Sanyo AVP4232 -PDP NTSC-M, ATSC Schematic

FILE NO.

SERVICE MANUAL AVP4232

PRODUCT CODE No.

PDP TV

1 682 345 30: NTSC-M, ATSC

REFERENCE No.:SM0915029

CONTENTS

Safety precautions………………………………………………………………………..… Alignment instructions …………………………….…….………………………………… 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 7 14 15 16 26 27 32

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

servicing please read the following points carefully.

Safety Precautions

Please read the “Points for attention for the Maintenance & Repair of PDP” and “Criterion for Identifying the Defects on Screen” as below, before inspecting and adjusting the TV set.

1. “Points for attention for the Maintenance & Repair of PDP”

To avoid possible danger, damage or jeopardy to health and to prevent PDP screen from new damage, the maintenance people must read the following carefully. If they ignore the following warnings, there will be deathful risks:

1.1 Screens vary from one model to another and therefore not interchangeable. Be sure to use the same type of screen in the replacement.

1.2 The operation voltage is approximately 350V for PDP module (including screen, driving circuit, logic circuit and power module). If you want to conduct maintenance work on PDP module when the set is in normal operation or just after the power is off, you must take proper measures to avoid electric shock and never have direct contact or touch with the circuitry of the working module or metal parts. That’s because within a short time relatively high voltage still remains on the capacitor of the driving part even after the power is off. Make sure to begin relevant maintenance operation at least one minute after the power is off.

1.3 Don’t apply on the module any power supply that is higher than the specification. If the power supply used deviates from the value given in the specification, there might be a possibility of leading to fire or damage to the module.

1.4 Never have operation or mounting work under unsuitable environment such as areas in the vicinity of water – bathroom, laundry, water chute of kitchen – sources of fire, heat-radiation parts or direct exposure to sunlight. Otherwise there will be kickbacks.

1.5 In case foreign substances such as water, liquid, metal slices or others fall into the module carelessly power must be cut off immediately. Keep the module as it is and do not move anything on the module. Otherwise it might be possible to contact the high voltage or cause shock short circuit so that it may lead to fire or electric shock.

1.6 If there is smoke, abnormal smell or sound from the module, please cut the power off immediately. Likewise in case the screen doesn’t work when the power is on or during the operation, please also cut off the power at once. No more operation in this case.

1.7 Do not remove or plug its connection wire when the module is in operation or right after the power is off. That’s because there remains a relatively high voltage on the capacitor of the driving circuit. If there is a need to remove or plug in the connection wire, please wait at least one minute after the power is off.

1.8 Considering the module has a glass faceplate, please avoid extrusion by external force lest it should cause glass breakage that may get people injured. Two people are needed in cooperation to move this module lest contingency takes place.

1.9 The complete TV set is designed on the basis of full consideration of thermal dissipation by convection, with the round hole on the top for heat emission. To avoid overheat, please do not have any covering on the hole during normal operation and never put it in the place where the space is narrow and in bad ventilation.

1.10 There is quite a number of circuits in PDP that are integrated ones. Please be on guard against static electricity. During maintenance operation be sure to cover yourself with anti-static bag and before operation make sure to have it sufficiently grounded.

1.11 There are a big number of connection wires distributed around the screen. Please take care not to touch or scuff them during maintenance or removing the screen, because once they are damaged the screen will fail to work and it’s not possible to repair it. If the connection wires, connectors or components fixed by the thermotropic glue need to disengage when service, please soak the thermosopic glue into the alcohol and then pull them out in case of damage.

1.12 Connector for the circuit board of the screen part is relatively fine and delicate. Please take care in the replacement operation lest it should get damaged.

1.13 Special care must be taken during transportation and handling because strenuous vibration could lead to screen glass breakage or damage on the driving circuitry. Be sure to use a strong outer case to pack it up before transportation or handling.

1.14 Please put it for storage in an environment in which the conditions are under control so as to prevent the temperature and humidity from exceeding the scope stipulated in the specification. For prolonged storage please cover it with anti-moisture bag and have them piled and stored in one place. The environmental conditions are tabulated as below:

Temperature Scope for operation 0~50centigrade Scope for storage -15~60centigrade Humidity Scope for operation 20%~80% Scope for storage 20%~80%

1.15 If a fixed picture is displayed for a long time, difference in its brightness and color may occur compared with movable pictures. But it doesn’t show any problem and the reason is that there is reduced density of fluorescent powder in the former. On the other hand, even if changes take place in the picture, it can keep its brightness for a period of time (several minutes). It’s a feature inherent with plasma and it’s not abnormal. However please try as much as possible to avoid showing a still picture of high brightness for a long time during operation.

1.16 As a digitalized display devise, this module is provided with error diffusion technology and the gray scale and false enhancement of contour can be displayed by reusing of sub-field. As compared with cathode ray tube, it can be found in the moving picture that at the brim of the face of a person there are some wrong colors.

1.17 During the display of graph (indicating the gradual change in brightness horizontally or vertically) resulting from gray scale test it can be found that the brightness for the two adjacent levels is uneven. This is caused by the reuse of sub-field, the display of load rectification and the electrolysis.

1.18 The screen front plate is of glass. Please make sure that the screen has been put in place during erection. If it is not in place before the erection begins it may lead to screen crack or breakage.

1.19 Make sure the screw used in the mounting of the screen is of the original specs lest it should cause damage to the screen due to mismatch. Special care should be taken not to use too long or too big screw.

1.20 Care must be taken to guard against dust during assembling or dismantling, especially to avoid

dirt from falling in between the screen and the glass lest it should harm the receiving and viewing effect.

1.21 There is piece of insulator stuck on the rear chassis corresponding to the power supply board. It is used to isolate the cool part from the hot part. Please take care to keep it intact lest it should become a potential safety trouble.

1.22 In addition to plasma screen, the glass is a part of high value. It has such functions as anti-radiation, adjustment of color temperature etc. Please handle it carefully.

Alignment instructions

1. Test equipment

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

2 Alignment flow-chart

The alignment flow-chart is shown as fig-1

Connect to the center signal source and check if various functions of TV (station leaking, analog control), earphone and speaker output are normal

Input AV/SVIDEO signal source and check the functions

Input HD signal source and check the function

Input VGA signal source and check the display, various functions (analog control) and H/V center.

Input HDMI signal source and check the display, various functions (analog control) and H/V center.

Insert the USB device and check the function

Check if DDC and FLASH are written

Produce the digital processing board

Combined test for general assembly

White balance adjustment

Preset ex-factory

Check the accessories and pack

Fig-1 adjustment flow-chart

3 Unit adjustments

Connect all the boards according to wiring diagram, connect with power and observe the display.

3.1 Method for using factory menu: a) Press “INPUT”, “2”, “5”, ”8” and “0” in turn to enter level-one 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) When the cursor move to a certain adjust item, press “ VOL+” and “VOL –“ to adjust value; e) Press “MENU” to exit to the level-one factory menu; f) Press “EXIT” to exit the factory menu. g) After exit the factory menu, press “SLEEP” to enter the factory menu again as long as power on. h) “Power on mode” item of “Otherseting” menu: on= turn on; off =standby; memory=memory

function of turn on

3.2 White balance adjustment

3.2.1 Before adjustment Before adjustment, the unit should keep working for over 30 minutes to be in a stable status. a) In VGA channel, input VESA800*600/60HZ chessboard signal(VG848 Timing 854, pat 914),

enter user menu ADVANCE and perform AUTO to let picture display integrity, enter the factory

menu ADC Setting and perform ADC AUTO to do ADC correction. b) In YPbPr channel, input 480i/60HZ 75%color bar and gray scale signal (VG848 Timing 968, PAT

918), enter the factory menu ADC Setting and perform ADC AUTO.

3.2.2 Four groups white balance adjustments (HDMI and VGA) Allowable error range is below: a) 12000K: The white balance error range of the gray scale lower than 10IRE: X=(-15, +15) Y=(-50, +50) The white balance error range of the gray scale between 10IRE and 30IRE: X=(-10, +10) Y=(-20, +20) The white balance error range of the gray scale higher than 30IRE: X=(-5, +5) Y=(-15, +15) b) 9300K: The white balance error range of the gray scale lower than 10IRE: X=(-15, +15) Y=(-50, +50) The white balance error range of the gray scale between 10IRE and 30IRE: X=(-10, +10) Y=(-20, +20) The white balance error range of the gray scale higher than 30IRE: X=(-5, +5) Y=(-15, +15) c) 6500K: The white balance error range of the gray scale lower than 10IRE: X=(-15, +15) Y=(-50, +50) The white balance error range of the gray scale between 10IRE and 30IRE: X=(-10, +10) Y=(-20, +20)

The white balance error range of the gray scale higher than 30IRE: X=(-5, +5) Y=(-15, +15) For BESTBUY, it needs to check if the white balance of 50IRE gray scale is up to the mustard at 9300K and 6500K (BBY channel of CA210).

3.2.2.1 ATV channel adjustment (same for AV, S-VIDEO) Input 21-channel signal to the TV AIR, enter the factory menu “Color Temp”, set “Color Mode” to COOL, 1 1-gray scale will display, fixed G GAIN, adjust R GAIN, B GAIN to let the color coordinate of the ninth level be (272, 278); fixed G OFF, adjust R OFF, B OFF to let the color coordinate of the third level be (272, 278). Adjust R GAIN, B GAIN, R OFF and B OFF repeatedly until the value of the two levels gray-scale are (272, 278) then press MENU return to the previous menu or press SAVE TO EEPROM to store the value. Check if the color temperature of NORMAL and WARM is up to the mustard, if not, adjust R-GAIN/B-GAIN/R-OFF/B-OFF till accord with the requirement.

3.2.2.2 DTV channel adjustment (same for HDMI) Input 26-channel signal to the TV AIR, enter the factory menu “Color Temp”, set “Color Mode” to COOL, 1 1-gray scale will display, fixed G GAIN, adjust R GAIN, B GAIN to let the color coordinate of the ninth level be (272, 278); fixed G OFF, adjust R OFF, B OFF to let the color coordinate of the third level be (272, 278) then press MENU return to the previous menu or press SAVE TO EEPROM to store the value. Check if the color temperature of NORMAL and W ARM is up to the must ard, if not, adjust R GAIN/ B GAIN/R OFF/B OFF till accord with the requirement.

3.2.2.3 YPbPr channel adjustment Input 1920*1080I/60Hz 8-level gray scale signal of VG848 to YPbPr, enter the factory menu “Color Temp”, set “Color Mode” to COOL, fixed G GAIN, adjust R GAIN, B GAIN to let the color coordinate of the seventh level be (272, 278); fixed G OFF, adjust R OFF, B OFF to let the color coordinate of the second level be (272, 278). Adjust R GAIN, B GAIN, R OFF and B OFF repeatedly until the value of the two levels gray-scale are (272, 278) then press MENU return to the previous menu or press SAVE TO EEPROM to store the value. Check if the color temperature of NORMAL and W ARM is up to the must ard, if not, adjust R GAIN/ B GAIN/R OFF/B OFF till accord with the requirement.

3.2.2.4 VGA channel adjustment Input 800*600/60Hz 8-level gray scale signal of VG848 to VGA, enter the factory menu “Color Temp”, set “Color Mode” to COOL, fixed G GAIN, adjust R GAIN, B GAIN to let the color coordinate of the seventh level be (272, 278); fixed G OFF, adjust R OFF, B OFF to let the color coordinate of the second level be (272, 278). Adjust R GAIN, B GAIN, R OFF and B OFF repeatedly until the value of the two levels gray-scale are (272, 278) then press MENU return to the previous menu or press SAVE TO EEPROM to store the value. Check if the color temperature of NORMAL and W ARM is up to the must ard, if not, adjust R GAIN/ B GAIN/R OFF/B OFF till accord with the requirement.

4 Performance check

4.1 TV function Connect RF terminal with central signal source, enter CHANNEL menu and perform auto search, check if there are channels be skipped. Check the speaker and the picture. Especially notice that the single should include NTSC and ATSC.

4.2 A V/S-Video terminals

Input AV/S signal, check if the picture and sound is normal.

4.3 YPbPr/YCbCr terminal Input YUV signal (VG848 signal), separately input the signal of table1 and check if the display and sound is normal.

Table1 YUV signal format No. Resolution 1

2 3 4 5 6 7 8

720x480i 15.734 59.94/60 13.5 480i 720x480p 31.469 59.94/60 27.00 480p 1280x720p 44.96 59.94 74.18 720p(59p) 1280x720p 45.00 60.00 74.25 720p(60p) 1920x1080i 33.75 59.94 74.25 1080i(59i) 1920x1080i 33.75 60.00 74.25 1080i(60i) 1920x1080p 67.5 60 149.00 1080p(60p) 1920x1080p 67.43 59.94 148.35 1080p(59p)

H-frequency (kHz)

V-frequency (Hz)

Pixel clock pulse frequency (MHz)

Remark

4.4 VGA terminal Input the VGA signal (VG848 signal generator), separate input format signal of table1 and table2 and check the display and sound. If the image is slight deflection of the H-field, press “Advance” of OPTION menu to do auto correction.

Table2 VGA signal format

No. Resolution

720x400 31.469 70.086 28.322 IBM (1)

640x480 31.469 59.94 25.175 IBM

800x600 37.879 60.317 40 VESA

1024x768 48.363 60.004 65 VESA

1360x768 47.71 60.01 85.50 VESA

H-frequency (kHz)

V-frequency (Hz)

Pixel clock pulse frequency (MHz)

Remark

4.5 HDMI terminal Input HDMI signal (VG848 signal generator), separate input signal of table1 and check the display and sound.

4.6 presetting before ex-factory Enter the factory menu and select SHIPMENT, the unit will preset the data automatically. Perform the step after factory menu adjustment. SHIPMENT will perform the steps below:

1) Clear the program information of the channel

2) Clear VCHIP information

3) Default setting of user analog

4) Menu Language is English

5) Set AIR/CABLE to AIR

6) Power on mode is Off

Method of software update

Please follow listed below steps:

1. Copy all files to your computer, Include three files ISP_Tool_V43.exe: Debug Tool software for Dynex to update Dynex_32HV36_new.bin: New software for Dynex 32 LCD， (Note: Maybe the update filename no as same as Dynex_32hv36_new.bin, the filename only for example) Dynex32_software_update.doc: Document of software update

2. Cable Connect

The debug tool board one port connect your computer LPT, the other port connect to

Dynex32LCD RS232.

3. Connect the Dynex to Power Socket. The Power LED will turn Red. You can update the software at TV Power on of TV Standby.

4. Run Debug Tool Software Double click the file of ISP_Tool_V43.exe , then you can see the follow picture.

5. Click the icon of Device (If not the first time to run this software we can skip step 5)

Set the Device information as below

6. Click the icon of Connect

7. If cable connect is ok, you can get the follow picture. If failure please double check the cable connect and try again.

8. Click the icon of Read

Click the follow Icon of Read

to Select the update software for Dynex

Select Open Icon. Then will appear the follow picture.

Open

9. Click the Icon of Auto

Then will appear the follow picture

Please click the Icon of Run, the software will be updated to Dynex. It will take about 10 minutes.

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