KE-42MR1/42MR1E/MR42M1 PANEL MODULE SERVICE MANUAL PDP Module Name NP42D2MF01 NP42D3MF01 KE-42MR1 AEP Model KE-42MR1 K Model KE-42MR1E HK Model KE-42MR1E ME Model KE-MR42M1 CH Model FLAT PANEL COLOR TV
Contents 1. Confirmation Common Manual ･･･････････････････････ P1～P20 2. Confirmation Manual ･･････････････････････････････ P21～P44 3. Repair Manual ････････････････････････････････････ P45～P63 4.
PDP (NP series) Confirmation Common Manual Ver.
PDP Malfunction Phenomenon No Picture Power-off Alarm protection When you turn-on the main power, the LED light-off after few minutes. Go to Page 8 due to check more details. Power-on Malfunction Phenomenon The LED is lighting, but not appear pictures. No Priming The priming does not appear on screen. Go to Page 10 due to check more details. No Signal The priming is on screen, but not appear pictures. Go to Page 10 due to check more details.
PDP Malfunction Phenomenon Abnormal Screen Abnormal Color No lighting sell are on screen at white pattern. Go to Page 11 due to check more details. Abnormal Block Colorful blocks appear on screen at color bar pattern. Go to Page 11 due to check more details.
PDP Malfunction Phenomenon Vertical Vertical Line Single Line Only one line is always lighting. Go to Page 12 due to check more details. Two Lines two lines are lighting. Go to Page 13 due to check more details. Many Lines Many lines are lighting. Go to Page 14 due to check more details.
PDP Malfunction Phenomenon Vertical Vertical Block One Black Block One block is always nolighting by one IC. Go to Page 15 due to check more details. One Zebra Block Zebra block appears by one IC. Go to Page 16 due to check more details. Many Black Blocks Many block appear by one data relay board. Go to Page 16 due to check more details.
PDP Malfunction Phenomenon Horizontal Horizontal Line One Black Block One black line appears on screen. Go to Page 17 due to check more details. Two Lines Two lines appear on screen. Go to Page 18 due to check more details. Horizontal Block Half block does not go out. Go to Page 19 due to check more details.
PDP Malfunction Phenomenon Screen Defect Lighting strip Check our specification . Black strip Check our specification .
No Picture Panel Alarm FPC Opened Panel alarm line go through the edge of the FPC. CHECK POINT FPC cutting at scan side and TCP side. REWORK We can not rework this. Panel Grid Opened Alarm Protection Panel alarm line go through the edge of panel. This case is caused by sulfur issue. CHECK POINT Panel Grid condition. Vs Protection REWORK We can not rework this. High Voltage Circuit Broken Next parts will be broken, Scan Board, Common Board, High Voltage Board, Scan Relay Board.
No Picture Vd Protection TCP Broken In case of shortage between Vd line and GND in TCP, Vd protection will be worked. CHECK POINT Shortage between Vd line and GND, TCP surface Alarm Protection REWORK We can not rework this. Data Relay Board Broken In case of shortage between Vd line and GND in data relay board, Vd protection will be worked. CHECK POINT Shortage between Vd line and GND on data relay board. 5V Protection REWORK Change the data relay board.
No Picture High Voltage Circuit Broken No Priming No Signal Next parts will be broken, Vp or Vbw line on Scan Board, Vsw line on Common Board, (High Voltage Board). CHECK POINT Fuse on board, Vp, Vbw and Vsw line of Power HIC. REWORK Change the scan or common board (High voltage board). Digital Board Broken Digital is not working. CHECK POINT fuse on digital board, LVDS cable REWORK Change the digital board. Vacuum Tube Cracking With big noise. CHECK POINT Vacuum tube REWORK We can not rework this.
No Picture Abnormal screen High Voltage Circuit Broken Next parts will be broken, Vbw line on Scan Board, Vsw line on Common Board, (High Voltage Board). CHECK POINT fuse on board, Vbw or Vsw line on board. 11 REWORK Change the scan or common board (High voltage board).
Vertical The output of TCP The output of TCP is fixed at low level or high level. This line is very clear and constant. CHECK POINT One line is no-lighting or lighting at any pure color signal (red, green blue and black) Single Line REWORK We can not rework this. Data Grid Open Damaged data grid in panel EX) Sulfur, scratch CHECK POINT The surface condition of panel grid. REWORK We can not rework this.
Vertical The output of TCP The closed outputs of TCP are Shortage. CHECK POINT Two lines are lighting at two colors. Two Lines REWORK We can not rework this. Data Grid Shortage The grids of panel are shortage due to foreign material. CHECK POINT The surface condition of panel grid. REWORK We can not rework this.
Vertical Many Lines Data Grid Open Damaged data grid in panel EX) Sulfur, scratch CHECK POINT The surface condition of panel grid. REWORK We can not rework this.
Vertical TCP Broken TCP is not working. CHECK POINT The surface of TCP is damaged. Black Block REWORK We can not rework this. Data Relay Board The buffer IC is not working on signal lines. The connector on data relay board is opened by the cracking of solder. CHECK POINT Input signal condition. 15 REWORK Change the data relay board.
Vertical Zebra Block Data Relay Board The lead of the buffer IC or the connector on data relay board are shortage by foreign material. CHECK POINT Input signal condition. Many Blocks REWORK Change the data relay board. Data Relay Board The lead of the buffer IC or the connector on data relay board are shortage by foreign material. CHECK POINT Input signal condition. 16 REWORK Change the data relay board.
Horizontal The output of Scan IC The output of scan IC is fixed at low level or high level. This line is very clear and constant. CHECK POINT One line is no-lighting or lighting at white signal. Single Line REWORK Change the scan relay board. Scan Relay Board Mis-contact between FPC and the connector of scan relay board. CHECK POINT The output of scan IC. Reconnection. REWORK Reconnect the FPC.
Horizontal Two Lines Scan Relay Board The output of scan IC are shortage. This line is not clear and not constant. CHECK POINT FPC insert shifting. Foreign material in connector. The lead of scan IC. REWORK Clean in the connector. Reconnect the FPC. Change the scan relay board.
Horizontal Scan IC broken Scan IC is not working. CHECK POINT The surface of scan IC. Block REWORK Change the scan relay board. Scan Board The output of scan board is not working. CHECK POINT The output of Scan Board. REWORK Change the scan board.
Voltage Information Label A Since July 2003 40 x 17mm 55 x 25mm 20 x 17mm 55 x 15mm Sample Dimension Label B By June 2003 Sample Dimension Vs 20 Vd Vbw Vsw Vp Vw
PDP (NP42D2MF01) Confirmation Manual Ver.
Flow Chart Check process Type,Serial Number Page 23 NG Take pictures (Module and shipment box) Panel Crack Page 24 NG Flexible Cable Page 25 OK NG Connectors Page 26-28 OK OK Take pictures Take pictures If you can confirm visual malfunction, take pictures Tester Checking Page 29-35 OK Phenomenon Reappearance OK Strip Defect Vertical Line Page 36-37 Page 38-42 Input it in your line again Each Horizontal Line Page 43 No Display Writing Issues Page 29-35 Page 29-35 Judgement (Make C-PDP Failu
Serial Number Module Number and Panel ID Type Name SERIAL NO. Serial Number Panel ID NEC NP42D2MF01 211200192 211200192 Vd=65V Vs=190.
Panel Crack Panel Crack Check the surface of glass whether crack or not. This issue may be caused by transportation or treatment after shipment. We would like you to take some pictures, the broken module, the outside box, and inform the shipment date. If you do not the pictures, we can dispose the broken modules on our responsibility.
Flexible Cable Flexible Cable Check the Flexible Cables whether scratched, broken, or not. Cutting cable or broken In this case, it caused by handling them at customers line. We would like you to be careful to handle the modules.
Connectors Connectors Condition 6 connectors Data Relay Board (Left) 10 connectors Data Relay Board (Right) 13 connectors We would like you to be careful to handle the modules at assembling. 26 5 connectors Digital Board 5 connectors High Voltage Board 5 connectors Scan Relay Board (Up) Common Relay Board 3 connectors Common Bypass Board Scan Relay Board (Down) Check the Cables or Connectors whether connected and locked, or not.
Connector Checking 2 Each Connector High Voltage Board - Digital Board Scan Relay Board - Flexible Cable Locked Unlocked 27 Common Relay Board - Flexible Cable
Connector Checking 3 Each Connector Digital Board - High Voltage Board High Voltage Board - Data Relay Board Locked Unlocked 28 High Voltage Board - Scan Relay Board
Tester Checking 1 Fuse Glass Fuse on High Voltage Board Chip Fuse on Digital Board (F301 、 F302) (FＵ８０１) OK: Shortage OK: Shortage NG: Opened NG: Opened 29
Tester Checking 2 Fuse Resistance and Chip Fuse on High Voltage Board Fuse Resistance Fuse Resistance (R10), (R4), (R6) (R7), (R3) Chip Fuse Resistance Chip Resistance (R20) (R9) On High Voltage Board R10 OK: About 2.2 Ω On High Voltage Board R4 OK: About2.2 Ω R4 R3 R6 OK: About2.2 Ω R20 OK: About 10 Ω R10 R7 OK: About2.2 Ω NG： Opened R7 R20 R3 OK: About2.
Tester Checking 3 Fuse Resistance on High Voltage Board Fuse (R2) Resistance and Chip Fuse on High Voltage Board R2 R2 OK: About2.2 Ω NG： Opened Fuse Resistance Fuse Resistance on High Voltage Board on High Voltage Board (R90) (R1) R90 R1 R1 OK: About2.2 Ω R90 OK: About2.
Tester Checking 4 Data IC Check between (#1 pin or #2 pin) and GND Data Relay Board (Right) #1 pin or #2 pin at CN12 （Vd Voltage Line of Data IC） OK: Opened NG: Shortage Check the resistance between (#1 pin or #2 pin) and GND with tester. In case of shortage, it is caused by malfunction of data IC. Check the surface of data IC after removing the heat sink and Take some pictures.
Tester Checking 5 Parts Location High Voltage Board PH2203F 33
Tester Checking 6 Power HIC A B U PH2203F on High Voltage Board C A B C D E F G H I J K PH2203F M Checking point D E F G U PH2203F L N O P Q T I J S R K Turn this board over, and Check each points Judgment OK： more than ＫΩ Between A and B Between C and U Between J and O Between A and U Between F and U Between L and M Between B and C Between G and H Between P and T Between B and E Between H and J Between Q and T L M NG：Shortage T N O S Between B and M Between I and J Between B
Tester Checking 7 Scan IC Scan Relay Board (Up) Scan Relay Board (Down) NEGA 1 POSI 2 POSI 1 NEGA 2 Judgment OK： More than ＫΩ NG：Shortage Checking Point Between NEGA and POSI 35
Strip Defect 1 Strip Defect Compare with specification 1 strip 2 strip 36 2 strip
Strip Defect 2 Strip Defect 3 strip 3 strip 37 3 strip
Vertical Line 1 Vertical Line Single line Open Mode All Red Pattern All Green Pattern All Blue Pattern All Black Pattern Black 1 Line Red 1 Line Red 1 Line No Appearance Red 1 Line Open Mode [Check Point] a) The broken data flexible cable. If OK, Data IC Broken.
Vertical Line 2 Vertical Line Two lines Shortage Mode All Red Pattern Blue 1 Line All Green Pattern All Blue Pattern All Black Pattern No Appearance Red 1 Line No Appearance Shortage between Red and Blue [Check Point] a) This phenomenon is caused by panel issues.
Vertical Line 3 Vertical Line block 1/2 data IC Block (Width 30mm) [Check Point] a) The broken surface IC on data IC. b) The broken data flexible cable.
Vertical Line 4 Vertical Line block 1 data IC Block [Check Point] a) Lacking connector between Data Relay board and Data IC. b) The broken data flexible cable.
Vertical Line 5 Vertical Line block Many data IC Block [Check Point] a) Lacking connector between Data Relay board and Scan or Common board. b) The broken data flexible cable. C)Shortage between leads in connector. Foreign Material etc.
Horizontal Line Horizontal Line single line, two lines or block Single Two lines Block Block a) The broken surface IC on scan IC driver. Check the resistance between NEGA and POSI on scan IC board. ( Normal: KΩ Level) b) The broken scan flexible cable. c) Lacking connector between scan IC and scan board. d) Shortage between each pins on scan IC by foreign metal material. e) Contact malfunction between connector and flexible cable on scan relay board.
42HD2 Board Location Common Flexible Cable A Common Bypass Board Common Relay Board Common Flexible Cable B Scan Relay Board Scan Relay Board (Down) (up) Scan Flexible Cable A High Voltage Board Common Flexible Cable C Digital Board Scan Flexible Cable B Scan Flexible Cable D Scan Flexible Cable D Data Relay Board (Right) Data Relay Board (Left) Data TCP Data Flexible Cable A B C D E F G H I J 44 K L M N O P
PDP (NP42D2MF01) Repair Manual Ver.
Repair Flow Chart Repair Preparation Testing Page 47 Mounting Setting Panel Setting Page 48 Remove Connectors Connect Supply cable Voltage Adjustment Page 49-51 Aging Page 52 Remove Screws Remove Old Boards Remove Module Page 53 Page 59-60 Page 61 Inspection Page 52 OK Install New Boards Page 58 Page 62 NG Analysis Based on Analysis Manual Drive screws Input line Page 53 Connect Connectors Page 54-57 46
Preparation Tools a) Driver b) Wrist Discharge c) Signal Generator (PC) d) Supply Package e) Mounting f ) Tester g) Cushion ---------- Plus Type ---------- Prevent Electrostatic ---------- To Stand Module ---------- To put the Module on ATTENTION Replacing the boards, always use the wrist band to prevent electrostatic.
Pre-setting Put the cushion on a table and repaired module on cushion ATTENTION Put panel like catching all surface on cushion.
Common Bypass Board High Voltage Board 5 Connectors Digital Board 5 Connectors Data Relay Board (Left) 13 Connectors Data Relay Board (Right) 10 Connectors Heat sink 11 Connectors Attention Scan Relay Board 5 Connectors Common Relay Board 3 connectors Remove the repairing Board Scan Relay Board 5 Connectors Repair 1 Remove connectors and cables (1) Be careful to deal with the connectors and cables. Remove the heat sink on the data relay boa board rd before removing the data relay board.
Repair 1 Remove connectors and cable (2) How to remove the connectors Flat Cable (Type B) Flat Cable (Type A) Locked Unlocked Be careful to remove the connectors because the structure of each connector is different. Or, it is possible to broken the connectors.
Repair 1 Remove connectors and cable (3) How to remove the connectors Cable (Type D) Flat Cable (Type C) Locked Unlocked Be careful to remove the connectors because the structure of each connector is different. Or, it is possible to broken the connectors.
Remove the repairing Board Scan Relay Board 8 Screws Repair 2 Remove the Boards High Voltage Board 22 Screws Digital Board 6 Screws Data Relay Board 4 Screws Data Relay Board 5 screws ATTENSION Do not drop the screwdriver or screws on the board.
Repair 3 Install the new boards Scan Relay Board 8 Screws Install the new board High Voltage Board 22 Screws Digital Board 6 Screws Data Relay Board 4 Screws Data Relay Board 5 screws ATTENSION Install the same number board as module3 Do not add any stress board. Be careful of the length of a screw.
Repair 4 Connecting (1) Check the cables and in sockets Flat Cable (Type A) Socket (Type A) ATTENSION ATTENSION Check the surface of grids whether it is tearing or not. Check whether there are some foreign materials or not in socket.
Scan Relay Board 5 Connectors Repair 4 Connecting (2) Connect some connectors High Voltage Board 5 Connectors Digital Board 5 Connectors Data Relay Board (Left) 13 Connectors Data Relay Board (Right) 10 Connectors Heat sink 11 Connectors ATTENSION Please check that connector connection of a red circled is made normally.
Repair 4 Connecting (3) Connection Condition High Voltage Board (Photograph) － Digital Board Scan Relay Board (Photograph) － FFC Cable Locked Unlocked 56 Common Relay Board (Photograph) － FFC Cable
Repair 4 Connecting (4) Connection Condition Digital Board (Photograph) － High Voltage Board High Voltage Board (Photograph) － Data Relay Board Locked Unlocked 57 High Voltage Board (Photograph) － Scan Relay Board
Check working Mounting Setting ATTENTION Do not stand the module directly on table. ----- Broken the flexible cable To fix the connectors from supply board. ----- Broken scan & common board Adjust supply board to the suitable voltage (Vs) of panel.
11 10 9 8 7 6 5 4 3 2 1 Voltage Adjustment (1) VSW、 VSW、-VW Adjustment In case of no measuring land on the board, please refer pin assignments. Adjust the [-VW(±0.5V)] with VR4 at TP330 on High Voltage Board. VP NC VSW NC VBW NC GND GND GND NC -VW TP328 (VSW) VR4 (-VW) VR2 (VSＷ) VR101 TP330 (-VW) Adjust the [VSW(±0.5V)] with VR2 at TP328 on High Voltage Board.
Voltage Adjustment (2) VBW 、 VP Adjustment In case of no measuring land on the board, please refer pin assignments. Measuring VBW which is between TP329 and TP330(–VW). Adjust VBW by VR3. (Tolerance:+/- 0.5 volt) 11 10 9 8 7 6 5 4 3 2 1 VP NC VSW NC VBW NC GND GND GND NC -VW TP327 (VP) VR3 (VBW) VR1 (VP) TP329 (VBW) Measuring VP which is between TP327 and GND. Adjust VP by VR1. (Tolerance:+/- 1.
Check working Aging White Pattern ACTION Aging on all white pattern for at least 30 min. ATTENTION Do not use fixed signals to aging. For example windows pattern or window pattern.
Check working Inspection Red ACTION Green Color Bar Blue Gray Scale Inspect the screen condition under all red, all green, all blue, color bar and gray scale. List the replaced result as attached sheet. ATTENTION In case of some black strips or light strip, to aging more for one hours with all white pattern.
Stocking Condition ATTENTION To stock the modules in the room keeping on standard temperature and humidity. To keep the modules sideways as following picture.
4.
NP42D2MF01AA, AB Upper compatible if no terms. Name of Package(board) High Voltage Board PKG42D2G1 Version 01A None PKG42B3J4/42D2J4/35B2J4 Data Relay Board (Left) PKG42D2J1 Data Relay Board (Right) PKG42D2J2 Common Relay Board Conditions Note This version of the board shall be used with Digital board 01A-01 to 02A-02. "01A" and "01C" are not available so please use "03A". At that time, "02A-05" or "02A-06"of Digital board should be combined.
9-878-233-01 Sony EMCS Corporation Ichinomiya TEC English 2004DL08-Data Made in Japan 2004.
