PLASMA CONTROL BOARD ROM UPGRADE PROCEDURE

COMBATING MAL-DISCHARGE ISSUES

Updated 08/29/2009

Field Service Group P.O. Box 240007 Huntsville, AL 35813-6407

June 22, 2009

Re: Notice of Repair method Dear Sir/ Madam: LG Electronics has developed a new repair method for reducing PDP mal-discharge symptoms. The new method allows you to download the Control Board ROM software to correct PDP mal-discharge symptoms not eliminated by alignment, instead of replacing the PDP panel.

If you encounter this type of situation, please request the Control Board ROM Download Jig by email. Please send all requests to smickles@lge.com. Your request must include the following information: 1. Service Center Name 2. Account Number 3. Contact Name 4. Mailing Address

Please view the video prior to attempting the repair to ensure you fully understand how to perform the software download using the jig. Download the zipped file and then follow the download guide. All software is included in the zip file.

When completing the warranty claim it is very important that you use the defect code SCDS for all Control Board ROM software download cases.

Thank you for your support in this matter and we appreciate the service you have performed for LG Electronics.

Sincerely,

Tracey Janey, Director Field Service

EXPLANATION:

Occasionally a set is encountered that has Mal-discharge (see the next two images on the next two pages). When this type of issue is encountered it is of the utmost importance that all adjustments be checked and corrected. It is possible that this will resolve the condition. If however, after adjusting all adjustments correctly and according to the specific Panels voltage label the problem still exist, then it is necessary to upgrade the Controls boards ROM software. This document explains the procedure for the Controls boards ROM software upgrade.

Plasma Control board ROM Update

Mal-Discharge Example High Bright:

The below Image show Mal-discharge high bright, clearly defined.

Plasma Control board ROM Update

Mal-Discharge Example Low Bright

The below Image show Mal-discharge Dark Area, clearly defined.

Plasma Control board ROM Update

Preliminary Set-Up Precautions: Perform Normal Panel Alignment first:

VERY IMPORTANT: Before beginning with the Control board ROM upgrade, it is of the utmost importance that ALL Panel Adjustments be accurately set in accordance to the Panels Label. Failure to do so will negate the added benefits of performing this upgrade to the software. EXAMPLE OF PANEL LABEL SMPS Vs

SMPS Va Y-SUS Set-up Y-SUS -Vy Y-SUS Vsc Y-SUS Ve

Z-SUS Z-Bias

Plasma Control board ROM Update

ROM Download JIG Classification.

Name Type Vendor Input Output 32FD 42SD Application Model 42HD 50HD 60HD FHD USB Port 4 pin/ 15pin / D-SUB 32F1 42V5A/6/7/8 42X3/4, G1 50X3/4, G1 60X6/7 50H1/2, 60H1/2, 71H1/2 1. Connect to USB port 2. Connect to CTRL B/D 3. Add 5V Power on 4. Run the ROM upgrade program
See Table

USB JIG Buffer Bluechips

How To Use

Picture

Plasma Control board ROM Update

Jig Board Identification (Layout)

6 5

1-1. ROM D/L JIG Description 1. Pattern Signal connector 1. Pattern Signal connector FHD LVDS: FHD I2C Pattern FHD LVDS: FHD I2C Pattern Cable: FHD LVDS cable Cable: FHD LVDS cable XGA LVDS: XGA I2C Pattern XGA LVDS: XGA I2C Pattern Cable: LVDS cable Cable: LVDS cable Information of I2C transmits to & receive from Information of I2C transmits to & receive from Control B/D Control B/D

Information of I2C Pattern transmits. Information of I2C Pattern transmits.

7 3 2. ROM Download connector 2. ROM Download connector D-Sub: It is connected to D-sub for serial download D-Sub: It is connected to D-sub for serial download in condition of PDP Set (not module) in condition of PDP Set (not module) Cable: D-Sub to D-Sub cable or D-Sub to 4pin cable Cable: D-Sub to D-Sub cable or D-Sub to 4pin cable 4Pin: Execute Serial download by Connecting 4Pin 4Pin: Execute Serial download by Connecting 4Pin Connector in Control B/D to 4Pin Serial Download Connector in Control B/D to 4Pin Serial Download (16Mbit/32Mbit) Cable: 4pin cable (16Mbit/32Mbit) Cable: 4pin cable 12Pin: Execute When 4022H ASIC is used for Control B/D 12Pin: Execute When 4022H ASIC is used for Control B/D Cable: 12pin cable Cable: 12pin cable 15Pin: Execute download In EPP Mode (16Mbit/32Mbit) 15Pin: Execute download In EPP Mode (16Mbit/32Mbit) Cable: 15pin cable Cable: 15pin cable 3. PC to USB Jig connecting connector 3. PC to USB Jig connecting connector () Cable () Cable
Application Model 42G1/42G2/ 50G1/50G2/60H2/60H3 32G1/ 42X4A/ 50X4P/ 42G1/42G2/ 50G1/50G2/50H2/50H3/60H2/60H3 42V5/6, 42X2/ 50X2 32F1, 42V7/8, 42X2A/3/3A/4/4A, 50X3/4/4P, 60X5A/6/7, 71H1

2 4 1

Switch: When 3 is connected to D-Sub, Switch: When 3 is connected to D-Sub,

select data line (1 or 9) select data line (1 or 9) there are 2 kinds of main Assy (VSC) there are 2 kinds of main Assy (VSC)

No

Connector D-Sub 4Pin 12Pin 15Pin

Plasma Control board ROM Update

Jig Cable Identification

No Picture Name D-Sub to D-Sub Cable (P/No: 6850TD9007C) Using Jig to PDP TV Connector No Remark

1-2. Connecting Cable

Package

15pin Direct cable (++type)

Basic

4Pin Cable

Jig to Module

Additional

12Pin Cable

Jig to Module

Additional

15Pin Cable (P/No: 6631T12002P)

Jig to Module

Basic

USB Cable (P/No: 6850TDU002A)

Jig to Computer

Basic

Plasma Control board ROM Update

Step 1 through 3: Unpacking the ROM Software Upgrade Files

1. Download PDP-ROM-CTRL-Software-Files.exe from hard disk by clicking on the Icon

1-a Select Run

If Adobe running inside Browser as a plug in.

1-b Select Run

1-a Select Open

If Adobe not running inside browser

2. Either way, when the Self-Extracting exe file is ran,

a folder is created named; C:\PDP ROM CTRL Software Files In sub folders under this folder are additional files: \Drivers (Installation drivers for USB and Jig) \Program (FlashDown Program to run ROM download program) \CTL PWB Software (All ROM Software upgrade files)

3. REMEMBER THESE Folder locations. 9

Plasma Control board ROM Update

Step 4 through 5: Installing the USB drivers

4. When USB Download Board is connected to PC very first time,
Window pops up stating New Hardware Found then another pop up window appears as seen in the left picture. You should select and then click Refer to fig. 1

Fig. 1

5. On the next screen another Window pops up as you see on the right
picture. Uncheck Search removable media (floppy, CD-ROM) and check Now click Browse and find the driver folder that was unzipped in Step 2.

and then click

Refer to fig. 2 Fig. 2

10

Plasma Control board ROM Update

Step 6 through 8: Installing the USB drivers

6. Another window appears as it searches for best driver to install.
Refer to fig. 3 below

8. Another window appears as

installation completes. Click
Fig. 3

Refer to fig. 5 below

7. Another window appears as it finds the best driver to install.

Refer to fig. 4 below

Fig. 4

Fig. 5

11

Plasma Control board ROM Update

Step 9 through 10: Installing the drivers

9. After the installation of the USB driver, another
Window pops up stating New Hardware Found then another pop up window appears as seen below. You should select and then click

10. On the next screen another Window pops puts as below. Uncheck Search removable media (floppy, CD-ROM) and check Confirm Driver location is still accurate.

Refer to fig. 6 below

Or click Browse and find the driver folder that was unzipped in Step 2 and then click Refer to fig. 7 below

Fig. 6

Fig. 7

12

Plasma Control board ROM Update

Step 11 through 12: Installing the drivers

11. After searching the drivers, a new window appears asking
you to select the best driver as seen below. Refer to fig. 8 below You should select Even though it states its not digitally signed, it is OK to use this file. Click Continue to step 12

12. Another window appears as installation completes.

Refer to fig. 9 below Click

Fig. 9

* This Installation is needed only the first time the jig is

Fig. 8

used. Remember to use the same USB port each time the jig is used.

13

Plasma Control board ROM Update

Step 13: Connecting the Jig to the Plasma Television (4 Pin Cable) G1 Panels
WARNING: External 5V MUST be supplied to the Control board before beginning download. Failure to do so, may cause a corruption of the internal memory and the board will fail. If this happens, try applying external 5V and then re-downloading the software. Use the STAND-BY 5V from the Power Supply, (not the M5V). This will revive the Control Board.

Fuses Jump +5V to bottom leg.

Location: Top left hand side of PWB. Example from a 50G1 Panel Control PWB.

Make sure to disconnect the ribbon connector from the Y-SUS to the Control board as well as any connections to the Z-SUS board.

1. Connect Control PWB to JIG

Panel Types (Models): 42,50 G1,G2 60,H2,H3 series USB Cable P/N: 6850TDU002A

PC PC

USB Type JIG Or 4 Pin Cable Serial (4p)

14

Plasma Control board ROM Update

Step 13: Connecting the Jig to the Plasma Television (15 Pin Cable)
WARNING: External 5V MUST be supplied to the Control board before beginning download. Failure to do so, may cause a corruption of the internal memory and the board will fail. If this happens, try applying external 5V and then re-downloading the software. Use the STAND-BY 5V from the Power Supply, (not the M5V). This will revive the Control Board.

Fuses Jump +5V to Left side.

Location: Top left hand side of PWB. Example from a 50X3 Panel Control PWB.

Make sure to disconnect the ribbon connector from the Y-SUS to the Control board as well as any connections to the Z-SUS board.

1. Connect Control PWB to JIG Panel Types (Models): 42, 50, X2A, X3, X4, and 60 X5A,X6,X7 series USB Cable PC PC P/N: 6850TDU002A

USB Type JIG 15Pin Cable Epp (15p)

15

Plasma Control board ROM Update

Step 13: Connecting the Jig to the Plasma Television (12 Pin Cable)
WARNING: External 5V MUST be supplied to the Control board before beginning download. Failure to do so, may cause a corruption of the internal memory and the board will fail. If this happens, try applying external 5V and then re-downloading the software. Use the STAND-BY 5V from the Power Supply, (not the M5V). This will revive the Control Board.

Fuses Jump +5V to bottom leg.

Location: Center left hand side of PWB. Example from a 42G2 Panel Control PWB.

Make sure to disconnect the ribbon connector from the Y-SUS to the Control board as well as any connections to the Z-SUS board.

1. Connect Control PWB to JIG

Panel Types (Models): 42, 50,X2 series

USB Cable P/N: 6850TDU002A PC PC

USB Type JIG

12Pin Cable Epp (12p)

16

Plasma Control board ROM Update

Step 14 through 16: Starting the Flash Down Program

14. When you extracted the file PDP-ROM-CTRL-Software-Files.exe it created a folder: C:\PDP ROM CTRL Software Files. It also created sub folders under this same directory. Additional folders: \Drivers \Program \CTL PWB Software 15. Using Windows Explorer, navigate to the \Program sub-Folder and right click on the FlashDown31.exe file. (See Fig. 10 ) Fig. 11 16. When you right click on the file, a menu comes up. Scroll down to Send To This opens another drop down window. ( Select Create Shortcut Close Windows Explorer. A new Icon was created on your Desktop allowing you quick access to the FlashDown program. . DOUBLE CLICK THE DESKTOP ICON TO START THE FLASHDOWN PROGRAM. See Fig. 11) Fig. 10

17

Plasma Control board ROM Update

Step 17: Setting up the Flash Down Program

Select Flash Size (16MBit/32Mbit) Select Flash Size (16MBit/32Mbit) 16M: 32 inch VGA model (32F) 16M: 32 inch VGA model (32F) 32M: All other models 32M: All other models Mode Select (15 Pin // 4 Pin(D-Sub)) Mode Select (15 Pin 4 Pin(D-Sub)) 15 Pin: Parallel Mode (EPP Mode) 15 Pin: Parallel Mode (EPP Mode) 4 Pin (D-Sub): Serial Mode 4 Pin (D-Sub): Serial Mode

Fig. 13

Serial Clk Rate Serial Clk Rate It is only used to select 4 Pin (D-SUB) It is only used to select 4 Pin (D-SUB) It must designate 13 ~ 15 or 5 It must designate 13 ~ 15 or 5 (13 is recommended) (13 is recommended) If an error occurs, try changing number If an error occurs, try changing number Open Open Navigate to and open SVC ROM file Navigate to and open SVC ROM file Pls check SVC Bulletin and Appendix Pls check SVC Bulletin and Appendix LGDP4022H LGDP4022H If you need upgrade V5/V6 model, If you need upgrade V5/V6 model, check blank check blank Check ASIC of CTRL Board Check ASIC of CTRL Board 12Pin Connect must be connected to CTRL 12Pin Connect must be connected to CTRL B/D B/D Display status. Display status. Display download process status bar. Display download process status bar. 1 Address reading. 1 Address reading. Write address that you want and Write address that you want and Find button is reading from ROM file Find button is reading from ROM file Read Button is reading from flash memory Read Button is reading from flash memory

9 8

18

Button for download (Auto) Button for download (Auto)

Plasma Control board ROM Update

Step 18 through 19: Starting the Flash Down Program

18. Choose Flash ROM Size
PDP Module has 2 types of ROM size. One is 32M, the other is 12M Check the Generic label on the ROM IC and select Correct size. 16M

32M

19. Download Mode Select:

Select the type of connection 4 Pin

15 Pin

19

Plasma Control board ROM Update

Step 20: Identifying the Type of Panel and Type of ROM on the Control PWB

50G1 Panel

42V6A Panel Identifying the Panel Type By the Silk Screen on the Control Board. Example of a 50G1, 42V6A and 50X3 Panel Control Board. 50X3 Panel

20

Plasma Control board ROM Update

Step 21 through 22: Starting the Flash Down Program

21. Choose SVC ROM file
1) Click 2) Find SVC ROM file (*.Bin or *.Hex) Note: If a 42V5 or 6 panel is being upgraded, LGDP4022H must be checked.

After clicking Open, navigate to the CTL PWB Software folder. Then select the correct file in accordance to the Panel. As shown in the Excel Table. (Go to Table) The program should remember this folder after the first time used. But please continue to check it is the right folder each time program is used.

22. Update SVC ROM to CTRL Board

1) Click the Auto button to Begin the download process.

21

Plasma Control board ROM Update

Step 23: Downloading the file to the Control board ROM.

Clearing of the ROM file Happens first.

Writing to the ROM file happens 2nd.

Verify the downloaded file happens 3rd.

The downloaded file was OK happens 4th.

22

Plasma Control board ROM Update

Step 24: Comparing the Check-Sum (Looking for a match)

After Downloading, confirm Check Sum in the window matches the File Name Check Sum.

23

Plasma Control board ROM Update

ERROR: Flash Down Program Doesnt Receive Acknowledgement for Control Board
Possible Cause 1: When Mode select is wrong.

Possible Cause 2: When serial Clk Rate is too low. Try raising the value. (13 is recommended)

Possible Cause 3: Forgot to add 5V supply to Control PWB. Possible Cause 4: 15 pin or 4 pin Cable is not connected to Control PWB. Possible Cause 5: If USB Driver is not installed in your computer

24

Plasma Control board ROM Update

ERROR: Flash Down Program cant communicate with TV

If you select incorrect Flash ROM Size (32M and 16M), its possible the Check Sum would not match. Correct the Flash Size and click Auto again.

25

Plasma Control board ROM Update

ERROR: Time Out, Cant receive information from the Flash ERROR: No USB Download B/D Check Connection

Control board not powered up. (Make sure you are using external 5V to keep Control board alive). Cables not connected properly to the jig or the control board.

USB Cable not connected properly to the jig or Bad USB Cable.

WARNING: External 5V MUST be supplied to the control PWB before beginning Download. Failure to do so, may cause a Corruption of the internal memory and the board will fail. If this happens, try applying external 5V and then re-downloading the software. Use the Stand-By 5V from the Power Supply. Make sure to disconnect the ribbon connector from the Y-SUS to the Control board as well as any connections to the Z-SUS board.

26

Plasma Control board ROM Update

ERROR: Writing failed

In this case, you need to change serial Clk rate. Normally 15 will give you success in ROM Downloading but some of computers will show an error with 15. If this happens, please use 13 as the Serial Clock Rate

27

Plasma Control board ROM Update

FINAL STEPS: CORRECTING THE PANEL LABEL WHEN REQUIRED

If the Excel chart indicated a modified Voltage Adjustment, it ONLY HAS TO BE DONE If after the ROM download there is still Mal-Discharge. If no Mal-Discharge is detected, Then modifying the voltage adjustment from the original voltage label is not necessary. As an example, the 50X4 panel shows the Vs and Vzb voltage must be changed After the software is updated. In this case, the Panel Label must the altered to Reflect the change so any Servicer following will know to adjust to a different value. Example pulled from the ROM Chart
No
19

Category
50XGA 50X4

Model
PDP50X4####

ROM Ver.
50X4_3DA2K

Check-sum
AAC8

Voltage Adj. Vs(188), Vzb(95)

BEFORE

AFTER

Vs 188V 95V Please use new values

28

Plasma Control board ROM Update

Appendix: Table for SVC ROM file information

No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 50XGA 42XGA 42X3 42X3A 42X4 42X4A 42G1 50X2 50X2A 42X2A 42X1A 42X2 32VGA 32F1 Category Model 32F10110 32F10010 32F10010 32F1X042 PDP42X1#### PDP42X2000# PDP42X2002# PDP42X202## PDP42X208## PDP42X30###.AKLGG PDP42X30###.AKLTG PDP42X400## PDP42X402## PDP42X40523 PDP42G1#### PDP50X2033# PDP50X205## ROM Ver. 32F1_4DA1J_984E.bin 32F1_4DA1A_9CC9.bin 32F1_4DA4F_4303.bin 32F1_4DA4F_4303.bin 42X1A2DICS01_C3F5.bin 42X2DNCS4_CD21.bin 42X2ADNACS2_8D10.bin 42X2ATDCS2_64C0.bin 42X3_3DCS4_88D4.bin 42X3A3DCS3_7FDD.bin 42X4_CS1A_5A20.bin 42X4A0CS4A_1612.bin 42G1_4DA2D_82C8.bin 50X2DNCS2_CAC9 .hex 50X2A_DNCS2_6CDC.bin 50X3DNSC02_2E14.bin 50X3 50X4 50G1 42V6 42V6A PDP50X30### PDP50X4#### PDP50G1000# PDP42V6000# PDP42V6001# 50X3DNCS2A_2EC5.bin 50X4_3DA2K_AAC8.bin 50G1_3CS1C_FAAC.bin 42V63MNCS1_93A2 .hex 42V6A3MN03B_831F.bin Check-sum 984E 4C93 4303 4303 C3F5 CD21 8D10 64C0 88D4 7FDD 5A20 1612 82C8 CAC9 6CDC 2E14 2EC5 AAC8 FAAC 93A2 831F (Note1) Vset-up 5 ~10V (Note1) Vset-up 5 ~10V (Note1) Vs 3V down (Note1) Vs(188), Vzb(95) (Note1) Vset-up 5 ~10V (Note1) Vs(185),Vy(75) (Note1) Vset-up(230) (Note1) Vs(185), Vzb(140) (Note1) Vset-up (100) (Note1) Vset-up (100) (Note1) Vzb(95) Voltage Adj.

Back to Jig Page 6

Back to Procedure Page 21

Comment Before Dec, 2007 After Jan, 2008

Blue Dielectric layer Transparent Dielectric layer

All set except 50PY2DR 50PY2DR only

18 19 20 21 22

23 42VGA 24 25 26 27 28 20 30 31 60XGA 71HD

42V7

PDP42V70###

42V70CS4CD_89C6.bin

89C6

1.check part no of Y-SUS,Z-SUS, CTRL B/D first Y-SUS: 6871QYH036D, Z-SUS: 6871QZH041B, CTRL: 6871QCH053G 2. if any of them doesn't match below part no. pls replace Y,Z,CTRL as KIT 3. Part No is the same above part No, pls apply CS ROM

42V5 42V8 42V8A 42V8B 60X5A 60X7 71H1 71H2

PDP42V50### PDP42V80301 PDP42V80#11 PDP42V806## PDP60X505## PDP60X7#### PDP71H10### PDP71H20###

42V52MNCS1_A140.hex 42V84CS01_A147.bin 42V8A4DA2F_80A5.bin 42V8B4CS1A_76C5.bin 60X5ACS02_FFF2.bin 60X7_4CS01_1DA5.bin 71H13CS01_CECC.bin

71H23DN01K_ChecksumFF3F.bin

A140 A147 80A5 76C5 FFF2 1DA5 CECC FF3F (Note1) Vzb(85)

(Note 1) This Excel chart should have been extracted in Step 2 to: C:\PDP ROM CTRL Software Files\SVC ROM Mastersheet.xls 1) First Pre-align to normal values, then perform ROM Download. 2) If you cant solve mal-discharge with ROM Download please adjust voltage to new value. (If mal-discharge disappears after ROM download, do not adjust voltage to new value) 3) If adjust voltage must be changed, please change voltage value with an indelible pen.

This concludes the Control board ROM Download instructions