LG 60PZ550, 60PZ540 Schematic

PLASMA TV

SERVICE MANUAL

CAUTION

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

CHASSIS : PU13A

MODEL : 60PZ550 50PZ550-UA MODEL : 60PZ540 50PZ540-UB

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

Internal Use Only

Printed in Korea

P/NO : MFL67001503(1101-REV00)

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Only for training and service purposes

CONTENTS

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

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

SPECIFICATION.........................................................................................................................4

ADJUSTMENT INSTRUCTION ..................................................................................................6

BLOCK DIAGRAM ...................................................................................................................13

EXPLODED VIEW ...................................................................................................................14

CIRCUIT DIAGRAM .....................................................................................................................

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Only for training and service purposes

SAFETY PRECAUTIONS

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 X-RADIATION, 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 the circuitry that may be inadvertently introduced during the service operation.

If any fuse (or Fusible Resistor) in this monitor 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.

Due to high vacuum and large surface area of picture tube, extreme care should be used in handling the Picture Tube. Do not lift the Picture tube by it's Neck.

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/10watt 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 exposed metallic part. 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

1.5 Kohm/10W

To Instrument's exposed METALLIC PARTS

Good Earth Ground such as WATER PIPE, CONDUIT etc.

AC Volt-meter

IMPORTANT SAFETY NOTICE

0.15uF

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Only for training and service purposes

SPECIFICATIONS

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

1. Application Range

(1) This spec sheet is applied all of PDP TV with PU13A chassis.

2. Specification

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 (100 V - 240 V ~ 50 / 60 Hz)

* Standard Voltage of each product is marked by models

(4) Specification and performance of each parts are followed each drawing and specification by part 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 : UL, CSA, IEC specification, CE EMC : FCC, ICES, IEC specification, CE

Model Name

60PZ550-UA

60PZ540-UB

Remark

Safety : UL1492, CSA C22.2.No.1

EMC : FCC Class B, IC Class B

Market

NORTH AMERICA

CANADA / MEXICO

Model Name

60PZ550-UA

60PZ540-UB

Brand

Market

NORTH AMERICA

CANADA / MEXICO

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Only for training and service purposes

4. General Specification

No Item Specification Remark

1. Receiving System 1) ATSC / NTSC-M

2. Available Channel 1) VHF : 02~13

2) UHF : 14~69

3) DTV : 02-69

4) CATV : 01~135

5) CADTV : 01~135

3. Input Voltage 1) AC 100 V - 240 V ~ 50 / 60 Hz N.America Mark : 110V, 60Hz

4. Market NORTH AMERICA, KOREA

5. Screen Size 127 cm (50 inch) Wide(1920 × 1080) 50PZ550/540

152 cm (60 inch) Wide(1920 × 1080) 60PZ550/540

6. Aspect Ratio 16:9

7. Tuning System FS

8. PDP Module PDP50R3#### (1920 × 1080) 50PZ550/540 PDP60R3#### (1920 × 1080) 60PZ550/540

9. Operating Environment 1) Temp : 0 deg ~ 40 deg

2) Humidity : ~ 80 %

10. Storage Environment 1) Temp : -20 deg ~ 60 deg

2) Humidity : ~ 85 %

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Only for training and service purposes

ADJUSTMENT INSTRUCTION

1. Application Range

This spec. sheet applies to PU13A Chassis applied PDP TV all models manufactured in TV factory.

2. Specification

(1) Because this is not a hot chassis, it is not necessary to use

an isolation transformer. However, the use of isolation

transformer will help protect test instrument. (2) Adjustment must be done in the correct order. (3) The adjustment must be performed in the circumstance of

25 cC ± 5 cC of temperature and 65 % ± 10 % of relative

humidity if there is no specific designation. (4) The input voltage of the receiver must keep 100 V - 240 V,

50 / 60 Hz. (5) The receiver must be operated for about 5 minutes prior to

the adjustment when module is in the circumstance of over

15 cC

- In case of keeping module is in the circumstance of 0 cC, it should be placed in the circumstance of above 15 cC for 2 hours

- In case of keeping module is in the circumstance of below

-20 cC, it should be placed in the circumstance of above 15 cC for 3 hours.

O After RGB Full White in HEAT-RUN Mode, the receiver

must be operated prior to the adjustment.

O Enter into HEAT-RUN MODE

1) Press the POWER ON KEY on R/C for adjustment.

2) OSD display and screen display PATTERN MODE.

- Set is activated HEAT run without signal generator in this mode.

- Single color pattern ( WHITE ) of HEAT RUN MODE uses to check panel.

Caution) When still image is displayed for a period of 20 minutes

or longer (especially where W/B scale is strong. Digital pattern 13ch and/or Cross hatch pattern 09ch), there can some afterimage in the black level area.

3. Adjustment items

3-1. Board-level adjustment

- Mac address and Idfile(ESN) Download (Except For Mexico/Canada Models)

- Adjust 480i Comp1 adj.

- Adjust 1080p Comp1 adj.

- Adjust 1920*1080 RGB adj.

- EDID/DDC download

Above adjustment items can be also performed in Final Assembly if needed. Both Board-level and Final assembly adjustment items can be check using In-Start Menu 1. Adjust Check.

3-2. Final assembly adjustment

- White Balance adjustment

- RS-232C functionality check

- Factory Option setting per destination

- Ship-out mode setting (In-Stop)

3-3. Etc.

- Ship-out mode

- Service Option Default

- USB Download(S/W Update, Option)

4. MAC Address and ESN Key Write

4-1. Equipment & Condition

- Play file: Serial.exe

- MAC Address edit

- Input Start / End MAC address

4-2. Download method

(1) Communication Prot connection

Connect: PCBA Jig-> RS-232C Port== PC-> RS-232C Port

(2) MAC Address Download

- Com 1,2,3,4 and 115200(Baudrate)

- Port connection button click(1)

- Load button click(2) for MAC Address write.

- Start MAC Address write button(3)

- Check the OK Or NG

(3) Input the ESN Key (Except For Mexico/Canada Models)

- download Model sending Key file

- input by 1 by SET so as not to be duplicated

5. LAN PORT + ESN INSPECTION

5-1. Equipment & Condition

- Each other connection to LAN Port of IP Hub and Jig

5-2. MAC Address & ESN Key confirmation

- Push “IN-START” Key in service remote controller.

5-3. LAN PORT INSPECTION(PING TEST)

- LAN Port connection with PCB

- Network setting at MENU Mode of TV

- setting automatic IP

- Setting state confirmation

-> If automatic setting is finished, you confirm IP and MAC Address.

- remove LAN CABLE

6. ADC adjustment

6-1. Overview

ADC adjustment is needed to find the optimum black level and gain in Analog-to-Digital device and to compensate RGB deviation.

6-2. Equipment & Condition

(1) Jig (RS-232C protocol) (2). Internal pattern is used. No external signal is needed.

6-3. Adjustment

(1) Adj. protocol

(2) Check adjust device

Pattern Generator : (MSPG-925FA) Adjust 480i Comp1 (MSPG-925FA:model :209 , pattern :65) Adjust 1080p Comp1 (MSPG-925FA:model :225 , pattern :65) Adjust RGB (MSPG-925FA:model :225 , pattern :65) The PU02A have not ECHO.

7. EDID(The Extended Display Identification Data) / DDC(Display Data Channel) download

7-1. Overview

It is a VESA regulation. A PC or a MNT will display an optimal resolution through information sharing without any necessity of user input. It is a realization of °∞Plug and Play°±.

7-2. Equipment

- Adj. R/C

- Since embedded EDID data is used, EDID download jig, HDMI cable and D-sub cable are not need.

7-3. Download method

(1) Press Adj. key On the Adj. R/C, press Adj. key then select

EDID D/L. By pressing Enter key, EDID download will

begin. (2) If Download is successful, OK is displayed. (3) If Download is a failure, NG is displayed. (4) Re-try download

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Only for training and service purposes

7-4. EDID DATA(PCM)

- Reference: Download is only possible in POWER ON MODE.

- HDMI

EDID Block 0, Bytes 0-127 [00H-7FH] Block Type: EDID 1.3

EDID Block 1, Bytes 128-255 [80H-FFH] Block Type: CEA EDID Timing Extension Version 3

RGB [C/S: 1C] EDID Block 0, Bytes 0-127 [00H-7FH] Block Type: EDID 1.3

7-5. EDID DATA(AC-3)

- Reference: Download is only possible in POWER ON MODE.

- HDMI

EDID Block 0, Bytes 0-127 [00H-7FH] Block Type: EDID 1.3

EDID Block 1, Bytes 128-255 [80H-FFH] Block Type: CEA EDID Timing Extension Version 3

RGB [C/S: 1C] EDID Block 0, Bytes 0-127 [00H-7FH] Block Type: EDID 1.3

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Only for training and service purposes

Vender ID C/S1 C/S2

HDMI1 10 9C D2

HDMI2 20 9C C2

HDMI3 30 9C B2

HDMI4 40 9C A2

Vender ID C/S1 C/S2

HDMI1 10 9C 60

HDMI2 20 9C 50

HDMI3 30 9C 40

HDMI4 40 9C 30

8. White Balance adj.

8-1. Overview

(1) W/B adj.: Objective & How-it-works

1) Objective: To reduce each Panel’s W/B deviation

2) How-it-works: When R/G/B gain in the OSD is at 192, it means the panel is at its Full Dynamic Range. In order to prevent saturation of Full Dynamic range and data, one of R/G/B is fixed at 192, and the other two is lowered to find the desired value.

8-2. Equipment

(1) Color Analyzer : CA-210 (NCG: CH 9 / WCG: CH12 /PDP

Module:CH10)

(2) Adj. Computer

(During auto adj., RS-232C protocol is needed) (3) Adj. R/C (4) Video Signal Generator MSPG-925F 720p/216Gray

(Model:217, Pattern:78)

-> Only when internal pattern is not available

- Color Analyzer Matrix should be calibrated using CS-1000

8-3. Equipment connection map

8-4. Adj. Command (Protocol)

O Protocol

- LEN: Number of Data Byte to be send

- CMD: Command

- VAL: FOS Data

- CS: Checksum of sent Data

- A: Acknowledge Ex) [Send: JA_00_DD] / [Ack: A_00_okDDX]

O RS-232C Command used during auto-adj.

Ex) wb 00 00 -> Begin white balance auto-adj.

wb 00 10 -> Gain adj.

ja 00 ff -> Adj. data jb 00 c0 ... ... wb 00 1f -> Gain adj. complete *(wb 00 20(Start), wb 00 2f(End)) -> Off-set adj.

wb 00 ff -> End white balance auto-adj.

8-5. Auto Adj. method

(1) Set TV in adj. mode using POWER On Key (2) Zero calibrate probe then place it on the center of the

Display (3) Connect Cable(RS-232C) (4) Select mode in adj. Program and begin adj. (5) When adj. is complete (OK Sign), check adj. status per

mode

(Warm, Medium, Cool)

(6) Remove probe and RS-232C cable to complete adj.

- Adj. must begin w/ command “wb 00 00”, and end “wb 00 ff” and adj. offset if needed.

- Offset adjust limit value. Offset Min = 34 (Decimal) Offset Max = 94 (Decimal)

8-6. Manual adj. method

Dynamic contrast : off Dynamic color : off OPC : Off Energy saving mode : Off

(1) Set TV Picture Mode to Standard and in Advanced

Control, set Dynamic Contrast and Color ‘ Off ’ . (2) Set TV in adj. mode using POWER On Key (3) Press ADJ key -> EZ adjust using adj. R/C (4) Using CH + / - KEY, select 10.TEST PATTERN then press

Enter to place in HEAT RUN mode and wait for 30

minutes. (4) Zero calibrate the probe of Color Analyzer, then place it on

the center of LCD module within 10 cm of the surface. (5) Press ADJ key -> 7. White-Balance then press the cursor

to the right (KEY

(When

G is pressed Full White internal pattern will be

displayed)

(6) One of R Gain / G Gain / B Gain should be fixed at 192,

and the rest will be lowered to meet the desired value. (7) Adj. is performed in COOL, MEDIUM, WARM 3 modes of

color temperature (8) Off set Adjust in MEDIUM, WARM 2 modes of color

temperature ( Only THX Model )

V If internal pattern is not available, use HDMI input. In EZ

Adj. menu 7.White Balance, you can select one of 3 options: None, Inner, HDMI. Default is inner. By selecting HDMI, you can adjust using HDMI signal.

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Only for training and service purposes

Model 100 Point WB mode WB Adj. Program

Non THX Model lists.

50PZ550-UA Only Adjust Medium Use Matrix

60PZ550-UA (Color Temperature) Adj. Program

50PZ540-UB mode RUN_Matrix_ADJ

60PZ540-UB ( Matrix Type )

V Adj. condition and cautionary items

(1) Lighting condition in surrounding area

Surrounding lighting should be lower than 10 lux. Try to isolate adj. area into dark surrounding.

(2) Probe location

- PDP : Color Analyzer (CA-100, CA-100+, CA210) probe should be firmly attached to the Module

- LCD : Color Analyzer (CA-210) probe should be within

10cm and perpendicular of the module surface (80°~ 100°)

- In case of LCD, B/L on should be checked using no

signal or Full white Pattern

8-7. Reference (White Balance adj.

coordinate and color temperature)

O Standard color coordinate and temperature using CS-1000 O Luminance: Full white 216 Gray

O Standard color coordinate and temperature using CA-210(CH

10)

- Gain color coordinate

O Pattern : Full white 216 Gray

9. 3D Function Test

9-1. 3D Pattern Inspection

(Pattern Generator MSHG-600 or MSPG-6100, HDMI mode

NO. 872 , pattern No. 83)

(1) Please input 3D test pattern like below

(2) When 3D entrance OSD is automatically displayed, Push

the OK key

(3) When took off 3D shutter glasses, Check whether viewing

the pattern like below picture)

9-2. 2D TO 3D CONVERT INSPECTION

(1) Input Combination Pattern like (Fig.1) in HDMI Input

(2) Enter the Swap Button(Yellow Color)

Check the separated line in the SET

* When you enter the swap button. Depth value is set to

Maximum value(20) automatically Worker has to enter the ETC Key Before using the swap button

9-3. RF Glasses , 3D RF Emitter Check

* Power Only Mode * MSHG-600 or MSPG-6100

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Only for training and service purposes

(Fig.1)

* Test Scenario (1) Set TV in adj. mode using Power Only Key (2) HDMI 1.4 Frame Packing 3D images are input to the 3D

Video Player (3) Check the 3D Video Display. (4) If RF emitter signal is correctly received to RFreceiver, the

lamp of RF tester turn on

10. Option selection per country

10-1. Overview

O Option selection is only done for models in Non-USA North

America due to rating

O Applied model: PU13A Chassis applied USA Model(Not

Canada, Mexico)

10-2. Method

(1) Press ADJ key on the Adj. R/C, then select Country Group

Menu (2) Depending on destination, select KR or US, then on the

lower option, select US, CA, MX. Selection is done using

+, - KEY

10-3. Ship-out (Default) mode check

(Instop)

O After final inspection, press In-Stop key of the Adj. R/C and

check that the unit goes to Stand-by mode.

10-4. POWER Supply Unit PCB Ass'y Va/Vs

Voltage adjustment.

(1) Test equipment : D.M.M 1EA (2) Connection Diagram for Measuring : refer to (Fig.1)

(3) Vs adjustment (refer fig.1)

1) Connect + terminal of D.M.M. to Vs pin of P811, connect

-terminal to GND pin of P811

2) After turning VR901, voltage of D.M.M adjustment as same as Vs voltage which on label of panel left/top ( deviation ; ± 0.5V)

(4) Va adjustment (refer fig.1)

1) After receiving 100% Full White Pattern, HEAT RUN.

2) Connect + terminal of D.M.M. to Va pin of P811, connect

-terminal to GND pin of P811

- After turning VR502,voltage of D.M.M adjustment as same as Va voltage which on label of panel left/top (deviation; ± 0.5V)

11. USB Download (S/W Update, *.epk File 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 staring.

(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.

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Only for training and service purposes

(Fig.1)

* After downloading, have to adjust TOOL OPTION again.

(1) Push "IN-START" key in service remote controller. (2) Select "Tool Option 1" and Push “OK” button. (3) Punch in the number. (Each model has their number.) (4) Completed selecting Tool option.

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Only for training and service purposes

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Only for training and service purposes

BLOCK DIAGRAM

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LGE Internal Use Only

EXPLODED VIEW

590

200

400

520

300

305

301

602

202

203

501

205

209

207

208

240

601

303

304

302

580

910

900

120

206

204

201

570

560

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 X-RADIATION, Shock, Fire, or other Hazards. Do not modify the original design without permission of manufacturer.

IMPORTANT SAFETY NOTICE

A10

LV1

A12

LGE Internal Use Only

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