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Training Manual
KDL-55EX500
Models: AZ1K Chassis
KDL-55EX500
KDL-55EX501
KDL-60EX500
Triage and Troubleshooting Guide
Course: CTV-65

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Table of Contents

   Summary of Contents for Sony KDL-55EX500

  • Page 1 Training Manual KDL-55EX500 Models: AZ1K Chassis KDL-55EX500 KDL-55EX501 KDL-60EX500 Triage and Troubleshooting Guide Course: CTV-65...
  • Page 2: Table Of Contents

    Table of Contents Section 1 - AZ1K Chassis Models Overview ..... 3 Normal Operation .............. 12 Failure Symptoms .............. 12 AZ1K Chassis Models Covered ........5 No Power/Dead Set (No RED Standby LED) ....12 Model Introduction ............5 55” Power Supply System Block Diagram ..... 14 AV Input &...
  • Page 3 Table of Contents Flowchart ............... 35 Distorted Video (All Inputs) ..........25 WIDE Mode Button (Aspect Ratio) Troubleshooting Protection Mode 6X(55”) & 7X Troubleshooting Method ..............25 Flowchart ............... 36 Unique Main Video Board (A-Board) or Video Troubleshooting Flowchart ........37 LVDS Cable Effects .............
  • Page 4: Section 1 - Az1k Chassis Models Overview

    Section 1 - AZ1K Chassis Models Overview TCON/HFR Board D1-Board Balancer LVDS Cable Board G5E-Board A-Board Switch Unit HRK-Board Speaker Speaker 55" Model 55” OVERALL PCB LOCATION DIAGRAM FIGURE CTV-65...
  • Page 5 AZ1K Chassis Models Overview TV Rear View Inverter Inverter G8S-Board Switch Unit TCON A-Board Speaker Speaker HRK-Board 60” OVERALL PCB LOCATION DIAGRAM FIGURE 1-2 CTV-65...
  • Page 6: Az1k Chassis Models Covered

    (FIXED) technology which enhances sharpness and delivers smooth motion for fast-action sports and movies. Sony® HDTVs exceed Energy Star 3.0 requirements. In addition, they RF Input incorporate advanced power saving features such as Light Sensor® This is a 75 ohm connection for either terrestrial NTSC and ATSC (8VSB) technology that adjusts backlight intensity based on ambient room lighting or cable QAM64 and QAM256 signals.
  • Page 7: Component/composite Video & Audio Inputs

    AZ1K Chassis Models Overview Component/Composite Video & Audio Inputs HDMI/DVI Video Input and DVI Video Red, Blue, & Green Jacks - Component Video Inputs Both the HDMI and DVI formats contain digital video. In the case of the HDMI format the audio is also digital and is part of the video and audio Red &...
  • Page 8: Audio Outputs

    AZ1K Chassis Models Overview Audio Outputs Fixed Analog Audio Output This audio output can be used to listen to the TV audio through an external AV stereo system. The audio level at the output is set to a fixed level and cannot be turned off or adjusted.
  • Page 9: 55" Model Overall Pcb Block Diagram

    AZ1K Chassis Models Overview 55” Model Overall PCB Block Diagram Switch Unit A-Board  Power Key Keys  Function Keys HRK-Board  LEDs SIRCS  IR Sensor Optical Digital Audio Output  Ambient Light Level Sensor RF Input Analog Audio Output 1 Composite Input ...
  • Page 10: 60" Models Overall Pcb Block Diagram

    AZ1K Chassis Models Overview 60” Models Overall PCB Block Diagram Switch Unit A-Board Keys  Power Key  Function Keys HRK-Board Power/  LEDs SIRCS  IR Sensor Optical Digital Audio Output  Ambient Light Level Sensor RF Input Analog Audio Output ...
  • Page 11: Pcb And Component Descriptions

    AZ1K Chassis Models Overview PCB and Component Descriptions D1-Board (55") Reference Figures 1-3 The D1-Board develops the high-volatge that drives the CCFL backlight system. It takes the 400V from the Main Power supply PFC circuit on the G5E-Board and develops approximately 2KVrms to initially ignite the A-Board lamps and 1KVrms to drive the backlight Cold-Cathode-Fluorescent Lamps The circuits located on the A-Board perform all Video and Audio processing...
  • Page 12: Lcd Panel Assembly

    AZ1K Chassis Models Overview LCD Panel Assembly The LCD Panel Assembly includes the LCD Panel, TCON/HFR Board , and CCFL Backlight system. The LCD Panel contains the actual liquid crystals, color filters, and polarizers. The liquid crystals are manipulated by the applied voltage to pass a specific amount of light - from the backlight- depending on the level of voltage applied.
  • Page 13: Section 2 - Troubleshooting Procedures

    Section 2 - Troubleshooting Procedures Power Symptom Troubleshooting Failure Symptoms Reference Figures 2-1, 2-2, 2-3, and 2-4 Normal Operation No Power/Dead Set (No RED Standby LED) Reference Figure 2-1 and 2-2 In a dead set condition there will be No RED Standby LED illumination in 110VAC is applied directly to the G5E-Board or G8S-Board.
  • Page 14 AZ1K Chassis Models Overview the Main Power supply. A loss of the REG12V will cause a “Dead Set” condition on these models. Check for the 12V at CN6201/pin 9 on the G5E-Board or CN2/pin 9. If the 12V is missing replace the power supply board.
  • Page 15: 55" Power Supply System Block Diagram

    AZ1K Chassis Models Overview 55” Power Supply System Block Diagram D1-Board CN6704 LCD Panel Assembly 1.1KV (~2KV Strike Voltage) CCFL CN6705 Balancer Board Backlights Backlight Inverter High Voltage Circuits CN6702 CN6703 CN6600 PANEL A-Board G5E-Board CN6401 CN6301 400V CN6201 CN201 AU12V IC8151 IC6301...
  • Page 16: G5e-board Connector Diagram

    AZ1K Chassis Models Overview G5E-Board Connector Diagram 7 - LD 6 – 12V 5 - Ground 5 – 400V 4 – BL-ER 4 – NC 3 – BL-ON 3 – Ground 2 – Dimmer 2 – NC 1 – H-Symc 1 –...
  • Page 17: 60" Power Supply System Block Diagram

    AZ1K Chassis Models Overview 60” Power Supply System Block Diagram G8S-Board Backlight HV Inverter Board CCFL Z301 Backlights Backlight HV Inverter Power Board Supply LCD Panel Assembly A-Board PANEL CN201 AU12V IC8151 R106 Audio Output Amp Panel RC101 L201 RC102 RC201 LVDS RL101...
  • Page 18: G8s-board Connector Diagram

    AZ1K Chassis Models Overview G8S-Board Connector Diagram 1 – UNREG24V 2 – UNREG24V 3 – UNREG24V 4 – UNREG24V 5 – UNREG24V 6 – Ground 7 – Ground 8 – Ground 9 – Ground 10 – Ground 1 – REG12V 2 –...
  • Page 19: Protection Mode Symptom Troubleshooting

    *Low Voltage Protection (LVP) Reference Figures 2-5, 2.6, and 2-7 *Over Voltage Protection (OVP) The KDL-55EX500, KDL-55EX501, and KDL-60EX500 include the following protection mode blink patterns (or self-diagnostics). A loss or excessive condition of the AU12Vdc secondary voltage from the main power supply will cause a 2X blink pattern on the Standby-LED.
  • Page 20: Blink - Balancer Failure (55" Model Only)

    NOTE: All models will make three attempts to power up before a 6X 6X Blink - Backlight System Failure (55” Models) error is activated. The SONY logo (Backlight) will display on the screen The 55” models have both a 4X and 6X blink protection mode. The 4X and the tones (with Volume up) will be heard three times.
  • Page 21: 7x Blink - Temperature Failure

    AZ1K Chassis Models Overview 7X Blink - Temperature Failure In either case the A-Board must be replaced to fix the problem. These models do not display a temperature warning OSD dialogue box before shutting-off and going into a 7X Standby-LED blink pattern. It will just shut-off and activate a 7X without any usually warning on the screen.
  • Page 22: 55" Model Protection Mode System Block Diagram

    AZ1K Chassis Models Overview 55” Model Protection Mode System Block Diagram A-Board G5E-Board CN6201 CN6102 CN201 Input Main Interface DC_Detect RECT Circuit & RECT Dimmer IC400 MTK5388 BL_ON BL_ERR 3.3V Standby 3.3V STBY Power ON CN6401 Dimmer BL_ON BL_ERR BL_ERR 4X &...
  • Page 23: 60" Model Protection Mode System Block Diagram

    AZ1K Chassis Models Overview 60” Model Protection Mode System Block Diagram A-Board G8S-Board CN201 Input AU12V Interface DC_Detect RECT Fuse Circuit Dimmer 1V to 3V BL_ON IC400 BL_ERR MTK5388 Backlight_ERR IC4305 Temp Temp_ERR Sensor Protection Circuit LCD Panel Assb Q8153, Q8155 Audio_ERR Q8158, Q8160, Q8156...
  • Page 24: All Models Power Board Protection Circuits Block Diagram

    AZ1K Chassis Models Overview All Models Power Board Protection Circuits Block Diagram G5E-Board (55") 60" Model ONLY G8S-Board (60") CN6102 (55") CN1 (60") To Inverter Board Reg 24V To Inverter Board Reg 12V To A-Board Power Input Supply & PFC Circuits G5E-Board &...
  • Page 25: Video Symptom Troubleshooting

    AZ1K Chassis Models Overview Video Symptom Troubleshooting Video Anomaly: • Poor Detail Reference Figure 1-8 Moving Video Distortion (e.g. Bars) • Normal Operation • Static H/V Lines (Any Color) All video processing is performed by IC400 (MT5388) on the A-Board. •...
  • Page 26: Missing Video (all Inputs)

    AZ1K Chassis Models Overview in some cases, down to the component level, and in almost all cases, 2) Check for TCON 12V at CN4152/pins 4 - 10 & CN6151/pin 2 down to at least the board level. For example, if the distortion appears in a) No 12V.
  • Page 27: Unique Main Video Board (a-board) Or Lvds Cable Effects

    AZ1K Chassis Models Overview The aspect ratio can be easily changed using the “WIDE” key on the • Color Distortion - A color distortion can be caused by a remote controller. If the distortion follows the video then the A-Board is defective IC400 or LVDS cable.
  • Page 28: Unique Tcon/hfr Board Effects

    AZ1K Chassis Models Overview Unique TCON/HFR Board Effects • 2” Vertical Solid White or Black Bar- The bar will be approximately 2" because this is the area that is controlled • 2” Vertical Transparent Colored Bar- The bar will be by a single drive IC that is located across the top of the LCD approximately 2"...
  • Page 29: Video System Block Diagram

    AZ1K Chassis Models Overview Video System Block Diagram A-Board User Menu Service Mode TM701 NTSC/ATSC RF Input IC4302 Tuner NAND FLASH User Data Video 1 (Component & Composite) White Balance GAMMA Video 2 (Composite / S-Video) Video 3 (Component) LVDS Cable LCD Panel Assembly CN4152 PC Input...
  • Page 30: Audio Symptom Troubleshooting

    AZ1K Chassis Models Overview Audio Symptom Troubleshooting Missing or Distorted Main Speaker Audio - All Inputs Reference Figure 2-9 In this case, the most likely defective is the A-Board. Before you replace the A-Board perform the following test procedures to confirm the actual Normal Operation defective component.
  • Page 31: Audio System Block Diagram

    AZ1K Chassis Models Overview Audio System Block Diagram A-Board HDMI IN 1 IC6601 HDMI HDMI IN 2 Digital Receiver/ Audio HDMI IN 3 Switch CN8302 (EDID) HDMI IN 4 SPDIF Digital Audio Output (Optical) TM701 RF Input NTSC/ATSC CN8301 Tuner IC400 FIXED Analog LR Audio...
  • Page 32: Section 3 - Service Mode

    Section 3 - Service Mode Service Mode Access Service Mode Access Display > 5 > Volume + > Power Reset Self Check, Press 8 > 0 keys anel operation time by hour (max 99999 ) (Reset Panel operation Time , Press 7 > 0 keys ) oot count (max 99999 ) otal operation time by hour (max 99999 ) SERVICE MODE...
  • Page 33: Section 4 - Triage & Troubleshooting Flowcharts

    Section 4 - Triage & Troubleshooting Flowcharts Triage Flowchart Triage Flowchart A (AZ1K 55", 60" Models) Start Triage GO TO Go to Power-ON “No Standby LED” “Standby” LED Triage Sheet Troubleshooting Replacement Parts Flowchart B GO TO Go to “Standby” LED Protection Mode “Protect Blink Code”...
  • Page 34: Power-on Troubleshooting Flowchart

    Triage & Troubleshooting Flowcharts Power-ON Troubleshooting Flowchart Power-ON Troubleshooting Flowchart B (AZ1K 55", 60" Models) Check STBY 3.3V at CN6201/pin 1 CN2 - 60" (In STBY Mode) NOTE: Confirm all connections between circuit boards before replacing Replace Is voltage Unit will Not 3.3V G5E-Board or Power-ON...
  • Page 35: Protection Mode 2x, 3x, & 4x Troubleshooting Flowchart

    Triage & Troubleshooting Flowcharts Protection Mode 2X, 3X, & 4X Troubleshooting Flowchart NOTES: Protection Mode Troubleshooting 1) All Red Blink patterns will occur on the Front Panel Flowchart C 1 (AZ1K 55" & 60" Models) Red “Standby” LED 2) All voltage are measured prior to unit shutdown 3) Confirm all connections between circuit boards Unit Shuts OFF RED LED...
  • Page 36: Flowchart

    6X Blink Pattern 5X Blink Pattern (No Backlight) TCON/HFR Error 60" Models voltage Replace 24V Before G8S-Board Shutdown Is “SONY” logo Check LVDS connection Displayed and between Tones Heard? Backlight ON LCD Panel (TCON) & A Brds Before Shut Down? Check Backlight-ON...
  • Page 37: Protection Mode 6x(55") & 7x Troubleshooting Flowchart

    Triage & Troubleshooting Flowcharts Protection Mode 6X(55”) & 7X Troubleshooting Flowchart NOTES: Protection Mode Troubleshooting 1) All Red Blink patterns will occur on the Front Panel Flowchart C 3 (AZ1K 55" & 60" Models) Red “Standby” LED 2) All voltage are measured prior to unit shutdown 3) Confirm all connections between circuit boards Unit Shuts OFF RED LED...
  • Page 38: Video Troubleshooting Flowchart

    Triage & Troubleshooting Flowcharts Video Troubleshooting Flowchart Video Troubleshooting Flowchart D (AZ1K 55" & 60" Models) Missing or Distorted Video NOTE : Confirm all connections between circuit boards before replacing All Video Inputs : Composite Check External Device Video Missing or Replace Component and Connections...
  • Page 39: Audio Troubleshooting Flowchart

    Triage & Troubleshooting Flowcharts Audio Troubleshooting Flowchart Audio Troubleshooting Flowchart E (AZ1K 55" & 60" Models) NOTE: Confirm all connections between Missing or Distorted Audio circuit boards before replacing (Speaker Outputs ) All Video Inputs : Composite Check External Device Component Is Audio Replace...
  • Page 40: Appendix

    Appendix LCD Panel Distortion Pictures The following distortions and anomalies where fixed by replacing the LCD Panel. 2' Solid Black Bar Distortion Timing Distortion Double Image Distortion Ghosting Distortion 2" Solid White Bar Distortion Sharp Lines & Missing Pixels CTV-65...
  • Page 41: Tcon/hfr Board Distortion Pictures

    Appendix TCON/HFR Board Distortion Pictures The following distortions and anomalies where fixed by replacing the TCON/HFR Board. Large Blooming Distortion Two Small Blooming Distortions GAMMA Type Distortion 2" Transparent Colored Bar Distortion Complete Washout Distortion 2" Transparent Colored bar Distortion CTV-65...
  • Page 42: Tcon/hfr Board Distortion Pictures Continued

    Appendix TCON/HFR Board Distortion Pictures Continued The following distortions and anomalies where fixed by replacing the TCON/HFR Board. 2" White Bar w/ Random Colored Lines Exact Half-Screen Distortion Complete Washout w/ Colored Lines CTV-65...
  • Page 43: Video Board Distortion Pictures

    Appendix Video Board Distortion Pictures The following distortions and anomalies where fixed by replacing the Video Board. Green Carpet Raster Multi-Colored Carpet Raster Text Bleed Lines Random Size Vertical Bars Overall Red Tinting Solarization CTV-65...
  • Page 44: Video Board Distortion Pictures Continued

    Appendix Video Board Distortion Pictures Continued The following distortions and anomalies where fixed by replacing the Video Board. Partial Washout w/ Random Video Bar Overall Blue Tinting w/ Soft Vertical Lines Green Raster Overall Green Tinting w/ Video Ghosting Overall Red Tinting CTV-65...
  • Page 45 Sony Electronics 2007 Sony Electronics, Inc. EMCSA - A Service Company 16530 Via Esprillo San Diego, CA 92127 CTV650310 03/30/10 Reproduction in whole or part without written permission is prohibited. All rights reserved...

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Kdl-60ex500Kdl-55ex501

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