Sony AZ1K Schematic
KDL-40EX500
Training Manual
Models: AZ1K Chassis
KDL-32EX301 KDL-32EX500 KDL-46EX400
KDL-32EX400 KDL-40EX500 KDL-46EX500
KDL-40EX400 KDL-40EX501 KDL-46EX501
KDL-40EX401
Triage and Troubleshooting Guide
Course: CTV-61
Table of Contents
Section 1 - AZ1K Chassis Models Overview ..................... 3
AZ1K Chassis Models Covered ....................................... 5
Model Introduction ........................................................... 5
AV Input & Output Descriptions ....................................... 5
RF Input ............................................................................... 5
Composite Video & Audio Inputs ......................................... 5
Component/Composite Video & Audio Inputs ...................... 6
HDMI/DVI Video Input and DVI Video ................................. 6
PC Video & Audio Input (and DVI Audio) ............................. 6
USB 2.0 Side Connection - Photos & Music ........................ 6
Audio Outputs .................................................................. 7
Fixed Analog Audio Output .................................................. 7
Digital Audio Output (Optical) .............................................. 7
32’” & 40” Models Overall PCB Block Diagram ............... 8
46” Models Overall PCB Block Diagram .......................... 9
PCB and Component Descriptions ................................ 10
A-Board ............................................................................. 10
G2LE-Board (32") or G2HE-Board (40") ............................ 10
GD2-Board (46") ................................................................ 10
Backlight Inverter Board (32" & 40") .................................. 10
H2-Board ........................................................................... 10
Switch Unit ......................................................................... 10
LCD Panel Assembly ..........................................................11
Section 2 - Troubleshooting Procedures ......................... 12
Power Symptom Troubleshooting .................................. 12
Normal Operation .............................................................. 12
Failure Symptoms .............................................................. 12
No Power/Dead Set (No RED Standby LED) .............. 12
32” & 40” Power Supply System Block Diagram ........... 14
G2LE-Board & G2HE-Board Connector Diagram ......... 15
46” Power Supply System Block Diagram ..................... 16
GD2-Board Connector Diagram .................................... 17
Protection Mode Symptom Troubleshooting .................. 18
Failure Symptoms .............................................................. 18
2X Blink - Main Power Error ........................................ 18
3X Blink- Audio Error ................................................... 18
4X Blink - Balancer Failure (46” Models ONLY) .......... 19
5X Blink - TCON & HFR Failure .................................. 19
6X Blink - Backlight System Failure (32” & 40” Models) 19
6X Blink - Backlight System Failure (46” Models) ........ 19
7X Blink - Temperature Failure .................................... 20
32” & 40” Models Protection Mode System Block Diagram
21
46” Models Protection Mode System Block Diagram .... 22
All Models Power Board Protection Circuits Block Dia-
gram ........................................................................... 23
Video Symptom Troubleshooting ................................... 24
Normal Operation .............................................................. 24
Troubleshooting ................................................................. 24
Missing or Distorted Video (Individual Inputs) ................... 24
Missing Video (All Inputs) .................................................. 25
CTV-61 i
Table of Contents
Skewing LVDS Connector Troubleshooting Method .... 25
Distorted Video (All Inputs) ................................................ 25
WIDE Mode Button (Aspect Ratio) Troubleshooting
Method ................................................................... 25
Unique Main Video Board (A-Board) or LVDS Cable Ef-
fects ....................................................................... 26
Unique TCON/HFR Board Effects ............................... 27
Unique LCD Panel Assembly Effects ........................... 27
Common Main Video Board (A-Board) and LCD Panel
Assembly Effects ................................................... 27
Video System Block Diagram ........................................ 28
Audio Symptom Troubleshooting ................................... 29
Normal Operation .............................................................. 29
Failure Symptoms .............................................................. 29
Missing or Distorted Main Speaker Audio - All Inputs .. 29
Missing or Distorted Main Speaker Audio - Individual
Inputs ..................................................................... 29
Audio System Block Diagram ........................................ 30
chart ........................................................................... 35
Protection Mode 6X(46”) & 7X Troubleshooting Flowchart
36
Video Troubleshooting Flowchart .................................. 37
Audio Troubleshooting Flowchart .................................. 38
Appendix ............................................................................. 39
LCD Panel Distortion Pictures ....................................... 39
TCON/HFR Board Distortion Pictures ........................... 40
TCON/HFR Board Distortion Pictures Continued .......... 41
Video Board Distortion Pictures ..................................... 42
Video Board Distortion Pictures Continued ................... 43
Section 3 - Service Mode .................................................. 31
Service Mode Access .................................................... 31
Section 4 - Triage & Troubleshooting Flowcharts .......... 32
Triage Flowchart ............................................................ 32
Power-ON Troubleshooting Flowchart ........................... 33
Protection Mode 2X, 3X, & 4X Troubleshooting Flowchart
34
Protection Mode 5X & 6X(32”, 40”) Troubleshooting Flow-
CTV-61 ii
Section 1 - AZ1K Chassis Models Overview
G2LE-Board (32")
G2HE-Board (40")
A-Board
Backlight
Inverter
Board
32" & 40" Models
TCON
Board
Switch Unit
H2-Board
LVDS Cable
32” & 40” OVERALL PCB LOCATION DIAGRAM
FIGURE 1-1
CTV-61 3
GD2-Board
A-Board
Balancer
Board
46" Models
TCON
Board
Switch Unit
H2-Board
LVDS Cable
AZ1K Chassis Models Overview
46” OVERALL PCB LOCATION DIAGRAM
FIGURE 1-2
CTV-61 4
AZ1K Chassis Models Overview
Composite
PC Input
HDMI
Input
HDMI
Input
HDMI/DVI
Input
Digital Audio
Output
(Optical)
Analog Audio
Output
(FIXED)
Component Input
Component/Composite
Input
RF Input
USB
HDMI
Input
PC & DVI Audio Input
AZ1K Chassis Models Covered
KDL-32EX301 KDL-32EX500 KDL-46EX400
KDL-32EX400 KDL-32EX501 KDL-46EX500
KDL-40EX400 KDL-40EX500 KDL-46EX501
KDL-40EX401 KDL-40EX501
Model Introduction
All models, except the KDL-32EX301, contain a Full High-Definition
1920 X 1080 resolution panel. The KDL-32EX301 contains a 1280 X
720 resolution panel. The backlight is produced using a Cold Cathode
Fluorescent Lamp (CCFL) light system for all models. All models have the
Advanced Contrast Enhancer (ACE) feature and Dynamic Backlighting.
The Dynamic Contrast Ratio (DCR) for the 400 series is 140,000:1 and
for the 500 series it is 2150,00:1. All models contain the BRAVIA Engine™
2 digital video processor for superior resolution. Plus, 7 HD inputs (4
HDMI™, 2 component and 1 PC) are provided to connect all of your HD
devices including PLAYSTATION®3, Blu-ray Disc™ player and laptop or
desktop.
The BRAVIA Engine 2 fully digital video processor uses a collection of
unique Sony technologies to significantly reduce noise, enhance overall
image detail, and optimize contrast so every scene produces sharp,
vibrant, life-like images and color.
The EX500 series models contain the Motionflow™ 120Hz frame rate
technology which enhances sharpness and delivers smooth motion for
fast-action sports and movies. The EX300 and EX400 series models
contain the standard 60Hz frame rate.
AV Input & Output Descriptions
RF Input
This is a 75 ohm connection for either terrestrial NTSC and ATSC (8VSB)
or cable QAM64 and QAM256 signals.
Sony® HDTVs exceed Energy Star 3.0 requirements. In addition, they
incorporate advanced power saving features such as Light Sensor®
technology that adjusts backlight intensity based on ambient room lighting
conditions and Dynamic Backlight Control that adjusts backlight intensity
based on the brightness of the image on the screen.
CTV-61 5
Composite Video & Audio Inputs
Yellow Jack - Composite Video Input
Red & White Jacks - Right & Left Audio Input
NOTE: The second composite input is shared with one of the component
inputs. Reference the description of the component inputs for details on
activating the composite input.
AZ1K Chassis Models Overview
Select the appropriate input
for the input signal type
.
Auto – Auto Detection
Video 1
– Composite
Component 1
- Component
Component/Composite Video & Audio Inputs
Red, Blue, & Green Jacks - Component Video Inputs
Red & White Jacks - Right & Left Audio Input
NOTE: Composite video can be applied to the component input label
“VIDEO IN”. The yellow composite video connector is connected to
the green component connector. The audio is connected to the same
component audio inputs.
IMPORTANT: For automatic signal detection make sure the User Menu
item is set to “AUTO. “ Reference the below for the specific menu item.
The input can also locked to Video 1 (composite) or Component 1
(component) signal. However, the input will only process the chosen
signal type. If the other signal type is connected the picture will be lost or
black & white.
HDMI/DVI Video Input and DVI Video
Both the HDMI and DVI formats contain digital video. In the case of the
HDMI format the audio is also digital and is part of the video and audio
data stream over the single HDMI connection. In contrast, the DVI format
contains only digital video in its data stream. The audio is sent over a
separate Stereo Mini Jack audio connection. Furthermore, a DVI to HDMI
adapter is required to connect the DVI connector to the HDMI connector.
PC Video & Audio Input (and DVI Audio)
All EX models have a Personal Computer Input (PC-IN), which connects
directly to the PC 15 pin DIN connector (HD15 connector). Once connected
the TV functions as a video monitor and audio output (separate Stereo
Mini Plug) for the PC audio. There is a complete table of PC Input Signal
Compatibility in the Owners Manual for each model.
The Stereo Mini Plug is also used for a DVI audio connection at HDMI 1
video input. The DVI video is connected through an adapter to HDMI 1
input and the DVI audio to connected to the Stereo Mini Jack.
USB 2.0 Side Connection - Photos & Music
Connect a camera, USB-Enabled MP3 player, or USB storage device
directly to this side USB input to view JPG photos and MPEG1 & MPEG2
videos on the screen or listen to MP3 music files.
This USB connection is also used for TV Software updates using a USB
drive device.
CTV-61 6
Audio Outputs
Fixed Analog Audio Output
This audio output can be used to listen to the TV audio through an external
AV stereo system. The audio level at the output is set to a fixed level and
cannot be turned off or adjusted.
Digital Audio Output (Optical)
Connects to the optical audio input of any digital audio equipment that is
PCM/Dolby digital compatible. The following table shows the audio inputs
and the audio format which are present at the Optical Audio Output per
input format.
Audio Input Source Optical Output
Digital Tuner 5.1 (ATSC) 5.1 Dolby
HDMI 5.1 5.1 Dolby
All Analog Audio Inputs 2CH PCM
Analog Tuner (NTSC) 2CH PCM
SACD Format (HDMI) No Output
DVD Audio Format (HDMI) No Output
AZ1K Chassis Models Overview
CTV-61 7
32’” & 40” Models Overall PCB Block Diagram
CCFL Backlight HV Inverter
Circuits
Ba cklight System Error
Circuits
Backlight Inverter Board
A-Board
TV Microprocessor
MT 5388:
Video Processing
HDMI Processing
HDCP Processing
IP (Image Processor)
Scan Converter (Scalar)
HDMI Switcher
ATSC/NTSC Tuner
Temperature Sensor
Au dio Output Amplifier
Control
Power/Drive
LVDS
Keys
Power/
SIRCS
LCD Panel Assembly
LCD PANEL
Po wer Key
Function Keys
Switch Unit
LEDs
IR Sensor
H2-Board
Power
Ma in Power Supply
Standby Power Supply
G2LE-Board (32")
G2HE-Board (40")
Power
Control
Power
LCD Panel
R
L
RF Input
1 Compos ite Input
2 Component Inputs
(Composite can be applied to Component 1)
1 PC Input
3 HDMI Inputs
Optical Digital Audio Output
Analog Audio Output
CCFL
Backlight System
TCON/HFR
Power
AC
Input
*High Frame Rate (120HZ)
1 USB 2.0
AZ1K Chassis Models Overview
CTV-61 8
32” & 40” OVERALL PCB
BLOCK DIAGRAM
FIGURE 1-3
Balancer Board
A-Board
TV Microprocessor
MT 5388:
Video Processing
HDMI Processing
HDCP Processing
IP (Image Processor)
Scan Converter (Scalar)
HDMI Switcher
ATSC/NTSC Tuner
Temperature Sensor
Au dio Output Amplifier
Control
Power/Drive
LVDS
Keys
Power/
SIRCS
LCD Panel Assembly
LCD PANEL
Po wer Key
Function Keys
Switch Unit
LEDs
IR Sensor
H2-Board
Power
Ma in Power Supply
Standby Power Supply
AC Relay
Ba cklight HV Inverter
Circuits
GD2-Board
HV
Control
Power
LCD Panel
R
L
RF Input
1 Composite Input
2 Component Inputs
(Composite can be applied to Component 1)
1 PC Input
3 HDMI Inputs
Optical Digital Audio Output
Analog Audio Output
CCFL
Backlight System
TCON/HFR
Power
AC
Input
*High Frame Rate (120HZ)
1 USB 2.0
HV
46” Models Overall PCB Block Diagram
AZ1K Chassis Models Overview
CTV-61 9
46” OVERALL PCB
BLOCK DIAGRAM
FIGURE 1-4
AZ1K Chassis Models Overview
PCB and Component Descriptions
Reference Figures 1-3
A-Board
The circuits located on the A-Board perform all Video and Audio processing
functions. It also contains all the microprocessor control circuits. The
following circuits are included on this board.
• TV Microprocessor
• MT5388 Processor
- Video Signal Processing
- HDMI Signal Processing
- Scan Converter
- HDCP Processing
• Audio Amplifier
• Temperature Sensor
G2LE-Board (32") or G2HE-Board (40")
Except for some regulator circuits on the A-Board, the G2LE-Board or
G2HE-Board is the power supply system board for the 32” and 40” models,
which includes the following components and circuits.
• Main Power Supply
• 12V
GD2-Board (46")
Except for some regulator circuits on the A-Board, the GD2-Board is
the power supply system board for the 46” models, which includes the
following components and circuits.
• Main Power Supply
o 12V
o AU12V (Audio Amp)
• Standby Power Supply
o 3.3V for standby circuits
• Backlight High Voltage Inverter Power Supply
• Main/Inrush AC Input Relay
• Power Factor Control Circuit (PFC)
Backlight Inverter Board (32" & 40")
The 24V developed in the Main Power Supply on the G2LE-Board or
G2HE-Board powers the Backlight Inverter Board. The Inverter Board
takes that 24V and develops approximately 2KVrms to initially ignite
the lamps and 1KVrms to drive the backlight Cold-Cathode-Fluorescent
Lamps (CCFL) in normal operation.
H2-Board
• IR Sensor
• AU12V (Audio Amp)
• 24V (Backlight Inverter)
• Standby Power Supply
• 3.3V for standby circuits
• Power Factor Control Circuit (PFC)
Switch Unit
• Power Key
• Function Keys
CTV-61 10
LCD Panel Assembly
The LCD Panel Assembly includes the LCD Panel, TCON Board (300 &
400 series models), TCON/HFR Board (500 series models), and CCFL
Backlight system.
The LCD Panel contains the actual liquid crystals, color filters, and
polarizers. The liquid crystals are manipulated by the applied voltage to
pass a specific amount of light - from the backlight- depending on the level
of voltage applied.
The TCON performs all the control, timing, charge, and discharge functions
driving the operation of the LCD Panel. The HFR (High Frame Rate)
section performs the 60Hz to 120Hz frame refresh rate conversion.
A replacement LCD Panel assembly from parts will include the following
items.
32” & 40” Models:
1) LCD Panel and Backlighting Components
2) TCON/HFR Board
3) Inverter Board
AZ1K Chassis Models Overview
46” Models:
1) LCD Panel and Backlighting Components
2) TCON/HFR Board
3) Balancer Board
CTV-61 11
Section 2 - Troubleshooting Procedures
Power Symptom Troubleshooting
Normal Operation
Reference Figure 2-1 and 2-2
110VAC is applied to the G2LE-Board, G2HE-Board, or GD2-Board it can
be measured at CN6101 or CN6003. In the standby mode the AC power
passes through the main fuse F6101 or F6001. The is no main relay on
the G2LE & G2HE-Board so the AC power is applied directly to the Main
& Standby Power supply. The GD2-Board does have a Main AC Relay.
The AC power passes through R6003 (Inrush resistor), and D6001 and
is applied to the Main DC/DC Converter IC6501 and the Standby DC/DC
Converter IC6201. IC6501 is not active in the standby mode. However,
IC6201 is active in standby mode and outputs STBY 3.3Vdc as long as
AC power is applied to the TV. The Standby 3.3Vdc is supplied to the TVMicroprocessor, Switch Unit (Power Key), and HSR-Board (IR Sensor) in
the standby mode.
Once a ON command is received form the remote controller or the power
button on the Switch Unit the TV-Microprocessor outputs the Power-ON
signal. The Power-On signal is applied to the G2LE-Board, G2LE-Board,
or GD2-Board. On the power supply board the Power-On signal switches
the 19V from the standby power supply to activate the PFC and Main
Power supply IC6501. No relay click will be heard on the 32” or 40” models
because there is not a main relay. However, on the 46” models there is a
main relay and one relay click is heard at power-on. The relay engages to
bypass the inrush resistor R6003 during the ON state.
The main power supply IC6501 is now active and outputting all secondary
supplies. The 12Vdc secondary is the supply voltage for all the voltage
regulators on the A-Board. The AU12V is the supply voltage for the audio
output amplifier. The 32” and 40” models power supply will also output
24V which is the supply voltage for the backlight inverter board.
The GD2-Board in the 46” models will develop and output the backlight
high-voltage (1KV) to the Balancer board and the CCFL backlights.
Failure Symptoms
Reference Figures 2-1, 2-2, 2-3, and 2-4
No Power/Dead Set (No RED Standby LED)
In a dead set condition there will be No RED Standby LED illumination in
the Standby Mode (TV plugged into an active AC Outlet).
The following bullet list gives the possible failures for a “No Power/Dead
Set” condition.
• Loss of AC Power
• Loss of AC-OFF-DET
• Loss of Standby 3.3Vdc
• Loss of REG12V
• Loss of Power-On
• Defective Main Microprocessor
The first step in troubleshooting a “No Power/Dead Set” condition is to
confirm that 110ACV power from an active AC outlet is applied to the
G2LE-Board, G2LE-Baord, or GD2-Board. AC power is applied to, and
can be measured at CN6101 on the G2BE-Board or G2CE-Board and at
CN6003 on the GD2-Board.
Next, check for the presence of the AC-OFF-DET voltage at CN6401/pin 2
or CN6150/pin 2. If the AC-OFF-DET circuit is working properly 3V should
be measured. If the 3V is not present replace the G2BE-Board, G2CEBoard, or GD2-Board. If the 3V in not present either the main fuse or the
main power supply IC6501 is defective. In either case, replace the power
supply board.
After confirming the AC power and AC-OFF-DET, check for a defective
Standby 3.3Vdc power supply IC6201. To confirm a defective IC6201
check the 3.3V secondary voltage at CN6401/pin 1 or CN6150/pin 1.
As long as AC power is applied to the TV IC6201 should be active and
outputting 3.3Vdc. If the 3.3V is not present then IC6201 is defective.
Replacing the power supply board will fix the problem.
CTV-61 12
Finally, a “Dead Set” condition can be caused by a defective microprocessor
IC400. The microprocessor outputs the Power-On signal which activates
the switch Q6301 and IC6301 on the power supply board and passes
the 19V from the Standby power supply to active the relay (46” models),
PFC, and Main Power Supply IC6501. If the Power-On signal is not output
after receiving the Power-ON command the power supply board circuits
remain inactive and a “Dead Set” condition exists. The Power-On signal
can be checked at CN6401/pin 3 or CN6150/pin 3. It should measure
approximately 3.3Vdc If the measurement is 0Vdc before shut-off the TV
microprocessor is defective. Replace the A-Board. If the power-on voltage
is 3V before shutdown then the switch circuit on the power supply board
is defective. Replace the power supply board.
AZ1K Chassis Models Overview
CTV-61 13
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