LG HCS6000A User manual

MODEL : HCS6000A(LST-4600A)
MODEL : HCS6000A(LST-4600A)
SERVICE MANUAL
P/NO : 3829R
MAY, 2004
Printed in Korea
HD/SD PERSONAL VIDEO RECORDER
& RECEIVER WITH GEMSTAR
SERVICE MANUAL
CAUTION
BEFORE SERVICING THE UNIT, READ THE “SAFETY PRECAUTIONS”
IN THIS MANUAL.

1-1
SECTION 1
SUMMARY
CONTENTS
INTRODUCTION ......................................................................................................1-2
PRODUCT SAFETY SERVICING GUIDELINES FOR VIDEO PRODUCTS............1-3
SERVICING PRECAUTIONS....................................................................................1-4
SPECIFICATIONS .....................................................................................................1-5
LOCATION OF CUSTOMER CONTROLS ...............................................................1-7

1-2
INTRODUCTION
- Digital/Analog broadcasting recorder/receiver [HD/SD PERSONAL VIDEO RECORDER & RECEIVER] or
PVR(Personal Video Recorder)-STB(Set-Top Box) receives the ground wave HD Digital broadcasting pro-
gram /Analog NTSC or Cable broadcasting program and saves a video and audio signal at a HDD with a
specific form or offers additional related services..
- Configuration
The PCU is the IBM PPC405GP of the PowerPC series supporting PCI Bus I/F for PVR, and the tuner
receives a digital ground wave and transfers it as a TP signal, transmitting the NTSC signal of the ground
wave/the cable signal and transferring the audio signal to the SIF.
The MPEG Decoder uses the HD-II supporting MP@HL built with the AC-3 Decoder.
The PVR section transforms the TP data of a digital TV signal and an analog audio/video signal into the TP
by using the MPEG-II Encoder and saves only the necessary data to the HDD via the IDE I/F Chip.
Overall configuration
- System section
CPU, Main Memory, MPEG-II Decoder, Flash Memory, and System CPLD.
- MPEG Video/Audio Decoder section
HD-2, Memory, PLL IC, Audio Processor, Audio ADC, and so on.
- PVR section
TPN-II performing PCI I/F and TP De-Mux, Memory, MPEG-II Encoder, IDE I/F Chip, and 120GB HDD.
- Video/Audio input section
CVBS Decoder, and Audio processor
-1394 section
1394 1-Chip supporting D-VHS and MV Camcoder.
- Tuner
It can receive a signal from ATSC/NTSC/Cable, and send a signal from the ATSC as TP, an analog video sig-
nal as NTSC, and an audio signal as SIF.
- Front section
It is located at the front receiving various key inputs from users and displaying the status of a set-top box at
the VFD.
- Power section
It supplies a DC power to Main Digital Board, Front Board, and HDD with the input of AC 110V.

1-3
IMPORTANT SAFETY NOTICE
This manual was prepared for use only by properly trained audio-video service
technicians.
When servicing this product, under no circumstances should the original
design be modified or altered without permission from Zenith Electronics
Corporation. All components should be replaced only with types identical to
those in the original circuit and their physical location, wiring and lead dress
must conform to original layout upon completion of repairs.
Special components are also used to prevent x-radiation, shock and fire haz-
ard. These components are indicated by the letter “x” included in their compo-
nent designators and are required to maintain safe performance. No deviations
are allowed without prior approval by Zenith Electronics Corporation.
Circuit diagrams may occasionally differ from the actual circuit used. This way,
implementation of the latest safety and performance improvement changes
into the set is not delayed until the new service literature is printed.
CAUTION: Do not attempt to modify this product in any way. Never perform
customized installations without manufacturer’s approval. Unauthorized modi-
fications will not only void the warranty, but may lead to property damage or
user injury.
Service work should be performed only after you are thoroughly familiar with
these safety checks and servicing guidelines.
GRAPHIC SYMBOLS
The exclamation point within an equilateral triangle is intended to
alert the service personnel to important safety information in the
service literature.
The lightning flash with arrowhead symbol within an equilateral tri-
angle is intended to alert the service personnel to the presence of
noninsulated “dangerous voltage” that may be of sufficient magni-
tude to constitute a risk of electric shock.
The pictorial representation of a fuse and its rating within an equi-
lateral triangle is intended to convey to the service personnel the
following fuse replacement caution notice:
CAUTION: FOR CONTINUED PROTECTION AGAINST RISK
OF FIRE, REPLACE ALL FUSES WITH THE SAME TYPE AND
RATING AS MARKED NEAR EACH FUSE.
SERVICE INFORMATION
While servicing, use an isolation transformer for protection from AC line shock.
After the original service problem has been corrected, make a check of the fol-
lowing:
FIRE AND SHOCK HAZARD
1. Be sure that all components are positioned to avoid a possibility of adjacent
component shorts. This is especially important on items trans-ported to and
from the repair shop.
2. Verify that all protective devices such as insulators, barriers, covers, shields,
strain reliefs, power supply cords, and other hardware have been reinstalled
per the original design. Be sure that the safety purpose of the polarized line
plug has not been defeated.
3. Soldering must be inspected to discover possible cold solder joints, solder
splashes, or sharp solder points. Be certain to remove all loose foreign par-
ticles.
4. Check for physical evidence of damage or deterioration to parts and compo-
nents, for frayed leads or damaged insulation (including the AC cord), and
replace if necessary.
5. No lead or component should touch a high current device or a resistor rated
at 1 watt or more. Lead tension around protruding metal surfaces must be
avoided.
6. After reassembly of the set, always perform an AC leakage test on all
exposed metallic parts of the cabinet (the channel selector knobs, antenna
terminals, handle and screws) to be sure that set is safe to operate without
danger of electrical shock. DO NOT USE A LINE ISOLATION TRANS-
FORMER DURING THIS TEST. Use an AC voltmeter having 5000 ohms per
volt or more sensitivity in the following manner: Connect a 1500 ohm, 10
watt resistor, paralleled by a .15 mfd 150V AC type capacitor between a
known good earth ground water pipe, conduit, etc.) and the exposed metal-
lic parts, one at a time. Measure the AC voltage across the combination of
1500 ohm resistor and .15 mfd capacitor. Reverse the AC plug by using a
non-polarized adaptor and repeat AC voltage measurements for each
exposed metallic part. Voltage measured must not exceed 0.75 volts RMS.
This corresponds to 0.5 milliamp AC. Any value exceeding this limit consti-
tutes a potential shock hazard and must be corrected immediately.
TIPS ON PROPER INSTALLATION
1. Never install any receiver in a closed-in recess, cubbyhole, or closely fitting
shelf space over, or close to, a heat duct, or in the path of heated air flow.
2. Avoid conditions of high humidity such as: outdoor patio installations where
dew is a factor, near steam radiators where steam leakage is a factor, etc.
3. Avoid placement where draperies may obstruct venting. The customer
should also avoid the use of decorative scarves or other coverings that
might obstruct ventilation.
4. Wall- and shelf-mounted installations using a commercial mounting kit must
follow the factory-approved mounting instructions. A product mounted to a
shelf or platform must retain its original feet (or the equivalent thickness in
spacers) to provide adequate air flow across the bottom. Bolts or screws
used for fasteners must not touch any parts or wiring. Perform leakage tests
on customized installations.
5. Caution customers against mounting a product on a sloping shelf or in a tilt-
ed position, unless the receiver is properly secured.
6. A product on a roll-about cart should be stable in its mounting to the cart.
Caution the customer on the hazards of trying to roll a cart with small cast-
ers across thresholds or deep pile carpets.
7. Caution customers against using extension cords. Explain that a forest of
extensions, sprouting from a single outlet, can lead to disastrous conse-
quences to home and family.
A.C. Voltmeter
1500 OHM
10 WATT
Place this probe
on each exposed
metal part.
Good Earth Ground
such as the Water
Pipe, Conduit, etc.
0.15uF
PRODUCT SAFETY SERVICING GUIDELINES FOR VIDEO PRODUCTS

1-4
SERVICING PRECAUTIONS
CAUTION: Before servicing the HD/SD PERSONAL VIDEO
RECORDER & RECEIVER WITH GEMSTAR covered by
this service data and its supplements and addends, read and
follow the SAFETY PRECAUTIONS. NOTE: if unforeseen
circumstances create conflict between the following servic-
ing precautions and any of the safety precautions in this pub-
lications, always follow the safety precautions.
Remember Safety First:
General Servicing Precautions
1. Always unplug the HD/SD PERSONAL VIDEO
RECORDER & RECEIVER WITH GEMSTAR AC power
cord from the AC power source before:
(1) Removing or reinstalling any component, circuit board,
module, or any other assembly.
(2) Disconnecting or reconnecting any internal electrical
plug or other electrical connection.
(3) Connecting a test substitute in parallel with an elec-
trolytic capacitor.
Caution: A wrong part substitution or incorrect
polarity installation of electrolytic capacitors may result
in an explosion hazard.
2. Do not spray chemicals on or near this HD/SD PERSON-
AL VIDEO RECORDER & RECEIVER WITH GEMSTAR
or any of its assemblies.
3. Unless specified otherwise in this service data, clean
electrical contacts by applying an appropriate contact
cleaning solution to the contacts with a pipe cleaner,
cotton-tipped swab, or comparable soft applicator.
Unless specified otherwise in this service data, lubrication
of contacts is not required.
4. Do not defeat any plug/socket B+ voltage interlocks with
which instruments covered by this service manual might
be equipped.
5. Do not apply AC power to this HD/SD PERSONAL VIDEO
RECORDER & RECEIVER WITH GEMSTAR and / or any
of its electrical assemblies unless all solid-state device
heat sinks are correctly installed.
6. Always connect the test instrument ground lead to an
appropriate ground before connecting the test instrument
positive lead. Always remove the test instrument ground
lead last.
Insulation Checking Procedure
Disconnect the attachment plug from the AC outlet and turn
the power on. Connect an insulation resistance meter (500V)
to the blades of the attachment plug. The insulation resis-
tance between each blade of the attachment plug and acces-
sible conductive parts (Note 1) should be more than 1M-
ohm.
Note 1: Accessible Conductive Parts include Metal panels,
Input terminals, Earphone jacks,etc.
Electrostatically Sensitive (ES) Devices
Some semiconductor (solid state) devices can be damaged
easily by static electricity. Such components commonly are
called Electrostatically Sensitive (ES) Devices. Examples of
typical ES devices are integrated circuits and some field
effect transistors and semiconductor chip components.
The following techniques should be used to help reduce the
incidence of component damage caused by static electricity.
1. Immediately before handling any semiconductor compo-
nent or semiconductor-equipped assembly, drain off any
electrostatic charge on your body by touching a known
earth ground. Alternatively, obtain and wear a commer-
cially available discharging wrist strap device, which
should be removed for potential shock reasons prior to
applying power to the unit under test.
2. After removing an electrical assembly equipped with ES
devices, place the assembly on a conductive surface such
as aluminum foil, to prevent electrostatic charge buildup or
exposure of the assembly.
3. Use only a grounded-tip soldering iron to solder or unsolder
ES devices.
4. Use only an anti-static solder removal device. Some
solder removal devices not classified as “anti-static” can
generate electrical charges sufficient to damage ES
devices.
5. Do not use freon-propelled chemicals. These can
generate an electrical charge sufficient to damage ES
devices.
6. Do not remove a replacement ES device from its protec-
tive package until immediately before you are ready to
install it. (Most replacement ES devices are packaged with
leads electrically shorted together by conductive foam,
aluminum foil,or comparable conductive material).
7. Immediately before removing the protective material from
the leads of a replacement ES device, touch the protective
material to the chassis or circuit assembly into which the
device will be installed.
Caution: Be sure no power is applied to the chassis or
circuit, and observe all other safety precautions.
8. Minimize bodily motions when handling unpackaged
replacement ES devices. (Normally harmless motion such
as the brushing together of your clothes fabric or the lifting
of your foot from a carpeted floor can generate static elec-
tricity sufficient to damage an ES device.)

1-5
SPECIFICATIONS
♦CPU [PPC405GP Rev E]
• PowerPC405GP, 32-bit, 200MHz RISC Processor
• I Cache 16K, D Cache 8K
• SDRAM Controller(100MHz speed)
• External Peripheral Bus(up to 8 device)
• PCI 2.2 I/F(32-bit, 33MHz)]
• DMA, Interrupt Controller, Serial Port, GPIO, I2C
♦System Memory
• Main Memory : 32MB(K4S281632 x2)
• Flash Memory : 8MB(MEM29DL323x2)
• NVRAM : EEPROM(32KB, 105 Read/Write)
• Probe ROM : 512KB (Am29LV040)
♦MPEG 2 A/V Decoder [LGDT1102A]
• 1 HD(MP@HL) or 4 SD(MP@ML)
• ATSC all format Decoding
• Memory : SDRAM 32MB(K4S641632 x4)
• Graphics
• 2D Graphics
• HD Resolution(max. 1080x1920 x16-bit)
• BitBLT/Rendering Cursor Support(by H/W)
• Alpha Blending(6-bit level) Support
• Audio Decoder
• AC-3 Decoding
• MPEG Audio Layer 1, 2 Decoding
• SPDIF Output
♦PLL IC [LGDT1901A]
• HD-2 Video Clock Generation
• 27MHz VCXO input & Control Signals
♦System CPLD [EPM7256AETC]
• HD-2 I/F Signal
• Address Decode
• GPIO
♦Audio Processor [MSP4450]
• SIF Processing
• Audio Input Selection
• ADC/DAC
• Volume control
♦Video Decoder [VPX3226F]
• CVBS Decoding
• Video Processing
• 656 Data Output
• VBI/CC support
♦DVI Transmitter [Sil170]
• DVI output
• HDCP Support
♦I2C Controller [PCF8584]
• Tuner(ATSC/NTSC/Cable) I/F
• Gemstar I/F
• Front MiCOM I/F
♦TPN-II
• TP Processing for PVR
• PCI I/F
• SDRAM I/F 16MB(K4S641632)
• PVR Function
♦MPEG-2 Encoder [BCM7040]
• MPEG-2 Encoding (MP@ML)
• 656/I2S Input, TP output
• SDRAM I/F 16MB(K4S643232)
• PCI I/F
♦E-IDE Controller [ARS0303D]
• PCI I/F
• E-IDE Controller
♦ATSC/NTSC/CableTuner[TDVL-H100P]
• AT/NT/Cable NIM Tuner
• I2C I/F, TP/CVBS/SIF Out
♦Miscellaneous
• RS-232C
• RF Switch
• MiCOM( Timer, Gemstar Tuning)
• Gemstar I/F : Video Input, I2C
♦IEEE-1394[TSB43CA42]
• 1394 TP In/Out
• Link&PHY(1-Chip)
♦MUX CPLD [EPM7256AETC]
• 1394 TP In/Out
• Encoder TP, VSB TP, TPN-II TP In/Out
♦Gemstar Board
• GS501 : Gemstar Processor
• GS502 : AD Converter
• G-Link
♦Power Board
• Input: AC120V/60Hz
• Output
- Main Board : 9V,5V,3.3V,L_5V,L_33V
- Front Board : -28V,-24V,-21.5V
- HDD : 12V, 5V
♦HDD
• 120GB
• Ultra DMA-100
♦Front Panel
• I2C I/F, Power On/Off
• VFD Display
♦Remote Controller
• Basic TV
• PVR Function
System Specifications

1-6
♦Input
• Antenna In : Terrestrial [F Connector]
• Antenna In : Cable [F Connector]
• CVBS Video/Audio-1 [RCA Jack, 3EA]
• CVBS Video/Audio-1 [RCA Jack, 3EA]
♦Output
• Video Out
- Component Out : YPbPr [RCA Jack, 3EA]
- Composite Out : CVB S-1 [RCA Jack, 1EA]
- S-Video Out [Mini DIN Jack, 1EA]
• Composite Out : CVBS-2 [RCA Jack, 1EA]
• RGB Out : VGA [D-SUB 15-P, 1EA]
• DVI Out
• Audio Out
- Stereo Out -1 [RCA Jack, 2EA]
- Stereo Out-2 [RCA Jack, 2EA]
- SPDIF Out : Photo Link
• Serial Port
• IEEE-1394 Port [1394 2EA]
♦G-Link
• S/W Up-grade
• IR Blaster
♦Input
• AC120V/60Hz
♦Output
• Main Board : 9V,5V,3.3V,L_5V,L_33V
• Front Board : -28V,-24V,-21.5V
• HDD : 12V, 5V
♦Power Consumption : 35W
♦Main Board Size
• 213(D) x317(W) with Dummy[Unit : mm]
• 170(D) x317(W) [Unit : mm]
♦Gemstar Board Size
• 130(D) x48(W) [Unit: mm]
♦Power Board Size
• 247(D) x 93(W) [Unit: mm]
♦Front Panel Board Size
• 50(D) x 280(W) [Unit: mm]
♦430(W) x 69(H) x 297(D) [Unit: mm]
♦55(W) x 240(H) x 35(D) [Unit: mm]
In/out Connector Set-Top Box Size
Remote Controller Size
Power
Board Size

2-1
SECTION 2
CABINET & MAIN CHASSIS
CONTENTS
EXPLODED VIEWS .....................................................................................................................2-2
1. Cabinet and Main Frame Section ...........................................................................................2-2
2. Packing Accessory Section....................................................................................................2-3

2-2
EXPLODED VIEWS
1. Cabinet and Main Frame Section
467
467
273
272
271
465
275
471
471
274
A48A
A48B
250
467
467
471
A48
471
A47
A44
262
468
472
472
468
263
469
261
261
330
465
266
266
465
261
261
320
A46
264
467
467
A
4
3
2
1
BCD
NOTE) Refer to “SECTION 4 REPLACEMENT
PARTS LIST” in order to look for the
part number of each part.

2-3
2. Packing Accessory Section
INSTRUCTION ASSEMBLY
PACKING (RF)
BAG
CABLE
PACKING (LF)
BOX CARTON
806
804
803
801
802
803
822 D-SUB(RS23)
823 D-SUB(RGB)

3-1
SECTION 3
ELECTRICAL
CONTENTS
ELECTRICAL TROUBLESHOOTING GUIDE ..................................................................................................3-2
1. CPU(SYSTEM CONTROL) TROUBLESHOOTING.................................................................................3-2
2. ATSC/QAM FRONT_END TROUBLESHOOTING.................................................................................3-10
3. NTSC/FRONT_END TROUBLESHOOTING..........................................................................................3-12
4. VIDEO TROUBLESHOOTING ...............................................................................................................3-13
5. DVI TROUBLESHOOTING ....................................................................................................................3-22
6. AUDIO TROUBLESHOOTING ...............................................................................................................3-26
BLOCK DIAGRAM ..........................................................................................................................................3-33
1. OVERALL BLOCK DIAGRAM 1............................................................................................................3-33
2. OVERALL BLOCK DIAGRAM 2............................................................................................................3-34
CIRCUIT DIAGRAMS ......................................................................................................................................3-35
1. CPU & SYSTEM MEMORY CIRCUIT DIAGRAM..................................................................................3-35
2. CPU PERI & IR-IN & AUX-CTRL CIRCUIT DIAGRAM.........................................................................3-37
3. TERRESTRIAL FRONT_END CIRCUIT DIAGRAM .............................................................................3-39
4. HD2 & SDRAM CIRCUIT DIAGRAM .....................................................................................................3-41
5. DVI TRANSMITTER CIRCUIT DIAGRAM .............................................................................................3-43
6. VDP I/F & DISPLAY OUTPUT CIRCUIT DIAGRAM..............................................................................3-45
7. NTSC AUDIO PROCESSOR CIRCUIT DIAGRAM................................................................................3-47
8. POWER REGULATION CIRCUIT DIAGRAM ........................................................................................3-49
9. MPI CIRCUIT DIAGRAM........................................................................................................................3-51
10. PTC CIRCUIT DIAGRAM .....................................................................................................................3-53
11. BACK PLANE CIRCUIT DIAGRAM.....................................................................................................3-55
PRINTED CIRCUIT DIAGRAMS .....................................................................................................................3-57
1. DIGITAL MAIN PRINTED CIRCUIT DIAGRAMS(TOP).........................................................................3-57
2. DIGITAL MAIN PRINTED CIRCUIT DIAGRAMS(BOTTOM).................................................................3-59
3. MPI PRINTED CIRCUIT DIAGRAM(TOP) .............................................................................................3-61
4. PTC PRINTED CIRCUIT DIAGRAM ......................................................................................................3-63
5. BACK PLANE PRINTED CIRCUIT DIAGRAM......................................................................................3-65

3-2
ELECTRICAL TROUBLESHOOTING GUIDE
1. CPU(SYSTEM CONTROL) TROUBLESHOOTING
Start
Power is supplied normally?
YES
NO
Clock signals are OK?
YES
Reset signals are OK at the time of
power-on reset?
Chip selection signals are OK?
IIC channels are OK?
YES
YES
YES
Interrupt signals are OK?
Messages are output through
RS-232C port on PC terminal?
END
YES
YES
YES
NO (B) Clock check
(A) Power check
(C) Reset check
(D) CS check
(E) IIC check
(F) Interrupt check
(G) RS-232C check
NO
NO
NO
NO
NO

3-3
(A) Power check
2.5V is supplied to L101?
YES
NO
3.3V is supplied to IC104(37), IC105(37),
IC102(1), IC103(1), and IC201(3)?
YES
3.3V is supplied to IC106(14)?
(B) Clock check
25MHz clock is output from X101(3)?
Fig.01
YES
YES
37.5MHz clock is input to IC201(87)?
Fig.02
3.6864MHz clock is output from X102(3)?
Fig.03
YES
YES
NO Power Supply Check
IC950(2) : 3.3V
Power Supply Check
IC954(3) : 2.5V
Power Supply Check
IC950(2) : 3.3V
Check X101
Check IC101 & IC201
Check X102
NO
NO
NO
NO

3-4
Fig.01 X101(3) : 25MHz CPU Clock
Fig.02 IC201(87) : 37.5MHz PERI Clock
Fig.03 X102(3) : 3.6864MHz UART Clock

3-5
(C) Reset check
IC107(3) is reset?
YES
NO
IC106(4) is reset? Fig.04
YES
IC201(29, 56, 61, 64, 75) are reset?
YES
NO Check IC106
Check IC107
Check IC101 & 201
NO
Fig.04 IC106(4) : Reset signal

3-6
(D) CS check
Logic low pulse is seen at R138?
Fig.05
YES
NO
Logic low pulse is seen at R140?
YES
Logic low pulse is seen at R144?
YES
NO Check IC101, IC211
Check IC101, 104, 105
Check IC101, IC400
NO
Logic low pulse is seen at R143?
YES
Check IC101, IC201
NO
Fig.05 R138(1) : Flash CS signal

3-7
(E) IIC check
IIC SDA and SCL signals are output
from IC211(19 & 18)? Fig.06 & Fig.07
YES
NO
IIC SCL and SDA signals are output
from IC101(W17 & U15)?
YES
NO Check IC101
Check IC211
Fig.06 IC211(19) :
3.3V IIC SDA signal
Fig.07 IC211(18) :
3.3V IIC SCL signal

3-8
(F) Interrupt check
Logic high is input to IC101(D18) or R418?
YES
NO
Logic high is input to IC101(W20) or
CN201(7)?
YES
NO Check IC100, CN201(7)
Check IC100, IC400
Fig.08 IC101(D18) :
No Interrupt signal

3-9
(G) RS-232C check
RS-232C port setup is OK?
(Baudrate, Parity, Data Bit, Stop Bit)
YES
NO
IC204(10) is OK?(TxD signal)
Fig.09
YES
NO Check IC101, IC204
IC204(9) is OK?(RxD signal)
Fig.10
YES
NO Check IC101, IC204
Modify RS-232C port setup
Fig.09 IC204(10) : TxD signal
Fig.10 IC204(9) : RxD signal

3-10
2. ATSC/QAM FRONT_END TROUBLESHOOTING
Start
Power is supplied normally(TU300)?
YES
NO
RF signal is detected?
(using Spectrum Analyzer)
YES
Check error signal(TU300(22)). (using
Oscilloscope) High:normal, Low:Error
Check NIM Tuner(TU300)’s output
signals of DATA(Fig.01)
(pin 28,29,30,31,32,33,34,35),
packet clock(Fig.02)(pin 27) and
Byte clock(pin 36)(Fig.03).
END
YES
YES
YES
NO Check antenna connection.
Check the power lines(A9V, D5V_2,
D3.3V_2, P_30V_TU) referring the circuit
diagram.
Check the Voltage between L303 and
Ground.
5V : normal, 0~4V : change Q300.
Check the status of connection on PCB.
Change TU300.
NO
NO