Test Procedures .......................................................................................................................... 9-10
Part List Notes................................................................................................................................ 11
Main Part List.................................................................................................................................. 12
Figure 4. Main Parts Exploded View .............................................................................................. 13
Electrical Part List..................................................................................................................... 14-17
Voltage Conversion Instructions .................................................................................................. 18
Figure 5. Voltage Conversion Diagram .......................................................................................... 18
Figure 6. Top Cover Connection Diagram...................................................................................... 19
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) 1492 (71). With the unit AC switch first in the ON position, then in the
OFF position, measure from a known earth ground (metal water pipe,
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 HAZ ARD 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 be-
tween the jumpered AC plug and each exposed metallic cabinet part on the
unit. When the exposed metallic part has a return path to the chassis, the
reading should be between 1 and 5.2 Megohms. When there is no return path
to the chassis, the reading must be “infinite”. If it is not within the limits specified,
there is the possibility of a shock hazard, and the unit must be repaired and re checked before it is returned to the customer.
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.
3
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.
CAUTION: THE 802®C SYSTEM CONTROLLER CONTAINS NO USER-SERVICEABLE
PARTS. TO PREVENT WARRANTY INFRACTIONS, REFER SERVICING TO WARRANTY
SERVICE STATIONS OR FACTORY SERVICE.
functions of three equalizers, an automatic switching circuit, and an electronic crossover. The
802C system controller automatically selects the proper crossover function and equalization
curve for a given system application through use of a switching network operating in conjunction with the unit's output jacks. In addition to signal routing based on equalization requirements, the switching network indicates mode of operation on its front panel. The front panel
also includes high-cut and low-cut switches which decrease line output by 4dB at 55Hz and by
10dB at 16kHz. Sharp subsonic and ultrasonic band-limiting filters reduce power waste, stage
noise, high-frequency instability, and interference. The 802C system controller retains the
compact dimensions of its predecessor, the Bose
space of a standard 19" equipment rack with the optional RMK-8 Rack Mount Kit.
In an on-going process of manufacturing updates, as technology permits, Bose Corporation
has begun using SMD (surface mount devices) components on its 802C controller. The new
SMD components are such a space saving feature that this new version permits us to eliminate the "piggy-back" PCB and place all electronics on one single printed circuit board. This
manual will identify the different procedures, PCB layouts, and components where necessary.
There is no difference in the operation or function between the original 802C and the
802C SMD units.
C System Controller is a sophisticated signal processing device which combines the
®
802E active equalizer, and fits into one
6
DISASSEMBLY/ASSEMBLY PROCEDURES
Note: Refer to the Figures (2 and 3) for the
following procedures.
1. Top Cover Removal
1.1 Remove the four screws (two located
at the rear of the unit and one located on
each side of the unit) that secure the top
cover to the chassis.
1.2 Lift the rear of the top cover slightly
and slide it forward until the front of the top
cover is clear of the switches.
2. Top Cover Replacement
2.1 Align the front of the top cover with the
switches and LED's and slide the cover into
place.
2.2 Secure the top cover into place.
3. 302EQ ("piggy-back") PCB Removal
Note: The original 802C has two PCB's.
The following procedure will discuss the
removal of the "piggy-back" PCB.
Note: The "piggy-back" PCB does not
need to be removed when removing the
main PCB.
3.1 Perform procedure 1.
4.2 Perform procedure 2.
5. Main PCB Removal
5.1 Perform procedure 1.
5.2 Remove the 6 knurled nuts securing
the input and output jacks to the chassis.
5.3 Remove the 5 screws that secure the
main PCB to the chassis.
5.4 On the rear of the unit, at the XLR
jacks there is a small hole with a locking
screw inside (see Figure 1). Insert a small
flathead screwdriver into the hole and
rotate the locking screw 1/8 turn counterclockwise to release the locking tab.
5.5 Lift the front of the PCB up slightly.
Gently pull the PCB out while pushing on
the center of the XLR jacks.
6. Main PCB Replacement
6.1 Carefully slide the PCB into the chas-
sis while aligning the XLR jacks into their
housing.
6.2 Lock the XLR jacks into place by
inserting a small screwdriver into the small
hole in the XLR jack and rotate the screw
clockwise 1/8 turn.
3.2 Locate the four plastic stand-offs (three
are located in the corners of the PCB and
one is located between C125 and C225).
3.3 With small needle-nose pliers, squeeze
the retaining tab of each stand-off while
gently lifting up on the PCB to release the
lock. Grasp the PCB at the middle of each
side and lift the PCB off of the connectors.
4. 302EQ ("piggy-back") PCB Replacement
4.1 Replace the "piggy-back" PCB (on the
original 802C controller) by placing the
board over the connectors and pushing the
board down onto the stand-offs.
6.3 Replace the 5 screws that hold the
PCB into place in the chassis.
6.4 Perform procedure 2.
Figure 1. Locking Tab Screw Location
7
Figure 2. Original 802C PCB Exploded View
Figure 3. SMD 802C PCB Exploded View
8
TEST PROCEDURES
1. Mode Indicator Test
1.1 Depending on the output jack configu-
ration (see top cover diagram on page 17),
equalization curves and output vary. You
must test all modes of the 802C to assure
proper operation.
1.2 Perform the test below to verify that the
mode select operation is working properly.
Note: You can insert one or both of the
output jacks into the unit for this test.
LED Indicator Status
Output
Jacks
Inserted
No Jacks
Inserted
Inserted into
802 AMP
Inserted into
302 AMP
Inserted into
802 and 302
AMP
2. 802 Full Range Frequency Response
802
Full
Range
OnOffOff
OnOffOff
OffOnOff
OffOffOn
Passive
2-Way
Bi-
AMP
Note: Set both the Lo and Hi cut switches
IN for the following response table.
Lo and Hi Cut Switch Response Table
FrequencyOutputTolerance
55Hz+9.3dB± 1.8dB
750Hz0dB
(reference)
15kHz+6.9dB± 2.0dB
3. 302 Passive Frequency Response
3.1 Apply a 750Hz, 500mVrms signal to
the input of the 802C.
3.2 Reference a dB meter to the 302 AMP
output jacks.
3.3 Refer to the frequency response table
below and verify the response of the unit.
Passive Frequency Response Table
FrequencyOutputTolerance
30Hz-8.8dB± 2.5dB
55Hz+6.2dB± 1.5dB
150Hz-3.2dB± 1.5dB
250Hz+3.2dB± 1.8dB
750Hz0 dB
(reference)
3kHz0.9dB± 1.5dB
15kHz+15.3dB± 1.8dB
-
-
2.1 Apply a 750Hz, 500mVrms signal to
the input of the 802C.
2.2 Reference a dB meter to the 802 AMP
output jacks.
2.3 Refer to the frequency response table
below and verify the response of the unit.
Full Range Frequence Response Table
FrequencyOutputTolerance
55Hz+14.0dB± 1.5dB
30Hz0dB± 2.5dB
250Hz+2.7dB± 1.2dB
750Hz0dB
(reference)
3kHz+2.3dB± 1.5dB
7.5kHz+12.0dB± 1.5dB
15kHz+16.9dB± 1.8dB
-
4. Bi-Amp Frequency Response
Note: This test is performed with both the
802 AMP and the 302 AMP output jacks
used at the same time.
4.1 Apply a 750Hz, 500mVrms signal to
the input of the 802C.
4.2 Reference a dB meter to the 802 AMP
output jacks (while in the Bi-Amp mode).
4.3 Refer to the frequency response table
below and verify the response of the unit.
802 Bi-Amp Frequency Response Table
FrequencyOutputTolerance
55Hz-20.1dB± 2.5dB
230Hz+2.6dB± 1.8dB
750Hz0 dB
(reference)
15kHz+17.0dB± 1.8dB
-
9
TEST PROCEDURES
4.4 Apply a 100Hz, 500mVrms signal to
the input of the 802C.
4.5 Reference a dB meter to the 302 AMP
output jacks (while in the Bi-Amp mode).
4.6 Refer to the frequency response table
below and verify the response of the unit.
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 PCB 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. RC-4156 is to be used ONLY as a replacement for U5 and U6. This replaces the selected
LS-404 IC previously used in these locations. Due to the higher current needs of the RC-4156,
DAMAGE could occur to the power supply if this IC is used in other locations on the PCB.
Part Number change for U2 and U3 9/18/01 Also U5 and U6 has been replaced by part number
192166 which is an LS404 IC. The RC4156 is nolonger available.
U1, 8, 9 QUAD OP AMP, LS-404 120535/192166 4
U2 VOLT REG, 78L15 121116-1
U3 VOLT REG, 79L15 121117-1
U4QUAD NAND CD-4011121854
U5, 6 QUAD OP AMP, RC4156 192166 4
U7, 10QUAD AW. SW. CD4066119837
DescriptionPart
Number
Note
17
VOLTAGE CONVERSION INSTRUCTIONS
Voltage Conversions are to be performed on Military units. However it is possible to convert
a 110 Volt unit (by replacing the transformer) and a 220 Volt European unit.
1. 220 Volt to 110 Volt Conversion
Note: Conversions must be performed
with the line cord disconnected from any
power source. Refer to Figure 3 below for
the following procedures. The jumpers
listed in parentheses refer to the SMD
units.
1.1 Perform disassembly procedure 3,
PCB removal.
1.2 Locate jumper LK-31, (LK-35) in front
of the power transformer (near the line
cord), and remove it.
1.3 Add jumpers LK-32 (LK-42) and LK-33
(LK-43).
For European 220 Volt units.
1.4 Remove the 220 Volt line cord and
replace it with a 110 Volt line cord. Make
certain the line cord is properly installed in
the strain relief.
2. 110 Volt to 220 Volt Conversion
2.1 Perform disassembly procedure 3,
PCB removal.
2.2 Remove the two jumpers LK-32 (LK-
42) and LK-33 (LK-43).
For units with a 110 Volt transformer.
2.2 Remove the 110 Volt transformer and
C1 capacitor, and install 220 Volt components (see the part list).
2.3 Add jumper LK-31 (LK-35). Line cord
replacement is optional.