Sony KE-42MR1E Service Manual Download

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PANEL MODULE SERVICE MANUAL

PDP Module Name

FLAT PANEL COLOR TV

KE-42MR1/42MR1E/MR42M1

NP42D2MF01
NP42D3MF01

KE-42MR1 AEP Model

KE-42MR1 K Model

KE-42MR1E HK Model

KE-42MR1E ME Model

KE-MR42M1 CH Model

Summary of Contents for KE-42MR1E

Page 1: ...PANEL MODULE SERVICE MANUAL PDP Module Name FLAT PANEL COLOR TV KE 42MR1 42MR1E MR42M1 NP42D2MF01 NP42D3MF01 KE 42MR1 AEP Model KE 42MR1 K Model KE 42MR1E HK Model KE 42MR1E ME Model KE MR42M1 CH Model ...

Page 2: ...Contents 1 Confirmation Common Manual P1 P20 2 Confirmation Manual P21 P44 3 Repair Manual P45 P63 4 THE PARTS INFORMATION P64 P65 ...

Page 3: ...1 PDP NP series Confirmation Common Manual Ver 1 ...

Page 4: ... power the LED light off after few minutes Go to Page 8 due to check more details The priming does not appear on screen The LED is lighting but not appear pictures PDP Malfunction Phenomenon Go to Page 10 due to check more details The priming is on screen but not appear pictures Go to Page 10 due to check more details ...

Page 5: ...creen at white pattern Go to Page 11 due to check more details Colorful blocks appear on screen at color bar pattern PDP Malfunction Phenomenon Go to Page 11 due to check more details Abnormal Screen Abnormal Color Abnormal Block ...

Page 6: ...tical Line Single Line Two Lines Many Lines Only one line is always lighting Go to Page 12 due to check more details two lines are lighting Go to Page 13 due to check more details Many lines are lighting Go to Page 14 due to check more details ...

Page 7: ...k One Zebra Block Many Black Blocks One block is always no lighting by one IC Go to Page 15 due to check more details Zebra block appears by one IC Go to Page 16 due to check more details Many block appear by one data relay board Go to Page 16 due to check more details ...

Page 8: ...ine Horizontal Block One Black Block One black line appears on screen Go to Page 17 due to check more details Two Lines Two lines appear on screen Go to Page 18 due to check more details Half block does not go out Go to Page 19 due to check more details ...

Page 9: ...7 Lighting strip PDP Malfunction Phenomenon Check our specification Screen Defect Black strip Check our specification ...

Page 10: ...nel This case is caused by sulfur issue Next parts will be broken Scan Board Common Board High Voltage Board Scan Relay Board CHECK POINT FPC cutting at scan side and TCP side CHECK POINT Panel Grid condition CHECK POINT Fuse on boards Power HIC Between NEGA and POSI on scan relay board REWORK Change the Scan Common board and Scan relay board REWORK We can not rework this REWORK We can not rework ...

Page 11: ...NT Shortage between Vd line and GND TCP surface In case of shortage between Vd line and GND in data relay board Vd protection will be worked CHECK POINT Shortage between Vd line and GND on data relay board In case of no supply from supply board 5V protection will be worked CHECK POINT Fuse on digital board REWORK We can not rework this REWORK Change the data relay board REWORK Change the digital b...

Page 12: ...Vsw line of Power HIC CHECK POINT fuse on digital board LVDS cable Next parts will be broken Vp or Vbw line on Scan Board Vsw line on Common Board High Voltage Board REWORK Change the scan or common board High voltage board REWORK Change the digital board Vacuum Tube Cracking With big noise CHECK POINT Vacuum tube REWORK We can not rework this ...

Page 13: ... High Voltage Circuit Broken CHECK POINT fuse on board Vbw or Vsw line on board Next parts will be broken Vbw line on Scan Board Vsw line on Common Board High Voltage Board REWORK Change the scan or common board High voltage board ...

Page 14: ...tch CHECK POINT One line is no lighting or lighting at any pure color signal red green blue and black CHECK POINT The surface condition of panel grid The output of TCP is fixed at low level or high level This line is very clear and constant REWORK We can not rework this REWORK We can not rework this ...

Page 15: ...tage The grids of panel are shortage due to foreign material CHECK POINT Two lines are lighting at two colors CHECK POINT The surface condition of panel grid The closed outputs of TCP are Shortage REWORK We can not rework this REWORK We can not rework this ...

Page 16: ...14 Many Lines Vertical Data Grid Open Damaged data grid in panel EX Sulfur scratch CHECK POINT The surface condition of panel grid REWORK We can not rework this ...

Page 17: ...IC is not working on signal lines The connector on data relay board is opened by the cracking of solder CHECK POINT The surface of TCP is damaged CHECK POINT Input signal condition TCP is not working REWORK We can not rework this REWORK Change the data relay board ...

Page 18: ...ard are shortage by foreign material CHECK POINT Input signal condition REWORK Change the data relay board Many Blocks Data Relay Board The lead of the buffer IC or the connector on data relay board are shortage by foreign material CHECK POINT Input signal condition REWORK Change the data relay board ...

Page 19: ...e connector of scan relay board CHECK POINT One line is no lighting or lighting at white signal CHECK POINT The output of scan IC Reconnection The output of scan IC is fixed at low level or high level This line is very clear and constant REWORK Change the scan relay board REWORK Reconnect the FPC ...

Page 20: ...oard CHECK POINT FPC insert shifting Foreign material in connector The lead of scan IC The output of scan IC are shortage This line is not clear and not constant REWORK Clean in the connector Reconnect the FPC Change the scan relay board ...

Page 21: ...en Horizontal The output of scan board is not working CHECK POINT The surface of scan IC CHECK POINT The output of Scan Board Scan IC is not working REWORK Change the scan relay board REWORK Change the scan board Scan Board ...

Page 22: ...20 Sample Sample 55 x 15mm 20 x 17mm Dimension Label B 55 x 25mm 40 x 17mm Dimension Label A Since July 2003 By June 2003 Vs Vd Vbw Vsw Vp Vw Voltage Information ...

Page 23: ...21 PDP NP42D2MF01 Confirmation Manual Ver 2 ...

Page 24: ... Writing Issues Page 38 42 Page 43 Page 29 35 Each Judgement Make C PDP Failure Description sheet Flexible Cable NG OK Page 24 Page 25 Page 26 28 Page 23 Phenomenon Take pictures Module and shipment box Take pictures If you can confirm visual malfunction take pictures Take pictures Input it in your line again OK Page 29 35 Page 36 37 Page 29 35 Flow Chart ...

Page 25: ...L NO 211200192 Vd 65V Vs 190 1V CODE AA 01 212211041621 Panel ID Serial Number Example Type Name NP42D2MF01AA Serial Number 211200192 NEC NP42D2MF01 211200192 Type Name Serial Number Module Number and Panel ID ...

Page 26: ...tment after shipment We would like you to take some pictures the broken module the outside box and inform the shipment date If you do not the pictures we can dispose the broken modules on our responsibility Check the surface of glass whether crack or not Panel Crack ...

Page 27: ...Cable Cutting cable or broken In this case it caused by handling them at customers line We would like you to be careful to handle the modules Flexible Cable Check the Flexible Cables whether scratched broken or not ...

Page 28: ... Up 5 connectors Common Bypass Board Data Relay Board Left 10 connectors Data Relay Board Right 13 connectors Scan Relay Board Down 5 connectors Connectors Check the Cables or Connectors whether connected and locked or not Connectors Condition We would like you to be careful to handle the modules at assembling ...

Page 29: ...27 Connector Checking 2 High Voltage Board Digital Board Each Connector Scan Relay Board Flexible Cable Locked Unlocked Common Relay Board Flexible Cable ...

Page 30: ...28 Connector Checking 3 Each Connector Digital Board High Voltage Board High Voltage Board Data Relay Board Locked Unlocked High Voltage Board Scan Relay Board ...

Page 31: ...29 Tester Checking 1 Fuse Glass Fuse on High Voltage Board F301 F302 OK Shortage NG Opened Chip Fuse on Digital Board FＵ８０１ OK Shortage NG Opened ...

Page 32: ...ce R10 R4 R6 Chip Fuse Resistance R20 On High Voltage Board Fuse Resistance R7 R3 Chip Resistance R9 On High Voltage Board R4 R20 R10 R3 R10 OK About 2 2 Ω R4 OK About2 2 Ω R6 OK About2 2 Ω R20 OK About 10 Ω NG Opened R7 OK About2 2 Ω R3 OK About2 2 Ω R9 OK About 10 Ω NG Opened R6 R7 R9 ...

Page 33: ...n High Voltage Board R1 Fuse Resistance on High Voltage Board R2 R1 R2 R1 OK About2 2 Ω NG Opened R90 OK About2 2 Ω NG Opened R90 R2 OK About2 2 Ω NG Opened Fuse Resistance on High Voltage Board R90 Resistance and Chip Fuse on High Voltage Board ...

Page 34: ...tage Line of Data IC OK Opened NG Shortage Check between 1 pin or 2 pin and GND Check the resistance between 1 pin or 2 pin and GND with tester In case of shortage it is caused by malfunction of data IC Check the surface of data IC after removing the heat sink and Take some pictures ...

Page 35: ...33 Tester Checking 5 Parts Location High Voltage Board PH2203F ...

Page 36: ... Between L and M Between B and C Between G and H Between P and T Between B and E Between H and J Between Q and T Between B and M Between I and J Between B and N Between J and K L F PH2203F A B C D E F G H Turn this board over and Check each points PH2203F G H M E D C B A Judgment OK more than ＫΩ NG Shortage I K J N O P Q R S T U I J K L M N O P Q S R T U ...

Page 37: ...35 Tester Checking 7 Scan IC NEGA 1 Checking Point Between NEGA and POSI Scan Relay Board Up Scan Relay Board Down Judgment OK More than ＫΩ NG Shortage POSI 1 NEGA 2 POSI 2 ...

Page 38: ...36 Strip Defect 1 Compare with specification 1 strip 2 strip 2 strip Strip Defect ...

Page 39: ...37 Strip Defect 2 3 strip 3 strip 3 strip Strip Defect ...

Page 40: ...t Red 1 Line Open Mode a The broken data flexible cable If OK Data IC Broken All Red Pattern All Green Pattern All Blue Pattern All Black Pattern Black 1 Line Red 1 Line Red 1 Line No Appearance Open Mode Vertical Line Single line ...

Page 41: ... Shortage between Red and Blue a This phenomenon is caused by panel issues All Red Pattern All Green Pattern All Blue Pattern All Black Pattern Blue 1 Line Red 1 Line No Appearance Shortage Mode No Appearance Vertical Line Two lines ...

Page 42: ...40 Vertical Line 3 Vertical Line Check Point a The broken surface IC on data IC b The broken data flexible cable 1 2 data IC Block Width 30mm block ...

Page 43: ...41 Vertical Line 4 Vertical Line Check Point 1 data IC Block a Lacking connector between Data Relay board and Data IC b The broken data flexible cable block ...

Page 44: ...e 5 Vertical Line Check Point Many data IC Block a Lacking connector between Data Relay board and Scan or Common board b The broken data flexible cable C Shortage between leads in connector Foreign Material etc block ...

Page 45: ...tween NEGA and POSI on scan IC board Normal KΩ Level b The broken scan flexible cable c Lacking connector between scan IC and scan board d Shortage between each pins on scan IC by foreign metal material e Contact malfunction between connector and flexible cable on scan relay board CN01 CN04 CN06 CN09 Check the contact by pushing Horizontal Line ...

Page 46: ... High Voltage Board Common Bypass Board Scan Relay Board up Scan Flexible Cable A A B C D E F G H I J K L M N O P Scan Flexible Cable B Scan Flexible Cable D Scan Flexible Cable D Scan Relay Board Down Common Flexible Cable A Common Flexible Cable B Common Flexible Cable C Data TCP Data Flexible Cable ...

Page 47: ...45 PDP NP42D2MF01 Repair Manual Ver 2 ...

Page 48: ...e screws Connect Connectors Mounting Setting Connect Supply cable Aging Inspection Remove Module Input line Analysis Repair Testing Page 47 Page 48 Page 49 51 Page 52 Page 52 Page 53 Page 53 Page 54 57 Page 58 Page 61 Page 62 Based on Analysis Manual NG OK Voltage Adjustment Page 59 60 Repair Flow Chart ...

Page 49: ...st Discharge Prevent Electrostatic c Signal Generator PC d Supply Package e Mounting To Stand Module f Tester g Cushion To put the Module on ATTENTION Replacing the boards always use the wrist band to prevent electrostatic Preparation ...

Page 50: ...48 Put the cushion on a table and repaired module on cushion ATTENTION Put panel like catching all surface on cushion Pre setting ...

Page 51: ...with the connectors and cables Be careful to deal with the connectors and cables Be careful to deal with the connectors and cables Remove the heat sink on the data relay boa Remove the heat sink on the data relay boa Remove the heat sink on the data relay boa Remove the heat sink on the data relay board before removing the data relay board rd before removing the data relay board rd before removing...

Page 52: ...ors and cable 2 How to remove the connectors Flat Cable Type A Flat Cable Type B Locked Unlocked Be careful to remove the connectors because the structure of each connector is different Or it is possible to broken the connectors ...

Page 53: ...le Type D Locked Unlocked Repair 1 Remove connectors and cable 3 Be careful to remove the connectors because the structure of each connector is different Or it is possible to broken the connectors How to remove the connectors ...

Page 54: ...ard Be careful to not make the screw dust Shortage factor Common Bypass Board Common Relay Board 8 screws Digital Board 6 Screws High Voltage Board 22 Screws Data Relay Board 4 Screws Data Relay Board 5 screws Scan Relay Board 8 Screws Scan Relay Board 8 Screws Remove the repairing Board ...

Page 55: ...Do not add any stress board Be careful of the length of a screw Marking length of 8mm making length of 5mm Common Bypass Board Common Relay Board 8 screws Digital Board 6 Screws High Voltage Board 22 Screws Data Relay Board 4 Screws Data Relay Board 5 screws Scan Relay Board 8 Screws Scan Relay Board 8 Screws ...

Page 56: ...onnecting 1 Check the cables and in sockets Flat Cable Type A Socket Type A ATTENSION Check the surface of grids whether it is tearing or not ATTENSION Check whether there are some foreign materials or not in socket ...

Page 57: ... exchange the signal relay PKG finally please attach a heat sink 9 screws Scan Relay Board 5 Connectors High Voltage Board 5 Connectors Common Bypass Board Common Relay Board 3 connectors Digital Board 5 Connectors Data Relay Board Left 13 Connectors Data Relay Board Right 10 Connectors Heat sink 11 Connectors Scan Relay Board 5 Connectors ...

Page 58: ...56 Repair 4 Connecting 3 Locked Unlocked High Voltage Board Photograph Digital Board Scan Relay Board Photograph FFC Cable Common Relay Board Photograph FFC Cable Connection Condition ...

Page 59: ...57 Connection Condition Locked Unlocked Digital Board Photograph High Voltage Board High Voltage Board Photograph Data Relay Board High Voltage Board Photograph Scan Relay Board Repair 4 Connecting 4 ...

Page 60: ...ing Setting ATTENTION Do not stand the module directly on table Broken the flexible cable To fix the connectors from supply board Broken scan common board Adjust supply board to the suitable voltage Vs of panel Writing issue ...

Page 61: ...SW 0 5V with VR2 at TP328 on High Voltage Board Adjust the VW 0 5V with VR4 at TP330 on High Voltage Board TP328 VSW TP330 VW VR2 VSＷ VR4 VW NC 1 11 VW VSW VBW VP 8 7 10 5 3 4 2 NC NC NC GND 9 GND GND 6 In case of no measuring land on the board please refer pin assignments Voltage Adjustment 1 ...

Page 62: ... is between TP327 and GND Adjust VP by VR1 Tolerance 1 5 volt Measuring VBW which is between TP329 and TP330 VW Adjust VBW by VR3 Tolerance 0 5 volt VR3 VBW VR1 VP TP327 VP TP329 VBW NC 1 11 VW VSW VBW VP 8 7 10 5 3 4 2 NC NC NC GND 9 GND GND 6 In case of no measuring land on the board please refer pin assignments ...

Page 63: ...61 Check working Aging ATTENTION Do not use fixed signals to aging For example windows pattern or window pattern ACTION Aging on all white pattern for at least 30 min White Pattern ...

Page 64: ...e black strips or light strip to aging more for one hours with all white pattern ACTION Inspect the screen condition under all red all green all blue color bar and gray scale List the replaced result as attached sheet Red Green Blue Color Bar Gray Scale ...

Page 65: ...63 Stocking Condition ATTENTION To stock the modules in the room keeping on standard temperature and humidity To keep the modules sideways as following picture ...

Page 66: ...9S899281 PKG42D2E2 01E 42D2 Scan Relay PKG BTM 9 885 049 73 PKG42B3J3 BOARD HT4 9S899282 PKG42B3J3 01A 42B3 D2 Common Relay PKG 9 885 049 74 PKG42B3J4 BOARD HT4 9S899284 PKG42B3J4 42D2J2 35B2J4 01B 42B3 D2 35B2 Common Bypass PKG KE 42MR1 AEP NP42D3MF01AA BA 9 885 063 26 Panel Module NP42D3MF01BA NP42D2MF01BA Panel Module for service AA BA S N 2500001 9 885 058 67 PKG42D3G1 BOARD HT4 9S899540 PKG42...

Page 67: ... PKG42D2E2 01D 01E Digital Board 01A 01 01A 02 PKG42D2C1 02A 01 02A 02 02A 04 02A 05 02A 06 02A 06 Note Do not combine the boards in green and yellow cells 01D 01E 01B 01B 01B 01A 01A 01A and 01C are not available so please use 03A At that time 02A 05 or 02A 06 of Digital board should be combined 01A 01 to 02A 02 are no longer available Please use 02A 05 or 02A 06 of Digital board At that time 03A...

Page 68: ...Sony EMCS Corporation Ichinomiya TEC 9 878 233 01 English 2004DL08 Data Made in Japan 2004 4 ...

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