Sony KDL-22EX425 User manual

LCD DIGITAL COLOR TV
SERVICE MANUAL AZ2-F CHASSIS
MODEL COMMANDER DESTINATION
9-888-401-51
KDL-22EX425 RM-YD064 BRAZIL
KDL-32EX425 RM-YD064 BRAZIL
KDL-32EX525 RM-YD064 BRAZIL
KDL-40EX525 RM-YD064 BRAZIL
KDL-46EX525 RM-YD064 BRAZIL
LEVEL
3
CONFIDENTIAL
HISTORY INFORMATION FOR THE FOLLOWING MANUAL:
CONFIDENTIAL
ELECTRICAL SERVICE MANUAL
INTERNAL ONLY
ORIGINAL MANUAL ISSUE DATE: 2/2011
REVISION DATE SUBJECT
2/21/2011 No revisions or updates are applicable at this time.

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KDL-22EX425/32EX425/32EX525/40EX525/46EX525
KDL-22EX425/32EX425/32EX525/40EX525/46EX525
TABLE OF CONTENTS
SECTION TITLE PAGE
Safety-Related Component Warning ............................................................................................................................................................................... 3
Safety Check-Out............................................................................................................................................................................................................... 5
SECTION 1: DIAGRAMS................................................................................................................................................................................................... 6
1-1. Circuit Boards Location ...................................................................................................................................................................................... 6
1-2. Printed Wiring Boards and Schematic Diagrams Information ............................................................................................................................ 8
1-3. Block Diagrams .................................................................................................................................................................................................. 9
1-4. Connector Diagrams ........................................................................................................................................................................................ 11
1-5. Schematics and Supporting Information .......................................................................................................................................................... 15
BATS (Main) Board Schematic Diagram (KDL-22EX425 Only) (1 of 12)......................................................................................................... 15
BATS (Main) Board Schematic Diagram (KDL-22EX425 Only) (2 of 12)......................................................................................................... 16
BATS (Main) Board Schematic Diagram (KDL-22EX425 Only) (3 of 12)......................................................................................................... 17
BATS (Main) Board Schematic Diagram (KDL-22EX425 Only) (4 of 12)......................................................................................................... 18
BATS (Main) Board Schematic Diagram (KDL-22EX425 Only) (5 of 12)......................................................................................................... 19
BATS (Main) Board Schematic Diagram (KDL-22EX425 Only) (6 of 12)......................................................................................................... 20
BATS (Main) Board Schematic Diagram (KDL-22EX425 Only) (7 of 12)......................................................................................................... 21
BATS (Main) Board Schematic Diagram (KDL-22EX425 Only) (8 of 12)......................................................................................................... 22
BATS (Main) Board Schematic Diagram (KDL-22EX425 Only) (9 of 12)......................................................................................................... 23
BATS (Main) Board Schematic Diagram (KDL-22EX425 Only) (10 of 12)....................................................................................................... 24
BATS (Main) Board Schematic Diagram (KDL-22EX425 Only) (11 of 12)....................................................................................................... 25
BATS (Main) Board Schematic Diagram (KDL-22EX425 Only) (12 of 12)....................................................................................................... 26
BATV (Main) Board Schematic Diagram (KDL-32EX425/32EX525/40EX525/46EX525 Only) (1 of 12) ......................................................... 29
BATV (Main) Board Schematic Diagram (KDL-32EX425/32EX525/40EX525/46EX525 Only) (2 of 12) ......................................................... 30
BATV (Main) Board Schematic Diagram (KDL-32EX425/32EX525/40EX525/46EX525 Only) (3 of 12) ......................................................... 31
BATV (Main) Board Schematic Diagram (KDL-32EX425/32EX525/40EX525/46EX525 Only) (4 of 12) ......................................................... 32
BATV (Main) Board Schematic Diagram (KDL-32EX425/32EX525/40EX525/46EX525 Only) (5 of 12) ......................................................... 33
BATV (Main) Board Schematic Diagram (KDL-32EX425/32EX525/40EX525/46EX525 Only) (6 of 12) ......................................................... 34
BATV (Main) Board Schematic Diagram (KDL-32EX425/32EX525/40EX525/46EX525 Only) (7 of 12) ......................................................... 35
BATV (Main) Board Schematic Diagram (KDL-32EX425/32EX525/40EX525/46EX525 Only) (8 of 12) ......................................................... 36
BATV (Main) Board Schematic Diagram (KDL-32EX425/32EX525/40EX525/46EX525 Only) (9 of 12) ......................................................... 37
BATV (Main) Board Schematic Diagram (KDL-32EX425/32EX525/40EX525/46EX525 Only) (10 of 12) ....................................................... 38
BATV (Main) Board Schematic Diagram (KDL-32EX425/32EX525/40EX525/46EX525 Only) (11 of 12) ....................................................... 39
BATV (Main) Board Schematic Diagram (KDL-32EX425/32EX525/40EX525/46EX525 Only) (12 of 12) ....................................................... 40
G1A Board Schematic Diagram (KDL-22EX425 Only) .................................................................................................................................... 43
GE2A Board Schematic Diagram (KDL-32EX425/32EX525 Only) .................................................................................................................. 45
GE3A Board Schematic Diagram (KDL-40EX525/46EX525 Only) .................................................................................................................. 48
HLR2 Board Schematic Diagram ..................................................................................................................................................................... 50
HMS3 Board Schematic Diagram .................................................................................................................................................................... 52
SECTION 2: ELECTRICAL PARTS LIST........................................................................................................................................................................ 54
APPENDIX A: ENCRYPTION KEY COMPONENTS..................................................................................................................................................... A-1

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KDL-22EX425/32EX425/32EX525/40EX525/46EX525
KDL-22EX425/32EX425/32EX525/40EX525/46EX525
SAFETY-RELATED COMPONENT WARNING
There are critical components used in LCD color TVs that are important for safety. These components are identied with shading and
!
mark on the schematic diagrams and the electrical parts list. It is essential that these critical parts be replaced only with the part number
specied in the electrical parts list to prevent electric shock, re, or other hazard.
NOTE: Do not modify the original design without obtaining written permission from the manufacturer or you will void the original parts and
labor guarantee.
USE CAUTION WHEN HANDLING THE LCD PANEL
When repairing the LCD panel, be sure you are grounded by using a wrist band.
When installing the LCD panel on a wall, the LCD panel must be secured using the 4 mounting holes on the rear cover.
To avoid damaging the LCD panel:
Údo not press on the panel or frame edge to avoid the risk of electric shock.
Ú do not scratch or press on the panel with any sharp objects.
Údo not leave the module in high temperatures or in areas of high humidity for an extended period of time.
Údo not expose the LCD panel to direct sunlight.
Ú avoid contact with water. It may cause a short circuit within the module.
Ú disconnect the AC adapter when replacing the backlight (CCFL) or inverter circuit.
(High voltage occurs at the inverter circuit at 650Vrms.)
Ú always clean the LCD panel with a soft cloth material.
Ú use care when handling the wires or connectors of the inverter circuit. Damaging the wires may cause a short.
Úprotect the panel from ESD to avoid damaging the electronic circuit (C-MOS).
LEAKAGE CURRENT HOT CHECK CIRCUIT
• Avoid contact with water as it may a short circuit within the module.
• If the surface of panel becomes dirty, please wipe it off with a soft material. (Cleaning with a dirty or rough cloth may
damage the panel.)
• If you want to replace with the new backlight (CCFL) or inverter circuit, must disconnect the AC adapter because high
voltage appears at inverter circuit about 650Vrms.
• Handle with care wires or connectors of the inverter circuit. If the wires are pressed cause short and may burn or take
fire.
Leakage Current Hot Check Circuit
KLV-32U100M (UC) 5

4
KDL-22EX425/32EX425/32EX525/40EX525/46EX525
KDL-22EX425/32EX425/32EX525/40EX525/46EX525
Th
e c
i
rcu
i
t
b
oar
d
s use
d
i
n t
h
ese mo
d
e
l
s
h
ave
b
een processe
d
us
i
ng
Lead Free Solder. The boards are identified by the LF logo located
close to the board designation e.g. H1 etc [ see example ]. The
servicing of these boards requires special precautions to be taken as
outlined below.
example
It is strongly recommended to use Lead Free Solder material in order to guarantee optimal quality of new solder joints.
Lead Free Solder is available under the following part numbers :
Due to the higher melting point of Lead Free Solder the soldering iron tip temperature needs to be set to 370 degrees centigrade.
This requires soldering equipment capable of accurate temperature control coupled with a good heat recovery characteristics.
rebmuntraP retemaiD skrameR
91-500-046-7 mm3.0 gK52.0
02-500-046-7 mm4.0 gK05.0
12-500-046-7 mm5.0 gK05.0
22-500-046-7 mm6.0 gK52.0
32-500-046-7 mm8.0 gK00.1
42-500-046-7 mm0.1 gK00.1
52-500-046-7 mm2.1 gK00.1
62-500-046-7 mm6.1 gK00.1

5
KDL-22EX425/32EX425/32EX525/40EX525/46EX525
KDL-22EX425/32EX425/32EX525/40EX525/46EX525
SAFETY CHECK-OUT
After correcting the original service problem, perform the following
safety checks before releasing the set to the customer:
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
touching high-wattage resistors.
3. Check that all control knobs, shields, covers, ground straps, and
mounting hardware have been replaced. Be absolutely certain that
you have replaced all the insulators.
4. Look for unauthorized replacement parts, particularly transistors,
that were installed during a previous repair. Point them out to the
customer and recommend their replacement.
5. Look for parts which, though functioning, show obvious signs of
deterioration. Point them out to the customer and recommend their
replacement.
6. Check the line cords for cracks and abrasion. Recommend the
replacement of any such line cord to the customer.
7. Check the antenna terminals, metal trim, “metallized” knobs, screws,
and all other exposed metal parts for AC leakage. Check leakage as
described below.
Leakage Test
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
instructions.
2. A battery-operated AC milliampmeter. The Data Precision 245
digital multimeter is suitable for this job.
3. Measuring the voltage drop across a resistor by means of a VOM
or battery-operated AC voltmeter. The “limit” indication is 0.75
V, so analog meters must have an accurate low voltage scale.
The Simpson’s 250 and Sanwa SH-63TRD are examples of
passive VOMs that are suitable. Nearly all battery-operated digital
multimeters that have a 2 VAC range are suitable (see Figure A).
How to Find a Good Earth Ground
A cold-water pipe is a guaranteed earth ground; the cover-plate
retaining screw on most AC outlet boxes is also at earth ground. If the
retaining screw is to be used as your earth ground, verify that it is at
ground by measuring the resistance between it and a cold-water pipe
with an ohmmeter. The reading should be zero ohms.
If a cold-water pipe is not accessible, connect a 60- to 100-watt
trouble- light (not a neon lamp) between the hot side of the receptacle
and the retaining screw. Try both slots, if necessary, to locate the hot
side on the line; the lamp should light at normal brilliance if the screw
is at ground potential (see Figure B).
To Exposed Metal
Parts on Set
0.15 µF
Earth Ground
AC
Voltmete
r
(0.75V)
Trouble Light
AC Outlet Box Ohmmeter
Cold-water Pipe
Figure A. Using an AC voltmeter to check AC leakage. Figure B. Checking for earth ground.

6
KDL-22EX425/32EX425/32EX525/40EX525/46EX525
KDL-22EX425/32EX425/32EX525/40EX525/46EX525
SECTION 1: DIAGRAMS
1-1. CIRCUIT BOARDS LOCATION
SWITCH
UNIT
HLR2 HMS3
G1A
TCON
BATV
Figure 1-1. KDL-22EX425
SWITCH
UNIT
HLR2 HMS3
GE2A
TCON
BATV
Figure 1-2. KDL-32EX425/32EX525

7
KDL-22EX425/32EX425/32EX525/40EX525/46EX525
KDL-22EX425/32EX425/32EX525/40EX525/46EX525
SWITCH
UNIT
HLR2 HMS3
GE3A
TCON
BATV
Figure 1-3. KDL-40EX525
SWITCH
UNIT
HLR2 HMS3
GE3A
TCON
BATV
Figure 1-4. KDL-46EX525

8
KDL-22EX425/32EX425/32EX525/40EX525/46EX525
KDL-22EX425/32EX425/32EX525/40EX525/46EX525
G
D
S
B1 E1
C2
B2 C1E2
2
3
4
5
6
7
8
9
–
1
G
D
S
B2 E2C1
B1 C2
E1
B2 E2C1
B1 C2E1
B2 E2
C1
B1 C2E1
B1 E1
E2
C1(B2)C2
B1
E2
C1
C2
(B2)
E1
(B2)
E1
E2
B1
C2C1
B1
E1
C2
B2
C1
E2
G
SS
D
G
D
B1
E1
C2
B2
C1
E2
B1
E2
C2C1(B2)
E2
B1
C1
C2E1(B2)
C2
B1
C1
E2E1(B2)
C2
B1
C1
E2
B2
E1
C2
Ver.1.6
Transistor
(FET)
Transistor
Transistor
Transistor
Transistor
Transistor
Transistor
Transistor
Transistor
Transistor
Discrete semiconductor
(Chip semiconductors that are not actually used are included.)
Diode
Diode
Diode
Diode
Diode
Diode
Diode
Diode
Diode
Diode
Source
Source
Anode Anode
(NC)
(NC)
Cathode
Anode
Cathode
Common
Cathode Cathode
Common
Cathode Cathode
Common
Common
Common
Common
Cathode
Anode
Base Emitter
Collector
Base Emitter
Collector
Drain
Gate
Gate
Drain
Device Printed symbol Terminal name Circuit
Terminal name of semiconductors in silk screen
printed circuit ( )
Anode
Anode
Anode Cathode
Anode Anode
Cathode
Transistor
(FET)
Transistor
(FET)
Emitter
Collector
Base
Transistor
Source
Gate
Drain
Cathode
Anode
Anode Cathode
Anode
Anode
*
18
11
17
16
15
14
13
12
10
21
20
19
23
22
REFERENCE INFORMATION
RESISTOR
: RN METAL FILM
: RC SOLID
: FPRD NONFLAMMABLE CARBON
: FUSE NONFLAMMABLE FUSIBLE
: RW NONFLAMMABLE WIREWOUND
: RS NONFLAMMABLE METAL OXIDE
: RB NONFLAMMABLE CEMENT
: ADJUSTMENT RESISTOR
COIL
: LF-8L MICRO INDUCTOR
CAPACITOR
: TA TANTALUM
: PS STYROL
: PP POLYPROPYLENE
: PT MYLAR
: MPS METALIZED POLYESTER
: MPP METALIZED POLYPROPYLENE
: ALB BIPOLAR
: ALT HIGH TEMPERATURE
: ALR HIGH RIPPLE
1-2. PRINTED WIRING BOARDS AND
SCHEMATIC DIAGRAMS INFORMATION
All capacitors are in µF unless otherwise noted. pF : µµF 50WV or
less are not indicated except for electrolytics and tantalums.
All electrolytics are in 50V unless otherwise specied.
All resistors are in ohms. kΩ=1000Ω, MΩ=1000kΩ
Indication of resistance, which does not have one for rating
electrical power, is as follows: Pitch : 5mm
Rating electrical power : 1/4 W
1/4 W in resistance, 1/10 W and 1/16 W in chip resistance.
: nonammable resistor
: fusible resistor
: internal component
: panel designation and adjustment for repair
: earth ground
: earth-chassis
All variable and adjustable resistors have characteristic curve B,
unless otherwise noted.
Readings are taken with a color-bar signal input.
Readings are taken with a 10MΩdigital multimeter.
Voltages are DC with respect to ground unless otherwise noted.
Voltage variations may be noted due to normal production
tolerances.
All voltages are in V.
S : Measurement impossibility.
: B+line.
: B-line. (Actual measured value may be different).
: signal path. (RF)
Circled numbers are waveform references.
The components identied by shading and
!
symbol are critical for safety. Replace
only with part number specied.
The symbol indicates a fast operating fuse and is displayed on the component
side of the board. Replace only with fuse of the same rating as marked.
NOTE: The components identied by a red outline and a mark contain condential
information. Specic instructions must be adhered to whenever these components
are repaired and/or replaced.
See Appendix A: Encryption Key Components in the back of this manual.

9
KDL-22EX425/32EX425/32EX525/40EX525/46EX525
KDL-22EX425/32EX425/32EX525/40EX525/46EX525
1-3. ENGINEERING BLOCK DIAGRAM
DDR3
1Gb/2Gb
DDR3
1Gb/2Gb
One NAND
2Gb
USB
HUB
Ether
PHY
Audio
AMP RMII
YCbCr /
CVBS
CVBS
RGB
TMDS
TMDS TMDS
SPDIF
USB2.0
L/R
TS
LVDS
LED
IR Remote Rx
Ladder
GPIO
UART
SIRCS GPIO
IIC
Temp.
Sensor
IIC
PWM
Human Sensor
IIS
Audio
Sub AMP
L/R
Lumi Sensor
Key (Normal)
HDMI
EQSW
XReality
HORUS
(Si Tu- S)
HYDRA
(ISDB Demod)
SEKITO2
(DVB-S2 Demod)
ATV
CATV
IF
TS TS
IF
ASCOT2Ssip
(Si Tu- T)
60HzCCFL/
60HzLED
BCAS
L/R
PCAUDIO (Shared
w/HDMI)
L/R
HP/ LINE
OUT
BATS BOARD
FIGURE 3-1. KDL-22EX425

10
KDL-22EX425/32EX425/32EX525/40EX525/46EX525
KDL-22EX425/32EX425/32EX525/40EX525/46EX525
48M
32.76
8K
[PST3629]
GND
Push
P
A
N
E
L
[LM75B]
DDR3
–1333
2Gb
DDR3
–1333
2Gb
One–
NAND
Muxed
2Gb
[RTL8201E]
[TPS2553DBV]
[GL850G]
12M
[TPS2553DBV]
H/L
[D–510D]
[D–510D]
[NJU72040V]
41M
[LNBH23]
[MIC2005]
[SEKITO2]
[GAIA1a]
41M
[HORUS3]
27M
4M
[ASCOT2Sip]
[Sil9287B]
0
0
XReality
HDMI1
(ARC)
HDMI2
HDMI3
Aerial
Cable
Satellite
PCPC
COMP
CVBS
SPDIF
Main
SPEAKER
HP/Line
Out
Assist
SPEAKER
Analog Video
Digital Video/TS/TMDS
Analog Audio Analog Signal
PWM
I2C
SPI
X_SYSTEM1_RST
AUDIO_MON
X_FAULT
Main Speaker_Out_LR
X_SYSTEM1_RST
Assist Speaker_Out
SPDIF
HP/Line Out LR
HP_/ Line Out Det
PC_5V, PC_DDC
PC_LR
PC_R,PC_G,PC_B,PC_H,PC_V
PC_CON_Det
Cr_Det
ASPECT1
COMP_Y, Pb, Pr
VideoB_Det
COMP2_LR
VideoA_Det
VIDEO_CV
VIDEO1_LR
CEC3
DDC4
HPD4
CEC4
DDC_5V_4
TMDS4
CEC2
DDC3
HPD3
DDC_5V_3
TMDS3
CEC1
TMDS2
DDC2
HPD2
DDC_5V_2
ARC
TMDS1
DDC1
HPD1
DDC_5V_1
EQ SW
3.3->1
I2CA
X_SYSTEM1_RST
TCON
Reset
Ether
PHY
X’tal
Temp
Sensor
Audio
Power AMP
HDMI4
Ether
KEY
LED
TMDS
DDC
CEC
Line Out_LR
Power_Control
MAIN_PWR
Power_KEY
KEY
Light_Sensor_Det
STBY_LED
POWER_LED
TL-JIG
UARTA(LOG)
Hotel
UARTC(Hotel/ECS)
BACKLIGHT_ON
DIMMER
BACKLIGHT_MON
SYSTEM2_PWR
Human Sensor
Human_Sensor_Det
X_AUDIO_MUTE1
PFC_PWR
OPAMP
AC_MON
I2CA
X’tal
DIMMER_DC
USB2
Current
Limit
USB1
USB
HUB
X’tal
Power
Tuner_LR
Current
Limit
USB3
Wifi
USB4
BD
AC_MON
PFC_MON POWER_KEY POWER_LED REC_LED X_SYSTEM1_RST
DIMMER
DC_MON KEY Light_Sensor_Det
UARTA (LOG)
PFC_PWR DEBUG_LED1 Human_Sensor_Det
LVDS
PEL3
UARTD
PANEL_SEL
5V
Aerial
Ext Demod
X’tal
LNA Ext Demod
IFAGC
DDC
I2CB
I2CB
Satellite Silicon
Tuner
X’tal
Silicon
Tuner
Zero-IF
IF1
X’tal
DiSEqC_Out
IFAGC
IF2
DiSEqC_In
27MHz
SW
COMP_Y
COMP_Pb
COMP_Pr
PC_G
PC_B
PC_R
PC_H
PC_V
PC_LR
VIDEO1_LR
COMP2_LR
Tuner_LR
VIDEO_CV
COMP_Y
S1.8V
LDO
3.3V
LDO
DDC
5V
STBY 3.3V
2.5V
LDO
TCON-ON
SYSTEM2_PWR
DDC
REG_12V
T-CON_VCC
REG12V
AUDIO_12V
REG_12V
BACKLIGHT_MON X_AUDIO_MUTE1 X_AUDIO_MUTE2 PANEL_PWR_Det
5V
UARTE
PC_CON_DET
Crystal
VIDEOA_DET VIDEOB_DET CR_DET
TIMER_LED
PIC_MUTE_LED
REC_LED
Temp Sensor
X_Hotel_PWR_CTRL
Current
Limit
5V
I2CA (EQSW, Temp Sensor, Hotel Clock)
I2CB (Ext Demod)
LOGO
DMD_RST
X_AUDIO_MON
STBY_LED TIMER_LED MAIN_PWR MAIN_SS_MON
DIMMER_DC
TS2
TS1
LNA
/ECS
Light Sensor
X_TCON_RST SA_MODE BINT TCON_RDY
IF1
Main Speaker_Out_LR
S1.2V
LDO
PEM_LOG
I2CA(Hotel_Clock)
DEBUG_LED2
DEBUG_LED3
DMD_CLK_ENABLE1
PANEL_PWR
Atreyu_SPDIF
BACKLIGHT_ON SYSTEM2_PWR SYSTEM1_PWR PIC_MUTE_LED
1.5V
3.3V
MODE_PEM
I2CC (Panel, RGB Sensor)
DMD_CLK_ENABLE2
HDMIEQ_INT
DMD_RST
DMD_CLK_ENABLE1
DMD_CLK_ENABLE2
X_SYSTEM1_RST
X_SYSTEM1_RST
Reset
SIRCS
UARTB (RF-Remote)
UARTC (IR Blaster/ECS)
MS
TS
Panelless
AC_MON
Reset
H Con.
Audio
Power AMP
Assist Speaker_Out_LR
Sircs
SIRCS
AUDIO_12V
REG12V
SYSTEM2_PWR
DDC 1.2V
SYSTEM1_PWR
DDC
REG_12V
3.4V
LDO
SYSTEM2_PWR
X_RF_RST NMI X_HOTEL_PWR_CTRL DATA1
HP_DET
X_WIFI_RST
SPDIF_SEL
BACKLIGHT
DIMMER2
LVDS_ODD
LVDS_EVEN
SA_MODE/LUT_SEL0
PEM_WDT/XBUSY/BINT
I2C_C
MODE_PEM/TCON_RDY
LUT_SEL1/X_TCON_RST/LR_FLAG
T_PANEL_SEL
Digital Audio UART
REG_12V
FIGURE 3-2. KDL-32EX425/32EX525/40EX525/46EX525