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Plasma TV & Grand Wega Projection TV

1. 45 22 Optical Unit Removal 46 23 Screen Mirror Replacement 50 24 Troubleshooting TV Shutdown 53 25 Power Supply 54 26 Fan Control KF 60DX100 56 27 Grand Wega Lamp Control 59 Lamp ODE FAO S NT 59 Lamp ON Display eessussess 62 Power Block Location amp Removal 62 Troubleshoolilig eie dae Eoo eio Ee corem Soto tunt 63 28 Video Process 65 Sony Plasma TV KZ 32TS1U KZ 41TS1U Introduction This training manual has been organized to provide a quick diagnosis of problems in Sony Plasma screen TV models KZ 32TS1U and KZ 41TS1U The circuitry in these two TV sets is similar but the boards and plasma panels are mounted differently Because the Plasma TV set is a new design concept Chapter 1 will cover normal Plasma TV operation The last chapter will cover plasma principles concepts only necessary for background information Repairs to these TV models involve identifying and replacing a circuit board the plasma panel or other parts such as the fan or the on off switch This manual is divided into thirteen chapters Table of Contents Chapter 1 Normal Operation This 16x9 plasma screen TV operates differently from a picture tube TV 2 Self Diagnostics The front panel Standby light blinks to
2. 10 usec div timebase FIGURE 12 2 DIGITAL VIDEO OUTPUT WAVESHAPES TO THE PLASMA PANEL Location of Digital Input Connector CN 1 on the Plasma Panel CN1 on the B Board plasma panel CN1204 FIGURE 12 3 LOCATION OF DIGITAL VIDEO SIGNAL CONNECTOR CN1 33 12 Video Signal Flow Digital Video Signal to Plasma Panel Video signals Out 0 3 are digital video signals applied to the plasma video panel Out 0 is the LSB Least Significant Bit and Out 3 is the MSB Most Significant Bit The digital video signal is accompanied by a clock signal for timing e Missing Clock signals CLK Out produce a dark screen no picture with normal sound e Missing LSB signals Out 0 or Out 1 produce a picture without detail as shown in figure 12 4 FIGURE 12 4 TV Picture missing Out 0 or Out 1 LSB Picture Detail TV Picture missing Out 0 or Out 1 LSB picture detail Splotches appear on faces or areas where there should be detailed lines 34 Chapter 13 What is Flat Screen Plasma Technology The flat panel plasma display is the latest display technology and offers the following TV monitor features e Bright screen light easily viewable in any environment e High resolution for excellent image quality e Large flat screen sizes e Wide viewing angle e Light weight Flat screen plasma panels consist of cells that produce light Three such cells of red green and blue light form a cluster known as a pixel Th
3. 0040 PlsmaPand PDP ooo Twer Ubowd 100 Awo Wide iC Bboara 0200 AD Gonvener B board 00 EPROM M boar o0 System iC Bboard E E 1000 V Chip Q board 2000 PLD B board 4000 Real Time Clock IC B board 8000 Scan Converter B board Service Mode EEP ROM Initialize hole Area Common White Balance Prog Gamma Tuner Prog Preset Last Memory User Memor Figure 6 3 Service Mode EEP ROM Initialize 6 Service Mode service Mode Chroma Decoder Hue Sub Contrast Sub Color Sharp Gain Sharp fO Y Out Level C Out Level Figure 6 4 Service Mode Chroma Decoder Service Mode General Blue Only AGC Wide AGC Narrow 32k Clock Out Watch Error Serial Number Fan Status Vs Va Sett Figure 6 5 Service Mode General service Mode Manual Control AD Converter IP Converter 4 scan Converter SC Indirect PDP Chroma Decoder Combfilter Audio Amp Figure 6 6 Service Mode Manual Control 1 2 10 6 Service Mode Service Mode Manual Control Combfilter Audio Amp Audio Sw Closed Caption Auto Wide PLD Figure 6 7 Service Mode Manual Control 2 2 service Mode Preset Edit Save Area Select Service Mode service Status Signal Syne Power Supply Fan amp Temp Status Warning Status Operation Time 00009H Software Verscen Te Figure 6 9 Service Mode Service Status 11 Chapter 7 Adjustments when the B Boa
4. HV ANTENNA POSITION 61 27 Grand Wega Lamp Control 2 Lamp ON Time Display The time the lamp is ON in hours is stored in the service mode within the Option E category 1 Enter the service mode remote Display 5 Vol Power ON 2 Use the 5 button to locate the Option E category Button 5 moves up to Option E from the bottom of the list 3 Change this first Lamp Time item data from O to 1 using the 3 button 4 The lamp time is displayed on the screen in hours Lamp On Time Reset 5 oreset the time follow the procedure above return to step 3 Lamp Time item but change the data to 0 and press MUTE then Enter The hours will reset to 000 3 Power Block Location amp Removal From the back of the TV set the Power Block is located at the bottom center Figure 27 3 shows the Power Block right and its HV wires terminated at the lamp socket left L ET uN Fami Power Block Assembly Power Block FIGURE 27 3 HV LAMP CONNECTOR The Power Block assembly and HV connector is one assembly and must be removed together 1 Remove the two screws from the HV socket as shown in Figure 27 3 2 Lift the Power Block as an assembly up and outward see Figure 27 4 3 Remove the top and bottom covers and unplug the two board connectors not shown 62 27 Grand Wega Lamp Control i h 7 EFF E Pa J cy EM 1 ANE 7 E E Y s m a E A i o AAN od dd Adm
5. Audio Problem 1 2 ck fuses PS1601 2 Dark Screen sound OK eo Determining if the optical unit is OK for quick tests Dead Set no relays heard op also ck for open BiMetal fuse under rear fan Dead Set DeadSet relaysclick click See Standby indicator blinks ESC LED blinks 3 times 1 Ck lamp cover Sw Stby LED blinks 4 times 1 Fan 2 A Bd Stby LED blinks 5 times PT Stby LED blinks 6 times to 1 ck fuses PS1601 2 Stby LED blinks 9 times Video Distortion Tuner amp composite Video Video Distortion component video Video Distortion all inputs Symptom optical unit 40 Chapter 18 Board Locations FIGURE 18 1 BOARD LOCATIONS Optical M Board BC Board Power Block pu Lamp Power Bottom BB Board Supply A Board U Board G Board Power Supply FIGURE 18 2 BOARD LOCATION 41 Chapter 19 Adjustments White Balance Brightness The service manual shows a series of white balance and brightness level adjustments for the TV Twin Video inputs and component inputs They can be touched up when changing the BB and BC boards and must be adjusted when replacing the M board Geometric Distortion There are no adjustments for geometric distortion That is adjusted in the preassembled optical unit If there is geometric distortion inspect the mirror top area of the TV for damage Convergence Convergence is not adjusted in this set The LCD
6. Twin View Mode On Screen Display to Check the Optical Unit You can use the On Screen Display Menu to check the circuitry after the BB board If the screen displays no black or white picture or a distorted picture press the Menu button on the remote control If the screen displays the OSD menu undistorted the optical unit assembly is working along with the OSD circuit in the later stages of the BB board where the OSD circuit is See Figure 14 1 If the OSD Menu is present this also means the BB and BC boards are the primary suspects causing the video distortion Video Problem that does not appear in the MILD Picture Mode When watching an NTSC program from the tuner or video 1 4 inputs this video signal passes through the DRC and MID circuits on the BB board By selecting the MILD picture setting this video signal is diverted around the DRC stage Therefore if the NTSC video problem does not appear when selecting the MILD mode the problem is on the BB board in the DRC circuit 67 Video Problem Only with a single input or feature Table 28 3 lists a feature and or input that has a picture distortion and the corresponding board that is most likely responsible for the problem For example if a video problem only appeared while watching a TV station but not in a video input the most likely cause is shown by the 1 under the A board column A board defect The 2 under the U board column indicates a lesser possibility that the A V sel
7. If the problem is in component video change the BC board FIGURE 28 5 FLOW CHART ISOLATING THE VIDEO PROBLEM USING THE TWIN PICTURE MODE Press the Twin Mode button on the remote control and make the If the video problem is Yes stationary the optical unit RIGHT picture larger optical assembly is Does the problem remian defective Replace it where it is on the screen No Moves to a picture Do both pictures have yas Change the the same problem BB board MID circuit problem Make the LEFT picture il Change the larger Where is the BB board defect DRC circuit problem Different Pix BC and BC4 boards are both ics Change BCA board suspect Unplug the BC4 board and jump the A board s CN1901 pin 1 to pins 3 and 5 Problem gone NO Change BC board 4 16 02 70 SON Y is a trademark of Sony Electronics SONY Sony Electronics Inc EMCS A Service Company 1 Sony Drive TVP130402 Park Ridge New Jersey 07656 este All Rights Reserved 2002
8. NVM 1C9002 is Section 3 2 page 39 transplanted to the new M board 43 Chapter 20 Service Mode Access Conventional From the remote press Display 5 Vol Power ON Category selection buttons 2 up and 5 down Item selection buttons 1 amp 4 Data change 3 amp 6 Store data Mute Enter New The details of New Category Option E for lamp information and fan control are clarified and is shown in Table 20 1 Table 20 1 Contents of Service Mode Option E Item Name Description Typical Data number Lamp Time Lamp operating time in hours Hours shown when data is changed to 1 Reset when data 0 is stored mute enter Lamp Off Lamp time after TV turns OFF 020sec 1 5 seconds Fan Off Fan time after TV turns OFF 0 0 mins 1 2 mins Fan 1 RPM 1 LCD Fan speed TV ON 3 speeds 0 slow Fan 2 RPM1 Lamp Fan speed TV ON 3 speeds 0 slow Fan 2 RPM2 Lamp Fan speed TV OFF 3 speeds P CTL Sht 1 LCD video position Correction 1 after hours P CTL Sht 2 LCD video position Correction 2 after hours LCD Fan speed after TV is OFF 3 speeds e 44 Chapter 21 Determining if the Optical Unit is OK The optical unit can fail producing e V Shut down by loading down the power supply e White or black screen e Missing a color If the TV shuts down probably without a Standby LED fault indication the optical unit can be unplugged and the TV powered up to see if the TV remains ON No
9. TV turn ON within two seconds the Powr Block or power supply board fuses are bad If CTL is OVdc at turn ON the controlling M board is bad or one of the Fans is not rotating no fan causes no lamp ON and shutdown See the Fan Control Fan Troubleshooting in Chapter 26 or just check the self diagnostic Chapter 16 63 Defect No backlight repair flow chart The following flow chart will help you quickly ID the problem board but you must be careful High Voltage at a very High Current is present not like a TV s FBT where there is low current Be aware that if the backlight does not start at power ON the lamp HV circuitry is repeatedly instructed to try to turn ON for two seconds and again five seconds later until the TV shuts down Therefore you must keep away from the HV when the TV is plugged into AC To use this flow chart you will need a DVM to determine which board is defective Cll Gnd Power Block Side View pP With the TV unplugged bend down the left C101 capacitor on the Power Block as shown to make cylinder G1 visible Symptom Fan ON but Backlight OFF Standby LED blinks A V muted TV shuts down after 3 minutes Connector WARNING At TV turn ON LETHAL HV at high current unliked an FBT outputs the Power Block Observe spark gap cylinder G1 for HV from two feet away or more Close front panel lamp door so HV can start Corner top view Watch the G1 spark gap behind Does Ctl whit
10. a a a da ena e z E La i F TA Ka Tri P T iat e mo a Dow T s V a T LUE mt Y A M rr be c o L ed pa i LE Uer a A pur Tre D dg T A TE POWER BLOCK ASSEMBLY vni Tcl ria er a a E cw FIGURE 27 4 COMPLE 4 Troubleshooting Defect Unreliable backlight starting As the gas discharge tube reaches the end of life the most common symptom is unreliable starting at power ON especially when the lamp is cold Replace the lamp Defect No backlight repair procedure The lamp will not turn ON because of a defective e Lamp e Power block board no HV e Control engine M board no turn ON signal e Fusible resistor s on the power supply G board Concept When the backlight bulb lamp reaches the end of life and does not ignite the internal resistance across its two terminals remain high open circuit This causes the HV to climb to 25kV and arc across the spark gap device G1 on the Powre block proving the Power Block and controlling M board are working The HV arcing makes an audible frying sound and light is visible The HV arcing lasts two seconds stops for five seconds and repeats until the TV shuts down in three minutes Troubleshooting procedure If the Power Block arcs the bulb is either defective or not plugged in No arcing Measure the HV control signal input to the white wire of the 3 wire connector on top of the Power Block If this CTL input voltage is correct at 5Vdc at
11. conductive mesh tape between the bezel and plasma panel refer to Figure 9 6 If you want to test the TV before installing the shield attach the rear circuit board assembly plug it in and turn on the TV set Without the rear shield in place you will get horizontal lines of interference on the TV channels from the power supply After testing remove the rear circuit board assembly to install the shield Install the rear shield with the decorative top control panel Put the top ferrite assembly inside the shield or you will not be able to fasten the rear cover later on Make sure the shield mates with the metal on all four sides to complete the shield Attach the rear circuit board assembly Replace the two conductive mesh tapes over the upper and lower holes in the rear shield refer to Figure 9 2 Put the back cover in place 27 Chapter 10 Standby Power Power ON otandby Power Standby power is present when e The TV is plugged in e The front panel ON OFF switch is latched in e he red standby light within the ON OFF button is lit CN7 VSA C IC21 IC22 ON GO CONTROL OV TV OFF VCE EM Go FIGURE 10 1 POWER ON 1TVP13 1431 3 14 02 Circuit Operation Refer to Figure 10 1 The standby power must be kick started by a 6V pulse available when the TV is first plugged into AC The 6V pulse comes from regulator IC1 and passes through C16 into the standby power supply circuit Within the standby power supply is IC
12. indicate major and minor problems 3 Board Selection by Defect Listing of possible defects and where they may be 4 Plasma Panel picture Listing of possible plasma panel screen defects Defects 5 Board Location Location of replaceable boards in model KZ 32TS1U 6 Service Mode oervice Mode access and contents 7 Adjustments Adjustments after the B board is replaced 8 Plasma Panel Pictured procedure to avoid problems in access and reassembly Replacement KZ32TS1U KZ32TS1U and KZ42TS1U have separate pictured procedures 9 Plasma Panel Pictured procedure to avoid problems in access and reassembly Replacement KZ42TS1U KZ32TS1U and KZ42TS1U have separate pictured procedures 10 Standby power Power Location and circuit operation for Standby voltage and Power ON ON circuit description sequence 11 Fan Drive circuit Fan Operation troubleshooting and testing description 12 Video Flow circuit oignal levels description and symptoms when missing description 13 Plasma Display Plasma Cell Operating Concepts Technology Chapter 1 Normal Operation Black top and bottom letterbox borders Even though this TV has a wide 16x9 screen it is still possible to receive a picture with top and bottom black bands Movies are shot in many aspect ratios The most common ratios are 4 3 1 85 1 and 2 35 1 The picture displayed is dependent upon what aspect ratio the movie was shot in and how different it is from your TV screen s as
13. induced electrical feedback signal to adjust cell timing The triad combination of one red one green and one blue cell produces one pixel SCAN ELECTRODE SUSTAIN ELECTRODE TRANSPARENT m TRANSPARENT FACE PLATE PROTECTION f f LAYER ELECTRIC Y DISCHARG f LAYER 5N AN RIB M P HS A PHOSPHOR BACK PLATE BLUE PHOSPHOR RED PHOSPHOR GREEN DATA ELECTRODE FIGURE 13 1 PLASMA CELL STRUCTURE 4TVP131435 4 15 02 35 Cell Intensity Screen Brightness The intensity of the cell is determined not by how bright it glows but by how often it fires within a field or frame The more times it fires the brighter the cell seems but actually they fire at full intensity each time The number of times it fires is based upon the phosphor persistence and is usually a maximum of eight times per frame 16 FIGURE 13 2 SONY 16 X 9 PLASMA PANEL SEGMENTS Cell Selection and Screen Layout Within each panel the individual cells to be fired are selected based upon the horizontal and vertical grid similar to a multiplication table The screen is divided into eight panels as shown in Figure 13 2 36 Sony KF 60DX100 Introduction This portion of the training manual has been organized to enable you to quickly diagnose problems in the Grand Wega 60 Projection TV model KF 60DX100 This Hi Scan 16x9 aspect ratio LCD TV has a high brightness long life backlight that is user replaceable Repairs involve deter
14. light should now be lit red while the TV is OFF Standby sleep light Figure 6 1 2 Using a Sony remote control aimed at the TV in the standby mode quickly press Display 5 Volume Power ON and MENU If the TV turned ON when 5 was pressed you did not press the next Volume button fast enough and will have to try again 3 The following new service Mode menu shown in Figure 6 2 will appear above the user menu Use the remote control joystick to move and change the data as before Store data as in previous service modes by pressing Mute and then Enter Service Mode Service Menu EEP ROM Initialize Chroma Decoder AD Converter White Balance General Manual Control vedi Preset Edit service Status Figure 6 2 Service Mode Display Service Mode Contents Table 6 1 Service Mode Contents Service Category Contents EEP ROM Initialize See Figure 63 for a list of Initialize contents Selecting a line like Common reveals two options OK or cancel Selecting OK stores default data and causes the TV to reboot You must press Menu when the TV turns back ON to return to the service mode Do not select OK unless you have read what you are resetting to default levels Whole Area Resets the entire EPROM and requires a full TV alignment afterwards The serial number elapse operation time and diagnostic are erased This is used when the TV is made For service you can individually reset EPROM contents Commo
15. orange Red signal CN5002 pin 11 15Vdc CN5005 pin 7 5Vp p orange Vert sync CN5005 pin 9 5Vp p Horiz sync If the screen is black the optical unit or BB board may be bad Determine which one by unplugging the CN5002 power connector to the optical unit If the screen becomes white the BB board is bad A white screen is normal if the optical unit loses power it passes all the backlight If the screen remains black the optical unit is bad If the screen is missing a color the RGB signals entering the optical unit CN5005 have to be verified before accusing the optical unit of the failure The signal levels are given in Table 21 1 45 Chapter 22 Optical Unit Removal The optical unit contains the video output portion of the TV in one assembly with three colored LCD panels and the C board The optical unit is held in with just two screws but the TV board assembly and the power block board must be pulled out to access these screws The optical unit is replaced as an assembly Procedure a Remove the lower back panel and the three support brackets Figure 22 1 FIGURE 22 1 THREE SUPPORT BRACKETS b Lift the TV board assembly up and outward Figure 22 2 46 22 Optical Unit Removal FIGURE 22 2 IV BOARD ASSEMBLY SLIDES OUTWARDS c Remove the two screws holding the lamp socket Figure 22 3 The power block HV wires are not long enough to permit the power block to swing out of the Nes Ex icum Power Blo
16. supply and the voltage applied to the fan motor 8 6Vdc slow Vs Va Setting The main plasma panel voltages Vs and Va are set using Uvrs and Uvra The 32 TV uses Uvrs 82 and Uvra 106 The 42 TV uses 93 and 128 respectively Vs and Va needs adjustment if the logic board within the plasma panel is replaced Manual Control See Figure 6 6 and 6 7 These are all preset to 00 except for PDP 20 Preset Edit See Figure 6 8 This section presets the parameters for a new video input signal 6 Service Mode oervice Status See Figure 69 This section displays the status of the input signal and TV condition oignal sync Format freq and sync polarity of the input signal Power Supply Low voltage output of the power supply in voltage DC Fan amp Temp The fan voltage and power supply temperature Within this category is a No Ack Dev Points to an IC that is not communicating with the Main Micro using a 4 digit defect code number See No Acknowledge Device table 6 2 Warning Status Shows completion of communications from the Main Micro B board to memory IC and to 15 others Operation Time Elapse TV ON time Software amp PLD version Software in Main micro and Panel Micro Defect Code SuspecediG DefectCode Suspected IC 0001 Aude Processor Aboard 0002 Audo Swich Q boar n AV Swich 1G Uboard 0008 VChip boar 00 8D Comb fiter IC B boardy 0020 Color Decoder B boardy
17. will remove the rear circuit board assembly and the rear shield Before you can pull off the plasma panel a Remove the back panel to expose the input circuit board assembly and shield Circuit Board Shield Assembly FIGURE 9 2 BACK WIRES 23 9 Plasma Panel Replacement KZ 42TSIU b Seven connectors must be removed Three connectors have a catch that must be pulled or squeezed to separate the connector The remaining four connectors are simply unplugged Remove the conductive mesh tape that shields the ribbon connector and unplug the white ribbon cable Figure 9 3 by pulling it straight out Do not fold the ribbon cable Squeeze Pull Catch Squeeze l Connector Connector Connector 7 Machine Ribbon Cable Screws behind the tape FEE ETET Circuit Board Unplug Assembly Connector FIGURE 9 3 REMOVE 7 CONNECTORS AND 7 SCREWS c Remove the seven machine screws around the circuit board assembly and pull off the assembly d Remove the rear shield with the top decorative panel to expose the circuitry Figure 9 4 Power Supply B Board FIGURE 9 4 REAR SHIELD REMOVED 24 9 Plasma Panel Replacement KZ 42TSIU e Place the TV face down on some books so the TV is level Rails Stand FIGURE 9 5 LEVEL THE TV ON BOOKS f Remove the two rails with the center B board and TV stand Conductive Mesh Tape Conductiv Mesh Tap Conductive Handles Mesh Tape FIGURE
18. 10 and T1 IC10 is an oscillator that starts and feeds small transformer T1 T1 outputs standby 5Vdc to the Micro CPU B board and standby 3 3Vdc to the plasma panel Another T1 output not shown supplies voltage to the end of C16 to keep the standby power supply ON after the kick start pulse had decayed Therefore the standby power supply starts and runs as long as the TV is plugged into AC regardless of the TV s Power ON switch position Power ON Power ON can be initiated only after the front panel Power ON button has been pressed 84101 closed on the Q board causing the red Standby light beneath this button to light standby 5Vdc present See figure 10 1 This switch closure releases Micro CPU 1C1004 B board permitting IC1004 to turn ON the TV Then the TV may be turned ON e From the front panel by pressing the channel or buttons e From the front panel by pressing the Power ON button twice e From the remote by pressing the channel or buttons or the individual channel numbers e From the remote by pressing the Power ON button 20 Circuit Operation Once standby power is available to the Micro CPU IC1004 B board IC1004 can respond to either the channel buttons or power ON button to turn ON the TV Two commands are output IC1004 to turn ON the Plasma panel CPU GO and RDP GO both go high at CN1 pins 5 and 6 The power ON path has to go through the plasma panel After the panel has initialized it will output two comm
19. 1oo2 onzo Figure 8 13 Unused Test Connectors CN3008 21 8 Plasma Panel Replacement KZ 32TSIU e Mount the input connector cover that contains the AC socket Figure 8 3 e Test the TV by plugging in AC and a VHF signal The TV will operate for at least 30 minutes without the fan connected There will be horizontal noise bars of interference from the power supply when the rear shield is not installed e Install the TV shield and fan Make sure the shield makes contact to the conductive mesh on all four sides and the shield is screwed into the center TV board assembly or you will have interference on the TV stations Fan amp Shield Figure 8 2 e Install the rear panel 22 Chapter 9 Plasma Panel Replacement KZ 42TS1U The KZ 32TS1U and the KZ 42TS1U are mechanically different and have separate procedures for the Plasma Panel removal Handling Precautions e After removing the plasma panel from the TV note that there are flex cables located at the bottom and both sides of the panel that are susceptible to damage Only rest the plasma panel topside down so the cables are not damaged The 32 Plasma panel is shown The 42 is similar Bottom Flex Cables Panel Bottom zsif j del Dium i A t L 5 iT i 5 Tr ae ee 1 a LI E Jl a L E LIS ma Flex x Cables Top Figure 9 1 Plasma Panel Standing Upside Down Procedure In the following pictured steps you
20. 3009 pin 2 This LOW is applied to Main CPU and permits the temperature of the power supply board to adjust the Main CPU fan drive output voltage Typically at start up the fan drive voltage at CN1001 pin 24 drops from 5Vdc down to 1 5Vdc to produce 8 6Vdc at CN3009 pin 1 to run the fan at slow speed Troubleshooting No Fan Rotation If the fan is unplugged or there is no fan rotation detected Main CPU reacts by turning ON the Fan drive signal CN1001 pin 24 to 5Vdc every two seconds for a very short time that may be difficult to detect except on a peak reading DVM This results in 12 volt fan run voltages that appear at the fan terminals CN3009 pin 1 every two seconds as long as the TV is ON 30 Fan or Q board To determine if the fan Q board or B board is causing NO fan rotation turn ON the TV and 1 Measure the voltage at the fan connector CN3009 pin 1 red wire with the fan connected loaded 2 Normal 12Vdc means the fan is bad Replace the fan 3 CN3009 pin 12 OVdc You must inspect CN3005 pin 1 and CN1001 pin 24 at power ON e CN3005 pin 1 on the power supply board normally 13Vdc e CN1001 pin 24 on the B board normally 5V pulse at power ON The pulse can be read with a peak DVM 4 Is CN3005 pin 1 OVdc Replace the power supply board 5 Is CN1001 pin 24 at OVdc or stays at 5Vdc at power ON e 5Vdc at CN1001 pin 24 during power ON means the B board is OK so the Q board is bad e OVdc at CN1001 pin 24 during power ON m
21. 9 6 RAILS AND STAND REMOVED g Mark the position of the conductive mesh tape around the plasma panel before removing them They are necessary to prevent interference on the screen h With a partner lift the plasma screen off by the handles Figure 9 6 PLACE THE PANEL UPSIDE DOWN ON THE FLOOR SEE FIGURE 9 7 The power supply board must be removed from the panel if the panel is to be replaced Only clean the inside of the screen with Sony cloth p n X 4034 197 1 25 9 Plasma Panel Replacement KZ 42TSIU Glass Plasma Panel Screen Bottom FIGURE 9 7 SCREEN UPSIDE DOWN ON FLOOR Heassembly In the reverse order of removal The inside of the TV screen is coated so do not clean or leave oil on it by touching it The inside surface scratches easily Clean the inside of the TV screen if there is film or fingerprints Use the Sony p n X 4034 197 1 soft cloth and diluted mild window cleaner if necessary A 5096 mix of water and window cleaner is OK Do not use dishwashing detergent or soaps Place the screen in the bezel Mount the rails B board and stand Plug in four connectors from the B board into the plasma panel as shown in Figure 9 8 CN9004 next to connector 2 is not used The fourth connector is under the B board Reattach these 4 connectors P 1 s j 1 4 pp y i E E i Imm Eu uox T cw E Mm FIGURE 9 8 ATTACH 4 CONNECTORS 26 Attach the
22. OM ID check error B board EEPROM read write error B board Color Decoder IC error B board Panel will not initialize start Plasma panel Low B at start up Plasma panel power supply board Table 2 2 Cause of Standby LED Blinking in a Pattern TV Shutdown Times Standby Cause Suspected board LED blinks 2times times Plasma Plsmapanelemo error Plasma Plasma panel times ee TV temperature at critical E LEES board Fan or possibly B board 4 times 5Vdc output voltage excessive or Power Supply Output CN1 pin 9 10 A ENDE 5 times Digital 3 3Vdc output voltage excessive or Power Supply Output CN pin 5 6 6 times Analog 6Vdc output voltage excessive or Power Supply Output CN1 pin 13 14 HUN Mert E Chapter 3 Board Selection by Defect Table 3 1 shows the boards that could cause the symptoms listed The most likely board is designated 1 second likely 2 etc Two 1 means both boards have an equal probability To resolve the conflict testing is performed in the Standby Power ON Fan Drive Video Flow circuit descriptions Chapters 10 12 or the Plasma Panel picture defects Chapter 4 For isolation purposes the TU tuner board may be unplugged and the TV will work displaying video inputs Table 3 1 Plasma TV model KZ 32TS1U KZA2TS1U Board Selection by Defect A A Probable Circuit Board Failure Symptom Audio Problem all inputs Audio Problem TV channels deselect SAP Dark Sc
23. OSITE IC3011 TUNER VIDEO V us COMPONENT i VIDEO AE gt R Cr Cb A13 T C14 1924 SEL ey Ln ET meri A NS S 7 CN702 CN5005 LCD PANEL o o eee o gt oe o o gt o o gt omo o o gt amo i o gt o emm o gt o gt i i i o o gt emo i o o me o o mm o gt o gt amm o gt o gt a o mo o gt o gt e o FIGURE 28 1 VIDEO PROCESS KF60DX100 9TVP131447 4 15 02 65 Table 28 1 Video Circuit Board Inputs Outputs puts Outputs e TV Tuner S Video e NTSC Input switching e TV Output to rear panel e Composite Video e Component video pass e Composite S video to BC4 through bd e Component video to BC Bd Component video inputs Composite Video V or Comb filter separates the Y amp C e Separate Y amp C Outputs for o video Y amp C from the composite V video the BC Bd signal e S Video Y amp C Creates a Main and Sub Main picture component Component video inputs picture video path video Channels video into the Main Sub picture component DRC amp Sub picture video video paths Main picture component Switches picture location RGB and Sync Output to video when NTSC video is input the LCD light box oub picture component Adds User Menu into the assembly video video path C e RGB and Sync input Independent RGB processing e Display outputs onto mirror into separate RGB LCD panels Troubleshooting Video
24. R T grace Q Y 3 RY cnaso2 vee ESTEE 3TI7T 1511415 P9 meal e 22 Wie X 01931 77 SIHOS L F16016 3A STANDBY ay E STBY LED ui H POWER Ic9004 SUPPLY STBY 5V STBY 5V MAIN fi y b o CN1605 dd CN1914 POWER PWR CONTROL A A CN1921 m CN9001 M BD MCN ei 33V CN1604 CN1926 5V gmi ERROR REG CN1606 CN1909 PS1601 SU PS1602 a 11V did HHT CNt613 FL CN1914 4 5V arm 4 5V 2 134 CN1603 CN1915 A BD 2 0V TO LAMP DRIVER BD FIGURE 25 1 POWER ON BLOCK KF 60DX100 94 5TVP13 1438 4 11 02 Power ON sequence After the Main Micro IC9004 M board receives standby power CN1921 pin 16 IC9004 can respond to the power ON command from either the remote IR or the switch on the front panel H3 board The TV power ON steps are 1 The front panel power ON button is pressed CN1921 pin 48 goes LOW 0Vdc see Figure 25 2 for the location of CN1921 CN9001 Main Micro IC9004 outputs a HIGH 5Vdc to energize the power relay CN1921 pin 21 goes to 5Vdc This 5Vdc passes through the A board into the power supply G board at CN1605 pin 5 5Vdc If the Bi metal fuse under the lamp fan 2 is closed CN1614 pin 1 amp 3 connected then the power ON command into CN1605 pin 5 2 5Vdc can energize the power relay RY1601 on the A board Within the G board power relay RY1601 contacts close passing AC to the Main pow
25. SONY Training Manual Plasma IV amp Grand Wega Projection TV Models KZ 32TS1U KZ 41TS1U KF 60DX100 ares KF 60DX100 Diagnostic Guides Course TVP 13 Table of Contents KZ 32TS1U KZ A2TS1U INTOducuo Nuit 1 1 Normal Operation 2 2 Self Diagnostics 3 3 Board Selection by Defect 4 4 Plasma Panel Picture Defects 5 5 Board Location 6 6 Service Mode 7 7 Adjustments when the B Board is Replaced 12 8 Plasma Panel Replacement ASARCPA EZ WU M 15 9 Plasma Panel Replacement KZ dT2TS TU ut 23 10 Standby Power Power ON 28 x ee 28 11 Fan Drive Circuit 30 12 Video Signal Flow 32 13 What is Flat Screen Plasma Technology 35 Theory of Operation sssssse 35 KF 60DX100 INTOQUCHON ainia 37 15 Normal Operation 38 16 Self Diagnostics 39 17 Board Selection by Defect 40 18 Board Locations 41 19 Adjustments 42 20 Service Mode 44 21 Determining if the Optical Unit is OK
26. a CLK OUT OUT3 HD15 fB CN3002 Uii EET VGA les any e Y 1 PLASMA COMPONENT BY E DISPLAY VIDEO Y R Y B Y Q BOARD b Y Cr Cb jJ SYNC gt H V H V V A A cR am E Signal Levels FIGURE 12 1 VIDEO SIGNAL FLOW 3TVP13 1433 4 12 02 The tuner signal levels Table 12 1 were taken with an NTSC generator set to channel 3 The S video levels Table 12 2 were taken using a DVD player The component signal levels Y R Y B Y in Table 12 3 were also taken using a DVD player Table 12 1 Tuner Input Signal Name Signal Level Tuner Video generator channel 3 CN3004 pin 1 1 2Vp p GNSQUUpIn 10 ee Table 12 2 S Video Input S Video Signal Name Signal Level E ETE CNG00T pin E UE 32 Table 12 3 Component Video Input Signal Name Signal Level yo opina Topp Y CN3002 pin 2 EE CN3002 pin 6 EE Table 12 4 Digital Video Signal Output to Plasma Panel Signal Name Out0 i Outt 4 S EET CLK Out CN1204 pin 8 9 CN 1 pin 13 15 0 7Vp p CN1204 pin 10 11 CN 1 pin 17 19 0 7Vp p The main digital signal level is shown but there are ten spikes of power supply noise in the body of the waveshape that are not shown bringing the signal level to 6Vp p The noise is also present on the TV screen when the rear shield is not installed Waveshape Waveshape Signal Name Out 0 l Out 1 Signal Name Out 2 CLK Out Out 3 Approx 30MHz
27. al Level from G board from BB board CN5002 pin 1 7Ndc CN5005 pin 1 2 5Vp p white Blue signal CN5002 pin 3 4 5Vdc CN5005 pin 3 2 0Vp p orange Green signal CN5002 pin 7 8 3 3Vdc CN5005 pin 5 2 4Vp p orange Red signal CN5002 pin 11 15Vdc CN5005 pin 7 5Vp p orange Vert sync CN50095 pin 9 oVp p Horiz sync Black Screen If the screen is black the optical unit or BB board may be bad First see if the Menu feature functions Press the Menu button on the remote control If the screen displays the OSD menu the optical unit assembly is working and the BB board is suspect If there is still no display remove the input power to the optical unit by unplugging the power connector CN5002 see Figure 28 2 If the screen becomes white the BB board is bad A white screen is normal if the optical unit loses power the optical unit passes all the backlight If the screen remains black the optical unit is bad CN5002 Power In CN5005 RGB sync in gray orange CN5001 DATA blanking red CN5004 S Data white FIGURE 28 2 OPTICAL UNIT CONNECTORS TOP VIEW Video Screen Distortion Distortion defects or interference can enter the video chain at any of its five boards used in the video processing chain You can use some features to help determine where the video problem is The features most helpful in isolation are the On Screen Display OSD menu the MILD picture mode activity in Video 5 6 inputs and the
28. an Rotation Detection When drive voltage to the fan is present the fan rotation detector output will ground out the 5Vdc input at CN1908 pins 8 amp 10 This ground OVdc keeps the Main Micro from turning OFF the TV If either fan stops rotating CN1908 pins 8 or 10 will rise to 5Vdc This 5Vdc is detected by Min Micro IC9004 CN9020 pin 45 and 1C9004 shuts off the TV in five seconds CN9020 can be accessed from under the A board Tilt the TV board assembly up and locate the marked pin 57 Troubleshooting If the backlight does not start and the TV shuts down with the Standby LED blinking four times one or both of the two fans has stopped The suspected boards are A board fan regulators G board power supply and M board fan control Procedure 1 At power ON measure fan voltage from the power supply at CN1613 any pin 11Vdc to the A board No voltage Replace the A board 2 Atthe A board or the fan connector see the fan wire colors in Figure 26 2 measure the fan s drive voltage at CN1908 pin 6 and 9 5Vdc and 9Vdc respectively at power ON If both voltages are present the fans should be rotating Replace the fan if there is voltage but no rotation 3 With the fan rotating there should be OVdc at CN1908 pin 8 and 10 If either is 5Vdc replace the corresponding fan see Figure 26 2 At this time fan 1 is part of the light box optical assembly and not available separately 4 There should be OVdc entering and le
29. ands to turn ON the remainder of the power supply and energize the surge relay These commands are V8A GO and VCE GO from CN 7 pins 6 and 8 When both of these two commands go HIGH the power supply outputs the remainder of the voltages and the TV turns ON Within the power supply board three separate regulated supplies reside PS1 PS2 and PS3 As shown in Figure 10 2 these power supplies feed output transformers T4 T5 and T2 respectively T4 outputs the Vs sustain driver voltage and T5 outputs the Va address driver voltage for the plasma panel The remainder of the TV voltages come from T2 VSA GO ys Power supply CN 7 pin 6 Control i Mi power ON C21 IC22 va 3 2Vdc from Plasma panel CN 7 pins 6 8 VCE GO PS 3 T2 TV Volt CN 7 pin 8 T2 oe FIGURE 10 2 POWER SUPPLY CONTROL CONCEPT 4 16 02 29 Chapter 11 Fan Operation The fan is turned on when the TV is powered ON and blows air out of the TV The TV will only shutdown when the power supply thermistor reaches a critical temperature set in the service mode not if the fan stops Fan Operation The fan runs at one of three speeds based upon the temperature of the power supply board The power supply board temperature is monitored by a thermistor that feeds IC6 not shown The output voltage of this thermistor circuit at CN 1 pin 4 is a linear function of the temperature O degrees C OVdc 100 degrees C 4 7Vdc The Main CPU on the B board monitors the fan s rotat
30. ar to a fluorescent tube in operation and testing The tube s two terminals that are used for the light discharge measure open circuit infinity resistance The gas discharge tube requires a high voltage to start but once started lamp current is detected the applied voltage is reduced across its terminals Not only is the applied voltage reduced when current is drawn Power Block relay clicks but the voltage across the tube lamp drops because the tube s resistance has dropped at ignition like a fluorescent tube The Power Block voltage reduction relay clicks one second after the lamp ignites The phosphor that coats the tube takes about one minute to glow at a uniform level near maximum brightness Lamp Starting Sequence The lamp is instructed to turn ON when the TV turns ON The Micro B board signals the Power Block to generate 25kV necessary to start the Lamp Refer to Figure 27 1 when following this lamp ON sequence 1 When Main Micro IC9004 receives a power ON command 0Vdc at A board s CN1901 pin 4 the Main Micro informs Lamp Control IC9502 via serial data 2 Lamp Fan IC9502 checks to see if the fan is rotating before turning ON the lamp 3 he Lamp Control IC9502 in turn outputs a HIGH 5Vdc which passes through the A board CN1908 pin 1 to turn on the Lamp Driver Board 4 The Power Block Board generates an initial 25kV at low current to start the gas discharge tube The lamp ignites 5 Once the tube starts the
31. asma Panel defects for illustrations Chapter 4 Plasma Panel Picture Defects Board Location Ref Figure 4 1 EIE White Noise replaces 1 4 of the picture Vertical or Colored rain Horizontal in a black black white background line through the picture Normal Pix d f Normal Pix Black lower Black upper Black top bottom half half just white noise g A Dark Screen with sound can be caused by the plasma 9 panel or the TV circuitry Measure the DC voltages and signal entering the plasma panel to determine which is defective Dark scr en Power Supply Board Check DC and signal video levels at CN23 amp CN 1 Normal Voltages with TV ON any input CN23 pin 1 55Vdc CN23 pin 3 5Vdc CN23 pin 8 10 78Vdc 32 or 82Vdc 42 CN 23 CN1 pins 13 amp 15 gray wires 1Vp p 30MHz 1 If these input voltages signals are OK the plasma panel is suspect CN1 is on the plasma panel below 13 15 gt cn1 the Power Supply board gray wires 4 Chapter 5 Board Location PLASMA PLASMA BOARD Y BOARD X FIGURE 5 1 BOARD LOCATION KZ 32TS1U sweses anon Chapter 6 Service Mode Service Mode Access 1 The TV must be in the Standby Mode as indicated by the front panel red light Refer to Figure 6 1 for the location of the standby light If this Standby light is OFF plug the TV into AC press the front panel Power button and then shut off the TV from the remote control The Standby
32. aving the A board going to the M board at CN1920 pin 23 This connector is accessible from under the bottom A board Tilt the TV board assembly package up and locate the connector under the M board If this A board output voltage is 5Vdc not the same as input replace the A board If CN1920 pin 23 is OVdc replace the M board 98 Chapter 27 Grand Wega Lamp Control DANGER There is High Voltage at very High Current dangerous enough to cause Death On Contact Keep away from the Power Block and lamp socket when the TV is turned ON see Figure 27 3 Follow the repair procedure closely and be aware that the HV periodically turns ON automatically This Lamp Control document is divided into these four major sections 1 Lamp Operation 3 Power Block Location amp Removal e Gas Discharge Tube Concept 4 Troubleshooting e Lamp Starting Sequence e Defect Unreliable backlight starting e New HV Detector Circuit e Defect No backlight repair procedure 2 Lamp On Time Display e Defect No backlight repair flow chart e Lamp On Time Reset 1 Lamp Operation Gas Discharge Tube Concept This LCD TV screen display panel is similar to most computer laptop displays because they both have a colored LCD panel and backlight To produce an image on the screen the LCD panel s colored cells will either allow or block light from the backlight In this TV the source of light is a long life gas discharge tube lamp The gas discharge tube is simil
33. ck Assembly Power Block Lamp Driver Board FIGURE 22 3 REMOVE TWO HV LAMPSOCKET SCREWS d Lift the Lamp board assembly up and outward figure 22 4 47 22 Optical Unit Removal FIGURE 22 4 POWER BLOCK UP AND OUT e Loosen the two screws under the optical unit Figure 22 5 The screws are part of the optical unit Optical Unit Assembly Screen Power ETT E TV Block Assembly Board 1 _ A z i ar e FIGURE 22 5 OPTICAL UNIT SCREWS EXPOSED f Slide out the optical unit 48 22 Optical Unit Removal Optical Unit TV Board Lamp Assembly Lens Assembly Power Block Assembly FIGURE 22 6 OPTICAL UNIT ASSEMBLY g Dust the optical unit lens with a soft cloth before installing Specks of dirt are magnified so clean it carefully 49 Chapter 23 Screen Mirror Replacement The entire top of the projection TV is replaced as an assembly containing the screen mirror and speakers Procedure a Remove the back lower panel b From the back remove the center support bracket 4 Top Assembly Screws rd Center Support Bracket FIGURE 23 1 REMOVE THE REAR CENTER SUPPORT BRACKET AND SCREWS Also from the back remove the four screws securing the top assembly to the lower electronics Figure 23 1 Refer to Figure 23 2 From the front of the TV pull the two side panels off to expose the control panel screws Remove the top two screws of the control panel and loosen the
34. control circuitry is bad Refer to Figure 27 1 for the following HV detector circuit description Normal Operation At power ON Main Micro IC9004 instructs Lamp Control IC9502 both on M board to output a HIGH at Ctl A board CN1908 pin 1 This HIGH is applied to the Power Block to start the 25kV necessary for the lamp ignition If the lamp starts to draw current the Power Block closes the relay to reduce lamp voltage and grounds the PRT line CN1908 pin 3 or the end gray wire on the Power Block The PRT protect line is a signal to tell the Main Micro the lamp is drawing current working When LOW OVdc the Main Micro in turn unmutes the A V lines and a picture with sound appears all within 20 seconds after turn ON Defect The LAMP LED blinks continuously The main Micro looks at the PRT signal CN1908 pin 3 and the antenna signal to determine if the lamp or Power Block is defective Table 27 1 When HV appears without a load bad bulb arcing in the spark gap on the Power Block creates RF that is picked up by the nearby antenna wire This RF signal is brought back to the A board at CN1908 pin 12 The RF signal only passes through the A board to get to the M board CN9501 pin 50 where it is rectified On the M board a DC voltage developed after the RF signal is rectified indicates the presence of HV normal Power Block operation If there is HV and no current draw the conclusion is that the lamp is bad so the Main Micro continuousl
35. d A board fan control G Bd Power supply or M 5 times Power Block board cannot turn Power Block board or the Lamp on the lamp 6 times Low or missing 5Vdc G board or a load on the 5V line any board If the problem is not on the G board unplug each board then power ON the TV to see if 5Vdc appears at CN1604 pin 1 Remove the BB board first 9 times L R Audio Output speaker line G board power supply or A board audio output monitored for OVac Check 15Vdc fuses PS1601 amp 1602 on G board This self diagnostic information is also stored in memory and viewable on the TV screen It is accessed by aiming the remote at the TV and pressing the following buttons Display 5 Vol Power Half of the list above will be shown on the TV screen Moving the joystick left or right permits you to see the remaining self diagnostic categories The number of times the failure has occurred is displayed to the right of the intermittent problem Clearing this memory requires you to exit this program by shutting off the TV entering the regular service mode Display 5 vol Power and pressing 8 Enter 39 Chapter 17 Board Selection by Defect This table shows the boards that could cause the symptoms listed The most likely board is designated 1 the second likely 2 etc Table 17 1 Symptoms and Related Circuit Board nee Probable board failure Symptom A BB BC C G PS Lamp M Micro Video Video optical Driver unit
36. e C101 Turn ON the TV Do you wire change to hear a HV frying noise or see light 5Vdc at TV turn board Does Lamp light from the G1 body ON Replace M Finished Is there 255 350 The circuitry is working Vdc Across the Unplug the TV Power Block Inspect the HV socket for connector Replace Power corrosion white powder Replace the UL200 Lamp Supply G board Remove 2 screws and unplug the lamp socket Lay the HV connector down away from metal or This Ctl voltage will only people Turn ON the TV be present for 2 seconds Is there arcing at G1 and then again for 2 more seconds 5 seconds later FIGURE 27 5 DEFLECT BACKLIGHT DOES NOT LIGHT 4 16 02 Replace the Power Block 64 Chapter 28 Video Process Video Signal Flow The video signal flow is shown in Figure 28 1 The video signal is input the U board through the BC and BB boards to the final C board within the sealed optical unit optical assembly The A board is an interconnect board that passes the video signal from one board to another and performs the initial TV tuner function Table 28 1 explains the function of each board and their inputs outputs dx D as RA FP MR OK MED 22 3D COMB FILTER CN2001 CN1901 BC4BD pee pot 15 3 5H e e e e e 4 CN2001 UM CNI917 O TV OUT V e C _ 12004 MAIN S VIDEO mE AN A2 Y SUB Y C sw SUB 24 C p p COMP
37. e brightness of the individual cell determines the color of the pixel The number of pixels on the screen is determined by the size of the screen There are typically thousands of pixels on a screen and there are three cells for each pixel Theory of Operation Cell Operation Each plasma cell functions much like a neon gas discharge tube or neon bulb The bulb consists of two electrodes in a tubular glass envelope filled with neon gas When a voltage of approximately 65 70V for a neon bulb is applied the gas ionizes resistance drops and passes electricity During ionization an orange glow around the negative electrode is produced Both electrodes appear to glow if AC is applied Varying the current that is allowed to flow by changing the external series resistance through the bulb controls the brightness Cell Structure Refer to Figure 13 1 for the plasma cell structure In a plasma cell plasma replaces the neon gas in the tube Plasma is a collection of charged particles containing an equal number of ions and electrons with properties similar to gas except they are conductive and affected by magnetic fields When the Scan and Sustain electrode mounted on the glass faceplate voltage reaches the electrical arc potential the cell s predominate neon and xenon contents emit UV light The UV light is converted to visible light by the red green or blue phosphor of that cell The data also called index or address electrode produces an
38. eans the B board is bad Replace the B board Testing the fan The fan should be tested by applying voltage to it Voltage Test The fan starts running when 6Vdc is applied 0 1A You can also quickly start it using a 9V battery Apply the positive voltage to the red wire and negative to the blue wire Hesistance Test A resistance check will only show you that a fan is not shorted Resistance readings will not tell you if the fan will run with voltage applied Applying the ohmmeter positive leads produces these high resistances Reversing the leads permits you to read a diode in the Hall device t Fan terminals 1 7Meg ohms with ohmmeter s 1 5v Infinity battery FIGURE 11 2 FAN RESISTANCE TESTS 31 Chapter 12 Video Signal Flow The video signal processing is performed on three boards TU Q and B and the plasma panel as shown in Figure 12 1 The composite video or component video is selected in the B board The OSD is inserted into the video path not shown later on in the B board signal chain The output of the B board is digital video and applied to the plasma panel The video switching control for ICs on the TU Q and B boards come from the Main CPU which is also on the B board ruBoARD CNI02 1577777 7s MEM d CN3004 p cae ee ista 111311574 TUNER VIDEO L CN1 S VIDEO qe OUT 1 IC3014 CN3001 CHROMA SW Y STATES VIDEO 8 Egi PM E j VIDEO ah
39. ector IC is defective on the U board a second board choice The remaining boards that process the other input signals are not suspect because the problem does not appear with another input Table 28 3 Board causing a Video Problem Video Problem U board BC board BC4 board BB board Optical Unit A board appears only with Assembly TV Tuner 1 Video input 1 4 S Video 1 3 r 2 Video 5 6 Component Video TV Out Mild Menu setting CCD SD Twin Picture 2 ES INN IES IE poo PO FO IS AAA 2 OLI AA Any input including NEN a A NENNEN The Mild Menu video selection Vivid Standard Movie Mild routes the signal around the Digital Reality Creation Circuitry feeding it directly into the MID IC Noisy NTSC input signals can fool the DRC circuit into introducing false picture improvements adding to the noise making the MILD mode useful with noisy signals Using Twin View Mode to Locate the Video Problem Twin View Signal Path Concept This TV has the ability to display two pictures side by side on the same screen In the Twin View picture mode Figure 28 3 both main and sub signal paths are used to produce the dual picture The difference in the two paths is that the main path contains the DRC picture enhancement circuit left picture Both main and sub picture paths arrive at the MID circuit BB board to be assembled into a single picture The rules for this Twin View video processing are 1 The DRC circu
40. eps to follow you will remove the rear panel the shield the board assembly and both support rails to free the plasma screen that is connected to the front bezel 15 8 Plasma Panel Replacement KZ 32TSIU SAA MAA A LN A ILLI y ra 0 Le da 1 do da 0 87 E EMGATNNS 3 aaa TT numm pm E E p mm m Uu eee UN E hi Et ad ANNA Fan amp Shield e Remove Figure 8 2 Back Removed a Begin by removing the back panel to expose the shield shown in figure 8 2 b Unplug the fan and remove the shield Plasma Power Panel Supply Board Lower Board TV Board Board Assembly Layout Assembly Figure 8 3 Circuit Boards 16 8 Plasma Panel Replacement KZ 32TSIU The lower board assembly behind the input jacks must be removed because the plasma panel cannot be slid out from underneath it There is a lip under the board assembly that prevents the panel from being slid sideways c Remove the input connector cover four screws VHF input jack la TV Board Assembly Screw O Oy y MIO OOO O GIN TENOR ais EA i e Remove the Input Connector Cover Input Connector Cover Figure 8 4 Input Panel The TV boards are in an assembly held in by four black screws Two can be easily seen at the right in Figure 8 5 The left two are behind the plate In the next three steps you will lower the front Q board to remove all the screws and pull out the H1 board cable harness from the assembly d Remove two scr
41. er supply The Main power supply outputs various voltages to power the TV Only the 15 voltages CN1606 pin 2 6 that go to the audio output stage are fused Fusible resistors are in the 33Vdc and 17Vdc outputs at CN1605 pin 1 2 Hear Panel VHF iN BEEN CN9001 Bottom 1 A Board M BB BC Board Connectors FIGURE 25 2 IV BOARD ASSEMBLY BOTTOM VIEW OF A BOARD 55 Chapter 26 Fan Control KF 60DX100 This Sony Grand Wega LCD Projection TV has two fans that start when the TV is turned ON and stop five seconds after the TV is turned OFF Fan 2 is located at the rear and is visible as soon as the rear panel is removed It cools the lamp block assembly underneath it Fan 1 is hidden under the LCD Optical assembly light box Both fans contain Hall effect devices and circuitry that monitor fan rotation If the Main Micro M board detects no rotation from either fan the TV shuts down within five seconds In addition to this protection if the temperature of the lamp assembly reaches a critical level the TV will also turn OFF Areplaceable Bi Metal fuse located under fan 2 lamp cooling will open if the lamp assembly gets excessively hot Power Supply G Board Main Regulator IC1908 LCD Fan 1 Micro M Board Regulator IC1909 Lamp Fan 2 A Board FIGURE 26 1 FAN CONTROL BLOCK 4 16 02 Fan Drive Refer to Figure 26 1 The power supply board s 11Vdc CN1613 pin 1 4 source powers both fans In between the power
42. ews holding the front Q board in the TV board assembly see Figure 8 5 Fold it down e Remove the four black screws holding the TV board assembly Gradually pull the assembly toward you f Snake the H1 Board cable harness out the back to free the TV board assembly see Figure 8 6 a m DV FLOS e tet 2 Screws 2 u IA ie La XOT QR ee ee jo T e O ol Plate PE IR IIA AA E e d te a A a r A E i a i i adi ri u E zi Ap mi a eel ll Remove TV Board Assembly 1 e Fold Down board Figure 8 5 Remove TV Board Assembly 1 17 8 Plasma Panel Replacement KZ 32TSIU Remove the TV Board Assembly 2 e Snake the H1 board harness out H1 Board the back hole Cable Harness Figure 8 6 Remove TV Board Assembly 2 In the next two steps the TV must be supported while face down and the base removed Phone Book s e Insert Books Phone Figure 8 7 Base Removal 1 BOOK S g Lay the TV face down on a clean soft cloth Bubble wrap was used in these pictures because it was clean and soft h Use books to lift the base off the floor 18 8 Plasma Panel Replacement KZ 32TSIU Support Brackets c Fr y A Top View Figure 8 8 Base Removal 1 i Remove the base j Lay the TV screen flat on the floor Support Brackets Bezel P S and Plasma Screen e Remove bracket Figure 8 9 Base Removal 2 k Remove the two s
43. increased current is detected and the Power Block e Increases the lamp current internal to the Power Block so the lamp can go to maximum brightness e Grounds the PRT line protect line at CN1908 pin 3 so the Main Micro knows the lamp is working 6 The Main Micro M board can now unmute the audio and video because the fan and lamp are both working 7 The lamp reaches almost full screen brightness in one minute 99 PENAS E LL POWER at GAP 25kV TO GAS DISCHARGE 255V cepe ned i HV Se reo inu COVER POWER i WHIGRY 280 ieonnD SUPPLY s 22 i S8001 7 et l G BD CTL wes H3 BD ON 5V HOV NM Ol eect ee J OFF 0V ICNI908 CN1901 POWER egere ae SS ERE E E J An eo STBY LED LAMP COMES ON GN1920 DIE ES AO 1 WHEN CN1908 PIN 1 5V CN9501 2 POWER BLOCK BD OUTPUTS 27kV IGNITION 1 VOLTAGE THEN 25kV RUN S sal E p M BD MICRO LAMP DEFECTIVE es TS TV FRONT STBY LED BLINKS CONTINUOUSLY POWER BLOCK BD DEFECTIVE STBY LED BLINKS 5 TIMES LAMP COVER SW OPEN HV DET ter STBY LED BLINKS 3 TIMES WIRE FIGURE 27 1 LAMP CONTROL KF 60DX100 Meese uds New HV Detector Circuit The purpose of the HV Detector circuit on the M board is to identify the cause of no backlight The front panels LEDs use this information The LAMP LED blinks continuously if the lamp is defective or the Standby LED will blink five times if the HV or
44. ion and run voltage This fan status is available as an OK or NG indication in the user menu and service mode In addition the service mode displays the power supply temperature If the power supply temperature reaches critical 92 degrees for the 32 TV or 80 degrees for the 42 TV the Main CPU discontinues the CPU GO and RDP GO signals and the TV shuts down After shutdown the Standby light repeatedly blinks three times to indicate that high temperature was the cause of shutdown ss o ds co qum ge A gt ec c T S rv ee PM A ets woe MIL M RS SM Cra e eg VE vise m SA EO ce ile ix ra Toe POWER SUPPLY BD ici ge FAN Pss 13V DRIVE 5V 5V DRIVE 18k i gt l ROTATION ic214c22 0V 0 d 9v CONTROL eae ee FAN m CN3003 FB secre sr es cs UA ONIDOT TL 1 A TSHBITS CN7 ig 24 PSL PG DOWN WHEN CN1 PLASMA THERMO BBD M Um oes MAIN 4 3V 32 92 C CN1 te CPU GO CPU 3 76V 42 80 C CN1203 RDP_GO FIGURE 11 1 FAN DRIVE zi ago 41602 Fan Drive Voltage When the TV is turned ON the Main CPU B board outputs 5Vdc CN1001 pin 24 to the fan drive block at CN1001 pin 24 This allows the fan drive block Q board to output 12Vdc connector CN3009 pin 1 to the run the fan at start up A run voltage from 8 to 12Vdc will always be present as long as the TV is ON Fan Rotation Detection Within the fan a Hall device detects rotation and grounds the voltage at CN
45. it can only be used for a 480i NTSC input signal 2 he DRC picture will always be the larger picture 3 When both NTSC pictures are the same size the LEFT picture will be the DRC picture using the main signal path 4 When there is a High Definition HD picture input video 5 or 6 the RIGHT picture will be the DRC picture 5 The RIGHT picture CANNOT select a HD video 5 or 6 input Video switching in both the BC and BB boards will ensure these rules are followed Figure 28 3 shows the displayed signals with different inputs 68 Main Two NTSC 480i Left High Definition pictures displayed 480p 720p 1080i amp Right NTSC 480i FIGURE 28 3 VARIOUS TWN PICTURE DISPLAYS WITH NTSC AND OR HIGH DEFINITION HD SIGNALS HD INPUT FROM VIDEO 5 OR 6 Two 480i NTSC Pictures Input Refer to Figure 28 4 which indicates where the larger picture s signal comes from When either both pictures are the same size Figure 28 4a OR if the LEFT picture is the larger picture Figure 28 4b the DRC circuit BB board is used to improve the quality of the 480i NTSC signal The main picture from IC3006 BC board is positioned on the LEFT side by the MID circuit on the BB board When the picture on the LEFT becomes the larger Figure 28 4c the Main and Sub input signals switch BC board and the MID process 1C509 BB board also switches the picture position This double signal crossing allows the channels to be at the sa
46. me place on the screen but the signal paths are different This switching is done to ensure the high quality DRC signal is employed by the larger picture As the user increases the picture size from smaller to larger a slight delay occurs when the right picture just begins to enlarge This allows both the SEL switch ICs BC board and the MID circuit BB board to switch positions The picture freezes for a moment until both switches have been made and then the picture frame continues to increase in size Main pix Sub pix Main pix from IC301 1 IC3006 IC3006 amp DRC FIGURE 28 4 TWIN PICTURE MODE ANALOG INPUTS One 480i NTSC Picture Input and One HD 480p 720p 10801 Picture Input When one twin view picture contains a HD signal that HD picture always takes the SUB signal lower path Figure 28 1 into the MID IC509 and appears on the LEFT side of the screen 69 Conclusion Troubleshooting What does all this mean How can we use this video path switching to determine which board contains the video problem Refer to the flowchart in Figure 28 5 to determine if the problem is in the A U BC BC4 BB board or the optical unit optical assembly just by noting where the video problem moves as you increase the picture size in the Twin View Mode Does the NTSC picture have a picture defect Does the problem appear in all inputs video component If the problem is in the Tuner and video 1 4 change the U board
47. mining which circuit board is defective access to the board and alignment afterwards This portion of the training manual is divided into 14 sections Table of Contents Contents This LCD Projector has a lamp and no convergence Look here for details when the Standby LED blinks Listing of possible defects and related boards by probability Picture of the boards in the TV Video adjustments when changing the BB BC or M board No convergence adjustments Chapters 15 Normal Operation 16 Self Diagnostics 17 Board Selection by Defect 18 Board Location 19 Adjustments 20 Service Mode 21 Determining if the Optical Unit is Access and new contents oymptoms are Shutdown white or black screen or missing color 22 Optical Unit Removal 23 Screen Mirror Replacement 24 Troubleshooting TV Shutdown 25 Power ON Circuit Description Pictured steps The entire top of the TV is replaced as an assembly Dead set and Shutdown flow charts Standby circuit description and power ON sequence 26 Fan Control Description Fan Drive Signal Rotation Detection and Troubleshooting 27 Lamp Control Circuit Description Operation Operation Time Removal and Troubleshooting 28 Video Process Block Diagram of the Video flow showing CCD amp OSD entry points Troubleshooting charts and tables for shutdown dark screen white screen or video distortion 37 Chapter 15 Normal Operation satellite reception shows picture s
48. n Resets items that are not signal related such as language Orbit Diagnostic errors serial number color system and TV ON elapsed time White Balance Resets Low Mid and High Temperatures to midgain in preparation for alignment after B board replacement Prog Gamma Is not used Tuner Resets channels back to 2 13 and clears the Favorite channels Prog Preset Erases user station names Last Memory Resets user video and audio preface settings User Mem Is not used Factory Resets user settings to default except diagnostics and serial number Tuner Micom Same as Tuner Chroma Decoder oee Figure 6 4 for a content list Preset contrast sharpness color and output levels as shown in Figure 6 4 The Hue for NISC 8 Y Delay 8 and Cb Cr Offset 8 sharp fo is the frequency the sharpness peaks 0 2 5M 1 3 2M 2 4M 3 off Set to 3 AD Converter Adjust the brightness and hue for each input video component and RGB Preset these levels after the B board is replaced and touch up See adjustments for the procedure White Balance White balance adjustments at low middle and high brightness levels Preset these levels after the B board is replaced and touch up See adjustments for the procedure General See Figure 6 5 for a content list AGC Wide amp Narrow Data affects capturing stations during auto programming wide 14 and operation Narrow 13 Fan Status Displays the temperature of the power
49. or the three types of video inputs are set in the AD Converter area of the service mode All three types of video inputs RGB YUV and Video are shown in Figure 7 3 and Table 7 1 Adjust each one by feeding the corresponding white input to the back of the TV or temporally preset them to these default values shown Use the remote control joystick to select and change the data 12 7 Adjustments when the B Board Needs to be Replaced Ec gr Helps ptm A j V A Services Mode AG Convarter A E AA T Service Mode ere Mode Bubto nt AGE i o 80 Converter D Converter Re Gain E 100 YUY Ea libration Vidas Calibration P 5 Subiont Y iden Md Buntent YUV Tu HR NER NIIT UM S E E a e Er o o Figure 7 3 A D Converter Preset Default Levels 3 13 02 Table 7 1 A D Converter WB amp Brightness Default Levels RGB YUV Component Video Video Composite Video ltem 32 42 ltem Level 42 ltem Level 42 Level Level Level Level Blue Gain Red Blas Green Bias Bue Bias Blue Gain Red Bias Green Bias Blue Bias 150 13 White Balance In the service mode you will preset the RGB gain levels for the High Middle and Low color temperatures then check the white balance as brightness is increased from minimum to maximum Figure 7 4 Shows the RGB levels for the 32 TV and Figure 7 5 shows the levels for the 42 TV Use the remote control joystick to select and change the data p
50. osition of the x Store the data by pressing Mute and then Enter Check the white balance as you increase the TV s brightness level bar from low to middle to high screen brightness The white areas of the picture should remain white even as the brightness is changed If the white balance is off return to the stop service mode and touch up the R G or B adjustment level KZ32TS1U Figure 7 4 shows the White Balance levels from a 32 Plasma TV White Balance White Balance White Balance Color Temp High Color Temp Mid Color Temp Low FIGURE 7 4 WHITE BALANCE PRESET DEFAULT LEVELS MODEL KZ 32TS1U KZ A2TS1U Figure 7 5 shows the White Balance levels from a 42 Plasma TV White Balance White Balance White Balance Color Temp High Color Temp Mid Color Temp Low FIGURE 7 5 WHITE BALANCE PRESET DEFAULT LEVELS MODEL KZ 42TS1U 14 Chapter 8 Plasma Panel Replacement KZ 32TS1U The KZ 32TS1U and the KZ 42TS1U are mechanically different and have separate procedures for removal of the Plasma Panel Handling Precautions After removing the plasma panel from the TV note that there are flex cables located at the bottom and both sides of the panel that are susceptible to damage oo the flex cables are not damaged only rest the plasma panel topside down as shown in figure 8 1 Bottom Flex Cables Panel Bottom Flex Cables Top Figure 8 1 Plasma Panel Standing Upside Down Procedure KZ32TS1U In the st
51. p cover sw Reo tical 4 times Fan A G M board 5 times Lamp board ud 6 times G board 9 times G or A board Problem with G M or A boards Measure CN1605 pins 4 and 5 at power ON Nena CN1605 pin 4 7Vdc CN1605 pin 5 5Vdc Optical Unit Top View G board bad or Sw bad CN5002 Defect CN1605 pin 4 OVac G board defective CN1605 pin 5 OVac M or A board is bad Power Supply CN1614 G Board Measure CN1921 pin 21 at power ON CN1921 is under the TV board assembly Ovdc M board bad 5Vdc A board bad CN1605 FIGURE 24 1 TV DEAD SHUTS DOWN FLOWCHART 93 The Standby power supply circuit and power ON sequence is simple and easy to figure out by looking at the simplified Figure 11 1 The only outstanding servicing precaution you must make note of is the over voltage zener diode on the A board at CN1901 pin 3 in Figure 25 1 If it shorts it will load down the standby 5Vdc and the Chapter 25 Power Supply TV will not respond to a power ON command dead TV set Standby Power Supply The standby power supply is located on the G board with the main power supply Standby voltage is output when the TV is plugged into AC Standby 7Vdc is output CN1605 pin 4 into the bottom A board where it is regulated down to 5Vdc and passed onto the Main Micro on the M board via CN1921 pin 16 rc a SMP B28 ba BI METAL FUSE p Giro LOCATED Ve NE Bs POWER UNDER REA
52. panels are positioned at the factory for convergence Figure 19 1 shows a crosshatch pattern If convergence is off the top mirror assembly and the optical unit where the LCD panels are located are both suspect If the misconvergence is on one side of the screen accompanied by geometric distortion the mirror may have broken from their mounts In this case reinstall the mirror or replace the entire upper assembly mirror screen bezel and speakers as one assembly P N A 1603 167 A A lt mm m E EA m al E TTT pen Figure 19 1 Typical Crosshatch using an External Generator 42 Table 19 1 Adjustments after Board Replacement Board Adjustment Service Manual page Replaced Light Box 1 Screen Center Adjustment to center the picture Section 3 5 page 43 Optical 2 Vertical Stripe Adjustments There are alternate even and Unit odd rows of dots across the screen L R Adj the even dots section 3 3 page 42 to the same brightness as the odd dots First adj red dots with a Red field then Green and finally Blue You must be at the screen to see the even vs odd dots A board Picture Adjustments RF video and component inputs are Section 3 2 page 39 adjusted for consistent white level and color BB board Secon 92 page 39 BC board Same as above except component video levels need not be Section 3 2 page 39 adjusted M board Same as for the A or BB boards unless the
53. pect ratio Ref Figure 1 1 below zc LL 4x3 TV 16x9 TV Subtitle Mode Figure 1 1 Display of a 2 35 1 Aspect Ratio Movie The 1 85 1 aspect ratio movie will display without the black bands on this 16x9 screen TV 16 9 1 77 1 aspect ratio because their 1 85 and 1 77 aspect ratios are almost the same The extra wide 2 35 1 aspect ratio movie camera is still used in the film industry mostly overseas It produces the black borders even on a 16x9 1 77 1 TV screen In this TV you may choose the Subtitle screen mode from the menu to fill the top of the screen leaving only a black band at the bottom for the subtitle Fan Noise Once the TV is turned on the fan starts The fan itself makes no noise but air flowing through the TV does especially when the TV is enclosed This low level of air turbulence is normal The Main CPU monitors the fan run voltage rotation and ambient temperature of the power supply This information is available to the user from the User Status menu as an OSD on screen display OK or NG indication Details such as the temperature are in the Service Mode see Section 6 Video Inversion to prevent border burn in After a undetermined period of use some plasma cells will not be as bright as others causing an incorrect tint because one of the red green or blue plasma cells will darken leaving the others bright Burn in can be prevented from the user menu From the Screen Saver menu Picture Inversion ma
54. quares The compression of satellite conveyed Dish video signals results in pictures that show small squares larger than the detail the TV is capable of producing This problem is compounded by the DRC circuit which cannot enhance the picture detail by analyzing the picture s larger squares and making improvements When high compression is used the DRC circuit cannot properly analyze the picture To ensure that the DRC circuit does not add more noise the TV menu has a MILD picture mode i e VIVID STANDARD MOVIE amp MILD that bypasses the DRC operation The MILD mode can be used on any noisy program Lamp Life Estimated lamp life is about 6000 hours P N XL2000U A 1601 753 A The lamp life will be shortened if the lamp is repeatedly started or run at elevated temperatures Lamp Warm Up The backlight lamp is similar to a fluorescent tube but has a two level brightness and delay circuit to prolong life At turn ON the lamp gradually increases to the first level of low very brightness Three seconds later a lamp relay on the lamp board will click to move to toward the second brightness level After the lamp relay clicks the lamp will take a minute to gradually reach almost full brightness Lamp Remains ON Although the audio and video is muted immediately at turn OFF the TV remains on for five seconds afterwards During these five seconds the lamp steps to a lower brightness while the fans continue to cool The lamp tha
55. rd is Replaced If the B board is replaced the A D Converter levels and white balance need to be adjusted or the brightness and tint range will not be consistent when switching inputs These settings are made from the service mode for each input Tuner Video and Component type and the data is saved in a NVM IC on the TV s B board Service Mode Access 1 The TV must be in the Standby Mode as indicated by the front panel light If this Standby light is OFF plug the TV into AC press the front panel Power button and then shut off the TV from the remote control The Standby light should now be lit while the TV is OFF Ref Figure 7 1 otandby Mode otanaby sleep light must be red Figure 7 1 2 Using a Sony remote control aimed at the TV in the standby mode press Display 5 Volume Power ON and MENU quickly If the TV turned ON when 5 was pressed you did not press the next Volume button fast enough and will have to try again 3 The following new service Mode menu shown in figure 7 2 will appear above the normal user menu Use the remote control joystick to move and change the data as before Store the new data by pressing Mute and then Enter as before Service Mode Service BE Menu Ng EEP ROM Initialize ze Chroma Decoder AD Converter White Balance General peli Manual Control Menu Preset Edit Service Status Figure 7 2 Service Mode Display A D Converter Adjustments White balance and brightness levels f
56. reen sound OK Dark Picture sound OK deselect Power Save on the remote Dead Set No relay click at plug in LS ESE ER AE NENNEN UE NN ce WE GANE Dead Set Stby light OFF No response to front panel pwr button Plug in relay click AS heard Dead Set Except for Stby light ON No response to pwr button Plug in relay click heard Fan not cooling front panel Standby indicator blinking See the TV menu and Fan block diagram in Section 7 Fan NG No voltage to fan Temp NG Fan not working Noise Bars across the screen horizontal The rear metal shield must contact the conductive mesh on all four sides and be screwed to the center TV board assembly Standby Indicator blinking 2 times A Standby Indicator blinking 3 times 3 Standby Indicator blinking 4 5 or 6 times 02 Video Distortion With composite and S video input only Video Distortion With component Y R Y B Y input only Video Distortion With both composite and component inputs Try using the menu s picture inversion to clean the screen first Symptom B H1 Power Supply After B board replacement adjustments for brightness and color balance are necessary See Adjustments The entire power supply board is listed in the service manual as Switching Regulator The 32 and 42 TV sets do not use the same Switching Regulator power supply and therefore have different part numbers See Possible Pl
57. remaining four by Ya inch Tilt the control panel forward as shown in Figure 23 2 50 23 Screen Mirror Replacement Remove Screws Tilt Out M 1 2 Pull off L amp R Panels Loosen FIGURE 23 2 PULL OFF THE FRONT SIDE PANELS amp LOOSEN CONTROL PANEL f From the front remove the remaining four screws Figure 23 3 4 Screws x LOS EC T ou Bu 3 _ H am F ts m i s Img a is Hp wet 7 A EET T ot E r pe d EU i A p a JA d x I a Ex 6 ae hr i e LIS ahs FIGURE 23 3 REMOVE THE TOP FOUR SCREWS g With the help of another person lift the top assembly off Do not leave the glass mirror in the top assembly exposed to dust and children Clean the lens with a soft cloth Figure 23 4 before installing the top assembly 51 23 Screen Mirror Replacement Lens FIGURE 23 4 BOTTOM TV BASE 52 Chapter 24 Troubleshooting TV Shutdown The TV can be disabled because of open bimetal fuse fan not working lamp not working short on the 5Vdc line and an imbalance in either audio output stage START POWER ON Replace M board TV Dead No Relay click at power ON attempt Relays Click then TV shuts down No Unplug optical unit power CN 5002 TV powers w white screen Standby LED indicator blinking On the power supply bd Short CN1614 If TV comes ON replace bimetal fuse under fan Stby LED blinks 3 times Lam
58. rmally when all four cables to the optical unit are removed the TV will display a no picture bright white screen with sound OK If only the RGB signal input cable at CN5005 were unplugged the screen would be 4 bright sound OK CN5002 Sonera CN5005 RGB sync in gray Orange CN5001 DATA blanking red CN5004 S Data white FIGURE 21 1 OPTICAL UNIT CONNECTORS TOP VIEW White or Dark Screen In a conventional TV a loss of signal results in a white screen This is also true in this LCD projection TV However if the screen is dark with normal sound the LCD optical unit or the previous circuit board may be bad On the other hand a dark screen without sound indicates video and audio muting by the Main Micro This is because of either a communications problem with another IC a fan defect a lamp circuit defect or an audio output failure which may also cause TV shutdown but not a video failure If the screen is white there may be no input to the optical unit Check for loss of input voltage at CN5002 and RGB input signal at CN5005 If the input voltages and signals are present the optical unit is suspect Table 21 1 Optical Unit Input Voltages and Signal Levels color bar input Input Voltage Level Input Signal Level from G board from BB board CN5002 pin 1 7Vdc CN5005 pin 1 2 5Vp p white Blue signal CN5002 pin 3 4 5Vdc CN5005 pin 3 2 0Vp p orange Green signal CN5002 pin 7 8 3 3Vdc CN5005 pin 5 2 4Vp p
59. supply and fan is the A board On the A board is regulator IC1908 that provides switched 5Vdc to the LCD fan 1 and IC1909 to provide switched 9Vdc to the Lamp fan 2 NETA CNT920jpin 19 ONT920pin 22 ONTO2OIpIN 22 CN1914 pin 1 2 3 or 4 11Vdc supply CN1914 pin 1 2 3 or 4 11Vdc supply Five voltages from CN1920 are input the A Board along with the supply voltage at CN1914 11Vdc When these voltages are input the A Board will output 5V and 9V to power their respective fans 56 e o o oo o o am wm o o gt ae o o o o o o o o o o o o gt o r CN1614 ES LE I ec ROMER y E 1601 V Y 7V 7V CNT1604 PWR SUPPLY BD WU A eso Cee A ETT Ca ay 14 Gel CN1914 penes TT ri Ta Ts Tats WIS STBY Wy HALL FAN 1 i 26 i E PWR 8V ine EAN 4 DEVICES H OV ES i zi gt FAN 1 bs Ted ree i 3 Rie li aconto WW leq MAIN aH oy CONTROL 2V MENA ae uu FAN 2 bd cm i E NV 4 LILLITP ae E BI METAL 22 E 2 PW 9V RED FAN 2 FUSE 5V ON asos VET UNDER 0V OFF x FAN 2 23 Tov 5V SHUTDOWN OV NORMAL CN9501 stay D1902 CN1908 M BD CN1920 OV oy N 5V J B METAL M BD A eect E E aa L w ei SEE E eese HALL DEVICES q CN5402 DETECT FAN H3 BD ROTATION His 4508 STANDBYLED CN1908 TV REAR A BD FAN BOARD LOCATION FIGURE 26 2 FAN CONTROL KF 60DX100 ruiz 1442 4 16 02 F
60. symptoms can be classified into three groups e White Screen Video path open on any video signal board e Black Screen BB board or optical unit are suspect e Video Screen Distortion Narrow down by checking the features In a conventional TV a loss of video signal results in a white screen with normal TV sound This is also true in this LCD projection TV However if the screen is dark with normal sound either the LCD optical unit or the previous BB circuit board may be bad On the other hand a dark screen without sound indicates both video and audio muting and not a problem in the video chain Muting is caused by 1 the Main Micro because of a communications problem with another IC 2 a fan defect 3 a lamp circuit defect or 4 an audio output failure which will also cause TV shutdown Muting the AN is not a video failure A video failure does not affect the sound White Screen If the screen is white there may be no input to the light box Press the Menu button If an OSD menu appears the optical unit is good and the previous stages are bad BC or BB board If no OSD use Table 28 2 and a DVM to verify these inputs to the optical unit before changing it Measure the input voltage at CN5002 and verify RGB input signal at CN5005 If the input voltages and signals are both present the optical unit is suspect 66 Table 28 2 Optical Unit Input Voltages and Signal Levels color bar input Input Voltage Level Input Sign
61. t remains ON when the TV is muted is only noticeable if the room is dark Delayed TV ON If the TV is turned OFF and back ON within five seconds before the lamp goes off the TV will come back ON unmute However if the TV is turned ON after the lamp has turned OFF the TV remains audio and video muted for 30 seconds This allows time for the lamp to cool off before being turned back on Turning a lamp on and off quickly shortens its life No Convergence Adjustments The positioning of the three colored LCD panels is performed at the factory oince there are not three beams to converge convergence is a matter of positioning the three LCD panels with minor adjustments at the factory If there are geometric distortions check the cabinet for shifted mirror front lens and cabinet deformation weights added to the cabinet before suspecting the optical unit assembly that contain the LCD panels 38 Chapter 16 Self Diagnostics The front panel Lamp LED flashes continuously when the lamp reaches end of life and fails to ignite The front panel Standby LED blinks to indicate a more serious fault If the TV starts and shuts down the LED will repeatedly blink a number of times to indicate the reason for shutdown The boards that can cause TV shutdown are listed in Table 16 1 Table 16 1 Self Diagnosis blinks 3 times Lamp cover door is not closed Lamp cover switch not shorted T board CUM tampa NT 4 times Fan rotation is not detecte
62. upport brackets 19 8 Plasma Panel Replacement KZ 32TSIU Handles Power Supply Handles N Board Figure 8 10 Plasma Screen Handles Finally remove the plasma screen use the four black handles to lift Only place the top of the plasma screen down The other three sides have vulnerable flex cables present Bottom Flex Cables Panel Bottom Flex Cables Top Figure 8 11 Plasma Panel Standing Upside Down m Remove the power supply board mounted on the larger metal heat sink 20 Figure 8 12 Front Glass Screen n The inside of the TV screen is coated so do not clean or leave oil on it by touching it The inside surface scratches easily Clean the inside of the TV screen if there is film or fingerprints Use the Sony p n X 4034 197 1 soft cloth and diluted mild window cleaner if necessary A 5096 mix of water and window cleaner is OK Do not use dishwashing detergent or soaps Reassembly Assemble in the reverse order Screw the power supply board onto the Plasma Panel Figure 8 10 Position the Plasma Panel into bezel Figure 8 10 Fasten left and right support brackets over the handles Figure 8 9 onake the H1 board cable harness into the TV board assembly rear and secure the assembly Figures 8 6 amp 8 8 Plug in the connectors Make sure these test connectors on the B and Q boards are empty Figure 8 13 shows the location of empty CN1003 CN1002 CN1201 and CN3008 Ld CN1003 on
63. y be selected to clean the screen black becomes white and white becomes black momentarily restoring normal brightness to the cells If this Inversion function were set for AUTOmatic picture inversion would occur at a specified time every day if the TV were ON This picture inversion may alarm a viewer that is not aware that this is normal for this TV Picture Shift Picture Orbit To reduce the possibility of a stationary image permanently burnt into the plasma screen phosphor the picture can be set to automatically move in a circular orbit pattern The menu s picture orbit can be set to small medium or large orbit range and its cycle time can be 10 30 60 seconds or 5 minutes Picture Orbit must be turned ON normally OFF if the user usually watches constant pattern images such as movies with borders stock market scenes etc Chapter 2 Self Diagnostics Standby Sleep Light The front panel Standby LED blinks to indicate a fault Refer to Figure 2 1 If the TV does not start up the LED continually blinks to indicate a problem Standby sleep TV light Se 5n J Figure 2 1 If the TV starts and shuts down the LED will repeatedly blink to indicate the reason for shutdown or A V muting Table 2 1 shows the boards that can cause the Standby LED to blink continuously and Table 2 2 shows the boards that cause shutdown Table 2 1 Causes of Continuously Blinking LED No TV A V black screen Cause Suspect Board EEPR
64. y blinks the front panel LAMP LED 60 27 Grand Wega Lamp Control Table 27 1 How the Main Micro Determines if the Lamp or Circuitry is Bad Condition PRT Protect Visual Arcing at G1 RF at CN1908 pin 12 CN1908 pin 3 Lor v Lamp LED blinks Continuously HV OK High 5Vdc Yes at power ON and repeats every 5 Lamp bad seconds later until TV shutdown 3 mins Standby LED blinks 5 times No HV High 5Vdc None Power Block PS fuses or M board bad Defect The Standby LED blinks five times At power ON when the Power block is instructed to turn ON HIGH white wire to Power Block CN1908 pin 1 but no current is drawn HIGH at end gray wire CN1908 pin 3 the lamp or the Power Block is defective To determine which is defective the antenna signal explained in the last paragraph is used by the Main Micro only when the PRT line CN1908 pin 3 remains HIGH no lamp current During this defect PRT HIGH forces the Main Micro IC9004 to request information about the presence of HV via serial data from Lamp Control IC1952 If RF HV is not detected the Main Micro keeps the audio and video muted blinks the Standby LED blink five times and shuts down the TV in three minutes HV antenna positioning After repairs reposition the black HV antenna near one of the HV leads as shown in Figure 27 2 If it is not positioned as shown the LAMP LED will NOT flash during a lamp defect HV ANT WIRE s fa FIGURE 27 2

Plasma TV & Grand Wega Projection TV

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Plasma TV &amp; Grand Wega Projection TV

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Plasma TV & Grand Wega Projection TV