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Sony KDS-R60XBR1 - 60" Rear Projection TV, Training Manual, Page: 42 / 122

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Sony KDS-R60XBR1 - 60

TVP-21 

39

Disassembly Procedures

DSU-Board Removal

1

To access the DSU-Board, remove 

the Chassis assembly from the 

Bottom Cabinet.  For instructions on 

removing the Chassis reference 

Chapter 3 – Chassis Assembly 

Removal. 

DSU-Board Removal

2

After removing the Chassis 

assembly, remove 16 screws and 

the Connector Cover to remove 

DMB outer shield.

When all screws are removed, 

pull the left-side of the shield out 

first to clear the i -link connectors 

on the right-side of the shield.

Once i-link connectors are clear 

pull shield straight off.

Screws

Connector 

Cover

Summary of Contents for KDS-R60XBR1 - 60" Rear Projection TV

Page 1: ...Models KDS R50XBR1 KDS R60XBR1 Diagnostics and Troubleshooting Course TVP 21 Training Manual ...

Page 2: ...n 60 Power ON Sequence 61 Troubleshooting Flowchart 62 Power On 62 Technologies Features 1 Technology 1 Silicon Crystal Reflective Display SXRD 1 Features 3 Advanced Iris 3 PC Input 4 Non Technical Triage Flowcharts 5 Technical Troubleshooting Flowcharts 14 Disassembly Procedures 24 Screen Frame Removal 24 Rear Sub Plastic Cover Removal 26 Chassis Assembly Removal 27 Optics Block Fan Removal 29 Pow...

Page 3: ...g Flowcharts 69 Troubleshooting Flowchart Step Descriptions 73 Lamp Error Lamp LED 73 Temperature Error 2X 73 Lamp Cover Plug Error 3X 74 Fan Error 4X 75 Lamp Drive Error 5X aka Lamp Power Supply Block 76 Low B Error 6X 77 Audio Output Error 7X 78 Panel Error 9X 78 Chapter 5 Video Processing System 80 Overall Block Diagram 80 Overall System Description 81 Video Circuits Functional Description 82 T...

Page 4: ...nd the liquid crystal material The light only passes through the liquid crystal material once The liquid crystals modulate the light as it passes through the panel o The liquid crystals when layered from a 90 degree angular orientation after so many layers Therefore light is completely passed when no potential is applied to the liquid crystals o The Panel depth is thicker then the SXRD technology ...

Page 5: ...he way back out of the panel o The liquid crystals when layered maintain the same angular orientation between layers Therefore light is blocked when no potential is applied to the liquid crystals o Panel depth is greatly decreased due to the LCD drivers and the liquid crystal materials are jointly sealed directly to the silicon chip substrate o The distance between pixels is greatly diminished no ...

Page 6: ...range between blanking and reference white level Basically the video scene is measure for overall brightness level and the iris s aperture opening is increased of decreased to either increase the whites in the brighter scenes or decrease the blacks in the darker scenes Subsequently achieving a contrast ratio for the SXRD models approaching10 000 1 500 cd m2 0 025 cd m2 250 cd m2 0 05 cd m2 Black W...

Page 7: ...ereo Mini Plug for the PC There is a complete table of PC Input Signal Compatibility in the Owners Manual Page 100 Table A provides the suggested PC Input Signals for best display results due to the 60Hz Vertical frequency Table A PC Input Signal Compatibility Chart Best Results Signal Format Horizontal Pixel Vertical line Horizontal Frequency kHZ Vertical Frequency Hz VGA 640 480 31 5 60 SVGA 800...

Page 8: ...No Yes Is Video Distorted Is Audio Present No No No No Yes Yes Yes Yes GO TO Triage Power ON Flowchart BT GO TO Triage Protection Mode Flowchart CT1 2 3 4 GO TO Triage Missing or Distorted Video Flowchart DT GO TO Triage Video Input Flowchart ET GO TO Triage Missing or Distorted Audio Flowchart FT No Problem Found Unit Fully Operational AT Is Red Power Standby LED Flashing ...

Page 9: ... TV OK Set Remote to TV mode Install New Batteries ASU DSU Assembly Go to Appendix for Part Table A 1 A 2 G Board A 1138 898 A F Board A 1119 915 A Possible Component Failures Yes Does TV Turn On from Remote Replace Remote Control RM Y914 Problem Solved No No Yes 2005 SXRD Triage Power ON Flowchart BT Technician GO TO Power ON Troubleshooting Flowchart B Isolate Component Failure 4 Refer to the SX...

Page 10: ...3 098 A S2 A 1123 099 A High Temperature Warning is displayed before Shutdown for 1 5 mins then 2X Does unit still shutdown 2X Problem Solved Yes NOTE Except for the Lamp LED all flash patterns will occur on the Front Panel Red Power Standby LED Replace Optical Block Go to Appendix for Part Tables A 1 A 2 Replace ASU DSU Assembly Go to Appendix for Part Tables A 1 A 2 Confirm TV is a least 4 inche...

Page 11: ...eferred to as the Lamp Power Supply Block Replace ASU DSU Assembly Go to Appendix for Part Tables A 1 A 2 Replace ASU DSU Assembly Go to Appendix for Part Tables A 1 A 2 Primary Failure Component Secondary Failure Component Technician GO TO Protection Mode Troubleshooting Flowchart C2 Technician GO TO Protection Mode Troubleshooting Flowchart C2 Possible Component Failures Possible Component Failu...

Page 12: ...Part Tables A 1 A 2 Replace ASU DSU Assembly Go to Appendix for Part Tables A 1 A 2 Primary Failure Component Secondary Failure Component Technician GO TO Protection Mode Troubleshooting Flowchart C3 Technician GO TO Protection Mode Troubleshooting Flowchart C3 Possible Component Failures Possible Component Failures Isolate Component Failure Isolate Component Failure NOTE Except for the Lamp LED a...

Page 13: ...23 098 A S2 A 1123 099 A Replace Optical Block Go to Appendix for Part Table A 1 A 2 Replace ASU DSU Assembly Go to Appendix for Part Table A 1 A 2 Technician GO TO Protection Mode Troubleshooting Flowchart C4 Primary Failure Component Secondary Failure Component Possible Component Failures Isolate Component Failure NOTE Except for the Lamp LED all flash patterns will occur on the Front Panel Red ...

Page 14: ...T is to test individual inputs All Inputs Video 1 2 3 Composite S Video Video 4 5 Component Video Video 6 7 HDMI Video 8 PC IN ATSC NTSC SUB NTSC Tuners RF Memory Stick i Link Replace ASU DSU Assembly Go to Appendix for Part Tables A 1 A 2 Replace Optical Block Go to Appendix for Part Tables A 1 A 2 Primary Failure Component Secondary Failure Component Technician GO TO Video Distortion Troubleshoo...

Page 15: ...ions ET Premium Channels Digital Channels Distorted or Missing HDMI Distorted or Missing Only Replace Q Box 50 A 1152 713 A 60 A 1152 712 A Video 1 2 3 OK ATSC Tuner Memory Stick Video Distorted Troubleshoot CableCard System Replace PD Board PC IN Distorted or Missing Only Reference the POD 01 CableCard Training Manual Replace ASU DSU Assembly Go to Appendix for Part Tables A 1 A 2 Replace ASU DSU...

Page 16: ...SU DSU Assembly Go to Appendix for Part Tables A 1 A 2 All Inputs Audio 1 2 3 Composite S Video Audio 4 5 Component Video Audio 6 7 HDMI Audio 8 PC IN ATSC NTSC SUB NTSC Tuners RF Memory Stick i Link Replace K Board A 1138 895 A or AK Board A 1123 095 A Replace G Board A 1138 898 A Replace ASU DSU Assembly Go to Appendix for Part Tables A 1 A 2 Replace ASU DSU Assembly Go to Appendix for Part Tabl...

Page 17: ...bleshooting Flowchart B GO TO Protection Mode Troubleshooting Flowchart C1 2 3 4 GO TO No Video Troubleshooting Flowchart D GO TO Video Distortion Troubleshooting Flowchart E GO TO Missing or Distorted Audio Troubleshooting Flowchart G No Problem Found Unit Fully Operational A NOTE Reference Chapter 2 Pages 28 30 for detailed flowchart step descriptions Does Green Power Standby LED Turn ON Is Red ...

Page 18: ...down Is voltage 5V Present Replace G Board A 1138 898 A No Yes Replace ASU DSU Assembly Go to Appendix for Part Tables A 1 A 2 B G Board If video distortion check SW9V Check Connections between DSU Board Q Box Confirm Unit is connected to AC Outlet Is AC 110V Present at CN6014 Replace F Board A 1119 915 A OK Yes GO TO FlowChart C1 2 3 4 Protection Modes Red LED Flashes NOTE Reference Chapter 3 Pag...

Page 19: ...entilation areas and and confirm adequate local room temperature No Replace S1 S2 Boards S1 A 1123 098 A S2 A 1123 099 A High Temperature Warning is displayed before Shutdown for 1 5 mins then 2X Does unit still shutdown 2X Problem Solved Yes Does unit still shutdown 2X Replace Optical Block Go to Appendix for Part Tables A 1 A 2 Problem Solved Yes No Confirm that High Voltage Lamp connections are...

Page 20: ... 859 11 Fan 4 1 787 333 11 Drive Feedback No 5X Flash Pattern Lamp Driver Check Supply Voltage At X1 Connector Before Shutdown Is Voltage 380V Present Check Lamp ON Voltage CN2390 pin 4 Before Shutdown Does voltage go low 3 3V to 0 13V Replace Lamp Power Supply Block 1 468 936 12 No Yes Yes No Lamp Driver Board Replace G Board A 1138 898 A Does Spark Gap Light 3 Attempts 20 Sec Intervals Replace L...

Page 21: ...ns 9 15 CN6502 pin 6 Before Shutdown Are voltages 11V 5V Present Replace G Board A 1138 898 A Check Thermostat Continuity Is it 5 Ohms Yes No Replace Thermostat 1 576 885 11 Replace ASU DSU Assembly Go to Appendix for Part Tables A 1 A 2 Replace ASU DSU Assembly Go to Appendix for Part Tables A 1 A 2 Replace ASU DSU Assembly Go to Appendix for Part Tables A 1 A 2 NOTES 1 Except for the Lamp LED al...

Page 22: ...down 9X Problem Solved No Yes Does unit still Shutdown 9X Check Voltage Supplies to C Board CN6900 pins 4 6 Before Shutdown Are voltages 6 5V Present Problem Solved GO TO Flowchart B Power Supply Troubleshooting No GO TO Flowchart B Power Supply Troubleshooting Yes No Yes ASU Board C Board NOTE Also call Panel Error NOTE Includes C Board Replace ASU DSU Assembly Go to Appendix for Part Tables A 1 ...

Page 23: ...TO Video Distortion Troubleshooting Flowchart E Check Separate Inputs GO TO Protection Mode Troubleshooting Flowcharts C1 2 3 4 GO TO Optical Block Troubleshooting Flowchart F Replace Q Box 50 A 1152 713 A 60 A 1152 712 A ALL OSD s can be Displayed No Video D Only User menu and QM OSD missing All other OSD OK NOTE The main objective of Flowchart E is to test individual inputs All Inputs Video 1 2 ...

Page 24: ... Q Box 50 A 1152 713 A 60 A 1152 712 A Video 1 2 3 OK ATSC Tuner Memory Stick Video Distorted Troubleshoot CableCard System Replace PD Board A 1152 716 A All Inputs Video 1 2 3 Composite S Video Video 4 5 Component Video Video 6 7 HDMI Video 8 PC IN ATSC NTSC SUB NTSC Tuners RF Memory Stick i Link GO TO Optical Block Troubleshooting Flowchart F PC IN Distorted or Missing Only Reference the POD 01 ...

Page 25: ...wchart D Does OSD display No Turn ON PANEL SERVICE MODE OSD Yes In this case there is LCD drive however No video Therefore check video processing system In this case there is no LCD drive to the panels Therefore check the supply voltage to the C Brd Bright Raster is Displayed Dark Raster is Displayed Replace Optical Block Go to Appendix for Part Tables A 1 A 2 Use JUMP button on remote to display ...

Page 26: ...embly Go to Appendix for Part Table A 1 A 2 All Inputs Audio 1 2 3 Composite S Video Audio 4 5 Component Video Audio 6 7 HDMI Audio 8 PC IN ATSC NTSC SUB NTSC Tuners RF Memory Stick i Link Is 14V Present Replace G Board A 1138 898 A No Yes Check Speaker Resistance CN3003 Connections on K Board 10 6 ohms Connections OK Replace K Board A 1138 895 A or AK BoardA 1123 095 A No Repair or Replace Speake...

Page 27: ...e the two lower screen frame brackets Open the Lamp Door and remove 1 screw in the lower left hand corner when view from the rear of the unit Slide front cover to the right and remove Lower Front cover Slide to the Right Screw Lamp Housing 2 Remove 4 screws securing the lower screen frame brackets Screws Screen Frame Removal ...

Page 28: ...ght other screws Go around to the front of the unit Hold the screen frame assembly and the rear mirror assembly together at the top while removing the last top center screw Pull the Screen Frame assembly off and lay down on a soft pad Screen Frame Removal cont 4 Disconnect 2 connectors CAUTION Do not stand the Screen Frame assembly on the metal brackets Connectors Hold Together Metal Brackets ...

Page 29: ...ind sub cover Disconnect fan cable to completely remove cover Screws Shields Screws Release Wire Tie Bracket 3 Remove 4 screws and release the one wire tie Slide the bracket up slightly and pull off Disconnect the S1 Board Remove both shields to access the ASU Board CN2006 CN2010 CN2100 4 The ASU Board can be probed for troubleshooting at this point of the disassembly process It can not be remove ...

Page 30: ...sembly CAUTION Be extremely careful not to damage C Board cables while removing the Chassis Assembly Screws Small Cover Disconnect C Board cables 3 Lift Tabs Lift the two locking tabs and slide chassis straight out until it is stopped by the vertical bracket right side CAUTION Be extremely careful not to damage C Board cables when sliding the chassis out Gentle push cables under the DMB assembly B...

Page 31: ...side of the chassis assembly Disconnect Fan connector 5 Angle the left side of Chassis assembly out Slide the Chassis to the left around the vertical bracket and pull chassis out CAUTION Do not remove the vertical bracket This bracket is critical support for the Upper mirror and screen block Angle out Slide to the left Around vertical bracket 6 Completely remove the Chassis assembly and disconnect...

Page 32: ... assembly Screws Vertical Bracket 3 Detach the Power Supply Block from the fan housing Disconnect the power supply cable Remove wires from the two wire holders Squeeze the small tabs at the top of the board to remove board and lay to the side the red wires will remain attached Squeeze Tabs Disconnect Power cable Release wires Optics Block Power Supply Block and Fan Assembly Removal Fan Assembly Op...

Page 33: ...k the gray plastic cover must first be removed Remove the 8 screws securing the Optics cover Lift the 2 tabs and carefully slide cover back Also remove vertical bracket 1 screw CAUTION Lift the C Board cables and carefully feed them through the slot in the plastic cover Optical Block Cover Screws Lift Tabs Feed cabling through the slot Power Supply Block Screws Bracket ...

Page 34: ...ng the Optics Block CAUTION Do Not Touch the 6 screws mounted in the black plastic under the lower front cover Lower Front cover Screw Lamp Housing Slide to the Right Screws 6 The Power Supply Block must be removed with the Optics Block because they are attached by 1 internal screw inside the Lamp Housing The left edge also blocks the Optics Block from being removed To remove the Lamp Housing lift...

Page 35: ...ll cabling must be removed from Optics Block The cabling does not come as part of a new Optics Block Optics Block Power Supply Block and Fan Assembly Removal cont Screw 8 CAUTION Take care not to damage black plastic divider light shield when removing and installing the Optics Block Do not remove or damage black tape on the lens The black tape reduces glare and reflections Plastic divider Tape ...

Page 36: ...white tabs and dismount the Power Supply Block Power Supply Block Only Removal 2 Lay the Power Supply Block face down to the side of the unit Remove 1 screw securing the cable guide Remove 1 screw to dismount the Lamp plug CAUTION Be careful not to damage the Lamp plug detector switch when removing and installing the Power Supply Block Squeeze Tabs Disconnect Cables Release Cables Dismount Lamp Ja...

Page 37: ...t Direct the Lamp Jack out 3 The Power Supply Block including the Lamp Plug Cable Guide is pull out underneath the Fan assembly Carefully direct the Lamp Plug through the slot in the Lamp housing Note cable loop when re installing Ballast CAUTION Be careful not to damage Lamp Plug detector switch ...

Page 38: ... slide out the chassis Remove all wires from wire holders Disconnect USB cable Slide Out Wire Holders Wire Holders USB Cable 2 Remove 16 screws Small Cover and the Connector Cover to remove DMB outer shield When all screws are removed pull the left side of the shield out first to clear the i link connectors on the right side of the shield Once i link connectors are clear pull shield straight off D...

Page 39: ...first disconnect the CableCard ribbon cable Remove 2 white cable clamps that hold down the ribbon cable Disconnect the cable from the CableCard board by lifting the Tan connector tab CAUTION Make sure that the blue heat sink pads remain in place Also insure that black plastic wire protector remains in place Disconnect the LVDS cable located at the bottom of the Q Box assembly under the gray tape D...

Page 40: ...rame CAUTION Be carefully not to pull too far out and damage the wires still connected Screws Peel Back tape custom 6 Disconnect all cables on the Q Box module except for the CableCard ribbon cable This cable remains apart of the Q Box NOTE Reattach all wires before securing the replacement Q Box to the chassis assembly Disconnected Wires Disconnected Wires Unscrew RF connector Disconnected Wires ...

Page 41: ...TVP 21 38 Disassembly Procedures Access Removal of Q Box PD Board cont Digital Module Block DMB 7 Q Box assembly includes the QM QI QT and QH boards ...

Page 42: ...nce Chapter 3 Chassis Assembly Removal DSU Board Removal 2 After removing the Chassis assembly remove 16 screws and the Connector Cover to remove DMB outer shield When all screws are removed pull the left side of the shield out first to clear the i link connectors on the right side of the shield Once i link connectors are clear pull shield straight off Screws Connector Cover ...

Page 43: ...ttom of the framing holding the Q Box and PD Board Push the framing to the left until the two connectors between the ASU Board and the DSU Board completely separate DSU Board Under Shield Separate Connectors 4 Release wire wrap and disconnect the two RF connectors at the antenna switch Connectors PD Board Wire wrap ...

Page 44: ...or procedure Detach CableCard assembly from the Chassis assembly Remove 3 screws Lay the CableCard assembly to the side Screws Connector 6 Grasp the top and bottom of the DSU Board shield on the far left side of the Chassis assembly and pull out The Q Box PD Board and DSU board will swing outward together Pull Pull Swing out ...

Page 45: ...emblies to the right Remove 6 screws and squeeze the two white tabs to release the DSU Board from the shield CAUTION Do not attempt to pull board off at this point because connectors on both sides of the board must first be disconnected Disconnect all connectors on front and back sides of the DSU Board Screws Connectors Tabs Front Side LVDS Cables under tape Front Side Connectors ...

Page 46: ...move the shields on the ASU Board Reference Chapter 2 Rear and Sub Plastic Cover Removal ASU G Board Removal 2 Remove 5 screws from the DMB shield This will free the DMB and DSU Board assembly so the connectors in step 4 can be separated Release 2 wire holders and disconnect wires behind the ASU Board as shown in the picture inset Wire Holders Release wires Disconnect Disconnect Shields Screws ...

Page 47: ...edure with the other side of the Chassis assembly until the connector is completely separated Lift the complete ASU Borad DMB and DSU Board assembly off the G Board assembly and set to the side Pull up Pull up Holder Down Connector DMB ASU Board G Board 4 To remove the ASU Board first remove connector cover 2 screws indicate by red circles and separate the connectors between the ASU Board and the ...

Page 48: ...nt 5 Disconnect all cables on the ASU Board Remove 4 screws squeeze the 2 white tabs and lift ASU Board off assembly Disconnect Screws Tabs ASU Board G Board Tabs 6 To removal the G Board press the 4 gray tabs in and lift G Board off the lower chassis frame ...

Page 49: ...TVP 21 46 Disassembly Procedures Wire Routing Diagrams Wire Routing Diagrams ...

Page 50: ...TVP 21 47 Disassembly Procedures Wire Routing Diagrams cont ...

Page 51: ...TVP 21 48 Disassembly Procedures Wire Routing Diagrams cont ...

Page 52: ...TVP 21 49 Disassembly Procedures Wire Routing Diagrams cont ...

Page 53: ...TVP 21 50 Disassembly Procedures Wire Routing Diagrams cont ...

Page 54: ...Amplifier K Board Audio Interface AK Board HDMI DVI PD Board AC Input Lamp Ballast Board Power Power Power Audio Digital Audio Analog Video Digital Video Digital Data Bus Data Bus Data Bus Ambient Temp Sensor S1 Board Lamp Temp Sensor S2 Board Data Bus On Off Lamp Door Switch T1 Board Main Power Supply 5V Stdby Supply G Board IR Sensor LED H2 Board Front Panel Switches H1 Board ROOK LCD Drivers Te...

Page 55: ...oltages to initial ignite the High Voltage Mercury Vapor Arc Lamp After the initial high voltage the Lamp Power Supply Block regulates the lamp voltage down to approximately 60V during normal operation The lamp voltage must be strictly regulated to keep the current in the Lamp from running away and destroying the lamp ASU Board Audio Video Switching System Control Audio Processing The ASU Board pe...

Page 56: ...d area that includes the Q Box module and PD Board HDMI However the Q Box module and PD Board are separate and individual parts as described below Q Box Module The Q Box module includes the QM QH QI and QT boards and performs the following functions ASTC Signal Processing and Control CableCard Processing and Control ATI Microprocessor o TheATI microprocessor becomes the Main microprocessor the TV ...

Page 57: ...mp Temperature Sensor IC T1 Board Lamp Door Switch T3 Board Lamp Plug Connection Detection Switch H1 Board Channel Up Down Button Volume Up Down Button Input Select Button Menu Button H2 Board Front LED s i Link STBY Lamp Power Timer H3 Board Front AV Input S Video Composite Audio LR ...

Page 58: ...TVP 21 55 Chapter 2 Initial Contact Analysis ...

Page 59: ...ous models The Red Power Standby LED was a good indicator of a properly functioning Standby 5V power supply The Standby 5V is active as long as the unit is plugged into the AC outlet and the Red Power Standby LED glow However in the absents of the Red Power Standby LED the Green Power Standby LED is the next best indicator of a proper functioning Standby 5V power supply If the Green Power Standby ...

Page 60: ... Video Distorted No Yes Is the Video Distorted If video is present however it is distorted you are directed to the Video Distortion Troubleshooting Flowchart E The procedures in this flowchart are designed to troubleshoot an individual input problem Is Audio Present No Yes Is Audio Present Finally if the Green Power Standby LED glows steady and the video is present and undistorted then the only fun...

Page 61: ... Power Supply Block Audio K Brd IC6401 9V Reg IC6402 5V Reg 380V 14V 110V AC Stdby 5V AC_Relay From ASU Brd 11V 9V 5V 6 5V 16 5V 18V 5V ASU Brd C Brd ASU Brd DSU Brd ASU Brd DSU Brd ASU Brd DSU Brd ASU Brd DSU Brd 6 5V DSU Brd DSU Brd K Brd 2 5V 3 3V 6 5V ASU Brd DSU Brd Q Box 11V 9V DSU Brd Q Box Thermostat Near Lamp Stdby 5V 31 1 2 6 22 24 26 49 50 41 1 1 1 2 CN6014 1 3 CN6015 CN6501 CN6408 4 8V...

Page 62: ... Circuit DC DC Converter 5V Reg PS2102 PS2101 PS2100 3 15A 3 15A 3 15A Fan Drive Circuit To Sub Tuner STBY 5V To Fan 5 Drive Circuit Sub 11V Sub 6 5V ATSC 5V SW 9V H2 Board IR Sensor From G Board DSU Board TV Micro DSU Board K Board Audio Video STBY 5V STBY 5V ASU Board Regulators Figure 3 2 ...

Page 63: ... distortions and inefficiencies in the AC power network when connected directly to the AC power network The PFC circuit works basically like a switch mode power supply SMPS in that it converts the rectified AC into a pulse train using a switching or chopper circuit The pulses are then filtered or smoothed and the result is a regulated DC output The PFC circuit differs from a SMPS in that it has the a...

Page 64: ...it The TV Microprocessor located on the DSU Board receives a ON command when either the ON OFF button is pressed on the remote or the TV front panel The Green Power Standby LED on the TV front panel begins flashing immediately after the ON command is received and processed The Green Power Standby LED continues flashing The TV microprocessor sends the AC RELAY signal to turn the AC Relay ON and REC...

Page 65: ...6502 Pin41 or at Thermostat Before Shutdown Is voltage 5V Present Replace G Board A 1138 898 A No Yes Replace ASU DSU Assembly Go to Appendix for Part Tables A 1 A 2 B G Board If video distortion check SW9V Check Connections between DSU Board Q Box Confirm Unit is connected to AC Outlet Is AC 110V Present at CN6014 Replace F Board A 1119 915 A OK Yes GO TO FlowChart C1 2 3 4 Protection Modes Red L...

Page 66: ...s are working fine If there is still no video displayed or audio heard then your troubleshooting efforts should be turn to solving a video audio or lamp section defect If the Green Power Standby LED flashes continuously then there is a communications problem between the microprocessors In most cases it will be a communications problem between the TV microprocessor on the DSU Board and the ATI microp...

Page 67: ...d is Yes AC is present at CN6014 then the next step is to check if the Standby 5V power supply is functioning properly Check for Standby 5V at CN6502 on G Board remove ASU Board shields to access CN6502 An alternative Standby 5V checkpoint is at the Thermostat connector or directly at the Thermostat on the left rear side of the TV no need to remove any shields Yes Is voltage 5V Present If the Stan...

Page 68: ...White Reference Figure 4 7 for Fan Locations 0 05V IC2103 D5V Regulator Power Supply Block Ballast Board Fan Error 4X Lamp HV 5X Lamp Prot Lamp LED Flash Temp 2X Temp 2X Lamp Door 3X Digital Audio Amplifier K Board Audio Output 7X SXRD Protection Overall Block Diagram Audio Interface AK Board Low B 6X Temp 2X 1 5 7 10 CN2301 I2C Bus Lamp Connector 3X NOTE Except for the Lamp LED all flash patterns...

Page 69: ... in the previous bullet list Notice that in some cases the same flash pattern will occur for different failures in these cases you will apply further troubleshooting procedures to identify the exact area of the failure Protection Circuits Functional Description NOTES The titles for the protection circuits in this section are those used in the unit specific Service manual excepts for those indicated ...

Page 70: ...TV are monitor for rotation If any one of the fans stops rotating for any reason such as an obstacle blocking the blades or a defective fan the DE microprocessor will receive an error signal The TV will shutdown and a 4X flash pattern on the Standby Power LED will occur Lamp Driver Error 5X Power Standby Red LED Flash Pattern This protection circuit monitors the output of the Lamp Driver aka Lamp P...

Page 71: ...by Red LED Flash Pattern This DE microprocessor monitors the I2C communications between itself and the C Board S1 Board and S2 Board This protection circuit will trigger if the previously mention devices do not send an acknowledgement over the I2C bus during initial TV power up or if the I2C bus communications between these devices is interrupted during normal operation In either case the DE micro...

Page 72: ...TVP 21 69 4 Protection Circuits Troubleshooting Flowcharts Flowchart C 1 Figure 4 2 ...

Page 73: ...TVP 21 70 4 Protection Circuits Flowchart C 2 Figure 4 3 ...

Page 74: ...TVP 21 71 4 Protection Circuits Flowchart C 3 Figure 4 4 ...

Page 75: ...TVP 21 72 4 Protection Circuits Flowchart C 4 Figure 4 5 ...

Page 76: ...he error message dialog box is displayed for approximately 1 5 minutes and then the TV shuts down The dialog give the owner the oppurtunity to set the TV to High Altitude Mode which will increase the fan speed Insert photo of the High Temperature error display The main objective when a 2X flash pattern occurs is to determine which of the following possible defects are causing the excessive temperat...

Page 77: ...A 1 S1 Board 2 S2 Board NOTE The S2 Board is mounted in difficult to get to spot Therefore the best way to substitute for the board with very little disassembly is to have a extra wire harness between S Board and Main Wire Harness to connect the substitute board at the interconnect jack 3 Optical Block C Board If the TV still shuts down 2X after the previous substitutions then there is a problem wi...

Page 78: ...A 1152 714 A Fan Error 4X 4X Flash Pattern Fan Rotation The main objective when this error occurs is to determine which of the four fans have stopped rotating Visually check the two rear exhaust Fans 1 4 Reference Figure 4 7 for fan locations fans first for rotation Both fans should begin rotating immediately after the TV power button is pressed Check rear fans 1 4 that are visually accessiblefor r...

Page 79: ...tage is above 1V Check Fan Drive DR and Feedback FB Voltage Levels at CN2301 pins6 8 DR CN2301 pins 5 7 FB Befroe Shutdown If both feedback voltages are at the proper level then the fans are rotating however the DE microprocessor is not processoring the information accurately In this case the problem is with the DE microprocessor Replace the ASU DSU assembly Lamp Drive Error 5X aka Lamp Power Supp...

Page 80: ...or 6X particularly a missing Sub 11V output However theoretically a defective TV microprocessor output can also cause this error and therefore consider this component when troubleshooting Your first step in troubleshooting this error is to eliminate the TV microprocessor as a suspect for the failure Check for the presents of the AC Relay voltage at CN6502 pin 31 on the G board This is the switched ...

Page 81: ...nt between the C Board S1 Board or S2 Board and the DE microprocessor One or more of these three boards have failure to communicate or acknowledge the De microprocessor Therefore the fist step in solving the problem is to check for loose or damaged connections between all three boards and the ASU Board or the DSU Board Reference Figure 4 8 Secure and or repair connections where needed Check Secure ...

Page 82: ...esents 6 5V Once again if the voltages are missing the defect exists in the power supply reference Flowchart B for Power Supply Troubleshooting procedures If the power supplies are present at all the boards the troubleshooting process comes down to a process of elimination by substituting know good boards Substitute the boards in the following sequence for the most efficient and cost effective resu...

Page 83: ...Main Analog Tuner ATSC Digital Tuner CableCard Controler Digital Video User Menu QM Service Mode Graphics HDMI Digital Video Main Tuner Analog Video Sub Picture Analog Video Main Picture Analog Video Driver Driver Driver Video LVDS i Link Video 6 7 HDMI DVI IRIS LVDS 1080i 480i 790p 480p Video 1 Video 2 Video 3 CableCard PCMCIA Antenna Switch RF LVDS LVDS LVDS IRIS Control From ASU Board DE Microp...

Page 84: ...ds a DVI to HDMI adaptor in order to connect to the HDMI connector input Typical external devices are the DVD DVR Satellite Receivers A V Receiver and Set Top Box units Video 8 Video 8 connects directly to a Personal Computer or PC monitor output source using a HD15 or SVGA cable The input accepts VGA SVGA XGA WXGA and SXGA resolution signals from the PC A separate Stereo Mini Plug transports the ...

Page 85: ...s applied to the Main Chroma Decoder IC7701 on the DSU Board The Digital Module Block DMB is the interface for all digital video inputs ATSC Tuner CableCard Memory Stick i Link and HDMI The ATI microprocessor controls the switching for all digital inputs except for the HDMI it also generates the User Menu and QM Service mode graphics NOTE The Main NTSC Tuner is located in the DMB however the signa...

Page 86: ... of the particular size LCD panels The IFP also performs the same process on the sub picture signal for developing the picture for the right pane in twin picture display mode however the sub picture is only at the 480i format resolution level The IFP IC4610 receives the PC Input directly on the DSU Board The IFP is compatible with the VGA SVGA XGA WXGA and the SXGA formats at the 60hz vertical fre...

Page 87: ...TVP 21 84 5 Video Processing System No Video Flowchart D Figure 5 2 Troubleshooting Flowcharts ...

Page 88: ...TVP 21 85 5 Video Processing System Video Distortion Flowchart E Figure 5 3 ...

Page 89: ...TVP 21 86 5 Video Processing System Optical Block Flowchart F Figure 5 4 ...

Page 90: ... on all video input sources or if there is missing video only on one or two video input sources Is Video Missing on All Inputs 1 2 3 etc No Yes If the video is missing only on one or two inputs then you will go to the Video Distortion troubleshooting flowchart E which will be discussed in the next flowchart description However if there is no video on all video input sources the next question to ask ...

Page 91: ... a defective Q Box module Another important OSD test is to attempt to display the ROOK test patterns Note that the ROOK is located on the C board and therefore is at the end of the video path just before the Optical Block the C board is part of the Optical Block Consequently if the ROOK test patterns can be displayed then this effectively indicates that the Optical Block is OK and the defective ex...

Page 92: ...icro Q Box ATI Micro C Board ROOK DSU Board TV Micro Bus Switch TV Service Mode WE Service Mode Panel Service Mode ATI Test Patterns ATI Service Mode ROOK Test Patterns LVDS Cable LVDS Cable WE Micro IFP LCD Display On Screen Display Sources Figure 5 5 ...

Page 93: ...o Processing System ASU Board DE Micro Q Box ATI Micro C Board ROOK DSU Board TV Micro Bus Switch LVDS Cable WE Micro IFP LCD Display User Menu Interface Memory Interface PC Display On Screen Display Sources Figure 5 6 ...

Page 94: ... TV is OK and the external device needs to be service or the connection to the TV repaired If the external devices and their connections are OK then the next step is to troubleshoot the problem by accessing and displaying each video input shown in the flowchart Video 1 2 3 Distorted ATSC Tuner Memory Stick Video OK Premium Channels Digital Channels Distorted or Missing HDMI Distorted or Missing Onl...

Page 95: ...firm proper Optical Block operation is to access and display the ROOK test patterns Turn ON PANEL SERVICE MODE Internal Signal Generator Because the ROOK IC7701 located on the C Board generates the test patterns the patterns are applied directly to the LCD drive IC s and LCD panels bypassing all other video processing circuits Therefore the Optical Block is isolated for troubleshooting purposes If ...

Page 96: ...I DVI Audio 3 Audio 4 Audio 5 CableCard PCMCIA Antenna Switch RF DAC Q Box Audio 1 Audio Out AK Board K Board SPDIF to IIS Converter S Master Amplifier System Audio Output Var Fix Audio 1 PC Audio Input Audio 8 Mini Stereo Jack Composite 1 Composite 2 Composite 3 Component1 Component2 AUDIO ATSC Tuner Memory Stick I Link L R Audio 2 H3 Board DSU Board AUDIO NTSC Tuner Q Box Audio 2 CN7950 CN7952 C...

Page 97: ...ources is first applied to the ATI microprocessor and the single output is D A digital to analog converter The resulting analog single passes through the DSU Board before being applied to the ASU Board and IC507 The analog switcher IC507 single output analog audio single is applied to an A D 9analog to digital converter The output digital signal is in the SPDIF Sony Phillips Digital Interface The A...

Page 98: ...TVP 21 95 6 Audio Processing System Troubleshooting Flowchart ...

Page 99: ...ice and cables are OK then the next step is to replace the unique board or module associated with that particular input source Check Individual Audio Inputs For example consider the symptom of all or only one or two the Video 1 3 4 and 5 inputs are faulty Logically the only device that could cause this symptom is the switcher IC507 on the ASU Board The most likely problem is one or more the switch...

Page 100: ...6 5V If either the 3 3V or 6 5V are missing then the problem exists in the power supply circuits Replace the G Board If both the 3 3V and 6 5V are OK then the next step is to check the 14V power supply voltage directly connected to the K Board The 14V powers the digital output amplifier circuits Check Power Supply voltage at G Board CN6408 pin 1 IMPORTANT To access the CN6408 when checking the 14V ...

Page 101: ...xxx 9100001 to 91xxxxx 9900001 to 99xxxxx ASU DSU Assembly A 1152 715 A A 1152 715 B Optical Block A 1148 155 A A 1168 495 A Table A 2 KDS R60XBR1 ASU DSU Assembly Optical Replacement KDS R60XBR1 Serial Number Range 2000001 to 20xxxxx 9000001 to 90xxxxx 9800001 to 98xxxxx 9100001 to 91xxxxx 9900001 to 99xxxxx ASU DSU Assembly A 1152 714 A A 1152 714 B Optical Block A 1127 174 A A 1168 494 A ...

Page 102: ...TVP 21 99 Appendix 2005 SXRD Service Mode Options ...

Page 103: ...h Micro Each Micro generates it s own service OSD TV Micro Use to display Software and NVM version information DM Micro Use to display DMB test patterns check tuning status Host ID and save user and service related data WE Micro IFP Device control DE Micro Use to display C board test patterns and adjust H V center ...

Page 104: ...Service Mode SERVICE MODE Item 1 Device 1 TV Micro DM Micro Scroll Service Modes Device n Item n Item Up Down 1 4 Scroll Categories Buttons 2 5 Buttons Jump Button Change Data 3 6 WE Micro Buttons DE Micro TVP21 101 ...

Page 105: ... IC7002 TV Micro IC7551 Bus SW IC4610 IFP IC910 2 Rook IC7300 ATI IC7342 LVDS TX IC4200 LVDS RX IC5 DE Micro IC951 2 DSU Rook WE Service OSD To LCD driver TV Service OSD C DE Service IIC DM Service OSD ASU QM TVP21 102 ...

Page 106: ...e the data from 0 to 1 with the 3 button Micro versions are displayed to the right of each key device To verify micro version Enter service mode Display 5 Vol Power The first service item is VERSION Scroll to Item NVVR by pressing the 1 button Toggle the data from 0 to 1 with the 3 button NVM versions are displayed to the right of each key device ...

Page 107: ...atterns that take the same path as the graphics generated in the DMB To display the DMB internal test pattern Enter service mode Display 5 Vol Power Once in service mode press the JUMP button one time on the remote to enter DM service mode You will be in the QM Info Screen Scroll to Item 1 PATN or Item 2 GTPN using the 1 button on the remote You can scroll through the various test patterns using t...

Page 108: ...s 14 White 1080i 480i 21 35 with the same patterns as above 480p 41 55 with the same patterns as above 720p 61 75 with the same patterns as above 480i 21 35 with the same patterns as above 480p 41 55 with the same patterns as above 720p 61 75 with the same patterns as above The available PATN test patterns for the DMB are listed below Please note that MUTE or Volume does not work in this case Some...

Page 109: ...s Enter service mode Display 5 Vol Power Press the JUMP button three times until you arrive at the PANEL service mode Once in Panel Service Mode press the 2 button five times until you arrive at Device 5 TEST_PAT Once in TEST_PAT you must enable the test patterns by toggling the data from 0 to 1 by pressing the 3 button one time Note the screen will turn all white however service OSD will still be...

Page 110: ... PAT_ENB PAT_RGB can be used These patterns do not have White Balance correction enabled To display individual patterns scroll to item 4 MODE under Device 5 TEST_PAT with the 1 button To display test patterns press the 3 button on the remote Data Value 0 Plain white 1 Stripe 2 Checker small 3 Lattice 4 Cross hatch 5 Cross point 6 Ramp 7 Stair Step 8 Checker large 9 Diagonal 10 Window Note if IPT_E...

Page 111: ...H V center for multiple Wide modes Use the below Service Items to adjust 1 TG Device VST_POS for V center Initial Data 12 Adjust 1 25 Primary item for V center adjustment First try to adjust with VST_POS if you must change more than 13 11 then start to change with FMDVPOS If VST_POS is changed greater than these limits then there could be issues with Gamma HST_POS for H center Initial Data 261 17 ...

Page 112: ... Enter service mode Display 5 Vol Power Press JUMP button on remote three times until you arrive at PANEL service mode Scroll to Device TG by pressing the 2 button one time Once in Device TG scroll to item 4 VST_POS to adjust vertical center Use the 3 and 6 buttons to adjust as needed Scroll to item 5 HST_POS to adjust horizontal center Use the 3 and 6 buttons to adjust as needed Note after adjust...

Page 113: ...mp time is shown to the right To reset the lamp timer Scroll to Item 1 LMPRST by pressing the 1 button Toggle the data from 0 to 1 with the 3 button and write changes by pressing mute enter To check operation time Scroll to item 2 OPERAT by pressing the 1 button Note lamp and operation time are written to NVM after power off is performed by the remote or front panel button If AC On Off is performe...

Page 114: ...P 21 111 Appendix DMB Diagnostics The following Information can be determined in QM service mode ATI Software version System Status Tuning status POD Key User and Service data can be saved to memory stick ...

Page 115: ...e DM service mode Press the 3 button one time to display the system status screen Indicates SW version Error RED Warning YELLOW OK Good Valid GREEN Disabled GRAY Information CYAN Label Text WHITE MEANING standard COLOR Error RED Warning YELLOW OK Good Valid GREEN Disabled GRAY Information CYAN Label Text WHITE MEANING standard COLOR Color Code Chart ...

Page 116: ...creen Key Items to check include Verify the In Band and OOB status are LOCK SNR Signal to Noise Ratio There is no hard value to confirm signal strength is at an acceptable level but as a rule of thumb a SNR of 20 is usually acceptable SNR of 25 30 is preferred Note if uncorrected errors is high it could indicate a weak or noisy signal is being received and the DMB is unable to correct There is no ...

Page 117: ...us Enter service mode Display 5 Vol Power Press the JUMP button one time to arrive at DM service mode Press the 3 button six times to display the ATSC Module Boot Diagnostics Verify the POD Key status is OK and view HOSTID Verify I Link status Verify memory stick status if memory stick is inserted ...

Page 118: ...ow the user service data stored within the Digital Module to be read written to a Memory Stick This feature allows for a module to be replaced by Service personnel while preserving the user s TV configuration data This feature will store load both the factory default data which is model specific as well as the user s current settings ...

Page 119: ...be saved to memory stick as follows Enter Service Mode Display 5 Vol Power Once in service mode press the JUMP button on remote to enter DM service mode You will be in the QM Info screen Scroll down to item 12 WUSR using the 1 button Insert a memory stick and toggle the data from 0 1 using the 3 button ...

Page 120: ...w DMB as follows Enter Service Mode Display 5 Vol Power Once in service mode press the JUMP button on remote to enter DM service mode You will be in the QM Info screen Scroll down to item 13 RUSR using the 1 button Insert the memory stick containing the saved data and toggle the data from 0 1 using the 3 button ...

Page 121: ...sition Enter service mode Display 5 Vol Power Press the JUMP button one time to arrive at DM service mode Scroll to item 8 GFXX or item 9 GFXY with the 1 button Adjust graphics position for each item by changing data with the 3 and 6 buttons 8 GFXX H position 9 GFXY P position ...

Page 122: ...rks of Sony Electronics 2005 Sony Electornics Inc EMCSA A Service Company 1 Sony Drive Park Ridge New Jersey 07656 Reproduction in whole or part without written permission is prohibited All rights reserved TVP211205 12 30 05 ...

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