KDF-E42A10 - E50A10 CH - Mix-5 (Training Manual)

Training Manual
KDF-E50A10
MIX-5 LCD Rear Projection Chassis

Theory of Operation and Troubleshooting
MODELS: KDF-E42A10 KDF-E50A10
Course : TVP-20
Table of Contents
Chapter 1 Circuit Description .......................................... 1 Features .......................................................................... 1 New Circuit Descriptions ................................................. 1
AGU Board .......................................................................... 3 B Board ................................................................................ 3 C Board................................................................................ 3 QU Board ............................................................................. 3 QT Board ............................................................................. 3 QM Board ............................................................................ 4 P Board ................................................................................ 4 GT Board ............................................................................. 4 HPC Board........................................................................... 4 HC Board ............................................................................. 4 HB Board ............................................................................. 4 HA Board ............................................................................. 4
Fan Locations ........................................................................11
Protect Monitoring...............................................................11
Lamp Position and Lamp Cover Monitor ................................11 Thermal Protection .................................................................11 Fan Protection ....................................................................... 13 Lamp and Lamp Driver Protection ........................................ 13 OVP and LVP Protection ....................................................... 13 Speaker Protection ............................................................... 13
Alternate Diagnostics History............................................. 14
Chapter 2 Service and Troubleshooting ....................... 16 Overview........................................................................ 16 Circuit Board Locations ................................................. 16 AGU Board Test Points .................................................. 18 Service Mode................................................................. 21
Navigating the Service Mode ............................................. 21 Adjustment Items ............................................................... 23
Test Graphics ........................................................................ 23 QM Graphics ......................................................................... 23 BE Micro Graphics ................................................................ 24
Video Input Switching ...................................................... 4 Video Processing ............................................................. 6

Chimera Process IC ................................................................ 6
Audio Process ................................................................. 8 Power Supply .................................................................. 9

Standby Supply.................................................................... 9 Main Switching Regulator .................................................... 9
White Balance Adjustments ............................................... 24
System Control and Protection .......................................11

System Control ...................................................................11
Chapter 3 - Troubleshooting Flowcharts ......................... 25 Introduction .................................................................... 25 Initial Contact Flowchart ................................................ 26 Power Supply Troubleshooting ..................................... 27
No Power Flowchart .......................................................... 28
Protect Mode Troubleshooting....................................... 29 CTV-33 i
Table of Contents (cont)

Protect Mode Flowchart ..................................................... 30 Dust ................................................................................... 72
Video Troubleshooting ................................................... 31

QM Graphics ......................................................................... 31 BE Graphics .......................................................................... 31 Lamp Does Not Light ............................................................ 32
No Video Flowchart ........................................................... 33 Video Distortion Flowchart ................................................. 34
Audio Troubleshooting ................................................... 35

Audio Flowchart ................................................................. 36 No Power Field Troubleshooting Flowchart..................... 37 Lamp Failure Field Troubleshooting Flowchart .................. 38 Using OSD Graphics for Video Failures Field Troubleshooting Flowchart ............................................................... 39
Chapter 4 - Disassembly ................................................... 40 Introduction .................................................................... 40 New Locking Connectors............................................... 42 Rear Cover Removal ..................................................... 41 B Block Removal ........................................................... 43 Chasssis Removal ......................................................... 50 Re-Installing the Wire Harness ...................................... 60 Lamp Driver and Optical Block Removal ....................... 61 Lamp Driver Disassembly.............................................. 66 Optical Block Replacement ........................................... 70 Appendix............................................................................. 71
Pixel Failure ....................................................................... 71
CTV-33
ii
Chapter 1 Circuit Description

Features
Several new features have been introduced into the MIX-5 chassis. They are as follows:
New Circuit Descriptions

In Figure 1-1, an overall block diagram of the various major circuits is shown. A brief discussion of each board and the circuits contained within will be discussed.
Slim Cabinet Design: Re-design of the projection lamp and circuit

board layouts allow the units depth to be reduced by approximately 4 inches over previous models.
New Wega Engine: A second generation Composite to Component

Process (CCP2), Digital Reality Creation (DRC), and Chimera IC (replacing the previous Multi-Image Driver), have been designed to further improve picture quality. friendlier way to navigate through the various menu items.
Wega Gate: A new Graphics User Interface allows the customer a Full HDTV Reception: An integrated ATSC tuner and decoding circuits
allow the reception of unscrambled VSB and QAM signals along with legacy NTSC signals. by the cable company) to receive authorized, scrambled channels.
Cable Card Slot: Allows the insertion of a special PCMCIA card (provided Front Component Video Inputs: Once only reserved for the rear
inputs 4 and 5, component video connectors are now provided at the front Video 2 inputs. graphics.
PC Input: Accepts standard HD15 PC monitor cable to view your PC
TVP-20
Chapter 1 - Circuit Description
FAN 1 FAN 2 FAN 3 FAN 4
CABLE CARD
NTSC TUNER ATSC TUNER
HC
A/V2 INPUT
QU
QT
ATSC DECODER
QM
LED INDICATORS IR RECEIVER
HB
FUNCTION KEYS
HA
L R
AUDIO AMP
A/V1 INPUT
K
A/V SWITCHING TV MICRO AUDIO PROCESS/AMP IRIS MOTOR DRIVE FAN MOTOR DRIVE
A/V3 INPUT
L/R OUT
COMPONENT INPUT 4 COMPONENT INPUT 5

HDMI INPUT HDMI
VIDEO PROCESS PC INPUT
LCD PANEL DRIVE
TO LCD PANELS
P
PC INPUT
AGU
PC INPUT
HPC
POWER SUPPLY
GT
LAMP DRIVE
LAMP
FIGURE 1-1 FIGURE 1-1 MIX-5 MIX5 CHASSIS OVERALL BLOCK DIAGRAM CHASSIS OVERALL BLOCK DIAGRAM TVP-20 2
AGU Board
Essentially the brains of the television, this board contains the following key circuits:
Television Microprocessor: Controls all system control
Chimera Micro: Controls how Chimera Micro handles and processes video information. Also controls fan speed and lamp driver turn-on. Monitors fan rotation and various temperature conditions within the unit for protection
processes of the television. Monitors key power supply voltages. Master controller for the other microprocessors in the unit. Also generates the service OSD graphics via a UART bus to the ATI Micro on the QM board.
LVDS Transmitter: Converts the 8-bit component and
synchronization signals to a single serial stream (Low Voltage Differential Signaling) for transmission to the C board.
Audio and Video Switching: Selects the various inputs (except

PC) based on the users request.
C Board
Contains the LVDS receiver to convert the video and synchronization signals for processing by the panel drive circuits for the 3 LCD panels. Final scaling of the video signal to the native panel resolution is performed. Contains the BE Micro to control scaling and generate test patterns of C board isolation if a video problem occurs. Gamma correction is also performed here. A digital thermometer IC resides on this board to monitor the operating temperature of the optical assembly for fan speed control or shutdown protection if necessary.
Audio Processing: Volume control, equalization, and various
sound processes. All analog audio is converted to digital for amplication by the class-D amplier on the K board.
Fan Motor Drive and Control: Drives and monitors the 4 fans
located throughout the unit.
Iris Motor Drive and Control: Adjusts the iris in the lens
assembly to increase contrast ratio during low level video scenes.
QU Board
PCMCIA slot for the Cable Card (POD)
B Board
Uses the following key circuits for video processing:
QT Board
Contains the following circuits:
CCP2: Decodes composite and Y/C signals to component level. DRC: Compares the two elds of a 480i interlaced signal to bump
the resolution to 480p
Integrated ATSC, NTSC Tuner: To receive terrestrial ATSC,

NTSC and Cable signals.
Chimera: Performs the same basic functions as the Multi-Image
OOB Mixer: Receives Out-Of Band signal to control the Cable

Card for program authorization.
Driver in previous models. Controls various picture quality settings. The analog component signals are A/D converted in this circuit.
Cable Card Interface Demodulator Circuits for ATSC, NTSC, and QAM
TVP-20
QM Board
MPEG1, MPEG2, and digital audio decoding. User Menus, QM service and test pattern graphics are generated here.
Video Input Switching

Referring to Figure 1-2, all video input sources (except PC input) are controlled and routed by IC8400 and IC8003 located on the AGU board. The PC input is sent directly to the B board and will be covered in the video processing section. Composite video signals are received via the demodulated NTSC signal from the QT board along with video inputs 1, 2, and 3. Note two distinct changes in this chassis design: 1. The Video 2 input located at the front of the unit has jacks for composite and component video sources. There is no Y/C input. 2. The Video 3 input has no Y/C input. It is composite only. Y/C is available only at the Video 1 input. Note that even though IC8400 outputs sub-video signals, they are used in the North American models. This chassis has an integrated NTSC/ATSC tuner but it is essentially one tuner. Therefore, twin picture viewing is not available. All main-path signals are sent to the B board for processing via CN8404.
P Board
HDMI receiver
GT Board
Main power supply generating the voltages used throughout the television.
HPC Board
Interface for HD15 connector to view graphics output from a computer. L/R audio inputs are also provided.
HC Board
Allows access to the Video 2 input at the front of the television. Component inputs along with a composite are provided for the rst time.
HB Board
Remote control IR receiver and LED indicators. Also contains a digital thermometer IC to send ambient cabinet temperature readings to the B board for protection.
HA Board
Front panel function keys.
TVP-20
QT
NTSC CV
CN8006
8
1 3 5 7 9 11 13 15 17 19
CN8404
MAIN Y MAIN Pb MAIN Pr MAIN CV/Y MAIN C SUB Y SUB Pb SUB Pr SUB HS SUB VS
VIDEO 1 VIDEO 3 VIDEO 4 VIDEO 5
CV/YC CV ONLY Y Pb Pr Y Pb Pr
TO B BOARD
IC8400 VIDEO SW
NOT USED IN USA MODEL
CN8400
CV
VIDEO 2
CN8814
Y Pb Pr
HC
VIDEO 6 HDMI
1 3 5
CN8402
Y Pb Pr
14 12 10
IC8003 VIDEO SW
AGU
FIGURE 1-2 FIGURE 1-2 MIX-5 CHASSIS VIDEO SWITCHING MIX5 VIDEO SWITCHING BLOCK DIAGRAM
TVP-20
Video Processing
In Figure 1-3, the video process circuits are shown. Note that video signals arrive via 3 different inputs.
receiver to return the serial data back to parallel, A process IC to scale the video signal to the panel resolution (1280 X 720), and 3 ICs to drive the individual LCD panels.
PC Input: The PC input from the HPC board is the only signal not
processed by IC4300. The RGB and sync signals are A/D converted and handled directly by IC4500.
Analog Signals: All analog signals selected by the video switching ICs
on the AGU board are input to IC4300. They will be processed based on the format and sync rate of the signal. Composite and Y/C signals are decoded to component and passed through a noise reduction circuit. The processed analog signals will exit IC4300 as 8-bit Y/Pb/Pr.
Digital Video Signals: ATSC and QAM encoded digital signals are
processed by the QM board and sent directly to IC4300 as 8-bit Y and 8-bit Pb/Pr. If any of the digital or analog signals are 480i, the TV Micro will sense this and route the signal through the DRC IC4701. Pattern recognition algorithms will reduce the dithering effect of the interlaced signal for conversion to 480p. All other resolutions (480p, 1080i, and 720p) will be passed in their native format.
Chimera Process IC
IC4500 (Chimera) performs the necessary video signal processing to the selected source. Items such as white-balance, color, luminance, and pedestal levels, etc. are performed. This chassis does not have a subvideo path for twin picture viewing but IC4500 is capable of processing this feature. All functions of video processing are controlled by IC4600 Chimera Micro. The video signal exiting IC4500 will be 10-bit Y/Pb/Pr. The parallel data will be organized into a serial stream by LVDS IC5400 for noise-free transmission to the C board (not shown). The C board contains an LVDS
TVP-20
CABLE CARD (POD)
QU
MPEG2 DECODER
8-BIT RGB OSD 8-BIT DTV Y
QM
8-BIT DTV Pb/Pr

CN5003
IC4701 DRC
IC4500 CHIMERA
IC5400 LVDS TX
TO C BOARD
FROM AGU BOARD
MAIN MAIN MAIN MAIN MAIN
Y Pb Pr CV/Y C
1 3 5 7 9
IC4300 CCP-X
PC INPUT
IC4700 CHIMERA MICRO
HPC
IC4601 A/D CONV
B
FIGURE 1-3 MIX-5 CHASSIS VIDEO PROCESS BLOCK DIAGRAM TVP-20
FIGURE 1-3 MIX5 VIDEO PROCESS
Audio Process
Audio Switching and processing is performed on the AGU board by IC8800 as illustrated in Figure 1-4. The only audio source not handled by IC8800 is the ATSC digital signal. All sources are processed by IC8803. Features such as bass, treble, BBE, and True Surround are accomplished here. The processed audio exits to the K board where IC3006 converts the signal to PWM for amplication by the class-D amplier IC3005. D/A converter IC8805 on the AGU board provides L/R analog audio for connection to an external amplier.
SPDIF SDA LRCLK SCLK MCLK
CN8403
OPTICAL OUT
4 10 12 10 12
QM
IC8604 CONV
QT
VIDEO 1 VIDEO 3 VIDEO 4 VIDEO 5
NTSC AU_L NTSC AU_R

AU_L/R AU_L/R
CN8006
10 12
IC8801 A/D CONV
AU_L/R AU_L/R
VIDEO 2
CN8400
AU_L AU_R
HC
VIDEO 6 HDMI
4 5
IC8800 AUDIO SW
IC8803 AUDIO PROCESSOR
IC3006 S-MASTER PROCESSOR
CN8402
AU_L AU_R
IC3005 S-MASTER AMP

IC8805 D/A CONV
8 7
P
CN8815
AU_L AU_R
PC INPUT
HPC
1 3
L/R AUDIO OUT
AGU
MIX-5 CHASSIS AUDIO SWITCHING AND PROCESSING BLOCK DIAGRAM TVP-20 8
FIGURE 1-4 FIGURE 1-4 MIX5 AUDIO SWITCHING AND PROCESS
Power Supply
The GT board contains the necessary circuits to provide standby and operating voltages for the television. The power supply consists of 2 independent switching regulators to generate standby and main power. Refer to Figure 1-5 for the following descriptions.
event occurs. Once RY6001 engages, the main switching regulator becomes active and generates the various voltages shown in the diagram. Note the in-rush current relay RY6002. It is engaged once the Set 5V is generated by the main supply to shunt the current limiting resistor across it. NOTE: B+ for the lamp driver board is supplied via CN6018-1. This voltage is approximately 270VDC. When checking this voltage be aware that it utilizes an isolated ground at pin 3. This voltage must be checked by reading across these connector pins.
Standby Supply
The standby switching regulator circuit consists of IC6008, T6004, and other components not shown here. The circuit generates a regulated 10.5V source that is used exclusively by the Cable Card (POD). This 10.5V source is further regulated to 5VDC by IC6004 and IC6006. The standby 5V for TV Micro IC8002 is generated by IC6004. This 5V source also supplies power to the IR receiver on the HB board and the main AC relay via a thermal fuse that will be discussed shortly. Note the SUB ON command entering the GT board at CN6019-13. This line is high only when a Cable Card is inserted into the slot. This causes B+ switches Q6000 and Q6009 to turn on the Q15V and Q5V lines to supply continuous power to the Cable Card. Without a Cable Card inserted these voltages are not present.
Main Switching Regulator

The main switching regulator consists of IC6000 and T6000 along with other components not shown. When the unit is powered up, the AC RLY line entering at CN6019-12 goes high turning on relay driver Q6007 and R6001. Note the voltage supplied to the relay via CN6019-11 (RLY VCC). This voltage originates from the AGU board and is supplied through a thermal fuse located in the lamp housing. If this fuse opens, the main relay will not engage. This failure causes the protection circuits to ash the power LED 6 times, giving and erroneous B+ loss indication. It is always important to listen for the RY6001 engaging when this protect
TVP-20

CN6018
1 3
2 4, 5 1
LAMP DC LAMP GND
TO LAMP DRIVER TO C BOARD
CN6009
17V 6V 3.3V
RY6001
+10V REG IC6012
RY6002
Q6007
SET 5V
SWITCHING REGULATOR IC6000 T6000
+9V REG IC6003
+5V REG
IC6002
+3.3V REG IC6007
DC-DC CONV
IC6009
9,10 16 19,20 23,24 28 31,32 35 38,40 45,46 49
CN6019
FAN VCC SET 9V SET 5V SET 3.3V STBY 5V B_12V AU 5V UNREG 6V Q 10.5V Q 5V
TO AGU BOARD
CN6002
3,4 1,2
AU VCC AU GND
TO K BOARD
11 12 13
CN6019
RLY VCC AC RLY SUB ON
SWITCHING REGULATOR IC6008 T6004
B+ SWITCH
Q6000 , 6009
+5V REG IC6005
AGU
+5V REG IC6004
GT
FAN HOUSING THERMAL FUSE
STBY 5V
FIGUREFIGURE 1-5 1-5 MIX-5 CHASSIS POWER SUPPLY BLOCK DIAGRAM MIX-5 CHASSIS POWER SUPPLY BLOCK TVP-20 10
System Control and Protection

Primary control and protection of the television is accomplished by TV Micro (SAIPH) IC8002 located on the AGU board as illustrated in Figure 1-6. Certain control of video processing and protect monitoring are also accomplished by the Chimera Micro IC4100 on the B Board but all commands are carried out by the TV Micro by communications via the 3.3V IC BUS.
to protect the unit. If a problem occurs in any of these areas, the TV Micro will turn the unit off and ash the power LED in a number of sets to indicate what caused the shutdown. Even if the Chimera Micro detects a problem, it communicates this to the TV Micro.
Lamp Position and Lamp Cover Monitor

The T1 board contains a switch to monitor the lamp access cover. It is closed when the locking handle for the cover is turned fully clockwise to secure the door. This is necessary to assure proper airow to cool the lamp. Note that the switch is in series with another located on the T2 board. This switch is closed when the lamp is fully seated into the high voltage cable connector in order to assure that no arcing occurs between the lamp pins and socket if the lamp were not pushed fully forward. This switch also completes the ground path for both switches keeping the lamp cover and lamp switch lines low. If either of the switches fails or is opened, the unit will shut down and the power LED will ash in sequences of 3.
System Control
The unit is powered up by a high originating from pin 134 of IC8002. During this period, the ATSC Decoder on the QM board along with the Chimera and Chimera Micro are polled. The green power LED on the front of the unit will be ashing. Assuming that none of the monitored protect lines indicate a problem, the following events will occur. Pin 143 (Fan Drive) goes high to allow the starting of the 4 fans. Chimera Micro IC4100 on the B Board sends a high to CN8003-19, through the AGU board and exiting CN8410-10 to start the Lamp Driver. The Power LED on the front panel will stop ashing and remain a steady green. Systems control at this point will control items such as input and/or channel selection, sync frequency detection and customer controls.
Thermal Protection
The S2 board, located inside the lamp housing, has a digital thermometer IC located on it. This IC sends temperature information to the TV Micro via the 5V IC bus. Fan speed is varied according to the temperature feedback. If the temperature exceeds a pre-determined level, the unit will shut down and the power LED will ash 2 times. The same thermal IC is also located on the C board (not shown) to monitor the LCD panel temperature and the HB board to monitor ambient temperature within the cabinet
Fan Locations
Figure 1-7 illustrates the location of the 4 fans. Fan 1 (located inside the Optical Block) is the only fan that cannot be replaced individually. Fans 2, 3, and 4 can be ordered and replaced as seperate items.
Protect Monitoring
TV Micro IC8002 on the AGU board and Chimera Micro IC4100 on the B board monitor various switches, temperature sensors, and voltage lines
TVP-20
11

8X 6X 10X
K
THERMAL IC7021
CN8401
B_12V Q 10.5V AC RLY
OVP DET
31,32 46,45 12
LVP DET
OVP DET
HB
2X
CN8001
SP_PROT
13
TP3601 5V_SDA
+5V
Q8019 Q8022
THERMAL IC603
THERMAL IC7180
S2
CN8410
SDA SCL LAMP PROT LAMP CTL HV DET LAMP CVRLAMP CVR+
TP3602 5V_SCL
3 4 7 10 13 14 15
78
79
134
126
127
128
3.3V_SCL
3.3V_SDA
BE_OVP
LB_ERR
ATSC_OVP
MAIN_ON
5X
7X
SP_PROT
FAN_ERR FAN_DRIVE
LAMP DRIVER
IC8002 TV MICRO (SAIPH)
149
38 143
4X
3X
LAMP COVER SW
T1
CN8403
LAMP POS GND
1 2
IC8703
5V I2C
3 4
FAN1 PWR FAN1 PROT
CN8002
LAMP POS SW
T2
CN8003 TO B BOARD
LAMP CVR HV DET LAMP CTL LAMP PROT
IC8704 FAN CONTROL
IC8702
6 7
9 10
FAN2 PWR FAN2 PROT

FAN3 PWR FAN3 PROT
IC8701
8 5 19 7
IC8700
12 13
FAN4 PWR FAN4PROT
AGU
FIGURE 1-6 FIGURE 1-6 SYSCONAND PROTECTION MIX-5 CHASSIS SYSCON AND PROTECT BLOCK DIAGRAM
TVP-20
12
Chapter 1 - Circuit Description Fan Protection

All 4 fans in the television are monitored for rotation. If a fan is operating properly, the rotation protect line for each fan will be less than 1VDC. If any of the fan protect lines rises above 1-volt, the unit will shut down and ash the power LED 4 times.
Speaker Protection
If any DC voltage appears on the left or right speaker lines, a high will enter the AGU board at CN8001-13. The unit will shut down and the power LED will ash 7 times. Table 1-1 lists the protect features, number of LED ashes, and causes.
Lamp and Lamp Driver Protection

The Lamp Driver board (ballast) monitors the voltage and current being sent to the lamp. When the lamp is red from a cold start the voltage can reach upwards of 26KV. Once the lamp starts and ionization of the gas begins, the voltage is immediately dropped to around 20-30 volts and slowly raised to an operating voltage of roughly 90 volts. During these sequences, the current and voltage curves are monitored for abnormalities. A weak or defective lamp can affect these curves as can a failure of the Lamp Driver circuits. Any event in this stage will cause a high to appear at CN8410-7 which sends the high to the B board via CN8003-8. The unit will shut down and ash the Lamp LED on the front cover. The Lamp Driver is also monitored to verify the proper startup of the high voltage circuit. If the Lamp Driver fails to generate the required high voltage to start the lamp, the unit will shut down and ash the power LED 5 times.
Blinks 2 3 4 5 6 7 8 10
Error Cause Excessive Panel or Lamp Temperature Ventilation or sensor IC failure Lamp not fully seated or lamp cover Lamp Position/Cover open Fan Rotation Error Lamp Driver Low B+ Error Speaker Protection B+ Over-Voltage ATSC Over-Voltage Fan not rotating or defective fan Ballast did not start B12V too low DC detected on speaker line B 12V too high Q10.5V too high
OVP and LVP Protection

The regulated 12V generated on the GT board is monitored at CN8401, pins 31 and 32. OVP and LVP circuits (consisting of zener diodes and transistors), monitor this voltage. If the 12V line rises above 12VDC or drops below 8.2VDC the unit will shut down and ash the power LED 6 times for a low-voltage condition or 8 times for a over-voltage problem. Q10.5V is monitored at CN8401 pins 45 and 46. If this voltage rises above 12VDC the unit will shut down and the power LED will ash 10 times.
TABLE 1-1 MIX-5 CHASSIS DIAGNOSTICS EVENT INDICATION TVP-20 13
Diagnostics History
A history of protect events can be viewed by turning the unit off and re-starting by pressing the DISPLAY, 5, VOL-, and POWER buttons, in sequence on the remote commander. A view of the above diagnostics features will appear. If an event occurred of any of the protect circuits, a 1 will appear in the extreme right hand column. A zero will appear if no event occurred. This feature is useful for troubleshooting intermittent problems or multiple protect events of more than one item to assist in determining where the failure might be occurring. The protect event column does not keep a running tally of events. It will always show 1 when an event has occurred even if it has happened more than once. The event column can be reset back to zero by pressing the number 8 followed by ENTER on the remote commander. This is not the same as pressing these keys to reset the television as is done in the service mode.
Alternate Diagnostics History

A history of diagnostic events can also be viewed in the service mode. Power the unit down and press DISPLAY, 5, VOL+, and POWER, in sequence, to enter the service mode. The rs Item adjustment group STATUS_1 will appear. By scrolling through these items all of the protect events mentioned will appear. If an event occured the data will have changed from zero to one. This record will remain unless the data is set back to zero and saved. An additional set of status information is available by continuing to scroll and located the STATUS_2 items. If more than one diagnostics event has occured, the data will have changed from zero to one.
TVP-20
14
FAN 3
FAN 4
FAN 1 INSIDE OPTICAL BLOCK
FAN 2 INSIDE LAMP HOUSING
FIGURE 1-7 FIGURE 1-7 FAN LOCATIONS FAN LOCATIONS TVP-20 15
Chapter 2 Service and Troubleshooting

Overview
The approach to troubleshooting the MIX-5 chassis is similar to those used for previous chassis designs for rear projection LCD televisions. All repairs under warranty are performed at board level. The only exception to this rule involves the T1 and T2 boards. As of this writing, these boards are not available as an assembly.The T1 and T2 boards contain switches for the lamp position and lamp cover detection. These will need to be replaced at component level and the same switch is used on both boards. This chapter will familiarize the technician with the board and optical block locations. The AGU board is an excellent source of voltage and signal test points since it contains the TV Micro and virtually all video, audio, bus data, and voltages pass through it. It is easy to access for measurements if needed. The layout of the MIX-5 chassis is dramatically different than previous designs. The goal to create a slimmer cabinet design made it necessary to relocate virtually every circuit board long with the lamp and lamp driver assembly. The main wiring harness is secured to the cabinet rather than an independent chassis. Locking connectors are used at all cable to cable and cable to board locations. Accessing the lamp driver or optical block requires the removal of the chassis since they are behind the circuit boards. Chapter 3 covers a step-by-step procedure for replacing each of the major components. These procedures have been developed and tested numerous times to provide the quickest method to replace the required components. Once the technician becomes familiar with this chassis, service times will be at an acceptable level. The latter part of this chapter will provide troubleshooting owcharts to assist in determining what boards or major components should be brought to the customers home to successfully complete the repair at that time. The owcharts will be structured so that a person performing a triage diagnostics can gather enough information from the customer to advise the eld technician on what to bring for the repair. In cases where multiple boards or components are needed to bring to the repair site, additional owchart information will be provided to assist the technician in performing a couple of checks to replace the most likely component the rst time.
Circuit Board Locations

Figure 2-1 illustrates the locations of the major circuit boards and optical block. The upper left photo is taken from the left side of the unit as viewed from the rear. Note the B Block assembly. It contains the B, QM, and QT boards. This assembly is replaced as a single unit when servicing, It also contains the # 4 cooling fan. To the left of the B Block assembly is the housing for the PCMCIA Cable Card slot. Above this is the RF switching assembly. Note the main cooling fan (#3). The lower-left photo shows the location of the T1 board (lamp door switch), S2 board (lamp housing thermal sensor IC), T2 board (lamp position detect switch), and the thermal protect fuse for the lamp housing. The right-side photo illustrates the location of the AGU, K, GT, and C board/Optical Block assembly. The AGU board plugs directly into the GT board via a perpendicular connector. This required pulling the assembly outward for illustration purposes.
TVP-20
16

LAMP DRIVER (LOCATED BEHIND CABLE CARD SLOT)
PCMCIA CABLE CARD SLOT
B BLOCK ASSEMBLY
C BOARD AND OPTICAL BLOCK
K BOARD
AGU BOARD
S2 BOARD
T1 BOARD
GT BOARD
THERMAL FUSE
T2 BOARD
FIGURE 2-1 FIGURE 2-1 MIX-5 CHASSIS CIRCUITBOARD LOCATIONS MIX-5 CHASSIS CIRCUIT BOARD LOCATIONS
TVP-20
17
AGU Board Test Points

As mentioned previously, the AGU Board provides a good source of test points for voltage and signal testing if needed. The plastic cover containing the input labels can be removed for access to all of the connectors. It is secured by 6 screws located at the input jacks. In Figure 2-2, the layout of the various connectors is shown. The pin mounting of most of the connectors is single-sided. A few have two-sided pin congurations (one side even numbered pins, the other odd numbered). Note connector CN8008. This connector is not visible with the plastic cover installed unless the small access door is removed. This connector is a test interface for factory adjustments and is not utilized for eld service. The labels on most of the connectors can be read on the circuit board silk screen and are self-explanatory in most cases. Items such as voltages, and audio video signals are obvious. The following list contains voltages for certain sensing or command signals and their proper levels. CN8002: This is the common connector for all four fan motors. The fan drive voltage for any operating fan (pins 3, 6, 9, and 12) is 5VDC. The fanprotect feedback line for each fan is 0.08VDC. This voltage should remain well below 1 VDC for a correctly operating fan. The location of each fan is as follows: Fan 1: Located inside the Optical Block. As of this writing, this assembly must be replaced if the fan fails. Fan 2: Located on top of the Lamp Chamber. When the Lamp Driver board is replaced, this fan will be encountered. It is replaceable as a separate assembly. Fan 3: Main fan located to the left of the B Block assembly. Replaced as separate unit. Fan 4: Located in the B Block assembly. It is also available as a seperate component. CN8403 Pin 1: Connects to T2 board containing the lamp position
switch. The other side of the lamp position switch is connected to ground. As mentioned in Chapter 1, the lamp position switch is in series with the lamp cover switch. The voltage at this point is normally zero-volts. CN8410: Various control and sensing is located at this connector. Pins 3 and 4: Temperature feedback from the S2 board containing the digital thermometer IC. The DC voltage will uctuate rapidly from 3.4 to 3.9VDC due to the bus activity. Pin 7: Lamp protect. A low should normally be read. A high (5VDC) indicates a defective lamp or lamp driver. Pin 10: Lamp control. The Chimera Micro on the B board sends a high of 2.8VDC to turn the lamp driver on. Pin 13: HV Detect. Normally low. Goes high if the lamp ballast circuit does not start up. Pin 14 and 15: Connects to T1 board. Both pins should be normally low. This is a good test point to determine if the lamp cover or lamp position switch is open or defective. CN8003: The monitoring points of CN8410 exit to the B board. The normal voltages will be the same as those found on CN8410. CN8005 Pin 11: RF switching block control. Low (zero volts) for cable input and 5VDC for antenna (terrestrial) input. CN8401: Commands to turn on the GT board power supply and supply standby voltage to the main relay. Pin 10: Labeled 12VDC but test unit read 10.44VDC Pin 11: Relay VCC 5VDC Pin 12: AC Relay command to turn on main relay RY6001. 3.07VDC. Pin 13: Sub On. 2.99VDC with no Cable Card inserted. Zero VDC with card inserted.
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CN8406: Iris motor drive and feedback. High drive voltages indicate a defective motor. High Hall Device out and low inputs indicate a defective motor. Low or non-existing drive or Hall Device voltages indicate drive circuit failures. Voltages for a properly functioning test unit were as follows: Pin 1: Pin 2: Pin 3: Pin 4: Pin 5: Pin 6: Pin 7: Pin 8: 4.49VDC 3.67VDC 4.65VDC 2.8VDC 4.55VDC 6.46VDC 4.49VDC 5.27VDC
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PC AUDIO L
FAN1 POWER
TUNER R
MCLK
+11V
PC AUDIO R SW 5V
3 5
FAN1 PROTECT
TUNER L AFT TUNER CV

SCL SDA
5 7 8
10 11
BCLK LR CLK LR DATA

SPEAKER PROT AUDIO MUTE
3 4 5
13 14
AU_R AU_L Pr
Pb Y
2 3
4
FAN2 POWER
FAN2 PROTECT
5 6
FAN3 POWER
SW 3.3V
15
FB -
FAN3 PROTECT
10
FAN4 POWER
12
FAN4 PROTECT
13
CN8002
CN8001
K BOARD AUDIO
CN8402
HDMI IN
DRIVE HOUT -
2 3
4
CN8406
HIN -
IRIS MOTOR
HOUT + HIN +
FB +
5 6
7
DRIVE +
MAIN Y
MAIN Pb
MAIN Pr
MAIN CV/Y
CN8404
CN8814
VIDEO_2 Y
VIDEO_2 Pb
MAIN C
VIDEO_2 Pr
CN8006
CN8403
LAMP POS SW
ATSC SPDIF
CN8004
FUNCTION KEYS LED INDICATORS
THERMAL SDA
CN8800 (not used)

CN8410
CN8815
THERMAL SCL
LAMP PROTECT
5V SDA
TP3601 TP3602
IC8002 TV MICRO (SAIPH)
LAMP CONTROL
10
CN8400
VIDEO_2 CV
VIDEO_2 AU_L
HV DETECT LAMP COVER LAMP COVER +
13 14
15
5V SCL
VIDEO_2 AU_R
HV DETECT
LAMP PROTECT LAMP COVER

LAMP CONTROL
7 8
19
CN8003
+12V
10
RELAY VCC
11
B +12V
CN8405
CN8005
CN8008 TEST JIG
AC RELAY
12
V1
V3
V4
V5
SUB ON
13
PC 3.3V
SET 9V
16
SET 5V
20
CN8401
SET 3.3V
24
ANT SWITCH
11
STBY 5V
28
Q 5V
13
AUDIO 5V
35
Q10.5V
14
AUDIO GND
36
UNREG 6V
38
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FIGURE 2-2 MIX-5 CHASSIS AGU BOARD TEST POINTS FIGURE 2-2 AGU BOARD TEST POINTS
Q 10.5V
46
Q 5V
49
20
Service Mode
Accessing the service mode is accomplished in the same way as has been used in past Sony television products. Press DISPLAY, 5, VOL+, and POWER in sequence on the remote commander to enter the service mode. OSD graphics for the Main Micro data settings will appear at the top of the screen. Although the service mode allows access to a large amount of adjustments, most will never need to be adjusted unless data becomes corrupted. In certain cases, such as board change-outs, items such as white balance or picture size may need to be adjusted.
Navigating the Service Mode

There are 3 major categories of adjustments in the MIX-5 Chassis 1. TV Micro 2. QM 3. BE Micro These categories are selected by pressing JUMP on the remote commander. Within each of these categories are groups of adjustment data. Figure 2-3 illustrates the steps needed to navigate within each individual category.
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CCPM 1 SHPC 0 Wide Zoom WSL: 0 1 SERVICE Video 1 CCPM 2 PACK 0 Wide Zoom WSL: 0 4 SERVICE Video 1 CCPM 3 AD1E 0 Wide Zoom WSL: 0 0 SERVICE Video 1
GROUP 1
GROUP 2
GROUP 3
CCPM 1 SHPC
0 Wide Zoom WSL: 0
1 SERVICE Video 1
CCPM 1 FUP2
1 Wide Zoom WSL: 0
0 SERVICE Video 1
CCPM 1 YNR
2 Wide Zoom WSL: 0
0 SERVICE Video 1
ADJUSTMENT ITEM 1
ADJUSTMENT ITEM 2
ADJUSTMENT ITEM 3
CCPM 1 SHPC
0 Wide Zoom WSL: 0
1 SERVICE Video 1
DATA CHANGE
CCPM 1 SHPC
0 Wide Zoom WSL: 0
2 SERVICE Video 1
MUTE + ENTER
SAVE DATA
"0" + ENTER EEPROM READBACK
MIX-5 CHASSIS SERVICE MENU NAVIGATION TVP-20 22
FIGURE 2-3 FIGURE 2-3 SERVICE MENU NAVIGATION
Adjustment Items
Graphics selection (for troubleshooting and picture adjustments) and white balance will usually be the only two areas of the service mode that require access. 3 sets of test pattern graphics are contained within the service mode located in the QM sub-group. White balance adjustments are located within the BE Micro sub-group.
The data value should be set at zero. Using the 3 key on the remote commander will change this data and different test pattern graphics will appear with each increase of the data value. There are 4 sets of 20 graphics (data 1 to 80. Each set of graphics is redundantly generated but in different resolutions. They are as follows: 1-20 21-40 1080i 480i
Test Graphics
Various test patterns are generated to assist in picture quality checks and alignments. They are also useful for troubleshooting video problems since patterns are generated in various locations. Graphics are generated in 3 different circuits: Main TV Micro (Saiph): Data display for general alignment and diagnostics history. These graphics will appear as large green letters and are the rst to appear when entering the service mode. The Main TV Micro does not generate the graphics. It sends the appropriate data to the QM ATI Micro where the graphics are generated. QM Board: Customer menus originate here. The QM board also generates its own service data. The adjustment data graphics are displayed as blue. Various test pattern graphics are also generated. C board: The BE Micro generates test pattern graphics along with its own adjustment data graphics. The letters displayed are green and noticeably smaller than the Main TV Micro graphics. Since the test pattern graphics in this location are generated just before the video drives the LCD panels, they are useful when attempting to isolate the Optical Block assembly during a video failure resulting in loss of video or distortion.
41-60 480p 61-80 720p NOTE: These graphics are valuable in verifying proper scaling of the 4 major ATSC resolution formats. Verication of each resolution can be seen by pressing the 4 key on the remote to move back to the INFO group. Change the data from zero to one and a palette will appear with information about the ATI Micro and signal performance. One of the items is the current resolution format. This palette can be left on while returning to the PATN group and viewing the different sets of pattern resolutions. A second set of test patterns can be displayed by moving to item 2 in the QM Mode. This item is labeled GPTN. These are addition test graphics and all are in high resolution (1080i) and originate from the same area that the customer menu is generated. The patterns will not ll the entire screen because of this. All of the above graphics are generated on the QM board and are useful for video troubleshooting. If they can be displayed, the B board and Optical Block are eliminated as potential causes of the failure.
QM Graphics
Once the service mode has been activated, press JUMP on the remote commander to change the category to the QM group. Once the QM adjustment data category has been reached (the adjustment graphics will change from green to blue), the rst adjustment item will appear as INFO and is labeled as item 0. Press the 1 key on the remote commander to move to the next adjustment item labeled 1. This item is named PATN,
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Chapter 2 Service and Troubleshooting BE Micro Graphics

Use the JUMP key to enter the BE MICRO category. Press the 5 key (rather than the 2 key since the group is located near the end of the catagory) to maneuver through the adjustment groups. The BE Micro graphics are located in category 32 labeled D8909TPN. The rst item is TPNSW. The default data is zero. Changing the data to 1 will cause a at eld to be displayed. By default, the eld should be approximately 70IRE white. The color of the eld can be changed by the next item. Item 01 is labeled TPNRGB. The default data is 0007 for a white screen. Changing the data progressively downward changes the eld to the primary and secondary color elds. The last setting (zero) generates a black screen. Be aware that the adjustment data graphics cannot be seen while in this mode. It is not necessary to change the TPNSW data to see these at-eld patterns. Any time you enter the TPNRGB group and change data, the various colored elds will appear. This group of adjustment graphics is extremely useful when troubleshooting video problems that appear to originate in a single panel color. Be certain to return the data back to white screen before exiting the BE group. If this is not done, none of the test patterns in the BE group can be seen. If it is left set to a primary or secondary color, the test graphics will also appear that way. Item 4 is labeled TPN Mode. Various test patterns generated by the BE Micro in 10809i mode are generated here. IMPORTANT: Be certain to exit the BE Micro group before turning the unit off. Always turn the unit off in the QM or Main Micro service group. If this is not done, the unit will display the BE Micro data when it is turned back on and there will be no way to turn them off. If this occurs, simply unplug the AC power to perform a hard reset and plug the unit back in.
White Balance Adjustments

In general, white balance adjustments are not required on a regular basis with LCD-type displays. Changes in backlight color temperature will occur over time but this occurs at an extremely slow rate and is not normally noticed by the customer. White balance adjustments are occasionally required when the optical block is changed and denitely when another person alters the data settings. The adjustment data for white balance is located in the BE Micro category. Use the JUMP button on the remote commander to access this category. Press the 2 button to locate the CTT group. This group is located 10 steps from the initial BE Micro page so you will have to press the 2 button this many times. Once in the CTT group, 6 adjustment items are found to adjust white balance. There are 3 background (R_BKG, G_BKG, B_BKG) and 3 drive adjustment items (R_DRIVE, G_DRIVE, B_DRIVE). The background adjustments affect the low light areas of the video and the drive adjustments the highlight areas. The adjustment data for each item is a 4-digit hexadecimal number. Previous chassis designs utilized a 3-digit binary number system and this is something the technician should be aware of.
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Chapter 3 - Troubleshooting Flowcharts

Introduction
The following owcharts will assist in determining what boards or major components need to be brought to the service site in order to raise the possibility of a successfully completed repair without a second visit. The owcharts are structured to allow one to triage the repair based on input from the customer. In many cases, multiple boards may need to be brought to the location. Flowcharts A through F are specically designed to provide guidance to a person who is attempting to analyze a particular failure based on information gathered from the customer. This can be difcult at times since the person gathering information from the customer has some (or extensive) knowledge about the product. The customer will have very little, or none. The responses received from the customer will vary greatly because of this. Use the initial owcharts as a guide and your experience with customer relations as to how the questions should be asked. Some of the owcharts contain information boxes specically designed to route the technician to additional test procedures to provide assistance to the technician once he or she is on location with the recommended parts. These owcharts provide addtional troubleshooting information and may require reading voltages. Their purpose is to gather additional on-site information and raise the possibility of installing the most likely part to x the failure if multiple items are brought to the location. The owcharts are categorized by major circuit groups ans symptoms. Each group contains supporting text to provide insight and troubleshooting tips to understand and properly diagnose the potential cause of the failure.
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Chapter 3. Troubleshooting Flowcharts
Initial Contact Flowchart
A
Start
MIX-5 Chassis Initial Contact Troubleshooting Flowchart A
Does unit turn ON?

Yes
No
GO TO Power Supply Troubleshooting Flowchart B
Is video distorted?
No
Yes
GO TO Video Distortion Troubleshooting Flowchart E
Is GREEN or RED LED Flashing?

Green
Red
GO TO Protection Mode Troubleshooting Flowchart C
Is audio present?
No
GO TO Audio Troubleshooting Flowchart F
Yes
Is video present?
Yes
No
GO TO No Video Troubleshooting Flowchart D
Distorted
Yes
No
Done
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26
Power Supply Troubleshooting

One feature that has been removed from the MIX-5 chassis design is the red standby LED. In previous models, the power/standby LED remained lit in red. It turned green when the power was turned on. The power LED in the MIX-5 chassis will turn red, but only for diagnostics indications. A lit standby LED was a good troubleshooting tool since it clearly indicated a functioning standby power supply (one of the rst items to check when a unit will not turn on). Without the standby LED to provide a clear indication of standby power, other methods must be used to test this stage. The rst test is to listen carefully for the sound of two relay clicks. The main relay (RY6001) should engage followed by the in-rush current relay (RY6002) engaging approximately 1.5 seconds later. It is possible to hear only one relay click. This indicates the in-rush current relay may not have engaged and the unit will go into protect shutdown with and 6-blink diagnostics indication. Refer to Figure 1-5 in Chapter 1 for an illustration to this explanation. The B 12V line is monitored for excessively low or high conditions and the power LED will blink 6 or 8 times respectively if there is a problem. The Q10.5V is also monitored for over-voltage and will cause the diagnostics to blink the LED 10 times. If the entire switching regulator fails to start, the diagnostics circuit will blink the power LED 6 times. This can be misleading since it could cause the technician to immediately suspect the GT power supply board as the culprit. Flowchart B will aid in determining the likely cause based on symptoms in the eld. Note the directive to Flowchart G to further isolate the cause by noting various symptoms and taking voltage measurements. A Note on 6-Blink Shutdown Indications: Any time the power supply does not start, the Main Micro (IC8002) on the AGU board will detect the loss of B12V. Since the Main Micro (IC8001) is always running on standby voltage, it assumes there has been a failure of the B12V line (in fact, there technically is). If the main relay (RY6001) were to fail, the main switching regulator would not turn on (even though IC8001 has commanded it to). This causes a misleading diagnostics
indication. Any excessive loading of the secondary voltages can cause the switching regulator to turn off since there is over-current monitoring within the circuit. If the thermal fuse (located within the lamp assembly) were to open, standby 5V would no longer be applied to the main relay (RY6001). The main switching supply would never turn on and an erroneous 6-blink shutdown would occur. If a 6-blink shutdown occurs, always listen for the sound of relay clicking. If none is heard, the main relay could be defective (unlikely), the standby supply has failed, or the thermal fuse is open. The presence of standby 5V is easily checked by reading the voltage at the thermal fuse. The location of this fuse is illustrated in Figure 2-1. If no voltage appears on either side, the standby supply is not working. If 5VDC appears on one side and not the other, the fuse is open. If voltage appears on both sides, the main relay is defective or is not being told to turn on.
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No Power Flowchart
B
Unit Does Not Turn On
MIX-5 Chassis No Power Troubleshooting Flowchart B
Audio Present?
Video problem Go to flowchart D
Green LED Lights Steady after while?

No
Yes
GO TO No Video Troubleshooting Flowchart D
Clicking Noise Heard?

Yes
No
Verify unit is plugged in and has AC power. If AC OK: GT Board A1113732A *AGU Board A1129346A Thermal Fuse 157691211
Continues Flashing?
Yes
B Block A1167541A
No
Go to field troubleshooting flowchart G
Red LED Flashes?
Yes
Go To Protect Mode Troubleshooting C
No
Green LED Flashing?

Yes
No
GT Board A1113732A B Block A1167541A
Power OK. Check for Video Problem
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Protect Mode Troubleshooting

The self-diagnostics feature incorporated within the MIX-5 chassis is a valuable tool in determining what board might be the likely cause of a failure. In most cases it leads the technician towards the potential source of the failure. In some cases, the diagnostics indication is rather vague. A perfect example of this would be a 4-blink event indicating a cooling fan failure. This could be caused by lack of B+ drive to the fans, lack of fan control, or the failure of a singe fan. In a situation such as this, the technician must arrive at the service location with the AGU board, 3 different fans and the optical block. Figure 1-7 in Chapter 1 species the location of the 4 fans used in this chassis. Fan 1, located inside the optical block is not available for replacement. The other 3 fans, Fan 2 inside the lamp driver/housing assembly, Fan 3 (main intake), and Fan 4 inside the B Block assembly can be replaced as individual items. CN8002 on the AGU board supplies power to all 4 fans. This is observed in Figure 2-2 in this Chapter. The fan rotation-detect lines for each individual fan is also located at this connector. Each fan receives approximately 5VDC of drive voltage under nominal conditions. The rotation-detect lines are normally low (less than 1VDC). In past chassis designs, overtemperature conditions and fan rotation errors were included in the same diagnostics error indication. If a thermal IC failed, the fans would not be turned on. This unit must turn the fans on to detect rotation. This allows a moment for each rotation-detect to be tested before the unit goes into protect mode. It also allows the ability to check if the fans are receiving drive voltage. Protect events occurring with a 6-blink diagnostics indication can be misleading. This is covered in the section dealing with a no power condition as explained in Flowchart B. Dont become dependent on the self-diagnostics feature of this television. Use it as an additional tool in isolating the cause of a problem. Traditional analysis of symptoms based on what you see or hear (or dont see or hear) should always be utilized in conjunction with this feature.
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Protect Mode Flowchart
C
Red Standby LED Flashing
MIX-5 Chassis Protect Mode Troubleshooting Flowchart C

*OPTICAL BLOCK PART NUMBERS KDF-E42A10 KDF-E50A10 A1123071 A A1123069 A
See Flowchart G for additional information about this protect event
6X
Possible ventilation problem S2 board A1103763A HB board A1103767A Optical Block*
Yes
GT board A1113732A Thermal fuse 157691211
2X
Yes
No
No
3X
Yes
Check for proper lamp positioning or loose lamp cover. S7150 T1 board S7155 T2 board 178659111 (same switch)
7X
Yes
K board A1115002A
No
No
4X
Yes
**AGU board A1129346A Fan 2 178723111 Fan 3 178737311 B block A1167541A Optical Block*
8X
Yes
GT board A1113732A
No
No
5X
Yes
Lamp Driver 146893611 Lamp A1124850A
10X
Yes
GT board A1113732A
No
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Video Troubleshooting
Since virtually all video processing is performed on the B board, failures are likely to be traced to this point. This is especially true if distortion is evident in the picture. Since most of the video processing is done at the digital level, the distortions will usually appear as digital blocking or loss of picture detail. Failures on the QM board can also create the same distortions but it is part of the B Bock and replaced together with the B Board. Flowchart D provides some guidance in determining the cause of a failure of video. The AGU board is responsible for routing all video sources other than the ATSC digital information. Failures here would cause a loss of one or more of the video inputs (including the PC input) but would not affect signals from the ATSC tuner. A powerful tool for troubleshooting a loss of video (or distortion) is the internal service data graphics and various test graphics generated on the QM and C boards. When the service mode is entered (unit turned off and DISPLAY, 5, VOL+, POWER pressed in sequence on the remote commander) the default graphics will be the general service mode. Large green letters will appear on the screen. This is an indication that the Main Micro on the AGU board is communicating graphic data ATI Micro on the QM board (where all digital video decoding is performed for ATSC signals). It also eliminates the B and C boards as the possible cause of the loss of or distortion in the video signal since the graphics are being processed.
In the QM service group, press the 1 key on the remote to select Item 1 labeled PATN. Using the 3 key to change the data value will scroll you through various test patterns. 4 groups of 20 patterns are available for each resolution. They are as follows: 1-20: 21-40: 41-60: 61-80: 1080i 480i 480p 720p
Additional graphics are available by selecting item 2 (GPTN). All of these graphics are 1808i and generated by the same circuit that displays the customer user menu so they will not ll the screen entirely.
BE Graphics
The BE Micro located on the C board directly generates graphics to the scaling IC just before the LCD panel drivers. Press the JUMP button on the remote until smaller green letters and numbers appear. The fact that these can be seen is a good indication that the C board is functioning properly and the optical block will not need replacement. Additional test graphics are located in this circuit. The most useful is the ability to generate various at eld patterns in white, black, and each primary and secondary color. This is extremely useful for troubleshooting suspected problems with a particular LCD panel. These patterns are accessed by going to group 32 while in the BE mode. Use the 5 key on the remote to scroll to this group number. It is called D8909TPN. Using the 1 key, scroll to Item 1 labeled PNRGB. By pressing the 3 and 6 key on the remote various at eld colors are displayed as mentioned above.
QM Graphics
In situations where video failures occur only when ATSC channels are selected, the graphics generated by the QM board are helpful. By pressing JUMP on the remote Commander, the test data graphics will change from green to blue. If these graphics appear, the circuits on the B and C boards are functioning. The B block should be replaced. Other test pattern graphics are available to assist in alignment and overall examination of how well the unit is scaling the various formats specied by the ATSC.
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NOTE: Always return screen to white (data 0007) when nished. If this is not done, additional test graphics located in the BE micro will be displayed in that color. None will be displayed if left in black eld (data 0000) mode. Do not turn the unit off while in the BE service mode. When you turn the unit off and back on, the BE graphics will still be present and you will not be able to control them because the remote commander is back in the conventional mode. If you accidentally do this, unplug the unit to perform a hard reset of the microprocessors and the unit will operate correctly.
Lamp Does Not Light

If the lamp fails to light, there will be video (for obvious reasons). Note in Flowchart D that you are directed to Flowchart G. This owchart is for use in the eld to further determine the cause of a lamp not turning on. By reading voltages with a multi-meter, it can be determined if the lamp is not lighting because of a failed lamp, lamp driver, or power supply issue.
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No Video Flowchart
MIX-5 Chassis No Video Troubleshooting Flowchart D

*OPTICAL BLOCK PART NUMBERS
No Video
KDF-E42A10 KDF-E50A10
A1123071 A A1123069 A
Tuner only?
No
Yes
B Block A1167541A
Lamp Lights?
No
Lamp A1124850A Lamp Driver 146893611
Yes
Video Inputs 1 through 6?
Yes
**AGU Board A1129346A
See lamp troubleshooting flowchart H
No
Any OSD Graphics Displayed?

Yes
No
Optical Block*
Video 7 (DVI)?
No
Yes
P Board A1129345A
See OSD troubleshooting flowchart I
Video 7 (DVI)?
Yes
IC7200 HPC Board 670460001
All Video Sources Affected?

No
Yes
B Block A1167541A
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Video Distortion Flowchart
MIX-5 Chassis Video Distortion Troubleshooting Flowchart E

Video Distortion
OSD OK?
No
Optical Block*
Push on top part of cabinet to make screen move.
Yes
Lines or Graphic Patterns?

No
Yes
**B Block A1167541A
Does Dark Spot Move?
Yes
Dust in Optical Block or Pixels Unlit
No Yes
AGU Board A1129346A B Block A116764A
Dust on Rear of Screen.
Video Level Problem?
Dark or colored specks?
Colored
Pixel Failure See ESI bulletin for pixel guidance
NOTE: See Appendix of training manual for clarication of pixel failure and dust particle issues
Dark
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Audio Troubleshooting
All switching and processing of audio signals are performed on the AGU board. Amplication is done on the K board. In a situation where no audio is present from all inputs, the AGU or K board could be the cause. A simple way to isolate this issue is to use the televisions audio output jacks and connect them to an external amplier. If audio is present, the K board is not the cause. The problem resides on the AGU board. Audio troubleshooting Flowchart F provides a quick check of the audio symptoms and what board(s) should be brought to the service site.
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Audio Flowchart
F
Audio Problem
MIX-5 Chassis Audio Troubleshooting Flowchart F
Audio Present?
No
Internal Speakers Turned Off?

Yes
No
AGU Board A1129346A K Board A1115002A
Yes
Done
Tuner Only?
Yes
B Block A1167541A
All Channels
No
Verify Unit not in SAP Mode
No
Yes
Any Or All Other Inputs?

No
Yes
*AGU Board A1129346A
Distorted
Yes
All inputs?
No
Yes
Done
AGU Board A1129346A K Board A1115002A
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No Power Field Troubleshooting Flowchart
G
No power
MIX-5 Chassis No Power Troubleshooting Flowchart G

THERMAL FUSE
Power LED blinking 6X?

No
Yes
5VDC both sides of thermal fuse?
One side
Thermal fuse 157691211
Both Sides
GT board A1113732A
PWR LED blinking green?

No
Yes
B Block A1167541A
5VDC either side of thermal fuse?

No
Yes
3VDC No CN8401-12 AGU board?

Yes
No
AGU board A1129346A
GT board A1113732A
GT board A1113732A
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Lamp Failure Field Troubleshooting Flowchart
H
No Backlight
MIX-5 Chassis Lamp Troubleshooting Flowchart H
Does lamp LED light?
Yes
Replace Lamp. Problem Fixed?

Yes
No
Replace lamp driver board 146893611
No
Done
2.8VDC CN8410-10 AGU board?

Yes
No
B Block A1167541A
Backlight seen on screen?

No
Yes
Video problem. Go to flowchart D
Replace lamp driver board 146893611

No
Lamp lights?
380VDC No CN6018-1 on GT board?

No
Yes
Yes
Look into main intake fan at rear. If lamp lit, mirror is broken.
GT board A1113732A
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Using OSD Graphics for Video Failures Field Troubleshooting Flowchart
MIX-5 Chassis OSD Graphics Troubleshooting Flowchart I

No Video All Inputs
Enter Service Mode
NOTE: If no OSD graphics can be displayed but the lamp is lighting, check to make sure the LVDS cable from the B Block going to the Optical Block is not loose or damaged at either end before deciding to replace the Optical Block. Replace if damaged. (PN 183009921 )
LVDS cable
Initial Service Graphics Displayed?

Yes
No
Press JUMP Multiple times on remote commander
Any OSD Graphics Displayed?

No
Yes
QM service graphics?
Yes
B Block A1167541A
No
Press JUMP on remote commander
*Optical Block
BE Micro graphics?
Yes
B Block A1167541A
No
*Optical Block
TVP-20
39
Chapter 4 - Disassembly
Introduction
The MIX5 LCD rear-projection television chassis is used in the KDFE42A10 and KDF-E50A10 models. The new design decreases the depth of the unit to provide for a more slim design as compared with previous models. This new design required the relocation of the lamp and lamp-driver along with the circuit boards. Access to these components requires a bit more effort. The use of locking connectors on all of the circuit boards requires that the service technician be familiar with them to avoid damage to the connectors and/or circuit board assemblies. The purpose of this document is to familiarize the technician with the layout of the chassis and the types of connectors being used. Illustrated step-by-step procedures are also covered to assist in proper disassembly and re-assembly of the unit. Rather than provide a complete disassembly of the unit from front to back, the procedures in this document are broken down into steps covering the most common repairs involving the following components: B Block Replacement: This assembly contains virtually all of the circuits necessary to process the audio and video signals. The primary circuit boards are the QM, QT, and B boards. All of these boards are contained inside a shielded assembly and must be replaced as an entire unit. Lamp Driver: This board is not as easily accessible as were prior designs The entire chassis must be removed to access this circuit. Optical Block: Although the design is greatly simplied from previous optical assemblies, the entire chassis must be removed to access it. As with all new chassis designs, once you have the proper service procedure information and have serviced a couple of units, repair times should remain relatively the same as previous chassis repairs.
40
Chapter 4. Chassis Disassembly
Rear Cover Removal
E42A10
1 Pull down the claw Lamp door
E50A10
TVP-20
41
New Locking Connectors

Three types of locking connectors are used to secure the wiring to the circuit boards. Other types of locking connectors are used for cable-to-cable connections and these have been used in the past so they will not be covered. The connectors used on the circuit boards are of a small design and it is not easy to identify the locking mechanisms used unless one is already aware of them. Because of their small size, they could be easily damaged if an attempt is made to pull them directly out of their socket. The illustration below shows the 3 types of connectors and how they are released. Remember: The connectors are easily removed if the locks are disengaged. If you are exerting effort, the lock is not released and the connector will be be damaged
TYPE 1
TYPE 2
TYPE 3
LIFT ONE SIDE AT A TIME BY PUSHING TAB IN WITH SMALL SCREWDRIVER
SQUEEZE DOWN ON TAB TO RELEASE
SQUEEZE LOCKING TAB TOWARDS CONNECTOR BEFORE PULLING FREE
CAUTION! IF THE TYPE 2 FEMALE CONNECTOR HAS A SLOT (AS SHOWN) MAKE SURE THE LOCK TAB SEATS INSIDE THIS SLOT.
TVP-20
LOCKING CONNECTOR TYPES
42
B Block Removal
The following steps apply if only the B Block assembly is to be removed. If the Lamp Driver or Optical Block is to be replaced, go to the section on Chassis Removal which will prepare for access to the these items.
DISCONNECT GROUND WIRE
REMOVE 7 SELF-TAPPING SCREWS
SLIDE ASSEMBLY BACK TO END OF MOUNTING SLOTS AND LIFT TO RELEASE
B BLOCK ASSEMBLY REMOVAL STEP 1
B BLOCK REMOVAL STEP 1
TVP-20
43
UNPLUG CONNECTOR
DISCONNECT 2 GROUND WIRE SETS
REMOVE BOTH RF CABLES. NOTE CONDUCTIVE TAPE ON LEFT CONNECTOR
TVP-20
44
REMOVE GROUND CONNECTOR
DISCONNECT
B BLOCK REMOVAL STEP 3 TVP-20 45

Swing the B Block assembly outward as shown. Remove the four connectors on the left side of the B Block. Take note as to what type of locking connectors they are and remove each carefully and correctly. CAUTION: Swing the B Block outward with care. Observe the LVDS cable whenever the assembly is swung out. It is easy to damage the cable if it is snagged.
LVDS
TYPE 2
TYPE 1
TYPE 2

TVP-20
46

Remove the connectors illustrated below. Take note as to how each connector locks. The plastic spacer block shown is not supplied with the replacement assembly. This spacer block is secured with a long, silver colored, machine screw. The screw secures the spacer block and is also used to adjust the postion of the block to raise and lower the rear cabinet for vertical centering adjustment.
SWING B BLOCK ASSEMBLY OUTWARD AS SHOWN AND REMOVE LISTED CONNECTORS
Fan Connector
CN8403 AGU Board

Lamp Protect Connector Switch
Wire Holder
Remove cables
Spacer is not included with B Block Assembly

B BLOCK REMOVAL STEP 5 47
TVP-20

Once the B Block assembly has been removed, place it on a at surface as shown. The plastic housing behind the cable card assembly is now removed.
REMOVE SELF TAPPING SCREW
DO NOT REMOVE THIS SCREW AT THIS TIME!
SPREAD EDGES OF PLASTIC AND REMOVE FROM CABLE CARD ASSEMBLY
B BLOCK REMOVAL STEP 6 B BLOCK REMOVAL STEP 6

TVP-20 48

Once the cable card assembly has been removed, as shown below, only the B Block will remain. Be certain to tranfer the plastic chassis locking mount and screw-on RF connector to the replacement unit.
PLASTIC CHASSIS MOUNT NOT INCLUDED WITH REPLACEMENT PART
LIFT CABLE LOCK UP AND CAREFULLY REMOVE FLAT CABLE
FLIP ASSEMBLY OVER
KEEP THIS RF CONNECTOR . DOES NOT COME W/ REPLACEMENT UNIT
REMOVE MACHINE SCREW AND SLIDE CABLE CARD ASSEMBLY UP AND OUT . DO THIS BEFORE REMOVING THE RF CABLE !
REMOVE CONNECTOR
B BLOCK REMOVAL STEP 7 7 B BLOCK REMOVAL STEP TVP-20 49
Chasssis Removal
The following steps will provide the proper steps for removal of the chassis assembly which includes the B Block, AGU Board, GT Board, and Wire Harness Assembly. Once the chassis has been removed, access to the Lamp Driver and Optical Block will be achieved.
REMOVE 11 SELF-TAPPING SCREWS AND LEFT AND RIGHT STAYS (SUPPORT BRACKETS)
SLIDE ASSEMBLY BACK TO END OF MOUNTING SLOTS AND LIFT TO RELEASE
SLIDE B BLOCK ASSEMBLY BACK TO END OF MOUNTING SLOTS AND LIFT TO RELEASE CHASSIS REMOVAL STEP 1
CHASSIS REMOVAL STEP 1 TVP-20 50
LOOSEN PURSE LOCKS AND ONE CABLE RETAINER AND PULL WIRE HARNESS LOOSE
Chassis Removal Step 2
GROUND CABLES AND RF CONNECTORS DO NO NEED TO BE REMOVED IF CHASSIS IS BEING PULLED
UNPLUG RF SWITCHING CONNECTOR

SWING B BLOCK ASSEMBLY OUTWARD AS SHOWN
PLACE FINGER IN SLOT, LIFT CHASSIS SLIGHTLY AND PULL OUT 1/2 INCH
CHASSIS REMOVAL STEP 4 Chassis Removal Step 4 TVP-20 53
CN8001
CN8406
CN8814
CN8004
REMOVE 5 CONNECTORS FROM AGU BOARD. CAUTION: RELEASE LOCKING MECHANISM FROM EACH CONNECTOR BEFORE PULLING OUT!
CN8400

NOTE: Observe how the main wire harness is secured at the upper portion of the cabinet. The B Block assembly will not re-install correctly if the cable is mounted too high.
LOOSEN WIRE HARNESS FROM HOLDERS. UNPLUG 7 CONNECTORS AS SHOWN. SQUARES ARE CONNECTORS . CIRCLES ARE WIRE HOLDERS . CAUTION: RELEASE LOCKING MECHANISM ON CONNECTORS BEFORE REMOVING!
REMOVE GROUND WIRES FROM PURSE LOCKS
CHASSIS REMOVAL STEP 6 CHASSIS REMOVAL STEP 6 TVP-20 55
CN604
CN602
REMOVE 2 CONNECTORS FROM OPTICAL BLOCK CAUTION: RELEASE LOCKING MECHANISMS BEFORE PULLING CONNECTOR !
REMOVE LVDS CONNECTOR FROM LEFT SIDE OF B BLOCK BY SQUEEZING LOCK RELEASE PINS ON SIDES CHASSIS REMOVAL STEP 7
Swing B Block Assembly out to position shown. Place main cable harness on top of bracket as shown.
Chassis Removal STEP CHASSIS REMOVAL Step 8 8
TVP-20
57
CN6002
CN6002
FAN
REMOVE 2 CONNECTORS FROM GT BOARD AND ONE FAN CONNECTOR . CAUTION: RELEASE LOCKING MECHANISMS BEFORE PULLING OUT CONNECTORS!
CHASSIS REMOVAL STEP 9

Place the chassis assembly aside to begin the next steps to remove the Lamp Driver or Optical Block. Note how the wire harness is rested on top of the B Block to protect the connectors from snagging onto other items.
CHASSIS REMOVAL STEP 10
Re-Installing the Wire Harness

When re-installing the chassis, it is important to install the wire harness properly. If it is not, the B Block assembly will not seat correctly and wires may be damaged. The most important step is to place the harness in the upper retainers as shown below so that it rests below the cabinet ridge to clear the back side of the B Block.
POSITION HARNESS RETAINERS POINTING DOWNWARD AND THEN WRAP AROUND CABLE TO KEEP BELOW CABINET EDGE
GROUND WIRES FOR RF SWITCHING ASSEMBLY IN LOWER PURSE LOCKS
SECURE HARNESS WITH RETAINER AT BOTTOM CORNER OF B BLOCK ASSEMBLY
WIRE HARNESS POSITION TVP-20 60
WIRE HARNESS POSITIONING
Lamp Driver and Optical Block Removal

The following steps will remove these items from the cabinet assembly. The units will be seperated and each can be serviced from that point.
REMOVE CABLES FROM RETAINERS
LOOSEN 2 SCREWS LOCATED UNDER C BOARD WITH LONG SCREWDRIVER
REMOVE 2 SCREWS AT BASE OF LAMP DRIVER ASSEMBLY AND PULL FAN HOUSING OFF
OPTICAL BLOCK AND LAMP DRIVER ASSEMBLY REMOVAL STEP 11 OPTICAL BLOCK AND LAMP DRIVER ASSEMBLY REMOVAL STEP
TVP-20
61
NOTE PLACEMENT OF WIRES WHEN RE-ASSEMBLING
SWING COVER OUT TO THE LEFT
LEFT SIDE OF BRACKET HAS TONGUE THAT SEATS INSIDE OF LAMP HOUSING
OPTICAL BLOCK AND LAMP DRIVER REMOVAL STEP 2
OPTICAL BLOCK AND LAMP DRIVER ASSEMBLY REMOVAL STEP 2 TVP-20 62
TEMPORARILY SECURE FAN AND LVDS CABLES AS SHOWN
Remove Screw
OPTICAL BLOCK AND LAMP DRIVER REMOVAL STEP 3

Carefully remove the Optical Block and Lamp Driver Assembly together
OPTICAL BLOCK AND LAMP DRIVER ASSEMBLY REMOVAL STEP 4 OPTICAL BLOCK AND LAMP DRIVER REMOVAL STEP 4 TVP-20 64
The Lamp Driver and Optical Block must now be seperated in order to service the units individually.
ROTATE THE OPTICAL BLOCK AND LAMP DRIVER ASSEMBLIES TO EXPOSE THE BOTTOM SIDE. PLACE ON SOFT PADDING TO PREVENT DAMAGE TO LENS ASSEMBLY
USE CAUTION NOT TO DAMAGE THE SWITCH ON THE T2 BOARD
REMOVE SILVER SELFTAPPING SCREW SECURING LAMP CONNECTOR
REMOVE HV LEAD FROM PURSE LOCK
ASSEMBLIES CAN NOW BE SEPARATED
OPTICAL BLOCK AND LAMP DRIVER (BALLAST) REMOVAL STEP 5

Lamp Driver Disassembly

This step disassembles the Lamp Driver housing to gaIn access to the Lamp Driver board. NOTE: When re-installing the lamp connector to the brackets, make sure the connector is installed as shown. The connector should sit at on the bracket and the tabs on the ends should seat ush with the bracket. If not done correctly, the lamp cannot be installed.
REMOVE LAMP PLUG FROM T2 BOARD BRACKET
NOTE: WHEN REASSEMBLING, MAKE SURE THE LAMP CONNECTOR IS INSERTED CORRECTLY INTO BRACKET OR LAMP WILL NOT INSERT
T2 BOARD BRACKET SHOWN ABOVE DOES NOT COME WITH REPLACEMENT BRACKET . DO NOT LOSE!
TVP-20
LAMP DRIVER DISASSEMBLY STEP 1
66
RELEASE 3 CLAWS INSIDE OF HOUSING SECURING FAN DUCT
REMOVE FAN DUCT BY GRASPING AS SHOWN. DO NOT GRAB AT SIDES
Lamp Driver Removal Step 2
LAMP DRIVER DISASSEMBLY STEP 2 TVP-20 67
UNDRESS RF ANTENNA WIRE AT TOP OF ASSEMBLY. NOTE THE LOCATION FOR REASSEMBLY
REMOVE ONE SELFTAPPING SCREW
NOTE POSITION OF WIRES FOR REASSEMBLY
RELEASE 3 CLAWS
Lamp Driver Removal Step 3
NOTE: FAN WILL BE LOOSE AND HAS 3 RUBBER CUSHIONS ON TOP AND 3 ON BOTTOM
REMOVE 2 SCREWS AND LOOSEN HV LEADS FROM FASTENERS TO REMOVE LAMP DRIVER BOARD

Optical Block Replacement

Replacement Optical Blocks are shipped as shown, minus the Iris and LVDS cables. Transfer these cables and any cloth tape pieces to the new Optical Block.
PLASTIC DUCT COVER COMES WITH REPLACEMENT ASSEMBLY BUT MUST BE REMOVED TO ACCESS LVDS AND IRIS CABLES .
IRIS AND LDVS CABLES DO NOT COME WITH REPLACEMENT UNIT
FAN CABLE COMES WITH REPLACEMENT ASSEMBLY OPTICAL BLOCK REPLACEMENT
OPTICAL BLOCK REPLACEMENT TVP-20 70
Appendix
Pixel Failure
Pixel failure is dened as one or more pixels that fail to pass light, are always passing light, or intermittently cause either of the previously mentioned symptoms. One must be extremely lucky to experience an LCD panel with zero pixel defects. A typical Sony LCD Projection unit utilizes 3.28 million pixels between the three LCD panels. LCD panels with zero defects are possible to manufacture, but it would require rejecting a large amount of them and that would make the cost rise to an unacceptable level. Determining whether a particular LCD panel requires replacement due to pixel failure is a somewhat subjective procedure. No ofcial specications exist due to the various LCD panel manufacturers due and violations of non-disclosure agreements. Combining several common sense criteria can help determine if the pixel issue warrants a panel replacement (the entire optical block for a projection unit). 1. A pixel that is continuously lit is far more obvious than one that never lights. The color of the pixel that is stuck on is also important. The eye is the most sensitive to green, somewhat to red, and very little to blue. 2. The number of defective pixels is also important. If only one pixel is out then 99.99999% of the pixels on the panel are operating properly. This is quite acceptable. As several or more pixel failures are approached, the next criteria are of importance. 3. The area of the pixel failure will determine how easily it is noticed. Pixel failures in the center area of the screen that constitutes 1/3 of the screen are more noticeable than those in the outlying areas. This is where the customer is concentrating his viewing. As can be seen, pixel issues can be somewhat ambiguous. The greatest problem to deal with is that once the customer has found a defective pixel (or pixels) they are going to dwell on it. The following is a generalized approach that should assist the technician in dealing with a customer who is complaining about pixel problems. Try not to let the customer show you where the pixel failure(s) are. Tell the customer that you would like to view the picture for a moment with an active video signal. It is during this period of time that the technician should attempt to locate any defective pixels. If one cannot be found easily, the panel is probably acceptable and should not be replaced. If one or more pixels are easily spotted, the panel should be replaced. Handle each pixel issue on an individual basis.
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71
Appendix
Dust
Dust will always be an issue with projection LCD devices. Large amounts of air are needed to pass around the lamp, lenses and mirrors to keep the LCD panels cool. When dust becomes and issue is dependent on several factors such as environmental conditions, cumulative hours of use, etc. Dust particles will appear as dark spots that are larger than the size of an individual pixel. It must rst be determined if the particle(s) are on the LCD panels or the screen. The simplest way to do this is to grab the top of the screen and rock it back and forth a small amount. If the dust is on the LCD panel, the spot(s) will move to different locations on the screen. If they follow the rocking motion of the screen, the dust is on the back side of the Fresnel lens assembly. It could also reside between the layers of the screen. Doing this helps to determine if the screen or the optical block requires cleaning. Dust on the LCD assembly or the screen are not covered by the warranty. Under normal conditions, noticeable dust may appear well out of the warranty period and should be considered as normal maintenance like any other type of projection television. Dust accumulating on the rear of the screen is easily cleaned using a soft cotton cloth and water. The use of paper towels or tissues is not recommended since these tend to scratch the surface. Cleaning of the LCD panels requires more time. The optical assembly must be removed and access gained to the panels. This will require the removal of the LCD driver board. Blowing a low pressure stream of compressed air may remove the particles. In some cases, such as a large number of dust particles, simply blowing air into the cavity that houses the LCD panels only moves them to other areas of the panels. In this case it will be necessary to remove the LCD panel assembly. CAUTION: Handle the LCD assembly with extreme care! Although the LC panels are durable, it is possible to knock one or more of the panels out of alignment. This would cause a mis-convergence of the colors on the screen. It is very difcult to realign the panels. Check the ESI website on a regular basis to see if any up-to-date service routines have been posted regarding this procedure.
LCD Panel
Dust
DUST PARTICLE
Glass covering
FIGURE 2-5 DUST PARTICLE ON LCD PANEL
TVP-20
72
and i.Link are trademarks of Sony Electronics
TVP201205R1
2005 Sony Electornics, Inc. EMCSA - A Service Company 1 Sony Drive Park Ridge, New Jersey 07656 Reproduction in whole or part without written permission is prohibited. All rights reserved
12/15/05

KDF-E42A10 - E50A10 CH - Mix-5 (Training Manual)

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Training Manual

MIX-5 LCD Rear Projection Chassis

Alternate Diagnostics History............................................. 14

Video Input Switching ...................................................... 4 Video Processing ............................................................. 6

Audio Process ................................................................. 8 Power Supply .................................................................. 9

White Balance Adjustments ............................................... 24

System Control and Protection .......................................11

Protect Mode Troubleshooting....................................... 29 CTV-33 i

Table of Contents (cont)

Video Troubleshooting ................................................... 31

No Video Flowchart ........................................................... 33 Video Distortion Flowchart ................................................. 34

Audio Troubleshooting ................................................... 35

Chapter 1 Circuit Description

New Circuit Descriptions

Slim Cabinet Design: Re-design of the projection lamp and circuit

New Wega Engine: A second generation Composite to Component

PC Input: Accepts standard HD15 PC monitor cable to view your PC

Chapter 1 - Circuit Description

FAN 1 FAN 2 FAN 3 FAN 4

NTSC TUNER ATSC TUNER

LED INDICATORS IR RECEIVER

COMPONENT INPUT 4 COMPONENT INPUT 5

VIDEO PROCESS PC INPUT

LCD PANEL DRIVE

Chapter 1 - Circuit Description

Television Microprocessor: Controls all system control

LVDS Transmitter: Converts the 8-bit component and

Audio and Video Switching: Selects the various inputs (except

Audio Processing: Volume control, equalization, and various

Integrated ATSC, NTSC Tuner: To receive terrestrial ATSC,

Chimera: Performs the same basic functions as the Multi-Image

OOB Mixer: Receives Out-Of Band signal to control the Cable

Chapter 1 - Circuit Description

Video Input Switching

Chapter 1 - Circuit Description

VIDEO 1 VIDEO 3 VIDEO 4 VIDEO 5

NOT USED IN USA MODEL

Chapter 1 - Circuit Description

Chapter 1 - Circuit Description

CABLE CARD (POD)

8-BIT RGB OSD 8-BIT DTV Y

8-BIT DTV Pb/Pr

FROM AGU BOARD

MAIN MAIN MAIN MAIN MAIN

IC4700 CHIMERA MICRO

IC4601 A/D CONV

FIGURE 1-3 MIX5 VIDEO PROCESS

Chapter 1 - Circuit Description

NTSC AU_L NTSC AU_R

IC8801 A/D CONV

IC8803 AUDIO PROCESSOR

IC3006 S-MASTER PROCESSOR

IC3005 S-MASTER AMP

L/R AUDIO OUT

MIX-5 CHASSIS AUDIO SWITCHING AND PROCESSING BLOCK DIAGRAM TVP-20 8

FIGURE 1-4 FIGURE 1-4 MIX5 AUDIO SWITCHING AND PROCESS

Chapter 1 - Circuit Description

Main Switching Regulator

Chapter 1 - Circuit Description

LAMP DC LAMP GND

TO LAMP DRIVER TO C BOARD

SWITCHING REGULATOR IC6000 T6000

+9V REG IC6003