JBL BP-1200.1 Service manual
BP1200.1
1 CHANNEL
POWER AMPLIFIER
SERVICE MANUAL
JBL Consumer Products
250 Crossways Park Dr.
Woodbury, New York 11797 Rev0 1/2004
BP1200.1
1
CONTENTS
Specifications ........................... .....................…..........................…..........1
Features ........... .... .........……………………… …… …………………........... 2
Test Conditions and Notes ............................. .....................….................2
Typical System Configuration (Wiring) ............ .....................…................3
Controls and Connections ............................. .....................…...........…...4
Bulletin JBL2004-04........................... .....................….........…………......5
Amplifier Expl o ded Vi ew............. .... .... ...... ........... .. ........…........ ... ............6
Block Diagram....................................... .....................…...…....................7
Parts Lists..... .... .............. .... .... ...........…... . ...... ............... …….. .... .............8
Integrated Circuit Diagrams........................ .....................…...................14
Transistor Diagrams.................................... .....................…..................16
Printed Circuit Boards (Top View).....……... .....................…..................18
Schematic Diagrams................... …..........................…............………...20
Packaging ........ ............... ...… ……………… ............... .... ..…............ .... ..3 2
BP1200.1 Specifications
Number of Channels . . . . . . . . ………………... . 1
4 Ohms . . . . . . . . . . . . . . . . . . ………………. . . 600W
2 Ohms . . . . . . . . . . . . . . . . . ……………. . ….. 1200W
T.H.D. @ 4 Ohms rated Power . . . . .. . . . . . . . . 0.10%
Frequency Response . . . . . . . . . . . . .. . …. . . . 10Hz ~ 320 Hz
Signal to noise Ratio . . . . . . . . . . . . …. . . . . . . >100dB
Maximum Current Draw . ………………….. . . . 114A
Fuse size. . . . . . . . . . . . . . . ………………. . . . 40A x 3
Input Sensitivity. . …….. . . . . . . . . . .………. . . 250mV ~ 4V
Minimum Speaker Impedance…………………..1 ohm
External Dimensions
Length . . . . . . . . . . . . ……………….. . . 14 13/16 (376mm)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3/16 (274mm)
Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 11/1 6 (68mm )
JBL continually strives to improve its products. New m aterials, production met hods and design refinements are i ntroduc ed
into existi ng model s wit hout notice as a routine expression of our desi gn philosophy. For this reason, BP S eri es
Automotive Amplifiers may differ in some respects from their published specifications and descriptions, but will always
equal or exceed the ori ginal specifications unless other wise stated.
BP-1200.1
2
Features
1-Channel Operation
Advanced MOSFET Oversized Floating Rail Power Supply ( Auto turn on )
Floating Ground Factory - Head - Unit Speaker - Level input
Variable Input Sensitivity (250mV - 4V)
Fully Complementary Output Stage with Class-D Voltage Amplification
Gold-plated Power, Input and Output Connectors
2-Ohm Stable
Test Conditions and Notes
1 Channel Automotive Amplifier
All tests to be done, unless otherwise specified, from 10Hz to 320Hz at 14.4V DC into 2 ohm loads and adjust
the units gain so that with a .775 volt input signal the unit is at its maximum rated output. All measurements
will be done using an Audio precision system one and the supply voltage.
An A+ line voltage of 14.4V DC shall be applied to the unit under test for all measurements unless otherwise
specified. The voltage applied to the unit shall be measured at the power connection on the Amplifier.
Signal Source
Unless otherwise specified, all tests shall be conducted with the Audio Signal Generator output configured to
be balanced, less than or equal to 50 ohm source impedance, and floating. The signal source "GND" shall be
connected to the Amplifier PWR GND at the Amplifier.
Output Load
Unless otherwise specified, all tests shall be conducted with 2 ohm resistive loads having less than 10%
reactive components at any frequency below 350Hz. Each resistor shall have a value that remains within 1%
while dissipating the rated output of the unit under test.
Power Indicator LED steadily illuminates for normal operation. LED blinks when
protection circuitry is engaged, and during power up.
BP-1200.1
3
Power
Antenna
Antenna Input
Cassette/Receiver
Power Supply
Wires
Typical System Configuration
Cassette/CD Tuner
(Head Unit)
1 Channel Automotive Amplifier
CD Player or Changer
Power
Antenna
Relay
Power Supply
Antenna Motor Ground
Remote Antenna
Remote On/Off
Black - Power Ground
Ignition
Switch
Vehicle Battery
Fuse
Fuse
Black Power
Red - Main +12V
Line
Level
Input
Remote On/Off
60 Amp (Not Included)
Fuse
Power Ground
Main +12V
Amplifier
Power
Connection
Speakers
Chassis Ground
1 Channel Automotive Amplifier
4
Controls and Connections
BP-1200.1
- + - +
Controls and Connections
1. It allows left and right input channels to be
connected to the amplifier using RCA plugs.
2. Speaker Output Connector - Connect speaker
wiring to these connectors. See wiring instruc tions on page 4 for more information.
85
FUSES 40Ax3
SPEAKER OUTPUTS
2
34
6 7
POWER
5. Input-Level Control - Adjusts input sensitivity
for pre-amp level and speaker level inputs.
6. The electronic crossover is a 12dB/oct.
Low pass filter which can be Set at any frequency
between 32Hz and 320Hz.
7. The bass boost control will provide up to 6dB of boost
at 50Hz.
3. Fuse - 40Ax3 Amp ATC type Fuses.
8.It allows left and righ input channels such as high level
speaker output signals to be the amplifier.
4. Power Connection for 12V+, GND and REM
connections for power wires. See wiring instruc tions on page 4 for more information.
Mounting the Amplifier
The JBL BP Series amplifiers can be mounted in virtually any location inside the vehicle.
However, make sure to keep the amplifier away from heater vents or ducts.
1. At the chosen site, use the amplifier as a mounting template and mark the locations of the
four mounting holes.
2. Drill a small pilot hole at each marked location.
3. Mount the amplifier and securely tighten the mounting screws.
Service Bulletin
5
Service Bulletin JBL2000-04 - November 2000 Warranty labor rate: MINOR
To: All JBL Service Centers
Models: BP300.1, BP600.1, BP1200.1
Subject: Muting during intense bass passages
The JBL BP series amplifier is designed with the following protection circuits:
Thermal (excess heat)
DC voltage on the output terminals (overdriving or “clipping”)
Short Circuit (excessive current)
Under certain large signal conditions during intense bass passages, the unit will go into protection. These
amplifiers are behaving as designed. As the unit is driven into hard clipping, the protection circuit found in BP
Series amps was engineered to protect your loudspeakers from being destroyed by a severely clipped output
signal. This can be remedied easily by turning the volume down somewhat on your music source.
In the event you receive a BP series amplifier with the complaint: “Under a large signal input, with
music that is composed of high-level bass, the amplifier mutes for 2-3 seconds, and then returns to
normal operation”, the following modification will effectively increase the amount of clipping that is allowed to
occur before the protection circuit engages by increasing the threshold at which the amplifier mutes - for the
benefit of customers who use the amps in SPL competition, or for customers who insist on driving the
amplifiers into this potentially hazardous zone.
1) Turn the amplifier upside-down and remove the Phillips screws holding the bottom cover on.
2) Locate and change R510 from 47K to 4.7K ohms 1/5W (JBL part# RE212047200).
3) Locate and change R511 from 22K to 2.2K ohms 1/4W (JBL part# QAF0450-222).
4) If it is not already present, add new part - 4.7uf 50v electrolytic capacitor (JLB part# EC070114760) in
parallel with R511. Polarity: The negative side of the capacitor must be connected to the junction of
R510/R511, which can be discovered with an ohmmeter.
NOTE: Using the correct soldering techniques, you should be able to make these changes from the top of the
PCB without its removal.
5) Replace bottom cover; test amplifier
Model Serial number Status Action
BP300.1
BP600.1
BP1200.1
All Serial numbers affected Modify if Needed
Change R510 from 47K to 4.7K ohms
Change R511 from 22K to 2.2K ohms
Add 4.7uf 50v electrolytic cap in parallel with R511
1 Channel Automotive Amplifier
6
x4
22
BP-1200.1 Mechanical Exploded View
x3
17
18
x3
19
20
BP-1200.1
21
23
x4
12
11
9
13
10
14
x5
6
5
8
4
3
HEAT SINK
1
REFLECTOR
2
SCREW
3
LED CAP
4
SUB PCB
5
SCREW
6
HEAT SINK
7
P.C.B
8
HEAT SINK
15
2
1
25
16
9
10
11
12
13
14
15
T.R BRACKET "1060A"
T.R BRACKET "1062C"
T.R BRACKET "1061B"
SCREW
SCREW
FRONT PANEL
MA-HS-65-1080-0
MA-IL-65-1025-0
MA-IL-65-1025-0
MA-IL-65-1024-0
PB014087010
MN-SC-00-5-30-08
MA-HS-65-1080-0
PB011344010
MA-HS-65-1080-0
MA-BR-02-1060-0
MA-BR-02-1062-0
MA-BR-02-1061-0
MN-SC-00-2-40-16
MN-SC-00-5-30-06
MA-FP-65-3787-0
Q'TYMFR PARTSNOMENCLATURE
SCREW
1
16
REAR PANEL
1
17
SCREW
18
1
SCREW
19
1
FUSE
20
1
SCREW
21
1
BOTTOM COVER
22
1
SCREW
23
1
SCREW
24
1
BADGE
25
1
26
1
27
1
28
10
29
5
30
1
MB-SC-04-3-30-08
MA-RP-65-3788-0
MB-SC-04-3-30-08
MB-SC-05-2-20-06
FU030120401
MN-SC-00-5-30-08
MA-BC-65-2806-0
MN-SC-00-2-30-06
MO-SC-03-2-30-08
MA-BG-65-1026-0
Q'TYMFR PARTSNOMENCLATURE
1
3
1
3
3
1
1
6
4
1
BP1200.1
7
LOW - IN
HI - IN
BUFFER
L+
L-
PRE
AMP
DRIVER
REM
POWER AMP
PROTECTION
POWER
SUPPLY
P.W.M
R+
R-
L+
L-
+
+
-
+ VCC
GND
-VEE
R+
R-
REM
DC +12
GND
BP-1200.1
8
Rev 0
1 Channel Automotive Amplifier
BP1200.1 Parts List
REF. NO REF. NO
Main PCB, Preamp, Crossover, Power Supply and Power
Amplifier
F.E.T
Q211,212,213
Q214,215,216
Q311,312,313
Q314,315,316
Q241,242,243
Q244,341,342
Q343,344
Q742,743,744
Q745,746,752
Q753,754,755
Q756
TRANSISTORS
Q101,501,502
Q504,505,507
Q702,704,705
Q706
Q102,204,205
Q232,233,304
Q305,332,333
Q401
Q103,202,203
Q234,235,302
Q303,334,335
Q402,403,701
Q201,301
Q231,331
Q503,506,703
Q741,751
DIODES
D101,102,202
D232,302,332
D402,403,601
D602,704,731
D740,741,751
D201,231,301
D331,401
D404,701
D501,771,772
D773,774
D702
D761,762,763
D764
I.C
U101
U102,103,104
U105
U106
U107,109
U108
U111,702
U701
U761
U762
PART NO. PART NO.DESCRIPTION DESCRIPTIONQ'TY
FE109641210
FE106401110
FE132050105
TR031981100
TR010273100
TR010233100
TR035030101
TR013810201
TR012661200
DI041480000
DI052420040
DI040040010
DI001504111
DI054040011
DI003040999
IC007455900
IC001007200
IC017007400
IC009140600
IC051043100
IC007036100
IC001039300
IC017049400
IC006781204
IC006791204
P-CH MOSFET ( IRF9640 )
N-CH MOSFET ( IRF640 )
N-CH MOSFET ( IRF3205 )
SMALL SIGNAL NPN (C3198GR)
SMALL SIGNAL NPN (C1027Y)
SMALL SIGNAL PNP (A1023Y)
VIDEO NPN (2SC3503)
VIDEO PNP (2SA1381)
SMALL SIGNAL PNP (A1266GR)
SWITCHING (1N4148)
ZENER (0.5W) (1N5242)
RECTIFIER (1N4004)
RECTIFIER (PR1504)
FAST RECOVERY (1N5404)
FAST RECOVERY (MUR3040PT)
DUAL OP AMP (KIA4559P)
DUAL OP AMP (TL072CP)
QUAD OP AMP (TL074CN)
14-STAGE COUNTER
( MC14060 )
SHUNT REGULATOR
( KIA431 )
PRECISION COMPARATOR
(LM361)
COMPARATOR (KIA393P)
P.W.M (TL494CN)
VOLTAGE REGULATOR
(KIA7812)0
VOLT AGE REGULATOR
(KIA7912)
RESISTORS
R101,104,111
R114,146,149
R165,166,167
R171,174,178
R405,407,409
R411,412,416
R419,420,421
12
8
10
10
10
12
2
2
5
15
5
2
5
1
4
1
3
1
1
2
1
2
1
1
1
R504,512,513
R601,604,611
R614,726,727
R728
R102,103,105
R106,602,603
R605,606
R112,113,115
R116,612,613
R615,616
R120,122,153
R154,414,510
R121,123,124
R125,401,402
R126,155,175
R709,710
R127,163,403
R129
R130
R131,132,735
R133,147,162
R170,179,180
R201,231,301
R331,729,739
R742,752
R134
R135
R136
R140,143,506
R141,144
R142,145,708
R150
R151
R152,164,176
R418
R161,168,410
R736
R169,743,744
R745,746,747
R753,754,755
R756,757
R172
R173,177
R202,232,302
R332
R203,303
R204,234,304
R334
R205,206,235
R236,305,306
R335,336
R207,237,307
R337
R208,209,210
R211,212,213
R238,239,240
RE202010300
RE212100300
RE212390300
RE202047300
RE212010300
RE202022200
RE202015200
RE212022300
RE212033200
RE202056200
RE202001300
RE202015300
RE202012300
RE202470300
RE306022200
RE212075300
RE212047200
RE202047800
RE202082300
RE202047200
RE202010500
RE202022000
RE202100000
RE204022000
RE212470000
RE212091000
RE202330000
RE202010000
RE305015200
RE314010000
CARBON FILM 1/5W 5%
( 10K OHM )
METAL FILM 1/5W 1%
( 100K OHM )
METAL FILM 1/5W 1%
( 390K OHM )
CARBON FILM 1/5W 5%
( 47K OHM )
METAL FILM 1/5W 1%
( 10K OHM )
CARBON FILM 1/5W 5%
( 2.2K OHM )
CARBON FILM 1/5W 5%
( 1.5K OHM )
METAL FILM 1/5W 1%
( 22K OHM )
METAL FILM 1/5W 1%
( 3.3K OHM )
CARBON FILM 1/5W 5%
( 5.6K OHM )
CARBON FILM 1/5W 5%
( 1K OHM )
CARBON FILM 1/5W 5%
( 15K OHM )
CARBON FILM 1/5W 5%
( 12K OHM )
CARBON FILM 1/5W 5%
( 470K OHM )
CARBO N FILM 2W 5%
( 2.2K OHM )
METAL FILM 1/5W 1%
( 75K OHM )
METAL FILM 1/5W 1%
( 4.7K OHM )
CARBON FILM 1/5W 5%
( 10 OHM )
CARBON FILM 1/5W 5%
( 75K OHM )
CARBON FILM 1/5W 5%
( 4.7K OHM )
CARBON FILM 1/5W 5%
( 1M OHM )
CARBON FILM 1/5W 5%
( 22 OHM )
CARBON FILM 1/5W 5%
( 100 OHM )
CARBON FILM 1/2W 5%
( 22 OHM )
METAL FILM 1/5W 1%
( 470 OHM )
METAL FILM 1/5W 1%
( 91 OHM )
CARBON FILM 1/5W 5%
( 330 OHM )
CARBON FILM 1/5W 5%
( 1 OHM )
CARBON FILM 2W 5%
( 1.5K OHM )
METAL FILM 1/2W 1%
( 10 OHM )
Q'TY
31
8
8
6
6
5
3
1
1
3
14
1
1
1
3
2
3
1
1
4
4
11
1
2
4
2
4
8
4
20
1 Channel Automotive Amplifier
9
Rev 0
BP1200.1 Parts List
BP-1200.1
REF. NO REF. NOPART NO. PART NO. DESCRIPTIONDESCRIPTION Q'TY
R241,308,309
R310,311,312
R313,338,339
R340,341
R214,215,216
R217,218,219
R242,243,244
R245,315,316
R317,318,319
R342,343,345
R128,148,314
R344,413,415
R712,738
R220,320
R233,333
R246,346
R247,347
R404
R406
R408
R417,505,740
R501,502
R503
R507
R508,509
R511
R700
R701
R703,733
R704
R705
R706
R707
R711
R715
R723,725
R724
R731
R732,737
R734
R741,751
R761
R764,765
R771,772
CAPACITOR
C101,102,197
C200,732
C106,405,509
C706,713,777
C779
C108
C171,172,178
C180,184,193
C505
RE202100300
RE306047000
RE212051000
RE908010013
RE202470000
RE212011300
RE212330000
RE202220300
RE202033300
RE306001300
RE202820300
RE306022800
RE202056300
RE202022300
RE202390300
RE202033200
RE202068200
RE202027200
RE202018200
RE204010000
RE212105200
RE202047000
RE202027300
RE202012200
RE202051300
RE202022500
RE202330300
RE202043200
RE203220000
RE306100000
RE305039200
RE305010000
EC040112200
EC040111010
EC050112200
EC040114700
CARBON FILM 1/5W 5%
( 100K OHM )
CARBON FILM 2W 5%
( 47 OHM )
METAL FILM 1/5W 1%
( 51 OHM )
SHUNT 3 LEAD 5W
( 0.01 OHM )
CARBON FILM 1/5W 5%
( 470 OHM )
METAL FILM 1/5W 1%
( 11K OHM )
METAL FILM 1/5W 1%
( 330 OHM )
CARBON FILM 1/5W 5%
( 220K OHM )
CARBON FILM 1/5W 5%
( 33K OHM )
CARBON FILM 2W 5%
( 1K OHM )
CARBON FILM 1/5W 5%
( 820K OHM )
CARBON FILM 2W 5%
( 2.2 OHM )
CARBON FILM 1/5W 5%
( 56K OHM )
CARBON FILM 1/5W 5%
( 22K OHM )
CARB ON FILM 1/5W 5%
( 390K OHM )
CARBON FILM 1/5W 5%
( 3.3K OHM )
CARBON FILM 1/5W 5%
( 6.8K OHM )
CARBON FILM 1/5W 5%
( 2.7K OHM )
CARBON FILM 1/5W 5%
( 1.8K OHM )
CARBON FILM 1/2W 5%
( 10 OHM )
METAL FILM 1/5W 1%
( 10.5K OHM )
CARBON FILM 1/5W 5%
( 47 OHM )
CARBON FILM 1/5W 5%
( 27K OHM )
CARBON FILM 1/5W 5%
( 1.2K OHM )
CARBON FILM 1/5W 5%
( 51K OHM )
CARBON FILM 1/5W 5%
( 2.2M OHM )
CARBON FILM 1/5W 5%
( 330K OHM )
CARBON FILM 1/5W 5%
( 4. 3K OHM )
CARBON FILM 1/4W 5%
( 220 OHM )
CARBON FILM 2W 5%
( 100 OHM )
CARBON FILM 1W 5%
( 3.9K OHM )
CARBON FILM 2W 5%
( 10 OHM )
ELECTROLYTIC "SMS"
( 22uF/16V )
ELECTROLYTIC "SMS"
( 100uF/16V )
ELECTROLYTIC "SMS"
( 22uF/25V )
ELECTROLYTIC "SMS"
( 47uF/16V )
Q'TY
26
2
2
2
2
1
1
1
3
2
1
1
2
1
1
1
2
1
1
1
1
1
1
2
1
1
2
1
2
1
2
2
5
7
1
7
C206,236,306
C336
C403
C408,709,733
C501,502,508
C538
C701
C703,704
C716,717,718
C719,720
C771,772
C773,775
C764,765
C103,104
C107,118,160
C161,166,232
C332
C138,142,164
C163,170,173
C174,175,177
C179,183,190
C191,192,194
C195,196,199
C203,233,291
C303,333,401
C402,404,510
C705,707,715
C721,722,724
C725,726,731
C774,776,778
C780
C167,176,198
C210,310,240
C340
C201,231,301
C331
C407
C105,506,714
C131
C132
C134
C135
C140,141,162
C409
C168,205,235
C305,335,503
C504,712,762
C763,766,767
C204,234,304
C334
C207,307,406
C711,761
C208,209,308
C309,507
C2 37,768
C702,723
EC070122221
EC070112210
EC070114760
EC111211000
EC050171010
EC040111000
EC050122200
EC070111000
EC060114710
EC071048221
CC011101100
CC011470100
CC011331200
CC011104600
CC051104020
CC011050100
CC011102200
MC001110400
MC091412407
MC091468307
MC091410407
MC091418307
MC001110300
MC001410530
MC001422401
MC001110200
MC081222511
MC001722511
MC091410507
ELECTROLYTIC "SHL"
( 2200uF/50V )
ELECTROLYTC "SMS"
( 220uF/50V )
ELECTROLYTIC "SMS"
( 4.7uF/50V )
ELECTROLYTIC "BP"
( 10uF/200V )
ELECTROLYTIC "SXE"
( 100uF/25V )
ELECTROLYTIC "SMS"
( 10uF/16V )
ELECTROLYTIC "RX"
( 2200uF/25V )
ELECTROLYTIC "SMS"
( 10uF/50V )
ELECTROLYTIC "SMS"
( 470uF/35V )
ELECTROLYTIC "CE-HC"
( 8200uF/50V )
CERAMIC DISK 50V "NPO"
( 100pF )
CERAMIC DISK 50V "NPO"
( 47pF )
CERAMIC DISK 50V (330pF)
CERAMIC DISK 50V (0 .1uf)
CERAMIC RADIAL MLCC
( 0.1uf )
CERAMIC DISK 50V "NPO"
( 5pF )
CERAMIC DISK 50V (0.001uf)
MYLAR 5% 50V (0.1uf)
MYLAR 5% 50V "TL" (0.12uf)
MYLAR 5% 50V "TL" (0.068uf)
MYLAR 5% 50V "TL" (0.1uf)
MYLAR 5% 50V "TL" (0.018uf)
MYLAR 5% 50V (0.01uf)
MYLAR 5% 63V "BOX"
( 1uf )
MYLAR 5% 63V "BOX"
( 0.22uf )
MYLAR 5% 50V (0.001uf)
MYLAR 5% 100V (2.2uf)
MYLAR 5% 250V "TL" (2.2uf)
MYLAR 5% 50V "TL" (1uf)
Q'TY
4
1
3
4
1
2
5
2
2
2
2
7
3
37
7
4
1
3
1
1
1
1
4
12
4
5
5
2
2
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