R6107
10ohm 19V EX400 Series No Connection

IC902
Standby IC400
STBY 3.3V MT5388
3.3V 1 1
Power
Supply

3V AC-OFF-DET
2 2

CN6401
32” & 40” POWER SUPPLY SYSTEM DIAGRAM
FIGURE 2-1

CTV-61 14
 AZ1K Chassis Models Overview
G2LE-Board & G2HE-Board Connector Diagram
1 – UNREG24V 15 – TCON-ON
2 – UNREG24V 14 – TCON 12V
3 – UNREG24V 13 – NC
4 – UNREG24V 12 – DIMMER
5 – UNREG24V CN6402 CN6401 11 – BL-ON
6 – Ground 10 – BL-ERR
7 – Ground 9 – REG12V
8 – Ground 8 – REG12V
9 – Ground 7 – Ground
10 – Ground 6 – Ground
11 – BL-ERR 5 – Ground
12 – BL-ON 4 – AU12V
13 – NC 3 – POWER -ON (3V)
14 - Dimmer 2 – AC-OFF-DET (3V)
1 – STBY 3.3V

G2LE-Board (32")
G2HE-Board (40")

F1

AC Input
CN6101

G2LE-BOARD & G2HE-BOARD CONNECTOR DIAGAM

FIGURE 2-2

CTV-61 15
 AZ1K Chassis Models Overview
46” Power Supply System Block Diagram
GD2-Board
CN6704 LCD Panel
Assembly
HV
Backlight Inverter High Voltage Circuits 1.1KV (~2KV Strike Voltage) CCFL
IC6601 Balancer Board
Q6601 Backlights
HV
Q6602

19V 400V CN6705

LCD
A-Board
PANEL
CN6150 CN201
AU12V F1
IC8151
R6003 IC6501 4 4 LCD
Audio Output Amp
Main Panel
R6536 Power
D6001 LVDS
CN6003 F6001 L6501 D6502 0.1ohm Supply IC8301
Cable
& Line Out Amp TCON/
PFC 12V HFR
LVDS 12V
Q6502 14 10 8
IC266 5V
RY6002 From To CN201
5V Reg
AC VSense Q6151 Tuner
Input
D6002 PFC_OUT 12V IC231 5V
R6013 R6301 9 9 To USB
AC_DET 5V Reg
To Optical Out
AC_DET IC232 IC267
1V Reg 3V Reg
VCC PS6151
To Micro
ON/OFF IC268 IC269
1.25V Reg 1V Reg
19V
To Micro To Micro
CN6151 To DDR
12V TCON 12V
Q6151 2

Switch
To CN6150 A-Board
3V 15 15 TCON ON
Circuit
IC6301 3V Power ON
PH6300 3 3
Q6301
R6201
10ohm 19V

IC6201
Standby IC400
STBY 3.3V MT5388
3.3V 1 1
Power
Supply

3V AC-OFF-DET
2 2

CN6150 46” POWER SUPPLY SYSTEM DIAGRAM

FIGURE 2-3
CTV-61 16
 AZ1K Chassis Models Overview
GD2-Board Connector Diagram
HV 1.1KV
HV 1.1KV

6 - NC
5 - LD CN6704 CN6705
5 - Ground
4 – Ground
CN6151 4 – Ground
3 – Ground
3 – TCON 12V
2 – FB CN6158 2 – TCON 12V
1 – 12V
1 – NC

15 – TCON-ON
14 – TCON 12V
13 – NC
12 – DIMMER
CN6150 11 – BL-ON
10 – BL-ERR
9 – REG12V
8 – REG12V
7 – Ground
GD2-Board 6 – Ground
5 – Ground
4 – AU12V
3 – POWER -ON (3V)
2 – AC-OFF-DET (3V)
1 – STBY 3.3V

AC Relay

F6001

CN6003
AC Input

GD2-BOARD CONNECTOR DIAGAM

FIGURE 2-4
CTV-61 17
 AZ1K Chassis Models Overview

Protection Mode Symptom Troubleshooting • Excessive 24V Level (OVP) (32” & 40” models)
Reference Figures 2-5 and 2-6 • Excessive PFC Voltage (OVP)
The KDL-32S5100 and KDL-32XBR9 include the following protection • Excessive PFC Temperature (OTP)
mode blink patterns (or self-diagnostics). *Low Voltage Protection (LVP)
Possible Error *Over Voltage Protection (OVP)
Protect Description Blink Pattern
Location A loss or excessive condition of the AU12Vdc secondary voltage from the
G2LE, G2HE, GD2- main power supply IC6501 will cause a 2X blink pattern on the Standby-
Main Power Error 2 LED. The 12Vdc can be checked at CN6401/pin 4. The
Board, or A-Board
A-Board or G2LE, If the measurement is 0V or rises above 12Vdc (approaches 15V) before
Audio Error 3
G2HE, GD2-Board the TV shutdown the G2LE-Board, G2LE, GD2-Board is defective.
Balancer Error LCD Panel, A-Board, If approximately 12Vdc is present and remains below 12Vdc before shut-
4
(46” Only) or GD2-Board off then the A-Board is defective.
TCON/HFR Board or An excessive 24Vdc (32” & 40” models) secondary voltage from the main
TCON Error 5
A-Board power supply IC6501 will also cause a 2X blink pattern on the Standby-
TCON/HFR Board or LED. The 24Vdc can be measured at CN6402/pin 3 before TV shutdown.
HFR Error 5
A-Board If the voltage rises above the 24V level (approaches 27) before TV
Inverter Board (32”, shutdown then the power supply is defective, replace the G2LE, G2HE ,
40”), G2LE, G2HE, GD2-Board to fix the problem.
Backlight Error 6
GD2-Board, LCD Pan- Finally, there are PFC protection circuits on the power supply board that
el, or A-Board when activated will cause a 2X blink protection mode (reference Figure 2-
Temperature Error 7 Ventilation or A-Board 7). The PFC circuit is monitor for both over-voltage and over-temperature.
NOTE: All red protection mode LED blink patterns occur using the Therefore, if the AU12V and 24V circuits checkout okay, there could still
Standby-LED at the lower left front of the TV. be a problem on the power supply board in the PFC circuit causing the 2X
blink. Replace the G2LE, G2HE, GD2-Board to fix this condition.

Failure Symptoms 3X Blink- Audio Error

2X Blink - Main Power Error The Audio error can occur due one of the following error conditions.

A 2X protection mode blink pattern can be activated due one of the • Shorted or Damaged Speaker Connections
following defects on the G2LE-Board, G2HE, GD2-Board.. • Defective Audio Amplifier (A-Board)
• Loss of AU12V (LVP)* • Loss of AU12V (Open F1 on A-Board)
• Excessive AU12V Level (OVP)* The first thing to check when a 3X blink protection mode occurs is the
physical condition of the speakers and speaker connections. The speakers
CTV-61 18

should measure 8 ohms. Shorted speakers or connections can cause a
3X blink protection mode.
If the speakers and connections check okay, then the defective component
is on the A-Board. Either a open F1 or defective audio amplifier will cause
a 3X blink protection mode. In either case, replace the A-Board to fix this
condition.
4X Blink - Balancer Failure (46” Models ONLY)
In most cases, a 4X protection mode indicates a defective lamp or lamps.
Therefore, replace the LCD panel to fix this condition. If the 4X protection
is still present after replacing the LCD panel, there could be a problem
on the A-Board or GD2-Board. First replace the A-Board then the GD2-
Board.
5X Blink - TCON & HFR Failure
The 5X blink protection mode indicates a communications error between
the TCON/HFR board and the MT5388 microprocessor on the A-Board.
First replace the TCON/HFR Board if the 5X protection mode blink pattern
occurs. If the TCON/HFR Board does not repair the problem then replace
the A-Board.
6X Blink - Backlight System Failure (32” & 40” Models)
NOTE: All models will make three attempts to power up before a 6X
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
third attempt the TV will turn off and the Standby LED will blink a 3X
protection mode.
In most cases, if the backlight momentarily illuminates and the TV
shuts off and a 6X is activated than one or more of the backlight lamps
are defective. The LCD Panel assembly panel must be replaced for a
defective lamp.
If a 6X blink pattern is activated than a defect has occurred in one of the
following areas.
CTV-61
AZ1K Chassis Models Overview
• Defective Panel Lamp(s)
• Defective Backlight Inverter Board
• Defective TV Microprocessor
• Defective 24V Power Supply
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
components.
1) Momentary Backlight and 6X
a) Defective Lamp(s)
b) Defective Backlight Inverter Board
2) No Backlight and 6X
a) Defective TV Microprocessor
b) Defective 24V Power Supply
c) Defective Backlight Inverter Board
IMPORTANT: Before replacing the LCD Panel assembly check the
backlight Inverter Board outputs. A failure of one of the inverter outputs
will also cause this same symptom (Momentary Backlight & 6X).
If there is no backlight before the TV shuts off and activates a 6X, than
check the “Backlight ON” signal from the TV microprocessor and the
24V power supply from the G2LE, G2HE, GD2-Board.
If the “Backlight ON” and 24V power supply are okay than the Backlight
Inverter board has failed and must be replaced. This will be a rare
occurrence but the Inverter board can cause a “No Backlight” condition
and must be considered.
6X Blink - Backlight System Failure (46” Models)
The 46” models have both a 4X and 6X blink protection mode. The 4X
blink will, in most cases, be caused by a defective lamp.
Because all the Backlight HV Inverter circuits are located on the GD2-
Board, a 6X blink protection mode will be fixed, in most cases, by
replacing the GD2-Board. If the GD2-Board does not repair the problem
replace the A-Board. The BL-ON and Dimmer signals come from the
19
 AZ1K Chassis Models Overview

microprocessor on the A-Board. A shorted or open BL-ON signal will failed.

cause this 3X condition. Also a shorted Dimmer will cause this 3X • Main Microprocessor IC3002 (A-Board)
condition.
• Temperature Sensor IC3502 (A-Board)
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
CTV-61 20
 AZ1K Chassis Models Overview
32” & 40” Models Protection Mode System Block Diagram

G2LE-Board (32") A-Board

G2HE-Board (40")
AC
CN6000 CN6401
Input CN201
Main 12V 3V
RECT 8 9 Interface DC_Detect
PS Circuit

RECT & 2X
24V
PFC 3
IC400
CN6402
MTK5388

CN6401
1 1 3.3V Standby 3.3V
STBY
PS
3V
SW 3 3 Power ON

1V to 3V Dimmer
13 BL_ON
3V
12 BL_ERR
0V
11 INV_ERR
IC4305 6X
Temp
Sensor Temp_ERR
Protection Circuit 70C
Q8153, Q8155 7X
HV Inverter Board Q8158, Q8160, Audio_ERR
CN001
Q8156 3X
24V IC8151
6
Dimmer
1 Audio
BL_ON
2 Amp
BL_ERR
3
CN8151
LCD Panel Assb CN8152

CN4152
TCON
Backlight Inverter SDA (I2C)
High Voltage BL* TCON_ERR
Corcuits
HFR 5X
HFR_ERR
5X

*BL - Backlight

PROTECTION CIRCUITS DIAGRAM

FIGURE 2-5
CTV-61 21
 AZ1K Chassis Models Overview
46” Models Protection Mode System Block Diagram
GD2-Board A-Board

AC
CN6003 CN6150 CN201
Input
Main 12V Interface 3V
RECT 8 9 DC_Detect
PS Circuit

RECT & 2X
PFC
IC400
MTK5388

3.3V
STBY 1 1 Standby 3.3V
PS
3V
SW 3 3 Power ON

1V to 3V Dimmer
13
3V BL_ON
12
0V BL_ERR
11 BL_ERR
CN1004
IC4305 4X & 6X
Temp
Sensor Temp_ERR
Protection Circuit
Q8153, Q8155
70C 7X
Q8158, Q8160, Audio_ERR
Q8156 3X
CN6150
IC8151
Dimmer
12 Audio
BL_ON
11 Amp
BL_ERR
10
CN8151
LCD Panel Assb
CN8152

CN4152
B
A TCON
HV L SDA (I2C)
Backlight Inverter TCON_ERR
High Voltage A 5X
BL* HFR
Circuits HV N HFR_ERR
C 5X
FB E
R
LD
12V
CN6702

*BL - Backlight

PROTECTION CIRCUITS DIAGRAM

FIGURE 2-6
CTV-61 22
 AZ1K Chassis Models Overview
All Models Power Board Protection Circuits Block Diagram

G2LE-Board (32")
G2HE-Board (40") 32" 40" Models ONLY
GD2-Board (46")
CN6101
CN6402
Reg 24V
D6301 3 To Inverter Board
IC6301 Reg 12V
AC 9 To A-Board
PFC Main
Input
OVP Power
Supply
D6302 & G2HE-Board &
30V 15V
PFC G2LE-Board
Zener Zener
OTP 24V 12V Protection
OVP OVP circuits will
PFC
OTP cause a 2X
blink pattern
Latch Circuit
Q6202, 6203

19V Switch Circuit 3V 3 Power-ON

Q6101, 6102 Pulls
CN6401 From A-Board
Power_ON
Low

OVP – Over Voltage Protection

OTP – Over Temperature Protection

PROTECTION CIRCUITS DIAGRAM

FIGURE 2-7
CTV-61 23

Video Symptom Troubleshooting
Reference Figure 1-8
Normal Operation
All video processing is performed by IC400 (MT5388) on the A-Board.
The RF input is first processed by the RF Tuner and is then applied to
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
circuit applies the selected input to IC400. IC6601 also contains the EDID
(Extended Display Identification Data), which is part of the HDMI hand-
shake process.
All other inputs (Composite, Component, PC, and USB) are connected
directly to IC400 inputs.
The USER, White Balance, and Gamma data is stored in IC4302.
Both the USER Menu and Service Mode screen are generated by, and
output from IC400.
IMPORTANT:
1) Confirm the TV has the most recent Software Version installed.
Go to the User Menu for the present TV software revision and
the ASC web site for the most recent software version.
2) Before proceeding with the following video troubleshooting
procedures it is assumed that the TV is turning on with the
Green Power-LED illuminated, Backlight is illuminated
(brightened raster), and the Audio is present.
Troubleshooting
When a video problem occurs you will experience one of the two following
symptoms.
Input Status:
• Missing or Distorted Video (Individual Inputs)
• Missing or Distorted Video (All Inputs)
CTV-61
AZ1K Chassis Models Overview
Video Anomaly:
• Poor Detail
• Moving Video Distortion (e.g. Bars)
• Static H/V Lines (Any Color)
• Static Missing Pixels (Any Color)
• Static Bars (Solid Black or White, Transparent Color)
• White Balance
• Gamma
The main objective when troubleshooting one of the previously listed
symptoms is to determine if the defect exists in the following sections of
the TV system.
• LCD Panel Assembly
• TCON/HFR Board
• A-Board
Missing or Distorted Video (Individual Inputs)
The primary objective is to locate the defective component through
activating each individual video input and checking for any abnormal
symptoms on the screen. If the video distortion appears only in one or
two video inputs then the next step is to eliminate the possibility of a
defective or improperly connected external device such as, a STB, DVR
or DVD player. The quickest way to troubleshooting the external devices
is to swap the suspect device with a known good device at the input in
question.
If the external device or connections are defective then the TV is okay
and the external device and connections need to be serviced. If the
external devices and their connections are okay, then the next step is to
troubleshoot the problem by accessing and displaying each video input.
The rationale behind this troubleshooting method is that each of these
video inputs takes an altogether or somewhat different path through the
video processing system. This fact enables you to determine the defect,
24

in some cases, down to the component level, and in almost all cases,
down to at least the board level. For example, if the distortion appears in
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.
The reason for this conclusion is because the HDMI signals are the only
signals to pass through IC6601 before being applied to IC400. All other
input signals bypass IC6601. The composite and component signals go
directly to the video processor IC400.
Although all the individual input circuits are located on a single board (A-
Board), the previously described troubleshooting procedure can still serve
as a reliable confirmation of a defective component on the A-Board before
replacing the board.
The same deductive reasoning can be applied when troubleshooting
video defects using the other video inputs shown on the flowchart (Section
4). This method simply involves knowing the path the input signal must
take through the video processing system to reach the display. With this
knowledge you can effectively divide the video system into distinct areas,
and therefore, isolate the defect.
Missing Video (All Inputs)
If the video is completely missing you will first use the User Menu (On-
Screen-Display - OSD) in an attempt to isolate the defect to the A-Board
or the TCON/HFR Board.
If the OSD can be displayed then the TCON/HFR Board is okay, and
you can safely assume the defect exists on the A-Board. However, if the
OSD cannot be displayed you need to do further troubleshooting because
either IC400 on the A-Board is not sending the OSD or the TCON/HFR
Board is not able to process the OSD and display it on the LCD Panel.
If the OSD cannot be displayed then the LVDS signal levels must be
checked to reliably determine whether the A-Board or the TCON/HFR
Board is defective.
1) Check for USER Menu OSD Display
a) USER Menu Displays. Replace A-Board
b) USER Menu Does Not Display. Go to Step 2
CTV-61
AZ1K Chassis Models Overview
2) Check for TCON 12V at CN4152/pins 4 - 10 & CN6151/pin 2
a) No 12V. Check connections between A-Board & Panel
b) 12V Present. Go to Step 3
3) Check LVDS Cable Video Signal Levels at CN4152
a) LVDS Video Signal(s) Low or Missing. Replace A-Board
b) LVDS Video Signal(s) Okay. Replace TCON/HFR Board
Skewing LVDS Connector Troubleshooting Method
It maybe difficult or impossible to check the LVDS signal while in the field.
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
TCON/HFR Board. When performing this method it is important to keep
the 12V end of the connector connected while dislodging the LVDS video
connections. Therefore, find the 12V using a voltmeter. The 12V is usually
on one end of the connector (usually left-side on bottom mount or top on
side mount connect).
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
the is no video reaction on the screen while skewing the connector then
the TCON/HFR Board is defective.
Distorted Video (All Inputs)
The following paragraphs describe the unique and common effects the LCD
Panel Assembly, TCON/HFR Board, and A-Board have on the displayed
video concerning possible distortions. Knowing how each component
affects the displayed video can be very helpful in troubleshooting a
distorted video condition.
NOTES: Reference Appendix for picture examples of unique distortions
for the LCD Panel, TCON/HFR Board, and the A-Board
WIDE Mode Button (Aspect Ratio) Troubleshooting Method
A quick test to determine if the A-Board, TCON/HFR, or LCD Panel is
causing the distortion is to change the panel aspect ratio (or picture size).
25

The aspect ratio can be easily changed using the “WIDE” key on the
remote controller. If the distortion follows the video then the A-Board is
causing the distortion. If the distortion remains stationary after changing
the aspect ratio then the LCD Panel assembly is causing the distortion.
WIDE Mode
Button
WIDE Mode
Function
Unique Main Video Board (A-Board) or LVDS Cable Effects
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-
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
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,
if either the picture size or geometry is abnormal the A-Board
is defective. Only the A-Board can cause such a distortion.
CTV-61
AZ1K Chassis Models Overview
• Color Distortion - A color distortion can be caused by a
defective IC400 or LVDS cable. The individual color signals
are spread out over the LVDS twist pair wires. For example,
the Red signal may be broken up into three components and
sent over three different LVDS twisted pairs. Therefore, this
distortion will display as a poor reproduction of a particular
color not an overall loss of one color. Use a Red, Green, and
Blue raster generator to confirm a poor reproduction of a
single color.
• 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
SNR should be in the range of 25db to 30db and there should
be zero Errors.
Signal Diagnostics
Product Support
Signal Diagnostics
Screen
26

Unique TCON/HFR Board Effects
• 2” Vertical Transparent Colored Bar- The bar will be
approximately 2" because this is the area that is controlled
by a single drive IC that is located across the top of the LCD
Panel assembly.
• Video Timing - The Video Timing distortion may appear as a
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.
• Half or Full Screen Video Distortion - In this case, the key
distinguishing factor is the presence of undistorted video
behind the color distortion. The distortion is basically an
overlay (transparent color half-screen or bar) in front of the
good video coming from the A-Board.
• White or Colored Blooming - The bloomings may come
down from the top of the screen and vary in size.
• GAMMA Irregularity - A GAMMA distortion will appear
as a overall brightness problem or a localized area color
distortion.
Unique LCD Panel Assembly Effects
• Line(s) of Pixels (Fixed Position) - Poor physical connection
(or bonding) between the LCD Panel and the flex cables will
cause a loss of line(s) of pixels. The pixel drive lines can be
open (no drive) or shorted (drive all the time). Depending on
the type of failure the line(s) or pixel(s) will be black, white, or
colored (red, green, or blue). These lines and pixels will also
be very sharp in detail.
• 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-61
AZ1K Chassis Models Overview
• 2” Vertical Solid White or Black Bar- The bar will be
approximately 2" because this is the area that is controlled
by a single drive IC that is located across the top of the LCD
Panel assembly.
• Horizontal Bar- Any horizontal bar of any color will be caused
by a defective LCD Panel assembly
• White Balance (WB) Irregularity - A WB irregularity will
show up as an overall poor reproduction of white. A white
raster can be used to determine if a WB or gamma irregularity
has occurred. WB will cover the complete picture, where as,
gamma will be in specific zones or specific color areas in the
picture. WB adjustment data is stored in the EEPROM IC4302
on the A-Board. The WB data stored in IC4302 is set to the
middle value of the data span. The TCON/HFR Board also
contains WB data, which is specifically set for the associated
LCD Panel.
• GAMMA Irregularity - Gamma Correction affects the overall
picture brightness level and individual color (RGB) brightness
levels. Gamma adjustment data is stored in the EEPROM
IC4702 The TCON/HFR Board also contains GAMMA
data, which is specifically set for the associated LCD Panel.
The data may become corrupted causing irregular gamma
adjustment. Therefore, a gamma distortion can show up as a
color brightness irregularity in specific zones or specific color
areas in the picture, as well as an irregularity in overall picture
brightness.
27
 AZ1K Chassis Models Overview

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-61 28

Audio Symptom Troubleshooting
Reference Figure 2-9
Normal Operation
The HDMI digital audio signal is first applied to the HDMI Receiver/Switch
IC6601 and then to the MT5388 on the 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.
All other audio inputs are applied directly to IC400. The MT5388 IC400.
outputs the audio signal as a SPDIF signal for the Optical output. The
FIXED analog audio output passes through an amplifier IC8301 and then
is applied to CN8301.
The main speaker audio comes from IC400 and passes through amplifier
IC8151 and then to CN8151 and CN8152 speaker connections..
The AU12V from the G2LE, G2HE, or GD2-Board is the power supply for
the audio output amplifier IC8151.
IMPORTANT:
• Confirm the TV has the most recent Software Version
installed. Go to the User Menu for the present TV software
revision and the ASC web site for the most recent software
version.
Failure Symptoms
The first step when a “Missing or Distorted Audio” defect occurs is to
determine if audio is missing or distorted on all audio input sources or
only on one or a select number of audio input sources.
Input Status:
• Missing or Distorted Audio on All Inputs
• Missing or Distorted Audio on Individual Inputs
CTV-61
AZ1K Chassis Models Overview
Missing or Distorted Main Speaker Audio - All Inputs
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
defective component.
1) Check for audio at the Analog FIX or DIGITAL Audio Outputs
a) No or Distorted Audio (Replace A-Board)
b) Audio Present & Undistorted. Go to Step 2
2) Check for AU12V at CN201/pin 1 on A-Board
a) No AU12V - Check connections between the Power Supply
board and the A-Board
b) AU12V Present replace A-Board
Missing or Distorted Main Speaker Audio - Individual Inputs
If only one or a select number of input sources are experiencing a problem,
then the individual inputs must be checked separately. The external
devices and their associated cables connected to the faulty input should
be checked first.
Substitute a known good device and cable on the suspected faulty input.
Connect the device and cable at separate times to determine if the device
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
that particular input source.
For example, consider the symptom of all HDMI inputs are faulty. Logically
the only device that could cause this symptom is the HDMI switcher
IC6601 on the A-Board. In this case, replace the A-Board.
29
 AZ1K Chassis Models Overview

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
G2LE-Board (32")
G2HE-Board (40") CN8152
GD2-Boad (46")
CN6401 (32", 40")
CN6150 (46") CN201
AC F1
AU12V 1 1
PS6401

AUDIO SYSTEM
FIGURE 2-9

CTV-61 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-61 31
 Section 4 - Triage & Troubleshooting Flowcharts
Triage Flowchart

A Triage Flowchart A
(AZ1K 32", 40", & 46" 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, 4

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-61 32
 Triage & Troubleshooting Flowcharts
Power-ON Troubleshooting Flowchart
Power-ON Troubleshooting Flowchart B
(AZ1K 32", 40", 46" Models) Check STBY 3.3V
at CN6401/pin 1 CN6150 - 46"
(In STBY Mode)
NOTE: Confirm all connections
B between circuit boards before replacing
Replace
Unit will Not Is voltage No G2LE-Board
3.3V
Power-ON Present? G2HE-Board
(All Models) GD2-Boad

Yes

Press
Check Power_ON
TV & Remote at CN6401/pin 3 CN6150 - 46"
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 CN6401/pin 9
(In STBY Mode)) Unplug and Plug AC
Blink Pattern
Power Cord .
Confirm Unit is CN6150 - 46"
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 CN6101? Replace
Check G2LE-Board
CN6003 - 46" AC_OFF_DET
at CN6401/pin 2
G2HE-Board
Yes GD2-Boad
CN6150 - 46"
Check Main Fuse
F6101 IP3N-Board
(0 ohms) Is voltage
F6001 - 46" No
3V
Present?
Replace
Is Fuse Yes G2LE-Board Yes
Open? G2HE-Board
GD2-Boad
Replace
No A-Board

CTV-61 33
 Triage & Troubleshooting Flowcharts

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 32" & 40" 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

4X Blink Pattern
2X Blink Pattern 3X Blink Pattern
Balancer
AU12V LVP & SW12V OVP Audio 46" Models ONLY

Check Check LD
Check AU12V at Speakers & Volatge
CN6401/pin 4 Connections CN6702/pin 5
*Before Shutdown CN6150 - 46"

Is voltage
Replace Do 0V Replace
Is voltage 0V or 12V
12V
Present?
No G2LE-Board
G2HE-Board
Speakers
Measure
No ■ Replace Present?
LCD Panel

GD2-Boad Speaker(s)
8 ohms
? 12V
Yes
Yes Replace
Check SW12V at
G2LE-Board
CN6401/pin 9
CN6150 - 46" Replace G2HE-Board
*Before Shutdown
A-Board GD2-Boad
(>) Greater Than
(~) Approximately (Does
not exceed) Is Replace
Voltage >12V G2LE-Board Is Problem No Replace
~12V or >12V G2HE-Board Solved? A-Board
? GD2-Boad

Yes
~12V
Problem
Replace Sloved
A-Board

CTV-61 34
 Triage & Troubleshooting Flowcharts

Protection Mode 5X & 6X(32”, 40”) Troubleshooting Flowchart

NOTES:
Protection Mode Troubleshooting
1) All Red Blink patterns will occur on the Front Panel C2
Red “Standby” LED Flowchart C 2 (AZ1K 32", 40", 46" 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

Check 24V at
CN6402/pin 3
*Before Shutdown
6X Blink Pattern
5X Blink Pattern
(No Backlight)
TCON/HFR Error Is
32" & 40" Models ONLY
voltage Replace
No
24V Before G2LE-Board
Is “SONY” logo Shutdown G2HE-Board
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 CN201/pin 12
Is
No Repair *Before Shutdown
connection Check
Connection
OK? Inverter HV Outputs
*Before Shutdown Is
Yes
voltage
No Check for
3V Before Open or Short
Check TCON 12V supply Shutdown
CN6403/pins 1 & 2 CN6151 - 46" Are Yes Replace ?
Select outputs
Inverter Board
missing? Yes Replace
A-Board
No Check Dimmer signal at
Is 12V CN201/pin 13
Yes Replace
Present *Before Shutdown
TCON/HFR Brd Replace
? LCD Panel
Assembly
No
Is
Is voltage
Replace Check for
Issue No Replace 1V to 3V Before
G2LE-Board Short
Resolved A-Board Shutdown
G2HE-Board
? ?
GD2-Boad
Yes Replace
A-Board
Issue
Resolved Replace
Inverter Board

CTV-61 35
 Triage & Troubleshooting Flowcharts
Protection Mode 6X(46”) & 7X Troubleshooting Flowchart

NOTES:
1) All Red Blink patterns will occur on the Front Panel Protection Mode Troubleshooting
C3
Red “Standby” LED Flowchart C 3 (AZ1K 32", 40", 46" 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

Temperature Threshold
6X Blink Pattern Ambient 80°C
(No Backlight) 7X Blink Pattern
Temperature Error
46" Models ONLY

Check HV at Does
CN6704 & CN6705 Yes unit Shut-Down
*Before Shutdown Immediately after
Power ON
?
No
Is
voltage Clear unit ventilation areas
No Replace and confirm adequate local
HV Before
GD2-Board room temperature
Shutdown
?
Yes

Does unit still No Issue

Check Backlight-ON Check Dimmer signal at shutdown (7X)? Resolved
signak at CN201/pin 13
CN201/pin 12 *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
GD2-Board

CTV-61 36
 Triage & Troubleshooting Flowcharts
Video Troubleshooting Flowchart
D Video Troubleshooting
Flowchart D (AZ1K 32", 40", 46" 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
Backlight ON ?
Flowchart C 2
?
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-61 37
 Triage & Troubleshooting Flowcharts
Audio Troubleshooting Flowchart

E
Missing or Distorted Audio
(Speaker Outputs )
Audio Troubleshooting
Flowchart E (AZ1K 32", 40", 46" Models)
NOTE: Confirm all connections between
circuit boards before replacing

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
CN6150 - 46"
at CN6401/pin 4 (across Speakers)
& Connections

Replace
Is 12V No G2LE-Board
8 ohms
Present? G2HE-Board No
& Replace
GD2-Boad
Connections Speaker(s)
Yes OK?

Yes

Replace
A-Board

CTV-61 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-61 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-61 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-61 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-61 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-61 43
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2007 Sony Electronics, Inc.

EMCSA - A Service Company
16530 Via Esprillo
San Diego, CA 92127
CTV610110 Reproduction in whole or part without written permission is prohibited. All rights reserved 03/30/10