Sanyo PDP-32XS7 Schematic

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PDP TV

SERVICE MANUALPDP-32XS7

FILE NO.

PRODUCT CODE No.

PRODUCT CODE No.
1 682 344 44

REFERENCE No.:SM0915054

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

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Note: This maintenance manual is intended only for the reference of the maintenance people.
Please pay attention to the following points before carrying out the maintenance work.

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

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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 thermotropic 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

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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

PM5518 (video signal generator)
VG-848 (VGA, HDMI signal generator)
VG-849 (digital video signal generator)
CA210 (color analyzer)

2. Power test

Connect main board, power board and IR board according the wiring diagram, connect the power
and press “standby” to turn on the TV.
Test the pin voltage of XS15, the data is shown in table1:

Table1 voltage data of XS15

Pin1 Pin2 Pin3 Pin4 Pin5 Pin6 Pin7 Pin8 Pin9 Pin10 Pin11

LC-26HUXX 8.55-9.45V 0 4.75-5.5V 0 11.69-12.92V 0 4.75-5.5V 0 H

LC-32HUXX 8.55-9.45V 0 4.85-5.36V 0 11.4-12.6V 0 4.85-5.36V 0 H

Test the pin voltage of XS16, the data is shown in table2:

Table2 voltage data of XS16

Pin1 Pin2 Pin3 Pin4 Pin5 Pin6

LC-26HUXX 0 4.75-5.5V 0 8.55-9.45V 0 30.4-33.6V

LC-32HUXX 0 4.85-5.36V 0 8.55-9.45V 0 31.36-32.64V

Test the pin voltage of XS11, the data is shown in table3:

Table3 voltage data of XS11

Pin1 Pin2 Pin3 Pin4 Pin5

LC-26HUXX 20.25-23.63V 0

LC-32HUXX 22.8-25.2V 0

3. Alignment flow-chart

The alignment flow-chart is shown as fig-1

Check DDC, FLASH, HDCP and power control IC

Combined test for general assembly

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Factory initialization setup

IF channel voltage of TV and AGC voltage adjustment

White balance adjustment

Performance check

Preset ex-factory

Fig-1 adjustment flow-chart

4. Adjustment instruction

4.1 Unit adjustments
Connect all the boards according to wiring diagram, then power on and observe the display.
Method for entering factory menu: press “INPUT”, “2”, “5”, ”8” and “0” in turn to enter factory
menu; press “CH+” and “CH-” to select adjustment items and press “VOL+” and “VOL-” to adjust
value items, press “MENU” repeatedly to exit.
Method for software upgrading: When software upgrading please enter factory menu first, select
ISP of OPTION, set ISP to 1 and you can begin to upgrade. After upgrade finished, it needs to set
ISP back to 0. If the picture can’t display when upgrading, it needs to solder JB1 on main board.
Please unsolder JB1 again after upgrading.

4.2 Initialization
Enter factory menu, select “OPTION”, “EEPROM” and “HOTEL OPTION” sub-menu, adjustment of
items to see table4.

Table1 sub-menu adjustment

Items Preset Introduce

HOTEL 0 1: HOTEL OPTION of factory menu is optional

0: HOTEL OPTION of factory menu is not optional

LOGO 1 1: display LOGO in no signal or turn on

0: no LOGO display

ADC PRESCALE 046 Software will preset the data according unit

SIF PRESCALE 02E Software will preset the data according unit

BACK LIGHT FF Software will preset the data according the type of panel

ALL COLOR 1 1: white balance of each channel auto offset based on the HDMI white

balance

0: white balance of each channel adjust the offset base separately

Note: don’t set ALL COLOR to 1after the offset adjustment, if you do so, the

adjusted parameter of each channel will recover to the parameter of HDMI.

EEPROM-MEMORAY

RECALL

> EEPROM Initialization (operate when EEPROM data chaos)

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4.3 Adjustment for AFT voltage and AGC voltage of IF channel in TV

4.3.1 IF AFC adjustment
Disconnect J1(B face), input 38.9MHz PAL signal of 80dB to the pole of J1 near L11, Adjust L5

to value 1.25V of TP2. Enter factory menu, adjust TDA4470 from BG to LL, input 33.9MHz SECAM
signal of 80dB, adjust R71 to value 1.25V of TP2 then solder J1.

4.3.2 IF AGC adjustment

Input 184.25MHz(PAL/BG) RF signal of 60dBuv to RF terminal, adjust R64 to value 4V of TP4
and there should be no obvious snowy picture. Increase the signal to 90dBuv and it should be
display normally and no obvious noise.

4.4 White balance adjustment

4.4.1 white balance adjustment of HDMI

a. Input VG-849 signal from HDMI: TIMING854 (800* 600/60Hz) and eighth-level gray scale

signal of PAT920. Use color analyzer CA210 to adjust white balance.

b. Enter submenu of COLOR TEMP, Select 9300k of color temperature

c. Fixed value of B OFF, adjust R OFF and G OFF, let the color coordinate of the second level
be (285, 293) and the brightness be about 3nit-6nit. Fixed value of B GAIN, adjust R GAIN and G
GAIN, let the color coordinate of the seventh level be (285, 293). Adjustment R OFF, GOFF, R GAIN
and G GAIN repeatedly until the value of the two levels gray-scale are (285, 293).

4.4.2 VGA/YPBPR/AV white balance check and correct

a. Input VG-848 signal of VGA to VGA terminal: TIMING854(800*600/60Hz) (PATIERN:CROSS)
and auto adjust to full screen, then input PAT948 black/white signal, enter factory menu ADC ADJ,
select AUTOTUNE and wait for OK display. Input PAT920(8 gray levels), check if the white balance
is normal, if not, enter COLOR TEMP menu and set ALL COLOR to 0 and fine adjust according the
method of 4.4.1c)

b. Connect VG-848 signal of YPBPR to YPBPR terminal and input TIMING972(1080i/60HZ)
100% color bar of PAT976(include black/white bars), Enter ADC ADJ submenu, select AUTOTUNE
and wait for OK display. Input PAT920(8 gray levels), check if the white balance is normal, if not, set
ALL COLOR to 0 and fine adjust according the method of 4.4.1c)

c. Input AV signal (PM5518, 8 gray levels, NTSC) to VIDEO1 terminal, check if the white
balance is normal, if not, set ALL COLOR to 0 and fine adjust according the method of 4.4.1c)

Note: it can’t set back to 1 once ALL COLOR changes to 0.

5. Performance check

5.1 TV function
Enter searching menu → auto search, connect RF-TV terminal with central signal source and check
if the picture is normal, if there are channels be skipped. Check TXT and parental control.

5.2 AV, YPbPr terminals
Input AV/S, YPbPr/YCbCr HD signal, check if it is normal.

5.3 VGA terminal
Insert VGA terminal, input VGA format signal of 640X480@60 Hz and check if the display is normal.

5.4 check sound channel
Check the speaker of each channel.

5.5 other function check
Check the turn on/turn off timer, asleep timer, picture/sound mode, OSD, freeze/mute, stereo, etc.

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5.6 presetting before ex-factory

Item Setting Item Setting Item Setting

PICTURE MODE STANDARD BALANCE 50 OSD LANGUAGE English

COLOR MODE NORMAL VOLUME 50 OSD HPOSITION 50

NR WEAK SLEEP TIMER OFF OSD VPOSITION 50

ZOOM FULL TTX LANGUAGE WEST OSD HALFTONE 50

SOUND MODE STANDARD BLUE SCREEN OFF OSD DURATION 15

AVC OFF WSS OFF

6. Software instruction

Table6 software instruction

No. Code No. Type Function Flash written

before paste

NS14 5270008001 ATMEGA8L Power image Yes

NS3 5272540001 PM25VF040 Main CPU program Yes

NB3 5272402002 24C02N-10SI27 HDMI EDID Yes

NB7 5272402002 24C02N-10SI27 VGA EDID Yes

NS5 5272404002 24C02N-10SI27 Store some important

information

No No written

Method

Written with

instrument like

ALL11

software

Method of software upgrading

1. The tools and software demanded

1) Please confirm that PC has the software of ISP_TOOL and install the parallel interface drive
program Port95nt.

2) ISP_TOOL icon is bellow:

3) One parallel cable (25 pins) and one VGA cable (15 pins), the parallel cable connects the PC and
the upgrade instrument, the VGA cable connects the TV and the upgrade instrument.

2. The steps for upgrading software

1) Please confirm that the connection wires and the upgrade instrument are connected well before
the software written and then power on the TV.

2) Double click the icon ISP_TOOL to open it:

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3) Press “Connect“ to connect TV, if the connection is done successfully as shown below, then
press “enter”.

Note: if it appears error, check the connection wires and check if ISP item of the factory menu is set
to 1, if not, please set it to 1.

4) After connection is done, it needs to read the Binary document. Press “Read” as shown below:

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5) Search the document needed to write in the “Read” check box.

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Select

6) Select the document then the window will appear as shown below:

7) Press “Auto” to select the writing function.

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Select the items shown in the picture above:
(a) Read File
(b) Program
(c) Exit ISP
(d) Erase Device
(e) File Area

8) Press “Run” to begin the writing program, wait till the blue bar is complete.

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