Models: AZ1K Chassis

KDL-32EX301 KDL-32EX500 KDL-46EX400

KDL-32EX400 KDL-40EX500 KDL-46EX500
KDL-40EX400 KDL-40EX501 KDL-46EX501
KDL-40EX401
Triage and Troubleshooting Guide
Course: CTV-61
Training Manual
KDL-40EX500
CTV-61 i
Section 1 - AZ1K Chassis Models Overview ..................... 3
AZ1K Chassis Models Covered ....................................... 5
Model Introduction ........................................................... 5
AV Input & Output Descriptions ....................................... 5
RF Input ............................................................................... 5
Composite Video & Audio Inputs ......................................... 5
Component/Composite Video & Audio Inputs ...................... 6
HDMI/DVI Video Input and DVI Video ................................. 6
PC Video & Audio Input (and DVI Audio) ............................. 6
USB 2.0 Side Connection - Photos & Music ........................ 6
Audio Outputs .................................................................. 7
Fixed Analog Audio Output .................................................. 7
Digital Audio Output (Optical) .............................................. 7
32 & 40 Models Overall PCB Block Diagram ............... 8
46 Models Overall PCB Block Diagram .......................... 9
PCB and Component Descriptions ................................ 10
A-Board ............................................................................. 10
G2LE-Board (32") or G2HE-Board (40") ............................ 10
GD2-Board (46") ................................................................ 10
Backlight Inverter Board (32" & 40") .................................. 10
H2-Board ........................................................................... 10
Switch Unit ......................................................................... 10
LCD Panel Assembly ..........................................................11
Section 2 - Troubleshooting Procedures ......................... 12
Power Symptom Troubleshooting .................................. 12
Table of Contents
Normal Operation .............................................................. 12
Failure Symptoms .............................................................. 12
No Power/Dead Set (No RED Standby LED) .............. 12
32 & 40 Power Supply System Block Diagram ........... 14
G2LE-Board & G2HE-Board Connector Diagram ......... 15
46 Power Supply System Block Diagram ..................... 16
GD2-Board Connector Diagram .................................... 17
Protection Mode Symptom Troubleshooting .................. 18
Failure Symptoms .............................................................. 18
2X Blink - Main Power Error ........................................ 18
3X Blink- Audio Error ................................................... 18
4X Blink - Balancer Failure (46 Models ONLY) .......... 19
5X Blink - TCON & HFR Failure .................................. 19
6X Blink - Backlight System Failure (32 & 40 Models) 19
6X Blink - Backlight System Failure (46 Models) ........ 19
7X Blink - Temperature Failure .................................... 20
32 & 40 Models Protection Mode System Block Diagram
21
46 Models Protection Mode System Block Diagram .... 22
All Models Power Board Protection Circuits Block Dia-
gram ........................................................................... 23
Video Symptom Troubleshooting ................................... 24
Normal Operation .............................................................. 24
Troubleshooting ................................................................. 24
Missing or Distorted Video (Individual Inputs) ................... 24
Missing Video (All Inputs) .................................................. 25
CTV-61 ii
Table of Contents
Skewing LVDS Connector Troubleshooting Method .... 25
Distorted Video (All Inputs) ................................................ 25
WIDE Mode Button (Aspect Ratio) Troubleshooting
Method ................................................................... 25
Unique Main Video Board (A-Board) or LVDS Cable Ef-
fects ....................................................................... 26
Unique TCON/HFR Board Effects ............................... 27
Unique LCD Panel Assembly Effects ........................... 27
Common Main Video Board (A-Board) and LCD Panel
Assembly Effects ................................................... 27
Video System Block Diagram ........................................ 28
Audio Symptom Troubleshooting ................................... 29
Normal Operation .............................................................. 29
Failure Symptoms .............................................................. 29
Missing or Distorted Main Speaker Audio - All Inputs .. 29
Missing or Distorted Main Speaker Audio - Individual
Inputs ..................................................................... 29
Audio System Block Diagram ........................................ 30
Section 3 - Service Mode .................................................. 31
Service Mode Access .................................................... 31
Section 4 - Triage & Troubleshooting Flowcharts .......... 32
Triage Flowchart ............................................................ 32
Power-ON Troubleshooting Flowchart ........................... 33
Protection Mode 2X, 3X, & 4X Troubleshooting Flowchart
34
Protection Mode 5X & 6X(32, 40) Troubleshooting Flow-
chart ........................................................................... 35
Protection Mode 6X(46) & 7X Troubleshooting Flowchart
36
Video Troubleshooting Flowchart .................................. 37
Audio Troubleshooting Flowchart .................................. 38
Appendix ............................................................................. 39
LCD Panel Distortion Pictures ....................................... 39
TCON/HFR Board Distortion Pictures ........................... 40
TCON/HFR Board Distortion Pictures Continued .......... 41
Video Board Distortion Pictures ..................................... 42
Video Board Distortion Pictures Continued ................... 43
CTV-61 3
Section 1 - AZ1K Chassis Models Overview
32 & 40 OVERALL PCB LOCATION DIAGRAM
FIGURE 1-1
G2LE-Board (32")
G2HE-Board (40")
A-Board
Backlight
Inverter
Board
32" & 40" Models
TCON
Board
Switch Unit
H2-Board
LVDS Cable
CTV-61 4
AZ1K Chassis Models Overview
GD2-Board
A-Board
Balancer
Board
46" Models
TCON
Board
Switch Unit
H2-Board
LVDS Cable
46 OVERALL PCB LOCATION DIAGRAM
FIGURE 1-2
CTV-61 5
AZ1K Chassis Models Overview
AZ1K Chassis Models Covered
KDL-32EX301 KDL-32EX500 KDL-46EX400
KDL-32EX400 KDL-32EX501 KDL-46EX500
KDL-40EX400 KDL-40EX500 KDL-46EX501
KDL-40EX401 KDL-40EX501
Model Introduction
All models, except the KDL-32EX301, contain a Full High-Denition
1920 X 1080 resolution panel. The KDL-32EX301 contains a 1280 X
720 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 the 400 series is 140,000:1 and
for the 500 series it is 2150,00:1. 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 PLAYSTATION3, Blu-ray Disc player and laptop or
desktop.
The BRAVIA Engine 2 fully digital video processor uses a collection of
unique Sony technologies to signicantly 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 Motionow 120Hz frame rate
technology which enhances sharpness and delivers smooth motion for
fast-action sports and movies. The EX300 and EX400 series models
contain the standard 60Hz frame rate.
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
Input
Digital Audio
Output
(Optical)
Analog Audio
Output
(FIXED)
Component Input
Component/Composite
Input
RF Input
USB
HDMI
Input
PC & DVI Audio Input
RF Input
This is a 75 ohm connection for either terrestrial NTSC and ATSC (8VSB)
or cable QAM64 and QAM256 signals.
Composite Video & Audio Inputs
Yellow Jack - Composite Video Input
Red & White Jacks - Right & Left Audio Input
NOTE: 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.
CTV-61 6
AZ1K Chassis Models Overview
Component/Composite Video & Audio Inputs
Red, Blue, & Green Jacks - Component Video Inputs
Red & White Jacks - Right & Left Audio Input
NOTE: 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 specic 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 Detection
Video 1 Composite
Component 1 - Component
HDMI/DVI Video Input and DVI Video
Both 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.
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 & Music
Connect 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 les.
This USB connection is also used for TV Software updates using a USB
drive device.
CTV-61 7
AZ1K Chassis Models Overview
Audio Outputs
Fixed Analog Audio Output
This 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 xed 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 Output
Digital Tuner 5.1 (ATSC) 5.1 Dolby
HDMI 5.1 5.1 Dolby
All Analog Audio Inputs 2CH PCM
Analog Tuner (NTSC) 2CH PCM
SACD Format (HDMI) No Output
DVD Audio Format (HDMI) No Output
CTV-61 8
AZ1K Chassis Models Overview
32 & 40 OVERALL PCB
BLOCK DIAGRAM
FIGURE 1-3
32 & 40 Models Overall PCB Block Diagram
CCFL Backlight HV Inverter
Circuits
Backlight System Error
Circuits
Backlight Inverter Board
A-Board
TV Microprocessor
MT5388:
Video Processing
HDMI Processing
HDCP Processing
IP (Image Processor)
Scan Converter (Scalar)
HDMI Switcher
ATSC/NTSC Tuner
Temperature Sensor
Audio Output Amplifier
Control
Power/Drive
LVDS
Keys
Power/
SIRCS
LCD Panel Assembly
LCD PANEL
Power Key
Function Keys
Switch Unit
LEDs
IR Sensor
H2-Board
Power
Main Power Supply
Standby Power Supply
G2LE-Board (32")
G2HE-Board (40")
Power
Control
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
CCFL
Backlight System
TCON/HFR
Power
AC
Input
*High Frame Rate (120HZ)
1 USB 2.0
CTV-61 9
AZ1K Chassis Models Overview
46 OVERALL PCB
BLOCK DIAGRAM
FIGURE 1-4
Balancer Board
A-Board
TV Microprocessor
MT5388:
Video Processing
HDMI Processing
HDCP Processing
IP (Image Processor)
Scan Converter (Scalar)
HDMI Switcher
ATSC/NTSC Tuner
Temperature Sensor
Audio Output Amplifier
Control
Power/Drive
LVDS
Keys
Power/
SIRCS
LCD Panel Assembly
LCD PANEL
Power Key
Function Keys
Switch Unit
LEDs
IR Sensor
H2-Board
Power
Main Power Supply
Standby Power Supply
AC Relay
Backlight HV Inverter
Circuits
GD2-Board
HV
Control
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
CCFL
Backlight System
TCON/HFR
Power
AC
Input
*High Frame Rate (120HZ)
1 USB 2.0
HV
46 Models Overall PCB Block Diagram
CTV-61 10
AZ1K Chassis Models Overview
PCB and Component Descriptions
Reference 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 Amplier
Temperature Sensor
G2LE-Board (32") or G2HE-Board (40")
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)
Standby Power Supply
3.3V for standby circuits
Power Factor Control Circuit (PFC)
GD2-Board (46")
Except for some regulator circuits on the A-Board, the GD2-Board is
the power supply system board for the 46 models, which includes the
following components and circuits.
Main Power Supply
o 12V
o AU12V (Audio Amp)
Standby Power Supply
o 3.3V for standby circuits
Backlight High Voltage Inverter Power Supply
Main/Inrush AC Input Relay
Power Factor Control Circuit (PFC)
Backlight Inverter Board (32" & 40")
The 24V developed in the Main Power Supply on the G2LE-Board or
G2HE-Board powers the Backlight Inverter Board. 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.
H2-Board
IR Sensor
Switch Unit
Power Key
Function Keys
CTV-61 11
AZ1K Chassis Models Overview
LCD Panel Assembly
The LCD Panel Assembly includes the LCD Panel, TCON Board (300 &
400 series models), TCON/HFR Board (500 series models), and CCFL
Backlight system.
The LCD Panel contains the actual liquid crystals, color lters, and
polarizers. The liquid crystals are manipulated by the applied voltage to
pass a specic 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.
32 & 40 Models:
1) LCD Panel and Backlighting Components
2) TCON/HFR Board
3) Inverter Board
46 Models:
1) LCD Panel and Backlighting Components
2) TCON/HFR Board
3) Balancer Board
CTV-61 12
Section 2 - Troubleshooting Procedures
Power Symptom Troubleshooting
Normal Operation
Reference Figure 2-1 and 2-2
110VAC is applied to the G2LE-Board, G2HE-Board, or GD2-Board it can
be measured at CN6101 or CN6003. In the standby mode the AC power
passes through the main fuse F6101 or F6001. The is no main relay on
the G2LE & G2HE-Board so the AC power is applied directly to the Main
& Standby Power supply. The GD2-Board does have a Main AC Relay.
The AC power passes through R6003 (Inrush resistor), and D6001 and
is applied to the Main DC/DC Converter IC6501 and the Standby DC/DC
Converter IC6201. IC6501 is not active in the standby mode. However,
IC6201 is active in standby mode and outputs STBY 3.3Vdc as long as
AC power is applied to the TV. The Standby 3.3Vdc is supplied to the TV-
Microprocessor, Switch Unit (Power Key), and HSR-Board (IR Sensor) 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 G2LE-Board, G2LE-Board,
or GD2-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 IC6501. No relay click will be heard on the 32 or 40 models
because there is not a main relay. However, on the 46 models there is a
main relay and one relay click is heard at power-on. The relay engages to
bypass the inrush resistor R6003 during the ON state.
The main power supply IC6501 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 amplier. The 32 and 40 models power supply will also output
24V which is the supply voltage for the backlight inverter board.
The GD2-Board in the 46 models will develop and output the backlight
high-voltage (1KV) to the Balancer board and the CCFL backlights.
Failure Symptoms
Reference 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
Loss of AC-OFF-DET
Loss of Standby 3.3Vdc
Loss of REG12V
Loss of Power-On
Defective Main Microprocessor
The rst step in troubleshooting a No Power/Dead Set condition is to
conrm that 110ACV power from an active AC outlet is applied to the
G2LE-Board, G2LE-Baord, or GD2-Board. AC power is applied to, and
can be measured at CN6101 on the G2BE-Board or G2CE-Board and at
CN6003 on the GD2-Board.
Next, check for the presence of the AC-OFF-DET voltage at CN6401/pin 2
or CN6150/pin 2. If the AC-OFF-DET circuit is working properly 3V should
be measured. If the 3V is not present replace the G2BE-Board, G2CE-
Board, or GD2-Board. If the 3V in not present either the main fuse or the
main power supply IC6501 is defective. In either case, replace the power
supply board.
After conrming the AC power and AC-OFF-DET, check for a defective
Standby 3.3Vdc power supply IC6201. To conrm a defective IC6201
check the 3.3V secondary voltage at CN6401/pin 1 or CN6150/pin 1.
As long as AC power is applied to the TV IC6201 should be active and
outputting 3.3Vdc. If the 3.3V is not present then IC6201 is defective.
Replacing the power supply board will x the problem.
CTV-61 13
AZ1K Chassis Models Overview
Finally, a Dead Set condition can be caused by a defective microprocessor
IC400. The microprocessor outputs the Power-On signal which activates
the switch Q6301 and IC6301 on the power supply board and passes
the 19V from the Standby power supply to active the relay (46 models),
PFC, and Main Power Supply IC6501. 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 CN6401/pin 3 or CN6150/pin 3. It should measure
approximately 3.3Vdc If the measurement is 0Vdc before shut-off the TV
microprocessor is defective. Replace the A-Board. If the power-on voltage
is 3V before shutdown then the switch circuit on the power supply board
is defective. Replace the power supply board.
CTV-61 14
AZ1K Chassis Models Overview
A-Board
AU12V
12V
3V
F6101
AC
Input
D6301
TH6301
CN6402
STBY 3.3V
L6302
19V
24V
Power ON
Panel 12V
IC902
Standby
3.3V
Power
Supply
CN6101
Switch
Circuit
Q6101
Q6102
IC6301
Main
Power
Supply
&
PFC
Backlight
HV Inverter
Board
LCD
PANEL
IC400
MT5388
CCFL
Backlights
TCON/
HFR
LCD Panel
Assembly
VCC
R6342
0.1ohm
R6107
10ohm
VSense
CN201 CN6401
Q6302
Q6303
Q6304
5V
IC8151
Audio Output Amp
1.1KV (~2KV Strike Voltage)
LVDS
Cable
F1
G2LE-Board (32")
G2HE-Board (40")
AC-OFF-DET 3V
LCD
Panel
9 9
4 4
3
ON/OFF
AC_DET
PFC_OUT
Q6403
TCON 12V
PS6402
PS6401
AC_DET
D6302
1
2
1
2
CN6401
CN6403
1
2
3 3 PH6103
TCONON
15 15
IC231
5V Reg
IC266
5V Reg
5V
To
Tuner
IC232
1V Reg
IC267
3V Reg
IC268
1.25V Reg
To Micro
IC269
1V Reg
To Micro To Micro
To DDR
To USB
To Optical Out
IC8301
Line Out Amp
A-Board
10 14
To CN6401
From
Q6403
LVDS 12V
CN201
8
D6308
R6302 L6303
3V
12V
19V
12V
12V
EX500 Series ONLY
EX400 Series No Connection
HFR on
EX500
Series
Only
32 & 40 Power Supply System Block Diagram
32 & 40 POWER SUPPLY SYSTEM DIAGRAM
FIGURE 2-1
CTV-61 15
AZ1K Chassis Models Overview
F1
AC Input
CN6401
CN6402
1 UNREG24V
2 UNREG24V
3 UNREG24V
4 UNREG24V
5 UNREG24V
6 Ground
7 Ground
8 Ground
9 Ground
10 Ground
11 BL-ERR
12 BL-ON
13 NC
14 - Dimmer
15 TCON-ON
14 TCON 12V
13 NC
12 DIMMER
11 BL-ON
10 BL-ERR
9 REG12V
8 REG12V
7 Ground
6 Ground
5 Ground
4 AU12V
3 POWER-ON (3V)
2 AC-OFF-DET (3V)
1 STBY 3.3V
G2LE-Board (32")
G2HE-Board (40")
CN6101
G2LE-Board & G2HE-Board Connector Diagram
G2LE-BOARD & G2HE-BOARD CONNECTOR DIAGAM
FIGURE 2-2
CTV-61 16
AZ1K Chassis Models Overview
A-Board
AU12V
12V
3V
F6001
AC
Input
D6001
CN6704
STBY 3.3V
L6501
19V
Power ON
IC6201
Standby
3.3V
Power
Supply
CN6003
Switch
Circuit
IC6301
Q6301
IC6501
Main
Power
Supply
&
PFC
Balancer Board
LCD
PANEL
IC400
MT5388
CCFL
Backlights
TCON/
HFR
LCD Panel
Assembly
VCC
R6536
0.1ohm
R6201
10ohm
VSense
CN201 CN6150
Q6502
5V
IC8151
Audio Output Amp
1.1KV (~2KV Strike Voltage)
LVDS
Cable
F1
GD2-Board
AC-OFF-DET 3V
LCD
Panel
9 9
4 4
ON/OFF
AC_DET
PFC_OUT
Q6151
TCON 12V
PS6151
AC_DET
D6002
1
2
1
2
CN6150
CN6151
2
3 3 PH6300
TCONON
15 15
IC231
5V Reg
IC266
5V Reg
5V
To
Tuner
IC232
1V Reg
IC267
3V Reg
IC268
1.25V Reg
To Micro
IC269
1V Reg
To Micro To Micro
To DDR
To USB
To Optical Out
IC8301
Line Out Amp
A-Board
10 14
To CN6150
From
Q6151
LVDS 12V
CN201
8
D6502
R6013 R6301
3V
12V
19V
12V
RY6002
HV
HV
Backlight Inverter High Voltage Circuits
IC6601
Q6601
Q6602
19V 400V
CN6705
R6003
46 Power Supply System Block Diagram
46 POWER SUPPLY SYSTEM DIAGRAM
FIGURE 2-3
CTV-61 17
AZ1K Chassis Models Overview
F6001
AC Input
CN6151
CN6150
CN6158
CN6705
CN6003
AC Relay
6 - NC
5 - Ground
4 Ground
3 TCON 12V
2 TCON 12V
1 NC
HV 1.1KV
HV 1.1KV
GD2-Board
CN6704
15 TCON-ON
14 TCON 12V
13 NC
12 DIMMER
11 BL-ON
10 BL-ERR
9 REG12V
8 REG12V
7 Ground
6 Ground
5 Ground
4 AU12V
3 POWER-ON (3V)
2 AC-OFF-DET (3V)
1 STBY 3.3V
5 - LD
4 Ground
3 Ground
2 FB
1 12V
GD2-Board Connector Diagram
GD2-BOARD CONNECTOR DIAGAM
FIGURE 2-4
CTV-61 18
AZ1K Chassis Models Overview
Protection Mode Symptom Troubleshooting
Reference Figures 2-5 and 2-6
The KDL-32S5100 and KDL-32XBR9 include the following protection
mode blink patterns (or self-diagnostics).
Protect Description Blink Pattern
Possible Error
Location
Main Power Error 2
G2LE, G2HE, GD2-
Board, or A-Board
Audio Error 3
A-Board or G2LE,
G2HE, GD2-Board
Balancer Error
(46 Only)
4
LCD Panel, A-Board,
or GD2-Board
TCON Error 5
TCON/HFR Board or
A-Board
HFR Error 5
TCON/HFR Board or
A-Board
Backlight Error 6
Inverter Board (32,
40), G2LE, G2HE,
GD2-Board, LCD Pan-
el, or A-Board
Temperature Error 7 Ventilation or A-Board
NOTE: 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 Error
A 2X protection mode blink pattern can be activated due one of the
following defects on the G2LE-Board, G2HE, GD2-Board..
Loss of AU12V (LVP)*
Excessive AU12V Level (OVP)*
Excessive 24V Level (OVP) (32 & 40 models)
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 IC6501 will cause a 2X blink pattern on the Standby-
LED. The 12Vdc can be checked at CN6401/pin 4. The
If the measurement is 0V or rises above 12Vdc (approaches 15V) before
the TV shutdown the G2LE-Board, G2LE, GD2-Board is defective.
If approximately 12Vdc is present and remains below 12Vdc before shut-
off then the A-Board is defective.
An excessive 24Vdc (32 & 40 models) secondary voltage from the main
power supply IC6501 will also cause a 2X blink pattern on the Standby-
LED. The 24Vdc can be measured at CN6402/pin 3 before TV shutdown.
If the voltage rises above the 24V level (approaches 27) before TV
shutdown then the power supply is defective, replace the G2LE, G2HE ,
GD2-Board to x 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 G2LE, G2HE, GD2-Board to x this condition.
3X Blink- Audio Error
The Audio error can occur due one of the following error conditions.
Shorted or Damaged Speaker Connections
Defective Audio Amplier (A-Board)
Loss of AU12V (Open F1 on A-Board)
The rst thing to check when a 3X blink protection mode occurs is the
physical condition of the speakers and speaker connections. The speakers
CTV-61 19
AZ1K Chassis Models Overview
should measure 8 ohms. Shorted speakers or connections can cause a
3X blink protection mode.
If the speakers and connections check okay, then the defective component
is on the A-Board. Either a open F1 or defective audio amplier will cause
a 3X blink protection mode. In either case, replace the A-Board to x this
condition.
4X Blink - Balancer Failure (46 Models ONLY)
In most cases, a 4X protection mode indicates a defective lamp or lamps.
Therefore, replace the LCD panel to x this condition. If the 4X protection
is still present after replacing the LCD panel, there could be a problem
on the A-Board or GD2-Board. First replace the A-Board then the GD2-
Board.
5X Blink - TCON & HFR Failure
The 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 (32 & 40 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 3X
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(s)
b) Defective Backlight Inverter Board
2) No Backlight and 6X
a) Defective TV Microprocessor
b) Defective 24V Power Supply
c) Defective Backlight Inverter Board
IMPORTANT: Before replacing the LCD Panel assembly check the
backlight Inverter Board outputs. A failure of one of the inverter outputs
will also cause this same symptom (Momentary Backlight & 6X).
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 G2LE, G2HE, GD2-Board.
If the Backlight ON and 24V power supply are okay than the Backlight
Inverter board has failed and must be replaced. This will be a rare
occurrence but the Inverter board can cause a No Backlight condition
and must be considered.
6X Blink - Backlight System Failure (46 Models)
The 46 models have both a 4X and 6X blink protection mode. The 4X
blink will, in most cases, be caused by a defective lamp.
Because all the Backlight HV Inverter circuits are located on the GD2-
Board, a 6X blink protection mode will be xed, in most cases, by
replacing the GD2-Board. If the GD2-Board does not repair the problem
replace the A-Board. The BL-ON and Dimmer signals come from the
CTV-61 20
AZ1K Chassis Models Overview
microprocessor on the A-Board. A shorted or open BL-ON signal will
cause this 3X condition. Also a shorted Dimmer will cause this 3X
condition.
7X Blink - Temperature Failure
These 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 rst 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 x the problem.
CTV-61 21
AZ1K Chassis Models Overview
A-Board
3X
IC400
MTK5388
2X
Standby 3.3V
DC_Detect
Main
PS
&
PFC
AC
Input
STBY
PS
CN6401
CN6000
3V
Power ON SW
RECT
IC4305
Temp
Sensor
70C
HV Inverter Board
BL_ERR
BL_ON
Dimmer
24V
CN001
12V
BL_ERR
BL_ON
Dimmer
INV_ERR
6X
Temp_ERR
7X
IC8151
Audio
Amp
Protection Circuit
Q8153, Q8155
Q8158, Q8160,
Q8156
Audio_ERR
LCD Panel Assb
TCON
TCON_ERR
5X
HFR_ERR
5X
SDA (I2C)
HFR
8
1 1
3 3
6
1
2
3
CN8151
CN8152
CN4152
G2LE-Board (32")
G2HE-Board (40")
Interface
Circui t
3
24V
BL*
Backlight Inverter
High Voltage
Corcuits
*BL - Backlight
1V to 3V
3V
0V
13
12
11
CN201
9
CN6401
CN6402
3V
3.3V
RECT
32 & 40 Models Protection Mode System Block Diagram
PROTECTION CIRCUITS DIAGRAM
FIGURE 2-5
CTV-61 22
AZ1K Chassis Models Overview
A-Board
3X
IC400
MTK5388
2X
Standby 3.3V
DC_Detect
Main
PS
&
PFC
AC
Input
STBY
PS
CN6003
3V
Power ON SW
RECT
IC4305
Temp
Sensor
70C
BL_ERR
BL_ON
Dimmer
CN6150
12V
BL_ERR
BL_ON
Dimmer
BL_ERR
4X & 6X
Temp_ERR
7X
IC8151
Audio
Amp
Protection Circuit
Q8153, Q8155
Q8158, Q8160,
Q8156
Audio_ERR
LCD Panel Assb
TCON
TCON_ERR
5X
HFR_ERR
5X
SDA (I2C)
HFR
8
1 1
3 3
12
11
10
CN8151
CN8152
CN4152
GD2-Board
Interface
Ci rcuit
BL*
Backlight Inverter
High Voltage
Circuits
*BL - Backlight
1V to 3V
3V
0V
13
12
11
CN201
9
CN1004
CN6150
3V
3.3V
RECT
B
A
L
A
N
C
E
R
HV
HV
FB
LD
12V
CN6702
PROTECTION CIRCUITS DIAGRAM
FIGURE 2-6
46 Models Protection Mode System Block Diagram
CTV-61 23
AZ1K Chassis Models Overview
IC6301
Main
Power
Supply
&
PFC
AC
Input
12V
OVP
Reg 12V
D6301
PFC
OVP
Switch Circuit
Q6101, 6102
30V
Zener
To A-Board
Power-ON
From A-Board
Pulls
Power_ON
Low
G2LE-Board (32")
G2HE-Board (40")
GD2-Board (46")
OVP Over Voltage Protection
OTP Over Temperature Protection
CN6401
3
3V
Latch Circuit
Q6202, 6203
G2HE-Board &
G2LE-Board
Protection
circuits will
cause a 2X
blink pattern
Reg 24V
15V
Zener
24V
OVP
9
3 To Inverter Board
CN6402
19V
PFC
OTP
D6302
CN6101
OTP
32" 40" Models ONLY
PROTECTION CIRCUITS DIAGRAM
FIGURE 2-7
All Models Power Board Protection Circuits Block Diagram
CTV-61 24
AZ1K Chassis Models Overview
Video Symptom Troubleshooting
Reference Figure 1-8
Normal Operation
All video processing is performed by IC400 (MT5388) on the A-Board.
The RF input is rst 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 rst applied to a HDMI switch circuit (IC6601). The switch
circuit applies the selected input to IC400. IC6601 also contains the EDID
(Extended Display Identication 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) Conrm 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.
Troubleshooting
When 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-61 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 conrmation 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 owchart (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 rst 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 3
3) 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 Method
It maybe difcult or impossible to check the LVDS signal while in the eld.
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, nd 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 ashing 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 Method
A 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-61 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 Effects
A 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 conrm 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 conrm 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-61 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 ex 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 ashing across the screen. These lines
and pixels will be very sharp in detail, like a specic 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 specic zones or specic 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 specically 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 specically 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 specic zones or specic color
areas in the picture, as well as an irregularity in overall picture
brightness.
CTV-61 28
AZ1K Chassis Models Overview
A-Board
IC400
MTK5388
(HDCP)
LCD Panel Assembly
TCON/
HFR
LCD
Panel
CCFL
Backlight
System
CN4152
1
/
49
IC4302
NAND FLASH
User Data
White Balance
GAMMA
User Menu Service Mode
IC303
Sub
Micro
4
/
10
LVDS 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
IC6601
HDMI
Switch
(EDID)
Video 3 (Component)
USB 2.0
TCON 12V 12V
From Power
Supply Board
HDMI IN 4
TM701
NTSC/ATSC
Tuner
Video System Block Diagram
VIDEO SYSTEM
FIGURE 2-8
CTV-61 29
AZ1K Chassis Models Overview
Audio Symptom Troubleshooting
Reference Figure 2-9
Normal Operation
The HDMI digital audio signal is rst applied to the HDMI Receiver/Switch
IC6601 and then to the MT5388 on the A-Board.
The RF input is rst 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 amplier IC8301 and then
is applied to CN8301.
The main speaker audio comes from IC400 and passes through amplier
IC8151 and then to CN8151 and CN8152 speaker connections..
The AU12V from the G2LE, G2HE, or GD2-Board is the power supply for
the audio output amplier IC8151.
IMPORTANT:
Conrm 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 Symptoms
The rst 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 conrm the actual
defective component.
1) Check for audio at the Analog FIX or DIGITAL Audio Outputs
a) 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-Board
a) No AU12V - Check connections between the Power Supply
board and the A-Board
b) AU12V Present replace A-Board
Missing or Distorted Main Speaker Audio - Individual Inputs
If 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 rst.
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-61 30
AZ1K Chassis Models Overview
Video 2 (Composite/S-Video)
LR Audio
A-Board
IC400
MTK5388
(HDCP)
HDMI IN 1
Video 1 (Component & Composite)
RF Input
PC IN
LR Audio
HDMI IN 2
Video 3 (Component)
IC6601
HDMI
Receiver/
Switch
(EDID)
TM701
NTSC/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
CN6401 (32", 40")
CN6150 (46") CN201
AC
HDMI IN 3
HDMI IN 4
IC8151
Output
Amplifier
LR Audio
1 1
USB 2.0
G2LE-Board (32")
G2HE-Board (40")
GD2-Boad (46")
IC8301
Amp
CN8151
PS6401
CN8152
IF
Audio System Block Diagram
AUDIO SYSTEM
FIGURE 2-9
CTV-61 31
Section 3 - Service Mode
SERVICE MODE
FIGURE 3-1
Service Mode Access
Service 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-61 32
Section 4 - Triage & Troubleshooting Flowcharts
Triage Flowchart
Triage Flowchart A
(AZ1K 32", 40", & 46" Models)
Start
Triage
Is
Video Missing
or Distorted
?
No
Yes
No
No
No
Yes
Yes
Yes
GO TO
Power-ON
Troubleshooting
Flowchart B
GO TO
Protection Mode
Troubleshooting
Flowcharts C1, 2, 3, 4
GO TO
Missing or Distorted
Video Troubleshooting
Flowchart D
GO TO
Missing or Distorted
Audio Troubleshooting
Flowchart E
No Problem
Found
Unit Fully
Operational
A
Is
RED
Standby LED
ON?
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-61 33
Triage & Troubleshooting Flowcharts
Power-ON Troubleshooting Flowchart B
(AZ1K 32", 40", 46" Models)
Unit will Not
Power-ON
(All Models)
Is
Standby LED
illuminated
RED?
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 CN6401/pin 1
(In STBY Mode)
B
Confirm Unit is
securely plugged into
an active AC Outlet
Is
110VAC Present
at CN6101?
Repair AC Outlet or
Replace AC-Power Cord
OK
Yes
GO TO
FlowCharts 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
IP3N-Board
Is voltage
3V
Present?
No
Yes
Check
AC_OFF_DET
at CN6401/pin 2
Is voltage
12V
Present?
No
Yes
Replace
G2LE-Board
G2HE-Board
GD2-Boad
Check SW_12V
at CN6401/pin 9
(In STBY Mode))
Check Power_ON
at CN6401/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
Replace
G2LE-Board
G2HE-Board
GD2-Boad
CN6003 - 46"
F6001 - 46"
CN6150 - 46"
CN6150 - 46"
CN6150 - 46"
CN6150 - 46"
Replace
G2LE-Board
G2HE-Board
GD2-Boad
Power-ON Troubleshooting Flowchart
CTV-61 34
Triage & Troubleshooting Flowcharts
Protection Mode 2X, 3X, & 4X Troubleshooting Flowchart
Protection Mode Troubleshooting
Flowchart C1 (AZ1K 32" & 40" Models)
Unit Shuts OFF
RED LED
Blinking
C1
2X Blink Pattern
AU12V LVP & SW12V OVP
~12V
Check AU12V at
CN6401/pin 4
*Before Shutdown
NOTES:
1) All Red Blink patterns will occur on the Front Panel
Red Standby LED
2) All voltage are measured prior to unit shutdown
3) Confirm all connections between circuit boards
before replacing
Yes
No
(>) Greater Than
(~) Approximately (Does
not exceed)
Replace
A-Board
3X Blink Pattern
Audio
>12V
Check SW12V at
CN6401/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

Replace
G2LE-Board
G2HE-Board
GD2-Boad
Replace
G2LE-Board
G2HE-Board
GD2-Boad
CN6150 - 46"
CN6150 - 46"
4X Blink Pattern
Balancer
46" Models ONLY
Check LD
Volatge
CN6702/pin 5
Is voltage
0V or 12V
Present?
Replace
LCD Panel
0V
12V
Replace
G2LE-Board
G2HE-Board
GD2-Boad
Is Problem
Solved?
Problem
Sloved
Replace
A-Board
No
Yes
CTV-61 35
Triage & Troubleshooting Flowcharts
Protection Mode 5X & 6X(32, 40) Troubleshooting Flowchart
5X Blink Pattern
TCON/HFR Error
Is
connection
OK?
Repair
Connection
No
Yes
C2
NOTES:
1) All Red Blink patterns will occur on the Front Panel
Red Standby LED
2) All voltage are measured prior to unit shutdown
3) 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 32", 40", 46" Models)
Unit Shuts OFF
RED LED
Blinking
Is
Issue
Resolved
?
Issue
Resolved
Yes
No
Is
voltage
24V Before
Shutdown
?
Yes
No
Check 24V at
CN6402/pin 3
*Before Shutdown
Check
Inverter HV Outputs
*Before Shutdown
Is
Backlight ON
Before Shut
Down?
Yes
Are
Select outputs
missing?
No
Yes
No
Replace
LCD Panel
Assembly
Check Backlight-ON
signak at
CN201/pin 12
*Before Shutdown
Is
voltage
3V Before
Shutdown
?
Replace
A-Board
Yes
No
Replace
Inverter Board
Replace
Inverter Board
Is SONY logo
Displayed and
Tones Heard?
Check for
Open or Short
Check Dimmer signal at
CN201/pin 13
*Before Shutdown
Is
voltage
1V to 3V Before
Shutdown
?
Check for
Short
Replace
A-Board
Replace
G2LE-Board
G2HE-Board
6X Blink Pattern
(No Backlight)
CN6151 - 46"
Replace
G2LE-Board
G2HE-Board
GD2-Boad
32" & 40" Models ONLY
CTV-61 36
Triage & Troubleshooting Flowcharts
Protection Mode 6X(46) & 7X Troubleshooting Flowchart
Protection Mode Troubleshooting
Flowchart C3 (AZ1K 32", 40", 46" Models)
C3
7X Blink Pattern
Temperature Error
Clear unit ventilation areas
and confirm adequate local
room temperature
No Does unit still
shutdown (7X)?
Issue
Resolved
Yes
Does
unit Shut-Down
Immediately after
Power ON
?
Yes
No
Temperature Threshold
Ambient 80C
NOTES:
1) All Red Blink patterns will occur on the Front Panel
Red Standby LED
2) All voltage are measured prior to unit shutdown
3) Confirm all connections between circuit boards
before replacing
Replace
A-Board
Unit Shuts OFF
RED LED
Blinking
Is
voltage
HV Before
Shutdown
?
Yes
Check HV at
CN6704 & CN6705
*Before Shutdown
No
Check Backlight-ON
signak at
CN201/pin 12
*Before Shutdown
Is
voltage
3V Before
Shutdown
?
Replace
A-Board
Yes
No
Check for
Open or Short
Check Dimmer signal at
CN201/pin 13
*Before Shutdown
Is
voltage
1V to 3V Before
Shutdown
?
Check for
Short
Replace
A-Board
Replace
GD2-Board
Replace
GD2-Board
No
Yes
6X Blink Pattern
(No Backlight)
46" Models ONLY
CTV-61 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 Line
of 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 Connections
Swap 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 Cable
If Damaged
Replace
A-Board
Video Troubleshooting
Flowchart D (AZ1K 32", 40", 46" Models)
Replace
A-Board
Replace
A-Board
Is
Backlight ON
?
Go To
Flowchart C2
Replace
A-Board
Yes
Or check LVDS cable Video &
Clock Signal Levels at
CN4152/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-61 38
Triage & Troubleshooting Flowcharts
Audio Troubleshooting Flowchart
NOTE: Confirm all connections between
circuit boards before replacing
Is Audio
Present?
Check
Fix 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
Check
Voltage fromPower Supply
at CN6401/pin 4
Is 12V
Present?
Yes
Yes
Replace
Speaker(s)
No
No
Yes
Is
External Device
& connection OK
?
Repair External
Device
Check External Device
and Connections
Swap Devices and
connections
All Video Inputs :
Composite
Component
HDMI
PC IN
ATSC/NTSC (Tuner)
USB
Audio Troubleshooting
Flowchart E (AZ1K 32", 40", 46" Models)
Replace
A-Board
Replace
A-Board
Replace
A-Board
Replace
G2LE-Board
G2HE-Board
GD2-Boad
CN6150 - 46"
CTV-61 39
Appendix
LCD 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 xed by replacing the LCD Panel.
CTV-61 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 xed by replacing the TCON/HFR Board.
CTV-61 41
Appendix
2" White Bar w/ Random Colored Lines Exact Half-Screen Distortion
Complete Washout w/ Colored Lines
TCON/HFR Board Distortion Pictures Continued
The following distortions and anomalies where xed by replacing the TCON/HFR Board.
CTV-61 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 xed by replacing the Video Board.
CTV-61 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 xed by replacing the Video Board.
and i.Link are trademarks of Sony Electronics
2007 Sony Electronics, Inc.
EMCSA - A Service Company
16530 Via Esprillo
San Diego, CA 92127
Reproduction in whole or part without written permission is prohibited. All rights reserved
CTV610110 03/30/10