RAINING
2005
Projection Television
Training Manual
2006
Including…
Down-to-1
High Speed Troubleshooting
1080p 720p
DLP™ LCD
V29 V28
WD-52627 WD-52527 WD-52528
WD-62628 WD-62527 WD-62528
V30
WD-52628 WD-62827 WD-73727
WD-62628 WD-73827
V31
WD-62927
WD-73927
TABLE of CONTENTS
Introduction
About Mitsubishi Electric US ................................................................................. 1
I
II
Introduction
About Mitsubishi Electric US Companies
Mitsubishi Electric US markets an extensive line of consumer, commercial and industrial electrical and electronics
products. Mitsubishi Electric has more than 2,000 employees in 30 locations throughout the USA.
www.MitsubishiElectric.com
Mitsubishi Digital Electronics America, Inc. Mitsubishi Electric Automotive America, Inc.
Mitsubishi Digital Electronics America, Inc. (MDEA) Mitsubishi Electric Automotive America (MEAA) of-
manufactures and markets a premium line of high defini- fers all aspects of engineering, manufacturing, sales and
tion, microdisplay, projection, plasma and LCD flat panel marketing, distribution and service of electrical and elec-
televisions and displays; advanced video products such tronic systems and components for automobile manu-
as DVD and digital VHS components; presentation facturers and industrial engine manufacturers.
products and projectors; dye sublimation printers; medi- www.meaa-mea.com
cal and time-lapse VCRs; security digital video record-
ers; and photo kiosks. www.mitsubishi-tv.com Mitsubishi Electric Automation, Inc.
Mitsubishi Electric Automation, Inc. (MEAU) is a sup-
Elevator & Escalator Division plier of factory automation solutions that include auto-
Mitsubishi Electric’s Elevator & Escalator Division mar- mation platforms; programmable logic controllers; hu-
kets and services elevators and escalators throughout man machine interfaces; programming and control soft-
the United States. The division designs and installs pre- ware; industrial computers; variable frequency drives,
mier vertical transportation systems, including high-speed servo motors and amplifiers; motion controllers; com-
elevators and the world’s only spiral escalators. puter numerical controllers; robots; uninterruptible power
www.MitsubishiElectric.com supplies; and industrial sewing equipment.
www.meau.com
Heating, Ventilation & Air Conditioning Division
Mitsubishi Electric HVAC Advanced Products Division Mitsubishi Electric Power Products, Inc.
offers Mr. Slim split-ductless air conditioners; CITY Mitsubishi Electric Power Products, Inc. (MEPPI) is
MULTI, an inverter technology-driven simultaneous responsible for serving the North American electric util-
cooling and heating system; PlasmaPure room air puri- ity, rail transportation, and water treatment industries with
fication systems; and Jet Towel hand dryers. electrical and electronic products, systems and services.
www.MitsubishiElectric.com/hvac MEPPI also provides equipment and services for broad-
band over powerline systems.
Semiconductor Division www.meppi.com
Mitsubishi Electric’s Semiconductor Division markets Within MEPPI is the Diamond Vision Division, which
advanced digital and mixed-signal products that pro- markets and installs large-scale video displays for sta-
vide unmatched flexibility, design reuse, innovative pack- diums and arenas, as well as LED displays for indoor
aging options, ultra-low power and proven high quality and outdoor applications.
across a wide range of technologies. www.diamond-vision.com
www.mitsubishichips.com.
1
Mitsubishi Electric US Products & Services
2
Chapter 1
Display Technologies & PTV Product Line
Display Technologies CRT Technology - V27 Chassis
Mitsubishi’s Digital Television Product Line for 2005- This is the most mature technology of the four. It may
2006 consists of several different display technologies. even be viewed as somewhat “low tech” by some
They are categorized as either Rear Projection or Di- people. However, Mitsubishi’s product line includes all
rect View. the latest digital features. As such, it can still offer the
Rear Projection Television Technologies: best “bang for the buck” of all the technologies. The
• CRT V27 Chassis is used in 55”, 65” and 73” models.
• LCD
• DLP™ LCD Technology - V28 Chassis
• LCoS While LCD projection television is certainly not new,
recent strides have improved this technology so that Mit-
Direct View Television Technologies: subishi can offer it in 4 models this year.
• Plasma
• LCD DLP Technology - V29/V30/V31 Chassis
Mitsubishi, the first to bring DLP technology to market
This training manual is directed towards Projection Tele- in a rear projection television, marks another “first” by
vision technologies. introducing 1080p DLP in 9 different rear projection
models. This is twice the resolution of High Definition.
Each technology offers its own strengths and weak- It will come in 52, 62 and 73 inch screen sizes, with the
nesses. Otherwise, only one type would need to be made 73 inch models being the largest DLP models ever avail-
available. Understanding the differences in each tech- able.
nology will aid the technician when discussing a given
set’s performance with a consumer. Tables 1-1 and 1- LCoS
2 outline some of the strengths and weaknesses of each Mitsubishi’s use of LCoS technology is in the form of a
one. Of course, the strengths and weaknesses will change 3 chip system carried over in the 82” rear projection
as each technology evolves over time. model WL-82913.
1-1
Light Engines picture as light reflects off the surface of the display de-
The CRT technology used in the V27 chassis is electri- vice.
cally the same as the V25 chassis. Since the V25 Train-
ing Manual covers it in-depth, no further discussion will An LCD must use 3 devices to produce a color picture.
be necessary. DLP and LCoS can be configured as either single, or 3
device engines. Mitsubishi currently uses a single chip
LCD, DLP and LCoS are known as “Micro-Display” DLP and a 3 chip LCoS system.
technologies. The Light Engines are configured differ-
ently for each. The LCD Light Engine, shown in Figure 1-1, uses 3
LCD “Panels” to individually produce the red, green
LCD uses the “light transmissive” method of producing and blue elements of the picture. Dichroic mirrors sepa-
a picture as light passes through the panel. DLP and rate the red, green and blue elements of light, and an X-
LCoS use the “light reflective” method of producing a Prism is used to re-combine the 3 colors after the pic-
tures have been produced.
X Projection
Prism Lens
Mirror Mirror
LCD LCD
LCD
Red Green Blue
Lens
Dichroic
Mirror
Lens Dichroic
Lens
Mirror
Lamp Mirror
1-2
Color Wheel
Projection
Lens
Lamp
TIR
Prism
Shaping
Lens
Condensing Lens Relay
Lens
DMD
The single device DLP Light Engine, shown in Figure Figure 1-3 shows an LCoS engine in a 3 chip arrange-
1-2, produces a color picture using a color wheel and ment. Like LCD, it produces each color individually.
the “field sequential” method of displaying the red, green And like DLP, it uses reflective light to produce the pic-
and blue elements of the picture. ture.
LCoS
Dichroic
Mirror
TIR
Mirror Blue Prism
Green Projection
Lamp Lens
LCoS
Dichroic TIR X
Prism Prism Prism
TIR
Mirror Red
Prism
LCoS
1-3
Performance Improvement SmartShutter™ is a dynamic aperture system that im-
Technologies proves black levels and adds a large palette of dark
The 2005-2006 PTV product line uses several new grey shades. It does this by reducing light output during
performance improvement technologies for LCD and dark scenes without negatively affecting other picture
DLP displays. characteristics.
LCD Improvements:
• Quick Motion™ Shown in Figure 1-4, the SmartShutter High Contrast
• SmartShutter™ Unit (HCU) is located in the light path between the lamp
output and the optics.
DLP Improvements:
• 1080p The HCU is a motor driven device that dims the lamp
• Dark Detailer™ output by physically blocking it with movable louvers.
• 10,800 RPM Color Wheel See Figure 1-5. As dark scenes are detected, the lou-
vers move from position A, full light output, through
Quick Motion™ is an advanced high speed drive sys- positions B, C and D to accurately control the amount
tem that derives faster response from LCDs, virtually of light necessary as the picture brightness varies. It is
eliminating the blurs that often occur when the moving controlled by the PWB-Motor Driver.
picture has fast motion.
LCD
Drive Fan
PWB SmartShutter
Projection Control PWB
Lens
Lamp
SmartShutter
High Contrast Unit
(HCU)
1-4
A
Motor
Louvers
Lighting
D C
Area
1-5
720p DMD Chip 1080p DMD Chip
Pixel Arrangement Square Pixel Arrangement Diagonal Pixel Arrangement
Final Pixel Image 1280X720 1920X1080
720p DMD
1080p DMD
1-6
The data is divided into two subframes, each with half the original data. During one of the
subframes, the image is shifted down by 1/2 pixel. The eye integrates the two consecutive
subframes to create the final image. This process is completd every 1/60 of a second, dis-
playing all of the data, every frame, just as is the case for other traditional DMDs.
The resulting image exhibits the same pixel resolution as the original input data in both hori-
zontal and vertical directions, using half the number of mirrors. The gaps are also minimized
in the process, resulting in an image that is not only full resolution, but smooth in appearance -
without the typical pixel gaps.
1-7
1080p Module Dark Detailer
Dynamic Black
(DB) Module
Figure 1-9: DLP Light Engine - 1080p and Dark Detailer Modules
1-8
Figure 1-11: One Sided Dynamic Aperture
Because some people can experience a “rainbow ef- • The Interface PWB between the Chassis and
fect” due to differences in their persistence of vision, a Light Engine is convenient for troubleshooting.
10,800 RPM Color Wheel is now used in the 2005- • Access to the Electrical Chassis is improved for
2006 DLP product line. This represents a 50% speed troubleshooting and PWB replacement.
increase over last years 7,200 RPM wheel. • LED diagnostics have been expanded to
simplify troubleshooting.
Service Technologies
The 2005-2006 PTV product line carries several tech- These topics will be discussed further in this manual.
nologies that affect service. They are:
• PWBs are constructed with Lead Free Solder. 2005-2006 PTV Product Line
• Mirror area is easier to access on 52” LCD & Specifications for the 2005-2006 PTV product line are
all DLP to simplify cleaning. given starting on the following page.
• Elimination of ribbon cables in the Electrical
Chassis improves reliability.
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1-17
1-18
Chapter 2
Disassembly and Service
V28 / V28+ LCD Optical Engine
FAN-PLATE
LAMP-FAN
LAMP-FAN
BRACKET INTAKE
COVER
LIGHT
ENGINE
PWB
INTERFACE
BALLAST COVER
& BALLAST
ENGINE-PLATE
2
2-1
V29 / V30 / V30+ / V31 DLP Optical Engine
Bottom Plate
Engine Plate
Lamp Fan
(120W Version) (note on 150W version
Lamp Fan is in front)
Ballast Cover
Lamp Cartridge
Interface PWB
Wedge location
Used on 52” and 62” models
after adjustment/before locking
2-2
Engine replacement instructions are included in the applicable service manuals as
well as being included with the replacement part when it is shipped.
LCD engine has a contrast control shutter unit. If this unit is not
functioning the TV may not turn on. Error code can report “5-6”,
you may want to check CN5.
2-3
MODEL-CHASSIS IDENTIFICATION
V29 / V30 / V30+ / V31 V28 / V28+
EXTERNAL TESTING
(WD-52627 PICTURED)
The PWB chassis can be operated outside
of the cabinet for testing. This gives access
for voltage or signal measurements on all
PWBs.
2-4
PWB LOCATIONS TERMINAL-PWB
POWER PWB
RISER PWB
MICRO PWB
FMT PWB
E2P PWB
DM PWB
DEMOD2 PWB
DEMOD1 PWB
2-5
PWB NAME PWB FUNCTION LAYER CIRCUIT
Converts input AC current to DC supply voltages and creates
POWER1 2 layer V28 POWER SUPPLY
ballast board voltage.
Converts input AC current to DC supply voltages and creates
POWER2 2 layer V29 POWER SUPPLY
ballast board voltage.
Analog inputs and outputs for audio and video. Also houses PINJACKS
the audio select circuitry. All analog audio and video AUDIO SWITCH
TERMINAL connected to the terminal PWB are sent to the PWB-MICRO 2 layer
then eventually to the DM for processing before conversion in
the PWB-FMT.
Final processing and amplifier for audio. Main and sub video TV MICRO
switching. TV micro processor and system 5 micro processor PIC MICRO
well as HDMI decoding. HDMI
MICRO 4 layer
AUDIO CONTROL
AUDIO AMP
VIDEO SWITCH
TVGuide data slicer and RS232 transceiver. Accepts G+ (TVGuide)
composite video from SUB-Y signal from video switch on M-LINK (RS232)
RISER 4 layer
PWB-MICRO, slices the data from the carrier signal and
sends it to the PWB-DM.
Digital and analog video/audio signal processing. All video X226 (ATI Xilleon 226)
signals are converted to digital YPrPb and output to PWB- MPEG encoder
FMT. All Audio signals converted to analog left and right A/D converter
DM signals and sent to PWB-MICRO for final processing and 6 layer DPM7
amplification POD (CableCard)
1394
TUNERS
DEMOD1 Demodulates ATSC signal from main tuner. 4 layer T313R
DEMOD2 Demodulates sub signal. V30+ and V31 only 4 layer T310R
Converts digital YPrPb video signal, input from DM, to TMDS SUITE
FMT-V28 (DVI) RGB video signal, output to engine. The format output 6 layer FMT MICRO
is 720p TMDS Transmitter
Converts digital YPrPb video signal, input from DM, to TMDS ADC
(DVI) RGB video signal, output to engine. The format output PRELUDE
FMT-V29 is 1080p 8 layer SUITE
FMT MICRO
TMDS Transmitter
Allows for an analog input connect in the front of the TV. This
FRONT 2 layer Front Inputs
signal is passed to the Terminal PWB.
Receives IR signal from remote control and sends the
PREAMP commands to the TV micro and to System5 micro on the 2 layer Remote Control IR
PWB-MICRO.
Limit switch detects the presence of a filter installed. This
SW-FILTER circuit sends a signal to the TV micro to turn off the TV if a 2 layer Filter Detect
filter is not detected. V28/V28+ only
Limit switch detects the presence of a lamp installed. This
SW-LAMP circuit sends a signal to the TV micro to turn off the TV if a 2 layer Lamp Detect
lamp is not detected.
Houses the lamp/engine/fan protection circuitry. Sends signal FAN CONTROL
INTERFACE to the FMT or the PWB-MICRO to turn TV off if there is 2 layer CONNECTORS
sensor or fan failure.
Front panel control buttons. Sends signal to TV micro on
CONTROL 2 layer Panel Buttons
PWB-MICRO.
EE2PROM stores many of the data variables for adjustment
E2P 4 layer
and other functions.
Generates DC voltages to DLP engine (V29/V30/V30+/V31
ENG-PWR only) 4 layer V29 only : engine power
2-6
MIRROR ACCESS
Remove (10) screws maked “A” below for 52” and 62” models and (19) screws maked “A” below for
73” models. Panel can then be removed to expose the mirror and inside of the upper cabinet
(73” models)
2-7
LCD ENGINE ACCESS PANEL
Remove (2) screws shown below to gain access to the LCD engine area for cleaning of debris
(V28/V28+ only).
2-8
Lead Free Solder Displays used to indicate Pb-free
Mitsubishi's 2005-2006 product line, including the V28, PCBs will be marked, indicating the level of Pb-free
V29, V30 and V31 chassis, will be constructed using construction. Table 2-1 defines the levels by phase and
lead free solder. shows the different symbols that will be displayed on
the PCB. Additionally, a PCB constructed using Pb-
This is the first part of a 3 phase program to eliminate free solder may be simply marked LFS.
the lead content in all MDEA's electronic products. The
3 phases are: When possible, the indication will be placed close to
• Phase 1… PCB's constructed using Pb-free the part number that is screened onto the PCB (not the
solder. PCB surface finishing and components part label). Figure 2-1 is an example of a PCB show-
may contain Pb. ing the display and its location.
• Phase 2… Solder, PCB surface finishing and
component lead plating is Pb-free. Components Pb free solder differs from conventional leaded solder.
may have internal Pb. • The amount of tin in Pb-free solder is greater.
• Phase 3… Solder, PCB surface finishing and • The melting point of Pb-free solder is higher.
components are Pb-free. (100% Pb-free)
Pb-Free
Display
2-9
Also, Lead-free solder does not "wet" as well as leaded Temperature… Use the same soldering temperature
solder. That means it has trouble adhering to both the as you would with tin-lead solder, about 700 F. If hot-
soldering iron tip and the surface being soldered. To ter, you may be making it more difficult to solder. The
counteract this, the flux used is more corrosive. Lead- higher temperature causes oxidation to form faster, mak-
free solder also does not change from solid to liquid or ing wetting even more difficult. Excessive temperatures
back again all at once. It passes through a soft state. can also lengthen the cooling time, allowing micro-cracks
So, the melting process actually occurs through a range to form within the joint.
of temperatures.
Thermal Recovery… Use a soldering iron with good
This makes a significant impact when repairing PCBs thermal recovery. When the iron is first applied to a
using Pb-free solder. Problems that can be encoun- cool joint, the heat transfer causes the tip temperature
tered working with Pb-free solder are: to drop. A higher powered iron will bring the tip back
• Excessive heat can cause the PCB to warp, up to the proper temperature faster. Using a shorter tip
detaching surface mount components. will also improve thermal recovery.
• Excessive heat may cause thermal damage to
components. Thermal Conduction… Use the widest tip possible in
• Excessive heat can cause plastics such as relation to the joint being soldered. This will allow the
connectors, relays, LEDs, electrolytic capaci- heat to conduct to the joint better. Also keep the tip
tors, etc. to melt or warp. wetted for better heat transfer.
• Higher temperatures can cause surface oxida-
tion resulting in poor solder spread-ability and Tip Cleanliness… Important! Keep the soldering
wet-ability. iron tip clean at all times using a damp sponge. Re-tin
• The flux is more corrosive. the tip before returning the iron to its stand. To extend
• The time required for a good solder connection the tip life, do not leave the iron on when it is not being
may be longer. used for longer periods of time.
• Poor wet-ability can cause solder balls.
• Higher temperatures can cause flux spattering. De-soldering… For the same reasons as soldering,
• Soldering iron tip life is shortened. increasing the temperature for de-soldering is not desir-
• Duller finish solder joint can appear to be a able. However, if a vacuum de-soldering tool is used,
"cold" solder joint. the solder must remain molten from the tip, all the way
to the entrance to the filter. If the solder hardens along
Pb-free Hand Soldering the way, it can clog the tool.
Hand soldering with lead-free solder doesn’t necessar-
ily require higher soldering temperatures. The melting Solder
time will be slightly slower than with leaded solder, re- When performing repairs, it is necessary to use solder
quiring an increase in contact time. The solder joint will as that is compatable with that used in the original manu-
also look different. It will have a dull finish that is similar facture. Leaded solder cannot be used when soldering
in appearance to a "cold" solder connection when using PCBs manufactured with Pb-free solder. And, Pb-free
leaded solder. solder cannot be used on PCBs manufactured using
leaded solder.
To help eliminate problems working with lead free sol-
der, consider the following points. The Mitsubishi standard for service requires the use of
Tin-Silver-Copper ( Sn-96.5, Ag-3.0, Cu-0.5) solder.
It can be obtained through the Parts Department.
Order part number: PB FREE SOLDER
2-10
Chapter 3
Adustments
Service Mode
Activation of the Service Mode is also the same
on all chassis, Press “MENU-2-4-5-7”. The
procedure for using the Service Mode has not
changed:
• “AUDIO” selects a function
• “VIDEO” selects a specific adjust-
ment item
• “UP & DN’ buttons adjusts data
• “ENTER” saves data changes.
3-1
Data Transfer MENU-2-4-5-7-0
Display Description
Copy Engine E2PROM to DM Transfers Engine data to DM E2PROM
Restore Backup Restores data to factory values
UPLOAD TERMINAL BOARD DATA DO NOT USE
Download WB Alignment to FMT Transfers Engine data to FMT
Table 3-2: DLP Chassis Data Transfer Choices
Red = 4% overscan
White = 5% overscan
Green = 6% overscan
Cyan = 7% overscan
Yellow = 10% overscan
3-2
V28 Mechanical Adjustments
In the V28 chassis, the Mechanical Adjuster is accessed Preliminary
from the rear. Refer to the disassembly instructions and (Refer to Figure 3-3)
remove the BACK-COVER. 1) Loosen the Fixing Screw (1) and (2) in the
Slide -Lock-Mate.
Tools Required: 2) Loosen Nuts (1) and (2) on the Adjuster
• 2mm L shaped Allen wrench 3) Loosen [A-1] and [A-2] on the Adjuster (4mm
• 4mm L shaped Allen wrench Allen wrench)
• Hex wrench
3-3
Keystone Distortion Adjustment
(Figure 3-4)
1) Loosen [A-1] and [A-2] so they clear
[A-3].
2) For distortion at the top of the picture
rotate [A-3] counter-clockwise.
3) For distortion at the bottom of the pic-
ture rotate [A-3] clockwise.
Rotation Adjustment
(Figure 3-5)
Clockwise Rotation Needed
1) Loosen [A-2].
2) Use [A-1] to adjust rotation.
After Adjustment
1) Tighten Nuts (1) and (2).
2) Tighten Slide Lock-Mate screw (1) and (2).
3) Insure [A-1] and [A-2] are flush against [A-3
3-4
DLP Chassis Mechanical Adjustments
Test Signal Activation Required Tools
Use the same procedure as in the V28 chassis. • 4mm hex wrench (10 inches long mnimum)
(MENU-2-4-5-7-REW) • 5mm Allen wrench (10 inches long minimum)
• 10mm hex or Phillips driver
Prelminary
Mechanical Optical Engine Adjustments are made using the UNIT-ADJUSTER shown in Figure 3-6. The UNIT-AD-
JUSTER is mounted under the Light Engine on the Engine Plate. It is accessed from the front of the set through the
opening for the Card Reader. Refer to the model specific Disassembly Instructions and remove the:
• Back Cover
• Speaker Grille
• Card Reader
[A-1]
VERT. KEYSTONE
[A-2]
4mm Hex
ROTATION
4mm Hex
[B-1] [A-3]
LOCKING SCREW HORIZ. KEYSTONE
5mm Allen Wrench 4mm Hex
3-5
RUBBER
WEDGE
Adjustment Procedures
Adjustment Locations
The Mechanical Adjustment are accessed through the CAUTION: Do Not force an adjustment past
front opening for the Card Reader. Locations of the the end of it’s range, UNIT-ADJUSTER damage
adjustments are shown in Figure 3-9 may result.
[A-2]
[A-1]
Access
[A-3]
[B-1]
3-6
Rotation Adjustment
Adjust [A-2] to remove any picture rotation
After Adjustment
1) Slide the rubber wedge under the Engine slowly until it makes solid contact. (Figure 3-8 and Figure 3-11)
2) Tighten side locking screw [B-2]. (Figure 3-7)
3) Check the picture, re-adjustment may be required (usually Rotation).
4) Tighten front locking screw. (Figure 3-9)
RUBBER
WEDGE
3-7
Electrical Adjustments
The only Servicer electrical adjustments are picture position (centering). These adjustments are the same on all
chassis (V28 / V29 / V30 / V30+ / V31). They are also the same as last years DLP models. They are repeated here
as a reference.
3-8
Chapter 4
Down-to-1 Troubleshooting
The goal of Down-to-1 troubleshooting is… using a
minimum amount of time and test equipment, make
an accurate diagnosis of a failure 9 out of 10 times.
The 2005-2006 Micro-Display product line lends itself
to this discipline very well.
Figure 4-1: Front Panel LEDs
Using The Front Panel LEDs
The front panel LEDs, Figure 4-1, provide an indica- Normal Indications… The LEDs provide the cus-
tion of the sets operation, and the possible cause of a tomer with status information that indicates several nor-
malfunction. There are three front panel LEDs, “Power”, mal operational modes. Normal indications are give in
“Status” and “Lamp”. Which LED is lit, the color and Table 4-1.
whether it is blinking or steady indicates to the customer
the current status, or a possible malfunction. Using the Abnormal Indications… The LEDs also provide the
Front Panel LEDs is similar for LCD and DLP based customer with status information indicating abnormal con-
sets. The indications are also listed in the Owners Guide. ditions. Abnormal indications are give in Table 4-2.
Normal LED Indications
POWER STATUS LAMP Power
Condition
LED LED LED Status
Off Off Off Stby Off
Green Off Off P-0N Power On
30
Blinks Set cannot be turned On until
Off Off Seconds
Green Lamp has cooled.
After Off
Blinks
Off Off Stby Booting after AC applied
Green
Slow Blinks
Off Off Stby On Timer is set
Green
Table 4-1
4-1
Self Diagnostics…When an abnormal condition is in- 1) With the TV Off
dicated by the front panel LEDs. Or, when the TV turns 2) Press and hold the front panel "MENU" and
On and then shuts Off, the Self Diagnostics help isolate "DEVICE" buttons for 5 seconds.
the problem. This is similar to the Self Diagnostic fea- 3) The LED will flash the Error Code indicating
ture on previous model TVs. For both the V28 and what caused the TV to shut Off.
V29/30/31 Chassis, it has been greatly expanded. 4) The Error Code will be repeated 5 times.
When the LED stops flashing, the mode is
The Self Diagnostics activation procedure is described automatically terminated.
as follows:
4-2
Interface Troubleshooting Figure 4-2 shows the layout of the Interface for the
The Interface PWB provides the service technician with LCD, V28 Chassis. Figure 4-3 shows the layout for
a convenient test point for many of the peripheral com- the DLP, V29/30/31 chassis. These layouts are as the
ponents such as the Engine, Lamp Circuit, Fans and technician is viewing the PWB from the rear of the set.
Sensors. It is easily accessible as it is located in the
center of the set, directly in the rear of both the LCD To save time, use the Symptom/Cause information along
and DLP models. with the Circuit Block Diagrams to make checks on the
Interface PWB first.
V28
Figure 4-2: V28 Chassis PWB Interface Layout… As viewed from the rear.
V29/30/31
Figure 4-3: V29/30/31 Chassis PWB Interface Layout… As viewed from the rear.
4-3
Symptom/Cause Troubleshooting • Power Supply PWB
Use the following symptom/cause charts to determine • Micro & Terminal PWB
the most likely cause of a failure.
First use the PWB Symptom Cause chart to narrow
The areas covered are: down the problem to a PWB. Then check the connec-
• PWB Symptom/Cause tions to the PWB specified. The additional charts can
• Optical Engine help repair the set without ordering a PWB.
4-4
OPTICAL ENGINE TROUBLESHOOTING
Sym ptom Ca use W ha t to che ck
FMT does not turn on lamp due to fault Check error code on front pannel. Check problem
detection indicated.
No DC supply to ballast Check power PW B PL connector for approx. 340VDC.
Check connec tions PL-JE, JE-CN2
No Light
No Lamp enable signal Check FMT output Lamplitz FB pin 1. Check
connections FB-FB, CJ3-CJ3
Lamp end of life Repace lamp and check
Ballast Broken Replace ballast and check
FMT does not turn on video Check diagnostic code. Check circuit indicated.
No DVI cable not connec ted chec k DVI c onnections
Picture, Engine power missing Check connec tions PA2-CN102
bad Engine is blanked. Check control connec tions FC-FC, KC-CN3100.
picture FMT not providing video signal Check FMT Board.
Engine broken Replace engine and check.
High No power to Shutter Check 18V from Power board PB pin4. Check
Contrast connections PB-PB, KD-CN1
Unit not No c ontrol of shutter Check connec tions CN5-JG, JG-KD, KD-CN2
W ork ing FMT does not control shutter Replace FMT and check.
(V28) Shutter broken Replace engine.
Fan not working. Temp s ensor. Check error code and chec k indicated fan or s ensor.
Set Shuts Filter clogged (V28) Check filter and clean or replace.
down after Temp sensor problem Check error code. Check connections DT-KB, LT-KB.
a while Check sensor
Air path blocked Check air flow from each engine fan.
4-5
POWER PWB TROUBLESHOOTING
SYMPTOM CHECK POINT POSSIBLE CAUSE
Check +15VS @ connector PD pin 1 Check Q9E00 circuit
ERROR CODE 51
Check -15VS @ connector PD pin 7 Check Q9E00 circuit
Check doubler circuit
ERROR CODE 34 Check 340VDC @ connector PL
Check ballast circuit
IC9A24 circuit
Check 3.3V @ connector PA2 pin 1
ERROR CODE 48 Zener D9A43
Check 18V @ L9A45/C9A82 Q9A13 circuit
IC9A23 circuit
Check 12VS @ connector PD pin 14
Zener D9A41
IC9A21 circuit
ERROR CODE 41 Check 5VS @ connector PC pin 8 Q9A12 circuit
Zener D9A47
F9E10
Check 4.5V @ connector PD pin 19
F9E11
CHECK ALL FUSES
T9A10 circuit
Check 18V @ TP18VS
IC9A10 circuit
NO POWER
IC9A22 circuit
Check 5VSL @ connector PD pin 16
Zener D9A39
Check connector PD pin 20 for HIGH (active) PC9A21 circuit
4-6
M icro & T erminal PWB T roubleshooting
Sym ptom Possible Ca use s
4-7
4-8
Chapter 5
Block Diagrams & Signal Path
The simplified Block Diagrams should help in isolating In the V30+ and V31 chassis models, a Hard Disc Drive
problems to a specific PWB. (HDD) has been added. The additional Power Supply
5-1
PWB Part Number Models
ASSY-PWB-POWER1 930B933001 All V28 models
WD-52627 / WD-52628 / WD-62627 /
ASSY-PWB-POWER2 934C159001
WD-62628 / WD-73727
WD-62727 / WD-62927 / WD-73827 /
ASSY-PWB-POWER2 934C159002
WD-73927
Table 5-1: PWB-POWER Part Numbers
for the HDD is located on the PWB-POWER for these Switch Mode Regulator
two chassis types. The Switch Mode Regulator (SMR) on the PWB-
POWER is the initial source for all DC Supplies except
Due to differences between the various chassis there the DC supply for the Ballast.
are three version of the PWB-POWER. These are listed
in Table 5-1. Figure 5-2 shows a simplified diagram of the Switch
Mode Regulator. This circuitry is conventional and is
5-2
the same on all three of the PWB-POWER boards. It Although the SMR circuitry is the same on all PWB-
is the original source for both Standby and Switched POWER boards, the Standby and Switched DC to DC
supplies. Converter circuitry does vary according to chassis type.
5-3
Figure 5-3A: V28 PWB-POWER DC to DC Supplies
5-4
Figure 5-3B: DLP PWB-POWER DC to DC Supplies
5-5
Ballast DC Supply
This circuit is the same on all three
Power boards. A simplified version
of the circuit is shown in Figure 5-4.
5-6
Figure 5-6: V29/V30/V30+/V31 Fan Supplies
5-7
Figure 5-7: DLP Engine Power Supply
5-8
Figure 5-9
5-9
Figure 5-10
5-10
Video Signal Path The selected Main and Sub Video signals are directed
Analog Video Path through the PWB-RISER to A/D Converters on PWB-
The Video signal path is also similar on all the chassis DM. The outputs from the A/D Converters are directed
types. Figure 5-11 illustrates the Basic Analog Video to 3DYC, Line Double and PIP/POP circuitry.
Signal Path. The Tuners are located on the PWB-DM.
The Analog video from the Tuners is directed through The signals from the PWB-DM are directed to the
PWB-RISER to the Video Select Circuitry on PWB- PWB-FORMAT. The signals are digital Y,Pb,Pr. In
MICRO. the V28 chassis the signals are in 720p format. In the
DLP chassis the signals are in the 1080i format.
The Video Select circuitry is comprised of IC2K01 and
IC2KO2. IC2K01 selects the Sub Video signal source On the PWB-FORMAT the signals are processed and
and the External Video Input source for the Main Pic- converted to the drive format for that specific Engine. In
ture. It then forwards the External Main Picture signal the DLP PWB-FORMAT, the signals are converted from
to IC2K02. IC2K02 selects the main picture source 1080i to 1080p.
from the signals from IC2K01, an External Component
input or the Main Tuner..
5-11
Digital Video Signal Path In the V31 chassis a conventional VGA input is added
Figure 5-12 illustrates the Basic Digital Video Signal on the PWB-FORMAT.
Path. The Digital Signal output from the Main Tuner is
an I.F. signal. The signal from the Main Tuner is di- Note the in the V30+ and V31 chassis the PWB-
rected to PWB-DEMOD1. DEMOD2 is added to process HD signals from the Sub
Tuner. This allows the Sub Tuner HD signals to be se-
The Demodulated Output (MPEG) signals are direct lected as the PIP/POP sub picture signal source.
back to PWB-DM and via the POD circuitry to the
MPEG Decoder. The output of the MPEG Decoder is As a reference for troubleshooting, Figures 5-13 through
processed by Doubler and PIP/POP circuitry and is di- 5-15 are more detailed Video Signal Path diagrams:
rected to the PWB-FORMAT. Figure 5-13: Analog Video Signal Path
Figure 5-14: Digital Video Signal Path
Note that Prelude and A/D Converter circuitry added Figure 5-15: Record Signal Path
in the DLP chassis PWB-FORMAT. These used for
signal conversion to 1080p and to process signals from Shaded Areas differ from the V28 circuity.
a PC. In V29 through V30+ chassis PC connection is
though one of the HDMI inputs on the rear of the TV.
5-12
Figure 5-13: Analog Video Signal Path
5-13
Figure 5-14: Analog Video Signal Path
5-14
Figure 5-16: Sound Signal Path
Sound Signal Path
Figure 5-16 shows the Sound Signal Path in both LCD The only new circuitry is Speaker Short Detect circuit
and DLP chassis. The Sound Circuitry is the same on shown in Figure 5-17.
both LCD and DLP chassis. IC3J01 on PWB-TER-
MINAL select the analog sound signal source.
The selected signal is directed to PWB-DM.
The signal is converted to a digital I2S format
and is applied the Digital Sound Selection por-
tion of the HD Processor.
5-15
Control Circuitry
Overall Control Circuitry • IC8G01 FORMAT µPC on PWB-FORMAT
There are 5 Control µPCs in the LCD and DLP chassis. • IC7R05 TVGOS µPC on PWB-RISER
• IC7A00 TV µPC on PWB-MICRO
• IC8001 DM µPC on PWB-DM Figure 5-18 shows the interconnect paths between the
• IC7P01 SYS-5 µPC on PWB-MICRO five µPCs, and the command input paths from the Re-
mote Control and the Front Panel buttons.
5-16
Lamp Control Circuitry
Figure 5-19 shows the Lamp Control Circuitry in V28 Figure 5-20. Mainly in the V28 the LAMP-EN com-
chassis, and Figure 5-20 the circuitry in the DLP chas- mand is from the FMT µPC, and in the DLP chassis it
sis. Differences from the V28 chassis are shaded in comes from the Light Engine
5-17
Engine Protect Circuitry DET status line. The FILTER-DET line is shaded in
This circuitry monitors the temperature in the Light En- Figure 5-21.
gine, and Lamp, and also monitors the operation of the
various cooling fans. Figure 5-21 shows the Engine Short & Speaker Protect Circuitry
Protect circuitry in the V28 chassis, and Figure 5-22 As a quick reference, the Short Protect circuitry is illus-
the Engine Protect circuitry in the DLP chassis. The trated in Figure 5-23 There are two Short Protect cir-
main difference between the two circuits is there is no cuits, one for Standby Supplies and one for Switched
Air Filter in the DLP chassis, so there is no FILTER Supplies (PON supplies)..
5-18
Figure 5-22: DLP Engine Protect Circuitry
5-19
5-20
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