Sanyo 42XR56DZ Schematic

FILE NO.

SERVICE MANUA

LCD TV

LCD-42XR56DZ

PRODUCT CODE No.

PRODUCT CODE No. 1 682 346 41

REFERENCE No.:SM0915057

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

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:

Temperature Scope for operation

~ +35

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 “9232KE5601JL”, connect power board, digital board, IR board

correctly; then power on and press key “standby” .

a) Test voltage of socket X801 each pin in turn listed as Table 1.

Tabl e 1 Voltage of X801 each pin

X801 Pin1 2 3 4

Voltage

8.55 V～9.45 V

4.85 V～5.35 V

11.4 V～12.6 V

5、6 7 、8

9 10 11

4.85 V～5.35 V

b) Test voltage of socket XV03 each pin in turn listed as Table 2.

Tabl e 2 Voltage of XV03 each pin

XV03

Voltage

Pin1、2 3、4、5

23.8 V～25.2 V

>2.5

1.2 Adjustment flow chart as Fig.1

Check if DDC、、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 are

normal.

Input AV/SVIDEO/SCART signal，check if

functions of every channel are normal.

Input high-definition component signal

(mode), check if every YPbPr function is

normal.

Check accessories and packing.

setup before leaving factory

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 “9232KE5601JL”, connect power board, digital board,

SCART interface board, IR board, key board and side AV board correctly; then power on,

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 “CH+” and “CH-” can move cursor to each page of initial factory menu, then press

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

c) Press keys “CH+” and “CH-” can move cursor upwards and downwards within one adjustment

page;

d) Move cursor to one adjustment item, then press keys “VOL-” and “VOL+” 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 “POWER MODE” is used to set power-on mode, “Standby” means the

set will be in standby state after power-on; “MEM” means the set will be in the state before

the last power-off; “ForceOn” means the set will be working automatically after power-on,

this mode is also used for factory-machine-aging; default setting should be “Standby” mode

unless specified by customer requirement;

k) Factory menu item “ISP MODE” is used to upgrade 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;

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

after execute the item, the set will be started up again and the startup guided picture will be

displayed;

m) 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;

n) 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;

o) Factory menu item “MST Debug” :default setting “OFF” is used for engineering models

whose RS232 functions can measure up to design specifications; setting “ON” is convenient

for debugging by developing tools; 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;

p) Factory menu item “BACKLIGHT” is used to adjust backlight brightness, adjust the item and

test voltage of X802-2# (PWM) to measure up to the maximum PWM voltage in panel

specification;

q) 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 again;

r) Factory menu item “AUDIO Curve” is used to adjust audio curve; without special customer

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

again;

If the software has been upgraded or EEPROM has data already, please execute item

“RESET ALL” before adjustment for the first time.

2.1.3 ADC calibration

ADC calibration of VGA channel

a) Switch to VGA 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 ADJUST” and press key “OK” to enter into interior factory menu; d) Input VGA signal (VG-848 Timing:856(1024×768/60 Hz)，Pattern 920 Gray 8 step(H)),

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

adjustment completion.

ADC calibration of YPbPr channel

a) Switch to YPbPr 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 ADJUST” and press key “OK” to enter into interior factory menu; d) Input YPbPr signal (VG848 Timing 972（1080i）,Pattern 918 SMPTE 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 “ENTER” to begin adjustment automatically, a

prompt “success” displayed under “AUTO ADC” means auto-adjustment completed

successfully;

e) Input YPbPr signal (VG848 Timing 978（483P）,Pattern 918 SMPTE 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 “ENTER” to begin adjustment automatically, a

prompt “success” displayed under “AUTO ADC” means auto-adjustment completed

successfully;

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 DVI/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 “HDMI1” or

other HDMI channels, then move cursor to item “TEMPERTURE”, press keys “▲” and “▼”

to select item “COOL”;

e) Adjust items “R GAIN、G GAIN、B GAIN” to set chromaticity coordinates of the 14

is （272、278）;

f) Adjust item “R Offset、G Offset、B Offset” to set chromaticity coordinates of the 4

（272、278）;

g) During adjustment , make sure that color temperature of bright step is (X=272±10 Y=278±10)

and color temperature of dark step is (X=272±10 Y=278±10);

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

except DTV channel;

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

bright step: allowable error is ±10, dark step: allowable error is ±10;

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

save data;

step

step is

j) 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 step Gray signal and the same adjustment method as HDMI channel’s; exit menu “W/B

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

k) DTV channel adjustment: switch to DTV channel, input 16 step Gray signal, enter into

factory menu, then begin adjustment followed by steps “e, f, g”;

l) 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 effect the value of Lv a little:

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 effect 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, check if the output of speakers is

normal, check if the picture is normal.

3.2 AV/S-Video port

Input AV/S-Video signal respectively, check if the picture, the sound and other functions 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 YPbPr/YCbCr port

Input YUV signal from signal generator VG-848 with YUV formats as Tabl e 4 respectively, check

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

channel, switching signal format, etc.

Table 4 YUV 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)

frequency

（kHz）

Vertical frequenvy

（Hz）

Dot-pulse

frequency

（MHz）

Remark

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)

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 - 23.94/24 - -

17 1920×1080 - 25 - -

18 1920×1080 - 29.97/30 - -

480p (NTSC

PROG)

480p (NTSC

PROG)

3.5 VGA port

Input VGA signal from signal generator VG-848 with VGA formats as Tab le 5 respectively, check

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

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

automatically.

Table 5 VGA 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 1440×900 - 60 - -

17 1680×1050 - 60 - -

18 1360×768 47.7 60 85.5 -

frequency

（kHz）

Vertical

frequenvy

（Hz）

Dot-pulse

frequency

（MHz）

Remark

3.6 HDMI port

Input HDMI signal from signal generator VG-849 with the formats as Table 4 and Table 5 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 、turn-off of sleeping time 、

picture/sound mode、OSD、stereo and digital audio interface, etc.;

b) Check if audio only digital programs (RADIO) are normal;

c) For UK models, check if MHEG function of digital programs are normal; d) Check if common interface（CI：Common Interface）is normal;

e) For New Zealand models, check if function of logic channel number (LCN) is normal, check

if function of Over Air Download（OAD）is normal;

f) For France, UK and Italy models, check if function of logic channel number (LCN) is

normal.

4 User menu setup before leaving factory

Enter into page “LOCK” of user menu, select submenu item “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 6

Table 6 Instruction of factory software burning

Instruction of

No. Part No. Part type

N111 5276405001 MX25L6405DMI-12G FLASH Yes

N108 5272404002 AT24C04 HDMI KEY Yes

NA04 5272402002 AT24C02 HDMI EDID Yes

NA05 5272402002 AT24C02 HDMI EDID Yes

NA06 5272402002 AT24C02

N106 5272402002 AT24C02 VGA EDID Yes

software

function

HDMI EDID

(supporting

the3rd HDMI)

Burned

before

SMT

Yes

Note 1: Write-protect setup method

Enter into burning interface of

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

Setting”, set item “Protect” as “All Protect”; be sure to select item “Config” before burning

software, and write-protect must be re-set after burning program ALL-100 startup every time.

Burning method

burned with program

ALL100, write-protect setup,

refer to Note 1 in detail

burned with program ALL100

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; for the normal erasing process, make sure hardware write-protect of Flash

is canceled;

Fig. 2 Write-protect setup

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

to say connecting is successful;

Fig. 3 Device MX25L64 successful connection

If failing to connecting, select the first menu “Device” and select item “MX25L64” manually, 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 configuration as Fig. 5

Fig. 5 Burning Configuration

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

and Program

normal burning steps are as follows:

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

displayed.

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