LG 60LN549E-ZE User Manual

Internal Use Only

North/Latin America http://aic.lgservice.com Europe/Africa http://eic.lgservice.com Asia/Oceania http://biz.lgservice.com

LED TV

SERVICE MANUAL

CHASSIS : LD3AG

MODEL : 60LN549E 60LN549E-ZE

CAUTION

BEFORE SERVICING THE CHASSIS, READ THE SAFETY PRECAUTIONS IN THIS MANUAL.

Printed in KoreaP/NO : MFL67800112 (1309-REV00)

CONTENTS

CONTENTS .............................................................................................. 2

SAFETY PRECAUTIONS ........................................................................ 3

SERVICING PRECAUTIONS ................................................................... 4

SPECIFICATION ...................................................................................... 6

ADJUSTMENT INSTRUCTION ............................................................. 10

TROUBLESHOOTING GUIDE ................................................................ 19

BLOCK DIAGRAM ................................................................................. 25

EXPLODED VIEW .................................................................................. 26

SCHEMATIC CIRCUIT DIAGRAM ..............................................................

Only for training and service purposes

- 2 -

SAFETY PRECAUTIONS

IMPORTANT SAFETY NOTICE

Many electrical and mechanical parts in this chassis have special safety-related characteristics. These parts are identified by in the Schematic Diagram and Exploded View. It is essential that these special safety parts should be replaced with the same components as recommended in this manual to prevent Shock, Fire, or other Hazards. Do not modify the original design without permission of manufacturer.

General Guidance

An isolation Transformer should always be used during the servicing of a receiver whose chassis is not isolated from the AC power line. Use a transformer of adequate power rating as this protects the technician from accidents resulting in personal injury from electrical shocks.

It will also protect the receiver and it's components from being damaged by accidental shorts of th e cir cuitry that may be inadvertently introduced during the service operation.

If any fuse (or Fusible Resistor) in this TV receiver is blown, replace it with the specified.

When replacing a high wattage resistor (Oxide Metal Film Resistor, over 1 W), keep the resistor 10 mm away from PCB.

Keep wires away from high voltage or high temperature parts.

Before returning the receiver to the customer,

always perform an AC leakage current check on the exposed metallic parts of the cabinet, such as antennas, terminals, etc., to be sure the set is safe to operate without damage of electrical shock.

Leakage Current Cold Check(Antenna Cold Check)

With the instrument AC plug removed from AC source, connect an electrical jumper across the two AC plug prongs. Place the AC switch in the on position, connect one lead of ohm-meter to the AC plug prongs tied together and touch other ohm-meter lead in turn to each exposed metallic parts such as antenna terminals, phone jacks, etc. If the exposed metallic part has a return path to the chassis, the measured resistance should be between 1 MΩ and 5.2 MΩ. When the exposed metal has no return path to the chassis the reading must be infinite. An other abnormality exists that must be corrected before the receiver is returned to the customer.

Leakage Current Hot Check (See below Figure)

Plug the AC cord directly into the AC outlet.

Do not use a line Isolation Transformer during this check. Connect 1.5 K / 10 watt resistor in parallel with a 0.15 uF capacitor between a known good earth ground (Water Pipe, Conduit, etc.) and the exposed metallic parts. Measure the AC voltage across the resistor using AC voltmeter with 1000 ohms/volt or more sensitivity. Reverse plug the AC cord into the AC outlet and repeat AC voltage measurements for each exp ose d metallic par t. Any voltage measured must not exceed 0.75 volt RMS which is corresponds to

0.5 mA. In case any measurement is out of the limits specified, there is possibility of shock hazard and the set must be checked and repaired before it is returned to the customer.

Leakage Current Hot Check circuit

Only for training and service purposes

- 3 -

SERVICING PRECAUTIONS

CAUTION: Before servicing receivers covered by this service manual and its supplements and addenda, read and follow the

SAFETY PRECAUTIONS on page 3 of this publication. NOTE: If unforeseen circumstances create conict between the

following servicing precautions and any of the safety precautions on page 3 of this publication, always follow the safety precautions. Remember: Safety First.

General Servicing Precautions

1. Always unplug the receiver AC power cord from the AC power source before;

a. Removing or reinstalling any component, circuit board

module or any other receiver assembly.

b. Disconnecting or reconnecting any receiver electrical plug

or other electrical connection.

c. Connecting a test substitute in parallel with an electrolytic

capacitor in the receiver. CAUTION: A wrong part substitution or incorrect polarity installation of electrolytic capacitors may result in an explosion hazard.

2. Test high voltage only by measuring it with an appropriate high voltage meter or other voltage measuring device (DVM, FETVOM, etc) equipped with a suitable high voltage probe. Do not test high voltage by "drawing an arc".

3. Do not spray chemicals on or near this receiver or any of its assemblies.

4. Unless specied otherwise in this service manual, clean electrical contacts only by applying the following mixture to the contacts with a pipe cleaner, cotton-tipped stick or comparable non-abrasive applicator; 10 % (by volume) Acetone and 90 % (by volume) isopropyl alcohol (90 % - 99 % strength) CAUTION: This is a ammable mixture. Unless specied otherwise in this service manual, lubrication of contacts in not required.

5. Do not defeat any plug/socket B+ voltage interlocks with which receivers covered by this service manual might be equipped.

6. Do not apply AC power to this instrument and/or any of its electrical assemblies unless all solid-state device heat sinks are correctly installed.

7. Always connect the test receiver ground lead to the receiver chassis ground before connecting the test receiver positive lead. Always remove the test receiver ground lead last.

8. Use with this receiver only the test xtures specied in this service manual. CAUTION: Do not connect the test xture ground strap to any heat sink in this receiver.

Electrostatically Sensitive (ES) Devices

Some semiconductor (solid-state) devices can be damaged easily by static electricity. Such components commonly are called Electrostatically Sensitive (ES) Devices. Examples of typical ES devices are integrated circuits and some eld-effect transistors and semiconductor “chip” components. The following techniques should be used to help reduce the incidence of component damage caused by static by static electricity.

1. Immediately before handling any semiconductor component or semiconductor-equipped assembly, drain off any electrostatic charge on your body by touching a known earth ground. Alternatively, obtain and wear a commercially available discharging wrist strap device, which should be removed to prevent potential shock reasons prior to applying power to the unit under test.

2. After removing an electrical assembly equipped with ES devices, place the assembly on a conductive surface such as aluminum foil, to prevent electrostatic charge buildup or exposure of the assembly.

3. Use only a grounded-tip soldering iron to solder or unsolder ES devices.

4. Use only an anti-static type solder removal device. Some solder removal devices not classied as “anti-static” can generate electrical charges sufcient to damage ES devices.

5. Do not use freon-propelled chemicals. These can generate electrical charges sufcient to damage ES devices.

6. Do not remove a replacement ES device from its protective package until immediately before you are ready to install it. (Most replacement ES devices are packaged with leads electrically shorted together by conductive foam, aluminum foil or comparable conductive material).

7. Immediately before removing the protective material from the leads of a replacement ES device, touch the protective material to the chassis or circuit assembly into which the device will be installed. CAUTION: Be sure no power is applied to the chassis or circuit, and observe all other safety precautions.

8. Minimize bodily motions when handling unpackaged replacement ES devices. (Otherwise harmless motion such as the brushing together of your clothes fabric or the lifting of your foot from a carpeted oor can generate static electricity sufcient to damage an ES device.)

General Soldering Guidelines

1. Use a grounded-tip, low-wattage soldering iron and appropriate tip size and shape that will maintain tip temperature within the range or 500 °F to 600 °F.

2. Use an appropriate gauge of RMA resin-core solder composed of 60 parts tin/40 parts lead.

3. Keep the soldering iron tip clean and well tinned.

4. Thoroughly clean the surfaces to be soldered. Use a mall wirebristle (0.5 inch, or 1.25 cm) brush with a metal handle. Do not use freon-propelled spray-on cleaners.

5. Use the following unsoldering technique

a. Allow the soldering iron tip to reach normal temperature.

(500 °F to 600 °F) b. Heat the component lead until the solder melts. c. Quickly draw the melted solder with an anti-static, suction-

type solder removal device or with solder braid.

CAUTION: Work quickly to avoid overheating the circuit

board printed foil.

6. Use the following soldering technique. a. Allow the soldering iron tip to reach a normal temperature

(500 °F to 600 °F)

b. First, hold the soldering iron tip and solder the strand

against the component lead until the solder melts.

c. Quickly move the soldering iron tip to the junction of the

component lead and the printed circuit foil, and hold it there only until the solder ows onto and around both the component lead and the foil. CAUTION: Work quickly to avoid overheating the circuit board printed foil.

d. Closely inspect the solder area and remove any excess or

splashed solder with a small wire-bristle brush.

Only for training and service purposes

- 4 -

IC Remove/Replacement

Some chassis circuit boards have slotted holes (oblong) through which the IC leads are inserted and then bent at against the circuit foil. When holes are the slotted type, the following technique should be used to remove and replace the IC. When working with boards using the familiar round hole, use the standard technique as outlined in paragraphs 5 and 6 above.

Removal

1. Desolder and straighten each IC lead in one operation by gently prying up on the lead with the soldering iron tip as the solder melts.

2. Draw away the melted solder with an anti-static suction-type solder removal device (or with solder braid) before removing the IC.

Replacement

1. Carefully insert the replacement IC in the circuit board.

2. Carefully bend each IC lead against the circuit foil pad and solder it.

3. Clean the soldered areas with a small wire-bristle brush. (It is not necessary to reapply acrylic coating to the areas).

"Small-Signal" Discrete Transistor Removal/Replacement

1. Remove the defective transistor by clipping its leads as close as possible to the component body.

2. Bend into a "U" shape the end of each of three leads remaining on the circuit board.

3. Bend into a "U" shape the replacement transistor leads.

4. Connect the replacement transistor leads to the corresponding leads extending from the circuit board and crimp the "U" with long nose pliers to insure metal to metal contact then solder each connection.

Power Output, Transistor Device Removal/Replacement

1. Heat and remove all solder from around the transistor leads.

2. Remove the heat sink mounting screw (if so equipped).

3. Carefully remove the transistor from the heat sink of the circuit board.

4. Insert new transistor in the circuit board.

5. Solder each transistor lead, and clip off excess lead.

6. Replace heat sink.

Diode Removal/Replacement

1. Remove defective diode by clipping its leads as close as possible to diode body.

2. Bend the two remaining leads perpendicular y to the circuit board.

3. Observing diode polarity, wrap each lead of the new diode around the corresponding lead on the circuit board.

4. Securely crimp each connection and solder it.

5. Inspect (on the circuit board copper side) the solder joints of the two "original" leads. If they are not shiny, reheat them and if necessary, apply additional solder.

3. Solder the connections. CAUTION: Maintain original spacing between the replaced component and adjacent components and the circuit board to prevent excessive component temperatures.

Circuit Board Foil Repair

Excessive heat applied to the copper foil of any printed circuit board will weaken the adhesive that bonds the foil to the circuit board causing the foil to separate from or "lift-off" the board. The following guidelines and procedures should be followed whenever this condition is encountered.

At IC Connections

To repair a defective copper pattern at IC connections use the following procedure to install a jumper wire on the copper pattern side of the circuit board. (Use this technique only on IC connections).

1. Carefully remove the damaged copper pattern with a sharp knife. (Remove only as much copper as absolutely necessary).

2. carefully scratch away the solder resist and acrylic coating (if used) from the end of the remaining copper pattern.

3. Bend a small "U" in one end of a small gauge jumper wire and carefully crimp it around the IC pin. Solder the IC connection.

4. Route the jumper wire along the path of the out-away copper pattern and let it overlap the previously scraped end of the good copper pattern. Solder the overlapped area and clip off any excess jumper wire.

At Other Connections

Use the following technique to repair the defective copper pattern at connections other than IC Pins. This technique involves the installation of a jumper wire on the component side of the circuit board.

1. Remove the defective copper pattern with a sharp knife. Remove at least 1/4 inch of copper, to ensure that a hazardous condition will not exist if the jumper wire opens.

2. Trace along the copper pattern from both sides of the pattern break and locate the nearest component that is directly connected to the affected copper pattern.

3. Connect insulated 20-gauge jumper wire from the lead of the nearest component on one side of the pattern break to the lead of the nearest component on the other side. Carefully crimp and solder the connections. CAUTION: Be sure the insulated jumper wire is dressed so the it does not touch components or sharp edges.

Fuse and Conventional Resistor Removal/Replacement

1. Clip each fuse or resistor lead at top of the circuit board hollow stake.

2. Securely crimp the leads of replacement component around notch at stake top.

Only for training and service purposes

- 5 -

SPECIFICATION

NOTE : Specifications and others are subject to change without notice for improvement

1. Application range

This specification is applied to the LED TV used LD3AG chassis.

2. Requirement for Test

Each part is tested as below without special appointment.

1) Temperature: 25 °C ± 5 °C(77 °F ± 9 °F), CST: 40 °C ± 5 °C

2) Relative Humidity: 65 % ± 10 %

3) Power Voltage : Standard input voltage (AC 100-240 V~, 50/60 Hz) * Standard Voltage of each products is marked by models.

4) Specification and performance of each parts are followed

ea ch drawing and s pe cificatio n b y p art number in accordance with BOM.

5) The receiver must be operated for about 5 minutes prior to

the adjustment.

3. Test method

1) Performance: LGE TV test method followed

2) Demanded other specification

- Safety : CE, IEC specification

- EMC : CE, IEC

4. Model General Specification

No. Item Specication Remarks

1 Market EU(PAL Market-37Countries) DTV & Analog (Total 37 countries)

DTV (MPEG2/4, DVB-T) :37 countries UK/Italy/Germany/France/Spain/Sweden/Finland/Netherlands/ Belgium/Luxemburg/Greece/Denmark/Czech/Austria /Hungary/Swiss/Croatia/Turkey/Norway/Slovenia/Poland/ Ukraine/Portugal/Ireland/Morocco/Latvia/Estonia/Lithania/ Rumania/Bulgaria/Russia/Slovakia/Bosnia/Serbia/Albania/ Kazakhstan/Belarus

DTV (MPEG2/4, DVB-T2): 8 countries

UK/Denmark/Sweden/Finland/Norway/Ireland/Ukraine/Kazakhstan

DTV (MPEG2/4, DVB-C): 37 countries

UK/Italy/Germany/France/Spain/Sweden/Finland/Netherlands/ Belgium/Luxemburg/Greece/Denmark/Czech/Austria /Hungary/Swiss/Croatia/Turkey/Norway/Slovenia/Poland/ Ukraine/Portugal/Ireland/Morocco/Latvia/Estonia/Lithania/ Rumania/Bulgaria/Russia/Slovakia/Bosnia/Serbia/Albania/ Kazakhstan/Belarus

DTV (MPEG2/4,DVB-S): 29 countries

Italy/Germany/France/Spain/Netherlands/Belgium/Luxemburg/ Greece/Czech/Austria/Hungary/Swiss/Croatia/Turkey/ Slovenia/Poland/Portugal/Morocco/Latvia/Estonia/Lithuania/ Rumania/Bulgaria/Russia/Slovakia/Bosnia/Serbia/Albania/ Belarus

Supported satellite : 22 satellites

HISPASAT 1C/1D, ATLANTIC BIRD 2, NILESAT 101/102, ATLANTIC BIRD 3, AMOS 2/3, THOR 5/6, IRIUS 4, EUTELSAT-W3A, EUROBIRD 9A, EUTELSAT-W2A, HOTBIRD 6/8/9, EUTELSAT-SESAT, ASTRA 1L/H/M/KR, ASTRA 3A/3B, BADR 4/6, ASTRA 2D, EUROBIRD 3, EUTELSAT-W7, HELLASSAT 2, EXPRESS AM1, TURKSAT 2A/3A, INTERSAT10

Only for training and service purposes

- 6 -

No. Item Specication Remarks

Analogue TV

1) PAL-BG

2) PAL-DK

2 Broadcasting system

3 Receiving system

4 Scart Jack (1EA) PAL, SECAM Scart 1 Jack is Full scart and support RF-OUT(analog).

5 Component Input (1EA)

6 RGB Input RGB-PC

7 HDMI Input (3EA)

8 Audio Input (1EA) RGB/DVI/Component Audio

9 SDPIF out (1EA) SPDIF out

10 External Speaker out (1EA) Stereo, 1W (8 Ω), Single-End 3P Phone Jack type

11 External Speaker out Control (1EA) Phone Jack 3P Phone Jack type

12 Earphone out (1EA)

13 USB

14 DVB

15 RS232C(1EA) Interactive mode support

16 Ethernet (1EA)

3) PAL-I/I’

4) SECAM L/L’

Digital TV

1) DVB-T/C/T2

Satellite Digital TV

1) DVB-T/C/S/S2

Analog : Upper Heterodyne Digital : COFDM , QAM

Y/Cb/Cr Y/Pb/Pr

HDMI1-DTV/DVI HDMI2-DTV HDMI3-DTV

Antenna, AV1, AV2, Component, RGB, HDMI1, HDMI2, HDMI3

EMF, DivX HD, For SVC (download)

DVB-T

DVB-C

Analogue TV : (RF) VHF: E2 to E12, UHF : E21 to E69 (CATV) S1 to S20, HYPER: S21 to S47

Digital TV : VHF, UHF

Satellite TV : VHF, UHF, C-Band, Ku-Band

* DVB-T2 (T2 model only support ) * DVB-S/S2 (Satellite model only support )

► DVB-T

- Guard Interval (Bitrate_Mbit/s) 1/4, 1/8, 1/16, 1/32

- Modulation : Code Rate QPSK : 1/2, 2/3, 3/4, 5/6, 7/8 16-QAM : 1/2, 2/3, 3/4, 5/6, 7/8 64-QAM : 1/2, 2/3, 3/4, 5/6, 7/8 ► DVB-T2

- Guard Interval (Bitrate_Mbit/s) 1/4, 1/8, 1/16, 1/32, 1/128, 19/128, 19/256,

- Modulation : Code Rate QPSK : 1/2, 2/5, 2/3, 3/4, 5/6 16-QAM : 1/2, 2/5, 2/3, 3/4, 5/6 64-QAM : 1/2, 2/5, 2/3, 3/4, 5/6 256-QAM : 1/2, 2/5, 2/3, 3/4, 5/6 ► DVB-C

- Symbolrate : 4.0Msymbols/s to 7.2Msymbols/s

- Modulation : 16QAM, 64-QAM, 128-QAM and 256-QAM ► DVB-S

- symbol rate DVB-S2 (8PSK / QPSK) : 2 ~ 45Msymbol/s DVB-S (QPSK) : 2 ~ 45Msymbol/s

- viterbi DVB-S mode : 1/2, 2/3, 3/4, 5/6, 7/8 DVB-S2 mode : 1/2, 2/3, 3/4, 3/5, 4/5, 5/6, 8/9, 9/10

Phone Jack type Video only(Rear)

Analog(D-SUB 15PIN) *LN549E-ZA model only support

PC(HDMI version 1.3) Support HDCP The number of Input ports is different by model.

RGB/DVI & Component Audio common port * Component/DVI Audio (LP63xH-ZA model support) * Component/RGB/DVI Audio (LN549E-ZA model support)

JPEG, MP3, DivX HD * 1EA (LP63xH-ZA model support ) * 2EA (LN549E-ZA model support )- USB IN, Wireless Dongle : Wireless Dongle port only use for Wireless

CI : UK, Finland, Denmark, Norway, Sweden, Russia, Spain, Ireland,

Luxemburg, Belgium, Netherland

CI+ : France(Canal+), Italy(DGTVi)

CI : Switzerland, Austria, Slovenia, Hungary, Bulgaria CI+ : Switzerland(UPC,Cablecom), Netherland(Ziggo),

Germany(KDG,CWB), Finland(labwise)

Support only communication with Pro :Centrc Server Support only LP63xH-ZA model

Only for training and service purposes

- 7 -

5. Supported video resolutions (2D)

5.1. Component Input (Y, CB/PB, CR/PR)

No. Resolution H-freq(kHz) V-freq(Hz) Pixel clock(MHz) Proposed

1 720*576 15.625 50.00 13.5 SDTV ,DVD 576I

2 720*480 15.73 60.00 13.5135 SDTV ,DVD 480I

3 720*480 15.73 59.94 13.50 SDTV ,DVD 480I

4 720*576 31.25 50.00 27.00 SDTV 576P

5 720*480 31.50 60.00 27.027 SDTV 480P

6 720*480 31.47 59.94 27.00 SDTV 480P

7 1280*720 37.50 50.00 74.25 HDTV 720P

8 1280*720 45.00 60.00 74.25 HDTV 720P

9 1280*720 44.96 59.94 74.176 HDTV 720P

10 1920*1080 28.125 50.00 74.25 HDTV 1080I

11 1920*1080 33.75 60.00 74.25 HDTV 1080I

12 1920*1080 33.72 59.94 74.176 HDTV 1080I

13 1920*1080 56.25 50.00 148.50 HDTV 1080P

14 1920*1080 67.50 60.00 148.50 HDTV 1080P

15 1920*1080 67.432 59.94 148.352 HDTV 1080P

16 1920*1080 27.00 24.00 74.25 HDTV 1080P

17 1920*1080 26.97 23.94 74.176 HDTV 1080P

18 1920*1080 33.75 30.00 74.25 HDTV 1080P

19 1920*1080 33.71 29.97 74.176 HDTV 1080P

5.2. RGB Input (PC) - HD Model

No. Resolution H-freq(kHz) V-freq.(Hz) Pixel clock(MHz) Proposed DDC

1. 640*480 31.469 59.94 VESA(VGA) O

2. 800*600 37.879 60.31 VESA(SVGA) O

3. 1024*768 48.363 60.00 VESA(XGA) O

4. 1152*864 54.348 60.053 VESA O

5.3. RGB Input (PC) - FHD Model

No. Resolution H-freq(kHz) V-freq.(Hz) Pixel clock(MHz) Proposed DDC

1 640*350 31.468 70.09 25.17 EGA X

2 720*400 31.469 70.08 28.32 DOS O

3 640*480 31.469 59.94 25.17 VESA(VGA) O

4 800*600 37.879 60.31 40.00 VESA(SVGA) O

5 1024*768 48.363 60.00 65.00 VESA(XGA) O

6 1152*864 54.348 60.053 80.00 VESA O

7 1360*768 47.712 60.015 85.50 VESA (WXGA) O

8 1920*1080 66.587 59.934 138.5 HDTV 1080P O

Only for training and service purposes

- 8 -

5.3. HDMI Input(PC/DTV)

No. Resolution H-freq(kHz) V-freq.(Hz) Pixel clock(MHz) Proposed Remark

PC(DVI) DDC

1 640*350 31.468 70.09 25.17 EGA X

2 720*400 31.469 70.08 28.32 DOS O

3 640*480 31.469 59.94 25.17 VESA(VGA) O

4 800*600 37.879 60.31 40.00 VESA(SVGA) O

5 1024*768 48.363 60.00 65.00 VESA(XGA) O

6 1152*864 54.348 60.053 80.00 VESA O

7 1360*768 47.712 60.015 85.50 VESA (WXGA) O

8 1280*1024 63.981 60.020 108.0 VESA (SXGA) O

9 1920*1080 67.50 60.00 148.5 HDTV 1080P O

DTV

1 720*480 31.47 59.94 27.00 SDTV 480P

2 720*480 31.50 60.00 27.027 SDTV 480P

3 720*576 31.250 50.00 27.00 SDTV 576P

4 1280*720 37.50 50.00 74.25 HDTV 720P

5 1280*720 45.00 60.00 74.25 HDTV 720P

6 1280*720 44.96 59.94 74.176 HDTV 720P

7 1920*1080 28.125 50.00 74.25 HDTV 1080I

8 1920*1080 33.75 60.00 74.25 HDTV 1080I

9 1920*1080 33.72 59.94 74.176 HDTV 1080I

10 1920*1080 56.250 50.00 148.50 HDTV 1080P

11 1920*1080 67.50 60.00 148.50 HDTV 1080P

12 1920*1080 67.432 59.94 148.352 HDTV 1080P

13 1920*1080 27.00 24.00 74.25 HDTV 1080P

14 1920*1080 26.97 23.976 74.176 HDTV 1080P

15 1920*1080 33.75 30.00 74.25 HDTV 1080P

Only for training and service purposes

- 9 -

ADJUSTMENT INSTRUCTION

1. Application Range

This specification sheet is applied to all of the LED TV with LD3AG chassis.

2. Designation

(1) The adjustment is according to the order which is designated

and which must be followed, according to the plan

can be changed only on agreeing. (2) Power adjustment : Free Voltage. (3) Magnetic Field Condition: Nil. (4) Input signal Unit: Product Specification Standard. (5) Reserve after operation : Above 5 Minutes (Heat Run) Temperature : at 25 °C ± 5 °C Relative humidity : 65 ± 10 % Input voltage : 220 V, 60 Hz (6) Adjustment equipments: Color Analyzer(CA-210 or CA-110),

DDC Adjustment Jig, Service remote control. (7) Push the "IN STOP" key - For memory initialization.

Case1 : Software version up

1. After downloading S/W by USB , TV set will reboot automatically.

2. Push “In-stop” key.

3. Push “Power on” key.

4. Function inspection

5. After function inspection, Push “In-stop” key.

Case2 : Function check at the assembly line

1. When TV set is entering on the assembly line, Push “In-stop” key at rst.

2. Push “Power on” key for turning it on.

→ If you push “Power on” key, TV set will recover

channel information by itself.

3. After function inspection, Push “In-stop” key.

3. Main PCB check process

▪ APC - After Manual-Insert, executing APC

* Boot file Download

(1) Execute ISP program "Mstar ISP Utility" and then click

"Config" tab.

(2) Set as below, and then click "Auto Detect" and check "OK"

message. If "Error" is displayed, check connection between computer, jig, and set.

(3) Click "Read" tab, and then load download file(XXXX.bin)

by clicking "Read"

(1)

filexxx.bin

which

(4) Click "Connect" tab. If "Can't" is displayed, check connection

between computer, jig, and set.

(2)

(3)

Please Check the Speed : To use speed between from 200KHz to 400KHz

(5) Click "Auto" tab and set as below. (6) Click "Run". (7) After downloading, check "OK" message.

(4)

filexxx.bin

(5)

(7)...........OK

(6)

* USB DOWNLOAD

(1) Put the USB Stick to the USB socket. (2) Automatically detecting update file in USB Stick.

- If your downloaded program version in USB Stick is Low, it didn't work. But your downloaded version is High, USB data is automatically detecting.

(3) Show the message "Copying files from memory". (4) Updating is starting.

(5) Updating Completed, The TV will restart automatically. (6) If your TV is turned on, check your updated version and

Tool option. (explain the Tool option, next stage)

* If downloading version is more high than your TV have, TV

can lost all channel data. In this case, you have to channel recover. if all channel data is cleared, you didn’t have a DTV/ ATV test on production line.

Only for training and service purposes

* After downloading, have to adjust Tool Option again.

- 10 -

(1) Push "IN-START" key in service remote control. (2) Select "Tool Option 1" and push "OK" key. (3) Punch in the number. (Each model has their number)

3.1. ADC Process

(1) ADC

- Enter Service Mode by pushing "ADJ" key,

- Enter Internal ADC mode by pushing "►" key at "8. ADC Calibration".

EZ ADJUST

0. Tool Option1

1. Tool Option2

2. Tool Option3

3. Tool Option4

4. Tool Option5

5. Commercial Tool Option

6. Country Group

7. Area Option

8.ADC Calibration ►

9. White Balance

10. 10 Point WB

11. Test Pattern

12 EDID D/L

13. Sub B/C

14. Ext. Input Adjust

ADC Calibration

ADC Comp 480i

ADC Comp 1080p

ADC RGB

Start Reset

<Caution> Using "P-ONLY" key of the Adjustment remote

control, power on TV.

If there is no Component Input, disappear “ADC Comp” message.

* ADC Calibration Protocol (RS232)

No. Item CMD 1 CMD 2 Data 0 Enter Adjust MODE

ADC adjust ADC Adjust A D 1 0

Adjust ‘Mode In’

A A 0 0

When transfer the ‘Mode In’, Carry the command. Automatically adjustment (The use of a internal pattern)

Adjust Sequence ▪ aa 00 00 [Enter Adjust Mode] ▪ xb 00 40 [Component1 Input (480i)] ▪ ad 00 10 [Adjust 480i Comp1] ▪ xb 00 60 [RGB Input (1024*768)] ▪ ad 00 10 [Adjust 1024*768 RGB] ▪ aa 00 90 End Adjust mode * Required equipment : Adjustment remote control.

3.2. Function Check

3.2.1. Check display and sound

■ Check Input and Signal items. (cf. work instructions)

1. TV

2. AV

3. COMPONENT (480i)

4. RGB (PC : 1024 x 768 @ 60hz)

5. HDMI

6. PC Audio In * Display and Sound check is executed by Remote controller

Caution : Not to push the INSTOP KEY after completion if the

function inspection.

4. Total Assembly line process

4.1. Adjustment Preparation

▪ W/B Equipment condition

ca210 : LED -> CH14, Test signal: Inner pattern(80IRE)

▪ Above 5 minutes H/run in the inner pattern. (“power on” key

of adjust remote control)

▪ If it is executed W/B adjustment in 2~3 minutes H/run, it is

adjusted by Target data

Mode Temp Coordinate spec Model

Cool 13,000 k

Warm 6,500 k

▪ Normal line

Aging

time

(Min)

1 0-2 281 287 295 310 320 342 2 3-5 280 285 294 308 319 340 3 6-9 278 284 292 307 317 339 4 10-19 276 281 290 304 315 336 5 20-35 275 277 289 300 314 332 6 36-49 274 274 288 297 313 329 7 50-79 273 272 287 295 312 327 8 80-119 272 271 286 294 311 326 9 Over 120 271 270 285 293 310 325

▪ Aging chamber

Aging time

(Min)

1 0-5 280 285 294 308 319 340 2 6-10 276 280 290 303 315 335 3 11-20 272 275 286 298 311 330 4 21-30 269 272 283 295 308 327 5 31-40 267 268 281 291 306 323 6 41-50 266 265 280 288 305 320 7 51-80 265 263 279 286 304 318 8 81-119 264 261 278 284 303 316 9 Over 120 264 260 278 283 303 315

* Connecting picture of the measuring instrument

(On Automatic control) Inside PATTERN is used when W/B is controlled. Connect to auto controller or push Adjustment R/C P-ONLY → Enter the mode of White-Balance, the pattern will come out.

X=0.269 (± 0.002) Y=0.273 (± 0.002)

X=0.285 (± 0.002) Y=0.293 (± 0.002)

60LN549E-ZAMedium 9,300 k

X=0.313 (± 0.002) Y=0.329 (± 0.002)

Cool Medium Warm

X y x y x y

271 270 285 293 313 329

Cool Medium Warm

271 270 285 293 313 329

Only for training and service purposes

- 11 -

Full White Pattern

RS-232C Communication

CA-210

COLOR ANALYZER TYPE : CA-210

* Auto-control interface and directions

(1) Adjust in the place where the influx of light like floodlight

around is blocked. (illumination is less than 10 lux).

(2) Adhere closely the Color analyzer(CA210) to the module

less than 10 cm distance, keep it with the surface of the Module and Color analyzer's prove vertically.(80° ~ 100°).

(3) Aging time

- After aging start, keep the power on (no suspension of power supply) and heat-run over 5 minutes.

- Using 'no signal' or 'POWER ONLY' or the others, check the back light on.

▪ Auto adjustment Map(RS-232C)

RS-232C COMMAND [CMD ID DATA] Wb 00 00 White Balance Start Wb 00 ff White Balance End

RS-232C COMMAND [CMD ID DATA]

MIN

CENTER

(DEFAULT)

MAX

Cool Mid Warm Cool Mid Warm

R Gain jg Ja jd 00 172 192 192 192

G Gain jh Jb je 00 172 192 192 192

B Gain ji Jc jf 00 192 192 172 192

R Cut 64 64 64 128

G Cut 64 64 64 128

B Cut 64 64 64 128

Color Temperature : COOL, Medium, Warm. One of R Gain/G Gain/ B Gain should be kept on 0xC0, and adjust other two lower than C0.(When R/G/B Gain are all C0, it is the FULL Dynamic Range of Module)

* Manual W/B process using adjust Remote control.

▪ After enter Service Mode by pushing "ADJ" key, ▪ Enter White Balance by pushing "►" key at "9. White

Balance".

EZ ADJUST

0. Tool Option1

1. Tool Option2

2. Tool Option3

3. Tool Option4

4. Tool Option5

5. Commercial Tool Option

6. Country Group

7. Area Option

8. ADC Calibration

9. White Balance ►

10. 10 Point WB

11. Test Pattern

12. EDID D/L

13. Sub B/C

14. Ext. Input Adjust

Whit Balance

Color Temp. ◄ ►

R-Gain

G-Gain

B-Gain

R-Cut

G-Cut

B-Cut

Test-Pattern

Backlight

Reset To Set

Cool

172

192

100

4.2. DPM operation confirmation (Only Apply for MNT Model)

Check if Power LED Color and Power Consumption operate as standard.

■ Set Input to RGB and connect D-sub cable to set

■ Measurement Condition: (AC 100-240V~, 50/60 Hz)

■ Confirm DPM operation at the state of screen without Signal

4.3. DDC EDID Write (RGB 128Byte )

■ Connect D-sub Signal Cable to D-Sub Jack.

■ Write EDID DATA to EEPROM (24C02) by using DDC2B

protocol.

■ Check whether written EDID data is correct or not. * For Service main Assembly, EDID have to be downloaded to

Insert Process in advance.

4.4. DDC EDID Write (HDMI 256Byte)

■ Connect HDMI Signal Cable to HDMI Jack.

■ Write EDID DATA to EEPROM(24C02) by using DDC2B

protocol.

■ Check whether written EDID data is correct or not. * For Service main Assembly, EDID have to be downloaded to

Insert Process in advance.

4.5. EDID data

(1) All Data : HEXA Value (2) Changeable Data : *: Serial No : Controlled / Data:01 **: Month : Controlled / Data:00 ***: Year : Controlled ****: Check sum

4.5.1. Auto Download

■ After enter Service Mode by pushing “ADJ” key,

■ Enter EDID D/L mode.

■ Enter “START” by pushing “OK” key. * Caution : Never connect HDMI & D-sub Cable when EDID

downloaded.

EZ ADJUST

0. Tool Option1

1. Tool Option2

2. Tool Option3

3. Tool Option4

4. Tool Option5

5. Tool Option Commercial

6. Country Group

7. Area Option

8. ADC Calibration

9. White Balance

10. 10 Point WB

11. Test Pattern

12. EDID D/L ►

13. Sub B/C

14. Ext. Input Adjust

EDID

HDMI1 NG

HDMI2 NG

HDMI3 NG

RGB NG

Start Reset

EDID

HDMI1 OK

HDMI2 OK

HDMI3 OK

RGB OK

Start Reset

* After you finished all adjustments, Press "In-start" key and

compare Tool option and Area option value with its BOM, if it is correctly same then unplug the AC cable. If it is not same, then correct it same with BOM and unplug AC cable. For correct it to the model's module from factory Jig model.

* Push the "IN STOP" key after completing the function

inspection. And Mechanical Power Switch must be set “ON”.

Only for training and service purposes

- 12 -

* EDID data and Model option download (RS232)

NO Item CMD 1 CMD 2 Data 0

Enter download MODE

EDID data and Model option download

Download ‘Mode In’

A A 0 0

Download A E 00 10

When transfer the ‘Mode In’, Carry the command.

Automatically download (The use of a internal data)

4.5.2. Manual Download

(1) Use the proper signal cable for EDID Download

- Analog EDID : Pin3 exists

- Digital EDID : Pin3 exists (2) Never connect HDMI & D-sub Cable at the same time. (3) Use the proper cables below for EDID Writing. (4) Download HDMI1, HDMI2 separately because HDMI1 is

different from HDMI2.

For Analog For HDMI EDID

D-sub to D-sub DVI-D to HDMI or HDMI to HDMI

No. Item Condition Hex Data

1 Manufacturer ID GSM 1E6D

2 Version Digital : 1 01

3 Revision Digital : 3 03

(1) FHD RGB EDID data

0 1 2 3 4 5 6 7 8 9 A B C D E F 00 00 FF FF FF FF FF FF 00 1E 6D a b 10 c 01 03 68 A0 5A 78 0A EE 91 A3 54 4C 99 26 20 0F 50 54 A1 08 00 31 40 45 40 61 40 71 40 81 80 30 01 01 01 01 01 01 02 3A 80 18 71 38 2D 40 58 2C 40 45 00 A0 5A 00 00 00 1E 66 21 50 B0 51 00 1B 30 50 40 70 36 00 A0 5A 00 00 00 1E 00 00 00 FD 00 3A 60 3E 1E 53 10 00 0A 20 20 20 20 20 20 d 70 d 00 e

(2) FHD HDMI EDID data

0 1 2 3 4 5 6 7 8 9 A B C D E F 00 00 FF FF FF FF FF FF 00 1E 6D a b 10 c 01 03 80 A0 5A 78 0A EE 91 A3 54 4C 99 26 20 0F 50 54 A1 08 00 31 40 45 40 61 40 71 40 81 80 30 01 01 01 01 01 01 02 3A 80 18 71 38 2D 40 58 2C 40 45 00 A0 5A 00 00 00 1E 66 21 50 B0 51 00 1B 30 50 40 70 36 00 A0 5A 00 00 00 1E 00 00 00 FD 00 3A 60 3E 1E 53 10 00 0A 20 20 20 20 20 20 d 70 d 01 e 80 02 03 22 F1 4E 10 9F 04 13 05 14 03 02 12 20 21 90 22 15 01 26 15 07 50 09 57 07 f A0 f 01 1D 80 18 71 1C 16 20 58 2C 25 00 20 C2 B0 31 00 00 9E 01 1D 00 72 51 D0 1E 20 6E 28 55 00

C0 20 C2 31 00 00 1E 02 3A 80 18 71 38 2D 40 58 2C D0 45 00 A0 5A 00 00 00 1E 01 1D 00 BC 52 D0 1E 20 E0 B8 28 55 40 C4 8E 21 00 00 1E 00 00 00 00 00 00 F0 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 e

(5) Detail EDID Options are below

a. Product ID

MODEL NAME HEX EDID Table DDC Function

HD/FHD Model 0001 01 00 Analog/Digital

b. Serial No: Controlled on production line. c. Month, Year:

Week : '01' -> '01', Year : '2012' -> '16' fix

d. Model Name(Hex):

cf) TV set’s model name in EDID data is below.

Model name MODEL NAME(HEX)

LG TV 00 00 00 FC 00 4C 47 20 54 56 0A 20 20 20 20 20 20 20 (LG TV)

e. Checksum: Changeable by total EDID data.

EDID C/S data

Check sum

(Hex)

Block 0 43 5C

DE (HDMI1)

Block 1

BE (HDMI3)

FHD

HDMI RGB

f. Vendor Specific(HDMI)

Input MODEL NAME(HEX)

HDMI1 67030C001000B82D

HDMI2 67030C002000B82D

HDMI3 67030C003000B82D

4.6. Outgoing condition Configuration

■ When pressing IN-STOP key by SVC remocon, Red LED are blinked alternatively. And then automatically turn off.

(Must not AC power OFF during blinking)

4.7. HI-POT Test

4.7.1. HI-POT auto-check preparation

- Check the POWER cable and SIGNAL cable insertion condition

4.7.2. HI-POT auto-check

(1) Pallet moves in the station. (POWER CORD / AV CORD is

tightly inserted) (2) Connect the AV JACK Tester. (3) Controller (GWS103-4) on. (4) HI-POT test (Auto)

- If Test is failed, Buzzer operates.

- If Test is passed, GOOD Lamp on and move to next process automatically.

4.7.3. Checkpoint

(1) Test voltage

- Touchable Metal : 1.5 KV / min at 100 mA

- SIGNAL : 3 KV / min at 100 mA

(2) TEST time: 1 second. (case : mass production ) (3) TEST POINT

- Touchable Metal => LIVE & NEUTRAL : Touchable Metal.

- SIGNAL => LIVE & NEUTRAL : SIGNAL.

-CE (HD43MI2)

Only for training and service purposes

- 13 -

5. Model name & Serial number D/L

▪ Press "Power on" key of service remote control.

(Baud rate : 115200 bps) ▪ Connect RS232 Signal Cable to RS-232 Jack. ▪ Write Serial number by use RS-232. ▪ Must check the serial number at the Diagnostics of SET UP

menu. (Refer to below).

5.1. Signal Table

CMD LENGTH ADH ADL DATA_1 . . . Data_n CS DELAY

CMD : A0h LENGTH : 85~94h (1~16 bytes) ADH : EEPROM Sub Address high (00~1F) ADL : EEPROM Sub Address low (00~FF) Data : Write data CS : CMD + LENGTH + ADH + ADL + Data_1 +...+ Data_n Delay : 20ms

4) Check the model name Instart menu. → Factory name displayed. (ex 42LD450-ZA)

5) Check the Diagnostics.(DTV country only) → Buyer model displayed.(ex 42LD450)

5.2. Comand Set

Adjust mode CMD(hex) LENGTH(hex) Description

EEPROM WRITE A0h 84h+n n-bytes Write (n = 1~16)

* Description

FOS Default write : <7mode data> write Vtotal, V_Frequency, Sync_Polarity, Htotal, Hstart, Vstart, 0, Phase Data write : Model Name and Serial Number write in EEPROM,.

5.3. Method & notice

(1) Serial number D/L is using of scan equipment. (2) Sett ing of scan equ ipm ent operated by Manufac turing

Technology Group.

(3) Serial number D/L must be conformed when it is produced in

production line, because serial number D/L is mandatory by D-book 4.0.

* Manual Download(Model Name and Serial Number)

If the TV set is downloaded by OTA or Service man, sometimes model name or serial number is initialized.(Not always) There is impossible to download by bar code scan, so It need Manual download.

1) Press the "Instart" key of Adjustment remote control.

2) Go to the menu "5.Model Number D/L" like below photo.

3) Input the Factory model name or Serial number like photo.

Only for training and service purposes

- 14 -

6. CI+ Key Download method

+ Key Value

6.1. Download Procedure

(1) Press "Power on" key of a service Remote control. (Baud rate : 115200 bps) (2) Connect RS232-C Signal Cable. (3) Write CI+ Key through RS-232-C. (4) Check whether the key was downloaded or not at ‘In Start’

menu. (Refer to below).

=> Check the Download to CI+ Key value in LGset.

1. Check the method of CI+ Key value a. Check the method on Instart menu

2. Check the method of CI+ key value (RS232)

1) Into the main ass’y mode (RS232 : aa 00 00)

CMD 1 CMD 2 Data 0

A A 0 0

2) Check the mothed of CI+ key by command (RS232 : ci 00 20)

CMD 1 CMD 2 Data 0

C I 2 0

3) result value i 01 OK 1d1852d21c1ed5dcx

7. Commercial Feature inspection

7.1. LG Logo inspection

(1) Turn on TV. (2) Check LG Logo operation when TV is turning on. (Check

LG Logo is displayed well or not.)

7.2 Welcome Screen Function check

(Image File must be in USB LG_DTV folder) (1) Press “IN STOP” key. (2) Turn on TV. (3) Insert USB. (4) Press “MENU” key. (5) Move cursor to OPTION and press “7” key 7 times. (6) Move cursor to “LOGO Image Download” key and select it.

b. Check the method of RS232C Command

1) Into the main ass’y mode (RS232 : aa 00 00)

CMD 1 CMD 2 Data 0

A A 0 0

2) Check the key download for transmitted command (RS232 : ci 00 10)

CMD 1 CMD 2 Data 0

C I 1 0

3) Result value

- Normally status for download : OKx

- Abnormally status for download : NGx

Only for training and service purposes

- 15 -

(7) Select image file.

(8) Check displayed image status(color, size) when TV is

turning on.

<Image for test- 720x576> Please use this image for test.

(9) Try this inspection with various resolution images. * Must Restore to LG Logo. (10) Press “MENU” key. (11) Move cursor to OPTION and press “7” key 7 times.

7.3. USB Cloning Function check

● CASE 1. Clock LED Model

(12) Select accurate CPU S/W le and check “LOGO Image”

button. (Press yellow color key on Remote Control.)

(13) Check LG Logo operation when TV is turning on.

Only for training and service purposes

- 16 -

If the clock LED of TV 2 is on and TV 1, 2 had a same TV channels → USB cloning is success!!

● CASE 2. No Clock LED Model

7.4. Check Commercial features concerning Output.(IR Out/SPK Out/External Clock)

Model Info Commercial Feature

Name IR Out External Speaker out External Clock

LN549E-ZA O O X

7.4.1. External SPK Out and Volume control

(1) Connect external speaker to speaker out port with phone

jack on TV side as below.

(2) Check the Max. speaker output is 1W or not. Sine wave

with 1KHz will be displayed.

(3) Press Vol. control button up/down in turns and check the

waveform of Oscilloscope

Button of Vol. control Waveform of Oscilloscope

UP(+)

DOWN(-)

If the auto volume of TV 2 is on and TV 1, 2 had a same TV channels → USB cloning is success!!

Only for training and service purposes

7.4.2. IR Out

- 17 -

< Equipment & Condition > ▪ Simple Jig (commercial check JIG) ▪ Power only mode

(1) Connect each other RS232C port on the Commercial

Check JIG. (2) Press any key on SVC Remote-control. (3) Check the LED status of the Check JIG.

- IR LED(OK condition: blinking) (LED #1)

7.4.3. External Clock

< Equipment & Condition > ▪ Simple Jig (External Clock Assy) ▪ Power only mode

(1) Connect external Clock Assy to CLOCK INTERFACE. (2) Check the LED CLOCK.

Check LED Clock in Power on mode.

* After nishing 7.1 ~ 7.4 inspections, press “IN STOP” key.

Only for training and service purposes

- 18 -

TROUBLESHOOTING GUIDE

1. Check the booting Voltage

Make sure the Stand-by Voltage.

P401 3, 5pin : +3.5V_ST

Yes

Make sure the Micom voltage.

L301 : +3.5V_ST

Yes

Make sure the CLK of X300

Is 10MHz.

Yes

Push Micom Reset(SW300) and

make sure the PWR_ON

P401 1pin : 3.3V

Yes

Make sure the Multi Voltage.

P401 9, 10pin : 24V, 13~15pin : 12V

Make sure the Power

Connector.

Exchange the L301.

Exchange the X300.

Re-download of

Firmware.

Exchange the circuit

board.

Make sure the disconnection of

Main board 3.5V circuit.

Exchange the Mstar(IC101)

Or Main board

Exchange the Circuit board.

Yes

Make sure the Output Voltage of IC

402/3/7.

IC402 : 2.5V, IC403: 1.1V, IC407 :

1.5V, Q403 : 3.3V

Yes

Make sure the voltage of LVDS

Power.

Q409 : 12V

Yes

Make sure the output of MSTAR

LVDS.

Yes

Make sure the Inverter control

P401 2pin : High

Yes

Exchange the LCD Module.

Exchange the

IC402/3/7, Q403.

Exchange the Q409.

Exchange the Mstar(IC101)

or Main board.

Exchange the circuit or

check the LCD module.

Only for training and service purposes

- 19 -

2. Digital TV Video

Check the Stand-by Voltage

P401 3, 5pin : +3.5V_ST

Yes

Check the Tuner 3.3V

; L2606

Yes

Check the Tuner 1.8V.

IC2603 2pin : 1.8V

Yes

Check the IF_P/N signal

TU2601~3 10/11pin

Yes

Check the LVDS output signal of

Mstar IC.

3. Analog TV Video

Check the RF cable and RF signal.

Exchange the L2606.

Exchange the IC2603.

Exchange the Tuner.

Exchange the Mstar(IC101)

or Main board.

Yes

Check the Tuner 3.3V

; L2606

Yes

Check the Tuner 1.8V.

IC2603 2pin : 1.8V

Yes

Check the CVBS signal

TU2601~3 8pin

Yes

Check the LVDS output signal of

Mstar IC.

Only for training and service purposes

Exchange the L2606.

Exchange the IC2603.

Exchange the Tuner.

Exchange the Mstar(IC101)

or Main board.

- 20 -

4. Component Video

Make sure the input signal type and

our TV can support the signal.

Yes

Check Component cable(gender)

defect or status of conductor

Yes

Make sure the JK1603, COMP Y/Pb/

Pr signal

Yes

Make sure the Rear_COMP_DET

signal.

Yes

Exchange Component Jack.

Exchange the R9912.

Make sure the LVDS output signal of

Mstar IC.

Exchange the Mstar(IC101)

5. RGB Video (LN549E Only)

Make sure the input signal type and

Our TV can support the signal.

Yes

Check the RGB cable defect or

status of conductor.

Yes

Check the EDID, I2C signal.

Yes

Check the JK1104 H/V_Sync/R/G/B

signal.

Download the EDID data, exchange

the Mstar(IC101) or Main board.

or Main board.

Exchange the D-SUB Jack.

Yes

Check the DSUB_DET signal.

Yes

Check the LVDS output signal of

Mstar IC.

Only for training and service purposes

Exchange the resistor R1146 / R1147.

Exchange the Mstar(IC101) or Main

board.

- 21 -

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