Training Manual KDL32EX308 AZ1L Direct-View LCD Television Chassis Circuit Description and Troubleshooting Guide MODELS: KDL22EX308 KDL32EX308 Course : CTV-68
Table of Contents Chapter 1 – Introduction ..................................................... 1 Power Supply....................................................................... 4 Overview.......................................................................... 1 Features .......................................................................... 1 KDL22EX308 .......................................................................... 4 720p Panel......................................................
Table of Contents (Continued) Introduction .................................................................... 24 LCD Panel Basics .............................................................. 24 Gate Drivers....................................................................... 27 Source Drivers ................................................................... 27 Diagnosing a Failed TCON ............................................ 27 TCON Failures .....................................................
Chapter 1 – Introduction Overview The AZ1L chassis is one of several designs for the 2010 model line of Sony Bravia® LCD televisions. Several models will be released incorporating this chassis. This training manual will cover the EX308 series consisting of the following models: KDL22EX308 KDL32EX308 The chassis design revolves around the video processing circuits located on the BAL board. The key difference between models is determined by the size of the LCD panel and its manufacturing source.
Chapter 1 - Introdcution USB2.0 Side Input Bravia® Sync This feature was available in selected 2008 models and allowed the viewing of JPEG formatted pictures and playback of MP3 audio files. The media content has been expanded this year to allow playback of MPEG1 and MPEG2 format video content. An optional wireless network adapter can be inserted to connect to a wireless home network. By utilizing the CEC feature of HDMI 1.
Chapter 2 – Overall Circuit Descriptions Overview The primary circuits contained in the AZ1L chassis consists of a main circuit board (designated as the BAL board), power supply (GD1 Or G2LE) which varies based on the size of the LCD display, and the LCD panel assembly. The TCON circuit (normally mounted external to the LCD panel) is contained inside the panel assembly. The remaining small boards contain switches, sensors and LED’s.
Chapter 2 - Overall Circuit Description Power Supply KDL22EX308 The KDL22EX308 utilizes the GD1 power supply board. There are 3 distinct sections on the power supply: Standby Supply: Continuously operational as long as AC power is applied, the standby supply generates 3.3VDC for the circuits requiring power while the unit is turned off. An unregulated 15-volt line is present to provide power to the main relay, PFC and main power supply at turn-on.
Chapter 2 - Overall Circuit Description L RF COMPOSITE OR COMPONENT 1 TUNER ANALOG AUDIO IN COMPONENT 2 COMPOSITE 3 IC4200 AUDIO SW D/A AMP R ANALOG AUDIO OUT DIGITAL AUDIO DIGITAL TUNER IN OPTICAL AUDIO OUT ANALOG VIDEO IN HDMI 1 HDMI 2 HDMI 3 HDMI 4 IC2200 HDMI SWITCH EQ IC9000 A/V DECODER VIDEO PROCESS IC5000 SUBMICRO LVDS PC HD15 EITHERNET LCD PANEL USB2.
Chapter 2 - Overall Circuit Description L RF COMPOSITE OR COMPONENT 1 TUNER ANALOG AUDIO IN IC4200 AUDIO SW D/A AMP ANALOG AUDIO OUT COMPONENT 2 COMPOSITE 3 R DIGITAL AUDIO DIGITAL TUNER IN OPTICAL AUDIO OUT ANALOG VIDEO IN HDMI 1 HDMI 2 HDMI 3 HDMI 4 IC2200 HDMI SWITCH EQ IC9000 A/V DECODER VIDEO PROCESS IC5000 SUBMICRO LVDS INVERTER PC HD15 EITHERNET LCD PANEL USB2.
Chapter 3 – Troubleshooting Introduction • The Main Board (BAL) • Power Supply (G1D or G2LE) Keeping the software in the television up-to-date is a procedure that is normally handled by the owner of the television. Most customers who own computers and other digital devices are familiar with and are accustomed to updating the firmware and software in their products.
Chapter 3 - Troubleshooting Software Update Responsibility Checking the Software Version Software updates are designed to be performed by the customer. Warranty repairs in which the issue can be resolved by a software update are not reimbursable. Most issues involving software updates are handled by the customer service center and should not be directed to an authorized service center. It is the responsibility of the servicer to prevent service calls for issues that involve software updates.
Chapter 3 - Troubleshooting Special Software Instructions for BAL Board or LCD Panel Replacement The 2010 models utilize a “generic” type BAL board. In the past, many different main boards needed to be stocked due to differences in software requirements. The software loaded on the board was specific to the model and its features along with the type of LCD panel installed during production. Replacement BAL boards will now be stocked with basic software.
Chapter 3 - Troubleshooting Video Failures Problems that develop in the video circuits can appear as subtle or major distortions, a loss of one or more colors, improper video level, or a complete loss of video. When troubleshooting LCD display devices the problem must be isolated to 3 major components: The main board where the video processing is performed, the TCON board, or the LCD panel.
Chapter 3 - Troubleshooting Video Distortion No Video Backlights turned on ? This is, perhaps, the more difficult failure to diagnose. It is difficult when talking to the customer on the phone because an accurate description of the problem must be obtained in order to determine which part (or parts) to bring to the location. It may also be difficult for the technician when the problem is witnessed.
Chapter 3 - Troubleshooting TCON: Since the TCON allocates the RGB video information based on specific timing information, the distortions tend to be fixed and usually appear as symmetrical patterns that occupy most (or a significant portion) of the display. Some examples of TCON errors: • No video • Thin vertical lines spanning most or all of the display • More that one column of wide vertical columns which may appear black or any color, or may contain distorted video.
Chapter 3 - Troubleshooting Video Distortion Is distortion across entire screen? Yes No Improper of missing colors? Yes BAL Board Any horizontal lines ? Yes No Vertical lines or bars ? No Yes Lines move when widemode changed ? Yes BAL Board No TCON (LCD Panel ) TCON (LCD Panel ) LCD Panel No Any single or isolated vertical lines ? Yes LCD Panel No More than 1 vertical band? Yes TCON (LCD Panel) FIGURE 3-3 VIDEO DISTORTION TROUBLESHOOTING FLOWCHART CTV-68 13
Chapter 3 - Troubleshooting Audio Troubleshooting Won’t Power On Since all audio signals are input, processed and amplified by the BAL board, any issue involving the loss of audio or audio distortions which is present at all inputs would dictate that issue is remedied by replacement of the BAL board. It is possible that a software update might be required but it is very unusual for this to affect all sources. Once again, check with the Sony technical support website regarding this issue.
Chapter 3 - Troubleshooting No Power Does red standby LED on front panel light? Yes Press power button while monitoring pin 3 of CN6150 on power supply board No Is standby LED blinking ? High (3.
Chapter 3 - Troubleshooting Protection Shutdown Critical voltages and circuit operations are monitored by the CPU on the BAL board. If a fault is detected the unit will be forced to shut down by the CPU. The monitored circuit in which the fault occurred will cause the CPU to flash the standby LED in groups of repeating sequences. The number of blinks in these groups identifies which voltage or circuit caused the protection event. Not all of the available protect codes are used.
Chapter 3 - Troubleshooting Protect Shutdown.
Chapter 3 - Troubleshooting Backlight Issues Under normal circumstances, any failures in the backlighting system will cause the unit to shut down. If one or more of the fluorescent backlights fails to turn on, or if the high voltage inverter circuit fails to turn on, the unit will shut down and the standby LED will blink in groups of 6. This feature is useful for failures which are intermittent or when the customer is not sure what is causing the television to shut down sometimes.
Chapter 3 - Troubleshooting Test Points The drawing in Figure 3-7 contains the board-to-board connector and pin information for the KDL22EX308 to identify voltages, signal and control lines for troubleshooting purposes. Figure 3-8 illustrates the same information for the KDL32EX308. All critical voltages and control signals are easily accessed at the power supply board.
Chapter 3 - Troubleshooting CN6701 1 HV 2 LV CN6702 CN6001 AC IN (N) 1 AC IN (H) 2 1 HV 2 LV CN6703 1 HV 2 LV CCFL HV TO BALANCER CN6704 1 HV 2 LV CN3800 STBY3.3V 1 CN6150 AUDIO_12V 2 1 STBY3.
Chapter 3 - Troubleshooting CN6402 1~5 UNREG24V 6~10 GND 11 BL_ERR 12 BL-ON AC IN (N) 1 13 N/C AC IN (H) 2 14 DIMMER TO INVERTER CN3800 CN6401 STBY3.3V 1 1 STBY3.
Chapter 3 - Troubleshooting GD1 BAL SWITCH BLOCK HLR FIGURE 3-9 KDL22EX308 BOARD LOCATIONS CTV-68 22
Chapter 3 - Troubleshooting GD2LE BAL SWITCH BLOCK HLR FIGURE 3-10 KDL32BX300 BOARD LOCATIONS CTV-68 23
Chapter 4 – Appendix TCON Troubleshooting Introduction Beginning in the fall of 2008, Sony announced the availability of limited TCON replacement boards to service LCD panels beginning with certain models going back to 2006. For many years technicians have been asking about the availability of these components. In the relatively small percentage of units that experienced a failure of the TCON board, replacement of the entire LCD panel was mandatory.
Chapter 4 - Appendix Figure 4-1 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 1366 by 768 at 60HZ refresh rate panel.
Chapter 4 - Appendix LVDS TRANSMITTER LVDS RECEIVER VIDEO PROCESS TIMING CONTROL BU TCON SOURCE DRIVERS GATE DRIVERS LCD PANEL FIGURE 4-1 TYPICAL LCD TIMING CONTROL CTV-68 26
Chapter 4 - Appendix Gate Drivers Referring to Figure 4-1, note the IC’s located along the side of the panel. These IC’s are mounted on a flexible cable(s) which are bonded to the LCD panel. Their function is to activate each row of pixels one at a time starting with the first line at the top. As each line is activated, the source drivers turn on the appropriate liquid crystals for the frame of video about to be displayed. This continues from top to bottom until the entire frame of video is displayed.
Chapter 4 - Appendix DEFECTIVE DRIVE IC DEFECTIVE TAB BOND OR DRIVE IC DEFECTIVE TAB BOND OR DRIVE IC FIGURE 4-2 TYPICAL LCD PANEL FAILURES CTV-68 28
Chapter 4 - Appendix Failures involving the LCD panel are usually displayed with the following symptoms: • Physical damage such as cracks in the panel, a single pixel or group of pixels that always on or off, or random sections of the panel which are completely dark. • Source driver failure. This symptom appears as a single vertical band around 1 to 2 inches (depending on the panel size) and can be black, white, or any other color. It can also contain video information with distortion.
Chapter 4 - Appendix Figure 4-3 illustrates 2 examples of a loss of control data to the drive IC’s. In the first example, an entire group of column drivers has lost the data stream for red. The second example involves the complete loss of drive data for all RGB information to the right side of the screen. This is sometimes caused by the flat cable connecting the TCON to the LCD panel coming loose. The area of missing video can be dark or completely white depending on the panel design.
Chapter 4 - Appendix Examples of Actual TCON Failures The remaining illustrations show other TCON failures that have been encountered in the field. The idea is to get a grasp of the concept of TCON induced failures to avoid unnecessary parts replacement. MULTIPLE SOURCE DRIVE IC FAILURE REPETATIVE STAIONARY LINES CTV-68 MULTI-COLORED LINES.
Chapter 4 - Appendix MULTIPLE EVENLY SPACED LINES NOT AFFECTED BY PICTURE ZOOMING SYMETRICAL RED BOXES LOADED SOURCE DRIVE DATA LINE CTV-68 32
Chapter 4 - Appendix LCD Panel Failures Below are some photos of actual LCD panel failures. Note that most issues tend to be isolated to a certain area of the screen with the exception of failures of the source drivers. The source drivers can cause thin horizontal line issues and can also affect a large area of the screen.
Chapter 4 - Appendix CTV-68 SOURCE TAB BOND FAILURE GATE TAB BOND FAILURE MULTIPLE PIXEL FAILURE GATE TAB BOND FAILURE 34
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