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Training Manual
KDP-57XBR2
Projection Television
Troubleshooting
RA-3/3A, RA-4/4A, RA-5A, RA-6 Chassis
Practical Troubleshooting Tips
Course: TVP-14

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Table of Contents

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   Summary of Contents for Sony KDP-57XBR2

  • Page 1 Training Manual KDP-57XBR2 Projection Television Troubleshooting RA-3/3A, RA-4/4A, RA-5A, RA-6 Chassis Practical Troubleshooting Tips Course: TVP-14...
  • Page 2: Table Of Contents

    Table of Contents 1. Introduction ........1 The RA-5A Chassis 15. Troubleshooting The RA-3/3A Chassis the RA-5A Chassis .......67 2. The RA-3/3A Chassis ......2 Overview..............67 3. Power Supply Troubleshooting ..3 16. Power Supply Troubleshooting ...68 The Main Power Supply ........6 Overview..............
  • Page 3 28. Auto Registration Troubleshooting ......... 113 Overview............... 113 Flash Focus Errors ..........115 Error Codes ............119 29. Model-to-Chassis Cross Reference ........ 120...
  • Page 4: Introduction

    Chapter 1 - Introduction In the fall of 1996, Sony Electronics introduced a troubleshooting course (TVP-06) that covered troubleshooting of the AP and RA-1 chassis, along with the prior EX and EXR model sets. The course provided some useful and practical approaches to repairing failures that might occur in each of the circuits, and allowed the technician to focus on troubleshooting more than theory of operation.
  • Page 5: The Ra-3/3a Chassis

    1. Features Chapter 2 - The RA-3/3A Chassis Overview The RA-3 chassis introduced a major redesign in the convergence circuits that made it much easier for the technician to converge the set with greater accuracy and speed. It is know as Flash Focus and allowed the customer to perform more thorough convergence realignment should it drift out of range.
  • Page 6: Power Supply Troubleshooting

    3. RA-3/3A Power Supply Troubleshooting Chapter 3 - RA-3/3A Power Supply Troubleshooting he Standby Power Supply The standby supply is a simple switched-mode type utilizing a single transistor, transformer and feedback circuitry to generate approximately 7VDC provided to a 5-volt regulator IC. Regulation will be provided by changing the oscillation frequency based on current demand.
  • Page 7 3. RA-3/3A Power Supply Troubleshooting T602 FB621 R607 4.7 OHMS D601 C617 D602 R620 FROM TO RY601 T601/1 POWER RELAY D623 AC Hi SIDE IC655 R609 5V REG 7.2VDC BAO5T D667 CN605 C614 R616 STANDBY C616 C650 +5V TO Q601 D607 A BOARD 2SK2845...
  • Page 8 3. RA-3/3A Power Supply Troubleshooting Once the FET has been changed along with R607, you will need to disconnect the secondary voltage line by lifting D667. This is very important since switch-mode supplies draw very small amounts of current while running unloaded and the load from the 5-volt line must be kept from drawing any current.
  • Page 9: The Main Power Supply

    The Main Power Supply The main power supply is still a somewhat conventional style that has been used in Sony televisions for many years. It is only active when the unit is powered up by energizing the main relay RY601. It has earned a dubious reputation amongst technicians due to its insatiable appetite for several sets of switching transistors before the technician finally got it repaired, and, rightfully so.
  • Page 10 3. RA-3/3A Power Supply Troubleshooting Once C620 has charged, the upper transistor will lose its large B-E current and turn off. The impedance of the primary in T604 will determine how fast C620 is charged and this will vary depending on the amount of current in the control winding at pin 7 and 8 of T604.
  • Page 11 3. RA-3/3A Power Supply Troubleshooting AUDIO AUDIO T605 AUDIO D665 +15V C659 C658 -15V IC653 D660 R656 D659 IC652 R652 R654 +135V C662 FROM IC001/62 A BOARD R655 CN1601 50V/DIV 5uS T/DIV CN652 D666 D658 C664 R677 T604 PRT PROT. D668 LATCH C622...
  • Page 12 3. RA-3/3A Power Supply Troubleshooting Troubleshooting Once a few standard procedures are followed, this power supply is not too difficult to repair. The greatest obstacle is the precise timing required for the two transistors inside of IC601 to work together. They form a classical AB-type amplifier design.
  • Page 13 3. RA-3/3A Power Supply Troubleshooting No AC Current Is Read: You have a supply that will not start. This is not common, but can occur. Bring the AC voltage up to 40 volts. It is recommended to not exceed this level just in case you accidentally cause the oscillator to start while probing around with the scope and meter.
  • Page 14 3. RA-3/3A Power Supply Troubleshooting B+ Regulator Troubleshooting B+ Voltage Too High: This symptom can be a little troublesome to work with because the unit will be going into shutdown protect and there is the possibility of damaging components (particularly the horizontal output transistor). Once again, the main relay is going to be jumped, but this method works quite well if the proper steps are carefully followed.
  • Page 15: Shutdown & Self-diagnostics

    4. RA-3/3A Shutdown and Self-Diagnostics Chapter 4 - RA-3/3A Shutdown and Self-Diagnostics Overview Another new feature introduced in the RA-3 Chassis is self-diagnostics capability. By utilizing the timer LED on the front panel, it can be flashed in sequences when a failure occurs to assist in troubleshooting. It works rather well in most situations, but can also mislead the technician.
  • Page 16 4. RA-3/3A Shutdown and Self-Diagnostics Protection Circuits Not Covered By Self-Diagnostics There are four protect circuits that are not monitored by diagnostics. Consequently, they will not be identified by the timer LED or stored into the diagnostics page. Referring to Figure 4-1, the standby 5V regulator IC655 is protected against over-voltage to its input and excessive current at the output.
  • Page 17: Deflection Circuits

    5. RA-3/3A Deflection Circuits Chapter 5 - RA-3/3A Deflection Circuits Overview Like the RA-2 chassis, the RA-3 utilizes a simple deflection circuit design much like those found in many of the direct-view models. Figures 5-1A and 5-1B illustrate the simplicity of this design. High voltage and horizontal sweep are accomplished with a single horizontal output transistor driving a flyback transformer and deflection yokes.
  • Page 18 5. RA-3/3A Deflection Circuits CN506 FROM Q502 T504 FBT TO HY H OUT BLOCK COLLECTOR 200V 135V HEATERS CN505 +12V FOCUS R584 PACK D522 CN502 R548 R545 -12V C536 R598 CN504 D532 R594 R586 D528 C541 IC502 R536 R538 TO A C550 R544 C547...
  • Page 19 5. RA-3/3A Deflection Circuits Once the new transistor has been installed, it is always a good idea to re-solder the connections on the horizontal drive transformer. These transformers handle a lot of current to forward bias the B-E junction of the output transistor.
  • Page 20 5. RA-3/3A Deflection Circuits to the horizontal deflection yoke return. One more waveform is required, however. Vertical rate parabolic correction cannot be injected directly into the horizontal circuit, which is tuned for 15.75KHZ. The parabolic correction must be gated to provide horizontal-rate pulses that can be accepted by the horizontal deflection circuit.
  • Page 21 It is almost a given that F651 and/or F652 on the G board will also open. . The first check that you should perform (and this applies to all Sony televisions of the last seven years) is to check the voltage level of the clock and data lines on the I C bus.
  • Page 22 5. RA-3/3A Deflection Circuits Check for V drive out of pins 34 and 35 of the Y/C Jungle IC206. Since this unit shuts down during a vertical failure, you will have to override by shorting the main relay. Unplug all three CRT sockets when doing this. It is obvious why this unit shuts down during a vertical failure.
  • Page 23: Video Process Troubleshooting

    6. RA-3/3A Video Process Troubleshooting: T & S Models Chapter 6 - RA-3/3A Video Process Troubleshooting: T & S Models Overview One of the more significant video features introduced in the RA-3 chassis was addition of component video input. This was added to all models from the T series all the way up to the V line. Since DVD and satellite boxes were offering this video format, it was a welcomed addition, which took advantage of its better picture quality capabilities.
  • Page 24 6. RA-3/3A Video Process Troubleshooting: T & S Models overall view of the video path. More detailed block diagrams will appear towards the end of this section. They can also be found in the TVP-10 training manual. The goal at this point is to isolate the area in which the problem exists and since there is a main and sub video path along with OSD, these features can be used to help locate where it is occurring.
  • Page 25 6. RA-3/3A Video Process Troubleshooting: T & S Models With AKB and high voltage ruled out, the following tests can be performed: The OSD feature is the first tool. Press the menu button on the remote. If you do not have a remote, press channel up or down.
  • Page 26 IC206 is the cause. Many A boards have been be ordered and installed and the problem would still exist. It is important to remember that on all Sony televisions, the OSD will not function until the unit has completed all initialization routines and this includes the AKB circuit.
  • Page 27 6. RA-3/3A Video Process Troubleshooting: T & S Models IC1905 PIP PROCESSOR SDA9288 Q1916 TO IC1901/6 Q1914 Q1917 Q1918 YOUT YUV SW. BUFFER Y IN Y AMP BUFFER BUFFER U IN UOUT RY IN Q1905 TO IC1901/1 VOUT V IN BUFFER RY OUT X IN...
  • Page 28 6. RA-3/3A Video Process Troubleshooting: T & S Models V Model Video Troubleshooting These models have several additional features not found on the lower-end sets. A 3D comb filter provides higher quality cross-talk separation along with noise reduction circuitry for the Y component. This is why the S video inputs are routed through the comb filter.
  • Page 29 6. RA-3/3A Video Process Troubleshooting: T & S Models view video where it is inserted into the Y/C Jungle into a separate port. By engaging this function, you can get a good idea of where the video loss is occurring. When the twin boxes appear, the main video source will be displayed in the right box and the sub video in the left.
  • Page 30 6. RA-3/3A Video Process Troubleshooting: T & S Models IC202 4MB EDO MSM514265C D BOARD DYC0 2 31 Q210 Q210 BUFFER 5 34 IC203 DYC0 BUFFER I016 CONVERTER 7 36 FL203, uPC659 Q215, 10 39 ALTE MRAS B.P.F. Q206,212 Q201, 204 LCAS IC204 BUFFER...
  • Page 31 6. RA-3/3A Video Process Troubleshooting: T & S Models MAIN C FROM IC1702/58 Q1418 DY FROM IC1405/86 EY IN YOUT BUFFER CN204 Q1420 Q220 ERY IN DU FROM IC1405/90 PB-Y RYOUT ROUT BUFFER BUFFER Q219 GOUT BUFFER TO CG Q1419 EBY IN DV FROM IC1405/88 PR-Y...
  • Page 32: Troubleshooting The Ra-4 Chassis

    Chapter 7 - Troubleshooting the RA-4 Chassis Overview The RA-4 chassis represented a great leap forward for Sony in the rear projection television market. One of its most outstanding introductory features was the ability to perform line doubling of the standard 480i NTSC scan rate.
  • Page 33: Power Supply Troubleshooting

    8. RA-4/4A Power Supply Troubleshooting Chapter 8 - RA-4/4A Power Supply Troubleshooting Overview The RA-4 chassis introduced a new, simpler, standby power supply. Major design changes occurred in the main power supply. An oscillator circuit was now being employed that was independent of the output stages. This oscillator provided the necessary drive signal to two, independent, driver circuits that shared the distribution of power requirements for the set.
  • Page 34 8. RA-4/4A Power Supply Troubleshooting L6002 L6001 C6001 R6002 VD6001 TO STANDBY C6002 SUPPLY D6001 F6001 CN6004 SPARK FROM C6004 R6001 RY6001 TO SOFT POWER START RELAY PROTECTION SPARK Q6002 GAPS TO IC6003/2 Q6004 C6007 C6012 R6017 E AMP- SWITCHING D6002 R6031 L6003...
  • Page 35 8. RA-4/4A Power Supply Troubleshooting VCC Switching This circuit is responsible for supplying power to the main relay along with the main oscillator and power switching circuits. It is quite different from conventional designs used in previous models. In Figure 8-3, it is shown that rather than using the relay high command from the CPU to directly control a relay drive transistor, an optical- isolator, IC6011, is turned on by Q6104.
  • Page 36 8. RA-4/4A Power Supply Troubleshooting Regulation is provided by varying the operating frequency based on the error amp input at IC6003/pin 1. Initial soft start is provided by keeping Q6006 on for about three seconds at turn on due to C6016 charging. This will pull down the regulation error loop and cause the IC to run at high frequency while the secondary voltages are charging their filter capacitors.
  • Page 37: Unit Will Not Power Up

    8. RA-4/4A Power Supply Troubleshooting F6002 FROM SWITCHING B+ SWITCHING B+ Q6008 FROM VCC SOURCE FB6002 R6025 D6015/K T6002 PIT FROM IC6003/9 C6026 C6019 D6019 D6022 R6027 MTZJ MTZJ E1 OSCILLATOR C6020 -20C -20C FROM IC6003/10 C6025 C6022 FB6001 R6024 D6016 E2 OSCILLATOR C6018...
  • Page 38: Shorted Switching Transistors

    8. RA-4/4A Power Supply Troubleshooting Two rapid relay clicks followed by a third click one to three seconds later: If this condition occurs, the unit is going into protect mode. The timer LED may assist you on this problem as this unit utilizes self-diagnostics although not all protect lines are monitored.
  • Page 39 8. RA-4/4A Power Supply Troubleshooting is the most common result obtained. IC1601 and its connection to the 135V line are the next check. The most common cause of excessive B+ is an open or increase in value of the resistor connecting the 135V to IC1601 (R6115 in this chassis).
  • Page 40: Protect Circuit Troubleshooting

    9. RA-4/4A Protect Circuit Troubleshooting Chapter 9 - RA-4/4A Protect Circuit Troubleshooting Overview The protect circuits in the RA-4 chassis contain several additional sections of monitoring than the RA-3. The high voltage and horizontal deflection circuits are separate, so monitoring deflection loss is necessary. Several more low voltage lines are also monitored.
  • Page 41 9. RA-4/4A Protect Circuit Troubleshooting Audio: DC voltage has been detected on one or both of the audio out lines. The set is shut down to protect the speakers. This is usually caused by shorted audio amp IC406. WDT: A communications error has occurred. The main CPU is unable to communicate with the Y/C jungle IC. The timer LED blinks continuously at one-second intervals and as soon as 101 of them occur, a failure is registered.
  • Page 42 9. RA-4/4A Protect Circuit Troubleshooting The other lines monitored are not detected by IC1009 and, therefore, will not be indicated by the self-diagnostics. Figure 9-2 provides a detailed view of these. This includes over-current (or loss of) the +19, +22 and +7 volt lines.
  • Page 43: Overview

    10. RA-4/4A Deflection Circuit Troubleshooting Chapter 10 - RA-4/4A Deflection Circuit Troubleshooting Overview With the introduction of scan line doubling, the RA-4 chassis introduced new circuit designs. The horizontal scan rate operates at 31.5KHZ instead of the conventional 15.75KHZ. The YC/Jungle IC is replaced by a separate video process (IC511) and a horizontal jungle (IC507).
  • Page 44: Troubleshooting

    10. RA-4/4A Deflection Circuit Troubleshooting Figure 10-2 illustrates the output section of the horizontal deflection stage. Since no flyback transformer is utilized, pulses will be generated by the collapse of the field in the horizontal deflection yokes and T5002. This transformer will provide a boosted voltage for the dynamic focus correction circuit via R5055 and D5015.
  • Page 45 10. RA-4/4A Deflection Circuit Troubleshooting Once the new transistor has been installed, it is always a good idea to re-solder the connections on the horizontal drive transformer. These transformers handle a lot of current to forward bias the B-E junction of the output transistor.
  • Page 46 10. RA-4/4A Deflection Circuit Troubleshooting R5064 +12V (D) R5015 Q5013/E Q5003 FROM CN5004 R5025 R5060 C5022 H OUT R5045 Q5007 IC512/11 VDSP R5006 R5036 R5041 PIN E/W C5018 R5010 R5024 Q5017 Q5012 R5066 D5018 R5037 D5012* Q5011 R5065 R5014 R5056 R5044 Q5020 Q5018...
  • Page 47: Vertical Deflection

    10. RA-4/4A Deflection Circuit Troubleshooting R5023 R5058 R5013 Q5009 CN506 H D5006 R5020 D5002 PROTECT C5011 TO IC1009/PIN 3 Q5015 A BOARD R5004 R5063 C5002 C5020 D5014 Q5019 C5026 D5008 R5018 FROM R5072 C5041 Q5006 R5042 R5069 R5033 AC VOLTAGE R5030 Q5014 R5068...
  • Page 48 10. RA-4/4A Deflection Circuit Troubleshooting IC512 VDSP A BOARD CXD2018A FROM R713 H IN FROM IC1008 1/2 H MAIN CPU IC508/5 R709 R779 C675 R757 V DRIVE XSOP R756 IC514 C678 C644 C651 FROM R692 R534 R700 TO IC507/2 BOARD H JUNGLE CN5004 IC516/3...
  • Page 49: Vertical Deflection Troubleshooting

    IC has not cured the problem? The first check that you should perform (and this applies to all Sony televisions of the last seven years) is to check the voltage level of the clock and data lines on the I C bus.
  • Page 50: High Voltage Circuit Troubleshooting

    11. RA-4/4A High Voltage Circuit Troubleshooting Chapter 11 - RA-4/4A High Voltage Circuit Troubleshooting Overview The RA-4 chassis reintroduced the separate high voltage circuit that had been eliminated in the RA-2 and RA-3 chassis. This design offers better control of the high voltage level, resulting in more stable brightness and picture size fluctuations.
  • Page 51 11. RA-4/4A High Voltage Circuit Troubleshooting 210V HEATERS D BOARD BLOCK +135V T8003 R8183 D8013 T8002 T8001 Q8007 C8020 D8011 C8023 FOCUS BLOCK FROM PS8001 R8039 R8019 D8007 DRIVE R8038 C8018 C8014 D8010 R8199 D8014 R8200 STOP1) L8004 C8025 C8021 NL8001 C8012 D8003...
  • Page 52 11. RA-4/4A High Voltage Circuit Troubleshooting If a clean pulse appears with AC current staying well below 1.5 amps, re-connect Q8008 and Q8002 (or the short if you disabled it this way). Apply power once again and continue monitoring the flyback pulse. Do not worry about excessive high voltage problems.
  • Page 53 11. RA-4/4A High Voltage Circuit Troubleshooting TO HV R8119 R8128 R8139 PROTECT 2 IC8008/3 R8136 C8082 IC8007 1/4 C8070 7.2V C8076 R8174 TO IC8002/5 R8126 BLOCK HV REGULATION CN8006 6.9V C8068 D8041 Q8024 IC8007 1/4 RD13M R8127 C8052 +12V Q8025 R8093 D BOARD R8138...
  • Page 54 11. RA-4/4A High Voltage Circuit Troubleshooting +12V R8084 +12V C8029 R8027 D8015 R8067 R8015 Q8022 R8114 R8060 R8031 R8085 R8027 C8019 C8066 R8095 R8071 IC8008 R8083 DRIVE R8021 R8028 Q8010 R8010 Q8009 Q8018 C8045 R8044 IC8002 R8113 R8059 C8033 R8082 -12V D BOARD C8064...
  • Page 55 11. RA-4/4A High Voltage Circuit Troubleshooting D8021 +12V +12V HV STOP 2 C8071 R8116 D8027 R8176 5.9V D8025 IC8010 FROM Q8027 R8091 TO HD Q8019 HV STOP 2 BUFFER D8036 R8111 Q8005/B R8170 C8062 9.3V C8092 R8087 C8053 C8065 R8106 D8030 R8115 IC8008...
  • Page 56 11. RA-4/4A High Voltage Circuit Troubleshooting Q8027/B HV STOP 1 +135V +12V R8175 R8165 D8026 +12V C8096 D8040 R8164 FROM R8103 Q8021 TO HD T8003/11 R8163 R8094 C8075 BUFFER Q8028 C8075 Q8005/B R8162 R8161 R8122 R8092 C8054 CN8003 JUMPER R8171 R8160 C8086 PLUG...
  • Page 57: Video Circuit Troubleshooting

    Chapter 12 - RA-4 Video Circuit Troubleshooting Overview As mentioned earlier in this manual, the RA-4 chassis introduced Sony’s first rear projection television with line doubling capability. New circuitry was designed to perform this task. The DRC , or digital reality creator, was added to assist in doubling the horizontal scan lines by interpolating the video information for each of the 480 interlaced lines of the incoming NTSC signal.
  • Page 58 12. RA-4 Video Circuit Troubleshooting MAIN Y/COMP. IC1305 IC306 TU501 MAIN IC1307 BOARD MAIN CHROMA YUV SW. COMB MAIN TUNER DECODER CCD MIX FILTER MAIN Y TU501 COMPOSITE IC511 VIDEO BOARD IC1008 IC515 TUNER PROCESSOR MAIN A/V SWITCH CM501 GLASS COMB COMPOSITE IC1302...
  • Page 59 12. RA-4 Video Circuit Troubleshooting Video Appears In Both Boxes: The main and sub video process paths are working correctly. The MID is sending the video directly into IC511. The problem is likely located on the BR board. The DRC circuit on this board is constantly running and not controlled by the I²C bus.
  • Page 60 12. RA-4 Video Circuit Troubleshooting TO Q1354/B LUMINANCE BUFFER DYC00 A BOARD TO Q1358/B CHROMA DYCO1 BUFFER Q1349 IC1306 R1414 3D COMB FILTER FROM uPD64081BGF-3BA IC1305/30 LUMINANCE/ COMPOSITE FSCI Q1348 R1434 C1496 FROM Y BUFFER DYC09 C1493 Q1448 DYC02 R1544 IC1309 C1490 8 BIT ADC...
  • Page 61 12. RA-4 Video Circuit Troubleshooting Q1366 IC1307 MAIN YUV SW. C1483 CV-Y CCD MIX R1543 CLPP CXA2119M SELY R1546 FROM COMB FILTER AYO C1376 IC1306/84 Q1367 R1393 Q1328 N FROM COMB FILTER ACO R1401 Q1331 IC1306/83 R1400 C1385 R1405 C1381 R1402 C1332 Q1332...
  • Page 62 12. RA-4 Video Circuit Troubleshooting FROM Q1343 TO Q1324 FSC DETECT. CCD BUFFER FROM Q1366/E COMPOSITE Q1328 VIDEO Y C1482 TO IC1305/34 MAIN CHROMA DVD Y CV Y SEL Y R1538 C1457 FROM IC1305/18 Y1 IN IC1307 C1456 MAIN YUV SWITCH CB1 IN FROM IC1305/19 CXA2119M...
  • Page 63 12. RA-4 Video Circuit Troubleshooting FROM CN516 A BOARD 8 BIT Y CN302 8 BIT CN301 RC-Y M-B-Y M-R-Y IC306 IC305 RC-B-Y 8 BIT C 3 CH 8 BIT CN302 8 BIT IC562 RC-VD A BD. CN511 CONV. IC304 RC-HD CDX2070Q IC644 IC645...
  • Page 64 12. RA-4 Video Circuit Troubleshooting CN001 CN002 IC014 S-B-Y IC003 M-B-Y SBADC MAIN ADC S-R-Y M-R-Y M VD IC002 M HD B CH S-HD S-VD IC008 IC010 C CH CONTROLLER IC013 MEMORY IC001 MEMORY MID-V MID 12C MID-H MID Y-S MID R-Y MID B-Y IC009...
  • Page 65 12. RA-4 Video Circuit Troubleshooting FROM IC1008/61 0 SYNC SEL CN002 CN513 CN503 Q524, Q540 EY IN R OUT BUFFER Q516, Q539 ECB IN G OUT BUFFER ECR IN TO CN701 Q510, Q538 B OUT CR BOARD Q546 BUFFER TCACR SW Q530 Q501 IK IN...
  • Page 66: Troubleshooting The Ra-4a Chassis

    1. Features Chapter 13 - Troubleshooting the RA-4A Chassis Overview The RA-4A chassis shares many of the circuit designs with its predecessor, the RA-4. It is still reserved for use in the high-end XBR series, which includes the KP53XBR300 and the KP61XBR300. Its greatest feature was the introduction of a “high definition ready”...
  • Page 67: Video Circuit Troubleshooting

    14. RA-4A Video Circuit Troubleshooting Chapter 14 - RA-4A Video Circuit Troubleshooting As illustrated in Figure 14-1, many of the same processes are performed to the incoming video signals. All composite and S video sources are routed through the 3D comb filter and chroma decoder for the main video signal.
  • Page 68 14. RA-4A Video Circuit Troubleshooting H + V SYNC IC511 TO DEFLECTION VIDEO PROCESSOR SYNC CIRCUITS TO TUBES INPUT 12 H SYNC O720P TO IC515 FROM FOR AUDIO OSD CPU SWITCHING IC1009/61 IC1403 IC1307 IC1303 MAIN YUV MAIN YUV INPUT SELECT 480I ODTV...
  • Page 69 14. RA-4A Video Circuit Troubleshooting Gray Background Appears With Two Black Boxes: IC511 is OK. This signal is generated by the MID . The main and sub video paths are not working. Since a failure in both paths at the same time is unlikely, suspect A/V switch, IC515 or a crack in the board.
  • Page 70: The Ra-5a Chassis

    Chapter 15 - Troubleshooting the RA-5A Chassis Overview The RA-5A chassis is Sony’s first high definition, 16:9 aspect ratio, rear projection television to incorporate a DTV tuner and decoder as an integrated part of the chassis. This tuner/decoder assembly is known as the “Q Box”. It contains a HDTV tuner, MPEG2 and Digital Dolby®...
  • Page 71: Power Supply Troubleshooting

    16. RA-5A Power Supply Troubleshooting Chapter 16 - RA-5A Power Supply Troubleshooting Overview The standby power supply has been changed from a switch-mode to a conventional, analog type. Although simple to troubleshoot, it will be covered since it contains an OVP monitoring circuit that can cause the unit to shut down.
  • Page 72 16. RA-5A Power Supply Troubleshooting Activating the oscillator is accomplished by closing the main power relay RY6001 when the set is turned on. This will provide approximately 340VDC to Q6008, a startup voltage to pin 18 of IC6002 along with a sample of the unregulated B+ to pin1.
  • Page 73: Troubleshooting The Primary Power Supply

    16. RA-5A Power Supply Troubleshooting Troubleshooting the Primary Supply Since this supply is the starting point for the operation of all necessary power supply operating voltages, it can generate erroneous symptoms that could lead a technician in the wrong direction. The secondary supply is dependent on the primary supply running.
  • Page 74 16. RA-5A Power Supply Troubleshooting business. This supply has ± supply rails, so do not forget to read across them for low resistance readings. A quick visual check for overheated components is also a good idea. Check for open fuse links on the secondary lines, as these are valuable clues.
  • Page 75 16. RA-5A Power Supply Troubleshooting T6002 AUDIO D6530 D BOARD R6041 PIT-AU GROUND 0.1 OHM -19V IC6001 DRIVER R6015 D6116 MCZ3001D Q6507 +19V PRIMARY C6028 POWER R6014 SUPPLY R6013 C6022 PS101 -15V R6033 C6033 D6105 Q6003 +15V PS102 R6021 -22V FROM Q6001 C6034...
  • Page 76: Overview

    17. RA-5A Protect Circuit Troubleshooting Chapter 17 - RA-5A Protect Circuit Troubleshooting Overview As illustrated in Figure 17-1, several circuits are monitored for protection. Some lines are monitored by the self- diagnostics feature while others are not. The self-diagnostics feature can assist in isolating a particular circuit. Below is an example of the diagnostics page which is entered by pressing “DISPLAY”, “5”, “VOL –”, and “POWER”: Self Check +B OCP...
  • Page 77 17. RA-5A Protect Circuit Troubleshooting The above protection circuits have dedicated communications line with IC001. The 135V OCP/OVP, Low B and H Stop have direct connections. V Stop and AKB notify IC001 by way of the video process IC3006, which announces the event via the data bus line.
  • Page 78: Troubleshooting

    17. RA-5A Protect Circuit Troubleshooting STANDBY 5V T6003 SOURCE R6111 100 STANDBY R6064 2.2k D6017 Q6010 D2016 AC IN R6065 PH6004 R6060 PROTECT C6065 2.2k R6067 R6112 FROM 19V OCP +15V D BOARD (SEC P.S.) (SEC P.S.) +19V R6133 D6015 D6122 AUDIO Q6101...
  • Page 79: Shutdown - No Diagnostics Indication

    17. RA-5A Protect Circuit Troubleshooting Shutdown – No Diagnostics Indication Since RY6001 and RY6002 are engaging, there are the five monitoring circuits mentioned earlier that will cause the unit go into protect as shown in Figure 17-2. Monitoring AC current draw while letting the unit go into protect will assist in determining whether the failure is current, or voltage related and steer you to the circuits to check first.
  • Page 80: Deflection Circuit Troubleshooting

    18. RA-5A Deflection Circuit Troubleshooting Chapter 18 - RA-5A Deflection Circuit Troubleshooting Overview The deflection circuits in the RA-5A chassis are similar to the RA-4/4A chassis in that horizontal sweep and HV are generated in separate circuits. Pincushion correction is performed in a different manner and HV protection is not monitored as part of the self-diagnostics feature.
  • Page 81 It is a drive component with heavy current usage and heat dissipation, and it is usually the cause of the failure. The first check that you should do (and this applies to all Sony televisions of the last seven years) is to check the voltage level of the clock and data lines on the I C bus.
  • Page 82 18. RA-5A Deflection Circuit Troubleshooting Repeat Vertical Output IC Failure: If IC1509 fails immediately upon replacement or soon thereafter; it is usually the fault of C8015. This is the boost capacitor. It charges to almost 30VDC during the lower half of the vertical sweep to provide additional voltage to allow the beam to retrace to the top rapidly.
  • Page 83: High Voltage Circuit Troubleshooting

    19. RA-5A High Voltage Circuit Troubleshooting Chapter 19 - RA-5A High Voltage Circuit Troubleshooting Overview Figure 19-1 illustrates a block diagram to give an overall view of the circuitry on the D board for generating high voltage. The main components consist of a regulator stage to vary the B+ level to the flyback transformer for HV level control, a driver and output stage to switch the flyback on and off, a flyback transformer to generate HV and a LOT transformer to generate heater voltage and 200VDC for CRT cathode bias.
  • Page 84 19. RA-5A High Voltage Circuit Troubleshooting Troubleshooting High voltage circuit failures generally fall into four categories: No HV, low HV, excessive HV and excessive current. The latter two will cause the HV circuit to cease operating and, depending on which protect IC detected the problem, may shut the entire set down.
  • Page 85 19. RA-5A High Voltage Circuit Troubleshooting than 7.5V, the HV block is defective. If it is significantly lower, check the PWM signal at pin 3. If the positive duty cycle exceeds the negative, IC8008 is sensing the low HV and trying to compensate. Check for clean pulses at Q8038-C.
  • Page 86 19. RA-5A High Voltage Circuit Troubleshooting +15V H PULSE Q8029 R8138 LATCH D8023 D8016 R8157 BLOCK Q8022 D8008 SAMPLE R8151 R8150 FROM IC8008 +15V +15V R8141 D8014 IC8007 MTZJ-5.18 R8142 Q8028 D8015 D8025 R8223 Q8021 D8043 T8005 SAMPLE R8153 D8038 R8102 R8099 R8128...
  • Page 87: Video Path Troubleshooting

    20. RA-5A Video Path Troubleshooting Chapter 20 - RA-5A Video Path Troubleshooting Overview The RA-5A chassis incorporates a DTV tuner and decoder circuits in a shielded board known as the “Q Box”. MPEG2 decoding of ATSC broadcast signals along with Digital Dolby® decoding circuitry allows for reception of all current formats.
  • Page 88 20. RA-5A Video Path Troubleshooting IC7205, IC7603 CRT B QM BD. C BD. DTV TUNER MAIN SIGNAL PATH AND PROCESS NTSC INPUT/ PIP CRT G IC8801 CRT R IC7806, IC8601 IC7807 IC8703, IC8902 MID PROCESS NTSC PROCESS MAIN MN-SB- CN8601/ PATH CN8801 CN005...
  • Page 89 20. RA-5A Video Path Troubleshooting Video Appears in Right Box Only: The sub-video path is working correctly. An interruption in the main video processing has occurred. The problem is likely to be on the B board since most of the processing occurs there. The Q Box routes the main and sub-video into the MID circuits for side-by-side display.
  • Page 90: The Ra-6 Chassis

    1. Features Chapter 21 - Troubleshooting the RA-6 Chassis Overview The RA-6 chassis is found in the KP51HW40 and KP57HW40 models. It provides an affordable “high definition ready” set with a 16:9 aspect ratio. It is also found in the KP43HT20, KP53/61HS20 and KP53/61HS30 as a “High Scan”...
  • Page 91: 22. Ra-6 Power Supply Troubleshooting

    22. RA-6 Power Supply Troubleshooting Chapter 22 - RA-6 Power Supply Troubleshooting General Description The power generation and distribution has been simplified by utilizing a traditional analog standby supply providing unregulated B+ for the main AC relay and regulated 5V for the main CPU, NVM and IR receiver (not shown). More detail on this circuit will be covered later in the shutdown troubleshooting section.
  • Page 92 22. RA-6 Power Supply Troubleshooting AC H RY6002 AC L R6050 R6002 D6007 RY6003 R6064 R6040 0.1 1/2W R6038 D6002 R5007 Q6006 R6037 IC5003 0.47 R6003 C6047 T6001 D6009 -5V REG PH6002 D6004 D6005 SENSE D5010 IC5004 D5006 D6003 +6V REG Q6005 R6008 +11V...
  • Page 93 22. RA-6 Power Supply Troubleshooting Dead Supply. Switching Transistors Shorted: A more cautious approach must be taken when this happens. There is slight possibility that excessive current or a higher possibility that line transients caused them to fail and the loss of a newly installed set is not only frustrating, but costly in parts and wasted time. Static resistance readings of the secondary lines to ground are the first order of business.
  • Page 94 22. RA-6 Power Supply Troubleshooting 3. If a problem exists that warrants protection, a third relay click will be heard. This is actually RY6002 and RY6003 releasing simultaneously and will occur from one to several seconds later. Refer to Chapter 23 for troubleshooting the protect circuits.
  • Page 95 23. RA-6 Protect Circuit Troubleshooting Chapter 23 - RA-6 Protect Circuit Troubleshooting General Description As illustrated in Figure 23-1, several circuits are monitored for protection. Some lines are monitored by the self- diagnostics feature while others are not. The self-diagnostics feature can assist in isolating a particular circuit. Below is an example of the diagnostics page which is entered by pressing “DISPLAY”, “5”, “VOL –”, and “POWER”: Self Check: +B OCP...
  • Page 96: Protect Circuit Troubleshooting

    23. RA-6 Protect Circuit Troubleshooting AUDIO: DC voltage has been detected on the speaker lines. This is usually caused by audio output IC708. The audio circuits are located on the A board. WDT: A communications error has occurred. The main CPU is unable to communicate with the Y/C jungle IC. The timer LED blinks continuously at one-second intervals and as soon as 101 of them occur, a failure is registered.
  • Page 97 23. RA-6 Protect Circuit Troubleshooting Shutdown – No Diagnostics Indication The first step necessary is to listen for the sequence of relay clicks when the unit is powered up. If two clicks are heard less than 500ms apart followed by a third click at least one second later, the protect circuit is activating. The initial rapid clicks indicate the main supply is powering up and the inrush relay RY6003 is activating.
  • Page 98 23. RA-6 Protect Circuit Troubleshooting AU+19V D5026 D5017 IC5006 STBY AU-19V TRANS. C5050 9.8V -15V D5022 Q5005 D5001 D5023 R5010 RY6002 C5051 +15V D5025 D5015 Q5001 R5043 R5016 Q5007 AU+19V R5021 R5020 D5024 D5031 D5033 Q5002 R5046 R5013 D5032 R5028 R5026 RELAY +22V...
  • Page 99: 24. Ra-6 Deflection Circuit Troubleshooting

    24. RA-6 Deflection Circuit Troubleshooting Chapter 24 - RA-6 Deflection Circuit Troubleshooting The deflection circuits in the RA-6 chassis are identical to the RA-5A chassis in that horizontal sweep and HV are generated in separate circuits. Horizontal Deflection Troubleshooting Referring to Figure 24-1, horizontal sweep is generated in the conventional way using an H drive signal from pin 40 of IC309 on the A board.
  • Page 100 It is a drive component with heavy current usage and heat dissipation, and it is usually the cause of the failure.. The first check that you should perform (and this applies to all Sony televisions of the last seven years) is to check the voltage level of the clock and data lines on the I C bus.
  • Page 101 24. RA-6 Deflection Circuit Troubleshooting Repeat Vertical Output IC Failure: If IC1509 fails immediately upon replacement or in a short amount of time, it is usually the fault of C8015. This is the boost capacitor. It charges to almost 30VDC during the lower half of the vertical sweep to provide additional voltage to allow the beam to retrace to the top rapidly.
  • Page 102: 25. Ra-6 High Voltage Circuit Troubleshooting

    25. RA-6 High Voltage Circuit Troubleshooting Chapter 25 - RA-6 High Voltage Circuit Troubleshooting General Description Figure 25-1 illustrates a block diagram in order to provide an overall view of the circuitry on the D board for generating high voltage. The main components consist of a regulator stage to vary the B+ level to the flyback transformer for HV level control, a driver and output stage to switch the flyback on and off, a flyback transformer to generate HV and a LOT transformer to generate heater voltage and 200VDC for CRT cathode bias.
  • Page 103 25. RA-6 High Voltage Circuit Troubleshooting Troubleshooting High voltage circuit failures generally fall into four categories: No HV, low HV, excessive HV and excessive current. The latter two will cause the HV circuit to cease operating and a high will be sent to IC704 on the A board to place the unit into protect-mode.
  • Page 104 25. RA-6 High Voltage Circuit Troubleshooting High Voltage Shutdown: Verification of an over-voltage or over-current condition must be checked first. Monitor the AC current draw at shutdown to determine which is causing the condition. Excessive Current: If the AC current exceeds 2A or more immediately at turn-on, begin by disconnecting the HV block from the circuit.
  • Page 105 25. RA-6 High Voltage Circuit Troubleshooting +15V H PULSE R8138 Q8029 LATCH D8023 D8016 R8157 BLOCK Q8022 D8008 SAMPLE R8151 R8150 FROM IC8008 +15V +15V R8141 D8014 IC8007 MTZJ-5.18 R8142 Q8028 D8015 D8025 R8223 Q8021 D8043 T8005 SAMPLE R8153 D8038 R8102 R8099 R8128...
  • Page 106: 26. Ra-6 Video Circuit Troubleshooting

    26. RA-6 Video Circuit Troubleshooting Chapter 26 - RA-6 Video Circuit Troubleshooting General Description The video process circuitry in the RA-6 chassis follows a similar processing path as the RA-5A chassis with the exception on an on-board DTV tuner and decoder. Two NTSC tuners are incorporated along with video inputs 1~4 to allow the connection of composite or S video sources.
  • Page 107 26. RA-6 Video Circuit Troubleshooting CV/Y MAIN TUNER IC303 COMB MAIN SUB TUNER U BOARD VIDEO 1 IC305 IC004 IC2007 VIDEO 2 SWITCH A BOARD SWITCH COMB VIDEO 3 SUB Y IC301 VIDEO 4 SUB C VIDEO 5 IC306 COMP. VIDEO 6 S W .
  • Page 108 26. RA-6 Video Circuit Troubleshooting Video failures fall into three main categories: 1. No video 2. Distorted video 3. Improper level Although the video signals are routed through many different paths depending on the type of signal being received, these different pathways can be used to an advantage when diagnosing video failures. The picture & picture feature provided by the MID circuitry provides a useful diagnostic tool.
  • Page 109 26. RA-6 Video Circuit Troubleshooting CV : 1V p-p MAIN MAIN MAIN Y/CV TUNER TO 3D COMB U BOARD CV IN RF CH 13 (480i) MAIN C 75% CB IC2007 CV : 1V p-p 2D COMB TUNER CV IN CXD2073 CV : 1.5V p-p CV IN CV IN...
  • Page 110 26. RA-6 Video Circuit Troubleshooting Y : 0.9V CXA2103-1 SCON,SCOL,SHUE (ADJUST RF,VIDEO,& DVD C : 0.5V IC303 YCT-MAIN A BOARD PD6482 CXA2103 3D-COMB MAIN 37,38,39 22,23,24 Y/CV C Y : 1.2V 88 96 : 1.1Vp-p Y : O.7V 1.1Vp-p (MAIN) 480i : 0.5Vp-p CV : 0.9Vp-p 0.5Vp-p...
  • Page 111 26. RA-6 Video Circuit Troubleshooting IC3303 D.R.C. INPUT SIGNAL 480i ONLY CXD29095Q C : 8 BIT YP 8 BIT Y : 8 BIT 174-181 164-171 122-154 3.2Vp-p 3.2Vp-p DIGITA DIGITA Y :1.0Vp-p 0.9Vp-p 0.9Vp-p 6-13 17-24 IC3304 FROM 8 BIT TLC5733A IC305 [MAIN]480P/1080i...
  • Page 112: Troubleshooting The Akb Circuits

    Chapter 27 - Troubleshooting the AKB Circuits Overview The AKB (Automatic Cathode Bias) circuit, often referred to as IK, has been incorporated into Sony televisions for many years. In the beginning it created problems for technicians because they were either unaware of it or did not understand how it worked.
  • Page 113 27. Troubleshooting the AKB Circuits D732 +200V R736 R739 C735 R732 R742 TO FOCUS BLOCK D733 D734 CN737 L731 SG731 R741 C732 CG BOARD Q733 Q722 D731 R736 FROM CN731 FOCUS C733 BLOCK R733 H G1 G1 Q731 C734 SG732 R735 CN734 R737...
  • Page 114 27. Troubleshooting the AKB Circuits If you could actually “see” the IK pulses, troubleshooting would be a snap. If the service mode is entered on a direct-view television, the VPOS can be adjusted to bring the picture centering down and the three IK pulses can be seen as faint lines.
  • Page 115 27. Troubleshooting the AKB Circuits CRT elements, improper G2 cutoff or intermittent components, or connections on the IK return line (rare). Verify G2 cutoff and adjust if necessary. If G2 was set too low, this may have been the problem. Measure the DC voltage on all three cathodes.
  • Page 116: Auto Registration Troubleshooting

    28. Auto Registration Troubleshooting Chapter 28 - Auto Registration Troubleshooting Overview The RA-4 projection television chassis was the first to introduce a new registration system for converging the red, green and blue colors of each CRT. The number of course adjustments were substantially reduced. SUB, MID, BOW and 4 -family wave adjustments were eliminated.
  • Page 117 28. Auto Registration Troubleshooting verified with a calibrated external source, the internal crosshatch can be centered by changing and saving the value of “TPHP” and “TPVP” at the beginning of the PJE group. When replacing an A board in most models, the NVM for the main CPU will be flashed with default data. This is general service data.
  • Page 118: Flash Focus Errors

    28. Auto Registration Troubleshooting Fortunately, the RA-5A and RA-6 chassis have included a new set of instructions known as “COPY” and “ALCOPY”. Convergence is adjusted in the FULL mode, saved and Flash Focus offset rewritten. ALCOPY is selected from the PJE menu and the data changed from 0 to 1. Pressing “Mute” – “Enter” copies the data from the FULL mode to all the others.
  • Page 119 28. Auto Registration Troubleshooting The configuration shown will adjust horizontal centering and skew based on the top and bottom sensors and horizontal size by using the left and right pair. Vertical centering, skew and vertical size will occur by the flags changing their position by 90°...
  • Page 120 28. Auto Registration Troubleshooting Flash Focus Errors The primary causes of errors appearing during a Flash Focus session are: 1. Insufficient brightness level of the flags striking the sensor(s). 2. One or more of the colors “out of range” of the sensors. 3.
  • Page 121: Error Codes

    28. Auto Registration Troubleshooting A single digit change in the data for each option will move the affected flag a considerable distance. These alignments should only be adjusted if the flags display unevenly after correct centering, size and skew have been confirmed with a calibrated source.
  • Page 122 28. Auto Registration Troubleshooting Below is a list of possible error codes and suggested remedies. Table 28-1 ERROR CODE DESCRIPTION REMEDY Check if flags are hitting sensor properly. Adjust Sensor 0 low output VUP if necessary. Could be a sensor problem. Check if flags are hitting sensor properly.
  • Page 123: Model-to-chassis Cross Reference

    28. Auto Registration Troubleshooting Chapter 29 - Model-to-Chassis Cross Reference MODEL CHASSIS MODEL CHASSIS MODEL CHASSIS MODEL CHASSIS KP43T70 RA-3 KP53XBR200 RA-4 KDP57XBR2 RA-5A KP43HT20 RA-6 KP46C70 RA-3 KP61XBR200 RA-4 KDP65XBR2 RA-5A KP51HW40 RA-6 KP48S70 RA-3 KP53XBR300 RA-4A KP53HS20 RA-6 KP48S72 RA-3 KP61XBR300 RA-4A...
  • Page 124 , Flash Focus, DRC and MID are trademarks of Sony ©2002 Sony Electronics Inc. EMCS - A Service Company 1 Sony Drive TVP140702 07/18/02 Park Ridge, New Jersey 07656 Reproduction in whole or part without written permission is prohibited. All rights reserved...

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