S/M NO.

: DSP220PEF0

Service Manual
42" PLASMA PDP TV

CHASSIS : SP-220P
Model : DPP-42A1LASB

Caution
: In this Manual, some parts can be changed for improving. their performance without notice in the parts list. So, if you need the latest parts information, please refer to PPL(Parts Price List)in Service Information Center.

Contents
I. Parts with exception of MODULE 1. Safety Precaution 2. Product Specification 2-1. SPECIFICATION 2-2. Available Input Signal 2-3. Remote Control Setup Code 3. The Features of Inside 4. DPP-42A1LASB Block Diagram 5. Default Setting in User Menu OSD 5-1. Picture Mode 5-2. Sound 5-3. Screen 5-4. Features 6. Service Mode 7. Power PCB 7-1. Input and Environmental Requirement 7-2. Output Characteristics 7-3. Function of Protection 7-4. Connector Specification 8. Power Adjustment 8-1. Vs (Sustain Voltage) 8-2. Vs (Adress Voltage) 8-3. 5Vcntl 9. Noticeable Points While Assembling 10. Software Upgrade Method 11. Trouble Shooting 12. Assembly List 13. STRUCTURE OF PDP SET 14. EXPLODED VIEW 2 3 3 5 6 27 28 29 29 29 30 30 31 33 33 33 33 34 35 35 36 37 38 41 44 59 61 66

II. Parts of MODULE 1. Confirmation Manual 2. Repair Manual

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I. Parts with the exception of MODULE

1. Safety Precautions
1. Safety Precautions (1) When moving or laying down a PDP Set, at least two people must work together. Avoid any impact towards the PDP Set. (2) Do not leave a broken PDP Set on for a long time. To prevent any further damages, after checking the condition of the broken Set, make sure to turn the power (AC) off. (3) When opening the BACK COVER, you must turn off power (AC) to prevent any electric shock. When PDP is operating, high voltage and high current inside the Set can cause electric shocks. (4) When loosening screws, check the position and type of the screw. Sort out the screws and store them separately for reassembling. Because screws holding PCBs are working as electric circuit GROUNDING, make sure to check if any screw is missing when assembling/reassembling. Do not leave any screws inside the set. (5) If you open the BACK COVER, you will see a Panel Gas Exhaust Tube (Picture. 1-1) inside the bracket. If this part is damaged, the entire PDP PANEL must be replaced. Therefore, when working with the set, be careful not to damage this part. Picture 1-1. Panel Gas Exhaust Tube (6) A PDP Set contains different kinds of connector cables. When connecting or disconnecting cables, check the direction and position of the cable beforehand. (7) Connect/disconnect the connectors slowly with care especially FFC (film) cables and FPC cables. Do not connect or disconnect connectors instantaneously with force, and handle them carefully for reassembling. (8) Connectors are designed so that if the number of pins or the direction does not match, connectors will not fit. When having problem in plugging the connectors, check their kind, position, and direction.

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2. Product Specification
2-1. SPECIFICATION ITEM 1. GENERAL 1-1. MODEL NO 1-2. CHASSIS NO 1-3. SCREEN SIZE 1-4. COUNTRY 1-5. RESOLUTION 1-6. REMOCON TYPE 1-7. SAFETY STANDARD 1-8 .TUNIG METHOD 1-9. MEMORY CHANNEL 2. MECHANICAL 2-1. APPEARANCE 1) WITHOUT STAND 2) WITH STAND 2-2. WEIGHT 1) WITHOUT STAND 2) WITH STAND 3. ELECTRICAL 3-1. VIDEO INPUT 3-2. DTV/DVD INPUT 3-3. SCART INPUT 3-4. PC INPUT 3-5. DVI INPUT 3-6. TV INPUT 1) COLOR STANDARD 2) ANTENNA IN 3) RECEPTION CHANNEL SPECIFICATION DPP-42A1LASB SP-220P 42 (16:9) Europe 852(H) x 480(V) R-53J17 CE(CLASS B), CB VS 99CH REMARK

W x H x D =1260 x 653 x 91 mm W x H x D =1260 x 748.5 x 300 mm 33 Kg 38.75 Kg COMPOSITE(NTSC, PAL, SECAM, PAL-M/N, NTSC4.43) & S-VHS(50/60Hz Y/C) 1 Port 1080i, 720P, 480P , 480i, 576P, 576i (Y, Pb/Cb, Pr/Cr COMPONENT SIGNAL) 2 Ports SCART(COMPOSITE, R,G,B, SOUND R/L) 2 Ports VGA ~ SXGA(Dot clock : 110MHz), 15 PIN D-SUB 1 Port DVI-D INPUT (DVI Jack) 1 Port PAL B/G+I/I+D/K, L-SECAM, L--SECAM ONE INPUT 75 Unbalanced (DIN Standard) VHF LOW : E2 ~ S6 Ch. VHF HIGH : S7 ~ S36 Ch. UHF : S37 ~ E69 Ch. L-SECOM : FB, FC1, FC PIF : 38.90MHz (PAL, L-SECAM) 33.9 MHz (L-SECAM) SIF : 33.40MHz (B/G), 32.90MHz (I/I), 32.4MHz (D/K, L-SECAM), 40.4MHz (L-SECAM) VIDEO 1 Port, DTV/DVD 2 Ports, PC 1 Port, DVI 1 Port 10W(R) + 10W(L) AC 100V~240V, 50/60Hz
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4) IF & SUBCARRIER

3-7. SOUND INPUT 3-8. SPEAKER OUTPUT 3-9. POWER REQUIREMENT

Product Specification

ITEM 3-10. POWER CONSUMPTION 3-11. RS-232 CONTROL 3-12. AV OUTPUT 3-13. FUNCTION 1) SCALING

SPECIFICATION 270W RS-232 Communication (EXTERNAL UPGRADE) SCART(CVBS, SOUND R/L) 2 Ports DVI : Screen Mode (16:9, 4:3, Panorama) PC : Screen Mode (16:9, 4:3, Panorama), H/V Position, Auto TV / VIDEO / DVD (480, 576 i/p) : Screen Mode (16:9, 4:3, Panorama, LB (16:9), LBS (16:9), 14:9, LB (14:9), LBS (14:9) Auto) 18 Languages (English, Greek, Dutch, German, Russian, Rumanian, Swedish, Danish, Finnish, Norwegian, Spanish, Italian, Franch, Polish, Portuguese, Czech, Hungarian, Slovakian) TV, Video, S-Video / TV, Video, S-Video Still, Sleep Mode, Sound Mode, Timer, Screen Mode, Teletext (Level 1.5), WSS 42(106 cm) DIAGONAL 16 : 9 852(H)X480(V) 1,073,000,000 Colors ( 10bits for each RGB) 1.08(H) x 1.08(V)mm (1 Pixel = a Set of RGB Cells ) 1500cd/m2(WITH FILTER GLASS) 10000:1 (Dark Room) 160 degree(VERTICAL/HORIZONTAL) PUSH-PULL S/W : AC POWER BUTTON SOFT S/W: MOVE/CH(UP, DOWN), VOLUME(LEFT, RIGHT), MENU, INPUT SELECT Power, Universal Selection (TV, VIDEO/DVD, CATV/SAT), 10 KEYS(0~10), Recall, VCR /DVD KEY (F.R/SLOW, Play, F.F/SLOW, Stop, PAUSE, OPEN/CLOSE, PREV, NEXT ), MENU, TV, AV, Component, PC/DVI, STILL, PREV PR, MUTE, PR (UP/DOWN), VOL(UP/DOWN), SCREEN MODE / MIX, Screen Size, Sleep Timer, I-II / CYAN, Sound Mode / Index, Red, Green, Yellow, TXT, Reveal, Update, Expand, Subpage, Hold, PIP, SWAP, PR+, PR-, Position, Sourse REMOTE CONTROL, INSTRUCTION MANUAL, POWER CORD STAND, WALL HANGER
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REMARK

2) OSD

3) PIP / POP 4) OTHERS 4. OPTICAL 4-1. SCREEN SIZE 4-2. ASPECT RATIO 4-3. NUMBER OF PIXELS 4-4. DISPLAY COLOR 4-5. CELL PITCH 4-6. PEAK LUMINANCE 4-7. CONTRAST RATIO 4-8. VIEWING ANGLE 5. USERCONTROL & ACCESSORIES 5-1 CONTROL BUTTON(SET)

5-2. REMOTE CONTROL (R-52M17)

5-3. ACCESSORIES 5-4. OPTIONAL PARTS

Product Specification
2-2 Available Input Signal
(1) PC & DVI
Resolution 640 X 480 720 X 400 800 X 600 1024 X 768 H Freq. (KHz) 31.469 37.861 37.500 31.469 35.156 37.879 48.363 V Freq. (Hz) 59.940 72.809 75.000 70.087 56.250 60.317 60.004 Remark DOS VESA VESA IBM VESA VESA VESA DVI O O O O O O O PC O O O O O O O

(2) Component
z z z z 1080i 50 / 60Hz 720p 50 / 60Hz 576p - 50 / 60Hz 480p - 50 / 60Hz

(3) Video
z PAL, PAL M, PAL N z NTSC, NTSC 4.43 z SECAM

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Product Specification

2-3. Remote Control Setup Code

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Product Specification

VCR Maker (BRAND) NAME CANON CAPEHART CARENA CARREFOUR CASIO CATHAY CATRON CGE CIHAN CLARIVOX CIMLINE CLATRONIC COMBITECH CONDOR CONTINENTAL EDISON CORVUS CRAIG CROSLEY CROWN CROWN/ ONWA CURTISMATHES CYRUS DAEWOO DANSAI DAWA DAYTRON DE GRAAF DECCA DECCA(UK) DEGRAAF DEITRON DENKO DENON DESMET DIAMANT DIXI DOMOH DORIC DUAL DUMONT DYNATECH ELBE ELCATECH ELIN ELSAY ELTA EMERSON ESC ESSELTE ETZUKO EUROMAN EUROPHON FENNER FERGUSON FIDELITY FINLANDIA

CODE NUMBER (3DIGIT) LIST 147 061 065 009 039 021 061 039 155 029 029 033 021 044 148 008 160 009 148 060 175 001 021 155 021 113 039 054 015 021 029 113 155 055 078 155 160 021 015 039 021 029 056 029 021 009 021 148 029 155 061 061 016 029 015

148 171 044

090 133 148 155

061 061 090 056 021

171 155 171

029 061 064 171

009 029 061 177 044 039

021 033 061 064 155 171 055

047 065 090 148 155 166 175 049 054 065 113 148

039 039 148 036 113 029 011 056

044 065 090 112 148 155 054 065 148 155 175 189 148 155 148 029 032 039 060 073 127 148 155 057 061 064

155 021 039 039

023 039 044 090 094 100 104 108 112 130 131 165 056 148 162 049 054 065 113 175

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3. The Features of Inside

DPP-42A1LASB Inside Features

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4. DPP-42A1LASB Block Diagram

4850710S22 DVI Audio Key PCB DVI

PC Audio PC (D-SUB) LVDS 4859004460

Component1,2

12V,5V,STB 4850710S21 3.3V 4850708S16

AV1

4850705N31 LED PCB AV2 4859004060 FFC Cable Main Tuner Speaker L Speaker R S-VHS RS-232 Upgrade AV3 Sub Tuner 4850712S03 33V,17V 4850706S35

SUB B/D

AV3 PCB

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5. Default Setting in User Menu OSD

1. Picture Mode
1) Mode Normal Brightness Contrast Sharpness Colour Tint 50 50 8 50 50 Dynamic 40 80 10 55 50 Cinema 55 35 6 45 50 User Undefined Undefined Undefined Undefined Undefined

DVI & PC Input - Only brihgtness and contrast are available.

2) Default value of other functions in picture mode Function Colour Temp N.R. CTI Default Value Normal NR1 On

z z

N.R. means the noise reduction DVI & PC don't support N.R. and CTI functions

2. Sound
1) Mode Normal 120 Hz 500 Hz 1.5 kHz 5 kHz 10 kHz 32 32 32 32 32 Movie 50 38 28 40 48 Music 48 38 15 42 56 News 15 32 50 32 15 User Undefined Undefined Undefined Undefined Undefined

2) Default value of other functions in sound mode

Function Balance Effect AVC

Default Value 0 Off Off

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Default Setting in User Menu OSD

3. Screen
16 : 9 4 : 3 Component TV AV PC DVI O O O O O O O O O O Panorama O O O O O LB (16:9) X O O X X LBS (16:9) X O O X X 14 : 9 X O O X X LB (14:9) X O O X X LBS (14:9) X O O X X Auto X O O X X

H. Position, V. Position, and Auto screen size is available only in PC mode.

4. Features
1) Mode Function Default Value Background 10 Language English Child Lock Off MGDI On Auto Power Off

DVI & PC don't support MGDI function.

2) Time Setting
Function Clock Auto Clock Off Timer Off Time Wake Timer Wake Time Wake Prog. Wake Vol. On Off PM 12:00 Off PM 12:00 1 20

Default Value Undefined

3) ISM Function Default Value Pixel Shift

Off

Low Bright
Off

Image Invert
Off

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6. Service Mode

To enter SERVICE MODE, A. Press VOL -> MUTE -> RECALL -> MUTE button of remote controller (R-53J17) or B. Press S9 button of SERVICE REMOTE CONTROLLER.

[Note] In the first line, there is the model name and the version of the upgraded program on the PDP set.

1. Default Value of Pw318B_1 and Pw318B_2

Sub Bias Sub Gain Pw318B_1 Pw318B_2 32 32 12 12 Bias R 25 Bias G 23 Bias B 38 Gain R 12 Gain G 16 Gain B 20

1) Pw318B_1 z z z z z z z z z z Sub Bias : For BRIGHTNESS adjustment (All inputs) Sub Gain : For CONTRAST adjustment (All inputs) Bias R : For R BRIGHTNESS adjustment (All inputs) Bias G : For G BRIGHTNESS adjustment (All inputs) Bias B : For B BRIGHTNESS adjustment (All inputs) Gain R : For R CONTRAST adjustment (All inputs) Gain G : For G CONTRAST adjustment (All inputs) Gain B : For B CONTRAST adjustment (All inputs)

2) Pw318B_2 Sub Bias : For DVI BRIGHTNESS adjustment Sub Gain : For DVI CONTRAST adjustment

2. Pw3300_1
Function Default Value Function Default Value R Offset 100 Y Offset 105 G Offset 100 Pb Offset 125 B Offset 100 Pr Offset 125 R Gain 94 Y Gain 90 G Gain 97 Pb Gain 203 B Gain 94 Pr Gain 196

z z

RGB offset values will be set by executing RGB Auto Cal in service mode. YPbPr offset values will be set by executing YPbPr Auto Cal in service mode.

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Service Mode
z The automatically set offset values may different from the default value depend on B/D. However, the main B/D should be replaced or contact Kunpo R&D center in Korea if the OFFSET values differ more than 20 from default value.

3. Pw3300_2 & Pw2250

AV Brt Pw3300_2 Pw2250 127 127 AV Cont 75 75

4. Msp34X0
Function Default Value Sc pScale 21 Fm pScale Nic pScale 25 51

z -

In Msp34X0, Sc pScale : Prescale adjustment for external input (AV, Component, PC, DVI etc.)

Fm pScale : FM/AM prescale adjustment Nic pScale : NICAM prescale adjustment

5. Misc
Function Default Value TV Auto Off On TXT Lang Auto TXT T/F TOP

z z

Tst Ptrn AT shows five cycled patterns (white, black, red, green, blue) every 1 minute automatically Tst Ptrn MA shows five cycled patterns manually by pressing volume up key.

6. Panel
Function Default Value Sync Mode AUTO Bright Mode 100% Power Mode Gamma Mode Panel Temp 100% 2.2N **.*

Panel Temp indicates the current temperature of the panel.

7. Reset
z z z Level 1 Resets all data in E2PROM other than HDCP key, EDID, RGB offset and YPbPr offset of Pw3300_1. Level 2 Resets all data in E2PROM other than the exception of Level 1 and Pw318B_1. Factory Resets the data of auto search, language setting, time setting, and the user menu values that could be reset by Initialize function in Feature mode.
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7. Power PCB

1. Input and Environmental Requirement

Input Requirement Norminal Input Voltage Input Voltage Variation Range Nominal Frequency Frequency Variation Range Phase Description AC100V to AC240V AC85V to AC276V 50 / 60 Hz 45Hz to 65Hz Single 30A zero-pk max. at cold start Inrush Current and any specified line, load and temperature conditions Environment Requirement Operating Temperature Range Operating Humidity Range Storage Temperature Range Storage Humidity Range Cooling Condition Description -10 to 50 deg. 10 to 90 % -20 to 60 deg. 10 to 90 % Free Air

2. Output Characteristics
Output Circuit Vs Vd 5V (ctrl) 5V DTV3.4V DTV2.5V 33VT 12V 17V (Audio) -17V (Audio) 5V (STBY) Norminal Voltage Load Ripple

Voltage [V] Adjustment [V] Variation [A] Noise [mV p-p] 175 60 5.1 5.1 3.4 2.5 33.0 12.0 17.0 -17.0 5.0 160 - 190 55 - 65 4.75 - 5.25 4.75 - 5.25 -------0.4 - 1.5 0.01 - 2.5 1.2 - 4.0 0.5 - 4.5 0.5 - 2.0 0.2 - 2.0 0 - 0.05 0 - 2.0 0 - 0.7 0 - 0.7 0.03 - 1.0 500 / 500 300 / 300 30 / 200 50 / 200 50 / 200 50 / 200 100 / 400 100 / 400 100 / 400 100 / 400 50 / 200

3. Function of Protection
Protection Over Current Output Circuit Vs Vd 5V (ctrl) 5V 12V Trip Point 1.7A or more 3.0A or more 13.0 - 25.5A Shut down by Under Voltage (Total Current) 1.76A or more Shut down by Under Voltage Notes Shut down by Under Voltage Shut down by Under Voltage

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Power PCB

33V 17V -17V Vs Vd 5V (ctrl)

0.08A or more 1.0A or more 1.0A or more 220V or less 86V or less

Shut down by Under Voltage Shut down by Under Voltage Shut down by Under Voltage Shut down Shut down

5.5 - 7.0 5V Over Voltage 12V 33V 17V -17V 13 - 17V 36 - 44V 19 - 24V -19 - -24V

Shut down

Shut down Shut down Shut down Shut down

4. Connector Specification
Connector Type Maker The number of pins 1 2 3 4 5 Pin No. 6 7 8 9 10 GND GND 12V 12V GND Vd Vd NC Vs Vs 2.5V GND GND -17V CN803 (PV) CN806 CN804 (PM) CN801 (PA) CN805 CN01

YMW025-10R B10P-VH YMW025-08R YMW025-06R B4P-VH YFW800-02 YEONHO 10 5V Stand_by POWER GND GND 5V JST 10 LVP GND GND GND GND YEONHO 8 3.4V 3.4V GND GND 2.5V YEONHO 6 33VT GND +17 GND GND JST 4 5Vctrl 5Vctrl GND GND YEONHO 2 AC(L) AC(N)

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8. Power Adjustment

Power Adjustment Adjusting to standard power voltages, which are written in the upper right side of PDP module. These values were already adjusted by PDP module makers while producing. Therefore, if there are some problems in

picture after adjusting, you should classify that PDP module as a fault and contact to PDP module maker. z Input Video Pattern 100 IRE Full White Pattern

Figure 3. Voltage Adjustment Label

1. Vs (Sustain Voltage) : Discharge Sustain Voltage

z z z z Measurement Equipment : Digital Volt Meter (DC volt mode) Adjusting TP : TP204 Adjusting Location : RV203 Optimum Adjusting Voltage : The voltage which is written in the label located in upper right side of the PDP module. (Typical Voltage : 187V)

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Power Adjustment

2. Va (Address Voltage) : Data Input Voltage

z z z z Measurement Equipment : Digital Volt Meter (DC volt mode) Adjusting TP : TP206 (Vd) Adjusting Location : RV204 (Vd ADJ) Optimum Adjusting Voltage : The voltage which is written in the label located in upper right side of the PDP module. (Typical Voltage : 65V)

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Power Adjustment
3. 5Vcntl (5V control)
z z z z Measurement Equipment : Digital Volt Meter (DC volt mode) Adjusting TP : TP203 Adjusting Location : RV201 Optimum Adjusting Voltage : The voltage which is written in the label located in upper right side of the PDP module. (Typical Voltage : 5.2V)

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9. Noticeable Points While Assembling

1. Insertion of Ring Core (EMI Filter) to Speaker Cable (L,R), AV3 Cable and their position
Coil the Ring Core (Filter EMI, S/N: 5PZCA2009A) 2 turns with Speaker Cable (L,R) as shown in the figure below. Coil the Ring Core (Filter EMI, S/N: 5PZCAT3035) 1 Turn with AV3 Cable as shown in the figure below.

Speaker Cable 2 Turn

AV3 Cable 1 Turn

Speaker & AV3 Cable Allocation (Separate with Power Cable)

Speaker Cable 2 Turn (No Ring Core in Key Cable)

Speaker & KEY Cable Allocation

2. Insertion of Ring Core to the Power Cable

Insert a Ring Core(Filter EMI, S/N : 5PZCA2009A) to 8 pin and 6 pin Power Cable

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Noticeable Points While Assembling

3. LVDS Cable Connection

CABLE LVDS, S/N : 4856818800 a. DIGITAL B/D part CLAMP WIRE, S/N : 4856818800 CLAMP WIRE, S/N : 4856815900 (Place these CLAMP WIRES as shown in the figure below) * Make LVDS Cable not to touch on the Terminal Plate while connecting.

b. VIDEO B/D part

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Noticeable Points While Assembling

4. Shieldron Tape on SCART Input

Tape EMI, S/N : 485A100071 (Position: From top of Scart to Terminal Channel Gasket)

5. Shieldron Tape on DVI Input

Tape EMI, S/N : 485A100571 (attach vertically, 3 X 4.2 Cm) (Position: From top of DVI to Terminal Channel Gasket)

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10. Software Upgrade Method

1. Check whether MAIN PCB is connected to SUB PCB (PA901 to P901). 2. Connect 9-PIN serial cable to the serial port of the computer. 3. Connect the opposite end of the serial cable to RS-232C port of SUB PCB. 4. Run Flashupgrader.exe in the PC to excute the program as shown below.

5. Select current Upgrade file - Click Choose... button to select the file you want to upgrade. - Select the file (pwSDK.inf) that you want to upgrade.

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SOFTWARE UPGRADE Method

6. Select correct COM Port and Baud Rate(115200) as shown below. Then press Flash button to finish setup.

7. Turn on the ac power and then upgrade program will start the download as shown below.

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SOFTWARE UPGRADE Method

8. When the upgrading is complete, a window (below) will be opened. Press Finish button to complete the process.

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11. Trouble Shooting

Before starting Trouble Shooting

z Trouble diagnosing and repairing of set mean find out which PCBs or blocks are not working and replace them with new PCBs. Repairing the broken PCBs are not necessary. R&D center. z This Trouble Shooting list only contains representative and simple PCB trouble diagnosis and Module Exchange method. Therefore, if you find sets that are difficult to diagnose or to repair, contact R&D center. z Basic Trouble Diagnosis procedure 1) Check problem Symptoms 2) Open Back Cover 3) Trouble Diagnosis & Replace broken PCB 4) Adjust new PCB module 5) HEATRUN for at least 30 minutes, inputting Full White test pattern 6) Full Function test 7) Repair Complete z Required Equipment for trouble diagnosis 1) Digital Multimeter (User Mode : measure DC Voltage, measure Diode Voltage, Short-open test) 2) Screwdriver (or electric screwdriver), Plastic adjusting tool 3) Oscilloscope (for detailed examination only) z z Before replacing PCBs, you MUST turn the AC switch OFF. After replacing High Voltage Board (Power PCB, Y-SUS, Z-SUS, Data B/D, Scan B/D), and Main & Sub PCB, extra adjustment might be needed. (Refer to Power Adjustment) z z Dust or extraneous materials may cause bad connections. Therefore, try to apply soft brush, air fresher, or breath to clean the dust or extraneous materials. While assembling the set in factory, it could have bad connection. Try to Keep the broken PCBs and return them to service center or

reassemble the necessary connectors and also check the state of the connectors. z After the set is repaired, leave Back Cover open for followings. Run HEAT

RUN for at least 30 minutes by displaying Full White test pattern of Service Mode (Refer to Service Manual I. Service Mode part). conditions and basic functions (remote control operation etc.) z After Back Cover is closed, redo HEAT RUN for at least one hour with Full Check the screen

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Trouble Shooting
White input using Test Pattern of Service Mode. Check the screen conditions and basic functions. z Caution 1 !! When disconnecting / connecting connectors, you MUST turn OFF the AC power and check the direction and position of the connectors before working. z Caution 2 !! Whenever you reassemble connectors connecting High Voltage Board and POWER PCB (CN805, CN806), remaining voltage still exists in the POWER PCB could cause electric shock and damage the set. Therefore always To be

reassemble the connectors several minutes after AC power is off.

more careful, using a Multimeter you should check to see if Vs is less than 10V and then connect connectors.

Definition
z z z z z z z Red LED Stand by state (ready for operating) Green LED The set is turned on and operating Shut Down While green LED, power PCB does not make any operating sound or noise (i.e. Power relay does not operate normally) Weak Discharge The screen looks like BLACK, but there are little discharged cells on the screen Abnormal Discharge Shows unexpected discharged cells on the image No Signal OSD is working but no images are displaying No Raster Not even OSD is displaying

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Trouble Shooting

1. No Signal or No Raster

Check Start

Does No Signal screen appear?

Is a weak discharge detected in the screen?

Check AC connection Check CN805, CN806 connectors Check Power S/W ON

Is the signal input Jack properly connected?

Check the connection of Jack (PDP and AV device)

Is LVDS connection correctly connected?

Check LVDS connection between Digital B/D and Main B/D

Does input source (AV device) work?

Check AV device

Check other connections in all Boards. Are they OK?

Connect correctly

Is input selection in the correct mode?

Correct the input mode

Replace Main B/D and/or Sub B/D

Replace Main B/D and/or Sub B/D

Done

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Trouble Shooting
2. No Sound

Check Start

N
Is an image displaying on screen? Go to the section of No Image

N
Is the sound jack of external device properly connected?

Connect the jack and check the sound again

Y Y
Is mute key pressed?

Cancel the mute and check the sound again

Is speaker cable correctly connected? (check P603, P604)

Connect the cable and check the sound again

Y N
Is input source TV? Replace Main B/D

N
Connect the cable

Is the connection between PA901 and P901 OK?

N
Is sound OK? Replace Sub B/D

Y N
Is sound OK? Replace speakers

DONE

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Trouble Shooting

3. Shut Down

Check Start

Turn AC power OFF

Open BACK COVER

Disconnect CN806 of Power PCB

Set Power PCBs voltage switch to LOW

Turn AC power ON (Stand By)

Turn on the set (Green LED)

Y
Is SHUT DOWN occured?

Go to Low Voltage Shut Down part in this trouble shooting

Connect CN806 back and disconnect CN801, CN803,CN804, CN805

Set Power PCBs voltage switch to HIGH

Go to High Voltage Shut Down part in this trouble shooting

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Trouble Shooting

A) Low Voltage Shut Down

Check Start

Turn AC power off

Disconnect CN805 of Power PCB

Turn on the set after AC power on

N
Is SHUT DOWN occured?

Turn AC power off

Turn AC power off

Connect CN805 back and disconnect CN 801, CN803, CN804 of Power PCB

Replace Main B/D

Disconnect P6 of Y-SUS B/D

Connect all connectors and set Power PCBs voltage switch to High

Turn on the set after AC power on

Done

Y
Is SHUT DOWN occured?

Turn AC power off Turn AC power off

Disconnect P2, P3 of Z-SUS

Connect P6 back and disconnect P1 of Z-SUS B/D

Go to Z-SUS, Digital B/D, Data B/D Shut Down part

Go to Y-SUS, Scan B/ D Shut Down part

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Trouble Shooting

B) Z-SUS, Digital B/D, Data B/D Shut Down

Check Start

Turn on the set after AC power on

N
Is SHUT DOWN occured? Turn AC power off

Turn AC power off

Connect P2 of Z-SUS B/D

Replace Z-SUS B/D

Turn on the set after AC power on

Connect P2, P3 back and turn on the set after AC power on

Y Y
Is SHUT DOWN occured?

N
Is SHUT DOWN occured?

Replace Digital B/D

Replace Data B/D

Go back to Low Voltage Shut Down part again

Connect all cables and set voltage switch to High

Connect all cables and set voltage switch to High

Connect all cables and set voltage switch to High Done

Done

Done

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Trouble Shooting

C) Y-SUS, Scan B/D Shut Down

Check Start

Disconnect P3, P4 of Y-SUS

Turn on the set after AC power on

Is SHUT DOWN occured?

Turn AC power off

Turn AC power off

Replace Scan B/D

Replace Y-SUS B/D

Connect all cables and set voltage switch to High

Connect all cables and set voltage switch to High

Done

Done

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Trouble Shooting

D) High Voltage Shut Down

Check Start

Disconnect P1 of Z-SUS

Turn the set on after AC power on

Y
Is Shut Down occured?

Turn AC power off

Turn AC power off

Disconnect three metal plates between Y-SUS and Scan B/D

Connect P1 of Z-SUS back

Turn the set on after AC power on

Disconnect P5 of Y-SUS and P3 of Z-SUS

Y
Is Shut Down occured?

N
Turn the set on after AC power on

Turn AC power off

Turn AC power off

Y
Is Shut Down occured?

Replace Y-SUS B/D

Replace SCAN B/D

Turn AC power off

Turn AC power off

Connect all cables and assemble the set

Connect all cables and assemble the set

Replace Z-SUS B/D

Replace Data B/D

Done

Done

Connect all cables and assemble the set

Connect all cables and assemble the set

Done

Done

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Trouble Shooting

4. No Key Operation

Check Start

Turn on the Power S/W (AC ON)

N Does LED turn on to red light?

Check the AC connection Check the Power S/W on

Turn on the set using remote control

Dees LED turn on to green light?

Replace the Main B/D

Check the connector of Key PCB

Replace the Key PCB

Check if the Key is working

Replace the Main B/D

Done

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Trouble Shooting
5. No Remote Control Operation

Check Start

Turn on the Power S/W (AC ON)

Does LED turn on to red light?

Check the AC connection Check the Power S/W on

Turn on the set using remote control

Y Dees LED turn on to green light?

Check the other buttons of remote control

Check the battery of remote control

Are all buttons working properly?

Y Done

N N Put the battery Is there battery?

Replace the Main B/D

Try to turn on the set using Key button

Y Dees LED turn on to green light? Replace the LED PCB

Replace the Main B/D

Done

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Trouble Shooting

6. No Key and Remote Control Operation

Check Start

Check the battery of remote control

Replace the LED PCB

Turn the AC Power ON

Try to turn on the set using remote control

Is the remote control working?

Y
Replace the Key PCB

Replace the Main B/D

Done

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Trouble Shooting

7. Weak Discharge or Abnormal Discharge

Check Start

Check the Vs and Va of Power PCB

N Are they normal? Set the values to typical voltages

Y Replace the Y-SUS

Do you still see the weak discharge or abnormal discharge on the screen?

Do you still see the weak discharge or abnormal discharge on the screen?

N Done

Replace the Z-SUS

Do you still see the weak discharge or abnormal discharge on the screen?

Replace the Scan B/D

Done

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Trouble Shooting

8. Not Even Weak Discharge

Check Start

Is Power B/D working? Does it make normal sound?

Replace the Power B/D

Replace Y-SUS, Z-SUS, and Scan B/D

Is the set correctly working?

Done

9. Particular Input Signal (Video, PC, TV, or Component) Does Not Work

Check Start

Is the input Jack correctly connected?

N Connect the input correctly

Is the input TV?

Replace Main and Sub B/Ds

Replace Main B/D

Done

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Trouble Shooting

10. Others
A) Set Is Making Unusual Noise Check the connection of Power PCB and Module. If they are OK, replace the Power PCB and check the symptom again.

B) Occasionally, the set does not operate normally. Turning off and on the AC power make the set to operate normal again Upgrade the software first. If you still see the same symptom, replace the Main and Sub B/D.

C) Images are abnormal Check the default values of service mode and user mode. If they are OK, replace the Main and Sub B/D. If they are not OK, upgrade the

software and check the symptom again.

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12. Assembly List

* Assy of module is listed on the next page.
No. PCB ASS'Y CODE 1 2 3 4 5 6 7 8 9 4851413800 4853293700 4853220100 4854962100 4859004060 4859004460 4859003750 4856815900 4856818800 ASS'Y NAME BACK COVER ASSY BRKT DR BRKT POWER MODULE BUTTON CH CABLE FFC CABLE LVDS CABLE PHONE PLUG CLAMP WIRE CLAMP WIRE CONNECTOR CONNECTOR CONNECTOR CONNECTOR CONNECTOR CONNECTOR CONNECTOR CONNECTOR CONNECTOR CONNECTOR CONNECTOR CONNECTOR CORD POWER AS CTRL BOARD AS DECO SENSOR FILTER EMI FILTER EMI FILTER EMI AS FRAME HORIZENTAL FRAME SUPPORT L AS FRAME SUPPORT R AS GLASS FILTER HEAT SINK ASS'Y DESCRIPTION 21728+26162 ALDCS 8 SECC T1.0 ABS GY 1.0-K-30P-50MM 1001-31FC+1001-31FC+42A1LASB=560 PLUG+CABLE 1365AWG26=150B EGI T0.4+TUBE+PIE 3.2 AKKL-3140-A-RT 12505HS-05+12505TS+ULW=650 12505HS-10+12505HS-10+USW=600 YMH025-06R+YMH025-06R+ULW=200 YMH025-10+YMH025-10R+ULW=300 YMH025-08R+YMH025-08R+ULW=300 YH396-10V+YH396-10V+ULW=700 YH396-08V+YH396-08V+ULW=250 YH396-04V+YH396-04V+ULW=700 25045HP-03+25048HS-03+ULW=150 YH396-04V+YH396-05V+ULW=700 YH396-10V+YH396-09V+ULW=700 12505HS-12+12505HS-12+USW=850 EU LP-33+LS-60=2.0M(LF) Digital BOARD PC ZCAT3035-1330 ZCAT2035-0930A DPP-42A1LASB SECC T1.6 38232+38234 38233+38234 M4203-JW1245 AL ANODIZHG+TAPE

10 4850705N31 11 4850710S22 12 4850706S35 13 4850710S21 14 4850708S16 15 4850710S23 16 4850708S23 17 4850704S63 18 4850703N40 19 4850704N35 20 4850710N24 21 4850712S03 22 48599DM001 23 485AS11290 24 4855553900 25 5PZCAT3035 26 5PZCA2009A 27 PTFEPWG089 28 4853823100 29 4851C02800 30 4851C02900 31 485A102280 32 4957000800

-59-

Assembly List

33 4852090701 34 4850M10410 35 4850M10110 36 PTMPMSG089 37 PTSBMSG089 38 485A106070 39 485A106270 40 48A8310000 41 485A100071 42 485A100571 43 4853633300 44 4853635200 45 48B5353J17 46 485AS11590 47 485AS11690 48 485AS11490 49 485AS11390 50 485AS11090 51 485AS11190

MASK FRONT MODULE PDP MODULE POWER PCB MAIN MANUAL AS PCB SUB MANUAL AS SHIELDRON SHIELDRON SPEAKER SYSTEM TAPE EMI TAPE EMI TERMINAL COVER TERMINAL PLATE TRANSMITTER REMOCON X-LEFT BOARD AS X-RIGHT BOARD AS Y-DRV BTM BOARD AS Y-DRV TOP BOARD AS Y-SUS BOARD AS Z-SUS BOARD AS

ABS GY PDP42V7 1H217WA DPP-42A1LASB DPP-42A1LASB (5 AND 3)X85X1T(ANGLE) 41X53X18T SS-63A01 CU+NI T0.13 VER1 CU+NI 30X42XT0.2 A5052 T1.0 A5052 T1.0 R-53J17 (AAA) Data LEFT BOARD Data RIGHT BOARD Scan BTM BOARD Scan TOP BOARD Y-SUS BOARD Z-SUS BOARD

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13. STRUCTURE OF PDP SET

-61-

STRUCTURE OF PDP SET

COMPONENT

PICTURE

REMARK

1). PDP MODULE (With F/SUPPORT)

1a). Y-SUS B/D

1b). Z-SUS B/D

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STRUCTURE OF PDP SET

COMPONENTS 1d) Data Relay PKG(L)

PICTURE

REMARK

1e) Data Relay PKG(R)

1f) Scan Relay PKG-T

1g) Scan Relay PKG-B

-63-

STRUCTURE OF PDP SET

COMPONENT

PICTURE

REMARK

1h) Digital PKG

2) MAIN BOARD

3) SUB BOARD

4) POWER BOARD

-64-

STRUCTURE OF PDP SET

COMPONENTS 5) FRONT MASK

PICTURE

REMARK

6) FILTER GLASS

7) BACK COVER

-65-

66

DAEWOO ELECTRONICS CORP.

686, AHYEON-DONG, MAPO-GU, SEOUL, KOREA. C.P.O. BOX 8003 SEOUL KOREA

PRINTED DATE : Nov. 2005

MODEL : PDP42V7####
CAUTION
1. BEFORE SERVICING THE PDP MODULE, READ THE SAFETY PRECAUTIONS IN THIS MANUAL. 2. WHEN REPLACEMENT PARTS ARE REQUIRED, BE SURE TO USE REPLACEMENT PARTS SPECIFIED BY THE MANUFACTURER.

English

PDP MODULE SERVICE MANUAL

[PDP42V7#### Module]
CONTENTS
. . . . Safety Precautions/Technical Feature Formation and Specification of Module Adjustment Trouble Shooting
1. Checking for No Picture 2. Hitch Diagnosis Following Display Condition
2-1. All or 1/2 of the screen doesnt be shown 2-2. Screen doesnt be shown as Data TCP 2-3. It is generated unusual pattern of Data TCP IC unit 2-4. Regular Stripe is generated about the quantity of one Data TCP IC or more 2-5. Screen doesnt be shown at all as Scan FPC 2-6. Regular stripe is generated at regular internal on the whole screen 2-7. Data copy is generated to stripe direction 2-8. One or more stripe is generated on the screen 2-9. One or more horizontal line is generated on screen 2-10. Lightness of screen is wholly darken though there is input-signal-pattern 2-11. Different color is shown partially during full-white-screen or electric discharge is generated during full-black-screen 2-12. Some lightness of some color doesnt not generated well

3. Checking for component damage

3-1. Y IPM(IC15) or Z IPM(IC2) damage 3-2. Pass Top FET(Y B/D: HS2) damage 3-3. FET Assy(Y B/D: HS1) damage 3-4. SCAN IC(Y DRV B/D: IC1~8) damage 3-5. TCP damage 3-6. Crystal(CTRL B/D: X1) damage

4. Shift breakdown component compatibility consideration

4-1. Scan IC follows in application, compatibility of Y DRV Top, Bottom B/D

. Block Diagram . Safety Components List . Records of Revision for Boards, Components and ROM DATA * Annexing : Schematic Diagram

- 2 -

. Safety Precautions/Technical Feature

1. Safety Precautions
When servicing of PDP Module, it should be not enforced into another way aside next rule, or a unaccustomed person should not repairing. When using/handling this PDP Module, pay attention to the below warning and cautions. (9) If the power cable is damaged, or if the connector is loose, do not use the product: otherwise, this can lead to fire or electric shock. (10) If the power connector or the connector of the power cable becomes dirty or dusty, wipe it with a dry cloth. Otherwise, this can lead to fire. (11) PDP Module uses a high voltage (Max.450V dc). Keep the cautions concerning electric shock and do not touch the Device circuitry when handling the PDP Unit. And because the capacitor of the Device circuitry may remain charged at the moment of Power OFF, standing by for 1 minute is required in order to touch the Device circuitry.

Warning
Indicates a hazard that may lead to death or injury if the warning is ignored and the product is handled incorrectly.

Indicates a hazard that can lead to injury or damage to property if the caution is ignored and the product is handled incorrectly.

2) CAUTIONS
(1) Do not place this product in a location that is subject to heavy vibration, or on an unstable surface such as an inclined surface. The product may fall off or fall over, causing injuries. (2) Before disconnecting cable from the product, be sure to turn off the power. Be sure to hold the connector when disconnecting cables. Pulling a cable with excessive force may cause the core of the cable to be exposed or break the cable, and this can lead to fire or electric shock. (3) This product should be moved by two or more persons. If one person attempts to carry this product alone, he/she may be injured. (4) This product contains glass. The glass may break, causing injuries, if shock, vibration, heat, or distortion is applied to the product. (5) The temperature of the glass of the display may rise to 80C or more depending on the conditions of use. If you touch the glass inadvertently, you may be burned. (6) If glass surface of the display breaks or is scratched, do not touch the broken pieces or the scratches with bare hands. You may be injured. (7) PDP Module requires to be handled with care not to be touched with metal or hard materials, and must not be stressed by heat or mechanical impact. (8) There are some exposed components on the rear panel of this product. Touching these components may cause an electric shock. (9) When moving the product, be sure to turn off the power and disconnect all the cables. While moving the product, watch your step. The product may be dropped or all, leading to injuries of electric shock.

1) WARNING
(1) Do not touch Signal and Power Connnector while this product operates. Do not touch EMI ground part and Heat Sink of Film Filter. (2) Do not supply a voltage higher than that specified to this product. This may damage the product and may cause a fire. (3) Do not use this product in locations where the humidity is extremely high, where it may be splashed with water, or where flammable materials surround it. Do not install or use the product in a location that does no satisfy the specified environmental conditions. This may damage the product and may cause a fire. (4) If a foreign substance (such as water, metal, or liquid) gets inside the product, immediately turn off the power. Continuing to use the product, it is may cause fire or electric shock. (5) If the product emits smoke, and abnormal smell, or makes an abnormal sound, immediately turn off the power. Continuing to use the product, it may cause fire or electric shock. (6) Do not disconnect or connect the connector while power to the product is on. It takes some time for the voltage to drop to a sufficiently low level after the power has been turned off. Confirm that the voltage has dropped to a safe level before disconnecting or connecting the connector. (7) Do not pull out or insert the power cable from/to an outlet with wet hands. It may cause electric shock. (8) Do not damage or modify the power cable. It may cause fire or electric shock.

- 3 -

English

Caution

(10) In order to protect static electricity due to C-MOS circuitry of the Drive part, wear a wrist band to protect static electricity when handling. (11) If cleaning the Panel, wipe it with a soft cloth moistened with water or a neutral detergent and squeezed, being careful not to touch the connector part of the Panel. And dont use chemical materials like thinner or benzene. (12) If this product is used as a display board to display a static image, image sticking occurs. This means that the luminance of areas of the display that remain lit for a long time drops compared with luminance of areas that are lit for a shorter time, causing uneven luminance across the display. The degree to which this occurs is in proportion to the luminance at which the display is used. To prevent this phenomenon, therefore, avoid static images as much as possible and design your system so that it is used at a low luminance, by reducing signal level difference between bright area and less bright area through signal processing. (13) Because PDP Module emits heat from the Glass Panel part and the Drive circuitry, the environmental temperature must not be over 40C. The temperature of the Glass Panel part is especially high owing to heat from internal Drive circuitry. And because the PDP Module is driven by high voltage, it must avoid conductive materials. (14) If inserting components or circuit board in order to repair, be sure to fix a lead line to the connector before soldering. (15) If inserting high-power resistor(metal-oxide film resistor or metal film resistor) in order to repair, insert it as 10mm away as from a board. (16) During repairs, high voltage or high temperature components must be put away from a lead line. (17) This is a Cold Chassis but you had better use a cold transformer for safety during repairs. If repairing electricity source part, you must use the cold transformer. (18) Do not place an object on the glass surface of the display. The glass may break or be scratched. (19) This product may be damaged if it is subject to excessive stresses (such as excessive voltage, current, or temperature). The absolute maximum ratings specify the limits of these stresses. (20) The recommended operating conditions are conditions in which the normal operation of this product is guaranteed. All the rated values of the electrical specifications are guaranteed within these conditions. Always use the product within the range of the recommended operating conditions. Otherwise, the reliability of the product may be degraded.

(21) This product has a glass display surface. Design your system so that excessive shock and load are not applied to the glass. Exercise care that the vent at the corner of the glass panel is not damaged. If the glass panel or vent is damaged, the product is inoperable. (22) Do not cover or wrap the product with a cloth or other covering while power is supplied to the product. (23) Before turning on power to the product, check the wiring of the product and confirm that the supply voltage is within the rated voltage range. If the wiring is wrong or if a voltage outside the rated range is applied, the product may malfunction or be damaged. (24) Do not store this product in a location where temperature and humidity are high. This may cause the product to malfunction. Because this product uses a discharge phenomenon, it may take time to light (operation may be delayed) when the product is used after it has been stored for a long time. In this case, it is recommended to light all cells for about 2 hours (aging). (25) This product is made from various materials such as glass, metal, and plastic. When discarding it, be sure to contact a professional waste disposal operator. (26) If faults occur due to arbitrary modification or disassembly, LG Electronics is not responsible for function, quality or other items. (27) Use of the product with a combination of parameters, conditions, or logic not specified in the specifications of this product is not guaranteed. If intending to use the product in such a way, be sure to consult LGE in advance. (28) Within the warranty period, general faults that occur due to defects in components such as ICs will be rectified by LGE without charge. However, IMAGE STICKING due to misapplying the above (12) provision is not included in the warranty. Repairs due to the other faults may be charged for depending on responsibility for the faults. (29) In assembling Module into SET, in case Film Filter and as a protective film is bared, static electricity of exfoliated protective film which is bared from beginning X-Board down ward getting TCP to no getting TCP should not influence on TCP. Also Filter after protective film is bared or in the storage can be charged with electricity, so the EMI ground part of Film Filter should be used after Grounding.

- 4 -

2. Technical Feature
PDP Module is a display device to be divided into a Panel part and a Drive part. The Panel part consists of Electrodes, Phosphor, various dielectrics and gas, and the Drive part includes electronic circuitry and PCB. PDP42V7#### model produced in the LG electronic is 42inches color Plasma display module of WVGA(852(H)x480(V)), and it is a display device giving concrete to bright image by using AC Plasma technology of LG electronic.

1) General Specification
(1) Model Name (2) Number of Pixel (3) Pixel Pitch (4) Cell Pitch (5) Display area (6) Outline dimension (7) Color arrangement (8) Number of COLRO (9) Weight (10) Aspect Ratio (11) Peak Brightness (12) Contrast Ratio (13) POWER CONSUMPTION (14) Lifetime : : : : : : : : : : : : : : PDP42V7#### 852(H) x 480(V) (1pixel=3 RGB cells) 1080 m(H) x 1080 m(V) 320 m(H) x 1080 m(V) (Base: Green Cell) 920.1(H) x 518.4(V)0.5mm 1005(H) x 597(V)x 60.6(D)1mm RGB Closed type (R)1024 x (G)1024 x (B)1024 14.7Kg0.5Kg 100Kg5Kg(5EA/1BOX) 16:9 Typical 1500dc/(1/10 White Window) Avergae 100:1(Light room 100 Lx at center) Typical 10000:1(Dark room 1/10 White Window) (White Window Pattern at Center) : Typical 200 W(Full White) * Note 1) : Over 60,000 Hrs (Initial brightness 1/2)

2) Block Diagram
LVDS Input

Controller Signal

Mentioned voltage follows a standard of each Board input voltage Full White standard

* Note 1) It can be changed maximum 300W according to input image.

- 5 -

English

. Formation and Specification of Module

No 1 2 3 4 No

Connector P1[Z SUS B/D] P5[Y SUS B/D] P6[Y SUS B/D] P9[CTRL B/D] Part No. 6871QCH053A 1 6871QCH073A 6871QCH053B 6871QCH053C 2 3 6871QDH084A 6871QDH105A 6871QDH085A 6871QDH106A 6871QRH055A 4 6871QRH055B 6871QRH066A 6871QLH047A 5 6871QLH047B 6871QLH056A 6871QYH036A 6 6871QYH036B 6871QYH050A 7 6871QZH041A 6871QZH052A

Input Voltage & Signal 5V, Va, Vs Vs 5V Control Signal Description PWB(PCB) ASSY PWB(PCB) ASSY PWB(PCB) ASSY PWB(PCB) ASSY PWB(PCB) ASSY PWB(PCB) ASSY PWB(PCB) ASSY PWB(PCB) ASSY PWB(PCB) ASSY PWB(PCB) ASSY PWB(PCB) ASSY PWB(PCB) ASSY PWB(PCB) ASSY PWB(PCB) ASSY PWB(PCB) ASSY PWB(PCB) ASSY PWB(PCB) ASSY PWB(PCB) ASSY PWB(PCB) ASSY LVDS CTRL B/D ASSY HITACHI COPPER LVDS CTRL B/D ASSY LVDS OUTER SIDE CTRL B/D ASSY PB-FREE FFC & CON LVDS OUTER SIDE CTRL B/D ASSY YDRV TOP B/D ASSY HITACHI COPPER YDRV TOP B/D ASSY YDRV BTM B/D ASSY HITACHI COPPER YDRV BTM B/D ASSY XR B/D ASSY PB-FREE FFC & CON XR B/D ASSY HITACHI COPPER XR B/D ASSY XL B/D ASSY PB-FREE FFC & CON XL B/D ASSY HITACHI COPPER XL B/D ASSY YSUS B/D ASSY PB-FREE FFC & CON YSUS B/D ASSY HITACHI COPPER YSUS B/D ASSY ZSUS B/D ASSY HITACHI COPPER ZSUS B/D ASSY

The composition and specification of Initial production module Revision information refers to Revision for Boards, Components and ROM DATA

- 6 -

. Adjustment
1. Application Object
This standard is applied to the PDP42V7#### PDP Module which is manufactured by the manufacturing team of PDP promotion department or elsewhere.

3-2. Connection diagram of measuring instrument and setting up the initial voltage
(1) For connection diagram of measuring instrument, refer to Fig. 1.(Connection diagram of measuring instrument that adjusting the voltage wave form) (2) Setting up the initial voltage(Voltage Label) Vcc: 5V, Va: 65V, Vs: 187V But, Initially setting up voltage can be changed by the set up range according to the Modules characteristic.

2. Notes
(1) Without any special specification, the Module should be at the condition of preliminaries more than 10minutes before adjusting. - Service signal : 100% Full White signal - Service DC voltage : Vcc: 5V, Va: 65V, Vs: 187V - DC/DC Pack voltage : Vsc=115V -Vy: -85V - Preliminaries environment : Temp (25 ! 5C), Relative humidity (65!10%) (2) Module should get the Aging for the equilibrium after finish the assembling. Aging condition is shown below. - Service signal: 100% Full White, Red, Green, Blue pattern signal(Service time of each pattern : within 5minutes/cycle) - Service DC voltage : Match the voltage with the set up voltage in the first adjustment. - Aging time : More than 30 minutes - Aging environment : Temp (25!2C), Relative humidityLess than 65% (3) Module adjustment should be followed by below sequence. - Setting up the Vsc/-Vy voltage(Vsc=115V, -Vy=-85V) - Adjusting the voltage wave form(Refer to adjustment) - 25!5C, 65!10% (4) Without any special specification, you should adjust the Module in the environment of Temp (25!5C) and Relative humidity (65!10%) Caution) If you let the still image more than 10 minutes(especially The Digital pattern or Cross Hatch Pattern which has clear gradation), after image can be presented in the black level part of screen.

3-3. How to Adjust

(1) Adjusting Vset-up Voltage Wave form
Connect the measuring instrument to be (Fig. 1). Turn on the measuring instrument with Caution of (Fig. 1). Connect the oscilloscope probe to B39(Bead) of Y B/D bottom and GND. Turn the VR1 of Y B/D and make the A waveform Fig. 2 to be 10!2s.

(2) Adjusting Vset-down Voltage Wave form

Turn the VR2 of YSUS B/D and make the B waveform Fig. 2 to be 100!2s.

3. Adjustment after Assembling

3-1. Using Tools
(1) Digital oscilloscope : More than 200MHz (2) DVM(Digital Multimeter) : Fluke 87 or similar one (3) Signal generator : VG-825 or similar one (4) DC power supply or PSU - DC power supply for Vs (1) : Should be changeable between 0V to 200V/ more than 10A - DC power supply for Va (1) : Should be changeable between 0V to 100V/ more than 5A - DC power supply for 5V (1) :Should be changeable between 0V to 10V/ more than 10A - DC-DC Converter Jig (1) : The Jig which has equivalent voltage output of PDP42V7#### Module after taking the Vs, Va, 5V voltage - Voltage stability of power supply : Within !1% for Vs/Va, within !3% for 5V (Fig. 2) Y, Z set-up Waveform

(3) Checking the DC/DC pack voltage

Convert the signal of signal generator to the 100% Full White signal. Connect the GND terminal of DVM to the right leg of R53 on the Y B/D and set the Plus terminal to the left leg of R53 to check the Vsc voltage(115!1V) and when there is abnormality in voltage turn the variable resistor(VR3) of DC/DC Pack(Vsc) PS1 on Y B/D to adjust. Connect the GND terminal of DVM to the right leg of R78 on the Y B/D and set the Plus terminal to the left leg of R78 to check the -Vy voltage(-85!1V) and when there is abnormality in voltage turn the variable resistor(VR4) of DC/DC Pack(-Vy) PS1 on Y B/D to adjust.

- 7 -

English

DC Power Supply for 5V

DC Power Supply for Va Power Signal Generator(VG-825)

DC Power Supply for Vs

<Caution> (1) The power of the signal generator should be turned on before turning on the power of DC power supply. (2) The voltage of DC power supply , in standard of Module input voltage, should be preset as below. Vcc: 5V, Va: 65V, Vs: 187V (3) The power of power supply must turned on by this sequence. Reverse direction When turning off. * Module on : 5V ( Va ( Vs, Module off: Vs ( Va ( 5V (4) Signal generator should be selected with 852)480(WVGA) mode. Also the PSU(Power Supply Unit) use is possible (Fig. 1) Connection diagram of measuring instrument

- 8 -

. Trouble Shooting
1. Checking for no Picture
A screen doesnt display at all and condition of black pattern or power off. (1) Check whether the CTRL B/D LED(D1, D2, D3, D4, D5) is turned on or not. (2) Check the power and signal cable of CTRL B/D. (3) X B/D, Y B/D, Z B/D is well plugged in. (4) Check the connection of X B/D, Y B/D and Z B/D to CTRL B/D. (5) Measure the output wave of X, Y, Z B/D with oscilloscope(more than 200MHz) and find the trouble of B/D by comparing the output wave with below figure. - Measure Point fo Y B/D : Bead B39 - Measure Point fo Z B/D : Bead B28 - Measure Point fo X B/D : P3 (6) Check the SCAN(Y side) IC (7) Check the DATA(X side) TCP IC (8) Replace the CTRL B/D. (9) Check the Fuse of Y, Z B/D is open and replace when open. (10) Check the input voltage. (Vcc=5V/Va=65V/Vs=187V)

Y B/D Output wave (1frame)

Z B/D Output wave (1frame)

- 9 -

English

Y B/D Output wave(1SF)

Z B/D Output wave(1SF)

X B/D Output wave(1frame): Va measurement

- 10 -

2. Hitch Diagnosis Following Display Condition

2-1. All or 1/2 of the screen doesnt be shown
(1) In case of all of the screen doesnt be shown, Confirm the 8pin connection of X B/D to Z B/D is well plugged in which is correspond (2) In case of 1/2 of the screen doesnt be shown XR B/D - Confirm the 60pin connection of CTRL B/D to XR B/D is well plugged in which is correspond XL B/D - Confirm the 5pin connection of XR B/D to XL B/D is well plugged in which is correspond - Confirm the 60pin connection of CTRL B/D to XL B/D is well plugged in which is correspond (3) Replace relevant X B/D.

2-2. The screen doesnt be shown as Data TCP

(Include not be shown part of DataTCP quantity or a part) (1) The problem between Data TCP and X B/D is more possible that the screen is not be shown as data TCP. (2) Confirm the connector of Data TCP is well connected to X B/D. Correspond to the part that screen is not showing (3) Confirm whether the Data TCP is failed. (Inclusion examination with the naked eye(IC Burnt and others) IC is Fail: Replace the Module In case of shorting the X B/D by foreign or PCB pattern is open: When TCP IC is not Fail, replace the X B/D.

[ Example of the screen display form

(Anything of the 14 Data TCP can be shown beside below pictures)

[ Relationship between screen and X B/D

Screen X B/D Left of the Screen 1/2 <--> Right X B/D Right of the Screen 1/2 <--> Left X B/D

: All : Partial : not at all

[ Screen Display Form

[ How to examine Data TCP IC

Left of the Screen(1/2) Display Not display Right of the Screen(1/2)

[ 1/4 of the screen doesnt be shown

Equality with 2-1

Change (Va Power) into CATHOD, (GND) into ANODE and then examine the Diode to the forward or reverse direction. Burnt of (IC) and others examine with the naked eye.

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2-3. It Generates Unusual Pattern of Data TCP IC unit

(1) In case of generating unusual pattern of Data TCP IC unit as below picture, there is problem in the Signal(CLK, data, STB) or connector that is input into Data TCP IC (2) In case of <case 1> - Confirm the connection of Data TCP connector and IC Fail. - Replace the relevant X B/D. (3) In case of <case 2>, <case 3> - Confirm the connection of Data TCP connector and connector that is connected from CTRL to X B/D. - Check the foreign on the CTRL B/D and X B/D. - Replace the relevant X B/D or CTRL B/D. (4) In case of <case 4>, <case 5> - Confirm the connector that is connected from CTRL to X B/D - Replace relevant X B/D or CTRL B/D - Confirm the connection of Z B/D and XR B/D(8pin), XR B/D and XL B/D(5pin) power connector.

2-4. Regular Stripe is Generated about the Quantity of one Data TCP IC or more
(1) In case of generating regular stripe about the quantity of one Data TCP IC or more, check the connection of connector or foreign. (2) Confirm the connection connector/foreign of XB/D or CTRL B/D to X B/D correspond to unusual screen. (3) Replace relevant XB/D or CTRL B/D.

[ Screen Display Form

It comes out partial field about the quantity of one IC or more or It may come out together at other field of screen.

[ Screen Display Form

<Case 1> Unusual screen comes out about one TCP IC quantity or more

<Case 2>

Unusual screen comes out about 1/2 of screen or equal distances of all screen

<Case 3>

Unusual screen comes out about 4/14 quantity of screen or 3/14

<Case 4>

Unusual screen comes out about 1/2 quantity of screen

<Case 5>

Unusual screen comes out about all screen

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2-5. The screen display has a problem for Scan FPC.

(1) Its may be a problem between Scan FPC and Y DRV B/D. (2) Check the connection of Y DRV B/D and Scan FPC. (3) If the Scan IC is failed, replace the Y DRV B/D.

2-6. The screen has a vertical line with regular gap. (A vertical stripe flash at especial color)
(1) This is a problem about CTRL B/D. (2) Replace the CTRL B/D.

[ Screen Display Form

one eighth of screen

[ Screen Display Form

The screen display is very good The screen display is poor

The screen has a vertical line with regular gap

[ Check a method of SCAN IC

2-7. A data copy is happened into vertical direction

(1) In this case, its due to incorrect marking of scan wave. (2) Replace the Y DRV B/D or Y B/D.

[ Screen Display Form

Change the Vpp Pin into ANODE and GND Pin into CATHOD and then test the Diode with forward or reverse direction.

<Display Pattern>

<Case 1 : Entire Copy>

<Case 2 : Top Copy> <Case 3 : Bottom Copy> <Case 4 : Entire Copy>

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2-8. The screen has one or several vertical line

(1) In this case, It isnt a problem about CTRL B/D or X B/D. (2) It may cause followings. - Its out of order a panel - Open or short of DATA TCP FPC attached panel - Its out of order a DATA TCP attached panel (3) Replace Module.

2-11. The screen displays other color partially on full white screen or happens discharge partially on full black screen.
(1) Check the declination of Y B/D set up, set down wave. (2) Measure each output wave with oscilloscope(more than 200MHz) and compare the data with below figure data. Adjust the Y B/D Set_up(A) and Set_down(B) declination by changing VR1 and VR2 as same writing on the adjustment label. - Measuring Point of Y B/D : B39

[ Screen Display Form

It may show several vertical lines in a quarter or other division part of screen including left case.

2- 9. The screen has one or several horizontal line

(1) In this case, it isnt a problem about CTRL B/D or Y B/D. (2) It may cause followings. - Its out of order a panel - Open or short of SCAN FPC attached panel - Its out of order a SCAN IC attached panel (3) Replace Y DRV B/D

Y Output Voltage Wave form

2-12. It doesnt display a specified brightness at specified color

(1) Check the connector of CTRL B/D input signal. (2) Replace the CTRL B/D.

[ Screen Display Form

It may show several horizontal lines including left case.

2-10. The screen displays input signal pattern but the brightness is dark
(1) In this case, Z B/D operation isnt complete. (2) Check the power cord of Z B/D. (3) Check the connector of Z B/D and CTRL B/D. (4) Replace the CTRL B/D or Z B/D.

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3. Checking for Component Damage

3-1. Y IPM(IC 15) or Z IPM(IC 2) Damage
(1) When the internal Sustain_IGBT or ER_FET of Y IPM(IC 15) or Z IPM(IC 2) is damaged, VS FUSE is open and screen doesnt be shown. O Test Point: B32~GND(Y B/D), B28~GND(Z B/D) O Wave format: B32(Y B/D) or B28(Z B/D) has no output wave.

3-3. FET Assy(Y B/D: HS1) Damage

(1) When Set_Up FET is damaged, screen doesnt be shown O Test Point: Enlarge the after measuring GND~B32(Y B/D) O Wave format: Set_up waveform does not come out.

Set_up waveform does not come out

<When the Set_Up FET is damaged>

<IPM Normal Output Wave>

O

(2) When Set_Down FET is damaged, electric discharge of entire screen is generated. O Test Point: Enlarge the after measuring GND~B32(Y B/D) O Wave format: Set_down waveform does not come out.

Measurance position: Sustain section enlarge the after measuring B32 wave of Y B/D and B28 wave of Z B/D. (Full White Pattern)

3-2. Pass Top FET(Y B/D: HS2) Damage

(1) When Pass Top FET is damaged, electric discharge of entire screen is generated. O Test Point: Enlarge the after measuring GND~B32(Y B/D) O Wave format: When the Set_dn does not descend until -Vy.

Set_down waveform does not come out

<When the Set_Down FET is damaged>

It does not descend until -Vy

<Reset section normal output wave> <When the Pass Top FET is damaged>
O

Measurance position: Reset section enlargement wave of B32(Y B/D) (Full White Pattern)

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3-4. SCAN IC(Y DRV B/D: IC1~8) Damage

(1) In case of SCAN IC poor, one horizontal line may open at screen. O Test Point: ICT measurance of GND~Y DRV B/D output O Wave format: As shown below figure.

(4) In case of shorting the SCAN IC output by a dust, foreign substance, it may overlap two horizontal lines on screen. O Test Point: ICT measurance of GND~Y DRV B/D output O Wave format: As shown below figure.

<When SCAN IC output is short> <When SCAN IC is poor> (2) Screen may not shown when SCAN IC is damaged by SCAN IC poor, external electricity or spark. O Test Point: ICT measurance of GND~Y DRV B/D output O Wave format: Output wave format isnt output (You can see the damage for Y DRV B/D Top or Bottoms SCAN IC)
Section

(3) Screen shaked horizontally when Y DRV B/D Top and Bottom cable is poor O Test Point: ICT measurance of GND~Y DRV B/D output O Wave format: As shown below figure.

<When Y DRV B/D Top and Bottom cable is poor>

<SCAN IC Normal Output Wave > Measurance position: SCAN section enlarge the after measuring output ICT of Y DRV B/D. (Full White Pattern)

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3-5. TCP Damage

(1) In case of shorting or opening the IC output of TCP, it may show one or several vertical lines. O Test Point: Enlarge the after measuring output TP of GND~TCP O Wave format: As shown output below figure. In case of normal wave output, when STB signal is generated, maintain High output. And when STB signal is generated again must be fall Low. But when IC of TCP is poor, STB signal is not generated Output falls with Low.

3-6. Crystal(CTRL B/D: X1) Damage

(1) When Crystal is damage, the screen doesnt be shown. O Test Point: Measuring 3pin of GND~Crystal(CTRL B/D: X1) O Wave format: Output wave doesnt come out

(2) In case of unusual launch of the Crystal, it may blink the screen. O Wave format: As shown below figure

<When IC output of COF is poor> (2) In case of being damage IC of TCP or power resistance, the screen doesnt be shown or happens discharge partially. O Test Point: Enlarge the after measuring output TP of GND~TCP O Wave format: Output wave doesnt come out

<When Crystal is poor>

<Crystal Normal Output Wave >

Measurance position: Measuring output 3pin of Crystal(X1: 100MHz) on CTRL B/D (Full White Pattern)

<TCP Normal Output Wave >

O

Measurance position: Enlarge the after measuring output TP of TCP (Full White Pattern)

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4. Shift breakdown component compatibility consideration

4-1. Scan IC follows in application, compatibility of Y DRV Top, Bottom B/D
(1) When B/D applicated FD3284F is breakdown, you must mutually only replace Top B/D and Bottom B/D applicated FD3284F. (2) When IC of B/D applicated FD3284F IC is breakdown, you must only replace FD3284F IC. Different IC application being not right B/D applicated FD3284F TOP: 6871QDH084A BTM: 6871QDH085A Only use B/D applicated FD3284F TOP: 6871QDH084A BTM: 6871QDH085A

When B/D is breakdown

B/D applicated FD3284F TOP: 6871QDH084A BTM: 6871QDH085A

When IC is breakdown

Only use FD3284F IC IC: 0ILNRFE001A

[ When replacing the IC, notice To prevent dust, fix the same IC after removing the silicon and then it again stick the IC. Silicon Part No.: 7254Q00002A(Tube Type) 7254Q00002B(Can Type)

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. Block Diagram

DC Power Supply for 5V

DC Power Supply for Va

DC Power Supply for Vs

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. Safety Components List

(1) The safety components list of PDP42V7#### Model is as below. (2) A component of necessary used. (3)
S S

mark is important to keep products security. Therefore in exchanging a component, appointed component is

is an abbreviated word which is instead of <Safety>mark.

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. Records of Revision for Boards, components and ROM DATA

1. Boards
No. 1 2 3 4 Date 2005.03.04 2005.03.04 2005.03.04 2005.03.04 Board LVDS CTRL B/D ASSY HITACHI COPPER LVDS CTRL B/D ASSY LVDS OUTER SIDE CTRL B/D ASSY PB-FREE FFC & CON LVDS OUTER SIDE CTRL B/D ASSY 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 2005.03.04 2005.03.04 2005.03.04 2005.03.04 2005.03.04 2005.03.04 2005.03.04 2005.03.04 2005.03.04 2005.03.04 2005.03.04 2005.03.04 2005.03.04 2005.03.04 2005.03.04 YDRV TOP B/D ASSY HITACHI COPPER YDRV TOP B/D ASSY YDRV BTM B/D ASSY HITACHI COPPER YDRV BTM B/D ASSY XR B/D ASSY PB-FREE FFC & CON XR B/D ASSY HITACHI COPPER XR B/D ASSY XL B/D ASSY PB-FREE FFC & CON XL B/D ASSY HITACHI COPPER XL B/D ASSY YSUS B/D ASSY PB-FREE FFC & CON YSUS B/D ASSY HITACHI COPPER YSUS B/D ASSY ZSUS B/D ASSY HITACHI COPPER ZSUS B/D ASSY 6871QDH084A 6871QDH105A 6871QDH085A 6871QDH106A 6871QRH055A 6871QRH055B 6871QRH066A 6871QLH047A 6871QLH047B 6871QLH056A 6871QYH036A 6871QYH036B 6871QYH050A 6871QZH041A 6871QZH052A Initial Product Initial Product Initial Product Initial Product Initial Product Initial Product Initial Product Initial Product Initial Product Initial Product Initial Product Initial Product Initial Product Initial Product Initial Product Part Number 6871QCH053A 6871QCH073A 6871QCH053B 6871QCH053C Note Initial Product Initial Product Initial Product Initial Product

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2. COMPONENTS
No. 1 2 3 4 5 Date 2005.03.04 2005.03.04 2005.03.04 2005.03.04 2005.03.04 COMPONENT Y IPM(YSUS B/D: IC15) Z IPM(ZSUS B/D: IC2) SCAN IC(YDRV B/D: IC1~8) TCP FET(Y B/D: HS1) Part Number 4921QP1031A 4921QP1031A 0ILNRFE001A 0ILNRD1002A 4921QF2007A Remark Initial Product Initial Product Initial Product Initial Product Initial Product (Set_up/Set_dn FET Ass y)

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3. ROM DATA
No. 1 2 Date 2005.03.04 2005.03.04 ROM Data Version 42V73DN03 42V73LV03 Contents Inner Type LVDS Initial ROM Data External Type LVDS Initial ROM Data

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3828VD0143R

March, 2005 Printed in Korea