Sanyo ABL279 Schematic

FILE NO.

SERVICE MANUALAVL279

PRODUCT CODE No.

LCD TV

1 682 343 20: NTSC-M

MTS/SAP

ZOOM CCD SLEEP

LIST

PICTURE

FAVORITE

AUDIO

PIP

P.POSITION SWAP FREEZE

REFERENCE No.:SM0915024

CONTENTS

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

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

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

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

IC block diagram………………………………………………………………………..……

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

Troubleshooting….…..………………………………………………………………..……

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

APPENDIX-A: 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.

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 oC

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

Digital Multi-meter 54200 (Signal generator) PC (FLASH writing programs have to be installed first, W24CXX.EXE) VG849 (HDMI signal generator) CA210 (White balancer) DVD player (with HDMI output) Monitor

2. The alignment flow chart (see below figure)

FLASH write N501, N142, N710, N801

Production of main board, high frequency board,

Analog board power test

Digital board power test

Test of Button board and IR board

Combined test for general assembly

Aging

ADC emendation and white balance adjustment

Connect to central signal source, chec various TV functions (station search, system identify, modulate quantity control etc), check i the output of earphone and speaker are normal Picture and sound of AV-out is normal. (check stereo/SAP and CCD, VCHIP for America) .

Fig.1 Flow process of alignment

Check accessories and then packing

Input VGA signal, check if display is normal in

the state of PC and various functions (analog

control), line/ field center etc.

Input HDMI and HDTV signal (use a connection wire, input audio signal from D-sub Audio in), check if HDCP KEY, picture and sound are normal

Input YPbPr/YcbCr 1/2 signal and check i

picture, sound and analog quantity control is

normal in the state of COMPONENT.

Input AV1/S/AV2 signal, check various functions under each terminal (system identify, analog control etc), check if Picture and sound of AV-out is normal. (S-terminal and AV1 share the same audio channel, the output picture from AV-out is colorless in the status of S-terminal)

3. Flash writing programs

Connect the digital board, analog board, trans-connect board and power board according the wiring diagram.

Flash write N710, N711

a) Flash write W24CXX.EXE to N710, N711 with self-made flash write tool on the line.

b) Upgrade software from USB interface.

Note: N710, N711 may upgrade from HDMI and VGA interface respectively. a) and b) can be done at the same time.

4. Unit adjustment

Connect the digital board, analog board, trans-connect board, button board, IR board and power board according the wiring diagram. Put the power on and observe if the display is normal.

4.1 Adjustment of Digital board and Analog board

a) Press POWER button on the remote control, the indicator light on IR receive board turns blue.

b) Press the buttons “INPUT, 2, 5, 8, 0” one by one to enter factory menu, select ”Result” item, and

check if each item in this page is “√”, otherwise, the IC mentioned in the item is failure.

c) Check if picture and sound are normal of all the channels, if STEREO/SAP can be identified

correctly. Check AV-OUT function: the picture and sound of AV-OUT should be the picture and sound of the current channel at TV/AV1/S/AV2, AV-OUT of other signal source don’t need to check.

4.2 Adjustment of unit connection

Turn on the TV and check if it is normal: display LOGO about 2 seconds later, display picture about 10 seconds later.

4.3 Aging

a) Turn on the TV, select TV channel without signal input.

b) Aging for an hour in the aging room.

4.4 White balance adjustment of ACD (use CA210, VG849 generator) Enter MENU →Picture → Picture Settings, set ”Preset” to standard.

Note:

1) Press ”▲” and “▼” to switch factory menu item, and ”ENTER” to access, press”◄” and “►” to select adjustment item, press”▲“ and “▼“or input digital data to adjust value of the item, press ”EXIT” to exit.

2) Coordinate of cold color temperature 12000K is (X=270, Y=283), coordinate of warm color temperature 7500K is (X=300, Y=306), coordinate of normal color temperature 9300K is (X=285, Y=293).

4.4.1 Adjustment of YPBPR, VGA, ADC

a) Press” INPUT, 2.5.8.0”one by one to enter factory menu. b) Press”▼“ to move cursor to “Adc Calibrate” item, press” ENTER” to access.

c) Input YPrPb signal (VG-848, Timing 978(483P), Pattern 984 SMPTE Color Bar), move

cursor to START and press “ENTER” to auto adjust until complete

d) Input YPRPB signal (VG-848, Timing 976(720P), Pattern 984 SMPTE Color Bar), move

cursor to START and press “ENTER” to auto adjust until complete

e) Move cursor to Source, press ”ENTER” switch to Anolog RGB(VGA). Input VGA signal

(VG-848 Timing 856(1024*768/60HZ), Pattern 920 Gray 8 step(H)), move cursor to START and press “ENTER” to auto adjust until complete

4.4.2 Adjustment of white balance

Input HDMI signal and check the white balance at HDMI channel.

a) Enter “color temperature setting” menu, select “color temperature” of “NORMAL”.

b) Input 16-level gray signal of the mode 1024*768 @60HZ (TIMING:856, PATTERN:921).

c) Fix BLUE GAIN at 1000, adjust RED GAIN, BLUE GAIN to set the color coordinates of

fourteenth level to (X=285, Y=293).

d) Set the color coordinates of warm color temperature (WARM) to (X=300, Y=306) using the

same method.

e) Set the color coordinates of cool color temperature (COOL) to (X=270, Y=283) using the same

method.

f) Check if the color coordinates of the cool/warm color temperature at YPBPR (include

480P,720P), VIDEO(NTSC) and TV channels are within the scope of the correspond value (permit ±8 error).

5 Functional Inspection

5.1 TV function

Connect RF-AIR terminal to the central signal source, Enter the channels menu → scan channels, select input type “Antenna” to auto search and check if there is station skipping. Check if search (→Find channel), the output of earphone and speakers, and the picture are normal.

5.2 AV/S-Video terminal

Connect AV/S-Video signal, check if they are normal.

5.3 YPBPR terminal

Input YUV signal (VG-848 signal generator), separate input the YUV format signal of table 1 and check if the display and sound are normal.

Table1 YUV signal format

H-frequency (KHz) V-frequency (Hz) Signal

1 15.734 59.94 SDIV 480i

2 31.469 59.94 HDIV 480p

3 45 59.94 HDIV 720p

4 45 60 HDIV 720p

5 33.75 59.94 HDIV 1080i

6 33.75 60 HDIV 1080i

5.4 VGA terminal

Input VGA signal (VG-848 signal generator), separate input the VGA format signal of table1 and table 2, check if the image and sound is normal. If the image is deflection of H-field, select Auto Sync correction of the Screen Settings menu. If the image is slight disturb, adjust Phase correction of the Screen Settings menu.

5.5 HDMI terminal

HDMI signal format receive the three high-definition signals: 480P/60Hz, 720P/60Hz, 1080I/60Hz, except for the table 2 signal. Check if the image (contain HDCP ON and OFF) and sound is normal. Select any a kind of suitable signal and check if the sound is normal when change the sampling frequency of the sound (32K/44.1K/48K). Select any a kind of suitable signal and check if the image is normal when change the picture formats (RGB/YUV4:4:4/YUV4:2:2). Input DVI signal through DVI-HDMI trans-connection wire, input audio signal from DVI/VGA AUDIO and check if it is normal.

Table 2 VGA signal format

No Resolution H-frequency(kHz) V-frenquency(Hz)

720 X 400 31.469 70.086 28.322 IBM

2 640 X 480 31.50 60.00 25.18 DOS

640 X 480 37.90 72.00 31.50 VESA

4 640 X 480 37.50 75.00 31.50 VESA

640 X 480 43.30 85.00 36.00 VESA

6 800 X 600 35.16 56.25 36.00 VESA

800 X 600 37.90 60.00 40.00 VESA

8 800 X 600 46.90 72.19 49.50 VESA

800 X 600 48.08 75.00 50.00 VESA

10 800 X 600 48.08 85.00 56.25 VESA

1024 X 768 48.40 60.00 65.00 VESA

12 1024 X 768 56.50 70.00 75.00 VESA

13 1024 X 768 60.00 75.00 78.75 VESA

Point clock pulse frenquency(MHz)

Remark

6 Ex-factory preset

There are 6 items in the factory menu: Adc Calibrate, White Balance, Picture mode, Audio, Result, Backlight. Except for Adc Calibrate and White Balance, the data of the other items is fixed by software and do not need to change at normal situation.

Table 3 Picture analog setting

CVBS Vivid Standard Movies Pro Custom

Contrast 30 25 20 30 25

Brightness 20 25 20 30 25

Saturation 30 25 20 26 25

Tint 25 25 25 25 25

Sharpness 25 25 25 30 25

YPBPR Vivid Standard Mild Pro Custom

Contrast 30 25 20 30 25

Brightness 20 25 20 30 25

Saturation 30 25 20 26 25

Tint 25 25 25 25 25

Sharpness 25 25 25 30 25

D-SUB Vivid Standard Mild Pro Custom

Contrast 30 25 20 30 25

Brightness 20 25 20 30 25

Saturation 30 25 20 26 25

Tint 25 25 25 25 25

Sharpness 25 25 25 30 25

HDMI Vivid Standard Mild Pro Custom

Contrast 30 25 20 30 25

Brightness 20 25 20 30 25

Saturation 30 25 20 26 25

HDMI Vivid Standard Mild Pro Custom

Tint 25 25 25 25 25

Sharpness 25 25 25 30 25

Note: in the status of factory (P2), it can change the settings of the preset picture and sound modes; in the other status, adjusted settings are stored in Custom mode.

7 Preset ex-factory of user menu

Enter “setting→ reset all”, press “ok“ to select “reset”, turn off the power after turn on guide display.

Working principle analysis of the unit

1. Starting of the system

The system adopts 264MHz, 32bit MIPS CPU of Linux operating system. It needs bootstrap routine to start the unit after power-on, which stored in N142 (serial Flash in the block diagram). After bootstrap routine finish, start the Linux operating system and application programs from N141 (Nand Flash).

2. Video signal flow

Antenna reception signal send to digital-analog integrative tuner (contain HF and IF amplifier circuit), which integrate decoder for analog NTSC, direct output NTSC composite video signal, and integrate digital IF amplifier circuit. The tuner is controlled by the command (SDA and SCL) of N1 (X240H), select appropriate channel to store the signal into X240H. For the channel resource is fixed, it can’t transmit the analog and digital program at the same time, X240 reception signal from the tuner is analog CVBS (NTSC program) or the digital differential IF signal (ATSC/Clear QAM program), only one of them. The digital IF signal is demodulated and MPEG decoded in X240. AV and S-video signal via matched component direct send to N1 (X240H) video switch, A/D conversion and digital decode; YPbPr via matched component send to video switcher N701(PI5V330Q), the selected signal and D-Sub signal send to N502 (AD9880) ADC, then output 24bit RGB/YCbCr 4:2:2 to N1; HDMI also via N502 (AD9880) output 24bit YCbCr 4:2:2 to N1. The all video signals (contain DTV video) send to X240H image scale and OSD superposition, then output RGB signal of 24bit to LVDS switcher N561 (THC63LVDM83R), in there the signal is converted into 3 pairs low voltage differential signals and 1 pair clock signal, then send to LCD panel.

3. Audio signal flow

Sound signal (SIF, AV sound, YPbPr and D-Sub) via NB04 HEF4052BT (sound diverter switch) to output signal, it send to N201 (MPS4440G on 53# board) sound processing and switch of audio, select I2S digital audio signal, send to X240H video-sound synchronization, then send back to N201. Likewise, I2S audio signal of HDMI send to X240H video-sound synchronization, then send back to N201. At last, sound signal send to N201 D/A convert and process of sound effect. Select left/right audio channel, their send to sound amplifier NV01 (TPA3008) amplify, then send to speaker.

4. Function of ATMEGA 8

a. key scan and infrared control b. power on/off c. VGA control d. Brightness control of backlight e. Timing N801 communicates with N1 (X240) by UART

Block diagram

YPbPr1

YPbPr2

VGA RGB/YCbCr 24Bit RS-232

HDMI

I2SII (HDMI) USB

SPDIF

AV 1 / S

AV 2

Digital IF 24Bit

TUNER

CVBS

BKL Control

BKL-EN

V-AV OUT

PowerControl

SIF I2S I I2S

UART KEY

L/R-AVOUT IR

L/R-AV1

L/R-AV2

L/R-VGA/DVI

L/R-YPbPr1

L/R-YPbPr2

HDTV SW.

PI5V330

RECEIVER

AD9880

VIDEO SW.

PI5V331

AUDIO SW.

HEF4052

Serial FLASH

512K

AUDIO

PROCESSOR

MSP4440

LCD TV

CONTROLLER

X240H

AND FLASH

16/32M

RGB

AUDIO AMP.

TPA3008

HP AMP

JW1109

DDR SDRAM

32/64/128M

LVDS

THC63LVDM83R

LCD

PANEL

MEGA8

SPEAKER

HEAD

PHONE

IC block diagram

1. X240H

Block diagram is below:

Function of X240H:

1) Decoder of VSB/QAM, control of TUNER

2) 264MHz, 32bit MIPS CPU

3) MPEG decoder and format switch of HD and SD

4) NTSC Video Decoder with 3D Comb

5) USB 1.1 interface

6) Two I2S input/output

7) S/PDIF output

2. AD9880

The AD9880 offers designers the flexibility of an analog interface and High-Definition Multimedia Interface (HDMI) receiver integrated on a single chip. Also included is support for High bandwidth Digital Content Protection (HDCP).

Main pins instruction: 83, 84: SCL, SDA 49, 50: DDCSCL, DDCSDA, connect with E2PROM (store EDID) and external HDMI 51, 52: MCL, MDA, connect with E2PROM (store HDCP KEY) 66, 71, 77: R, G, B input for VGA 68, 74, 79: YPbPr input 90: PIXCLK 24 bit digital signal

3. MSP4440G

Main pins instruction: 2, 3: SCL, SDA 27, 28: left-right audio of audio power amplification 24, 25: left-right audio of earphone 36, 37: left-right audio of AV OUT 67: SIF input of TV

4. THC63LVDM83R

The THC63LVDM83R transmitter converts 28bits of CMOS/TTL data into LVDS (Low Voltage Differential Signaling) data stream. A phase-locked transmit clock is transmitted in parallel with the data streams over a fifth LVDS link. At a transmit clock frequency of 85MHz, 28bits of RGB data and 4bits of LCD timing and control data (HSYNC, VSYNC, CNTL1, CNTL2) are transmitted at a rate of 595Mbps per LVDS channel. Also available is THC63LVDM63R that converts 21bits of CMOS/TTL data into LVDS (Low Voltage Differential Signaling) data stream. Both transmitters can be programmed reduced swing LVDS through a dedicated pin for low power consumption and EMI.

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