Sony KP-53XBR300, KP-61XBR300 Service manual

RA-4ASERVICE MANUAL

CHASSIS

MODEL COMMANDER DEST. CHASSIS NO.

–––––––– ––––––––––––––– –––––– ––––––––––––––

KP-53XBR300 KP-53XBR300 KP-61XBR300 KP-61XBR300

RM-Y902 US SCC-P21A-A

RM-Y902

Canadian

SCC-P21A-A

RM-Y902 US SCC-P21B-A

RM-Y902

Canadian

SCC-P21B-A

MODEL COMMANDER DEST. CHASSIS NO.

–––––––– ––––––––––––––– –––––– ––––––––––––––

POWER

SYSTEM

DVD/

DBS

MUTING

OFF

VTR

CABLE

DVD/VTR

DBS/CABLE

FUNCTION

OFF

FREEZE

AUDIO SWAP

POTITION

ZOOM IN

LEFT RIGHT

TV/DBS

GUIDE ACTIVE

CC PICTURE MODE

DISPLAY TV/VIDEO

ANT

ENTER

JUMP

VOL CH

RESET

RM-Y902

MICROFILM

∗ Please file according to model size........

KP-61XBR300KP-53XBR300

COLOR REAR VIDEO PROJECTOR

53 61

KP-53XBR300/61XBR300

RM-Y902RM-Y902

SPECIFICATIONS

– 2 –

SAFETY CHECK-OUT

Fig. B. Checking for earth ground.

Trouble Light

AC Outlet Box

Ohmmeter

Cold-water Pipe

( US model only )

KP-53XBR300/61XBR300

RM-Y902RM-Y902

After correcting the original service problem, perfom the follow-

ing safety checks before releasing the set to the customer:

l. Check the area of your repair for unsoldered or poorly-sol-

dered connections. Check the entire board surface for solder splashes and bridges.

2. Check the interboard wiring to ensure that no wires are “pinched” or contact 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, through functioning, show obvious signs of deterioration. Point them out to the customer and recom mend 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 condition of the monopole antenna (if any). Make sure the end is not broken off, and has the plastic cap on it. Point out the danger of impalement on a broken antenna to the customer, and recommend the antenna’s replacement.

8. Check the B+ and HV to see they are at the values specified. Make sure your instruments are accurate;be suspicious of your HV meter if sets always have low HV.

9. Check the antenna temminals, metal trim, “metallized” knobs, screws, and all other exposed metal parts for AC leakage. Check leakage as described below.

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 0.5mA (500 microampers) . Leakage current can be measured by any one of three methods.

1. A commercial leakage tester, such as the Simpson 229 or RCA WT-540A. Follow the manufacturers’ instructions to usc these instruments.

2. A battery-operated AC milliammeter . The Data Precision 245 digital multimeter is suitable for this job.

3. Measuring the voltage drop across a resistor by means of a VOM or battery-operated AC voltmeter. The “limit” indication is 0.75V, so analog meters must have an accurate lowvoltage scale. The Simpson 250 and Sanwa SH-63Trd are examples of a passive VOM that is suitable. NearIy all battery operated digital multimeters that have a 2V AC range are suitable. (See Fig. A)

HOW TO FIND A GOOD EARTH GROUND

A cold-water pipe is guaranteed earth ground;the cover-plate retaining screw on most AC outlet boxes is also at earth ground. If the retaining screw is to be used as your earth-ground, verify that it is at ground by measuring the resistance between it and a coldwater pipe with an ohmmeter. The reading should be zero ohms. If a cold-water pipe is not accessible, connect a 60-l00 watts trouble light (not a neon lamp) between the hot side of the receptacle and the retaining screw. Try both slots, if necessary, to locate the hot side of the line, the lamp should light at normal brilliance if the screw is at ground potential. (See Fig. B)

Fig. A. Using an AC voltmeter to check AC leakage.

1.5

To Exposed Metal Parts on Set

1.5k

Ω

Earth Ground

AC voltmeter (0.75V)

– 3 –

KP-53XBR300/61XBR300

RM-Y902RM-Y902

SELF DIAGNOSIS FUNCTION

1. Summary of Self-Diagnosis Function

• This device includes a self-diagnosis function.

• In case of abnormalities, the TIMER/STANDBY indicator automatically blinks. It is possible to predict the abnormality location by the number of blinks. The Instruction Manual describes blinking of the TIMER/STANDBY indicator.

• If the symptom is not reproduced sometimes in case of a malfunction, there is recording of whether a malfunction was generated or not. Operate the remote command to confirm the matter on the screen and to predict the location of the abnormality.

2. Diagnosis Items and Prediction of Malfunction Location

• When a malfunction occurs the TIMER/STANDBY indicator only blinks for one of the following diagnosis items. In case of two or more malfunctions, the item which first occurred blinks. If the malfunctions occurred simultaneously, the item with the lower blink count blinks first.

• The screen display displays the results regarding all the diagnosis items listed below. The display “ 0 ” means that no malfunctions occurred.

metisisongaiD

NOtonrewoP•0

noitcetedPCOB+semit2.tiucrichcaenimetsysylppusrewopfotiucrictrohS

noitcetedPVOB+semit3

potsnoitcelfedlacitreVsemit4

noitcetedytilamronbatuooediVsemit5

potsnoitcelfedlatnoziroHsemit6

noitceted

ytilamronbaegatlovhgiH

noitcetedytilamronbaoiduAsemit8

* : 000 the range of values for number of operations is 000-255. For 256 or higher there is

no count up and the number remains at 255.

3. Blinking count display of TIMER/STANDBY indicator

YBDNATS/REMIT

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sknilbforebmuN

semit7nekorbsi8008Q .raeppat'useodretsaR000VH:7

noitcnuflamdesoppuSnoitidnoC

.nepo106F .nepo706R

tiucrictrohs106Q

tiucric-trohs106RDV

.nekorbsi5006CI .nekorbsi1016CI

.nekorbsi)tuoV(4005CI .nekorbsi)PSDV(215CI

.tiucricdraob

)draobA(425,615,015Q

.nekorbera4016,3016SP

* One blink is not used for self-diagnosis.

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]metsySylppuSrewoPniaM[

.nekorbera216Rdna106CI

.nekorbsi)TUOH(3105Q

.nekorbsi)elgnuJH(705CI

.nekorbera3062,2062,1062CI

sisongaid-fleS

,yalpsidneercs

stluseR:metisisongaiD

.rewopehtnonruttonnaC

.knilbt'nseodDEL

edomybdnatsehtotseoG

enilB+fotiucrictrohS

edomybdnatsehtotseoG

tiucricylppusrewopfonoitcnuflaM

.yllatnozirohenilenootseogretsaR000potSV:4

Cnisrehtodna1037,1027,1017CI,tuooediV

.raeppat'nseodretsaR000potSH:6

.tuotonsidnuosehT

.sisongaidflesehtrofsknilbnehtdna

edomybdnatsehtotseoG

,sdnoces03.xorppasknilbDELYBDNATS/REMIT

000PCOB+:2

000PVOB+:3

000BKA:5

000oiduA:8

< FRONT PANEL >

•EXAMPLE

• +B overcurrent 2 times

• +B overvoltage 3 times

TIMER/STANDBY indicator

• Vertical deflection stop 4 times

Lamp ON : 0.3 seconds Lamp OFF : 0.3 seconds

Lamp OFF :

3.0 seconds

Release of TIMER/STANDBY indicator blinking.

• The TIMER/STANDBY indicator blinking display is released by turning OFF the power switch on the TV main unit or removing the plug from the power.

– 4 –

KP-53XBR300/61XBR300

4. Self-diagnosis screen displays

• In cases of malfunctions where it is not possible to determine the symptom such as when the power goes off occasionally or when the screen disappears occasionally, there is a screen display on whether the malfunction occurred or not in the past (and whether the detection circuit operated or not) in order to allow confirmation.

• Quickly press the remote command button in the following order from the standby state.

DISPLAY b Channel 5 b VOL – b POWER

˘ Be aware that this differs from the method of entering the service mode (volume + ).



Self-diagnosis screen display

Self Check

2 : +B OCP 000 3 : +B OVP 000 4 : V Stop 000 5 : AKB 000 6 : H Stop 000 7 : HV 000 8 : Audio 000 9 : WDT 000

÷

2 : +B OCP 000

Diagnosis

Results

000 the range of values for number of

operations is 000-255. For 256 or higher there is no count up and the number remains at 255.

RM-Y902RM-Y902

5. Self-Diagnosis Screen Display

• The results display is not automatically cleared. In case of repairs and after repairs, check the self-diagnosis screen and be sure to return the results display to “ 0 ”.

• If the results display is not returned to “ 0 ” it will not be possible to judge a new malfunction after completing repairs.

1. Power off (Set to the standby mode)

2. DISPLAY b Channel 5 b VOL + b POWER (Service Mode)

3. Channel 8 b ENTER (Test reset = Factory preset condition)

• When ending the self-diagnosis screen completely, turn the power switch OFF on the remote commander or the main unit.

– 5 –

KP-53XBR300/61XBR300

RM-Y902RM-Y902

6. Self-diagnosis function operation

OCP Low B and +B line detect DET SHORT, and shut-down POWER ON RELAY.

Reset by turning power on/off. In case of +B is loaded approx. 1.5A or more, microcomputer detects it via IC6102.

OVP In case of +B becomes approx. 150V or more, POWER ON RELAY shuts down and microcomputer detects it via IC6102.

Reset by turning power on/off just the same as OCP.

V Stop In case of V Drive disappeared, Q5005 detecs it and shut-down POWER ON RELAY. Microcomputer detects it and makes LED

blinking.

AKB IK detection. Makes LED blinking in case of microcomputer doesn’t detect IK returns of IC511 (CXA2101AQ) 30 seconds or

more.

H Stop In case of H DRIVE is disappeared, Q5006 detects it and shut-down POWER ON RELAY shuts down.

Microcomputer receives H Stop data from Q5006 and makes LED blinking.

HV Stop In case of HV becomes 33KV or more. IC8006 and IC8010 detect it and shut-down

POWER ON RELAY. Microcomputer makes LED blinking.

Audio In case of DC component overlaps the output of Audio Amp., POWER ON RELAY shuts down.

Microcomputer detects it and makes LED blinking.

Self-diagnosis block diagram

D3102

TIMER/STANDBY

5 6713

2. OVP

3. OCP

4. V.STOP

6. H.STOP

7. HV STOP

8. AUDIO

IC1009

OSD-CPU

IC1008

MAIN-CPU

BUS

4850

8. Audio

IC1007

EEPROM

Audio AMP

R1802

5. AKB

49 47 50

BUS

5. AKB

IC2601, 2602, 2603

CXA2101AQ

DC Detect

IC511

MCP

IC512

CXD2018Q

VDSP

IC5004 V Drive

6. H STOP

Q5006

H PULSE

Detector

Q5005

V Pulse Detector

C Board

IC8006,8010

HV Detector

4. V.STOP (V Pulse)

6. H.STOP

7. HV.STOP

3. OVP

2. OCP

IC6102

OVP Buffer

OCP Buffer

– 6 –

OVP DETECT

OCP DETECT

KP-53XBR300/61XBR300

RM-Y902RM-Y902

Section Title Page –––––– –––– ––––

SELF DIAGNOSIS FUNCTION............................................ 4

1. GENERAL

Remote Control ....................................................................... 9

Installing and Connecting the Projection TV .......................... 9

Basic Set Up .......................................................................... 18

Using Your New Projection TV ............................................ 19

Adjusting Your SET UP (menus) .......................................... 23

Operating Video Equipment.................................................. 34

Operating a Cable Box or DBS Receiver.............................. 35

2. DISASSEMBLY

2-1. Screen Frame Assy and HC Board Removal ............ 37

2-2. Rear Board Removal ................................................. 37

2-3. Main Bracket Removal ............................................. 37

2-4. Service Position......................................................... 37

2-5. G Board Removal...................................................... 38

2-6. Terminal Board and U Board Removal ..................... 38

2-7. K Board Removal...................................................... 38

2-8. BM, BR and BD Board Removal.............................. 38

2-9. BA Board Removal ................................................... 39

2-10. DS Board Removal ................................................... 39

2-11. A and D Board Removal ........................................... 39

2-12. Reflection Mirror Removal ....................................... 40

2-13. HA and HB Board Removal...................................... 40

2-14. Picture Tube Removal ............................................... 41

2-15. High-Voltage Cable Installation and Removal.......... 41

3. SET-UP ADJUSTMENTS

3-1. Screen Voltage Adjustment (Rough Alignment) ....... 42

3-2. Focus Lens Adjustment............................................. 42

3-3. Screen (G2) Adjustment............................................ 42

3-4. Focus VR Adjustment ............................................... 42

3-5. Deflection Y ork Tilt Adjustment ............................... 43

3-6. 2-Pole Magnet Adjustment (Green, Red).................. 43

3-7. 4-Pole Magnet Adjustment........................................ 43

3-8. Defocus Adjustment (Blue) ....................................... 43

3-9. Electrical Adjustment by Remote Commander......... 44

3-10. Registration Adjustment ............................................ 50

3-11. Auto Registration Error Code List ............................ 53

4. SAFETY RELATED ADJUSTMENTS

4-1. HV Regulation Circuit Check and Adjustment......... 54

4-2. HV Hold Down Circuit Operation and Adjustment .. 54

4-3. +B OVP Confirmation .............................................. 54

5. CIRCUIT ADJUSTMENTS

5-1. TV Input Sub Contrast Adjustment

(MCD1 SCON) ......................................................... 55

5-2. Video Input Sub-Contrast Adjustment

(MCD3-SCON) ......................................................... 55

5-3. P & P Sub-Contrast Adjustment (MCD2-SCON) ..... 55

5-4. P & P Sub-Contrast Adjustment (MCD4-SCON) ..... 55

5-5. 480 I Sub-Contrast Adjustment(MCP2-SCON)....... 56

5-6. Video 5 Input Sub-Contrast Adjustment

(MCP3-scon) ............................................................. 56

5-7. Sub-HUE and Sub-Color Adjustment

(MCD1-SHUE,SCOL) .............................................. 56

5-8. Video Input Sub-HUE and Sub-Color Adjustment

(MCD3-SHUE,SCOL) .............................................. 56

5-9. P & P Sub-HUE and Sub-Color Adjustment

(MCD2-SHUE,SCOL) .............................................. 57

Section Title Page –––––– –––– ––––

5-10. P & P Sub-HUE and Sub-Color Adjustment

(MCD4-SHUE,SCOL) .............................................. 57

5-11. P & P Sub Contrast Adjustment (MCD1-SCON)...... 57

5-12. P & P Sub Contrast Adjustment (MCD2-SCON)...... 57

5-13. Sub-HUE and Sub-Color Adjustment

(SCD1-SHUE,SCOL) ............................................... 58

5-14. Sub-HUE and Sub-Color Adjustment

(SCD2-SHUE,SCOL) ............................................... 58

5-15. Video 5 Input Sub-HUE and Sub-Color Adjustment

(MCP3-SHUE,SCOL)............................................... 58

5-16. Display Position Adjustment (OSD-HPOS)............. 59

5-17. Caption Vision Position Adjustment

(MCCD-CCDH) ........................................................ 59

5-18. Mid Display Position Adjustment (MID-HPOS) ..... 59

6. DIAGRAMS

6-1. Block Diagram (1)..................................................... 61

Block Diagram (2)..................................................... 64

Block Diagram (3)..................................................... 67

Block Diagram (4)..................................................... 69

Block Diagram (5)..................................................... 71

Block Diagram (6)..................................................... 74

Block Diagram (7)..................................................... 77

Block Diagram (8)..................................................... 79

6-2. Frame Schematic Diagram ........................................ 81

6-3. Circuit Boards Location ............................................ 84

6-4. Printed Wiring Boards and Schematic Diagrams...... 84

• A (1/4)Board ........................................................... 89

• A (2/4)Board ........................................................... 93

• A (3/4)Board ........................................................... 97

• A (4/4)Board ......................................................... 100

• BA Board .............................................................. 104

• BM Board ............................................................. 107

• BR Board .............................................................. 115

• BD Board .............................................................. 120

• DS Board .............................................................. 123

• D(1/2) Board ......................................................... 127

• D(2/2) Board ......................................................... 130

• K Board................................................................. 139

• CR Board .............................................................. 143

• CG Board .............................................................. 144

• CB Board .............................................................. 145

• ZR Board .............................................................. 147

• ZG Board .............................................................. 148

• ZB Board .............................................................. 150

• U Board................................................................. 151

• HA Board .............................................................. 153

• HB Board .............................................................. 153

• HC Board .............................................................. 153

• G Board................................................................. 157

6-5. Semiconductors ....................................................... 160

7. EXPLODED VIEWS

7-1. Cover (KP-53XBR300)........................................... 162

7-2. Cover (KP-61XBR300)........................................... 163

7-3. Chassis..................................................................... 164

7-4. Picture Tube ............................................................ 165

8. ELECTRICAL PARTS LIST ................................. 166

– 7 –

KP-53XBR300/61XBR300

RM-Y902RM-Y902

SHORT CIRCUIT THE ANODE OF THE PICTURE TUBE AND THE

(CAUTION)

ANODE CAP TO THE METAL CHASSIS, CRT SHIELD, OR CARBON PAINTED ON THE CRT, AFTER REMOVING THE ANODE.

WARNING!! AN ISOLATION TRANSFORMER SHOULD BE USED DURING ANY SERVICE TO AVOID POSSIBLE SHOCK HAZARD, BECAUSE OF LIVE CHASSIS. THE CHASSIS OF THIS RECElVER IS DIRECTLY CONNECTED TO THE AC POWER LINE.

SAFETY-RELATED COMPONENT WARNING!!

COMPONENTS IDENTIFIED BY SHADING AND MARK ! ON THE SCHEMATIC DIAGRAMS, EXPLODED VIEWS AND IN THE

PARTS LIST ARE CRITICAL TO SAFE OPERATION. REPLACE THESECOMPONENTS WITH SONY P ARTS WHOSE PART NUMBERS APPEAR AS SHOWN IN THIS MANUAL OR IN SUPPLEMENTS PUBLISHED BY SONY. CIRCUIT ADJUSTMENTS THAT ARE CRITICAL T O SAFEOPERATION ARE IDENTIFIED IN THIS MANUAL. FOLLOW THESE PROCEDURES WHENEVER CRITICAL COMPONENTS ARE REPLACED OR IMPROPER OPERATION IS SUSPECTED.

APRES A VOIR DECONNECTE LE CAP DE L ’ANODE, COUR TCIR-

(ATTENTION)

CUITER L’ANODE DU TUBE CATHODIQUE ET CELUI DE L’ANODE DU CAP AU CHASSIS METALLIQUE DE L’APPAREIL, OU AU COUCHE DE CARBONE PEINTE SUR LE TUBE CATHOD-

IQUE OU AU BLINDAGE DU TUBE CATHODIQUE.

ATTENTION!! AFIN D’EVITER TOUT RISQUE DELECTROCUTION PROVENANT D’UN CHÁSSIS SOUS TENSION, UN TRANSFORMA TEUR D’ISOLEMENT DOIT ETRE UTILISÉ LORS DE TOUT DEPANNAGE. LE CHÁSSIS DE CE RECEPTEUR EST DIRECTEMENT RACCORDÉ Á L’ALIMENTATION SECTEUR.

ATTENTION AUX COMPOSANTS RELATIFS ÁLA

SÉCURITÉ!!

LES COMPOSANTS IDENTIFIÉS PAR UNE TRAME ET PAR UNE MAPQUE ! SUR LES SCHÉMAS DE PRINCIPE, LES VUES EX-

PLOSÉES ET LES LISTES DE PIECES CONT D’UNEIMPORTANCE CRITIQUE POUR LA SÉCURITÉ DU FONCTIONNEMENT. NE LES REMPLACER QUE PAR DES COMPOSANTS SONY DONT LE NUMÉRO DE PIÉCE EST INDIQUÉ DANS LE PRÉSENT MANUEL OU DANS DES SUPPLÉMENTS PUBLIÉS PAR SONY. LES RÉGLAGES DE CIRCUIT DONT L ’IMPORTANCE EST CRITIQUE POUR LA SÉCURITÉ DU FONCTIONNEMENT SONT IDENTIFIES DANS LE PRÉSENT MANUEL. SUIVRE CES PROCÉDURES LORS DE CHAQUE REMPLACEMENT DE COMPOSANTS CRITIQUES, OU LORSQU’UN MAUVAIS FONCTIONNEMENT EST SUSPECTÉ.

– 8 –

SECTION 1

GENERAL

The operating instructions mentioned here are partial abstracts from the Operating Instructions Manual. The page numbers of the Operating Instruction Manual remain as in the manual. (Part no : 3-867-651-11)

– 9 –