Sony KDP-51WS550 - 51" High Definition Projection... Installation guide

Training Manual
Course: TVP-16
AX-1 Chassis
Models: KDP-51WS550
KDP-57WS550
KDP-65WS550
Diagnostics and Troubleshooting
KDP-51WS550

Table of Contents
1. AX-1 chassis PCB Interconnections
and Functional Descriptions .............1
Overview................................................................. 1
2. New Features....................................5
Manual Convergence ............................................ 5
Digital Visual Interface (DVI) ................................ 5
Q-Box...................................................................... 7
3. AX-1 Chassis Power Supplies......10
Overall Block Diagram ......................................... 10
Standby Power Supply and Power ON Circuit .. 11
Q-Box, Primary and High Voltage
Power Supplies.................................................... 12
4. AX-1 Protection Circuits ................18
AX-1 Protection Circuits Overall
Block Diagram ...................................................... 18
AX-1 Protection Circuit Schematic Diagrams .. 20
5. AX-1 Video Processing..................29
AX-1 Acceptable Formats ................................... 29
Simplified Main, Sub and OSD Video Path ...... 29
Troubleshooting..................................................... 34
6. AX-1 System Control Circuits .......36
Overview................................................................ 36
7. AX-1 Deflection Circuits .................38
AX-1 Vertical Deflection Circuit .......................... 38
AX-1 Horizontal Deflection Circuit...................... 39
8. AX-1 Audio Circuit...........................41
AX-1 Audio Block Diagram ................................. 41
9. AX-1 Service Mode and
Adjustments .........................................43
Entering Service Mode and Sequence
of Adjustments...................................................... 43

1
1. AX-1 Chasis PCB Interconnections and Functional Descriptions
Chapter 1 - AX-1 Chassis PCB Interconnections
and Functional Descriptions
ŸMEMORY
STICK
INTERFACE
ŸATSC TUNER
Ÿi.LINK
PROCESSING
ŸMS
PROCESSING
i.LINK INTERFACE
ŸAD/DC POWER
ŸAUDIOAMP
ŸMAIN/SUB TUNERS
ŸREGULATORS
QH
SPEAKERS
AC INPUT
Q BOX
A
DATA
DATA
FIGURE 1-1 - AX-1 OVERALL PCB INTERCONNECTION DIAGRAM TVP16.1-1 1/30/04
ŸMID
ŸDRC
ŸA/D
BM
DATA & POWER
AUDIO SIGNAL
AC
ŸPRIMARY
POWER
SUPPLY
ŸHV POWER
SUPPLY
ŸH-OUT
ŸV-OUT
D
ŸQ-BOX
POWER
SUPPLY
G2
AC/DC
POWER
AC/DC
POWER
ŸAVSWITCH
UA
A/VINPUTS
ŸMAINMICRO
ŸPF MICRO
ŸVIDEO PROCESSOR
ŸAUDIO PROCESSOR
MA
DC
POWER
DATA
D/CPOWER
ŸVELOCITY
MODULATION
VM
FOCUS
BLOCK
ŸFRONT VIDEO
INPUTS
HB
SIGNAL
SIGNAL
ŸDVI
INTERFACE
UD
DATA
ŸFRONT
BUTTONS
ŸIRSENSOR
HA
DRIVE
SIGNAL
VIDEO
OUT
CR
VIDEO
OUT
CG
VIDEO
OUT
CB
ANTENNA
SWITCH
ŸFLASH
FOCUS
SENSORS
SR ŸDIGITAL
REG.
ŸPJED CPU
ŸPJE DRIVE
AD
ŸSUB-
DEFLECTION
DS
210V &
HEATERS
MAINH/V
DEFLECTION
RED CRT
GREEN CRT
BLUE CRT
SUB-
DEFLECTION
DATA
RGB
AUDIO SUB-TUNER
MAIN TUNER
ATSC TUNER
RF
Overview
This chapter provides a high-level overall block view of the AX-1 chassis PCB interconnects and the functions
performed on each PCB.
Figure 1-1 provides a schematic type diagram showing how all the PCBs are interconnected within the complete
system. Also shown is a brief list of the functions performed on each PCB.
For further details concerning the functions performed on each PCB, reference Table 1-1. This table provides a
detailed list of the circuits located on each PCB in the column label circuits.
Inthecolumnlabeled“BoardReplacementAdjustments”isalistofadjustmentsthatmustbecheckedorperformed
when that particular board is replaced.
The column label “Comments” provides repair comments, such as, if the particular board can be removed from
the unit and if the unit will remain powered for troubleshooting, and what symptoms are to be expected when the
board is removed.
Both Figure 1-1 and Table 1-1 are excellent troubleshooting tools that allow the technician to quickly get to the
area they need to be troubleshooting when a defect occurs.

2
1. AX-1 Chasis PCB Interconnections and Functional Descriptions
Table 1-1 –AX-1 Chassis PCB Functional Descriptions
Board Circuits Board Replacement
Adjustments Comments
A
Field
Repairable
•A/C Input
•AC Relay
•Zero Protect
•STBY 5V
PS
•+9V Reg.
•+3.3V Reg.
•+5V Reg.
•Main & Sub.
Tuners
•Audio Amp.
AC Rect. (D6005)
feeds Q-Box,
Primary and HV
Power Supplies
AD
NOTField
Repairable
•PJED
•Digital
REGI.
•-5V Reg.
•+3.3V Reg.
•Write PJED
service data
•Touch-up
Registration
Can be
disconnected. Unit
remains powered.
With total mis-
convergence
displayed.
BM
NOTField
Repairable
•AD-DRC
•MID-XA
•A/D SRAM
•+1.8V Reg.
•+2.5V Reg’s
•Main Picture
Contrast, Color,
and Hue
Can be
disconnected. Unit
remains powered
with No Audio &
Video
C
Field
Repairable
CR, CG, CB
•RGB Drive Can be
disconnected. Unit
remains powered
with no video
D
Field
Repairable
•H & V Drive
•Pin Cushion
•HV-Power
Supply
•Pri.-Power
Supply
•Audio +/-
14V
•+210V
•+12V Reg.
•+/-15V (Pri)
•+/-17V
•+33V
•+135V
•+/-15V
•(T5200
Vert.)
•Heater
(T5200)
•Size & Geometry
•Check G2
•Check Electrical
Focus
•Check Hold-
Down
Cannot be
disconnected. Unit
will not be powered
ON. Two relay clicks
can be heard (AC
Relay ON and then
OFF). No self-
diagnostic
Stdby/Timer LED
flash sequence.

3
1. AX-1 Chasis PCB Interconnections and Functional Descriptions
D
Field
Repairable
(Cont.)
•Protection
Circuits
HV Protect
HD Drive
Protect
Beam Current
Protect
+135 OVP/OCP
•Size & Geometry
•Check G2
•Check Electrical
Focus
•Check Hold-
Down
Cannot be
disconnected. Unit
will not be powered
ON. Two relay clicks
can be heard (AC
Relay ON and then
OFF). No self-
diagnostic
Stdby/Timer LED
flash sequence.
DS
Field
Repairable
•Sub-
Deflection
Drive Amps
•Touch-up
Registration
Can be
disconnected. Unit
will remain powered.
With total mis-
convergence
displayed.
G2
Field
Repairable
•Q-Box
Power
Supply
•+9V
•+5V Reg
•
Cannot be
completely
disconnected
because it supplies
the Primary Supply
with DC Start
Voltage (PRI-VCC).
Can be Unloaded
(disconnect
Secondary voltages).
HA
Field
Repairable
•Key Input
•LED
•IR Sensor
Can be
disconnected. Unit
will remain powered.
HB
Field
Repairable
•Front Video
Input
•I-Link Input
Can be
disconnected. Unit
will remain powered.
QH
NOT Field
Repairable
•Memory
Stick
Interface
Board
Can be
disconnected. Unit
will remain powered.
MA
NOT Field
Repairable
•Main Micro
•PF Micro
•Video
Processor
•CRT RGB
Drive
•Audio
Processor
•5V Reg.
•3.3V Reg.
•Main &Sub
Contrast
•Color & Hue
•S-Lin
•White Balance
•Color Balance
•Sub Bright
•Write A0-Main
Data
•Write A2-PF
Data
Cannot be
disconnected.
Q
-
Box Module
•
Can be

4
1. AX-1 Chasis PCB Interconnections and Functional Descriptions
Q-Box Module
NOTField
Repairable
•ATSC
Tuner
•QM Brd
•QT Brd
•QI Brd
•I-Link
Processing
•Memory
Stick
Processing
Can be disconnected.
Unit will remain
powered.
SR
NOTField
Repairable
•Flash
Focus
Sensor
Can be disconnected.
With no Flash Focus
function.
UA
Field Repairable
•A/V Switch
Terminal
board
•Sub-Video
Comb Filter
•Sub Picture
Contrast, Color,
and Hue
Can be disconnected.
Unit will remain
powered with no
video
UD
NOTField
Repairable
•DVI
Decode
•3.3V Reg.
•2.5V Reg.
Can be disconnected.
Unit will remain
powered.
VM
Field Repairable
•Velocity
Modulation Can be disconnected.
Unit will remain
powered.

5
2. New Features
Chapter 2 - New Features
+ + + + + + +
+ + + + + + +
+ + + + + + +
+ + + + + + +
+ + + + + + +
+ + + + + + +
+ + + + + + +
+ + + + + + +
+ + + + + + +
Full/Normal
Move Select End:Menu
FIGURE 2-1 - MANUAL
CONVERGENCE PATTERN
Manual Convergence
This feature allows the end-user to make point-by-point (Fine) convergence (ref. Figure 2-1) adjustment using
theremote control. Before this featurecan be accessed, theFlash Focus feature mustbe performed. The Flash
Focus does not set the convergence settings back to factory settings; this is performed through the Reset
function.
There is no USER copy function so the end-user must make their adjustments in each screen mode (Full/
Normal, Zoom, Wide Zoom, Memory Stick/High Definition inputs).
For optimal adjustment, the following pre-adjustment steps are recommended:
Allow the unit to warm up for 30 minutes before adjustment.
Set the Mode to “Pro” or “Movie”.
Lower Picture Level (eliminate any flaring along cross edges).
Stand back approximately three to five feet when making adjustment.
Note: Press reset to set Mode and Picture back to original settings.
Note: If AC power is removed, Flash Focus must be performed again to access Manual Convergence.
DigitalVisualInterface(DVI)
Introduction
As the digital display technology (e.g. Plasma and LCD) grows, so does the need to replace the present
analog HD component connection between external digital device (e.g. Digital TV/Satellite Receiver) and the
HDTV set. The issue is the inherent picture quality problems caused by Digital-to Analog (D/A) and Analog-to-
Digital (A/D) conversion processes.
For example, if you have a digital Plasma Display HDTV and a Digital TV/Satellite Receiver, the digital video
signal in the Digital TV/Satellite Receiver must be converted to an analog component video signal and then
sent to the HDTV where it must be converted back to a digital signal video to drive the Plasma display.
Because of the two video signals conversion steps and the possible analog signal loss across the connection
between the HDTV and the Digital TV/Satellite Receiver, the picture quality will suffer. Even with an analog
CRT the Digital TV/Satellite Receiver, video signal must go through D/A conversion, which can adversely
affect picture quality.

6
2. New Features
X7001
14.31818MHz
1 2 910 17 18 23 24 6 7 14 16
IC7004
DVI-DECODER
94
95
R7021
10kHz
TO
CN7002/
PIN 1 (5V)
CN7001
24P MOLEX
CONNECTOR
R x 2-R x 2+ R x 1-
R x 1+R x 0- R x C+
R x C- SCL SDA 5V HPD
IC7001
NVM
R x 0+
IC7005
MCU IC7006
NVM
2
3
5V
5V
3.3V 2.5V
5V
CN7002
SDA, SCL
SDA,
SCL
X7002
12MHz
10
8
6
13
4
3
2
1
5V
Y
PB
PR
SET-UP
MUTE
VGA
RESET
5V
FIGURE 2-2 - UD BOARD BLOCK (DVI DECODER)
CN2304/
PIN 1
5V
CONNECTOR
TVP16.2-2 1/30/04
3.3V
REG
2.5V
REG
3.3V
2.5V
5V
D7001
COMPONENTOUT
1
9
17
8
16
24
EDID
HDCP
The resolution to this dilemma is the creation of a complete end-to-end standard digital video interface, ala DVI.
The DVI interface is a high-speed digital video interface allowing uncompressed high-definition content to be
passed to another DVI equipped device such as an HDTV set. DVI is the only digital interface capable of
accommodating uncompressed digital data such as HD video. DVI also has the bandwidth to support higher
audio fidelity.
DVI has a bandwidth of up to 5 Gigabits/sec, which is more then enough to accommodate an uncompressed HD
video transmission typically requiring 2.2 Gigabits/sec bandwidth.
DVI Connector and Decoding Block
Ref. Figure 2-2
The DVI Molex connector and Decoding circuitry for the AX-1 chassis are located on the UD-Board (NOTE: This
board is NOT field repairable). Figure 2-2 shows a block diagram for the UD-Board. The DVI signal (from a
Digital TV/Satellite Receiver) is received at the 24-pin Molex connector CN7001. There are three serial data
differential channels RX0+/RX0-, RX1+/RX1-, RX2+/RX2- and one reference clock differential channel RXC+/
RXC-.
IC7001 NVM is also connected to the external device through the SDA and SCL (I2C) bus. IC7001 stores the
EDID (Extended Display Identification Data).
EDID is sent to inform the STB or external digital device of the TV’s identity and capabilities.
HDCP is an Authentication protocol between the external digital device (transmitter) and the TV (receiver) that
affirms to the transmitter that the receiver is authorized to receive the protected digital video information.
CN 7001/pin 14 (5V) is supplied from the external digital device to power IC7001 (NVM) so EDID can be sent
when the TV set is OFF. If the TV set is ON, IC7001 will receive 5V from CN7002 through D7001.
CN7001/pin 16 is the Hot Plug Detect pin (HPD). The TV set supplies 5V to the external digital device to verify
proper connection between the two devices.

7
2. New Features
QM
MICRO-CONTROL
AUDIO/VIDEO
PROCESSING
QI
i.LINK
QT
ATSC
TUNER
BOARD
INTERCONNECT
BOARD
INTERCONNECT
i.LINK FRONT
i.LINK REAR
i.LINK REAR
FROM
ANT.SWITCH
TO UA BOARD
ANALOG VIDEO/AUDIO OUT
(Y/Pb/PR)
(LT & RT)
TO MA & G2 BOARDS
POWER/DATA
COMMUNICATIONS
MEMORY
STICK
INPUT
DIGITAL AUDIO OUT
REAR
USB
CN7300
CN7309
FIGURE 2-3 - Q-BOX INTERNAL BLOCK DIAGRAM TVP16.2-3 1/30/04
PCM
RF
The DVI Decoder, IC7004 receives the three channels of digital video data and outputs analog component video
(Y, PB, PR) to CN7002/pins 10, 8 and 6 respectively.
Q-Box
The Q-Box processes ATSC (off-the-air digital broadcast) broadcast, Memory Stick and I-Link signals. The
boardsincluded in the Q-Boxare the QM, QIandQT. The QM performsallQ-Module video andaudioprocessing.
The QI board is the I-Link interface and the QT is the “off-the-air” or terrestrial (from antenna switch) signal
interface. The Memory Stick feature uses an external interface board QH, which is connected to the Q-Box via
USB cable.
The Q-Box outputs the 1080i signal format for all selected inputs.
The Q-Box is replaced as an assembly (including QM, QI, and QT boards) if found defective.
The following text and diagrams will help in troubleshooting and determine a possible defective Q-Box. Figure 2-
3 is a block diagram showing all the external connections to the Q-Box.
The Q-Box processes the following digital signals:
HDTV Terrestrial Signal (RF)
Memory Stick Images or Movies
I-Link Data
The digital signals are processed and D/A converted by the Q-Box processor on the QM board. The Component
Video (Y/PB/PR) and Audio (LT/RT) analog signals are then output to the UA (AV Switcher). Digital audio is also
output from the Q-Box on the rear (Digital Optical connector) of the unit in PCM/Dolby Digital format.

8
2. New Features
FIGURE 2-4 - Q-BOX CONNECTOR/PIN DETAIL
Q-BOX
CN7300
CN7309
VIDEO
AUDIO
NOT
USED
9V
9V
5V
(RESET)
3.2V
DATA TO
Q-BOX
MICRO RT
DATA FROM
Q-BOX
MICRO
LT
Y
PB
PR
RF
POWER &
COMMUNICATION
END VIEW OF
Q-BOX