Sanyo DP40142 Schematic

FILE NO

SERVICE MANUAL
LED TV

LED-DP40142

PRODUCT CODE No.:
CHASSIS NO. : P40142-00

REFERENCE No.: SM0945018-00

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

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5

11

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14

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

please read the following points carefully.

Safety precautions

servicing

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 high voltage. 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 installations 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 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.

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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 ~+ 35 oC

Humidity Scope for operation 20% ~ 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.

Scope for storage

Scope for storage 5% ~ 90%

0 ~+ 60oC

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 nece ssary to use specified screw lest it sh ould 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.

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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

Pin10,11,

12

4.75-

5.25V

Pin13 Pin14 Pin15 Pin16

On:2V-5.5V

Off: 0-0.5V

<0.5V

2.5-5V
PWM

2-5V

P802 Pin1,2 Pin3,4 Pin5,6,7 Pin8,9

Voltage GND 22.8-25.2V GND

11.4-

12.6V

For40”

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

Table2 voltage data of P803

For40”

P803 Pin1,2,3,4,5 Pin6,7,8,9,10 Pin11 Pin12 Pin13 Pin14

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

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(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

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

Preset ex-factory

Check the accessories and packing

Fig-1 adjustment flow-chart

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(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 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.

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.

Notice:

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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 (For factory used only, don't do it 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

MODE

15.734 1716 Negitive 27 1440 124 114

59.94Hz 720x480i

LINE(kHz)

FRAME

(Hz)

59.94 525 Negitive 480 3 15

LINE (pixel)

FIELD
(lines)

LINE

FIELD

8

(MHz)

LINE (pixel)

FRAME

(lines)

LINE (pixel)

FRAME

(lines)

LINE (pixel)

FRAME

(lines)

59.94Hz 720x480P

60Hz 1280x720P

60Hz 1920X1080i

60Hz 1920X1080P

31,469 858 Negitive 27 720 62 60

59.94 525 Negitive 480 6 30

45 1650 Positive 74.25 1280 40 220

60 750 Positive 720 5 20

33.75 2200 Positive 74.25 1920 44 148

60 1125 Positive 1080 5 15

67.5 2200 Positive 148.5 1920 44 148

60 1125 Positive 1080 5 36

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

FREQ FREQ PERIOD

MODE

VGA 60Hz 31.469 800 Negitive 25.175 640 96 40

640x480 59.94 525 Negitive 480 2 25

SVGA 60Hz 37.879 1056 Positive 40 800 128 88

800x600 60.317 628 Positive 600 4 23

XGA 60Hz 48.363 1344 Negitive 65 1024 136 160

1024x768 60.004 806 Negitive 768 6 29

SXGA 60Hz 63.981 1688 Positive 108 1280 112 248

1280x1024 60.02 1066 Positive 1024 3 38

WXGA 60Hz 47.776 1664 Negitive 79.5 1280 128 192

1280x768 59.87 798 Positive 768 7 20

WXGA 60Hz 47.712 1792 Positive 85.5 1360 112 256

1360x768 60.015 795 Positive 768 6 18

59.94Hz 720x480i 15.734 1716 Negitive 27 1440 124 114

59.94 525 Negitive 480 3 15

LINE(kHz)

FRAME(Hz)

LINE (pixel)

FIELD(lines)

SYNC

POLARITY

LINE

FIELD

PIXEL

CLOCK

(MHz)

Display

LINE (pixel)

FRAME

(lines)

SYNC

WIDTH

LINE (pixel)

FRAME

(lines)

BACK

PORCH

LINE (pixel)

FRAME

(lines)

59.94Hz 720x480P 31.469 858 Negitive 27 720 62 60

59.94 525 Negitive 480 6 30

60Hz 1280x720P 45 1650 Positive 74.25 1280 40 220

60 750 Positive 720 5 20

60Hz 1920X1080i 33.75 2200 Positive 74.25 1920 44 148

60 1125 Positive 1080 5 15

60Hz 1920X1080P 67.5 2200 Positive 148.5 1920 44 148

60 1125 Positive 1080 5 36

24Hz 1920x1080P 27 2750 Positive 74.25 1920 44 148

24 1125 Positive 1080 5 36

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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 detects 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.

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3. Working principle analysis of the unit

1. NTSC signals flow:
Antenna signal will be sent to tuner ENV56U05D8F,then Tuner will demodulate and output
standard video signal TV-CVBS, and sound SIF signal.
TV-CVBS will be sent to the master control IC ZR39748 for 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 wi ll be tr an sf or m in to di gi ta l I 2S sig na l and sent
to digital amplifier TAS5707L.

2. C o mposi te /Component signal flow
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 term i na l via matched resistance is fed to ZR39748 to bass
adjust and volume control, the sound signal will b e t r a n s f o r m i n t o di g i t a l I 2 S s i g n a l and sent
to digital amplifier TAS5707L.

3. HDMI signal flow
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 ZR39748
to bass adjust and volume control, the sound signal will be transformed into digital I2S
s i g n a l and sent to digital amplifier TAS5707L.

4. USB signal flow
USB signal via USB connector sent to Z R 39 7 4 8 and its A/D conversion to YPbPr output for
ZR39748, then output R/G/B of 24 bit to back end module to Video decode, de-interlace
an d image scale, then send to LVDS level drive for panel display.

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4. SSB40T 40” Block Diagram

4-1 Block Diagram

IR Board

IR

SSB40T 60Hz

Main Board

Flash
32Mb

HDMI HDMI

HDMI 2

HDMI 1

HDMI 2
HDMI 1

DTV system IC

USB I/F

DDR2 512Mb -1066

Zoran

ZR39748

Composite

Panel out

R_out

Audio

AMP

TAS5707L

LVDS out

Audio output

Tuner IF +/-

Digital audio out

Composite audio In
Component audio In

Component

L-out

Keypad

USB

USB 1

Y

Pb Pr

/CVBS

Component / Composite

Panasonic tuner

Coaxial

RL

Coaxial

OUT

RF

ANT /

CABLE

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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

• Audio Inputs

• 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

• External 16-bit DDR2 Required

• DDR2-800 for most design configurations

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• DDR2-1066 for 1080p with overdrive designs

• 64MByte typical for most designs

• Power

• 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)
developed 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
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.

® 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

• High performance CPU

• 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

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• 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

• Image processing

• Up to 10-bit processing

• De-interlacing

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

• 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

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- Letterbox support

- Pan and Scan support

- 10-bit processing

• Vertical scaler

- 5-tap FIR, 64-phase FIR

- Programmable up scaler [64x]

- Programmable down scaler [1/32x]

1.2.3. Video Input

• Integrated HDMI link and PHY

• Three physical ports (BGA package)

- One physical port (QFP package)

• Single instance of the PHY

• HDMI v1.4a-compliant

• Supports up to 1080p input resolution

• Standby power CEC monitor

• Supports all DTV resolutions (480i/576i/480p/576p/720p/1080i/1080p)

• Capable of carrying IEC61937 compressed audio (Dolby Digital, etc.)

• Integrated High-bandwidth Digital Content Protection (HDCP) cipher

• Direct capture of video, audio, and control information in distinct memory buffers

• Integrated high definition (HD) capture/video inputs

• Color space conversion

• Downscaling to either 4:2:2 or 4:4:4 output to memory

• One (1) YPbPr input

- Up to 165MHz sample rate (Up to 1080p)

- Sync Modes: sync on green (SOG) or luma (SOY) input, mid-point and sync tip clamping

- SOG or SOY inputs: AC coupled
Low pass filter (500 KHz)
Dynamic range 0.5-2.0V
>1MOhm DC input impedance

- Coast input and support

- Activity/polarity detectors with timing measurement HSYNC present
VSYNC present
SOG/SOY present

• 2nd YPbPr input available using S-Video and SIF lines (BGA package)

• One (1) RGB input

- Separate HSYNC, VSYNC inputs
TTL level-compatible

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