Yorkville AP Series Quick Repair Guide 电路图.pdf

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1、The Yorkville In-House Method for Repairing AP Series Amps At Yorkville, we have developed a method of rebuilding AP series power boards in the shortest possible time. This method is valid for repairing about 95% of all AP amp failures and is essentially the same process for each of the different mo

2、dels in the AP line. This process was not designed to correct problems other than blown outputs and collateral losses. We still see an occasional failure in other areas, but about 95% of all amps that you receive in PROTECT mode, will benefit directly from this method. This uniformity of approach is

3、 possible because all AP series amps share the same basic circuit topography and protection circuits. The rail voltages and the number of output devices may change, but overall they remain more alike than they are different. Only the AP800 & AP1020 have enough differences to warrant a comment or two

4、. The entire program rests on the experience we gained while rebuilding these boards. What became apparent was the fact that we needed to focus on rebuilding the board and not trying to ANALYZE the problem. As you can imagine, this practice goes against just about everything we have practiced as rep

5、air technicians. But, by using this method, we were able to reduce turn-around time and expense by more than 50%. In fact, with practice, an average technician can do a full meltdown rebuild in about 90 minutes. The exception to this rule would be the AP 6040, which runs about 3 hours for an average

6、 rebuild. The root of this system is the practice of NEVER measuring TO-92 style transistors. They are always replaced because it takes about 5 minutes to replace them and they cost next to nothing compared to the cost of analysis and the risk of a failed rebuild. I instituted this policy after disc

7、overing that these little transistors have a really nasty habit of “half- failing”. By this I mean that we were testing these things in the normal fashion and they were showing “good”, but when powered up to operating voltage, they would do all kinds of inexplicable things. As soon as I mandated the

8、 practice of always replacing these little transistors, these strange post-rebuild malfunctions disappeared and departmental efficiency went way up. RadioFans.CN 收音机爱 好者资料库 Determining which channel is blown In order to determine which channel(s) requires repair, it is only necessary to open the cha

9、ssis and flip the upper circuit board out of the chassis without disconnecting any wires ( be sure to insulate the board from touching the chassis when in this position). Then all you need to do, is turn on the power and measure the voltage across ZD7 on each power board. (The location of ZD7 is sho

10、wn on the M1146 Diodes & Semis PDF) If the voltage here is less than the zener rated voltage of 16volts, the board under test is blown and probably in DC offset. Locating Defective Parts Attached to this file are 3 PDFs that locate and identify all the components which require measuring. For the pur

11、pose of clarity I have divided the components into 4 groups, each with its own colour. Further to this, I separated the parts into 2 PDFs, one for resistors and one for semiconductors. In order to provide maximum clarity, I have expanded isolated areas of the circuit board, showing only the area of

12、the board, which is home to the suspect components. By doing this I have cropped out half of the output transistors, emitter resistors and tier diodes (MR854) from view. Please be certain to test these none-visible parts along with the rest of the output devices , resistors and diodes. The PDF Colou

13、r Coding Green These are the large transistors and Fets. Simply test these with your diode checker and replace any shorted units. You will almost never need to replace the tier Fets, they never seem to fail, but we check them anyway. Although it is not shown on the PDF, you will need to check the ou

14、tput crowbar TRIAC for shorts, along with everything else. Blue These are all the diodes to be measured (remember, we only show 4 of the 8 MR854 tier diodes which must all be measured). The only significant measurement in this group will be a short circuit which signifies a diode to be replaced. Rad

15、ioFans.CN 收音机爱 好者资料库 Red NEVER MEASURE THESE, Always replace these 8 transistors Yellow These are the resistors to be measured. You are only interested in units, which measure open circuit, all other readings are meaningless at this time Please note that we are only measuring resistors of 249 ohms o

16、r less, with the exception of the 2 x 3K resistors and the 10K trim pot. The Process With the component side up and the heatsinks farthest from you. We use a continuity checker (you may use a diode checker) and begin by checking the 8 emitter resistors for open circuit. I immediately cut out any com

17、ponents that measure defective, We do not unsolder the lead fragments until I have cut away all the various bad parts. Next. Measure the MR854 tier diodes and cutout any bad ones. Now measure all the transistors outlined in GREEN, cut out or remove any which are shorted. The output devices must obvi

18、ously be unsoldered to remove them from the board. Please note that it is not uncommon to find it necessary to unsolder and isolate all of the output bases and emitters in order to find all the shorted output devices. Now measure all diodes in BLUE (except theMR854 that you have already done) and cu

19、t out any that read short. When that is done you may measure all resistors shown in YELLOW, and cut out any that read open circuit. It is also a good idea to check the bias trim pot (orange colour) just to be safe. Once you have located and cut out all the short and open components, it is time to un

20、solder and remove all the remaining pieces of the component lead wires from the board. After that, collect all the parts you need and install them to the board. For the sake of efficiency, I have small parts bins on the bench which have quantities of all the values of resistors I need and all the di

21、odes as well. I only go to the main parts bins to get the big transistors required for the job. (10 different resistors and 6 different diodes will cover 90% of the work). I also keep the mandatory TO-92 devices on my desk because they are always replaced on every job. RadioFans.CN 收音机爱 好者资料库 After

22、you have replaced all the defective parts, it is time to repeat the measurement process. This is a precaution against installing the wrong value or inverting the polarity of a diode and things like that. This time the values you measure will be quite close to the value of the installed resistors (ex

23、cept for R11 which usually reads about 16ohms). When you are satisfied that all the right parts are in the right places and measuring the appropriate value, you may proceed to a soft start power up of the board. If all goes well, you need only set the bias and return the board to the chassis. Except

24、ions to the rules There will be rare occasions when the voltage amp will be compromised as well as the current amp. In this case it is only necessary to use the same basic process to repair the voltage stage. And as always, just replace the small signal transistors as we do for the current amp stage

25、. In order to effectively deal with the voltage amp, it will probably be necessary to electrically isolate the voltage amp from the current amp. To do this I have created a PDF called “Separate voltage and current amps AP4040”. When you are finished the repair, just restore the original connections

26、for normal operation. The AP6040 is a special case as a rebuild. This is due to the fact that a 6040 is really pretty much 2 AP4020s on each output circuit board. In order to repair these boards, you should treat them as a permanently bridged AP4020. Repair each half of each channel as if they were

27、separate AP4020s. Due to the high currents generated in the bridged condition, these amps are more susceptible to destroying circuit board traces than their un-bridged counterparts. Please keep a sharp lookout for bad traces on this board. Because this amp is really 4 complete amps an two boards, we

28、 found the rebuild times to be twice what they are for our regular two channel amps. VCD SOLDERSIDE M1146-6.00 B A BRIDGE M1126 BLANK SIZE=14.750X10.850 M1146-6.00 2oz.COPPER D G G S DRILL M1146-6.00 J33 D20A4148 J23 D14148 C21N R610K0 J30 R71 100K D94148 C3 22U 10V TAB7 J32 16AWG 5.5PUR J21 R32R2 R

29、42R2 D24148 R15150R R104K7 R7150R R351K D3 4148 R16 12K R11 22R R1439R R13 27K R812K R19249R R5249R R268R R37 27K R38 27K R39 91K R67 22K 0.5W 1 R51220R0 R49 1R/1W R30 620R R31 39R R47 39R C32 10U 63V R272R2 R412R2 R26470R R203K D11BAV21 J11 TAB6 TAB4 R64 33K R65 10R Q1 BC550 Q4 BC550 Q2 BC560 Q3 BC

30、560 Q9 BC550 Q10 BC560 Q8 BC550 RT1 10K VBE C4470P R63 5R6 5WATT TAB3 #3894 TAB1 GS Q11 MTP10N15L GS Q12 MTP8P20 J16 ZD9 16V/1W ZD8 16V/1W C1 1N5 J6 C9 200V 4N7 C20A2N2/500V C16 470P C12 22N C13 22N R35A 20K WC7 16AWG 7YEL TAB2 J3 Q16A MJE340 R29A 3K6 5WATT R84 200R J29 R52 5WATT 0R15 R53 0R15 5WATT

31、 R57 0R1 5WATT R56 0R1 5WATT R59 0R1 5WATT R58 0R1 5WATT R61 0R1 5WATT R60 0R1 5WATT R29 3K6 5WATT R45 3K6 5WATT Q22 YS6927 . R63A39R Q24 YS6927 . R66 22K 0.5W Q26 YS6927 . Q21 YS6927 . Q28 YS6927 . Q13 YS6900 . Q14 YS6900 . Q16 YS6900 . Q18 YS6900 . Q20 YS6900 . D44148 Q23 YS6927 . Q27 YS6927 . D15

32、 MR854 D14 MR854 D13 MR854 R205 47K D21 MR854 D19 MR854 D18 MR854 D17 MR854 D16 MR854 D22 MR854 J22 R44 1/2W 1R ZD412V ZD124V7 C6 330U 16V C7 330U 16V Q7 2N6517 C11 220N 250V Q30 TRIAC MAC224-4 DC_PROT J9 R68A3K3 R62 3R9 2WATT D10BAV21 TP4 TP5 TP7 TP6 TP8 TP9 TP10 TP1 J20 R212K2 ZD5 12V D5 4148 R23

33、4K7 R24 220K R25 220K R42 4K7 R223K ZD716V/.5W C26 #5896 80V 4700u D74148 C25 #5896 80V 4700u Q41 MJE350 FUNCTION Q6 . . MJL1302A R1810K0 Q40 MJE340 FUNCTION R69A3K3 C24 #5896 80V 4700u C27 #5896 80V 4700u R86 470R Q21A BC560 Q20A BC550 1 MX1 CABLE=#3706 J2 R59A 10R C21 10U 16V R85R47/1W R81 220R R6

34、6A 10R WC6 C23 #5896 80V 4700u V TR R45A1K R72 1W 4K7 C28 #5896 80V 4700u R4839R C5 22U 10V R70A10K J15 Q15 YS6900 . Q17 YS6900 . Q25 YS6927 . R42A 56K TAB5 R65A 10R J13 J24 Q19 YS6900 . D30 1N4004 J18 J17 R82 200R Q29 MBS4992 L1 4uH R33 1R/1W C14 220N 250V 22N D20 MR854 R36 91K ZD104V7 WC6 J10 EY3

35、EY9 R7018K R67A10K Q5 . . MJL3281A ZD11 4V7 R55 220R0 R28 1/2W 1R D15A 4148 R68 22K 0.5W ZD1333V R40B 20K C30 22N J14 EY2 R69 22K 0.5W R401K C19 10N 250V R50270R R43 470R D17A4148 C8 1U 63V EY5 D31 1N4004 R80 220R 1 2 R32 39R C29 #5896 80V 4700u R39A 7K5 R41A 7K5 R9249R R38A56K R44A 1K C25A 4U7 10V

36、R46A4K7 R47A1K5 R49A2K R50A 4K7 R51A 1K5 1 HOLDER=#3676 R71A33R R43A 3K R56A 17K8 C17220P R58A 39R J12 R139R R62A 47R5 U1 4N35 C18A 22U 16V C19A 22U 16V #3894 Q15A MJE350 C26A 4U7 10V C22 #5896 80V 4700u R732K R74 330R Q31 AS35 D14A 4148 D13A 4148 R40A220R D16A 4148 D18A 4148 R46 1K J1 D19A4148 D23A

37、4148 D22A 4148 Q14A BC560 Q17A BC550 J4 R61A47R C29A 330U 16V Q12A MPSA42 Q13A MPSA92 U2 4N35 R83 200R R60A 220K 2W C27A 10u 160V C28A 160V 10u Q18A MJE340 Q19A MJE350 C23A 500V 10P C22A 500V 10P TP5A D21A4148 J26 HS2 #3894 HS1 #3894 EY8 EY7 EY4 1+ 1- 2+ 2- JB2 . . . EY6 C31 22N R34 270R JZD3 R17 24

38、9R J5 R57A150R C30A 33u 16V R72A 33R R53A 2K C31A 33u 16V EY1 R45A 3K6 5WATT J34 1+ 1- 2+ 2- JB3 . . . R1239R J19 R55A21K5 R64A150R V TR V TR V TR V TR V TR V TR V TR V TR V TR V TR V TR V TR V TR V TR V TR C10 2N2/500V 11 10 9 8 7 6 5 4 3 2 1 #DESCRIPTION OF CHANGEVER#DATE MODEL(S):- D . OCT/12/00

39、AUG/12/99 JUL/08/99 JAN/27/99 . SEP/10/98 JUL/45/98 JUN/19/98 FEB/12/98 V . 6.00 5.00 4.00 3.00 . 2.00 1.02 1.01 1.00 N PC#6083_REDO_GND_TRACKS PC#6278_ADD_R86-C17_AT_Q41 CORRECT_ERROR_IN_SPKONS SPKON_JACKS_RE-CONFIGURED PC#5908_U1,U2_4N35-TLP621 R64A_C30A/R72A_C31A/R71A PC#5806_ADD_33R_33u/16V_ACRO

40、SS_R57A PC#5798_R72_4K7_1/2W-4K7_1W PC#5767_C10/C15/C20A_2N2_TO_PT#5427 RENAMED_M1126A-M1146 AP4040 M1146.PCB_DATABASE_HISTORY C152N2/500V GND GND R- R+ L+ L- NFB PRTCT SIG CLIP TSENSE CLIM ASSEMBLY M1146-6.00 BLANK SIZE=14.750X10.850 PCBMECH M1146-6.00 10 WITH FLAT SIDE UP AS SHOWN. Q31 IS HAND INS

41、ERTED AND BENT OVER9 T126 TYPE DEVICE 8 7 6 5 4 PRODUCTION NOTES MOUNTING HARDWARE FOR Q11,Q12 3 USE #XXXX SMALL BODY 1R 1W MOUNTING HARDWARE FOR Q40,Q41 MOUNTING HARDWARE FOR Q5,Q6 T264 DEVICE #8741 4-40X 1/2 BOLT BLU WHT BLK YEL RED FOR R33,R49 COOLED FROM WAVE SOLDER IS 6 INCH/LB INITIAL TORQUE F

42、OR TO-3S IS 8 INCH/LB MOUNTING DETAILS FOR 5W MOUNTING DETAILS FOR Q30 TRIAC 16AWG 16AWG 16AWG 16AWG 16AWG OUTPUT - OUTPUT + TAB 7 TAB 6 TAB 5 TAB 4 TAB 3 TAB 2 TAB 1 TAB WIRE COLOURS USE #8799 TO MOUNT TRIAC Q30 MOUNTING HARDWARE FOR TO3 OUTPUTS TORQUE 4 INCH/LB TORQUE 4 INCH/LB TORQUE 4 INCH/LB 2

43、1 #8701 4-40 KEPS NUT #8701 4-40 KEPS NUT #8701 4-40 KEPS NUT #3797 THERMO PAD #3797 THERMO PAD #8871 4-40X 1/2 BOLT PCB PCB PCB HEATSPREADER HEATSPREADER HEATSPREADER HEATSPREADER #3846 MICA T-220 DEVICE #8667 SHOULDER WASHER #3501 BELL WASHER #3501 BELL WASHER #3501 BELL WASHER #8741 4-40X 1/2 BOL

44、T R29, R29A R45 AND R45A 5 WATT RESISTORS ADD #8629 SPACERS ONLY ON 3 2 1 AGAINST THE COPPER SURFACE MARKED 2 AND 3 ARE BENT FLAT IT IS IMPERATIVE THAT LEGS BEND LEGS IN DIRECTION SHOWN DO NOT CUT LEGS AFTER MOUNTING DEVICE IMPORTANT 1/4 OF TRANSISTOR BEND DOWN 1/4 FROM BODY FINAL TORQUE AFTER HEATS

45、INK HAS #8835 BOLT #8663 SPACER #3815 MICA TO-3 TRANSISTOR #8800 6-32 KEPS NUT BOTH SIDES OF THE MICA PAD MICA GREASE IS REQUIRED ON 4 RED 13 RED 2.5 BLK 18 BLK 3.5 19 YELL 2.5 YELL 14BLK BLK SPACER USED AS A THIS CAPS IS JUMPER WIRE TO SOLDER BLUE M1146AP-4040 HOLE HOLE MARCONI MARCONI YEL NOTE #6

46、- OUTPUT + OUTPUT VER:6.00 B A BRIDGE YEL YEL RED BLK BLK BLK BLK M1146 AP-4040 M1146 2 oz. COPPER +145V +78V GND -78V -145V P:1146V60.PRN In order to separate the voltage amp from the current amp. It is only necessary to remove jumpers J11 and J12 (highlighted in red) and then make the two new conn

47、ections as shown by the BLUE dotted lines. CLINCH ORIGINLONG AXIS SHORT AXIS INSERT ORIGIN 9V30 Pcb MechM1146 BlankSize - 14750 x10850 TAB NORMAL SOCKET SOCKET WITH DIRECTION NORMAL LARGE SOCKET UPSIDE DOWN SPACER USED AS A THIS CAP IS BLK 18 9V30 YELL 2.5 19 YELL JUMPER SOLDER BLK 14 BLK 4 RED 13 R

48、ED 2.5 BLK 3.5 M1146 Top Assy WIRE TO V T R V T R V T R V T R V T R V T R V T R V T R V T R V T R V T R GUIDE ETCH V T R V T R E B C E B C GUIDE ETCH V T R 1- 2+ 1+ 2+ 1+ 2- 2- NL4MP-1 1- SPEAKON 4C V T R GUIDE ETCH V T R GUIDE ETCH GUIDE ETCH 1- 2+ 1+ 2+ 1+ 2- 2- NL4MP-1 1- SPEAKON 4C Function Func

49、tion FunctionFunction Function BIAS TRIM Function Function Function Function FunctionFunction 3676 6517 6880 6925 5896 5834 5882 5882 3628 5896 3820 6880 6752 5896 5896 5896 5896 5896 3628 70057004 5896 10R 33K 7K5 56K 4148 4N7 1K 39R 4148 10R 1K5 2K 3K3 4148 47R0 4148 4007 4148 220K 4148 20K0 150R 470P 4148 249R 151R 10K0 10K0 1N 4148 22N 1R 1.0W 4148 1R 1.0W 220R0 4V7 68R 10R 620R100K 4148 2N2 2N2 BC550C 4148 16V0 39R0 33U 16V 10K 2N2 39R39R0 4148 470P 4V7 91K 10R 39R0 1U 63V 2K2 18K 4K7 16V0 151R 12V0 3K 150R 220P 470R 4148 20K0 1