Philips 55PP9401 Schematic

Philips Consumer Electronics

Technical Service Data

Service and Quality Service Publications Dept. One Philips Drive P.O. Box 14810 Knoxville, TN 37914

IMPORTANT SAFETY NOTICE

First Published: 05-17-2001 Rev. Date: 09-30-2004 Print Date: 09-30-2004

Safety Notes

WARNING

SAFETY CHECKS

- FIRE AND SHOCK HAZARD

- IMPLOSION

- X-RADIATION

- LEAKAGE CURRENT COLD CHECK

- LEAKAGE CURRENT HOT CHECK

- PICTURE TUBE REPLACEMENT

- PARTS REPLACEMENT

TV SAFETY NOTES

SAFETY PRECAUTIONS FOR TV CIRCUITS

PRECAUTIONS DURING SERVICE

SAFETY CHECK AFTER SERVICING

PRODUCT SAFETY GUIDELINES FOR ALL PRODUCTS

PREVENTION OF ELECTROSTATIC DISCHARGE (ESD)

REFER TO SAFETY GUIDELINES

SAFETY NOTICE: ANY PERSON ATTEMPTING TO SERVICE THIS CHASSIS MUST FAMILIARIZE HIMSELF WITH THE CHASSIS AND BE AWARE OF THE NECESSARY SAFETY PRECAUTIONS TO BE USED WHEN SERVICING ELECTRONIC EQUIPMENT CONTAINING HIGH VOLTAGES.

CAUTION: USE A SEPARATE ISOLATION TRANSFORMER FOR THIS UNIT WHEN SERVICING

GENERAL SAFETY NOTES

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 or "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 on the schematics 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 ____ _ ____ _ ____ _ ____

SAFETY CHECKS

fter 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

IMPLOSION

X-RADIATION

LEAKAGE CURRENT COLD CHECK

LEAKAGE CURRENT HOT CHECK

PICTURE TUBE REPLACEMENT

PARTS REPLACEMENT

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 on the schematic diagrams and /or exploded views.

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 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 ____ _ ____ _ ____ _ ____

ac leakage test or resistance test from the line cord to

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.

ddition 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

umper 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 metallic cabinet part and a

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

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.

. 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.)

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

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).

C 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.

With the instrument

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

TV SAFETY NOTES

SAFETY CHECKS

IMPLOSION

X-RADIATION

PICTURE TUBE REPLACEMENT

PARTS REPLACEMENT

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.

TV-VCR COMBI SAFETY NOTES

IMPORTANT SAFETY PRECAUTIONS

Prior to shipment from the factory, our products are strictly inspected for recognized product safety and electrical codes of the countries in which they are to be sold. However, in order to maintain such compliance, it is equally important to implement the following precautions when a set is being serviced.

SAFETY PRECAUTIONS FOR TV CIRCUITS

1. Before returning an instrument to the customer, always make a safety check of the entire instrument,

including, but not limited to, the following items:

a. Be sure that no built-in protective devices are defective or have been defeated during servicing. (1) Protective shields are provided on this chassis to protect both the technician and the customer. Correctly replace all missing protective shields, including any removed for servicing convenience. (2) When reinstalling the chassis and/or other assembly in the cabinet, be sure to put back in place all protective devices, including but not limited to, nonmetallic control knobs, insulating fishpapers, adjustment and compartment covers/shields, and isolation resistor/capacitor networks. Do not operate this instrument or permit it to be operated without all protective devices correctly installed and functioning. Servicers who defeat safety features or fail to perform safety checks may be liable for any resulting damage.

b. Be sure that there are no cabinet openings through which an adult or child might be able to insert their fingers and contact a hazardous voltage. Such openings include, but are not limited to, (1) spacing between the picture tube and the cabinet mask, (2) excessively wide cabinet ventilation slots, and (3) an improperly fitted and/or incorrectly secured cabinet back cover.

c. Do a

ANY MEASUREMENTS NOT WITHIN THE LIMITS SPECIFIED HEREIN INDICATE A POTENTIAL SHOCK HAZARD THAT MUST BE ELIMINATED BEFORE RETURNING THE INSTRUMENT TO THE CUSTOMER OR BEFORE CONNECTING THE ANTENNA OR ACCESSORIES.

LEAKAGE CURRENT CHECK

d. X-Radiation and High Voltage Limits - Because the picture tube is the primary potential source of X-radiation in solid-state TV receivers, it is specially constructed to prohibit X-radiation emissions. For continued X-radiation protection, the replacement picture tube must be the same type as the original. Also, because the picture tube shields and mounting hardware perform an X-radiation protection function, they must be correctly in place. High voltage must be measured each time servicing is performed that involves B+, horizontal deflection or high voltage. Correct operation of the X-radiation protection circuits also must be reconfirmed each time they are serviced. (X-radiation protection circuits also may be called "horizontal disable" or "hold down.") Read and apply the high voltage limits and, if the chassis is so equipped, the X-radiation protection circuit specifications given on instrument labels and in the Product Safety & X-Radiation Warning note on the service data chassis schematic. High voltage is maintained within specified limits by close tolerance safety-related components/adjustments in the high-voltage circuit. If high voltage exceeds specified limits, check each component specified on the chassis schematic and take corrective action.

2. Read and comply with all caution and safety-related notes on or inside the receiver cabinet, on the receiver chassis, or on the picture tube.

3. Design Alteration Warning - Do not alter or add to the mechanical or electrical design of this TV receiver. Design alterations and additions, including, but not limited to circuit modifications and the addition of items such as auxiliary audio and/or video output connections, might alter the safety characteristics of this receiver and create a hazard to the user. Any design alterations or additions will void the manufacturer's warranty and may make you, the servicer, responsible for personal injury or property damage resulting therefrom.

4. Picture Tube Implosion Protection Warning - The picture tube in this receiver employs integral implosion protection. For continued implosion protection, replace the picture tube only with one of the same type number. Do not remove, install, or otherwise handle the picture tube in any manner without first putting on shatterproof goggles equipped with side shields. People not so equipped must be kept safely away while picture tubes are handled. Keep the picture tube away from your body. Do not handle the picture tube by its neck. Some "in-line" picture tubes are equipped with a permanently attached deflection yoke; because of potential hazard, do not try to remove such "permanently attached" yokes from the picture tube.

5. Hot Chassis Warning

a. Some TV receiver chassis are electrically connected directly to one conductor of the ac power cord and may be serviced safely without an isolation transformer only if the ac power plug is inserted so that the chassis is connected to the ground side of the ac power source. To confirm that the ac power plug is inserted correctly, with an ac voltmeter, measure between the chassis and a known earth ground. If a voltage reading in excess of 1.OV is obtained, remove and reinsert the ac power plug in the opposite polarity and again measure the voltage potential between the chassis and a known earth ground.

b. Some TV receiver chassis normally have 85Vac (RMS) between chassis and earth ground regardless of the ac plug polarity. This chassis can be safety-serviced only with an isolation transformer inserted in the power line between the receiver and the ac power source, for both personnel and test equipment protection. Some TV receiver chassis have a secondary ground system in addition to the main chassis ground. This secondary ground system is not isolated from the ac power line. The two ground systems are electrically separated by insulation material that must not be defeated or altered.

6. Observe original lead dress. Take extra care to assure correct lead dress in the following areas: a. near sharp edges, b. near thermally hot parts - be sure that leads and components do not touch

thermally hot parts, c. the ac supply, d. high voltage, and e. antenna wiring. Always inspect in all areas

for pinched, out of place, or frayed wiring. Check ac power cord for damage.

7. Components, parts, and/or wiring that appear to have overheated or are otherwise damaged should be replaced with components, parts, or wiring that meet original specifications. Additionally, determine the cause of overheating and/or damage and, if necessary, take corrective action to remove any potential safety hazard.

PRECAUTIONS DURING SERVICE

. Parts identified by the symbol are critical for safety. Replace only with part number specified.

B. In addition to safety, other parts and assemblies are specified for conformance with regulations applying to spurious radiation. These must also be replaced only with specified replacements.

Examples: RF converters, RF cables, noise blocking capacitors, and noise blocking filters, etc.

C. Use specified internal wiring. Note especially:

1) Wires covered with PVC tubing

2) Double insulated wires

3) High voltage leads

D. Use specified insulating materials for hazardous live parts. Note especially:

1) Insulation Tape

2) PVC tubing

3) Spacers

4) Insulators for transistors

E. When replacing ac primary side components (transformers, power cord, etc.), wrap ends of wires securely about the terminals before soldering.

F. Observe that the wires do not contact heat producing parts (heatsinks, oxide metal film resistors, fusible resistors, etc.)

G. Check that replaced wires do not contact sharp edged or pointed parts.

H. When a power cord has been replaced, check that 10-15 kg of force in any direction will not loosen it.

I. Also check areas surrounding repaired locations.

J. Use care that foreign objects (screws, solder droplets, etc.) do not remain inside the set.

K. Crimp type wire connector When replacing the power transformer in sets where the connections between the power cord and power transformer primary lead wires are performed using crimp type connectors, in order to prevent shock hazards, perform carefully and precisely the following steps.

Replacement procedure

1) Remove the old connector by cutting the wires at a point close to the connector. Important: Do not re-use a connector (discard it).

2) Strip about 15 mm of the insulation from the ends of the wires. If the wires are stranded, twist the strands to avoid frayed conductors.

3) Align the lengths of the wires to be connected. Insert the wires fully into the connector.

4) Use the crimping tool to crimp the metal sleeve at the center position. Be sure to crimp fully to the complete closure of the tool.

L. When connecting or disconnecting the VCR connectors, first, disconnect the ac plug from the ac supply socket.

SAFETY CHECK AFTER SERVICING

Examine the area surrounding the repaired location for damage or deterioration. Observe that screws, parts and wires have been returned to original positions. Afterwards, perform the following tests and confirm the specified values in order to verify compliance with safety standards.

1. Clearance Distance

When replacing primary circuit components, confirm specified clearance distance (d) and (d') between soldered terminals, and between terminals and surrounding metallic parts. (See graphic bllow)

Table 1 : Ratings for selected area

AC Line Voltage Region Clearance Distance

(d) (d')

USA or > 3.2 mm 110 to 130 V CANADA (0.126 inches)

Note: This table is unofficial and for reference only. Be sure to confirm the precise values.

2. LEAKAGE CURRENT CHECKS

VCR SAFETY NOTES

FIRE & SHOCK HAZARD (VCR)

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

2. Always replace all protective devices such as insulators and barriers after working on a set.

3. Check for damaged insulation on wires including the ac cord.

4. Check across-the-line components for damage and replace if necessary.

5. After re-assembly of the unit, always perform an ac leakage test on the exposed metallic parts of the cabinet such as the knobs, antenna terminals, etc. to be sure the set is safe to operate without danger of electrical shock. Do not use a line isolation transformer during this test. Use an ac voltmeter having 5000 ohms per volt or more sensitivity in the following manner: Connect a 1500 ohm 10 wan resistor, paralleled by 0.15 MFD ac type capacitor, between a known good earth ground (water pipe, conduit, etc.) and the exposed metallic parts, one at a time. Measure the ac voltage across the combination 1500 ohm resistor and 0.15 MFD capacitor. Reverse the ac plug on the set and repeat ac voltage measurements again for each exposed metallic part. Voltage measured must not exceed O.6 volts R.M.S. This corresponds to 0.4 milliamp ac. Any value exceeding this limit constitutes a potential shock hazard and must be corrected immediately.

GENERAL

Power Supply-This receiver is designed for operation on 120 Volts, 6OHz alternating current (ac) only. Never connect to a supply having a different frequency or voltage.

IMPORTANT NOTICE

This device employs many circuits, components, and mechanical parts designed for protection against fire, shock and RF interference. For continued safety any servicing should be performed by qualified personnel and exact replacement parts should be used. Under no circumstances should the original design be altered.

PRODUCT SAFETY GUIDELINES FOR ALL PRODUCTS

CAUTION: Do not modify any circuit. Service work should be performed only after you are thoroughly

familiar with all of the following safety checks. Risk of potential hazards and injury to the user increases if safety checks are not adhered to.

USE A SEPARATE ISOLATION TRANSFORMER FOR THIS UNIT WHEN SERVICING.

PREVENTION OF ELECTROSTATIC DISCHARGE (ESD)

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 field-effect transistors and semiconductor "chip" components. The following techniques should be used to help reduce the incidence of component damage caused by electrostatic discharge (ESD).

1. Immediately before handling any semiconductor component or semiconductor-equipped assembly, drain off any ESD on your body by touching a known earth ground. Alternatively, obtain and wear a commercially available discharging ESD wrist strap, which should be removed for 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 solder removal device. Some solder removal devices not classified as "antistatic (ESD protected)" can generate an electrical charge sufficient to damage ES devices.

5. Do not use freon·propelled chemicals. These can generate electrical charges sufficient 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 feet from a carpeted floor can generate static electricity (ESD) sufficient to damage an ES device.)

NOTE to CATV system Installer:

This reminder is provided to call the CATV system installer's attention to article 820-22 of the NEC that provides guidelines for proper grounding and, in particular, specifies that the cable ground shall be connected to the grounding system of the building, as close to the point of cable entry as practical.

Philips Consumer Electronics

Technical Service Data

Service and Quality Service Publications Dept. One Philips Drive P.O. Box 14810 Knoxville, TN 37914

Manual 7618

Model no.: 55PP9401 First Published: 10-06-2004 Rev. Date: 10-11-2004 Print Date: 2004-10-11

General Information

REFER TO SAFETY GUIDELINES

CAUTION: USE A SEPARATE ISOLATION TRANSFORMER FOR THIS UNIT WHEN SERVICING

GENERAL INFORMATION

7618 General Information page 2

SPECIFICATIONS

7618 General Information page 3

7618 General Information page 4

SERVICING PRECAUTIONS General Servicing Guidelines

1. Always unplug the instrument AC power cord from the AC power source before: a. Removing or reinstalling any component, circuit board, module, or any other instrument assembly. b. Disconnecting or reconnecting any instrument electrical plug or other electrical connection. c. Connecting a test substitute in parallel with an electrolytic capacitor in the instrument. d. Discharging the picture tube anode.

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, FETV OM, etc.) equipped with a suitable high voltage probe. Do not test high voltage by drawing an arc. The H.V. Distribution Box has an internal 400MW resistor (bleeder resistor) connected from the high voltage to ground. After power is removed from the instrument the high voltage will discharge through the high voltage bleeder resistor. If the tubes have high voltage after power is removed, then the bleeder resistor is defective or the bleeder ground is disconnected.

3. Discharge the picture tube’s anode at any of the R, G, or B outputs on the H.V. Distribution Box only by (a) first connecting one end of an insulated clip lead to the degaussing or kine aquadag grounding system shield at the point where the picture tube socket ground lead is connected, and then (b) touching the other end of the insulated clip lead to the picture tube high voltage distribution box R, G, or B output, using an insulated handle to avoid personal contact with high voltage.

4. Do not spray chemicals on or near this instrument or any of its assemblies.

5. Unless specified otherwise, clean electrical contracts by applying the following mixture to the contacts with a pipe cleaner, cotton-tipped stick, or comparable nonabrasive applicator: 10% (by volume) Acetone and 90% (by volume) isopropyl alcohol (90% -99% strength).

CAUTION: This is a flammable mixture. Unless specified otherwise, lubrication of contacts is not required.

6. Do not defeat any plug/socket B+ voltage interlocks with which instruments might be equipped.

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

Always connect the test instrument ground lead to the appropriate instrument chassis ground before connecting the test instrument positive lead. Always remove the test instrument ground lead last.

Use only the specified test fixtures with this instrument.

CAUTION: Do not connect the test fixture ground strap to any heat sink in this instrument.

Electrostatically Sensitive (ES) Devices

7618 General Information page 5

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 field-effect transistors and semiconductor chip components. The following techniques should be used to help reduce the incidence of component damage caused 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 for 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 desolder ES devices.

4. Use only an anti-static type solder removal device. Some solder removal devices not classified as anti-static can generate electrical charges sufficient to damage ES devices.

5. Do not use Freon -propelled chemicals. These can generate electrical charges sufficient 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 lea ds electrically shorted together by conductive foam, aluminum foil or comparable conductive material.)

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 floor can generate charges sufficient to damage ES devices.

General Soldering Guidelines

7618 General Information page 6

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

2. Use an appropriate gauge of 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 small wire -bristle (0.5 inch or 1.25 cm) brush with a metal handle. Do not use Freon -propelled spray-on cleaners.

5. Use the following desoldering 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. Quickly draw away 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 normal temperature (500°F to 600°F). b. First, hold the soldering iron tip and solder 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 flows onto and around both the component lead and the foil.

CAUTION: Work quickly to avoid overheating the circuit board printed foil or components. d. Closely inspect the soldered area and remove any excess or splashed solder with a small wire-

bristle brush.

IC Removal/Replacement

7618 General Information page 7

Some chassis circuit boards have slotted holes (oblong) through which the IC leads are inserted and then bent flat 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 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 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 Devices Removal/Replacements

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 circuit board.

4. Insert new transistor in circuit board.

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

6. Replace heat sink.

Diode Removal/Replacement

7618 General Information page 8

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

2. Bend the two remaining leads perpendicularly 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.

Fuses and Conventional Resistor Removal/Replacement

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

2. Securely crimp leads of replacement component around stake 1/8 inch from top.

3. Solder the connections.

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

SMD Components

7618 General Information page 9

Circuit Board Foil Repair

7618 General Information page 10

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 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 cutaway 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:

7618 General Information page 11

Use the following technique to repair 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 a hazardous condition will not exist if the jumper wire opens.

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

3. Connect insulated 20 -gauge jumper wire from 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 that it does not touch components or sharp edges.

Frequency Synthes is (FS) Tuning Systems

1. Always unplug the instrument AC power cord before disconnecting or reconnecting FS tuning system cables and before removing or inserting FS tuning system modules.

2. The FS tuner must never be disconnected from the FS tuning control module while power is applied to the instrument.

3. When troubleshooting intermittent problems that might be caused by defective cable connections to the FS tuning system, remove the instrument AC power as soon as the defective connector is found and fi nish confirming the bad connection with a continuity test. This procedure will reduce the probability of electrical overstress of the FS system semiconductor components.

X-radiation Shielding

7618 General Information page 12

X-ray shield plates should not be unnecessarily removed during service. If the shields are removed, ensure that they are correctly replaced and secured before returning the set to the customer.

Technical Cautions

7618 General Information page 13

High Voltage Connector

7618 General Information page 14

7618 DFU Information

Directions For Use (DFU)

For Customer Operating Instructions, please visit our web site: www.p4c.philips.com.

Philips Consumer Electronics

Technical Service Data

Service and Quality Service Publications Dept. One Philips Drive P.O. Box 14810 Knoxville, TN 37914

Manual 7618

Model no.: 55PP9401 First Published: 10-06-2004 Rev. Date: 10-11-2004 Print Date: 2004-10-11

Disassembly

REFER TO SAFETY GUIDELINES

CAUTION: USE A SEPARATE ISOLATION TRANSFORMER FOR THIS UNIT WHEN SERVICING

Disassembly Procedure

LOWER REAR BOARD

1. Remove 15 Hex Head tapping screws.

2. Remove the lower rear board.

REAR COVER ASSEMBLY

1. Remove all Hex Head tapping screws except the two located on the top portion of the rear cover with clearance holes covered by strips of black tape.

2. Slowly back out the last two screws enough to clear the clearance holes of the rear cover.

3. Lift the rear cover off the cabinet.

REAR COVER MIRROR

1. Slowly lay down the rear cover with the mirror facing up.

2. Remove all Hex Head tapping screws (left to right, top to bottom, or vice versa).

3. Remove plastic holders to release the mirror.

4. Carefully lift the mirror off the rear cover.

SCREEN FRAME

1. Remove the four Hex Head screws from the botto m part of the screen frame.

2. Carefully detach the screen frame from the retainer of the cabinet (side to side).

3. Remove three screws from the corner bracket of both bottom corners of the screen frame.

4. Carefully remove the bottom part of the screen frame.

5. Carefully slide the screen assembly off the frame.

CONTROL PANEL ASSEMBLY

1. Detach the speaker grill assembly.

2. Remove two Hex Head screws on the sides of the control panel assembly.

3. Unplug two cables to release the control panel assembly.

POWER SUPPLY PWB

1. Make sure power is off (AC cord unplugged).

2. Unplug all cables to the power supply PWB.

3. Remove 1 Hex Head screw.

4. Pull out the power supply board off the slot (follow grounding procedures).

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