Sanyo LCD- DP55441 Schematic

FILE NO

SERVICE MANUAL L

CD TV

LCD-

PRODUCT CODE No.: CHASSIS NO. :

P55441-00 P

55441-01

DP55441

113027304

REFERENCE No.:SM0945009-01

CONTENTS

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

2. Alignment instructions and method of software upgrading.....................................

3. Working principle analysis of the unit...................................................................

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

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

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

7. Troubleshooting guide..........................................................................................

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

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

Removing or Installing the Stand

3 5

16 18

20 22 27

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 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.

replacing or welding any components or

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 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

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

bad effect will result.

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 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.

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

~+ 35

Humidity

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 operation Scope for storage

0 ~

+ 40oC

0% ~

0% ~ 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 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.

2. Alignment instructions

2.1. Test equipment

VG-848 (Video, YPbPr and VGA signal generator) VG-849 (

Video, YPbPr, VGA and

HDMI signal generator) FLUKE 54200(TV signal generator) CA210 (white balancer)

2.2. 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

P802 Pin1,2

Voltage

GND 11.6-12.8V

Pin3,4 Pin5,6,7

GND 11.6-12.8V

For55”

Pin8,9 Pin10,11,

4.75-

5.25V

Pin13 Pin14 Pin15 Pin16

On:2V-5.5V

Off: 0-0.5V

<0.6V

2.5-5V PWM

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

Table2 voltage data of P803/P804

For55”

P803/P804

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

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

Pin11 Pin12 Pin13 Pin14

2-5V

2.3. 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 earphone and speaker.

Check if DDC, HDCP KEY, FLASH are written

Combined test for general assembly

White balance adjustment

Input AV/SVIDEO signal and check the function

Input HD signal and check the function of YPbPr

Input VGA 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

2.4. Adjustment instruction

At any input source then press the remote controller buttons “<”, “EXIT” and “>” to enter factory mode. During Factory menu, if “MENU” or “EXIT” key is pushed, system will exit factory mode.

2.4-1. Source Calibration

4-1.1. Set the TV input source to YPbPr; ASTRO-859 signal setting to PG2 program number 933(1080i).

(PG2 mode Timing 933 and Pattern 924 100% Color Bar.)

4-1.2. Entering into factory Mode: Press up or down key of remote control to select “Auto Calibration”, Press

「OK」 key to start.

-> Source calibration performed automatically when finished that will show OK.

4-1.3. Change input source to PC.

Change Astro-859 Timing to No.953 (640x480@60Hz) and pattern on 953(8step V-grayscale). Repeat step 4-1.2 to do source calibration,

2.4-2. Color Temperature Adjustment & Check 4-2.1. Set input source.

Set the signal generator Astro-859 timing to PG2-924 on Video & YPbPr, PG2-860 on HDMI, and PG2-963

on PC. Pattern sets 956 on all of the source.

Then press Astro-859 “FORMAT” key and key, then adjust RGB value to R:204, G:204, B:204

4-2.2. In factory mode OSD menu, select “Color Temperature” item, press “OK” key to enter the item.

R, G, B drive values are set for Warm, Medium, and Cool independently.

4-2.3. Set Color Temperature for “Warm”, “Medium” and “Cool” with following spec table.

Color temperature(for 42")

Color Temp. Cool Medium Warm

x 0.267 y 0.271

Tolerance ± 0.01

0.281

0.288

± 0.01

If the x and y value are larger than specification,

Decrease Red drive from default value. Increase Blue drive from default value.

If the x or y or both x and y value is/are smaller than specification.

Decrease Blue drive from default value

According to a x and y value, please following adjustment of 1 or 2.

1 If x value is higher than spec

Decrease Red drive from default value.

2 If y value is higher than spec,

Increase Blue drive from default value

4-2.4 Exit Factory Mode:

After finishing adjusting color temperature, press [MENU] or [EXIT] to exit factory mode.

0.301

0.310

± 0.01

2.5. Items of Factory menu

Vendor may customize design and add adjustment items Factory menu as far as all required items are included.

Press up and down key can move high light item from Color Temperature Warn -> Color Temperature Medium -> Color Temperature Cool ->Preset Channel-> Source Calibration -> Reset to Default.

The NVRAM Clear and Reset to Default items will have a check dialog “YES” and “NO” to do or not. Push “Enter” key can select high light item function. (Press left and right can adjust value) Display model name, firmware version and released date on top.

5-1) Color Temperature for Warm

Press up or down key can select high light item function. Press enter key to enter the item. Following data for color temp shall be edited manually.

-R, G, B data for each preset.

-Press “Up” or “Down” key to select “R”, “G”, “B” item

-Press “Left” or “Right” key to set the “R”, “G”, “B” value.

-Press “MENU” or “EXIT” item to exit to factory mode

5-2) Color Temperature for Medium

Press up or down key can select high light item function. Press enter key to enter the item. Following data for color temp shall be edited manually.

-R, G, B data for each preset.

-Press “Up” or “Down” key to select “R”, “G”, “B” item

-Press “Left” or “Right” key to set the “R”, “G”, “B” value.

-Press “MENU” or “EXIT” item to exit to factory mode

5-3) Color Temperature for Cool

Press up or down key can select high light item function. Press enter key to enter the item. Following data for color temp shall be edited manually.

-R, G, B data for each preset.

-Press “Up” or “Down” key to select “R”, “G”, “B” item

-Press “Left” or “Right” key to set the “R”, “G”, “B” value.

-Press “MENU” or “EXIT” item to exit to factory mode

5-4) Time Clear

Press up or down key can select high light item function. Press “Left” & “Right” key to select the item. The timer on bottom is to record power on time for panel life. It was set one time on production only.

5-5) Preset Channel

This is for factory to do some tests.

5-6) 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: Channel table, Mode 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 to do the initial or not.

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

5-7) Full Power

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.

Press right key to turn on Full Power and OSD stay display until press enter key to recover from Full Power.

5-8) Source Calibration

Auto Calibration (gain/offset) must be adjusted color by firmware automatic adjustment in PC, and Video3(Component) input source.

This item will have a result dialog “OK” or “NG”.

5-9) Reset to Default

This function is same as “NVRAM Clear”, but it will power off automatically after processing this function.

5-10) RF Burn In

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 “TV”, Input Configuration is “Antenna” and channel is NTSC channel 2.

5-11) USB F/W Upgrade

The function is using USB device to upgrade firmware via USB port. Copy the firmware file to USB device root path. Execute this function to update firmware, the following OSD will display. Note: After finishing updated, the system will reboot automatically

5-12) Protocol Switch

This is for debugging only. It is no use for service.

5-13) EDID Write

This is for writing EDID on the VGA source.

5-14) MEMC Demo Mode

To separate screen into two parts that left side is 60Hz and right side is 120Hz for display.

5-15) MEMC Level

Changing MEMC level to Weak, Medium or Strong.

2.6. Performance check

Signal

name

Table4

Signal mode

Resolution

YPbPr

frequency(Hz)

signal format

Vertical

→

Channel Scan, check if there are channels be

Horizontal frequency

(KHz) (MHz)

Dot clock

frequency

Remarks

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

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

6-3 YPbPr/YCbCr terminal Input YPbPr signal (VG-859 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.)

1 2 3 720P/60 4 1080i/60 1920x1080 60 33.75 74.25 5 1080p/60 1920x1080 60 67.5 148.5

480i 720x480 59.94 15.73 27

480P 720x480 59.94 31.47 27

1280x720 60 45 74.25

6-4

PC(

VGA) terminal

Input

PC(V

GA) signal (VG-859 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 Menu->PC->Auto Adjust to perform auto-correct.

Signal mode

Signal

name

VGA 640 x 480 2 SVGA 800 x 600 3

XGA 1024 x 768

Resolution

Table5

signal format

Horizontal

frequency

Vertical

frequency(Hz)

59.941 31.469 25.175

60.317 37.879 40

60.004 48.363 65

(KHz) (MHz)

Dot clock

frequency

Remarks

W-XGA

5 6 SXGA 1280 x 1024

1280 x 768 1360 x 768

59.87 47.776 79.5

60.015 47.712 85.5

60.02 63.981 108

6-5 HDMI terminal Input HDMI signal (VG-859 signal generator), separately input the signals listed in table6 and check the display and sound (32KHz, 44.1KHz, 48KHz) at any situation (power on, channel switch and format convert, etc.)

Table6

HDMI

signal format

1 2 3

Signal mode

Signal

name

VGA 640 x 480 59.94 31.469 25.175

SVGA 800 x 600 60.317 37.879 40

XGA 1024 x 768 60.004 48.363 65

Resolution Vertical frequency(Hz) (KHz) (MHz)

Horizontal

frequency

Dot clock

frequency

Remarks

W-XGA

5 6

SXGA 1280 x 1024 7 8 9 720P/60

10 1080i/60 1920x1080 60 33.75 74.25 11 1080p/60 1920x1080 60 67.5 148.5 12 1080p/24 1920x1080 24 27 74.25

480i 720x480 59.94 15.734 27

480P 720x480 59.94 31.5 27.03

1280 x 768 59.87 47.776 79.5 1360 x 768 60.015 47.712 85.5

60.02 63.981 108

1280x720 60 45 74.25

6-6 other functions check a) Check the turn on/turn off timer, sleep timer, picture/sound mode, OSD, stereo and analog TV Close Caption, V-

Chip, etc.

3. Working principle analysis of the unit

1. NTSC/ATSC signal flow: Antenna reception NTSC/ATSC signal will be send to tuner U32, demodulating and output These

differential IF+ IF- signal interlace and scaler, then output LVDS level drive for panel display. The

differential signals amplifying, bass adjusting and volume control, the sound signal will I2S signal by

scaler

2. AV VIDEO signal flow Video path AV signal switch

differential IF+ IF- signal .

will send to the master control IC U1 to video/MPEGII decode, de-

will be fed into U1 to demodulate audio signals , after demodulating, pre-

and sent to digital amplifier U5 amplifying,

by menu “Inpput list”

then Tuner will be

be transform into digital

then output to speaker.

via terminal socket, the signal and the Video1 path AV signal will be fed to U1 to perform video decode, de-interlace and scaler, then output LVDS drive level for panel display. Audio signal from AV the sound signal will be amplifying,

output to speaker.

3. PC/YPrPb signal flow

terminal

via matched resistance is fed to U1 to bass adjust and volume control,

transfered into digital I2S signal by scaler IC

and sent to digital amplifier U5

PC and the Video2 and Video3 path YPbPr signal are via terminal sent to U1 A/D conversion, output R/G/B of 24 bit to back end module to digital decode, image scale, then send to LVDS level drive for panel display. Sound signal of PC/YPrPb

terminal

via matched resistance

and

sent to U1 to bass adjust and volume control, the sound signal will be transform into digital I2S signal by scaler IC and sent to digital amplifier U5 amplifying,

4. HDMI signal flow HDMI video signal via terminal sent to level for panel display. HDMI audio signal via decoder built-in terminal sent to to bass adjust and volume control, the sound signal will scaler IC and sent to digital amplifier

then output to speaker.

amplifying,

to digital decode, image scale, then output LVDS drive

U1 is

transform into digital I2S signal by

fed to back end

then output to speaker.

5. MEDIA signal flow The JPEG file via USB terminal send to U1 to MPEG decode , image scale , then output LVDS drive level for panel display .

4. Block diagram-SANYO 55” ATSC model System Diagram

DDRII 512M

ProMOS

V59C1512164QDJ25

Block diagram-POWER-55”

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