Zenith DVB-413 Service manual
SERVICE MANUAL
Summary
Cabinet & Main Chassis
3
5
Zenith Electronics Corporation
201 James Record Road
Copyright
©
2004 by Zenith Electronics Corporation
...............................................
CONTENTS
SECTION 1 . . . .SUMMARY
SECTION 2 . . . .CABINET & MAIN CHASSIS
SECTION 3 . . . .ELECTRICAL
SECTION 4 . . . .MECHANISM
SECTION 5 . . . .REPLACEMENT PARTS LIST
SECTION 1
SUMMARY
CONTENTS
PRODUCT SAFETY SERVICING GUIDELINES FOR VIDEO PRODUCTS ............. 1-3
SERVICING PRECAUTIONS .................................................................................................. 1-4
• General Servicing Precautions
• Insulation Checking Prodedure
• Electrostatically Sensitive Devices
SPECIFICATIONS ...................................................................................................................... 1-5
1-2
1-3
IMPORTANT SAFETY NOTICE
This manual was prepared for use only by properly trained audio-video service
technicians.
When servicing this product, under no circumstances should the original
design be modified or altered without permission from Zenith Electronics
Corporation. All components should be replaced only with types identical to
those in the original circuit and their physical location, wiring and lead dress
must conform to original layout upon completion of repairs.
Special components are also used to prevent x-radiation, shock and fire hazard. These components are indicated by the letter “x” included in their component designators and are required to maintain safe performance. No deviations
are allowed without prior approval by Zenith Electronics Corporation.
Circuit diagrams may occasionally differ from the actual circuit used. This way,
implementation of the latest safety and performance improvement changes
into the set is not delayed until the new service literature is printed.
CAUTION: Do not attempt to modify this product in any way. Never perform
customized installations without manufacturer’s approval. Unauthorized modifications will not only void the warranty, but may lead to property damage or
user injury.
Service work should be performed only after you are thoroughly familiar with
these safety checks and servicing guidelines.
GRAPHIC SYMBOLS
The exclamation point within an equilateral triangle is intended to
alert the service personnel to important safety information in the
service literature.
The lightning flash with arrowhead symbol within an equilateral triangle is intended to alert the service personnel to the presence of
noninsulated “dangerous voltage” that may be of sufficient magnitude to constitute a risk of electric shock.
The pictorial representation of a fuse and its rating within an equilateral triangle is intended to convey to the service personnel the
following fuse replacement caution notice:
CAUTION: FOR CONTINUED PROTECTION AGAINST RISK
OF FIRE, REPLACE ALL FUSES WITH THE SAME TYPE AND
RATING AS MARKED NEAR EACH FUSE.
SERVICE INFORMATION
While servicing, use an isolation transformer for protection from AC line shock.
After the original service problem has been corrected, make a check of the following:
FIRE AND SHOCK HAZARD
1. Be sure that all components are positioned to avoid a possibility of adjacent
component shorts. This is especially important on items trans-ported to and
from the repair shop.
2. Verify that all protective devices such as insulators, barriers, covers, shields,
strain reliefs, power supply cords, and other hardware have been reinstalled
per the original design. Be sure that the safety purpose of the polarized line
plug has not been defeated.
3. Soldering must be inspected to discover possible cold solder joints, solder
splashes, or sharp solder points. Be certain to remove all loose foreign particles.
4. Check for physical evidence of damage or deterioration to parts and components, for frayed leads or damaged insulation (including the AC cord), and
replace if necessary.
5. No lead or component should touch a high current device or a resistor rated
at 1 watt or more. Lead tension around protruding metal surfaces must be
avoided.
6. After reassembly of the set, always perform an AC leakage test on all
exposed metallic parts of the cabinet (the channel selector knobs, antenna
terminals, handle and screws) to be sure that set is safe to operate without
danger of electrical shock. DO NOT USE A LINE ISOLATION TRANSFORMER DURING THIS TEST. Use an AC voltmeter having 5000 ohms per
volt or more sensitivity in the following manner: Connect a 1500 ohm, 10
watt resistor, paralleled by a .15 mfd 150V AC type capacitor between a
known good earth ground water pipe, conduit, etc.) and the exposed metallic parts, one at a time. Measure the AC voltage across the combination of
1500 ohm resistor and .15 mfd capacitor. Reverse the AC plug by using a
non-polarized adaptor and repeat AC voltage measurements for each
exposed metallic part. Voltage measured must not exceed 0.75 volts RMS.
This corresponds to 0.5 milliamp AC. Any value exceeding this limit constitutes a potential shock hazard and must be corrected immediately.
TIPS ON PROPER INSTALLATION
1. Never install any receiver in a closed-in recess, cubbyhole, or closely fitting
shelf space over, or close to, a heat duct, or in the path of heated air flow.
2. Avoid conditions of high humidity such as: outdoor patio installations where
dew is a factor, near steam radiators where steam leakage is a factor, etc.
3. Avoid placement where draperies may obstruct venting. The customer
should also avoid the use of decorative scarves or other coverings that
might obstruct ventilation.
4. Wall- and shelf-mounted installations using a commercial mounting kit must
follow the factory-approved mounting instructions. A product mounted to a
shelf or platform must retain its original feet (or the equivalent thickness in
spacers) to provide adequate air flow across the bottom. Bolts or screws
used for fasteners must not touch any parts or wiring. Perform leakage tests
on customized installations.
5. Caution customers against mounting a product on a sloping shelf or in a tilted position, unless the receiver is properly secured.
6. A product on a roll-about cart should be stable in its mounting to the cart.
Caution the customer on the hazards of trying to roll a cart with small casters across thresholds or deep pile carpets.
7. Caution customers against using extension cords. Explain that a forest of
extensions, sprouting from a single outlet, can lead to disastrous consequences to home and family.
A.C. Voltmeter
1500 OHM
10 WATT
Place this probe
on each exposed
metal part.
Good Earth Ground
such as the Water
Pipe, Conduit, etc.
0.15uF
PRODUCT SAFETY SERVICING GUIDELINES FOR VIDEO PRODUCTS
1-4
SERVICING PRECAUTIONS
CAUTION : Before servicing the DVD covered by this service
data and its supplements and addends, read and follow the
SAFETY PRECAUTIONS. NOTE : if unforeseen circumstances create conflict between the following servicing precautions and any of the safety precautions in this publications, always follow the safety precautions.
Remembers Safety First:
General Servicing Precautions
1. Always unplug the DVD AC power cord from the AC
power source before:
(1) Removing or reinstalling any component, circuit board,
module, or any other assembly.
(2) Disconnection or reconnecting any internal electrical
plug or other electrical connection.
(3) Connecting a test substitute in parallel with an elec-
trolytic capacitor.
Caution : A wrong part substitution or incorrect
polarity installation of electrolytic capacitors may result
in an explosion hazard.
2. Do not spray chemicals on or near this DVD or any of
its assemblies.
3. Unless specified otherwise in this service data, clean
electrical contacts by applying an appropriate contact
cleaning solution to the contacts with a pipe cleaner,
cotton-tipped swab, or comparable soft applicator.
Unless specified otherwise in this service data, lubrication
of contacts is not required.
4. Do not defeat any plug/socket B+ voltage interlocks with
whitch instruments covered by this service manual might
be equipped.
5. Do not apply AC power to this DVD and/or any of its
electrical assemblies unless all solid-state device heat
sinks are cerrectly installed.
6. Always connect test instrument ground lead to the
appropriate ground before connection the test instrument
positive lead. Always remove the test instrument ground
lead last.
Insulation Checking Procedure
Disconnect the attachment plug from the AC outlet and turn
the power on. Connect an insulation resistance meter(500V)
to the blades of the attachment plug. The insulation resistance between each blade of the attachment plug and accessible conductive parts (Note 1) should be more than 1Mohm.
Note 1 : Accessible Conductive Parts including Metal panels, Input terminals, Earphone jacks, etc.
Electrostatically Sensitive (ES) Devices
Some semiconductor (solid state) devices can be damaged
easily by static electricity. Such components commonly are
called Electrostatically Sensitive (ES) Devices. Examples of
typical ES devices are integrated circuits and some field
effect transistors and semiconductor chip components.
The following techniques should be used to help reduce the
incidence of component damage caused by static electricity.
1. Immediately before handling any semiconductor component or semiconductor-equipped assembly, drain off any
electrostatic charge on your body by touching a known
earth ground. Alternatively, obtain and wear a commercially available discharging wrist strap device, which
should be removed for potential shock reasons prior to
applying power to the unit under test.
2. After removing an electrical assembly equipped with ES
devices, place the assembly on a conductive surface such
as aluminum foil, to prevent electrostatic charge buildup or
exposure of the assembly.
3. Use only a grouned-tip soldering iron to solder or unsolder
ES devices.
4. Use only an anti-static solder removal device. Some
solder removal devices not classified a “anti-static” can
generate electrical charges sufficient to damage ES
devices.
5. Do not use freon-propelled chemicals. These can
generate electrical charge sufficient to damage ES
devices.
6. Do not remove a replacement ES device from its protec
tive package until immediately before you are ready to
install it. (Most replacement ES devices are packaged with
leads electrically shorted together by conductive foam,
aluminum foil, or comparable conductive material).
7. Immediately before removing the protective material from
the leads of a replacement ES device, touch the protective
material to the chassis or circuit assembly into which the
device will be installed.
Caution : Be sure no power is applied to the chassis or
circuit, and observe all other safety precautions.
8. Minimize bodily motions when handling unpackaged
replacement ES devices. (Normally harmless motion such
as the brushing together of your clothes fabric or the lifting
of your foot from a carpeted floor can generate static electricity sufficient to damage an ES device.)
1-5
SPECIFICATIONS
• GENERAL
Power requirements: AC 120 V , 60 Hz
Power consumption: 12W
Dimensions (Approx.): 430 x 39 x 242 mm (W x H x D) without foot
Weight (Approx.): 2.2 kg
Operating temperature: 5 °C to 35 °C (41 °F to 95 °F)
Operating humidity: 5 % to 90 %
• OUTPUTS
VIDEO OUT: 1 Vp-p 75 Ω, sync negative, RCA jack x 1/ SCART (TO TV)
AUDIO OUT: 2.0 Vrms (1 KHz, 0 dB), 600 Ω,
RCA jack (L, R) x 1/ SCART (TO TV)
DIGITAL OUT (COAXIAL): 0.5 V (p-p), 75 Ω, RCA jack x 1
• System
Laser: Semiconductor laser, wavelength 650 nm
Signal system: PAL / NTSC
Frequency response: DVD (PCM 96 kHz): 8 Hz to 44 kHz
DVD (PCM 48 kHz): 8 Hz to 22 kHz
CD: 8 Hz to 20 kHz
Signal-to-noise ratio: More than 100 dB (ANALOG OUT connectors only)
Harmonic distortion: Less than 0.008%
Dynamic range: More than 90 dB (DVD/CD)
• Accessories
Video cable (1), Audio cable (1), Remote control (1), Batteries (2)
2-1
SECTION 2
CABINET & MAIN CHASSIS
CONTENTS
1. EXPLODED VIEWS ................................................................................................................2-2
1. Cabinet and Main Frame Section ...........................................................................................2-2
2. Packing Accessory Section....................................................................................................2-3
2-2
EXPLODED VIEWS
1. Cabinet and Main Frame Section
A
5
4
3
2
1
BCD
250
463
A44
300
465
463
320
467
A46
SCART, 5.1CH
MODEL
ONLY
463
261
260
A00
463
463
A47
A41
279
KARAOKE MODEL
ONLY
283
A48
261
A43
261
A49
452
261
280
452
A42
2-3
2. Packing Accessory Section
BATTERY
808
PACKING SHEET
804
PACKING
OPTIONAL PARTS
803
806
820
OWNER'S MANUAL
RF CABLE
810
CABLE SET ASS'Y
801
REMOCON
900
BOX CARTON
802
PACKING
803
811
812
PLUG ASS'Y 1WAY(YELLOW)
PLUG ASS'Y 1WAY(BLACK)
PLUG ASS'Y 2WAY
3-1
SECTION 3
ELECTRICAL
CONTENTS
ELECTRICAL TROUBLESHOOTING GUIDE......................................................................3-2
1. Power check flow.....................................................................................................................3-2
2. System operation flow ............................................................................................................3-3
3. Test & debug flow....................................................................................................................3-4
4. KARAOKE Flow (KARAOKE MODEL ONLY) .......................................................................3-10
DETAILS AND WAVEFORMS ON SYSTEM TEST AND DEBUGGING ....................3-11
1. SYSTEM 27MHz CLOCK, RESET SIGNAL ...........................................................................3-11
2. SDRAM CLOCK......................................................................................................................3-12
3. TRAY OPEN/CLOSE SIGNAL ................................................................................................3-12
4. SLED CONTROL RELATED SIGNAL(NO DISC CONDITION) .............................................3-14
5. LENS CONTROL RELATED SIGNAL(NO DISC CONDITION) .............................................3-14
6. LASER POWER CONTROL RELATED SIGNAL(NO DISC CONDITION)............................3-15
7. DISC TYPE JUDGEMENT WAVEFORM ................................................................................3-16
8. FOCUS ON WAVEFORM ........................................................................................................3-17
9. SPINDLE CONTROL WAVEFORM(NO DISC CONDITION...................................................3-18
10. TRACKING CONTROL RELATED SIGNAL(System checking).........................................3-19
11. RF WAVEFORM ....................................................................................................................3-20
12. M3355 AUDIO OPTICAL AND COAXIAL OUTPUT(ASPDIF) .............................................3-20
13.M3355 VIDEO OUTPUT WAVEFORM ...................................................................................3-21
14. AUDIO OUTPUT FROM AUDIO DAC ..................................................................................3-22
BLOCK DIAGRAMS ..................................................................................................................3-24
1. Overall Block Diagram ..........................................................................................................3-24
2. Power(SMPS) Block Diagram ...............................................................................................3-25
3. SERVO Block Diagram ..........................................................................................................3-26
4. MPEG & MEMORY Block Diagram .......................................................................................3-27
5. VIDEO & AUDIO Block Diagram ...........................................................................................3-28
6. KARAOKE Block Diagram(KARAOKE MODEL ONLY) .......................................................3-29
CIRCUIT DIAGRAMS................................................................................................................3-30
1. Power(SMPS) Circuit DIAGRAM...........................................................................................3-30
2. AV/JACK Circuit DIAGRAM ...................................................................................................3-32
3. SYSTEM Circuit DIAGRAM ...................................................................................................3-34
4. DRIVER Circuit DIAGRAM.....................................................................................................3-36
5. TIMER Circuit DIAGRAM .......................................................................................................3-38
6. 5.1CH, SCART Circuit DIAGRAM .........................................................................................3-40
7. KARAOKE Circuit DIAGRAM(KARAOKE MODEL ONLY)...................................................3-42
• CIRCUIT VOLTAGE CHART ....................................................................................................3-44
PRINTED CIRCUIT DIAGRAMS ............................................................................................3-50
1. MAIN P.C.BOARD ...................................................................................................................3-50
2. KEY P.C.BOARD.....................................................................................................................3-52
3. TIMER P.C.BOARD .................................................................................................................3-53
4. SMPS P.C.BOARD ..................................................................................................................3-54
3-2
ELECTRICAL TROUBLESHOOTING GUIDE
No 5V_A
No 5.2VA
Is 5.2VA section working?
Is 5.2V present at emitter
of Q107?
Replace Q107.
Is there a DC voltage At
(+) terminal of BD101?
Is there a DC voltage at
R101?
Replace IC101.
Check F101
1. Power check flow
No VF+
Is 5.2VA section working?
Replace D102.
Check F102
NO
NO
YES
YES
YES
YES
Replace R101.
YES
Replace BD101.
YES
YES
A. B.
NO
NO
NO
NO
3-33-3
2. System operation flow
Power on
1.initializes SERVO, DSP and RISC registers
2.write RISC code to SDRAM
3.Reset RISC
Show LOGO
SLED at Inner Side?
SLED Moves to Inner Position
Tray Closed?
Tray Close to closed position
1.Judge whether have disc and disc type
2.Jump to related disc reading procedure
Received
Open/close key?
1.Execute Pressed Key and IR Key
2.System operation on routine loop
1.Stop playback and open tray
2.Display tray open message and LOGO
Receive
close key?
no
yes
no
yes
no
yes
no yes
3-4
3. Test & debug flow
Test
Check the AC Voltage
(110V or 220V)
Switch on the Power PCBA
Check the Power PART
Is
the DC Voltage
Outputs OK? (5.2V,5V,1.8V
,3.3V,8V,12V)
Check the Power PART
Is
3.3V, 1.8V,5V,12V and 8V
outputs normal on main
PCB
Check the IC105 or diode
Connect to PC RS232 Cable and
Update the flash memory code
Update
Flash(IC502)
Successfully?
A
1.Check 27MHz system clock.
2.Check system reset circuit.
3.Check flash R/W enable signal PRD
4.Check RS232 Signals
5.Check flash memory related circuit
Replace flash(IC502)
Yes
yes
yes
Yes
No
No
No
No
3-5
Show LOGO
A
yes
Reset or Power on
Flash
Memory operates
Properly?
Check connection on lines between FLASH
& M3355 and the FLASH access time
whether is suitable or not.
SDRAM
works properly?
Check connection lines between
SDRAM(IC503) & M3355 and the
SDRAM is damaged.
M3355
VIDEO outputs
properly?
Check the related circuit of M3355.
(IC501 PIN 2.3.7.8 check)
Have
TV signal output?
Does
Tray move inside
when it is not at closed
position?
Check the filtering and amp circuit of
TV signal .(IC604)
B
No No
YES
YES
YES
YES
No
NO
NO
Normal
TROUT & TRIN
signals?
NO
Check the load OPEN &
CLOSE switch
Normal
TRCLOSE &TROPEN
signal?
NO
Check the Tray control IO pins
on M3355.
Normal
LOAD+ & LOAD
signal
NO
Check the Tray control amplifying
circuit on Motor driver.(IC201)
Check the cable connection between
main PCBA and loader. (MECHA)
Check AV cable
connection to TV set
NO
YES
YES
YES
Does
the SLED move
to inner side when it is at
outer position
on?
B
Yes
Motor
Driver DRVSB
Pin is High?
Check the connection line of
DRVSB signal
Motor
Driver DRVSB
Pin is High?
Check the related circuit of
FOCUS.
SLED+
and SLED- output
properly ?
Check the amp circuit on
motor driver.
C
No
Check the cable connection
with MECHA.
Optical
Lens has movements
for searching
Focus?
Proper Focus outputs
to motor driver?
Check Focus connection on
M3355 and motor driver.
Proper F+
& F- outputs?
Check the amp circuit on
motor driver.
Check cable connect on with
pick-up head.
yes
No
Do not put in disc and tray
close.
No
No
No
Yes
Yes
Yes
Yes
Yes
No
No
3-7
Laser turns on when
reading disc?)
C
Yes
LD01 or LD02 output
properly?
Check the laser power circuit
on M3355 and connecting to
power transistor. (Q201, Q202)
Collector
voltage of power
transistor is OK?
( Q201, Q202)
Check the related circuit on
laser power TR
D
No
Yes
Check cable connection between
transistor output and pick-up head.
Check the RF connection
between MD and M3355.
Put disc in?
Proper RF signal?
Laser off
Check the related circuit
on M3355 RF signal
Does spindle rotate?
Disc ID is correct?
Proper
Spindle signal on
M3355
Check spindle related
circuit on M3355
Proper RF signal?
Check the related circuit
on M3355 RF signal
Check the RF connection
between MD and M3355.
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
No
No
No
No
No
No
3-8
Focus ON OK?
D
Yes
Proper
signals on A, B, C,
D of M3355
Check the related circuit
on M3355 SBAD signal .
No
No
Check the related circuit
on M3355
.Proper SBAD signal
on M3355?
Check connections between
M3355 and pick-up head.
Track On OK?
Check cable connection on
pick-up head.
Proper tracking signal
on M3355?
Proper
M3355 track signal
on M3355?
Check the related
circuit on M3355
Check the track connection
on M3355 and motor driver.
Yes
No
E
. Proper FE signal
on M3355?
Check the related circuit
on M3355 FE signal
Disc is play?
T+ & T- output
properly?
Check the tracking control
amp circuit on motor driver.
Check RF signal waveform.
Yes
Yes
No
No
No
No
No
Yes
Yes
Yes
No
3-9
Normal
Audio output
when disc playback?
E
DAC received
correct data
stream?
Check connection between M3355
& Audio DAC. (Check DAC_RST#,
SER3, BCLK, LRCK,MCLK
Normal
Audio DAC
out? (IC601)
Check the related circuit of
Audio DAC. (Check Audio
out Pin 14, 15,18,19)
Check Audio filter, amplify, mute
circuit. (IC602 Application circuit)?
TEST END
Communications
between IR.VFD Front panel key
& M3355 & Front u-com(IC901)
is normally?
Check communication lines
on M3355.
Check the cable connection
on Front panel.
Yes
Normal
IR. VFD & Front
panel key
functions?
Yes
Yes
No
No No
NoNo
Yes
Yes
Yes
3-10
Start
Insert the MIC jack
Is the MIC signal at the
IC801 pin3.
Does the MIC
signal input to the IC501
pin213.
Is the MIC signal at the
IC801 pin2.
Replace IC501
Check pattern
Replace the VR801
Replace IC801
Is the MIC signal at the
IC801 pin3 normal?
Replace the mic jack
NO
Yes
Yes
NO
NO
Yes
NO
Yes
4. KARAOKE Flow(KARAOKE MODEL ONLY)
3-11
DETAILS AND WAVEFORMS ON SYSTEM TEST AND DEBUGGING
1. SYSTEM 27MHz CLOCK, RESET SIGNAL
1) M3355 main clock is at 27MHz(X501)
3.1V,27MHz
FIG 1-1
2) M3355 reset is low active
5.2VA
PWR_CTL(CN505 PIN7)
M_RESET(CN505 PIN9)
TRST
FIG 1-2
3-12
2. SDRAM CLOCK
3. TRAY OPEN/CLOSE SIGNAL
OPEN(CN203 PIN3)
CLOSE(CN203 PIN4)
LM-(IC201 PIN14)
LM+(IC201 PIN13)
OPEN
CLOSE
1) SDRAM clock is at 135MHz
IC503 PIN38
CLK=135MHz,Vp-p=3.3V
FIG 2-1
1) Tray open/close waveform
FIG 3-1
3-13
2) Tray open waveform
OPEN(CN203 PIN3)
CLOSE(CN203 PIN4)
LM-(IC201 PIN14)
LM+(IC201 PIN13)
FIG 3-2
OPEN(CN203 PIN3)
CLOSE(CN203 PIN4)
LM-(IC201 PIN14)
LM+(IC201 PIN13)
3) Tray close waveform
FIG 3-3
3-14
4. SLED CONTROL RELATED SIGNAL(NO DISC CONDITION)
SLEGP(2.1V/1.5V/0.85V)
(IC501 PIN80)
DRVSB(3.3V/0V)
(IC501 PIN22)
SLED+(7.3V/4V/2.4V)
(IC201 PIN16)
SLED-(7.3V/4V/2.4V)
(IC201 PIN15)
FIG 4-1
5. LENS CONTROL RELATED SIGNAL(NO DISC CONDITION)
FOCUS(2.1V/1.5V/0.9V)
(IC501 PIN76)
FOCUS+(3.5V/2.8V/2V)
(IC201 PIN25)
FOCUS-(3.4V/2.8V/2.1V)
(IC201 PIN26)
FIG 5-1
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