Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
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
• SPECIFICATIONS………………………………………………………….…….…….6
• SAFETY INFORMATION……………………………………………….……….…….7
• TEST PROCEDURES…………………………………………………….…………….17
• PCB LAYOUTS…………………………………………………………………..…….30
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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.
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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
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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.
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
1.2 Remove side left, right (3 each) & rear (5 nos.) M4X5, Allen Head screws (11 nos.)
2.1 Place the top cover and fit side and rear screws mentioned in 1.2
Transformer
3.3 Remove bottom heatsink fitting screws M4X10 Self Tap Black.
(DJA2500 – 3 nos/heatsink, DJA4000 – 5 nos./heatsink)
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.
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.
7.5 Disconnect the wire harnesses which are connected to Input board.
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
9.5 Remove mounting screws M3X6 Pan Head Machine screws (qty 4 nos.)
9.6 Push the board backward & then lift it upward carefully.
10.1 Place the Control board and align it to mounting holes & re-fit the hardware as mentioned in 9.5
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Control board Control/Led board
Mtg.
screws
Transformer
Mtg. screws
DJA2500 DJA4000
11.5 Remove mounting screws M3X6 Pan Head Machine screws (qty 2 nos.)
11.6 Push the board backward & then lift it upward carefully.
12.1 Place the Led board and align it to mounting holes & re-fit the hardware as mentioned in 11.5
12.4 Remove Speak-on connector screws (M3 X 6 Machine screws) & Jack nut (DJ2500) on rear
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
DJA4000 Output board inside view DJA4000 Output board rear view
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.)
DJA2500 DJA4000
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18.0 Transformer Removal
18.3 Remove transformer mounting hex Bolt & plain washer from chassis bottom.
19.1 Place the transformer in the chassis & align mounting hole.
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
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
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.
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.
- Feed 1KHz signal & adjust output at just clipping level.
Power Output in V
Load
Ch 1 Ch 2
59V 59V 4Ω
66V 66V 8Ω
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
7) SUB WOOFER MEASUREMENTS
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- Connect the amplifier in stereo mode with 4Ω loads at 1 kHz.
- 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.
- Using the XO control at the rear set the required frequency. Following are the frequencies at which
output is 21V(+/-1V).
FREQ FREQ Variation
43Hz +/-5Hz
63Hz +/-5Hz
120Hz +/-10Hz
140Hz +/-10Hz
180Hz +/-25Hz
9) X TALK MEASUREMENT:
- Connect the amplifier in stereo mode with 4Ω loads at 1 kHz.
- 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
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.
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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)
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 .
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)
1) SENSITIVITY
- Drive single channel into 4 ohms load in Stereo mode at 1 kHz.
- 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.
Power Output in V
Load
Ch 1 Ch 2
82.5V 82.5V 4Ω
87V 87V 8Ω
Power Output in V
Load
Ch 1 Ch 2
75V 75V 4Ω
85V 85V 8Ω
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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
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
7) SUB WOOFER MEASUREMENTS
9) X TALK MEASUREMENT:
- Connect the amplifier in stereo mode with 4Ω loads at 1 kHz.
- 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
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.
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 .
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13) FAN TEST
FAN speed increases when the temperature on the heat-sink goes above 60 °C.
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COMPONENT PIN CONFIGURATION
1. IC 4558 /LM358 2. IC 7812/7912
COLLECTOR
2
1
BASE
3
EMITTER
1 2 3
2SA1943
COLLECTOR
2
1
BASE
3
EMITTER
1 2 3
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TROUBLESHOOTING
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• 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.
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SPARES LIST
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LAYOUTS & LEGENDS
1. Input Pcb
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2. PSU
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5. DJA2500 Output Pcb
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7. Power Amp Pcb
DJA2500 DJA4000
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PCB SCHEMATICS
1. Input Pcb
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2. LED & OUTPUT Pcb
3. DJA2500 PSU
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4. DJA400 PSU
36
6. DJA4000 Power Amp
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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
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