Service Manuals, User Guides, Schematic Diagrams or docs for : Sanyo Monitor Sanyo_DP55441_P55441-04_Z6DH_[SM]
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FILE NO
SERVICE MANUAL LCD-DP55441
PRODUCT CODE No.: 1-130-273-04
LCD TV CHASSIS NO. :
P55441-04
REFERENCE No.:SM0945017-00
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 ................................................................................................... 27
7. Troubleshooting guide .......................................................................................... 32
8. Schematic diagram .............................................................................................. 36
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 installation 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 ~+ 50 oC
Scope for storage -20 ~+ 60oC
Humidity Scope for operation 20% ~ 90 %
Scope for storage 10% ~ 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
For 55"
P802 Pin1,2 Pin3,4 Pin5,6,7 Pin8,9 Pin10 Pin11,12 Pin13 Pin14 Pin15 Pin16
11.6- 4.75- On:2V-5.5V 2.5-5V 2-5V
Voltage GND 22.8-25.2V GND NA <0.6V
12.8V 5.25V Off: 0-0.5V PWM
b) Test the pin voltage of P803/P804/power board, the data is shown in table2:
Table2 voltage data of P803/P804
For 55"
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 & PC 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 any 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-> MEMC demo mode-> MEMC level.
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. (Refer 4.4.4 Preset channel table).
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.
7
Notice:
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.
12) MEMC demo mode
For factory test MEMC.
13) MEMC level
For factory test MEMC.
(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
MODE SYNC PIXEL SYNC BACK
FREQ PERIOD Display
POLARITY CLOCK WIDTH PORCH
LINE(kHz) LINE (pixel) LINE (MHz) LINE (pixel) LINE (pixel) LINE (pixel)
FRAME FIELD FIELD FRAME FRAME FRAME
8
(Hz) (lines) (lines) (lines) (lines)
15.734 1716 Negitive 27 1440 124 114
59.94Hz 720x480i 59.94 525 Negitive 480 3 15
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 VGA terminal
Input VGA signal (VG848 signal generator), separately input the signals listed in table5 and check the display and
sound. If the image is deflection of the Horizontal and vertical, select Menu->Setup->Auto Adjust to perform auto-
correct.
Table5 VGA signal format
SYNC PIXEL SYNC BACK
FREQ PERIOD Display
POLARITY CLOCK WIDTH PORCH
Mode
LINE (pixel) LINE (pixel)
LINE(kHz) LINE (pixel) LINE LINE (pixel)
(MHz) FRAME FRAME
FRAME(Hz) FIELD(lines) FIELD FRAME(lines)
(lines) (lines)
VGA 60Hz 31.469 800 Negative 25.175 640 96 40
640x480 59.941 525 Negative 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 Negative 65 1024 136 160
1024x768 60.004 806 Negative 768 6 29
WXGA 60Hz 47.776 1664 Negative 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
SXGA 60Hz 63.981 1688 Positive 108 1280 112 248
1280x1024 60.02 1066 Positive 1024 3 38
6-5 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
MODE LINE(kHz) LINE (pixel) LINE (MHz) LINE (pixel) LINE (pixel) LINE (pixel)
9
FRAME(Hz) FIELD(lines) FIELD FRAME FRAME FRAME
(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
6-6 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 detect 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 send to tuner ENV56U05D8F, t h e n T u n e r w i l l b e demodulating and
output standard video signal TV-CVBS, and sound SIF signal.
TV-CVBS will send to the master control IC ZR39748 to 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. PC signal flow
PC signal via terminal socket sent to ZR39748 A/D, PC 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.
Sound signal of PC t e r m i n a l via matched resistance a n d sent 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.
4. 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 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.
5. 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.
Sound signal of USB signal v i a matched resistance a n d sent 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.
11
4. SSE55T 55" Block Diagram
4-1 Block Diagram
12
4-2. Power/B block diagram.
13
IC block diagram
1. Zoran ZR748
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