Sanyo PDP-63XR7HB User manual

Brand: Sanyo

Model: PDP-63XR7HB

Category: CRT TVs

Type: User manual

CONTENTS

Safety precautions………………………………………………………………………..…

Alignment instructions …………………………….…….…………………………………

Method of software upgrading……………………………………………………………..

Working principle analysis of the unit……………………………….………….………….

Block diagram…………………………………..………………………………….…………

IC block diagram………………………………………………………………………..……

Wiring diagram …………………………………………………………………………….

Troubleshooting guide ………………………………………………………………..……

Schematic diagram…………………………………………………………………………

APPENDIX-A: Assembly list

APPENDIX-B: Exploded View

Stand installation

Wall mounting instructions

Safety Precautions

Please read the “Points for attention for the Maintenance & Repair of PDP” and “Criterion for

Identifying the Defects on Screen” as below, before inspecting and adjusting the TV set.

1. “Points for attention for the Maintenance & Repair of PDP”

To avoid possible danger, damage or jeopardy to health and to prevent PDP screen from new

damage, the maintenance people must read the following carefully. If they ignore the following

warnings, there will be deathful risks:

1.1 Screens vary from one model to another and therefore not interchangeable. Be sure to use

the same type of screen in the replacement.

1.2 The operation voltage is approximately 350V for PDP module (including screen, driving

circuit, logic circuit and power module). If you want to conduct maintenance work on PDP

module when the set is in normal operation or just after the power is off, you must take proper

measures to avoid electric shock and never have direct contact or touch with the circuitry of the

working module or metal parts. That’s because within a short time relatively high voltage still

remains on the capacitor of the driving part even after the power is off. Make sure to begin

relevant maintenance operation at least one minute after the power is off.

1.3 Don’t apply on the module any power supply that is higher than the specification. If the

power supply used deviates from the value given in the specification, there might be a

possibility of leading to fire or damage to the module.

1.4 Never have operation or mounting work under unsuitable environment such as areas in the

vicinity of water – bathroom, laundry, water chute of kitchen – sources of fire, heat-radiation

parts or direct exposure to sunlight. Otherwise there will be kickbacks.

1.5 In case foreign substances such as water, liquid, metal slices or others fall into the module

carelessly power must be cut off immediately. Keep the module as it is and do not move

anything on the module. Otherwise it might be possible to contact the high voltage or cause

shock short circuit so that it may lead to fire or electric shock.

1.6 If there is smoke, abnormal smell or sound from the module, please cut the power off

immediately. Likewise in case the screen doesn’t work when the power is on or during the

operation, please also cut off the power at once. No more operation in this case.

1.7 Do not remove or plug its connection wire when the module is in operation or right after the

power is off. That’s because there remains a relatively high voltage on the capacitor of the

driving circuit. If there is a need to remove or plug in the connection wire, please wait at least

one minute after the power is off.

1.8 Considering the module has a glass faceplate, please avoid extrusion by external force lest

it should cause glass breakage that may get people injured. Two people are needed in

cooperation to move this module lest contingency takes place.

1.9 The complete TV set is designed on the basis of full consideration of thermal dissipation by

convection, with the round hole on the top for heat emission. To avoid overheat, please do not

have any covering on the hole during normal operation and never put it in the place where the

space is narrow and in bad ventilation.

1.10 There is quite a number of circuits in PDP that are integrated ones. Please be on guard

Note: This maintenance manual is intended only for the reference of the maintenance people.

Please pay attention to the following points before carrying out the maintenance work.

against static electricity. During maintenance operation be sure to cover yourself with anti-static

bag and before operation make sure to have it sufficiently grounded.

1.11 There are a big number of connection wires distributed around the screen. Please take

care not to touch or scuff them during maintenance or removing the screen, because once they

are damaged the screen will fail to work and it’s not possible to repair it.

If the connection wires, connectors or components fixed by the thermotropic glue need to

disengage when service, please soak the thermotropic glue into the alcohol and then pull them

out in case of damage.

1.12 Connector for the circuit board of the screen part is relatively fine and delicate. Please

take care in the replacement operation lest it should get damaged.

1.13 Special care must be taken during transportation and handling because strenuous

vibration could lead to screen glass breakage or damage on the driving circuitry. Be sure to use

a strong outer case to pack it up before transportation or handling.

1.14 Please put it for storage in an environment in which the conditions are under control so as

to prevent the temperature and humidity from exceeding the scope stipulated in the

specification. For prolonged storage please cover it with anti-moisture bag and have them piled

and stored in one place. The environmental conditions are tabulated as below:

Temperature Scope for operation 0~50centigrade

Scope for storage -15~60centigrade

Humidity Scope for operation 20%~80%

Scope for storage 20%~80%

1.15 If a fixed picture is displayed for a long time, difference in its brightness and color may

occur compared with movable pictures. But it doesn’t show any problem and the reason is that

there is reduced density of fluorescent powder in the former. On the other hand, even if

changes take place in the picture, it can keep its brightness for a period of time (several

minutes). It’s a feature inherent with plasma and it’s not abnormal. However please try as much

as possible to avoid showing a still picture of high brightness for a long time during operation.

1.16 As a digitalized display devise, this module is provided with error diffusion technology and

the gray scale and false enhancement of contour can be displayed by reusing of sub-field. As

compared with cathode ray tube, it can be found in the moving picture that at the brim of the

face of a person there are some wrong colors.

1.17 During the display of graph (indicating the gradual change in brightness horizontally or

vertically) resulting from gray scale test it can be found that the brightness for the two adjacent

levels is uneven. This is caused by the reuse of sub-field, the display of load rectification and

the electrolysis.

1.18 The screen front plate is of glass. Please make sure that the screen has been put in place

during erection. If it is not in place before the erection begins it may lead to screen crack or

breakage.

1.19 Make sure the screw used in the mounting of the screen is of the original specs lest it

should cause damage to the screen due to mismatch. Special care should be taken not to use

too long or too big screw.

1.20 Care must be taken to guard against dust during assembling or dismantling, especially to

avoid dirt from falling in between the screen and the glass lest it should harm the receiving and

viewing effect.

1.21 There is piece of insulator stuck on the rear chassis corresponding to the power supply

board. It is used to isolate the cool part from the hot part. Please take care to keep it intact lest

it should become a potential safety trouble.

1.22 In addition to plasma screen, the glass is a part of high value. It has such functions as

anti-radiation, adjustment of color temperature etc. Please handle it carefully.

Alignment instructions

1. Alignment equipment

PM5515 (video signal generator)

VG-848/VG-849 (YUV,VGA,DVI/HDMI signal generator)

CA100 (white balancer)

2. Alignment flow-chart

The alignment flow-chart is shown as fig-1

Fig-1 adjustment flow-chart

Check if DDC and FLASH are flash written

To produce main board and analog board

All testing

White balance adjustment

Connect with central signal source, then check each function of TV such as

station leaking, analog control etc., check the output of headphone and speaker

Input AV/SVIDEO and HD signal, then check each function of all the terminals

Input VGA, HDMI signal, check if the display is normal, check eac

function such as analog control etc., check horizontal /vertical center etc.

Preset ex-factory

Check the accessories and pack them in box

Check RS232 function.

3. Adjusting instruction

3.1 Unit adjustments

Connect all the boards according the wiring diagram, then power on and check if the display is

normal.

The method for using factory menu

The first press the “source” button, then press the “2580“ buttons enter factory menu. Press the

“SLEEP” button to select the adjustment page menu, press ▲and ▼to select item, press ◄and

► to adjust the value, press “MENU” button to exit the factory menu. If the unit does not turn off,

you can press the “SLEEP” button to enter factory menu again. Turn off the unit to exit the

factory menu.

3.2 EEPROM initialization

Enter page one of the factory menu, select the EEPROM INITIALIZE to ON, turn off the unit

then turn on again.

Note: it needs a little long time to display the LOGO after turn on again.

3.3 White balance adjustment

The 16 level gray-scale signal (DVI:TIMING978 PATTAN921, HDMI:TIMING853, PATTERN992)

sends to DVI/HDMI channel from VG-848/VG-849, enter the user menu and set color to 0, then

enter the factory menu white balance adjustment page. Select the normal color temperature

item, fixed GGAIN to be 128, adjust B, RGIAN to let the third color coordinate on the right be

(280, 290); fixed the GOFFSET to be 128H, adjust B, ROFFSET to let the third color coordinate

on the left be (280,290) at 5 nits.

Select the cool color temperature, adjust the color coordinate be (270, 283)

Select the warm color temperature, adjust the color coordinate be (300, 320)

After adjustment, switch to AV, VGA and YPbPr and have a check. If there is some deviation in

some channel, please adjust it independently.

Note: after adjust the white balance in HDMI, it will store the data to other channels.

4 Performance check

4.1 TV function

Connect RF-TV terminal to the central signal source and enter the setting menu, set the

country category, then enter the search menu → auto search, , check if there is station skipping.

Check the manual search, fine turning, the output of speaker and earphone and picture. Open

the PIP and POP modes, connect the earphone and check the display and sound.

4.2 AV/S-video input terminal

Input AV/S signal, check if the picture and sound is normal. Open the PIP and POP modes,

connect the earphone and check the display and sound.

4.3 YPbPr /YCbCr terminal

Input the YUV signal (VG-848 signal generator), separate input YUV format signal of table 1,

check if the image and sound is normal. If the image is deflection of the H-field, select auto

sync correction of the SCREEN menu. If the image is slight disturb, adjust the FINE TUNE

correction of the SCREEN menu. Open the PIP mode, connect the earphone, and check if the

image and sound is normal.

Table 1 YUV format signal

No H-frequency (KHz) V-frequency (KHz) Signal

15.734 59.94 SDTV 480i

31.469 59.94 HDTV 480p

44.955 59.94 HDTV 720p

33.716 59.94 HDTV 1080i

67.5 60 HDTV 1080P

15.625 50 SDTV 576i

31.25 50 HDTV 576p

37.5 50 HDTV 720p

33.75 50 HDTV 1080i

56.25 50 HDTV 1080P

4.4 VGA terminal

Input the VGA signal (VG-848 signal generator), separate input VGA format signal of table 2,

check if the image and sound is normal. If the image is deflection of the H-field, select auto

sync correction of the SCREEN menu. If the image is slight disturb, adjust the FINE TUNE

correction of the SCREEN menu. Open the PIP mode, connect the earphone, and check if the

image and sound is normal.

4.5 HDMI terminal

HDMI signal format receive the three high definition signal: 480P, 576P, 720P/50/60Hz,

1080I/50/60Hz, 1080P/50/60Hz except for the table 2 signal. Check if the image (contain

HDCP ON and OFF) and sound is normal (use VG-849 generator). If the image is deflection of

the H-field, perform manual correction according the SCREEN menu. Open the PIP mode,

connect the earphone, and check if the image and sound is normal. Input DVI audio signal and

check if it is normal.

TABLE2 VGA signal format

No Resolution H-frequency(kHz) V-frenquency(Hz)

Point clock pulse

frenquency(MHz)

Remark

1 720x400 31.469 70.086 28.322 IBM

640x480 31.469 59.94 25.175 IBM

3 640x480 37.861 72.809 31.5 VESA

4 640x480 37.5 75 31.5 VESA

640x480 43.269 85.008 36 VESA

6 800x600 35.156 56.25 36 VESA

800x600 37.879 60.317 40 VESA

8 800x600 48.077 72.188 50 VESA

800x600 46.875 75 49.5 VESA

10 800x600 53.674 85.061 56.25 VESA

1024x768 48.363 60.004 65 VESA

12 1024x768 56.476 70.069 75 VESA

13 1024x768 60.023 75.029 78.75 VESA

14 1024x768 68.667 84.98 94.486 VESA

15 1280x1024 63.98 60.02 108.00 VESA

4.6 Clock function

Enter user menu clock setting item, set the clock and calendar then power off, power on again

and check if the clock and calendar is stored.

4.7 RS232 function

Connect to RS232 port of PC, check if the control is normal.

4.8 Ex-factory setting of user menu

1) select TV channel

2) picture menu, Mode: Standard, color temperature: nature

3) sound menu, Volume: 20, Balance: 00, Earphone volume:20, Mode: music, BBE: off, AVC:

off

4) image menu, Mode: Auto

5) channel menu, Color mode: Auto, Sound mode: DK

6) setup menu, Child Lock: Off, Menu Language: English, OSD transparency :7, OSD time out:

15s, Blue Screen: On.

Note: the 4) and 5) items should be set according to clients require. The user menu may be

different depending on the clients.

5. Method for software flash-written

Some chips should be flash-written first then be paste, the method is shown in talbe3.

No. Code Type Function

Written

before

paste

Method

NA01 5272402002 IC_AT24C

02BN10S

U-1.8

First road

HDMI

EDID

Yes

Program code 568HW0002B, instrument

ALL-100, “select factory”: ATMEL/Serial

EPROM/type AT24C02, click “Run’ to load

the program, select “Binary”, “FF”, then

press “OK”.

NA02 5272402002 IC_AT24C

02BN10S

U-1.8

Second

road

HDMI

EDID

Yes

Program code 568HW0006H, instrument

ALL-100, “select factory”: ATMEL/Serial

EPROM/type AT24C02, click “Run’ to load

the program, select “Binary”, “FF”, then

press “OK”.

NA03 5272402002 IC_AT24C

02BN10S

U-1.8

Third road

HDMI

EDID

Yes

Program code 568HW0006I, instrument

ALL-100, “select factory”: ATMEL/Serial

EPROM/type AT24C02, click “Run’ to load

the program, select “Binary”, “FF”, then

press “OK”.

NB02 5272421001 IC_24LCS

21A/SN

VGA EDID Yes

Program code 568HW0003C, instrument

ALL-100, “select factory”: ATMEL/Serial

EPROM/type AT24C21, click “Run’ to load

the program, select “Binary”, “FF”, then

press “OK”.

N601 5270915001 IC_P89LP

C915FDH

Power

manage

Yes

Program code 568HW0017D, instrument

ALL-100, “select factory”: PHILIPS

/MPU/MCU/type 89LPC915, click “Run’ to

load the program, select “intel HEX”, “FF”,

then press “OK”.

N802 5272900801 IC_S29AL

008D70TF

I020

Main CPU

program

Yes

Program code 568HW0017A, instrument

ALL-100, “select factory”: SPANSTON /

EEPROM/FLASH/type S29AL008D -TF-02,

click “Run’ to load the program, select

“Binary”, “FF”, then press “OK”.

N803 5272432001 IC_24LC3

2A/SN

E2PROM No

Method of software upgrading

1. Software install instrument

a) Double click “PXSDKToolkitV1.0.5” to install the upgrade flat

b) Execute “ISPWriter3.exe” to enter IAP program

2. Instrument

Upgrade board (667.42HW36-90), USB wire (one male terminal and one mini terminal),

VGA cable(665.D0002-510 with pin4 and pin11)

3. Upgrade method when the unit is normal

a) Click “ISPWRITER3” icon on the desk to open the upgrade software, click “OPEN” of

the tool bar to begin communication, enter the factory menu and select “Enter Update

Mode” of the first OSD page to enter the upgrade mode.

b) Click “BIN” of the tool bar and select the upgrade software, click “PROG” on the tool

bar to begin upgrade.

3. BIN 5. PROG

Select the upgrade software

c) The upgrade is over when appear “ISP OVERFLOW”, click “Reboot” of the start-up

the unit, then the upgrade is complete.

4. Upgrade method when the unit can power on normally

Click “ISPWRITER3” icon on the desk to open the upgrade software, click “OPEN” on the tool

bar to begin communication, then click “DIAL” on the tool bar to test the state of the unit, power

on the unit now to enter the upgrade automatically, then perform according 3), 4).

6. Reboot

Working principle analysis of the unit

Antenna reception signal RF will be sent to integrative tuner (contain HF and IF amplifier circuit), the

tuner is controlled by the command (SDA and SCL) of the MCU N801(M16C), select appropriate

channel to system switch, via HF amplifier and IF amplifier decode, output video signal CVBS and

second sound signal SIF.

CVBS, AV1, AV2, S-Video signal (Y signal of S-Video and AV1 video share the same channel) and

D-SUB signal via matched resistance, the signal separately through alone channel send to main IC

NS01 (SVP-WX68) video switch, A/D transition, digital decode, image scale and OSD superposition,

then send to LVDS level drive for LCD screen.

Video signal of YPbPr1, YPbPr2 via matched resistance to video switch NB05 (PI5V330), after

switch the select signal will be sent to main IC NS01 (SVP-WX68) video switch, A/D transition,

digital decode, image scale and OSD superposition, then send to LVDS level drive for LCD screen.

HDMI1, HDMI2, HDMI3 digital signal via digital video switch NA04(PS301), select one signal to

send to main IC NS01 (SVP-WX68) video and audio separate first, video signal via digital decode,

image scale and OSD superposition to output LVDS level drive for LCD screen; digital audio signal

I2S will be sent to N103 (SGTV58xy audio process and volume control).

Audio signal of AV1, AV2(AV1 and S-Video share the same audio channel), YPbPr1, YPbPr2.

D-SUB/DVI HDMI and SIF signal will be sent to audio processor N103 (SGTV58xy) sound switch,

the select signal output through three ways. One way via volume, treble and bass control, sound

effect processing, then separate to left and right channel and send to sound amplifier NA01,

NA02(TPA3001D1) amplifying, then send to speaker; one way also separate to left and right

channel and send to earphone amplifier N104 (NJW1109) volume control and amplify, then send to

earphone socket; the other way send to AV OUT.

SDA/S I/O

I2C

I2 C

SIF1

HDMI I2S

AV Out

Mono TV-CVBS

D-SUB Audio

AV1 CVBS/ S_Video-Y LVDS

YPbPr2

S_Video- C

YPbPr1

AV2 CVBS

AV2

I2C

AV1/SV

RGB

YPbPr1

YPbPr

Program Update

YPbPr2

I2C

HDMI

IR / KEY / LED

Power

Standby Control

SVP-WX68

ADC

Decoder

Deinterlace

Scaler

Lvds driver

DDR

(4X32 Mbit)

PDP

PANEL

(63FH-

XD01)

SGTV58XY

AV1

JS-6S/121A2-A2

MCU(m16c)

TPA3001

OUT

JW1109

(2X15W)

HDMI1

D-SUB

PI5V330

MCU

LPC915

HDMI2

PS301

Flash

EDID

HDMI3

EDID

AV1

S-VIDEO

JS-6S/121A2-A2

YPbPr1

YPbPr2

YPbPr1

YPbPr2

SUB

RTC

audio

video

tuner

Audio

Audio out

Audio processor

Switch

Audio amplifier

Earphone amplifier

Speaker

tuner

switch

power manage

RS232 update

key

power baord

board

Block diagram

IC block diagram

1. DPTV-SVP-WX68

Video signal from TUNER1, AV, RGB signal, Y and C signal , YUV, YPbPr signal via matched

resistance, the signal separately through alone channel send to mainSVP-WX68 video switch, A/D

transition, digital decode, image scale and OSD superposition, then send to LVDS level drive for

LCD screen.

2. SGTV58xy

SGTV58xy has ten input channels for analog audio, SIF, audio of AV1,AV2 (AV1 and S-Video share

the same audio channel),YPbPr1, YPbPr2, D-SUB/DVI switched inside the IC by the software

control, the select audio via volume, treble/bass and sound effect processing to sound amplifier

through left/right channel, then send to speaker.

Pin Description

92, 93: SDA, SCL

37, 38: left/right channel output to sound amplifier

34, 35: left/right channel of earphone

32, 33: AV OUT (right/left)

43, 44: USB audio (right/left)

51, 52, 47, 48: YPbPr 1,2 audio (right/left)

53, 54, 49, 50: AV IN (right/left)

57, 58: VGA audio (right/left)

59, 60: TV MONO

81: TV SIF input

3. TPA3001D1

The TPA3001D1 is a 20-W mono bridge-tied load (BTL) class-D audio power amplifier with high

efficiency, eliminating the need for heat sinks. The TPA3001D1 can drive 4-Ω or 8-Ω speakers with

only a ferrite bead filter required to reduce EMI.

The gain of the amplifier is controlled by two input terminals,GAIN1 and GAIN0. This allows the

amplifier to be configured for a gain of 12, 18, 23.6, and 36 dB. The differential input stage provides

high common mode rejection and improved power supply rejection.

The amplifier also includes depop circuitry to reduce the amount of pop at power-up and when

cycling SHUTDOWN.

The TPA3001D1 is available in the 24-pin thermally enhanced TSSOP package (PWP) which

eliminates the need for an external heat sink.

Wiring diagram

sound amplify board

vedio interface board

KEY board

IR board

main board

panel

power

Trouble shooting guide

Power on

A red indicato

hts?

Check power board, IR board, power manage

IC N601(P89LPC915) and power cord

A blue indicato

hts?

Check if the pin2 of X401 is low level?

Check if CPU 42#, FLASH 26# is square

wave? Check the peripheral circuit of CPU

and FLSH/EEPROM.

Yes, turn the unit on

Panel is light

on?

Check if each power supply, LVDS signal is

normal?

Yes

Check if the picture of eac

channel is normal?

Check the signal inputted from the channel to

in IC or IC and its peripheral circuit or the

output of LVDS is normal

Check if the sound of each

channel is normal?

Check the signal inputted from the channel to

in IC is normal or IC(SGTV58xy/TPA3001)

and its periphery is normal.

Check if each power suppl

of the main board is normal?

1.No raster, no picture, no sound

Check if the power supply indicator light is on.

Check 5V-S,

3.3V-SB

Cut off the connection

etween power boar

and main

oard, and tes

5V-S on power board

Check powe

manage IC

Power boar

has problem

Check if the indicator is

blue?

Power board has proble

Check CPU

(N801), FLASH

(N802) powe

supply.

Check if the pin2 o

X401is low level.

No raster, no picture, no sound.

Indicator is on

Yes

Indicator is off

Yes

o Abnormal

ormal

Power manage

IC has

roble

Abnormal

ormal

Check periphery o

L801

CPU and FLASH

Check if N801 10# turn to

high level 200ms later whe

CPU power on

Yes

Check if N801 42#, N802

26# is square wave

Check N801 reset circuit, i

CPU is reset

Yes

Check N801 crystal

and N806

Check the periphery o

801

N802

N803

N806

mal

Abnormal

Note: when check N801(CPU) pin10 is low voltage, you may disconnect R616 and test if V603

collector output low voltage first, then output high voltage all the while (the low voltage is CPU reset

signal, it turns to high voltage when working normally), if not, it’s power manage IC problem. Is there

square wave in FLASH pin26? If not, disconnect R851 and test if the square wave output from

N806 pin3, if still not, check N801 pin46-48 and N806. Check N801 pin42, if it has no square wave,

disconnect R856 and has a test again, if it has, perhaps N802(FLASH) is error. When check the

periphery of N801, N802 and N803, besides check the weld of the components, you may test the

pins of the resistance row connect N801, N802 and N803 with oscillograph, if the square wave is

abnormal, it indicates that one of them (N801, N802, N803) works abnormally and the SDL, SCL is

error, N802 in all probability. If RS51/RS52 connect N801 and NS01 is error, it will also cause the

phenomena of no raster, no picture and no sound.

2.With sound but no picture

Note: Please refer to checking procedure (4) to get the methods for checking the phenomenon of no

picture but with sound of HDMI channel.

With sound but no picture.

Display logo?

Check if all other channel

has no

icture.

Check the white

alance value o

the factory menu

Re-write the

software an

have a test

Check the signal

wave of XS01 wit

oscillograph.

Is the panel light or produce the

high voltage when power on

Check the input signal of N301

and N302 and

ower su

Power board

dama

ed.

The panel

damaged.

Connect the

wire well

Yes

ormal

ormal Abnormal Abnormal

Abnormal

ormal

Follow the inpu

signal an

check the circuit

EEPROM

irritation an

adjust again

o Ye s

Is LVDS wire

normal?

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Sanyo PDP-63XR7HB User manual

Brand: Sanyo

Model: PDP-63XR7HB

Category: CRT TVs

Type: User manual

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Sanyo PDP-63XR7HB User manual

Sanyo PDP-63XR7HB User manual

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