Akai PDP-5016 Service Manual

SERVICE MANUAL

Model:

PDP-5016

Safety Precaution

Technical Specifications

Block Diagram

Circuit Diagram

Basic Operations & Circuit Description

Main IC Specifications

Trouble Shooting Manual of PDP Module

Spare Part list

Exploded View

If You Forget Your V-CHIP Password

Software Upgrade

This manual is the latest at the time of printing, and does not include the modification which may be made after the printing, by the constant improvement of product.

Safety Precaution

CAUTION

RISK OF ELECTRIC SHOCK

DO NOT OPEN

The lightning flash with arrowhead symbol, within an equilateral triangle, is intended to alert the user to the presence of uninsulated “dangerous voltage” within the product’s enclo sure that may be of sufficient magnitude to constitute a risk of electric shock to persons.

CAUTION: TO REDUCE THE RISK OF ELECTRIC SHOCK, DO NOT REMOVE COVER (OR BACK). NO USER-SERVICEABLE PARTS INSIDE. REFER SERVICING TO QUALIFIED SERVICE PERSONNEL ONLY.

PRECAUTIONS DURING

SERVICING

1. In addition to safety, other parts and

assemblies are specified for conformance with

such regulations as those applying to spurious

radiation. These must also be replaced only

with specified replacements.

Examples: RF converters, tuner units, antenna

selection switches, RF cables, noise-blocking

capacitors, noise-blocking filters, etc.

2. Use specified internal Wiring. Note especially:

1) Wires covered with PVC tubing

2) Double insulated wires

3) High voltage leads

3. Use specified insulating materials for hazardous

live parts. Note especially:

1) Insulating Tape

2) PVC tubing

3) Spacers (insulating barriers)

4) Insulating sheets for transistors

5) Plastic screws for fixing micro switches

4. When replacing AC primary side components

(transformers, power cords, noise blocking

capacitors, etc.), wrap ends of wires securely

about the terminals before soldering.

5. Make sure that wires do not contact heat

generating parts (heat sinks, oxide metal film

resistors, fusible resistors, etc.)

6. Check if replaced wires do not contact sharply

edged or pointed parts.

7. Make sure that foreign objects (screws, solder

droplets, etc.) do not remain inside the set.

The exclamation point within an equilateral triangle is intended to alert the user to the presence of important operating and maintenance (servicing) instructions in the literature accompanying the appliance.

MAKE YOUR CONTRIBUTION

TO PROTECT THE

ENVIRONMENT

Used batteries with the ISO symbol

for recycling as well as small accumulators

(rechargeable batteries), mini-batteries (cells) and

starter batteries should not be thrown into the

garbage can.

Please leave them at an appropriate depot.

WARNING:

Before servicing this TV receiver, read the

SAFETY INSTRUCTION and PRODUCT

SAFETY NOTICE.

SAFETY INSTRUCTION

The service should not be attempted by anyone

unfamiliar with the necessary instructions on this

apparatus. The following are the necessary

instructions to be observed before servicing.

1. An isolation transformer should be connected in

the power line between the receiver and the

AC line when a service is performed on the

primary of the converter transformer of the set.

2. Comply with all caution and safety related

provided on the back of the cabinet, inside the

cabinet, on the chassis or picture tube.

3. To avoid a shock hazard, always discharge the

picture tube's anode to the chassis ground

before removing the anode cap.

4. Completely discharge the high potential voltage

of the picture tube before handling. The picture

tube is a vacuum and if broken, the glass will

explode.

5. When replacing a MAIN PCB in the cabinet,

always be certain that all protective are

installed properly such as control knobs,

adjustment covers or shields, barriers, isolation

resistor networks etc.

6. When servicing is required, observe the original

lead dressing. Extra precaution should be given

to assure correct lead dressing in the high

voltage area.

7. Keep wires away from high voltage or high

tempera ture components.

8. Before returning the set to the customer,

always perform an AC leakage current check

on the exposed metallic parts of the cabinet,

such as antennas, terminals, screwheads,metal

overlay, control shafts, etc., to be sure the set

is safe to operate without danger of electrical

shock. Plug the AC line cord directly to the

AC outlet (do not use a line isolation

transformer during this check). Use an AC

voltmeter having 5K ohms volt sensitivity or

more in the following manner.

Connect a 1.5K ohm 10 watt resistor paralleled

by a 0.15µF AC type capacitor, between a

good earth ground (water pipe, conductor etc.,)

and the exposed metallic parts, one at a time.

Measure the AC voltage across the combination

of the 1.5K ohm resistor and 0.15 uF

capacitor. Reverse the AC plug at the AC

outlet and repeat the AC voltage measurements

for each exposed metallic part.

The measured voltage must not exceed 0.3V

RMS.

This corresponds to 0.5mA AC. Any value

exceeding this limit constitutes a potential

shock hazard and must be corrected

immediately.

The resistance measurement should be done

between accessible exposed metal parts and

power cord plug prongs with the power switch

"ON". The resistance should be more than

6M ohms.

AC VOLTMETER

PRODUCT SAFETY NOTICE

Many electrical and mechanical parts in this

apparatus have special safety-related

characteristics.

These characteristics are offer passed

unnoticed by visual spection and the protection

afforded by them cannot necessarily be obtained

by using replacement components rates for a

higher voltage, wattage, etc.

The replacement parts which have these

special safety characteristics are identified by

marks on the schematic diagram and on the parts

list.

Before replacing any of these components,

read the parts list in this manual carefully. The

use of substitute replacement parts which do not

have the same safety characteristics as specified

in the parts list may create shock, fire, or other

hazards.

9. Must be sure that the ground wire of the AC

inlet is connected with the ground of the

apparatus properly.

Good earth ground such as the water pipe, conductor, etc.

AC Leakage Current Check

Place this probe on each exposed metallic part

Technical Specifications

MODEL :

PDP-5016

50” Plasma Display

DATE FIRST ISSUED

REVISIONS

ISSUED DATE DESCRIPTION RAISED BY :

ISSUE

1

RAISED BY

CHECKED BY

NUMBER OF PAGES

9

SPECIFICATION AGREED : SIGNATURE DATE

R & D DEPARTMENT

COMMERCIAL DEPARTMENT

PRODUCTION DEPARTMENT

Q/A DEPARTMENT

CUSTOMER

SPECIFICATION APPROVED :

.

NOTE :

Only documents stamped “Controlled Document” to be used for manufacture of production parts.

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DATE :

Technical Specifications

PDP-5016

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1. Standard Test Conditions

All tests shall be performed under the following conditions, unless otherwise specified.

1.1 Ambient light ≦0.1Cd/m

: 150ux (When measuring IB, the ambient luminance

2

)

1.2 Viewing distance

: 50cm in front of PDP

1.3 Warm up time

: 30 minutes

1.4 PDP Panel facing

: no restricted

1.5 Measuring Equipment

: PC, Chroma 2225 signal generator (with Chroma digital

additional card) or equivalent, Minolta CA100 photometer

1.6 Magnetic field

: no restricted

1.7 Control settings

: Brightness, Contrast, Tint, Color set at Center(50)

1.8 Power input

: 100~240Vac

1.9 Ambient temperature : 20°C ± 5°C (68°F ± 9°F)

1.10 Display mode

: 31.5KHz/60Hz (Resolution 1366 x 768)

1.11 Other conditions

:

1.11.1 With image sticking protection of PDP module, the luminance will descend by time on a same still screen and rapidly go down in 5 minutes. When

measuring the color tracking and luminance of a same still screen, be sure t o accomplish the measurement in one minute to ensure its accuracy.

1.11.2 Due to the structure of PDP, the extra-high-bright same screen should not

hold over 5 minutes for fear of branding on the panel.

Technical Specifications

PDP-5016

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ELECTRICAL CHARACTERISTICS

2. Power Input

2.1 Voltage

: 100 ~ 240VAC

2.2 Input Current

: 5.0 /2.5A

2.3 Maximum Inrush Current

: <30 A (FOR AC110V ONLY)

Test condition : Measured when switched off for at least 20 mins

2.4 Frequency

: 50Hz to 60Hz(±3Hz)

2.5 Power Consumption

: ≤ 480W Test condition : full white display with maximum brightness and contrast

2.6 Power Factor

: Meets IEC1000-3-2

2.7 Withstanding voltage

: 1.5kVac or 2.2kVdc for 1 sec

3. Display

3.1 Screen Size : 50” Plasma display

3.2 Aspect Ratio : 16:9

3.3 Pixel Resolution : 1366x768

3.4 Peak Brightness : 1000 cd/m² (Panel module without filter)

3.5 Contrast Ratio (Dark room) : 4000:1 (Panel module without filter)

3.6 Viewing Angle : Over 160°

3.7 OSD language : English

4. Signal

4.1 AV & Graphic input

4.1.1 TV standard : NTSC,PAL/N,PAL/M

4.1.2 TV Tuning system : PLL 181CH

4.1.3 CATV : 125CH

4.1.4 Composite signal : CVBS

4.1.5 Y,C Signal : S-Video

4.1.6 Component signal : Y, Pb/Cb, Pr/Cr, HDTV compatible

4.1.7 Graphic I/P : Analog: D-sub 15pin detachable cable Digital: DVI

4.1.8EDID compatibility : DDC 1.3

4.1.9 I/P frequency : f

: 31.5kHz to 60kHz/fV: 56.25Hz to 75Hz (1024X768

H

recommended)

Technical Specifications

PDP-5016

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4.2 Audio input Audio I/P(L/Rx5) : 1 for DVI / D-Sub 1 for Y/ Pb/Pr 1 for Y/ Cb/Cr

1 for CVBS

1 for S-Video

4.3 AV output Audio&Video O/P(RCAx3) : Monitor out(Video & Audio L/R)

4.4 Other function

: PIP/POP/PBP, Picture size, Picture Still, Sound mode,Last

memory, Timer, MTS

5. Environment

5.1 Operating environment

5.1.1 Temperature : 5º to 33°C

5.1.2 Relative humidity: 20% to 85%(non-condensing)

5.2 Storage and Transport

5.2.1 Temperature : -20°C to 60°C(-4º to 140°F)

5.2.2 Relative humidity: 5% to 95%

6. Panel Characteristics

6.1 Type : LG50X2

6.2 Size : 50”, 1190mm(width)x7005mm(height)x59mm(depth)±1 mm)

6.3 Aspect ratio : 16:9

6.4 Viewing angle : Over 160°

6.5 Resolution : 1366X768

6.6 Weight : 22.0kg ±0.5 kg (Net)

6.7 Color : 1024(R)X1024(G)X1024(B) COLORS

6.8 Contrast : Average 60:1 (In a bright room with 150Lux at center) Typical 4000:1 (In a dark room 1/100 White Window

pattern at center).

6.9 Peak brightness : Typical 1000cd/㎡ (1/25 White Window)

6.10 Color Coordinate Uniformity

: Contrast; Brightness and Color control at normal

setting

Test Pattern : Full white pattern

Average of point A,B,C,D and E +/- 0.01

Technical Specifications

PDP-5016

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6.11 Color temperature

: Contrast at center (50); Brightness center (50); Color temperature set at Natural x=0.300±0.02 y=0.300±0.02

6.12 Cell Defect Specifications Subject to Panel supplier specification as appends.

7. Front Panel Control Button

7.1 CH Up / Down Button : Push the key to changing the channel up or down.

When selecting the item on OSD menu. Volume Up/ Down Button : Push the key to increase the volume up or down. When selecting the adjusting item on OSD menu increase or decrease the data-bar.

Menu Button : Enter to the OSD menu.

Source Select Button : Push the key to select the input signals source.

7.2 Stand by Button : Switch on main power, or switch off to enter power Saving modes.

7.3 Main Power Switch : Turn on or off the unit.

8. OSD Function

8.1 Picture : State (Normal,Dark,Bright,User); Display (Bright,contrast,Color,Hue)

Temp (warm,Cool,Normal,User); Position (H-posit,V-posit,Phase,H-size,Auto Adjust)

8.2 Sound : Setup (Mode,AVC,Volume,Balance);

Equalizer (120HZ,500HZ,1.5KHZ,5KHZ,10KHZ) BBE Setup (Gain,Treble,Bass)

8.3 OSD : Size (Panorama,16:9,Normal,Anamorphic,Letter Box,TV Mode)

OSD Set (Language,OSD Position,Time Out) Option (Burn Protect, Version) V-Chip , C/C

8.4 Layout : Layout (Full Screen,PIP,Split Screen,Grid,POP 3,POP 12)

PIP Set (Sub Win Source,Sub Win Size,PIP Size.PIP Position)

8.5 Time : Sleep (30Min,60Min,90Min,120Min,180Min)

Wake Up (Time Edit,Volume,TV Mode,Channel) Time Set

8.6 TV Set : TV Set (Auto Search,Manul Search,System,MTS,Auto Fine,Fine)

CH Edit

Technical Specifications

PDP-5016

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9. Agency Approvals

Safety UL60950

Emissions FCC class B

10. Reliability

11.1 MTBF

: 20,000 hours(Use moving picture signal at 25°C ambient)

11. Accessories : User manual x1, Remote control x1, Stand x1, Power cord x1, Battery x 2, Accessories box x 1,Speaker x 2,Speaker wire x2

Technical Specifications

12. Support the Signal Mode

A .D-Sub Mode (VGA or DVI)

PDP-5016

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NO.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Resolution

640 x 400 640 x 480 640 x 480 640 x 480 640 x 480 720 x 400 800 x 600 800 x 600 800 x 600 800 x 600 832 x 624 1024 x 768 1024 x 768 1024 x 768 1152 x 864 1152 x 864 1152 x 864 1280 x 960 1280 x 1024

Horizontal

Frequency

(KHz)

31.47

31.50

35.00

37.50

37.86

31.47

35.16

37.90

46.90

48.08

49.00

48.40

56.50

60.00

54.53

63.86

67.52

60.02

64.00

Vertical

Frequency

(Hz)

70.08

60.00

67.00

75.00

72.81

70.08

56.25

60.32

75.00

72.19

74.00

60.00

70.00

75.00

61.13

70.02

75.02

60.02

60.01

Dot Clock

Frequency

(MHz)

25.17

25.18

30.24

31.50

28.32

36.00

40.00

49.50

50.00

57.27

65.00

75.00

78.75

80.37

94.51

108.03

108.04

108.00

B.DTV Mode

NO.

1 2 3 4 5 6 7 8

Resolution

480 i

576 i 480p(720x480) 576p(720x576)

720p(1280x720)

720p(1280x720) 1080i(1920x1080) 1080i(1920x1080)

Horizontal

Frequency

(KHz)

15.734

15.625

31.468

31.25

45.00

37.50

28.125

33.75

Vertical

Frequency

(Hz)

59.94

50.00

59.94

50.00

60.00

50.00

60.00

Dot Clock

Frequency

(MHz)

13.50

27.00

74.25

- When the signal received by the Display exceeds the allowed range, a warning message “Out Of Range” shall appear on the screen.

- You can confirm the input signal format from the “OSD Menu”.

Technical Specifications

13. Remote Control

PDP-5016

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󱦯 Power ( ): Press to turn on and off. 󱦱 Mute ( again or press 󱦳 P.STILL: Press to freeze the picture. Press again to restore the picture. 󱦵 P.SIZE: Press to cycles through the picture size: Normal, Fill Screen, Anamorphic, Letter Box or TV Mode, Panorama.. 󱦷 P. MODE: Press to cycles through the picture mode: Normal, Bright, Dark, User. 󱦹 S.SELE: Press to cycles through the sound select: Main window sound or Sub window sound. 󱦻 PIP: Press to turns on PIP (picture-in picture) feature. Such as Full Screen, PIP or Split Screen. 󱦽 SWAP: Press to switches the Main window or Sub window pictures. 󱦿 PIP CH+ : Press to select Sub window Channel Up. PIP CH- : Press to select Sub window Channel Down.

󱧁 TIME: Press to display the current time. 󱧂 SLEEP: Press repeatedly until it displays

the time in minutes (30 Min, 60 Min, 90 Min, 120 Min, 180 Min or Off ) that you want the PDP to remain on before shutting off. To cancel Sleep Time, press SLEEP repeatedly until Sleep Off appears. And you can press

or to select sleep time shut down.

󱧃 MTS: Press repeatedly to cycle through the Multi-channel TV sound (MTS) options: Mono, Stereo and SAP (Second Audio Program).

󱧄 INFO: Press to display on-screen information. Press it again to turn the display off. 󱧅 CH Erase, CH Save buttons: Press to erase or save channel. 󱧆 C/C: Press to select the Closed Caption mode. 󱧇 V-Chip: Press to select the child protect mode. 󱧈 Number buttons: Press 0~9,100 to select a channel; the channel changes after 2

seconds.

󱧉 PIP Source: Press to select the signal for Sub Window.(Only for PIP.) 󱧊 F.WHITE: Press to show a full white picture. 󱧋 PREV: Press it returns to the last viewed channel.(Only for TV.)

): Press to mute the sound. Press

to restore the sound.

󱦯

󱦳 󱦵 󱦻 󱦽 󱧁 󱧂

󱧅

󱧉 󱧊 󱧌

󱧍 󱧐

󱧓

󱦱

󱦹 󱦷

󱦿 󱧄 󱧃 󱧇 󱧆

󱧈

󱧋 󱧏 󱧎 󱧑

󱧒

(Continued on next page)

CONTINUATION PAGE

Technical Specifications

󱧌 SOUND: Press to select different sound system, such as Normal, Flat, News, Cinema, User or BBE Digital. 󱧍 PICTURE: Press to select “BRIGHTNESS”, “COLOR”, “CONTRAST”, ”HUE” or “SHARPNESS”, and you can use

󱧎 EXIT: Press to return or exit OSD menu. 󱧏 SOURCE: Press to select the signal sources directly. Such as TV, AV1, S-VIDEO,

YCbCr, YPbPr, Analog RGB or Digital RGB.

󱧐 MENU: Press to display the OSD Menu. 󱧑 OK: Press to enter or conﬁrm. 󱧒

used for the selection of the program when the OSD Menu is not shown on the screen. 󱧓 used for the adjustment of volume when the OSD Menu is not shown on the screen.

/ : They are used as / buttons in the OSD Menu screen and they can be

/ : They are used as

/ buttons in the OSD Menu screen and they can be

or to adjust.

PDP-5016

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PHYSICAL CHARACTERISTICS

14. Power Cord

Length : 1.8m nominal

Type : optional

15. Cabinet

15.1 Color

: silver colour as defined by colour plaque reference number

15.2 Weight

Net weight : 51.8kg Gross weight : 74kg

15.3 Dimensions (with stand&speak) Width : 1227.8mm

Height : 739.8mm Depth : 120.6mm

Block Diagram

Product Specification of PDP Module

LVDS Input

Control Signal

(Serial Interface)

APL Data

Memory

Input

Controller

Interface Controller

Driver Timing Controller

Display data, Driver timing

Color Plasma Display Panel

1366 X 768 pixels

Scan Driver

Vs(180V~190V)

Va(55V~65V)

Vcc(+5V)

Common sustain driver

Address Driver

☞ Applied Voltage level is specified at the time when Full-White pattern is displayed on the panel.

Block Diagram

Speaker

SCART1

Video2

S-Video

Tuner x 2

Sub Board

TDA8946

Audio AMP

MSP34x0G

Audio Decoder

uPD64083

Separator

M52790

A/V Switch

3D Y/C

Main Board

Z86229

V-Chip / CC

VPC3230D

Vide Decoder

SDA5550

TVText Pro

PW1231

De-

Interlacer

Z86229

V-Chip / CC

VPC3230D

Video Decoder

Processor

PW181

Image

AD9883A

ADC

Sil161B

DVI Receiver

MAX232C

RS232C

W78E65B

System Control

THC63LVDM83

LVDS

Transmitter

YCrCb

YPbPr

D-SUB15

DVI

D-SUB9

IR

Keypad

LED

LDVS

Header

Circuit Diagram

- Power supply board of PDP Module, USP650M-50LP

- Main (Video) board

- Audio/Tuner board

- Keypad board

- Remote control receiver board

- Remote control board