Philips 32R5, 7538 Service Manual

Color Television Chassis

Service Service Service

ServiceManual

Contents Contents

6. Block Diagrams and Testpoints 00

7. Electrical Diagrams and PWB's Diagram PWB MAIN CHASSIS SECTION 1 1 13 MAIN CHASSIS SECTION 2 2 13 MAIN CHASSIS SECTION 3 3 13 MAIN CHASSIS SECTION 4 4 13 MAIN CHASSIS SECTION 5 5 13 MAIN CHASSIS SECTION 6 6 13 MAIN CHASSIS SECTION 7 7 13 CRT PANEL APT145 , APT 146 8 0 KEYBOARD(ASW116)& IR RECVR(ALR016) 9 PRO-VIDEO JACK PANEL AVJ177 10 17 DIODE MODULATOR PANEL AWR006/007 11 18 INTERCONNECT WIIRING DIAGRAM 12 R5 MAIN CHASSIS PCB (TOP VIEW) 13 MAIN CHASSIS PCB (BTM VIEW) 14 CRT PCB APT146 15 CRT PCB APT145 16 PRO-VIDEO JACK PANEL PCB AVJ177 17 DIODE MODULATOR PCB AWR006/007 18

8. Adjustments 00

9. Circuit Description 00

10. Spare Parts List 00

32R5

7538

©

Copyright 2001 Philips Consumer Electronics B.V. Eindhoven, The Netherlands. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted, in any form or by means, electronic, mechanical, photographic, or otherwise without the prior permission of Philips.

Published by Philips Consumer Electronics Subject to modification 2005 Sep 27

WARNING: Before removing the CRT anode cap, turn the unit OFF and short the

HIGH VOLTAGE to the CRT DAG ground. SERVICE NOTE: The CRT DAG is not at chassis ground.

IMPORTANT SAFETY NOTICE

Proper service and repair is important to the safe, reliable operation of all Philips Consumer Electronics Company** Equipment. The service procedures recommended by Philips and described in this service manual are effective methods of performing service operations. Some of these service operations require the use of tools specially designed for the purpose. The special tools should be used when and as recommended.

It is important to note that this manual contains various CAUTIONS and NOTICES which should be carefully read in order to minimize the risk of personal injury to service personnel. The possibility exists that improper service methods may damage the equipment. It also is important to understand that these CAUTIONS and NOTICES ARE NOT EXHAUSTIVE. Philips could not possibly know, evaluate and advise the service trade of all conceivable ways in which service might be done or of the possible hazardous consequences of each way. Consequently, Philips has not undertaken any such broad evaluation. Accordingly, a servicer who uses a service procedure or tool which is not recommended by Philips must first satisfy himself thoroughly that neither his safety nor the safe operation of the equipment will be jeopardized by the service method selected.

** Hereafter throughout this manual, Philips Consumer Electronics Company will be referred to as Philips.

WARNING

Critical components having special safety characteristics are identified with a by the Ref. No. in the parts list and enclosed within a broken line* (where several critical

components are grouped in one area) along with the safety symbol or exploded views. Use of substitute replacement parts which do not have the same specified safety characteristics may create shock, fire, or other hazards. Under no circumstances should the original design be modified or altered without written permission from Philips. Philips assumes no liability, express or implied, arising out of any unauthorized modification of design. Servicer assumes all liability.

* Broken Line ____ _ ____ _ ____ _ ____

on the schematics

or "S"

SAFETY CHECKS

After the original service problem has been corrected, a complete safety check should be made. Be sure to check over the entire set, not just the areas where you have worked. Some previous servicer may have left an unsafe condition, which could be unknowingly passed on to Your customer. Be sure to check all of the following:

FIRE AND SHOCK HAZARD

1. Be sure all components are positioned in such a way as to avoid the possibility of adjacent component shorts. This is especially important on those chassis which are transported to and from the service shop.

2. Never release a repaired unit unless all protective devices such as insulators, barriers, covers, strain reliefs, and other hardware have been installed in accordance with the original design.

3. Soldering and wiring must be inspected to locate possible cold solder joints, solder splashes, sharp solder points, frayed leads, pinched leads, or damaged insulation (including the ac cord). Be certain to remove loose solder balls and all other loose foreign particles.

4. Check across-the-line components and other components for physical evidence of damage or deterioration and replace if necessary. Follow original layout, lead length, and dress.

5. No lead or component should touch a receiving tube or a resistor rated at 1 watt or more. Lead tension around protruding metal surfaces or edges must be avoided.

6. Critical components having special safety characteristics are identified with an 'S' by the Ref. No. in the parts list and enclosed within a broken line* (where several critical

components are grouped in one area) along with the safety symbol diagrams and /or exploded views.

on the schematic

7. When servicing any unit, always use a separate isolation transformer for the chassis. Failure to use a separate isolation transformer may expose you to possible shock hazard, and may cause damage to servicing instruments.

8. Many electronic products use a polarized ac line cord (one wide pin on the plug). Defeating this safety feature may create a potential hazard to the servicer and the user. Extension cords which do not incorporate the polarizing feature should never be used.

9. After reassembly of the unit, always perform an ac leakage test or resistance test from the line cord to all exposed metal parts of the cabinet. Also, check all metal control shafts (with knobs removed), antenna terminals, handles, screws, etc., to be sure the unit may be safely operated without danger of electrical shock.

* Broken line ____ _ ____ _ ____ _ ____

IMPLOSION

1. All picture tubes used in current model receivers are equipped with an integral implosion system. Care should always be used, and safety glasses worn, whenever handling any picture tube. Avoid scratching or otherwise damaging the picture tube during installation.

2. Use only replacement tubes specified by the manufacturer.

X-RADIATION

1. Be sure procedures and instructions to all your service personnel cover the subject of X-radiation. Potential sources of X-rays in TV receivers are the picture tube and the high voltage circuits. The basic precaution which must be exercised is to keep the high voltage at the factory recommended level.

2. To avoid possible exposure to X-radiation and electrical shock, only the manufacturer's specified anode connectors must be used.

3. It is essential that the service technician has an accurate HV meter available at all times. The calibration of this meter should be checked periodically against a reference standard.

4. When the HV circuitry is operating properly there is no possibility of an X-radiation problem. High voltage should always be kept at the manufacturer's rated value - no higher - for optimum performance. Every time a color set is serviced, the brightness should be run up and down while monitoring the HV with a meter to be certain that the HV is regulated correctly and does not exceed the specified value. We suggest that you and your technicians review test procedures so that HV and HV regulation are always checked as a standard servicing procedure, and the reason for this prudent routine is clearly understood by everyone. It is important to use an accurate and reliable HV meter. It is recommended that the HV reading be recorded on each customer's invoice, which will demonstrate a proper concern for the customer's safety.

5. When troubleshooting and making test measurements in a receiver with a problem of excessive high voltage, reduce the line voltage by means of a Variac to bring the HV into acceptable limits while troubleshooting. Do not operate the chassis longer than necessary to locate the cause of the excessive HV.

6. New picture tubes are specifically designed to withstand higher operating voltages without creating undesirable X-radiation. It is strongly recommended that any shop test fixture which is to be used with the new higher voltage chassis be equipped with one of the new type tubes designed for this service. Addition of a permanently connected HV meter to the shop test fixture is advisable. The CRT types used in these new sets should never be replaced with any other types, as this may result in excessive X-radiation.

7. It is essential to use the specified picture tube to avoid a possible X-radiation problem.

8. Most TV receivers contain some type of emergency "Hold Down" circuit to prevent HV from rising to excessive levels in the presence of a failure mode. These various circuits should be understood by all technicians servicing them, especially since many hold down circuits are inoperative as long as the receiver performs normally.

LEAKAGE CURRENT COLD CHECK

1. Unplug the ac line cord and connect a jumper between the two prongs of the plug.

2. Turn on the power switch.

3. Measure the resistance value between the jumpered ac plug and all exposed cabinet parts of the receiver, such as screw heads, antennas, and control shafts. When the exposed metallic part has a return path to the chassis, the reading should be between 1

megohm and 5.2 megohms. When the exposed metal does not have a return path to the chassis, the reading must be infinity. Remove the jumper from the ac line cord.

LEAKAGE CURRENT HOT CHECK

1. Do not use an isolation transformer for this test. Plug the completely reassembled receiver directly into the ac outlet.

2. Connect a 1.5k, 1OW resistor paralleled by a 0.15uF. capacitor between each exposed metallic cabinet part and a good earth ground such as a water pipe, as shown below.

3. Use an ac voltmeter with at least 5000 ohms/volt sensitivity to measure the potential across the resistor.

4. The potential at any point should not exceed 0.75 volts. A leakage current tester may be used to make this test; leakage current must not exceed 0.5milliamp. If a measurement is outside of the specified limits, there is a possibility of shock hazard. The receiver should be repaired and rechecked before returning it to the customer.

5. Repeat the above procedure with the ac plug reversed. (Note: An ac adapter is necessary when a polarized plug is used. Do not defeat the polarizing feature of the plug.)

OR

With the instrument completely reassembled, plug the AC line cord directly into a 120V AC outlet. (Do not use an isolation transformer during this test.) Use a leakage current tester or a metering system that complies with American National Standards Institute (ANSI) C101.1 Leakage Current for Appliances and Underwriters Laboratories (UL) 1410, (50.7). With the instrument AC switch first in the on position and then

in the off position, measure from a known earth ground (metal water pipe, conduit, etc.) to all exposed metal parts of the instrument (antennas, handle brackets, metal cabinet, screw heads, metallic overlays, control shafts, etc.), especially any exposed metal parts that offer an electrical return path to the chassis. Any current

measured must not exceed 0.5 milliamp. Reverse the instrument power cord plug in

the outlet and repeat the test. See graphic below.

PICTURE TUBE REPLACEMENT

The primary source of X-radiation in this television receiver is the picture tube. The picture tube utilized in this chassis is specially constructed to limit X-radiation emissions. For continued X-radiation protection, the replacement tube must be the same type as the original, including suffix letter, or a Philips approved type.

PARTS REPLACEMENT

Many electrical and mechanical parts in Philips television sets have special safety related characteristics. These characteristics are often not evident from visual inspection nor can the protection afforded by them necessarily be obtained by using replacement components rated for higher voltage, wattage, etc. The use of a substitute part which does not have the same safety characteristics as the Philips recommended replacement part shown in this service manual may create shock, fire, or other hazards

Chassis Identification and Interchangability

Chassis Identification

An identification label is located on the outside of the cabinet back. The first four characters (25R5) indicate the basic chassis series. The next two numbers (01) identify the total Electronic Package in the Cabinet. The last two letters (AA) are used to identify production changes that do not affect the basic function of the chassis versions. Minor changes may not be identified within the letters, however, they will be called out on the schematic as Early Production (E.P.) and Late Production (L.P.) changes. When ordering parts or requesting technical assistance or information, the complete chassis number must be supplied (e.g., 25R501 -OOAA).

INTERCHANGEABILITY NOTICE

Important: While the following holds true in most cases, always refer to the most up-to-date service information for confirmation of interchangeability. The 8 digit Base No. identifies a family of assemblies. The remaining 4 characters (called the Group No.) indicate the type of interchangeability within the family.

Example: Base No. Group No. 00APP012 A001

Note: Families having different Base No's. cannot be interchanged.

The ninth digit (first digit of the Group No.) identifies the group interchangeability level. This will be an alpha character. Higher groups may replace lower groups, but lower groups cannot be substituted for higher groups. Example: 00APP012 A001 00APP012 B002 00APP012 C003

00APP012 B002 can be replaced by a C003 but not by an A001. In addition, a C003 can be used in place of either a B002 or an A001.

The last two digits of the identification number indicate running changes. When a particular identification number is initially assigned, it will be A001. Any change which does not significantly change the operational characteristics or the external wiring configuration is a running change within the group. This allows bidirectional interchangeability within the group. Example: A001 can be used in place of A003, and A003 can be used in place of A001. However, if a significant change does occur which will only allow higher revision substitution, the group identifier (9th position character) must change.

Example: 00APP012 A001 (Early Production) 00APP012 A002 00APP012 A003 00APP012 B004 00APP012 B005 00APP012 B006 (Late Production

00APP012 A001 is the initial identification number. all assemblies in the "A" group (9th position character) are interchangeable with each other. All of the assemblies in the "B" group are interchangeable with each other, and any "B" group assembly can be substituted for an "A" group. However, an "A" group assembly cannot be substituted for a "B" group assembly.

Chassis Breakdown List

NOTE: THE LOCATION OF INFORMATION IN THE MANUAL IS INDICATED BY BOTH PAGE NUMBER AND MICROFICHE FRAME NUMBER. PAPER MANUAL USERS SHOULD REFER ONLY TO THE PAGE NUMBERS. MICROFICHE MANUAL USERS SHOULD REFER ONLY TO THE FRAME NUMBERS. CHASSIS BREAKDOWN NOTES:

1. ITEMS SHOWN INDENTED IN THE PARTS LIST BELOW ARE SUB-ASSEMBLY TYPE ITEMS TO THE ITEM SHOWN ABOVE IT.

# INDICATES A "NON-REPLACEABLE/REPAIR ONLY TYPE OF ASSEMBLY.

R5 CHASSIS BREAKDOWN LIST

20R501 00APT145 CRT Module # 00EMR590 Main Chassis 00ALR016 IR Assembly 00AVJ177 Jack Panel 003403130005 Varactor Tuner Typical Model: PA5020C1

25R501 00APT146 CRT Module # 00EMR525 Main Chassis 00ALR016 IR Assembly 00ASW116 Keyboard 003403130005 Varactor Tuner Typical Model: 25T222

25R502 00APT146 CRT Module # 00EMR535 Main Chassis 00ALR016 IR Assembly 00ASW116 Keyboard 003403130005 Varactor Tuner Typical Model: TP2526

25R503 00APT146 CRT Module # 00EMR515 Main Chassis 00ALR016 IR Assembly 00ASW116 Keyboard 003403130005 Varactor Tuner Typical Model:TS2552

25R504 00APT146 CRT Module # 00EMR545 Main Chassis 00ALR016 IR Assembly 00ASW116 Keyboard 003403130005 Varactor Tuner Typical Model: CT2526

25R505 00APT146 CRT Module # 00EMR555 Main Chassis 00ALR016 IR Assembly 00ASW116 Keyboard 003403130005 Varactor Tuner Typical Model: TS2582C1

27R501 00APT146 CRT Module # 00EMR587 Main Chassis 00ALR016 IR Assembly 00ASW116 Keyboard 003403130005 Varactor Tuner Typical Model: CT2747

27R502 00APT146 CRT Module # 00EMR537 Main Chassis 00ALR016 IR Assembly 00ASW116 Keyboard 003403130005 Varactor Tuner Typical Model: CT2743C101

27R503 00APT146 CRT Module # 00EMR557 Main Chassis 00ALR016 IR Assembly 00ASW116 Keyboard 003403130005 Varactor Tuner

Typical Model: HD2716

27R504 00APT146 CRT Module # 00EMR507 Main Chassis 00ALR016 IR Assembly 00ASW116 Keyboard 003403130005 Varactor Tuner Typical Model: CC2762

27R505 00APT146 CRT Module # 00EMR597 Main Chassis 00ALR016 IR Assembly 00AVJ177 PRO Video Jack Panel 00ASW116 Keyboard 00AWR006 Diode Modulator 36 003403130005 Varactor Tuner Typical Model: PA5027

27R506 00APT146 CRT Module # 00EMR543 Main Chassis 00ALR016 IR Assembly 00ASW116 Keyboard 003403130005 Varactor Tuner Typical Model: LS2940

27R507 00APT146 CRT Module # 00EMR563 Main Chassis 00ALR016 IR Assembly 00ASW116 Keyboard 003403130005 Varactor Tuner Typical Model: LS2961

27R508 00APT146 CRT Module # 00EMR573 Main Chassis 00ALR016 IR Assembly 00ASW116 Keyboard 003403130005 Varactor Tuner Typical Model: 27TP82

27R509 00APT146 CRT Module # 00EMR583 Main Chassis 00ASW116 Keyboard 00ALR016 IR Assembly 003403130005 Varactor Tuner Typical Model: LP2970C1

27R510 00APT146 CRT Module # 00EMR547 Main Chassis 00ALR016 IR Assembly 00ASW116 Keyboard 003403130005 Varactor Tuner Typical Model: CC2772

27R511 00APT146 CRT Module # 00EMR553 Main Chassis 00ALR016 IR Assembly 00ASW116 Keyboard 003403130005 Varactor Tuner Typical Model: LS2960

27R512 00APT146 CRT Module

# 00EMR586 Main Chassis 00ALR016 IR Assembly 00ASW116 Keyboard 003403130005 Varactor Tuner N /A Typical Model: TP2782C1

27R513 00APT146 CRT Module # 00EMR577 Main Chassis 00ASW116 Keyboard 00ALR016 IR Assembly 003403130005 Varactor Tuner Typical Model: FS2770B1

32R502 00APT146 CRT Module # 00EMR562 Main Chassis 00ALR016 IR Assembly 00ASW116 Keyboard 00AWR007 Diode Modulator 36 003403130005 Varactor Tuner Typical Model: TP3287C1

32R503 00APT146 CRT Module # 00EMR532 Main Chassis 00ALR016 IR Assembly 00ASW116 Keyboard 00AWR007 Diode Modulator 36 003403130005 Varactor Tuner Typical Model: TS3262C1

32R504 00APT146 CRT Module # 00EMR542 Main Chassis 00ALR016 IR Assembly 00ASW116 Keyboard 00AWR007 Diode Modulator 36 003403130005 Varactor Tuner Typical Model: FS3262

32R505 00APT146 CRT Module # 00EMR592 Main Chassis 00ALR016 IR Assembly 00ASW116 Keyboard 00AVJ177 Jack Panel 35 00AWR007 Diode Modulator 36 003403130005 Varactor Tuner Typical Model: PA5032C1

32R506 00APT146 CRT Module # 00EMR582 Main Chassis 00ALR016 IR Assembly 00ASW116 Keyboard 00AWR007 Diode Modulator 36 003403130005 Varactor Tuner Typical Model: FP3272A1

32R507 00APT146 CRT Module # 00EMR512 Main Chassis 00ALR016 IR Assembly 00ASW116 Keyboard 00AWR007 Diode Modulator 36 003403130005 Varactor Tuner Typical Model: FS3270

20R501

00APT145 CRT Module # 00EMR590 Main Chassis 00ALR016 IR Assembly 00AVJ177 Jack Panel 003403130005 Varactor Tuner Typical Model: PA5020C1