CAP-100 / CAP-150 Service manual
Contents
1. oz UoN tS LOOC LT gt PRE O L PREAMP OUT TAPE R gt PRE O R RCA JACKS r TAPE L 15 54 45V SSM2143 RLYS RLY6 RLY7 4 1 1 0 tuF 50 RLY8 O tuF 50V 0 tuF 50V CD7 91 LEFT 605 __ _ CD6 0 tuF 50V 10 10 m MUTE BAL 1 E 10 7 2 2 2 4 C Bypass 92 21 19 1 si 3 INNA 9 9 z 1 4 o 3 1 4 4 O 917 210 93 5 ti 5 ae 5 az mm 319 AMP L NER g lI de 99K 0 4 ke 7 NE TO BAL CONTROL 7 21 48 1 J4 BAL 1 D FROM VOL CONTROL 21 7 3 TO AMP R RIGHT SSM2143 Ma Y RLY3 RLY1 1 1 PREAMP IN PRE I L XLR2 4 Sun ge Ll co RCA JACKS pre i R 5 O tuF 50V2. bd 1 R116 ne 0114 O 1uF 100V C117 1 15 144148 100UF 63 Qs ene one sov x o D112 1N4148 gt c 011 Co E 1N4148 Q106 0107 10bF 100V R124 2N6517 2N6517 B AAA Q114 14K3 2N6519 X bro 25 389 1 OS 02 2sk389 Q108 A Q108 8 de R18 118K 2 6 R106 105 7 US VV 3151 Sols 100 100 c102 l 10 10pF 100V 13 14 O uF 50V 4 1799112 0105 o TL431ILP c R12 E 2N6519 E Lto B 1 15 R1041K15 sloe os gt AAA WN ieot QUO ey PEGBODR GAR 0109 E 2N6517 Zs E 2N6517 2N6519 o 121 Q104 C103 100UF 10V GND R111 R10 0 1uF 50V 5 85 109 3 254109 Ij 100 100 51 Q103 A TL431ILP Q103 B 2 1000 25V i C104 C105 C106 VE 7 02 01 OliuF 50 e C116 C115 ESR c oe E e Q112 nk sk R101 2N6517 Zar 0 1uF 100V ofz 0101 0102 E B d 100UF 63V 3 4K02 2N6519 2N6519 4K02 10pF 100V v ND Riga c c c 1N4148 GNDA R108 zE u C101 118K 100K 0109 v 10pF 100V am eis e nius 2N6517 D108 v 0 1uF 50V M ie NV 1N4148 R107 D107 R119 1S p 1N4148 v DATED DRAWN CHECKED
3. 0 4 oz UoN LOOC LC Hn 1000uF 6 3V BR4 CON1 1 CON1 4 CON1 X2 3 en 1000uF 6 3V 5 1000uF 6 3V dU CON1 x8 CON1 X6 7 F2 0 75 BR5 CON1 AC1 TAB6 T1 CON1 AC2 BEI HCE12F1 PRI SEC c1 1000uF 16V c4 1000uF 16V ES E R2 100 MN 1000uF 1 O luF 50V 1000uF 16V c2 c6 c5 c3 TO MAIN XFMR 52 0 tuF 250V CH ND R4 C7 aog ANN p QT3 QT2 QT4 4 7 QT5 T QT7 QT6 47 DATED DRAWN CHECKED No REV COMPANY R6 100 CLASSE AUDIO INC 00 AC SECTION O 1uF 250V ZOND C14 CHGND psn BOF 2XRO4 1 oF 1 V1 C2 FBK2 GND1 GND1 E2 1 gt B gt 60VDC 100uF 100V 2 MPS2222TR N 2 gt x Ope ac 5 ES 2 gt 3 KR 2 oo o T U3 NON 2SA1294 RO9 CHANGE BOARD SIZE amp MOSFET CHANGE R6 TO 5501151 CHANGE R5 TO 3299 1 501 COMPANY CLASSE AUDIO INC TITLE CAP INTERGATED AMPLIFIER DESC OUTPUT SECTION DRAWING NO BOF 3XRO9 DRAWN NDN DATE NOV 5 02 SHEET 1 OF 1
4. GNDD JUMPER cst JUMPER SV 5 ju BALIZCTR TAPE CTR 0 REG4 CTR 50V BAL1 CTR REG3 CTR GNDD REG4 CTR REG2 CTR REG3 CTR REGI CTR vi REC2 CTR 50 OPF XI REGI CTR 12MHz 4 24 2 L F m 53 c5 c2 35 50V 74HC14 P347 cs2 U4 10PF 10 P33 1 J2 SB E 5V p30 POWER CTR ENC2 OUT 051833 15 PNE tee os SEPA CTR ENC1 OUT a6 9 IRsT p17 29 x RST 9 gt GND INTO P15 18 74HC125 SE GNDD p14 He LEE 8 0 aie 55 aT 2 P2 H2 ej v a O 1UF 50V O 1UF 50V amp POSDA 5 5 POO SCL P10 x Es IC1 12 GNDD GNDD 2 DGND CLR LATCHS S 1 ENC2 OUT ENCIZOUT UNUSED UNUSED SEPA UNUSED CS4 KEYPAD 57 SWS CS3 CS3310 CS2 LATCH2 CSKLATCH UNUSED UNUSED I 6 1_ WI4 LL SC Ug B 29 SDA 74HC244 5V UNUSED UNUSED SEL_PREV POWER swi W5 1 WILL o l isiued t ahh UNUSED UNUSED SEL NEXT MUTE L Es I W4 LL W12 L O 1UF 50V 74HC125 o6 9 4 U8 B 5V GNDD ili COL COLO J6 383 SOLDER SDE 383 RI DGND 45V cs4 U7 LTV817 74HC14 U4 D 74HC125 74 14 U4 C 74HC14 U4 E 200 74HC14 04 12 R6 R13 100 CLASSE AUDI
5. August 22 2007 Date CLASS Model Number CAP 100 CAP 150 Class Audio Inc Subject Service manual Class 4 Py 3 Class Audio Inc 5070 Francois Cusson Lachine Qu bec Canada H8T1B3 www classeaudio com Page 1 of 12 PRO SVR_LEGACY 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 Fuses 11 Voltage Change 12 Schematics 13 The contents 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 whatsoever without prior written permission from Class Audio Incorporated PRO SVR_LEGACY Page 2 of 12 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
6. 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 7Q resistor and 10Q 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 the transistor is good 2SC3264 NPN Positive lead Negative lead Result B Conductive B E Conductive Infinite Infinite E B Infinite E Infinite 2SA1295 PNP Positive lead Negative lead Result B Infinite B E Infinite Conductive Infinite E B Conductive E Infinite PRO SVR_LEGACY Page 8 of 12 Calibrations and Adjustments Bias adjustment No
7. 10 10 w 12 3 Rec3 gt e T REG 1 R5 2 2 RI 9912 E b 3 1 1 Kees o AA 0 15 Si AAVN o1 e L 488K 4 4 4 99 o AAA i PHONO INPUTS 4 99K A R2 T ud R 7 42 7 4 99k 5 VEU 4 RLY4 RLY2 A 1E EE 7815UC Q1 O tuF SOV 1 co2 330uF 25V 162 IC3 04 To oT 0 1uF 50V 65 57 c1 C3 1 3 9 9 415 REG 40 gt lt REG_2 2 PHONO 2 2 G m Nene SUPPLY MESH 5 SL R3 3 3 AAA LAAA o2 o o 212912 t n 2 4 488 5 416k HoH R J9 zb 4 99K aa 3 199K 1 e 0 4 EA rl Ff 112 sS o e e 1 15 c6 c8 c2 C4 C12 mm 7915UC Q2 Jm 1K x TAPE OUT BYPASS Sloot bos MUTE qoot 45V BALI REG4 REGS GNDD TLO72ACP REG2 Stools NC AA A I 7 REG1 to NC 1K 6 gt oS E c o S DATED DRAWN CHECKED ECO No REV CLASSE AUDIO INC TITLE DRAWING No BOF1XR02 sheer or 5V 4A SLO BLO RL1 U F1 JW1aEN DC5V L 5 Q1 TIP102 6EF8 TAB2 1 4003 AC RECEPTACLE D1 GND AC1 AC2 1000uF 6 3V
8. ECO REV COMPANY CLASSE AUDIO INC TITLE BOF4XRO2 CAP151 GAIN STAGE PCB DRAWING No 5 OF 1 4700UF 63V C4 4700UF 63V 2200uF 35V 2200uF 35 COMPANY CLASSE AUDIO INC CAP150 DC POWER SUPPLY DRAWING No BOF 5XRO2 IE 12V 12V 12V 12V CON4 A CON3 A C101 2 Lou C201 jC202 aw C106 C206 100uF 35V 100uF 35V Q102 12V TiP102 C105 C205 C 27 R101 A A GNb 17 4K R104 GND 150 SEN R107 Q101 10 R102 21 5K Nine R103 12V 49R9 86K6 C109 R105 R108 C103 7K50 10 CON5 CON6 1 1 eE C204 Q203 0103 TIP107 Sloot 100uF 35V TIP107 m C208 100uF 35V AA 100uF 35V R106 I R206 7 50 107 7 50 MR E 12 12V _ CON2 MAN 1 1 GND GND DATED DRAWN CHECKED ECO REV COMPANY TITLE CLASSE AUDIO INC CAP100 PREAMPLIFIER DRAWING No BOF 6XRO4 sHEETD or 3 U2
9. 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 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 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 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 information 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 PRO SVR_LEGACY Page 3 of 12 4 12 DC main supply DC auxiliary supply AC mains Heatsink Capacitors Remote XFMR Sup
10. 4 8 pals 027 7 026 0 0 50 Pete Dee 707 ADR P5H D24 P4 D23 022 AR L LED 2 021 AR R LED gt gt GNDD P1 020 SEPA LED gt N w w 22 5 5 16 037 TAPE LED ne a 22 spA P5 2T 036 BAL2 LED 53 153 4 SCL P14 His 035 BALI LED GNDD TE ix RAD oe ren MX28 2 032 REG3 LED D5 RED 2 P10 5 031 REG2 LED D4 RED DATED DRAWN CHECKED ECO No REV H CEXT P9 030 REGI LED cu 02 RED 3 3NF 50V 012 01 RED 045 043 042 041 040 E 100 PANEL PCB DRAWING No BOF7XRO5 SHEET Dor 2 3300PF 100V R106 47K5 R108 133K 1 2 15 3300PF 100V R206 47K5 133K 202 o N N a ESS C101 ND ND 5 3 OT LTOUT Loo of GND 101 J103 J102 R203 511 i N 0o x pe 59 N 59 3 ND ND foots of Lo 1 99 RTOUT Loo H ol lo NO J201 J203 420 9202 15V b Q102 or Tie103 B c
11. O R12 383 C7 0 1UF 50V 00 PANEL PCB MEN s 1 2 50 SCL GROUND POT TO CHASSIS CLASSE AUDIO INC pr LEDI pi 016 11 Give 58 88 Pe 013 Dla Ls ADDRESS 76H cous 5V A S 14 Coma A 05 SAA1064 posu 3 13 veg ps p27 1 02 4 G NCS 0 1UF 50V 5 D26 11 L ta 025 172 ADR 5 024 547 11 4 P4 4 D23 0 8 MPS2222 P3 022 510 92 12 9 2 GNDD Lo I 22 DP NC4 25 leo P 5 5 MXIA 2 PS2222 24156 p14 20 035 2 5 LNG 2 P135 He 034 647 gt gt s 03 MXIA MX1 P12 H7 033 518 MSD 5 2 MX2 032 510 cous 59 5 2 P10 H5 0313 1 H CEXT 9 030 141 3 x GNDD GNDD 3 3NF 50V 2047 046 045 J3 GNDD D44 Q4 D43 MPS2222 D42 4 041 040 OH E D17 C D16 VOL2 5 S 5 015 VOL3 5 5 5 014 MUTE1 4 RE 013 2 S 5 MPS2222 ADDRESS 70H D12 MUTES 2 05 5V 2 LB LB LB3 A 06 SAA1064 010 BALZ
12. fuses 4A Classe part number GDB 4A The rail fuses are located on the heatsink board B0F3X Control board fuse 0 75A Classe part number 225 750 The control board fuse is located on top of the supply board B0F2X Mosfet fuses 0 50A Classe part number 225 500 The Mosfet fuses are centered on the heatsink board B0F3X PRO SVR_LEGACY Page 11 of 12 Voltage Change EXTRA PRECAUTIONS SHOULD BE TAKEN WHEN REPAIRING MODIFYING OR FROM MAIN SOURCE AND CAPACITORS MUST BE DISCHARGED USING A 100W TROUBLESHOOTING IN THE POWER SUPPLY AREA UNIT MUST DISCONNECT INCANDESCENT BULB 1 Set the jumper position according to the table 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 Jumper positions main transformer Mains Jumper 1 Jumper 2 Jumper3 Varistor 100VAC A E 221 120 221 220 391 441 240VAC B D 391 441 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 PRO SVR_LEGACY Page 12 of 12
13. m 0 i R12 150 27 R15 GND Q101 19 cng 15 gt LTOUT T R116 100uF 35V 7 50 10 co7 C103 E 330PF 100V B e e 15 0103 C105 TBD TIP107 cus C12 C1H7 C106 1000PF 100V _ R114 7 5 Y 15 15V GND A 15V 4 15 0202 17102 C218 C21 C216 C213 E R212 150 27 R215 GND 10 Q201 C219 Clu ew 15 R213 R216 100uF 35V 7 50 10 207 C208 C203 330PF 100V B e M 15 C205 0203 107 C215 C212 C217 C214 C206 1000 100V e R214 75KO gt 7KS E JAA S D GND 15 Tee1 9 15 DATED DRAWN CHECKED REV COMPANY p6 22 0p CHECKED CLASSE AUDIO INC TITLE CAP151 PHONO PCB DRAWING No BOF 9XRO2 SHEET 1
14. mber 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 BOF1X Complete PCB input BOF 1XR x BOF2X Complete PCB supply BOF2XR x BOF3X Complete PCB heatsink BOF3XR x BOF4X Complete PCB amplifier BOF4XR x BOF5X Complete PCB caps BOF5XR x BOF6X Complete PCB preamp BOF6XR x BOF7X Complete PCB front panel BOF7XR x BOF9X Complete PCB phono BOF9XR x PRO SVR_LEGACY Page 10 of 12 Fuses EXTRA PRECAUTIONS SHOULD BE TAKEN WHEN REPAIRING MODIFYING OR FROM MAIN SOURCE AND CAPACITORS MUST BE DISCHARGED USING A 100W TROUBLESHOOTING IN THE POWER SUPPLY AREA UNIT MUST DISCONNECT INCANDESCENT BULB HOLDING THE FUSES VERY TIGHTLY A LOOSE FUSE HOLDER CAN TRANSLATE INTO T WHEN REPLACING FUSES PLEASE MAKE SURE THAT THE FUSE HOLDERS ARE DISTORTION ON TOP OF THE SIGNAL CAP 100 Main fuses For 100 120v units 4 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 CAP 150 Main fuses For 100 120 units 5 slo blo Classe part number GDC 5A For 220 240v units 4 slo blo Classe part number GDC 4A The main fuse is located at the back of the unit on the rear panel Rail
15. ortion on top of the signal PRO SVR_LEGACY Page 6 of 12 Troubleshooting Guide Symptom Possible cause Unit won t turn on Check connections Check fuses Check soft start circuit Check relays Check power supply circuits positive rail negative rail supply Mosfet 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 supply Mosfet Blown fuses Check for short between fuse and ground Check power supply circuits positive rail negative rail supply Mosfet No output Check connexions Check output relays Check power supply circuits positive rail negative rail supply Check output transistors Mosfet Unit turn into protection Check for smoked and or burned components Check power supply circuits positive rail negative rail supply Check source and load Check protection circuit Check sensor wires between sensor PCB and control PCB Check outputs transistors and Mosfet drivers Mosfet Excessive buzz and or hum Check electrical lines Check for a ground loop in the system Oscillation Check source Check capacitors on main board Check 4 70 resistor Intermittent signal Check connections Replace shield wires PRO SVR LEGACY Page 7 of 12
16. ply PCB Display Block diagrams PRO SVR_LEGACY 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 J 11 Proceed with a post repair visual inspection Take the time to check if every wire is reconnected properly every screw is bolted no soldering and or metal residues lying in the unit every fuse has been replaced etc Turn the bias trimpots counter clockwise until a click is heard Since there is no soft start sequence of the CAP 100 CAP 150 it is impossible to use a bypass to perform a slow start up Connect Main supply and turn on the unit If one or more supply are not within specifications return to the troubleshooting guide If every supply is within specifications report to calibration and adjusments to adjust bias and DC offset Note that bias can be adjusted to 20mV and the following tests can be performed before the unit is send to the burn in bench for a 24 hours warm up Connect the unit to a load and to a source using single ended inputs Perform a test with a 200Hz a 2kHz and a 20kHz tone both sinus wave and sq
17. te Bias adjustment should be made without any load connected to the amplifier s output and no signal connected to the amplifier s input 1 gt Since it is impossible to connect a multimeter to both emitter s resistors in order 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 Connect the positive probe of a millivoltmeter to the test point and the negative probe to the positive speaker post of the channel to be adjusted Turn trimpots counterclockwise until it reaches 0Q A click should be heard Turn on amplifier and let it warm up for 15 minutes on idle Adjust trimpot to get a 20mV reading Let the amplifier warm up for a 24 hours period with signal and load Remove signal and load and reconnect the multimeter Readjust to 24mV 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 12 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 nu
18. uare wave Check the output with a oscilloscope on 4 ohms and 8 ohms loads Take special cares about oscillation and phase correlation between channels Connect the unit to a small speaker and short the input Check for any noise 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 Redo steps 7 to 11 before shipping to the customer PRO SVR LEGACY Page 5 of 12 Protection Modes and Indicators The front LED display shows the status of the amplifier When starting up normally the CAP100 CAP150 will show a FLASHING MUTE LED for about 20 sec However there is no protection on the CAP100 CAP150 The CAP100 CAP150 is equipped with four rail protection 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 cover 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 make sure that the fuse holder are holding the fuses very tightly A loose fuse holder can translate into dist
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