Sony KE-42MR1, KE-42MR1E, KE-42MR42M1 manual

PANEL MODULE SERVICE MANUAL PDP Module Name FLAT PANEL COLOR TV KE-42MR1/42MR1E/MR42M1 NP42D2MF01 NP42D3MF01 KE-42MR1 AEP Model KE-42MR1 K Model KE-42MR1E HK Model KE-42MR1E ME Model KE-MR42M1 CH Model[...]

Contents 1. Confirmation Common Manual ･･･････････････････････ P1 ～ P20 2. Confirmation Manual ･･････････････････････････････ P21 ～ P44 3. Repair Manual ･････････････････････････････[...]

1 PDP (NP series) Confirmation Common Manual Ver.1[...]

2 Malfunction Phenomeno n No Picture Power-off Power-on Alarm protection No Priming No Signal W hen you tu rn-o n the m ain powe r, the LED lig ht-o ff aft er few mi nutes. Go to Pag e 8 due to che ck more detail s. The prim ing does not appea r on screen. The LED is lighting, but not ap pear pictures. PDP Malfunction Phenomenon Go to Pag e 10 due [...]

3 No lig hting sell are on scree n at whi te patter n. Go to Pag e 11 due to che ck more details . Colorful bl ocks ap pear on scree n at color bar pa ttern. PDP Malfunction Phenomenon Go to Pag e 11 due to c heck mor e det ails. Abnormal Screen Abnormal Colo r Abnormal Block[...]

4 PDP Malfunction Phenomenon Vertical Vertical Line Single Line T w o Lines Many Li nes Only one line is always lighting. Go to Pag e 12 due to che ck more detail s. two li nes ar e lighti ng. Go to Pag e 13 due to che ck more detail s. Many l ines are lig hti ng. Go to Pag e 14 due to che ck more detail s.[...]

5 PDP Malfunction Phenomenon Vertical Vertical Block One Black Block One Zebra Block Many Black Blocks One block is alw ays no- lighti ng by one IC. Go to Pag e 15 due to c heck mor e det ails. Zebra bl ock a ppears by on e IC. Go to Pag e 16 due to che ck more detail s. Many blo ck appear b y one d ata rel ay board. Go to Pag e 16 due to che ck mo[...]

6 PDP Malfunction Phenomenon Horizontal Horizontal Li ne Horizontal Block One Black Block One black line appea rs on screen. Go to Pag e 17 due to che ck more detail s. T w o Lines Two lin es a ppear o n screen. Go to Pag e 18 due to che ck more detail s. Half bl ock does n ot go out. Go to Pag e 19 due to che ck more detail s.[...]

7 Lighting strip PDP Malfunction Phenomenon Check our speci ficatio n . Screen Defect Black strip Check o ur speci ficatio n .[...]

8 Alarm Protection Panel Alarm FPC Opened No Picture Panel alar m li ne g o thro ugh th e edg e of the FPC. Vs Protection Panel Grid Opened High Voltage Circuit Broken Panel alar m li ne g o thro ugh th e edg e of pane l. Th is case is ca used by su lf ur issue . Next parts will be broken, Scan Board, C omm on Bo ard, High V oltag e Board, Sc an R [...]

9 Alarm Protection No Picture In case o f shortag e betw een Vd lin e and GND in TCP, Vd protection will be worked . Vd Protection 5V Protection TCP Broken Data Relay Board Broken Digital Board Br oken CHECK POINT Shortag e betw een V d lin e and GND, TCP s ur fac e In case o f shortag e betw een Vd lin e and GND i n d ata rel ay boar d, Vd protect[...]

10 No Priming No Signal High Voltage Circuit Broken No Picture Digital Board Br oken Digital is not working. CHECK POINT Fuse on b oard, V p, Vbw and Vsw line of Power HIC. CHECK POINT fuse on dig ital bo ard, LVDS cabl e Next parts will be broken, Vp or Vbw line on Sca n Boar d, Vsw line on Comm on Bo ard, (H igh Voltag e Board) . REW ORK Change t[...]

11 No Picture Abnormal screen High Voltage Circuit Broken CHECK POINT fuse on boar d, Vbw or Vsw l ine o n boar d. Next parts will be broken, Vbw line on Sc an Boar d, Vsw l ine o n Comm on Bo ard, (H igh Voltag e Board) . REW ORK Change th e s can or com mon boar d (Hig h vol tage bo ard).[...]

12 Single Line The output of TCP Vertical Data Grid Open Dama ged data grid in panel EX) Sulfur , scratch CHECK POINT One lin e is no-lig hting or l ighti ng at any pure col or sign al (re d, gree n blue and black) CHECK POINT The sur face c onditi on of pan el gr id. The outp ut of TCP is fix ed at low level or high level. This lin e is very clear[...]

13 T w o Lines The output of TCP Vertical Data Grid Shortage The grids o f panel are sh ortag e due to foreig n materi al. CHECK POINT Two lin es are l ighti ng a t two col ors. CHECK POINT The sur face c onditi on of pa nel g rid. The clos ed outputs of TCP are Shortag e. REW ORK W e can n ot rework this. REW ORK W e can n ot rework this.[...]

14 Many Li nes Vertical Data Grid Open Dama ged data grid in panel EX) Sulfur , scratch CHECK POINT The sur face c onditi on of pan el gr id. REW ORK W e can n ot rework this.[...]

15 Black Block TCP Broken Vertical Data Relay Board The buffer IC is n ot working on signal lines. The co nnect or on data r elay b oard is open ed by th e crackin g of sol der. CHECK POINT The surfac e of TCP is damag ed. CHECK POINT Input sig nal conditi on. TC P i s n ot wor kin g. REW ORK W e can n ot rework this. REW ORK Change th e data relay[...]

16 Zebra Block Vertical Data Relay Board The le ad of t he bu ffer IC or th e connect or on data re lay boar d are shortag e by for eign ma terial. CHECK POINT Input sig nal conditi on. REW ORK Change th e data relay bo ard. Many Blocks Data Relay Board The le ad of t he bu ffer IC or th e connect or on data re lay boar d are shortag e by for eign [...]

17 Single Line The output of Scan IC Horizontal Scan Relay Bo ard Mis-cont act betw een FPC and th e connect or of sca n rela y boar d. CHECK POINT One lin e is no-lig hting or l ighti ng at white signal. CHECK POINT The output of scan IC. Reco nnecti on. The o utput of sca n IC is fix ed at l ow level or high level. This lin e is very clear an d c[...]

18 T w o Lines Horizontal Scan Relay Bo ard CHECK POINT FPC insert shifting. Foreign mate rial in connecto r. The lead of scan IC . The output of sca n IC are shortag e. Th is line is not c lear and not constant. REW ORK Clean in the connecto r. Reco nnect the FPC . Change th e s can relay boar d.[...]

19 Block Scan IC broken Horizontal The output of sca n board is not wor ki ng . CHECK POINT The surfac e of sca n IC. CHECK POINT The outp ut of Scan Board. Scan IC is not w orking. REW ORK Change th e s can relay boar d. REW ORK Change th e s can board. Scan Board[...]

20 Sample Sample 55 x 15mm 20 x 17mm Dimension Label B 55 x 25mm 40 x 17mm Dimension Label A Since July 2003 By June 2003 Vs Vd Vbw Vs w Vp Vw Voltage Informa tion[...]

21 PDP (NP42D2MF01) Confirmation Manual Ver.2[...]

22 Type,Ser ial N umb er Check pr ocess Panel Crac k OK NG NG Con nectors OK Tester Checking Reappe aran ce OK Strip D efect Vert ical Line Horiz ontal Line No Display W riti ng Issues Page 38-4 2 Page 43 Page 29-3 5 Each Judge ment (Mak e C-PD P Failure D escri ption she et) Flexible Cable NG OK Page 24 Page 25 Page 26-2 8 Page 23 Phenomeno n Take[...]

23 SERIAL NO. 211200192 Vd=65V Vs=190.1V CODE AA-01 212211041621 Panel ID Serial Num ber Exam ple : Type N ame NP42D 2MF0 1AA Serial Numbe r 　 211200192 NEC NP42 D2MF01 211200192 ********************* * ********************* * ********************* * T y pe Nam e Serial Number Module Nu mber and Pan el ID[...]

24 Panel Crack This issue ma y be caused by transportation or treatm ent after shipm ent. We would like y ou to take s ome pictures, the br oken module, the outside box , and inform the shipment date. If you do not the pictures, we can dispos e the broken modules on our responsibility . Check the surfac e of glass whether crac k or not. Panel Cra c[...]

25 Flexible Cable Cutting cable or brok en In this case, it caused by handlin g them at cu stomers line. We would like y ou to be car eful to handle the modules. Flexible Cable Check the F lexible Cables whether scr atched, broken, or not.[...]

26 High Voltage Board 5 connectors Comm on Relay Board 3 connectors Digital Board 6 connectors Scan Relay Board (Up) 5 connectors Comm on Bypass Board Data Relay Board (Lef t) 10 connectors Data Relay Board (Right) 13 connectors Scan Relay Board (Do wn) 5 connectors Connectors Check the Cables or Connectors whether connected and locked, or not. Con[...]

27 Connector Checking 2 High Voltage Board 　　 　 - Digital Board Each C onnect or Scan Relay Board 　　 - Flexible Cable Locked Unlocked Common Relay Board - Flexible Cable[...]

28 Connector Checking 3 Each C onnect or Digital Board - High Voltage Board High Voltage Board - Data Relay Board Locked Unlocked High Voltage Board - Scan Relay Board[...]

29 Tester Checking 1 Fuse Glass Fuse o n Hig h Volt age Bo ard (F30 1 、 F302) OK: Shortag e NG: O pened Chip Fuse on Digital Board (F Ｕ８０１ ) OK: Shortag e NG: Opene d[...]

30 Tester Checking 2 Fuse Resistance and Chip F use on Hi gh Vol tag e Boar d Fuse Resista nce (R10), ( R4), (R 6) Ch ip F use Re sis ta nce (R20) On High Volt age B oard Fuse Resista nce (R7), (R3) Ch ip Re si st an ce (R9) On High Volt age B oard R4 R20 R10 R3 R10 OK: Abo ut 2.2 Ω R4 　 OK: About2.2 Ω R6 OK: About 2.2 Ω R20 OK: Abo ut 10 Ω ?[...]

31 Tester Checking 3 Fuse Fuse Resista nce on Hi gh Volt ag e Boar d (R1) Fuse Resista nce on Hi gh Voltag e Board (R2) R1 R2 R1 OK: Ab out2.2 Ω 　　　 NG ： Opened R90 OK: A bout2.2 Ω 　　　　 NG ： Opened R90 R2 OK: About 2.2 Ω 　　　　 NG ： Open ed 　 Fuse Resista nce on Hi gh Voltag e Board (R90) Resistance and Chip F use on [...]

32 Tester Checking 4 Data IC Data Relay Board (Right ) #1 pi n or # 2 pi n at CN1 2 （ Vd Volt age Li ne of Data IC ） OK: Opened NG: Shortag e Check between (#1 pin or #2 pin) and GND Check th e resista nce b etween ( #1 pi n or #2 pin) and GN D with test er. In case o f shortag e, it is caus ed by malfu nction of d ata IC. Check th e surfac e o[...]

33 Tester Checking 5 Part s Loca tion Hig h Volt age Bo ard PH2203F[...]

34 Tester Checking 6 Power HIC PH2203F on High Vo ltage Boa rd Checking point 　　 Between A and B Betw een C an d U Betwee n J and O 　　 Between A and U Between F a nd U B etwee n L an d M 　　 Between B and C Between G and H B etwee n P an d T Betwee n B and E Betwee n H a nd J Betw een Q an d T Betwee n B and M Betw een I a nd J Betwee n [...]

35 Tester Checking 7 Scan IC NEGA 1 Checking Point Betwee n NEGA a nd POSI Scan R elay Board (Up) Sc an Rela y Bo a rd (Dow n) Judgm ent 　　 OK ： More t han ＫΩ 　　 NG ： Shortag e POSI 1 NEGA 2 POSI 2[...]

36 Strip Defect 1 Compare w ith sp ecification 1 strip 2 strip 2 strip Strip D efect[...]

37 Strip Defect 2 3 strip 3 strip 3 strip Strip D efect[...]

38 Vertical Line 1 [Chec k Poin t] Red 1 Line Open Mode a) The broken data flexible ca ble. If OK, Data IC Brok en. All Red Pa ttern All Green P attern All Blue Pattern All Black Pattern Black 1 Line Red 1 Line Red 1 Line No Ap pearan ce Op en Mo de Vert ical Line Single lin e[...]

39 Vertical Line 2 [Chec k Poin t] Shorta ge betw een Red and Blue a) This phenome non is caused by pan el issues. All Red Patter n All Green P attern All Blue Pattern All Black Pattern Blue 1 Line Red 1 Line No Ap pearan ce Shortage Mode No Ap pearan ce Vert ical Line Two lines[...]

40 Vertical Line 3 Vert ical Line [Chec k Poin t] a) The broken surface IC on da ta IC. b) The broken data flexible ca ble. 1/2 data IC Bloc k (Width 30mm ) block[...]

41 Vertical Line 4 Vert ical Line [Chec k Poin t] 1 data IC Block a) Lackin g co nnector be tween Data Relay board a nd Da ta IC. b) The broken data flexible ca ble. block[...]

42 Vertical Line 5 Vert ical Line [Chec k Poin t] Many data IC Blo ck a) Lackin g co nnector be tween Data Relay board a nd S can or Commo n bo ard. b) The broken data flexible ca ble. C)Shorta ge betw een l eads in conne ctor. Foreign Ma terial etc. block[...]

43 Horizontal Li ne single line, tw o line s or block Single Two lines Block Block a) The broken surface IC on scan IC dri ver. Check the resistan ce be tween NEGA and POSI on scan IC board . ( Nor mal: K Ω Leve l) b) The broken scan flex ible cabl e. c) La cking co nnec tor bet ween sc an IC an d scan b oard. d) Shortag e between ea ch pins on sc[...]

44 42HD2 Board Location Data Relay Board (Right) Data Relay Board (Lef t) Comm on Relay Board Digital Board High Voltage Board Comm on Bypass Board Scan Relay Board (up) Scan Flexib le Cable A A B C D E F G H I J K L M N O P Scan Flexib le Cable B Scan Flexib le Cable D Scan Flexib le Cable D Scan Relay Board (Down) Comm on Flexib le Cable A Comm o[...]

45 PDP (NP42D2MF01) Repair Manual Ver.2[...]

46 Prepar ati on Panel Se tting Remov e Co nnect ors Remove Screws Remov e Old B oards Install New Boards Drive screws Con nect Con nectors Mounti ng Setting Con nect Sup ply cabl e Aging Inspecti on Remove Modu le Input lin e Analy sis Repair Testing Page 47 Page 48 Page 49-5 1 Page 52 Page 52 Page 53 Page 53 Page 54-5 7 Page 58 Page 61 Page 62 Ba[...]

47 Tools a) Driver ---------- Plus Type b) Wrist Discharge ---------- Prevent Electrostatic c ) Signal Generat or (PC) d) Supply Pack age e) Mounting ---------- To Stand Module f) T e s t e r g) Cushion ---------- To put the Module on A TTE NTI ON Replacing the boards, always use the wr ist band to prevent electrostatic . Preparation[...]

48 Put the cushion on a table an d repaired module on cus hion A TTE NTI ON Put panel like c atching all sur face on cushion. Pre-setting[...]

49 Remove the re pairing Board High Voltage Board 5 Connectors Scan Relay Board 5 Connectors Comm on Bypass Board Comm on Relay Board 3 connectors Digital Board 5 Connectors Data Relay Board (Right) 10 Connectors Data Relay Board (Lef t) 13 Connectors Attent ion Attent ion Attent ion Attent ion 　　　　 　　　　 　　　　 　　　　 Be[...]

50 Repair 1 　 　 　 　 Remove connec tors a nd cable (2 ) How to remove the connecto rs Flat Cable (Type A) Flat Cable (Type B) Locked Unlocked Be car eful to remov e the connectors b ecause the structur e of each connector is diff erent. Or, it is possible to broken th e connectors.[...]

51 Flat Cable (Type C) Cable (Type D) Locked Unlocked Repair 1 　 　 　 　 Remove connec tors a nd cable (3 ) Be car eful to remov e the connectors b ecause the structur e of each connector is diff erent. Or, it is possible to broken th e connectors. How to remove the connecto rs[...]

52 Repair 2 Remo ve the Boards A TTENSION Do not drop the screwdriv er or screws on the board. Be careful to n ot mak e the screw dust --- ---- Shorta ge factor Comm on Bypass Board Comm on Relay Board 8 screws Digital Board 6 Screws High Voltage Board 22 Screws Data Relay Board 4 Scr ews Data Relay Board 5 sc rews Scan Relay Board 8 Screws Scan Re[...]

53 Repair 3 Ins tall the new boards Install the n ew board A TTENSION 　　 　　 　　 　　 Install the sam e number board as module3 Do not add any stre ss board. Be carefu l of the length of a scr ew. Marking: length of 8mm making: length of 5mm Comm on Bypass Board Comm on Relay Board 8 screws Digital Board 6 Screws High Voltage Board 22 S[...]

54 Repair 4 Conne cting (1 ) Check the cab les and in so ckets Flat Cable (Type A) Socket (Type A) A TTENSION Check th e surface of grids whether it is 　　　 　　　 　　　 　　　 　 　 　 　 tearing or not. A TTENSION Check whether ther e are som e for eign materi als or not in socket.[...]

55 Repair 4 Conne cting (2 ) Connect so me connecto rs A TTENSION 　　 　　 　　 　　 Pleas e check that connector conne ction of a red circled is mad e normally . When you exchange th e signal relay PKG, finally pleas e atta ch a heat sink ( 9 scr ews) Scan Relay Board 5 Connectors High Voltage Board 5 Connectors Comm on Bypass Board Comm [...]

56 Repair 4 Conne cting (3 ) Locked Unlocked High Voltage Board (Photograph) 　　　 － 　 Digital Board Scan Relay Board (Photograph) 　　 －　 FF C Cable Common Relay Board (Photograph) －　 FFC Cable Connection C ondition[...]

57 Connection C ondition Locked Unlocked Digital Board (Photograph) －　 High Voltage Board High Voltage Board (Photograph) －　 Data Relay Board High Voltage Board (Photograph) －　 Scan Relay Board Repair 4 Conne cting (4 )[...]

58 Check w orking Mounting Setting A TTE NTI ON Do not stand the module direc tly on table. ----- Broken the flex ible cable To fix the connectors from supply board. ----- Broken scan & common board A djust supply board to the suitable voltage (Vs) of panel. ----- Writing issue[...]

59 VSW VSW VSW VSW 、 、 、 、 - - - -VW Adju stment VW Adjustment VW Adjustment VW Adjustment VR10 1 Adjust the [VSW( ± 0.5V)] w ith VR2 at TP3 28 on High Volt age B oard. Adjust the [-VW( ± 0.5V)] w ith VR4 at TP3 30 on High Volt age B oard. TP328 ( VS W ) TP330 ( -V W ) VR2 (VS Ｗ ) VR4 (-VW ) NC 1 11 -VW VSW VBW VP 8 7 1 0 5 3 4 2 NC NC [...]

60 Voltage Adjustment (2) VBW VBW VBW VBW 、 、 、 、 VP Adjustmen t VP Adjustmen t VP Adjustmen t VP Adjustmen t Measuring VP which i s betw een TP327 and GND . Adj ust V P by VR1 . (To ler ance: +/- 1. 5 volt ) Measuring VBW which is be tween TP3 29 an d TP33 0(–VW ). Adjust VBW by VR3. (To ler ance: +/- 0. 5 vo lt) VR3 (VB W) VR1 (VP) TP32[...]

61 Check w orking Aging A TTE NTI ON Do not u se fixed signals to agin g. For example window s pattern or window pattern. ACT IO N Aging on all wh ite pattern for at least 30 min. White Patte rn[...]

62 Check w orking Inspection A TTE NTI ON In case of some black s trips or light strip, to aging more for one hours with all wh ite pattern. ACT IO N Inspect the screen condition under all red, all gr een, all blue, color bar and gray scale. List the replaced r esult as attached sheet. Red Green Blue Color Bar Gray Scale[...]

63 Stocking Condi tion A TTE NTI ON To stock the modules in the room keeping on standard temperature and humidity. To keep the modules side ways as following picture.[...]

64 4. THE PARTS INFORMA TION PDP Module R epai r Parts Li st Sony M ode l nam e NPD PDP M odule Part N um be r Spare Part s Nam e Supplie r' s Part Num be r V e rsion Note KE -42M R 1 ( AEP) N P 42D2M F 01 AA 9-885- 053-32 P anel M odule NP42D 2M F01AA NP42D 2M F01A A - Panel M odule f or s ervic e S/ N :2200001~ 9-885- 049-66 P KG42D 2G1 BO A[...]

65 NP 4 2 D 2 M F 0 1 AA , AB Upper c om pat ible if no ter m s . Nam e of P ac kage( boa rd) Vers i on R eplac ea ble Vers ion C ondit ion s Note H ig h Volt ag e B o ar d 01A PKG42D2G1 0 1C 03A 03A T his vers i on of th e boar d sh all be us ed w it h D igit al boar d 02 A - 05 or 02A-06 . Co m m o n By p as s Bo ard 01A PKG42B3J 4/42D2J4/35 B 2J[...]

Sony EMCS Corporation Ichinomiya TEC 9-878-233-01 English 2004DL08-Data Made in Japan  2004. 4[...]