TVP28

LA-5 Rear-Projection LCD Television Chassis

Theory of Operation and Troubleshooting

Training Manual

MODEL: KDF46E3000 KDF50E3000

Course : TVP-28

KDF50E3000

TVP25 i

Distortions in the Video .......................................................11Foreign Material .....................................................................11

Chapter 3 - Audio Processing ........................................... 17Audio Processing ........................................................... 17

Optical Out ......................................................................... 17Troubleshooting ............................................................. 17

Chapter 4 - Power Supply ................................................. 20Standby Supply ............................................................. 20Main Switching Supply .................................................. 20

Turn On .............................................................................. 20Main Switching Regulator .................................................. 20Lamp Driver Voltage .......................................................... 20

Troubleshooting .................................................................Dead Supply ..........................................................................

Chapter 5 - Protect Circuits .............................................. 23Thermal Protection (7X) ................................................ 23

Lamp Cover Protection (6X) .............................................. 23Lamp Ballast Protection (5X) ............................................. 24Fan Rotation Detect (9X) ................................................... 24Voltage Protection (2X LVP, 3X OVP) ................................ 24Lamp Protect (Lamp LED) ................................................. 24Although labeled as a protect cicrcuit, this event indicates a

lamp that is no longer functional. When the unit is turned on, the ballast will make 3 attempts during a 60 second period to ignite the lamp. If the lamp does not ignite on the third attempt, t ........................................................ 24

Chapter 1 – Introduction ..................................................... 1Features .......................................................................... 1

LCD Panels .......................................................................... 1New Customer Menu ........................................................... 1Internet Video Linking .......................................................... 1HDMI 1.3 Support ................................................................ 1Bravia™ Theater Sync ......................................................... 21080p Input .......................................................................... 2

New Circuit Descriptions ................................................. 2Overall Block Diagram ......................................................... 2

BE Board ................................................................................. 2U Board ................................................................................... 3HCE Board .............................................................................. 3CE Board ................................................................................ 3HAE Board .............................................................................. 3HBE Board .............................................................................. 3SE Board ................................................................................. 3G Board ................................................................................... 3

Major Component Locations ............................................ 5

Chapter 2 – Video Processing ............................................ 6Video Process ................................................................. 6

Analog Video Sources ......................................................... 6Digital Video Sources .......................................................... 6LVDS Transmitter ................................................................. 6LCD Panel Processing ......................................................... 7No Video .............................................................................. 9

Table of Contents

TVP25 ii

Table of Contents (Continued)Troubleshooting ............................................................. 26Diagnostics History ........................................................ 30

Clearing the Diagnostics History ........................................ 30G Board Test points ....................................................... 31Cooling Fan Locations ................................................... 32

Chapter 6 - Service Mode .................................................. 33Service Mode ................................................................. 33

Factory Reset .................................................................... 33New Remote Commands ................................................... 33Lamp Hours Reset ............................................................. 35Model and Serial Number Information ............................... 36

Model Number Data .............................................................. 36Serial Number Data .............................................................. 36

Test Patterns .................................................................. 37PAWN (Optical Block) Graphics ......................................... 37QM Graphics ...................................................................... 38

Exiting the Service Mode ............................................... 38

Chapter 7 - Disassembly ................................................... 39Overview ........................................................................ 39Locking Connectors ....................................................... 39Separator Cover ............................................................ 41Lamp Removal .............................................................. 42Optical Block Removal .................................................. 46Exhaust Fan Replacement ............................................ 56Optical Block Adjustment ............................................... 49

Appendix ............................................................................. 58Triage Troubleshooting .................................................. 58

Initial Contact Flowchart A ..................................................... 61Initial Contact Troubleshooting Flowchart B .......................... 62Protect Mode Troubleshooting Flowchart C1 ........................ 63Protect Mode Troubleshooting Flowchart C2 ........................ 64Protect Mode Troubleshooting Flowchart C3 ........................ 65No VideoTroubleshooting Flowchart D1 ............................... 66Lamp Troubleshooting Flowchart D2 .................................... 67OSDTroubleshooting Flowchart D3 ...................................... 68Video Distortion Troubleshooting Flowchart E ...................... 69Audio Troubleshooting Flowchart F ...................................... 70

TVP-28 1

Chapter 1 – Introduction

The LA5 chassis is Sony’s introduction of a new LCD rear-projection television chassis line for 2007. The electrical portion of the chassis design is used in 2 distinct model designs. The first model is the KDF37H1000. Its compact design should fit into most entertainment system wall unit openings that were originally designed for CRT televisions.

The second model design will be the KDF46E3000 and KDF50E3000. These models will differ from the KDF37H1000 in that a different lamp chamber and optics will be used. Due to the differences in physical design and the resolution panels, the 46 and 50-inch models will be covered in this training manual. The KDF37H1000 is covered in a separate training manual (TVP25).

Features

LCD PanelsThe optical block is very similar to those used in past models and some physical design changes have been introduced to increase brightness and contrast ratios. The most significant change is the increase in the native LCD resolution. This is the first Sony rear projection LCD television to introduce 1920 X 1080 native resolution on the LCD panels. This resolution was previously only available on the SXRD projection units.

New Customer MenuThe customer Graphics User Interface (GUI) has been improved to make navigation of the setup features easier. They are similar to the graphics used on the PlayStation® Portable (PSP2®). Known as X Media Bar (pronounced cross media bar) or, simply XMB the menu system also contains software to interface with a new optional device that links the home television with the internet. This will be described next.

Internet Video LinkingYet another first for Sony, the Bravia™ model lineup will include a Digital

Media Exchange (DMEX) interface. By attaching an optional interface device, known as Bravia Internet Video Link, customers will have the ability to access internet video entertainment via a broad-band connection. Local news, weather and traffic along with access to selected digital media streaming can be viewed on the television independent of a computer.

A special DMEX USB port on the rear of the television will allow bi-directional communication with the Bravia Internet Video Link via the Xross Media Bar™ feature included in the television. The device will send the video information into one of the HDMI inputs on the TV. Sony will partner with selected channels on the internet and these will automatically appear on the screen for the customer to select as they become available..

HDMI 1.3 SupportHDMI version 1.3 has added several features to enhance picture and audio quality along with bi-directional communication between HDMI equipped devices. The added features that apply to display products are as follows:

Speed: Single link bandwidth is increased from 4.9GBS to 10.2GBS

Deep Color™: Increases RGB and component sample level from 24-bit to 30, 36, and 48 bit.

xvYCC: Removes previous color space limitations to allow for the reproduction of every color perceivable by the human eye.

CEC: Short for Consumer Electronics Control. Allows communication among HDMI devices for control. Uses the industry standard A/V link protocol. For example: Equipment can be set up so that when a DVD disc is inserted into a player, the television will turn on with the proper input setting along with the audio equipment turning on and being set for the proper input and audio format.

The only HDMI 1.3 feature supported by the LA5 chassis is the CEC function.

Chapter 1 - Introdcution

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Bravia™ Theater SyncA feature incorporated within the television to utilize the CEC feature of HDMI 1.3

1080p InputThe unit can receive 1080p source content (including 24fps) via the HDMI inputs only. All other video sources below 1080p resolution are up-scaled to the native 1080 panel resolution.

New Circuit Descriptions

Overall Block DiagramIn Figure 1-1, an overall block diagram of the various major circuits is shown. A brief discussion of each board and the circuits contained within will be discussed.

BE Board

All of the video and audio processing is located on this board. The ATI Micro (for ATSC digital processing) and TV Micro are also located here. Many of the circuits are identical to the previous year’s LA4 chassis except the ATSC/NTSC tuner is no longer incorporated on a separate board and is now part of the BE board. The video processing and scaling IC has also been changed to a new type known as the Image Format Processor (IFP). This will be explained in the video process circuit description.

Additional circuits include a LVDS (Low Voltage Differential Signal) circuit for transmission of video data to the optical block assembly. Two HDMI inputs are input directly to the BE board and is the first design in a LCD rear projection chassis where the HDMI signals remain in digital format all the way through the video processing. The Main TV Micro is also located on this board

The BE Board is enclosed within a shielded assembly. This assembly is the replacement part and is known as the “BE Block Assembly” and will be supplied with the circuit board and shield intact. The cooling fan mounted on top of the assembly will not be included with the replacement part.


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U Board

This board contains video and audio switching circuits to select all of the available analog signals including the NTSC video and audio from the tuner located on the BE board. The selected signals are input to the BE board and processed in various ways depending on the format and resolution of the signal.

Audio processing is also present on this board and includes audio digital signal processing and an amplifier circuit to drive the speakers.

HCE Board

Located on the right side of the unit, near the front, this board contains the jacks for the Video 2 front inputs. Composite and component signals are accepted. There is no S-Video (Y/C) input on this board. The only S-video input is located on the U board at the video 1 input. The board also contains a digital thermometer IC to send temperature data to the Main Micro on the BE board for fan speed control and, if necessary, shut the unit down if internal cabinet temperatures exceed a specified level.

CE Board

This board is part of the optical block assembly and cannot be replaced individually. Digital RGB video signals are received from the BE board and processed by a scaling IC to match the resolution of the LCD panels. RGB drivers control each LCD panel. 2 EEPROMS are also utilized to store data pertaining to white balance and gamma.

This board is included with the optical block assembly and cannot be replaced as an individual item.

HAE Board

Not shown in this block diagram, the manual input buttons (power, channel selection, etc.) for the user are located here.

HBE Board

Not shown on this block diagram, and located on the front cabinet, the remote IR receiver, user control buttons, and Power LED are mounted here.

SE Board

Located inside the lamp chamber, the SE board contains an additional digital thermometer IC to monitor the temperature surrounding the lamp for fan speed control and shutdown for excessive temperature levels.

G Board

This board contains the standby 5-volt supply and main switching regulator to provide most of the voltages required by the unit. Fan control and drivers are also included to run and maintain the proper speed of the 3 cooling fans inside the unit. This board is essentially the same as the one used in last year’s LA4 chassis. Since 4 cooling fans were used in that chassis, there will be 4 fan drive outputs from the G board. Outputs 1, 3, and 4 are used with no connection to fan 2 output.


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FIGURE 1-1LA5 46/50” OVERALL BLOCK DIAGRAM

COMPOSITE 2COMPONENT 2

HDMI 1

HDMI 2

VIDEO 2THERMAL

SENSE

VIDEO 1Y/C_COMP

VIDEO 3COMP

COMPONENT 1

AUDIO OUT

RLCD

GLCD

BLCD

LVDS RXLCD DRIVERS

THERMAL SENSE

CE

AC INPUT

POWER SUPPLYFAN CTL/DRIVERS

G

MAIN TV MICROATSC/NTSC TUNER

ATSC DECODERVIDEO PROCESSHDMI RECEIVERS

LVDS TX

IRIS MOTOR

LAMPBALLAST

NTSC A/V

A/V INPUTSA/V SWITCHAUDIO DSPAUDIO AMP

U

SUB WOOFER

L

R

FAN 1

FAN 3

FAN 4

COMPONENT 3 BE

LAMPTHERMAL

SENSE

SEHCE


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Major Component LocationsFigure 1-2 illustrates the locations of the major component that are accessable when the front bezel and screen are removed.

LAMP DRIVER LOCATED

INSIDE LAMP CHAMBER

LAMP CHAMBER

OPTICAL BLOCK

G BOARD

U BOARD

BE BOARD

FIGURE 1-2MAJOR COMPONENT LOCATIONS

CTV-37 6

Chapter 2 – Video Processing

Video ProcessAll selected video sources are processed by the circuits on the BE board. The concept is to take the various inputs of analog and digital signals and produce a uniform resolution of video to be sent to the CE board for scaling to the native LCD panel resolution of 1920 X 1080. Referring to Figure 2-1, a description of the various circuits and paths is given.

Analog Video SourcesAll analog sources are selected by the U board and input at CN3009. Composite, Y/C and component formats are available depending on what input is selected. Composite signals from the NTSC tuner and video inputs 1, 2, and 3 are shared on the same line as the Y input from a Y/C source at pin 9. If the source is Y/C, the chrominance component is input at pin 6. Only the video 1 input at the rear of the television has a Y/C jack.

Component input is available from the front component 2 input (located on the HC board) along with component 1 and 3 located at the rear. Component video enters at pins 1, 7 and 10 of CN3009. Note that the signal may be Y/Pb/Pr or RGB.

All of the analog signals are A/D converted and initially processed by CCP (Composite to Component Processor) IC3202 located on the BE board. Composite sources are comb-filtered, decoded and separated into component video. A similar process occurs to a Y/C source without the need for comb-filtering. Component sources are merely processed for contrast and video level.

If the source signal resolution is 480i, it will enter DRC IC5000 where it will undergo a line doubling process and exit as 960i resolution. All other input resolutions will bypass DRC and enter the Image Format Processor (IFP) where they will be scaled to 1080p and output as 10-bit RGB..

Digital Video SourcesDigital video input can originate from the ATSC tuner or the HDMI inputs. Both sources are processed by the ATI Micro IC7300. The ATI Micro contains demodulation and decoding circuits for the MPEG2 compressed data stream from digital TV sources such as ATSC or QAM. Unlike NTSC analog signals, the ATSC digital information is sent as Differential IF directly to the ATI Micro. The IF signal is demodulated and decompressed within the ATI Micro. The decompressed video exits IC7300 as 8-bit Y/Pb/Pr into the CCP IC3202. Like 480i analog sources, 480i digital content is line-doubled by DRC IC5000.

Note that the HDMI inputs are processed by HDMI receiver IC4506 and HDMI Micro IC3607. IC7300 is tasked to process the selected HDMI input. Each HDMI input has it own EDID (Extended Display Information Data) IC. This is simply an EEPROM containing data regarding the display capabilities of this chassis and is read by the HDMI transmitting device to determine what resolutions can be transmitted. The HDCP (High-Bandwidth Digital Content Protection) key code is embedded within IC7300 to provide an authorized connection with the HDMI transmitting device.

LVDS TransmitterThe 10-bit RGB video must now be transmitted to the CE board and must be accomplished without introducing noise into the signals. This could be accomplished by sending each data line as a differential pair but would require 64 wires to do so. The LVDS transmitter IC5900 processes each 10-bit parallel data line for the RGB and converts them into differential serial data.

IC5900 contains 5 sets of 16-bit input lines. The 10-bit RGB data is divided among these 35 inputs along with H and V sync. The LVDS transmitter has 12 output lines (10 for video and sync along with 2 lines dedicated to clock information to synchronize the LVDS receiver on the optical block.

Chapter 2 Video Processing

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LCD Panel ProcessingAs part of the optical block assembly, the CE board contains a LVDS receiver and other circuits to provide the necessary control of the RGB digital data for allocation to the LCD panels. A digital thermometer IC is also located on this board to monitor the temperature within the optical block assembly and vary the fan speed as needed. White balance and gamma correction are also preformed on this board.


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IC5107IFP

IC5900LVDS

TX

IC9004LVDS

RX

EPSON

IC9301 R DRV

8-BIT + SYNC

IC4506HDMI

RX

IC3607HDMI

MICRO

24-BIT OSD

HDMI 1

HDMI 2

IC9302 G DRV

IC9300 B DRV

RLCD

GLCD

BLCD

IC9006 32K NVM

IC9103 256K NVMIC3202

CCPXA

7CR8CB/C7CB/B

Y/CV 9

FROMU BOARD

CN3009

ATSC/NTSC

TUNER

TO U BOARD

CN3009TUNER CV 4

EDIDX2

IC5000DRCMFV1

IC7300ATI XILLEON PROCESSOR

10-BIT RGB1080p 60FPS

DE MICRO

CE

BE

THERMAL

ALL ANALOG SIGNALS

FIGURE 2-1VIDEO PROCESS BLOCK DIAGRAM


TVP-28 9

TroubleshootingFailures occurring in the video process circuits on the LA5 chassis can appear as improper video levels, distortion in the video, a loss of a primary color, or no video at all. In cases where no video is present, it is important to determine if the backlight lamp is on. Most of the actual processing of the video signals is performed on the BE board, with the CE board primarily tasked to allocating the RGB video data to their corresponding LCD panel. Gamma correction and white balance is also performed on this board. Determining whether the video failure occurs on all or some of the available inputs is also necessary to assist on isolating the cause.

In cases where a loss of video or distortion in the video appears on all inputs, it is vital that the optical block be eliminated as the cause. It is an expensive replacement part and more difficult to replace than the other components. Internal graphics are generated on the BE board and the CE board on the optical block. These graphics include test patterns. When these patterns are called up in the service mode, they provide a useful tool to isolate the cause of the video failure. Figure 2-2 illustrates where the various graphics sources are generated in this chassis.

Distortions in the picture are approached much in the same way as a loss of video. The main difference is that distortions can be caused by electrical failures or mechanical and contamination issues within the optical block.

No VideoIn a case where the customer complaint is “no video”, the first item to check for is the lighting of the backlight lamp. When the unit is first powered up the green power LED will begin flashing in one second intervals. With a normal, healthy lamp, the LED should blink about 17 seconds before it stops and remains steadily lit. Once this occurs video should display on the screen with OSD graphics indicating the type of input selected. Video programming will also appear if an input with an active signal was last used. If the previous scenario does not occur one ofthe following scenarios will happen:

Unit turns off and power LED starts blinking red: This is not a video problem. The unit has entered the protect mode and the blink sequence will identify which protect circuit activated. Troubleshooting procedures for this event are covered in a different chapter.

Power LED continues blinking green: A green blinking power LED indicates the main microprocessor is busy. This is normal at turn-on as certain circuits are polled by the microprocessor during the initialization period and can occur for up to 20 seconds. If the microprocessor cannot complete the initialization the LED will blink for up to 2 minutes and then light steadily. Graphics or video may or may not appear on the screen. In most cases there will be no video or OSD and random patterns or lines might appear. This is usually caused by the ATI micro located on the BE board. The easiest way to verify this is to turn the unit off and enter the service mode. If the green main micro service graphics appear at the top of the screen, the optical block is OK.

No video or OSD graphics appear: Those who are experienced with troubleshooting LCD-based display devices will attempt to determine if backlighting is present. It is usually easy to tell the difference between a panel that is off and one that has backlighting but some lighting conditions may make this difficult. The best way is to look into the rear of the unit to see if the lamp is lit. It is very unusual for a lamp to not light without placing the unit into protect shutdown but it has been known to occasionally happen. If the lamp is lit it now becomes very important to determine if the screen is backlit. If you are not sure, try turning the unit off after it has been running for a few minutes and see if the screen appears to get darker. It is much easier to identify backlighting when it is turned off. If it is determined that the screen is not displaying backlighting but the lamp is definitely lit, the mirror is probably broken. This occurs from extremely rough handling and is usually found on stock or newly purchased units.

If it is determined that backlighting is occurring, the next step is to determine if the loss of video is occurring on the CE board in the optical block or the BE board video processing circuits. One simple test is to turn the unit off and enter the service mode by pressing “DISPLAY”, “5”, “VOL+” and “POWER” on the remote. If the main micro service graphics appear, the optical block has been effectively eliminated as the cause.


TVP-28 10

If graphics do not appear, press the “JUMP” button on the remote up to 3 times to see if graphics are displayed. If graphics appear at any time during this sequence, the optical block has once again been eliminated as the cause of the no video condition. The inability to display graphics does not necessarily point to the optical block since the Image Format Processor IC on the BE board is the common point and could be the entire reason for no video or OSD. The flowcharts in Figures 2-3, 2-4 and 2-5 should assist in isolating a no-video problem.

SERVICE TIP: One final method can be tried to eliminate the optical block as the cause of a no video/no OSD condition. Since the EPSON IC on the CE board generates its own test patterns they can be activated (assuming data transfer is occurring between the BE and CE boards). Turn the unit off and unplug AC power from the unit and wait about 10 seconds before re-applying. The reason this is done is the service page that appears is whatever the last person to access the service mode left it at. In other words, if someone else serviced the unit and was viewing the lamp hours page and then turned the unit off, that is the page that will automatically appear the next time the service mode is activated. By unplugging the AC power the main micro will receive a hard reset so that next time the service mode is entered the default opening graphics will be page 0 with the version numbers of the various micro processors displayed. Since you won’t be able to see the graphics because of the no video condition it is important to start from this page.

The next step is to press the “5” key 20 times. This will move you backward through the service page groups and is the shortest way to get to the EPSON graphics test pattern activation. Be sure to press the “5” key slowly (about once a second) to allow the microprocessor to react. Once this task is completed, press the “3” key on the remote. If you have navigated to the correct page this will turn on the graphics generator and you should see a white field appear. If it does, the optical block is probably OK. This does not completely eliminate the optical block but would certainly point to the BE board or LVDS cable between the BE and CE boards as the likely cause.

OSD graphics appear: If graphics appear indicating a selected channel or input but there is no active video, it can now be assumed that the optical block is functioning properly. At this point it must be determined if the video failure is occurring on all input sources. If all inputs are affected the BE board is the cause. The replacement board will be supplied with the shielded housing and be known as the BE block assembly. If all analog inputs are affected it could be the BE board or the U board. If a single analog input is not working the U board would be suspect. Digital input only failures are caused by the BE board.


TVP-28 11

Distortions in the VideoTo an experienced technician (especially those familiar with pixel-based display devices) finding the cause of a picture that is abnormal is usually a simple task because the display is operating, there is video present, and there is some kind of distortion that usually gives a clue as what the cause is. Trying to get a customer to explain why the picture is not right is another story. Distortion in the picture generally falls into 2 categories: Electrical or mechanical. Mechanical issues can be dirt contamination, damaged screens, physically distorted LCD panels or polarizers, damaged lenses or even a loss of bonding on one of the pins of the flex cable sending timing pulses to the LCD panel. Mechanically caused distortions have one thing in common: the distortion tends to be in a fixed location and does not usually involve the entire picture.

Electrical distortions can, however, be stationary and fixed but generally involve the entire picture unless the problem is occurring in the final process stages driving the LCD panels. If a tab bond on a panel fails, this is a mechanical problem. If the LCD drive IC fails to send timing pulses to a particular line on the panel it is considered an electrical problem. What is interesting is that both of these causes produce the same result. There will usually be one vertical line of red, blue or green continuously lit. If multiple vertical lines of one color appear and are evenly spaced, this is an electrical problem and usually involves the loss of one data line prior to being de-multiplexed by the LCD drive circuits.

As a rule, mechanical distortions generally occur in the optical block, mirror and screen. Electrical distortions in the optical block usually tend to be fixed lines or spots of distortion that may be of improper colors. Electrical failures in the front end video processing circuits almost always affect the entire picture. It is very unlikely that you will see the digital video processor cause a single colored line or spot on the screen. Use the flowchart in Figure 2-6 to assist in troubleshooting video distortion problems.

Foreign Material

Dust, dirt and smudges can occur behind the screen, on the mirror or lens, and inside the optical block (usually at the LCD panels. Foreign material on the screen or mirror will cause dark spots or smudges. A simple way to determine if the foreign material is on the screen or mirror is to gently pull the top of the screen towards you and rock it back and forth. If the spot stays in the same place of the screen while it is moved, the material is definitely on the screen or most likely on the mirror. Removal of the screen and a thorough cleaning will usually rectify the problem.

If the spot moves around on the screen when it is rocked, the culprit is on the lens or inside the optical block. The lens will cause a dark spot or out-of-focus area in the picture depending on how dense the foreign material is. Fingerprints are notorious for causing large out-of-focus spots.

If there are single or multiple spots and the foreign material is located on the LCD panels they will not be dark. They will usually appear as one of the secondary colors (magenta, cyan, or yellow). This can be caused by defective pixels or dirt. Defective pixels are rather well defined whereas foreign materials can appear in various shapes and sized and usually have a soft edge. The only way to be sure is to remove the optical block and clean it.

With the optical block removed from the unit, remove the CE board. This will give you enough access to blow compressed air inside the LCD/Prism assembly. Use the canned-type cleaners since they do not produce large amounts of air pressure. If a compressor is used, be sure to regulate the air pressure so that is does not exceed 20lbs. The only way to test the success of your work is to re-install the optical block and check the picture. If the spots still exist and have moved or the number of spots has minimized, the optical block will need to be removed and the procedure tried again. If the spot (or spots) have not changed there is a possibility of a physical defect on one or more of the LCD panels or a more aggressive cleaning must be performed and this involves the removal of the LCD assembly. Always check for any up-to-date procedures for cleaning the type of optical block you are servicing to see how it can be done and how far you are allowed to safely disassemble the optical block


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RLCD

GLCD

BLCD

IC5107IFP

IC5900LVDS

TX

IC9004LVDS RX

EPSON

IC9301 R DRV

8-BIT + SYNC

IC4506HDMI

RX

IC3607HDMI

MICRO

24-BIT OSD

CE

VIDEO 6HDMI

VIDEO 7HDMI

IC7300ATI XILLEON PROCESSOR

IC9302 G DRV

IC9300 B DRV

IC3202CCPXA

7CR8CB/C7CB/B

Y/CV 9

CN3009

ATSC/NTSC

TUNER

CN3009

TUNER CV 4

EDIDX2

IC5000DRCMFV1

BE

FIGURE 2-2OSD GRAPHICS SOURCES


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LA5 CHASSIS NO VIDEO FLOWCHART D1

No Video

No

Yes

Yes

No

LampLamp Driver

Optical Block

BE Board

BE boardLamp Lights?

Any OSD Graphics

Displayed?

Tuner only ?Yes

Analog inputs only?

U BoardBE BOARD

Yes

No

Yes

No

No

All Video Sources Affected?

See lamp troubleshooting flowchart D2

See OSD troubleshooting flowchart D3

HDMI inputs?Yes

BE Board

D1

FIGURE 2-3


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LA5 CHASSIS LAMP TROUBLESHOOTING

No Backlight

No

Replace lampDoes lamp LED light?

Backlighting seen on screen?

Yes

No

D2

At least160VDC across pin 1 and 3 of CN6501

on G board?

Look into main exhaust fan for

lit lamp.

Yes Video problemGo to D1

Lamp Lit ?

Yes

No

Mirror broken

Power LED blinking red

5X?

Yes

Lamp Driver Board

No

NoG Board

5VDC pin 2 and 2.8VDC pin 1 of

CN6804 G board?

Yes

BE BoardNo

Yes

Lamp Driver Board

FIGURE 2-4


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No Video All Inputs

BE BoardInitial Service

Graphics Displayed?

No

D3

Enter Service Mode

Any OSD Graphics

Displayed?

No

Optical Block

Yes **QM service graphics?

Yes

**CE board graphics?

No

YesBE Board

Press “JUMP” onremote commander

No

Optical Block

Yes


NOTE: If no OSD graphics can be displayed but the lamp is lighting, check to make sure the LVDS cable from the BE Board going to the Optical Block is not loose or damaged at either end before deciding to replace the Optical Block. Replace if damaged .

** See “Service Mode” in this chapter for information regarding access to the various graphics and test patterns .

FIGURE 2-5


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Video Distortion

No

Distortion stationary?

Single or multiple lines of

same color?

Does Spot Move?

No

Push on top part of cabinet

to make screen move .

Dust on Rear of Screen.

Yes Dust in Optical Block or Pixels

Unlit

Darkor colored specks?

Yes

E

Tilt ortrapeziod distortion?

Upper cabinet or mirror distortion

All inputs affected?

QM Service graphics OK?

BE Board

No Panel service graphics OK ?

No

BE Board

Yes

Yes

NOTE: All signals are processed by BE Board .Analog signal distortions could be caused by U Board but is rare . Distortions occurring from front video inputs are probably due to faulty HCE Board.

Yes

Yes

Dark

Colored

Pixel Failure . Contact Technical

SupportNo

No

Yes

No

Check LVDS connectors at BU1 and Optical Block . If OK replace Optical Block

Optical Block

FIGURE 2-6

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Chapter 3 - Audio ProcessingAudio ProcessingFigure 3-1 illustrates the audio switching, processing and amplifier circuits. All audio sources are selected and processed by DSP IC2002. L/R analog audio exits IC2002 to be amplified by IC2009.

Digital tuner and HDMI audio are sent to IC2002 in digital format. The DSP also outputs L/R audio for the rear output jacks along with SPDIF format digital audio for the optical out transmitter.

Optical OutThe optical output jack at the rear of the unit will pass all selected audio sources except for Super Audio CD (SACD) or DVD audio sources hooked up to the HDMI inputs (for obvious copyright protection reasons). All analog sources (including that from the NTSC tuner) are output as 2-channel 48KHZ PCM. DVD players hooked up to the HDMI inputs will output 2-channel PCM regardless of what the HDMI audio output on the DVD player is set to. The internal speakers will output DVD audio regardless of what the HDMI audio of the DVD player is set to (unlike previous year’s models).

If an ATSC compliant digital channel is received by cable TV (QAM) or terrestrial (8VSB) and a Digital Dolby® audio signal is embedded in the content, the optical out will pass this signal for use with a surround-sound amplifier that is compatible with Digital Dolby® 5.1 standards. Table 3-1 offers an overall view of what is output from the optical jack based on input selection.

TroubleshootingSince all audio processing and amplification is performed on the U board, problems causing distortion or the loss of 1 or both channels will likely be fixed by replacing this board. If the failure is isolated to digital sources only (digital tuner or HDMI) the failure is more likely to reside on the BE board. The troubleshooting flowchart in Figure 3-2 will also serve as a guide to assist in determining the audio problem.

AUDIO SOURCE OPTICAL OUTPUT

DIGITAL TUNER 5.1 5.1 OR 2CH PCM

DVD HDMI 5.1 2CH PCM

ALL ANALOG AUDIO INPUTS 2CH PCM

NTSC TUNER 2CH PCM

SACD VIA HDMI NO OUTPUT

DVD AUDIO VIA HDMI NO OUTPUT

TABLE 3-1OPTICAL OUTPUT TRUTH TABLE

TVP-28 18

Chapter 3. Audio Processing

FIGURE 3-1AUDIO PROCESS BLOCK DIAGRAM

U

Y/C_COMPOSITE 1

COMPOSITE 3

COMPONENT 1

COMPONENT 3

L

R

IC2009CLASS D

AUDIO AMP

HDMI 1 ANALOG

OPTICAL OUT

L/R AUDIO OUT

IC2002AUDIO SW

DSP

IC7300ATI MICRO

HDMI 1

HDMI 2IC4506

HDMI RX

NTSC TUNER L/R

DIGITAL PCM AUDIO

COMPOSITE 2

COMPONENT 2

ATSC/NTSC TUNER

ATSC

HCE

BE

TVP-28 19

Chapter 3. Audio Processing

FIGURE 3-2AUDIO TROUBLESHOOTING FLOWCHART

AudioProblem

No

Yes

Yes

Audio Present ?

All Channels

Distorted

Yes

All inputs?

No

No

Internal Speakers

Turned Off ?

Turn Speakers On

Yes

No

Done

F

Yes

Tuner Only ?Yes

BE board

No

U board

No

TVP-28 20

Chapter 4 - Power SupplyMost of the supply voltages used in the unit originate on the G board. The primary circuits consist of a standby supply and a main switching regulator. Below is a brief description of each circuit. Figure 4-1 illustrates an overall block diagram of the power supply.

Standby SupplyThe standby supply is an independent circuit consisting of a transformer T6300 and IC6300. The output is maintained at a constant 5VDC to provide power to the TV Micro on the BE board. This voltage is also supplied to the main relay on the power supply and the IR receiver on the HBE board.

Main Switching SupplyThe main switching regulator supplies all of the voltages used by the television. Although additional regulation circuits are present on the BE board, they derive their sources from here.

Turn OnA high from the TV Micro IC3002, located on the BE board, enters at pin 2 of CN6904. This turns on main relay RY6001 via rely driver Q6007. Initial current draw passes through R6259 to limit current surge at turn-on. Once the main switching regulator starts, 5VDC is generated by IC6002. This turns on RY6002 to shunt R6259. The normal time period between RY6001 engagement and RY6002 turning on is less than 500ms.Optical isolator PH6001 monitors the voltage drop across R6259. If RY6002 does not close within 2 seconds, the relay high going to Q6007 is grounded by the latch circuit consisting of Q6003 and Q6004. The unit will shut down and the Power LED will blink in sequences of 3.Note the RELAY_VCC supplying power to RY6001. This voltage originates from the STBY_5V generated in the standby supply, exits CN6804-7, passes through a thermal fuse located on the lamp chamber housing, and returns to CN6804-9. If this fuse opens, the main relay will not engage and the unit will go into protect mode with 3 blinks of the POWER LED.

Main Switching RegulatorThe main power supply consists of IC6000 and T6000. IC6000 drives 2 switching transistors (not shown) to generate several output voltages from the secondary windings of T6000. All of the voltages except Lamp Power and Audio 28V are common to chassis ground. The later voltages have their own ground isolated from the chassis. Voltage measurements for these two lines must be made across their connectors.The 10.5V source exiting at CN6904-29 is monitored on the BE board for over and under-voltage conditions. If this voltage exceeds 17 volts, the unit will enter the protect mode and flash the POWER LED 8 times. If the voltage drops below 8.2 volts, the unit will also enter the protect mode with 3 LED blinks.

Lamp Driver VoltageVoltage for the lamp ballast is output at CN6501-1. This voltage is derived, unregulated, from the rectified AC source. Filtering of the rectified source is performed with a doubling circuit so the DC voltage should be around 280VDC. Note that the ground for the lamp driver voltage is AC hot ground.

TVP-28 21

Chapter 4. Power Supply

RY6002

SWITCHINGREGULATOR

IC6300T6300

PH6001OPTICAL

ISOLATER

+5V

LAMP DC

LAMP GND

1

3

CN6501

4 +17V

6 +3.3V

CN6009

SWITCHINGREGULATOR

IC6100T6301

3

AU_28V1

AU_GND

CN6002

Q6003Q6004LATCH

Q6007

D6000 D6034

D6029

D6018

CN6904D6020

IC60025V REG

IC60039V REG

RY6001

D6305

R6259

TO LAMPDRIVER

TO CE BOARD

TO U BOARD CN2504

TO BE BOARD CN3002

G

LAMP CHAMBER THERMAL FUSE

IC60073.3V REG

35 +5V

2 P_ON

38 +9V

37 +10.5V

RELAY_VCC9

STBY_5V7

CN6804

UNREG 280V

3

10.5V2

GND

1 10.5VTO CE BOARD

CN8150

CN6019

FIGURE 4-1POWER SUPPLY BLOCK DIAGRAM

TVP-28 22


Go To Protect Flowchart C1

No power

No

Yes

Yes

Thermal fusePower LED blinking 3X?

PWR LED blinking green ?

5VDC either side of thermal

fuse?

Yes

No

No

G Board

One side

B

Yes

5VDC both sides of

thermal fuse?

BE Board

G Board

3VDCCN6904-14G board?

No

Both Sides

G Board

BE Board

Relay clicks heard?

Yes

No

1 or 2 clicks?

1G board

Not power supply problem

2 Power LED blinking?

Yes

No

FIGURE 4-2POWER SUPPLY TROUBLESHOOTING FLOWCHART

TVP-28 23

Chapter 5 - Protect CircuitsSeveral key areas of the LA5 chassis are monitored for temperature and voltage conditions. In all cases, the unit will shut down and display a diagnostics indication. The POWER LED will blink red in a set number of frequencies, depending on what was detected. The flashes occur at one-second intervals followed by a 3 second separation interval of no flashes. All protect circuits are monitored by the TV Micro IC3002 on the BE board. Figure 5-1 illustrates a block diagram of the protect circuits.

Thermal Protection (7X)Due to the use of a high-intensity lamp, it is crucial that temperatures be monitored within the unit. This is important to control fan speed and protect the unit from damage if the temperatures become excessive. There are 2 locations within the unit where temperatures are monitored.

SE Board: This board is located inside the lamp chamber and is the more critical of the two. A digital thermometer IC is on the board. It sends constant temperature information to the TV Micro IC3002. If the temperature exceeds a specified level, a graphic warning will appear on the screen warning the customer that excessive temperature levels have been reached. If the temperature does not drop, the unit will shut down and display 7 blinks. This is the only sensor of the 3 that protects the unit from over-temperature conditions. The other sensors are used to control fan speed for their particular location.

HC Board: This board is located at the front of the unit where the Video 2 and component 2 inputs are located. The internal temperature of the cabinet is monitored and the fan speeds adjusted accordingly. The temperature sensing IC’s on both boards communicate with the TV Micro via a common I²C bus.

Thermal Fuse: Should the temperature inside the lamp chamber rise dramatically to unsafe levels, a thermal fuse located on the housing will open. This fuse supplies STBY_5V to the main relay RY6001 via CN6804-9. When this fuse fails, no relay clicking will be heard since the main relay cannot engage. This failure can mislead technicians because the TV Micro on the BE board (which is always running on standby 5 volts) detects the loss of 10.5V from the main switching supply and does not know that the reason is because the main relay did not engage. The unit will not turn on and will display a red 3-blink sequence of the POWER LED.

Lamp Cover Protection (6X)The TE board contains a switch to ensure that the lamp cover is in place and securely fastened. If the lamp cover is not securely fastened, the proper airflow from the cooling fans would be interrupted causing overheating within the lamp chamber. If the switch opens, the lamp cover line at CN6804-17 will go high causing the unit to shut down and display 6 blinks.

TVP-28 24

Chapter 5. Protect Circuits

Lamp Ballast Protection (5X)The Lamp Driver board (ballast) monitors the voltage and current being sent to the lamp. The ballast is started by a high (3.3V) appearing at CN6804-1 that originates from the TV Micro IC3002 on the BE board. The ballast is also supplied with 280VDC from the G board via CN6501-1. When the lamp is fired from a cold start the voltage can reach upwards of 26KV. Once the lamp starts and ionization of the gas begins, the voltage is immediately dropped to around 20-30 volts and slowly raised to an operating voltage of roughly 90 volts.

During these sequences, the current and voltage curves are monitored for abnormalities. A weak or defective lamp can affect these curves as can a failure of the Lamp Driver circuits. Any event in this stage will cause a high to appear at CN6804-4 which sends the high to the BE board via CN6904-18. The unit will shut down and blink the Lamp LED on the front cover.

The Lamp Driver is also monitored to verify the proper startup of the high voltage circuit. If the Lamp Driver fails to generate the required high voltage to start the lamp, the HV_DET line at CN6804-5 will go high and the unit will shut down and blink the power LED 5 times.

Fan Rotation Detect (9X)All 3 cooling fans inside the unit are monitored for rotation. Each fan has 3 wires: B+, Ground, and Fan Protect. The Fan Protect line will be zero volts if the fan is rotating properly and will rise up to 3 volts if no rotation occurs. All 3 protect lines are applied to an or-gate array. If any of the fans sends a high, it will be detected by the TV Micro. The unit will shut down and blink 9 times.

Voltage Protection (2X LVP, 3X OVP)Since the 10.5V source on the G board is monitored to provide feedback for the regulation circuits of the main switching supply, this voltage must be monitored to prevent damage caused by a drastic rise in the other voltages generated from the secondary lines. Monitoring of the 10.5V source is performed on the BE board. If the voltage rises above 17 volts or drops below 8.2 volts, the unit will shut down. If the cause was due to excessive voltage, the LED will blink in sets of 2. If an under-voltage situation occurs, 3 blinks will be displayed.

NOTE: CN6804 on the G board provides a convenient test point for the protect lines. Those that operate on a high/low state are normally low and go high when a protect event occurs. The data bus on pins 16 and 18 can be checked for activity or loading. The normal DC on the bus is 4.6 volts with 5VPP data pulses.

Lamp Protect (Lamp LED)Although labeled as a protect cicrcuit, this event indicates a lamp that is no longer functional. When the unit is turned on, the ballast will make 3 attempts during a 60 second period to ignite the lamp. If the lamp does not ignite on the third attempt, the unit will shut down and the lamp LED on the front bezel will blink continuously.NOTE: Another symptom of a lamp nearing the end of its life is cycling. If the customer complains of a picture that appears and disappears in a predictable cycle, the lamp is probably weak. It is very unusual for the lamp to not light at all without a lamp or ballast error (5X) to occur.

TVP-28 25


FIGURE 1-5LA5 46/50" PROTECT CIRCUIT BLOCK DIAGRAM

11+5V

CN6804

10 FAN_PROT

13SDA_5V

15SCL_5V

IC180THERMSENSE

LAMP COVER+ 17

18

G

14

18

HV_DET

LAMP_PROT

4LAMP_PROT

6GND

2LAMP _5V

LAMP CTL 1

3LAMP_SEL

5HV_DET

STBY_5V

RELAY_VCC

LAMP CHAMBER THERMAL FUSE

LAMPDRIVER

(BALLAST)3

CN6906

FAN1_PROT

6 FAN2_PROT

8 FAN3_PROT

2 FAN4_PROT

CN6802

FAN PROTECT

LAMP_COVER20

SCL_5V24

26 SDA_5V

CN6904

7X

9X

6X

5X

LAMP LED

SC

L_5V

3 4S

DA

_5V

IC3002TV MICRO

37 +10.5V

LVP

OVP

3X

2X

1LAMP DC

3LAMP GND

CN6501

7

9

CN3006

LAMP COVER-

SCL_5V34 SDA_5V

HCU

CN2500

S150

TE

FAN2 NOT USED IN THIS CHASSIS

BE

IC160THERMSENSE

SE

THERMSENSE

FIGURE 5-1PROTECT CIRCUITS BLOCK DIAGRAM

TVP-28 26


TroubleshootingSeveral critical circuits are monitored in the LA5 chassis. If a malfunction occurs in any of these areas the unit will turn itself off and display a diagnostics indication via the power on LED. The LED normally glows green when the unit is functioning properly. When in the diagnostics display feature is enabled, it will turn red and flash in repetitive sets. The blinks occur at one-second intervals followed by a 3 second separation.

In most cases, the diagnostics indication provides a useful tool to indicate where the potential failure lies. In other cases, several circuits may cause the particular diagnostics indication. Use the flowcharts later in this chapter to assist in locating the cause. The following is a list of the diagnostics indications and the possible causes. The flowcharts in Figures 5-2, 5-3 and 5-4 can be used to assist in isolating the cause of a protect shutdown.

2 Blinks: 10.5V from the G board is monitored for over-voltage on the BE board. This condition is caused by a regulation failure on the G board and replacing the board should rectify the problem.

3 Blinks: The 10.5V source from the main switching supply generated on the G board is monitored for under-voltage. The circuits monitoring this voltage line are located on the BE board. This symptom is usually caused by a failure of the main switching regulator to run, such as a main converter or main relay failure. The most common cause of this event is the thermal fuse opening on the lamp chamber housing which causes a loss of STBY5V to the main relay. The presence of 5 volts on both pins of the thermal fuse should always be checked before replacing the G board.

5 Blinks: The lamp ballast has not started or is giving an erroneous alarm. This problem is not known to be caused by external circuit failures. The lamp ballast must be replaced.

6 Blinks: The lamp cover switch is open. Check the lamp and lamp cover to make sure they are properly seated. If they are, the lamp chamber will require disassembly to examine the switch for failure or damage.

7 Blinks: Excessive temperature has been detected by the thermal IC on the S board located on the lamp chamber or the HC board located on the front bezel. A failure of either IC can also generate a false symptom.

If the unit goes into thermal protect shutdown as soon as it is turned on, it is safe to assume that one of the thermal IC’s has failed. If the problem occurs after the unit has been running a while, check for proper ventilation around the unit and examine the fan intake areas for signs of dust or hair buildup.

SERVICE TIP: Most thermal protect shutdown events that occur after the unit has been running a while are caused by inadequate ventilation. The thermal sense IC located on top of the lamp chamber is the only one that can command a shutdown so the thermal problem is being detected in the lamp chamber. The thermal sensors on the HC and CE board are used for controlling fan speed for the chassis and optical block fan. If the unit is shutting down with a thermal error within a 2 minute time frame, look into the main exhaust port at the rear of the unit right behind the lamp chamber. Make sure the main exhaust fan is rotating freely. There have been instances where the fan was “rocking” back and forth rather than rotating. The rocking motion can be sufficient enough to fool the rotation detect circuit into thinking the fan is working properly. Replace the main exhaust fan if this symptom occurs.

8 Blinks: DC has been detected on one or both of the speaker lines.

9 Blinks: One or all of the 3 fans is sending a high indicating a loss of rotation. Observe the #3 fan (main intake) and #4 fan (on top of the BE block) for rotation. If either fan turns at turn-on, lamp-drive B+ is present. If both fans are not turning, replace the G board.

The #1 fan (inside the optical block) cannot be observed for rotation. The drive voltage and protect return line must be checked with a DVM to determine which is at fault. The drive voltages for the lamps is usually around 7 to 9VDC and the protect lines should read close to zero VDC. A defective fan or a fan not rotating will always raise the error line to 3 volts rather quickly.

NOTE: Even though a fan is observed to be rotating, it is possible that the rotation detect of that fan is sending an erroneous protect event. If the drive voltages to all 3 fans is present, it is possible to momentarily ground the protect lines for each fan to see if the unit remains on. This is an effective tool for troubleshooting and isolating the fans and the connectors are easily accessed on the G board.

TVP-28 27


Red Power LED Flashing

No

No

Yes

Yes

No

G Board2X

6XYes

8X

C1

3X Yes

5X

No

Lamp Cover LooseTE Board

U board

Yes

Low B+See Flowchart C-3 for

additional information about this protect event

If failure occurs after running for awhile suspect ventilation issue. If it occurs at turn-on:

HCE or SE boardPossible BE board

Lamp Driver

7XYes

No

9XYes

Fan ErrorSee Flowchart C-2 for


No

FIGURE 5-2PROTECT TROUBLESHOOTING FLOWCHART C1

TVP-28 28


LA5 CHASSIS FAN ERROR FLOWCHART C2

9XFan Error

C2

Any fans rotating?

Yes

No

3.3VDC CN6904-12 G

Board?

BE Board

No

G boardYes

G Board

CN69061 - FAN1 DRIVE3 - FAN1 ERROR4 - FAN2 DRIVE (NOT USED)6 - FAN2 ERROR (NOT USED)7 - FAN3 DRIVE8 - FAN3 ERROR

CN68021 – FAN4 DRIVE2 – FAN4 ERROR

Any drive voltages missing?

Check fan drive and error line voltages at CN6906 on G Board **

Normal fan drive voltage : 5 to 7VDCNormal error voltage : 0.0VDC

Yes

No Any protect line > 0.2VDC?

No

BE Board

Replace affected fan

Yes


TVP-28 29


LA5 CHASSIS LOW B+ ERROR FLOWCHART

3XLow B+ Error

C3

Any relay clicks heard?

Yes

No

5VDC present both pins of

thermal fuse?

Neither pin

G board

One pin

10.5VDC IC6002 -1 on G

board?

Yes

No

G board

BE board

Thermal Fuse


TVP-28 30


Diagnostics HistoryCertain protect events are monitored by the Main Micro on the BE board. Those that are monitored are stored into NVM for retrieval. Each time a monitored protect event occurs a failure will register in the right column. Each diagnostic event will register a “0” if none has occurred. If there has been a recorded event a “1” will appear on the appropriate line. Bear in mind that the unit does not keep a running count of failures. It will only tell you than one has occurred but not how many times.

The diagnostics history page is retrieved by turning the unit off and pressing the following buttons on the remote commander in sequence: “DISPLAY”, “5”, “VOL-”, and “POWER”. The unit will turn on and you may have to wait several seconds for the display to appear once the backlights have turned on. This feature is illustrated in Figure 5-5

Clearing the Diagnostics HistoryOnce the diagnostics page has been viewed for a history of protect events (and there are any present) the failure counts must be cleared to be useful at a later time. This is accomplished by pressing the “8” followed by the “0” key on the remote (not “8”, “ENTER” as in past models).

SELF DIAGNOSTICS PAGE

A “1” WILL REGISTER IF A FAILURE HAS OCCURRED.

FIGURE 5-5SELF-DIAGNOSTICS PAGE

TVP-28 31


G Board Test pointsThe connectors on the G board provide access to virutally all important voltage and protect lines. Use the test points illustrated in Figure 5-6 to assist in troubleshooting a protect event.

FIGURE 5-6G BOARD TEST POINTS

CN65011 – LAMP DC (310 TO 340VDC)3 – LAMP GROUND

CN60021 – AUDIO 28V3 – AUDIO GROUND

CN69061 – FAN1 POWER (OPTICAL BLOCK)2 – GROUND3 – FAN1 PROTECT4 – FAN2 POWER (NOT USED)6 – FAN2 PROTECT7 – FAN3 POWER (LAMP CHAMBER)8 – FAN3 PROTECT

CN68021 – FAN4 POWER (B BLOCK2 – FAN4 PROTECT3 - GROUND

CN68041 – LAMP CONTROL (2.5~5VDC)2 – LAMP 5V3 – LAMP SELECT4 – LAMP PROTECT (NORM LOW)6 – HV DETECT (NORM HIGH 3.3V)7 – STBY 5V (TO THERMAL FUSE)8 – GROUND9 – RELAY VCC (FROM THERMAL FUSE)11 – 3.3V17 – LAMP COVER (NORM LOW)

CN60093 – GROUND4 – 17V6 – 3.39 – MUTE (NORM LOW)11 – SDA12 - SCL

CN69042 – POWER ON HIGH (2.8V)9 – STBY 5V10 – FAN PROTECT (NORM LOW)12 – FAN CONTROL (3.3V)14 – HV DETECT (NORM 3.3V)16 – LAMP CONTROL (NORM 3.2V)18 – LAMP PROTECT (NORM LOW)20 – LAMP COVER (NORM LOW)22 – AC RELAY (3.3V)28 – FAN1 CONTROL (NORM 2.2V)30 – FAN4 CONTROL (NORM 1.4V)32 – FAN3 CONTOL (NORM 1.5V)36 – 5V38 – 9V40 – 10.5V

THERMAL FUSE TEST

POINTS

FIGURE 5-6G BOARD TEST POINTS

TVP-28 32


Cooling Fan Locations

FIGURE 5-7COOLING FAN LOCATIONS

FAN 1 LOCATED INSIDE OPTICAL

BLOCK

FAN 3 (EXHAUST) LOCATED ON REAR OF LAMP CHAMBER

FAN 3 LOCATED ON TOP OF BE BLOCK

FIGURE 5-7COOLING FAN LOCATIONS

TVP-28 33

Chapter 6 - Service ModeService ModeThe service mode is accessed by pressing “DISPLAY”, “5”, “VOL+”, and “POWER” (in sequence) on the remote commander when the unit is turned off. If the remote was set properly to the “TV” mode and the buttons were pressed in adequate time, the initial service mode graphics should appear on the screen along with whatever video input source was last selected.

The service adjustment data is located in 2 locations: The Main Micro (IC3002) and ATI Micro (IC7300) both located on the BE board inside the shielded BE Block assembly. IC3002 Main TV Micro controls what data is displayed on the screen and is the interface for the remote commander to select and change data. When the unit enters the service mode the Main TV Micro graphics are displayed. Graphics data is also displayed for the ATI Micro and is accessed by pressing the “JUMP” button on the remote. Figure 6-1 illustrates both adjustment categories.

Once inside of either category, the “2 and “5 keys on the remote are pressed to maneuver up and down groups of adjustment data. Within each group are adjustment items and these are selected with the “1” and “4” keys. The adjustment, or data settings for each item is changed by using the “3” or “6” keys.

Factory ResetIn previous Sony television designs, the unit could be returned to “out-of-box” condition by entering the service mode and pressing “8” followed by “ENTER” on the remote. The word “RESET” would appear on the screen. Pressing the “MUTE” button would cause the unit to turn off and then back on again.

Performing a factory reset on the LA5 chassis is done differently. With the unit turned on, press and hold the “UP” button on the joystick while aiming the remote at the television. Press the “POWER” button on the front of the unit. The television will power down and turn back on after a few seconds asking what language you would like to use.

New Remote CommandsThe button commands for reading and writing data in the service mode has changed. The “0” key is now used instead of “ENTER” to execute a command. The table below lists these commands.

OPERATION COMMAND BUTTONS SERVICE PAGE DISPLAY

INITIALIZE DATA "7" "MUTE"

INI- INI-EXE

CUSTOMER SETTINGS RESET

"8" "MUTE" "0"

RST- RST-EXE RST-EXE

READ NVM DATA"9" "0"

READ READ

WRITE DATA TO NVM

"MUTE" "0"

WRITE WRITE

SERVICE MODE REMOTE COMMANDS

TVP-28 34


QM DATATV MICRO DATA

“JUMP” KEY

FIGURE 6-1SERVICE MODE GRAPHICS

FIGURE 6-1SERVICE MODE PAGES

TVP-28 35


Lamp Hours ResetResetting the lamp hours is a function that can be performed by the customer. When the customer menu is displayed, one of the items in the toolbox menu is “Lamp Replacement”. If the customer selects this, he will be asked if the lamp has been changed. If “yes” is selected, the lamp hours will be reset to zero.

Another method to view and reset the lamp hours is within the service mode. The technician will have the advantage of viewing the number of hours on the lamp. The user cannot see this in the customer menu. Figure 6-2 illustrates the adjustment page for lamp hours. It is in an adjustment group labeled “TIME” and located on page 1. Note the lamp hours are displayed in high and low number sets indicating the most and least significant bits. Also note the display is in hexadecimal format. You will need to convert to decimal in order to get the lamp usage in hours. To reset the lamp hours, go back to page 0 and change the data from “zero” to “1”. Press “MUTE” followed by “0” on the remote commander to reset the hours.

Since the customer has the ability to reset the lamp hours, this function is not an accurate tool to determine accrued operating hours of the unit. On page 2 within the same group is an item labeled PANL”. This displays the accrued hours on the LCD panel and cannot be reset.

NOTE: LAMP HOURS ARE DISPLAYED IN HEX FORMAT. RIGHT SIDE IS LOW

NUMBER LEVEL AND THE LEFT SIDE HIGH NUMBER.

FIGURE 2-3 LAMP HOURS VIEW AND RESET

LAMP HOURS RESET BY CHANGING DATA TO “1” FOLLOWED BY “MUTE”, “0” ON THE

REMOTE COMMANDER

FIGURE 6-2LAMP HOURS VIEW AND RESET

TVP-28 36


Model and Serial Number InformationIf the BE Block is replaced, the EEPROM on the new board will have default data for the model and serial number of the unit you are servicing. Locate the group named “MODEL” in the TV MICRO category. The first page, 0, is the model adjustment.

Model Number DataReferring to Figure 6-3, changing the data from 1 up through 7 will change the model display. Only the first 3 models are valid US models. Select the correct model followed by “MUTE” and “0” to write the data to NVM.

Serial Number DataThe replacement BE board will have all zeros entered into the serial number field. Page 1 of the “MODEL” group is “SN1”. Changing the data on this page will advance the number in the right column (least significant bit) of the serial number display. Page 2 (SN2) changes the next digit to the left. Continue advancing through the pages (8 pages) and change data until all 8 serial number digits correspond to the correct serial number of the unit.

MODEL AND SERIAL INFO PAGES

CHANGE DATA TO CORRECT MODEL NUMBER DISPLAY

CHANGE DATA FOR SERIAL NUMBER DIGITS 1 THROUGH 8

FIGURE 6-3MODEL AND SERIAL NUMBER PAGES

TVP-28 37


Test PatternsInternal test patterns are generated in 2 places on the LA5 chassis. The first sets are created by the ATI Micro IC7300 on the BE board. The graphic information is sent to DCP IC3500 as 24-bit (8-bit each) RGB data. The other set of test patterns is generated by EPSON IC8700 (scaling) on the CE board. User interface via the remote commander and control of the graphics selected are performed by the TV Micro IC3002 on the BE board. The presence of graphic generators on both boards provides a useful tool when troubleshooting video failures. If clean test patterns can be displayed from the EPSON IC on the CE board, there is a good chance that the optical block can be eliminated as the cause of the problem. Figure 6-4 illustrates where the test pattern graphics are generated.

PAWN (Optical Block) GraphicsWhen the service mode is entered, the presence of green data graphics indicates the Main Micro category. Within a group called PAWN_TSP there are several items that can be used to call up test pattern graphics. Use the “5” key on the remote to scroll to the group since it is near the end of all the groups. Once PAWN_TSP has been located, page 0 is labeled “TPNS”. Using the “3” key, change the data from 0 to 1. This activates the pattern generator located in the EPSON IC on the CE board. The default test pattern should be a flat field of approximately 75% white. Other test patterns may appear depending on the data setting in another page called “mode”

Press the “1” key to advance to page 4 labeled “MODE”. Changing the data on this page will call up the various test patterns from the EPSON IC.

Go back to page 1 to the item labeled “RGB”. Any data change on this page will change the color of the test pattern. 7 different colors can be displayed; white, each of the primary and secondary colors, and black. The default data value is 7 for white with 0 being black. The ability to control which primary color is on is a great tool for studying the individual LCD panels for uniform operation.

NOTE: Be certain to return the RGB value to 7 (white) before exiting this page. If this is not done, all test graphics on the CE board will display

CHANGE DATA TO “1” TO ACTIVATE TEST

PATTERNS

DEFAULT SHOULD BE WHITE FIELD

FIGURE 6-4CE BOARD TEST PATTERN ACTIVATION

whatever color condition was selected. If the RGB data is left on “0” (black field) you will not be able to see any test graphics.

TVP-28 38


FIGURE 6-5QM TEST PATTERN

PAGE 1 DISPLAYS TEST PATTERNS

DATA VALUE CHANGES TYPE OF

PATTERN

FIGURE 6-5QM TEST PATTERNS

QM GraphicsThe test pattern graphics generated by ATI Micro IC7300 are helpful in determining if the video process circuits at DCP IC3500 are functioning properly. Since virtually all video processing is performed on the BE board, these test graphics are not as useful for video failure isolation like previous designs in which the ATI Micro was located on a separate board (QM board). They are however, useful for testing the scaling circuits within the DCP IC.

If the TV MICRO graphics are displayed, press the “JUMP” button on the remote to enter the QM category. The data graphics at the top of the screen will turn to blue characters. Advance to the next page to item “PATN”.

The data value should be set at zero. Using the “3” key on the remote commander will change this data and different test pattern graphics will appear with each increase of the data value. There are 4 sets of 20 graphics (data 1 to 80). Each set of graphics is redundantly generated but in different resolutions. They are as follows:

1-20 1080i

21-40 480i

41-60 480p

61-80 720p

An example of the first pattern (color bars at 1080i) is shown in Figure 6-5

Exiting the Service ModeAfter powering the unit off from the service mode, it is a good idea to wait at least 2 minutes before turning the unit back on. The reason for this is that the television will remain in a cool-down mode for 2 minutes. During this time the main power supply is still running to keep the fans running. Once the fans have stopped and the 2 clicks of the main and inrush current relays releasing are heard, the unit can be turned back on. This assures an adequate reset of the internal software.

TVP-28 39

Chapter 7 - DisassemblyOverviewThe most significant design change for the LA5 chassis involves how the unit is disassembled to gain access to all of the major components. In previous rear-projection television designs, a rear cover was removed in order to remove and replace circuit boards, fans, and the optical block. The LA5 chassis is designed with a solid rear cabinet and access is accomplished by removal of the front bezel just the same as was required to clean or replace the mirror and screen parts.

This may seem awkward at first but the design has 2 advantages. By not having a removable rear cover, the unit is considerably more rigid so tilt and geometric distortions are minimized due to reduce cabinet flexing. The other advantage is the opening size when the front bezel is removed to obtain easier viewing and replacement of the components.

The down-side to this design is the fact that the service technician will be working very close to the mirror and it is easy to touch it with your hair, arms, or hands. Removal of the bezel also exposes the rear of the screen and dust contamination may occur. Proper cleaning materials should be on hand when re-assembling the unit.

Locking ConnectorsVirtually all of the harness connectors (especially those connected to circuit boards) have a locking mechanism to improve connection reliability. Observe the connectors closely before attempting to remove. If the locking mechanism is properly released, the connecter will come out with very little effort. Using force will only result in wires pulled from the connector or damaged pads on the circuit board. The connectors for the LVDS cable supplying video from the BE board to the CE board on the optical block are the most delicate. Use caution when removing them and when re-installing. If the connector does not slide back in easily with a soft click, turn it over and try the other way. A sample of the connectors is shown if Figure 7-1. FIGURE 7-1

LOCKING CONNECTORS

ALL CONNECTORS HAVE LOCKING TABS THAT MUST BE SQUEEZED TO RELEASE.

LVDS CONNECTOR

FIGURE 7-1LOCKING CONNECTORS

TVP-28 40

Chapter 7. Disassembly

Front Bezel (Screen Frame) RemovalSimilar to previous methods of removing a bezel to obtain access to the mirror and screen, remove all screws on the right, left and top edges marked with an arrow as shown in Figure 7-2. Once this is done, stand in front of the unit and slide the ornamental cover to the left and lift it away. Remove the 3 screws where the ornamental cover used to be and remove the screen assembly.

REMOVE 16 SCREWS MARKED WITH ARROWS SLIDE ORNAMENTAL COVER OFF AND REMOVE 3 SCREWS

FIGURE 7-2SCREEN FRAME REMOVAL

TVP-28 41


Separator CoverThis cover is secured by 5 screws. The speaker and HB board harnesses must be unplugged. Once this is done, lift up the small plastic tabs at the bottom of the assembly as illustrated in Figure 7-3. This will remove the cover along with the HB board and speakers.

FIGURE 7-3SEPARATOR COVER REMOVAL

UNPLUG HBE BOARD AND

SPEAKER CONNECTORS

REMOVE 8 SELF-TAP SCREWS INDICATED BY

LIFT PLASTIC TABS TO RELEASE ASSEMBLY

FIGURE 7-3SEPARATOR COVER REMOVAL

TVP-28 42


Lamp RemovalThe outer lamp cover is removed by releasing the 3 claws and removing from the rear cabinet as shown in Figure 7-4. The inner door is removed by sliding the latch towards the front of the unit and pulling it out of the chamber. Remove the lamp by unseating the high voltage connector and sliding it out.

FIGURE 7-4LAMP COVER AND LAMP REMOVAL

REMOVE OUTER DOOR BY RELEASING 3 LOCK CLIPS

SLIDE LAMP COVER DOOR LATCH IN DIRECTION OF

ARROW TO RELEASE.

PULL LAMP COVER FROM CHAMBER

PULL SLIGHTLY ON LAMP SOCKET TO UNSEAT IT AND PULL LAMP FROM

CHAMBER

FIGURE 7-4LAMP REMOVAL

TVP-28 43


Lamp Driver RemovalThe lamp driver (ballast) board can be removed without disassembling the cabinet. Remove the lamp door and lamp as shown in Figure 7-4. Inside the lamp chamber at the outer left side is a single screw securing a bracket. Remove this screw and bracket as illustrated in Figure 7-5. Reach behind the lamp socket and pull the plastic assembly towards you about ½”. This will release the assembly and it should easily come out of its retainer.

The lamp control and B+ cables will have enough slack to pull the assembly partially out of the chamber. Remove the cables from the integrated retaining hooks. In Figure 7-6, the remaining steps are shown for removal of the board. When installing the new board be certain the high voltage leads do not cross and are parallel as shown in the illustration.

TVP-28 44


FIGURE 7-5LAMP DRIVER REMOVAL (STEPS 1 THROUGH 3)

STEP 1 STEP 2

STEP 3

REMOVE SCREW AND PULL COVER

TOWARDS YOU

PULL LAMP DRIVER TOWARDS YOU UNTIL

IT STOPS

PULL LAMP DRIVER PARTIALLY OUT OF CHAMBER AND REMOVE CABLES FROM

PLASTIC HOOKS

FIGURE 7-5LAMP DRIVER REMOVAL (STEPS 1 ~ 3)

TVP-28 45


STEP 4

UNPLUG LAMP B+ AND CONTROL CABLES AND

REMOVE FROM CHAMBER

STEP 5

REMOVE 1 SCREW AND LAMP CONTROL

CONNECTOR

STEP 6

NOTE POSITION OF HV ANTENNA WHEN RE-

ASSEMBLING

LIFT LAMP DRIVER OFF AND REMOVE 1 SCREW TO

RELEASE LAMP SOCKET

FIGURE 7-5LAMP DRIVER REMOVAL (STEPS 4 ~ 6)

TVP-28 46


Optical Block RemovalThe lamp must be removed prior to this procedure. The optical block is secured by 2 screws along the bottom edge that must be removed as shown in Figure 7-7. Spring clips are used in conjunction with the screws to retain the assembly. Be certain not to lose these clips. Tension on the LVDS cable should also be released. This cable originates from the BE board, runs along the bottom of the chassis, and passes over the right side of the G board before plugging into the optical block. It is secured with a cable tie with the other wire harnesses on the G board and MUST be released to give some slack to the cable. Unplug the LVDS cable from the BE board and lay it over the lens to keep it out of the way and prevent it from snagging when removing the optical block.

Once the steps in figure 7-7 have been completed, release the wires routed along the back side of the optical block and carefully pull the assembly outward as illustrated in Figure 7-8. CN3750 can now be accessed for removal from the BE board.

The replacement optical block will not come with the LVDS or iris motor cables. Transfer the cables from the old assembly to the new one.

TVP-28 47


FIGURE 7-7OPTICAL BLOCK REMOVAL (STEP 1)

UNPLUG CN6009 AND CN6019

REMOVE 2 MACHINE SCREWS

AND SPRINGS

UNPLUG LVDS CONNECTOR


TVP-28 48


REMOVE WIRE HARNESSES FROM RETAINERS AT REAR OF

OPTICAL BLOCK

SWING OPTICAL BLOCK OUTWARD AND UNPLUG CN3750

FROM THE BE BOARD


TVP-28 49


Optical Block AdjustmentAn access cover located at the rear of the unit behind the optical block can be removed to expose mechancial adjustments to tilt or skew the optical block assembly if needed. Adjust the tilt to change vertical centering of the picture and the skew to remove keystone distortions.WARNING: Do not remove the Phillips screws unless the optical block is installed or the adjustment components will fall out.

FIGURE 7-8BOPTICAL BLOCK ADJUSTMENTS

REAR ACCESS PANEL REMOVED

SKEW ADJUSTTILT (CENTERING) ADJUST

REMOVE PHILLIPS SCREWS TO ADJUST. DO NOT REMOVE SCREWS IF

OPTICAL BLOCK IS OUT!

TVP-28 50


G board RemovalIn order to gain access to the BE block, chassis cooling fan and the U board the entire chassis must be removed from the unit. If only the G board needs replacement, it is not necessary to remove the entire chassis.

Remove the 6 screws and indicated connectors as shown in Figure 7-9. The board is then lifted out. These same screws will have to be removed if the chassis removed to gain access to the BE block for removal.

FIGURE 7-9G BOARD REMOVAL

CN6802

CN6804

CN6906 CN6802

CN6906

CN6009

CN6904CN6501

REMOVE 6 SCREWS

FIGURE 7-9G BOARD REMOVAL

TVP-28 51


Chassis RemovalRemove 2 screws securing the bottom of the chassis and one screw at the intake cover as illustrated in Figure 7-10. The intake cover must be removed before the chassis can be slid out. The 2 screws securing the upper portion of the chassis have internal retainers and cannot be pulled out so they must be completely loosened and left intact. Unplug all indicated connectors. The LVDS cable can be placed aside by laying it in front of the optical block to prevent it from getting snagged and damaging it while removing the chassis.

As shown in Figure 7-11, remove the cables from the purse lock and slide the vent cover rearward followed by the chassis assembly. Note the rail on the chassis and the slots on the vent cover. These must align when the cover in installed. If performed properly the vent cover will slide back and forth easily. There is a ground wire near that location going from the B block to the G board that may interfere since they are very close together. Simply manipulate the ground wire to clear the cover as it is slid into place.

Slide the chassis out and disconnect CN3750 from the BE board. If access to the BE board is required, the G Board must be removed. Remove the 6 screws securing the G board and lift it off the chassis.

TVP-28 52


FIGURE 7-10CHASSIS REMOVAL (STEP 1)

CN6501

CN2000CN2500 CN2501

CN6906

CN6802

CN6804

CN6009

CAREFULLY UNPLUG LVDS CONNECTOR AND LAY CABLE IN FRONT OF

OPTICAL BLOCK

REMOVE 3 SCREWS

LOOSEN 2 SCREWS. THEY

ARE HELD IN WITH RETAINING CLIPS


TVP-28 53



REMOVE VENT COVER BY SLIDING REARWARD. CHASSIS CAN NOW BE

REMOVED

REMOVE CABLES FROM PURSE LOCK

NOTE;WHEN RE-INSTALLING VENT

COVER ALIGN SLOT ON COVER WITH RAIL ON

CHASSIS. COVER MUST SLIDE ON EASILY


TVP-28 54


U Board RemovalIn order to gain access to the BE block for removal, the U board must be removed. Follow the steps in Figure 7-12 to accomplish this.

FIGURE 7-12U BOARD REMOVAL

USE FLAT-BLADE SCREWDRIVER TO

RELEASE CONNECTOR

REMOVE 3 SELF-TAP SCREWS

REMOVE MACHINE SCREWS

REMOVE NUT FROM RF

CONNECTOR

FIGURE 7-12U BOARD REMOVAL

TVP-28 55


BE Block RemovalReferring to Figure 7-13, the B block is secured to the chassis with one screw and two retaining claws. The replacement assembly will be supplied as a completely shielded unit minus the cooling fan. The fan must be transferred to the new assembly.

CN3008TO HB BOARD

CN3750IRIS MOTOR

REMOVE LABELED

CONNECTORS IF STILL INSTALLED

REMOVE SELF-TAP SCREW

CN3002TO G

BOARD

LIFT PLASTIC RETAINER TABS AND SLIDE

ASSEMBLY IN DIRECTION OF ARROWS. TRANSFER FAN TO NEW ASSEMBLY

FIGURE 7-13BE BLOCK REMOVAL

TVP-28 56


Exhaust Fan ReplacementIn order to gain access to the main exhaust fan, the entire lamp chamber must be removed. Begin by removing the lamp. Unplug the cables shown in Figure 7-14. The lamp chamber is secured to the cabinet with 3 screws along the lower edge. A plastic tab must be lifted as shown in the illustration to release the housing. Remove the lamp chamber from the television to gain access to the fan housing.

FIGURE 7-14LAMP CHAMBER REMOVAL

LIFT THIS CLIP UP TO RELEASE HOUSING

UNPLUG MAIN HARNESS AT CN6804

ON G BOARD

REMOVE 3 SCREWS

UNPLUG DOOR SWITCH, FAN AND THERMAL SENSOR

CONNECTORS

FIGURE 7-14LAMP CHAMBER REMOVAL

TVP-28 57


Referring to Figure 7-15, the fan housing halves are held together with 2 screws and 6 locking tabs. When lifting the tabs, do this with just enough force to disengage. These tabs are easily broken.

Once the housing halves are separated, remove the fan and be careful not to lose any of the 4 cushions located on each corner. They will need to be transferred to the replacement fan. Note the label side of the fan and install it the same way.

FIGURE 7-15EXHAUST FAN REMOVAL

CUSHIONS MUST BE TRANSFERRED

TO NEW FAN

CAREFULLY LIFT CLIPS ON BOTH SIDES TO

RELEASE COVER HALVES

FIGURE 7-15EXHAUST FAN REMOVAL

TVP-25 58

Appendix

Triage TroubleshootingGetting a unit repaired on a first visit is the key to maintaining low turn-around times and customer satisfaction. The primary way to accomplish this is to “triage” the unit before making the service call. This chapter contains triage worksheets to assist in determining what part (or parts) should be brought to the locations to increase the likelihood of a successful fist time repair. The worksheet is designed for technical or non-technical personnel.This chapter also contains troubleshooting flowcharts which are specifically designed for the technician. They are especially useful when multiple parts are brought to a location. It is much easier to make a few voltage and/or visual checks to determine which part is most likely to repair the problem. They will also become useful if a part is brought to the location but does not repair the problem. A few checks can be made to increase the likelihood that the correct part will be brought on the second visit.

Appendix

TVP-28 59

Sony KDF46E3000 Technical Triage Summary Sheet

1. Confirm the symptom from the customer.CHASSIS: LA52. Select that symptom from the chart.

3. Bring all the boards listed for that symptom.4. Follow the troubleshooting charts in the technical guides to isolate the board.5. Chart Color Code RED DOT: Most likely defective part BLUE Triangle: Possible defective part LAST UPDATED: 7/19/07 BLACK TEXT: Board and Part # that may correct the symptom7) The Troubleshooting Flowchart required to determine the actual defective part is listed for each column in the last row of each table.

Reference

Symptoms - Shutdown. Power LED blinking red diagnostics sequences

No Power Video - missing or distorted

2 3 4 5 6 7** 8 9

No Green Power LED (Dead Set)

Stationary colored lines or

dots

Analog Inputs Only

Video 2 0nly

No video all Inputs No Audio

Part #

BE BOARD N/A ▲ ▲ ▲ ▲ A-1310-234-AG BOARD ▲ N/A ▲ A-1244-397-AU BOARD N/A ▲ A-1243-786-A

HCE BOARD N/A A-1234-134-ASE BOARD N/A A-1283-525-ATE BOARD N/A A-1283-526-A

LAMP DRIVER N/A 8-597-056-00 OPTICAL BLOCK N/A ▲ A-1310-251-A

EXHAUST FAN N/A 8-835-860-31CHASSIS FAN N/A ▲ 1-787-333-21

LAMP F-93-0890-00THERMAL FUSE N/A 1-910-028-27

LVDS CABLE N/A ▲ 1-834-118-11

Flowchart Reference C1 C1 C1 C1 C1 C1 C1 B E D1 D1 D1 F

Problem POWER POWER LAMP DOOR TEMP AUDIO FAN

**IF TEMPERATURE ERROR OCCURS IMMEDIATELY, SUSPECT SE OR HCE BOARD. IF 2 TO 5 MINUTES AFTER TURN-ON

Appendix

TVP-28 60

Sony KDF50E3000 Technical Triage Summary Sheet

1. Confirm the symptom from the customer.CHASSIS: LA52. Select that symptom from the chart.

3. Bring all the boards listed for that symptom.4. Follow the troubleshooting charts in the technical guides to isolate the board.5. Chart Color Code RED DOT: Most likely defective part BLUE Triangle: Possible defective part LAST UPDATED: 7/19/07 BLACK TEXT: Board and Part # that may correct the symptom7) The Troubleshooting Flowchart required to determine the actual defective part is listed for each column in the last row of each table.

Reference

Symptoms - Shutdown. Power LED blinking red diagnostics sequences

No Power Video - missing or distorted

2 3 4 5 6 7** 8 9

No Green Power LED (Dead Set)

Stationary colored lines or

dots

Analog Inputs Only

Video 2 0nly

No video all Inputs No Audio

Part #

BE BOARD N/A ▲ ▲ ▲ A-1310-234-AG BOARD ▲ N/A ▲ A-1244-397-AU BOARD N/A ▲ ▲ A-1243-786-A

HCE BOARD N/A A-1234-134-ASE BOARD N/A A-1283-525-ATE BOARD N/A A-1283-526-A

LAMP DRIVER N/A 8-597-056-00 OPTICAL BLOCK N/A ▲ A-1310-249-A

EXHAUST FAN N/A 8-835-860-31CHASSIS FAN N/A ▲ 1-787-333-21

THERMAL FUSE N/A 1-910-028-27LAMP F-93-0890-00

LVDS CABLE N/A ▲ 1-834-118-11

Flowchart Reference C1 C1 C1 C1 C1 C1 C1 B E D1 D1 D1 F

Problem POWER POWER LAMP DOOR TEMP AUDIO FAN

Appendix

TVP-28 61

LA5 CHASSIS INITIAL CONTACT FLOWCHART A

Start

No

Yes

No

No

No

Yes

Yes

Yes

GO TOPower Supply

TroubleshootingFlowchart B

GO TOProtection Mode Troubleshooting

Flowchart C1

GO TONo Video

TroubleshootingFlowchart D1

GO TOVideo Distortion Troubleshooting

Flowchart E

GO TOAudio

TroubleshootingFlowchart F

Done

Power LED blinks green at

turn ON?

Is video distorted?

Is audio present?

A

Distorted

No

Yes

Is video present?

Does lamp LED blink red? Replace Lamp

Yes

No

Yes

No

Is red power LED Flashing?

Initial Contact Flowchart A

Appendix

TVP-28 62

Go To Protect Flowchart C1

No power

No

Yes

Yes

Thermal fusePower LED blinking 3X?

PWR LED blinking green ?

5VDC either side of thermal

fuse?

Yes

No

No

G Board

One side

B

Yes

5VDC both sides of

thermal fuse?

BE Board

G Board

3VDCCN6904-14G board?

No

Both Sides

G Board

BE Board

Relay clicks heard?

Yes

No

1 or 2 clicks?

1G board

Not power supply problem

2 Power LED blinking?

Yes

No

Initial Contact Troubleshooting Flowchart B

Appendix

TVP-28 63

Red Power LED Flashing

No

No

Yes

Yes

No

G Board2X

6XYes

8X

C1

3X Yes

5X

No

Lamp Cover LooseTE Board

U board

Yes

Low B+See Flowchart C-3 for


If failure occurs after running for awhile suspect ventilation issue. If it occurs at turn-on:

HCE or SE boardPossible BE board

Lamp Driver

7XYes

No

9XYes

Fan ErrorSee Flowchart C-2 for


No

Protect Mode Troubleshooting Flowchart C1

Appendix

TVP-28 64LA5 CHASSIS FAN ERROR FLOWCHART C2

9XFan Error

C2

Any fans rotating?

Yes

No

3.3VDC CN6904-12 G

Board?

BE Board

No

G boardYes

G Board

CN69061 - FAN1 DRIVE3 - FAN1 ERROR4 - FAN2 DRIVE (NOT USED)6 - FAN2 ERROR (NOT USED)7 - FAN3 DRIVE8 - FAN3 ERROR

CN68021 – FAN4 DRIVE2 – FAN4 ERROR

Any drive voltages missing?

Check fan drive and error line voltages at CN6906 on G Board **

Normal fan drive voltage : 5 to 7VDCNormal error voltage : 0.0VDC

Yes

No Any protect line > 0.2VDC?

No

BE Board

Replace affected fan

Yes


Appendix

TVP-28 65

LA5 CHASSIS LOW B+ ERROR FLOWCHART

3XLow B+ Error

C3

Any relay clicks heard?

Yes

No

5VDC present both pins of

thermal fuse?

Neither pin

G board

One pin

10.5VDC IC6002 -1 on G

board?

Yes

No

G board

BE board

Thermal Fuse


Appendix

TVP-28 66LA5 CHASSIS NO VIDEO FLOWCHART D1

No Video

No

Yes

Yes

No

LampLamp Driver

Optical Block

BE Board

BE boardLamp Lights?

Any OSD Graphics

Displayed?

Tuner only ?Yes

Analog inputs only?

U BoardBE BOARD

Yes

No

Yes

No

No

All Video Sources Affected?

See lamp troubleshooting flowchart D2

See OSD troubleshooting flowchart D3

HDMI inputs?Yes

BE Board

D1

No VideoTroubleshooting Flowchart D1

Appendix

TVP-28 67LA5 CHASSIS LAMP TROUBLESHOOTING

No Backlight

No

Replace lampDoes lamp LED light?

Backlighting seen on screen?

Yes

No

D2

At least160VDC across pin 1 and 3 of CN6501

on G board?

Look into main exhaust fan for

lit lamp.

Yes Video problemGo to D1

Lamp Lit ?

Yes

No

Mirror broken

Power LED blinking red

5X?

Yes

Lamp Driver Board

No

NoG Board

5VDC pin 2 and 2.8VDC pin 1 of

CN6804 G board?

Yes

BE BoardNo

Yes

Lamp Driver Board

Lamp Troubleshooting Flowchart D2

Appendix

TVP-28 68

No Video All Inputs

BE BoardInitial Service

Graphics Displayed?

No

D3

Enter Service Mode

Any OSD Graphics

Displayed?

No

Optical Block

Yes **QM service graphics?

Yes

**CE board graphics?

No

YesBE Board


No

Optical Block

Yes


NOTE: If no OSD graphics can be displayed but the lamp is lighting, check to make sure the LVDS cable from the BE Board going to the Optical Block is not loose or damaged at either end before deciding to replace the Optical Block. Replace if damaged .

** See “Service Mode” in this chapter for information regarding access to the various graphics and test patterns .

OSDTroubleshooting Flowchart D3

Appendix

TVP-28 69

Video Distortion

No

Distortion stationary?

Single or multiple lines of

same color?

Does Spot Move?

No

Push on top part of cabinet

to make screen move .

Dust on Rear of Screen.

Yes Dust in Optical Block or Pixels

Unlit

Darkor colored specks?

Yes

E

Tilt ortrapeziod distortion?

Upper cabinet or mirror distortion

All inputs affected?

QM Service graphics OK?

BE Board

No Panel service graphics OK ?

No

BE Board

Yes

Yes

NOTE: All signals are processed by BE Board .Analog signal distortions could be caused by U Board but is rare . Distortions occurring from front video inputs are probably due to faulty HCE Board.

Yes

Yes

Dark

Colored

Pixel Failure . Contact Technical

SupportNo

No

Yes

No

Check LVDS connectors at BU1 and Optical Block . If OK replace Optical Block

Optical Block

Video Distortion Troubleshooting Flowchart E

Appendix

TVP-28 70

AudioProblem

No

Yes

Yes

Audio Present ?

All Channels

Distorted

Yes

All inputs?

No

No

Internal Speakers

Turned Off ?

Turn Speakers On

Yes

No

Done

F

Yes

Tuner Only ?Yes

BE board

No

U board

No

Audio Troubleshooting Flowchart F

and i.Link are trademarks of Sony Electronics

2007 Sony Electornics, Inc.SEL Service Company

16530 Vill EsprilloNational Training Dept. MZ3215

San Diego, CA 92127Reproduction in whole or part without written permission is prohibited. All rights reserved

TVP280807 10/15/07

TVP28

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