Sony KDP-51WS550 Training Manual
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Sony KDP-51WS550 Training Manual

Ax-1 chassis
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AX-1 Chassis
Models:
KDP-51WS550
KDP-57WS550
KDP-65WS550
Diagnostics and Troubleshooting
Course: TVP-16
KDP-51WS550
Training Manual

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Summary of Contents for Sony KDP-51WS550

  • Page 1 Training Manual KDP-51WS550 AX-1 Chassis Models: KDP-51WS550 KDP-57WS550 KDP-65WS550 Diagnostics and Troubleshooting Course: TVP-16...

  • Page 2: Table Of Contents

    Table of Contents 1. AX-1 chassis PCB Interconnections 5. AX-1 Video Processing ....29 and Functional Descriptions .....1 AX-1 Acceptable Formats ........29 Overview ..............1 Simplified Main, Sub and OSD Video Path ..29 2. New Features ........5 Troubleshooting ............. 34 Manual Convergence ..........

  • Page 3: Chassis Pcb Interconnections

    1. AX-1 Chasis PCB Interconnections and Functional Descriptions Chapter 1 - AX-1 Chassis PCB Interconnections and Functional Descriptions Overview This chapter provides a high-level overall block view of the AX-1 chassis PCB interconnects and the functions performed on each PCB. Figure 1-1 provides a schematic type diagram showing how all the PCBs are interconnected within the complete system.
  • Page 4 1. AX-1 Chasis PCB Interconnections and Functional Descriptions Table 1-1 – AX-1 Chassis PCB Functional Descriptions Board Circuits Board Replacement Comments Adjustments • AC Rect. (D6005) A/C Input • feeds Q-Box, AC Relay Field • Primary and HV Zero Protect Repairable •...
  • Page 5 1. AX-1 Chasis PCB Interconnections and Functional Descriptions • • Cannot be Protection Size & Geometry disconnected. Unit Circuits • Field Check G2 will not be powered HV Protect Repairable • Check Electrical ON. Two relay clicks Drive (Cont.) Focus can be heard (AC Protect •...
  • Page 6 1. AX-1 Chasis PCB Interconnections and Functional Descriptions • Q-Box Module Can be disconnected. ATSC Unit will remain Tuner NOT Field powered. • Repairable QM Brd • QT Brd • QI Brd • I-Link Processing • Memory Stick Processing • Can be disconnected.

  • Page 7: New Features

    2. New Features Chapter 2 - New Features Manual Convergence This feature allows the end-user to make point-by-point (Fine) convergence (ref. Figure 2-1) adjustment using the remote control. Before this feature can be accessed, the Flash Focus feature must be performed. The Flash Focus does not set the convergence settings back to factory settings;...
  • Page 8 2. New Features The resolution to this dilemma is the creation of a complete end-to-end standard digital video interface, ala DVI. The DVI interface is a high-speed digital video interface allowing uncompressed high-definition content to be passed to another DVI equipped device such as an HDTV set. DVI is the only digital interface capable of accommodating uncompressed digital data such as HD video.

  • Page 9: Q-Box

    2. New Features The DVI Decoder, IC7004 receives the three channels of digital video data and outputs analog component video (Y, PB, PR) to CN7002/pins 10, 8 and 6 respectively. Q-Box The Q-Box processes ATSC (off-the-air digital broadcast) broadcast, Memory Stick and I-Link signals. The boards included in the Q-Box are the QM, QI and QT.
  • Page 10 2. New Features Q-BOX CN7300 POWER & COMMUNICATION (RESET) DATA FROM 3.2V Q-BOX MICRO DATA TO Q-BOX CN7309 MICRO VIDEO AUDIO END VIEW OF Q-BOX USED FIGURE 2-4 - Q-BOX CONNECTOR/PIN DETAIL...
  • Page 11 2. New Features Figure 2-4 give connector/pin details for viewing Q-Box operating voltages and output signals for troubleshooting. The signals that should be present on the various pins are illustrated in waveforms 2-5 to 2-10. The operating DC voltages of 9V and 5V are labeled on the diagram. Note the different scan rates for the Y-Signal in waveforms 2-7 and 2-8.

  • Page 12: Chassis Power Supplies

    3. AX-1 Chassis Power Supplies Chapter 3 - AX-1 Chassis Power Supplies Overall Block Diagram A BOARD G2 BOARD D6005 Q-BOX TO: Q-B0X 9V & 5V PCONT Q6102 POWER (QM BOARD) RECT SUPPLY RELAY DC START D6123 VOLTAGE STBY 5V STBY POWER AC IN...

  • Page 13: Standby Power Supply And Power On Circuit

    3. AX-1 Chassis Power Supplies When troubleshooting the AX-1 chassis power supply system, keep this sequential DC Start voltage structure in mind. For example, if the HV power supply fails, it may be actually a failure of the Primary Power Supply, which supplies the DC Start voltage to the HV Power Supply, or the problem could be further up in the system in the Q- Box Power Supply, which supplies the DC Start voltage to the Primary Power Supply.

  • Page 14: Q-Box, Primary And High Voltage Power Supplies

    3. AX-1 Chassis Power Supplies TV will have problems turning ON. If C6120 became defective (open circuit), the AC voltage input can only go as low as 105VAC before erratic TV turn-ON function. At the same time the AC Relay is energizing, Q6109 is turning ON. When Q6109 turns ON, it shorts the emitter to base on Q6107 and it turns OFF.
  • Page 15 3. AX-1 Chassis Power Supplies • 10V regulator (IC6501/pin 10) Note: The 10V output at IC6900/pin 10 passes through D6901 and is then fed back into IC6900/ pin 14, supplying power to the internal driver transistor for the Low & High side output FETS Q6900 and Q6901.
  • Page 16 3. AX-1 Chassis Power Supplies • If the 9V line comes to proper level but the 5V line is 0V, check for a shorted condition in the circuits the 5V line supplies. 2) The Q-Box Power Supply can be safely tested by unloading the +9V and 5V lines. Disconnect CN6902. This will completely unload the power supply, but still send necessary feedback to IC6900 for proper power supply operation.
  • Page 17 3. AX-1 Chassis Power Supplies A BOARD CN6900 CN6012 R6918 T6900 R6907 R6909 IC6902 R6904 296V D6909 146V R6900 C6919 V-SENSE 2.5V Q6900 D6914 IC6900 (15V) D6904 R6902 120Vp-p 144V 3001D 90kHz D6902 154V 4.7V C6916 Q6901 D6901 R6920 10.3V D6905 C6911 D6910...
  • Page 18 3. AX-1 Chassis Power Supplies D6502 A BOARD CN6400 +14/+22V R6508 CN6000 C6500 R6421 C6501 -14/-22V R6429 T6703 R6406 D6503 L6500 +17V L6512 R6400 C6503 C6504 146V R6401 -17V V-SENSE 2.7V Q6400 D6411 A BOARD IC6400 (15V) D6406 R6402 MCZ30 100Vp-p 140V D6413...
  • Page 19 3. AX-1 Chassis Power Supplies The notable differences between the Primary and Q-box Power Supply circuit description and operation are as follows: • No connection on IC6400/pin 18. Remember this was the initial voltage supply to start the IC internal circuits, so the IC itself could produce the running voltage at IC6400/pin 8.

  • Page 20: Protection Circuits

    4. AX-1 Protection Circuits Chapter 4 - AX-1 Protection Circuits AX-1 Protection Circuits Overall Block Diagram MA BOARD A BOARD LOW B+ IC0001 PROT. MAIN MICRO Q0008 AC RELAY ZERO - DET IC0002 Q6110 PF MICRO Q6111 Q6112 A BOARD LATCH Q6105 A6108...
  • Page 21 4. AX-1 Protection Circuits Reference Figure 4-1 B+ OCP (Q6803) monitors the current draw on the +135V line. If the current should increase due to an excessive load on the +135V line, the Latch will be triggered and shut OFF the AC-Relay. Also note that there is a direct connection from the B+ OCP circuit to IC0001 Main Microprocessor for self-diagnostics indication processing.

  • Page 22: Protection Circuit Schematic Diagrams

    4. AX-1 Protection Circuits AX-1 Protection Circuit Schematic Diagrams Direct Latch/AC-Relay Shut-OFF Circuits (B+ OVP, B+ OCP, IK-Prot 2 and DC Regulator protection) FROM R6113 AC RELAY R6118 IC0002 RY6000 P-CONT D6115 Q6102 R6111 MA BOARD Q6105 A BOARD Q6108 C6119 R6123 R6122...
  • Page 23 4. AX-1 Protection Circuits FBT Over Current Protection (IK-Prot 1) (Reference Figure 4-2) The secondary current in FBT is monitor by Q8007 at FBT/pin 1 (ABL). The +135V is used as the reference voltage through the resistor voltage divider consisting of R8040, R8039, R8038, R8037, R8043, R8036, and R8035.
  • Page 24 4. AX-1 Protection Circuits Vertical and IK-Prot 1 Protection Circuits A BOARD MA BOARD IC0401 AC RELAY IO-SDAT CRT DRIVE V-PROT. RY6501 IC0002 H-PROT. PF MICRO CN0001 CN2003 CN2005 V-DY (-) CN0002 A BOARD CN2006 FEEDBACK +135V CN5004 CN5015/PIN 3 R8040 D8007 R8039...
  • Page 25 4. AX-1 Protection Circuits Vertical Deflection Protection (V-Prot) (Reference Figure 4-3) The operation of the vertical deflection circuit is monitored using the vertical feedback signal from the VDY (CN5015/pin3) and the feedback pulse developed at IC5004/pin 3 (vertical drive IC). When the vertical circuit is working properly, the vertical feedback signal is fed direct to the Y/C CRT Drive IC0401/pin56 through R0426, and the feedback pulse is generated at Vertical Drive IC5101/pin3.
  • Page 26 4. AX-1 Protection Circuits (Reference Figure 4-4) The HV level is monitored through the HV Regulator circuit IC8004. IC8004 and resistor network RV8002, R8017, R8014 and R8015 are part of the HV regulation circuit (feedback path for IC8002 HV power supply converter).
  • Page 27 4. AX-1 Protection Circuits Excessive HV Circuit (Reference Figure 4-5) The HV is monitored at FBT/pin 5 using two comparator circuits (A & B) located in IC8001. Comparator A will be triggered when there is a sustained excessive HV (or gradual HV increase), and comparator B will trigger on a momentary (or fast increase) HV spike.
  • Page 28 4. AX-1 Protection Circuits AX-1 5V Regulator and White Balance Protection Circuits O_STBY_LED O_AC_RELAY STBY AC RELAY IC0001 A BOARD 26 2 6 35 3 5 RY6000 MAIN MICRO IO_SDAT I_LB_ERR HA BOARD 2.5V R0077 Q0008 IO_SDAT IC0002 PF MICRO R0081 R0082 IO_SDAT...
  • Page 29 4. AX-1 Protection Circuits 7, IC9201/pin 7 and IC9301/pin 7 develops an IK feedback pulse, which is directly proportional to the current drawn by each cathode in the CRT. The IK feedback pulse passes through buffer transistors Q9102, Q9202 and Q9302, and then the sequence of the three IK feedback pulses is applied to the base of buffer Q9104.
  • Page 30 4. AX-1 Protection Circuits Q2006 monitors for a positive DC voltage condition and Q2005 monitors for a negative DC voltage condition on the audio output lines. If there is a positive DC voltage present, Q2005 will turn ON causing the base of Q2008 to become negative with respect to the emitter, turning it ON.

  • Page 31: Video Processing

    5. AX-1 Video Processing Chapter 5 - AX-1 Video Processing AX-1 Acceptable Formats The acceptable inputs for this chassis are listed in Table 5-1: Table 5-1 - DA-4 and DA-4X Inputs Inputs Format Analog TV stations Air (Ch. 2-69) or Cable (1-125) NTSC Digital TV stations Air (1-99) in 18 ATSC digital formats Video 1-4...
  • Page 32 5. AX-1 Video Processing Reference Figure 5-1 All video signals from the Main Tuner, Sub Tuner, Q-box (ATSC Tuner, Memory Stick, and I-Link) and Video Inputs 1-7 are first fed into the AV Switcher (IC1501). The Main Video coming from the Main Tuner, Q-Box or Video 1-7 is directed to the A/D converter (IC3101) to be digitized.
  • Page 33 5. AX-1 Video Processing • Channel Number PJED Microprocessor: • PJED Service Mode Items ATI Microprocessor (In Q-Box): • User Digital Channel Menu Detailed Video Path Diagrams The following diagrams give a more detailed illustration of the Main Video, Sub Video and OSD paths throughout the AX-1 Chassis.
  • Page 34 5. AX-1 Video Processing Figure 5-2 illustrates in detail all the video input sources to the AV Switcher (IC1501). Outputs on the AV Switcher are the Main, Sub and Monitor Out. The Main and Sub video signals leave the UA board and are fed through the A board on their way to BM board for processing.
  • Page 35 5. AX-1 Video Processing IC1501 A/V SWITCH SUB-Y IC1507 YCT-SUB UA BOARD MAIN SUB_RGB (OSD) CV/Y PB CN1502 CN2015 A BOARD R2103 Q2000 CV/Y R2098 CN2005 CN0001 IC0401 MAIN Y SUB Y SUB_RGB Y/C CRT IC0002 IC0001 DRIVE MAIN MICRO PJED MICRO MENU...

  • Page 36: Troubleshooting

    5. AX-1 Video Processing Troubleshooting To troubleshoot a video problem use the various inputs and outputs, along with the various video formats. By using a particular input with a particular video format, circuits can be exercised and/or bypassed to determine which circuit is causing the problem.
  • Page 37 5. AX-1 Video Processing IC3201 DRC (BM-board) Memory Stick Input: Exercised: (Normal Picture Mode) Q-Box IC1501 AV switch (UA-board) IC3101 A/D (BM-board) IC3201 DRC (BM-board) IC3301 MID circuit (BM-board) IC3303 D/A (BM-board) IC0401 Y/C CRT Drive (MA-board) CRT Drive AMPS (CR, CG, CB boards) Bypassed: Main Tuner Sub Tuner...

  • Page 38: System Control Circuits

    6. AX-1 System Control Circuits Chapter 6 - AX-1 System Control Circuits Overview There are three microprocessors controlling various functions on the AX-1 chassis. The Main Microprocessor (IC0001), Platform (PF) Microprocessor (IC0002) and the ATI Microprocessor (Q-Box) all interface with and control specific functions on the AX-1 chassis.
  • Page 39 6. AX-1 System Control Circuits Platform Microprocessor (IC0002) Reference Figure 6-2 The Platform (PF) Microprocessor performs all the actual control of the various Video, Audio ICs and Interface with the PJED CPU. It controls the Video Switcher (IC1501), DRC (IC3201), MID (IC3301) and Main and Sub Decoders (IC3101 &...

  • Page 40: Deflection Circuits

    7. AX-1 Deflection Circuits Chapter 7 - AX-1 Deflection Circuits AX-1 Vertical Deflection Circuit +15V -15V R5114 IC8003 V DRIVER 400mVpp 400mVpp BOOST VD(-) PB V OUT VD(+) IC0401 Y/C JUNGLE R5107 R5112 D5102 +15V VD(-) 20Vpp C5108 C5109 VD(+) R5108 R5113 MA BOARD...

  • Page 41: Horizontal Deflection Circuit

    7. AX-1 Deflection Circuits AX-1 Horizontal Deflection Circuit 45Vpp (HDT) T5001 MA BOARD Q5004 R5019 R5021 12Vpp R5020 IC0401 C5015 R5025 CN5004 CN2006 Q5005 CRT DRIVE C5016 Q5008 R5031 Q5009 CN0001 CN2005 1Vpp D5003 Q5001 +135V D5005 A BOARD H-OUT R6604 HEATER T5200...
  • Page 42 7. AX-1 Deflection Circuits The waveforms shown on Figure 7-2 are the typical horizontal circuit signal shapes. The difference between this set and a conventional set is the horizontal frequency, which is 33.75KHz as opposed to 15.75KHz scan rate in the conventional set.

  • Page 43: Audio Circuit

    8. AX-1 Audio Circuit Chapter 8 - AX-1 Audio Circuit AX-1 Audio Block Diagram ATSC SIGNAL CN1508 MEMORY STICK IC1601 Q-BOX SIGNAL i.LINK SIGNAL 3.5Vpp V7 DVI IC1504 SWITCH (L) CONTROL FROM IC1505 UA BOARD IC1501/PIN 74 SWITCH (R) VIDEO SWITCHER FROM MON.
  • Page 44 8. AX-1 Audio Circuit Also, input to IC1502 is audio from the ATSC Tuner, Memory Stick, i.LINK® and DVI through switching ICs IC1504 and IC1505. The control from the switching function in these ICs comes from the serial porter at IC1501/ pin74 (the video switcher IC).

  • Page 45: Service Mode And Adjustments

    9. AX-1 Service Mode and Adjustments Chapter 9 - AX-1 Service Mode and Adjustments Entering Service Mode and Sequence of Adjustments Set unit to FULL picture mode. Input an external Cross Hatch Pattern (do not use internal pattern generator for adjustments). Enter Service Mode: Press DISPLAY –...
  • Page 46 9. AX-1 Service Mode and Adjustments Flash Focus. Should pass. NOTE: Flash Focus should be performed until all the fine adjustment data settings are within the Fine Data Limit as per Table 9-1. Table 9-1 – Coarse and Fine Data Limits CENT H (coarse) -135 to +205 CENT V (coarse)
  • Page 47 9. AX-1 Service Mode and Adjustments SKEW (Horizontally/Vertically) FIGURE 9-3 - SKEW ADJUSTMENT TVP16.9-3 11/10/03 LIN (Horizontally/Vertically) FIGURE 9-4 - LINEARTY ADJUSTMENT TVP16.9-4 11/10/03 SIZE (Horizontally/Vertically) FIGURE 9-5 - SIZE ADJUSTMENT TVP16.9-5 11/10/03...
  • Page 48 9. AX-1 Service Mode and Adjustments PIN (Horizontally/Vertically) FIGURE 9-6 - PINCUSHION ADJUSTMENT TVP16.9-6 11/10/03 BOW (Horizontally/Vertically) FIGURE 9-7 - BOW ADJUSTMENT TVP16.9-6 11/10/03 KEY (Vertically) FIGURE 9-8 - KEYSTONE ADJUSTMENT TVP16.9-8 11/10/03...
  • Page 49 9. AX-1 Service Mode and Adjustments MSIZ (Horizontally) FIGURE 9-9 - MID-PICTURE SIZE ADJUSTMENT TVP16.9-9 11/10/03 MLIN (Horizontally) FIGURE 9-10 - MID-PICTURE LINEARITY ADJUSTMENT TVP16.9-10 11/10/03...
  • Page 50 Sony Electronics ® ©2004 Sony Electronics Inc. EMCS - A Service Company 1 Sony Drive TVP160104 1/14/04 Park Ridge, New Jersey 07656 Reproduction in whole or part without written permission is prohibited. All rights reserved...

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