Contact Information, Preliminary Matters, Specifications,
Plasma Overview, General Troubleshooting Steps,
Disassembly Instructions, Voltage and Signal Distribution
No Main Power Switch (Vacation Switch).
Troubleshooting:
Circuit Board Operation, Troubleshooting and Alignment of :
• Switch Mode Power Supply No VS On command input to SMPS
• Y-SUS Board Delivers Logic Signals and FG5V to Y-Drive board.
• Y-Drive Board
• Z-SUS Output Board (Also uses one Z-SUB board for bottom panel connector)
• Control Board
• X Drive Boards (2)
• Main Board
•Interconnect Diagram: 11X17 Foldout Section used as a quick reference sheet.
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August 2010 42PJ350 Plasma
Overview of Topics to be Discussed
Overview of Topics to be Discussed
42PJ350 Plasma Display
The first section will cover Contact Information and Important Safety Precautions
for the Customers Safety as well as the Technician and the Equipment.
Basic Troubleshooting Techniques which can save time and money sometimes
can be overlooked. These techniques will also be presented.
The next section will get the Technician familiar with the Disassembly, Identification
and Layout of the Plasma Display Panel.
At the end of this Section the Technician should be able to Identify the Circuit
Boards and have the ability and knowledge necessary to safely remove and
replace any Circuit Board or Assembly.
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August 2010 42PJ350 Plasma
LG Contact Information
LG Contact Information
Customer Service (and Part Sales) (800) 243-0000
Technical Support (and Part Sales) (800) 847-7597
USA Website (GSFS)http://gsfs-america.lge.com
Customer Service Websiteus.lgservice.com
Knowledgebase Websitelgtechassist.com
LG Web Traininglge.webex.com
LG CS Academylgcsacademy.com
LCD-DV:
PLASMA:
PDP Panel Alignment Handbook, Schematics with Bookmarks
Published July 2010 by LG Technical Support and Training
LG Electronics Alabama, Inc.
201 James Record Road, Huntsville, AL, 35813.
New: Software Downloads
Technical Assistance
Presentations with Audio/Video
and Screen Marks
http://136.166.4.200
New Training Materials on
New Training Materials on
the Learning Academy site
the Learning Academy site
4
August 2010 42PJ350 Plasma
Preliminary Matters (The Fine Print)
Preliminary Matters (The Fine Print)
IMPORTANT SAFETY NOTICE
IMPORTANT SAFETY NOTICE
The information in this training manual is intended for use by persons possessing an adequate
background in electrical equipment, electronic devices, and mechanical systems. In any attempt
to repair a major Product, personal injury and property damage can result. The manufacturer or
seller maintains no liability for the interpretation of this information, nor can it assume any
liability in conjunction with its use. When servicing this product, under no circumstances should
the original design be modified or altered without permission from LG Electronics. Unauthorized
modifications will not only void the warranty, but may lead to property damage or user injury.
If wires, screws, clips, straps, nuts, or washers used to complete a ground path are removed for
service, they must be returned to their original positions and properly fastened.
CAUTION
CAUTION
To avoid personal injury, disconnect the power before servicing this product. If electrical power
is required for diagnosis or test purposes, disconnect the power immediately after performing
the necessary checks. Also be aware that many household products present a weight hazard.
At least two people should be involved in the installation or servicing of such devices.
Failure to consider the weight of an product could result in physical injury.
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August 2010 42PJ350 Plasma
(Electrostatic Static Discharge)
ESD Notice
ESD Notice
Today’s sophisticated electronics are electrostatic discharge (ESD) sensitive. ESD can weaken or damage
the electronics in a manner that renders them inoperative or reduces the time until their next failure.
Connect an ESD wrist strap to a ground connection point or unpainted metal in the product. Alternatively,
you can touch your finger repeatedly to a ground connection point or unpainted metal in the product. Before
removing a replacement part from its package, touch the anti-static bag to a ground connection point or
unpainted metal in the product. Handle the electronic control
repackaging a failed electronic control assembly in an anti-static bag, observe these same precautions.
Regulatory Information
Regulatory Information
This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to
Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful
interference when the equipment is operated in a residential installation. This equipment generates, uses,
and can radiate radio frequency energy, and, if not installed and used in accordance with the instruction
manual, may cause harmful interference to radio communications. However, there is no guarantee that
interference will not occur in a particular installation. If this equipment does cause harmful interference to
radio or television reception, which can be determined by turning the equipment off and on, the user is
encouraged to try to correct the interference by one or more of the following measures: Reorient or relocate
the receiving antenna; Increase the separation between the equipment and the receiver; Connect the
equipment to an outlet on a different circuit than that to which the receiver is connected; or consult the
dealer or an experienced radio/TV technician for help.
(Electrostatic Static Discharge)
assembly by its edges only. When
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August 2010 42PJ350 Plasma
Safety and Handling, Checking Points
Safety and Handling, Checking Points
Safety & Handling Regulations
1.Approximately 10 minute pre-run time is required before any adjustments are performed.
2.Refer to the Voltage Sticker inside the Panel when making adjustments on the Power Supply, Y-SUS and Z-SUS Boards.
3.Always adjust to the specified voltage level (+/- ½ volt) unless otherwise specified.
4.Be cautious of electric shock from the PDP module since the PDP module uses high voltage, check that the Power Supply
and Drive Circuits are completely discharged because of residual current stored before Circuit Board removal.
4.C-MOS circuits are used extensively for processing the Drive Signals and should be protected from static electricity.
5.The PDP Module must be carried by two people. Always carry vertical NOT horizontal.
6.The Plasma television should be transported vertically NOT horizontally.
7.Exercise care when making voltage and waveform checks to prevent costly short circuits from damaging the unit.
8.Be cautious of lost screws and other metal objects to prevent a possible short in the circuitry.
9.New Panels and Frames are much thinner than previous models. Be Careful with flexing these panels. Be careful
with lifting Panels from a horizontal position. Damage to the Frame mounts or panel can occur.
10. New Plasma models have much thinner cabinet assemblies and mounts.
Be extremely careful when moving the set around as damage can occur.
Checking Points to be Considered
1. Check the appearance of the Replacement Panel and Circuit Boards for both physical damage and part number accuracy.
2. Check the model label. Verify model names and board model matches.
3. Check details of defective condition and history. Example: Y-SUS or Y-Drive Board Failure, Mal-discharge on screen, etc.
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August 2010 42PJ350 Plasma
Basic Troubleshooting Steps
Basic Troubleshooting Steps
Define, Localize, Isolate and Correct
• Define
failure. Use your senses Sight, Smell, Touch and Hearing. Look for burned parts and check
for possible overheated components. Capacitors will sometimes leak dielectric material and
give off a distinct odor. Frequency of power supplies will change with the load, or listen for
relay closing etc. Observation of the front Power LEDs may give some clues.
• Localize
and after giving a thorough examination using your senses the first check should always be
the DC Supply Voltages to those circuits under test. Always confirm the supplies are not
only the proper level but be sure they are noise free. If the supplies are missing check the
resistance for possible short circuits.
• Isolate
Oscilloscope to make a final determination of the failure. Look for correct Amplitude
Phasing and Timing of the signals also check for the proper Duty Cycle of the signals.
Sometimes “glitches” or “road bumps” will be an indication of an imminent failure.
Look at the symptom carefully and determine what circuits could be causing the
After carefully checking the symptom and determining the circuits to be checked
To further isolate the failure, check for the proper waveforms with the
• Correct
check the DC Supplies for proper levels. Make all necessary adjustments and lastly always
perform a Safety AC Leakage Test before returning the product back to the Customer.
The final step is to correct the problem. Be careful of ESD and make sure to
8
August 2010 42PJ350 Plasma
42PJ350 PRODUCT INFORMATION SECTION
42PJ350 PRODUCT INFORMATION SECTION
This section of the manual will discuss the specifications of the
42PJ350 Advanced Single Scan Plasma Display Television.
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August 2010 42PJ350 Plasma
42PJ350 Specifications
42PJ350 Specifications
42" Class (41.6" diagonal)
•600Hz Sub Field Driving
•High Definition Resolution
1080P PLASMA HDTV
•3M:1 Dynamic Contrast Ratio
•TruSlim Frame
•Picture Wizard II (Easy Picture Calibration)
•Smart Energy Saving
•Intelligent Sensor
•Dual XD™ Engine
•AV Mode (Cinema, Sports, Game)
•Clear Voice II
•ISFccc® Ready
•24P Real Cinema
•USB 2.0 (JPEG, MP3)
•3 HDMI™ 1.3 Inputs
•SIMPLINK™ Connectivity
For Full Specifications
See the Specification Sheet
•Dolby® Digital 5.1 Decoder
•Infinite Sound
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August 2010 42PJ350 Plasma
42PJ350 Logo Familiarization Page 1 of 3
42PJ350 Logo Familiarization Page 1 of 3
600Hz Sub Field Firing:
Capture every moment. Tired of streaky action or unclear plays during the
game? See sports, fast action and video games like never before. The 600Hz
refresh rate virtually eliminates motion blur.
3.000,000 : 1 Contrast Ratio
Stunning detail. No more worrying about dark scenes or dull colors.
The Mega Contrast ratio of 3,000,000:1 delivers more stunning colors and
deeper blacks than you can imagine.
TruSlim Design:
At less than 1" thick the new TruSlim Frame trims away distraction without
compromising screen size.
USB 2.0:
View videos and photos and listen to music on your TV through USB 2.0.
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August 2010 42PJ350 Plasma
42PJ350 Logo Familiarization Page 2 of 3
42PJ350 Logo Familiarization Page 2 of 3
HD RESOLUTION 720P HD Resolution Pixels: 1365 (H) × 768 (V)
See and experience more. Pictures are sharper.
Colors are more vibrant. Entertainment is more real.
Everything looks better on an HDTV.
HDMI (1.3 Deep Color) Digital multi-connectivity
HDMI (1.3 Deep color) provides a wider bandwidth (340MHz,
10.2Gbps) than that of HDMI 1.2, delivering a broader range of colors,
and also drastically improves the data-transmission speed.
Invisible Speaker
Personally tuned by Mr. Mark Levinson for LG
TAKE IT TO THE EDGE newly introduces ‘Invisible Speaker’ system,
guaranteeing first class audio quality personally tuned by Mr. Mark
Levinson, world renowned as an audio authority. It provides Full Sweet
Spot and realistic sound equal to that of theaters with its Invisible
Speaker.
Dual XD Engine
Realizing optimal quality for all images
One XD Engine optimizes the images from RF signals as another XD
Engine optimizes them from External inputs. Dual XD Engine presents
images with optimal quality two times higher than those of previous
models.
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August 2010 42PJ350 Plasma
42PJ350 Logo Familiarization Page 3 of 3
42PJ350 Logo Familiarization Page 3 of 3
AV Mode "One click" Cinema, Sports, Game mode.
AV Mode is three preset picture and audio settings. It allows the viewer
to quickly switch between common settings. It includes Cinema, Sports,
and Game Modes.
Clear Voice Clearer dialogue sound
Automatically enhances and amplifies the sound of the human voice
frequency range to provide high-quality dialogue when background
noise swells.
Save Energy, Save Money
It reduces the plasma display’s power consumption.
The default factory setting complies with the Energy Star requirements
and is adjusted to the comfortable level to be viewed at home.
(Turns on Intelligent Sensor).
Save Energy, Save Money
Home electronic products use energy when they're off to power features like clock
displays and remote controls. Those that have earned the ENERGY STAR use as much
as 60% less energy to perform these functions, while providing the same performance at
the same price as less-efficient models. Less energy means you pay less on your energy
bill. Draws less than 1 Watt in stand by.
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August 2010 42PJ350 Plasma
600Hz Sub Field Driving
600Hz Sub Field Driving
(600 Hz Sub Field Driving)
•600 Hz Sub Field Driving is achieved by using 10 sub-fields per frame process
(vs. Comp. 8 sub-field/frame)
•No smeared images during fast motion scenes
Original Image10 Sub Fields Per Frame
Sub Field firing occurs using wall charge and polarity differences between Y-SUS and Z-SUS signals.
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August 2010 42PJ350 Plasma
42PJ350 Remote Control
42PJ350 Remote Control
p/n AKB72914201
TOP PORTION
BOTTOM PORTION
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August 2010 42PJ350 Plasma
42PJ350 Rear and Side Input Jacks
42PJ350 Rear and Side Input Jacks
REAR
INPUTS
AC In
USB for Music, Photos
and Software
Upgrades
SIDE
INPUTS
USB
HDMI 3
Composite
Video/Audio
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August 2010 42PJ350 Plasma
42PJ350 Dimensions
Power:
285W (Typical)
0.2W (Stand-By)
27-1/8"
688.34mm
24-5/6"
617.22mm
There must be at least 4 inches of Clearance on all sides
11-7/16”
290mm
Model No.
Serial No.
Label
38-7/8"
955.06mm
15-3/4"
400mm
Remove 4 screws
to remove stand
for wall mount
2-3/16"
55.88mm
4-9/16”
116mm
15-3/4"
400mm
2-13/16"
71.43mm
Weight:
3-15/16”
100mm
47.6 lbs with Stand
41.1 lbs without Stand
2-3/16"
56mm
18-3/4"
476.25mm
10-3/16"
259.08mm
17August 2010 42PJ350 Plasma
DISASSEMBLY SECTION
DISASSEMBLY SECTION
This section of the manual will discuss Disassembly, Layout and Circuit
Board Identification, of the 42PJ350 Advanced Single Scan Plasma Display Panel.
Upon completion of this section the Technician will have a better
understanding of the disassembly procedures, the layout of the printed
circuit boards and be able to identify each board.
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August 2010 42PJ350 Plasma
Removing the Back Cover
Removing the Back Cover
To remove the back cover, remove the 32 screws
(The Stand does not need to be removed).
PAY CLOSE ATTENTION TO THE TYPE, SIZE AND LENGTH
Of the screws when replacing the back cover.
Improper type can damage the front.
Indicated by the arrows.
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August 2010 42PJ350 Plasma
Circuit Board Layout
Circuit Board Layout
FPC
FPC
FPCFPC
Y-Drive Board
Y-SUS
FPCFPC
Identifying the Circuit Boards
Identifying the Circuit Boards
Panel Voltage and Panel ID Label
Power Supply
(SMPS)
Control
FPC
Z-SUS
Z-SUB
Main Board
FPC
IR/LED
Board
Conductive Tape
Soft Touch
Keyboard
Left “X”
TCP
Heat Sink
Conductive Tape
Invisible Speakers
20
AC In
Side
Input
(part of
main)
Right “X”
Conductive Tape
August 2010 42PJ350 Plasma
42PJ350 Connector Identification Diagram
42PJ350 Connector Identification Diagram
PANEL
p/n: EAJ60716204 (PDP42T10000.ADLGB)
P201P202P303
Y-DRIVE
p/n: EAJ60716215 (PDP42T10000.ADLGB)
Board
p/n: EBR63633601
P206
P811
SMPS
P201
POWER SUPPLY
Board
Y-SUS
p/n: EAY60912401
Board
p/n: EBR63038301
P204P205P206
P163
P101
P101
P211P106
P209
p/n: EBR63632301
n/c
P121
CONTROL
Board
P161
Top row Odd
Back row Even
SC101
LN
P102
P162
P813
LVDS
P2
Z-SUS
Board
p/n: EBR63038801
P1
p/n: EBR63634601
Z-SUB Board
P301
P704
P703
MAIN
P801
Board
P900
n/c
P4
P3
P2
P1
P233
P100
P101
FRONT IR
p/n: EBR65007704
AC
In
LEFT X Board
P201P202P203P204P205P206P301P302P303P304P305P306
Speakers (Front Right)
Front “Soft Switch” Key Pad
p/n: EBR63628801
P232P211
P331 P311
21
p/n: EBR63628701
p/n: EAB60962801p/n: EAB60962801
August 2010 42PJ350 Plasma
Speakers (Front Left)
p/n: EBT60953602
RIGHT X Board
Disassembly Procedure for Circuit Board Removal
Disassembly Procedure for Circuit Board Removal
Note: 1) Remember to be cautious of ESD as some semiconductors are CMOS and prone to static failure.
Switch Mode Power Supply Board Removal
Disconnect the following connectors: P811, P813 and SC101.
Remove the 8 screws holding the SMPS in place.
Remove the board. When replacing, be sure to readjust the Va/Vs voltages in accordance with the Panel
Label. Also, re-confirm VSC, -Vy and Z-Bias as well.
Note: The Y-SUS does not come with the
Y-SUS Board Removal
Remove the Left Vertical Brace. 4 screws, 2 metal tap and 2 plastic tap.
Disconnect the following connectors: P201, P203, P206, P211 and Ribbon Cable P101.
To remove P101, lift up on the locking mechanism and pull the ribbon cable out.
Remove the 16 screws holding the Y-SUS in place. Do not run the set with P211removed.
Remove the Y-SUS board. When replacing, be sure to readjust the Va/Vs voltages in accordance with the
Panel Label.
Confirm VSC, -Vy and Z-bias as well.
Note: The Y-SUS does not come with the
Y-Drive Board Removal
connectors between the Y-SUS and Y-Drive
connector to the Lower Y-Drive
Board Standoff
Disconnect P101~P106 Connectors to the Panel
Remove P106 by lifting up on the locking mechanism and pull the ribbon cable out.
Do not run the set with P106 connector removed.
Remove the 7 screws holding the Y-Drive board in place.
Lift up slightly, the slide to the left. Remove the Y-Drive Board.
Note: Y-SUS, Z-SUS and Y-Drive boards are mounted on board stand-offs that have a small collar.
The board must be lifted slightly to clear these collars. Behind each board are “Chocolate” (dense rubber
like material) that act as shock absorbers. They may make the board stick when removing.
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August 2010 42PJ350 Plasma
Collar
Disassembly Procedure for Circuit Board Removal (2)
Disassembly Procedure for Circuit Board Removal (2)
Z-SUS Board Removal
Disconnect the following connectors: P1 and P2, then P4 by pulling out the locking mechanism and pulling out the
FPC to the panel. Note, slide a thin object (top side) between ribbon and connector to remove.
Remove the 9 screws holding the board in place.
Lift up slightly to clear the screw stand-offs and pull the Z-SUS upward to unseat P3/P2 from the Z-SUB board and
remove the Z-SUS board.
When replacing, be sure to readjust the Va/Vs voltages in accordance with the Panel Label.
Confirm VS, -Vy and Z-bias (VZB) as well.
Z-SUB Board Removal
Remove the two screws in the Z-SUB board. Remove P1 by pulling out the locking mechanism and pulling out
the FPC to the panel, See note above concerning P4 removal. Pull down and remove Z-SUB.
Main Board Removal
Disconnect the following connectors: P703 LVDS and P301 (press gently inward on the locking tabs) and pull
out, P704 and P801. Remove 1 screw in the decorative plastic piece and remove.
Remove the 4 screws holding the Main board in place and Remove the board.
Control Board Removal
Disconnect the following connectors: P121 LVDS, P101 Ribbon and P102. Then P161, P162 Ribbons by lifting
up the locking tab. Remove the 1 screws holding the Control board in place. Lift up the bottom and pull down to
unseat it from the two metal supports at the top and Remove the board. Pay attention to the top right back side
of the board. There is a piece of rubber (Chocolate) that may fall off. Be sure to replace the rubber piece.
Front IR and Key Pad Removal
FRONT IR/INTELLIGENT SENSOR and POWER BUTTON:
Disconnect P100 and P101. Note: P101 is a ribbon connector. Lift up the locking mechanism and slide the
ribbon cable out. Remove the Board by lifting up on the top tabs, lift the board and remove.
KEY PAD:
The Key Pad is a thin strip of static sensitive material attached to the front glass. It is not removable.
23
August 2010 42PJ350 Plasma
X Drive Circuit Board Removal Continued
X Drive Circuit Board Removal Continued
Make sure AC is removed.
Lay the Television down carefully on a padded surface.
Make sure to use at least two people for this process so as not to flex the panel glass.
a)Remove the Back Cover.
b)Remove the Stand (4 Stand Screws were removed during back removal).
c)Disconnect the two connector on the left side of the Main board, P704 and P801.
d)Remove the Stand Metal Support Bracket (5 Screws) 2 Plastic tap thread and 3 Metal thread.
e)Remove the two Vertical support Braces marked “E”.
Note: There are 4 Screws per/brace, 2 Plastic tap thread and 2 Metal thread.
(Note, the right brace has a Grounding wire from the AC input which must also be removed).
f)Remove the 7 screws holding the Heat Sink. (Warning: Never run the set with this heat sink removed).
To remove the heat sink, lift up to release the tacky Chocolate (heat transfer material) and slide the
heat sink to the left to clear the connector wires on the right side.
Note: There are three large pieces of conductive tape on the heat sink that must be removed.
Also, note that there several pieces of Chocolate heat transfer material attached all the way across the
underside of the heat sink. There is a mark on either
side of the tape on the heat sink which shows its locations.
X-DRIVE LEFT, AND X-DRIVE RIGHT REMOVAL:
Heat sink
Chocolate
Heat transfer
material
Disconnect all TCP ribbon cables from the defective X-Drive board and all other Ribbon cables going to
the board.
Remove the (3 Left or Right X) or (5 Center X) screws holding the defective X-Drive board in place.
Remove the board. Reassemble in reverse order. Recheck Va / Vs / VScan / -VY / Z-Drive.
24
August 2010 42PJ350 Plasma
Getting to the X Circuit Boards
Getting to the X Circuit Boards
E
Left
Warning:
Never run the TV with the
TCP Heat Sink removed
F
Heat Sink
With Stand removed
E
Right
D
C
Ground
Wire
D
B
Warning Shorting Hazard: Conductive Tape. Do not allow to touch energized circuits.
25
August 2010 42PJ350 Plasma
Left and Right X Drive Connector Removal
Left and Right X Drive Connector Removal
Disconnect connector P233
See below to Remove the Connections on the X-Boards.
From the X-Boards to the Control Board.
There may be tape on these connectors.
P232, P331
Are the same
Remove tape (if present) and Gently
locking mechanism upward and remove the ribbon
cable from the connector.
Removing Connectors to the TCPs.
pry the
Va from the
Y-SUS to
Left X Only
Connectors from Left and Right X Boards
P211 to P311
Left X to Right X
P211, P311
Are the same
Carefully lift the TCP ribbon up and off.
It may stick, be careful not to crack TCP.
(See next page for precautions)
Gently lift the locking mechanism
upward on all TCP connectors
Left X: P201~206
Right X: P301~306
Cushion (Chocolate)
TCP
26
Example
Flexible ribbon cable connector
August 2010 42PJ350 Plasma
TCP (Tape
TCP (Tape
Carrier
Carrier
Package) Generic Removal Precautions
Package) Generic Removal Precautions
T
a
b
Lift up the lock as shown using your fingernail.
(The Lock can be easily broken.
It needs to be handled carefully.)
T
a
b
Separate the TCP from the connector as shown.
TCP Film can be easily damaged.
Handle with care.
The TCP has two small tabs on each
side which lock the ribbon cable
fully into the connector. They have
to be lifted up slightly to pull the
connector out.
Note: TCP is usually stuck down
to the Chocolate heat transfer
material, be Very Careful when
lifting up on the TCP ribbon cable.
Tab
27
Tab
August 2010 42PJ350 Plasma
Left and Right X Drive Removal
Left and Right X Drive Removal
Remove the 4 screws in Left or Right X-Boards, (9 Total)
Shared with the
Left X
Shared with the
Right X
The Left X Board drives the Right 5/16 of the side of the screen vertical electrodes
The Center X Board drives the Center 3/8 of the of the screen vertical electrodes
The Right X Board drives the Left 5/16 of the side of the screen vertical electrodes
28
August 2010 42PJ350 Plasma
CIRCUIT OPERATION, TROUBLESHOOTING AND CIRCUIT ALIGNMENT SECTION
CIRCUIT OPERATION, TROUBLESHOOTING AND CIRCUIT ALIGNMENT SECTION
42PJ350 Plasma Display
This Section will cover Circuit Operation, Troubleshooting and Alignment of the
Power Supply, Y-SUS Board, Y-Drive Boards, Z-SUS Board, Control Board,
Main Board and the X Drive Boards.
At the end of this Section the technician should understand the operation of each
circuit board and how to adjust the controls. The technician should be able with
confidence to troubleshoot a circuit board failure, replace the defective circuit and
perform all necessary adjustments.