LG pdp_repairguide full Datasheet

NOTE:  Active links in this document  are outlined in blue.

LG Electronics Alabama, Inc.

Plasma One Point Repair 2004

Contents

໲. Visual repair Index ໳. Introduction to Plasma ໴. Service Adjustments ໵. Trouble shooting

1

60’’ Known Visual problems with boards that fixed

Visual repair Index

Page # 37

Control Board & Y-Driver Amp

Page # 40

Y-Driver Top

Page # 38

Y- Amp

Page # 41

Control Board

60’’ Known Visual problems with boards that fixed

Page # 43

Y-Driver - Top

Page # 46

Page # 44

VSC- Board

Page # 47

Page # 39

Y-Driver Amp

Page # 42

X-Board upper right

Page # 45

Y-Driver - Top

Page # 48

VSC- Board

X- Board ( Top Right)

Y-Driver amp and X-Drive Top

2

50’’ Known Visual problems with boards that fixed

Visual repair Index

Page # 49

Fig # 13

Page # 49

Fig # 13

Y-Driver Amp upper

Page # 52

VSC Board

Page # 50

Control board

Page # 53

X-Board upper right

50’’ Known Visual problems with boards that fixed

Page # 56

Page # 55

X- Board ( Lower Right)

Page # 58

Page # 56

X- Board ( Lower Left)

Page # 59

Page # 51

Control Board

Page # 54

Y- Driver Amp bottom

X- Board ( Bottom Left)

Page # 57

Control Board

Page # 60

Y- Driver Bottom

Y- Driver Amp and X-Drive Top

Control Board

3

42’’ Known Visual problems with boards that fixed

Visual repair Index

Page # 61

Data @ X-Board – Yes/ tested for shorted FOC IC – Ribbon shorted/ Defective Panel

Page # 64

Display’s waves - VSC

Page # 62

Installed Y- Driver Amp bottom no Change/ Defective Panel

Page # 65

42’’ Known Visual problems with boards that fixed

Page # 67

Y-Driver - Top

Page # 70

Page # 68

VSC- Board

Page # 71

Page # 63

Data @ X-Board – Yes/ tested for shorted FOC IC – Ribbon shorted/ Defective Panel

Page # 66

Y-Driver - TopY-Driver - Top

Page # 69

Y-Driver - Top

Page # 72

Y-Driver Amp upper

Control BoardControl board

4

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5

Introduction to Plasma

How the power supply works

Voltages for VS: Supplies support to the Y-Amplifier for horizontal grid voltage. If the required voltage is not + or – 3% you may see the following in the picture: lines from side to side or left to right, half picture top or bottom, intermittent shutdown or dead.

Voltages for VA: Supplies support to the Z-Amplifier for vertical grid voltage. If the required voltage is not + or – 3% you may see the following in the picture: Comets, washout, bleeding, intermittent shutdown or dead.

To start to understand plasma one must look for why this voltage is not within specifications. In LG – Zenith line of plasmas there are several power supply set-ups as follows: 60” plasma is made-up of a primary and secondary power supply followed by a DC to DC converter. This is to support the massive current that’s required to sustain picture quality.

The 50” and 42” plasma power supplies are consolidated into one board. In the 60” anyone of the three parts could be out of adjustment. In the fifty and forty two the voltages need to be still verified in chronological order. In most cases if your facing a dead set scenario this is caused by a shorted Y or X-driver board.

Testing for defective Y-drive boards can be done by looking for a voltage drop if this is located in the Y-sustain disconnect power and remove one Y-driver boards at a time until Y-sustain voltage is accurate. If Y-sustain does not respond with proper voltage supplied replace. Testing for defective X-driver boards can be done by powering down and disconnecting each X-driver and powering on each quadrant at a time.

Pulse Frequency Coefficient: (PFC) adjustment is Located the primary supply and is for aligning grid voltage. The panels grid voltage averages 360 to 380 volts depending on panel circuit.

Known symptoms:

No Power Intermittent Power Picture dimming to bright during certain seines Primary colors off, Hue or flesh tones Colors bleeding

Left to Right picture is dark to bright

Introduction to Plasma

1. X B/D

Receiving LOGIC signal from CONTROL B/D to make ADDRESS

PULSE generating address discharge by an ON/OFF operation,

and supplies this waveform to COF IC (data) or ribbon IC.

X B/D

2. Z sustain B/D

Responsible for making SUSTAIN PULSE and ERASE PULSE that that generates SUSTAIN discharge in panel by receiving LOGIC signals the CONTROL B/D.

The Sustain discharge waveform is supplied to panel through FPC (Z B/D).

Composed of IPM,FET,DIODE, electrolytic capacitor, E/R coil.

3. Y drive B/D

1) This is a path to supply SUSTAIN ,RESET waveform which is made

from Y SUSTAIN B/D to panel through SCAN DRIVER IC.

2) Supplies the waveform that selects Horizontal pulse (Y SUSTAIN pulse) sequentially.

- Potential difference is 0V between GND and Vpp of DRIVER IC in SUSTAIN period.

- Generated potential difference between GND and Vpp only in SCAN period.

• E/R (Energy recovery)

• COF (Chip On Film)

• IPM (Intelligent Power Module)

Z B/D

Y SUB--

Y SUB

AMP B/D

Scan drive IC

Introduction to Plasma

4. Y sustain B/D

Generates SUSTAIN, RESET waveform, VSC (SCAN) voltage

and supplies it to the Y DRIVER B/D.

Composed of IPM, DIODE, electrolytic capacitor, FET.

AMP B/D

YY--AMP B/D

5. Control (logic) Board

Creates signal processing (Contour noise, reduction ISM,..) and an order of many FET switching IC’s on/ off of each DRIVER B/D with R,G,B to each 8bit input COF ribbon IC.

Supply voltages 3.3V/ 5V.

6. IPM (Intelligent Power Module)

Connected to Z B/D and Y B/D, making Sustain waveform.

Sustaining and supplying a square wave to panel, creating video.

Composition

CAPACITORS/ DIODES/ IC LINEAR/ RESISTORS, TRANSISTORS and FETS.

• E/R (Energy recovery)

• IPM (Intelligent Power Module)

DIG CONTROL B/D

Z-APM B/D

Introduction to Plasma

7. Ctrl B/D

CTRL B/D supplies video signal to COF. So if there is a bar defect on panel this may be the ctrl b/d creating this problem.

Flow, address signal

In the figure to the right shows data path to COF IC In this description you can see how missing data can affect the panel.

8. Checking order

1. Confirm Y, Z SUS signal cable.

2. Check Y DRV IC FAIL

3. Check Y sus b/d voltages (-Vy.Vscw)

4. Check Y ,Z-SUS IPM fail

5. Replace CTRL b/d

A. Mal-discharge problem Y-drive, Z -b/d.

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IC

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B. Check VA and VS Voltage if occurred.

Introduction to Plasma

9. Check FPC

In case of horizontal 1 or more line, it is due to FPC or panel inside .ctrl b/d, Y b/d is just normal. First , clean the FPC electrode with a cloth to clean off the ribbon connection removing particles.

Horizontal line.

COF ribbon to panel open Cell/ break down

10. Checking address COF input of resistor and IC

COF resistor check

Ⴇ

Check the both side of resistor With Digital multi meter(DMM) .

If the resistor is okay, the resistor value should be 10വif open

replace resistor.

Resistor

11. COF (Chip On Film)

Supplied with the X B/D waveform to the panel, controls grid & zones by

switching on or off the 96 pin COF IC.

the higher the resolution, the less spare space on the IC.



• E/R (Energy recovery)

• COF (Chip On Film)

• IPM (Intelligent Power Module)

Open

COF IC

Introduction to Plasma

Vertical defect (line)

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1 line open or short

This phenomenon is due to COF IC inside short or adherence part of the Film and rear panel electrode problem. In this case, replace the panel.

1 electrode open

Line open or short with same distance.

This is an ASIC of Ctrl b/d defect. ASIC defective, replace the ctrl b/d.

Will cause

1 line open

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No image in the specific area (see the screen location 2)

1) Check the related X-Board’s power connector.

2) Check the signal cable between Controller PCB & X-Board.

Fig # 01

1

4

2

5

3

6

3) Replace X-Board

Correlation between screen & X Boards

Screen Location X Board

1) Top left 3/10 l X Top-right / Bottom-left B/D

2) Center top 2/5 l X Center Top B/D

3) Top right 3/10 l X Top-left / Bottom-right B/D

4) Bottom left 3/10 l X Top-left / Bottom-right B/D

5) Center bottom 2/5 l X Center Top B/D

6) Bottom right 3/10 l X Top-right / Bottom-left B/D

Visual Troubleshooting

2. Known Tips as to no data and partial display

No image/ Data COF IC.

1) Caused by X Board’s having no power or connections.

Data COF is totally or partially not displayed

2) Check the connector between COF IC & X-Board.

3) Data COF IC is defective, replace the related X-Boards.

12

Fig # 02

Examples,

Non-image

Non Image white

Partially displayed

Regular vertical line with one or more Data COF IC

1) Check the related X Board’s power connector.

Fig # 03

1

4

1) This is caused by X Board output IC being defective. When COF ICs have data this means the data transfer between the

Controller PCB and X Board is missing.

2) Check all related X Board connections.

3) Replace that X Board or CTRL PCB or both if needed.

Fig # 04

2

5

3

6

Partial error or total error with One or more

ICs are defective.

2) Check the signal cable between Controller PCB & X-Board.

3) Replace X-Board

Correlation between screen & X Boards

Screen Location X Board

1) Top left 3/10 l X Top-right / Bottom-left B/D

2) Center top 2/5 l X Center Top B/D

3) Top right 3/10 l X Top-left / Bottom-right B/D

4) Bottom left 3/10 l X Top-left / Bottom-right B/D

5) Center bottom 2/5 l X Center Top B/D

6) Bottom right 3/10 l X Top-right / Bottom-left B/D

Visual Troubleshooting

13

Address Bar ( Vertical ) & partial no-picture

Visual Troubleshooting

Fig # 05

Related X-Board power supply voltage check

Related X-Board Connector check

Related X-Board & Controller Board Connector check

Related X-Board replacement

Module (Panel ) check

14

Fig # 06

Bottom left 3/10 of the screen with no-pictureBottom left 3/10 of the screen with vertical bar

Fig # 07

Y- Board

VR 424

B61 (TP;sus_up)

VR 301

Controller

Board

VSC

Board

P200

Side A/V L/F

Z- Board

VR 301

B61

(TP;sus_out)

Bar (Horizontal) half -picture

Fig # 08

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Fig # 09

Visual Troubleshooting

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Y-Drive Board ( Top ) Drive IC check

Y-Drive Board replacement

Fig # 10

Controller

Board

VSC

Board

P200

Y- Board

VR 424

VR 301

Z- Board

VR 301

B61

(TP;sus_out)

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15

B61 (TP;sus_up)

Side A/V L/F

Vertical Lines

Visual Troubleshooting

6. One or more vertical lines in the screen.

1) Irregular vertical line is not related to Controller PCB or X Board.

2) It is mainly caused by the followings open (or short).

- Panel itself defect

- DATA COF FPC attached to panel is open or short.

- DATA COF attached to panel itself is defective

There can be several lines in ¼ inch wide area.

It can be seen on the both side, right and left.

The area is sometimes over ¼ inch wide.

7. One or more horizontal lines in the screen.

1) Irregular vertical line is not related to Controller PCB or Y Board.

2) It is mainly caused by the followings open (or short).

- Y FPC connector ය reinsertion

- Open because of Y Driver Board’s connector dry joint ය

Y DRV Board replacement

- Panel itself is defective, Y FPC attached to panel itself

is open or short

There can be several horizontal lines

8. Regular vertical lines in the whole screen. (mainly in one specific color, regular line is flicking)

1) This problem is related to CONTROL PCB.

2) Replace CONTROL PCB

Fig # 11

Regular vertical lines in the whole screen

16

Vertical Lines

Visual Troubleshooting

9. Vertical Data copy

1) This happens when scan wave is not reproduced properly.

2) Replace Y-Board

10. Grid X and Y Layout by screen size.

60’’

X

Y

X

Y

50’’

40’’42’’

Fig # 46

X

Y

17

Dark picture

Visual Troubleshooting

10. Input signal pattern is displayed but the screen is dark.

1) It happens when Z Board is not operating well.

2) Check whether Z Board’s power connector is plugged properly.

3) Check whether the signal connector between Controller PCB & Z Board is plugged.

4) Replace Z Board or controller PCB.

11. Input signal is white pattern but other colors are displayed in spots, missing data.

1) Check the slope & waveform of Y Board set up, set down.

2) Check the slope of Z Board’s ramp waveform

3) Measure each Board’s output waveform by over 200MHz scope and reference Fig. 12 and 13.

it is possible to control Y Board’s setup slope by adjusting VR2 and Z Board’s ramp slope by adjusting VR1.

Fig # 12

Fig # 13

- Y B/D measurement point : B61 ( SUS_UP OUTPUT ) - Z B/D measurement point : B61 ( SUS_OUT )

V-set-up

( 200V~240V)

Vs (170 ~ 185V)

0V

140ᓪ

< Y Sustain voltage wave>

20s5ᓪ

170s5ᓪ

VCC ( 90~110V)

10V

Vs (170 ~ 185V)

0V

3ᓪs2ᓪ

23ᓪ

< Z Ramp voltage wave >

18

Dark picture at Top, Bottom or Center

Visual Troubleshooting

Fig # 14

13. A specific brightness of one color is not clear.

1) Check CTRL Board’s input signal connector.

2) Replace CTRL Board.

14. With a full white pattern, the picture is darker toward

the center.

1) Dark picture will occur when the Z-board is missing its ramp

waveform/ see Fig # 15

2) Check the connection between CTRL PCB and the Z-board

signal cable.

3) If the signal cable is -OK- Replace the Z-Board.

Fig # 15

Vs (170 ~ 185V)

Fig # 16

3ᓪs2ᓪ

23ᓪ

< Z Ramp voltage wave >

19

No picture

1) Check CTRL PCB’s LED (D1~ D4).

2) Check the power or signal cable inputting into CTRL PCB.

3) Check X Board, Y Board and Z Board’s power connector.

4) Check the connector between CTRL PCB, X Board, Y Board, and Z Board respectively.

5) Measure Y Board’s output waveform with over 200MHz oscilloscope and compare it to Fig 17 below.

- Y Board measurement point : ( SUS_UP OUTPUT )

- X Board measurement point : ( SUS_DN OUTPUT )

6) Test data X Board waveform @ COF IC See Fig 34 page 26.

7) No Signal - Replace Controller PCB

V_SYNC

Fig # 17

amplified

Visual Troubleshooting

< Y Board output wave - 1 Frame > < Y Board output wave (amplified) - 1 SF >

20

Voltage Adjustment

Fig # 18

TP5 GND

Service Adjustment

When replacing power board,

Be sure to follow Power Assembly voltage Proc.

PFC +

PFC -

VR801

VS · 1V

PFC PACK

VA Adjust

VR8401

VS Adjust

VR8501

TP3

GND

TP6 VA

TP4

VS

21

DMM

+

1. PFC adjustment

-. Select 100% White Pattern signal and Pre-Heat panel.

-. Connect DMM with TP PFC+ and TP PFC – (GND).

-. adjust VR801 to 380V (within ·1V ).

2. VA adjustment

-. Connect DMM + terminal with P814 #1 Pin.

-. Turn VR8401 (VA) to adjust the voltage on DMM to VA voltage value marked on label @ bottom- right of panel. (allowable tolerance :

·0.5V )

3. VS adjustment

-. Connect DMM’s + terminal with P803 # 9 Pin.

-. Turn VR 8501 (VS)to adjust the voltage with DMM to Vs voltage value marked on label @ bottom- right of panel.

Voltage Adjustment

Service Adjustment

Fig #47

Problem: The picture above is an example of distorted

text.

Cure: VA & VS voltage adjustment is needed when

the following items are found:

• Distorted text

• Blocked text

• Pixilated picture

• Dots running from side to side

• Tearing in the picture

• Video smear

Fig # 48

Fig # 49

22

60’’ Test points and voltage adjustments.

VS adjustment

VA adjustment

Service Adjustment

VA adjust

VR8401

VA test point

TP-6

The voltage settings

change from model

to model and are

labeled and located

at the top center of

the screen.

23

VS adjust

VR8501

VS test point

TP-4

50’’- 26 series Test points and voltage adjustments.

VS/ VA

Test Points

The voltage settings

change from model

to model and are

labeled and located

at the top center of

VA adjustment

VS adjustment

the screen.

VS test point

TP1

the screen.

Service Adjustment

VA test point

VA adjust

RV601

VS adjust

RV401

24

50’’- 28 Series Test points and voltage adjustments.

Service Adjustment

VS adjustment

VA adjustment

VA test point

TP2

VS/ VA

Test Points

VS test point

TP1

The voltage settings

change from model

to model and are

labeled and located

at the top center of

the screen.

Five B +

RV203

VS adjust

RV401

VA adjust

RV601

25

42’’ with tuner test points and voltage adjustments.

VS adjustment

VA adjustment

VS test point

TP-2

Service Adjustment

The voltage settings

change from model

to model and are

labeled and located

at the top center of

the screen.

VA test point

TP-1

VS adjust

RV601

26

VA adjust

RV401

42’’ early model, Test points and voltage adjustments.

VS/ VA

VA adjustment

VS adjustment

VS/ VA test points

VS/ VA

Test Points

The voltage settings

change from model

to model and are

labeled and located

at the top center of

the screen.

Service Adjustment

VA adjust

RV751

VS adjust

R671

27

Primary power supply adjustment/ coefficient/ Example 60’’.

Test Points

PFC adjustment

Pulse Frequency - Coefficient (PFC) adjustment is Located the primary supply and is for aligning grid

Test Points

voltage. The panels grid voltage averages 360 to 380 volts depending on panel circuit.

Service Adjustment

PFC adjustment

Known symptoms

1. Intermittent Power

2. Picture dimming to bright during certain seines

3. Primary colors off, Hue or flesh tones

4. Colors bleeding

5. Left to Right picture is dark to bright

:

28

Y-amp, Test points and voltage adjustments.

Service Adjustment

6871QYH023A

Y- VA test points

Fig # 61

/ Example 60’’

VA adjust

VR1

V_SYNC

amplified

6871QYH027A

Y- VA test points

/ Example 42’’

VA adjust

V Set-up

< Y Board output wave - 1 Frame > < Y Board output wave (amplified) - 1 SF >

29

Z-Sus, Test points and voltage adjustments.

Service Adjustment

6871QZH020B

Z- VA test points

/ Example 50’’

Fig # 62

VA adjust

VR1

VA adjust

VR1

VA adjust

VR1

V_SYNC

amplified

6871QYH027A

Y- VA test points

/ Example 42’’

VA adjust

VR1

< Y Board output wave - 1 Frame > < Y Board output wave (amplified) - 1 SF >

30

Testing COF IC for Defective Panel/ Example 50’’

If an X-Board is found defective there is a slim possibility that the panel could cause the new X-Board Installed to fail due to panel short test by performing Diode Check as in the above figures.

Panel Testing

31

FOC IC

Defective Panel with shorted COF IC/ Example 50’’.

Panel Testing

Fig # 52

Fig # 53

Fig # 54

Rotating Bar

If an X-Board is found defective there is a slim possibility that a pixel could be found defective in the responsible quadrant. This is caused by an arch in the panel caused at the point of the IC’s failure.

Fig # 55

The above FIGURE 55 shows the defective cell damage. Figure 56 shows the panel ribbon attached to panel. We identified that for this panel the ribbons integrated IC was shorted.

Rotating Bar

Fig # 56

COF IC

Fig # 57

Open resistor

due to defective IC and panel

Note: In figure 55 is 1 defective cell this is caused by an arch in the panel, this caused COF IC too short.

32

Testing Y driver board for problems/ Example 50’’.

1) Problem occurs when IC shorts and loss of signal to panel.

2) Check the con. between CTRL & Z Board’s signal cable. 5) Sustain-up Waveform example

Fig # 58

3) The following image is the test point for waveform.

4) To the right is two test points for shorted IC’s 50’’.

Fig # 59

Panel Testing

33

Defective Panel with excessive etching

Panel Testing

Fig # 49

Red

Most etching can be identified be using a Green/ Blue or Red background and by adjusting the intensity down. If the one color is displayed that CAUSED the etching the color will be low in intensity compared to the rest of the screen.

Etching considerations for extreme cases you need to run white balance or heat run in 6 hour increments upto 24 hours. If you can’t perform a proper white balance after 24 hours the panel is not within spec and the panel will not work/ display properly.

Fig # 50

Blue

Fig # 51

Green

34

Etching Correction (Activating Heat Run) for Defective Panel

To enter in to White Balance (Heat Run), Press Power On (1). Then, press adjust right (2) to activate Blue, Green and Red. With the Heat run activated on White Balance run for 6 hours and check color background by pressing adjust right (2) for testing picture quality. Complete and repeat if needed not to exceed 24 hours.

1

2

Panel Testing

35

Troubleshooting

No

Does the LED on the front of the

unit light with the A/C switch ON?

Yes

Check sources output by the SMPS.

Is a source missing or low?

Yes

Unload the SMPS. Check for all of

the output voltages from the SMPS.

Are all of the voltages present?

Yes

Reload the SMPS one connector at

a time and test the output voltages.

Do any of the voltages drop when

the connector is connected?

Yes

Replace the PWB associated with

that shorted line.

No

Does the power control line

change at power ON?

No

change at power ON?

Yes

Check the connectors which would

normally have V applied from the

SMPS for shorts to ground. Do any

Does the power control line

Unload the PWB causing the

shorted line and retest for the short

on the same line. Does the short

Replace the suspected PWB.

shorts exist?

Does the power control line

change at power ON?

No

still exist?

Yes

No

Power Section

No Picture

Replace the VSC PWB.

Replace the Control PWB.

No

Check the Control PWB for

No

Check the Control PWB for

power function. Is power

Do all the fans begin to turn?

At power ON is 12V applied to

Replace the fan that is not

present?

No

all of the fans?

Yes

starting up.

Yes

No

Check for 12V from SMPS.

Is it present at Power ON?

36

Replace the PWB associated

with that shorted line and

retest for any other shorts to

ground.

60’’ Known Visual problems with boards that fixed

Fig # 19

Control Board & Y-Driver Amp

Visual Problems

Check & Adjust: PFC / VS / VA voltages to panel

specifications

Check Y-Sustain Sub-amp wave form

Okay? Replace Y-Sustain Amp

Not Resolved? Replace Digital Control board

Digital

Control

v.s.c

Board

Y Sustain WF test point

Y Sustain WF

Digital Control board

37

60’’ Known Visual problems with boards that fixed

Fig # 20

Y- Amp

Visual Problems

Check & Adjust: PFC / VS / VA voltages to panel

specifications

Check Y-Sustain Sub-amp wave form

Okay? Replace Y-Sustain Amp

Not Resolved? Replace Digital Control board

Digital

Control

v.s.c

Board

Y Sustain WF test point

Y Sustain WF

Digital Control board

38

60’’ Known Visual problems with boards that fixed

Fig # 21

Y-Driver Amp

Visual Problems

Check & Adjust: PFC / VS / VA voltages to panel

specifications

Check Y-Sustain Sub-amp wave form

Okay? Replace Y-Sustain Amp

Not Resolved? Replace Digital Control board

Digital

Control

v.s.c

Board

Y Sustain WF test point

Y Sustain WF

Digital Control board

39

60’’ Known Visual problems with boards that fixed

Fig # 22

Y-Driver Top

Visual Problems

Check & Adjust: PFC / VS / VA voltages to panel

specifications

Check Y-Sustain Sub-amp wave form

Okay? Replace Y-Sustain Amp

Not Resolved? Replace Digital Control board

Digital

Control

v.s.c

Board

Y Sustain WF test point

Y Sustain WF

Digital Control board

40

60’’ Known Visual problems with boards that fixed

Fig # 23

Digital Control Board

Visual Problems

Check & Adjust: PFC / VS / VA voltages to panel

specifications

Check Y-Sustain Sub-amp wave form

Okay? Replace Y-Sustain Amp

Not Resolved? Replace Digital Control board

Digital

Control

v.s.c

Board

Y Sustain WF test point

Y Sustain WF

Digital Control board

41

60’’ Known Visual problems with boards that fixed

Fig # 24

Y-Driver Bottom

Visual Problems

Check & Adjust: PFC / VS / VA voltages to panel

specifications

Check Y-Sustain Sub-amp wave form

Okay? Replace Y-Sustain Amp

Not Resolved? Replace Digital Control board

Digital

Control

v.s.c

Board

Y Sustain WF test point

Y Sustain WF

Digital Control board

42

42’’ Known Visual problems with boards that fixed

Fig # 25

Y-Driver - Top

Visual Problems

Check & Adjust: PFC / VS / VA voltages to panel

specifications

Check Y-Sustain Sub-amp wave form

Okay? Replace Y-Sustain Amp

Not Resolved? Replace Digital Control board

Digital

Control

v.s.c

Board

Y Sustain WF test point

Y Sustain WF

Digital Control board

43

42’’ Known Visual problems with boards that fixed

Fig # 26

VSC- Board

Visual Problems

Check & Adjust: PFC / VS / VA voltages to panel

specifications

Check Connection VSC and Digital board

Okay? Replace VSC board

Not Resolved? Replace Digital board

VSC to Digital cable

VSC Board

Digital Control

44

42’’ Known Visual problems with boards that fixed

Fig # 27

Y-Driver - Top

Visual Problems

Check & Adjust: PFC / VS / VA voltages to panel

specifications

Check Y-Sustain Sub-amp wave form

Okay? Replace Y-Sustain Amp

Not Resolved? Replace Digital Control board

Digital

Control

v.s.c

Board

Y Sustain WF test point

Y Sustain WF

Digital Control board

45

42’’ Known Visual problems with boards that fixed

Fig # 28

VSC- Board

Visual Problems

Check & Adjust: PFC / VS / VA voltages to panel

specifications

Check Connection VSC and Digital board

Okay? Replace VSC board

Not Resolved? Replace Digital board

VSC to Digital cable

46

42’’ Known Visual problems with boards that fixed

Fig # 29

X- Board ( Top Right)

Visual Problems

Check & Adjust: PFC / VS / VA voltages to panel

specifications

Check X-board wave form

Okay? Replace X-Board

Not Resolved? Check for C.O.F IC Short

X-Board WF test point

ER down X- board

47

C.O.F IC test 4 Defective Panel

42’’ Known Visual problems with boards that fixed

Fig # 30

X-Drive Board

Visual Problems

Check & Adjust: PFC / VS / VA voltages to panel

specifications

Check Y-Sustain Sub-amp wave form

Okay? Replace Y-Sustain Amp

Not Resolved? Replace Digital Control board

Digital

Control

v.s.c

Board

Y Sustain WF test point

Y Sustain WF

Digital Control board

48

50’’ Known Visual problems with boards that fixed

Fig # 31

Fig # 13

Fig # 31

Fig # 13

Y-Driver Amp upper

Visual Problems

Check & Adjust: PFC / VS / VA voltages to panel

specifications

Not okay, Check Y-Sustain Sub-amp wave form

Okay, Replace Y-Sustain Amp

Not okay. Replace Digital Control board

Digital

Control

v.s.c

Board

Y Sustain WF test point

Y Sustain WF

Digital Control board

49

50’’ Known Visual problems with boards that fixed

Fig # 32

Digital Control board

Visual Problems

Check & Adjust: PFC / VS / VA voltages to panel

specifications

Check Y-Sustain Sub-amp wave form

Okay? Replace Y-Sustain Amp

Not Resolved? Replace Digital Control board

Digital

Control

v.s.c

Board

Y Sustain WF test point

Y Sustain WF

Digital Control board

50

50’’ Known Visual problems with boards that fixed

Fig # 33

Digital Control Board

Visual Problems

Check & Adjust: PFC / VS / VA voltages to panel

specifications

Check Y-Sustain Sub-amp wave form

Okay? Replace Y-Sustain Amp

Not Resolved? Replace Digital Control board

Digital

Control

v.s.c

Board

Y Sustain WF test point

Y Sustain WF

Digital Control board

51

50’’ Known Visual problems with boards that fixed

Fig # 34

VSC Board

Visual Problems

Check & Adjust: PFC / VS / VA voltages to panel

specifications

Check X-board wave form

Okay? Replace X-Board

Not Resolved? Check for C.O.F IC Short

X-Board WF test point

ER down X- board

52

C.O.F IC test 4 Defective Panel

50’’ Known Visual problems with boards that fixed

Fig # 36

X-Board upper right

Visual Problems

Check & Adjust: PFC / VS / VA voltages to panel

specifications

Check X-board wave form

Okay? Replace X-Board

Not Resolved? Check for C.O.F IC Short

X-Board WF test point

ER down X- board

53

C.O.F IC test 4 Defective Panel

50’’ Known Visual problems with boards that fixed

Fig # 35

Y- Driver Amp bottom

Visual Problems

Check & Adjust: PFC / VS / VA voltages to panel

specifications

Check Y-Sustain Sub-amp wave form

Okay? Replace Y-Sustain Amp

Not Resolved? Replace Digital Control board

Digital

Control

v.s.c

Board

Y Sustain WF test point

Y Sustain WF

Digital Control board

54

50’’ Known Visual problems with boards that fixed

Fig # 37

X- Board ( Bottom Left)

Visual Problems

Check & Adjust: PFC / VS / VA voltages to panel

specifications

Check X-board wave form

Okay? Replace X-Board

Not Resolved? Check for C.O.F IC Short

X-Board WF test point

ER down X- board

55

C.O.F IC test 4 Defective Panel

50’’ Known Visual problems with boards that fixed

Fig # 38

X- Board ( Upper Right)

Visual Problems

Check & Adjust: PFC / VS / VA voltages to panel

specifications

Check X-board wave form

Okay? Replace X-Board

Not Resolved? Check for C.O.F IC Short

X-Board WF test point

ER down X- board

56

C.O.F IC test 4 Defective Panel

50’’ Known Visual problems with boards that fixed

Fig # 39

Digital Control Board

Visual Problems

Check & Adjust: PFC / VS / VA voltages to panel

specifications

Check Y-Sustain Sub-amp wave form

Okay? Replace Y-Sustain Amp

Not Resolved? Replace Digital Control board

Digital

Control

v.s.c

Board

Y Sustain WF test point

Y Sustain WF

Digital Control board

57

50’’ Known Visual problems with boards that fixed

Fig # 40

Y- Driver Bottom

Visual Problems

Check & Adjust: PFC / VS / VA voltages to panel

specifications

Check Y-Sustain Sub-amp wave form

Okay? Replace Y-Sustain Amp

Not Resolved? Replace Digital Control board

Digital

Control

v.s.c

Board

Y Sustain WF test point

Y Sustain WF

Digital Control board

58

50’’ Known Visual problems with boards that fixed

Fig # 41

X-Drive Top

Visual Problems

Check & Adjust: PFC / VS / VA voltages to panel

specifications 61

Check X-Board waveform

Okay? Check for C.O.F IC Short

Shorted? Defective Panel

Y Sustain WF

Y Sustain WF test point

59

Y Sustain Sub-Amp board

50’’ Known Visual problems with boards that fixed

Fig # 42

Digital Control Board

Visual Problems

Check & Adjust: PFC / VS / VA voltages to panel

specifications

Check Y-Sustain Sub-amp wave form

Okay? Replace Y-Sustain Amp

Not Resolved? Replace Digital Control board

Digital

Control

v.s.c

Board

Y Sustain WF test point

Y Sustain WF

Digital Control board

60

Known Visual problems & found panel defective

Fig # 43

Visual Problems

Check & Adjust: PFC / VS / VA voltages to panel

specifications

Check X-Board waveform

Okay? Check for C.O.F IC Short

C.O.F IC – Ribbon shorted/ Part of Panel Defective Panel

X-Board WF test point

X-Board Sustain WF

61

Shorted? Defective Panel

C.O.F IC test 4 Defective Panel

Known Visual problems & found panel defective

Fig # 45

Visual Problems

Check & Adjust: PFC / VS / VA voltages to panel

specifications

Check X-Board waveform

Okay? Check for C.O.F IC Short

Data @ X-Board – Yes/ tested for shorted C.O.F IC – Ribbon shorted/ Defective Panel

X-Board WF test point

X-Board Sustain WF

63

Shorted? Defective Panel

C.O.F IC test 4 Defective Panel

Known Visual problems & found panel defective

Fig # 46

Display’s waves – V.S.C Board defective

Visual Problems

Check & Adjust: PFC / VS / VA voltages to panel

specifications

Check Connection VSC and Digital board

Okay? Replace VSC board

Not Resolved? Replace Digital board

VSC to Digital cable

VSC Board

Digital Control

64

50’’ Known Visual problems with boards that fixed

Fig # 47

Display’s Vertical Bars – Defective Y-Sub-amp

Visual Problems

Check & Adjust: PFC / VS / VA voltages to panel

specifications

Check Y-Sustain Sub-amp wave form

Okay? Replace Y-Sustain Amp

Not Resolved? Replace Digital Control board

Digital

Control

v.s.c

Board

Y Sustain WF test point

Y Sustain WF

Digital Control board

65

50’’ Known Visual problems with boards that fixed

Fig # 48

Display’s Vertical Bars – Defective Y-Sub-amp

Visual Problems

Check & Adjust: PFC / VS / VA voltages to panel

specifications

Check Y-Sustain Sub-amp wave form

Okay? Replace Y-Sustain Amp

Not Resolved? Replace Digital Control board

Digital

Control

v.s.c

Board

Y Sustain WF test point

Y Sustain WF

Digital Control board

66

50’’ Known Visual problems with boards that fixed

Fig # 49

Y-Driver - Top

Visual Problems

Check & Adjust: PFC / VS / VA voltages to panel

specifications

Check Y-Sustain Sub-amp wave form

Okay? Replace Y-Sustain Amp

Not Resolved? Replace Digital Control board

Digital

Control

v.s.c

Board

Y Sustain WF test point

Y Sustain WF

Digital Control board

67

Known Visual problems & found panel defective

Fig # 44

Visual Problems

Check & Adjust: PFC / VS / VA voltages to panel

specifications

Check Y-Sustain Sub-amp wave form

Okay? Check for C.O.F IC Short

C.O.F IC – Ribbon shorted/ Part of Panel Defective Panel

Y-Sustain Sub-amp test point

Y Sustain WF

62

Shorted? Defective Panel

C.O.F IC test 4 Defective Panel

Known Visual problems & found panel defective

Fig # 50

VSC- Board

Visual Problems

Check & Adjust: PFC / VS / VA voltages to panel

specifications

Check Connection VSC and Digital board

Okay? Replace VSC board

Not Resolved? Replace Digital board

VSC to Digital cable

VSC Board

Digital Control

68

Known Visual problems & found panel defective

Fig # 51

Y-Driver - Top

Visual Problems

Check & Adjust: PFC / VS / VA voltages to panel

specifications

Check Y-Sustain Sub-amp wave form

Okay? Replace Y-Sustain Amp

Not Resolved? Replace Digital Control board

Digital

Control

v.s.c

Board

Y Sustain WF test point

Y Sustain WF

Digital Control board

69

Known Visual problems & found panel defective

Visual Problems

Fig # 52

Y-Driver Amp upper

Y Sustain WF test point

Y Sustain WF

Check & Adjust: PFC / VS / VA voltages to panel

specifications

Check Y-Sustain Sub-amp wave form

Okay? Replace Y-Sustain Amp

Not Resolved? Replace Digital Control board

Digital

Control

v.s.c

Board

Digital Control board

70

Known Visual problems & found panel defective

Fig # 53

Digital Control board

Visual Problems

Check & Adjust: PFC / VS / VA voltages to panel

specifications

Check Y-Sustain Sub-amp wave form

Okay? Replace Y-Sustain Amp

Not Resolved? Replace Digital Control board

Digital

Control

v.s.c

Board

Y Sustain WF test point

Y Sustain WF

Digital Control board

71

Known Visual problems & found panel defective

Fig # 54

Digital Control Board

Visual Problems

Check & Adjust: PFC / VS / VA voltages to panel

specifications

Check Y-Sustain Sub-amp wave form

Okay? Replace Y-Sustain Amp

Not Resolved? Replace Digital Control board

Digital

Control

v.s.c

Board

Y Sustain WF test point

Y Sustain WF

Digital Control board

72

RS-232 (Activating remote link) for controlling Panel

Installation & Set-up

Type of connector : D-Sub 9-pin male

* Use a null modem cable.

Wire the 7-Wire cable so that each pair of data lines cross between the two devices. These data line pairs are RXD (Receive data) and TXD (Transmit data), DTR (DTE side ready) and DSR (DCE side ready), and RTS (Ready to send) and CTS (Clear to send).

When using the 3-Wire cable connected to RXD, TXD and GND; Pin No. 4 (DTR) and Pin No. 6 (DSR) must be connected to the monitor. (The cable must be disconnected from the Monitor to be able to use the remote control and Monitor front panel controls.)

* With the RS-232 input connected, the Monitor cannot be controlled by both an external control device and the remote control at the same time. The Monitor can only be controlled by either the remote control or the external control device.

Hyper terminal

No. Pin Out/ key

1 No connection

2 RXD (Receive data)

3 TXD (Transmit data)

4 DTR (DTE side ready)

5 GND

6 DSR (DCE side ready)

7 RTS (Ready to send)

8 CTS (Clear to send)

9 No Connection

73

RS-232 (Activating remote link) for controlling Panel

Installation & Set-up

7-Wire Cable Configuration

• The Monitor is available to switch between external adjustment and remote control adjustment using a control line.

Note: If the control line is high, the monitor is controlled by the external control device. If the control line is low, the Monitor is controlled by the Monitor's remote control.

3-Wire Cable Configuration

• When using a 3-Wire cable configuration, there is no control line. The external equipment can command the Monitor to "change into remote control adjustment mode”. When using a 3-Wire cable configuration, there is no control line. The external control device must put the Monitor into the "change into remote control adjustment mode“. The Monitor will then be able to be controlled by the remote control. If the Monitor is turned back on, it will revert back to external device control.

• The external control device must put the Monitor into the "change into remote control adjustment mode "function in 7Wire Configuration.

3-Wire Cable Configuration

• When using a 3-Wire cable configuration, there is no control line. The external equipment can command the Monitor to "change into remote control adjustment mode”. (When using a 3-Wire cable configuration there is no control line. The external control device must put the Monitor into the "change into remote control adjustment mode“ & The Monitor will then be able to be controlled by the remote control). If the Monitor is turned back on, it will revert back to external device control.

• The external control device must put the Monitor into the "change into remote control adjustment mode"function in 7Wire Configuration.

74

Definition of cell defect

y

Panel Testing

1) Cell defect definition

- Non-ignition dot (dark defect): In a ignited cell, the cell that an extinguished size is less than 50%. Cells which are not working.

- Non-extinguishing dot(brightness defect): In an extinguished cell, the cell that a ignited size is more than 50%. Cell which is always working “ON”.

- Unstable Dot (Flickering): Cell which repeats on (brightness) and off (darkness).

- Uncontrollable Dot : Cell which is brighter or stays on

longer than other cells around it because of unstable working condition.

A -ZONE : 70%

of Displa

Area

2) Test results are satisfied with each full red, green, blue, black and white test pattern.

- Specifically, The full white test pattern is used to decide the

number of continuous cell defects, The full black test pattern is used to decide the number of Non-extinguishing cell defects.

- The decision distance is 2.2m (3H, 60”) away from the panel, intensity of illumination is between 100 Lux and 200 Lux.

3) Cell defects do not increase or progress as time goes on.

PDP CELL DISPLAY AND DEFECT ZONES: Display Dot Diagram

1st Pixel

row

2nd Pixel

row

Pixel

row

Pixel

row

1st Pixel column

R G B R G B

2nd Pixel column

Pixel

Sub-Pixel or Cell

75

RS-232 program codes

Panel Testing

P

5

5 0

0

W

P

2

4

6

2

,

D

D P

P

D

4

P

0

4

V

0

2

VFUNCTION

2

,

W

P

2

5

4

2

0

,

W

V

B

2

/

6

4

H

B

P

P 6

6 0

0 W

W 2

2 6

6

,

P

D

P

5

5 0

0 W

W 2

2 8

8 A

A

XXS-VIDEO

XXCOMPONENT

P

6

D

0

P

W

6

2

0

6

W

A

P

S

S T

T A

A R

R TTYPE

TTYPE

7D6D5D4D3D2D1DFUNCTION

H

ST

E

A

X

R

C

T

O

BI

D

T

E

0ED501110D5-BIT, DOUBLE-STARTXXXPOWER ON

08D500010D5-BIT, DOUBLE-STARTXXXSYSTEM OFF

C404XXXXXXXPOWER ON

C504XXPOWER OFF

C504XXPOWER OF F

C504XXXXSYSTEM OFF

C504XXXXSYSTEM O FF

9804XXRGB & POWER ON

9804XXRGB-1

C604XXRGB 2

5A04XXVIDEO & POWER ON

5A04XXVIDEO

5104XXS-VIDEO & POWER ON

BF04XXCOMPONENT & POWER ON

D404FUTURECOMPONENT 2

7704XXXX16:9 (ASPECT RATIO)

7604XXXX4:3 (ASPECT RATIO)

AF04XXXXZOOM (ASPECT RATIO)

76

Plasma Cell Defect Form

(01) (02) (03) (04) (05) (06)

A-Zone

Visual Problems

Fax to:

LG Tech Support Fax #: 256.774.4051 Email: [email protected]

(16) (A) (B) (C) (D) (07)

(15) (E) (F) (G) (H) (08)

B-Zone

(14) (13) (12) (11) (10) (09)

Description:

Non-Extinguishing Pixels Pixel that remains on/ illuminating the Sub-pixel Red/ Blue/ Green.

Non-Illuminating Pixels Pixel that remains off/ not illuminating the Sub-pixel Red/ Blue/ Green.

Model Number :_____________Serial Number :____________ Servicer Acct :_____________

Customer's Name :______________Date of Purchase:_____________ RA# :

A-Zone (A -H) Cell Defects Location(s) Quantity

Non-Extinguishing Pixels

(Red) _______ ________ (Blue) _______ ________ (Green) _______ ________

Flickering Pixels or Non-Illuminating Pixels

(Red) _______ ________ (Blue) _______ ________ (Green) _______ ________

B-Zone (1 -16) Cell Defects Location(s) Quantity

Non-Extinguishing Pixels

(Red) _______ ________ (Blue) _______ ________ (Green) _______ ________

Flickering Pixels or Non-Illuminating Pixels

(Red) _______ ________ (Blue) _______ ________

77

(Green) _______ ________

___________

Definition of cell defect

Panel Testing

Div.

Zone A - Zone B - Zone A - Zone B - Zone A – Zone B – Zone

* N<3 [Cells / RGB screen]

Non

ignition

Dot

And

Unstabl

e Dot

Uncontr

ollable

Dot

Non

extingui

shing

Dot

Defect

distance

Total

Defect

Stain

Total N<

[Cell/ full screen] *2cell conjunction point:

N<

0

*include Unstable dot:

4

N <

N=0

N=0 N=0 N=0 N=0 N = 0 N = 0

50mm ˺ 50mm ˺

N < 25 [Cell/ full screen] N < 25 [Cell/ full screen] N < 35[Cell/ full screen]

*1˺D˺5, N˺3 *Dപ5, N=0

42ˑ 50ˑ

* N<5 [Cells /

9

RGB screen]

[Cell/ full screen]

conjunction point:

con

N˺2 [Cells/ RGB screen]

Total N˺6 [Cells

/ full screen]

15

TotalnN<

*2cell

2*3cell

N<

junction point:

N =0

*Unstable dot: N<

7

•N< [Cells / RGB screen]

TotalnN< 4

[Cell/full screen]

*2cell

conjunction point:

N<*3cell

conjunction point:

Unstable dot:

N <

N=2

* 1˺D˺5, N˺3 * Dപ5, N=0

N = 0

* N< [Cells /

RGB screen]

[Cell/ full screen]

conjunction point:

N˺3 [Cells / RGB screen]

Total N˺ [Cells /

full screen]

11

TotalnN<

*1cell

N<*3cell

N = 0

*Unstable dot:

N<

* N<11 [Cells /

RGB screen]

TotalnN<

[Cell/ full screen]

*2cell

conjunction point:

2*3cell

N<

conjunction point:

N =0

*Unstable dot:

N<

11

N 2 [Cells / RGB screen]

Total N6 [Cells /

full screen]

D ˻5cm, N 1 (D: Centimeter)

; however, including conjunction cell,

N = 0

* 1<D<5, N < 3 (Stain Distance:˻50 mm) * D>5, N = 0 (Stain Distance:˻50mm)

60ˑ

* N<12 [Cells /

33

RGB screen]

TotalnN<

[Cell/ full screen]

*2cell

conjunction point:

2*3cell

N<

conjunction point:

N =0

*Unstable dot:

N <

N 3 [Cells / RGB screen]

Total N9 [Cells /

full screen]

36

12

78

60’’ PZ90V

Configuration diagram

X-Board (L-TOP)

Y-Driver Board (Bottom)

Y-Board

Y-Driver Board (Bottom)

X-Board ( L-Bottom) X-Board ( R- Bottom)

DC/DC Board

Controller Board

VSC Board

X-Board (R-TOP)

POWER Board

PFC Board

Z-Board

Great Company Great People

79

50’’ PV10

Configuration diagram

X-Board (L-TOP)

Y-Driver Board (Bottom)

Y-Board

Y-Driver Board (Bottom)

X-Board ( L-Bottom)

Great Company Great People

X-Board (C-TOP)

DC/DC Board

Controller Board

VSC Board

POWER Board

X-Board ( C-Bottom)

80

X-Board (R-TOP)

Speaker RSpeaker L

Z-Board

Tuner Board

X-Board ( R- Bottom)

50’’ PZ60,70

Configuration diagram

X-Board (L-TOP)

Y-Driver Board (Bottom) DC/DC Board Down

Y-Board

Y-Driver Board (Bottom)

X-Board ( L-Bottom) X-Board ( R- Bottom)

Great Company Great People

X-Board (C-TOP)

Controller Board UP

VSC Board Down

X-Board ( L-Bottom)

POWER Board

A/V Box-Board

81

Rv401

Vs

Rv601

Va

POWER Board

X-Board (R-TOP)

Z-Board

50’’ PZ90V

X-Board (L-TOP)

Y-Driver Board (Bottom)

Y-Board

DC/DC Board

Controller Board UP

X-Board (C-TOP)

Rv401

Vs

Rv601

Va

POWER Board

Configuration diagram

X-Board (R-TOP)

Z-Board

Y-Driver Board (Bottom)

X-Board ( L-Bottom) X-Board ( R- Bottom)

Great Company Great People

VSC Board Down

X-Board ( C-Bottom)

82

42’’ PZ10

Configuration diagram

DC/DC Board

Y-Driver Board (Bottom)

Y-Board

Y-Driver Board (Bottom)

X-Board L

Great Company Great People

Controller Board

VSC Board

X-Board C

83

POWER Board

Tuner Board

Speaker RSpeaker L

Z-Board

X-Board R

42’’ PZ60,70

Configuration diagram

X-Board (L-TOP)

Y-Driver Board (Bottom)

X-Board ( L-Bottom)

Controller Board Down

VSC Board UP

A/V Board

X-Board (R-TOP)

POWER Board

Z-BoardY-Board

X-Board ( R- Bottom)

Great Company Great People

84

42’’ PZ90V

Y-Driver Board (Bottom)

Configuration diagram

Y-Driver Board (Bottom)

Control Board + X-Board L

Great Company Great People

VSC Board

85

POWER Board

A/V Board

Z-BoardY-Board

X-Board R