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1、PRO-SVR_LEGACY Page 1 of 14 Date: August 22, 2007 Model Number: CAP-80 / CAP-101 Class Audio Inc. Subject: Service manual Class Audio, Inc. 5070 Franois Cusson Lachine, Qubec Canada H8T1B3, RadioFans.CN PRO-SVR_LEGACY Page 2 of 14 Table of Contents Introduction 3 Important Notes on Servicing 3 Order
2、ing 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 13 IR Interface Information 14 Schematics 15 The conten
3、ts of this document as well as the files associated with it contain confidential information that is proprietary to Class 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 wh
4、atsoever without prior written permission from Class Audio Incorporated. RadioFans.CN PRO-SVR_LEGACY Page 3 of 14 Introduction Please read this manual carefully before commencing servicing! Only qualified and authorized personnel should attempt to service this product. The lightning flash with arrow
5、head symbol, within an equilateral triangle, is intended to alert the user to the presence of uninsulated dangerous voltage within the products enclosure that may be of sufficient magnitude to constitute a risk of electric shock to persons. The exclamation point within an equilateral triangle is int
6、ended to alert the user to the presence of important operating and maintenance (servicing) instructions. Class 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 Ph
7、one: (978) 664-2870 E-mail: Europe Phone: 44 (0) 1903 221 700 E-mail: Asia Phone: (852) 2790 8903 E-mail: classebwgroup.hk Rest of the World Phone: (514) 636-6384 E-mail: Important Notes on Servicing 1.ALWAYS observe ESD precautions when handling electronic modules or PCBAs. 2.NEVER exchange boards
8、with a different revision number, unless authorized by Class. 3.ALWAYS use Class 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 informati
9、on. Remember to quote the serial number of the unit on all replacement part orders and the Class order number when returning defective parts for credit. RadioFans.CN PRO-SVR_LEGACY Page 4 of 14 Block diagrams RadioFans.CN PRO-SVR_LEGACY Page 5 of 14 Start Up Procedure When receiving a unit, an assid
10、uous 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
11、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.
12、2. Turn the bias trimpots, counter clockwise until a click is heard. 3. Since there is no soft-start sequence of the CAP-80 / CAP-101, it is impossible to use a bypass to perform a slow start up. 4. Connect Main supply, and turn on the unit. 5. If one or more supply are not within specifications, re
13、turn to the troubleshooting guide. 6. If every supply is within specifications, report to calibration and adjusments to adjust bias and DC offset. Note that bias can be adjusted to 14mV, and the following tests can be performed before the unit is send to the burn-in bench for a 24 hours warm-up. 7.
14、Connect the unit to a load, and to a source using single ended inputs. 8. 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 channe
15、ls. 9. Connect the unit to a small speaker, and short the input. Check for any noise. 10. Put the unit on a burn-in bench, and let it sit for 24 hours, then readjust bias. Let the unit on the burn- in bench for another 72 hours. 11. Redo steps 7 to 11 before shipping to the customer. RadioFans.CN PR
16、O-SVR_LEGACY Page 6 of 14 Protection Modes and Indicators The front LED display shows the status of the amplifier. When starting up normally, the CAP80 / CAP101 will show a countdown from 20 to 0. However, there is no protection on the CAP80 / CAP101. The CAP80 / CAP101 is equipped with four rail pr
17、otection fuses. In the event that one or more of these fuses would blow, 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 c
18、over and look for damaged or burned components. If no other components than the fuses appear to be damaged, the technician can then replace the broken fuses with the same value and rating (please report to fuses section). The rail fuses are located on the main board. When replacing fuses, please mak
19、e sure that the fuse holder are holding the fuses very tightly. A loose fuse holder can translate into distortion on top of the signal. RadioFans.CN PRO-SVR_LEGACY Page 7 of 14 Troubleshooting Guide Symptom Possible cause Unit won t turn on Check connections; Check fuses; Check soft-start circuit; C
20、heck relays; Check power supply circuits (positive rail, negative rail, Mosfet supply). Smoked and/or burned components Check for short between components and ground; Check output transistors; Check output relays; Check power supply circuits (positive rail, negative rail, Mosfet supply). Blown fuses
21、 Check for short between fuse and ground; Check power supply circuits (positive rail, negative rail, Mosfet supply). No output Check connexions; Check output relays; Check power supply circuits (positive rail, negative rail, Mosfet supply); Check output transistors. Unit turn into protection Check f
22、or smoked and/or burned components; Check power supply circuits (positive rail, negative rail, Mosfet supply); Check source and load; Check protection circuit; Check sensor wires between sensor PCB and control PCB; Check outputs transistors and Mosfet drivers. Excessive buzz and/or hum Check electri
23、cal lines; Check for a ground loop in the system. Oscillation Check source; Check capacitors on main board; Check 4.7? resistor. Intermittent signal Check connections; Replace shield wires. RadioFans.CN PRO-SVR_LEGACY Page 8 of 14 Output Transistors Testing and Replacement PLEASE NOTE THAT THESE TES
24、TS 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 technicia
25、n 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
26、blown output transistors, you must also replace positive and negative Mosfet drivers and bias transistor. Carefully inspect 4.7? resistor and 10? soft start resistor, and replace if necessary. Replace any burnt component or board. Pins : 1 Base 2 Collector 3 Emitter You should have these results, if
27、 the transistor is good. 2SC3263 (NPN) Positive lead Negative lead Result B C Conductive B E Conductive C B Infinite C E Infinite E B Infinite E C Infinite 2SA1294 (PNP) Positive lead Negative lead Result B C Infinite B E Infinite C B Conductive C E Infinite E B Conductive E C Infinite RadioFans.CN
28、PRO-SVR_LEGACY Page 9 of 14 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. Since it is impossible to connect a multimeter to both emitter s resistors in orde
29、r to measure and adjust bias without disassembling the heatsink from the chassis, we provided a test point to ease the bias procedure. It is located near the bias trimpot. 2. Connect the positive probe of a millivoltmeter to the test point and the negative probe to the positive speaker post of the c
30、hannel to be adjusted. 3. Turn trimpots counterclockwise until it reaches 0?. A click should be heard. 4. Turn on amplifier, and let it warm up for 15 minutes on idle. 5. Adjust trimpot to get a 14mV reading. 6. Let the amplifier warm up for a 24 hours period with signal and load. 7. Remove signal a
31、nd load, and reconnect the multimeter. 8. Readjust to 20mV. 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 co
32、nnected to the output posts, scale setted to mV. DC offset should be less than 10mV. RadioFans.CN PRO-SVR_LEGACY Page 10 of 14 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 lo
33、cation, 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 Description Classe part number B151X Complete PCB, input B151XR(x) B152X Complete PCB, supply B152XR(x) B153X
34、 Complete PCB, display B153XR(x) B154X Complete PCB, main B154XR(x) RadioFans.CN PRO-SVR_LEGACY Page 11 of 14 Updates 1. On board B154X, replace R122, R126, R222 and R226 with Classe part number RN55D7680. 2. On board B154X, replace RV101 and RV201 with Classe part number 3299W-1-202. 3. On board B1
35、54X, replace R134 and R234 with Classe part number A211-1004. 4. On board B154X, replace R128, R129, R228 and R229 with Classe part number A211-1001. 5. Replace shield wires with newer type. RadioFans.CN PRO-SVR_LEGACY Page 12 of 14 Fuses EXTRA PRECAUTIONS SHOULD BE TAKEN WHEN REPAIRING, MODIFYING,O
36、R 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
37、 TOP OF THE SIGNAL. Main fuses: For 100 120v units: 4A slo-blo, Classe part number GDC-4A For 220 240v units: 3.15A slo-blo, Classe part number GDC-3.15A The main fuse is located at the back of the unit, on the rear panel. Rail fuses: 4A, Classe part number GDB-4A The rail fuses are located on the m
38、ain board (B154X). Control board fuse: 0.75A, Classe part number 225.750 The control board fuse is located on top of the supply board (B152X) Mosfet fuses: 0.50A, Classe part number 225.500 The Mosfet fuses are centered on the main board (B154X) RadioFans.CN PRO-SVR_LEGACY Page 13 of 14 Voltage Chan
39、ge 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 v
40、aristor, 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 t
41、ransformer (see tables below) Primary wires, main transformer Mains 1 2 3 4 5 6 7 8 Varistor 100VAC White OrangeGrayYellowBlue Blue BlackBlue140 120VAC White OrangeBlueBlackBlueGrayYellowBlue140 220VAC White - - YellowBlue Blue BlackBlue250 240VAC White - - YellowBlueGrayBlackBlue250 Connector posit
42、ions Jumpers, auxiliary transformer Mains Position 1 Position 2 Position 3 Position 4 Position 5 100/120VAC In Out Out Out In 220/240VAC Out Out In Out Out 1 2 3 4 5 6 7 8 RadioFans.CN PRO-SVR_LEGACY Page 14 of 14 IR Interface Information Press and hold: AMP + LINE 1 = Turns on Amplifier # 1 AMP + L
43、INE 2 = Turns on Amplifier # 2 AMP + LINE 3 = Turns on Amplifier # 3 AMP + BAL 1 = Turns on Amplifier # 4 AMP + BAL 2 = Turns on Amplifier # 5 AMP + BAL 3 = Turns on Amplifier # 6 J3 J2 J1 J0 ADDRESS RC Button Auto ON Note X X X X 0 Amp1 No QC setting X X X Out 1 Amp2 No X X Out X 2 Amp3 No X X Out
44、Out 3 Amp4 No X Out X X 4 Amp5 No X Out X Out 5 Amp6 No X Out Out X 0 Amp1 No X Out Ot Out 0 Amp1 Yes On with AC Out X X X 0 DC No Out X X Out 1 DC No Out X Out X 2 DC No Out X Out Out 3 DC No Out Out X X 4 DC No Out Out X Out 5 DC No Out Out Out X 0 DC No Out Out Out Out 0 DC Yes On with AC RadioFans.CN RadioFans.CN RadioFans.CN RadioFans.CN RadioFans.CN B154XR08.sch-1 - Mon Aug 20 08:51:40 2007 RadioFans.CN
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