KDF-E42A10_E50A10 Ch.mix-5 (Training Manual)

MIX-5 LCD Rear Projection Chassis

Theory of Operation and Troubleshooting

Training Manual

KDF-E50A10

MODELS: KDF-E42A10 KDF-E50A10 Course : TVP-20

CTV-33 i

Fan Locations ........................................................................11

Protect Monitoring ...............................................................11Lamp Position and Lamp Cover Monitor ................................11Thermal Protection .................................................................11Fan Protection ....................................................................... 13Lamp and Lamp Driver Protection ........................................ 13OVP and LVP Protection ....................................................... 13Speaker Protection ............................................................... 13

Alternate Diagnostics History ............................................. 14

Chapter 2 – Service and Troubleshooting ....................... 16Overview ........................................................................ 16Circuit Board Locations ................................................. 16AGU Board Test Points .................................................. 18Service Mode ................................................................. 21

Navigating the Service Mode ............................................. 21Adjustment Items ............................................................... 23

Test Graphics ........................................................................ 23QM Graphics ......................................................................... 23BE Micro Graphics ................................................................ 24

White Balance Adjustments ............................................... 24

Chapter 3 - Troubleshooting Flowcharts ......................... 25Introduction .................................................................... 25Initial Contact Flowchart ................................................ 26Power Supply Troubleshooting ..................................... 27

No Power Flowchart .......................................................... 28Protect Mode Troubleshooting ....................................... 29

Chapter 1 – Circuit Description .......................................... 1Features .......................................................................... 1New Circuit Descriptions ................................................. 1

AGU Board .......................................................................... 3B Board ................................................................................ 3C Board ................................................................................ 3QU Board ............................................................................. 3QT Board ............................................................................. 3QM Board ............................................................................ 4P Board ................................................................................ 4GT Board ............................................................................. 4HPC Board ........................................................................... 4HC Board ............................................................................. 4HB Board ............................................................................. 4HA Board ............................................................................. 4

Video Input Switching ...................................................... 4Video Processing ............................................................. 6

Chimera Process IC ................................................................ 6

Audio Process ................................................................. 8Power Supply .................................................................. 9

Standby Supply .................................................................... 9Main Switching Regulator .................................................... 9

System Control and Protection .......................................11System Control ...................................................................11

Table of Contents

CTV-33 ii

Protect Mode Flowchart ..................................................... 30Video Troubleshooting ................................................... 31

QM Graphics ......................................................................... 31BE Graphics .......................................................................... 31Lamp Does Not Light ............................................................ 32

No Video Flowchart ........................................................... 33Video Distortion Flowchart ................................................. 34

Audio Troubleshooting ................................................... 35Audio Flowchart ................................................................. 36“No Power” Field Troubleshooting Flowchart ..................... 37Lamp Failure Field Troubleshooting Flowchart .................. 38Using OSD Graphics for Video Failures Field Troubleshoot-

ing Flowchart ............................................................... 39

Chapter 4 - Disassembly ................................................... 40Introduction .................................................................... 40New Locking Connectors ............................................... 42Rear Cover Removal ..................................................... 41B Block Removal ........................................................... 43Chasssis Removal ......................................................... 50Re-Installing the Wire Harness ...................................... 60Lamp Driver and Optical Block Removal ....................... 61Lamp Driver Disassembly .............................................. 66Optical Block Replacement ........................................... 70

Appendix ............................................................................. 71Pixel Failure ....................................................................... 71

Table of Contents (cont)Dust ................................................................................... 72

TVP-20 1

Chapter 1 – Circuit Description

Features

Several new features have been introduced into the MIX-5 chassis. They are as follows:

Slim Cabinet Design: Re-design of the projection lamp and circuit board layouts allow the unit’s depth to be reduced by approximately 4 inches over previous models.

New Wega Engine™: A second generation Composite to Component Process (CCP2), Digital Reality Creation (DRC), and Chimera IC (replacing the previous Multi-Image Driver), have been designed to further improve picture quality.

Wega® Gate: A new Graphics User Interface allows the customer a friendlier way to navigate through the various menu items.

Full HDTV Reception: An integrated ATSC tuner and decoding circuits allow the reception of unscrambled VSB and QAM signals along with legacy NTSC signals.

Cable Card Slot: Allows the insertion of a special PCMCIA card (provided by the cable company) to receive authorized, scrambled channels.

Front Component Video Inputs: Once only reserved for the rear inputs 4 and 5, component video connectors are now provided at the front Video 2 inputs.

PC Input: Accepts standard HD15 PC monitor cable to view your PC graphics.

New Circuit Descriptions

In Figure 1-1, an overall block diagram of the various major circuits is shown. A brief discussion of each board and the circuits contained within will be discussed.

Chapter 1 - Circuit Description

TVP-20 2

FIGURE 1-1MIX5 CHASSIS OVERALL BLOCK DIAGRAM

HC

LED INDICATORSIR RECEIVER

HB

FUNCTION KEYS

HA

POWER SUPPLYGT

A/V SWITCHINGTV MICRO

AUDIO PROCESS/AMPIRIS MOTOR DRIVEFAN MOTOR DRIVE

AGU

VIDEO PROCESSPC INPUT

B

LCD PANEL DRIVE

C

A/V1 INPUT

A/V3 INPUT

COMPONENT INPUT 5

PC INPUT

L/R OUT

QM

ATSC DECODER

LAMP DRIVE LAMP

FAN 1 FAN 2 FAN 3 FAN 4

TO LCDPANELS

PC INPUT

HPC

HDMI

PHDMI INPUT

QT

NTSC TUNERATSC TUNER

QU

CABLE CARD

COMPONENT INPUT 4

A/V2 INPUT L

R

AUDIO AMP

K

FIGURE 1-1MIX-5 CHASSIS OVERALL BLOCK DIAGRAM


TVP-20 3

AGU BoardEssentially the “brains” of the television, this board contains the following key circuits:

Television Microprocessor: Controls all system control processes of the television. Monitors key power supply voltages. Master controller for the other microprocessors in the unit. Also generates the service OSD graphics via a UART bus to the ATI Micro on the QM board.

Audio and Video Switching: Selects the various inputs (except PC) based on the user’s request.

Audio Processing: Volume control, equalization, and various sound processes. All analog audio is converted to digital for amplification by the class-D amplifier on the K board.

Fan Motor Drive and Control: Drives and monitors the 4 fans located throughout the unit.

Iris Motor Drive and Control: Adjusts the iris in the lens assembly to increase contrast ratio during low level video scenes.

B BoardUses the following key circuits for video processing:

CCP2: Decodes composite and Y/C signals to component level.

DRC: Compares the two fields of a 480i interlaced signal to bump the resolution to 480p

Chimera: Performs the same basic functions as the Multi-Image Driver in previous models. Controls various picture quality settings. The analog component signals are A/D converted in this circuit.

Chimera Micro: Controls how Chimera Micro handles and processes video information. Also controls fan speed and lamp driver turn-on. Monitors fan rotation and various temperature conditions within the unit for protection

LVDS Transmitter: Converts the 8-bit component and synchronization signals to a single serial stream (Low Voltage Differential Signaling) for transmission to the C board.

C BoardContains the LVDS receiver to convert the video and synchronization signals for processing by the panel drive circuits for the 3 LCD panels. Final scaling of the video signal to the native panel resolution is performed. Contains the BE Micro to control scaling and generate test patterns of C board isolation if a video problem occurs. Gamma correction is also performed here. A digital thermometer IC resides on this board to monitor the operating temperature of the optical assembly for fan speed control or shutdown protection if necessary.

QU BoardPCMCIA slot for the Cable Card (POD)

QT BoardContains the following circuits:

Integrated ATSC, NTSC Tuner: To receive terrestrial ATSC, NTSC and Cable signals.

OOB Mixer: Receives Out-Of Band signal to control the Cable Card for program authorization.

Cable Card Interface Demodulator Circuits for ATSC, NTSC, and QAM


TVP-20 4

QM BoardMPEG1, MPEG2, and digital audio decoding. User Menus, QM service and test pattern graphics are generated here.

P BoardHDMI receiver

GT BoardMain power supply generating the voltages used throughout the television.

HPC BoardInterface for HD15 connector to view graphics output from a computer. L/R audio inputs are also provided.

HC BoardAllows access to the Video 2 input at the front of the television. Component inputs along with a composite are provided for the first time.

HB BoardRemote control IR receiver and LED indicators. Also contains a digital thermometer IC to send ambient cabinet temperature readings to the B board for protection.

HA BoardFront panel function keys.

Video Input SwitchingReferring to Figure 1-2, all video input sources (except PC input) are controlled and routed by IC8400 and IC8003 located on the AGU board. The PC input is sent directly to the B board and will be covered in the video processing section.

Composite video signals are received via the demodulated NTSC signal from the QT board along with video inputs 1, 2, and 3. Note two distinct changes in this chassis design:

1. The Video 2 input located at the front of the unit has jacks for composite and component video sources. There is no Y/C input.

2. The Video 3 input has no Y/C input. It is composite only. Y/C is available only at the Video 1 input.

Note that even though IC8400 outputs sub-video signals, they are used in the North American models. This chassis has an integrated NTSC/ATSC tuner but it is essentially one tuner. Therefore, twin picture viewing is not available. All main-path signals are sent to the B board for processing via CN8404.


TVP-20 5

FIGURE 1-2MIX5 VIDEO SWITCHING

AGU

QT

HC

P

CV/YCVIDEO 1

VIDEO 6

VIDEO 3 CV ONLY

HDMI

VIDEO 2

VIDEO 4

VIDEO 5

Y Pb Pr

Y Pb Pr

IC8003VIDEO SW

IC8400VIDEO SW

MAIN Y

MAIN PrMAIN Pb

13

7 MAIN CV/Y5

9 MAIN CSUB YSUB PbSUB PrSUB HSSUB VS

1113

1715

19

TO B BOARD

CN8404

CN8400

CN8814

CN8402

CV 1

YPbPr

135

YPbPr

141210

NTSC CV 8CN8006

NOT USED IN USA MODEL

FIGURE 1-2MIX-5 CHASSIS VIDEO SWITCHING BLOCK DIAGRAM


TVP-20 6

Video ProcessingIn Figure 1-3, the video process circuits are shown. Note that video signals arrive via 3 different inputs.

PC Input: The PC input from the HPC board is the only signal not processed by IC4300. The RGB and sync signals are A/D converted and handled directly by IC4500.

Analog Signals: All analog signals selected by the video switching IC’s on the AGU board are input to IC4300. They will be processed based on the format and sync rate of the signal. Composite and Y/C signals are decoded to component and passed through a noise reduction circuit. The processed analog signals will exit IC4300 as 8-bit Y/Pb/Pr.

Digital Video Signals: ATSC and QAM encoded digital signals are processed by the QM board and sent directly to IC4300 as 8-bit Y and 8-bit Pb/Pr.

If any of the digital or analog signals are 480i, the TV Micro will sense this and route the signal through the DRC IC4701. Pattern recognition algorithms will reduce the “dithering” effect of the interlaced signal for conversion to 480p. All other resolutions (480p, 1080i, and 720p) will be passed in their native format.

Chimera Process IC

IC4500 (Chimera) performs the necessary video signal processing to the selected source. Items such as white-balance, color, luminance, and pedestal levels, etc. are performed. This chassis does not have a sub-video path for twin picture viewing but IC4500 is capable of processing this feature. All functions of video processing are controlled by IC4600 Chimera Micro.

The video signal exiting IC4500 will be 10-bit Y/Pb/Pr. The parallel data will be organized into a serial stream by LVDS IC5400 for noise-free transmission to the C board (not shown). The C board contains an LVDS

receiver to return the serial data back to parallel, A process IC to scale the video signal to the panel resolution (1280 X 720), and 3 IC’s to drive the individual LCD panels.


TVP-20 7

B

MAIN Y

MAIN PrMAIN Pb

13

7MAIN CV/Y5

9MAIN C

CN5003IC4300CCP-X

8-BIT DTV Pb/Pr

8-BIT DTV Y

8-BIT RGB OSD

IC4701DRC

IC4500CHIMERA

QM

IC4700CHIMERA

MICRO

HPC

IC4601A/D CONV

PC INPUT

IC5400LVDS TX TO C BOARD

FIGURE 1-3MIX5 VIDEO PROCESS

FROM AGU BOARD

MPEG2 DECODER

QU

CABLE CARD(POD)

FIGURE 1-3MIX-5 CHASSIS VIDEO PROCESS BLOCK DIAGRAM


TVP-20 8

Audio ProcessAudio Switching and processing is performed on the AGU board by IC8800 as illustrated in Figure 1-4. The only audio source not handled by IC8800 is the ATSC digital signal. All sources are processed by IC8803. Features such as bass, treble, BBE, and True Surround are accomplished here.

The processed audio exits to the K board where IC3006 converts the signal to PWM for amplification by the class-D amplifier IC3005. D/A converter IC8805 on the AGU board provides L/R analog audio for connection to an external amplifier.

FIGURE 1-4MIX5 AUDIO SWITCHING AND PROCESS

AGU

HC

P

AU_L/RVIDEO 1

VIDEO 6

VIDEO 3 AU_L/R

HDMI

VIDEO 2

VIDEO 4

VIDEO 5

IC8800AUDIO SW

CN8402

AU_R 5

SPDIF 4CN8403

QTNTSC AU_LNTSC AU_R

1012

AU_L/R

AU_L/R

AU_L 4CN8400

OPTICAL OUT

HPC

PC INPUT AU_L 1

AU_R 3

AU_L 8AU_R 7

CN8815

IC8803AUDIO

PROCESSOR

IC8801A/D CONV

IC8805D/A CONV

L/R AUDIO OUT

K

IC3006S-MASTER

PROCESSOR

IC3005S-MASTER

AMP

CN8006

IC8604CONV

LRCLK 12SCLKMCLK

1012QM

SDA 10

FIGURE 1-4MIX-5 CHASSIS AUDIO SWITCHING AND PROCESSING BLOCK DIAGRAM


TVP-20 9

Power SupplyThe GT board contains the necessary circuits to provide standby and operating voltages for the television. The power supply consists of 2 independent switching regulators to generate standby and main power. Refer to Figure 1-5 for the following descriptions.

Standby SupplyThe standby switching regulator circuit consists of IC6008, T6004, and other components not shown here. The circuit generates a regulated 10.5V source that is used exclusively by the Cable Card (POD). This 10.5V source is further regulated to 5VDC by IC6004 and IC6006. The standby 5V for TV Micro IC8002 is generated by IC6004. This 5V source also supplies power to the IR receiver on the HB board and the main AC relay via a thermal fuse that will be discussed shortly.

Note the SUB ON command entering the GT board at CN6019-13. This line is high only when a Cable Card is inserted into the slot. This causes B+ switches Q6000 and Q6009 to turn on the Q15V and Q5V lines to supply continuous power to the Cable Card. Without a Cable Card inserted these voltages are not present.

Main Switching RegulatorThe main switching regulator consists of IC6000 and T6000 along with other components not shown. When the unit is powered up, the AC RLY line entering at CN6019-12 goes high turning on relay driver Q6007 and R6001. Note the voltage supplied to the relay via CN6019-11 (RLY VCC). This voltage originates from the AGU board and is supplied through a thermal fuse located in the lamp housing. If this fuse opens, the main relay will not engage. This failure causes the protection circuits to flash the power LED 6 times, giving and erroneous B+ loss indication. It is always important to listen for the RY6001 engaging when this protect

event occurs.

Once RY6001 engages, the main switching regulator becomes active and generates the various voltages shown in the diagram. Note the in-rush current relay RY6002. It is engaged once the Set 5V is generated by the main supply to shunt the current limiting resistor across it.

NOTE: B+ for the lamp driver board is supplied via CN6018-1. This voltage is approximately 270VDC. When checking this voltage be aware that it utilizes an isolated ground at pin 3. This voltage must be checked by reading across these connector pins.


TVP-20 10

RY6002

SET 5V

RY6001

SWITCHINGREGULATOR

IC6000T6000

LAMP GND

CN6018

17VCN6009

6V3.3V

AU VCCCN6002

AU GND1,2

IC6003

IC6012

IC6002

+10V REG

+9V REG

+5V REG

+3.3V REGIC6007

IC6009

DC-DC CONV

SWITCHINGREGULATOR

IC6008T6004

Q6000 , 6009

+5V REGIC6005

IC6004+5V REG

CN6019

B+ SWITCH

AGU

FAN HOUSING THERMAL FUSE

TO C BOARD

TO LAMPDRIVER

STBY 5V

TO AGU BOARD

TO K BOARD

GT

24, 51

3,4

RLY VCC11AC RLYSUB ON13

12

FAN VCC9,10CN6019

SET 9V16SET 5V19,20

SET 3.3V23,24

B_12VAU 5V35

UNREG 6V38,40Q 10.5V45,46

Q 5V49

31,3228 STBY 5V

Q6007

FIGURE 1-5MIX-5 CHASSIS POWER SUPPLY BLOCK

1 LAMP DC3

FIGURE 1-5MIX-5 CHASSIS POWER SUPPLY BLOCK DIAGRAM


TVP-20 11

System Control and ProtectionPrimary control and protection of the television is accomplished by TV Micro (SAIPH) IC8002 located on the AGU board as illustrated in Figure 1-6. Certain control of video processing and protect monitoring are also accomplished by the Chimera Micro IC4100 on the B Board but all commands are carried out by the TV Micro by communications via the 3.3V I²C BUS.

System ControlThe unit is powered up by a high originating from pin 134 of IC8002. During this period, the ATSC Decoder on the QM board along with the Chimera and Chimera Micro are polled. The green power LED on the front of the unit will be flashing. Assuming that none of the monitored protect lines indicate a problem, the following events will occur.

Pin 143 (Fan Drive) goes high to allow the starting of the 4 fans. Chimera Micro IC4100 on the B Board sends a high to CN8003-19, through the AGU board and exiting CN8410-10 to start the Lamp Driver. The Power LED on the front panel will stop flashing and remain a steady green. Systems control at this point will control items such as input and/or channel selection, sync frequency detection and customer controls.

Fan Locations

Figure 1-7 illustrates the location of the 4 fans. Fan 1 (located inside the Optical Block) is the only fan that cannot be replaced individually. Fans 2, 3, and 4 can be ordered and replaced as seperate items.

Protect MonitoringTV Micro IC8002 on the AGU board and Chimera Micro IC4100 on the B board monitor various switches, temperature sensors, and voltage lines

to protect the unit. If a problem occurs in any of these areas, the TV Micro will turn the unit off and flash the power LED in a number of sets to indicate what caused the shutdown. Even if the Chimera Micro detects a problem, it communicates this to the TV Micro.

Lamp Position and Lamp Cover Monitor

The T1 board contains a switch to monitor the lamp access cover. It is closed when the locking handle for the cover is turned fully clockwise to secure the door. This is necessary to assure proper airflow to cool the lamp. Note that the switch is in series with another located on the T2 board. This switch is closed when the lamp is fully seated into the high voltage cable connector in order to assure that no arcing occurs between the lamp pins and socket if the lamp were not pushed fully forward. This switch also completes the ground path for both switches keeping the lamp cover and lamp switch lines low. If either of the switches fails or is opened, the unit will shut down and the power LED will flash in sequences of 3.

Thermal Protection

The S2 board, located inside the lamp housing, has a digital thermometer IC located on it. This IC sends temperature information to the TV Micro via the 5V I²C bus. Fan speed is varied according to the temperature feedback. If the temperature exceeds a pre-determined level, the unit will shut down and the power LED will flash 2 times. The same thermal IC is also located on the C board (not shown) to monitor the LCD panel temperature and the HB board to monitor ambient temperature within the cabinet


TVP-20 12

AGU

IC8002TV MICRO

(SAIPH)

SDA 3SCL 4

CN8401

CN8410

S2

THERMALIC7180

LAMP DRIVER

LAMP PROT 7LAMP CTL 10

HV DET 13LAMP CVR- 14

T1LAMP

COVER SW

T2LAMP POS

SW

LAMP CVR+ 15

LAMP POS 1CN8403

GND 2

LAMP CVR 8HV DET 5

LAMP CTL 19LAMP PROT 7

CN8003

TO B BOARD

78 79

Q8019

Q8022

+5V

TP36025V_SCL

TP36015V_SDA

3.3V_SCL

3.3V_SDA

ATSC_OVP

126 127 128

BE_OVP

LB_ERR

FAN_DRIVE 143

FAN_ERR38

IC8704FAN

CONTROL

5V I2C

IC8703

IC8702

IC8701

IC8700

FAN3 PWR9FAN3 PROT10

FAN4 PWR12FAN4PROT13

FAN1 PWR3FAN1 PROT4

FAN2 PWR6FAN2 PROT7

OVP DET

LVP DET

OVP DET

B_12V 31,32Q 10.5V 46,45

CN8002

FIGURE 1-6SYSCON AND PROTECTION

AC RLY 12

134

MAIN

_ON

K

CN8001SP_PROT 13

SP_PROT149

C

THERMALIC603

HB

THERMALIC7021

7X

2X

3X

4X

10X

6X

8X

5X

FIGURE 1-6MIX-5 CHASSIS SYSCON AND PROTECT BLOCK DIAGRAM


TVP-20 13

Fan Protection

All 4 fans in the television are monitored for rotation. If a fan is operating properly, the rotation protect line for each fan will be less than 1VDC. If any of the fan protect lines rises above 1-volt, the unit will shut down and flash the power LED 4 times.

Lamp and Lamp Driver Protection

The Lamp Driver board (ballast) monitors the voltage and current being sent to the lamp. When the lamp is fired from a cold start the voltage can reach upwards of 26KV. Once the lamp starts and ionization of the gas begins, the voltage is immediately dropped to around 20-30 volts and slowly raised to an operating voltage of roughly 90 volts. During these sequences, the current and voltage curves are monitored for abnormalities. A weak or defective lamp can affect these curves as can a failure of the Lamp Driver circuits. Any event in this stage will cause a high to appear at CN8410-7 which sends the high to the B board via CN8003-8. The unit will shut down and flash the Lamp LED on the front cover.

The Lamp Driver is also monitored to verify the proper startup of the high voltage circuit. If the Lamp Driver fails to generate the required high voltage to start the lamp, the unit will shut down and flash the power LED 5 times.

OVP and LVP Protection

The regulated 12V generated on the GT board is monitored at CN8401, pins 31 and 32. OVP and LVP circuits (consisting of zener diodes and transistors), monitor this voltage. If the 12V line rises above 12VDC or drops below 8.2VDC the unit will shut down and flash the power LED 6 times for a low-voltage condition or 8 times for a over-voltage problem.

Q10.5V is monitored at CN8401 pins 45 and 46. If this voltage rises above 12VDC the unit will shut down and the power LED will flash 10 times.

Speaker ProtectionIf any DC voltage appears on the left or right speaker lines, a high will enter the AGU board at CN8001-13. The unit will shut down and the power LED will flash 7 times.

Table 1-1 lists the protect features, number of LED flashes, and causes.

Blinks Error Cause

2Excessive Panel or Lamp Temperature Ventilation or sensor IC failure

3 Lamp Position/CoverLamp not fully seated or lamp cover open

4 Fan Rotation Error Fan not rotating or defective fan

5 Lamp Driver Ballast did not start

6 Low B+ Error B12V too low

7 Speaker Protection DC detected on speaker line

8 B+ Over-Voltage B 12V too high

10 ATSC Over-Voltage Q10.5V too high

TABLE 1-1MIX-5 CHASSIS DIAGNOSTICS EVENT INDICATION


TVP-20 14

Diagnostics HistoryA history of protect events can be viewed by turning the unit off and re-starting by pressing the DISPLAY, 5, VOL-, and POWER buttons, in sequence on the remote commander. A view of the above diagnostics features will appear. If an event occurred of any of the protect circuits, a “1” will appear in the extreme right hand column. A zero will appear if no event occurred. This feature is useful for troubleshooting intermittent problems or multiple protect events of more than one item to assist in determining where the failure might be occurring. The protect event column does not keep a running tally of events. It will always show “1” when an event has occurred even if it has happened more than once.

The event column can be reset back to zero by pressing the number “8” followed by “ENTER” on the remote commander. This is not the same as pressing these keys to reset the television as is done in the service mode.

Alternate Diagnostics HistoryA history of diagnostic events can also be viewed in the service mode. Power the unit down and press DISPLAY, 5, VOL+, and POWER, in sequence, to enter the service mode. The firs Item adjustment group “STATUS_1” will appear. By scrolling through these items all of the protect events mentioned will appear. If an event occured the data will have changed from zero to one. This record will remain unless the data is set back to zero and saved.

An additional set of status information is available by continuing to scroll and located the “STATUS_2” items. If more than one diagnostics event has occured, the data will have changed from zero to one.


TVP-20 15

FIGURE 1-7FAN LOCATIONS

FAN 4

FAN 3

FAN 1INSIDE OPTICAL

BLOCK

FAN 2INSIDE LAMP

HOUSING

FIGURE 1-7FAN LOCATIONS

TVP-20 16

Chapter 2 – Service and Troubleshooting

OverviewThe approach to troubleshooting the MIX-5 chassis is similar to those used for previous chassis designs for rear projection LCD televisions. All repairs under warranty are performed at board level. The only exception to this rule involves the T1 and T2 boards. As of this writing, these boards are not available as an assembly.The T1 and T2 boards contain switches for the lamp position and lamp cover detection. These will need to be replaced at component level and the same switch is used on both boards.

This chapter will familiarize the technician with the board and optical block locations. The AGU board is an excellent source of voltage and signal test points since it contains the TV Micro and virtually all video, audio, bus data, and voltages pass through it. It is easy to access for measurements if needed.

The layout of the MIX-5 chassis is dramatically different than previous designs. The goal to create a slimmer cabinet design made it necessary to relocate virtually every circuit board long with the lamp and lamp driver assembly. The main wiring harness is secured to the cabinet rather than an independent chassis. Locking connectors are used at all cable to cable and cable to board locations. Accessing the lamp driver or optical block requires the removal of the chassis since they are behind the circuit boards.

Chapter 3 covers a step-by-step procedure for replacing each of the major components. These procedures have been developed and tested numerous times to provide the quickest method to replace the required components. Once the technician becomes familiar with this chassis, service times will be at an acceptable level.

The latter part of this chapter will provide troubleshooting flowcharts to assist in determining what boards or major components should be brought to the customer’s home to successfully complete the repair at that time. The flowcharts will be structured so that a person performing a “triage” diagnostics can gather enough information from the customer to advise the field technician on what to bring for the repair. In cases where multiple

boards or components are needed to bring to the repair site, additional flowchart information will be provided to assist the technician in performing a couple of checks to replace the most likely component the first time.

Circuit Board LocationsFigure 2-1 illustrates the locations of the major circuit boards and optical block. The upper left photo is taken from the left side of the unit as viewed from the rear. Note the B Block assembly. It contains the B, QM, and QT boards. This assembly is replaced as a single unit when servicing, It also contains the # 4 cooling fan. To the left of the B Block assembly is the housing for the PCMCIA Cable Card slot. Above this is the RF switching assembly. Note the main cooling fan (#3).

The lower-left photo shows the location of the T1 board (lamp door switch), S2 board (lamp housing thermal sensor IC), T2 board (lamp position detect switch), and the thermal protect fuse for the lamp housing.

The right-side photo illustrates the location of the AGU, K, GT, and C board/Optical Block assembly. The AGU board plugs directly into the GT board via a perpendicular connector. This required pulling the assembly outward for illustration purposes.

Chapter 2 Service and Troubleshooting

TVP-20 17

PCMCIA CABLE CARD SLOT

LAMP DRIVER (LOCATED BEHIND

CABLE CARD SLOT)

T1 BOARDS2 BOARD

T2 BOARD

THERMAL FUSE

AGU BOARD

GT BOARD

K BOARD

FIGURE 2-1MIX-5 CHASSIS CIRCUIT BOARD LOCATIONS

B BLOCK ASSEMBLY C BOARD AND

OPTICAL BLOCK

FIGURE 2-1MIX-5 CHASSIS CIRCUIT BOARD LOCATIONS


TVP-20 18

AGU Board Test PointsAs mentioned previously, the AGU Board provides a good source of test points for voltage and signal testing if needed. The plastic cover containing the input labels can be removed for access to all of the connectors. It is secured by 6 screws located at the input jacks. In Figure 2-2, the layout of the various connectors is shown.

The pin mounting of most of the connectors is single-sided. A few have two-sided pin configurations (one side even numbered pins, the other odd numbered). Note connector CN8008. This connector is not visible with the plastic cover installed unless the small access door is removed. This connector is a test interface for factory adjustments and is not utilized for field service.

The labels on most of the connectors can be read on the circuit board silk screen and are self-explanatory in most cases. Items such as voltages, and audio video signals are obvious. The following list contains voltages for certain sensing or command signals and their proper levels.

CN8002: This is the common connector for all four fan motors. The fan drive voltage for any operating fan (pins 3, 6, 9, and 12) is 5VDC. The fan-protect feedback line for each fan is 0.08VDC. This voltage should remain well below 1 VDC for a correctly operating fan. The location of each fan is as follows:

Fan 1: Located inside the Optical Block. As of this writing, this assembly must be replaced if the fan fails.

Fan 2: Located on top of the Lamp Chamber. When the Lamp Driver board is replaced, this fan will be encountered. It is replaceable as a separate assembly.

Fan 3: Main fan located to the left of the B Block assembly. Replaced as separate unit.

Fan 4: Located in the B Block assembly. It is also available as a seperate component.

CN8403 Pin 1: Connects to T2 board containing the lamp position

switch. The other side of the lamp position switch is connected to ground. As mentioned in Chapter 1, the lamp position switch is in series with the lamp cover switch. The voltage at this point is normally zero-volts.

CN8410: Various control and sensing is located at this connector.

Pins 3 and 4: Temperature feedback from the S2 board containing the digital thermometer IC. The DC voltage will fluctuate rapidly from 3.4 to 3.9VDC due to the bus activity.

Pin 7: Lamp protect. A low should normally be read. A high (5VDC) indicates a defective lamp or lamp driver.

Pin 10: Lamp control. The Chimera Micro on the B board sends a high of 2.8VDC to turn the lamp driver on.

Pin 13: HV Detect. Normally low. Goes high if the lamp ballast circuit does not start up.

Pin 14 and 15: Connects to T1 board. Both pins should be normally low. This is a good test point to determine if the lamp cover or lamp position switch is open or defective.

CN8003: The monitoring points of CN8410 exit to the B board. The normal voltages will be the same as those found on CN8410.

CN8005 Pin 11: RF switching block control. Low (zero volts) for cable input and 5VDC for antenna (terrestrial) input.

CN8401: Commands to turn on the GT board power supply and supply standby voltage to the main relay.

Pin 10: Labeled 12VDC but test unit read 10.44VDC

Pin 11: Relay VCC 5VDC

Pin 12: AC Relay command to turn on main relay RY6001. 3.07VDC.

Pin 13: Sub On. 2.99VDC with no Cable Card inserted. Zero VDC with card inserted.


TVP-20 19

CN8406: Iris motor drive and feedback. High drive voltages indicate a defective motor. High Hall Device out and low inputs indicate a defective motor. Low or non-existing drive or Hall Device voltages indicate drive circuit failures. Voltages for a properly functioning test unit were as follows:

Pin 1: 4.49VDC

Pin 2: 3.67VDC

Pin 3: 4.65VDC

Pin 4: 2.8VDC

Pin 5: 4.55VDC

Pin 6: 6.46VDC

Pin 7: 4.49VDC

Pin 8: 5.27VDC


TVP-20 20

V1 V3 V4 V5

CN8401CN8008TEST JIGCN8005

CN8405

CN8003

CN8410

CN8403

CN8404

CN8002 CN8001 CN8402CN8406

CN8814

CN8004

CN8400

IC8002TV MICRO

(SAIPH)

CN8006

CN8815CN8800

(not used)

FAN1 POWER 3FAN1 PROTECT 4FAN2 POWER 6FAN2 PROTECT 7FAN3 POWER 9FAN3 PROTECT 10FAN4 POWER 12FAN4 PROTECT 13

LAMP POS SW 1ATSC SPDIF 4

MAIN Y 1MAIN Pb 3MAIN Pr 5MAIN CV/Y 7MAIN C 9

TP3601

TP3602

5V SDA

5V SCL

ANT SWITCH 11Q 5V 13Q10.5V 14

+12V 10RELAY VCC 11AC RELAY 12SUB ON 13SET 9V 16SET 5V 20SET 3.3V 24STBY 5V 28AUDIO 5V 35AUDIO GND 36UNREG 6V 38Q 10.5V 46Q 5V 49

FUNCTION KEYSLED INDICATORS

VIDEO_2 CV 2VIDEO_2 AU_L 4VIDEO_2 AU_R 5

IRIS MOTOR

HDMI IN

Y 6

AU_L 3Pr 4Pb 5

+11V 1AU_R 2

HIN + 6FB + 7DRIVE + 8

HOUT - 3HIN - 4HOUT + 5

FB - 1DRIVE - 2

VIDEO_2 Y 1VIDEO_2 Pb 3VIDEO_2 Pr 5

K BOARD AUDIO

AUDIO MUTE 14

LR CLK 4LR DATA 5SPEAKER PROT 13

MCLK 1BCLK 3

SW 3.3V 15SDA 11

AFT 7TUNER CV 8SCL 10

TUNER R 3TUNER L 5

SW 5V 5

PC AUDIO L 1PC AUDIO R 3

HV DETECT 5

LAMP COVER 8LAMP CONTROL 19

LAMP PROTECT 7

THERMAL SDA 3THERMAL SCL 4LAMP PROTECT 7LAMP CONTROL 10

LAMP COVER - 14LAMP COVER + 15

HV DETECT 13

B +12V 2PC 3.3V 3

FIGURE 2-2AGU BOARD TEST POINTS

FIGURE 2-2MIX-5 CHASSIS AGU BOARD TEST POINTS


TVP-20 21

Service ModeAccessing the service mode is accomplished in the same way as has been used in past Sony television products. Press “DISPLAY”, “5”, “VOL+”, and “POWER” in sequence on the remote commander to enter the service mode. OSD graphics for the Main Micro data settings will appear at the top of the screen.

Although the service mode allows access to a large amount of adjustments, most will never need to be adjusted unless data becomes corrupted. In certain cases, such as board change-outs, items such as white balance or picture size may need to be adjusted.

Navigating the Service ModeThere are 3 major categories of adjustments in the MIX-5 Chassis

1. TV Micro

2. QM

3. BE Micro

These categories are selected by pressing “JUMP” on the remote commander. Within each of these categories are groups of adjustment data. Figure 2-3 illustrates the steps needed to navigate within each individual category.


TVP-20 22

FIGURE 2-3MIX-5 CHASSIS SERVICE MENU NAVIGATION

CCPM 1SHPC

0 1 SERVICE

Wide ZoomWSL: 0

Video 1

CCPM 1SHPC

0 1 SERVICE

Wide ZoomWSL: 0

CCPM 1SHPC

0 1 SERVICE

Wide ZoomWSL: 0

CCPM 1FUP2

1 0 SERVICE

Wide ZoomWSL: 0

CCPM 2PACK

0 4 SERVICE

Wide ZoomWSL: 0

CCPM 3AD1E

0 0 SERVICE

Wide ZoomWSL: 0

CCPM 1YNR

2 0 SERVICE

Wide ZoomWSL: 0

Video 1 Video 1

Video 1Video 1Video 1

Video 1CCPM 1SHPC

0 2 SERVICE

Wide ZoomWSL: 0

Video 1

25 5 2

14 14

36

MUTE + ENTERSAVE DATA

"0" + ENTEREEPROM READBACK

FIGURE 2-3SERVICE MENU NAVIGATION

GROUP 1 GROUP 2 GROUP 3

ADJUSTMENT ITEM 1 ADJUSTMENT ITEM 2 ADJUSTMENT ITEM 3

DATA CHANGE

_ +


TVP-20 23

Adjustment ItemsGraphics selection (for troubleshooting and picture adjustments) and white balance will usually be the only two areas of the service mode that require access. 3 sets of test pattern graphics are contained within the service mode located in the QM sub-group. White balance adjustments are located within the BE Micro sub-group.

Test GraphicsVarious test patterns are generated to assist in picture quality checks and alignments. They are also useful for troubleshooting video problems since patterns are generated in various locations. Graphics are generated in 3 different circuits:Main TV Micro (Saiph): Data display for general alignment and diagnostics history. These graphics will appear as large green letters and are the first to appear when entering the service mode. The Main TV Micro does not generate the graphics. It sends the appropriate data to the QM ATI Micro where the graphics are generated.QM Board: Customer menus originate here. The QM board also generates its own service data. The adjustment data graphics are displayed as blue. Various test pattern graphics are also generated.C board: The BE Micro generates test pattern graphics along with its own adjustment data graphics. The letters displayed are green and noticeably smaller than the Main TV Micro graphics. Since the test pattern graphics in this location are generated just before the video drives the LCD panels, they are useful when attempting to isolate the Optical Block assembly during a video failure resulting in loss of video or distortion.

QM GraphicsOnce the service mode has been activated, press “JUMP” on the remote commander to change the category to the QM group. Once the QM adjustment data category has been reached (the adjustment graphics will change from green to blue), the first adjustment item will appear as “INFO” and is labeled as item 0. Press the “1” key on the remote commander to move to the next adjustment item labeled “1”. This item is named “PATN”,

The data value should be set at zero. Using the “3” key on the remote commander will change this data and different test pattern graphics will appear with each increase of the data value. There are 4 sets of 20 graphics (data 1 to 80. Each set of graphics is redundantly generated but in different resolutions. They are as follows:1-20 1080i21-40 480i41-60 480p61-80 720pNOTE: These graphics are valuable in verifying proper scaling of the 4 major ATSC resolution formats. Verification of each resolution can be seen by pressing the “4” key on the remote to move back to the “INFO” group. Change the data from “zero” to “one” and a palette will appear with information about the ATI Micro and signal performance. One of the items is the current resolution format. This palette can be left on while returning to the “PATN” group and viewing the different sets of pattern resolutions.A second set of test patterns can be displayed by moving to item 2 in the QM Mode. This item is labeled GPTN. These are addition test graphics and all are in high resolution (1080i) and originate from the same area that the customer menu is generated. The patterns will not fill the entire screen because of this. All of the above graphics are generated on the QM board and are useful for video troubleshooting. If they can be displayed, the B board and Optical Block are eliminated as potential causes of the failure.


TVP-20 24

BE Micro GraphicsUse the “JUMP” key to enter the BE MICRO category. Press the “5” key (rather than the “2” key since the group is located near the end of the catagory) to maneuver through the adjustment groups. The BE Micro graphics are located in category 32 labeled D8909TPN. The first item is TPNSW. The default data is zero. Changing the data to “1” will cause a flat field to be displayed. By default, the field should be approximately 70IRE white. The color of the field can be changed by the next item.Item 01 is labeled TPNRGB. The default data is 0007 for a white screen. Changing the data progressively downward changes the field to the primary and secondary color fields. The last setting (zero) generates a black screen. Be aware that the adjustment data graphics cannot be seen while in this mode. It is not necessary to change the TPNSW data to see these flat-field patterns. Any time you enter the TPNRGB group and change data, the various colored fields will appear. This group of adjustment graphics is extremely useful when troubleshooting video problems that appear to originate in a single panel color. Be certain to return the data back to white screen before exiting the BE group. If this is not done, none of the test patterns in the BE group can be seen. If it is left set to a primary or secondary color, the test graphics will also appear that way.Item 4 is labeled TPN Mode. Various test patterns generated by the BE Micro in 10809i mode are generated here.IMPORTANT: Be certain to exit the BE Micro group before turning the unit off. Always turn the unit off in the QM or Main Micro service group. If this is not done, the unit will display the BE Micro data when it is turned back on and there will be no way to turn them off. If this occurs, simply unplug the AC power to perform a hard reset and plug the unit back in.

White Balance AdjustmentsIn general, white balance adjustments are not required on a regular basis with LCD-type displays. Changes in backlight color temperature will occur over time but this occurs at an extremely slow rate and is not normally noticed by the customer. White balance adjustments are occasionally required when the optical block is changed and definitely when another person alters the data settings.

The adjustment data for white balance is located in the BE Micro category. Use the “JUMP” button on the remote commander to access this category. Press the “2” button to locate the “CTT” group. This group is located 10 steps from the initial BE Micro page so you will have to press the “2” button this many times.

Once in the “CTT” group, 6 adjustment items are found to adjust white balance. There are 3 background (R_BKG, G_BKG, B_BKG) and 3 drive adjustment items (R_DRIVE, G_DRIVE, B_DRIVE). The background adjustments affect the low light areas of the video and the drive adjustments the highlight areas.

The adjustment data for each item is a 4-digit hexadecimal number. Previous chassis designs utilized a 3-digit binary number system and this is something the technician should be aware of.

TVP-20 25

Chapter 3 - Troubleshooting FlowchartsIntroduction

The following flowcharts will assist in determining what boards or major components need to be brought to the service site in order to raise the possibility of a successfully completed repair without a second visit. The flowcharts are structured to allow one to “triage” the repair based on input from the customer. In many cases, multiple boards may need to be brought to the location. Flowcharts A through F are specifically designed to provide guidance to a person who is attempting to analyze a particular failure based on information gathered from the customer. This can be difficult at times since the person gathering information from the customer has some (or extensive) knowledge about the product. The customer will have very little, or none. The responses received from the customer will vary greatly because of this. Use the initial flowcharts as a guide and your experience with customer relations as to how the questions should be asked.Some of the flowcharts contain information boxes specifically designed to route the technician to additional test procedures to provide assistance to the technician once he or she is on location with the recommended parts. These flowcharts provide addtional troubleshooting information and may require reading voltages. Their purpose is to gather additional on-site information and raise the possibility of installing the most likely part to fix the failure if multiple items are brought to the location.The flowcharts are categorized by major circuit groups ans symptoms. Each group contains supporting text to provide insight and troubleshooting tips to understand and properly diagnose the potential cause of the failure.

TVP-20 26

Chapter 3. Troubleshooting Flowcharts

Initial Contact Flowchart

MIX-5 Chassis Initial Contact Troubleshooting Flowchart A

Start

No

Yes

Is GREENor RED LED

Flashing?

Green

No

No

No

Red

Yes

Yes

Yes

GO TOPower Supply

TroubleshootingFlowchart B

GO TOProtection Mode Troubleshooting

Flowchart C

GO TONo Video

TroubleshootingFlowchart D

GO TOVideo Distortion Troubleshooting

Flowchart E

GO TOAudio

TroubleshootingFlowchart F

Done

Does unitturn ON?

Is video distorted?

Is audio present?

A

Distorted

No

Yes

Is video present?

TVP-20 27


Power Supply Troubleshooting

One feature that has been removed from the MIX-5 chassis design is the red standby LED. In previous models, the power/standby LED remained lit in red. It turned green when the power was turned on. The power LED in the MIX-5 chassis will turn red, but only for diagnostics indications. A lit standby LED was a good troubleshooting tool since it clearly indicated a functioning standby power supply (one of the first items to check when a unit will not turn on).Without the standby LED to provide a clear indication of standby power, other methods must be used to test this stage. The first test is to listen carefully for the sound of two relay clicks. The main relay (RY6001) should engage followed by the in-rush current relay (RY6002) engaging approximately 1.5 seconds later. It is possible to hear only one relay click. This indicates the in-rush current relay may not have engaged and the unit will go into protect shutdown with and 6-blink diagnostics indication. Refer to Figure 1-5 in Chapter 1 for an illustration to this explanation.The B 12V line is monitored for excessively low or high conditions and the power LED will blink 6 or 8 times respectively if there is a problem. The Q10.5V is also monitored for over-voltage and will cause the diagnostics to blink the LED 10 times.If the entire switching regulator fails to start, the diagnostics circuit will blink the power LED 6 times. This can be misleading since it could cause the technician to immediately suspect the GT power supply board as the culprit.Flowchart B will aid in determining the likely cause based on symptoms in the field. Note the directive to Flowchart G to further isolate the cause by noting various symptoms and taking voltage measurements.A Note on 6-Blink Shutdown Indications: Any time the power supply does not start, the Main Micro (IC8002) on the AGU board will detect the loss of B12V. Since the Main Micro (IC8001) is always running on standby voltage, it assumes there has been a failure of the B12V line (in fact, there technically is). If the main relay (RY6001) were to fail, the main switching regulator would not turn on (even though IC8001 has commanded it to). This causes a misleading diagnostics

indication. Any excessive loading of the secondary voltages can cause the switching regulator to turn off since there is over-current monitoring within the circuit. If the thermal fuse (located within the lamp assembly) were to open, standby 5V would no longer be applied to the main relay (RY6001). The main switching supply would never turn on and an erroneous 6-blink shutdown would occur.If a 6-blink shutdown occurs, always listen for the sound of relay clicking. If none is heard, the main relay could be defective (unlikely), the standby supply has failed, or the thermal fuse is open. The presence of standby 5V is easily checked by reading the voltage at the thermal fuse. The location of this fuse is illustrated in Figure 2-1. If no voltage appears on either side, the standby supply is not working. If 5VDC appears on one side and not the other, the fuse is open. If voltage appears on both sides, the main relay is defective or is not being told to turn on.

TVP-20 28


MIX-5 Chassis “No Power” Troubleshooting Flowchart B

Unit Does Not Turn On

No

Yes

No

Yes

No

Verify unit is plugged in and has AC power. If AC OK:

GT Board A1113732A*AGU Board A1129346AThermal Fuse 157691211

GT Board A1113732AB Block A1167541A

B Block A1167541A

Power OK. Check for Video Problem

Clicking Noise Heard?

Green LED Flashing?

Continues Flashing?

Yes

Red LED Flashes?

Go To Protect Mode

Troubleshooting C

Yes

No

B

Go to field troubleshooting

flowchart G

Green LED Lights Steady after while?

GO TONo Video

TroubleshootingFlowchart D

Yes

No

Audio Present? Video problemGo to flowchart D

No Power Flowchart

TVP-20 29


Protect Mode Troubleshooting

The self-diagnostics feature incorporated within the MIX-5 chassis is a valuable tool in determining what board might be the likely cause of a failure. In most cases it leads the technician towards the potential source of the failure. In some cases, the diagnostics indication is rather vague. A perfect example of this would be a 4-blink event indicating a cooling fan failure. This could be caused by lack of B+ drive to the fans, lack of fan control, or the failure of a singe fan.

In a situation such as this, the technician must arrive at the service location with the AGU board, 3 different fans and the optical block. Figure 1-7 in Chapter 1 specifies the location of the 4 fans used in this chassis. Fan 1, located inside the optical block is not available for replacement. The other 3 fans, Fan 2 inside the lamp driver/housing assembly, Fan 3 (main intake), and Fan 4 inside the B Block assembly can be replaced as individual items.

CN8002 on the AGU board supplies power to all 4 fans. This is observed in Figure 2-2 in this Chapter. The fan rotation-detect lines for each individual fan is also located at this connector. Each fan receives approximately 5VDC of drive voltage under nominal conditions. The rotation-detect lines are normally low (less than 1VDC). In past chassis designs, over-temperature conditions and fan rotation errors were included in the same diagnostics error indication. If a thermal IC failed, the fans would not be turned on. This unit must turn the fans on to detect rotation. This allows a moment for each rotation-detect to be tested before the unit goes into protect mode. It also allows the ability to check if the fans are receiving drive voltage.

Protect events occurring with a 6-blink diagnostics indication can be misleading. This is covered in the section dealing with a “no power” condition as explained in Flowchart B.

Don’t become dependent on the self-diagnostics feature of this television. Use it as an additional tool in isolating the cause of a problem. Traditional analysis of symptoms based on what you see or hear (or don’t see or hear) should always be utilized in conjunction with this feature.

TVP-20 30


MIX-5 Chassis “Protect Mode” Troubleshooting Flowchart C

Red Standby LED Flashing

No

No

Yes

Yes

No

Possible ventilation problemS2 board A1103763AHB board A1103767A

Optical Block*

Check for proper lamp positioning or loose lamp

cover.S7150 T1 boardS7155 T2 board

178659111 (same switch)

**AGU board A1129346AFan 2 178723111Fan 3 178737311

B block A1167541AOptical Block*

2X

3X

6X Yes

7XYes

No

Yes

8X

C

4X

No

Yes

5X

No

Lamp Driver 146893611Lamp A1124850A

GT board A1113732AThermal fuse 157691211

K board A1115002A

GT board A1113732A

*OPTICAL BLOCK PART NUMBERS

KDF-E42A10 A1123071 AKDF-E50A10 A1123069 A

10X

No

GT board A1113732AYesYes

See Flowchart G for additional information about this protect

event

Protect Mode Flowchart

TVP-20 31


Video Troubleshooting

Since virtually all video processing is performed on the B board, failures are likely to be traced to this point. This is especially true if distortion is evident in the picture. Since most of the video processing is done at the digital level, the distortions will usually appear as digital blocking or loss of picture detail. Failures on the QM board can also create the same distortions but it is part of the B Bock and replaced together with the B Board. Flowchart D provides some guidance in determining the cause of a failure of video.

The AGU board is responsible for routing all video sources other than the ATSC digital information. Failures here would cause a loss of one or more of the video inputs (including the PC input) but would not affect signals from the ATSC tuner.

A powerful tool for troubleshooting a loss of video (or distortion) is the internal service data graphics and various test graphics generated on the QM and C boards. When the service mode is entered (unit turned off and “DISPLAY”, “5”, “VOL+”, “POWER” pressed in sequence on the remote commander) the default graphics will be the general service mode. Large green letters will appear on the screen. This is an indication that the Main Micro on the AGU board is communicating graphic data ATI Micro on the QM board (where all digital video decoding is performed for ATSC signals). It also eliminates the B and C boards as the possible cause of the loss of or distortion in the video signal since the graphics are being processed.

QM GraphicsIn situations where video failures occur only when ATSC channels are selected, the graphics generated by the QM board are helpful. By pressing “JUMP” on the remote

Commander, the test data graphics will change from green to blue. If these graphics appear, the circuits on the B and C boards are functioning. The B block should be replaced. Other test pattern graphics are available to assist in alignment and overall examination of how well the unit is scaling the various formats specified by the ATSC.

In the QM service group, press the “1” key on the remote to select Item 1 labeled “PATN”. Using the “3” key to change the data value will scroll you through various test patterns. 4 groups of 20 patterns are available for each resolution. They are as follows:

1-20: 1080i

21-40: 480i

41-60: 480p

61-80: 720p

Additional graphics are available by selecting item 2 (GPTN). All of these graphics are 1808i and generated by the same circuit that displays the customer user menu so they will not fill the screen entirely.

BE GraphicsThe BE Micro located on the C board directly generates graphics to the scaling IC just before the LCD panel drivers. Press the “JUMP” button on the remote until smaller green letters and numbers appear. The fact that these can be seen is a good indication that the C board is functioning properly and the optical block will not need replacement.

Additional test graphics are located in this circuit. The most useful is the ability to generate various “flat field” patterns in white, black, and each primary and secondary color. This is extremely useful for troubleshooting suspected problems with a particular LCD panel.

These patterns are accessed by going to group 32 while in the BE mode. Use the “5” key on the remote to scroll to this group number. It is called “D8909TPN”. Using the “1” key, scroll to Item 1 labeled “PNRGB”. By pressing the “3” and “6” key on the remote various flat field colors are displayed as mentioned above.

TVP-20 32


NOTE: Always return screen to white (data 0007) when finished. If this is not done, additional test graphics located in the BE micro will be displayed in that color. None will be displayed if left in black field (data 0000) mode.

Do not turn the unit off while in the BE service mode. When you turn the unit off and back on, the BE graphics will still be present and you will not be able to control them because the remote commander is back in the conventional mode. If you accidentally do this, unplug the unit to perform a hard reset of the microprocessors and the unit will operate correctly.

Lamp Does Not LightIf the lamp fails to light, there will be video (for obvious reasons). Note in Flowchart D that you are directed to Flowchart G. This flowchart is for use in the field to further determine the cause of a lamp not turning on. By reading voltages with a multi-meter, it can be determined if the lamp is not lighting because of a failed lamp, lamp driver, or power supply issue.

TVP-20 33


MIX-5 Chassis “No Video” Troubleshooting Flowchart D

No Video

No

Yes

Yes

NoLamp A1124850A

Lamp Driver 146893611

Optical Block*

B Block A1167541A

B Block A1167541A

Lamp Lights?

Any OSD Graphics

Displayed?

Tuner only?Yes

Video Inputs1 through 6?

**AGU Board A1129346A

Yes

No

Yes

Video 7(DVI)?

No

No

D


KDF-E42A10 A1123071 AKDF-E50A10 A1123069 A

P Board A1129345A

Video 7(DVI)?

IC7200 HPC Board670460001

No

Yes

Yes

All Video Sources Affected?

See lamp troubleshooting flowchart H

See OSD troubleshooting flowchart I

No Video Flowchart

TVP-20 34


MIX-5 Chassis “Video Distortion” Troubleshooting Flowchart E

Video Distortion

No

Yes

Yes

Dark

Optical Block*

**B Block A1167541A

AGU Board A1129346AB Block A116764A

Pixel FailureSee ESI bulletin for pixel

guidance

OSD OK?

Lines or Graphic

Patterns?

Video Level Problem?

Yes

Does Dark Spot Move?

No

No

Push on top part of cabinet

to make screen move.

Dust on Rear of Screen.

Yes Dust in Optical Block or Pixels

Unlit

E

Darkor colored specks?


KDF-E42A10 A1123071 AKDF-E50A10 A1123069 A

Colored

Video Distortion Flowchart

NOTE: See Appendix of training manual for clarification of pixel failure and dust particle issues

TVP-20 35


Audio Troubleshooting

All switching and processing of audio signals are performed on the AGU board. Amplification is done on the K board. In a situation where no audio is present from all inputs, the AGU or K board could be the cause. A simple way to isolate this issue is to use the television’s audio output jacks and connect them to an external amplifier. If audio is present, the K board is not the cause. The problem resides on the AGU board.

Audio troubleshooting Flowchart F provides a quick check of the audio symptoms and what board(s) should be brought to the service site.

TVP-20 36


MIX-5 Chassis Audio Troubleshooting Flowchart F

AudioProblem

No

Yes

Yes

AGU Board A1129346AK Board A1115002AAudio Present?

All Channels

Distorted

Yes

All inputs?

No

No

Internal Speakers

Turned Off?

Done

Yes

No

Verify Unit not in SAP Mode

Done

F

Yes

Tuner Only? B BlockA1167541A

Yes

No

Any Or All Other Inputs?

*AGU Board A1129346A

AGU Board A1129346AK Board A1115002A

No

Yes

Audio Flowchart

TVP-20 37


MIX-5 Chassis No Power Troubleshooting Flowchart G

No power

No

Yes

Yes

Thermal fuse157691211

Power LED blinking 6X?

PWR LED blinking green?

5VDC either side of thermal

fuse?

Yes

No

No

GT boardA1113732A

One side

G

Yes

No

5VDC both sides of

thermal fuse?

B BlockA1167541A

GT boardA1113732A

3VDCCN8401-12AGU board?

No

THERMAL FUSE

Both Sides

GT boardA1113732A

AGU boardA1129346A

“No Power” Field Troubleshooting Flowchart

TVP-20 38


MIX-5 Chassis Lamp Troubleshooting Flowchart H

No Backlight

No

Yes

Yes

Replace lamp driver board

146893611

Does lamp LED light?

Backlight seen on screen?

Lamp lights?

Yes

No

No

Done

Yes

No

H

Yes

2.8VDC CN8410-10 AGU board?

B Block A1167541A

Yes

No

GT boardA1113732A

No

Replace Lamp. Problem Fixed?

Video problem. Go to flowchart D

Look into main intake fan at rear. If lamp lit, mirror

is broken.

380VDC CN6018-1 on

GT board?

No

Replace lamp driver board

146893611

Lamp Failure Field Troubleshooting Flowchart

TVP-20 39


MIX-5 Chassis OSD Graphics Troubleshooting Flowchart I

No Video All Inputs

B Block A1167541A

Initial Service Graphics

Displayed?

No

I


KDF-E42A10 A1123071 AKDF-E50A10 A1123069 A

Enter Service Mode

Any OSD Graphics

Displayed?

No

*Optical Block

Yes QM service graphics?

Yes

BE Micro graphics?

No

Yes B Block A1167541A

Press “JUMP”Multiple times on

remote commander

No

*Optical Block

Yes

Press “JUMP” onremote commander

NOTE: If no OSD graphics can be displayed but the lamp is lighting, check to make sure the LVDS cable from the B Block going to the Optical Block is not loose or damaged at either end before deciding to replace the Optical Block. Replace if damaged. (PN 183009921 )

LVDS cable

Using OSD Graphics for Video Failures Field Troubleshooting Flowchart

40

Chapter 4 - Disassembly

Introduction

The MIX5 LCD rear-projection television chassis is used in the KDF-E42A10 and KDF-E50A10 models. The new design decreases the depth of the unit to provide for a more slim design as compared with previous models.

This new design required the relocation of the lamp and lamp-driver along with the circuit boards. Access to these components requires a bit more effort. The use of locking connectors on all of the circuit boards requires that the service technician be familiar with them to avoid damage to the connectors and/or circuit board assemblies.

The purpose of this document is to familiarize the technician with the layout of the chassis and the types of connectors being used. Illustrated step-by-step procedures are also covered to assist in proper disassembly and re-assembly of the unit.

Rather than provide a complete disassembly of the unit from front to back, the procedures in this document are broken down into steps covering the most common repairs involving the following components:

B Block Replacement: This assembly contains virtually all of the circuits necessary to process the audio and video signals. The primary circuit boards are the QM, QT, and B boards. All of these boards are contained inside a shielded assembly and must be replaced as an entire unit.

Lamp Driver: This board is not as easily accessible as were prior designs The entire chassis must be removed to access this circuit.

Optical Block: Although the design is greatly simplified from previous optical assemblies, the entire chassis must be removed to access it.

As with all new chassis designs, once you have the proper service procedure information and have serviced a couple of units, repair times should remain relatively the same as previous chassis repairs.

Chapter 4. Chassis Disassembly

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3

3

1 Pull down the claw

Lamp door

E42A10

E50A10

Rear Cover Removal


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LIFT ONE SIDE AT A TIME BY PUSHING TAB IN WITH

SMALL SCREWDRIVER

LOCKING CONNECTOR TYPES

SQUEEZE LOCKING TAB TOWARDS CONNECTOR BEFORE PULLING FREE

CAUTION! IF THE TYPE 2 FEMALE CONNECTOR HAS A SLOT (AS SHOWN)

MAKE SURE THE LOCK TAB SEATS INSIDE THIS SLOT.

TYPE 1 TYPE 2

SQUEEZE DOWN ON TAB TO RELEASE

TYPE 3

New Locking ConnectorsThree types of locking connectors are used to secure the wiring to the circuit boards. Other types of locking connectors are used for cable-to-cable connections and these have been used in the past so they will not be covered. The connectors used on the circuit boards are of a small design and it is not easy to identify the locking mechanisms used unless one is already aware of them. Because of their small size, they could be easily damaged if an attempt is made to pull them directly out of their socket. The illustration below shows the 3 types of connectors and how they are released.

Remember: The connectors are easily removed if the locks are disengaged. If you are exerting effort, the lock is not released and the connector will be be damaged


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B Block RemovalThe following steps apply if only the B Block assembly is to be removed. If the Lamp Driver or Optical Block is to be replaced, go to the section on Chassis Removal which will prepare for access to the these items.

B BLOCK REMOVAL STEP 1B BLOCK ASSEMBLY REMOVAL STEP 1

SLIDE ASSEMBLY BACK TO END OF MOUNTING

SLOTS AND LIFT TO RELEASE

REMOVE 7 SELF-TAPPING SCREWS

DISCONNECT GROUND WIRE


TVP-20 44B BLOCK REMOVAL STEP 2

DISCONNECT 2 GROUND WIRE SETS

REMOVE BOTH RF CABLES. NOTE

CONDUCTIVE TAPE ON LEFT CONNECTOR

UNPLUG CONNECTOR

B BLOCK REMOVAL STEP 2


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DISCONNECT

REMOVE GROUND

CONNECTOR



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LVDS

TYPE 2

TYPE 1

TYPE 2

Swing the B Block assembly outward as shown. Remove the four connectors on the left side of the B Block. Take note as to what type of locking connectors they are and remove each carefully and correctly. CAUTION: Swing the B Block outward with care. Observe the LVDS cable whenever the assembly is swung out. It is easy to damage the cable if it is snagged.



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Remove the connectors illustrated below. Take note as to how each connector locks. The plastic spacer block shown is not supplied with the replacement assembly. This spacer block is secured with a long, silver colored, machine screw. The screw secures the spacer block and is also used to adjust the postion of the block to raise and lower the rear cabinet for vertical centering adjustment.


Remove cables

Wire Holder

Fan Connector

Lamp Protect Connector

Switch

CN8403AGU Board

Spacer is not included with B Block Assembly

SWING B BLOCK ASSEMBLY OUTWARD AS SHOWN AND REMOVE LISTED CONNECTORS


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Once the B Block assembly has been removed, place it on a flat surface as shown. The plastic housing behind the cable card assembly is now removed.


REMOVE SELF TAPPING SCREW

SPREAD EDGES OF PLASTIC AND REMOVE

FROM CABLE CARD ASSEMBLY

DO NOT REMOVE THIS SCREW AT

THIS TIME!


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Once the cable card assembly has been removed, as shown below, only the B Block will remain. Be certain to tranfer the plastic chassis locking mount and screw-on RF connector to the replacement unit.

FLIP ASSEMBLY OVER

LIFT CABLE LOCK UP AND CAREFULLY REMOVE FLAT CABLE

REMOVE CONNECTORREMOVE MACHINE SCREW

AND SLIDE CABLE CARD ASSEMBLY UP AND OUT . DO

THIS BEFORE REMOVING THE RF CABLE!

KEEP THIS RF CONNECTOR. DOES NOT COME W/REPLACEMENT UNIT


PLASTIC CHASSIS MOUNT NOT INCLUDED WITH REPLACEMENT PART


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Chasssis RemovalThe following steps will provide the proper steps for removal of the chassis assembly which includes the B Block, AGU Board, GT Board, and Wire Harness Assembly. Once the chassis has been removed, access to the Lamp Driver and Optical Block will be achieved.

REMOVE 11 SELF-TAPPING SCREWS AND LEFT AND RIGHT STAYS (SUPPORT

BRACKETS)

SLIDE ASSEMBLY BACK TO END OF MOUNTING

SLOTS AND LIFT TO RELEASE

SLIDE B BLOCK ASSEMBLY BACK TO END OF MOUNTING SLOTS

AND LIFT TO RELEASE

CHASSIS REMOVAL STEP 1



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Chassis Removal Step 2

LOOSEN PURSE LOCKS AND ONE CABLE RETAINER AND

PULL WIRE HARNESS LOOSE



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UNPLUG RF SWITCHING

CONNECTOR

GROUND CABLES AND RF CONNECTORS DO NO NEED TO BE REMOVED

IF CHASSIS IS BEING PULLED


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PLACE FINGER IN SLOT, LIFT CHASSIS SLIGHTLY AND PULL

OUT 1/2 INCH

SWING B BLOCK ASSEMBLY OUTWARD AS SHOWN



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CN8001

CN8814

CN8406

CN8004

CN8400REMOVE 5 CONNECTORS FROM AGU

BOARD. CAUTION: RELEASE LOCKING MECHANISM FROM EACH CONNECTOR

BEFORE PULLING OUT!



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LOOSEN WIRE HARNESS FROM HOLDERS. UNPLUG 7 CONNECTORS AS SHOWN. SQUARES ARE CONNECTORS .CIRCLES ARE WIRE HOLDERS.CAUTION: RELEASE LOCKING MECHANISM ON CONNECTORS BEFORE REMOVING!

REMOVE GROUND WIRES FROM PURSE LOCKS


NOTE: Observe how the main wire harness is secured at the upper portion of the cabinet. The B Block assembly will not re-install correctly if the cable is mounted too high.


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REMOVE 2 CONNECTORS FROM OPTICAL BLOCKCAUTION: RELEASE LOCKING MECHANISMS BEFORE PULLING CONNECTOR !

REMOVE LVDS CONNECTOR FROM LEFT SIDE OF B BLOCK

BY SQUEEZING LOCK RELEASE PINS ON SIDES


CN604

CN602



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Swing B Block Assembly out to position shown.

Place main cable harness on top of bracket as shown.



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REMOVE 2 CONNECTORS FROM GT BOARD AND ONE FAN CONNECTOR .CAUTION: RELEASE LOCKING MECHANISMS BEFORE PULLING OUT CONNECTORS!

CN6002

CN6002

FAN



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Place the chassis assembly aside to begin the next steps to remove the Lamp Driver or Optical Block. Note how the wire harness is rested on top of the B Block to protect the connectors from snagging onto other items.


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WIRE HARNESS POSITIONING

POSITION HARNESS RETAINERS POINTING DOWNWARD AND THEN WRAP AROUND CABLE TO KEEP

BELOW CABINET EDGE

GROUND WIRES FOR RF SWITCHING ASSEMBLY IN

LOWER PURSE LOCKS

SECURE HARNESS WITH RETAINER AT BOTTOM CORNER OF B BLOCK

ASSEMBLY

WIRE HARNESS POSITION

Re-Installing the Wire Harness

When re-installing the chassis, it is important to install the wire harness properly. If it is not, the B Block assembly will not seat correctly and wires may be damaged. The most important step is to place the harness in the upper retainers as shown below so that it rests below the cabinet ridge to clear the back side of the B Block.


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Lamp Driver and Optical Block Removal

The following steps will remove these items from the cabinet assembly. The units will be seperated and each can be serviced from that point.

OPTICAL BLOCK AND LAMP DRIVER ASSEMBLY REMOVAL STEP 1

LOOSEN 2 SCREWS LOCATED UNDER C BOARD WITH LONG

SCREWDRIVER

REMOVE 2 SCREWS AT BASE OF LAMP DRIVER ASSEMBLY AND PULL FAN HOUSING OFF

REMOVE CABLES FROM RETAINERS



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OPTICAL BLOCK AND LAMP DRIVER REMOVAL STEP 2

NOTE PLACEMENT OF WIRES WHEN RE-ASSEMBLING

LEFT SIDE OF BRACKET HAS TONGUE THAT

SEATS INSIDE OF LAMP HOUSING

SWING COVER OUT TO THE LEFT



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Remove Screw

TEMPORARILY SECURE FAN AND LVDS CABLES

AS SHOWN



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Carefully remove the Optical Block and Lamp Driver Assembly together



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OPTICAL BLOCK AND LAMP DRIVER (BALLAST) REMOVAL STEP 5

ROTATE THE OPTICAL BLOCK AND LAMP DRIVER ASSEMBLIES TO EXPOSE

THE BOTTOM SIDE. PLACE ON SOFT PADDING TO PREVENT DAMAGE TO

LENS ASSEMBLY

USE CAUTION NOT TO DAMAGE THE SWITCH

ON THE T2 BOARD

REMOVE SILVER SELF-TAPPING SCREW SECURING LAMP

CONNECTOR

REMOVE HV LEAD FROM PURSE LOCK

ASSEMBLIES CAN NOW BE SEPARATED


The Lamp Driver and Optical Block must now be seperated in order to service the units individually.


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Lamp Driver Disassembly

This step disassembles the Lamp Driver housing to gaIn access to the Lamp Driver board.NOTE: When re-installing the lamp connector to the brackets, make sure the connector is installed as shown. The connector should sit flat on the bracket and the tabs on the ends should seat flush with the bracket. If not done correctly, the lamp cannot be installed.

T2 BOARD BRACKET SHOWN ABOVE DOES NOT COME WITH REPLACEMENT BRACKET .

DO NOT LOSE!

LAMP DRIVER DISASSEMBLY STEP 1

REMOVE LAMP PLUG FROM T2

BOARD BRACKET

NOTE: WHEN RE-ASSEMBLING, MAKE SURE THE LAMP CONNECTOR IS

INSERTED CORRECTLY INTO BRACKET OR LAMP

WILL NOT INSERT



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Lamp Driver Removal Step 2

RELEASE 3 CLAWS INSIDE OF HOUSING

SECURING FAN DUCT

REMOVE FAN DUCT BY GRASPING AS SHOWN. DO NOT

GRAB AT SIDES



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Lamp Driver Removal Step 3

REMOVE ONE SELF-TAPPING SCREW

RELEASE 3 CLAWS

NOTE POSITION OF WIRES FOR RE-

ASSEMBLY

UNDRESS RF ANTENNA WIRE AT TOP OF ASSEMBLY. NOTE

THE LOCATION FOR RE-ASSEMBLY



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REMOVE 2 SCREWS AND LOOSEN HV LEADS FROM

FASTENERS TO REMOVE LAMP DRIVER BOARD

NOTE: FAN WILL BE LOOSE AND HAS 3 RUBBER CUSHIONS ON

TOP AND 3 ON BOTTOM



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OPTICAL BLOCK REPLACEMENT

IRIS AND LDVS CABLES DO NOT COME WITH REPLACEMENT UNIT

FAN CABLE COMES WITH

REPLACEMENT ASSEMBLY

OPTICAL BLOCK REPLACEMENT

PLASTIC DUCT COVER COMES WITH REPLACEMENT ASSEMBLY

BUT MUST BE REMOVED TO ACCESS LVDS AND IRIS CABLES .

Optical Block Replacement

Replacement Optical Blocks are shipped as shown, minus the Iris and LVDS cables. Transfer these cables and any cloth tape pieces to the new Optical Block.

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Appendix

Pixel FailurePixel failure is defined as one or more pixels that fail to pass light, are always passing light, or intermittently cause either of the previously mentioned symptoms. One must be extremely lucky to experience an LCD panel with zero pixel defects. A typical Sony LCD Projection unit utilizes 3.28 million pixels between the three LCD panels. LCD panels with zero defects are possible to manufacture, but it would require rejecting a large amount of them and that would make the cost rise to an unacceptable level.

Determining whether a particular LCD panel requires replacement due to pixel failure is a somewhat subjective procedure. No official specifications exist due to the various LCD panel manufacturers due and violations of non-disclosure agreements. Combining several common sense criteria can help determine if the pixel issue warrants a panel replacement (the entire optical block for a projection unit).

1. A pixel that is continuously lit is far more obvious than one that never lights. The color of the pixel that is “stuck on” is also important. The eye is the most sensitive to green, somewhat to red, and very little to blue.

2. The number of defective pixels is also important. If only one pixel is out then 99.99999% of the pixels on the panel are operating properly. This is quite acceptable. As several or more pixel failures are approached, the next criteria are of importance.

3. The area of the pixel failure will determine how easily it is noticed. Pixel failures in the center area of the screen that constitutes 1/3 of the screen are more noticeable than those in the outlying areas. This is where the customer is concentrating his viewing.

As can be seen, pixel issues can be somewhat ambiguous. The greatest problem to deal with is that once the customer has found a defective pixel (or pixels) they are going to dwell on it. The following is a generalized approach that should assist the technician in dealing with a customer who is complaining about pixel problems.

Try not to let the customer show you where the pixel failure(s) are. Tell the customer that you would like to view the picture for a moment with an active video signal. It is during this period of time that the technician should attempt to locate any defective pixels. If one cannot be found easily, the panel is probably acceptable and should not be replaced. If one or more pixels are easily spotted, the panel should be replaced. Handle each pixel issue on an individual basis.

Appendix

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DustDust will always be an issue with projection LCD devices. Large amounts of air are needed to pass around the lamp, lenses and mirrors to keep the LCD panels cool. When dust becomes and issue is dependent on several factors such as environmental conditions, cumulative hours of use, etc.

Dust particles will appear as dark spots that are larger than the size of an individual pixel. It must first be determined if the particle(s) are on the LCD panels or the screen. The simplest way to do this is to grab the top of the screen and rock it back and forth a small amount. If the dust is on the LCD panel, the spot(s) will move to different locations on the screen. If they follow the rocking motion of the screen, the dust is on the back side of the Fresnel lens assembly. It could also reside between the layers of the screen. Doing this helps to determine if the screen or the optical block requires cleaning.

Dust on the LCD assembly or the screen are not covered by the warranty. Under normal conditions, noticeable dust may appear well out of the warranty period and should be considered as normal maintenance like any other type of projection television. Dust accumulating on the rear of the screen is easily cleaned using a soft cotton cloth and water. The use of paper towels or tissues is not recommended since these tend to scratch the surface.

Cleaning of the LCD panels requires more time. The optical assembly must be removed and access gained to the panels. This will require the removal of the LCD driver board. Blowing a low pressure stream of compressed air may remove the particles. In some cases, such as a large number of dust particles, simply blowing air into the cavity that houses the LCD panels only moves them to other areas of the panels. In this case it will be necessary to remove the LCD panel assembly.

CAUTION: Handle the LCD assembly with extreme care! Although the LC panels are durable, it is possible to knock one or more of the panels out of alignment. This would cause a mis-convergence of the colors on the screen. It is very difficult to realign the panels. Check the ESI website on a regular basis to see if any up-to-date service routines have been posted regarding this procedure.

LCD Panel

Glass covering

DustLCD Panel

Glass covering

Dust DUST PARTICLE

FIGURE 2-5DUST PARTICLE ON LCD PANEL

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2005 Sony Electornics, Inc.EMCSA - A Service Company

1 Sony DrivePark Ridge, New Jersey 07656

Reproduction in whole or part without written permission is prohibited. All rights reservedTVP201205R1 12/15/05

Documents

KDF-E42A10_E50A10 Ch.mix-5 (Training Manual)