Sony DVP-S350, DVP-S570d, DVP-C650d, DVP-S360 DVP-C660, DVP-S500d Training Manual
...
S®
Training Manual
Troubleshooting
Course: DVD-03
Digital Video Player
Sony DVD Players
Models: DVP-S300 DVP-S570d
DVP-S330 DVP-C600d
DVP-S350 DVP-C650d
DVP-S360 DVP-C660
DVP-S500d DVP-C670d
DVP-S530d DVP-S3000
DVP-S550d DVP-S7000
DVP-S560d DVP-S7700
Model Gen Intro Year MSRP Optical RF Amp ARP A/V Decod A DSP Servo DSP
DVP S300 2 1997 $599.99 KHS180A SSI33P3720A CXD1865R L6402GQC27 MB86342PF CXD8730R
DVP S330 3 1999 $349.00 KHM220AAA SSI33P3722 CXD8784R CXD1930G none CXD8791Q
DVP S350 4 2000 $ KHM220AAA SSI33P3722 CXD9576R CXD1932Q none CXD9569R
DVP S360 4 2000 $299.00 KHM220AAA SSI33P3722 CXD9576R CXD1932Q none CXD9569R
DVP S500d 2 1997 $599.99 KHS180A SSI33P3720A CXD1865R L6402GQC27 MB86342PF CXD8730R
DVP S530d 3 1999 $499.00 KHM220AAA SSI33P3722 CXD8784R CXD1930G CXD1901R CXD8791Q
DVP S550d 3 1999 $599.00 KHM220AAA SSI33P3722 CXD8784R CXD1930G CXD1901R CXD8791Q
DVP S560d 4 2000 $399.00 KHM220AAA SSI33P3722 CXD9576R CXD1932Q CXD1939R CXD9569R
DVP S570d 4 2000 $599.00 KHM220AAA SSI33P3722 CXD9576R CXD1932Q CXD1939R CXD9569R
DVP C600d 2 1998 $699.00 KHS180A SSI33P3720A CXD1865R L6402GQC27 MB86342PF CXD8730R
DVP C650d 3 1999 $599.00 KHM220AAA SSI33P3722 CXD8784R CXD1930BQ CXD1901R CXD8791Q
DVP C660 4 2000 $449.00 KHM220AAA SSI33P3722 CXD9576R CXD1932Q CXD1939R CXD9569R
DVP C670d 4 2000 $549.00 KHM220AAA SSI33P3722 CXD9576R CXD1932Q CXD1939R CXD9569R
DVP S3000 1 1997 $699.00 KHS180A SSI33P3720A discrete ICs CXD2545Q
DVP S7000 1 1996 $999.00 KHS180A SSI33P3720A discrete ICs none CXD2545Q
DVP S7700 2 1998 $999.00 KHS180A SSI33P3720A CXD1865R L6402GQC27 none CXD8730R
Gen = Generation based upon internal ICs used.
MSRP = Manufacturer’s Suggested Retail Price (List price)
ARP = Advanced RF Processor (analog input, separate digital DVD & CD process, spindle motor control)
A/V Decod = (MPEG) Audio/Video Decoder
A DSP = Audio Digital Sound Processor (Dolby AC-3 decoding)
Servo DSP = Focus, Trackin
g
, Sled Digital Servo Processor
Internal IC Numbers
How to Use This Book 2
Modern Soldering Techniques 3
IC Removal - Which Method? 3
IC Installation 7
First Generation DVD Players
Symptom 1 - Intermittent loss of brighness during PB 11
Symptom 2 - No color or color change hue 13
Symptom 3 - No DVD disc detected at start up. CD PB OK 17
Symptom 4 - Intermittent or distorted DVD audio 19
Symptom 5 - No PB or picture freeze on some dual layer discs 21
Second Generation DVD Players
Symptom 1 - No response to the Power ON button 23
Symptom 2 - Powers OFF two seconds after turn ON 27
Symptom 3 - Plays CD, but not DVD discs 31
Symptom 4 - No PB. Disc stops spinning 33
Symptom 5 - One color, picture distortion or dark screen 35
Third Generation DVD Players
Symptom 1 - Green Power light does not stay ON 37
Chip Select Waveforms 48
Symptom 2 - Audio distortion after warm-up 51
Symptom 3 - Spindle motor rotates immediately at Power
ON. No tray open 53
Table of Contents
Symptom 4 - Unit powers OFF during PB or if left ON 55
Symptom 5 - Picture freezes or powers OFF trying to PB
dual layer discs 57
Symptom 6 - DVD-C650 only - Powers ON, but no buttons
work. Error code E27 displayed 59
Symptom 7 - DVP-C650 only - Tray does not rotate 61
Symptom 8 - Tray does not Eject. Displays “LOCKED” 62
Fourth Generation DVD Players
Symptom 1 - No PB. Display = “No disc” or “C:13:00” 63
Symptom 2 - Powers OFF after powering ON 65
Symptom 3 - The tray open button has no effect 65
Symptom 4 - No chroma from the S video output jack 67
Symptom 5 - Digital picture blocks during the movie 71
Symptom 6 - Tray does not Eject. Displays “LOCKED” 72
Test Mode - Third Generation 73
Test Mode Access 73
Tests 73
Appendix
Service Bulletin List i
Service Bulletins iii
1
NOTES
2
How to Use This Book
Purpose
DVD players and camcorders have moved into the digital age where signal routing is less important than IC communications. You can learn a
little about how ICs communicate and add to your service strategy for
DVD player repairs by examining previous DVD player failures that have
occurred across the USA.
Book Structure
This book is organized into five sections:
1. List of DVD Models categorized into generations
2. Table of Contents
3. Modern Soldering Methods
4. Common Symptoms for Sony DVD Players:
First Generation
Second Generation
Third Generation
Fourth Generation
5. Service Bulletins
List of DVD Models categorized into generations
Locate the DVD player you are working on in the chart and note the generation it falls in.
Modern Soldering Methods
Even though the technician has identified the defective part, the repair
cannot be completed unless the old part is removed without damaging the
board and the new part installed without solder bridges. This skill can
only be acquired by following all the steps that other technicians have
mastered.
Common Symptoms for DVD Players
DVD repairs across the USA were examined and repetitive symptoms
were extracted. For each common symptom, a strategy was developed
to determine which part has failed. This was done to each of the four
generations of DVD players.
Service Bulletins
The first page in this group contains a list of the DVD bulletins, a description of each bulletin, and the models to which the bulletin pertains. This
list is followed by the DVD service bulletins to date.
Using this Book
1. Go to the “DVD Model List” before the Table of Contents.
2. From the DVD Model List, find your DVD model and note the generation it falls under.
3. Return to the Table of Contents to find the first, second, third or fourth
generation heading that corresponds to your DVD player.
4. Match the symptoms of your DVD player to the ones listed.
5. Go to the corresponding page for the troubleshooting information.
Mechanical problems like broken gears are not listed.
If your symptom is not listed, you do not have a common problem.
3
Modern Soldering Techniques
This section is an excerpt from the Sony videotape (p/n T-MODSOL-9) by
the same name. This document only shows how to remove and install
multi-pin ICs used on many Sony products. The removal of these fine
lead large-scale integrated circuits (LSI) requires modern methods. After
replacing the IC, checking each pin for solder bridges is essential to prevent IC damage.
IC Removal - Which method?
Choose one of three methods for removing the ICs based upon the density of parts about the defective IC.
Cutting the IC’s leads in a high-density board is the best method for IC
removal. If there are many small parts about the defective IC the hot air
and Chip Quick removal methods may desolder local components. If you
choose the chip quick method, keep solder to a minimum on the IC pins.
Use the CUT OUT IC removal method when there
are many parts surrounding the IC
IC Removal - Cut Out method
This method requires a minimum of tools to cut the legs off the IC and
clean the board:
• Knife
• cutters
• dental pick
• soldering iron
• solder wick
Use a sharp knife blade each time you remove an IC because the knife
was not originally intended to cut metal. Break off the old blade segments
of knife before cutting to expose a new sharp blade.
1. You must place the new blade at the legs where they meet the IC
body. Angle the blade into the body slightly to avoid slipping off the IC
legs.
IC
Blade
2. Along the IC legs, hold the knife at a shallow 20 - 30 degree angle.
3. Place your finger above the blade for control as you press down and
rock the blade down.
IC
20-30 degrees
4
4. You should apply enough pressure to shear off 4-5 legs as you rock
the blade while pressing down. DO NOT let the blade point touch the
board.
5. Reposition the blade back along the legs and repeat. Do not cut the
last leg off or you will lose control and the blade point will hit the board.
Use cutters to nip these last IC legs or unsolder and lift the leg with a
dental pick. Remove the IC body.
6. Use a standard soldering iron to heat and push the legs off the lands.
Push only in the direction of the lands so they are not damaged.
Wipe across
the land
IC Lands
7. Remove the solder on the lands using a solder wick looped about the
soldering iron for better control.
5
IC Removal - Hot Air method
This method requires the following:
• Hot Air Controller
• Desoldering Tips
• Flux Pen
• Tweezers
In the following steps you will use the Hot Air Controller to heat up all the
pins while you lift the IC off the board with tweezers.
1. Apply flux from a pen to remove the oxide layer from the IC pins during heating. Removing the oxide establishes a uniform temperature
on all the IC pins for removal and prevents an IC leg from still being
attached to the land when lifting the IC. These low residue pens are
made by Kester and distributed by companies such as
www.mcmelectronics.com and www.newark.com.
2. If you cannot find a hot air tip that will cover the IC, attach a single
1/8” (0.125”) diameter tip that will heat all the pins if you move the tip
around the IC pins.
3. Start at 0 air flow and maximum heat so the tip will warm up fast.
4. After warm up increase the air flow slightly (to #1 of 10) and position
the hot air tip over the pins of the IC. Do not touch the IC with the tip.
Count the nearby components and make sure they do not move away
by controlling the airflow. Insert tweezers at the corner of the IC.
5. Gently lift the IC with the tweezers.
6. Remove the solder on the lands using a solder wick looped about the
soldering iron for better control.
IC Removal - Hot Air method using butane torch
The hot air controller is effective, but expensive. The butane torch is
similar in performance and inexpensive (about $100). In Weller’s PyroPen,
hot air comes from a controlled flame.
6
Put safety goggles on before using the butane torch. Circle the IC leads
with the torch flame and flip the IC over when the IC is loose.
IC Removal - Chip Quick Method
Chip Quick is a low temperature solder that remains molten longer than
ordinary solder, giving you time to unsolder the IC. Chip Quick is best for
removing medium to large scale ICs when there are few parts about the
IC. This method takes about the same time as the hot air method and
requires about the same level of skill.
The Chip Quick package (P/N = T99856421) contains:
• Low Temperature Solder
• Flux
• Wick
1. Apply the Chip Quick flux to all the leads of the IC. (Medium size IC
shown for removal).
2. Melt the Chip Quick solder along the IC leads. Keep the solder molten
by running your iron along the IC leads.
3. Insert tweezers and lift the IC up.
7
4. Remove the blobs of Chip Quick by heating and removing with a solder
sucker.
5. The remaining Chip Quick is removed with a solder wick. Move the
wick in the same direction as the lands of foil.
IC Installation
Once the solder and bridges are cleaned off with a solder wick, the new
IC can be installed. You must prevent static charges from damaging the
new IC by using a grounded wrist strap. The amount of static electric you
generate depends upon the humidity level and the clothing worn that day.
Some days you will not generate enough static electricity to damage the
new IC.
To solder all the IC leads without creating bridges, you need a constant tip
temperature soldering iron.
The constant tip temperature makes soldering uniform and increases the
speed of the soldering so you don’t have to resolder missed leads. Since
these constant tip temperature irons have a 5-10 second warm-up time
there is no reason to leave these irons on when in use.
8
1. Whichever iron you use, clean the tip by dipping it into a cleaner or
tinner. Kester and Multicore manufacture these. A dirty tip will cause
you to mis-solder some IC leads as you drag the solder across the IC
pins.
2. Tin one land on the board, then position the IC over the lands.
3. With the IC in place solder the lead to the tined land.
4. Check the IC position and solder another lead to hold the IC in place.
5. Apply flux from a pen to all the IC leads to stop solder bridges.
6. Using the magnifying glass, place the iron’s tip furthest away from you
on the IC pins and apply enough solder for 10 lands. Using the flat
part of the iron, drag the solder blob down the pins in a side by side
motion (zigzag pattern) allowing the solder blob to touch (heat) each
IC lead and land. Only a small amount of solder resides at each land.
At first it looks at though the lead was not soldered.
9
7. After soldering all the pins, run a dental pick across the pins to see if
movement reveals an unsoldered one.
9. Using a low flux solder means you do not have to clean the board of
flux with a flux remover…
8. Most technicians forget to inspect for bridges after installing the IC.
When power is turned ON, a bridge will take out the new IC or damage another related parts. Therefore it is important to inspect the pins
for bridges before approving your own work.
10. Remove the excess flux by spraying the area lightly with flux remover.
11. Place a towel over the work and dab the flux off with the stiff bristles of
the brush. This leaves the work clean without the cotton fibers leftover
had you used a cotton swab.
Sony is a registered trademark of Sony.
Chip Quick is a registered trademark of Chip Quick Inc; Mashpee, Mass.
10
NOTES
11
First Generation DVD
The first generation Sony DVD player consisted of two models, the DVPS3000 and the DVP-S7000. They housed separate laser assemblies to
play DVDs and CDs. Much of the video processing was done by discrete
medium size ICs. Failures across the country have been very low so
there is not much feedback history.
Symptom 1: Intermittent loss of brightness in the picture during PB
Cause: 1. Broken Video jack solder connection
2. A/V Decoder IC281 broke solder connection
3. A/V Decoder IC281 defective.
Repair Procedure
1. Check both video jacks for broken solder connections.
2. Press down on IC281 when the intermittent occurs. Resolder all the
pins if the condition responds to movement. Use flux on the pins to
prevent solder bridges and inspect the pins before powering the unit
on.
3. If the problem appears thermal, cool off the IC to see if the brightness
returns. Replace IC281.
12
1ST GENERATION - A/V DECODER / XTAL LOCATION SYMPTOM 1, 2
12/7/00
MB - 75 Board
X001
X002
IC002
X003
A/V
Decoder
IC281
X280
Shield
R213
13
First Generation DVD
The first generation Sony DVD player consisted of two models, the DVPS3000 and the DVP-S7000.
Symptom 2: No color or colors changing in the picture.
Cause: 1. X280 (66MHz) crystal near IC281 on the main board.
2. X003 (27MHz) crystal in the “can” on the main board.
Repair procedure
1. Turn the unit ON. The Xtals will start immediately. Check the 66MHz.
crystal by placing a scope and frequency counter (using a X10 probe)
on the crystal (corner nearest IC281) or on either side of R213 that is
in series with the Xtal. If the signal is off frequency or below 0.9Vp-p,
replace the crystal.
2. Perform the 27MHz free run adjustment by grounding TP025 and setting RV001 for 27MHz
+100Hz at TP018.
14
1ST GENERATION - 66 MHz XTAL SYMPTOM 2
12/28/0021DVD03
FL281 FL282
BUFFER
CONTROL
IC217
MPEG
VIDEO
DECODER
IC281
117
R213
220
DECRYPT
IC184
3.3V
1V p-p
1.8Vdc
LETTERBOX
IC310
27 MHz
PLL IC002/16
R216
22
87
X280
66 MHz
15
1ST GENERATION - 27 MHz DISTRIBUTION SYMPTOM 2
1/8/01
22DVD03
PLL
IC002
21
18
19
16
LPF
IC006
R027
100K
RV001
27 MHz
FREE RUN
-5V
D001
R022
22
27 MHz
4.7Vdc
42
TP025
MB-78 BOARD
FL012
FL037
BUFF
IC012
FL036
MPEG AUDIO DEC IC381/27
VIDEO DECODER IC281/87
VIDEO ENCODER IC475/8
LETTER BOX IC310/91
SUB PIX IC312/123
VIDEO EQ IC317/89
DATA PROCESS IC181/3
DECRYPT IC184/21, 43
BUFF CONTROL IC217/24
TP025
RV001
27MHz
IC002
SHIELD ON
MB-78 BOARD
X003
TP018
27MHZ ADJ
1) GND TP025
2) ADJ. RV001
FOR 27MHz + 100HZ
AT TP018
27MHz
TP018
X003
27 MHz
16
NOTES
17
First Generation DVD
The first generation Sony DVD player consisted of two models, the DVPS3000 and the DVP-S7000.
Symptom 3: No DVD disc detected at start up. CDs
may PB OK.
Cause: Laser assembly or Spindle motor is at end of its life.
Repair procedure
You will check the DVD RF level and use that to determine if the laser
output is sufficient to play back DVDs.
1. Check the DVD laser output at CN760/pin 1 on the MB board. Although there may not be an eye pattern because the DVD only starts
to play, you should see RF at CN760/pin 1. Normally there is a 1.6Vpp eye pattern at CN760/pin 1. The minimum operating RF level is
0.9Vp-p. The CD RF test point is at a different location.
2. If the DVD RF level is above 0.9Vp-p, suspect the spindle motor. Even
though the DVD disc spins, replace the spindle motor (P/N = 1-698944-11). Often when the spindle motor is bad, the RF eye pattern is
not clear or the waveform squeezes and expands like a musical accordion before shutting down.
18
1ST GENERATION - RF CHECK POINTS SYMPTOM 3/5
1/3/01
2
IC765
AMP
RF PROCESS
IC770
DVD
RF
27 mVp-p
CN980
CN760
MB-78 BOARDTT-701 BOARD
IC770
RF
MB-78 BOARD
22
21
CN980
CN760
CN886
TP891
23DVD03
2
1
12
34
12
34
5
1.6Vp-p
BOARD
LAYOUT
19
First Generation DVD
The first generation Sony DVD player consisted of two models, the DVPS3000 and the DVP-S7000.
Symptom 4: Intermittent or distorted sound when playing DVD movies only (not CDs).
Cause: Audio Control IC380 is defective.
Repair Procedure
1. Replace IC380 CXD8603BR (P/N = 8-759-490-29).
20
1ST GENERATION - A/V PROCESS SYMPTOM 4
12/28/00
24DVD03
RF
PROCESS
IC770
DATA
PROCESS
IC181
DECRYPT
IC184
BUFFER
CONT
IC217
MPEG
VIDEO
DECODER
LETTER
BOX
IC310
SUB
PIX
IC312
NTSC
VID
ENCODER
IC475
AUDIO
CONTROL
IC380
MPEG
AUDIO
DECODER
IC381
DIG
FILTER
IC801
D/A
CONV
IC802
RF
TT-701
BD
VIDEO
OUT
AUDIO
OUT
AUDIO
CONTROL
IC380
21
First Generation DVD
The first generation Sony DVD player consisted of two models, the DVPS3000 and the DVP-S7000.
Symptom 5: No PB or Picture freezes when playing
parts on some dual layer (gold) discs.
Cause: 1. Laser getting weak.
2. ROM IC093 cannot PB marginal spec gold discs.
Repair procedure
You will measure the DVD RF level going to the servo (not video) stages
and use that level for making the laser performance judgement.
1. See service bulletin 47 to locate TP891 (same as CN886/pin 5). Less
than 0.95Vp-p means you should replace the optical assembly. Align
the unit for all three disc types (CD, DVD single and dual layer).
2. If the RF level is normal at approximately 1.5Vp-p, replace ROM IC093
as in service bulletin 43R2 depending upon the model.
Alignment after laser replacement
The Tilt, focus, and Tracking adjustments are performed automatically
from the test mode using the remote and test discs. After the test mode is
accessed and “drive automatic adjustment” is entered, you are prompted
to load the first DVD disc for alignment. Afterwards the screen prompts
you to replace the disc with a dual layer DVD and then finally with a CD to
complete the alignment. The procedure is as follows:
• Access the Test Mode by pressing the following buttons on the remote: Time, Clear, then Power.
• From the Test Mode Menu, select 1. Drive Auto Adjustment.
• From the Auto submenu, select 0. All (discs – one at a time).
• The screen will prompt you as to what disc to place on the tray and
what buttons to press to complete the alignment.
22
NOTES
23
Second Generation DVD
The second generation DVD players consist of models DVP-S300, DVPS500d, DVP-C600d, and DVP-S7700.
Symptom 1: No response to the Power ON button.
Cause: There are three common causes for this symptom.
1. A damaged power supply;
2. A short on another board that causes no power supply output voltage;
or
3. A defective front panel encoder (ref #165 in the DVP-S500d service
manual) preventing IC604 from reading the power ON button by locking up its program so the unit may not turn ON (intermittent turn ON).
Repair Procedure:
The power supply runs all the time when 120VAC is input, producing E
+5V. The +3.3V, +5V and
+12V outputs are switched ON when the unit is
turned ON. You first need to determine if the basic power supply is defective.
1. Unplug the cable from the only connector on the power supply, CN201.
Look for E+5Vdc at CN201/pin 6 (alternate test point is at PS312)
from the power supply board. If there is no voltage, the power supply
is inoperative. The most common cause is a shorted main oscillator
MOSFET transistor, Q103, which has taken out the main fuse. Q103
P/N = 9-880-437-01 which is a 2SK2798 for the USA models.
If the new Q103 fails or there is still no output voltage, replace the
associated control parts Q101, Q102 and D104.
2. If the power supply does produce the E+5, the front panel rotary en-
coder or a short in another board is suspected. The encoder is attached to a ribbon cable that plugs into CN103 of the front panel board.
Unplug the encoder, plug in the power supply cable and press the
power ON button to verify the defect.
3. If the unit still did not power up, you may leave the rotary encoder
cable detached while you look for the short circuit that is preventing
your unit from responding to the Power ON button. This is because
the front panel must be removed to reseat the encoder cable and it is
more important that you locate the problem. Either use your ohm
meter to locate a short at the power supply connector CN201 or repeatedly press the power button while monitoring the output voltages
to see which one is missing:
CN201/pin 1 = +5.2Vdc
CN201/pin 2 = +5.2Vdc
CN201/pin 3 = Ground
CN201/pin 4 = +3.3Vdc
CN201/pin 5 = Ground
CN201/pin 6 = E5.Vdc
CN201/pin 7 = Ground
CN201/pin 8 = P Cont (input)
CN201/pin 9 = AU +12Vdc
CN201/pin 10 = AU Ground
CN201/pin 11 = AU –12Vdc
CN201/pin 12 = -12Vdc
CN201/pin 13 = Ground
CN201/pin 14 = Motor +12Vdc
CN201/pin 12 = Motor Ground
Use the +3.3V and 5V distribution diagrams in this book (symptom 2) to
locate the shorted IC.
24
2ND GENERATION - POWER SUPPLY SYMPTOM 1
1/8/01
Q103 OSC.
2SK2178
T101
Q101
2SK2798
Q102
2SC2377
Q211 SW.
2SJ488
Q311 SW.
2SA1679
IC611
3.3V REG.
Q511,
Q512
SWITCH
Q312
INV.
14
6
11
4
1
11
12
D104
2.4V
D211
D211
D611
P511
P311
P312
P211
CN201
HS-930 SU
BOARD
MTR+12V
AV+12V
E+5V
+5.2V
P CONT.
3.3V
AV-12V
-12V
4DVD03 1294
2
8
P CONT.
25
2ND GENERATION - POWER ON SYMPTOM 1
1/16/01
IC604
IF MICON
POWER SUPPLY
EVER
5V
CN103
POWER
P/N 1-475-685-11
P CONT.
IC611,Q311,
Q211
FL88 BD.
MB78 BD.
HS930 SW BD.
18DVD03 1307
ROTARY
ENCODER
JOG WHEEL
ENTER
BUTTON
26
NOTES
27
Second Generation DVD
The second generation DVD players consist of models DVP-S300, DVPS500d, DVP-C600d and DVP-S7700.
Symptom 2: Powers OFF two seconds after turn ON
Cause: There are two causes for this symptom –
1. An internal IC short will load down a power supply voltage. This removes the voltages to the other ICs and communications end. Once
IC communications end, Syscon shuts down the DVD player because
it senses a defect.
2. At power ON the laser must be detected at home position or the unit
will detect a malfunction and shut down. If the sled motor is frozen,
the laser will not return to home.
Repair Procedure:
If the power supply board makes a chirping noise when you press the
power button, an output is being loaded down. Measure the output voltages to find out which one. The most common shorted ICs are:
2nd Generation Players - Shorted ICs
Function IC # Ref # in DVP-S500d
Large Gate Array (LGA) CX8728Q IC804
Audio DSP CX8730R IC506
If the power supply is OK, the sled may be defective on these older units.
Remove the lid that houses the mechanism and slide the laser away from
home at the spindle motor. At power ON, the laser should travel to the
spindle motor (home) then move outward. If home is not detected, the
laser assembly will incorrectly remain where it is and the unit will shut
down. The sled motor assembly is P/N = X-394-713-71.
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