elem Energy 2 Service Manual

1 1
1 1
1
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Index
Soldering point.
Male connector.
M/F faston connector.
Test point.
Supply voltage.
Logic supply ground.
Analog supply ground.
Chassis ground.
Earth ground.
Flag joined with one or more flags
GENERALMUSIC S.p.A. Sales Division: 47842 S.Giovanni in Marignano (RN) ITALY - Via delle Rose, 12 - tel. 0541/959511 - fax 0541/957404 GENERALMUSIC on the NET: http://www.generalmusic.com
Technical Specifications, Introduction, Test Procedures & Adjustments
2
Top & Bottom Assembly Views
5
Response Curves
7 8
Wiring Connections Diagram
9
Block Diagram
10
Inputs, Drivers & SOA Processor Board
11
Spare Part List
12
Protections Board, Controls & Display Board
Power Supply Board and Amplifier Board
6
SERVICE MANUAL
CODE: 277287
Warnings
with the same signal name inscribed.
Address
ATTENTION
Observe precautions when handling electrostatic sensitive devices.
Notice
Service must be carried out by qualified personnel only.Any tampering carried out by unqualified personnel during the guarantee period will forfeit the right to guarantee. For a correct operation of the instrument, after having switched off, be careful to wait at least 3 seconds before switching on again. To improve the device's specifications, the schematic diagrams may be subject to change without prior notice. All components marked by this symbol have special safety characteristics, when replacing any of these components use only manufacturer's specified parts. The (µ) micro symbol of capacitance value is substituted by U. The (
) omega symbol of resistance value is substituted by E. The electrolytic capacitors are 25Vdc rated voltage unless otherwise specified. All resistors are 1/8
unless otherwise specified.
All switches shown in the "OFF" position. All DC voltages measured to ground with a voltmeter 20KOhm/V.
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✔ ✔ ✔ ✔ ✔
HIGH PERFORMANCE POWER AMPLIFIER
ENERGY 2
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22
22
2
TECHNICAL SPECIFICATIONS
Dimensions: (WxHxD) 483x88x507mm (2U)
Weight: 23 Kg - 50.6 lbs
Power Requirements: 230Vac±10% 50/60Hz 2000VA
or 115Vac±10% 50/60Hz 2000VA Load selector: * 2** 4 Output Power: (2 stereo/parallel)* 900Watts
(4 stereo/parallel)** 1000Watts (8 stereo/parallel)** 500Watts (4 bridge)* 1800Watts (8 bridge)** 2000Watts (16 bridge)** 1000Watts
Max. Undistorted Out: (2 stereo/parallel)* 120±2Vpp
(4 stereo/parallel)** 180±5Vpp
Input Sensitivity: (constant sensitivity) 0.775Vrms (0dB)
(constant gain) 1.65Vrms (+6.5dB)
Input Impedance: (balanced) 30K
(unbalanced) 15K
Voltage Gain: (constant sensitivity) 38±0.5dB
(constant gain) 32±0.5dB
Slew Rate: 23V/µS Damping Factor: (8 stereo/parallel) >400
Frequency Response (-0.2dB) 20Hz÷20KHz
at Full Power: (-3dB) 10Hz÷80KHz
IMD: (SMPTE 60Hz/7KHz 4:1) <0.02%
THD: (THD+N) <0.02%
S/N Ratio: (unweighted) >100dB
Crosstalk: (1KHz) >90dB
INTRODUCTION
Power Performances
The amplifier Energy 2 operates in AB class using the last BJT generation in plastic package, it has been designed using a Floating Bridge Configuration: this configuration, making the most from the double stage power supply, enables to obtain very consistent power with very high dynamics and low distortion even at low impedances.
Double Stage Power Supply
For each amplifier section in the Mains Transformer there are two secondary windings which are connected in parallel or in series according to the effective power requirements. In this manner the amplifier only receives the necessary voltage when there is an effective demand of power with a considerable reduction of dissipated heat.
Protections
Loudspeaker protection: in case of the breakdown of the output BJTs or other
fault condition, a DC Sensor on power output circuit is able to interrupt the amplifier circuit avoiding that current peaks reach the load. Moreover a Soft Start circuit delays the connection of the speakers by the Output Relay every time the amplifier is turned on, when it is turned off the relay disconnect the load immediately.
Thermal protection and cooling system: Inside the amplifier there is an highly sophisticated cooling system able to protect it from overheat and to ensure the upmost efficiency and reliability. The cooling system has two separate heat sink structures (for positive and negative rails) for each channel constructed with tinplated copper, instead of alluminium, for more efficiency. Air flow thru the unit is ensured by two variable speed fans controlled by the SOA circuit, if the temperature rise again the control circuit gradually reduces the power supply to the final stage and at the same time enables the input limiter. As soon as the temperature reaches the normal level , the amplifier gradually returns to normal operation. The amplifier protect itself, by entering in a complete muting status, only in extremely abnormal operating condition (e.g.obstruction of the air vents) and in case of temperature rising further.
SOA processors: In conjunction with the thermal protection the SOA processors constantly detect the power dissipation of the output BJT ensuring that they always remain in their Safe Operating Area. In this particular amplifier the SOA processors are three per channel, the first and most important checks the signal output stage, the second SOA circuit checks the ground output stage and the third circuit checks the voltage translator stage, all three circuits operate accordly.
Current Limiters: These circuits detect the current on final and translator stages, accordly with SOA processors limiting the excessive current on the load, and finally enable the Input Limiter.
Transformer Thermal Protection: This protection disconnects the load (muting the amplifier) until the cooling restores the normal temperature.
Anti-Clipping Limiter: The input signal is constantly checked to instantly recognize a possible amplifier clip, this circuit is an efficient limiter that operate without an excessive dynamic compression to obtain the better listening, it operates accordly the protection circuit.
TEST PROCEDURES & ADJUSTMENTS
Precaution
To prevent short circuit during any test, the oscilloscope must be
EARTH insulated, this occurs because some test require to connect its
probe to the amplifier output, non-compliance may cause damages to oscilloscope inputs circuitry.
Before removing or installing any modules and connectors, disconnect
the amplifier from AC MAINS and measure the DC supply voltages
across each of the power suppliy capacitors. If your measurement on any of the caps is greater than 10Vdc, connect a 100 50W resistor across the applicable caps to discharge them for your safety. Remember to remove the discharge resistor immediately after discharging caps. Do not power up the amplifier with the discharge resistor connected.
Read these notes entirely before proceeding to any operation. These
notes are not comprehensive of all damages that possibly occur, but includes some specifically advices, checks and adjustments relative to this amplifier.
Visual Check
Remove top and bottom covers from the amplifier chassis.
Use compressed air to clear dust in the amplifier chassis.
Before proceed to supply the amplifier check visually the internal assem-
bly, if appears an evident damage find the most possible reasons that cause it.
Check the wiring cables for possible interruptions or shorts.
If the damage has burnt a printed circuit board don’t try to repair it,
replace with a new one.
Test Instruments
Audio Generator
Dual Trace Oscilloscope
Digital Multimeter2 1000W, 4 2000W, 100 50W resistors
1 Mains cord terminated with insulated Faston
Variac (0÷250Vac)
Temperature Meter
Initial Setup
Turn the amplifier on bottom side.
Disconnect the Power Switch from the amplifier internal mains line and
reconnect it directly to the Mains Line with the other cord. Set the Variac at zero voltage and connect it between the amplifier mains socket and the Mains Line.
Set the amplifier controls as follows:
MODE on parallel (PAR), MINIMUM LOAD on 4Ω, EARTH selector on grounds attached, SENSITIVITY on 0.775V and turn full clockwise the level potentiometers.
Short R63 and R175 on the Inputs, Drivers & SOA Processor Board to
de-activate the limiters on each channel.
The procedures that follow must be executed subsequently in the order
specified.
The procedures are divided in two phases: the first initial test is intended
to locate the most probably faults, the second final test is intended to verify and to adjust the amplifier with load connected.
Protections & Ac Supply Check
Turn the amplifier on top side.
Remove the Main Transformer secondary fuses (4 x16A) and then check
them with the Multimeter.
Turn on the amplifier, the relais on the Main Transformer primary winding
must be turn on one a time, the fans go immediately to the max. speed and after some seconds return to the slow speed, and also the output relay must turn on. During this time the protect red led lights.
If somethings goes different, the amplifier has probably some problem on
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3 3
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the Protections Board, first of all check its supplies: CN4 pin 6 = +24Vdc CN4 pin 9 = -24Vdc CN6 pin 8 = +15Vdc CN6 pin 11 = -15Vdc
If the fans don't start or go only to the max. speed, you must check the
Fan Driver circuit (TR1,2,4,6). If all the circuit is good, you must check on the Inputs, Drivers & SOA Processor Board the TR16,17,18,19,22 and the SOA Processor circuits preceding the transistors; to check them quickly disconnect CN3 and CN6 the fan must go only at slower speed.
If the Primary Tranformer Relais don't start (also selecting 2Ω or 4
minimum load switch) check their driver circuits, the fault must be prob­ably in the Transformer Relais Driver circuit on the Protections Board , refer to schematics.
If the Outputs Relay doesn't start the fault must probably located in the
relay driver or in Soft Start circuit on the Protections Board , refer to schematics.
Turn off the amplifier and check with the multimeter if the SCR on Con-
trolled Bridge Boards are shorted. If one or more are shorted, replace it
with a new one, check also the bridges.
Set the oscilloscope CH1 to 10V/div. 5mS and connect its probe to R48
side TR19(c) on Protections Board, turn on the amplifier: a series of pulses appear on the screen that will became stable about +15Vdc, these pulses activate the SCR on the Controlled Bridge Boards to slowly charge the capacitors. If the pulses aren't displayed your amplifier has probably some fault on Soft Start circuit, refer to schematics.
Set the Variac at the nominal mains voltage, measure with the Multimeter
the AC supply voltages between the secondaries: 43±3Vac
Switch to 2 minimum load and measure again the voltages: 33±3Vac.
Re-set the minimum load at 4 and the Variac at zero voltage, turn off
the amplifier and put the fuses back on its holders.
Dc Supply Initial Check
SETUP:
Connect the audio generator to a channel input and set it to 1KHz 775mV
RMS
(0dB) sinusoidal signal. Connect the CH1 scope GND clip to the output GND and connect the oscilloscope probe tips CH1/2 to the channel outputs before the relay, set both to DC 20V/div. 200µS/div.
Turn on the amplifier and afterwards increase the Variac slowly monitor-
ing the Outputs with the oscilloscope CH1/2 connected, it should display the sinusoidal input signal amplified with no distortions, if a distortion or a protection trip occur, turn off the amplifier, wait some minutes and discon­nect the supplies from the Power Amplifier Board that doesn't work properly, to do this you must disconnect the red and the blue wires from capacitors, continue to check the supplies.
CAUTION: Before re-connecting the Power Amplifier Boards to the
supplies, you must have the capacitors discharged for your safety: connect a 100
ΩΩ
ΩΩ
50W resistor across the caps and remove the resis-
tor just after they are discharged.
Finally verify the DC supplies at the capacitor terminals: 58±2Vdc
If one or more voltages don’t correspond:
Check the SCR located on Controlled Bridge Board and its driver transis-
tor (TR9,10,13,14) located on Power Supply Board, particularly check the insulation from the heating and the driver transistors and the diodes D19, 20, 21, 22. Re-check the rectifiers, capacitors and transformers disconnecting them from circuitry, refer to schematics.
Channels Initial Check
Re-set the Variac at zero voltage and eventually re-connect the damaged
Power Amplifier Board that you have previously disconnected from supply.
Set up the Variac slowly and check on the oscilloscope display the output
of the damaged channel:
If a dc voltage is present, turn off the amplifier and check all the output
transistors TR13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, their drivers TR5, 7, 9, 11 and all active and passive components interested with the signal path, particularly also include TR29, 30, 31, 32, 33, 34 and D15, 16 for channel A or TR1, 2, 3, 4, 5, 6 and D1, 2 for channel B mounted on Inputs, Drivers & SOA Processor Board.
If appears a simmetrical clipping before the maximum output voltage
(refer to technical spec.), the supply translator circuit of the channel under test, located on Power Supply Board doesn't work properly: check its driver circuit refer to schematics.
If appears an asimmetrical clipping before the maximum output voltage
(refer to technical spec.), the grounding power amplifier doesn't work properly; this fault can also be checked measuring the dc voltage be­tween output ground and the +Vcc and the voltage between output ground and -Vcc for the channel under test, all measures must be simmetrical near 28Vdc without input signal, if not, check the virtual ground driver (R115/R142 ch.A or R52/R47 ch.B) located on Inputs, Drivers & SOA Processor Board, refer to schematics.
If no signal appears: try to disconnect R41,46 to deactivate the signal
deletion caused by SOA circuit, then checked the right operation of the channel, check the cable connections of SOA circuits, check its active and passive components and verify its adjustments. If also the signal doesn't appear check the input circuits, refer to schematics.
Note: If one or more of described faults appear only with the load
connected (see the following checks) may be that one or more output, ground or voltage translator transistors is interrupted.
Dc Supply Final Check
These procedures are intended for one channel at a time, repeat these
operation for the other channel.
SETUP:
Connect the CH1 scope GND clip to the output GND. Connect the CH1 probe tip to the CHA amplifier output before the relay. Connect the CH2 probe tip to the red wire (+Vcc1). Set both to DC 20V/div. 200µS/div. Insert the temperature meter through two transistor cases interstice located at centre of heatsink of CHA on the Power Supply Board . Connect the 4 2000W load to CHA out. Connect the audio generator to the channel input CHA and set it to 1KHz 775mV
RMS
(0dB) sinusoidal signal, and set the amplifier to Stereo mode. Connect the Mains Line as described in the initial setup section. Set the LEVEL potentiometers at zero. Set the Variac at zero voltage.
Increase slowly the Variac to reach the mains voltage: check that the
supply circuit operate correctly measuring +28±2Vdc on the red wire (+Vcc1) and -28±2Vdc on the blue wire (-Vcc1) respect the CHA GND output.
Increasing the CHA input level check the right operation of the Supply
Voltage Translator: verifying that the CH2 voltage level remain the same until the CH1 signal reach 26Vp, afterwards increasing the input level the voltage of CH1 must envelope externally the CH2 signal with an offset of 10÷12V.
Increasing the level of input signal the envelope is stopped more about
100±5Vdc and the signal clip must occur at 180±5Vpp. Decrease the level and connect the CH2 probe to the blue wire (-Vcc1), repeat the test for the negative supply.
Connect the 2Ω instead 4 load and verify that the output signal must be
limited at 64±2Vp. If it doesn't happen check the limit circuit (TR23 for CHA, TR24 for CHB) on Power Supply Board.
Disconnect the fan and wait until the temperature reaches 110±5°C: the
primary transformer relais switch to 2 minimum load and the fan, re­connecting it, goes at maximum speed (23Vdc).
Turn off the Amplifier and the Variac. Connect CH1 scope GND tip to R38
terminal side CN2 (SCR cathode) and its probe tip to R41 side CN2 (SCR gate), set it to 200mV/div. 1mS/div.
Turn on the Amplifier and the Variac simultaneously and verify that the
voltage on the SCR gate shift from 0 to 0.8Vp in less than one second.
Repeat the last test after moving the CH1 GND tip to R44 side CN2 and
its probe tip on R46 side CN2 to check the second SCR.
Repeat all these tests for CHB, where Vcc1 become Vcc2, CN2, R38,
R41, R44, R46 become CN3, R48, R50, R53, R55 respectively.
Channel Final Check
These procedures are intended for one channel at a time, repeat these
operation for the other channel.
If you have already repaired the channel under test:
Verify, with the Multimeter, the insulation between the heatsink and the TR8,10 transistors collectors. Turn the trimmer VR1 full clockwise and VR2 full counter-clockwise to re­adjust the Bias current.
SETUP:
Connect the scope CH1 and the amplifier as described in Dc Supply Final Check section. Connect the CH2 probe tip to the heatsink of the channel under test. Insert the temperature meter through the PTC R27 (for CHB) or through the TR15,16 (for CHA) interstice located on the Power Amplifier Board at centre of heatsink. Set the LEVEL potentiometers at maximum.
INITIAL TEST:
Increase slowly the Variac. The channel output signals must be symmetri­cal respect the GND without visible distortion and oscillation. If there is a distortion read the section ADVICES and proceed to check the other channel. Increasing the level of input signal the signal clip must occur at 180± 5Vpp.
BANDWIDTH CHECK:
Decrease the level to obtain a 50Vp output signal, sweep the generator
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44
44
4
frequency from 20Hz to 20KHz, the output level must have not detectable level changes. Set back the frequency at 1KHz.
BIAS ADJUSTMENT:
Disconnect the fan and wait until the temperature reaches 50°C, set the input level at zero, measure with the Multimeter the voltage across the tips of R34 and the tips of R40, adjust VR1 trimmer to read 1±0.05mVdc. Verify that the temperature is not changed and adjust VR2 trimmer to read 1±0.05mVdc across the tips of R30 and the tips of R43. Set the CH1 an CH2 scopes at 0.2V/div. 200µS/div., adjust the input level until the sinewave reach 0.5Vp, no crossover distortion must be detect­able: if necessary re-adjust VR2 until the distortion disappears without exceed 6mVdc between R30 and R43 terminals. Re-connect the fan.
OUTPUT CURRENT CHECK (GROUND AMPLIFIER):
Connect the ground clip of CH1 scope at the CHA amplifier ground out, and its probe tip to the emitter of TR16 and CH2 probe tip to TR21 emit­ter. Vary the input level to obtain 0.5Vp on output and verify that the differ­ence of their peaks are less than 0.1V. Verify the correct division of the output current between the output tran­sistor, connecting alternatively CH2 probe tip to the TR17 and TR18 emitters checking that their peak levels are within 10% themselves. Moving the CH1 probe tip on TR21 emitter, repeat the measure with the CH2 tip connected alternatively to TR19 and TR20 emitters.
OUTPUT CURRENT CHECK (SIGNAL AMPLIFIER):
Connect the ground clip of CH1 scope at the CHA amplifier output, and its probe tip to the emitter of TR13 and CH2 probe tip to TR24 emitter. Vary the input level to obtain 0.5Vp on output and verify that the differ­ence of their peaks are less than 0.1V. Verify the correct division of the output current between the output tran­sistor, connecting alternatively CH2 probe tip to the TR14 and TR15 emitters checking that their peak levels are within 10% themselves. Moving the CH1 probe tip on TR24 emitter, repeat the measure with the CH2 tip connected alternatively to TR22 and TR23 emitters.
SHORT CIRCUIT SENSOR CHECK:
Short the load temporarely and verify that the current protection sensor (TR3, TR4) limits simmetrically the signal at 0.8±0.1Vp.
Input Circuit Check
These procedures are intended for one channel at a time, repeat these
operation for the other channel.
SIGNAL/CLIP SENSOR CHECK:
Set the LEVEL pot to minimum, then increase the level and check the SIGNAL/CLIP led activity: it must turn on (green light) when the amplifier output is higher than 0.5Vp.
CMRR ADJUSTMENT:
Temporarily disconnect pin 3 from pin 1 and short the pin 2 (positive input) and pin 3 (negative input) of XLR or Jack plug. Adjust the trimmer VR7 (CHA) or VR4 (CHB) on Inputs, Drivers & SOA Processor Board to obtain the minimum output level. Re-set the genera­tor plug with the input signal at pin 2 (positive input) and pin 3 (negative input) short with pin 1 (GND).
GAIN ADJUSTMENT:
Set the input signal to 0dB. Connect the Multimeter on the output of the channel under test, set it in dB scale if available, set the input SENSITIV­ITY at 1.65V
RMS
, adjust the trimmer VR6 (CHA) or VR5 (CHB) to obtain
32dB (30.8V
RMS
) on the output.
Set the SENSITIVITY to 0.775V
RMS
and verify that the Multimeter show
38.5 dB (84.1V
RMS
).
LIMITER ADJUSTMENT:
Remove the shorts from R175 (CHA) and from R63 (CHB) on Inputs, Drivers & SOA Processor Board, connect CH2 probe tip to IC7 pin 14
(CHA) or to IC4 pin 8 (CHB) and set it at 5V/div. 2mS/div., change the generator frequency to 100Hz, increase the signal to obtain about 40Vp on output and adjust the VR10 (CHA) or VR3 (CHB) for the minimum signal on CH2 trace without CH1 trace attenuation. Change the frequency to 10KHz and adjust the C56 (CHA) or C37 (CHB) to minimize the signal on CH2 scope without CH1 attenuation. Re-set the generator at 1KHz, increase the signal and verify that the clipping remain costant with the limiter intervention indicated by the red colour of the SIGNAL/CLIP led.
SOA ADJUSTMENT:
Set the scope sensitivity at 5V/div. (both channels). Connect the CH1 GND clip to S6 and its probe tip to IC6 (CHA) or IC3 (CHB) pin 8, connect CH2 probe tip to IC10 (CHA) or IC5 (CHB) pin 8 set both at 5V/div. 200µs/div.. Insert the temperature meter through the PTC R27 (for CHB) or through the TR15,16 (for CHA) interstice located on the Power Amplifier Board at the centre of heatsink. Verify that the two scope traces are located about 11±0.5Vdc. Short temporarely the load, verify that both the traces move to the scope screen centre and the fans turn to maximum speed. Disconnect the fan and leave the temperature increasing until reaches 70°C disconnect the load and adjust: VR8 (CHA) VR2 (CHB) to have the scope negative trace at 10.5Vdc. VR9 (CHA) VR1 (CHB) to have the scope positive trace at 11.5Vdc. Short again the load, verify that the scope traces move more about 2V from the screen centre when the temperature reach 100±5°C; re-active the fans, they would go at the max. speed, decrease the input level at zero and verify that the voltage remains at 28±2V until the temperature reaches 85±2°C on the heatsink, then change the load back to 4Ω.
AMPLIFIER BRIDGE MODE CHECK:
Set the amplifier in BRIDGE mode (input signal to channel A) and MINI­MUM LOAD at 2, connect the CH2 probe to the bridge output: the output voltage must be 120±2Vp.
SIGNAL TO NOISE RATIO CHECK:
Disconnect the audio generator and short the input (pin 1,2,3 of XLR plug shorted) the output signal (noise) must be less 1mV.
OFFSET SENSOR CHECK:
Set the Variac to zero voltage output, disconnect the load. Turn on the amplifier, connect temporarily (by means of a suitable 100K resistor with a conductor wire) the positive terminal of C4 (CHA) or C5 (CHB) to +15Vdc supply (CN6 pin 8): the PROTECT led must turn on in 3 seconds approx., the output relay must switch off. Remove the connection, wait until the leds turn off and after some sec­onds repeat the check with -15Vdc supply (available on CN6 pin 11), the led PROTECT must turn on again.
SLEW RATE CHECK:
Set the scope sensitivity to 10V/div. 1µS/div. and set the generator to 1KHz square wave mode. Check the output square wave rising and falling edge slopes: both must be 20V/µS or more.
Advices
Check the channels one at time to determine which is right (note: if you
have a spare amplifier module that you know as right, use it).
If you have determinate that the problem is a short on a rail, you must
check the output transistors. To determine which transistor devices are bad, use a soldering iron to lift one leg of each emitter pin and measure the emitter-collector resistance on each device. Unsolder and lift one leg of each base pin and check the base-collector resistance of each transistor and replace any that measure as a short.
If all the transistors are OK, unsolder and lift one leg of each diode and
check them.
Check the circuit board for open foil traces.
Use the Multimeter as Ohm-meter to check the resistors, particularly the
base and emitter resistors of damaged transistor.
Check all active components (transistor and diodes) on the signal path
before a faulted component.
Check all active components (transistor and diodes) connected to the
output net when a output transistor has been faulting.
If the input sinewave appears to be distorted during the negative cycle,
you can assume that the problem is located somewhere in the circuitry of the positive rail. If the positive cycle appears distorted, you can assume that the problem is in the circuitry of the negative rail. Refer to the schematics.
Transistor Packages
TO92
BC337, BC550, BC560
1=Collector
2=Base
3=Emitter
2N5550, 2N5401
1=Emitter
2=Base
3=Collector
TO126
MJE340, MJE350, MJE802
1=Emitter
2=Collector
3=Base
TO220
TIP127, MJE15030, MJE15031
1=Base
2=Collector
3=Emitter
4=Collector
TO264
MJE21193, MJE21194
1=Base
2=Collector
3=Emitter
BTW69
1=Kathode
2=Anode
3=Gate
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