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Service Training of 46" PTV
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PDP Whole Components
·MODULE There are 1 pc. panel and 10 pc.s PCB including 2 pc.s X/Y Sustainer board4 pc.s X/Y extension board2 pc.s W PCB 1 pc. DIF and 1 pc. Power board in the Module. ·SET There are 1 pc. Surface Filter and 9 pc.s PCBs including 1 pc. Audio board1 pc. VIF board1 pc. Power Line Filter1 pc. Keypad board1 pc. Receiver board2 pc.s L/R Speakers and 1 pc. Video board ,1 pc. Tuner board in the SET. isplaying your vision!
Easy maintenance of Plasma Display
Parts position
Audio Board DIF Board
X-Sustainer
Y- FPC Extension board (upper and lower)
X- FPC Extension board(upper and lower)
Speaker
Speaker
Tuner
Ac Line filter Y-Sustainer Power Supply
VIF
W- FPC Extension board (left and right)
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Block diagram of system
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PCB function
1.Power(1).Input voltage:AC 110V240V47Hz63Hz. Input range:90V(Min)265V(Max) auto regulation. (2).To provide power for PCBs. 2.VIF(Video InterFace)To converter TV signals, S signalsAV signalsPC signals and D-SUB signals to digital ones and to transmit to DIF. 3.DIF(Digital InterFace)Dealing with the digital signal for output to panel. 4.X-Sustainer / Y-Sustainer(1). Receiving the signals from DIF and high voltage supply. (2). Output scanning waveform for Module. 5.X / Y-FPC extension boardReceive signal from X / Y sustainer, output horizontal scanning waveform to the panel. 6.W-COF extension board Output addressing signals. 7.Audio BoardAmplifying the audio signal to the internal or external speakers of which selected. 8.TV tuner board : To convert TV RF signal to video and audio signal to VIF board. Audio output to the Audio board.
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Basic operation of Plasma Display
1. After turning on power switch, power board sends Vsby +5V Volt to Micro Processor IC waiting for ON signals from Key Switch or Remote Receiver. 2. When the ON signal from Key Switch or Remote Receiver is detectedMicro Processor will send ON Control signals to Power. Then Power sends volts(VsVxg VwVfVddVcc and +9V)to PCBs working. This time VIF will send signals to display back light OSD on the panel and start to search available signal sources. If the audio signals inputthem will be amplified by Audio AMP and transmitted to Speakers. 3. If some abnormal signals are detectedfor example:over voltsover currentover temperature and under voltsthe system will be shut down by Power off.
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VIF Board
VIF System Structure
D-SUB DVI
ADC Converter TMDS Receiver De_ Interlace Video Decoder
First To a 3D Y/C separating IC
Scalar Chip
Output to DIF
Y/Cb/Cr S-Video Composite Tuner
Micro_Controller
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VIF System Block Diagram
ADC Converter : AD9888 KS
The AD9888 is a complete 8 bit , 205 MSPS monolithic analog interface optimized for capturing RGB graphics signals. Its 205 MSPS encode rate capability and full-power analog bandwidth of 500 MHz supports resolutions up to UXGA(1600 x1200 @ 75 Hz).
TMDS Receiver: SIL151ACT100
The Sil153BCT100 receiver uses Panel Link Digital technology to support high resolution displays up to SXGA(25MHz~112MHz) . The Sil153B receiver supports up to true color panels (24 bit/pixel, 16.7M colors) in 1 or 2 pixels/clock mode. In addition , the receiver data output is time staggered to reduce ground bounce that affects EMI.
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VIF System Block Diagram
VIDEO Decoder:SAA7118E
The SAA7118E decoder is a ADC, too. But it can deal with the ordinary TV signals. The SAA7118E can be input Composite S-video Component signals and its outputs are digital Y(Luminance) , C(Chromaticity) signals.
And it also can adjust brightness , contrast , saturation , hue .
De-interlace:SIL504CM208
The Sil504 transfer interlacing signals into progressive signals. The advantage of progressive signals is that the scanning rate doubling to let the screen more stable and non-flickering. Besides, the sources of input may have 24 0r 30 or 25 frames per sec, so the de-interlaced chip shall tell from the differences and processing the signals. The basic function of de-interlaced IC is to combine the odd and even sub-frames to a frame , and the processing needs a memory IC(SDRAM) to store these signals for processing . For the improving the quality of image sake , more and more TVs or DVD players all have the functions of progressive scanning.
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VIF System Block Diagram
Image Processor Chip:PW171-20U(system on chip)
Image Processor chip:PW171-20U(system on chip) Scaling function :
The Image scalars provide high quality up and down image scaling . For the applications of VIF , the input signals could be VGA , SVGA , XGA formats , and its output fixed at 852 x 480 @60 HZ . For example , SVGA format:800 x 600 @75Hz , first scaling down : Horizontal 800 640Vertical 600 480 , 75 frames / sec after frame rate conversion become 60 frames per sec. Then scaling up 640 852 , to accomplish the scaling function. Micro Processor Function :
This chip includes microprocessor(on-chip 80x86) ; selectable function and I/O interface control . With 3 groups of 8-bit programmable I/O , 1 group of RS-232 communication port , IR decoder ,timer and a PWM generator OSD Function :
The on-screen-display(OSD) can be used for startup screens , menus , and scribble functions
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DIF Board
DIF Structure
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Three Functions of DIF :
(1)Image Signals Processing
Transfer image signal into RGB signal respectively and according to the characteristic of a frame needed to process and adjust the signal.
(2)Waveform Controlling
This function is accomplished by IC106, it generate the controlling waveform signals of X,Y sustainer
(3)Power Controlling
The functions of APC (auto power control) are important to panel ; if APC were abnormal, it may cause power failure or even panel broken
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APC Function
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APC Function
After image data is transmitted to APC by signals processing unitthe Calculate Display Ratio begins to calculate the ratio of pattern. After checking and calculating pattern(A ,B , C) , the numbers of pattern , then sending the data of display and switching count to the window memory . . The APC is performing mathematical calculations , by reducing the sustain frequency and closing some sub-fields to accomplish. There is reference for judgment. The relative parameters has been tested by experiments to determine, so if the parameters of APC are not the optimal parameter , it may cause panel broken , scan IC burned , power supply failure.
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Power Board
Power Board Layout
VS VXG VCC VF VSB
VW
VAU
Volts settings position isplaying your vision!
Power Output Spec.
Name
Vsb Vdd Vcc Vau Vfan Vf Vs Vw Vxg Vaux
Output
5V 5V 5V 9V 12V 15V 170V 65V -160V 380V
Max Load
1.0A 2.0A 3.0A 2.0A 0.5A 0.6A 290W 80W 0.1A 65W
Peak load
cancelled
50A 6A 1A
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X Sustainer
X Sustainer Layout
J3: W - Vw 65V input J1:X - input PX2:VXG,VCC input
PX1:VF,VW,VS input
J302:X L output
J301:X U output
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X Sustainer Power Spec.
Input item Vcc Vf Vs Vxg Vw Vs Vxg Vw Input volt(VDC) 5 15 170 -160 65 170 -160 65 Input current(mA) 240 70 (Full white) 1.2A 40 40 1.2A 40 40 Normal range:1.0~1.5A Normal range:40~150mA Normal range:1.0~1.5A Remark
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X Sustainer CKT instruction
We have 2 sorts of low volt systemTo provide 5V and 15V for driving waveform.
65VThe volt of X - Vxe(Vw) is 65V. And there are 2 sets CKT in X one is 65V for +NAMARIthe other is 65V for W COF. The 65V in Y Vysc is to produce 35V for Bulk during addressing period.
High volts are 170V and -160V for PDP driving volts.
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Y Sustainer
Y Sustainer Lay out
J302:Y - output connects to Y - FPC J301:Y - output connects to Y - FPC
J3:To input W signals to 20PIN
J1:Y input power VccVf VsVyscVw
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Y Sustainer Power Spec.
Input Item Input Volts (VDC)
5 15
Input Current (mA)
240 70 (Full White) 1.2A
Remark
Vcc Vf
Normal range:40~150mA
Vs
170
Normal range:1.0~1.5A
Vysc Vw
65 65
8 40
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Y Sustainer CKT instruction
We have 2 sorts of low volt systemTo provide 5V and 15V for driving waveform.
65VThe 65V in Y Vysc to produce 35V for Bulk during addressing period.
High volts are 170V and -160V for PDP driving volts.
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Easy maintenance of Plasma Display
PCB failure analysis
1. DIF:a.Abnormal noise on screen. b.No picture 2. VIF: a.Lacking colorBad color scale. b.No voice. c.No picture but with signals outputOSD and back light. d. Abnormal noise on screen 3. POWER:No pictureno power output. 4. X - Sustainer: a.No picture. b.Color not enough. c.Flash on screen. 5. Y - Sustainer:Darker picture with signals. DIFVIFPOWX - Sus. Dark pictureDIFVIFPOWX - Sus. OK 6. Audio Bard: a.No voice.Make sure status:Mute / Internal,External speaker b. Noise c.Input power : DC 300V380V 7. X/Y - Sustainer:The component working temperature is about 55. If the temperature rises abnormalthis may be a error point.
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PCB failure analysis
8. X extension PCB fail
No picture 9. Y extension PCB fail
Darker picture
Brighter picture
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Main Repair Flow Chart-1
Defective PDP
Judgment
CPT responsibility
Customer responsibility N
Can not repair
Out-of-warranty Repair Warranty ?
Y
Repair ?
Out-0f-warranty Not repair What's wrong
Panel screen defect
Power failure
Signal failure
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Main Repair Flow Chart-2
Disassemble and Check
Disassemble and Check
Replace PCB Replace Module Adjustment
Next flow chart
QA Test Repair Center Send back to Customer
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Flow Chart:Power Failure-1
Power OK ? Y PDP switch ON ? Y Stand-By Red light OK Y N AC inlet Fuse burned ? Y Y N CFM Power cord OK
N
Turn on power switch
Replace Fuse
Plug out connector PV/ CN , Check CN connector= 5 volts(1+ , 6 - ) ? N Y N
Power board Fuse burned ? Y Replace Fuse
N
Replace power board
Check CN connector= 5 volts (1+ , 6 - ) ? Y
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Flow Chart:Power Failure-2
N Voltage = 4.9V ~5.3V ? Y Replace VIF board Check PD connector= 5 volts(1+ , 4 - ) Power on to check voltage = 4.9V~5.3V ? Y PD voltage from 5V drops to 0V ? Y N Plug out the PY,PX1,PX2 one by one and After power on can not start PD voltage ? Y Replace DIF board N Adj. VR151 make sure Voltage = 4.9V ~5.3V N Adj. VR253 make sure Voltage = 4.9V ~5.3V Y
Plug out PX1,PX2,PY one by one to check X /Y board OK? N Check the signals from DIF to X,Y,W board ? N
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Failure status of example 1.No picture
Standby indicator(red) does not work.
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1. 2.
Check if the power is on. Check if the fuse is burnt out.
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2.Power is on but no picture.
The indicator worked after starting up.
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1. 2. 3. 4.
Maybe VIF failed. Maybe DIF failed. Replace the VIF first. If it doesn't work, then replace DIF. But after action as above, it still doesn't work. Replace X sustainer boards.
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3.Picture indistinct(IW)
Replace the Y sustainer board.
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4.For the figure as below, check the connection of X FPC. If the connection is
O.K. Replace the X extension board.
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5.For the figure as below, check the connection of Y FPC. If the connection is
O.K. Replace the Y extension board.
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6.For the figure as below, check the connection between W side PCB with COF.
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It's caused by bad connection of COF.
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7.There is something wrong on the left side of the panel.
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We have a bad connection.
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8.There is something wrong on the upper side of the panel.
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We have a bad connection.
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9.There is something wrong with image.
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1. 2. 3. 4.
Maybe VIF failed. Maybe DIF failed. Replace the VIF first. If it doesn't work, then replace DIF. But after action as above, it still doesn't work. Replace X sustainer boards.
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10.There is a stripe on the screen. Replace X extension board.
(But if it still does not wok , then it was caused by the bus electrode problem -> panel's problem.)
Stripe
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11.The status as below, replace DIF board.
First, we thought there is something wrong in Y FPC. But not. Why ????? 1.As general display abnormal isn't caused by failed extension board. 2.As figure above shown, we knew something wrong in upper display and high brightness. So the extension board didn't fail.
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3.So we found...................
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12.The status as below, replace video board.
Still in Searching.
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13.This is called I.W. Adjust the Vs voltage by DVM.
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VS VXG
VCC
VF
VSB
VW
VAU
Volts settings position isplaying your vision!
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Power board output spec.
Name
Vsb Vdd Vcc Vau Vfan Vf Vs Vw Vxg Vaux
Output
5V 5V 5V 9V 12V 15V 170V 65V -160V 380V
Max Load
1.0A 2.0A 3.0A 2.0A 0.5A 0.6A 290W 80W 0.1A 65W
Peak load
50A 6A 1A
*Vs & Vxg check the barcode label of Module
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14.Vertical noise line on whole screen ?
No. This caused by Pixel Works IC on VIF. The only way is to replace VIF.
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Panel failure
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Panel W electrode line off.
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X and W electrodes line off.
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Panel lost gas.
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In principle that Panel failure can't be repaired. So what could we do? Inform the retailer fax RMA to manufacture for replacement.
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FAQ (Frequently Asked Questions) 1. Power on the PDP set yet without any picture on the screen a. First check both ends of the power cable are plugged into the socket appropriately then make sure power switch being turned on, survey the red standby light is lamped, if the red standby light is not lamped it means maybe input power has some problem or the safety fuse of AC line filter is burned. b. If the red standby light is lamped it means input power is OK, press key to power on the PDP set if standby light turn to green successfully it means maybe there is something wrong with VIF , DIF or X,Y sustainer. 2.At cable TV mode only find few television channels In OSD manu select TV function and press enter into sub-manu, then at source mode choose CATV and execute TV Program thus all CATV channels would be found. 3. How to do with image sticking? When static image is being displayed on the screen for a long period of time may cause image
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sticking on the screen. When image sticking occurred, the only way to clear up the image sticking is press "Full White" key, using full white image to burn in the screen till image sticking disappear. 4. The signal from PC can`t output to the screen Maybe PC input signal resolution out of PDP set accepted range, please reduce the resolution to1024×768 or lower. If still have problem, check whether the signal line is connected properly or not. 5. The sound of external speaker is not loud enough Check whether the speaker cables are connected appropriately or not Whether the impedance of external speaker match that of audio board output or not, PDP audio output power is 10W × 2, the impedance of audio board output is about 8, if the impedance of external speaker is 16 or higher may cause audio output power decrease 50% or more .
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6. There are some noise being found on the higher CATV channels Maybe the signal quality from cable station is too weak or no good, please inform the cable station to improve the signal quality. 7. The signal from DVD player can`t output to the screen? Check the signal cables from DVD output to PDP input are connected appropriately and check the type of terminal (CVBS, S-Video or the component) then check whether PDP signal input select is correct or not. If all connection and setting are OK then maybe the problem is DVD output having some trouble or PDP set VIF board breakdown. 8 How to clean the screen? Use a soft cotton cloth to clean the screen gently, if also unclean may wet the soft cotton cloth by alcohol and try again. (Other solutions may cause surface filter damage)
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