Sony PDP-01 Plasma Training

Training Manual
KE-61XBR950
Plasma Television
Models: KE-37XS910 KE-42XS910 KE-50XS910 KDE-42XBR950 KDE-50XBR950 KDE-61XBR950
Diagnostics and Troubleshooting Course: PDP-01
Table of Contents
Introduction ...........................................1 1. Plasma Panel Troubleshooting ....3
Overview ................................................................. 3 Pixel Control ........................................................... 4 Plasma Panel Troubleshooting ............................ 4 Troubleshooting ..................................................... 41 Disassembly .......................................................... 52
4. Troubleshooting the KDE42/50/61XBR950 ..........................64

Overview ................................................................ 64 Plasma Panel Block Diagram ............................. 64 Troubleshooting ..................................................... 66 Disassembly .......................................................... 72
2. Troubleshooting the KE37/42XS910 .....................................13

Overview ................................................................ 13 Signal Processing ................................................ 13 The Plasma Panel ................................................ 15 Troubleshooting ..................................................... 17 Disassembly .......................................................... 26
5. Disassembling the KDE61XBR950 .....................................79

Overview ................................................................ 79 Disassemblyling the KDE61XBR950 ................ 79
3. Troubleshooting the KE50XS910 ....................................37

Overview ................................................................ 37 Signal Processing ................................................ 37 The Plasma Panel ................................................ 39
PDP-01 - Introduction
Plasma display devices are becoming the choice of many consumers, as evidenced by the amount of this product on the display floor of any electronics goods store and the increasing number of sale ads. Although still relatively high in price when compared to other display devices such as CRT and LCD, the gap is rapidly narrowing. The appeal of owning a futuristic flat television that can be configured to virtually any installation layout keeps the demand for plasma growing every year. Geometric distortions, beam landing errors and convergence issues are non-existent. The narrow viewing angle of rear-projection televisions is also overcome. Although one would normally think of plasma devices as relatively new in the display market, the technology is not new. Development of plasma-type displays began in 1971 using a monochrome platform. Color displays began to appear in the early 1980s. New developments in panel designs have increased the brightness, resolution and contrast, along with greater longevity in panel life. Claims of 60,000 hours of useful brightness are being heard, equating to about ten years of normal viewing time. The amount of research and development, along with highly sophisticated manufacturing processes are what keep plasma displays in the relatively high price range. This factor gives the product great viability in the service industry. The complex circuitry, however, requires todays technician to keep abreast on these changes in display methods to remain competitive. The purpose of this manual is to help the technician better understand this technology to accomplish this. Once of the unique aspects of these display devices is the modular construction of the unit itself. The abundant use of LSI devices, along with a greater demand for on-site repairs, requires that technicians perform most repairs at board level. The glass-plasma panel itself can be replaced in about the same amount of time as replacing picture tubes in a CRT projection set if being done for the first time. Once you become familiar with the procedure and the chassis, the time will become even less due to the lack of extensive alignment procedures required in CRT sets. This course is written with a primary emphasis on practical troubleshooting approaches to plasma-type display devices, particularly the 2003/2004 models introduced by Sony. In-depth theory will not be discussed. If basic plasma theory is desired, refer to training manual TVP-13. The technician merely needs to learn the basics of plasma technology, particularly how the panel is controlled, in order to appropriately diagnose the point of failure. This will require a fresh, new approach in responding to what may or may not appear on the screen. Self-diagnostic circuits also provide a valuable tool in isolating a particular failure. Knowledge of the basics and practical approaches presented in this manual should convince most technicians that servicing plasma displays is no more difficult than any other display device. This manual will cover six different models ranging from 37" to 61". The model series includes the XS910 (available in 37", 42" and 50"), and the XBR950 series (available in 42", 50" and 61"). There are several distinctions among these models. The XBR series uses a separate media box to receive ATSC and NTSC broadcasts and cable DTV signals along with analog and digital inputs, making them a true High Definition television. The XS910 series does not have a media box. It has a built-in NTSC tuner and relies on external devices to supply standard and high definition signals. These types of televisions are known as High Definition Ready. From a repair standpoint, the key difference among each model is the design of the plasma panel. Four different designs are used. In attempting to cover such a large variety of designs, this manual will be arranged so that basic panel operation and troubleshooting is covered first. Even though there are different panel designs, the underlying concept of controlling a plasma panel is universal among them. Understanding how the panel is controlled is important for troubleshooting purposes. The remaining task is identifying the boards and their nomenclature. Once this is clear, it is only a matter of becoming familiar with the unique layout of the different panels. The subsequent chapters will cover each model based on its panel usage along with procedures and tips to aid in properly servicing the specific design.
Detailed procedures will also be covered for the proper disassembly, re-assembly and adjustments (if required). The first item the technician will notice is that plasma televisions use a large number of screws. Removal of the rear cover can involve up to 60 screws of varying type and size. Many other screws are used for shielding and panel support brackets, not to mention circuit board mounting. It is important to return all screws to their original location. Placement of all wires is also crucial for minimizing signal interference and to prevent damage to wiring when re-assembling the unit. This is especially true when installing support brackets and the rear cover.
1. Plasma Panel Troubleshooting
Chapter 1 - Plasma Panel Troubleshooting

Overview
LCD and plasma display devices are similar in how they control light output from a particular pixel. Although they each generate a source of light in a different manner, the use of horizontal and vertical control grids allows for timing a particular pixel for display. In Figure 1-1, a typical layout for a plasma display panel is shown. The horizontal control lines (usually referred to as scan control lines) determine which horizontal line of red, green and blue pixels will be ready to be activated at a particular time. High voltage pulses of up to 230 volts are sent to the scan lines. Notice the use of separate X and Y driver boards. Each board handles every other scan line. Working in unison, the odd and even scan lines are energized with alternately phased pulses to place the plasma chambers in a sustain condition. The Y-Drive (or High Voltage) board sends scan-drive pulses to a group of drive ICs since the initial charging for each scan requires the most power. These ICs are mounted on separate circuit boards (usually two) or directly onto the flexible PC cable molded into the panel, depending on the design. The X-Drive board connects to the panel without drive ICs since its primary function is to reverse the plasma chamber charge. The moment a certain horizontal row of pixels is activated, the appropriate intersecting, vertical control lines determine which pixels will light. These are known as address or data lines. All of this is timed by a logic control circuit (sometimes referred to as a digital board) that receives the incoming digital RGB signal and allocates the information to the appropriate pixel. This forms a grid pattern to control each intersecting point. It is a simple concept and the understanding of this sequence is critical to analyzing any abnormalities noted on the display. Some panel designs use addressing lines at the top and bottom of the panel. This is known as a dual-scan and is found in newer panel designs, particularly in larger ones. The amount of addressing control is shared so that only half of the vertical distance of the screen is controlled by each of the upper and lower addressing line inputs.
SECOND ADDRESS BOARDS FOR DUAL SCAN
COMMON OR X SCAN BOARD
PLASMA DISPLAY PANEL
HV OR Y SCAN BOARD
DATA OR ADDRESS BOARD
LOGIC CONTROL BOARD
RGB DATA
FIGURE 1-1 BASIC PLASMA DISPLAY CONTROL
PDP01.1-1
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Pixel Control
Lighting a Pixel
In Figure 1-2, a simplified layout of a plasma discharge chamber is shown. Inert gases (usually xenon and neon) are exited by an electrical charge. In order to sustain this state, the electrical charge must be constantly changing. As mentioned previously, the X and Y drivers send alternating pulses to accomplish this. This voltage is at a level near the required amount to excite the gasses by introducing free electrons. The address lines apply the necessary voltage to complete the firing of the plasma material. This phenomenon causes a release of ultraviolet light. Each plasma gas chamber resides over a particular red, green or blue phosphor stripe applied vertically on the panel. By controlling the amount of UV radiation from the plasma chamber across each vertical stripe, color images can be displayed with great accuracy.
SCAN ELECTRODE (TRANSPARENT) FACE PLATE PROTECTION LAYER ELECTRIC LAYER DISCHARGE RIB SUSTAIN ELECTRODE (TRANSPARENT)
BACK PLATE PHOSPHOR (RED) PHOSPHOR (GREEN) DATA ELECTRODE
PHOSPHOR (BLUE)
FIGURE 1-2 - PLASMA CELL STRUCTURE

Creating a Picture
PDP01.1-2
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Referring back to Figure 1-1, the scan lines determine which pixel row is active at a given time. The electrodes of the scan control lines are transparent, allowing the light from each phosphor stripe to emit from the panel. The address lines work in a unique method to control light output from each pixel. Whenever a particular scan line is active, the address lines will determine which pixel along that line will light. This is done eight times for each field of video information and is controlled by an 8-bit data word. These are called sub-fields. Unlike CRT displays, which are controlled by varying the level of electron beam emissions, each pixel is controlled eight times at 256 possible levels. The more times a particular pixel is fired during the sub-field scan period, the brighter the pixel. If the incoming video signal is sampled at a 10-bit rate for each of the RGB components, a color combination of 700 million is achieved!
Plasma Panel Troubleshooting

General
Due to the use of different display panel designs, this chapter of the manual will attempt to cover troubleshooting techniques universal to plasma displays. Differences among the panel designs will only require separate board layouts and disassembly procedures. These differences will be covered in the chapters to follow. The first critical item to determine is whether the display panel is the cause of the defect. In most cases, it is quite evident if the panel is the cause. Other failures may not be so obvious. The main reason for eliminating a fault

in the panel is to prevent wasted time. A complete disassembly of the unit is required to access the various circuit boards and flexible cables for further diagnosis and visual inspection. This is very time consuming. Plasma panel failures are not common and most are caused by improper handling and shipping damage resulting in cracks to the glass envelope and the release of the internal gasses. They are also quite expensive and, therefore, not something that should be replaced needlessly. The use of scan, addressing and timing pulses can produce interesting symptoms on the display. Single lines, vertically or horizontally, may be lit when they are not supposed to be. Entire halves or quadrants of the screen may be lit bright white or appear completely dark. Failures on the logic control board or distortions and level drops of the scan pulses produce a myriad of rainbow color effects. The panel may not display any video at all. The remainder of this chapter will attempt to cover the various symptoms that can develop with each particular circuit or panel defect. Once again, keep in mind that in most cases the panel itself is usually not the cause of the defect. There are some panel designs that have driver components mounted directly to the flexible cables encased within the glass assembly and this would force a replacement of the panel. NOTE: Due to the complex digital processing involved with plasma displays, unusual symptoms may appear on the screen that may make it difficult to determine the failure. Always check the Sony Service website at HTTP:/ /service.sel.sony.com for any FPR or service bulletins that may be present regarding the model you are about to service. An abundance of information is located on the ESI site and is updated daily. Do this before going on the service call to minimize the amount of time needed to complete the repair.
Troubleshooting a No Display Condition

This tends to be the most difficult symptom to approach since there are many potential sources to prevent the panel from going active. Failures of any number of B+ lines, the scan and address drivers, or a loss of video information could be the cause. In the case of B+ lines, most units will go into protect shutdown and may not even generate indications of having done so. There is, however, one important observation that can assist in isolating the panel and/or drivers as the cause. A unique phenomenon occurs whenever a plasma display is powered up. It is known as priming. Priming is performed by the scan drivers. A large positive and negative pulse is sent to each X and Y scan-line at initial turnon. Residual charges in each pixel are cleared along with the necessary boost to begin discharging from the gasses. Once the pixels are primed, they will continue to discharge a small amount of light, known as sustaining. This generates a raster similar to that found on CRT devices although it is lower in level and lacks scan lines. It is easier to detect in low ambient light conditions. The easiest way to identify pixel lighting is to observe the screen while turning the unit on and off. With the unit off, you have an idea of what true black is. If the pixels are lighting, you will see the difference between the true black and reference black. The use of a magnifying glass (such as those used for beam landing on a CRT) helps to see if the pixels are emitting light at a low level. This is an important function to verify. It tells you the panel is functioning and the scan and addressing pulses are present along with all of the necessary B+ voltages. It usually indicates a loss of video signal data entering the logic board and troubleshooting should focus on the video processing circuits rather than the panel and driver assembly. It is possible that a failure could have occurred on the logic board but this is unlikely. The absence of priming or sustaining a raster brings the focus of troubleshooting to the panel and associated circuits to drive it. If the plasma panels glass envelope is compromised, allowing the escape of the gasses and there is no evidence of breakage, it becomes necessary to check for the presence of scan and addressing pulses to isolate the failure to the panel or driver circuits. The means to accomplish this varies between panel designs. They will be covered in the chapters of this manual pertaining to each model. If an oscilloscope is available, scan-pulses can be verified by connecting to the inputs of the scan driver board(s). These boards are easily identified by their location on the side of the panel. Figure 1-3 shows a typical scandriver layout. There will be one or two boards with several IC drivers. The driver boards will be connected to a

scan generator known as a Y-SUS or High Voltage board depending on the panel design. Placing a scope probe on the pins of the connector to the scan drivers will display high-voltage pulses around 230VPP at about 4s in duration. If these pulses are present, the panel should be priming the pixels. If priming is not occurring, there is a possibility of a compromise in the panel glass.
CHECK FOR PULSES AT INPUT PINS
FIGURE 1-3 - TYPICAL SCAN DRIVER LAYOUT

Distortions in the Display Video
PDP01.1-3
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As mentioned earlier, distortions displayed on the screen will present new and sometimes interesting patterns that will be unfamiliar to most television technicians. Like CRT displays, however, the symptoms on the screen give excellent clues as to where the problem may lie. CRT display abnormalities are diagnosed based on what the technician knows about video processing and scanning technology. Likewise, abnormalities on plasma displays are generally clear pointers to a particular circuit involved in the pixel scanning. Once the concept is understood, troubleshooting is as easy, if not easier, than CRT symptoms. Remove the need for purity, convergence, geometry, picture sizing and centering, and you will find plasma technology is not quite so intimidating. The sections to follow will attempt to cover different types of distortions you may encounter, along with general tests and recommended solutions. Keep in mind that an attempt is being made to generalize up to four different panel design layouts but the idea is to get the technician familiar with resulting display abnormality. Detailed analysis specific to each panel can be found in its corresponding section.
Vertical Line Abnormalities

Since the addressing lines time the vertical plane of the pixels, attention is focused in this area of the panel drive signals. In cases where multiple lines appear with color across the entire screen, the addressing lines are not the cause. Figure 1-4 illustrates two examples of address drivers utilizing single or multiple ICs. In both cases, the address information from the logic board is de-multiplexed by the drivers to control the vertical address lines within the panel. Notice the drivers are mounted directly to the flexible PC cable, which is part of the glass panel. They are not replaceable with conventional equipment and a failure at this point requires replacement of the entire plasma panel.
MULTIPLE DRIVE ICs
SINGLE DRIVE IC
FIGURE 1-4 - EXAMPLE OF ADDRESS DRIVERS

Below are some examples of the different symptoms that can appear.
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Single Black, White, or Colored Vertical Line: Figure 1-5 illustrates an externally generated red raster in which a single vertical line appears. The line may be dark, white or one of the primary pixel colors. A dark or white line indicates a loss of drive to a single row of pixels and the type of panel used determines whether it will display as white or black. A colored line is caused by that particular address location being turned on continuously. This can be caused by a defective drive IC, or leakage or shorts between the pads of the flexible PC connector pads. If the panel is a single-scan design (address drivers only on the bottom), the lines usually extend from top to bottom. In a dual scan panel, the line(s) will begin at the top or bottom and end exactly at the middle of the screen.
SINGLE DARK, WHITE, OR DIFFERENT COLORED LINE
SCAN DRIVER, FLEX CABLE OR PANEL. MUST REPLACE PANEL
ADDRESS BOARD
ADDRESS BOARD
FIGURE 1-5 - SINGLE VERTICAL LINE FAILURE

PDP01.1-5 2/27/04

Multiple Cluster of Black or White Lines: In Figure 1-6, an example is shown where multiple adjacent lines are not receiving a signal. In almost all cases, the lines affected correspond directly to the number of outputs demultiplexed by a drive IC. The problem can be a failed drive IC or loss of signal to that particular IC. A close inspection of the drive IC at the point where the abnormality is located should be performed first. Most failures of the drive IC will reveal signs of overheating such as cracks or burn holes. If this is found, the panel must be replaced. If the drive IC appears intact, inspection of the flexible PC cable should be performed paying close attention to the contact pads and the locking connector. Corrosion or foreign material could be the cause. If the cable and connector appear OK, it will be necessary to check signals at the connector. This is easily done since there are other drive connectors in which to compare proper voltages and signals. TIP: Some panel designs (such as the KE50XS910) have a relay board to distribute the drive signals from the logic board. In this case, the cables for adjacent address lines at the relay board can be swapped. If the line defect moves to another part of the screen, the drive IC was not receiving a signal. If the line defect remains in the same place, the drive IC is defective and the panel must be replaced.
LINE MAY BE BLACK OR WHITE DEPENDING ON PANEL DESIGN
DRIVE IC OR ADDRESS BOARD FAILURE
ADDRESS BOARD
ADDRESS BOARD
FIGURE 1-6 - MULTIPLE VERTICAL LINE FAILURE

PDP01.1-6 2/27/04
Multiple Colored Vertical Lines: Figures 1-7 illustrates another vertical line distortion. Although this may appear to be an addressing line failure, the fact that they contain colors eliminates this possibility. Notice the distinct cutoff point at the middle of the screen. All current plasma designs used in Sony products split the horizontal scan signals between two driver boards. Although this appears to be a vertical issue, it is caused by the scan circuits, not the address circuits. Suspect a failure in the Y-SUS board. Other models refer to this circuit as a high voltage board.
FIGURE 1-7 - MULTIPLE COLORED LINES

Horizontal Line Abnormalities
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In figure 1-8, a thin line of missing video indicates a loss of signal to an individual line. This can be caused by an individual scan line being inoperative due to an open connection to the panel or a failure of the drive IC to provide the necessary voltage to that line. Since the scan driver IC performs a de-multiplexing of the incoming signal, the failure lies either within or after the drive IC. If the panel design uses a scan drive board in which the flexible cable is part of the panel and driver board, or if the drive ICs are part of the flexible PC, the panel must be replaced. In panel designs where the driver board contains connectors to the panel flex-cables, a thorough inspection of the flexible cable connecting the panel to the driver board should be performed. If the pads on the flexible cable are OK, a check of each scan-drive output from the driver IC must be made with an oscilloscope to eliminate the panel assembly as the cause.
SCAN DRIVE BOARDS AND DRIVERS
DRIVE IC, FLEX CABLE, OR DEFECTIVE PANEL
FIGURE 1-8 - SINGLE SCAN LINE FAILURE
PDP01.1-9
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Figure 1-9 illustrates a failure of a large number of horizontal scan lines. Most panel designs use two separate boards for the scan drivers. The point to note is that any failure of a scan IC will prevent display of succeeding lines to the point where the board ends at the middle of the panel. The first IC that fails to light up the scan lines is the culprit. In some cases, a visual inspection of the drive ICs may reveal the failed component. Look for any signs of scorching or burn holes as shown in figure 1-10. Scan ICs damaged due to overheating will usually cause the self-diagnostics circuits to indicate a panel failure alarm. How this alarm is displayed varies from model to model and is covered in training material specific to that model.
SCAN BOARDS AND DRIVERS FAILED IC
FIGURE 1-9 - MULTIPLE SCAN LINE FAILURE
PDP01.1-9
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BURN HOLE
SURFACE CRACK
FIGURE 1-10 - DAMAGED SCAN DRIVE IC
PDP01.1-10
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1. Plasma Panel Troubleshooting Abnormal Luminance and/or Color

In Figure 1-11, one of any number of symptoms is shown that can be caused by a failure in the scan drive circuitry. Background video may or may not be present. There might only be luminance component. The key symptom to observe is the analog appearance of the distortion. Video signals processed before reaching the panel will usually have a digital-appearing distortion. If the scan drive board is at fault, the distortion will tend to have a smear to it and will appear whether a signal is input or not.
FIGURE 1-11 - ABNORMAL COLORS
PDP01.1-11
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Another example of distortion caused by the scan circuits is shown in Figure 1-12. The upper or lower half of the screen video will have distortion similar to colored snow. This symptom is deceiving and leads one to believe the logic or scan drive board to be at fault due to the digital appearance. The clue here, once again, is how the distortion occurs in exactly one half of the screen. The two boards containing the scan driver ICs should be examined for any signs of component overheating by looking at or carefully touching any semiconductor devices. Distortions such as this can be caused by leaky components causing a load on the voltage lines or unwanted oscillations.
FIGURE 1-12 - SCAN DRIVE DISTORTION
PDP01.1-12
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1. Plasma Panel Troubleshooting Replacing a Defective Panel

Once it is determined that the plasma panel needs replacement, the proper procedures must be followed to remove it from the unit. This procedure varies from model to model. This is covered in the additional chapters of this training manual. Due to varying tolerances of plasma panels, certain voltage settings must be adjusted for that particular panel. Most replacement panels will come with the Logic, Address and Scan boards installed and pre-adjusted. In cases where the panel does not, a label is located on the rear of the panel indicating the proper voltages settings unique to that panel. All panels require the proper setting of the scan (Vs) and address (Va). Other panels may require one or two additional voltages to be properly adjusted. These will also be indicated on the label. Figure 1-13 illustrates a typical label indicating the proper scan and address voltages. Note the two additional voltages (Vw and Vx) indicated on the label. The method for adjusting panel voltages is dependent on the panel design used. Some can be adjusted on the power supply board and others will appear on the scan boards. Certain models require an interface jig to change EEPROM data. Be certain to check for the latest updates regarding panel voltage adjustments pertaining to the model you are servicing by accessing the Sony service website at HTTP://service.sel.sony.com.
PANEL TYPE PANEL SERIAL NUMBER
VOLTAGE SETTINGS
FIGURE 1-13 - TYPICAL PANEL LABELS
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2. Troubleshooting the KE37/42XS910
Chapter 2 - Troubleshooting the KE37/42XS910

Overview
The KE37/42XS910 is a high-definition-ready plasma television with a built-in NTSC tuner along with the necessary video processing circuitry to accept composite, Y/C, component, and DVI video sources along with analog L/R audio. Other plasma models function as monitoring devices and rely on an external receiver (known as a Media Box) to receive and process video and audio. This chapter will point out the circuits that are unique to this model along with a description of each boards function. Practical troubleshooting methods will be discussed followed by a systematic procedure for disassembling and re-assembling the unit. Plasma televisions rely on a large gassed-filled glass panel to generate video. It is important that this glass panel be properly braced and secured by brackets and the back cover assembly. A considerable amount of shielding is also required due to the high voltage levels generated by the scan drivers. Because of this, a large number of screws are utilized. A full disassembly can require the removal of a hundred screws or more! Another factor is the use of a number of circuit boards spread throughout the rear of the large panel assembly. This requires the use of many wiring harness mounts and paths. It is extremely important to route these wires in their correct configuration to minimize interference and prevent any wires from being pinched or cut. Clearances between shields, brackets and the rear cover are minimal so this is quite important. An extensive use of illustrations will be used to assist the technician in routing the wiring correctly and return all of the screws back to their original location.
Signal Processing
Overall Block Diagram
Referring to Figure 2-1, an overall block diagram demonstrates the various paths for the different video and audio inputs. A NTSC tuner is located on the A board. A/V inputs 1, 2 and 3 accept composite or Y/C video along with L/R audio. A/V inputs 4 and 5 accept component video only, along with L/R audio. Video resolutions of 480i, 480p, 1080i and 720p are supported. The DVI input receives differential RGB digital video information along with analog L/R audio. The UD board contains the receiver/decoder to convert the digital signal to Y/CB/CR along with HDCP control. The HM board contains a Memory Stick slot for display of JPEG still pictures and MPEG1 audio/video playback. The information from the memory stick is processed and sent via a LVDS (Low Voltage Differential Signal) transmitter to the MS2F board. The video and/or audio signals are processed and D/A converted. Audio is sent to A/V switch2 while video information is sent to the DIC2 board. NOTE: The MS2F board is enclosed within a shielded assembly (known as the DM Block) containing the DIC2 and DE2 boards. Although the service manual refers to this as a replaceable assembly, it is not. The boards inside must be replaced individually. All non-component video signals and analog L/R audio are controlled by AVSW1 and AVSW2. Component and DVI video are routed through a component interface and applied to a video switch. This video switch allows the selection of DVI, component, Y/C or composite video signals to be routed to the main video process path. The sub-video path can only accept signals from the tuner and inputs 1 through 3 and is, therefore, limited to 480i resolutions only. The main and sub video are routed to the DIC2 (Digital Imaging Core) board. Necessary standby and switched voltages are generated by the regulator block (sometimes referred to as PSU). Analog audio is received by the K board where it is amplified to drive a set of speakers.
13
REGULATOR BLOCK
ANT IN INPUT 1 INPUT 2 INPUT 3 H2 BOARD
NTSC TUNER
A BOARD
DIC2 BOARD
DE2 BOARD
MAIN V AVSW1 AVSW1 SUB V AUDIO
VIDEO SW
CCP2 MAIN DRC MID CCP2 MAIN
DCP
PANEL DRIVER
TO PANEL
TV MICRO
PANEL MICRO
INPUT 4 INPUT 5 DVI INPUT UD BOARD COMP I/F AUDIO PROCESS MS2F BOARD MEMORY HM STICK BOARD INPUT MID UC K BOARD AUDIO AMP L TO R SPEAKERS
FIGURE 2-1 - KE37/42XS910 SERIES OVERALL BLOCK
PDP01.2-1
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Video Signal Processing

Referring to Figure 2-2, the main, sub and memory stick paths are shown entering the DIC2 board. Main video is processed by CCP2 (Composite to Component Processor) if it is component. If the main video signal is 480i, the DRC performs the necessary line doubling to 960i. The sub video path only receives composite or Y/C sources. It is, therefore, impossible to display a side-by-side twin view of two signals higher than 480i resolution. 480p resolutions and above can only be processed by the main path and the picture will always be on the left side when Twin View is selected. All video signals above 480i are processed by MID and D/A converted to 16bit component (8bit Y and 8bit CB/ CR). The digital component signal is sent via a LVDS transmitter to the DE2 board. The DE2 board serves as an interface between the video processing circuits and display panel. DCP (Digital Component Processor) performs the necessary scaling of the video signal to conform to the native resolution of the panel. The scaled video is sent to the panel driver as 4:2:2 and is processed to 4:4:4 10bit RGB where the logic board (not shown) allocates the video information to its corresponding pixels. Note that the DE2 board contains two micro-controllers. One controls the television functions and user interface while the other controls the panel driver. The TV micro-controller generates menu and service OSD. Keep this in mind as it becomes an important tool in troubleshooting video problems when trying to isolate the DIC2 and DEC2 boards as the cause. A NVM IC contains the customer preference settings along with service setup data. The NVM IC connected to the panel micro-controller contains necessary information for the panel such as white balance and gamma settings.
14
MAIN VIDEO CV/YC/YUV
DE 2 BOARD (KE37/42SX910) LPF CCP2 MAIN DRC MID LVDS TX LVDS RX DCP OSD PANEL DRIVER LVDS TX TO PLASMA PANEL DE 3 BOARD (KE50SX910)
FROM A BOARD SUB VIDEO CV/YC MS VIDEO LPF CCP2 SUB
LOCAL BUS CTL SIG OUT PANEL CTL SIG IN MICRO I2 C BUS
SIRCS I2C BUS
TV MICRO
DIC2 BOARD
IC4408 NVM
NVM IC4001
FIGURE 2-2 - KE37/42XS910 SERIES VIDEO PROCESSING
PDP01.2-2
3/23/04
The Plasma Panel

Figure 2-3 shows a layout of the plasma panel and associated circuit boards necessary to control the pixels. The Y-SUS and X-SUS boards generate the necessary pulses to sustain each horizontal line of pixels so that the address lines controlled by the ABUSL and ABUSR boards can light each vertical row of pixels. The scan and address line timing is controlled by the logic board. Notice the use of eight drive ICs from the Y-SUS board to the panel. The Y-drive signal utilizes the most energy to sustain the pixel lighting. This circuit consumes the most power and is a likely suspect when a failure occurs causing a completely dead panel display. These drivers should always be inspected when the panel does not light, especially if a panel failure warning appears from the diagnostics circuits. They are also part of the flexible cable molded into the panel, so the entire panel must be replaced. A new panel assembly is supplied with the logic, scan and address boards installed, thereby eliminating the need for most panel alignments (especially gamma). The logic board receives RBG digital data at CN1 from the DE2 board (not shown). Data from the DE2 is received via LVDS transmission and converted back to 30-bit parallel RGB to be allocated to each necessary pixel in accordance with scan and address timing. The logic board also contains NVM data for voltage settings unique to the panel installed in the unit. If the logic board is replaced to complete a repair, the NVM IC can be physically swapped to transfer these settings for the existing panel. It is an eight-pin surface mounted IC designated as M19 on this model. The necessary voltages for the audio, video and panel drive circuits are generated by the PSU board. Power control is achieved via a logic high command from the DE2 board. The logic board sends several control lines to the PSU board to turn on certain voltages for the Y and X-SUS boards. Voltage and current protection is monitored by several circuits.
15
FPC
XBB
FPC AND SCAN ICs
PLASMA PANEL
FPC
XBB
FPC
FPC
FPC
FPC
FPC
FPC
FPC
FPC
Y-SUS BOARD
ADM1 ADM2 ADM3 ADM4 ADM5 ADM6 ADM7 ADM8 ABUSL BOARD CN51 CN6 ABUSR BOARD CN41 CN4 LOGIC BOARD CN2
X-SUS BOARD
CN21
CN31 FROM DE2 BOARD AC IN
CN3
RGB INPUT (LVDS) CN1 POWER CTL PSU BOARD POWER SUPPLY TO A, DIC2, DE2 BOARDS
PDP01.2-3 3/23/04
TO PANEL BOARDS
FIGURE 2-3 - KE37/42XS910 PANEL AND DRIVERS
Protect and Self-Diagnostics

The power/standby LED will indicate certain faults detected by the protection monitoring circuits to assist in diagnosing where a potential failure may be located. Any of the five fault indications will result in a unit that will not power up or may power up and then shut down. The LED will blink in 0.5-second intervals followed by a three second separation period. They are as follows: Four blinks: One or more of the cooling fan motors is not functioning. Fan rotation feedback lines for each fan are monitored. If one fan is not rotating, check for B+ to that fan. If present, replace the fan. If B+ is present, or if all fans are not rotating, replace the A board. Six Blinks: This indicates a B+ power error. The switched 5V line on the power supply board is not present. If the power control line (VCEGO) at CN7 pin 8 is going high, replace the PSU board. If not, the DE2 board may be at fault. Seven Blinks: A DC voltage has been detected on one or more of the speaker lines. Replace the K board. Eight Blinks: An over-voltage condition has been detected at the DC-DC converter located on the X-SUS board. Replace the board. Nine Blinks: A panel module or over-temperature failure has been detected. There are two thermistors located on the panel. One detects the temperature of the large heat sink on the Y-SUS board and the other, the overall temperature of the panel assembly. Over-current is also detected for the scan drive circuits. If the LED blinks
16

panel alarm when first turned on, the panel monitoring circuits have detected a fault. This fault can be caused by a loss of the scan or address voltages. An over-current condition on these lines will also trigger a panel alarm. This is usually caused by a shorted scan-drive IC. Signs of overheating, such as cracks and/or blistering, usually occur on the IC surface. Over-temperature conditions will usually occur if the unit has been running for a while. This can be caused by excessive ambient room temperatures or improper installation of the display device.
Troubleshooting
Overview
Due to the large amount of digital processing, along with scan and address methods used, plasma televisions can generate symptoms that are unfamiliar to most technicians. The following troubleshooting techniques should help to isolate the cause in most cases. Documentation of unusual symptoms or known failures will be kept updated on the ESI server. Check the service website at HTTP://service.sel.sony.com for the latest bulletins regarding the model you are servicing. Circuit failures in a plasma television generally fall into three categories: 1. Dead set 2. Protection events 3. No or distorted video Units that exhibit no signs of operation require a few checks be done to determine if the power supply is at fault. The DE2 board contains the television micro-controller that is responsible for turning on certain switched voltages on the power regulator board along with telling the panel circuits to begin operating. Protect shutdown events are identified by the number of times the timer LED blinks. Most protect events are caused by excessive current on a voltage line or the loss of a certain voltage. A no video condition requires elimination of the plasma panel and its associated drive circuits before analyzing the video process circuits. The most important item to remember when servicing plasma displays is: If any lighting of the pixels is seen, the panel, along with the scan and address boards, is OK. It also indicates the presence of the required voltages for these circuits. Video distortions are easily isolated between the process circuits and panel/drive circuits by how they appear on the screen. Panel failures will usually display a fixed distortion or missing video on a horizontal or vertical axis. Video process circuit failures tend to be more random and usually across the entire screen. Since all repairs are board level, each scenario above will be approached using flowchart diagrams to properly isolate the failure to a particular board.
Troubleshooting a No Power Condition

If a set fails to turn on or appears dead the first item to check is whether the power supply is operational. The PSU board has a standby section generating a 3.3V and 5V source. If these are operating, the unit is not dead. The flowchart in Figure 2-4 is an initial starting point to determine this. If the standby circuit is operational, the next step is to determine if the power supply is at fault or is not being told to turn on. There are other voltages turned on by the Logic board. The symptom will usually be no picture with audio and the pixels on the panel are not priming. Using the flowchart in Figure 2-5 should lead you in the right direction.
17
Unit will not turn on
STBY LED lit or blinking?
No
STBY 3.3V at CN9002 pins 1~4?
Yes
Replace DE2 board
Yes
No Replace PSU board
Continuous blinking or groups?
Groups
Go to protect diagnostics chart Fig 2-6
Continuous
No Does panel light?
Go to power supply troubleshooting chart Fig 2-5
Yes
PSU board probably OK. Go to video Troubleshooting
FIGURE 2-4 - KE37/42XS910 DEAD SET PRELIMINARY CHECK
PDP01.2-4
3/23/04
18

Power Supply Troubleshooting (Standby OK)
High at CN7 pin 8 on PSU board?
No
High at CN3301 pin 5 on DE2 board?
No
Replace DE2 board
Yes
Yes Replace Logic board
VCC 5V at CN23 pin 3 PSU board? Yes
No
5V reg failure Replace PSU board
High at CN7 pin 6 on PSU board? Yes
No
Replace Logic board
No 63VDC (VA) at CN23 pin 1 on PSU board? High at CN7 pin 12 on PSU board? Yes Replace PSU board No Replace Logic board
Yes
85VDC (VA) at CN23 pin 9 on PSU board? Yes Replace Logic board
No
High at CN7 pin 14 on PSU board?
No
Replace Logic board
Replace PSU board
FIGURE 2-5 - KE37/42XS910 POWER SUPPLY TROUBLESHOOTING
PDP01.2-5
4/16/04
19
2. Troubleshooting the KE37/42XS910 Self-Diagnostics Troubleshooting

Figure 2-6 shows a flowchart to aid in locating the cause of self-diagnostics indications displayed by the standby/ power LED. A history of any diagnostics events can be viewed by pressing Display, 5, Volume , and the Power buttons, in order, on the remote commander when the unit is off.
Self-diagnostics indication
Four blinks of STBY/PWR LED?
Yes
More than one fan not rotating?
Yes
Check for 14VDC at CN9002 pin 10 of PSU board. Replace PSU if not present. Replace A board if present
No
No Check connections to fan. Replace fan if OK
Six blinks?
Yes
5VDC at CN9002 pin 9 PSU board? Yes
No Replace PSU board
No
Replace DE2 board
Seven blinks?
Yes
Replace K board
No
Eight blinks?
Yes
Replace X-SUS board
Nine blinks?
Yes
Go to "No Video" troubleshooting flowchart Figure 2-7
FIGURE 2-6 - KE37/42XS910 DIAGNOSTICS TROUBLESHOOTING
PDP01.2-6
4/16/04
20
2. Troubleshooting the KE37/42XS910 Video Circuit Troubleshooting

Video circuit failures manifest themselves in two different ways: No video at all or abnormalities in the picture display. In cases where no video is displayed, it is crucial to determine if the plasma panel is able to prime. Priming involves the generation of scan signals on the horizontal address lines to light the pixels just to the point where they emit a small amount of light. Once this is accomplished, the address lines complete the necessary firing of each pixel to generate the appropriate level of each pixel color to reproduce and image. If the panel is priming, it is a good indication that everything is OK with the glass panel and associated drive circuits. Focus will now turn to the video process circuits. If the panel is not priming and there is audio, a check of the required voltages is necessary to eliminate power supply line failures as the cause. Use the flowchart in Figure 2-5 to determine if this is the cause. If the power supply voltages appear OK, there may be a failure of the Y-SUS or X-SUS board. Only these boards are required to function to prime the panel. If the panel has been compromised and there are no visible signs of cracks, the only way to determine this is to check for scan pulses exiting the Y-SUS board. These pulses are quite large (170 to 230VPP). If present, it indicates the panel has lost its inert gas. A panel alarm may also be indicated by the standby/power LED. It will be flashing in sequences of nine. This is usually caused by an over-current condition and the likely suspect is a shorted scan drive IC. These drivers usually exhibit signs of overheating damage with burn holes and cracks appearing on their surface. The panel design used in this model incorporates the drivers on the flexible cable, which is part of the glass panel. Replacement of the panel is required if this occurs. Figure 2-7 is a flowchart that is helpful as a starting point for a no video condition with functional audio. If audio cannot be heard, it is best to return to the power supply troubleshooting flowcharts. If the problem is determined to be in the video process circuits, the A, DIC2 and DE2 boards must be isolated as the cause. The flowchart in Figure 2-8 will provide assistance. NOTE: The DIC2 and DE2 boards are enclosed within a shielded assembly known as the DM block. In order to access these boards for removal, the shield assembly must be taken apart. There is a LVDS cable connecting the two boards and this cable is looped outside of the shields. It is protected by a plastic cover. It is very important to remove this plastic cover and unplug both ends of the LVDS cable before attempting to separate the boards from the housing. Failure to do so will cause the shield to snag the LVDS connectors and damage them. The connectors are easily removed by pinching the release tabs and pulling them out. This is shown in Figure 29
21
No Video
Yes Is panel Priming?* Go to flowchart Figure 2-8
No
*Panel priming is determined by observing the screen for signs of pixel lighting. It is a dark raster similar to reference black in CRT units. It is best detected by turning the unit on and off to distinguish the difference between "true black" (panel off) and reference black (panel lit).
Signs of overheating on any scan-drive ICs? No
Yes Replace panel assembly
VS (85VDC) CN23-8 on PSU board? Yes
No
Go to power supply troubleshooting flowchart Figure 2-5
VS (85VDC) CN23-8 on PSU board?
No
Go to power supply troubleshooting flowchart Figure 2-5
Yes
Check for 85VPP scan pulses on connectors between Y-SUS board and scan drive ICs. Replace Y-SUS if none present. Replace Panel if pulses present.
FIGURE 2-7 - KE37/42XS910 INITAL "NO VIDEO" CHECK

22
PDP01.2-7
4/20/04
No video Panel is primed, audio OK
Can OSD be displayed?
No
LVDS connector from DE2 to Logic board connected?
No
Replace DE2 board
Yes
Yes Re-seat connector
Picture on right side when Twin View engaged?
No
Replace DIC2 board
Yes
Does component video input display picture?
Yes
Replace DIC2 board
No
Can picture from Memory Stick be displayed?
Yes
Replace A board
No Replace DIC2 board
FIGURE 2-8 - KE37/42XS910 VIDEO PROCESS TROUBLESHOOTING
PDP01.2-8
3/2/04
23
REMOVE PLASTIC COVER
LVDS CONNECTORS
DM BLOCK
FIGURE 2-9 - DM BLOCK LVDS CONNECTORS
PDP01.2-9
3/4/04
Troubleshooting Display Panel Abnormalities

Symptoms appearing on the screen during panel and drive circuit failures are generally easy to identify. Since the panel is controlled by intersecting scan and address lines, distortions, abnormal colors or missing pixel data will manifest themselves as horizontal or vertical lines or may occur in entire blocks. If you have acquired this only this chapter for troubleshooting the KE37/42XS910 model, obtain the section in Chapter 1, which contains additional information applying to general plasma theory and troubleshooting. In Figure 2-10, some examples of address circuit failures are shown. If one or more vertical lines of video information are missing or filled with a solid color, the panel will likely have to be replaced. Address information is sent to the right and left address boards (ABUSL and ABUSR). Each board processes the RBG digital data, which is then sent to each ADM processor. The ADM processors send ten lines of multiplexed data to the Flexible PC connectors. Each FPC contains three drive ICs where the signals are de-multiplexed to 57 lines each for the address lines on the panel. Single line failures are caused by problems in the drive outputs. Since the drivers are mounted to the FPC assembly, the panel must be replaced. Multiple lines of missing video, creating a block of no information, can be caused by the logic or address boards. It is unlikely that three drive ICs have failed. Suspect the address board first, followed by the logic board. Figure 2-11 illustrates potential symptoms that might be seen if a failure occurs in the scan drive circuits. The scan drive ICs are mounted to flexible PC cables so any single missing lines of video will require a panel replacement. If one-half of the picture is missing information, examine the drive ICs on the FPC adjacent to the failure for signs of overheating to determine whether the panel or Y-SUS board should be replaced.
24
FPC
XBB
FPC AND SCAN ICs
FPC
XBB
FPC
FPC
FPC
FPC
FPC
FPC
FPC
FPC
Y-SUS BOARD
ADM1
ADM2 ADM3 ADM4 ADM5 ABUSL BOARD
ADM6 ADM7 ADM8 ABUSR BOARD
X-SUS BOARD
LOGIC BOARD
BLANK OR DIFFERENT COLORED LINE
MULTIPLE MISSING LINES
FIGURE 2-10 - KE37/42XS910 PANEL ADDRESS FAILURES
PDP01.2-10
3/23/04
FPC
XBB
FPC AND SCAN ICs
FPC
XBB
FPC
FPC
FPC
FPC
FPC
FPC
FPC
FPC
Y-SUS BOARD
ADM1 ADM2 ADM3 ADM4 ABUSL BOARD
ADM5
ADM6
ADM7
ADM8
X-SUS BOARD
ABUSR BOARD
LOGIC BOARD
SINGLE MISSING SCAN LINES
ONE-HALF SCREEN MISSING

PDP01.2-11 3/23/04
FIGURE 2-11 - KE37/42XS910 PANEL SCAN FAILURES
25
Disassembly
Overview
This section will cover the required steps to disassemble the unit down to panel replacement. Due to the large number of screws involved, be sure to have a container to place them in during the procedure. It is extremely important to place the plasma television on a repair stand of adequate size along with a piece of foam padding to protect the screen. Be certain the padding is at least of the screen size to prevent flexing of the glass panel, which is easily damaged. The glass can withstand moderate bending but the barrier ribs separating the vertical lines of pixels are easily damaged by minor flexing. HINT: Most of the screws securing shields and circuit boards are 3mm machine with attached flat washers. Larger machine and self-tapping screws are allocated to support brackets and the rear cover.
Speaker Housing and Rear Cover Removal

As shown in figure 2-12, remove the left and right rear speaker covers by pulling upward, using the finger access holes. This exposes the rear cover screws on each side. Remove the following screws for the rear cover: Four 5X25 machine (black) securing the stand. The stand must be removed first. Fourteen 4X16 black, self tap (black) Sixteen 3X6 machine (black) Six 4X10 machine (black) Six 5X10 machine (black)
FINGER HOLES FOR REMOVAL
FIGURE 2-12 - SPEAKER COVER REMOVAL

26
PDP01.2-12
3/4/04

Y-SUS BOARD PSU BOARD X-SUS BOARD
K BOARD
A BOARD (UNDER SHIELD)
DM BLOCK (DIC2, DE2, MS2A)

PDP01.2-13 3/23/04
FIGURE 2-13 - KE37/42XS910 BOARD LAYOUT
Once the rear cover has been removed, the view shown in figure 2-13 is seen. The Y-SUS, X-SUS, Logic, Scan Drive and Address boards are not visible as they are located under the shields. Use this view as a guide when re-assembling the unit to properly dress the cable harnesses. Removal of the left and right speaker housing is shown in Figure 2-14. This step is not necessary if the plasma panel is to be replaced.
REMOVE 9 SCREWS (4x12 SELF TAP)
FIGURE 2-14 - SPEAKER HOUSING REMOVAL

PDP01.2-14 3/2/04
27
2. Troubleshooting the KE37/42XS910 A Board and DM Block Removal

Figure 2-15 illustrates the location of the video input and processing circuit boards. The cover over the video input jacks must be removed. This cover also secures the AC input receptacle. The earth ground wire must also be removed as shown. The metal shield above the input connectors covers the A board. Use caution when removing the nylon lock nuts as it is easy for them to fall out when lifting the shield. The DM block must be removed after the video input cover and A board shield since it attaches to the A board with a large connector (CN8001). Remove two connectors CN1813 and CN1814 (not shown) at the bottom of the DM block. Loosen the four machine screws securing the DM block and GENTLEY lift it from the A board.
REMOVE TWO 3X6 MACHINE SCREWS AND NYLON LOCK PINS
REMOVE NUTS SECURING DVI CONNECTOR
REMOVE FOUR 6x12 SELF-TAP SCREWS AND GROUND WIRE
FIGURE 2-15 - VIDEO INPUT COVER AND SHIELD REMOVAL
PDP01.2-15
3/4/04
There is a LVDS connector located on the upper part of the DM block connected to the Logic board. LVDS cables use thin wires. They are easily damaged. Remove the two LVDS and one communication connector as shown in Figure 2-16.
28
MEMORY STICK LVDS CONNECTOR
COM CONNECTOR
DE2 TO LOGIC BOARD LVDS CONNECTOR
FIGURE 2-16 - DM BLOCK REMOVAL
PDP01.2-16
3/4/04
In Figure 2-17, removal of the A board is shown. The listed connectors are removed along with the RF input cable to the tuner. Four 3X6 machine screws secure the board. Remove the board and place in a safe location.
CN8003
CN8002 CN8005 CN8001
CN8601
CN8230
FIGURE 2-17 - A BOARD REMOVAL
PDP01.2-17
3/4/04
29
2. Troubleshooting the KE37/42XS910 K Board Removal

In Figure 2-18, removal of the K board is shown. The board has a shield on top that has been removed. The shield is secured with two 3X6 machine screws. The bottom shield securing the K board is attached to the chassis with four 3X6 machine screws. Remove the three cable and two ground connectors as shown. Remove the cables from the purse-lock retainers. Unplug all connectors attaching cables to cables. Set cable harness to the right side and out of the way. Note the layout of the cables in this picture. It will be useful when re-assembling the unit.
UNPLUG ALL CABLE CONNECTORS
CN3061
CN3001
CN3062
GROUND CONNECTORS
FIGURE 2-18 - K BOARD REMOVAL

Power Supply Removal
PDP01.2-18
3/4/04
Figure 2-19 shows the power supply (PSU) board after the fan bracket (not shown) has been removed. The board is secured by seven 3X6 machine screws. If the board is going to be removed for replacement of the panel, only CN6, CN7 and CN23 need to be removed. The remaining connectors are for the K and DM block. Simply place the DM block on top of the PSU board and remove the assembly with the K board and fan cables as shown in Figure 2-20.
30
CN23
CN6
CN7
FIGURE 2-19 - POWER SUPPLY REMOVAL
PDP01.2-19
3/4/04
FIGURE 2-20 - DM AND PSU REMOVAL
PDP01.2-20
3/4/04
31
2. Troubleshooting the KE37/42XS910 Lower Shield Removal

If the panel is going to be replaced, the lower shield assembly that held the A board and DM block must be removed. Figure 2-21 illustrates this. It is secured by four 3x6 machine and two 3X12 self-tapping screws. The self-tapping screws only need to be loosened.
REMOVE FOUR 3X6 MACHINE SCREWS
LOOSEN SELFTAPPING SCREWS
FIGURE 2-21 - LOWER SHIELD REMOVAL
PDP01.2-21
3/23/04
Y-SUS and X-SUS Shield Removal

Figure 2-22 shows the Y-SUS board shield and its removal procedure. This shield must be removed to access the Y-driver boards and ICs for inspection and/or replacement. This photo shows the K board installed. Unless the K board needs replacement, it can be left intact. Two 3X6 machine and four 3X12 self-tap screws are securing the unit. Pay close attention to the self-tap screw located below the fan motor. Unplug the fan motor and remove the shield. Figure 2-23 demonstrates the removal of the X-SUS shield. Note the layout or the wiring in the purse-lock retainers and the removal of ground connections for reference when re-installing the shield.
32
UNPLUG FAN CABLE REMOVE TWO 3x6 MACHINE SCREWS
REMOVE FOUR 4x12 SELF-TAP SCREWS
FIGURE 2-22 - Y-SUS SHIELD REMOVAL
PDP01.2-22
3/4/04
REMOVE ONE 3x6 MACHINE SCREW AND GROUND CABLE
UNPLUG FAN REMOVE TWO 3x6 MACHINE SCREWS
UNPLUG SPEAKER CONNECTORS AND GROUND LUGS REMOVE FOUR 3x6 SELF-TAP SCREWS
FIGURE 2-23 - X-SUS SHIELD REMOVAL
PDP01.2-23
3/4/04
33
2. Troubleshooting the KE37/42XS910 Panel Removal

Once all of the above circuit boards and shields have been removed, the panel is ready for removal. Two large brackets are attached to the panel with four 5X10 machine screws. Although the brackets do not come with the panel, they should be left intact to ease the removal. The replacement panel will come with disposable brackets to assist in installation. The original brackets can then be transferred to the new panel. By removing the four 4X8 machine and four 4X12 self-tap screws securing the bracket to the top and bottom of the filter glass assembly, the panel can be lifted out. This is illustrated in Figures 2-24 and 2-25. Notice the location of the Logic and Address boards in Figure 2-24. NOTE: Panel replacement should only be performed in the shop. The removal of a large number of self-tap screws creates a considerable amount of plastic contaminants. Accumulated dust, along with the plastic pieces, can easily fall onto the backside of the filter glass. This must be thoroughly removed using air from a compressor. It is extremely important to remove all contaminants before installing the new panel. The replacement panel will come with the Logic, Address, Y-SUS and X-SUS boards installed. The serial number of the panel will need to be documented if it is replaced. The label containing the serial number is visible above the Y-SUS board after the shield has been removed as outlined in Figure 2-22. A view of the label will be shown next in the Y-SUS board removal.
LOGIC BOARD
ADDRESS BOARDS
REMOVE FOUR 4x16 SELF-TAP SCREWS AT BOTTOM
REMOVE FOUR 4x8 MACHINE SCREWS AT TOP
FIGURE 2-24 - PANEL BRACKET REMOVAL
PDP01.2-24
3/4/04
34
FIGURE 2-25 - KE37/42XS910 PANEL REMOVAL
PDP01.2-25
3/23/04
Y-SUS and X-SUS Board Removal

Should the need arise to replace the Y-SUS or X-SUS boards, removal is illustrated in Figure 2-26 for the Y-SUS board and Figure 2-27 for the X-SUS board. Note Figure 2-27 and the location of the panel serial number and voltage adjustment labels. Also note the Y-Scan drive ICs located on the large flexible PC cables attached to the plasma panel in Figure 2-26. Both boards require the removal of nine screws each in order to properly unplug the large connectors. The mounting holes on the boards sit on top of a post with a shank that prevents horizontal movement of the boards unless lifted slightly.
REMOVE NINE SILVER 3x6 MACHINE SCREWS
FIGURE 2-26 - Y-SUS BOARD REMOVAL
PDP01.2-26
3/23/04
35
REMOVE NINE 3X6 MACHINE SCREWS
LABELS FOR PANEL ID AND VOLTAGE SETTINGS
FIGURE 2-27 - X-SUS BOARD REMOVAL
PDP01.2-27
3/23/04
36
3. Troubleshooting the KE50XS910
Chapter 3 - Troubleshooting the KE50XS910

Overview
The KE50XS910 is a high-definition-ready plasma television with a built-in NTSC tuner along with the necessary video processing circuitry to accept composite, Y/C, component and DVI video sources along with analog L/R audio. Other plasma models function as monitoring devices and rely on an external receiver (known as a Media Box) to receive and process video and audio. This chapter will point out the circuits that are unique to this model along with a description of each boards function. Practical troubleshooting methods will be discussed followed by a systematic procedure for disassembling and re-assembling the unit. Plasma televisions rely on a large, gassed-filled glass panel to generate video. It is important that this glass panel be properly braced and secured by brackets and the back cover assembly. A considerable amount of shielding is also required due to the high voltage levels generated by the scan drivers. Because of this, a large number of screws are utilized. A full disassembly can require the removal of a hundred screws or more! Another factor is the use of a number of circuit boards spread throughout the rear of the large panel assembly. This requires the use of many wiring harness mounts and paths. It is extremely important to route these wires in their correct configuration to minimize interference and prevent any wires from being pinched or cut. Clearances between shields, brackets and the rear cover are minimal so this is very important. An extensive number of illustrations will be used to assist the technician in routing the wiring correctly and returning all of the screws back to their original location.
Signal Processing
Overall Block Diagram
Referring to Figure 3-1, an overall block diagram demonstrates the various paths for the different video and audio inputs. A NTSC tuner is located on the A board. A/V inputs 1, 2 and 3 accept composite or Y/C video along with L/R audio. A/V inputs 4 and 5 accept component video only along with L/R audio. Video resolutions of 480i, 480p, 1080i and 720p are supported. The DVI input receives differential RGB digital video information along with analog L/R audio. The UD board contains the receiver/decoder to convert the digital signal to Y/CB/CR along with HDCP control. The HM board contains a Memory Stick slot for display of JPEG still pictures and MPEG1 audio/video playback. The information from the memory stick is processed and sent via a LVDS (Low Voltage Differential Signal) transmitter to the MS2F board. The video and/or audio signals are processed and D/A converted. Audio is sent to A/V switch2 while video information is sent to the DIC2 board. NOTE: The MS2F board is enclosed within a shielded assembly (known as the DM Block) containing the DIC2 and DE3 boards. Although the service manual refers to this as a replaceable assembly, it is not. The boards inside must be replaced individually. All non-component video signals and analog L/R audio are controlled by AVSW1 and AVSW2. Component and DVI video are routed through a component interface and applied to a video switch. This video switch allows the selection of DVI, component, Y/C or composite video signals to be routed to the main video process path. The sub-video path can only accept signals from the tuner and inputs 1 through 3 and is, therefore, limited to 480i resolutions only. The main and sub video are routed to the DIC2 (Digital Imaging Core) board. Necessary standby and switched voltages are generated by the regulator block (sometimes referred to as PSU). Analog audio is received by the K board where it is amplified to drive a set of speakers.
37
REGULATOR BLOCK
ANT IN INPUT 1 INPUT 2 INPUT 3 H2 BOARD
NTSC TUNER
A BOARD
DIC2 BOARD
DE3 BOARD
MAIN V AVSW1 AVSW1 SUB V AUDIO
VIDEO SW
CCP2 MAIN DRC MID CCP2 MAIN
DCP
PANEL DRIVER
TO PANEL
TV MICRO
PANEL MICRO
INPUT 4 INPUT 5 DVI INPUT UD BOARD COMP I/F AUDIO PROCESS MS2F BOARD MEMORY HM STICK BOARD INPUT MID MICRO K BOARD AUDIO AMP L TO R SPEAKERS
FIGURE 3-1 - KE50XS910 SERIES OVERALL BLOCK
PDP01.3-1
4/16/04
Video Signal Processing

Referring to Figure 3-2, the main, sub and memory stick paths are shown entering the DIC2 board. Main video is processed by CCP2 (Composite to Component Processor) if it is component. If the main video signal is 480i, the DRC performs the necessary line doubling to 960i. The sub video path only receives composite or Y/C sources. It is, therefore, impossible to display a side-by-side twin view of two signals higher than 480i resolution. 480p resolutions and above can only be processed by the main path and the picture will always be on the left side when Twin View is selected. All video signals above 480i are processed by MID and D/A and converted to 16bit component (8bit Y and 8bit CB/CR). The digital component signal is sent via a LVDS transmitter to the DE3 board. The DE3 board serves as an interface between the video processing circuits and display panel. DCP (Digital Component Processor) performs the necessary scaling of the video signal to conform to the native resolution of the panel. The scaled video is sent to the panel driver as 4:2:2 and is processed to 4:4:4 10bit RGB where the Digital Video board (not shown) allocates the video information to its corresponding pixels. Note that the DE3 board contains two micro-controllers. One controls the television functions and user interface while the other controls the panel driver. The TV micro-controller generates menu and service OSD. Keep this in mind as it becomes an important tool in troubleshooting video problems when trying to isolate the DIC2 and DE3 boards as the cause. A NVM IC contains the customer preference settings along with service setup data. The NVM IC connected to the panel micro-controller contains necessary information for the panel such as white balance and gamma settings.
38
MAIN VIDEO CV/YC/YUV
LPF
CCP2 MAIN DRC MID LVDS TX
DE 3 BOARD
FROM A BOARD SUB VIDEO CV/YC LPF CCP2 SUB
LVDS RX
DCP OSD
PANEL DRIVER
LVDS TX TO PLASMA PANEL
LOCAL BUS CTL SIG OUT PANEL CTL SIG IN MICRO I2 C BUS
SIRCS I2C BUS
TV MICRO
DIC2 BOARD
IC4408 NVM
NVM IC4001
FIGURE 3-2 - KE50XS910 SERIES VIDEO PROCESSING
PDP01.3-2
4/16/04
The Plasma Panel

Figure 3-3 shows a layout of the plasma panel and associated circuit boards necessary to control the pixels. 30bit RGB data is received by the interface board and processed for timing by the scan and address circuits. The Digital Video board distributes the properly timed information. The Y-SUS and X-SUS boards generate the necessary pulses to sustain each horizontal line of pixels so that the address lines, which are controlled by the left and right address boards, can light each vertical row of pixels. The scan and address line timing is controlled by the digital video board. Notice the use of 12 drive ICs from the Y-SUS board to the panel. The Y-drive signal utilizes the most energy to sustain the pixel lighting. Consequently, this circuit consumes the most power and is a likely suspect when a failure occurs causing a completely dead panel display. These drivers should always be inspected when the panel does not light, especially if a panel failure warning appears from the diagnostics circuits. They are mounted on a two circuit boards and the flexible PC cables between the panel and the boards are permanently attached, requiring an entire panel replacement if there is a failure. The Interface board receives RBG digital data from the DE3 board (not shown). Data from the DE3 is received via LVDS transmission and converted back to 30-bit parallel RGB to be allocated to each necessary pixel in accordance with scan and address timing. The Interface board also contains NVM data for the voltage settings specific to the panel installed in the unit. If the Interface board is replaced to complete a repair, the NVM IC can be physically swapped to transfer these settings for the existing panel. The necessary voltages for the audio, video and panel drive circuits are generated by the Regulator board. Power control is achieved via a logic high command from the DE3 board.
39
SCAN DRIVER BOARDS
ADDRESS BOARD
ADDRESS BOARD
FPC YSUS BOARD
FPC XSUS BOARD
PLASMA PANEL
FPC
FPC
ADDRESS BOARD
ADDRESS BOARD
LVDS FROM DE3 BOARD
INTERFACE BOARD
CONTROL
DIGITAL VIDEO BOARD
REGULATOR BOARD
AC INPUT
TO PANEL BOARDS
FIGURE 3-3 - KE50XS90 PANEL AND DRIVE BOARDS
PDP01.3-3
3/23/04
Protect and Self-Diagnostics

The power/standby LED will indicate certain faults detected by the protection monitoring circuits to assist in diagnosing where a potential failure may be located. Any of the five fault indications will result in a unit that will not power up or, may power up and then shut down. The LED will blink in 0.5-second intervals, followed by a three second separation period. They are as follows: Four blinks: One or more of the cooling fan motors is not functioning. Fan rotation feedback lines for each fan are monitored. If one fan is not rotating, check for B+ to that fan. If present, replace the fan. If B+ is present or if all fans are not rotating, replace the A board. Six Blinks: This indicates a B+ power error. The switched 5V line on the power supply board is not present. If the power control line (VCEGO) at CN7 pin 8 is going high, replace the PSU board. If not, the DE3 board may be at fault. Seven Blinks: A DC voltage has been detected on one or more of the speaker lines. Replace the K board. Eight Blinks: An over-voltage condition has been detected at the DC-DC converter located on the X-SUS board. Replace the board. Nine Blinks: A panel module or over-temperature failure has been detected. There are two thermistors located on the panel. One detects the temperature of the large heat sink on the Y-SUS board and the other the overall temperature of the panel assembly. Over-current is also detected for the scan drive circuits. If the LED blinks a
40

panel alarm when first turned on, the panel monitoring circuits have detected a fault. This fault can be caused by a loss of the scan or address voltages. An over-current condition on these lines will also trigger a panel alarm. This is usually caused by a shorted scan-drive IC. Signs of overheating, such as cracks and/or blistering, usually appear on the IC surface. Over-temperature conditions will usually occur if the unit has been running for a while. This can be caused by excessive ambient room temperatures or improper installation of the display device.
Troubleshooting
Overview
Due to the large amount of digital processing, along with scan and address methods used, plasma televisions can generate symptoms that are unfamiliar to most technicians. The following troubleshooting techniques should help to isolate the cause in most cases. Documentation of unusual symptoms or known failures will be kept updated on the ESI server. Check the service website at HTTP://service.sel.sony.com for the latest bulletins regarding the model you are servicing. Circuit failures in a plasma television generally fall into three categories: 1. Dead set 2. Protection events 3. No or distorted video Units that exhibit no signs of operation require a few checks be done to determine if the power supply is at fault. The DE3 board contains the television micro-controller that is responsible for turning on certain switched voltages on the power regulator board along with telling the panel circuits to begin operating. Protect shutdown events are identified by the number of times the timer LED blinks. Most protect events are caused by excessive current on a voltage line or the loss of a certain voltage. A no video condition requires elimination of the plasma panel and its associated drive circuits before analyzing the video process circuits. The most important item to remember when servicing plasma displays is: If any lighting of the pixels is seen, the panel along with the scan and address boards are OK. It also indicates the presence of the required voltages for these circuits. Video distortions are easily isolated between the process circuits and panel/drive circuits by how they appear on the screen. Panel failures will usually display a fixed distortion or missing video on a horizontal or vertical axis. Video process circuit failures tend to be more random and usually across the entire screen. Since all repairs are board level, each scenario above will be approached using flowchart diagrams to properly isolate the failure to a particular board.
Self-Diagnostics Troubleshooting
Figure 3-4 shows a flowchart to aid in locating the cause of self-diagnostics indications displayed by the standby/ power LED. A history of any diagnostics events can be viewed by pressing Display, 5, Volume , and the Power buttons, in order, on the remote commander when the unit is off.
41

Self-diagnostics indication
Four blinks of STBY/PWR LED?
Yes
More than one fan not rotating?
Yes
Check for 14VDC at CN3 pin 10 of Regulator board. Replace Regulator if not present. Replace A board if present
No
No Check connections to fan. Replace fan if OK
Six blinks?
Yes
5VDC at CN3 pin 9 Regulator board?
No
Replace Regulator board
No
Yes Replace DE2 board
Seven blinks?
Yes
Replace K board
No
Eight blinks?
Yes
Replace X-SUS board
Yes Nine blinks?
Panel alarm. Go to "No Video" flowchart Figure 3-7
FIGURE 3-4 - KE37/42XS910 DIAGNOSTICS TROUBLESHOOTING
PDP01.3-4
4/20/04
Troubleshooting a No Power Condition

If a set fails to turn on or appears dead, the first item to check is whether the power supply is operational. The Regulator board has a standby section generating a 3.3V and 5V source. If these are operating, the unit is not dead. The flowchart in Figure 3-5 is intended as a guide to determine if the Regulator board is at fault. One of the items referred to in the flowchart is a red and green LED located on the Interface board. The red LED indicates standby while the green indicates power-on. This board is difficult to see but looking down the bottom of the regulator board from the top of the unit, a lit LED is easily detected. If unit is laying face down with the rear cover removed, the lower shield assembly holding the A board can be lifted after the screws are removed. This
42

is covered later in this chapter in the disassembly section. The red LED may be flashing three times and is a valuable indicator when troubleshooting a no video condition. It is mentioned in the flowcharts to follow. Figure 3-6 shows the Interface board and the LED locations.
Unit will not power up
Is red or green LED on Interface board lit? Yes Which LED is lit?
No
3.3VDC at pin 11 of R1 on Interface board?
No
Green (D4001)
Power supply is on Go to "No picture (black screen)" flow chart
Yes
Replace Power Supply board
Red (D4002)
Check Pin 2 of D17 connector on DIGITAL VIDEO assembly. Disconnect flexible cable between D15 on DIGITAL VIDEO and No R4 on INTERFACE assembly. Clean edge contacts of the flexible cable and reconnect it to the connectors.
Is there 3.3V at the check point? No Replace DE3 board
Is 3V (approx) on Pin 4 of R6 on Interface Board?
Yes Replace Digital Video board
Yes Disconnect flexible cable between D15 on DIGITAL VIDEO and R4 on INTERFACE assembly. Clean edge contacts of the flexible cable and reconnect it to the connectors.
Is there 3.3V at Pin 11 of D17 on D VIDEO?
No Replace Interface board
Does the symptom still occur?
No Finish
Yes Replace Interface board
Does the symptom still occur?
No Finish
Yes Replace Digital Video board
FIGURE 3-5 - KE50XS910 POWER SUPPLY FLOWCHART
PDP01.3-5
3/18/04
43
D4001 STBY (RED) D4002 PWR-ON (GREEN)
CAN BE VIEWED BY LIFTING A BOARD AND LOWER SHIELD ASSEMBLY
FIGURE 3-6 - LED INDICATORS ON INTERFACE BOARD PDP01.3-6
3/18/04
44
3. Troubleshooting the KE50XS910 Video Circuit Troubleshooting

Video circuit failures manifest themselves in two different ways: No video at all and abnormalities in the picture display. In cases where no video is displayed, it is crucial to determine if the plasma panel is able to prime. Priming involves the generation of scan signals on the horizontal address lines to light the pixels just to the point where they emit a small amount of light. Once this is accomplished, the address lines complete the necessary firing of each pixel to generate the appropriate level of each pixel color to reproduce an image. If the panel is priming, it is a good indication that everything is OK with the glass panel and associated drive circuits. Focus will now turn to the video process circuits. If the panel is not priming and there is audio, a check of the required voltages is necessary to eliminate power supply line failures as the cause. The presence of audio is an important clue as it indicates the power supply is turning on. Several voltage lines specifically allocated to the panel drive circuits are monitored for low voltage conditions. Any failure of these monitored lines will cause the interface board to enter a protect status. When this occurs, the red LED on the Interface board will be flashing in sequences of three. A panel alarm may also be indicated by the standby/power LED. It will be flashing in sequences of nine. This is usually caused by an over-current condition and the likely suspect is a shorted scan drive IC. These drivers usually exhibit signs of overheating damage with burn holes and cracks appearing on their surface. The panel design used in this model incorporates the drivers on two boards permanently attached to the flexible cables, which are part of the glass panel. Replacement of the panel is required if this occurs. Figures 3-7, 3-8 and 3-9 contain flowcharts to assist in isolating the cause of a no video condition caused by a failure of the panel to light or prime. If the problem is determined to be in the video process circuits, the A, DIC2 and DE3 boards must be isolated as the cause. The flowchart in Figure 3-10 will provide assistance.
45

No video No panel priming
Is red LED on Interface board lit? Yes Is D4002 flashing 3X? No *Connect pin 7 of R6 (MASK) on INTERFACE board to GND
No
Power supply problem Go to "No Power" flow chartFig 3-5 R6
Yes
There is a missing voltage. Go to the flowchart in Figure 3-8 for further diagnosis
GND = white screen 10K = color bars
* A 10K resistor to ground will produce color bar pattern
Does the screen display full white Image?
No
Check D5401 and D5402 (red and green LED) on DIGITAL VIDEO board
Are these LEDs lit? Yes
No
Replace Digital Video assembly
Yes
6.5VDC pin 7 of conncetor R1 on Interface board?
No
Check Power Supply board
Switch S5201 on Digital Video board set to normal?
No Set the SW to normal
Yes Yes Replace Y-SUS board Replace Interface board. Does the symptom still occur? Yes Replace X -SUS board Yes Finish
No
Finish
Is normal picture now displayed on screen?
No
Input signal problem. Go to video process flowchart in Figure 3-10
FIGURE 3-7 - NO VIDEO TROUBLESHOOTING FLOWCHART
PDP01.3-7
3/9/04
46
Red LED (D4002) on Digital Video board flashing 3 times
Set switch SW5201 to "off". LED still blinkng? Yes Check VSUS (215-22-V) and VADR (55-60V) on Power Supply.*
No
Go to "Missing Low Voltage" flowchart Fig 3-9
*V-SUS CN8 pin 9 VADR CN12 pin 1 Power Supply Board
Which voltage is low or missing? VSUS
VADR
Disconnect D2 connector on Digital Video board. Recheck VADR voltage. NOTE: Should check within a few seconds before shutdown Is the VADR voltage normal?
Disconnect Y4 connector on Y Drive board. Re-check VSUS voltage. NOTE: Should check within a few seconds before shutdown Is the VSUS voltage normal? Yes Check resistance between PSUS and VH on Y Drive assembly
Yes
Replace Panel assembly
No Replace Power Supply assembly
No Reconnect Y4 connector on Y Drive & disconnect X2 connector on X Drive. Re-check VSUS voltage Short? (normally high impedance) Yes
No NOTE: Should check within a few seconds before shutdown Is the VSUS voltage normal? Yes Replace X Drive assembly Replace Power Supply assembly
No
PSUS & VH TEST POINT Scan-Drive IC shorted Replace panel
Replace Y Drive assembly
FIGURE 3-8 - KE50XS910 POWER SUPPLY WARNING
PDP01.3-8
3/18/04
47

Low voltage Warning Red LED on interface board flashing 3X
Set switch S5201 on interface board to "OFF"
3.3VDC at TP K2038 on Y-SUS board?
Yes
Replace Y Drive assembly.
No
3.3VDC at TP K1017 on X-SUS board? No
Yes
Replace X Drive assembly.
16.5VDC at connector X2 pin on X-SUS board? Yes
No
Replace INTERFACE assembly.
Replace Digital Video assembly.
Has red LED stopped blinking?
No
Replace Power Supply assembly
Yes Finish
FIGURE 3-9 - KE50XS910 LOW VOLTAGE TROUBLESHOOTING

48
PDP01.3-9
3/9/04
No video Panel is primed, audio OK
Can OSD be displayed?
No
LVDS connector from DE2 to Logic board connected?
Yes
Replace DE3 board
Yes
No Re-seat connector
Picture on right side when Twin View engaged?
No
Replace DIC2 board
Yes
Does component video input display picture?
Yes
Replace DIC2 board
No
Can picture from Memory Stick be displayed?
Yes
Replace A board
No Replace DIC2 board
FIGURE 3-10 - KE50XS910 VIDEO PROCESS TROUBLESHOOTING
PDP01.3-10
3/23/04
49

NOTE: The DIC2 and DE3 boards are enclosed within a shielded assembly known as the DM block. In order to access these boards for removal, the shield assembly must be taken apart. There is a LVDS cable connecting the two boards and this cable is looped outside of the shields. It is protected by a plastic cover. It is very important to remove this plastic cover and unplug both ends of the LVDS cable before attempting to separate the boards from the housing. Failure to do so will cause the shield to snag the LVDS connectors and damage them. The connectors are easily removed by pinching the release tabs and pulling them out. This is shown in Figure 311
REMOVE PLASTIC COVER
LVDS CONNECTORS
DM BLOCK
FIGURE 3-11 - DM BLOCK LVDS CONNECTORS

Troubleshooting Display Panel Abnormalities
PDP01.3-11
3/9/04
Symptoms appearing on the screen during panel and drive circuit failures are generally easy to identify. Since the panel is controlled by intersecting scan and address lines, distortions, abnormal colors or missing pixel data will manifest themselves as horizontal or vertical lines and may occur in entire blocks. If you have acquired only this chapter for troubleshooting the KE50XS910 model, obtain the section in Chapter 1, which contains additional information applying to general plasma theory and troubleshooting. In Figure 3-12, some examples of address circuit failures are shown. If one or more vertical lines of video information are missing or filled with a solid color, the panel will likely have to be replaced. Note the use of address boards and drive ICs on the upper and lower ends of the panel. This model uses a dual-scan panel. Address control is shared so that the upper and lower drivers scan half of the panel. Another unique feature of the panel used in this model is the display of white whenever drive information is lost for the address line(s). Most panel designs display a dark section whenever a drive failure occurs so this is important to remember for this model. Single line failures are caused by problems in the drive outputs. Since the drivers are mounted to the FPC assembly, the panel must be replaced. Multiple lines of missing video creating a block of no information can be caused by the Digital Video or Address boards. It is unlikely that three drive ICs have failed. Suspect the address board first, followed by the Digital Video board. If an entire block of video is missing, the address drive signals can be swapped to see if the block can be moved to another area of the screen. The Digital Video board distributes the drive information to all of the Address boards and there is sufficient movement in the FPC cables to accomplish this. If the missing block of video remains in the same location, one of the address drive ICs has failed and the panel must be replaced. If the block can be moved, the Digital Video board is at fault. Figure 3-13 illustrates potential symptoms that might be seen if a failure occurs in the scan drive circuits. The scan drive ICs are mounted to a pair of circuit boards that has the FPC cables bonded to them. Any single missing lines of video will require a panel replacement. If one-half of the picture is missing information, examine the drive ICs on the FPC adjacent to the failure for signs of overheating to determine whether the panel or Y-SUS board should be replaced.
50

NOTE: Whenever a scan drive IC fails, no output will appear from that IC or any of the succeeding drivers on that board. If the top IC on one board were to fail, only half of the video would be displayed.
BLANK OR DIFFERENT COLORED LINES
MISSING BLOCK OF VIDEO
SCAN DRIVER BOARDS
ADDRESS BOARD
ADDRESS BOARD
FPC YSUS BOARD
FPC XSUS BOARD
FPC
FPC
ADDRESS BOARD
ADDRESS BOARD
INTERFACE BOARD
DIGITAL VIDEO BOARD
FIGURE 3-12 - KE50XS910 PANEL ADDRESS FAILURES
PDP01.3-12
3/8/04
51

SINGLE HORIZONTAL LINES OF MISSING VIDEO MULTIPLE HORIZONTAL LINES OF MISSING VIDEO
SCAN DRIVER BOARDS
ADDRESS BOARD
ADDRESS BOARD
FPC DEFECTIVE IC YSUS BOARD
FPC XSUS BOARD
FPC
FPC
ADDRESS BOARD
ADDRESS BOARD
INTERFACE BOARD
DIGITAL VIDEO BOARD
FIGURE 3-13 - KE50XS910 PANEL SCAN FAILURES
PDP01.3-13
3/8/04
Disassembly
Overview
This section will cover the required steps to disassemble the unit down to panel replacement. Due to the large number of screws involved, be sure to have a container in which to place them during the procedure. It is extremely important to place the plasma television on a repair stand of adequate size along with a piece of foam padding to protect the screen. Be certain the padding is at least of the screen size to prevent flexing of the glass panel, which is easily damaged. The glass can withstand moderate bending but the barrier ribs separating the vertical lines of pixels are easily damaged by minor flexing. HINT: Most of the screws securing shields and circuit boards are 3mm machine with attached flat washers. Larger machine and self-tapping screws are allocated to support brackets and the rear cover.
52
3. Troubleshooting the KE50XS910 Speaker Housing and Rear Cover Removal

As shown in figure 3-14, remove the left and right rear speaker secured by two 4X16 self-tap screws each. The rear cover screws will now be exposed. Remove the following screws for the rear cover: Four 5X40 machine (black) securing the stand. The stand must be removed first. Fourteen 4X16 black, self tap (black) Eight 3X6 machine (black) Six 4X10 machine (black) Eight 5X10 machine (black)
REMOVE TWO 4x16 SELF-TAP
FIGURE 3-14 - KE50XS910 SPEAKER COVER REMOVAL
PDP01.3-14
3/9/04
53

Once the rear cover has been removed, the view shown in figure 3-15 is seen. The Y-SUS, X-SUS, Scan Drive and Address boards are not visible as they are located under the shields. Use this view as a guide when reassembling the unit to properly dress the cable harnesses.
Y-SUS BOARD
DIGITAL VIDEO BOARD
REGULATOR BOARD
X-SUS BOARD
Y-SUS BOARD
A BOARD (UNDER SHIELD)
DM BLOCK DIC2, DE3 BOARDS

PDP01.3-15 3/9/04
FIGURE 3-15 - KE50XS910 CIRCUIT BOARDS

A Board and DM Block Removal
Figure 3-16 illustrates the location of the video input and processing circuit boards. The cover over the video input jacks must be removed. This cover also secures the AC input receptacle. The earth ground wire must also be removed as shown. The metal shield above the input connectors covers the A board. Use caution when removing the nylon lock nuts as it is easy for them to fall out when lifting the shield. The DM block must be removed after the video input cover and A board shield since it attaches to the A board with a large connector (CN8001). Remove two connectors CN1813 and CN1814 (not shown) at the bottom of the DM block. Loosen the four machine screws securing the DM block and GENTLEY lift it from the A board. There is a LVDS connector located on the upper part of the DM block connected to the Interface board. LVDS cables use thin wires. They are easily damaged. Remove the two LVDS and one communication connector as shown in Figure 3-17.
54

If the DM block is not going to be serviced, it can be rested on top of the PSU board. There are several power cables between the DM and PSU and this avoids unnecessary removal.
REMOVE TWO 3X6 MACHINE SCREWS AND NYLON LOCK PINS
REMOVE NUTS SECURING DVI CONNECTOR
REMOVE FOUR 6x12 SELF-TAP SCREWS AND GROUND WIRE
FIGURE 3-16 - VIDEO INPUT COVER AND SHIELD REMOVAL
PDP01.3-16
3/8/04
MEMORY STICK LVDS CONNECTOR
COM CONNECTOR
DE3 TO LOGIC BOARD LVDS CONNECTOR
FIGURE 3-17 - DM BLOCK REMOVAL
PDP01.3-17
3/8/04
55

In Figure 3-18, removal of the A board is shown. The listed connectors are removed along with the RF input cable to the tuner. Four 3X6 machine screws secure the board. Remove the board and place in a safe location.
CN8003
CN8002 CN8005 CN8001
CN8601
CN8230
FIGURE 3-18 - KE50XS910 A BOARD REMOVAL
PDP01.3-17
3/8/04
K Board Removal
In Figure 3-19, removal of the K board is shown. The board has a shield on top that has been removed. The shield is secured with two 3X6 machine screws. The bottom shield securing the K board is attached to the chassis with four 3X6 machine screws. Remove the three cable and two ground connectors as shown. Remove the cables from the purse-lock retainers. Unplug all connectors attaching cables to cables. Set cable harness to the right side and out of the way.
CN3001
CN3062
GROUND CONNCETOR
CN3061
FIGURE 3-19 - KE50XS910 K BOARD REMOVAL
PDP01.3-19
3/9/04
56
3. Troubleshooting the KE50XS910 Power Supply Removal

Figure 3-20 illustrates the power supply (Regulator) board. The board is secured by seven 3X6 machine screws. If the board is going to be removed for replacement of the panel, the connectors from the DM block can remain connected. Place the DM block on top of the Regulator board and remove together.
CN9 CN8 CN12
CN11 CN6 CN3 CN7 CN2
CN4
CN10
CN5
CN1
PDP01.3-20 3/8/04
FIGURE 3-20 - KE50XS910 POWER SUPPLY BOARD
Lower Shield Removal

If the panel is going to be replaced, the lower shield assembly that held the A board and DM block must be removed. Figure 3-21 illustrated this. It is secured by four 3x6 machine and two 3X12 self-tapping screws. The self-tapping screws only need to be
REMOVE FOUR 3X6 MACHINE SCREWS
LOOSEN SELFTAPPING SCREWS
FIGURE 3-21 - LOWER SHIELD REMOVAL
PDP01.3-21
3/8/04
57
3. Troubleshooting the KE50XS910 Y-SUS and X-SUS Shield Removal

Figure 3-22 shows the Y-SUS board shield and its removal procedure. This shield must be removed to access the Y-driver boards and ICs for inspection and/or replacement. This photo shows the K board installed. Unless the K board needs replacement, it can be left intact. Nine 3X6 machine screws are securing the unit. Two 3X6 machine screws for ground connections must also be removed. Unplug the cooling fan connector. When lifting the shield, note the cable for CN2301. This must be unplugged from the Y-SUS board before the shield can be removed completely. Note the layout of all wiring for proper re-assembly.
REMOVE FIVE 3x6 SCREWS
CONNECTOR CN2301 UNDER SHIELD
REMOVE TWO 3x6 SCREWS FOR GROUND
DISCONNECT SPEAKER
REMOVE FOUR 3x6 SCREWS
FIGURE 3-22 - KE50XS910 Y-SUS SHIELD REMOVAL
PDP01.3-22
3/8/04
Figure 3-23 demonstrates the removal of the X-SUS shield. Remove ten 3X6 machine screws (nine securing the board and one for a ground connector). Note the layout or the wiring in the purse-lock retainers and the removal of ground connections for reference when re-installing the shield.
REMOVE NINE 3X6 SCREWS
DISCONNECT FAN
CONNECTOR CN1201 UNDER SHIELD
REMOVE 3X6 SCREW FOR GROUND
DISCONNECT SPEAKER
FIGURE 3-23 - KE50XS910 X-SUS SHIELD REMOVAL
PDP01.3-23
3/8/04
58
3. Troubleshooting the KE50XS910 Panel Removal

Once all of the above circuit boards and shields have been removed, the panel is ready for removal. Two large brackets are attached to the panel with four 5X10 machine screws. Although the brackets do not come with the panel, they should be left intact to ease the removal. The replacement panel will come with disposable brackets to assist in installation. The original brackets can then be transferred to the new panel. Remove three 4X12 self-tap screws on the left and right sides of the panel as illustrated in Figure 3-24. Next, remove four, 4X8 machine and four 4X12 self-tap screws securing the bracket to the top and bottom of the filter glass assembly as illustrated in Figure 3-25.
REMOVE THREE 4X16 GOLD SELF-TAP SCREWS
FIGURE 3-24 - KE50XS910 PANEL SIDE SCREWS
PDP01.3-24
3/8/04
59
REMOVE FOUR 4x6 MACHINE SCREWS AT TOP
REMOVE FOUR 4x16 SELFTAP SCREWS AT BOTTOM
FIGURE 3-25 - KE50XS910 UPPER AND LOWER PANEL BRACKETS

PDP01.3-25 3/23/04
Although the service manual includes the removal of the speaker assemblies for panel replacement, it is not necessary. It is easier to leave the speakers intact since the left and right gaskets for the panel rest on the edge of the speaker housings. It is important to secure the speaker connectors with a piece of tape since they will tend to fall onto the filter glass and get in the way when the new panel is installed. This is demonstrated in Figure 326
SECURE SPEAKER WIRES AND CONNECTORS ON BOTH SIDES TO CABINET
FIGURE 3-26 - KE50XS910 SPEAKER CONNECTORS
PDP01.3-26
3/23/04
60

The panel can now be lifted from the filter glass assembly and demonstrated in Figure 3-27. NOTE: Panel replacement should only be performed in the shop. The removal of a large number of self-tap screws creates a considerable amount of plastic contaminants. Accumulated dust along with the plastic pieces can easily fall onto the backside of the filter glass. This must be thoroughly removed using air from a compressor. It is extremely important to remove all contaminants before installing the new panel. The KE50SX910 is unique in that the replacement panel does not come with the digital, interface, address and scan drive boards installed. All circuit boards must be transferred to the replacement panel. As of the writing of this manual, the policy regarding panel replacement of this model has not been determined. This is mainly due to the requirement of an interface jig to adjust the scan and address voltages for the replacement panel. Check for the latest information regarding this matter on the ESI website.
FIGURE 3-27 - KE50XS910 PANEL REMOVAL

Y-SUS and X-SUS Board Removal
PDP01.3-27
3/8/04
Should the need arise to replace the Y-SUS or X-SUS boards, removal is illustrated in Figure 3-28 for the Y-SUS board and Figure 3-29 for the X-SUS board. Note Figure 3-28 and the location of the panel serial number label. Also note the Y-Scan drive ICs located on the two circuit boards attached to the panel.
61
FIGURE 3-28 - KE50XS910 Y-SUS BOARD
PDP01.3-28
3/8/04
FIGURE 3-29 - KE50XS910 X-SUS BOARD
PDP01.3-29
3/8/04
62
3. Troubleshooting the KE50XS910 Interface and Digital Video Boards

Figure 3-30 illustrates the location of the Interface and Digital Video boards. Note the seven FPC cables that are identical in size. These are the sources of address information to the address drive boards. The cables can be swapped in order to determine if a section of missing video is caused by the address drivers or the Digital Video board.
CABLES ON DIGITAL VIDEO BOARD CAN BE SWAPPED TO TROUBLESHOOT PANEL ADDRESS PROBLEMS
FIGURE 3-30 - KE50XS910 INTERFACE AND DIGITAL VIDEO BOARDS

PDP01.3-30 3/8/04
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4. Troubleshooting the KDE42/50/61XBR950
Chapter 4 - Troubleshooting the KDE42/50/61XBR950

Overview
The key difference between the XBR950 and XS910 model series is the use of an external Media Box to receive NTSC and ATSC broadcast signals. The tuner and decoding circuitry is also capable of receiving and processing Quadrature Amplitude Modulation (QAM) used by cable companies to encode the audio and video information for transmission. The media box also receives the external input sources including composite, SVideo, component and DVI sources. It is not serviceable in the field. Replacement of the entire unit is required if a failure occurs. The plasma display panel in the XBR950 models functions as a monitor device only. The lack of internal video and audio processing circuits reduces the amount of on-board circuitry and wiring. This makes it easier to diagnose and service the display assembly. This chapter will point out the circuits that are unique to this model along with a description of each boards function. Practical troubleshooting methods will be discussed followed by a systematic procedure for disassembling and re-assembling the unit. Plasma televisions rely on a large, gassed-filled glass panel to generate video. It is important that this glass panel be properly braced and secured by brackets and the back cover assembly. A considerable amount of shielding is also required due to the high voltage levels generated by the scan drivers. Because of this, a large number of screws are utilized.
Plasma Panel Block Diagram

Audio/Video Input
As illustrated in Figure 4-1, audio and video information is input to the panel assembly from the Media Receiver Box. The audio and video arrive on two separate cables. The audio cable is black and the video white. The DEM board receives this data and functions as an interface between the incoming protocol and the format used by the Digital Board for control of the scan and address lines for the panel. Audio information is received from the Media Box via UART protocol (Universal Asynchronous Receiver/ Transmitter). The information is received by differential transmission known as LVDS. The DEM board routes the data to the K board (not shown) for audio processing and amplification. Video information is received via DVI-D, a differential digital RGB format. This information is processed by a TDMS receiver and sent to circuitry to scale the incoming video to conform to the panel resolution. Control data between the Media Box and panel is carried by the audio cable while HDCP key data is handled by the video cable. The Digital board processes and allocates the RGB information for application to the address control lines. Timing for the scan drivers is also generated here.
Panel Drive Circuits

A dual-scan panel is used in this chassis. Addressing control is achieved by placing de-multiplexing and driver circuits at the top and bottom of the plasma panel. Each row of address drivers is responsible for controlling one half of the screen. The High Voltage board (known as Y-SUS in other panel designs) generates properly timed pulses to activate each scan line as needed to coincide with the address information. Each of the four Data Relay boards contains six drive ICs. Each drive IC receives multiplexed data. This data is de-multiplexed, expanded and amplified for each address line of the panel. The number of lines per drive IC varies upon the horizontal resolution of the panel based on its size. The drive ICs are mounted on the flexible PC cables, which are integrated with the glass panel. A failure of any of these drivers requires replacement of the panel.
64

The High Voltage board generates timed scan pulses (also multiplexed) to the scan drive ICs in the Scan Drive board. The flexible PC cables from the panel do not have the drivers mounted on them as do some panel designs. They are attached to the Scan Drive board with locking connectors. If a scan drive IC failure occurs, the board can be replaced. A more in-depth look at plasma display theory and general troubleshooting is available in Chapter 1 of the PDP01 training manual.
SCAN DRIVER BOARDS
DATA RELAY BOARD
DATA RELAY BOARD
HIGH VOLTAGE BOARD
PLASMA PANEL
COMMON RELAY BOARD
DATA RELAY BOARD
DATA RELAY BOARD
AUDIO DATA FROM MEDIA BOX VIDEO DATA AC IN G1 BOARD PFC (61" 0NLY) G2 BOARD POWER SUPPLY DEM BOARD DIGITAL BOARD TO PANEL BOARDS
FIGURE 4-1 KDE42/50/61XBR950 PLASMA PANEL BOARDS
PDP01.4-1
3/9/04
Protection and Self-Diagnostics

The panel-drive and power supply circuits are monitored for over-current or under-voltage conditions. If a failure occurs on one of these monitored lines, the power/standby LED will flash a designated number of times depending on which line a fault was detected. Below is a list of possible fault indications:
65

LED blinks red and green alternately: A panel error is indicated. A missing voltage or over-current condition on the panel drivers has been detected. Four blinks: An over-temperature condition exists. The panel is monitored to protect against overheating. Six blinks: VD (70VDC) on the power supply is not present. This usually indicates an inoperative power supply. Seven blinks: DC voltage has been detected on one or more of the speaker lines. Audio drive IC failures are usually the cause.
Troubleshooting
Due to the large amount of digital processing, along with scan and address methods used, plasma televisions can generate symptoms that are unfamiliar to most technicians. The following troubleshooting techniques should help to isolate the cause in most cases. Documentation of unusual symptoms or known failures will be kept updated on the ESI server. Check the service website at HTTP://service.sel.sony.com for the latest bulletins regarding the model you are servicing. Shutdown - Self-Diagnostics Indication The flowchart in Figure 4-2 will assist in locating the cause of a protect event with blinking LED.
Protection shutdown PWR/STBY LED flashing
Red and green alternating blinks?
Yes
Disconnect and reconnect AC power to panel
TP3804 on DEM board momentarily low?
No
No
Yes Go to Figure 4-3 No video flowchart Replace DEM board
Yes Seven blinks?
Replace K board
No
Six blinks?
Yes
*VD (70VDC) missing Replace Power Supply board
* VD can be checked at CN1010 pin 6 on Power Supply board.
No
Yes Four blinks?
If LED stops blinking after power is turned off and then back on, panel temperature reached limit. If protection returns immediately, thermal sensor is disconnected or has failed
FIGURE 4-2 - KDE42/50/61XBR950 SELF-DIAGNOSTICSTROUBLESHOOTING

PDP01.4-2 4/20/04
66

Troubleshooting No Video Failures of the plasma display can appear as no video or abnormalities in the displayed image. In cases of a no video symptom, it is important to determine if the panel is priming. Priming is a term describing the dim lighting of the pixels, which produce a dark gray background raster similar to a CRT display. Ambient lighting may make it difficult to detect. Turning the unit on and off and observing the screen helps to tell the difference between a true black and primed panel. NOTE: It is important to determine panel priming if no video is displayed. The presence of priming indicates the scan drive circuits are operational and the required voltages are present. The media box and/or the connections between it and the panel are suspect. The flowchart in Figure 4-3 will assist in locating a no video condition.
No video on display
Panel priming?
Yes
Input signal problem. Check Media Box and connections to panel.
No
Panel alarm? Yes
No
Replace Power Supply board
*VS test point Measure across
*VS (190VDC) present at Y Drive boards?
No
VS (190VDC) present at CN101-9 Power Suuply?
Yes
Check for damaged scan drive IC's. Replace Scan Drive board and HV board if found.
Yes
No Replace G board
VD (70VDC) at CN12-1 on Data Relay board?
No
Disconnect CN12 from Data Relay board
VD (70VDC) at CN1010-6 on G board?
Yes Check for damaged drive IC's on address cables.
Replace G board
Glass envelope of panel compromised. Replace panel
IC damage?
No
Burnt Address drive IC
Yes Replace panel
Replace shorted Data Relay board
FIGURE 4-3 - KDE42/50XBR950 NO VIDEO TROUBLESHOOTING
PDP01.4-3
3/18/04
67
4. Troubleshooting the KDE42/50/61XBR950 Troubleshooting Display Panel Abnormalities

Symptoms appearing on the screen during panel and drive circuit failures are generally easy to identify. Since the panel is controlled by intersecting scan and address lines, distortions, abnormal colors or missing pixel data will manifest themselves as horizontal or vertical lines and may occur in entire blocks. If you have acquired only this chapter for troubleshooting the KDE42/50/61XBR950 models, obtain the section in Chapter 1 of the entire manual (PDP-01), which contains additional information applying to general plasma theory and troubleshooting. In Figure 4-4, some examples of address circuit failures are shown. If one or more vertical lines of video information are missing or filled with a solid color, the panel will likely have to be replaced. Note the use of address boards and drive ICs on the upper and lower ends of the panel. This model uses a dual-scan panel. Address control is shared so that the upper and lower drivers scan half of the panel.
SCAN DRIVER BOARDS
DATA RELAY BOARD
DATA RELAY BOARD
HIGH VOLTAGE BOARD
PLASMA PANEL
COMMON RELAY BOARD
DATA RELAY BOARD
DATA RELAY BOARD
AUDIO DATA FROM MEDIA BOX VIDEO DATA DEM BOARD DIGITAL BOARD
FIGURE 4-4 - KDE42/50/61XBR950 PANEL ADDRESS FAILURES
PDP01.4-4
3/10/04
68

Single line failures are caused by problems in the drive outputs. Since the drivers are mounted to the FPC assembly, the panel must be replaced. Multiple lines of missing video creating a block of no information can be caused by the Digital Video or Address boards. If the missing video covers an area larger than what is controlled by a single drive IC, suspect the Address Relay board. It is unlikely that more than one drive IC has failed. Close examination of the flexible PC cable in the affected are should be performed. Look for shorts or corrosion between the pads of the cable or signs of overheating of the drive IC mounted on the cable. This is illustrated in Figure 4-5.
BURNT SPOT ON DRIVE IC
FIGURE 4-5 - DAMAGED ADDRESS DRIVE IC
PDP01.4-5
3/12/04
Figure 4-6 illustrates potential symptoms that might be seen if a failure occurs in the scan drive circuits. The scan drive ICs are mounted to a pair of circuit boards, each controlling half of the screen. Failures occurring on any of the drive ICs will cause a loss of scan on any subsequent drivers below the failed IC. For example, if the second IC from the top on the upper address board fails, no video will appear from that point to the middle of the screen. Any single missing lines of video will require a panel replacement. Damaged drive ICs will usually cause a panel alarm failure if excessive current is being drawn. Whether or not there is a panel warning, both Scan Drive boards should be examined closely for any signs of overheating. This can appear as cracks or holes on the surface of the IC. Figure 4-7 illustrates an example of a failed IC. NOTE: The locks securing the flexible PC cables from the panel to the driver board are delicate and easily damaged when attempting to release the cable. By removing the Scan Drive board and twisting it as shown in Figure 4-8, all four locks can be disengaged at once by using the cables to lift the lock tabs. Due to the short length and radius of the bend on the FPC cables, they are difficult to re-insert. When reinstalling the cables, close the lock tab almost to the point of locking and insert the cable into the slot of the tab. Lift the lock tab slightly with one hand and push the cable in until seated. Press the lock tab firmly to secure and check to see if the cable is locked. If the cable is inserted properly, you should not be able to see the contact pads.
69
SCAN DRIVER BOARDS
DATA RELAY BOARD
DATA RELAY BOARD
HIGH VOLTAGE BOARD
PLASMA PANEL
COMMON RELAY BOARD
DATA RELAY BOARD
DATA RELAY BOARD
AUDIO DATA FROM MEDIA BOX VIDEO DATA DEM BOARD DIGITAL BOARD
FIGURE 4-6 - KDE42/50/61XBR950 PANEL SCAN FAILURES
PDP01.4-1
3/9/04
70
BURN HOLE
CRACK
FIGURE 4-7 - DAMAGED SCAN DRIVE IC
PDP01.4-7
3/12/04
FIGURE 4-8 - UNLOCKING FLEX CABLES FROM DRIVER BOARD

PDP01.4-8 3/12/04
71
Disassembly
Overview
This section will cover the required steps to disassemble the unit down to panel replacement. Although this chapter covers the 42, 50, and 61-inch models, disassembly of the KDE61XBR950 will be covered in Chapter 5 due to the significantly different design of the components housing the panel. Due to the large number of screws involved, be sure to have a container in which to place them during the procedure. It is extremely important to place the plasma television on a repair stand of adequate size along with a piece of foam padding to protect the screen. Be certain the padding is at least of the screen size to prevent flexing of the glass panel, which is easily damaged. The glass can withstand moderate bending but the barrier ribs separating the vertical lines of pixels are easily damaged by minor flexing. HINT: Most of the screws securing shields and circuit boards are 3mm machine with attached flat washers. Larger machine and self-tapping screws are allocated to support brackets and the rear cover.
Speaker Housing and Rear Cover Removal

As shown in Figure 4-9, remove the left and right rear speaker covers secured by two 4X16 self-tap screws each. The rear cover screws on both sides will now be exposed. Remove the following screws for the rear cover: Twenty 4X16 black, self tap (black) Three 3X8 machine (black) Eight 5X16 machine (black)
REMOVE SPEAKER COVERS ON BOTH SIDES
FIGURE 4-9 - KDE42/50XBR950 SPEAKER COVER REMOVAL

PDP01.4-9 3/12/04
72

Once the rear cover has been removed, the view shown in Figure 4-10 is seen. The High Voltage (Scan), Scan Drive, DEM, K and Power Supply boards are easily visible. Note the long, flat metal brackets covering the upper and lower DPC cables connected to the data relay boards. These function as heat sinks for the drive ICs mounted to the cable. Use this view as a guide when re-assembling the unit to properly dress the cable harnesses.
K BOARD
POWER SUPPLY BOARD
HIGH VOLTAGE BOARD
UPPER AND LOWER SCAN RELAY BOARDS
DEM BOARD
FIGURE 4-10 - KDE42/50XBR950 CIRCUIT BOARD LOCATIONS

PDP01.4-10 3/11/04
DEM, K and Power Supply Board Removal

Removal of these boards can be accomplished as one assembly. They are mounted on an assembly and attached by three brackets to the display panel. Once the necessary connectors are removed, the bracket screws can be removed and the entire assembly lifted out of the unit. Be careful to lift the assembly straight up and avoid any unnecessary flexing to avoid stress to the Power Supply board. Figures 4-11, 4-12, 4-13 and 4-14 illustrate the necessary connectors to remove. Figure 4-15 illustrates the screws securing the four brackets to be removed. Once this is done, the entire assembly can be lifted out.
REMOVE CABLES FROM RETAINERS AND PLACE ASIDE
REMOVE CN3801 (LVDS)
REMOVE CN3302 AND CN3303
FIGURE 4-11 - DISCONNECT DEM BOARD
PDP01.4-11
3/12/04
73
REMOVE CN1009 AND CN1010. REMOVE FROM PURSE LOCKS AND SET ASIDE.
FIGURE 4-12 - DISCONNECT POWER SUPPLY BOARD PDP01.4-12
3/11/04
REMOVE LEFT AND RIGHT SPEAKER CONNECTORS. PEEL GROUND TAPE BACK FROM PANEL
FIGURE 4-13 - SPEAKER CONNECTOR REMOVAL
PDP01.4-13
4/20/04
74
UNPLUGG SENSOR FROM HIGH VOLTAGE BOARD DISCONNECT SENSOR FROM PANEL ABOVE REGULATOR BOARD
FIGURE 4-14 - THERMAL SENSORS REMOVAL
PDP01.4-14
3/12/04
REMOVE EIGHT 4x16 SELF-TAP SCREWS AND LIFT ENTIRE ASSEMBLY FROM PANEL
FIGURE 4-15 - PANEL BRACKET REMOVAL
PDP01.4-15
3/12/04
75
4. Troubleshooting the KDE42/50/61XBR950 Panel Removal

Once the brackets and boards have been removed, the panel control and drive boards can be viewed as shown in Figure 4-16. Once this stage has been achieved, the entire panel assembly can be lifted out if replacement is necessary. Note the location of the labels containing the panel-type and serial number information. These numbers will be necessary to record if the panel is to be replaced. The required Vs and Vd voltages for that particular panel are also located here. If a new panel is installed, it will have the high voltage, address and logic board installed. If the G board is replaced, the voltages on the new board must be adjusted to the existing panel. Figure 4-17 illustrates the locations of the test points and variable resistors for these adjustments. NOTE: Panel replacement should only be performed in the shop. The removal of a large number of self-tap screws creates a considerable amount of plastic contaminants. Accumulated dust along with the plastic pieces can easily fall onto the backside of the filter glass. This must be thoroughly removed using air from a compressor. It is extremely important to remove all contaminants before installing the new panel.
PANEL TYPE AND SERIAL # VS & VA VOLTAGES UPPER DATA RELAY BOARDS HIGH VOLTAGE (SCAN) BOARD
COMMON AND RELAY RETURN BOARDS
LOGIC BOARD
LOWER DATA RELAY BOARDS

PDP01.4-16 3/12/04
FIGURE 4-16 - PANEL ASSEMBLY AND BOARD LOCATIONS
CN1009
G BOARD
CN1006
RV1501 VD ADJ
CN1010 TP1501 VD RV1701 VS ADJ TP1701 VS
FIGURE 4-17 - VS AND VD ADJUSTMENT
76
4. Troubleshooting the KDE42/50/61XBR950 High Voltage and Common Board Removal

The High Voltage board is shown in Figure 4-18. Thirteen 3X6 machine screws secure it to the panel. Once the wired connectors are removed, the board can be lifted slightly and pulled away from the scan drive boards. Do not forget to remove the thermal sensor located on the large heat sink, as the new board does not come with one.
TEMPERATURE SENSOR
FIGURE 4-18 - HIGH VOLTAGE BOARD
PDP01.4-18
3/12/04
Whenever the High Voltage board is replaced, four different voltages must be checked and re-adjusted as necessary. These voltages vary from panel to panel. Many of the panels do not have a label defining these voltages although newer productions will. If the panel has such a label, it will be located on the rear of the panel just above the Common Relay board. It will define the following voltages, which can fall into these specified ranges: VBW: 90 or 100VDC VP: 194 to 233VDC VSW: 160 or 170 -VW: -60 to 79VDC
Note: If the panel does not have a label, the Technical Support line will need to be called. Provide the panel type and serial number from the label at the top right corner of the panel and the proper voltages can be looked up in a database.
77

Figure 4-19 illustrates the adjustment and test point locations for the voltages listed above. They are located on the High Voltage Board.
VSW ADJ AND TEST POINT
VBW ADJ AND TEST POINT VP ADJ AND TEST POINT
FIGURE 4-19 - VOLTAGE ADJUST AND TEST POINTS

PDP01.4-18 3/23/04
78
5. Disassembling the KDE61XBR950
Chapter 5 - Disassembling the KDE61XBR950

Overview
The KDE61XBR950 is unique when compared to the KDE42/50XBR950 in that its panel design is different. The video processing and panel control circuits are the same. The troubleshooting procedures for video and panel drive in the 42/50-inch models apply to the 61" model. An additional power supply board is used in the KDE61XBR950. It is called the G1 board. It contains a PFC (Power Filter Control) circuit to boost and stabilize the rectified AC. This is sent to a G2 board, which is similar to the G board used on the smaller models. This chapter will focus on proper disassembly of the 61" model. The panel is secured to the filter (front) glass in a different manner. The disassembly procedure is also quite different. NOTE: Due to the large amount of digital processing along with scan and address methods used, plasma televisions can generate symptoms that are unfamiliar to most technicians. The following troubleshooting techniques should help to isolate the cause in most cases. Documentation of unusual symptoms or known failures will be kept updated on the ESI server. Check the service website at HTTP://service.sel.sony.com for the latest bulletins regarding the model you are servicing. A large number of screws will be removed so be sure to have a container in which to place them during the procedure. It is extremely important to place the plasma television on a repair stand of adequate size along with a piece of foam padding to protect the screen. Be certain the padding is at least of the screen size to prevent flexing of the glass panel, which is easily damaged. The glass can withstand moderate bending but the barrier ribs separating the vertical lines of pixels are easily damaged by minor flexing. HINT: Most of the screws securing shields and circuit boards are 3mm machine with attached flat washers. Larger machine and self-tapping screws are allocated to support brackets and the rear cover.
Disassembling the KDE61XBR250

Rear Cover Removal
Removal of the rear cover does not require disassembly of the speaker housings as in some models. All rear cover screws are machine type. Remove the following screws and lift the rear cover off: Twenty 4X12 machine screws securing the perimeter. Five 3X8 machine screws securing the A/V input jacks. Twelve 5X16 machine screws in the center area. Note the location of four large step-washers. These mount the unit to the optional stand.
79
5. Disassembling the KDE61XBR950 Speaker Housing Removal

Remove four 4X16 self-tap screws (marked by an arrow) for the left and right speaker housing as shown in Figure 5-1. Pull the housings off the panel.
PULL HOUSING OFF
REMOVE FOUR 4X16 SELF-TAP SCREWS
FIGURE 5-1 - KDE61XBR950 SPEAKER HOUSING REMOVAL

PDP01.5-1
3/15/04
Filter Glass Bracket Removal

The filter glass bracket must be disassembled and removed from the rear in order to remove the plasma panel. Access to the mounting screws for the four large brackets can only be achieved if the filter glass bracket is removed. These brackets and the circuit boards mounted to it must be separated from the old panel when a new one is being installed. Begin by removing the speaker wire connectors as illustrated in Figure 5-2. Peel back the conductive tape to access the connectors. Note the ground wire for each speaker connector. A 4X16 gold-colored self-tap screw secures them. There are two of these screws one each side and four on the top and bottom. The filter glass bracket is secured to the panel by these and must be removed.
80
LEFT SPEAKER CONNECTOR
RIGHT SPEAKER CONNECTOR
REMOVE GROUND AND PEEL OFF TAPE
FIGURE 5-2 - SPEAKER WIRE REMOVAL

PDP01.5-2 3/15/04
81

The four metal bars located around the perimeter of the panel are removed next. Remove the two black bars from each side. They are secured by two 3X8 machine screws each. This is illustrated in Figure 5-3. The long silver colored bars are removed next. They are secured by six 1.5X2 screws. This is also illustrated in Figure 5-3. Do not remove the screws at each end securing a small bracket. It is not necessary. Once the proper screws have been removed, strike the end of the bar with a leather or plastic mallet until it moves slightly as shown in Figure 5-4. The bar is then pulled away from the panel assembly
REMOVE SIX 1.5X2 SELFTAP SCREWS EACH BAR
REMOVE TWO 3X8 SELFTAP SCREWS
FIGURE 5-3 - KDE61XBR950 FILTER GLASS BARS
PDP01.5-3
3/15/04
PANEL ID LABLES
FIGURE 5-4 - LOOSENING THE PANEL BARS
PDP01.5-4
3/15/04
82

Once the bars have been removed from all four sides, the filter glass bracket can be lifted from the front filter glass. The plasma panel, along with the four brackets securing the circuit boards, is now resting on the front filter glass. The only thing keeping contaminants from entering the area between the plasma panel and the filter glass is the gaskets sealing the area. Do not lift the panel up unless you intend to replace it as cleaning of the surfaces will need to be performed. NOTE: When re-installing the upper and lower bars, note that the lower bar contains the Sony name. The upper bar is blank. The bars also contain an alignment pin. The pin location is identified by a small dimple in the bar. This dimple is aligned with a slot in the clear plastic edge of the filter glass bracket before the bar is pressed into place. This is illustrated in Figure 5-5.
FIGURE 5-5 - ALIGNMENT SLOT FOR PANEL BARS

PDP01.5-5 3/15/04
Panel Removal If the panel must be removed for replacement, two people will be required due to the considerable weight of the plasma assembly. Figure 5-5 illustrates a panel where the filter glass bracket assembly has been removed. Once the panel has been separated from the front filter glass, the four metal brackets around the perimeter of the
83

panel must be removed. The top and bottom brackets are secured by four 4X16 gold-colored self tap screws at the end of each cross brace. The side brackets are secured by two 3X16 machine screws at each end. Each bracket contains a sealing gasket so use caution when removing them to avoid distorting or damaging the gaskets. Note the labels indicating the panel type and serial number along with the Vs and Vd voltages. These are viewed back in Figure 5-4.
TOP AND BOTTOM BRACKETS SECURED BY FOUR 4X16 SELFTAP SCREWS EACH
SIDE BRACKETS SECURED BY TWO 3X16 MACHINE SCREWS
FIGURE 5-6 - REAR FILTER GLASS BRACKET REMOVED
PDP01.5-6
3/15/04
DEM, K, G1 and G2 Board Removal

Before the new panel can be installed, the boards listed above must be transferred to it. The replacement panel will come with the Logic, High Voltage, Common and Address boards installed and aligned to the panel. Remove the following connectors from the indicated circuit boards: Remove the connectors from the DEM board as illustrated in Figure 5-7. Remove two connectors and the temperature sensor from the High Voltage board as illustrated in Figure 5-8. Remove the panel sensor as shown in Figure 5-9. Undo any tape securing wires to the plasma panel. The cross-member brackets can now be disengaged from the panel by removing two 5X12 machine screws for each bracket as illustrated in Figure 5-10. The cross members are attached to sub-chassis frames holding the various circuit boards and can now be lifted from the panel assembly. Use caution to avoid any unnecessary flexing of the assembly as it is being moved. The G2 board is susceptible to the most strain.
84
REMOVE WIRING FROM RETAINERS AND DRESS ASIDE.
REMOVE CN3801, CN3303, AND CN3302
FIGURE 5-7 - DEM BOARD CONNECTORS
PDP01.5-7
3/15/04
REMOVE CN105 AND CN106 REMOVE THERMAL SENSOR
FIGURE 5-8 - HIGH VOLTAGE BOARD CONNECTORS
PDP01.5-8
3/15/04
85
REMOVE THERMAL SENSOR FROM PANEL
FIGURE 5-9 - PANEL THERMAL SENSOR
PDP01.5-9
3/15/04
REMOVE TWO 5X12 MACHINE SCREWS FROM ALL FOUR CROSS MEMBERS
FIGURE 5-10 - CROSS-MEMBER BRACKET
PDP01.5-10
3/15/04
86
5. Disassembling the KDE61XBR950 Scan, Address and High Voltage Boards Location
Figure 5-11 illustrates the location of the High Voltage, Scan Drive and Address Relay boards. Note the heat sinks that are unique to this model attached to the Scan Drive ICs.
DATA RELAY (ADDRESS) BOARDS
HIGH VOLTAGE (SCAN) BOARD SCAN DRIVER BAORDS
FIGURE 5-11 - KDE61XBR950 PANEL BOARDS LOCATION

PDP01.5-11 3/23/04
Whenever the High Voltage board is replaced, four different voltages must be checked and re-adjusted as necessary. These voltages vary from panel to panel. Many of the panels do not have a label defining these voltages although newer productions will. If the panel has such a label, it will be located on the rear of the panel above the Common Relay board. It will define the following voltages, which can fall into theses specified ranges: VBW: 90 or 100VDC VP: 194 to 233VDC VSW: 160 or 170 -VW: -60 to 79VDC
Note: If the panel does not have a label, the Technical Support line will need to be called. Provide the panel type and serial number from the label at the top right corner of the panel and the proper voltages can be looked up in a database.
87

Figure 5-12 illustrates the adjustment and test point locations for the voltages listed above. They are located on the High Voltage Board.
VSW ADJ AND TEST POINT
VBW ADJ AND TEST POINT VP ADJ AND TEST POINT
FIGURE 5-12 - VOLTAGE ADJUST AND TEST POINTS

PDP01.4-18 3/20/04
88
and i.LINK are trademarks of Sony Electronics
PDP010304
2004 Sony Electronics Inc. EMCS - A Service Company 1 Sony Drive Park Ridge, New Jersey 07656 Reproduction in whole or part without written permission is prohibited. All rights reserved
3/18/04

Sony PDP-01 Plasma Training

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Training Manual

Diagnostics and Troubleshooting Course: PDP-01

4. Troubleshooting the KDE42/50/61XBR950 ..........................64

2. Troubleshooting the KE37/42XS910 .....................................13

5. Disassembling the KDE61XBR950 .....................................79

3. Troubleshooting the KE50XS910 ....................................37

1. Plasma Panel Troubleshooting

Chapter 1 - Plasma Panel Troubleshooting

COMMON OR X SCAN BOARD

PLASMA DISPLAY PANEL

DATA OR ADDRESS BOARD

LOGIC CONTROL BOARD

FIGURE 1-1 BASIC PLASMA DISPLAY CONTROL

1. Plasma Panel Troubleshooting

BACK PLATE PHOSPHOR (RED) PHOSPHOR (GREEN) DATA ELECTRODE

FIGURE 1-2 - PLASMA CELL STRUCTURE

Plasma Panel Troubleshooting

1. Plasma Panel Troubleshooting

Troubleshooting a No Display Condition

1. Plasma Panel Troubleshooting

CHECK FOR PULSES AT INPUT PINS

FIGURE 1-3 - TYPICAL SCAN DRIVER LAYOUT

Vertical Line Abnormalities

1. Plasma Panel Troubleshooting

MULTIPLE DRIVE ICs

FIGURE 1-4 - EXAMPLE OF ADDRESS DRIVERS

SINGLE DARK, WHITE, OR DIFFERENT COLORED LINE

SCAN DRIVER, FLEX CABLE OR PANEL. MUST REPLACE PANEL

FIGURE 1-5 - SINGLE VERTICAL LINE FAILURE

1. Plasma Panel Troubleshooting

LINE MAY BE BLACK OR WHITE DEPENDING ON PANEL DESIGN

DRIVE IC OR ADDRESS BOARD FAILURE

FIGURE 1-6 - MULTIPLE VERTICAL LINE FAILURE

1. Plasma Panel Troubleshooting

FIGURE 1-7 - MULTIPLE COLORED LINES

SCAN DRIVE BOARDS AND DRIVERS

DRIVE IC, FLEX CABLE, OR DEFECTIVE PANEL

FIGURE 1-8 - SINGLE SCAN LINE FAILURE

1. Plasma Panel Troubleshooting

FIGURE 1-9 - MULTIPLE SCAN LINE FAILURE

FIGURE 1-10 - DAMAGED SCAN DRIVE IC

1. Plasma Panel Troubleshooting Abnormal Luminance and/or Color

FIGURE 1-11 - ABNORMAL COLORS

FIGURE 1-12 - SCAN DRIVE DISTORTION

1. Plasma Panel Troubleshooting Replacing a Defective Panel

FIGURE 1-13 - TYPICAL PANEL LABELS

2. Troubleshooting the KE37/42XS910

Chapter 2 - Troubleshooting the KE37/42XS910

2. Troubleshooting the KE37/42XS910

ANT IN INPUT 1 INPUT 2 INPUT 3 H2 BOARD

MAIN V AVSW1 AVSW1 SUB V AUDIO

CCP2 MAIN DRC MID CCP2 MAIN

FIGURE 2-1 - KE37/42XS910 SERIES OVERALL BLOCK

Video Signal Processing

2. Troubleshooting the KE37/42XS910

MAIN VIDEO CV/YC/YUV

FROM A BOARD SUB VIDEO CV/YC MS VIDEO LPF CCP2 SUB

SIRCS I2C BUS

FIGURE 2-2 - KE37/42XS910 SERIES VIDEO PROCESSING

The Plasma Panel

2. Troubleshooting the KE37/42XS910

FPC AND SCAN ICs

CN31 FROM DE2 BOARD AC IN