Sony HKDV-900 User manual

HD DIGITAL VIDEO CONTROLLER
HKDV-900
MAINTENANCE MANUAL
1st Edition (Revised 2)
Serial No. 10001 and Higher

HKDV-900
!WARNING
This manual is intended for qualified service personnel only.
To reduce the risk of electric shock, fire or injury, do not perform any servicing other than that
contained in the operating instructions unless you are qualified to do so. Refer all servicing to
qualified service personnel.
!WARNUNG
Die Anleitung ist nur für qualifiziertes Fachpersonal bestimmt.
Alle Wartungsarbeiten dürfen nur von qualifiziertem Fachpersonal ausgeführt werden. Um die
Gefahr eines elektrischen Schlages, Feuergefahr und Verletzungen zu vermeiden, sind bei
Wartungsarbeiten strikt die Angaben in der Anleitung zu befolgen. Andere als die angegeben
Wartungsarbeiten dürfen nur von Personen ausgeführt werden, die eine spezielle Befähigung
dazu besitzen.
!AVERTISSEMENT
Ce manual est destiné uniquement aux personnes compétentes en charge de l’entretien. Afin
de réduire les risques de décharge électrique, d’incendie ou de blessure n’effectuer que les
réparations indiquées dans le mode d’emploi à moins d’être qualifié pour en effectuer d’autres.
Pour toute réparation faire appel à une personne compétente uniquement.
Attention-when the product is installed in Rack:
1. Prevention against overloading of branch circuit
When this product is installed in a rack and is
supplied power from an outlet on the rack, please
make sure that the rack does not overload the supply
circuit.
2. Providing protective earth
When this product is installed in a rack and is
supplied power from an outlet on the rack, please
confirm that the outlet is provided with a suitable
protective earth connection.
3. Internal air ambient temperature of the rack
When this product is installed in a rack, please make
sure that the internal air ambient temperature of the
rack is within the specified limit of this product.
4. Prevention against achieving hazardous
condition due to uneven mechanical loading
When this product is installed in a rack, please make
sure that the rack does not achieve hazardous
condition due to uneven mechanical loading.

1 (E)
HKDV-900
Table of Contents
Manual Structure
Purpose of this manual ........................................................................................ 3 (E)
Related manuals................................................................................................... 3 (E)
Contents ............................................................................................................... 4 (E)
1. Service Overview
1-1. Main Parts Layouts ............................................................................... 1-1 (E)
1-2. Removing/Reinstalling the Cabinets ..................................................... 1-2 (E)
1-2-1. Top Panel ............................................................................. 1-2 (E)
1-2-2. Front Panel ........................................................................... 1-2 (E)
1-3. Removing/Reinstalling the Boards ....................................................... 1-3 (E)
1-3-1. CP-365 Board ....................................................................... 1-3 (E)
1-3-2. CP-364 Board ....................................................................... 1-3 (E)
1-4. Replacing the Rotary Encoder .............................................................. 1-4 (E)
1-5. Replacing the Switching Regulator ....................................................... 1-5 (E)
1-6. Replacing the NV-RAMs ...................................................................... 1-5 (E)
2. Troubleshooting
2-1. Normal Diagnostic Function (Power ON Test) .................................... 2-1 (E)
2-2. Self Diagnostic Mode ............................................................................ 2-1 (E)
2-2-1. Required Tool ....................................................................... 2-2 (E)
2-2-2. Location of Knobs and Buttons on the Front Panel ............. 2-2 (E)
2-2-3. Starting and Quitting of the Self Diagnostic Mode .............. 2-3 (E)
2-2-4. Selecting and Executing of the Test Item ............................ 2-3 (E)
2-2-5. Test Procedure ...................................................................... 2-4 (E)
2-3. Troubleshooting .................................................................................... 2-8 (E)
2-3-1. Troubleshooting for the Power-on Sequence Error ............. 2-8 (E)
2-3-2. Troubleshooting for Test Selection Error .......................... 2-12 (E)
2-3-3. Troubleshooting for ROM Version Display Error .............2-13 (E)
2-3-4. Troubleshooting for ROM Test Error ................................ 2-13 (E)
2-3-5. Troubleshooting for RAM Test Error ................................ 2-13 (E)
2-3-6. Troubleshooting for NV-RAM Test Error ......................... 2-14 (E)
2-3-7. Troubleshooting for LED Test Error .................................. 2-14 (E)
2-3-8. Troubleshooting for 7SEG LED Test Error .......................2-18 (E)
2-3-9. Troubleshooting for Switch Test Error .............................. 2-18 (E)
2-3-10. Troubleshooting for Rotary Encoder Test Error ................ 2-20 (E)
2-3-11. Troubleshooting for RS-422A Test Error .......................... 2-22 (E)

2 (E) HKDV-900
3. Spare Parts
3-1. Notes on Repair Parts .................................................................................. 3-1
3-2. Exploded View ............................................................................................ 3-2
3-3. Electrical Parts List ..................................................................................... 3-4
3-4. Packing Materials & Supplied Accessories .............................................. 3-15
3-5. Power Cords .............................................................................................. 3-15
4. Semiconductor Pin Assignments
5. Block Diagram
Overall ......................................................................................................... 5-1
6. Schematic Diagrams
CP-364 ......................................................................................................... 6-2
CP-365 ......................................................................................................... 6-8
7. Board Layouts
CP-364 ......................................................................................................... 7-2
CP-365 ......................................................................................................... 7-4

3 (E)
HKDV-900
Purpose of this manual
This is the maintenance manual of the HD Digital Video Controller HKDV-900.
This manual is intended for use by service engineers, and describes how to maintain
the unit, and contains information on primary services (removing the boards, self-
diagnostics, troubleshooting, parts list, semiconductor pin assignments, block
diagram, schematic diagrams and board layouts).
Related manuals
Beside this Maintenance Manual, the following manuals are available for the unit:
..
..
.Operation Manual (Supplied with the unit)
This manual describes the precautions during operation of the unit and describes
each block.
Part number: 3-204-566-0X
..
..
.Installation Manual (Supplied with the unit)
This manual describes the operating environment, power supply, installation
space, matching cables, signal inputs/outputs, setting the switches on board and
rack mounting.
Part number: 3-204-595-0X
..
..
.“Semiconductor Pin Assignments” CD-ROM (Available on request)
This “Semiconductor Pin Assignments” CD-ROM allows you to search for
semiconductors used in B&P Company equipment.
Semiconductors that cannot be searched for on this CD-ROM are listed in the
maintenance manual for the corresponding unit. The maintenance manual contains
a complete list of all semiconductors and their ID Nos., and thus should be used
together with the CD-ROM.
Part number: 9-968-546-XX
Manual Structure

4 (E) HKDV-900
Contents
The following is a summary of all the sections of this manual.
Section 1 Service Overview
Contains the location of the main parts, and describes how to remove/reinstall the
cabinets and boards, replace the rotary encoder, switching regulator, and NV-RAM.
Section 2 Troubleshooting
Explains the self-diagnostics and troubleshooting.
Section 3 Spare Parts
Contains the exploded view and the spare parts list.
Section 4 Semiconductor Pin Assignments
Contains information on semiconductors used for the unit.
It includes a complete list of the semiconductors and their ID Nos. for retrieving
information on “Semiconductor Pin Assignments”CD-ROM, which is available
separately.
Please refer to this section together with the “Semiconductor Pin Assignments”CD-
ROM.
Information on the semiconductors not contained in the CD-ROM at the time of
issue of this manual, if any, is given in this section as well.
Section 5 Block Diagram
Contains the overall block diagram.
Section 6 Schematic Diagrams
Contains the schematic diagrams for mounted circuit boards.
Section 7 Board Layouts
Contains the board layouts for mounted circuit boards.

1-1 (E)
HKDV-900
Section 1
Service Overview
1-1. Main Parts Layouts
No. Board name Function
1CP-364 board CPU and Volume Board
2CP-365 board 7SEG LED and Switch Board
CP-364 board
CP-365 board
2
2
Switching regulator
Rotary encoder

1-2 (E) HKDV-900
1-2. Removing/Reinstalling the Cabinets
1-2-1. Top Panel
1. Remove the three screws, and then remove the top
panel in the direction of the arrow.
2. Re-attach the top panel in reverse order of step 1.
PSW3 x6
Top panel
1-2-2. Front Panel
1. Remove the top panel. (Refer to Section 1-2-1.)
2. Remove the eight knobs.
3. Remove the four screws (PSW4 x10) to remove the
right and left rack angles.
4. Remove the two screws (PSW3 x6), and then remove
the front panel in the direction of the arrow.
5. Re-attach the front panel in reverse order of steps 2
to 4.
PSW3 x6
PSW4 x10
PSW3 x6
PSW
4 x10
Rack angle
Knob
Front panel
Rack angle
1-2. Removing/Reinstalling the Cabinets

1-3 (E)
HKDV-900
1-3. Removing/Reinstalling the Boards
1-3-1. CP-365 Board
1. Remove the top panel. (Refer to Section 1-2-1.)
2. Remove the front panel. (Refer to Section 1-2-2.)
3. Insert a flat screwdriver into the groove of the connec-
tors (CN1 and CN2), push it to the front (Fig. 1) and
disconnect the harnesses from the connectors. (Fig. 2)
4. Remove the five screws to remove the CP-365 board.
n
Be careful not to drop the isolating plate because it is
not fixed.
5. Re-attach the CP-365 board in reverse order of steps 3
and 4.
6. After replacing the CP-365 board, execute the self
diagnostic tests. (Refer to Section 2-2, “Self Diagnos-
tic Mode”.)
Fig.1
Fig.2
PSW3 x6
CP-365 board
Isolating plate
Flat screwdriver
Groove
Connector
Connector
(CN1)
Connector
(CN2)
Harness
1-3-2. CP-364 Board
1. Remove the top panel. (Refer to Section 1-2-1.)
2. Remove the front panel. (Refer to Section 1-2-2.)
3. Remove the CP-365 board. (Refer to Section 1-3-1.)
4. Disconnect the harnesses from the connectors (CN402
to CN409) on the CP-364 board.
5. Remove the two screws which fixing the power
switch.
6. Remove the five screws, and then remove the holder
assembly in the direction of the arrow.
7. Remove the screw to remove the harnesses (green +
yellow).
8. Disconnect the two harnesses (white and brown) from
the AC inlet.
n
Slide the terminal cover in the direction of arrow A, and
then pull the terminal block out in the direction of arrow B.
PSW3 x6
CN402 to CN409
CP-364 board
PSW3 x6
PSW3 x6
PSW3 x6
Holder assembly
Power switch
PSW
4 x8
AC inlet
Harness
(white)
Harness
(green +
yellow)
Harness (brown) AC inlet
Terminal cover
Terminal block
B
A
1-3. Removing/Reinstalling the Boards

1-4 (E) HKDV-900
9. Remove the eight hexagon screws.
10. Remove the six screws (PSW3 x6) to remove the CP-
364 board.
n
The SW cap is not a component of the CP-364 board.
When replacing the CP-364 board, remove the SW cap
and reuse it.
11. Re-attach the CP-364 board in reverse order of steps 4
to 10.
12. After replacing the CP-364 board, check the NV-RAM
and execute the self diagnostic test. (Refer to Sections
1-6, “Replacing the NV-RAMs”, 2-2, “Self Diagnostic
Mode”.)
1-4. Replacing the Rotary Encoder
1. Remove the CP-365 board. (Refer to Section 1-3-1.)
2. Disconnect the harnesses from the connectors (CN402
to CN409) on the CP-364 board.
3. Remove the two screws which fixing the power
switch.
4. Remove the five screws, and then remove the holder
assembly in the direction of the arrow.
5. Remove the hexagon nut and washer to remove the
replacing rotary encoder from the holder assembly.
6. Attach a new rotary encoder in reverse order of steps 2
to 5.
7. After replacing the rotary encoder, execute the self
diagnostic test. (Refer to Section 2-2, “Self Diagnostic
Mode”.)
Power switch
PSW3 x6
PSW3 x6
CP-364 board
Hexagon
screws
SW cap
PSW3 x6
CN402 to CN409
CP-364 board
PSW3 x6
PSW3 x6
PSW3 x6
Holder assembly
Power switch
Rotary encoder
Hexagon nut
Washer
Holder assembly
1-3. Removing/Reinstalling the Boards
1-4. Replacing the Rotary Encoder