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Sanyo_DP40142_P40142-00_Z7CA_[SM]


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                 FILE NO

SERVICE MANUAL   LED-DP40142
                 PRODUCT CODE No.:
LED TV           CHASSIS NO. : P40142-00




                    REFERENCE No.: SM0945018-00
                                                           CONTENTS


1. Safety precautions ................................................................................................. 3
2. Alignment instructions ............................................................................................ 5
3. Working principle analysis of the unit ................................................................... 11
4. Block Diagram ..................................................................................................... 12
5. IC block diagram .................................................................................................. 14
6. Wiring diagram ................................................................................................... 26
7. Troubleshooting guide .......................................................................................... 31
8. Schematic diagram .............................................................................................. 35
APPENDIX-A: Assembly list
APPENDIX-B: Exploded View
Removing or Installing the Stand
Attention: This service manual is only for service personnel to take reference with. Before servicing
please read the following points carefully.

Safety precautions
1. Instructions
Be sure to switch off the power supply before replacing or welding any components or
inserting/plugging in connection wire anti static measures to be taken (throughout the entire
production process!):
a) Do not touch here and there by hand at will;
b) Be sure to use anti static electric iron;
c) It's a must for the welder to wear anti static gloves.
Please refer to the detailed list before replacing components that have special safety requirements.
Do not change the specs and type at will.

2. Points for attention in servicing of LCD
2.1 Screens are different from one model to another and therefore not interchangeable. Be sure to
Use the screen of the original model for replacement.
2.2 The operation voltage of LCD screen is high voltage. Be sure to take proper measures in
protecting yourself and the machine when testing the system in the course of normal operation or
right after the power is switched off. Please do not touch the circuit or the metal part of the module
That is in operation mode. Relevant operation is possible only one minute after the power is switched
off.
2.3 Do not use any adapter that is not identical with the TV set. Otherwise it will cause fire or damage
 to the set.
2.4 Never operate the set or do any installations work in bad environment such as wet
bathroom, laundry, kitchen, or nearby fire source, heating equipment and devices or exposure to
sunlight etc. Otherwise bad effect will result.
2.5 If any foreign substance such as water, liquid, metal slices or other matters happens to fall into
the module, be sure to cut the power off immediately and do not move anything on the module lest it
should cause fire or electric shock due to contact with the high voltage or short circuit.
2.6 Should there be smoke, abnormal smell or sound from the module, please shut the power off at
once. Likewise, if the screen is not working after the power is on or in the course of operation, the
power must be cut off immediately and no more operation is allowed under the same condition.
2.7 Do not pull out or plug in the connection wire when the module is in operation or just after the
power is off because in this case relatively high voltage still remains in the capacitor of the driving
circuit. Please wait at least one minute before the pulling out or plugging in the connection wire.
2.8 When operating or installing LCD please don't subject the LCD components to bending, twisting or
extrusion, collision lest mishap should result.
2.9 As most of the circuitry in LCD TV set is composed of CMOS integrated circuits, it's necessary to
pay attention to anti statics. Before servicing LCD TV make sure to take anti static measure and
ensure full grounding for all the parts that have to be grounded.
2.10 There are lots of connection wires between parts behind the LCD screen. When servicing or
moving the set please take care not to touch or scratch them. Once they are damaged the screen
would be unable to work and no way to get it repaired.
If the connection wires, connections or components fixed by the thermo tropic glue need to disengage
when service, please soak the thermo tropic glue into the alcohol and then pull them out in case of
damage.


                                                  3
2.11 Special care must be taken in transporting or handling it. Exquisite shock vibration may lead to
breakage of screen glass or damage to driving circuit. Therefore it must be packed in a strong case
before the transportation or handling.
2.12 For the storage make sure to put it in a place where the environment can be controlled so as to
prevent the temperature and humidity from exceeding the limits as specified in the manual. For
prolonged storage, it is necessary to house it in an anti-moisture bag and put them altogether in one
place. The ambient conditions are tabulated as follows:


                   Temperature       Scope for operation       0 ~+ 35 oC
                                     Scope for storage         0 ~+ 60oC
                   Humidity          Scope for operation       20% ~ 90 %
                                     Scope for storage         5% ~ 90%

2.13 Display of a fixed picture for a long time may result in appearance of picture residue on the
screen, as commonly called "ghost shadow". The extent of the residual picture varies with the
maker of LCD screen. This phenomenon doesn't represent failure. This "ghost shadow" may remain
in the picture for a period of time (several minutes). But when operating it please avoid displaying
still picture in high brightness for a long time.

3. Points for attention during installation
3.1 The front panel of LCD screen is of glass. When installing it please make sure to put it in place.
3.2 For service or installation it's necessary to use specified screw lest it should damage the screen.
3.3 Be sure to take anti dust measures. Any foreign substance that happens to fall down between
the screen and the glass will affect the receiving and viewing effect
3.4 When dismantling or mounting the protective partition plate that is used for anti vibration and
insulation please take care to keep it in intactness so as to avoid hidden trouble.
3.5 Be sure to protect the cabinet from damage or scratch during service, dismantling or mounting.




                                                  4
 2. Alignment instructions
 (1) Test equipment
        VG-859 (YPbPr, VGA, HDMI signal generator)
        FLUKE 54200(TV signal generator)
        CA210 (white balancer)
 (2) Power test
 Connect main board, power board and IR board according the wiring diagram, connect
 the power and press power key (Remote controller or Keypad) button to turn on the TV.
    a) Test the pin voltage of P802/power board , the data is shown in table1:

                                                Table1 voltage data of P802
                                                             For40"
                                                              Pin10,11,
 P802      Pin1,2      Pin3,4       Pin5,6,7      Pin8,9                     Pin13       Pin14      Pin15   Pin16
                                                                  12
                                                   11.4-        4.75-      On:2V-5.5V              2.5-5V   2-5V
Voltage     GND     22.8-25.2V       GND                                                 <0.5V
                                                   12.6V        5.25V      Off: 0-0.5V             PWM


     b)        Test the pin voltage of P803/power board, the data is shown in table2:
                                               Table2 voltage data of P803
                                                           For40"
  P803         Pin1,2,3,4,5      Pin6,7,8,9,10       Pin11                Pin12                  Pin13              Pin14
 Voltage       22.8-25.2V            GND              NC                  2V-5V             2.5-5V PWM               NC




                                                              5
(3) Alignment flow-chart
   The alignment flow-chart is shown as fig-1



                        Check if DDC, HDCP KEY, FLASH are written


                             Combined test for general assembly


                                   White balance adjustment


                    Connect to the center signal source and check each
                    Function of TV (station leaking, analog control, etc.)
                    Check the output of speaker.



                             Input AV signal and check the function


                     Input HD signal and check the function of YPbPr


                 Input USB signal and check if the display is normal, check
                 the function (analog control), horizontal/vertical center, etc.


                 Input HDMI signal and check if the display is normal, check
                 the function (analog control), horizontal/vertical center, etc.



                                        Preset ex-factory


                            Check the accessories and packing

                                    Fig-1 adjustment flow-chart




                                                  6
(4) Adjustment instruction

At any input source then press the "", "EXIT" and "OK" (Remote control) to enter factory mode
During Factory menu, if "MENU" key is pushed, system will exit factory mode.

(5) Items of Factory menu
When in Component/ Video (Composite)/ ANT inputs then press the "Left -> Exit -> OK" key of remote control to
enter factory mode..
During Factory menu, if "MENU" or "EXIT" key is pushed, system will exit factory mode.
Press up and down key can move high light item from Color Temperature -> Timer Clear -> Preset Channel-
>NVRAM Clear-> Full Power -> Source Calibration -> Reset to Default -> RF Burn In -> USB F/W Upgrade ->
UART Enable-> Bypass Gamma.
The Timer Clear, NVRAM Clear and Reset to Default items will have a check dialog "yes or no" to do or not.
Push "Enter" key can select high light item function. (Press left and right can adjust value)
Display panel Burn in Time on the bottom.
Display model name, firmware version and released date on top.




     1)    Factory Color Temp data edit
            This is used for Factory adjusts color temperature. Don't change this value.
    2) Timer Clear
            Reset the timer which records hours of LCD panel burn in (Don't clear timer after FW update.)
            This item will have a check dialog "yes or no" to do or not.
            - Time in factory mode: Time function shall be displayed automatically. Saving the total time of system
              power on (LCD turn on), and count the time automatically. The timer is continuous and saved (per 60
              minutes) forever, unless it will be reset by doing "Timer Clear".
    3) Preset channel
            Load preset channel for production line.
    4) NVRAM CLEAR
            Initialize program's default values to NVRAM for following adjustment items accuracy.
            In factory mode it is the first and important step to make sure all values are default value and correct
            - Reset settings: Gamma table, Channel table (Favorite channel, Channel label etc.), Model table
              (H/V Position, Clock, Phase), Source dependent setting (Contrast, Brightness etc.), Common setting
              (Volume, Language etc.), Parental Control (Rating, Password etc), Closed Caption.
           To avoid a mistake initial process after factory setting is done. This item will have a check dialog "yes
         or no" to do the initial or not.
    Notice:

                                                        7
         After this item is processed then the DUT needs to be powered off then AC powered off.
    5)   Full power (For factory test only)
         This is for power consumption testing.
         To measure the maximum power consumption of TV set, we adjust the value of following items to
         maximum.
         - Video: Contrast maximum value, Brightness maximum value, Backlight maximum value.
         - Audio: Volume maximum value, Bass default value, Treble default value.
         Press enter key to turn on Full Power and OSD stay display until press enter key to recover from Full
         Power
    6) Source Calibration (For factory used only, don't do it without correct machine).
         Source Calibration (gain/offset) must be adjusted color by firmware automatic adjustment in PC, and
         Component input source.
         This item will have a result dialog "OK" or "NG".
     7) Reset to Default
          Reset all settings of OSD menu to default value.
          - Reset settings: Channel table, Model table (H/V Position, Clock, Phase), Source dependent setting
                 (Contrast, Brightness etc.), Common setting (Volume, Language etc.), Parental Control (Rating,
                 Password etc), Closed Caption.
          - Please execute Reset to Default once after FW is upgraded.
     8) RF Burn In (For factory test only)
          Use "snow" pattern for burn in. Selected items are "On" and "Off".
          While turn on burn in mode, firmware will automatically turn off "Auto power off" function.
          If there is no power supply suddenly, firmware will re-enter burn in mode automatically when power
                 supply is back
          Pressed the "Power" key, firmware will automatically turn off burn in mode.
          Burn in mode: Source is "ANT/Cable" and channel is NTSC channel 3.
     9) USB F/W Upgrade
          - We don't recommend upgrade FW here. We recommend upgrade FW in normal power on status (not
          in factory menu), just plug in USB with correct FW file name. (Refer to item 7)
          Upgrade firmware through USB.
     10) UART Enable (For factory test only)
          Enable to communicate with Auto-Alignment system.
     11) Bypass Gamma
            For factory test value of gamma.


 (6) Performance check
 6-1 TV function
 Connect RF to the center signal source, enter Channel menu  auto tuning, check if there are channels be
 skipped, check if the picture and speaker are normal.

 6-2 AV terminals
 Input Video signal, check if the picture and sound are normal.

 6-3 YPbPr terminal
 Input YUV signal (VG859 signal generator), separately input the YUV signals listed in table4 and check if
 the display and sound are normal at any situation (power on, channel switch and format convert, etc.)

                                           Table4 YUV signal format
                                                     SYNC         PIXEL                    SYNC          BACK
                       FREQ         PERIOD                                    Display
                                                   POLARITY       CLOCK                    WIDTH        PORCH
      MODE
                     LINE(kHz)     LINE (pixel)                             LINE (pixel) LINE (pixel) LINE (pixel)
                                                     LINE
                      FRAME          FIELD                        (MHz)       FRAME        FRAME        FRAME
                                                     FIELD
                        (Hz)          (lines)                                  (lines)      (lines)      (lines)

                          15.734          1716      Negitive           27          1440          124          114
59.94Hz 720x480i           59.94           525      Negitive                        480             3             15

                                                        8
                          31,469            858        Negitive                  27            720                 62           60
59.94Hz 720x480P           59.94            525        Negitive                                480                   6           30
                              45           1650        Positive                74.25          1280                 40           220
60Hz 1280x720P                60            750        Positive                                720                   5           20
                           33.75           2200        Positive                74.25          1920                 44           148
60Hz 1920X1080i               60           1125        Positive                               1080                   5           15
                            67.5           2200        Positive                148.5          1920                 44           148
60Hz 1920X1080P               60           1125        Positive                               1080                   5           36

 6-4 HDMI terminal
 Input HDMI signal (VG859 signal generator), separately input the signals listed in table6 and check the display
 and sound (32 KHz, 44.1 KHz, 48 KHz) at any situation (power on, channel switch and format convert, etc.)

                                           Table6 HDMI signal format

                                                     SYNC         PIXEL                         SYNC               BACK
      FREQ             FREQ          PERIOD                                      Display
                                                   POLARITY       CLOCK                         WIDTH             PORCH


                                                                               LINE (pixel)   LINE (pixel)       LINE (pixel)
                      LINE(kHz)     LINE (pixel)     LINE
      MODE                                                        (MHz)          FRAME          FRAME              FRAME
                     FRAME(Hz)      FIELD(lines)    FIELD
                                                                                  (lines)        (lines)            (lines)

VGA 60Hz                  31.469             800    Negitive      25.175                640             96                 40
640x480                     59.94            525    Negitive                            480                  2             25
SVGA 60Hz                 37.879            1056    Positive              40            800            128                 88
800x600                    60.317            628    Positive                            600                  4             23
XGA 60Hz                   48.363           1344    Negitive              65           1024            136                160
1024x768                   60.004            806    Negitive                            768                  6             29
SXGA 60Hz                 63.981            1688    Positive          108              1280            112                248
1280x1024                   60.02           1066    Positive                           1024                  3             38
WXGA 60Hz                 47.776            1664    Negitive          79.5             1280            128                192
1280x768                    59.87            798    Positive                            768                  7             20
WXGA 60Hz                 47.712            1792    Positive          85.5             1360            112                256
1360x768                   60.015            795    Positive                            768                  6             18
59.94Hz 720x480i          15.734            1716    Negitive              27           1440            124                114
                            59.94            525    Negitive                            480                  3             15
59.94Hz 720x480P          31.469             858    Negitive              27            720             62                 60
                            59.94            525    Negitive                            480                  6             30
60Hz 1280x720P                45            1650    Positive         74.25             1280             40                220
                              60             750    Positive                            720                  5             20
60Hz 1920X1080i             33.75           2200    Positive         74.25             1920             44                148
                              60            1125    Positive                           1080                  5             15
60Hz 1920X1080P              67.5           2200    Positive         148.5             1920             44                148
                              60            1125    Positive                           1080                  5             36
24Hz 1920x1080P               27            2750    Positive         74.25             1920             44                148
                              24            1125    Positive                           1080                  5             36

                                                            9
 6-5 other functions check
 a) Check the turn on/turn off timer, sleep timer, picture/sound mode, OSD, stereo and analog TV Teletext, etc.

  (7) USB Software updated
(1) Insert the USB with the firmware which the file name is matched with the model name in factory mode.
(2) If system detects the same firmware file name, USB upgrade message would appear automatically.
(3) Press Left key to select "Yes", and then press OK key to start the upgrading.
(4) Upgrading is starting, please wait for the progress finish.
(5) When the progress completed, please follow the instruction to remove USB and restart by AC off then on.




                                                       10
3. Working principle analysis of the unit
1. NTSC signals flow:
Antenna signal will be sent to tuner ENV56U05D8F,t h e n T u n e r w i l l demodulate and output
standard video signal TV-CVBS, and sound SIF signal.
TV-CVBS will be sent to the master control IC ZR39748 for video decode, de-interlace and scaler,
then output LVDS level drive for panel display.
The sound IF (SIF) will be fed into ZR39748, after demodulating, pre-amplifying, bass adjusting
and volume control, the sound signal w i l l b e t r a n s f o r m i n t o d i g i t a l I 2 S s i g n a l and sent
to digital amplifier TAS5707L.

2. Composite/Component signal flow
Composite signal and Component signal will be fed to ZR39748 to perform video decode, de-
interlace and scaler, then output LVDS drive level for panel display.
Audio signal from Composite/Component terminal via matched resistance is fed to ZR39748 to bass
adjust and volume control, the sound signal will b e t r a n s f o r m i n t o d i g i t a l I 2 S s i g n a l and sent
to digital amplifier TAS5707L.

3. HDMI signal flow
Two HDMI video signals are directly fed to the master control IC ZR39748 to digital decode, image
scale, then output LVDS drive level for panel display. HDMI audio signal via decoder built-in ZR39748
to bass adjust and volume control, the sound signal will b e t r a n s f o r m e d i n t o d i g i t a l I 2 S
s i g n a l and sent to digital amplifier TAS5707L.

4. USB signal flow
USB signal via USB connector sent to ZR39748 and its A/D conversion to YPbPr output for
ZR39748, then output R/G/B of 24 bit to back end module to Video decode, de-interlace
and image scale, then send to LVDS level drive for panel display.




                                                        11
                        4. SSB40T 40" Block Diagram
4-1 Block Diagram

                 SSB40T 60Hz                                                                   Panel out

                                                                                                                                                   R_out

                                                                                                                               Audio
           Main Board                                                                                                          AMP




                                                                                                    LVDS out
                                                            DDR2 512Mb -1066                                                  TAS5707L
                                                                                                                                                   L-out




                                                                                                               Audio output




                                                                                                                                                                             Keypad
IR Board                         Flash
                                 32Mb
                                                          DTV system IC                                        Tuner IF +/-

   IR
                                                             Zoran
                                                            ZR39748                             Digital audio out

                                    HDMI 2                                                      Composite audio In

                                    HDMI 1                                                      Component audio In
                                                                                Component
                                                                   Composite




                        HDMI      HDMI

                        HDMI 2   HDMI 1




                                                USB I/F




                                                                                                                                                           Panasonic tuner


                                                                                              Y
                                             USB                                            /CVBS      Pb       Pr        L     R        Coaxial             RF

                                                                                                                                         Coaxial
                                             USB 1                                             Component / Composite                      OUT                   ANT /
                                                                                                                                                               CABLE




                                                                               12
 5. IC block diagram

1. Zoran ZR748



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