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This publication is intended to aid the technician in servicing the First Series of DLP television.

This manual will explain the basic theory of operation of the major modules. This manual covers the AC In CBA, Formatter CBA, Audio CBA, A/V In/Out CBA and the Light Engine along with practical troubleshooting tips and suggestions. It is designed to assist the technician in becoming familiar with chassis operation, increase confidence and improve overall efficiency in servicing the product. Note: This publication is intended to be used only as a training aid. Never use training diagrams alone to troubleshoot. It is not meant to replace service data. TCE Electronic Service Information for this instrument contains specific information about parts, safety and alignment procedures and must be consulted before performing any service. The information in this manual is as accurate as possible at the time of publication. Circuit designs and drawings are subject to change without notice.

FOREWORD

SAFETY INFORMATION CAUTION


Safety information is contained in the appropriate Thomson Consumer Electronics Service Data. All product safety requirements must be complied with prior to returning the instrument to the consumer. Servicers who defeat safety features or fail to perform safety checks may be liable for any resulting damages and may expose themselves and others to possible injury.

All integrated circuits, all surface mounted devices, and many other semiconductors are electrostatically sensitive and therefore require special handling techniques.

Second Edition 0704 - First Printing Copyright 2004 Thomson Trademark(s) Registered Marca(s) Registrada(s) Printed in U.S.A.

Prepared by Thomson Technical Training Department, INH905 PO Box 1976 Indianapolis, Indiana 46206 U.S.A.

CONTENTS
Introduction ................................................................................5 Chassis Introduction & Electrical Overview ..............................9 DLP Technology Overview .........................................................12 Light Engine Overview .............................................................15 AC In CBA Overview (power supplies) .....................................20 DM2CR Overview.......................................................................22 Formatter CBA Overview...........................................................24 Audio Switching Overview........................................................26 Audio Processing Overview .....................................................28 Video Switching Overview...........................................................30 System Control ..........................................................................32 Service Tips ...............................................................................33 Service Menu's & Diagnostics...................................................34 Troubleshooting.........................................................................35

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Introduction

Fig. 1 DLP
modules. There is no component level troubleshooting. Alignments are also reduced. With DLP Technology, convergence and geometry alignments are not needed. The First Series of DLP has only one mechanical and a couple of electrical adjustments. There are basically three advatages about HDTV that provides a superior viewing experience: (1) resolution, (2) aspect ratio, and (3) digital video and digital sound.

This new generation of television uses Digital Light Processing (DLP) Technology from Texas Instruments (TI) to display a high quality HDTV picture in a lightweight cabinet. The heart of DLP Technology is a specially design semiconductor, a color wheel, and a high output light bulb. These devices are housed in a cabinet that is 16" deep and weights approximately 100 pounds. These advantage make the TV a pleasure to watch and to position in most viewing locations Improved serviceability is another advantage of televisions using DLP Technology. The set is lightweight and easy to move or place on a bench. Electrically, the set contains seven

Resolution
Resolution is measured by calculating the number of active lines of pixels. A analog NTSC television only has a resolution of about 200,000 pixels (480

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vertical pixels x 440 horizontal pixels = 211,200 pixels). The HDTV (ATSC) format is capable of more than 2 million pixels (1,920 x 1,080 = 2, 073,600). More pixels equals more detail in the picture. In summary, HDTV is capable of resolution that is up to 10 times the resolution of the picture on a regular, analog TV.

Features
The picture settings can be customized to fit viewing taste and match the lighting conditions where the unit is located by using personal presets and/or the automatic picture quality settings: Vibrant, Natural, Cinematic. Each Input Jack can be adjusted to a different setting and the unit automatically adjusts the picture settings to its unique value when that input is selected. Elaborate on-screen Help Text helps the user learn more about the features of the First Series of DLP and helps them to use them more effectively. The GUIDE Plus+ System on-screen programming guide helps the user navigate through hundreds of channels so they can quickly see whats on and tune directly to a specific show from the guide. The user can use the Sort feature to search listings and can even set up reminders to watch a certain show via the GUIDE Plus+ systems Watch menu. Integrated ATSC Tuner with QAM Thomson was the first to offer an integrated ATSC tuner in its HDTVs (no need for a set-top box to receive and decode over the air ATSC programming). The new tuner in the First Series of DLP can also decode the QAM (Quadrature Amplitude Modulation) digital cable signal. There is no need for a cable box to view nonencoded standard, digital cable programming. Note: a cable box is necessary to view scrambled (encoded) and/or premium channels.

Aspect Ratio
When the standards were being developed for television broadcasting in 1941 by the (National Television Standards Committee (NTSC), it made sense to adopt the 4 x 3 aspect ratio that the film industry was using at that time. The 16 x 9 aspect ratio was originally developed back in the 50s by the movie industry (also called widescreen format). When the standards for ATSC were being developed by the Advanced Television Standards Committee, the 16 x 9 aspect ratio was chosen as the format for HDTV. The widescreen format made sense because its much closer to the way we see. Our field of vision is actually much wider than tall because of our peripheral vision.

Digital Video Signal and Digital Sound


The analog television broadcast system (NTSC) that has been used in the United States for the past 50 years transmits signals as analog electronic waves. These waves can suffer degradation as the signal travels to the receiver. Digital signals, in contrast, can be reproduced precisely because the images are transmitted and received digitally. This produces a signal that is capable of displaying studio-quality video and Dolby Digital 5.1 channel sound.

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Fig. 2 DLP with stand FireWire DTVLink with Two-Way


from the TV. A high-speed connection, such as a DSL (Digital Subscriber Line) unit or cable modem is needed to use the web browser, along with a subscription to an ISP (internet service provider). Digital photos can be accessed directly from a PC and display on the TV. The browser has limitations and might not be able to interpret all files, such as streaming audio, video and PDFs.

The DLP will allow you to hookup and control components via 1394 (FireWire) cable. This is accomplished via the 2-way DTVLink jacks and you can network high-speed compatible 1394 digital components. The twoway jacks allow the audio and video signals to flow in and out of the 1394 components.

NetConnect
With an Ethernet connection and a web browser built into the instrument, the internet can be accessed directly

Audio System
The sound system has a total of 60 watts total power. It has front speakers with two 1" tweeters and two 5"

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midrange drivers to create incredible sound. A 7-band on-screen graphic equalizer allows customization of the sound quality. SRS TruSurround provides surround sound technology and with two rear speaker outputs. For those who want to hook up a home theatre audio system, there is an optical Dolby Digital output as well as a 50-watt center channel input.

Record Output Jacks


Because the VCRs in most households are analog and can not recognize the ATSC digital signal, recording HDTV broadcasts was not possible without purchasing additional equipment. For this reason a Video Record Output Jack and Audio Output L/R jacks are provided on the DLP. These video and audio output record jacks enables the recording of both NTSC analog and ATSC digital programming.

CinemaScreen
Check out the black, borderless frame around your HDTVs screen. This is not just a design feature the CinemaScreen actually improves contrast by providing a brighter, sharper picture. Feel like youre part of the picture with CinemaScreen.
Digital Light Processing, DLP are trademarks of Texas Instruments. All other products and names may or may not be trademarks or registered trademarks of their respective companies.

Fig. 3 Side View

Page 8

Chassis Introduction Electrical Overview

&
circuit board and it is responsible for converting the video signals into a format that the light engine can use. The fifth is the DM2CR which contains the ATSC tuner, NTSC tuner and the QAM digital cable decoder. The DM2CR also serves as the system control for the instrument. The sixth module is the light engine and seventh is the lamp power supply.

The chassis in the First Series of DLP is made up of seven (7) major modules. These include the AC In CBA which contains the Standby and Run power supplies. The Audio CBA which processes all audio signals. The A/V In/Out CBA has the in/out jacks and also does all the video and audio switching. The fourth is the Formatter

Light Engine

Lamp Power Supply

Lamp Assembly

Fig. 4 First Series of DLP Light Engine Assembly


Formatter CBA

Audio CBA Standby & Run Power Supply CBA DM2CR A/V In/Out CBA

Fig. 5 ATC311 Chassis Assembly Page 9

120VAC
J12101

AC In CBA
Relay Doubler Bridge

J24252 1 2 1 2

To Lamp Pwr Suply To Lamp Door Switch

Left X-over Right X-over


J22101

J11901

Audio CBA
J11902 J11501 J11903 J24603

+12VS
J24251

Standby Power Supply


+21V -21V +6VS +5VS -5VS +12VS +33VS PwrFail

On/Off

Run (Main) Power Supply


Pwr_Good
J24702

+12VR
4

+9VR +12VR

Aud-Pwr 3
J13602

+6VS
J24604

SW
Degauss +5VR

SW
J24602 7 16 14

J13604

6 4 2 8 14 13 J24605

+5VR

BW902

DM2CR
J13603 5 4 14 J22105

Formatter CBA
BV401
I C_Clk I 2 C_Dat
2

BP503

8 13 1 3

Pwr_Good

EEPROM
IW501

+5VR 2 +12VR

(RUN 2) (RUN 2)

+9VR

3.3V & 2.5V +2.5VR 9 Reg 5


I 2 C_Clk I 2 C_Dat 6 7

+3.3VR

12

To Light Engine

Pr 10 Pb 12 V-Sync
6 8 2

H/V Sync
2

J22104 J26905 J26903

H-Sync FSW

Digital Signal Processing IW601 IW701 IW801 IW901 DVI Video

Red

BEP

A/V In/Out CBA J26904


J26901 J28901 J26104 J32402

1 5 3 8

Y Pr Pb V-Sync BV402

IV401

Green Blue

18 9 2 23

To Light Engine

Rx/Dim

H-Sync 7

Chroma/Luma DRAM
IW702/03/4/ 05/06/07

Luma

Tx/lamp_Lit

BW901

Front A/V In

IR
J32401

FPA
J23401 J23402

Lite Pipe

IW702/3/4

Fig. 6 Chassis Block Diagram and Interconnect


Chassis Electrical Overview There are five (5) major circuit boards in the First Series of DLP chassis (minus the light engine). These include the AC In CBA, Audio processing CBA, the DM2CR, the A/V In/Out CBA and the Formatter CBA. The AC In CBA provides the Standby DC power and the Run supply DC power. Both power supplies are switch mode power supplies and are very similar. The main difference is that the run supply has an on/off circuit that is controlled by the system control micro in the DM2CR. An AC doubler on the AC In CBA is used to generate power for the lamp power supply.

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Note: A valuable troubleshooting tip is to listen for the lamp power supply relay click when AC is plugged in. Since the relay is power by the +12VS source, if the relay doesnt click this is a good indication the standby power supply is inoperative. The Audio CBA is responsible for final processing of all baseband audio signals. This includes volume, equalization, balance and Surround Sound. The audio output power amplifiers that drive the internal speakers are also located on the Audio CBA. Audio for the audio out jacks as well as the FAV (Front Audio Video) circuit are supplied by the Audio CBA. Power (+/-21V) for the Audio CBA is provided by the standby supply. The DM2CR module contains both an NTSC and ATSC tuner section as well as the NTSC PIP tuner (see DM2CR Module Overview for more details). The tuners are capable of processing both digital and analog RF signals (ATSC & NTSC) from either terrestrial or cable sources. The DM2CR is also 256QAM digital cable compatible. The DM2CR has 2 DTV Link connectors which are a compressed digital video inputs offering an IEEE-1394 type video connection for consumer devices such as satellite receivers, cable receivers, and digital recorders that meet the CEA specifications for DTV Link. DTV Link is better known as 1394 or FireWire for digital televisions. Audio and video information is carried on a single wire. The DM2CR module performs the NTSC decoding of component, SVHS, and composite video signals. The DM2CR also recovers the teletext, closed caption and GemStar data signals that accompany any input video.

All 1H video inputs (NTSC) including signals from the A/V In/Out circuit board are up-converted to 2H by the DM2CR. The video output to the formatter CBA is YPrPb component. Any 2H component (YPrPb) that is input to the A/V In/Out CBA is routed directly to the formatter. The audio and video in/out jacks are located on the A/V In/Out CBA. The A/ V CBA also provides audio and video switching for external video and audio signals. The auto detected 1H and 2H video signal are routed via the A/V In/ Out circuit board. The 1H and 2H NTSC is routed to the DM2CR for upconversion. Any 2H component external video signal is routed directly to the formatter circuit for final processing. The formatter circuit board is responsible for converting the analog video from either the DM2CR or the analog inputs from the A/V In/Out circuit board into a format that is compatible with the light engine. All functions and circuits on the formatter circuit board is monitored and controlled by the system control microcomputer in the DM2CR module. This is accomplished via the RUN 2 I2C clock and data bus. The same I2C bus is also routed through the formatter board to the light engine. The 2H and 2.14H external video inputs are applied to the formatter circuit board (via connector BV402) where it is applied to the BEP (back end processor) for processing into an analog RGB signal. The NTSC and the ATSC analog video signal (2H) from the DM2CR is also input to the formatter (via connector BV401). The video is applied to IV401 for conversion to RGB. The RGB output from IV401 is then applied to the Digital Signal processing circuits where it is digitized and output to the light engine as DVI (Digital Video Interface).

Page 11

Fig. 7 DLP Device (MMD) MMD (DLP) Technology Overview


Texas Instruments Digital Light Processing (DLP) technology provides an all digital projection display that offers superior picture quality in terms of resolution, brightness, contrast, and color fidelity. The DLP device consists of an array of movable mcromirrors. Each mirror is independently controllable and is used to modulate reflected light. The mirror is controlled by loading data into the memory cell located below the mirror. The data electrostatically controls the mirrors tilt angle which controls whether video passes through the projection lens and onto a screen or reflected away. Until recently, light-valve technologies for projection display applications have been unable to take full advantage of the economies and stability offered by the digital revolution. Increasing digital content has been incorporated into the transmission and signal processing chain from source material to the projection display light valve. Ultimately, however, the light valve itself is analog in nature and subject to analog

Graphics, text and artwork courtesy of Texas Instruments. Digital Light Processing, DLP are registered trademarks of Texas Instruments.

Fig. 8 Micro Mirror Device (Exploded View)

Page 12

limitations. The possibility of an alldigital (source-to-eye) display was realized in 1987 with the invention of the DLP device at Texas Instruments. The Digital Mirror Device (DMD) is an array of fast digital micromirrors, monolithically integrated onto and controlled by a memory chip. Digital Light Processing (DLP) systems present bright, seamless images to the eye, with the characteristics that we have come to expect from digital technology, namely high image fidelity and stability. DLP-based displays exhibit no lag or smearing of the image from one digital frame to the next. The first DLP-based projection display products were introduced to the market in April 1996.

DISPLAY OPERATION
As shown in Figure 8, each digital light switch of the DMD is an aluminum micromirror, 16 micrometer square, that can reflect light in one of two directions, depending on the state of an underlying memory cell. The mirror is rotated by electrostatic attraction produced by voltage differences developed across an air gap between the mirror and the memory cell. The mirror rotation is limited by mechanical stops to 10 degrees. With the DLP cell in the on state, the mirror rotates to +10 degrees. With the DLP cell in the off state, the mirror rotates 10 degrees.

When we combine the DLP device with a suitable light source and projection optics, the mirror reflects incident light either into or out of the projection lens by a simple beam-steering action. Thus, the on state of the mirror appears bright and the off state of the mirror appears dark. The fast switching time of the mirrors enables the use of a pulse width modulation technique for the production of gray scale. The DLP device accepts electrical words representing gray levels of brightness at its input and then outputs digital light as optical words to the eye. Because of the short pulse duration, the optical words are interpreted by the eye of the observer as analog light containing up to one billion or more color and gray scale combinations per pixel. Furthermore, the fast switching time results in a lag free image. Digital light is accurate because the light pulse durations are determined by the precise division of time. The resulting projected image faithfully reproduces the original source material and the image is stable, independent of temperature or age of the projector, and is free from photo degradation effects, even up to brightness levels necessary for electronic cinema. The tiny gaps between the mirrors diminish objectionable pixilation effects and create a seamless image that has long been the hallmark of DMD-based projection displays.

Page 13

DISPLAY CONFIGURATIONS
Three configurations of DLP projection systems are currently being manufactured, differentiated by the number of chip, one, two, or three. First Series DLP uses a one chip configuration. Figure 9 shows a simplified example of a one-chip system. The configuration choice depends on the intended market application and is based on a tradeoff between light utilization efficiency, brightness, power dissipation, lamp technology, weight, volume, and cost. The single-chip projector is self-converged, lower in cost, and permits the very lightest portable designs.
Graphics, text and artwork courtesy of Texas Instruments. Digital Light Processing, DLP are registered trademarks of Texas Instruments.

Fig. 9 One chip Projection System

Page 14

Fig. 10 DLP Light Engine Light Engine Overview


The imager in the light engine is a single DLP device with an array of 1280x720 (921,600) micro-mirrors. Another part of the light engine is the color wheel that is used to sequentially display red, green, and blue images on the imager. The light engine contains a Driver circuit board that contains the TI chipset. Alignment information is stored in a EEPROM located on the engine driver board. These alignments include color temperature and color wheel index. Two cooling fans are located in the light engine, one for the DMD device and one for UHP (Ultra High Pressure) lamp. Color Wheel Operation The color wheel contains 6 segments; 2 reds, 2 greens, and 2 blues and spins at a rate of 120Hz (7200 RPM). This means for every incoming 60Hz frame from the chassis, 12 color sub frames are displayed on the imager at a rate of 720Hz.

Driver CBA

DLP Device Light Tunnel

Fig. 11 DLP Light Engine Page 15

Inputs to Light Engine The inputs to the light engine include the Power Supplies (+2.5VR, +3.3VR, +12VR, +5VR). The Power_Good signal is an active high signal which indicates that all run supplies are at an acceptable level. This signal is used to give the engine an advance warning that the supplies are going down in case of an AC loss. The Power_Good signal must go low a minimum of 1ms prior to the supplies dropping so that the light engine processing circuitry can park the mirrors in a reliable state prior to power loss. Another input is the DVI encoded video from the formatter circuit. Control of the light engine is accomplished via the I2C Run 2 data bus from the DM2CR module.
DVI Video From Formatter CBA

Cooling fans The lamp and DLP device cooling fans are powered by the light engine driver board. The DLP device fan speed is varied depending on the reading a temperature sensor in the light engine driver module. The temperature is monitored by the DM2CR by reading a temperature sensor via the I2C bus. At normal room temperature the fan voltage should be about 8V, but will rise to a maximum of 12V as the room temperature rises. The lamp fan runs at 8 Volts at all times. Fan rotation is monitored by DM2CR. When a stopped or locked fan is detected the DM2CR shuts down the instrument down and fan error codes are logged.

To Lamp Pwr Supply

TxC Tx2 Tx1 Tx0 J5


I2 C_Clk I C_Dat
(RUN 2 Bus)
2

Lamp_en

J4 J3

Lamp On

DLP Processing
DVI Rx Bus Exp RDRAM DDP1010 EEPROM FLASH

Thermal Cut Off


CW Index H

Light Engine Housing


Thermal Cut Off Switch

CW Index L J2 Mtr1 Mtr2 Mtr3

J8 DMD Fan

CW Motor

Pwr_Good P1 +5VR +12VR +3.3VR +2.5VR


LVDS_A LVDS_B

Temp Sensor

Light Engine
From Lamp Pwr Supply

DLP Device

DLP Driver CBA

Fan PWM Fan Detect

Fan Drive

J7 J1 Lamp Fan

Fig. 12 DLP Light Engine Block Diagram

Page 16

Light Engine Start up


Figure 13 shows the start-up sequence of the light engine. The light engine takes approximately 10 seconds to power up and display a picture after the power button is pressed. It takes nearly 25 seconds for the lamp to increase to full brightness.

initialization. The first step is to start the color wheel spinning. This takes approximately 3 seconds until the color wheel locks up at (7200 RPM). 3. When the DLP processing circuitry senses the color wheel is spinning, it will strike the lamp by activating the lamp_en signal to the lamp ballast board. This is a DC voltage and can be measured on connector J4 (4) on the Light Engine driver board. In the standby mode the voltage is ~0 volts. After the color wheel is spinning the voltage increases to 5 VDC and the bulb begins to light. With the screen lit the voltage will be 2.5 ~ 3.25 VDC. 4. The DM2CR microprocessor polls the Ballast_lamplit input pin signal from the light ballast via connector J4(1) to determine if the bulb has been successfully lit. When the micro detects this signal, it then passes it along to the DLP processing circuitry by outputting the User_Lamplit signal.

1. The ACIN run supplies(5VR,


9VR,12VR) and the Power_Good are turned on. These are fed from the ACIN board (P24702) to the formatter board (BP503). The formatter board generates 3.3VR and routes it along with the other supplies on connector BW902 to the light engine connector P1. These voltages can be measured at connector BW902 on the formatter board: Pin 2 (5VR), Pin 3 (Power_Good ~ 3.3Vdc), Pin 5 (2.5VR), Pin 9 (3.3VR) and Pin 12 (12VR). The DM2CR micro then brings the DLP processing circuitry out of reset by writing to the light engine bus expander IC. 2. Once the DLP processing circuitry is brought out of reset the processing circuit micro, DDP1010, on the light engine driver circuit begins

5. When the DLP processing circuitry


detects the User_Lamplit signal, it does a soft reset and is ready to receive I2C commands from the DM2CR and to display video.

Power Power_Good TI_Reset Ballast_Lamp_en Ballast_Txd_Lamplit User_Lamplit DDP1010 State DMD State
Reset Init CW Init Lamp Reset Init I2C I2C Delay Unpark Mirrors Running

Mirrors Parked

Display Image

Fig. 13 DLP Light Engine Startup Sequence Page 17

Sights & Sounds of Startup


1. AC Plug In: A. Relay K24251 located on the power supply board, ACIN, clicks indicating that standby supplies, +/-5Vdc, +12Vdc, +6Vdc, +33Vdc, are up and running. B. Power LED and Porch Light illuminate: DM2CR is booting up, this takes approximately 30-45 seconds. C. Power LED Off: DM2CR has successfully booted up and is in standby mode. 2. Press Power On: Power LED turns on and the DM2CR relay clicks. 3. The run power supplies are turned on (5VR, 9VR,12VR on the ACIN board and the 3.3VR from the formatter board). Power_Good line goes high when supplies are stable. 4. The Color Wheel starts, taking approximately 3 seconds before it locks in @ 7200 RPM. When the Color Wheel is spinning, the Lamp strikes. The lamp becomes brighter and brighter taking approximately 10-20 seconds for the lamp to reach full brightness. 5. The Lamp and DLP fans turns On: The DM2 micro reads the Ballast_lamplit input pin. This signal comes from the ballast and indicates that the lamp has started successfully. When the micro detects this signal, it then passes it along to the DDP1010 by writing the User_Lamplit signal. The fans are turned on by the DDP1010 by it writing the high pulse width bytes to PWM0 (Lamp fan) and PWM1 (DLP fan).
BW902-Formatter Description Pin # Ground 1 5 VR 2 Power Good 3 Ground 4 2.5VR 5 2.5VR 6 Ground 7 Ground 8 3.3VR 9 3.3VR 10 Ground 11 12VR 12 P1-Light Engine Voltage Pin # 0 12 5 Vdc 11 3.3 Vdc 10 0 9 2.5Vdc 8 2.5Vdc 7 0 6 0 5 3.3Vdc 4 3.3Vdc 3 0 2 12Vdc 1

Pin

J4 Connector-Light Engine Description VDC VDC


off

At turn-on

1 2 3 4 5

Ballast Lamp Lit Ground 5VR Ballast Enable Line 5VR

L L 0 0 0

H (5v) 0 5 5 5

VDC run L 0 5
2.5~3.25

Lamp Start-up-Cool Down


When the set is tuned off via the power button or remote, the unit displays a blue screen and slowly dims the screen leaving the lamp and power supplies on for about 20 seconds. During this 20 second interval the user can turn the set back on immediately in case he inadvertently shut it off (refer to Fig. 14). After the 20 second interval, the lamp and DLP fan are turned off but the run supplies and lamp fan are left on for an additional 2 minutes to allow for lamp cool down.

After the lamp is turned off, the user will not be allowed to turn the set on for 30 seconds. If he tries to the power LED will flash which indicates the lamp is in cool down mode. UHP (Ultra High Pressure) lamps can be damaged during a hot strike (when the lamp is turned on before it has had a chance to cool down from the previous on time). Because of this issue the following sequence is used to power up and shut down the lamp.

Page 18

TV & Lamp Off Power On

Video 10 Sec Full Bright 25 Sec Display Mode Power Off Lamp On Video On Power Return Power Loss Lamp Standby Lamp OnVid/Audio Mute Cool Down 'Lamp OffFans On'

Timer (Fans Off)

30 Sec

20 Sec
Timer *

30 Sec

Timer **
2 Min Timer

Pwr On

Fans Off

* If Power On is pressed during the


20 sec Lamp Standby timer, the set returns to normal operation immediately.

** If Power On is pressed during the


30 sec Cool timer, the Power LED blinks.

Fig. 14 DLP Lamp Startup-Cooldown


Power On: T he UHP (Ultra High
Pressure) lamp can be damaged or its life span shortened by turning it on while hot (a hot strike). For this reason, multiple protective measures have been taken in the form of multiple timers. When the Power button on the front panel or the remote control is pressed, the TV & the Lamp turns on immediately.

Display Mode: Both the lamp and the


video and audio are turned on immediately when the power button is pressed. When the unit is powered on, video can be seen in approximately 10 seconds, however full brightness takes approximately 2530 seconds due to lamp warm-up time.

Power Return: In the case of a power


outage, when the power returns a 30 second timer is activated. The unit will not turn back on before the 30 seconds have timed out because the system doesnt know if power was lost for 10 seconds or 10 minutes, therefore the system must ensure that the lamp has cooled before turning on.

Lamp Cool-Down: After the standby timer expires (20 seconds), the lamp is turned off and enters the Cool-Down mode. When the lamp is turned off two timers are activated. The first is a 30 sec. timer that prevents the instrument from being turned on until the cool-down timer has expired. After 30 seconds, the unit can be powered up again. If the Power On is pressed before the 30 second cool down timer has expired, the Power LED blinks slowly. Its important to realize that this is normal and is done to protect the lamp. After the 30 seconds cool down timer expires the unit will start normally. The second is a two minute timer that keeps the lamp fan running to cool the lamp if the unit is left off.
When the set is tuned off via the power button or remote, the unit displays a blue screen and slowly dims the screen leaving the lamp and power supplies on for about 20 seconds. During this 20 second interval the user can turn the set back on immediately in case it was inadvertently shut off. After the 20 second interval, the lamp is turned off but the run supplies and lamp fan are left on for an additional 2 minutes to allow for lamp cool down. After the lamp is turned off, the user will not be allowed to turn the set on for 30 seconds. Attempting to power on the instrument will cause the LED to flash indicating the lamp is in cool down mode.

Lamp Standby: Whenever the unit is


powered off, video is immediately blanked but the lamp remains on. A 20 second timer is activated. This is done in case the customer accidentally turned off the unit or has changed their mind. If power on is pressed before the 20 second timer runs out, video is immediately unblanked.

Page 19

AC In CBA Overview The standby and main (run) power supplies are located on the AC In circuit board. The standby supply is on whenever the unit has 120V AC applied. A voltage doubler is also located on the AC In CBA. This doubler produces the high voltage that is required for the lamp power supply. The relay that routes the AC to the doubler is the relay that is heard when the unit is plugged in. The relay is operated by routing the +12VS voltage through the lamp door switch. This is a safety feature that shuts off the lamp and supply when the customer accessible lamp door is opened. The outputs of the standby supply includes +/- 21V for the Audio circuit board, +6VS, +5VS, -5VS, +12VS and +33VS to the DM2CR. A power fail (PwrFail) signal is generated by the standby supply and is routed to the DM2CR is the event that AC is lost or that supply malfunctions. The PwrFail signal is an early warning for the DM2CR to perform emergency shutdown housekeeping procedures.

J24252

Relay
120VAC

Doubler

To 1 Lamp 2 PwrSupply
1 2 1 2

AC In CBA

Bridge
+12VS

Lamp Door Switch

J24251

Standby Power Supply


+21V -21V +6VS

On/Off

Main (Run) Power Supply


Pwr_Good

J13101

J24603 To Audio CBA 3 +6VS 5 To DM2CR J24604


1

+5VS -5VS +12VS +33VS PwrFail

+12VR

+9VR +12VR

SW
On/Off +5VR

SW
J24602
16 14 To Formatter/Driver CBA 7 4

J24605
6 4 2
To DM2CR

+5VR

8 14 13

J24702

To AV In/Out CBA

Fig. 15 AC In CBA Block Diagram

Page 20

The main (run) supply provides the +5VR and the +12VR that is required by the A/V In/Out circuit board. The +9VR, +12VR, +5VR and the Power_Good signal are generated by the run supply. The Power_Good signal informs the light engine (via the formatter CBA) that

all run voltages are nominal. This signal goes low if the run supply turns off. This allows the light engine to perform preshutdown house keeping functions. The run supply is turn on via the On/Off signal from the DM2CDR (via connector J24605-13).

Standby & Run Power Supply CBA

Fig. 16 AC In CBA

Fig. 17 AC In CBA Service Position Page 21

Ant A Ant B

SPLITTER SWITCH &


256 QAM Decoder

ATSC Tuner & NTSC Main Tuner NTSC Pip Tuner

ATSC

4.5MHz NTSC Audio BPF

DM2CR
J22104
SWITCH_R SWITCH_L AUD_R AUD_L R-Out

VSB Decoder

U11603 Audio

7 To/From 3 AV In 5 Out CBA 1

(2) 1394 Firewire Input 31 29

DTV Decoder
PIP_CV Main CV Y_VOUT1 C_OUT1 Pr_OUT1 Pb_OUT1 Y_VOUT2 C_OUT2 Pb_OUT2 Pr_OUT2

NTSC ATSC Audio


1H CV L-Out

To/From 25 A/V In 27 Out CBA


12 18 14 16

23

U23501 GPIP

U22500 TL851
Video Decoder

SD Video Filter/Buffer

Rec Out

2H Y 2H Pb 2H Pr Horz Vert OSD

D1_Out

9 Bit
Digital Video

HD Video Filters & Buffers

J22104

J22105 DEINT_Y 1 DEINT_Pb 2 DEINT_Pr 5 DEINT_V 7 DEINT_H 9 FSW 13


(2H, 2.14H)

To Formatter CBA

Fig. 18 DM2CR Module Block Diagram


DM2CRCR Module Overview The DM2CR module has 2 RF inputs labeled ANTENNA A and B. Antenna A is input to a Tuner/IF module that contains a tuner section and dual IF section. The tuner is capable of processing both digital and analog RF signals (ATSC & NTSC) from either terrestrial or cable sources. The tuner is a single conversion, electronically aligned tuner with improved crossmodulation, UHF image rejection, and local oscillator phase noise performance over previous tuners. Performance is tailored to handle the predicted signal environment during transition to digital terrestrial television (HDTV) service, 256QAM digital cable, as well as providing cable ready NTSC performance as specified by the FCC. Antenna B input is the PIP tuner and is NTSC only. The DM2CR has 2 DTV Link connectors which are a compressed digital video inputs offering an IEEE-1394 type video connection for consumer devices such as satellite receivers, cable receivers, and digital recorders that meet the specifications for DTV Link. DTV Link is better known as 1394 or FireWire for digital televisions. Audio and video information is carried on a single wire.

Page 22

The DM2CR module contains a GPIP IC (U23501) and performs the following: NTSC processing ATSC decoding Process YPrPb Process S-Video Decode Y+C Adaptive combing composite video Performs PIP function Recover Teletext, closed caption and Gemstar data Digitize all 1H video inputs Outputs digitized YPrPb of

TL851 is an video decoder, display processor with scan rate converter. For 1H video inputs, the output will be upconverted to 2H 480p and the display will be locked to the incoming video. The TL851 recovers HDTV video signals in YPbPr format from digital bit streams output from the VSB (visidual side band) decoder and processes them for display. The HD output will be YPrPb, either 1080i, for HD inputs (1080i, 1080p, or 720p) or 1920x480p for SD (standard definition) inputs. The TL851 also generates the text and graphics for the OSD (on-screen display). The TL851 outputs two types of video, Analog SD video (2H NTSC), Analog ATSC video (YPrPb) along with the appropriate audio. The HD video output provided to the chassis consists of YPrPb, Horizontal and Vertical sync signals.

Audio C A/V In/Out CB DM2CR

DM2CR

Fig. 19 DM2CR Module Page 23

From AC In CBA

BP503

8 13 1 3

BW902
Pwr_Good +5VR +12VR 3

EEPROM
IW501
5 4
Internal Analog ATSC & NTSC From DM2CR

BV401 I2C_CLK
I2C_DAT Y Pr Pb V-Sync H-Sync FSW

(RUN 2) (RUN 2)

+9VR

Dual DC-DC 3.3V/2.5V

To 2 DLP 12 Driver +3.3VR 9 CBA +2.5VR 5

14 10 12 6

V-Sync H-Sync Red Green Blue Red

Vert Tx0 DVI Tx1 2 Tx IW901 Tx2 2 TxC

6 7

(2H) 8 2

BEP
From 5 A/V In/Out 3 CBA

Y Pr Pb V-Sync

IV401

IW601 Blue 8

A/D

Grn

8 8

Lun-IC
IW701

Digital RGB (720P)

FPGA IW801
48bit Vid to 24bit Vid 720P

24bit Vid 720P

18 9 2 23

2 2

To DLP Driver CBA

A/D Clk DVI Output

BW901

(Ext 2H & 8 2.14H) H-Sync 7 BV402

Luma DRAM
IW702/3/4

Chroma DRAM
IW705/6/7

Formatter CBA

Fig. 20 Formatter Block Diagram


Formatter Module Overview The formatter circuit board is responsible for converting the analog video from either the DM2CR and analog inputs from the A/V In/Out circuit board into a format that is compatible with the light engine. DC power for the formatter circuit board as well as the light engine is supplied by the main (run) power supply located on the AC In CBA. These supplies include +5VR, +12VR, +3.3VR and +2.5VR. A Pwr_Good from the run supply is routed through the formatter CBA. This signal tells the light engine that supplies are at nominal value. All functions and circuits on the formatter circuit board are monitored and controlled by the system control microcomputer in the DM2CR. This is accomplished via the RUN 2 I2C clock and data bus. The same I2C bus is also routed through the formatter board to the light engine. The 2H and 2.14H external inputs along with sync are applied to connector BV402. Next it is applied to the BEP (back end processor) for processing into an analog RGB signal. The NTSC and the ATSC analog video signal (2H) from the DM2CR is applied to connector BV401. The video is also applied to IV401 for conversion to RGB. The RGB output from IV401 is then applied to the Analog to Digital (A/D) converter IW601.

Page 24

Its output is 8 bit digital red, green and blue video data stream. This digital video is next applied to the Lun-IC, IW701. IW701 converts the three separate digital video streams to a 48 bit 720P digital RGB signal. This 48 bit signal is then processed by the FPGA IC IW801. The output from IW801 is a 24 bit 720P signal that the DVI transmitter can use. The DVI transmitter IW901 converts the 24 bit signal to the DVI format. These outputs exit the formatter circuit board via connector

BW901 and are sent to the light engines DVI receiver. The DVI transmitter and receiver incorporate HDCP (High Bandwidth Digital Content Protection. The HDCP encryption format covers all high bandwidth applications such as computers, DVD players and HDTV (ATSC). Whenever the connector BW901 is disconnected the DVI transmitter turns off. This is done to protects against and prevents any video pirating. Refer to "Service Tips" for method of checking (scope) the DVI output of the Formatter CBA.

Y BV401-14

Pr BV401-10

Pb BV401-12

DVI Video Waveform BV901-18/9/2/23

Fig. 21 Typical Formatter Input/Output Waveforms Page 25

To/From DM2CR J26903 J26901


FAV AUD IN R FAV AUD IN L FAV H-P R FAV H-P L

7 5
SWITCH_R SWITCH_L

3
SEL_AUD_R

1 21 22
SEL_AUD_L

I2C_CLK

I2C_DAT

6 4 2

+12VR +5VR +12VS

9 7 2 4

37 35

U26901 Aud/Vid Switch


59

From AC In CBA

J26904

Aux R Audio (X4) Aux L Audio (X4)

1 79

61 (RUN 1)

DVI_1 AUDR DVI_1 AUDL

72 70

(RUN 1) 43 (RUN 1) 42

I2C_DAT I2C_CLK (RUN 1)

3 2

A/V Input Output CBA


FAV Headphone R FAV Headphone L

AUD_R AUD_L

To/From Audio CBA 5


7 10 12

J26905

Fig. 22 Audio Switching Block Diagram

Audio Switching Overview The A/V In/Out circuit board is broken down into its two (2) basic functions; these are audio switching and video switching. The audio switching circuitry for the external audio inputs are located on the A/V In/Out module. Source selection for DVI audio and the analog external audio inputs including FAV audio jacks is provided by the audio switching IC U26901. The audio switching is controlled via the I2C RUN 1 bus from the DM2CR module. Also the DM2CR module performs demodulation of the audio from off-air sources (NTSC and ATSC). These off air baseband audio sources from the DM2CR is routed through the A/V In/ Out circuit board to the Audio board for final processing. The external audio input jacks are located on the A/V In/ Out circuit board. L/R inputs include audio from Aux1, Aux2, Aux3, Aux4 and DVI. The Front Audio Video (FAV) panel has one set of L/R audio jacks that is applied to the switching IC

Page 26

U26901. The selected baseband audio signal output from U26901 is looped through the DM2CR module and back to the A/V In/Out CBA where it then sent to the audio processing circuit board. The FAV Headphone L/R audio from the Audio board is simply routed through the A/V In/Out board to the FAV. When the DVI audio input is selected it is

routed to the DM2CR for decoding into analog audio and is then routed back through the I/V In/Out CBA and on to the Audio circuit board for final processing. Power supplies for the A/V In/Out board include the +12VR, +12VS and +5Vr and is supplied by the AC In CBA.

Fig. 23 A/V In/Out CBA Service Position

Page 27

U11501 11 4 12 13 3 BUS 15 EXPDR


I2 C_DAT (RUN 1)

FAV_SPKR_MUTE SUB_CONT TRUS PA_MUTE I2C_DAT (RUN 1) I2C_CLK (RUN 1) 19 20

Sub Woofer

Ext Spkr

Cntr Spkr

Int Spkr

24 R 8 I2C CTL 9 3 7 11 7 PA_R 11 PA_L L 6

(RUN 1) I2C_CLK

9 TRU SUR- 10 ROUND

R_OUT L_OUT

42 MDR 43 MDL R L 1 TR 44 TL 41 CDR 40 CDL

U11702
3 5 1

3 2

U11701
15 16

To/From A/V Input Output CBA

U11551 5 7 AMP 2 1
R_AUD L_AUD

AMP 7

VOL 26 EQU BAL 28

U11801 AUDIO

SW11902 Power Amp

AUDIO CBA
10 12 FAV_Headphone_R FAV_Headphone_L

U11490
3 1 6 7

U11460 1 3
5 7

Audio OUT

J11501

Fig. 24 Audio Processing Block Diagram Audio Processing Overview


All of the audio circuitry is located on three assemblies. The audio switching and the audio jacks are located on the A/V In/Out CBA. The DM2CR module performs demodulation of the audio from off-air sources (NTSC and ATSC). The Audio circuit board performs the base-band audio processing such as volume control, graphic equalizer, subwoofer output, and power amplification along with speaker switching. The audio circuit board also contains the SRS and Tru Surround feature processing circuitry. The analog audio from the DM2CR is routed back to the A/V IN/OUT board where it is cabled to the Audio board. There it is input to a differential amplifier, U11551. This amp is used to eliminate ground loops caused by the long cable routing. The output of U11551 is fed to the input of the SRS/FOCUS processing blocks, U11701 & U11702, and directly to one input of the audio processor, U11801. The processor selects one of three inputs, the direct signal (no SRS) from U11551, Regular SRS or TruSurround from U11701 or SRS/ FOCUS from a combination of U11701 and U11702. The analog input for the SRS/ TruSurround circuit is taken off the output of the amplifier, U11551. These produce two signals which are sent to inputs on the audio processing IC, U11801, along with the direct signal. The processor IC selects which input signal is required for the customerselected mode. The first block, composed of IC U11701, performs either Regular SRS or TruSurround. The second block, composed of IC U11702 performs Focus mode.

Page 28

Regular SRS mode is selected by using the midpoint of the output of the SRS block and placing it in Regular mode. Focus is always on but its output isnt selected. SRS Focus mode is composed of Regular SRS plus Focus. The SRS block is placed in Regular mode and the Focus output is also selected. TruSurround mode is selected by placing the SRS block in TruSurround mode and using its output. The audio processor (U11801) has three input signals applied to the selector, direct audio from U11551, SRS from U11701 and Focus from U11702. After the signal is selected in the processor, volume control is applied. The DLP system does not have a separate tone control function but a 7-band graphic equalizer is available. After the equalizer, L and R signals are summed and split off to form two signal paths. The summation stage output signals are run through a highpass filter for the main channels, and a matching lowpass filter for the subwoofer. The subwoofer volume is therefore controlled by the main volume, but a fader is provided in the subwoofer path (accessed by the Subwoofer Level menu) so that its level may be adjusted relative to the

main channels. Three analog outputs from the processor provide the Left, Right, and subwoofer signals. The PA_L and PA_R audio signals from the audio processor are routed to three circuit areas, first to U11460, which drives the HiFi Output jacks located on the Audio module, second to the main power amplifier, U11901 and third to the headphone amplifier, U11490. The output of U11490 is routed through the A/V IN/OUT module to the headphone jack which is located on the FAV module. The subwoofer output from the processor is routed to connector, J11801. The subwoofer amplifier module plugs into this connector. Also present on the connector are two control lines that sense the presence of the subwoofer option and turn the amplifier and power supply off and on. As mentioned previously the Audio module also contains a bus expander,11501, that is connected to the system microcomputer inDM2CR via the I2C bus. The bus expander on the Audio Module uses its ports to select the following functions, FAV Speaker Mute, SubWoofer Control, SubWoofer Detect and Power Amp Mute.

Fig. 25 Audio Processing CBA Service Position Page 29

J26901 FAV CV FAV Y FAV C


6 10 12

A/V Input/ Output CBA


68 75 30 71 62 50 52 54 57 58 60 49 Combed C

Main CV Y_VOUT1 C_OUT1 Pr_OUT1 Pb_OUT1 Y_VOUT2 C_OUT2 Pb_OUT2 Pr_OUT2

J26903

Aux CV (X4) Aux Y/C (X2) Aux Y (X2) Aux Pr (X2) Aux Pb (X2)
I2 C_Clk I2 C_Dat

32 28 23 8 6 2 1H Video Switch U26901

31 29 23 25 To 27 DM2CR 12 18 14 16

I2 C_Clk

42 (RUN 1) 43 (RUN 1)

34 65 64

8 To Formatter 6 CBA 4 2 1

J28901 HD_Y HD_PB HD_PR HD_H HD_V (External 2H & 2.14H)

35 27 26 25 22 23

33

34 1 DVI_R DVI_G DVI_B DVI_HSYNC DVI_VSYNC


I 2 C_Dat

83 Frame 46 84 Comb 47 (RUN 1) Combed Y 93 U16301 Sel. CV I 2 C_Dat RX0 (+/-) RX1 (+/-) RX2 (+/-) TXC (+/-) 17/18 9/10 1/2 23/24 J22201
I2 C_Dat

U28901 2H Video Switch 30 31

23 18 31 26 19
I2 C_Clk

4 2 3 5

2/3 DVI Receiver 51/52 U22201 48/49 5/6 15 14

DVI Input

I2 C_Clk

(RUN 1)

(RUN 1)

Fig. 26 Video Switching Block Diagram Video Switching Overview


The A/V In/Out circuit board is broken down into its two (2) basic functions, video switching and audio switching. The A/V In/Out circuit board has external input jacks that accepts four Composite Video (CV), two S-Video, two component video (YPrPb) and one DVI digital video. The video inputs on the A/ V In/Out board can be either 1H NTSC, 2H NTSC or 2.14H NTSC. The Front A/ V (FAV) panel has one component video input as well as a S-Video connector which is routed through the A/V In/Out CBA. The A/V In/Out CBA also has a DVI input. DVI (Digital Video Interface) combined with HDCP (Hi-Bandwidth Digital Copy Protection) creates a new uncompressed protected digital interface (called DVI-HDTV) for hooking an HD Monitor to a Video Source (for example, a set-top box or DVD player). This interface is not only uncompressed, but it is also high speed (3.96 GB/s) making it a perfect solution when the best picture quality and minimal signal loss are required.

Page 30

Fig. 27 A/V In/Out CBA Service Position

The DVI receiver IC U22201 decodes the DVI video and then outputs RGB with horizontal and vertical sync. This signal is then applied to U28901 for switching and matrix conversion to YPrPb. This YPrPb video is then routed directly to the Formatter circuit board. The switching for NTSC/1H sources (composite, S-Video, and component) is provided by IC U26901 for rear input jacks and the FAV jacks. All video switching ICs are monitored and controlled via the I2C bus.

A frame comb filter is provided to optimally comb any composite source into an S-Video (Y/C) output source which is routed back into U26901. All composite and luma inputs to U26901 have sync detectors that are readable via the I2C bus which allows for automatic source detection. Source selection for HD/2H/2.14H sources (component and DVI) are provided for rear inputs (2 component and 1 DVI) with the IC U28901. This IC is a 4-input video switch with signal format detection.

Page 31

A/V In/Out DM2CR


2

J22104

21 20 21 Run1 20 10 Run2 11 5 4 J26903

3 2 J26905

3 2

Audio Processing
J11501

I C Clk

Sys Con U13100

I 2C Dat I 2C Clk I 2C Dat


J22105

Formatter
BV401 BW901

6 7

J5

Light Engine

Fig. 28 AC System Control Block Diagram


System Control Overview The system control microcomputer for the HDLP50W151 is IC U13100 and is located in the DM2CR. The system control micro is responsible for monitoring and controlling the A/V In/Out CBA, the Audio Processing CBA, the Formatter circuit board and the Light Engine. There are two busses, the Run1 buss and the Run2 buss. The Run1 buss controls the A/V In/Out CBA and the Audio CBA. The Run2 buss controls the Formatter and Light Engine. Its important to realize that if the DM2CR does not see the Formatter and/or Light Engine the DM2CR goes into what is referred to as a Stand Alone Mode. In this mode the DM2CR will output video even if the Formatter and/or the Light Engine has failed. If the Run2 I2C buss is pulled low by a failed light engine, the I2C buss will return on the formatter circuit board if connector BW901 is disconnected. If disconnecting BW901 does not return I2C operation then the formatter circuit board is responsible for pulling down the I2C buss. The photo below indicates a convenient point to check the I2C buss.

Fig. 29 Formatter I2C Test Point Location Page 32

Service Tips
. 1. If light engine has entered cool down mode (30 sec timer), Power LED blinks slowly 3 times if power on button is pressed. Unit will turn on after timer has expired. See Lamp Startup/Shutdown Flowchart. 2. When AC is applied, instrument will not respond for 50 to 60 seconds. The DM2CR module must boot-up and perform internal diagnostic. 3. The lamp cooling fan and the DLP device fan operates whenever the unit is turned on. If failure in fan circuit occurs, unit starts up normally (with video) then shuts down. 4. Before replacing light engine, always confirm picture quality issues by accessing the test patterns in the service menu 80. All patterns accept the checker board are generated by the formatter CBA. The checker board is generated by the light engine. 5. The Safety Interlock Switch must bypassed whenever the rear cabinet is removed for service (see photo below). The connector can jumped or the switch can be taped closed.

Jumper with alligator clip

Page 33

6. To scope the DVI output of the formatter CBA see test points in photo below. Do not disconnect the DVI connector or the transmitter on Formatter will turn off. See page 25 of training manual.

Use formatter case as ground

Typical Waveform

Service Menus & Diagnostics


Service menus and diagnostics procedure are critical to effectively diagnose failures and problems in the instrument. The following is a summary of the HDLP50W151 service menus. Service Menu (V:76): Turn instrument on, then press and hold Channel Down & Menu simultaneously. Next, select Service Alignment in menu, then volume Up to V:76 then Channel Up and Down to desired adjustment. After selecting adjustment, Volume Up/Down changes value of adjustment. Press off to exit. Test Patterns (V:80): Enter service menu and volume up to V:80. Channel up to the patterns. The skip button toggles the pattern and the menu button toggles between the pattern and normal video. To exit, press the off button. Usage Clock (V:90): Enter service menu and volume up to V:90. Channel up for usage clock. Press off to exit. Error Codes (V:50): Enter service menu and volume up to V:50. Channel up for first failure code. Channel up for next of 8 failure codes. Pressing clear removes error code. Last error is most recent failure code. I.E: if four (4) errors are listed, four is the most recent. To exit, press the off button.

Page 34

DLP Service & Troubleshooting


DLP Light Engine
The following information describes the normal start-up and cool down sequence of the DLP Light Engine. Understanding how the light engine starts and stops will help in troubleshooting the instrument. which strikes the lamp. It takes approximately 1020 seconds for the lamp to reach full brightness. The DC voltage decreases to 2.5 ~ 3.25Vdc. 6. The Lamp and DLP fans turn On. The DM2CR micro reads the Ballast_lamplit input pin J4 (1) on the light ballast. This signal comes from the ballast and indicates that the lamp has started successfully. When the DM2CR micro detects this signal, it then passes it along to the DDP1010 by writing the User_Lamplit signal. The fans are turned on by DDP1010 writing the high pulse width bytes to PWM0 (Lamp fan) and PWM1 (DLP fan). The connectors J1 (1) (Lamp Fan) supplies 8 Vdc to cool the bulb. The DLP fan is connected to J7 (1) (DMD Fan) and supplies 8 ~12 Vdc to operate. 7. Video should now be present on the screen.
Pin

Turn-on Sequence
1. AC Plug In: A. Relay K24251 located on the ACIN board clicks indicating that standby supplies, +/5VS, +6VS +33VS, are up and the 300 V supply is present at connector X1 on the Light Ballast power supply. B. Power LED and Porch Light illuminate: DM2CR software is booting up, this takes approximately 30-45 seconds. C. Power LED Off: DM2CR has successfully booted up and is in standby mode. 2. Press Power On: Power LED turns on and the DM2CR internal relay clicks. 3. The ACIN run supplies are turned on (5VR, 9VR,12VR). These are fed from the ACIN board (P24702) to the formatter board (BP503). The formatter board generates 3.3VR and routes it along with the other run supplies on connector BW902 to the light engine connector P1. These voltages can be measured at connector BW902 on the formatter board: Pin 2 (5VR), Pin 3 (Power_Good ~ 3.3Vdc), Pin 5 (2.5VR), Pin 9 (3.3VR) and Pin 12 (12VR). 4. The Color Wheel starts turning taking approximately 3 seconds before it locks in @ 7200 RPM. 5. The lamp_en signal, 5Vdc, on the Light Engine driver board J4 (4), is sent to the lamp ballast board

J4 Connector-Light Engine Description VDC VDC


off

At turn-on

1 2 3 4 5

Ballast Lamp Lit Ground 5VR Ballast Enable Line 5VR

L L 0 0 0

H (5v) 0 5 5 5

VDC run L 0 5
2.5~3.25

Lamp Cool Down Sequence


There are three timers associated with the cool down procedure. 1. The first, a standby timer, is engaged when the power off command is received. The video & audio are muted leaving the power supplies and fans on for 20 seconds. The screen turns blue and slowly fades out even though the bulb is still lit. During this 20 second interval the user can immediately turn the set back on. 2. Second after the standby timer expires the lamp is turned off and the instrument enters the CoolDown Mode. When the lamp is turned off, the user will not be allowed to turn the set on for 30 seconds. During this 30 seconds the run supplies and Lamp fan continue to run cooling the lamp. If a Power On command is received before the 30 second cool down timer has expired, the Power LED will blink slowly. After this timer expires the unit will start normally. If there is a power loss after the power has been restored this 30 second timer is also activated. 3. The final cooldown timer is a two minute timer that allows the Lamp fan to continue to run cooling the lamp after the standby timer expires and the lamp is turned off.

BW902-Formatter Description Pin # Ground 1 5 VR 2 Power Good 3 Ground 4 2.5VR 5 2.5VR 6 Ground 7 Ground 8 3.3VR 9 3.3VR 10 Ground 11 12VR 12

P1-Light Engine Voltage Pin # 0 12 5 Vdc 11 3.3 Vdc 10 0 9 2.5Vdc 8 2.5Vdc 7 0 6 0 5 3.3Vdc 4 3.3Vdc 3 0 2 12Vdc 1

Page 35

DLP Service & Troubleshooting

Important: Before replacing any circuit boards, recover the "Failure codes using Chipper Check.
Also, its very important when troubleshooting to accurately identify the symptom in order to quickly isolate which circuit board or item has failed.

Symptom: Cycles, Shutdown, No Start

Plug set in.

1A

1B Check lamp switch and power supply voltages: +/-5,6,33 VS and the 300V supply

Do you hear the relay K24251 click ?

NO

YES 2A 2B Does the power LED light and then turn off ? NO Are the power supply voltages supplied to the DM-2CR Module correct? 2C NO Suspect Power supply problem

YES YES Continue to page 37. 2D Suspect DM-2CR module problem.

Page 36

3A Press power button.

4A Does the power LED light up or flash and the relay click ?

4B Inspect ALL Cables for proper seating. Replace any that appear to have been stressed.

NO

YES 5A Check connector P1 on the LIght Engine for the following run voltages. Pin 2 5 VDC Pin 3 3.3 VDC Pin 9 3.3 VDC Pin 12 12 VDC

6A Are they correct ?

6B Suspect power supply voltages and Formatter PCB.

6C Suspect DM2-CR Module

NO

NO

YES 7A Do you hear the color wheel spinning at least momentarily? NO 7B 7C NO Contact Tech-Line for further assistance

Hookup Chipper Check and review the error codes. Attempt a Hardreboot.

YES

Continue to page 38

Page 37

8A

8B If missing, suspect formatter/power board

Check on J4(3,5) for 5VR at turn on.

NO

NOTE J4(4) Connector-Light Engine Ballast enable line 0VDC in Stby, 5VDC at turnon, 2.5~ 3.25 in run 9A

YES

9B

9C Unplug J4 connector and recheck pin 4 on the light engine Suspect Lamp ballast power supply

Is the lamp being struck (lit)? Refer to note for measurements

NO

NO

YES 9D YES Physically inspect the connector on the lamp power supply. NO

10A

10B Does the bulb increase up to full brightness? Physically inspect the Lamp and connector

10C Contact Tech-Line for further assistance

NO

NO

NOTE J4 (1) connector is low in standby goes H (5VDC) at turn-on then low for the run mode

YES

11A

11B

Check J4(1) connector for the correct voltage. Refer to note.

NO

Suspect Lamp ballast power supply

NO

Suspect DM-2CR

YES

Contact Tech-Line

Page 38

Symptom: Stuck pixels (Black and/or White)


1. The stuck pixel specification is 0 for stuck on (bright) and 2 for stuck off (dark) anywhere on screen. 2. Access the test patterns in the service menu 80. Using either the info. button or the skip button on the remote control select the White Screen for dark pixels or the Dark Screen for bright pixels.
PATTE R N B order C rosshatch Verti cal Li nes Hori zontal B order Li nes Hori zontal Li nes C rosshatch RGB C olorbar Whi te S creen B lack S creen B W C hecker B oard S OU R C E DM DM DM DM DM DM DM DM Li ght E ngi ne

Symptom: Pixelization, Digital Freezing &/or Digital Noise/Artifacts


1. Check for a weak ATSC terrestrial (check strength of terrestrial signal) signal can cause pixelization or freezing. An external antenna can dramatically improve ATSC reception. If signal is OK go to next step. 2. Check operation of PIP, NTSC input, ATSC input, OSD and On Screen Guide. If any of these modes function OK, suspect DM2CR. 3. Go to service menu #80 and toggle to the checkerboard pattern. If the unit displays the symptom suspect the Formatter CBA. If the display is OK, suspect DM2CR. 4. Apply 2H YPrPb to an external input. Applying a 2H signal to an external input bypasses around the DM2CR and is input directly into the Formatter CBA. If problem remains suspect the Formatter CBA. If the problem is not present on the external input, suspect the DM2CR.

Page 39

Symptom: Instrument starts up normally with video then shuts down (Instrument runs 20-30secs)
Note: When unit shuts down, Power LED blinks three (3) times. Set restarts automatically after 20-30 seconds. Unit continues to cycle 1. Suspect failure of lamp cooling fan or DLP device cooling fan.

Symptom: Poor Picture Quality (spots, discoloration, color impurities, etc.)


1. Whenever dealing with picture quality issues, always check the quality of signal source before servicing unit. 2. Supply a 2H signal into the component inputs and see if the quality of the picture increases. If so, suspect a problem in the formatter or DM-2CR. 3. Access the test patterns in the service menu #80. The formatter CBA generates all patterns except the checkerboard. The light engine generates the checkerboard pattern.

Symptom: Rotated or Offset Picture


1. Perform mechanical rotation adjustment of light engine and/or use service menu 76 to adjust horizontal and vertical centering.

Symptom: Dead Set, Power LED stays ON when AC is applied


(relay will click when the AC is applied) 1. The DM2CR is powered by the standby supply and when AC is first applied the DM2CR goes through a boot up sequence. If the Power LED remains on when AC is applied (should go off in 20-25sec), the DM2CR is not booting up properly. Refer to page 17-18 for the startup sequence.

Page 40

NOTES

Page 41

TDLPTRNGMAN1

Printed in USA

Chassis Part Symbol Defective Circuit ATC311B LW907 ATC311B K24251 ATC311 Q24606 Power Supply Power Supply Power Supply Power Supply

Symptom Replaced the lamp and the ballast but still no lamp, no dc at pin 5 or 6 of BW902. Found bad connection at LW907. The lamp does not start, the color wheel starts and stops. Found no dc at J24252, relay K24251 open coil.

solution Resolder LW907 Replace relay K24251

No audio, no Color in 1H mode. HD worked ok, found one leg of Q24606 broken (12VDC). . replace Q24606 Unit going into shutdown. Three blink error code. Neither fan would run and light would not light. J24702 was found loose going to the formatter board J24702 The picture would go off after a short period of time. The tuner and audio was still working. Found the AC interlock causing the problem, the little plastic arm appeared to cause. You Secure interlock would hear the color wheel start up and then stop. switch SW13101.

ATC311B J24702

ATC311B SW13101

Power Supply

Chassis

Part Symbol Defective Circuit

ATC311B Ligh Engine Video

Symptom solution Color spot on the screen, looking at the lens though the lamp found a piece of plastic. removed the plastic and now it's fine remove plastic

DLP ALIGNMENT PROCEDURES


Operating Conditions Unless otherwise noted, the following conditions must be observed when aligning the TV: 1. Chassis must be operated from a 120 VAC isolation transformer with line voltage set to 120 VAC. 2. All voltages and waveforms referenced are with respect to Ground 3. A 10X probe must be used for oscilloscope and frequency measurements. TV Service Screen The service screen is provided to facilitate instrument alignment and service adjustments. The service screen is accessed by pressing a two-button combination on the front control panel of the instrument.
Using the Front Panel Controls to enter Service Screen

DLP ALIGNMENT PROCEDURES


3. Once a parameter (P) has been selected for a particular alignment the VOLtand VOLu buttons can be used to change the value (V) of the alignments selected. Most Electrical adjustments for the DLP instrument must be done using Chipper Check. 2. Press Volume Up Until V is 50. 3. Press Channel Up to View The First Error. 4. Press Channel Up/Down to View the Next/Previous Error. 5. Press Clear to Clear the Error Code that is Currently Being Displayed. 6. Press Power Off to Return to the P:0 V:50 Display. 7. Press Power Off Again to Return to Normal TV Viewing. To use the Error Code charts, first look up the Type displayed in the error code (Fig. 4). Then find the Type number (Hex) in the first error code chart (Fig. 5). The description column indicates the general area of the problem and the Detail column gives additional information for some Error Codes. If the Error Code Type is 21 or 22, additional information is available as shown in Fig. 6. Refer to the last string of hex characters referred to as Data or Code in Fig. 4. The first two characters hex value of the string refer to the Chip information in Fig. 4. The second two characters hex value in the string refer to the Bus information in Fig. 4. The third two characters hex value in the string refer to the Details information in Fig. 4. If the Error Code Type is 41, additional information is available as shown in Fig. 5. Refer to the last string of hex characters referred to as Data or Code in Fig. 2. The firsttwocharacters hex value refer to the Watchdog information in Fig. 5.

Error Codes
If certain failures occur in the chassis, error codes will be stored in the chassis EEprom. These error codes can be accessed by entering the service menu and setting the VALUE to 50. With the VALUE set to 50, pressing the Channel up button will toggle through the 6 error codes. Error code 0 stores the error code for the first failure experienced by the instrument. Similarly, error code 1 stores the error code for the second failure. Error code 2 stores the error code for the third failure. Error code 3 displays the error code for the most recent failure experienced by the instrument. Information is displayed in the following order: Error #, Date, Time, Type, Count, Code. If an Error of the same TYPE is already logged, then the error will overwrite the existing error of that type and the count will be increased. Error codes are summarized in Fig. 5. The presence of Empty for the error code indicates that no failures have occurred since the time the error codes were reset. The error codes can (and should) be reset to 0 after servicing. Press the clear button to clear the error code that is currently being displayed. 1. Enter the Service Menu.

Service Alignment Selection 3. Press Menu on the keyboard or OK on the remote control to activate the Alignment Screen.

1. Turn on the TV and select the channel that will be used for the alignment procedure. 2. With the instrument ON press and hold the Menu button and then the CHq button. 3. The TV set should immediately display the service screen Menu as shown.

Service Alignment Screen 4. Once the Alingment Screen has been activated use the VOLu button on the keyboard or remote to adjust the value (V:0) to the desired value. Service Screen
Entering the Service Alingment Mode

1. Bring up the Service Screen. 2. Once in the service screen use CHq button on the keyboard or the down arrow on the remote control to highlight item 2 Service Alignment.

NOTE: When the service mode is accessed, the parameter will be 0. Parameter 0 is used to input the security code. The security code is necessary to protect the factory alignments from inadvertent modification. Attempting to change the parameter (P) using CHq or CHp before the proper security code has been entered will cause the instrument to exit the service mode. A valid security code is entered (using VOLtor VOLu). Security Codes When the Service Alignment Screen is first entered, the parameter (P) will come up set at 0, which corresponds to the security code function. 1. With the parameter (P) set to 0 adjust the value (V) (using VOLtor VOLu) to 76 for access to the Electrical Alignments. Once the security code has been set, individual alignments can be accessed by pressing CHq or CHp changing the parameter (P) number.

Error # Date Time Type

Count

Code

0: 0.0.0 0:0:0 Type=21 Count=4 Code = 4002010000000000

Fig. 4 Error Code Screen

2.

Page 3-1

Page 3-2

DLP
Type (hex) 1 2 Description Chassis (General) Convergence 0 0 30 31 32 33 34 35 36 10 14 15 16 11 12 13 0 0 40 41 42 43 44 45 46 47 1 0 0 0 0 0 0 0 0 Data ("Code") (hex) 2 3 4 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Additional Data Additional Data Additional Data Additional Data 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 5 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 6 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 7 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

DLP
Additional Data Description IIC Errors ("Code") 21,22,23 Bus 0 5 Bus 1 Run 1 Bus 2 Run 2 Bus 21,22 Details 1 chip did not acknowledge when was expected to 2 some hardware error detected, maybe one of the lines is grounded 3 some software error, e.g. not enough memory, or could not acquire the mutex to the driver Chip Bus Module Comment 1E 5 Bus DM2CR Broadcom VSB/QAM 34 Run 2 Driver DDP1010 Light Engine Controller 40 Run 2 Deflection Deflection DAC 42 Run 2 Driver PCF8574 I/O Expander 50 5 Bus DM2 VSB 54 5 Bus DM2 GPIP 54 Run 2 Formatter Lunar IC 58 Run 2 Formatter Ortho FPGA 5A Run 2 Driver AD5241 70 Run 2 Formatter DVI Transmitter 74 Run 2 Driver DVI Receiver 78 Run 1 Audio Audio Bus Expander 80 5 Bus DM2 Micronas Audio Processor 84 Run 1 A/V Input CXA2151 2H Switch 88 Run 2 BEP TA1316 Back End Video Processor 88 Run 2 Formatter TA1360 Back End Video Processor 8C Run 1 Audio Sound Processor 8C Run 2 Deflection TA1317 Deflection Processor 8E 5 Bus DM2 Dual IF 90 Run 1 A/V Input LA79500 1H A/V Switch 92 Run 2 Driver LM75 Digital Temperature Sensor 98 Run 2 Formatter AD9883A A/D A0 5 Bus DM2 DM2 Main EEProm A0 Run 2 Deflection Deflection EEProm (lower 256 bytes) A0 Run 2 Formatter Formatter Eeprom (lower 256 bytes) A2 Run 2 Deflection BEP EEProm (upper 256 bytes of Deflection EEProm) A2 Run 2 Formatter Fomatter Eeprom (upper 256 bytes) A4 5 Bus DM2 Tuner EEProm AA Run 2 Service Module MD2 VGA Eeprom AC Run 2 Driver MD2 Driver Eeprom (lower 256 bytes) AE Run 2 Driver MD2 Driver Eeprom (upper 256 bytes) B0 5 Bus DM2 Link Lock B8 5 Bus DM2 Link Lock B8 Run 1 A/V Input Frame Comb C0 5 Bus DM2 PIP Tuner C4 5 Bus DM2 Main Tuner PLL C6 5 Bus DM2 Main Tuner DAC DC Run 2 Convergence Convergence Micro

Chassis Power

4 5 6 7 8

Deflection XRP Back End Processor Back End Video DLP

Parity Error Loop Fault Output Inactive Bus Fault Other I2C REF_EE Initial Power Fault Other Invalid Handle Power Supply Fault EEProm Corrupt POR XRP BEP POR Algorithm Error Driver Fan Fail Lamp Fail No Lamp Strike No Lamp Lit Color Wheel Lamp Shutoff UART Status DDP1010 Reset

0 0 0 0 0

Data

21 22 23 31 32 41 51 61

IIC Read IIC Write IIC Bus Latched App (General) Reset Count Watchdog Guide Audio

Process Termination Audio Exception

0 0 0 0 0 0 0 0 0 0 ignore 0 0 0 0 0 0 ? ? ? ? ? ? ? ? Reset Count 0 0 0 0 0 0 Task Id Task Id Task Id Task Id Task Id Task Id Task Id Task Id Process Exit Code 0 0 0 0 0 0 0 0 0 0 0 0

Chip Chip

Bus Bus Bus

Details Details

Fig. 5 Error Code Chart

Additional Data Description (Type 32) This is a count of all system resets since the field code was last cleared. This includes AC dropouts, forced system resets in the code, and resets due to unknown causes.

Fig. 6 Error Code Data

DLP
Additional Data Description (Type 41) The first Task Id is the first task to count down to zero. The remaining 7 Ids are any tasks whose counts are at or below 16. Thread Name Hex Value Thread Name UNKNOWN_TASK_ID = 0, APG_TASK_ID, AV_MAIN_DRV_TASK_ID, AV_PIP_DRV_TASK_ID, CA_MAIN_TASK_ID, CA_PIP_TASK_ID, CC_TASK_ID, CC_DRAW_TASK_ID, CHANACQ_MAIN_TASK_ID, CHANACQ_PIP_TASK_ID, CHANEPG_MAIN_ENUM_TASK_ID, CHANEPG_PIP_TASK_ID, CHANEPG_VBI_TASK_ID, CHANEPG_RECORD_TASK_ID CHANEPG_1394_TASK_ID COMPORT_TASK_ID, DC_TASK_ID, EEPROM_TASK_ID, EPG_ACQ1_TASK_ID, EPG_ACQ2_TASK_ID, EPG_ACQ3_TASK_ID, HWCTRL_TASK_ID, ICP_TASK_ID, IIC_IST_TASK_ID, LINE_SELECT_ID, OSD1394_CONS_TASK_ID, OSD1394_PROD_TASK_ID, POWERFAIL_TASK_ID, SCHED_TASK_ID, SWITCHING_TASK_ID, TIMER_TASK_ID, TRANSPORTLILIB_DATA_TASK_ID, OBSOLETE_01_TASK_ID, OBSOLETE_02_TASK_ID, TPSIMULATOR_TASK_ID, IEEE1394TASK_ID, IEEE1394_MON_TASK_ID, TUNER0_ATSC_NTSC_ID, TUNER1_NTSC_ID, UI_TASK_ID, UPG_TASK_ID, WATCHDOG_TASK_ID, TV_PWR_TASK_ID, SOCK_CLIENT_TASK_ID, VIDEO_CCD_TASK_ID, FACTORY_TASK_ID, MODE_DETECT_TASK_ID, DEFLECTION_TASK_ID, BEP_TASK_ID, CHASSIS_REFRESH_TASK_ID, PIP_MOVEMENT_TASK_ID, PIP_VERTICAL_TASK_ID, DM2_TASK_ID, IE_MONITOR_THREAD_TASK_ID, IE_MAINWND_TASK_ID, AUDIO_APU_TASK_ID, PER_UPD_TASK_ID, AV_DRV_AUDIO_STATUS_TASK_ID, PipXDSDataThread, CHAN_ACQ_0_STATE_TASK_ID, CHAN_ACQ_1_STATE_TASK_ID, HWCTL_LINE_MON_TASK_ID, HWCTL_POWER_STATUS_TASK_ID, FLASH_TASK_ID, 00 1 2 3 4 5 6 7 8 9 A B C D E F 10 11 12 13 14 15 16 17 18 19 1A 1B 1C 1D 1E 1F 20 21 22 23 24 25 26 27 28 29 2A 2B 2C 2D 2E 2F 30 31 32 33 34 35 36 37 38 39 3A 3B 3C 3D 3E 3F SOCKET_IN_TASK_ID, SOCKET_OUT_TASK_ID, SOCKET_ERR_MON_TASK_ID, OBSOLETE_03_TASK_ID, TUNER0_MONITOR_THREAD_ID, TUNER1_MONITOR_THREAD_ID, IE_MONITOR_TASK_ID, AUDIO_STATUS_TASK_ID, FPA_SCAN_TASK_ID, FPIR_TIMEOUT_TASK_ID, FPIR_REM_TASK_ID, FPIR_KBDKY_TASK_ID, FPIR_KBDPTR_TASK_ID, FPIR_KEYUP_TASK_ID, FPIR_KEYREPEAT_TASK_ID, KEYMGR_TASK_ID, SockThreadIn_TASK_ID, SOCKET_CLIENT_TASK_ID, SOCKET_CLIENT_ERR_TASK_ID,
AV_DRV_VIDEO_STATUS_TASK_ID,

DLP
Additional Data Description (Type 51) The guide process should never terminate so if it does die, the exit code will likely be one of the following exception values: Exception Exception Value ACCESS_VIOLATION DATATYPE_MISALIGNMENT BREAKPOINT SINGLE_STEP ARRAY_BOUNDS_EXCEEDED FLT_DENORMAL_OPERAND FLT_DIVIDE_BY_ZERO FLT_INEXACT_RESULT FLT_INVALID_OPERATION FLT_OVERFLOW FLT_STACK_CHECK C0000005 80000002 80000003 80000004 C000008C C000008D C000008E C000008F C0000090 C0000091 FLT_UNDERFLOW INT_DIVIDE_BY_ZERO INT_OVERFLOW PRIV_INSTRUCTION IN_PAGE_ERROR ILLEGAL_INSTRUCTION NONCONTINUABLE_EXCEPTION STACK_OVERFLOW INVALID_DISPOSITION GUARD_PAGE INVALID_HANDLE

Hex Value 40 41 42 43 44 45 46 47 48 49 4A 4B 4C 4D 4E 4F 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97

Value
C0000093 C0000094 C0000095 C0000096 C0000006 C000001D C0000025 C00000FD C0000026 80000001 C0000008

Fig. 7 Error Code DataFig.

RTC_TASK_ID, IEE1394_CA_TASK_ID, FIREWALL_TASK_ID EEPROM_CALLBACK_TASK_ID, EEPROM_WD_TASK_ID, XDS_TASK_ID, DLP_TASK_ID, MODELLIB_TASK_ID, IEEE1394INPUT_TASK_ID, IEEE1394OUTPUT_TASK_ID HDCP_TASK_ID,

DLP ALIGNMENT PROCEDURES Vertical and Horizontal Centering


Vertical and Horizontal centering adjustments should only be performed after replacing the Light Engine.
Accessing Internal Test Patterns 9. Pressing the Power or On/Off button on the keyboard or remote control will cause the instrument to exit the adjustment mode and return to the (P:0) (V:80) display. Mechanical Picture Adjustment

DLP
1. Turn on the TV and select the channel that will be used for testing. 2. Select the Service Screen Menu. 3. Select 2 Service Alignment item. 4. Use the VOLu on the keyboard or remote to adjust parameter zero (P:0) to a value of eighty (V:80). 5. With parameter zero value at eighty (V:80) press the CHp button on the front keyboard or remote control to put the instrument into the vertical and horizontal centering mode. 6. Use the Skip or Info button on a remote control to bring up
the first test pattern, border crosshatch pattern.

1. Turn on the TV and select the channel that will be used for testing. 2. Select the Service Screen Menu. 3. Select 2 Service Alignment item. 4. Once the Service Alignment screen is displayed use the VOLu on the keyboard or remote to adjust parameter zero (P:0) to a value of eighty (V:80). 5. With parameter zero (P:0) value at eighty (V:80) press the CHp button on the front keyboard or remote control. This puts the instrument into the vertical and horizontal centering mode as shown below. This allows the technician to select one of several internally generated test patterns. (see table below) These may be used for alignment or troubleshooting. The patterns and their source are shown in the table below.

1. With the back cover removed loosen the two (2) lowest of the three (3) T20 screws holding the light engine in position.

7. Use the CHq and CHp on the front panel or Up and Down arrows on a remote control to adjust the vertical positioning of the upper and lower horizontal lines. Adjust the lines so that they are equal distance from the edge of the protective shield frame. 8. Use the VOLt and VOLu on the front panel or Right and Left arrows on a remote control to adjust the horizontal positioning of the left and right vertical lines. Adjust the lines so that they are equal distance from the edge of the protective shield frame. 9. Press the Menu button on the front panel or remote control to toggle the display from the crosshatch to channel video. Insure proper looking video display. 10.Pressing the Power or On/Off button on the keyboard or remote control will cause the instrument to exit the adjustment mode and return to the (P:0) (V:80) display. Pressing the Power or On/Off button on the keyboard or remote control a second time will cause the instrument to exit the Service Menu.

Light Engine Screw positions 2. Turn on the TV and select the channel that will be used for testing. 3. Put the instrument into the Service Alignment mode. 4. Use the VOLu on the keyboard or remote to adjust parameter zero (P:0) to a value of eighty (V:80). 5. With parameter zero value at eighty (V:80) press the CHp button on the front keyboard or remote control to put the instrument into the vertical and horizontal centering mode. 6. Use the Skip or Info button on a remote control to bring up
the crosshatch pattern.

Vertical and Horizontal Centering Screen


PATTERN Border Crosshatch Vertical Lines Horizontal Border Lines Horizontal Lines Crosshatch RGB Colorbar White Screen Black Screen BW Checker Board SOURCE DM DM DM DM DM DM DM DM Light Engine

7. While supporting the light engine lamp enclosure back off the tension on the third upper screw until the light engine will rotate with light pressure. 8. While viewing the crosshatch on the front screen rotate the light engine so that the horizontal lines are parallel with the cabinet frame. 9. Press the Menu button on the front panel or remote control to toggle the display from the crosshatch to channel video. Insure that tuned video and croshatch pattern are displayed with proper geometry. 10. Tighten the light engine screws and perform the electrical centering procedure.
11. Pressing the Power or On/Off button on the keyboard or remote control will cause the instrument to exit the adjustment mode and return to the (P:0) (V:80) display. Pressing the Power or On/Off button on the keyboard or remote control

GEMSTAR
To activate the Gemstar service menu, while in TV mode press Menu, then item 1 GUIDE Plus+ Menu. Then item 2 GUIDE Plus+ Setup. When the GUIDE Plus+ menu is displayed press GO BACK and then the INFO button on the remote control. The Gemstar Service Menu can be cleared with the CLEAR button.

Pattern Table
6. Pressing the Skip or Info button on a remote control will bring up the test patterns one after the other. 7. Pressing Go Back or Reset on the remote control will display the first test pattern. 8. Pressing Menu on the keyboard or remote control will toggle the display between the test pattern and the tuned channel video.

a second time will cause the instrument to exit the Service Menu.
Electrical Vertical and Horizontal Centering

Page 3-3

Page 3-4

VERTICAL

TO E8 RED BIAS <21-B> TP50 TO E7 GRN BIAS E5003


E5007

TP24 RED OUTPUT 194V

TECHNICAL TRAINING

1 0 1 0 1 0 1 0 1 0

0 1 0 1 0 1 0 1 0 1

1 0 1 0 1 0 1 0 1 0

1 0 0 1 0 1 1 0

0 1 1 1 0 0 1 0

0 1 1 0 1 1 0 0

0 1 0 1 0 1 1 1

1 0 0 1 0 1 1 0

Cable CARD
What is it and how to Troubleshoot TVs that use it?

FOREWORD
The intent of this manual is to answer some of the more common questions associated with the CableCARD and its use with Digital Cable Ready televisions. Basic information regarding CableCARD operation is covered in this manual to help service technicians in understanding the overall CableCARD system. Information about the cable system is generic in nature and is provided so the servicing technician can make logical decisions when troubleshooting DCR TVs that are using the CableCARD.

Note: The Host TV displays found in this manual are for a Motorola
CableCARD. Different CableCARD manufactures or software versions of the Motorola CableCARD may have alternate information displayed by the Host TV.

SAFETY INFORMATION CAUTION


Safety information is contained in the appropriate Service Data. All product safety requirements must be complied with prior to returning the instrument to the consumer. Servicers who defeat safety features or fail to perform safety checks may be liable for any resulting damages and may expose themselves and others to possible injury.

All integrated circuits, all surface mounted devices, and many other semiconductors are electrostatically sensitive and therefore require special handling techniques.

First Edition - First Printing Copyright 2005 TTE Technology, Inc. Trademark(s) Registered Marca(s) Registrada(s) RCA and associated marks are trademarks of THOMSON S.A. used under license to TTE CORPORATION. Printed in U.S.A.

Prepared by Thomson, Inc for TTE Technology, Inc. Technical Training Department, INH905 PO Box 1976 Indianapolis, Indiana 46206 U.S.A.

Contents
FOREWORD .............................................................. 3 SAFETY INFORMATION CAUTION .......................... 3 Introduction .............................................................. 5 Digital Cable Head-end ............................................ 6 CableCARD............................................................ 7 Copy Control Information (CCI) ............................ 10 OOB Signal ............................................................. 11 Authentication Process ......................................... 12 CableCARD Tools Menu ..................................... 14 Reset....................................................................... 16 CableCARD Tools Diagnostic Info .................... 17 IDCR (2-way Communications) ............................. 21 CableCARD Troubleshooting Procedure For Authorized Service Technicians ..................................... 22 ERROR Codes ........................................................ 24 CableCARD Troubleshooting Troubleshooting in the Home for Installers ......................... 27 Authentication Process Flow Chart ..................... 30 Common Problems ................................................ 31 Acronyms ................................................................ 32

Note: The Host TV displays found in this manual are for a Motorola
CableCARD. Different CableCARD manufactures or software versions of the Motorola CableCARD may have alternate information displayed by the Host TV.

Page 4

Introduction
Since the introduction of Digital Cable Ready sets and the CableCARD, the service industry has been left with more questions than answers when it comes to troubleshooting a DCR TV with CableCARD. Cable Card, what is it and how to troubleshoot TVs that use it? covers basic information about the CableCARD, Head-end system, copy protection, Out of Band Tuner, CableCARD Tools Menu, and ICDR or 2-way communications on digital cable systems. This manual will help to answer some of the more common questions. What is a CableCARD? This manual will answer that question and provide information about the operation and processes a CableCARD must do to function in a Host TV that is connected to a digital cable system. What does the CableCARD do? Basic CableCARD operation from the time it is first inserted till it has been authorized by the Cable Company is covered in this manual. There is a three (3) step authentication process that the Host TV and CableCARD go through in order to function together. What is the CableCARD Tools Menu? The different tools used in diagnosing a CableCARD include: Network Setup CableCARD Status CableCARD Paring Conditional Access What is the future of CableCARD? Today DCR TVs are currently available. IDCR or Interactive Digital Cable Ready sets are the future. These sets will allow the end user several options of interactivity using just the remote control for the TV. This requires 2-way communication between the Cable Company and the Host TV. This manual follows up with helpful information about the CableCARD. For example, the current list of error codes from Cable Labs is listed in an easy to follow chart. It lists the code number, error condition, the device at fault, and recommended action(s) to resolve the issue. Also included is a Troubleshooting section for installers. This will give servicing technicians a better understanding of what an installer goes through to isolate down a defective CableCARD or cable system problem. Finally, with all the new terms associated with the DCR and CableCARD, there is a list of the most common Acronyms used.

Page 5

Digital Cable Head-end


This section provides general information relating to the Head-end system used with digital cable systems and the CableCARD. It will cover the basic concept of operation. This general information should be used to better understand the operation of the CableCARD and Digital cable to make logical decisions while troubleshooting. The purpose of the Digital Cable Head-end is to provide communications and connectivity between the cable companys content and the subscribers viewing device. What takes place between the Head-end and the subscribers home is transmission of the signal via cable. The digital transmission from the Head-end contains content information, OOB (Out Of Band) signal, encryption data, Conditional Access (CA) information, and Copy control information (CCI). This data transmission is present for each digital channel received by the subscriber. All these signals are controlled and combined by the Head-end device. Control of the head end is done by the cable company operator. Content is the digital information relative to the program content being transmitted via digital signal. Audio and video programs are converted to digital form and transmitted via the head-end to the subscribers home. Both encrypted and unencrypted content can be transmitted. Once in the subscribers home, the encrypted digital content needs to be decrypted for viewing. The CableCARD provides the method to decrypt for viewing. The OOB signal contains CCI, CA, and decryption information used to protect the content from piracy. This is a complex decoding system that requires the Host TV, CableCARD, and Head-end be paired before decryption is allowed. If pairing stops, the CableCARD is designed to block all encrypted content from being
Phone Line

Cable

Content Server Digital Cable Head-End Cable Operator

Phone Line

Cable

Host

Figure 1; Cable System

Page 6

viewed. Information about the Host TV and CableCARD is provided by the subscriber to the cable operator. The cable operator then sets up the Head-end to pair the CableCARD with the Host TV. CCI has little or nothing to do with viewing content. CCI is used to prevent additional copies of the program from being made or recording of the content for viewing later. Conditional Access is used to allow access to subscription content. If the subscriber pays for a channel(s), CA lets the CableCARD know what channel(s) have been subscribed to. This entire information package is transmitted by the Head-end to the subscribers home in digital format. Along the way, there are several possible connections, amplifiers, and taps that can affect the digital signal. If the CableCARD is not able to decode the digital signal, pairing wont take place and encrypted content viewing will be stopped or blocked.

CableCARD
The CableCARD is a Personal Computer-Memory Card International Association (PCMCIA) card used with digital cable systems to control content viewing. This card is used to decode digitally encoded cable signals that the end user has subscribed to. CableCARD, when inserted into the Host TV, controls the tuning and decoding of digital channels found on the cable system. It will only allow those channels that are paid for by the customer to be viewed. It also provides Copy Control Information (CCI) to the Host TV.

CableCARD Operation
NOTE: The CableCARD provides only Conditional Access capability. Normal Digital Cable Ready (DCR) reception (Un-conditional Access Programming) can occur without the CableCARD being inserted. In other words in the clear channels can be viewed with out the use of the CableCARD, provided the digital cable is connected to the cable input. In order for the CableCARD and the Host TV to function together there are certain protocols that have to be met. The Host TV first must recognize the CableCARD as a valid cable card and not just a PCMCIA card. After the CableCARD has been recognized by the Host TV, but before the pairing processes has been completed, a channel list is downloaded from the cable company. The new channel list replaces any previous lists for the cable input. The cable channel list cannot be changed while the CableCARD is inserted. This process is verified by accessing the channel search menu and starting a search for Cable input only. The following Page 7

screen will come up indicating the channel list for this system has been received.

!
A Channel Search is not availabe for the Cable Input because a list of available channels has already been received from the cable company. You can go to the Parental Controls menu to set up the channel list for the Cable Input.

Continue

Figure 2; Channel Search OSD after Channel List from CableCARD Downloaded

Next handshaking between the CableCARD and the Host TV takes place. This handshaking involves passing security codes and certificate information that both the Host TV and CableCARD validate. If this process is successful, the CableCARD tells the Host TV to display the pairing screen. This screen instructs the consumer to contact the cable service provider to pair the CableCARD to the Host TV. This pairing process requires information from the Host TV and CableCARD to be given to the cable service representative. Once this information is provided to the cable company Conditional Access System (CA), the head-end will send digital data to the CableCARD in the OOB signal. This data instructs the CableCARD as to what service(s) have been authorized and what to decode for viewing. The pairing information, found in the CableCARD Pairing menu, is displayed when the card is first inserted into the host TV. Pairing information is also brought up by pressing MENU + 9 + 9 + 9 on the remote control. This is a universal access for all CableCARD devices. The information displayed consists of:

Cable Card ID Host ID Data Field Unit Address

In order to start cable service for this device, please contact your cable provider (xxx) xxx-xxxx CableCARD(tm):000-298-685-510-0 Host:024-000-018-543-1 Data:310-974-124-10 UnitAddress:000-02986-85510-224

Figure 3; Paring OSD

If the on-screen prompt does not appear within a minute or two of the CableCARD being inserted it indicates the CableCARD module has not been detected by the Page 8

Host TV. If this is the first time a CableCARD has been inserted, or if the CableCARD previously worked but recently stopped, the CableCARD may be defective and a new one should be obtained from the cable provider. If the CableCARD is recognized, as indicated by on-screen prompts, there will be further instructions to continue the installation. If the card is detected but determined to be invalid the following screen appears:

!
Please call your cable operator and report an invalid CableCARD.

Continue

Figure 4; Invalid Card OSD

The Conditional Access System can revoke the authorization of the CableCARD forcing it to reinitialize (Pair) with the Host TV. Until they are reinitialized, all conditional access (CA) programming will be blocked except for the unencrypted channels. When this happens the Host TV will display the pairing screen as if the CableCARD was inserted for the first time.

Page 9

Copy Control Information (CCI)


Copy Control Information (CCI) can be added to each program supplied by the Cable Service Provider. CCI has different levels that dictate if a program can be recorded and how many times it may be recorded. There are four levels of CCI. The following table shows the different levels.

CCI values: (0) Copy Freely (1) Copy No More (2) Copy Once (3) Copy Never

The level of CCI for each program is determined by program provider or the Cable Service Provider. This level is then passed from the Head-end to the cable card in the OOB data channel. The cable card decodes the CCI and passes it to the Host unit in the clear. The host unit is required to control output of the program based on the CCI value. For example; if the CCI level is 0 (copy freely) the program is allowed to be viewed and available on any of the Host outputs for recording. If the level is 3 (copy never), the Host can only display the program and is required to block all recording of the program. CCI can present a problem when using a Digital Video Recording device. The DVR may not record or other functions of the DVR such as pause, review, etc. may not work. The CCI levels for DVR operation are level 00 and 10. All other levels will prevent DVR operation. However; all levels of CCI will allow a "display only" Host TV to view the program. NOTE: Copy never programs can be recorded using a Personal Video Recorder (PVR) and played back within 90 minutes. This is for PVR pause and other features, but not for long term storage. After the 90 minutes are up, the program will still be on the PVR. When accessed to play the program, the PVR will display an error message.

Page 10

OOB Signal
QPSK (Quadrature Phase Shift Keying) is a digital frequency modulation technique used for sending data over coaxial cable networks. Since its both easy to implement and resistant to noise, QPSK is used by DCR systems for sending data to and from the headend. The QPSK receiver circuit in the Host TV tunes and demodulates the QPSK Forward Data Channel (FDC). The serial data in the FDC is used primarily to send conditional access entitlement messages from the cable provider to the CableCARD either allowing or blocking program material that is encrypted. Program material that is not encrypted will pass through the CableCARD regardless of the entitlement. Tuning of the QPSK receiver circuit is under control of the CableCARD. This receiver circuit is generally known as the OOB or Out of Band Tuner. The OOB data is seperate from the normal program material coming in on the standard set of frequencies.The normal program content is managed by the INB or In Band Tuner. The OOB tuner in the Host TV is separate from the normal QAM, ATSC and NTSC tuners. The tuning range of the OOB tuner is between 70 and 130 MHz, falling within the cable frequency allocation from 54 to 1000 MHz. A CableCARD must be inserted for the OOB to be tuned. Whether the CableCARD is paired to the Host TV or not, the OOB is tuned. CableCARD pairing is determined by comparing incoming information from the cable provider via the OOB tuner data to the information contained in the CableCARD. The OOB circuitry is inactive if a CableCARD is not inserted. When a CableCARD is inserted, the Host TV initiates a handshake with the CableCARD. If successful, the Host TV then activates the OOB tuner and decoder circuits as instructed by the CableCARD. The OOB circuitry is only connected to the CableCARD interface. There is no direct control of OOB data by the Host TV.

OOB Forward Data Channel vs OOB Reverse Channel Data


The out-of-band forward data channels are primarily for control and access messages, application code download and electronic program guide content. If capacity is available, other data services may be transmitted through this channel as well. Out-of-band communications are always available to the Host TV, no matter which analog or digital channels are tuned. For on-demand applications, the out-of-band forward channels may be used to support control and signaling flows between the Host TV and the Cable Company headend. The out-of-band reverse data channels carry all data from the Host TV to the headend equipment for two-way communication. Two way communication is detailed in the section titled "IDCR (2-Way Communication)".

Page 11

Authentication Process
To provide authentication, the CableCARD verifies security data stored in the Host TV. This authentication ensures that the CableCARD will pair with certified Host TV devices only. The authentication process is comprised of three steps that are used to verify the Host TV certificate. 1. The CableCARD checks to see that the digital signature of the certificate supplied by the Host TV represents an accurate signature matching the certificate authority. If the certificate is NOT authentic, encrypted services are blocked to the Host TV device. Once the CableCARD successfully authenticates the Host TV certificate, the CableCARD is authorized to begin descrambling certain content for the Host TV. 2. The CableCARD ID, Unit Address, Data Field and the Host TVs unique identification numbers are provided by the customer to the Cable Company to update the headend. The Host TV certificate is then verified against certificate revocation lists (CRL) stored at the cable headend. Once the headend has verified the Host TV certificate has not been placed on the CRL, the headend will send a Host TV ID validation message back to the CableCARD. 3. While the CableCARD is waiting for the Host TV ID Validation message from the headend, the CableCARD requests the a Duffie-Hellman key from the Host TV. This authentication key is compared to one derived in the CableCARD. Only after all three steps have been completed successfully is the CableCARD able to send all authorized services, including those with copy protection restrictions, to the Host TV device. This Authentication process is checked on a regular basis for each channel selected or when the Host TV and CableCARD are reset.

Page 12

START

Cable Card Inserted first time

Host communicates with Cable CARD

OSD indicating Cable CARD was detected is displayed

Communication complete. Waiting for information from Cable Co.

Down loading of Channel list occurs

Channel list loaded into HOST memory and channel search blocked for cable

Paring Information Screen is displayed for customer.

Host and Cable CARD wait for cable co to send paring information

Customer must contact Cable Operator and provide displayed information

Cable operator sets up customer in their system.

Paring between Cable CARD and HOST occurs

Data transfer from head end to host / cable card occurs

CA channels available for viewing

Host and Cable CARD are paired and decryption of CA channels occurs.

Channel Viewing by customer

Figure 5; Authentication (Paring) Process

Page 13

CableCARD Tools Menu


Selections under CableCARD Tools Menu provide additional information about the status of the CableCARD. The following is an example of the CableCARD Tools menu. Each menu option has information that is useful in pairing up or troubleshooting the CableCARD. Note: The following information is based on a Motorola CableCARD. Other CableCARD manufactures may have alternate information displayed by the Host TV.

Figure 6; CableCARD Tools Menu

Network Setup
Network setup is used to manually retune the OOB channel frequency. By selecting Hunt, the CableCARD will start the process of searching for the OOB channel. When Successful, Status will indicate TUNED_STATE and OOB Msgs: will have a value other then zero. The LKC indicates the frequency of the OOB signal. In this case it is 75.250MHz.

Network Setup LKC: 75.250 EEM: Status: TUNED_STATE OOB Msgs:3356 Hunt

SUCCESS! Network Provider found. Frequency: 75.250,EMM:

Exit

Figure 7; Network Setup OSD

Page 14

CableCARD Status
The CableCARD Status menu displays information about the Manufacture, Download Status, Entitlement Management, and OOB Channel. o Manufacture: Is the manufacture code and or name of the CableCARD. This display may just show the manufacture code and not the manufactures name. o Version: Is the software version of the CableCARD. o Unit Address is used to pair the card with the host set. This information is also found in other sections of the tools menu. o Out of band channel indicates the OOB frequency. This is the last known good carrier only. Tuned or not tuned is a static state that represents the condition of the network when Network Setup was last run. To get current state, run network setup.
CableCARD(tm) Status Manufacture:0x00 (Motorla) Version:03.34 Unit Address:0011CD9446 000-02986-85510-224 Download Status Segments left to download: State:Wait To Start Entitlement Management Messages EEM Provider ID:1 Out of Band Channel Last Known Carrier:75.250 Tuned

Figure 8; CableCARD Status OSD

CableCARD Pairing
The pairing option brings up the same display that MENU + 9 + 9 + 9 brings up. This is the same display that comes up when the CableCARD is inserted but has not been paired.
In order to start cable service for this device, please contact your cable provider (xxx) xxx-xxxx CableCARD(tm):000-298-685-510-0 Host:024-000-018-543-1 Data:310-974-124-10 UnitAddress:000-02986-85510-224

Figure 9; CableCARD Paring OSD

Page 15

Conditional Access
Conditional access option provides some of the same information that the other menu options provide but adds information about the currently tuned channel. This additional information deals with the Copy Control Information (CCI) and Packet Identification Number (PID). o ECM PID or Entitlement Control Message Packet Identification number: Used for verification that the correct ECM is sent for each program. o Component PID: Used for error handling o Host Validation: Information used to verify that paring has taken place. Some systems do not automatically store this value. This requires it to be given to the cable operator. o The Copy Protection Key indicates wheather or not the program is using CCI. The CCI value is the level of copy protection being used for the currently tuned program.

Conditional Access Unit Address: 0011CD9446 000-02986-85510-224 State: Subscribed ECM PID: 0x0000 Component PIDs: 0x00410x0040x0000 0x0000 0x0000 0x0000 Host Validation: Valid 09 Copy Protection Key: Disabled CCI: 00

Figure 10; CableCARD Conditional Access OSD

Reset
The CableCARD Reset option allows the consumer to perform a manual reset without removing the CableCARD. Reset is a complete reset of the CableCARD. The channel list is removed form the Host TV and Host TV validation process is reset. If after Reset the pairing screen comes up, the cable company may have revoked the CableCARD. This will require the CableCARD to be re-paired with the Host TV. Reset should be used anytime there is a problem with receiving channels, channel freeze, wrong channel list stored, or some channels missing. Some Host TVs will reset the CableCARD automatically when the CableCARD is detected as being locked up.

Page 16

Figure 11; CableCARD RESET OSD

CableCARD Tools Diagnostic Info


This following is for various RCA / Scenium products only. Other manufacture's menus will vary.

Figure 12-1; CableCARD Diagnostic Info

Page 17

Diagnostic Info screen displays certain information about the CableCARD and Host TV. This information provides the cable company / installer or servicing technician with details about: Out Of Band (QPSK / FCD) Host TV and CableCARD Certificates Virtual Channel PSIP Channel Number of Audios Physical Channel Program Number Signal Strength Video PID Audio PID PCR PID CCI Byte Broadcast Flag

Figure 12-2; CableCARD Diagnostic Info

Each title has a state or data value assigned during normal operation. Reviewing this information will assist in troubleshooting a CableCARD problem. Out Of Band (QPSK / FCD) The states for Out Of Band (QPSK / FCD) are Locked and Unlocked. When the CableCARD is receiving and decoding OOD data, the Out Of Band (QPSK / FCD) will show LOCKED. If the CableCARD cant decode the OOB data, the

Page 18

Out Of Band (QPSK / FCD) will show Unlocked. Unlocked indicates a problem with the CableCARD or cable system. Host TV and CableCARD Certificates Certificates for TV Digital Cable and CableCARD are verified on a regular basis. Any time the channel is changed or the CableCARD is inserted the certificates are checked. If the certificates are valid, the display will read Verified. If the certificates arent read, the display will read Insert CableCARD. The other option is Failure. Failure under TV Digital Cable indicates a problem with the Host TV and Failure under CableCARD indicates a problem with the CableCARD. Virtual Channel Virtual Channel is the displayed channel number. Channel mapping by the cable company can assign any number to a given frequency. This assignment becomes the virtual channel number for a given frequency. In the example, 93-2 is the number that will be displayed in the channel banner. The (0x005d-0x0002) is the HEX equivalent of 93-2. PSIP Channel PSIP channel is the Program and System Information Protocol channel. This will change depending on what input is selected. Other possibilities are: Analog Channel PSIP Channel (associated with HD digital channels) PAT / PMT (CableCARD or cable company) Input 1 Input 2 Input 3 etc. Number of Audios If there are more then one audio channel (SAP) then the number will indicate how many there are. Physical Channel This is the actual channel number for the currently tuned channel. This number can be different from the virtual channel number because of channel mapping. (See Virtual Channel) Program Number Program number is used to display what sub channel of the physical channel the set is tuned to. In this example, 2 is the program number. Signal Strength Signal strength is a number indication of how strong the tuned channel signal is. The higher the signal strength number, the stronger the signal is and vise versa. Signal Strength is an indication of signal to noise ratio only, not an actual measurement of the signal energy.

Page 19

Video and Audio PID Packet Identification number identifies the data sub stream for Audio and Video. PCR PID PCR or Program Clock Reference Packet Identification number is the data sub stream for the encoder / decoder synchronization. CCI Byte Copy Control Information Byte displays the level of copy protection the currently tuned station has. See the section on page 10 Copy Control Information (CCI) for the different values. Broadcast Flag Broadcast Flag is a sequence of digital bits that indicates if a program is protected from unauthorized redistribution. The state for this is on or off. Broadcast Flag allows content to be copied but blocks the transmission of content over an unauthorized system. This is different from the CCI Byte that protects content from being copied.

If set is tuned to an input, only the Out of Band, TV and CableCARD Certificates will be displayed, all other information will show as "not applicable".

Figure 12-3; CableCARD Diagnostic Info

Page 20

IDCR (2-way Communications)


The future of the Host TV is to provide two way communications between the Cable Company and the Host TV through the CableCARD. The two way communications will allow the subscriber to access pay per view channels with out contacting the cable operator to set it up. With two way communications, the Host TV will transmit data information back to the Head-end in much the same way the Head-end sends data to the Host. This requires that the Host TV be capable of transmitting digital data via the cable connection. Transmission of data is not only used for pay per view, it is used to maintain the CA and CCI information. It also allows the cable company to monitor what the subscriber is viewing to better serve the subscriber. Currently only set top boxes (STB) have two way communication using a CableCARD device. This setup provides the subscriber with many more features over the Host / CableCARD setup. These extra features include: Interactive TV, Pay-Per-View, Video on Demand, and the ability to change subscription options without contacting the Cable Company. To tell if a set is capable of two way communication, look for the logo:

IDCR or Interactive Digital Cable Ready has the ability to provide two way communication on a digital cable system. The arrows in the logo indicate two way signal transfer. All devices in this system must be able to transmit in both directions. This includes the Head-end, amplifiers, splitters, DVR, VCR, and any other device placed in the path of the cable signal.

Cable

Content Server Digital Cable Head-End Cable Operator


Cable

Host

Figure 13; IDCR System

Page 21

CableCARD Troubleshooting Procedure


For Authorized Service Technicians

1. Remove CableCARD and reset Host TV by unplugging Host TV from AC power for one (1) minute. 2. Reapply AC power and turn Host TV on. Initiate a complete channel search for the cable input. This will clear any previous channel list stored by the CableCARD. 3. Access a valid cable channel. Is station audio and video clear? If Yes, go to step # 4. If No, continue troubleshooting Host TV and the Cable System to correct. Once you have resolved any cable signal noise problems, continue to step #4. 4. Insert the CableCARD and wait for the on-screen display (OSD) prompts (see Authentication Process on page 12). Did the CableCARD Pairing OSD appear? If Yes, contact the cable company and provide them with information to begin the pairing process. If No, go to step # 5. 5. Access the CableCARD Tools Menu and RESET the CableCARD. If RESET option is not available, remove the CableCARD and reinsert it. Did the CableCARD Pairing OSD appear? If Yes, go to step #8. If No, go to step # 6 6. Confirm that the OOB signal has been found and is locked. No CableCard processes are allowed to take place without a locked OOB signal. Depending on the available diagnostic menus you may use either option a. or b. to determine the presence of a valid OOB signal a. In the available CableCard tools or diagnostic menus search for indications that the Out of Band or OOB is tuned, LCK or Locked. i. If the OOB signal is not locked, go to step #7 ii.If the OOB signal is locked, go to step #8 If there are no OOB indicators in the available diagnostic menus and tool, use option b. to verify the presence of a valid OOB signal b. Enter the channel search options and attempt to initiate a search for cable channels. i. If a cable channel search is allowed, this would indicate the OOB signal is invalid or missing. Go to step #7. Page 22

ii.If a cable channel search is not allowed because a cable company channel list has already downloaded, this is an indication a valid OOB signal has been acquired. Go to step #8 7. Suspect CableCARD or cable system failure. Common cable system components known to cause the loss of the OOB signal are: Splitters Amplifiers Defective cables (Inside and Outside) Other devices connected before the Host TV (VCR, DVD, DVR, etc.) Bad Ground on the Grounding Block If possible, connect the Host TV directly to the main cable before it enters the residence. This eliminates many of the system components listed in step #7. Once the cable system has been repaired, go back to step #6 and confirm OOB has been found and is locked. After OOB has been confirmed, go to step #8. 8. Access the CableCARD Pairing screen from the CableCARD Tools Menu. Contact the cable company and provide them with information required to authorize the CableCARD. 9. Once the CableCARD has been authorized, attempt to access any encrypted channel. If encrypted channels can be viewed, go to step #10. If not, contact the cable company and report the issue for resolution. Note: In many cases only the premium or pay per view channels are encrypted. If unable to view encrypted channels, suspect the CableCARD or an authorization failure. 10. If encrypted channels can be viewed, the system is working.

Page 23

ERROR Codes

CableCard error codes are displayed on the Host TV in a format similar to the one on the right. The code its self is 161-XX where XX is the code number. The following tables list the codes currently being used.

A technical problem is preventing you from receiving all cable services at this time. Please call your cable operator and report error code 161-xx to have this problem resolved.

161-

Error Condition

Device
Card Card Host Card Card Card Host Card Host Card Host

Action
Reset Host / Cable CARD Reset Host / Cable CARD Report error if problem continues Troubleshoot Host TV Reset Host / Cable CARD Reset Host / Cable CARD Reset Host / Cable CARD Report error if problem continues Troubleshoot Host TV Reset Host / Cable CARD Report error if problem continues Troubleshoot Host TV Reset Host / Cable Card Troubleshoot Host TV

Comments

1 Card READY Signal does not go active 2 Host reads incorrect CIS values 3 configuration register
Host writes incorrect value to Card Host sets command channel bit but Host sets extended channel bit but

4 Card fails to set bit within 5-seconds 5 Card fails to set bit within 5-seconds 6 Invalid Buffer negotiation -Card7 Invalid Buffer negotiation -Host8 Invalid Buffer negotiation -Card9 Invalid Buffer negotiation -Host10 11 12 13 14 15 16 17 18 19 20 21
Card doesn't respond to Host open transport within 5-seconds Host doesn't respond to Card request to open resource manager within 5seconds Host responds to open resource manager session response -resource manager non-existent Host response to open resource manager session response -resource manager unavailable Host response to open resource manager session response -Incorrect version of resource manager Host resopnse to open resorce manager session response -resorce manager bussy Host resopnse to open resorce manager session response -invalid status byte Card fails to respond to profile_INQ within 5-seconds Host reource response -no application information resource Host resource response -no host control resource Host resource response -no system time resource Host resource response -no MMI resource

Host

Troubleshoot Host TV

Host

Troubleshoot Host TV

Host

Troubleshoot Host TV

Host

Troubleshoot Host TV

Host Card Host Host Host Host

Troubleshoot Host TV Reset Host / Cable CARD Troubleshoot Host TV Troubleshoot Host TV Troubleshoot Host TV Troubleshoot Host TV

Page 24

ERROR Codes

161-

Error Condition
Host resource response -no low speed

Device
Host

Action
Troubleshoot Host TV

Comments
If OOB reverse path not available, then some application will be unavailable. Card may have some operation problems (i.e. downloading software) Only clear channels may be viewed. Not a failure condition

22 communications 23 resource

Host resource response no homing Host resource response -no copy Host resource response -unknown Host fails to respond to open session Host response to open application info

Host Host Host Host Host

Troubleshoot Host TV Troubleshoot Host TV Troubleshoot Host TV Troubleshoot Host TV Troubleshoot Host TV

24 protection resource 25 resource identifier

26 request within 5-seconds

27 resource session -application info non28


existent Host response to open application info resource session -application info unabailabe Host response to open application info Host response to pen application info Host response to open application info invalid status byte Card request to open conditional access session to the Host times out after 5-seconds Card response to conditional access conditional access non-existent Card response to conditional access conditional access unavailable Card response to conditional access Card response to conditional access Card response to conditional access Card fails to respond to CA_INFO_INQ Card request to open copy protection

Host

Troubleshoot Host TV

29 incorrect version of application info 30 application info bussy 31 32 33 34

Host Host Host Host Host Host Host Host Host Card

Troubleshoot Host TV Troubleshoot Host TV Troubleshoot Host TV Troubleshoot Host TV Troubleshoot Host TV Troubleshoot Host TV Troubleshoot Host TV Troubleshoot Host TV Troubleshoot Host TV Reset Host / Cable CARD Report error if problem continues Troubleshoot Host TV Only clear channels may be viewed. Only clear channels may be viewed. Only clear channels may be viewed. Only clear channels may be viewed.

35 incorrect version of conditional access 36 conditional access bussy 37 invalid status byte 38 within 5-seconds

39 session to the Host times out after 540 41


seconds Host response to open copy protection resource session -copy protection nonexistent Host response to open copy protection resource session -copy protection unavailable Host response to open copy protection

Host

Host

Troubleshoot Host TV

Host

Troubleshoot Host TV

42 resource session -copy protection busy

Host

Troubleshoot Host TV

Page 25

ERROR Codes

161-

Error Condition
Host response to open copy protection Host doesn't support Cable CARD

Device
Host Both Both Host

Action
Troubleshoot Host TV Host / Card Incompatibility Host / Card Incompatibility Reset Host / Cable CARD Troubleshoot Host TV Troubleshoot Host TV

Comments
Only clear channels may be viewed. Only clear channels may be viewed. Only clear channels may be viewed. A copy protected channel will stop being descrambled a copy protected channel will stop being descrambled A copy protected channel will stop being descrambled A copy protected channel will stop being descrambled Only clear channels may be viewed. User may see frozen picture on scrambled channels User may see frozen picture on scrambled channels User may see frozen picture on scrambled channels Not a failure condition Not a failure condition Not a failure condition Not a failure condition Not a failure condition Not a failure condition Not a failure condition Not a failure condition Not a failure condition Not a failure condition Used when an S-Card is inserted into an M-Host

43 resource session -invalid status byte 44 device's copy protection system

45 Host and Cable CARD wont Pair 46 Host response to CP-SYNC -Host busy 47 support 48 status
Host response to CP-SYNC -no CP

Host

Host response to CP_SYNC -invalid

Host

Troubleshoot Host TV

49 CP_OPEN_REQ

Host fails to respond to

Host Host Both

Troubleshoot Host TV Troubleshoot Host TV Reset Host / Cable Card

50 Invalid Host certificate


Write error (WE) occurs after

51 completion of any transfer from Host to 52


Cable CARD Read error (RE) occurs after completion of any transfer from Card to Host Card fails to respond to any request Invalid session APDU from Host Invalid session APDU from Card Invalid SPDU tag from Host Invalid SPDU tag from Card Invalid APDU tag from Host Invalid APDU tag from Card Transport ID from Host that has not been created and confirmed by Card Transport ID from Card that has not bee created by Host Session ID from Host that has not been created and confirmed by card Session ID from Cable CARD device Imcompatible Cable CARD device

Both

Reset Host / Cable Card Reset Host / Cable CARD Report error if problem continues None None None None None None None None None None Replace Cable CARD Reset Host / Cable CARD Report error if problem continues

53 within 5-seconds 54 55 56 57 58 59 60 61 62

Card Host Card Host Card Host Card Host Card Host Host Host Card

63 that has not been created by Host 64 inserted

65 Card resource limit reached

Page 26

CableCARDTM Troubleshooting
Troubleshooting in the Home for Cable Installers
1. It is recommended that a couple of extra CableCARDs be used for troubleshooting. This will help eliminate the CableCARD as a possible problem. 2. Before installing the new CableCARD, the installer should check that the Digital Cable Ready (DCR) TV, also referred to as a Host TV, is functional without a CableCARD. a. Verify Host TV Operation: This is confirmed by connecting the RF cable to the correct input of the Host TV (there may be connections for a terrestrial antenna) and verifying good picture quality. The Host TV will display all non-encrypted analog and digital content. (The Host TV must not receive the RF signal via a Set Top Box or accessory RF modulator.) This step only eliminates basic TV circuitry as a potential problem. NOTE: This does not eliminate the Host TV it only verifies basic operation of the HTV. A channel search on the Cable Input may be required to add any channels which were re-mapped with the CableCARD. b. Install the CableCARD and check that it is inserted properly. When inserting cable card, push carefully but firmly until you feel the card click into place. When correctly inserted the card may or may not be flush with the back of the slot, this varies according to manufacturer. Once the host has established communication with the card, onscreen information will be displayed indicating the card was inserted and detected. c. Verify RF from Cable System: A cable set top box can be used to confirm reception of encrypted digital services. This will ONLY indicate that the cable signal is correct for the Set Top Box. The data for the Cable CARD could still be a problem. 3. If the first Cable CARD installed does not result in a User Interface screen (also referred to as Man Machine Interface screen) within 2 - 5 minutes, try unplugging the AC cord of the Host TV and reconnecting it (this should reset the Host TV and CableCARD), then try to access the User Interface screen again. This screen is accessed by the industry agreed-upon remote combination of MENU+9+9+9. If this is still unsuccessful, try another CableCARD.

Page 27

a. To eliminate the possibility of a damaged CableCARD or Host TV, the installer should look closely at the CableCARD to ensure that none of the pinholes are blocked or clogged. b. Check the Host TV Interface (CableCARD slot): Using a flashlight, look in the CableCARD slot on the Host TV to ensure that there are no bent pins. c. If the CableCARD is inserted correctly but the CableCARD menu is not displayed or is grayed out, try the RESET option in the menu, if present. 4. If the second CableCARD is successful, make sure the Cable Co Customer Service Rep or Dispatcher knows the new MAC ID and Cable CARD ID to complete the paring. 5. Check the CableCARD Tools menu options. If the second CableCARD fails to bring up the User Interface screen, the installer should refer to the diagnostic menus of the Host TV for further troubleshooting. The installer can pull up the User Interface screen manually through the menu choices. The installer can confirm the status of the CableCARD and the Forward Data Carrier (FDC). The list of CableCARD options will vary, depending on your cable service provider or CableCARD manufacturer. 6. If the CableCARD is still having problems, the installer should report the problem to the Cable Company dispatcher for troubleshooting. If the cable company dispatcher (head end personnel) has completely checked their channel set-up, confirmed the accounting/billing system is correct, and has confirmed normal channel map with other DCR TVs at the headend, then go on to the next step. 7. If the installer determines that the Host TV device is the problem (unit failed either item 2a or 3b above) and can go no further in correcting the problem, or if the installer determines that the pairing screen cannot be displayed with multiple CableCARDs, the installer should consider the Host TV is at fault. 8. If using a Set Top Box (STB) allows the customer to receive services on the suspected Host TV, the STB should be used until the customer resolves the issue with the Host TV manufacturer. 9. If the installer is able to install the CableCARD device and access the User Interface screen (also referred to as MMI screen), and has relayed the information to the dispatcher, but is still not receiving encrypted programming, this programming may be protected through the use of copy protection directive. The installer needs to ensure that the information passed to the cable operator is correct. Relay again the Host ID, CableCARD ID and Data ID (Motorola only). Cable operator will send a hit to the CableCARD once the information is checked and verified. The CableCARD must be paired Page 28

to the Host before copy protected programming can be displayed. Note that it may take several minutes from the time operator sends the authorization till it reaches the Host TV. 10. The MMI screens should be checked to verify if the authorization has been received. For Scientific Atlanta systems the pairing screen should say Authorization Received. For Motorola the Conditional Access MMI State parameter should say Subscribed. If encrypted programming is still not displayed, the Host TV may be the problem. Items to consider: Make sure the dispatcher is addressing the CableCARD through the right plant or head end. OOB (FDC) signal levels and adjacent channel interference should be checked. Verifying that the dispatcher has the correct numbers is not always sufficient. There are reports from the field that the authorization may have to be sent two or three times to authorize the card.

Page 29

Authentication Process Flow Chart


The following flow chart adds a possible solution to key steps in the authentication process if that process fails to complete. The 80% and 20% columns in each box indicate which device is suspect that percent of the time. Looking at the first process failed decision (YES), the CableCARD would be suspect 80% of the time while the Host TV is suspect 20% of the time.

START

Cable Card Inserted first time

Host communicates with Cable CARD

Note: If the pairing process fails at any time, wait 15 minutes and try the process again.

80%
OSD indicating Cable CARD was detected is displayed Communication complete waiting for information from Cable Co. Process Failed? YES Suspect Cable CARD

20%
Suspect Host TV

of the time of the time

NO Down loading of Channel list occurs Channel list loaded into HOST memory and channel search blocked for cable

Process Failed?

YES

Suspect Cable System

Suspect Host TV or Cable Card

NO Paring Information Screen is displayed for customer. Host and Cable CARD wait for cable co to send paring information Suspect Cable Card or Cable System

Process Failed?

YES

Suspect Host TV

NO

Customer must contact Cable Operator and provide displayed information

Cable operator sets up customer in their system. NO Data transfer from head end to host / cable card occurs NO

Process Failed?

YES

Suspect Cable System

Suspect Host TV or Cable Card

Paring between Cable CARD and HOST occurs

Process Failed?

YES

Suspect Cable System or Pairing Process.

Suspect Host TV or Cable Card

Encrypted channels available for viewing

Host and Cable CARD are paired and decryption of encrypted channels occurs.

Process Failed?

YES

Suspect Cable Card or Cable System or Pairing Process.

Suspect Host TV

NO Channel Viewing by customer

Figure 14; Authentication Process Flow Chart

Page 30

Common Problems
The following are common issues related to Cable CARD and Host TV operation. 1. Cant view encrypted channels: CableCARD not authorized for these channels CableCARD defective 2. Cant get CableCARD to pair with Host TV: Weak signal on cable Wrong or defective splitter in cable system Amplifier in cable system not passing OOB signal No direct connection to cable input on Host TV. (VCR, DVR, STB, etc between cable head-end and Host TV) 3. CableCARD was working but stopped or locked up: Host TV and CableCARD lost sync (RESET Host TV and CableCARD) CableCARD failed CA system lists CableCARD ID as revoked 4. Cant get CableCARD to work but set top box will work: Wrong or defective CableCARD Weak cable signal to Host TV Network Setup incorrect; Hunt for new OOB channel. Wrong Configuration at Head-end 5. Missing channels after CableCARD was inserted: Cable head-end not sending out the correct channel map Missing channels are scrambled and not authorized for viewing 6. Cable channel list changed after CableCARD was inserted: See # 5 Missing Channels after CableCARD was inserted 7. Cable channel list is incorrect when CableCARD is inserted: See # 5 Missing Channels after CableCARD was inserted 8. Receiving error message 161-XX, what does it mean: Refer to Error code table on page 24

Page 31

Acronyms
AIT Application Information Table API Application Program Interface ATSC Advanced Television System Committee AWT Abstract Windowing Toolkit BFS Broadcast File System. BNF Backus-Naur Form CA Conditional Access CATV Cable TV CCI Copy Control Information CORBA Common Object Request Broker Architecture CP Content Protection CRC Cyclic Redundancy Check CRL Certificate Revocation List DAVIC Digital Audio Visual Council DECT Digital Enhanced Cordless Telecommunications DHCP Dynamic Host Configuration Protocol DII Down load Info Indication DOCSIS Data-Over-Cable Service Interface Specification DSM-CC Digital Storage MediaCommand and Control. Part 6 of the MPEG-2 standard DSM-CC-OC Digital Storage MediaCommand and Control Object Carousel DSM-CC-UU Digital Storage MediaCommand and Control User to User DTD Document Type Definition DVB Digital Video Broadcasting DVS Digital Video Subcommittee DTVCC Digital Television Closed Captioning EAS Emergency Alert System ECM Entitlement Control Message EE Execution Engine EIA Electronic Industry Alliance EN European Norms EPG Electronic Program Guide ES Elementary Stream ETS European Telecommunications Standard ETSI European Telecommunications Standard Institute ExCCI Extended Copy Control Information FCC Federal Communications Commission GEM Globally Executable MHP GSM Global System for Mobile Communications HAVi Home Audio/Video interoperability. HDNI Home Digital Network Interface HDTV High Definition Television HTML Hypertext Mark-up Language

Page 32

HTTP Hypertext Transport Protocol IETF Internet Engineering Task Force IP Internet Protocol ISO International Organization for Standardization ITU International Telecommunication Union ITV Interactive Television JDK Java Development Kit JFIF JPEG File Interchange Format JMF Java Media Framework JSSE Java Secure Socket Extension LMDS Local Multipoint Distribution System MA Monitor Application MAC Media Access Control MHP Multimedia Home Platform MMDS Multipoint Microware Distribution System MMI Man Machine Interface MPEG Moving Picture Expert Group MSO Multiple Service Operator MIME multipurpose internet mail extensions NCTA National Cable Telecommunications Association NPT Normal Play Time NTSC National Television Systems Committee NVOD Near-Video-On-Demand OCAP OpenCable Application Platform OOB channel Out-Of-Band channel OOB-FDC Out-Of-Band Forward-Data-Channel OOB-RDC Out-Of-Band Reverse-Data-Channel OS Operating System PCR Program Clock Reference PES Packetized Elementary Stream PHILA POD Host Interface License Agreement PID Packet Identification number PMT Program Map Table POD Point of Deployment module PPV Pay-per-view PSIP Program and System Information Protocol PSTN Public Switched Telephone Network PVR Personal Video Recorder RCMM Root Certificate Management Messages RMI Remote Method Invocation SCTE Society of Cable Telecommunications Engineers SDP Session Description Protocol

Page 33

SI Service Information SMATV Satellite Master Antenna TV SSL Secure Sockets Layer STC System Time Clock TLS Transport Layer Security UI User Interface URI Universal Resource Identifier URL Uniform Resource Locator UTC Coordinated Universal Time VBI Vertical Blanking Interval VCT Virtual Channel Table VOD Video-On-Demand XAIT Extended Application Information Table

Page 34

TCableCardTroubleshootingGuide

Prepared by Thomson, Inc for TTE Technology, Inc. Technical Training Department, INH905 PO Box 1976 Indianapolis, Indiana 46206 U.S.A.

VERTICAL

TO E8 RED BIAS <21-B> TP50


TO E7 GRN BIAS

TP24

RED OUTPUT 194V

E5003
E5007

Product Support & Technical Training

Mail Stop INH905

1 0 1 0 1 0 1 1 0 1 0 1 0 0 1 0 1 0 1 0 1 0 1 0 0 1 0 1 Box P.O. 0 11976 1 0 1 0

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0 1 1 0

GENERAL INFORMATION SERIES

GIS 05-001
File In Appropriate Section of Your Thomson Technical Bulletin Binder

DLP UHP Lamp / Lamp Ballast Characteristics


DATE: 02/16/2005 In the DLP line up there are several different Lamp / Ballast venders. For each vender the Lamp design is mated with the ballast design and the light engine that controls the ballast. These parts are NOT interchangeable between venders. When replacing a lamp or ballast always refer to the service model with suffix to insure the correct part is ordered. As with all troubleshooting, a good understanding of the circuit or process is needed. We will cover the fundamentals of Lamp Strike or Ignition, Lamp Lit (Burn), and Defective Lamp. After the fundamentals have been covered we can begin to troubleshoot the Lamp and Lamp Ballast.

Basic Lamp Construction:

Arc Tube

Reflector

Hg
Back Connector

Lead Wire

Side Connector

WARNING: EYE DAMAGE MAY RESULT FROM DIRECTLY VIEWING THE LIGHT PRODUCED BY THE LAMP. ULTRAVIOLET RADIATION EYE PROTECTION IS REQUIRED DURING SERVICING.
First Edition - First Printing Copyright 2005 Thomson, Inc. Trademark(s) Registered Marca(s) Registrada(s) RCA and the RCA logos are trademarks of THOMSON S.A. used under license to TTE Corporation Printed in U.S.A. Prepared by Thomson, Inc for TTE Technology, Inc. Technical Training Department, INH905 PO Box 1976 Indianapolis, Indiana 46206 U.S.A. TTI GIS 04-001

The basic construction of a Lamp consists of: Arc Tube Back Connector Reflector (Lamp Assembly) Lead Wire Side Connector

Arc Tube: This is where the arc takes place and is also known as the burner. Internal to the arc tube are two electrodes made of tungsten. Surrounding these electrodes is mercury vapor and other gasses. To generate the arc, the electrodes are supplied with high voltage. Once the arc has jumped the gap between the electrodes, current starts to flow and the lamp is lit. The operating pressure inside the Arc Tube is around 200 bar.

There are two connectors, Back Connector and Side Connector. These connectors provide electrical connection between the Ballast Supply and the Arc Tube through the Lamp Assembly.

Reflector (Lamp Assembly): The reflector reflects the light generated by the Arc Tube into a focused beam used by the light engine.

Arc Tube

Reflector

Hg
Back Connector

Lead Wire

Side Connector

Hg

This symbol indicates that the lamp in the HDTV contains mercury. Disposal of these materials may be regulated due to enviromental considerations. For disposal or recycling information, pleas contact your local authorities or the Electronic Industries Alliance: www.eiae.org

Page 2

TTI GIS 05-001

Lamp Output

ng Oper ati Lamp

e Voltag

Value

# Strikes

to start (H

) OT lamp

# Strikes to start

(cold lamp)

NEW

Life Span (t)

REPLACE

Characteristics of UHP Lamp


Lamp Characteristics The above graph shows the characteristics of a UHP lamp over its life cycle. As the lamp ages, the light output decreases with the erosion of the electrodes. Because of the eroding electrodes, both the lamp operating voltage and number of strikes required to start a cold lamp increases. The number of strikes required to start a hot lamp also increases over time but starts out slightly higher than cold strikes. A HOT strike is defined as striking a lamp that is above room temperature.

There are several conditions that decrease or shorten the life of the lamp. A few are listed here: Heat (Improper Ventilation) Shock (moving unit while in operation) Fast paced cycling set on and off

Heat is by far the worst condition of them all. With out proper ventilation, the lamp life can be reduced by 75% or better. Thermo protection is used to shutdown the lamp if excessive heat is detected.

Lamp Strike (Ignition) The voltage required to ignite the lamp varies by lamp manufacture. Also, the number of ignition cycles it takes to light the lamp may vary. As the lamp ages, more ignition cycles may be required to start the lamp. Typically, the ignition voltage is from 5Kv to 20Kv.

Page 3

TTI GIS 05-001

When the lamp is hot it is more difficult to ignite then when cold. As the temperature increases so does the pressure in the Arc Tube. With the higher pressure, the lamp may require additional strike times to get the Arc Tube to light.

When a lamp fails to strike there is an indication besides the obvious lack of light output. If the lamp fails to strike the DLP front panel LED will blink a sequence (see service data or IB for number of times power LED blinks for each model). In DM3 based models this will repeat for up to 5 minutes after which time the power LED will start to flash rapidly for about 1 minute. The blinking of the power LED occurs after each failed attempt to strike the lamp. The LED blinking sequence is not a replace lamp indicator, this only indicates that the lamp has failed to strike. A open lamp door will also cause the LED to blink in the same manner. Multiple strike failures could indicate a defective lamp or lamp ballast supply.

Lamp Lit (Burn) Once the lamp starts to draw current, the voltage to the lamp drops significantly. This indicates the lamp is in the operating state. The typical voltage for operating is approximately 70-100VAC. This is measured between the lamp back and side connectors. As the lamp ages this voltage will increase. When the voltage reaches approximately 125VAC, the ballast supply will send information to the light engine indicating the lamp is defective. At that point the Light Engine will shutdown the ballast supply.

Defective Lamp As the lamp ages two things happen. One is the number of strikes to start the lamp operating increases and the other is the lamp operating voltage increases. A lamp is considered defective when it consistently takes more than three strikes to light the lamp or the lamp operating voltage exceeds approximately 125VAC. Depending on the set, some will strike the lamp indefinitely others will stop after 5 minutes. A defective lamp may never strike or take several minutes to light. Another indication of a defective lamp is when the lamp lights and after reaching full brightness it shuts off. A lamp nearing the end of life is verified by monitoring the lamp run voltage. The lamp is considered

Page 4

TTI GIS 05-001

defective if the run voltage is within a few volts of 125VAC. NOTE: As the lamp lights and heats up the lamp run voltage climbs slightly.

WARNING: EYE DAMAGE MAY RESULT FROM DIRECTLY VIEWING THE LIGHT PRODUCED BY THE LAMP. ULTRAVIOLET RADIATION EYE PROTECTION IS REQUIRED DURING SERVICING.

Lamp Troubleshooting Tips Lamp lights and shuts down: Thermo protection (poor ventilation) Lamp run voltage exceeding approximately 125V

Lamp intermittent or wont light consistantly after 3 strikes: Remove Lamp assembly and check for loose connectors on lamp, tighten as needed. If the lamp successfully lights, check lamp run voltage. If over 120VAC, suspect lamp. During strikes, is the spark gap on the ballast supply arcing and making noise? Yes, suspect lamp. No, see Ballast Supply Troubleshooting. Lamp door open or defective lamp door switch

Lamp Ballast Supply Troubleshooting Tips 1. Check to make sure all supply voltages are present at the lamp ballast supply. 2. Remove Lamp assembly from instrument 3. Start set and monitor spark gap on ballast supply 4. Is the ballast supply spark gap arcing and making noise? Yes, suspect Lamp. No, suspect ballast supply.

NOTE: Measuring the lamp voltage during a strike will damage most meters. It is recommended that the lamp voltage only be measured when the lamp is lit.

Hg

This symbol indicates that the lamp in the HDTV contains mercury. Disposal of these materials may be regulated due to enviromental considerations. For disposal or recycling information, pleas contact your local authorities or the Electronic Industries Alliance: www.eiae.org

Page 5

TTI GIS 05-001

Questions About New Technology?


The General Information Series (GIS) has been developed to keep you up to date in the rapidly changing field of consumer electronics. New technology is emerging continuously and the GIS newsletter has been created to keep you informed in this ever changing industry. To make this publication successful, we need your input! Your suggestions and ideas are needed to make sure that we cover the subjects that interest you. These may include training topics, troubleshooting procedures, new technology overviews or just about anything that interests you in the world of consumer electronics. We'll review all the suggestions and respond with articles on the most popular responses. Please send your ideas and suggestions to the address listed below.

TTI GIS 04-001

Printed In U.S.A.

THOMSON TECHNICAL COMMUNICATION


Television

Troubleshooting Flow Chart

TFC-04004C

The information contained herein is provided solely to assist qualified Technician in the diagnosis of the problem described. It is not intended as a modification or alteration of the product.
REVISION DATE: 04/15/2005 Model(s): ATC311 DLP HDLP (50, 60, 61) W151 or HD (50, 61) LPW42 TOPIC: DLP Troubleshooting SYMPTOM: Cycles, Shutdown, No Start

Plug set in. Do not Press the power button.

1A

1B
Check lamp interlock switch (J13101) and the 12VS supply on J13101.

NOTE 1 Refer to the service information for the correct voltage & pin-out locations.

Do you hear the relay K24251 click ?

NO

YES

2A
Does the power LED light and then turn off ?

2B
NO

2C
Check the standby power supplies to the DM-2CR. +- 5,6,12,33 vdc on connectors J24604, J24605. Refer to Note 1

NO

Suspect Power Supply.

YES

YES

2D
Continue to page 2.

Suspect DM-2CR Module.

Product Safety Information


Product Safety information is contained in the appropriate Thomson Service Data covering models/chassis referenced herein. All specified Product Safety requirements and testing shall be complied with prior to returning equipment to the customer. Servicers who defeat safety features or fail to perform safety checks may be liable for any resulting damages and may expose themselves and others to possible injury.
First Edition First Printing Copyright 2003 Thomson multimedia Inc. Printed in U.S.A. Trademark(s) Registered Marca(s) Registrada(s)

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3A

Press power button.

Note 2 The DM-2 reboot sequence is Press & Hold "Pwr" and "CH Down" at the same time on the FPA for three seconds.

4A

4B Check the FPA, IR Preamp, DM-2CR and inspect all cables for proper seating. Replace any that appear to have been stressed.

Does the power LED light up or flash and the relay click ?

NO

YES 5A Disconnect J26403 (Audio +21VDC) on 5A AC power the supply board. If the set runs suspect a problem on the audio board

6A 6A Are the voltages on the P1connector "Light Engine"correct? Refer to Chart 1 on page 4

6B Check the power supply voltages supplied to the Formatter PCB. Connector BP503 Refer to Note 1

NO

YES

7A Does the color 7A wheel spin or at least attempt to spin? NO

7B Hookup Chipper Check and review the error codes. Attempt a Hardreboot. Refer to Note 2

YES

Continue to page 3

Product Safety Information


Product Safety information is contained in the appropriate Thomson Service Data covering models/chassis referenced herein. All specified Product Safety requirements and testing shall be complied with prior to returning equipment to the customer. Servicers who defeat safety features or fail to perform safety checks may be liable for any resulting damages and may expose themselves and others to possible injury.
First Edition First Printing Copyright 2003 Thomson multimedia Inc. Printed in U.S.A. Trademark(s) Registered Marca(s) Registrada(s)

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8A 8B On J4(3,5) is the 5VR there at turn on?


NO

If missing, check the power supply input to the formatter board

9A

YES 9B Is the lamp lighting?


NO

Confirm that on the X1 connector, (located on the lamp ballast power supply), that the DC voltage is ~ 300 VDC. Also referencing Chart 2 measure the DC voltage on connector J4 (4) on the "Light Engine"

YES 10A 10B Does the lamp increase up to full brightness?


NO

Suspect Lamp, Lamp ballast power supply

YES 11A 11B Is the voltage correct on J4(1) connector? Refer to Chart 2 on page 4
NO

Suspect DM2-CR Module

YES

Suspect a defective Light Engine.

Product Safety Information


Product Safety information is contained in the appropriate Thomson Service Data covering models/chassis referenced herein. All specified Product Safety requirements and testing shall be complied with prior to returning equipment to the customer. Servicers who defeat safety features or fail to perform safety checks may be liable for any resulting damages and may expose themselves and others to possible injury.
First Edition First Printing Copyright 2003 Thomson multimedia Inc. Printed in U.S.A. Trademark(s) Registered Marca(s) Registrada(s)

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THOMSON INC.

CHART 1 BW902 Description Pin # Ground 1 5 VR 2 Power Good 3 Ground 4 2.5VR 5 2.5VR 6 Ground 7 Ground 8 3.3VR 9 3.3VR 10 Ground 11 12VR 12 Voltage 0 5 Vdc 3.3 Vdc 0 2.5Vdc 2.5Vdc 0 0 3.3Vdc 3.3Vdc 0 12Vdc P1 Pin # 12 11 10 9 8 7 6 5 4 3 2 1

CHART 2 J4 Connector Pin 1 2 3 4 5 Description Ballast Lamp Lit Ground 5VR Ballast Enable Line 5VR DC voltages in the off mode L L 0 0 0 DC voltages at turn-on H (5v) 0 5 2.5 5 DC voltages at run L 0 5 3.25 5

Product Safety Information


Product Safety information is contained in the appropriate Thomson Service Data covering models/chassis referenced herein. All specified Product Safety requirements and testing shall be complied with prior to returning equipment to the customer. Servicers who defeat safety features or fail to perform safety checks may be liable for any resulting damages and may expose themselves and others to possible injury.
First Edition First Printing Copyright 2003 Thomson multimedia Inc. Printed in U.S.A. Trademark(s) Registered Marca(s) Registrada(s)

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THOMSON INC.

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