Sony KDL-22EX355 Page 2 Service Training Manual Download

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SERVICE / TRAINING MANUAL

LCD Digital Color TV

AZ3TK

Chassis

Segment: P-2L

9-883-896-01

Self Diagnosis

Supported model

KDL-40EX455

Summary of Contents for KDL-22EX355

Page 1: ...Digital Color TV AZ3TK Chassis Segment P 2L 9 883 896 01 SelfDiagnosis Supported model Version Date Subject 1 0 7 13 2012 Original Manual Release Date ORIGINAL MANUAL ISSUE DATE 7 2012 HISTORY INFORMATION FOR THE FOLLOWING MANUAL ...

Page 2: ...SERVICE TRAINING MANUAL LCD Digital Color TV AZ3TK Chassis Segment P 2L 9 883 896 01 SelfDiagnosis Supported model KDL 40EX455 ...

Page 3: ...MODEL LIST MODEL COMMANDER DESTINATION MODEL COMMANDER DESTINATION 9 883 896 01 KDL 22EX355 RM YD081 BRAZIL KDL 32EX355 RM YD081 BRAZIL KDL 40EX455 RM YD081 BRAZIL ...

Page 4: ...pply Board G22 G32 G40 Removal 17 KDL 22EX355 Only 17 KDL 32EX355 40EX455 Only 18 LCD Panel Removal 19 KDL 22EX355 Only 19 KDL 32EX355 40EX455 Only 20 Reattaching the Bezel to the LCD Panel 21 Cleaning the LCD Panel 21 Connectors 22 KDL 22EX355 Only 22 KDL 32EX355 Only 22 KDL 40EX355 Only 23 Screws 23 Accessories and Packaging 24 Optional Accessories 24 Miscellaneous 24 Wire Dressing 25 Section 5 ...

Page 5: ...355 32EX355 40EX455 ii TABLE OF CONTENTS Completing Service Requirements When Replacing the LCD Panel 33 Verifying the Panel ID Code 34 Resetting Panel Operation Time 35 Appendix A Encryption Key Components A 1 ...

Page 6: ...There are critical components used in LCD color TVs that are important for safety These components are identified with shading and mark on the schematic diagrams and the parts list It is essential that these critical parts be replaced only with the part number specified in the parts list to prevent electric shock fire or other hazard NOTE Do not modify the original design without obtaining written...

Page 7: ... frame edge to avoid the risk of electric shock 2 Do not scratch or press on the panel with any sharp objects 3 Do not leave the module in high temperatures or in areas of high humidity for an extended period of time 4 Do not expose the LCD panel to direct sunlight 5 Avoid contact with water It may cause a short circuit within the module 6 Disconnect the AC power when replacing the backlight or in...

Page 8: ... such as a thinner alcohol or benzine for cleaning Periodic vacuuming of the ventilation openings is recommended to ensure proper ventilation Do Not use paper towels any type of abrasive pad rags rubber or vinyl materials to clean the screen Using these materials could easily scratch the screen which may result in permanent damage Do Not use any cleaning product containing alkaline acid cleaner sc...

Page 9: ... Check leakage as described in Leakage Test LEAKAGE TEST The AC leakage from any exposed metal part to earth ground and from all exposed metal parts to any exposed metal part having a return to chassis must not exceed 0 5 mA 500 microamperes Leakage current can be measured by any one of three methods 1 A commercial leakage tester Follow the manufacturers instructions provided with the tester 2 A b...

Page 10: ... 8 W 8 W 1 127 V CA THD 10 sinal 1 KHz Alto falante de 8 Ohms Nível de entrada 500 mVrms KDL 22EX355 5 W 5 W 1 127 V CA THD 10 sinal 1 KHz Alto falante de 8 Ohms Nível de entrada 500 mVrms Entradas Saídas CABLE ANTENNA Terminal externo de 75 ohms para entradas RF VIDEO IN 1 2 VÍDEO 1 Vp p 75 ohms não balanceados sincronização negativa ÁUDIO 500 mVrms Típico Impedância 47 Kohms COMPONENT IN YPBPR V...

Page 11: ...nexão Kit de cinto de segurança Nome do modelo KDL 40EX455 KDL 32EX355 KDL 22EX355 Energia e outros Requisito de energia Consumo de energia W 1 3 W 7 7 W 2 0 1 em uso em modo de espera Menos do que 1 W Tamanho da tela cm Aprox 101 6 Aprox 80 0 Aprox 54 8 polegadasmedidas diagonalmente 40 31 5 classe 32 21 6 classe 22 Resolução da tela 1 080 linhas vertical 1 366 pontos horizontal 768 linhas vertic...

Page 12: ...el G32 Board for the 32 model and G40 Board for the 40 model the IR Board H Board the L Board L32 for the 32 model and L40 for the 40 model the Switch Unit and the LCD Panel Assembly which includes the TCON Board NOTE For connector part number information refer to Connectors on page 22 For Wire Dressing information refer to Wire Dressing on page 25 SWITCH UNIT H G A BOARD LAYOUT FOR KDL 22EX355 ...

Page 13: ...KDL 22EX355 32EX355 40EX455 4 SECTION 1 FEATURES AND OVERVIEW SWITCH UNIT H G L A BOARD LAYOUT FOR KDL 32EX355 SWITCH UNIT H G L A BOARD LAYOUT FOR KDL 40EX455 ...

Page 14: ...oard L Board is used to connect and convert the FFC LVDS cables OVERALL CIRCUIT DESCRIPTION The Block Diagram on page 10 provides an overview of the AZ3TK chassis The following are descriptions of the boards and their functions MAIN BOARD Common to all models utilizing the AZ3TK chassis the Main Board A Board contains most of the video processing circuitry along with all audio processing Control o...

Page 15: ...o 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 A new LCD Panel Assembly from parts will include the following items LCD Panel TCON Board LED Backlight system TCON BOARD The TCON Board communicates between the LCD Panel and the microprocessor...

Page 16: ...onnectivity Certain features not working correctly photo or video file viewing SECTION 2 TROUBLESHOOTING SelfDiagnosis Supported model SELF DIAGNOSIS FUNCTION Critical voltages and circuit operations are monitored by the CPU on the Main Board If an error is detected the Self Diagnosis function in the TV will force the TV to shut down by the CPU The monitored circuit in which the fault occurred wil...

Page 17: ...002 MAIN_ POWER 000 003 DC_ALERT1 000 003 AUDIO_PROT 000 004 BALANCER_ERR 000 0 0 0 R R E _ N O C T 5 0 0 005 PANEL_ID_NVM_ERR 000 006 BACKLIGHT_ERR 000 0 0 0 R R E _ P M E T 7 0 0 00031 00046 00031 Home Exit SELF CHECK SAMPLE SELF CHECK DIAGNOSIS PAGE 2X Blink Main Power Error A loss of REG12V from the power supply triggers this protect event The usual cause is a failure of the main switching sup...

Page 18: ...cause the TV to run hotter than normal TRIAGE CHART Use this general Triage Chart to determine what may possibly be causing the error before going out to the customers location 1 Confirm the symptom from the customer RED DOT Primary Most likely defective part 2 Select that symptom from the chart BLUE Triangle Secondary Possible defective part 3 Bring the primary component listed for that symptom 5...

Page 19: ...mposite RF HDMI 1 PC HD15 POWER SUPPLY SWITCH UNIT LED IR RX LCD PANEL TCON LED BACKLIGHTS A H L R ANALOG AUDIO OUT OPTICAL AUDIO OUT MT5389 A V DECODER A V PROCESS TUNER USB HDMI 2 LVDS BACKLIGHT POWER AC IN CLASS D AUDIO AMP G CONNECTOR L MAIN BOARD 32 40 ONLY IR BOARD OVERALL BLOCK DIAGRAM ...

Page 20: ...9 10 11 12 13 NC ON OFF DET 14 15 AC IN N AC IN H 1 2 CN9302 A DET ACD 5 2V 1 2 3 4 PS_ON 24VA 5 6 7 CN701 12V 11 12 DIM ON OFF 13 14 GND 8 10 G CN901 LCD PANEL TCON LED BACKLIGHTS LED1 1 N C LED2 2 3 4 CN8501 LED1 1 N C LWD2 2 3 4 CN8502 5 N C MAIN BOARD POWER SUPPLY ALL MODELS 30 40 ONLY POWER AND CONTROL BLOCK DIAGRAM ...

Page 21: ...n on page 16 No Power Is standby LED blinking No Yes No See Protection Shutdown flowchart Yes Does red standby LED on front panel light Press power button while monitoring pin 4 of CN6401 on power supply board High 3 3V on pin 4 Yes No Main Board Power Supply Board High 3 3V on pin 1 Yes No Power Supply Board Power Supply Board NO POWER FLOWCHART ...

Page 22: ... 5X No Yes LCD Panel 6X Yes 7X No Immediately After a While Check room temperature and ventilation around unit Power Supply Board Main Board SONY logo appears before shutdown Yes No LCD Panel Power Supply Board Main Board PROTECTION SHUTDOWN FLOWCHART For Part Number information Refer to Section 4 Disassembly Part Number Information on page 16 ...

Page 23: ... LVDS connector at TCON while unit is running This may need to be done more than once Any flashes seen on screen Yes No Any OSD graphics present No Main Board No LCD Panel Yes Yes Main Board LCD Panel NO VIDEO FLOWCHART For Part Number information Refer to Section 4 Disassembly Part Number Information on page 16 ...

Page 24: ...stortion Is distortion across entire screen Any horizontal lines No No Yes Yes Improper of missing colors Yes Main Board No Vertical lines or bars No Yes Lines move when wide mode changed Yes No LCD Panel TCON Board Main Board LCD Panel Any single or isolated vertical lines Yes LCD Panel More than 1 vertical band No Yes LCD Panel TCON Board VIDEO DISTORTION FLOWCHART ...

Page 25: ... of Table Top Stand B To avoid damaging the AC Power Supply Cord remove the screw from the AC Cover and disconnect the AC Power Cord REF NO PART NO DESCRIPTION ASSEMBLY INCLUDES REF NO PART NO DESCRIPTION ASSEMBLY INCLUDES 1 4 438 330 01 REAR COVER 22IRST 2 KDL 22EX355 ONLY 1 4 438 331 01 REAR COVER 32IRST 2 KDL 32EX355 ONLY 1 4 438 332 01 REAR COVER 40IRST 2 KDL 40EX455 ONLY 2 4 421 136 01 BRACKE...

Page 26: ... Encryption Key Components in the back of this manual KDL 22EX355 ONLY A Remove screws and disconnect connectors from A Board B Detach the Side Bracket from A Board C Remove screws and disconnect connectors from G22 Board D Slide out Left and Right Speakers then disconnect connectors E Release clips and disconnect connector from H Board F Lift up Switch Unit and disconnect connector MAIN BOARD A A...

Page 27: ...t Insulator from the Back Chassis E C D F B A G H 101 1 895 281 11 L32 BOARD MOUNTED KDL 32EX355 ONLY 101 1 895 282 11 L40 BOARD MOUNTED KDL 40EX455 ONLY 102 4 446 821 01 SHEET INSULATOR 32IRST KDL 32EX355 ONLY ORDER THIS PART WHEN REPLACING THE LCD PANEL 102 4 446 820 01 SHEET INSULATOR 40IRST KDL 40EX455 ONLY ORDER THIS PART WHEN REPLACING THE LCD PANEL 103 1 895 291 11 G32 BOARD MOUNTED KDL 32E...

Page 28: ...ANEL REMOVAL KDL 22EX355 ONLY A Remove screws from LCD Bracket then release Bezel clips and gently lift up LCD Panel to detach from Bezel B Remove screws from LCD Bracket and lift up to detach from LCD Panel Screws Use CAUTION to avoid breaking the Bezel clips Bezel clips Screws REF NO PART NO DESCRIPTION ASSEMBLY INCLUDES REF NO PART NO DESCRIPTION ASSEMBLY INCLUDES 151 4 438 333 01 BEZEL 22IRST ...

Page 29: ...lift up Panel Brackets B Press Bezel tabs and tilt up Panel Brackets C Remove screws and lift up Bottom Frame D C Panel Bracket Bezel tab B Panel Bracket Bezel tab A D Gently detach the LCD Panel from the Bezel Refer to Figure 1 when pulling the Bezel away from the LCD Panel Remove all of the double sided tape before reattaching the LCD Panel to the Bezel refer to Figure 2 FIGURE 1 FIGURE 2 201 4 ...

Page 30: ... securing the double sided tape PN 4 435 135 01 to the new Bezel remove the paper protecting the tape before replacing the LCD Panel CLEANING THE LCD PANEL CAUTION When cleaning the TV be sure to unplug the power cord to avoid any chance of electric shock Clean the cabinet of the TV with a dry soft cloth and wipe the LCD screen gently with a soft cloth Stubborn stains may be removed with a cloth s...

Page 31: ...PTION ASSEMBLY INCLUDES REF NO PART NO DESCRIPTION ASSEMBLY INCLUDES 251 1 910 106 73 CONNECTOR ASSEMBLY 22 14P MB PSU 252 1 910 106 72 CONNECTOR ASSEMBLY 22 12P MB KEYBD 301 1 910 106 78 CONNECTOR ASSEMBLY 32 14P MB L32 302 1 910 106 77 CONNECTOR ASSEMBLY 32 14P MB PSU 303 1 910 106 79 LVDS CONNECTOR ASSEMBLY 32 30P FFC REF NO PART NO DESCRIPTION ASSEMBLY INCLUDES REF NO PART NO DESCRIPTION ASSEM...

Page 32: ...components are repaired and or replaced See Appendix A Encryption Key Components in the back of this manual KDL 40EX355 ONLY REF NO PART NO DESCRIPTION ASSEMBLY INCLUDES REF NO PART NO DESCRIPTION ASSEMBLY INCLUDES 351 1 910 106 83 CONNECTOR ASSEMBLY 40 14P MB L40 352 1 910 106 82 CONNECTOR ASSEMBLY 40 14P MB PSU 353 1 910 106 84 LVDS CONNECTOR ASSEMBLY 40 30P FFC 354 1 910 106 81 CONNECTOR ASSEMB...

Page 33: ...ly recommends that you use the screws provided with the TV CAUTION These screws cannot be used to secure the TV to the Wall Mount Brackets 4 432 604 41 MANUAL INSTRUCTION 4 432 961 41 GUIDE QUICK SET UP 4 416 690 42 SUPPLEMENT STAND INSTALLATION OPTIONAL ACCESSORIES PART NO DESCRIPTION 4 414 470 01 SUPPORT BELT KIT MISCELLANEOUS PART NO DESCRIPTION 4 262 708 04 CLAMPER CABLE REMOTE COMMANDER PART ...

Page 34: ...KDL 22EX355 32EX355 40EX455 25 SECTION 4 DISASSEMBLY PART NUMBER INFORMATION WIRE DRESSING BOARD LAYOUT FOR KDL 22EX355 BOARD LAYOUT FOR KDL 32EX355 BOARD LAYOUT FOR KDL 40EX455 ...

Page 35: ...andards are detailed for each of these protocols the real world dictates that occasional errors may occur that could prevent devices from operating or communicating properly Keeping the software in the television up to date is a procedure that is normally handled by the owner of the television Most customers who own computers and other digital devices are familiar with and are accustomed to updati...

Page 36: ...ing the customer menu Póngase en contacto con Sony Sitio Web de soporte técnico Teléfono de contacto en Brasil Número de serie Versión del software Región capital y metropolitana Otras regiones www sony co br contato Sitio Web de soporte técnico www sony AR CONTACTANOS Teléfono de contacto en Argentina 011 6770 7669 4003 SONY 7669 0800 880 SONY 7669 Tenga la siguiente información a mano Favor de r...

Page 37: ...when either the Main Board LCD Panel or TCON Board are replaced UPDATING THE SOFTWARE After replacing the Main Board LCD Panel or TCON Board you MUST UPDATE the SOFTWARE to the latest version ACCESSING SERVICE ADJUSTMENT MODE 1 TV must be in Standby mode 2 Press the following buttons on the Remote Commander within a second of each other DISPLAY Channel 5 Volume POWER DISPLAY POWER Onscreen cursor ...

Page 38: ...LACING THE MAIN BOARD The following must be performed after replacing the Main Board to ensure that all of the features for the TV will be available View the Status Information Select the Panel ID Add the Serial Number Add the Model Name VIEWING THE STATUS INFORMATION After replacing the Main Board you MUST UPDATE the SOFTWARE to the latest version 5 Verify the latest software is installed before ...

Page 39: ... proceeding to the next step Verified Status Information 10 Press to select Panel Selection Sound Adjust Wide Band Tuning Range Scan Self diagnosis history Status Information LVDS Spectrum 0 25 Panel Selection LTY400HM10 SERIAL NUMBER EDIT 8500001 MODEL NAME EDIT KDL 40EX455 Set Home Exit Service Mode 11 Using the table below press the or on screen cursor buttons to select the correct Panel Code f...

Page 40: ...et Home Exit Service Mode 16 Using the navigation buttons press to be able to select the first digit CAUTION The Serial Number can only be selected once Be sure to verify the information is correct before saving the changes Sound Adjustment Wide Band Tuning Range Scan Self diagnosis history Status Information LVDS Spectrum 0 25 Panel Selection LTY400HM10 SERIAL NUMBER EDIT _ _ _ _ _ _ _ MODEL NAME...

Page 41: ...e ADDING THE MODEL NAME Verify before proceeding to the next step Verified Status Information Selected the Panel ID Added the Serial Number CAUTION The Model Name can only be selected once Be sure to verify the information is correct before saving the changes 23 Press until MODEL NAME EDIT is selected Sound Adjustment Wide Band Tuning Range Scan Self diagnosis history Status Information LVDS Spect...

Page 42: ...40EX455 Set Home Exit Service Mode 27 Verify the Model Name is correct before proceeding to the next step 28 When the complete model name is displayed press 29 When the confirmation screen displays press to select YES and then press 30 Proceed to Selecting the Panel ID Code 31 Press POWER to exit Service Mode COMPLETING SERVICE REQUIREMENTS WHEN REPLACING THE LCD PANEL The following must be perfor...

Page 43: ...atest software is not installed update the software and then proceed to Selecting the Panel ID Code VERIFYING THE PANEL ID CODE 5 Press to select Panel Selection Sound Adjust Wide Band Tuning Range Scan Self diagnosis history Status Information LVDS Spectrum 0 25 Panel Selection LTY400HM10 SERIAL NUMBER EDIT 8500001 MODEL NAME EDIT KDL 40EX455 Set Home Exit Service Mode 6 Using the table below ver...

Page 44: ...000 003 DC_ALERT1 000 003 AUDIO_PROT 000 004 BALANCER_ERR 000 005 TCON_ERR 000 005 PANEL_ID_NVM_ERR 000 006 BACKLIGHT_ERR 000 007 TEMP_ERR 000 00031 00046 00031 Home Exit SELF CHECK TOTAL OPERATION TIME PANEL OPERATION TIME BOOT COUNT 10 Press 7 0 11 Verify Panel Operation Time has been changed to 00000 Back 002 MAIN_ POWER 000 003 DC_ALERT1 000 003 AUDIO_PROT 000 004 BALANCER_ERR 000 005 TCON_ERR...

Page 45: ...ion Sony LCSC Technical Services Service Publication Department 9 883 896 01 English 2012GJ74WEB 1 Printed in USA 2012 7 is a trademark of Sony Electronics Reproduction in whole or part without written permission is prohibited All rights reserved ...

Page 46: ... manual shall be utilized for replacement and or repair 3 Disassembly decryption or reverse engineering component s is strictly prohibited 4 Any board in which the Servicer replaces an encryption key component must be placed back into the set it orignally came from and the replaced defective component MUST BE DESTROYED Boards cannot be swapped 5 If a Circuit Board identified with a red outline and...

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