Models: AZ1K ChassisKDL-55EX500KDL-55EX501KDL-60EX500

Triage and Troubleshooting GuideCourse: CTV-65

Training Manual

KDL-55EX500

CTV-65 i

Section 1 - AZ1K Chassis Models Overview ..................... 3AZ1K Chassis Models Covered ....................................... 5Model Introduction ........................................................... 5AV Input & Output Descriptions ....................................... 5

RF Input ............................................................................... 5Composite Video & Audio Inputs ......................................... 5Component/Composite Video & Audio Inputs ...................... 6HDMI/DVI Video Input and DVI Video ................................. 6PC Video & Audio Input (and DVI Audio) ............................. 6USB 2.0 Side Connection - Photos & Music ........................ 6

Audio Outputs .................................................................. 7Fixed Analog Audio Output .................................................. 7Digital Audio Output (Optical) .............................................. 7

55” Model Overall PCB Block Diagram ........................... 860” Models Overall PCB Block Diagram .......................... 9PCB and Component Descriptions ................................ 10

A-Board ............................................................................. 10G5E-Board (55") or G8S-Board (60") ................................ 10D1-Board (55") ................................................................... 10Backlight Inverter Board (60") ............................................ 10HRK-Board ........................................................................ 10Switch Unit ......................................................................... 10LCD Panel Assembly ..........................................................11

Section 2 - Troubleshooting Procedures ......................... 12Power Symptom Troubleshooting .................................. 12

Table of ContentsNormal Operation .............................................................. 12Failure Symptoms .............................................................. 12

No Power/Dead Set (No RED Standby LED) .............. 1255” Power Supply System Block Diagram ..................... 14G5E-Board Connector Diagram .................................... 1560” Power Supply System Block Diagram ..................... 16G8S-Board Connector Diagram .................................... 17Protection Mode Symptom Troubleshooting .................. 18

Failure Symptoms .............................................................. 182X Blink - Main Power Error ........................................ 183X Blink- Audio Error ................................................... 184X Blink - Balancer Failure (55” Model Only) .............. 195X Blink - TCON & HFR Failure .................................. 196X Blink - Backlight System Failure (60” Models) ........ 196X Blink - Backlight System Failure (55” Models) ........ 197X Blink - Temperature Failure .................................... 20

55” Model Protection Mode System Block Diagram ...... 2160” Model Protection Mode System Block Diagram ...... 22All Models Power Board Protection Circuits Block Diagram ......................................................................... 23Video Symptom Troubleshooting ................................... 24

Normal Operation .............................................................. 24Troubleshooting ................................................................. 24Missing or Distorted Video (Individual Inputs) ................... 24Missing Video (All Inputs) .................................................. 25

Skewing LVDS Connector Troubleshooting Method .... 25

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Table of Contents

Distorted Video (All Inputs) ................................................ 25WIDE Mode Button (Aspect Ratio) Troubleshooting

Method ................................................................... 25Unique Main Video Board (A-Board) or LVDS Cable Effects ..................................................... 26Unique TCON/HFR Board Effects ............................... 27Unique LCD Panel Assembly Effects ........................... 27Common Main Video Board (A-Board) and LCD Panel Assembly Effects ....................................... 27

Video System Block Diagram ........................................ 28Audio Symptom Troubleshooting ................................... 29

Normal Operation .............................................................. 29Failure Symptoms .............................................................. 29

Missing or Distorted Main Speaker Audio - All Inputs .. 29Missing or Distorted Main Speaker Audio - Individual

Inputs ..................................................................... 29Audio System Block Diagram ........................................ 30

Section 3 - Service Mode .................................................. 31Service Mode Access .................................................... 31

Section 4 - Triage & Troubleshooting Flowcharts .......... 32Triage Flowchart ............................................................ 32Power-ON Troubleshooting Flowchart ........................... 33Protection Mode 2X, 3X, & 4X Troubleshooting Flowchart ....................................................................... 34Protection Mode 5X & 6X(60”) Troubleshooting

Flowchart ....................................................................... 35Protection Mode 6X(55”) & 7X Troubleshooting Flowchart ....................................................................... 36Video Troubleshooting Flowchart .................................. 37Audio Troubleshooting Flowchart .................................. 38

Appendix ............................................................................. 39LCD Panel Distortion Pictures ....................................... 39TCON/HFR Board Distortion Pictures ........................... 40TCON/HFR Board Distortion Pictures Continued .......... 41Video Board Distortion Pictures ..................................... 42Video Board Distortion Pictures Continued ................... 43

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Section 1 - AZ1K Chassis Models Overview

55” OVERALL PCB LOCATION DIAGRAM FIGURE 1-1

G5E-Board

A-Board

Balancer Board

55" Model

TCON/HFR Board

Switch Unit

HRK-Board

LVDS Cable

D1-Board

Speaker Speaker

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AZ1K Chassis Models Overview

60” OVERALL PCB LOCATION DIAGRAM FIGURE 1-2

G8S-Board

TCON A-Board

SpeakerSpeaker

InverterInverter

Switch Unit

HRK-Board

TV Rear View

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AZ1K Chassis Models Overview

AZ1K Chassis Models CoveredKDL-55EX500 KDL-55EX501KDL-60EX500

Model IntroductionAll models contain a Full High-Definition 1920 X 1080 resolution panel. The backlight is produced using a Cold Cathode Fluorescent Lamp (CCFL) light system for all models. All models have the Advanced Contrast Enhancer (ACE) feature and Dynamic Backlighting. The Dynamic Contrast Ratio (DCR) for all models is 150,000:1. All models contain the BRAVIA Engine™ 2 digital video processor for superior resolution. Plus, 7 HD inputs (4 HDMI™, 2 component and 1 PC) are provided to connect all of your HD devices including PLAYSTATION®3, Blu-ray Disc™ player and laptop or desktop.The BRAVIA Engine 2 fully digital video processor uses a collection of unique Sony technologies to significantly reduce noise, enhance overall image detail, and optimize contrast so every scene produces sharp, vibrant, life-like images and color.The EX500 series models contain the Motionflow™ 120Hz frame rate technology which enhances sharpness and delivers smooth motion for fast-action sports and movies.Sony® HDTVs exceed Energy Star 3.0 requirements. In addition, they incorporate advanced power saving features such as Light Sensor® technology that adjusts backlight intensity based on ambient room lighting conditions and Dynamic Backlight Control that adjusts backlight intensity based on the brightness of the image on the screen.

AV Input & Output Descriptions

Composite

PC Input

HDMI Input

HDMI Input

HDMI/DVI InputDigital Audio

Output(Optical)

Analog Audio Output (FIXED)

Component Input

Component/Composite Input

RF Input

USB

HDMI Input

PC & DVI Audio Input

RF InputThis is a 75 ohm connection for either terrestrial NTSC and ATSC (8VSB) or cable QAM64 and QAM256 signals.

Composite Video & Audio InputsYellow Jack - Composite Video InputRed & White Jacks - Right & Left Audio InputNOTE: The second composite input is shared with one of the component inputs. Reference the description of the component inputs for details on activating the composite input.

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AZ1K Chassis Models Overview

Component/Composite Video & Audio InputsRed, Blue, & Green Jacks - Component Video InputsRed & White Jacks - Right & Left Audio InputNOTE: Composite video can be applied to the component input label “VIDEO IN”. The yellow composite video connector is connected to the green component connector. The audio is connected to the same component audio inputs.IMPORTANT: For automatic signal detection make sure the User Menu item is set to “AUTO. “ Reference the below for the specific menu item. The input can also locked to Video 1 (composite) or Component 1 (component) signal. However, the input will only process the chosen signal type. If the other signal type is connected the picture will be lost or black & white.

Select the appropriate input for the input signal type.Auto – Auto DetectionVideo 1 – CompositeComponent 1 - Component

HDMI/DVI Video Input and DVI VideoBoth the HDMI and DVI formats contain digital video. In the case of the HDMI format the audio is also digital and is part of the video and audio data stream over the single HDMI connection. In contrast, the DVI format contains only digital video in its data stream. The audio is sent over a separate Stereo Mini Jack audio connection. Furthermore, a DVI to HDMI adapter is required to connect the DVI connector to the HDMI connector.The EX500 series models contain the BRAVIA® Sync™ feature (or HDMI CEC). With this feature external devices with HDMI CEC capabilities can be operated and controlled using only the TV remote controller. Devices such as, Blu-ray Disc™ players, Surround Sound Systems, Handycam® camcorders, and Cybershot® digital still cameras can all be controlled over the HDMI connection.

PC Video & Audio Input (and DVI Audio)All EX models have a Personal Computer Input (PC-IN), which connects directly to the PC 15 pin DIN connector (HD15 connector). Once connected the TV functions as a video monitor and audio output (separate Stereo Mini Plug) for the PC audio. There is a complete table of PC Input Signal Compatibility in the Owners Manual for each model.The Stereo Mini Plug is also used for a DVI audio connection at HDMI 1 video input. The DVI video is connected through an adapter to HDMI 1 input and the DVI audio to connected to the Stereo Mini Jack.

USB 2.0 Side Connection - Photos & MusicConnect a camera, USB-Enabled MP3 player, or USB storage device directly to this side USB input to view JPG photos and MPEG1 & MPEG2 videos on the screen or listen to MP3 music files.This USB connection is also used for TV Software updates using a USB drive device.

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AZ1K Chassis Models Overview

Audio Outputs

Fixed Analog Audio OutputThis audio output can be used to listen to the TV audio through an external AV stereo system. The audio level at the output is set to a fixed level and cannot be turned off or adjusted.

Digital Audio Output (Optical)Connects to the optical audio input of any digital audio equipment that is PCM/Dolby digital compatible. The following table shows the audio inputs and the audio format which are present at the Optical Audio Output per input format.

Audio Input Source Optical OutputDigital Tuner 5.1 (ATSC) 5.1 DolbyHDMI 5.1 5.1 DolbyAll Analog Audio Inputs 2CH PCMAnalog Tuner (NTSC) 2CH PCMSACD Format (HDMI) No OutputDVD Audio Format (HDMI) No Output

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AZ1K Chassis Models Overview

55” OVERALL PCB BLOCK DIAGRAM

FIGURE 1-3

55” Model Overall PCB Block Diagram

Backlight High-Voltage Circuits

D1-Board

AC Input

A-Board

TV Microprocessor MT5388 Processor :

Video ProcessingHDMI ProcessingHDCP ProcessingIP (Image Processor)Scan Converter (Scalar)

ATSC/NTSC Tuner Temperature Sensor Audio Output Amplifier

Control

HV Drive

LVDS

Keys

SIRCS

LCD Panel Assembly

LCD PANEL

Power Key Function Keys

Switch Unit

Power

Main Power Supply Standby Power Supply AC Relay

G5E-Board

Power

Control

Power

LCD Panel

R

L

Optical Digital Audio Output

Analog Audio Output

CCFLBacklight System

*High Frame Rate (120HZ)Standard Frame Rate (60Hz)

TCON/HFR Board

BALANCER

Power

RF Input

1 Composite Input

2 Component Inputs(Composite can be applied to Component 1)

1 PC Input

4 HDMI Inputs

USB 2.0

Power

Control

LEDs IR Sensor Ambient Light Level Sensor

HRK-Board

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AZ1K Chassis Models Overview

60” OVERALL PCB BLOCK DIAGRAM

FIGURE 1-4

Inverter Board

A-Board

TV Microprocessor MT5388:

Video ProcessingHDMI ProcessingHDCP ProcessingIP (Image Processor)Scan Converter (Scalar)

HDMI Switcher ATSC/NTSC Tuner Temperature Sensor Audio Output Amplifier

Control

HV

LVDS

Keys

Power/SIRCS

LCD Panel Assembly

LCD PANEL

Power Key Function Keys

Switch Unit

LEDs IR Sensor Ambient Light Level Sensor

HRK-Board

Power

Main Power Supply Standby Power Supply AC Relay

G8S-Board

24V

Power

LCD Panel

R

L

RF Input

1 Composite Input

2 Component Inputs(Composite can be applied to Component 1)

1 PC Input

3 HDMI Inputs

Optical Digital Audio Output

Analog Audio Output

CCFLBacklight System

TCON/HFRPower

AC Input

*High Frame Rate (120HZ)

1 USB 2.0

Control & 24V

Inverter Board HV

60” Models Overall PCB Block Diagram

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AZ1K Chassis Models Overview

PCB and Component DescriptionsReference Figures 1-3

A-Board The circuits located on the A-Board perform all Video and Audio processing functions. It also contains all the microprocessor control circuits. The following circuits are included on this board.

• TV Microprocessor• MT5388 Processor - Video Signal Processing - HDMI Signal Processing - Scan Converter - HDCP Processing• Audio Amplifier• Temperature Sensor

G5E-Board (55") or G8S-Board (60")Except for some regulator circuits on the A-Board, the G2LE-Board or G2HE-Board is the power supply system board for the 32” and 40” models, which includes the following components and circuits.

• Main Power Supply• 12V• AU12V (Audio Amp)• 24V (Backlight Inverter) (60”)

• Standby Power Supply• 3.3V for standby circuits

• Power Factor Control Circuit (PFC)

D1-Board (55")The D1-Board develops the high-volatge that drives the CCFL backlight system. It takes the 400V from the Main Power supply PFC circuit on the G5E-Board and develops approximately 2KVrms to initially ignite the lamps and 1KVrms to drive the backlight Cold-Cathode-Fluorescent Lamps (CCFL) in normal operation. The backlight ON and Dimmer functions are also performed on the D1-Board.

Backlight Inverter Board (60")There are two (right and left) Inverter boards in the 60” models. NOTE: The Inverter boards are not available as separate parts. If a Inverter board is found to be defective the complete LCD Panel assembly must be replaced.The 24V developed in the Main Power Supply on the G8S-Board powers the Backlight Inverter Boards. The Inverter Board takes that 24V and develops approximately 2KVrms to initially ignite the lamps and 1KVrms to drive the backlight Cold-Cathode-Fluorescent Lamps (CCFL) in normal operation.

HRK-Board• Function LEDs`• IR Sensor• Ambient Light Level Sensor

Switch Unit• Power Key• Function Keys

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AZ1K Chassis Models Overview

LCD Panel AssemblyThe LCD Panel Assembly includes the LCD Panel, TCON/HFR Board , and CCFL Backlight system.The LCD Panel contains the actual liquid crystals, color filters, and polarizers. The liquid crystals are manipulated by the applied voltage to pass a specific amount of light - from the backlight- depending on the level of voltage applied.The TCON performs all the control, timing, charge, and discharge functions driving the operation of the LCD Panel. The HFR (High Frame Rate) section performs the 60Hz to 120Hz frame refresh rate conversion.A replacement LCD Panel assembly from parts will include the following items.55” Models:1) LCD Panel and Backlighting Components2) TCON/HFR Board 3) Balancer Board60” Models:1) LCD Panel and Backlighting Components2) TCON/HFR Board 3) Inverter Boards

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Section 2 - Troubleshooting Procedures

Power Symptom Troubleshooting

Normal OperationReference Figure 2-1 and 2-2110VAC is applied directly to the G5E-Board or G8S-Board. It can be measured at CN6102 or CN1 respectively. In the standby mode the AC power passes through the main fuse F6101 or F101. The AC power passes through R6118 or R106 (Inrush resistors), and D6001 and is applied to the Main DC/DC Converter IC6301 and the Standby DC/DC Converter IC6103 on the G5E-Board. IC6301 is not active in the standby mode. However, IC6103 is active in standby mode and outputs STBY 3.3Vdc as long as AC power is applied to the TV and the RED Standby LED is illuminated on the front panel. The Standby 3.3Vdc is supplied to the TV-Microprocessor, Switch Unit (Power Key), and HRK-Board (IR Sensor) in the standby mode. The G8S-Board has three separate power supplies for the 24V, 12V, and Standby 3.3V supplies. However, the basic operation is the same as the G5E-Board. Only the Standby 3.3V is active in the Standby mode.Once a ON command is received form the remote controller or the power button on the Switch Unit the TV-Microprocessor outputs the Power-ON signal. The Power-On signal is applied to the G5E-Board or G8S-Board. On the power supply board the Power-On signal switches the 19V from the standby power supply to activate the PFC and Main Power supply IC6301. One relay click is heard at power-on. The relay engages to bypass the inrush resistors R6118 or R106 during the ON state.The main power supply IC6301 (Z501, 60”) is now active and outputting all secondary supplies. The 12Vdc secondary is the supply voltage for all the voltage regulators on the A-Board. The AU12V is the supply voltage for the audio output amplifier. The 60” model’s power supply (Z301) will also output 24V which is the supply voltage for the backlight inverter boards.The D1-Board in the 55” model will develop and output the backlight high-voltage (1KV) to the Balancer board and the CCFL backlights.

Failure SymptomsReference Figures 2-1, 2-2, 2-3, and 2-4

No Power/Dead Set (No RED Standby LED)In a dead set condition there will be No RED Standby LED illumination in the Standby Mode (TV plugged into an active AC Outlet).The following bullet list gives the possible failures for a “No Power/Dead Set” condition.

• Loss of AC Power (Dead AC Wall Outlet)• Loss of AC-OFF-DET• Loss of Standby 3.3Vdc• Loss of REG12V• Loss of Power-On• Defective Main Microprocessor

The first step in troubleshooting a “No Power/Dead Set” condition is to confirm that 110ACV power from an active AC wall outlet is applied to the G5E-Board or G8S-Board. AC power is applied to, and can be measured at CN6102 on the G5E-Board and at CN1 on the G8S-Board.Next, check for the presence of the AC-OFF-DET voltage at CN6201/pin 2 or CN2/pin 2. If the AC-OFF-DET circuit is working properly 3V should be measured. If the 3V is not present replace the G5E-Board or G8S-Board. If the 3V is present, then the Standby Power supply, Main power supply, or Main microprocessor is defective. Further troubleshooting is necessary to determine the defective component.After confirming the AC power and AC-OFF-DET, check for a defective Standby 3.3Vdc power supply. Check for the 3.3V secondary voltage at CN6201/pin 1 or CN2/pin 1. As long as AC power is applied to the TV the Standby power supply should be active and outputting 3.3Vdc. If the 3.3V is not present then Standby power supply is defective. Replacing the power supply board will fix the problem.If the Standby 3.3V is okay, the next step is to check the REG12V from

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AZ1K Chassis Models Overview

the Main Power supply. A loss of the REG12V will cause a “Dead Set” condition on these models. Check for the 12V at CN6201/pin 9 on the G5E-Board or CN2/pin 9. If the 12V is missing replace the power supply board.Finally, a “Dead Set” condition can be caused by a defective microprocessor IC400. The microprocessor outputs the Power-On signal which activates the switch circuit on the power supply board and passes the 19V from the Standby power supply to active the Relay, PFC, and Main Power Supply circuits. If the Power-On signal is not output after receiving the Power-ON command the power supply board circuits remain inactive and a “Dead Set” condition exists. The Power-On signal can be checked at CN6201/pin 3 or CN2/pin 3. It should measure approximately 3.3Vdc If the measurement is 0Vdc after pressing the power button then the TV microprocessor is defective. Replace the A-Board. If the power-on voltage is 3V after pressing the power button then the switch circuit on the power supply board is defective. Replace the power supply board.

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AZ1K Chassis Models Overview

55” Power Supply System Block Diagram

55” POWER SUPPLY SYSTEM DIAGRAM FIGURE 2-1

A-Board

AU12V

12V

3V

F6101

AC Input

D6301

CN6704

STBY 3.3V

L6301

19V

Power ON

IC6103Standby

3.3VPower Supply

CN6102

SwitchCircuitIC6104

IC6301Main

Power Supply

&PFC

Balancer Board

LCD PANEL

IC400MT5388

CCFL Backlights

TCON/HFR

LCD Panel Assembly

VCC

R63500.1ohm

R615310ohm

VSense

CN201CN6201

Q63035V

IC8151Audio Output Amp

1.1KV (~2KV Strike Voltage)

LVDS Cable

F1

G5E-Board

AC-OFF-DET3V

LCD Panel

9 9

4 4

ON/OFF

AC_DET

PFC_OUT

Q6403 TCON 12V

PS6401

AC_DET

D6302

1

2

1

2

CN6201

CN6403

2

33PH6301

TCON ON15 15

IC2315V Reg

IC2665V Reg

5V

To Tuner

IC2321V Reg

IC2673V Reg

IC2681.25V Reg

To MicroIC2691V Reg

To Micro To MicroTo DDR

To USBTo Optical Out

IC8301Line Out Amp

A-Board

LVDS 12V

CN4152

D6309

R6314 R6315

3V

12V

19V

12V

RY6102

HV

HVBacklight Inverter High Voltage Circuits

400V

CN6705

R6118

D1-Board

PS6402

814 10

CN6301CN6401

CN6703 CN66002

2

3

3

6

6

4

4

CN6702FBLD12V

12VBL-ON

DIM

212V

CN201

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AZ1K Chassis Models Overview

F6001

AC Input

CN6403

CN6201

CN6401

CN6301

CN6003

AC Relay

6 – Ground5 - Ground4 – Ground3 – TCON 12V2 – TCON 12V1 – REG12V

G5E-Board

15 – TCON-ON14 – TCON 12V 13 – NC12 – DIMMER11 – BL-ON10 – BL-ERR 9 – REG12V8 – REG12V7 – Ground6 – Ground5 – Ground4 – AU12V3 – POWER-ON (3V)2 – AC-OFF-DET (3V)1 – STBY 3.3V

7 - LD6 – 12V5 - Ground4 – BL-ER3 – BL-ON2 – Dimmer1 – H-Symc

5 – 400V4 – NC3 – Ground2 – NC1 – 12V

IC6103

D1-Board

7 - LD6 – 12V5 - Ground4 – BL-ER3 – BL-ON2 – Dimmer1 – H-Symc

5 – 400V4 – NC3 – Ground2 – NC1 – 12V

HV

HV

G5E-Board Connector Diagram

G5E-BOARD & D1-BOARD CONNECTOR DIAGAM FIGURE 2-2

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AZ1K Chassis Models Overview

60” Power Supply System Block Diagram

60” POWER SUPPLY SYSTEM DIAGRAM FIGURE 2-3

A-Board

AU12V

12V

3V

F101

AC Input

RC101RC102

CN4

STBY 3.3V

24V

Power ON

Panel 12V

Z401Standby

3.3VPower Supply

CN1

BacklightHV Inverter

Board

LCD PANEL

IC400MT5388

CCFL Backlights

TCON/HFR

LCD Panel Assembly

CN201CN2

5V

IC8151Audio Output Amp

HV

LVDS Cable

F1

G8S-Board

AC-OFF-DET3V

LCD Panel

9 9

4 4

3

Q751 TCON 12V

F751

1

2

1

2

CN2

CN3

1

2

33PH201

TCON ON15 15

IC2315V Reg

IC2665V Reg

5V

To Tuner

IC2321V Reg

IC2673V Reg

IC2681.25V Reg

To MicroIC269

1V Reg

To Micro To MicroTo DDR

To USBTo Optical Out

IC8301Line Out Amp

A-Board

1014

To CN2

From Q751

LVDS 12V

CN4152

8

3V

12V

19V

12V

12V

BacklightHV Inverter

Board

24V

RL101

R106

HV3

CN5

Z50112V

Power Supply

Z30124V

Power Supply

L201L202

RC201RC202

Z251PFC

Q208SwitchCircuit

Power ON

PH202

CN201

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AZ1K Chassis Models Overview

G8S-Board

CN5

1 – UNREG24V2 – UNREG24V3 – UNREG24V4 – UNREG24V5 – UNREG24V6 – Ground7 – Ground8 – Ground9 – Ground10 – Ground11 – BL-ERR12 – BL-ON13 – NC14 - Dimmer

1 – UNREG24V2 – UNREG24V3 – UNREG24V4 – UNREG24V5 – UNREG24V6 – Ground7 – Ground8 – Ground9 – Ground10 – Ground

CN4

CN2

15 – TCON-ON14 – TCON 12V 13 – NC12 – DIMMER11 – BL-ON10 – BL-ERR 9 – REG12V8 – REG12V7 – Ground6 – Ground5 – Ground4 – AU12V3 – POWER-ON (3V)2 – AC-OFF-DET (3V)1 – STBY 3.3V

AC InputCN1

F101

1 – REG12V2 – TCON12V3 – TCON12V4 – Ground5 – Ground6 – Ground

CN3

RY101

F751

Z301 Z501

Z401

G8S-Board Connector Diagram

G8S-BOARD CONNECTOR DIAGAM FIGURE 2-4

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AZ1K Chassis Models Overview

Protection Mode Symptom TroubleshootingReference Figures 2-5, 2.6, and 2-7The KDL-55EX500, KDL-55EX501, and KDL-60EX500 include the following protection mode blink patterns (or self-diagnostics).

Protect Description Blink Pattern Possible Error Location

Main Power Error 2 G5E, G8S-Brd, or A-Brd

Audio Error 3 A-Brd or G5E, G8S-Brd

Balancer Error (55”) 4 LCD Panel, A-Brd, D1-Brd, or G5E-Brd

TCON Error 5 TCON/HFR Brd or A-Brd

HFR Error 5 TCON/HFR Brd or A-Brd

Backlight Error 6 G8S-Board,D1-Brd, LCD Panel,or A-Board

Temperature Error 7 Ventilation or A-BoardNOTE: All red protection mode LED blink patterns occur using the Standby-LED at the lower left front of the TV.

Failure Symptoms

2X Blink - Main Power ErrorA 2X protection mode blink pattern can be activated due one of the following defects on the G5E-Board or G8S-Board..

• Loss of AU12V (LVP)*• Excessive AU12V Level (OVP)*• Excessive 24V Level (OVP) (60” Model)• Excessive PFC Voltage (OVP)

• Excessive PFC Temperature (OTP)*Low Voltage Protection (LVP)*Over Voltage Protection (OVP)A loss or excessive condition of the AU12Vdc secondary voltage from the main power supply will cause a 2X blink pattern on the Standby-LED. The 12Vdc can be checked at CN6201/pin 9 or CN2/pin 9.If the measurement is 0V or rises above 12Vdc (approaches 15V) before the TV shuts down then the G5E-Board or G8S-Board is defective.If approximately 12Vdc is present and remains below 12Vdc before shutdown then the A-Board is defective.An excessive 24Vdc (60” Model) secondary voltage from the power supply Z301 will also cause a 2X blink pattern on the Standby-LED. The 24Vdc can be measured at CN4/pin 3 or CN5/pin3 on the G8S-Board before the TV shuts down. If the voltage rises above the 24V level (approaches 27) before the TV shuts down then the power supply is defective, replace the G8S-Board to fix the problem.Finally, there are PFC protection circuits on the power supply board that when activated will cause a 2X blink protection mode (reference Figure 2-7). The PFC circuit is monitor for both over-voltage and over-temperature. Therefore, if the AU12V and 24V circuits checkout okay, there could still be a problem on the power supply board in the PFC circuit causing the 2X blink. Replace the G5E-Board or G8S-Board to fix this condition.

3X Blink- Audio ErrorThe Audio error can occur due one of the following error conditions.

• Shorted or Damaged Speaker Connections• Defective Audio Amplifier (A-Board)• Loss of AU12V (Open F1 on A-Board)

The first thing to check when a 3X blink protection mode occurs is the physical condition of the speakers and speaker connections. The speakers should measure 8 ohms. Shorted speakers or connections can cause a 3X blink protection mode.

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AZ1K Chassis Models Overview

If the speakers and connections check okay, then the defective component is on the A-Board. Either a open F1 or defective audio amplifier will cause a 3X blink protection mode. In either case, replace the A-Board to fix this condition.

4X Blink - Balancer Failure (55” Model Only)In most cases, a 4X protection mode indicates a defective lamp or lamps. A defective panel can be confirmed by checking the LD protection voltage level at CN6702/pin 5. In normal operation LD should be 12V. If the voltage goes low then replace the LCD panel to fix this condition. If the voltage is 12V then there could be a problem on the A-Board or D1-Board. First replace the D1-Board then the A-Board.

5X Blink - TCON & HFR FailureThe 5X blink protection mode indicates a communications error between the TCON/HFR board and the MT5388 microprocessor on the A-Board. First replace the TCON/HFR Board if the 5X protection mode blink pattern occurs. If the TCON/HFR Board does not repair the problem then replace the A-Board.

6X Blink - Backlight System Failure (60” Models)NOTE: All models will make three attempts to power up before a 6X error is activated. The SONY logo (Backlight) will display on the screen and the tones (with Volume up) will be heard three times. After the third attempt the TV will turn off and the Standby LED will blink a 6X protection mode.In most cases, if the backlight momentarily illuminates and the TV shuts off and a 6X is activated than one or more of the backlight lamps are defective. The LCD Panel assembly panel must be replaced for a defective lamp.If a 6X blink pattern is activated than a defect has occurred in one of the following areas.

• Defective Panel Lamp(s)• Defective Backlight Inverter Board

• Defective TV Microprocessor• Defective 24V Power Supply

When troubleshooting a 6X backlight system failure it is key to notice if the backlights illuminate before the TV shuts off. The following list shows the possible backlight status and blink pattern and the possible failed components.

1) Momentary Backlight and 6X a) Defective Lamp (Part of LCD Panel Assb) b) Defective Backlight Inverter Brd (Part of LCD Panel Assb)2) No Backlight and 6X a) Defective TV Microprocessor b) Defective 24V Power Supply c) Defective Backlight Inverter Brd (Part of LCD Panel Assb)

IMPORTANT: If there is no backlight before the TV shuts off and activates a 6X, than check the “Backlight ON” signal from the TV microprocessor and the 24V power supply from the G8S-Board.If the “Backlight ON” and 24V power supply are okay than the Backlight Inverter board has failed and the LCD Panel Assembly must be replaced.

6X Blink - Backlight System Failure (55” Models)The 55” models have both a 4X and 6X blink protection mode. The 4X blink will, in most cases, be caused by a defective lamp (Reference 4X Blink description).The visual symptom for a 6X Blink error for the 55” model will be “No Backlight Illumination” before shutdown. Because all the Backlight HV Inverter circuits are located on the D1-Board, a 6X blink protection mode will be fixed, in most cases, by replacing the D1-Board. If the D1-Board does not repair the problem replace the A-Board. The BL-ON and Dimmer signals come from the microprocessor on the A-Board. A shorted or open BL-ON signal will cause this 6X condition. Also a shorted Dimmer will cause this 6X condition.

CTV-65 20

AZ1K Chassis Models Overview

7X Blink - Temperature FailureThese models do not display a temperature warning OSD dialogue box before shutting-off and going into a 7X Standby-LED blink pattern. It will just shut-off and activate a 7X without any usually warning on the screen.The main objective when a 7X blink pattern occurs is to determine which of the following possible defects is causing the excessive temperature condition.

• Excessive Ambient Room Temperature• Dust or Debris Blocking the TV Ventilation Apertures• Defective Temperature Sensor IC4305 or MT5388

microprocessor (A-Board)The first step is to notice how long it takes the TV to shut-off and trigger a 7X blink protection mode.If the TV has an actual excessive temperature condition it will take a considerable period of time to shut-off and indicate a 7X blink protection mode. This is because it will take time for the TV to heat up and for the temperature sensor to detect the excessive temperature and shut the TV off If the TV takes a considerable period of time to shut-off check the following items:

• The TV should not be located too close to any heating elements.

• The TV should have at least 4 inches of clearance around all sides to ensure adequate ventilation.

• Check that all vented areas on the TV are clear of all Dust and Debris.

If the TV shuts-off immediately (Not an Actual Excessive Temperature Condition) after Power-ON then one of the following components has failed.

• Main Microprocessor IC3002 (A-Board)• Temperature Sensor IC3502 (A-Board)

In either case the A-Board must be replaced to fix the problem.

CTV-65 21

AZ1K Chassis Models Overview

55” Model Protection Mode System Block Diagram

55” PROTECTION CIRCUITS DIAGRAM FIGURE 2-5

A-Board

3X

IC400MTK5388

2X

Standby 3.3V

DC_Detect Main PS&

PFC

AC Input

STBYPS

CN61023V

Power ONSW

RECT

IC4305Temp

Sensor70C

BL_ERRBL_ON

DimmerCN6703

12V

BL_ERR4X & 6X

Temp_ERR7X

IC8151Audio Amp

Protection CircuitQ8153, Q8155Q8158, Q8160,

Q8156Audio_ERR

LCD Panel Assb

TCON

TCON_ERR5X

HFR_ERR5X

SDA (I2C)

HFR

121110

CN8151CN8152

CN4152

G5E-Board

Interface Circuit

BL*Backlight Inverter

High Voltage Circuits

*BL - Backlight

1V to 3V3V0V

CN201

CN6600

CN6201

3V

3.3V

RECT

BALANCER

HV

HV

FB

LD12V

CN6702

D1-Board 400V

32

4

CN6301

CN6401

8

1

3

1

3

9

Dimmer

BL_ON

BL_ERR

DimmerBL_ON

BL_ERR

12

11

10

CN6704CN6705

5

2

CTV-65 22

AZ1K Chassis Models Overview

60” PROTECTION CIRCUITS DIAGRAM FIGURE 2-6

60” Model Protection Mode System Block Diagram

TCON-HFR

A-Board

3X

IC400MTK5388

2XDC_Detect

AC Input CN2CN1

RECT

IC4305Temp

Sensor70C

HV Inverter Board

BL_ERRBL_ONDimmer

24V

AU12V

BL_ERRBL_ONDimmer

Backlight_ERR6X

Temp_ERR7X

IC8151Audio Amp

Protection CircuitQ8153, Q8155Q8158, Q8160,

Q8156Audio_ERR

LCD Panel Assb

TCON_ERR5X

HFR_ERR5X

SDA (I2C)

CN8151CN8152

CN4152

G8S-Board

Interface Circuit

24V

BL

Backlight Inverter

High Voltage Corcuits

1V to 3V3V0V

131211

CN201

9

CN4

HV Inverter Board

Backlight Inverter

High Voltage Corcuits

24V

LCDPanelLCD

Panel

12V PS

CN5

HV HV

Fuse

3

3

3

3

24V PS

3

8

111213

CTV-65 23

AZ1K Chassis Models Overview

PROTECTION CIRCUITS DIAGRAM FIGURE 2-7

All Models Power Board Protection Circuits Block Diagram

Power Supply& PFCCircuits

AC Input

12V OVP

Reg 12VREC

PFC OVP

Switch Circuit

30V Zener

To A-Board

Power-ON From A-BoardPulls

Power_ON Low

G5E-Board (55")G8S-Board (60")

OVP – Over Voltage ProtectionOTP – Over Temperature Protection

CN2 (60")CN6201 (55")

33V

Latch Circuit

G5E-Board & G8S-Board Protection circuits will cause a 2X blink pattern

Reg 24V

15V Zener

24V OVP

9

3 To Inverter Board

CN4CN5

19V

PFC OTP

REC

CN6102 (55")CN1 (60")

OTP

60" Model ONLY

3 To Inverter Board

CTV-65 24

AZ1K Chassis Models Overview

Video Symptom TroubleshootingReference Figure 1-8

Normal OperationAll video processing is performed by IC400 (MT5388) on the A-Board. The RF input is first processed by the RF Tuner and is then applied to IC400. Both the ATSC and NTSC signal are processed by IC400. All four HDMI inputs are first applied to a HDMI switch circuit (IC6601). The switch circuit applies the selected input to IC400. IC6601 also contains the EDID (Extended Display Identification Data), which is part of the HDMI hand-shake process.All other inputs (Composite, Component, PC, and USB) are connected directly to IC400 inputs.The USER, White Balance, and Gamma data is stored in IC4302.Both the USER Menu and Service Mode screen are generated by, and output from IC400.IMPORTANT:

1) Confirm the TV has the most recent Software Version installed. Go to the User Menu for the present TV software revision and the ASC web site for the most recent software version.

2) Before proceeding with the following video troubleshooting procedures it is assumed that the TV is turning on with the Green Power-LED illuminated, Backlight is illuminated (brightened raster), and the Audio is present.

TroubleshootingWhen a video problem occurs you will experience one of the two following symptoms.Input Status:

• Missing or Distorted Video (Individual Inputs)• Missing or Distorted Video (All Inputs)

Video Anomaly:• Poor Detail• Moving Video Distortion (e.g. Bars)• Static H/V Lines (Any Color)• Static Missing Pixels (Any Color)• Static Bars (Solid Black or White, Transparent Color)• White Balance• Gamma

The main objective when troubleshooting one of the previously listed symptoms is to determine if the defect exists in the following sections of the TV system.

• LCD Panel Assembly• TCON/HFR Board• A-Board

Missing or Distorted Video (Individual Inputs)The primary objective is to locate the defective component through activating each individual video input and checking for any abnormal symptoms on the screen. If the video distortion appears only in one or two video inputs then the next step is to eliminate the possibility of a defective or improperly connected external device such as, a STB, DVR or DVD player. The quickest way to troubleshooting the external devices is to swap the suspect device with a known good device at the input in question.If the external device or connections are defective then the TV is okay and the external device and connections need to be serviced. If the external devices and their connections are okay, then the next step is to troubleshoot the problem by accessing and displaying each video input.The rationale behind this troubleshooting method is that each of these video inputs takes an altogether or somewhat different path through the video processing system. This fact enables you to determine the defect,

CTV-65 25

AZ1K Chassis Models Overview

in some cases, down to the component level, and in almost all cases, down to at least the board level. For example, if the distortion appears in a HDMI input but not in any other inputs (e.g. composite or component) then most likely the HDMI Switcher (IC6601) is causing the distortion. The reason for this conclusion is because the HDMI signals are the only signals to pass through IC6601 before being applied to IC400. All other input signals bypass IC6601. The composite and component signals go directly to the video processor IC400.Although all the individual input circuits are located on a single board (A-Board), the previously described troubleshooting procedure can still serve as a reliable confirmation of a defective component on the A-Board before replacing the board.The same deductive reasoning can be applied when troubleshooting video defects using the other video inputs shown on the flowchart (Section 4). This method simply involves knowing the path the input signal must take through the video processing system to reach the display. With this knowledge you can effectively divide the video system into distinct areas, and therefore, isolate the defect.

Missing Video (All Inputs)If the video is completely missing you will first use the User Menu (On-Screen-Display - OSD) in an attempt to isolate the defect to the A-Board or the TCON/HFR Board.If the OSD can be displayed then the TCON/HFR Board is okay, and you can safely assume the defect exists on the A-Board. However, if the OSD cannot be displayed you need to do further troubleshooting because either IC400 on the A-Board is not sending the OSD or the TCON/HFR Board is not able to process the OSD and display it on the LCD Panel.If the OSD cannot be displayed then the LVDS signal levels must be checked to reliably determine whether the A-Board or the TCON/HFR Board is defective.1) Check for USER Menu OSD Display a) USER Menu Displays. Replace A-Board b) USER Menu Does Not Display. Go to Step 2

2) Check for TCON 12V at CN4152/pins 4 - 10 & CN6151/pin 2 a) No 12V. Check connections between A-Board & Panel b) 12V Present. Go to Step 33) Check LVDS Cable Video Signal Levels at CN4152 a) LVDS Video Signal(s) Low or Missing. Replace A-Board b) LVDS Video Signal(s) Okay. Replace TCON/HFR Board

Skewing LVDS Connector Troubleshooting MethodIt maybe difficult or impossible to check the LVDS signal while in the field. Therefore, a quick and somewhat reliable method of checking the TCON/HFR operation is to skew the LVDS connector out of the its mount at the TCON/HFR Board. When performing this method it is important to keep the 12V end of the connector connected while dislodging the LVDS video connections. Therefore, find the 12V using a voltmeter. The 12V is usually on one end of the connector (usually left-side on bottom mount or top on side mount connect).When skewing the connector if color flashing occurs on the screen then the TCON/HFR Board is most likely okay and the A-Board is defective. If the is no video reaction on the screen while skewing the connector then the TCON/HFR Board is defective.

Distorted Video (All Inputs)The following paragraphs describe the unique and common effects the LCD Panel Assembly, TCON/HFR Board, and A-Board have on the displayed video concerning possible distortions. Knowing how each component affects the displayed video can be very helpful in troubleshooting a distorted video condition. NOTES: Reference Appendix for picture examples of unique distortions for the LCD Panel, TCON/HFR Board, and the A-Board

WIDE Mode Button (Aspect Ratio) Troubleshooting MethodA quick test to determine if the A-Board, TCON/HFR, or LCD Panel is causing the distortion is to change the panel aspect ratio (or picture size).

CTV-65 26

AZ1K Chassis Models Overview

The aspect ratio can be easily changed using the “WIDE” key on the remote controller. If the distortion follows the video then the A-Board is causing the distortion. If the distortion remains stationary after changing the aspect ratio then the LCD Panel assembly is causing the distortion.

Unique Main Video Board (A-Board) or LVDS Cable EffectsA video distortion that has soft edges and/or is moving through the video is most likely caused by a defect in the video processing circuitry. All video processing circuitry is located on the A-Board. Therefore, replace the A-Board if the video distortion has soft edges and/or is moving through the video on the screen. Macro-Blocking (digital picture breakup) is a good example of this type of distortion. Be careful though, macro-blocking can also be caused by a weak RF signal when the TV is in the tuner mode.

• Poor Picture Detail - Loss of overall picture detail. A loss of information on the LVDS lines from IC400 will cause poor overall picture detail.

• Abnormal Picture Size or Geometry- The video signal scaler circuit is located on the main video board A-Board. Therefore, if either the picture size or geometry is abnormal the A-Board is defective. Only the A-Board can cause such a distortion.

• Color Distortion - A color distortion can be caused by a defective IC400 or LVDS cable. The individual color signals are spread out over the LVDS twist pair wires. For example, the Red signal may be broken up into three components and sent over three different LVDS twisted pairs. Therefore, this distortion will display as a poor reproduction of a particular color not an overall loss of one color. Use a Red, Green, and Blue raster generator to confirm a poor reproduction of a single color.

• Loss of a Single Color - A loss of a single color can only be caused by a defective MT5388 (IC400). Use a Red, Green, and Blue raster generator to confirm a complete loss of a single color.

• RF Signal Distortion - A weak video signal from the antenna or cable connection can cause RF video distortions. The signal strength of the Digital Signals can be checked in the USER menu. Go to the Product Support and Signal Diagnostic item to check signal strength and errors. NOTE: This is only for digital channels. No information will display for analog channels. The SNR should be in the range of 25db to 30db and there should be zero Errors.

WIDE Mode Button

Signal Diagnostics Screen

WIDE Mode Function

Product Support

Signal Diagnostics

CTV-65 27

AZ1K Chassis Models Overview

Unique TCON/HFR Board Effects• 2” Vertical Transparent Colored Bar- The bar will be

approximately 2" because this is the area that is controlled by a single drive IC that is located across the top of the LCD Panel assembly.

• Video Timing - The Video Timing distortion may appear as a double image or ghosting type distortion.

• Loss of Half Screen Video - Half the screen will have live video and the other half will be a white raster.

• Half or Full Screen Video Distortion - In this case, the key distinguishing factor is the presence of undistorted video behind the color distortion. The distortion is basically an overlay (transparent color half-screen or bar) in front of the good video coming from the A-Board.

• White or Colored Blooming - The bloomings may come down from the top of the screen and vary in size.

• GAMMA Irregularity - A GAMMA distortion will appear as a overall brightness problem or a localized area color distortion.

Unique LCD Panel Assembly Effects• Line(s) of Pixels (Fixed Position) - Poor physical connection

(or bonding) between the LCD Panel and the flex cables will cause a loss of line(s) of pixels. The pixel drive lines can be open (no drive) or shorted (drive all the time). Depending on the type of failure the line(s) or pixel(s) will be black, white, or colored (red, green, or blue). These lines and pixels will also be very sharp in detail.

• Random Line(s) of Pixels (Random Movement) - The TCON board controls the charging and timing of the pixels. If the TCON Board is partially defective random lines and/or pixels will be seen flashing across the screen. These lines and pixels will be very sharp in detail, like a specific line of pixels are randomly turned off and on.

• 2” Vertical Solid White or Black Bar- The bar will be approximately 2" because this is the area that is controlled by a single drive IC that is located across the top of the LCD Panel assembly.

• Horizontal Bar- Any horizontal bar of any color will be caused by a defective LCD Panel assembly

Common Main Video Board (A-Board) and LCD Panel Assembly Effects

• White Balance (WB) Irregularity - A WB irregularity will show up as an overall poor reproduction of white. A white raster can be used to determine if a WB or gamma irregularity has occurred. WB will cover the complete picture, where as, gamma will be in specific zones or specific color areas in the picture. WB adjustment data is stored in the EEPROM IC4302 on the A-Board. The WB data stored in IC4302 is set to the middle value of the data span. The TCON/HFR Board also contains WB data, which is specifically set for the associated LCD Panel.

• GAMMA Irregularity - Gamma Correction affects the overall picture brightness level and individual color (RGB) brightness levels. Gamma adjustment data is stored in the EEPROM IC4702 The TCON/HFR Board also contains GAMMA data, which is specifically set for the associated LCD Panel. The data may become corrupted causing irregular gamma adjustment. Therefore, a gamma distortion can show up as a color brightness irregularity in specific zones or specific color areas in the picture, as well as an irregularity in overall picture brightness.

CTV-65 28

AZ1K Chassis Models Overview

A-Board

IC400MTK5388

(HDCP)

LCD Panel Assembly

TCON/HFR

LCD Panel

CCFL BacklightSystem

CN41521/

49

IC4302NAND FLASH

User DataWhite BalanceGAMMA

User Menu Service Mode

IC303Sub

Micro

4/

10LVDS 12V

LCD Panel

LVDS Cable

RF Input

Video 2 (Composite / S-Video)

Video 1 (Component & Composite)

PC Input

HDMI IN 1

HDMI IN 2

HDMI IN 3

IC6601HDMISwitch(EDID)

Video 3 (Component)

USB 2.0

TCON 12V 12V

From Power Supply Board

HDMI IN 4

TM701NTSC/ATSC

Tuner

Video System Block Diagram

VIDEO SYSTEM FIGURE 2-8

CTV-65 29

AZ1K Chassis Models Overview

Audio Symptom TroubleshootingReference Figure 2-9

Normal OperationThe HDMI digital audio signal is first applied to the HDMI Receiver/Switch IC6601 and then to the MT5388 on the A-Board.The RF input is first applied to the Tuner and then to the IC400. The Tuner outputs the ATSC and NTSC signals as an IF signal to IC400.All other audio inputs are applied directly to IC400. The MT5388 IC400. outputs the audio signal as a SPDIF signal for the Optical output. The FIXED analog audio output passes through an amplifier IC8301 and then is applied to CN8301.The main speaker audio comes from IC400 and passes through amplifier IC8151 and then to CN8151 and CN8152 speaker connections..The AU12V from the G5E, or G8S-Board is the power supply for the audio output amplifier IC8151.IMPORTANT:

• Confirm the TV has the most recent Software Version installed. Go to the User Menu for the present TV software revision and the ASC web site for the most recent software version.

Failure SymptomsThe first step when a “Missing or Distorted Audio” defect occurs is to determine if audio is missing or distorted on all audio input sources or only on one or a select number of audio input sources.Input Status:

• Missing or Distorted Audio on All Inputs• Missing or Distorted Audio on Individual Inputs

Missing or Distorted Main Speaker Audio - All Inputs

In this case, the most likely defective is the A-Board. Before you replace the A-Board perform the following test procedures to confirm the actual defective component.

1) Check for audio at the Analog FIX or DIGITAL Audio Outputsa) No or Distorted Audio (Replace A-Board)b) Audio Present & Undistorted. Go to Step 2

2) Check for AU12V at CN201/pin 1 on A-Boarda) No AU12V - Check connections between the Power Supply

board and the A-Boardb) AU12V Present replace A-Board

Missing or Distorted Main Speaker Audio - Individual InputsIf only one or a select number of input sources are experiencing a problem, then the individual inputs must be checked separately. The external devices and their associated cables connected to the faulty input should be checked first.Substitute a known good device and cable on the suspected faulty input. Connect the device and cable at separate times to determine if the device or cable is causing the problem. Replace the device or cabling if found to be defective. However, if the external device and cables are okay, then the next step is to replace the common board or module associated with that particular input source.For example, consider the symptom of all HDMI inputs are faulty. Logically the only device that could cause this symptom is the HDMI switcher IC6601 on the A-Board. In this case, replace the A-Board.

CTV-65 30

AZ1K Chassis Models Overview

Video 2 (Composite/S-Video)

LR Audio

A-Board

IC400MTK5388

(HDCP)

HDMI IN 1

Video 1 (Component & Composite)

RF Input

PC IN

LR Audio

HDMI IN 2

Video 3 (Component)

IC6601HDMI

Receiver/Switch(EDID)

TM701NTSC/ATSC

Tuner

Digital Audio

R

L

FIXED Analog Audio Output

Digital Audio Output (Optical)

LR Audio

SPDIF

Audio IN (DVI)LR Audio

LR Audio

LR Audio

I2S

F1

CN8302

CN8301

AU12V

CN6201 (55")CN2 (60") CN201

AC

HDMI IN 3

HDMI IN 4

IC8151 Output

Amplifier

LR Audio

11

USB 2.0

G5E-Board (55")G8S-Board (60")

IC8301Amp

CN8151

PS6402 (55")No Fuse (60")

CN8152

IF

Audio System Block Diagram

AUDIO SYSTEM FIGURE 2-9

CTV-65 31

Section 3 - Service Mode

SERVICE MODE FIGURE 3-1

Service Mode AccessService Mode Access

Display > 5 > Volume + > Power

Total operation time by hour (max 99999 )

Boot count (max 99999 )

Panel operation time by hour (max 99999 )(Reset Panel operation Time , Press 7 > 0 keys )

Reset Self Check, Press 8 > 0 keys

CTV-65 32

Section 4 - Triage & Troubleshooting FlowchartsTriage Flowchart

Triage Flowchart A (AZ1K 55", 60" Models)

StartTriage

Is Video Missing

or Distorted ?

No

Yes

No

No

No

Yes

Yes

Yes

GO TOPower-ON

TroubleshootingFlowchart B

GO TOProtection Mode Troubleshooting

Flowcharts C1, 2, 3

GO TOMissing or Distorted

Video TroubleshootingFlowchart D

GO TOMissing or Distorted

Audio TroubleshootingFlowchart E

No Problem Found

Unit Fully Operational

A

Is RED

“Standby” LEDON?

Is “Standby” LED

Flashing Red?

Is Audio Missing or

Distorted?

Go to “No Standby LED”

Triage Sheet Replacement Parts

Go to “Protect Blink Code”

Triage Sheet Suggested Parts

Go to “Audio”

Triage Sheet Suggested Parts

Go to “Video”

Triage Sheet Suggested Parts

CTV-65 33

Triage & Troubleshooting Flowcharts

Power-ON Troubleshooting Flowchart B (AZ1K 55", 60" Models)

Unit will Not Power-ON

(All Models)

Is “Standby” LED

illuminatedRED?

What is the State of the

“Power” & “Standby” LEDs?

No

Yes“Power” Glows Steady Green

No

Press TV & Remote

POWER Button

Initial Power-ON OK Troubleshoot Video,

Backlight, Panel, or Audio Problem

Check STBY 3.3V at CN6201/pin 1(In STBY Mode)

B

Confirm Unit is securely plugged into an active AC Outlet

Is 110VAC Present

at CN6102?

Repair AC Outlet or Replace AC-Power Cord

OK

Yes

GO TOFlowCharts C1, 2, 3

Protection Modes

“Standby” Red LED Blink Pattern

Confirm Remote Control Operation

Check Main Fuse F6101

(0 ohms)

Is voltage 3.3V

Present?

No

Yes

NOTE: Confirm all connections between circuit boards before replacing

Is Fuse Open?

No

Yes

Is voltage 3V

Present?

No

Yes

Check AC_OFF_DET

at CN6201/pin 2

Is voltage 12V

Present?

No

Yes

Replace G5E-Board or

G8S-Board

Check SW_12V at CN6201/pin 9(In STBY Mode))

Check Power_ON at CN6201/pin 3(In STBY Mode)

Is voltage 3.3V

Present?

Replace A-Board

Replace A-Board

Cycle AC power while checking for 12V. Unplug and Plug AC Power Cord .

Yes

No

CN1 - 60"

F101 - 60"

CN2 - 60"

CN2 - 60"

CN2 - 60"

CN2 - 46"

Replace G5E-Board or

G8S-Board

Replace G5E-Board or

G8S-Board

Power-ON Troubleshooting Flowchart

CTV-65 34

Triage & Troubleshooting Flowcharts

Protection Mode 2X, 3X, & 4X Troubleshooting Flowchart

Protection Mode Troubleshooting Flowchart C 1 (AZ1K 55" & 60" Models)

Unit Shuts OFFRED LED Blinking

C1

2X Blink PatternAU12V LVP & SW12V OVP

~12V

Check AU12V at CN6201/pin 4

*Before Shutdown

NOTES:1) All Red Blink patterns will occur on the Front Panel Red “Standby” LED2) All voltage are measured prior to unit shutdown3) Confirm all connections between circuit boards before replacing

Yes

No

(>) Greater Than(~) Approximately (Does not exceed)

Replace A-Board

3X Blink PatternAudio

>12V

Check SW12V at CN6201/pin 9

*Before Shutdown

Is Voltage

~12V or >12V?

Is voltage 12V

Present?

Yes

Check Speakers & Connections

Do Speakers Measure 8 ohms

?

No Replace Speaker(s)

Replace A-Board

■

CN2 - 60"

CN2 - 60"

4X Blink PatternBalancer

Check LD Volatge

CN6403/pin 7

Is voltage 0V or 12VPresent?

Replace LCD Panel

0V

12V

Is Problem Solved?

Problem Sloved

Replace A-Board

No

Yes

Replace G5E-Board or

G8S-Board

Replace G5E-Board or

G8S-Board

Replace G5E-Board or

G8S-Board

CTV-65 35

Triage & Troubleshooting Flowcharts

Protection Mode 5X & 6X(60”) Troubleshooting Flowchart

5X Blink PatternTCON/HFR Error

Is connection

OK?

Repair Connection

No

Yes

C2NOTES:

1) All Red Blink patterns will occur on the Front Panel Red “Standby” LED2) All voltage are measured prior to unit shutdown3) Confirm all connections between circuit boards before replacing

Check LVDS connection between

LCD Panel (TCON) & A Brds

Replace A-Board

Check TCON 12V supply CN6403/pins 1 & 2

Is 12V Present

?

Replace TCON/HFR Brd

No

Yes

Protection Mode Troubleshooting Flowchart C2 (AZ1K 55" & 60" Models)

Unit Shuts OFFRED LED Blinking

Is Issue

Resolved?

Issue Resolved

Yes

No

Is voltage

24V Before Shutdown

?

Yes

No

Check 24V at CN4/pin 3

*Before Shutdown

Is Backlight ON Before Shut

Down?

Yes

No

Yes

No

Replace LCD Panel Assembly

Check Backlight-ONsignak at

CN2/pin 11*Before Shutdown

Is voltage

3V Before Shutdown

?

Replace A-Board

Yes

No

Is “SONY” logo Displayed and Tones Heard?

Check for Open or Short

Check Dimmer signal at CN2/pin 12

*Before Shutdown

Is voltage

1V to 3V Before Shutdown

?

Check for Short

Replace A-Board

6X Blink Pattern(No Backlight)

CN3 - 46"

Replace G5E-Board or

G8S-Board

Replace G8S-Board

Is Issue

Resolved?

Issue Resolved

Replace A-Board

60" Models

Replace LCD Panel Assembly

CTV-65 36

Triage & Troubleshooting Flowcharts

Protection Mode 6X(55”) & 7X Troubleshooting Flowchart

Protection Mode Troubleshooting Flowchart C 3 (AZ1K 55" & 60" Models)C3

7X Blink PatternTemperature Error

Clear unit ventilation areas and confirm adequate local

room temperature

NoDoes unit still shutdown (7X)?

Issue Resolved

Yes

Does unit Shut-Down

Immediately after Power ON

?

Yes

No

Temperature ThresholdAmbient 80°C

NOTES:1) All Red Blink patterns will occur on the Front Panel Red “Standby” LED2) All voltage are measured prior to unit shutdown3) Confirm all connections between circuit boards before replacing

Replace A-Board

Unit Shuts OFFRED LED Blinking

Is voltage

HV Before Shutdown

?

Yes

Check HV at D1-Brd Output

*Before Shutdown

No

Check Backlight-ONsignak at

CN201/pin 11*Before Shutdown

Is voltage

3V Before Shutdown

?

Replace A-Board

Yes

No

Check for Open or Short

Check Dimmer signal at CN6201/pin 12

*Before Shutdown

Is voltage

1V to 3V Before Shutdown

?

Check for Short

Replace A-Board

Replace D1-Board

Replace G5E-Board

No

Yes

6X Blink Pattern(No Backlight)

55" ModelsCheck 390V connection CN6301 on (G5E-Brd) to

CN6601 (D1-Brd)

Is Connection

Okay?

Repair Connection

No

Yes

CTV-65 37

Triage & Troubleshooting Flowcharts

Video Troubleshooting Flowchart

Missing or Distorted Video

Is Video Missing or Distorted on All

Inputs?

No

Yes No

Yes

Can User Menu be

Displayed?

No

D

All Video Inputs :� Composite � Component� HDMI� PC IN� ATSC/NTSC (Tuner)� USB

Is Video Missing or Distorted

?

Missing

Distorted

Is Single Pixels

or Complete Lineof Pixels missing?

Yes

No

Yes

NOTE: Confirm all connections between circuit boards before replacing

Is Distortion Present in User Menu

OSD?

No

Yes

Is External Device & connection OK

?

Repair External Device

Check External Device and ConnectionsSwap Devices and

connections

Skew (or Rock) the LVDS connector from its socket at the TCON/HFR Brd.

(Reference TM for Details)

Are Flashes of color

displayed?

Yes

No

No

Check LVDS cable for Physical Damage

Replace LCD Panel

Replace TCON/HFR Board

Replace LVDS CableIf Damaged

Replace A-Board

Video Troubleshooting Flowchart D (AZ1K 55" & 60" Models)

Replace A-Board

Replace A-Board

Is Backlight ON

?

Go To Flowchart C2 or C3

Replace A-Board

Yes

Or check LVDS cable Video & Clock Signal Levels atCN4152/pins 1 - 49 using an Oscilloscope .

TM – Training Manual

Sharp Horizontal or Vertical Lines

Cable OK

Does Distortion follow

picture size when changing

WIDE mode?

Perform WIDE Mode Test(Reference TM for Dertails)

Replace A-Board

Replace TCON/HFR Board

No

Yes

CTV-65 38

Triage & Troubleshooting Flowcharts

Audio Troubleshooting Flowchart

NOTE: Confirm all connections between circuit boards before replacing

Is Audio Present?

CheckFix Audio Output

No

Missing or Distorted Audio(Speaker Outputs )

Is Audio Missing or Distorted

on All Inputs ?

No

Yes

Yes

E

Check Speaker Resistance at

CN8301 & CN8302 (across Speakers)

& Connections

8 ohms &

Connections OK?

No

CheckVoltage from Power Supply

at CN6201/pin 4

Is 12V Present?

Yes

Yes

Replace Speaker(s)

No

No

YesIs

External Device & connection OK

?

Repair External Device

Check External Device and ConnectionsSwap Devices and

connections

All Video Inputs :� Composite � Component� HDMI� PC IN� ATSC/NTSC (Tuner)� USB

Audio Troubleshooting Flowchart E (AZ1K 55" & 60" Models)

Replace A-Board

Replace A-Board

Replace A-Board

CN2 - 60"

Replace G5E-Board or

G8S-Board

CTV-65 39

AppendixLCD Panel Distortion Pictures

2' Solid Black Bar Distortion Timing Distortion

Double Image Distortion Ghosting Distortion

2" Solid White Bar Distortion Sharp Lines & Missing Pixels

The following distortions and anomalies where fixed by replacing the LCD Panel.

CTV-65 40

Appendix

TCON/HFR Board Distortion Pictures

Large Blooming Distortion Two Small Blooming Distortions

GAMMA Type Distortion 2" Transparent Colored Bar Distortion

Complete Washout Distortion 2" Transparent Colored bar Distortion

The following distortions and anomalies where fixed by replacing the TCON/HFR Board.

CTV-65 41

Appendix

2" White Bar w/ Random Colored Lines Exact Half-Screen Distortion

Complete Washout w/ Colored Lines

TCON/HFR Board Distortion Pictures ContinuedThe following distortions and anomalies where fixed by replacing the TCON/HFR Board.

CTV-65 42

Appendix

Video Board Distortion Pictures

Green Carpet Raster Multi-Colored Carpet Raster

Text Bleed Lines Random Size Vertical Bars

Overall Red Tinting Solarization

The following distortions and anomalies where fixed by replacing the Video Board.

CTV-65 43

Appendix

Video Board Distortion Pictures Continued

Partial Washout w/ Random Video Bar Overall Blue Tinting w/ Soft Vertical Lines

Green Raster Overall Green Tinting w/ Video Ghosting

Overall Red Tinting

The following distortions and anomalies where fixed by replacing the Video Board.

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2007 Sony Electronics, Inc.EMCSA - A Service Company

16530 Via EsprilloSan Diego, CA 92127

Reproduction in whole or part without written permission is prohibited. All rights reservedCTV650310 03/30/10