AS FILE NO. SERVICE MANUAL Remote Control Plasma Color Television DP42545 (U.S.A.) (CANADA) ORIGINAL VERSION Chassis No. 42545-00 NOTE: Match the Chassis No. on the unit’s back cover with the Chassis No. in the Service Manual. If the Original Version Service Manual Chassis No. does not match the unit’s, additional Service Literature is required. You must refer to “Notices” to the Original Service Manual prior to servicing the unit. AS Contents Specifications Safety Instructions . . . . . . . . .
SAFETY INSTRUCTIONS SAFETY PRECAUTIONS WARNING: The chassis of this receiver has a floating ground with the potential of one half the AC line voltage in respect to earth ground. Service should not be attempted by anyone not familiar with the precautions necessary when working on this type of equipment. READING SHOULD NOT EXCEED 750 mV. AC VOLTMETER (5000 ohms per volt or more sensitivity) The following precautions must be observed: TELEVISION RECEIVER 1.
SERVICE ADJUSTMENTS GENERAL This set has an On-screen Service Menu system included in the CPU that allows remote operation for most of the service adjustments. Volume – : Enter Service Menu ON-SCREEN SERVICE MENU SYSTEM 1. Enter the Service Menu: • While pressing the Volume (–) button on the televi- ▼ CH ▲ POWER VOL sion, press the Number Key 1 on the remote control unit. The Service Menu will now appear. Service Menu Display __SERVICE Item No.
ON-SCREEN SERVICE MENU No.
No.
No.
No.
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No.
No.
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SERVICE ADJUSTMENTS (Continued) 3. Set the television to following conditions: WHITE BALANCE ADJUSTMENT Composite (External Video Input) 1. Connect a color-bar generator to the external (composite) video input terminal. 2. Switch the generator to the white pattern. SPORTS Color Enhancer: Normal Picture Size: Full Display Area: 16:9 AUTO Color Enhancer: Normal Picture Size: Full Display Area: 16:9 4. Enter the Service Mode. The Menu display will appear. 3.
POWER FAILURE CIRCUIT The CPU (IC801) is programmed so the set will go to the standby mode when there is a circuit failure as described below. (Refer to”Power Supply Lines” page 38.) 1. Power Failure 1: Detected voltage failure for analog circuit. (Connected to IC801 pin 52.) (Normal: High, Failure: Low) 2. Power Failure 2: Detected voltage failure for Audio AMP IC. (Connected to IC801 pin 53.) (Normal: Low; Failure: High) 3. Power Failure 3: Detected voltage failure for digital circuit.
MECHANICAL DISASSEMBLY BACK CABINET REMOVAL – SIDES Remove 24 screws to take the side cabinets off. (A:3X8, 6pcs; B:4X12, 18pcs) B B B B B B A A B B B A B A B B A B SERVICE DIGITAL AUDIO OUTPUT A AC IN120V DIGITAL ANTENNA IN UHF/VHF/CATV B B B B B BACK CABINET REMOVAL– CENTER Remove 32 screws to take the back cabinet off.
BOARD LOCATIONS 4 6 6 2 3 1 5 1: Main Board 4: Key SW Board 2: D-TU (Digital) Board 5: Control Board 3: Filter Board 6: Speakers 1: MAIN BOARD REMOVAL 4: KEY SW BOARD REMOVAL Remove 4 screws (3X8) to take the main board with the shield case (assembly parts) off. Remove a screw (4X12) to take the key switch board with the panel, button, and holder (assembly parts) off.
MECHANICAL DISASSEMBLY (CONT.) STAND REMOVAL Position TV face down on a padded or cushioned surface to protect the screen and finish. AC IN 12 0V Remove 2 screws (6X18) from each foot and remove. ATV /VHF/C UHF SERVICE IN DIGITALENNA ANT IO DIGITAL AUD TPUT OU FILTER GLASS REMOVAL 1. Remove the key switch board. 2. Disconnect the following socket connections. Control Board ~ Main Board: K8E Speakers ~ Main Board: KSP8LR 3.
4. Remove 20 screws (G:3X8) to take the filter glass and upper plates off. G G F F G F F G F G G F G G F G G F F F F G G F F G G F G F G F G F G F G G FRONT CABINET REMOVAL 1. Remove 18 screws (F:4X12) to take the filter glass with upper and lower plates (assembly parts) off. 2. Remove the speakers. 3. Remove a screw (4X10) to take the control board and holder off.
MECHANICAL DISASSEMBLY (CONT.) PANEL MODULE REMOVAL 1. Remove the key switch board. 2. Disconnect the following socket connections. Main Board ~ Power Unit: CN8004, CN8007 D-TU Board ~ Power Unit: CN8010 Filter Board ~ Power Unit: CN800 Control Board ~ Main Board: K8E Speakers ~ Main Board: KSP8LR PDP Module ~ Main Board: K8L 3. Remove the main board, D-TU board, and filter board. 4. Remove the 16 screws from the panel holders (Mounting Brackets) to take the panel module off.
POWER UNIT REMOVAL Remove 9 screws to take the power unit off. ATTENTION ■ This PDP TV uses several different kinds of screws. Using the correct screw is required to prevent damage. ■ The gasket is provided to prevent interference to other radio and television receivers. The gasket should be returned to its previous position after servicing. ■ Lead wires should be redressed to previous positions after servicing.
CHASSIS ELECTRICAL PARTS LIST CAUTION: To Protect against electrical shock and for continued product safety, refer to SAFETY PRECAUTIONS, and PRODUCT SAFETY NOTICE on Page 2. PRODUCT SAFETY NOTICE PRODUCT SAFETY SHOULD BE CONSIDERED WHEN A REPLACEMENT IS MADE IN ANY AREA OF A RECEIVER. COMPONENTS INDICATED BY A STAR (★) IN THIS PARTS LIST AND THE SCHEMATIC DIAGRAM DESIGNATE COMPONENTS IN WHICH SAFETY CAN BE OF SPECIAL SIGNIFICANCE.
Schematic Location Part No.
Schematic Location C317 C320 C321 C322 C628 C629 C802 C803 C804 C805 C807 C808 C829 C830 C831 C832 C833 C834 C835 C836 C840 C841 C842 C844 C845 C846 C847 C848 C849 C850 C851 C852 C853 C854 C855 C856 C857 C860 C861 C862 C863 C864 C872 C883 C1051 C1052 C1053 C1121 C1122 C1125 C1126 C1127 C1128 C1130 Part No.
Schematic Location C1711 C1712 C1713 C1714 C1716 C1771 C1772 C2001 C2002 C2003 C2004 C2005 C2006 C2007 C2008 C2009 C2010 C2011 C2012 C2013 C2014 C2015 C2016 C2017 C2018 C2019 C2020 C2021 C2022 C2023 C2024 C2025 C2026 C2027 C2028 C2029 C2030 C2031 C2032 C2033 C2034 C2035 C2036 C2037 C2038 C2039 C2040 C2041 C2042 C2043 C2044 C2045 C2046 C2047 Part No.
Schematic Location C3252 C3253 C3254 C4101 C4102 C4103 C4104 C4106 C4107 C4108 C4109 C4111 C4112 C4113 C4114 C4116 C4117 C4118 C4119 C4120 C4121 C4122 C4127 C4128 C4131 C4133 C4139 C4142 C4148 C4151 C4156 C4157 C4162 C4163 C4164 C4167 C4168 C4169 C4172 C4173 C4174 C7002 C7003 C7004 C7005 C7006 C7007 C7008 C7009 C7010 C7011 C7012 C7014 C7015 Part No.
Schematic Location IC1202 IC1701 IC1771 IC2001 IC2002 IC2003 IC2004 IC3251 IC3252 IC4101 IC7001 IC7003 IC7004 IC7005 IC7006 IC7007 IC7008 Part No.
Schematic Location Part No. Q008 (Cont.
Schematic Location Q1123 Q1124 Q1125 Q1126 Q1127 Q1201 Q1202 Part No.
Schematic Location Part No.
Schematic Location Q8025 Part No.
Schematic Location R212 R213 R301 R302 R303 R304 R305 R306 R307 R308 R311 R312 R318 R319 R327 R328 R333 R334 R335 R336 R800 R801 R802 R803 R804 R805 R806 R807 R808 R809 R810 R811 R812 R813 R815 R816 R817 R819 R820 R821 R822 R823 R824 R827 R828 R829 R831 R832 R833 R834 R835 R836 R837 R838 R839 R841 R842 R843 R844 Part No.
Schematic Location R909 R915 R916 R917 R918 R919 R920 R921 R1001 R1006 R1007 R1009 R1011 R1012 R1014 R1015 R1018 R1021 R1024 R1027 R1030 R1035 R1038 R1041 R1042 R1043 R1044 R1045 R1046 R1047 R1048 R1049 R1050 R1051 R1052 R1053 R1055 R1057 R1066 R1067 R1071 R1072 R1073 R1075 R1076 R1077 R1078 R1079 R1080 R1081 R1082 R1083 R1084 R1085 R1086 R1087 R1088 R1123 R1124 Part No.
Schematic Location R1716 R1717 R1718 R1719 R1721 R1772 R1773 R1774 R1775 R1776 R1777 R1853 R2001 R2002 R2005 R2006 R2007 R2008 R2009 R2010 R2011 R2012 R2013 R2014 R2015 R2016 R2017 R2018 R2019 R2020 R2021 R2022 R2023 R2024 R2028 R2030 R2045 R2046 R2047 R2048 R2049 R2050 R2051 R2052 R2053 R2054 R2055 R2056 R2057 R2058 R2059 R2060 R2061 R2062 R2063 R2064 R2065 R2066 R2067 Part No.
Schematic Location R2162 R2163 R2164 R2165 R2166 R2167 R2168 R2169 R2170 R2171 R2172 R2173 R2174 R2175 R2176 R2177 R2178 R2179 R2180 R2181 R3251 R3252 R3253 R3254 R4101 R4102 R4103 R4104 R4106 R4107 R4108 R4113 R4116 R4117 R4122 R4123 R4124 R4127 R4136 R4138 R4139 R4141 R4144 R4145 R4146 R4147 R4148 R4149 R4157 R4159 R4161 R4162 R4164 R4166 R4167 R4168 R4171 R4177 R4179 Part No.
Schematic Location Part No. Schematic Location Description MISCELLANEOUS ★ A201 A5501 K8O2 K1001 K1002 K1003 K1004 SW801 645 067 2064 610 318 3282 645 037 9956 645 068 2230 652 001 5081 645 071 4511 645 068 0571 645 068 0571 645 055 6678 Part No.
CABINET PARTS LIST 3 4 5 6 7 8 1 2 9 10 15 11 3 POW ER 14 12 13 ACCESSORY PARTS LIST CABINET PARTS LIST KEY NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 PARTS NO. 610 320 2266 645 074 6338 610 320 2327 610 320 2259 610 320 2433 610 312 3301 610 321 0162 610 320 2365 610 320 2358 610 320 3775 610 320 2440 610 320 2334 610 322 3544 645 067 1333 610 313 4093 DESCRIPTION KEY NO.
COMPONENT AND TESTPOINT LOCATIONS MAIN BOARD PARTS SIDE SCR817 A B K8F K8FA C K8L D E 11 SCR801 SCR803 R911 TP5VST C863 R2023 R2026 C2069 TP-DAOUT C2063 R2036 C2066 RB2006 RB2004 C2050C2039 C2056 C2090 C2053 C2060 R2128 Q2020 R2019 R2129 C2080 Q2102 Q2101 R2131 R2103 IC1201 TPSIZ R1201 1 C1229 C1205 C1228 C1204 R1216 C1203 C1219 L1201 B10N11500 PARTS SIDE D TPS C1214 C1213 C1235 R1217 C1207 C1233 C1211 C1232 C1210 C1209 C1231 C1208 C1230 C1206 PWB,MAIN J3TR Q2103 R2114 L211
D E E C1229 C1205 C1228 C1204 R1216 C1203 TPSIZ TPMOUT_V R1201 L1201 B10N11500 XL1008 K1001 C1214 D803 X1701 16 F — 37 — C1147 C1143 R1150 R1151 C1142 R1148 C1144 L1135 R1149 C1141 TPCR C1146 C1131 R1131 Q1122 C1127 R1126 R1124 R1132 R1130 R1128 R1127 C1125 R1125 C1129 L1129 C1126 K1003 G R1147 Q1125 R1123 C1157 R1129 C1155 XL1009 R847 X840 16 1 C1153 R894 8 IC1103 9 5 1 4 IC804 R1175 C1138 R1142 R1146 R1143 C1140 R1144 Q1124 C1135 L1134 C1139 R1137 XL1015 R861 R889 R896 R8
1 H K1003_1 K1004_1 K1004 SCR812 G K1003 K1002 F — 38 — R1012 Q1002 R1015 R1041 R1042 R1035 C1202 R1205 R1074 R1005 R1003 C1234 R1053 K1001 E R2122 C2103 C2115 C1051 C1708 D R041 R035 R024 R025 C036 C026 C2028 C2049 R2086 C2023 C2020 C2021 R2050 C2065 R2079 R2075 R2077 R2069 R2076 C2015 TP2021 C2029 C042 C045 C2031 R2074 C2054 C2073 C2059 R2072 C2058 C2079 C2078 TP2018 C2002 C2003 R2021 C2005 R2064 R2059 R2060 C2025 R2052 R2056 R2055 R2020 R2066 C
D R1213 C1222 C1224 R1214 C1220 C1215 R1208 R1218 R1205 C1223 C1225 B10N11500 PWB,MAIN J3TR SOLDER SIDE C — 39 — TP622 R203 C202 R206 R204 C208 C209 R213 C212 C213 C216 C032 C024 C108 C302 C111 R309 R334 R335 R336 R327 C7004 R301 K8L_16 K8L_12 K8L_3 K8L_1 C3253 R3251 R3252 C3254 C3251 K8L_17 K8L_10 K8L_8 K8L_5 FCT8K01 R3254 C7008 R7022 R329 R331 R332 C322 C7009 R7021 R7020 C3252 C7007 C7517 C7013 C7005 C7014 C321 R330 K8L_21 K8L_13 K8L_28 K8L_29 K8L_20 K8L_9
COMPONENT AND TESTPOINT LOCATIONS (Cont.
BLOCK DIAGRAM DATA BUS LINES IC801 DM OUT 42 DM SOUT 35 9 DM SIN 36 10 8 IC805 11 Serial Line 2 SW 1 DM SCLK 37 BUSY 38 SCL1 29 1 SDA1 30 13 15 IC803 IIC Bus SW SCL 14 SDA 5 IC804 EEPROM 24CL16BT (3.
5 D-TU PF3 38 2,3,4 D_3.
BLOCK DIAGRAM SIGNAL LINES Audio U/V (Analog) Tuner (A201) IC1201 AV Switch 6(L) 7(R) TV_L/R Video 1 Input AV1_L/R Component 2 AV2_L/R Component 3 AV3_L/R M-Out_L/R Q1201(L) Q1202(R) Audio Output 44(L) 42(R) 2(L) 4(R) 8(L) 10(R) 14(L) 15(R) SELECT 30(L) 36(L) L/R 1(R) 35(R) DTV_L/R 27(L) 4(R) 7(L) 10(R) 1-4 IC005 AMP DTV_L/R Q003(L) Q008(R) 3(L) 1(L) 5(R) 7(R) Q004(L) Q002(R) DTV_L/R (Digital) Main 21(L) 10(R) IC101 Audio AMP 26(L) 24(R) 15(L) 11(R) Audio Out Mute IC004 D/A Conver
— 44 — K6502 AV3_Y, Cb, Cr AV2_Y, Cb, Cr DTV Output Digital Tuner D-TU Input (Y/Cb/Cr) Component 3 Input (Y/Cb/Cr) Component 2 37(V/Y) Filter Q4104/Q4103 (Y) Q4107/Q4106 (Cr) Q4102/Q4101 (Cb) Y,Cr,Cb (480i) 6(Y) 8(Y) 16(Cr) 3(Cr) 11(Cb) 5(Cb) 9(Y) 1(Cr) 14(Cb) 1(V) 9(Y) 43(V) DCYA(0-7) DCCA(0-7) K8G DTV_Y, Cb, Cr AV1_C (Composite & Y/C) TV_V V, Y 17 Video 1 Input U/V (Analog) Tuner (A201) IC1201 AV Switch IC3251 Buffer Switch IC7001 LVDS Transmitter K8L PDP Module ADR(0-7) AD
— 45 — Digital - RGB 24bit Digital Y Cb Cr 8bit / 10bit C Cb Cr R G B MainCVBS-2/Y-2 MainCVBS-1/Y-1 SW 8bit A/D Cr/R Digital RGB Input I/F ITU - R656/ YCbCr8bit/ YCbCr16bit Input I/F 8bit A/D 8bit A/D 10bit A/D Cb/B C/G MainCVBS/Y A/D Block Clamp Sync. Process HV Separation Sync. Generate Block SW Sub - Contrast Sub - Brightness Sub - Color Sub - TINT Sub-Picture Adjustment Input - I/F Block R/G/B Cb/Cr C 3-D Comb 3-L Comb YCS YCS + Color Decoder F/E Block Sync. Sep.
IC BLOCK DIAGRAMS (Cont.
Scan Converter (IC301) Data LC74986NWF Input Processing 8 24 VPA2[7:0] 118 125 VPA3[7:0] 128 135 8 8 Sharpness RGB 110 117 Y YCbCr VPA1[7:0] Cb Y Color Tint Cr 82 89 VPB2[7:0]*1 92 99 24 Scaling Processing 81 Horizontal and vertical enlargement Horizontal reduction 44 51 ROUT[7:0] 54 61 GOUT[7:0] 64 71 BOUT[7:0] 82 89 ROUT_2[7:0]*1 92 99 GUOT_2[7:0]*1 24 Dithering G Gamma correction R White balance Contrast Black balance Brightness YCbCr Output Processing
IC BLOCK DIAGRAMS (Cont.
A/D Converter (IC4101) AUTO CLAMP LEVEL ADJUST RAIN A/D CLAMP 8 ROUTA AUTO CLAMP LEVEL ADJUST GAIN A/D CLAMP 8 GOUTA AUTO CLAMP LEVEL ADJUST B AIN A/D CLAMP 8 MIDSCV HSYNC COAST CLAMP FILT DTACK SYNC PROCESSING AND CLOCK GENERATION HSOUT VSOUT SOGOUT SOGIN REF SCL SDA B OUTA SERIAL REGISTER AND POWER MANAGEMENT A0 — 49 — AD9985 REF BYPASS
IC BLOCK DIAGRAMS (Cont.
TROUBLESHOOTING FLOW CHARTS NO POWER Is LED flashing? Yes No Is fuse (F601) open? Check Varistor (VA601). Main Power Module is broken. No No All 0V Is the voltage to all lines supplied? Yes (except '5V_ST' and '3.3V_ST' lines) Check '5V_ST' or '3.3V_ST' line from Main Power Unit to CPU (IC801). Check arround CPU (IC801). Yes Main Power Module is broken. (or the voltage to some lines is not supplied.) After a few seconds, the set will be switched off. Check 'Power Failure' Circuit.
TROUBLESHOOTING FLOW CHARTS (Cont.
NO VIDEO All Modes? No Check: (Analog) TV only Line: A201 17pin - IC1201 43pin (CV) Parts: Around A201 (U/V Tuner) Check: Yes Video 1 only Video 1, TV only Line: IC1201 1pin (Composite Video: CV), 9pin (S-Input: Y), Q2104/Q2103 - IC2001 163pin (S-Input: C) Parts: Around Q2103, Q2104 Check: Parts: Around IC1201 (AV Switch), Q2102, Q2101, Q2106 Component 2 only Check: Component 3 only Check: Line: IC1103 9pin (Y), 1pin (Cr), 14pin (Cb) Line: IC1103 8pin (Y), 16pin (Cr), 11pin (Cb) Check: Com
CONTROL PORT FUNCTIONS System Control (CPU : IC801) Pin Name 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 VHOLD HLF DA1/SCL3/RXD2 DA0/SDA3/TXD2 TB2IN/DIGR0 P91/TB1IN P90/TB0IN BYTE CNVss Xcin/DIGG0 Xcout/DIGB0 RESET Xout Vss Xin Vcc OSC1/OSCHLF OSC2 P83/INT1 P82/INT0 OUT1 OUT2 P77/HC1 P76/TA3OUT P75/HC0 P74/TA2out P73/CTS2/RTS2 P72/SCL2/CLK2 P71/SCL1/RXD2 P70/SDA1/TXD2 P67/SDA2 R/DIGR1 G/DIGR1 B/DIGR1 P63/TxD0
Pin Name Function I/O Description 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 DIG_GO P-FAIL1 P-FAIL2 P-FAIL3 FAN_LOCK LINE_OFF THEM_DET TC_RESET DM_RESET PANEL_READY PANEL/DM_RESET Hsync RESERVED OPTION Vsync OUT IN IN IN IN IN IN OUT OUT IN IN IN OUT IN OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT IN IN IN OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT IN IN IN OUT I/O IN P43/A19 P42/A18 P41
For parts or service contact SANYO Fisher Service Corporation 21605 Plummer Street Chatsworth, CA 91311 (U.S.A.) 300 Applewood Crescent, Concord, Ontario L4K 5C7 (CANADA) March / 2005 / 2000 SMC Printed in U.S.A.
Chassis No. 42545-00 NOTES ON SCHEMATIC DIAGRAMS 1. All resistance values in ohms K=1,000 M=1,000,000. 2. Unless otherwise noted on schematic, all capacitor values less than 1 are expressed in µF (Micro Farad), and the values more than 1 are in pF. 3. Unless otherwise noted on schematic, voltage reading taken with VOM from point indicated to chassis ground. Voltage reading taken using color-bar signal VHF channel 5, all controls at normal. Line voltage at 120 volts.
MODEL DP42545 Chassis No. 42545-00 Main Board_P 1/3 R1078 1/10GZ0C R1041 1/10GJ820C AUDIO OUT_R M_MUTE J3002 1/8GZ000 J3006 1/8GZ000 J3003 1/8GZ000 J3007 1/8GZ000 J3004 1/8GZ000 J3008 1/8GZ000 25KZ C1225 0.1LZF R1211 Q1201 1/10GJ AH 56C J3005 1/8GZ000 J3009 1/8GZ000 J3010 1/8GZ000 C1223 25KZ 0.1LZF 1 A_9V 16EM22T C1217 10KM1LZB L109 1/8GZ 000 GND-2 P_FAIL2 C130 C132 16EM 16EM 470T 470T L102 L2PK100MG C139 10KK 0.18LZB C138 10KK 0.18LZB C124 10KK 0.18 LZB C116 25KZ 0.
Chassis No. 42545-00 8 9 10 11 12 13 14 3 4 5 6 3.
Chassis No. 42545-00 5 C7018 25KZ 0.