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Sony KE-42MR1, KE-42MR1E, KE-42MR42M1 Service Manual

Flat panel color tv panel module
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KE-42MR1/42MR1E/MR42M1
PANEL MODULE SERVICE MANUAL
PDP Module Name
KE-42MR1 AEP Model
NP42D2MF01
KE-42MR1 K Model
NP42D3MF01
KE-42MR1E HK Model
KE-42MR1E ME Model
KE-MR42M1 CH Model
FLAT PANEL COLOR TV

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Summary of Contents for Sony KE-42MR1, KE-42MR1E, KE-42MR42M1

  • Page 1 KE-42MR1/42MR1E/MR42M1 PANEL MODULE SERVICE MANUAL PDP Module Name KE-42MR1 AEP Model NP42D2MF01 KE-42MR1 K Model NP42D3MF01 KE-42MR1E HK Model KE-42MR1E ME Model KE-MR42M1 CH Model FLAT PANEL COLOR TV...
  • Page 2 1. Confirmation Common Manual 2. Confirmation Manual 3. Repair Manual ････････････････････････････････････ 4. THE PARTS INFORMATION Contents ･･･････････････････････ ･･････････････････････････････ ････････････････････････････ P1～P20 P21～P44 P45～P63 P64～P65...
  • Page 3 PDP (NP series) Confirmation Common Manual Ver.1...
  • Page 4 No Picture Malfunction Phenomenon PDP Malfunction Phenomenon Power-off Power-on The LED is lighting, but not appear pictures. Alarm protection When you turn-on the main power, the LED light-off after few minutes. Go to Page 8 due to check more details. No Priming The priming does not appear on screen.
  • Page 5 PDP Malfunction Phenomenon Abnormal Screen Abnormal Color Abnormal Block No lighting sell are on screen at white pattern. Go to Page 11 due to check more details. Colorful blocks appear on screen at color bar pattern. Go to Page 11 due to check more details.
  • Page 6 PDP Malfunction Phenomenon Vertical Vertical Line Single Line Only one line is always lighting. Go to Page 12 due to check more details. Two Lines two lines are lighting. Go to Page 13 due to check more details. Many Lines Many lines are lighting.
  • Page 7 PDP Malfunction Phenomenon Vertical Vertical Block One Black Block One block is always no- lighting by one IC. Go to Page 15 due to check more details. One Zebra Block Zebra block appears by one IC. Go to Page 16 due to check more details.
  • Page 8 PDP Malfunction Phenomenon Horizontal Horizontal Line Horizontal Block One Black Block One black line appears on screen. Go to Page 17 due to check more details. Two Lines Two lines appear on screen. Go to Page 18 due to check more details. Half block does not go out.
  • Page 9 PDP Malfunction Phenomenon Screen Defect Lighting strip Check our specification . Black strip Check our specification .
  • Page 10 Panel Alarm Alarm Protection Vs Protection No Picture FPC Opened Panel alarm line go through the edge of the FPC. CHECK POINT FPC cutting at scan side and TCP side. Panel Grid Opened Panel alarm line go through the edge of panel.
  • Page 11 Vd Protection Alarm Protection 5V Protection No Picture TCP Broken In case of shortage between Vd line and GND in TCP, Vd protection will be worked. CHECK POINT Shortage between Vd line and GND, TCP surface Data Relay Board Broken In case of shortage between Vd line and GND in data relay board, Vd protection will be worked.
  • Page 12 High Voltage Circuit Broken No Priming No Signal Digital Board Broken Vacuum Tube Cracking No Picture Next parts will be broken, Vp or Vbw line on Scan Board, Vsw line on Common Board, (High Voltage Board). CHECK POINT Fuse on board, Vp, Vbw and Vsw line of Power HIC.
  • Page 13 Abnormal High Voltage Circuit Broken screen No Picture Next parts will be broken, Vbw line on Scan Board, Vsw line on Common Board, (High Voltage Board). CHECK POINT fuse on board, Vbw or Vsw line on board. REWORK Change the scan or common board (High voltage board).
  • Page 14 The output of TCP Single Line Data Grid Open Vertical The output of TCP is fixed at low level or high level. This line is very clear and constant. CHECK POINT One line is no-lighting or lighting at any pure color signal (red, green blue and black) Damaged data grid in panel EX) Sulfur, scratch...
  • Page 15 The output of TCP Two Lines Data Grid Shortage Vertical The closed outputs of TCP are Shortage. CHECK POINT Two lines are lighting at two colors. The grids of panel are shortage due to foreign material. CHECK POINT The surface condition of panel grid. REWORK We can not rework this.
  • Page 16 Many Lines Data Grid Open Vertical Damaged data grid in panel EX) Sulfur, scratch CHECK POINT The surface condition of panel grid. REWORK We can not rework this.
  • Page 17 TCP Broken Black Block Data Relay Board Vertical TCP is not working. CHECK POINT The surface of TCP is damaged. The buffer IC is not working on signal lines. The connector on data relay board is opened by the cracking of solder. CHECK POINT Input signal condition.
  • Page 18 Zebra Block Data Relay Board Many Blocks Data Relay Board Vertical The lead of the buffer IC or the connector on data relay board are shortage by foreign material. CHECK POINT Input signal condition. The lead of the buffer IC or the connector on data relay board are shortage by foreign material.
  • Page 19 The output of Scan IC Single Line Scan Relay Board Horizontal The output of scan IC is fixed at low level or high level. This line is very clear and constant. CHECK POINT One line is no-lighting or lighting at white signal.
  • Page 20 Two Lines Scan Relay Board Horizontal The output of scan IC are shortage. This line is not clear and not constant. CHECK POINT FPC insert shifting. Foreign material in connector. The lead of scan IC. REWORK Clean in the connector. Reconnect the FPC.
  • Page 21 Scan IC broken Block Scan Board Horizontal Scan IC is not working. CHECK POINT The surface of scan IC. The output of scan board is not working. CHECK POINT The output of Scan Board. REWORK Change the scan relay board. REWORK Change the scan board.
  • Page 22 Voltage Information By June 2003 Sample 40 x 17mm Dimension Sample 20 x 17mm Dimension Since July 2003 55 x 25mm 55 x 15mm Vd Vbw Vsw Vp Vw...
  • Page 23 PDP (NP42D2MF01) Confirmation Manual Ver.2...
  • Page 24 Check process Type,Serial Number Page 23 Panel Crack Page 24 Flexible Cable Page 25 Connectors Page 26-28 Tester Checking Page 29-35 Phenomenon Reappearance Strip Defect Vertical Line Page 36-37 Page 38-42 Judgement (Make C-PDP Failure Description sheet) Flow Chart Take pictures (Module and shipment box) Take pictures Take pictures If you can confirm visual malfunction, take pictures...
  • Page 25 Module Number and Panel ID Type Name Serial Number SERIAL NO. NEC NP42D2MF01 211200192 211200192 Vd=65V ********************** Vs=190.1V ********************** ********************** CODE AA-01 Example : Type Name NP42D2MF01AA Serial Number　 211200192 Serial Number Panel ID 212211041621...
  • Page 26 Panel Crack Panel Crack Check the surface of glass whether crack or not. This issue may be caused by transportation or treatment after shipment. We would like you to take some pictures, the broken module, the outside box, and inform the shipment date.
  • Page 27 Flexible Cable Flexible Cable Check the Flexible Cables whether scratched, broken, or not. Cutting cable or broken In this case, it caused by handling them at customers line. We would like you to be careful to handle the modules.
  • Page 28 Connectors Connectors Condition Check the Cables or Connectors whether connected and locked, or not. Common Bypass Board High Voltage Board 5 connectors Digital Board 6 connectors Data Relay Board (Left) 10 connectors Data Relay Board (Right) 13 connectors We would like you to be careful to handle the modules at assembling.
  • Page 29 Each Connector High Voltage Board 　 　　- Digital Board Locked Unlocked Connector Checking 2 Common Relay Board Scan Relay Board 　 　- Flexible Cable - Flexible Cable...
  • Page 30 Connector Checking 3 Each Connector Digital Board High Voltage Board High Voltage Board - High Voltage Board - Data Relay Board - Scan Relay Board Locked Unlocked...
  • Page 31 Fuse Glass Fuse on High Voltage Board (F301 、 F302) Tester Checking 1 Chip Fuse on Digital Board (FＵ８０１) OK: Shortage NG: Opened OK: Shortage NG: Opened...
  • Page 32 Fuse Resistance and Chip Fuse on High Voltage Board Fuse Resistance (R10), (R4), (R6) Chip Fuse Resistance (R20) On High Voltage Board Tester Checking 2 R10 OK: About 2.2 Ω R4　 OK: About2.2 Ω R6 OK: About2.2 Ω R20 OK: About 10 Ω 　　　NG：...
  • Page 33 Fuse Resistance and Chip Fuse on High Voltage Board Fuse Resistance on High Voltage Board (R1) R1 OK: About2.2 Ω 　　　NG： Opened Tester Checking 3 Fuse Resistance on High Voltage Board Fuse Resistance on High Voltage Board (R2) R2 OK: About2.2 Ω 　　　　NG：...
  • Page 34 Data IC Check between (#1 pin or #2 pin) and GND Data Relay Board (Right) #1 pin or #2 pin at CN12 （Vd Voltage Line of Data IC） Check the resistance between (#1 pin or #2 pin) and GND with tester. In case of shortage, it is caused by malfunction of data IC.
  • Page 35 Tester Checking 5 Parts Location High Voltage Board PH2203F...
  • Page 36 Power HIC PH2203F on High Voltage Board PH2203F Turn this board over, and Check each points Checking point 　　Between A and B Between C and U 　　Between A and U Between F and U 　　 Between B and C Between G and H Between B and E Between H and J Between B and M Between I and J...
  • Page 37 Scan IC Scan Relay Board (Up) NEGA 1 POSI 1 Checking Point Tester Checking 7 POSI 2 NEGA 2 Judgment 　　OK： More than ＫΩ 　　NG：Shortage Between NEGA and POSI Scan Relay Board (Down)
  • Page 38 Strip Defect 1 Strip Defect Compare with specification 2 strip 2 strip 1 strip...
  • Page 39 Strip Defect 2 Strip Defect 3 strip 3 strip 3 strip...
  • Page 40 Vertical Line 1 Single line Vertical Line Open Mode All Red Pattern All Green Pattern All Blue Pattern All Black Pattern Black 1 Line Red 1 Line No Appearance Red 1 Line Red 1 Line Open Mode a) The broken data flexible cable. [Check Point] If OK, Data IC Broken.
  • Page 41 Vertical Line 2 Two lines Vertical Line Shortage Mode All Red Pattern All Green Pattern All Blue Pattern All Black Pattern Blue 1 Line No Appearance No Appearance Red 1 Line Shortage between Red and Blue [Check Point] a) This phenomenon is caused by panel issues.
  • Page 42 Vertical Line 3 block Vertical Line 1/2 data IC Block (Width 30mm) [Check Point] a) The broken surface IC on data IC. b) The broken data flexible cable.
  • Page 43 Vertical Line 4 block Vertical Line 1 data IC Block [Check Point] a) Lacking connector between Data Relay board and Data IC. b) The broken data flexible cable.
  • Page 44 Vertical Line 5 block Vertical Line Many data IC Block [Check Point] a) Lacking connector between Data Relay board and Scan or Common board. b) The broken data flexible cable. C)Shortage between leads in connector. Foreign Material etc.
  • Page 45 Horizontal Line single line, two lines or block Horizontal Line Single Two lines Block Block a) The broken surface IC on scan IC driver. Check the resistance between NEGA and POSI on scan IC board. ( Normal: KΩ Level) b) The broken scan flexible cable. c) Lacking connector between scan IC and scan board.
  • Page 46 Common Flexible Cable A Common Flexible Cable B Common Flexible Digital Board Cable C Data Relay Board (Right) Data TCP Data Flexible Cable 42HD2 Board Location Common Bypass Board Data Relay Board (Left) High Voltage Board Scan Flexible Cable A Scan Flexible Cable B...
  • Page 47 PDP (NP42D2MF01) Repair Manual Ver.2...

  • Page 48: Table Of Contents

    Repair Flow Chart Repair Testing Page 47 Preparation Mounting Setting Page 58 Panel Setting Connect Supply cable Page 48 Voltage Adjustment Remove Connectors Page 59-60 Page 49-51 Aging Page 61 Remove Screws Page 52 Inspection Remove Old Boards Page 52 Page 62 Remove Module Analysis...

  • Page 49: Preparation

    Tools a) Driver b) Wrist Discharge c) Signal Generator (PC) d) Supply Package e) Mounting f ) Tester g) Cushion ATTENTION Replacing the boards, always use the wrist band to prevent electrostatic. Preparation ---------- Plus Type ---------- Prevent Electrostatic ---------- To Stand Module ---------- To put the Module on...

  • Page 50: Panel Setting

    Pre-setting Put the cushion on a table and repaired module on cushion ATTENTION Put panel like catching all surface on cushion.

  • Page 51: Remove Connectors

    Repair 1　 　 　 　 Remove connectors and cables (1) Remove the repairing Board Common Bypass Board Digital Board 5 Connectors Data Relay Board (Right) 10 Connectors Attention Attention　　　　 　　　　Be careful to deal with the connectors and cables. Be careful to deal with the connectors and cables. Attention Attention 　　　　...
  • Page 52 Repair 1　 　 　 　 Remove connectors and cable (2) How to remove the connectors Flat Cable (Type B) Flat Cable (Type A) Locked Unlocked Be careful to remove the connectors because the structure of each connector is different. Or, it is possible to broken the connectors.
  • Page 53 Repair 1　 　 　 　 Remove connectors and cable (3) How to remove the connectors Cable (Type D) Flat Cable (Type C) Locked Unlocked Be careful to remove the connectors because the structure of each connector is different. Or, it is possible to broken the connectors.

  • Page 54: Remove Screws

    Repair 2 Remove the Boards Remove the repairing Board Common Bypass Board High Voltage Board 22 Screws Digital Board 6 Screws Data Relay Board 4 Screws Data Relay Board 5 screws ATTENSION Do not drop the screwdriver or screws on the board. Be careful to not make the screw dust ------- Shortage factor...

  • Page 55: Install New Boards

    Repair 3 Install the new boards Install the new board Common Bypass Board Digital Board 6 Screws Data Relay Board 4 Screws ATTENSION 　　Install the same number board as module3 　　 　　 　　 Do not add any stress board. Be careful of the length of a screw. High Voltage Board 22 Screws Data Relay Board 5 screws...

  • Page 56: Connect Connectors

    Repair 4 Connecting (1) Check the cables and in sockets Flat Cable (Type A) ATTENSION Check the surface of grids whether it is 　　　 　 　 　 　 tearing or not. Socket (Type A) ATTENSION 　　　 　　　 　　　 Check whether there are some foreign materials or not in socket.
  • Page 57 Repair 4 Connecting (2) Connect some connectors Common Bypass Board High Voltage Board 5 Connectors Digital Board 5 Connectors Data Relay Board (Left) Data Relay Board (Right) 13 Connectors 10 Connectors Heat sink 11 Connectors ATTENSION 　　Please check that connector connection of a red circled is made normally. 　　...
  • Page 58 High Voltage Board (Photograph) 　　　 －　Digital Board Locked Unlocked Repair 4 Connecting (3) Connection Condition Scan Relay Board (Photograph) Common Relay Board (Photograph) 　　 －　FFC Cable －　FFC Cable...
  • Page 59 Repair 4 Connecting (4) Connection Condition High Voltage Board (Photograph) Digital Board (Photograph) High Voltage Board (Photograph) －　Scan Relay Board －　High Voltage Board －　Data Relay Board Locked Unlocked...

  • Page 60: Mounting Setting

    Check working Mounting Setting ATTENTION Do not stand the module directly on table. To fix the connectors from supply board. Adjust supply board to the suitable voltage (Vs) of panel. ----- Broken the flexible cable ----- Broken scan & common board ----- Writing issue...

  • Page 61: Voltage Adjustment

    VSW、 、 、 、 - - - - VW Adjustment VW Adjustment VW Adjustment VW Adjustment Adjust the [-VW(±0.5V)] with VR4 at TP330 on High Voltage Board. Voltage Adjustment (1) In case of no measuring land on the board, please refer pin assignments. VR4 (-VW) VR2 (VSＷ) Adjust the [VSW(±0.5V)] with VR2...
  • Page 62 VBW 、 、 、 、 VP Adjustment VP Adjustment VP Adjustment VP Adjustment Measuring VBW which is between TP329 and TP330(–VW). Adjust VBW by VR3. (Tolerance:+/- 0.5 volt) Voltage Adjustment (2) In case of no measuring land on the board, please refer pin assignments. VR3 (VBW) VR1 (VP) Measuring VP which is between TP327 and GND.
  • Page 63 Check working ACTION Aging on all white pattern for at least 30 min. ATTENTION Do not use fixed signals to aging. For example windows pattern or window pattern. Aging White Pattern...

  • Page 64: Inspection

    Check working Inspection Green Blue Color Bar Gray Scale ACTION Inspect the screen condition under all red, all green, all blue, color bar and gray scale. List the replaced result as attached sheet. ATTENTION In case of some black strips or light strip, to aging more for one hours with all white pattern.
  • Page 65 Stocking Condition ATTENTION To stock the modules in the room keeping on standard temperature and humidity. To keep the modules sideways as following picture.
  • Page 66 4. THE PARTS INFORMATION PDP Module Repair Parts List Sony Model name NPD PDP Module Part Number KE-42MR1 (AEP) NP42D2MF01 AA 9-885-053-32 Panel Module NP42D2MF01AA S/N:2200001~ 9-885-049-66 PKG42D2G1 BOARD HT4-9S899418 KE-42MR1 (K) 9-885-049-68 PKG42D2C1 BOARD HT4-9S899419 S/N:2000001~ 9-885-053-70 PKG42D2C1 BOARD HT4-9S899493...
  • Page 67 NP42D2MF01AA, AB Upper compatible if no terms. Name of Package(board) Version Replaceable Version High Voltage Board None PKG42D2G1 Common Bypass Board PKG42B3J4/42D2J4/35B2J4 Data Relay Board (Left) PKG42D2J1 Data Relay Board (Right) PKG42D2J2 Common Relay Board PKG42B3J3 01A, 01C Scan Relay Board (Top) PKG42D2E1 01A, 01B, 01C Scan Relay Board (Bottom)
  • Page 68 English 2004DL08-Data Sony EMCS Corporation Made in Japan Ichinomiya TEC  2004. 4 9-878-233-01...

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