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Panasonic_GP8DU_PDP_replacement_[TM]


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Technical Guide
          Preliminary
  Plasma Display Television

       GP8DU Chassis

 Panel Replacement Procedure




 Panasonic Services Company
     National Training Center
                                  Prepared by
                                 Jean Magloire
                Panasonic Services Company
                               National Training




                                             Warning
This service information is designed for experienced repair technicians only and is not
designed for use by the general public. It does not contain warnings or cautions to advise
non-technical individuals of potential dangers in attempting to service a product. Products
powered by electricity should be serviced or repaired only by experienced professional
technicians. Any attempt to service or repair the product or products dealt with in this
service information by anyone else could result in serious injury or death.
                                      Table of Contents
Equipment List: .....................................................................................................1
Panel Handling Precautions..................................................................................1
Preparation of the new Panel................................................................................2
Removal of the Defective Chassis PC Boards ......................................................4
  Rear Cabinet Removal ......................................................................................4
  Board Description..............................................................................................5
Disassembly and Reassembly Procedure ............................................................5
  Removal of the fans ..........................................................................................5
  Removal of the metal frame ..............................................................................6
  Removal of the power supply board (P board) ..................................................6
  Removal of the PB board and metal frame .......................................................7
  Removal of the D board ....................................................................................7
  Transferring the SU-Board ................................................................................8
  Transferring the SD-Board ................................................................................8
  Transferring the SC-Board (37, 42inch) ............................................................9
  Transferring the SS2-Board ............................................................................10
  Transferring the SS3-Board ............................................................................10
  Transferring the SS-Board ..............................................................................11
  Transferring the AC Inlet .................................................................................12
  Installation of the power supply board (P board) .............................................12
  Transferring the C1 and C2 Boards flexible ribbon cable assembly ................13
  Removal of the C3 and C4 Boards flexible ribbon cable (HD Models Only)....13
  Removal of the front cabinet from the plasma display panel ...........................14
  Removal of the Panel from the stand ..............................................................16
  Removal of the stand brackets ........................................................................16
  Installation of the D board ...............................................................................17
  Installation of the PB board and metal frame ..................................................17
  Installation of the metal frame .........................................................................17
  Installation of the front escutcheon..................................................................18
  Installation of the fans .....................................................................................20
Lead Dressing.....................................................................................................20
  Connector Connection:....................................................................................21
  Lead Dressing 2 ..............................................................................................22
Additional Information for 37 and 50-inch Models ...............................................23
Adjustments ........................................................................................................24
  Driver Set-up ...................................................................................................24
  Initialization Pulse Adjustment.........................................................................25
     Drive Waveform ...........................................................................................25
  Adjustment Volume Locations .........................................................................26
  Test Point Locations........................................................................................27
Serviceman Mode and Adjustment procedure of the new panel .........................28
Serviceman mode (Electronic Controls)..............................................................29
  CAT (computer aided test) Mode ....................................................................30
     CAT mode menu..........................................................................................30
   How to access the CAT Mode .........................................................................30
   I2C Mode .........................................................................................................31
   I2C Menu Structure..........................................................................................32
Alignment Procedures.........................................................................................33
   Pedestal Setting ..............................................................................................33
   NTSC White Balance Adjustment....................................................................34
   HD Panel White Balance Adjustment ..............................................................35
   Sub Brightness Setting....................................................................................36
Examples of Defective Panels ............................................................................37
Service Contact Information................................................................................40
                                Objective
This disassembly procedure assists the technician in disassembling a defective
Plasma Display television. It shows a complete service procedure broken down
into three steps:
    1. Complete removal of the printed circuit boards and the defective plasma
        panel from the chassis assembly.
    2. Lead dressing
    3. Adjustment of critical voltages and picture settings
The example unit shown in the guide is a TH-42PX50U but the procedures listed
here are similar for other models of the GP8DU and GP8HDU chassis.
Equipment List:
   1. Electric Screwdriver (Part # EY6220B or equivalent)
   2. Digital Volt Ohmmeter
   3. Oscilloscope
   4. Anti-static 5 foot by 4 foot foam cushioning
   5. Plasma Stand
   6. Screw storage bin
   7. Large flat work area
   8. Isolation Transformer
   9. Colorimeter for white balance adjustment (Sencore CP5000 or equivalent)
   10. A Video Signal Generator capable of providing NTSC, 480i, 480p, 720p,
       1080i and PC with adjustable brightness levels. (Sencore VP300 or
       equivalent)


Panel Handling Precautions
Plasma Display Panels use a high voltage power supply, disconnect the AC from
the unit and wait one minute for the voltage to dissipate.

Use extreme care when servicing the Plasma Display Panel. The glass used in
the plasma panel is thin, and its structure is extremely susceptible to impact.
Rough handling of the unit can crack the glass or cause pixel defect errors. Be
sure to transport the Panel in the upright position, the unit is designed to absorb
force vertically not horizontally.

Numerous flexible printed leads with extremely soft structure are used around the
panel. Be very careful during handling not to damage these by pulling, bending or
subjecting them to excessive force. When inserting a ribbon cable into a socket,
verify that the cable is straight; angled insertion can create an electrical short
circuit.

Anti-static measures should be applied, especially when connecting and
disconnecting the ribbon cables.

A protective sheet is attached to the back of the replacement panel to prevent
scratches and accumulation of debris. Be sure to remove the protective sheet
and wipe the surface with a soft cloth before installation.

A low torque setting is recommended when installing screws in the panel
assembly.




                                         1
Preparation of the new Panel
  1. The replacement panel is shipped in
     a special shipping crate; retain this
     crate to return the defective panel.




                                                 Figure 1. Panel Shipping Crate
  2. Carefully remove the top of the crate,
     remember you will have to reuse the
     crate to return ship the defective
     panel. Slide the panel out the opened
     end.




                                              Figure 2. Removal of Panel from crate




                                      2
3. The replacement panel is
   packed in an escutcheon
   frame and a cardboard panel.
   Protective cushioning
   surrounds the panel. These
   items must be saved and
   used to return the defective
   panel.



                                       Figure 3. Packing of the Panel

Caution: Use extreme care when handling the Plasma Display Panel. The
glass used in the plasma panel is thin, and its structure is extremely
susceptible to impact. Therefore it is recommended that two individuals
handle the Plasma Display Panel to avoid accidental damage.

4. Remove the four screws that secure the protective cardboard on the new
   panel. Place the protective cardboard aside.




        Figure 4. Panel on Table              Figure 5. Cardboard Removal



5. Unwrap the protective packaging from
   the new panel.

   Important Note:
   The new panel comes with the C1 - C4
   boards preinstalled. However, the lead
   cables that connect C1 to C2 and C3 to
   C4 might be missing. Check for board
   jumpers. If missing, remove and transfer
   to the new panel.                            Figure 6. Unwrapping the
                                                          Panel


                                   3
Removal of the Defective Chassis PC Boards

Rear Cabinet Removal
  Remove the 43 screws
  as indicated in Figure 7,
  and then pull away the
  rear cover. Place it in a
  secure location.




                                           Figure 7. Back Cover Screws




                              Figure 8. Board Layout



                                       4
Board Description
Note: The boards are listed in sequential order for quick removal.
Board                                 Board
                  Function                                   Function
Name                                   Name
1 P       Power Supply               6 SD         Scan out (Down)
2         Audio Power, Fan           7
   PB                                     SC      Scan Drive
          Control
3         Format Converter,          8            Sustain Connector (Up)
   D                                      SS2
          Plasma AI Processor                     (42 inches only)
4         DC-DC Converter,           9            Sustain Connector (Down)
   PA                                     SS3
          Power SOS                               (42 inches only)
4         AV Terminal, AV           10
   H                                      SS      Sustain Drive
          Switch
4 DT      ATSC Interface            11 C1         Data Driver (Up Left)
4 DV      HDMI Interface            14 C4         Data Driver (Down Left)
4         Digital Signal
   DG                                     K       Remote receiver, Keyscan
          Processor
4         Speaker out, Audio
   Z                                      S       Power Switch
          AMP
5 SU      Scan out (Up)
                           Table 1. Board Description

Disassembly and Reassembly Procedure
Caution: Wait 1 minute for the electrolytic capacitors to discharge before
removing any PCB from the unit.

Removal of the fans
   1. Unlock the cable clampers of the fans to free the cables.

   2. Disconnect the
      connectors
      PB31, PB33,
      and PB34 from
      the PB board.

   3. Remove the
      three screws that
      secure each of                     Figure 9. Fans Location
      the three fans.

   4. Place the fans in a secure location




                                        5
Removal of the metal frame
   1. Unlock the cable clampers to
      free the cable.
   2. Disconnect the speaker
      connectors (SP-L and SP-R)
      and the black connector that
      couples the K board and the
      DG board.
   3. Disconnect the connectors
      DG3 and DG5 of the DG
      board, PB7 of the PB board
      and PA10 of the PA board.
   4. Remove the five screws that
      hold the metal frame as                 Figure 10. Metal Frame
      indicated in figure 10.
   5. Remove the metal frame and
      place it aside.

Note: The metal frame contains the Z, DT, H, DG, and PB boards.

Removal of the power supply board (P board)
   1. Unlock the cable
      clampers to free
      the cables.
   2. Disconnect the
      couplers (P2, P5,
      P9, P10, P11, P12,
      P23, P25 and P30)
      from the P board.
   3. Remove the six
      screws as
      indicated in Figure
      11.
   4. Installation of the P
      board will be
      performed later.

                                          Figure 11. P Board




                                      6
Removal of the PB board and metal frame
  1. Unlock all the cable clampers of
     the PB board metal frame to free
     the cables.

  2. The connector PB7 is already
     disconnected from the PB board.
     The connectors (PB30, and PB5)
     are already disconnected from the
     P board.

  3. Disconnect the connectors D20
     and D25 from the D board. The          Figure 12. PB Board Metal Frame
     connectors D3 and D5 are already
     disconnected from the DG board.

  4. Remove the three screws as indicated in Figure 12 and remove the PB-
     Board metal frame. The PB board remains attached to the metal frame.

  5. Place the PB board and metal frame aside.

Removal of the D board
  1. Disconnect the flexible cables
     (D31, D32, D33 and D34).
  2. Remove the four screws of the D
     board as indicated in figure 13 and
     place the D board aside.




                                                   Figure 13. D Board




                                        7
Transferring the SU-Board
  1. Remove the 2 screws of the SU
     board as indicated in figure 14.
  2. Disconnect the bridge connector
     (SU45 or SC45) and slide the SU-
     board to the left to disconnect the
     coupler (SC41 -SU41) from the SC
     board.
  3. Remove the flexible cables (SU1,
     SU2, SU3, SU4) and place the SU
     board aside. Installation is
     performed after the removal of the
     SC board.

Transferring the SD-Board
  1. Remove the two screws of the SD
     board as indicated in figure 14.
  2. Disconnect the bridge connector
     (SD46 or SC46) and slide the SD
     board to the left to disconnect from
     the coupler (SC42 -SD42) on the
     SC board.
  3. Remove the flexible cables (SD1,
                                                 Figure 14. SU and SD boards
     SD2, SD3, SD4) connected to the
     SD-Board, and place the SD board
     aside. Installation is performed after the removal of the SC board.




                                      8
Transferring the SC-Board (37, 42inch)
  1. Disconnect from adjoining boards
     any cable that originates from the
     SC board.
  2. Remove the six screws that attach
     the SC board to the panel. Place
     the SC board aside.
  3. Remove the rubber insulator
     located underneath the SC board
     and transfer it to the new panel.
     (See figure 16.)




  4. Transfer the SC-Board to the new
     panel.
  5. Connect the flexible cables (SU1,
     SU2, SU3, SU4) to the SU board
     and slide the SU board to the right
     into the coupler (SC41) of the SC-         Figure 15. SC Board
     Board.
  6. Connect the flexible cables
     (SD1, SD2, SD3, SD4) to the
     SD board and slide the SD
     board to the right into the
     coupler (SC42) of the SC-
     Board.
  7. Install the screws that secure
     the SD and SU boards to the
     new panel.




                                           Figure 16. Rubber Insulator




                                      9
Transferring the SS2-Board
  1. Disconnect the coupler (SS23)
     from the SS2 board.
  2. Disconnect the flexible cable
     (SS55). See figure 17 and 17B.
  3. Remove the two screws that
     attach the SS2-Board to the panel.
  4. Place the SS2 board aside.
     Installation is performed after the
     removal of the SS board.

Transferring the SS3-Board
  1. Disconnect the coupler (SS22)
     from the SS3 board.
  2. Disconnect the flexible cable
     (SS56). See figure 17 and 17B.
  3. Remove the two screws that
     attach the SS3-Board to the panel.
  4. Place the SS3 board. Installation
     is performed after the removal of
     the SS board.


                                            Figure 17. SS2 and SS3 boards




                                           Figure 17B. SS Board Connector




                                     10
Transferring the SS-Board
  1. Disconnect the connector C24
     from the C2 board.
  2. Disconnect the connector C32
     from the C3 board.
  3. Disconnect the connector SS34
     from the SS board.
  4. Disconnect the flexible cables
     (SS52, and SS53) from the SS
     board.
  5. Remove the six screws that
     hold the SS board in place and
     place the SS board aside.




                                              Figure 18. SS Board
  6. Remove the rubber insulator
     located underneath the SS
     board and transfer it to the
     new panel. (See figure 19.)
  7. Transfer the SS board to the
     new panel.
  8. Reinstall the SS2 and SS3
     boards.




                                           Figure 19. Rubber Insulator




                                      11
Transferring the AC Inlet
  1. Remove the two screws that attach
     the AC inlet to the panel as
     indicated in figure 20.
  2. Transfer the AC inlet to the new
     panel.




                                                Figure 20. AC Inlet

Installation of the power supply board (P board)
  5. Unlock the cable
     clampers to free
     the cables.

  6. Connect the
     couplers (P2, P5,
     P9, P10, P11, P12,
     P23, P25 and P30)
     to the P board.

  7. Mount the six
     screws as
     indicated in Figure
     21.




                                         Figure 21. P Board




                                   12
Transferring the C1 and C2 Boards flexible ribbon cable assembly
   1. Remove the three screws of
      the cable bracket.
   2. Unlock the sockets C11 and
      C21 to disconnect the two
      ribbon cables that attach the
      D board to the C1 and C2
      boards.
   3. Install the flexible cables and
      bracket to the new panel.
   4. Remove the lead cable that is
      connected between the
      socket C12 and C22 of the C1
      and C2 boards. Transfer the
      cable to the new panel.             Figure 22. Upper C Boards Flex Cables
Note: The new panel comes with preinstalled C boards.
Note: Reinstallation of the ribbon cables into a socket requires special care.
Verify that the cable is straight; angled insertion can create an electrical short
circuit.

Removal of the C3 and C4 Boards flexible ribbon cable (HD Models
Only)
   1. Remove the three screws that
      attach the angle bracket to the
      panel.
   2. Remove the two screws that
      attach the metal plate to the
      panel.
   3. Unlock the sockets C41 and
      C11 to disconnect the two
      flexible cables that attach the
      D board to the C3 and C4
      boards.
   4. Remove the lead cable that is
      connected between the
      sockets C33 and C43 of the
      C3 and C4 boards. Transfer
      the flexible cable, bracket,
      and metal plate to the new
      panel.

Note: Pay careful attention when
connecting the ribbon cables to the        Figure 23. Lower C Boards Flex. Cables


                                         13
D board and the C boards. Verify that the cable is straight; angled insertion can
create an electrical short circuit.

Removal of the front cabinet from the plasma display panel
   1. Remove the 8
      screws as
      indicated in
      figure 24.

      Note: The
      metal plate at
      the bottom left
      side of the
      picture
      automatically
      falls off when
      the screws are
      removed.
      Place it aside
      for installation
      into the new
      panel.
                                Figure 24. Removal of Front Escutcheon


   2. Remove the three screws of the
      right stand bracket as indicated
      in figure 25.
   3. Disconnect the connector S1 of
      the S board.
   4. Free the cable from the retainers.
      .




                                              Figure 25. Right Stand Bracket


                                        14
5. Remove the three screws of the
   left stand bracket as indicated in
   figure 26.




                                              Figure 26. Left Stand Bracket

6. Make sure all the wiring connected to the
   front panel is unattached.
7. With the help of an assistant, the Cabinet can
   now be removed from the panel by tilting the
   bottom out and lifting up slightly. Place it in a
   secure location.




                                                            Figure 27.
                                                       Escutcheon Removal




                                        15
Removal of the Panel from the stand
With the help of an assistant,
remove the plasma panel from
the servicing stand. Lay it, facing
down, on a flat surface such as a
table covered with a cushioned
anti-static mat, and a soft cloth to
avoid scratching the glass.




Removal of the stand                        Figure 28. Panel on Table
brackets
Note: Perform this task only after removing the plasma
television from the stand. The television should be placed
face down on a table equipped with a cushioned anti-static
mat and a soft cloth.

   1. Remove the 4 screws securing the left stand bracket.

   2. Repeat the procedure for the right stand bracket.

   3. Transfer the stand brackets to the new panel.




                                                              Figure 29. Stand
                                                                  Bracket




                                       16
Installation of the D board
   1. Install the D board to the new panel
      and secure it with 4 screws.
   2. Connect the flexible cables (D31,
      D32, D33 and D34).

   Note: Reinstallation of the ribbon
   cables into a socket requires special
   care. Verify that the cable is straight;
   angled insertion can create an
   electrical short circuit.


                                                     Figure 30. D Board
Installation of the PB board and metal frame
   1. Install the PB-Board metal frame
      and secure it with three screws as
      indicated in Figure 31.
   2. Connect the connector PB7 to the
      PB board.
   3. Connect the connectors (D3, D5,
      D20, and D25) to the D board.
   4. Route the lead cables through the
      cable clampers. Lock the cable
      clampers.

                                               Figure 31. PB Board Metal Frame
Installation of the metal frame
   1. Install the metal frame and
      secure with it with 5 screws.
   2. Connect the speaker
      connectors (SP-L and SP-R)
      and the black connector that
      couples the K board and the
      DG board.
   3. Connect the connectors DG3
      and DG5 of the DG board,
      PB7 of the PB board and
      PA10 of the PA board.
   4. Route the cables through the               Figure 32. Metal Frame
      clampers. Fasten the
      clampers.



                                          17
Installation of the front escutcheon
  1. Verify that the front Escutcheon cover and the
     panel are free of dust and fingerprints.

  2. Install the front escutcheon cover by tilting
     the bottom away from the panel and then
     pushing down from the top. Once the top is
     secured, push the bottom in to lock it in place.

  Caution: If the top is not tightly pushed down
  from the top and held securely in place, pushing
  the bottom in can cause the bottom edge to cut
  the bottom ribbon cables.

  3. Secure the escutcheon with two screws on
     the left and right sides.
  4. Connect the connector S1 to the S board.
                                                        Figure 33. Escutcheon
                                                                Install




                                       18
5. Install the three screws of the
   right stand bracket as indicated
   in figure 34.




                                           Figure 34. Right Stand Bracket

6. Install the three screws of the left
   stand bracket as indicated in
   figure 35.




                                           Figure 35. Left Stand Bracket




                                      19
Installation of the fans
   1. Secure the three
      fans using the
      three mounting
      screws with rubber
      bushings.
   2. Connect the
      connectors PB31,
      PB33, and PB34
      from the PB board.
   3. Route the lead                    Figure 36. Fans Location
      cables through the
      cable clampers. Fasten the clampers.

Note: Defective Panels are considered hazardous waste please follow the
disposal instructions included with the replacement panel.

Lead Dressing
TH-42PX50U




                      Figure 37. Lead Dressing Location




                                     20
Connector Connection:
P2, P5, P9, P10, P11, P12, P23, P25, P30
D3, D5, D25
PB5, PB7, PB30
SC2, SC20, SC23,
SS11, SS12
DG3, DG5
C24, C32




                           Table 3. Lead Dressing




                                     21
Lead Dressing 2
TH-42PX50U




                          Figure 38. Lead Dressing 2

Connector Connection:

PB31, PB33, PB34




              Table 4. Lead Dressing 2




                                    22
                      Figure 39. Example of Lead Dressing

Figure 39 shows an example of harness with a triple wound clamper.


Additional Information for 37 and 50-inch Models
Standard definition 37 and 42-inch screens as well as 50-inch high definition
screens have differences that require slightly different techniques in disassembly
and reassembly. Please refer to the appropriate service manual for lead dressing
instructions.




                                       23
Adjustments                                         Panel Label information
       Driver Set-up
Item / Preparation
Input an APL 100 % white signal.
Set the picture controls to:
Picture mode = Normal
White Balance = Cool
Aspect = 16:9

Note: To perform the following adjustments,             Figure 40. Panel Label
please refer to the panel information label
located on the heat sink of the panel. See Figure 40 for more information about
the panel label.
                                      TH-42PX50U
Name               Test point             Voltage                         Volume
Vsus           TPVSUS               188V 



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