How To Repair A Blown Car Audio Amplifier
At that place have been some changes in the download procedures and a re-write of this page was needed. To simplify for those who take been here earlier, the pertinent information volition exist put at the top. The old page is below. You can click HERE to leap by the brusque version.
This tutorial is for those who are serious about learning to repair car audio amplifiers of all types (course B, class AB, course D). Information technology covers amplifiers made in the mid 80's up until amplifiers being currently produced (2019). Many of the circuits beingness used today have been in utilize for 20+ years. Some of the common class D circuits in utilize today (and covered in the tutorial) date back to about 2003. The material covers overall design and the components/circuits usually used in many of those amplifiers.
One more quick note... If you're going into a field that involves electronic blueprint, especially if sound is of interest to yous, this tutorial is an first-class fashion to connect the dots between the theory taught in schools and the real world. I thought that later getting an instruction that I would be able to look into a piece of electronic equipment and immediately fully understand what I was looking at. It'southward not that straightforward. Sure, the knowledge gained in schoolhouse taught me a lot just certainly left a lot to be learned as it related to pieces of electronic equipment.
- Now to the buy procedure... Instead of downloading from PayLoadz as buyers did in the by, you lot will download from my server. The process isn't as automated and may take a scrap longer (perchance several emails over a day or two) but it will allow me to update the file easier.
- The buyer volition e-mail me (babin_perry@yahoo.com) and ostend that the tutorial is withal available. While most of what I've posted on the net is free, this isn't. The price of the tutorial is $49.95US.
- The buying/downloading process is multi-role as mentioned before. If information technology is still available and y'all want to buy it, two things have to exist washed. The gild in which they're done isn't important but I demand both to grant access to the files. This may have multiple emails simply I by and large respond quickly when I'g available (about 16-xviii hours a day).
- You will send me your IP4 address. For those who recollect they're giving something that could exist a security risk, research it. Your IP accost is known to every website yous visit. They use that address to send the data you requested (the information that makes up the web folio) when yous clicked a link to become to a new page. To discover your IP address, Google ' what is my IP address '. You'll have loads of sites that will tell yous what it is. Bear in mind that this isn't the address that starts with 192.168... That'due south your local router or gateway. Yous demand your public IP4 accost.
- Make the payment via PayPal to my email address (babin_perry@yahoo.com). Ask any questions you have before making the payment to make sure that everything can become as smoothly as possible. For those who feel that this is risky... I've had a presence on the net for a flake over 18 years. On the DIYAudio forum, I have more than 30k posts helping others try to repair amps. Feel costless to read the various repair threads. My user name is Perry Babin. You can even enquire if anyone at that place thinks this is risky.
- You must download to and utilize the tutorial with a desktop or laptop figurer (plug into charger before starting the download) so get the IP from the computer on which you intend to use the tutorial.
- In the by, I've posted the tutorial in .iso format so information technology could easily be burned to a DVD. People no longer use DVDs so I may kickoff uploading as a zipped file. For now, expect an iso file. If y'all use Windows ten, the capability to mount an iso file is as easy every bit a right-click and choose 'mount' from the card. If you lot're unfamiliar with the process, click HERE.
- For a express time, those who purchased the tutorial at any time and tin provide proof that they purchased it, will be granted access to the newest version.
I last thing...
I STRONGLY recommend that you download and apply the Safari browser in the 'browsers' folder of the download folder. It works better than whatsoever of the newer browsers with the Flash files in the tutorial (and there are many). Most all newer browsers cause you grief if you attempt to view Flash content. The older Safari browser works perfectly with those files.
There is an agile customs of car audio amplifier technicians at that place.
This tutorial contains interactive Flash graphics and cannot be fully utilized on well-nigh phones and tablets. If you buy this, you will need to apply it on a standard laptop/notebook or desktop figurer. |
- Introduction:
The information contained in this tutorial is from 30 years of experience working on amplifiers such as those from Rockford, Sony, Autotek, Coustic, Planet Audio, Kenwood, Pioneer, JVC and just about any other make sold in the U.s.a.. This tutorial has information and tips that will help you repair hundreds of different models of amplifiers. It is too interactive (demos allow yous to change the input values on various sample circuits and run across how the output changes). In that location are no service manuals (service information provided by the manufacturer for a given model of amplifier) from any company that are even remotely interactive. Since many amplifier manufacturers offering goose egg tech back up (not fifty-fifty schematic diagrams), this may exist one of the few sources of information to help you repair some models. For motorcar sound amplifiers, there is nothing else similar this at any price.This tutorial contains a considerable corporeality of information specifically related to troubleshooting at the component level. It includes commonly used alternating part numbers for the most common semiconductor failures. If you want to get into the repair business organisation, this disc will provide some very important information. If you are already in the repair business and are interested in repairing car amplifiers, this tutorial tin can help you become started with very little effort. If you are in the repair business, you already know that more and more equipment is disposable (not worth repairing when information technology breaks). Car sound amplifiers are i of the few money making types of consumer electronics to be repaired.
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- What this Tutorial will exercise for Someone New to Motorcar Sound Amplifier Repair:
The data provided in this tutorial volition aid yous to avoid making the most mutual mistakes and volition greatly increase your chances of success. As yous read through this page, you'll realize that the new amps are much more complex and much more difficult to repair than the erstwhile school Rockford and Orion amps that started the car audio revolution. This tutorial makes getting started much easier.
Many people inquire for personal pedagogy to help learn to repair amplifiers. In most all cases it's impractical and would be prohibitively expensive (considering that almost experienced techs charge betwixt $60 and $100 an hour as their base labor rate). Compare the equivalent to 1 hour of a tech looking over your shoulder while you're working on an amp to what you arrive the tutorial. In one hour, you'd likely non even exist able to finish a single repair. During that repair, the tech would be able to requite you a few pointers and perchance a few specifics simply unless you were taking accurate notes (which would cut into that hour), you would non remember much of what you were told. For the cost of the tutorial, you get graphics, conspicuously written notes, a few video clips and many real world examples relating to actual repairs. This gives you the ability to go back and review the information to refresh your memory or to read something you may have missed the first fourth dimension yous read through the material.
The basic repair tutorial (free online) is far more than than you'd get in an 60 minutes of personal instruction and the information there is absolutely insignificant in scope compared to what'southward in the total tutorial.
The tutorial begins at the almost basic level. In that location are suggestions for the types of amps you should start with and those to avoid until you accept a fleck more experience... and advice for amps that you should avoid altogether. For amplifiers with mutual problems, y'all are told what to look for and how to correct the problem and then that the amp is, many times, more than reliable than when information technology rolled off of the assembly line. Of course, the information goes well beyond the basics. For those who are at a more avant-garde level, data and suggestions are provided for some of the largest amplifiers currently on the market. Although this project began in 2002, the information covers many of the amps from the early 80s also as some of the newest amps on the marketplace. The information is continually existence updated to insure that the data continues to be both useful and relevant.
I help quite a few new techs. There are some that take been struggling for more than than a year (sometimes quite a bit longer). It'south clear that some things are not obvious and without the cognition of an experienced tech, the same mistakes are fabricated time after time. From what I see (from those with and without the tutorial), the data in this tutorial tin take at least a year off of the learning curve. Without the information in this tutorial many techs, even two years on, are making plush mistakes that they would have avoided.
Information technology may seem similar I'thou simply trying to increment sales by using using scare tactics. That'due south not the case. In fact, if I believe that someone isn't well suited for this type of work, I'll tell them that they should non buy information technology. As an example, if you 'think' you're interested in doing this blazon of piece of work but couldn't exist bothered to read 100% of the bones repair page online, you are not a good candidate for this type of work. If someone is genuinely interested in learning to do this type of piece of work (either as a hobby or professionally) and they don't desire to learn by trial and error (which more often than not ways lots of expensive, frustrating errors), they can do no better than the information in this tutorial. The circuits in many of the new amplifiers are almost impossible to sympathise without assist and there are very few options when you lot need amp repair information. At that place may be only a few people on the entire planet that are willing and capable of helping you. You can observe plenty of people who are willing to provide unsafe and costly advice merely it takes someone with real experience to betoken you in the right direction.
After the purchase, I will gladly provide support (via e-mail) for amplifiers with which I'm familiar. If you demand help with an amplifier model that I've never had on the bench, I'll provide suggestions to help y'all through the troubleshooting procedure. I'thou generally available more than 12 hours a day. I too help those who haven't purchased the tutorial. If you have a question about a repair, feel free to email me. If yous haven't seen it yet, I have a bones repair information page on my car audio site. THIS is a direct link to the folio. If you need help with a repair, please read that page very advisedly and in its entirety. It will permit y'all to ask questions and nowadays data in a mode that makes helping you every bit efficient as possible.
To the fathers who are interested in auto audio electronics and are struggling to become their sons away from video games, this may exist something that both of y'all can be interested in (particularly if they're only getting a motorcar).
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- Feedback and Samples of my Other Work:
Although I generally no longer sell the tutorial on eBay, I did in the past. If you're interested in what buyers call up most the tutorial, read their eBay feedback Hither.For those who found this page from a Google search and are not familiar with my websites, yous can visit them by clicking the links below. The tutorial is in the aforementioned style as the Basic Car Audio Electronics website just contains a wealth of information related to repairing auto audio amplifiers that is not included on the site.
Basic Car Audio Electronics
Amplifier Repair Primer
Amplifier in Protect Fashion - Troubleshooting
Shield Ground Testing for Head Units
Basic Calculator Operation Tutorial
Basic Macro Photography Tutorial
Air Rifle Links and Demos
Basic Get-Kart Mechanics
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- Test Tones CD:
Only available with tutorial purchase.Back To The Carte
- Updates:
Due to significant health bug, I was forced to retire. At that place will exist no more updates. The final update was in 2019. At that place is data on amplifiers from the 1980s upwards until many currently being produced. Many of those designs have been in use for years and volition continue to be used in newer amps. Typically, amps are updated externally but use tried and true designs internally. Information technology's sort of like a machine engine. They don't design a brand new engine from the block up for every new year model.Old text:
I will no longer listing every new detail in the updated version of the tutorial. Realize that most amplifiers in beingness are using designs from well earlier the last update of this tutorial. More updates are coming just don't let the date of the last noted update brand you believe that information technology's obsolete. The IC that's used in MANY of the largest amps on the market place was released in 2006. Virtually no amps on the market employ technology that hasn't been in use for at least 10 years.Dorsum To The Card
- Previous Updates:
The following listing of updates will give you an idea of what's in the tutorial. If you have questions about specific information regarding the content of the tutorial, feel gratuitous to electronic mail me.December 2014 -- Updated! - At to the lowest degree five of the Tech Tips pages accept been improved or have new content.
- More information on course D amplifiers using the HIP4080 has been added to the Basic Grade D Troubleshooting folio.
- New substitute parts take been added for some hard to find parts.
- The general notes pages for the MTX and Kicker amps likewise as the MTX 7801 and 81000 have been updated
- On the Ability Supply Troubleshooting page, data for the Pioneer PA2027A has been added. This IC has been disruptive for a lot of new technicians, mainly considering the internal circuitry is rarely provided in most Pioneer service manuals.
June 2014 -- Updated! I don't mostly list updates and there accept been many betwixt 2011 and 2014 that are non listed but I decided to list these because some were fairly significant, especially those for several types of class D amps. Most of these updates were produced between January and June of 2014.
- If you repair the older BD blazon amps (BD1000A1 and similar), there have been significant updates with regards to simpler troubleshooting. The information allows y'all to troubleshoot with piffling or no hazard of dissentious components if you make a mistake. The troubleshooting is much more than footstep past step than it was before.
- For the relatively new amps like the T1500-1bd, new information and troubleshooting techniques. These allow you to exam the drive circuits with about no chance of causing impairment to the output transistors if in that location is some un-expected problem with the drive circuit.
- There have been significant updates to the Bones Class D Troubleshooting page. Significantly more than information has been provided for the protection circuits as well as other troubleshooting. This applies to many of the Hifonics and similar amplifiers that use the HIP4080 driver IC.
- Many of the graphics (static and interactive) accept been updated/replaced/added. Many brand it easier to sympathize the related text.
- Many of the various Tech Tips accept been updated. Some new ones added.
- The older Rockford amp page (former style punch 45/150, etc...) has been updated with new, cleaner graphics as well every bit other data.
Like the rest of the data included in this tutorial, you won't find data like this anywhere else. Near of the information yous find on diverse other sites (especially those with videos) is incomplete and can oft lead to more impairment than was present initially.
Dec, 2011 -- Updated! - A new type of course D amp is added to generic class D section. The new page is Generic Course D - Type seven for those who already take the tutorial. This blazon of form D is particularly decumbent to failure due to the high operating temperature of the components on the audio driver board. The page shows the parts that fail and shows the components needed to make a heat spreader to reduce the operating temperature of the two drivers that get so hot (under normal operating weather) that they volition impairment the board. The materials used are quite hard to notice if you don't know exactly what to await for. It besides gives an overview of the fashion the power supply voltage is produced for the driver board.
- I've found that certain pages continually demand to be referred to by myself and buyers. To arrive easier to get to the most commonly referred to pages, I've added a quick-link directory above the rest of the directory items. These include links to all of the class D and tech tips pages in the directory too as the sound and power supply troubleshooting pages.
- The bones course D troubleshooting folio (which covers a wide range of amplifiers) has had quite a few updates including more than clarifications/specifics, additional content and new graphics.
- The vintage Orion amp page has been updated to prove one common blazon of harm done past new techs and how to make the repair of the damaged surface area reliable if you happen to see this type of damage. Boosted information is provided to show how to quickly remove the blue insulator cloth from the backs of transistors without making common mistakes that will lead to more impairment.
- The Vintage Rockford page has too been updated to better help those who are trying to get their old school amps working once more. For those who accept purchased replacement driver boards for their old DSM amps and tin't determine which way to install them because they look completely different, a new image shows you precisely what to look for on the two boards (old and new) to get them properly installed. For those who take amps with broken bass and treble pots and cannot detect replacements, a new image has been added to bear witness the value of the resistors and how to install those resistors in place of the cleaved/missing treble pot. The amp will operate perfectly fine without the bass pot but will self destruct or destroy speakers if the treble pot is missing.
- A section has been added to show how to view waveforms using the scope in differential way. This is very useful when y'all accept a waveform with relatively low amplitude that's biased with meaning DC. This is NOT the same equally switching to AC coupling. This is on the Tech Tips 8 page. Other data has besides been added to that page.
- The Checking Semiconductors has been updated to better explain the transistor/semiconductor testing process.
- New techniques are shown to desolder solder pads in tight locations when you desire to supercede an IC or other component from the elevation of the board. This helps prevent burning adjacent components (most often capacitors). The burning of the capacitors isn't often a problem but it looks bad and can be avoided. Many techs would say that it's best to remove the entire amp from the sink and replace the component by desoldering/soldering from the bottom of the board merely that's impractical on amps that take hours to detach and reassemble when but a single op-amp needs to be replaced.
- More information about a different version of the Form D - Blazon 2 amps. This is 1 of the most popular cloned circuits and is used in many thousands of amps that have been produced. This is a new lath and layout and it has its ain (new) listing of problems. This page has had other updates also regarding the older boards. Information technology seems that these amps have a never-ending list of issues and without knowing what they are, the amps volition boomerang on you lot virtually every time yous repair 1.
- The Concluding Blocks folio has been updated to provide more information/help when dealing with melted terminal blocks. This is a very common problem and if yous don't take whatsoever experience or guidance when repairing them, they can be very time consuming to repair. Replacement blocks are typically VERY difficult to get and repairing a block, fifty-fifty if its housing is a bit melted/distorted, is meliorate than running wires out of the amp (in well-nigh cases).
- The oscilloscope page has had some updates including new graphics and content. Since many people that apply the basic repair page online needed this data, most of the information is available on page 73 of the site (page numbers won't testify up in Chrome or Safari just will evidence up in Firefox and IE).
- Other minor additions...
- Getting contact cleaner into potentiometers that don't accept whatsoever credible openings
- Taking voltage readings on ICs that are mounted on vertical boards and can't be probed with standard probes
- Determining whether a board has more than than ii layers of copper and finding openings in the inner copper (in instance you need to drill into the board)
July, 2011 -- Updated! - Much of the new information that has been added recently is from questions that I receive via electronic mail and from the car sound forum at the DIYAudio.com site. Afterward doing this piece of work for as long equally I accept, it'south easy to take for granted that those new to repair will sympathize certain points. For almost any question that I've seen more than than once, I've included information that clearly answers those questions.
A few examples...
- Drivers were mentioned and most people understood them merely there were enough that remained somewhat confused then I added quite a fleck of information on drivers and provided several case with photos.
- Disassembly and cleaning of potentiometers was covered because it tin can be useful and isn't something that's intuitive. I thought cleaning potentiometers (without disassembly) was obvious only it appears that it wasn't and so I've added a department that explains how to make clean diverse types of potentiometers without disassembling them.
- The removal of spring-clips was covered but I didn't cover getting the really stubborn ones off. That'south now included.
- Some terms accept been better divers and a few more than added at the beginning of the tutorial. Virtually all were introduced when they needed to exist only it seems that it'due south ameliorate to introduce some of them earlier. This seems to aid some of those new to repairs.
- More information has been added for those who don't yet have a scope to aid them to better sympathise what their meter is telling them.
These are only a few examples of the new content. Some new graphics have been added and some images were replaced equally better examples became available.
November, 2010 -- Updated! - A new page has been added to help introduce head unit repair. This page includes a number of tips to help you lot avoid costly mistakes. Head units are very fragile compared to amplifiers and simple mistakes tin cost $50 or more than to resolve. It currently covers ribbon cable replacement, power amplifier IC replacement and several other common repairs.
- A tutorial for a relatively new type of form D amp has been added. This is Class D - Blazon half dozen for those who already have the tutorial. The page includes voltages and waveforms (like the pages for other types of class D amps).
- Additional information has been added for amps that use multiple ability supplies (both in serial and in parallel configurations).
July, 2010 -- Updated! - Once again, there have been lots of small updates and improvements. Boosted data has been added to many of the pages. Several new pages have been added, including the new switching power supply design tutorial (which covers the actual pattern of a power supply suitable to power a machine sound amplifier). Since and so many aspects of amp repair have been covered previously, at that place are unlikely to be any significant additions unless a new type of amplifier is introduced. Most of the changes will be minor (but useful) updates that continue to make this tutorial as good equally it can possibly exist.
December, 2009 -- Updated! - Equally usual, there take been lots of small-scale updates and improvements. Approximately 40 pages have been edited to brand them better (including more images).
- On the power supply troubleshooting page, more data has been added that shows multiple transformer configurations (some of which are only now being introduced in the newer amps).
- On the Checking Semiconductors page, graphics have been added and improved to make them more articulate. Additional text has also been added to make it easier to understand the process of checking transistors.
- On the Amplifier Basics pages, there are improved graphics as well as boosted data.
- On the Basic Class D troubleshooting page, additional information has been provided covering the over-current protection circuit used in many of the class D amps.
- An entirely new page has been added roofing a type of class D amp that has non previously been covered. This is a relatively new pattern and not much is available elsewhere for it.
- The items above are just a few of the improvements made in the last 6 months.
June, 2009 -- Updated! - There have been many updates since September. Here are a few of the more of import ones.
- I've added a page to help troubleshooting the class D amps like to the Massive 1500 and 3000 that are so popular. The information includes waveforms and instructions to test the excursion with and without the output transistors in the circuit. This can be very helpful if you lot accept an amplifier that'due south cartoon excessive current.
- A new page has been added that shows how to brand an inexpensive heater/pre-heater that tin make removing SMD electrolytic capacitors much easier and reduce the chance of damaging the solder pads. This is especially helpful when working on boards with a high density of components. This page also introduces you to using solder paste.
- More information has been added for the course D amps with the numbers machined off or encapsulated in epoxy (including information on how to safely remove the epoxy to allow replacement of the ICs under information technology).
- More than data has been added to show you how to repair badly damaged boards. Information technology includes data on the best blazon of fillers to repair holes (when necessary).
- A section has been added for rewinding transformers. Many times, the power transformer will short and the windings will exist burned. Sometimes it'southward as elementary as removing the onetime wire and re-winding it. Sometimes the core is damaged and isn't usable. I've provided sources for both the magnet wire and the cores and suggestions for the type of core material you lot'll demand to select.
- More than data on protection circuit troubleshooting has been added. This seems to be 1 of the nearly difficult types of bug for new techs.
- Many times, an amp will have water impairment that will crusade damage that's well-nigh impossible to encounter. To make it worse, the manufacturer of the amps that near commonly have this problem will provide absolutely no tech back up. A section has been added to tell you what to look for. The signs of damage are very hard to meet until yous know precisely what to look for.
- Many amps have last blocks that tin can't be readily soldered. I found a solution and show how to make the blocks solderable. This is becoming a bigger trouble as these types of terminal blocks age and the solder connections begin to fail.
- More than 800 files accept been updated since September. Many of the graphics files were replaced with better ones or cleaned up. About all of the text based pages in the repair section take had some information added or have had sections re-written to make them meliorate.
September, 2008 -- Updated! - I've added more parts suppliers and boosted resources to find parts. This helps salve time when looking for replacement parts.
- I've added to the list of Tech Tips including a department on rewinding failed power transformers. Information technology includes sources for the wire and cores. If yous have to rewind or replace a transformer in an amplifier this will make the chore much easier.
- I've expanded the page dedicated to terminal blocks. Almost people don't call up about the final blocks when repairing an amplifier. Many times, the blocks are damaged so badly that they're not usable. About are not available from the manufacturer. If yous repair an amp with damaged terminal blocks (something that's not always obvious) and y'all don't have the cognition to repair the blocks, yous've wasted your time repairing the electronic faults in the amplifier. Of grade, I've added new amps with the screw sizes. Some of the other improvements are better graphics and more detailed information about obtaining replacement screws.
- I've expanded the section that shows y'all how to produce reliable repairs on badly damaged circuit boards. If you work on onetime school amplifiers, this information tin can help you make repairs that will be very reliable.
- To make troubleshooting easier, more information showing the voltages on the pins of various ICs have been added. This allows you to confirm that the voltages in the amps are as they should be. This is something that will continually expanded in the future.
- Fifty-fifty more than data has been added for class D amplifiers. As always, I try to keep the information as upwardly to date equally possible. This information pertains to many of the amplifiers that use the sound driver boards with the defaced driver ICs.
- Since March, more 100 pages have been updated in some way. More than 300 graphics files have been added, replaced or improved in some manner.
March, 2008 -- Updated! - Lately, I've been working to brand the tutorial more user friendly. Many of the about contempo updates involve linking relevant pages to the text. I've besides been trying to clarify data to meliorate arrange those new to repair work. I utilize questions from buyers (and others who I help with amp repairs) to make the information easier to understand.
- I've added markers to pages that prove yous the information yous should print and keep handy while working on the start few amps. These 'crook sheets' will assistance y'all troubleshoot the most common faults.
- Of class, I've added new data. New applets, as well as lots of new graphics showing examples of various problems and solutions. Approximately 400 graphics files take been added or modified/improved since the last update. In some cases, I've replaced older, smaller graphics with new or resized graphics. Some of the original graphics were designed when 800x600 was a commonly used screen resolution. The new, larger graphics allow you to see much more than detail at higher screen resolutions.
- A new folio has been added to help yous clean really noisy potentiometers. Many of the potentiometers are very difficult to obtain as replacement parts. This will help you salvage some of the potentiometers that are non readily available. This goes well beyond spraying contact cleaner into the pot and turning it. It also explains how things other than a dirty resistive rails can cause problems.
- I've added more data on course D amps. Some of this information covers a relatively common problem with one blazon of course D driver board. This is a trouble that took quite a bit of time to find initially but has saved many hours of wasted time for other amps with similar bug.
September, 2007 -- Updated! - For many of the amplifiers being produced in China and Korea, the manufacturers will not provide schematics (they probably don't want you to know that they tin can't/don't design their own amplifiers). Fortunately, MANY of the manufacturers use precisely the same circuits. If y'all've ever been to the ampguts site, you've no doubt seen how many of the amplifiers use precisely the same board (this is specially true for class D amplifiers). I've collected several schematics that cover nigh of the Chinese/Korean amps and I group them together so you tin can come across which schematic to use for a given type of circuit. The schematics won't always lucifer 100% but in most cases, they make information technology MUCH easier to troubleshoot the circuit.
July, 2007 -- Updated! - I've significantly expanded the information provided for one of the ii well-nigh commonly used class D amplifier circuits (multiple manufacturers use the same PWM drive and output circuits - Kicker, Orion, JBL, Memphis...). The information includes waveforms from virtually every signal in the PWM generation/output circuits.
- For those with minimal skills when working with metal, I've included an entirely new section. It shows tools (and the use thereof) that are required when in that location are issues with the heatsink or when you need to produce new clamps (for missing or melted clamps). This doesn't happen often but it'south good to know. This is a companion to the MEHSA replacement tutorial I added last calendar month.
June, 2007 -- Updated! - I've added a page detailing the replacement of the MEHSA insulators if you'd like to do away with them. The section includes relatively detailed instructions on making the replacement clamps. I tell you lot how to accurately measure out the altitude betwixt centers for the mounting screws (holes have to be drilled in the clamps). I suggest some free cad software to aid you lot in the process. I even show you the finished clamp on an 800a2. This too comes in handy for amplifiers where someone has broken off a screw in the sink. In this case, they had tried to remove information technology which fabricated it too much of a mess to try to repair. A new, heavy duty clamp (fabricated to use sufficient pressure to the transistors adjacent to the missing screw) got the amp dorsum into service reliably.
- I've added at to the lowest degree one example of an amplifier that had a badly damaged lath. The repair on information technology left it stronger than information technology always was and in that location was niggling evidence that it was and so badly damaged. This was one of the times when it was of import to have some mechanical bent to get the job done.
Apr, 2007 -- Updated! - I've added a significant amount of new information about special/unusual resistors and capacitors. This includes information on how to read their values and what the markings mean.
- I've added a page that offers several solutions for customers who repeatedly burn down the RCA shield on their head units. Open shields on the signal source can crusade some amplifiers to fail. This volition salvage you some headaches with certain types of problem customers.
March, 2007 -- Updated! - I've added a new page giving suggestions on making ultra reliable wiring harnesses for the workbench. Information technology's vitally important to be able to trust your test equipment. This includes the demote wiring. Some of it takes a beating. The tips I provide will insure that you don't have to continually repair the cables y'all use repeatedly all day long.
- The 'Terminal Blocks' page has been expanded to prove problems and solutions for damaged blocks besides as piece of work-arounds for blocks that use screws that are essentially unavailable. This will be very helpful if you accept i of these amps for repair and the screws are missing or damaged across use.
- I've updated/expanded the data on several of the class D troubleshooting pages.
- Of course, I've added new photos of amplifiers that assist identify missing or burned components in the amplifiers.
February, 2007 -- Updated! - I've updated and expanded the page showing how to check most common semiconductors. This includes new graphics and more detailed instructions.
- I've added information on the sizes of the last block screws for the most common amps. The data includes bore, thread pitch and length. For amps that employ similar terminal blocks, I've included photos then you can match them up. Many times, the screws used in terminal blocks are not bachelor locally. This information will allow y'all to lodge the right replacement screws the first time (no guessing at the size and thread-pitch).
- I've included the instructions for making jumpers for the JL 500/i amp. These permit yous to separate the two boards then y'all can check waveforms and voltages on the components betwixt the boards. Without these jumpers, y'all have to separate the boards, solder a wire to the test betoken, plug the boards back in and then take the measurements using the jumper wire. The jumpers allow you full admission to the surface area between the boards.
- The power supply troubleshooting flowchart has been expanded. It covers more defects and provides more tips to aid make the repair more reliable.
- If you've worked on MTX amps, y'all've noticed that the power supplies are very dissimilar from most other amps. A new section has been added to prove the differences (including waveforms). It also tells you lot how the MTX amps operate differently in the way they switch the PWM drive output on. Much of this information also applies to Sony class D amps as well as some of the Xtant amps.
- In many sections, I simply showed the schematic symbols for diverse circuits. Now there are more photos of the components on actual circuit boards. For example, in that location are most 5 different types of voltage regulators used in various amplifiers. For each one, I provide a photo of the regulators in an amplifier. This will help you to more than rapidly identify the circuits when you're troubleshooting a trouble.
- The 'Amplifier Nuts' folio has been expanded including more item and graphics to help those who are new to amplifier repair.
- The 'Repair Introduction' page has been expanded. Now there is more than information on the means diverse components neglect and the problems they cause.
- New links have been provided on many pages to aid y'all find the information yous need more quickly and more easily.
December, 2006 -- Updated! - Well over 400 new files and photos have been added or updated since Oct. The updates on the repair notes include several issues that can exist tough to find. At this bespeak, in that location are more than than 3000 photos of amplifier circuit boards (not 3000 different amps). These are very handy when you receive an amp that has missing parts or parts burned beyond recognition. Many manufacturers volition not provide any information about their amps so you either accept to find another amp of the same model or gauge at the values. I've also added two new video clips.
Oct, 2006 -- Updated! - I've added a folio showing many of the mutual problems and solutions for one of the virtually common grade D amp designs (used past several different manufacturers).
- More video clips take been added (more than 30 video clips at this time).
September, 2006 -- Updated! - More data has been added to assistance in repairing older ('BBQ' pit style amps). This covers a lot of the other Rockford amps also.
- More video clips accept been added.
- A new interactive op-amp demo has been added to help those who don't understand the various op-amp circuit configurations.
August, 2006 -- Updated! - Recently I've been calculation small video clips that bear witness common repair procedures. The following is a partial list of the types of procedures shown:
- Replacing surface mount components (transistors, resistors and ICs)
- Removing/replacing spring clamps
- Removing the types of transistors that are soldered to the insulators
- Other miscellaneous, just important tasks
July, 2006 -- Updated! - I've added a new page defended to helping buyers to empathize how a scope is used for quick troubleshooting. The folio includes notes on the various test points including what they should run across and what to look for if the proper indicate isn't present.
- More than than 300 files added, edited or modified this calendar month alone.
June, 2006 -- Updated! - I've added a folio dealing with repairing amplifiers that take thermal harm to the circuit boards. Many times, the copper foil traces will exist damaged when an amplifier fails. This is very common in the power supply section. This new page takes yous through one such repair.
- A new page helps you to more reliably repair amplifiers that accept concrete damage. This page tells you how to perform repairs that will produce very reliable repairs. This is especially helpful for single sided circuit boards.
- I've added a new page that helps you to more efficiently troubleshoot problems in the power amplifier phase of an amplifier. This includes data for troubleshooting inside the feedback loop where discrete differential amplifiers are used.
- An unabridged page is now defended to the replacement of power transistors that are soldered in place. These are used in amplifiers from Rockford, Pioneer and Digital Designs. The page takes you lot through a repair where the previous repair was non properly performed. It shows y'all how to prevent making the same mistakes as well as tips to brand the repair as reliable equally possible.
- In that location have been updates to both the Equipment and Tech Tips pages. Minor revisions accept been made to other pages as well.
March, 2006 -- Updated! - The tutorial includes relatively high resolution images of the internals of more than 100 amplifiers. The images can be used to determine the values of burned or missing components or only to help familiarize yourself with the layouts of different amplifiers. Co-ordinate to a search of the folders with amplifier images (I didn't count them), there are more than 1500 large, high quality images (500kB-1MB per image file).
- I've at present begun to add waveform images for both the sound and power supply sections of both linear and form D amplifiers. Some of the waveforms are an overlay on the schematic. Others betoken to points on the circuit board (IC and transistor terminals/pins generally). Virtually of these are in flash format. This allows me to include many loftier resolution waveforms. You lot simply zoom in to conspicuously see the waveform of involvement. In that location are also waveform images that are named and so that you know what they are (those are in the folders of the corresponding amplifier). There are more than than 300 waveform images as of now.
- I've also begun adding more descriptions of repairs and the troubleshooting procedures. Some of the repairs were simple and some were very circuitous. For those only starting with this type of work, this will be very helpful.
- For those who practice non all the same accept an oscilloscope, I've added images that show the waveform and the equivalent DC voltages (every bit they would read using a digital multi-meter). I have values/images for all pins of the HIP4080, the TL494/594 and the SG3525. Even if you lot have a scope, these are helpful to allow you determine whether the waveforms you accept are right or non. Most all of the scope images show the vertical amplifier (volts/div) and timebase (fourth dimension/div) settings so that you lot at present how to fix your scope. Some of the images show the entire face up of the scope (and all of its controls). Others testify the waveform on a scope that displays the values on the CRT.
- I've included more datasheets with suggestions for stocking the most common parts. The datasheets included include power transistors (FET and BJT), op-amps, regulators, muting transistors, driver ICs and more. Nearly 100 are included every bit of at present. These can generally be downloaded but it's quicker to grab them from disc than to find them on the internet.
- A new page helping you to better/more efficiently utilise your meter when testing components.
- I've added 2 new pages that help those who are completely new to electronics and/or repair work. 1 includes descriptions of various components including quick-links to more detailed information (also included on the tutorial disc).
July, 2005 -- Updated! I've added more information to help ease newbies into the technical aspects of the tutorial. I've likewise updated information technology to include all of the actress material (test questions, applets and demos) that are included on the full version of the site CD.
- Protection Circuit troubleshooting with 4 new interactive demos
- Interactive audio and power supply troubleshooting flowcharts
- It contains...
- Troubleshooting basics chapter to assist those who are new to electronics including v new interactive demos (January 2006)
- Protection circuit troubleshooting with 4 new interactive demos
- Interactive audio and power supply troubleshooting flowcharts
- Audio troubleshooting basics with an image or two of audio waveforms
- Basic excursion diagrams for different types of output transistor configurations
- Class D nuts with data about the HIP4080 driver IC including:
- Pin out descriptions
- Typical power supply configurations
- Typical op-amp supply voltages for unlike types of power supplies
- Drive output diagrams
- Suggestions for setting upward a workbench for repairs
- Suggestions dealing with customers and reducing headaches when dealing with them
- Images that testify the location of diverse parts (output transistors, power supply FETs, rectifiers, thermistors...) on various amplifiers.
- Tech tips and basic troubleshooting suggestions (more 80 different tips to help you salvage fourth dimension, endeavor and money)
- Schematic symbols used in amplifier schematic diagrams including:
- Resistors
- Potentiometers
- Diodes
- Bipolar Junction Transistors
- N-Aqueduct Field Result Transistors
- P-Channel Field Issue Transistors
- Junction Field Effect Transistors
- Suggestions for specific tools (desoldering pumps, irons, screwdrivers...)
- Power supply design/operation nuts with actual oscilloscope waveform images
- A very detailed caption of the most popular power supply driver IC (TL594) including interactive Flash demos showing:
- Comparators
- Fault amp input and dead time command
- PWM comparator performance with 3 inputs (all interactive)
- PWM comparator operation with 4 inputs (all interactive)
- Lockout voltage and regulation
- Tips on getting an amplifier's ability supply to come on when the amplifier continually goes into protection (this is very helpful)
- Bones power supply schematics with 3 different types of power supply MOSFET driver circuits
- Information nearly different comparators used in power supply protection circuits
- Information almost thermal protection and the types of devices used in those circuits
- Links to some of the near popular replacement parts datasheets (including some hard to detect datasheets)
- Common parts package outlines with pin configurations including:
- TO-218 Transistors
- TO-220 Transistors
- TO-92 Transistors (both Japanese and American types)
- 14 Pivot quad op-amp
- 8 Pin dual op-amp
- 9 Pin dual op-amp with power feed-through circuit
- Circuit board layout information including:
- Foil layout and component orientation
- Silk screen definitions
- Internal cake diagrams of the 2 most popular op-amp configurations
- Common op-amp circuits used as buffers, inverting amplifiers and not-inverting amplifiers
- Information on negative feedback circuits using detached differential pairs or op-amps
- Data about 4 different types of voltage regulators found in amplifiers including:
- Simple shunt regulators
- Current boost shunt regulators
- Fixed regulators
- Resistor-programmable regulators
- Basic description of 2 types of muting circuits
- Relay muting
- JFET muting
- Data about the generation of higher_than_rail drive voltage for common collector amplifiers
- Notes on the equipment needed for repairs
- Power supplies (pictures of both linear and switching power supplies)
- Dummy loads
- Voltmeters - The following DMMs are shown on the tutorial.
- Fluke 77
- Fluke 79
- Fluke 27
- Fluke eleven
- Fluke 112
- Oscilloscopes:
In the tutorial, I cover a pregnant number of oscilloscope features and give quite a few suggestions for ownership a used scope. As of at present, virtually every feature that yous'll need is shown and explained. I fifty-fifty show some advanced features that are not necessary but are available. Some of the scopes were purchased on eBay and for those scopes, I tell you approximately what they price and/or what you can expect to pay.
Besides included are high resolution images of the internals of more than 100 amplifiers (3000+ images). For someone who isn't familiar with the various amplifiers on the market, the photos volition show them what they might encounter. Many times I utilise them as a reference. If an amp has missing components or components that are burned across recognition, I tin refer back to the photos to determine what I need to repair the amp. Even if the exact amplifier that you need isn't available, there may well be 1 that'southward similar enough to be of help. There are many amplifiers that utilize very similar circuits. Many times, the only divergence is the way it's laid out on the board. The photos more often than not include 1 overall image of the amplifier. Then each section (power supply drive, audio bulldoze, preamp...) is photographed to allow you lot to see the fine details. In general, the resolution is high plenty then that the values of tiny surface mountain components (frequently simply 0.05" wide) tin easily be read.
Back To The Menu
- Updates:
- Cost of the Tutorial:
The price is $49.95US. If it only included all of the information listed above, information technology would be a bargain but information technology includes far more than than what's listed. Since the boilerplate labor charge to repair an amplifier is ~$40-$70, it will have very little fourth dimension to recover the cost of this tutorial. If you have any questions, Email me.Before purchasing the tutorial, you should sympathize the following. Please read advisedly. This will aid make this a pleasant transaction for both of united states.
- Notes:
- All prices on this folio refer to U.s. dollars.
Back To The Card
Delight read the following section very carefully if you're because buying the tutorial as a download. Treat EVERYTHING between this text and the button used to order the download version of the tutorial as if it is in bold cherry-red flashing text. Everything is that important to accept a trouble-free transaction
- This download is almost certainly going to fail if you lot try to download to a mobile device. The tutorial was written starting 10+ years ago and the format is designed to exist used with a laptop or desktop figurer with a mouse. It'south essentially unusable on a pocket-sized brandish using finger swiping/selecting.
- This tutorial volition work on Windows and Mac computers. If your estimator works on my BCAE1.COM site, it should have no problem with the tutorial.
- Browser Problems and Missing Images... In recent years, the back up for Flash content has inverse from one source to multiple sources. The effect is that non all browsers handle flash content equally they should. If this happens in your preferred browser, correct-click the link for the page in the directory on the right and select 'open up in new tab' or 'open in new window'. When opened outside of the frameset, the flash content should load properly. You can endeavour this on the bcae1.com site if you don't quite sympathize how it will work.
- You lot should have a static IP address (not absolutely necessary but information technology tin prevent bug associated with the download). If you don't know whether you lot have a static IP or not, click HERE. Note the IP address. Restart your computer. If you have the same IP address when yous bank check it a 2d time, yous likely accept a static IP address.
- If you don't have a fast internet connection It may impractical to download this file. It's 4GB+ and will have a day or more if you're trying to download it on a slow connection.
- Remember, fire a re-create to a DVD or buy a couple of small, cheap wink drives to shop fill-in copies. If your computer crashes (hard bulldoze failure, etc...) and the copy you lot downloaded is lost, having information technology on a DVD means that you'll be able to reinstall the files at no cost.
Begin Installation Instructions Basic process, expanded with images below:
Download
Unzip (will consequence in iso file)
Mount iso file
Open new drive produced in 'my computer' (or whatever its' called now) when you mounted the file
In the 4 files seen when you open the new 'drive', open the alphabetize.htm file and read the instructions in the showtime paragraph
- The file yous download is a 'zip' file. You will take to unzip that file. The unzipped file will exist an 'iso' file.
This is what you'll have later you've unzipped the file:
- To read the .iso file directly from your difficult drive (after unzipping), you lot will need to 'mount' information technology. For win10, you can right-click and choose mountain. For earlier versions of Windows, use Virtual CloneDrive. After installing it, right-click the .iso file and select 'mount' from the dialog box. From that signal on, the tutorial will show up equally a new drive on your computer. You can access it like whatsoever other drive. Showtime by double-clicking the 'index.htm' file. Bookmark that file in your browser.
Note:
It appears that slysoft has gone out of concern. You lot can still download the software recommended to a higher place past going to majorgeeks.com.When you mount an ISO file, information technology adds what appears to be another/new drive to your figurer. Beneath, I had no 'H' drive. That'southward the ISO file later it has been mounted. If you lot open up that drive, yous will see the iv files, not the ISO file.
Later mounting, the computer should bring upward a dialog box asking what you lot want to do. Choose 'view files'.
After choosing to view the files, you volition encounter a list of 4 files. Open up 'index.htm' in your browser.
The following is what you should meet when you open the index.htm file. In the first paragraph (please read all of that page (that was a waste of fourth dimension typing that)) there is a link to the tutorial'due south chief page.
This is the folio that you will bookmark.
- Running the tutorial from the ISO file results in good functioning simply information technology could cause some issues with bookmarked pages or folders pinned to the menu on the taskbar. At that place is a workaround that takes a few minutes to set up (mainly waiting on the computer). Later mounting the ISO file, open the newly created drive (created when you mounted the ISO file) and copy the 4 objects (i binder - repair_tutorial and 3 files) to the same newly created folder you made when you unzipped to ISO. From that point, you lot will not accept to mountain the ISO because you lot can bookmark or link directly to the files. Doing this, the bookmarks won't be lost. The repairtutorial.htm file is the tutorial. You'll want a shortcut to this file on your desktop. I'd also suggest pinning the semiconductor datasheets and the miscellaneousstuff folders to the taskbar. If you regularly go to the Rockford, Kicker, whatever folders, pin those as well
- If you accept any questions about this tutorial, email me before you lot effort to download it.
Source: http://www.bcae1.com/repairtutorialcdinfo.htm
Posted by: hyltonfrivis99.blogspot.com
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