Sony KDL22EX308 Flat Panel Television User Manual
Contents
1. Training Manual KDL32EX308 AZ1L Direct View LCD Television Chassis Circuit Description and Troubleshooting Guide MODELS KDL22EX308 KDL32EX308 Course CTV 68 Table of Contents Chapter 1 Introduction pp 1 SII EUM 1 muli mE 1 P20D ael uie ust since plcna atra tue E EPI 1 ee redeas LT 1 BRAVIA Internet 1 Enhanced Cross Media Bar 1 U552 0 Side sesiones mer di ate Ctt diu the ticis 2 RES 2 Consumer Electronics Control 2 P PET PEE THEE 2 COLO ret 2 Bravia SVG edat dalle usitas a paid dede 2 Advanced Contrast Enhancer ACE 2 Interactive Program Guide 2 Digital Living Network Alliance DLNA 2 Ambient SENSO ensita Ced Cu enu b 2 Chapter 2 Overall Circuit Descriptions 3 GIN 3 Overall Circuit Description 3 shi reo MT 3 AIV Decoder IC9000 FALIGIO PF OCSSS ING on a FU IVINS WIRE t 3 OE E ut ME 3 LVDS Tran Sim2. Tuner The tuner is a combination ATSC NTSC unit It can receive traditional analog NTSC signals via cable or terrestrial along with ATSC digital signals via terrestrial 8VSB cable 64 or 256 QAM Analog Video Input Switch The analog video is A D converted and scaled if necessary to 1920 X 1080p 60HZ resolution CTV 68 Digital Audio and Video Decoder The 2 and Digital Dolby audio streams are received from the tuner for decompression All video sources which are not native 1280 X 720p 60HZ are scaled to this resolution Digital audio content is output to 1 4200 for processing and amplification Audio Processing 4200 selects and processes all audio sources The audio content is processed digitally amplified and sent to the speakers HDMI Switch 2000 functions as a switch for the 4 HDMI inputs It also serves as an equalizer to match the low impedance of the input jacks to the high impedance of the input to 1 9000 2000 also contains a shared memory for the EDID information for each HDMI input When a particular HDMI input is selected IC9000 loads the proper EDID information into the shared memory CPU 5000 controls most of the operation of the television All user inputs are processed here 5000 also monitors key voltages and protection circuits to shut the unit down if a problem is detected LVDS Transmitter Integrated into IC9000 is a Low Voltage Differential Signaling LVDS tra
3. file if necessary and the procedure for loading the software into the television e Network Downloads Internet software updates are becoming more prevalent as more and more models incorporate home network capabilities This method is the most practical since the television will check for the latest version of software The models using the AZ1L chassis provide the customer with a choice of turning the automatic software update feature on or off If set to on the television will lookup software information while the unit is in standby If a newer version is available it will be downloaded and installed without any input from the customer e Built in Tuner OTA or cable sources having the proper station that is transmitting software update data packets Although the ability to transmit software update is possible in this way it is the least common and is reserved for particular situations where a critical update is forced thereby updating the unit without any input from the customer Software Update Responsibility Software updates are designed to be performed by the customer Warranty repairs in which the issue can be resolved by a software update are not reimbursable Most issues involving software updates are handled by the customer service center and should not be directed to an authorized service center It is the responsibility of the servicer to prevent service calls for issues that involve software updates Exceptions to
4. single row of lit or unlit pixels The TCON simply cannot cut out a single line of information Figure 4 2 illustrates some typical symptoms of failures that are caused by the LCD panel 2f Chapter 4 Appendix mm mm mm um mm mm um umm um um mm DEFECTIVE DRIVE IC DEFECTIVE TAB BOND OR DRIVE IC DEFECTIVE TAB BOND OR DRIVE IC FIGURE 4 2 TYPICAL LCD PANEL FAILURES CTV 68 28 Failures involving the LCD panel are usually displayed with the following symptoms e Physical damage such as cracks in the panel a single pixel or group of pixels that always on or off or random sections of the panel which are completely dark e Source driver failure This symptom appears as a single vertical band around 1 to 2 inches depending on the panel size and can be black white or any other color It can also contain video information with distortion A single vertical line that is dark or colored This may be due to a tab bonding failure from the IC to the panel but either cause requires the replacement of the panel Gate driver failure These IC s operate in a bucket brigade fashion As mentioned earlier the gates drivers scan each horizontal line starting at the top If any one of the gate drivers fails all of the subsequent drivers below it will fail to operate properly This symptom is usually indicated by normal video on the upper portion of the screen fol
5. thin vertical line regardless of color e Any thin vertical lines isolated to a specific area of the screen Asinge vertical column of lines of any color or containing distorted video e Any fixed horizontal lines Blotches of black or improperly colored areas e Ghosting of images in which the entire image is repeated one or more times A thorough understanding of how the video is processed throughout the chain of circuits all the way to the panel is important A past article written for the Sony Newsletter describes in detail how this process works A copy of the article is included in the appendix section of this training manual The troubleshooting flowchart in Figure 3 3 will assist in isolating which component is causing the distortion 12 Video Distortion Is distortion across entire screen No Any horizontal lines Any single o isolated vertical lines More than 1 vertical band CTV 68 Improper of Vertical lines Yes when wide issing colors or bars mode changed No FIGURE 3 3 VIDEO DISTORTION TROUBLESHOOTING FLOWCHART Chapter 3 Troubleshooting 13 Audio Troubleshooting Since all audio signals are input processed and amplified by the BAL board any issue involving the loss of audio or audio distortions which is present at all inputs would dictate that issue is remedied by replacement of the BAL board It is possible that a softwar
6. this are certain cases whereby the customer is unable or unwilling to perform the task In this situation the servicer will be notified and receive the proper authorization for reimbursement It is the servicer s responsibility however to make certain that any unit requiring a legitimate service is running the latest software version and to install it if necessary Examples of Software Correctable Symptoms Always check the Sony Technical Support site for any known and listed issues that are software related Most symptoms that are correctable by software updates involve communications issues with other devices or minor glitches in the operation of a specific function Below is a list of some of the symptoms that may be corrected with a software update e Fluctuations in picture brightness e Intermittent picture freezing or noise e Problems with certain inputs especially HDMI e Intermittent or distorted audio e Erratic remote control operation e Unit turns on and off by itself Loss of color e Internet connectivity e Certain features not working correctly CTV 68 Chapter 3 Troubleshooting Checking the Software Version The easiest way to check the version of software is to use the customer menu Engage the XMB graphics by pressing HOME on the remote commander Scroll left on the graphics icons until the end is reached Scroll up and select the Product Support icon Select Contact Sony The informati
7. E is ee cud n Rd 27 Diagnosing a Failed 2 29 Troubleshooting a DEAD 29 Examples of Actual TCON Failures 31 LCD Panel Fall fes 33 Chapter 1 Introduction Overview The AZ1L chassis is one of several designs for the 2010 model line of Sony Bravia LCD televisions Several models will be released incorporating this chassis This training manual will cover the EX308 series consisting of the following models KDL22EX308 KDL32EX308 The chassis design revolves around the video processing circuits located on the BAL board The key difference between models is determined by the size of the LCD panel and its manufacturing source This manual will describe the new circuit features and individually describe the models based on these differences Features Several new features are introduced in the EX M chassis model lineup along with some carryovers from the previous year 720p Panel The EX308 models incorporate a native 1366 X 768 WXGA resolution panel All video signals exit the video process circuits as 720 60HZ RGB resolution is 8 bit to provide 256 levels of gray scale CCFL Backlighting Many of the 2010 Sony television models are introducing edge lit LED backlighting The EX308 series incorporates traditio
8. HOOTING FLOWCHART CTV 68 15 Protection Shutdown Critical voltages and circuit operations are monitored by the CPU on the BAL board If a fault is detected the unit will be forced to shut down by the CPU The monitored circuit in which the fault occurred will cause the CPU to flash the standby LED in groups of repeating sequences The number of blinks in these groups identifies which voltage or circuit caused the protection event Not all of the available protect codes are used Models that are LED backlit do not use the 4 blink balancer error as this circuit is found in models that are backlit with fluorescent lamps The following list contains the protect circuits and diagnostics codes used in the EX700 models The troubleshooting flowchart in Figure 3 5 provides guidance in locating the possible component causing the shutdown 2X A loss of REG12V from the power supply triggers this protect event The causes range from a failure of the REG12V line power supply failure power supply shutdown or a problem with the detection circuit on the BAL board If a failure occurs on the power supply board that causes a loss of the REG12V line the standby LED will not light when power is applied to the television After about 10 seconds the standby LED will light briefly and begin blinking in groups of 2 3X The REG 5V and D3 3V source originating on the BAL board is monitored for low voltage conditions by CPU IC5000 A failure causing a 3X shu
9. NVERTER AC IN FIGURE 2 1 22EX308 OVERALL BLOCK DIAGRAM CTV 68 5 Chapter 2 Overall Circuit Description RF COMPOSITE OR COMPONENT 1 COMPONENT 2 COMPOSITE 3 HDMI 1 HDMI 2 HDMI 3 HDMI 4 PC HD15 EITHERNET USB2 0 AC IN CTV 68 i ANALOG AUDIO OUT 1 4200 AUDIO SW D A AMP OPTICAL AUDIO OUT 5000 1 9000 SUB 2200 AN MICRO HDMI DECODER SWITCH VIDEO EQ PROCESS INVERTER LED SWITCH IR RX UNIT RGB SENSOR B CONTROL POWER SUPPLY HLR G2LE FIGURE 2 2 32EX308 OVERALL BLOCK DIAGRAM Chapter 3 Troubleshooting Introduction Most troubleshooting of this chassis focuses on the 3 major components used e The Main Board BAL e Power Supply G1D or G2LE e LCD Panel This chapter will provide practical troubleshooting procedures based on the various symptoms that will appear when a particular circuit fails to operate properly Typical failure symptoms will be discussed along with troubleshooting flowcharts for each symptom Always remember to log on to the Sony technical support site at to access the latest technical bulletins along with triage charts to quickly identify the most likely part to complete the repair based on the symptom Software Updates The subject of software updates is a very important item to point out at this point The televisions of today have advanced to the point where they are not sim
10. SHOOTING FLOWCHART CTV 68 Chapter 3 Troubleshooting Video Distortion This is perhaps the more difficult failure to diagnose It is difficult when talking to the customer on the phone because an accurate description of the problem must be obtained in order to determine which part or parts to bring to the location It may also be difficult for the technician when the problem is witnessed If the problem is specific to one or more inputs it should be easy to determine if the fault lies on the BAL board or a device that is plugged into it If the distortion occurs at all inputs it must be analyzed based on what appears on the display and isolated to the BAL board TCON or LCD panel These components usually cause distortions that are unique to the specific circuit Below is an example of the typical distortions BAL Board Since the video signal is processed on a frame by frame basis it is very unlikely that a distortion that is occurring on a specific part of the display panel is originating here Distortion problems originating in the video process circuits tend to affect the entire picture Listed below are some examples e Improper color reproduction or no color e Improper luminance levels e Lack of detail in the picture e Distortions that change with movement in the video e Diagonal lines video 11 TCON Since the TCON allocates the RGB video information based on specific timing information the distortion
11. about the availability of these components In the relatively small percentage of units that experienced a failure of the TCON board replacement of the entire LCD panel was mandatory This is not only costly from a warranty standpoint but it also makes it near impossible to justify an out of warranty repair since the replacement LCD panel can easily cost 2 3 or more of the price of the entire television The reason why TCON assemblies have not been available in the past was due to the large amount of correction data stored within NVM data points located on the board Tolerance issues during the manufacture of the LCD panels required white balance gamma and uniformity corrections to compensate for these inherent production issues There are other items for correct panel operation but the above mentioned items are the most critical Over the years panel tolerances have improved dramatically and variances in uniformity have been reduced to the point where a TCON loaded with average data results in a satisfactory picture when installed as areplacement on a panel Most Sony television models also have white balance data located on the video process board Although the TCON is loaded with data to properly white balance the panel the ability to adjust white balance from the B boards is present to compensate for shifts in white balancing due to panel aging and this mainly involves color balance shifting of the fluorescent backlight lamps which tend to sh
12. affect a large area of the screen SHOESOURCE SOURCE DRIVE IC FAILURE O Payless d payless com Buy one item get second item of equal or lesser value at half price Continental U S only GATE TAB BOND FAILURE CTV 68 33 TN i 1 less SHOESOURCE Pay payless com Buy one item get second item of equal or lesser value at half price Continental U S only SOURCE TAB BOND FAILURE MULTIPLE PIXEL FAILURE CTV 68 Chapter 4 Appendix E F HELP amp SU PPORT GRO 17 PS 54 1 3 For details free programs services amp informatio cancer patients amp their ams offer hope to those who need it most AMERICAN ieged i CANCER SREY 3I 8 300 M F 8 3 E 61234 23 4888 S 30am BBm 57 GATE TAB BOND FAILURE LE tole aT T H til GATE TAB BOND FAILURE 34 S ONY and i Link are trademarks of Sony Electronics SONY 2007 Sony Electornics Inc SEL Service Company 16530 Vill Esprillo National Training Dept MZ3215 CTV68030810 San Diego CA 92127 3 10 10 Reproduction in whole or part without written permission is prohibited All rights reserved
13. ame basis The video frames are converted and scaled to 8 or 10 bit RGB information It is virtually impossible for the video process circuits to cause a problem on a specific area of the screen Failures on this board usually appear as distortions color level shifts video level shifts noise that involves the entire picture or no picture at all The TCON can generate symptoms that appear to be video process related but the video process circuits cannot produce the symptoms of a failed TCON circuit LVDS Cable Failures Although problems with the LVDS cable or connectors can generate symptoms of TCON failures this usually tends to be intermittent and wiggling of the connectors will usually provoke a change in the symptom on the screen LVDS cables and connectors have become rather robust over the past few years and most problems are caused by technicians who damage them and this is generally quite obvious upon close examination LCD Panel Failures Some LCD panel failures could possibly be mistaken for TCON issues Other than damage to the LCD glass most panel failures are isolated to a particular area of the screen Since the TCON disperses the pixel data to groups of line and column drive IC s situated on the outer edges of the panel it is unlikely that more than one of these IC s would fail at the same time Multiple columns of stuck on or stuck off pixels are therefore more likely to be the fault of the TCON circuits The same applies to a
14. anges the problem is located on the video process board If they stay in the same place they are originating in the TCON or LCD panel CTV 68 Chapter 4 Appendix DEFECTIVE TCON DATA OUTPUT DEFECTIVE TCON OR LOOSE TCON TO PANEL CONNECTING CABLE FIGURE 4 3 LCD TIMING CONTROL FAILURES 30 Examples of Actual TCON Failures The remaining illustrations show other TCON failures that have been encountered in the field The idea is to get a grasp of the concept of TCON induced failures to avoid unnecessary parts replacement REPETATIVE STAIONARY LINE CTV 68 Chapter 4 Appendix MULTIPLE SOURCE DRIVE IC FAILURE MULTI COLORED LINES NOTE THE PRE TM RE TRAE MEAT SENCE OF SOME ACTIVE VIDEO INDICATING THE VIDEO PROCESSOR IS NOT THE CAUSE 31 input or 4 No signal Check the externa select another input using the INPUT button Lope i MULTIPLE EVENLY SPACED LINES NOT AFFECTED BY PICTURE ZOOMING LOADED SOURCE DRIVE DATA LINE CTV 68 Chapter 4 Appendix 21 RETURN DIEE SYMETRICAL RED BOXES 32 Chapter 4 Appendix LCD Panel Failures Below are some photos of actual LCD panel failures Note that most issues tend to be isolated to a certain area of the screen with the exception of failures of the source drivers The source drivers can cause thin horizontal line issues and can also
15. ds this up to 48 bit giving the ability to generate a color depth of 2 8 trillion levels CTV 68 Chapter 1 Introdcution Bravia Sync By utilizing the CEC feature of HDMI 1 3 this feature allows the customer to easily control the various Sony devices within their home entertainment system provided that all of the other devices have this feature included Advanced Contrast Enhancer ACE By monitoring the overall level of the video signal the backlights are dynamically controlled and reduced during low light level scenes to enhance the contrast ratio Interactive Program Guide IPG An interactive guide is included to provide continuously updated program information at no charge to the customer The guide provided by TV Guide is part of the XMB graphics feature Program material is updated from the local PBS station when the television is off Digital Living Network Alliance DLNA An industry standard networking protocol has been developed by leading manufacturers to allow other devices such as a compatible computer to communicate with the television via an Ethernet connection to your home network This gives the ability to view photos audio and movie content directly from your computer via the network Future plans include the ability to download software updates for the television via the home network RGB Ambient Sensor Asensor located on the lower left portion of the front bezel monitors ambient light levels to adj
16. e update might be required but it is very unusual for this to affect all sources Once again check with the Sony technical support website regarding this issue Audio problems that are input specific especially the HDMI and digital sources such as the USB input and tuner are more likely to point to the need for a software update and this is especially true if the problem is intermittent Power Supply Troubleshooting Failures in the power supply circuits that prevent the unit from turning on are caused by one of the following scenarios e Complete failure of the standby and main power supplies e Failure of the main supply including the main switching regulator PFC circuit main relay and other components required to turn the circuits on e The power supply is not receiving a turn on command from the CPU Completely Dead Set A complete power supply failure is generally the result of severe transients in the AC line such as those incurred during an electrical storm The EX308 model line utilizes a red standby LED located on the lower left front bezel that is lit whenever the unit is receiving AC power and is turned off The KDL32EX308 model incorporates an eco switch located on the lower right side which removes all AC power from the unit and produces the same symptom of a unit that has been unplugged or lost its AC power This switch should be checked first whenever the standby LED is not lighting This switch is not available o
17. ed and adjusted in the service mode The adjustments are Segment Data model ID and Destination region ID The procedures for the software installation are located on the ASC website http www sony adjustment procedures located in the service manual This new method of supplying main boards significantly reduces the complexity of replacing LCD panels and main boards Information about the LCD panel is stored on the TCON circuits This information is automatically loaded onto the main board when the unit is powered up The need to lookup data in the LCD panel manual is no longer necessary With the correct software version and proper settings of the Segment and Destination data the BAL board and or the TCON or LCD panel can be replaced more efficiently CTV 68 Chapter 3 Troubleshooting Video Failures Problems that develop in the video circuits can appear as subtle or major distortions a loss of one or more colors improper video level or a complete loss of video When troubleshooting LCD display devices the problem must be isolated to 3 major components The main board where the video processing is performed the TCON board or the LCD panel In some cases the TCON may not be available as a separate component and replacement of the LCD panel is required to rectify a TCON problem Distortion in the video signal that affects all inputs can be challenging at times since any of the above mentioned compo
18. es 3 3VDC for the circuits requiring power while the unit is turned off An unregulated 15 volt line is present to provide power to the main relay PFC and main power supply at turn on Main Supply Once the power supply receives a power on command from the CPU on the BAL board the main switching supply is turned on to provide a regulated 12V source a dedicated un regulated 15V for the audio circuits and an unregulated 24V source for the inverter circuit CTV 68 Chapter 2 Overall Circuit Description Inverter The inverter receives the unreg24V from the G2LE board and generates the required high voltage AC to power the backlight lamps As of the writing of this manual the inverter is not available as a replacement part The LCD panel assembly must be replaced Switch Unit This board contains the power channel and volume up down and menu buttons HLR Board The power standby and timer LED s are located on this board along with the IR remote receiver and ambient room light sensor for controlling backlight and RGB levels Chapter 2 Overall Circuit Description ANALOG AUDIO OUT 4200 AUDIO SW D A AMP RF COMPOSITE OR COMPONENT 1 COMPONENT 2 COMPOSITE 3 OPTICAL AUDIO OUT 5000 HDMI 1 IC9000 SUB 1 2200 MICRO HDMI 2 HDMI AN SWITCH DECODER HDMI 4 PROCESS HD15 EITHERNET USB2 0 LED SWITCH IR RX UNIT RGB SENSOR POWER SUPPLY HLR I
19. f the diagnostics history page Entry to this page is achieved while the television is powered down and pressing the following buttons on the remote commander DISPLAY 5 VOL POWER CTV 68 Chapter 3 Troubleshooting This feature is useful for failures which are intermittent or when the customer is not sure what is causing the television to shut down sometimes Once a corrective action is determined the error events should be cleared to zero This is accomplished by pressing the 8 key followed by the 0 key on the remote commander SELF CHECK ddl 000 REB 002 MAIN J AUD_PROT 004 BALANCER 005 0095 ERR 005 10 BACKLITE 007 TEMP ERR FAN ERR ERROR BLINK COUNT 00005 00095 00000 OPERATING HOURS FIGURE 3 6 DIAGNOSTICS HISTORY PAGE 18 Chapter 3 Troubleshooting Test Points The drawing in Figure 3 7 contains board to board connector and pin information for the KDL22EX308 to identify voltages signal and controllines for troubleshooting purposes Figure 3 8 illustrates the same information for the KDL32EX308 All critical voltages and control signals are easily accessed at the power supply board Use this drawing in conjunction with the previously discussed troubleshooting techniques and flowcharts for testing operating voltages and control signals Circuit Board and Connector Locations Figure 3 9 illustrates the rea
20. i Wer CEP Sui ne enna 3 CTV 63 SUD DIV DS 4 22 SOG Rm 4 C10 CELER 4 TU 4 VU FUG Tae cece 4 Fe EDO Al Chic C EET 4 Chapter 3 Troubleshooting 7 7 Sotware gagales costis 7 Software Update Responsibility 8 Examples of Software Correctable Symptoms 8 Checking the Software Version pp 8 Special Software Instructions for BAL Board or LCD Panel FRE DIACOINISIVE RR TTA USA EIE 9 Mc Mp 10 Audio Troubleshooting Leeeeseeeeeese 14 Power Supply Troubleshooting 14 Completely Dead Set vic E eis eis ce 14 Wont POWO sisi 14 Backllgnmtlssues es 18 No Backlight No Shutdown pp 18 Diagrnosucs FISIOPV ett 18 Circuit Board and Connector Locations 19 Chapter 4 Appendix esee eee 24 TCON Troubleshooting 24 CTV 63 Table of Contents Continued E o 24 LOD Panel BaslGS nive A o Ir EIU 24 RTT 27 Source DIV CS us acce duxi b eani
21. ical rows of pixels In this example the panel has a horizontal resolution of 1366 pixels Each pixel is made up of a red green and blue liquid crystal which means there are 4 098 columns to control The source drive IC s contain shift registers along with buffer switches Shift registers are used to convert serial data to parallel By using this method the TCON is able to transmit control information to each of the source drivers using serial data lines If the TCON is transmitting 8 bit data to the panel each data line is capable of controlling 256 lines exiting the source drivers Understanding how the gate and source drivers work together makes it easier to observe a problem on the screen and determine if the failure is panel or TCON related Diagnosing a Failed TCON In order for this concept to move forward successfully it is important that the service industry be able to properly identify the symptoms of TCON issues to avoid unnecessary service calls and repair costs Accurate analysis of TCON failures will reduce costs significantly both in parts costs and time when warranty repairs are involved and will reduce the number of COD repairs that are lost CTV 68 Chapter 4 Appendix Agood approach when determining a TCON failure is a good understanding of which symptoms ARE NOT caused by the TCON Examples are as follows Video Process Failures All video inputs received by the video process circuits are handled on a frame by fr
22. ice is plugged into the USB2 0 side input that contains JPEG format photos The detection of the device will appear in the XMB graphics icons along with thumbnail views of the photos stored on the device The photos can be viewed individually or be displayed as a slide show USB2 0 Side Input This feature was available in selected 2008 models and allowed the viewing of JPEG formatted pictures and playback of MP3 audio files The media content has been expanded this year to allow playback of MPEG and MPEG2 format video content An optional wireless network adapter can be inserted to connect to a wireless home network HDMI 1 3 This new version of HDMI introduces several new enhancements and features and the EX 1 chassis supports 3 of the new features Consumer Electronics Control CEC A standardized protocol for the control of consumer electronics devices allows for communication and control via the HDMI cable on products that have this feature Any brand of electronic equipment that is CEC compliant can communicate with another to generate operational commands The Bravia Sync feature uses the CEC format to control other Sony devices in the system xvYCC The previous color bandwidth limitations applied for compatibility with analog signals are no longer present with digital signals This allows for 1 8 times more colors Deep Color The previous HDMI specifications limited the RGB sample level to 24 bit Deep Color expan
23. ift towards the magenta spectrum as they age The main issue with previous LCD panel designs was the uniformity CTV 68 adjustment data Due to variances across the LCD panel it was impossible to achieve even white balance across the screen For this reason small zones across and down the LCD panel required individual white balance compensation Without this correction the picture would have blotches of different color in sections of the screen Better tolerances during manufacturing have reduced the reliance on this uniformity data and allows for the replacement of TCON boards with satisfactory results As mentioned in the beginning not all LCD panels will have a TCON board available This will mainly be determined by availability of components from the LCD panel vendor along with decisions by Sony based on sales quantity and failure history of the TCON assemblies Most technicians have experienced the use of the LCD panel replacement manual This manual was created to properly identify the type of LCD panel installed in a unit based on its serial number since some units changed to a different type of LCD panel during the manufacturing production The plan is to use this document to also provide TCON information and whether one is available and if available which TCON is the proper replacement part for that particular panel LCD Panel Basics LCD panels have steadily evolved over the last several years New designs of the physical
24. lowed by distorted video from the point of the failed IC and downward e Any horizontal lines The gate drivers are activated by a single source of timing information so any single horizontal line or groups or random horizontal lines are caused by an output failure from a gate driver or a loss of the tab bond to the panel CTV 68 Chapter 4 Appendix TCON Failures Failures in the timing control circuits of the TCON can produce symptoms of absolutely no video or generate lines and patterns that usually cover all or a substantial part of the screen Determining if the TCON is the cause of a no video condition is a bit more difficult since there are no indications on the screen to analyze Troubleshooting a DEAD TCON Many of the Sony television models over the last few years will detect a TCON that has completely failed The communications data between the video process circuits and the TCON will cease to communicate if the TCON fails completely This will cause the television to shut down and display a diagnostics code indicating a failure of the TCON Not all chassis designs have this feature and it is not found on older models The typical scenario when this failure arises is for the technician to bring a video process board to the repair location It is usually safe to assume that the problem lies on the TCON board if the replacement video board does not remedy the problem since it is highly unlikely that a replacement board with
25. n the KDL22EX308 CTV 68 Chapter 3 Troubleshooting Won t Power On This situation assumes that the red standby LED is lit when AC power is applied to the unit A lit standby LED indicates that the standby power supply is operational and the CPU on the BAL board is at least partly operational In this case it is likely that the main power supply is either not being turned on or it has failed Service Tip If the standby LED is lit but the unit will not power on remove AC power from the unit This can be done by unplugging the AC cord or turning off the eco switch Wait about 20 seconds and re apply AC power You should hear a distinct click of the main relay which will engage for about 5 minutes 20 seconds before releasing again If the relay clicks on the power on command line from the CPU is functional Use the power on button on the right side of the unit to attempt a turn on and eliminate a defective remote control system The troubleshooting flowchart in Figure 3 4 will assist in isolating the power problem 14 Chapter 3 Troubleshooting No Power Press power Does red standby Yes button while High 3 3V LED on front panel monitoring pin 3 of on oin 39 light CN6150 on power P supply board Is standby LED blinking No Is Eco switch on side of unit turned off 46 52 60 No FIGURE 3 4 NO POWER TROUBLES
26. nal cold cathode fluorescent lamps CCFL to generate the necessary backlighting for the LCD panel A self contained direct inverter circuit supplies the necessary high voltage to drive the backlight lamps CTV 68 Wireless Internet Ready An optional wireless network adapter is available to connect the television to a home network These models have an Ethernet port on the rear for direct connection to the home network Plugging the optional wireless network adapter into the USB2 0 port on the side of the television allows for wireless connectivity when conditions do not allow direct connections The wireless adapter supports up to 802 11N BRAVIA Internet Video Once available as an optional device to connect to the television this feature is now an integral part of the product The rear of the television contains an Ethernet port to connect to a high speed network Access to online music and video through partnered websites is possible Personalized widgets are small applications that can be placed on the screen and accessed with the touch of a button to bring up programming such as weather stocks and sports information Enhanced Cross Media Bar XMB A new graphics user interface with rich 3 D graphics allowing the user to customize the setup of the television and to access various adjustments and control optional devices Optional external devices can also be detected and displayed One example would be when a USB storage dev
27. nents can cause this Fortunately each of these components tends to generate unique symptoms when a problem occurs Some distortions may occur that could be caused by either of these components but a good understanding of the circuits and further investigation will isolate the suspected circuit The following sections will cover the various scenarios of problems that may occur in the video processing circuits No Video A video complaint be caused by a number of reasons The first step is to determine if the condition is present from all input sources If any video source is working properly the TCON can be assumed to be OK The backlights are also functioning properly Although it is unusual for a backlight failure to cause a complete loss of video the unit will shut down if a backlight power or open LED is detected there have been cases where the backlights have failed to turn on without the unit shutting down If the loss of video occurs on all inputs the problem will require additional diagnostic work The presence of audio is an important sign to check for Missing audio accompanying a loss of video helps to eliminate the TCON as the cause and would point to the BAL board as the culprit If audio is present the next step is to determine if the video loss is occurring in the video process circuits on the BAL board or the LVDS cable link from the BAL board to the TCON or the TCON itself CTV 68 Chapter 3 Troublesho
28. nsmitter This circuit converts the 8 bit parallel RGB video information into a set of high speed serial lines for noise free transmission to the TCON board Power Supply KDL22EX308 The KDL22EX308 utilizes the GD1 power supply board There are 3 distinct sections on the power supply Standby Supply Continuously operational as long as AC power is applied the standby supply generates 3 3VDC for the circuits requiring power while the unit is turned off An unregulated 15 volt line is present to provide power to the main relay PFC and main power supply at turn on Main Supply Once the power supply receives a power on command from the CPU on the BAL board the main switching supply is turned on to provide a regulated 12V source along with a dedicated un regulated 15V for the audio circuits Inverter The high voltage for the fluorescent backlights is generated by this circuit Out of phase AC voltage of approximately 1000VRMS is applied to the balancer circuit If the inverter circuit fails to start for whatever reason the unit will shut down with a 6 blink error code displayed by the timer LED KDL32EX308 Referring to Figure 2 2 the KDL32EX308 utilizes the G2LE power supply board All of the other circuits are the same as the KDL22EX308 except for the following circuits There are 2 distinct sections on the power supply Standby Supply Continuously operational as long as AC power is applied the standby supply generat
29. on illustrated in Figure 3 1 will appear Compare the package version listed on the screen with the version available on line Install the software if the on line version is a higher numbered version 8 Contact Sony Please contact Sony directly if you have questions on the use of your televisi www sony com tvsupport 1 800 222 SONY 7669 1 877 899 SONY 76 Consult the Warranty Card Website Support United States Phone Contact Canada Phone Contact Other Countries Contact Please have the following information available Model Name See rear or side of TV Serial Number See rear or side of TV Software Version PKG1 049AAL INSTALLED SOFTWARE VERSION FIGURE 3 1 CHECKING THE SOFTWARE VERSION RETURN URN Ela Special Software Instructions for BAL Board or LCD Panel Replacement The 2010 models utilize a generic type BAL board In the past many different main boards needed to be stocked due to differences in software requirements The software loaded on the board was specific to the model and its features along with the type of LCD panel installed during production Replacement BAL boards will now be stocked with basic software Once the replacement board is installed in the unit the most current software is to be installed using a USB storage device containing the necessary software downloaded from the ASC support web page In addition to software installation for specific models 2 items must be check
30. oting Service Tip If a service call is made for a no video complaint a warranty repair would require the technician to bring a BAL board to the location The technician will install the board hopefully the correct one and if the video problem is not remedied it is safe to assume the problem might reside in the TCON One method to test a TCON which works rather well in most cases is to remove the LVDS connector at the LCD panel the TCON board is internal to this panel while the unit is running Be certain to release the lock tabs and handle the connector carefully to avoid damage Carefully insert and remove the connector while slightly rocking it Observe the screen as you do this If any activity appears on the screen flashes lines or patterns The TCON is OK The unit may shut down within a 10 to 20 second period because the protect circuits have detected a TCON failure If this happens simply re insert the LVDS connector turn the unit back on and try the procedure again Normally you should be able to detect something on the screen within a matter of seconds The troubleshooting flowchart in Figure 3 2 should provide assistance in isolating the cause of the video loss 10 No Video Backlights turned on Any OSD graphics present Unplug LVDS connector at TCON while unit is running This may need to be done more than once Any flashes seen on screen FIGURE 3 2 NO VIDEO TROUBLE
31. ply a television anymore They are evolving into devices that are designed to integrate with numerous other devices found in the home Some examples are Portable audio and video devices still cameras home computer networks and accessing the internet to name a few Communications with these varying devices requires that the television be compatible with varying communications protocols Although standards are detailed for each of these protocols the real world dictates that occasional errors may occur that could prevent devices from operating or communicating properly CTV 68 Keeping the software in the television up to date is a procedure that is normally handled by the owner of the television Most customers who own computers and other digital devices are familiar with and are accustomed to updating the firmware and software in their products If a customer contacts the Sony Customer Support Center and it is deemed to be correctable with a software update the issue is handled at the customer level ooftware updates can be performed in the following ways e Manual Downloads Software updates can be retrieved from the Sony Support Site at where they can be downloaded and placed on a USB thumb drive to be loaded into the product The instructions for downloading the software file vary from chassis to chassis and sometimes from model to model Read the instructions included with the software file to properly format the USB device unzip the
32. r of a KDL22EX308 with the cover removed The location of the major circuit boards and connectors for voltage checks is provided An illustration of the KDL32EX308 is shown in Figure 3 10 CTV 68 19 Chapter 3 Troubleshooting CN6701 CN6702 CN6001 DH CCFL HV TO oo BALANCER CN6704 CN3800 mew 6 TCON 12V r r rir 9 CN6150 STBY3 3V 4 POWER ON AUDIO 12V AUDIO GND REG12V GND CN2561 REG12V BL ERR BL ON DIMMER TCON 12V TCON ON FIGURE 3 7 KDL22bX308 TEST POINTS CTV 68 20 Chapter 3 Troubleshooting CTV 68 CN6402 BL ON DIMMER CN6401 TO INVERTER CN3800 12 AUDIO 12V AUDIO GND 6 7 REG12V GND CN2561 o N gt FIGURE 3 8 KDL32EX308 TEST POINTS 21 Chapter 3 Troubleshooting FIGURE 3 9 KDL22EX308 BOARD LOCATIONS CTV 68 22 Chapter 3 Troubleshooting i d EI 2 E iu gre SWITCH B FIGURE 3 10 KDL32BX300 BOARD LOCATIONS CTV 68 23 Chapter 4 Appendix TCON Troubleshooting Introduction Beginning in the fall of 2008 Sony announced the availability of limited TCON replacement boards to service LCD panels beginning with certain models going back to 2006 For many years technicians have been asking
33. s tend to be fixed and usually appear as symmetrical patterns that occupy most or a significant portion of the display Some examples of TCON errors e No video e Thin vertical lines spanning most or all of the display e More that one column of wide vertical columns which may appear black or any color or may contain distorted video Multi colored vertical line patterns with a repetitive pattern Service Tip Whenever vertical lines of distortion appear select an inactive input or disconnect the antenna in the tuner mode The idea is to not have a high definition signal as the source This allows the picture zoom functions to operate Change the zoom mode from the remote commander If the lines follow the normal and zoom modes the problem resides on the BAL board If the lines remain fixed throughout the various zoom modes the TCON is at fault CTV 68 Chapter 3 Troubleshooting LCD Panel Distortions originating from the LCD panel tend to be localized with the exception of horizontal line issues A failure of a gate driver can cause a horizontal distortion with all video content below that point appearing distorted Depending on which gate driver has failed the distortion may only cover a small area of the bottom of the screen or a large area of the screen if the driver failed near the top of the panel With the exception of visible physical damage listed below are some examples of LCD panel related distortions e Any single
34. structure of the LCD crystals have greatly improved the contrast ratio and viewing angle Quicker response times and increased refresh rates have helped to reduce the motion smear associated with LCD displays Backlighting design has also aided in producing a picture with color temperatures to make the images as true as possible With all these design improvements one aspect of the LCD panel remains relatively the same Processing of the video signal Figure 4 1 illustrates a typical LCD panel and the associated video processing circuits as found in the WAX3 chassis The various formats and resolutions of video signals are processed on the BU1 board All video signals exit the video processor in the native resolution of the LCD panel In this design the resolution is for a 1366 by 768 at 60HZ refresh rate panel 48 horizontal lines are discarded to match up to the 720 resolution of the ATSC specifications so the video will exit as 720p The LCD panel used in this model processes 8 bit RGB video data Before the video information can be sent to the TCON board it must be converted to a format that allows for practical and noise free transmission The large number of parallel lines to transmit the 8 bit RGB data would need to be sent on differential lines for noise reduction This would require 48 lines just for the video The TCON circuit also requires B ground connections a communications bus sync and a clocking line transmitted differentiall
35. system will cause the unit to shut down If one or more of the fluorescent backlights fails to turn on or if the high voltage inverter circuit fails to turn on the unit will shut down and the standby LED will blink in groups of 6 The first step to determine the cause of the failure is to observe the screen of the television when it is first turned on If the backlights turn on before the shutdown it is likely that one of the lamps has failed to turn on and the LCD panel must be replaced If the backlights do not turn on the high voltage inverter did not start and depending on the method of generating high voltage replacement of the power supply or inverter board is necessary No Backlight No Shutdown It is possible for a symptom of no backlighting to occur that does not cause the television to go into protective shutdown Dynamic dimming control of the backlights is performed by monitoring information from the TCON board This is in the form of data and determines the brightness level of the backlights based on video content If the TCON fails to process the RGB video data or if the dimmer data line fails the backlights will not turn on Audio will be present if the selected input has it available The television will remain on indefinitely with the green Power LED lit If the TCON is available it can be replaced to resolve the issue If not the LCD panel must be replaced Diagnostics History Figure 3 6 illustrates an example o
36. tdown would require replacement of the BAL board 5X A communications error with the timing control circuits has occurred oince both of these circuits are located on the TCON board replacement of the board should remedy the problem In rare cases a loose or defective LVDS cable could be the cause If the TCON board is not available as a separate part the entire LCD panel must be replaced CTV 68 Chapter 3 Troubleshooting 6X If the inverter circuits fail to generate high voltage or one or more of the backlight lamps fails to light the television will shut down and display this diagnostics error 7X A digital thermometer IC located on the BAL board provides a temperature reading of the chassis and LCD panel If the temperature exceeds a pre determined point the unit will shut down If this problem occurs immediately at turn on the temperature sensing IC has failed and replacement of the BAL board is required If this occurs after the unit has been running for a while check for ventilation issues that could cause the unit to run hotter than normal 16 CTV 68 Shutdown Standby LED Blinking Protect Chapter 3 Troubleshooting Does standby LED light After a While Immediately SONY logo appears before shutdown FIGURE 3 5 PROTECT SHUTDOWN TROUBLESHOOTING FLOWCHART 17 Backlight Issues Under normal circumstances any failures in the backlighting
37. ter 4 Appendix control lines is not even close to the number of horizontal or vertical rows of pixels so the LCD panel must use this information to further expand the ability to turn on each individual crystal The process will be explained in the gate and source driver paragraphs All of this is accomplished by the TCON board The term is short for Timing Control Other LCD panel manufacturers may have a different name for this particular circuit but the term used by Sony will always be TCON 25 Chapter 4 Appendix LVDS TRANSMITTER LVDS RECEIVER VIDEO PROCESS TIMING CONTROL SOURCE DRIVERS GATE DRIVERS FIGURE 4 1 TYPICAL LCD TIMING CONTROL CTV 68 26 Gate Drivers Referring to Figure 4 1 note the IC s located along the side of the panel These IC s are mounted on a flexible cable s which are bonded to the LCD panel Their function is to activate each row of pixels one at a time starting with the first line at the top As each line is activated the source drivers turn on the appropriate liquid crystals for the frame of video about to be displayed This continues from top to bottom until the entire frame of video is displayed The process is repeated for the next frame This rate can vary from 60 times per second or be increased to 120 or 240 as found in the high frame rate panels Source Drivers These IC s provide the control voltages to turn on each RGB segment of the vert
38. the same failure was received One trick to check most TCONS for functionality is to loosen the LVDS connector at the TCON as shown In Figure 4 3 while the unit is turned on Handle the LVDS connector with care and be certain to fully release the lock tabs Gently rock the cable in and out of the connector while observing the screen for any response Depending on the chassis the symptoms of the screen may be gentle white flashes intermittent colored lines or a screen full of random patterns The idea at this point is to provoke some kind of response on the screen TCON boards that have failed will not usually generate any type of response on the screen Another helpful procedure is to rapidly heat and or cool the TCON with hot air devices or circuit coolant and watch for patterns to appear on the screen 29 Figure 4 3 illustrates 2 examples of a loss of control data to the drive IC s In the first example an entire group of column drivers has lost the data stream for red The second example involves the complete loss of drive data for all RGB information to the right side of the screen This is sometimes caused by the flat cable connecting the TCON to the LCD panel coming loose The area of missing video can be dark or completely white depending on the panel design Service Tip Select an inactive input or one that is known to be a 4 3 SD source and toggle between the normal and zoom modes If the lines follow the zoom ch
39. ust the brightness and contrast level of the picture This new version is also capable of measuring the color temperature of the ambient light to adjust the white balance of the displayed picture based on what type of light source is present in the room Chapter 2 Overall Circuit Descriptions Overview The primary circuits contained in the AZ1L chassis consists of a main circuit board designated as the BAL board power supply GD1 Or G2LE which varies based on the size of the LCD display and the LCD panel assembly The TCON circuit normally mounted external to the LCD panel is contained inside the panel assembly The remaining small boards contain switches sensors and LED s Overall Circuit Description Figure 2 1 illustrates an overall block diagram of the KDL22EX308 Figure 2 2 illustrates an overall block diagram for the KDL32EX308 Both chassis designs share most of the same circuits with the power supply and high voltage circuits to supply the lamp voltages being the significant difference Below is a description of the components and their function for the KDL22EX308 BAL Board Common to all models utilizing the AZ1L chassis the BAL board contains most of the video processing circuitry along with all audio processing Control of the television is accomplished via CPU IC5000 Below is a list of the key components located on the BAL board AIV Decoder IC9000 This IC performs several functions including the following
40. y SO we can see that up to 60 lines would be required for an 8 bit video signal and significantly more lines for a 10 bit processor The practical way to transmit this information is to convert the parallel video data to a serial stream and this is accomplished by the Low Voltage Differential Signaling LVDS transmitter The LVDS transmitter contains a circuit to serialize the parallel data The parallel video information along with sync and clocking data are transmitted via twisted line pairs Depending on the logic level current is sent along one or the other of the twisted pair of wires The receiving end of the wires is loaded with a resistor usually around 100 to 120 ohms The receiver detects the polarity of the voltage drop across the resistor to determine the logic level The current level swings in the wire are about 3ma with a voltage differential of around 350mv This allows for transmission of the video signal with minimal EMI The LVDS receiver on the TCON board converts the serialized data back to parallel This data is processed by the timing control IC to allocate the RGB data into serial streams for processing by the LCD panel The TCON transmits the pixel control data to the panel via flat flexible circuit board cables which can number 2 or 4 depending on the bit rate and refresh timing of the panel A 1366 X 768 panel requires about 180 lines to transmit control information and B from the TCON This number of CTV 68 Chap
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