JBL DS-10 Service manual

ARC SUB10/DS-10

Powered Subwoofer

SERVICE MANUAL

JBL Consumer Products Inc. 250 Crossways Park Drive Woodbury, N.Y. 11797 1-800-336-4JBL in the USA

A Harman International Company

Rev A 10/2000

Amplifier/Subwoofer ARC SUB10/DS-10

SAFETY INFORMATION

Warning

Any person performing service of this unit will be exposed to hazardous voltages and the risk of electric shock. It is assumed that any person who removes the amplifier from this cabinet has been properly trained in protecting against avoidable injury and shock. Therefore, any service procedures are to be performed by qualified service personnel ONLY!

Caution

This unit does not have a power switch. Hazardous voltages are present within the unit whenever it is plugged in.

Before the amplifier is plugged in, be sure its rated voltage corresponds to the voltage of the AC power source to be used. Incorrect voltage could cause damage to the amplifier when the AC power cord is plugged in. Do not exceed rated voltage by more than 10%: operation below 90% of rated voltage will cause poor performance or may shut the unit off.

Leakage/Resistance Check

Before returning the unit to the customer, perform a leakage or resistance test as follows:

Leakage Current. Note there is no power switch on this unit. When the power plug is plugged in, the unit is live. Connect the unit to its rated power source. Using an ammeter, measure the current between the neutral side of the AC supply and chassis ground of the unit under test. if leakage current exceeds 0.5mA, the unit is defective. Reverse the polarity of the AC supply and repeat.

List of Safety Components Requiring Exact Replacements

F1 Fuse SLO BLO 0.63A 250V T type.

UL approved

PWRCORD SPT-2 or better with polarized plug, UL

approved wired with the hot side to fused side. Use with factory replacement panel strain relief only.

TRX Transformer. Use only factory replacement.

DBR Bridge diode. Use only factory replacement.

C1, 2 3300uF, 50V electrolytic filter caps. Be sure

replacement part is at least the same working voltage and capacitance rating. Also the lead spacing is important. Incorrect spacing may cause premature failure due to internal cabinet pressure and vibration.

C6 10uF 50V ±20% Elect. Radial NP Safety Part

See Page 15 Service Bulletin

R29 470W 0.25W ±5% METAL OXIDE Safety Part

S53AMI Power Amp module. Use only factory

replacement

CMC1 mc4438 Safety Part

L1 mc4436 Safety Part

Resistance. Measure the resistance from either side of the line cord to chassis ground. If it is less than 500k ohms, the unit is defective.

WARNING! DO NOT return the unit to the customer if it fails one of these tests until the problem is located and corrected.

Critical Components

All components identified with the IEC symbol in the parts list and the schematic diagram designate components in which safety can be of special significance when replacing a

component identified with . Use only the replacement parts designated in the parts list or parts with the same rating of resistance, wattage or voltage.

Amplifier/Subwoofer ARC SUB10/DS-10

TABLE OF CONTENTS

SAFETY INFORMATION ...............................................2

TABLE OF CONTENTS .................................................3

GENERAL SPECIFICATIONS .......................................3

DETAILED SPECIFICATIONS.......................................4

ARC SUB10/DS-10 CONTROLS AND

THEIR FUNCTION.........................................................6

CAUTIONS AND WARNINGS .......................................7

ARC SUB10/DS-10 BLOCK DIAGRAM ........................9

SPEAKER CONNECTIONS.........................................10

TROUBLESHOOTING .................................................11

ARC SUB10 / DS-10 TEST SET UP AND

PROCEDURE...............................................................12

ARC SUB10 / DS-10 POWER AMP

MODULE TESTING FLOW CHART ............................13

SERVICE BULLETIN JBL9903 - APRIL 1999 ............14

SERVICE BULLETIN JBL2000-01

JANUARY 2000............................................................15

TROUBLESHOOTING TIPS AND SOLUTIONS

TO COMMON SERVICE PROBLEMS ........................16

CABINET EXPLODED VIEWS ....................................17

AMPLIFIER EXPLODED VIEW ...................................18

ARC SUB10/DS-10 PACKING EXPLODED VIEWS...19

ARC SUB10 Version 5 PCB........................................20

ARC SUB10/DS-10 Version 5.1 PCB..........................21

ARC SUB10/DS-10 ELECTRICAL PARTS LIST ........22

ARC SUB10/DS-10 INTEGRATED CIRCUITS &

TRANSISTORS ............................................................23

ARC SUB10/DS-10 SCHEMATIC................................24

GENERAL SPECIFICATIONS

Amplifier Power (RMS) ........100watts

Driver 10" ..............High-Polymer Laminate

Inputs ................Line Level and Speaker Level

Outputs ...............Speaker Level (only active if Speaker Level Inputs are used)

High-Pass Frequency .........High-Pass filter at 180Hz (only active if Speaker Level Inputs are used)

Frequency Response .........50Hz - 150Hz

(determined by crossover setting)

ARC SUB10 DS-10

Dimensions (HxWxD)........11-1/2 x 17-1/8 x 16-1/2" 14-1/4 x 14-1/4 x 16"

(292 X 435 X 419mm) (362 x 362 x 406mm)

Weight ................27lbs/12.3 kg 27 lbs/12.3kg

Amplifier/Subwoofer ARC SUB10/DS-10

DETAILED SPECIFICATIONS

LINE VOLTAGE Yes/No Hi/Lo Line Nom. Unit Notes

US 120vac/60Hz Yes 108-132 120 Vrms Normal Operation

EU 230vac/50-60Hz Yes 207-264 230 Vrms Normal operation, MOMS required

Parameter

Amp Section

Type (Class AB, D, other)

Load Impedance (speaker)

Rated Output Power 100 Watts 1 input driven Peak power

THD @ Rated (RMS) Power

THD @ 1 Watt 0.1 % 0.5 22k filter

DC Offset 10 mV-DC 20 @ Speaker Outputs

Damping factor

Input Sensitivity

Input Frequency 40 Hz 50 Nominal Freq.

Line input

Speaker/Hi Level Input

Signal to Noise

SNR-A-Weighted 100 dBA 70 relative to rated power A-Weighting filter

SNR-unweighted 80 dBr 70 relative to rated power 22k filter

SNR rel. 1W-unweighted 65 dBr 55 relative to 1W Output 22k filter

Residual Noise Floor 1 mVrms

Residual Noise Floor

Specificatio

0.3

100

2.6

1.5

Unit

n/a

Ohms

mVrms

Vrms

mVrms(max)

QA Test

Limits

n/a Class D Preferred...Sink required for Class

n/a Nominal

1 22k filter

40 Measured at amplifier board Measure at amp board THD < 0.1% 50 Watts

± 2dB

2 Volume @max, w/ A/P Swept Bandpass

Volume @max, using DVM or A/P (BW=20 KHz)

Conditions Notes

Z-curve required

50 Watts

@ 50Hz

To Rated power/Vol @ Max Single input driven Un-Balanced GND

Zo=600

To Rated power/Vol @ Max Single input driven Un-Balanced GND

Zo=600

Measurement (Line freq.+ harmonics) (BW=20 Khz)

Input Impedance

Line Input 10K ohms n/a Nominal Zin Minimum, (test frequency 1 Khz)

Speaker/Hi Level Input 4.7K ohms n/a Nominal Zin Minimum, (test frequency 1 Khz)

Filters

Speaker in LP 2nd order variable

Subsonic filter (HPF) 2nd order

Speaker out HP filter

Left & Rigth 200 Hz

Left & Rigth 100 Hz

50-150

± 10

± 10 ± 10

-3db Point

Speaker input - Spkr out 4 Ohms

Speaker input - Spkr out 8 Ohms

Amplifier/Subwoofer ARC SUB10/DS-10

Limiter

THD at Max. Output Power

n/a n/a functional

Maximum Output Power

Maximum THD as a result of limiting.

Features

Volume pot Taper (lin/log)

HP Speaker out functional Refer to filter section

Input Configuration

Line In & LFE YES — functional LR dual RCA jack

Spkr/Hi Level In YES — functional Spring type connector

Signal Sensing (ATO)

Auto-Turn-On YES functional Auto - on selection switch in Auto Bicolor LED (Green=signal/ red= No signal)

ATO Input testfrequency 40 Hz functional “

ATO Line level in 5 mV functional "

ATO Level Speaker in 50 mV functional "

ATO Turn-on time

Auto Mute/ Turn-OFF Time

Power on Delay time

Transients/Pops

ATO Transient 5 mV-peak 50

Turn-on Transient 2 Vpk-pk 2 @ Speaker Outputs AC Line cycled from OFF to ON

Turn-off Transient 2 Vpk-pk 2 @ Speaker Outputs AC Line cycled from ON to OFF

—

LOG

0.1 sec. 5 AC Power Applied

— functional

ms functional

minutes

17 T before muting, after signal is removed Auto turn of time (T) must be 3>T<15

Amp connected and AC on, then input signal applied

Minutes

Efficiency

Efficiency 65 % 64 Nominal Line voltage 120 VAC / 230 VAC

Stand-by Input Power

Power Cons. @ rated power

Protection

Short Circuit Protection

Thermal Protection

Line Fuse Rating

US (120v) version Amps 0.6 Type-T or Slo Blo-250 V Internal fuse

EU Amps TBD Type-T or Slo Blo-250 V External fuse with UL/SEMKO rated holder

YES

Watts

18 @ nom. line voltage Auto turn of time (T) must be 3>T<15

80 @ nom. line voltage

functional

Direct short at output Amplifier should resume operation after short

@1/8 max unclipped Power IEC Noise

using driver load

Minutes

75 Watts @ 4 Ohms nominal line voltage

circuit condition removal

Temperature rise in accessible metal parts should not exceed 35K rise for 120v version or 30K rise for European versions (refer to requirements sheet).

Amplifier/Subwoofer ARC SUB10/DS-10

ARC SUB10/DS-10 CONTROLS AND THEIR FUNCTION

1. Volume Control - adjusts the level of volume of the

subwoofer relative to the rest of the system.

2. Power LED - This light will be RED when the unit is

plugged in and not receiving a signal; when the unit receives a signal, the light will cycle to GREEN. If no signal is received after 5 minutes the light will cycle back to RED (standby) until a signal is present again.

3. Crossover Frequency - This controls the highest

frequency the subwoofer will reproduce. It allows a seamless transition from the subwoofer to the satellite speakers. When the control is at the “50” position, very few high frequencies will be heard. This position is best suited to large main speakers. For most applications, the control should be set somewhere near the mid position. For listeners using very small speakers, best results will be obtained with the control at the “150” position.

4. Low Level Input Jacks - These left and right Line

Level Inputs are normally used when the receiver/ processor has line-level “pre-amp out ” or “subwoofer out” jacks.

5. High Level Inputs - These High Level Inputs are for

receivers that do not have line-level “pre-amp out” or “subwoofer out” jacks. When a pair of main or satellite speakers are attached to the OUTPUT terminals, frequencies below 180 Hz are attenuated by the high-pass filter.

Note: DS-10 controls are shown here

Volume

Min

Power

Crossover

Frequency

Low

Level

Max

150

SPKR

OUT

Amplifier/Subwoofer ARC SUB10/DS-10

CAUTIONS AND WARNINGS

BEFORE THIS AMPLIFIER IS PLUGGED IN, make sure its rated voltage corresponds to the voltage of the AC power source to be employed. Failure to use the correct voltage could cause damage to the amplifier when the AC power cable is plugged in. Do not exceed the rated voltage by more than 10%; operation below 90% will degrade performance or cause the unit to shut off.

1. TROUBLE SHOOTING BEFORE OPENING

Check connections, control settings, driver and other possible external problems. If there is Output, determine if all controls and Inputs function properly. Rotate Pots over full range while applying lateral and vertical oscillating forces to locate possible intermittent function. High Level Inputs should be tested individually both differentially (signal from "-" to "+" with normal output) and in common mode (signal from low level ground to both "+" and "-" shorted together, giving virtually no output). While passing a signal, corner drop the enclosure a few inches to expose possible intermittent problems. Check woofer for rubbing of voice coil or tears in cone or surround. Check cabinet for loose extraneous articles which may have been pushed into port.

2. REMOVING THE AMPLIFIER.

There are voltages and hot components at many points in the amplifier which can, if contacted, cause personal injury. Be extremely careful. Any adjustments or service procedures that require operation of the amplifier out of its enclosure should be performed only by trained service personnel. Refer to PCB drawings for locations of hazards and familiarize yourself with their locations before starting.

A. Remove the subwoofer grille.

B. Remove the (4) 1” Black PPH screws attaching the

woofer to the cabinet.

Verify AC plug is disconnected. See WARNINGS in section

To prevent loose hardware from reducing safety spacings, it is essential that all hardware be replaced in the same manner as it was removed, with lock washers under all nuts, proper torque on screws and thread locking sealer on the transformer nuts.

If line core or strain relief are replaced, it is necessary to seal them completely to panel with an approved conformal coating to prevent air "whistling" through any openings from woofer pressure.

To reduce the risk or electric shock and/or fire, replace items as marked on schematic with the safety marking only with the exact replacements listed in the safety component list, page 2. If exact replacements are not available, order them from the factory or an authorized service center.

A. Check fuse F1. If blown visually check transformer for

discoloration, and large capacitors (C1, C2) for bulges or venting. Check for shorts with an Ohmmeter, (see schematic).

C. Remove the woofer, unplug the two connecting wires.

D. Remove the (8) ¾” screws black pph screws

attaching the ampifier assembly to the cabinet.

E. Remove the ampifier assembly.

F. For access to the input panel, first remove the three

outer screws. Remove knob and nuts from potentiometers. Cut away the sealant securing the cover to the faceplate. The input PCB should now pull out completely.

3. TROUBLE SHOOTING AFTER REMOVAL

B. With ohmmeter, verify voice coil of woofer is 3.9

ohms, and windings of transformer are continuous.

C. Examine board and wiring for obvious damage,

broken or poorly soldered connections, or discoloration.

D. Repair or replace items identified above.

E. For live power testing, attach a 4 ohm 100 watt

resistor to the output wires.

F. If the LED is not on, check for fuse continuity and

then for cold solder joints on CMC1 and bridge diode.

G. With a signal present at the input, the output to the

power amp is at pin #8 of U1. If the signal is not present at pin 8, there is a problem with preamp section. Most likely, a cold solder joint will be the

Amplifier/Subwoofer ARC SUB10/DS-10

problem. Track back the signal path to locate problem.

H. If signal present at pin 8, but still no sound, check

for cold solder joints on all power resistors, R4a and R4b and the the power amp module. If C24 is blown, C6 is not soldered or is defective. Check the signal at R2. On the down signal side, the voltage signal should be very small. If signal is similar on both sides of R2, the amp module is likely defective.

I. If you hear a mechanical clicking noise from the amp

module, this indicates that the short circuit protection has been engaged. Check that Q3, Q4 and Q5 are soldered correctly. Also check that Q3 is not shorted to power amp case.

J. If you have to replace the power module, be very,

very patient with the solder removal from this single sided PCB. COMPLETELY REMOVE SOLDER

BEFORE TRYING TO REMOVE THE MODULE!

(See page 23)

K. Assembly notes. Top side soldering as below:

J5: solder both ends

RCA jack (chassis) to the line neutral of AC

cord. Resistance should be >100MW .

B) Hi-Pot Test

If a UL approved Hi-Pot tester is available, test line & neutral of AC cord to outer shell of RCA jack (chassis) at 1100VAC for 2 seconds. Observe all of instrument manufacturer's instructions and safety warnings in performing this test.

Connect subwoofer system to a music source. Play at high level while checking for air leaks around panel edge, driver, panel jacks and controls, and voice coil problems such as rubbing or loose turns. With the crossover "frequency" set to 50Hz, very little of the voice content should be heard.

4. REASSEMBLY

Follow all disassembly instructions in reverse order. If the input plate has been removed, it must be re-sealed with a small bead of silicon seal or air leaks may result.

J3: solder both ends

J1: solder both ends

R48: solder GND end

At junction of C7a/C7b: Pin to GND

Crossover pot Gnd wire from PDB pad to POT barrel. (Only physical contact required between pot body and faceplate).

After repair, inspect for possible safety hazards, including loose hardware, missing lock washers, correct fuse and lead dress of primary wires (these must be held in position with cable ties so that they cannot touch secondary components). With ohmmeter, check that panel is connected to signal ground.

It is essential that the following safety insulation test be performed prior to returning the Power SubWoofer to the customer, using one of the following methods.

A) Insulation Resistance Test

With a 500VDC Insulation Tester, Check insulation from the outer metal contact of the

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