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KDL32L5000
Course : CTV-55
Table of Contents
Chapter 1 Introduction ..................................................... 1 Introduction ...................................................................... 1 Features .......................................................................... 1 Overall Circuit Description ............................................... 1
A Board ................................................................................ 1
Video Processing .................................................................... 1 Power Supply .......................................................................... 1 Inverter .................................................................................... 1 H1 Board ................................................................................. 2 H2 Board ................................................................................. 2
Power On ........................................................................... 12 PFC Circuit ........................................................................ 12 Standby Power Supply ...................................................... 12 Main Switching Supply....................................................... 12
Protection ...................................................................... 12 Chapter 4 Inverter and Backlighting ............................. 16 Overview........................................................................ 16 Operation ....................................................................... 16 Chapter 5 Protection and Service Mode ....................... 19 Protection ...................................................................... 19
Self Diagnostics History ..................................................... 21
Clearing the History .............................................................. 21
Chapter 2 Video and Audio Processing Circuits ........... 5 Video Process ................................................................. 5
RF Sources .......................................................................... 5 Composite Video ................................................................. 5 Component Video ................................................................ 5 HDMI Inputs ......................................................................... 5 PC Input ............................................................................... 5
Status Information.............................................................. 23
CTV-55
Chapter 1 Introduction
Introduction
The EX2K chassis is the rst release of new models for the 2009 production year. 4 models are included in this chassis series: KDL22L5000 KDL26L5000 KDL32L5000 KDL33L540 KDL37L5000
Figure 1-1 illustrates an overall block diagram of the circuits incorporated into the EX2K chassis models. 4 major circuits are included along with peripheral circuits and devices. They are described as follows:
A Board
Common among the various models using the EX2K chassis, the A board contains most of the circuitry used by the television to process the audio and video signals. The only difference among the various models is the data which is written and stored in various locations to properly communicate with the type of LCD panel used. Audio output is available as L/R analog from RCA jacks or up to 5.1 channel surround sound via an optical jack.
The models are designated as entry-level designs for the Bravia directview LCD televisions. The LCD panel is labeled as 720p with a native display resolution of 1366 X 768. The television is, however, able to accept video input resolutions up to 1080p 60HZ via the component, PC or HDMI inputs.
Features
A/V Input Sources 3 HDMI inputs (2 rear, 1 side) 2 composite inputs. (Video 1 shared with component 1 input) Y/C input on side 2 component inputs (rear only) PC input (15 pin D-sub) RF input for ATSC/NTSC tuner
Video Processing
All video sources, regardless of resolution are processed to a resolution of 8-bit RGB at1366 X 768 with a refresh rate of 60HZ. This processed video exits the A board as Low Voltage Differential Signaling (LVDS) where it is received by the Timing Control (TCON) board mounted on the LCD panel. All of the available input sources are mounted directly to the A board.
Power Supply
The G2BE board receives the 120VAC input and generates the required standby and switched voltages for the other circuits in the television.
Automatic Contrast Enhancer (ACE): Backlight level changes with varying scene brightness to increase contrast level and reduce power consumption. Bravia Link Compatible: Allows the connection and control of optional Bravia Link modules such as DVD players and wireless link devices. 24p True Cinema: Allows for 24 frame lm content to be viewed in its original form when connected to devices able to output this format. This format can only be viewed via the HDMI inputs.
Inverter
The inverter board, mounted on the left side of the LCD panel (as viewed from the rear) generates the approximately 1KV of AC voltage to operate the cold-cathode uorescent lamps for backlighting of the LCD panel. Its operating voltage is supplied by a 24VDC source from the G2BE power supply board.
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H2 Board
Located on the lower left corner of the front bezel, this board contains the power, standby and picture off/timer LED indicators. The infrared receiver for the remote controller is also located here.
CTV-55
Chapter 1 - Introduction
RF
R
VIDEO 3
COMPOSITE OR COMPONENT 1
COMPONENT 2
A/V DECODER VIDEO PROCESS VIDEO SWITCH AUDIO PROCESS AUDIO AMP TV MICRO
TCON
INVERTER
PC HD15
PC AUDIO
LCD PANEL
A
VIDEO 2 HDMI 2
(SERVICE ONLY)
USB2.0
SIDE INPUTS
POWER SUPPLY
SWITCHES
LED IR RX
H1
H2
G2BE
Chapter 1 - Introduction
TCON
A BOARD
INVERTER
G2BE BOARD
H1 BOARD
H2 BOARD
Component Video
There are 2 component inputs at the rear of the unit. As mentioned previously, component 1 serves as an input for composite video if that is what is inserted into the Y component jack. Input resolutions accepted by the component inputs range from 480i 30HZ up to 1080p 60HZ. 1080p 24HZ is not supported by the component inputs. This resolution is only supported by the HDMI inputs.
RF Sources
The dual function tuner is capable of receiving NTSC and ATSC encoded signals. Although over-the-air NTSC will cease to broadcast in 2009, other sources of NTSC content (such as VCRs, cable television and satellite receivers) will remain that use this format as their output. NTSC RF sources are demodulated inside the tuner and exit as composite video directly to IC401. ATSC digital sources (8VSB terrestrial and QAM cable) exit the tuner as differential IF and must be demodulated by IC7101. The demodulated digital bit stream containing the overhead and payload data packets is input to IC401 where an internal decoder decompresses and separates the audio, video and control content.
HDMI Inputs
There are 3 HDMI inputs on this chassis: HDMI 1 and 3 in the rear and HDMI 2 on the side. The Consumer Electronics Control (CEC) specications of the HDMI 1.3 standard is supported giving the customer the ability to control other devices conforming to this standard that are connected to the television via the HDMI inputs. Resolutions supported by the HDMI inputs include all ATSC resolutions including 1080p 24HZ.
PC Input
The PC input is via a VGA 15 pin D-sub connector with RGB analog input. The following resolutions are supported from a PC with these output capabilities: VGA XGA 640 480 1024 768 1280 768 1360 768 31.5KHZ X 60HZ 37.9KHZ X 60HZ 48.4KHZ X 60HZ 47.4KHZ X 60HZ 47.8KHZ X 60HZ 47.7KHZ X 60HZ SVGA 800 600 WXGA 1280 768
Composite Video
Composite video input 1 shares the same input jacks as the component 1 input. The composite jack is simply inserted into the Y component input and is automatically detected as such. If there are any problems with auto detection of the composite or component source this input can be changed from auto detect to manual selection by the customer in the user menu.
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RF
TUNER
ATSC DIFF/IF
IC7101 DEMOD
NTSC
LVDS 720p/60HZ
IC401 MT5386
TCON
LCD PANEL
A
FIGURE 2-1 VIDEO PROCESS BLOCK DIAGRAM CTV-55 7
Troubleshooting
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 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.
Since all of the video inputs and processing is located on the A board, failures causing a loss of video or distortions in the picture need to be isolated to the A 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.
No Video
If a total loss of video occurs (including OSD graphics) the most likely course of action is to bring a replacement A 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. There are cases where the A board can cause a no-backlight issue without a protection shutdown but you will have brought the A board with you anyways. If the replacement A board does not resolve the issue and the backlights are lighting, the LCD panel is the only other likely culprit. The presence of OSD graphics with a no video condition certainly eliminates the LCD panel as the cause and the A board will almost certainly x the problem.
Troubleshooting Flowchart
The troubleshooting owchart in Figure 2-2 provides guidance in isolating a loss of video or distortions in the picture.
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All inputs?
Yes
Video Failure
No
Distortion stationary ?
No
A Board
Yes
Distorted
A Board
Symentrical ?
Yes
LCD Panel
No
Backlights turning on ?
Yes
No
Backlight failure
Multi-colored
A Board
Single Color
Yes
A Board
LCD Panel
Unplug LVDS connector at TCON while unit is running . This may need to be done more than once
No
LCD Panel
A Board
Audio Process
As with the video inputs, all audio sources are directly input and processed on the A board. Referring to Figure 2-3, the external analog audio signals are selected by switches within IC8101 and IC8102. The selected audio is input directly to the audio processor located within IC401 where it is converted to I2C digital format for processing. Analog audio from the tuner is received as IF and also input directly to IC401. Digital audio information is available from the demodulated ATSC tuner signal along with the 3 HDMI sources. This audio is converted by the Digital Front End processor, also located inside IC401, and sent to the audio processor where equalization and surround sound effects can be controlled. The processed audio exits IC401 as I2C audio for amplication by the class-D audio amplier IC801. SPDIF format audio is output for use by the optical output line. Analog L/R audio is also generated by IC802 for the RCA jacks at the rear of the unit.
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10
ATSC/NTSC TUNER
IF
IC7101 DEMOD
ATSC
2CH PCM
NTSC TUNER
HDMI 1
2CH PCM
NO OUTPUT
HDMI 2
DIGITAL FE
NO OUTPUT
HDMI 3
USB2.0
2CH PCM
I2S
ETHERNET
N/A
ANALOG IF
I2S
AUDIO PROCESSOR
OPTICAL OUT
VIDEO 2 Y/C_COMPOSITE
IC8101 SWITCH
ANALOG
IC401
HDMI 1 AUDIO
PC
IC8102 SWITCH
I2S
L R
A
FIGURE 2-3 AUDIO PROCESS BLOCK DIAGRAM CTV-55 11
Power On
A power on high command enters CN6201-1 from the A board. The high enters inverter transistor Q6201 to turn on PH6103. The hot chassis standby 12V is switched by Q6102 to turn on the main AC relay RY6101. The standby 12V is also sent to the PFC circuit and to the main switching supply to turn it on.
Protection
PFC Circuit
The Power Factor Control circuit adds additional efciency to the switch mode supply by bringing the current and voltage in phase to simulate a DC resistive load on the AC line. By varying the duty cycle of the pulldown on the coil (L800) the voltage exiting the PFC circuit is boosted to generate approximately 395 volts. Note the AC relay RY6101 has a thermistor (TH6101) across the contacts. When the unit is not powered on AC voltage ows through the thermistor, is rectied by D6301 and passes through the coil of the PFC circuit. Since the PFC circuit is not functioning the rectied voltage will be approximately 160VDC and is used by the standby power supply circuits.
Certain circuits in the power supply are monitored for over-voltage, overcurrent and over-temperature conditions. If one or more of these detection lines is activated the main relay RY6101 will turn off along with the PFC and main switching supply circuits. If any of these circuits are activated the main switching supply will stop and the standby LED will blink in groups of 3. The following circuits in the power supply are monitored: REG 12V and UNREG24V OVP: If one or both of these voltage lines becomes excessive the corresponding zener diode (D6204 or D6205) will re and active the latch transistors (Q6202 or Q6203) to ground the power on command. PFC OCP and OTP: An over-current or excessive temperature condition in the PFC circuit will cause a high to be applied at the latch circuit consisting of Q6104 and Q6105. This performs the same function as the previously described latch circuit but will occur on the hot ground side of the turn-on command.
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12
AC IN
F1 4A
TH6101
T
D6301
AC IN
CN6202
1~4
RY6101
UNREG_24V
5~6
GND
TO INVERTER
CN6201
4
UNREG_15V
6
11
8
AU GND
REG 12V
GND
TO A BOARD
STBY 3.3V
POWER_ON
STBY 12V
STBY 3.3V
PH6103
Q6102 Q6201
REG 12V
D6205
UNREG 24V
D6204
Q6202 Q6203
Troubleshooting
Power supply failures generally fall into 3 categories which are covered below. Use of the power supply troubleshooting owchart in Figure 32 and the voltage test points in Figure 3-3 will guide the technician in isolating a power supply failure. Standby Supply Failure: In this case the microprocessor located on the A board is not functioning. The set will be completely dead. The rst step to take is to remove AC power for about 10 seconds and then re-apply. In a properly functioning unit, the microprocessor will send a power-on high command to the power supply for approximately 2 seconds. During this time the click of the main relay will be heard as it engages followed by another click when it releases. This is, of course, assuming that the unit was not in the power on state when the AC power was removed. In this case the unit would simply turn on. If the relay engages for about 2 seconds and then releases, this indicates a functioning standby supply and operational microprocessor. If no relay click is heard, the presence of standby 3.3V will need to be veried to eliminate the standby supply or a faulty microprocessor or power on command to the power supply. Main Switching Supply Failure: When this failure occurs, the sound of the main relay engaging is heard followed by its release within 10 seconds. The unit will usually generate a 3 blink error indication on the standby LED. Protection: If the PFC over-current or over-temperature, or the REG12V or UNREG24V over-voltage detection circuits are activated, the main relay, PFC and main switching supply will be stopped and produce the same symptoms as described for a main switching supply failure. Main switching supply failures and on-board protection activation are both remedied by replacing the power supply. There is a possibility that a situation may occur where the replacement of the power supply will not solve the problem. If there is an excessive current draw on any of the secondary voltage lines of the main switching supply, the oscillator circuit located inside IC6501 of the main switching supply will stop functioning because it has its own over-current detect circuit. In this case, replacement of the power supply
will not resolve the issue and the excessive load on one of the secondary lines (UNREG24V, UNREG15V, or REG12V) must be located to determine if the A board or inverter board are the cause.
Unit Does Not Turn On
Disconnect AC power for at least 30 seconds. Re-apply AC power
Yes
G2BE Board
No
No
No
G2BE Board
Yes
G2BE Board
A Board
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CN6201 1 POWER ON 2 AC_DET 3 STBY 3.3V 4, 5 UNREG 15V 6, 7 UNREG GROUND 8~10 REG GROUND 11`13 REG 12V
CN6101 AC IN
CN4202 TO H2 BOARD
Troubleshooting
Most backlight failures will cause the unit to shutdown and generate a 6-blink error indication. Since an inverter failure or defective uorescent lamp can cause either symptom it is import to know whether the backlights have turned on when the shutdown and error indication occurs. This is easily checked when the technician is present during the failure but a bit tricky when attempting to triage the repair by having the customer determine if the backlights are turning on, In most instances it is relatively easy for a technician with experience to check and see if the backlights are turning on. Ambient lighting conditions and a failure of the customer to comprehend backlighting may make this difcult over the phone. In these cases it is sometimes helpful to ask the customer if the screen appears to go darker when the unit shuts down since it is easier to observe the backlights when they turn off rather than when they rst start because the sound of the main relay turning off can be a clue as to when to observe the screen for a change in brightness. The point here is to try and determine whether the backlights are turning on before the unit shuts down. If they turn on before the shutdown the LCD panel will most likely require replacement. The troubleshooting owchart in Figure 4-2 will assist in isolating the cause of a 6-blink shutdown. IMPORTANT: If a unit is found to be turning on with no backlights, yet it is not shutting down (power LED remains steady green), do not replace the LCD panel or inverter board. There cannot be a defective backlight or inverter board without a 6-blink shutdown. Anytime the backlights do not turn on and the unit does not shut down it is usually caused by the microprocessor. A failure event occurred during initialization and the microprocessor hangs. One of the last output lines to go active is the backlight on command to turn on the inverter. This is why the backlights never come on and there is no self-diagnostics shutdown.
Operation
Referring to Figure 4-1, at the time the unit is powered on, the following string of events occur to light the uorescent lamps: IC401 on the A board sends a power on high command to CN6201-1 on the G2BE board. This engages the main relay and starts the main switching supply. 24VDC is applied to CN001 on the inverter board. During this time the microprocessor inside IC401 is performing initialization routines and turning on regulator circuits located on the A board. After approximately 5 seconds, a high command (3.3V) is applied from CN202-2 on the A board to CN001 on the inverter. This starts the oscillators and drive circuits to begin the lighting of the uorescent lamps. The lamps are struck with approximately 2 to 3 times their operating voltage of 1KV AC to begin ionization of the gasses within the lamps. Once the lamps begin to draw current, the inverters function as a ballast circuit to maintain control of the current. If one or more of the lamps fail to ignite, or if either of the inverter circuits fails to operate, an error detection circuit located on the inverter board will send a high command to CN202-1 on the A board. The unit will shut down and the standby LED will blink in groups of 6.
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INVERTER DRIVE
OSC
INVERTER DRIVE
ERROR DETECT
CN001
CN202
INV_ERR BACKLIGHT_ON DIMMER
1 2 3
IC401
CN6201 -1
1
POWER_ON
CN201
POWER_ON
13
G2BE
Yes
LCD Panel
Yes
A Board
No
Yes
Inverter Board
Yes
A Board
No
G1BE Board
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19
TCON 12V
CN201
REG 12V
11
Q401 SWITCH
5X
D203A
IC201 5V
IC202 1V
IC206 2.5V
V_DROP_DET
LOW B+ 3X
Q211
IC401
IC207 1.25V
IC203 9V
IC211 TU5V
D214B
CN202 INV_ERR
1
IC801 AUDIO AMP
BACKLIGHT ERROR 6X
SPEAKER PROTECT 8X
A
FIGURE 5-1 PROTECTION BLOCK DIAGRAM CTV-55 20
Service Mode
The service mode is entered in the traditional method of pressing the DISPLAY, 5, VOL+ and POWER keys on the remote commander, in sequence, while the unit is powered off. If the sequence is properly executed the service mode opening page should display as illustrated in Figure 5-2. Note that several items appear on the page. Each item can be selected by using the UP and DOWN feature of the joystick on the remote or with the volume and channel buttons on the top of the television. Most of the items in the list are set at factory default values and should not be changed. The only 2 items of concern to the service technician are the Self Diagnostics History and Status Information lines.
Status Information
By selecting this item the page illustrated in Figure 5-4 will appear. This feature is particularly useful for troubleshooting complaints of picture quality issues from antenna or cable sources. Important information such as the type of input selected on the television (cable or antennal), the physical channel, operating frequency and modulation type are displayed. Although Automatic Gain Control (AGC) and Signal-to-Noise Ratio numbers are displayed it is best to use the signal level disgnaostics in the customer menu as illustrated in Figure 5-5.
When viewing the customer signal diagnostics a signal strength meter along with an error count column is displayed. There should be no errors displayed and the signal level meter should read higher than 30%. The AGC level is not reliable. The SNR level is important and should display the following minimum values for reliable picture quality: 8VSB: 64QAM: 256 QAM: 16 or greater 24 or greater 28 or greater
CTV550309
2009 Sony Electronics, 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
7/20/09