Training Manual
KDL-40EX500
Models: AZ1K Chassis KDL-32EX301 KDL-32EX500 KDL-32EX400 KDL-40EX500 KDL-40EX400 KDL-40EX501 KDL-40EX401
Triage and Troubleshooting Guide Course: CTV-61
KDL-46EX400 KDL-46EX500 KDL-46EX501
Table of Contents Section 1 - AZ1K Chassis Models Overview ..................... 3
Normal Operation .............................................................. 12
AZ1K Chassis Models Covered....................................... 5 Model Introduction ........................................................... 5 AV Input & Output Descriptions ....................................... 5
Failure Symptoms .............................................................. 12 No Power/Dead Set (No RED Standby LED) .............. 12
HDMI/DVI Video Input and DVI Video ................................. 6
32” & 40” Power Supply System Block Diagram ........... 14 G2LE-Board & G2HE-Board Connector Diagram ......... 15 46” Power Supply System Block Diagram ..................... 16 GD2-Board Connector Diagram .................................... 17 Protection Mode Symptom Troubleshooting.................. 18
PC Video & Audio Input (and DVI Audio) ............................. 6
Failure Symptoms .............................................................. 18
USB 2.0 Side Connection - Photos & Music ........................ 6
2X Blink - Main Power Error ........................................ 18
Audio Outputs .................................................................. 7
3X Blink- Audio Error ................................................... 18
Fixed Analog Audio Output .................................................. 7
4X Blink - Balancer Failure (46” Models ONLY) .......... 19
Digital Audio Output (Optical) .............................................. 7
5X Blink - TCON & HFR Failure .................................. 19
32’” & 40” Models Overall PCB Block Diagram ............... 8 46” Models Overall PCB Block Diagram.......................... 9
6X Blink - Backlight System Failure (32” & 40” Models)19
PCB and Component Descriptions ................................ 10
7X Blink - Temperature Failure .................................... 20
RF Input ............................................................................... 5 Composite Video & Audio Inputs ......................................... 5 Component/Composite Video & Audio Inputs...................... 6
A-Board ............................................................................. 10 G2LE-Board (32") or G2HE-Board (40")............................ 10 GD2-Board (46") ................................................................ 10 Backlight Inverter Board (32" & 40") .................................. 10 H2-Board ........................................................................... 10 Switch Unit ......................................................................... 10
6X Blink - Backlight System Failure (46” Models) ........ 19
32” & 40” Models Protection Mode System Block Diagram 21 46” Models Protection Mode System Block Diagram .... 22 All Models Power Board Protection Circuits Block Diagram........................................................................... 23 Video Symptom Troubleshooting ................................... 24
LCD Panel Assembly ..........................................................11
Normal Operation .............................................................. 24
Section 2 - Troubleshooting Procedures ......................... 12 Power Symptom Troubleshooting.................................. 12
Missing or Distorted Video (Individual Inputs) ................... 24
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Troubleshooting ................................................................. 24 Missing Video (All Inputs) .................................................. 25
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Table of Contents
Skewing LVDS Connector Troubleshooting Method .... 25
chart ........................................................................... 35
Distorted Video (All Inputs) ................................................ 25
Protection Mode 6X(46”) & 7X Troubleshooting Flowchart 36 Video Troubleshooting Flowchart .................................. 37 Audio Troubleshooting Flowchart .................................. 38
WIDE Mode Button (Aspect Ratio) Troubleshooting Method ................................................................... 25 Unique Main Video Board (A-Board) or LVDS Cable Effects ....................................................................... 26 Unique TCON/HFR Board Effects ............................... 27 Unique LCD Panel Assembly Effects ........................... 27 Common Main Video Board (A-Board) and LCD Panel Assembly Effects ................................................... 27
Video System Block Diagram ........................................ 28 Audio Symptom Troubleshooting................................... 29 Normal Operation .............................................................. 29
Appendix............................................................................. 39 LCD Panel Distortion Pictures ....................................... 39 TCON/HFR Board Distortion Pictures ........................... 40 TCON/HFR Board Distortion Pictures Continued .......... 41 Video Board Distortion Pictures ..................................... 42 Video Board Distortion Pictures Continued ................... 43
Failure Symptoms .............................................................. 29 Missing or Distorted Main Speaker Audio - All Inputs .. 29 Missing or Distorted Main Speaker Audio - Individual Inputs ..................................................................... 29
Audio System Block Diagram ........................................ 30 Section 3 - Service Mode .................................................. 31 Service Mode Access .................................................... 31 Section 4 - Triage & Troubleshooting Flowcharts .......... 32 Triage Flowchart ............................................................ 32 Power-ON Troubleshooting Flowchart........................... 33 Protection Mode 2X, 3X, & 4X Troubleshooting Flowchart 34 Protection Mode 5X & 6X(32”, 40”) Troubleshooting FlowCTV-61
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Section 1 - AZ1K Chassis Models Overview
TCON Board
Backlight Inverter Board
G2LE-Board (32") G2HE-Board (40")
LVDS Cable
A-Board
Switch Unit
H2-Board
32" & 40" Models
32” & 40” OVERALL PCB LOCATION DIAGRAM FIGURE 1-1 CTV-61
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AZ1K Chassis Models Overview
TCON Board
Balancer Board
LVDS Cable
GD2-Board
A-Board Switch Unit H2-Board
46" Models
46” OVERALL PCB LOCATION DIAGRAM FIGURE 1-2 CTV-61
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AZ1K Chassis Models Overview
AZ1K Chassis Models Covered KDL-32EX301
KDL-32EX500
KDL-46EX400
KDL-32EX400
KDL-32EX501
KDL-46EX500
KDL-40EX400
KDL-40EX500
KDL-46EX501
KDL-40EX401
KDL-40EX501
AV Input & Output Descriptions USB
Composite
Model Introduction
All models, except the KDL-32EX301, contain a Full High-Definition 1920 X 1080 resolution panel. The KDL-32EX301 contains a 1280 X 720 resolution panel. The backlight is produced using a Cold Cathode Fluorescent Lamp (CCFL) light system for all models. All models have the Advanced Contrast Enhancer (ACE) feature and Dynamic Backlighting. The Dynamic Contrast Ratio (DCR) for the 400 series is 140,000:1 and for the 500 series it is 2150,00:1. All models contain the BRAVIA Engine™ 2 digital video processor for superior resolution. Plus, 7 HD inputs (4 HDMI™, 2 component and 1 PC) are provided to connect all of your HD devices including PLAYSTATION®3, Blu-ray Disc™ player and laptop or desktop.
HDMI Input
HDMI Input
Component/Composite Input Component Input PC Input
Digital Audio Output (Optical)
The BRAVIA Engine 2 fully digital video processor uses a collection of unique Sony technologies to significantly reduce noise, enhance overall image detail, and optimize contrast so every scene produces sharp, vibrant, life-like images and color. The EX500 series models contain the Motionflow™ 120Hz frame rate technology which enhances sharpness and delivers smooth motion for fast-action sports and movies. The EX300 and EX400 series models contain the standard 60Hz frame rate. Sony® HDTVs exceed Energy Star 3.0 requirements. In addition, they incorporate advanced power saving features such as Light Sensor® technology that adjusts backlight intensity based on ambient room lighting conditions and Dynamic Backlight Control that adjusts backlight intensity based on the brightness of the image on the screen.
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PC & DVI Audio Input
RF Input
HDMI/DVI Input
Analog Audio Output (FIXED)
HDMI Input
RF Input This is a 75 ohm connection for either terrestrial NTSC and ATSC (8VSB) or cable QAM64 and QAM256 signals.
Composite Video & Audio Inputs Yellow Jack - Composite Video Input Red & White Jacks - Right & Left Audio Input NOTE: The second composite input is shared with one of the component inputs. Reference the description of the component inputs for details on activating the composite input.
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AZ1K Chassis Models Overview
Component/Composite Video & Audio Inputs
HDMI/DVI Video Input and DVI Video
Red, Blue, & Green Jacks - Component Video Inputs
Both the HDMI and DVI formats contain digital video. In the case of the HDMI format the audio is also digital and is part of the video and audio data stream over the single HDMI connection. In contrast, the DVI format contains only digital video in its data stream. The audio is sent over a separate Stereo Mini Jack audio connection. Furthermore, a DVI to HDMI adapter is required to connect the DVI connector to the HDMI connector.
Red & White Jacks - Right & Left Audio Input NOTE: Composite video can be applied to the component input label “VIDEO IN”. The yellow composite video connector is connected to the green component connector. The audio is connected to the same component audio inputs. IMPORTANT: For automatic signal detection make sure the User Menu item is set to “AUTO. “ Reference the below for the specific menu item. The input can also locked to Video 1 (composite) or Component 1 (component) signal. However, the input will only process the chosen signal type. If the other signal type is connected the picture will be lost or black & white.
PC Video & Audio Input (and DVI Audio) All EX models have a Personal Computer Input (PC-IN), which connects directly to the PC 15 pin DIN connector (HD15 connector). Once connected the TV functions as a video monitor and audio output (separate Stereo Mini Plug) for the PC audio. There is a complete table of PC Input Signal Compatibility in the Owners Manual for each model. The Stereo Mini Plug is also used for a DVI audio connection at HDMI 1 video input. The DVI video is connected through an adapter to HDMI 1 input and the DVI audio to connected to the Stereo Mini Jack.
Select the appropriate input for the input signal type. Auto – Auto Detection Video 1 – Composite Component 1 - Component
USB 2.0 Side Connection - Photos & Music Connect a camera, USB-Enabled MP3 player, or USB storage device directly to this side USB input to view JPG photos and MPEG1 & MPEG2 videos on the screen or listen to MP3 music files. This USB connection is also used for TV Software updates using a USB drive device.
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AZ1K Chassis Models Overview
Audio Outputs Fixed Analog Audio Output This audio output can be used to listen to the TV audio through an external AV stereo system. The audio level at the output is set to a fixed level and cannot be turned off or adjusted.
Digital Audio Output (Optical) Connects to the optical audio input of any digital audio equipment that is PCM/Dolby digital compatible. The following table shows the audio inputs and the audio format which are present at the Optical Audio Output per input format.
Audio Input Source Digital Tuner 5.1 (ATSC) HDMI 5.1 All Analog Audio Inputs Analog Tuner (NTSC) SACD Format (HDMI) DVD Audio Format (HDMI)
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Optical Output 5.1 Dolby 5.1 Dolby 2CH PCM 2CH PCM No Output No Output
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AZ1K Chassis Models Overview
32’” & 40” Models Overall PCB Block Diagram Switch Unit
Power Key Function Keys
LEDs IR Sensor
H2-Board
A-Board
Keys
Power/ SIRCS
Optical Digital Audio Output
Analog Audio Output
RF Input
1 Composite Input 2 Component Inputs (Composite can be applied to Component 1) 1 PC Input
3 HDMI Inputs
1 USB 2.0
TV Microprocessor MT5388: Video Processing HDMI Processing HDCP Processing IP (Image Processor) Scan Converter (Scalar) HDMI Switcher ATSC/NTSC Tuner Temperature Sensor Audio Output Amplifier
R L *High Frame Rate (120HZ)
LCD Panel Assembly LVDS
Power
TCON/HFR
LCD Panel
G2LE-Board (32") G2HE-Board (40")
LCD PANEL
Control
Power
AC Input
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Main Power Supply Standby Power Supply
Power
Backlight Inverter Board Control
Power
CCFL Backlight HV Inverter Circuits Backlight System Error Circuits
Power/Drive
CCFL Backlight System
32” & 40” OVERALL PCB BLOCK DIAGRAM FIGURE 1-3 8
AZ1K Chassis Models Overview
46” Models Overall PCB Block Diagram Switch Unit
Power Key Function Keys
LEDs IR Sensor
H2-Board
A-Board
Keys
Power/ SIRCS Optical Digital Audio Output
RF Input
Analog Audio Output
1 Composite Input 2 Component Inputs (Composite can be applied to Component 1) 1 PC Input
3 HDMI Inputs 1 USB 2.0
TV Microprocessor MT5388: Video Processing HDMI Processing HDCP Processing IP (Image Processor) Scan Converter (Scalar) HDMI Switcher ATSC/NTSC Tuner Temperature Sensor Audio Output Amplifier
R L *High Frame Rate (120HZ)
LCD Panel Assembly LVDS Power
TCON/HFR
LCD Panel
GD2-Board
LCD PANEL
Control Power
AC Input
Main Power Supply Standby Power Supply AC Relay Backlight HV Inverter Circuits
Power
Control HV
HV
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Power/Drive
Balancer Board
CCFL Backlight System
46” OVERALL PCB BLOCK DIAGRAM FIGURE 1-4 9
AZ1K Chassis Models Overview
PCB and Component Descriptions Reference Figures 1-3
A-Board The circuits located on the A-Board perform all Video and Audio processing functions. It also contains all the microprocessor control circuits. The following circuits are included on this board. • TV Microprocessor
GD2-Board (46") Except for some regulator circuits on the A-Board, the GD2-Board is the power supply system board for the 46” models, which includes the following components and circuits. •
o •
• MT5388 Processor
AU12V (Audio Amp)
o
3.3V for standby circuits
Standby Power Supply
•
Backlight High Voltage Inverter Power Supply
•
- Scan Converter
Main/Inrush AC Input Relay
•
Power Factor Control Circuit (PFC)
• Audio Amplifier
Backlight Inverter Board (32" & 40")
• Temperature Sensor
The 24V developed in the Main Power Supply on the G2LE-Board or G2HE-Board powers the Backlight Inverter Board. The Inverter Board takes that 24V and develops approximately 2KVrms to initially ignite the lamps and 1KVrms to drive the backlight Cold-Cathode-Fluorescent Lamps (CCFL) in normal operation.
Except for some regulator circuits on the A-Board, the G2LE-Board or G2HE-Board is the power supply system board for the 32” and 40” models, which includes the following components and circuits. Main Power Supply •
12V
•
AU12V (Audio Amp)
•
24V (Backlight Inverter)
Standby Power Supply •
•
o
- HDMI Signal Processing
G2LE-Board (32") or G2HE-Board (40")
•
12V
- Video Signal Processing
- HDCP Processing
•
Main Power Supply
3.3V for standby circuits
H2-Board •
IR Sensor
Switch Unit •
Power Key
•
Function Keys
Power Factor Control Circuit (PFC)
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AZ1K Chassis Models Overview
LCD Panel Assembly The LCD Panel Assembly includes the LCD Panel, TCON Board (300 & 400 series models), TCON/HFR Board (500 series models), and CCFL Backlight system. The LCD Panel contains the actual liquid crystals, color filters, and polarizers. The liquid crystals are manipulated by the applied voltage to pass a specific amount of light - from the backlight- depending on the level of voltage applied. The TCON performs all the control, timing, charge, and discharge functions driving the operation of the LCD Panel. The HFR (High Frame Rate) section performs the 60Hz to 120Hz frame refresh rate conversion. A replacement LCD Panel assembly from parts will include the following items. 32” & 40” Models: 1) LCD Panel and Backlighting Components 2) TCON/HFR Board 3) Inverter Board 46” Models: 1) LCD Panel and Backlighting Components 2) TCON/HFR Board 3) Balancer Board
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Section 2 - Troubleshooting Procedures Power Symptom Troubleshooting Normal Operation
Failure Symptoms Reference Figures 2-1, 2-2, 2-3, and 2-4
Reference Figure 2-1 and 2-2
No Power/Dead Set (No RED Standby LED)
110VAC is applied to the G2LE-Board, G2HE-Board, or GD2-Board it can be measured at CN6101 or CN6003. In the standby mode the AC power passes through the main fuse F6101 or F6001. The is no main relay on the G2LE & G2HE-Board so the AC power is applied directly to the Main & Standby Power supply. The GD2-Board does have a Main AC Relay. The AC power passes through R6003 (Inrush resistor), and D6001 and is applied to the Main DC/DC Converter IC6501 and the Standby DC/DC Converter IC6201. IC6501 is not active in the standby mode. However, IC6201 is active in standby mode and outputs STBY 3.3Vdc as long as AC power is applied to the TV. The Standby 3.3Vdc is supplied to the TVMicroprocessor, Switch Unit (Power Key), and HSR-Board (IR Sensor) in the standby mode.
In a dead set condition there will be No RED Standby LED illumination in the Standby Mode (TV plugged into an active AC Outlet).
Once a ON command is received form the remote controller or the power button on the Switch Unit the TV-Microprocessor outputs the Power-ON signal. The Power-On signal is applied to the G2LE-Board, G2LE-Board, or GD2-Board. On the power supply board the Power-On signal switches the 19V from the standby power supply to activate the PFC and Main Power supply IC6501. No relay click will be heard on the 32” or 40” models because there is not a main relay. However, on the 46” models there is a main relay and one relay click is heard at power-on. The relay engages to bypass the inrush resistor R6003 during the ON state.
The first step in troubleshooting a “No Power/Dead Set” condition is to confirm that 110ACV power from an active AC outlet is applied to the G2LE-Board, G2LE-Baord, or GD2-Board. AC power is applied to, and can be measured at CN6101 on the G2BE-Board or G2CE-Board and at CN6003 on the GD2-Board.
The main power supply IC6501 is now active and outputting all secondary supplies. The 12Vdc secondary is the supply voltage for all the voltage regulators on the A-Board. The AU12V is the supply voltage for the audio output amplifier. The 32” and 40” models power supply will also output 24V which is the supply voltage for the backlight inverter board. The GD2-Board in the 46” models will develop and output the backlight high-voltage (1KV) to the Balancer board and the CCFL backlights.
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The following bullet list gives the possible failures for a “No Power/Dead Set” condition. • Loss of AC Power • Loss of AC-OFF-DET • Loss of Standby 3.3Vdc • Loss of REG12V • Loss of Power-On • Defective Main Microprocessor
Next, check for the presence of the AC-OFF-DET voltage at CN6401/pin 2 or CN6150/pin 2. If the AC-OFF-DET circuit is working properly 3V should be measured. If the 3V is not present replace the G2BE-Board, G2CEBoard, or GD2-Board. If the 3V in not present either the main fuse or the main power supply IC6501 is defective. In either case, replace the power supply board. After confirming the AC power and AC-OFF-DET, check for a defective Standby 3.3Vdc power supply IC6201. To confirm a defective IC6201 check the 3.3V secondary voltage at CN6401/pin 1 or CN6150/pin 1. As long as AC power is applied to the TV IC6201 should be active and outputting 3.3Vdc. If the 3.3V is not present then IC6201 is defective. Replacing the power supply board will fix the problem.
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AZ1K Chassis Models Overview Finally, a “Dead Set” condition can be caused by a defective microprocessor IC400. The microprocessor outputs the Power-On signal which activates the switch Q6301 and IC6301 on the power supply board and passes the 19V from the Standby power supply to active the relay (46” models), PFC, and Main Power Supply IC6501. If the Power-On signal is not output after receiving the Power-ON command the power supply board circuits remain inactive and a “Dead Set” condition exists. The Power-On signal can be checked at CN6401/pin 3 or CN6150/pin 3. It should measure approximately 3.3Vdc If the measurement is 0Vdc before shut-off the TV microprocessor is defective. Replace the A-Board. If the power-on voltage is 3V before shutdown then the switch circuit on the power supply board is defective. Replace the power supply board.
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AZ1K Chassis Models Overview
32” & 40” Power Supply System Block Diagram G2LE-Board (32") G2HE-Board (40")
CN6402 24V
IC6301 Main Power Supply & PFC CN6101
F6101
D6301
R6342 D6308 0.1ohm
TH6301 L6302
Q6302 Q6303
CN6401
AU12V
R6302
L6303
4
4
CN201 F1
12V
14
12V
AC_DET
10
9
9
8
IC266 5V Reg
5V
IC231 5V Reg
5V
PS6401
To Tuner
CN6403 12V
To USB To Optical Out
Q6403
12V
3V
15
3
3
1
1
2
2
TCON ON
STBY 3.3V
3V CN6401
IC267 3V Reg
IC268 1.25V Reg
IC269 1V Reg
To Micro
To Micro To DDR
HFR on EX500 Series Only
A-Board
Power ON
EX500 Series ONLY EX400 Series No Connection
19V IC902 Standby 3.3V Power Supply
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TCON 12V
2
To CN6401 3V 15 PH6103
Panel 12V
1
TCON/ HFR
CN201
To Micro
ON/OFF
R6107 10ohm
LVDS Cable
IC232 1V Reg
19V
LCD Panel
LVDS 12V
AC_DET
Switch Circuit Q6101 Q6102
CCFL Backlights
LCD PANEL
IC8301 Line Out Amp
From Q6403
PFC_OUT
VCC
1.1KV (~2KV Strike Voltage)
IC8151 Audio Output Amp
PS6402
VSense D6302
3
A-Board
Q6304
AC Input
LCD Panel Assembly
Backlight HV Inverter Board
IC400 MT5388
AC-OFF-DET
32” & 40” POWER SUPPLY SYSTEM DIAGRAM FIGURE 2-1 14
AZ1K Chassis Models Overview
G2LE-Board & G2HE-Board Connector Diagram 1 – UNREG24V 2 – UNREG24V 3 – UNREG24V 4 – UNREG24V 5 – UNREG24V 6 – Ground 7 – Ground 8 – Ground 9 – Ground 10 – Ground 11 – BL-ERR 12 – BL-ON 13 – NC 14 - Dimmer
CN6402
CN6401
15 – TCON-ON 14 – TCON 12V 13 – NC 12 – DIMMER 11 – BL-ON 10 – BL-ERR 9 – REG12V 8 – REG12V 7 – Ground 6 – Ground 5 – Ground 4 – AU12V 3 – POWER -ON (3V) 2 – AC-OFF-DET (3V) 1 – STBY 3.3V
G2LE-Board (32") G2HE-Board (40")
F1
AC Input CN6101
G2LE-BOARD & G2HE-BOARD CONNECTOR DIAGAM FIGURE 2-2 CTV-61
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AZ1K Chassis Models Overview
46” Power Supply System Block Diagram GD2-Board
LCD Panel Assembly
CN6704 HV
Backlight Inverter High Voltage Circuits IC6601 Q6601 Q6602 19V
1.1KV (~2KV Strike Voltage)
Balancer Board
HV CN6705
400V
LCD PANEL
A-Board CN6150
R6003 CN6003
D6001
F6001
R6536 L6501 D6502 0.1ohm Q6502
AC Input
RY6002
AU12V
IC6501 Main Power Supply & PFC
R6013
R6301
4
4
CN201 F1
IC8151 Audio Output Amp
12V
14
10
From Q6151
PFC_OUT
12V
AC_DET
9
9
8
IC266 5V Reg
5V
IC231 5V Reg
5V
To Tuner
PS6151
To USB To Optical Out
To Micro
19V
Q6151
R6201 10ohm
CN6151 12V
To CN6150 3V 15 PH6300
3V
15
3
3
1
1
2
2
TCON ON
IC267 3V Reg
IC268 1.25V Reg
IC269 1V Reg
To Micro
To Micro To DDR
A-Board
Power ON
19V IC6201 Standby 3.3V Power Supply
STBY 3.3V
3V CN6150
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TCON 12V
2
TCON/ HFR
CN201
IC232 1V Reg
ON/OFF
Switch Circuit IC6301 Q6301
LVDS Cable
LVDS 12V
AC_DET
VCC
LCD Panel
IC8301 Line Out Amp
VSense D6002
CCFL Backlights
IC400 MT5388
AC-OFF-DET
46” POWER SUPPLY SYSTEM DIAGRAM FIGURE 2-3 16
AZ1K Chassis Models Overview
GD2-Board Connector Diagram HV 1.1KV HV 1.1KV
5 - LD 4 – Ground 3 – Ground 2 – FB 1 – 12V
CN6704
CN6705
CN6151 CN6158
CN6150
GD2-Board
6 - NC 5 - Ground 4 – Ground 3 – TCON 12V 2 – TCON 12V 1 – NC
15 – TCON-ON 14 – TCON 12V 13 – NC 12 – DIMMER 11 – BL-ON 10 – BL-ERR 9 – REG12V 8 – REG12V 7 – Ground 6 – Ground 5 – Ground 4 – AU12V 3 – POWER -ON (3V) 2 – AC-OFF-DET (3V) 1 – STBY 3.3V
AC Relay
F6001
CN6003 AC Input
GD2-BOARD CONNECTOR DIAGAM FIGURE 2-4 CTV-61
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AZ1K Chassis Models Overview
Protection Mode Symptom Troubleshooting
• Excessive 24V Level (OVP) (32” & 40” models)
Reference Figures 2-5 and 2-6
• Excessive PFC Voltage (OVP)
The KDL-32S5100 and KDL-32XBR9 include the following protection mode blink patterns (or self-diagnostics).
• Excessive PFC Temperature (OTP)
Protect Description
Blink Pattern
Main Power Error
2
Audio Error
3
Balancer Error (46” Only)
4
TCON Error
5
HFR Error
5
Backlight Error
6
Temperature Error
7
Possible Error Location G2LE, G2HE, GD2Board, or A-Board A-Board or G2LE, G2HE, GD2-Board LCD Panel, A-Board, or GD2-Board TCON/HFR Board or A-Board TCON/HFR Board or A-Board Inverter Board (32”, 40”), G2LE, G2HE, GD2-Board, LCD Panel, or A-Board Ventilation or A-Board
NOTE: All red protection mode LED blink patterns occur using the Standby-LED at the lower left front of the TV.
Failure Symptoms 2X Blink - Main Power Error A 2X protection mode blink pattern can be activated due one of the following defects on the G2LE-Board, G2HE, GD2-Board.. • Loss of AU12V (LVP)* • Excessive AU12V Level (OVP)*
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*Low Voltage Protection (LVP) *Over Voltage Protection (OVP) A loss or excessive condition of the AU12Vdc secondary voltage from the main power supply IC6501 will cause a 2X blink pattern on the StandbyLED. The 12Vdc can be checked at CN6401/pin 4. The If the measurement is 0V or rises above 12Vdc (approaches 15V) before the TV shutdown the G2LE-Board, G2LE, GD2-Board is defective. If approximately 12Vdc is present and remains below 12Vdc before shutoff then the A-Board is defective. An excessive 24Vdc (32” & 40” models) secondary voltage from the main power supply IC6501 will also cause a 2X blink pattern on the StandbyLED. The 24Vdc can be measured at CN6402/pin 3 before TV shutdown. If the voltage rises above the 24V level (approaches 27) before TV shutdown then the power supply is defective, replace the G2LE, G2HE , GD2-Board to fix the problem. Finally, there are PFC protection circuits on the power supply board that when activated will cause a 2X blink protection mode (reference Figure 27). The PFC circuit is monitor for both over-voltage and over-temperature. Therefore, if the AU12V and 24V circuits checkout okay, there could still be a problem on the power supply board in the PFC circuit causing the 2X blink. Replace the G2LE, G2HE, GD2-Board to fix this condition.
3X Blink- Audio Error The Audio error can occur due one of the following error conditions. • Shorted or Damaged Speaker Connections • Defective Audio Amplifier (A-Board) • Loss of AU12V (Open F1 on A-Board) The first thing to check when a 3X blink protection mode occurs is the physical condition of the speakers and speaker connections. The speakers
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AZ1K Chassis Models Overview should measure 8 ohms. Shorted speakers or connections can cause a 3X blink protection mode.
•
Defective Panel Lamp(s)
If the speakers and connections check okay, then the defective component is on the A-Board. Either a open F1 or defective audio amplifier will cause a 3X blink protection mode. In either case, replace the A-Board to fix this condition.
•
Defective Backlight Inverter Board
•
Defective TV Microprocessor
•
Defective 24V Power Supply
4X Blink - Balancer Failure (46” Models ONLY) In most cases, a 4X protection mode indicates a defective lamp or lamps. Therefore, replace the LCD panel to fix this condition. If the 4X protection is still present after replacing the LCD panel, there could be a problem on the A-Board or GD2-Board. First replace the A-Board then the GD2Board.
5X Blink - TCON & HFR Failure The 5X blink protection mode indicates a communications error between the TCON/HFR board and the MT5388 microprocessor on the A-Board. First replace the TCON/HFR Board if the 5X protection mode blink pattern occurs. If the TCON/HFR Board does not repair the problem then replace the A-Board.
6X Blink - Backlight System Failure (32” & 40” Models) NOTE: All models will make three attempts to power up before a 6X error is activated. The SONY logo (Backlight) will display on the screen and the tones (with Volume up) will be heard three times. After the third attempt the TV will turn off and the Standby LED will blink a 3X protection mode. In most cases, if the backlight momentarily illuminates and the TV shuts off and a 6X is activated than one or more of the backlight lamps are defective. The LCD Panel assembly panel must be replaced for a defective lamp. If a 6X blink pattern is activated than a defect has occurred in one of the following areas.
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When troubleshooting a 6X backlight system failure it is key to notice if the backlights illuminate before the TV shuts off. The following list shows the possible backlight status and blink pattern and the possible failed components. 1) Momentary Backlight and 6X a) Defective Lamp(s) b) Defective Backlight Inverter Board 2) No Backlight and 6X a) Defective TV Microprocessor b) Defective 24V Power Supply c) Defective Backlight Inverter Board IMPORTANT: Before replacing the LCD Panel assembly check the backlight Inverter Board outputs. A failure of one of the inverter outputs will also cause this same symptom (Momentary Backlight & 6X). If there is no backlight before the TV shuts off and activates a 6X, than check the “Backlight ON” signal from the TV microprocessor and the 24V power supply from the G2LE, G2HE, GD2-Board. If the “Backlight ON” and 24V power supply are okay than the Backlight Inverter board has failed and must be replaced. This will be a rare occurrence but the Inverter board can cause a “No Backlight” condition and must be considered.
6X Blink - Backlight System Failure (46” Models) The 46” models have both a 4X and 6X blink protection mode. The 4X blink will, in most cases, be caused by a defective lamp. Because all the Backlight HV Inverter circuits are located on the GD2Board, a 6X blink protection mode will be fixed, in most cases, by replacing the GD2-Board. If the GD2-Board does not repair the problem replace the A-Board. The BL-ON and Dimmer signals come from the
19
AZ1K Chassis Models Overview microprocessor on the A-Board. A shorted or open BL-ON signal will cause this 3X condition. Also a shorted Dimmer will cause this 3X condition.
failed.
7X Blink - Temperature Failure
In either case the A-Board must be replaced to fix the problem.
•
Main Microprocessor IC3002 (A-Board)
•
Temperature Sensor IC3502 (A-Board)
These models do not display a temperature warning OSD dialogue box before shutting-off and going into a 7X Standby-LED blink pattern. It will just shut-off and activate a 7X without any usually warning on the screen. The main objective when a 7X blink pattern occurs is to determine which of the following possible defects is causing the excessive temperature condition. •
Excessive Ambient Room Temperature
•
Dust or Debris Blocking the TV Ventilation Apertures
•
Defective Temperature Sensor microprocessor (A-Board)
IC4305
or
MT5388
The first step is to notice how long it takes the TV to shut-off and trigger a 7X blink protection mode. If the TV has an actual excessive temperature condition it will take a considerable period of time to shut-off and indicate a 7X blink protection mode. This is because it will take time for the TV to heat up and for the temperature sensor to detect the excessive temperature and shut the TV off If the TV takes a considerable period of time to shut-off check the following items: •
The TV should not be located too close to any heating elements.
•
The TV should have at least 4 inches of clearance around all sides to ensure adequate ventilation.
•
Check that all vented areas on the TV are clear of all Dust and Debris.
If the TV shuts-off immediately (Not an Actual Excessive Temperature Condition) after Power-ON then one of the following components has
CTV-61
20
AZ1K Chassis Models Overview
32” & 40” Models Protection Mode System Block Diagram
AC Input
A-Board
G2LE-Board (32") G2HE-Board (40") CN6000
CN6401
Main PS & PFC
RECT RECT
12V
CN201
8
24V
3V
Interface Circuit
9
DC_Detect
2X
3
IC400 MTK5388
CN6402
CN6401
STBY PS SW
1
1
3.3V
3
3
3V
1V to 3V 3V 0V
13 12 11
Protection Circuit Q8153, Q8155 Q8158, Q8160, Q8156
HV Inverter Board CN001 24V 6 Dimmer 1 BL_ON 2 BL_ERR 3
Standby 3.3V
Power ON Dimmer BL_ON BL_ERR
IC4305 Temp Sensor 70C
INV_ERR
6X
Temp_ERR
7X
Audio_ERR
3X
IC8151 Audio Amp LCD Panel Assb
CN8151 CN8152
CN4152
Backlight Inverter High Voltage Corcuits
TCON BL*
SDA (I2C)
HFR
TCON_ERR
5X
HFR_ERR
5X
*BL - Backlight
PROTECTION CIRCUITS DIAGRAM FIGURE 2-5 CTV-61
21
AZ1K Chassis Models Overview
46” Models Protection Mode System Block Diagram
A-Board
GD2-Board
AC Input
CN6003
Main PS & PFC
RECT
RECT
CN6150
12V
CN201
SW
1
1
3
3
Power ON
1V to 3V 3V 0V
Protection Circuit Q8153, Q8155 Q8158, Q8160, Q8156 CN6150
LCD Panel Assb
LD 12V CN6702
Dimmer BL_ON BL_ERR IC4305 Temp Sensor 70C
BL_ERR
4X & 6X
Temp_ERR
7X
Audio_ERR
3X
IC8151 Audio Amp
Dimmer 12 BL_ON 11 BL_ERR 10
FB
Standby 3.3V
3V
CN1004
HV
2X
3.3V
13 12 11
HV
DC_Detect
IC400 MTK5388
STBY PS
Backlight Inverter High Voltage Circuits
3V
Interface Circuit
9
8
B A L A N C E R
CN8151 CN8152
CN4152
TCON
BL*
SDA (I2C)
HFR
TCON_ERR
5X
HFR_ERR
5X
*BL - Backlight
PROTECTION CIRCUITS DIAGRAM FIGURE 2-6 CTV-61
22
AZ1K Chassis Models Overview
All Models Power Board Protection Circuits Block Diagram
G2LE-Board (32") G2HE-Board (40") GD2-Board (46")
CN6101
CN6402
Reg 24V
D6301
AC Input
32" 40" Models ONLY
IC6301 Reg 12V Main Power Supply & PFC
PFC OVP D6302
OTP
PFC OTP
3
9
30V Zener 24V OVP
To Inverter Board
To A-Board
G2HE-Board & G2LE-Board Protection circuits will cause a 2X blink pattern
15V Zener 12V OVP
Latch Circuit Q6202, 6203
19V
Switch Circuit Q6101, 6102
3V
Pulls Power_ON Low
CN6401
3
Power-ON From A-Board
OVP – Over Voltage Protection OTP – Over Temperature Protection
PROTECTION CIRCUITS DIAGRAM FIGURE 2-7 CTV-61
23
AZ1K Chassis Models Overview
Video Symptom Troubleshooting Reference Figure 1-8
Normal Operation All video processing is performed by IC400 (MT5388) on the A-Board. The RF input is first processed by the RF Tuner and is then applied to IC400. Both the ATSC and NTSC signal are processed by IC400. All four HDMI inputs are first applied to a HDMI switch circuit (IC6601). The switch circuit applies the selected input to IC400. IC6601 also contains the EDID (Extended Display Identification Data), which is part of the HDMI handshake process. All other inputs (Composite, Component, PC, and USB) are connected directly to IC400 inputs. The USER, White Balance, and Gamma data is stored in IC4302. Both the USER Menu and Service Mode screen are generated by, and output from IC400. IMPORTANT: 1) Confirm the TV has the most recent Software Version installed. Go to the User Menu for the present TV software revision and the ASC web site for the most recent software version. 2) Before proceeding with the following video troubleshooting procedures it is assumed that the TV is turning on with the Green Power-LED illuminated, Backlight is illuminated (brightened raster), and the Audio is present.
Troubleshooting When a video problem occurs you will experience one of the two following symptoms. Input Status: •
Missing or Distorted Video (Individual Inputs)
•
Missing or Distorted Video (All Inputs)
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Video Anomaly: •
Poor Detail
•
Moving Video Distortion (e.g. Bars)
•
Static H/V Lines (Any Color)
•
Static Missing Pixels (Any Color)
•
Static Bars (Solid Black or White, Transparent Color)
•
White Balance
•
Gamma
The main objective when troubleshooting one of the previously listed symptoms is to determine if the defect exists in the following sections of the TV system. •
LCD Panel Assembly
•
TCON/HFR Board
•
A-Board
Missing or Distorted Video (Individual Inputs) The primary objective is to locate the defective component through activating each individual video input and checking for any abnormal symptoms on the screen. If the video distortion appears only in one or two video inputs then the next step is to eliminate the possibility of a defective or improperly connected external device such as, a STB, DVR or DVD player. The quickest way to troubleshooting the external devices is to swap the suspect device with a known good device at the input in question. If the external device or connections are defective then the TV is okay and the external device and connections need to be serviced. If the external devices and their connections are okay, then the next step is to troubleshoot the problem by accessing and displaying each video input. The rationale behind this troubleshooting method is that each of these video inputs takes an altogether or somewhat different path through the video processing system. This fact enables you to determine the defect,
24
AZ1K Chassis Models Overview in some cases, down to the component level, and in almost all cases, down to at least the board level. For example, if the distortion appears in a HDMI input but not in any other inputs (e.g. composite or component) then most likely the HDMI Switcher (IC6601) is causing the distortion. The reason for this conclusion is because the HDMI signals are the only signals to pass through IC6601 before being applied to IC400. All other input signals bypass IC6601. The composite and component signals go directly to the video processor IC400. Although all the individual input circuits are located on a single board (ABoard), the previously described troubleshooting procedure can still serve as a reliable confirmation of a defective component on the A-Board before replacing the board. The same deductive reasoning can be applied when troubleshooting video defects using the other video inputs shown on the flowchart (Section 4). This method simply involves knowing the path the input signal must take through the video processing system to reach the display. With this knowledge you can effectively divide the video system into distinct areas, and therefore, isolate the defect.
Missing Video (All Inputs) If the video is completely missing you will first use the User Menu (OnScreen-Display - OSD) in an attempt to isolate the defect to the A-Board or the TCON/HFR Board. If the OSD can be displayed then the TCON/HFR Board is okay, and you can safely assume the defect exists on the A-Board. However, if the OSD cannot be displayed you need to do further troubleshooting because either IC400 on the A-Board is not sending the OSD or the TCON/HFR Board is not able to process the OSD and display it on the LCD Panel. If the OSD cannot be displayed then the LVDS signal levels must be checked to reliably determine whether the A-Board or the TCON/HFR Board is defective. 1) Check for USER Menu OSD Display a) USER Menu Displays. Replace A-Board b) USER Menu Does Not Display. Go to Step 2
CTV-61
2) Check for TCON 12V at CN4152/pins 4 - 10 & CN6151/pin 2 a) No 12V. Check connections between A-Board & Panel b) 12V Present. Go to Step 3 3) Check LVDS Cable Video Signal Levels at CN4152 a) LVDS Video Signal(s) Low or Missing. Replace A-Board b) LVDS Video Signal(s) Okay. Replace TCON/HFR Board
Skewing LVDS Connector Troubleshooting Method It maybe difficult or impossible to check the LVDS signal while in the field. Therefore, a quick and somewhat reliable method of checking the TCON/ HFR operation is to skew the LVDS connector out of the its mount at the TCON/HFR Board. When performing this method it is important to keep the 12V end of the connector connected while dislodging the LVDS video connections. Therefore, find the 12V using a voltmeter. The 12V is usually on one end of the connector (usually left-side on bottom mount or top on side mount connect). When skewing the connector if color flashing occurs on the screen then the TCON/HFR Board is most likely okay and the A-Board is defective. If the is no video reaction on the screen while skewing the connector then the TCON/HFR Board is defective.
Distorted Video (All Inputs) The following paragraphs describe the unique and common effects the LCD Panel Assembly, TCON/HFR Board, and A-Board have on the displayed video concerning possible distortions. Knowing how each component affects the displayed video can be very helpful in troubleshooting a distorted video condition. NOTES: Reference Appendix for picture examples of unique distortions for the LCD Panel, TCON/HFR Board, and the A-Board
WIDE Mode Button (Aspect Ratio) Troubleshooting Method A quick test to determine if the A-Board, TCON/HFR, or LCD Panel is causing the distortion is to change the panel aspect ratio (or picture size).
25
AZ1K Chassis Models Overview The aspect ratio can be easily changed using the “WIDE” key on the remote controller. If the distortion follows the video then the A-Board is causing the distortion. If the distortion remains stationary after changing the aspect ratio then the LCD Panel assembly is causing the distortion.
•
Color Distortion - A color distortion can be caused by a defective IC400 or LVDS cable. The individual color signals are spread out over the LVDS twist pair wires. For example, the Red signal may be broken up into three components and sent over three different LVDS twisted pairs. Therefore, this distortion will display as a poor reproduction of a particular color not an overall loss of one color. Use a Red, Green, and Blue raster generator to confirm a poor reproduction of a single color.
•
Loss of a Single Color - A loss of a single color can only be caused by a defective MT5388 (IC400). Use a Red, Green, and Blue raster generator to confirm a complete loss of a single color.
•
RF Signal Distortion - A weak video signal from the antenna or cable connection can cause RF video distortions. The signal strength of the Digital Signals can be checked in the USER menu. Go to the Product Support and Signal Diagnostic item to check signal strength and errors. NOTE: This is only for digital channels. No information will display for analog channels. The SNR should be in the range of 25db to 30db and there should be zero Errors.
WIDE Mode Button
WIDE Mode Function
Unique Main Video Board (A-Board) or LVDS Cable Effects A video distortion that has soft edges and/or is moving through the video is most likely caused by a defect in the video processing circuitry. All video processing circuitry is located on the A-Board. Therefore, replace the ABoard if the video distortion has soft edges and/or is moving through the video on the screen. Macro-Blocking (digital picture breakup) is a good example of this type of distortion. Be careful though, macro-blocking can also be caused by a weak RF signal when the TV is in the tuner mode. •
Poor Picture Detail - Loss of overall picture detail. A loss of information on the LVDS lines from IC400 will cause poor overall picture detail.
•
Abnormal Picture Size or Geometry- The video signal scaler circuit is located on the main video board A-Board. Therefore, if either the picture size or geometry is abnormal the A-Board is defective. Only the A-Board can cause such a distortion.
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Signal Diagnostics
Product Support
Signal Diagnostics Screen 26
AZ1K Chassis Models Overview Unique TCON/HFR Board Effects •
2” Vertical Transparent Colored Bar- The bar will be approximately 2" because this is the area that is controlled by a single drive IC that is located across the top of the LCD Panel assembly.
•
Video Timing - The Video Timing distortion may appear as a double image or ghosting type distortion.
•
Loss of Half Screen Video - Half the screen will have live video and the other half will be a white raster.
•
Half or Full Screen Video Distortion - In this case, the key distinguishing factor is the presence of undistorted video behind the color distortion. The distortion is basically an overlay (transparent color half-screen or bar) in front of the good video coming from the A-Board.
•
White or Colored Blooming - The bloomings may come down from the top of the screen and vary in size.
•
GAMMA Irregularity - A GAMMA distortion will appear as a overall brightness problem or a localized area color distortion.
Unique LCD Panel Assembly Effects •
Line(s) of Pixels (Fixed Position) - Poor physical connection (or bonding) between the LCD Panel and the flex cables will cause a loss of line(s) of pixels. The pixel drive lines can be open (no drive) or shorted (drive all the time). Depending on the type of failure the line(s) or pixel(s) will be black, white, or colored (red, green, or blue). These lines and pixels will also be very sharp in detail.
•
Random Line(s) of Pixels (Random Movement) - The TCON board controls the charging and timing of the pixels. If the TCON Board is partially defective random lines and/or pixels will be seen flashing across the screen. These lines and pixels will be very sharp in detail, like a specific line of pixels are randomly turned off and on.
CTV-61
•
2” Vertical Solid White or Black Bar- The bar will be approximately 2" because this is the area that is controlled by a single drive IC that is located across the top of the LCD Panel assembly.
•
Horizontal Bar- Any horizontal bar of any color will be caused by a defective LCD Panel assembly
Common Main Video Board (A-Board) and LCD Panel Assembly Effects •
White Balance (WB) Irregularity - A WB irregularity will show up as an overall poor reproduction of white. A white raster can be used to determine if a WB or gamma irregularity has occurred. WB will cover the complete picture, where as, gamma will be in specific zones or specific color areas in the picture. WB adjustment data is stored in the EEPROM IC4302 on the A-Board. The WB data stored in IC4302 is set to the middle value of the data span. The TCON/HFR Board also contains WB data, which is specifically set for the associated LCD Panel.
•
GAMMA Irregularity - Gamma Correction affects the overall picture brightness level and individual color (RGB) brightness levels. Gamma adjustment data is stored in the EEPROM IC4702 The TCON/HFR Board also contains GAMMA data, which is specifically set for the associated LCD Panel. The data may become corrupted causing irregular gamma adjustment. Therefore, a gamma distortion can show up as a color brightness irregularity in specific zones or specific color areas in the picture, as well as an irregularity in overall picture brightness.
27
AZ1K Chassis Models Overview
Video System Block Diagram
A-Board
RF Input
TM701 NTSC/ATSC Tuner
User Menu
IC4302 NAND FLASH User Data White Balance GAMMA
Video 1 (Component & Composite) Video 2 (Composite / S-Video)
Video 3 (Component)
LVDS Cable CN4152
PC Input HDMI IN 1
HDMI IN 2
HDMI IN 3
IC6601 HDMI Switch (EDID)
Service Mode
1 / 49
IC400 MTK5388 (HDCP)
LVDS 12V
4 / 10
LCD Panel Assembly LCD Panel
TCON/ HFR
HDMI IN 4
TCON 12V
12V
LCD Panel
CCFL Backlight System
From Power Supply Board
USB 2.0
IC303 Sub Micro
VIDEO SYSTEM FIGURE 2-8 CTV-61
28
AZ1K Chassis Models Overview
Audio Symptom Troubleshooting
Missing or Distorted Main Speaker Audio - All Inputs
Normal Operation
In this case, the most likely defective is the A-Board. Before you replace the A-Board perform the following test procedures to confirm the actual defective component.
Reference Figure 2-9
The HDMI digital audio signal is first applied to the HDMI Receiver/Switch IC6601 and then to the MT5388 on the A-Board. The RF input is first applied to the Tuner and then to the IC400. The Tuner outputs the ATSC and NTSC signals as an IF signal to IC400. All other audio inputs are applied directly to IC400. The MT5388 IC400. outputs the audio signal as a SPDIF signal for the Optical output. The FIXED analog audio output passes through an amplifier IC8301 and then is applied to CN8301. The main speaker audio comes from IC400 and passes through amplifier IC8151 and then to CN8151 and CN8152 speaker connections.. The AU12V from the G2LE, G2HE, or GD2-Board is the power supply for the audio output amplifier IC8151. IMPORTANT: •
Confirm the TV has the most recent Software Version installed. Go to the User Menu for the present TV software revision and the ASC web site for the most recent software version.
Failure Symptoms The first step when a “Missing or Distorted Audio” defect occurs is to determine if audio is missing or distorted on all audio input sources or only on one or a select number of audio input sources. Input Status: •
Missing or Distorted Audio on All Inputs
•
Missing or Distorted Audio on Individual Inputs
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1) Check for audio at the Analog FIX or DIGITAL Audio Outputs a) No or Distorted Audio (Replace A-Board) b) Audio Present & Undistorted. Go to Step 2 2) Check for AU12V at CN201/pin 1 on A-Board a) No AU12V - Check connections between the Power Supply board and the A-Board b) AU12V Present replace A-Board
Missing or Distorted Main Speaker Audio - Individual Inputs If only one or a select number of input sources are experiencing a problem, then the individual inputs must be checked separately. The external devices and their associated cables connected to the faulty input should be checked first. Substitute a known good device and cable on the suspected faulty input. Connect the device and cable at separate times to determine if the device or cable is causing the problem. Replace the device or cabling if found to be defective. However, if the external device and cables are okay, then the next step is to replace the common board or module associated with that particular input source. For example, consider the symptom of all HDMI inputs are faulty. Logically the only device that could cause this symptom is the HDMI switcher IC6601 on the A-Board. In this case, replace the A-Board.
29
AZ1K Chassis Models Overview
Audio System Block Diagram A-Board
HDMI IN 1
IC6601 HDMI Receiver/ Switch (EDID)
HDMI IN 2 HDMI IN 3 HDMI IN 4
TM701 NTSC/ATSC Tuner
RF Input
Digital Audio
I2S CN8302
SPDIF
Digital Audio Output (Optical)
IF
IC400 MTK5388
USB 2.0
LR Audio
LR Audio LR Audio
Video 2 (Composite/S-Video)
LR Audio
Video 3 (Component)
LR Audio
PC IN
LR Audio
Audio IN (DVI)
CN8151
LR Audio
G2LE-Board (32") G2HE-Board (40") GD2-Boad (46")
L
IC8151 Output Amplifier
R CN8152
CN6401 (32", 40") CN6150 (46") AU12V
FIXED Analog Audio Output
(HDCP)
Video 1 (Component & Composite)
AC
CN8301 IC8301 Amp
CN201 1
F1
1
PS6401
AUDIO SYSTEM FIGURE 2-9 CTV-61
30
Section 3 - Service Mode Service Mode Access
Service Mode Access Display > 5 > Volume + > Power
Reset Self Check, Press 8 > 0 keys
Panel operation time by hour (max 99999 ) (Reset Panel operation Time , Press 7 > 0 keys )
Boot count (max 99999 )
Total operation time by hour (max 99999 )
SERVICE MODE FIGURE 3-1 CTV-61
31
Section 4 - Triage & Troubleshooting Flowcharts Triage Flowchart Triage Flowchart A (AZ1K 32", 40", & 46" Models)
A Start Triage
Is RED “Standby” LED ON?
No
Go to “No Standby LED” Triage Sheet Replacement Parts
GO TO Power-ON Troubleshooting Flowchart B
Yes
Is “Standby” LED Flashing Red?
Yes
Go to “Protect Blink Code” Triage Sheet Suggested Parts
GO TO Protection Mode Troubleshooting Flowcharts C1, 2, 3, 4
No
Is Video Missing or Distorted ?
Yes
Go to “Video” Triage Sheet Suggested Parts
GO TO Missing or Distorted Video Troubleshooting Flowchart D
Go to “Audio” Triage Sheet Suggested Parts
GO TO Missing or Distorted Audio Troubleshooting Flowchart E
No
Is Audio Missing or Distorted ?
Yes
No
No Problem Found Unit Fully Operational
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32
Triage & Troubleshooting Flowcharts
Power-ON Troubleshooting Flowchart Power-ON Troubleshooting Flowchart B (AZ1K 32", 40", 46" Models)
Check STBY 3.3V at CN6401/pin 1 (In STBY Mode)
CN6150 - 46"
NOTE: Confirm all connections between circuit boards before replacing
B
Is voltage 3.3V Present?
Unit will Not Power-ON (All Models)
Replace G2LE-Board G2HE-Board GD2-Boad
No
Yes
Press TV & Remote POWER Button
Check Power_ON at CN6401/pin 3 (In STBY Mode)
CN6150 - 46"
Confirm Remote Control Operation
Is “Standby” LED illuminated RED?
What is the State of the “Power” & “Standby” LEDs?
Yes
Confirm Unit is securely plugged into an active AC Outlet
GO TO FlowCharts C1, 2, 3 Protection Modes
OK
No
Repair AC Outlet or Replace AC-Power Cord
CN6003 - 46"
Yes
No
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Initial Power -ON OK Troubleshoot Video, Backlight, Panel, or Audio Problem
Check SW_12V at CN6401/pin 9 (In STBY Mode)) CN6150 - 46"
Is voltage 12V Present?
Replace A-Board
Cycle AC power while checking for 12V. Unplug and Plug AC Power Cord .
No
Yes Check AC_OFF_DET at CN6401/pin 2 CN6150 - 46"
Check Main Fuse F6101 (0 ohms)
Is Fuse Open?
No
Yes
“Standby” Red LED Blink Pattern
No
Is 110VAC Present at CN6101?
“Power” Glows Steady Green
Is voltage 3.3V Present?
Replace G2LE-Board G2HE-Board GD2-Boad
IP3N-Board F6001 - 46"
Yes
Replace G2LE-Board G2HE-Board GD2-Boad
Is voltage 3V Present?
No
Yes
Replace A-Board
33
Triage & Troubleshooting Flowcharts
Protection Mode 2X, 3X, & 4X Troubleshooting Flowchart NOTES: 1) All Red Blink patterns will occur on the Front Panel Red “Standby” LED 2) All voltage are measured prior to unit shutdown 3) Confirm all connections between circuit boards before replacing
C1 Unit Shuts OFF RED LED Blinking
Is voltage 12V Present?
CN6150 - 46"
Replace G2LE-Board G2HE-Board GD2-Boad
No
Yes Check SW12V at CN6401/pin 9 *Before Shutdown
(>) Greater Than (~) Approximately (Does not exceed)
Is Voltage ~12V or >12V ? ~12V
Replace A-Board
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CN6150 - 46"
Replace G2LE-Board G2HE-Board GD2-Boad
46" Models ONLY
Check Speakers & Connections
Do Speakers Measure 8 ohms ? Yes
>12V
4X Blink Pattern Balancer
3X Blink Pattern Audio
2X Blink Pattern AU12V LVP & SW12V OVP
Check AU12V at CN6401/pin 4 *Before Shutdown
Protection Mode Troubleshooting Flowchart C 1 (AZ1K 32" & 40" Models)
Replace A-Board
Check LD Volatge CN6702/pin 5
No
■ Replace
Is voltage 0V or 12V Present?
0V
Replace LCD Panel
No
Replace A-Board
Speaker(s) 12V
Replace G2LE-Board G2HE-Board GD2-Boad
Is Problem Solved? Yes
Problem Sloved
34
Triage & Troubleshooting Flowcharts
Protection Mode 5X & 6X(32”, 40”) Troubleshooting Flowchart NOTES: 1) All Red Blink patterns will occur on the Front Panel Red “Standby” LED 2) All voltage are measured prior to unit shutdown 3) Confirm all connections between circuit boards before replacing
C2
Protection Mode Troubleshooting Flowchart C 2 (AZ1K 32", 40", 46" Models)
Unit Shuts OFF RED LED Blinking Check 24V at CN6402/pin 3 *Before Shutdown
6X Blink Pattern (No Backlight)
5X Blink Pattern TCON/HFR Error
Is “SONY” logo Displayed and Tones Heard?
Check LVDS connection between LCD Panel (TCON) & A Brds
Is connection OK?
No
Check TCON 12V supply CN6403/pins 1 & 2
Repair Connection
Are Yes Select outputs missing?
CN6151 - 46"
No
Yes
Replace TCON/HFR Brd
Is Issue Resolved ?
No
Replace LCD Panel Assembly No
Replace A-Board
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Replace G2LE-Board G2HE-Board
Check Backlight-ON signak at CN201/pin 12 *Before Shutdown
Replace Inverter Board
Is voltage 3V Before Shutdown ?
No
Yes Check Dimmer signal at CN201/pin 13 *Before Shutdown
Is voltage 1V to 3V Before Shutdown ?
Check for Open or Short
Replace A-Board
Check for Short
Replace A-Board
Yes
Issue Resolved
No
Yes
Check Inverter HV Outputs *Before Shutdown
No
Replace G2LE-Board G2HE-Board GD2-Boad
Is Backlight ON Before Shut Down? Yes
Yes
Is 12V Present ?
Is voltage 24V Before Shutdown ?
32" & 40" Models ONLY
Replace Inverter Board
35
Triage & Troubleshooting Flowcharts
Protection Mode 6X(46”) & 7X Troubleshooting Flowchart NOTES: 1) All Red Blink patterns will occur on the Front Panel Red “Standby” LED 2) All voltage are measured prior to unit shutdown 3) Confirm all connections between circuit boards before replacing
Protection Mode Troubleshooting Flowchart C 3 (AZ1K 32", 40", 46" Models)
C3 Unit Shuts OFF RED LED Blinking
Temperature Threshold Ambient 80°C
6X Blink Pattern (No Backlight)
7X Blink Pattern Temperature Error
46" Models ONLY
Check HV at CN6704 & CN6705 *Before Shutdown
Is voltage HV Before Shutdown ?
Yes
Does unit Shut-Down Immediately after Power ON ? No
No
Clear unit ventilation areas and confirm adequate local room temperature
Replace GD2-Board
Yes
Check Backlight-ON signak at CN201/pin 12 *Before Shutdown
Is voltage 3V Before Shutdown ? Yes
Does unit still shutdown (7X)?
Check Dimmer signal at CN201/pin 13 *Before Shutdown
No
Issue Resolved
Yes
No
Check for Open or Short
Replace A-Board
Is voltage 1V to 3V Before Shutdown ? Yes
No
Check for Short
Replace A-Board
Replace A-Board
Replace GD2-Board
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Triage & Troubleshooting Flowcharts
Video Troubleshooting Flowchart Video Troubleshooting Flowchart D (AZ1K 32", 40", 46" Models)
D Missing or Distorted Video All Video Inputs : Composite Component HDMI PC IN ATSC/NTSC (Tuner) USB
NOTE : Confirm all connections between circuit boards before replacing
Is Video Missing or Distorted on All Inputs ?
Check External Device and Connections Swap Devices and connections
No
Is External Device & connection OK ?
Yes
Replace A-Board
No
Yes
Is Video Missing or Distorted ?
Repair External Device
Distorted
Is Distortion Present in User Menu OSD ?
Missing
Is Backlight ON ?
No
Go To Flowchart C 2
No
Replace A-Board
Yes Yes
Sharp Horizontal or Vertical Lines
Can User Menu be Displayed ?
Yes
Replace A-Board
No
Or check LVDS cable Video & Clock Signal Levels at CN4152/pins 1 - 49 using an Oscilloscope .
Yes
Skew (or Rock) the LVDS connector from its socket at the TCON/HFR Brd. (Reference TM for Details)
Replace LCD Panel
TM – Training Manual
Are Flashes of color displayed ?
Yes
No
Replace TCON/HFR Board
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Is Single Pixels or Complete Line of Pixels missing?
Replace A-Board
No
Replace LVDS Cable If Damaged
Check LVDS cable for Physical Damage
Cable OK
Perform WIDE Mode Test (Reference TM for Dertails)
Does Distortion follow picture size when changing WIDE mode ?
Yes
Replace A-Board
No
Replace TCON/HFR Board
37
Triage & Troubleshooting Flowcharts
Audio Troubleshooting Flowchart Audio Troubleshooting Flowchart E (AZ1K 32", 40", 46" Models)
E
NOTE: Confirm all connections between circuit boards before replacing
Missing or Distorted Audio (Speaker Outputs ) All Video Inputs : Composite Component HDMI PC IN ATSC/NTSC (Tuner) USB
Is Audio Missing or Distorted on All Inputs ?
No
Check External Device and Connections Swap Devices and connections
Yes
Yes
Replace A-Board
No
Repair External Device
Check Fix Audio Output
Is Audio Present?
Is External Device & connection OK ?
No
Replace A-Board
Yes
Check Voltage from Power Supply at CN6401/pin 4
Is 12V Present? Yes
No
CN6150 - 46"
Replace G2LE-Board G2HE-Board GD2-Boad
Check Speaker Resistance at CN8301 & CN8302 (across Speakers) & Connections
8 ohms & Connections OK?
No
Replace Speaker(s)
Yes
Replace A-Board
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Appendix LCD Panel Distortion Pictures
The following distortions and anomalies where fixed by replacing the LCD Panel.
2' Solid Black Bar Distortion
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Timing Distortion
Double Image Distortion
Ghosting Distortion
2" Solid White Bar Distortion
Sharp Lines & Missing Pixels
39
Appendix
TCON/HFR Board Distortion Pictures The following distortions and anomalies where fixed by replacing the TCON/HFR Board.
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Large Blooming Distortion
Two Small Blooming Distortions
GAMMA Type Distortion
2" Transparent Colored Bar Distortion
Complete Washout Distortion
2" Transparent Colored bar Distortion
40
Appendix
TCON/HFR Board Distortion Pictures Continued The following distortions and anomalies where fixed by replacing the TCON/HFR Board.
2" White Bar w/ Random Colored Lines
Exact Half-Screen Distortion
Complete Washout w/ Colored Lines
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Appendix
Video Board Distortion Pictures
The following distortions and anomalies where fixed by replacing the Video Board.
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Green Carpet Raster
Multi-Colored Carpet Raster
Text Bleed Lines
Random Size Vertical Bars
Overall Red Tinting
Solarization
42
Appendix
Video Board Distortion Pictures Continued
The following distortions and anomalies where fixed by replacing the Video Board.
Partial Washout w/ Random Video Bar
Overall Blue Tinting w/ Soft Vertical Lines
Green Raster
Overall Green Tinting w/ Video Ghosting
Overall Red Tinting
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CTV610110
2007 Sony Electronics, Inc. EMCSA - A Service Company 16530 Via Esprillo San Diego, CA 92127 Reproduction in whole or part without written permission is prohibited. All rights reserved
03/30/10
