Dja2500 - 4000 Service Manual PDF

STUDIOMASTER PROFESSIONAL SERVICE MANUAL
DJA2500/DJA4000

AUDIOPLUS: A1, A2, GIRIRAJ INDUSTRIAL ESTATE, MAHAKALI CAVES ROAD, ANDHERI (EAST),
MUMBAI-400093, TEL No: 022-30880743, 30880749, 30880757.
Web site:- www.audioplus-india.com, www.studiomasterprofessional.com E mail:- support@audioplus-
india.com
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TABLE OF CONTENTS
• INTRODUCTION ………………………………………………………………..…….4
• TOOLS & EQUIPMENTS REQUIRED………………………………………..………5
• SPECIFICATIONS………………………………………………………….…….…….6
• SAFETY INFORMATION……………………………………………….……….…….7
• AMPLIFIER BLOCK DIAGRAM……………………………………..…….………….8
• AMPLIFIER WIRING DIAGRAM………………………………….…………….……9
• DISASSEMBLY/ASSEMBLY PROCEDURE………………………….……….….. ..11
• TEST PROCEDURES…………………………………………………….…………….17
• COMPONENT PIN CONFIGURATION…………………………….…………………26
• TROUBLESHOOTING & FAULT CHART……………………………………………27
• SPARES LIST ……………………………………………………….…………………29
• PCB LAYOUTS…………………………………………………………………..…….30
• SCHEMATICS WITH AC & DC VOLATGES……………………………………..….34
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INTRODUCTION
The information presented in this manual is intended for competent technical personnel to carry out service and
product support for the Studiomaster Professional DJA series Amplifiers who is familiar to these amplifiers and
who has knowledge related to electronic theory, and is able to carry out servicing, fault finding and repair of this
amplifier series.
WARNING:
- Failure to follow appropriate service and safety procedures when servicing this product may result in
personal injury, destruction of expensive components and failure of the product to perform as specified.
For these reasons, we advise all Studiomaster Professional product owners that any servicing required,
should only be performed by an authorized Studiomaster Retailer or the appointed service
representative.
- There are potentially dangerous and lethal voltages present within the power amplifier, and it is the
responsibility of the technician to exercise common safety practices to protect himself, his co-workers
and the end user.
• Turn the unit OFF and remove mains cable from mains socket during disassembly and parts
replacement.
• In particular, always exercise caution when working on an amplifier with the cover removed. Do
not leave it unattended if it is still connected to the mains supply.
• Never expose the amplifier or your test equipment to rain or moisture or an environment where it
may be splashed by water or other liquids and also never work on an amplifier with wet hands as
doing so may cause electric shock.
• Recheck all connections before power supply has been turned on.
IMPORTANT:
- The presentation or sale of this manual to any individual or firm does not constitute authorization,
certification, recognition of any applicable technical capabilities, or establish a principal-agent
relationship of any form.
- The data provided is believed to be accurate and applicable to the units indicated in this manual. The
research, engineering, and service departments of Studiomaster Professional are continually striving to
improve Studiomaster Professional products. Modifications are therefore inevitable and specification
are subject to change without notice or obligation to retrofit. Should any discrepancy appear to exist,
please contact you Distributor’s Service Centre.
THIS DOCUMENT CONTAINS PROPRIETORY INFORMATION OF

“STUDIOMASTER PROFESSIONAL” WHICH BEING FURNISHED
ONLY FOR THE PURPOSE OF SERVICING THE IDENTIFIED
STUDIOMASTER PROFESSINAL PRODUCT BY AUTHORISED SERVICE
CENTER AND SHALL NOT BE REPRODUCED OR USED FOR ANY OTHER
PURPOSE.
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TOOLS AND EQUIPMENT REQUIRED
1. Multi-bit screwdriver set, M3, M4 & M17 Spanner and good quality hand tools.
2. A set of short medium bristled artist or horsehair brushes.
3. Methanol alcohol or a non-corrosive, non-lubricant solvent.
4. Digital multimeter with a 20 kHz bandwidth.
5. Audio signal generator.
6. Dual-trace oscilloscope.
7. Power supply board with a 60-watt series lamp on one socket, along with a shorting switch for the
lamp.
8. Variac 10KWA with AC voltage and current displays.
9. Analogue multi-meter with a sensitivity of minimum 20kΩ/V, and a maximum resistance scale of
10MΩ.
10. Resistive load – 4 Ohm 3000Watts Max (Qty. - 2)
2 Ohm 4000Watts Max (Qty. - 2)
8 Ohm 1500Watts Max (Qty. - 2)
It is advisable to use fine tip long meter probes and insulate the exposed metal of the probes with heatshrink
sleeving and leave only the tips exposed. This prevents accidental shorting while taking readings on any PCB.
If there is mains supply variation, with a Variac, you can adjust mains supply voltage going to
amplifier there by you can get correct power. An audio signal generator and an oscilloscope are required if the
waveform is to be monitored, and power measurements are to be made on an amplifier. They are also required
to check an amplifier where there is no apparent fault and no output either. However, all these methods are
recommended only for skilled technicians, experienced with class AB and class H amplifiers.
IMPORTANT NOTE:
This DJA series amplifier uses the latest technology in circuitry and fabrication.. If a technician attempting to
repair these amplifiers does not have extensive experience in working with PTH boards and SMT technology,
and with class AB/class H amplifier circuitry, it is strongly recommended that repairs at the component level
should not be attempted. In such a case, the technician should only attempt to identify the faulty module, and
replace it with a fresh module. The defective module should be sent back to Audioplus for repairs.
Even an experienced technician would be advised to work only on the power supply section of the amplifiers
that is if the fault exists in the bridge rectifiers, main filter condensers, regulated supplies or the mains
transformer. Attempting to work on the power amplifier module is fraught with danger, as to get access to the
components and to unsolder and solder the PCB; it is necessary to detach the PCB with the power transistors
and thermal sensor from the heatsink. In this condition it is impossible to power up the module without
damaging the power transistors, as there is no heatsink to remove the quiescent dissipation.
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SPECIFICATIONS
DJA2500 DJA4000
Output Power
Continuous Power @ 1% THD
Single Channel 4Ω, 1x 1100W RMS 4Ω, 1x 1700W RMS
8Ω, 1x 700W RMS 8Ω, 1x 1000W RMS
Stereo 4Ω, 2x 900W RMS 4Ω, 2x 1400W RMS
8Ω, 2x 600W RMS 8Ω, 2x 900W RMS
Bridge 8Ω, 1800W RMS 8Ω, 2800W RMS
EIA Power @ 1% THD
Single Channel 4Ω, 1x 1250W RMS 4Ω, 1x 2400W RMS
8Ω, 1x 750W RMS 8Ω, 1x 1350W RMS
Stereo 4Ω, 2x 1100W RMS 4Ω, 2x 1900W RMS
8Ω, 2x 700W RMS 8Ω, 2x 1200W RMS
Bridge 8Ω, 2200W RMS 8Ω, 3800W RMS
Frequency Response 20 Hz-20KHz (-3dB)
Damping Factor >350: 1 (8Ω)
Signal to Noise Ratio > 90dB 'A' Weighted
Cross Talk >50 dB @ 1 KHz
Input sensitivity 0.775 Vrms.
Input Impedance 20kΩ Balanced, 10kΩ Un-balanced
Protections DC, Short circuit, Soft-start, Over Heat, Limit
Input connector (per panel) XLR, 1/4” Stereo Jack per channel
4 WAY SPEAKON Connectors &
Output Connector (per panel) Binding Posts
Cooling Two variable speed fans
Front Panel controls Volume controls for CH1 & CH2
Indicators Power on, signal, Clip, Bass boost, Protect
Rear Controls EQ Frequency Control
Mode selection (Mono/Bridge/Parallel), Sub/Low Cut, EQ
Rear Switches Processing
Supply Voltage 240Volt/50Hz
AC Fuse Rating T15AL/250Volt T25AL/250Volt
Dimensions (W x D x H ) 2U, 482 x 456 x 88 mm 3U, 482 x 495 x 130 mm
Net Weight 12 Kg 38Kg
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SAFETY INFORMATION
1. Parts that have special safety characteristics are identified by the symbol ! On schematics or by
special notes on the parts list. Use only replacement parts that have critical characteristics
recommended by the manufacturer.
2. Make leakage current or resistance measurements to determine that exposed parts are acceptably
insulated from the supply circuit before returning the unit to the customer. Use the following checks to
perform these measurements:
A. Leakage Current Hot Check-With the unit completely re-assembled, plug the AC line cord directly
into a 240V AC outlet. (Do not use an isolation transformer during this test.) Use a leakage current
tester or a metering system. With the unit AC switch first in the ON position, then in the OFF position,
measure from a known earth ground (metal water pipe, conduit, etc.) to all exposed metal parts of the
unit ( handle bracket, metal cabinet, screw heads, metallic overlays, control shafts, etc.), especially any
exposed metal parts that offer an electrical return path to the chassis. Any current measured must not
exceed 0.5 mA. Reverse the unit power cord plug in the outlet and repeat test. ANY
MEASUREMENTS NOT WITHIN THE LIMITS SPECIFIED HEREIN INDICATE A POTENTIAL
SHOCK HAZARD THAT MUST BE ELIMINATED BEFORE RETURNING THE UNIT TO THE
CUSTOMER.
B. Insulation Resistance Test Cold Check-

(1) Un-plug the power supply and connect a jumper wire between the two prongs of the plug.
(2) Turn on the power switch of the unit.
(3) Measure the resistance with an ohmmeter between the jumpered AC plug and each exposed
metallic cabinet part on the unit. When the exposed metallic part has a return path to the chassis, the
reading should be between 1 and 5.2 Mega Ohms. When there is no return path to the chassis, the
reading must be “infinite”. If it is not within the limits specified, there is the possibility of a shock
hazard, and the unit must be repaired and re-checked before it is returned to the customer.
ELECTROSTATIC DISCHARGE SENSITIVE (ESDS) DEVICE HANDLING
We recommend the following precautions when repairing, replacing or transporting ESDS devices:
• Perform work at an electrically grounded work station.
• Wear wrist straps that connect to the station or heel straps that connect to conductive floor mats.
• Avoid touching the leads or contacts of ESDS devices or PC boards even if properly grounded. Handle
boards by the edges only.
• Transport or store ESDS devices in ESD protective bags, bins, or totes. Do not insert unprotected
devices into materials such as plastic, polystyrene foam, clear plastic bags, bubble wrap or plastic trays.
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AMPLIFIER BLOCK DIAGRAM
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AMPLIFIER WIRING DIAGRAM
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DISASSEMBLY/ASSEMBLY PROCEDURES
1. Top Cover Removal
1.1 Remove transformer mounting hex Bolt
1.2 Remove side left, right (3 each) & rear (5 nos.) M4X5, Allen Head screws (11 nos.)
2.0 Top Cover Replacement.
2.1 Place the top cover and fit side and rear screws mentioned in 1.2
2.2 Fit the transformer mounting hex bolt.
Transformer
3. Power Amplifier PCB Removal
3.1 Perform procedure 1.
3.2 Disconnect the wire looms going to power amp pcb.
3.3 Remove bottom heatsink fitting screws M4X10 Self Tap Black.
(DJA2500 – 3 nos/heatsink, DJA4000 – 5 nos./heatsink)
3.4 Lift the board upward carefully.
4. Power Amplifier PCB Replacement
4.1 Re-connect the wire harness as mentioned in 3.2.
4.2 Place the module in to the chassis.
4.3 Align the mounting holes and refit it by screws mentioned in 3.3
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Screws from bottom side Screws from bottom side
5.0 PSU PCB removal
5.2 Disconnect the wire harness going from PSU to Power amp, Input board, Output board, Front Control board
& Transformer. Also remove fan tunnel.
5.3 Remove 4 X M3X6 Pan Head Black Machine screws fitted at corners.
5.4 Lift the board upward carefully.
6.0 PSU PCB Replacements
6.1 Place the PSU board and align mounting holes.
6.2 Re-fit the hardware as mentioned in 5.3
6.3 Re-connect harnesses as mentioned in 5.2
Fan tunnel
PSU Board
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7.0 Input PCB removal
7.2 Remove M3X6 Pan Head Black Machine screws (2 nos.) fitted from inside.
7.3 Remove XLR to chassis screws M3X8 Pan Head Self Tap screws (qty 4 nos.), jack nuts (2 nos.) on rear.
7.4 Push the board backward and lift it carefully.
7.5 Disconnect the wire harnesses which are connected to Input board.
8.0 Input PCB Replacement
8.1 Re-connect harness as mentioned in 7.5
8.2 Place the Input board and align it to mounting holes on rear & re-fit the hardware as mentioned in 7.3 & 7.2.
M3X6
Internal screws Jack Nut XLR Screws
9.0 Front Control PCB removal
9.2 Remove the control knobs on front.
9.3 Remove the transformer by removing bottom bolt.
9.4 Disconnect the wire harness going to control pcb.
9.5 Remove mounting screws M3X6 Pan Head Machine screws (qty 4 nos.)
9.6 Push the board backward & then lift it upward carefully.
10.0 Front Control PCB Replacement
10.1 Place the Control board and align it to mounting holes & re-fit the hardware as mentioned in 9.5
10.3 Re-fit the transformer as mentioned in 9.3
10.4 Re-fit the knobs as mentioned in 9.2
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Control board Control/Led board
Mtg.
screws
Transformer
Mtg. screws
DJA2500 DJA4000
11.0 LED PCB (DJA2500) removal
11.4 Disconnect the wire harness going to Led pcb.
11.5 Remove mounting screws M3X6 Pan Head Machine screws (qty 2 nos.)
11.6 Push the board backward & then lift it upward carefully.
12.0 LED PCB (DJA2500) Replacement
12.1 Place the Led board and align it to mounting holes & re-fit the hardware as mentioned in 11.5

Led Pcb Mounting screws
12.0 Output Board removal
12.2 Remove wires going to output board
12.3 De-solder binding post connector from inside.
12.4 Remove Speak-on connector screws (M3 X 6 Machine screws) & Jack nut (DJ2500) on rear
12.5 Push the board inside & lift it upward carefully.
13.0 Output board Replacement
13.1 Place the Output board to its position.
13.2 Re-fit hardware as mentioned in 12.4.
13.4 Re-solder the binding post leads and connect the wires as mentioned in 12.2
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DJA2500 Output board inside view DJA2500 Output board rear view
Binding Post soldering leads Jack nut
DJA4000 Output board inside view DJA4000 Output board rear view
Binding Post soldering leads
16.0. Fan Removal
16.2 For DJA2500, remove bottom screws M4X10 Self Tap Black screws black (4nos.) & in DJA4000, remove
rear screws M4X10 Self Tap Black screws black (8nos.)
16.3 Lift the fan upward. .
17.0 Fan Replacement
17.1 Refit Fans using screws as mentioned in 16.2
DJA2500 DJA4000
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18.0 Transformer Removal
18.2 Remove all transformer connections.
18.3 Remove transformer mounting hex Bolt & plain washer from chassis bottom.
18.4 Remove transformer by lifting it upward.
19.0 Transformer Replacement
19.1 Place the transformer in the chassis & align mounting hole.
19.2 Fit bottom bolt & washer as per 18.3
19.3 Reconnect all wires as per 18.2
Note: After replacement of all above mentioned assy please refit the top cover as mentioned in
2.0
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TEST PROCEUDRES
A. PSU TEST PROCEDURE
DC3
DC4
DC2
DC5
DC1
GND
AC1 AC2 AC3 AC4 AC5
Make secondary wire connections of transformer and measure the voltages as mentioned below
- Keep on/off switch in off.

- Keep Variac in series mode.
- Switch on the power supply. Mains voltage: 240V, 50Hz.
- Check that mains voltage is not less than 175V
- If there is no loading then switch Variac to parallel mode.
- Check the AC/DC voltages as mentioned below.
DJA2500:
AC VOLATGES
A) AC1, AC5: 13V
B) AC2: 88V
C) AC3: 31V
D) AC4: 176V
DC VOLTAGES
All DC voltages are with reference to GND
A) DC1, DC5: +15.5V
B) DC2, DC4: HV= +/-120V, LV=+/-60V
C) DC3: +/- 11.7V
DJA4000:
AC VOLATGES
E) AC1, AC5: 13V
F) AC2: 104V
G) AC3: 31V
H) AC4: 205V
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DC VOLTAGES
All DC voltages are with reference to GND
D) DC1, DC5: +15.5V
E) DC2, DC4: HV= +/-143V, LV=+/-70V
F) DC3: +/- 11.7V
- Switch off the mains supply.
B. AMPLIFIER UNIT TEST PROCEDURE DJA2500
1. Select the Amplifier in pre setting using switch on the Back plate.
- Amplifier in Stereo Mode.
- CROSSOVER/LOWCUT switch in OFF position.
- EQ Processing in OFF position
2. Keep Variac at minimum position.
3. Connect amplifier mains plug to Variac socket.
4. Turn on the unit & increase mains supply slowly and check that there is no loading (rapid increase in
primary current).
5. If there is no loading, adjust supply voltage to 240VAC.
- Observe that when power is switched ON, POWER ON LED will turn on.
- After a short delay of 5 sec. the amplifier turns on.
- The PROTECT and TEMP LED’S, will switch on with power on condition and then will switch off
with some delay.
6. DC OFFSET VOLTAGE
Check the DC voltage at the Output points. The DC offset voltage should be within ± 10 mV.
7. BIAS ADJUSTMENT
On the driver transistor 2SC4793 & 2SA1837 (either one accessible in the unit) w. r. t ground there
should be 1.3V (±0.2V) measured. If not adjust preset on the power amp PCB to get 1.3V (±0.2V)
8. AMP PERFORMANCE MEASUREMENT:
1) SENSITIVITY
- Drive single channel into 4 ohms load in Stereo mode at 1 kHz.
- Increase the input to get 66V (1100 W) just clipped output.
- The input required to get 66V output is the rated sensitivity.
- The Specification for the Sensitivity is 1.3V (±0.3V)
Input connectors check:
XLR balanced: Use XLR balance male connector (pin 2 “+”, pin 3 “-“& pin 1-gnd) from generator to
XLR socket and check sensitivity as above.
Stereo jack – Use stereo jack connector (Tip “+”, Ring “-“and Shield –GND) from generator to JACK
socket and check sensitivity as above.
2) FREQUENCY RESPONSE MEASUREMENT:

- Apply input of the rated sensitivity and adjust the output to 30V using gain control pot.
- Change the frequency of the applied input and note the output reading.
FREQUENCY 20Hz 1KHz 20K

OUTPUT/ CH 28-32V 30V 28-32V
3) POWER V/S THD
I. Stereo Mode Single Channel Driven.

- Single channels driven in various load conditions.
- Gain pot MAX.
- Feed 1KHz signal & adjust output at just clipping level.
Power Output in V
Load
Ch 1 Ch 2
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66V 66V 4Ω
72V 72V 8Ω
II. Stereo Mode Dual Channel Driven
- Both channels driven in various conditions
- Gain pot MAX.
Power Output in V
Load
Ch 1 Ch 2
59V 59V 4Ω
66V 66V 8Ω
III. Parallel Mode:

- Feed Input to Channel 1 only.
- Both channels connected to appropriate loads.
- Mono mode selected from the Back Plate mode selection switch.
- Check that you get the similar power as per Stereo mode.
- Make sure that the Channel 2 input is not connected.
IV. Bridge Mode:

- Input to Channel 1 only.
- Load connected to Bridge connector with load as specified.
- Channel 1 control MAX.
- Bridge mode selected from the Back Plate mode selection switch.
Power Output
Load
(V)
117V 8Ω
4) SIGNAL TO NOISE LEVEL MEASUREMENT:

- Connect the Amplifier in Stereo Mode with 4 Ω loads.
- Check the output power level with the given frequency filters and observe the readings for both the
channel.
- Noise should be less than 2mV
5) LIMITER TEST:
- Output is set to 66V with rated sensitivity input in 4ohm load.
- Increase input to 5Vand keep the CH pot max.
- Output should be about 70V
6) LOW CUT MEASUREMENT:

- Connect the amplifier in stereo mode with 4Ω loads at 1 kHz.
- Feed input to Left channel at rated sensitivity and Set output to 30 V in 4Ω loads using gain control
pot.
- Drive single channel, Put the switch @ the rear into low-cut mode
- Using the XO control at the rear set the required frequency. Following are the frequencies at which
output is about 21V(+/-1V).
FREQ FREQ Variation
43Hz +/-5Hz
63Hz +/-5Hz
120Hz +/-10Hz
140Hz +/-10Hz
180Hz +/-25Hz

7) SUB WOOFER MEASUREMENTS
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- Drive single channel, Put the switch @ the rear into subwoofer mode
- Feed input to Left channel at rated sensitivity and Set output to 30V at 10Hz @ 4Ω loads using gain
control pot.
output is 21V(+/-1V).
FREQ FREQ Variation
43Hz +/-5Hz
63Hz +/-5Hz
120Hz +/-10Hz
140Hz +/-10Hz
180Hz +/-25Hz

8) EQ processing measurements:

- Feed input to Left channel to get output of 15V at 100Hz
- Turn the EQ Processing switch ON.
- Output boost to 30V (+/-1V)
9) X TALK MEASUREMENT:
- Connect input to both the channel feeding input of rated sensitivity. Set the gain pot of both the
channels to MAX position. Set output to 66V.
- Feed input to channel 1KHz and take readings of the both channel.
- Similarly feed input to Right channel and take readings of the both channel.
Output
Input Applied To
Channel 1 Output Channel 2 output
CH 1 66V <1mV
CH 2 <1mV 66V
10) LED TESTING:
Power LED
It turns on when power switch turn ON.
PROTECT A
It glows in case of Thermal & DC protection of CH A.
PROTECT B
It glows in case of Thermal & DC protection of CH B.

Signal and clip LED
Channel CLIP LED Indication Signal LED Indication
Left Channel 0/P 66V ±3V 1V ±0.2V
Right Channel O/P 66V ±3V 1V ±0.2V

EQ Processing LED
It Glows when the EQ Processing Switch is Turned ON.
11) SHORT CIRCUIT TEST:
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Stereo mode single channel driven at 4 ohms:-
During short circuit test output signal reduces & becomes square wave.
Primary current CH1 Primary current CH2
POWER(V) Before
Before short After short After short
short
66V 9A(±0.5A) 4A(±0.5A) 9A(±0.5A) 4A(±0.5A)
Bridge Mode @ 8 OHM LOAD

Primary Current
POWER(V)
Before short After short
113V 15A(±0.5A) 11A(±0.5A)
12) DC PROTECTION
Remove the Transformer secondary except the one used to drive the control circuit (±15V). At the
amplifier output connect a DC power supply. Start increasing the voltage from zero and observe
where the RELAY starts Chattering.
DC protection starts at + 6 volts & -14volts .
13) FAN TEST

FAN speed increases when the temperature on the heat-sink goes above 60 °C.
14) BURN IN TEST.

Settings:
Amplifier in stereo mode with music signal, output clipping level driven
into 4 ohm load.
Observe that amplifier doesn’t go in to protect even after 4 hrs.
15) Factory settings.

- Front Level controls at min.
- Power switch OFF
- Mode selection switch in Stereo position
- EQ Processing switch OFF
- Bass Boost switch OFF
- Frequency control at 45Hz
C. AMPLIFIER UNIT TEST PROCEDURE DJA4000
1. Select the Amplifier in pre setting using switch on the Back plate.
- Amplifier in Stereo Mode.
- CROSSOVER/LOWCUT switch in OFF position.
- EQ Processing in OFF position
2. Keep Variac at minimum position.
3. Connect amplifier mains plug to Variac socket.
4. Turn on the unit & increase mains supply slowly and check that there is no loading (rapid increase in
primary current).
5. If there is no loading, adjust supply voltage to 240VAC.
- Observe that when power is switched ON, POWER ON LED will turn on.
- After a short delay of 5 sec. the amplifier turns on.
- The PROTECT and TEMP LED’S, will switch on with power on condition and then will switch off
with some delay.
6. DC OFFSET VOLTAGE
Check the DC voltage at the Output points. The DC offset voltage should be within ± 10 mV.
7. BIAS ADJUSTMENT
On the driver transistor 2SC4793 & 2SA1837 (either one accessible in the unit) w. r. t ground there
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should be 1.5V (±0.2V) measured. If not adjust preset on the power amp PCB to get 1.3V (±0.2V)
8. AMP PERFORMANCE MEASUREMENT:
1) SENSITIVITY
- Increase the input to get 82V (1680 W) just clipped output.
- The input required to get 82V output is the rated sensitivity.
- The Specification for the Sensitivity is 1.2V (±0.3V)
Input connectors check:
XLR balanced: Use XLR balance male connector (pin 2 “+”, pin 3 “-“& pin 1-gnd) from generator to
XLR socket and check sensitivity as above.
Stereo jack – Use stereo jack connector (Tip “+”, Ring “-“and Shield –GND) from generator to JACK
socket and check sensitivity as above.
2) FREQUENCY RESPONSE MEASUREMENT:

- Apply input of the rated sensitivity and adjust the output to 30V using gain control pot.
- Change the frequency of the applied input and note the output reading.
FREQUENCY 20Hz 1KHz 20K

OUTPUT/ CH 28-32V 30V 28-32V
3) POWER V/S THD
II. Stereo Mode Single Channel Driven.

- Single channels driven in various load conditions.
- Gain pot MAX.
Power Output in V
Load
Ch 1 Ch 2
82.5V 82.5V 4Ω
87V 87V 8Ω
II. Stereo Mode Dual Channel Driven

- Both channels driven in various conditions
- Gain pot MAX.
Power Output in V
Load
Ch 1 Ch 2
75V 75V 4Ω
85V 85V 8Ω
III. Parallel Mode:

- Feed Input to Channel 1 only.
- Both channels connected to appropriate loads.
- Mono mode selected from the Back Plate mode selection switch.
- Check that you get the similar power as per Stereo mode.
- Make sure that the Channel 2 input is not connected.
IV. Bridge Mode:

- Input to Channel 1 only.
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- Load connected to Bridge connector with load as specified.
- Channel 1 control MAX.
- Bridge mode selected from the Back Plate mode selection switch.
Power Output
Load
(V)
150V 8Ω
4) SIGNAL TO NOISE LEVEL MEASUREMENT:

- Connect the Amplifier in Stereo Mode with 4 Ω loads.
- Check the output power level with the given frequency filters and observe the readings for both the
channel.
- Noise should be less than 2mV
5) LIMITER TEST:
- Output is set to 82V with rated sensitivity input in 4ohm load.
- Increase input to 4Vand keep the CH pot max.
- Output should be about 85V
6) LOW CUT MEASUREMENT:

- Feed input to Left channel at rated sensitivity and Set output to 30 V in 4Ω loads using gain control
pot.
- Drive single channel, Put the switch @ the rear into low-cut mode
output is about 21V(+/-1V).
FREQ FREQ Variation
43Hz +/-5Hz
63Hz +/-5Hz
120Hz +/-10Hz
140Hz +/-10Hz
180Hz +/-25Hz

7) SUB WOOFER MEASUREMENTS

- Drive single channel, Put the switch @ the rear into subwoofer mode
- Feed input to Left channel at rated sensitivity and Set output to 30V at 10Hz @ 4Ω loads using gain
control pot.
output is 21V(+/-1V).
FREQ FREQ Variation
43Hz +/-5Hz
63Hz +/-5Hz
120Hz +/-10Hz
140Hz +/-10Hz
180Hz +/-25Hz

8) EQ processing measurements:

- Feed input to Left channel to get output of 15V at 100Hz
- Turn the EQ Processing switch ON.
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- Output boost to 30V (+/-1V)
9) X TALK MEASUREMENT:
- Connect input to both the channel feeding input of rated sensitivity. Set the gain pot of both the
channels to MAX position. Set output to 66V.
- Feed input to channel 1KHz and take readings of the both channel.
- Similarly feed input to Right channel and take readings of the both channel.
Output
Input Applied To
Channel 1 Output Channel 2 output
CH 1 82V <1mV
CH 2 <1mV 82V
10) LED TESTING:
Power LED
It turns on when power switch turn ON.
PROTECT A
It glows in case of Thermal & DC protection of CH A.
PROTECT B
It glows in case of Thermal & DC protection of CH B.

Signal and clip LED
Channel CLIP LED Indication Signal LED Indication
Left Channel 0/P 75V ±3V 1V ±0.2V
Right Channel O/P 75V ±3V 1V ±0.2V

EQ Processing LED
It Glows when the EQ Processing Switch is Turned ON.
11) SHORT CIRCUIT TEST:
Stereo mode single channel driven at 4 ohms:-

During short circuit test output signal reduces & becomes square wave.
Primary current CH1 Primary current CH2
POWER(V) Before
Before short After short After short
short
80V 14A(±1A) 13A(±1A) 14A(±1A) 13A(±1A)
Bridge Mode @ 8 OHM LOAD

Primary Current
POWER(V)
Before short After short
150V 25A(±2A) 20A(±2A)
12) DC PROTECTION
Remove the Transformer secondary except the one used to drive the control circuit (±15V). At the
amplifier output connect a DC power supply. Start increasing the voltage from zero and observe
where the RELAY starts Chattering.
DC protection starts at + 5 volts & -14volts .
24
13) FAN TEST
FAN speed increases when the temperature on the heat-sink goes above 60 °C.
14) BURN IN TEST.

Settings:
Amplifier in stereo mode with music signal, output clipping level driven
into 4 ohm load.
Observe that amplifier doesn’t go in to protect even after 4 hrs.
15) Factory settings.

- Front Level controls at min.
- Power switch OFF
- Mode selection switch in Stereo position
- EQ Processing switch OFF
- Bass Boost switch OFF
- Frequency control at 45Hz
25
COMPONENT PIN CONFIGURATION
1. IC 4558 /LM358 2. IC 7812/7912

3. Bridge Rectifier 4. Transistor 2SA1943
COLLECTOR
2
1
BASE
3
EMITTER
1 2 3

2SA1943

5. Transistor 2SC5200 6. 2SA1837/2SC4793
COLLECTOR
2
1
BASE
3
EMITTER
1 2 3
2SC5200

26
TROUBLESHOOTING
Fault Possible Causes/Rectification

• Make sure the power cord is securely seated in the IEC socket and plugged
all the way into the AC outlet.
• Make sure the AC outlet is live (check with a tester or lamp).
• Make sure the front panel POWER switch is in the ON position.
• If nothing is illuminated, and you are certain that the AC outlet is live, it will
be necessary to have your amplifier serviced. There are no user serviceable
parts inside. Refer to “Fault Chart” on the next page to find out how to
No Power proceed.
• Loudspeaker cables or connectors are not wired correctly or they are faulty.
Check all cabling, referring to these instructions for the correct connections.
The best way to check a suspect cable is to swap it with a known good cable.
• Loudspeaker is not working. Connect the loudspeaker cable to a known good
loudspeaker leaving all equipment set to the same levels. If the problem
disappears, the loudspeaker is probably not working correctly.
• Are the channel Level controls turned up? Slowly turn them up and see if you
hear any-thing.
• Is the signal source turned up? Make sure the signal level from the mixing
console (or whatever device immediately precedes the amplifier) is high
enough to produce sound in the amplifier. The SIG LEDs should be blinking
to indicate that signal is present.
• If the speakers are wired for BRIDGE mode, make sure the AMP MODE
switch is set to BRIDGE.
• If the amplifier has gotten extremely hot, the thermal protection circuit may
have activated. Allow the amplifier to cool down and normal operation should
resume.
• Are there fuses in the speakers, or in-line fuses in the speaker wire? Check to
see if they’re blown.
No Sound or Low Output • Check that if fuse on Power-amp module is blown
• The power amplifier is clipping. The signal level is exceeding the limits of
your system and you must reduce the level from your mixer or signal source.
• Ensure that no equipment in the signal chain is being over driven. For
example: input(s) or summing bus in the mixing console, equalizers etc.
• Is the input connector plugged completely into the jack? Check the speaker
connections and verify that all connections are tight and that there are no stray
strands of wire shorting across the speaker terminals.
• If possible, listen to the signal source with headphones plugged into the
console. If it sounds bad there, the problem is not in the amplifier.
Distorted Sound • Loudspeakers not working properly.
• Incorrect EQ settings in the electronic equip-ment. Ensure all EQ settings and
filters on the mixing console or preamplifier and on other equipment are set
for normal operation. Ensure level controls on electronic crossovers and
as-sociated amplifiers are correctly set and that all cables and connections for
such equipment are connected and working properly.
• Loudspeaker not working properly. Swap with a good one.
• Is the POWER ON LED illumi-nated? If not, make sure the AC outlet is live.
• The fuses inside the amplifier may have blown. These are not a user-
Partial Sound (frequency band missing) serviceable.
• Are both Level controls set to the same posi-tion?
• Check your source signal to make sure the left and right signals are balanced.
• Are the speaker impedances matched? Differ-ent speaker loads can cause
different volume levels on each side.
• Try switching sides: Turn off the amp, swap the speaker cables at the amp,
turn the amp back on. If the same side is still louder, the problem is with your
speaker cabling. If the other side is louder now, the problem is with the mixer,
One side is louder than the other the amp, or the line-level cabling.
27
• Check the polarity of the speaker cable connections. You may have your
positive and negative reversed at one end of one speaker cable.
• Make sure the Clip LEDs are not lighting continuously. If so, turn down the
Poor Bass response signal source or the amp Level controls.
• Check the signal cable between the mixer and the amplifier. Make sure all
connections are good and sound.
• Make sure the signal cable is not routed near AC cables, power transformers,
or other EMI-inducing devices.
• Is there a light dimmer or other SCR-based device on the same AC circuit as
the amplifier? Use an AC line filter, or plug the amplifier into a different AC
circuit.
• If possible, listen to the signal source with headphones plugged into the
console. If it sounds noisy there, the problem is not in the amplifier.
• Is there a cable-TV audio feed in your system? An incorrect ground may
causes a "ground loop" hum.
• Sometimes it helps to plug all the audio equip-ment into the same AC circuit
Noise/Hum so they share a common ground.
FAULT CHART
Fault Possible Reason
Check fuse in the primary (rear panel) and/or
No power
Check +/-12V supply on PSU.
High Bias: Check preset setting if it is disturbed.
Output devices are short, replace them
Bridge rectifiers have failed
Transformer is short/open
Filter capacitors on the power amp or PSU have gone bad.
Amplifier Dead(high loading) DC on the output: Check bias setting or output device has failed.
±12V supply not present on the power amp board and/or
either of the ±LV & HV voltages not present and/or
Inter cabling from input to power amp PCB, Input to front control pcb, PSU to front
control pcb is not properly connected and/or
Output devices are short, replace the same.
Check fan by giving external 12V DC, it may be faulty if so replace it. Or ,
Fan not working Check thermal switch loom and/or
Bridge rectifier (in the secondary AC1 & AC5) is faulty. Replace it.
Protect LED continues glow DC on output or heatsink temperature is too high.
28
SPARES LIST
Item no Description Location

Power cord Chassis
Power Switch Front Panel
Input Board Chassis
DJA2500 Mains transformer Chassis
DJA2500 Power Supply (PSU) Board Chassis
DJA2500 Power Amp Module Chassis
DJA2500 Led/Control Board Front Panel
DJA2500 Output Board Chassis
Power cord for DJA4000 Chassis
DJA4000 Mains transformer Chassis
DJA4000 Power Supply (PSU) Board Chassis
DJA4000 Power Amp Module Chassis
DJA4000 Led/Control Board Front Panel
DJA4000 Output Board Chassis
Handles for DJA2500 Chassis
Handles for DJA4000 Chassis
Fans for DJA2500 Chassis
Fans for DJA4000 Chassis
10000MFD/63 Volt Capacitor for DJA2500 PSU Board
10000MFD/80 Volt Capacitor for DJA4000 PSU Board
Bridge Rectifier GBJ3510 for DJA2500 PSU Board
Bridge Rectifier GBJ5006 for DJA4000 PSU Board
IC Regulator 7812 PSU Board
IC Regulator 7912 PSU Board
Bridge Rectifier (small) KBPC210 PSU Board
DJA2500 -PSU, Output
Relay 12V DC, 30A YL-224-A-S-12VDC DJA4000 -PSU, control
boards
Thermister NTC10 OHM 8A EMC Board
NTC 10D-20 EMC Board
T15 AMP fuse for DJA2500 Chassis
T25 AMP fuse for DJA4000 Chassis
Resistor 0.33 OHMS 5W Power Amp Module
Resistor 680 OHMS 3W Power Amp Module
Resistor 100 OHMS 1/2W Power Amp Module
Diode Rectifier FR607 1000V/6A Power Amp Module
IRF540 MOSFET Power Amp Module
IRF640 MOSFET Power Amp Module
SMSMCTRS011 Transistor 2SA1837 Power Amp Module
SMSMCTRS032 Transistor 2SC4793(NPN) Power Amp Module
SMSMCTRS039 Transistor 2SA1943(O) PNP Power Amp Module
SMSMCTRS040 Transistor 2SC5200 (O) NPN Power Amp Module
29
LAYOUTS & LEGENDS
1. Input Pcb
30
2. PSU
3. DJA2500 Led-Control Pcb
4. DJA4000 Led-Control Pcb
31
5. DJA2500 Output Pcb
6. DJA4000 Output Pcb
32
7. Power Amp Pcb
DJA2500 DJA4000

33
PCB SCHEMATICS
1. Input Pcb
34
2. LED & OUTPUT Pcb
3. DJA2500 PSU
35
4. DJA400 PSU
5. DJA2500 Power Amp
36
6. DJA4000 Power Amp
37
AUDIOPLUS
A1 & A2, Giriraj Ind. Estate,
Mahakali Caves Road, Andheri (E),
Mumbai-400093 (India).
Phone.: +91-22-4286 9000 / 4286 9001
Fax +91-22-26871453
E-mail: info@audioplus-india.com
Studiomaster Professional reserves the right to make modification to its manual without
notice.
REV. 001/DJA2500_4000 SERVICE/AUG 2013
38

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STUDIOMASTER PROFESSIONAL SERVICE MANUAL

• TOOLS & EQUIPMENTS REQUIRED………………………………………..………5

• AMPLIFIER BLOCK DIAGRAM……………………………………..…….………….8

• AMPLIFIER WIRING DIAGRAM………………………………….…………….……9

• DISASSEMBLY/ASSEMBLY PROCEDURE………………………….……….….. ..11

• COMPONENT PIN CONFIGURATION…………………………….…………………26

• TROUBLESHOOTING & FAULT CHART……………………………………………27

• SPARES LIST ……………………………………………………….…………………29

• SCHEMATICS WITH AC & DC VOLATGES……………………………………..….34

THIS DOCUMENT CONTAINS PROPRIETORY INFORMATION OF

Net Weight 12 Kg 38Kg

B. Insulation Resistance Test Cold Check-

ELECTROSTATIC DISCHARGE SENSITIVE (ESDS) DEVICE HANDLING

1.1 Remove transformer mounting hex Bolt

2.0 Top Cover Replacement.

2.2 Fit the transformer mounting hex bolt.

3. Power Amplifier PCB Removal

3.1 Perform procedure 1.

3.2 Disconnect the wire looms going to power amp pcb.

3.4 Lift the board upward carefully.

4. Power Amplifier PCB Replacement

4.1 Re-connect the wire harness as mentioned in 3.2.

4.2 Place the module in to the chassis.

5.1 Perform procedure 1.

5.4 Lift the board upward carefully.

6.0 PSU PCB Replacements

6.1 Place the PSU board and align mounting holes.

6.2 Re-fit the hardware as mentioned in 5.3

6.3 Re-connect harnesses as mentioned in 5.2

7.1 Perform procedure 1.

7.4 Push the board backward and lift it carefully.

8.0 Input PCB Replacement

8.1 Re-connect harness as mentioned in 7.5

Internal screws Jack Nut XLR Screws

9.0 Front Control PCB removal

9.1 Perform procedure 1.

9.2 Remove the control knobs on front.

9.3 Remove the transformer by removing bottom bolt.

9.4 Disconnect the wire harness going to control pcb.

10.0 Front Control PCB Replacement

10.2 Re-connect harness as mentioned in 9.5

10.3 Re-fit the transformer as mentioned in 9.3

10.4 Re-fit the knobs as mentioned in 9.2

11.0 LED PCB (DJA2500) removal

11.1 Perform procedure 1.

11.4 Disconnect the wire harness going to Led pcb.

12.0 LED PCB (DJA2500) Replacement

10.2 Re-connect harness as mentioned in 11.4

12.0 Output Board removal

12.1 Perform procedure 1.

12.2 Remove wires going to output board

12.3 De-solder binding post connector from inside.

12.5 Push the board inside & lift it upward carefully.

13.0 Output board Replacement

13.1 Place the Output board to its position.

13.2 Re-fit hardware as mentioned in 12.4.

Binding Post soldering leads Jack nut

Binding Post soldering leads

16.0. Fan Removal

16.1 Perform procedure 1.

16.3 Lift the fan upward. .

17.0 Fan Replacement

17.1 Refit Fans using screws as mentioned in 16.2