Sony KZ-32TS1U, KZ-41TS1U, KF-60DX100 Service Manual

Training Manual

Plasma TV & Grand Wega Projection TV

Models: KZ-32TS1U

KZ-41TS1U KF-60DX100

KZ-32TS1U

Diagnostic Guides

Course: TVP-13

KF-60DX100

Table of Contents

KZ-32TS1U // KZ-42TS1U

Introduction ...........................................1

1. Normal Operation .............................2

2. Self-Diagnostics................................3

3. Board Selection by Defect...............4

4. Plasma Panel Picture Defects .........5

5. Board Location..................................6

6. Service Mode.....................................7

7. Adjustments when the

B Board is Replaced............................12

8. Plasma Panel Replacement -

KZ-32TS1U ............................................15

9. Plasma Panel Replacement -

KZ-42TS1U ............................................23

10. Standby Power / Power ON..........28

Power ON .............................................................. 28

11. Fan Drive Circuit ............................30

12. Video Signal Flow ..........................32

13. What is Flat Screen

Plasma Technology? ...........................35

Theory of Operation ............................................ 35

KF-60DX100

Introduction ..........................................37

15. Normal Operation ..........................38

16. Self-Diagnostics.............................39

17. Board Selection by Defect............40

18. Board Locations.............................41

19. Adjustments ....................................42

20. Service Mode..................................44

21. Determining if the

Optical Unit is OK ................................45

22. Optical Unit Removal ....................46

23. Screen / Mirror Replacement.......50

24. Troubleshooting -

TV Shutdown ........................................53

25. Power Supply .................................54

26. Fan Control - KF-60DX100............56

27. Grand Wega Lamp Control...........59

Lamp Operation ................................................... 59

Lamp ON Display ................................................. 62

Power Block Location & Removal..................... 62

Troubleshooting.................................................... 63

28. Video Process ................................65

Sony Model KZ-32TS1U // KZ-41TS1U TV Diagnostic Guide

Sony Plasma TV KZ-32TS1U/KZ-41TS1U Introduction

This training manual has been organized to provide a quick diagnosis of problems in Sony Plasma screen TV models KZ-32TS1U and KZ-41TS1U. The circuitry in these two TV sets is similar, but the boards and plasma panels are mounted differently.

Because the Plasma TV set is a new design concept, Chapter 1 will cover normal Plasma TV operation. The last chapter will cover plasma principles / concepts (only necessary for background information).

Repairs to these TV models involve identifying and replacing a circuit board, the plasma panel or other parts such as the fan or the on/off switch. This manual is divided into thirteen chapters:

Table of Contents

Chapter Contents

1. Normal Operation This 16x9 plasma screen TV operates differently from a picture tube TV.

2. Self Diagnostics The front panel Standby light blinks to indicate major and minor problems.

3. Board Selection by Defect Listing of possible defects and where they may be.

4. Plasma Panel picture

Defects

5. Board Location Location of replaceable boards in model KZ-32TS1U.

6. Service Mode Service Mode access and contents.

7. Adjustments Adjustments after the B board is replaced.

8. Plasma Panel

Replacement KZ32TS1U

9. Plasma Panel

Replacement KZ42TS1U

10. Standby power / Power

ON circuit description

11. Fan Drive circuit

description

12. Video Flow circuit

description

13. Plasma Display

Technology

Listing of possible plasma panel screen defects

Pictured procedure to avoid problems in access and reassembly. KZ32TS1U and KZ42TS1U have separate pictured procedures.

Location and circuit operation for Standby voltage and Power ON sequence.

Fan Operation, troubleshooting, and testing.

Signal levels, description and symptoms when missing.

Plasma Cell Operating Concepts

Sony Model KZ-32TS1U // KZ-41TS1U TV Diagnostic Guide

Chapter 1 - Normal Operation

Black top and bottom (letterbox) borders – Even though this TV has a wide 16x9 screen, it is still possible to

receive a picture with top and bottom black bands. Movies are shot in many aspect ratios. The most common ratios are 4:3, 1.85:1 and 2.35:1. The picture displayed is dependent upon what aspect ratio the movie was shot in and how different it is from your TV screen’s aspect ratio. Ref Figure 1-1 below:

2:35:1 Movie

4x3 TV

Figure 1-1 - Display of a 2:35:1 Aspect Ratio Movie

The 1.85:1 aspect ratio movie will display without the black bands on this 16x9 screen TV (16/9 = 1.77:1 aspect ratio) because their 1.85 and 1.77 aspect ratios are almost the same. The extra wide 2.35:1 aspect ratio movie camera is still used in the film industry (mostly overseas). It produces the black borders even on a 16x9 (1.77:1) TV screen. In this TV, you may choose the “Subtitle” screen mode from the menu to fill the top of the screen, leaving only a black band at the bottom for the subtitle.

Fan Noise – Once the TV is turned on, the fan starts. The fan itself makes no noise but air flowing through the TV does, especially when the TV is enclosed. This low level of air turbulence is normal. The Main CPU monitors the fan run voltage, rotation and ambient temperature of the power supply. This information is available to the user from the User Status menu as an OSD (on screen display OK or NG indication). Details such as the temperature are in the Service Mode (see Section 6).

Video Inversion to prevent border burn in – After a (undetermined) period of use, some plasma cells will not be as bright as others, causing an incorrect tint (because one of the red, green or blue plasma cells will darken, leaving the others bright). Burn in can be prevented from the user menu. From the Screen Saver menu, “Picture Inversion” may be selected to “clean” the screen (black becomes white and white becomes black momentarily), restoring normal brightness to the cells.

If this Inversion function were set for AUTOmatic, picture inversion would occur at a specified time every day if the TV were ON. This picture inversion may alarm a viewer that is not aware that this is normal for this TV.

Picture Shift / Picture Orbit – To reduce the possibility of a stationary image permanently “burnt” into the plasma screen phosphor, the picture can be set to automatically move in a circular “orbit” pattern. The menu’s “picture orbit” can be set to small, medium or large orbit range and its cycle time can be 10, 30, 60 seconds or 5 minutes. Picture Orbit must be turned ON (normally OFF) if the user usually watches constant pattern images such as movies with borders, stock market scenes, etc.

16x9 TV

Subtitle Mode

Sony Model KZ-32TS1U // KZ-41TS1U TV Diagnostic Guide

Figure 2-1

Chapter 2 - Self-Diagnostics

Standby/Sleep Light

The front panel Standby LED blinks to indicate a fault. Refer to Figure 2-1. If the TV does not start up, the LED continually blinks to indicate a problem.

Standby/sleep light

If the TV starts and shuts down, the LED will repeatedly blink to indicate the reason for shutdown or A/V muting. Table 2-1 shows the boards that can cause the Standby LED to blink continuously and Table 2-2 shows the boards that cause shutdown.

Table 2–1 - Causes of Continuously Blinking LED – No TV A/V (black screen)

Cause Suspect Board EEPROM ID check error B board EEPROM read /write error B board Color Decoder IC error B board Panel will not initialize (start) Plasma panel Low B+ at start up Plasma panel, power supply board

Table 2-2 - Cause of Standby LED Blinking in a Pattern - TV Shutdown

Times Standby

LED blinks

2 times Plasma panel error Plasma panel

Cause Suspected board

3 times Internal TV temperature at critical Q board, Fan, or possibly B board 4 times Digital 5Vdc output voltage excessive or

too low.

5 times Digital 3.3Vdc output voltage excessive or

too low.

6 times Analog 6Vdc output voltage excessive or

too low.

Power Supply Output CN1/pin 9 / 10 B board is the load - CN101. Power Supply Output CN1/pin 5 / 6 B board is the load - CN101. Power Supply Output CN1/pin 13 / 14 B board is the load - CN101.

3. Board Selection by Defect

Chapter 3 - Board Selection by Defect

Table 3-1 shows the boards that could cause the symptoms listed. The most likely board is designated #1, second likely #2, etc. Two #1 means both boards have an equal probability. To resolve the conflict, testing is performed in the Standby/Power ON, Fan Drive, Video Flow circuit descriptions (Chapters 10-12) or the Plasma Panel picture defects (Chapter 4).

For isolation purposes, the TU (tuner board) may be unplugged and the TV will work, displaying video inputs.

Table 3-1 - Plasma TV model KZ-32TS1U / KZ42TS1U Board Selection by Defect

Probable Circuit Board Failure

Symptom B* H1 Power

Supply**

Audio Problem – all inputs 2 1 Audio Problem – TV channels (deselect SAP) Dark Screen – sound OK 1 2 1 Dark Picture – sound OK (deselect Power Save

on the remote) Dead Set - No relay click at plug in 2 1 3 Dead Set – Stby light OFF. No response to

front panel pwr button. Plug-in relay click heard.

Dead Set – Except for Stby light ON. No response to pwr button. Plug-in relay click heard.

Fan not cooling (front panel Standby indicator blinking.) See the TV menu and Fan block diagram in Section 7. Fan NG = No voltage to fan. Temp NG = Fan not working.

Noise Bars across the screen (horizontal) The rear metal shield must contact the conductive mesh

Standby Indicator blinking 2 times Standby Indicator blinking 3 times Standby Indicator blinking 4, 5 or 6 times Video Distortion – With composite and S video

input only. Video Distortion – With component (Y, R-Y, B-

Y) input only. Video Distortion – With both composite and

component inputs. Try using the menu’s “picture inversion” to “clean” the screen first.

Symptom B * H1 Power

*After B board replacement, adjustments for brightness and color balance are necessary. See Adjustments. **The entire power supply board is listed in the service manual as “Switching Regulator”. The 32” and 42”

TV sets do not use the same Switching Regulator power supply and therefore have different part numbers. ***See Possible Plasma Panel defects for illustrations.

2 1

1 1

3 2 1 4

2 1 3

3 2 1

on all four sides and be screwed to the center TV board assembly.

2 1 3 (2 = fan) 2 1 2 1

2 1

1 2 3

Supply

Q TU Plasma

Panel

***

Q TU Plasma

Panel

Chapter 4 - Plasma Panel Picture Defects

Board Location – Ref. Figure 4-1

Vertical or Horizontal black / white line through the picture.

Sony Model KZ-32TS1U // KZ-41TS1U TV Diagnostic Guide

Colored rain in a black background.

White Noise replaces 1/4 of the picture

d) e) f)

Normal Pix

Black lower half

Power Supply Board

CN 23

13, 15 gray wires

Normal Pix

Black upper half

g) A Dark Screen with sound can be caused by the plasma panel or the TV circuitry. Measure the DC voltages and signal entering the plasma panel to determine which is defective.

Dark screen? Check DC and signal video levels at CN23 & CN 1. Normal Voltages with TV ON, any input CN23/pin 1 = 55Vdc CN23/pin 3 = 5Vdc CN23/pin 8-10 = 78Vdc (32") or 82Vdc (42") CN1/pins 13 & 15 (gray wires) = 1Vp-p @ 30MHz If these input voltages/signals are OK, the plasma panel is suspect. CN1 is on the plasma panel below

CN 1

the Power Supply board.

White noise

Black top, bottom just white noise

PLASMA

BOARD Y

5. Board Location

Chapter 5 - Board Location

POWER SUPPLY

BOARD

PLASMA

BOARD X

B BOARD

Q BOARD

TU BD.

VHF

FIGURE 5-1 - BOARD LOCATION - KZ-32TS1U

8TVP13 1444 4/10/02

6. Service Mode

Figure 6-1

Chapter 6 - Service Mode

Service Mode Access

1. The TV must be in the Standby Mode as indicated by the front panel red light. Refer to Figure 6-1 for the location of the standby light. If this Standby light is OFF, plug the TV into AC, press the front panel Power button and then shut off the TV from the remote control. The Standby light should now be lit (red) while the TV is OFF.

Standby/sleep light

2. Using a Sony remote control aimed at the TV in the standby mode, quickly press: Display, 5, Volume +, Power ON and MENU. If the TV turned ON when 5 was pressed, you did not press the next Volume + button fast enough and will have to try again.

3. The following new service Mode menu shown in Figure 6-2 will appear above the user menu. Use the remote control joystick to move and change the data as before. Store data as in previous service modes, by pressing “Mute” and then “Enter”.

Service Menu

Normal User Menu

Figure 6-2 - Service Mode Display

6. Service Mode

ial number, elapse operation time and diagnostic are erased.

= 8.

Service Mode Contents

Table 6-1 - Service Mode Contents

Service Category Contents

EEP ROM Initialize See Figure 6-3 for a list of Initialize contents. Selecting a line (like “Common”)

reveals two options: OK or cancel. Selecting OK stores default data and causes the TV to reboot. You must press Menu when the TV turns back ON to return to the service mode. Do not select OK unless you have read what you are resetting to default levels.

Whole Area - Resets the entire EPROM and requires a full TV alignment afterwards. The ser This is used when the TV is made. For service, you can individually reset EPROM contents:

Common - Resets items that are not signal related, such as: language, Orbit, Diagnostic errors, serial number, color system and TV ON elapsed time. White Balance – Resets Low, Mid and High Temperatures to midgain in preparation for alignment after B board replacement.

Prog. Gamma - Is not used. Tuner - Resets channels back to 2-13 and clears the Favorite channels. Prog. Preset - Erases user station names. Last Memory - Resets user video and audio preface settings. User Mem – Is not used Factory – Resets user settings to default except diagnostics and serial number. Tuner Micom- Same as Tuner.

Chroma Decoder See Figure 6-4 for a content list. Preset contrast, sharpness, color and output levels

as shown in Figure 6-4. The Hue for NTSC = 8, Y Delay = 8, and Cb/Cr Offset Sharp fo is the frequency the sharpness peaks. 0=2.5M, 1=3.2M, 2=4M, 3=off. Set to 3.

AD Converter Adjust the brightness and hue for each input (video, component and RGB). Preset

these levels after the B board is replaced and touch up. See adjustments for the procedure.

White Balance White balance adjustments at low, middle and high brightness levels. Preset these

levels after the B board is replaced and touch up. See adjustments for the procedure.

General See Figure 6-5 for a content list.

AGC Wide & Narrow - Data affects capturing stations during auto programming (wide = 14) and operation (Narrow = 13).

Fan Status - Displays the temperature of the power supply and the voltage applied to the fan motor (8.6Vdc = slow).

Vs / Va Setting - The main plasma panel voltages Vs and Va are set using Uvrs and Uvra. The 32” TV uses Uvrs = 82 and Uvra = 106. The 42” TV uses 93 and 128 respectively. Vs and Va needs adjustment if the logic board within the plasma

panel is replaced. Manual Control See Figure 6-6 and 6-7. These are all preset to 00 except for: PDP =20. Preset Edit See Figure 6-8. This section presets the parameters for a new video input signal.

6. Service Mode

Service Status See Figure 6-9. This section displays the status of the input signal, and TV

condition. Signal/sync - Format, freq, and sync polarity of the input signal. Power Supply – Low voltage output of the power supply in voltage DC. Fan & Temp - The fan voltage and power supply temperature. Within this category

is a No Ack Dev - Points to an IC that is not communicating with the Main Micro using a 4-digit defect code number. See No Acknowledge Device table 6-2.

Warning Status – Shows completion of communications from the Main Micro (B board) to memory IC and to 15 others.

Operation Time – Elapse TV ON time. Software & PLD version – Software in Main micro and Panel Micro.

Table 6–2 - Service Mode - Service Status under Fan and Temp, No Acknowledge Device

Defect Code Suspected IC Defect Code Suspected IC 0001 Audio Processor (A board) 0002 Audio Switch (Q board) 0004 AV Switch IC (U board) 0008 V Chip (Q board) 0010 3D Comb filter IC (B board) 0020 Color Decoder (B board) 0040 Plasma Panel (PDP) 0080 Tuner (TU board) 0100 Auto Wide IC (B board) 0200 A/D Converter (B board) 0400 EPROM (M board) 0800 System IC (B board) 1000 V Chip (Q board) 2000 PLD (B board) 4000 Real Time Clock IC (B board) 8000 Scan Converter (B board)

Figure 6-3 Service Mode - EEP ROM Initialize

Figure 6-4 Service Mode – Chroma Decoder

6. Service Mode

Figure 6-5 Service Mode –General

Figure 6-6 Service Mode – Manual Control 1/2

Figure 6-7 Service Mode – Manual Control 2/2

6. Service Mode

Figure 6-8 Service Mode –Preset Edit

Figure 6-9 Service Mode –Service Status

7. Adjustments when the B Board Needs to be Replaced

Chapter 7 - Adjustments when the B Board is Replaced

If the B board is replaced, the A/D Converter levels and white balance need to be adjusted or the brightness and tint range will not be consistent when switching inputs. These settings are made from the service mode for each input (Tuner, Video and Component) type and the data is saved in a NVM IC on the TV’s B board.

Service Mode Access

1. The TV must be in the Standby Mode as indicated by the front panel light. If this Standby light is OFF, plug the TV into AC, press the front panel Power button and then shut off the TV from the remote control. The Standby light should now be lit while the TV is OFF. Ref. Figure 7-1.

Standby Mode Standby/sleep light must be red

Figure 7-1

2. Using a Sony remote control aimed at the TV in the standby mode, press: Display, 5, Volume +, Power ON and

MENU, quickly. If the TV turned ON when 5 was pressed, you did not press the next Volume + button fast enough and will have to try again.

3. The following new service Mode menu shown in figure 7-2 will appear above the normal user menu. Use the

remote control joystick to move and change the data as before. Store the new data by pressing Mute, and then Enter, as before.

Service Menu

Normal User Menu

Figure 7-2 - Service Mode Display

A/D Converter Adjustments White balance and brightness levels for the three types of video inputs are set in the AD Converter area of the

service mode. All three types of video inputs (RGB, YUV and Video) are shown in Figure 7-3 and Table 7-1. Adjust each one by feeding the corresponding white input to the back of the TV or temporally preset them to these default values shown. Use the remote control joystick to select and change the data.

7. Adjustments when the B Board Needs to be Replaced

Figure 7-3 - A/D Converter Preset Default Levels

3/13/02

Table 7-1 A/D Converter (WB & Brightness) Default Levels

RGB YUV (Component Video) Video (Composite Video)

Item 32”

Level

42” Level

Item Level 42”

Level

Item Level 42”

Level Sub Cont RGB 104 110 SubCont YUV 102 106 SubCont Video 68 65 Red Gain 100 114 Sub Bri YUV 146 145 SubBrt Video 150 142 Green Gain 128 128 Cb Offset YUV 30 31 Cb Offset Video 32 34 Blue Gain 129 131 Cr Offset YUV 31 31 Cr Offset Video 32 34 Red Bias 142 139 Green Bias 148 147 Blue Bias 150 150

7. Adjustments when the B Board Needs to be Replaced

LEVELS - MODEL KZ-32TS1U

White Balance In the service mode, you will preset the RGB gain levels for the High, Middle and Low color temperatures, then

check the white balance as brightness is increased from minimum to maximum. Figure 7-4 Shows the RGB levels for the 32" TV and Figure 7-5 shows the levels for the 42" TV. Use the remote control joystick to select and change the data (position of the x). Store the data by pressing “Mute” and then “Enter”.

Check the white balance as you increase the TV’s brightness level bar from low to middle to high screen brightness. The white areas of the picture should remain white even as the brightness is changed. If the white balance is off, return to the stop service mode and touch up the R, G or B adjustment level.

KZ32TS1U Figure 7-4 shows the White Balance levels from a 32" Plasma TV.

White Balance Color Temp: High

R G B

X X X

White Balance Color Temp: Mid

R G B

X X X

FIGURE 7-4 - WHITE BALANCE PRESET DEFAULT

KZ-42TS1U Figure 7-5 shows the White Balance levels from a 42" Plasma TV:

White Balance Color Temp: High

R G B

X X X

White Balance Color Temp: Mid

R G B

X X X

FIGURE 7-5 - WHITE BALANCE PRESET DEFAULT

LEVELS - MODEL KZ-42TS1U

White Balance Color Temp: Low

R G B

White Balance Color Temp: Low

R G B

X X X

8. Plasma Panel Replacement - KZ-32TS1U

Chapter 8 - Plasma Panel Replacement - KZ-32TS1U

The KZ-32TS1U and the KZ-42TS1U are mechanically different and have separate procedures for removal of the Plasma Panel.

Handling Precautions

After removing the plasma panel from the TV, note that there are flex cables located at the bottom and both sides of the panel that are susceptible to damage.

So the flex cables are not damaged, only rest the plasma panel topside down as shown in figure 8-1.

Bottom Flex Cables

Panel Bottom

Flex Cables

Top

Figure 8-1 - Plasma Panel Standing Upside Down

Procedure – KZ32TS1U

In the steps to follow, you will remove the rear panel, the shield, the board assembly and both support rails to free the plasma screen that is connected to the front bezel.

Fan & Shield Ÿ Remove

8. Plasma Panel Replacement - KZ-32TS1U

Figure 8-2 - Back Removed

a) Begin by removing the back panel to expose the shield, shown in figure 8-2. b) Unplug the fan and remove the shield.

Plasma Panel

Power Supply Board

Lower Board Assembly

Board

Layout

Figure 8-3 - Circuit Boards

TV Board Assembly

8. Plasma Panel Replacement - KZ-32TS1U

Figure 8-4 - Input Panel

The lower board assembly (behind the input jacks) must be removed because the plasma panel cannot be slid out from underneath it. There is a lip under the board assembly that prevents the panel from being slid sideways.

c) Remove the input connector cover (four screws + VHF input jack)

TV Board Assembly

Ÿ Remove the

Input Connector Cover

Screw

The TV boards are in an assembly held in by four black screws. Two can be easily seen at the right in Figure 8-

5. The left two are behind the plate. In the next three steps, you will lower the front Q board to remove all the screws and pull out the H1 board cable harness from the assembly.

d) Remove two screws holding the front Q board in the TV board assembly (see Figure 8-5). Fold it down. e) Remove the four black screws holding the TV board assembly. Gradually pull the assembly toward you. f) Snake the H1 Board cable harness out the back to free the TV board assembly (see Figure 8-6).

2 Screws

Plate

Remove TV Board Assembly 1 Ÿ Fold Down board

Figure 8-5 - Remove TV Board Assembly 1

Remove the TV Board Assembly 2

Figure 8-6 - Remove TV Board Assembly 2

Phone

Ÿ Snake the H1 board harness out

the back hole

8. Plasma Panel Replacement - KZ-32TS1U

H1 Board Cable Harness

In the next two steps, the TV must be supported while face down and the base removed.

Book(s)

Ÿ Insert Books

Figure 8-7 - Base Removal 1

Phone Book(s)

g) Lay the TV face down on a clean soft cloth. Bubble wrap was used in these pictures because it was clean

and soft.

h) Use books to lift the base off the floor.

Top View

8. Plasma Panel Replacement - KZ-32TS1U

Support

Brackets

Figure 8-8 - Base Removal 1

i) Remove the base. j) Lay the TV screen flat on the floor.

Bezel, P.S and Plasma Screen Ÿ Remove bracket

Support Brackets

Figure 8-9 - Base Removal 2

k) Remove the two support brackets.

8. Plasma Panel Replacement - KZ-32TS1U

Figure 8-11 - Plasma Panel Standing Upside Down

Handles

Figure 8-10 - Plasma Screen Handles

Power Supply Board

Handles

l) Finally, remove the plasma screen – use the four black handles to lift. Only place the top of the plasma

screen down. The other three sides have vulnerable flex cables present.

Bottom Flex Cables

Panel Bottom

Top

m) Remove the power supply board (mounted on the larger metal heat sink).

Flex Cables

+ 51 hidden pages