Black Box IC515C Service Manual Page 1

Training ManualCourse: TVP-14Projection TelevisionTroubleshootingPractical Troubleshooting TipsRA-3/3A, RA-4/4A, RA-5A, RA-6 ChassisKDP-57XBR2

73. RA-3/3A Power Supply TroubleshootingOnce C620 has charged, the upper transistor will lose its large B-E current and turn off. The impedance of th

9724. RA-6 Deflection Circuit TroubleshootingIC8005H DRIVECTL23614T8003HOT14321H OUTH RET142135H OUTH RET14H OUTH RET14T8002HDTQ8020Q8016Q8004Q8030Q80

9824. RA-6 Deflection Circuit TroubleshootingV DEFV RETV DEFV RETV DEFV RET-15V+15VR8047L8003D8004C8015CN8006-3VDRV+CN8006-5VDRV-R8147R8041R8032R8018R

9925. RA-6 High Voltage Circuit TroubleshootingChapter 25 - RA-6 High Voltage Circuit TroubleshootingFIGURE 25-1 - HIGH VOLTAGE STAGE - RA-6 CHASSIST8

10025. RA-6 High Voltage Circuit TroubleshootingTroubleshootingHigh voltage circuit failures generally fall into four categories: No HV, low HV, exces

10125. RA-6 High Voltage Circuit TroubleshootingHigh Voltage Shutdown: Verification of an over-voltage or over-current condition must be checked firs

10225. RA-6 High Voltage Circuit Troubleshooting567+-321+-567+-321+-D8014MTZJ-5.18D8013MTZJ-5.18RV8002R8102R8223R8153FBTABLD8038R8099R8139+15VFBTABLR8

10326. RA-6 Video Circuit TroubleshootingChapter 26 - RA-6 Video Circuit TroubleshootingGeneral DescriptionThe video process circuitry in the RA-6 cha

10426. RA-6 Video Circuit TroubleshootingIC004A/VSWITCHIC63DCOMBIC20072DCOMBIC303YCTMAINIC305YUVSWITCHIC301YCTSUBIC306COMP.SW.IC3408MIDIC3410D/AIC3414

10526. RA-6 Video Circuit TroubleshootingVideo failures fall into three main categories:1. No video2. Distorted video3. Improper levelAlthough the vid

10626. RA-6 Video Circuit TroubleshootingIC2004AV SW.CXA2069Q8MAINRFCV INMAINY/CVOUT44CV : 1V p-pTU2MAINTUNER63CV : 1V p-pTU2SUBTUNERSUBRFCV INRF CH

83. RA-3/3A Power Supply TroubleshootingC622C624R61923145654 3 1522A BOARD78R654C662T604 PRTD666D603C602R610R611C620IC601MXO841AB-FC612N21RY60112VSTBY

10726. RA-6 Video Circuit Troubleshooting8483 48YC37,38,3933343522,23,24Y PBPRY PBPRCXA2103-1SCON,SCOL,SHUE(ADJUST RF,VIDEO,& DVDIC303YCT-MAINCXA2

10826. RA-6 Video Circuit TroubleshootingIC3303D.R.C.CXD29095QY : 8 BIT C : 8 BITYPB PR 8 BITINPUT SIGNAL 480i ONLY164-171 122-154174-181635031YPBPR6-

10927. Troubleshooting the AKB CircuitsChapter 27 - Troubleshooting the AKB CircuitsOverviewThe AKB (Automatic Cathode Bias) circuit, often referred t

11027. Troubleshooting the AKB Circuits7131D7361FROMFOCUSBLOCKC732R732G2SG731Q733R741R742L731R736R739+200VD732C735CN731FROMA BD.CN204R736C734R737R746Q

11127. Troubleshooting the AKB CircuitsIf you could actually “see” the IK pulses, troubleshooting would be a snap. If the service mode is entered on

11227. Troubleshooting the AKB CircuitsCRT elements, improper G2 cutoff or intermittent components, or connections on the IK return line (rare). Veri

11328. Auto Registration TroubleshootingChapter 28 - Auto Registration TroubleshootingOverviewThe RA-4 projection television chassis was the first to

11428. Auto Registration Troubleshootingverified with a calibrated external source, the internal crosshatch can be centered by changing and saving the

11528. Auto Registration TroubleshootingFIGURE 28-1 - SENSOR LOCATION AND NUMBER01 23Fortunately, the RA-5A and RA-6 chassis have included a new set o

11628. Auto Registration TroubleshootingFIGURE 28-2 - CONVERGENCE FLAG DISPLAY 1FIGURE 28-3 - CONVERGENCE FLAG DISPLAY 2The configuration shown will a

93. RA-3/3A Power Supply TroubleshootingTroubleshootingOnce a few standard procedures are followed, this power supply is not too difficult to repair.

11728. Auto Registration TroubleshootingFlash FocusTM ErrorsThe primary causes of errors appearing during a Flash FocusTM session are:1. Insufficient

11828. Auto Registration TroubleshootingFIGURE 28-4 - FLASH FOCUSTM ERRORDURING SERVICE MODE01 23ERROR GLO LEVEL S3FIGURE 28-5 - ERROR CODE STORED IN

11928. Auto Registration TroubleshootingBelow is a list of possible error codes and suggested remedies.Table 28-1 ERROR CODE DESCRIPTION REMEDY 01

12028. Auto Registration TroubleshootingChapter 29 - Model-to-Chassis Cross ReferenceMODEL CHASSIS MODEL CHASSIS MODEL CHASSIS MODEL CHASSISKP43T70 RA

©2002 Sony Electronics Inc.EMCS - A Service Company1 Sony DrivePark Ridge, New Jersey 07656Reproduction in whole or part without written permission is

103. RA-3/3A Power Supply TroubleshootingNo AC Current Is Read: You have a supply that will not start. This is not common, but can occur. Bring the

113. RA-3/3A Power Supply TroubleshootingB+ Regulator TroubleshootingB+ Voltage Too High: This symptom can be a little troublesome to work with becaus

124. RA-3/3A Shutdown and Self-DiagnosticsChapter 4 - RA-3/3A Shutdown and Self-DiagnosticsOverviewAnother new feature introduced in the RA-3 Chassis

134. RA-3/3A Shutdown and Self-Diagnostics5623718489874R665R664R663R659R661D672C662C663R691D674D675MTZJ10BD663D661Q654R675Q655Q658R690D680D676MTZJ-3-9

145. RA-3/3A Deflection CircuitsChapter 5 - RA-3/3A Deflection CircuitsHSYNCINFIGURE 5-1A - HORIZONTAL DEFLECTION (PART 1)464041435210102543 6541C517C

155. RA-3/3A Deflection CircuitsTO ABOARDIC206PIN 43H+H-DYR142675310982146315T504 FBTCN506CN505CN504C541C549R532C542C531D532L504 HLCT502PMTR594C550R54

165. RA-3/3A Deflection CircuitsOnce the new transistor has been installed, it is always a good idea to re-solder the connections on the horizontaldri

Table of Contents1. Introduction ...1The RA-3/3A Chassis2. The RA-3/3A Chassis ...23. Power S

175. RA-3/3A Deflection Circuitsto the horizontal deflection yoke return. One more waveform is required, however. Vertical rate paraboliccorrection

185. RA-3/3A Deflection CircuitsVertical Deflection TroubleshootingNo Vertical Deflection: The first instinct of the technician is to go after the ver

195. RA-3/3A Deflection CircuitsCheck for V drive out of pins 34 and 35 of the Y/C Jungle IC206. Since this unit shuts down during a verticalfailure,

206. RA-3/3A Video Process Troubleshooting: T & S ModelsChapter 6 - RA-3/3A Video Process Troubleshooting:T & S ModelsOverviewOne of the more

216. RA-3/3A Video Process Troubleshooting: T & S ModelsIC1601MAINVCHIPPJEDIC002SYSCONIC1702COMBFILTERCVCYIC1101A/VSWITCHMONITOR OUTCVCMCRGBRGBRGB

226. RA-3/3A Video Process Troubleshooting: T & S ModelsWith AKB and high voltage ruled out, the following tests can be performed:The OSD feature

236. RA-3/3A Video Process Troubleshooting: T & S ModelsFIGURE 6-2 - SWITCHING AND COMB FILTER (S MODELS)8115411031712433758Q1102BUFFER56MAIN VOUT

246. RA-3/3A Video Process Troubleshooting: T & S Models151445312211109Q1920V BUFFERQ1914Y BUFFER131FROM J1106COMPONENTINPUTPBPRSY OUT 1FROMIC1101

256. RA-3/3A Video Process Troubleshooting: T & S ModelsCVCYCOMPONENTYUV4 UV5Y/CVCMYMYSYSCSUVSYYUVYUVYUVCOMPONENT YUV OR PIP YUVYUVMAINYUVCYTOTUBE

266. RA-3/3A Video Process Troubleshooting: T & S Modelsview video where it is inserted into the Y/C Jungle into a separate port. By engaging thi

28. Auto RegistrationTroubleshooting ... 113Overview... 113F

276. RA-3/3A Video Process Troubleshooting: T & S ModelsQ211, 214BUFFERFL202,Q203, 207B.P.F.Q201, 204INVERTER14132728292 315 347 3610 396244111210

286. RA-3/3A Video Process Troubleshooting: T & S ModelsFIGURE 6-7 - VIDEO PROCESSING (V MODELS)Q220BUFFERDY FROM IC1405/86P+P/DFB FROMIC1405/ 93Q

291. FeaturesChapter 7 - Troubleshooting the RA-4 ChassisOverviewThe RA-4 chassis represented a great leap forward for Sony in the rear projection tel

308. RA-4/4A Power Supply TroubleshootingChapter 8 - RA-4/4A Power Supply TroubleshootingOverviewThe RA-4 chassis introduced a new, simpler, standby p

318. RA-4/4A Power Supply TroubleshootingFIGURE 8-1 - AC INPUT & SWITCHING B+AC(W)AC(L)CN6004SPARKGAPR6001R6002C6001F600110ATO IC6003/2E AMP-(IF L

328. RA-4/4A Power Supply TroubleshootingFIGURE 8-3 - VCC SWITCHSTANDBYSOURCEVOLTAGEFROM D6003/KR6043R6042D6035RD12ESB2C6037 R6040Q6012PFROMD6015/KVCC

338. RA-4/4A Power Supply TroubleshootingG BOARDFROM Q6011/CVCC SW.FROM IC6005/4REGULATIONFROMIC6011/3VCC SW.D6010R6020LOW B+ PROTECTFROM D6002.3SWITC

348. RA-4/4A Power Supply TroubleshootingFIGURE 8-5 - CONVERTERFROM SWITCHING B+FROM VCC SOURCED6015/KFROM IC6003/9E1 OSCILLATORFROM IC6003/10E2 OSCIL

358. RA-4/4A Power Supply TroubleshootingTwo rapid relay clicks followed by a third click one to three seconds later: If this condition occurs, the un

368. RA-4/4A Power Supply TroubleshootingFIGURE 8-6 - REGULATIONFROMQ6006/ESOFTSTART11V135VV OUTSENSEIC6101VCC CONTROLLERSE135NCOLLECTOR R6128IC6005VC

11. FeaturesChapter 1 - IntroductionIn the fall of 1996, Sony Electronics introduced a troubleshooting course (TVP-06) that covered troubleshootingof

379. RA-4/4A Protect Circuit TroubleshootingChapter 9 - RA-4/4A Protect Circuit TroubleshootingOverviewThe protect circuits in the RA-4 chassis contai

389. RA-4/4A Protect Circuit TroubleshootingIC007MAINNVMIC6102OVP OCPuP393CRM +5V+135VT601/711V+22V+19V+15V+7VR6118MA BOARDQ101LVP+5VD3102CN3101CN514O

399. RA-4/4A Protect Circuit Troubleshooting31234126587G BOARD3 42 15643FROM RM+5VD6101FROM+135VR6102IC6103REF. VOLTAGEuPC1093J-1TC6103R6103R6101R6104

4010. RA-4/4A Deflection Circuit TroubleshootingChapter 10 - RA-4/4A Deflection Circuit TroubleshootingA BOARD11011128976532489FROMIC516/7HS BUFFER+12

4110. RA-4/4A Deflection Circuit Troubleshooting18176543265421121110986D BOARDQ5020/EPIN OUT141414FIGURE 10-2 - H OUTDF VCCD5015C5045R5062R5055CN5002+

4210. RA-4/4A Deflection Circuit TroubleshootingOnce the new transistor has been installed, it is always a good idea to re-solder the connections on t

4310. RA-4/4A Deflection Circuit Troubleshooting4Q5013/EH OUTD BOARDFIGURE 10-3 - PIN AMPFROMIC512/11VDSPPIN E/WCN5004R5006R5010Q5003+12V (D)NPR5014Q5

4410. RA-4/4A Deflection Circuit TroubleshootingD BOARD89C5020R5063Q5019R5072R5069R5068NFROMC5041AC VOLTAGEDIVIDER INH OUTR5027N-12VFROM IC6001R5024Q5

4510. RA-4/4A Deflection Circuit TroubleshootingTODBOARDCN5004COUNTDOWNPROCESSOR(CDP)DSPVCOIIC BUSDECODERLPFLDF161887522231736121314111724454447 64851

4610. RA-4/4A Deflection Circuit TroubleshootingVertical Deflection TroubleshootingNo Vertical Deflection: The first instinct of the technician is to

21. FeaturesChapter 2 - The RA-3/3A ChassisOverviewThe RA-3 chassis introduced a major redesign in the convergence circuits that made it much easier f

4711. RA-4/4A High Voltage Circuit TroubleshootingChapter 11 - RA-4/4A High Voltage Circuit TroubleshootingHVREGBLOCK12D BOARDTO HV REGPWMBLOCK5674321

4811. RA-4/4A High Voltage Circuit TroubleshootingD BOARD+135V6743211234678918171615131211101HV23456789101211HVT8001HDTFROMHVDRIVEQ8007D8011D8007R8019

4911. RA-4/4A High Voltage Circuit TroubleshootingIf a clean pulse appears with AC current staying well below 1.5 amps, re-connect Q8008 and Q8002 (or

5011. RA-4/4A High Voltage Circuit TroubleshootingHVBLOCK3D BOARD657910823121FIGURE 11-3 - HV REGULATION CONTROLR8119TO HVPROTECT 2IC8008/37.2VR8174IC

5111. RA-4/4A High Voltage Circuit TroubleshootingD BOARD321765657R8027+12VPHDRIVE R8021R8010R8031C8019R8028Q8009D8015C8029R8027Q8010R8044R8059TOQ8008

5211. RA-4/4A High Voltage Circuit Troubleshooting321231231FIGURE 11-5 - HV STOP 1R8176+12VQ8027FROMHV STOP 2ABLR8170C8092D8036R8116C8071C8062R8106R81

5311. RA-4/4A High Voltage Circuit Troubleshooting6543613215676579 9A BOARDD BOARDR8165+135VR8164R8163R8161R8162FROMABLT8003/11CN8003JUMPERPLUGC8086R8

5412. RA-4 Video Circuit TroubleshootingChapter 12 - RA-4 Video Circuit TroubleshootingOverviewAs mentioned earlier in this manual, the RA-4 chassis i

5512. RA-4 Video Circuit TroubleshootingTU501MAINTUNERTU501SUBTUNERCOMPOSITE+S VIDEO1-5VIDEO 5COMPONENTVIDEOSELECTOUTIC3063DCOMBFILTERCM501GLASSCOMBIC

5612. RA-4 Video Circuit TroubleshootingNN35612463626460596132315658525453494240384547343536252971213181924A BOARD41C697C698D524D525R876R875J5053 4VD5

33. RA-3/3A Power Supply TroubleshootingChapter 3 - RA-3/3A Power Supply Troubleshootinghe Standby Power SupplyThe standby supply is a simple switched

5712. RA-4 Video Circuit TroubleshootingA BOARD4171022|20|17|132467696575960756174|6766658483509|2|9928|13111012309816|19|26|222|571039363431132928271

5812. RA-4 Video Circuit TroubleshootingFIGURE 12-4 - MAIN CHROMA DECODER1237363526A BOARD32 34 38 39141516101819203022828R1543FROM COMBFILTER AYOIC13

5912. RA-4 Video Circuit TroubleshootingA BOARD24 28 4 27123567910112012 13 14 822161718C1482FROM Q1343FSC DETECT.FROM Q1366/ECOMPOSITEVIDEO YFROM IC1

6012. RA-4 Video Circuit TroubleshootingBR BOARD108624IC3063 CH8 BITADCIC30313.5MHzPLLIC466SYNCSHIFTIC30154MCLOCKIC305TBCIC6441 MBMEMORYIC6451 MBMEMOR

6112. RA-4 Video Circuit TroubleshootingBM BOARDIC003MAIN ADCIC002ACHPLLIC008C CHPLLIC001MEMORYIC009MIDCPUIC005NVMIC014SBADCB CHPLLIC013MEMORYIC010MID

6212. RA-4 Video Circuit TroubleshootingBM BOARDBR BOARDBD BOARDA BOARD20181614OR139121086426789152112313646362613537394159656636384067686933314546474

631. FeaturesChapter 13 - Troubleshooting the RA-4A ChassisOverviewThe RA-4A chassis shares many of the circuit designs with its predecessor, the RA-4

6414. RA-4A Video Circuit TroubleshootingChapter 14 - RA-4A Video Circuit TroubleshootingIC515A/VSWITCHTU501MAINTUNERTU502SUBTUNERCOMPOSITEAND S VIDEO

6514. RA-4A Video Circuit TroubleshootingV4YUVINPUTIC1403MAIN YUVSELECTIC1307MAIN YUVSWIC1303SWIC1008MAIN CPUDTVSYNCV5DTVINPUTIC511VIDEO PROCESSORYUVH

6614. RA-4A Video Circuit TroubleshootingGray Background Appears With Two Black Boxes: IC511 is OK. This signal is generated by the MIDTM. The maina

43. RA-3/3A Power Supply TroubleshootingFB621D601D602FROMT601/1AC HiSIDER6074.7 OHMSR620C617D623Q6012SK2845R608C609C608R604HOTGROUNDR609R605Q602PROT.C

671. FeaturesChapter 15 - Troubleshooting the RA-5A ChassisOverviewThe RA-5A chassis is Sony’s first high definition, 16:9 aspect ratio, rear projecti

6816. RA-5A Power Supply TroubleshootingChapter 16 - RA-5A Power Supply Troubleshooting5612348765ACINPUTIC6106MM1476AFGNDVINVOUTGNDC6179C6137++++++R60

6916. RA-5A Power Supply TroubleshootingPH6005OPTICALISOLATORNCHNCHIC6002DRIVERMCZ3001D16129151826 8 10 1412C60991IC6107ERROR DET.uPC1093C31ACRECT.+FR

7016. RA-5A Power Supply TroubleshootingTroubleshooting the Primary SupplySince this supply is the starting point for the operation of all necessary p

7116. RA-5A Power Supply Troubleshootingbusiness. This supply has ± supply rails, so do not forget to read across them for low resistance readings.A

7216. RA-5A Power Supply TroubleshootingVSENSE1IC6001DRIVERMCZ3001D161298151814102PH6002OPTICALISOLATOR42IC6101CONTROLDM-58541PRIMARYPOWERSUPPLYACACD6

7317. RA-5A Protect Circuit TroubleshootingChapter 17 - RA-5A Protect Circuit TroubleshootingOverviewAs illustrated in Figure 17-1, several circuits a

7417. RA-5A Protect Circuit TroubleshootingPOWEROFFLATCH15VOVPIC3006VIDEOPROCESSOR22VOCPAC INOVP+135VOCPSUB6.5VOVPOCPIC001MAIN MICROC246X+135VOCPA25 C

7517. RA-5A Protect Circuit TroubleshootingT6003STANDBYP.S2341R6119Q6119Q6105D6015AC INCN6001R6112100AC RELAYRY6001D6001BRIDGERECT.STBY 5VQ6120D6111C6

7617. RA-5A Protect Circuit TroubleshootingShutdown – No Diagnostics IndicationSince RY6001 and RY6002 are engaging, there are the five monitoring cir

53. RA-3/3A Power Supply TroubleshootingOnce the FET has been changed along with R607, you will need to disconnect the secondary voltage line byliftin

7718. RA-5A Deflection Circuit TroubleshootingChapter 18 - RA-5A Deflection Circuit TroubleshootingOverviewThe deflection circuits in the RA-5A chassi

7818. RA-5A Deflection Circuit TroubleshootingIC8005H DRIVECTL23614T8003HOT14321H OUTH RET142135H OUTH RET14H OUTH RET14T8002HDTQ8020Q8016Q8004Q8030Q8

7918. RA-5A Deflection Circuit TroubleshootingIC5004V OUTLA78045B19A20IC3006VIDEOPROCESSORCXA2150AQ252452 537 124355+15V-15VFROMSECP.S(G BD.)R055S DAT

8019. RA-5A High Voltage Circuit TroubleshootingChapter 19 - RA-5A High Voltage Circuit TroubleshootingFIGURE 19-1 - HIGH VOLTAGE STAGE - RA-5A CHASSI

8119. RA-5A High Voltage Circuit TroubleshootingTroubleshootingHigh voltage circuit failures generally fall into four categories: No HV, low HV, exces

8219. RA-5A High Voltage Circuit Troubleshootingthan 7.5V, the HV block is defective. If it is significantly lower, check the PWM signal at pin 3. I

8319. RA-5A High Voltage Circuit Troubleshooting567+-321+-567+-321+-D8014MTZJ-5.18D8013MTZJ-5.18RV8002R8102R8223R8153FBTABLD8038R8099R8139+15VFBTABLR8

8420. RA-5A Video Path TroubleshootingChapter 20 - RA-5A Video Path TroubleshootingOverviewThe RA-5A chassis incorporates a DTV tuner and decoder circ

8520. RA-5A Video Path TroubleshootingCBBD.7/17/0220.1TVP14ANALOGTUNERSIC002SW.Q9, Q11, Q13MIXERIC7806,IC7807DRCPROCESSIC8801OSDIC001MAIN MICROIC7205,

8620. RA-5A Video Path TroubleshootingVideo Appears in Right Box Only: The sub-video path is working correctly. An interruption in the main videopro

63. RA-3/3A Power Supply Troubleshootingjob properly. Since they are part of a loop, one affects the other. This is where many technicians run intod

871. FeaturesChapter 21 - Troubleshooting the RA-6 ChassisOverviewThe RA-6 chassis is found in the KP51HW40 and KP57HW40 models. It provides an affor

8822. RA-6 Power Supply TroubleshootingChapter 22 - RA-6 Power Supply TroubleshootingGeneral DescriptionThe power generation and distribution has been

8922. RA-6 Power Supply Troubleshooting34IC60031618SENSEVD16121511982134798121011151314181617+6V REG-5V REG43 212IC501CONTROLDM-584 15TIMEROCPVC1FBR60

9022. RA-6 Power Supply TroubleshootingDead Supply. Switching Transistors Shorted: A more cautious approach must be taken when this happens.There is

9122. RA-6 Power Supply Troubleshooting3. If a problem exists that warrants protection, a third relay click will be heard. This is actually RY6002 an

9223. RA-6 Protect Circuit TroubleshootingChapter 23 - RA-6 Protect Circuit TroubleshootingGeneral DescriptionAs illustrated in Figure 23-1, several c

9323. RA-6 Protect Circuit Troubleshooting2831434445437224IC309Y/CJUNGLE2625Q5003,Q5004LATCHIC704MAIN uCOMMAINRELAYD5014D5007AUDIOPROTECTSTBYUNREG7.5V

9423. RA-6 Protect Circuit TroubleshootingShutdown – No Diagnostics IndicationThe first step necessary is to listen for the sequence of relay clicks w

9523. RA-6 Protect Circuit TroubleshootingSTBYTRANS.5VREGR5016R5026IC5006D5001567231R5038D5020R5020Q5002D5007CN6-5CN6-4TO 135VOVPIC5002-5SELF DIAGNOST

9624. RA-6 Deflection Circuit TroubleshootingChapter 24 - RA-6 Deflection Circuit TroubleshootingThe deflection circuits in the RA-6 chassis are ident