Sanyo 22XR9DZ Schematic

FILE NO.

SERVICE MANUA

LCD TV

L

LCD-22XR9DZ

PRODUCT CODE No.

PRODUCT CODE No.
1 682 346 40

REFERENCE No.:SM0915055

CONTENTS

Safety precautions………………………………………………………………………..…

Alignment instructions …………………………….…….…………………………………

Method of software upgrading……………………………………………………………..

Working principle analysis of the unit……………………………….………….………….

Block diagram…………………………………..………………………………….…………

IC block diagram and instruction…………………………………………………………..……

Wiring diagram …………………………………………………………………………….

Troubleshooting guide ………………………………………………………………..……

Schematic diagram…………………………………………………………………………

APPENDIX-A: Main assembly list

APPENDIX-B: Exploded View

3

5

11

15

18

19

23

24

27

Attention: This service manual is only for service personnel to take reference with. Before

servicing please read the following points carefully.

Safety precautions

1. Instructions

Be sure to switch off the power supply before replacing or welding any components or
inserting/plugging in connection wire Anti static measures to be taken (throughout the entire
production process!):
a) Do not touch here and there by hand at will;
b) Be sure to use anti static electric iron;
c) It’s a must for the welder to wear anti static gloves.
Please refer to the detailed list before replacing components that have special safety requirements.
Do not change the specs and type at will.

2. Points for attention in servicing of LCD

2.1 Screens are different from one model to another and therefore not interchangeable. Be sure to
use the screen of the original model for replacement.

2.2 The operation voltage of LCD screen is 700-825V. Be sure to take proper measures in
protecting yourself and the machine when testing the system in the course of normal operation or
right after the power is switched off. Please do not touch the circuit or the metal part of the module
that is in operation mode. Relevant operation is possible only one minute after the power is
switched off.

2.3 Do not use any adapter that is not identical with the TV set. Otherwise it will cause fire or
damage to the set.

2.4 Never operate the set or do any installation work in bad environment such as wet bathroom,
laundry, kitchen, or nearby fire source, heating equipment and devices or exposure to sunlight etc.
Otherwise bad effect will result.

2.5 If any foreign substance such as water, liquid, metal slices or other matters happens to fall into
the module, be sure to cut the power off immediately and do not move anything on the module lest it
should cause fire or electric shock due to contact with the high voltage or short circuit.

2.6 Should there be smoke, abnormal smell or sound from the module, please shut the power off at
once. Likewise, if the screen is not working after the power is on or in the course of operation, the
power must be cut off immediately and no more operation is allowed under the same condition.

2.7 Do not pull out or plug in the connection wire when the module is in operation or just after the
power is off because in this case relatively high voltage still remains in the capacitor of the driving
circuit. Please wait at least one minute before the pulling out or plugging in the connection wire.

2.8 When operating or installing LCD please don’t subject the LCD components to bending, twisting
or extrusion, collision lest mishap should result.

2.9 As most of the circuitry in LCD TV set is composed of CMOS integrated circuits, it’s necessary
to pay attention to anti statics. Before servicing LCD TV make sure to take anti static measure and
ensure full grounding for all the parts that have to be grounded.

2.10 There are lots of connection wires between parts behind the LCD screen. When servicing or
moving the set please take care not to touch or scratch them. Once they are damaged the screen

would be unable to work and no way to get it repaired.
If the connection wires, connections or components fixed by the thermotropic glue need to
disengage when service, please soak the thermotropic glue into the alcohol and then pull them out
in case of dagmage.

2.11 Special care must be taken in transporting or handling it. Exquisite shock vibration may lead to
breakage of screen glass or damage to driving circuit. Therefore it must be packed in a strong case
before the transportation or handling.

2.12 For the storage make sure to put it in a place where the environment can be controlled so as to
prevent the temperature and humidity from exceeding the limits as specified in the manual. For
prolonged storage, it is necessary to house it in an anti-moisture bag and put them altogether in one
place. The ambient conditions are tabulated as follows:

o

Temperature Scope for operation

5

~ +35

C

Scope for storage -15~ +45 oC

Humidity Scope for operation 20% ~ 80%

Scope for storage <= 80%

2.13 Display of a fixed picture for a long time may result in appearance of picture residue on the
screen, as commonly called “ghost shadow”. The extent of the residual picture varies with the
maker of LCD screen. This phenomenon doesn’t represent failure. This “ghost shadow” may remain
in the picture for a period of time (several minutes). But when operating it please avoid displaying
still picture in high brightness for a long time.

3. Points for attention during installation

3.1 The front panel of LCD screen is of glass. When installing it please make sure to put it in place.

3.2 For service or installation it’s necessary to use specified screw lest it should damage the screen.

3.3 Be sure to take anti dust measures. Any foreign substance that happens to fall down between
the screen and the glass will affect the receiving and viewing effect

3.4 When dismantling or mounting the protective partition plate that is used for anti vibration and
insulation please take care to keep it in intactness so as to avoid hidden trouble.

3.5 Be sure to protect the cabinet from damage or scratch during service, dismantling or mounting.

Alignment instructions

Test equipment

PM5518 (video signal generator)
VG-848 (VGA, YPbPr signal generator)
VG-849 (HDMI digital video signal generator)
CA210 (color analyzer)

1 Alignment flow

1.1 Voltage of power supply test

According to the wiring diagram specified by product specification, connect power board, digital

board, IR/key board and backlight board correctly; then power on and press key ‘
voltage of socket X801 each pin in turn listed as Table 1.

‘ .Test

Tabl e 1 Voltage of X801 each pin

X801 Pin1 2 3

Voltage Note:1 Note:2 0 12 V±5% 0 NC 5 V±5% 0 5 V±5% 0 Note:3

4、5 6、7

8 9 10 11 12 13

Note:1 Control of backlight switch (BLK_ON): high level (4.7±0.2V): on； low level(≤0.5V): off

2 Adjustment of backlight brightness (ADJ_PWM): continuous adjustment in factory menu

within 2-3.6V

3 Control of power switch (PWR_ON/OFF): high level (3.3±0.2V): on； low level(≤0.5V): off

1.2 Adjustment flow chart as Fig.1

Check if EDID, HDCP KEY and FLASH

have been burned.

combination adjustment for general

assembly

white balance adjustment

Connect to central signal source, check if

TV functions are normal -omitted channel,

analog parameters control, etc; check if

output of earphone and speaker is normal.

Input AV or SCART signal，check if every

function is normal.

Input high-definition component signal

(mode), check if every YPbPr function is

normal.

setup before leaving factory

Check if other functions are normal –LCN, CI,

OAD, etc.

Input HDMI signal，check if the display is normal;

check if every function is normal –analog

parameter control, horizontal/vertical center, etc.

Input VGA signal，check if the display is normal;

check if every function is normal -analog

parameter control, horizontal/vertical center, etc.

Fig.1 Adjustment flow chart

2 Alignment instruction

2.1 Unit adjustment

2.1.1 According to the wiring diagram specified by product specification, connect power board,

digital board, IR/key board and backlight board correctly; then power on and press key ‘

‘ , check if

the display is normal.

2.1.2 Using method of factory menu

a) First press key “SOURCE”，then press number key “2、5、8、0” in turn to enter into initial

factory menu;

b) Press keys “▲” and “▼” can move cursor to each page of initial factory menu, then press

key “OK” to enter into adjustment menu of each page;

c) Press keys “▲” and “▼” can move cursor upwards and downwards within one adjustment

page;

d) Move cursor to one adjustment item, then press keys “◄” and “►” can adjust it;

e) Press key “MENU” can exit adjustment menu of one page to its superior factory menu;

f) Press key “EXIT” can exit factory menu at any time;

g) Press key “OK” can enter into inferior factory menu;

h) Factory menu item “ADC Calibrate” is used to correct ADC of VGA and Component channel;

i) Factory menu item “W/B ADJUST” is used to adjust white balance;

j) Factory menu item “CUSTOM CHANNEL PRESET” : first delete all DTV/ATV programs for

factory adjustment, then preset ATV channel data according to customer order requirements;

please execute the item to clear out all programs for factory adjustment before leaving

factory;

k) Factory menu item “FACTORY CHANNEL PRESET” is used to preset factory programs

data; it is necessary to connect to central signal source for DTV searching programs. Now

digital frequency of central signal CH28(529.5 MHz) and CH33(564.5 MHz) are distributed

to Australia programs. Primary preset programs would not be modified along with the

changing of central signals, so please select item DTV in menu Channel to manual search

digital programs, the process will spend about 15s;

l) Factory menu item “RESET ALL” is used to reset factory menu data and user menu data; all

preset data of EEPROM will be deleted -white balance, program preset, etc; then the set will

be started up again and the startup guided picture will be displayed also;

m) Factory menu item “ISP MODE” is used to upgraded unit software from VGA port when the

item is set as “ON” and the set is connected to ISP adjustment equipment; DDC function of

VGA port will be recovered when the item is set as “OFF”; the value of the item can not be

kept in the memory, that is to say the item is reset as “OFF” after power-on again;

n) Factory menu item “POWER MODE” is used to set power-on mode, “Standby” means the

set will be in Standby state after power-on; “ForceOn” means the set will be working

automatically after power-on , the mode is also used for factory-machine-aging; default

setting should be “Standby” mode unless specified by customer requirement;

o) Factory menu item “BACKLIGHT” is used to adjust backlight brightness, test voltage of

X801-2# (PWM) and adjust the item to meet the requirement of maximum PWM voltage in

panel specification;

p) Factory menu item “SSC ADJUST” is used to adjust expended functions of frequency

content, the software having been preset according to model need not be adjusted;

q) Factory menu item “Debug Only” is used to adjust audio and video parameters –picture

mode parameter, volume curve, etc; the software having been preset according to model

need not be adjusted unless special customer requirements;

r) If the software has been upgraded or EEPROM has data, please select and execute

operation “RESET ALL” before adjustment for the first time.

2.1.3 ADC correction of D-SUB channel

a) Switch to D-SUB channel;
b) Press key “SOURCE”, then press number keys “2、5、8、0” to enter into initial factory menu;

c) Move cursor to item “ADC Calibrate” and press key “OK” to enter into interior factory menu;
d) Input D-SUB signal (VG-848 Timing:856(1024×768/60 Hz)，Pattern:920 8 step Gray),

move cursor to item “MODE”，press keys “▲” and “▼” to select item “RGB”, then move

cursor to item “AUTO ADC” and press key “OK” to begin adjustment automatically until a

prompt “success” for adjustment completion is displayed.

2.1.4 ADC correction of Component channel

a) Switch to Component channel;
b) Press key “SOURCE”，then press number keys “2、5、8、0” to enter into initial factory menu;

c) Move cursor to item “ADC Calibrate” and press key “OK” to enter into interior factory menu;

d) Input Component signal (VG-848 Timing:969(PAL)，Pattern:918 100% color bar), move

cursor to item “MODE”，press keys “▲” and “▼” to select item “YPbPr（SD）”, then move

cursor to item “AUTO ADC” and press key “OK” to begin adjustment automatically until a

prompt “success” for adjustment completion is displayed;

e) Input Component signal (VG-848 Timing:972(1080i)，Pattern:918 100% color bar), move

cursor to item “MODE”，press keys “▲” and “▼” to select item “YPbPr（HD）”, then move

cursor to item “AUTO ADC” and press key “OK” to begin adjustment automatically until a

prompt “success” for adjustment completion is displayed.

2.2 White balance adjustment

Unless specified by customer, default COOL color temperature is 12000K, chromaticity
coordinates is （ 272 、278 ） ; default Normal color temperature is 9300K, chromaticity
coordinates is（285、293）; default Warm color temperature is 6500K, chromaticity coordinates
is （313、329）.

2.3 White balance adjustment processes

The set should be working above 30 minutes before white balance adjustment for it would be in

a stabler state. Use white balance apparatus CA-210 and switch to its BBY channel.

a) Switch to HDMI channel；
b) Press key “SOURCE”, then press number keys “2、5、8、0” in turn to enter into initial factory

menu;

c) Move to item “W/B ADJUST” and press key “OK” to enter into interior factory menu;
d) Input HDMI signal （VG-848 Timing: 856(1024×768/60 Hz)，Pattern:921 16 step Gray）,

move cursor to item “MODE”, press keys “▲” and “▼” to select item “HDMI”, then move
cursor to item “TEMPERTURE”, press keys “▲” and “▼” to select item “Normal”；

e) Fix item “G GAIN”, adjust item “R GAIN、B GAIN” to set chromaticity coordinates of the 13

step is （285、293）；

f) Fix item “G OFFSET”, adjust item “R OFFSET、B OFFSET” to set chromaticity coordinates

th

of the 4

step is （285、293）；

g) During adjustment , make sure that color temperature of bright step is (X=285±10,Y=293±15)

and color temperature of dark step is (X=285±10,Y=293±20);

h) Then move cursor to item “COPY ALL” to copy white balance data to the other channels;

i) Check if color temperature of COOL and WARM meet requirements as below:

COOL: allowable error of bright step is (X±10, Y±15), allowable error of dark step is (X±10,Y±25);

WARM: allowable error of bright and dark step are both (X±10,Y±20);

otherwise adjust items “R_GAIN /B_GAIN/R_OFF/B_OFF” to meet requirements and then save

data;

j) Operation “Copy All” should be done for mode “Cool/Warm” , too;
k) Switch to other channels ATV, AV，COMPONENT and D-SUB , check if color temperature of

COOL，NORMAL and WARM meet requirements; otherwise adjust them respectively with

16 grey step signal and the same adjustment method as HDMI channel’s; exit menu “W/B

ADJUST” after adjustment and the data would be saved automatically;

l) Check if the picture of every channel is normal after adjustment;

m) Adjustment rules for reference as below:

adjust B gun: adjust B gun value downwards , then coordinates of X、Y will rise;
adjust B gun value upwards , then coordinates of X、Y will descent;

adjust R gun will effect the coordinate of X and the value of Lv a little:

th

adjust R gun value upwards , then coordinate of X will rise;

adjust R gun value downwards , then coordinate of X will descent;

adjust G gun will effect the coordinate of Y and the value of Lv a lot:

adjust G gun value upwards , then coordinate of Y will rise;

adjust G gun value downwards , then coordinate of Y will descent;

note: default color temperature for SANYO customer is Normal; change to picture mode

Dynamic, adjust chromaticity coordinates of color temperature Normal and Cool;

only adjust chromaticity coordinates of color temperature Cool for other customers when

picture mode is Dynamic.

3 Performance check

3.1 TV functions

Connect RF port to central signal source, first enter into menu Channel, then search programs
automatically, check if there is any omitted program of ATV、DTV, check if the output of speakers

is normal, check if the picture is normal.

3.2 AV IN/OUT function

Input AV signal to AV IN port, check if the picture, the sound and other functions are normal;

Switch to TV or AV channel, connect AV O UT port to another TV set, check if the picture, the

sound and other functions of AV OUT channel are normal.

3.3 SCART port

Input signal to SCART port, check if the picture, the sound and other functions are normal;

Switch to TV channel, check if the picture, the sound and other functions of SCART OUT

channel are normal.

3.4 Component port

Input Component signal from signal generator VG-848 with the formats as Tabl e 2 respectively,

check if the display and the sound are normal under the circumstances of power-on/off,

switching channel, switching signal format, etc.

Table 2 Component receiving signal formats

Horizontal

No. Definition

1 720×480 15.734 60 13.5 480i (NTSC)

2 720×480 15.734 59.94 13.5 480i (NTSC)

3 720×576 15.625 50 13.5 576i (PAL)

4 720×480 31.469 60 27

5 720×480 31.469 59.94 27

6 720×576 31.25 50 27 576p (PAL PROG)

7 1280×720 45 59.94 74.18 720p (59p)

8 1280×720 45 60 74.25 720p (60p)

9 1280×720 37.5 50 74.25 720p (50p)

10 1920×1080 33.75 59.94 74.25 1080i (59i)

frequency

（kHz）

Vertical frequenvy

（Hz）

Dot-pulse

frequency

（MHz）

Remark

480p (NTSC

PROG)

480p (NTSC

PROG)

11 1920×1080 33.75 60 74.25 1080i (60i)

12 1920×1080 28.125 50 74.25 1080i (50i)

13 1920×1080 67.5 59.94 148.35 1080p (59p)

14 1920×1080 67.5 60 148.5 1080p (60p)

15 1920×1080 56.25 50 148.5 1080p (50p)

16 1920×1080 33.75 30 74.25 1080p (30p)

17 1920×1080 33.716 29.97 74.176 1080p (29.97p)

18 1920×1080 28.125 25 74.25 1080p (25p)

19 1920×1080 27 24 74.25 1080p (24p)

20 1920×1080 26.973 23.98 74.176 1080p (23.98p)

3.5 D-SUB port

Input D-SUB signal from signal generator VG-848 with the formats as Table 3 respectively,

check if the display and the sound are normal; if there is any deviation of line or field, enter into

main menu and select items “Picture->Screen->Auto Adjusting” in turn to correct them

automatically.

Table 3 D-SUB receiving signal formats

Horizontal

No. Definition

1 640×480 31.469 59.94 25.175 IBM

2 720×400 31.469 70.086 28.322 IBM

3 640×480 37.861 72.809 31.5 VESA

4 640×480 37.5 75 31.5 VESA

5 800×600 35.156 56.25 36 VESA

6 800×600 37.879 60.317 40 VESA

7 800×600 48.077 72.188 50 VESA

8 800×600 46.875 75 49.5 VESA

9 1024×768 48.363 60.004 65 VESA

10 1024×768 56.476 70.069 75 VESA

11 1024×768 60.023 75.029 78.75 VESA

12 1152×864 67.5 75 108 VESA

13 1280×960 60 60 108 VESA

14 1280×1024 63.98 60.02 108 VESA

15 1280×1024 80 75 135 SXGA

16 1360×768 47.7 60 85.5 WXGA

17 1440×900 55.9 60 106.5

18 1680×1050 65.3 60 146.25

frequency

（kHz）

Vertical

frequenvy

（Hz）

Dot-pulse

frequency

（MHz）

Remark

WXGA+(Only for Panel Native Format）

WSXGA+(Only for Panel Native Format）

3.6 HDMI port

Input HDMI signal from signal generator VG-849 with the formats as Table 2 and Table 3
respectively, check if the display and the sound（32 KHz、44.1 KHz、48 KHz）are normal under

the circumstances of power-on/off, switching channel, switching signal format, etc.

3.7 Other functions check

a) Check if the functions are normal -timing turn-on/off、sleeping turn-off、picture/sound mode、

OSD、stereo and digital audio interface, etc.;

b) Check if Audio Only digital programs (MHEG Only for UK model) are normal;

c) Check if MHEG function of digital programs for UK model are normal;

d) Check if function of logic channel number (LCN) is normal;
e) For Europe models, check if general interface（CI：Common Interface）is normal;
f) For OAD models of specific customer, check if function of Over Air Download（OAD）is

normal.

4 User menu setup before leaving factory

Enter into page “LOCK” of user menu, select submenu “Restore Factory Default” to preset

items before leaving factory as below:

a) Clear out all programs information;

b) Clear out information of parental control (VCHIP);

c) Default setup of user analog data;

d) Set Menu Language as English;

e) Set Power on MODE as Off.

5 Instruction of factory software burning as Table 4

Table 4 Instruction of factory software burning

Instruction

No. Part No. Part type

N111 5276405001 MX25L64050 FLASH Yes

N108 5272404002 AT24C04 HDCP KEY Yes

NA05 5272402002 AT24C02 HDMI EDID Yes

N106 5272402002 AT24C02 VGA EDID Yes

of software

function

Burned

before

SMT

Burning method

burned with program

ALL100, write-protect setup,

refer to Note 1 in detail

burned with program ALL100

burned with program ALL100

burned with program ALL100

Note 1: Write-protect setup method

Enter into interface AUTO of burning

program ALL-100, select item “Config”, press item

“config Setting”, set item “Protect” as “All Protect”, set item “SRWD” as “Enable”, then

press key “OK” to complete write-protect setup.

Be sure to select item “Config” before burning software, and write-protect must be re-set after

burning program ALL-100 startup every time.

Note 2: Burning and upgrading software method with burning tool ISP

1） Main board upgrading: connect 4-core line of burning tool ISP to Debug port（location No. X807）

of main board;

Unit upgrading: connect both VGA ports between burning tool ISP and main board, then enter

into factory menu and set item “ISP Mode” as “ON”;

2） Use on-line burning tool of Mstar, enter into menu “Device”, select item “WP Pin pull to high

during ISP” as Fig. 2 to make sure hardware write-protect of Flash is canceled and the erasing

process will be normal;

Fig. 2 Write-protect setup

3) Select menu “Connect”, a dialog “Device Type is MX25L64” will be displayed as Fig. 3 to show

succeeding in connecting

Fig. 3 Device MX25L64 successful connection

If failing to connecting, select the first menu “Device” and manual select item “MX25L64”, then

press key “Connect”.

4) Press key “Read”，select burning file (for example MERGE.bin) as Fig. 4.

Fig. 4 Burning file

5) Select menu “Auto”, then select items “All chip”, “program” and other switches as Fig. 5

Fig. 5 Burning Config

6) Press key “Run” as Fig. 4 to begin burning software, there are two steps for the process: Erase

and Program

normal burning processes are as follows:

the first course “Erasing…， Flash Status: 03” will be lasting for a moment, otherwise skipping
over means unsuccessful erasing; please confirm process （2） and then burn software again;

the following course “Programming…，Flash Status:00” will be done until a prompt “Pass” is

displayed.

7) A prompt “Pass” will be displayed beside the key “Run” for successful burning as Fig. 6

Fig. 6 A prompt “Pass” beside the key “Run” for successful burning

8) Need not exit from ISP burning interface and only repeat the process 3）and 5）to go on burning

software for other sets.

Note 3: On-line burning and upgrading method from USB port

1） Be sure to format a U disk as FAT32;

2） Copy program file to the U disk with the name “Merge.bin”;