Clicking faults in LG plasma TVs

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  • fzabkar
    Badcaps Veteran
    • Mar 2009
    • 772
    • Australia
    #1

    Clicking faults in LG plasma TVs

    I have an intermittent clicking fault in an LG 42PJ350 plasma TV. I saw the problem once, but I have not been able to reproduce it after taking the back off the set. I am proposing to compile as much information about this problem as I can.

    Here are just a few related threads:
    Tags: None
    • fzabkar
      Badcaps Veteran
      • Mar 2009
      • 772
      • Australia
      #2
      Re: Clicking faults in LG plasma TVs

      PSU = p/n EAY60912401

      IC701 = MC81F4316

      IC701 markings:
      • V1.2A-D99D
        F4316MSF17
        KOREA


      Datasheets for PSU ICs:

      ICE3BR1565JF, Infineon, FF CoolSET, TO-220-6, 68W/125W, 67kHz, 1.5ohm RDSon:
      *** could not find datasheet

      Infineon Solution for LED TV SMPS (shortform catalogue):
      https://cdn.badcaps-static.com/pdfs/...ed91163bc3.pdf

      ICE3BR0665JF, Infineon, FF CoolSET, TO-220-6, 110W/200W, 67kHz, 0.65ohm RDSon, 650V:
      https://cdn.badcaps-static.com/pdfs/...1a485dfec1.pdf

      ICE3BR1065JF, Infineon, FF CoolSET, TO-220-6, 80W/144W, 67kHz, 1.0ohm RDSon, 650V:



      ICE3BR2565JF, Infineon, FF CoolSET, TO-220-6, 55W/90W, 67kHz, 2.5ohm RDSon, 650V:

      AN-EVAL3BR2565JF, 40W 18V SMPS Evaluation Board with CoolSET-F3R ICE3BR2565JF:


      ENPC Workshop: Auxiliary Power Supply Solution --- CoolSET:
      https://cdn.badcaps-static.com/pdfs/...e3bff90cb7.pdf

      ICE3BR2565JF OR ICE3BR1565JF OR ICE3BR1065JF OR ICE3BR0665JF filetype:pdf


      L6599A, STMicroelectronics, high-voltage resonant controller:
      https://cdn.badcaps-static.com/pdfs/...475bf7d342.pdf

      AOD484, Alpha & Omega, 30V 25A N-Channel MOSFET:


      PC-17K1, Kodenshi, photocoupler, 1 channel:


      D15XB-60H, Shindengen, 600V 15A, Bridge Rectifier:


      SDURF1040CTR, SANGDEST, dual ULTRAFAST PLASTIC RECTIFIER, ITO-220AB, 10A 400V:


      FQPF27P06, Fairchild, P-Channel QFET MOSFET -60V, -17A, 26mohm:
      https://cdn.badcaps-static.com/pdfs/...51f9616739.pdf

      FMEN-220A, Sanken, dual Schottky Barrier Diode, 100V 20A:
      https://cdn.badcaps-static.com/pdfs/...3aceca0c52.pdf

      KIA431A, KEC semiconductor, PROGRAMMABLE PRECISION REFERENCE, TO-92, 1%, 2.5V:


      KIA2431A, KEC semiconductor, PROGRAMMABLE PRECISION REFERENCE, TO-92, 1%, 1.24V:


      TK13A60D, Toshiba, N-Channel MOS Type (p-MOS VII), 600V 13A:
      http://toshiba.semicon-storage.com/i...dName=TK13A60D

      FMX-22S, Sanken, dual High Frequency Rectifier, 200V 10A:


      FQPF10N20C, Fairchild, N-Channel QFET MOSFET 200V, 9.5A, 360 mohm:


      FCF10D60, Nihon (NIEC), dual FRED diode, 10A 600V:


      FML-G13S, Sanken, High Frequency Rectifier, 300V 5A:
      https://cdn.badcaps-static.com/pdfs/...79a5e57c44.pdf

      SD14N60, Infineon, MOSFET 600V 14A TO220F:
      *** could not find datasheet

      R2A20117, Renesas, Power Factor Correction Controller IC:
      (R2A20117)
      https://cdn.badcaps-static.com/pdfs/...c97488ec96.pdf (R2A20111)

      https://cdn.badcaps-static.com/pdfs/...9b0eeb4c40.pdf (R2A20118)

      MC81F4316, ABOV Semiconductor, 8-bit Single-chip Microcontroller, 28-pin, 16KB flash, 512B RAM, 2.2V - 5.5V @ 4.2MHz:


      MC81F4315, ABOV Semiconductor, 8-bit Single-chip Microcontroller, 28-pin, 16KB flash, 512B RAM, 2.2V - 5.5V @ 4.2MHz:

        Comment

        • fzabkar
          Badcaps Veteran
          • Mar 2009
          • 772
          • Australia
          #3
          Re: Clicking faults in LG plasma TVs

          Diagram of PFC voltage detection circuit (may contain errors):
          • BR- is the negative terminal of the bridge rectifier (hot side of PSU).
            GND is the Vss pin of U701 (cold side of PSU).

          Code:
               from auxiliary     D609
      supply (ZD301) >------>|-----+---------------.
                     |        |
                 +5V  .-. 2K7     |
                 ___  | | R628     |
                 |   | |       |
                 1|   '-'4       |
                .-|------|-.       |
                | |   | |       |
                | |  |/ |       |
             PC103 | V -> |  |       |
                | -  |> |       |
                | |   | |       |
                '-|------|-'       |
                 2|   3|       |/
                 .-.   +----->|------| Q605
              R727 | |   |   D    |>
               1K | |   z        |
                 '-'   A        |
                 |   | ZD601     |
                 V   |        |
                U701-4 ===       |
                    GND       |
              .--------.          |
         0 ohm  |    |          |
          R114  |    |          |
          ___   z    |          .-.
        .--|_0_|--->A    |       R123 | |
        |      | IC102 |        1K5 | |     +5V
     C110 ---     | TL431 |          '-'     ___
       ---     |    |          |      |
        |      |    +--------------------+----.1   | 4
        '-----------+    |          | .-|------|-.
              |    |          | | |   | |
             ===    |          .-. | |  |/ |
             BR-   ---       R122 | | | V -> |  |
                  ---       1K5 | | | -  |> |
                  | C109       '-' | |   | |
         680K 680K 560K |          | '-|------|-' R728
        680K 680K 620K   |          +----'2  3|  ___
         __  __  __  |          |   PC101 +--|___|--> U701-27
         | | | | | |  |       ZD101 z      |  1K   PFC_detect
        .-..-..-..-..-..-. |          A      |      to CPU
        | || || || || || | |          |     .-.
 from      | || || || || || | |  13K   20K   |   R733 | |
 APFC      '-''-''-''-''-''-' | R115  R118   |   22K | |
 supply     | | | | | |  |  ___   ___  |/      '-'
  o-+----+------' '--' '--' '---+--|___|-+-|___|-+-| Q101    |
   |  |  R108 R110 R112       |    | |>      |
   |+  |+   R109 R111 R113     .-.12K  |  |     ===
  === ===                | |R117 --- |     GND
  /-\ /-\                | |   --- |     Vss
   |  |                 '-' C111 |  |    U701-24
 C617|  |C616               |    |  |
  o-+----+--------------------+-------------+-------+---+
   2x 150uF         |
    450V         ===
    105C         BR-

            Comment

            • fzabkar
              Badcaps Veteran
              • Mar 2009
              • 772
              • Australia
              #4
              Re: Clicking faults in LG plasma TVs

              Links to training manual, service manual, exploded view. and parts list:


              http://www.jordansmanuals.com/Defaul...&Model=42PJ350

              http://www.jordansmanuals.com/Servic...rts%20List.csv

                Comment

                • fzabkar
                  Badcaps Veteran
                  • Mar 2009
                  • 772
                  • Australia
                  #5
                  Re: Clicking faults in LG plasma TVs

                  I will post the diagram for the AC Detect circuit in due course.

                  In the meantime I would very much appreciate opinions on the function of IC102 (TL431). I confess I don't understand what it does. AISI, C110 would be charged by Iref (the current out of the reference pin) until its voltage reaches 2.5V, at which point IC102 would turn on thereby switching off PC101. But why?

                    Comment

                    • fzabkar
                      Badcaps Veteran
                      • Mar 2009
                      • 772
                      • Australia
                      #6
                      Re: Clicking faults in LG plasma TVs

                      Here are some hires scans of the rear of the PSU.
                      Attached Files

                        Comment

                        • fzabkar
                          Badcaps Veteran
                          • Mar 2009
                          • 772
                          • Australia
                          #7
                          Re: Clicking faults in LG plasma TVs

                          Trying again ...
                          Attached Files

                            Comment

                            • fzabkar
                              Badcaps Veteran
                              • Mar 2009
                              • 772
                              • Australia
                              #8
                              Re: Clicking faults in LG plasma TVs

                              ... and again ...
                              Attached Files

                                Comment

                                • fzabkar
                                  Badcaps Veteran
                                  • Mar 2009
                                  • 772
                                  • Australia
                                  #9
                                  Re: Clicking faults in LG plasma TVs

                                  AC Detect circuit:
                                  Code:
                                          63V
    D303  C308            D307
        47uF R307
   o-->|---+---+----+----+----------------->|----+------> VCC
 from    |  |  |  |            |    IC301
 auxiliary  |  |  .-.2K |            |+  ICE3BR1565JF
 winding   |  |+ | |  |        C307 ===
 of xfmr   z === | |  |        33uF /-\
       A /-\ '-'  |         50V  |
    ZD301 |  |  | |/ 2SC3198        |
       |  |  +--| Q301         ===
       |  |  | |>            BR-
       |  |  |  | J121  ___
       |  |  z  '-o--o--|___|-----.
       |  |  A           |
       |  |  |ZD302    R125   |
       '---+----+       10K   o
           |         J20 )     +5V
           ===           o     ___
           BR-           |      |
                       +----.1   | 4
                       | .-|------|-.
                       | | |   | |
                      .-. | |  |/ | PC-17K1
                      | | | V -> |  |
      240K 150K         1K8 | | | -  |> |
     240K 150K 100K          '-' | |   | |
      __  __  __          | '-|------|-' R729
      | | | | | |         +----+2  3|  ___
     .-..-..-..-..-. |         |  |PC102 +--|___|--> U701-28
     | || || || || | |         |  |   |  10K   AC_detect
     | || || || || | |      IC101 |  |   |      to CPU
     '-''-''-''-''-' | R119   KIA431 |  |   |
  D102  | | | | | | ___      \_|_  |   .-.
  o-->|---' '--' '--' +-|___|--+---+--->/_\\ |   | |47K
     R103 R105 R107 |    |  |   |  |   | |R732
 Active   R104 R106  | 100K .-. |   |  |C112 '-'
             ---   | | ---  |  ---   |
          C108 ---   | | ---  |  ---   |
             |  91K '-' |C113 |  |   ===
             |  R120 |  |   |  |   GND
             '--------+---+-----+----'
                       |
                      ===
                      BR-

                                    Comment

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