Sanyo LCD-DP42410 User manual

FILE NO
SERVICE MANUAL
LCD TV
LCD-DP42410
PRODUCT CODE No.: 113026104
CHASSIS NO. :
P42410-00
SSB42TTZA1I (SET)
P42410-01
SSB42TTZA2I (SKD)
P42410-02 SSB42TTZA3I (SKD-old bezel)
REFERENCE No.:SM0945007-00

CONTENTS
1. Safety precautions .................................................................................................3
2. Alignment instructions and method of software upgrading.....................................5
3. Working principle analysis of the unit ................................................................... 15
4. Block diagram ......................................................................................................16
5. IC block diagram..................................................................................................18
6. Wiring diagram ...................................................................................................20
7. Troubleshooting guide..........................................................................................22
8. Schematic diagram ..............................................................................................27
APPENDIX-A: Assembly list
APPENDIX-B: Exploded View
Removing or Installing the Stand

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Attention: This service manual is only for service personnel to take reference with. Before servicing
please read the following points carefully.
Safety precautions
1. Instructions
Be sure to switch off the power supply before replacing or welding any components or
inserting/plugging in connection wire Anti static measures to be taken (throughout the entire production
process!):
a) Do not touch here and there by hand at will;
b) Be sure to use anti static electric iron;
c) It’s a must for the welder to wear anti static gloves.
Please refer to the detailed list before replacing components that have special safety requirements.
Do not change the specs and type at will.
2. Points for attention in servicing of LCD
2.1 Screens are different from one model to another and therefore not interchangeable. Be sure to
Use the screen of the original model for replacement.
2.2 The operation voltage of LCD screen is high voltage . Be sure to take proper measures in
protecting yourself and the machine when testing the system in the course of normal operation or
right after the power is switched off. Please do not touch the circuit or the metal part of the module
That is in operation mode. Relevant operation is possible only one minute after the power is switched
off.
2.3 Do not use any adapter that is not identical with the TV set. Otherwise it will cause fire or damage
to the set.
2.4 Never operate the set or do any installation work in bad environment such as wet bathroom,
laundry, kitchen, or nearby fire source, heating equipment and devices or exposure to sunlight etc.
Otherwise bad effect will result.
2.5 If any foreign substance such as water, liquid, metal slices or other matters happens to fall into the
module, be sure to cut the power off immediately and do not move anything on the module lest it should
cause fire or electric shock due to contact with the high voltage or short circuit.
2.6 Should there be smoke, abnormal smell or sound from the module, please shut the power off at
once. Likewise, if the screen is not working after the power is on or in the course of operation, the
power must be cut off immediately and no more operation is allowed under the same condition.
2.7 Do not pull out or plug in the connection wire when the module is in operation or just after the
power is off because in this case relatively high voltage still remains in the capacitor of the driving
circuit. Please wait at least one minute before the pulling out or plugging in the connection wire.
2.8 When operating or installing LCD please don’t subject the LCD components to bending, twisting or
extrusion, collision lest mishap should result.
2.9 As most of the circuitry in LCD TV set is composed of CMOS integrated circuits, it’s necessary to
pay attention to anti statics. Before servicing LCD TV make sure to take anti static measure and
ensure full grounding for all the parts that have to be grounded.
2.10 There are lots of connection wires between parts behind the LCD screen. When servicing or
moving the set please take care not to touch or scratch them. Once they are damaged the screen
would be unable to work and no way to get it repaired.
If the connection wires, connections or components fixed by the thermo tropic glue need to disengage
when service, please soak the thermo tropic glue into the alcohol and then pull them out in case of
damage.

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2.11 Special care must be taken in transporting or handling it. Exquisite shock vibration may lead to
breakage of screen glass or damage to driving circuit. Therefore it must be packed in a strong case
before the transportation or handling.
2.12 For the storage make sure to put it in a place where the environment can be controlled so as to
prevent the temperature and humidity from exceeding the limits as specified in the manual. For
prolonged storage, it is necessary to house it in an anti-moisture bag and put them altogether in one
place. The ambient conditions are tabulated as follows:
Temperature
Scope for operation
5 ~+ 35
o
C
Scope for storage
0 ~ + 40
o
C
Humidity Scope for operation 0% ~ 90 %
Scope for storage 0% ~ 90%
2.13 Display of a fixed picture for a long time may result in appearance of picture residue on the
screen, as commonly called “ghost shadow”. The extent of the residual picture varies with the maker
of LCD screen. This phenomenon doesn’t represent failure. This “ghost shadow” may remain
in the picture for a period of time (several minutes). But when operating it please avoid displaying still
picture in high brightness for a long time.
3. Points for attention during installation
3.1 The front panel of LCD screen is of glass. When installing it please make sure to put it in place.
3.2 For service or installation it’s necessary to use specified screw lest it should damage the screen.
3.3 Be sure to take anti dust measures. Any foreign substance that happens to fall down between the
screen and the glass will affect the receiving and viewing effect
3.4 When dismantling or mounting the protective partition plate that is used for anti vibration and
insulation please take care to keep it in intactness so as to avoid hidden trouble.
3.5 Be sure to protect the cabinet from damage or scratch during service, dismantling or mounting.

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2. Alignment instructions
2.1. Test equipment
VG-848 (Video, YPbPr and VGA signal generator)
VG-849 (Video, YPbPr, VGA and HDMI signal generator)
FLUKE 54200(TV signal generator)
CA210
(white balancer)
2.2. Power test
Connect main board, power board and IR board according the wiring diagram, connect
the power and press power key(Remote controller or Keypad) button to turn on the TV.
a) Test the pin voltage of P802/power board , the data is shown in table1:
Table1
voltage data of P802
For42”
P802 Pin1,2
Pin3,4 Pin5,6,7
Pin8,9 Pin10,11,12
Pin13 Pin14
Pin15 Pin16
Voltage
GND 22.8-25.2V
GND 11.4-12.6V
4.75-5.25V On:2V-5.5V
Off: 0-0.5V <0.6V
2.5-5V
PWM
2-5V
b) Test the pin voltage of P803/power board, the data is shown in table2:
Table2 voltage data of P803
For42”
P803 Pin1,2,3,4,5 Pin6,7,8,9,10
Pin11 Pin12 Pin13 Pin14
Voltage
22.8-25.2V GND NC 2V-5V 2.5-5V PWM NC

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2.3. Alignment flow-chart
The alignment flow-chart is shown as fig-1
Check if DDC, HDCP KEY, FLASH are written
Combined test for general assembly
White balance adjustment
Connect to the center signal source and check each
Function of TV (station leaking, analog control, etc.)
Check the output of earphone and speaker.
Input AV/SVIDEO signal and check the function
Input HD signal and check the function of YPbPr
Input VGA signal and check if the display is normal, check
the function (analog control), horizontal/vertical center, etc.
Input HDMI signal and check if the display is normal, check
the function (analog control), horizontal/vertical center, etc.
Preset ex-factory
Check the accessories and packing
Fig-1 adjustment flow-chart

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2.4. Adjustment instruction
At any input source then press the remote controller buttons “<”, “EXIT” and “>” to enter factory mode.
During Factory menu, if “MENU” or “EXIT” key is pushed, system will exit factory mode.
2.4-1. Source Calibration
4-1.1. Set the TV input source to YPbPr; ASTRO-859 signal setting to PG2 program number 933(1080i).
(PG2 mode Timing 933 and Pattern 924 100% Color Bar.)
4-1.2. Entering into factory Mode: Press up or down key of remote control to select “Auto Calibration”, Press
「OK」key to start.
-> Source calibration performed automatically when finished that will show OK.

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4-1.3. Change input source to PC.
Change Astro-859 Timing to No.953 (640x480@60Hz) and pattern on 953(8step V-grayscale).
Repeat step 4-1.2 to do source calibration,
2.4-2. Color Temperature Adjustment & Check
4-2.1. Set input source.
Set the signal generator Astro-859 timing to PG2-924 on Video & YPbPr, PG2-860 on HDMI, and PG2-963
on PC. Pattern sets 956 on all of the source.
Then press Astro-859 “FORMAT” key and key, then adjust RGB value to R:204, G:204, B:204

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4-2.2. In factory mode OSD menu, select “Color Temperature” item, press “OK” key to enter the item.
R, G, B drive values are set for Warm, Medium, and Cool independently.
4-2.3. Set Color Temperature for “Warm”, “Medium” and “Cool” with following spec table.
Color temperature(for 42")
Color Temp. Cool Medium Warm
x 0.267
0.281
0.301
y 0.271
0.288
0.310
Tolerance ± 0.01
± 0.01
± 0.01
If the x and y value are larger than specification,
Decrease Red drive from default value.
Increase Blue drive from default value.
If the x or y or both x and y value is/are smaller than specification.
Decrease Blue drive from default value
According to a x and y value, please following adjustment of 1 or 2.
1 If x value is higher than spec
Decrease Red drive from default value.
2 If y value is higher than spec,
Increase Blue drive from default value
4-2.4 Exit Factory Mode:
After finishing adjusting color temperature, press [MENU] or [EXIT] to exit factory mode.

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2.5. Items of Factory menu
Vendor may customize design and add adjustment items Factory menu as far as all required items are
included.
Press up and down key can move high light item from Color Temperature Warn -> Color Temperature
Medium -> Color Temperature Cool ->Preset Channel-> Source Calibration -> Reset to Default.
The NVRAM Clear and Reset to Default items will have a check dialog “YES” and “NO” to do or not.
Push “Enter” key can select high light item function. (Press left and right can adjust value)
Display model name, firmware version and released date on top.

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5-1) Color Temperature for Warm
Press up or down key can select high light item function.
Press enter key to enter the item.
Following data for color temp shall be edited manually.
-R, G, B data for each preset.
-Press “Up” or “Down” key to select “R”, “G”, “B” item
-Press “Left” or “Right” key to set the “R”, “G”, “B” value.
-Press “MENU” or “EXIT” item to exit to factory mode
5-2) Color Temperature for Medium
Press up or down key can select high light item function.
Press enter key to enter the item.
Following data for color temp shall be edited manually.
-R, G, B data for each preset.
-Press “Up” or “Down” key to select “R”, “G”, “B” item
-Press “Left” or “Right” key to set the “R”, “G”, “B” value.
-Press “MENU” or “EXIT” item to exit to factory mode
5-3) Color Temperature for Cool
Press up or down key can select high light item function.
Press enter key to enter the item.
Following data for color temp shall be edited manually.
-R, G, B data for each preset.
-Press “Up” or “Down” key to select “R”, “G”, “B” item
-Press “Left” or “Right” key to set the “R”, “G”, “B” value.
-Press “MENU” or “EXIT” item to exit to factory mode
5-4) Time Clear
Press up or down key can select high light item function.
Press “Left” & “Right” key to select the item.
The timer on bottom is to record power on time for panel life.
It was set one time on production only.
5-5) Preset Channel
This is for factory to do some tests.
5-6) NVRAM Clear
Initialize program’s default values to NVRAM for following adjustment items accuracy.
In factory mode it is the first and important step to make sure all values are default value and correct.
- Reset settings: Channel table, Mode table (H/V Position, Clock, Phase), Source dependent setting
(Contrast, Brightness etc.), Common setting (Volume, Language etc.), Parental Control (Rating,
Password etc), Closed Caption.
To avoid a mistake initial process after factory setting is done. This item will have a check dialog to do the
initial or not.
NOTICE:
After this item is processed, the DUT needs to be powered off then AC powered off.
5-7) Full Power
This is for power consumption testing.
To measure the maximum power consumption of TV set, we adjust the value of following items to maximum.

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- Video: Contrast maximum value, Brightness maximum value, Backlight maximum value.
- Audio: Volume maximum value.
Press right key to turn on Full Power and OSD stay display until press enter key to recover from Full Power.
5-8) Source Calibration
Auto Calibration (gain/offset) must be adjusted color by firmware automatic adjustment in PC, and
Video3(Component) input source.
This item will have a result dialog “OK” or “NG”.
5-9) Reset to Default
This function is same as “NVRAM Clear”, but it will power off automatically after processing this function.
5-10) RF Burn In
Use “snow” pattern for burn in. Selected items are “On” and “Off”.
While turn on burn in mode, firmware will automatically turn off “Auto power off” function.
If there is no power supply suddenly, firmware will re-enter burn in mode automatically
when power supply is back.
Pressed the “Power” key, firmware will automatically turn off burn in mode.
- Burn in mode: Source is “TV”, Input Configuration is “Antenna” and channel is NTSC channel 2.
5-11) USB F/W Upgrade
The function is using USB device to upgrade firmware via USB port.
Copy the firmware file to USB device root path.
Execute this function to update firmware, the following OSD will display.
Note: After finishing updated, the system will reboot automatically
5-12) Protocol Switch
This is for debugging only. It is no use for service.
5-13) EDID Write
This is for writing EDID on the VGA source.

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5-14) MEMC Demo Mode
To separate screen into two parts that left side is 60Hz and right side is 120Hz for display.
5-15) MEMC Level
Changing MEMC level to Weak, Medium or Strong.
2.6. Performance check
6-1 TV function
Connect RF to the center signal source, enter Channel menu → Channel Scan, check if there are channels be
skipped, check if the picture and speaker are normal.
6-2 AV/S-Video terminals
Input AV/S-Video signal, check if the picture and sound are normal.
6-3 YPbPr/YCbCr terminal
Input YPbPr signal (VG-859 signal generator), separately input the YUV signals listed in table4 and check if
the display and sound are normal at any situation (power on, channel switch and format convert, etc.)
Table4 YPbPr signal format
Signal mode Horizontal
frequency
Dot clock
frequency
No
Signal
name Resolution Vertical frequency(Hz)
(KHz) (MHz)
Remarks
1
480i 720x480 59.94 15.73 27
2
480P 720x480 59.94 31.47 27
3
720P/60
1280x720 60 45 74.25
4
1080i/60
1920x1080 60 33.75 74.25
6-4 PC( VGA) terminal
Input PC(V GA) signal (VG-859 signal generator), separately input the signals listed in table5 and check the
display and sound. If the image is deflection of the Horizontal and Vertical, select Menu->PC->Auto Adjust to
perform auto-correct.
Table5 PC signal format
Signal mode Horizontal
frequency
Dot clock
frequency
No
Signal
name Resolution
Vertical
frequency(Hz)
(KHz) (MHz)
Remarks
1
VGA 640 x 480
59.941 31.469 25.175
2
SVGA 800 x 600
60.317 37.879 40
3
XGA 1024 x 768
60.004 48.363 65
4
1280 x 768
59.87 47.776 79.5
5
W-XGA
1360 x 768
60.015 47.712 85.5
6
SXGA 1280 x 1024
60.02 63.981 108

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6-5 HDMI terminal
Input HDMI signal (VG-859 signal generator), separately input the signals listed in table6 and check the display
and sound (32KHz, 44.1KHz, 48KHz) at any situation (power on, channel switch and format convert, etc.)
Table6 HDMI signal format
Signal mode Horizontal
frequency
Dot clock
frequency
No
Signal
name Resolution Vertical frequency(Hz)
(KHz) (MHz)
Remarks
1
VGA 640 x 480 59.94 31.469 25.175
2
SVGA 800 x 600 60.317 37.879 40
3
XGA 1024 x 768 60.004 48.363 65
4
1280 x 768 59.87 47.776 79.5
5
W-XGA
1360 x 768 60.015 47.712 85.5
6
SXGA 1280 x 1024
60.02 63.981 108
7
480i 720x480 59.94 15.734 27
8
480P 720x480 59.94 31.5 27.03
9
720P/60
1280x720 60 45 74.25
10
1080i/60
1920x1080 60 33.75 74.25
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1080p/60
1920x1080 60 67.5 148.5
12
1080p/24
1920x1080 24 27 74.25
6-6 other functions check
a) Check the turn on/turn off timer, sleep timer, picture/sound mode, OSD, stereo and analog TV Close Caption, V-
Chip, etc.

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3. Working principle analysis of the unit
1. NTSC/ATSC signal flow:
Antenna reception NTSC/ATSC signal will be send to tuner U32, t h e n T u n e r w i ll b e
demodulating and output differential IF+ IF- signal .
These differential IF+ IF- signal will send to the master control IC U1 to video/MPEGII decode, de-
interlace and scaler, then output LVDS level drive for panel display.
The differential signals will be fed into U1 to demodulate audio signals , after demodulating, pre-
amplifying, bass adjusting and volume control, the sound signal will b e t ra ns f or m i nt o d ig it a l
I 2 S s ig n a l b y scaler I C and sent to digital amplifier U5 amplifying, then output to speaker .
2. AV/S-VIDEO signal flow
S-VIDEO & Video path AV signal switch by menu “Inpput list” via terminal socket, the signal and
the Video2 path AV signal will be fed to U1 to perform video decode, de-interlace and scaler, then
output LVDS drive level for panel display.
Audio signal from AV terminal via matched resistance is fed to U1 to bass adjust and volume control,
the sound signal will be transfered into digital I2S signal by scaler IC and sent to digital amplifier U5
amplifying, output to speaker .
3. PC/YPrPb signal flow
PC and the Video2 path YPbPr signal are via terminal sent to U1 A/D conversion, output R/G/B of
24 bit to back end module to digital decode, image scale, then send to LVDS level drive for panel
display.
Sound signal of PC/YPrPb t e r m i na l via matched resistance a n d sent to U1 to bass adjust and
volume control, the sound signal will be transform into digital I2S signal by scaler IC and sent to digital
amplifier U5 amplifying, then output to speaker .
4. HDMI signal flow
HDMI video signal via terminal sent to U1 to digital decode, image scale, then output LVDS drive
level for panel display. HDMI audio signal via decoder built-in terminal sent to U1 is fed to back end
to bass adjust and volume control, the sound signal will be transform into digital I2S signal by
scaler IC and sent to digital amplifier U5 amplifying, then output to speaker .
5. MEDIA signal flow
The JPEG file via USB terminal send to U1 to MPEG decode , image scale , then output LVDS
drive level for panel display .

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4. Block diagram-SANYO 42” ATSC model System Diagram
DTV system IC
RENESAS
DTV-C7
R8J66977BG
Flash
MXIC
MX2 L320 DM2I
DDRII 12M
Samsung
K4T 1163QG-HCF7
Tuner
Samsung
DTVA 0CVH1019B
HDMI 2
PC
Panel out
Main Board
HDMI 1
Keypad
Audio
AMP
ST
STA335W
IF +/-
LVDS out
R_out
L-out
Composite
42" MEMC
Digital audio out
(Coaxial)
PrPb
Y
Audio I2S output
ANT / CABLE
USB
Component
Side
HDMI
IR / LED Board
Light Sensor
PC audio audio Line Out
DRV602PW
S_Video

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Block diagram-POWER-42”

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5.IC block diagram
5-1. Renesas R8J66975-RFJZ , R8J66977BG-RFJZ
Model - SubModel Surround Maximum panel size Number of HDMI ports
R8J66975BG-RFJZ Simple surround WSXGA+
(1680 x 1050)
3
R8J66977BG-RFJZ Simple surround FullHD
(1920 x 1080)
3
Features
Main CPU
32bit RISC Super-H architecture SH3 CPU core
Demodulator
ATSC A/53 compliant 8VSB receiver /w QAM.
IF AGC control interface x1ch
System decoder (Stream demultiplexer)
Video and audio ES stream filtering x1
Section filtering: max. 32 PIDs
MPEG video decoder
Single ISO-13818-2 MP@ML or MP@HL support
Supports decoding of all ATSC-compliant formats
JPEG decoder
Decode Base-line JPEG file
2D Graphics
CEA-608/CEA-708-B closed caption support
Display processor, Video input/output
Full 10bit processing
MPEG Noise Filter (De-blocking/De-ringing)
Over Drive (Panel resolution : up to WXGA)
Inputs : CVBS x3, Y/C x2, YPbPr x2, RGB x1, HDMI x3
Outputs : 10-bit dual LVDS
Audio decoder, Audio input/output
ATSC A/52 Clear QAM compliant audio decoding support
Sound Demodulator
 Inputs : SIF x1, Stereo x6
 Outputs : PCM (I2S) x2, S/PDIF x1, Stereo x1
Peripheral interfaces
UART x1, Legacy serial interface x2, USB High Speed x1
General purpose I/Os
Memory interfaces
Serial Flash
16b width DDR2 800Mbps(5-5-5) SDRAM x 1
Power, clock and package
1.26(±0.06)V, 1.82(±0.08)V, 3.3(±0.15)V
25MHz X’tal
376pin PBGA

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5-2. Block diagram

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42” Block