Note: This maintenance manual is intended only for the reference of the maintenance people.
Please pay attention to the following points before carrying out the maintenance work.
Safety Precautions
Please read the “Points for attention for the Maintenance & Repair of PDP” and “Criterion for
Identifying the Defects on Screen” as below, before inspecting and adjusting the TV set.
1. “Points for attention for the Maintenance & Repair of PDP”
To avoid possible danger, damage or jeopardy to health and to prevent PDP screen from new
damage, the maintenance people must read the following carefully. If they ignore the following
warnings, there will be deathful risks:
1.1 Screens vary from one model to another and therefore not interchangeable. Be sure to use the
same type of screen in the replacement.
1.2 The operation voltage is approximately 350V for PDP module (including screen, driving circuit,
logic circuit and power module). If you want to conduct maintenance work on PDP module when the
set is in normal operation or just after the power is off, you must take proper measures to avoid
electric shock and never have direct contact or touch with the circuitry of the working module or
metal parts. That’s because within a short time relatively high voltage still remains on the capacitor
of the driving part even after the power is off. Make sure to begin relevant maintenance operation at
least one minute after the power is off.
1.3 Don’t apply on the module any power supply that is higher than the specification. If the power
supply used deviates from the value given in the specification, there might be a possibility of leading
to fire or damage to the module.
1.4 Never have operation or mounting work under unsuitable environment such as areas in the
vicinity of water – bathroom, laundry, water chute of kitchen – sources of fire, heat-radiation parts or
direct exposure to sunlight. Otherwise there will be kickbacks.
1.5 In case foreign substances such as water, liquid, metal slices or others fall into the module
carelessly power must be cut off immediately. Keep the module as it is and do not move anything on
the module. Otherwise it might be possible to contact the high voltage or cause shock short circuit
so that it may lead to fire or electric shock.
1.6 If there is smoke, abnormal smell or sound from the module, please cut the power off
immediately. Likewise in case the screen doesn’t work when the power is on or during the operation,
please also cut off the power at once. No more operation in this case.
1.7 Do not remove or plug its connection wire when the module is in operation or right after the
power is off. That’s because there remains a relatively high voltage on the capacitor of the driving
circuit. If there is a need to remove or plug in the connection wire, please wait at least one minute
after the power is off.
1.8 Considering the module has a glass faceplate, please avoid extrusion by external force lest it
should cause glass breakage that may get people injured. Two people are needed in cooperation to
move this module lest contingency takes place.
1.9 The complete TV set is designed on the basis of full consideration of thermal dissipation by
convection, with the round hole on the top for heat emission. To avoid overheat, please do not have
any covering on the hole during normal operation and never put it in the place where the space is
narrow and in bad ventilation.
1.10 There is quite a number of circuits in PDP that are integrated ones. Please be on guard against
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static electricity. During maintenance operation be sure to cover yourself with anti-static bag and
before operation make sure to have it sufficiently grounded.
1.11 There are a big number of connection wires distributed around the screen. Please take care
not to touch or scuff them during maintenance or removing the screen, because once they are
damaged the screen will fail to work and it’s not possible to repair it.
If the connection wires, connectors or components fixed by the thermotropic glue need to disengage
when service, please soak the thermotropic glue into the alcohol and then pull them out in case of
damage.
1.12 Connector for the circuit board of the screen part is relatively fine and delicate. Please take
care in the replacement operation lest it should get damaged.
1.13 Special care must be taken during transportation and handling because strenuous vibration
could lead to screen glass breakage or damage on the driving circuitry. Be sure to use a strong
outer case to pack it up before transportation or handling.
1.14 Please put it for storage in an environment in which the conditions are under control so as to
prevent the temperature and humidity from exceeding the scope stipulated in the specification. For
prolonged storage please cover it with anti-moisture bag and have them piled and stored in one
place. The environmental conditions are tabulated as below:
Temperature Scope for operation 0~50centigrade
Scope for storage -15~60centigrade
Humidity Scope for operation 20%~80%
Scope for storage 20%~80%
1.15 If a fixed picture is displayed for a long time, difference in its brightness and color may occur
compared with movable pictures. But it doesn’t show any problem and the reason is that there is
reduced density of fluorescent powder in the former. On the other hand, even if changes take place
in the picture, it can keep its brightness for a period of time (several minutes). It’s a feature inherent
with plasma and it’s not abnormal. However please try as much as possible to avoid showing a still
picture of high brightness for a long time during operation.
1.16 As a digitalized display devise, this module is provided with error diffusion technology and the
gray scale and false enhancement of contour can be displayed by reusing of sub-field. As compared
with cathode ray tube, it can be found in the moving picture that at the brim of the face of a person
there are some wrong colors.
1.17 During the display of graph (indicating the gradual change in brightness horizontally or
vertically) resulting from gray scale test it can be found that the brightness for the two adjacent
levels is uneven. This is caused by the reuse of sub-field, the display of load rectification and the
electrolysis.
1.18 The screen front plate is of glass. Please make sure that the screen has been put in place
during erection. If it is not in place before the erection begins it may lead to screen crack or
breakage.
1.19 Make sure the screw used in the mounting of the screen is of the original specs lest it should
cause damage to the screen due to mismatch. Special care should be taken not to use too long or
too big screw.
1.20 Care must be taken to guard against dust during assembling or dismantling, especially to avoid
dirt from falling in between the screen and the glass lest it should harm the receiving and viewing
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effect.
1.21 There is piece of insulator stuck on the rear chassis corresponding to the power supply board.
It is used to isolate the cool part from the hot part. Please take care to keep it intact lest it should
become a potential safety trouble.
1.22 In addition to plasma screen, the glass is a part of high value. It has such functions as
anti-radiation, adjustment of color temperature etc. Please handle it carefully.
2. “Criterion for Identifying the Defects on Screen”
The PDP produced by our Company at present uses the following criterion for identifying the defective
points:
2.1 Model PS-42XX:
There may appear three kinds of defective points for this model as shown in Fig.1, i.e., bright spot
(remain bright); dark spot (non-illuminating); flickering spot (continuously flickering).
However they should not exceed the specification as in table 1. Otherwise the product shall be deemed
as sub-standard.
H
Zone B
W/4 W/2 W/4
Figure 1Defective Points
Zone A
W
H/4
H/2
H/4
Table 1 Criterion for Three Kinds of Defective Points
Kind Area A Area B Remark
Dark spots No more than 2 No more than 8
Bright spot No more than 1 No more than 2
Total number of defective
points in A and B shall not
exceed 8. The distance
Flickering spot No more than 1 No more than 2
between two defective
points shall not be shorter
than 15mm.
2.2 Model PH-42XX:
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Table 2 Cell Defect Specifications
Defect
Number of Cell Defects (N)
►Total N≤4 [cells/full screen]
Non-Ignition
1)
Dot*
+Unstable Dot*2)
A-zone
B-zone
►N≤2 [cells/each R,G,B screen]
►N=0 [adjacency of 2-cells/full-white screen]
►Total N≤11 [cells/full screen]
►N≤5 [cells/each R,G,B screen]
►N≤5 [adjacency of 2-cells/full-white screen]
=0[adjacency of 3-cells/full-white screen]
Uncontrollable
3)
Dot*
Non-Extinguishing
4)
Dot*
A-zone ►N≤1 [cells/each R,G,B screen]
B-zone ►Total N≤3 [cells/ full screen]
A-zone ►N=0
B-zone ►N=0
►Total sum of all defects N≤17 [cells/full-white screen]
Specification
Distance between two defects
(D)
►A-Zone:≥100mm
►B-Zone: N≤2
(100mm circle/screen: 2points
allowed)
►A, B Zone overlap: N≤2
(100mm circle/screen: 2points
allowed)
►N≤6, for the stain of which longer-axis length is 5mm or
Stain*
5)
►N=0, for the stain of which longer-axis length is longer than
shorter.
►D≥50mm
5mm.
1) Non-Ignition Dot (Dark Defect) is defined as “A cell of which more than 50% area is not ignited”
2) Unstable Dot (Flickering) is defined as “A cell which repeats On and Off”
3) Uncontrollable Dot is defined as “A cell which is distinctly brighter or darker than other cells around it”
and/or “A cell of which color is distinctly different from that of other cells around it”
4) Non-Extinguishing Dot (brightness defect) is defined as “A cell of which more than 50% area is
always ON”
5) Stain is defined as “A blob due to local color contamination in white or simple color pattern”
●The decision distance is 3H away from the panel, intensity of illumination is between 100 Lux and 200
Lux.
H
V/4
V
A -Zone
(25% of display area)
B -Zone
(75% of display area)
V/2
V/4
H/4 H/2 H/4
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2.3 Model PH-50XX:
There may appear three kinds of defective points for this model as shown in Fig.3 i.e., bright spot
(remain bright); dark spot (non-illuminating); flickering spot (remain flickering).
However they should not exceed the specification as in table 3. Otherwise the product shall be deemed
as sub-standard.
Table 3 Criterion for Three Kinds of Defective Points
H
Zone B
Figure 2 Defective Points
Zone A
W
H/4
H/2
H/4
W/4 W/2 W/4
Item Kind Area A Area B Remark
1 Dark spots No more than 4 No more than 10
2 Bright spot No more than 1 No more than 3
Total number of defective
points in A and B shall not
exceed 14. The distance
3 Flickering spots No more than 1 No more than 3
between two defective
points shall not be shorter
than 10mm.
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Alignment instructions
1. Test equipment
PM5515 (video signal generator)
VG-849 (YUV, VGA, HDMI signal generator)
CA100 (white balancer)
2. The alignment flow chart (see below figure)
Connect with central signal source, then check each function of TV such as
station missing, analog control etc., check the output of headphone and speaker
Input AV/SVIDEO signal, then check each function of all the terminals
Input HD signal (format), then check each function of the terminal
Input VGA, HDMI signal, check if the display is normal, check each
function such as analog control etc., check horizontal /vertical center etc.
3. Description of adjustment
3.1 Unit adjustment
To produce digital board and analog board
Check the accessories and pack them in box
Check DDC and FLASH
All testing
Adjust white balance
Preset ex-factory
Fig-1 adjustment flow-chart
Connect the digital processing board, analog board, power board, power filter board and button
board according to the wiring diagram 203-PH42FB8-01JL. Connect with power and observe the
display.
Method for using factory menu: press ”INPUT” button, then press”2580” to enter level one factory
menu. Press ”CH+” and “CH-“ to select adjustment page, then press “OK” to access. Press “CH+”
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and “CH-“ to move cursor up and down, when the cursor stays on a certain adjustment item, press
“VOL-“ and “VOL+” to adjust. Press “MENU” exit to the level one factory menu; press “EXIT” to exit
from the factory menu at any situation.
Note: channel switch isn’t available at adjustment menu, only after return to level one factory menu,
you can switch channel.
3.2 adjustment of white balance
3.2.1 input 16 level gray-scale signal from VG849 to HDMI channel (TMIING: select a support
format of HDMI), enter white balance adjustment page of factory menu, select cool color
temperature of item, fixed WBGG_HDMI to 50H, adjust WBRG_HDMI, WBBG_HDMI, let the color
coordinate of third level on the right be (270,283) at 120nits; fixed WBBO_HDMI to 50H, adjust
WBRO_HDMI, WBGO_HDMI, let the color coordinate of third level on the left be (270,283) at 5nits.
The brightness of 120nits and 5nits may obtain by adjusting the contrast and brightness of menu.
3.2.2 input 16 level gray-scale signal from VG849 to AV channel (TMIING:968), enter white balance
adjustment page of factory menu, select cool color temperature of item, fixed WBGG_NTSC to 50H,
adjust WBRG_NTSC, WBBG_ NTSC, let the color coordinate of third level on the right be (270,283)
at 120nits; fixed WBBO_ NTSC to 50H, adjust WBRO_ NTSC, WBGO_ NTSC, let the color
coordinate of third level on the left be (270,283) at 5nits. The brightness of 120nits and 5nits may
obtain by adjusting the contrast and brightness of menu.
3.2.3 input 16 level gray-scale signal from VG849 to VGA channel (TMIING: select a support format
of VGA), enter white balance adjustment page of factory menu, select cool color temperature of
item, fixed WBGG_VGA to 128, adjust WBRG_ VGA, WBBG_VGA, let the color coordinate of third
level on the right be (270,283) at 120nits; fixed WBGO_VGA to 128, adjust WBRO_VGA,
WBBO_VGA, let the color coordinate of third level on the left be (270,283) at 5nits. The brightness
of 120nits and 5nits may obtain by adjusting the contrast and brightness of menu.
3.2.4 input 16 level gray-scale signal of 480I from VG849 to YPbPr channel, enter white balance
adjustment page of factory menu, select cool color temperature of item, fixed WBRG_YPbPr480I,
WBGG_YPbPr480I, WBBG_YPbPr480I to 128, and WBRO_YPbPr480I to 128, adjust
WBRO_YPbPr480I, WBBO_YPbPr480I, let the color coordinate of third level on the left be (270,283)
at 5nits. The brightness of 5nits may obtain by adjusting the contrast and brightness of menu.
Input format signals separately list on table 1, repeat the operation above until the white balance
pass muster.
Note: the white balance adjustment of VGA and YPBPR must be done at the situation that the white
balance adjustment of HDMI is accurate.
4 Performance check
4.1 TV function
Connect RF-TV terminal to the central signal source, enter the setup menu→ auto search, check if
there is station skipping, the output of earphone and speaker, the picture are normal.
4.2 AV/S-VIDEO terminal
Input AV/S signal, check if the picture and sound are normal.
4.3 YPbPr/YCbCr terminal
Input YUV signal (VG-849 signal generator), separate input YUV format signal of table 1 and check
if the picture and sound are normal.
Table 1 YUV signal format
No H-frequency (KHz) V-frequency (KHz) Signal
1 15.734 59.94 SDTV 480i
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2 31.469 59.94 HDTV 480p
3 44.955 59.94 HDTV 720p
4 33.716 59.94 HDTV 1080i
4.4 VGA terminal
Input VGA signal (VG-849 signal generator), separate input VGA format signal of table 2 and check
if the picture and sound are normal. If the image is deflection of the H-field, select manual correction
of Advanced Video Menu.
4.5 HDMI terminal
HDMI signal format receives the three high-definition signals: 480I, 480P, 720P/60Hz, 1080I/60Hz,
except for the table 2 signal. Check if the image (contain HDCP ON and OFF) and sound are
normal.
Table 2 VGA signal format
No Resolution H-frequency(kHz) V-frenquency(Hz)
1 720 X 400 31.469 70.086 28.322 IBM
2 640 X 480 31.469 59.94 25.175 IBM
3 640 X 480 37.861 72.809 31.5 VESA
4 640 X 480 37.5 75 31.5 VESA
5 640 X 480 43.269 85.008 36 VESA
6 800 X 600 35.156 56.25 36 VESA
7 800 X 600 37.879 60.317 40 VESA
8 800 X 600 48.077 72.188 50 VESA
9 800 X 600 46.875 75 49.5 VESA
10 800 X 600 53.674 85.061 56.25 VESA
11 1024 X 768 48.363 60.004 65 VESA
12 1024 X 768 56.476 70.069 75 VESA
13 1024 X 768 60.023 75.029 78.75 VESA
Point clock pulse
frenquency(MHz)
Remark
5 Ex-factory setting of user menu
1) Select TV channel, volume: 25
2) Video menu, Picture Mode: Nature, Aspect Ratio: Wide
3) Video menu, Advanced Video Menu:
Noise Reduction——Spatial: On
Noise Reduction——Speckle: Off
Noise Reduction——Temporal: On
Sharpness: 0
6) Feature menu, Sleep Timer: Off, Menu Language: English
Note: Except for Color Temperature of Cool, the Advanced Video Menu of YPbPr/YCbCr and VGA
channels sets according to the adjustment of factory.
Trouble shooting
Before servicing please check to find the possible causes of the troubles according to the table
below.
1.Antenna(signal):
Picture is out of focus or jumping z Bad status in signal receiving
z Poor signal
z Check if there are failures with the electrical connector or
the antenna.
z Check if the antenna is properly connected.
Fringe in picture z Check if the antenna is correctly oriented.
z Maybe there is electric wave reflected from hilltop or
building.
Picture is interfered by stripe
shaped bright spots
There appear streaks or light color
on the screen
2.TV set:
Symptoms Possible cause
Unable to switch the power on z Check to see if the power plug has been inserted
No picture and sound z Check to see if the power supply of liquid crystal TV has
Deterioration of color phase or
color tone
Screen position or size is not
proper
z Possibly due to interference from automobile, train, high
voltage transmission line, neon lamp etc.
z Maybe there is interference between antenna and power
supply line. Please try to separate them in a longer
distance.
z Maybe the shielded-layer of signal wire is not connected
properly to the connector.
z Check if interfered by other equipment and if interfered
possibly by the equipment like transmitting antenna, non
professional radio station and cellular phone.
properly into the socket.
been switched on. ( as can be indicated by the red LED
at the front of the TV set)
z See if it’s receiving the signal that is transmitted from
other source than the station
z Check if it’s connected to the wrong terminal or if the
input mode is correct.
z Check if the signal cable connection between video
frequency source and the liquid crystal TV set is correct.
z Check if all the picture setups have been corrected.
z Check is the screen position and size is correctly set up.
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Symptoms Possible cause
Picture is twisted and deformed z Check to see if the picture-frame ratio is properly set up.
Picture color changed or colorless z Check the “Component” or “RGB” settings of the liquid
crystal TV set and make proper adjustment according to
the signal types.
Picture too bright and there is
distortion in the brightest area
Picture is whitish or too bright in
the darkest area of the picture
No picture or signal produced from
the displayer if “XXX in search”
appears.
There appears an indication “outside the receivable scope)
Remote control cannot work
properly
No picture and sound, but only
hash.
Blur picture z Check if the antenna cable is correctly connected.
No sound z Check if the “mute” audio frequency setting is selected.
When playing VHS picture search
tape, there are lines at the top or
bottom of the picture.
z Check if the contrast setting is too high.
z Possibly the output quality of DVD broadcaster is set too
high.
z It maybe also due to improper terminal connection of the
video frequency signal in a certain position of the
system.
z Check if the setting for the brightness is too high
z Possibly the brightness grade of DVD player
(broadcaster) is set too high.
z Check if the cable is disconnected.
z Check if it’s connected to the proper terminal or if the
input mode is correct.
z Check if the TV set can receive input signal. The signal is
not correctly identified and VGA format is beyond the
specified scope.
z Check if the batteries are installed in the reverse order.
z Check if the battery is effective.
z Check the distance or angle from the monitor.
z Check if there is any obstruct between the remote control
and the TV set.
z Check if the remote control signal- receiving window is
exposed to strong fluorescence.
z Check if the antenna cable is correctly connected, or if it
has received the video signal correctly.
z Of if it has received the right video signal.
z Check if the sound volume is set to minimum.
z Make sure the earphone is not connected.
z Check if the cable connection is loose.
z When being played or in pause VHS picture search tape
sometimes can’t provide stable picture, which may lead
to incorrect display of the liquid crystal TV, In this case
please press “auto” key on the remote control so as to
enable the liquid crystal TV set to recheck the signal and
then to display correct picture signal
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Method of software upgrading
1. Connect RS-232 cable to computer and TV set. The cable must be a female to female RS-232
cable, and the line is TXD to RXD and RXD to TXD cross-link. It’s popular for PC to PC
connection.
2. If the computer has no RS-232 serial port(e.g. Notebook PC),you needs a additional USB to serial
port cable.
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3. Copy the update tools (iDev.exe) to the path you want to do it, and double click it.
4. Select “setup” menu.
5. Confirm the Serial port is right. Base on the port which using for update. And set the band rate to
115200 (default).
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6. Select the “Image path” menu.
7. Confirm it’s the right file.
8. If it’s not right(Maybe you didn’t select it before),click the “…”button to select “*.ecc” file. Sometimes
the image file you got it will be “*.rar ”or “*.zip” zip file, needs unzip it first.
13
9. You also can click the setup button to select and config, but please don’t select the red
one(update boot sector).
10. Then click the “down” button.
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11. You can see the “waiting” window.
12. Then power (off then) on the TV set.
13. After download, it will be burning.
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14. Last it will be finished
15. Press the (IR/ locate keypad) power key and holding for several second to force power off TV set,
then power on again. It would be ok now. If it’s failure you can try once again.
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