LG 60PZ550 User manual

PLASMA TV
SERVICE MANUAL
CAUTION
BEFORE SERVICING THE CHASSIS,
READ THE SAFETY PRECAUTIONS IN THIS MANUAL.
CHASSIS : PU13A
MODEL : 60PZ550 50PZ550-UA
MODEL : 60PZ540 50PZ540-UB
North/Latin A erica http://aic.lgservice.co
Europe/Africa http://eic.lgservice.co
Asia/Oceania http://biz.lgservice.co
Internal Use Only
Printed in Korea
P/NO : MFL67001503(1101-REV00)

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CONTENTS
CONTENTS ............................................................................................................................... 2
SAFETY PRECAUTIONS ...........................................................................................................3
SPECIFICATION.........................................................................................................................4
ADJUSTMENT INSTRUCTION ..................................................................................................6
BLOCK DIAGRAM ...................................................................................................................13
EXPLODED VIEW ...................................................................................................................14
CIRCUIT DIAGRAM .....................................................................................................................

- 3 - LGE Internal Use OnlyCopyright ©2011 LG Electronics Inc. All rights reserved.
Only or training and service purposes
SAFETY PRECAUTIONS
Many electrical and mechanical parts in this chassis have special sa ety-related characteristics. These parts are identi ied by in
the Schematic Diagram and Exploded View.
It is essential that these special sa ety parts should be replaced with the same components as recommended in this manual to
prevent X-RADIATION, Shock, Fire, or other Hazards.
Do not modi y the original design without permission o manu acturer.
Ge eral Guida ce
An isolatio Tra sformer should always be used during the
servicing o a receiver whose chassis is not isolated rom the AC
power line. Use a trans ormer o adequate power rating as this
protects the technician rom accidents resulting in personal injury
rom electrical shocks.
It will also protect the receiver and it's components rom being
damaged by accidental shorts o the circuitry that may be
inadvertently introduced during the service operation.
I any use (or Fusible Resistor) in this monitor is blown, replace it
with the speci ied.
When replacing a high wattage resistor (Oxide Metal Film
Resistor, over 1 W), keep the resistor 10 mm away rom PCB.
Keep wires away rom high voltage or high temperature parts.
Due to high vacuum and large sur ace area o picture tube,
extreme care should be used in ha dli g the Picture Tube.
Do not li t the Picture tube by it's Neck.
Leakage Curre t Cold Check(A te a Cold Check)
With the instrument AC plug removed rom AC source, connect
an electrical jumper across the two AC plug prongs. Place the
AC switch in the on position, connect one lead o ohm-meter to
the AC plug prongs tied together and touch other ohm-meter
lead in turn to each exposed metallic parts such as antenna
terminals, phone jacks, etc.
I the exposed metallic part has a return path to the chassis, the
measured resistance should be between 1 MΩ and 5.2 MΩ.
When the exposed metal has no return path to the chassis the
reading must be in inite.
An other abnormality exists that must be corrected be ore the
receiver is returned to the customer.
Leakage Curre t Hot Check (See below Figure)
Plug the AC cord directly into the AC outlet.
Do ot use a li e Isolatio Tra sformer duri g this check.
Connect 1.5 K/10watt resistor in parallel with a 0.15 uF capacitor
between a known good earth ground (Water Pipe, Conduit, etc.)
and the exposed metallic parts.
Measure the AC voltage across the resistor using AC voltmeter
with 1000 ohms/volt or more sensitivity.
Reverse plug the AC cord into the AC outlet and repeat AC
voltage measurements or each exposed metallic part. Any
voltage measured must not exceed 0.75 volt RMS which is
corresponds to 0.5 mA.
In case any measurement is out o the limits speci ied, there is
possibility o shock hazard and the set must be checked and
repaired be ore it is returned to the customer.
Leakage Curre t Hot Check circuit
1.5 Kohm/10W
To Instrument's
exposed
METALLIC PARTS
Good Earth Ground
such as WATER PIPE,
CONDUIT etc.
AC Volt-meter
IMPORTANT SAFETY NOTICE
0.15uF

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Only for training an service purposes
SPECIFICATIONS
NOTE : Specifications an others are subject to change without notice for improvement .
1. Application Range
(1) This spec sheet is applie all of PDP TV with PU13A chassis.
2. Specification
Each part is teste as below without special appointment.
(1) Temperature : 25 °C ± 5 °C (77 °F ± 9 °F), CST : 40 °C ± 5 °C
(2) Relative Humi ity : 65 % ± 10 %
(3) Power Voltage : Stan ar input voltage (100 V - 240 V ~ 50 / 60 Hz)
* Stan ar Voltage of each pro uct is marke by mo els
(4) Specification an performance of each parts are followe each rawing an specification by part number in accor ance with
BOM.
(5) The receiver must be operate for about 5 minutes prior to the a justment.
3. Test Method
(1) Performance : LGE TV test metho followe .
(2) Deman e other specification
Safety : UL, CSA, IEC specification, CE
EMC : FCC, ICES, IEC specification, CE
Mo el Name
60PZ550-UA
60PZ540-UB
Remark
Safety : UL1492, CSA C22.2.No.1
EMC : FCC Class B, IC Class B
Market
NORTH AMERICA
CANADA / MEXICO
Mo el Name
60PZ550-UA
60PZ540-UB
Bran
LG
Market
NORTH AMERICA
CANADA / MEXICO

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4. Ge eral Specificatio
No Item Speci ication Remark
1. Receiving System 1) ATSC / NTSC-M
2. Available Channel 1) VHF : 02~13
2) UHF : 14~69
3) DTV : 02-69
4) CATV : 01~135
5) CADTV : 01~135
3. Input Voltage 1) AC 100 V - 240 V ~ 50 / 60 Hz N.America Mark : 110V, 60Hz
4. Market NORTH AMERICA, KOREA
5. Screen Size 127 cm (50 inch) Wide(1920 ×1080) 50PZ550/540
152 cm (60 inch) Wide(1920 ×1080) 60PZ550/540
6. Aspect Ratio 16:9
7. Tuning System FS
8. PDP Module PDP50R3#### (1920 ×1080) 50PZ550/540
PDP60R3#### (1920 ×1080) 60PZ550/540
9. Operating Environment 1) Temp : 0 deg ~ 40 deg
2) Humidity : ~ 80 %
10. Storage Environment 1) Temp : -20 deg ~ 60 deg
2) Humidity : ~ 85 %

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ADJUSTMENT INSTRUCTION
1. Applicatio Ra ge
This spec. sheet applies to PU13A Chassis applied PDP TV
all models manu actured in TV actory.
2. Specificatio
(1) Because this is not a hot chassis, it is not necessary to use
an isolation trans ormer. However, the use o isolation
trans ormer will help protect test instrument.
(2) Adjustment must be done in the correct order.
(3) The adjustment must be per ormed in the circumstance o
25 cC ± 5 cC o temperature and 65 % ± 10 % o relative
humidity i there is no speci ic designation.
(4) The input voltage o the receiver must keep 100 V - 240 V,
50 / 60 Hz.
(5) The receiver must be operated or about 5 minutes prior to
the adjustment when module is in the circumstance o over
15 cC
- In case o keeping module is in the circumstance o 0 cC,
it should be placed in the circumstance o above 15 cC or
2 hours
- In case o keeping module is in the circumstance o below
-20 cC, it should be placed in the circumstance o above
15 cC or 3 hours.
OA ter RGB Full White in HEAT-RUN Mode, the receiver
must be operated prior to the adjustment.
OEnter into HEAT-RUN MODE
1) Press the POWER ON KEY on R/C or adjustment.
2) OSD display and screen display PATTERN MODE.
- Set is activated HEAT run without signal generator in this
mode.
- Single color pattern ( WHITE ) o HEAT RUN MODE uses
to check panel.
Caution) When still image is displayed or a period o 20 minutes
or longer (especially where W/B scale is strong. Digital
pattern 13ch and/or Cross hatch pattern 09ch), there
can some a terimage in the black level area.
3. Adjustme t items
3-1. Board-level adjustme t
- Mac address and Id ile(ESN) Download
(Except For Mexico/Canada Models)
- Adjust 480i Comp1 adj.
- Adjust 1080p Comp1 adj.
- Adjust 1920*1080 RGB adj.
- EDID/DDC download
Above adjustment items can be also per ormed in Final
Assembly i needed. Both Board-level and Final assembly
adjustment items can be check using In-Start Menu 1.
Adjust Check.
3-2. Fi al assembly adjustme t
- White Balance adjustment
- RS-232C unctionality check
- Factory Option setting per destination
- Ship-out mode setting (In-Stop)
3-3. Etc.
- Ship-out mode
- Service Option De ault
- USB Download(S/W Update, Option)
4. MAC Address a d ESN Key Write
4-1. Equipme t & Co ditio
- Play ile: Serial.exe
- MAC Address edit
- Input Start / End MAC address
4-2. Dow load method
(1) Communication Prot connection
Connect: PCBA Jig-> RS-232C Port== PC-> RS-232C Port
(2) MAC Address Download
- Com 1,2,3,4 and 115200(Baudrate)
- Port connection button click(1)
- Load button click(2) or MAC Address write.
- Start MAC Address write button(3)
- Check the OK Or NG
(3) Input the ESN Key (Except For Mexico/Canada Models)
- download Model sending Key ile
- input by 1 by SET so as not to be duplicated

5. LAN PORT + ESN INSPECTION
5-1. Equipme t & Co ditio
- Each other connection to LAN Port o IP Hub and Jig
5-2. MAC Address & ESN Key co firmatio
- Push “IN-START” Key in service remote controller.
5-3. LAN PORT INSPECTION(PING TEST)
- LAN Port connection with PCB
- Network setting at MENU Mode o TV
- setting automatic IP
- Setting state con irmation
-> I automatic setting is inished, you con irm IP and MAC
Address.
- remove LAN CABLE
6. ADC adjustme t
6-1. Overview
ADC adjustment is needed to ind the optimum black level and
gain in Analog-to-Digital device and to compensate RGB
deviation.
6-2. Equipme t & Co ditio
(1) Jig (RS-232C protocol)
(2). Internal pattern is used. No external signal is needed.
6-3. Adjustme t
(1) Adj. protocol
(2) Check adjust device
Pattern Generator : (MSPG-925FA)
Adjust 480i Comp1
(MSPG-925FA:model :209 , pattern :65)
Adjust 1080p Comp1
(MSPG-925FA:model :225 , pattern :65)
Adjust RGB (MSPG-925FA:model :225 , pattern :65)
The PU02A have not ECHO.
7. EDID(The Exte ded Display
Ide tificatio Data) / DDC(Display
Data Cha el) dow load
7-1. Overview
It is a VESA regulation. A PC or a MNT will display an optimal
resolution through in ormation sharing without any necessity
o user input. It is a realization o °∞Plug and Play°±.
7-2. Equipme t
- Adj. R/C
- Since embedded EDID data is used, EDID download jig,
HDMI cable and D-sub cable are not need.
7-3. Dow load method
(1) Press Adj. key On the Adj. R/C, press Adj. key then select
EDID D/L. By pressing Enter key, EDID download will
begin.
(2) I Download is success ul, OK is displayed.
(3) I Download is a ailure, NG is displayed.
(4) Re-try download
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7-4. EDID DATA(PCM)
- Re erence: Download is only possible in POWER ON
MODE.
- HDMI
EDID Block 0, Bytes 0-127 [00H-7FH]
Block Type: EDID 1.3
EDID Block 1, Bytes 128-255 [80H-FFH]
Block Type: CEA EDID Timing Extension Version 3
RGB [C/S: 1C]
EDID Block 0, Bytes 0-127 [00H-7FH]
Block Type: EDID 1.3
7-5. EDID DATA(AC-3)
- Re erence: Download is only possible in POWER ON
MODE.
- HDMI
EDID Block 0, Bytes 0-127 [00H-7FH]
Block Type: EDID 1.3
EDID Block 1, Bytes 128-255 [80H-FFH]
Block Type: CEA EDID Timing Extension Version 3
RGB [C/S: 1C]
EDID Block 0, Bytes 0-127 [00H-7FH]
Block Type: EDID 1.3
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Vender ID C/S1 C/S2
HDMI1 10 9C D2
HDMI2 20 9C C2
HDMI3 30 9C B2
HDMI4 40 9C A2
Vender ID C/S1 C/S2
HDMI1 10 9C 60
HDMI2 20 9C 50
HDMI3 30 9C 40
HDMI4 40 9C 30

8. White Bala ce adj.
8-1. Overview
(1) W/B adj.: Objective & How-it-works
1) Objective: To reduce each Panel’s W/B deviation
2) How-it-works: When R/G/B gain in the OSD is at 192, it
means the panel is at its Full Dynamic
Range. In order to prevent saturation o
Full Dynamic range and data, one o
R/G/B is ixed at 192, and the other two is
lowered to ind the desired value.
8-2. Equipme t
(1) Color Analyzer : CA-210 (NCG: CH 9 / WCG: CH12 /PDP
Module:CH10)
(2) Adj. Computer
(During auto adj., RS-232C protocol is needed)
(3) Adj. R/C
(4) Video Signal Generator MSPG-925F 720p/216Gray
(Model:217, Pattern:78)
-> Only when internal pattern is not available
- Color Analyzer Matrix should be calibrated using CS-1000
8-3. Equipme t co ectio map
8-4. Adj. Comma d (Protocol)
OProtocol
<Command Format>
- LEN: Number o Data Byte to be send
- CMD: Command
- VAL: FOS Data
- CS: Checksum o sent Data
- A: Acknowledge
Ex) [Send: JA_00_DD] / [Ack: A_00_okDDX]
ORS-232C Command used during auto-adj.
Ex) wb 00 00 -> Begin white balance auto-adj.
wb 00 10 -> Gain adj.
ja 00 -> Adj. data
jb 00 c0
...
...
wb 00 1 -> Gain adj. complete
*(wb 00 20(Start), wb 00 2 (End)) -> O -set adj.
wb 00 -> End white balance auto-adj.
8-5. Auto Adj. method
(1) Set TV in adj. mode using POWER On Key
(2) Zero calibrate probe then place it on the center o the
Display
(3) Connect Cable(RS-232C)
(4) Select mode in adj. Program and begin adj.
(5) When adj. is complete (OK Sign), check adj. status per
mode
(Warm, Medium, Cool)
(6) Remove probe and RS-232C cable to complete adj.
- Adj. must begin w/ command “wb 00 00”, and end “wb 00
” and adj. o set i needed.
- O set adjust limit value.
O set Min = 34 (Decimal)
O set Max = 94 (Decimal)
8-6. Ma ual adj. method
Dynamic contrast : o
Dynamic color : o
OPC : O
Energy saving mode : O
(1) Set TV Picture Mode to Standard and in Advanced
Control, set Dynamic Contrast and Color ‘ O ’ .
(2) Set TV in adj. mode using POWER On Key
(3) Press ADJ key -> EZ adjust using adj. R/C
(4) Using CH + / - KEY, select 10.TEST PATTERN then press
Enter to place in HEAT RUN mode and wait or 30
minutes.
(4) Zero calibrate the probe o Color Analyzer, then place it on
the center o LCD module within 10 cm o the sur ace.
(5) Press ADJ key -> 7. White-Balance then press the cursor
to the right (KEY G)
(When Gis pressed Full White internal pattern will be
displayed)
(6) One o R Gain / G Gain / B Gain should be ixed at 192,
and the rest will be lowered to meet the desired value.
(7) Adj. is per ormed in COOL, MEDIUM, WARM 3 modes o
color temperature
(8) O set Adjust in MEDIUM, WARM 2 modes o color
temperature ( Only THX Model )
V I internal pattern is not available, use HDMI input. In EZ
Adj. menu 7.White Balance, you can select one o 3
options: None, Inner, HDMI. De ault is inner. By selecting
HDMI, you can adjust using HDMI signal.
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Model 100 Point WB mode WB Adj. Program
Non THX Model lists.
50PZ550-UA Only Adjust Medium Use Matrix
60PZ550-UA (Color Temperature) Adj. Program
50PZ540-UB mode RUN_Matrix_ADJ
60PZ540-UB ( Matrix Type )

VAdj. condition and cautionary items
(1) Lighting condition in surrounding area
Surrounding lighting should be lower than 10 lux. Try
to isolate adj. area into dark surrounding.
(2) Probe location
- PDP : Color Analyzer (CA-100, CA-100+, CA210)
probe should be irmly attached to the Module
- LCD : Color Analyzer (CA-210) probe should be within
10cm and perpendicular o the module sur ace
(80°~ 100°)
- In case o LCD, B/L on should be checked using no
signal or Full white Pattern
8-7. Refere ce (White Bala ce adj.
coordi ate a d color temperature)
O Standard color coordinate and temperature using CS-1000
O Luminance: Full white 216 Gray
O Standard color coordinate and temperature using CA-210(CH
10)
- Gain color coordinate
O Pattern : Full white 216 Gray
9. 3D Fu ctio Test
9-1. 3D Patter I spectio
(Pattern Generator MSHG-600 or MSPG-6100, HDMI mode
NO. 872 , pattern No. 83)
(1) Please input 3D test pattern like below
(2) When 3D entrance OSD is automatically displayed, Push
the OK key
(3) When took o 3D shutter glasses, Check whether viewing
the pattern like below picture)
9-2. 2D TO 3D CONVERT INSPECTION
(1) Input Combination Pattern like (Fig.1) in HDMI Input
(2) Enter the Swap Button(Yellow Color)
Check the separated line in the SET
* When you enter the swap button. Depth value is set to
Maximum value(20) automatically Worker has to enter the
ETC Key Be ore using the swap button
9-3. RF Glasses , 3D RF Emitter Check
* Power Only Mode
* MSHG-600 or MSPG-6100
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(Fig.1)

* Test Scenario
(1) Set TV in adj. mode using Power Only Key
(2) H MI 1.4 Frame Packing 3 images are input to the 3
Video Player
(3) Check the 3 Video isplay.
(4) If RF emitter signal is correctly received to RFreceiver, the
lamp of RF tester turn on
10. Option selection per country
10-1. Overview
O Option selection is only done for models in Non-USA North
America due to rating
O Applied model: PU13A Chassis applied USA Model(Not
Canada, Mexico)
10-2. Method
(1) Press A J key on the Adj. R/C, then select Country Group
Menu
(2) epending on destination, select KR or US, then on the
lower option, select US, CA, MX. Selection is done using
+, - KEY
10-3. Ship-out (Default) ode check
(Instop)
OAfter final inspection, press In-Stop key of the Adj. R/C and
check that the unit goes to Stand-by mode.
10-4. POWER Supply Unit PCB Ass'y Va/Vs
Voltage adjust ent.
(1) Test equipment : .M.M 1EA
(2) Connection iagram for Measuring : refer to (Fig.1)
(3) Vs adjustment (refer fig.1)
1) Connect + terminal of .M.M. to Vs pin of P811, connect
-terminal to GN pin of P811
2) After turning VR901, voltage of .M.M adjustment as
same as Vs voltage which on label of panel left/top (
deviation ; ± 0.5V)
(4) Va adjustment (refer fig.1)
1) After receiving 100% Full White Pattern, HEAT RUN.
2) Connect + terminal of .M.M. to Va pin of P811, connect
-terminal to GN pin of P811
- After turning VR502,voltage of .M.M adjustment as
same as Va voltage which on label of panel left/top
(deviation; ± 0.5V)
11. USB Download (S/W Update,
*.epk File Download)
(1) Put the USB Stick to the USB socket
(2) Automatically detecting update file in USB Stick
- If your downloaded program version in USB Stick is Low,
it didn’t work.
But your downloaded version is High, USB data is
automatically detecting
(3) Show the message “Copying files from memory”
(4) Updating is staring.
(5) Updating Completed, The TV will restart automatically.
(6) If your TV is turned on, check your updated version and
Tool option. (explain the Tool option, next stage)
* If downloading version is more high than your TV have,
TV can lost all channel data. In this case, you have to
channel recover. if all channel data is cleared, you didn’t
have a TV/ATV test on production line.
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(Fig.1)

* A ter downloading, have to adjust TOOL OPTION again.
(1) Push "IN-START" key in service remote controller.
(2) Select "Tool Option 1" and Push “OK” button.
(3) Punch in the number. (Each model has their number.)
(4) Completed selecting Tool option.
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BLOCK DIAGRAM

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EXPLODED VIEW
590
200
400
520
300 305 301
602
202
203
501
205
209
207 208
240
601
303
304
302
580
910
900
120
206
204
201
570 560
Many electrical and mec anical parts in t is c assis ave special safety-related c aracteristics. T ese
parts are identified by in t e Sc ematic Diagram and EXPLODED VIEW.
It is essential t at t ese special safety parts s ould be replaced wit t e same components as
recommended in t is manual to prevent X-RADIATION, S ock, Fire, or ot er Hazards.
Do not modify t e original design wit out permission of manufacturer.
IMPORTANT SAFETY NOTICE
A10
LV1
A12
A4
A2

Copyright © 2010 LG Electronics Inc. All rights reserved.
Only for training and service purposes
LGE Internal Use Only

Copyright © 2010 LG Electronics Inc. All rights reserved.
Only for training and service purposes
LGE Internal Use Only

Copyright © 2010 LG Electronics Inc. All rights reserved.
Only for training and service purposes
LGE Internal Use Only

Copyright © 2010 LG Electronics Inc. All rights reserved.
Only for training and service purposes
LGE Internal Use Only

Copyright © 2010 LG Electronics Inc. All rights reserved.
Only for training and service purposes
LGE Internal Use Only

Copyright © 2010 LG Electronics Inc. All rights reserved.
Only for training and service purposes
LGE Internal Use Only