Sanyo PDP-32XS7 Schematic
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FILE NO. |
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SERVICE MANUAL |
PDP-32XS7 |
PDP TV
PRODUCT CODE No.
1 682 344 44
MENU SOURCE
REFERENCE No.:SM0915054
CONTENTS
Safety precautions………………………………………………………………………..… 1 Alignment instructions …………………………….…….………………………………… 3 Method of software upgrading…………………………………………………………….. 6
Working principle analysis of the unit……………………………….………….………….12
Block diagram…………………………………..………………………………….…………13 IC block diagram………………………………………………………………………..……14 Wiring diagram ……………………………………………………………………………. 19
Troubleshooting guide ………………………………………………………………..…… 20
Schematic diagram………………………………………………………………………… 25
APPENDIX-A: Assembly list
APPENDIX-B: Exploded View
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:
1.1Screens vary from one model to another and therefore not interchangeable. Be sure to use the same type of screen in the replacement.
1.2The 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.
1.3Don’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.
1.4Never 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.
1.5In 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.
1.6If 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.
1.7Do 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.
1.8Considering 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.
1.9The 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.
1.10There 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 |
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Scope for storage |
-15~60centigrade |
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Humidity |
Scope for operation |
20%~80% |
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Scope for storage |
20%~80% |
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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.
1.21There 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.
1.22In 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
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Pin1 |
Pin2 |
Pin3 |
Pin4 |
Pin5 |
Pin6 |
Pin7 |
Pin8 |
Pin9 |
Pin10 |
Pin11 |
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LC-26HUXX |
8.55-9.45V |
0 |
4.75-5.5V |
0 |
11.69-12.92V |
0 |
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4.75-5.5V |
0 |
H |
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LC-32HUXX |
8.55-9.45V |
0 |
4.85-5.36V |
0 |
11.4-12.6V |
0 |
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4.85-5.36V |
0 |
H |
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Test the pin voltage of XS16, the data is shown in table2:
Table2 voltage data of XS16
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Pin1 |
Pin2 |
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Pin3 |
Pin4 |
Pin5 |
Pin6 |
LC-26HUXX |
0 |
4.75-5.5V |
0 |
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8.55-9.45V |
0 |
30.4-33.6V |
LC-32HUXX |
0 |
4.85-5.36V |
0 |
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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
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Pin1 |
Pin2 |
Pin3 |
Pin4 |
Pin5 |
LC-26HUXX |
20.25-23.63V |
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0 |
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LC-32HUXX |
22.8-25.2V |
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0 |
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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.
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Table1 sub-menu adjustment |
Items |
Preset |
Introduce |
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HOTEL |
0 |
1: HOTEL OPTION of factory menu is optional |
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0: HOTEL OPTION of factory menu is not optional |
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LOGO |
1 |
1: display LOGO in no signal or turn on |
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0: no LOGO display |
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ADC PRESCALE |
046 |
Software will preset the data according unit |
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SIF PRESCALE |
02E |
Software will preset the data according unit |
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BACK LIGHT |
FF |
Software will preset the data according the type of panel |
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ALL COLOR |
1 |
1: white balance of each channel auto offset based on the HDMI white |
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balance |
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0: white balance of each channel adjust the offset base separately |
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Note: don’t set ALL COLOR to 1after the offset adjustment, if you do so, the |
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adjusted parameter of each channel will recover to the parameter of HDMI. |
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EEPROM-MEMORAY |
> |
EEPROM Initialization (operate when EEPROM data chaos) |
RECALL |
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4 |
4.3Adjustment 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.
4.4White balance adjustment
4.4.1white 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).
4.4.2VGA/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 |
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Item |
Setting |
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Item |
Setting |
PICTURE MODE |
STANDARD |
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BALANCE |
50 |
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OSD LANGUAGE |
English |
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COLOR MODE |
NORMAL |
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VOLUME |
50 |
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OSD HPOSITION |
50 |
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NR |
WEAK |
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SLEEP TIMER |
OFF |
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OSD VPOSITION |
50 |
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ZOOM |
FULL |
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TTX LANGUAGE |
WEST |
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OSD HALFTONE |
50 |
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SOUND MODE |
STANDARD |
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BLUE SCREEN |
OFF |
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OSD DURATION |
15 |
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AVC |
OFF |
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WSS |
OFF |
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6. Software instruction
Table6 software instruction
No. |
Code No. |
Type |
Function |
Flash written |
Method |
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before paste |
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NS14 |
5270008001 |
ATMEGA8L |
Power image |
Yes |
Written |
with |
NS3 |
5272540001 |
PM25VF040 |
Main CPU program |
Yes |
instrument like |
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NB3 |
5272402002 |
24C02N-10SI27 |
HDMI EDID |
Yes |
ALL11 |
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NB7 |
5272402002 |
24C02N-10SI27 |
VGA EDID |
Yes |
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NS5 |
5272404002 |
24C02N-10SI27 |
Store some important |
No |
No |
written |
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information |
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software |
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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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