Sony RDR-VX521 User manual

SERVICE MANUAL
VIDEO CASSETTE RECORDER/
DVD RECORDER
SPECIFICATIONS
RMT-D224A
Refer to the SERVICE MANUAL of VHS MECHANI-
CAL ADJUSTMENT MANUAL VII for MECHANICAL
ADJUSTMENTS. (9-921-790-11)
— Continued on next page —
RDR-VX521/VX530
Photo: RDR-VX530
US Model
RDR-VX521/VX530
Canadian Model
Mexican Model
RDR-VX530
System
[DVD recorder section]
Laser
Semiconductor laser
Audio recording format
Dolby Digital
Video recording format
MPEG Video
[VCR section]
Format
VHS NTSC standard
Video recording system
Rotary head helical scanning FM system
Video heads
Double azimuth four heads
Video signal
NTSC color, EIA standards
Tape speed
SP: 33.35 mm/s (1
3
/8 inches/s)
EP: 11.12 mm/s (
7
/16 inches/s)
LP: 16.67 mm/s (
11
/16 inches/s),
playback only
Maximum recording/playback time
8 hrs. in EP mode (with T-160 tape)
Rewind time
Approx. 1 min (with T-120 tape)
[Tuner section]
Channel coverage
VHF 2 to 13
UHF 14 to 69
CATV A-8 to A-1, A to W, W+1 to W+84
Antenna
75-ohm antenna terminal for VHF/UHF
[Timer section]
Clock
Quartz locked
Timer indication
12-hour cycle
Timer setting
12 programs in total (max.)
Inputs and outputs
LINE 1 IN and LINE 2 IN
VIDEO IN, phono jack (1 each)
Inputsignal:1Vp-p,75ohms,unbalanced,
sync negative
AUDIO IN, phono jacks (2 each)
Input level: 327 mVrms
Input impedance: more than 47 kilohms
LINE 2 IN
S VIDEO, 4-pin, mini-DIN jack
Y: 1.0 Vp-p, unbalanced, sync negative
C: 0.286 Vp-p, load impedance 75 ohms
DV IN, 4-pin jack, i.LINK S100
LINE OUT
VIDEO OUT, phono jack (1)
Output signal: 1 Vp-p, 75 ohms,
unbalanced, sync negative
AUDIO OUT, phono jacks (2)
Standard output: 327 mVrms
Load impedance: 47 kilohms
Output impedance: less than 10 kilohms
DX-13A MECHANISM

— 2 —
DIGITAL AUDIO OUT
OPTICAL, Optical output jack
−18 dBm (wave length: 660 nm)
COAXIAL, phono jack
Output signal: 0.5 Vp-p, 75 ohms
COMPONENT VIDEO OUT (Y, PB, PR)
Phono jack
Y: 1.0 Vp-p/P
B , P R : 0.7 Vp-p, 75 ohms
S VIDEO OUT
4-pin, mini-DIN jack
Y: 1.0 Vp-p, unbalanced, sync negative
C: 0.286 Vp-p, load impedance 75 ohms
SET TOP BOX CONTROL
(US, Canadian)
Mini jack
General
Power requirements
120 V AC, 60 Hz
Power consumption
36 W
Power back-up
Back-up duration:
0 min (US, Canadian),
30 min (Mexican)
Operating temperature
5°C to 35°C (41°F to 95°F)
Storage temperature
−20°C to 60°C (−4°F to 140°F)
Operating humidity
25% to 80%
Dimensions including projecting parts
and controls (w/h/d)
Approx. 430 ×82 ×334 mm
(Approx. 17 ×3 1/
4 ×131/ 4 inches)
Mass
Approx. 4.8 kg (Approx. 10.6 lbs)
Supplied accessories
Remote commander (remote) (1)
Size AA (R6) batteries (2)
Antenna cable (1)
Audio/video cord (1)
Set top box controller (1) (US, Canadian)
Design and specifications are subject to change
without notice.

— 3 —
WARNING!!
WHEN SERVICING, DO NOT APPROACH THE LASER
EXIT WITH THE EYE TOO CLOSELY. IN CASE IT IS
NECESSARY TO CONFIRM LASER BEAM EMISSION,
BE SURE TO OBSERVE FROM A DISTANCE OF MORE
THAN 25 cm FROM THE SURFACE OF THE
OBJECTIVE LENS ON THE OPTICAL PICK-UP BLOCK.
CAUTION
Use of controls or adjustments or performance of procedures
other than those specified herein may result in hazardous
radiation exposure.
SAFETY-RELATED COMPONENT WARNING!!
COMPONENTS IDENTIFIED BY MARK 0OR DOTTED
LINE WITH MARK 0ON THE SCHEMATIC DIAGRAMS
AND IN THE PARTS LIST ARE CRITICAL TO SAFE
OPERATION. REPLACE THESE COMPONENTS WITH
SONY PARTS WHOSE PART NUMBERS APPEAR AS
SHOWN IN THIS MANUAL OR IN SUPPLEMENTS
PUBLISHED BY SONY.
CAUTION:
The use of optical instrument with this product will increase eye
hazard.
Fig. A. Using an AC voltmeter to check AC leakage.
1.5 k Ω 0.15 µFAC
voltmeter
(0.75 V)
To Exposed Metal
Parts on Set
Earth Ground
LEAKAGETEST
The AC leakage from any exposed metal part to earth ground
and from all exposed metal parts to any exposed metal part having
a return to chassis, must not exceed 0.5 mA (500 microamperes).
Leakage current can be measured by any one of three methods.
1. A commercial leakage tester, such as the Simpson 229 or RCA
WT-540A. Follow the manufacturers' instructions to use these
instruments.
2. A battery-operated AC milliammeter. The Data Precision 245
digital multimeter is suitable for this job.
3. Measuringthe voltagedropacrossaresistorbymeansofaVOM
or battery-operated AC voltmeter. The “limit” indication is
0.75V,soanalogmetersmusthaveanaccuratelow-voltagescale.
The Simpson 250 and Sanwa SH-63Trd are examples of a
passiveVOM that is suitable. Nearly all battery operated digital
multimeters that have a 2VAC range are suitable. (See Fig. A)
1. Check the area of your repair for unsoldered or poorly-soldered
connections. Check the entire board surface for solder splashes
and bridges.
2. Check the interboard wiring to ensure that no wires are
“pinched” or contact high-wattage resistors.
3. Lookforunauthorizedreplacementparts,particularlytransistors,
that were installed during a previous repair. Point them out to
the customer and recommend their replacement.
4. Look for parts which, though functioning, show obvious signs
ofdeterioration. Point them out to the customer and recommend
their replacement.
5. Check the line cord for cracks and abrasion. Recommend the
replacement of any such line cord to the customer.
6. Check the B+ voltage to see it is at the values specified.
7. Check the antenna terminals, metal trim, “metallized” knobs,
screws,andallotherexposed metal parts forACleakage. Check
leakage as described below.
SAFETY CHECK-OUT
After correcting the original service problem, perform the following
safety checks before releasing the set to the customer:
Unleaded solder
Boards requiring use of unleaded solder are printed with the lead-
free mark (LF) indicating the solder contains no lead.
(Caution: Some printed circuit boards may not come printed with
the lead free mark due to their particular size.)
: LEAD FREE MARK
Unleaded solder has the following characteristics.
•Unleaded solder melts at a temperature about 40°C higher than
ordinary solder.
Ordinary soldering irons can be used but the iron tip has to be
applied to the solder joint for a slightly longer time.
Soldering irons using a temperature regulator should be set to
about 350°C.
Caution: The printed pattern (copper foil) may peel away if the
heated tip is applied for too long, so be careful!
•Strong viscosity
Unleaded solder is more viscous (sticky, less prone to flow) than
ordinary solder so use caution not to let solder bridges occur such
as on IC pins, etc.
•Usable with ordinary solder
It is best to use only unleaded solder but unleaded solder may
also be added to ordinary solder.
ATTENTION AU COMPOSANT AYANT RAPPORT
À LA SÉCURITÉ!
LES COMPOSANTS IDENTIFIÉS PAR UNE MARQUE 0
SUR LES DIAGRAMMES SCHÉMATIQUES ET LA LISTE
DES PIÈCES SONT CRITIQUES POUR LA SÉCURITÉ
DE FONCTIONNEMENT. NE REMPLACER CES COM-
POSANTS QUE PAR DES PIÈCES SONY DONT LES
NUMÉROS SONT DONNÉS DANS CE MANUEL OU DANS
LES SUPPLÉMENTS PUBLIÉS PAR SONY.

— 4 —
TABLE OF CONTENTS
Precautions
1Safety Precautions ······························································ 5
2Servicing Precautions ························································ 7
3ESD Precautions································································· 8
4Handling the Optical Pick-up ·············································9
5Reset operation after IC203 was replaced ························ 10
1. General
Hookups and Settings ······················································1-2
Quick Guide to Disc Types··············································1-6
DVD Playback ·································································1-8
DVD Recording ·····························································1-11
DVD Editing··································································1-13
VCR Playback ·······························································1-17
VCR Recording ·····························································1-18
Dubbing (TAPA yDVD) ···········································1-21
DV/D8 Dubbing (DV/D8 tDVD) ······························1-22
Settings and Adjustments ··············································1-23
Additional Information··················································1-26
2. Disassembly and Reassembly
2-1 Cabinet and PCB ····························································2-1
2-1-1 Cabinet Top Removal ·····················································2-1
2-1-2 Botton Cover Removal ···················································2-1
2-1-3 Ass’y Front Panel Removal············································2-1
2-1-4 Function Timer PCB Removal ·······································2-1
2-1-5 Chassis Removal ····························································2-2
2-1-6 VCR Main PCB Removal ··············································2-2
2-2 Circuit Board Locations ·················································2-3
2-3 VCR Deck Parts Locations ············································2-4
2-3-1 Top View ········································································2-4
2-3-2 Bottom View···································································2-6
2-4 VCR DECK····································································2-7
2-4-1 Ass’y Holder Cassette Removal·····································2-7
2-4-2 Ass’y Lever Arm Removal ·············································2-7
2-4-3 Lever FL Door Removal ················································2-8
2-4-4 Slider FL Drive, Gear FL Cam Removal ·······················2-8
2-4-5 Gear Worm Wheel Removal···········································2-9
2-4-6 Cable Flat Removal ························································2-9
2-4-7 Ass’y Motor Loading Removal ····································2-10
2-4-8 Bracket Gear, Gear Joint 2, 1 Removal ························2-10
2-4-9 Gear Loading Drive, Slider Cam,
Ass’y Lever Load S, T Removal ··································2-11
2-4-10Gear Loading Drive, Slider Cam,
Ass’y Lever Load S, TAssembly·································2-11
2-4-11Lever Pinch Drive, Lever Tension Drive Removal·······2-12
2-4-12Ass’y Lever Tension, Ass’y Band Brake Removal ······2-12
2-4-13Ass’y Lever Brake S, T Removal·································2-13
2-4-14Ass’y Gear Idle Removal ·············································2-13
2-4-15Disk S, T Reel Removal ···············································2-14
2-4-16Ass’y Holder Clutch Removal ·····································2-14
2-4-17Ass’y Lever Up Down, Ass’y Gear Center Removal ···2-15
2-4-18Guide Cassette Door Removal ·····································2-15
2-4-19Ass’y Lever Unit Pinch, Plate Joint,
Spring Pinch Drive Removal········································2-16
2-4-20Ass’y Lever #9 Guide Removal ···································2-16
2-4-21FE Head Removal ························································2-17
2-4-22Ass’yACE Head Removal ···········································2-17
2-4-23Ass’y Slider S, T Removal ···········································2-18
2-4-24Plate Ground Deck,Ass’y Cylinder Removal··············2-18
2-4-25Hook Capstan, Belt Pulley Removal ····························2-19
2-4-26Ass’y Motor Capstan Removal ····································2-19
2-4-27Ass’y Post #8 Guide Removal ·····································2-20
2-4-28Ass’y Level Head Cleaner Removal ····························2-20
2-4-29How to Eject the Cassette Tape ····································2-20
2-5 The Table of Cleaning, Lubrication and
Replacement Time about Principal Parts ·····················2-21
3. Block Diagram ..........................................................3-1
4. PCB Diagrams
4-1 VCR Main PCB·······························································4-3
4-2 DVD Jack Main PCB ······················································4-7
4-3 DV Jack PCB·································································4-11
4-4 Front Jack PCB······························································4-11
4-5 Function Timer PCB······················································4-13
5. Schematic Diagrams
5-1 S.M.P.S (VCR Main PCB) ··············································5-3
5-2 Power (VCR Main PCB) ·················································5-5
5-3 Logic (VCR Main PCB)··················································5-7
5-4 A/V (VCR Main PCB) ····················································5-9
5-5 Hi-Fi (VCR Main PCB) ················································5-11
5-6 Function Timer (Function Timer PCB) ·························5-13
5-7 Encoder (DVD Jack Main PCB) ···································5-15
5-8 Decoder (DVD Jack Main PCB) ···································5-17
5-9 Video Decoder and Connector
(DVD Jack Main PCB)··················································5-19
5-10 DV Interface and 1394 Connector
(DVD Jack Main PCB)··················································5-21
5-11 Component/Super Out (Front Jack PCB) ······················5-23
6. Alignment and Adjustments
6-1 VCR Adjustment ·····························································6-1
6-1-1 Reference·········································································6-1
6-1-2 Head Switching Point Adjustment ··································6-3
6-2 VCR Mechanical Adjustment ··········································6-4
6-2-1 Tape Transport System and Adjustment Locations ·········6-4
6-2-2 Tape Transport System Adjustment ·································6-5
6-2-3 Reel Torque ···································································6-10
7. Troubleshooting ·················································7-1
8. Repair Parts List
8-1 Exploded Views ·······························································8-2
8-1-1 Cabinet Assembly ····························································8-2
8-1-2 VCR Deck Section (Top Side) ········································8-3
8-1-3 VCR Deck Section (Bottom Side)···································8-4
8-2 Electrical Parts List ·························································8-5

— 5 —
PRECAUTIONS
1 SAFETY PRECAUTIONS
1) Before returning an instrument to the customer, always make a
safety check of the entire instrument, including, but not limited
to, the following items:
(1) Be sure that no built-in protective devices are defective or have
been defeated during servicing.
(1)Protective shields are provided to protect both the technician
and the customer. Correctly replace all missing protective
shields, including any removed for servicing convenience.
(2)When reinstalling the chassis and/or other assembly in the
cabinet, be sure to put back in place all protective devices,
including, but not limited to, nonmetallic control knobs,
insulating fish papers, adjustment and compartment covers/
shields,andisolation resistor/capacitornetworks.Donotoperate
this instrument or permit it to be operated without all protective
devices correctly installed and functioning.
(2) Be sure that there are no cabinet openings through which adults
or children might be able to insert their fingers and contact a
hazardous voltage. Such openings include, but are not limited
to, excessively wide cabinet ventilation slots, and an improperly
fitted and/or incorrectly secured cabinet back cover.
(3) Leakage Current Hot Check-With the instrument completely
reassembled, plug the AC line cord directly into a 120V AC
outlet. (Do not use an isolation transformer during this test.)
Use a leakage current tester or a metering system that complies
with American National Standards institute (ANSI) C101.1
Leakage Current forAppliances and Underwriters Laboratories
(UL) 1270 (40.7). With the instrument’s AC switch first in the
ONpositionandthenintheOFFposition,measure from a known
earth ground (metal water pipe, conduit, etc.) to all exposed
metal parts of the instrument (antennas, handle brackets, metal
cabinets, screwheads, metallic overlays, control shafts, etc.),
especially any exposed metal parts that offer an electrical return
path to the chassis.
Any current measured must not exceed 0.5mA. Reverse the
instrument power cord plug in the outlet and repeat the test. See
Fig. 1.
Anymeasurementsnotwithinthelimitsspecifiedhereinindicate
apotentialshockhazardthatmustbeeliminatedbeforereturning
the instrument to the customer.
(4) Insulation Resistance Test Cold Check-(1) Unplug the power
supply cord and connect a jumper wire between the two prongs
of the plug. (2) Turn on the power switch of the instrument. (3)
Measurethe resistance with an ohmmeter between the jumpered
AC plugandallexposedmetalliccabinetpartsontheinstrument,
such as screwheads, antenna, control shafts, handle brackets,
etc. When an exposed metallic part has a return path to the
chassis,thereadingshouldbebetween1and5.2megohm.When
thereis no returnpathtothechassis,thereadingmustbeinfinite.
If the reading is not within the limits specified, there is the
possibilityofashockhazard,andtheinstrumentmustberepared
and rechecked before it is returned to the customer. See Fig. 2.
DEVICE
UNDER
TEST
(READING SHOULD
NOT BE ABOVE
0.5mA)
LEAKAGE
CURRENT
TESTER
EARTH
GROUND
TEST ALL
EXPOSED METER
SURFACES
ALSO TEST WITH
PLUG REVERSED
(USING AC ADAPTER
PLUG AS REQUIRED)
2-WIRE CORD
Fig. 1 AC Leakage Test
Fig. 2 Insulation Resistance Test
2) Read and comply with all caution and safety related notes on or
inside the cabinet, or on the chassis.
3) DesignAlterationWarning-Donotalteroraddtothemechanical
or electrical design of this instrument. Design alterations and
additions, including but not limited to, circuit modifications and
the addition of items such as auxiliary audio output connections,
mightalterthesafetycharacteristicsofthisinstrumentandcreate
a hazard to the user. Any design alterations or additions will
make you, the servicer, responsible for personal injury or
property damage resulting therefrom.
4) Observe original lead dress. Take extra care to assure correct
lead dress in the following areas:
(1) near sharp edges, (2) near thermally hot parts (be sure that
leads and components do not touch thermally hot parts), (3) the
AC supply, (4) high voltage, and (5) antenna wiring. Always
inspect in all areas for pinched, out-of-place, or frayed wiring,
Do not change spacing between a component and the printed-
circuit board. Check the AC power cord for damage.
5) Components,parts,and/or wiringthatappeartohave overheated
or that are otherwise damaged should be replaced with
components, parts and/ or wiring that meet original
specifications.
Additionally, determine the cause of overheating and/or damage
and, if necessary, take corrective action to remove any potential
safety hazard.
Antenna
Terminal
Exposed
Metal Part
ohm ohmmeter

— 6 —
6) Product Safety Notice-Some electrical and mechanical parts
have special safety-related characteristics which are often not
evident from visual inspection, nor can the protection they give
necessarilybeobtainedbyreplacingthemwithcomponents rated
for higher voltage, wattage, etc. Parts that have special safety
characteristics are identified by shading, an ( ) or a ( ) on
schematics and parts lists. Use of a substitute replacement that
does not have the same safety characteristics as the
recommended replacement part might create shock, fire and/or
other hazards. Product safety is under review continuously and
new instructions are issued whenever appropriate.

— 7 —
2 SERVICING PRECAUTIONS
CAUTION: Before servicing units covered by this service manual
and its supplements, read and follow the Safety Precautions section
of this manual.
Note: If unforseen circumstances create conflict between the
following servicing precautions and any of the safety precautions,
always follow the safety precautions. Remember: Safety First.
2-1 General Servicing Precautions
(1) a. Always unplug the instrument’sAC power cord from theAC
power source before (1) re-moving or reinstalling any
component, circuit board, module or any other instrument
assembly, (2) disconnecting any instrument electrical plug or
other electrical connection, (3) connecting a test substitute in
parallel with an electrolytic capacitor in the instrument.
b. Do not defeat any plug/socket B+ voltage interlocks with
which instruments covered by this service manual might be
equipped.
c. Do not apply AC power to this instrument and/or any of its
electrical assemblies unless all solid-state device heat sinks
are correctly installed.
d. Always connect a test instrument’s ground lead to the
instrument chassis ground before connecting the test
instrument positive lead. Always remove the test instrument
ground lead last.
Note: Refer to the Safety Precautions section ground lead last.
(2) The service precautions are indicated or printed on the cabinet,
chassis or components. When servicing, follow the printed or
indicated service precautions and service materials.
(3) The components used in the unit have a specified flame
resistance and dielectric strength.
When replacing components, use components which have the
same ratings. Components identified by shading, by ( ) or by
() in the circuit diagram are important for safety or for the
characteristics of the unit. Always replace them with the exact
replacement components.
(4) An insulation tube or tape is sometimes used and some
components are raised above the printed wiring board for safety.
The internal wiring is sometimes clamped to prevent contact
with heating components. Install such elements as they were.
(5) After servicing, always check that the removed screws,
components, and wiring have been installed correctly and that
the portion around the serviced part has not been damaged and
so on. Further, check the insulation between the blades of the
attachment plug and accessible conductive parts.
2-2 Insulation Checking Procedure
Disconnect the attachment plug from the AC outlet and turn the
power ON. Connect the insulation resistance meter (500V) to the
blades of the attachment plug. The insulation resistance between
each blade of the attachment plug and accessible conductive parts
(see note) should be more than 1 Megohm.
Note: Accessible conductive parts include metal panels, input
terminals, earphone jacks, etc.

— 8 —
3 ESD PRECAUTIONS
Electrostatically Sensitive Devices (ESD)
Some semiconductor (solid state) devices can be damaged easily
by static electricity.
Such components commonly are called Electrostatically Sensitive
Devices (ESD). Examples of typical ESD devices are integrated
circuits and some field-effect transistors and semiconductor chip
components.Thefollowingtechniquesshouldbeusedtohelpreduce
the incidence of component damage caused by static electricity.
(1) Immediately before handling any semiconductor component or
semiconductor-equipped assembly, drain off any electrostatic
charge on your body by touching a known earth ground.
Alternatively, obtain and wear a commercially 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 ESD
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
ESD devices.
(4) Use only an anti-static solder removal devices. Some solder
removal devices not classified as “anti-static” can generate
electrical charges sufficient to damage ESD devices.
(5) Do not use freon-propelled chemicals. These can generate
electrical charges sufficient to damage ESD devices.
(6) Do not remove a replacement ESD device from its protective
package until immediately before your are ready to install it.
(Most replacement ESD devices are packaged with leads
electrically shorted together by conductive foam, aluminum foil
or comparable conductive materials).
(7) Immediately before removing the protective materials from the
leadsof a replacementESDdevice,touchtheprotectivematerial
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 ESD devices. (Otherwise harmless motion such as
the brushing together of your clothes fabric or the lifting of
your foot from a carpeted floor can generate static electricity
sufficient to damage an ESD device).

— 9 —
4 HANDLING THE OPTICAL PICK-UP
The laser diode in the optical pick up may suffer electrostatic
breakdown because of potential static electricity from clothing and
your body.
The following method is recommended.
(1) Place a conductive sheet on the work bench (The black sheet
used for wrapping repair parts.)
(2) Place the set on the conductive sheet so that the chassis is
grounded to the sheet.
(3) Place your hands on the conductive sheet (This gives them the
same ground as the sheet.)
(4) Remove the optical pick up block
(5) Perform work on top of the conductive sheet. Be careful not to
let your clothes or any other static sources to touch the unit.
◆Be sure to put on a wrist strap grounded to the sheet.
◆Be sure to lay a conductive sheet made of copper etc. Which is
grounded to the table.
Fig.3
(6) Short the short terminal on the PCB, which is inside the Pick-
UpASS’Y, before replacing the Pick-Up. (The short terminal is
shorted when the Pick-Up Ass’y is being lifted or moved.)
(7) After replacing the Pick-up, open the short terminal on the PCB.
THE UNIT
WRIST-STRAP
FOR GROUNDING
1M
1M CONDUCTIVE SHEET

— 10 —
5 Reset operation after IC203 was replaced
Be sure to perform the reset by the method described below, if the
IC203 (FLASH MEMORY) used on the DVD Jack Main board
was replaced.
Resetting method
1. Enter theAdjustment mode, and press two times the “1” button
on the remote commander.
(For an entering method of Adjustment mode, see 6-1. VCR
Adjustment.)
The tray will automatically open and the version information
will be displayed on the TV screen.
2. Turn the power off.