Sony TVP-08 Installation guide

S®
Training Manual
Circuit Description and Troubleshooting
Course:TVP-08
Projection
Television

Course Description
and Troubleshooting:
RA-4Chassis
Prepared by: National Training Department
Sony Service Company
A Division of Sony Electronics Inc.
Course presented by______________________________________
Date___________________________________________________
Student Name ___________________________________________

Sony Service Company
ADivisionofSonyElectronicsInc©1998
AllRights Reserved
PrintedinU.S.A.
Sony and Trinitron are registered trademarks of Sony.

Features 1
Overview 1
Picture 1
Audio 1
Self-Diagnostics 3
Board Descriptions 5
Power Supply Block 7
AC Input 7
Power ON 7
Converter 7
Regulation 7
Protection 7
AC Input and Switching B+ 9
Overview 9
AC Input 9
B+ Rectifier 9
Standby Power Supply 11
Overview 11
Standby Switching supply 11
Vcc Switch (Power On) 13
Overview 13
Power ON 13
DC Protect 13
AC Protect 13
Soft Start 15
Overview 15
Soft Start - Power ON 15
Converter 17
Overview 17
Operation 17
T602 Secondary (Audio B+) 19
Overview 19
Operation 19
T601 Secondary-1 21
Overview 21
+/- 15 Volts 21
+ 11 Volts 21
+/- 22 Volts 21
Distribution 21
T601 Secondary-2 23
+7 Volts 23
+135 Volts 23
-135 Volts 23
+33 Volts 23
Table of Contents

Distribution 23
Regulation 25
Overview 25
Operation 25
DC Protection 27
Overview 27
Shut Down 27
+135 Volt Over Voltage 27
+135 Volt Over Current Protection 27
+19, +22, +7 Volt LVP 27
PS Troubleshooting 29
Overview 29
Troubleshooting 29
Protection Block 31
Overview 31
Diagnostic Indication 31
Circuit Description 33
Reset 35
Overview 35
Initial Reset 35
Power ON Reset 35
System Block Diagram 37
Overview 37
B (Standby) Bus 37
M (Main) Bus 37
P (Auto Registration) Bus 37
MID Bus 37
Video Path Block 39
Inputs 39
Main Video 39
Sub-Video 39
IC511 Video Processor 39
Input Switching 41
Overview 41
Inputs 41
Outputs 41
Main Y and C Buffers 43
Overview 43
Y Buffer 43
Sync Separator 43
C Buffer 43
3D Comb Filter 45
Overview 45
What is a 3D Comb Filter? 45
Circuit Description 45
Main Chroma Decoder 49
Overview 49
C Processing 49

Y Processing 49
H and V Sync 49
3.58 MHz 49
Main YUV Switch 51
Overview 51
Inputs 51
Output Selection 51
DRC - Digital Reality Creation 53
DRC Block 57
Overview 57
Inputs 57
DRC Processing 57
Outputs 57
Troubleshooting 57
MID - Multi Image Driver 59
MID Block 63
Overview 63
MID Inputs 63
MID Processing 63
MID Outputs 63
MID Troubleshooting 63
Video Processor 65
Overview 65
Video Processing 65
Sync Processing 65
IK/AKB 69
Overview 69
Video Drive 69
IK 69
Troubleshooting 69
Sync Paths 71
Overview 71
Sync Paths 71
Deflection Block 73
Overview 73
Vertical 73
Horizontal 73
High Voltage 73
Convergence 73
Horizontal Deflection Block 75
Horizontal Jungle 77
Overview 77
H Drive 77
H Out 79
Overview 79
H Drive 79
H Out 79
Horizontal Centering 79

Pin Amp 81
Overview 81
Pin Amp 81
H Protect/HP 83
Overview 83
HP 83
H Protect 83
Vertical Deflection Block 85
H BLK Delay and 1/2 H + Odd/Even 87
Overview 87
H BLK Delay 87
1/2 H and Odd/Even 87
VDSP 89
Overview 89
VCO 89
CDP 89
DSP 89
DAC 89
V Out 91
Overview 91
V Out 91
V Protect 91
High Voltage Block 93
HV Drive 95
Overview 95
HV Drive 95
Peak Drive 95
HV Regulation Control 99
Overview 99
Regulation Control 99
+12 High Voltage LVP 99
HV Regulation PWM 101
Overview 101
Sawtooth Generator 101
PWM 101
HV Stop 2 103
Overview 103
ABL 103
Hold Down 103
HV Stop 1 105
Overview 105
ABL 105
High Voltage Block Tap 105
+125 Volt OVP 105
Convergence Block 107
Overview 107
Convergence 107
Auto Focus (Auto Registration) 107

Sensor Amp 109
Overview 109
Auto Focus 109
Circuit Description 113
BD Input 115
Overview 115
Digital Convergence 115
BD Output 117
Overview 117
IC1707 Regi Correction 117
Convergence Out 119
Overview 119
Regi Mute 119
Convergence Amp 119
Service Mode 121
Overview 121
Normal Service Mode 121
PJED Mode 121
Protection Block 127
Overview 127
Diagnostic Indication 127
Circuit Description 129

1
Features
Overview
The models covered by this manual are the new KP53XBR200 and the
KP61XBR200. These two models are electrically identical. The differ-
ences have to do with screen size. Therefore they use different cabinets,
screens, mirrors and tubes. These sets also have a Self Diagnostic sys-
tem.
Picture
The two models share the following picture features:
··
··
·Advanced Pro-Optic System – Sony technology that allows full cor-
ner to corner focusing.
··
··
·New Extended Definition CRT – Allows corner to corner focusing to
be increased by 25% over last year’s model.
··
··
·MICROFOCUS Lens System
··
··
·Digital Reality Creation (DRC) – DRC uses line doubling and pat-
tern recognition algorithms to take the NTSC signal to a near HDTV
equivalent. This will be discussed in more detail later.
··
··
·Double Scan Technology
··
··
·Auto Focus Full Digital Convergence – Allows the setting of V and
H center and skew by the customer. This convergence system can
produce a sharper picture and is less susceptible to drift due to aging
or shipment.
··
··
·High Performance Video Processor
··
··
·3D Digital Comb Filter
··
··
·Brightview Dual Component Screen – The screen contains a Thin
Film Fresnel that brightens and sharpens the picture, and a Fine Pitch
Lenticularscreenthatachieves higherresolution byusing blackstripes
to increase contrast.
··
··
·Built-in High Contrast Screen
··
··
·First Surface Mirror – Unlike most mirrors, the reflective surface is
on the front of the mirror glass. This improves brightness and con-
trast, and eliminates ghosting caused by the reflected light passing
through the glass.
··
··
·Advanced Velocity Modulation
··
··
·Advanced High Voltage Regulation – Eliminates distortion and fo-
cus fluctuations that occur when changes in brightness levels cause
changes in the high voltage.
··
··
·Noise Reduction
··
··
·Shading Compensation – Eliminates color shift and hot spots that
can occur due to the angle of the picture tubes to the mirror.
··
··
·Wideband Video Amplifier
··
··
·Multi Image Driver – Digital-editing technology that provides versatil-
ity in controlling on-screen images. Used in Picture and Picture and
Channel Index modes.
··
··
·Twin View Picture-in-Picture – Allows for viewing two pictures si-
multaneously and the ability to expand either image up to double its
normal size.
··
··
·Free Layout Picture-in-Picture –Allowsthe PIPwindow tobe placed
anywhere on the screen.
··
··
·XDS (Extended Data Service) – Receives data information services
that some stations may broadcast. This data includes time, station
call letters, etc.
Audio
The two models share the following audio features:
··
··
·MTS Stereo with dbx NR
··
··
·Dolby Pro Logic Surround Sound
··
··
·Front Left/Right Audio Power - 20Wx2
··
··
·Center Audio Power – 20W
··
··
·Surround Audio Power – 15Wx2
··
··
·Center speaker input for use with a separate Dolby Pro Logic A/
V Reciever

2
NOTES

3
Self-Diagnostics
Overview
The RA-4 chassis employs a Self-Diagnostic system that uses the Timer
LED and an on screen menu to help indicate where the problem with the
set has occurred. You will generally have to use the flashing LEDs since
thesetwill be shutdown. AC power mustbe disconnected inorder to turn
the set off once shutdown has occurred.
When a failure occurs, all of the circuits covered by the Self-Diagnostics,
except AKB, send a signal to the OSD CPU. The OSD CPU sends data
to the Main CPU that indicates how many times the Timer LED will flash.
The AKB circuit located in the Video Processor IC sends data over the
I2C bus directly to the Main CPU. In addition, each circuit, except AKB
and High Voltage, send a signal to the latch circuit to shut the set down
when failure occurs.
•EXAMPLE
<Diagnosis Items>
• +B overcurrent
• +B overvoltage
• Vertical deflection stop
< FRONT PANEL >
TIMER/STANDBY indicator
The number of times the LED blinks may correspond to that shown in the
following table:
Diagnosis item Standby/ Self-diagnosis
sleep lamp, screen display,
Number of blinks Diagnosis item:Results
• Power not ON Not lit
+B OCP detection LED blinks 2 times 2 : +B OCP XX
+B OVP detection LED blinks 3 times 3 : +B OVP XX
V detection LED blinks 4 times 4 : V STOP XX
AKB detection LED blinks 5 times 5 : AKB XX
H detection LED blinks 6 times 6 : H STOP XX
HV abnormality detection LED blinks 7 times 7 : HV XX
Audio abnormality detection LED blinks 8 times 8 : AUDIO XX
*
: XX the range of values for number of operations is 00-99. For 99 or higher there is no count up
and the number remains at 99.
<Number of Blinks>
2 times
3 times
4 times
Lamp OFF :
3.0 seconds
Lamp ON : 0.3 seconds
Lamp OFF : 0.3 seconds
If the problem is intermittent and you can get the set to operate, you can
display a menu showing the number of times failures have occurred. This
is done by pressing the following sequence of buttons on the remote.
Display Channel 5 Vol - Enter
The display will look as follows.
SELF CHECK
2 : +B OCP XX
2 : +B OCP XX
3 : +B OVP XX
4 : V STOP XX
5 : AKB XX
6 : H STOP XX
7 : HV XX
8 : AUDIO XX
9 : WDT XX
XX the range of values for number of
operations is 00-99.
For 99 or higher there is no count up
and the numberremainsat 99.
Diagnosis
Results

4

5
Board Descriptions
Overview
The models covered by this manual are the new KP53XBR200 and the KP61XBR200. These two models are electrically identical. The differences
have to do with screen size. The table below shows which circuits are present on each of the boards. This will help if you are doing board level (SAYS)
or component level repair.
Name Circuits contained
A Tuners, A/V switching, RGB processing, H Jungle, VDSP, Syscon
BD Auto registration (Digital Convergence)
BM MID (Multi Image Driver)
BR DRC (Digital Reality Creation)
CR,CB,CG CRT drive and IK feedback.
D H and V deflection, Sub-deflection, HV, HV Regulation
G Power supply
HA Front panel controls, Power and Timer LEDs
HB Front video inputs, Auto Focus and Setup buttons
HC Remote sensor
K Audio Processing and Audio Outputs
U S Link Input/Output
ZR,ZG,ZB Hor. and Vert. deflection and sub-deflection coils, VM

6
HC
HA
HB
CG
ZB
CB
GDBD BRBMAU
K
CR
ZR
ZG

7
Power Supply Block
AC Input
When the unit is first plugged in, AC power passes through two line filters
and is applied to the Standby Power Supply. This is a switching power
supplythat producestheVcc sourcevoltage andthestandby +5V(RM+5V)
for System Control. When the set is turned ON, the AC input is applied
through RY6001 Power Relay to the switching B+ rectifier, which supplies
power to the Converter circuit. The switching B+ rectifier is monitored at
eachofits outputs. Thenegative side ofthe switchingB+ rectifier ismoni-
tored to ensure that RY6002 is activated. RY6002 is closed to bypass the
In-RushCurrent LimiterResistorwhen theset isturnedON. When RY6002
is closed, it shunts In-Rush Current Limiter Resistor so that the negative
side of the bridge is connected to ground. If the relay is not closed, a
voltage will be developed to shut down the set. The positive side of the
switching B+ rectifier is monitored to hold the secondary voltages down if
the AC voltage should be too low. This is performed by monitoring the
switchingB+ voltageandapplying thatvoltage tothe softstart circuit. This
is done because of the excessive current draw when the switching B+ is
low.
Power ON
When Power ON is selected using the remote or the front panel switch, a
signal is sent from IC1008 Main-CPU to the Vcc switch section on the G
board. The Vcc circuit sends voltage from the Standby supply to the Os-
cillator and Soft Start circuits. When this voltage reaches IC6003 Oscilla-
tor, it begins oscillating. The Soft Start circuit is activated at the same
time. This circuit keeps the oscillator at a certain frequency (175KHz) for
a specified period of time. This keeps the initial start up voltage low and
prevents excessive back EMF from destroying the converter transistors.
Whenregulation begins,the normaloperating frequencyisaround73KHz.
Converter
When the Oscillator circuit begins oscillating, it outputs two signals that
are 180 degrees out of phase. These signals are applied to the converter
circuit. The converter circuit contains two Driver ICs that drive two push
pull transistor circuits. These circuits drive two transformers that create
the AC voltages, which are rectified by the two secondary supply circuits
to power the rest of the set.
Regulation
Once the secondary supplies begin to generate DC voltages we can be-
gin to regulate their output. This is done using the +11 volt and +135 volt
lines. The +11 volt line is used to power the regulation circuit while the
+135 volt line is monitored to regulate the supplies. The +135 volt line is
sent to the regulation circuit to produce an error voltage that is fed back to
the oscillator circuit. This voltage controls the pulse width and frequency
of the oscillator. Changes in the frequency cause changes in efficiency of
thetransformers, whichinturn causethevoltage tobecome lowerorhigher.
Protection
In addition to the three protection circuits on the AC side of the supply,
thereareadditional circuitson the DCside. The +135Vline is checkedfor
OVP and OCP. If one of these conditions occurs, a voltage is sent to the
protect latch to turn it ON. The latch shuts down the set by turning OFF
the Vcc switch. A voltage is also sent to the System Control circuit for the
self-diagnostic system. In addition, the 11V line is compared to the +19,
+22 and +7 volt lines. If these voltages fall below a specified level, the
protect latch will be activated and the set will shut down. There is no
indication in the self-diagnostic menu that this circuit has been activated.

8

9
AC Input and Switching B+
Overview
The AC Input and Switching B+ circuit is used to filter the AC line voltage
and generate the DC voltage necessaary to run the switching supply.
AC Input
AC enters the G board at CN6004 when the unit is plugged in. It then
passes through F6001 and L6001 and L6002 Line Filters. L6002/3 is
the High side of the AC line and splits off to two places. It is used to
power the Standby +5V supply and is connected to one of the contacts
of RY6001 Power Relay.
There are a few protection components in place in addition to F6001
Fuse. There are two spark gaps across the AC line at CN6004 AC Input.
There is also one across the AC line after F6001 Fuse. Two capacitors,
C6001and C6002,are presenton eitherside ofL6001 LineFilter. VD6001
is a VDR across the L6002/1 and 3 for spike protection.
Troubleshooting
Problems in this area are usually the result of line spikes or lightning. If
you have a dead set and suspect lightning damage, you should remove
the G board by removing one screw and pulling it out. A quick visual
check can be performed by looking on both sides of the board for burnt
traces or components. If F6001 is open, be sure to check for any burnt
components. If everything looks OK, then check the voltage across
VD6001. If the line voltage is not present there, continue to work your
way back checking across the AC line until you find an open component.
B+ Rectifier
When power is turned ON, the AC line voltage is applied across D602
Bridge Rectifier because RY6001 Power Relay is closed. D602/3 + out-
puts 130 volts which is filtered by C6008, C6010 and L6003. This volt-
age is used as the B+ for the switching power supply converter circuit
and is fused by F6002. D602/4 is connected to ground through R6010
In-Rush Current Limiter at initial power ON. When the secondary sup-
plies begin to run, RY6002 will be closed which connects D602/4 - to Hot
ground.
Switching B+ Low Voltage Protect
Both outputs of the D602 Bridge Rectifier are monitored to cause shut-
down of the set. D602/3 + has a sample voltage sent to the Soft Start
circuit to monitor for under voltage. If the voltage at this point is too low,
theSoft Startcircuit willraise thefrequencyoftheswitching supply,thereby
lowering the secondary output voltages and disabling regulation. The
lowering of the secondary voltages will also cause RY6002 to open or
may shut the set down. Due to the fact that the power supply voltages
will be lowered, the set will indicate an AKB shutdown by flashing the
Timer LED five times, pausing, and then repeating. This action will be
discussed in greater detail in the Soft Start section.
In-Rush Current Limiter Protect
D602/4 is monitored to ensure that the R6010 In-Rush Current Limiter
has been switched out of the circuit by RY6002. If it has not, a voltage
will be developed across it that is rectified and sent to the base of Q6004
AC Protect. If Q6004 AC Protect is turned on, IC6003 Oscillator will be
shut down. This will cause no output from the switching supply. Keep in
mind that there will be 150 volts present at F6002 since the power relay
is still turned ON. In addition, the Timer LED will flash twice, pause and
repeat. You will not be able to shut the set OFF using the remote or the
front panel switch. The set will have to be unplugged to attempt to re-
start the set.

10

11
Standby Power Supply
Overview
The Standby Power Supply is used to develop the voltages that are re-
quired by the set in order for it to turn ON. One of these voltages is used
to supply power to the System Control ICs. This voltage is a regulated 5
volts and is called RM+5. The other voltage is used as the source volt-
age for Vcc, which is the low voltage supply for the switching power
supply. The AC input to the standby supply is monitored for overvoltage.
It will shut the Vcc switch OFF if there is a problem.
Standby Switching Supply
The line AC from L6002/3 is rectified by D6001 and D6003 and filtered
by C6009. This voltage is monitored for overvoltage via D6035 and is
used to power the standby supply. This voltage then passes through
fusible resistor R6012, then to T603 SRT. IC6001 is connected to T6003/
1 and begins switching when the voltage arrives. IC6001 PWMSW is a
self-starting N-channel MOSFET switching device with a self contained
oscillator and error loop amplifier used for regulation.
RM+5
As IC6001 PWMSW voltages are induced in the secondary windings of
T6003 SRT, one of these voltages is used to develop the RM+5 line. The
signal from T6003/7 is rectified by D6120 and filtered by C6137, C6138
and L6113. This voltage is input to IC6104/1. IC6104 5-Volt Regulator
outputs 5 volts from pin 2. This is the RM+5 line on the G board. It is
called ST-5V on the A board.
Regulation
The secondary winding at pins 3 and 4 of T6003 SRT develops a voltage
that is rectified by D6015. This voltage is used for two purposes. It is the
source voltage for the Vcc switch and the feedback voltage for regula-
tion. This voltage passes through D6012, D6011 and R6021, and is
input to IC6001/4. Pin 4 is the regulation input for IC6001 PWMSW.

12