Sanyo 42XR8DA Schematic

FILE NO.

SERVICE MANUAL

LCD TV

LCD-32XR8DA

PRODUCT CODE No.

PRODUCT CODE No. 1 682 344 39: CCIR DVB-T

LCD-42XR8DA

PRODUCT CODE No.

PRODUCT CODE No. 1 682 344 40: CCIR DVB-T

REFERENCE No.:SM0915037

CONTENTS

Safety precautions………………………………………………………………………..… Alignment instructions and method of software upgrading……………………………… Working principle analysis of the unit……………………………….………….…………. Block diagram…………………………………..………………………………….………… IC block diagram………………………………………………………………………..…… Wiring diagram ……………………………………………………………………………. Troubleshooting guide ………………………………………………………………..…… Schematic diagram………………………………………………………………………… APPENDIX-A: Assembly list APPENDIX-B: Exploded View

1 3 11 12 13 18 19 24

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 0 ~ +50

Scope for storage -20 ~ +60 oC

Humidity Scope for operation 20% ~ 85%

Scope for storage 10% ~ 90%

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

1. Test equipment

VG-848 (YPbPr,VGA signal generator) VG-849 (HDMI signal generator) CA210 (white balancer)

2. Power test

Connect data processing board, power board and IR board according the wiring diagram, connect the power and press “standby” button to turn on the TV.

a) Test the pin voltage of X802, the data is shown in table1:

Table1 voltage data of X802

X802 Pin1 2 3 4 5, 6 7, 8 9 10 11

Voltage 8.55~9.45V 0 4.85~5.35V 0 11.4~12.6V 0 4.85~5.35V 0 >2.5

b) Test the pin voltage of XV01, the data is shown in table2:

Table2 voltage data of XV01

XV01 Pin1, 2 3, 4, 5

Voltage 23.8~25.2V 0

c) Test the pin voltage of X101, the data is shown in table3:

Table3 voltage data of X101

X101 Pin1 2

Voltage 31.4~32.6V 0

3. Alignment flow-chart

The alignment flow-chart is shown as fig-1

Check if DDC, HDCP KEY, FLASH are written

Combined test for general assembly

White balance adjustment

Connect to the center signal source and check each

function of TV (station leaking, analog control, etc.)

check the output of earphone and speaker.

Input AV/SVIDEO/SCART signal and check the function

Input HD signal and check the function of YPbPr

Input VGA signal and check if the display is normal, chec

the function (analog control), horizontal/vertical center, etc.

Input HDMI signal and check if the display is normal, chec

the function (analog control), horizontal/vertical center, etc.

Preset ex-factory

Check the accessories and packing

Fig-1 adjustment flow-chart

4. Adjustment instruction

4.1 Unit adjustments

4.1.1Connect all the boards according to wiring diagram, then power on and observe the display.

4.1.2 Method for entering factory menu: a) Press “SOURCE”, “2”, “5”, ”8” and “0” in turn to enter factory menu; b) Press “CH+” and “CH-” to move the cursor to the adjustment page of the level one factory menu,

then press ”OK” to enter; c) Press “CH+” and “CH-” to move the cursor up and down; d) Press “VOL-” and “VOL+” to adjust the item when the cursor move to a certain adjust item; e) Press “MENU” to exit to the previous factory menu; f) Press “EXIT” to exit the factory menu at any situation; g) Press “OK” to enter the sub factory menu; h) ADC ADJUST, ADC correction of VGA, Component channel; i) W/B ADJUST, white balance adjustment; j) POWER Mode, set the turn-on modes. Standby---standby when power on; Mem---memory;

ForceOn---power on; ForceOn can be used for aging; set the “power mode” to “Standby” when

preset ex-factory unless the client appointed it; k) ISP Mode, ON---soft upgrading through VGA port with ISP device, OFF---DDC function of VGA;

the setting will not be memory and will be “OFF” when power on again; l) REST ALL, initialization of the factory and user data; after this item is confirm, the unit will

restart and display the guiding image. m) Factory Data Reset, factory data initialization (including white balance adjustment, ADC

correction and other adjusted data); n) Factory Channel Preset, preset the factory channel; please connect to the center signal source

when operating; the present digital frequency is CH28 (529.5MHz), CH33 (564.5MHz) for

Australia and CH45 (666MHz) for UK, if the signal changes, perform “DTV manual search” in

“Channel” menu and the operation needs 15s or so. o) MST Debug, the default is OFF. OFF---RS-232 should match the design criterion; ON--- it

should be convenient for using exploitation tool to adjust. The setting will not be memory and will

be “OFF” when power on again; p) Backlight: adjust the backlight brightness, adjust the data and test the voltage of X804 pin2

(PWM), let the voltage to be the corresponding PWM voltage which the brightness is maximum.

It will be preset and doesn’t need adjust. q) SSC Adjust, adjust the frequency spectrum expand, it will be preset and doesn’t need adjust. r) AUDIO Curve, adjust the sound curve, it will be preset and doesn’t need adjust. s) Picture Mode, set the picture values of each channel. Normally, they are preset and needn’t

adjust. t) There is data in EEPROM after software upgrade, please perform Reset All before the first

adjustment.

4.2 ADC correction

4.2.1ADC correction in VGA channel a) Switch to VGA channel. b) Press” SOURCE”, then press “2, 5, 8, 0” in turn to enter the level one factory menu. c) Move the cursor to “ADC ADJUST” and press OK to enter the sub-menu. d) Input VGA signal (VG-848 Timing:856(1024x768/60Hz), Pattern:920 Gray 8 step(H)). Move the

cursor to “mode”, press CH+ and CH- to select “RGB”, move the cursor to “AUTO ADC” and

press OK to adjust automatically till complete.

4.2.2 ADC correction in YPbPr channel a) Switch to YPbPr channel. b) Press” SOURCE”, then press “2, 5, 8, 0” in turn to enter the level one factory menu. c) Move the cursor to “ADC ADJUST” and press OK to enter the sub-menu. d) Input YPbPr signal (VG-848 Timing:978(483P), Pattern:984 SMPTE Color Bar). Move the

cursor to “mode”, press CH+ and CH- to select “YPbPr(HD)”, move the cursor to “AUTO ADC”

and press ENTER to adjust automatically till complete. e) Input YPbPr signal (VG-848 Timing:978(483P), Pattern:984 SMPTE Color Bar). Move the

cursor to “mode”, press CH+ and CH- to select “YPbPr(SD)”, move the cursor to “AUTO ADC”

and press ENTER to adjust automatically till complete.

4.3 White balance adjustment The default of color temperature of COOL is 12000K and the coordinate is (272, 278); color temperature of NORMAL is 9300K and the coordinate is (285,293), color temperature of WARM is 6500K and the coordinate is (313,329).

4.3.1 Adjustment steps

Before the white balance adjustment, please let the unit working at least 30 minutes and at a stable situation, use BBY channel of the white balancer CA-210. a) Switch to HDMI channel; b) Press” SOURCE”, then press “2, 5, 8, 0” in turn to enter the level one factory menu. c) Move the cursor to “W/B ADJUST” and press OK to enter the sub-menu. d) Input DVI/HDMI signal 1024X768/60Hz 16 step Gray (Timing:856, Pattern:921). Move the

cursor to “MODE”, press CH+ and CH- to select “HDMI” or other HDMI channel, move the cursor to “TEMPERTURE” and press CH+ and CH- to select “COOL”.

e) Fix G GAIN, adjust R GAIN, B GAIN and let the color coordinate of the fourteenth scale be

(272,278).

f) Fix G OFFSET, adjust R OFFSET, B OFFSET and let the color coordinate of the third scale be

(272,278).

g) When adjusting, please keep the color temperature of high light to be X=272±5, Y=278±5 and

the low light to be X=272±8, Y=278±8. h) Move the cursor to “COPY ALL” and copy the data to the other channels. i) Check if the color temperatures of NORMAL and WARM are up to the mustard (low light

acceptable error:±8, high light acceptable error:±5), if not, adjust R-GAIN/ B-GAIN/ R-OFF/

B-OFF. j) Check the color temperature of COOL, NORMAL and WARM of other channels (ANALOGTV,

DVB-T, Video, YPbPr,VGA), if they are not up to the mustard then adjust and store the data

separately. k) The reference of adjustment rule is below:

B gun: lower B gun to increase X, Y coordinate data, while raise B gun to decrease the data.

R gun: raise R gun to increase X coordinate data, while lower R gun to decrease the data; (R

gun adjustment will affect X and Lv slightly).

G gun: raise G gun to increase Y coordinate data, while lower G gun to decrease the data; (G

gun adjustment will affect Y and Lv greatly).

5. Performance check

5.1 TV function Connect RF to the center signal source, enter Channel menu → auto search, check if there are channels be skipped, check if the picture and speaker are normal.

5.2 AV/S-Video terminals Input AV/S-Video signal, check if the picture and sound are normal.

5.3 YPbPr/YcbCr terminal Input YUV signal (VG848 signal generator), separately input the YUV signals listed in table4 and check if the display and sound are normal at any situation (power on, channel switch and format convert, etc.)

Table4 YUV signal format

No. Resolution

1 720X480 15.734 60 13.5 480i(NTSC)

2 720X480 15.734 59.94 13.5 480i(NTSC)

3 720X576 15.625 50 13.5 576i(PAL)

4 720X480 31.469 60 27 480p(NTSC PROG)

5 720X480 31.469 59.94 27 480p(NTSC PROG)

6 720X576 31.25 50 27 576p(PAL PROG)

7 1280X720 45 59.94 74.18 720p(59p)

8 1280X720 45 60 74.25 720p(60p)

9 1280X720 37.5 50 74.25 720p(50p)

10 1920X1080 33.75 59.94 74.25 1080i(59i)

11 1920X1080 33.75 60 74.25 1080i(60i)

12 1920X1080 28.125 50 74.25 1080i(50i)

H-frequecny

(kHz)

V-frequecny

(kHz)

Point clock pulse

frequecny (MHz)

Note

13 1920X1080 67.5 59.94 148.35 1080p(59p)

14 1920X1080 67.5 60 148.5 1080p(60p)

15 1920X1080 56.25 50 148.5 1080p(50p)

16 1920X1080 - 23.94/24 - -

17 1920X1080 - 25 - -

18 1920X1080 - 29.97/30 - -

5.4 VGA terminal Input VGA signal (VG848 signal generator), separately input the signals listed in table5 and check the display and sound. If the image is deflection of the Horizontal and vertical, select Picture->Screen->Auto Adjusting to perform auto-correct.

Table5 VGA signal format

No. Resolution

1 640X480 31.469 59.94 25.175 IBM

2 720X400 31.469 70.086 28.322 IBM

3 640X480 37.861 72.809 31.5 VESA

4 640X480 37.5 75 31.5 VESA

5 800X600 35.156 56.25 36 VESA

6 800X600 37.879 60.317 40 VESA

7 800X600 48.077 72.188 50 VESA

8 800X600 46.875 75 49.5 VESA

9 1024X768 48.363 60.004 65 VESA

10 1024X768 56.476 70.069 75 VESA

11 1024X768 60.023 75.029 78.75 VESA

12 1152X864 67.5 75 108 VESA

13 1280X960 60 60 108 VESA

14 1280X1024 63.98 60.02 108 VESA

15 1280X1024 80 75 135 SXGA

16 1440X900 - 60 - -

17 1680X1050 - 60 - -

18 1360X768 47.7 60 85.5 -

H-frequecny

(kHz)

V-frequecny (kHz)

Point clock pulse

frequecny (MHz)

Note

5.5 HDMI terminal Input HDMI signal (VG849 signal generator), separately input the signals listed in table4 and table5 and check the display and sound (32KHz, 44.1KHz, 48KHz) at any situation (power on, channel switch and format convert, etc.)

5.6 other functions check a) Check the turn on/turn off timer, sleep timer, picture/sound mode, OSD, stereo and digital sound

port, etc. b) Check the digital program, if Audio Only is normal. c) Check MHEG function of the digital program for UK unit. d) Check if “CI: Common Interface” is normal. e) Check logical channel number (LCN) for Australia.

f) Check logical channel number (LCN) for France, UK and Italy. g) Check OTA function for Australia special custom.

6. Presetting before ex-factory

Enter user menu LOCK page, select “Restore Factory Default” to preset the ex-factory. a) Clear the program information. b) Clear VCHIP, parental control, etc. c) Set the default data of user menu. d) Set Menu Language to English. e) Set Power on Mode to Off.

7. Software instruction

Table6 software instruction

No. Code No. Type Function written before

paste

N810 5272532003 EN25B32-100HIP FLASH

N807 5272404002 AT24C04 HDMI KEY

NA03 5272402002 AT24C02 HDMI EDID

NA04 5272402002 AT24C02 HDMI EDID

NA08 5272402002 AT24C02

N107 5272421002 AT24LC21A VGA EDID

HDMI EDID

(Australia only)

Yes Written with device like ALL11,

Yes

Note1: write-protect setting: enter ALL-100 interface, select Config and press “config setting”, set Protect to “All Protect”, select “config” when writing. The “write-protect” will be set again when ALL-100 program restart.

Note2: software writing and upgrade method with ISP writing-device (1) Main board upgrade: connect a four-pin wire of the ISP writing-device to Debug port(X806)

on the main board; Unit upgrade: connect VGA ports of the ISP writing-device and the main board, enter factory menu and set “ISP Mode” to “ON”.

(2) Using Mstar writing-tool on line, click “Connect” menu, if it displays “Device EN25B32“ as

shown in fig2, the connection is success, if it fails, select “EN25B52” of “Device” manually and press “Connect” again.

Method

write-protect, refer to note1.

Written with device like ALL11

Fig2 Device EN25B52 successful connection

(3) Click “Read” and select the file written (MERGE.bin for example) as shown in fig3.

Fig3 the written file

(4) Click “Auto”, select “All chip” , “program” and other items as shown if fig4.

Fig4 selected items

(5) Press “Run” in fig4 to begin writing and there are two steps: Erase and Program. (6) If the process of writing succeeds, it will display “Pass” near “Run” as shown in fig5.

Fig5

(7) Repeat step 2) and 5) to write the program to the other units without exit the ISP interface.

Note3: software writing and upgrade method with USB port (1) Make sure the USB device is formatted as FAT32. (2) Copy the program named Merge.bin to USB device. (3) Insert the USB device to USB port of the unit, power on and select RF-ATV channel, begin

USB upgrade after OSD disappear. It will display blue when read the data from USB device, while display red when write Flash. The flash must be pull out when display red. It will flicker in red and blue if the process of writing is abnormal.

(4) The method are not applicable to all the USB devices, try another one if a certain USB device

is inapplicable.

Working principle analysis of the unit

1. PAL/SECAM signal flow: Antenna reception PAL/SECAM signal will be send to tuner TDA1616, which contains frequency turning, HF and IF amplifier circuit and is controlled by master control IC MSD109 (comprises CPU) through I2C bus. The analog IF signal via intermediate frequency amplifying, video SAW filter K3953 and audio SAW filter K9656 to input to analog demodulate IC (IF) R2A10406NP, after demodulating and output standard video signal TV-CVBS and sound IF signal (SIF). TV-CVBS will send to the master control IC MSD109 to video decode, deinterlace and scale, then output LVDS level drive for panel display. The sound IF (SIF) will be fed into MSD109, after demodulating, pre-amplifying, bass adjusting and volume control, the sound signal will separate into L/R channels and input to earphone amplifier BH3547F amplifying, then output two ways. One way will be sent to earphone, another will be sent to digital sound amplifier R2A15112FP amplifying then sent to speaker.

2. DVB-T signal flow: Antenna reception DVB-T signal will be sent to tuner TDA1616, after frequency tuning, HF amplification, IF amplification and SAW FILTER, output IF signal to demodulation chip CE6353, via QAM demodulation, fed to MSD109 for information source decoding in the format of standard serial TS stream. HD video signal via decoding to A/D conversion and OSD superposition, at last output LVDS drive level for panel display. HD audio signal via decoder built-in MSD109, resumed to multi- channel sound of Dolby AC-3. The audio signal will be sent to back end to perform bass adjustment and volume control, then it will separate into L/R channels and input to earphone amplifier BH3547F amplifying, then output two ways. One way will be sent to earphone, another way will be sent to digital sound amplifier R2A15112FP amplifying then sent to speaker.

3. AV/SV signal flow SV signal and the first path AV signal switch automatically via S-terminal socket, the signal and the second path AV signal will be fed to MSD109 to perform video decode, deinterlace and scale, then output LVDS drive level for panel display. Audio signal from AV/SV via matched resistance is fed to external audio switch HEF4052 to switch, then it is directly sent to MSD109 to bass adjust and volume control, the sound will separate into L/R channels and input to earphone amplifier BH3547F amplifying, then output two ways. One way will be sent to earphone, another way will be sent to digital sound amplifier R2A15112FP amplifying then sent to speaker.

4. PC/YPrPb signal flow PC and the second path YPbPr signal are switched via external switcher PI5V330, then the signal and the first path YPbPr signal will be sent to MSD109 A/D conversion, output R/G/B of 24 bit to back end module to digital decode, image scale and OSD superposition, then send to LVDS level drive for panel display. Sound signal of PC/YPrPb via matched resistance and a-c couple are sent to MSD109 to bass adjust and volume control, the sound will separate into L/R channels and input to earphone

amplifier BH3547F amplifying, then output two ways. One way will be sent to earphone, another way will be sent to digital sound amplifier R2A15112FP amplifying then sent to speaker.

5. HDMI signal flow Three HDMI video signals via switcher PS321 are directly fed to the master control IC MSD109 to digital decode, image scale and OSD superposition, then output LVDS drive level for panel display. HDMI audio signal via decoder built-in MSD109 is fed to back end to bass adjust and volume control, the sound will separate into L/R channels and input to earphone amplifier BH3547F amplifying, then output two ways. One way will be sent to earphone, another way will be sent to digital sound amplifier R2A15112FP amplifying then sent to speaker.

Block diagram

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