Service Bulletin ..................................................................................................................... 106-107
Service Manual Revision History.................................................................................................108
®
E4 Series II Business Music System (see Figure 1) ............12
2
SAFETY INFORMATION
1. Parts that have special safety characteristics are identified by the symbol on schematics
or by special notes on the parts list. Use only replacement parts that have critical characteristics
recommended by the manufacturer.
2. Make leakage current or resistance measurements to determine that exposed parts are
acceptably insulated from the supply circuit before returning the unit to the customer.
Use the following checks to perform these measurements:
A. Leakage Current Hot Check-With the unit completely reassembled, plug the AC line cord
directly into a 120V AC outlet. (Do not use an isolation transformer during this test.) Use a
leakage current tester or a metering system that complies with American National Standards
Institute (ANSI) C101.1 "Leakage Current for Appliances" and Underwriters Laboratories (UL)
UL6500 / UL60065 / IEC 60065 paragraph 9.1.1. With the unit AC switch first in the ON position
and then in OFF position, measure from a known earth ground (metal waterpipe, conduit, etc.)
to all exposed metal parts of the unit (antennas, handle bracket, metal cabinet, screwheads,
metallic overlays, control shafts, etc.), especially any exposed metal parts that offer an electrical
return path to the chassis. Any current measured must not exceed 0.5 milliamp. Reverse the
unit power cord plug in the outlet and repeat test. ANY MEASUREMENTS NOT WITHIN THE
LIMITS SPECIFIED HEREIN INDICATE A POTENTIAL SHOCK HAZARD THAT MUST BE
ELIMINATED BEFORE RETURNING THE UNIT TO THE CUSTOMER.
B. Insulation Resistance Test Cold Check-(1) Unplug the power supply and connect a jumper
wire between the two prongs of the plug. (2) Turn on the power switch of the unit. (3) Measure
the resistance with an ohmmeter between the jumpered AC plug and each exposed metallic
cabinet part on the unit. When testing 3 wire products, the resistance measured to the product
enclosure should be between 2 and infinite MOhms. Also, the resistance measured to exposed
input/output connectors should be between 4 and infinite MOhms. When testing 2 wire products, the resistance measured to exposed input/output connectors should be between 4 and
infinite MOhms. If it is not within the limits specified, there is the possibility of a shock hazard,
and the unit must be repaired and rechecked before it is returned to the customer.
CAUTION: The Bose® E4 Series II Business Music System contains no
user-serviceable parts. To prevent warranty infractions,
refer servicing to warranty service stations or factory service.
PROPRIETARY INFORMATION
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OF
BOSE CORPORATION WHICH IS BEING FURNISHED ONLY FOR
THE PURPOSE OF SERVICING THE IDENTIFIED BOSE PRODUCT
BY AN AUTHORIZED BOSE SERVICE CENTER OR OWNER OF
THE BOSE PRODUCT, AND SHALL NOT BE REPRODUCED OR
USED FOR ANY OTHER PURPOSE.
WARRANTY
The Bose E4 Series II Business Music System is covered by a limited 5-year transferable
warranty.
3
PRODUCT DESCRIPTION
E-4 Series II Business Music System
The Bose® FreeSpace® E-4 Series II Business Music System is an integrated four-channel
digital signal processor and 400-Watt power amplifier for 70/100V business music applications.
The E-4 chassis provides a total of four source inputs (two Line In, one Mic/Line and one Mic/
Line/Page) to meet the needs of most business music installations. A Music on Hold (MOH)
output is also provided for simple integration into a phone system.
As a single component, the chassis provides all of the processing and control features required
for one to four zone business music applications. These features include:
•Auto Volume: When used with the optional FreeSpace Auto Volume Sense Mic, the E-4
system dynamically controls the program level in each zone so that the audio program
material can always be heard, regardless of the background noise.
•Scheduling: Allows you to program the E-4 system for automated on/off and source
selections according to time of day or day of week.
•Opti-Voice® Paging: Provides the appropriate sound level regardless of variations in
speech projection.
•Source Leveling: Automatically compensates for variations in source input levels.
•Dynamic Equalization: Maintains tonal balance at all listening levels.
•Room Equalization: Provides easy adjustment of tonal balance in each zone.
•Limiting: Protects loudspeakers from unwanted transient power loads.
•Signal Router: Meets the demands of most four-zone systems, allowing for any input signal
to be routed to any of the amplifier outputs.
•RS-232 Connection: Provides easy interfacing to your PC.
•Contact Closure Input: Allows remote power sequencing.
The integrated 400-Watt power amplifier features a patented power-sharing technology which
allocates power to each output.
For example, if you have a two-zone system that requires 5 Watts in zone 1 and 395 Watts in
zone 2, the FreeSpace E-4 Series II system distributes the power based on those needs.
The E-4 Series II also includes an easy-to-replace memory module, which holds a design file
and the current hardware configuration.
4
SPECIFICATIONS
Audio InputSource 1unbalanced RCA, shell grounded through a 301 Ohm resistor
Connectors:Source 2unbalanced RCA, shell grounded through a 301 Ohm resistor
Pagebalanced 4 pin Beau style: +, -, ground and contact closure in
Aux/Mic/Line 3 pin Beau style, +, - and ground
Mic 1-43 pin Beau style, +, - and ground
Direct In4 pin Beau style, +, -, ground, and contact closure in
Audio Output
Connectors:Line out4 pin Beau style, +, -, ground, and contact closure in
MOH out2 pin Beau style, + and Ground
Amp 1-42 pin, Beau style, + and -
Control Connectors:Remote 1-4RJ-45, 8 pin, ground shell
Standby In2 pin Beau style, contact closure in and ground
Dimensions:5.25"H x 16.5"W x 15.5"D (13.3 x 43.8 x 39.4 cm)
Weight:30 lbs (13.6 kg)
AC Mains input:IEC standard User selectable100/120 or 220/240V
3 pin50/60 Hz
receptacle300 Watts maximum
Overall Performance
NominalLimitsConditions
Gain:0 dB+1 dBat 1 kHz; input gain set to nominal 0 dB
Dynamic range:100 dB>/= 96 dBmeasured with ADC/DAC full scale mapped to
+17 dBV; this is THD +N measured at FS-60,
through A-weighting filter, and expressed in dB
below full scale
THD+N:.05%.1%at +10 Vrms output, for signal frequencies from
30 Hz to 20 kHz
Crosstalk at 1 kHz:-80 dB</= -70 dBterminate unused input terminals with 100 Ohm
balanced-connected resistors.
Crosstalk at 10 kHz:-60 dB</= -50 dBterminate unused input terminals with 100 Ohm
balanced-connected resistors.
Frequency response:30 - 20 kHz+3 dBreference 1 kHz, measured at 0 dBV input
Output noise:-70 dBV</= -65 dBVchannel noise measured through an A
weighting filter. Gain structure set to deliver
rated power and expressed in dBV
5
SPECIFICATIONS
Line Input Source 1 and 2
NominalLimitsConditions
Source impedance:200 Ohms10 to 2k Ohm frequency response specification maintained
Gain, all settings:20 dB to+/-1 dB1 kHz, 50 Ohm source
-20 dB
Maximum input level:+17 dBV>/= +17 dBVTHD+N </= 0.3%, 30-20 kHz, 0 dB gain
THD+N:.001%.01%at +10 dBV output, 1 kHz, 20 dB gain
Crosstalk at 1 kHz:-90 dB</= -80 dB
Crosstalk at 10 kHz:-70 dB</= -60 dB
Frequency response:30 to 20 kHz +/-1.5 dBreference 1 kHz, measured at 20 dB gain and
with 0 dBV output
Page and Aux/Mic Inputs
NominalLimitsConditions
Source impedance:200 Ohms10 to 2k Ohm frequency response specification maintained
Gain, all settings:20 dB to+/-1 dB1 kHz, 50 Ohm source
-20 dB
Maximum input level:+17 dBV>/= 10 dBVTHD+N </= 0.3%, 20-20 kHz, 0 dB gain
THD+N:.001%.01%at +10 dBV output, 1 kHz, 60 dB gain
Crosstalk at 1 kHz:-90 dB</= -80 dB
Crosstalk at 10 kHz:-70 dB</= -60 dB
Frequency response:30 Hz to+0/-0.5 dBReference 1 kHz, measured at 60 dB gain and
20 kHzwith 0 dBV output
Sense Mic inputs
NominalLimitsConditions
Source impedance:200 Ohms10 to 2k Ohm frequency response specification maintained
codec FS:+20 dBV
Gain, all settings:-60 dB to+/-1 dB1 kHz, 50 Ohm source
+20 dB
7
SPECIFICATIONS
Sense Mic inputs (continued)
NominalLimitsConditions
Maximum input level:+10 dBV>/= 7 dBVTHD+N </= 0.3%, 20-20 kHz, 0 dB gain
THD+N:-84 dB</= -80 dBat +10 dBV output, 1 kHz, 60 dB gain
Crosstalk at 1 kHz:-90 dB</= -80 dB
Crossalk at 10 kHz:-70 dB</= -60 dB
Frequency response:20 Hz to+0/-0.5 dBreference 1 kHz, measured at 60 dB gain and
20 kHzwith 0 dBV output
Direct Input
NominalLimitsConditions
Source impedance:200 Ohms10 to 2k Ohm frequency response specification maintained
with sources over this range
Input impedance
differential:+/> 10kOhms +/-20% at 1 kHz
CMRR referred
to output:92 dB>/= 60 dB at 1 kHz, 20 dB gain, 200 Ohm source
Gain:0 dB+/-1 dBfrom input connector to amplifier input stage
Maximum input level:+17 dBV>/= +17 dBVTHD+N </= 0.3%, 30-20 kHz, 0 dB gain
THD+N:.001%.01%at +10 dBV output, 1 kHz, 20 dB gain
Crosstalk at 1 kHz:-90 dB</= -80 dB
Crosstalk at 10 kHz:-70 dB</= -60 dB
Frequency response:30 Hz to+0/-0.5 dBreference 1 kHz, measured at 20 dB gain and
20 kHzwith 0 dBV output
Line Outputs
NominalLimitsConditions
Output impedance:200 Ohms+/-1%impedance at 1 kHz, each output
terminal
Maximum output level: +17 dBV>/= +17 dBV1 kHz, THD less than 0.1%, load 10 k Ohm,
differential
8
SPECIFICATIONS
Line Outputs (continued)
NominalLimitsConditions
CMRR referred
to output:92 dB>/= 60 dBat 1 kHz, 20 dB gain, 200 Ohm source
impedance
Output noise:-90 dBV</= -85 dBVA-weighted, set for 0 dB gain
THD+N:.001%.01%at +10 dBV output, 1 kHz, 20 dB gain
Crosstalk at 1 kHz:-90 dB</= -80 dBset for 0 dB gain, no limiting, terminate the
unused input with a 50 Ohm resistor
Crosstalk at 10 kHz:-70 dB</= -60 dB
Frequency response:30 Hz to+0/-1.0 dBreference 1 kHz, measured at 20 dB gain and
20 kHzwith 0 dBV output
Turn on/off pop:10 mV peak</= 50 mVpk as monitored by a listener, must be inaudible at
full gain using a Model 32 loudspeaker tapped
at 32W, with the unit set for no EQ and the
loudspeaker 3 feet from listener
Music on Hold (MOH)
NominalLimitsConditions
Output impedance:400 Ohms+/-1%impedance at 1 kHz
Maximum output level: +17 dBV>/= +17 dBV1 kHz, THD less than 0.1%, load 10 kOhm,
differential
Output noise:-90 dBV</= -85 dBVA-weighted, set for 0 dB gain
THD+N:.001%.01%at +17 dBV output, 1 kHz, 0 dB gain
Crosstalk at 1 kHz:-90 dB</= -80 dBset for 0 dB gain, no limiting, terminate the
unused input with a 50 Ohm resistor
Crosstalk at 10 kHz:-70 dB</= -60 dB
Frequency response:20 Hz to+0/-1.0 dBreference 1 kHz, measured at 0 dB gain and
15 kHzwith 0 dB output
Turn on/off pop:10 mV peak</= 50 mVpk as monitored by a listener, must be inaudible at
full gain using a Model 32 loudspeaker tapped
at 32W, with the unit set for no EQ and the
loudspeaker 3 feet from listener
9
SPECIFICATIONS
Power Amplifier
NominalLimitsConditions
Power bandwidth:30 Hz to1% THDloaded at 25 Ohms
20 kHz
Frequency response:30 Hz to+/-3 dBoutput voltage of 10 Vrms over a load
20 kHzimpedance of 12.5 Ohms to 1000 Ohms
THD+N at 70.7 Vrms,.05%.1%30 Hz to 20 kHz, 25 Ohm load, A weighted
200W:
THD+N at 70.7 Vrms, .5%1 %7 kHz, 12.5 Ohm load, A weighted
400W:
THD+N at 100 Vrms, .05%.1%30 Hz to 20 kHz, 25 Ohm load, A weighted
200W:
THD+N at 100 Vrms, .5%1%7 kHz, 12.5 Ohm load, A weighted
400W:
Sensitivity at 70V:11 dBV+/-1 dBV
Sensitivity at 100V:14 dBV+/-1 dBV
Gain:26 dB+/-0.5 dB
Output noise:-70 dBV-65 dBVA-weighted with a 20 kHz filter
Crosstalk at 1 kHz:-90 dB</= -80 dBset for 0 dB gain, no limiting, terminate the
unused input with a 50 Ohm resistor
Crosstalk at 10 kHz:-70 dB</= -60 dB
Turn on/off pop:10 mV peak</= 50 mVpk as monitored by a listener, must be inaudible at
full gain using a Model 32 loudspeaker tapped
at 32W, with the unit set for no EQ and the
loudspeaker 3 feet from listener
10
ELECTROSTATIC DISCHARGE SENSITIVE (ESDS)
DEVICE HANDLING
This unit contains ESDS devices. We recommend the following precautions when repairing,
replacing or transporting ESDS devices:
• Perform work at an electrically grounded work station.
• Wear wrist straps that connect to the station or heel straps that connect to conductive
floor mats.
• Avoid touching the leads or contacts of ESDS devices or PC boards even if properly
grounded. Handle boards by the edges only.
• Transport or store ESDS devices in ESD protective bags, bins, or totes. Do not insert
unprotected devices into materials such as plastic, polystyrene foam, clear plastic bags,
bubble wrap or plastic trays.
PART LIST NOTES
1. This part is not normally available from Customer Service. Approval from the Field Service
Manager is required before ordering.
2. The individual parts located on the PCBs are listed in the Electrical Part List.
3. This part is critical for safety purposes. Failure to use a substitute replacement with the
same safety characteristics as the recommended replacement part might create shock, fire
and/or other hazards.
4. This part is referenced for informational purposes only. It is not stocked as a repair part. Refer
to the next higher assembly for a replacement part.
AMPLIFIER MODULE REPAIR INFORMATION
The Amplifier / Power Supply PCB assembly, part number 278982-001, originally used in the
E4 Series II amplifier is no longer available. This is due to the Tripath amplifier driver module
going obsolete.
For amplifier board related failures in the E4 Series II, the amplifier module assembly used in
the FreeSpace® 4400 amplifier must be used as a replacement part. This requires some minor
modifications to the E4 II chassis and a kit of parts that includes adapter brackets, screws and
an EMI gasket. The entire amplifier assembly, including the heatsink, must be replaced. Refer to
service bulletin 278977-B2, located in the back of this manual as well as on the Bose® Service
web sites at http://intranet.bose.com/tsg or http://serviceops.bose.com for more information.
Required Parts:
•FreeSpace 4400 Amplifier Module Assembly , Bose
®
part number 301391
•FreeSpace 4400 Amplifier Module adapter kit, Bose part number 311963
Note: This procedure cannot be used on any of the E4 Series I amplifier versions. In addition,
it cannot be used on the E4 Series II Japan version, product code 036006.
11
PACKAGING PART LIST
Item
Description Part Number Qty. Note
Item
Description Part Number Qty. Note
FreeSp ace® E4 Series II Business Music System (see Figure 1)
Number
1 FS INSTALLER CD FOR E4 V2.000 279435-2000 1
2 BAG, POLY, 14.38 x 9.87 x 2mil 103351 1
3 FS E4 SERIES II OWNERS GUIDE 279145-001 1
4 FS E4 SERIES II QUICK START GUIDE 279146-001 1
5 LINE CORD, 120V, 16 AW G, DET, US/CA
LINE CORD, 240V, DETACHABLE, UK/SING
LINE CORD, 230V, DETACHABLE, EURO
LINE CORD, 100V, DETACHABLE, JAPAN
LINE CORD, 240V, DETACHABLE, AUS
6 FS E4 ACCESSORY KIT, ALL VERSIO N S 260549 1
7 BAG, POLY, HDPE 13.5 x 35 x 9.5 x 1mil 114522 1
8 PACKING, FOAM, PU, 16 X 4 X 1 268755 4
9 PACKING, FOAM, EPS 262031 2
10 CARTON, RSC, E4 SERIES II 279496-001 1
Accessory Kit Part List (not shown)
263453-006
173351
173352
173353
284241-006
1 3
Number
- CARTON, D-C, 266856 1
- CONNECTOR, HDR, 5.08MM SP, WEID, 2P 260621-02 5
- CONNECTOR, PLUG-IN 172930-02 7
- CONNECTOR, PLUG IN, 3 POS, MALE, BLK 172930-03 2
- CONNECTOR, PLUG-IN, 4P 172930-04 4
- FEET, CHASSIS 187478 4
- LABEL, VOLTAGE SELECT 170206 1
- BAG, POLY, ZI P LOCK, 2 MIL, 3X5" 260556-0305 5
1
2
3
4
REF
92x
8
5
7
6
4x
10
Figure 1. FreeSpace E4 Series II System Packaging View
12
Item
Description Part Number Qty. Note
MAIN PART LIST
FreeSp ace® E4 Series II Business Music System (see Figure 2)
FUSE DRAWER, 1P, BLK, 5 X 20MM
14 SWITCH, AC POWER, DPST, 16A, 250V 260600 1 3
15 SCREW, TAPP, #4-40 x . 5, PAN, XREC 170284-08 2
16 SCREW, JACK, RS-23 2 PO R T 260564 2
17 SCREW, 6-32, MACH, F LAT, XREC 190623-004 10
18
A
B
C
D
E
19 SCREW, 6-32, PH, INT, S EM 181248-004 9
20 SUPPORT, PCB, POST, MINI, 1.5" 260594-24 4
21 HARNESS, 20P, DS P / MI C SE NS 260511-1 1
22 HARNESS, 16P, DSP / R EM O U T 260512-1 1
23 HARNESS, 16P, DS P / U SER INT 260513-1 1
24 HARNESS, 34P, PS / PA / DSP 260514-1 1
25 AMP MODULE ASSY, FS 4400
J1 HEADER, 1X 8P, P2.54, ST, MALE 2101-3134+0 4
J2 HEADER, 1X 8P, P2.54, ST, MALE 2101-3134+0 4
J3 HEADER, 1X 11P, P2.54, ST, MALE 2101-3135+0 4
J4 HEADER, 1X 11P, P2.54, ST, MALE 2101-3135+0 4
Number
72
DISASSEMBLY PROCEDURES
Note: Refer to Figure 2 for the following
procedures.
1. Top Cover Removal
1.1 Remove the ten screws (1) that secure
the top cover (2) to the chassis (9).
1.2 Lift up on the back of the top cover and
slide it to the rear until it clears the front
edge of the chassis. Lift off the top cover.
2. LED Display PCB Removal
2.1 Perform procedure 1.
2.2 Remove the four screws (20) that secure
the LED PCB (19D) to the front panel. Lift
out the PCB.
2.3 Disconnect the ribbon cable (24) from
the LED display PCB (19D).
3. Fan Removal
4.2 Remove the six screws (18) that secure
the DSP/User Interface (19C), Wall Plate
Sense PCB (19B) and the Auto Volume PCB
(19A) to the rear panel.
4.3 Remove the two standoffs (17) that
secure the RS232 connector to the rear
panel.
4.4 Remove the two screws (20) that secure
the DSP/User Interface PCB (19C) to the
bottom of the chassis and carefully lift all of
the PCBs out of the unit.
Re-assembly Note: Be sure to replace both
screws when re-installing the DSP PCB. A
connection to chassis ground is made using
these screws.
4.5 Unplug the ribbon cables from J511 and
J512 on the DSP/User Interface PCB.
4.6 Using needle-nose pliers, compress the
ends of the standoffs that secure the DSP/
User Interface PCB to the other two boards.
3.1 Perform procedure 1.
3.2 Disconnect the 2-wire plug from the
lower power amp/power supply PCB assembly (26B).
3.3 Using a 5/16" nut driver remove the four
nuts (4) that secure the fan (3) to the chassis. Lift out the fan.
4. Auto Volume PCB, Wall Plate Sense PCB
and DSP/User Interface PCB Removal
Note: There are three PCBs being removed
in this procedure. The largest of the three,
mounted in the bottom of the chassis, is the
DSP/User Interface PCB. The Auto Volume
and Wall Plate Sense PCBs can be detached once this procedure is performed.
4.1 Disconnect the LED harness at J510
(24) and the power/output harness at
JH501 (25) from the DSP/User Interface
PCB (19C).
5. Power Supply/Power Amp Module
Removal
Note: The E4 II Power Supply/Power Amp
PCB assembly, part number 278982-001,
is no longer available. In the event of a
power amplifier module failure, the amplifier
module used in the FreeSpace® 4400 amplifier must be used as a replacement. Refer
to service bulletin 278977-B2 in the back of
this manual for the repair procedure.
5.1 Perform procedure 1.
5.2 Disconnect the large ribbon cable (25)
from the DSP PCB.
5.3 Remove the three screws (20) that
secure the PCB to the chassis standoffs.
5.4 Remove the three 11/32" nuts (29) that
secure the heatsink assembly (30) to the
chassis.
5.5 Remove the four screws (18) that
secure the PCB (26A&B) to the rear panel.
73
DISASSEMBLY PROCEDURES
CB
4)
Transistor Clips
C
(channels 1 & 2)
5.6 Slide the heatsink/PCB assembly forward while lifting the front of the PCB up
slightly.
5.7 Disconnect the fan harness from the
bottom PCB assembly and lift the heatsink
assembly out of the chassis. Disconnect the
power transformer from the lower amp PCB.
Note: Refer to Figures 2 and 4 for the
following procedures.
PCB Screws
Heatsink
eramic Insulators
Lower Amp P
Upper Amp PCB
PCB Supports
(channels 3 &
Figure 4. E4 II Amplifier Module Assembly
6. Upper Power Amplifier PCB Removal
Note: The Upper Power Amp PCB contains
the circuitry for channels 1 and 2.
6.1 Perform procedure 5.
with pliers in order to lift off the PCB. Try to
leave the ceramic insulators stuck to the
heatsink in their original positions if possible
as this will aid re-assembly.
7. Lower Power Amplifier Removal
Note: The Lower Power Amp PCB contains
the circuitry for channels 3 and 4 as well as
the power supply components for the unit.
7.1 Perform procedure 5.
7.2 Disconnect the harness going to the
larger PCB (26B) (channels 3 & 4).
7.3 Using a flat blade screwdriver, lift the top
of the transistor clip out of the groove of the
heatsink assembly. Repeat for all four
transistors. Retain the clips for re-use.
7.4 Remove the two screws that secure the
PCB to the heatsink. These screws go
through the heatsink and into the board
mount clip.
7.5 Gently lift the PCB off the two standoffs.
You may have to squeeze the standoff with
pliers in order to lift off the PCB. Retain the
ceramic insulators under the transistors for
re-use.
6.2 Disconnect the 34 pin ribbon cable that
8. Power Transformer Removal
connects to the upper amplifier PCB at PL8.
8.1 Perform procedure 5.
6.3 Disconnect the 4 wire power supply wire
that connects to the upper amplifier PCB at
PL12.
6.4 Using a flat blade screwdriver, pry the
top of the transistor clip out of the groove on
the heatsink assembly. Repeat for all four
transistors. Retain the clips for re-use.
8.2 Disconnect the power transformer
harness from the power supply/power amp.
8.3 Remove the nut (5) and washer (6) that
secure the power transformer (7). There
should also be a cup washer and rubber pad
on top of the transformer.
Note: Older units will have a bolt and flat
6.5 Remove the two screws that secure the
PCB to the heatsink. These screws go
through the heatsink and into the board
mount clip.
6.6 Gently lift the PCB off of the two stand-
washer.
8.4 Remove the two screws (15) that secure
the inlet assembly (9-13) to the rear panel.
Remove the ground nut (4). Lift out the
power transformer.
offs. You may have to squeeze the standoff
74
TEST PROCEDURE SETUP
Product Code Country VAC
Equipment Requirements
• 400 MHz Pentium-based PC with a minimum of 256 MB of RAM and 50 MB of of
available hard drive space
• 4x CD-ROM drive
• One of the following operating systems: Microsoft
• 800 x 600 display
• The Bose
®
E4 Series II Installer™ software version 2.0 or higher
• An RS-232 serial cable, M/F with DB9 connectors
• An oscilloscope
• An audio signal generator similar to an Audio Precision ATS-1
• A digit al multimeter
• Four 100 Ohm, 250 Watt load resistors
• One 2 Ohm, 250 Watt load resistor
Test Strategy and Conditions
Verify the customer complaint. Read any applicable notes that came in with the unit. Then
power up the unit and attempt communication using the Bose Installer program. If successful,
examine the error log files to try to determine the nature of the failure.
®
Windows® NT, 2000 or Vista
The amplifier will be put into a known state for test by first updating the unit’s microcode using
the Bose Installer program. This resets the unit, sets the EQ’s and gains to the proper levels
and maps the Zone 1 input to Zones 1 – 4 at the outputs. Once that is completed, the unit will
need to be configured so that Zone 1 input is mapped to the Zone 1 amplifier output, Zone 2 to
Zone 2, etc. Once this is completed the amplifier will be properly configured for test.
All AC audio measurements must be band limited to 30 kHz. AC power must be applied to the
amplifier product variants as follows:
036004 US/Canada 120 VAC/60 Hz
036005 UK/Singapore 230 VAC/50 Hz
036006 Japan 100 VAC/60 Hz
036007 Europe 230 VAC/50 Hz
036008 Australia 240 VAC/50 Hz
All audio inputs must be terminated with 600 Ohms. All line level outputs must be terminated
with 400 Ohms. All amplifier outputs must be terminated with 50 Ohms.
75
THE FREESPACE® INSTALLER™ FRONT PANEL
When your PC is connected to the E-4 system, the hardware panel in the Set Up Hardware
mode displays the system’s front panel.
Selecting one of the internal hardware functions (gray background) displays the controls in the
control pane.
Displays the “Input Gain” controls for one of the four input channels.
Displays the “Input EQ” controls for one of the four input channels.
Displays the “Page Set Up” controls for line 4.
Displays the “Source Assign” controls for one of the four channels.
Displays the “Auto Volume” controls for one of the four channels.
Displays the “Dynamic EQ On/Off” controls for one of the four channels.
Displays the “EQ” controls for one of the four channels.
Displays the “Output Gain” controls for one of the four channels.
Displays the “Zone Set Up” controls for one of the four zones.
76
System Setup
TEST PROCEDURE
To connect to the FreeSpace® E4 Series II system you must first have the FreeSpace Installer
software installed on your PC.
Note: The E4 Series II ships with the Installer software CD included in the carton. If you do not
have access to the software CD, you can download this software from the Bose Professional
Products web site at http://www.pro.bose.com. Click on Products, scroll down to the Discontinued Products link and click on it. On that page you will see links for the FreeSpace Installer
version 2.0 software.
• Connect the RS-232 serial data COM port of your PC to the RS-232 serial port on the rear
panel of the E4 II amplifier using an RS-232 DB9 connector serial cable. Ensure that the PC
used for testing is connected to the unit under test via an active COM port. Configure the PC
COM port as listed below.
Baud Rate:57.6K
Word size:8 bits
Parity:none
Stop Bits:one
Test Procedures
1. Speaker Output Relay Test
TM
1.1 With the unit disconnected from AC mains and the power switch in the OFF position, use an
Ohmmeter to measure a short across the output relays for all four amplifier outputs. Measure at
the following points:
Zone 1 speaker output – Measure zero ohms from Ch 1 pin 1 to pin 2
Zone 2 speaker output – Measure zero ohms from Ch 2 pin 1 to pin 2
Zone 3 speaker output – Measure zero ohms from Ch 3 pin 1 to pin 2
Zone 4 speaker output – Measure zero ohms from Ch 4 pin 1 to pin 2
2. Front Panel LED Test
2.1 Connect the unit under test to AC mains. Turn the unit ON by pressing the standby switch
on the front panel. Verify that the unit turns on.
2.2 Once you have turned the unit ON above, verify that the “System Status” LED and the four
“amp outputs” status LED’s are illuminated green. Verify that all other LED’s are off. This verifies
that the unit has passed its own power-on-self-test.
3. Wall Plate Connector Test
This test measures the voltage at the wallplate connectors. Using a multimeter, measure the DC
voltage from pins 1 to 8 for the four connectors sequentially.
3.1 Measure the +5VDC on each of the connectors from pins 1 to 8. Verify that the DC voltage
is in accordance with the table on the next page.
77
TEST PROCEDURE
Measure
Reference
Value pins
Value pins shorted
Input Level Measure at Gain
THD+N
Connector Output Noise (20 Hz – 22 kHz)
3.2 Short the eight pins of the connector together and measure the DC voltage. Verify that it is
5.1 Apply a 1kHz, 1Vrms (0dBV) signal into the Line In 1A & B input. Reference a dB meter to
the input signal. Measure the gain and distortion at the Zone 1 SPKR Output as shown in the
table below. Sweep the input frequency from 20Hz to 20kHz while monitoring the gain level to
verify that it remains in tolerance across the band.
Designator
open
5.2 Repeat step 5.1 for the inputs listed below.
(±±±± 1dB)
Line In 1A & 1B 1Vrms (0dBV) Zone 1 SPKR Output 6 dB < 1%
Line In 1A & 1B 1Vrms (0dBV) Music On Hold/PBX Out 0 dB < .1%
Line In 2A & 2B 1Vrms (0dBV) Zone 2 SPKR Output 6 dB < 1%
Aux Mic/Line 3 1Vrms (0dBV) Zone 3 SPKR Output 6 dB < 1%
Page/Mic/Line4 1Vrms (0dBV) Zone 4 SPKR Output 6 dB < 1%
Page/Mic/Line4 1Vrms (0dBV) Zone 4/Line Out 0 dB < .2%
(20-20 kHz)
78
TEST PROCEDURE
Measure at Volt age Level
Measure at Ref Des Gain
THD+N (20-30 kHz)
6. Verify Sequence Output Test
This test checks the Sequence DC voltage level on the Zone 4 Line Out jack. This voltage is
used to turn on remote amplifiers such as the Bose
6.1 Ensure that the unit in STANDBY with AC mains power applied and that the Power ON/OFF
switch on the rear panel is in the ON position. Using a DMM, measure the DC voltage level at
the Zone 4 Line Out jack from pin 4 (+12V) to pin 3 (GND). Verify that it is 0 VDC.
6.2 Press the STANDBY button on the front panel. Ensure that the amplifier powers up and that
the SYSTEM STATUS LED lights green. Using a DMM, measure the DC voltage level at the
Zone 4 Line Out jack from pin 4 (+12V) to pin 3 (GND). Verify that the DC voltage level is now
12 VDC+/-5%.
Zone 4 Line Out (J401 PIN 4) 0 VDC
Zone 4 Line Out (J401 PIN 4) 12 VDC +/-5%
7. Override (Direct input) Test
7.1 Apply a 1 kHz, 1 Vrms (0dBV) input to the Direct In/Control jack at pins 1 and 2 (J503). Hold
J503 Pin 4 open and verify that no signal is present at the Zone 1 (SK1), Zone 2 (SK2), Zone 3
(SK3), and Zone 4 (SK4) speaker output jacks. Reference a dB meter to the input. Short J503
Pin 4 to J503 Pin 3, and verify the following:
®
Model 1600/1800VI amplifiers.
(±±±±1dB)
Zone 1 SK1 30 dB < 1%
Zone 2 SK2 30 dB < 1%
Zone 3 SK3 30 dB < 1%
Zone 4 SK4 30 dB < 1%
8. Contact Closure Input Test
This test checks the remote standby functionality of the E4 Series II amplifier.
8.1 With the unit in operate mode, short pins 1 and 2 of J402 together (Remote ON/OFF jack).
The unit should turn off.
8.2 Remove the short. Verify that the unit returns to standby mode.
(i.e., standby LED is lit amber).
79
TEST PROCEDURE
9. Short Circuit Protection Test
9.1 Connect a 2 ohm, 250 Watt load resistor to the Zone 1 output.
9.2 Apply a 1 kHz, 126 mVrms (-18 dBV) signal into the Direct Input connector pins 1, 2 and 3.
Connect the plus side to pin 1 (+). Connect the minus side to pins 2 (-) and 3 (GND).
9.3 Verify that the amplifier goes into Protect mode.
Note: When the amplifier goes into protect mode the speakers are immediately disconnected,
and the amplifier is shut down for approximately 3.5 seconds. It is then restarted and checked
again after a 1 second stabilization period. If everything is not OK, 6 more off-wait-stabilize-reset
cycles are attempted. If after 6 retries within 1 minute, everything is still not OK, the amplifier is
returned to a state that requires a “Standby-On” cycle, a “hard power down” or some other form
of user intervention to restart.
9.4 Repeat steps 9.1 to 9.3 for the Zone 2, 3 and 4 outputs.
10. Code Revision Level Check
This test displays the code revision levels for the various microcontrollers used in the E4 II
amplifier. This will tell the repair technician whether or not he needs to update the code before
returning the unit.
10.1 Launch the Bose
tab and read the installed code revision levels for:
Reset the unit to the default factory settings. This will ensure that the unit is in the proper state
when installed after a repair.
11.1 With the unit in STANDBY or ON status, launch the Installer software.
11.2 Verify the following factory default settings; Line 1A and 1B Inputs mapped to Zone 1,
Zone 2, Zone 3 and Zone 4 outputs.
®
InstallerTM software, if not already open. Click on the “Service Hardware”
11.3 Save settings to flash memory. Power down the unit once the flash update is complete.
80
TROUBLESHOOTING
A
A
This section provides troubleshooting guidelines to use for solving problems you may
encounter servicing the E4 Series II systems.
♦ E4 Series II hardware indicators
• Normal operation
These are the indications of normal operation.
STANDBY
Unlit
SYSTEM STATUS
Green
MP OUTPUTS
Unlit or Green
UDIO SOURCES
Unlit, Amber, or Green
DIRECT INPUT
Unlit
AMP OUTPUTS
1234
AUDIO SOURCES
1234
SYSTEM
STATUS
DIRECT
INPUT
♦ System fault
A red SYSTEM STATUS LED indicates that
the system received an error from one of its
many internal components. A red SYSTEM
STATUS LED after AC power is switched on
may be caused by:
• A Power-On Self-Test failure
• A DSP error
• The DSP is offline
STANDBY
To determine the severity of the error, cycle
the unit’s power off and back on again. If the
SYSTEM STATUS indicator is now off, the
system has logged an error, but is still
operational.
When you check the error log using the
Installer™ software you can identify the
cause of the error, and determine an appropriate solution.
SYSTEM STATUS
Indicator is red
Switch the E4 unit to STANDBY and
then back to active again. If the
SYSTEM STATUS is green, the sys-
Have you cycled
the E4 in and out
of STANDBY?
Yes
Have you cycled
the E4 power
on and off?
Yes
No
tem may have logged an error.
Check the Installer™ software Error
Log.
1. Switch the E4 unit to STANDBY.
2. Set the POWER switch to OFF.
No
3. Wait for STANDBY indicator to
turn off.
4. Set the POWER switch to ON.
5. Press the STANDBY switch.
AMP OUTPUTS
1234
AUDIO SOURCES
1234
SYSTEM
STATUS
DIRECT
INPUT
System logged an error – Check the
Installer™ software Error Log.
STANDBY
Have you
disconnected all
input/output
cables?
Yes
Troubleshoot and
Repair Unit.
1. Switch the E4 unit to STANDBY.
2. Set the POWER switch to OFF.
No
3. Disconnect all input/output sig-
nal cables.
4. Set the POWER switch to ON.
5. Press the STANDBY switch.
6. Reconnect one cable at a time
and check the Error Log.
81
TROUBLESHOOTING
Amplifier fault
The AMP OUTPUT LEDs work in pairs (1
and 2, 3 and 4) and indicate the operating
status of the four amplifier output channels.
AMP OUTPUTS
1234
AUDIO SOURCES
1234
SYSTEM
STATUS
DIRECT
INPUT
STANDBY
Check for
• Shorted wiring
• Overdriven amplifier
(reduce output gain)
• Transformer saturation
• Entry in Installer™ software error log
When an amplifier fault occurs, the amplifier
mutes its outputs and indicates an error.
After a short period of time the amplifier will
try to operate again. If the fault condition
persists, the amplifier will attempt to restart
six times, after which it will remain muted.
Amplifier faults are typically caused by a
shorted loudspeaker line, an overdriven
amplifier, or a saturated output transformer.
• To check for a shorted loudspeaker line,
remove the loudspeaker connection from the
amplifier channel. If this resolves the problem, locate and correct the shorted loudspeaker line.
AMP OUTPUT
indicators are red
Has the E4 unit
shut down during
operation?
No
Is SYSTEM
STATUS indicator
green?
Yes
Does the Installer™
software Error Log list
any amplifier
faults?
No
Perform test procedures.
If unit passes, return to customer.
• Check the number of loudspeakers connected to the E4 unit.
Yes
No
Yes
Verify that the total sum of loudspeaker taps connected to the
E4 unit does not exceed 400W.
• Verify that there are no shorts on
the speaker output lines.
• Switch POWER to OFF.
• Disconnect the load and switch
POWER to ON.
• Verify that there are no shorts on
the speaker output lines.
See amplifier fault troubleshooting
section for course of action.
• To make sure that you are not overdriving
the E4 Series II output, change to a different
source. If the problem no longer exists, use
the Installer™ software to reduce the input
level of the original source that was
overdriving the output.
• To make sure an output transformer is not
being saturated, check to see if the correct
loudspeaker EQ setting is selected.
If none of these actions solve the problem,
read the instructions in the following flow
chart or check the error log using the Installer software.
82
TROUBLESHOOTING
Input clipping
If clipping is occurring at the input of an
amplifier channel, the source LED will blink
red.
AMP OUTPUTS
1234
AUDIO SOURCES
1234
SYSTEM
STATUS
DIRECT
INPUT
If this fault occurs:
• Reduce the output gain of the source, or
• Using the Installer™ software, reduce the
input gain for the channel that is clipping.
Direct input is active
STANDBY
No ST ANDBY and SYSTEM Indicators
STANDY & SYSTEM LEDs
are off - AC power is on
Is E4 unit
plugged into an
AC source?
Yes
Is the E4
POWER switch
set to ON?
Yes
Is STANDBY
indicator on?
No
Plug the E4 unit into an AC
receptacle.
No
Set E4 POWER switch to ON.
Yes
Press the STANDBY switch on the
E4 front panel.
If the DIRECT INPUT LED is red:
• Check that the DIRECT INPUT/CONTROL
contact closure is in the closed position.
• Check the device to which this input is
connected.
AMP OUTPUTS
1234
SYSTEM
STATUS
STANDBY
AUDIO SOURCES
1234
DIRECT
INPUT
No
Is SYSTEM STATUS
indicator red?
No
Is the unit properly
configured for the line
voltage?
Yes
Troubleshoot and
repair unit.
• Connect your PC to the E4 unit
Yes
and read the Error Log.
• Check the results of the Power On
self test (POST).
• Use the POST troubleshooting
chart for course of action.
• Set E4 POWER switch to OFF.
• Verify that E4 unit is configured for
the correct AC line voltage.
No
• Verify that the fuse is good.
• Verify that the AC receptacle is
live.
• Set POWER switch to ON.
83
TROUBLESHOOTING
E4 Series II system Error Log
The system Error Log is displayed when the
E4 Series II Installer™ software is in the
Service Hardware mode.
Contents of the Error Log
The Error Log displays system hardware
version numbers and records all alarms and
their causes as shown in the following
example.
The system hardware version numbers
appear at the top of the Error Log listing.
These are the version numbers of the
software installed in the hardware at the time
of manufacture. These version numbers do
not pertain to the Installer™ software installed on your PC.
Power-on self-test results
The power-on-self test (POST) results are
only displayed when an error has occurred.
The POST test checks the basic operation of
the E4 Series II hardware to determine if it is
capable of properly performing audio processing and amplification. During the POST
test, six major components of the hardware
are tested.
• Host controller – The host controller monitors and controls the operation of the system
hardware. A host controller failure will cause
the message, “Power-on self-test incomplete” to appear in the host controller test
section. The failure type for a host controller
is an SRAM address failure.
• Flash memory test – The flash memory
contains the configuration, design file, and
system event schedule. A flash failure will
cause the message, “Power-on self test
incomplete” to appear in the host controller
flash test section.
• Peripheral controller – The peripheral
controller monitors contact closures, front
panel connections and user interface connections for incoming event messages. Any
failures in these areas will cause the message, “Power-on self-test incomplete” to
appear in the peripheral controller flash test
section. If a user interface failure occurs,
check the user interface wiring for shorts.
• DSP test – The DSP performs all signal
processing and routing functions.
• Upper and lower amplifier test – The upper
and lower amplifier test determines if the
amplifiers are operating properly. An amplifier failure will cause the message, “Poweron self-test incomplete” to appear in the
upper or lower amplifier section of the POST
test results. Additional details on the exact
cause of an amplifier failure can be found in
the amplifier section of the Error Log.
• Front panel board test – The front panel
board test deter-mines if the USB port is
working properly. A USB failure will cause
the message, “Power-on self-test incomplete” to appear in this section of the POST
results.
Note: The USB port is not currently used for
communication with the E4. If a USB failure
occurs, the E4 will still function normally for
audio processing and amplification.
84
TROUBLESHOOTING
Amplifier alarms
Each amplifier section monitors its own
operation and performance. If a fault condition occurs, it is reported in the Amplifier
Alarm section of the Error Log. Upper amplifier alarms affect channels 1 and 2, and
Lower amplifier alarms affect channels 3
and 4.
The amplifier section of the alarm log indicates the following:
• Alarm type – The generated alarm type is
the first item.
• Amplifier status – When an alarm is
generated, the amplifier reports its current
operating status for diagnostic purposes.
The following items are reported in the
status:
Date & Time: Date and time when alarm
condition occurred.
Rail Voltage: The amplifier positive and
negative rail voltages. Normally, the amplifier
rail voltage should be between 100V and
190V. Voltages outside this range will cause
the amplifier to shut down. In the 70V mode,
a normal rail voltage is approximately 125V.
In the 100V mode, a normal rail voltage is
approximately 165V.
Temperature: The internal operating temperature of the amplifier. Normally, this will
be between 0° and 160° Fahrenheit (-18° to
71° Celsius).
Output Voltage: The actual output voltage of
the amplifier at the time of the alarm.
Output Current: The actual output current of
the amplifier at the time of the alarm.
Input Status: The status of the input signal to
the amplifier. Possible status messages are
DC sense fault, amplifier module fault, AC
power fault, sleep mode, high-frequency
sense fault, and retry fault.
Output Status: The status of the amplifier
output at the time of the alarm. Possible
status messages are “amplifier module
muted,” and “speaker relay off.”
Fan Speed: The fan speed at the time of the
alarm.
Operating Mode: The current setting of the
output voltage select switch, 70V or 100V.
Amplifier alarms – using output voltage and
current
Reviewing the output voltage and current
can help to diagnose a problem. Compare
the output voltage and current for each of
the two amplifier outputs to determine the
nature of the problem.
High Current
(>2A)
High Current
(<1A)
High Voltage
(>20V)
Driving an impedance <12 Ohms
• Reduce total loudspeaker load
• Check for partial short of loudspeaker line
Loudspeaker trans former saturation at
low frequency
•Check for proper
Speaker EQ setting
• Set Speaker EQ to
high-pass filter
Low Voltage
(<20V)
Short on loudspeaker line
Amplifier alarms – using rail voltage
Normally, the amplifier rail voltage should be
between 100V and 190V. In the 70V mode a
normal rail voltage is approximately 125V. In
the 100V mode a normal rail voltage is
approximately 165V.
By comparing the + and – rail voltages, you
can determine if you are driving an impedance which is too low (<12 Ohms). In this
case the difference between the two rails will
probably be greater than 20%. If one of the
rails shows a voltage, and the other does
not, the amplifier module should be replaced.
As you review all alarm records you can
compare the plus rail voltage in each of the
status sections. For example, a drop of 50%
in one status could indicate a brownout
condition occurred.
85
TROUBLESHOOTING
Amplifier alarms – input and output
status
The Input and Output Status sections display
the fault condition which caused the alarm
and the current status of the amplifier output.
A number of fault conditions can be displayed in the Input Status section:
DC Sense Fault: A power supply fuse, output
FET, amplifier module, or some combination
of the above has blown. The amplifier module should be replaced.
Amplifier Module Fault: When the Amplifier
Module fault occurs by itself it can be caused
by any of the following:
• Shorted loudspeaker line – Check the
loudspeaker line for shorts.
• System power exceeds 400W – Check that
system power does not exceed 400W.
• Loudspeaker transformer saturation –
Check that proper loudspeaker EQ is being
used or use a high-pass filter for loudspeaker EQ.
• Line voltage too high (surge) – Check Error
Log for a rail voltage that exceeds 150V, in
70V mode, or 190V, in 100V mode.
• Line voltage too low (brownout) – Check
Error Log for a rail voltage which is lower
than normal by at least 20%.
• 70/100V mode switched with unit operating
– Check that output voltage and AC input
voltage selector are correct.
• Blown power supply fuse (as opposed to
AC line fuse) – Replace the fuse and perform the test procedures in this manual. If
the fuse blows again, replace the amplifier
module and retest.
AC Power Fault: Might be an AC line dropout
or severe brownout, or simply AC power
turned off without first placing the E4 Series
II in standby mode. You can check that the
power has been removed from the unit, or
that you experienced a power dropout.
Sleep Mode: The host microcontroller has
told the amplifier and power supply to turn
off. This only occurs in conjunction with
another alarm (usually AC power fault),
because it in itself is not an alarm condition.
When an AC power dropout occurs, the
amplifier immediately shuts the amplifier and
loudspeaker relay off, then the other processing is shut down. This all happens fast
enough to prevent data loss or corruption,
and to prevent loud pops in the loudspeakers. When this occurs you should check the
alarm history to determine what other faults
occurred at this time.
High-Frequency Sense Fault: This protection
mode is designed to prevent damage to the
amplifier or loudspeakers from excessive
high-frequency audio or ultrasonic energy.
The amplifier is not capable of sustained
operation at full power in the 10kHZ to
20kHz (+) range.
Generally, this fault results in a one-time 3second dropout. If, when the amplifier tries
to restart after 3 seconds, the excess HF is
still present, the amp (and loudspeaker
relay) will remain off for another 3 seconds
and the loop repeats. Six of these in a row
will cause the amp to shut down, and will
trigger a Retry Fault.
When this fault occurs you can check your
program material for excessive high-frequency content, or for a potential ground
loop which has created an oscillation internal
to the system. You can also reduce the
output gain for this amplifier zone in an
attempt to reduce the high-frequency energy
going to the amplifier.
86
TROUBLESHOOTING
Retry Fault: The amplifier has tried to start
up or recover from a fault condition at least
six times. When this occurs, you will need to
place the E4 Series II system in standby and
then press the STANDBY button again to
clear the fault, at which time the system will
again try to start up.
When this occurs you should check the
alarm history section of the Amplifier Alarm
to determine the exact fault type that triggered the Retry Fault.
Input and Output Alarm History: This part of
the Error Log displays the sequence of fault
conditions where “0” is the initial fault reported followed by “1-6”. These occur over a
very short period of time.
Solving faults reported in the Error Log
When errors are reported in the Error Log,
you can try to solve the problem by performing one of the following actions:
• On the unit’s rear panel, turn the POWER
switch to OFF. Wait a few seconds and turn
the POWER switch to ON. Then press
STANDBY on the front panel.
• On the rear panel, turn the POWER switch
to OFF. Disconnect all input/output signal
cables. Wait a few seconds and turn the
POWER switch to ON. Then press
STANDBY on the front panel. Reconnect
one cable at a time and check the Error Log.
This normally occurs due to one of three
reasons:
• The PC and unit under test are not connected via a “straight-wired” serial cable.
• Another software application has control of
the serial port. Applications such as the Palm
OS, or other audio applications control the
serial port while they are open. Close these
applications and click the TRY AGAIN
button.
• The unit is connected to another communications port. If this is the case you should
select the appropriate COM port and click
the TRY AGAIN button.
Note: Before dismissing the “Choose COM
port” dialog, select the COM 2 port and click
the TRY AGAIN button. Not doing this will
cause the COM 1 port to be locked. If the
port locks, you must restart your computer.
Common Problems
Communications port error
When you receive the communications port
error dialog, the Installer™ software was not
able to locate an E4 Series II system on the
COM 1 port.
No audio in zone
If the system is powered on and operational,
but there is no sound, check the following:
• Do the front panel LEDs indicate normal
operation?
• Is the source operating?
• Is routing correct?
• Is output gain correct?
• Is the output gain muted?
• Is cabling correct?
87
TROUBLESHOOTING
No audio in zone (continued)
No audio in zone.
• Make sure that the audio sources
are connected to the E4 LINE in-
Are the AUDIO
SOURCES indicators
green?
Yes
Is AMP OUTPUT
indicator red?
No
Yes
puts and that there is an input sig-
No
nal from the source.
• Using the Installer™ software,
check that the input gain is raised.
• Make sure the source is on.
The amplifier is in “protect” mode.
Disconnect the load and see if the
output indicator changes to green.
If so:
• Check for a short in the output
line,
• Make sure no small strands of
wire are touching other wires,
• Make sure speakers are functioning correctly, or
• Using a voltmeter, check for a
voltage drop in the power line
when amplifier is being driven excessively hard.
User interface keypads do not operate
correctly
• Check wiring of RJ-45 connectors.
• Check for breaks/shorts in cable.
• Using the E4 Series II Installer™ software,
check the Error Log for a peripheral controller error.
User interface keypads
exhibit strange behavior
Is keypad connected
to the correct ZONE
on the E4 unit?
Yes
Is the keypad
connector wiring
correct?
No
Connect the keypad to the correct
zone on the E4 unit.
No
Correct the keypad connector
wiring.
Are the
AMP OUTPUTS
indicators green?
Yes
Perform test procedures.
If unit passes, return to
customer.
No
See amplifier fault troubleshooting
section for course of action.
Yes
Are all
sources to be
controlled assigned to
the ZONE? (Std. and
AV keypad)
Yes
Is the
page source
assigned to the ZONE?
(Paging keypad
only)
Yes
Does the Installer™
Error Log list any periph-
eral controller
faults?
No
Perform test procedures.
If unit passes, return to
customer.
No
Check source assignments
using Installer™ software.
No
Check source assignments
using Installer™ software.
Yes
See troubleshooting for the
peripheral controller.
88
TROUBLESHOOTING
Bad sound in a zoneAuto Volume does not calibrate
Bad sound
Is the sound
unnatural?
No
Is the AMP OUTPUT
indicator flashing?
No
Are input and
output indicators green
and sound is
distorted?
No
Verify that the correct Speaker EQ
is selected in the Installer™ soft-
Yes
ware for that zone.
Verify that the speakers are wired in
phase. Check the rear panel markings.
Reduce the input gain using
Yes
Installer™ software until the
indicator is solid green.
Verify that the input source signal
Yes
is clean. If source is from a mixer,
decrease the mixer gain.
Auto Volume calibration may fail if the
process cannot obtain an adequate source
level. This may be due to:
• Loudspeakers are tapped too high
• Maximum output gain is less than -20 dB
• Source is not operating
• Source level is too low
Calibration could also fail if the calculated
loop gain is not within required limits. This
may be due to:
• Broken microphone cable
• Loudspeakers are not connected
• Sensing microphone is not connected, or is
connected to the wrong zone
Is the input signal
clean at the E4 input?
No
Verify source
hardware settings
Verify that the loudspeakers are
not being overdriven or are damaged.
Yes
Verify that the total load impedance presented to the E4 output
is within specified limits for the
selected mode of operation.
89
THEORY OF OPERATION
Power Supply / Amplifier PCB Overview
CAUTION: There are dangerous voltages present on most of the power supply and amplifier
circuitry. Under normal conditions, it can take 5 to 10 minutes after power is removed for these
voltages to discharge to a safe level. Please use extreme caution and resist the temptation to
probe during this period.
®
The FreeSpace
Class-D switching power amplifiers, four separate microcontrollers (uCs), and numerous DSP,
interfaces, memory, logic, analog and communication devices. The accompanying software
includes error flagging and logging features that will usually help you isolate the cause of any
failures.
Power Supply
The E-4 Series II power supply section consists of four sections. First is the main high-voltage
DC supply formed by the toroidal 50/60 Hz transformer, bridge rectifier (BR1) and filter capacitors (C1-C4). This is a conventional unregulated split supply (the only addition is SW1 to change
transformer secondary taps). The raw DC output is about
volt output, and
nal line voltage, these sag to about
thermal protection in the event of a catastrophic power amplifier failure.
E-4 Series II is a complex system that employs high-voltage direct-coupled
+ 130VDC when SW1 is set for 70
+ 170VDC when SW1 is set for 100 volt output. At full power output and nomi-
+ 110V and + 150V respectively. Fuses F1-F4 provide
The next power supply section, formed around TOPswitch
®
regulator U2 and transformer TR2,
is referred to as the “Standby Supply” because it is operational whenever power is applied to the
unit and the rear panel power switch is on. Its purpose is to supply approximately 9 volts (locally
regulated to 5 volts) to several microprocessors and other circuitry. These microprocessors
respond to turn-on stimuli, i.e. power-up via the E-4’s real-time clock, computer control or user
intervention via standby switch or wall plate.
The TOPswitch IC performs all the functions of a complete 130 kHz SMPS flyback-mode controller and switch, i.e. slow-start, current limit, overvoltage lockout, fswitch dither, low current
skip-cycle, etc.
The other, large TOPswitch section formed around U1 and TR1 response to “wakeup” commands from the E-4’s main host processor, which operates from the standby supply. It provides
+ 22 volts (locally regulated to + 15V) and +10 volts (locally regulated to + 5V and + 3.3V) which
powers multiple analog, DSP, communications and indicator sections throughout the E-4. The
forth output from U1 and TR1 (labeled -160) is more accurately described as “180 volts above
the minus rail”. This voltage is locally regulated to 12 volts, and provides the gate-drive current
for the main output FETs.
Also included on the power supply schematic sheet are two other ancillary circuits. U3A is a
resettable one-shot whose output is normally high with AC power applied. If there is an AC line
dropout exceeding approximately 2 cycles, a logic 0 from U3A is used to immediately shut down
the amplifiers and DSP in time to save all current configuration data and prevent any spurious
thumps etc. from appearing at the speaker outputs.
Q1 and Q2 form a simple buffer that switches the cooling fan from low to high speed if either of
the Fan-U or Fan-L signals are at logic 0. This occurs when the power amplifier thermal sensors
report a heatsink temperature of over 160
o
F.
90
THEORY OF OPERATION
Power Amplifier
Refer to the power amplifier channel block diagram below for the following information.
The E-4 Series II power amplifier section employs a number of protective devices and communication circuits to ensure continued reliable operation, and to enable reporting and logging of
any fault conditions. In addition, there are several measurement circuits, whose primary purpose
is to provide information to Bose
configuration of the E-4 Series II unit itself, and the speakers connected to it. The block diagram
provides a simplified view of one of the four channels, however many of the peripheral functions
are shared with one or more other channels. Refer to the schematics for more information on
exactly how the circuitry and functions throughout the units various PCB assemblies.
The power amplifier module itself consists of a single heatsink assembly with two circuit boards
mounted to it back-to-back. The upper PCB contains amplifier circuitry for output zones (channels) 1 and 2; the lower PCB contains amplifier circuitry for output zones 3 and 4, plus power
supply components shared by the entire unit. The power amplifier module receives analog
inputs and 2-way serial communications from the E-4 Series II DSP and host processor sections
via a 34-pin ribbon cable. Power is also supplied from the Amp/PS module to the rest of the unit
via this cable.
Component designators in the block diagram refer to channel 4, see the schematic diagram to
find appropriate designators for other channels. The core of the power amplifier section is a pair
of high voltage MOSFETs (Q10 and Q11). These are driven by a “Class T” hybrid control module from modulation pattern to drive Q10 and Q11’s gates. Contained in the hybrid module itself
are a proprietary analog/DSP IC operating from a single +5 volt supply, and a pair of high
voltage half-bridge gate drive chips including charge pumps for high-side drive. There are also
other discrete components to perform level translation, gain scaling, buffering, etc.
®
FreeSpace® Installer™ software, enabling it to verify proper
91
THEORY OF OPERATION
The Tripath’s modulation pattern has a no-signal center frequency of about 700 kHz. The
switching frequency varies downward as the signal level increases, reaching about 100 kHz just
before clipping. Near clipping, the switching pattern is further adjusted to provide soft clipping
behavior. This appears to be oscillation when viewed on a scope, but all of the artifacts are well
above the audio band, and the “fuzz” actually helps reduce the audibility of clipping. Choke L4
and capacitor C41 form a 2-pole low-pass filter at approximately 70 kHz to remove the switching
frequency from the audio output. C42, R84 and R85 are a Zobel network whose main function is
to damp the resonance of the L4/C41 filter with very high impedance or nonexistent speaker
loads. This network also does double duty: the voltage across R84 and R85 is rectified to
determine if the amplifier is being fed a signal with too much high frequency content. You’ll
notice that there is no analog feedback from the audio output. All of the feedback in the amplifier is derived by comparing the actual FET switching transitions with the predicted transitions,
thus avoiding the inherent delay of the output LC filter. “Servo Amp” A1 provides DC feedback to
insure that the entire amplifier’s output DC offset remains very low. This is especially important
in distributed sound applications, where the speakers are connected through matching transformers that have very low impedance at DC.
The voltages across R87 and R86 are sensed differentially and level-shifted within the Tripath
module (this is how excessive current i.e. a shorted load is determined). This over-current, or
main rail voltages that are too high or too low will cause the module to shut down very quickly
and output a logic 1 on the module’s “Fault” pin.
Protection
PIC microcontroller, U14, monitors amplifier functions including the Tripath’s “Fault” pin (and
numerous other inputs) and responds by turning the amplifier on and off by means of the
Tripath’s “Mute” pin. The speakers are also disconnected under U14s control via relay K1.
In order for the amplifier to become fully functional at start-up, the following conditions must be
true:
•The AC power must be OK.
•The heatsink temperature must be below 160
o
F.
•The “Wakeup” line from the host processor must be high.
•The “Amplifier Off” command (I
•The main rail voltages must be within prescribed limits (
2
C) from the host processor must be absent, i.e. set to “On”.
+100-190V).
•There must not be DC at the output (after a 1 second “servo setting time”).
•There must not be excessive high frequency content at the output.
In addition to this series of tests at start-up, the determination is made whether the unit is set for
70V or 100V output by measuring the + rail voltage <140V = 70V mode, >150V = 100V mode.
70V mode causes a 1 (+5V) output on U14s “Vshift” pin. This 1 causes a small amount of
current to be sourced/sunk into Tripath pins 37 and 38. These currents cause the Tripaths
internal Overvoltage/Undervoltage limits to shift downward corresponding to the
+ 130V rails vs.
+ 170V.
Once the amplifier is up and running, all of these parameters are monitored continuously, with a
o
few minor adaptations. If the heatsink temperature exceeds 160
F, the fan is switched from low
to high speed operation. If the power dissipation is still excessive, and the heatsink exceeds
o
210
F, the amplifier will be shut down until the temperature is under 160oF. Once the initial
voltage measurements are made, the Tripaths internal overvoltage/undervoltage sensing is
relied upon.
92
THEORY OF OPERATION
If anything other than a shutdown command causes the amplifier to go into protect mode (i.e.
AC dropout, overvoltage/undervoltage, short circuit, DC or high frequency), the speakers are
immediately disconnected, and the amplifier is shut down for approximately 3.5 seconds. It is
then restarted and checked again after a 1 second stabilization period. If everything is not OK, 6
more off-wait-stabilize-reset cycles are attempted, normal operation can resume after any of
these. If after 6 retries within 1 minute, everything is still not OK, the amplifier is returned to a
state that requires a “Standby-On” cycle, a “hard power down” or some other form of user
intervention to restart.
Measurement
Measurement of the rail voltages and numerous other parameters are accomplished via an
internal 10-bit A/D converter section in PIC uC U14. Most inputs to the A/D are multiplexed
(under the PIC’s control) via 8-channel analog switch U15. The A/D’s output is truncated to 8
bits and incorporated into the I
Heatsink temperature is monitored via U12, which provides a calibrated output of 10mV/
Several gain, precision rectifier, average circuits are provided to condition the following signals
for measurement via the MPX - A/D section (via voltage across R91):
•Amplifier input voltage
•Amplifier output voltage
•Amplifier output current
To provide repeatable, reliable measurements, the time constant of all these averages is
approximately 100 mSec.
2
C datasteam going to the host processor on the DSP PCB.
o
F.
®
Bose
FreeSpace® Installer™ software uses these measurements to calculate answers to
questions , such as; “Is the amplifier set up and running properly, and providing adequate output
voltage?” “Is the speaker line tapped for the proper output power on this Zone?”
Fault Logging
The amplifier PIC microprocessors are in continuous communication with the E-4 Series II host
processor via the I
2
C serial link. Pin 26 of the PIC micro is connected high or low on the two
amplifier PCBs so the host can distinguish between the upper or lower amplifier PCB. If any of
the events mentioned in the protection section cause the amplifier to shut down, an “Amplifier
Status Record”: plus a set of amplifier measurements (Vout, Iout, TEMP, Vrail, etc.) is saved into
flash memory. Some of the more common fault conditions can be identified by careful dissection
of these status records.
Amplifier Operating States
Pins 4, 5 and 6 on the PIC microprocessor programming headers (JP1 lower) or (JP2 upper)
provide a binary indication of which one of 6 states of operation the amplifier is in. If you monitor
these pins, you can observe the states being walked though, and determine where operation is
getting interrupted.
93
THEORY OF OPERATION
Amplifier Operating States (continued)
The order is pin 4 = MSB, pin 6 = LSB. For example, if pins 4, 5 and 6 measured high (+5V),
high (+5V), low (0V), you would be in state 6. Some of the states are transitioned through so
quickly that you would need a storage scope to verify operation in that state (ex.: state 4). Below
is a brief description of the states:
State 0 Amps and speaker relay OFF-waiting for Wakeup and/or Amp On command.
State 1 Delay- Wakeup received, wait 1 second for rail voltages to stabilize.
State 2 Test supply rails - return to state 0 if out of range. If OK, set to 70V or 100V mode
according to rail voltages.
State 3 Un-Mute (turn-on) amplifier (speakers off). Return to state 0 if Off command
received. Wait 1 second, but go to state 6 immediately if high frequency input
detected.
State 4 Test for power OK, DC, high frequency, overheat, etc. + Tripath faults. Go to state 5
if OK. State 6 if not OK.
State 5 Normal operation - Set speaker relay On (amp still running). Reset retry count to 0.
Watch continuously for Off commands or any faults.
State 6 Retry state. If retry count = 6, go to state 0. Mute amp, set relay Off. Add 1 to retry
count. Wait 2.5 seconds, then go to state 3.
E4 Series II DSP Theory of Operation
1. Overview
The E-4 Series II DSP section consists of five boards manufactured as a single panel. Unregulated power is distributed to the boards and each, except the flash card, contains its own regulators. The DSP board contains the 56K DSP and the 80C251 host processor along with its
subordinate PIC processor for peripheral control. This board also carries the audio codecs and
their associated analog circuitry. Two audio inputs are line level and two may be configured for 0
to 60 dB of gain. The direct input bypasses the DSP and codecs and allows a signal to directly
drive the amplifier system. A ribbon cable transports the audio output signals, various control
and monitoring signals, and raw power between the amplifiers/power supply and the DSP
system.
A flash memory chip that holds the host operating program and system configuration information is mounted on a small card that plugs into the processor board. The LED board holds the
front panel indicator LEDs, standby button, and the USB interface connector. The wall plate
connectors, contact closure input, direct audio output, and music on hold output are on the Wall
Plate Sense board at the back of the unit. The Auto-Volume Mic Sense board is mounted above
the Wall Plate Sense board and also contains the RS-232 connector.
When the system is on, it can be in one of two states: standby or operating. When the system is
in standby, the host and peripheral processors are powered up and functioning as are the LED
and Wall Plate Sense boards. The power to the amplifiers, the Auto-Volume Mic Sense board,
the DSP section and the analog I/O circuitry and codecs is shut down. When you bring the unit
out of standby all sub-systems are powered.
94
THEORY OF OPERATION
2. DSP Board
Digital power on the DSP board is regulated by a 5 volt (U547) and a 3.3 volt (U550) voltage
regulator. The analog section of the board, running from plus and minus 15 volts (U548) (U549),
and 5 volts (U551), is powered only when the system is not in standby. Power on system reset
is managed by (U552).
The DSP is a Motorola 56362 (U517) running at 112.896 MHz. An internal PLL multiplies the
22.579 MHz crystal oscillator (U527) frequency by five. The oscillator runs from the 3.3V supply
and also drives a D flip-flop divide by 2 and level shifter that is made from ½ of (U525). The
112.896 output drives the MCLK inputs of the audio codecs and (U526) synchronous counter
that serves as the clock divider chain to provide the 2.822 MHz SCLK and the 44.1 kHz LRCK.
The DSP sub-system also has flash memory (U516) and three 128K by 8 static RAMs (U513,
U514, U515) running from the 3.3 volt power supply. The host processor holds the DSP subsystem in reset with power off when the E-4 Series II is in standby.
The host processor sub-system is always running when the E-4 Series II is powered up. The
host processor sub-system consists of (U520), an octal D flip-flop (U519) to latch the low order
address lines, (U521) used as a memory block decoder, (U518) a 32K by 8 static RAM and
(U701) the flash memory on the daughter card. It communicates with the outside world through
its RS-232 port buffered by a MAX202E (U524) or through the USB interface on the front panel
board.
The microprocessor (U544) serves as a peripheral controller to extend the I/O capacity of the
(U520). The host communicates with it over the I
and the USB bus interface (U106) that is mounted on the front panel board.
Pressing the standby button on the front panel sends a signal to the PIC that is relayed to the
host over the I2C interface. The host then sends a wakeup signal to the power supply by lowering a port line that is buffered by one section of (U522) that in turn drives PNP inverting transistor Q501.
Strobe signals from the PIC drive three gates on (U522) to gate serial clock signals from the
host that drive the three audio attenuators (U531, U203, U211) in the system, one on the DSP
board and two on the mic sense board. These gated clocks along with the serial data line and
the I/O clock for the wall plate board then are buffered through (U553) so that drive is disabled
when the unit is in standby and power is removed from the DSP analog section and the two rear
auxiliary boards.
Two serial in, parallel out shift registers (U545, U546) are driven by the PIC to provide control
bits to the gain controls on the two mic inputs. The final output bit from the second shift register,
controls NPN transistor Q503 to output a control signal.
The PIC also contains an eight input 10 bit A/D converter. The four sense lines from the auto
volume mic sense circuits drive the first four inputs and the four sense lines for the amplifier
sense circuits drive the second four inputs. Each input has a .01 uF capacitor to minimize high
frequency noise and a dual protection diode connected to ground and the 5V power rail. Header
JP501 is present to allow the PIC to be programmed on the circuit board.
2
C bus along with the real time clock (U523)
95
THEORY OF OPERATION
The analog section of the DSP board contains the two stereo codecs (U503, U507) and their
associated analog input and output circuitry. Line 1 and 2 each have two inputs that are resistively mixed and buffered through difference amplifiers (U529, U532). Each of the difference
amplifiers feed a channel of the volume control (U531) that in turn drives the two dual op-amps
(U501, U504) that convert the single ended signals to differential drive for the codec.
Mic in and Page in are balanced inputs, each driving an instrumentation amplifier (U537, U540).
These two channels each have a voltage regulator (U536, U539) that can be enabled by the
host to provide phantom power to external mics. The gain of the voltage regulator is controlled
by the host switching on analog switch sections (U541, U542, U543) that connect gain control
resistors. The range of gain is 0 to 60 dB in 10 dB increments.
The outputs of the instrumentation amplifiers are each served by ½ of an op amp (U538) to a
fixed DC offset of 2.5V to provide one half of the differential drive to the second codec. Each
channel is inverted by half of a dual op-amp (U505) to provide the second phase of differential
drive to the codec. Each of the four input channels is fed to a multiplexer (U535) that selects
one channel under host control for output as music on hold.
The four differential outputs of the codecs drive four identical circuits built around switchable
amplifiers (U509, U510, U511, U512). One differential input of each is configured as a low-pass
filter and differential to single ended converter and is fed from a codec output. The second input
is connected to a common input signal, the direct input. A PNP transistor circuit (Q502) detects
ground on the PTT input and switches the switchable amplifiers to the direct input while also
signaling the PIC to inform the host that an override is occurring. The four switchable amplifiers
drive the power amplifier inputs from the selected input signal path.
The outputs from the switchable amplifiers also drive four channels of amplitude sense circuitry.
Each sense path consists of an op-amp gain stage followed by a low pass filter, a high pass
filter and a precision rectifier/average circuit. The op-amps are contained in dual op amps
(U700, U706) and quad op-amps(U702, U703, U704, U705).
3. LED Board
The LED board contains the front panel indicator LEDs, the standby switch and the USB connector and interface circuitry. Power is applied to this board even when the E-4 Series II is in
standby and is regulated to 5V by U105 voltage regulator and to 3.3V by U107 voltage regulator. Serial input from the host on the DSP board drives a sequence of three serial in, parallel out
shift registers (U102, U103, U104) to drive the LEDs. To reduce power consumption three
inverters from U101 are configured as an oscillator to multiplex the LED drive. Two more of the
inverters are used to buffer and debounce the standby switch. When the standby button is
pushed the signal is detected by the PIC processor on the DSP board, which then communicates over the I
board to allow the host processor to communicate with an external PC through the USB interface IC (U106).
4. Auto-volume Microphone Sense Board
The auto-volume microphone sense board contains the input and level control circuitry for four
sense mics and an RS-232 connector to allow the E-4 system to communicate with an external
PC. Power is not applied to this board when the E-4 is in standby. The board regulates analog
power supply voltages with a positive 15V regulator (U216) and a negative 15V regulator
(U215). There is also a positive 8V regulator (U204) to provide power to the external sense
mics.
2
C bus with the host processor. The I2C lines also come onto the front panel
96
THEORY OF OPERATION
Each mic sense path consists of input protection circuitry and a resistor to the 8V supply followed by a 330uF DC blocking capacitor, input protection diodes to the plus and minus 15V rails
and an op-amp serving as an input gain stage of 37dB. The output of the op-amp passes
through another DC blocking cap to ½ of a volume control IC. This output passes through
another capacitor into an op-amp gain stage followed by a low-pass filter, a high pass filter and
finally a precision rectifier/average circuit and off the board to one of the PIC A/D inputs. There
are two attenuators (U203, U211), two dual op amps (U206, U213) and four quad op amps
(U207, U208, U214, U215) on the board.
5. Wall Plate Sense Board
The wall plate sense board contains the circuitry to scan up to four wall plates that are connected through four RJ-45 jacks and to drive the LEDs on the wall plates. In addition there are
connectors and passive protection components for the music on hold output, the line 4 expansion output and its associated control line, and the control input to allow an external device to
wake up the system.
Power is applied to the board even when the E-4 Series II is in standby and is regulated for the
board and the external wall plates by a voltage regulator (U401). The wall plate input lines are
scanned by three parallel in, serial out shift registers (U404, U405, U406) Resistors on the wall
plate sense board pull the input lines up, switch closures on the wall plates pull the inputs down.
Two serial in, parallel out shift registers (U402, U403) apply multiplexed drive to the LEDs on the
wall plates in the interim when the switches are not being scanned.
6. Flash Memory Board
The flash memory card is powered from the main DSP board. The board contains a 2 Mb, 5V
flash ROM (U701) and power supply bypass capacitor. This memory stores the system configuration data as well as the host microprocessor operating program.
97
ACCESSORIES
FreeSpaceRE4-II System Accessories
The following accessories are available for the FreeSpace¨E4 Series II System.
North America/JapanEurope/Australia
Standard User Interface provides control of
sources, volume and mute for a single zone.
Standard UI, North America/JapanPC029856
Standard UI, Europe/AustraliaPC029857
North America/JapanEurope/Australia
Auto Volume User Interface provides control of
sources, volume and Auto Volume operation for
a single zone.
Auto Volume UI, North America/Japan PC030101
Auto Volume UI, Europe/AustraliaPC030102
North America/JapanEurope/Australia
Multi-Zone Paging Interface provides selection
of individual zone, all page and page initiation.
Page UI, North America/JapanPC030103
Page UI, Europe/AustraliaPC030104
North America/JapanEurope/Australia
Auto Volume Sense Microphone, placed within a
system zone to measure background noise.
Auto Volume Sense Mic,
North America/JapanPC029859
Auto Volume Sense Mic,
Europe/AustraliaPC029860
Rack-mount ears used for mounting the E4 system within a standard 19-inch equipment rack.
FreeSpace E4-II Rack EarsPC029858
98
Figure 5. Flash Memory PCB
Component Layout
Figure 6. DSP PCB Assembly Component Layout
99
Figure 7. Wallplate Sense PCB Assembly Component Layout
Figure 8. Mic Sense PCB Assembly Component Layout
Figure 9. Front Panel Display PCB Assembly Component Layout
100
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