Category: LED Television Repair and service
Contents of this article
- Service mode access
- Troubleshooting
- LCD panel reset
- Blinking code and causes
SONY KDL-40EX651
CIRCUIT BOARDS DETAILS
MAIN BOARD
Common to all models the Main Board, designated as the BAPS Board, contains the TV control, video, and audio processing circuitry. All these functions are accomplished using the X-Reality Processor IC9000.
TUNER
The tuner is a combination ATSC/NTSC unit. It can receive traditional analog NTSC signals via cable or terrestrial along with ATSC digital signals via terrestrial (8VSB) or cable (64 or 256 QAM).
X-REALITY PROCESSOR
IC9000 performs the majority of the necessary audio and video processing on the Main Board.
TV Microprocessor: The CPU internal to the X-Reality processor controls all aspects of the television functions. Input from the user along with monitoring of critical circuits is also performed by this CPU.
Digital Audio and Video Decoder: The MPEG2 and Digital Dolby audio streams are received from the tuner for decompression. All video sources which are not native 1920 X 1080p 60HZ are scaled to this resolution. Digital audio content is output to the class D amplifier for processing and amplification.
HDMI Input and Switching: The customer can select the HDMI1, HDMI2, HDMI3, HDMI4 input via the HDMI switch IC5500. Each HDMI input contains a common EDI NVM (internal to IC5500) to provide display information data to any device connected via the HDMI inputs.
LVDS Transmitter: Integrated into IC9000 is a Low Voltage Differential Signaling (LVDS) transmitter. This circuit converts the 8-bit parallel RGB video information into a set of high speed serial lines for noisefree transmission to the TCON Board circuits located internally to the LCD Panel.
MAIN BOARD
Common to all models the Main Board, designated as the BAPS Board, contains the TV control, video, and audio processing circuitry. All these functions are accomplished using the X-Reality Processor IC9000.
TUNER
The tuner is a combination ATSC/NTSC unit. It can receive traditional analog NTSC signals via cable or terrestrial along with ATSC digital signals via terrestrial (8VSB) or cable (64 or 256 QAM).
X-REALITY PROCESSOR
IC9000 performs the majority of the necessary audio and video processing on the Main Board.
TV Microprocessor: The CPU internal to the X-Reality processor controls all aspects of the television functions. Input from the user along with monitoring of critical circuits is also performed by this CPU.
Digital Audio and Video Decoder: The MPEG2 and Digital Dolby audio streams are received from the tuner for decompression. All video sources which are not native 1920 X 1080p 60HZ are scaled to this resolution. Digital audio content is output to the class D amplifier for processing and amplification.
HDMI Input and Switching: The customer can select the HDMI1, HDMI2, HDMI3, HDMI4 input via the HDMI switch IC5500. Each HDMI input contains a common EDI NVM (internal to IC5500) to provide display information data to any device connected via the HDMI inputs.
LVDS Transmitter: Integrated into IC9000 is a Low Voltage Differential Signaling (LVDS) transmitter. This circuit converts the 8-bit parallel RGB video information into a set of high speed serial lines for noisefree transmission to the TCON Board circuits located internally to the LCD Panel.
Scan Converter: Signal processing circuit that performs resolution conversion
(aspect ratio) and interlaced to progressive scan (IP) conversion.
AUDIO AMPLIFIER
The main speaker audio amplifier (IC4601) and sub-woofer amplifier (IC4701) amplifies the digital audio output of the X-Reality processor and sends it to the speakers.
TEMPERATURE SENSOR
The temperature sensor detects over-temperature conditions on the Main Board, LCD Panel, or ambient room temperature and sends the shutdown signal to the processor.
POWER SUPPLY BOARD
There are different Power Supply Boards used in the models in this manual. The type of board depends on the size of LCD panel. They are:
# GL2 Board (for 32” models)
# GL4 Board (for 40” and 46” models)
There are 3 distinct sections on the power supply:
Standby Supply: Continuously operational as long as AC power is applied, the standby supply generates 3.3V for the circuits requiring power while the unit is turned off. An unregulated 19V line is present to provide power to the main relay, PFC and main power supply at turn-on.
Main Supply: Once the power supply receives a power-on command from the CPU on the Main Board, the main switching supply is turned on to provide a regulated 12V source and Audio 12V.
Converter: Generates the B+ and B- voltages for the LED backlights.
IR BOARD
Designated as the HL Board, the IR Board contains the power, standby, and timer LED’s that are located on this board along with the IR remote receiver and light level sensor.
The main speaker audio amplifier (IC4601) and sub-woofer amplifier (IC4701) amplifies the digital audio output of the X-Reality processor and sends it to the speakers.
TEMPERATURE SENSOR
The temperature sensor detects over-temperature conditions on the Main Board, LCD Panel, or ambient room temperature and sends the shutdown signal to the processor.
POWER SUPPLY BOARD
There are different Power Supply Boards used in the models in this manual. The type of board depends on the size of LCD panel. They are:
# GL2 Board (for 32” models)
# GL4 Board (for 40” and 46” models)
There are 3 distinct sections on the power supply:
Standby Supply: Continuously operational as long as AC power is applied, the standby supply generates 3.3V for the circuits requiring power while the unit is turned off. An unregulated 19V line is present to provide power to the main relay, PFC and main power supply at turn-on.
Main Supply: Once the power supply receives a power-on command from the CPU on the Main Board, the main switching supply is turned on to provide a regulated 12V source and Audio 12V.
Converter: Generates the B+ and B- voltages for the LED backlights.
IR BOARD
Designated as the HL Board, the IR Board contains the power, standby, and timer LED’s that are located on this board along with the IR remote receiver and light level sensor.
SWITCH UNIT
This board contains the power, channel and volume up/down, and menu buttons.
LCD PANEL ASSEMBLY
The LCD Panel Assembly includes the LCD Panel, TCON Board, and LED Backlight system. The LCD Panel contains the actual liquid crystals, color filters, and polarizers. The liquid crystals are manipulated by the applied voltage to pass a specific amount of light - from the backlite - depending on the level of voltage applied.
The TCON performs all the control, timing, charge, and discharge functions driving the operation of the LCD Panel. A new LCD Panel assembly from parts will include the following items.
# LCD Panel
# TCON Board
# LED Backlighting Components (varies)
TCON BOARD
The TCON Board communicates between the LCD Panel and the microprocessor on the Main Board.
NOTE: The TCON Board is not available as a replacement part for all models. To determine if the TCON Board is available as a replacement part, refer to the LCD Panels Manual.
This board contains the power, channel and volume up/down, and menu buttons.
LCD PANEL ASSEMBLY
The LCD Panel Assembly includes the LCD Panel, TCON Board, and LED Backlight system. The LCD Panel contains the actual liquid crystals, color filters, and polarizers. The liquid crystals are manipulated by the applied voltage to pass a specific amount of light - from the backlite - depending on the level of voltage applied.
The TCON performs all the control, timing, charge, and discharge functions driving the operation of the LCD Panel. A new LCD Panel assembly from parts will include the following items.
# LCD Panel
# TCON Board
# LED Backlighting Components (varies)
TCON BOARD
The TCON Board communicates between the LCD Panel and the microprocessor on the Main Board.
NOTE: The TCON Board is not available as a replacement part for all models. To determine if the TCON Board is available as a replacement part, refer to the LCD Panels Manual.
VIEWING THE SELF CHECK
DIAGNOSIS HISTORY
When an error is detected, the Self Check screen records the date(s) and the number of times the error occurred. This is helpful in confirming past occurrences of an error, and for determining if an error is intermittent when the customer is not sure what is causing the television to shut down. If the screen displays a “0”, no error has occurred.
1. Take the TV out of deep Standby mode by pressing POWER to turn on the TV.
2. Press POWER to turn the TV back off.
3. Press the following buttons on the Remote Commander within a second of each other:
DISPLAY > Channel 5 > Volume - > POWER
When an error is detected, the Self Check screen records the date(s) and the number of times the error occurred. This is helpful in confirming past occurrences of an error, and for determining if an error is intermittent when the customer is not sure what is causing the television to shut down. If the screen displays a “0”, no error has occurred.
1. Take the TV out of deep Standby mode by pressing POWER to turn on the TV.
2. Press POWER to turn the TV back off.
3. Press the following buttons on the Remote Commander within a second of each other:
DISPLAY > Channel 5 > Volume - > POWER
TROUBLESHOOTING
2X Blink - Main Power Error
A loss of REG12V from the power supply triggers this protect event. The usual cause is a failure of the main switching supply. In some instances, excessive loading on the secondary supply lines can cause the switching regulator to stop, or fail again, if a replacement board is installed. 3X Blink- DC Regulator/Audio Error/HDMI/Tuner Several items are monitored on the main board. Any error detected in the following circuits will cause the television to shut down and generate a 3X error:
# Loss of regulated B+ circuits
# Audio amplifier failure
# HDMI equalizer IC
# Tuner demodulator circuits
In most cases, replacement of the main board will remedy a 3X error.
4X Blink – Balancer Error
NOT USED IN THIS MODEL SERIES
5X Blink - TCON Error
The 5X blink protection mode indicates a communications error between the TCON Board and the X-Reality microprocessor on the Main Board. If the TCON is available for replacement, replace the TCON. If the TCON is not available, the LCD panel must be replaced since the TCON circuit is part of the LCD panel assembly. In rare cases a loose or defective LVDS cable could also be the cause.
6X Blink - Converter System Failure
An open LED in the backlight strings will cause an over-voltage condition in the converter circuits. The symptom will be a momentary appearance of the backlights (Sony logo may appear) followed by a 6X shutdown. Replacement of the LCD panel is required to remedy this condition. If the converter fails to generate voltage for the LED backlights, the lowvoltage protection circuits are activated and the television will shut down with a 6X error. Replacement of the Power Supply Board should remedy this condition.
A loss of REG12V from the power supply triggers this protect event. The usual cause is a failure of the main switching supply. In some instances, excessive loading on the secondary supply lines can cause the switching regulator to stop, or fail again, if a replacement board is installed. 3X Blink- DC Regulator/Audio Error/HDMI/Tuner Several items are monitored on the main board. Any error detected in the following circuits will cause the television to shut down and generate a 3X error:
# Loss of regulated B+ circuits
# Audio amplifier failure
# HDMI equalizer IC
# Tuner demodulator circuits
In most cases, replacement of the main board will remedy a 3X error.
4X Blink – Balancer Error
NOT USED IN THIS MODEL SERIES
5X Blink - TCON Error
The 5X blink protection mode indicates a communications error between the TCON Board and the X-Reality microprocessor on the Main Board. If the TCON is available for replacement, replace the TCON. If the TCON is not available, the LCD panel must be replaced since the TCON circuit is part of the LCD panel assembly. In rare cases a loose or defective LVDS cable could also be the cause.
6X Blink - Converter System Failure
An open LED in the backlight strings will cause an over-voltage condition in the converter circuits. The symptom will be a momentary appearance of the backlights (Sony logo may appear) followed by a 6X shutdown. Replacement of the LCD panel is required to remedy this condition. If the converter fails to generate voltage for the LED backlights, the lowvoltage protection circuits are activated and the television will shut down with a 6X error. Replacement of the Power Supply Board should remedy this condition.
7X Blink - Temperature Failure
If the temperature inside the television becomes excessive, the temperature sensor (located on the Main Board) notifies the TV to shut down and display a 7X error. Excessive temperature errors will always occur when the TV has been running a while and can be caused by excessive ambient heat or improper ventilation of the television. If the television shuts down immediately, this can be caused by a defective temperature sensing IC or failure of the communications bus between the IC and the microprocessor. Replacement of the Main Board is necessary.
8X Blink – Not listed in Self Check
The 8X blink code is mainly used during TV software development. Look in TV’s service Self Check for error code history and notice at the bottom of the list WDT (Watch Dog Timer) error codes, in particular notice 103 HOST_ WDT. If this error code appears, check for any additional documentation on the Sony ESI site.
10X Blink – IR Sync Transmitter Failure
NOT USED IN THIS MODEL SERIES
If the temperature inside the television becomes excessive, the temperature sensor (located on the Main Board) notifies the TV to shut down and display a 7X error. Excessive temperature errors will always occur when the TV has been running a while and can be caused by excessive ambient heat or improper ventilation of the television. If the television shuts down immediately, this can be caused by a defective temperature sensing IC or failure of the communications bus between the IC and the microprocessor. Replacement of the Main Board is necessary.
8X Blink – Not listed in Self Check
The 8X blink code is mainly used during TV software development. Look in TV’s service Self Check for error code history and notice at the bottom of the list WDT (Watch Dog Timer) error codes, in particular notice 103 HOST_ WDT. If this error code appears, check for any additional documentation on the Sony ESI site.
10X Blink – IR Sync Transmitter Failure
NOT USED IN THIS MODEL SERIES
RESETTING THE LCD PANEL TO
UPDATE THE SOFTWARE
NOTE: These steps are only required if the software did not update.
1. Take the TV out of deep Standby mode by pressing POWER to turn on the TV.
2. Press POWER to turn the TV back off.
3. Access Service Mode by pressing the following buttons on the Remote Commander within a second of each other:
DISPLAY > Channel 5 > Volume + > POWER
4. The DIGITAL Service Menu displays.
NOTE: There are 3 Service Menus for this model, DIGITAL, CHASSIS, and VPC.
5. Press JUMP or OPTIONS on the Remote Commander until the CHASSIS menu displays.
NOTE: These steps are only required if the software did not update.
1. Take the TV out of deep Standby mode by pressing POWER to turn on the TV.
2. Press POWER to turn the TV back off.
3. Access Service Mode by pressing the following buttons on the Remote Commander within a second of each other:
DISPLAY > Channel 5 > Volume + > POWER
4. The DIGITAL Service Menu displays.
NOTE: There are 3 Service Menus for this model, DIGITAL, CHASSIS, and VPC.
5. Press JUMP or OPTIONS on the Remote Commander until the CHASSIS menu displays.
6. Press 2 to move to the next
category until the 007 DL category displays.
7. Press 3 to increase the data
value to 1.
8. Press MUTING then press 0 to
WRITE (Save) the changes. When complete, the screen briefly indicates “WRITE”.
9. Exit service mode by turning the TV
power off.
SELECTING THE SEGMENT CODE
Before proceeding, update the software to the latest version. After updating the software, go into Service Mode to select the correct Segment Code data value.
Verify before proceeding to the next step:
; Updated the Software
1. Take the TV out of deep Standby mode by pressing POWER to turn on the TV.
2. Press POWER to turn the TV back off.
3. Access Service Mode by pressing the following buttons on the Remote Commander within a second of each other:
DISPLAY > Channel 5 > Volume + > POWER
4. The DIGITAL Service Menu displays.
NOTE: There are 3 Service Menus for this model, DIGITAL, CHASSIS, and VPC. If the DIGITAL Service Menu is not displayed, press JUMP or OPTIONS on the Remote Commander.
Before proceeding, update the software to the latest version. After updating the software, go into Service Mode to select the correct Segment Code data value.
Verify before proceeding to the next step:
; Updated the Software
1. Take the TV out of deep Standby mode by pressing POWER to turn on the TV.
2. Press POWER to turn the TV back off.
3. Access Service Mode by pressing the following buttons on the Remote Commander within a second of each other:
DISPLAY > Channel 5 > Volume + > POWER
4. The DIGITAL Service Menu displays.
NOTE: There are 3 Service Menus for this model, DIGITAL, CHASSIS, and VPC. If the DIGITAL Service Menu is not displayed, press JUMP or OPTIONS on the Remote Commander.
5. Press 2 to move to the next
category until the 002 MODEL category displays.
6. Using the table, press 3 to
increase the data value or 6 to decrease the data value, to select the
correct segment code data value.
7. Press MUTING then press 0 to
WRITE (Save) the changes.
8. Exit service mode by turning the TV
power off.
9. Cycle AC Power. (Unplug and Plug AC Cord from the AC Outlet).
10. Wait a minute while lights flash, and initial setup screen shows.
9. Cycle AC Power. (Unplug and Plug AC Cord from the AC Outlet).
10. Wait a minute while lights flash, and initial setup screen shows.
SELECTING THE DESTINATION
The correct destination needs to be selected after replacing the Main Board.
CAUTION: Selecting the incorrect destination may require replacing the Main Board.
Verify before proceeding to the next step:
Updated the Software
Selected the Segment Code
1. Take the TV out of deep Standby mode by pressing POWER to turn on the TV.
2. Press POWER to turn the TV back off.
3. Access Service Mode by pressing the following buttons on the Remote Commander within a second of each other:
DISPLAY > Channel 5 > Volume + > POWER
4. Press 2 to move to the next category until 002 MODEL category displays.
5. Press 1 to move to the next item until 001 DEST item displays.
The correct destination needs to be selected after replacing the Main Board.
CAUTION: Selecting the incorrect destination may require replacing the Main Board.
Verify before proceeding to the next step:
Updated the Software
Selected the Segment Code
1. Take the TV out of deep Standby mode by pressing POWER to turn on the TV.
2. Press POWER to turn the TV back off.
3. Access Service Mode by pressing the following buttons on the Remote Commander within a second of each other:
DISPLAY > Channel 5 > Volume + > POWER
4. Press 2 to move to the next category until 002 MODEL category displays.
5. Press 1 to move to the next item until 001 DEST item displays.
