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Course : CTV-45
Table of Contents
Chapter 1 Introduction ..................................................... 1 Overview.......................................................................... 1 Features .......................................................................... 1
Full HD 1080 Panel.............................................................. 1 Motionow ........................................................................ 1 Enhanced Cross Media Bar (XMB)...................................... 1 HDMI 1.3.............................................................................. 2
Consumer Electronics Control (CEC) ..................................... 2 xvYCC ..................................................................................... 2 Deep Color .............................................................................. 2
Board Layout ......................................................................11 52-inch V Series Models .................................................... 14 Board Layout ..................................................................... 14
Bravia Sync ....................................................................... 2 Advanced Contrast Enhancer (ACE) ................................... 2 Digital Media Port ................................................................ 2 Digital Media Extender (DMEX) ........................................... 2 Interactive Program Guide (IPG) ......................................... 2 Digital Living Network Alliance (DLNA) ................................ 2 4 HDMI Inputs ...................................................................... 2
Chapter 2 Overall Block Diagrams .................................. 3 Overview.......................................................................... 3 Overall Block Diagrams ................................................... 3 The V Series .................................................................... 3
32/37-inch Models Overall Block Diagram........................... 4 Board Layout ....................................................................... 6 42-inch Model ...................................................................... 8 Board Layout ....................................................................... 8 40 and 46-inch Models .......................................................11
Troubleshooting ............................................................. 27
No Video ............................................................................ 27 Video Distortions................................................................ 27 Troubleshooting Flowcharts ............................................... 27
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Troubleshooting ............................................................. 50
Inverter Failures ................................................................. 50
Inverter Does Not Start ......................................................... 50 Inverter Starts and Turns Off ................................................. 50
Troubleshooting Flowcharts........................................... 52
Balancer Board Removal ................................................... 52
Troubleshooting ............................................................. 37
Completely Dead Unit ........................................................ 37 Power Supply Shutdown.................................................... 37 Power Supply Troubleshooting Flowchart ......................... 37
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Diagnostics History ........................................................ 61 Troubleshooting Flowcharts........................................... 61 Troubleshooting Test Points .......................................... 61 Chapter 8 Appendix ........................................................ 69 Software Updates .......................................................... 69
Why Update? ..................................................................... 69 Checking the Version of Software...................................... 69 Performing the Update....................................................... 71 Downloading an Update .................................................... 72
Formatting the USB Device .................................................. 72 Installing the File(s) to the USB Device ................................ 72
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Chapter 1 Introduction
Overview
The EX-1 chassis is one of several designs for the 2008 model line of Sony Bravia LCD televisions. 22 models are available as of this writing ranging from 32 to 52. The models are grouped in categories beginning with the V series as an introductory product for a full HD 1080 panel. The W series is an intermediate level product and introduces a frame doubling circuit known as Motionow to provide a 120HZ refresh rate. Upgrade level televisions are available in the Z and XBR series models. NOTE: Although there are 5 XBR models, the 32 and 37-inch models are classied as entry-level models in that they do not contain the features found in the 40, 46, and 52-inch models. When referring to the XBR series, the term small XBR and large XBR will be used when necessary. The chassis design revolves around the video processing circuits located on the BU board. It remains relatively the same except for a couple of additional input features and 10-bit video processing found on the upperend models. 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.
Motionow
A frame-doubling circuit utilizing proprietary circuitry and algorithms is able to capture and compare the movement from one frame to another. By anticipating the location of a moving object, an additional frame is inserted to increase the frame refresh rate from 60HZ to 120HZ. The result is an exceptionally smooth picture during fast moving objects and scenes. This feature is available on the W, Z, and large XBR6 models. The customer has the option of changing the settings of the Motion Enhancement and Motion Compensation circuits to smooth the judder inherent with 24-frame lm-based content or can choose keep the judder for a lm-like experience.
Features
Several new features are introduced in the EX-1 chassis model lineup along with some carryovers from the previous year. The included features will vary based on the model series and will be indicated in the following descriptions:
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Chapter 1 - Introdcution
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.
xvYCC
The previous color bandwidth limitations applied for compatibility with analog signals are no longer present with digital signals. This allows for 1.8 times more colors.
Deep Color
The previous HDMI specications limited the RGB sample level to 24-bit. Deep Color expands this up to 48-bit giving the ability to generate a color depth of 2.8 trillion levels.
Bravia Sync
By utilizing the CEC feature of HDMI 1.3, this feature allows the customer to easily control the various Sony devices within their home entertainment system provided that all of the other devices have this feature included.
4 HDMI Inputs
3 inputs in the rear and one on the side are available for all models. This increases the available inputs to meet the expanding needs of additional devices.
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The V Series
This series consists of the following models: KDL32VL140 KDL32XBR6 KDL37XBR6 KDL40V4100 KDL40V4150 KDL42V4100 KDL46V4100 KDL52V4100
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Inverter
The inverter is mounted on the left side of the LCD panel (as viewed from the rear) and contains all of the circuitry necessary to generate the 1KVAC operating voltage for the uorescent backlights. It also contains on-board monitoring circuits to maintain even brightness among the lamps and to notify the BE Micro on the BU board if there is a failure of the inverter or if one or more of the lamps fails to light.
BU Board
Essentially the brains of the system, this board contains all of the input sources for video and audio information along with an on-board ATSC/ NTSC combination tuner. It also contains all of the video and audio switching and processing circuits. The front-end (FE) and back-end (BE) microprocessors to control the operation of the television and the video processor functions are located here. All video sources exit the BU board at the native resolution of the LCD panel (1920 X 1080, 60HZ). The BU board used in these models is specically congured for the panel types and sizes used. This includes physical, electrical and software congurations. Other models will have additional inputs, different processing schemes and different software which make the BU board specic to the panel type being used. Note that all input sources are directly connected to the BU board. The past use of separate boards for input switching, tuner, ATSC decoder and side video inputs has all been incorporated onto this single board.
H1 Board
Located at the top of the unit, the various user input buttons (power, channel and volume up/down, menu and input selection) are located here. The H1 board is mounted to the switch housing and is referred to as the switch or function block in the service manual.
H2 Board
The power, timer and standby LEDs are located on this board.
H3 Board
This board contains the IR receiver LED for the remote control. The same LED also serves as an ambient light sensor. All EX1 chassis models have the ability to automatically adjust the picture brightness and contrast level based on ambient lighting conditions. This feature is turned off by default but can be turned on by the customer in the user menu.
Power Supply
The 32-inch models contain a G1D board to provide the main operating voltages for the television. It supplies operating voltages to the BU board along with 24VDC for the inverter. The 37-inch model uses a G2D board which is essentially the same except the circuitry is designed to handle the increased current load of the larger panel.
LCD Panel
The 32 and 37-inch panels are full HD (1920 X 1080) utilizing Cold Cathode Fluorescent (CCFL) backlights. There are 16 lamps on the 32-inch and 20 on the 37-inch. The TCON board mounted to the panel is responsible for proper timing and allocation of the RGB data to the correct columns of LCD pixels. White balance and Gamma correction data is also stored on this board. This is why the TCON is not available as a separate service item. If there is a failure in the uorescent backlights, TCON or the LCD panel, they must be replaced as a single unit.
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VIDEO 1
VIDEO 3
L R
COMPONENT 1
COMPONENT 2
HDMI 1
HDMI 3
HDMI 4 DVI AUDIO
PC HD15
L/R AUDIO OUT
OPTICAL OUT USB 1.1
A/V DECODER VIDEO PROCESS VIDEO SWITCH AUDIO PROCESS AUDIO AMP BE MICRO
TCON
INVERTER
BU
LCD PANEL
VIDEO 2 HDMI 2
SIDE INPUTS
POWER SUPPLY
SWITCHES
LED
IR RECEIVER
H1
H3
H4
Board Layout
Figure 2-2 shows the board layout for the KDL32XBR6 and Figure 2-3 for the KDL37XBR6. Note that each picture illustrates the unit in assembled form. If the unit requires complete disassembly to replace the LCD panel these pictures provide guidance for the proper placement and routing of the various cables and wire harnesses. It is important that these be routed in their original positions to minimize EMI emissions.
H1 (FUNCTION BLOCK)
TCON
INVERTER
BU
G1D
H4
H3E
FIGURE 2-2 32XBR6 BOARD LOCATIONS 32-INCH CIRCUIT BOARD LAYOUT CTV-45 6
H1 (FUNCTION BLOCK)
TCON
INVERTER
G2D
BU
H4
H3E
42-inch Model
The KDL42V4100 model is unique in that the LCD panel conguration is unlike any of the other models. Referring to Figure 2-4, note that this model uses the same GD2 power supply found in the 37-inch model. The G2D board has an extra connector for supplying 24VDC and is used in this model to supply power to the second inverter board. 2 stand-alone inverters are used to drive the uorescent backlights. Each inverter board drives 10 of the 20 lamps. The inverter on the left side (as viewed from the rear) is the master and the right side the slave. A communications line is connected to the master inverter from the TCON board. Once the TCON receives RGB data from the BU board the inverters will turn on.
Board Layout
Figure 2-5 illustrates the board layout for the KDL42V4100.
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L R
VIDEO 3
COMPONENT 1
COMPONENT 2
HDMI 1
HDMI 3
A/V DECODER VIDEO PROCESS VIDEO SWITCH AUDIO PROCESS AUDIO AMP BE MICRO
PC HD15
INVERTER
TCON
INVERTER
BU
LCD PANEL
VIDEO 2 HDMI 2
SIDE INPUTS
POWER SUPPLY
SWITCHES
LED
IR RECEIVER
H1
H3
H4
G2D
FIGURE 2-4 42V4100 OVERALL BLOCK DIAGRAM 42-INCH V MODEL OVERALL BLOCK DIAGRAM CTV-45 9
H1 (FUNCTION SWITCH)
TCON
LEFT INVERTER
RIGHT INVERTER
G2D
BU
H3
H4
Board Layout
Figure 2-7 illustrates the board layout for the 40 and 46-inch V series models. The same boards are used for both sizes although the part numbers differ due to software on the BU board and larger balancer for the 46-inch.
IP5
This board contains the standby power supply, main switching power supply and inverter to drive the backlights. In past years, LCD panels at 40-inches and larger were driven by a stand-alone inverter (or 2 inverters for the 46 and 52-inch models. This year, the 40/46-inch V and W series use a power supply with an integrated inverter to provide the approximately 1KVRMS AC power for the lamps. This circuit will be covered in more detail later in this manual.
Balancer
Since the IP5 board provides a common power source for all of the lamps, a circuit must be used to assure that equal current is drawn by each lamp to prevent unequal brightness . This is one of the functions of the balancer. It is also responsible for distributing the high voltage to the lamps and to insure that all lamps are lit up or struck at turn-on. The 40-inch panel uses 20 backlights whereas the 46-inch uses 24.
LCD Panel
The 40 and 46-inch LCD panels are also native 1920 X 1080 resolution. Note that this block diagram also applies to the W series models. The only difference is the use of a frame-rate doubling circuit integrated with the TCON board. The V series do not incorporate this and have a panel refresh rate of 60HZ
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RF
VIDEO 1
L R
VIDEO 3
COMPONENT 1
COMPONENT 2
HDMI 1
HDMI 3
A/V DECODER VIDEO PROCESS VIDEO SWITCH AUDIO PROCESS AUDIO AMP BE MICRO
HFR*
PC HD15
TCON
BU
LCD PANEL
VIDEO 2 HDMI 2
SIDE INPUTS
SWITCHES
LED
IR RECEIVER
H1
H3
H4
IP5
FIGURE 2-6 40 AND 46-INCH V AND W SERIES OVERALL BLOCK DIAGRAM CTV-45 12
H1 (FUNCTION BLOCK)
TCON
BALANCER
IP5
BU
H3
H4
FIGURE 2-7 40 AND 46-INCH V AND W SERIES CIRCUIT BOARD LOCATIONS CTV-45 13
The W Series
The following models are included in this series: KDL40W4100 KDL40WL140 KDL46W4100 KDL46W4150 KDL46WL140 KDL52W4100 KDL52WL140 The major difference between the V and W series (other than cosmetics) is the addition of a high frame-rate circuit within the TCON board. These models utilize 120HZ refresh-rate panels. An additional board labeled as the Sony Logo Module contains a row of white LEDs to illuminate the Sony logo on the bottom front of the bezel. This feature can be turned off by the customer in the user menu. The block diagrams illustrated in Figures 2-6 through 2-8 are drawn to pertain to both the V and W series models with the differences noted in the diagrams.
D4 and D5 Boards
The most signicant difference is the use of separate inverter drivers and balancer boards. Due to the longer length of the backlight lamps, exterior current leakage occurs along the length of the lamps and they will tend to darken from one end to the other if a common AC voltage is applied to ionize the gasses. This is solved by using separate inverters to supply out-of-phase AC voltage to the lamps. The D4 and D5 boards output approximately 800VRMS of AC for a differential of 1600 volts. This necessitates the use of a separate power supply located on the G5 board.
Board Layout
Figure 2-9 illustrates the board layout for the 52V series model.
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14
L R
VIDEO 3
COMPONENT 1
COMPONENT 2
HDMI 1
HDMI 3
A/V DECODER VIDEO PROCESS VIDEO SWITCH AUDIO PROCESS AUDIO AMP BE MICRO
HFR*
TCON
PC HD15
BU
LCD PANEL
VIDEO 2 HDMI 2
SIDE INPUTS
IR RECEIVER
INVERTER
INVERTER
D4
D5
H4
SWITCHES
LED
POWER SUPPLY
H1
H3
G5
H1 (SWITCH UNIT )
TCON
D5
G5
LOWER LEFT BALANCER
UB
D4
H4
H3E
60HZ TCON
120HZ TCON
models, the following feature enhancements are included: 10-Bit Panel Processing: The RGB data exiting the board via the LVDS cable is 10-bit versus 8-bit. This increases the color depth from 256 to 1,024. Digital Media Port: Allows the use of special adapters to integrate portable digital media devices such as camcorders and MP3 players. Ethernet Port: Allows connection to a DLNA compliant server or devices for media le viewing. USB2.0 Port: MP3 audio les and JPG photos can be directly input to the television for viewing and listening.
Board Layout
Figure 2-12 illustrates the board layout for the 40 and 46-inch Z series models. The picture is of the 40-inch model. The 46-inch uses the same board layout but they are spaced further apart due to the larger size of the panel.
G4 Board
Unlike the V and W series which use an integrated power supply and backlight inverter on the IP5 board, the Z series contains a G4 board to generate the operating and standby voltages consistent with many previous designs.
52XBR Model
Figure 2-13 contains a layout of the overall block diagram used in the KDL52XBR6 model. Note the similarity with the 52-inch models for the V and W series with the exception of enhancements to the BU board as listed above in the 40/46Z and XBR models. The board layout for this model is the same as the 52W4100 shown in Figure 2-9.
D3 Board
The D3 board is a stand-alone inverter supplying approximately 1KVRMS of AC voltage for the panel backlights. It also contains on-board voltage monitoring for excessively low or high backlight voltage along with overcurrent monitoring. If a problem occurs in any of these circuits the unit will be told to shut down for protection.
BU Board
Although virtually identical to the BU board used in the V and W series
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18
RF
VIDEO 1
VIDEO 3
L R
SUBWOOFER DRIVE
AWF
COMPONENT 1
COMPONENT 2
HDMI 1
HDMI 3
HDMI 4 DVI AUDIO
PC HD15
L/R AUDIO OUT
OPTICAL OUT USB 1.1
DIGITAL MEDIA PORT
ETHERNET
A/V DECODER VIDEO PROCESS VIDEO SWITCH AUDIO PROCESS AUDIO AMP BE MICRO
HFR
BALANCER
TCON
BU
LCD PANEL
USB 2.0
VIDEO 2 HDMI 2
SIDE INPUTS
SWITCHES
LED
IR RECEIVER
POWER SUPPLY
INVERTER
H1
H3
H4
D3
TCON
BALANCER
D3
G4
BU
H1 (FUNCTION BUTTONS)
H3
H4
RF
VIDEO 1
VIDEO 3
L R
SUBWOOFER DRIVE
AWF
COMPONENT 1
COMPONENT 2
HDMI 1
HDMI 3
HDMI 4 DVI AUDIO
PC HD15
L/R AUDIO OUT
OPTICAL OUT USB 1.1
DIGITAL MEDIA PORT
ETHERNET
A/V DECODER VIDEO PROCESS VIDEO SWITCH AUDIO PROCESS AUDIO AMP BE MICRO
HFR
TCON
LCD PANEL
BU
INVERTER
INVERTER
IR RECEIVER
D4
D5
H4
POWER SUPPLY
SWITCHES
LED
H1
H3
G5
Component Inputs
There are 2 Y/Pb/Pr component inputs on this chassis. They are directly selected by IC4700. All HD formats up to 1080p 60HZ are supported except for 24P content. 24p is only supported via the HDMI inputs.
HDMI Inputs
HDMI input selection is performed by IC5200 and sends the selected input to IC4700. Each HDMI input has its own EDID information stored within a NVM IC. The following ICs (not shown) are attached to each input: HDMI 1: IC5101 HDMI 2: IC5191 HDMI 3: IC5131 HDMI 4: IC6161
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PC Input
Analog RGB input from a PC can be connected to the HD15 connector. The video process circuits will support conventional resolutions from 640 X 480 VGA up to 1920 X 1080 HD. EDID information for the PC HD material is contained within NVM IC5000.
LCD Panel
The LCD panel receives the 8-bit RGB video data from the BU board via a Low Voltage Differential Signaling (LVDS) cable. IC4700 contains the LVDS transmitter within and transmits a video resolution of 1920 X 1080 60HZ to match the native resolution of the panel.
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RF
TUNER
NTSC
ATSC
DIGITAL VIDEO
SUB VIDEO
IC7000 AMD
DIGITAL GPX
TCON
H/V SYNC
VIDEO 1
VIDEO 2
VIDEO 3
CC VIDEO
MAIN VIDEO
COMPONENT 1
IC4700 TRIDENT
1080 60HZ
LCD PANEL
COMPONENT 2
HDMI 1
HDMI 2
HDMI 3
HDMI 4
USB 1.1 PC HD15
120HZ HFR
ALL W SERIES
TCON
LCD PANEL
IC5000 EDID
IC3001 BE MICRO
BU
Ethernet Port
Devices that are DNLA (Digital Living Network Alliance) compliant can be used in a network setup to view and listen to content from PCs, mobile devices, gaming consoles, etc. DNLA provides the standards to allow many devices in the home to receive and send content among the network. Software upgrades can also be located on the internet and downloaded to the television should it become necessary. More information about the DLNA feature is described in the appendix section of this manual.
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25
RF
TUNER
NTSC
ATSC
DIGITAL VIDEO
VIDEO 1
SUB VIDEO
IC7000 AMD
DIGITAL GPX
VIDEO 2
VIDEO 3
H/V SYNC
CC VIDEO
MAIN VIDEO
COMPONENT 2
IC4700 TRIDENT
1080 60HZ
120HZ HFR
HDMI 1
HDMI 2
HDMI 3
HDMI 4
PC HD15
TCON
LCD PANEL
IC5000 EDID
USB 1.1
IC3001 BE MICRO
PHYSICAL INTERFACE
PHYSICAL INTERFACE
BU
Troubleshooting
Since virtually all of the video inputs and most of the video processing is located on the BU board, failures causing a loss of video or distortions in the picture need to be isolated to the BU board or the LCD panel. The combining of all video processing circuitry into 2 major components makes the troubleshooting approach to seem rather simplistic and in most cases it will be just so. As anyone who has experience servicing electronic products knows, things happen in the real world that can cause failures which do not follow the rules of the academic procedures found in this manual. Always research the latest service bulletins and/or troubleshooting tips on the Sony service website before making the service call.
interferences, video process failures and even mechanical problems in the LCD panel can cause video distortion. The up-side to display devices is that they are the most valuable tool in determining the source of the problem so long as one knows the basic theory of how they function. The Appendix section of this training manual contains a section on basic troubleshooting of LCD panel televisions. The primary objective when diagnosing no video or distortions in the video is to eliminate the LCD panel as the cause. Replacement of the LCD panel requires special authorization and, in some instances, will not be allowed due to economical reasons.
Troubleshooting Flowcharts
Due to the reduced number of circuit boards used in this chassis, troubleshooting video problems must focus on whether the problem lies on the BU board or the LCD panel. In a no video symptom the owchart asks if the backlights are lit. Hypothetically, the backlights must light or the unit will shut down and blink a balancer or inverter error but there have been cases in previous chassis designs where the backlights do not light and the unit did not enter the protect mode. The troubleshooting owchart in Figure 3-3 will provide some guidance in diagnosing a video problem.
No Video
If a total loss of video occurs (including OSD graphics) the most likely course of action is to bring a replacement BU board to the service location since the unit is serviced at board-level only. It is unlikely that a loss of voltage from the power supply is the cause since these voltages are monitored and the unit will likely experience a protection shutdown event rather than a no video condition. Although a failure of the backlights to turn on would certainly cause a no video condition, this too would cause the unit to shut down and indicate a failure via the self diagnostics feature. If the replacement BU board does not resolve the issue, the LCD panel is likely defective. The presence of OSD graphics with a no video condition certainly eliminates the LCD panel as the cause and the BU board will almost certainly x the problem.
Video Distortions
This is, by far, the most difcult failure to troubleshoot due to the many sources that can cause it. Noise emanating from the power supply, outside
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All inputs?
Yes
Video Failure
No
Distortion stationary ?
No
BU Board
Yes
Distorted
BU Board
Symentrical ?
Yes
LCD Panel
No
Backlights turning on ?
Yes
No
Backlight failure
Multi-colored
BU Board
Single Color
Yes
BU Board
LCD Panel
Yes
Unplug LVDS connector at TCON while unit is running . This may need to be done more than once
No
LCD Panel
BU Board
BU Board
HDMI
The 4 HDMI inputs are selected by HDMI switch and equalizer IC5200. The serial audio data is received by IC4700 where it is converted to I2S format. The digital audio data is transmitted via this bus to IC7300 and output to IC2002.
USB 2.0
MP3 audio les can be input to the USB side jack. The USB device is detected and a list of the available audio les can be viewed in the XMedia graphics menu. The audio can be listened to via the television speakers or and external amplier hooked up to the L/R analog outputs or optical output jack.
Ethernet (DLNA)
Audio or video le playback for the DLNA feature is not supported by any of the 2008 EX1 chassis models. Only JPEG les are supported.
Troubleshooting
Since all circuitry involving audio processing and amplication is located on the BU board, troubleshooting audio problems consists of determining whether the failure affects all inputs or it is input specic. Failures affecting all inputs would require changing the BU board whereas input specic problems would require eliminating the input device as the source.
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HDMI 1
HDMI 2
HDMI 3
IC4700 TRIDENT
I2S
AUDIO SOURCE
DIGITAL TUNER
DVD HDMI 5.1
ALL ANALOG INPUTS
NTSC TUNER
SACD VIA HDMI
DVD AUDIO VIA HDMI
OPTICAL OUTPUT
5.1 OR 2CH PCM
2CH PCM
2CH PCM
2CH PCM
NO OUTPUT
NO OUTPUT
2CH PCM
N/A
HDMI 4
USB2.0 ETHERNET
Z MODELS ONLY
ATSC/NTSC TUNER
NTSC AUDIO
ATSC AUDIO
USB2.0
ETHERNET
SPDIF
I2S
I2S
IC7500 ADC
PWM
L R
OPTICAL OUT
BU
FIGURE 4-1 AUDIO PROCESS CIRCUITS CTV-45 30
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31
F1 4A
NTC1
T
BD1
AC IN
CN603
1
UNREG_24V
GND
CN601
1
RY6101
UNREG_24V
GND
TO INVERTER
CN602
4
UNREG_13V
6
11
8
AU GND
REG 12V
GND
TO BU BOARD
STBY 3.3V
1
STBY 12V
POWER_ON
STBY 12V
STBY 3.3V
IC305
Q805
Q901 Q302
Q303
Warning: When the unit is turned off while still connected to AC power, the rectied 160 volts will pass through the PFC circuit and always be present. This voltage is referenced to hot ground. Use caution when near this circuit and make sure to use an isolation transformer when using grounded test equipment.
G5 Power Supply
Figure 5-4 illustrates the block diagram for the G5 power supply board used in the 52-inch V and W series models (including the 52XBR6). This power supply has a larger current capacity and dual PFC outputs. The 52-inch panels use 2 inverter boards (D4 and D5) requiring the dual PFC lines.
G4 Power Supply
This power supply is used in the 40 and 46-inch Z and XBR6 models and is shown in Figure 5-3. The standby and main switching supplies operate in the same manner as the previously covered power supply circuits.
PFC Output
These models use a stand-alone inverter located on the D3 board. The inverter requires 395VDC and this is supplied by the PFC circuit via CN6502 to the D3 board.
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33
F6001 6.3A
AC IN
R6009
HV+ OUT
AC IN
PFC
D6000
395VDC
HV- OUT
TO BALANCER
CN6154
INVERTER_ERR
BACKLIGHT_ON
5
RY6000
DIMMER
FROM BU BOARD
CN6151
1
REG 12V
GND
CN6150
NOT USED
UNREG 15V
STBY 12V
11
STBY 12V
REG 12V
GND
GND
10
3
GND
STBY3.3
FROM BU BOARD
AC_DET
PH6300
Q6303 Q6304 Q6404
PWR_ON
IP5 IP5
FIGURE 5-2 IP5 POWER SUPPLY/INVERTER BLOCK DIAGRAM CTV-45 34
395VDC
F6000 6.3A
AC IN
CN6501
1
PFC OUT
2
R6009
PFC GND
TO D3 BOARD
AC IN
PFC
D6000
395VDC
RY6000
CN6202
13
8
REG12V
REG12_GND
6
4
UNREG_GND
UNREG_15V
TO BU BOARD
STBY3.3
AC_OFF_DET
POWER_ON
PH6300
Q6303 Q6304 Q6407
G4
PFC OUT
F6000 6.3A
AC IN
2
R6009
PRI GND
TO D5 BOARD
CN6500
AC IN
PFC
D6000
390VDC
1
STBY 12V STBY 3.3V
PFC OUT
PRI GND
TO D4 BOARD
CN6100
1
REG 12V
3
RY6000
GROUND
TO TCON
CN6154
5
DIMMER
4
3
RLY_VCC (REG 12V)
BACKLIGHT
INV_ERR
TO BU BOARD
BALANCE_ERR
CN6153
7
BALANCE_ERR
INV_ERR
3
2
BACKLIGHT
DIMMER
TO D4 BOARD
REG12V
STBY 12V
CN6150
13
8
REG12V
REG12_GND
6
4
UNREG_GND
UNREG_15V
STBY3.3
TO BU BOARD
AC_OFF_DET
PH6300
Q6303 Q6304 Q6407
POWER_ON
G5
Troubleshooting
In order to properly diagnose a potential problem with the power supply it is important to determine if the power supply is completely dead or will not turn on when commanded to do so. There are a couple of important items to be aware of when rst examining the unit. In a properly functioning unit the standby 3.3V line will remain at this voltage for approximately 2 minutes after the AC source is removed. This is part of the AC detect routine and allows the BE Micro to remain running and clear the operational routines to prevent lockup because of a decaying standby voltage. If the unit was not in the on position before AC power was removed and has not had AC power applied for approximately 2 minutes, the BU board will output a power on command to turn on the relay as soon as AC power is returned. The power LED will not light. The distinct click of the AC relay can easily be heard and it will remain engaged for approximately 30 seconds before turning off. This is very important to know when determining if the standby supply, AC relay and BE micro on the BU board is functioning. If has been less than 2 minutes since AC power was disconnected the relay will not perform this routine. If the unit was turned on when the AC power was disconnected, it will power up completely regardless of how long AC power was disconnected. When the television is working properly the AC relay will not disengage at turn-off until approximately 20 seconds has elapsed. The following troubleshooting procedures will deal with general approaches to locating the problem. The troubleshooting owcharts at the end of this chapter are created to specically address the unit based on what power supply is used,
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37
No Power
No
Yes
Yes
Yes
Replace BU Board
Inverter Circuit
Note that each inverter-drive circuit feeds a pair of lamps. Since each pair of lamps is connected to the opposite end of a transformer they are driven with out-of-phase AC voltage. This is necessary to prevent parasitic capacitance between the lamps to prevent brightness uctuations. The AC voltage supplied to the lamps is not a steady voltage. The lamps are provided with a variable duty cycle of AC bursts. This is how the unit is able to vary the brightness of the backlights. The duty cycle of these burst will vary from 30% at minimum brightness up to 95% at maximum. The lamp brightness is controlled by the dimmer line exiting the BU board at CN1401-5. This control line is a negative going PWM signal that will vary its duty cycle from approximately 70% negative at low brightness to approximately 10% at high brightness. This duty cycle change affects the DC voltage at this point and it can be read with a DVM. The DC voltage reads 0.8 volts at low brightness and 3.1 volts at full brightness. Typical waveforms for the inverter output and dimmer PWM signals are shown in Figure 6-2. The inverter board also contains monitoring circuits (not shown) to detect a failure of one or more of the inverters or if one or more of the lamps fails to light. If either one of these situations occurs, the inverter will send out a high on the INV-ERR line to CN1401-3. This is detected by BE Micro IC3001 on the BU board. IC3001 will shut the unit down and the standby LED will blink in groups of 6. NOTE: Whenver an inverter error is detected, the unit will make 3 attempts to start the inverter. The AC relay will be heard cycling on and off during these attempts.
32/37-inch Backlighting
Figure 6-1 illustrates a block diagram of the circuits involved in generating the backlight voltage for the lamps. The smaller 32 and 37-inch panels use a single inverter board to supply an AC voltage of approximately 1000-volts RMS at 57KHZ.
Power-Up Sequence
Once the power on command is received at CN602-1 on the G board from BE Micro IC3001, the power supply starts and, along with other secondary voltages, outputs 24VDC to CN001 on the inverter board. Approximately 5 seconds after turn-on, the backlight on command goes high at CN1401-4 on the BU board. The oscillator on the inverter will start and the drive circuits for each pair of lamps will begin generating the necessary lamp voltage.
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LCD PANEL
INVERTER DRIVE
APPROXIMATELY IKV RMS
CN001
INV_ERR (NORMALLY LOW) BACKLIGHT_ON (3.3V ON) DIMMER (PWM)
CN1401
GND INV_ERR BACKLIGHT_ON DIMMER
2 3 4 5
IC3001 BE MICRO
CN1411
POWER_ON
1
POWER_ON
BU
2ms 1V/div
DIMMER MAX BACKLIGHT PWM
2ms 1V/div
DIMMER MINIMUM BACKLIGHT PWM
42-inch Backlighting
The KDL42V4100 is unique in that this model is the only one that uses this panel design and backlighting scheme. The board layout is shown in Figure 6-3. The G2D power supply used in the 37-inch panel contains an extra connector for an additional 24VDC source and this is used to power the additional inverter board found on this model.
INVERTER
CN24
Power-up and protection functions very much the same way as the system used in the 32/37-inch panels with the exception of the additional inverter. Due to the longer length of the backlight tubes, differential AC is applied to both ends of the uorescent lamps instead of using a common ground reference.
CN26
INVERTER
INVERTER DRIVE
INVERTER DRIVE
INVERTER DRIVE
APPROX IKV RMS
INVERTER DRIVE
LCD PANEL
CN23
CN001
INV_ERR (NORMALLY LOW) BACKLIGHT_ON (3.3V ON) DIMMER (PWM)
CN25
CN001
CN1401
GND INV_ERR BACKLIGHT_ON DIMMER
2 3 4 5
IC3001 BE MICRO
CN602-1
1
POWER_ON
CN1411
POWER_ON
BU
G2D
CN603
Inverter
Once the IP5 board receives a power on high at CN6150-1 the power supply begins generating the necessary voltages. The PFC circuit increases the rectied 160VDC to approximately 395VDC to supply power for the inverter switching transistors. The oscillator provides the necessary 41KHZ drive for the inverter switching transistors. The inverter stage outputs approximately 1000VRMS at 2 output lines that are 180 degrees out-of-phase. Note the inverter detect stage. The detector consists of small-value capacitors and diodes to detect the AC voltage. If either AC line fails to output the inverter detect circuits will output a high to CN6154-3. This will be detected by BE Micro IC3001 on the BU board and the unit will shut down and blink the standby LED in groups of 6. The event will also be registered into the diagnostics menu for viewing when entering that mode. This will be covered in Chapter 7. The inverter also has over-voltage and over-current detection circuits (not shown). If either circuit detects a malfunction the oscillator will stop and create an inverter detect failure.
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1000 VRMS
INVERTER
CN6701
12V FB GND LD
1 2 3 4 5
BALANCER ERROR (NORM LOW) GROUND INVERTER ERROR (NORM LOW) BACKLIGHT (3.3V ON) DIMMER (0.8 ~ 3.1VDC)
1 2 4 6
OSC/ DRV
INV DET
1 2 3 4 5
CN6154
CN1401
PFC
1
POWER_ON
IC3001 BE MICRO
CN6150
CN1411
IP5
BU
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45
TO LAMPS
REF
FEEDBACK
D5 Board
This board drives the opposite side of each lamp with 180 degree out-ofphase AC. Since the D4 board contains the master oscillator and drive circuits, this is how the 2 inverters are able to maintain their out-of-phase condition to drive the lamps. Note that the D5 board also contains an inverter detect circuit should one or more of the AC output lines fail. Although the intention is to warn the unit and shut it down when the inverter fails, this will not happen if the D4 board is still operational. The inverter detect circuit on the functioning D4 board will keep the inverter-error line low and prevent an inverter failure warning from being detected. The balancer error detect circuits will activate and shut the unit down with a 13-blink error instead. This subject, along with how to isolate it, will be covered in the troubleshooting section in this chapter.
G5 Board
Operating the same as the G4 board previously mentioned for the 40/46Z models, the G5 power supply provides an additional PFC 395VDC output for the second inverter board.
D4 Board
This board is similar to the D3 board used in the 40/46Z series models in that it generates dual out-of-phase AC voltage for the lamps. It also contains the master oscillator and drive circuits for the on-board inverter switching transistors. This oscillator and drive circuit is responsible for driving the switching transistors on the D5 board.
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LCD PANEL
1000 VRMS
1 BALANCER ERROR (NORM LOW) 2 GROUND 3 INVERTER ERROR (NORM LOW) 4 BACKLIGHT (3.3V ON) 5 DIMMER (0.8 ~ 3.1VDC)
CN6701
12V FB GND LD
1 2 4 6
INVERTER
OSC/ DRV
INV DET
CN6701
1 12VDC B+ 2 FB (FEEDBACK) 7.2VPP 4 GROUND 6 LD (LAMP DET) NORM HIGH (12V)
1 2 3 4 5
CN6702
CN1401
CN6600
D3
IC3001 BE MICRO
CN6502
CN6600
PFC
AC_RLY
POWER_ON
CN6150
CN1411
G4
BU
LCD PANEL
CN6706
12V FB GND LD
1 2 4 6
INVERTER
OSC / DRV
INV DET
800VRMS
INV DET
INVERTER
CN6703
CN6702
CN6950
CN6600
D4
CN5900
D5
CN6600
1 395VDC 3 HOT GND
CN6500 CN6501
CN6153
1 2 3 4 5 6
CN6154
1 BALANCER_ERR (NORM LOW) 2 GROUND 3 INV_ERR (NORM LOW) 4 BACKLIGHT_ON (3.3V ON) 5 DIMMER (PWM) 6 REG_12V
PFC
CN6154
CN6154
CN1401
IC3001 BE MICRO
POWER _ON
CN6150
CN1411
G5
BU
Troubleshooting
Failures that occur in the backlighting circuits that cause the unit to shut down can be caused by one or both of the following reasons: Inverter Failures Backlight Balancer errors
(0.1 ohm, 1/2 watt) in line with this voltage on the power supply and they occasionally open. Check for the backlight on command at CN1401-4 on the BU board. It should go high to around 3.3VDC about 5 seconds after the unit is turned on. It is extremely rare for this to be the cause but if it does not go high, There is a connection problem at the power on line or the BU board is defective. If all of the above checks out OK, replace the inverter board. Power Supply: If the power supply is not outputting the 395 volts, replace the board if the unit is under warranty. Models using the IP5 combination power supply and inverter would simply require replacing that board under this and the previous condition. BU Board: If the BE Micro on the FB board fails to send a 3.3V backlight on command the unit will shut down as if the inverter had failed. Be certain to record the serial number of the unit so the correct version of FB board can be ordered. The version of FB board is determined by which LCD panel was installed during the manufacturing process.
Inverter Failures
The following description will involve the single inverter panel. Panels using dual inverters have a slightly different reaction to inverter issues and these will be discussed separately. If the inverter fails to turn on, or if it turns on and goes into protective stop, the unit will shut down and the standby LED will blink in groups of 6 after the unit has made 3 attempts to start the inverter. Inverter circuits contain the necessary components to detect the presence of the high voltage AC generated by the switching transistors and transformer. If one or both of the differential phased AC lines fails to output, the inverter detect circuit will cause the normally low inverter error line to go high. This event is detected by IC3001 on the BU board. The event will also be recorded into NVM for display when the diagnostics page is called up and this feature will be covered in Chapter 7.
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Balancer Errors
When a balancer error occurs, we at least have the ability to observe the lighting of the lamps before the unit shuts down. The unit must a have a correctly functioning inverter to start the lamps and allow the balancer detect circuit to function. In some cases, the lamps may light long enough to see active video or snow for a couple of seconds. Observing the backlighting of the panel at this time is a great tool in determining what is causing the shutdown. NOTE: Unlike an inverter error where the unit will make 3 attempts to start the inverter, a blanacer error will cause the unit to cycle 2 times before the protect shutdown occurs. Remember, the purpose of the balancer detect circuit is to monitor a lamp that will not startup. Unless a particular model has a history of a related component causing balancer error shutdowns to occur, it will usually be a defective lamp and that will require replacement of the entire LCD panel. A lamp that is not lighting is difcult to spot due to the efciency of the diffuser panel to spread the light. In models that use inverter boards on both sides, observe the screen for uneven lighting from one side to another. This indicates a faulty inverter board and the side that is darkest is where the failed inverter resides.
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Troubleshooting Flowcharts
Due to the various LCD panel designs used in the EX1 chassis it becomes necessary to create troubleshooting owcharts that are specic to the type of inverter system used. Most balancer errors will end up being caused by a defective lamp in the panel but there is a possibility of an inverter related failure and this is especially true for the 52-inch panels using dual inverters. Failures within the inverter circuit(s) will require the use of a DVM to assist in isolating the cause. The Flowcharts contained within Figures 6-10 through 6-13 are specic to panel size and design and should prove to be a useful tool when troubleshooting the unit on-site or in the shop.
DO NOT REMOVE THE SCREWS UNDERNEATH THE COVER. THESE SECURE THE LAMP SOCKETS TO THE PANEL. IF THEY ARE REMOVED, DAMAGE TO THE BACKLIGHT LAMPS WILL OCCUR IF THE BALANCER BOARD IS MOVED.
Yes
LCD Panel
Yes
BU Board
No
32" Panel ?
No
Yes
Yes
Inverter Board
Yes
No
No
G1D Board
BU Board
Yes
Yes
Inverter Board
No
No
G1D Board
BU Board
Yes
Yes
Yes
IP5 Board
No
BU Board
Balancer
6X OR 13X?
6X
13X
Yes
IP5 Board
BU Board
Yes
Yes
LCD Panel
No
IP5 Board
IP5 Board
Yes
Yes
Yes
D3 Board
No
BU Board
Balancer
6X OR 13X?
6X
Yes
D3 Board
No
G4 Board
BU Board
Yes
Yes
LCD Panel
No
D3 Board
D3 Board
Yes
Yes
Yes
D4 Board
No
BU Board
Balancer
6X OR 13X?
6X
Yes
Yes
D4 Board
No
G5 Board
BU Board
Yes
Yes
LCD Panel
No
G5 Board
D4 or D5 Board
Backlight Protection
The inverter circuits are monitored to protect the lamps and the backlight circuits themselves. Monitoring of current drawn by the lamps is also important to protect the inverter and balancer boards.
Voltage Protection
Low-voltage protection is monitored at 3 locations and over-voltage protection at 2 places. The unit will shut down if a failure occurs at any of these monitoring points.
DC Detect (2X)
The regulated 12V line from the power supply enters the BU board at pin 1 of CN1411. This line is monitored directly by BE Micro IC3001 as DC_DET. If the REG12V line fails, the unit will shut down and the standby LED will blink in groups of 2.
DC Alert (3X)
This line monitors 3 potential events: Over-voltage of the REG5V from IC7132. Low voltage of the REG5V from IC7132 Low voltage of the REG 3.3V
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Trident (11X)
If a data reading error occurs between BE Micro IC3001 and Trident video processor IC4700, the data read will be attempted 2 more times and if still unsuccessful, the unit will shut down and blink the standby LED in groups of 11. Replacement of the BU board is recommended.
Other Protection
Power supply, Inverter and balancer errors are the most likely to be remedied outside of the BU board. The remaining protection circuits involve devices mounted on the BU board.
Temperature (7X)
IC3502 located on the BU board is a digital thermometer that sends data directly to IC3001 regarding temperature within the television cabinet. If the specied temperature is exceeded, the unit will shut down with a 7blink error. If the unit shuts down immediately after turn-on, suspect a defective IC3001 or an interruption of data on the I2C bus. Shutdown after extended periods of operation may be caused by excessive ambient temperatures or insufcient ventilation.
2X
REG 3.3V
CN1411
REG 12V
11
IC7132 5V REG
DC_ALERT
3X
Q3415 D7101
CN1401
FROM INVERTER
Q7101
BAL_ERR
INV_ERR
1 3
8X
IC3001 BE MICRO
7X
IC4700 TRIDENT
11X
12X or 14X
BU
FIGURE 7-1 PROTECT CIRCUIT BLOCK DIAGRAM CTV-45 60
Diagnostics History
Whenever a problem is detected by the self-diagnostics feature that causes the unit to shut down, the event is recorded and stored in NVM. This is particularly helpful when dealing with intermittent failures but not so helpful if the unit is always shutting down. The diagnostics history pages are retrieved by pressing the DISPLAY, 5, VOL and POWER buttons in sequence on the remote commander when the unit is off. The diagnostics history page will appear as shown in Figure 7-2 There are 2 pages containing failure history. Press the 1 key on the remote to view the second page. Pressing the 4 key returns to the rst page. Note that a running count is kept anytime one of the detection circuits is activated. This running count will continue until it is reset. This is performed by pressing the 8 key on the remote followed by the 0 key. This should always be done in order to clear the history and provide a clean table for future use. The diagnostics page also contains 4 sets of 5-digit numbers. The rst set, beginning at the left, indicates the number of hours, in decimal format, that the set has been operating. The next set is the boot count. This is the number of times the unit has been turned on. The third set is the number of hours the panel has been operating. This number can be reset to zeros by pressing the 7 key followed by the 0 key. Only the panel hours will be reset. The last group is not used in the EX1 chassis.
# BLINKS
EVENT COUNT
Troubleshooting Flowcharts
The troubleshooting owchart found in Figure 7-3 will assist in determining what component is the likely cause of the protect shutdown. Due to the large variances in panel backlight circuitry, shutdowns resulting in 6 or 13 blinks will refer you to another set of owcharts found in Chapter 6. These owcharts will steer you in the right direction based on the model of the unit you are servicing.
OPERATING HOURS
BOOT COUNT
PANEL HOURS
NOT USED
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Red Standby LED Flashing
7X Temperature
Yes
Immediately ?
No
Yes
BU Board
No
Yes
2X MAIN POWER
No
8X Speaker Protect
No
Yes
BU Board
3X DC ALERT
Yes
BU Board
11X TRIDENT
Yes
BU Board
No
No
5X TCON
Yes
NOT USED
12X or 14X?
Yes
LCD PANEL
No
No
Yes
6X BACKLIGHT
No
No
13X Balancer
Yes
CN1401 TO INVERTER 1 NOT USED 2 GROUND 3 INV_ERR (NORM LOW) 4 BACKLIGHT ON (3.2V) 5 DIMMER (PWM)
CN2001 TO SPEAKERS
CN601
1~5 6 ~ 10
CN1401
1 2 3 4 5
NOT USED GROUND INV_ERR (NORM LOW) BACKLIGHT ON (3.2V) DIMMER (PWM)
CN602
POWER ON (3.3V ON) AC_OFF_DET (NORM HIGH) STBY 3.3V UNREG 13V GROUND REG12V
CN2001 TO SPEAKERS
CN100
CN24
1~5 6 ~ 10
CN601
CN1401
1 2 3 4 5
NOT USED GROUND INV_ERR (NORM LOW) BACKLIGHT ON (3.2V) DIMMER (PWM)
CN603
CN1
1~5 6 ~ 10
CN23
1 2 3 4, 5 6 ~ 10 11 ~ 13
CN602
POWER ON (3.3V ON) AC_OFF_DET (NORM HIGH) STBY 3.3V UNREG 13V GROUND REG12V
CN2001 TO SPEAKERS
CN6154 1 BALANCER_ERR (NORM LOW) 2 GROUND 3 INV_ERR (NORM LOW) 4 BACKLIGHT_ON (HIGH ON) 5 DIMMER (PWM)
CN6701 1 REG_12V 2,3 FEEDBACK 4,5 GROUND 4,5 UNREG_13V 6,7 LD (BALANCER_ERR NORM 11.7VDC)
CN6150 1 PWR_ON 2 AC_OFF_DET 3 STBY_3.3V 4,5 UNREG_13V 6~10 GROUND 11,12 REG_12V
CN104 TO BU BOARD
CN1411 TO IP5 BOARD
CN2001 TO SPEAKERS
CN6700
CN6600
CN6103
CN1401 TO D3 BOARD
CN3201
1 2 3 4 5 6
GROUND DIMMER (PWM) BACKLIGHT_ON (3.3V ON) INV_ERR (NORM LOW) REG 12V BALANCER_ERR (NORM LOW)
CN6202
1 2 3 4 5 6~10 11~13
POWER_ON AC_OFF_DET (NORM 3.3V) STBY 3.3V NC UNREG 13V GROUND REG 12V
CN1411 TO G4 BOARD
TO SPEAKERS
CN2001
CN65
CN6501
CN53
1 GROUND 2 DIMMER (PWM) 3 BACKLIGHT_ON (HIGH ON) 4 INV_ERR (NORM LOW) 6 REG_12V 7 BALANCER_ERR (NORM LOW)
CN6153 TO D4 BOARD
CN6600
CN6700
CN6500
CN6150 TO TCON
1, 2 3, 4 REG_12V GROUND
CN6950 FROM
CN6150
1 2 3 4, 5 6~10 11,12
PWR_ON (3.3V ON) AC_OFF_DET (NORM HIGH) STBY_3.3V UNREG_13V GROUND REG_12V
CN1401
TO G5 BOARD
FROM G4 BOARD
CN58
CN6702
CN6703
TO D5 BOARD
FROM G5 BOARD
TO LEFT BALANCER
CN6154 TO BU BOARD 1 BALANCER ERROR (NORM LOW) 2 GROUND 3 INVERTER ERROR (NORM 3.1V HIGH) 4 BACKLIGHT (3.3V ON) 5 DIMMER (0.8 ~ 3.1VDC)
CN56
CN6706 TO BALANCER
CN2001 TO SPEAKERS
CN62
Chapter 8 Appendix
Software Updates
Sony televisions have become much more reliant on software and rmware over the last couple of years. Digital processing such as decoding the MPEG2 video and Digital Dolby signals along with scaling of the video signals to the display resolution requires program routines to perform these functions. Add control and protection of the television along with fancy GUI graphics and interfacing with other devices and you can see that these software and rmware les are becoming more complicated. The les containing operating commands within a televisions CPU or micro-controller are technically known as rmware since the information is stored within the controlling devices and may also reside in external NVM or ash memory. Some of the information could be classied as software since it can be changed to customize the unit. The word software appears on the television screen whenever one wants to check the current version in the unit and also appears whenever an update is being installed. For this reason, the word software will be used in this article when referring to any updates. An example would be an issue that arose in one state where an over-theair television station was failing to transmit a proper piece of information in the overhead data packet in its digital channel. When the customer performed the initial setup routine on their television (which includes the auto program to add available channels) the channel search would stop at this station and fail to continue scanning the OTA bands. The television would display most of the analog NTSC stations detected but no digital channels. A software update was provided to the customer to ignore this glitch in the stations data packet and continue the channel search. This incident affected an isolated region of the country that does not require an update be made available for all models sold. The software updates tend to be cumulative, in other words, the previously mentioned incident with the television station could arise somewhere else in the country and may be included in future update packages to keep all televisions from running across this problem.
Why Update?
In some cases, updates are necessary to resolve a glitch that may have appeared in the operating routine of the television. As mentioned in the beginning of this article, software programs have become quite complex and use of the product in the eld can sometimes expose a minor error in the routine of these programs. It should be noted that most software updates are not provided to increase the picture quality of the television. Proper handling of the video processing tends to be rather accurate at the time the units begin production. A majority of software updates are used to compensate for problems that are not necessarily the televisions fault.
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Chapter 8 - Appendix
Chapter 8 - Appendix
NOTE: Most updates are performed by the customer. In certain cases where access to the service mode is required, the technician will perform the update and then access the service mode to change or adjust any additional items. Always verify whether an update is required by a technical person. Failure to do so will result in a rejected warranty claim.
CTV-45
Chapter 8 - Appendix
Downloading an Update
Updates can be downloaded in several ways. The customer may be given a specic URL to do this or, if the update is required for all units, may be located on the Sony customer support website. If the update requires the expertise of a service technician it may be located in the ASC service website (currently ESI). The location for downloading an update will also contain documentation with the proper instructions for the install. Read this information very carefully. Some televisions have the update le located within a folder and others do not. If the television requires a folder, this is the rst item the unit will look for on the USB device. The le will be in zip format with the folder and update le included. If the update has a single le and a folder is not required it can be sent without having to compress it to a zip format.
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Chapter 8 - Appendix
BE Micro Update
Since the BE Micro controls the video processor, the screen will go blank with no video or graphics displayed. The Standby LED on the lower right corner will light a steady red while the PIC OFF/TIMER LED lights amber colored with a slow blink rate. This is the only indication that the update is still in progress.
Update Completion
Once the unit has completed the BE Micro update, active video and audio will once again appear followed by an indication that updating is being nalized. The last screen will indicate a successful install of the update and prompt the removal of the USB device. Press the center joystick button on the remote controller to clear the screen.
Notication of Update
This information will appear on 2 pages. The rst will indicate that a mandatory update will occur and the current software version is shown along with the version that will be installed. The second page explains the procedure and the approximate time it will take along with a warning not to interrupt or turn off power to the television during the procedure.
FE Micro Update
If active video was present before the USB device was installed it will return for several seconds. Another splash screen will appear with a moving progress bar. The FE Micro is contained within the AMD decoder IC. The BE Micro and video processor are still functioning and this is why graphics can be generated. This process may continue for several minutes. Once complete, the screen will return to active video (if present) for several seconds before the BE Micro begins its update.
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Chapter 8 - Appendix
INFORMATION PAGE
Chapter 8 - Appendix
BE MICRO UPDATING
FINAL INSTALLATION
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75
Chapter 8 - Appendix
Figure 8-4 illustrates a typical LCD panel and the associated video processing circuits as found in the WAX3 chassis. The various formats and resolutions of video signals are processed on the BU1 board. All video signals exit the video processor in the native resolution of the LCD panel. In this design, the resolution is for a 1280 by 768 at 60HZ refresh rate panel. 48 horizontal lines are discarded to match up to the 720p resolution of the ATSC specications so the video will exit as 720p. The LCD panel used in this model processes 8-bit RGB video data. Before the video information can be sent to the TCON board it must be converted to a format that allows for practical and noise-free transmission. The large number of parallel lines to transmit the 8-bit RGB data would need to be sent on differential lines for noise reduction. This would require 48 lines just for the video. The TCON circuit also requires B+, ground connections, a communications bus, sync, and a clocking line transmitted differentially so we can see that up to 100 lines would be required. The practical way to transmit this information is to convert the parallel video data to a serial stream and this is accomplished by the Low-Voltage Differential Signaling (LVDS) transmitter. The LVDS transmitter contains a circuit to serialize the parallel data. The parallel video information along with sync and clocking data are transmitted via twisted line pairs. Depending on the logic level, current is sent along one or the other of the twisted pair of wires. The receiving end of the wires is loaded with a resistor (usually around 100 to 120 ohms). The receiver detects the polarity of the voltage drop across the resistor to determine the logic level. The current level swings in the wire are about 3ma with a voltage differential of around 350mv. This allows for transmission of the video signal with minimal EMI. The LVDS receiver on the TCON board converts the serialized data back to parallel. This data is processed by the timing control IC to allocate the RGB data into serial streams for processing by the LCD panel. The LCD panel contains shift registers and drivers for all of the rows and columns of pixels on the panel. The drivers are mounted on exible circuit boards and bonded to the top and side of the panel. Without this arrangement the TCON would require an IC and connectors to transmit on 4,560 lines!
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Chapter 8 - Appendix
Panel Failures
The key to good troubleshooting when video quality issues are involved is the understanding what type of distortions cannot be generated by the panel. The loss of an entire color is highly unlikely. The LVDS transmitter does not handle the RGB data as groups. The data (along with sync and clock) is distributed among 6 separate transmission lines for an 8-bit panel. A 10-bit panel uses 12 transmission lines. If one of these lines fails the result is random, multiple colored lines appearing on the screen. Distortions caused by the panel will be stationary and, in almost all cases, will consist of a single line or multiple lines in a repetitive pattern. Any distortion that is not stationary (ying color spots, loss of detail, etc.) is being generated by the video process circuits on the B board. Although the TCON board is considered part of the LCD panel, we will focus on the panel itself and discuss TCON failures separately since it generates symptoms that are quite distinguishable from panel issues. Panel failures fall into 2 different categories: Physical and electrical.
Electrical Failures
There are multiple drive ICs located along the top and side of the panel to de-multiplex the data for all of the rows and columns of pixels. If one of these ICs fails there will be a cluster of missing information on the screen. The second photo in Figure 8-5 contains an illustration of a panel with such a failure.
Physical Failures
The most obvious failure is physical damage to the panel. This can appear as a small cluster of damaged pixels or a complete shattering of the panel glass. Another physical failure may appear as a single or several lines running vertically or horizontally across the screen. The lines may be brightly lit or dark. This is caused by a failure of the exible printed circuit where it is bonded to the panel edge. This is known as a tab bond issue. Do not confuse this with multiple vertical lines across the screen that are of the same color. This is electrical and usually caused by the TCON board. Figure 8-5 illustrates some examples of tab bonding issues.
SOURCE DRIVERS
VIDEO PROCESS
TIMING CONTROL
LVDS TRANSMITTER
LVDS RECEIVER
LCD PANEL
PANEL B+
BU1
TCON
GATE DRIVERS
Chapter 8 - Appendix
Chapter 8 - Appendix
TCON Failures
Failures of the TCON circuit can cause a variety of symptoms varying from evenly spaced multiple vertical lines of the same color, xed random patterns, colored blotches, or the complete loss of video. A complete failure of the TCON is difcult to determine since there is nothing on the display to help troubleshoot and has the same symptoms as a complete video process failure on the B board. A procedure to help in diagnosing this failure will be covered shortly. Figure 8-6 contains several photos of symptoms caused by a failure on the TCON board. Note the xed and symmetrical lines in the rst 3 photos. This is a classic timing IC failure on the TCON board. The fourth photo is interesting. Another task performed on the TCON board is gamma correction. The correction is performed in dened zones across the entire panel. The data is stored in an on-board EEPROM. If this data is corrupted for whatever reason, one or more of the zones will exhibit a severe white balance issue.
RELEASE TABS
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If the TCON is receiving B+ and functioning properly, the timing circuits are waiting for RGB data to allocate to the proper pixel. When a video processor failure occurs, there is simply no data being sent to the TCON and it does exactly what it is supposed to do: Keep all of the pixels dark. One trick that works rather well is to partially disconnect the LVDS connector from the TCON board while the unit is running. Do this very carefully! Both sides of the connector have release tabs that must be squeezed inward to release the connector. I have performed this over 30 times to the same television without and damage to the connector or electrical circuits. Release the connector and carefully pull it partially out of the socket being careful not to pull one side out much further than the other. Too much skewing can damage the connector and possibly cause a short on the B+ line. The idea is to remove some of the LVDS data entering the TCON. If the TCON is functioning the loss of data will cause the timer circuits to generate random patterns. These patterns may appear as a brief colored horizontal bar or continuously active random lines covering the entire screen. The type of response you get will depend on the panel design and how much LVDS data you have removed. Sometimes a momentary line will ash on the screen, other times the screen will ll with random patterns. If you dont see any response, try plugging the connector back in and pulling it out one more time watching the screen very closely for any reaction. Figure 5 illustrates 2 different types of patterns generated by the same unit. If you are able to generate any response on the screen, the TCON is most likely OK. A TCON that has completely failed (causing a no video condition) will not produce any pixel lighting on the screen.
SINGLE MOMENTARY LINE
Chapter 8 - Appendix
DLNA Overview
For many years there was talk about how the entire home would one day be on a network system. The customer would be able to watch TV, access music les, browse the internet, along with controlling devices such as lighting and heating/cooling and so on. Although systems have been developed for many years they were proprietary in nature and quite expensive to install. Another issue is that the television is primarily considered a separate entity whose function is to watch movies and TV programs along with gaming devices. The computer served its own function of running programs and accessing the internet. As the turn of the century came and went, consumers became exposed to new devices to store their audio, video and picture content. Prior to the year 2000 very few homes had many of the products we see today such as digital audio players, digital camcorders, PDAs, multi-media cell phones etc. Although the personal computer interfaces quite well with all of these devices customers found it to be a hassle to plug and unplug the devices and organize the material on their home computer. Since the consumers expectations were not being fullled, the concept of interoperability among these devices needed to be addressed. The introduction of wireless networks was a promising technology but there was still a problem with interconnecting these devices. A common method of communication and detection was needed. The Digital Living Network Alliance (DLNA) appears to have resolved this issue. DLNA provides an answer to the marketplace by providing a seamless environment where PC, CE and mobile devices can communicate and transfer information by providing the standards for this to happen. The customer will be able to manage and distribute pictures, video and audio content to television and monitor devices along with audio systems. By following these guidelines, manufacturers can design products that function in this platform.
Virtually all of the key leaders in the PC, CE and mobile device industry have jumped on board to support DLNA. This has created the guidelines for physical media, formats, network transport, streaming protocols and, of course, digital rights management. As long as manufacturers produce appealing products, and the DNLA standards evolve with the improvements and changes, the promising world of communication among consumer devices appears to be a reality. For more information, visit http://www. dlna.org.
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DLNA connectivity is provided in selected Sony televisions for the 2008 model year. As of this writing it is available on the Z4100 series which includes a 40 and 46-inch model and also the XBR6 models available in 40, 46, and 52-inch. The XBR7 and XBR8 high-end models being released this fall will also have the DLNA feature. An RJ45 Ethernet port will be available at the rear of the unit to allow a connection to a home network. Any le sharing will require the use of a DLNA compliant system and this requirement can be met with software. There are numerous choices of software available. Most are available at no charge. Some require a onetime fee and others a monthly service fee. Although DLNA allows the sharing of video, audio and pictures, the 2008 models containing this feature will only allow for sharing of photos. Once copyright protection issues are worked out we should see future models supporting movie and audio le content. Another feature that will become common is the ability of consumer products to check for any available software updates. This can be done manually or automatically checked for on a regular basis and notify the customer of a new software version. The customer can choose to install a newer version or the le may be written to force install an update. High-speed internet access is changing the way we receive our media content allowing yet another method of viewing movies and audio aside from the traditional cable and satellite sources. DLNA looks to be a promising feature to take advantage of this technology.
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2007 Sony Electornics, Inc. SEL Service Company 16530 Vill Esprillo National Training Dept. MZ3215 San Diego, CA 92127 Reproduction in whole or part without written permission is prohibited. All rights reserved
8/12/08