Sony KDP-57XBR2 - Digital High Definition Projection Tv Training Manual Download

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Training Manual

Course: TVP-14

Projection Television
Troubleshooting

Practical Troubleshooting Tips

RA-3/3A, RA-4/4A, RA-5A, RA-6 Chassis

KDP-57XBR2

Summary of Contents for KDP-57XBR2 - Digital High Definition Projection Tv

Page 1: ...Training Manual Course TVP 14 Projection Television Troubleshooting Practical Troubleshooting Tips RA 3 3A RA 4 4A RA 5A RA 6 Chassis KDP 57XBR2 ...

Page 2: ... Video Circuit Troubleshooting 54 13 Troubleshooting the RA 4A Chassis 63 Overview 63 14 Video Circuit Troubleshooting 64 The RA 5A Chassis 15 Troubleshooting the RA 5A Chassis 67 Overview 67 16 Power Supply Troubleshooting 68 Overview 68 Standby Power Supply 68 Primary Power Supply 68 Troubleshooting the Primary Power Supply 70 17 Protect Circuit Troubleshooting 73 Overview 73 Troubleshooting 75 ...

Page 3: ...28 Auto Registration Troubleshooting 113 Overview 113 Flash Focus Errors 115 Error Codes 119 29 Model to Chassis Cross Reference 120 ...

Page 4: ...itry design have occurred High Definition Television was finally getting underway and the competition for producing better performing projection televisions introduced new features that had never been seen before In some cases new troubleshooting approaches are needed to effectively deal with these new circuit designs Add replacement parts tracking and you have useful resources to document some pr...

Page 5: ...G board now contained the deflection circuits along with the usual power supply components rather than utilizing a separate D board Unlike previous sets which had a separate horizontal scan and high voltage sections the horizontal HV is handled with a single output and flyback to generate H scan and HV This makes deflection and HV problems easier to diagnose The A board handles video processing sy...

Page 6: ...reases the conduction of the FET This event will continue until two things occur Q601 reaches saturation and C614 charges This is how the on time of Q601 is controlled to change the frequency C616 will route the feedback voltage via R615 to Q602B This voltage will be smoothed out by C610 and C609 to provide a rising sawtooth to control the on time of Q602 Q602 will now become part of the RC networ...

Page 7: ...ntacts such as a heavy lightning strike Failures that might occur would be a dead supply or regulation problems If Q601 has shorted there is a high probability that something else caused the failure This is based upon a reliable history of this component We will start with a scenario of a shorted Q601 and then cover a no run condition next since you are most like to end up with this after replacin...

Page 8: ...Dead Standby Supply Q601 not Shorted Assuming very little AC current is being drawn and there are no chirping or ticking sounds you are dealing with a circuit that is not starting or is not able to sustain oscillation Verify the presence of B at Q601 Next read the voltage on the gate of Q601 The same voltage present on the drain should appear at the gate No voltage at gate No voltage indicates eit...

Page 9: ... going to be Q602 Based on previous experience with this type of power supply the B E junction is common to open Leaking or shorted C610 comes in at a close second Check for an increase in value or open at R615 and a decrease in value or open at C618 The Main Power Supply The main power supply is still a somewhat conventional style that has been used in Sony televisions for many years It is only a...

Page 10: ...wn pin 8 of T604 Current through the control winding will increase the impedance of T604 will decrease and the oscillator frequency will rise This will move the frequency further above the fixed resonant point of T605 which will increase its impedance The net effect will be a drop in secondary output voltages The opposite will occur should the 135V line decrease One more item to cover The soft sta...

Page 11: ...CK UP R668 D662 R617 C621 C623 2 IC654 DM 48 135V FROM IC001 62 CN1601 CN652 R677 R673 TO PROT LATCH Q652 RY DRIVE N Q658 LIMIT N R681 R680 R679 D665 C673 R676 P Q653 SOFT START R669 R666 C670 R670 C671 D668 24V R683 R621 R618 D665 C659 C658 D658 R655 C664 D660 D659 R656 R652 T605 PIT AUDIO GND AUDIO B AUDIO B 5V 5V 15V 15V 18V FIGURE 3 2 SWITCHING POWER SUPPLY AC 50V DIV 5uS T DIV 1 2W Ω R612 0 1...

Page 12: ... if a dynamic load such as a defective flyback or a shorted line still exists that was missed during the performance of static resistance checks It is going to involve jumping the main relay while controlling things with the variac This is a safe method so long as care is taken and the current is monitored closely Some technicians like to use a light bulb in series with the AC input to protect aga...

Page 13: ...ransistor and re applying AC voltage If the current problem is gone the current will not go much higher that 250ma with the horizontal circuit disconnected the over current source has been exposed and will be dealt with in the section on the deflection circuits If excessive current still exists its simply a matter of disconnecting secondary lines and trying to re apply power If disconnecting secon...

Page 14: ...o thinking there is insufficient 135V If the voltage at T604 pin 8 is much lower than pin 7 either the control winding is open or IC654 is aware of the 153V being too high and is trying to correct the problem by inducing more current into the winding Assuming the winding is not open extremely rare all that is left is an oscillator section has drifted so far off frequency so as to be out of range o...

Page 15: ...er defaults Beware that the service manual instructs you to enter the service mode to clear these and that is a mistake You can do it right from this screen Below is a description of each event B OCP Excessive current on the 135V line This is usually caused by flyback problems or secondary loads on the line The circuit could also be tripping for no reason This is why you should always monitor AC c...

Page 16: ...18V secondary line is also monitored for over voltage If the unit goes into shutdown with no diagnostic indicator this is where you will want to look next Here are some quick methods to locate the source The Standby 5V Circuit Monitor the anode of either D675 or D674 while applying AC power An oscilloscope or peak hold DVM is preferred but this can be done with a standard DVM If anything higher th...

Page 17: ...8 C515 R524 R527 12V D513 C529 R530 R563 R556 C538 C531 12V R526 R523 L503 R527 R509 C514 R532 C523 C518 R531 R535 R525 R551 R543 R550 C528 R542 C537 135V HP 5 1ATVP14 7 17 02 G BOARD Overview Like the RA 2 chassis the RA 3 utilizes a simple deflection circuit design much like those found in many of the direct view models Figures 5 1A and 5 1B illustrate the simplicity of this design High voltage ...

Page 18: ...2 R511 135V D507 D506 7 5V R522 High Voltage and Horizontal Deflection Troubleshooting Three major issues usually arise when a failure occurs in this circuit Either the horizontal output transistor fails the high voltage protect circuit engages or pincushion problems develop Horizontal Output Transistor Failure Occasionally you will be fortunate to have the output transistor fail and nothing else ...

Page 19: ...caution and close current monitoring For those of you fortunate enough to own the expensive test equipment to drive and test the flyback use the equipment in lieu of the above procedures High Voltage Shutdown The only protection for the circuit in this chassis is excessive high voltage This is monitored by IC502 as illustrated in Figure 5 1B Pin 7 is maintained at a constant 8 2V for reference Pin...

Page 20: ...503 open pincushion modulation transformer T502 or poor solder connections IMPORTANT NOTE If you have checked and or replaced everything in the pincushion circuit and you still have the problem there is one more component that can cause this The EEPROM IC004 located on the A board This has been found to be the source of the problem in several cases where a technician has replaced most or all of th...

Page 21: ...f it appears that multiple symptoms are present Although most television chassis will not produce vertical deflection some will generate other symptoms As an example The AA 2W used in Sony s KV32 36XBR200 sets will display a magenta raster with no video and insufficient vertical height that can easily cause a technician to look for separate failures and blame the y C Jungle IC Assuming the bus is ...

Page 22: ...y Due to the nature of the operational amp within IC1509 it is rare for this IC to be the cause Operational amplifiers have massive amounts of gain which is why they need negative feedback to keep them under control Gain problems are most likely to be caused by improper supply voltage very rare or problems in the feedback line The feedback line should always be checked with an oscilloscope when he...

Page 23: ...scan lines cross talk still occurs as the luminance frequency nears the chroma decoder window Component video does not utilize the 3 58 encoding and therefore is not restricted to the 1MHZ bandwidth on the chroma signal Using the 80 lines of resolution per MHZ you see that a maximum of 80 lines of resolution is available for chroma Component video allows us to open the chroma bandwidth to 3MHZ whi...

Page 24: ...des so it might not be there for you to hear You should look for the initial must haves and use the following steps to isolate the cause The first check is for the presence of high voltage You should be able to hear it come on If it does the next concern is if it is staying on You could be dealing with a HV shutdown Fortunately this chassis will indicate the shutdown by blinking the timer LED blin...

Page 25: ...te troublesome This is especially true if the distortion is subtle since you may not be able to see it on the oscilloscope screen The T and S line models do not digitize the video like the higher end units so distortion tends to be caused by either power supply noise or the Y C Jungle IC Video level problems can happen virtually anywhere Distorted Video Isolating the source of distortion by utiliz...

Page 26: ... set to go into over current protect The best way to isolate this problem is to read the collector voltage of each IK monitoring transistor Approximately 2VDC should appear there If one of the transistors is leaking you will see 5VDC since there is a zener diode D736 at Q734B that prevents this line from going any higher Service Bulletin 443 E08921862 deals with this issue NOTE This failure can be...

Page 27: ...905 BUFFER Q1907 BUFFER Q1903 BUFFER X1902 3 58MHz X1901 503 5kHz 11 12 13 CVBS Y IN CIN RY IN RU IN RV IN RY OUT RU OUT RV OUT XNTSC APC CERA SDA SCL VSYNC H SYNC VOUT UOUT YOUT IC1902 SUB DECODER CXA2019 20 19 18 38 29 26 1 8 7 6 32 39 34 37 36 SDA SCL TO IC1901 1 TO IC1901 2 U TO IC1901 3 Q1904 SUB Y BUFFER Q1908 BUFFER 5 22 02 7 1 3 1 D736 1 FROM FOCUS BLOCK C732 R732 G2 SG731 Q733 R741 R742 L...

Page 28: ...ion rather than a main picture with a small inset box There is also an additional component source available at the video 5 input Figure 6 5 illustrates the basic paths of the main and sub video and provides the key source for isolating video problems Figures 6 6 and 6 7 illustrate block diagrams with more detail to aid in isolating problems No Video As the initial steps mentioned in the previous ...

Page 29: ...4 or 5 input This causes the Y signal to bypass the A D converter IC203 3D comb filter IC204 and main decoder IC1402 Y switch IC1410 will route the component Y directly to IC1407 If component video appears troubleshoot the circuits listed above that were bypassed If component video does not appear suspect AV switch IC1702 or YUV controller IC1407 No Video in Either Box or No Boxes The presence of ...

Page 30: ...U BOARD CN1701 CN401 MAIN C MAIN Y IC204 3D COMB FILTER uPC64O81 MRAS X1 AYO MAO MA8 WE OE LCAS UCAS SDA SCL SDA SCL RAS I01 I016 VIN DB1 DB8 CLK PCL ALTE STO CSI IC203 A D CONVERTER uPC659 DYC0 2 DYC0 9 MIO 0 MIO 15 AO A8 IC202 4MB EDO MSM514265C TO IC1402 34 CVBS Y IN FSCOUT FROM IC206 57 YCJ KILLER FROM IC002 30 CN201 FSC1 ACO 84 3 1 7 2 Q210 BUFFER FL203 Q215 216 B P F Q206 212 BUFFER 30 FL201...

Page 31: ... MAIN Y FROM Q1402 MAIN Y SW FROM IC1409 7 FULL DVD FROM IC1409 1 COLOR FROM IC1409 5 HUE FROM IC1409 6 CN204 Q1422 YUVSW 6 7TVP14 5 22 02 A BOARD Q1418 BUFFER Q1420 BUFFER Q1419 BUFFER Q1403 SYNC BUFFER 23 19 13 18 6 8 9 P Y 12 5 PB Y PR Y DVD B Y DVD R Y DVD Y TV IN DL YSW YSW COLOR HUE YOUT RYOUT BYOUT TVOUT CLAMP IC1407 YUV CONT CXA2039 16 17 1 3 2 22 21 X202 57 63 55 4 3 27 BGP SDA SCL Y IN I...

Page 32: ...stments at specific areas of the screen to provide excellent geometry and convergence control throughout the entire screen area These adjustments could then be written to memory and by using special sensors located behind the front bezel allowed the customer to press a button and bring the convergence back to proper alignment This feature is known as Flash FocusTM The picture and picture circuitry...

Page 33: ...han a half second after the main relay energizes RY6002 is protected against failure by monitoring the voltage at pin 4 of D6002 If the relay does not shunt R6010 within five seconds C6013 at the base of Q6004 will charge and cause the collector to go low and stop the main power supply oscillator The main relay will remain engaged The standby supply consists of T6003 and IC6001 as the main compone...

Page 34: ...5V F6002 6 3A L6003 SWITCHING B DC TO SOFT START PROTECTION Q6002 AC TO STANDBY SUPPLY D6001 1 2 4 3 2 1 2 1 4 3 3 4 1 2 R6031 N 3 4 2 1 8 1TVP14 6 26 02 IC6001 TOP209 PWMSW G BOARD FIGURE 8 2 STANDBY SUPPLY AC FROM L6002 3 TO VCC SWITCH FOR AC OCP Q6013 B D6001 D6003 C6006 R6012 D6006 P6KE200 D6005 5 4 8 1 2 3 HOT GND R6004 R6021 D6011 MTZK9 1A C6014 C6017 D6012 D6015 C6015 2 1 4 3 5 7 T6003 SRT ...

Page 35: ...des direct power to the main relay which is tied to ground Notice the latch circuit consisting of Q6012 and Q6013 This is not the same latch circuit that would put the unit into conventional protect mode It is only activated if the unregulated B for the standby supply rises above an acceptable level which is monitored by the divider network R6042 and R6043 along with D6035 A variac with the capabi...

Page 36: ...rt This is done to protect the switching transistors from overheating since they will now have to maintain secondary voltages at a lower frequency Higher current will be needed and they will eventually fail Referring to Figure 8 5 IC 6002 and 6004 receive the square waves from IC6003 and utilize them to drive the switching transistors Q6007 Q6008 Q6009 and Q6010 These transistors work in pairs to ...

Page 37: ...lay high command from the CPU through the VCC switch circuitry and even the main relay itself Refer to Figure 8 3 to troubleshoot this circuit Relay clicks once If a relay click is heard it is very important to listen carefully for two rapid clicks They should be less the one half of a second apart This verifies the inrush current relay is engaging If only one and not two rapid clicks are heard th...

Page 38: ...e readings across the rails Do not lift components on the 135V line located before L6106 This will open the regulation loop and cause the supply to output maximum voltages If lifting secondary lines does not get rid of the problem the cause is a short in one of the two transformers or one of the driver ICs IC6002 6004 is the cause An effective way to test the drive and oscillator IC circuits is to...

Page 39: ... increase in value of the resistor connecting the 135V to IC1601 R6115 in this chassis If shorting pin 2 of IC1601 does not stop the over voltage problem short pin 4 of IC6005 If the voltage now drops replace IC6005 If it still does not drop IC6003 or one of the input components may be open Low B Check the voltage at IC6005 pin 1 and 2 There should be at least 6VDC difference with pin 2 being the ...

Page 40: ...the service manual instructs you to enter the service mode to clear these and that is a mistake You can do it right from this screen Let us briefly cover each one B OCP Excessive current on the 135V line This is usually caused by flyback problems or secondary loads on the line The circuit could also be tripping for no reason This is why you should always monitor AC current while the unit is shutti...

Page 41: ...BLOCK 9 1TVP14 5 23 02 Audio DC voltage has been detected on one or both of the audio out lines The set is shut down to protect the speakers This is usually caused by shorted audio amp IC406 WDT A communications error has occurred The main CPU is unable to communicate with the Y C jungle IC The timer LED blinks continuously at one second intervals and as soon as 101 of them occur a failure is regi...

Page 42: ...ady while the emitter rises This will also turn on Q6101 and the latch circuit Most protect circuits that monitor multiple lines are arranged in this manner Troubleshooting consists of checking the voltages across the blocking diodes Since they are normally reverse biased the voltages across them will be greater than 6V Even a DVM without peak hold can detect this For example If the 19V failed the...

Page 43: ...ed new circuit designs The horizontal scan rate operates at 31 5KHZ instead of the conventional 15 75KHZ The YC Jungle IC is replaced by a separate video process IC511 and a horizontal jungle IC507 High voltage is developed in a separate circuit and will be covered in Chapter 11 The vertical deflection circuit has had some notable changes such as its own digital deflection generator The output sta...

Page 44: ...nerates a positive and negative voltage source that will be applied to the red and blue CRTs This will provide the necessary offset for centering since these tubes are not in the center of the optical path Notice that the collector of Q5013 does not have a B source A negative 135V source is applied at the emitter and this voltage will vary based on conduction of the pincushion output transistor Q5...

Page 45: ...chnicians prefer to ring suspected transformers This is OK and is very good at detecting shorts in the windings However it is not 100 accurate Problems in transformers sometimes appear under full voltage and current load so the above procedure is very effective although it requires caution and close current monitoring Pincushion Circuit Troubleshooting The pincushion correction circuit in this cha...

Page 46: ...ace pulses are monitored by Q5019 After some clipping of the top and bottom of the spike it will be amplified by Q5014 As long as horizontal deflection is operating Q5014 will keep C5020 charged and Q5006 will be on Loss of the H pulse will cause Q5006 to turn off sending a high signal to IC1009 to shut the set down Troubleshooting this circuit requires extreme care Since the unit goes into immedi...

Page 47: ...ed by VDSP IC512 Synchronization is achieved by VS entering pin 22 Notice the H signal entering at pin 16 Since this unit generates internal interlaced horizontal scan the vertical must be phase locked to start the odd and even scan in the proper location The parabolic pincushion correction waveform exits pin 11 and vertical drive is output at pin 1 as a sawtooth Figure 10 6 shows the usual output...

Page 48: ...R692 R534 C630 C657 C660 C667 V DRIVE TO IC507 2 H JUNGLE PIN E W CN509 VBLK VP FIGURE 10 5 VDSP 10 5TVP14 5 28 02 D BOARD 5 3 4 1 2 6 7 6 3 5 4 7 1 3 R5028 15V CN5002 L5003 C5024 CN5009 DEF 5V C5033 C5035 C5029 D5017 RD24ESB1 R5075 R5073 R5043 C5049 R5047 C5028 R5038 R5021 L5004 CN5004 V DRIVE FROM IC512 11 15V CN5002 R5029 C5025 D5016 RD24ESB1 TO CIRCUIT NOT USED D5011 C5037 C5034 D5010 R5040 C5...

Page 49: ...nt or soon thereafter it is usually the fault of C5037 This is the boost capacitor It charges to almost 30VDC during the lower half of the vertical sweep to provide additional voltage to allow the beam to retrace to the top rapidly When this filter dries out or opens the output IC will attempt to accomplish the retrace but the negative feedback line will resist the sudden voltage kickback from the...

Page 50: ... and troubleshooting is relatively the same When regulation or shutdown problems occur diagnosis becomes more difficult because the circuit is critical for X radiation control and to protect the small CRTs The anode cap is very close to the grounded mounting brackets and the deflection yoke It can easily damage the CRT if it leaks out of the anode cap Regulation is performed at the driver and outp...

Page 51: ...art s and it is part of a critical safety circuit Place your scope probe somewhere near the HV output transistor or flyback Most scope probes are not able to handle the direct spike level from the flyback so this is a safe method Just turn up the gain a little on the scope and you will easily see the retrace pulse Apply full AC power with the variac and watch for the pulse assuming it appears befo...

Page 52: ... or all of the tubes displaying a bright raster before the shutdown Normal Current Draw This could be a true high voltage problem or a malfunctioning protect component It is not recommended to insert a HV probe into the anode cap of a CRT to check the HV level If the unit has excessive high voltage it can easily arc from the anode cap since you have lifted it A safer way is to disconnect one of th...

Page 53: ...iously described in Figure 11 3 Since the sawtooth signal is applied to the inverting input of IC8002 pin6 any rise of the DC voltage at the non inverting input at pin 5 will cause the comparator to output a high only when the level of the sawtooth is greater than the DC voltage input Since the sawtooth enters the inverting input the positive duration of the pulse is increased and the HV regulator...

Page 54: ...hs for the first set of protection components HV level is monitored from the HV block by pin 3 of IC8008 This is compared to a reference of 9 3VDC at pin 2 If the high voltage rises above acceptable levels 34KV pin 3 will exceed the reference Pin 1 will go high The H pulse driving the HV circuit will be grounded by Q8019 and the high signal will sent to OSD CPU IC1009 to flash the timer LED in seq...

Page 55: ...02 HV Stop 2 Referring to Figure 11 6 the second HV protect circuit is shown It functions in a similar manner as HV stop 1 with a few differences Q8031 monitors voltage from the flyback transformer rather than the HV block assembly Pin 5 of IC8010 will receive this signal and instead of comparing it to a fixed reference the ABL voltage is used The reason behind this design is to shut down the high...

Page 56: ... B HV STOP 1 TO HD BUFFER Q8005 B TO IC1009 OSD CPU FROM HV STOP 1 IC8010 1 IC8008 1 FIGURE 11 6 HV STOP 2 11 6TVP14 7 11 02 12V Troubleshooting Tips Since there are two sets of protect circuits isolating which one is activating is the first step This is easily accomplished by monitoring either anode of D8021 in Figure 11 6 to determine which circuit is sending the high signal This may only be use...

Page 57: ...he possibility of traveling either one of two paths The main or the sub All non component video for main viewing will route through the A D converter IC1309 not shown on this diagram and into the 3D comb filter IC1306 Even S video sources will be routed here The 3D comb filter contains noise reduction circuitry for the luminance signal and this will be done for S video sources Composite signals wi...

Page 58: ...utdown Fortunately this chassis will indicate the shutdown by blinking the timer LED in sets of seven In that case refer to the earlier chapter dealing with high voltage shutdown The next step is to wait at least 15 seconds and observe if the timer LED begins to blink in sequences of five You now know that you are dealing with an AKB error Go to Chapter 27 which specifically deals with AKB problem...

Page 59: ...ce If video signals are present at pins 67 69 and 69 of IC511 replace IC511 No signals at these pins indicate the BR board is not sending up converted video Check to see if video is entering the BR board and the 3 3V and 5V lines are OK If they are present replace the BR board It is not serviceable Video Appears In Left Box Only The sub video path is OK Once again the DRCTM is bypassed This leaves...

Page 60: ...ER FROM Q1345 E CHROMA C BUFFER FROM RESET Q1015 C R1509 FROM IC1008 MAIN CPU SCL SDA Q1359 N DB1 DB8 CLK IC1309 8 BIT ADC uPC659AGS PCL C1409 DYC00 DYCO1 AYO ACD IC1306 3D COMB FILTER uPD64081BGF 3BA FSCI DYC09 DYC02 MAO MAB ALTF STO MIOO MIO15 CSI ACI RSTB MWE MCAS MOE SCL SCA X1 MRAS LUMINANCE CHROMA P Q1349 C1496 R1434 N A0 A8 IO1 IO16 R1391 C1370 R1437 WE LCAS UCAS OE RAS IC1304 FRAME MEMORY ...

Page 61: ...ADR R1546 P Q1367 Q1366 N 9V 9V R1393 R1400 Q1331 R1405 Q1332 C1381 P C1376 C1389 R1463 V TIM HTIM SCP CPIN Q1321 P Y OUT U OUT Q1322 P R1375 9V Q1323 Q1338 P C1483 Q1328 N R1401 R1402 N R1408 R1464 CV Y SELY CLPP Q1330 R1374 9V C1457 C1456 C1435 R1383 P Q1343 R1445 IC1008 8 VP CN516 4 BR BOARD CN518 7 BM BOARD IC1008 7 HP CN516 2 BR BOARD CN518 8 BM BOARD TO IC1307 1 YI IN TO IC1307 2 CBI IN TO I...

Page 62: ...IC1008 33 FROM IC1008 34 FROM IC1008 36 IC1008 IS MAIN CPU R1530 C1464 C1463 R1503 FROM IC1305 16 SCP C1462 DVD Y CV Y SEL Y Y1 IN CB1 IN CR1 IN Y2 IN CB2 IN CR2 IN Y OUT CB OUT R IN G IN B IN YS YC1 P CBCLP CRCLP CLPP CR OUT Q1328 9V N R1538 TO Q1324 CCD BUFFER TO IC1305 34 MAIN CHROMA 9V Q1325 R1320 N R1527 TO CN516 10 BR CN518 1 BM R1309 9V R1537 Q1326 R1528 R1536 R1536 N TO CN516 8 BR CN518 3 ...

Page 63: ...RY IC645 1 MB MEMORY IC562 uP CONV CDX2070Q IC460 CLOCK DRIVER IC463 uP CONVERTER CXD2062Q IC641 CLOCK DRIVER IC304 uP CONV CXD2071R 2 4 6 8 10 13 14 FROM CN516 A BOARD CN302 M Y M B Y M R Y 8 BIT Y 8 BIT C M VD M HD 8 BIT Y 8 BIT C CN301 RC Y RC B Y RC HD RC VD TO A BD CN511 NOM Y BRMI CN302 13M 27M 12 6TVP14 6 11 02 FIGURE 12 6 DRC DIGITAL REALTY CREATION ...

Page 64: ...MORY IC009 MID CPU IC005 NVM IC014 SBADC B CH PLL IC013 MEMORY IC010 MID CONTROLLER 1 3 5 7 8 12 19 20 1 3 5 7 8 10 11 12 13 14 16 18 20 CN001 M Y M R Y M B Y M VD M HD VP MSCL MSDA MID 12C CN002 S Y S B Y S R Y S HD S VD MID V MID H MID Y S MID R Y MID B Y MID Y 12 7TVP14 6 10 02 FIGURE 12 7 MID BLOCK ...

Page 65: ...2 E FROM Q1002 E FROM Q1001 E FROM Q1003 E FROM IC1008 61 0 SYNC SEL Q546 Q530 MID XRC VD HD MID HD MID VD RC HD RC VD IC509 SYNC SW EY IN ECB IN ECR IN TCACR SW R OUT G OUT B OUT IK IN VM OUT VI IN HI IN R S H G S H B S H CRI IN CBI IN HP IN YI IN SCP SY SM IN LR1 IN LG1 IN LB1 IN VBIK HS OUT YS YM2 LR2 IN LG2 IN LB2 IN VS OUT IC511 VIDEO PROCESSOR CXA2101AQ C622 C617 C611 R635 0 OHMS OR Q620 Q52...

Page 66: ...rwent some changes to allow it to operate at 33 4KHZ in addition to 31 5KHZ in order to display 1080i The video 5 input allowed for either RGB or component video from a HD source Although video 4 provides for component input it will not accept the 1080i format Any 1180i format signals received will be directly routed to the video processor The HD video source is unavailable to the multi image driv...

Page 67: ...b video will pass through a glass comb filter and sub decoder This will provide the necessary sources for P P processing for the multi image driver The main video source will continue on to the BR board where the DRC circuitry will perform line doubling for 960i display Video 4 input allows non HD component video to bypass the decoder and comb filter for line doubling by the DRC Although the video...

Page 68: ...cture feature provided by the BM board will assist in localizing the area in which the signal is being lost Since this circuit has the ability to display the main and sub video sources simultaneously it is valuable as a first step The main path video should appear in the right box and the sub video in the left Engage P P with the remote and determine where the fault lies based on the following res...

Page 69: ...eo The idea is to narrow down the area in which the problem is present With the introduction of multiple A D and D A converters and digital processing circuits noise in the video is likely to be more common and can take on some strange symptoms Fortunately most digital noise problems have a distinct digital appearance They may be stationary on the screen or move around in a clock like stepping mot...

Page 70: ...ill place the 960 inter laced lines inside of the fixed 1080i scan rate The remaining 120 unused lines 60 above and 60 below will be moved into the over scan area by increasing vertical size 480p sources are converted to 960i by the MIDTM circuit and inserted into the 1080i fields in the same manner 720p is converted to 1080i by the MIDTM The power supply is of a new design Power supplies would be...

Page 71: ...er current conditions These will cause the unit to shut down without any indications from the diagnostics feature Several photo optical devices are used to latch certain lines to turn off the main relay or stop the oscillators from running These will be covered in Chapter 17 Standby Power Supply As illustrated in Figure 16 1 the standby power supply is rather unique in that the incoming AC voltage...

Page 72: ...ile Q6008 is off Current is monitored at R6083 and R6084 and input to pin 9 of IC6002 The voltage at this point is zero under normal operating conditions A rise above 2V causes the oscillator to run at high frequency Since the shift to high frequency may alleviate the over current condition a fluctuation of normal to high frequency bursts can occur Regulation is accomplished by monitoring the 6 5V...

Page 73: ... than 70VAC It is normally 2 5VDC at 120VAC The oscillator cannot start below 70VAC The old method of jumping the main relay and bringing up the AC voltage with a variac will not work in this power supply design Even with the main relay jumped and an external DC source applied to the V Sense line the oscillator will not start until at least 70VAC is reached At the 70VAC level the oscillator will s...

Page 74: ...isolated quickly Verify a legitimate problem by measuring the 6 5V at turn on If it stays at 6 5V suspect a faulty zener diode D6133 or Q6110 Q6111 and associated components If the over voltage condition is occurring locating the component is done by grounding pin 2 of IC6002 This should bring the 6 5V line below its normal voltage by forcing the oscillator to a higher frequency If not IC6002 is f...

Page 75: ... Secondary Supply Once the primary supply has been proven to be operating correctly the diagnostics checks are similar to servicing the primary supply As long as there is confirmation of no problems in the primary circuits the main AC relay RY6001 can be jumped and power applied with the variac AC current and the 135V line voltage must be monitored closely By monitoring AC current and the 135V lin...

Page 76: ...one B OCP Excessive current on the 135V line This is usually caused by flyback problems or secondary loads on the line The circuit could also be tripping for no reason This is why you should always monitor AC current while the unit is shutting down It will help to know if you are really dealing with an over current condition and a more cautious approach can be taken while troubleshooting B OVP The...

Page 77: ...1 AC In OVP The unregulated B in the standby supply primary is monitored by Q6010 and will turn on PH6004 to activate the protect latch This is illustrated in Figure 16 1 in Chapter 16 2 Audio Protect The speaker lines are monitored for DC component by Q2608 Q2609 and Q2610 on the K board 3 15V OVP Monitored by Q6101 and D6121 as shown in Figure 17 2 4 22V OCP Excessive current on or loss of 22V a...

Page 78: ...ur less that 500ms apart The timer LED will flash at one second intervals until the CRT cathodes return IK pulses and the picture will appear No Clicking Of Relays Look for one second flashes of the timer LED If none are present the standby supply is not operating or the main CPU IC001 is not operating If the timer LED flashes at any time the standby supply is OK Suspect problems in the relay driv...

Page 79: ...isk of further component damage is minimized while searching for the cause CN2103 on the K board should be disconnected first to eliminate the audio circuits If the shutdown persists monitor the voltage at pin 7 of IC8006 on the D board This pin should remain low unless excessive HV has occurred From this point it becomes a matter of checking voltages on the monitored lines with a peak hold DVM or...

Page 80: ...rts and it also may have been the reason for the failure Apply full AC power with the variac and watch for the horizontal pulse assuming it appears Monitor the AC current level closely while doing this If the unit is still going into protect mode this will have to be observed during the period from startup to shutdown Clean pulses should appear and be 11 to 13us wide Any deviation from the normal ...

Page 81: ... of multiple component replacement for a simple vertical problem You should always check the clock and data level whenever you have a strange problem and particularly if it appears that you more than one problem Although most television chassis will not produce vertical deflection some will generate other symptoms As an example The AA 2W used in Sony s KV32 36XBR200 sets will display a magenta col...

Page 82: ... of the operational amp within IC5004 it is rare for it to not be able to amplify properly Operational amps have massive amounts of gain which is why they need negative feedback to keep them under control Suspect IC5004 as the last possible cause Gain problems can be caused by improper supply voltage very rare or problems in the feedback line more likely This is why you should always scope the fee...

Page 83: ...uitry on the D board for generating high voltage The main components consist of a regulator stage to vary the B level to the flyback transformer for HV level control a driver and output stage to switch the flyback on and off a flyback transformer to generate HV and a LOT transformer to generate heater voltage and 200VDC for CRT cathode bias IC8008 is a PWM generator and driver to control the on an...

Page 84: ... rise above 7 5VDC which would signal a HV regulator problem Apply full AC power with the variac and watch for the pulses assuming it appears You are going to have to attempt to observe them during the startup and shutdown duration If the flyback is defective one of two waveforms is likely to appear The first may look like a sinusoidal waveform with a distinct ringing appearance This definitely in...

Page 85: ...A properly functioning and adjusted protect circuit will trip at 34 5 50KV so you should be able to see this with the probe High Voltage Exceeds 35KV Connect a DVM with peak hold to pin 12 of IC8008 The voltage should read approximately 7 5VDC A peak voltage of 7 5V or less indicates a defective HV block or IC8008 is loading the feedback line If the voltage level exceeds 7 5V by a considerable amo...

Page 86: ... R8153 FBT ABL D8038 R8099 R8139 15V FBT ABL R8151 R8157 R8150 R8141 15V Q8029 Q8028 IC8007 IC8006 D8025 D8015 D8023 D8016 D8008 Q8022 Q8021 R8138 R8142 15V 15V D8043 R8128 TO MAIN RELAY LATCH PROTECT H PULSE LATCH HV BLOCK SAMPLE FROM IC8008 T8005 SAMPLE FIGURE 19 2 HV PROTECT CIRCUITS RA 5A CHASSIS 19 2TVP14 1469 6 11 02 ...

Page 87: ...stribution to the red green and blue CRTs The AD board is mounted to the A board and contains the digital convergence circuitry along with a RGB output to IC3006 to display convergence data auto registration flags for the sensors during Flash FocusTM and internal crosshatch and dot patterns Although this chassis is currently a board level repair unit the distribution of the video signals among thr...

Page 88: ...g in sequences of five AKB troubleshooting will be covered in Chapter 27 Once high voltage and AKB have been ruled out try bringing up the customer menu If it appears there is a good chance the video process IC3006 is working properly If it does not appear try entering the service mode The OSD for this mode comes from the main CPU IC001 on the B board The appearance of the service data also confir...

Page 89: ... lack of video indicates a failure of both the main and sub video paths Since all decoding and video switching of the main and sub paths occur on the B board this is where the problem lies Video Level or Distortion The same procedures used to isolate a no video condition can be used to locate the source of distortion or level problems With the introduction of multiple A D and D A converters and di...

Page 90: ...e to accept two sources of HD video from external devices using component video It will not accept RGB or VGA sources The power supply contains far less components than previous models and is easier to troubleshoot New circuit designs and screen composition provide a sharper picture compared to previous models to take advantage of the high definition display capabilities The Flash FocusTM circuits...

Page 91: ...its own as long as start and correct sense voltage is present Once the supply is running it will supply its own stable power source known as VC1 and input it at pin 8 When pin 16 of IC6003 is high Q6006 will turn on 300VDC will be output at the source to C6047 and it will charge Current flows through the primary of the PIT entering pin 1 and exiting pin 2 R6076 and R6080 provide the ground return ...

Page 92: ... PS5006 PS5002 5A PS5001 5A 5V 6V 11V 15V 22V 22V 135V 15V TOIC5002 OCP FIGURE 22 1 MAIN POWER SUPPLY RA 6 CHASSIS 1 2 D6002 22 1TVP14 1470 7 11 02 Troubleshooting A failure in the main supply can occur due to several reasons Below are some possible scenarios 1 The oscillator and or drive circuits will not operate 2 Component failure due to excessive current or line transients 3 Regulation problem...

Page 93: ...ial current surge of 2A or more indicates an over current condition Begin removing secondary supply sources This can be done by lifting diodes or fuse links Start with the 135V line since this is the likely source Do not lift the diodes for the 135V This will open the regulation loop and cause the supply to output maximum power Disconnect at CN504 If the over current condition still exists the pro...

Page 94: ...es the LED to increase in brightness Pin 4 of PH6001 will pull down the voltage at pin 2 FB of IC6003 and the oscillator frequency will rise to reduce the output voltages at the secondary lines The opposite chain of events will occur if the 135V line should drop in voltage The use of variable DC voltages in the regulation loop allows for simple troubleshooting methods Excessive B The unit will shu...

Page 95: ...ear these and that is a mistake You can do it right from this screen B OCP Excessive current on the 135V line This is usually caused by flyback problems or secondary loads on the line The circuit could also be tripping for no reason This is why you should always monitor AC current while the unit is shutting down It will help to know if you are really dealing with an over current condition and a mo...

Page 96: ... The timer LED blinks continuously at one second intervals and as soon as 101 of them occur a failure is registered The above protection circuits have dedicated communications directly or indirectly with the main micro controller IC704 located on the A board The 135V OCP OVP Low B H Stop HV and AUDIO lines have direct connections V Stop and AKB notify IC709 by way of the video process IC309 which ...

Page 97: ...ry of T6001 are monitored for the loss of these voltages There is no current protection Only the 135V line is monitored for over current and this is displayed in the diagnostics feature Even though an over current condition may have been the original cause these lines are protected with fuse links One or more of the fuses may be open causing the shutdown Checking the fuses with an ohm meter is the...

Page 98: ...F DIAGNOSTICS D5022 RY6002 D5017 C5050 9 8V R5011 IC5005 IC5002 C5051 Q5005 R5010 R5013 5V AU 19V AU 19V 15V 15V AU 19V 22V IC5004 6V 135V D5019 D5023 D5033 D5026 D5024 R5043 D5025 R5046 D5032 D5031 Q5007 6V D5014 R5012 T6001 PIN 11 ABL Q5004 Q5003 D5015 R5021 RELAY HIGH R5028 Q5001 D5018 6V OVP 23V FIGURE 23 2 PROTECT CIRCUITS RA 6 CHASSIS 23 2TVP14 1471 7 11 02 ...

Page 99: ... way to utilize the soft start feature of the power supply to get an initial idea of the status of this circuit Place an oscilloscope probe near Q8027 and set the gain to 500mv Set sweep for horizontal frequency viewing Apply 120VAC to the set while watching the scope The soft start in the main supply will keep initial current at approximately 50 of normal level for about three seconds In this cha...

Page 100: ...number one cause of multiple component replacements for a simple vertical problem You should always check the clock and data level whenever you have a strange problem and particularly if it appears that you more than one problem Although most television chassis will not produce vertical deflection some will generate other symptoms As an example The AA 2W used in Sony s KV32 36XBR200 sets will disp...

Page 101: ...operational amp within IC5004 it is rare for it to be the cause Operational amps have massive amounts of gain which is why they need negative feedback to keep them under control Gain problems are most likely to be caused by improper supply voltage very rare or problems in the feedback line This is why you should always scope the feedback line when height or linearity problems arise In this chassis...

Page 102: ...f the circuitry on the D board for generating high voltage The main components consist of a regulator stage to vary the B level to the flyback transformer for HV level control a driver and output stage to switch the flyback on and off a flyback transformer to generate HV and a LOT transformer to generate heater voltage and 200VDC for CRT cathode bias IC8008 is a PWM generator and driver to control...

Page 103: ...trace pulse with a second lower level phantom pulse which also indicates a defective flyback If the retrace pulse looks great but starts to jitter and dance on the scope screen this usually indicates excessive loading of secondary lines In this unit it can be loads on T8004 Measure for shorts on the filament and 200V line The flyback transformer T8003 only has two load circuits and they are the HV...

Page 104: ...ould read approximately 7 5VDC A peak voltage of 7 5V or less indicates a defective HV block or IC8008 is loading the feedback line If the voltage level exceeds 7 5V by a considerable amount the feedback loop from the HV block is OK and the PWM generator is not operating properly or the tuning components at Q8034 are defective To isolate the problem take a peak reading at the output drain of Q8035...

Page 105: ...223 R8153 FBT ABL D8038 R8099 R8139 15V FBT ABL R8151 R8157 R8150 R8141 15V Q8029 Q8028 IC8007 IC8006 D8025 D8015 D8023 D8016 D8008 Q8022 Q8021 R8138 R8142 15V 15V D8043 R8128 TO MAIN RELAY LATCH PROTECT H PULSE LATCH HV BLOCK SAMPLE FROM IC8008 T8005 SAMPLE FIGURE 25 2 HV PROTECT CIRCUITS RA 6 CHASSIS 25 2TVP14 7 17 02 ...

Page 106: ...lti Image Driver Due to the Twin Picture feature and Component inputs several switching stages are incorporated to alter the path of incoming video It is these switching circuits along with main sub and component paths that add to the complexity of the video circuit design but these can be used to an advantage when attempting to isolate sources of video problems Even though board replacement is cu...

Page 107: ...IC3410 D A IC3414 YUV SW IC3303 DRC IC304 A D YUV RGB IC309 VIDEO PROCESS R G B RGB PJE OSD AD BOARD IC704 MAIN uCOM YUV YUV A BOARD TO CRT DRIVER BOARDS YUV YUV YUV YUV YUV YUV SUB Y SUB C MAIN TUNER SUB TUNER VIDEO 1 VIDEO 3 VIDEO 4 VIDEO 5 VIDEO 6 Y C CV Y C Y C FIGURE 26 1 VIDEO PATH RA 6 CHASSIS CV A BOARD U BOARD B BOARD 26 1TVP14 1477 7 17 02 VIDEO 2 ...

Page 108: ...its can be bypassed to further verify the operation of IC309 If you do not have a HD generator using the Twin Picture mode with main and sub tuner video will be adequate By using this feature the main and sub video paths are displayed together and a wealth of information can be obtained to isolate the video failure Video Appears in Right Box Only The sub video path is working correctly An interrup...

Page 109: ... 82V p p C 0 62Vp p Y PB PR V5 Y PB PR V6 TO YCT MAIN IC303 COMPONENT SWITCH IC306 TO YCT SUB IC301 Y PB PR 480i 75 CB Y 0 82Vp p PB O 53Vp p PR 0 53V p p Y PB PR 480P 75 CB Y 0 82Vp p PB O 53Vp p PR 0 53V p p FIGURE 26 2 VIDEO SWITCHING RA 6 CHASSIS 26 2TVP14 1474 6 13 02 U BOARD U BOARD screen or move around in a clock like stepping motion Minor or severe loss of picture detail is caused by one ...

Page 110: ... Y PB PR Y 1 1V PB 1 0Vp p PR 1 0Vp p SUB 480i RF V1 4 MAIN 480i RF V1 6 SUB MAIN 1080i 480P Y IN C IN CXA2103 2 SCON SCOL SHUE ADJUST RF VIDEO 46 48 IC301 YCT SUB CXA2103 3 2 1 33 34 35 41 42 43 27 28 25 Y O 5V PB 0 5Vp p PR 0 5Vp p Y PB PR Y PB PR Y PB PR IC306 COMP SW CXA2151 Y O 7V PB 0 5Vp p PR 0 5Vp p A19 Y C16 B Y A17 R Y Y PB PR C20 Y C22 B Y C21 R Y 88 96 IC2004 A V SW MAIN 1080i 480P V5 ...

Page 111: ...P P FREEZE V5 6 SUB 480i RF V1 4 41 11 YPB PR 8 BIT 44 46 42 YPB PR IC3410 8 BIT D A CXD2309Q 3 2Vp p DIGITA L 3 2Vp p DIGITA L 3 2Vp p DIGITA L 16 11 8 1 14 9 Y PB PR Y PB PR 2 7 12 SELECT PINS IC3414 Y PB PR SWITCH M52055FP IC704 PIN 52 L 16 11 8 H 1 14 9 Y 1 05V 1 85Vp p PB 1 05Vp p PR 1 05Vp p 3 5 6 Y B Y R Y Y 0 5Vp p B Y 0 5Vp p R Y 0 5Vp p 20 21 22 Y B Y R Y 64 63 62 IC309 VIDEO PROCESS R 2...

Page 112: ...televisions They are usually located on lines 19 20 and 21 so this will be used to explain the circuit further The pulse for the R signal will be on line 19 the green on line 20 and the blue on line 21 The video processor now has a timing reference in order to view each of these pulses as they are returned from their respective cathode When a cathode draws more current the pulse that it received w...

Page 113: ...D simply blinked at one second intervals indicating a problem but not where it was located High voltage and vertical deflection had to be checked first The newer models incorporating diagnostics will flash the timer LED at intervals of five followed by a three second separator Any failures in vertical deflection or high voltage will appear in the diagnostics well before AKB is expected There are t...

Page 114: ...for loss due to failure or short to G1 If OK read the DC voltage on each cathode NOTE It is very important to verify that G2 cutoff is set properly for this check The AKB circuit will correct for improper screen voltage by increasing or decreasing video drive If G2 is set too low the AKB circuit can blank the video Adjust each CRT to retrace lines and back off until they disappear On a properly fu...

Page 115: ... cathodes measure 180V or more suspect an intermittent CRT short Carefully tapping on each neck can sometimes locate the short Getting the customer to describe what the picture looks like when it blanks is also helpful although they are not always accurate in describing the color HINT The green CRT in a projection set is the most likely to have shorted elements Since it is pointing straight up it ...

Page 116: ...s labeled as the AD board In the RA 3 series the circuits reside on the A board Convergence is adjusted by entering the service mode and selecting the PJED group with the 2 or 5 keys PJED stands for Projection Engine Digital The lettering at the top of the screen will change from green to white Graphics for convergence alignment are generated as RGB signals by the convergence CPU and sent to the v...

Page 117: ...e to do so is a common cause of errors when writing sensor data With the new CRT installed and the yoke roughly positioned press 7 followed by enter The data in the convergence CPU registers will zero out and the convergence will be severely misaligned Now that any potential skew correction has been removed the yoke can be rotated to place the particular color as close as possible to the proper po...

Page 118: ...tration purposes Sensors 0 and 3 are used for horizontal centering skew and limited vertical size control Sensors 1 and 2 are used for vertical centering skew and limited horizontal size control It is important to know the numbers of these locations since they are identified when an error occurs during Flash Focusing If the model uses eight sensors the adjustment section of the service manual will...

Page 119: ...e by using the left and right pair Vertical centering skew and vertical size will occur by the flags changing their position by 90 for the next step as illustrated in figure 28 3 Each procedure is always performed twice since centering and skew adjustments will sometimes affect size The process will be repeated for the red and blue colors and if all goes well the auto registration alignment will e...

Page 120: ...ll encounter a unit in which another technician has improperly aligned the geometry and or convergence The customer may have also managed to alter the alignment settings by gaining knowledge of access to the service mode In such cases default settings of global size and centering should be entered and proper size and centering performed in the PJE mode by using a calibrated external generator In m...

Page 121: ...d if the flags display unevenly after correct centering size and skew have been confirmed with a calibrated source Error Codes Figure 28 4 illustrates what will appear on the screen if an error occurs This error message only appears while in the service mode Any errors that arise during a Flash FocusTM will be stored into the NVM and can be read in the PJE mode under PJE ERR This is shown in Figur...

Page 122: ...hanical H skew H center and or HMID data 32 H linearity or size loop overflow Check H size HLE and HRIV data 40 V center registration data overflow Check VMID data Confirm V center data is not near 511 for all modes 41 H center registration data overflow Check HMID data Confirm H center data is not near 511 for all modes 42 V SKEW registration data overflow Check VMID data Confirm V skew data is N...

Page 123: ...200 RA 4 KDP65XBR2 RA 5A KP51HW40 RA 6 KP48S70 RA 3 KP53XBR300 RA 4A KP53HS20 RA 6 KP48S72 RA 3 KP61XBR300 RA 4A KP53HS30 RA 6 KP48V80 RA 3 KP53HS10 RA 4B KP57HW40 RA 6 KP53N74 RA 3 KP61HS10 RA 4B KP61HS20 RA 6 KP53S70 RA 3 KP57XBR10W RA 4W KP61HS30 RA 6 KP53V80 RA 3 KP65XBR10W RA 4W KP61S70 RA 3 KP61V80 RA 3 KP43T75 RA 3A KP48S75 RA 3A KP48V85 RA 3A KP53N77 RA 3A KP53S75 RA 3A KP53V85 RA 3A KP61S...

Page 124: ...Inc EMCS A Service Company 1 Sony Drive Park Ridge New Jersey 07656 Reproduction in whole or part without written permission is prohibited All rights reserved TVP140702 07 18 02 Flash Focus DRC and MID are trademarks of Sony ...

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Sony KDP-57XBR2 - Digital High Definition Projection Tv, Training Manual

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