Bose 402, 802-II Service Manual
Contents
Safety Information.............................................................................................................................2
Electrostatic Discharge Sensitive (ESDS) Device Handling..........................................................3
Theory of Operation ...................................................................................................................... 5-8
Figure 1. Block Diagram....................................................................................................................8
Disassembly/Assembly Procedures .......................................................................................... 9-11
Test Setup Procedure .....................................................................................................................12
®
Test Procedures ................................................................................................................ 13-15
402
®
802
Test Procedures ................................................................................................................ 16-18
Part List Notes .................................................................................................................................19
Figure 2. 402, 802 II Original Version Exploded View .....................................................................20
Figure 3. 402, 802 II Current Version Exploded View ......................................................................20
Main Part List............................................................................................................................. 21-22
402 Electrical Part List .............................................................................................................. 23-28
802 II Electrical Part List .......................................................................................................... 29-35
402 II Electrical Part List .......................................................................................................... 36-42
802 III Electrical Part List......................................................................................................... 43-48
402 and 802 II Electrical Part List ............................................................................................ 49-50
Packaging Part List .........................................................................................................................51
Figure 4. Packaging Exploded View................................................................................................51
Frequency Response Curves................................................................................................... 52-64
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.
1
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. Refer to Paragraph 84 of UL 1270. 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.
2
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.
3
SPECIFICATIONS
Dimensions: 1.63" H x 19.0" W x 10" D (4.14 x 48.3 x 25.4 cm)
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 XLR
Output Connections: Balanced high frequency and low frequency XLR
Input Impedance: Balanced input, -10 dB level: 14 k W
Balanced input, +4 dB level: 6 k W
Unbalanced input (+ input used), -10 dB level: 12 k W
Unbalanced input (+ input used), +4 dB level: 4 k W
Output Impedance: 100 W nominal
Input Level: -10 dB or +4 dB, selectable
Output Level: 8.0 Vrms max. @ 1 kHz into 10 k W load
Low Frequency (LF)
Output Mode: Sum or normal
LF Output Level: -18 dB to +3 dB, variable
Crossover Frequency: 140 Hz (Bi-amp mode), Roll-off slope: -18 dB/oct.
Total harmonic distortion:
802: Midrange distortion of HF output:
402: Midrange distortion of HF output: < 0.2% at 1.4 V, 850 Hz
402, 802: Low frequency distortion of LF output: < 0.1 % at 160 mV, 80 Hz
Output Noise: Bi-amp mode, HF outputs: < 90µV
Bi-amp mode, LF outputs: < 40µV
Passive mode: < 90µV
< 0.2 % at 5.8 V, 700 Hz
Offset: All channels: < 15 mV
Power Requirements: 120 VAC, 50/60 Hz, 12 Watts (US/Can.)
230 VAC, 50/60 Hz, 12 Watts (Eur.)
100 VAC, 50/60 Hz, 12 Watts (Japan)
240 VAC, 50/60 Hz, 12 Watts (Aus./UK)
4
THEORY OF OPERATION
This discussion is an electrical overview of the 402® and 802® controllers. Equalization curves
are referenced and are located in the back of this manual. Additionally, the block diagram and
schematic diagrams 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, R10/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 -10 dB sources and a low gain setting for +4 dB 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. See
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 equal-
izer 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 con-
trollers. Currently, position 3 (NC) is not used.
5
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: At the controller outputs, only the positive (+) output pin is driven. The negative (-)
output pin is connected to signal ground through a series impedance identical to the positive (+)
pin. When used to drive a balanced input, the controller output provides equal common-mode
source impedances (100 W). This guarantees that any common-mode noise is induced equally
into the positive (+) and negative (-) legs of a differential input in order to take full advantage of
common-mode noise rejection.
7. Power Supply
The controllers use only a nominal amount of power. Therefore, full wave bridge rectifier Z1 and
regulators U13 and U14 are all that are needed to develop the quiet, stable +/- 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
controller's ground terminal, and the generator hot lead to the negative (-) input terminal.
Leave the positive (+) terminal unconnected.
If you need to connect the controller outputs to a single-ended (not differential) instrument,
connect the controller's output ground to the instrument ground, and the controller's positive (+)
output terminal to the instrument hot pin. Leave the negative (-) output pin unconnected.
Since the controllers are two channel devices, 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 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.
6
THEORY OF OPERATION
With a nominal AC power input voltage (100, 115, or 230, depending on the country), the AC
voltages at the transformer secondary should be:
between P3-1 and P3-3: 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 W
between P3-1 and P3-3: 6.9 W
For the 115 VAC version:
between P2-1 and P2-2: 45.4 W
between P3-1 and P3-3: 6.3 W
For the 230/240 VAC version:
between P2-1 and P2-2: 195 W
between P3-1 and P3-3: 7.1 W
Other DC voltages 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
7
THEORY OF OPERATION
Figure 1. Block Diagram
8
DISASSEMBLY/ASSEMBLY PROCEDURES
402® and 802® II First Variation (Removable Front Panel)
Note: Refer to Figure 2 for the following
procedures.
1. Top cover Removal
1.1 Remove the two screws (7) that secure
the top cover (2) to the front panel (9).
1.2 Remove the two screws (1) that secure
the top cover to the rear of the chassis.
1.3 Lift up the rear of the top cover and
slide it out from under the front panel.
2. Top cover Replacement
2.1 Place the top cover (2) onto the unit and
slide it under the front panel (9).
2.2 Secure the rear of the top cover using
the screws (1) removed in procedure 1.2.
2.3 Secure the front of the top cover using
the two screws (7) removed in procedure
1.1.
3. Front Panel Removal
3.1 Perform procedure 1.
3.2 Remove the two wires (14) that connect
to the power switch (10).
NOTE: On some earlier versions there was
hot melt applied to the wires.
3.3 Remove the two screws (7) that secure
the front cover to the bottom of the chassis.
3.4 Pull the front panel away from the
chassis.
4. Front Panel Replacement
4.1 Slide the front panel (9) onto the chas-
sis.
4.2 Replace the two screws (7) that secure
the front panel (9) to the bottom of the
chassis.
4.3 Connect the two wires (14) to the
power switch (10).
4.4 Perform procedure 2.
5. PCB Removal
5.1 Perform procedure 3.
5.2 Remove the 6 screws (5) that secure
the connectors (4) to the rear panel.
5.3 Disconnect the one line cord connector
(P1) and the two power transformer connectors P2) and (P3).
NOTE: If the Opti-Voice
on the PCB assembly remove the connector from the Opti-Voice PCB.
5.4 Remove the 5 screws (3) that secure
the PCB assembly (15) to the chassis.
5.5 Squeeze the two metal posts (not
shown) located at the two front corners of
the PCB and lift up the PCB. Slide the PCB
assembly towards the front of the chassis
and lift it out.
6. PCB Replacement
6.1 Slide the PCB assembly (15) into the
front of the unit aligning the connectors (4)
to the rear panel. Push the two front
corners of the PCB on to the two metal
posts.
6.2 Secure the PCB assembly to the chassis using the 5 screws (3) that were removed in procedure 5.4.
6.3 Secure the PCB to the rear panel using
the 6 screws (5) that were removed in
procedure 5.2.
6.4 Reconnect all connectors removed in
procedure 5.3.
6.5 Perform procedure 4.
®
PCB is installed
9
DISASSEMBLY/ASSEMBLY PROCEDURES
®
402
and 802® II First Variation (Removable Front Panel)
Note: Refer to Figure 2 for the following
procedures.
7. Transformer Removal
7.1 Perform procedure 1.
7.2 Disconnect the two wire harnesses (P2)
and (P3) from the transformer to the PCB.
7.3 Remove the two 11/32” hex nuts (12)
that secure the transformer (13) to the
chassis.
7.4 Lift the transformer up and away from
the chassis.
8. Transformer Replacement
8.1 Place the transformer (13) into the
chassis aligning it to the studs.
Note: Proper orientation is required for the
transformer wire harnesses.
8.2 Secure the transformer to the chassis
using the two 11/32” hex nuts (12) that was
removed in procedure 7.3.
8.3 Connect the two wire harnesses from
the transformer to the PCB.
8.4 Perform procedure 2.
10
DISASSEMBLY/ASSEMBLY PROCEDURES
402® and 802® II Second Variation
Note: Refer to Figure 3 for the following
procedures.
1. Top Cover Removal
1.1 Remove the 5 screws (1) that secure
the top cover (2) to the chassis.
1.2 Lift off the top cover .
2. Top Cover Replacement
2.1 Place the top cover (2) onto the chassis.
2.2 Secure the top cover to the chassis
using the 5 screws (1) that were remove in
procedure 1.1.
NOTE: The front panel is not removable.
3. PCB Removal
3.1 Perform procedure 1.
4.2 Secure the PCB assembly (5) to the
chassis using the 7 screws (3) removed in
procedure 3.4.
4.3 Secure the connectors (4) to the rear
panel using the 6 screws (6) removed in
procedure 3.3.
4.4 Connect the connectors for the line
cord and power transformer. If the
opti-Voice PCB was used, connect the
harness to the PCB.
4.5 Perform procedure 2.
5. Transformer Removal
5.1 Perform procedure 1.
5.2 Disconnect the two wire harnesses
from the transformer (11) to the PCB
assembly (5).
3.2 Disconnect the two power transformer
connectors and the two wires (12) going to
the power switch (9).
NOTE: If the opti-Voice
disconnect the harness at the opti-Voice
PCB.
3.3 Remove the 6 screws (6) that secure
the connectors (4) to the rear panel.
3.4 Remove the 7 screws (3) that secure
the PCB assembly (5) to the chassis.
3.5 Slide the PCB assembly towards the
front of the unit and lift up the rear of the
PCB to remove it from the chassis.
4. PCB Replacement
4.1 Place the PCB assembly into the
chassis aligning the connectors (4) with the
rear panel.
®
PCB is used,
5.3 Remove the two 11/32” hex nuts (10)
that secure the transformer to the chassis.
5.4 Lift the transformer up and away from
the chassis.
6. Transformer Replacement
6.1 Place the transformer (11) into the
chassis aligning it to the studs.
Note: Proper orientation is required for the
transformer wire harnesses.
6.2 Secure the transformer to the chassis
using the two 11/32” hex nuts (10) that
were removed in procedure 7.3.
6.3 Connect the two wire harnesses from
the transformer to the PCB.
6.4 Perform procedure 2.
11
TEST SETUP PROCEDURE
The controls on the back panel should be set as follows (unless otherwise specified):
1. Set the input switches to the -10 dB position.
2. Set the Mode switch to the number 2 (BA) position.
3. Set the Low Frequency Level control to the +3 dB position.
4. Set the Output Mode switch to the NORM position
input
switch
Input connections: connect pin 1 (-) and pin 3 (shield) together at the signal generator and
audio analyzer (oscilloscope and dB meter).
input
switch
Input and Output connection Diagram
mode
switch
Back Panel View
low freq.
switch
output
mode
switch
The following test procedures refer to the 402
and the 802 series III. These references are to the PCB assembly changes that were made
recently to accommodate the new series of 402 and 802 speakers.
The new PCB assembly can be identified by the label on the top side of the PCB near the
BOSE® logo. The following are the new PCB assembly part numbers:
259148 for the 402
259145 for the 802
®
, 402 series II, 802® series II
12
402® TEST PROCEDURES
Note: Perform the following tests on both
channels.
1. High Frequency Gain Test
1.1 Apply a 100 mVrms, 850 Hz signal to
the controller’s input terminals.
1.2 Reference a dB meter to the input of the
controller.
1.3 Measure the gain at the high frequency
output terminals. The gain should be +9.8
+ 1.0 dB.
1.4 Change the input switches to +4 dB.
1.5 The gain should be -3.4 + 1.0 dB.
2. Low Frequency Gain Test
Note: Set the input switches to the -10 dB
position.
2.1 Apply a 100 mVrms, 80 Hz signal to the
controller’s input terminals.
2.2 Reference a dB meter to the input.
2.3 Measure the gain at the low frequency
outputs. The gain should be +22.5 dB + 2.0
dB.
3.2 Reference a dB meter to the input
signal.
3.3 Measure the response at the high
frequency output terminals. Refer to the
frequency response table for the series of
402 you are testing.
402 Frequency Response Table
Full Range Mode
Frequency Output Tolerance
60 Hz -3.7 dB
105 Hz +8.5 dB
220 Hz +3.5 dB
850 Hz 0.0 dB reference
4 kHz +5.8 dB
14.5 kHz +13.3 dB
402 Series II Frequency Response Table
Full Range Mode
Frequency Output Tolerance
60 Hz +3.2 dB
90 Hz +10.0 dB
220 Hz +7.3 dB
600 Hz -2.4 dB
850 Hz 0.0 dB reference
4 kHz +5.6 dB
13.5 kHz +15.5 dB
±1.5 dB
±1.5 dB
±1.5 dB
±1.5 dB
±1.5 dB
±1.5 dB
±1.5 dB
±1.5 dB
±1.5 dB
±1.5 dB
±1.5 dB
2.4 Change the Output Mode switch to the
SUM position and measure the output at
channel 1. The gain should be +28.1 dB
+ 1.5 dB.
3. Frequency Response Test Full Range
Mode
Note: Set the Mode switch to the number 1
position (FR), the input switch to the -10 dB
position and the Output Mode switch to the
NORM position.
3.1 Apply a 100 mVrms, 850 Hz signal to
the controller’s input terminals.
4. Frequency Response Test Bi-Amp Mode
Note: Set the Mode switch to the number 2
position (BA).
4.1 Apply a 100mVrms, 850 Hz signal to
the controller’s input terminals.
4.2 Reference a dB meter to the input
signal.
4.3 Measure the output at the high frequency output terminals. Refer to the
frequency response table for the series of
402 you are testing.
13
402® TEST PROCEDURES
402 Frequency Response Table Bi-Amp Mode
Full Range Output
Frequency Output Tolerance
60 Hz -16.4 dB
105 Hz -4.8 dB
220 Hz +2.8 dB
850 Hz 0.0 dB reference
4 kHz +5.8 dB
14.5 kHz +13.3 dB
402 Series II Frequency Response Table
Bi-Amp Mode Full Range Output
Frequency Output Tolerance
60 Hz -13.0 dB
90 Hz -5.6 dB
220 Hz +6.8 dB
600 Hz -2.4 dB
850 Hz 0.0 dB reference
4 kHz +5.8 dB
13.5 kHz +15.5 dB
5. Low Frequency Response Bi-Amp Mode
5.1 Apply a 100mVrms, 80 Hz signal to the
controller’s input terminals.
5.2 Reference a dB meter to the input.
5.3 Measure the output at the low fre-
quency output terminals. Refer to the
frequency response table for the series
of 402 you are testing.
±1.5 dB
±1.5 dB
±1.5 dB
±1.5 dB
±1.5 dB
±1.5 dB
±1.5 dB
±1.5 dB
±1.5 dB
±1.5 dB
±1.5 dB
402 Series II Low Frequency Response Table
Bi-Amp Mode Low Frequency Output
Frequency Output Tolerance
40 Hz -6.2 dB
80 Hz 0.0 dB reference
100 Hz +1.3 dB
300 Hz -17.5 dB
6. Midrange Distortion Test
Note: Set the Input Mode switch to the +4
dB position for the following test procedures.
6.1 Set the mode switch to the number 1
(FR) position.
6.2 Apply a 7.5 Vrms, 850 Hz signal to the
controller’s input.
6.3 Measure the distortion at the high
frequency output terminals. The measurement should be < .1%.
7. High Frequency Distortion Test
7.1 Apply a 2.25 Vrms, 6 kHz signal to the
controller’s input terminals.
7.2 Measure the distortion at the high
frequency output terminals. The measurement should be < .2%.
8. Low Frequency Distortion Test Bi-Amp
Mode
±2 dB
±1 dB
±2 dB
402 Low Frequency Response Table Bi-Amp
Mode Low Frequency output
Frequency Output Tolerance
40 Hz -6.2 dB
80 Hz 0.0 dB reference
100 Hz +1.3 dB
300 Hz -17.5 dB
±2 dB
±1 dB
±2 dB
8.1 Set the mode switch to the 2 (BA)
position.
8.2 Apply a 1.6 Vrms, 80 Hz signal to the
controller’s input terminals.
8.3 Measure the distortion at the low frequency output terminals. The measurement
should be < .1%.
14
402® TEST PROCEDURES
9. Midrange Frequency Distortion Test
Bi-Amp Mode
9.1 Apply a 7.5 Vrms, 850 Hz signal to the
controller’s input terminals.
9.2 Measure the distortion at the high
frequency output terminals. The measurement should be < .1%.
10. High Frequency Distortion Test Bi-Amp
Mode
10.1 Apply a 2.25 Vrms, 6 kHz signal to the
controller’s input terminals.
10.2 Measure the distortion at the high
frequency output terminals. The measurement should be < .2%.
11. Clipping Headroom Test
11.1 Apply a 6.9 Vrms, 850 Hz signal to the
controller’s input terminals.
11.2 Measure the distortion (at an output
of 4.6
+ .5 Vrms) at the high frequency
output terminals. The measurement should
be < 1%.
12. Channel Separation Test Bi-Amp Mode
12.1 Apply a 7.5 Vrms, 850 Hz signal to the
controller’s input terminals.
12.2 Reference a dB meter to the left
channel output.
12.3 Measure the right channel output. It
should be > 40 dB.
13. Hum
13.1 Measure the hum and noise at the low
frequency outputs with no input signal
applied. The reading should be < 40 uV.
15
802® TEST PROCEDURES
Note: Perform the following tests on both
channels.
1. High Frequency Gain Test
1.1 Apply a 100 mVrms, 700 Hz signal to
the controller’s input terminals.
1.2 Reference a dB meter to the input of the
controller.
1.3 Measure the gain at the high frequency
output terminals. The gain should be +15.1
+ 1.0 dB.
1.4 Change the input switches to +4 dB.
1.5 The gain should be 2.0 + 1.0 dB.
2. Low Frequency Gain Test
Note: Set the input switches to the -10 dB
position.
2.1 Apply a 100 mVrms, 80 Hz signal to the
controller’s input terminals.
2.2 Reference a dB meter to the input.
2.3 Measure the output at the low fre-
quency outputs. The gain should be +23.5
dB + 2.0 dB.
2.4 Change the Output Mode switch to the
SUM position and measure the output at
channel 1. The gain should be +28.1 dB
+ 1.5 dB.
3. Frequency Response Test Full Range
Mode
Note: Set the Mode switch to the number 1
position (FR), the input switch to the -10 dB
position and the Output Mode switch to the
NORM position.
3.1 Apply a 100 mVrms, 700 Hz signal to
the controller’s input terminals.
3.2 Reference a dB meter to the input
signal.
3.3 Measure the response at the high
frequency output terminals. Refer to the
frequency response table for the series of
802 you are testing.
802 Series II Frequency Response Table
Full Range Mode
Frequency Output Tolerance
40 Hz +8.0 dB
55 Hz +13.5 dB
140 Hz +6.6 dB
700 Hz 0.0 dB reference
2.5 kHz +2.1 dB
6 kHz +9.6 dB
15 kHz +16.7 dB
802 Series III Frequency Response Table
Full Range Mode
Frequency Output Tolerance
40 Hz +1.9 dB
70 Hz +13.5 dB
140 Hz +7.5 dB
700 Hz 0.0 dB reference
2.5 kHz +1.8 dB
6 kHz +6.9 dB
15 kHz +13.8 dB
4. Frequency Response Test Bi-Amp Mode
Note: Set the Mode switch to the number 2
position (BA).
4.1 Apply a 100mVrms, 700 Hz signal to
the controller’s input terminals.
4.2 Reference a dB meter to the input
signal.
±1.5 dB
±1.5 dB
±1.5 dB
±1.5 dB
±1.5 dB
±1.5 dB
±1.5 dB
±1.5 dB
±1.5 dB
±1.5 dB
±1.5 dB
±1.5 dB
16
4.3 Measure the output at the high fre-
quency output terminals. Refer to the
frequency response table for the series of
802 you are testing.
802® TEST PROCEDURES
802 Series II Frequency Response Table
Bi-Amp Mode Full Range Output
Frequency Output Tolerance
40 Hz -21.0 dB
60 Hz -11.5 dB
700 Hz 0.0 dB reference
2.5 kHz +2.1 dB
6 kHz +9.6 dB
15 kHz +16.7 dB
802 Series III Frequency Response Table
Bi-Amp Mode Full Range Output
Frequency Output Tolerance
40 Hz -24.9 dB
70 Hz -10.6 dB
140 Hz +5.2 dB
700 Hz 0.0 dB reference
2.5 kHz +1.9 dB
6 kHz +7.0 dB
13 kHz +13.9 dB
±1.5 dB
±1.5 dB
±1.5 dB
±1.5 dB
±1.5 dB
±1.5 dB
±1.5 dB
±1.5 dB
±1.5 dB
±1.5 dB
±1.5 dB
802 Series III Low Frequency Response Table
Bi-Amp Mode Low Frequency output
Frequency Output Tolerance
40 Hz -6.2 dB
2 dB
±
80 Hz 0.0 dB reference
100 Hz +1.3 dB
300 Hz -17.5 dB
Note: Set the Input Mode switch to the +4
dB position for the following test procedures.
6. Midrange Distortion Test
6.1 Set the mode switch to the number 1
(FR) position.
6.2 Apply a 5.8 Vrms, 700 Hz signal to the
controller’s input.
6.3 Measure the distortion at the high
frequency output terminals. The measurement should be
< .2%.
1.5 dB
±
2 dB
±
5. Low Frequency Response Bi-Amp Mode
5.1 Apply a 100mVrms, 80 Hz signal to the
controller’s input terminals.
5.2 Reference a dB meter to the input.
5.3 Measure the output at the low fre-
quency output terminals. Refer to the
frequency response table for the series
802 you are testing.
802 Series II Low Frequency Response Table
Bi-Amp Mode Low Frequency output
Frequency Output Tolerance
40 Hz -6.2 dB
80 Hz 0.0 dB reference
100 Hz +1.3 dB
300 Hz -17.5 dB
±2 dB
±1.5 dB
±2 dB
7. High Frequency Distortion Test
7.1 Apply a 1.30 Vrms, 6 kHz signal to the
controller’s input terminals.
7.2 Measure the distortion at the high
frequency output terminals. The measurement should be < .2%.
8. Low Frequency Distortion Test Bi-Amp
Mode
8.1 Set the mode switch to the number 2
(BA) position.
8.2 Apply a 1.6 Vrms, 80 Hz signal to the
controller’s input terminals.
8.3 Measure the distortion at the low frequency output terminals. The measurement
should be < .1%.
17
802® TEST PROCEDURES
9. Midrange Frequency Distortion Test
Bi-Amp Mode
9.1 Apply a 5.8 Vrms, 700 Hz signal to the
controller’s input terminals.
9.2 Measure the distortion at the high
frequency output terminals. The measurement should be
10. High Frequency Distortion Test Bi-Amp
Mode
10.1 Apply a 1.30Vrms, 6 kHz signal to the
controller’s input terminals.
10.2 Measure the distortion at the high
frequency output terminals. The measurement should be < .2%.
< .1%.
11. Clipping Headroom Test
11.1 Apply a 5.8 Vrms, 700 Hz signal to the
controller’s input terminals.
11.2 Measure the distortion (at an output of
7.35 + .5 Vrms) at the high frequency
output terminals. The measurement should
be < .1%.
12. Channel Separation Test Bi-Amp Mode
12.1 Apply a 4.0 Vrms, 700 Hz signal to the
controller’s input terminals.
12.2 Measure the channel separation
across the high frequency output terminals.
It should be > 40 dB.
13. Hum
13.1 Measure the hum and noise at the low
frequency outputs with no input signal
applied. The reading should be < 40 uV.
18
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 not shown.
19
16
14
15
1
(2x)
3
2
3
(6x)
11
12
13
(2x)
4
5
(6x)
10
1
(5x)
9
8
(2x)
7
(2x)
6
Figure 2. 402®, 802® II Original
Version Exploded View
3
10
12
2x
11
2
2x
3
7x
4
Figure 3. 402, 802 II Current Version
5
6
6X
9
8
7
Exploded View
20
MAIN PART LIST
See Figure 2
Item
Number
1 SCREW, TAPP, #4-40 x .375, PAN, XREC 170284-06 2
2 COVER, CHASSIS, EQ, CNTLR 172180 1
3 SCREW, TAPP, #4-40 x .25, PAN, TORX 171796-04 5
4 CONNECTOR, XLR, MALE
CONNECTOR, XLR, FEMALE
5 SCREW, TAPP, #4-40 x .375, PAN, XREC 170284-06 6
6 CHASSIS, EQ, CONTROLLER 173002-03 1
7 SCREW, TAPP, #4-40 x .312, BTN, XREC 170285-05 2
8 SCREW, TAPP, #4-40 x .312, BTN, XREC 170285-05 2
9 FRONT PANEL, ASSEMBLY 172181 1
10 SWITCH, ROCKER, SPST, POWER 143960 1 3
11 LENS, LED, CHASSIS, CLEAR 144023 1
12 STND. HEX NUT, WASHER, KEPS 118260-08 3
13 TRANSFORMER, 100/120V
TRANSFORMER, 220/230V
Description Part Number Qty. Note
144004
189222-001
180128-1
180128-2
4
2
13
15
16 LINE CORD, 3 WIRE, USA/CAN
PCB ASSY, CONTROLLER. 402C
PCB ASSY, CONTROLLER, 802C
LINE CORD, 2 WIRE, 220V, EURO
LINE CORD, 2 WIRE, 100V, JAPAN
LINE CORD, 3 WIRE, 230V, UK
LINE CORD, 2 WIRE, 240V, AUST.
II
III
259145
259148
173242
173243
173244
173245
173246
1 1, 4
13
21
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