Sanyo DP32242 Schematic

FILE NO

SERVICE MANUAL LED TV

LED-DP32242

PRODUCT CODE No.: 1-130-292-04 CHASSIS NO. :

SSD32TA-00/ P32242-02

REFERENCE No.:SM0945010-02

CONTENTS

1. Safety precautions .................................................................................................

2. Alignment instructions ............................................................................................

3. W orking principle analysis of the unit ...................................................................

4. Block diagram ......................................................................................................

5. IC block diagram ..................................................................................................

6. Wiring diagram ...................................................................................................

7. T roubleshooting guide ..........................................................................................

8. Schematic diagram ..............................................................................................

APPENDIX-A: Assembly list APPENDIX-B: Exploded View

Removing or Installing the Stand

3 5

14 17

29 33 37

Attention:

please read the following points carefully.

Safety precautions

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

servicing

1. Instructions

Be sure to switch off the power supply before replacing or welding any components or inserting/plugging 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.

not change the specs and type at will.

connection wire Anti static measures to be taken (throughout the entire production

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 protecting right

yourself and the machine when testing the system in the course of normal operation or

after the power is switched off. Please do not touch the circuit or the metal part of the module

high voltage. Be

sure to take proper measures in

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, Otherwise

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. power

2.7 Do not pull out or plug in the connection wire when the module is in operation or just after the

power circuit.

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

kitchen, or nearby fire source, heating equipment and devices or exposure to sunlight etc.

bad effect will result.

Likewise, if the screen is not working after the power is on or in the course of operation, the

must be cut off immediately and no more operation is allowed under the same condition.

off because in this case relatively high voltage still remains in the capacitor of the driving

Please wait at least one minute before the pulling out or plugging in the connection wire.

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 would

If the connection wires, connections or components fixed by the thermo tropic glue need to disengage when service, please soak the thermo tropic glue into the alcohol and then pull them out in case of damage.

the set please take care not to touch or scratch them. Once they are damaged the screen

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 before

2.12 For the storage make sure to put it in a place where the environment can be controlled so as to

prevent prolonged place.

screen glass or damage to driving circuit. Therefore it must be packed in a strong case

the transportation or handling.

the temperature and humidity from exceeding the limits as specified in the manual. For

storage, it is necessary to house it in an anti-moisture bag and put them altogether in one

The ambient conditions are tabulated as follows:

Temperature

Scope for operation

~+ 50

Humidity

2.13

Display of a fixed picture for a long time may result in appearance of picture residue on the

screen, 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.

commonly called “ghost shadow”. The extent of the residual picture varies with the maker

Scope for storage Scope for operation Scope for storage

-20 ~

+ 60oC 20% ~ 5% ~ 90%

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

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

please take care to keep it in intactness so as to avoid hidden trouble.

2. Alignment instructions

(1) Test equipment

VG-859 (YPbPr, VGA, HDMI signal generator) FLUKE 54200(TV signal generator) CA210 (white balancer)

(2) Power test

Connect main board, power board and IR board according the wiring diagram, connect the power and press power key (Remote controller or Keypad) button to turn on the TV.

a) Test the pin voltage of P802/power board , the data is shown in table1:

Table1

voltage data of P802

For32”

P802 Pin1,2

Voltage GND 22.8-25.2V

Test the pin voltage of P803/power board, the data is shown in table2:

Pin3,4 Pin5,6,7

GND

Pin8,9 Pin10 Pin11,12

11.6-

12.8V

Table2 voltage data of P803

For32”

P803 Pin1,2,3,4,5 Pin6,7,8,9,10

Voltage 22.8-25.2V GND NC 2V-5V 2.5-5V PWM NC

Pin11 Pin12 Pin13 Pin14

4.75-

5.25V

On:2V-5.5V

Off: 0-0.5V

Pin13 Pin14 Pin15 Pin16

<0.6V

2.5-5V PWM

2-5V

(3) Alignment flow-chart

The alignment flow-chart is shown as fig-1

Connect to the center signal source and check each

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

Check the output of speaker.

Check if DDC, HDCP KEY, FLASH are written

Combined test for general assembly

White balance adjustment

Input AV signal and check the function

Input HD signal and check the function of YPbPr

Input USB signal and check if the display is normal, check

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

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

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

Preset ex-factory

Check the accessories and packing

Fig-1 adjustment flow-chart

(4) Adjustment instruction

At any input source then press the “←”, “EXIT” and “OK” (Remote control) to enter factory mode

During Factory menu, if “MENU” key is pushed, system will exit factory mode.

(5) Items of Factory menu

When in PC/ Component/ Video (Composite)/ ANT inputs then press the “Left -> Exit -> OK” key of remote control to enter factory mode.. During Factory menu, if “MENU” or “EXIT” key is pushed, system will exit factory mode. Press up and down key can move high light item from Color Temperature -> Timer Clear -> Preset Channel>NVRAM Clear-> Full Power -> Source Calibration -> Reset to Default -> RF Burn In -> USB F/W Upgrade -> UART Enable-> Bypass Gamma. The Timer Clear, NVRAM Clear and Reset to Default items will have a check dialog “yes or no” to do or not. Push “Enter” key can select high light item function. (Press left and right can adjust value) Display panel Burn in Time on the bottom. Display model name, firmware version and released date on top.

1) Factory Color Temp data edit This is used for Factory adjusts color temperature. Don't change this value.

2) Timer Clear Reset the timer which records hours of LCD panel burn in. (Don't clear timer after FW update.) This item will have a check dialog “yes or no” to do or not.

- Time in factory mode: Time function shall be displayed automatically. Saving the total time of system power on (LCD turn on), and count the time automatically. The timer is continuous and saved (per 60 minutes) forever, unless it will be reset by doing “Timer Clear”.

3) Preset channel

Load preset channel for production line. (Refer 4.4.4 Preset channel table).

4) NVRAM CLEAR

Initialize program’s default values to NVRAM for following adjustment items accuracy. In factory mode it is the first and important step to make sure all values are default value and correct

- Reset settings: Gamma table, Channel table (Favorite channel, Channel label etc.), Model table (H/V Position, Clock, Phase), Source dependent setting (Contrast, Brightness etc.), Common setting (Volume, Language etc.), Parental Control (Rating, Password etc), Closed Caption.

To avoid a mistake initial process after factory setting is done. This item will have a check dialog “yes

or no” to do the initial or not.

LINE (pixel)

Notice: After this item is processed then the DUT needs to be powered off then AC powered off.

5) Full power (For factory test only) This is for power consumption testing. To measure the maximum power consumption of TV set, we adjust the value of following items to

maximum.

- Video: Contrast maximum value, Brightness maximum value, Backlight maximum value.

- Audio: Volume maximum value, Bass default value, Treble default value. Press enter key to turn on Full Power and OSD stay display until press enter key to recover from Full Power

6) Source Calibration ( without correct machine). Source Calibration (gain/offset) must be adjusted color by firmware automatic adjustment in PC, and Component input source. This item will have a result dialog “OK” or “NG”.

7) Reset to Default Reset all settings of OSD menu to default value.

- Reset settings: Channel table, Model table (H/V Position, Clock, Phase), Source dependent setting (Contrast, Brightness etc.), Common setting (Volume, Language etc.), Parental Control (Rating, Password etc), Closed Caption.

- Please execute Reset to Default once after FW is upgraded.

8) RF Burn In (For factory test only)

Use “snow” pattern for burn in. Selected items are “On” and “Off”. While turn on burn in mode, firmware will automatically turn off “Auto power off” function. If there is no power supply suddenly, firmware will re-enter burn in mode automatically when power

supply is back

Pressed the “Power” key, firmware will automatically turn off burn in mode. Burn in mode: Source is “ANT/Cable" and channel is NTSC channel 3.

9) USB F/W Upgrade

- We don't recommend upgrade FW here. We recommend upgrade FW in normal power on status (not in factory menu), just plug in USB with correct FW file name. (Refer to item 7)

Upgrade firmware through USB.

10) UART Enable (For factory test only) Enable to communicate with Auto-Alignment system.

11) Bypass Gamma For factory test value of gamma.

6) Performance check

(

6-1 TV function Connect RF to the center signal source, enter Channel menu → auto tuning, check if there are channels be skipped, check if the picture and speaker are normal.

6-2 AV terminals Input Video signal, check if the picture and sound are normal.

6-3 YPbPr terminal Input YUV signal (VG859 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

FREQ PERIOD

SYNC

POLARITY

PIXEL

CLOCK

Display

SYNC

WIDTH

BACK

PORCH

15.734

MODE

LINE(kHz)

FRAME

(Hz)

LINE (pixel)

FIELD

(lines)

1716

LINE

FIELD

Negitive 27

(MHz)

FRAME

(lines)

1440

FRAME

(lines)

124

FRAME

(lines)

114

59.94Hz 720x480i

3 15

62 60

6 30

5 20

5 15

5 36

96 40

2 25

4 23

6 29

7 20

6 18

3 15

62 60

6 30

5 20

5 15

5 36

59.94Hz 720x480P

60Hz 1280x720P

60Hz 1920X1080i

60Hz 1920X1080P

59.94

31,469

59.94

33.75

67.5

525

858

525

1650

750

2200

1125

2200

1125

Negitive 480

Negitive 27

720

Negitive 480

Positive 74.25

1280

Positive 720

Positive 74.25

1920

Positive 1080

Positive 148.5

1920

Positive 1080

6-4 HDMI terminal Input HDMI signal (VG859 signal generator), separately input the signals listed in table6 and check the display and sound (32 KHz, 44.1 KHz, 48 KHz) at any situation (power on, channel switch and format convert, etc.)

Table6 HDMI signal format

220

148

FREQ FREQ PERIOD

MODE

VGA 60Hz 31.469

640x480 59.94

SVGA 60Hz 37.879

800x600 60.317

XGA 60Hz 48.363

1024x768 60.004

WXGA 60Hz 47.776

1280x768 59.87

WXGA 60Hz 47.712

1360x768 60.015

59.94Hz 720x480i 15.734

59.94

LINE(kHz)

FRAME(Hz)

LINE (pixel)

FIELD(lines)

800 Negitive

525 Negitive 480

1056 Positive 40

628 Positive 600

1344 Negitive

806 Negitive 768

1664 Negitive

798 Positive 768

1792 Positive 85.5

795 Positive 768

1716 Negitive

525 Negitive 480

SYNC

POLARITY

LINE

FIELD

PIXEL

CLOCK

(MHz)

25.175 640

79.5

Display

LINE (pixel)

FRAME

(lines)

800

1024

1280

1360

1440

SYNC

WIDTH

LINE (pixel)

FRAME

(lines)

128

136

128

112

124

BACK

PORCH

LINE (pixel)

FRAME

(lines)

160

192

256

114

59.94Hz 720x480P 31.469

59.94

60Hz 1280x720P 45

60Hz 1920X1080i 33.75

60Hz 1920X1080P 67.5

24Hz 1920x1080P 27

858 Negitive

525 Negitive 480

1650 Positive 74.25

750 Positive 720

2200 Positive 74.25

1125 Positive 1080

2200 Positive 148.5

1125 Positive 1080

2750 Positive 74.25

1125 Positive 1080

720

1280

1920

220

148

6-5 other functions check a) Check the turn on/turn off timer, sleep timer, picture/sound mode, OSD, stereo and analog TV Teletext, etc.

(7) USB Software updated

(1) Insert the USB with the firmware which the file name is matched with the model name in factory

mode.

(2) If system detect the same firmware file name, USB upgrade message would appear automatically. (3) Press Left key to select Yes, and then press OK key to start the upgrading. (4) Upgrading is starting, please wait for the progress finish. (5) When the progress completed, please follow the instruction to remove USB and restart by AC off

then on.

3. Working principle analysis of the unit

NTSC Antenna signal will be send to tuner ENV56U05D8F, output standard video signal TV-CVBS, and sound SIF signal

signals flow:

th en Tu ne r w il l b e

demodulating and

TV-CVBS will send to the master control IC ZR39748 to video decode, de-interlace and scaler, then output LVDS level drive for panel display. The sound IF (SIF) will be fed into ZR39748, after demodulating, pre-amplifying, bass adjusting and volume control, the sound signal digital amplifier

TAS5707L.

2. Composite/Component signal flow

wi ll be tr an sf or m in to dig it al I2 S si gn a l

and sent to

Composite signal and Component signal will be fed to ZR39748 to perform video decode, deinterlace and scaler, then output LVDS drive level for panel display. Audio signal from Composite/Component adjust and volume control, the sound signal will to digital amplifier

3. HDMI signal flow

TAS5707L

terminal

via matched resistance is fed to ZR39748 to bass

b e tr an sf or m int o di gi ta l I2 S si g n a l

and sent

Two HDMI video signals are directly fed to the master control IC ZR39748 to digital decode, image scale, then output LVDS drive level for panel display. HDMI audio signal via decoder built-in to bass adjust and volume control, the sound signal will and sent to digital amplifier

TAS5707L.

b e tr an sf or m in t o di gi ta l I2 S si g n a l

ZR39748

4. USB signal flow USB signal via USB connector sent to ZR39 7 48 , th e n output image scale, then send to LVDS level drive for panel display. Sound signal of USB signal volume control, the sound signal will amplifier

TAS5707L.

ZR3 9 74 8 and it s

R/G/B of 24 bit to back end module to Video decode,

A/D conversion to

YPbPr

output

f or

de-interlace and

vi a

matched resistance

b e tr an sf or m int o di gi ta l I2 S sig na l

a n d

sent to ZR39748 to bass adjust and

and sent to digital

4. SSD32T Block Diagram

4-1 B

lock Diagram

4-2. Power/B block diagram.

a. FSP(1st source) power block diagram.

b. Chicony(2nd source) power block diagram.

5. IC block diagram

1. Zoran ZR748

• Integrated Digital & Analog Demodulator

• 8VSB/QAM-B

• NTSC/BTSC/A2K

• Video Inputs

• Three (3) 1080p HDMI (v1.4a/DC)*

• One (1) 1080p YPbPr

• One (1) VGA, up to WUXGA resolution

• Two (2) CVBS*, One (1) S-Video

udio Inputs

• A

• Five (5) stereo L/R line-level*

• Internal Video/Audio Processing

• NTSC video decoder

• MPEG-2 decoder

• 10-bit video processing

• 1080i motion-adaptive de-interlacer

• ACM-2D color processor

• Graphics blending/overlay

• Audio DSP

• Video Outputs

• Dual-channel LVDS (1080p, up to 10bpp)

miniLVDS & RSDS (6/8bpp, up to 330MHz)

•

• LCD panel timing control signals (TCON)

• Audio Outputs

• One (1) stereo L/R DDX differential

• One (1) stereo L/R single-ended DDX

• Optional up-to-four (4) more single-ended DDX

• Optional up-to-three (3) I2S stereo pairs

• One (1) S/PDIF

• System Processors & Interfaces

• 300MHz system CPU

• TV microcontroller for standby mode

• One (1) USB 2.0

• External SPI Flash Memory: 2-16MByte

• 2-4MB typical for ATSC DTV application

xternal 16-bit DDR2 Required

• E

• DDR2-800 for most design configurations

DDR2-1066 for 1080p with overdrive designs

•

• 64MByte typical for most designs

• P

ower

• 1.1V core voltage, 1.8V memory I/F, 3.3V I/O

• Two Package Options

• 365-ball BGA, 23x23mm2

• 256-pin LQFP with e-pad, 28x28mm2

(*) Slight variation of support with QFP package

1.1. SupraHD® 748 IC Description

The SupraHD® 748 is a member of the SupraHD® family of DTV system-on-chip (SoC)

eveloped by Zoran. This device is intended to be used in ATSC high-definition digital television

implementations. This device includes all of the functionality required to support the television

implementations shown in the following block diagrams.

Figure 2 shows a typical ATSC system implementation using the SupraHD® 748.

Figure 3 shows the detailed block diagram of the SupraHD® 748.

Figure 4 shows the video and audio input/output options of the SupraHD® 748.

1.2. SupraHD® 748 Features

The following sub-sections list the features of the SupraHD® 748 per category. Note that features unique to the BGA package are indicated with a “(BGA package)” designation while QFP package features are indicated with “(QFP package)”.

1.2.1. Embedded Processing Unit

igh performance CPU

• H

• Integrated high-performance MIPS® 4KEc™ CPU operating at 300MHz

• 32-bit MIPS32 enhanced architecture

• 8 K instruction cache, 8 K data cache, (2-way set associative)

• Programmable memory management unit

• Multiply/Divide unit

• Power-down mode (triggered by WAIT instruction)

• EJTAG debug support

• Fully production-tested software suite

• ATSC/NTSC DTV application with customizable OSD

V-Chip for analog and digital channels

•

• PSIP parsing for channel map and EPG

• Analog and digital closed-captioning (EIA-608 and EIA-708)

• Royalty-free Zoran True Fonts for OSD and closed-captioning

•

Transport, video decode (single MP@HL), audio decode (AC-3, MPEG Layer I & II), graphics, and

display drivers

• Drivers for tuner, HDMI and analog inputs

• ThreadX royalty-free RTOS

1.2.2. Video Processing

mage processing

• I

• Up to 10-bit processing

• De-interlacing

- 1080i capable, per-pixel motion adaptive, multiple cadence detection, 8º low-angle interpolation

• Black bar detection

- Horizontal and vertical

• Image quality enhancements

• Noise reduction (up to 1080p)

- Temporal

- Spatial

- Impulse

• MPEG post-processing

- De-blocking

• Adaptive contrast control (histogram-based, fully-programmable)

• Advanced Color Management 2D

• Horizontal luma peaking with coring

• Sharpness control

- Vertical and horizontal LTI

- Horizontal CTI

- Y/C vertical peaking with adaptive coring

•Video scaling and composition

• Horizontal scaler

17-tap FIR, 64-phase FIR

- Programmable up scaler [64x]

- Waterglass scaler

- Programmable down scaler [1/32x]

- Non-linear scaler - 3-segment parabola, 17-tap FIR, 64-phase FIR

- Letterbox support

- Pan and Scan support

- 10-bit processing

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