Gateway 46” PTV Service Training

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Service Training of 46” PTV

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PDP Whole Components

••MODULE

MODULE

There are

There are

1

1

pc.

pc.

panel

panel

and

and

10

10

pc.s

pc.s

PCB

PCB

including

including

2

2

pc.s

pc.s

X/Y Sustainer board

X/Y Sustainer board

、

、

4

4

pc.s

pc.s

X/Y extension board

X/Y extension board

、

、

2

2

pc.s

pc.s

W PCB

W PCB

、

、

1

1

pc.

pc.

DIF

DIF

and

and

1

1

pc.

pc.

Power board in the Module.

Power board in the Module.

••SET

SET

There are

There are 11

pc. Surface Filter and 9 pc.s PCBs

pc. Surface Filter and 9 pc.s PCBs

including 1 pc. Audio board

including 1 pc. Audio board

、

、1 1

pc. VIF board

pc. VIF board

、

、1 1

pc.

pc.

Power Line Filter

Power Line Filter

、

、1 1

pc. Keypad board

pc. Keypad board

、

、1 1

pc.

pc.

Receiver board

Receiver board

、

、2 2

pc.s L/R Speakers and 1 pc.

pc.s L/R Speakers and 1 pc.

Video board ,1 pc. Tuner board in the SET.

Video board ,1 pc. Tuner board in the SET.

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Parts position

Y- FPC
Extension
board
(upper and
lower)

Tuner

DIF Board

Audio Board

X-Sustainer

X- FPC
Extension
board(upper
and lower)

Speaker

Speaker

W- FPC Extension board
(left and right)

Ac Line filter

VIF

Y-Sustainer

Power Supply

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Block diagram of system

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PCB function

1.Power：(1).Input voltage:AC 110V〜240V、47Hz〜63Hz.

Input range:90V(Min)〜265V(Max) auto regulation.

(2).To provide power for PCBs.

2.VIF(Video InterFace)：To converter TV signals, S signals、AV signals、PC signals

and D-SUB signals to digital ones and to transmit to DIF.

3.DIF(Digital InterFace)：Dealing with the digital signal for output to panel.

4.X-Sustainer / Y-Sustainer：(1). Receiving the signals from DIF and high

voltage supply.

(2). Output scanning waveform for Module.

5.X / Y-FPC extension board：Receive signal from X / Y sustainer, output

horizontal scanning waveform to the panel.

6.W-COF extension board： Output addressing signals.

7.Audio Board：Amplifying the audio signal to the internal or external

speakers of which selected.

8.TV tuner board : To convert TV RF signal to video and audio signal to VIF board.

Audio output to the Audio board.

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Basic operation of Plasma Display

1. After turning on power switch, power board sends Vsby +5V Volt to Micro Processor
IC waiting for ON signals from Key Switch or Remote Receiver.

2. When the ON signal from Key Switch or Remote Receiver is detected，Micro
Processor will send ON Control signals to Power. Then Power sends volts(Vs、Vxg、
Vw、Vf、Vdd、Vcc and +9V)to PCBs working. This time VIF will send signals to
display back light 、OSD on the panel and start to search available signal sources. If
the audio signals input，them will be amplified by Audio AMP and transmitted to
Speakers.

3. If some abnormal signals are detected（for example:over volts、over current、over
temperature and under volts），the system will be shut down by Power off.

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VIF Board

VIF System Structure

ADC

Converter

TMDS

Receiver

De_

Interlace

Video
Decoder

Scalar

Chip

Output
to DIF

D-SUB

DVI

Y/Cb/Cr

Micro_Controller

Composite

S-Video

Tuner

First To a 3D Y/C

separating IC

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VIF System Block Diagram

ADC Converter : AD9888 KS

The AD9888 is a complete 8 bit , 205 MSPS monolithic analog
interface optimized for capturing RGB graphics signals. Its 205 MSPS
encode rate capability and full-power analog bandwidth of 500 MHz

supports resolutions up to UXGA(1600 x1200 @ 75 Hz).

TMDS Receiver: SIL151ACT100

The Sil153BCT100 receiver uses Panel Link Digital technology to

support high resolution displays up to SXGA(25MHz~112MHz) . The Sil153B
receiver supports up to true color panels (24 bit/pixel, 16.7M colors) in 1 or
2 pixels/clock mode. In addition , the receiver data output is time staggered
to reduce ground bounce that affects EMI.

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VIF System Block Diagram

VIDEO Decoder:SAA7118E

The SAA7118E decoder is a ADC, too. But it can deal with the ordinary TV

signals. The SAA7118E can be input Composite 、S-video 、Component
signals and its outputs are digital Y(Luminance) , C(Chromaticity) signals.

And it also can adjust brightness , contrast , saturation , hue .

De-interlace:SIL504CM208

The Sil504 transfer interlacing signals into progressive signals. The
advantage of progressive signals is that the scanning rate doubling to let the
screen more stable and non-flickering. Besides, the sources of input may have
24 0r 30 or 25 frames per sec, so the de-interlaced chip shall tell from the
differences and processing the signals. The basic function of de-interlaced IC
is to combine the odd and even sub-frames to a frame , and the processing
needs a memory IC(SDRAM) to store these signals for processing . For the
improving the quality of image sake , more and more TVs or DVD players all
have the functions of progressive scanning.

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VIF System Block Diagram

Image Processor Chip:PW171-20U(system on chip)

Image Processor chip:

PW171-20U(system on chip)

◎ Scaling function :

The Image scalars provide high quality up and down image scaling . For the applications of
VIF , the input signals could be VGA , SVGA , XGA formats , and its output fixed at 852 x 480
@60 HZ . For example , SVGA format:800 x 600 @75Hz , first scaling down : Horizontal
800Î640、Vertical 600Î480 , 75 frames / sec after frame rate conversion become 60 frames per
sec. Then scaling up 640Î852 , to accomplish the scaling function.

◎ Micro Processor Function :

This chip includes microprocessor(on-chip 80x86) ; selectable function and I/O interface control .
With 3 groups of 8-bit programmable I/O , 1 group of RS-232 communication port , IR decoder
,timer and a PWM generator

◎ OSD Function :

The on-screen-display(OSD) can be used for startup screens , menus , and
scribble functions

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DIF Board

DIF Structure

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Three Functions of DIF :

(1)Image Signals Processing

Transfer image signal into R、G、B signal respectively and according to the
characteristic of a frame needed to process and adjust the signal.

(2)Waveform Controlling

This function is accomplished by IC106, it generate the controlling
waveform signals of X,Y sustainer

(3)Power Controlling

The functions of APC (auto power control) are important to
panel ; if APC were abnormal, it may cause power failure or
even panel broken

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APC Function

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APC

APC

Function

Function

After image data is transmitted to APC by signals processing unit，the Calculate Display
Ratio begins to calculate the ratio of pattern. After checking and calculating pattern(A ,B ,
C) , the numbers of pattern , then sending the data of display and switching count to the
window memory . .

The APC is performing mathematical calculations , by reducing the sustain frequency and
closing some sub-fields to accomplish. There is reference for judgment. The relative
parameters has been tested by experiments to determine, so if the parameters of APC are
not the optimal parameter , it may cause panel broken , scan IC burned , power supply
failure. 。

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Power Board

Power Board Layout

VS VCC VF

VW

VXG

VSB

VAU

Volts settings position

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Power Output Spec.

Name Output Max Load Peak load

Vsb 5V 1.0A

Vdd 5V 2.0A

Vcc 5V 3.0A

Vau 9V 2.0A

Vfan 12V 0.5A

Vf 15V 0.6A

Vs 170V 290W 50A

Vw 65V 80W 6A

Vxg -160V 0.1A 1A

Vaux 380V 65W

cancelled

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X Sustainer

X – Sustainer Layout

PX1:VF,VW,VS

input

PX2:VXG,VCC

input

J302:X – L output

J301:X –U output

J1:X - input

J3: W - Vw 65V input

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X – Sustainer Power Spec.

Input item

Input

volt(VDC)

Input

current(mA)

Remark

Vcc 5 240

Vf 15 70

(Full white)

Normal range:40~150mA

Vs 170 1.2A Normal range:1.0~1.5A

Vxg -160 40

Vw 65 40

Vs 170 1.2A Normal range:1.0~1.5A

Vxg -160 40

Vw 65 40

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X – Sustainer CKT instruction

We have 2 sorts of low – volt system：To provide 5V and 15V for
driving waveform.

65V：The volt of X - Vxe(Vw) is 65V. And there are 2 sets CKT in X：
one is 65V for +NAMARI；the other is 65V for W – COF. The 65V in Y
– Vysc is to produce 35V for Bulk during addressing period.

High volts are 170V and -160V for PDP driving volts.

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Y Sustainer

Y

Y ––

Sustainer

Sustainer

Lay out

Lay out

J3:To input W –
signals to 20PIN

J301:Y - output connects
to Y - FPC

J302:Y - output connects
to Y - FPC

J1:Y – input power：

Vcc，Vf， Vs，Vysc，Vw

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Y – Sustainer Power Spec.

Input Item Input

Volts

(VDC)

Input

Current

(mA)

Remark

Vcc 5 240

Vf 15 70

(Full White)

Normal range:40~150mA

Vs 170 1.2A Normal range:1.0~1.5A

Vysc 65 8

Vw 65 40

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Y – Sustainer CKT instruction

We have 2 sorts of low – volt system：To provide 5V and 15V for
driving waveform.

65V：The 65V in Y – Vysc to produce 35V for Bulk during addressing

period.

High volts are 170V and -160V for PDP driving volts.

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PCB failure analysis

1. DIF:a.Abnormal noise on screen. b.No picture

2. VIF: a.Lacking color、Bad color scale. b.No voice.

c.No picture but with signals output、OSD and back light.

d. Abnormal noise on screen

3. POWER:No picture、no power output.

4. X - Sustainer: a.No picture. b.Color not enough. c.Flash on screen.

5. Y - Sustainer:Darker picture with signals.

（DIF＋VIF＋POW＋X - Sus. ＝Dark picture：DIF＋VIF＋POW＋X - Sus. OK）

6. Audio Bard: a.No voice.（Make sure status:Mute / Internal,External speaker）

b. Noise c.Input power : DC 300V〜380V

7. X/Y - Sustainer:The component working temperature is about 55℃. If the

temperature rises abnormal，this may be a error point.

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PCB failure analysis

8. X extension PCB fail

No
picture

Brighter picture

9. Y extension PCB fail

Darker
picture

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Main Repair Flow Chart-1

Defective PDP

Judgment

CPT responsibility

Warranty ?

Customer responsibility

Repair ?

Can not

repair

N

Panel screen defect

Power failure

Signal failure

What’s wrong

Y

Out-of-warranty
Repair

Out-0f-warranty
Not repair

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Main Repair Flow Chart-2

Adjustment

Replace PCB

Replace Module

Repair Center

Send back to

Customer

QA Test

Next
flow
chart

Disassemble and
Check

Disassemble and
Check

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Flow Chart:Power Failure-1

N

Power OK ?

CFM Power cord OK

Y

Y

Stand-By Red light OK

PDP switch ON ?

Y

Y

Check CN connector= 5 volts

(1+ , 6 - ) ?

Y

N

AC inlet Fuse burned ?

Power board Fuse

burned ?

Y

Replace Fuse

N

Turn on power switch

Y

N

Y

Replace Fuse

N

Plug out connector PV/ CN
, Check CN connector= 5
volts(1+ , 6 - ) ?

N

Replace power board

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Flow Chart:Power Failure-2

N

Y

Y

N

Adj. VR151 make sure
Voltage = 4.9V ~5.3V

Voltage = 4.9V ~5.3V ?

Replace VIF board

Adj. VR253 make
sure Voltage =

4.9V ~5.3V

PD voltage from 5V

drops to 0V ?

Replace DIF

board

Plug out the PY,PX1,PX2
one by one and
After power on can not start
PD voltage ?

Plug out

PX1,PX2,PY one by

one to check X /Y

board OK?

Check the
signals from DIF
to X,Y,W board
?

N

N

Y

Y

N

N

Check PD connector= 5 volts(1+ , 4 - )
Power on to check voltage = 4.9V~5.3V ?

Y

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Failure status of example

1.No picture

Standby indicator(red)
does not work.

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Easy maintenance of Plasma Display

1. Check if the power is on.

2. Check if the fuse is burnt out.

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2.Power is on but no picture.

The indicator worked after
starting up.

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1. Maybe VIF failed.

2. Maybe DIF failed.

3. Replace the VIF first. If it doesn’t work, then replace DIF.

4. But after action as above, it still doesn’t work. Replace
X sustainer boards.

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3.Picture indistinct(IW)

Replace the Y sustainer board.

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4.For the figure as below, check the connection of X FPC. If the connection is

O.K. Replace the X extension board.

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5.For the figure as below, check the connection of Y FPC. If the connection is

O.K. Replace the Y extension board.

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6.For the figure as below, check the connection between W side PCB with COF.

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It’s caused by bad connection of COF.

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7.There is something wrong on the left side of the panel.

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We have a bad connection.

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8.There is something wrong on the upper side of the panel.

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We have a bad connection.

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9.There is something wrong with image.

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1. Maybe VIF failed.

2. Maybe DIF failed.

3. Replace the VIF first. If it doesn’t work, then replace DIF.

4. But after action as above, it still doesn’t work. Replace X
sustainer boards.

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10.There is a stripe on the screen. Replace X extension board.

(But if it still does not wok , then it was caused by the bus electrode problem ->
panel’s problem.)

Stripe

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11.The status as below, replace DIF board.

First, we thought there is something wrong in Y – FPC. But
not. Why ?????

1.As general display abnormal isn’t caused by failed
extension board.

2.As figure above shown, we knew something wrong in
upper display and high brightness. So the extension board
didn’t fail.

3.So we found……………….

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12.The status as below, replace video board.

Still in Searching.

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13.This is called I.W. Adjust the Vs voltage by DVM.

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VS VCC VF

VW

VXG

VSB

VAU

Volts settings position

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Power board output spec.

Name Output Max Load Peak load

Vsb 5V 1.0A

Vdd 5V 2.0A

Vcc 5V 3.0A

Vau 9V 2.0A

Vfan 12V 0.5A

Vf 15V 0.6A

Vs 170V 290W 50A

Vw 65V 80W 6A

Vxg -160V 0.1A 1A

Vaux 380V 65W

*Vs & Vxg check the barcode label of Module

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14.Vertical noise line on whole screen ?

No. This caused by Pixel Works IC
on VIF. The only way is to replace
VIF.

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Panel failure

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Panel W electrode line off.

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X and W electrodes line off.

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Panel lost gas.

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In principle that Panel failure can’t be
repaired. So what could we do? Inform
the retailer fax RMA to manufacture for
replacement.

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FAQ (Frequently Asked Questions)

1. Power on the PDP set yet without any picture on the screen

a. First check both ends of the power cable are plugged into the socket appropriately then

make sure power switch being turned on, survey the red standby light is lamped, if the red

standby light is not lamped it means maybe input power has some problem or the safety

fuse of AC line filter is burned.

b. If the red standby light is lamped it means input power is OK, press key to power on the

PDP set if standby light turn to green successfully it means maybe there is something

wrong with VIF , DIF or X,Y sustainer.

2.At cable TV mode only find few television channels

In OSD manu select TV function and press enter into sub-manu, then at source mode choose

CATV and execute TV Program thus all CATV channels would be found.

3. How to do with image sticking?

When static image is being displayed on the screen for a long period of time may cause image

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sticking on the screen.

When image sticking occurred, the only way to clear up the image sticking is press

”Full White” key, using full white image to burn in the screen till image sticking

disappear.

4. The signal from PC can‘t output to the screen

Maybe PC input signal resolution out of PDP set accepted range, please reduce the

resolution to1024×768 or lower. If still have problem, check whether the signal line is

connected properly or not.

5. The sound of external speaker is not loud enough

Check whether the speaker cables are connected appropriately or not

Whether the impedance of external speaker match that of audio board output or not,

PDP audio output power is 10W × 2, the impedance of audio board output is about

8Ω, if the impedance of external speaker is 16Ω or higher may cause audio output

power decrease 50% or more .

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6. There are some noise being found on the higher CATV channels

Maybe the signal quality from cable station is too weak or no good, please inform the cable

station to improve the signal quality.

7. The signal from DVD player can‘t output to the screen?

Check the signal cables from DVD output to PDP input are connected appropriately and check

the type of terminal (CVBS, S-Video or the component) then check whether PDP signal input

select is correct or not.

If all connection and setting are OK then maybe the problem is DVD output having some

trouble or PDP set VIF board breakdown.

8 How to clean the screen?

Use a soft cotton cloth to clean the screen gently, if also unclean may wet the soft cotton cloth

by alcohol and try again. (Other solutions may cause surface filter damage)