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Sony KDS-R50XBR1 Training Manual

Diagnostics and troubleshooting.
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Training Manual
Models:
KDS-R50XBR1
KDS-R60XBR1
Diagnostics and Troubleshooting
Course: TVP-21

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Table of Contents

   Summary of Contents for Sony KDS-R50XBR1

  • Page 1 Training Manual Models: KDS-R50XBR1 KDS-R60XBR1 Diagnostics and Troubleshooting Course: TVP-21...
  • Page 2: Table Of Contents

    Table of Contents Technologies & Features ............ 1 ASU-Board (Audio/Video Switching, System Control, & Audio Processing) ..............52 Technology ..............1 DSU-Board (Video Processing) ......... 53 Silicon Crystal Reflective Display (SXRD) ......1 AK-Board (Audio Output Processing) ........ 53 Features ................3 K-board (Audio Output Amplifier System) ......
  • Page 3 Audio Output Error (7X) ..........78 Troubleshooting Flowchart Step Descriptions ....63 Panel Error (9X) ............78 Chapter 4 - Protection Circuits ......... 65 Chapter 5 - Video Processing System ......80 Overall Block Diagram ........... 65 Overall Block Diagram ........... 80 Overall System Description ...........
  • Page 4: Technologies & Features

    Technologies & Features Technology TO MIRROR Silicon Crystal Reflective Display (SXRD) SXRD is Sony’s adaptation of Liquid Crystal on Silicon (LCoS) micro- POLARIZERS display technology. The SXRD technology is similar to the LCD LCD PANEL LAMP technology use in previous rear projection and direct TV products in that is uses liquid crystal materials to pass and block light to form the picture you see, however, this is where the similarities stop.
  • Page 5 Technologies & Features • SXRD Technology o Is a reflective device – light is directed into the panel from the front, the light passes through the liquid crystal material, and is then reflected back out through the same liquid crystal material by tan aluminized substrate. The light passes through the liquid crystal twice.
  • Page 6: Features

    Technologies & Features Features Advance Iris Full Open Full Closed Advanced Iris The Average Picture Level (APL) drives the Advanced Iris operation. APL 500 cd/m2 n video systems, as the average level of the picture signal is defined i White during active scanning time integrated over a frame period;...
  • Page 7: Pc Input

    Technologies & Features PC Input The 2005 SXRD models (KDS-R50XBR1 and KDS-R60XBR1) have a Personal Computer Input (PC-IN), which connects directly to the PC 15 pin DIM connector (HD15 connector). Once connected the TV functions as a video monitor and audio output (separate Stereo Mini Plug) for the PC.
  • Page 8: Non-technical Triage Flowcharts

    Non-Technical Triage Flowcharts 2005 SXRD Triage Initial Contact Analysis Flowchart AT Start Initial Analysis Does GO TO Green (Power/ Triage Standby) LED Power-ON Turn ON? Flowchart BT GO TO GO TO Red (Power/ Triage Is Video Triage Standby) LED Protection Mode Distorted? Video Input Flashing?
  • Page 9 Non-Technical Triage Flowcharts 2005 SXRD Triage Power-ON Flowchart BT Replace Q-Box 50" A-1152-713-A Technician 60" A-1152-712-A Green LED GO TO TV will Not Continuous Flash Create Service Power-ON Replace Turn- ON Ticket Troubleshooting ASU/DSU Assembly Flowchart B Go to Appendix for No Green LED Part # Tables A-1 &...
  • Page 10 Lamp Door & Lamp Plug is displayed before Shutdown Replace LAMP are securely seated & for 1.5 mins. then 2X undamaged Lamp Part Numbers KDS-R50XBR1 – 9-308-760-0 Clear unit ventilation areas KDS-R60XBR1 – 9-308-760-0 and and confirm adequate local room temperature Create Service Ticket...
  • Page 11 Non-Technical Triage Flowcharts 2005 SXRD Triage Protection Mode Flowchart CT2 NOTE: Except for the Lamp LED all flash Unit Shuts OFF patterns will occur on the RED LED Front Panel Flashing Red Power/Standby LED Fan Part Numbers 4X Flash 5X Flash NOTE: The Lamp Driver is Fan #1 –...
  • Page 12 Non-Technical Triage Flowcharts 2005 SXRD Triage Protection Mode Flowchart CT3 NOTE: Except for the Lamp LED all flash patterns will occur on the Unit Shuts OFF Front Panel RED LED Red Power/Standby LED Flashing 6X Flash 7X Flash Pattern Pattern (Low B+) (Audio Output ) Create Service...
  • Page 13 Non-Technical Triage Flowcharts 2005 SXRD Triage Protection Mode Flowchart CT4 NOTE: Except for the Lamp LED all flash patterns will occur on the Unit Shuts OFF Front Panel RED LED Red Power/Standby LED Flashing 9X Flash Pattern NOTE: Also call Microprocessor I 2C “Panel Error”...
  • Page 14 Non-Technical Triage Flowcharts 2005 SXRD Triage Missing or Distorted Video Flowchart DT Missing Video Distorted Video All Inputs: Video 1,2,3 (Composite & S-Video ) Triage Is Video Missing Video 4, 5 (Component Video ) NOTE: The main objective of GO TO or Distorted on Flowchart ET is to test individual Video 6, 7 (HDMI)
  • Page 15: Video Input

    Non-Technical Triage Flowcharts 2005 SXRD Triage Video Distortion Flowchart ET Video Input Check TV OK External Device Repair External Connections Devices or Swap Devices and Connections connections Good - Video 1,2,3 (Distorted) - Video 1,2,3 (OK) HDMI PC IN Premium Channels - ATSC Tuner &...
  • Page 16 Non-Technical Triage Flowcharts 2005 SXRD Triage Missing or Distorted Audio Flowchart FT All Inputs : Missing or Distorted Audio 1,2,3 (Composite & S-Video) Audio Audio 4, 5 (Component Video ) Audio 6, 7 (HDMI) (Speaker Outputs) Audio 8 (PC IN) ATSC, NTSC, SUB-NTSC Tuners (RF) Memory Stick Check...
  • Page 17: Technical Troubleshooting Flowcharts

    Technical Troubleshooting Flowcharts 2005 SXRD Initial Contact Analysis Flowchart A Start NOTE: Reference Chapter 2, Pages 28 - 30 Initial Analysis for detailed flowchart step descriptions Does GO TO Green (Power/ Power-ON Standby) LED Troubleshooting Turn ON? Flowchart B GO TO GO TO Red (Power/ Protection Mode...
  • Page 18: Troubleshooting Flowcharts

    Troubleshooting Flowcharts 2005 SXRD Power-ON Troubleshooting Flowchart B NOTE: Reference Chapter 3, Pages 35 - 37 for detailed flowchart step descriptions Check Standby5V at Cn6502/Pin41 Unit will Not or at Turn- ON If video Thermostat distortion “Before Shutdown” check SW9V Press Initial Power -ON OK TV or Remote...
  • Page 19 T1 & T3 Boards local room temperature Lamp-Door Replace LAMP Switch & Lamp Connector Switch Lamp Part Number Problem KDS-R50XBR1 – 9-308-760-0 Does unit still KDS-R60XBR1 – 9-308-760-0 shutdown (2X)? Solved Lamp and Door and switches OK ? Replace S1 & S2 Boards...
  • Page 20 ASU-Board CN2301/pins 2 & 11 Replace LAMP Check *Befroe Shutdown* Supply Voltage Lamp Driver Lamp Part Number Board KDS-R50XBR1 – 9-308-760-0 X1 Connector Check Fan Drive (DR) KDS-R60XBR1 – 9-308-760-0 *Before Shutdown* and Feedback (FB) Replaced Are (DR) Drive Voltage Levels at...
  • Page 21 Troubleshooting Flowcharts 2005 SXRD Protection Mode Troubleshooting Flowchart C -3 NOTES: 1) Except for the Lamp LED all flash patterns will occur on the Front Panel Red Power/Standby LED 2) All voltage are measured prior to unit Unit Shuts OFF shutdown RED LED 3) Reference Chapter 4, Pages 44 - 52 for...
  • Page 22 Troubleshooting Flowcharts 2005 SXRD Protection Mode Troubleshooting Flowchart C-4 Replace S1 & S2 Boards Unit Shuts OFF S1 A-1123-098-A RED LED S2 A-1123-099-A Flashing 9X Flash Pattern Does unit Problem NOTE: Also call still Shutdown Microprocessor I 2C Solved “Panel Error” Communications error Check &...
  • Page 23 Troubleshooting Flowcharts 2005 SXRD No Video Troubleshooting Flowchart D NOTE: Reference Chapter 5, Pages 57 – 61 No Video for detailed flowchart step descriptions All Inputs: GO TO Video 1,2,3 (Composite & S-Video ) Video Distortion Video 4, 5 (Component Video ) NOTE: The main objective of Troubleshooting Is Video Missing...
  • Page 24 Troubleshooting Flowcharts 2005 SXRD Video Distortion Troubleshooting Flowchart E NOTE: Reference Chapter 5, Pages 58 - 61 for detailed flowchart step descriptions Video Distorted All Inputs: Video 1,2,3 (Composite & S-Video) GO TO Video 4, 5 (Component Video ) Is Distortion on Optical Block Video 6, 7 (HDMI) All Video Inputs ?
  • Page 25: Troubleshooting

    Troubleshooting Flowcharts 2005 SXRD Optical Block Troubleshooting Flowchart F NOTE: Reference Chapter 5, Pages 59 - 61 for detailed flowchart step descriptions Optical Block Troubleshooting Turn ON Use “JUMP” button on PANEL SERVICE MODE remote to display Panel In this case there is LCD Does drive, however.
  • Page 26 Troubleshooting Flowcharts 2005 SXRD Missing or Distorted Audio Troubleshooting Flowchart G All Inputs : Missing or Distorted Audio 1,2,3 (Composite & S-Video) NOTE: Reference Chapter 6, Pages 68 - 70 Audio Audio 4, 5 (Component Video ) for detailed flowchart step descriptions Audio 6, 7 (HDMI) (Speaker Outputs) Audio 8 (PC IN)
  • Page 27: Disassembly Procedures

    Disassembly Procedures Screen Frame Removal Screen Frame Removal The lower front cover must be removed to access the screws that secure the two lower screen-frame brackets Open the Lamp Door and Slide to the Right remove 1 screw in the lower left hand corner when view Lower Front cover from the rear of the unit .
  • Page 28 Screen Frame Removal (cont.) Disassembly Procedures Hold Together Leave top -center screw for last Remove 9 screws to release front Screen Frame assembly. CAUTION: Leave the top-center Screws screw in place while removing the eight other screws. Go around to the front of the unit .
  • Page 29: Rear & Sub Plastic Cover Removal

    Disassembly Procedures Rear & Sub Plastic Cover Removal Rear and Sub Plastic Cover Removal & ASU-Board Access Remove 9 screws and pull rear plastic cover straight back and off. Screws Remove 5 screws and detach AC cord from the slot . Pull sub Detach plastic cover slowly straight AC Cord...
  • Page 30: Chassis Assembly Removal

    Disassembly Procedures Removal of Complete Chassis Assembly Chassis Assembly Removal Remove 6 screws and Screw disconnect the C-Board ribbon cable (Gentle press the Tan tab on the side of the connector to release cable. Disconnect C-Brd Connector Tan Tab 2 Screws 3 Screws Remove the small cover (3 screw) and disconnect C-Board cables.
  • Page 31 Disassembly Procedures Removal of Complete Chassis Assembly (cont.) Disconnect Cables on each side of the chassis assembly Slide Chassis out until it is stopped by the vertical bracket. Before attempting to remove the Chassis assembly disconnect the wires as illustrated in the photo. Disconnect connector Angle the left side of Chassis...
  • Page 32: Optics Block & Fan Removal

    Disassembly Procedures Optics Block , Power Supply Block , and Fan Assembly Removal Optics Block & Fan Removal Before the Optical Block can be removed the Fan assembly must be removed. First, remove cable clamp and wire tape. Assembly Tape Clamp Screws Remove the 5 screws and the...
  • Page 33 Optics Block , Power Supply Block , and Fan Assembly Removal Disassembly Procedures (cont.) Grasp the Fan assembly and pull out to remove . Power Supply Block Optical Block Cover Screws To access the Optics Block the gray plastic cover must first be removed.
  • Page 34 Optics Block , Power Supply Block , and Fan Assembly Removal Disassembly Procedures (cont.) Locking The Power Supply Block must be removed with the Optics T1-Board Block because they are Lamp Housing attached by 1 internal screw inside the Lamp Housing. The left edge also blocks the Optics Block from being Power Supply...
  • Page 35 Optics Block , Power Supply Block , and Fan Assembly Removal Disassembly Procedures (cont.) Plastic CAUTION: divider Take care not to damage black plastic divider (light shield) when removing and Tape installing the Optics Block. Do not remove or damage black tape on the lens.
  • Page 36: Power Supply Block Removal

    Power Supply Block (Only) Removal Disassembly Procedures Power Supply Block Removal Squeeze Tabs Use the following procedures to remove the Power Supply Block only without any other chassis disassembly. Disconnect the power and sensor Disconnect Cables cables. Release cables from 2 holders. Squeeze the 2 upper white tabs and dismount the Power Supply Release...
  • Page 37 Disassembly Procedures Power Supply Block (Only) Removal (cont.) The Power Supply Block (including the Lamp Plug & Cable Guide) is pull out underneath the Fan assembly. Direct the Carefully direct the Lamp Plug Lamp Jack out through the slot in the Lamp housing.
  • Page 38: Q-box & Pd-board Removal

    Access & Removal of Q -Box & PD-Board (Digital Module Block DMB ) Disassembly Procedures Q-Box & PD-Board Removal Slide Out The Chassis only needs to be slightly slid out to access the screws and wire holders to access the Q-Box and PD- board.
  • Page 39 Access & Removal of Q -Box & PD-Board (cont.) (Digital Module Block DMB ) Disassembly Procedures The Q-Box assembly and the PD-Board (HDMI) can now be access and removed. Q-Box To remove the PD-Board Assembly remove 2 screws, squeeze the 2 white tabs, and disconnect the 2 wires.
  • Page 40 Access & Removal of Q -Box & PD-Board (cont.) Disassembly Procedures (Digital Module Block DMB ) Remove 6 screws to free the Q - Box assembly. Firmly grasp the assembly at the top and bottom and pull to dislodge it from the chassis Screws frame.
  • Page 41 Disassembly Procedures Access & Removal of Q -Box & PD-Board (cont.) (Digital Module Block DMB ) Q-Box assembly includes the QM, QI, QT, and QH boards. TVP-21...
  • Page 42: Dsu-board Removal

    DSU-Board Removal Disassembly Procedures DSU-Board Removal To access the DSU-Board, remove the Chassis assembly from the Bottom Cabinet. For instructions on removing the Chassis reference Chapter 3 – Chassis Assembly Removal. After removing the Chassis assembly, remove 16 screws and Connector Cover the Connector Cover to remove...
  • Page 43 DSU-Board Removal (cont.) Disassembly Procedures Push Grasp the top and bottom of the framing holding the Q-Box and CableCard PD-Board . ASU-Board Q-Box Push the framing to the left until the two connectors between the ASU-Board and the DSU-Board DSU-Board completely separate.
  • Page 44 DSU-Board Removal (cont.) Disassembly Procedures Disconnect the CableCard ribbon Screws cable (Reference Chapter 6 page 14 for procedure). Detach CableCard assembly from the Chassis assembly. Remove 3 screws. Connector Lay the CableCard assembly to the side Grasp the top and bottom of the DSU-Board shield on the far left side of the Chassis assembly and pull out.
  • Page 45 Disassembly Procedures DSU-Board Removal (cont.) Front-Side Connectors To remove the DSU-Board Connectors continue to pull the DMB and the DSU-Board assemblies away from the Chassis frame (swinging the assemblies to the right). Remove 6 screws, and squeeze the two white tabs to release the DSU-Board from the shield.
  • Page 46: Asu & G Boards Removal

    Disassembly Procedures ASU & G-Board Removal ASU & G Boards Removal To access the ASU-Board and the G - Board, remove the Chassis assembly from the Bottom Cabinet (Reference Chapter 3 – Chassis Assembly Removal). Remove the shields on the ASU- Board (Reference Chapter 2 –...
  • Page 47 Disassembly Procedures ASU & G-Board Removal (cont.) Grasp one side of the Chassis assembly at a time and pull up while holding down the lower chassis assembly until connector between ASU-Board and the G-Board begins to separate. Repeat the above procedure with the other side of the Chassis assembly Pull up Connector...
  • Page 48 Disassembly Procedures ASU & G-Board Removal (cont.) Disconnect Disconnect all cables on the ASU- Board. Remove 4 screws, squeeze the 2 white tabs and lift ASU-Board off assembly. Screws ASU-Board Tabs To removal the G-Board press the 4 gray tabs in and lift G -Board off the lower chassis frame.
  • Page 49: Wire Routing Diagrams

    Wire Routing Diagrams Disassembly Procedures Wire Routing Diagrams TVP-21...
  • Page 50 Disassembly Procedures Wire Routing Diagrams (cont.) TVP-21...
  • Page 51 Disassembly Procedures Wire Routing Diagrams (cont.) TVP-21...
  • Page 52 Disassembly Procedures Wire Routing Diagrams (cont.) TVP-21...
  • Page 53 Disassembly Procedures Wire Routing Diagrams (cont.) TVP-21...
  • Page 54: Chapter 1 - Overall Block & Board Descriptions

    Chapter 1 - Overall Block & Board Descriptions Q-Box Module Video PC VGA Input HM-Board Digital (Digital ) H1-Board Connection  ATI Micro Memory Stick Front Panel Switches  ATSC Tuner Interface Video (Digital )  Main NTSC Tuner H2-Board ...
  • Page 55: Pcb And Module Descriptions

    1. Overall System Block PCB and Module Descriptions Lamp Power Supply Block (aka Ballast, Lamp Driver) The 380V volts developed in the Main Power Supply on the G-Board powers F-Board (Power Supply) the Lamp Power Supply Block. The Lamp Power develops approximately 12K voltages to initial ignite the High Voltage Mercury Vapor Arc Lamp.
  • Page 56: Dsu-board (video Processing)

    Memory Stick Signal Processing and Control • i-Link Signal Processing and Control The AK-Board (audio) takes the Sony/Phillips Digital Interface signal from the DSP on the ASU-Board and converts it to an IIS (PCM) signal for processing on the K-Board (audio).
  • Page 57: S1-board

    1. Overall System Block S1-Board Ambient Temperature Sensor IC S2-Board Lamp Temperature Sensor IC T1-Board Lamp Door Switch T3-Board Lamp Plug Connection Detection Switch H1-Board • Channel Up/Down Button • Volume Up/Down Button • Input Select Button • Menu Button H2-Board Front LED’s (i.Link, STBY, Lamp, Power, Timer) H3-Board...
  • Page 58: Chapter 2 - Initial Contact Analysis

    Chapter 2 - Initial Contact Analysis TVP-21...
  • Page 59: Detail Description Of The Steps In The Initial Contact Flowchart

    2. Initial Contact Analysis Detail description of the steps in the Initial Red Standby/Timer LED, as was the case on previous models. The Red Power/Standby LED was a good indicator of a properly functioning Contact Flowchart Standby 5V power supply. The Standby 5V is active as long as the unit is plugged into the AC outlet, and the Red Power/Standby LED glow.
  • Page 60 2. Initial Contact Analysis Is Video Is Audio Present? Present? Is Video Present? At this point the TV turns on properly and the Green Is Audio Present? Finally, if the Green Power/Standby LED glows Power/Standby LED is glowing steady. Consequently, this indicates a steady and the video is present and undistorted, then the only function properly function power supply system, and properly operating circuits left to check is the audio system.
  • Page 61: Chapter 3 - Power Supply System

    Chapter 3 - Power Supply System G-Board CN6501 AC Ground Lamp Power Supply Block 380V CN6015 CN6408 Audio K-Brd Standby 5V D6100 Stdby 5V Power Supply ASU-Brd DSU-Brd IC6101 ASU-Brd DSU-Brd Q-Box DSU-Brd Q-Box R6322 REC-ON (From ASU-Brd) IC6401 & Main ASU-Brd DSU-Brd...
  • Page 62 ASU-Board ATSC 5V DSU-Board SW 9V Video PS2100 IC2100 Sub 11V K-Board 9V Reg 3.15A Audio PS2101 IC2103 D5V & A5V Reg 3.15A IC2102 3.3V Reg Fan Protection Circuit From Fan Drive Circuit G-Board STBY 5V To Fan #5 Drive Circuit PS2102 Sub 6.5V DC/DC...
  • Page 63: Overall System Description

    3. Power Supply System The PFC circuit differs from a SMPS in that it has the added function of Overall System Description ensuring that the current drawn from the AC power network is in-phase with the AC power network voltage. When this condition is achieved the Reference Figures 3-1 &...
  • Page 64: Power-on Sequence

    3. Power Supply System Power-ON Sequence The AC power cord is plugged into the AC outlet and the AC Power AC voltage passes through F-Board (Main Fuse OK) and Applied is applied to the G-Board. The AC voltage supplied to the G-board is applied directly Standby 5V - ON to the AC-Relay and the Standby 5V power supply circuit.
  • Page 65: Troubleshooting Flowchart

    3. Power Supply System Troubleshooting Flowchart 2005 SXRD Power-ON Troubleshooting Power-On Flowchart B NOTE: Reference Chapter 3, Pages 35 - 37 for detailed flowchart step descriptions Check Standby5V at Cn6502/Pin41 Unit will Not or at Turn- ON If video Thermostat distortion “Before Shutdown”...
  • Page 66: Troubleshooting Flowchart Step Descriptions

    Unfortunately, there is no red standby LED on either of the two 2005 then the most likely defect suspect is the Q-Box module. The fact that SXRD models (KDS-R50XBR1 and KDS-R60XBR1). Therefore, the only the unit successfully completes the power-on sequence indicates that the way to visually check if the Standby 5V circuit is functioning is to press TV microprocessor is functioning properly.
  • Page 67 3. Power Supply System If the Standby 5V is not present at the checkpoints then the Standby 5V power supply is not functioning. In this case, replace the G-board. The next step is to confirm application of the AC voltage to the G-Board through the F-Board (Main Fuse).
  • Page 68: Chapter 4 - Protection Circuits

    Chapter 4 - Protection Circuits Overall Block Diagram ASU Board CN2301 0.05V White Fan 1 Lamp Reference S1-Board 0.05V White Figure 4-7 Fan 2 Lamp Ambient Temp. Temp (2X) for Fan 0.05V White Sensor Fan 3 Panel Locations 0.05V White Error Fan 4 Chassis S2-Board...
  • Page 69: Overall System Description

    4. Protection Circuits Overall System Description • Device Acknowledgement (9X Red Power/Standby LED Flash Pattern) Reference Figure 4-1 The Display Engine (DE) microprocessor monitors all protection circuits. The DE microprocessor employs eight unique Green Standby/Power The protection circuits (aka. self-diagnostics routines) for the 2005 LED flash patterns to identify one or more of the circuit failures listed in SXRD monitor the following circuits and conditions in and around the TV the previous bullet list.
  • Page 70: Lamp Cover Error (3x Power/standby Red Led Flash Pattern)

    4. Protection Circuits the blades or a defective fan the DE microprocessor will receive an error near the lamp. The DE microprocessor regularly queries IC7120 on the signal. The TV will shutdown and a 4X flash pattern on the Standby/ S1-Board over the I2C bus for temperature information.
  • Page 71 4. Protection Circuits condition or for the presents of any DC voltage level. If either of these conditions is detected the protection alerts the DE microprocessor of the failure and a 7X flash pattern on the Standby/Power LED will occur. Panel Error or Device Acknowledgement Error (9X Power/ Standby Red LED Flash Pattern) This DE microprocessor monitors the I2C communications between...
  • Page 72: Troubleshooting Flowcharts

    4. Protection Circuits Troubleshooting Flowcharts Flowchart C-1 Figure 4-2 TVP-21...
  • Page 73 4. Protection Circuits Flowchart C-2 Figure 4-3 TVP-21...
  • Page 74 4. Protection Circuits Flowchart C-3 Figure 4-4 TVP-21...
  • Page 75 4. Protection Circuits Flowchart C-4 Figure 4-5 TVP-21...
  • Page 76: Troubleshooting Flowchart Step Descriptions

    4. Protection Circuits Troubleshooting Flowchart Step Descriptions Lamp Error (Lamp LED) LAMP LED Flashing In most cases a flashing Lamp LED indicates a defective Lamp, and the Lamp must be replaced. However, an open circuit in the high-voltage cabling to the lamp will also case this failure indication. Therefore, before replacing the lamp confirm that the cabling and connections are good between the Lamp Drive board and the lamp.
  • Page 77: Lamp Cover/plug Error (3x)

    4. Protection Circuits 3) Optical Block (C-Board) Clear unit ventilation areas and and confirm adequate If the TV still shuts down (2X) after the previous substitutions then there local room temperature is a problem with the DE microprocessor, consequently, the ASU/DSU assembly must be replaced.
  • Page 78: Fan Error (4x)

    4. Protection Circuits • The door tab which depresses the detector switch Check rear fans (1 & 4 ) that are visually accessible for rotation • The lamp door detector switch • The lamp power plug • The lamp plug detector switch If the door, door switch, lamp, or lamp switch are found damaged then the appropriate component must be replaced.
  • Page 79: Lamp Drive Error ( 5x) (aka Lamp Power Supply Block)

    4. Protection Circuits The drive voltages should be 6V each. If both drive voltages are present however, the DE microprocessor is not processoring the information replace the non-rotating fan. However, if either of the drive voltages is accurately. In this case, the problem is with the DE microprocessor. missing then there is a defective drive circuit on the ASU-Board.
  • Page 80: Low B+ Error (6x)

    4. Protection Circuits If the spark gap does not illuminate, then the next step is to check the error, and therefore, consider this component when troubleshooting. 380V lamp driver supply voltage from the Main Power Supply (G-Board). Measure this voltage directly at the Lamp Driver board at the X1 connector Your first step in troubleshooting this error is to eliminate the TV at the top of the board.
  • Page 81: Audio Output Error (7x)

    4. Protection Circuits Audio Output Error (7X) these three boards have failure to communicate (or acknowledge) the De microprocessor. Therefore, the fist step in solving the problem is to check for loose or damaged connections between all three boards and 7X Flash the ASU-Board or the DSU-Board (Reference Figure 4-8).
  • Page 82 4. Protection Circuits Check Voltage Check Vottage Supply to Supplies to C-Board S1 & S2 boards CN6900/pins 4-6 CN2303/ pins 7 & 11 Check CN2303/pins 7 & 11 on both the S1-Board and the S2-Board for the presents of 5V. Check CN6900/pins 4 through 6 on the C-Board for the presents 6.5V.
  • Page 83: Chapter 5 - Video Processing System

    Chapter 5 - Video Processing System Overall Block Diagram ASU-Board Composite 1 Video 1 DSU-Board H3-Board Video 8 Composite 2 PC Input Video 2 Composite 3 Video 3 IC4300 Sub-Picture Video Component 1 CCP-X Video 4 Analog Video Optical Block (Analog) Component 2 Video 5...
  • Page 84: Overall System Description

    5. Video Processing System Overall System Description • Video 8 Reference Figure 5-1 Video 8 connects directly to a Personal Computer or PC monitor The 2005 SXRD model includes the following video input sources. output source using a HD15 or SVGA cable. The input accepts VGA, SVGA, XGA, WXGA, and SXGA resolution signals from the PC.
  • Page 85: Video Circuits Functional Description

    The Digital Module Block (DMB) is the interface for all digital video The i-Link connection is Sony’s IEEE-1394 or Fire-Wire connection. inputs (ATSC Tuner, CableCard, Memory Stick, i-Link, and HDMI). The The i-Link connection transports digital video, audio, and control ATI microprocessor controls the switching for all digital inputs except information between any i-Link compatible device.
  • Page 86 5. Video Processing System The Digital Reality Creator (DRC) is a line doubler and noise reduction circuit for the 480i signal. The DRC up-converts the 480i signal to a 1080i signal (High Definition Format). The DRC acts only as a noise reduction circuit fir the 1080i signal since it is already in a High Definition format.
  • Page 87: Troubleshooting Flowcharts

    5. Video Processing System Troubleshooting Flowcharts No Video Flowchart D Figure 5-2 TVP-21...
  • Page 88 5. Video Processing System Video Distortion Flowchart E Figure 5-3 TVP-21...
  • Page 89 5. Video Processing System Optical Block Flowchart F Figure 5-4 TVP-21...
  • Page 90: Troubleshooting Flowchart Step Descriptions

    5. Video Processing System Troubleshooting Flowchart Step Descriptions Is Video Missing When a video problem occurs you will experience one of the two following on All Inputs ? symptoms. 1,2,3 etc. • No Video • Distorted Video The main objective when troubleshooting one of the previously listed If the video is missing only on one or two inputs then you will go to the symptoms is to determine if the defective exists in the Optical Block, “Video Distortion”...
  • Page 91 5. Video Processing System If some OSD’s can be displayed then depending on what OSD’s are displayed will determine the defective area. As previously mention check User Menu or the User Menu, which is developed in the Q-Box module, to determine if any OSD be QM OSD be the defect is in the Q-Box module or in the ASU/DSU Assembly.
  • Page 92 5. Video Processing System TV Service Mode WE Service Mode DSU-Board C-Board ROOK LVDS Micro Display Cable ROOK Test Patterns Micro Switch LVDS Cable Q-Box ASU-Board Panel Service Mode Micro Micro ATI Service Mode ATI Test Patterns On-Screen Display Sources Figure 5-5 TVP-21...
  • Page 93 5. Video Processing System PC Display DSU-Board C-Board ROOK Micro Display Micro Switch LVDS Cable Q-Box ASU-Board On-Screen Display Sources Figure 5-6 Micro Micro User Menu Interface Memory Interface TVP-21...
  • Page 94: Video Distortion

    5. Video Processing System Video Distortion Check External Device Video Distorted Connections Swap Devices and connections The primary objective is to locate the defective component through viewing the individual video inputs. The first step when a “Distorted Good Video” defect occurs is to determine if the video distortion appears in all video input sources, or if the video distortion appears only in one or two video input sources.
  • Page 95: Optical Block

    5. Video Processing System The opposite of the previous conclusion is true if the video distortion displayed then the Optical Block is OK and the video processing circuits appears on the ATSC Tuner and Memory Stick inputs but not on the need to be examined.
  • Page 96: Chapter 6 - Audio Processing System

    Chapter 6 - Audio Processing System Overall Block Diagram ASU-Board J307 Audio Output Var/Fix Composite 1 Audio 1 H3-Board AK-Board K-Board Composite 2 Audio 2 CN501 S-Master Audio SPDIF to IIS Composite 3 Audio 3 Amplifier Converter Audio Component 1 Audio 4 System (Analog)
  • Page 97: Overall System Description

    Board and IC507. The analog switcher IC507 single output (analog audio single) is applied to an A/D 9analog to digital) converter. The output digital signal is in the SPDIF (Sony/Phillips Digital Interface). The ASU-Board sends the SPDIF signal to the AK-Board. TVP-21...
  • Page 98: Troubleshooting Flowchart

    6. Audio Processing System Troubleshooting Flowchart TVP-21...
  • Page 99: Troubleshooting Flowchart Step Descriptions

    6. Audio Processing System Troubleshooting Flowchart Step Descriptions device or cables are causing the problem. Obviously, you must replace the device or cabling if found to be defective (or Bad). However, if the external device and cables are OK, then the next step is to replace the Reference Figures 6-1 &...
  • Page 100 6. Audio Processing System supply circuits. Replace the G-Board. Check Audio Output If both the 3.3V and 6.5V are OK, then the next step is to check the 14V Var/Fix power supply voltage directly connected to the K-Board. The 14V powers the digital output amplifier circuits.
  • Page 101: Appendix

    Appendix ASU/DSU Assembly Part Numbers Per Serial Number Table A-1 KDS-R50XBR1 ASU/DSU Assembly & Optical Replacement 9000001 to 90xxxxx 9100001 to 91xxxxx Serial Number Range 9800001 to 98xxxxx 9900001 to 99xxxxx KDS-R50XBR1 ASU/DSU Assembly A-1152-715-A A-1152-715-B Optical Block A-1148-155-A A-1168-495-A Table A-2 KDS-R60XBR1 ASU/DSU Assembly &...
  • Page 102: 2005 Sxrd Service Mode Options

    Appendix 2005 SXRD Service Mode Options TVP-21...
  • Page 103 Appendix Service Mode Options There are 4 Service mode options for the  KDSR50/60XBR1 controlled by each Micro. Each Micro generates it’s own service OSD.  TV Micro: Use to display Software and NVM version  information. DM Micro: Use to display DMB test patterns, check tuning ...
  • Page 104 Navigating in Service Mode SERVICE MODE Item 1 Device 1 ・ ・ ・ Item Up/Down TV Micro Item n ・ ・ ・ Scroll Categories Buttons Device n Jump Buttons Button DM Micro Scroll Change Data Service Modes WE Micro Buttons DE Micro TVP21...
  • Page 105 Service OSD Path IC4610 IC951 Rook WE Service OSD To LCD IC7551 driver IC910 Bus SW Rook TV Service OSD IC7002 IC4200 TV Micro LVDS (RX) DE Service IIC DM Service OSD DE Micro IC7300 IC7342 LVDS (TX) TVP21...
  • Page 106 Appendix Verifying Micro Version To verify micro version:  Enter service mode [Display] + [5] +  [Vol. +] + [Power]. The first service item is VERSION.  Toggle the data from 0 to 1 with the  [3] button. Micro versions are displayed to the ...
  • Page 107 Appendix DMB Test Patterns The DMB is capable of displaying 2 sets of test  patterns. Service item “PATN” displays test patterns that take  the same path as the main video from the DMB. Service item “GTPN” displays test patterns that take ...
  • Page 108 Appendix DMB Test Patterns The available “PATN” test patterns for the DMB are listed below: Cross-hatch 1080i Color Bar + Color Ramp Window Color Bar White White/Blue Stair Step Horizontal Burst Horizontal Burst (Color) Horizontal Ramp Overscan Cross-hatch (thick) Diamond Dots White 480i 480i...
  • Page 109 Appendix C Board Test Patterns The Rook IC on the C board is capable of  displaying test patterns. These are very important in determining if a video defect is related to the Optical Block or prior video processing stage (ASU/DSU etc.) To display the C board test patterns take ...
  • Page 110 Appendix C Board Test Pattern Options To display flat color fields scroll to item 1 “IPT_RGB”  under Device 5 TEST_PAT with the [1] button. By default the data value will be 7 which displays an all white  screen. Press the [6] button to change data values and display the individual color fields.
  • Page 111 Appendix Electrical H/V Center Adjustment H/V center adjustment may be necessary if the optical  block is replaced. Unlike previous GW models H/V center is adjusted by the Rook ICs on the C board. Since the adjustment takes place at the end of the video ...
  • Page 112 Appendix H/V Center Adjustment Procedure Check H/V center with a monoscope  pattern with wide mode set to Full. Cross hair test pattern #11 can be used if no other source is available) To adjust H/V center take the following ...
  • Page 113 Appendix Lamp Timer To check the lamp timer take the  following steps: Enter Service mode [Display] + [5] +  [Vol. +] + [Power]. Press the [JUMP] button three times to  arrive at PANEL service mode. Once in PANEL service mode press ...
  • Page 114: Memory Stick

    Appendix DMB Diagnostics The following Information can be  determined in QM service mode: ATI Software version/System Status  Tuning status  POD Key  User and Service data can be saved to  memory stick. TVP-21...
  • Page 115: System Status

    Appendix System Status To view the system status Indicates SW version  page: Enter service mode [Display] +  [5] + [Vol. +] + [Power]. Press the [JUMP] button one  time to arrive at the DM service mode. Press the [3] button one time ...
  • Page 116 Appendix Confirming Tuning Status To check the tuning status:  Enter service mode [Display]  + [5] + [Vol. +] + [Power]. Press the [JUMP] button one  time to arrive at DM service mode. Press the [3] button seven ...
  • Page 117 Appendix Confirming Host ID and I.Link Status Verify memory stick status (if To check the Host ID, I.Link  memory stick is inserted) and MS status: Enter service mode [Display] +  [5] + [Vol. +] + [Power]. Press the [JUMP] button one ...
  • Page 118 Appendix User/Service Data Memory Stick Read/Write Feature The Digital Module service mode includes a  feature that will allow the user/service data stored within the Digital Module to be read/written to a Memory Stick. This feature allows for a module to be replaced by Service personnel while preserving the user’s TV configuration data.
  • Page 119 Appendix Writing User/Service Data to Memory Stick When the DMB is replaced user  data can be saved to memory stick as follows: Enter Service Mode [Display] + [5]  + [Vol. +] + [Power]. Once in service mode press the ...
  • Page 120 Appendix Saving User/Service Data to DMB When the DMB is replaced user  data can be written to the new DMB as follows: Enter Service Mode [Display] + [5]  + [Vol. +] + [Power]. Once in service mode press the ...
  • Page 121 Appendix User Menu H/V Adjustment To adjust the user  graphics position: Enter service mode  [Display] + [5] + [Vol. +] + [Power]. Press the [JUMP] button  one time to arrive at DM service mode. Scroll to item 8 GFXX or ...
  • Page 122 Sony Electronics 2005 Sony Electornics, Inc. EMCSA - A Service Company 1 Sony Drive Park Ridge, New Jersey 07656 TVP211205 12/30/05 Reproduction in whole or part without written permission is prohibited. All rights reserved...

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