Sony DVW-522 User manual

DVW-522/522P
DIGITAL VIDEOCASSETTE PLAYER
CONTROL PANEL EXTENSION KIT
BKDW-510
CONTROL PANEL CASE
BKDW-511
MAINTENANCE MANUAL Part 1
1st Edition (Revised 1)
Serial No. 10001 and Higher (DVW-522)
Serial No. 10001 and Higher (DVW-522P)

!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.

1
Table of Contents
Manual Structure
Purpose of this manual ............................................................................................... 5
Contents...................................................................................................................... 5
Relative manual.......................................................................................................... 6
1. Installation
1-1. Operating Conditions................................................................................... 1-1
1-2. Power Supply ...............................................................................................1-1
1-2-1. Voltage and Power Requirements ..............................................1-1
1-2-2. Power Cord .................................................................................1-1
1-3. Installation Space .........................................................................................1-2
1-4. Supplied Accessories and Packing Materials List.......................................1-3
1-5. Rack Mounting.............................................................................................1-4
1-6. Matching Connectors ................................................................................... 1-6
1-7. Signal Outputs..............................................................................................1-7
1-8. Switch/Shorting Land Settings on the Boards............................................. 1-9
1-9. Search Dial Mode Switching .....................................................................1-14
1-10. Installation of BKDW-510/511 .................................................................1-16
1-11. Setup Menu ................................................................................................1-19
1-11-1. Setup Menu Items .....................................................................1-22
1-11-2. Details of the Setup Menu ........................................................1-23
1-11-3. Setting Check Sheet ..................................................................1-28
2. Service Overview
2-1. Notes on Power Supply Block.....................................................................2-1
2-1-1. Warning on Primary Circuit and Electric Shock........................ 2-1
2-1-2. Notes on Resetting the Circuit Breaker ...................................... 2-1
2-2. Removal/Installation of Cabinet..................................................................2-1
2-2-1. Cabinet Removal/Installation .....................................................2-1
2-2-2. Removal/Installation of Plate MD ..............................................2-3
2-2-3. Connector Panel Removal/Installation ....................................... 2-4
2-2-4. Power Supply Panel Removal/Installation .................................2-4
2-3. Cassette Compartment Removal/Installation ..............................................2-5
2-4. Locations of Main Part ................................................................................2-7
2-4-1. Printed Circuit Board Locations ................................................. 2-7
2-4-2. Main Mechanical Part Locations ..............................................2-11
2-4-3. Function and Location of Sensors ............................................2-12
2-5. LED Indicator Infomation on Boards........................................................2-14
2-6. How to Pull out/Push in the Lower Control Panel ....................................2-16

2
2-7. Removal/Installation of Lower Control Panel Assembly .........................2-17
2-8. How to Take out the Cassette when the Tape is Slacking ........................ 2-18
2-9. Cleaning when the Heads are Clogged......................................................2-19
2-9-1. Cleaning by Cleaning Tape ...................................................... 2-19
2-9-2. Cleaning by Cleaning Cloth .....................................................2-19
2-10. Fixture and Measuring Equipment for Adjustment...................................2-21
2-10-1. Fixture .......................................................................................2-21
2-10-2. Measuring Equipment...............................................................2-21
2-11. ISR..............................................................................................................2-22
3. Error Messages
3-1. Error Message ..............................................................................................3-1
4. Periodic Maintenance and Inspection
4-1. Periodic Check .............................................................................................4-1
4-1-1. Hours Meter ................................................................................4-1
4-1-2. Periodic Check List.....................................................................4-2
4-2. Cleaning .......................................................................................................4-6
4-2-1. General Information for Cleaning ..............................................4-6
4-2-2. Rotary Heads Cleaning ...............................................................4-7
4-2-3. Upper Drum's Tape Running Surface Cleaning .........................4-8
4-2-4. Lower Drum's Tape Running Surface
and Lead Surface Cleaning .........................................................4-9
4-2-5. Stationary Heads Cleaning .......................................................4-10
4-2-6. Tape Running System and Tape Cleaner Cleaning..................4-11
4-2-7. Fan Motor Cleaning ..................................................................4-12
4-2-8. Cassette Compartment Cleaning ..............................................4-13
5. Maintenance Mode
5-1. Outline..........................................................................................................5-1
5-1-1. Operation to the Maintenance Mode ..........................................5-4
5-1-2. Menu Tree ...................................................................................5-6
5-2. Servo/DT System Check Mode (C0: SERVO/DT CHECK) ......................5-8
5-2-1. Servo System Check 1 (C00: INPUT CHECK) .......................5-10
5-2-2. Servo System Check 2 (C01: MOTOR CHECK) ....................5-16
5-2-3. Servo System Check 3
(C02: PLUNGER SOLENOID CHECK).................................5-23
5-2-4. Servo System Check 4
(C03: REEL/CAPSTAN MOTOR & FG CHECK) .................5-27
5-2-5. Digital DT System Check (C05: DIGITAL DT CHECK) .......5-29

3
5-3. RF System Check Mode (C1: RF CHECK) ..............................................5-32
5-4. Others Check Mode (C4: OTHERS CHECK) ..........................................5-34
6. Replacement of Plug-in Boards
6-1. General Information for Boards Replacement ............................................6-1
6-1-1. Index for Board Replacement .....................................................6-1
6-1-2. Plug-in Board Pulling Out/ Inserting..........................................6-2
6-2. Adjustment after VPR-1 Board Replacement .............................................6-4
6-2-1. Video Output Level Adjustment.................................................6-4
6-2-2. 27 MHz FREQ Adjustment ........................................................6-5
6-2-3. PB Clock Phase Setting ..............................................................6-5
6-3. Adjustment after APR-1 Board Replacement .............................................6-6
6-3-1. CUE Monitor Output Level Adjustment ....................................6-6
6-4. Adjustment after EQ-45 Board Replacement..............................................6-7
6-4-1. ADV Envelope Level Adjustment.............................................. 6-7
6-4-2. PLL Adjustment..........................................................................6-8
6-5. Adjustment after CUE-1 Board Replacement .............................................6-9
6-5-1. CUE PB Frequency Response Adjustment ................................6-9
6-5-2. CUE PB Level Adjustment.......................................................6-10
6-6. Adjustment after SS-52 Board Replacement.............................................6-11
6-6-1. Drum Servo System Adjustment ..............................................6-11
6-6-2. Digital DT System Adjustment ................................................6-12
7. Block Diagrams
7-1. Circuit Function of Printed Circuit Board ...................................................7-1
7-2. Overall..........................................................................................................7-2

5
Manual Structure
Purpose of this manual This manual is the maintenance manual of digital videocassette player DVW-522/
522P.
This manual describes the maintenance information of this unit, and replacement
procedure of plug-in boards.
Contents The following is a summary of all the sections for understanding the contents of this
manual.
Section 1 Installation
Describes installation conditions, connector information for peripheral hardware
connections, how to operate switches, setup menus for system setup and installation of
BKDW-510/511, etc.
Section 2 Service Overview
Explains the removal and installation of cabinet, the locations of main part, and the
fixture and measuring equipment for replacement of plug-in boards.
Section 3 Error Messages
Explains the error messages.
Section 4 Periodic Maintenance and Inspection
Explains the cleaning procedure and periodic check.
As for the replacement procedure of the periodic maintenance parts refer to the
“Maintenance Manual Part 2”.
Section 5 Maintenance Mode
Explains the maintenance mode (CHECK mode).
As for the ADJUST mode refer to the “Maintenance Manual Part 2”.
Section 6 Replacement of Plug-in Boards
Explains how to replace the plug-in boards, and how to adjust them after replacement.
As for the replacement of boareds except plug-in boards and power block refer to the
“Maintenance Manual Part 2”.
Section 7 Block Diagrams
Describes the circuit function of printed circuit board and the overall block diagrams.
As for the block diagrams for every circuit block refer to the “Maintenance Manual
Part 2”.
n
Some figures in this manual are drawn as DVW-510. Please understand in advance.

6
Relative manual Besides this “Maintenance Manual Part 1”, the following manuals are available for
this unit.
• Operation Manual (Supplied with this unit.)
This manual is necessary for application and operation of this unit.
• Maintenance Manual Part 2 (Not supplied with this unit.)
This manual describes the information items (adjustments, board layouts, schematic
diagrams, datailed parts list, etc.) that premise the service based on parts.
If this manual is required, please contact to Sony’s service organization.

1-1
1-1. Operating Conditions
Operating temperature : +5 °C to +40 °C
(Good air circulation is essential to prevent internal heat build-up. Place the
unit in location with sufficient air circulation. Do not block the ventilation
holes on the cabinet and the rear panel.)
Humidity : 25 % to 80 %
Storage temperature : –20 °C to +60 °C
Locations to avoid : • Areas where the unit will be exposed to direct sunlight of any other strong lights.
• Dusty areas or areas where it is subject to vibration.
• Areas with strong electric or magnetic fields.
• Areas near heat sources.
• Areas where is subjected to electricity noise.
• Areas where is subjected to static electricity noise.
Horizontal condition : Do not slant the front and rear of the unit more than 30°.
nFix the unit securely if it is operated at a slant.
1-2. Power Supply
1-2-1. Voltage and Power Requirements
This unit's power line has a switching regulator and is designed for 90 V through 265 V.
• Power voltage 90 — 265 V AC
• Power frequency 48 — 64 Hz
• Power consumption 150 VA (240 V), 105 W (100 V)
1-2-2. Power Cord
• Length approx. 2.4 m
• Plug
Section 1
Installation
12.7
11.9
12.511
Unit : mm
23.5
4.75
For DVW-522P (EK)
74.5
26.5
19.5
14
Safety earth
Neutral
For DVW-522 (UC)
Live
Unit : mm
Safety earth
(green/yellow) Neutral
GND
Live
1.5
6.3
Neutral
(blue)
Live (brown) 17
21

1-2
Mass 31 kg
Dimensions when Rack-mounted
15.9
416 (rail-installed width)
427 (unit width)
1-3. Installation Space
Notes on installation place
• The rear side must be at least 40 cm away from the walls for ventilation and maintenance.
• Two cooling fans are fitted. If either the intake or exhaust becomes clogged of the fans stop, damage
may result to the power unit etc.
The heat sinks provided on each board are rated on the assumption that cooling will be provided by the
fans. Consequently, the unit should not be operated too long without fan cooling (such as when the
connector panel is opened for checks etc.).
• When the unit is operated on a desk or similar condition, assure that the clearance above the unit is at
least 40 cm to provide accessivility to the printed circuit boards and other mechanical parts. Note that it
is not necessary to provide the space when the unit is mounted in a rack since the printed circuit boards
can be repaired after it is pulled out.
unit : mm
1-3. Installation Space
520
(454)
512.8
(47.1)
45.5
577 (maximum traveling distance)
415.9
218
18.3
457.5
454
263.5
123.8
12.7
47.1
1.2 (70.6)
105
158
104
481
465
36.7
148.2
220
19
427
364 31.5

1-3
1-4. Supplied Accessories and Packing Materials List
Supplied Accessories
Q’ty Part No. SP Description
1pc !1-551-812-11 s CORD, POWER (for DVW-522)
1pc !1-782-929-11 s CORD, POWER SUPPLY (BS 3P) (for DVW-522P)
1pc OPERATION MANUAL (E)
1pc OPERATION MANUAL (G) (for DVW-522P)
1pc OPERATION MANUAL (F) (for DVW-522P)
1pc MAINTENANCE MANUAL PART1
4pcs 7-682-965-01 s SCREW +PSW 4 x16
Packing Materials
Q’ty Part No. SP Description
1pc 2-990-242-01 s HOLDER (B), PLUG (for DVW-522)
1pc 3-613-640-01 o HOLDER (C), PLUG (for DVW-522P)
1pc 3-181-533-01 o CUSHION (LOWER)
1pc 3-181-534-02 o CUSHION (UPPER)
1pc 3-181-535-01 o SPACER (A)
1pc 3-181-536-01 o SPACER (B)
1pc 3-687-335-01 o INDIVIDUAL CARTON (for DVW-522)
1pc 3-687-336-01 o INDIVIDUAL CARTON (for DVW-522P)
1pc 3-701-616-01 o BAG, POLYETHYLENE
1pc 3-701-619-01 o BAG, POLYETHYLENE, STANDARD
1pc 3-701-634-00 o BAG, POLYETHYLENE
n
Safety Related Components Warning
Components marked !are critical to safe operation.
Therefore, specified parts should be used in the case of replacement.
1-4. Supplied Accessories and Packing Materials List

1-4
1-5. Rack Mounting
The unit can be mounted in a 19-inch standard rack.
It is recommended to use the following kit.
Rack Mount Kit: RMM-110 (optional accessory)
or
RACK-MOUNT SLIDES: MODEL 305
slide length 558.8 mm (22 inch)
(ACCURIDE)
Notes for rack mounting
• When several VTRs are mounted in a rack, keep the
spaces between the each VTRs in the rack 1U or more. It
is recommended to install a fan for ventilation. Good air
circulation is essential to prevent internal heat build-up in
a rack (5°C to 40°C must be met for all units).
• Never remove an upper lid and bottom plate during rack
mounting.
• Be sure to secure the rack to the floor to avoid accidents
when a unit is pulled out.
• Connect long enough cables on the connector panel,
considering that the unit is pulled out.
1. Remove the five screws on right and left side panels.
2. Install the inner members of the slide rails to the right
and left side panels with the screws removed.
1-5. Rack Mounting
B4x6
Inner member
B4x6
Inner member
Installation of Inner Member
3. Remove the four feet on the bottom plate.
If the unit is mounted in the rack with the feet attached,
they will contact the lower and the upper portions of the
rack and the unit cannot be pulled out from the rack.
4. Install the outer member brackets of the slide rails to
the rack. Adjust the distance from the edge of the slide
rail to the outside of the rack so that it meets the
specifications in the Fig. 1 or Fig. 2.
Outer member
Rack
L-angle
Bracket
Nut plate
50+5 mm
–0
‹Fig. 2›
‹Fig. 1›
More than 7 mm(Spacer)
Rack Bracket
Outer member
L-angle
Examples of Outer Members Installation

1-5
5. Remove the four screws on the right and left side
panels. (Be careful not to lose these four screws.)
Removal of Screws on Left and Right Side Panels
6. Install the L-angles to the holes described in step 5 with
the supplied screws (PSW4x16) for these L-angles.
c
Never use screws PSW4x16 to install the right and left
side panels without L-angles. Be sure to install the
panels with the screws B4x6 removed in step 5.
Screws for L-angles are longer than screws for only
panels. PSW4x16 without L-angles may cause trouble
in the unit.
Installation of L-angles
B4x6
B4x6
PSW4x16 L-angle
PSW4x16
L-angle PSW4x16
465
427
More than 7 mm
Spacer
Rack Mounting
‹Front view›
12.7
31.75
12.7
31.75
12.7
31.75
12.7
1-5. Rack Mounting

1-6
Sony Part No.
––––––
1-508-083-00
––––––
1-566-355-11 (NOTE 1)
1-561-929-00
1-566-356-11
––––––
VTR Side Connector
Panel Indication
VIDEO OUTPUT
MONITOR OUTPUT
HEADPHONES
CONTROL PANEL
RS232C
VIDEO DC AUDIO
1-6. Matching Connectors
When external cables are connected to the connector on a connector panel during
maintenance, the hardware listed below (or the equivalents) must be used.
Matching Cable Connector/Cable
Connector
BNC 75 Z, MALE
XLR 3P, FEMALE
JM-60 stereo phone plug
D-SUB 15P, MALE
JUNCTION SHELL 15P
D-SUB 25P, MALE
RFU ADAPTOR
AV CABLE
(NOTE 1)This connector is supplied with optional accessory BKDW-510.
1-6. Matching Connectors

1-7
1-7. Signal Outputs
1-7. Signal Outputs
OUTPUT
RF ADAPTOR
VIDEO............................................... RCA jack, 1.0 Vp-p, 75 Z, sync negative (for character superimpose)
DC...................................................... +5 V
AUDIO .............................................. RCA jack, –10 dBu, high impedance, unbalanced
COMPOSITE ........................................... BNCx2 (including 1 for character superimpose)
1.0 Vp-p, 75 Z, sync negative
MONITOR OUTPUT (R/L) .................... XLR 3-pinx2
+4 dBm (600 Zload), low impedance, balanced
CONTROL PANEL ................................. D-SUB 15-pin connector
RS232C .................................................... D-SUB 25-pin connector
HEADPHONES ....................................... JM-60 stereo phone jack
(Upper Control Panel) up to –12 dBu (8 Zload), unbalanced
‹Rear Panel›
VIDEO OUTPUT
1
2
(SUPER)
RF ADAPTOR
~AC IN
BREAKER
MONITOR OUTPUT
RL
RS232CCONTROL PANEL
COMPOSITE
VIDEO DC AUDIO

1-8
13
14
25
1
18
15 9
CONTROL PANEL: 15-pin (female)
‹external view›
CONTROL PANEL
Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Signal
KEY RX (–)
KEY RX (+)
NC
REG +8 V
REG +8 V
REG +8 V
REG +8 V (2)
NC
GND
KEY TX (+)
NC
KEY TX (–)
GND
GND
GND
RS232C: 25-pin (female)
‹external view›
RS232C
Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Signal
FG; Frame Ground
TXD; Transmitted Data (Output)
RXD; Received Data (Input)
RTS; Request to Send (Output)
CTS; Clear to Send (Input)
DSR; Data Set Ready (Input)
SG; Signal Ground
DCD; Data Carrier Detect (Input)
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
DTR; Data Terminal Ready (Output)
NC
NC
NC
NC
NC
1-7. Signal Outputs

1-9 (b)
CN119CN120
D E F G H J K L M N PR
1
2
3
4
5
6
7
S1554 S1551
S1552S1555
S1553
S1550
Output Level (dBm/600 ZZ
ZZ
Z)
+4 1) 0 –3 –20
ON OFF OFF OFF
OFF ON OFF OFF
OFF OFF ON OFF
OFF OFF OFF ON
ON OFF OFF OFF
OFF ON OFF OFF
OFF OFF ON OFF
OFF OFF OFF ON
1-8. Switch/Shorting Land Settings on the Boards
c
Never change the settings of the factory use switches.
APR-1 board
APR-1 board, on-board shorting lands and resistor selection (Board suffix No. 16 and higher)
Selecting output level
Audio Channel
MONITOR
L-CH
MONITOR
R-CH
Ref. No.
S1552-1
S1552-2
S1552-3
S1552-4
S1555-1
S1555-2
S1555-3
S1555-4
Fine Adjustment
(Address No.)
RV901
(F-5)
RV902
(D-5)
1-8. Switch/Shorting Land Settings on the Boards
APR-1 Board (A Side)
1) Factory Setting

1-10 (b)
Selecting fixed or variable MONITOR output level
Audio Channel
MONITOR
L-CH
MONITOR
R-CH
Audio Channel
MONITOR
L-CH
MONITOR
R-CH
Selection
Level Variable 2) Level Fixed 1)
OFF ON
ON OFF
OFF ON
ON OFF
Ref. No.
S1550-1
S1550-2
S1553-1
S1553-2
Fine Adjustment
(Address No.)
RV901
(F-5)
RV902
(D-5)
Ref. No.
S1551-1
S1551-2
S1554-1
S1554-2
1) Factory Setting
2) When the level variable is selected, the level is adjusted with the
PHONES level control.
Selecting output headroom
3) Factory Setting
1-8. Switch/Shorting Land Settings on the Boards
Output Headroom (dB)
–16 –18 –20 3)
OFF ON OFF
ON OFF OFF
OFF ON OFF
ON OFF OFF

1-9 (a)
CN119CN120
D E F G H J K L M N PR
1
2
3
4
5
6
7
R1038R1039
SL902
SL903
SL904
SL905
SL906
SL907
SL901 R939
SL900
SL908
SL909
SL910
SL911
R940
Output Level (dBm/600 ZZ
ZZ
Z)
+4 1) 0 –3 –20
OPEN SHORT OPEN OPEN
OPEN OPEN SHORT OPEN
OPEN OPEN OPEN SHORT
MOUNT NO MOUNT NO MOUNT NO MOUNT
OPEN SHORT OPEN OPEN
OPEN OPEN SHORT OPEN
OPEN OPEN OPEN SHORT
MOUNT NO MOUNT NO MOUNT NO MOUNT
1-8. Switch/Shorting Land Settings on the Boards
c
Never change the settings of the factory use switches.
APR-1 board
APR-1 board, on-board shorting lands and resistor selection (Board suffix No.41)
Selecting output level
Audio Channel
MONITOR
L-CH
MONITOR
R-CH
Ref. No.
SL902
SL903
SL904
R1038
SL905
SL906
SL907
R1039
Fine Adjustment
(Address No.)
RV901
(F-5)
RV902
(E-5)
1-8. Switch/Shorting Land Settings on the Boards
APR-1 Board (A Side)
1) Factory Setting

1-10 (a)
Selecting fixed or variable MONITOR output level
Audio Channel
MONITOR
L-CH
MONITOR
R-CH
Audio Channel
MONITOR
L-CH
MONITOR
R-CH
Selection
Level Variable 2) Level Fixed 1)
SHORT OPEN
NO MOUNT MOUNT
SHORT OPEN
NO MOUNT MOUNT
Ref. No.
SL908
SL909
SL910
SL911
Fine Adjustment
(Address No.)
RV901
(F-5)
RV902
(E-5)
Ref. No.
SL900
R939
SL901
R940
1) Factory Setting
2) When the level variable is selected, the level is adjusted with the
PHONES level control.
Selecting output headroom
3) Factory Setting
1-8. Switch/Shorting Land Settings on the Boards
Output Headroom (dB)
–16 –18 –20 3)
OPEN SHORT OPEN
SHORT OPEN OPEN
OPEN SHORT OPEN
SHORT OPEN OPEN