sony_kdl-32ex421_ex423_ex520_ex521_ex523_kdl-40ex520_kdl-46ex523_chassis_az2-f_sch

LCD DIGITAL COLOR TV

SERVICE MANUAL AZ2-F CHASSIS MODEL NAME REMOTE COMMANDER DESTINATION

9-888-385-51

KDL-32EX421 RM-YD071 LA KDL-32EX423 RM-YD071 LA KDL-32EX520 RM-YD063 MX/LA KDL-32EX520 RM-YD063 US/CNDKDL-32EX521 RM-YD063 MX/LA KDL-32EX521 RM-YD063 US/CND KDL-32EX523 RM-YD063 MX/LA KDL-32EX523 RM-YD063 US/CND KDL-40EX520 RM-YD063 MX/LA KDL-40EX520 RM-YD063 US/CND KDL-40EX521 RM-YD063 US/CND KDL-40EX521 RM-YD063 MX/LA KDL-40EX523 RM-YD063 MX/LA KDL-40EX523 RM-YD063 US/CND KDL-46EX520 RM-YD063 MX/LA KDL-46EX520 RM-YD063 US/CND KDL-46EX521 RM-YD063 MX/LA KDL-46EX521 RM-YD063 US/CND KDL-46EX523 RM-YD063 MX/LA KDL-46EX523 RM-YD063 US/CND

LEVEL 3CONFIDENTIAL

HISTORY INFORMATION FOR THE FOLLOWING MANUAL:

CONFIDENTIALELECTRICAL SERVICE MANUAL

INTERNAL ONLYORIGINAL MANUAL ISSUE DATE: 1/2011REVISION DATE SUBJECT

1/13/2011 No revisions or updates are applicable at this time.

2KDL-32EX421/32EX423/32EX520/32EX521/32EX523/40EX520/40EX521/40EX523/46EX520/46EX521/46EX523

KDL-32EX421/32EX423/32EX520/32EX521/32EX523/40EX520/40EX521/40EX523/46EX520/46EX521/46EX523

TABLE OF CONTENTS

SECTION TITLE PAGE

Safety-Related Component Warning ...............................................................................................................................................................................3

Safety Check-Out...............................................................................................................................................................................................................5

SECTION 1: DIAGRAMS ...................................................................................................................................................................................................61-1. Circuit Boards Location ......................................................................................................................................................................................61-2. Printed Wiring Boards and Schematic Diagrams Information ............................................................................................................................71-3. Block Diagram ....................................................................................................................................................................................................91-4. Schematics and Supporting Information ..........................................................................................................................................................10

BATV Board Schematic Diagram (1 of 12) .......................................................................................................................................................10BATV Board Schematic Diagram (2 of 12) ....................................................................................................................................................... 11BATV Board Schematic Diagram (3 of 12) .......................................................................................................................................................12BATV Board Schematic Diagram (4 of 12) .......................................................................................................................................................13BATV Board Schematic Diagram (5 of 12) .......................................................................................................................................................14BATV Board Schematic Diagram (6 of 12) .......................................................................................................................................................15BATV Board Schematic Diagram (7 of 12) .......................................................................................................................................................16BATV Board Schematic Diagram (8 of 12) .......................................................................................................................................................17BATV Board Schematic Diagram (9 of 12) .......................................................................................................................................................18BATV Board Schematic Diagram (10 of 12) .....................................................................................................................................................19BATV Board Schematic Diagram (11 of 12) .....................................................................................................................................................20BATV Board Schematic Diagram (12 of 12) .....................................................................................................................................................21GE2A Board Schematic Diagram (KDL-32EX421/32EX423/32EX520/32EX521/32EX523 ONLY) ................................................................. 24GE3A Board Schematic Diagram (All Except 32 Models) ...............................................................................................................................27HLR2 Board Schematic Diagram .....................................................................................................................................................................28HMS3 Board Schematic Diagram ....................................................................................................................................................................30

SECTION 2: ELECTRICAL PARTS LIST ........................................................................................................................................................................32

APPENDIX A: ENCRYPTION KEY COMPONENTS ..................................................................................................................................................... A-1



SAFETY-RELATED COMPONENT WARNING

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.

USE CAUTION WHEN HANDLING THE LCD PANELWhen repairing the LCD panel, be sure you are grounded by using a wrist band.

When installing the LCD panel on a wall, the LCD panel must be secured using the 4 mounting holes on the rear cover.

To avoid damaging the LCD panel:do not press on the panel or frame edge to avoid the risk of electric shock. do not scratch or press on the panel with any sharp objects. do not leave the module in high temperatures or in areas of high humidity for an extended period of time. do not expose the LCD panel to direct sunlight. avoid contact with water. It may cause a short circuit within the module. disconnect the AC adapter when replacing the backlight (CCFL) or inverter circuit.

(High voltage occurs at the inverter circuit at 650Vrms.) always clean the LCD panel with a soft cloth material. use care when handling the wires or connectors of the inverter circuit. Damaging the wires may cause a short. protect the panel from ESD to avoid damaging the electronic circuit (C-MOS).

LEAKAGE CURRENT HOT CHECK CIRCUIT

Avoid contact with water as it may a short circuit within the module.

If the surface of panel becomes dirty, please wipe it off with a soft material. (Cleaning with a dirty or rough cloth may

damage the panel.)

If you want to replace with the new backlight (CCFL) or inverter circuit, must disconnect the AC adapter because high

voltage appears at inverter circuit about 650Vrms.

Handle with care wires or connectors of the inverter circuit. If the wires are pressed cause short and may burn or take

fire.

Leakage Current Hot Check Circuit

KLV-32U100M (UC) 5



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.

For more information on the use of Lead Free Solder, please refer to http://www.sony-training.com

r e b m u n t r a P r e t e m a i D s k r a m e R 9 1 - 5 0 0 - 0 4 6 - 7 m m 3 . 0 g K 5 2 . 0 0 2 - 5 0 0 - 0 4 6 - 7 m m 4 . 0 g K 0 5 . 0 1 2 - 5 0 0 - 0 4 6 - 7 m m 5 . 0 g K 0 5 . 0 2 2 - 5 0 0 - 0 4 6 - 7 m m 6 . 0 g K 5 2 . 0 3 2 - 5 0 0 - 0 4 6 - 7 m m 8 . 0 g K 0 0 . 1 4 2 - 5 0 0 - 0 4 6 - 7 m m 0 . 1 g K 0 0 . 1 5 2 - 5 0 0 - 0 4 6 - 7 m m 2 . 1 g K 0 0 . 1 6 2 - 5 0 0 - 0 4 6 - 7 m m 6 . 1 g K 0 0 . 1



SAFETY CHECK-OUT

After correcting the original service problem, perform the following safety checks before releasing the set to the customer:

1. Check the area of your repair for unsoldered or poorly soldered connections. Check the entire board surface for solder splashes and bridges.

2. Check the interboard wiring to ensure that no wires are pinched or touching high-wattage resistors.

3. Check that all control knobs, shields, covers, ground straps, and mounting hardware have been replaced. Be absolutely certain that you have replaced all the insulators.

4. Look for unauthorized replacement parts, particularly transistors, that were installed during a previous repair. Point them out to the customer and recommend their replacement.

5. Look for parts which, though functioning, show obvious signs of deterioration. Point them out to the customer and recommend their replacement.

6. Check the line cords for cracks and abrasion. Recommend the replacement of any such line cord to the customer.

7. Check the antenna terminals, metal trim, metallized knobs, screws, and all other exposed metal parts for AC leakage. Check leakage as described below.

Leakage Test

The AC leakage from any exposed metal part to earth ground and from all exposed metal parts to any exposed metal part having a return to chassis, must not exceed 0.5 mA (500 microamperes). Leakage current can be measured by any one of three methods.

1. A commercial leakage tester, such as the Simpson 229 or RCA WT-540A. Follow the manufacturers instructions to use these instructions.

2. A battery-operated AC milliampmeter. The Data Precision 245 digital multimeter is suitable for this job.

3. Measuring the voltage drop across a resistor by means of a VOM or battery-operated AC voltmeter. The limit indication is 0.75 V, so analog meters must have an accurate low voltage scale. The Simpsons 250 and Sanwa SH-63TRD are examples of passive VOMs that are suitable. Nearly all battery-operated digital multimeters that have a 2 VAC range are suitable (see Figure A).

How to Find a Good Earth GroundA cold-water pipe is a guaranteed earth ground; the cover-plate retaining screw on most AC outlet boxes is also at earth ground. If the retaining screw is to be used as your earth ground, verify that it is at ground by measuring the resistance between it and a cold-water pipe with an ohmmeter. The reading should be zero ohms.

If a cold-water pipe is not accessible, connect a 60- to 100-watt trouble- light (not a neon lamp) between the hot side of the receptacle and the retaining screw. Try both slots, if necessary, to locate the hot side on the line; the lamp should light at normal brilliance if the screw is at ground potential (see Figure B).

To Exposed MetalParts on Set

0.15 F

Earth Ground

ACVoltmeter(0.75V)

Trouble Light

AC Outlet BoxOhmmeter

Cold-water Pipe

Figure A. Using an AC voltmeter to check AC leakage. Figure B. Checking for earth ground.



SECTION 1: DIAGRAMS

1-1. CIRCUIT BOARDS LOCATION

Switch Unit

HLR2 Board

BATV Board

HMS3 Board

T-CON

GE2A Board

WiFi Module(Only for EX423/523)

Figure 1-1. KDL-32EX421/32EX423/32EX520/32EX521/32EX523

Switch Unit

HLR2 Board

BATV Board

HMS3 Board

T-CON

GE3A Board

WiFi Module(Only for EX523)

Figure 1-2. KDL-40EX520/40EX521/40EX523



Switch Unit

HLR2 Board

BATV Board

HMS3 Board

T-CON

GE3A Board

WiFi Module(Only for EX523)

Figure 1-3. KDL-46EX520/46EX521/46EX523

1-2. PRINTED WIRING BOARDS AND SCHEMATIC DIAGRAMS INFORMATION

All capacitors are in F unless otherwise noted. pF : F 50WV or less are not indicated except for electrolytics and tantalums.All electrolytics are in 50V unless otherwise specifi ed.All resistors are in ohms. k=1000, M=1000kIndication of resistance, which does not have one for rating electrical power, is as follows: Pitch : 5mm Rating electrical power : 1/ 4 W1/ 4 W in resistance, 1/10 W and 1/16 W in chip resistance.

: nonfl ammable resistor : fusible resistor

: internal component : panel designation and adjustment for repair

: earth ground : earth-chassis

All variable and adjustable resistors have characteristic curve B, unless otherwise noted.Readings are taken with a color-bar signal input.Readings are taken with a 10M digital multimeter.Voltages are DC with respect to ground unless otherwise noted.Voltage variations may be noted due to normal production tolerances.All voltages are in V.S : Measurement impossibility.

: B+line.: B-line. (Actual measured value may be different).

: signal path. (RF)Circled numbers are waveform references.

The components identifi ed by shading and ! symbol are critical for safety. Replace only with part number specifi ed.

The symbol indicates a fast operating fuse and is displayed on the component side of the board. Replace only with fuse of the same rating as marked.

Les composants identifi es per un trame et une marque ! sont critiques pour la securite. Ne les remplacer que par une piece portant le numero specifi e.

Le symbole indique une fusible a action rapide. Doit etre remplace par une fusible de meme yaleur, comme maque.

NOTE: The components identifi ed by a red outline and a mark contain confi dential information. Specifi c 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.



G

D

S

B1 E1C2

B2 C1E2

2

3

4

5

6

7

8

9

1

G

D

S

B2 E2C1

B1 C2E1

B2 E2C1

B1 C2E1

B2 E2C1

B1 C2E1

B1 E1E2

C1(B2)C2

B1E2

C1C2

(B2)E1

(B2)E1

E2B1

C2C1

B1

E1

C2

B2

C1

E2

G

S S

D

G

D

B1

E1

C2

B2

C1

E2

B1

E2

C2C1(B2)

E2

B1

C1

C2E1(B2)

C2

B1

C1

E2E1(B2)

C2

B1

C1

E2

B2

E1

C2

Ver.1.6

Transistor(FET)

Transistor

Transistor

Transistor

Transistor

Transistor

Transistor

Transistor

Transistor

Transistor

Discrete semiconductor

(Chip semiconductors that are not actually used are included.)

Diode

Diode

Diode

Diode

Diode

Diode

Diode

Diode

Diode

Diode

Source

Source

Anode Anode

(NC)

(NC)Cathode

AnodeCathode

Common

Cathode Cathode

Common

Cathode Cathode

Common

Common

Common

Common

CathodeAnode

Base Emitter

Collector

Base Emitter

Collector

Drain

Gate

Gate

Drain

Device Printed symbol Terminal name Circuit

Terminal name of semiconductors in silk screenprinted circuit ( )

Anode

Anode

Anode Cathode

Anode Anode

Cathode

Transistor(FET)

Transistor(FET)

EmitterCollectorBase

Transistor

SourceGate

Drain

Cathode

AnodeAnode

CathodeAnodeAnode

*

18

11

17

16

15

14

13

12

10

21

20

19

23

22

REFERENCE INFORMATION RESISTOR : RN METAL FILM: RC SOLID: FPRD NONFLAMMABLE CARBON: FUSE NONFLAMMABLE FUSIBLE: RW NONFLAMMABLE WIREWOUND: RS NONFLAMMABLE METAL OXIDE: RB NONFLAMMABLE CEMENT: ADJUSTMENT RESISTOR

COIL : LF-8L MICRO INDUCTOR

CAPACITOR: TA TANTALUM: PS STYROL: PP POLYPROPYLENE: PT MYLAR: MPS METALIZED POLYESTER: MPP METALIZED POLYPROPYLENE: ALB BIPOLAR: ALT HIGH TEMPERATURE: ALR HIGH RIPPLE

9 KDL-32EX421/32EX423/32EX520/32EX521/32EX523/40EX520/40EX521/40EX523/46EX520/46EX521/46EX523

KDL-32EX421/32EX423/32EX520/32EX521/32EX523/40EX520/40EX521/40EX523/46EX520/46EX521/46EX5231-3. BLOCK DIAGRAM

27M

[HORUS3]

4M

[ASCOT2Sip] [GAIA1a]

41M

00

[SEKITO2]

[LNBH23]

[MIC2005]

[TPS2553DBV] [TPS2553DBV]

[GL850G] [RTL8201E]

12M

OneNANDMuxed

2Gb

DDR313332Gb

DDR313332Gb

48M

32.768K

GND

[PST3629]

[LM75B]

[Sil9287B]

[D510D]

[D510D]

[NJU72011RB]

[NJU72040V]

H/L

Push

PANEL

41M

CableSatellite

Aerial

HDMI1(ARC)

HDMI2

HDMI3

HDMI4

CVBS

COMP

PC

HP/Line Out

SPDIF

MainSPEAKER

LNA

Xtal

SW

LNA

XtalSilicon Tuner

Silicon Tuner

X_SYSTEM1_RST

IF1

IF2

Zero-IF

27MHz

Ext DemodIFAGC

Ext DemodIFAGC

Xtal

TS1

DiSEqC_OutDiSEqC_In

TS2

DDC

I2CB

DMD_RSTDMD_CLK_ENABLE1DMD_CLK_ENABLE2

I2CB

Current Limit

5V

MS H Con.

USB4BD

USB3Wifi

Current Limit

5V

USB2USB1

5VX_

SYST

EM1_

RST

USB HUB

Crystal

Current Limit

X_S

YS

TEM

1_R

ST

Ether

EtherPHY

BACKLIGHT

LVDS_ODDLVDS_EVEN

TCON

SA

_MO

DE

/LU

T_S

EL0

PEM

_WD

T/X

BU

SY

/BIN

TX

_PEM

_RS

T/LU

T_S

EL2

/X_F

RC

_RS

TM

OD

E_P

EM

/TC

ON

_RD

YLU

T_S

EL1

/X_T

CO

N_R

ST/

LR_F

LAG

T_PA

NEL

_SE

L

I2C

_C

SYSTEM1_PWR

REG_12V1.2V

DDC1.5V

SYSTEM2_PWR

DDC

Xtal

Xtal

AC_MON

Reset

Reset

SYSTEM2_PWR

3.3VDDC REG_12V

2.5VLDO

SYSTEM2_PWR

5V DDC

3.3VLDO

3.4VLDO

REG_12V

SYSTEM2_PWR

S1.8VLDO

S1.2VLDO

T-CON_VCC

REG12VREG12V

STBY 3.3V

AUDIO_12VAUDIO_12V

Pow

er

BACKLIGHT_ON

DIMMER_DCTCON-ON

MAIN_PWRBACKLIGHT_MON

PFC_PWRAC_MON

DIMMER2 Pow

er_C

ontro

l

UARTA(LOG)UARTD

PEM_LOG

MODE_PEM

UARTC(Hotel/ECS)I2CA(Hotel_Clock)

Reset

SIRCS

TL-J

IGH

otel

/EC

S

Temp Sensor

Sircs

TempSensor

SIRCS

I2CA

X_Hotel_PWR_CTRL

I2CA (EQSW, Temp Sensor, Hotel Clock)I2CB (Ext Demod)I2CC (Panel, RGB Sensor)

UARTA (LOG)UARTB (RF-Remote)UARTC (IR Blaster/ECS)

KEY

Light SensorHuman Sensor

LED

Light_Sensor_Det

Human_Sensor_Det

STBY_LEDPOWER_LED

TIMER_LED

PIC_MUTE_LEDREC_LED

Power_KEYKEY

UARTE

DIMMERDMD_CLK_ENABLE2DIMMER_DCLOGO

DEBUG_LED2

DEBUG_LED3PANEL_PWRDMD_CLK_ENABLE1DMD_RSTX_WIFI_RSTHP_DET

SPDIF_SEL

HDMIEQ_INTX_AUDIO_MON

DC

_MO

NK

EY

Light_Sensor_D

etH

uman_S

ensor_Det

PA

NE

L_SE

L

BA

CKLIG

HT_M

ON

PA

NE

L_PW

R_D

et

STB

Y_LE

DTIM

ER

_LED

MA

IN_PW

R

MA

IN_SS_M

ON

SY

STE

M2_PW

RS

YS

TEM

1_PWR

PIC

_MU

TE_LED

AC_M

ON

PFC

_MO

NP

OW

ER_K

EY

DE

BUG

_LED1

X_RF_R

STX_HO

TEL_PWR_CTRL

PO

WER

_LED

REC

_LED

X_SYSTEM1_R

ST

PFC

_PW

RX

_AU

DIO

_MU

TE1

X_A

UD

IO_M

UTE

2

BA

CKLIG

HT_O

NN

MI

PC

_CO

N_D

ET

VIDE

OA

_DET

VIDE

OB_D

ET

CR

_DE

T

LUT_S

EL2LU

T_SEL1

LUT_S

EL0

BIN

TTC

ON

_RD

YD

ATA

1

PanellessSPIUARTDigital AudioI2CAnalog Signal

PWMAnalog AudioAnalog Video

Digital Video/TS/TMDSX_AUDIO_MUTE1X_AUDIO_MUTE2

X_FAULT

Main Speaker_Out_LR

X_SYSTEM1_RSTAUDIO_MON

OPAMP AudioPower AMP

Main Speaker_Out_LR

Atreyu_SPDIF

TV_Out_LRTuner_LR

Line Out_LR

PC_LRCOMP2_LR

PC_V

VIDEO1_LRTuner_LR

PC_GPC_BPC_RPC_H

COMP_YCOMP_PbCOMP_Pr

OPAMP

SPDIF

HP/Line Out LRHP_/ Line Out Det

PC_R,PC_G,PC_B,PC_H,PC_VPC_LR

PC_5V, PC_DDC

PC_CON_Det

COMP_Y, Pb, PrVideoB_Det

Cr_Det

COMP2_LR

VideoA_Det

VIDEO_CVVIDEO1_LR

CEC3

DDC4

HPD4

CEC4

DDC_5V_4

TMDS4

CEC2

DDC3

HPD3DDC_5V_3

TMDS3

TMDS1DDC1

HPD1

CEC1TMDS2DDC2

HPD2

DDC_5V_1

DDC_5V_2

ARC

3.3->1

EQ SW

I2CA

Atreyu

TSXtal

IF1

TMDSDDCCEC

VIDEO_CV

COMP_Y

REG_12V

DIMMER

KDL-32EX421/32EX423/32EX520/32EX521/32EX523/40EX520/40EX521/40EX523/46EX520/46EX521/46EX523 10


1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 11 | 12 | 13 | 14 | 15 | 16 | 17 | 18 | 19 | 20 | 21 | 22

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

1-4. SCHEMATICS AND SUPPORTING INFORMATIONBATV BOARD SCHEMATIC DIAGRAM (1 OF 12)

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sony_kdl-32ex421_ex423_ex520_ex521_ex523_kdl-40ex520_kdl-46ex523_chassis_az2-f_sch

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