Entrenamiento en TV LCD Sony

Training Manual
EX-1 Direct-View LCD Television Chassis

Circuit Description and Troubleshooting Guide
MODELS:
KDL-32VL140
KDL-32XBR6
KDL-37XBR6
KDL-40V4100
KDL-40V4150
KDL-40W4100 KDL-46W4100 KDL-52W4100 KDL40VL160

KDL-40WL140 KDL-46WL140 KDL-52WL140 KDL46VL160
KDL-40XBR6 KDL-46XBR6 KDL-52XBR6
KDL-40Z4100 KDL-46Z4100 KDL-52V4100
KDL-46V4100 KDL-42V4100
Course : CTV-45
Table of Contents
Chapter 1 Introduction ..................................................... 1
Board Layout ......................................................................11
Overview.......................................................................... 1
Features .......................................................................... 1
52-inch V Series Models .................................................... 14

Board Layout ..................................................................... 14
Full HD 1080 Panel.............................................................. 1
The W Series ................................................................. 14
Motionow ........................................................................ 1
60HZ versus 120HZ TCON ............................................... 17
Enhanced Cross Media Bar (XMB)...................................... 1
40 and 46-inch Models ...................................................... 18
HDMI 1.3.............................................................................. 2
Board Layout ..................................................................... 18
Consumer Electronics Control (CEC) ..................................... 2

xvYCC ..................................................................................... 2
Deep Color .............................................................................. 2
Bravia Sync ....................................................................... 2

Advanced Contrast Enhancer (ACE) ................................... 2
Digital Media Port ................................................................ 2
Digital Media Extender (DMEX) ........................................... 2
Interactive Program Guide (IPG) ......................................... 2
Digital Living Network Alliance (DLNA) ................................ 2
4 HDMI Inputs ...................................................................... 2
Chapter 3 Video Process Circuits ................................. 22

Overview........................................................................ 22
V and W Series Video Process Circuits............................. 22
NTSC Tuner Signals ............................................................. 22
Composite and Y/C inputs .................................................... 22
Component Inputs ................................................................. 22
HDMI Inputs .......................................................................... 22
PC Input ................................................................................ 23
Front End Microprocessor and Decoder ............................... 23
Back End Microprocessor ..................................................... 23
Chapter 2 Overall Block Diagrams .................................. 3

Overview.......................................................................... 3
Overall Block Diagrams ................................................... 3
The V Series .................................................................... 3
LCD Panel ............................................................................. 23
32/37-inch Models Overall Block Diagram........................... 4
Troubleshooting ............................................................. 27
Board Layout ....................................................................... 6

42-inch Model ...................................................................... 8
Board Layout ....................................................................... 8
40 and 46-inch Models .......................................................11
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10-bit Video Processing ........................................................ 25

Ethernet Port ......................................................................... 25
USB 2.0 Input ........................................................................ 25
Digital Media Port .................................................................. 25
No Video ............................................................................ 27
Video Distortions................................................................ 27
Troubleshooting Flowcharts ............................................... 27
Table of Contents (Continued)

Chapter 4 Audio Process Circuits ................................. 29
Overview........................................................................ 29
General Audio Processing ................................................. 29
HDMI.................................................................................. 29
USB 2.0 ............................................................................. 29
Ethernet (DLNA) ................................................................ 29
Chapter 5 - Power Supply ................................................. 31
Overview........................................................................ 31
Power-Up Sequence ............................................................. 39

Inverter Circuit ....................................................................... 39
42-inch Backlighting........................................................... 42
40/46 V and W Series Backlighting ................................... 43
Inverter .................................................................................. 43
Balancer ................................................................................ 45
40/46 Z Series Backlighting ............................................... 47

All 52-inch Series Backlighting .......................................... 47
G5 Board ............................................................................... 47
D4 Board ............................................................................... 47
G1D/G2D Power Supplies ................................................. 31
D5 Board ............................................................................... 47
Power Factor Control (PFC) ................................................. 31
Standby Power Supply .......................................................... 31
Inverter Failures ................................................................. 50
Main Switching Supply .......................................................... 31
Inverter Does Not Start ......................................................... 50
IP5 Power Supply and Inverter .......................................... 33
Inverter Starts and Turns Off ................................................. 50
Integrated Lamp Inverter ....................................................... 33
Dual Inverter Circuits ......................................................... 51
G4 Power Supply ............................................................... 33
Balancer Errors .................................................................. 51
PFC Output ........................................................................... 33
Troubleshooting Flowcharts........................................... 52
G5 Power Supply ............................................................... 33
Completely Dead Unit ........................................................ 37
Power Supply Shutdown.................................................... 37
Power Supply Troubleshooting Flowchart ......................... 37
Balancer Board Removal ................................................... 52
Chapter 7 Protect Circuits ............................................. 58

Overview........................................................................ 58
Voltage Protection.............................................................. 58
DC Detect (2X) ...................................................................... 58
Chapter 6 - Panel Backlight Circuits ................................ 39

Overview........................................................................ 39
Backlight Protection ........................................................... 58
32/37-inch Backlighting...................................................... 39
Inverter Error (6X) ................................................................. 58
DC Alert (3X) ......................................................................... 58
Balancer Error (13X) ............................................................. 59
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ii
Table of Contents (Continued)

Other Protection................................................................. 59
Troubleshooting a Dead TCON .......................................... 80
Temperature (7X) .................................................................. 59
DLNA Overview ............................................................. 82
Speaker Protect (8X) ............................................................ 59

Trident (11X) ......................................................................... 59
TCON or HFR (12X 14X) ...................................................... 59
Diagnostics History ........................................................ 61

Troubleshooting Flowcharts........................................... 61
Troubleshooting Test Points .......................................... 61
Chapter 8 Appendix ........................................................ 69
Software Updates .......................................................... 69
Why Update? ..................................................................... 69
Checking the Version of Software...................................... 69
Performing the Update....................................................... 71
Downloading an Update .................................................... 72
Formatting the USB Device .................................................. 72
Installing the File(s) to the USB Device ................................ 72
Updating the Television...................................................... 73

Notication of Update ............................................................ 73
FE Micro Update ................................................................... 73
BE Micro Update ................................................................... 73
Update Completion ............................................................... 73
LCD Panel Troubleshooting........................................... 76

LCD Panel Basics .............................................................. 76
Panel Failures .................................................................... 77
Physical Failures ................................................................... 77
TCON Failures ................................................................... 79
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iii
Chapter 1 Introduction
Overview
Motionow
The EX-1 chassis is one of several designs for the 2008 model line of
Sony Bravia LCD televisions. 22 models are available as of this writing
ranging from 32 to 52. The models are grouped in categories beginning
with the V series as an introductory product for a full HD 1080 panel. The
W series is an intermediate level product and introduces a frame doubling
circuit known as Motionow to provide a 120HZ refresh rate. Upgrade
level televisions are available in the Z and XBR series models.
A frame-doubling circuit utilizing proprietary circuitry and algorithms is able

to capture and compare the movement from one frame to another. By
anticipating the location of a moving object, an additional frame is inserted
to increase the frame refresh rate from 60HZ to 120HZ. The result is an
exceptionally smooth picture during fast moving objects and scenes. This
feature is available on the W, Z, and large XBR6 models.
NOTE: Although there are 5 XBR models, the 32 and 37-inch models are
classied as entry-level models in that they do not contain the features
found in the 40, 46, and 52-inch models. When referring to the XBR series,
the term small XBR and large XBR will be used when necessary.
The chassis design revolves around the video processing circuits located
on the BU board. It remains relatively the same except for a couple of
additional input features and 10-bit video processing found on the upperend models. The key difference between models is determined by the size
of the LCD panel and its manufacturing source. This manual will describe
the new circuit features and individually describe the models based on
these differences.
Features
The customer has the option of changing the settings of the Motion
Enhancement and Motion Compensation circuits to smooth the judder
inherent with 24-frame lm-based content or can choose keep the judder
for a lm-like experience.
Enhanced Cross Media Bar (XMB)

A new graphics user interface with rich 3-D graphics allowing the user to
customize the setup of the television and to access various adjustments
and control of optional devices. Optional external devices can also be
detected and displayed. An example would be when a customer plugs
in the Bravia Internet Video Link device to access the internet. When the
device is detected, additional icons appear in the XMB graphics OSD to
allow control of the device. Other optional devices will become available
and will be described later.
Several new features are introduced in the EX-1 chassis model lineup
along with some carryovers from the previous year. The included features
will vary based on the model series and will be indicated in the following
descriptions:
Full HD 1080 Panel

All models have a 1920 X 1080 native resolution panel. All video signals
exit the video process circuits as 1080p 60HZ. The V, W and 32/37XBR6
series utilize an 8-bit panel and video processing while the Z and larger
XBR6 models use a 10-bit panel and video processing.
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Chapter 1 - Introdcution
HDMI 1.3
Digital Media Port
This new version of HDMI introduces several new enhancements and

features and the EX-1 chassis supports 3 of the new features.
Found on the high-end models, this port allows for the hookup of optional
devices that provide an interface with digital media products such as MP3
players and video cameras.
Consumer Electronics Control (CEC)

A standardized protocol for the control of consumer electronics devices
allows for communication and control via the HDMI cable on products that
have this feature. Any brand of electronic equipment that is CEC compliant
can communicate with another to generate operational commands. The
Bravia Sync feature uses the CEC format to control other Sony devices
in the system.
xvYCC
The previous color bandwidth limitations applied for compatibility with
analog signals are no longer present with digital signals. This allows for
1.8 times more colors.
Deep Color
The previous HDMI specications limited the RGB sample level to 24-bit.
Deep Color expands this up to 48-bit giving the ability to generate a color
depth of 2.8 trillion levels.
Bravia Sync
By utilizing the CEC feature of HDMI 1.3, this feature allows the customer
to easily control the various Sony devices within their home entertainment
system provided that all of the other devices have this feature included.
Advanced Contrast Enhancer (ACE)

By monitoring the overall level of the video signal, the backlights are
dynamically controlled and reduced during low light level scenes to
enhance the contrast ratio.
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Digital Media Extender (DMEX)

A USB 1.0 port is provided to supply a digital connection path to optional
modules such as the Bravia Internet Video Link. Selected web sites on
the internet can be accessed to play video clips or view local news, trafc,
and weather. Devices connected will automatically appear on the XMB
menu.
Interactive Program Guide (IPG)

An interactive guide is included to provide continuously updated program
information at no charge to the customer. The guide (provided by TV
Guide) is part of the XMB graphics feature. Program material is updated
from the local PBS station when the television is off.
Digital Living Network Alliance (DLNA)

An industry standard networking protocol has been developed by leading
manufacturers to allow other devices such as a compatible computer to
communicate with the television via an Ethernet connection to your home
network. This gives the ability to view photos, audio and movie content
directly from your computer via the network. If there are any rmware
upgrades available for the television, these can be downloaded to the
computer and sent directly to the television. The 2008 models in this
training manual will only support photos. Music and video media is not
supported.
4 HDMI Inputs
3 inputs in the rear and one on the side are available for all models. This
increases the available inputs to meet the expanding needs of additional
devices.
Chapter 2 Overall Block Diagrams

Overview
Overall Block Diagrams
The EX1 chassis for the 2008 model year is found in 22 models as of
this writing. The focal point of this chassis is the video processing circuits
located on the BU board. The digital decoder for ATSC signals along with
the video process IC remains the same among the models. As one moves
from the entry level models to the higher end units, additional features are
added to the video process circuits to extend the amount of components
that the television can interface with. This includes computer networking
and digital media devices. The Z models, along with the 40-inch and up
XBR6 series, utilize a 10-bit processing scheme for the LCD panel versus
8-bit for the others.
The following block diagrams illustrate an overall view of the various circuits
used and will be categorized based on panel size and video features.
Circuit descriptions will begin with the entry-level V series. There are
several similar circuits among the entire model line and these descriptions
will be discussed. As the diagrams and descriptions progress up the model
line, only the differences in boards and circuitry will be explained. More
detailed information for each circuit will appear in the chapters to follow.
The major factor separating the various models in the chassis line
(other than cosmetics) is panel size along with the original source of the
particular LCD panel in that model. These factors are what will determine
how the overall block diagrams are segregated. Different panel sizes
require different inverter circuits to light the backlights and that includes
differences in the power supplies.
The V Series
This series consists of the following models:
KDL32VL140
KDL32XBR6
KDL37XBR6
KDL40V4100
The EX1 chassis model lineup is separated into 3 categories:
KDL40V4150
V Series: These are the introductory level models for those wishing to
purchase a full HD 1920 X 1080 panel. It includes all those with a V in
the model number. Also included in this series is the smaller (32 and 37inch) XBR6 models.
KDL42V4100
KDL46V4100
KDL52V4100
W Series: Classied as intermediate level units, these models have the

120HZ frame-rate feature (known as MotionFlow) added to signicantly
increase the picture quality especially during fast moving scenes. They
will have a W in the model number.
Z Series: As upper-level models, additional features are included to
enhance picture quality. This includes 10-bit LCD panels, 120HZ refresh
rate and Wide Color Gamut backlights. Additional features include an
Ethernet port, USB 2.0 port and Digital Media port to interface with the
customers computer and portable devices.
CTV-45
Chapter 2 - Overall Block Diagrams
32/37-inch Models Overall Block Diagram
Inverter
Figure 2-1 illustrates an overall block diagram of the models utilizing the
32 and 37-inch LCD panels. This includes the KDL32VL140, KDL32XBR6
and KDL37XBR6.
The inverter is mounted on the left side of the LCD panel (as viewed from
the rear) and contains all of the circuitry necessary to generate the 1KVAC
operating voltage for the uorescent backlights. It also contains on-board
monitoring circuits to maintain even brightness among the lamps and to
notify the BE Micro on the BU board if there is a failure of the inverter or if
one or more of the lamps fails to light.
BU Board
Essentially the brains of the system, this board contains all of the input
sources for video and audio information along with an on-board ATSC/
NTSC combination tuner. It also contains all of the video and audio
switching and processing circuits. The front-end (FE) and back-end (BE)
microprocessors to control the operation of the television and the video
processor functions are located here. All video sources exit the BU board
at the native resolution of the LCD panel (1920 X 1080, 60HZ).
The BU board used in these models is specically congured for the
panel types and sizes used. This includes physical, electrical and
software congurations. Other models will have additional inputs, different
processing schemes and different software which make the BU board
specic to the panel type being used.
Note that all input sources are directly connected to the BU board. The
past use of separate boards for input switching, tuner, ATSC decoder and
side video inputs has all been incorporated onto this single board.
Power Supply
The 32-inch models contain a G1D board to provide the main operating
voltages for the television. It supplies operating voltages to the BU board
along with 24VDC for the inverter. The 37-inch model uses a G2D board
which is essentially the same except the circuitry is designed to handle
the increased current load of the larger panel.
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H1 Board
Located at the top of the unit, the various user input buttons (power,
channel and volume up/down, menu and input selection) are located here.
The H1 board is mounted to the switch housing and is referred to as the
switch or function block in the service manual.
H2 Board
The power, timer and standby LEDs are located on this board.
H3 Board
This board contains the IR receiver LED for the remote control. The same
LED also serves as an ambient light sensor. All EX1 chassis models have
the ability to automatically adjust the picture brightness and contrast level
based on ambient lighting conditions. This feature is turned off by default
but can be turned on by the customer in the user menu.
LCD Panel
The 32 and 37-inch panels are full HD (1920 X 1080) utilizing Cold Cathode
Fluorescent (CCFL) backlights. There are 16 lamps on the 32-inch and
20 on the 37-inch. The TCON board mounted to the panel is responsible
for proper timing and allocation of the RGB data to the correct columns of
LCD pixels. White balance and Gamma correction data is also stored on
this board. This is why the TCON is not available as a separate service
item. If there is a failure in the uorescent backlights, TCON or the LCD
panel, they must be replaced as a single unit.

RF
VIDEO 1
VIDEO 3
COMPONENT 1
COMPONENT 2
HDMI 1
HDMI 3
HDMI 4
DVI AUDIO
A/V DECODER
VIDEO PROCESS
VIDEO SWITCH
AUDIO PROCESS
AUDIO AMP
BE MICRO
TCON
PC HD15
INVERTER
L/R AUDIO OUT

OPTICAL OUT
BU
USB 1.1
LCD PANEL
VIDEO 2
HDMI 2
SIDE INPUTS
POWER SUPPLY
SWITCHES
H1
IR
RECEIVER
LED
H3
H4
G1D (32")
G2D (37")
FIGURE 2-1
32/37-INCH OVERALL BLOCK DIAGRAM
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Board Layout
Figure 2-2 shows the board layout for the KDL32XBR6 and Figure 2-3 for
the KDL37XBR6. Note that each picture illustrates the unit in assembled
form. If the unit requires complete disassembly to replace the LCD panel
these pictures provide guidance for the proper placement and routing of
the various cables and wire harnesses. It is important that these be routed
in their original positions to minimize EMI emissions.
H1
(FUNCTION
BLOCK)
TCON
INVERTER
BU
G1D
H4
H3E
FIGURE
2-2
32XBR6
BOARD
LOCATIONS
32-INCH CIRCUIT BOARD LAYOUT
CTV-45
H1
(FUNCTION
BLOCK)
TCON
INVERTER
G2D
BU
H4
H3E
FIGURE 2-3
37-INCH CIRCUIT BOARD LOCATIONS
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42-inch Model
The KDL42V4100 model is unique in that the LCD panel conguration
is unlike any of the other models. Referring to Figure 2-4, note that this
model uses the same GD2 power supply found in the 37-inch model. The
G2D board has an extra connector for supplying 24VDC and is used in
this model to supply power to the second inverter board.
2 stand-alone inverters are used to drive the uorescent backlights. Each
inverter board drives 10 of the 20 lamps. The inverter on the left side
(as viewed from the rear) is the master and the right side the slave. A
communications line is connected to the master inverter from the TCON
board. Once the TCON receives RGB data from the BU board the inverters
will turn on.
Board Layout
Figure 2-5 illustrates the board layout for the KDL42V4100.
CTV-45

RF
VIDEO 1
VIDEO 3
COMPONENT 1
COMPONENT 2
HDMI 1
HDMI 3
HDMI 4
DVI AUDIO
A/V DECODER
VIDEO PROCESS
VIDEO SWITCH
AUDIO PROCESS
AUDIO AMP
BE MICRO
INVERTER
PC HD15
INVERTER
TCON
L/R AUDIO OUT
OPTICAL OUT
BU
USB 1.1
LCD PANEL
VIDEO 2
HDMI 2
SIDE INPUTS
POWER SUPPLY
SWITCHES
H1
IR
RECEIVER
LED
H3
H4
G2D
FIGURE 2-4
42V4100 OVERALL BLOCK DIAGRAM
42-INCH V MODEL OVERALL BLOCK DIAGRAM
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H1
(FUNCTION
SWITCH)
TCON
RIGHT
INVERTER
LEFT
INVERTER
G2D
BU
H3
H4
FIGURE 2-5
42-INCH V MODEL CIRCUIT BOARD LOCATIONS
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10
40 and 46-inch Models
Board Layout
In Figure 2-6, an overall block diagram indicates the boards used in the
40 and 46-inch models of the V and W series models. These models differ
from the previously outlined V models in that a stand-alone inverter circuit
is used to power the backlights. The boards that differ from the previously
covered models will be explained below:
Figure 2-7 illustrates the board layout for the 40 and 46-inch V series
models. The same boards are used for both sizes although the part
numbers differ due to software on the BU board and larger balancer for
the 46-inch.
IP5
This board contains the standby power supply, main switching power
supply and inverter to drive the backlights. In past years, LCD panels at
40-inches and larger were driven by a stand-alone inverter (or 2 inverters
for the 46 and 52-inch models. This year, the 40/46-inch V and W series
use a power supply with an integrated inverter to provide the approximately
1KVRMS AC power for the lamps. This circuit will be covered in more
detail later in this manual.
Balancer
Since the IP5 board provides a common power source for all of the lamps,
a circuit must be used to assure that equal current is drawn by each lamp
to prevent unequal brightness . This is one of the functions of the balancer.
It is also responsible for distributing the high voltage to the lamps and to
insure that all lamps are lit up or struck at turn-on. The 40-inch panel
uses 20 backlights whereas the 46-inch uses 24.
LCD Panel
The 40 and 46-inch LCD panels are also native 1920 X 1080 resolution.
Note that this block diagram also applies to the W series models. The
only difference is the use of a frame-rate doubling circuit integrated with
the TCON board. The V series do not incorporate this and have a panel
refresh rate of 60HZ
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11
RF
VIDEO 1
VIDEO 3
COMPONENT 1
COMPONENT 2
HDMI 1
HDMI 3
HDMI 4
DVI AUDIO
A/V DECODER
VIDEO PROCESS
VIDEO SWITCH
AUDIO PROCESS
AUDIO AMP
BE MICRO
HFR*
*NOT AVAILABLE
IN V SERIES
BALANCER
PC HD15
L/R AUDIO OUT
TCON
OPTICAL OUT
LCD PANEL
BU
USB 1.1
VIDEO 2
HDMI 2
SIDE INPUTS
SWITCHES
H1
IR
RECEIVER
LED
H3
H4
POWER SUPPLY
BACKLIGHT INVERTER
IP5
FIGURE 2-6
40 AND 46-INCH V AND W SERIES OVERALL BLOCK DIAGRAM
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12
H1
(FUNCTION
BLOCK)
TCON
BALANCER
IP5
BU
H3
H4
FIGURE 2-7
40 AND 46-INCH V AND W SERIES CIRCUIT BOARD LOCATIONS
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13
52-inch V Series Models
The W Series
Figure 2-8 illustrates the overall block diagram for the 52-inch V series
models. Note that this block diagram also includes the W series with the
key difference being the use of an integrated frame-rate doubling circuit
on the TCON board.
The following models are included in this series:
D4 and D5 Boards
KDL46W4100
The most signicant difference is the use of separate inverter drivers

and balancer boards. Due to the longer length of the backlight lamps,
exterior current leakage occurs along the length of the lamps and they
will tend to darken from one end to the other if a common AC voltage is
applied to ionize the gasses. This is solved by using separate inverters
to supply out-of-phase AC voltage to the lamps. The D4 and D5 boards
output approximately 800VRMS of AC for a differential of 1600 volts.
This necessitates the use of a separate power supply located on the G5
board.
KDL46W4150
Board Layout
Figure 2-9 illustrates the board layout for the 52V series model.
KDL40W4100
KDL40WL140
KDL46WL140
KDL52W4100
KDL52WL140
The major difference between the V and W series (other than cosmetics)
is the addition of a high frame-rate circuit within the TCON board. These
models utilize 120HZ refresh-rate panels. An additional board labeled as
the Sony Logo Module contains a row of white LEDs to illuminate the
Sony logo on the bottom front of the bezel. This feature can be turned off
by the customer in the user menu.
The block diagrams illustrated in Figures 2-6 through 2-8 are drawn to
pertain to both the V and W series models with the differences noted in
the diagrams.
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14

RF
VIDEO 1
VIDEO 3
COMPONENT 1
COMPONENT 2
HDMI 1
HDMI 3
HDMI 4
DVI AUDIO
A/V DECODER
VIDEO PROCESS
VIDEO SWITCH
AUDIO PROCESS
AUDIO AMP
BE MICRO
UPPER
LEFT
BALANCER
HFR*
UPPER
RIGHT
BALANCER
TCON
*NOT AVAILABLE
IN V SERIES
PC HD15
L/R AUDIO OUT
LOWER
LEFT
BALANCER
OPTICAL OUT
LOWER
RIGHT
BALANCER
BU
USB 1.1
LCD PANEL
VIDEO 2
HDMI 2
SIDE INPUTS
SONY
LOGO
MODULE
IR
RECEIVER
(W SERIES
ONLY)
SWITCHES
H1
INVERTER
INVERTER
D4
D5
H4
POWER SUPPLY
LED
H3
G5
FIGURE 2-8
52-INCH V AND W SERIES OVERALL BLOCK DIAGRAM
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15
H1
(SWITCH UNIT)
TCON
UPPER
LEFT
BALANCER
UPPER
RIGHT
BALANCER
D5
G5
LOWER
LEFT
BALANCER
UB
D4
H4
LOWER
RIGHT
BALANCER
H3E
FIGURE 2-9
52-INCH V AND W SERIES CIRCUIT BOARD LOCATIONS
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16
60HZ versus 120HZ TCON

TCON boards containing the high frame-rate Motionow feature are
easily distinguished by appearance. Figure 2-10 illustrates this. 60HZ
TCON boards are smaller in size and the LVDS cable plugs into the
bottom of the board. The 120HZ TCON board are longer horizontally and
the LVDS cable plugs into the right side.
60HZ TCON
120HZ TCON
FIGURE 2-10
60HZ VS 120HZ TCON
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17
The Z and Large XBR Series
models, the following feature enhancements are included:
These are the top-of-the-line models in this chassis series. The following
models are included:
10-Bit Panel Processing: The RGB data exiting the board via the LVDS
cable is 10-bit versus 8-bit. This increases the color depth from 256 to
1,024.
KDL40Z4100 (available in black or silver trim)

KDL40XBR6
KDL46Z4100 (available in black or silver trim)
KDL46XBR6
KDL52XBR6
Note that the Z series is not available in a 52-inch size.
40 and 46-inch Models

An overall block diagram of the 40 and 46-inch models in the Z series is
shown in Figure 2-11. There are a couple of differences from the V and W
series layout and will be explained below.
Digital Media Port: Allows the use of special adapters to integrate portable
digital media devices such as camcorders and MP3 players.
Ethernet Port: Allows connection to a DLNA compliant server or devices
for media le viewing.
USB2.0 Port: MP3 audio les and JPG photos can be directly input to the
television for viewing and listening.
Board Layout
Figure 2-12 illustrates the board layout for the 40 and 46-inch Z series
models. The picture is of the 40-inch model. The 46-inch uses the same
board layout but they are spaced further apart due to the larger size of
the panel.
G4 Board
Unlike the V and W series which use an integrated power supply and
backlight inverter on the IP5 board, the Z series contains a G4 board
to generate the operating and standby voltages consistent with many
previous designs.
D3 Board
The D3 board is a stand-alone inverter supplying approximately 1KVRMS
of AC voltage for the panel backlights. It also contains on-board voltage
monitoring for excessively low or high backlight voltage along with overcurrent monitoring. If a problem occurs in any of these circuits the unit will
be told to shut down for protection.
52XBR Model
Figure 2-13 contains a layout of the overall block diagram used in the
KDL52XBR6 model. Note the similarity with the 52-inch models for the
V and W series with the exception of enhancements to the BU board as
listed above in the 40/46Z and XBR models. The board layout for this
model is the same as the 52W4100 shown in Figure 2-9.
BU Board
Although virtually identical to the BU board used in the V and W series
CTV-45
18
SUBWOOFER
DRIVE
RF
VIDEO 1
VIDEO 3
COMPONENT 1
AWF
XBR SERIES ONLY
COMPONENT 2
HDMI 1
HDMI 3
HDMI 4
DVI AUDIO
PC HD15
A/V DECODER
VIDEO PROCESS
VIDEO SWITCH
AUDIO PROCESS
AUDIO AMP
BE MICRO
HFR
BALANCER
L/R AUDIO OUT

TCON
OPTICAL OUT
USB 1.1
LCD PANEL
BU
DIGITAL
MEDIA PORT
ETHERNET
USB 2.0
VIDEO 2
HDMI 2
SONY
LOGO
MODULE
SIDE INPUTS
SWITCHES
H1
IR
RECEIVER
LED
H3
H4
POWER SUPPLY
G4 (Z SERIES)
G6 (XBR SERIES)
INVERTER
D3
FIGURE 2-11
40 AND 46-INCH Z SERIES OVERALL BLOCK DIAGRAM
CTV-45
19
TCON
BALANCER
D3
G4
H1
(FUNCTION
BUTTONS)
BU
H3
H4
FIGURE 2-12
40 AND 46-INCH Z SERIES CIRCUIT BOARD LOCATIONS
CTV-45
20
SUBWOOFER
DRIVE
RF
VIDEO 1
VIDEO 3
AWF
COMPONENT 1
COMPONENT 2
HDMI 1
HDMI 3
HDMI 4
DVI AUDIO
PC HD15
A/V DECODER
VIDEO PROCESS
VIDEO SWITCH
AUDIO PROCESS
AUDIO AMP
BE MICRO
UPPER
LEFT
BALANCER
HFR
UPPER
RIGHT
BALANCER
TCON
L/R AUDIO OUT

OPTICAL OUT
DIGITAL MEDIA
PORT
LCD PANEL
ETHERNET
BU
HDMI 2
INVERTER
INVERTER
USB 2.0
VIDEO 2
LOWER
RIGHT
BALANCER
LOWER
LEFT
BALANCER
USB 1.1
SONY
LOGO
MODULE
IR
RECEIVER
D5
D4
H4
SIDE INPUTS
POWER SUPPLY
SWITCHES
H1
LED
H3
G5
FIGURE 2-13
52XBR6 OVERALL BLOCK DIAGRAM
CTV-45
21
Chapter 3 Video Process Circuits

Overview
The video process circuits in the EX1 chassis has achieved yet another
reduction in the number of boards required. All of the input switching
and processing is accomplished on a single BU board. Even the side
video inputs have become part of this board. This signicantly affects
troubleshooting and parts replacement since the main goal of locating
video failures is to determine if the problem is located on the BU board or
the LCD panel and TCON board.
The BU board is the one common element among the various models
of the EX1 chassis and most of the features located on this board are
common. There are added circuits and functions as we move up the
model line from introductory to upper level. This applies to the BU board
and the TCON board. This chapter will discuss the operation of the video
process circuits and outlines the differences encountered between the
various models.
V and W Series Video Process Circuits

Referring to Figure 3-1 a simplied block diagram of the circuitry to select
and process all video signals is shown. The ATSC/NTSC combination
tuner is mounted directly on the BU board. All external input sources are
also mounted directly on the board. Descriptions for each of the major
components and functions are as follows:
picture frame. This includes ATSC and NTSC sources. The sub-picture
will appear on the right side and is approximately one-half the size of the
main picture. Since there is only one tuner in the unit, the input for the
main picture will automatically switch to one of the external inputs. Which
input is dependent on how the inputs were assigned in the customer setup
mode. If all inputs are set for auto-detect, the HDMI 1 input will appear by
default. If any other input was set to always it will go that input. The main
and sub pictures are not scalable.
Composite and Y/C inputs

Only the Video 1 input contains both a composite and Y/C jack. These
sources are selected by IC1301 and routed to IC4700 for processing and
up-scaling to 1080p 60HZ.
Component Inputs
There are 2 Y/Pb/Pr component inputs on this chassis. They are directly
selected by IC4700. All HD formats up to 1080p 60HZ are supported
except for 24P content. 24p is only supported via the HDMI inputs.
HDMI Inputs
HDMI input selection is performed by IC5200 and sends the selected input
to IC4700. Each HDMI input has its own EDID information stored within a
NVM IC. The following ICs (not shown) are attached to each input:
HDMI 1: IC5101
NTSC Tuner Signals
HDMI 2: IC5191
Signals received via NTSC tuner sources are demodulated within the tuner
and selected by video switch IC1301. The video signal is then sent to
video signal processor IC4700 (Trident). The 480i resolution is processed
and up-scaled to 1080p 60HZ for distribution to the LCD panel TCON.
HDMI 3: IC5131
HDMI 4: IC6161
Note that IC1301 has a main and sub video path exiting. All of the models
have picture-and-picture capability albeit with limited functionality. When
the P&P mode is engaged, only tuner sources are available in the sub-
CTV-45
22
Chapter 3 - Video Process

USB1.1 (DMEX)
This USB input is labeled DMEX (Digital Media Extender) on the rear
of the unit. If the customer chooses to purchase the optional Bravia
Internet Video Link box to access the internet, this port will provide 2-way
communication with that device and links with the customer GUI interface.
This port is also used to input software upgrades to the television via USB
storage devices.
PC Input
Analog RGB input from a PC can be connected to the HD15 connector.
The video process circuits will support conventional resolutions from
640 X 480 VGA up to 1920 X 1080 HD. EDID information for the PC HD
material is contained within NVM IC5000.
The LVDS data is transmitted to the TCON board where an LVDS receiver
is located. The LVDS receiver returns the serialized data to its original
8-bit parallel RGB format. In the V series models the panel has a refresh
rate of 60HZ. The RGB data is timed and allocated to the proper column
drivers for the LCD pixels to produce a picture. White balancing and
gamma correction are also performed to compensate for variances in the
LD panel.
The W series models use a TCON board with an additional circuit to double
the 60HZ refresh rate to 120HZ. This is a very sophisticated circuit that
can compare a previous and future frame to the current one and calculate
the motion of objects within each frame in order to generate the additional
frames with a with exceptionally smooth movement.
Front End Microprocessor and Decoder

IC7000 decodes the MPEG2 compressed ATSC signals received by
the tuner and separates the video and audio content. This IC is also
responsible for interface control of the video to IC4700. Customer menu
graphics are generated within IC7000.
Back End Microprocessor

IC3001 controls the operation of the unit and provides a user interface.
It also monitors key areas of the television for voltage, temperature and
speaker protection to turn the unit off if a problem is detected. Another
function of IC3001 is to control IC4700 and how it handles the various
formats of video signals received by the unit.
LCD Panel
The LCD panel receives the 8-bit RGB video data from the BU board via
a Low Voltage Differential Signaling (LVDS) cable. IC4700 contains the
LVDS transmitter within and transmits a video resolution of 1920 X 1080
60HZ to match the native resolution of the panel.
CTV-45
23
RF
TUNER
ATSC
DIGITAL VIDEO
NTSC
SUB VIDEO
VIDEO 1
VIDEO 2
VIDEO 3
IC1301
VIDEO
SWITCH
IC7000
AMD
ALL V AND 32/

37XBR SERIES
DIGITAL GPX
TCON
H/V SYNC
CC VIDEO
MAIN VIDEO
IC4700
TRIDENT
COMPONENT 1
LCD PANEL
1080
60HZ
COMPONENT 2
HDMI 1
120HZ
HFR
IC5200
HDMI
SWITCH
& EQ
HDMI 2
HDMI 3
HDMI 4
ALL W SERIES
TCON
USB 1.1
LCD PANEL
PC HD15
IC5000
EDID
IC5000
IC5000
IC5000
EDID
EDID
EDID
EDID X4
EDID 1: IC5101
EDID 2: IC5191
EDID 3: IC5131
EDID 4: IC5161
IC3001
BE MICRO
BU
FIGURE 3-1
V AND W SERIES VIDEO PROCESS CIRCUITS
CTV-45
24
Z Series Video Processing

As illustrated in Figure 3-2, the BU board used in the Z and 40-inch and
larger XBR models functions in much the same way as the preceding
descriptions of the V and W series with the following differences:
240HZ Refresh Rate

The model KDL52XBR7 introduced in the December of 2008 utilizes a
240HZ Motionow TCON and LCD panel.
10-bit Video Processing

IC4700 on the BU board outputs 10-bit RGB data instead of the 8-bit level
as found on the V and W series. This increases the levels of brightness
from 256 to 1,024.
Ethernet Port
Devices that are DNLA (Digital Living Network Alliance) compliant can be
used in a network setup to view and listen to content from PCs, mobile
devices, gaming consoles, etc. DNLA provides the standards to allow many
devices in the home to receive and send content among the network.
Software upgrades can also be located on the internet and downloaded
to the television should it become necessary. More information about the
DLNA feature is described in the appendix section of this manual.
USB 2.0 Input

USB storage devices that contain pictures in JPEG format or audio content
in MP3 format can be plugged directly into the television for photo viewing
or listening to music.
Digital Media Port

Optional devices are available to hook up portable digital video and audio
devices to the television. Content can be viewed or listened to along with
the ability to control the connected device by using the television screen
and remote controller as an interface device.
CTV-45
25
RF
ATSC
TUNER
DIGITAL VIDEO
NTSC
VIDEO 1
VIDEO 2
VIDEO 3
IC7000
AMD
SUB VIDEO
H/V SYNC
IC1301
VIDEO
SWITCH
DIGITAL MEDIA
PORT
DIGITAL GPX
CC VIDEO
MAIN VIDEO
IC4700
TRIDENT
COMPONENT 1
COMPONENT 2
HDMI 1
IC5200
HDMI
SWITCH
AND EQ
HDMI 2
HDMI 3
HDMI 4
1080
60HZ
120HZ
HFR
240HZ
HFR
XBR7
ONLY
TCON
LCD PANEL
PC HD15
IC5000
EDID
USB 1.1
ETHERNET
USB 2.0
IC5000
IC5000
IC5000
EDID
EDID
EDID
EDID X4
EDID 1:
EDID 2:
EDID 3:
EDID 4:
IC5101
IC5191
IC5131
IC5161
IC3001
BE MICRO
PHYSICAL
INTERFACE
PHYSICAL
INTERFACE
BU
FIGURE 3-2
Z SERIES VIDEO PROCESS CIRCUITS
CTV-45
26
Troubleshooting
Video Distortions
Since virtually all of the video inputs and most of the video processing is
located on the BU board, failures causing a loss of video or distortions
in the picture need to be isolated to the BU board or the LCD panel.
The combining of all video processing circuitry into 2 major components
makes the troubleshooting approach to seem rather simplistic and in most
cases it will be just so.
This is, by far, the most difcult failure to troubleshoot due to the many
sources that can cause it. Noise emanating from the power supply, outside
interferences, video process failures and even mechanical problems in
the LCD panel can cause video distortion.
As anyone who has experience servicing electronic products knows, things

happen in the real world that can cause failures which do not follow the
rules of the academic procedures found in this manual. Always research
the latest service bulletins and/or troubleshooting tips on the Sony service
website before making the service call.
No Video
If a total loss of video occurs (including OSD graphics) the most likely
course of action is to bring a replacement BU board to the service location
since the unit is serviced at board-level only. It is unlikely that a loss of
voltage from the power supply is the cause since these voltages are
monitored and the unit will likely experience a protection shutdown event
rather than a no video condition. Although a failure of the backlights to
turn on would certainly cause a no video condition, this too would cause
the unit to shut down and indicate a failure via the self diagnostics feature.
If the replacement BU board does not resolve the issue, the LCD panel is
likely defective.
The up-side to display devices is that they are the most valuable tool in
determining the source of the problem so long as one knows the basic
theory of how they function. The Appendix section of this training manual
contains a section on basic troubleshooting of LCD panel televisions. The
primary objective when diagnosing no video or distortions in the video is
to eliminate the LCD panel as the cause. Replacement of the LCD panel
requires special authorization and, in some instances, will not be allowed
due to economical reasons.
Troubleshooting Flowcharts
Due to the reduced number of circuit boards used in this chassis,
troubleshooting video problems must focus on whether the problem lies
on the BU board or the LCD panel. In a no video symptom the owchart
asks if the backlights are lit. Hypothetically, the backlights must light or the
unit will shut down and blink a balancer or inverter error but there have
been cases in previous chassis designs where the backlights do not light
and the unit did not enter the protect mode. The troubleshooting owchart
in Figure 3-3 will provide some guidance in diagnosing a video problem.
The presence of OSD graphics with a no video condition certainly

eliminates the LCD panel as the cause and the BU board will almost
certainly x the problem.
CTV-45
27
All inputs?
Yes
Video Failure
Distorted
Symentrical ?
BU Board
No
Lines single or
multi-colored
Backlight failure
Yes
OSD graphics
present ?
Yes
LCD Panel
No
None
Backlights
turning on ?
BU Board
Yes
No
No video or
distorted
video?
No
Distortion
stationary ?
Multi-colored
BU Board
Single Color
Yes
LCD Panel
BU Board
No
Heartbeat
LED on BU
board flashing ?
No
BU Board
Yes
Unplug LVDS
connector at
TCON while unit
is running . This
may need to be
done more than
once
Any flashes
seen on
screen?
No
LCD Panel
Yes
BU Board
FIGURE 3-3
VIDEO FAILURE TROUBLESHOOTING FLOWCHART
CTV-45
28
Chapter 4 Audio Process Circuits

Overview
HDMI
All audio processing and amplication are performed on the BU board.

The path of the audio processing differs depending on the source. Figure
4-1 illustrates an overall block diagram of the audio circuits on the BU
board.
The 4 HDMI inputs are selected by HDMI switch and equalizer IC5200.
The serial audio data is received by IC4700 where it is converted to I2S
format. The digital audio data is transmitted via this bus to IC7300 and
output to IC2002.
General Audio Processing
USB 2.0
All audio processing is selected and performed by IC2002. The IC

contains internal switching circuits along with a digital signal processor
for equalizer and sound effects control. Analog signals are A/D converted
before being processed. Digital audio sources are received via the I2S
audio data bus.
MP3 audio les can be input to the USB side jack. The USB device is
detected and a list of the available audio les can be viewed in the XMedia
graphics menu. The audio can be listened to via the television speakers
or and external amplier hooked up to the L/R analog outputs or optical
output jack.
Regardless of the audio source type, IC2002 outputs the processed audio
as PWM for amplication by IC2005. The selected audio is also output
as L/R analog to the rear audio output jacks and the optical output. Audio
content from the optical output jack is limited.
Ethernet (DLNA)
Included in Figure 4-1 is a truth table for the optical output. The only
time 5.1 channel audio is available is when it is received via ATSC tuner
sources. This includes terrestrial 8VSB and QAM from cable systems. If a
DVD player is connected via HDMI and the DVD output is set to 5.1, the
output from the optical jack will be 2-channel PCM only. All analog sources
are output as 48 KHZ 2CH PCM. The only time audio is not output is when
digital audio is input via the HDMI connectors from a SACD or DVD-Audio
disc.
Troubleshooting
CTV-45
Audio or video le playback for the DLNA feature is not supported by any
of the 2008 EX1 chassis models. Only JPEG les are supported.
Since all circuitry involving audio processing and amplication is located

on the BU board, troubleshooting audio problems consists of determining
whether the failure affects all inputs or it is input specic. Failures affecting
all inputs would require changing the BU board whereas input specic
problems would require eliminating the input device as the source.
29
Chapter 4 - Audio Process
HDMI 1
HDMI 2
HDMI 3
HDMI 4
IC5200
HDMI
SWITCH &
EQ
OP
AUDI
I2S
IC4700
TRIDENT
DIGITA
DVD HD
ALL ANA
NTSC T
USB2.0
SACD V
ETHERNET
Z MODELS
ONLY
DVD AU
ATSC/NTSC
TUNER
USB2.0
ATSC
AUDIO
NTSC
AUDIO
IC7000
AMD
FE MICRO
ETHERN
SPDIF
I2S
Y/C_COMPOSITE 1
I2S
COMPOSITE 2
COMPOSITE 3
COMPONENT 1
COMPONENT 2
IC2002
AUDIO SW
DSP
PWM
IC2005
CLASS D
AUDIO AMP
IC2004
LINE OUT
AMP
PC
HDMI 4 ANALOG
DIGITAL MEDIA PORT

(Z AND LARGE XBR
MODELS ONLY )
IC7500
D/A
L/R AU
FIGURE 4-1
AUDIO PROCESS CIRCUITS
OPTIC
CTV-45
30
BU
Chapter 5 - Power Supply

Overview
Several power supplies are used in the EX1 chassis. The type of power
supply is determined by LCD panel size and the type of inverter circuit
used to power the backlights.
All of the power supply designs contain on-board over-voltage and overcurrent monitoring to stop the switching supply if a problem is detected.
If the main switching supply is stopped, the unit will shut down and the
time LED will blink in groups of 2. This feature will be discussed in further
detail in Chapter 7 where the protection and self-diagnostics features are
explained.
G1D/G2D Power Supplies

In Figure 5-1, an overall block diagram is shown for the G1D and G2D
power supply circuits. These power supplies are used on the smaller V
series models. The G1D is used in the KDL32L140 and KDL32XBR6.
The G2D is used in the KDL37XBR6 and KDL42V4100 models. They are
virtually identical in design with the G2D have a larger current producing
capacity for the larger LCD panel backlighting. Both power supplies are
used in models to provide power to what is known as indirect inverters.
These inverters contain all of the necessary circuits for generating the highvoltage AC to power the backlights along with current and lamp detection
circuits. These inverters will be discussed in detail in Chapter 6.
The power supply consists of 3 major circuits:
By using a PWM generator, switching transistors and coils, the PFC circuit
pumps up the rectied 160VDC to approximately 395VDC. This voltage
supplies continuous power to the standby supply. Note that even when the
main relay RY6101 is open at turn-off, the thermistor NTC01 is passing
AC voltage to the bridge rectier B01. The PFC circuit is turned off but the
coils will pass the 160VDC to the standby power supply. PFC activation
is accomplished by the power on command entering at pin 1 of CN602
which is high (3.3V) at turn-on.
Standby Power Supply

This supply runs continuously whenever AC power is applied. It generates
12VDC for the relay RY6101 and 3.3VDC for the microprocessors on the
BU board, IR receiver on the H4 board and function LEDs on the H1
board.
Main Switching Supply

The main switching supply is activated when the power on high command
is received at pin 1 of CN602 from the BU board. This also activates
the PFC circuit and the DC voltage feeding the main supply rises to
approximately 395V. The main switching supply generates 24V for the
inverter board(s), unregulated 13V for the audio circuits, and regulated
12V for the BU board.
Note that the KDL42V4100 has dual inverters and that CN603 is used in
this model to provide an additional 24VDC source for a second inverter
board.
Power Factor Control (PFC)

The inductive load of the switching power supply circuits causes the voltage
and current to be 90 degrees out-of-phase. The PFC circuit compensates
for this and makes the power supply appear as a purely resistive load
and to use the AC input power more efciently. This circuit is only present
because of requirements by the Western European countries and Canada
so they are included on all power supply designs.
CTV-45
31
Chapter 5. Power Supply Circuits

AC
IN
F1
4A
NTC1
T
BD1
AC
IN
G2D ONLY
(42")
PFC
IC801
Q800
Q802
L800
CN603
1
UNREG_24V
GND
CN601
PRIMARY
POWER
SUPPLY
IC601
Q601, 602
T600
RY6101
STANDBY
POWER
SUPPLY
STBY
12V
UNREG_24V
GND
TO
INVERTER
CN602
4
UNREG_13V
AU GND
11
REG 12V
GND
STBY 3.3V
POWER_ON
TO BU
BOARD
STBY
12V
STBY
3.3V
IC305
Q805
Q901
Q302
Q303
G1D (32")
G2D (37")
FIGURE 5-1
G1/G2D POWER SUPPLY BLOCK DIAGRAM
CTV-45
32
IP5 Power Supply and Inverter

New to the 2008 EX1 chassis models, this combination power supply
and inverter is found in 40 and 46-inch V and W series models and is
illustrated in Figure 5-2. The basic functions of the PFC, standby and main
switching supply are the same as the previously described circuits of the
G1D and G2D power supplies with the following exception:
Integrated Lamp Inverter

The PFC circuit also supplies approximately 395VDC to an inverter circuit
consisting primarily of an oscillator/drive circuit and high-voltage step up
transformer and switching transistors.
Approximately 5 seconds after the unit is turned on, a high (3.3V) is received
via pin 4 of CN6154 from the BU board. This causes the inverter to output
approximately 1KV of 51KHZ AC to drive the uorescent backlights. The
lamp voltage consists of 2 180 degree out-of-phase voltages which are
sent to the balancer board. This AC voltage is not continuous. The duration
of the AC varies depending on the brightness setting of the backlights.
This is controlled by the dimmer line at pin 5 of CN6154. The dimmer
control is a negative going PWM signal that varies between approximately
6% at full brightness to 70% at minimum brightness.
Warning: When the unit is turned off while still connected to AC power,
the rectied 160 volts will pass through the PFC circuit and always be
present. This voltage is referenced to hot ground. Use caution when near
this circuit and make sure to use an isolation transformer when using
grounded test equipment.
G5 Power Supply
Figure 5-4 illustrates the block diagram for the G5 power supply board
used in the 52-inch V and W series models (including the 52XBR6). This
power supply has a larger current capacity and dual PFC outputs. The
52-inch panels use 2 inverter boards (D4 and D5) requiring the dual PFC
lines.
Operation of the inverter, along with example waveforms, is covered in

more detail in Chapter 6.
G4 Power Supply
This power supply is used in the 40 and 46-inch Z and XBR6 models and
is shown in Figure 5-3. The standby and main switching supplies operate
in the same manner as the previously covered power supply circuits.
PFC Output
These models use a stand-alone inverter located on the D3 board. The
inverter requires 395VDC and this is supplied by the PFC circuit via
CN6502 to the D3 board.
CTV-45
33
F6001
6.3A
CN6502
R6009
AC
IN
395VDC
PFC
AC
IN
D6000
HV+ OUT
IC6701
Q6706, 6707
T6800
Q6602, 6603
T6600, 6601
HV- OUT
INVERTER_ERR
INVERTER
BACKLIGHT_ON
DIMMER
REG 12V
GND
UNREG 15V
UNREG 15V GND
11
REG 12V
GND
GND
10
GND
STBY3.3
AC_DET
PWR_ON
TO
BALANCER
CN6154
FROM BU
BOARD
RY6000
IC6100
Q6100
Q6101
T6100
CN6151
PRIMARY
POWER
SUPPLY
STBY
12V
IC6200
T6200
STANDBY
POWER
SUPPLY
CN6150
STBY
12V
PH6300
Q6303
Q6304
NOT USED
FROM BU
BOARD
Q6404
IP5
IP5
FIGURE 5-2
IP5 POWER SUPPLY/INVERTER BLOCK DIAGRAM
CTV-45
34
CN6501
395VDC
F6000
6.3A
PFC OUT
PFC GND
TO D3
BOARD
R6009
AC
IN
395VDC
PFC
AC
IN
IC6200
T6200
STBY
12V
STANDBY
POWER
SUPPLY
D6000
STBY
3.3V
RY6000
CN6202
IC6100
Q6100
Q6101
T6101
RLY_VCC
(REG 12V)
PRIMARY
POWER
SUPPLY
STBY
12V
13
REG12V
REG12_GND
UNREG_GND
UNREG_15V
STBY3.3
AC_OFF_DET
POWER_ON
TO BU
BOARD
PH6300
Q6303
Q6304
Q6407
G4
FIGURE 5-3
G4 POWER SUPPLY BLOCK DIAGRAM
CTV-45
35

CN6501
F6000
6.3A
PFC OUT
PRI GND
PFC OUT
PRI GND
REG 12V
GROUND
DIMMER
BACKLIGHT
INV_ERR
BALANCE_ERR
BALANCE_ERR
INV_ERR
BACKLIGHT
DIMMER
REG12V
13
REG12V
REG12_GND
UNREG_GND
UNREG_15V
STBY3.3
AC_OFF_DET
POWER_ON
R6009
TO D5
BOARD
CN6500
AC
IN
390VDC
PFC
AC
IN
IC6200
T6200
STBY
12V
STANDBY
POWER
SUPPLY
D6000
STBY
3.3V
TO D4
BOARD
CN6100
RY6000
TO TCON
CN6154
RLY_VCC
(REG 12V)
TO BU
BOARD
CN6153
IC6100
Q6100
Q6101
T6101
STBY
12V
CN6150
PRIMARY
POWER
SUPPLY
PH6300
Q6303
Q6304
TO D4
BOARD
Q6407
TO BU
BOARD
G5
FIGURE 5-4
G5 POWER SUPPLY BLOCK DIAGRAM
CTV-45
36
Troubleshooting
In order to properly diagnose a potential problem with the power supply it
is important to determine if the power supply is completely dead or will not
turn on when commanded to do so. There are a couple of important items
to be aware of when rst examining the unit.
In a properly functioning unit the standby 3.3V line will remain at this
voltage for approximately 2 minutes after the AC source is removed.
This is part of the AC detect routine and allows the BE Micro to remain
running and clear the operational routines to prevent lockup because of a
decaying standby voltage.
If the unit was not in the on position before AC power was removed and
has not had AC power applied for approximately 2 minutes, the BU
board will output a power on command to turn on the relay as soon as AC
power is returned. The power LED will not light. The distinct click of the
AC relay can easily be heard and it will remain engaged for approximately
30 seconds before turning off. This is very important to know when
determining if the standby supply, AC relay and BE micro on the BU board
is functioning. If has been less than 2 minutes since AC power was
disconnected the relay will not perform this routine. If the unit was turned
on when the AC power was disconnected, it will power up completely
regardless of how long AC power was disconnected.
When the television is working properly the AC relay will not disengage at
turn-off until approximately 20 seconds has elapsed.
The following troubleshooting procedures will deal with general approaches
to locating the problem. The troubleshooting owcharts at the end of this
chapter are created to specically address the unit based on what power
supply is used,
CTV-45
Completely Dead Unit

Since the EX1 chassis models do not use a power standby LED, it becomes
necessary to determine if the standby power supply is operating. Unplug
the unit from the AC source and wait for 3 minutes. Plug the unit back
in and listen for the sound of the relay clicking. If it does, the standby
supply is operating. This also conrms that the BE Micro is able to turn on
the relay. At this point it is conrmed that the main switching regulator is
probably at fault although it is unusual for this to happen without the 12V
LVP circuit detecting it and shutting the unit down with a 2 blink diagnostics
indication.
Power Supply Shutdown

If the power supply manages to turn on and then turns off, there are a
couple of reasons that could cause this. If the main switching regulator
does not turn on, the loss of REG12V will be detected and the unit will
shut down and the standby LED will blink in sets of 2.
The same event occurs when there is excessive current being drawn on
the secondary supply lines from the main switching regulator which has
its own over-current detection circuit. This causes the switching oscillator
to stop and one of the results is the loss of the REG12V line.
Power Supply Troubleshooting Flowchart

The troubleshooting owchart in Figure 5-5 will assist in determining the
cause of a no power condition.
37
No Power
Unplug unit from

AC and wait 3
minutes. Reapply AC power .
Relay click
heard ?
No
STBY3.3V
CN1411 -3 on
BU board?
No
Yes
Replace Power
Supply
Replace Power
Supply
Yes
POWER_ON
3.3V CN1411 -1
BU Board?
Yes
Replace Power
Supply
No
Replace BU
Board
FIGURE 5-5
NO POWER TROUBLESHOOTING FLOWCHART
CTV-45
38
Chapter 6 - Panel Backlight Circuits

Overview
Inverter Circuit
All models in the EX1 chassis series use uorescent tubes to provide the
backlighting necessary for the LCD panel. The Z and W series models
use conventional cold-cathode uorescent (CCFL) lights while the Z
series utilize Wide Color Gamut lamps (WCGCCFL). The lamps on all
panels are arranged horizontally and evenly spaced from top to bottom.
The number of lamps ranges from 16 for the 32-inch panels to 24 for the
52-inch.
Note that each inverter-drive circuit feeds a pair of lamps. Since each
pair of lamps is connected to the opposite end of a transformer they are
driven with out-of-phase AC voltage. This is necessary to prevent parasitic
capacitance between the lamps to prevent brightness uctuations.
The primary difference among the various panel sizes and designs is the
type of backlighting circuitry and monitoring that is used. The following
diagrams and circuit descriptions will be covered separately based on
these differences.
32/37-inch Backlighting
Figure 6-1 illustrates a block diagram of the circuits involved in generating

the backlight voltage for the lamps. The smaller 32 and 37-inch panels
use a single inverter board to supply an AC voltage of approximately
1000-volts RMS at 57KHZ.
Power-Up Sequence
Once the power on command is received at CN602-1 on the G board from
BE Micro IC3001, the power supply starts and, along with other secondary
voltages, outputs 24VDC to CN001 on the inverter board.
Approximately 5 seconds after turn-on, the backlight on command goes
high at CN1401-4 on the BU board. The oscillator on the inverter will
start and the drive circuits for each pair of lamps will begin generating the
necessary lamp voltage.
CTV-45
The AC voltage supplied to the lamps is not a steady voltage. The lamps
are provided with a variable duty cycle of AC bursts. This is how the unit
is able to vary the brightness of the backlights. The duty cycle of these
burst will vary from 30% at minimum brightness up to 95% at maximum.
The lamp brightness is controlled by the dimmer line exiting the BU board
at CN1401-5. This control line is a negative going PWM signal that will
vary its duty cycle from approximately 70% negative at low brightness to
approximately 10% at high brightness. This duty cycle change affects the
DC voltage at this point and it can be read with a DVM. The DC voltage
reads 0.8 volts at low brightness and 3.1 volts at full brightness. Typical
waveforms for the inverter output and dimmer PWM signals are shown in
Figure 6-2.
The inverter board also contains monitoring circuits (not shown) to detect
a failure of one or more of the inverters or if one or more of the lamps fails
to light. If either one of these situations occurs, the inverter will send out
a high on the INV-ERR line to CN1401-3. This is detected by BE Micro
IC3001 on the BU board. IC3001 will shut the unit down and the standby
LED will blink in groups of 6.
NOTE: Whenver an inverter error is detected, the unit will make 3 attempts
to start the inverter. The AC relay will be heard cycling on and off during
these attempts.
39
Chapter 6. Backlight Circuits

INVERTER
LCD PANEL
INVERTER
DRIVE
INVERTER
DRIVE
APPROXIMATELY
IKV RMS
CN001
INV_ERR (NORMALLY LOW)
BACKLIGHT_ON (3.3V ON)
DIMMER (PWM)
CN1401
GND
INV_ERR
BACKLIGHT_ON
DIMMER
2
3
4
5
CN601
PIN 1~5
24VDC
CN602-1
CN1411
POWER_ON
POWER_ON
POWER _ON
3.3V = ON
IC3001
BE
MICRO
BU
G1D (32")
G2D (37")
FIGURE 6-1
32/37-INCH PANEL BACKLIGHT DIAGRAM
CTV-45
40
2ms
1V/div
2ms
1V/div
DIMMER MINIMUM BACKLIGHT PWM
DIMMER MAX BACKLIGHT PWM
2ms
10V/div
Indirect coupling
2ms
10V/div
Indirect coupling
MAX BACKLIGHT AC DUTY CYCLE
MINIMUM BACKLIGHT AC DUTY CYCLE
FIGURE 6-2
INVERTER WAVEFORMS
CTV-45
41
42-inch Backlighting
The KDL42V4100 is unique in that this model is the only one that uses
this panel design and backlighting scheme. The board layout is shown in
Figure 6-3. The G2D power supply used in the 37-inch panel contains an
extra connector for an additional 24VDC source and this is used to power
the additional inverter board found on this model.
INVERTER
Power-up and protection functions very much the same way as the system
used in the 32/37-inch panels with the exception of the additional inverter.
Due to the longer length of the backlight tubes, differential AC is applied
to both ends of the uorescent lamps instead of using a common ground
reference.
CN24
CN26
INVERTER
INVERTER
DRIVE
INVERTER
DRIVE
INVERTER
DRIVE
INVERTER
DRIVE
APPROX
IKV RMS
LCD PANEL
CN23
CN25
CN001
CN001
INV_ERR (NORMALLY LOW)
DIMMER (PWM)
CN1401
GND
INV_ERR
BACKLIGHT_ON
DIMMER
2
3
4
5
CN601
PIN 1~5
24VDC
CN602-1
CN1411
POWER_ON
POWER_ON
POWER _ON
3.3V = ON
G2D
IC3001
BE
MICRO
BU
CN603
FIGURE 6-3
42-INCH PANEL BACKLIGHT DIAGRAM
CTV-45
42
40/46 V and W Series Backlighting

These LCD panels have a considerably different backlighting arrangement
than those seen in the previous circuit descriptions. High voltage for the
lamps is generated on a separate inverter circuit that is part of the power
supply board. A balancer circuit has been added in addition to the inverter
and will be explained separately. A basic block diagram is shown in Figure
6-4.
Inverter
Once the IP5 board receives a power on high at CN6150-1 the power
supply begins generating the necessary voltages. The PFC circuit
increases the rectied 160VDC to approximately 395VDC to supply
power for the inverter switching transistors. The oscillator provides the
necessary 41KHZ drive for the inverter switching transistors. The inverter
stage outputs approximately 1000VRMS at 2 output lines that are 180
degrees out-of-phase.
Note the inverter detect stage. The detector consists of small-value
capacitors and diodes to detect the AC voltage. If either AC line fails to
output the inverter detect circuits will output a high to CN6154-3. This will
be detected by BE Micro IC3001 on the BU board and the unit will shut
down and blink the standby LED in groups of 6. The event will also be
registered into the diagnostics menu for viewing when entering that mode.
This will be covered in Chapter 7.
The inverter also has over-voltage and over-current detection circuits (not
shown). If either circuit detects a malfunction the oscillator will stop and
create an inverter detect failure.
CTV-45
43

BALANCER
LCD PANEL
BALANCE
ERROR
DET
1000 VRMS
1
2
3
4
5
INVERTER
CN6701
12V
FB
GND
LD
1 12VDC B+
2 FB (FEEDBACK)
7.2VPP
4 GROUND
6 LD (LAMP DET)
1
2
4
6
OSC/
DRV
BALANCER ERROR (NORM LOW)

GROUND
INVERTER ERROR (NORM LOW)
BACKLIGHT (3.3V ON)
DIMMER (0.8 ~ 3.1VDC)
INV
DET
CN6154
1
2
3
4
5
BALANCER_ERR
GROUND
INVERTER_ERR
BACKLIGHT ON
DIMMER
POWER_ON
CN1401
PFC
NORM HIGH (12V)
CN6150
IC3001
BE
MICRO
CN1411
IP5
BU
FIGURE 6-4
40/46-INCH V AND W SERIES PANEL BACKLIGHT DIAGRAM
CTV-45
44

Balancer
The problem that arises when feeding high voltage to parallel arranged
uorescent lamps is making sure all of the lamps are struck or, in other
words, ignited to their ionization point. When the inverter is initially turned
on it generates a brief period of approximately 2 to 3 times the operating
voltage to strike the lamps. If one or more of the lamps does not ignite, the
remaining lamps that did will clamp the initial strike voltage and that lamp
will not light. The other issue is maintaining even current draw among all
of the lamps during normal operation to ensure even backlighting of the
panel. A circuit that is designed to balance the current among the lamps
is necessary.
The balancer performs several distinct functions and a basic block diagram
of the type used in a 40 model is illustrated in Figure 6-5.
Distribution of the high voltage: The 2 out-of-phase high voltage lines
are applied to each lamp with one line each feeding every other lamp. The
lamps are driven with every other lamp out-of-phase in order to localize
the high voltage eld around each lamp and keep them from causing
brightness uctuations in adjacent lamps and minimize interference to the
LCD panel.
Maintaining Lamp Current Balance: Since the lamps are being driven
by a common power source and are arranged in a parallel conguration,
variances in lamp tolerances and aging of the lamps requires that the
current drawn by the lamps be maintained steady to achieve balanced
brightness (hence, the name balancer board). Each lamp is supplied with
high voltage through the primary winding of a transformer. The secondary
windings of each transformer are connected in series to form a closed
loop. The circulating current in the secondary loop is what maintains the
balance of the current being drawn by the lamps.
As long as all of the lamps are drawing acceptable current, the magnetizing
energy between the primary and secondary of each transformer cancels
each other out and prevents an inductive ux from being generated. If
a lamps current draw drops, a differential in current will occur and the
secondary will induce the difference into the primary and maintain balance
in the current among the lamps. The circuit also helps during the initial
strike of the lamps at turn-on since any lamp that does not light in unison
CTV-45
with the others will receive a kick due to the imbalance on its transformer.
In theory, assuming all of the lamps are identical and consuming exactly
the same amount of current, the voltage in the secondary winding loop
would be near zero. In reality, there will be some voltage in the loop as
it performs its job of maintaining balance among the lamps and this is
acceptable to a certain point. This is where the secondary loop functions
as a protect circuit.
Open Lamp Protection: If one or more of the lamps fails to draw
adequate current, the unit must go into protect mode since an out of
balance condition can damage the other lamps and also cause damage
to the circuit board due to arcing. This generally occurs when a lamp has
weakened to the point where it will not turn on when struck. In this situation,
there will be little or no current in the primary winding of that lamp and the
current differential will cause an induced voltage between the primary and
secondary windings. Once the secondary loop induces into the primary
winding of the defective lamp, the primary begins to induce back into the
secondary. This causes the voltage level to rise in the loop.
4 sampling taps are taken along the secondary windings consisting of a
resistor divider network and a diode. If an imbalance occurs, the current
loop of the secondary windings will now function as a voltage loop. One
of the taps will detect a rise and the rectied voltage will exceed the zener
diode rating (7 volts). A comparator detects the zener diode ring and
sends a high to an inverter. Under normal conditions, the Lamp Detect
(LD) line will be high (12VDC) and goes low if one or more open lamps are
detected. This is dened as a balancer error and the unit will shut down
and blink the standby LED in groups of 13.
Feedback: The nal function of the balancer circuit is to provide feedback
to the inverter circuit in order indicate overall current draw by the lamps and
maintain steady drive voltage. An additional transformer is included in the
loop to provide an overall sample. This feedback signal is approximately
7.2VPP. This signal is sent back to the primary inverter (the one with the
oscillator) to keep the overall lamp brightness steady.
45

HV IN +
HV IN -
TO
LAMPS
REF
LD (LAMP DETECT)
NORM HIGH (12V)
FEEDBACK
40" FIGURE
PANEL BALANCER
6-5
40-INCH BALANCER DIAGRAM

CTV-45
46
40/46 Z Series Backlighting
D5 Board
The LCD panels in the Z series models include the KDL40Z4100,

KDL40XBR6, KDL46Z4100 and KDL46XBR6. All functions previously
described for the V and W series backlight circuits apply except that the
inverter is not integrated with the power supply.
This board drives the opposite side of each lamp with 180 degree out-ofphase AC. Since the D4 board contains the master oscillator and drive
circuits, this is how the 2 inverters are able to maintain their out-of-phase
condition to drive the lamps.
These models use a G4 power supply and a separate D3 board that

contains the inverter circuits. The balancer circuit is identical. A block
diagram of the backlighting circuits for this series is shown in Figure 6-6.
Note that the D5 board also contains an inverter detect circuit should one
or more of the AC output lines fail. Although the intention is to warn the
unit and shut it down when the inverter fails, this will not happen if the
D4 board is still operational. The inverter detect circuit on the functioning
D4 board will keep the inverter-error line low and prevent an inverter
failure warning from being detected. The balancer error detect circuits will
activate and shut the unit down with a 13-blink error instead. This subject,
along with how to isolate it, will be covered in the troubleshooting section
in this chapter.
All 52-inch Series Backlighting

All 52-inch EX1 chassis models utilize the backlighting circuitry illustrated
in Figure 6-7. The longer backlights require the use of a oating AC power
system to prevent exterior current leakage along the lamps. If a common
ground connection is used with a single phased AC at one end of the lamp,
brightness would be less in the middle of the lamp than at the edges. This
requires the use of a different power supply board and 2 inverters. Since
AC is applied to both ends of the lamps, separate balancers are required
on the left and right side of the panel.
G5 Board
Operating the same as the G4 board previously mentioned for the 40/46Z
models, the G5 power supply provides an additional PFC 395VDC output
for the second inverter board.
D4 Board
This board is similar to the D3 board used in the 40/46Z series models
in that it generates dual out-of-phase AC voltage for the lamps. It also
contains the master oscillator and drive circuits for the on-board inverter
switching transistors. This oscillator and drive circuit is responsible for
driving the switching transistors on the D5 board.
CTV-45
47

BALANCER
BALANCE
ERROR
DET
LCD PANEL
1000 VRMS
1 BALANCER ERROR (NORM LOW)

2 GROUND
3 INVERTER ERROR (NORM LOW)
4 BACKLIGHT (3.3V ON)
5 DIMMER (0.8 ~ 3.1VDC)
CN6701
12V
FB
GND
LD
1
2
4
6
INVERTER
INV
DET
1
2
3
4
5
OSC/
DRV
CN6701
1 12VDC B+
2 FB (FEEDBACK)
7.2VPP
4 GROUND
6 LD (LAMP DET)
NORM HIGH (12V)
CN6600
CN1401
D3
IC3001
BE
MICRO
CN6502
CN6600
1 395VDC
3 HOT GND
CN6702
BALANCER_ERR
GROUND
INVERTER_ERR
BACKLIGHT ON
DIMMER
PFC
AC_RLY
CN6150
POWER_ON
G4
CN1411
BU
FIGURE 6-6
40/46-INCH Z SERIES PANEL BACKLIGHT DIAGRAM
CTV-45
48

UPPER AND
LOWER LEFT
BALANCERS
UPPER AND
LOWER RIGHT
BALANCERS
BALANCE
ERROR
DET
BALANCE
ERROR
DET
LCD PANEL
CN6706
12V
FB
GND
LD
1
2
4
6
INVERTER
OSC /
DRV
1 12VDC B+
2 FB (FEEDBACK)
7.2VPP
4 GROUND
6 LD (LAMP DET)
CN6600
800VRMS
INV
DET
INVERTER
CN6950
CN6703
CN6702
INV
DET
D4
CN5900
D5
NORM HIGH (12V)
CN6600
1 395VDC
3 HOT GND
CN6154
CN6500
CN6501
CN6153
PFC
CN6154
1 BALANCER_ERR (NORM LOW)

2 GROUND
3 INV_ERR (NORM LOW)
4 BACKLIGHT_ON (3.3V ON)
5 DIMMER (PWM)
6 REG_12V
CN6154
1
2
3
4
5
6
BALANCER_ERR
GROUND
INVERTER_ERR
BACKLIGHT ON
DIMMER
REG_12V
POWER _ON
CN6150
G5
CN1401
IC3001
BE
MICRO
CN1411
BU
FIGURE 6-7
52-INCH PANEL BACKLIGHT DIAGRAM
CTV-45
49
Troubleshooting
Failures that occur in the backlighting circuits that cause the unit to shut
down can be caused by one or both of the following reasons:
Inverter Failures
Backlight Balancer errors
Inverter Failures
The following description will involve the single inverter panel. Panels
using dual inverters have a slightly different reaction to inverter issues
and these will be discussed separately.
If the inverter fails to turn on, or if it turns on and goes into protective stop,
the unit will shut down and the standby LED will blink in groups of 6 after
the unit has made 3 attempts to start the inverter. Inverter circuits contain
the necessary components to detect the presence of the high voltage AC
generated by the switching transistors and transformer. If one or both of
the differential phased AC lines fails to output, the inverter detect circuit
will cause the normally low inverter error line to go high. This event is
detected by IC3001 on the BU board. The event will also be recorded into
NVM for display when the diagnostics page is called up and this feature
will be covered in Chapter 7.
Inverter Does Not Start

If the inverter fails to start, this is easy to detect. The backlights should
turn on approximately 5 seconds after the unit is powered up. Except for
extremely high ambient lighting conditions, you should be able to detect
the lighting of the backlights. Many of the newer panels have multiple
holes in the rear of the panel where the backlights can be viewed even
if the rear cover is on. If the backlights never turn on and the unit shuts
down with a backlight failure indication it is safe to assume one of the
following circuits is the cause.
(0.1 ohm, 1/2 watt) in line with this voltage on the power supply and they
occasionally open. Check for the backlight on command at CN1401-4 on
the BU board. It should go high to around 3.3VDC about 5 seconds after
the unit is turned on. It is extremely rare for this to be the cause but if it
does not go high, There is a connection problem at the power on line or
the BU board is defective. If all of the above checks out OK, replace the
inverter board.
Power Supply: If the power supply is not outputting the 395 volts, replace
the board if the unit is under warranty. Models using the IP5 combination
power supply and inverter would simply require replacing that board under
this and the previous condition.
BU Board: If the BE Micro on the FB board fails to send a 3.3V backlight
on command the unit will shut down as if the inverter had failed. Be certain
to record the serial number of the unit so the correct version of FB board
can be ordered. The version of FB board is determined by which LCD
panel was installed during the manufacturing process.
Inverter Starts and Turns Off

This is easily identied by the brief presence of backlighting before the unit
shuts down. The EX1 chassis will attempt to run the inverter 3 times before
shutting down. The inverter board contains over-voltage and over-current
detection circuits. These circuits usually activate because of a problem on
the inverter board. On units that have balancer circuits, one item that can
cause an over-voltage shutdown of the inverter is the feedback from the
balancer board. If this feedback line fails, the inverter regulation line will
apply full power in an attempt to get a feedback reading. This excessive
voltage will activate the OVP circuit located on the nverter board. You will
need an oscilloscope to check the feedback line at pin 4 of CN6702 on
the DF1 board. It is normally around 7.2VPP a will have the same wave
shape as the AC power driving the lamps. If it is very low or not present,
the balancer is the most likely cause of the problem.
Inverter: Check for the presence of 395VDC at CN6600 on the DF1

board. This voltage line is referenced to hot ground so you will have to
read across pins 1 and 3 of the connector. There is a fusible resistor
CTV-45
50
Dual Inverter Circuits
Balancer Errors
The use of dual inverters can produce symptoms that will not be seen on
single inverter designs. Note that the DF4 board contains the oscillator to
drive the inverter on both the DF4 and DF5 boards. The common oscillator
and drive circuits are needed to keep the lamp voltages out-of-phase at
the opposite ends of the lamps. In this design a unique situation occurs if
the inverter fails on the DF5 board.
When a balancer error occurs, we at least have the ability to observe the
lighting of the lamps before the unit shuts down. The unit must a have a
correctly functioning inverter to start the lamps and allow the balancer
detect circuit to function. In some cases, the lamps may light long enough
to see active video or snow for a couple of seconds. Observing the
backlighting of the panel at this time is a great tool in determining what is
causing the shutdown.
Note that both inverters have a detect circuit. Both detect lines actually
tie together on the DF4 board. The problem with this design is that if
only the inverter on the DF5 board fails, the inverter on the DF4 board
will still be functioning because that is where the oscillator/drive circuits
are located. This will cause the functioning inverter on the DF4 board
to keep the inverter error detect line from activating since the common
point of both inverter detect lines are not or-gated to isolate them from
one another. The unit will never go into inverter protect shutdown. The
balancer error detect circuits will activate and the unit will shut down with
13 blinks instead of 6.
Since the DF4 board is operating, the backlights will light momentarily
but if one observes the screen closely, you should notice that the right
side is backlit with a little more intensity than the left side. It is subtle, but
you should be able to detect it. The same symptom could appear if the
inverter were to fail on the DF4 board with the oscillator/drive circuits still
functional. This would keep the DF5 board active and the symptoms and
shutdown events would be the same except the left side of the screen
would have a little brighter backlighting than the right before the unit shuts
down.
CTV-45
NOTE: Unlike an inverter error where the unit will make 3 attempts to start
the inverter, a blanacer error will cause the unit to cycle 2 times before the
protect shutdown occurs.
Remember, the purpose of the balancer detect circuit is to monitor a lamp
that will not startup. Unless a particular model has a history of a related
component causing balancer error shutdowns to occur, it will usually be a
defective lamp and that will require replacement of the entire LCD panel.
A lamp that is not lighting is difcult to spot due to the efciency of the
diffuser panel to spread the light.
In models that use inverter boards on both sides, observe the screen for
uneven lighting from one side to another. This indicates a faulty inverter
board and the side that is darkest is where the failed inverter resides.
51
Balancer Board Removal

A new High voltage connector is used to secure the wires from the inverter
to the balancer board(s). It contains an integrated locking device that must
be released before the connector can be pulled loose. This procedure is
illustrated in Figure 6-8. Once the lock is released, grasp the connector
as shown and pull it straight out of the socket. Do not rock the connector
to attempt to loosen it or you may damage the connector and/or circuit
board.
As noted in Figure 6-9, once the screws securing the plastic or metal
cover on the balancer board are removed there is usually no more screws
securing the balancer board. On some panels there may be an additional
screw securing the board once the cover is removed.
Due to the various LCD panel designs used in the EX1 chassis it becomes
necessary to create troubleshooting owcharts that are specic to the type
of inverter system used. Most balancer errors will end up being caused
by a defective lamp in the panel but there is a possibility of an inverter
related failure and this is especially true for the 52-inch panels using dual
inverters.
Failures within the inverter circuit(s) will require the use of a DVM to assist
in isolating the cause. The Flowcharts contained within Figures 6-10
through 6-13 are specic to panel size and design and should prove to be
a useful tool when troubleshooting the unit on-site or in the shop.
Do not remove the screws securing the long black plastic strip near the
edge of the panel. This contains the sockets for the tabs protruding from
the balancer board. The other side of these sockets secures a pin on the
end of each uorescent lamp. If this socket strip is loosened, damage to
one or more of the lamps is likely.
The balancer board is removed by pulling it sideways and out of the
sockets. This may require some effort and rocking of the board at the
top and bottom ends.
SLIDE LOCKING
TAB IN DIRECTION
OF ARROW TO
RELEASE
SQUEEZE BOTH
SIDES OF
CONNECTOR AND
PULL STRAIGHT OUT
FIGURE 6-8
HIGH VOLTAGE LOCKING CONNECTOR
CTV-45
52
DO NOT REMOVE THE

SCREWS UNDERNEATH THE
COVER. THESE SECURE THE
LAMP SOCKETS TO THE
PANEL. IF THEY ARE
REMOVED, DAMAGE TO THE
BACKLIGHT LAMPS WILL
OCCUR IF THE BALANCER
BOARD IS MOVED.
PULL BALANCER
BOARD IN
DIRECTION OF
ARROW TO
REMOVE
COVER REMOVAL
SCREWS
VIEW OF OTHER SIDE OF

BALANCER SOCKETS SECURING
BACKLIGHT LAMP
BALANCER REMOVAL ISSUE
FIGURE 6-9
BALANCER BOARD REMOVAL CAUTION
CTV-45
53

32/37" V SERIES
PANEL
BACKLIGHT
ERROR 6X
CN1401-3
ON BU BOARD
GOES HIGH
(3.3v)?
Yes
LCD Panel
No
Backlights Light
At turn-on?
BU Board
Yes
No
32" Panel ?
No
Yes
24VDC at
CN601-1 on G2D
Board ?
Yes
No
G1D Board
Yes
3.3VDC at
CN1401 -4 on BU
Board ?
Yes
Inverter Board
No
No
BU Board
G1D Board
24VDC at
CN601 -1 on G1D
Board ?
3.3VDC at
CN1401 -4 on BU
Board ?
Yes
Inverter Board
No
BU Board
FIGURE 6-10
32/37 BACKLIGHT TROUBLESHOOTING FLOWCHART
CTV-45
54
40/46" V AND W
SERIES PANEL ERROR
BACKLIGHT 6X
BALANCER 13X
Yes
Backlights Light
At turn-on?
3.3VDC
momentarily at
CN6154 -3
IP5
Board?
No
No
BU Board
6X OR 13X?
6X
13X
3.3VDC
momentarily at
CN6154 -4
IP5
Board?
Yes
Yes
7.2VPP
Feedback
CN6701-4 on IP5
Board?
Yes
IP5 Board
No
Balancer
IP5 Board
No
BU Board
Backlights
light at
turn-on?
No
IP5 Board
Yes
CN6701 -1 on IP5
board goes low ?
Yes
LCD Panel
No
IP5 Board
FIGURE 6-11
40/46 V SERIES BACKLIGHT TROUBLESHOOTING FLOWCHART
CTV-45
55
40/46" Z
SERIES PANEL ERROR
BACKLIGHT 6X
BALANCER 13X
Backlights Light
At turn-on?
Yes
3.3VDC
momentarily at
CN6154 -3
G4 Board ?
BU Board
Yes
D3 Board
No
Balancer
6X
395 VDC across

CN6502 on G4
Board?
Yes
13X
3.3VDC
momentarily at
CN6154 -4
G4 Board ?
G4 Board
Yes
CN6701 -6 on D3
board goes low ?
No
No
D3 Board
D3 Board
D3 Board
No
No
Backlights
light at
turn-on?
7.2VPP
Feedback
CN6701 -2 on D3
Board?
No
No
6X OR 13X?
Yes
BU Board
Yes
LCD Panel
FIGURE 6-11
40/49 Z SERIES BACKLIGHT TROUBLESHOOTING FLOWCHART
CTV-45
56
ALL 52-INCH
PANEL ERROR
BACKLIGHT 6X
BALANCER 13X
Backlights Light
At turn-on?
Yes
3.3VDC
momentarily at
CN6154 -3
G4 Board ?
Yes
No
No
D4 Board
Balancer
6X
395 VDC across

CN6500 on G5
Board?
Yes
13X
3.3VDC
momentarily at
CN6154 -4
G5 Board ?
G5 Board
Yes
CN6706 -6 on D3
board goes low ?
No
No
G5 Board
D4 or D5
Board
Yes
D4 Board
No
No
Backlights
light at
turn-on?
Yes
No
BU Board
6X OR 13X?
7.2VPP
Feedback
CN6706 -2 on D3
Board?
BU Board
Yes
LCD Panel
FIGURE 6-12
ALL 52 PANEL BACKLIGHT TROUBLESHOOTING FLOWCHART
CTV-45
57
Chapter 7 Protect Circuits

Overview
Backlight Protection
Key areas of the television are monitored for protection and, in all cases,
will shut the unit down. Once a fault has been detected and the unit has
shut down, the BE Micro IC3001 on the BU board will blink the standby
LED in repetitive sequences to indicate which fault was detected. The
fault will also be recorded into NVM so that the number of times the
event occurred can be displayed in the self-diagnostics mode. Figure 7-1
illustrates a simplied block diagram of the various circuits monitored for
protection.
The inverter circuits are monitored to protect the lamps and the backlight
circuits themselves. Monitoring of current drawn by the lamps is also
important to protect the inverter and balancer boards.
Voltage Protection
Low-voltage protection is monitored at 3 locations and over-voltage
protection at 2 places. The unit will shut down if a failure occurs at any of
these monitoring points.
DC Detect (2X)
The regulated 12V line from the power supply enters the BU board at
pin 1 of CN1411. This line is monitored directly by BE Micro IC3001 as
DC_DET. If the REG12V line fails, the unit will shut down and the standby
LED will blink in groups of 2.
Inverter Error (6X)

Entering the BU board at pin 3 of CN1401, the inverter error line is normally
low. This line goes high whenever the inverter loses one or both of the AC
lamp drive outputs. This may occur because of a failure of the inverter
or when the inverter is stopped because the OCP or OVP circuits on the
inverter board have detected a problem.
If IC3001 detects a high on the inverter error line the unit will make 3
attempts to get the inverter to start running. In almost all cases, the
backlights will never light. The exception to this is if the inverter is starting
but its over or under-voltage circuits are stopping it. During this cycle time
the clicking of the main relay will be heard as the unit turns on and off. If
the unit was last set to an input with active audio you may hear this for a
moment.
DC Alert (3X)
This line monitors 3 potential events:
Over-voltage of the REG5V from IC7132.
Low voltage of the REG5V from IC7132
Low voltage of the REG 3.3V
CTV-45
58
Chapter 7 - Protect Circuits

Balancer Error (13X)
Speaker Protect (8X)
This protect feature is not utilized in the models using the 32 and 37-inch
panels although it appears in the diagnostics screen. Only models that
use balancer boards have this feature.
Any DC detected on the speaker lines will cause this event. It is usually
caused by a failed audio amplier and since all audio components are
located on the BU board, this is the component to replace to resolve the
issue.
If one or more of the backlight lamps fails to light, the balancer loop will
cause the BAL_ERR line at pin 1 of CN1410 to go low from its normally
high state (11.5VDC). In virtually all cases you will see the backlights
turn on before the unit shuts down. Once a balancer error is detected
the unit turns off and blinks the standby LED in groups of 13. Unlike the
inverter error detection, the unit will not make another attempt once it
shuts down.
This event is most likely caused by a defective lamp. In the models that
use 52-inch panels it is possible that one of the 2 inverter boards has
failed and can be detected by one side of the screen appearing slightly
darker during the brief period before shutdown.
Other Protection
Power supply, Inverter and balancer errors are the most likely to be
remedied outside of the BU board. The remaining protection circuits
involve devices mounted on the BU board.
Temperature (7X)
IC3502 located on the BU board is a digital thermometer that sends data
directly to IC3001 regarding temperature within the television cabinet. If
the specied temperature is exceeded, the unit will shut down with a 7blink error.
If the unit shuts down immediately after turn-on, suspect a defective
IC3001 or an interruption of data on the I2C bus. Shutdown after extended
periods of operation may be caused by excessive ambient temperatures
or insufcient ventilation.
Trident (11X)
If a data reading error occurs between BE Micro IC3001 and Trident video
processor IC4700, the data read will be attempted 2 more times and if still
unsuccessful, the unit will shut down and blink the standby LED in groups
of 11. Replacement of the BU board is recommended.
TCON or HFR (12X 14X)

A communication error has occured from the TCON board. If the LVDS
cable is not defective or loose both conditions require the replacement of
the LCD panel.
# BLINKS
2
3
5
6
7
PROBLEM DETECTED
LOSS OF REG 12V
5V OR 3.3V OVP OR LVP
LOSS OF PANEL 12V
INVERTER NOT WORKING
EXCESSIVE TEMPERATURE
POSSIBLE SOLUTION
G BOARD
BU BOARD
NOT USED IN CHASSIS
INVERTER OR G BOARD
IF OCCURS IMMEDIATELY REPLACE
BU BOARD
8
11
12
13
DC DETECTED ON SPEAKER
TRIDENT IC PROBLEM
TCON ERROR
BALANCE ERROR (NOT USED IN
32 /37XBR6 MODELS)
BU BOARD
BU BOARD
LCD PANEL
LCD PANEL
14
HIGH FRAME RATE ERROR
LCD PANEL
SELF DIAGNOSTICS TABLE

CTV-45
59
DC_DET (MAIN _POWER)
2X
REG
3.3V
FROM
POWER
SUPPLY
CN1411
REG 12V
11
IC7132
5V REG
DC_ALERT
3X
Q3415
D7101
Q7101
CN1401
FROM
INVERTER
BAL_ERR
INV_ERR
1
3
BALANCER ERROR* 13X

INV_ERR 6X
*NOT USED IN
32/36XBR6
MODELS
IC2005
AUDIO
AMP
8X
IC3502
TEMP
SENSE
7X
IC4700
TRIDENT
HFR OR TCON
ERROR FROM
LCD PANEL
IC3001
BE MICRO
11X
12X or 14X
BU
FIGURE 7-1
PROTECT CIRCUIT BLOCK DIAGRAM
CTV-45
60
Diagnostics History
Troubleshooting Test Points
Whenever a problem is detected by the self-diagnostics feature that

causes the unit to shut down, the event is recorded and stored in NVM.
This is particularly helpful when dealing with intermittent failures but not
so helpful if the unit is always shutting down.
Figures 7-4 through 7-9 contain illustrations pointing to the important

and easily accessed test points for checking voltages and logic levels
of protect lines. They are grouped according to panel size and backlight
circuitry design.
The diagnostics history pages are retrieved by pressing the DISPLAY,

5, VOL and POWER buttons in sequence on the remote commander
when the unit is off. The diagnostics history page will appear as shown in
Figure 7-2
There are 2 pages containing failure history. Press the 1 key on the
remote to view the second page. Pressing the 4 key returns to the rst
page.
Note that a running count is kept anytime one of the detection circuits is
activated. This running count will continue until it is reset. This is performed
by pressing the 8 key on the remote followed by the 0 key. This should
always be done in order to clear the history and provide a clean table for
future use.
#
BLINKS
EVENT
COUNT
DIAGNOSTICS HISTORY (PAGE 1)
The diagnostics page also contains 4 sets of 5-digit numbers. The rst
set, beginning at the left, indicates the number of hours, in decimal format,
that the set has been operating. The next set is the boot count. This is the
number of times the unit has been turned on. The third set is the number
of hours the panel has been operating. This number can be reset to zeros
by pressing the 7 key followed by the 0 key. Only the panel hours will
be reset. The last group is not used in the EX1 chassis.
The troubleshooting owchart found in Figure 7-3 will assist in determining
what component is the likely cause of the protect shutdown. Due to the
large variances in panel backlight circuitry, shutdowns resulting in 6 or 13
blinks will refer you to another set of owcharts found in Chapter 6. These
owcharts will steer you in the right direction based on the model of the
unit you are servicing.
CTV-45
OPERATING
HOURS
BOOT
COUNT
PANEL
HOURS
NOT USED
DIAGNOSTICS HISTORY (PAGE 2)
FIGURE 7-2
SELF-DIAGNOSTICS PAGES
61
Immediately ?
C
7X
Temperature
Red Standby
LED Flashing
No
Check for possible

ventilation problem
Yes
Yes
BU Board
No
2X
MAIN POWER
Yes
POWER SUPPLY
(SEE POWER SUPPLY
TYPE IN APPROPRIATE
TRIAGE SHEET)
8X
Speaker
Protect
Yes
BU Board
No
No
3X
DC ALERT
Yes
BU Board
11X
TRIDENT
Yes
BU Board
No
No
5X
TCON
Yes
NOT USED
12X or 14X?
No
6X
BACKLIGHT
No
Yes
LCD PANEL
No
Yes
Go To Inverter
Troubleshooting
Flowchart
No
13X
Balancer
Yes
Go To Inverter
Troubleshooting
Flowchart
FIGURE 7-3
PROTECT TROUBLESHOOTING FLOWCHART
CTV-45
62
CN1401 TO INVERTER
1
NOT USED
2
GROUND
3
INV_ERR (NORM LOW)
4
BACKLIGHT ON (3.2V)
5
DIMMER (PWM)
CN601
1~5
24VDC
6~8
GND
CN602
1
2
3
4,5
6~10
11,12
CN3201
TO H1, H3 AND
H4 BOARDS
PWR_ON
AC_OFF_DET
STBY_3.3
UNREG 13V
GROUND
REG_12V
CN1411
TO G1D BOARD
CN2001
TO SPEAKERS
FIGURE 7-4
32-INCH TEST POINTS
CTV-45
63
CN601
1~5
6 ~ 10
UNREG 24V
GROUND
CN1401
1
2
3
4
5
NOT USED
GROUND
INV_ERR (NORM LOW)
BACKLIGHT ON (3.2V)
DIMMER (PWM)
CN3201
TO H1, H3 AND
H4 BOARDS
CN1411
TO G2D BOARD
CN602
1
2
3
4, 5
6 ~ 10
11 ~ 13
POWER ON (3.3V ON)

AC_OFF_DET (NORM HIGH)
STBY 3.3V
UNREG 13V
GROUND
REG12V
CN2001
TO SPEAKERS
FIGURE 7-5
37-INCH TEST POINTS
CTV-45
64
CN100
CN24
CN601
1~5
6 ~ 10
CN603
CN1
1~5
6 ~ 10
UNREG 24V
GROUND
CN1401
1
2
3
4
5
NOT USED
GROUND
INV_ERR (NORM LOW)
BACKLIGHT ON (3.2V)
DIMMER (PWM)
UNREG 24V
GROUND
CN1411
TO G2D BOARD
CN23
CN602
1
2
3
4, 5
6 ~ 10
11 ~ 13
POWER ON (3.3V ON)

STBY 3.3V
UNREG 13V
GROUND
REG12V
CN2001
TO SPEAKERS
FIGURE 7-6
42-INCH TEST POINTS
CTV-45
65
CN6154
2 GROUND
4 BACKLIGHT_ON (HIGH ON)
5 DIMMER (PWM)
CN102
LAMP HIGH
VOLTAGE !
CN6701
1 REG_12V
2,3 FEEDBACK
4,5 GROUND
4,5 UNREG_13V
6,7 LD (BALANCER_ERR
NORM 11.7VDC)
CN6150
1 PWR_ON
2 AC_OFF_DET
3 STBY_3.3V
4,5 UNREG_13V
6~10 GROUND
11,12 REG_12V
CN1401
TO IP5 BOARD
CN3201
TO H1, H3 AND
H4 BOARDS
CN104
TO BU BOARD
CN1411
TO IP5 BOARD
CN101
LAMP HIGH
VOLTAGE!
CN2001
TO SPEAKERS
FIGURE 7-7
40/46-INCH V AND W TEST POINTS
CTV-45
66
CN6700
CN6600
CN6103
1 PFC 395V
2 PFC GROUND
CN1401
TO D3
BOARD
CN3201
H1, H3,
H4 AND
LOGO
BOARDS
CN6702 FROM BU BOARD

CN6706 TO BALANCER
1
2,3
4,5
6,7
REG 12V
FEEDBACK
GROUND
LD (INV_ERR NORM LOW)
1
2
3
4
5
6
GROUND
DIMMER (PWM)
INV_ERR (NORM LOW)
REG 12V
BALANCER_ERR (NORM LOW)
CN6202
1
2
3
4
5
6~10
11~13
POWER_ON
AC_OFF_DET (NORM 3.3V)
STBY 3.3V
NC
UNREG 13V
GROUND
REG 12V
CN1411 TO
G4 BOARD
CN2001
TO
SPEAKERS
FIGURE 7-8
40/46-INCH Z SERIES TEST POINTS
CTV-45
67
CN65
CN6501
CN6153 TO D4 BOARD
1 PFC 395V
2 HOT GROUND
1 GROUND
2 DIMMER (PWM)
3 BACKLIGHT_ON (HIGH ON)
6 REG_12V
CN53
CN6500
CN6600
CN6950 FROM
CN6700
CN6150 TO TCON
1, 2
3, 4
CN6150
1
2
3
4, 5
6~10
11,12
CN58
FROM G5
BOARD
CN6706 TO BALANCER
CN6703
1 REG_12V
2, 3 FEEDBACK
4, 5 GROUND
6, 7 LD (BALANCER_ERR
NORMALLY 11.7VDC)
TO G5 BOARD
CN3201
TO H1, H3
AND H4
BOARDS
CN6154 TO BU BOARD
1 BALANCER ERROR
(NORM LOW)
2 GROUND
3 INVERTER ERROR
(NORM 3.1V HIGH)
4 BACKLIGHT (3.3V ON)
5 DIMMER (0.8 ~ 3.1VDC)
CN6702
CN56
CN1401
PWR_ON (3.3V ON)

STBY_3.3V
UNREG_13V
GROUND
REG_12V
FROM G4
BOARD
TO LEFT
BALANCER
REG_12V
GROUND
D4 BOARD
3 INV_DRVL
5 INV_DRVH
6 GROUND
8 V-FB1
10 REG_12V
CN1411
TO G5 BOARD
TO D5
BOARD
CN2001
TO SPEAKERS
CN62
FIGURE 7-9
52-INCH MODELS TEST POINTS
CTV-45
68
Chapter 8 Appendix
Software Updates
Sony televisions have become much more reliant on software and rmware
over the last couple of years. Digital processing such as decoding the
MPEG2 video and Digital Dolby signals along with scaling of the video
signals to the display resolution requires program routines to perform
these functions. Add control and protection of the television along with
fancy GUI graphics and interfacing with other devices and you can see
that these software and rmware les are becoming more complicated.
The les containing operating commands within a televisions CPU or
micro-controller are technically known as rmware since the information
is stored within the controlling devices and may also reside in external
NVM or ash memory. Some of the information could be classied as
software since it can be changed to customize the unit. The word
software appears on the television screen whenever one wants to check
the current version in the unit and also appears whenever an update is
being installed. For this reason, the word software will be used in this
article when referring to any updates.
Why Update?
In some cases, updates are necessary to resolve a glitch that may have
appeared in the operating routine of the television. As mentioned in the
beginning of this article, software programs have become quite complex
and use of the product in the eld can sometimes expose a minor error in
the routine of these programs.
It should be noted that most software updates are not provided to increase
the picture quality of the television. Proper handling of the video processing
tends to be rather accurate at the time the units begin production. A
majority of software updates are used to compensate for problems that
are not necessarily the televisions fault.
CTV-45
An example would be an issue that arose in one state where an over-theair television station was failing to transmit a proper piece of information
in the overhead data packet in its digital channel. When the customer
performed the initial setup routine on their television (which includes the
auto program to add available channels) the channel search would stop
at this station and fail to continue scanning the OTA bands. The television
would display most of the analog NTSC stations detected but no digital
channels. A software update was provided to the customer to ignore this
glitch in the stations data packet and continue the channel search. This
incident affected an isolated region of the country that does not require an
update be made available for all models sold.
The software updates tend to be cumulative, in other words, the previously
mentioned incident with the television station could arise somewhere else
in the country and may be included in future update packages to keep all
televisions from running across this problem.
Checking the Version of Software

In certain cases it may be necessary to check which versions of software
are currently installed in the unit. The best way is to enter the service
mode by pressing DISPLAY, 5, VOL+ and POWER, in sequence,
on the remote controller while the unit is off. The installed version of the
FE and BE Micros are listed on the rst page.
Another method is to enter the customer setup graphics and locate the
Product Support icon at the upper left of the group. When the Software
Update icon is selected the current installed software is displayed in
a coded format that can be mathematically converted to the software
version. This method is used by the initial tiers of customer support to
determine if the unit should receive an update.
69
Chapter 8 - Appendix
FIGURE 8-2
SOFTWARE VERSION CHECK VIA SERVICE MODE
FIGURE 8-1
SOFTWARE VERSION CHECK VIA XMB MENU
CTV-45
70
Performing the Update

Sony televisions manufactured in the last 3 years contain a USB port
located on the rear of the unit. On 2007 and 2008 models this port is
labeled DMEX/SERVICE. DMEX (Digital Medial Extender) is used
for optional devices such as the Bravia Internet Video Link to allow the
television to access selected internet websites. It also serves as the input
port for software updates via a USB storage device. Units manufactured
prior to 2007 have a hidden USB port that is accessed by removing a
small cover on the rear of the unit.
NOTE: Most updates are performed by the customer. In certain cases

where access to the service mode is required, the technician will perform
the update and then access the service mode to change or adjust any
additional items. Always verify whether an update is required by a
technical person. Failure to do so will result in a rejected warranty
claim.
In situations such as the television station issue described above, Sony

can send a USB device pre-loaded with the necessary software to update
the unit to resolve the issue. This is one way for customers to receive an
update for their television. The update will be supplied with full instructions
on how to install the le(s). Another way to receive updates is for the
customer to download the required le(s), place them on a USB device,
and then perform the update.
The 2008 model lineup includes a feature that can allow the television
to automatically receive updates should they become necessary. One
feature uses a selected local channel to provide the data for the update via
the onboard tuner. When the television is turned off, the tuner continues
to operate in standby and extracts update information in small groups.
Once the entire le has been extracted, the update can be installed by the
customer via the user menu.
Another option that is found on some of the upper-end models is the use of
an Ethernet port located on the rear of the unit. This allows the television
to be connected to a home network. This feature only works with networks
and devices that are set up to be DLNA (Digital Living Network Alliance)
compliant. Information on this system can be found at www.dlna.org.
The customer can download the update and retrieve it directly from the
computer on the home network. Be aware that although these features are
present on selected models, their practical use has not been nalized as
of this writing and will be covered if and when they become fully functional
for this years applicable models.
CTV-45
FIGURE 8-3
DMEX/SERVICE USB PORT
71
Downloading an Update
Updates can be downloaded in several ways. The customer may be given
a specic URL to do this or, if the update is required for all units, may be
located on the Sony customer support website. If the update requires the
expertise of a service technician it may be located in the ASC service
website (currently ESI). The location for downloading an update will also
contain documentation with the proper instructions for the install. Read this
information very carefully. Some televisions have the update le located
within a folder and others do not. If the television requires a folder, this is
the rst item the unit will look for on the USB device. The le will be in zip
format with the folder and update le included. If the update has a single
le and a folder is not required it can be sent without having to compress
it to a zip format.
Formatting the USB Device

It is important that the USB device not contain any additional les or folders
before placing the update information on it. The best way to do this is to
right click on the device in Windows Explorer and select format from the
dropdown menu. Make sure the le format is set for FAT32. If the USB
device is more than 2GB Windows Explorer will force FAT32. Formatting
the device will remove any hidden les or partitions that may reside on
the device.
Installing the File(s) to the USB Device

If the update information is in zipped format it is best to download the le
to your computers hard disc. When the le is opened, unzip its contents
directly to the USB device. This assures that the folder (if used) is properly
placed on the device with the update les inside the folder.
CTV-45
72
Updating the Television
BE Micro Update
The new 2008 EX1 chassis will be used as an example in this writing.
Procedures vary with chassis designs. Some require inserting the device
with the television off and then booting the update by turning it on. Most of
the units will read the device when it is inserted while they are powered on.
Updates for the EX1 chassis are performed by inserting the USB device
while the unit is turned on. The update may require up to 10 minutes. The
total update time in this example took 7 minutes and 20 seconds. The
following sequence of events will occur and is shown in the succeeding
illustrations:USB Detection and File Loading
Since the BE Micro controls the video processor, the screen will go blank
with no video or graphics displayed. The Standby LED on the lower right
corner will light a steady red while the PIC OFF/TIMER LED lights amber
colored with a slow blink rate. This is the only indication that the update is
still in progress.
Once the USB device is inserted it will be detected. A blue splash screen
will appear with the graphics at the upper left of the screen will displaying
a toolbox and the words Software Update. The le(s) are then copied
from the USB device.
Update Completion
Once the unit has completed the BE Micro update, active video and audio
will once again appear followed by an indication that updating is being
nalized. The last screen will indicate a successful install of the update
and prompt the removal of the USB device. Press the center joystick
button on the remote controller to clear the screen.
Notication of Update
This information will appear on 2 pages. The rst will indicate that a
mandatory update will occur and the current software version is shown
along with the version that will be installed. The second page explains the
procedure and the approximate time it will take along with a warning not
to interrupt or turn off power to the television during the procedure.
FE Micro Update
If active video was present before the USB device was installed it will
return for several seconds. Another splash screen will appear with a
moving progress bar. The FE Micro is contained within the AMD decoder
IC. The BE Micro and video processor are still functioning and this is
why graphics can be generated. This process may continue for several
minutes. Once complete, the screen will return to active video (if present)
for several seconds before the BE Micro begins its update.
CTV-45
73
SOFTWARE FILES UPLOADING
INFORMATION PAGE
UPDATE PROCEDURE INSTRUCTIONS
FE MICRO (AMD) UPDATING
FIGURE 8-3
SOFTWARE UPDATE SEQUENCE
CTV-45
74
TIMER LED WILL

BE BLINKING
STANDBY LED
STEADY RED
BE MICRO UPDATING
FINAL INSTALLATION
SOFTWARE INSTALL COMPLETE
CTV-45
FIGURE 8-3
SOFTWARE UPDATE SEQUENCE (CONT)
75
LCD Panel Troubleshooting

When a customer calls and is complaining of poor picture quality,
colored lines, or no picture at all, it is very important that the technician
rule out the LCD panel assembly as the cause. Technicians should be
using the triage system found on the ASC Portal site and in the back of the
training manuals to assist on which parts should be brought to the location
to service the unit. LCD panels are not suggested to be brought to the
service location based on the customers description of the problem. They
are expensive to ship and prone to damage. The technician must diagnose
the unit and obtain special authorization before the panel can be replaced.
In certain cases it may be determined that it is not economically feasible
to replace an LCD panel for a particular model and that replacement of
the unit would be the best option.
The purpose of this article is to assist the technician in determining if
the LCD panel is defective as efciently as possible. In many cases,
failures of the physical aspects of the panel (panel glass damage, tab
bonding issues) are easily recognized. Failures of the TCON board (which
is considered part of the panel) can sometimes lead the technician to
erroneously change a video process board and have wasted time only to
nd out that panel is the cause of the failure.
LCD Panel Basics

LCD panels have steadily evolved over the last several years. New designs
of the physical structure of the LCD crystals have greatly improved the
contrast ratio and viewing angle. Quicker response times and increased
refresh rates have helped to reduce the motion smear associated with
LCD displays. Backlighting design has also aided in producing a picture
with color temperatures to make the images as true as possible. With
all these design improvements, one aspect of the LCD panel remains
relatively the same: Processing of the video signal.
CTV-45
Figure 8-4 illustrates a typical LCD panel and the associated video
processing circuits as found in the WAX3 chassis. The various formats
and resolutions of video signals are processed on the BU1 board. All video
signals exit the video processor in the native resolution of the LCD panel.
In this design, the resolution is for a 1280 by 768 at 60HZ refresh rate
panel. 48 horizontal lines are discarded to match up to the 720p resolution
of the ATSC specications so the video will exit as 720p.
The LCD panel used in this model processes 8-bit RGB video data. Before
the video information can be sent to the TCON board it must be converted
to a format that allows for practical and noise-free transmission. The large
number of parallel lines to transmit the 8-bit RGB data would need to be
sent on differential lines for noise reduction. This would require 48 lines
just for the video. The TCON circuit also requires B+, ground connections,
a communications bus, sync, and a clocking line transmitted differentially
so we can see that up to 100 lines would be required. The practical way
to transmit this information is to convert the parallel video data to a serial
stream and this is accomplished by the Low-Voltage Differential Signaling
(LVDS) transmitter.
The LVDS transmitter contains a circuit to serialize the parallel data. The
parallel video information along with sync and clocking data are transmitted
via twisted line pairs. Depending on the logic level, current is sent along
one or the other of the twisted pair of wires. The receiving end of the wires
is loaded with a resistor (usually around 100 to 120 ohms). The receiver
detects the polarity of the voltage drop across the resistor to determine
the logic level. The current level swings in the wire are about 3ma with a
voltage differential of around 350mv. This allows for transmission of the
video signal with minimal EMI.
The LVDS receiver on the TCON board converts the serialized data back
to parallel. This data is processed by the timing control IC to allocate the
RGB data into serial streams for processing by the LCD panel. The LCD
panel contains shift registers and drivers for all of the rows and columns
of pixels on the panel. The drivers are mounted on exible circuit boards
and bonded to the top and side of the panel. Without this arrangement the
TCON would require an IC and connectors to transmit on 4,560 lines!
76
Panel Failures
The key to good troubleshooting when video quality issues are involved
is the understanding what type of distortions cannot be generated by the
panel. The loss of an entire color is highly unlikely. The LVDS transmitter
does not handle the RGB data as groups. The data (along with sync and
clock) is distributed among 6 separate transmission lines for an 8-bit
panel. A 10-bit panel uses 12 transmission lines. If one of these lines
fails the result is random, multiple colored lines appearing on the screen.
Distortions caused by the panel will be stationary and, in almost all cases,
will consist of a single line or multiple lines in a repetitive pattern. Any
distortion that is not stationary (ying color spots, loss of detail, etc.) is
being generated by the video process circuits on the B board.
Electrical Failures
There are multiple drive ICs located along the top and side of the panel
to de-multiplex the data for all of the rows and columns of pixels. If one
of these ICs fails there will be a cluster of missing information on the
screen. The second photo in Figure 8-5 contains an illustration of a panel
with such a failure.
Although the TCON board is considered part of the LCD panel, we will
focus on the panel itself and discuss TCON failures separately since it
generates symptoms that are quite distinguishable from panel issues.
Panel failures fall into 2 different categories: Physical and electrical.
Physical Failures
The most obvious failure is physical damage to the panel. This can appear
as a small cluster of damaged pixels or a complete shattering of the panel
glass. Another physical failure may appear as a single or several lines
running vertically or horizontally across the screen. The lines may be
brightly lit or dark. This is caused by a failure of the exible printed circuit
where it is bonded to the panel edge. This is known as a tab bond issue.
Do not confuse this with multiple vertical lines across the screen that are of
the same color. This is electrical and usually caused by the TCON board.
Figure 8-5 illustrates some examples of tab bonding issues.
SOURCE DRIVERS
VIDEO
PROCESS
TIMING
CONTROL
LVDS
TRANSMITTER
LVDS
RECEIVER
PANEL B+
BU1
TCON
LCD PANEL
GATE
DRIVERS
FIGURE 8-4
LCD PANEL DRIVE
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77
UPPER TAB BOND FAILURE
TAB BOND AND DRIVE IC FAILURE
UPPER TAB BOND FAILURE
SIDE TAB BOND FAILURE
FIGURE 8-5
LCD PANEL FAILURES
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78
TCON Failures
Failures of the TCON circuit can cause a variety of symptoms varying
from evenly spaced multiple vertical lines of the same color, xed random
patterns, colored blotches, or the complete loss of video. A complete
failure of the TCON is difcult to determine since there is nothing on the
display to help troubleshoot and has the same symptoms as a complete
video process failure on the B board. A procedure to help in diagnosing
this failure will be covered shortly.
Figure 8-6 contains several photos of symptoms caused by a failure on
the TCON board. Note the xed and symmetrical lines in the rst 3 photos.
This is a classic timing IC failure on the TCON board. The fourth photo
is interesting. Another task performed on the TCON board is gamma
correction. The correction is performed in dened zones across the entire
panel. The data is stored in an on-board EEPROM. If this data is corrupted
for whatever reason, one or more of the zones will exhibit a severe white
balance issue.
FIGURE 8-6
SAMPLES OF TCON FAILURES
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79
Troubleshooting a Dead TCON
This is a tough one. Fortunately, most of the 2007 Sony models now monitor
the TCON for communications and will shut down with a diagnostics
indication. In units that do not have this feature you will experience
the same symptom as a complete video process failure (no on-screen
graphics, no video, but audio is OK). Based on data gathered from our
panel refurbishing group, about 10 to 15% of TCON failures cause a no
video condition.
If a customer complains of no video from any source you will be asked to
bring a B board to the location since that is the most likely component to
x the problem. What if you install the board and still have no video? Did
you receive a defective B board? Did you overlook any other symptoms?
Make sure you have audio. This is critical. There have been numerous
issues of technicians troubleshooting older models in which the ATI
decoder IC for digital channels is located on a separate board (QM or QBox). When this decoder fails, it kills all video and audio. The technician
changed several parts based on a no video condition and did not bother
to check for the presence of audio. If it is veried that audio is present, the
following procedure can help isolate a defective TCON in most cases.
Warning: Do not attempt to check for data or voltages on the LVDS
connector at the TCON. This advice has been circulating around and is
not recommended. In Figure 4 a picture of the LVDS connector is shown.
In order to take a reading from one of the pins, you must insert your probe
between a narrow area that is shielded and at ground potential. Several
of the pins contain B+ for the TCON and panel. It is very easy to short
one of these pins to ground and if it is a B+ line it is guaranteed you will
be replacing a B board whether or not it was the original cause of the
problem. The LVDS connector is shown in Figure 8-7.
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RELEASE TABS
FIGURE 8-7
LVDS CONNECTOR
80
If the TCON is receiving B+ and functioning properly, the timing circuits
are waiting for RGB data to allocate to the proper pixel. When a video
processor failure occurs, there is simply no data being sent to the TCON
and it does exactly what it is supposed to do: Keep all of the pixels dark.
One trick that works rather well is to partially disconnect the LVDS
connector from the TCON board while the unit is running. Do this very
carefully! Both sides of the connector have release tabs that must be
squeezed inward to release the connector. I have performed this over
30 times to the same television without and damage to the connector or
electrical circuits. Release the connector and carefully pull it partially out
of the socket being careful not to pull one side out much further than the
other. Too much skewing can damage the connector and possibly cause
a short on the B+ line. The idea is to remove some of the LVDS data
entering the TCON.
If the TCON is functioning the loss of data will cause the timer circuits to
generate random patterns. These patterns may appear as a brief colored
horizontal bar or continuously active random lines covering the entire
screen. The type of response you get will depend on the panel design
and how much LVDS data you have removed. Sometimes a momentary
line will ash on the screen, other times the screen will ll with random
patterns. If you dont see any response, try plugging the connector back
in and pulling it out one more time watching the screen very closely for
any reaction. Figure 5 illustrates 2 different types of patterns generated
by the same unit.
SINGLE MOMENTARY LINE
If you are able to generate any response on the screen, the TCON is
most likely OK. A TCON that has completely failed (causing a no video
condition) will not produce any pixel lighting on the screen.
MOVING RANDOM PATTERNS
FIGURE 8-8
SAMPLE REACTIONS TO LVDS LOOSENING
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81
DLNA Overview
For many years there was talk about how the entire home would one
day be on a network system. The customer would be able to watch TV,
access music les, browse the internet, along with controlling devices
such as lighting and heating/cooling and so on. Although systems have
been developed for many years they were proprietary in nature and quite
expensive to install.
Virtually all of the key leaders in the PC, CE and mobile device industry
have jumped on board to support DLNA. This has created the guidelines
for physical media, formats, network transport, streaming protocols and,
of course, digital rights management. As long as manufacturers produce
appealing products, and the DNLA standards evolve with the improvements
and changes, the promising world of communication among consumer
devices appears to be a reality. For more information, visit http://www.
dlna.org.
Another issue is that the television is primarily considered a separate entity

whose function is to watch movies and TV programs along with gaming
devices. The computer served its own function of running programs and
accessing the internet.
As the turn of the century came and went, consumers became exposed
to new devices to store their audio, video and picture content. Prior to
the year 2000 very few homes had many of the products we see today
such as digital audio players, digital camcorders, PDAs, multi-media
cell phones etc. Although the personal computer interfaces quite well
with all of these devices customers found it to be a hassle to plug and
unplug the devices and organize the material on their home computer.
Since the consumers expectations were not being fullled, the concept
of interoperability among these devices needed to be addressed. The
introduction of wireless networks was a promising technology but there
was still a problem with interconnecting these devices. A common method
of communication and detection was needed.
The Digital Living Network Alliance (DLNA) appears to have resolved
this issue. DLNA provides an answer to the marketplace by providing a
seamless environment where PC, CE and mobile devices can communicate
and transfer information by providing the standards for this to happen.
The customer will be able to manage and distribute pictures, video and
audio content to television and monitor devices along with audio systems.
By following these guidelines, manufacturers can design products that
function in this platform.
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82
DLNA connectivity is provided in selected Sony televisions for the 2008
model year. As of this writing it is available on the Z4100 series which
includes a 40 and 46-inch model and also the XBR6 models available in
40, 46, and 52-inch. The XBR7 and XBR8 high-end models being released
this fall will also have the DLNA feature. An RJ45 Ethernet port will be
available at the rear of the unit to allow a connection to a home network.
Any le sharing will require the use of a DLNA compliant system and this
requirement can be met with software. There are numerous choices of
software available. Most are available at no charge. Some require a onetime fee and others a monthly service fee.
Although DLNA allows the sharing of video, audio and pictures, the 2008
models containing this feature will only allow for sharing of photos. Once
copyright protection issues are worked out we should see future models
supporting movie and audio le content. Another feature that will become
common is the ability of consumer products to check for any available
software updates. This can be done manually or automatically checked
for on a regular basis and notify the customer of a new software version.
The customer can choose to install a newer version or the le may be
written to force install an update.
High-speed internet access is changing the way we receive our media
content allowing yet another method of viewing movies and audio aside
from the traditional cable and satellite sources. DLNA looks to be a
promising feature to take advantage of this technology.
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83
and i.Link are trademarks of Sony Electronics
CTV450508
2009 Sony Electornics, Inc.

SEL Service Company
16530 Vill Esprillo
National Training Dept. MZ3215
San Diego, CA 92127
Reproduction in whole or part without written permission is prohibited. All rights reserved
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Training Manual

EX-1 Direct-View LCD Television Chassis

KDL-40W4100 KDL-46W4100 KDL-52W4100 KDL40VL160

Board Layout ......................................................................11

52-inch V Series Models .................................................... 14

Full HD 1080 Panel.............................................................. 1

The W Series ................................................................. 14

60HZ versus 120HZ TCON ............................................... 17

Enhanced Cross Media Bar (XMB)...................................... 1

40 and 46-inch Models ...................................................... 18

Board Layout ..................................................................... 18

Consumer Electronics Control (CEC) ..................................... 2

Bravia Sync ....................................................................... 2

Chapter 3 Video Process Circuits ................................. 22

Chapter 2 Overall Block Diagrams .................................. 3

LCD Panel ............................................................................. 23

32/37-inch Models Overall Block Diagram........................... 4

Board Layout ....................................................................... 6

10-bit Video Processing ........................................................ 25

Table of Contents (Continued)

Power-Up Sequence ............................................................. 39

40/46 Z Series Backlighting ............................................... 47

G1D/G2D Power Supplies ................................................. 31

Power Factor Control (PFC) ................................................. 31

Standby Power Supply .......................................................... 31

Inverter Failures ................................................................. 50

Main Switching Supply .......................................................... 31

Inverter Does Not Start ......................................................... 50

IP5 Power Supply and Inverter .......................................... 33

Inverter Starts and Turns Off ................................................. 50

Integrated Lamp Inverter ....................................................... 33

Dual Inverter Circuits ......................................................... 51

G4 Power Supply ............................................................... 33

Balancer Errors .................................................................. 51

PFC Output ........................................................................... 33

G5 Power Supply ............................................................... 33

Balancer Board Removal ................................................... 52

Chapter 7 Protect Circuits ............................................. 58

Chapter 6 - Panel Backlight Circuits ................................ 39

Backlight Protection ........................................................... 58

Inverter Error (6X) ................................................................. 58

DC Alert (3X) ......................................................................... 58

Balancer Error (13X) ............................................................. 59

Table of Contents (Continued)

Troubleshooting a Dead TCON .......................................... 80

Temperature (7X) .................................................................. 59

DLNA Overview ............................................................. 82

Speaker Protect (8X) ............................................................ 59

Diagnostics History ........................................................ 61

Updating the Television...................................................... 73

LCD Panel Troubleshooting........................................... 76

TCON Failures ................................................................... 79

A frame-doubling circuit utilizing proprietary circuitry and algorithms is able

Enhanced Cross Media Bar (XMB)

Full HD 1080 Panel

Digital Media Port

This new version of HDMI introduces several new enhancements and

Consumer Electronics Control (CEC)

Advanced Contrast Enhancer (ACE)

Digital Media Extender (DMEX)

Interactive Program Guide (IPG)

Digital Living Network Alliance (DLNA)

Chapter 2 Overall Block Diagrams