Sanyo LCE-24R45FHD Schematic

FILE NO.

SERVICE MANUAL

LED-LCD TV

LCE-24R45FHD

PRODUCT CODE No.

PRODUCT CODE No. 1 682 350 82: PAL-BG

NTSC(AV)

REFERENCE No.:SM0915171

CONTENTS

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

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

Instruction of software upgrading & boot burning ....................................................

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

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 must 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 necessary for the welder to wear anti static gloves. Please refer to the part list before replacing components that have special safety requirements. Do not replace with different components with different specs and type at will.

2. LCD servicing precautions

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

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 Operation range 0 ~ +50 oC

Storage range -20 ~ +60 oC

Humidity Operation range 20% ~ 85%

Storage range 10% ~ 90%

2.13 Display of a fixed picture for a long time may cause a permanent after-image on the screen, as commonly called “ghost shadow”. The degree of the after-image 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. Installation precautions

3.1 The front panel of LCD screen is made 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

2 Adjustment equipment

Digital multimeter Signal generator (54200) PC (presetting FLASH software) VG848, VG849 (VGA, YPbPr and HDMI signal generator) DVD player with HDMI output White balance apparatus (CA210) Monitor

3 Adjustment flow

3.1 Test voltage of power supply

3.1.1 Main board of non BBY model of which dimension is 26” or bigger than 26” According to wiring diagram ‘9242KC4201JL’, connect main board, power board, IR board and

key board correctly, switch on power supply, then press key ‘power’ to turn on the TV set.

a）Test voltage of socket X302 each pin in turn, please refer to voltage value as Table 1.

Table 1 Voltage of X302 each pin

X302 Pin1 2 3

Vol.

3.3 V～

5.0 V

1.0 V～

3.3 V

4、5 6、7

11.5 V～

12.5V

b）Test voltage of socket X301 each pin in turn, please refer to voltage value as Table 2.

Table 2 Voltage of X301 each pin

X301

Vol.

Pin1、2 3、4、5

23 V～25 V

3.1.2 Main board of non BBY model of which dimension is smaller than 26” According to wiring diagram ‘9222KC4201JL’, connect main board, power board, IR board and

key board correctly, switch on power supply, then press key ‘power’ to turn on the TV set.

a）Test voltage of socket X302 each pin in turn, please refer to voltage value as Table 3.

Table 3 Voltage of X302 each pin

X302 Pin1 2 3

3.3 V～5.0 V 1.0 V～3.3

Vol.

4、5 6、7

11.5 V～

12.5V

3.1.3 Main board of BBY model of which dimension is 19” and 22”. According to wiring diagram ‘9219KC7201JL’, connect main board, power board, IR board and

key board correctly, switch on power supply, then press key ‘power’ to turn on the TV set.

a）Test voltage of socket X302 each pin in turn, please refer to voltage value as Table 4.

Table 4 Voltage of X302 each pin

X302 Pin1 2 3

3.3 V～5.0 V 0 V～1.5

Vol.

4、5 6、7

11.5 V～

12.5V

8 9 10 11 12 13

31 V～

33 V

8 9 10 11 12 13

31 V～

33 V

8 9 10 11 12 13

0 0

4.7 V～

5.3 V

4.7 V～5.3 V

4.7 V～

5.3 V

4.7 V～

5.3 V

4.7 V～

5.3 V

3.3 V～5.0

3.3 V～

5.0 V

3.1.4 Main board of BBY model of which dimension is 24”. According to wiring diagram ‘9224KC7001JL’, connect main board, power board, IR board and

key board correctly, switch on power supply, then press key ‘power’ to turn on the TV set.

a）Test voltage of socket X301 each pin in turn, please refer to voltage value as Table 5.

Table 5 Voltage of X301 each pin

X301 Pin1 2 3

3.3 V～5.0 V 1.0 V～3.3

Vol.

4、5 6、7

11.5 V～

12.5V

0 0

8 9 10 11 12 13

4.7 V～5.3 V

4.7 V～

5.3 V

3.3 V～5.0

3.1.5 Main board of BBY model of which dimension is 32” and 37”. According to wiring diagram ‘9232KC7001JL’, connect main board, power board, IR board and

key board correctly, switch on power supply, then press key ‘power’ to turn on the TV set.

a）Test voltage of socket X302 each pin in turn, please refer to voltage value as Table 6.

Table 6 Voltage of X302 each pin

X302 Pin1 2 3

3.3 V～5.0 V 1.0 V～3.3

Vol.

4、5 6、7

11.5 V～

12.5V

0 0

8 9 10 11 12 13

4.7 V～5.3 V

4.7 V～

5.3 V

3.3 V～5.0

b）Test voltage of socket X301 each pin in turn, please refer to voltage value as Table 7.

Table 7 Voltage of X301 each pin

X301

Vol.

3.1.6 LE-24KC68 main board According to wiring diagram “9224KC6801JL”, connect main board, power board, IR board and key

board correctly, supply with the main power, then press key “power” to turn on the TV set.

a）Test voltage of each pin of socket X302, voltage values are listed as Table 3:

X302 Pin1 2 3 4 5

Vol.

3.3 V～

5.0 V

1.0V～

3.3 V

Table 3 X302 voltage values

4.7V～

5.3 V

4.7V～

5.3 V

Pin1、2 3、4、5

23 V～25 V

8 9

11.5V～

12.5V

10、11 12、13

4.7V～

5.3 V

6、7

0 0

11.5V～

12.5V

3.2 Adjustment flow chart as Fig.1

Connect to central signal source, check if each function of TV, such as omitted program, analog parameter control, etc. is normal? Check if output of earphones, speakers are normal?

Input AV/S-VIDEO signal, check if each function

Input HI definition signal (mode), check if each

Input VGA signal, check if display and each function, such as analog parameters control, H/V center, etc., are normal?

Input HDMI signal, check if display and each function, such as analog parameters control, H/V

Insert U disk, check if functions of MP3 and JPEG

Check if FLASH has been burned

Product main board on line

General assembly and adjustment

White balance adjustment

of both channels are normal?

function of YPbPr is normal?

are normal?

Setting before leaving factory

Check accessories and packing

Fig. 1 Adjustment flow

4 Adjustment instruction

4.1 Unit adjustment

4.1.1 According to wiring diagram ‘9242KC4201JL’ , ‘9222KC4201JL’, ‘9219KC7201JL’ , ‘9224KC7001J’ , "9224KC6801JL" or ‘9232KC7001JL’, connect main board, power board, key board and IR board correctly, switch on power supply, check if display is normal?

4.1.2 Instruction of factory menu a）First press key ‘Program source’, then press number keys “2、5、8、0” in turn to enter initial

factory menu;

b）Press keys “” and “” to move cursor to each adjustment page of initial factory menu, then

press “” to enter into its adjustment menu;

c）Press keys “” and “” to move cursor upwards or downwards within any adjustment page; d）Press keys “” and “” to adjust any item when cursor is moved onto it; e）Press key “Menu” to exit to initial menu from any adjustment page; f）Press key “Exit” to exit from factory menu in any case; g）Set item “Aging Mode” as “On” to enter into factory aging mode.

4.2 White balance adjustment

4.2.1 Before adjustment The unit should be working for above 30 minutes to be in stabler state; Use apparatus CA210 to

adjust white balance;

For model of which dimension is bigger than 26”, only 9300K color temperature (that is “normal”) is needed adjustment, To guarantee BBY test requirements to be met when color temperature are 12000K and 6500K, make sure that chromaticity coordinates of bright scale are (X=285±5, Y=293±8) and chromaticity coordinates of dark scale are (X=285±8, Y=293±12);

For model of which dimension is 26” or smaller than 26”, only 8000K color temperature (that is “normal”) is needed adjustment, To guarantee test requirements to be met when color temperature are 9300K and 6500K, make sure that chromaticity coordinates of bright scale are X=295±5, Y=305±8) and chromaticity coordinates of dark scale are (X=295±8, Y=305±12);

4.2.2 White balance adjustment of HDMI channel

Input 16-grey-scale signal with format of 800×600/60 Hz (VG848: Timing is 854，PAT is 921),

enter into submenu “color temperature adjustment” of factory menu;

For model of which dimension is bigger than 26”, select “normal” color temperature (that is

9300K), fix item “G Offset”, adjust items “R Offset, B Offset” to set chromaticity coordinates of the 3 scale as （285±8, 293±12）and guarantee luminance within the range of 3 nit to 5 nit; fix item “G GAIN”, adjust items “R GAIN, B GAIN” to set chromaticity coordinates of the reverse 3

scale as （285±8, 293±12）; adjust items “R Offset, B Offset” and “R GAIN, B GAIN” repeatedly until chromaticity coordinates of both scales are all （285, 293）;

For model of which dimension is 26” and small than 26”, select “normal” color temperature (that is

8000K), fix item “G Offset”, adjust items “R Offset, B Offset” to set chromaticity coordinates of the 3 scale as （295±8, 305±12）and guarantee luminance within the range of 3 nit to 5 nit; fix item “G GAIN”, adjust items “R GAIN, B GAIN” to set chromaticity coordinates of the reverse 3

scale as （295±5, 305±8） ; adjust items “R Offset, B Offset” and “R GAIN, B GAIN” repeatedly until chromaticity coordinates of both scales are all （295, 305）;

Set item “ALL COLOR” as “ON” after completing adjustment.

4.2.3 White balance adjustment of YPbPr channel

ADC calibration of SD mode: Input color-bar signal with format of 480i/60 Hz (VG848: Timing is 968，PAT is 918), enter into submenu “ADC adjustment” of factory menu and select item “AUTO COLOR”, system will begin calibration automatically, please note whether picture and data are abnormal clearly or not (main abnormal data phenomena are that several data are very different from the other or about 1000 more than the other); it is failed to calibrate ADC if data are abnormal clearly, so it is necessary to do the calibration again;

ADC calibration of HD mode: Input color-bar signal with format of 1080i/60 Hz (VG848: Timing is 972，PAT is 918), enter into submenu “ADC adjustment” of factory menu and select item “AUTO COLOR”, system will begin calibration automatically, please note whether picture and data are abnormal clearly or not (main abnormal data phenomena are that several data are very different from the other or about 1000 more than the other); it is failed to calibrate ADC if data are abnormal clearly, so it is necessary to do the calibration again;

White balance adjustment: Input 16-grey-scale signal with format of 1080i/60 Hz (VG848: Timing is 972，PAT is 921), check if white balance is normal, if not, enter into submenu “color temperature adjustment” of factory menu, set item “ALL COLOR” as “OFF”, please refer to step 4.2.2 to adjust white balance for model of which dimension is 26” , bigger than 26” or smaller than 26” respectively;

Note: Item “ALL COLOR” must not be altered as “ON” again once set as “OFF”.

4.2.4 White balance adjustment of VGA channel Auto-calibration: Input square signal with format of 800×600/60 Hz (VG848: Timing is 854，PAT is CROSS) to do calibration automatically in order to make window filled with picture;

ADC calibration: Input monochrome signal with format of 800×600/60 Hz (VG848: Timing is 854， PAT is 948), enter into submenu “ADC adjustment” of factory menu and select item “AUTO COLOR”, system will begin calibration automatically, please note whether picture and data are abnormal clearly or not (main abnormal data phenomena are that several data are very different from the other or about 1000 more than the other); it is failed to calibrate ADC if data are abnormal clearly, so it is necessary to do the calibration again;

White balance adjustment: Input 16-grey-scale signal with format of 800×600/60 Hz (VG848: Timing is 854，PAT is 921), check if white balance is normal, if not, enter into submenu “color temperature adjustment” of factory menu, set item “ALL COLOR” as “OFF”, please refer to step 4.2.2 to adjust white balance for model of which dimension is 26” , bigger than 26” or smaller than 26” respectively;

Note: Item “ALL COLOR” must not be altered as “ON” again once set as “OFF”.

4.2.5 White balance adjustment of AV channel

Input 16-grey-scale signal with format of PAL (VG848: Timing is 969，PAT is 921), check if white balance is normal, if not, enter into submenu “color temperature adjustment” of factory menu, set item “ALL COLOR” as “OFF”, please refer to step 4.2.2 to adjust white balance for model of which dimension is 26” , bigger than 26” or smaller than 26” respectively;

Note: Item “ALL COLOR” must not be altered as “ON” again once set as “OFF”.

4.2.6 Auto-white balance adjustment

4.2.6.1 ADC pre-calibration

Enter into factory menu, set “Program source” as “YPbPr”, input color-bar signal with format of 480i/60 Hz (VG848: Timing is 968，PAT is 918), enter into submenu “ADC adjustment” of factory menu and select item “AUTO COLOR”, system will begin calibration automatically; input color-bar signal with format of 1080i/60 Hz (VG848: Timing is 972，PAT is 918), enter into submenu “ADC

adjustment” of factory menu and select item “AUTO COLOR”, system will begin calibration automatically,

Press key “Menu” to be back to upper menu, set “Program source” as VGA”, input monochrome signal with format of 800×600/60 Hz (VG848: Timing is 854，PAT is 948), enter into submenu “ADC adjustment” of factory menu and select item “AUTO COLOR”, system will begin calibration automatically,

4.2.6.2 White balance adjustment (models except LC-19KC72, LC-22KC72)

TV set should be working for above 30 minutes to be in stabler state before white balance adjustment; connect CA210 to USB port of PC with data line; connect VG848 and TV to COM port of PC or virtual COM port respectively (default connection: VG848 to COM5,TV to COM1, the connection can be altered and saved in administrator window with password “xoceco” if necessary); output signal of VG848 must be sent to AV1, YPbPr, VGA and HDMI1 channels of TV;

Open program file “White_Balance.exe”, load configure file “AdjustConfig.txt”, then connect CA210, VG848 and TV respectively according to the instruction on interface. Note: set probe to “0-CAL” before connecting CA210, press “connect CA210”, set probe back to “MEAS” after prompt “CA-210 connection and calibration are normal !” appears on the left-down side; BBY channel is used by CA210 for BBY models, for other models, channels except BBY are used by CA210; please enter into administer window with password “xoceco” to alter and save apparatus setting if it is different; At last, press “Begin auto-white-balance-adjustment”, auto-adjustment will be completed until prompt “Adjustment is successful” appears.

4.2.6.3 White balance adjustment (models except LC-19KC72, LC-22KC72)

Open program file “White_Balance.exe”, if current working progress includes AV channel, enter into channel setting of administer window to make sure no YPBPR576i@60 but AV is chosen, or load configure file “AdjustConfigAV.txt”; if current working progress includes YPBPR channel, enter into channel setting of administer window to make sure no AV but YPBPR576i@60 is chosen, or load configure file “AdjustConfigYPBPR.txt.txt”; then connect CA210, VG848 and TV respectively according to the instruction on interface. Note: set probe to “0-CAL” before connecting CA210, press “connect CA210”, set probe back to “MEAS” after prompt “CA-210 connection and calibration are normal !” appears on the left-down side; BBY channel is used by CA210 for BBY models, for other models, channels except BBY are used by CA210; please enter into administer window with password “xoceco” to alter and save apparatus setting if it is different; At last, press “Begin auto-white-balance-adjustment”, auto-adjustment will be completed until prompt “Adjustment is successful” appears.

5 Performance check

5.1 TV port

Connect RF port to central signal source, first enter into channel menu, then auto search programs, check if there is any omitted program ,output of speakers and picture are normal

5.2 AV/S-Video port

Input AV/S signal to corresponding terminal respectively, check if picture and sound are normal.

5.3 YPbPr/YCbCr port

Input YUV signal from signal general VG848 with YUV format listed as Table 8, check if picture and sound are normal.

Table 8 YUV signal format

NO. Definition

1 720×480i@59.94/60 Hz 15.734 59.94/60 13.5 480i(59.94/60p) 2 720×480p@59.94/60 Hz 31.469 59.94/60 27.00 480p(59.94/60p)

3 1280×720p@59.94/60 Hz 44.96 59.94/60 74.18 720p(59.94/60p) 4 1920×1080i@59.94/60 Hz 33.75 59.94 74.25 1080i(59.94/60i) 5 1920×1080p@23.98/24 Hz 27.00 23.98/24 74.25 1080p(23.98/24p)

6 1920×1080p@59.94/60 Hz 67.50 59.94/60 148.50 1080p(59.94/60p)

H. Fre.

kHz

V. Fre.

Dot-pulse Fre.

MHz

Note

5.4 VGA port

Input VGA signal from signal general VG848 with VGA format listed as Table 9, check if picture and sound are normal, if not, enter into menu to do auto-calibration.

Table 9 VGA signal format

NO. Definition

1 720×400@70 Hz 31.47 70.08 28.32 DOS 2 640×480@60 Hz 31.50 60.00 25.18 VESA 3 800×600@60 Hz 37.90 60.00 40.00 VESA

4 1024×768@60 Hz 48.40 60.00 65.00 VESA

1280×1024@60 Hz 63.98 60.02 108.00 VESA

1360×768@60 Hz 47.71 60.01 85.50 VESA

1920×1080@60 Hz 67.16 59.96 173.00 VESA

H. Fre.

kHz

V. Fre.

Dot-pulse Fre.

MHz

Note

(only for Full HD panel)

(only for 1366X768 panel)

(only for Full HD panel)

5.5 HDMI port

Input HDMIsignal from signal general VG849 with VGA format listed as Table 8&9 , check if picture and sound are normal

5.6 USB port Inset U disk, check if JPEG picture and MP3 music are displayed normally

5.7 AV OUT port

Check if picture and sound of AV OUT are normal

5.8 Check other functions

Check if time-on/off, sleeping time, picture/sound mode, OSD, still picture/mute and microcrystalline-magical-picture, etc., are normal.

6 User menu setting before leaving factory

Enter into factory menu, select item ‘Reset’, TV set will be preset automatically before leaving

factory. Be sure to do the step after completing adjustments in factory.

7 Instruction for software burning in factory as Table 10

Table 10 Instruction for software burning in factory

Loc. Part No. Part Type

N104 5273206001 MX25L3206E

Instruction for

software function

Main CPU

program

Burned before

SMT

Yes Burned software with ALL11

Method of burning

Instruction of software upgrade

Instruction of software upgrade for KC# model:

1. Save upgrade file “flash.img” into the root directory of a U disk;

2. Insert the U disk into USB port of TV set, press key “power” until TV set is in “standby” state, then power on TV set again;

3. Press key “program source” until menu “program source” display, then press keys “2”, “5”, “8”, “0” by turn to enter into factory menu, please refer to the following Fig. 1;

Fig. 1 “Program source” menu

Fig. 2 Factory menu

4. Press keys of remote control “▲”,”▼” to select item “ISP”, press key “enter” to begin updating progress, a prompt “Updating, Pls, Waiting…” is displaying, wait for a while until menu display (TV set is unable to accept other operation now), please refer to the Fig. 3;

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