Sony KV-32HS500 Training Manual

Sony KV-32HS500 Training Manual

Direct view/projection television troubleshooting, da-4 & da-4x chassis
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KV-36HV500
Direct View/Projection
Television Troubleshooting
DA-4 & DA-4X Chassis
Models:
DA-4
KV-32HS500
KV-32HV600
KV-34XBR800
KV-36HS500
KV-36XBR800
KV-40XBR800
Theory of Operation & Practical Troubleshooting Tips
Course: C31P15
DA-4X
KP-57WV600
KP-57WV700
KP-65WV600
KP-65WV700
Training Manual
KV-57WV700

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Summary of Contents for Sony KV-32HS500

  • Page 1 Training Manual KV-36HV500 KV-57WV700 Direct View/Projection Television Troubleshooting DA-4 & DA-4X Chassis Models: DA-4 DA-4X KV-32HS500 KP-57WV600 KV-32HV600 KP-57WV700 KV-34XBR800 KP-65WV600 KV-36HS500 KP-65WV700 KV-36XBR800 KV-40XBR800 Theory of Operation & Practical Troubleshooting Tips Course: C31P15...
  • Page 2: Table Of Contents

    Table of Contents 1. DA-4 & DA-4X Introduction and 5. DA-4 & DA-4X Video Procesing ..45 PCB Interconnection ......1 DA-4 & DA-4X Acceptable Inputs ....45 Introduction ............1 Overall Block Diagram ........45 6. DA-4 & DA-4X Chassis DA-4 & DA-4X PCD Interconnection ....1 Deflection Circuit .........51 2.
  • Page 3: Pcb Interconnection

    1. Introduction and DA-4 & DA-4X PCB Interconnection Chapter 1 - Introduction and DA-4 & DA-4X PCB Interconnection Introduction Overview The C31P15 course covers the DA-4 (Direct View) and the DA-4X (Projection) chassis. The content includes new features such as Memory Stick and DVI. Also included is theory of operation and troubleshooting tips for all major circuits (Power Supplies, Protection, Deflection, Communications and Audio) in the DA-4 and DA-X chassis.
  • Page 4 1. Introduction and DA-4 & DA-4X PCB Interconnection • • Board Level Additional H-Protect H-Protect • • Repair Circuits on DA- V-Protect V-Protect • • 4X chassis: AD-DRC AD-DRC • • • MID-XA MID-XA Extra • • HD-ADC HD-ADC • •...
  • Page 5 1. Introduction and DA-4 & DA-4X PCB Interconnection • • Possible KV-40XBR800 Component ONLY Correction • Level Repair Correction • Power Supply Possible DA-4X chassis Component ONLY • Unreg. 7V Level Repair • Unreg. 5V • +/- 15V • +/- 19V •...
  • Page 6 1. Introduction and DA-4 & DA-4X PCB Interconnection • • Board Level All models and Memory Memory Repair both DA-4 and Stick® Stick® DA-4X Processor Processor chassis’s Different Part# for DA-4 & DA-4X • • Board Level DA-4X chassis Flash Repair ONLY Focus...
  • Page 7 1. Introduction and DA-4 & DA-4X PCB Interconnection Figure 1-1 illustrates the PCB interconnections for both the DA-4 and DA-4X chassis. DVI MOLEX ANTENNA CONNECTOR SPEAKERS SWITCH HA/HC (XBR) INPUT KV40XBR 800 ONLY KEYS CONVERTER SIRCS LANDING AC/DC POWER CORRECTION AUDIO POWER MAIN MICRO MAIN MICRO...
  • Page 8: New Features (Da-4 Chassis)

    2. New Features (DA-4 Chassis) Chapter 2 - New Features (DA-4 & DA-4X Chassis) Three new features will be discussed in this section: • Scrolling Index • DVI Interface • Memory Stick® Interface Scrolling Index The Scrolling Index allows you to select your main video from a scrolling index of video pictures.
  • Page 9 2. New Features (DA-4 Chassis) accommodating uncompressed digital data such as HD video. DVI also has the bandwidth to support higher audio fidelity. DVI has a bandwidth of up to 5 Gigabits/sec, which is more then enough to accommodate an uncompressed HD video transmission that typically requires 2.2 Gigabits/sec bandwidth.
  • Page 10: Memory Stick® Interface

    Ø Compression format: JPEG Ø File format: DCF compliant NOTE: Most Sony brand digital still and video cameras automatically record still images using DCF (Design rule for Camera File system) compliant directory and file names as shown in Figure 2-3:...
  • Page 11 The DA-4 and DA-4X Memory Stick® viewer cannot display any of the following: Ø Images recorded on digital still cameras and digital video cameras that are not Sony brand. Ø Images recorded using products that are not DCF complaint, including the following Sony products: •...
  • Page 12 2. New Features (DA-4 Chassis) Memory Stick Interface and Processing Block MEMORY STICK CN7201 HM BOARD MS-SDI+ MS-INS MS-SCLK+ MS-SDO+ MS-DIR+ MS-BS+ MS-SDI 3.3V MS-DIR- MS-SCLK- MS-SDO- MS-BS- CN7202 CN3603 DIFF. - AMPS TO CRT & BUFFER DRIVE B BOARD CN3601 CN104 MS1 BOARD...
  • Page 13 2. New Features (DA-4 Chassis) 100us 100us Waveform 2-2 Waveform 2-1 MS - SDI (-) MS - SDI (+) The MS-INS is applied to the B Board/pin B3 and forwarded on to the MS1- Board. The MS-Data signals are amplified on the HM-Board and then applied to the B Board/pins A4/B4 through A8/B8 where they are converted from differential format to single data lines, and further amplified and applied to the MS1-Board.
  • Page 14: Power Supply (Da-4 & Da-4X Chassis)

    3. Power Supply (DA-4 & DA-4X Chassis) Chapter 3 - Power Supply (DA-4 & DA-4X Chassis) This chapter will cover the power supply section for both the DA-4 and DA-4X chassis. The degauss circuit for the DA-4 chassis will also be discussed. The power supplies for the DA-4 and DA-4X chassis are almost identical except in the following two main areas: 1) High Voltage (HV) development: The HV on the DA-4 chassis is Switch-mode power supply derived, whereas the HV on the DA-4X chassis is scan derived.
  • Page 15 3. Power Supply (DA-4 & DA-4X Chassis) DA-4 Overall Power Supply Block Description Once 120V AC power is applied to the TV set (set plugged into the AC outlet), the Standby 5V power supply (located on the A-board) is active and outputs regulated 5V (reference Figure 3-1). The STBY 5V is sent to the M-board to partially power-up system control IC2300 and is also sent to the HA/HC board to power the Remote Control Sensor (SIRCS).
  • Page 16 3. Power Supply (DA-4 & DA-4X Chassis) Three relay clicks will be heard when the set is first turned on in the following order: 1) Degauss Relay (RY501) 2) AC Relay (RY6501) 3) Inrush Current Relay (RY6502) DA-4 STBY 5V Power Supply and Power-On Switching Circuit TO D-BOARD T502 AC TO D6530...
  • Page 17 3. Power Supply (DA-4 & DA-4X Chassis) Power-ON Switching Circuit Reference Figure 3-2 during the following circuit description: In the Standby mode, System Control (IC2300) is partially powered (using STBY 5V) and waiting for an ON command from either the Front Panel Controls (IC2300/pins 93 and 94) or the Remote Control (IC2300/pin 7). Once the ON command is received, IC2300/pin 69 (AC_RLY) outputs a high, which is applied to the base of Q6527 (turning Q6527 ON).
  • Page 18 3. Power Supply (DA-4 & DA-4X Chassis) DA-4 Main Switching Power Supply Circuit TO A BD. A-BOARD AUDIO VCC CN6701 CN514 (36.5V) D6530 AC RECT. CN6503 TO IC8002/PIN 1 HV POWER SUPPLY UNREG D6513 C6546 T6502 FROM RY6501 L6516 PS6506 R6526 R6646 D6516...
  • Page 19 3. Power Supply (DA-4 & DA-4X Chassis) Main Switching Power Supply Operation Reference Figure 3-3 for the following circuit description: AC signal is applied to the rectifier block D6530. The AC component is filtered-out by the filter circuit (shown in block form).
  • Page 20 3. Power Supply (DA-4 & DA-4X Chassis) Over Voltage Protection (OVP) and Under Voltage Protection (UVP): The voltage at IC6501/pin 8 (VC1) is monitored by circuitry inside IC6501 for Under-voltage and Over-voltage conditions. The two conditions are as follows: OVP – greater than 33V UVP –...
  • Page 21 3. Power Supply (DA-4 & DA-4X Chassis) DA-4 High Voltage (HV) Power Supply Circuit R8054 R8055 FROM D6530 AC-RECT. R8051 T8001 ARCING 116V R8058 R8053 PROTECTION V-SENSE Q8014 CIRCUIT D8015 IC8002 D8012 2.4V R8056 R8085 D8030 D8013 3001D L8002 121V R8096 111V Q8013...
  • Page 22: Da-4X Chassis Power Supply

    3. Power Supply (DA-4 & DA-4X Chassis) DA-4X Chassis Power Supply VD501 T510 T511 STBY 5V A BOARD STBY 5V POWER SUPPLY INPUT FH501 CN514 CN6701 FROM Q6503 UNREG 7V G BOARD UNREG 11V RY6701 RELAY) UNREG 5V FROM D508,D509 MAIN POWER R6705...
  • Page 23 3. Power Supply (DA-4 & DA-4X Chassis) • Unreg-5V • Unreg-11V • • • 36.5V • +135 The +200V, HV, FV, G2, and Heater are all scan derived on the D-board in the DA-4X chassis. The horizontal output Q8043 drives T8004 to produce the +200 and Heater voltages, and also drives T8005 (FBT) to produce HV, FV, G2 and ABL voltages.
  • Page 24 3. Power Supply (DA-4 & DA-4X Chassis) Standby 5V Power Supply Reference Figure 3-6 during the following circuit description: The Standby Power Supply (located on the A-board) is operational as long as the set is plugged into an AC outlet. AC power is applied to T502 through fuse FH501, and chokes L510 and L511.
  • Page 25 3. Power Supply (DA-4 & DA-4X Chassis) DA-4X Main Switching Power Supply Circuit D6519 A-BOARD CN6701 36.5V CN514 C6560 R6702 FROM R6508 RY6701& L6701 D6702 RY6702 T6703 D6511 R6710 UNREG R6712 PS6508 PS6509 D6502 R6711 279V UNREG 141V R6714 V-SENSE 2.7V Q6701 IC6701...
  • Page 26 3. Power Supply (DA-4 & DA-4X Chassis) Main Switching Power Supply Operation Reference Figure 3-7 for the following circuit description: AC signal is applied to the rectifier block D6702. The AC component is filtered-out by the filter circuit (shown in block form).
  • Page 27 3. Power Supply (DA-4 & DA-4X Chassis) UVP – less then 8V If either of these two conditions occurs at IC6501/pin 8, the unit will go into protection mode. The self- diagnostic indicator will flash four time times, pause and then repeat. Troubleshooting Tips (ref.
  • Page 28: Da-4X Regulators

    3. Power Supply (DA-4 & DA-4X Chassis) DA-4 & DA-4X Regulators DA-4 & DA-4X Regulator Interconnect Diagram D BOARD DA4X ONLY IC8010 UNREG 7V DA4 & DA4X A BOARD *IC8004 (DA4X) IC6500 +15V 12V REG IC504 5V REG UNREG 7V IC502 3.3V 3.3V REG...
  • Page 29: Protection Circuits

    4. DA-4 & DA-4X Protection Circuits Chapter 4 - DA-4 & DA-4X Protection Circuits DA-4 Protection Circuits M BOARD Overall Block Diagram SYSCON AC-RELAY IC2300 CHASSIS TEMPERATURE AC RELAY (7X) PROTECTION RY6501 DATA TH5002 D BOARD CRT DRIVE Q6527 IC2801 B+ OCP Q5004 (2X)
  • Page 30 4. DA-4 & DA-4X Protection Circuits The important thing to note on this diagram is the protection circuits that have a direct connection to the CPU and those that do not. The protection circuits that have a direct connection will produce a more reliable flash sequence e.g.
  • Page 31 4. DA-4 & DA-4X Protection Circuits DA-4 Direct AC-Relay Shut-Off Protection Circuits FROM IC2300 R6509 R6528 TO AC RELAY AC_RLY RY6501 Q6527 M-BOARD R6530 R6532 Q6530 +135V D-BOARD Q6532 R8040 C6596 R6537 IC2300 R6538 R8039 (INRUSH) (B+ OVP) (LOW HV) (OCP) R8038 D6537...
  • Page 32 4. DA-4 & DA-4X Protection Circuits Inrush Current Relay Protection Circuit (Reference Figure 4-2) The current rating of the AC relay (RY65010) is 117mA at 153VAC. To keep the current below 117mA resistor R6515 (Inrush Current Resistor) is in series with the AC input during the initial power-up of the TV. After the initial power-up current surge, R6516 is bypassed when RY6502 (Inrush Relay) is energized and the switch is closed.
  • Page 33 4. DA-4 & DA-4X Protection Circuits High is applied to the base of Q6532, turning it ON, which then applies a Low to the base Q6530, turning it ON (activating the latch). Once the latch is activated, the voltage at the base of Q6527 is reduced and it turns OFF, removing the ground path for the AC Relay and it turns OFF.
  • Page 34 4. DA-4 & DA-4X Protection Circuits Both comparators receive a sample of the HV from FBT/pin 5, which is input to IC8001/pin 5 and IC8001/pin3. A reference voltage (Vref) of 2.2V is developed at IC8014/pin 3 and applied to IC8001/pins 2 and 6. Once the voltage at either IC8001/pin 5 or 3 increases above the reference voltage due to an excessive HV conditions, a High will be output at either IC8001/pin 7 or 1.
  • Page 35 4. DA-4 & DA-4X Protection Circuits DA-4 Temperature (Q5031), B+OCP, Vertical Deflection Protection Circuits M-BOARD D-BOARD B-BOARD IC2300 SYSCON AC RELAY IC2801 V-PROT. RY6501 IO-SDAT H-PROT. R2824 +135V V-DY (-) FEEDBACK D5006 R5104 R8040 CN5002/PIN 5 D8007 Q5018 R5105 R8039 Q5010 R5164 R8038...
  • Page 36 4. DA-4 & DA-4X Protection Circuits The TV video is muted, the AC relay shuts down and the Stby/Timer LED flashes a 7X sequence. B+OCP Protection Circuit (Reference figure 4-4) The current in the +135V line is monitored using R5013 and Q5004. R5013 is the current sensing resistor. The current in the +135V line flows directly through R5013.
  • Page 37 4. DA-4 & DA-4X Protection Circuits In vertical shut down mode, only the video is muted, the AC power and Audio remain ON and the Stby/ Timer LED flashes a 4X sequence. DA-4 Regulated 5V and White Balance Protection Circuit AC RELAY RY6501 IC2300 SYSCON...
  • Page 38 4. DA-4 & DA-4X Protection Circuits White Balance Protection Circuit (IK Protection) (Reference Figure 4-5) The condition of each CRT cathode (RGB) must be monitored in order to maintain optimal white balance. Each cathode is monitored by the individual driver IC9001, 9002 and 9003 on the CH/CX board. Each driver IC9001/ pin 7, IC9002/pin 7 and IC9003/pin 7 develops an IK feedback pulse, which is directly proportional to the current drawn by each cathode in the CRT.
  • Page 39: Da-4X Protection Circuits

    4. DA-4 & DA-4X Protection Circuits DA-4X Protection Circuits Overall Block Diagram M BOARD AC-RLY LOW B+ SYSCON AC RELAY (5V) IC2300 RY6701 Q2314 DATA Q6503 B BOARD LATCH Q6502, Q6504 G BOARD IC2801 Y/C CRT DRIVE D6523 D6526 D6525 D6527 IN RUSH RELAY...
  • Page 40 4. DA-4 & DA-4X Protection Circuits (Reference Figure 4-6) Q2314 monitors the 5V dc level. If the dc level falls below 4.5V, Q2314 detects this error and the AC input is disconnected. RY6702 is used to remove the Inrush Current resistor from the AC input circuit after initial set turn-on. If the relay failures to activate, AC input is disconnected.
  • Page 41 4. DA-4 & DA-4X Protection Circuits DA-4 Direct AC-Relay Shut-Off Protection Circuits TO AC RELAY RY6701 R6525 D6524 FROM IC2300 Q6503 R6523 AC RELAY R6504 R6526 Q6502 Q6504 C6575 R6528 R6527 (INRUSH) (+15 OVP) (B+ OCP) (B+ OVP) (AC PROT.) D6523 D6525 D6507...
  • Page 42 4. DA-4 & DA-4X Protection Circuits Once the latch is activated, the voltage at the base of Q6503 is reduced and it turns OFF, removing the ground path for the AC Relay and it turns OFF. The TV shuts down and the Stby/Timer LED flashes a 7X sequence +15 OVP (Reference Figure 4-7) The circuit monitoring the condition of the +15V line is a simple 20V zener diode.
  • Page 43 4. DA-4 & DA-4X Protection Circuits DA-4X Horizontal, Vertical, IK, and HV Protection Circuits IC2801 IC2300 Y/C CRT DRIVE SYSCON SDAT H PROT. V PROT M BOARD B BOARD C2828 CN2804 CN510 R2862 A BOARD CN508 CN803 Q9102 Q9104 IC8005/ R8260 PIN 16 V-DY...
  • Page 44 4. DA-4 & DA-4X Protection Circuits HV Protection (Reference Figure 4-8) Also attached to the H-Prot. input IC2801/pin 57 is the HV-PROT. This circuit is actually monitoring two functions: HV OVP and Beam Current through D8043 and D8025 respectively. If an excessive HV or Beam current condition should occur, IC8006/pin 5 will go High, which will cause IC8006/pin 7 to output a High.
  • Page 45 4. DA-4 & DA-4X Protection Circuits DA-4X HV OVP, and FBT OCP Protection Circuits Q8042 T8006 Q8041 C8160 H-DRIVE FROM IC2801 +135V D BOARD Q8022 Q8021 R8198 R8132 R8131 R8195 IC8007 IC8006 R8194 R8193 +15V R8192 R8169 REF. REF. (FBT +15V D8043 D8025...
  • Page 46 4. DA-4 & DA-4X Protection Circuits As the current in the FBT secondary increases, the ABL line will pull increasingly more current through the voltage divider network at the top of R8190 and less current will flow through R8190. The voltage drop across R8190 will decrease, causing the combined voltage drop across R8191 and R8190 to decrease.
  • Page 47: Da-4X Video Procesing

    5. DA-4 & DA-4X Video Processing Chapter 5 - DA-4 & DA-4X Video Processing DA-4 and DA-4X Acceptable Formats The acceptable inputs for these chassis are listed in Table 5-1: Table 5-1 - DA-4 and DA-4X Inputs Inputs Format Analog TV stations Air (Ch.
  • Page 48 5. DA-4 & DA-4X Video Processing Video Processing Circuit Description (Reference Figure 5-1) 5 ms The Main and Sub Tuners are located on the A board. The video path is through the M board for each tuner starting at the A board CN525/pins 39 and 49, which connects to the B board CN2302/pin 39 and 49;...
  • Page 49 5. DA-4 & DA-4X Video Processing Video inputs 5 and 6 are also located on the U board, but are connected to IC1505 Video Switch. Video inputs 5 and 6 are component inputs. The component signal outputs from IC1505 can be viewed at Cn1502/ pins B17 (Y), A16 (PB) and B14 (PR) reference Waveforms 5-4 and 5-5.
  • Page 50 5. DA-4 & DA-4X Video Processing All the video signals pass through the A-board unprocessed and are then applied to the B-board through CN2002 (A-board) and CN3203 (B-board). All video processing is performed on the B-board (DRC and MID processing). The DRC circuit will double the horizontal frequency for input signals with 15.75KHz (NTSC) horizontal inputs.
  • Page 51 5. DA-4 & DA-4X Video Processing CH BOARD IC9001 V-IN Q9009 200V IC9002 Q9010 V-IN 200V Q9001 B BOARD IC9003 Q9011 V-IN D BOARD 200V 200V HEATER FIGURE 5-3 - DA-4 CH BOARD (HS) C31P15-5-3 10/7/02 Troubleshooting (Board Level) (Reference Figure 5-1) The DA-4 and DA-4X chassis’s video processing circuits can be evaluated to board level simple by using the various inputs.
  • Page 52 5. DA-4 & DA-4X Video Processing Video Inputs 5 and 6: (1080i Input) Note: 480i will add the DRC circuit IC1505 Video Switch (U-borad) before the MID circuit. IC2006 Component I/F (M-board) MID circuit (B-board) IC2801 CRT Drive (B-board) DVI Input IC1505 Video Switch (M-board) MID circuit IC2801 CRT Drive (B-board)
  • Page 53: Deflection Circuit

    6. DA-4 & DA-4X Deflection Circuits Chapter 6 - DA-4 & DA-4X Chassis Deflection Circuits 152Vp-p DA-4 Horizontal Deflection Circuit B BOARD HDT T5002 R5151 Q5026 12Vp-p R5126 R5150 IC2801 C5071 R5129 CN508 CN5009 Q5036 JUNGLE C5070 18 18 Q5035 Q5028 CN510 CN2804...
  • Page 54 6. DA-4 & DA-4X Deflection Circuits PWM Circuit (Reference Figure 6-1) The PWM circuit (Q5003) has two functions. First, it provides a regulated 102Vdc output for the horizontal output transistor Q5030. Second, it compensates for horizontal pincushion affect and keeps the picture vertical edges straight.
  • Page 55: Vertical Deflection Circuit

    6. DA-4 & DA-4X Deflection Circuits DA-4 Vertical Deflection Circuit +15V -15V IC5004 V-DRIVE FB-PCS V-OUT BOOST B BOARD 1.5Vp-p IC2801 C5019 D5002 JUNGLE CN509 CN5001 V-PROT. VD(-) +15V 2828 2727 VD(+) D BOARD CN510 CN2804 L5001 R5029 A BOARD V-DY 1.7Vp-p 61Vp-p...
  • Page 56: Da-4X Horizontal Deflection Circuit

    6. DA-4 & DA-4X Deflection Circuits DA-4X Horizontal Deflection Circuit +12V HDT T8002 1kVp-p Q8024 B BOARD R8123 +135V 3.5Vp-p R8125 Q8023 IC2801 C8059 CN508 CN8031 JUNGLE 1818 Q8030 104Vp-p R8119 CN2804 CN510 IC8009 A BOARD FROM H-CENT H-DY(B) PS8005 Q8039 H-CENT D BOARD...
  • Page 57: Da-4X Vertical Deflectin Circuit

    6. DA-4 & DA-4X Deflection Circuits The pulses are amplified and output to the HOT T5001/pin 4. To control the output voltage, the horizontal output is sampled (IC8005/pin 12) and used to change the pulse width of the H drive pulses. These changes regulate the output voltage to +102Vdc at T5001/pin 4.
  • Page 58: Da-4X Chassis Communication Bus Networks

    7. DA-4 & DA-4X Data Communication Bus Networks Chapter 7 - DA-4 & DA-4X Data Communication Bus Networks There are three data communications networks used in the DA-4 and DA-4X chassis’s. All three consist of data and clock lines, which communicate with multiple ICs. Refer to Table 7-1. Table 7-1 - Data Communications Bus Networks Network Location...
  • Page 59 7. DA-4 & DA-4X Data Communication Bus Networks (Reference Figure 7-1) Main Micro IC2300 generates the clock signal for communications bus network SDAT, SCLK and BDAT, BCLK. Bus network SDAT, SCLK is used to send data to most of the ICs in the TV set. Network BDAT, BCLK is dedicated communications to the NVM IC2302 on the M-board.
  • Page 60: Da-4X Audio Circuits

    8. DA-4 & DA-4X Audio Circuits Chapter 8 - DA-4 & DA-4X Audio Circuits DA-4 and DA-4X Audio Block Diagram FROM HB AUDIO OUT J1501 J1501 J1501 J1501 CN2006 CN2006 J1509 J1508 BOARD J1502 A1LR A3LR A4LR A7LR TU1LR TU2LR A5LR A6LR A2LR...
  • Page 61 8. DA-4 & DA-4X Audio Circuits (Reference Figure 8-1) IC1502 is an Audio/Video Switch (located on the U-board), which selects both audio and video using the I C bus from Main Micro IC2300 (not shown). The following audio inputs are available to IC1502: •...
  • Page 62 , HDTV and Memory Stick are trademarks of Sony Electronics ©2002 Sony Electronics Inc. EMCS - A Service Company 1 Sony Drive C31P15112 11/15/02 Park Ridge, New Jersey 07656 Reproduction in whole or part without written permission is prohibited. All rights reserved...

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