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Samsung 64" Plasma BN44-00516A PSU Repair

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    Samsung 64" Plasma BN44-00516A PSU Repair

    This is a PN64E8000GFXZA TV that I've had for about 8 years. It has occasionally 'glitched' where it would go off periodically and then come back on with no issues for weeks. Last week it went 'pop' while my wife was watching it and then it runs up past the splash screen, but then as soon as it displays an actual picture for maybe 1 second, it does the click, power cycle and keeps going around that loop, picture appears, and then it reboots.

    So we bought a new TV but, being an EE, I wanted to check the blown one out. I took out the SMPS PCB which is BN44-00516A and, straight away, I could see that one of the pins of the QP802 FET was burnt, see picture. The source pin which goes to ground was open cct from the PCB because the track had blown around it roughly where I've drawn a red circle (see 2nd picture). [EDIT] I measured the FET after removing it and it's single-digit ohms between any 2 pins so it has clearly applied high voltage to the components on the source and gate pins although the source is directly to a big ground track which is why it blew the copper around the pin; the gate obviously tried to feed high voltage to RP803 & RP804 and they are open cct too.

    I can't find a schematic for the BN44-00516A but I've found the cct for the BN44-00333A and the circuit for ICP801 driving QP802 & QP804 on my PCB seems very similar to the 333A schematic where ICP801 drives QP802 & QP803. If anyone can provide the actual 516A schematic that would be great.

    It appears that the circuit is a dual phase switcher where the cct associated with QP802 is the same as that associated with QP804 but, in my bad PCB, many of the components between QP802 and the push-pull pair QP807/8 are blown e.g. R803/4 are both open circuit (5 Meg).

    I've ordered a repair kit that includes many major parts but the concern is that ICP801 is blown or at least the side that drives QP802 may have been damaged.

    I'll end this post here but any input, advice or comments are welcome and appreciated.
    Attached Files
    Last edited by Gandalf_Sr; 09-07-2020, 09:29 AM.

    #2
    Re: Samsung 64" Plasma BN44-00516A PSU Repair

    So, to summarize and keep going, I figured that ICP801 is actually running but may be damaged too - then I found a repair kit at tvrepairkit which includes the following parts:

    Fuses (2) FS801S, FM802S
    Transistors (4) QS802, QS804, QP804, QP802
    Integrated Circuits (4) IC801, UQ802, US801
    Diodes (1) DP802
    Capacitors (4) CS825, CX802, CX851, CX857

    But I will also need Replacements for the following:

    Transistors QP807, QP808
    Diode DP807
    Resistors RP803, RP804, RP813, RP810
    Capacitors CP811, CP832
    Inductor LF802

    I've tested RP814 and it seems fine at 10 Ohms so I'm hopeful that the IC is OK but if I get the right one with the kit, I'll replace it anyway.

    The kit I purchased includes the IC but I've heard that it may be a PIC microcontroller and that it needs programming, I can do the programming no problem but where would I get the code from? I'm not even sure that it is a PIC and I've attached a picture showing makings as follows...

    21A5P4M SPC1012T G4

    and searching for SPC1012T reveals that it's a Power Factor correction IC so maybe the one that comes with my kit is going to be a drop in replacement?

    Can anyone help me out with the Transistors QP807, QP808 and diode DP807 identification? I don't want to assume that they are the same as shown on the 333A schematic.

    Thanks in advance for any help you can give.
    Attached Files

    Comment


      #3
      Re: Samsung 64" Plasma BN44-00516A PSU Repair

      Regarding the microcontroller see the posts 22 and 27 in this thread - https://www.badcaps.net/forum/showth...-00516A&page=2
      Those posts were from 2017 so i don`t know if anyones found a fix since then .Surely the PIC in the kit should be pre-programmed ?
      Last edited by SMDFlea; 09-07-2020, 09:30 AM.
      All donations to badcaps are welcome, click on this link to donate. Thanks to all supporters

      Comment


        #4
        Re: Samsung 64" Plasma BN44-00516A PSU Repair

        Originally posted by SMDFlea View Post
        Regarding the microcontroller see the posts 22 and 27 in this thread - https://www.badcaps.net/forum/showth...-00516A&page=2
        Those posts were from 2017 so i don`t know if anyones found a fix since then .Surely the PIC in the kit should be pre-programmed ?
        Thanks, I read that and was probably getting mixed up as they are talking about UQ802 which is a voltage controller. I am pretty sure that my ICP801 (SPC1012T) is not a PIC - it has no Microchip marking that I can see and it's available all over the place for around $5 including on Amazon. So, assuming that is the part that comes with my kit, I will just change it out.

        Right now, I'm working through the parts in the drive circuit between ICP801 and QP802 and many are bad, QP808 is bad, it's a KTM2907 on the 333A schematic.

        Comment


          #5
          Re: Samsung 64" Plasma BN44-00516A PSU Repair

          I recently replaced a BN44-00515A power supply due to cracked solder joints on the FETs attached to heat sinks. I tried a re-flow of the solder joints but the FETs were already stressed from the bad solder joints and fully failed after the re-flow.

          I got my Power Supply from ENCOMPASS.COM for about $130.00 after I turned the core in to them. The one I got was new, but they might have a factory refurb board too.
          They call me......."threadkiller"

          Comment


            #6
            Re: Samsung 64" Plasma BN44-00516A PSU Repair

            Thanks, I'll bear that in mind.

            I now have the parts from Digikey plus the other parts from tvrepairkit arrived today. I should get to this this week.

            Comment


              #7
              Re: Samsung 64" Plasma BN44-00516A PSU Repair

              So a quick report is that, I fitted the parts today and fixed the problem. I had to replace the SPC1012T power factor correction IC along with the push pull pair of driver transistors and twin diode which were not part of the repair kit.

              I'll update this post with the details of all the parts I used as they may be handy for others.

              Comment


                #8
                Re: Samsung 64" Plasma BN44-00516A PSU Repair

                Here's the fuller update promised. See the attached marked up schematic which is not actually for the BN44-00516A, it's for the -00333A but it's the only one I could find (from this forum) and it's close enough to understand what was going on. I haven't marked all the components but those I have marked or checked match the reference designators on the 00516A PCB.

                What I believe happened was that QP802 failed (it was marked HAE147 but the not failed QP804 was marked HAX147, I couldn't find either part number but is the E part a lower voltage rating?) and went short cct between all pins, the main fault current flow was to ground (FET source) which explains why the PCB track around that pin had vaporized. Now we had VAC_A connected to the right hand side of LP802 and the whole chain back through DP807, QP807, QP809, and ICP801 got zapped, the weakest links failed so that when I went through and tested, the following components were damaged:

                QP802, single digit ohms between all pins
                RP803, RP804, RP810, open cct
                QP807, QP808, open cct (high M ohms)

                LP802, DP807, RP815, CP811 all tested good.

                The fact that the TV was working and then looping through multiple power resets when asked to display a bright picture suggests that there was half of the PF correction circuit working indicating that ICP801 and QP804 were good. However, as the repair kit I bought for $35 included ICP801, QP804, DP801 and several other caps, I changed them too. While I had ICP801 off the PCB, I tested the surrounding components on the QP804 side and found that they all tested good.

                You can see on the lower right of the schematic the part numbers I replaced; QP807, QP808 are the same number but different prefix. I measured the forward voltage of the working DP807 and made a guess at a substitute in terms of voltage and current, it seems to work.

                I tried to run it up on the bench but never got VS or VA to come on despite grounding VS_ON - there's a comment in the Fast Track Trouble Shooting Manual that says that VA, VS won't come on unless they are loaded in some early models - so I threw it back in the TV, crossed fingers, and powered on! All seems to work just fine.

                RP804 should be 3.3 Ohms, not 3.3k
                Attached Files
                Last edited by Gandalf_Sr; 09-21-2020, 07:50 AM.

                Comment

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