Sony KZ-32TS1U Training Manual
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Sony KZ-32TS1U Training Manual

Plasma tv & grand wega projection tv
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Plasma TV &
Grand Wega Projection TV
Models:
KZ-32TS1U
KZ-41TS1U
KF-60DX100
KZ-32TS1U
Diagnostic Guides
Course: TVP-13
Training Manual
KF-60DX100

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Summary of Contents for Sony KZ-32TS1U

  • Page 1 Training Manual Plasma TV & Grand Wega Projection TV Models: KZ-32TS1U KZ-41TS1U KF-60DX100 KZ-32TS1U KF-60DX100 Diagnostic Guides Course: TVP-13...

  • Page 2: Table Of Contents

    Table of Contents KZ-32TS1U // KZ-42TS1U KF-60DX100 Introduction ...........1 Introduction ..........37 1. Normal Operation ......2 15. Normal Operation ......38 2. Self-Diagnostics ........3 16. Self-Diagnostics ......39 3. Board Selection by Defect ....4 17. Board Selection by Defect ....40 4. Plasma Panel Picture Defects ..5 18.

  • Page 3: Introduction

    This training manual has been organized to provide a quick diagnosis of problems in Sony Plasma screen TV models KZ-32TS1U and KZ-41TS1U. The circuitry in these two TV sets is similar, but the boards and plasma panels are mounted differently.

  • Page 4: Normal Operation

    Sony Model KZ-32TS1U // KZ-41TS1U TV Diagnostic Guide Chapter 1 - Normal Operation Black top and bottom (letterbox) borders – Even though this TV has a wide 16x9 screen, it is still possible to receive a picture with top and bottom black bands. Movies are shot in many aspect ratios. The most common ratios are 4:3, 1.85:1 and 2.35:1.

  • Page 5: Self-Diagnostics

    Sony Model KZ-32TS1U // KZ-41TS1U TV Diagnostic Guide Chapter 2 - Self-Diagnostics Standby/Sleep Light The front panel Standby LED blinks to indicate a fault. Refer to Figure 2-1. If the TV does not start up, the LED continually blinks to indicate a problem.

  • Page 6: Board Selection By Defect

    Panel picture defects (Chapter 4). For isolation purposes, the TU (tuner board) may be unplugged and the TV will work, displaying video inputs. Table 3-1 - Plasma TV model KZ-32TS1U / KZ42TS1U Board Selection by Defect Probable Circuit Board Failure...

  • Page 7: Plasma Panel Picture Defects

    Sony Model KZ-32TS1U // KZ-41TS1U TV Diagnostic Guide Chapter 4 - Plasma Panel Picture Defects Board Location – Ref. Figure 4-1 Vertical or Colored rain Horizontal in a black black / white background. line through the picture. White Noise replaces 1/4...

  • Page 8: Board Location

    5. Board Location Chapter 5 - Board Location POWER SUPPLY BOARD PLASMA PLASMA BOARD X BOARD Y B BOARD Q BOARD TU BD. FIGURE 5-1 - BOARD LOCATION - KZ-32TS1U 8TVP13 1444 4/10/02...

  • Page 9: Service Mode

    Figure 6-1 2. Using a Sony remote control aimed at the TV in the standby mode, quickly press: Display, 5, Volume +, Power ON and MENU. If the TV turned ON when 5 was pressed, you did not press the next Volume + button fast enough and will have to try again.
  • Page 10 6. Service Mode Service Mode Contents Table 6-1 - Service Mode Contents Service Category Contents EEP ROM Initialize See Figure 6-3 for a list of Initialize contents. Selecting a line (like “Common”) reveals two options: OK or cancel. Selecting OK stores default data and causes the TV to reboot.
  • Page 11 6. Service Mode Service Status See Figure 6 -9. This section displays the status of the input signal, and TV condition. Signal/sync - Format, freq, and sync polarity of the input signal. Power Supply – Low voltage output of the power supply in voltage DC. Fan &...
  • Page 12 6. Service Mode Figure 6-4 Service Mode – Chroma Decoder Figure 6-5 Service Mode –General Figure 6-6 Service Mode – Manual Control 1/2...
  • Page 13 6. Service Mode Figure 6-7 Service Mode – Manual Control 2/2 Figure 6-8 Service Mode –Preset Edit Figure 6-9 Service Mode –Service Status...

  • Page 14: Adjustments When The B Board Is Replaced

    Figure 7-1 2. Using a Sony remote control aimed at the TV in the standby mode, press: Display, 5, Volume +, Power ON and MENU, quickly. If the TV turned ON when 5 was pressed, you did not press the next Volume + button fast enough and will have to try again.
  • Page 15 7. Adjustments when the B Board Needs to be Replaced Figure 7-3 - A/D Converter Preset Default Levels 3/13/02 Table 7-1 A/D Converter (WB & Brightness) Default Levels YUV (Component Video) Video (Composite Video) Item 32” 42” Item Level 42” Item Level 42”...
  • Page 16 White Balance Color Temp: Mid Color Temp: Low Color Temp: High FIGURE 7-4 - WHITE BALANCE PRESET DEFAULT LEVELS - MODEL KZ-32TS1U KZ-42TS1U Figure 7-5 shows the White Balance levels from a 42" Plasma TV: White Balance White Balance White Balance...

  • Page 17: Plasma Panel Replacement - Kz-32Ts1U

    8. Plasma Panel Replacement - KZ-32TS1U Chapter 8 - Plasma Panel Replacement - KZ-32TS1U The KZ-32TS1U and the KZ-42TS1U are mechanically different and have separate procedures for removal of the Plasma Panel. Handling Precautions After removing the plasma panel from the TV, note that there are flex cables located at the bottom and both sides of the panel that are susceptible to damage.
  • Page 18 8. Plasma Panel Replacement - KZ-32TS1U Fan & Shield Ÿ Remove Figure 8-2 - Back Removed a) Begin by removing the back panel to expose the shield, shown in figure 8-2. b) Unplug the fan and remove the shield. Power...
  • Page 19 8. Plasma Panel Replacement - KZ-32TS1U The lower board assembly (behind the input jacks) must be removed because the plasma panel cannot be slid out from underneath it. There is a lip under the board assembly that prevents the panel from being slid sideways.
  • Page 20 8. Plasma Panel Replacement - KZ-32TS1U Remove the TV Board Assembly 2 Ÿ Snake the H1 board harness out H1 Board the back hole Cable Harness Figure 8-6 - Remove TV Board Assembly 2 In the next two steps, the TV must be supported while face down and the base removed.
  • Page 21 8. Plasma Panel Replacement - KZ-32TS1U Support Brackets Top View Figure 8-8 - Base Removal 1 Remove the base. Lay the TV screen flat on the floor. Support Brackets Bezel, P.S and Plasma Screen Ÿ Remove bracket Figure 8-9 - Base Removal 2...
  • Page 22 8. Plasma Panel Replacement - KZ-32TS1U Power Supply Handles Handles Board Figure 8-10 - Plasma Screen Handles Finally, remove the plasma screen – use the four black handles to lift. Only place the top of the plasma screen down. The other three sides have vulnerable flex cables present.
  • Page 23 The inside of the TV screen is coated so do not clean or leave oil on it by touching it. The inside surface scratches easily. Clean the inside of the TV screen if there is film or fingerprints. Use the Sony p/n X-4034- 197-1 soft cloth and diluted mild window cleaner if necessary.
  • Page 24 8. Plasma Panel Replacement - KZ-32TS1U • Mount the input connector cover that contains the AC socket (Figure 8-3). • Test the TV by plugging in AC and a VHF signal. The TV will operate for at least 30 minutes without the fan connected.

  • Page 25: Plasma Panel Replacement - Kz-42Ts1U

    9. Plasma Panel Replacement - KZ-42TS1U Chapter 9 - Plasma Panel Replacement - KZ-42TS1U The KZ-32TS1U and the KZ-42TS1U are mechanically different and have separate procedures for the Plasma Panel removal. Handling Precautions • After removing the plasma panel from the TV, note that there are flex cables located at the bottom and both sides of the panel that are susceptible to damage.
  • Page 26 9. Plasma Panel Replacement - KZ-42TS1U b) Seven connectors must be removed. Three connectors have a catch that must be pulled or squeezed to separate the connector. The remaining four connectors are simply unplugged. Remove the conductive mesh tape that shields the ribbon connector and unplug the white ribbon cable (Figure 9-3) by pulling it straight out.
  • Page 27 With a partner, lift the plasma screen off by the handles (Figure 9-6). PLACE THE PANEL UPSIDE DOWN ON THE FLOOR – SEE FIGURE 9-7. The power supply board must be removed from the panel if the panel is to be replaced. Only clean the inside of the screen with Sony cloth p/n X-4034-197-1.
  • Page 28 The inside of the TV screen is coated so do not clean or leave oil on it by touching it. The inside surface scratches easily. Clean the inside of the TV screen if there is film or fingerprints. Use the Sony p/n X-4034- 197-1 soft cloth and diluted mild window cleaner if necessary.
  • Page 29 9. Plasma Panel Replacement - KZ-42TS1U • Attach the conductive mesh tape between the bezel and plasma panel (refer to Figure 9-6). • If you want to test the TV before installing the shield, attach the rear circuit board assembly, plug it in and turn on the TV set.

  • Page 30: Standby Power / Power On

    10. Standby Power / Power ON Chapter 10 - Standby Power / Power ON Standby Power Standby power is present when: • The TV is plugged in. • The front panel ON/OFF switch is latched in. • The red standby light within the ON/OFF button is lit. CN4100/CN3006 S4101 H1 BOARD...
  • Page 31 10. Standby Power / Power ON Circuit Operation Once standby power is available to the Micro CPU IC1004 (B board), IC1004 can respond to either the channel buttons or power ON button to turn ON the TV. Two commands are output IC1004 to turn ON the Plasma panel. CPU_GO and RDP_GO both go high at CN1/pins 5 and 6.

  • Page 32: Fan Drive Circuit

    11. Fan Operation Chapter 11 - Fan Operation The fan is turned on when the TV is powered ON and blows air out of the TV. The TV will only shutdown when the power supply (thermistor) reaches a critical temperature (set in the service mode), not if the fan stops. Fan Operation The fan runs at one of three speeds based upon the temperature of the power supply board.
  • Page 33 11. Fan Operation Fan or Q board? To determine if the fan, Q board or B board is causing NO fan rotation, turn ON the TV and: 1. Measure the voltage at the fan connector CN3009/pin 1 (red wire) with the fan connected (loaded). 2.

  • Page 34: Video Signal Flow

    12. Video Signal Flow Chapter 12 - Video Signal Flow The video signal processing is performed on three boards (TU, Q and B) and the plasma panel as shown in Figure 12-1. The composite video or component video is selected in the B board. The OSD is inserted into the video path (not shown) later on in the B board signal chain.
  • Page 35 12. Video Signal Flow Table 12-3 - Component Video Input Signal Name Location Signal Level CN3002/pin 4 1.0p-p CN3002/pin 2 0.8Vp-p CN3002/pin 6 0.4p-p Table 12-4 - Digital Video Signal Output to Plasma Panel Signal Name From B Board To Plasma Panel Wire Color Signal Level * Out 0 +/-...
  • Page 36 12. Video Signal Flow Digital Video Signal to Plasma Panel Video signals Out 0 – 3 are digital video signals applied to the plasma video panel. Out 0 is the LSB (Least Significant Bit) and Out 3 is the MSB (Most Significant Bit). The digital video signal is accompanied by a clock signal for timing.

  • Page 37: What Is Flat Screen Plasma Technology

    13. What is Flat Screen Plasma Technology? Chapter 13 -What is Flat Screen Plasma Technology? The flat panel plasma display is the latest display technology and offers the following TV / monitor features: • Bright screen light, easily viewable in any environment •...
  • Page 38 The more times it fires, the brighter the cell seems (but actually they fire at full intensity each time). The number of times it fires is based upon the phosphor persistence and is usually a maximum of eight times per frame. FIGURE 13-2 SONY 16 X 9 PLASMA PANEL SEGMENTS Cell Selection and Screen Layout Within each panel, the individual cells to be fired are selected based upon the horizontal and vertical grid similar to a multiplication table.

  • Page 39: Introduction

    Sony Model KZ-32TS1U // KZ-41TS1U TV Diagnostic Guide Sony KF- 60DX100 Introduction This portion of the training manual has been organized to enable you to quickly diagnose problems in the Grand Wega 60" Projection TV model KF-60DX100. This Hi-Scan, 16x9 aspect ratio, LCD TV has a high brightness, long life backlight that is user replaceable.

  • Page 40: Normal Operation

    Sony Model KZ-32TS1U // KZ-41TS1U TV Diagnostic Guide Chapter 15 - Normal Operation Satellite reception shows picture squares – The compression of satellite conveyed (“Dish”) video signals results in pictures that show small squares larger than the detail the TV is capable of producing. This problem is compounded by the DRC circuit, which cannot enhance the picture detail by analyzing the picture’s larger squares...

  • Page 41: Self-Diagnostics

    Sony Model KZ-32TS1U // KZ-41TS1U TV Diagnostic Guide Chapter 16 - Self-Diagnostics The front panel Lamp LED flashes continuously when the lamp reaches end of life and fails to ignite. The front panel Standby LED blinks to indicate a more serious fault. If the TV starts and shuts down, the LED will repeatedly blink a number of times to indicate the reason for shutdown.

  • Page 42: Board Selection By Defect

    Sony Model KZ-32TS1U // KZ-41TS1U TV Diagnostic Guide Chapter 17 - Board Selection by Defect This table shows the boards that could cause the symptoms listed. The most likely board is designated #1, the second likely #2, etc. Table 17-1 Symptoms and Related Circuit Board...

  • Page 43: Board Locations

    Sony Model KZ-32TS1U // KZ-41TS1U TV Diagnostic Guide Chapter 18 - Board Locations FIGURE 18-1 - BOARD LOCATIONS Optical M Board BC Board Unit Power Block Bottom (Lamp Power BB Board A Board Supply) U Board G Board (Power Supply)

  • Page 44: Adjustments

    19. Adjustments Chapter 19 - Adjustments White Balance / Brightness The service manual shows a series of white balance and brightness level adjustments for the TV, Twin, Video inputs and component inputs. They can be touched up when changing the BB and BC boards and must be adjusted when replacing the M board.
  • Page 45 19. Adjustments Table 19-1 - Adjustments after Board Replacement Board Adjustment Service Manual page Replaced Light Box 1. Screen Center Adjustment to center the picture. Section 3-5, page 43 (Optical 2. Vertical Stripe Adjustments – There are alternate even and Unit) odd rows of dots across the screen (L-R).

  • Page 46: Service Mode

    5. Adjustments Chapter 20 - Service Mode Access: Conventional – From the remote press Display, 5, Vol +, Power ON. Category selection = buttons 2 (up) and 5 (down). Item selection = buttons 1 & 4. Data change = 3 & 6. Store data = Mute, Enter. New: The details of New Category “Option E”...

  • Page 47: Determining If The Optical Unit Is Ok

    5. Adjustments Chapter 21 - Determining if the Optical Unit is OK The optical unit can fail, producing: • TV Shut down by loading down the power supply. • White or black screen. • Missing a color. If the TV shuts down (probably without a Standby LED fault indication), the optical unit can be unplugged and the TV powered up to see if the TV remains ON.

  • Page 48: Optical Unit Removal

    22. Optical Unit Removal Chapter 22 - Optical Unit Removal The optical unit contains the video output portion of the TV in one assembly with three colored LCD panels and the C board. The optical unit is held in with just two screws, but the TV board assembly and the power block board must be pulled out to access these screws.
  • Page 49 22. Optical Unit Removal FIGURE 22-2 - TV BOARD ASSEMBLY SLIDES OUTWARDS c) Remove the two screws holding the lamp socket (Figure 22-3). The power block HV wires are not long enough to permit the power block to swing out of the way. Power Block Assembly Power Block...
  • Page 50 22. Optical Unit Removal FIGURE 22-4 - POWER BLOCK UP AND OUT e) Loosen the two screws under the optical unit (Figure 22-5). The screws are part of the optical unit. Optical Unit Assembly Screen Power Assembly Block Board FIGURE 22-5 - OPTICAL UNIT SCREWS EXPOSED f) Slide out the optical unit.
  • Page 51 22. Optical Unit Removal Optical Unit TV Board Lamp Assembly Assembly Lens Power Block Assembly FIGURE 22-6 - OPTICAL UNIT ASSEMBLY g) Dust the optical unit lens with a soft cloth before installing. Specks of dirt are magnified, so clean it carefully.

  • Page 52: Screen / Mirror Replacement

    23. Screen / Mirror Replacement Chapter 23 - Screen / Mirror Replacement The entire top of the projection TV is replaced as an assembly containing the screen, mirror and speakers. Procedure a. Remove the back (lower) panel. b. From the back, remove the center support bracket. 4 Top Assembly Screws Center Support Bracket...
  • Page 53 23. Screen / Mirror Replacement Remove Screws Tilt Out 1/2" Pull off L & R Panels Loosen FIGURE 23-2 - PULL OFF THE FRONT SIDE PANELS & LOOSEN CONTROL PANEL f. From the front, remove the remaining four screws (Figure 23-3). 4 Screws FIGURE 23-3 - REMOVE THE TOP FOUR SCREWS g.
  • Page 54 23. Screen / Mirror Replacement Lens FIGURE 23-4 - BOTTOM TV BASE...

  • Page 55: Troubleshooting - Tv Shutdown

    9. Screen / Mirror Replacement Chapter 24 - Troubleshooting - TV Shutdown The TV can be disabled because of: open bimetal fuse, fan not working, lamp not working, short on the 5Vdc line and an imbalance in either audio output stage. START POWER Replace M...

  • Page 56: Power Supply

    25. Power Supply Chapter 25 - Power Supply The Standby power supply circuit and power ON sequence is simple and easy to figure out by looking at the simplified Figure 11-1. The only outstanding servicing precaution you must make note of is the over voltage zener diode on the A board at CN1901/pin 3 in Figure 25-1.
  • Page 57 25. Power Supply Power ON sequence After the Main Micro IC9004 (M board) receives standby power (CN1921/pin 16), IC9004 can respond to the power ON command from either the remote (IR) or the switch on the front panel H3 board. The TV power ON steps are: 1.

  • Page 58: Fan Control - Kf-60Dx100

    Chapter 26 - Fan Control - KF-60DX100 This Sony Grand Wega LCD Projection TV has two fans that start when the TV is turned ON and stop five seconds after the TV is turned OFF. Fan 2 is located at the rear and is visible as soon as the rear panel is removed.
  • Page 59 26. Fan Control - KF-60DX100 CN1614 POWER SUPPLY 1601 CN1604/ PWR SUPPLY BD. CN1926 CN1613/ CN1605/ CN1914 CN1914 CN9001/ CN1921 IC1905 A BD. STBY HALL FAN 1 DEVICES PWR 5V FAN 1 IC1908 DATA FAN 1 IC9004 IC9502 CONTROL 1.2V MAIN FAN/ MICRO...
  • Page 60 26. Fan Control - KF-60DX100 Troubleshooting If the backlight does not start and the TV shuts down with the Standby LED blinking four times, one or both of the two fans has stopped. The suspected boards are: A board (fan regulators), G board (power supply) and M board (fan control).

  • Page 61: Grand Wega Lamp Control

    27. Grand Wega Lamp Control Chapter 27 - Grand Wega Lamp Control DANGER: There is High Voltage at very High Current, dangerous enough to cause Death On Contact. Keep away from the Power Block and lamp socket when the TV is turned ON (see Figure 27-3). Follow the repair procedure closely and be aware that the HV periodically turns ON automatically.
  • Page 62 27. Grand Wega Lamp Control SPARK GAP POWER BLOCK BD. R1613 270V 25kV TO GAS F1601 R1654 DISCHARGE 6.3A LAMP 255V- WIRE CN1602 LAMP COVER 350V COLOR R1655 T BD. BOARD WHI GRY POWER SUPPLY S8001 H3 BD. CTL= G BD. ON=5V OFF=0V CN1908...
  • Page 63 27. Grand Wega Lamp Control Table 27-1 - How the Main Micro Determines if the Lamp or Circuitry is Bad Condition PRT (Protect) Visual Arcing at G1/ RF at CN1908/pin 12 CN1908/pin 3 Normal Low (0Vdc) None Lamp LED blinks Continuously (HV OK. High (5Vdc) Yes at power ON and repeats every 5 Lamp bad)

  • Page 64: Lamp On Display

    27. Grand Wega Lamp Control 2. Lamp ON Time Display The time the lamp is ON in hours is stored in the service mode within the “Option-E” category. 1. Enter the service mode (remote = Display, 5, Vol +. Power ON). 2.

  • Page 65: Troubleshooting

    27. Grand Wega Lamp Control FIGURE 27-4 - COMPLETE POWER BLOCK ASSEMBLY 4. Troubleshooting Defect – Unreliable backlight starting As the gas discharge tube reaches the end of life, the most common symptom is unreliable starting at power ON, especially when the lamp is cold. Replace the lamp. Defect - No backlight repair procedure The lamp will not turn ON because of a defective: •...
  • Page 66 27. Grand Wega Lamp Control Defect – No backlight repair flow chart: The following flow chart will help you quickly ID the problem board, but you must be careful. High Voltage at a very High Current is present (not like a TV’s FBT where there is low current). Be aware that if the backlight does not start at power ON, the lamp HV circuitry is repeatedly instructed to try to turn ON for two seconds and again five seconds later until the TV shuts down.

  • Page 67: Video Process

    28. Grand Wega Video Process Chapter 28 - Video Process Video Signal Flow The video signal flow is shown in Figure 28-1. The video signal is input the U board, through the BC and BB boards to the final C board within the sealed optical unit optical assembly. The A board is an interconnect board that passes the video signal from one board to another and performs the initial TV tuner function.
  • Page 68 28. Grand Wega Video Process Table 28-1 - Video Circuit Board Inputs / Outputs Board Input(s) Board Function Output(s) • TV Tuner, S Video • NTSC Input switching • TV Output to rear panel, • Composite Video • Component video pass- •...
  • Page 69 28. Grand Wega Video Process Table 28-2 – Optical Unit Input Voltages and Signal Levels (color bar input) Input Voltage Level Input Signal Level (from G board) (from BB board) CN5002/pin 1 - 7Vdc CN5005/pin 1 2.5Vp-p (white) (Blue signal) CN5002/pin 3,4 5Vdc CN5005/pin 3...
  • Page 70 28. Grand Wega Video Process Video Problem Only with a single input or feature Table 28-3 lists a feature and/or input that has a picture distortion and the corresponding board that is most likely responsible for the problem. For example, if a video problem only appeared while watching a TV station but not in a video input, the most likely cause is shown by the #1 under the A board column (A board defect).
  • Page 71 28. Grand Wega Video Process Main/ Main/ Left = High Definition Two NTSC (480i) (480p, 720p, 1080i) & pictures displayed Right = NTSC (480i) FIGURE 28-3 - VARIOUS TWN PICTURE DISPLAYS WITH NTSC AND/OR HIGH DEFINITION (HD) SIGNALS. (HD INPUT FROM VIDEO 5 OR 6) Two 480i (NTSC) Pictures Input Refer to Figure 28-4, which indicates where the larger picture’s signal comes from.
  • Page 72 28. Grand Wega Video Process Conclusion / Troubleshooting What does all this mean? How can we use this video path switching to determine which board contains the video problem? Refer to the flowchart in Figure 28-5 to determine if the problem is in the A, U, BC, BC4, BB board or the optical unit optical assembly just by noting where the video problem moves as you increase the picture size in the Twin View Mode.
  • Page 73 Sony Electronics Sony Electronics Inc. EMCS - A Service Company 1 Sony Drive TVP130402 04/22/02 Park Ridge, New Jersey 07656 All Rights Reserved ©2002...

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