Training Manual

KDL40XBR9

EX-2M Direct-View LCD Television Chassis

Circuit Description and Troubleshooting Guide
MODELS:

KDL40Z5100 KDL40XBR9
KDL46Z5100 KDL46XBR9
KDL52Z5100 KDL52XBR9

Course : CTV-57

Table of Contents
Chapter 1 Introduction ..................................................... 1

Analog Signals ...................................................................... 12

Overview.......................................................................... 1
Features .......................................................................... 1

USB1.1 (DMEX) .................................................................... 12

Full HD 1080 Panel.............................................................. 1

240HZ Motionow ............................................................ 1
Enhanced Cross Media Bar (XMB)...................................... 1
BRAVIA Internet Video ..................................................... 1
USB2.0 Side Input ............................................................... 2
HDMI 1.3.............................................................................. 2
Consumer Electronics Control (CEC) ..................................... 2
xvYCC ..................................................................................... 2
Deep Color .............................................................................. 2

USB 2.0 Input ........................................................................ 12

Digital Media Port .................................................................. 12
Ethernet Port ......................................................................... 13
PC Input ................................................................................ 13
Front End Microprocessor and Decoder ............................... 13
LCD Panel ............................................................................. 13

No Video ............................................................................ 15
Video Distortions................................................................ 15
Troubleshooting Flowchart ................................................ 15

Advanced Contrast Enhancer (ACE) ................................... 2

Chapter 4 Audio Process Circuits ................................. 18

Overview........................................................................ 18

Digital Media Port ................................................................ 2

General Audio Processing ................................................. 18

Digital Media Extender (DMEX) ........................................... 2

HDMI.................................................................................. 18

Interactive Program Guide (IPG) ......................................... 2

USB 2.0 ............................................................................. 18

Digital Living Network Alliance (DLNA) ................................ 2

Ethernet (DLNA) ................................................................ 18

Bravia Sync ....................................................................... 2

Chapter 2 Overall Circuit Descriptions ........................... 3

Overview.......................................................................... 3
Overall Block Diagram ..................................................... 3
Board Layouts...................................................................... 4

Chapter 3 Video Process Circuits ................................. 12

Overview........................................................................ 12
Video Process Circuits....................................................... 12

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HDMI Inputs .......................................................................... 12

Optical Output .................................................................... 18

Troubleshooting ............................................................. 18
Chapter 5 - Power Supply and Protection ....................... 20
Overview........................................................................ 20
Power Supply ................................................................ 20
40-inch Models .................................................................. 20
46 and 52-inch Models ...................................................... 20

Protection ...................................................................... 23
i

Table of Contents (Continued)

Diagnostics History ........................................................ 23
Troubleshooting Test Points .......................................... 23
Chapter 6 - Panel Backlight Circuits ................................ 30
Overview........................................................................ 30
40-inch Backlighting........................................................... 30
Power-on Sequence ............................................................. 30
Inverters ................................................................................ 30

52-inch Backlighting........................................................... 32

Troubleshooting .................................................................
Inverter Failures .....................................................................
Balancer Errors ......................................................................

Troubleshooting Flowchart ................................................

Chapter 7 Appendix ........................................................ 36
LCD Panel Troubleshooting........................................... 36
LCD Panel Basics .............................................................. 36
Panel Failures .................................................................... 37
Physical Failures ................................................................... 37

TCON Failures ................................................................... 39

Troubleshooting a Dead TCON .......................................... 40

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ii

Chapter 1 Introduction
Overview

240HZ Motionow

The EX-2M chassis is one of several designs for the 2009 model line of
Sony Bravia LCD televisions. Several models will be released during the
rst half of 2009. This training manual will cover the rst batch of models
and will include the following:

A frame-quadrupling circuit utilizing proprietary circuitry and algorithms is

able to capture and compare the movement from one frame to another. By
anticipating the location of a moving object, additional frames are inserted
to increase the frame refresh rate from 60HZ to 240HZ. The result is an
exceptionally smooth picture during fast moving objects and scenes. This
feature is available on all of the Z5100 and XBR9 models.

KDL40Z5100
KDL46Z5100
KDL52Z5100
KDL40XBR9
KDL46XBR9
KDL52XBR9
The chassis design revolves around the video processing circuits located
on the BU board. The key difference between models is determined by
the size of the LCD panel and its manufacturing source. This manual will
describe the new circuit features and individually describe the models
based on these differences.

Features
Several new features are introduced in the EXM chassis model lineup
along with some carryovers from the previous year.

Full HD 1080 Panel

All models have a 1920 X 1080 native resolution panel. All video signals
exit the video process circuits as 1080p 60HZ. The RGB resolution is 10bit to provide 1,024 levels of gray scale for improved picture resolution.

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The customer has the option of changing the settings of the Motion
Enhancement and Motion Compensation circuits to smooth the judder
inherent with 24-frame lm-based content or can choose keep the judder
for a lm-like experience.

Enhanced Cross Media Bar (XMB)

A new graphics user interface with rich 3-D graphics allowing the user to
customize the setup of the television and to access various adjustments
and control of optional devices. Optional external devices can also be
detected and displayed. One example would be when a USB storage
device is plugged into the USB2.0 side input that contains JPEG format
photos. The detection of the device will appear in the XMB graphics icons
along with thumbnail views of the photos stored on the device. The photos
can be viewed individually or be displayed as a slide show.

BRAVIA Internet Video

Once available as an optional device to connect to the television, this
feature is now an integral part of the product. The rear of the television
contains an Ethernet port to connect to a high speed network. Access to
online music and video through partnered websites is possible.
Personalized widgets are small applications that can be placed on the
screen and accessed with the touch of a button to bring up programming
such as weather, stocks and sports information.

Chapter 1 - Introdcution

USB2.0 Side Input

Advanced Contrast Enhancer (ACE)

This feature was available in selected 2008 models and allowed the
viewing of JPEG formatted pictures and playback of MP3 audio les. The
media content has been expanded this year to allow playback of MPEG2
format video content.

By monitoring the overall level of the video signal, the backlights are
dynamically controlled and reduced during low light level scenes to
enhance the contrast ratio.

HDMI 1.3

Digital Media Port

This new version of HDMI introduces several new enhancements and

features and the EX2M chassis supports 3 of the new features.

This port allows for the hookup of optional devices that provide an
interface with portable digital media products such as MP3 players and
video cameras.

Consumer Electronics Control (CEC)

Digital Media Extender (DMEX)

A standardized protocol for the control of consumer electronics devices

allows for communication and control via the HDMI cable on products that
have this feature. Any brand of electronic equipment that is CEC compliant
can communicate with another to generate operational commands. The
Bravia Sync feature uses the CEC format to control other Sony devices
in the system.

xvYCC
The previous color bandwidth limitations applied for compatibility with
analog signals are no longer present with digital signals. This allows for
1.8 times more colors.

Deep Color
The previous HDMI specications limited the RGB sample level to 24-bit.
Deep Color expands this up to 48-bit giving the ability to generate a color
depth of 2.8 trillion levels.

Bravia Sync
By utilizing the CEC feature of HDMI 1.3, this feature allows the customer
to easily control the various Sony devices within their home entertainment
system provided that all of the other devices have this feature included.

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A USB 1.0 port is provided in the rear of th unit to provide a digital

connection path to control optional modules such as the BRAVIA DVD
Link and BRAVIA Wireless Link. Devices connected will automatically
appear on the XMB menu. This USB port is also used to install software
updates for thte television.

Interactive Program Guide (IPG)

An interactive guide is included to provide continuously updated program
information at no charge to the customer. The guide (provided by TV
Guide) is part of the XMB graphics feature. Program material is updated
from the local PBS station when the television is off.

Digital Living Network Alliance (DLNA)

An industry standard networking protocol has been developed by leading
manufacturers to allow other devices such as a compatible computer to
communicate with the television via an Ethernet connection to your home
network. This gives the ability to view photos, audio and movie content
directly from your computer via the network. Future plans include the
ability to download software updates for the television through the home
network.

Chapter 2 Overall Circuit Descriptions

Overview
The focal point of the EX2M chassis is the video processing circuits
located on the BU board. The digital decoder for ATSC signals along with
the video process IC remains the same among the models. The size of
the LCD panel used in each model is the primary difference in circuit
layout. Different power supplies and inverter circuits are used based in the
size of the LCD panel and the number of uorescent backlights.

Overall Block Diagram

The block diagram in Figure 2-1 illustrates an overall view of the various
circuits used for the various sized Z5100 and XBR9 models.

BU Board
Essentially the brains of the system, this board contains all of the input
sources for video and audio information along with an on-board ATSC/
NTSC combination tuner. It also contains all of the video and audio
switching and processing circuits. The front-end (FE) microprocessor is
contained within IC7000 and is responsible for all handling of the various
video resolutions that are input to the television along with the generation
of OSD graphics for the user menu. It also serves as the ATSC decoder
for the MPEG2 video and Digital Dolby audio content. The third function
is to process the various video formats and resolutions to insure that all
are scaled to the native resolution of the LCD panel. All video sources exit
the BU board as 10-bit RGB 1920 X 1080 at 60HZ refresh rate.
All audio processing is performed on the BU board. This includes switching,
A/D conversion of analog sources, equalization and amplication to drive
the speakers
The TV Micro IC3002 is located on the BU board. It is responsible for
control of the television via the user interfaces. Monitoring of key circuits
and voltages is also performed to provide protection of the unit and shut
it down if necessary along with providing diagnostics codes to assist in
determining the cause a failure.

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The BU board used in these models is specically congured for the panel
types and sizes used. Note that all input sources are directly connected to
the BU board. The past use of separate boards for input switching, tuner,
ATSC decoder and side video inputs has all been incorporated onto this
single board.

Power Supply
Models using the 40-inch LCD panel contain a G6N power supply whereas
the 46 and 52-inch models use a G7N power supply circuit.

Inverters
The inverters provide high voltage to the uorescent lamps via a oating
ground differential AC voltage. The 40 and 46-inch panels use the D1N
and D2N. The 52-inch panels use the same layout except the inverter
boards are known as the D3N and D4N.

Switch Unit
Known as the H1 board in previous models, this board contains the
power, channel up/down, volume up/down and menu control buttons. It is
located on the lower right side of the television as viewed from the front.

HL5 Board
Used exclusively in the XBR9 models, this board contains the POWER/
STANDBY, PICTURE OFF/TIMER and HD SIGNAL LEDs. It also contains
the IR receiver and photo sensor for ambient room light detection.

HL3 and HSN Boards

Used on the Z5100 models, the HL3 board contains the above listed
function LEDs. The HSN board contains the IR receiver and photo
detector.

Chapter 2 - Overall Block Diagrams

LCD Panel
All LCD panels in the Z5100 and XBR9 models have a resolution of 1920
X 1080 with 240HZ refresh rate. The backlights are Wide Color Gamut
Cold Cathode Fluorescent Lamps (WCG-CCFL)

Board Layouts
Figures 2-2 through 2-7 illustrate the circuit board locations for each model.
The Z5100 and XBR9 models are very similar with the exception of the
speaker layout and LED and IR receiver boards. These illustrations are
also useful to properly dress the wire harnesses when major component
replacements are performed.

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Chapter 2 - Overall Block Diagrams

RF
VIDEO 1

VIDEO 3
COMPOSITE/
COMPONENT 1

COMPONENT 2

COMPOSITE 2
HDMI 1
A/V DECODER
VIDEO PROCESS
VIDEO SWITCH
AUDIO PROCESS
AUDIO AMP
TV MICRO

DVI AUDIO

HDMI 2
HDMI 3

HDMI 4

240 HZ
HFR

TCON

PC HD15

L/R AUDIO OUT

OPTICAL OUT

LCD PANEL

USB 1.1

DIGITAL
MEDIA PORT

ETHERNET

BU

SONY
LOGO
MODULE

SWITCH
UNIT

LED & IR
RECIVER
(XBR9)

HL5

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LED
(Z5100)

HL3

IR
RECEIVER
(Z5100)

HSN

INVERTER

INVERTER

D1N (40/46")
D3N (52")

D2N (40/46")
D4N (52")

POWER SUPPLY

AC IN

FIGURE 2-1
OVERALL BLOCK DIAGRAM

G6N (40")
G7N (46/52")

Chapter 2 - Overall Block Diagrams

D1N

D2N

TCON

BU

G6N

SWITCH
UNIT

HL3

HSN

40Z5100 BOARD
FIGURE LOCATIONS
2-2

KDL40Z5100 BOARD LAYOUT

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Chapter 2 - Overall Block Diagrams

D1N

D2N

TCON

RIGHT
TWEETER

BU

LEFT
TWEETER

G6N

SWITCH
UNIT

HL5

RIGHT
SPEAKER
HOUSING

LEFT
SPEAKER
HOUSING

FIGURE 2-3
KDL40XBR9 BOARD LAYOUT
40XBR9 BOARD LOCATIONS

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Chapter 2 - Overall Block Diagrams

D1N
TCON

D2N

BU
G7N

SWITCH
UNIT

HL3

HSN

46Z5100 BOARD LOCATIONS

FIGURE 2-4
KDL46Z5100 BOARD LAYOUT
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Chapter 2 - Overall Block Diagrams

D1N
TCON

D2N

RIGHT
TWEETER

LEFT
TWEETER

BU
G7N

SWITCH
UNIT
HL5

RIGHT
SPEAKER
HOUSING

LEFT
SPEAKER
HOUSING

46XBR9 BOARD LOCATIONS

FIGURE 2-5
KDL46XBR9 BOARD LAYOUT
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Chapter 2 - Overall Block Diagrams

D3N

TCON

D4N

BALANCER

BU
G7N

SWITCH
UNIT

HL3

HSN

52Z5100 BOARD LOCATIONS

FIGURE 2-6
KDL52Z5100 BOARD LAYOUT
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10

Chapter 2 - Overall Block Diagrams

LEFT
TWEETER

RIGHT
TWEETER

D3N

TCON

D4N

BALANCER

BU
G7N

SWITCH
UNIT
HL5

LEFT
SPEAKER
HOUSING

RIGHT
SPEAKER
HOUSING

52XBR9 BOARD LOCATIONS

FIGURE 2-7
KDL52XBR9 BOARD LAYOUT
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11

Chapter 3 Video Process Circuits

Overview
All of the input switching and processing for the EX2M chassis is
accomplished on a single BU board. Even the side video inputs have
become part of this board. This signicantly affects troubleshooting and
parts replacement since the main goal of locating video failures is to
determine if the problem is located on the BU board or the LCD panel and
TCON board.
The BU board is the one common element among the various models
of the EX2M chassis and most of the features located on this board are
common. The part numbers for the BU boards is different based on what
LCD panel it is sending video to along with the proper communications
protocol for the TCON board.

Video Process Circuits

Referring to Figure 3-1 a simplied block diagram of the circuitry to select
and process all video signals is shown. The ATSC/NTSC combination
tuner is mounted directly on the BU board. All external input sources are
also mounted directly on the board. Descriptions for each of the major
components and functions are as follows:

Analog Signals
All analog signals are directly selected by IC7000. By monitoring the
selected input and its sync frequency, IC7000 will process the video
accordingly so that resolution is always 1920 X 1080p upon exiting the
BU board. The signal format is 10-bit RGB converted to LVDS format.

Note the Composite 1 and Component 1 input. Composite or component

input is possible via the same set of jacks. The Y component contains
a switch that is used to detect the insertion of a connector and this is
mainly used for the auto-detect feature if it is selected in the video input
and labeling feature. The R-Y connector also has a switch. If component
cables are inserted the unit will automatically switch to component input
mode. If a composite signal is input to the Y jack the unit will automatically
treat the signal accordingly. This input selection can also be forced to one
or the other within the customer setup menu.

HDMI Inputs
HDMI input selection is performed by IC5000 and sends the selected input
to IC7000. Unlike previous designs, there are no external EDID ICs for
each of the inputs. EDID information is now contained within IC5000.

USB1.1 (DMEX)
This USB input is labeled DMEX (Digital Media Extender) on the rear of
the unit. If the customer chooses to purchase optional Bravia Link devices,
such as DVD Link, this port will provide 2-way communication with that
device and links with the customer GUI interface. This port is also used to
input software upgrades to the television via USB storage devices.

USB 2.0 Input

USB storage devices that contain JPEG format pictures, MP3 audio les
and MPEG2 video can be plugged directly into the television for viewing
and/or listening. The XMB graphics will display thumbnails of the content
within the USB device.

Digital Media Port

Optional devices are available to hook up portable digital video and audio
devices to the television. Content can be viewed or listened to along with
the ability to control the connected device.

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12

Chapter 3 - Video Process

Ethernet Port
Devices that are DNLA (Digital Living Network Alliance) compliant can be
used in a network setup to view and listen to content from a network PC,
mobile devices, gaming consoles, etc. DNLA provides the standards to
allow many devices in the home to receive and send content among the
network.
Future plans include software upgrades that can be located on the internet
and downloaded to the television should it become necessary.

PC Input
Analog RGB input from a PC can be connected to the HD15 connector.
The video process circuits will support conventional resolutions from
640 X 480 VGA up to 1920 X 1080 HD. EDID information for the PC HD
material is also contained within IC5101

Front End Microprocessor and Decoder

IC7000 decodes the MPEG2 compressed ATSC signals received by
the tuner and separates the video and audio content. This IC is also
responsible for detection of video input resolutions and processing those
signals so that all video exiting the BU baord is 1920 X 1080p 60HZ.
Customer menu graphics are generated within IC7000.

LCD Panel
The LCD panel receives the 10-bit RGB video data from the BU board via
a Low Voltage Differential Signaling (LVDS) cable. IC7000 contains the
LVDS transmitter within and transmits a video resolution of 1920 X 1080
60HZ to TCON board. The TCON board contains a frame-rate quadrupling
circuit for a net refresh rate of 240HZ.

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13

Chapter 3 - Video Process

ATSC IF

TUNER

RF

NTSC CV

NTSC
AUDIO
TO DSP
D1_DET

COMPOSITE 1
COMPONENT 1
1920 X1080
60HZ

D1_PR_DET

IC7000
AMD

COMPOSITE 2
SIDE INPUT

240HZ
HFR

COMPONENT 2
HDMI 1
SIDE
INPUT

HDMI 2
HDMI 3
HDMI 4

IC5000
HDMI
SWITCH
EQ AND
EDID

TCON

LCD PANEL

DIGITAL MEDIA
PORT

PC HD15
IC5101
EDID

USB 1.1
ETHERNET
USB 2.0
SIDE INPUT

PHYSICAL
INTERFACE
PHYSICAL
INTERFACE

BU

FIGURE 3-1
OVERALL VIDEO PROCESS BLOCK DIAGRAM
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14

Chapter 3 - Video Process

Troubleshooting

Video Distortions

Since virtually all of the video inputs and most of the video processing is
located on the BU board, failures causing a loss of video or distortions
in the picture need to be isolated to the BU board or the LCD panel.
The combining of all video processing circuitry into 2 major components
makes the troubleshooting approach to seem rather simplistic and in most
cases it will be just so.

This is, by far, the most difcult failure to troubleshoot due to the many
sources that can cause it. Noise emanating from the power supply, outside
interferences, video process failures and even mechanical problems in
the LCD panel can cause video distortion.

As anyone who has experience servicing electronic products knows, things

happen in the real world that can cause failures which do not follow the
rules of the academic procedures found in this manual. Always research
the latest service bulletins and/or troubleshooting tips on the Sony service
website http://www.sony.com/asp before making the service call.

No Video
If a total loss of video occurs (including OSD graphics) the most likely
course of action is to bring a replacement BU board to the service location
since the unit is serviced at board-level only. It is unlikely that a loss of
voltage from the power supply is the cause since these voltages are
monitored and the unit will likely experience a protection shutdown event
rather than a no video condition. Although a failure of the backlights to
turn on would certainly cause a no video condition, this too would cause
the unit to shut down and indicate a failure via the self diagnostics feature.
If the replacement BU board does not resolve the issue, the LCD panel is
the only other likely culprit.
The presence of OSD graphics with a no video condition certainly
eliminates the LCD panel as the cause and the BU board will almost
certainly x the problem.

The up-side to display devices is that they are the most valuable tool in
determining the source of the problem so long as one knows the basic
theory of how they function. The Appendix section of this training manual
contains a section on basic troubleshooting of LCD panel televisions. The
primary objective when diagnosing no video or distortions in the video is
to eliminate the LCD panel as the cause. Replacement of the LCD panel
requires special authorization and, in some instances, will not be allowed
due to economical reasons.

Troubleshooting Flowchart
Due to the reduced number of circuit boards used in this chassis,
troubleshooting video problems must focus on whether the problem lies
on the BU board or the LCD panel. In a no video symptom the owchart
asks if the backlights are lit. Hypothetically, the backlights must light or the
unit will shut down and blink a balancer or inverter error but there have
been cases in previous chassis designs where the backlights do not light
and the unit did not enter the protect mode. The troubleshooting owchart
in Figure 3-2 will provide some guidance in diagnosing a video problem.

Service Tip: The BU board contains a ashing heartbeat LED visible in

the upper right corner. This is illustrated in Figure 3-2. Always observe this
green LED to make sure it is ashing. If it is steadily lit, IC7000 has failed
and is the certain cause of the no-picture condition. In virtually all cases of
a failure of IC7000 the LED will not ash. Some replacement BU boards
may not have this LED installed. Rarely does a failure on this board cause
an existing LED to not light at all.

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15

Chapter 3 - Video Process

IC7000 HEARTBEAT
LED

FIGURE 3-2
BU BOARD HEARTBEAT LED
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16

Chapter 3 - Video Process

All inputs?

Yes

Distortion
stationary ?

Video Failure

Distorted

Symentrical ?

BU Board

No

Active video
anywhere on
screen?

If no 6X or 13X
BU Board

Yes

OSD graphics
present ?

Yes

TCON or
LCD Panel

No

None

Backlights
turning on ?

BU Board

Yes

No

No video or
distorted
video?

No

No

BU Board

Yes

Yes

TCON or
LCD Panel

BU Board

No

Heartbeat
LED on BU
board flashing ?
No

BU Board

Yes

Unplug LVDS
connector at
TCON while unit
is running . This
may need to be
done more than
once

Any flashes
seen on
screen?

No

TCON
(LCD Panel )

BU IC7000
HEARTBEAT LED

Yes

BU Board

FIGURE 3-3
VIDEO TROUBLESHOOTING FLOWCHART
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17

Chapter 4 Audio Process Circuits

Overview

USB 2.0

All audio processing and amplication are performed on the BU board.

The path of the audio processing differs depending on the source. Figure
4-1 illustrates an overall block diagram of the audio circuits on the BU
board.

MP3 audio les can be input to the USB side jack. The USB device is
detected and a list of the available audio les can be viewed in the XMB
graphics menu. The audio can be listened to via the television speakers
or and external amplier hooked up to the L/R analog outputs or optical
output jack.

General Audio Processing

All analog audio processing is selected and performed by IC2003. The IC
contains internal switching circuits along with a digital signal processor
for equalizer and sound effects control. Analog signals are A/D converted
before being processed.
Digital audio sources are selected by IC7000. The audio information is
converted to I2S format for processing by IC2003. Note that IC2003 also
has an I2S line exiting to IC7000. This allows the graphics generator
inside IC7000 to insert sounds to the XMB graphics to create introduction
and selection sounds when the GUI is activated and as the customer
navigates through the graphics icons. This feature can be turned off in the
audio settings section of the setup menu.
Regardless of the audio source type, IC2003 outputs the processed audio
as PWM for amplication by IC2201. IC2301 outputs L/R analog to the rear
audio output jacks. Note that audio from a selected DMP device is routed
through IC2301 and then sent to IC2003 for processing. This is because
the audio signal from a DMP device is differential L/R and IC2003 cannot
accept this type of input. IC2301 converts the differential audio signal to
conventional L/R analog for use by IC2003.

HDMI
The 4 HDMI inputs are selected by HDMI switch and equalizer IC5000.
The serial audio data is received by IC7000 where it is converted to I2S
format. The I2S digital audio data is transmitted via the bus to IC2003.

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Ethernet (DLNA)
MP3 audio les may be read from a DLNA compliant computer on the
home network.

Optical Output
IC2003 outputs the SPDIF format signal for use by the optical output
transmitter. Included in Figure 4-1 is a truth table for the optical output.
The only time 5.1 channel audio is available from a tuner source is when a
digital ATSC source is received and 5.1 channel audio is being transmitted.
This includes terrestrial 8VSB and QAM from cable systems. If a DVD
player is connected via HDMI and the DVD output is set to 5.1, the output
from the optical jack will also be in 5.1 channel audio. Previous years of
Sony models did not pass the 5.1 channel audio from a DVD player and
down-converted it to 2-channel PCM. All analog sources are output as 48
KHZ 2CH PCM. The only time audio is not output is when digital audio is
input via the HDMI connectors from a SACD or DVD-Audio disc.

Troubleshooting
Since all circuitry involving audio processing and amplication is located
on the BU board, troubleshooting audio problems consists of determining
whether the failure affects all inputs or it is input specic. Failures affecting
all inputs would require changing the BU board whereas input specic
problems would require eliminating the input device as the source.

18

Chapter 4 - Audio Process

OPTICAL OUTPUT TRUTH TABLE

HDMI 1
HDMI 2
HDMI 3

HDMI 4

AUDIO SOURCE

IC5000
HDMI
SWITCH &
EQ

DIGITAL TUNER

5.1 OR 2CH PCM

DVD VIA HDMI

5.1 OR 2CH PCM

ALL ANALOG INPUTS

NTSC TUNER

IC7000
AMD

USB2.0
ETHERNET

ATSC/NTSC
TUNER

OPTICAL OUTPUT

2CH PCM
2CH PCM

SACD VIA HDMI

NO OUTPUT

DVD AUDIO VIA HDMI

NO OUTPUT

USB2.0

2CH PCM

ETHERNET

2CH PCM

DIGITAL

ANALOG
I2S
I2S

COMPOSITE 1
COMPONENT 1
COMPOSITE 2
COMPONENT 2
PC

IC2003
AUDIO SW
DSP

PWM

IC2201
CLASS D
AUDIO AMP

SPDIF

OPTICAL OUT

DVI

DIGITAL
MEDIA PORT

DMP
AUDIO

IC2301
LINE OUT
AMP

L/R AUDIO OUT

BU
FIGURE 4-1
AUDIO PROCESS CIRCUITS

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19

Chapter 5 - Power Supply and Protection

Overview
The EX2M chassis utilizes a power supply design that has been found in
Sony televisions for many years. A standby supply is constantly running
to generate the necessary 3.3V for the TV micro, IR receiver and other
circuits. Once the main relay is engaged at power-on, a Power Factor
Control (PFC) circuit is activated to boost the rectied AC voltage. The
primary switching supply is also activated to provide regulated 12V and
audio 15V.
Protection is provided by monitoring key voltages, temperature and proper
operation of the backlight lamps and high voltage circuits providing the
power to them.

Power Supply
40-inch Models
A block diagram of the power and protection circuits is shown in Figure
5-1. Once AC power is applied current ows through R6022 to provide AC
power to bridge rectier D6000. This supplies a continuous 160VDC and
is only used by the standby power supply.

The G6N board has areas of protection monitoring which includes PFC
over-temperature and various over and under-voltage monitoring (not
shown). The activation of any these protect lines will pull down and latch
the power on command entering pin1 of CN6100. The REG12V line is
monitored by TV micro IC3002 on the BU board so any time a protection
circuit is activated on the G6N board the unit will shut down with a 2-blink
diagnostics error.

46 and 52-inch Models

Since these models use the G7N power supply board, certain components
are labeled differently along with different numbers for the connectors.
This is illustrated in Figure 5-2. The 52 models also use D3N and D4N
inverter boards. Other than the different nomenclature of components, the
operation is the same as described above for the 40-inch models.

When the unit is power on, the main relay RY6000 is engaged by the
power-on command to Q6300. PRI_VCC is now applied to the main
relay and PFC circuit. The closing of the main relay shunts R6300 and
activates the PFC circuit and main switching supply. The PFC voltage is
now approximately 390VDC.
The main switching supply is now active, providing REG12V and AUDIO
15V to operate the television. Note that the switched PRI_VCC from
Q6300 is also applied to CN6500 and CN6501 for the inverter circuits.

CTV-57

20

Chapter 5. Power Supply and Protection

D6000
RECT

1
2
3

PFC

1
2
3

1
2
3
4
5
6
7

R6022
Q6300

PRI_VCC

CN6600

CN6501

PRI_VCC
PFC GND
PFC OUT

PFC OUT
PFC GND
PRI_VCC

CN6500

PRI_VCC
PFC GND
PFC OUT

TO D2N
BOARD

INVERTER
CN6702

CN6103

H_SYNC
DIMMER
BACKLIGHT_ON
INV_ERR
GND
12V
BALANCER_ERR

H_SYNC
DIMMER
BACKLIGHT_ON
INV_ERR
GND
REG12V
BALANCER_ERR

D1N

RY6000
12X

AC IN

STANDBY
SWITCHING
SUPPLY

1
2
3
4
5
6

1~4
5~8

MAIN
SWITCHING
SUPPLY

11~13
8~9
6, 7
4, 5
3
2
1

CN6102

CN1002

BALANCER_ERR
GND
INV_ERR
BACKLIGHT_ON
DIMMER
HSYNC

CN6101

REG12V
REG12V_GND

CN6100

REG12V
REG12V_GND
UNREG_15_GND
UNREG_15V
STBY3.3V
AC_OFF_DET
POWER_ON

BALANCER_ERR
GND
INV_ERR
BACKLIGHT_ON
DIMMER
HSYNC

TO
TCON

CN1003

REG12V
REG12V_GND
UNREG_15_GND
UNREG_15V
STBY3.3V
AC_OFF_DET
POWER_ON

G6N

14X

HFR ERR
TCON ERR

FROM
TCON

NOT USED
6X

10X

IC7000
AMD

8X

SPKR
PROT

IC3002
TV MICRO
2X

3X

REG 5V
OVP
LVP

7X

IC3007
TEMP
SENSE

BU

FIGURE 5-1
40 POWER SUPPLY AND PROTECTION BLOCK DIAGRAM
CTV-57

21

Chapter 5. Power Supply and Protection

D6501
RECT

1
2
3

PFC

1
2
3

R6117

Q6305

PRI_VCC

1
2
3
4
5
6
7

CN6600

CN6501

PFC OUT
PFC GND
PRI_VCC

PRI_VCC
PFC GND
PFC OUT

CN6502

PRI_VCC
PFC GND
PFC OUT

TO D2N (46")
TO D4N (50")

INVERTER

CN6201

CN6702

H_SYNC
DIMMER
BACKLIGHT_ON
INV_ERR
GND
REG12V
BALANCER_ERR

H_SYNC
DIMMER
BACKLIGHT_ON
INV_ERR
GND
12V
BALANCER_ERR

D1N (46")
D3N (52")

RY6101
12X

AC IN

STANDBY
SWITCHING
SUPPLY

1
2
3
4
5
6

1~4
5~8

MAIN
SWITCHING
SUPPLY

11~13
8~9
6, 7
4, 5
3
2
1

CN6204

CN1002

BALANCER_ERR
GND
INV_ERR
BACKLIGHT_ON
DIMMER
HSYNC

BALANCER_ERR
GND
INV_ERR
BACKLIGHT_ON
DIMMER
HSYNC

CN6203

REG12V
REG12V_GND

CN6202

REG12V
REG12V_GND
UNREG_15_GND
UNREG_15V
STBY3.3V
AC_OFF_DET
POWER_ON

TO
TCON
CN1003

REG12V
REG12V_GND
UNREG_15_GND
UNREG_15V
STBY3.3V
AC_OFF_DET
POWER_ON

G7N

14X

HFR ERR
TCON ERR

FROM
TCON

13X (52" ONLY)

6X
10X

IC7000
AMD

8X

SPKR
PROT

IC3002
TV MICRO
2X

3X

REG 5V
OVP
LVP

7X

IC3007
TEMP
SENSE

BU

FIGURE 5-2
46/52 POWER SUPPLY AND PROTECTION BLOCK DIAGRAM
CTV-57

22

Chapter 5. Power Supply and Protection

Protection

Diagnostics History

Referring once again to Figure 5-1, the protection circuits will be covered.
All protection monitoring that will generate diagnostics codes is performed
on the BU board and detected by TV micro IC3002. The protections circuits
will be described by the number of blink codes.

Whenever a problem is detected by the self-diagnostics feature that

causes the unit to shut down, the event is recorded and stored in NVM.
This is particularly helpful when dealing with intermittent failures but not
so helpful if the unit is always shutting down.

2X Main Power: The REG12V line from the power supply is monitored
directly by IC3002 via a resistor/divider network (not shown).
3X DC_ALERT1: The switched REG5V generated on the BU board is
monitored for over and under-voltage conditions.
6X Backlight: One or both of the inverters has failed. In the 40 and 46inch models, a failed backlight lamp will also generate this error.
7X Temperature: IC3007 on the BU board is a digital thermometer and
will notify IC3002 once a maximum acceptable temperature inside the
television cabinet has been reached.
8X Audio Protect: DC voltage has been detected on one or both of the
speaker output lines. This circuit is designed to protect the speakers from
damage.

The diagnostics history pages are retrieved by pressing the DISPLAY,

5, VOL and POWER buttons in sequence on the remote commander
when the unit is off. The diagnostics history page will appear as shown in
Figure 5-3
There are 2 pages containing failure history. Press the 4 key on the
remote to view the second page. Pressing the 1 key returns to the rst
page.
Note that a running count is kept anytime one of the detection circuits is
activated. This running count will continue until it is reset. This is performed
by pressing the 8 key on the remote followed by the 0 key. This should
always be done in order to clear the history and provide a clean table for
future use.

9X Fan Error: This feature is not used in this model

The diagnostics page also contains 3 sets of 5-digit numbers to indicate

operating and panel hours along with a boot count to indicate how many
times the unit has been turned on. The panel hours can be reset to zero
by pressing the 7 key followed by the 0 key.

10X DTT Watchdog Timer: Communications from the AMD IC7000 have
stopped.

Troubleshooting Flowcharts

12X HFR (High Frame Rate) Error: The frame quadrupling circuit on the
TCON has failed.

The troubleshooting owcharts found in Figures 5-4 and 5-5 will assist in
determining what component is the likely cause of no power or protect
shutdown.

13X Balancer: Available only on the 52-inch models, one or more open
backlight lamps has been detected.
14X TCON Error: The timing control IC located on the TCON is not
communicating with IC7000.

CTV-57

Troubleshooting Test Points

Figures 5-6 through 5-8 contain illustrations pointing to the important
and easily accessed test points for checking voltages and logic levels
of protect lines. They are grouped according to panel size. Photos of the
XBR9 models are illustrated but can be used for the Z5100 models since
the only difference is the type of speakers used.

23

Chapter 5. Power Supply and Protection

SELF CHECK
PAGE 1

DIAGNOSTICS
BLINK
CODE

002
003
012
006
007
008
009
010
005
013

EVENT
COUNT

MAIN POWER
DC ALERT1
HFR ERR
INV ERR
TEMP ERR
AUD PROT
FAN ERR
DTT WDT
DC ALERT3
BALANCER

000
000
000
004
000
000
000
000
000
004

000 POWER ON TIME

001 BOOT COUNT
002 PANEL ON TIME

TOGGLE PAGES
WITH 1 AND 4' KEY
ON REMOTE

DETECTED EVENTS
HIGHLIGHTED IN RED

00007
00046
00005

SELF CHECK
DIAGNOSTICS

PAGE 2

014 TCON ERR

000
FIGURE 5-3
SELF DIAGNOSTICS PAGES

CTV-57

24

Chapter 5. Power Supply and Protection

No Power

REMOVE AC POWER
FOR AT LEAST 30
SECONDS AND REAPPLY. DOES MAIN
RELAY CLICK?

Yes

Replace
G6N board (40")
G7N board (46/52")

No

3.3VDC
CN6100 -3 G6N
CN6202 -3 G7N?

No

Replace
G6N board (40")
G7N board (46/52")

Yes

3.3VDC at turn on
CN6100 -1 G6N
CN6202 -1 G7N?

No

Replace
BU board

Yes

Replace
G6N board (40")
G7N board (46/52")

FIGURE 5-4
NO POWER TROUBLESHOOTING FLOWCHART
CTV-57

25

Chapter 5. Power Supply and Protection

Immediately ?

Shutdown
Red Standby
LED Flashing

7X
Temperature

No

Check for possible

ventilation problem

Yes

Yes

BU Board

No

2X
MAIN POWER

Yes

G6N (40")
G7N (46/52")

8X
Speaker
Protect

Yes

BU Board

No
No

3X
DC ALERT

Yes

BU Board

No

Yes

BU Board

No

No

6X
BACKLIGHT

11X

Yes

Go To Panel Error
Troubleshooting
Flowchart

12X or 14X

Yes

TCON on LCD
PANEL

No
No

13X
Balancer

Yes

LCD Panel

FIGURE 5-5
PROTECT MODE TROUBLESHOOTING FLOWCHART
CTV-57

26

Chapter 5. Power Supply and Protection

CN6702
1. H SYNC
2. DIMMER
3. BACKLIGHT ON
4. INV ERR
5. GND
6. 12V
7. BALANCER ERROR

CN6550
HV

CN6600
CN6103

CN6501
1. PRI 12V
2. PRI GND (HOT)
3. PFC 390V

CN6500
1. PRI 12V
2. PRI GND (HOT)
3. PFC 390V

CN6005

CN6102
1. BALANCER ERROR
2. GND
3. INV ERR
4. BACKLIGHT ON
5. DIMMER
6. H SYNC

CN6903
1. SLAVE FAIL
2. PWM
3. LD
4. HV SENSE 2
5. SS
6. FB
7. DUTY
8. ENABLE
8. GND
9. SYNC
10. REG 12V

CN6101
1~4. REG 12
5~8. REG 12 GND

CN6100
1. POWER ON
2. AC OFF DET
3. STBY 3.3
4, 5. UNREG 15V
6, 7. UNREG GND
8~10 REG 12V GND
11~13 REG 12V

CN6850
HV

CN6800

CN6102
CN3002
CN7800

CN1003

CN2201

FIGURE 5-6
40 TEST POINTS
CTV-57

27

Chapter 5. Power Supply and Protection

CN6650
HV

CN6702
1. H SYNC
2. DIMMER
3. BACKLIGHT ON
4. INV ERR
5. GND
6. 12V
7. BALANCER ERROR

CN6850
HV

CN6703

CN6800

CN6600

CN6501
1. PRI 12V
2. PRI GND (HOT)
3. PFC 390V

CN6502
1. PRI 12V
2. PRI GND (HOT)
3. PFC 390V

CN6201

CN6203
1~4. REG 12
5~8. REG 12 GND
CN6202
1. POWER ON
2. AC OFF DET
3. STBY 3.3
4, 5. UNREG 15V
6, 7. UNREG GND
8~10 REG 12V GND
11~13 REG 12V

CN6903
1. SLAVE FAIL
2. PWM
3. LD
4. HV SENSE 2
5. SS
6. FB
7. DUTY
8. ENABLE
8. GND
9. SYNC
10. REG 12V

CN6102
CN3002
CN7800

CN1003

CN2201

CN6104
CN6204
1. BALANCER_ERR
2. GND
3. INV_ERR
4. BACKLIGHT_ON
5. DIMMER
6. H SYNC

FIGURE 5-7
46 TEST POINTS
CTV-57

28

Chapter 5. Power Supply and Protection

CN6650
HV

CN6702
1. H SYNC
2. DIMMER
3. BACKLIGHT ON
4. INV ERR
5. GND
6. 12V
7. BALANCER ERROR

CN6850
HV
CN6703

CN6701
1. 12V
4, 5 GND
6, 7 LD

CN6800

CN6600
CN6201

CN6501
1. PRI 12V
2. PRI GND (HOT)
3. PFC 390V

CN6502
1. PRI 12V
2. PRI GND (HOT)
3. PFC 390V

CN6203
1~4. REG 12
5~8. REG 12 GND

CN6202
1. POWER ON
2. AC OFF DET
3. STBY 3.3
4, 5. UNREG 15V
6, 7. UNREG GND
8~10 REG 12V GND
11~13 REG 12V

CN6104

CN6903
1. SLAVE FAIL
2. PWM
3. LD
4. HV SENSE 2
5. SS
6. FB
7. DUTY
8. ENABLE
8. GND
9. SYNC
10. REG 12V

CN6102
CN3002
CN7800
CN1003
CN2201

CN6204
1. BALANCER_ERR
2. GND
3. INV_ERR
4. BACKLIGHT_ON
5. DIMMER
6. H SYNC

FIGURE 5-8
52 TEST POINTS
CTV-57

29

Chapter 6 - Panel Backlight Circuits

Overview
The Z5100 and XBR9 models used in the EX2M chassis series use
uorescent lamps to provide the backlighting necessary for the LCD
panel. Wide Color Gamut lamps are used to provide a broader range of
the color spectrum. The lamps on all panels are arranged horizontally and
evenly spaced from top to bottom. The number of lamps ranges from 16
for the 40-inch panels to 24 for the 52-inch.
Although the various sizes among the models use a relatively similar
backlighting method, differences in the power supplies and backlight
inverters will appear. They will be discussed in the following sections,

40-inch Backlighting
Figure 6-1 illustrates a block diagram of the circuits used to control and
operate the backlights for the KDL40Z5100 and KDL40XBR9. This panel
size uses a G6N power supply to generate a 390V PFC voltage along with
a PRI_VCC of approximately 12VDC which supplies operating voltage to
the D1N and D2N inverter circuits. Both of these voltages are referenced
to hot ground.
The use of left and right inverter circuits creates a oating ground AC circuit
to supply differential AC voltage to both ends of the lamps. This helps to
insure steady brightness across the length of each lamp. The D1N board
serves as the master (containing the oscillator and drive circuits) while the
D2N board is the slave having only the inverter switching circuits. This is
how the 2 inverters remain locked out of phase.

The TV micro performs its initialization routine lasting approximately 5

seconds during which other circuits on the BU board are initialized. Once
this initialization routine is complete, the backlight on command at pin 4 of
CN6102 on the G6N board goes high to 3.3VDC. This command is sent to
the D1N inverter board to start the high voltage for the backlights.

Inverters
Once the circuits on the D1N board are operating, control of the D2N board
is also achieved. Both inverter circuits operate out of phase to supply a
45KHZ AC sine wave at approximately 800VRMS per side. Both inverter
circuits contain protection circuits to monitor over-voltage and over-current
conditions. If a problem occurs on one or both of the inverters an inverter
failure high will be generated and is easily measured at pin 3 of CN6102
on the G6N board. This will cause the unit to shut down and blink the
POWER/STBY LED on the front bezel to blink in groups of 6.
The 40-inch panels do not utilize and external balancer circuit that was
found in the previous years of models. Models that used a balancer circuit
had the ability to monitor for an open lamp condition and shut the unit down
with a 13-blink error code. If one or more of the uorescent backlights fails
to light, the resulting loss of load will cause an overvoltage condition in the
inverter circuit and the unit will shut down with a 6 blink error code just as
if the inverter had failed.

Power-on Sequence
TV micro IC 3002 on the BU board sends a power on command to pin 1
of CN6100 on the G6N board to turn on the main relay, PFC and main
switching relay. The necessary operating voltages are now generated for
the televisions circuits.

CTV-57

30

Chapter 6. Backlight Circuits

LCD PANEL

INVERTER
OSC /
DRV

CN6600

1 PRI_VCC
3 HOT GND
5 PFC 390 V
CN6102
1
2
3
4
5
6

BALANCER_ERR (NOT USED)

GROUND
INV_ERR (NORM LOW)
BACKLIGHT_ON (3.3V ON)
DIMMER (PWM)
REG_12V

CN6703

CN6600

CN6702

CN6500
CN6501

CN6153

PFC

800VRMS

INV
FAIL

INV
FAIL

INVERTER

CN6950

D1N

CN6800

D2N

CN6102

1
2
3
4
5
6

BALANCER_ERR
GROUND
INVERTER_ERR
BACKLIGHT ON
DIMMER
H_SYNC

POWER ON

CN6100

G6N

CN1003

IC3002
TV
MICRO

CN1002

BU

FIGURE 6-1
40 PANEL BACKLIGHT DIAGRAM
CTV-57

31

Chapter 6. Backlight Circuits

46-inch Backlighting
Figure 6-2 illustrates the backlighting circuits for the KDL46Z5100 and
KDL46XBR9. The only difference is the use of a G7N power supply to
handle the larger current requirements of the larger panel. The operation
of the circuit is the same as the design for the 40-inch models except the
connector numbers are different for the G7N board.
The part numbers for the D1N and D2N boards are also different due to
their larger current capacity.

52-inch Backlighting
Figure 6-3 illustrates the block diagram of the backlight circuits for the
KDL52Z5100 and KDL52XBR9. The operation is the same as previously
described with the following differences:
The inverter boards used are the D3N and D4N. Once again, they are
basically the same in operation as the D1N and D2N found in the 40
and 46-inch models. The same G7N power supply found in the 46-inch
models is also used.
A single, external balancer circuit is used to distribute the high voltage,
maintain even current draw amongst the parallel connected lamps and
to monitor for an open lamp. The D3 board provides a 12VDC operating
voltage for the balancer circuit along with monitoring for an open lamp
via the LD line at pin 6 and 7 of CN6701. This LD line is normally high
(12VDC) and goes low if an open lamp is detected. An inverter located on
the D3N board will reverse this logic line and it becomes a balancer error
line that is normally low. An open lamp condition will cause this line to go
high and the unit will shut down with a 13-blink error code.

CTV-57

32

Chapter 6. Backlight Circuits

LCD PANEL

INVERTER
OSC /
DRV

CN6600

1 PRI_VCC
3 HOT GND
5 PFC 390 V
CN6204
1 BALANCER_ERR (NOT USED)
2 GROUND
3 INV_ERR (NORM LOW)
4 BACKLIGHT_ON (3.3V ON)
5 DIMMER (PWM)
6 REG_12V

CN6703

CN6600

CN6702

CN6501
CN6502

CN6153

PFC

800VRMS

INV
FAIL

INV
FAIL

INVERTER

CN6950

D1N

CN6800

D2N

CN6204

1
2
3
4
5
6

BALANCER_ERR
GROUND
INVERTER_ERR
BACKLIGHT ON
DIMMER
H_SYNC

POWER ON

CN6202

G6N

CN1003

IC3002
TV
MICRO

CN1002

BU

FIGURE 6-2
46 PANEL BACKLIGHT DIAGRAM
CTV-57

33

Chapter 6. Backlight Circuits

BALANCER

CN3

INVERTER

CN6701
12V
GND
LD

6,7 LD (NORM HIGH)

CN6600
1 PR__VCC
3 HOT GND
5 PFC 390V

CN6204
1 BALANCER_ERR (NORM LOW)
2 GROUND
3 INV_ERR (NORM LOW)
4 BACKLIGHT_ON (3.3V ON)
5 DIMMER (PWM)
6 H SYNC

CN6702

CN6501
CN6502

CN6201

INV
FAIL

INVERTER

CN6950

CN6703

CN6600

PFC

800VRMS

INV
FAIL

OSC/
DRV

1
4,5
6,7

LCD PANEL

D3N

CN6800

D4N

CN6204

1
2
3
4
5
6

BALANCER_ERR
GROUND
INVERTER_ERR
BACKLIGHT ON
DIMMER
H_SYNC

POWER ON

CN6202

G7N

CN1003

IC3002
TV
MICRO

CN1002

BU

FIGURE 6-3
BACKLIGHT
DIAGRAM
EX2M 52" 52
LCDPANEL
BACKLIGHT
CONTROL
AND MONITORING
CTV-57

34

Chapter 6. Backlight Circuits

PANEL ERROR
BACKLIGHT 6X
BALANCER 13X

Backlights Light
At turn-on?

Even lighting
across screen?

Yes

No

LCD Panel

13X

D2N board (40/46")

D4N board (52")

D1N board (40/46")

D3N board (52")

6X

PFC 390 V ACROSS

PINS 3 AND 5 CN6501
ON G6N (40")
G7N (46/52")?

No

LCD Panel

Left Side

Right Side

Yes

No

6X OR 13X*?
*52" only

Dark left side or

right side?

G6N board (40")

G7N board (46/52")

Yes

PRI 12V ACROSS

PINS 1 AND 3 CN6501
ON G6N (40")
G7N (46/52")?

Yes

D1N board (40/46")

D3N board (52")

No

G6N board (40")

G7N board (46/52")

FIGURE 6-4
BACKLIGHT TROUBLESHOOTING FLOWCHART
CTV-57

35

Chapter 7 Appendix
LCD Panel Troubleshooting
When a customer calls and is complaining of poor picture quality,
colored lines, or no picture at all, it is very important that the technician
rule out the LCD panel assembly as the cause. Technicians should be
using the triage system found on the ASC Portal site and in the back of the
training manuals to assist on which parts should be brought to the location
to service the unit. LCD panels are not suggested to be brought to the
service location based on the customers description of the problem. They
are expensive to ship and prone to damage. The technician must diagnose
the unit and obtain special authorization before the panel can be replaced.
In certain cases it may be determined that it is not economically feasible
to replace an LCD panel for a particular model and that replacement of
the unit would be the best option.
The purpose of this article is to assist the technician in determining if
the LCD panel is defective as efciently as possible. In many cases,
failures of the physical aspects of the panel (panel glass damage, tab
bonding issues) are easily recognized. Failures of the TCON board (which
is considered part of the panel) can sometimes lead the technician to
erroneously change a video process board and have wasted time only to
nd out that panel is the cause of the failure.

LCD Panel Basics

LCD panels have steadily evolved over the last several years. New designs
of the physical structure of the LCD crystals have greatly improved the
contrast ratio and viewing angle. Quicker response times and increased
refresh rates have helped to reduce the motion smear associated with
LCD displays. Backlighting design has also aided in producing a picture
with color temperatures to make the images as true as possible. With
all these design improvements, one aspect of the LCD panel remains
relatively the same: Processing of the video signal.

CTV-57

Figure 7-1 illustrates a typical LCD panel and the associated video
processing circuits as found in the WAX3 chassis. The various formats
and resolutions of video signals are processed on the BU1 board. All video
signals exit the video processor in the native resolution of the LCD panel.
In this design, the resolution is for a 1280 by 768 at 60HZ refresh rate
panel. 48 horizontal lines are discarded to match up to the 720p resolution
of the ATSC specications so the video will exit as 720p.
The LCD panel used in this model processes 8-bit RGB video data. Before
the video information can be sent to the TCON board it must be converted
to a format that allows for practical and noise-free transmission. The large
number of parallel lines to transmit the 8-bit RGB data would need to be
sent on differential lines for noise reduction. This would require 48 lines
just for the video. The TCON circuit also requires B+, ground connections,
a communications bus, sync, and a clocking line transmitted differentially
so we can see that up to 100 lines would be required. The practical way
to transmit this information is to convert the parallel video data to a serial
stream and this is accomplished by the Low-Voltage Differential Signaling
(LVDS) transmitter.
The LVDS transmitter contains a circuit to serialize the parallel data. The
parallel video information along with sync and clocking data are transmitted
via twisted line pairs. Depending on the logic level, current is sent along
one or the other of the twisted pair of wires. The receiving end of the wires
is loaded with a resistor (usually around 100 to 120 ohms). The receiver
detects the polarity of the voltage drop across the resistor to determine
the logic level. The current level swings in the wire are about 3ma with a
voltage differential of around 350mv. This allows for transmission of the
video signal with minimal EMI.
The LVDS receiver on the TCON board converts the serialized data back
to parallel. This data is processed by the timing control IC to allocate the
RGB data into serial streams for processing by the LCD panel. The LCD
panel contains shift registers and drivers for all of the rows and columns
of pixels on the panel. The drivers are mounted on exible circuit boards
and bonded to the top and side of the panel. Without this arrangement the
TCON would require an IC and connectors to transmit on 4,560 lines!

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Chapter 7 - Appendix

Panel Failures
The key to good troubleshooting when video quality issues are involved
is the understanding what type of distortions cannot be generated by the
panel. The loss of an entire color is highly unlikely. The LVDS transmitter
does not handle the RGB data as groups. The data (along with sync and
clock) is distributed among 6 separate transmission lines for an 8-bit
panel. A 10-bit panel uses 12 transmission lines. If one of these lines
fails the result is random, multiple colored lines appearing on the screen.
Distortions caused by the panel will be stationary and, in almost all cases,
will consist of a single line or multiple lines in a repetitive pattern. Any
distortion that is not stationary (ying color spots, loss of detail, etc.) is
being generated by the video process circuits on the B board.

Electrical Failures
There are multiple drive ICs located along the top and side of the panel
to de-multiplex the data for all of the rows and columns of pixels. If one
of these ICs fails there will be a cluster of missing information on the
screen. The second photo in Figure 7-2 contains an illustration of a panel
with such a failure.

Although the TCON board is considered part of the LCD panel, we will
focus on the panel itself and discuss TCON failures separately since it
generates symptoms that are quite distinguishable from panel issues.
Panel failures fall into 2 different categories: Physical and electrical.

Physical Failures
The most obvious failure is physical damage to the panel. This can appear
as a small cluster of damaged pixels or a complete shattering of the panel
glass. Another physical failure may appear as a single or several lines
running vertically or horizontally across the screen. The lines may be
brightly lit or dark. This is caused by a failure of the exible printed circuit
where it is bonded to the panel edge. This is known as a tab bond issue.
Do not confuse this with multiple vertical lines across the screen that are of
the same color. This is electrical and usually caused by the TCON board.
Figure 8-5 illustrates some examples of tab bonding issues.

SOURCE DRIVERS

VIDEO
PROCESS

TIMING
CONTROL

LVDS
TRANSMITTER

LVDS
RECEIVER

PANEL B+

BU1

TCON

LCD PANEL

GATE
DRIVERS

FIGURE 7-1
LCD PANEL DRIVE
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Chapter 7 - Appendix

UPPER TAB BOND FAILURE

TAB BOND AND DRIVE IC FAILURE

UPPER TAB BOND FAILURE

SIDE TAB BOND FAILURE

FIGURE 7-2
LCD PANEL FAILURES
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Chapter 7 - Appendix

TCON Failures
Failures of the TCON circuit can cause a variety of symptoms varying
from evenly spaced multiple vertical lines of the same color, xed random
patterns, colored blotches, or the complete loss of video. A complete
failure of the TCON is difcult to determine since there is nothing on the
display to help troubleshoot and has the same symptoms as a complete
video process failure on the B board. A procedure to help in diagnosing
this failure will be covered shortly.
Figure 7-3 contains several photos of symptoms caused by a failure on
the TCON board. Note the xed and symmetrical lines in the rst 3 photos.
This is a classic timing IC failure on the TCON board. The fourth photo
is interesting. Another task performed on the TCON board is gamma
correction. The correction is performed in dened zones across the entire
panel. The data is stored in an on-board EEPROM. If this data is corrupted
for whatever reason, one or more of the zones will exhibit a severe white
balance issue.

FIGURE 7-3
SAMPLES OF TCON FAILURES
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Chapter 7 - Appendix
Troubleshooting a Dead TCON
This is a tough one. Fortunately, most of the 2007 Sony models now monitor
the TCON for communications and will shut down with a diagnostics
indication. In units that do not have this feature you will experience
the same symptom as a complete video process failure (no on-screen
graphics, no video, but audio is OK). Based on data gathered from our
panel refurbishing group, about 10 to 15% of TCON failures cause a no
video condition.
If a customer complains of no video from any source you will be asked to
bring a B board to the location since that is the most likely component to
x the problem. What if you install the board and still have no video? Did
you receive a defective B board? Did you overlook any other symptoms?
Make sure you have audio. This is critical. There have been numerous
issues of technicians troubleshooting older models in which the ATI
decoder IC for digital channels is located on a separate board (QM or QBox). When this decoder fails, it kills all video and audio. The technician
changed several parts based on a no video condition and did not bother
to check for the presence of audio. If it is veried that audio is present, the
following procedure can help isolate a defective TCON in most cases.
Warning: Do not attempt to check for data or voltages on the LVDS
connector at the TCON. This advice has been circulating around and is not
recommended. In Figure 7-4 a picture of the LVDS connector is shown. In
order to take a reading from one of the pins, you must insert your probe
between a narrow area that is shielded and at ground potential. Several
of the pins contain B+ for the TCON and panel. It is very easy to short
one of these pins to ground and if it is a B+ line it is guaranteed you will
be replacing a B board whether or not it was the original cause of the
problem. The LVDS connector is shown in Figure 8-7.

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RELEASE TABS

FIGURE 7-4
LVDS CONNECTOR

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Chapter 7 - Appendix
If the TCON is receiving B+ and functioning properly, the timing circuits
are waiting for RGB data to allocate to the proper pixel. When a video
processor failure occurs, there is simply no data being sent to the TCON
and it does exactly what it is supposed to do: Keep all of the pixels dark.
One trick that works rather well is to partially disconnect the LVDS connector
from the TCON board while the unit is running. Do this very carefully!
Both sides of the connector have release tabs that must be squeezed
inward to release the connector. This was performed over 30 times to the
same television without any damage to the connector or electrical circuits.
Release the connector and carefully pull it partially out of the socket being
careful not to pull one side out much further than the other. Too much
skewing can damage the connector and possibly cause a short on the B+
line. The idea is to remove some of the LVDS data entering the TCON.
If the TCON is functioning the loss of data will cause the timer circuits to
generate random patterns. These patterns may appear as a brief colored
horizontal bar or continuously active random lines covering the entire
screen. The type of response you get will depend on the panel design
and how much LVDS data you have removed. Sometimes a momentary
line will ash on the screen, other times the screen will ll with random
patterns. If you dont see any response, try plugging the connector back
in and pulling it out one more time watching the screen very closely for
any reaction. Figure 7-5 illustrates 2 different types of patterns generated
by the same unit.

SINGLE MOMENTARY LINE

If you are able to generate any response on the screen, the TCON is
most likely OK. A TCON that has completely failed (causing a no video
condition) will not produce any pixel lighting on the screen.

MOVING RANDOM PATTERNS

FIGURE 7-5
SAMPLE REACTIONS TO LVDS LOOSENING
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5/18/09