Sony KP-HR53KR1, KP-HR61KR1 Service Manual

RA-4BSERVICE MANUAL

CHASSIS

MODEL COMMANDER DEST. CHASSIS NO.

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KP-HR53KR1 RM-Y902K Korean SCC-P35A-A KP-HR61KR1 RM-Y902K Korean SCC-P35B-A

MODEL COMMANDER DEST. CHASSIS NO.

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

POWER

SYSTEM

DVD/

DBS

MUTING

OFF

VTR

CABLE

DVD/VTR

DBS/CABLE

FUNCTION

FREEZE

OFF

AUDIO SWAP

POTITION

ZOOM IN

LEFT RIGHT

TV/DBS

GUIDE ACTIVE

PICTURE

MODE

DISPLAY TV/VIDEO

ANT

ENTER

JUMP

VOL CH

RESET

RM-Y902K

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

53 61

KP-HR53KR1

KP-HR61KR1

PROJECTION TV

KP-HR53KR1/HR61KR1

RM-Y902KRM-Y902K

SPECIFICATIONS

Projection system

3 picture tubes, 3 lenses, horizontal in- line system

Picture tube

7- inch high- brightness monochrome tubes (6.3 raster size), with optical coupling and liquid cooling system

Projection lenses

High performance, large diameter hybrid lens F1.1 Television system American TV standard

Channel coverage

VHF: 2– 13/ UHF: 14– 69/ CATV: 1– 125

Antenna

75 ohm external terminal for VHF/ UHF

Screen size (measured diagonally)

53 inches (KP- HR53KR1) 61 inches (KP- HR61KR1)

Inputs/ outputs

VIDEO 1/ 3 IN VIDEO 2 INPUT

S VIDEO IN (4- pin mini DIN): Y: 1 Vp- p, 75- ohms unbalanced, sync negative C: 0.286 Vp- p (Burst signal), 75 ohms VIDEO (phono jack): 1 Vp- p, 75- ohms unbalanced, sync negative AUDIO (phono jacks): 500 mVrms (100% modulation), Impedance: 47 kilohms

VIDEO 4 IN

S VIDEO IN (4- pin mini DIN): Y: 1 Vp- p, 75- ohms unbalanced, sync negative C: 0.286 Vp- p (Burst signal), 75 ohms VIDEO (phono jack): 1 Vp- p, 75- ohms unbalanced, sync negative Y: 1 Vp- p, 75 ohms, sync negative P B : 0. 7 Vp- p, 75 ohms P R : 0. 7 Vp- p, 75 ohms AUDIO (phono jacks): 500 mVrms (100% modulation), Impedance: 47 kilohms

VIDEO 5 (DTV) IN Maximum scanning rate: 1080i

Y: 1 Vp- p, 75 ohms, negative or tri- level sync P B : 0.7 Vp- p, 75 ohms P R : 0.7 Vp- p, 75 ohms or G: 0.7 Vp- p, 75 ohms B: 0.7 Vp- p, 75 ohms R: 0.7 Vp- p, 75 ohms HD: 0.5– 5 Vp- p, 2.2 kilohms VD: 0.6– 5 Vp- p, 2.2 kilohms

Note:

The VIDEO 5 (DTV) IN jacks are not compatible with a computer’s 5BNC (R/ G/ B/ HD/ VD) video output connectors. AUDIO (phono jacks): 500 mVrms (100% modulation), Impedance: 47 kilohms

SELECT OUT

VIDEO (phono jack): 1 Vp- p, 75- ohms unbalanced, sync negative AUDIO (phono jacks): 470 mVrms (100% modulation), Impedance: 47 kilohms

AUDIO (VAR) OUT (phono jacks): 700 mVrms (100%

modulation)

AUDIO (FIX) OUT (phono jacks): 500 mVrms (100%

modulation)

CONTROL S IN/ OUT: minijacks

Speaker

Front (Tweeter): 66 mm (25/8”)x2 Front (Woofer): 130 mm (5 160 mm (6

/8”)x2 (KP- HR53KR1)

/8”) x2 (KP- HR61KR1)

Speaker output

Front: 20 Wx2

Power requirement

220 V AC, 60 Hz

Power consumption

In use (Max.): 240 W In standby: 1 W

Dimensions (W/ H/ D)

1,218x1,459x635 mm (48x571/2x25 inches) (KP- HR53KR1) 1,372x1,558x670 mm (541/8x613/8x261/2 inches) (KP- HR61KR1)

Mass

84 kg (185 lbs 3 oz) (KP- HR53KR1) 102 kg (224 lbs 14 oz) (KP- HR61KR1)

Supplied accessories

Remote control RM- Y902K (1) Batteries size AA (R6) (2)

Design and specifications are subject to change without notice.

– 2 –

KP-HR53KR1/HR61KR1

SELF DIAGNOSIS FUNCTION

1. Summary of Self-Diagnosis Function

• This device includes a self-diagnosis function.

• In case of abnormalities, the TIMER/STAND BY indicator automatically blinks. It is possible to predict the abnormality location

by the number of blinks. The Instruction Manual describes blinking of the TIMER/STAND BY 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/STAND BY 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 malfunc-

tions occurred.

metisisongaiD

NOtonrewoP•0

noitcetedPCOB+semit2.tiucrichcaenimetsysylppusrewopfotiucrictrohS

noitcetedPVOB+semit3

potsnoitcelfedlacitreVsemit4

noitcetedytilamronbatuooediVsemit5

potsnoitcelfedlatnoziroHsemit6

noitceted

ytilamronbaegatlovhgiH

noitcetedytilamronbaoiduAsemit8

YBDNATS/REMIT

retacidnI

sknilbforebmuN

semit7nekorbsi8008Q .raeppat'useodretsaR000VH:7

noitcnuflamdesoppuSnoitidnoC

.nepo1006F .nepo2106R

.nekorbsi1006CI

.nepo2006F

]metsySylppuSrewoPniaM[

.tiucric-trohs2006,1006DV

.nekorbsi5006CI .nekorbsi1016CI

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

.tiucricsdraobBCdnaGC.RC

)draobA(425,615,015Q

.nekorbsi)TUOH(3105Q .nekorbsi)elgnuJH(705CI

.nekorbera4016,3016SP

]metsySylppuSrewoPybdnatS[

.rewopehtnonruttonnaC

.knilbt'nseodDEL

.nekorbera8006,7006,4006Qdna3006,2006CI

edomybdnatsehtotseoG

enilB+fotiucrictrohS

edomybdnatsehtotseoG

tiucricylppusrewopfonoitcnuflaM

.yllatnozirohenilenootseogretsaR000potSV:4

nisrehtodna1037,1027,1017CI,tuooediV

.raeppat'nseodretsaR000potSH:6

.nekorbera3062,2062,1062CI

.tuotonsidnuosehT

.sisongaidflesehtrofsknilbnehtdna

edomybdnatsehtotseoG

,sdnoces03.xorppasknilbDELYBDNATS/REMIT

RM-Y902KRM-Y902K

sisongaid-fleS

,yalpsidneercs

stluseR:metisisongaiD

000PCOB+:2

000PVOB+:3

000BKA:5

000oiduA:8

* : 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/STAND BY indicator

* One blink is not used for self-diagnosis.

< FRONT PANEL >

•EXAMPLE

• +B overcurrent 2 times

• +B overvoltage 3 times

• Vertical deflection stop 4 times

Lamp ON : 0.3 seconds

Lamp OFF : 0.3 seconds

TIMER/STAND BY indicator

Release of TIMER/STAND BY indicator blinking.

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

– 3 –

Lamp OFF :

3.0 seconds

KP-HR53KR1/HR61KR1

RM-Y902KRM-Y902K

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

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

Be aware that this differs from the method of

entering the service mode (volume + ).

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.

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.

– 4 –

KP-HR53KR1/HR61KR1

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

RM-Y902KRM-Y902K

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

R1802

5. AKB

49 47 50 48

Audio AMP

BUS

5. AKB

IC2002

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

– 5 –

OVP DETECT

OCP DETECT

KP-HR53KR1/HR61KR1

RM-Y902KRM-Y902K

Section Title Page –––––– –––– ––––

SELF DIAGNOSIS FUNCTION ............................................ 3

1. GENERAL

Remote Control ....................................................................... 8

Before You Begin .................................................................... 8

Installing and Connecting the Projection TV ........................ 11

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

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

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

Additional Operations ........................................................... 29

Additional Information .......................................................... 30

2. DISASSEMBLY

2-1. Rear Board Removal ................................................. 32

2-2. Main Bracket Removal .............................................. 32

2-3. Service Position ......................................................... 32

2-4. G Board Removal ...................................................... 32

2-5. Terminal Board and U Board Removal ..................... 33

2-6. BM, BR and BD Board Removal .............................. 33

2-7. K Board Removal ...................................................... 33

2-8. BA Board Removal ................................................... 33

2-9. DS Board Removal.................................................... 34

2-10. A and D Board Removal ........................................... 34

2-11. Beznet ASSY Removal ............................................. 34

2-12. HC and S Board Removal ........................................ 35

2-13. Mirror Cover Removal .............................................. 35

2-14. HA Board Removal ................................................... 35

2-15. Picture Tube Removal ............................................... 36

2-16. High-Voltage Cable Installation and Removal .......... 36

3. SET-UP ADJUSTMENTS

3-1. Screen Voltage Adjustment (Coarse Adjustment) ..... 37

3-2. Screen (G2) Adjustment (Fine Adjustment) .............. 37

3-3. Deflection York Tilt Adjustment ............................... 37

3-4. Focus Lens Adjustment ............................................. 37

3-5. Focus VR Adjustment ............................................... 38

3-6. 2-Pole Magnet Adjustment (Green, Red) .................. 38

3-7. 4-Pole Magnet Adjustment........................................ 38

3-8. Defocus Adjustment (Blue) ....................................... 38

3-9. Electrical Adjustment by Remote Commander......... 39

3-10. Registration Adjustment (PJE) .................................. 45

3-11. Auto Registration Error Code List ............................ 48

4. SAFETY RELATED ADJUSTMENTS

4-1. HV Regulation Circuit Check and Adjustment ......... 49

4-2. HV Hold Down Circuit Operation Check and

Adjustment ................................................................ 49

4-3. +B Max Voltage Confirmation .................................. 49

4-4. +B OVP Confirmation............................................... 49

5. CIRCUIT ADJUSTMENTS

5-1. TV Input Sub Contrast Adjustment

(MCD1 SCON) ......................................................... 50

5-2. Video Input Sub-Contrast Adjustment

(MCD3-SCON) ......................................................... 50

5-3. P & P Sub-Contrast Adjustment (MCD2-SCON) ..... 50

5-4. P & P Sub-Contrast Adjustment (MCD4-SCON) ..... 50

5-5. Sub-Contrast Adjustment(MCP2-SCON) ................ 51

5-6. Video 5 Input Sub-Contrast Adjustment

(MCP3-SCON) .......................................................... 51

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

(MCD1-SHUE,SCOL) .............................................. 51

Section Title Page –––––– –––– ––––

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

(MCD3-SHUE,SCOL) .............................................. 51

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

(MCD2-SHUE,SCOL) .............................................. 52

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

(MCD4-SHUE,SCOL) .............................................. 52

5-11. P & P Sub Contrast Adjustment (SCD1-SCON) ....... 52

5-12. P & P Sub Contrast Adjustment (SCD2-SCON) ....... 52

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

(SCD1-SHUE,SCOL) ............................................... 53

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

(SCD2-SHUE,SCOL) ............................................... 53

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

(MCP3-SHUE,SCOL) ............................................... 53

6. DIAGRAMS

6-1. Block Diagram (1) ..................................................... 55

Block Diagram (2) ..................................................... 58

Block Diagram (3) ..................................................... 61

Block Diagram (4) ..................................................... 63

Block Diagram (5) ..................................................... 65

Block Diagram (6) ..................................................... 68

Block Diagram (7) ..................................................... 71

Block Diagram (8) ..................................................... 73

6-2. Frame Schematic Diagram ........................................ 75

6-3. Circuit Boards Location ............................................ 78

6-4. Printed Wiring Boards and Schematic Diagrams ...... 78

• S Board ................................................................... 79

• A (1/4) Board .......................................................... 83

• A (2/4) Board .......................................................... 87

• A (3/4) Board .......................................................... 91

• A (4/4) Board .......................................................... 94

• BA Board ................................................................ 97

• BM Board ............................................................. 101

• BR Board .............................................................. 107

• BD Board .............................................................. 113

• DS Board .............................................................. 119

• D(1/2) Board ......................................................... 121

• D(2/2) Board ......................................................... 124

• K Board ................................................................. 133

• CR Board .............................................................. 137

• CG Board .............................................................. 138

• CB Board .............................................................. 139

• ZR Board .............................................................. 141

• ZG Board .............................................................. 142

• ZB Board .............................................................. 144

• U Board ................................................................. 145

• HA Board .............................................................. 147

• HC Board .............................................................. 147

• G Board ................................................................. 151

6-5. Semiconductors ....................................................... 154

7. EXPLODED VIEWS

7-1. Cover (KP-HR53KR1) ............................................ 156

7-2. Cover (KP-HR61KR1) ............................................ 157

7-3. Cabinet .................................................................... 158

7-4. Chassis ..................................................................... 159

7-5. Picture Tube ............................................................ 160

8. ELECTRICAL PARTS LIST ...................................... 161

– 6 –

(CAUTION)

SHORT CIRCUIT THE ANODE OF THE PICTURE TUBE AND THE ANODE CAP TO THE METAL CHASSIS, CRT SHIELD, OR CAR-

BON 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 PARTS WHOSE PART NUMBERS APPEAR AS SHOWN IN THIS MANUAL OR IN SUPPLEMENTS PUBLISHED BY SONY. CIRCUIT ADJUSTMENTS THAT ARE CRITICAL TO SAFEOPERATION ARE IDENTIFIED IN THIS MANUAL. FOLLOW THESE PROCEDURES WHENEVER CRITICAL COMPONENTS ARE REPLACED OR IMPROPER OPERATION IS SUSPECTED.

KP-HR53KR1/HR61KR1

RM-Y902KRM-Y902K

– 7 –

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 : 4-074-163-11)

– 8 –