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KDL-22EX308
User Manual
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User Manual
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User Manual
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Safety and Regulatory Booklet
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Operating Instructions
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Table of contents
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Sony KDL32EX308, KDL22EX308 User Manual

Training Manual
KDL32EX308
AZ1L Direct-View LCD Television Chassis
Circuit Description and Troubleshooting Guide
MODELS: KDL22EX308 KDL32EX308
Course : CTV-68
Table of Contents
Chapter 1 – Introduction ..................................................... 1
Overview .......................................................................... 1
Features .......................................................................... 1
Consumer Electronics Control (CEC) ..................................... 2
xvYCC ..................................................................................... 2
Deep Color .............................................................................. 2
Chapter 2 – Overall Circuit Descriptions ........................... 3
Overview .......................................................................... 3
Overall Circuit Description ............................................... 3
A/V Decoder IC9000 ............................................................... 3
Audio Processing .................................................................... 3
HDMI Switch ........................................................................... 3
CPU ........................................................................................ 3
LVDS Transmitter .................................................................... 3
KDL22EX308 .......................................................................... 4
KDL32EX308 .......................................................................... 4
Chapter 3 – Troubleshooting .............................................. 7
Introduction ...................................................................... 7
Software Updates ............................................................ 7
Special Software Instructions for BAL Board or LCD Panel
Replacement ............................................................... 9
Audio Troubleshooting ................................................... 14
Power Supply Troubleshooting ...................................... 14
Completely Dead Set ............................................................ 14
Won’t Power On .................................................................... 14
Backlight Issues ............................................................. 18
Diagnostics History ........................................................ 18
Circuit Board and Connector Locations ......................... 19
Chapter 4 – Appendix ........................................................ 24
TCON Troubleshooting .................................................. 24
CTV-63 i
Table of Contents (Continued)
Introduction .................................................................... 24
Diagnosing a Failed TCON ............................................ 27
Troubleshooting a “DEAD” TCON ......................................... 29
CTV-63 ii
Chapter 1 – Introduction

Overview

The AZ1L chassis is one of several designs for the 2010 model line of Sony Bravia® LCD televisions. Several models will be released incorporating this chassis. This training manual will cover the EX308 series consisting of the following models:
KDL22EX308
KDL32EX308
The chassis design revolves around the video processing circuits located on the BAL board. The key difference between models is determined by the size of the LCD panel and its manufacturing source. This manual will describe the new circuit features and individually describe the models based on these differences.

Features

Several new features are introduced in the EX-M chassis model lineup along with some carryovers from the previous year.

720p Panel

The EX308 models incorporate a native 1366 X 768 (WXGA) resolution panel. All video signals exit the video process circuits as 720p 60HZ. The RGB resolution is 8-bit to provide 256 levels of gray scale.
CCFL Backlighting
Many of the 2010 Sony television models are introducing edge-lit LED backlighting. The EX308 series incorporates traditional cold-cathode fluorescent lamps (CCFL) to generate the necessary backlighting for the LCD panel. A self contained (direct) inverter circuit supplies the necessary high voltage to drive the backlight lamps.
Wireless Internet Ready
An optional wireless network adapter is available to connect the television to a home network. These models have an Ethernet port on the rear for direct connection to the home network. Plugging the optional wireless network adapter into the USB2.0 port on the side of the television allows for wireless connectivity when conditions do not allow direct connections. The wireless adapter supports up to 802.11N.
BRAVIA™ Internet Video
Once available as an optional device to connect to the television, this feature is now an integral part of the product. The rear of the television contains an Ethernet port to connect to a high speed network. Access to online music and video through partnered websites is possible.
Personalized “widgets” are small applications that can be placed on the screen and accessed with the touch of a button to bring up programming such as weather, stocks and sports information.
Enhanced Cross Media Bar (XMB)
A new graphics user interface with rich 3-D graphics allowing the user to customize the setup of the television and to access various adjustments and control optional devices. Optional external devices can also be detected and displayed. One example would be when a USB storage device is plugged into the USB2.0 side input that contains JPEG format photos. The detection of the device will appear in the XMB graphics icons along with thumbnail views of the photos stored on the device. The photos can be viewed individually or be displayed as a slide show.
CTV-68 1
Chapter 1 - Introdcution
USB2.0 Side Input
This feature was available in selected 2008 models and allowed the viewing of JPEG formatted pictures and playback of MP3 audio files. The media content has been expanded this year to allow playback of MPEG1 and MPEG2 format video content. An optional wireless network adapter can be inserted to connect to a wireless home network.
HDMI 1.3
This new version of HDMI introduces several new enhancements and features and the EX-1 chassis supports 3 of the new features.
Consumer Electronics Control (CEC)
A standardized protocol for the control of consumer electronics devices allows for communication and control via the HDMI cable on products that have this feature. Any brand of electronic equipment that is CEC compliant can communicate with another to generate operational commands. The Bravia Sync feature uses the CEC format to control other Sony devices in the system.
xvYCC
The previous color bandwidth limitations applied for compatibility with analog signals are no longer present with digital signals. This allows for
1.8 times more colors.
Deep Color
Bravia® Sync
By utilizing the CEC feature of HDMI 1.3, this feature allows the customer to easily control the various Sony devices within their home entertainment system provided that all of the other devices have this feature included.
Advanced Contrast Enhancer (ACE)
By monitoring the overall level of the video signal, the backlights are dynamically controlled and reduced during low light level scenes to enhance the contrast ratio.
Interactive Program Guide (IPG)
An interactive guide is included to provide continuously updated program information at no charge to the customer. The guide (provided by TV Guide) is part of the XMB graphics feature. Program material is updated from the local PBS station when the television is off.
Digital Living Network Alliance (DLNA)
An industry standard networking protocol has been developed by leading manufacturers to allow other devices such as a compatible computer to communicate with the television via an Ethernet connection to your home network. This gives the ability to view photos, audio and movie content directly from your computer via the network. Future plans include the ability to download software updates for the television via the home network.
The previous HDMI specifications limited the RGB sample level to 24-bit. Deep Color expands this up to 48-bit giving the ability to generate a color depth of 2.8 trillion levels.
RGB Ambient Sensor
A sensor located on the lower left portion of the front bezel monitors ambient light levels to adjust the brightness and contrast level of the picture. This new version is also capable of measuring the color temperature of the ambient light to adjust the white balance of the displayed picture based on what type of light source is present in the room.
CTV-68 2
Chapter 2 – Overall Circuit Descriptions
Overview
The primary circuits contained in the AZ1L chassis consists of a main circuit board (designated as the BAL board), power supply (GD1 Or G2LE) which varies based on the size of the LCD display, and the LCD panel assembly. The TCON circuit (normally mounted external to the LCD panel) is contained inside the panel assembly. The remaining small boards contain switches, sensors and LED’s.
Overall Circuit Description
Figure 2-1 illustrates an overall block diagram of the KDL22EX308. Figure 2-2 illustrates an overall block diagram for the KDL32EX308. Both chassis designs share most of the same circuits with the power supply and high voltage circuits to supply the lamp voltages being the significant difference. Below is a description of the components and their function for the KDL22EX308.
BAL Board
Common to all models utilizing the AZ1L chassis, the BAL board contains most of the video processing circuitry along with all audio processing. Control of the television is accomplished via CPU IC5000. Below is a list of the key components located on the BAL board.
Digital Audio and Video Decoder: The MPEG2 and Digital Dolby audio streams are received from the tuner for decompression. All video sources which are not native 1280 X 720p 60HZ are scaled to this resolution. Digital audio content is output to IC4200 for processing and amplification.
Audio Processing
IC4200 selects and processes all audio sources. The audio content is processed digitally, amplified and sent to the speakers.
HDMI Switch
IC2000 functions as a switch for the 4 HDMI inputs. It also serves as an equalizer to match the low impedance of the input jacks to the high impedance of the input to IC9000. IC2000 also contains a shared memory for the EDID information for each HDMI input. When a particular HDMI input is selected, IC9000 loads the proper EDID information into the shared memory.
CPU
IC5000 controls most of the operation of the television. All user inputs are processed here. IC5000 also monitors key voltages and protection circuits to shut the unit down if a problem is detected.
A/V Decoder IC9000
This IC performs several functions including the following:
Tuner: The tuner is a combination ATSC/NTSC unit. It can receive traditional analog NTSC signals via cable or terrestrial along with ATSC digital signals via terrestrial (8VSB) or cable (64 or 256 QAM).
Analog Video Input Switch: The analog video is A/D converted and scaled (if necessary) to a 1920 X 1080p 60HZ resolution.
LVDS Transmitter
Integrated into IC9000 is a Low Voltage Differential Signaling (LVDS) transmitter. This circuit converts the 8-bit parallel RGB video information into a set of high speed serial lines for noise-free transmission to the TCON board.
CTV-68 3
Chapter 2 - Overall Circuit Description
Power Supply
KDL22EX308
The KDL22EX308 utilizes the GD1 power supply board. There are 3 distinct sections on the power supply:
Standby Supply: Continuously operational as long as AC power is applied, the standby supply generates 3.3VDC for the circuits requiring power while the unit is turned off. An unregulated 15-volt line is present to provide power to the main relay, PFC and main power supply at turn-on.
Main Supply: Once the power supply receives a power-on command from the CPU on the BAL board, the main switching supply is turned on to provide a regulated 12V source, along with a dedicated un-regulated 15V for the audio circuits.
Inverter: The high voltage for the fluorescent backlights is generated by this circuit. Out-of-phase AC voltage of approximately 1000VRMS is applied to the balancer circuit. If the inverter circuit fails to start, for whatever reason, the unit will shut down with a 6-blink error code displayed by the timer LED.
KDL32EX308
Inverter
The inverter receives the unreg24V from the G2LE board and generates the required high voltage AC to power the backlight lamps. As of the writing of this manual, the inverter is not available as a replacement part. The LCD panel assembly must be replaced.
Switch Unit
This board contains the power, channel and volume up/down and menu buttons.
HLR Board
The power, standby and timer LED’s are located on this board along with the IR remote receiver and ambient room light sensor for controlling backlight and RGB levels.
Referring to Figure 2-2 the KDL32EX308 utilizes the G2LE power supply board. All of the other circuits are the same as the KDL22EX308 except for the following circuits:
There are 2 distinct sections on the power supply:
Standby Supply: Continuously operational as long as AC power is applied, the standby supply generates 3.3VDC for the circuits requiring power while the unit is turned off. An unregulated 15-volt line is present to provide power to the main relay, PFC and main power supply at turn-on.
Main Supply: Once the power supply receives a power-on command from the CPU on the BAL board, the main switching supply is turned on to provide a regulated 12V source, a dedicated un-regulated 15V for the audio circuits and an unregulated 24V source for the inverter circuit.
CTV-68 4
COMPOSITE OR
COMPONENT
1
RF
COMPOSITE 3
COMPONENT 2
HDMI 1
PC HD15
POWER SUPPLY
INVERTER
SWITCH
UNIT
LED
IR RX
RGB SENSOR
LCD PANEL
BAL
GD1
HLR
L
R
ANALOG AUD IO OUT
OPTICAL AU DIO OUT
HDMI 3
IC4200
AUD IO SW
D/A
AMP
IC9000
A/V
DEC ODER
VIDEO
PROCESS
IC2200
HDMI
SWITCH
EQ
TUNER
ANALOG
VIDEO IN
EITHERNET
USB
2.0
ANALOG
AUD IO IN
HDMI 2
HDMI
4
LVDS
CCFL HV
AC IN
DIGITAL
TUNER IN
DIGITAL
AUD IO
IC5000
SUB
-
MICRO
Chapter 2 - Overall Circuit Description
CTV-68 5
22EX308 OVERALL BLOCK DIAGRAM
FIGURE 2-1
COMPOSITE OR
COMPONENT 1
RF
COMPOSITE 3
COMPONENT 2
HDMI 1
PC HD15
POWER SUPPLY
SWITCH
UNIT
LED
IR RX
RGB SENSOR
LCD PANEL
BAL
G2LE
HLR
L
R
ANALOG AUD IO OUT
OPTICAL AU DIO OUT
HDMI 3
IC4200
AUD IO SW
D/A
AMP
IC9000
A/V
DEC ODER
VIDEO
PROCESS
IC2200
HDMI
SWITCH
EQ
TUNER
ANALOG
VIDEO IN
EITHERNET
USB
2.0
ANALOG
AUD IO IN
HDMI 2
HDMI 4
LVDS
B+/CONTROL
AC IN
DIGITAL
TUNER IN
DIGITAL
AUD IO
IC5000
SUB-
MICRO
INVERTER
Chapter 2 - Overall Circuit Description
CTV-68 6
32EX308 OVERALL BLOCK DIAGRAM
FIGURE 2-2
Chapter 3 – Troubleshooting
Introduction
Most troubleshooting of this chassis focuses on the 3 major components used:
• The Main Board (BAL)
• Power Supply (G1D or G2LE)
• LCD Panel
This chapter will provide practical troubleshooting procedures based on the various symptoms that will appear when a particular circuit fails to operate properly. Typical failure symptoms will be discussed along with troubleshooting flowcharts for each symptom.
Always remember to log on to the Sony technical support site at http://
www.sony.com/asp to access the latest technical bulletins along with
triage charts to quickly identify the most likely part to complete the repair based on the symptom.
Software Updates
The subject of software updates is a very important item to point out at this point. The televisions of today have advanced to the point where they are not simply a television anymore. They are evolving into devices that are designed to integrate with numerous other devices found in the home. Some examples are: Portable audio and video devices, still cameras, home computer networks and accessing the internet to name a few.
Communications with these varying devices requires that the television be compatible with varying communications protocols. Although standards are detailed for each of these protocols, the real world dictates that occasional errors may occur that could prevent devices from operating or communicating properly.
Keeping the software in the television up-to-date is a procedure that is normally handled by the owner of the television. Most customers who own computers and other digital devices are familiar with and are accustomed to updating the firmware and software in their products. If a customer contacts the Sony Customer Support Center and it is deemed to be correctable with a software update, the issue is handled at the customer level.
Software updates can be performed in the following ways:
• Manual Downloads: Software updates can be retrieved from the Sony Support Site at http://esupport.sony.com where they can be downloaded and placed on a USB thumb drive to be loaded into the product. The instructions for downloading the software file vary from chassis to chassis and sometimes from model to model. Read the instructions included with the software file to properly format the USB device, unzip the file (if necessary) and the procedure for loading the software into the television.
• Network Downloads: Internet software updates are becoming more prevalent as more and more models incorporate home network capabilities. This method is the most practical since the television will check for the latest version of software. The models using the AZ1L chassis provide the customer with a choice of turning the automatic software update feature on or off. If set to on, the television will lookup software information while the unit is in standby. If a newer version is available, it will be downloaded and installed without any input from the customer
• Built-in Tuner: OTA or cable sources having the proper station that is transmitting software update data packets. Although the ability to transmit software update is possible in this way, it is the least common and is reserved for particular situations where a critical update is “forced”, thereby updating the unit without any input from the customer.
CTV-68 7
Chapter 3 - Troubleshooting
INSTALLED
SOFTWARE VERSION
Software Update Responsibility
Software updates are designed to be performed by the customer. Warranty repairs in which the issue can be resolved by a software update are not reimbursable. Most issues involving software updates are handled by the customer service center and should not be directed to an authorized service center. It is the responsibility of the servicer to prevent service calls for issues that involve software updates. Exceptions to this are certain cases whereby the customer is unable or unwilling to perform the task. In this situation, the servicer will be notified and receive the proper authorization for reimbursement.
It is the servicer’s responsibility, however, to make certain that any unit
requiring a legitimate service is running the latest software version and to install it if necessary.
Examples of Software Correctable Symptoms
Always check the Sony Technical Support site for any known and listed issues that are software related. Most symptoms that are correctable by software updates involve communications issues with other devices or minor glitches in the operation of a specific function. Below is a list of some of the symptoms that may be corrected with a software update:
Checking the Software Version
The easiest way to check the version of software is to use the customer menu. Engage the XMB graphics by pressing “HOME” on the remote commander. Scroll left on the graphics icons until the end is reached. Scroll up and select the “Product Support” icon. Select “Contact Sony”. The information illustrated in Figure 3-1 will appear. Compare the package version listed on the screen with the version available on line. Install the software if the on line version is a higher numbered version.
• Fluctuations in picture brightness
• Intermittent picture freezing or noise
• Problems with certain inputs (especially HDMI)
• Intermittent or distorted audio
• Erratic remote control operation
• Unit turns on and off by itself
• Loss of color
• Internet connectivity
• Certain features not working correctly
CTV-68 8
CHECKING THE SOFTWARE VERSION
FIGURE 3-1
Special Software Instructions for BAL Board or LCD Panel Replacement
The 2010 models utilize a “generic” type BAL board. In the past, many different main boards needed to be stocked due to differences in software requirements. The software loaded on the board was specific to the model and its features along with the type of LCD panel installed during production.
Replacement BAL boards will now be stocked with basic software. Once the replacement board is installed in the unit, the most current software is to be installed using a USB storage device containing the necessary software downloaded from the ASC support web page.
In addition to software installation for specific models, 2 items must be checked and adjusted in the service mode. The adjustments are Segment Data (model ID) and Destination (region ID). The procedures for the software installation are located on the ASC website (http://www.sony.
com/asp). The adjustment procedures are located in the service manual.
This new method of supplying main boards significantly reduces the complexity of replacing LCD panels and main boards. Information about the LCD panel is stored on the TCON circuits. This information is automatically loaded onto the main board when the unit is powered up. The need to lookup data in the LCD panel manual is no longer necessary. With the correct software version and proper settings of the Segment and Destination data the BAL board and/or the TCON or LCD panel can be replaced more efficiently.
Chapter 3 - Troubleshooting
CTV-68 9
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