Classe Audio CAV-180 Service manual

Classé Audio Inc.
Date:
July 17, 2007
Model Number:
CAV-180
Subject:
Service manual
Classé Audio, Inc. 5070 François Cusson Lachine, Québec Canada H8T1B3, www.classeaudio.com
PRO-SVR_LEGACY
Page 1 of 13
Table of Contents
Introduction 3
Important Notes on Servicing 3
Ordering Replacement Parts 3
Block Diagrams 4
Start up Procedure 5
Protection Modes and Indicators 6
Troubleshooting Guide 7
Output Transistors Testing and Replacement 8
Calibrations and Adjustments 9
Parts List 10
Updates 11
Fuses 12
Voltage Change 12
IR Interface Information 13
Schematics 14
The contents of this document as well as the files associated with it contain confidential information that is proprietary to Classé Audio
Incorporated and are intended solely for the purpose of servicing product. No part of its contents may be used, copied, disclosed, or conveyed to
any party in any manner whatsoever without prior written permission from Classé Audio Incorporated.
PRO-SVR_LEGACY
Page 2 of 13
Introduction
Please read this manual carefully before commencing servicing!
Only qualified and authorized personnel should attempt to service this product.
The lightning flash with arrowhead symbol, within an equilateral triangle, is intended
to alert the user to the presence of uninsulated dangerous voltage within the
product’s enclosure that may be of sufficient magnitude to constitute a risk of electric
shock to persons.
The exclamation point within an equilateral triangle is intended to alert the user to
the presence of important operating and maintenance (servicing) instructions.
Classé has a global product support network. For product assistance or to order replacement parts please
contact your nearest service center always quoting the unit serial number.
North America
Phone: (978) 664-2870 E-mail: classe@bwgroupusa.com
Europe
Phone: 44 (0) 1903 221 700 E-mail: classe@bwgroup.com
Asia
Phone: (852) 2790 8903 E-mail: classe@bwgroup.hk
Rest of the World
Phone: (514) 636-6384 E-mail: cservice@classeaudio.com
Important Notes on Servicing
1. ALWAYS observe ESD precautions when handling electronic modules or PCBAs.
2. NEVER exchange boards with a different revision number, unless authorized by Classé.
3. ALWAYS use Classé original replacement parts. The use of generic parts may void the warranty of
the unit.
Ordering Replacement Parts
There may be a delay in processing incomplete requests. Please be sure to include all required information.
Remember to quote the serial number of the unit on all replacement part orders and the Classé order number
when returning defective parts for credit.
PRO-SVR_LEGACY
Page 3 of 13
Block diagrams
PRO-SVR_LEGACY
Page 4 of 13
Start Up Procedure
When receiving a unit, an assiduous visual inspection must be performed. Do not connect the unit without
analysing the symptoms reported by the customer and the results of the inspection.
Using the troubleshooting guide, find the problem and proceed to the repair. Once this step is done, follow
these steps, known as the start-up procedure, to ensure that everything in the unit is in working condition.
1. Proceed with a post repair visual inspection. Take the time to check if every wire is reconnected
properly, every screw is bolted on, no soldering and/or metal residues lying in the unit, every fuse has
been replaced, etc.
2. Connect the unit to a variable transformer, setted to 0Vac.
3. Turn the bias trimpot (RV1) counter clockwise until a click is heard.
4. Connect the bypass wire to the variable transformer. This bypass is a power cord, modified on the
female side in order to bypass the soft start sequence. It is connected to the line tab on soft start PCB.
5. Slowly raise the voltage to 10Vac, and check positive and negative rails. Check fuses.
6. If one or more supply are not within specifications, return to the troubleshooting guide.
7. Slowly raise voltage until you hear relays click, this point is around 55Vac. Recheck every supply.
8. If one or more supply are not within specifications, return to the troubleshooting guide.
9. Raise voltage to 120Vac. Recheck every supply
10. If every supply is within specifications, unplug the unit and bypass from the variable transformer.
Reconnect only the unit.
11. Report to calibration and adjusments to adjust bias and DC offset. Note that bias can be adjusted to
10mV, and the following tests can be performed before the unit is send to the burn-in bench for a 24
hours warm-up.
12. Connect the unit to a load, and to a source using balanced inputs and single ended inputs,
independently.
13. Perform a test with a 200Hz, a 2kHz and a 20kHz tone, both sinus wave and square wave. Check the
output with a oscilloscope, on 4 ohms and 8 ohms loads. Take special cares about oscillation and phase
correlation between channels.
14. Connect the unit to a small speaker, and short the input. Check for any noise. Perform this step with
single ended inputs and balanced inputs, independently.
15. Put the unit on a burn-in bench, and let it sit for 24 hours, then readjust bias. Let the unit on the burnin bench for another 72 hours.
16. Redo steps 11 to 14 before shipping to the customer.
PRO-SVR_LEGACY
Page 5 of 13
Protection Modes and Indicators
The front LED shows the status of the amplifier. When starting up normally, the CAV180 will show a FLASHING
RED LED for about 15 seconds and if all is normal, the LED will go SOLID RED. If there is a fault, the LED will
go to a FLASHING GREEN LED. The CAV180 is not equipped with any protection fuses. In the event that the
protection is triggered, the technician will first need to identify and cure the cause of failure (please report to
troubleshooting guide). When the cause has been identified, disconnect the unit from the system including the
AC power. Remove the top cover and look for damaged or burned components.
PRO-SVR_LEGACY
Page 6 of 13
Troubleshooting Guide
Symptom
Unit won’t turn on
Smoked and/or burned
components
Blown fuses
No output
Unit turn into protection
Excessive buzz and/or hum
Oscillation
Intermittent signal
PRO-SVR_LEGACY
Possible cause
Check connections;
Check fuses;
Check soft-start circuit;
Check relays;
Check power supply circuits (positive rail, negative rail)
Check for short between components and ground;
Check output transistors;
Check power supply circuits (positive rail, negative rail).
Check for short between fuse and ground;
Check power supply circuits (positive rail, negative rail).
Check connexions;
Check output relays;
Check power supply circuits (positive rail, negative rail,);
Check output transistors.
Check for smoked and/or burned components;
Check power supply circuits (positive rail, negative rail,);
Check source and load;
Check protection circuit;
Check sensor wires between sensor PCB and control PCB;
Check outputs transistors and Mosfet drivers;
Perform updates, if necessary.
Check electrical lines;
Check for a ground loop in the system.
Check source;
Check capacitors on main board;
Check 4.7ƻ resistor.
Check connections;
Replace shield wires.
Page 7 of 13
Output Transistors Testing and Replacement
PLEASE NOTE THAT THESE TESTS ARE ONLY EFFECTIVE ON BIPOLAR TRANSISTORS.
DO NOT PERFORM THESE TESTS ON MOSFET DEVICES, AS THEY ARE LIKELY TO
BECOME SHORT DURING THE TEST.
You should check all pin combinaisons, as there is a chance that only one side of the transistor is short. When
replacing outputs transistors, the technician should first disconnect both outputs and main board to check if
the blown outputs were caused by a faulty component on the amplifier’s base. Blown output transistors should
be replaced by kits, not individually. These kits contains matched transistors for both rails of one channel.
When replacing blown output transistors, you must also replace positive and negative Mosfet drivers and bias
transistor. Carefully inspect 4.7ƻ resistor and 10ƻ soft start resistor, and replace if necessary. Replace any
burnt component or board.
Pins : 1
2
3
Base
Collector
Emitter
You should have these results, if the transistor is good.
2SC3263 (NPN)
Positive lead
B
B
C
C
E
E
Negative lead
C
E
B
E
B
C
Result
Conductive
Conductive
Infinite
Infinite
Infinite
Infinite
Negative lead
C
E
B
E
B
C
Result
Infinite
Infinite
Conductive
Infinite
Conductive
Infinite
2SA1294 (PNP)
Positive lead
B
B
C
C
E
E
PRO-SVR_LEGACY
Page 8 of 13
Calibrations and Adjustments
Bias adjustment:
Note: Bias adjustment should be made without any load connected to the amplifier’s output, and no signal
connected to the amplifier’s input.
1.
2.
3.
4.
5.
6.
Connect a multimeter to R5 leads and set the multimeter to mV scale.
Turn trimpot RV1 counterclockwise until it reaches 0ƻ. A click should be heard.
Turn on amplifier, and let it warm up for 15 minutes on idle.
Adjust trimpot RV1 to get a 10mV reading.
Let the amplifier warm up for a 24 hours period with signal and load.
Remove signal and load, and reconnect the multimeter, setted to mV scale, to R5 leads. Note the
reading, and readjust if necessary.
DC offset:
Note: DC offset adjustment should be made without any load connected to the amplifier’s output, and no
signal connected to the amplifier’s input.
On these units, DC offset can’t be adjusted. Measure DC offset using a voltmeter connected to the output
posts, scale setted to mV. DC offset should be less than 10mV.
PRO-SVR_LEGACY
Page 9 of 13
Parts List
This is not a detailed part list. It is a list of major chassis parts and PCBs. If you need to order a specific part,
please contact Classe Audio with the part location, PCB number, and model and serial number of the unit.
If you need a complete PCB, please replace the (x) in the Classe part number with the revision number printed
on the board.
Parts
B1D9X
B1DBX
B02AX
B2E1X
B2E2X
B2E3X
B2E4X
B2E5X
B2E7X
B2E8X
B1DAX
PRO-SVR_LEGACY
Complete
Complete
Complete
Complete
Complete
Complete
Complete
Complete
Complete
Complete
Complete
PCB,
PCB,
PCB,
PCB,
PCB,
PCB,
PCB,
PCB,
PCB,
PCB,
PCB,
Description
negative sensor
positive sensor
amplifier
capacitors
heatsink
speaker terminal
soft start
input
control
IR sensor
switch
Classe part number
B1D9XR(x)
B1DBXR(x)
B02AXR(x)
B2E1XR(x)
B2E2XR(x)
B2E3XR(x)
B2E4XR(x)
B2E5XR(x)
B2E7XR(x)
B2E8XR(x)
B1DAXR(x)
Page 10 of 13
Updates
1. On board B2E2X, replace R1 with Classe part number 3299X-1-202 (5 PCBs).
2. On board B02AX, replace R113 and R103 with following assembly. Use Classe part number A307-1078.
Connect the resistor assembly to the exterior pads of R113 and R103.
3. On board B2E7X, disconnect the ground wire and connect it to position GND7 on B2E3X PCB.
4. On board B2E2X (5 PCBs), make sure that Q1 and Q2 are part number 2SK79 and 2SK216. They
should be mounted on a small aluminium block, which is mounted to the chassis (see following pics). If
they are printed as ECX10N20 and ECX10P20, replace them, using the following guide.
Parts needed: G213-1029, Mosfet, x5; G213-1031, Mosfet, x5; G307-1078, Silpad, x10; 385-288, Screw,
x10; A306-1048, Lock washer, x10; MS-15795-803, Washer, x20; A306-1020, Shoulder washer, x10;
L252XR00, aluminium spacer, x10
PRO-SVR_LEGACY
Page 11 of 13
Fuses
EXTRA PRECAUTIONS SHOULD BE TAKEN WHEN REPAIRING, MODIFYING, OR
TROUBLESHOOTING IN THE POWER SUPPLY AREA. UNIT MUST BE DISCONNECT
FROM MAIN SOURCE AND CAPACITORS MUST BE DISCHARGED USING A 100W
INCANDESCENT BULB.
WHEN REPLACING FUSES, PLEASE MAKE SURE THAT THE FUSE HOLDERS ARE
HOLDING THE FUSES VERY TIGHTLY. A LOOSE FUSE HOLDER CAN TRANSLATE INTO
DISTORTION ON TOP OF THE SIGNAL.
Main fuses:
For 100 – 120v units: 10A slo-blo, Classe part number MDA-10A
For 220 – 240v units: 8A slo-blo, Classe part number MDL-8A
The main fuse is located at the back of the unit, on the rear panel.
Control board fuse: 0.50A, Classe part number 225.500
The control board fuse is located on top of the control board (B2E7X)
Voltage Change
EXTRA PRECAUTIONS SHOULD BE TAKEN WHEN REPAIRING, MODIFYING, OR
TROUBLESHOOTING IN THE POWER SUPPLY AREA. UNIT MUST BE DISCONNECT
FROM MAIN SOURCE AND CAPACITORS MUST BE DISCHARGED USING A 100W
INCANDESCENT BULB.
1. Set the primary wires of the main transformer as described below.
2. Replace the varistor, according to new line voltage, following Classe’s recommendations. If varistor is
not available, remove old varistor and leave it empty.
3. Set the jumpers accordingly on the auxiliary transformer located at the back of the unit on the top
main board on the left-hand side of the auxiliary transformer (see tables below)
Mains
100VAC
120VAC
220VAC
240VAC
N1
White
White
White
White
Mains
100/120VAC
220/240VAC
PRO-SVR_LEGACY
N2
Orange
Orange
-
Position 1
In
Out
Primary wires, main transformer
X1
X2
X3
X4
Gray
Yellow
Blue
Black
Blue
Black
Gray
Yellow
Yellow
Gray
Black
Black
Gray
Yellow
Jumpers, auxiliary transformer
Position 2
Position 3
Out
Out
Out
In
X7
Blue
Blue
X8
Orange
Orange
Position 4
Out
Out
Varistor
140
140
250
250
Position 5
In
Out
Page 12 of 13
IR Interface Information
Press and hold:
J3
X
X
X
X
X
X
X
X
Out
Out
Out
Out
Out
Out
Out
Out
PRO-SVR_LEGACY
AMP
AMP
AMP
AMP
AMP
AMP
J2
X
X
X
X
Out
Out
Out
Out
X
X
X
X
Out
Out
Out
Out
J1
X
X
Out
Out
X
X
Out
Ot
X
X
Out
Out
X
X
Out
Out
+
+
+
+
+
+
LINE 1
LINE 2
LINE 3
BAL 1
BAL 2
BAL 3
J0
X
Out
X
Out
X
Out
X
Out
X
Out
X
Out
X
Out
X
Out
=
=
=
=
=
=
Turns
Turns
Turns
Turns
Turns
Turns
ADDRESS
0
1
2
3
4
5
0
0
0
1
2
3
4
5
0
0
on
on
on
on
on
on
Amplifier
Amplifier
Amplifier
Amplifier
Amplifier
Amplifier
#
#
#
#
#
#
RC Button
Amp1
Amp2
Amp3
Amp4
Amp5
Amp6
Amp1
Amp1
DC
DC
DC
DC
DC
DC
DC
DC
1
2
3
4
5
6
Auto ON
No
No
No
No
No
No
No
Yes
No
No
No
No
No
No
No
Yes
Note
QC setting
On with AC
On with AC
Page 13 of 13
B1D9XR02.sch-1 - Tue Jul 17 12:04:49 2007
B1DBXR02.sch-1 - Tue Jul 17 12:01:57 2007
B2E1XR00.sch-1 - Tue Jul 17 12:00:17 2007
B2E3XR01.sch-1 - Tue Jul 17 12:00:38 2007
B2E4XR00.sch-1 - Tue Jul 17 12:02:42 2007
B2E5XR00.sch-1 - Tue Jul 17 12:01:07 2007
B2E8XR00.sch-1 - Tue Jul 17 12:06:43 2007