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CONFIDENTIAL
ELECTRICAL SERVICE MANUAL
INTERNAL ONLY
9-888-445-51
KDL-32EX525/40EX525
TABLE OF CONTENTS
KDL-32EX525/40EX525 2
KDL-32EX525/40EX525
There are critical components used in LCD color TVs that are important for safety. These components are identified with shading and !
mark on the schematic diagrams and the electrical parts list. It is essential that these critical parts be replaced only with the part number
specified in the electrical parts list to prevent electric shock, fire, or other hazard.
NOTE: Do not modify the original design without obtaining written permission from the manufacturer or you will void the original parts and
labor guarantee.
When installing the LCD panel on a wall, the LCD panel must be secured using the 4 mounting holes on the rear cover.
• Avoid contact with water as it may a short circuit within the module.
To avoid damaging the LCD panel:
Ú do not press on the panel• Ifortheframe edgeoftopanel
surface avoidbecomes
the risk ofdirty,
electric shock.
please wipe it off with a soft material. (Cleaning with a dirty or rough cloth may
Ú do not scratch or press on the panel with any sharp objects.
Ú do not leave the module in damage the panel.) or in areas of high humidity for an extended period of time.
high temperatures
Ú do not expose the LCD panel• If you want tosunlight.
to direct replace with the new backlight (CCFL) or inverter circuit, must disconnect the AC adapter because high
Ú avoid contact with water. It may cause a short circuit within the module.
Ú disconnect the AC adaptervoltage
when replacing
appears attheinverter
backlight (CCFL)
circuit aboutor650Vrms.
inverter circuit.
(High voltage occurs at the inverter circuit at 650Vrms.)
• Handle with care wires or connectors of the inverter circuit. If the wires are pressed cause short and may burn or take
Ú always clean the LCD panel with a soft cloth material.
Ú use care when handling thefire. wires or connectors of the inverter circuit. Damaging the wires may cause a short.
Ú protect the panel from ESD to avoid damaging the electronic circuit (C-MOS).
Leakage Current Hot Check Circuit
LEAKAGE CURRENT HOT CHECK CIRCUIT
KDL-32EX525/40EX525 3
KDL-32EX525/40EX525
The circuit boards used in these models have been processed using
Lead Free Solder. The boards are identified by the LF logo located
close to the board designation e.g. H1 etc [ see example ]. The
servicing of these boards requires special precautions to be taken as
outlined below.
example
It is strongly recommended to use Lead Free Solder material in order to guarantee optimal quality of new solder joints.
Lead Free Solder is available under the following part numbers :
Due to the higher melting point of Lead Free Solder the soldering iron tip temperature needs to be set to 370 degrees centigrade.
This requires soldering equipment capable of accurate temperature control coupled with a good heat recovery characteristics.
KDL-32EX525/40EX525 4
KDL-32EX525/40EX525
SAFETY CHECK-OUT
After correcting the original service problem, perform the following The AC leakage from any exposed metal part to earth ground and
safety checks before releasing the set to the customer: from all exposed metal parts to any exposed metal part having a
return to chassis, must not exceed 0.5 mA (500 microamperes).
1. Check the area of your repair for unsoldered or poorly soldered Leakage current can be measured by any one of three methods.
connections. Check the entire board surface for solder splashes and
bridges. 1. A commercial leakage tester, such as the Simpson 229 or RCA
WT-540A. Follow the manufacturers’ instructions to use these
2. Check the interboard wiring to ensure that no wires are “pinched” or instructions.
touching high-wattage resistors.
2. A battery-operated AC milliampmeter. The Data Precision 245
3. Check that all control knobs, shields, covers, ground straps, and digital multimeter is suitable for this job.
mounting hardware have been replaced. Be absolutely certain that
you have replaced all the insulators. 3. Measuring the voltage drop across a resistor by means of a VOM
or battery-operated AC voltmeter. The “limit” indication is 0.75
4. Look for unauthorized replacement parts, particularly transistors, V, so analog meters must have an accurate low voltage scale.
that were installed during a previous repair. Point them out to the The Simpson’s 250 and Sanwa SH-63TRD are examples of
customer and recommend their replacement. passive VOMs that are suitable. Nearly all battery-operated digital
multimeters that have a 2 VAC range are suitable (see Figure A).
Leakage Test
To Exposed Metal
Parts on Set
Trouble Light
Ohmmeter
AC Outlet Box
AC
0.15 µF Voltmeter
(0.75V)
Cold-water Pipe
Earth Ground
Figure A. Using an AC voltmeter to check AC leakage. Figure B. Checking for earth ground.
KDL-32EX525/40EX525 5
KDL-32EX525/40EX525
SECTION 1: DIAGRAMS
BATV
GE2
SWITCH
UNIT
TCON
HLR2 HMS3
KDL-32EX525 ONLY
BATV
GE3
SWITCH
UNIT
TCON
HLR2 HMS3
KDL-40EX525 ONLY
KDL-32EX525/40EX525 6
KDL-32EX525/40EX525
NOTE: The components identified by a red outline and a mark contain confidential
information. Specific instructions must be adhered to whenever these components
are repaired and/or replaced.
See Appendix A: Encryption Key Components in the back of this manual.
KDL-32EX525/40EX525 7
KDL-32EX525/40EX525
Common
9 Diode
Anode Anode
Common
10 Diode
Cathode Cathode
Common
11 Diode
Cathode Cathode
Anode Cathode
12 Diode Anode Anode
Cathode Anode
Transistor Source
13 Drain D D
(FET) Gate
G G
Transistor Source S S
14 Drain
(FET) Gate
D D
Transistor Source
15 Drain G G
(FET) Gate S S
Emitter
16 Transistor Collector
Base
C1 C2
C2 B1 E1
Transistor B1 B2
17 E2 B2 C1
E1 E2
C1 B2 E2
18 Transistor C1 C2
E1 B1 C2
B1 B2
C1 B2 E2 E1 E2
19 Transistor
E1 B1 C2
E1 E2
C1 B2 E2
20 Transistor B1 B2
E1 B1 C2
C1 C2
C1(B2) C2
E2 B1 E1
21 Transistor B1
C2 C1(B2)
E2 E2
(B2) E1(B2) E2
B1 E1 E2
22 Transistor B1
C1 C2
C1 C2
(B2) E1(B2) C2
E2 E1 B1
23 Transistor
C2 C1
B1
C1 C2
– Discrete semiconductor
Ver.1.6
(Chip semiconductors that are not actually used are included.)
KDL-32EX525/40EX525 8
KDL-32EX525/40EX525
1-3. BLOCK DIAGRAMS
Switch Unit BATV-Board WIFI Board
Keys Wireless LAN
Power Key
(EX523 Models Only)
Function Keys
HMS3-Board
HLR2-Board Motion Sensor
Power/
LEDs SIRCS
IR Sensor Optical Digital Audio Output
Light Level
Headphone/Analog Audio Output
X-Reality Processor
TV Microprocessor
RF Input
Video Processing R
HDMI Processing
Component HDCP Processing L
IP (Image Processor)
Composite Scan Converter (Scalar)
Audio Processing
PC Input Video Switcher LCD Panel Assembly
HDMI Switcher
4 HDMI Inputs ATSC/NTSC Tuner
Temperature Sensor LVDS
2 USB 2.0 Audio Output Amplifier TCON/HFR
Power
RJ45 Ethernet
LCD Panel
GE2-Board (32")
GE3-Board (40")
LED
Backlight System
Main Power Supply
Standby Power Supply
AC AC Relay
Input LED Backlight Power Supplies
USB1 Ether
X’tal DiSEqC_Out MS USB2
H Con. TCON
27MHz
DDC
DiSEqC_In
27M
Silicon
P
[LNBH23]
X_SYSTEM1_RST
X_SYSTEM1_RST
IFAGC TS2
Cable
5V
5V
A
[HORUS3] [SEKITO2] I2CB
DDR3
DMD_CLK_ENABLE2 USB4 USB3 Current Current
N
SW Limit Limit –1333
5V
DMD_CLK_ENABLE1
DMD_RST BD Wifi [TPS2553DBV] [TPS2553DBV]
2Gb
Current
E
X’tal
Limit One –
4M
Silicon USB Ether DDR3 BACKLIGHT
Aerial
[MIC2005]
X_PEM_RST/LUT_SEL2/X_FRC_RST
IF2
LNA Tuner Ext Demod NAND
LUT_SEL1/X_TCON_RST/LR_FLAG
L
0
0
HUB PHY
IFAGC TS1 [GL850G] [RTL8201E] Muxed –1333
[ASCOT2Sip] IF1 [GAIA1a] I2CB 2Gb
Crystal 2Gb
X’tal 12M
PEM_WDT/XBUSY/BINT
MODE_PEM/TCON_RDY
X_SYSTEM1_RST 41M
SA_MODE/LUT_SEL0
TMDS1
HDMI1 DDC1
T_PANEL_SEL
DDC_5V_1
(ARC) HPD1
ARC
LVDS_ODD
LVDS_EVEN
I2C_C
CEC1 I2CA
TMDS2
DDC2 EQ SW
HDMI2 DDC_5V_2
HPD2 [Sil9287B] TS
CEC2 X’tal SYSTEM2_PWR SYSTEM1_PWR
TMDS3 41M
1.5V 1.2V
DDC3 IF1 REG_12V
DDC REG_12V DDC
HDMI3 DDC_5V_3
HPD3
X’tal SYSTEM2_PWR SYSTEM2_PWR T-CON_VCC
3.3->1
CEC3 48M Reset
Power
Push 3.3V REG12V
TMDS4 TMDS X’tal AC_MON DDC REG_12V DDC REG_12V
DDC4 DDC
32.76
8K 5V REG12V
HDMI4 DDC_5V_4
HPD4
CEC
Reset
SYSTEM2_PWR
AUDIO_12V
AUDIO_12V
[PST3629] 2.5V 3.3V 3.4V S1.2V S1.8V
CEC4 STBY 3.3V
LDO LDO LDO LDO LDO
GND
Power_Control
TCON-ON
DIMMER_DC
DIMMER
BACKLIGHT_ON
COMP_Y BACKLIGHT_MON
MAIN_PWR
AC_MON
I2CA (EQSW, Temp Sensor, Hotel Clock) PFC_PWR
VideoA_Det I2CB (Ext Demod)
DIMMER2
VIDEO_CV I2CC (Panel, RGB Sensor)
PEM_LOG
CVBS
Hotel TL-JIG
VIDEO_CV UARTA(LOG)
VIDEO1_LR UARTA (LOG) UARTD
XReality
UARTB (RF-Remote) MODE_PEM
UARTC (IR Blaster/ECS) Reset
UARTC(Hotel/ECS)
I2CA(Hotel_Clock)
/ECS
X_Hotel_PWR_CTRL SIRCS
COMP_Y
COMP_Pb Temp
COMP COMP_Y, Pb, Pr COMP_Pr
I2CA
Sensor
Temp Sensor
VideoB_Det [LM75B]
COMP2_LR PC_G
PC_B
Cr_Det PC_R SIRCS
PC_H
PC_V DIMMER
Sircs
DMD_CLK_ENABLE2
DIMMER_DC
Tuner_LR LOGO
VIDEO1_LR
PC_CON_Det DEBUG_LED2
PC PC_R,PC_G,PC_B,PC_H,PC_V
PC_LR COMP2_LR DEBUG_LED3
PC_5V, PC_DDC PC_LR PANEL_PWR Power_KEY
Line Out_LR
DMD_CLK_ENABLE1
DMD_RST
KEY
KEY
OPAMP X_WIFI_RST UARTE
[NJU72040V] HP_DET
HP/Line HP_/ Line Out Det
HP/Line Out LR TV_Out_LR SPDIF_SEL
Out Tuner_LR X_AUDIO_MON
HDMIEQ_INT
LUT_SEL0
LUT_SEL1
LUT_SEL2
PC_CON_DET
CR_DET
VIDEOB_DET
VIDEOA_DET
X_AUDIO_MUTE2
X_AUDIO_MUTE1
PFC_PWR
BACKLIGHT_ON
NMI
X_SYSTEM1_RST
REC_LED
POWER_LED
X_RF_RST
X_HOTEL_PWR_CTRL
DEBUG_LED1
POWER_KEY
PFC_MON
AC_MON
MAIN_SS_MON
SYSTEM2_PWR
SYSTEM1_PWR
MAIN_PWR
PIC_MUTE_LED
TIMER_LED
STBY_LED
BACKLIGHT_MON
PANEL_PWR_Det
PANEL_SEL
Human_Sensor_Det
Light_Sensor_Det
KEY
DC_MON
PIC_MUTE_LED
OPAMP
[NJU72011RB]
Audio
Main Main Speaker_Out_LR Power AMP
[D–510D]
SPEAKER X_FAULT AUDIO_MON
X_AUDIO_MUTE2 X_SYSTEM1_RST
X_AUDIO_MUTE1
Digital Video/TS/TMDS
Analog Video
Digital Audio
Analog Audio
PWM
Analog Signal
UART
I2C
SPI H/L
Panelless
AC_IN
Rch Yamaichi
1 1 STBY3.3V
AC pigtail
AC-N 1 1
2 2 RS232_RXD
AC-L
CN6001
2 2
3 3 RS232_TXD TL- EX1JIG board
4 4 SIRCS_OUT
SFP79-02WLB JAM
5 5 SIRCS_IN
1-822-908-11
6 6 GND
CN9005
6pin connector 182113311
10 10 STBY_+3.3V
12 9 AUDIO+12.5V
14 8 AUDIO+12.5V
11 7 AUDIO+12.5V_GND
13 6 AUDIO+12.5V_GND GND 1
15 5 REG+12.5V_GND UARTD_TX 2
17 4 REG+12.5V_GND UARTD_RX 3
16 3 REG+12.5V RESET 4
18 2 REG+12.5V STBY_+3.3V 5
24 1 T- CON_VCC MODE_TVM 6
CN6001 UARTA_RX 7
G-B Harness
1-842-569-11 NC (MD2) 8
G-B
HEADER ASSEMBLY FOR PWB 10P UARTC_RX 9
R3 or RU board STBY3.3V
RS232_RXD
1
2
1
2
UARTC_TX 10
7 9 AC_OFF_DET GND 11
RS232_TXD 3 3
1 8 POWERON UARTA_TX 12
SIRCS_IN 4 4
6 7 BL_ERR ECS_MATRIX 13
SIRCS_OUT 5 5
5 6 BL_ON STBY_+3.3V 14
GND 6 6
2 5 DIMMER MODE_PEM 15
CN101
4 4 HSYNC/ DIMMER_DC PEM_LOG_RX 16
182018311
8 3 TCON_ON PEM_LOG_TX 17
3 2 PFC_PWR GND 18
9 1 GND CN9004
CN6002 1-774-667-51
1- 819- 452- 11 TL-EX1 Connector,FFC/FPC 18P
KDL-32EX525/40EX525 11
KDL-32EX525/40EX525
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