BOSE 502A, 502B, 502C Schematic

Panaray® Sound System

502 Array, Bass Box and Controller

©2006 Bose Corporation

Service Manual

Reference Number 170310-SM Rev. 03

Electronic Copy Only

CONTENTS

Contents......................................................................................................................................... 2-3

Safety Information.............................................................................................................................4

Warranty.............................................................................................................................................4

Specifications................................................................................................................................ 5-7

®

A Array Specifications...............................................................................................................5

502

502B Bass Module Specifications...................................................................................................6

502C Controller Specifications.................................................................................................... 6-7

Electrostatic Discharge Sensitive (ESDS) Device Handling .........................................................8

Parts Lists and Exploded Views ......................................................................................................8

Parts List Notes.................................................................................................................................9

Packaging Part List, 502A Array (see Figure 1)............................................................................10

Figure 1. 502A Array Packaging View ............................................................................................10

Packaging Part List, 502B Bass Box (see Figure 2) ....................................................................11

Figure 2. 502B Bass Box Packaging Exploded View .....................................................................11

Packaging Part List, 502C Controller (see Figure 3) ...................................................................12

Figure 3. 502C Controller Packaging View.....................................................................................12

Main Part List, 502A Array (see Figure 4) .....................................................................................13

Figure 4. 502A Array Exploded View ..............................................................................................14

Main Part List, 502B Bass Box (see Figures 5 and 6) .................................................................15

Figure 5. 502B Bass Box Exploded View .......................................................................................16

Figure 6. 502B Access Panel and Connector Views ......................................................................17

Main Part List, 502C Controller (chassis with removable front panel) (see Figure 7) .............18

Figure 7. 502C Controller Exploded View (removable front panel version)....................................19

Main Part List, 502C Controller (one-piece chassis) (see Figure 8)...........................................20

Figure 8. 502C Controller Exploded View (one-piece chassis version)..........................................20

Electrical Part Lists................................................................................................................... 21-30

502C Controller Main PCB Assembly...................................................................................... 21-30

Disassembly Procedures ...............................................................................................................31

502A Array Procedures ............................................................................................................. 31-34

Figure 9. 502A Array Exploded View ..............................................................................................32

Figure 10. 502A Array Wiring Diagram...........................................................................................33

502B Bass Module Procedures ............................................................................................... 34-35

502C Controller Disassembly Procedures ............................................................................. 35-36

Figure 11. 502B Bass Module Exploded View................................................................................37

Figure 12. 502B Bass Module Connector and Access Panel.........................................................38

Figure 13. 502B Bass Module Wiring Diagrams ............................................................................39

Figure 14. 502C Controller Exploded View (removable front panel version).................................40

Figure 15. 502C Controller Exploded View (one-piece chassis version)........................................40

Test Procedures ..............................................................................................................................41

502A Array T est Procedures ...........................................................................................................41

Figure 16. XLR input pin assignment ............................................................................................41

502B Bass Module Test Procedures ....................................................................................... 41-42

502C Controller Test Procedures ............................................................................................ 42-44

Figure 17. Unbalanced Connections ..............................................................................................45

Figure 18. 502C Controller Back Panel (Barrier Strip Version Shown)...........................................45

Accessory Kit Part Lists........................................................................................................... 46-51

502A PSA-5 Stand Adapter Parts List (see Figure 19) .................................................................46

Figure 19. PSA-5 Stand Adapter Kit ...............................................................................................46

502A CSB-5A Suspension Bracket Kit Parts List (see Figure 20) ..............................................47

Figure 20. CSB-5A Suspension Bracket Kit ...................................................................................47

2

CONTENTS

502B CSB-5B Suspension Bracket Kit Parts List (see Figure 21)..............................................48

Figure 21. CSB-5B Suspension Bracket Kit ...................................................................................48

502A WBP-5 Bi-Pivot Bracket Kit Parts List (see Figure 22)....................................................... 49

Figure 22. WBP-5 Bi-Pivot Bracket Kit ...........................................................................................49

502A WCB-5 U-Bracket Kit Parts List (see Figure 23) .................................................................50

Figure 23. WCB-5 U-Bracket Kit ....................................................................................................50

502A CVT-5 Transformer Assembly Kit Parts List (Figure 24) ....................................................51

Figure 24. CVT-5 Exploded View and Packaging...........................................................................51

Figure 25. CVT-5 Schematic ..........................................................................................................52

Theory of Operation.................................................................................................................. 53-55

502C Controller ...............................................................................................................................53

1. Differential Input Stage...............................................................................................................53

2. Equalizer for High Frequency Outputs .....................................................................................53

3. Output mode switch, Low frequency level control, and Normal/Sum mode stage..............53

4. Equalizer for Low Frequency Outputs ......................................................................................53

5. Mode switch ................................................................................................................................53

6. Output stage................................................................................................................................54

7. Power Supply ..............................................................................................................................54

8. Turn On/Off Muting Circuit.................................................................................................. .......54

9. Troubleshooting Tips............................................................................................................ 54-55

502C Controller EQ Curves ...................................................................................................... 56-61

Figure 26. Low Frequency EQ........................................................................................................56

Figure 27. Low Frequency EQ........................................................................................................56

Figure 28. Low Frequency EQ........................................................................................................57

Figure 29. Low Frequency EQ........................................................................................................57

Figure 30. High Frequency EQ.......................................................................................................58

Figure 31. High Frequency EQ.......................................................................................................58

Figure 32. High Frequency EQ.......................................................................................................59

Figure 33. High Frequency EQ.......................................................................................................59

Figure 34. High Frequency EQ.......................................................................................................60

Figure 35. High Frequency EQ.......................................................................................................60

Figure 36. High Frequency EQ.......................................................................................................61

Figure 37. 502C Controller Block Diagram.....................................................................................62

Service Manual Revision History...................................................................................................63

3

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® Panaray® 502® Sound 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 Panaray 502C Controller is covered by a limited 1-year warranty. The Panaray 502A
array speaker and Panaray 502B bass module are covered by a 5-year limited warranty.

4

SPECIFICATIONS

502A Array Specifications

Dimensions: 23.5"H x 5.75"W x 6.73"D

(59.7x14.6x17.1 cm)
Weight: 15 lbs. (6.8 kg.)
Transducer Complement: 5 - 4.5 " (11.4 cm) drivers
Enclosure Material: High-impact polystyrene
Nominal Impedance: 8 Ohms, 6.4 Ohms minimum
Sensitivity: 90 dB SPL (1W, 1m, 130 Hz-15 kHz)
Maximum Acoustic Output: 112 dB SPL average, 121 dB SPL peak
Frequency Range: 130 Hz - 15 kHz
Port Tuning Frequency: 135 Hz
Amplifier Power (Recommended): 150 - 600 watts continuous into 8 Ohms
Long-term power handling: 150 watts continuous
Beamwidth: 120° horizontal, 70° vertical
Input Connections: Parallel wired barrier strip (US/Can.)

Parallel wired XLR (Euro/Aus/UK/Japan)
Fusing: 4 ampere AGC (Buss) or 3AG (Littlefuse)

5

SPECIFICATIONS

502B Bass Module Specifications

Dimensions: 31.0"H x 14.0"W x 15.5"D

(78.7x 35.6x 39.4 cm)
Weight: 80 lbs. (36.4 kg.)
Transducer Complement: 1 - 12" woofer (high power)
Enclosure Material: 3/4" resin-core, vinyl wrapped
Port: High-impact polystyrene
Nominal Impedance: 8 Ohms, 6.4 Ohms minimum
Sensitivity: 90 dB SPL (1W, 1m, 55 Hz-150 Hz)
Maximum Acoustic Output: 115 dB SPL average, 122 dB SPL peak
Frequency Range: 50 Hz - 150 Hz
Power Handling: 450 watts continuous
Amplifier Power (Recommended): 450 - 1200 watts continuous into 8 Ohms
Input Connections: 2 parallel wired barrier strip (US/Can)

2 parallel wired XLR (Euro/Aus/UK/Japan)

2 parallel wired Speakon® connectors
Fusing: 7 ampere AGC (Buss) or 3AG (Littlefuse)

502C Controller Specifications

Dimensions: 120V/Barrier Strip 1.75"Hx19.0"Wx8.75"D (4.4x48.3x22.2cm)

220-240V/XLR 1.75"Hx19.0"Wx8.0"D (4.4x48.3x20.3cm)
Weight: 5.5 lbs. (2.5 kg.)
Chassis material: 16 gauge steel with painted/zinc coated finish
Cover plate material: Brushed aluminum,painted
Input Connections: Balanced barrier strip (US/Can)

Balanced XLR (Euro/Aus/UK/Japan)

Output Connections: Balanced barrier strip (US/Can)

Balanced High frequency & Low frequency
XLR (Euro/Aus/UK/Japan)

6

SPECIFICATIONS

502C Controller Specifications (continued)

Input Impedance: Balanced input, -10 dB level - 14k Ohms

Balanced input, +4 dB level - 6k Ohms
Unbalanced input (+ input), -10 dB level: 12k Ohms

Unbalanced input (+ input), +4 dB level: 4k Ohms
Output Impedance: 100 Ohms nominal
Input Level: -10 dB or +4dB, selectable
Output Level: 8.0 Vrms maximum into 600 Ohms
Low Frequency (LF) Output Mode: Sum or normal
LF Output Level: -18 dB to +3 dB, variable
Crossover Frequency: 140 Hz (Bi-amp), Roll-off slope: -18dB/octave
THD: Midrange distortion of HF output: - 0.1% at 5V, 600 Hz

Low frequency distortion of LF out: - 0.1 % at 5V, 80 Hz
Output Noise: Bi-amp mode, HF outputs - 90µV

Bi-amp mode, LF outputs - 40µV

Passive mode, - 90µV
Offset: All channels - 15mV
Power Requirements: 120 VAC,50/60 Hz, 12 watts (US/Can)

230 VAC,50/60 Hz, 12 watts (Euro)

100 VAC,50/60 Hz, 12 watts (Japan)

240 VAC,50/60 Hz, 12 watts (Aus/UK)

7

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.

PARTS LISTS AND EXPLODED VIEWS

The following section contains parts lists and exploded views for the Panaray® sound system.
The parts lists are broken down as follows:

- 502®A Array Parts List and Exploded View

- 502A Packaging Parts List and Exploded View

- 502B Bass Box Parts List and Exploded View

- 502B Packaging Parts List and Exploded View

- 502C Controller Main Assembly Parts List and Exploded View

- 502C Packaging Parts List and Exploded View

- 502C Electrical Parts List

- Accessory Kits Parts Lists and Exploded Views

NOTE: The notes section for the entire parts list is contained on page 8.
CAUTION: Use only accessory kit parts that are specified by Bose® Corporation in this service

manual. Substitute parts may not have the same safety characteristicsas the original parts.

8

PARTS LIST NOTES

1. This part is not normally available from Customer Service. Approval from the Field Service

Manager is required before ordering.

2. This part splits into 2 pieces. Each piece fits onto a corner of the bass box.

3. Current European units should contain 2 owner's manuals: the original version, P/N 143585,

and the German version of the owner's manual, P/N 171941. Future production units (except in
North America) will contain owner's manuals in 5 languages (German, French, Italian, Spanish
and English).

4. This illustration is typical of the internal layout of the 502® except as follows: (1) Barrier strip
connectors are used in the US/Canada version only. XLR connectors are used on all non-US
versions, and (2) The nut connected to the line cord is used on the US/Canada, UK and Austra­lian units only.

5. 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.

6. Refer to the 502C Electrical Parts List for components located on the PCB assembly.

7. This part is not illustrated.

8. These screws hold regulators U13 and U14 to the heatsink.

9. Early production runs of the 502C have 4 screws (instead of 2) that secure the cover to the

chassis.

10. Early production runs of the 502C with XLR connectors have 12 screws (instead of 6) that
secure the connectors to the chassis.

11. Early production runs of the 502C have 6 screws (instead of 4) that secure the front plate to
the cover and chassis.

12. Early production runs of the 502C with XLR connectors have 5 screws (instead of 2) that
secure the PCB to the chassis.

13. The line cord assembly consists of the following items:
(1) Line Cord-P/N 147428 (US/Canada), P/N 147430 (Euro), P/N 147429 (Japan), P/N 149025
(UK), P/N 149026 (Aus.),
(2) Strain Relief Bushing - P/N 144010 (US/Canada/UK/Aus), P/N 144011 (Euro/Japan),
(3) Connector Housing - P/N143964, and
(4) Connector Pin - P/N 143992. These parts are all safety controlled components. See Note 5.

9

PACKAGING PART LIST

502A Array (see Figure 1)

Item

Number

1 Literature Kit-Panaray®

which consists of:

A

B
C
D

E

2 Packing, Foam 143573 172321 2

3 Polybag 106595 - 1

4 Carton, 502A 143572 172541 1

*Product code 040170 (gray) and 040171 (white) are the RoHS compliant version of the
502A. Only RoHS compliant parts listed in the above chart can be used in the 502A with
product code 040170 and 040171.

Polybag
Owner's Manual
Registration Card
Warranty Service List
Envelope

Description XLR and Barrier

Version Product

code 003840,

004931, 004932

and 004933

149271 - 1
103351

143585
122157
122766
122785

1

*Speakon

Version
Product

code

040170 and

040171

103351
292721

-

-

-

Qty Note

1

Figure 1. 502A Array Packaging View

10

PACKAGING PART LIST

502B Bass Box (see Figure 2)

Item

Number

1 Literature Kit-Panaray®

Which consists of:
A
B

C
D
E

2 Packing End Cap, EPS

3 Polybag 119320 119320 1
4 Carton, 502B 143558 258887 1

*Product code 040090 (black) and 040091 (white) are a RoHS compliant version of
the 502B. Only RoHS compliant parts listed in the above chart can be used in the
502B with product code 040090 and 040091.

1

Polybag

Owners Manual

Registration Card

Warranty Service List

Envelope

(XLR and Barrier versions)

Packing End Cap, EP

(Speakon version)

Description XLR and Barrier

Version

PC 003841,
019769, 004934,
004935, 004936,

007698

149271 - 1
103351

143585
122157
122766
122785
139955

-

*Speakon®
Version PC
040090 and

040091

103351
292040

-

-

-

-

258886

Qty Note

1
1
1
1
1
4 2

Figure 2. 502B Bass Box Packaging Exploded View

11

PACKAGING PART LIST

502C Controller (see Figure 3)

Item

Number

Description Part Number Qty. Note

1 Crease Sheet, Die Cut 149823 1
2 Literature Kit, Panaray®, Consists of: 149271 1
A Poly bag 103351 1
B Owner's Manual 143585 1

Owner's Manual (German language) 171941 1 3
C Card, Registration 122157 1
D List, Warranty Service 122766 1
E Envelope 122785 1
3 Poly bag 110892 1
4 Insert 148354 1
5 Carton, 502C 148353 1

Figure 3. 502C Controller Packaging View

12

MAIN PART LIST

502A Array (see Figure 4)

Item

Number

1 Grille, Pro Gray

Grille, Arctic White

2 Insert, Threaded, Mach, M8x10.5, Gray

Insert, Threaded, Mach , M8x10.5, Wht

3 Nameplate, Dark Gray/Arctic White

Nameplate, Dark Arctic White/Dark Gray
4 Nut, Push-On,.078 125786 2
5 Driver, 4.5” 291025-001 5
6 Screw, HIRS, 8-10x5/8, PAN, XRC/SQ 289388-010 20
7 Gasket, Driver, 4.5" 128407 5
8 1234356789898989 119094-3R0 1
9 Capacitor, 5µF, Mylar 102770 1

10 Tape, Foam 118223 2
11 Terminal, Connector, Wire wrap 118008 4
12 Inductor, .75mH, Air core 293515-001 1
13 Washer, Flat Aluminum 123840 1
14 Gasket, Connector Panel 290316-001 1
15 Screw, 8-10, OVL HD, 1/2", BK (Gray)

Screw-8-10, OVL HD, 1/2", Zn (White)

Screw, Tapp, 8-10x .5, OVL CSK, BLK

16 Connector Panel, XLR, Gray

Connector Panel, XLR, White

Connector Panel, Barrier, Gray

Connector Panel, Barrier, White

Connector Panel, Speakon

Connector Panel, Speakon, White

17 Fuse holder, Knob with O-Ring 149268 1
18 Fuse-Standard Delay, 4A 104715-400 1
19 Fuse holder Body 149269 1
20 Washer, Neoprene 149270 1
21 Screw, Tapp, 4-16x1/2, PAN (XLR)

Screw, HIRS, 8-10x3/4, PAN (Barrier)

Screw, M2.6x5/8, Phillips, Flat (Speakon)

22 Connector, XLR, Dual

Connector, Barrier Strip, 4 pos.

Connector, Speakon, Panel Mount

23 Gasket, XLR Connector

Gasket , Barrier

Gasket, Speakon (inc. with item 22)

24 Batting, Polyester 142360 2
25 Foam, Acoustic 142361 1
26 Fuse holder Nut 171731 1

Product code 040170 (gray) and 040171 (white) are a RoHS compliant version of the 502A.
Only RoHS compliant parts listed in the above chart can be used in the 502A with product code
040170 and 040171.

Description Part Number Qty. Note

®

, Gray

142342-01
142342-02
143552-01

143552-02
130718-1B21
130718-1C31

148378-08

148379-08

290978-08

142344-01

142344-02

142344-03

142344-04

287072-003
287072-002

145724-08

137527-12

-

145717

148976-04

258213
146874
171243

-

1
2
1

4 Non-RoHS

Non-RoHS

RoHS

1 Non-RoHS

Non-RoHS
Non-RoHS
Non-RoHS

RoHS
RoHS

4
2
4

1
1
2

1
1
2

Non-RoHS
Non-RoHS

Non-RoHS
Non-RoHS
Non-RoHS

Non-RoHS
Non-RoHS

RoHS

RoHS

13

2

2x

1

25

24 2x

34

11

4x

2x

10

15x

7

5x

5x

5

6

8

9

15 4x

13
12

17

18

16

20

18

17

19

21

23

26

16

26

20

19

21

16

26

2x

20

19

18

14

17

XLR VARIATION
SHOWN

21

2x

22

22

22

21

23

23

22

23

Figure 4. 502A Array Exploded View

14

MAIN PART LIST

p

502B Bass Box (see Figures 5 and 6)

Item

Number

1 Cap, Top/Bottom, Gray

, Top/Bottom, Wh ite

Ca
2 Bolt-Mounting 143580 8
3 Acoustic Foam 145705 3
4 Bracket, Structural 290979 4
5 Nut , Hex, Mach Screw, 7/16-14 29 0980-4414 8
6 Washe r, Loc k, Ext, Stl, Zi nc Plat e 1 08261-43 8
7 Screw, HIRS, 8-10x3/4, HEXW, Hex 293205-010 16
8 Safety, Hook 171556 2
9 Screw, 6-10x1/2,PAN,XRC/SQ 290294-08 4

10 Ac ces s Pane l, Gray, XLR

Access Panel, White, XLR

Acces s Panel, Gr ay, Barr ier

Access P anel, White, Barri er

Access Pane l, 502 BEX, Black

Access Pane l, Gray, Speak on

Access Panel, White, Speakon

11 Fu se holder, Knob wit h O- Ring 149268 1
12 Fu se holder B ody (incl udes nut) 149269 1
13 Washer, Neoprene 149270 1
14 Fuse, Standard Delay,7A 104715-700 1
15 Foam Tape 103068 4
16 Sc rew, Ta pp, 4-16x1/2, (XLR)

Screw, HIRS, 8-10x3/4, (Barrier)

Screw, Tapp, 8-11x1, (Speakon)

17 Connector , XLR, Dual

Connector, Barrier Strip, 4 pos.

Connecto r, Speakon

18 Gasket, XLR Connector

Gasket, Barrier

Gasket, Speakon

19 Fu se holder Nut 171731 1
20 Ins ert , Ba rbed, 10/32”x 20mm 145712- 03 8
21 Sc rew, Mach, 10-32x 1-1½, PAN 2 91008-24 8
22 Woofer, 12”

(used with PC 0038 41, 01976 9, 004934,

004935, 004936, 007698 and 01074 4 only)

Woofer, 12”

(used with PC 0400 90 and 040091 onl y)

23 Screw, Mach, 8-10 x 1, PAN, Gray

Screw, Mach, 8-10 x 1, PAN, White

*Product code 040090 (black ) and 040091 (white) are a RoHS comp liant version of
the 502B. Only RoHS compliant parts listed in the above chart can be used in the
502B with product code 0 40090 and 040091.

Description Part Number Qty. Note

182582-0P

294312

142349-8RU
142349-9RU
142349-8SU
142349-9SU
142349-0CP

292035-001
292035-002

145724-08
289388-16
290988-08

145717

148976-04

258213-002

146874
171243
252384

144392 1 Non-RoHS

291380-001 RoHS
289388-016

289388-016

2

1

Non-RoHS

1

Non-RoHS

1

Non-RoHS

1

Non-RoHS

1

Non-RoHS
1
1

8
2
4
2
1
2
2
1
2

12
12

RoHS
RoHS

Non-RoHS

RoHS
RoHS

Non-RoHS

RoHS
RoHS

Non-RoHS

RoHS
RoHS

15

Figure 5. 502B Bass Box Exploded View

16

Barrier Strip Version

19

XLR Version

12

14

13

11

15

Speakon® Version

Figure 6. 502B Access Panel and Connector Views

16

16

17

17

18

18

17

MAIN PART LIST

502C Controller (removable front panel version) (see Figure 7)

Item

Number

1 Cover, Chassis, 502C 173003 1
2 Screw, Tapp, 4-40x.375, PAN, TORX

(US/Can.)
Screw, Tapp, 4-40x.375, PAN, TORX

(Euro/UK/Aus/Japan)
3 Plate, Front, Rack Mount Kit 173004 1
4 Screw, Tapp, 4-40x.312, BTN, XREC 170285-05 4 11
5 Lens, LED, Clear, Front Panel 144023 1
6 Switch, Rocker, SPST, AC Power 143960 1 5

7 PCB Assembly, 502C (US/Can)

PCB Assembly, 502C

(Euro/UK/Aus/Japan)
8 Screw, Mach, 4-40x.25, PAN, TORX

(US/Can)

Screw, Mach, 4-40x.25, PAN, TORX

(Euro/UK/Aus/Japan)
9 Transformer, 120V (US/Can.)

Transformer, 220-240V (Euro/UK/Aus)

Transformer, 100V (Japan)

10 Nut , Hex, STND, W asher, KEPS 118260-08 2
11 Insulat or, Standoff, PCB 143948 1 1, 5

12 Connector, Barrier Strip Assy,

6 position (US/Can.)

13 Screw, Tapp, 4-40x.5, PAN, TORX

(US/Can.)

14 Nut, Hex, #8-32, Steel (US/Can/UK/Aus.) 103237-832 1
15 Line Cord, 3 wire (US/Can.)

Line Cord, 2 wire (Euro)

Line Cord, 2 wire (Japan)

Line Cord, 3 wire (UK)

Line Cord, 3 wire (Aus)

16 Heatsink, PCB Mount 147165 1 1

- Screw, Tapp, 4-40x.375, PAN, XREC 170284-06 4 7, 8

- Chassis, 502, US/Canada
Euro/UK/AUS/Japan

Description Part Number Qty. Note

170284-06
170284-06

143940-1

143940-2
171796-04 5 12
171796-04 2

143950-1

143950-2

143950-3

143971 3

170284-08 6

143975
143977
143976
149023
149024

173002-01
173002-02

2
8

1
1

1 5

1 5, 13

1
1

9

9,10

1, 6
1, 6

1

18

Figure 7. 502C Controller Exploded View (removable front panel version)

19

MAIN PART LIST

502C Controller (one-piece chassis version) (see Figure 8)

Item

Number

Description Part Number Qty/

Assy.

1 Screw, 6-32, Mach, Flat, Xrec 190623-008 5
2 Screw, Mach, 4-40x.25, PAN, XREC 103140-04 9
3 Clip, Heatsink 188599 2
4 XFMR, US/Canada/Japan, 100V/120V

EUR/AUS/UK, 220V/240V

180128-1
180128-2

1

1
5 Nut, Hex, 8-32, Keps 118260-08 3
6 Insulator, 9.25x7.56x.015, D/C 143948 1 1, 5

7 Switch, Power, Rocker, SPST 143960 1 5
8 Lens, LED, Clear, Chassis 144023 1

9

Chassis, 502®, US/Canada
Euro/UK/AUS/Japan

198373-001
198373-002

1

1

10 Screw, Tapp, 4-40x.375, PAN, XREC 170284-06 6
11 PCB Assy, 502 (all versions) 143940-2 1 1, 6
12 Cover, Chassis, Controller 198374-001 1
13 Line Cord, 3-Wire, USA/Canada

2-Wire, EU
2-Wire, Japan
3-Wire, UK
3-Wire, Aus

173242
173243
173244
173245
173246

1

1

1

1

1

14 Tape, Foam, 0.50" 198408 1

1

5X

Note

5

1

5

13

5

9

4

C114

C113

14

4

5

2X

6

2

3

7

8

Figure 8. 502C Controller Exploded View (one-piece chassis version)

12

2

11

10

6X

9

20

ELECTRICAL PART LIST

502C Controller Main PCB Assembly

Resistors

Reference

Designator

W1 0 Ohm Jumper, Chip 124896
W2 0 Ohm Jumper, Chip 124896
W3 0 Ohm Jumper, Chip 124896
W4 0 Ohm Jumper, Chip 124896
W5 0 Ohm Jumper, Chip 124896
W6 0 Ohm Jumper, Chip 124896
W7 0 Ohm Jumper, Chip 124896
W8 0 Ohm Jumper, Chip 124896
W9 0 Ohm Jumper, Chip 124896
W10 0 Ohm Jumper, Chip 124896
W11 0 Ohm Jumper, Chip 124896
W12 0 Ohm Jumper, Chip 124896
W13 0 Ohm Jumper, Chip 124896
R1 1K, 1/8W,1%, Chip 124894-1001
R2 1K, 1/4W, 52mm, MF, 1% 121245-2211001
R3 1K, 1/4W, 52mm, MF, 1% 121245-2211001
R4 1K, 1/8W,1%, Chip 124894-1001
R5 100K, 1/4W, 52mm, CF, 2% 121243-1211042
R6 100K, 1/4W, 52mm, CF, 2% 121243-1211042
R7 2K, 1/8W, 1%, Chip 124894-2001
R8 8.06K, 1/8W, 1%, Chip 124894-8061
R9 8.06K, 1/8W, 1%, Chip 124894-8061
R10 2K, 1/8W, 1%, Chip 124894-2001
R11 3.65K, 1/8W, 1%, Chip 124894-3651
R12 2K, 1/8W, 1%, Chip 124894-2001
R13 4.02K, 1/8W, 1%, Chip 124894-4021
R13 4.02K, 1/8W, 1%, Chip 124894-4021
R14 4.02K, 1/8W, 1%, Chip 124894-4021
R14 4.02K, 1/8W, 1%, Chip 124894-4021
R15 30.1K, 1/8W, 1%, Chip 124894-3012
R17 2K, 1/8W, 1%, Chip 124894-2001
R18 2.32K, 1/8W, 1%, Chip 124894-2321
R19 13K, 1/8W, 1%, Chip 124894-1302
R20 100K, 1/8W, 1%, Chip 124894-1003
R21 511 Ohm, 1/8W, 1%, Chip 124894-5110
R22 3.16K, 1/8W, 1%, Chip 124894-3161
R23 1.33K, 1/8W, 1%, Chip 124894-1331
R24 0 Ohm Jumper, Chip 124896
R25 274 Ohm, 1/8W, 1%, Chip 124894-2740
R26 274 Ohm, 1/8W, 1%, Chip 124894-2740
R27 18.2K, 1/8W, 1%, Chip 124894-1822
R28 8.66K, 1/8W, 1%, Chip 124894-8661
R29 6.34K, 1/8W, 1%, Chip 124894-6341
R30 2.21K, 1/8W, 1%, Chip 124894-2211
R31 1.91K, 1/8W, 1%, Chip 124894-1911
R32 43.2K, 1/8W, 1%, Chip 124894-4322

Description Part Number Note

21

ELECTRICAL PART LIST

502C Controller Main PCB Assembly

Resistors (continued)

Reference

Designator

R33 3.92K, 1/8W, 1%, Chip 124894-3921
R34 2.43K, 1/8W, 1%, Chip 124894-2431
R35 2K, 1/8W, 1%, Chip 124894-2001
R36 41.2K, 1/8W, 1%, Chip 124894-4122
R37 3.01K, 1/8W, 1%, Chip 124894-3011
R38 6.81K, 1/8W, 1%, Chip 124894-6811
R39 6.81K, 1/8W, 1%, Chip 124894-6811
R40 4.75K, 1/8W, 1%, Chip 124894-4751
R41 5.90K, 1/8W, 1%, Chip 124894-5901
R42 5.11K, 1/8W, 1%, Chip 124894-5111
R43 221K, 1/8W, 1%, Chip 124894-2213
R44 1.10K, 1/8W, 1%, Chip 124894-1101
R45 49.9K, 1/8W, 1%, Chip 124894-4992
R46 68.1K, 1/8W, 1%, Chip 124894-6812
R47 6.98K, 1/8W, 1%, Chip 124894-6981
R48 5.49K, 1/8W, 1%, Chip 124894-5491
R49 14K, 1/8W, 1%, Chip 124894-1402
R50 14K, 1/8W, 1%, Chip 124894-1402
R64 0 Ohm Jumper, Chip 124896
R65 1K, 1/8W,1%, Chip 124894-1001
R66 1K, 1/4W, 52mm, MF, 1% 121245-2211001
R67 1K, 1/4W, 52mm, MF, 1% 121245-2211001
R68 1K, 1/8W,1%, Chip 124894-1001
R69 2K, 1/8W, 1%, Chip 124894-2001
R70 8.06K, 1/8W, 1%, Chip 124894-8061
R71 8.06K, 1/8W, 1%, Chip 124894-8061
R72 2K, 1/8W, 1%, Chip 124894-2001
R73 3.65K, 1/8W, 1%, Chip 124894-3651
R74 2K, 1/8W, 1%, Chip 124894-2001
R75 4.02K, 1/8W, 1%, Chip 124894-4021
R75 4.02K, 1/8W, 1%, Chip 124894-4021
R76 4.02K, 1/8W, 1%, Chip 124894-4021
R77 30.1K, 1/8W, 1%, Chip 124894-3012
R79 2K, 1/8W, 1%, Chip 124894-2001
R80 2.32K, 1/8W, 1%, Chip 124894-2321
R81 13K, 1/8W, 1%, Chip 124894-1302
R82 100K, 1/8W, 1%, Chip 124894-1003
R83 511 Ohm, 1/8W, 1%, Chip 124894-5110
R84 3.16K, 1/8W, 1%, Chip 124894-3161
R85 1.33K, 1/8W, 1%, Chip 124894-1331
R86 0 Ohm Jumper, Chip 124896
R87 274 Ohm, 1/8W, 1%, Chip 124894-2740
R88 274 Ohm, 1/8W, 1%, Chip 124894-2740
R89 18.2K, 1/8W, 1%, Chip 124894-1822
R90 8.66K, 1/8W, 1%, Chip 124894-8661
R91 6.34K, 1/8W, 1%, Chip 124894-6341

Description Part Number Note

22

ELECTRICAL PART LIST

502C Controller Main PCB Assembly

Resistors (continued)

Reference

Designator

R92 2.21K, 1/8W, 1%, Chip 124894-2211
R93 1.91K, 1/8W, 1%, Chip 124894-1911
R94 43.2K, 1/8W, 1%, Chip 124894-4322
R95 3.92K, 1/8W, 1%, Chip 124894-3921
R96 2.43K, 1/8W, 1%, Chip 124894-2431
R97 2K, 1/8W, 1%, Chip 124894-2001
R98 41.2K, 1/8W, 1%, Chip 124894-4122
R99 3.01K, 1/8W, 1%, Chip 124894-3011
R100 4.75K, 1/8W, 1%, Chip 124894-4751
R101 5.90K, 1/8W, 1%, Chip 124894-5901
R102 5.11K, 1/8W, 1%, Chip 124894-5111
R103 221K, 1/8W, 1%, Chip 124894-2213
R104 1.10K, 1/8W, 1%, Chip 124894-1101
R105 49.9K, 1/8W, 1%, Chip 124894-4992
R106 68.1K, 1/8W, 1%, Chip 124894-6812
R107 6.98K, 1/8W, 1%, Chip 124894-6981
R108 5.49K, 1/8W, 1%, Chip 124894-5491
R109 14K, 1/8W, 1%, Chip 124894-1402
R110 14K, 1/8W, 1%, Chip 124894-1402
R113 0 Ohm Jumper, Chip 124896
R117 0 Ohm Jumper, Chip 124896
R120 0 Ohm Jumper, Chip 124896
R125 0 Ohm Jumper, Chip 124896
R127 5.6K, 52mm, CF, 1/2W, 5% 121243-1515625
R128 100K, 1/4W, 52mm, CF, 2% 121243-1211042
R129 100K, 1/4W, 52mm, CF, 2% 121243-1211042
R130 4.75K, 1/8W, 1%, Chip 124894-4751
R131 4.75K, 1/8W, 1%, Chip 124894-4751
R132 4.75K, 1/8W, 1%, Chip 124894-4751
R133 2.43K, 1/8W, 1%, Chip 124894-2431
R134 4.75K, 1/8W, 1%, Chip 124894-4751
R135 4.75K, 1/8W, 1%, Chip 124894-4751
R136 4.75K, 1/8W, 1%, Chip 124894-4751
R137 2.43K, 1/8W, 1%, Chip 124894-2431
R138 4.75K, 1/8W, 1%, Chip 124894-4751
R139 4.75K, 1/8W, 1%, Chip 124894-4751
R140 4.75K, 1/8W, 1%, Chip 124894-4751
R141 2.43K, 1/8W, 1%, Chip 124894-2431
R142 4.75K, 1/8W, 1%, Chip 124894-4751
R143 4.75K, 1/8W, 1%, Chip 124894-4751
R144 4.75K, 1/8W, 1%, Chip 124894-4751
R145 2.43K, 1/8W, 1%, Chip 124894-2431
R146 47 Ohm, 1/4W, 52mm, CF, 2% 121243-1214702
R147 47 Ohm, 1/4W, 52mm, CF, 2% 121243-1214702
R148 47 Ohm, 1/4W, 52mm, CF, 2% 121243-1214702
R149 47 Ohm, 1/4W, 52mm, CF, 2% 121243-1214702

Description Part Number Note

23

ELECTRICAL PART LIST

502C Controller Main PCB Assembly

Resistors (continued)

Reference

Designator

R150 47 Ohm, 1/4W, 52mm, CF, 2% 121243-1214702
R151 47 Ohm, 1/4W, 52mm, CF, 2% 121243-1214702
R152 47 Ohm, 1/4W, 52mm, CF, 2% 121243-1214702
R153 47 Ohm, 1/4W, 52mm, CF, 2% 121243-1214702
R154 4.75K, 1/8W, 1%, Chip 124894-4751
R155 4.75K, 1/8W, 1%, Chip 124894-4751
R156 0 Ohm Jumper, Chip 124896
R157 10K, 1/2W, 52mm, CF, 5% 121243-1511035
R158 47.5K, 1/8W, 1%, Chip 124894-4752
R159 47.5K, 1/8W, 1%, Chip 124894-4752
R160 1K, 1/8W,1%, Chip 124894-1001
R161 4.32K, 1/8W, 1%, Chip 124894-4321
R162 0 Ohm Jumper, Chip 124896
R166 20K, 1/8W, 1%, Chip 124894-2002
R167 1K, 1/8W,1%, Chip 124894-1001
R168 4.32K, 1/8W, 1%, Chip 124894-4321
R169 0 Ohm Jumper, Chip 124896
R173 20K, 1/8W, 1%, Chip 124894-2002
R174 681 Ohm, 1/8W, 1%, Chip 124894-6810
R175 681 Ohm, 1/8W, 1%, Chip 124894-6810
R176 681 Ohm, 1/8W, 1%, Chip 124894-6810
R177 681 Ohm, 1/8W, 1%, Chip 124894-6810
R180 221K, 1/8W, 1%, Chip 124894-2213
R182 0 Ohm Jumper, Chip 124896
R183 221K, 1/8W, 1%, Chip 124894-2213
R184 49.9K, 1/8W, 1%, Chip 124894-4992
R185 49.9K, 1/8W, 1%, Chip 124894-4992
R191 47.5 Ohm, 1/8W, 1%, Chip 124894-47R5
R192 47.5 Ohm, 1/8W, 1%, Chip 124894-47R5
R193 47 Ohm, 1/4W, 52mm, CF, 2% 121243-1214702
R194 47 Ohm, 1/4W, 52mm, CF, 2% 121243-1214702
R195 47.5 Ohm, 1/8W, 1%, Chip 124894-47R5
R196 47.5 Ohm, 1/8W, 1%, Chip 124894-47R5
R197 47.5 Ohm, 1/8W, 1%, Chip 124894-47R5
R198 47.5 Ohm, 1/8W, 1%, Chip 124894-47R5
R199 6.81K, 1/8W, 1%, Chip 124894-6811
R200 10K, 1/8W, 1%, Chip 124894-1002
R201 17.8K, 1/8W, 1%, Chip 124894-1782
R203 221 Ohm, 1/8W, 1%, Chip 124894-2210
R204 221 Ohm, 1/8W, 1%, Chip 124894-2210
R205 47.5K, 1/8W, 1%, Chip 124894-4752
R207 47.5K, 1/8W, 1%, Chip 124894-4752
R208 10K, 1/8W, 1%, Chip 124894-1002
R209 47.5K, 1/8W, 1%, Chip 124894-4752
R210 475 Ohm, 1/8W, 1%, Chip 124894-4750
R212 4.75K, 1/8W, 1%, Chip 124894-4751

Description Part Number Note

24

ELECTRICAL PART LIST

502C Controller Main PCB Assembly

Capacitors

Reference

Designator

C1 1000pF, 10%, Chip 124956-1022
C2 1000pF, 10%, Chip 124956-1022
C3 22µF, 35V, Electrolytic 119944-220
C4 22µF, 35V, Electrolytic 119944-220
C5 0.1µF, +80/-20%, Chip 124959-104
C6 0.1µF, +80/-20%, Chip 124959-104
C7 100pF, 5%, Chip 124956-1012
C8 100pF, 5%, Chip 124956-1012
C9 .01µF, 5%, Film 137127-103
C10 680pF, 10%, Ceramic 137269-681
C11 .01µF, 5%, Film 137127-103
C12 0.0047µF, 5%, Film 137127-472
C13 0.0047µF, 5%, Film 137127-472
C14 .01µF, 5%, Film 137127-103
C15 .01µF, 5%, Film 137127-103
C16 0.1µF, +80/-20%, Chip 124959-104
C17 0.1µF, +80/-20%, Chip 124959-104
C18 .1µF, 5%, Film 137127-104
C19 .047µF, 5%, Film 137127-473
C20 .1µF, 5%, Film 137127-104
C21 100pF, 5%, Chip 124956-1012
C22 .1µF, 5%, Film 137127-104
C23 .1µF, 5%, Film 137127-104
C24 .47µF, 5%, Film 137127-474
C25 .1µF, 5%, Film 137127-104
C26 .1µF, 5%, Film 137127-104
C27 .47µF, 5%, Film 137127-474
C28 .47µF, 5%, Film 137127-474
C29 .22µF, 5%, Film 137127-224
C30 .22µF, 5%, Film 137127-224
C31 .1µF, 5%, Film 137127-104
C32 .1µF, 5%, Film 137127-104
C33 .22µF, 5%, Film 137127-224
C34 .022µF, 5%, Film 137127-223
C35 .18µF, 5%, Film 137127-184
C36 0.1µF, +80/-20%, Chip 124959-104
C37 0.1µF, +80/-20%, Chip 124959-104
C47 1000pF, 10%, Chip 124956-1022
C48 1000pF, 10%, Chip 124956-1022
C49 22µF, 35V, Electrolytic 119944-220
C50 22µF, 35V, Electrolytic 119944-220
C51 0.1µF, +80/-20%, Chip 124959-104
C52 0.1µF, +80/-20%, Chip 124959-104
C55 100pF, 5%, Chip 124956-1012
C56 100pF, 5%, Chip 124956-1012
C57 .01µF, 5%, Film 137127-103

Description Part Number Note

25

ELECTRICAL PART LIST

502C Controller Main PCB Assembly

Capacitors (continued)

Reference

Designator

C58 680pF, 10%, Ceramic 137269-681
C59 .01µF, 5%, Film 137127-103
C60 0.0047µF, 5%, Film 137127-472
C61 0.0047µF, 5%, Film 137127-472
C62 .01µF, 5%, Film 137127-103
C63 .01µF, 5%, Film 137127-103
C64 0.1µF, +80/-20%, Chip 124959-104
C65 0.1µF, +80/-20%, Chip 124959-104
C66 .1µF, 5%, Film 137127-104
C67 .047µF, 5%, Film 137127-473
C68 .1µF, 5%, Film 137127-104
C69 100pF, 5%, Chip 124956-1012
C70 .1µF, 5%, Film 137127-104
C71 .1µF, 5%, Film 137127-104
C72 .47µF, 5%, Film 137127-474
C73 .1µF, 5%, Film 137127-104
C74 .1µF, 5%, Film 137127-104
C75 .47µF, 5%, Film 137127-474
C76 0.1µF, +80/-20%, Chip 124959-104
C77 0.1µF, +80/-20%, Chip 124959-104
C78 .47µF, 5%, Film 137127-474
C79 .22µF, 5%, Film 137127-224
C80 .22µF, 5%, Film 137127-224
C81 .1µF, 5%, Film 137127-104
C82 .1µF, 5%, Film 137127-104
C83 .22µF, 5%, Film 137127-224
C84 .022µF, 5%, Film 137127-223
C85 .18µF, 5%, Film 137127-184
C86 0.1µF, +80/-20%, Chip 124959-104
C87 0.1µF, +80/-20%, Chip 124959-104
C95 Jumper, 0 Ohm 139942
C97 0.1µF, +80/-20%, Chip 124959-104
C98 0.1µF, +80/-20%, Chip 124959-104
C99 0.1µF, +80/-20%, Chip 124959-104
C100 0.1µF, +80/-20%, Chip 124959-104
C101 100pF, 5%, Chip 124956-1012
C102 100pF, 5%, Chip 124956-1012
C103 100pF, 5%, Chip 124956-1012
C104 100pF, 5%, Chip 124956-1012
C105 100pF, 5%, Chip 124956-1012
C106 100pF, 5%, Chip 124956-1012
C107 100pF, 5%, Chip 124956-1012
C108 100pF, 5%, Chip 124956-1012
C109 .0047µF, 1KV, Ceramic, 20%,

(US/Can)

Description Part Number Note

103447 5

26

ELECTRICAL PART LIST

502C Controller Main PCB Assembly

Capacitors (continued)

Reference

Designator

C109 .0047µF,20%,Metallized Paper,

(Euro/UK/Aus/Japan)

C110 10,000pF, +80/-20%, Chip 124959-103
C111 10,000pF, +80/-20%, Chip 124959-103
C112 10,000pF, +80/-20%, Chip 124959-103
C113 2200µF, 50V, 105C, Electrolytic, 20% 144000-222H 5

C114 2200µF, 50V, 105C, Electrolytic, 20% 144000-222H 5

C115 1µF, 50V, Electrolytic 137265-1R0
C116 1µF, 50V, Electrolytic 137265-1R0
C117 1µF, 50V, Electrolytic 137265-1R0
C118 1µF, 50V, Electrolytic 137265-1R0
C119 100pF, 5%, Chip 124956-1012
C120 100pF, 5%, Chip 124956-1012
C129 0.1µF, +80/-20%, Chip 124959-104
C130 0.1µF, +80/-20%, Chip 124959-104
C131 0.1µF, +80/-20%, Chip 124959-104
C132 0.1µF, +80/-20%, Chip 124959-104
C133 10,000pF, +80/-20%, Chip 124959-103
C142 1000pF, 10%, Chip 124956-1022
C143 1000pF, 10%, Chip 124956-1022
C144 1000pF, 10%, Chip 124956-1022
C145 1000pF, 10%, Chip 124956-1022
C146 1000pF, 10%, Chip 124956-1022
C147 1000pF, 10%, Chip 124956-1022
C148 1000pF, 10%, Chip 124956-1022
C149 1000pF, 10%, Chip 124956-1022
C150 0.1µF, +80/-20%, Chip 124959-104
C151 0.1µF, +80/-20%, Chip 124959-104
C152 22µF, Bi-polar, Electrolytic, 20% 147522-220
C153 22µF, 35V, Electrolytic 119944-220
C154 22µF, 35V, Electrolytic 119944-220
C155 22µF, 35V, Electrolytic 119944-220
C156 22µF, 35V, Electrolytic 119944-220
C157 22µF, 35V, Electrolytic 119944-220
C158 22µF, 35V, Electrolytic 119944-220
C159 22µF, 35V, Electrolytic 119944-220
C160 22µF, 35V, Electrolytic 119944-220
C161 0.1µF, +80/-20%, Chip 124959-104
C162 100pF, 5%, Chip 124956-1012
C163 100pF, 5%, Chip 124956-1012
C164 100pF, 5%, Chip 124956-1012

Description Part Number Note

146354 5

27

ELECTRICAL PART LIST

502C Controller Main PCB Assembly

Diodes

Reference

Designator

Z1 Bridge, 100V, 1A 143952
D1 1N4531, 5mm 136603
D2 1N4531, 5mm 136603
D3 1N4531, 5mm 136603
D4 1N4531, 5mm 136603
D5 1N4531, 5mm 136603
D6 1N4531, 5mm 136603
D7 1N4531, 5mm 136603
D8 1N4531, 5mm 136603
D9 1N4148, 52mm, Axial 116997 or 121501
D10 1N4531, 5mm 136603
D11 1N4148, 52mm, Axial 116997 or 121501
D12 1N4531, 5mm 136603
D13 1N4148, 52mm, Axial 116997 or 121501
D14 1N4531, 5mm 136603
D15 1N4148, 52mm, Axial 116997 or 121501
D16 1N4531, 5mm 136603
D17 1N4148, 52mm, Axial 116997 or 121501
D18 1N4531, 5mm 136603
D19 1N4148, 52mm, Axial 116997 or 121501
D20 1N4531, 5mm 136603
D21 1N4148, 52mm, Axial 116997 or 121501
D22 1N4531, 5mm 136603
D23 1N4148, 52mm, Axial 116997 or 121501
D24 1N4531, 5mm 136603
D25 Zener, 18V, 1W, 5% 116995-4746A
D26 Zener, 18V, 1W, 5% 116995-4746A
D27 Zener, 18V, 1W, 5% 116995-4746A
D28 Zener, 18V, 1W, 5% 116995-4746A
D29 Zener, 18V, 1W, 5% 116995-4746A
D30 Zener, 18V, 1W, 5% 116995-4746A
D31 Zener, 18V, 1W, 5% 116995-4746A
D32 Zener, 18V, 1W, 5% 116995-4746A
D33 Zener, 18V, 1W, 5% 116995-4746A
D34 Zener, 18V, 1W, 5% 116995-4746A
D35 Zener, 18V, 1W, 5% 116995-4746A
D36 Zener, 18V, 1W, 5% 116995-4746A
D37 1N4531, 5mm 136603
D38 1N4531, 5mm 136603
D39 1N4531, 5mm 136603
D40 Zener, 7.5V, 1W, 5% 116995-4737A
D41 LED, Green, Right Angle Mount 144027
D42 1N4531, 5mm 136603
D43 1N4531, 5mm 136603

Description Part Number Note

28

ELECTRICAL PART LIST

502C Controller Main PCB Assembly

Transistors

Reference

Designator

Q1 NPN, 2SC2812, 50T23 134741

Reference

Designator

U1 Op Amp, Quad 144008
U2 Op Amp, Quad 144008
U3 Op Amp, Quad 144008
U4 Op Amp, Quad 144008
U6 Op Amp, Quad 144008
U7 Op Amp, Quad 144008
U8 Op Amp, Quad 144008
U9 Op Amp 108568
U10 Op Amp 108568
U11 Op Amp 108568
U12 Op Amp 108568
U13 Regulator, Voltage, 3 terminal, +15V 143858
U14 Regulator, Voltage, 3 terminal, -15V 143806
U15 LM399N 137929

Description Part Number Note

Integrated Circuits

Description Part Number Note

Potentiometers and Switches

Reference

Designator

R126 Potentiometer, Dual-Ganged, 10K 143959-103
S1 4P4T, PCB Mount 143957
S2 Slide, DPDT 143958
S3 Slide, DPDT 143958
S4 Slide, DPDT 143958

Reference

Designator

K1 Relay, 24VDC, 4P4T 144017
K2 Relay, 24VDC, 4P4T 144017

Description Part Number Note

Relays

Description Part Number Note

29

ELECTRICAL PART LIST

502C Controller Main PCB Assembly

Connectors

Reference

Designator

J1 Harness Assy, Quick Disconnect 143968 5

J2 Harness Assy, Quick Disconnect 143968 5

J3 XLR, Female (Euro/Japan/UK/Aus) 189222-001
J4 XLR, Female (Euro/Japan/UK/Aus) 189222-001
P1 Header, 2 pin 143963
P2 Header, 2 pin 143963
P3 Header 143965
P4 Header, 12 pin 170250
P5 Header, 12 pin 170250
P6 Header, 6 pin (US/Can.) 143974
P7 Header, 6 pin (US/Can.) 143974
P8 Header, 6 pin (US/Can.) 143974
P9 XLR, Male (Euro/Japan/UK/Aus) 144004
P10 XLR, Male (Euro/Japan/UK/Aus) 144004
P11 XLR, Male (Euro/Japan/UK/Aus) 144004
P12 XLR, Male (Euro/Japan/UK/Aus) 144004

Description Part Number Note

30

DISASSEMBLY PROCEDURES

502A Array Procedures

Note: Refer to Figure 9 for the following

procedures.

1. Grille Removal

1.1 Remove the 2 screws (2) located on

each end of the grille (1) using a 7/64" hex
wrench. Grasp the grille on both ends and
pull it away from the array.

2. Driver Removal

2.1 Perform procedure 1.

2.2 Remove the 3 screws (6) that secure the

driver (5) to the array.

2.3 Lift the driver carefully away from the
array. Make a note of the wiring configura­tion and cut the wires connected to the driver
terminals as close to the terminals as pos­sible.

Re-assembly Notes:

1. Be sure to observe polarity when connect-

ing the replacement driver. Refer to the
wiring diagram, Figure 10.

2. Be sure that the driver gasket is properly
aligned so that it makes an airtight seal.

3. Passive Component Removal

3.1 Perform procedure 1.

3.2 Remove the 2 drivers located on the end

of the array opposite the serial number (refer
to procedure 2 above), but do not cut any
wires.

3.3 Resistor (8) or capacitor (9) removal:

Unwrap the component's leads from its
wirewrap terminal (11), and remove the
component from the array.

4. Connector Panel Removal

4.1 Remove 4 screws (15) that secure the

panel (16) to the array.

4.2 Grasp the panel and pull it away from
the array.
Re-assembly Note: When re-installing the
connector panel, ensure that the panel
gasket is correctly positioned so that it
makes an airtight seal.

5. Barrier Strip Connector Removal

5.1 Remove the 2 screws (21) that secure

the connector (22) to the connector panel
(16).

5.2 Unwrap the wires from the barrier strip
terminals, and remove the connector.

Re-assembly Note: When re-installing the
barrier strip, ensure that the gasket is
correctly positioned so that it makes an
airtight seal.

6. XLR Connector Removal

6.1 Remove the 4 screws (21) that secure

the connector (22) to the connector panel
(16).

6.2 Make a note of the wiring configuration
and cut the connector's leads as close to its
terminals as possible. Remove the connec­tor from the array.

Re-assembly Notes:

1. Observe polarity when connecting the

replacement XLR connector. Use the notes
from step 6.2.

2. When re-installing the XLR connector,
ensure that the gasket is correctly posi­tioned so that it makes an airtight seal.

3.4 Inductor (12) removal: Remove the
screw (6) and washer (13) that secure the
inductor to the array. Cut the inductor leads
as close to the terminals as possible.

31

2

2x

1

25

24 2x

34

11

4x

2x

10

15x

7

5x

5x

5

6

8

9

15 4x

13
12

17

18

16

20

18

17

19

21

22

23

22

21

23

26

16

26

20

19

23

21

22

16

26

2x

20

19

18

14

17

XLR VARIATION
SHOWN

21

22

23

2x

Figure 9. 502A Array Exploded View

32

BARRIER

Figure 10. 502A Array Wiring Diagram

33

SPEAKON XLR

DISASSEMBLY PROCEDURES

7. Speakon® Connector Removal

7.1 Remove the 4 screws that secure the

connector to the connector panel (16).

7.2 Make a note of the wiring configuration
and cut the connector's leads as close to its
terminals as possible. Remove the connec­tor from the array.

Re-assembly Notes:

1. Observe polarity when connecting the

replacement XLR connector. Use the notes
from step 6.2.

2. When re-installing the connector, ensure
that the gasket is correctly positioned so that
it makes an airtight seal.

8. Fuseholder Removal

8.1 Remove the connector panel using

procedure 4.

8.2 Remove the fuseholder nut (26) from the
fuseholder body (19).

8.3 Unsolder the wires from the fuseholder
terminals.

502B Bass Module Procedures

Note: Refer to Figures 11 and 12 for the

following procedures.

9. Access Panel Removal

9.1 Remove 12 screws (23) that secure the

access panel (10) to the unit.

9.2 Partially insert one of the screws into a
screw hole. Using the screw as a lever,
carefully remove the access panel.

10. Woofer Removal

10.3 Make a note of the wiring configuration

and disconnect the wires from the woofer
terminals. Carefully pull the woofer away
from the unit.

Re-assembly Notes:

1. Observe polarity when connecting the

woofer harness wires to the woofer.

2. Align the woofer gasket to provide an
airtight seal.

11. Barrier Strip Connector Removal

11.1 Remove the 2 screws (16) that secure

the connector (17) to the access panel (10).

11.2 Make a note of the wiring configuration
and unwrap the wires from the connector
terminals. Remove the connector.

Re-assembly Notes:

1. Use the note from step 10.2 to ensure

proper wiring connections.

2. Align the connector gasket to provide an
airtight seal.

12. XLR Connector Removal

12.1 Remove the 4 screws (16) that secure

the connector (17) to the access panel (10).

12.2 Make a note of the wiring configuration
and cut the connector leads as close to the
terminals as possible. Remove the connec­tor.

Re-assembly Notes:

1. Use the note from step 12.2 to ensure

proper wiring connections.

2. Align the connector gasket to provide an
airtight seal.

13. Fuseholder Removal

13.1 Remove the access panel using proce-

dure 9.

10.1 Remove the access panel using proce­dure 9.

10.2 Remove the 8 screws (21) that secure
the woofer (22) to the unit.

13.2 Remove the fuseholder nut (19) from
the fuseholder body (12).

13.3 Unsolder the wires from the fuseholder
terminals.

34

DISASSEMBLY PROCEDURES

14. Speakon® Connector Removal

14.1 Remove the 4 screws that secure the

connector to the access panel.

14.2 Make a note of the wiring configuration
and cut the connector leads as close to the
terminals as possible. Remove the connec­tor.

Re-assembly Notes:

1. Use the note from step 14.2 to ensure

proper wiring connections.

2. Align the connector gasket to provide an
airtight seal.

15. Fuseholder Removal

15.1 Remove the access panel using proce-

dure 9.

15.2 Remove the fuseholder nut (19) from
the fuseholder body (12).

16.2 Remove the 2 top screws (4) that
secure the top cover to the front plate (3).
Earlier units will have 3 screws on top.

16.3 Slide the top cover out from under the
front plate, and lift it off the unit.

16.4 Front Plate Removal: There are two
screws (4) on the bottom that hold the front
plate to the chassis. Remove the screws
and washers and pull the front plate away
from the chassis.

17. Main PCB Removal

17.1 Remove the top cover and front panel

using procedure 16.

17.2 Disconnect the following connectors:
P6-P8 (barrier strip connectors only), P1
(line cord assembly), P2 and P3 (trans­former connectors).

15.3 Unsolder the wires from the fuseholder
terminals.

502C Controller Disassembly
Procedures

Notes:

1. Refer to Figure 14 or 15 for the following

procedures.

2. Later production units have fewer screws
than earlier units. These quantity differences
are noted in the procedures below.

3. Unless otherwise specified, a T-10 Torx
bit is recommended for screw removal.

16. Top Cover/Front Plate Removal

WARNING: Be sure to unplug the unit from

the AC Mains before removing the top cover.
There are hazardous voltages inside the
chassis.

16.1 Remove the 2 screws (2) that secure
the top cover (1) to the back of the chassis.
Earlier units will have 4 screws.

17.3 XLR version: Remove the 6 screws
(2) that secure connectors (J3, J4, P9-12)
to the chassis. Earlier units have 12 screws.

17.4 Carefully scrape the glue away from
the terminals of power switch S5 (6).
Disconnect the terminals.

17.5 Barrier strip version: Remove the 5
screws (8) that secure the Main PCB (7) to
the chassis.

17.6 XLR version: Remove the 2 screws
(8) which secure the Main PCB to the chas­sis. Earlier units have 5 screws.

17.7 Squeeze the 2 metal posts (not shown­they are located in the 2 front corners of the
PCB) that secure the Main PCB to the
chassis bottom. Lift the PCB straight up.

17.8 Slide the PCB out towards the front of
the unit and pull it away from the chassis.

35

DISASSEMBLY PROCEDURES

18. Transformer Removal

18.1 Remove the top cover using procedure

16.

18.2 Disconnect P2 (transformer primary)
and P3 (transformer secondary) from the
Main PCB (7).

15.3 Remove the two 11/32" hex nuts (10)
and washers that secure the transformer (9)
to the chassis.

15.4 Lift the tranformer out of the chassis.

16. Barrier Strip Connector Removal

16.1 Remove the top cover using procedure

16.

16.2 Remove the 2 screws (13) that secure
the connector (12) to the chassis.

17. XLR Connector Removal

17.1 Remove the top cover and front panel

using procedure 16.

17.2 Remove 6 screws (2) that secure the
connectors to the chassis.

17.3 Remove the Main PCB using pro­cedure 27.

17.4 Unsolder the connector (J3, J4, P9-12)
from the Main PCB (7). Lift out the connec­tor.

16.3 Disconnect either P6, P7 or P8 and pull
the connector through the cutout in the
chassis.

36

Figure 11. 502B Bass Module Exploded View

37

Barrier Strip Version

19

XLR Version

12

14

13

11

15

16

16

17

17

18

18

Figure 12. 502B Bass Module Connector and Access Panel

38

SPEAKON WIRE DIAGRAM

Figure 13. 502B Bass Module Wiring Diagrams

39

Figure 14. 502C Controller Exploded View (removable front panel version)

1

5X

13

5

9

4

C114

C113

14

4

5

2X

6

2

3

7

8

12

11

10

6X

9

Figure 15. 502C Controller Exploded View (one-piece chassis version)

40

2

TEST PROCEDURES

502A Array T est Procedures

Note: All 502A procedures involve connect-

ing test equipment to the array's input
terminals. For the XLR input pin assignment,
see Figure 16 below.

Figure 16. XLR input pin assignment

1. Phase Test Male

1.1 Remove the grille using disassembly

procedure 1.

1.2 Apply an 8V DC voltage level to the
array's input terminals. Be sure to observe
polarity.

1.3 The cones of all 5 drivers should move
outward with the application of the DC
voltage.

2. Air Leak/Rub and Tick Test

2.1 Apply an 8 Vrms, 10 Hz signal to the

array's input terminals.

3. Shading Network Test

3.1 Apply a 2 Vrms, 2.5 kHz signal to the

array's input terminals.

3.2 Connect a 3 Ohm, 1W resistor in series
between the positive (+) amplifier output
and the array's positive (+) input.

3.3 Measure the voltage across the resistor.
It should be approximately .49V ± 0.1 Vrms.

3.4 If the measured voltage is outside the
specified range, check the following:
(1) Make sure that the passive components
are a 3 Ohm resistor, .75 mH inductor, and
5µF capacitor.
(2) Check all driver connections against the
502A wiring diagram in Figure 10.

4. Sweep Test

4.1 Apply an 8 Vrms, 10 Hz signal to the

array's input terminals.

4.2 Sweep the oscillator slowly from 10 Hz
to 5 kHz. There should not be any buzzes
or rattles from within the array enclosure.
Redress any wire or component that buzzes.
A "whooshing" noise at around 140 Hz is
acceptable.

2.2 Air Leak Test: Block the ports. Listen for
air leaks around the drivers and all cabinet
joints. If there is a "whooshing" noise, there
is probably an air leak in one of these loca­tions. Repair any air leaks as required.

2.3 Rub and Tick Test: No extraneous
noises such as rubbing, scraping, or ticking
should be heard. To distinguish between
normal suspension noise and rubs or ticks,
displace the cone of the driver slightly with
your fingers. If the noise can be made to go
away or get worse, it is a rub or a tick, and
the driver should be replaced. If the noise
stays the same, it is normal suspension
noise and the driver is fine. Suspension
noises will not be heard with program mate­rial.

502B Bass Module Test Procedures

Note: All 502B procedures require connect-

ing test equipment to the bass box's input
terminals. For the XLR input pin assignment,
see Figure 16.

1. Phase Test

1.1 Insert one hand into the bottom port of

the 502B. Gently touch the dust cap or cone
of the woofer. (The woofer is located above
the port hole).

1.2 Apply a 20 Vdc level to the 502B's input
terminals. Be sure to observer polarity when
applying the DC level. The woofer cone
should move outward towards the bottom
of the bass box.

41

TEST PROCEDURES

1.3 If the woofer cone deflects inward,

check all wiring.

2. Woofer Air Leak/Rub and Tick Test

2.1 Apply a 20 Vrms, 10 Hz signal to the

502B's input terminals.

2.2 Air Leak Test: Block the ports. Listen for
air leaks around the cabinet. If there is a
hissing or "whooshing" noise, there is prob­ably an air leak. Repair any air leaks as
required.

2.3 Rub and Tick Test: No extraneous
noises such as rubbing, scraping, or ticking
should be heard. To distinguish between
normal suspension noise and rubs or ticks,
displace the cone of the woofer slightly with
your fingers. If the noise can be made to go
away or get worse, it is a rub or a tick, and
the woofer should be replaced. If the noise
stays the same, it is normal suspension
noise and the driver is fine. Suspension
noises will not be heard with program mate­rial.

3. Sweep Test

3.1 Apply a 20 Vrms, 10 Hz signal to the

502B bass module input terminals.

3.2 Sweep the oscillator slowly from 10 Hz to
300 Hz. There should not be any loud,
extraneous sounds. If there are any loud
buzzes or distortion, the woofer may be
defective.

Note: A "whooshing" noise from the port
around 55 Hz and 105 Hz is acceptable.
There should not be any buzzes or rattles
from within the 502B enclosure. Redress any
wire or component that buzzes or rattles.

502C Controller Test Procedures

Test Setup

Input Connections: Connect an audio

signal generator to the positive (+) and
negative (-) input terminals for Channels 1
or 2. These procedures assume that the
person performing these tests is using test
equipment with unbalanced inputs and
outputs. Refer to Figure 17 for connection
information).

Output Connections: Connect test equip­ment to the positive (+) and negative (-)
output terminals for Channels 1 or 2 (low
and high frequency outputs).

All tests should be performed for both
channels.

All test equipment must be isolated from
ground (floated).

Some settings on the controller may need
to be changed for the various procedures.
These settings will be indicated throughout
the test procedures. Refer to Figure 18 for
a diagram of the controller's back panel.

The controls on the back panel should be
set as follows (unless otherwise specified):

• Mode switch should be set at 2 (Bi-Amp)

• Output mode switch should be set at
normal

• Input switches should be set at +4 dB

• Low frequency level potentiometer should
be set at +3 dB

1. Clipping Headroom Test

1.1 Apply a 4.73 Vrms, 600 Hz signal to the

input terminals.

42

1.2 Distortion (at an output voltage of 6.29
Vrms) should measure -1% (measure
across the High Frequency outputs).

TEST PROCEDURES

2. Gain Test

2.1 Set the input switches to -10 dB.

2.2 Apply a 100 mVrms, 600 Hz signal to the

input terminals.

2.3 Measure the gain at the high frequency
outputs. The gain (referenced to the input)
should be 16.5 ± 1.0 dB.

2.4 Change the input level switches to
+4 dB.

2.5 Measure the gain at the high frequency
outputs. The gain (referenced to the input)
should be 2.5 ± 1.0 dB.

3. Sum Output Mode Gain Test

3.1 Set the input switches to +4 dB.

3.2 Set the output mode switch to Normal

and the low frequency level potentiometer to
+3 dB.

3.3 Apply a 100 mVrms, 80 Hz signal to the
502C's input terminals.

3.4 Measure the gain at the Channel 1, low
frequency output. The gain (referenced to
the input) should be 8.7 ± 1.0 dB.

4. Frequency Response of High Frequency
(HF) Output (Full Range Mode)

4.1 Set the mode switch to 1 (Full Range).

Frequency (Hz) Response (dB)

40 -24.5 ± 2.0
140 +4.3 ± 1.5
600 REF
2200 +3.5 ± 1.5
5000 +12.5 ± 1.5
15000 +19.0 ± 1.5

5. Frequency Response of HF Output
(Bi-Amp Mode)

5.1 Set the mode switch to 2 (Bi-Amp).

5.2 Apply a 100 mVrms, 600 Hz signal to the

502C input terminals and reference your dB
meter to this frequency.

5.3 Measure the frequency response across
the HF outputs according to the table below.

Frequency (Hz) Response (dB)

40 -28.5 ± 2.0
140 +3.7 ± 1.5
600 REF
2200 +3.5 ± 1.5
5000 +12.5 ± 1.5
15000 +19.0 ± 1.5

6. Frequency Response of Low Fre­quency (LF) Output (Bi-Amp Mode)

6.1 Apply a 100 mVrms, 80 Hz signal to the

502C input terminals and reference your dB
meter to this frequency.

6.2 Measure the frequency response across
the LF outputs according to the table below.

4.2 Apply a 100 mVrms, 600 Hz signal to the
502C's input terminals and reference your
dB meter to this frequency.

4.3 Measure the frequency response across
the HF outputs according to the following
table.

Frequency (Hz) Response (dB)

40 -6.2 ± 2.0
80 REF
100 +1.3 ± 1.0
300 -17.5 ± 2.0

7. Midrange Distortion (Full Range Mode)

7.1 Set the mode switch to 1 (Full Range).

7.2 Apply a 3.75 Vrms, 600 Hz signal to the

502C input terminals.

43

TEST PROCEDURES

7.3 Measure the distortion across the HF

outputs. It should be - .1%.

8. High Frequency Distortion (Full Range
Mode)

8.1 Apply a 890 mVrms, 5 kHz signal to the

502C input terminals.

8.2 Measure the distortion across the HF
outputs. It should be - .2%.

9. Low Frequency Distortion (Bi-Amp
Mode)

9.1 Set the mode switch to 2 (Bi-Amp).

9.2 Apply a 1.6 Vrms, 80 Hz signal to the

502C input terminals.

9.3 Measure the distortion across the LF
outputs. It should be - .1%.

11. High Frequency Distortion (Bi-Amp
Mode)

11.1 Apply a 890 mVrms, 5 kHz signal to the

502C input terminals.

11.2 Measure the distortion across the HF
outputs. It should be - .2%.

12. Channel Separation (Bi-Amp Mode)­High Frequency

12.1 Set the mode switch to 2 (Bi-Amp).

12.2 Apply a 3.75 Vrms, 600 Hz signal to the

502C's input terminals.

12.3 Measure the channel separation across
the HF outputs. It should be > 40 dB.

10. Midrange Distortion (Bi-Amp Mode)

10.1 Apply a 3.75 Vrms, 600 Hz signal to the

502C input terminals.

10.2 Measure the distortion across the HF
outputs. It should be - .1%.

44

Input Connections

Amplifier

Hot (+) Shield/ground

To unbalanced input

on amplifier

Shield and ground

pin 1

Unconnected

pin 3

Amplifier

OUTPUT

Hot (+)
pin 2

To unbalanced input

on amplifier

INPUT LEVEL

–10 +4

SER. NO. D.O.M.

Output Connections

Figure 17. Unbalanced Connections

Input

connectors

INPUT

CH 1

Input

attenuator

switches

High frequency

output

connectors

Bass level

control

HIGH FREQ OUTPUT

MODE

INPUT LEVEL

4
3

–10 +4

CH 2

PROTECTED BY U.S. PATENT 3,038,964

2

1

Mode

switch

2 HC1 HC

LOW FREQ

LEVEL

.

0

.

OUTPUT MODE

.

.

.

.

.

NORM SUM

+3

-18

BOSE CORPORATION, FRAMINGHAM, MA 01701-9168
ENGINEERED AND MANUFACTURED IN U.S.A.

Bass mono

sum switch

Low frequency

output

connectors

LOW FREQ OUTPUT

+– +–+– +–+– +–

CH 1 CH 2

Figure 18. 502C Controller Back Panel (Barrier Strip Version Shown)

45

230V~AC
50/60Hz 12W

LISTED 411F

U

L

®

COMMERCIAL

SOUND

EQUIPMENT

ACCESSORY KIT PART LIST

502A PSA-5 Stand Adapter Parts List (see Figure 19)

Item

Number

1 Mounting Bracket 148513 2 1

- Har dware Kit, Consists of: 173535 1
2 Thumbscrew, M8x25mm, Black 173355 4
2 Washer, Thumbscrew 173356 4
3 Bolt, Button Head, 5mm, M8x12mm, Black
4 Bolt, Button Head, 5mm, M8x20mm, Black
5 Lock washer, M8 173450 10
6 Allen Wrench, 5mm 148544-1 1

- Poly bag, Hardware 173358 1 7

- I nstruction Sheet 148515 1 1, 7

- Poly sleeve 173357 2 1, 7

- Car t on, RSC 173359 1 1, 7

- Car t on, Divider 173360 1 1, 7

Description Part Number Qty.

148526-02 8
148526-10 2

Note

5

4

3

2

6

1

Figure 19. PSA-5 Stand Adapter Kit

46

ACCESSORY KIT PART LIST

502A CSB-5A Suspension Bracket Kit Parts List (see Figure 20)

Item

Number

1 Suspension Bracket 148519 2 1

- Hardware Kit, Consists of: 173536 1
2 Screw, Mach., Socket Cap, M8x12mm 148514 7
2 Lock washer, M8 173450 7
3 Quick Link, 1/8" 148520-1 5
4 Allen Wrench, 6mmx3" 148544-2 1

- Poly bag, Hardware 173362 1 7

- Instruction Sheet 148521 1 1, 7

- Poly sleeve, Bracket 173361 2 1, 7

- Carton 173363 1 1, 7

- Carton Divider 173364 1 1, 7

Description Part Number Qty.

Note

3

1

4

2

Figure 20. CSB-5A Suspension Bracket Kit

47

ACCESSORY KIT PART LIST

502B CSB-5B Suspension Bracket Kit Parts List (see Figure 21)

Item

Number

1 Left Angle Bracket 147005-1 1 1
1 Right Angle Bracket 147005-2 1 1

- Hardware Kit, Consists of: 173537 1
2 Screw, Hex Head, Mach., M8x20mm 148545-10 5
2 Lock washer, M8 173450 5
3 Quick Link, 3/16" 148520-2 2

- Poly bag, Hardware 173376 1 7

- Instruction Sheet 148527 1 1, 7

- Poly slee ve, Bracke t 173375 2 1, 7

- Tube, Packing 173377 1 1, 7

- Carton, Divider 173378 1 1, 7

Description Part Number Qty.

Note

1

2

3

Figure 21. CSB-5B Suspension Bracket Kit

48

ACCESSORY KIT PART LIST

502A WBP-5 Bi-Pivot Bracket Kit Parts List (see Figure 22)

Item

Description Part Number Qty. Note

Number

1 Wall Plate Assembly 146995 2 1
2 Attachment Plate, Stamped Metal 149030 2 1

- Hardware Kit, Consists of: 173534 1
3 Screw, Socket Head Cap, M8x25mm 148505 2
3 Nut, Elastic, 8mm 148542 2
4 Screw, Socket Head Cap, M6x25mm 148541 2
4 Nut, Elastic, 6mm 148543 2
5 Safety Cable 148506 2
6 Allen Wrench, 5mm 148544-1 1
7 Allen Wrench, 6mm 148544-2 1
8 Bolt, Button Head, 5mm, M8x16mm 148526-06 11
8 Lock washer, M8 173450 11

- Poly bag (Hardware) 173370 1 7

- I nstruction Sheet 148509 1 1, 7

- Poly sleeve, W all Plate Assembly 173371 2 1, 7

- Poly sleeve, Att achment Plate 173372 2 1, 7

- Carton, RSC 173373 1 1, 7

- Carton, Divider 173374 1 1, 7

1

8

4

3

2

5

7

6

Figure 22. WBP-5 Bi-Pivot Bracket Kit

49

ACCESSORY KIT PART LIST

502A WCB-5 U-Bracket Kit Parts List (see Figure 23)

Item

Number

Description Part Number Qty.

1 U-Bracket 148531 2 1
1 Bushing 148532 4 1

- Hardware Kit, Consists of: 173533 1
2 Locking Bracket 148536 2
3 Safety Cable 148506 2
4 Bolt, Button Head, 5mm, M8x12mm 148526-02 7
5 Bolt, Button Head, 5mm, M8x20mm 148526-10 5
6 Lock washer, M8 173450 11
7 Thumbscrew, M5x10mm 145750 3
8 Allen Wrench, 5mmx70mm 148544-1 1

- Poly bag, Hardware 173367 1 7

- Instruction Sheet 148537 1 1, 7

- Poly slee ve, U-Br acket 173365 2 1, 7

- Poly bag, Locking Bracket 173366 2 1, 7

- Carton, RSC 173368 1 1, 7

- Carton, Divider 173369 1 1, 7

6

4

Note

2

6

7

5

3

8

1

Figure 23. WCB-5 U-Bracket Kit

50

ACCESSORY KIT PART LIST

®

1

502A CVT-5 Transformer Assembly Kit Parts List (Figure 24)

Item

Number

- CVT-5 XFMR Assy Kit (Gray)
CVT-5 XFMR Assy Kit (White)
Which consists of

1 Transformer 143576 172030 1 5

2 Foam Adhesive 119604 119604 N/A
3 Cover-Transformer (Gray)

(White)

4 Gasket-Transformer Cover 143554 143554 1 5

5 Gasket Barrier 146873 146873 1 5

6 Connector- Barrier 148976-04 148976-04 1 5

7 Screw-#8 137527-12 137527-12 4
8 Owners Manual 172164 172164 1
9 Poly bag 173379 173379 1

10 Carton 173380 173380 1

*Product code 040170 (black) and 040171 (white) are a RoHS compliant version of
the 502A. Only RoHS compliant parts listed in the above chart can be used in the
502A with product code 040170 and 040171.

Description XLR and Barrier

Version, PC
003841, 019769,
004934, 004935,

004936, 007698

007699
007890

142358-01
142358-02

Speakon

Version,

PC 040170

and 040171

040089
040088

142358-01
142358-02

Qty Note

1

1 5

Figure 24. CVT-5 Exploded View and Packaging

51

Figure 25. CVT-5 Schematic

52

THEORY OF OPERATION

502C Controller

The following provides an overview of 502C electrical operation. Equalization curves are refer­enced and are located at the end of this section. Additionally, the 502C block diagram and
schematic should be referenced as required.

1. Differential Input Stage

The input stage features protection against RFI (radio frequency interference), ESD (electro­static discharge), and overvoltage. Referring to the Channel 1 circuit, R2/C1, R1/C120, R3/C2,
and R9,10/C7 provide low pass filtering to reduce the possibility of RFI. Diodes D1-D4, D25,
and D26 provide input clamping to protect against overvoltage and ESD.

Op-amp U1 amplifies the difference between the + and - input pins, and converts it to a single
ended signal that drives the equalizers. Gain switch S3 selects between two gains, a high gain
setting for -10dB sources and a low gain setting for +4db sources.

2. Equalizer for High Frequency Outputs

Op-amps U1, U2 and U3 constitute the principal equalization for the high frequency output.
Each stage makes a contribution to the total low or high frequency contouring required by the
loudspeaker. Op-amp U4 (pins 12, 13 and 14) implements a high pass filter suitable for the Full
Range mode, while op-amp U4 (pins 8, 9, and 10) is selected for a high pass filter with a higher
corner frequency for use in the Bi-amp mode. The circuitry is duplicated for both channels.
Refer to the high frequency equalization curves for more information about the stage by stage
response of the equalizer.

3. Output mode switch, Low frequency level control, and Normal/Sum mode stage

Output mode switch S2 (on the rear panel) controls op-amp summing amplifier U6 (pins 5, 6,
and 7). In the normal mode, the stage is not used, and the Channel 1 and Channel 2 low fre­quency outputs pass independent, 2-channel bass to 2 bass cabinets. In the sum mode, Chan­nels 1 and 2 are combined, and this "mono" bass signal appears at the Channel 1 low fre­quency output only. Potentiometer R126 (on the rear panel), Low Frequency Level, provides for
adjustment of the signal sent into the low frequency equalizer.

4. Equalizer for Low Frequency Outputs

After the normal/sum stage, there is op-amp stage U7 (pins 12, 13, and 14) and op-amp equal­izer stages U7 (pins 8, 9, and 10), U8 (pins 12, 13, and 14), and U8 (pins 8, 9, and 10). The
equalizer provides high pass, low pass, and contouring equalization. See the low frequency
equalization curves for more information about the stage by stage response of the equalizer.

5. Mode switch

Rotary switch S1 is located on the rear panel. It selects the four operating modes for the
Panaray® system. Currently, only Modes 1 (Full range) and 2 (Bi-Amp) are supported.

53

THEORY OF OPERATION

6. Output stage

NOTE: The components mentioned in this paragraph are for the high frequency output only.

The output stage is compatible with balanced signal transmission systems. Inverting op-amp
stage U9 (pins 1, 2, and 3) provides the output signal. Diodes D9, D10, D29 and D30 provide
output clamping to protect against overvoltage and ESD. Relays K1 and K2 clamp the outputs
to ground to protect against power on/off transients. When the relay is de-energized, as when
the AC power is off, the outputs are clamped. About 1.2 seconds after the power is turned on,
the relay is energized by transistor Q1 and allows audio to pass through the controller. When
the power is turned off, a fast acting detector de-energizes the relays to protect against power
off transients.

NOTE: In earlier production units (before August 1993), the output stage was differential. Not
only was the positive (+) output pin driven, but the negative (-) output pin was also driven (out of
phase). The output stage was changed so that only the positive (+) output pin is driven, while
the negative (-) output pin is connected to signal ground through a series impedance identical to
that of the positive (+) output pin. This alternative output stage design has improved characteris­tics into a variety of real world installation conditions. Both versions produce the same output
level when received by a balanced input.

7. Power Supply

The 502C uses full wave bridge rectifier Z1 and regulators U13 and U14 to develop the
+/-15 volt supply needed by the op-amps.

8. Turn On/Off Muting Circuit

Relays K1 and K2 clamp the outputs and are controlled by three sections of quad comparator
U15. U15 (pins 8, 9 and 14) drives the relay control transistor Q1 by pulling the relay-coil termi­nal to nearly 15 volts. This energizes the relay for normal audio operation. At power on, U15
(pins 8, 9 and 14) is prevented from energizing the relay until capacitor C152 can be charged up
sufficiently. This takes about 1.2 seconds, and mutes any turn-on transients. At power off, U15
(pins 2, 4, and 5) quickly detects the loss of AC power and causes Q1 to snap quickly off. This
de-energizes the relay in about 100 ms, before any transients can reach the output.

9. Troubleshooting Tips

If a differential output test generator isn't available, connect the generator ground to the 502C
ground terminal, and the generator hot lead to the negative (-) input terminal. Leave the positive
(+) terminal unconnected.

If you need to connect the 502C outputs to a single-ended (not differential) instrument, connect
the 502C output ground to the instrument ground, and the 502C positive (+) output terminal to
the instrument hot pin. Leave the negative (-) output pin unconnected.

Since the 502C is a two channel device, you can troubleshoot any problem occurring in only one
channel more easily by applying the identical signal to both Channel 1 and Channel 2 inputs and
signal tracing stage by stage, comparing the signal as it passes through the various stages. In
general, the corresponding Channel 1 and Channel 2 stages share the left and right hand sides
of the respective op-amps. This makes it easier to compare the stages.

54

THEORY OF OPERATION

Troubleshooting Tips (continued)

With a nominal AC power input voltage (100, 115, or 230, depending on the country), the AC
voltages at the transformer secondary between P3-1 and P3-3 should be 41.3 Vrms.

With a cold (i.e.-room temperature) power transformer, you should expect primary and second­ary resistances of:

For the 100 VAC version:

between P2-1 and P2-2: 41.8 Ohms
between P3-1 and P3-3: 6.9 Ohms

For the 115 VAC version:

between P2-1 and P2-2: 45.4 Ohms
between P3-1 and P3-3: 6.3 Ohms

For the 230/240 VAC version:

between P2-1 and P2-2: 195 Ohms
between P3-1 and P3-3: 7.1 Ohms

Other DC voltages that are of use in troubleshooting:

Turn On/Off Muting Circuit
Typical DC voltages after 2 seconds wake up

U15-1 Section not used
U15-2 +13.5
U15-3 -15.0
U15-4 +.15
U15-5 +3.2
U15-6 Section not used
U15-7 Section not used
U15-8 +7.5
U15-9 +13.5
U15-10 +7.5
U15-11 +9.7
U15-12 -15.0
U15-13 +13.5
U15-14 -13.9
Q1-collector -14.7

Power Supply

U13-1 +26.0
U14-2 -26.0

55

Gain

in dB

20

10

0

-10

-20

-30

-40
20

200

2K

Frequency in Hz

20K

Output is measured from U7 pins 1 and 14. 502C controls are set at: Mode 2 (Bi-amp),
Output Mode: Normal, Low Frequency level: +3dB, and Input Level: +4dB.

Figure 26. Low Frequency EQ

20

10

0

Response

Gain

in dB

-10

-20

-30

-40

20 200

Frequency in Hz

2K

Output is measured from U7 pins 7 and 8. 502C controls set as in Figure 26.

Figure 27. Low Frequency EQ

56

20K

Gain

in dB

20

10

0

-10

-20

-30

-40
20

200

Frequency in Hz

2K

Output is measured from U8 pins 1 and 14. 502C controls set as in Figure 26.

Figure 28. Low Frequency EQ

20

10

0

Gain

in dB

-10

-20

20K

-30

-40
20 200 2K

Frequency in Hz

Output is measured from U8 pins 7 and 8. 502C controls set as in Figure 26.

Figure 29. Low Frequency EQ

57

20K

30

20

10

0

Gain

in dB

-10

-20

-30

-40
20 200

2K

Frequency in Hz

Output is measured from U1 pins 7 and 8. 502C controls set as in Figure 26.

Figure 30. High Frequency EQ

30

20

20K

10

0

-10

-20

-30

-40

20

200

Frequency in Hz

2K 20K

Output is measured from U2 pins 1 and 14. 502C controls set as in Figure 26.

Figure 31. High Frequency EQ

58

Gain

in dB

30

20

10

0

-10

-20

-30

-40
20

200

Frequency in Hz

2K

Output is measured from U2 pins 7 and 8. 502C controls set as in Figure 26.

Figure 32. High Frequency EQ

30

20

10

0

Gain

in dB

-10

20K

-20

-30

-40

20

200

Frequency in Hz

2K

Output is measured from U3 pins 1 and 14. 502C controls set as in Figure 26.

Figure 33. High Frequency EQ

59

20K

30

20

10

0

Gain

in dB

-10

-20

-30

-40

20 200 2K 20K

Frequency in Hz

Output is measured from U3 pins 7 and 8. 502C controls set as in Figure 26.

Figure 34. High Frequency EQ

30

20

10

0

Gain

in dB

-10

-20

-30

-40
20 200 2K 20K

Frequency in Hz

Output is measured from U4 pins 7 and 8. 502C controls set as in Figure 26.

Figure 35. High Frequency EQ

60

30

20

10

0

Gain

in dB

-10

-20

-30

-40

20 200 2K 20K

Frequency in Hz

Output is measured from U4 pins 1 and 14. 502C controls set as in Figure 26 except:
Mode switch is set to 1 (Full Range Mode).

Figure 36. High Frequency EQ

61

Figure 37. 502C Controller Block Diagram

62

SERVICE MANUAL REVISION HISTORY

Date Revision

Level

5/93 01 Changed 502C’s J3, J4 XLR part

number to 189222-001.

5/05 02 Revised Figure 21 to correct exploded

view.
Added service manual revision page.
Updated front and back covers.

6/06 03 Speakon® Version and RoHS

compliant parts added.

Description of Change Change Drive

Pages

By

Part Number

Change

Error 38

New Version,

RoHS parts

Affected

29

18, 19, 22,
23, 24, 36,
37, 40, 42,

43, 62

63

SPECIFICATIONS AND FEATURES SUBJECT TO CHANGE WITHOUT NOTICE

Bose Corporation
The Mountain
Framingham Massachusetts USA 01701

P/N: 170310-SM R ev. 03; 6/2006 (P)
http://serviceops.bose.com