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http://www.instructables.com/id/Dell-W5001C-50quot-plasma-fix/
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Dell W5001C 50" plasma fix
by mr12volt on April 8, 2009
Table of Contents
License: Attribution Non-commercial No Derivative Works (by-nc-nd)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Intro: Dell W5001C 50" plasma fix  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
step 1: Symptoms  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
step 2: Teardown  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
step 3: Testing the Power Supply  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
step 4: Debugging on the Bench  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
step 5: Replacing the controller chip  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
step 6: Conclusion  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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Comments  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Summary of content (18 pages)

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Home Sign Up! Explore Community Submit All Art Craft Food Games Green Home Kids Life Music Offbeat Outdoors Pets Photo Ride Science Tech Dell W5001C 50" plasma fix by mr12volt on April 8, 2009 Table of Contents License: Attribution Non-commercial No Derivative Works (by-nc-nd) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Intro: Dell W5001C 50" plasma fix . . . . . . . . . . . . . . . . . . .
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License: Attribution Non-commercial No Derivative Works (by-nc-nd) Intro: Dell W5001C 50" plasma fix My buddy's Dell 50" W5001C plasma television conked out one day so I set out trying to fix it. The TV is about 4 years old, and it is out of warranty. Even the three year extended warranty that was offered for $1000 at the time of purchase would have done no good. (Remember when TV's used to last 20 years?) With no recourse for repair through official channels, what is one to do? "So what are my options?" 1.
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Image Notes 1. Dell W5001C 50" plasma step 2: Teardown To access the power supply, one must remove the sheet metal backing to the television. This is quite easy and only requires a T20 torx screwdriver and a common philips screwdriver. There are many torx screws around the periphery, four large philips mounting screws, and a couple smaller philips screws.
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Image Notes 1. Power supply 2. Input board with lots of analog and digital electronics. 3. Plasma drive electronics (mostly covered by heatsinks.) Image Notes 1. Power supply removed. 2. Power supply in a conductive bag. 3. Grounded metal frame. step 3: Testing the Power Supply Static Electricity Warning Some components on the power supply are CMOS integrated circuits and are therefore sensitive to static electricity. Before touching the circuit board, I make sure the TV is unplugged.
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Image Notes 1. The power supply board. 2. Va Testpoint 3. Un-isolated high voltage side. Be careful!! 4. Isolated voltages side. Still some high voltages around here so be careful! Image Notes 1. Nametag Image Notes 1. Table of node names and voltages on the circuit board. Image Notes 1. Va Testpoint Image Notes 1. Grounded metal backing of plasma screen. http://www.instructables.
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2. Metal mounting stud for power supply. Ground yourself on one of these before touching anything on the power supply to dissipate any static electricity. Image Notes 1. A multimeter Image Notes 1. Set one of the multimeter probes into one of the mounting studs before probing testpoint voltages. http://www.instructables.com/id/Dell-W5001C-50quot-plasma-fix/ Image Notes 1. Probing Va testpoint.
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step 4: Debugging on the Bench More testing in the lab revealed that the problem was a defective IC, U501 which is a Fairchild Semiconductor part KA3883. I ordered a replacement from digikey, 4973678-ND , which is a STMicroelectronics UC2843B, for $1.09. The original KA3883 is not generally available(discontinued?). UC2843B is higher quality drop-in replacement.
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Image Notes 1. 750ohm 25W resistor as a load used during testing of Va. Image Notes 1. Jumper across RTN and PS-ON to make board turn on. 2. More testpoints. Image Notes 1. Airpencil, usually used for surface mount soldering. http://www.instructables.
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step 5: Replacing the controller chip The first thing you need to do is get rid of the defective part, U501. One method is to remove the chip by getting rid of the solder holding it in place. Either use a solder sucker desoldering station (if you have access to one) or solder wick to remove the solder then pull the whole chip out. Careful with the solder wick. If you heat up a pad too much, you WILL lift a trace, effectively destroying the board. It's very hard so get it right with the solder wick.
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Image Notes 1. U501 is Fairchild KA3883 current mode pwm switch mode power supply controller. 2. Jellybean opamp Image Notes 1. Defective part. Image Notes 1. Desoldering station. 2. Regular soldering iron. 3. Soldering iron with a bore hole down the center through which solder can be sucked. 4. Air filter so solder does not get sucked into the pump. Image Notes 1. Desoldering wick (braided copper with flux) http://www.instructables.
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Image Notes 1. Holes cleared of solder using the solder sucking desoldering station and a touch of solder wick. 2. Still a little bit of solder in this one. Image Notes 1. SIP sockets (row of 4) attached to each side of the new part. Image Notes 1. Finished repair job. Image Notes 1. Reverse side of finished solder job. step 6: Conclusion Now install the board back onto the TV, and connect only the smaller connectors to test the board. Plug in the power to the TV and turn it on with the remote.
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Advertisements Comments 42 comments Add Comment jwoyshnar says: Sep 18, 2009. 7:18 PM REPLY Hello all, wondering if someone can help me out there. I tested the test points and came up with some odd numbers. Va was 132, the 5 volt was 10 and the 12v was 24. All other voltages were absent. Any help with this on where to turn next would be greatly appreciated. thanks mr12volt says: Sep 22, 2009. 6:22 AM REPLY jwoyshnar, My first inclination is to suspect your measurement device (multimeter,voltmeter?).
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IC's already, so I thought I would share them below. I'll post the part numbers for the 5 volt supply when I find them, and post progress on my repair in case someone else has a similar issue. Please feel free to correct any errors that I have made. Thank you again for making this instrucable. Aaron.
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why I bring it up. Electrolytics do degrade over time. whitby905 says: Jul 7, 2009. 9:17 AM REPLY Thanks for your reply mr12volt. In regards to the e-caps I can tell you that audibly (very faint) there appears to be some relationship to the fluctuation of the voltage...meaning that I can hear the cap altering buzzing with the voltage changes.
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chuckbox says: Aug 5, 2009. 5:21 PM REPLY What a great set of instructions. I have followed these to the same discovery on my tv.. My lower Y-board has the same burned area as above. Were you able to buy another Y-board or did you scrap the tv? Any ideas mr12volt says: Aug 6, 2009. 9:49 AM REPLY whitby905 and chuckbox, Do either of you have your dead Y-Buffer? I would like to photograph and disassemble it, and perhaps publish some detailed information on this second failure mode.
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mr12volt says: Jun 17, 2009. 2:55 PM REPLY manuts, I didn't trace out the Vscan circuit so I couldn't say exactly which components are involved in that circuit. As I have said in the other comments, you should look at the traces on the board to see which components the Vscan testpoint is connected to. Be aware of the component numbering. For this circuit board, all the components numbered in the 500's(or 400's or 200's or whatever the Vscan circuit is) more or less belong to the same circuit.
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Lez1pyt says: May 28, 2009. 10:39 AM REPLY How can an ordinary lay person do this or can they do this It seems very difficult mr12volt says: May 28, 2009. 1:58 PM REPLY Lez1pyt, You are correct, this instructable IS written at a fairly high level and is mostly intended for an audience with some electronics and soldering experience. However, I tried to explain in step 1 that this is simply a journal of my own experience fixing a plasma TV and should certainly not be attempted by everyone.
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Dandeman321 says: Apr 13, 2009. 8:39 AM REPLY How did you know to check that chip? mr12volt says: Apr 13, 2009. 10:34 AM REPLY I mentioned in Step 4 that I heated the chip with an air pencil and it caused the voltage to suddenly turn on. I had first noticed that after the whole board being on for a minute or two, the Va supply would come back to its normal 60volts. It was audible. There would be a slight buzzing when it went from the off state to the on state.