Sony KDL-32EX340, KDL-42EX440, KDL-42EX441 Schematic
Self Diagnosis
HISTORY INFORMATION FOR THE FOLLOWING MANUAL:
SERVICE MANUAL
Supported model
AZ3FK Chassis
ORIGINAL MANUAL ISSUE DATE: 7/2012
Version Date Subject
1.0 7/3/2012 Original Manual Release Date.
2.0 7/19/2012 New caution added on page ii.
Updated Service Adjustments section. Replaced pages 24 - 32.
3.0 9/4/2012 Added new Main Board information for Latin America region. Replaced page 16.
Segment: P-2LT
LCD Digital Color TV
9-883-895-03
Self Diagnosis
SERVICE MANUAL
Supported model
AZ3FK Chassis
Segment: P-2LT
LCD Digital Color TV
KDL-42EX440
9-883-895-03
MODEL LIST
MODEL COMMANDER DESTINATION MODEL COMMANDER DESTINATION
KDL-32EX340 RM-YD080 US/CND
KDL-42EX440 RM-YD080 US/CND
KDL-32EX340 RM-YD080 MX/LA
KDL-42EX440 RM-YD080 MX/LA
KDL-42EX441 RM-YD080 US
9-883-895-03
TABLE OF CONTENTS
Cautions and Warnings ...................................................................................ii
Section 1 - Features and Overview ................................................................1
Features ........................................................................................................1
Specications ................................................................................................1
Chassis Overview .......................................................................................... 3
Overall Circuit Description ............................................................................. 4
Main Board ...............................................................................................4
Power Supply Board ................................................................................. 4
IR Board .................................................................................................... 4
Switch Unit ................................................................................................ 4
LCD Panel Assembly ................................................................................ 5
Section 2 - Troubleshooting ...........................................................................6
Overview .......................................................................................................6
Updating the Software ..............................................................................6
Self Diagnosis Function ................................................................................. 6
Standby LED Blink Count .........................................................................6
Viewing the Self Check Diagnosis History ................................................ 7
Triage Chart ...................................................................................................8
Section 3 - Flow Charts and Diagrams ..........................................................9
Block Diagram ...............................................................................................9
No Power ..................................................................................................... 10
Standby LED Blinking .................................................................................. 12
No Video ......................................................................................................13
Section 4 - Disassembly/Part Number Information ....................................15
Table-Top Stand and Rear Cover Removal .................................................15
Chassis Assembly Removal ........................................................................ 16
Bezel Assembly Removal ........................................................................... 17
Connectors ..................................................................................................18
KDL-32EX340 Only ................................................................................18
KDL-42EX440/42EX441 Only ................................................................. 18
Screws ......................................................................................................... 19
Accessories and Packaging ........................................................................20
Miscellaneous .............................................................................................. 20
Wire Dressing .............................................................................................. 21
Section 5 - Updates and Adjustments .........................................................22
Overview .....................................................................................................22
Software Updates for Customers ................................................................22
Software Updates for Servicers ................................................................... 22
Software Update Responsibility .............................................................. 23
Checking the Software Version ...............................................................23
Examples of Software Correctable Symptoms .......................................23
Updating the Software ................................................................................. 24
Accessing Service Adjustment Mode ..........................................................24
Completing Service Requirements When Replacing the Main Board ......... 25
Viewing the Status Information ...............................................................25
Selecting the Panel ID Code ................................................................... 26
Adding the Serial Number ....................................................................... 27
Adding the Model Name .........................................................................28
Completing Service Requirements When Replacing the LCD Panel .......... 30
Verifying the Panel ID Code ....................................................................30
Resetting Panel Operation Time .............................................................31
Accessing Factory Adjustment Mode ..........................................................32
Adjusting the Color Temperature ............................................................32
Appendix A: Encryption Key Components ...............................................A-1
KDL-32EX340/42EX440/42EX441 i
CAUTIONS AND WARNINGS
CAUTION!!
These servicing instructions are for use by qualied service personnel only.
To reduce the risk of electric shock, do not perform any servicing other than
that contained in the operating instructions unless you are qualied to do so.
WARNING!!
An isolation transformer should be used during any service to avoid possible
shock hazard, in case of live chassis.
!
SAFETY-RELATED COMPONENT WARNING!!
There are critical components used in LCD color TVs that are important for
safety. These components are identied with shading and
schematic diagrams and the parts list. It is essential that these critical parts
be replaced only with the part number specied in the parts list to prevent
electric shock, re, or other hazard.
NOTE: Do not modify the original design without obtaining written permission
from the manufacturer or you will void the original parts and labor warranty.
!
mark on the
ATTENTION!!
For safety reasons, component level repair of the Power Supply Boards
and/or the Inverter Boards is prohibited.
ATTENTION!!
Ces instructions de service sont à l’usage du personnel de service qualié
seulement. Pour prévenir le risque de choc électrique, ne pas faire l’entretien
autre que celui contenu dans le Mode d’emploi à moins que vous soyez
qualié faire ainsi.
ALERTE!!
An d’eviter tout risque d’electrocution provenant d’un chássis sous tension,
un transformateur d’isolement doit etre utilisé lors de tout dépannage.
!
ATTENTION AUX COMPOSANTS
RELATIFS A LA SECURITE!!
Les composants identies par une trame et par une marque
schemas de principe, les vues explosees et les listes de pieces sont d’une
importance critique pour la securite du fonctionnement. Ne les remplacer
que par des composants Sony dont le numero de piece est indique dans le
present manuel ou dans des supplements publies par Sony. Les reglages
de circuit dont l’importance est critique pour la securite du fonctionnement
sont identies dans le present manuel. Suivre ces procedures lors de
chaque remplacement de composants critiques, ou lorsqu’un mauvais
fonctionnement suspecte.
!
sur les
ATTENTION!!
Pour des raisons de sécurité, Interdire de réparer ou remplacer les
composantes dans les blocs d’alimentation et/ou sur les modules d’inverseur.
KDL-32EX340/42EX440/42EX441 ii
CAUTIONS AND WARNINGS
SETTING UP AND CARRYING THE TV
● Disconnect all cables when carrying the TV.
● Carry the TV with the adequate number of people; larger size TVs require two or more people.
● Correct hand placement while carrying the TV is very important for safety and to avoid damage.
USE CAUTION WHEN HANDLING THE LCD PANEL
When repairing the LCD panel, be sure you are grounded by using a wrist band.
When installing the LCD panel on a wall, the LCD panel must be secured using the 4 mounting holes on the rear cover.
1. Do not press on the panel or frame edge to avoid the risk of electric shock.
2. Do not scratch or press on the panel with any sharp objects.
3. Do not leave the module in high temperatures or in areas of high humidity for an extended period of time.
4. Do not expose the LCD panel to direct sunlight.
5. Avoid contact with water. It may cause a short circuit within the module.
6. Disconnect the AC power when replacing the backlight or inverter circuit.
(High voltage occurs at the inverter circuit at 650Vrms).
7. Always clean the LCD panel with a soft cloth material.
8. Use care when handling the wires or connectors of the inverter
circuit. Damaging the wires may cause a short.
9. Protect the panel from ESD to avoid damaging the electronic
circuit (C-MOS).
10. During the repair, DO NOT leave the Power On for more than
1 hour while the TV is face down on a cloth.
KDL-32EX340/42EX440/42EX441 iii
CAUTIONS AND WARNINGS
CLEANING THE LCD PANEL
CAUTION: When cleaning the TV, be sure to unplug the power cord to avoid any chance of electric shock.
Clean the cabinet of the TV with a dry soft cloth.
Wipe the LCD screen gently with a soft cloth.
; Stubborn stains may be removed with a cloth slightly moistened with a solution of mild soap and warm water.
; If using a chemically pretreated cloth, please follow the instruction provided on the package.
; Never use strong solvents such as a thinner, alcohol or benzine for cleaning.
; Periodic vacuuming of the ventilation openings is recommended to ensure proper ventilation.
; Do Not use paper towels, any type of abrasive pad, rags, rubber or vinyl materials to clean the screen. Using these materials could easily scratch the
screen which may result in permanent damage.
; Do Not use any cleaning product containing alkaline/acid cleaner, scouring powder, or volatile solvent, such as alcohol, ammonia, benzine, thinner or
insecticide. Using any of these harsh cleaners may result in permanent damage to the screen.
; Do Not spray water or detergent directly onto the TV screen. If liquid drips into the bottom of the screen it may cause a failure.
KDL-32EX340/42EX440/42EX441 iv
CAUTIONS AND WARNINGS
To Exposed Metal
Parts on Set
0.15 µF
Earth Ground
AC
Voltmete
r
(0.75V)
Trouble Light
SAFETY CHECK-OUT
After correcting the original service problem, perform the following safety
checks before releasing the set to the customer:
1. Check the area of your repair for unsoldered or poorly soldered
connections. Check the entire board surface for solder splashes
and bridges.
2. Check the interboard wiring to ensure that no wires are “pinched”
or touching high-wattage resistors.
3. Check that all control knobs, shields, covers, ground straps, and
mounting hardware have been replaced. Be absolutely certain that
you have replaced all the insulators.
4. Look for unauthorized replacement parts, particularly transistors,
that were installed during a previous repair. Point them out to the
customer and recommend their replacement.
5. Look for parts which, though functioning, show obvious signs of
deterioration. Point them out to the customer and recommend their
replacement.
6. Check the line cords for cracks and abrasion. Recommend the
replacement of any such line cord to the customer.
7. Check the antenna terminals, metal trim, “metallized” knobs,
screws, and all other exposed metal parts for AC leakage. Check
leakage as described in “Leakage Test”.
The AC leakage from any exposed metal part to earth ground and from all
exposed metal parts to any exposed metal part having a return to chassis,
must not exceed 0.5 mA (500 microamperes). Leakage current can be
measured by any one of three methods.
1. A commercial leakage tester.
Follow the manufacturers’ instructions provided with the tester.
2. A battery-operated AC milliammeter.
LEAKAGE TEST
3. Measuring the voltage drop across a resistor by means of a VOM
or battery-operated AC voltmeter. The “limit” indication is 0.75 V, so
analog meters must have an accurate low voltage scale. Nearly all
battery-operated digital multimeters that have a 2 VAC range are
suitable. (see Figure A)
Figure A. Use an AC voltmeter to check AC leakage.
HOW TO FIND A GOOD EARTH GROUND
The cover-plate retaining screw on most AC outlet boxes is at earth ground.
Verify the AC outlet box retaining screw ground by connecting a 60W to
100W incandescent (not a neon or uorescent lamp) between the hot side of
the receptacle and the retaining screw. Try both slots, if necessary, to locate
the hot side on the line; the lamp should light at normal brilliance if the screw
is at ground potential. (see Figure B)
AC Outlet Box
Figure B. Checking for earth ground.
KDL-32EX340/42EX440/42EX441 v
SECTION 1 - FEATURES AND OVERVIEW
FEATURES
The AZ3FK chassis is one of several designs for the 2012 model line of
Sony Bravia® LCD televisions. This manual covers the following models:
KDL-32EX340
KDL-42EX440
KDL-42EX441
The features of the EX34x and EX44x series Edge LED LCD HDTV include:
● Brilliant Full HD 1080p picture quality
● Lifelike movement with Motionow™ XR120
● Digital Media Accessibility: photo, music and video
● Clear Resolution Enhancer for clear detail
● Bright picture & thin design with Edge LED backlight
● PIP (Picture in Picture): You can work on your PC and watch your
favorite TV program simultaneously
● BRAVIA® SyncTM: Allows your BRAVIA TV to communicate with
other Sony equipment supporting the Control for HDMI function
SPECIFICATIONS
System
Television system
Channel coverage Analog terrestrial: 2 - 69 / Digital terrestrial: 2 - 69
Panel system
Speaker output
Input/Output jacks
CABLE/ANTENNA
VIDEO IN
COMPONENT IN YP
HDMI IN 1/2
AUDIO OUT
DIGITAL AUDIO OUT
(OPTICAL)
PC IN
PC/HDMI IN 1 AUDIO IN Stereo mini jack, 500 mVrms, (Typical) / Impedance: 47 kilohms
USB
NTSC: American TV standard
ATSC (8VSB terrestrial): ATSC compliant 8VSB
QAM on cable: ANSI/SCTE 07 2000 (Does not incl ude CableCARD functionality)
Analog Cable: 1 - 135 / Digital Cable: 1 - 135
LCD (Liquid Crystal Display) Panel
KDL-42EX440/KDL-32EX340: 6 W + 6 W
KDL-42EX441: 8 W + 8 W
75-ohm external terminal for RF inputs
AUDIO: 500 mVrms (Typical) / Impedance: 47 kilohms
BP R (Component Video): Y: 1.0 Vp-p, 75 ohms unbalanced, sync negative
PB: 0.7 Vp-p, 75 ohms
P
R : 0.7 Vp-p, 75 ohms / Signal format: 480i, 480p, 720p, 1080i, 1080p
AUDIO: 500 mVrms (Typical) / Impedance: 47 kilohms
HDMI: Video: 480i, 480p, 720p, 1080i, 1080p, 1080/24p
Audio: Two channel linear PCM 32, 44.1 and 48 kHz, 16, 20 and 24bits, Dolby Digital
PC Input
500 mVrms (typical)
PCM/Dolby Digital optical signal
See the PC Input Signal Reference Chart for PC and HDMI IN
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evitagen cnys ,decnalabnu smho 57 ,p-pV 1 :OEDIV
evitisop ,smho 57 ,p-pV 7.0 ,BGR golana ,nip-51 bus-D
KDL-32EX340/42EX440/42EX441 1
SECTION 1 - FEATURES AND OVERVIEW
•Optional accessories availability depends on its stock.
•Design and specications are subject to change without notice.
*Dimensions and mass are approximate values.
Mass*
(lb)
14.1
31.1
7.7
17.0
without stand (kg)
(lb)
13.2
29.1
7.1
15.7
Remote control RM-YD080 (1)/ Size AA batteries (2)/ Operating Instructions (1)/ Quick Setup Guide (1)
Warranty Card (1)/ Safety and Regulatory Booklet (1)/ Software License (1)/
Stand installation guide (1)/ Table-Top Stand (1 set)/ Screw (3)
Optional accessories Connecting cables / Support Belt Kit / Wall-Mount Bracket: SU-WL500 (KDL-42EX441/42EX440),
SU-WL100 (KDL-32EX340)
Model name KDL-42EX441
KDL-42EX440
KDL-32EX340
Power and others
Power requirement
Power consumption
W 55W 59
in use
in standby
Screen size*
42 31.5
(32 class)
(measured diagonally)
(inches)
0.087.601)mc(
Display resolution 1,920 dots (horizontal) × 1,080 lines (vertical) 1,366 dots (horizontal) × 768 lines (vertical)
Speaker/Full range (2) (mm)
(inches)
40 × 100
(1
5
/8 × 4)
Dimensions* with stand (mm)
(inches)
983 × 643 × 233
38
3
/4 × 25 3/8 × 9 1/
4
753 × 510 × 213
29
3
/4 × 20 1/8 × 8 1/
2
without stand (mm)
(inches)
983 × 603 × 75
38
3
/4 × 23 3/4 × 3
753 × 471 × 71
29 3/4 × 18 5/8 × 2 7/
8
wall-mount hole pattern (mm) 001 × 002003 × 003
wall-mount screw size (mm) M6 (8~12 mm) M4 (6.5~10 mm)
with stand (kg)
110-240 V AC, 50/60 Hz (U.S.A./Canada /Mexico 120 V AC, 60 Hz)
Less than 0.15 W with 120 V AC and with 240 V AC less than 0.3 W
Supplied accessories
(42 class)
KDL-32EX340/42EX440/42EX441 2
SECTION 1 - FEATURES AND OVERVIEW
H
TCON
A
GL9
CHASSIS OVERVIEW
The primary circuits in the AZ3FK chassis consist of a Main Board (A Board), Power Supply Board (GL9 for the 32” models and GL10 for the 42” models), the
LCD Panel Assembly includes the Bezel Assembly, the IR Board (H Board) and the TCON Board.
NOTE: For connector part number information, refer to “Connectors” on page 18. For Wire Dressing information, refer to “Wire Dressing” on page 21.
A
GL10
TCON
BOARD LAYOUT FOR KDL-32EX340 ONLY BOARD LAYOUT FOR KDL-42EX440/42EX441 ONLY
H
KDL-32EX340/42EX440/42EX441 3
SECTION 1 - FEATURES AND OVERVIEW
OVERALL CIRCUIT DESCRIPTION
The “Block Diagram” on page 9 provides an overview of the AZ3FK
chassis. The following are descriptions of the boards and their functions.
MAIN BOARD
Common to all models utilizing the AZ3FK chassis, the Main Board (A
Board) contains most of the video processing circuitry along with all audio
processing. Control of the television is accomplished via a CPU embedded
within the MT5389 processor. Below is a list of the key components located
on the Main Board.
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).
MT5389 PROCESSOR
This IC performs the majority of the necessary audio and video processing
on the Main Board.
Analog Video Input Switch: All analog video sources are selected and
A/D converted and scaled (if necessary) to 1920 X 1080p 60HZ resolution.
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 1920 X 1080p 60HZ are scaled to this resolution.
Digital audio content is output to the class D amplier for processing and
amplication.
Audio Processing: Analog audio sources are selected and A/D converted
directly by the MT5389. The audio information is then processed digitally.
Digital audio from the tuner and HDMI sources is also input and processed.
Class D amplier provides the drive for the speakers.
HDMI Input and Switching: The customer can select the HDMI1 and
HDMI2 input. Each HDMI input contains a dedicated EDI NVM (not shown)
to provide display information data to any device connected via the HDMI
inputs.
CPU: The CPU internal to the MT5389 processor controls all aspects of
the television functions. Input from the user along with monitoring of critical
circuits is also performed by this CPU.
LVDS Transmitter: Integrated into the MT5389 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 circuits located internally to the LCD Panel.
POWER SUPPLY BOARD
There are 2 different Power Supply Boards used in the models in this
manual. The type of board depends on the size of LCD Panel. They are:
● GL9 for the 32” models
● GL10 for the 42” models
There are 3 distinct sections on the power supply:
Standby Supply: Continuously operational as long as AC power is applied,
the standby supply generates 3.3V for the circuits requiring power while the
unit is turned off. An unregulated 19V 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 Main Board, the main switching supply is turned on to
provide a regulated 12V source and Audio 12V.
Converter: Generates the B+ and B- voltages for the LED backlights.
IR BOARD
Designated as the H Board, the IR Board contains the power, standby
and timer LED’s that are located on this board along with the IR Remote
Receiver and light level sensor.
SWITCH UNIT
This board contains the power, channel and volume up/down, and menu
buttons.
KDL-32EX340/42EX440/42EX441 4
SECTION 1 - FEATURES AND OVERVIEW
LCD PANEL ASSEMBLY
The LCD Panel Assembly includes the LCD Panel, TCON Board and LED
Backlight system.
The LCD Panel contains the actual liquid crystals, color lters and polarizers.
The liquid crystals are manipulated by the applied voltage to pass a specic
amount of light - from the backlit - 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.
A new LCD Panel Assembly will include the following items:
● LCD Panel
● Bezel Assembly (includes H Board)
● TCON Board
● LED Backlight system
TCON BOARD
The TCON Board communicates between the LCD Panel and the
microprocessor on the Main Board.
NOTE: The TCON Board is not available as a replacement part for all
models. To determine if the TCON Board is available as a replacement
part, refer to the LCD Panels Manual.
KDL-32EX340/42EX440/42EX441 5
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