SERVICE MANUAL

XTR-400
ACTIVE SPEAKER SYSTEM
SUBWOOFER / SATELLITES

CONTENT’S:
Cautions, Connections, & Operations :....................................Page 2-4

Specifications:..............................................................................Page 4

Parts Lists:....................................................................................Page 5

PCBs:..........................................................................................Page 6-8

Schematics....................................................................................Page 9

Gemini Sound Products Corp.

120 Clover Place P.O. Box 6928
Edison, NJ 08818-6928
732-738-9003 (Phone) • 732-738-9006 (Fax)

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(2)
INTRODUCTION: OUTPUT SECTION:
Disconnect unit from the AC power source before making any connections.
Congratulations on your purchase of an XTR-400 speaker system
engineered & manufactured by Gemini Sound Products. This state of the
SPEAKER OUTPUTS (3): The speaker output connectors are Speakon™
art speaker system is backed up by a three-year warranty. The XTR-400
connectors that will accept cables with Speakon™ connectors. (These
offers ultimate fidelity, power handling, and an array of features that makes
cables must be purchased separately) The subwoofer is already connected
it a highly versatile, compact, self contained & powered speaker system.
internally, so you don’t have to worry about connecting it to the amplifier.

FEATURES: AC POWER SECTION:

• Active self-powered 400W rms tri-amp design. POWER SWITCH (8): turns the unit on and off.
• One 15-inch bandpass subwoofer. Features top-hat hardware for pole mounting of a
satellite speaker and metal corner protectors.
• Two high quality satellite speakers featuring 10-inch woofers and dual piezo horns housed in POWER LED (9): the power LED lights when the power is on.
trapezoidal cabinets. Satellite speakers are uniquely designed for placement on stands or for use
as floor monitors, and protected by full front metal grill and metal corners.
• Built-in active optimized crossovers.
FUSE (4): replace with proper type and rating.
• Sensitivity/Volume controls.
• Satellites equipped with reliable Speakon™ connectors for exceptional sound. AC INLET (6) is used to attach the power cord to the unit.
(cables must be purchased separately)
• Signal Ground Lift Switch for achieving the quietest possible hum-free operation.
• Airflow controlled by variable speed fan for maximum cooling and quietest possible operation. AC LINE VOLTAGE SELECTOR SWITCH (5) allows reconfiguring
• Mono or Stereo operation. amplifier for either 110-120V or 220-240V AC lines.
• AC line voltage selector switch allows reconfiguring amplifier for either 110-120V or 220-
240V AC lines.
• Compact design featuring large metal handles and casters for ease in transporting.
OPERATION:
CAUTIONS: STEREO OPERATION:
The unit has two channels for stereo operation. Each channel provides a
1. All operating instructions should be read before using this equipment.
separate signal at the speaker outputs. The following instructions are
for use with 8W speakers of matched power ratings. We suggest only
2. To reduce the risk of electrical shock, do not open the unit. There are,
using the speakers that come with the unit.
NO USER REPLACEABLE PARTS INSIDE. Please refer servicing to a
qualified Gemini Sound Products service technician.
1. With the power OFF, connect your input cables from your music source
In the USA: If you experience problems with this unit, please call 1 (732) 738-9003 for (such as your mixer) to the Channel 1 and Channel 2 INPUTS using the
Gemini Customer Service. Do not attempt to return this equipment to your dealer. XLR INPUT JACKS (1) or 1/4" PHONO INPUT JACKS (2).
3. Do not expose this unit to direct sunlight or to a heat source such as a
2. Connect your speakers to the Channel 1 and Channel 2 SPEAKER
radiator or stove.
OUTPUTS (3).
4. This unit should be cleaned only with a damp cloth. Avoid solvents or
3. With the SENSITIVITY/VOLUME CONTROLS (10) of both channels
other cleaning detergents.
set to zero (fully counter clockwise), turn the POWER SWITCH (8), ON.
Okay, now try playing some music and/or talking into your microphone,
5. When moving this equipment, it should be placed in its original carton
and set the level of your input as high as you think you’ll need it. This way
and packaging. This will reduce the risk of damage during transit.
it will be as high above the amplifier’s noise floor as possible so you’ll get
the best possible sound with the least amount of noise. Now play some
6. DO NOT EXPOSE THIS UNIT TO RAIN OR MOISTURE.
music and listen for audible distortion. If you do hear distortion decrease
the output level using the SENSITIVITY/VOLUME CONTROLS (10).
7. DO NOT USE ANY SPRAY CLEANER OR LUBRICANT ON ANY
CONTROLS OR SWITCHES.
MONO OPERATION:
Connect your MONO signal to the Channel 1 input (1 or 2). Now create a
CONNECTIONS: link by connecting the remaining Channel 1 input to a Channel 2 input
INPUT SECTION: (1 or 2) using a standard balanced cable (may be purchased separately).
There are two parallel input connectors (one female XLR and one 1/4” jack) per You can adjust the level of each satellite speaker using it’s channel’s
channel. Either can be used as an input or as a link to chain amplifiers. SENSITIVITY/VOLUME CONTROL (10).

XLR INPUT JACKS: XLR INPUT JACKS (1) electronically balanced
inputs accept a standard XLR male connector. Pin 1 = shield/ground, pin
2 = hot or positive (+) and pin 3 = cold or negative (-).
1/4" PHONO INPUT JACKS: 1/4" PHONO INPUT JACKS (2) accept a
balanced as well as an unbalanced line. The unbalanced line uses a
standard tip-sleeve connection. The tip is positive and the sleeve is
negative/ground. The balanced line uses a tip-ring-sleeve connection.
Tip = hot or positive (+), ring = cold or negative (-), and sleeve = shield/ground.
USING THE SIGNAL GROUND LIFT SWITCH:
Depending on how your sound system is hooked up, sometimes applying
the ground will create a quieter signal path. Sometimes lifting the ground
can eliminate ground loops and that annoying hum to give you quieter and
cleaner overall sound.
1. With the power amp ON, listen to the system in idle mode (no music or
signal) with the ground ON. The SIGNAL GROUND LIFT SWITCH (7) will
be in the left position.

SENSITIVITY/VOLUME CONTROLS: SENSITIVITY/VOLUME CONTROLS 2. Turn the power OFF before moving the SIGNAL GROUND LIFT SWITCH (7).
(10) control the input levels for each channel of the 2 satellite speakers. Now lift the ground by moving the SIGNAL GROUND LIFT SWITCH (7)
The volume level of the subwoofer is controlled automatically to match the to the right. Turn the power back ON and listen to determine which position
volume levels of the satellite speakers. It will always maintain a perfect makes the overall sound quieter with the least amount of noise and hum.
balance to give you incredible sound quality!
CAUTION: DO NOT DISCONNECT THE AC GROUND ON THE POWER AMPLIFIER IN ANY WAY.
SIGNAL GROUND LIFT SWITCH: SIGNAL GROUND LIFT SWITCH (7) THIS CAN BE VERY HAZARDOUS!!
is used to lift the balanced input connectors’ ground/shield from the
amplifier’s ground. When the signal ground lifted, the sound source
disconnects from the amplifier’s ground preventing ground loops which
can generate hum and noise. See the Signal Ground Lift Switch
Instructions for more detail.

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SETUP: SPECIFICATIONS:
There are various ways to set up this system: Subwoofer XTR-400SUB:
Amplifier’s Output Power:.........................230 Wrms on subwoofer channel
BASIC SETUP: Frequency response:……………………...........................….32 Hz - 100 Hz
Okay, this is your basic setup, perfect for small parties and venues. The Components:………………………...........................……………..15" woofer
ideal location for your subwoofer is close to a wall or in a corner. This Features:
will give you the fullest bass response. Your 2 satellite speakers can be Efficient band-pass cabinet design
placed up on stands on each side (stands must be purchased separately). Large metal handles
Metal protection corners
TWO-SYSTEM SETUP: Four 2" wheels
Amplifier assembly on the back
This setup is perfect for larger venues. This setup requires 2 XTR-400
35mm standmount cap on top
systems. This will give you a total of 800 watts rms! Place a subwoofer
Black carpet finish
on each side to the left and right. Using the high-hat hardware and
Rubber feet
connecting pole (which can be purchased separately), place the
Dimensions:..............................................................WxDxH: 20"x31"x24.5"
pole in the high-hat socket on the subwoofer, and a satellite speaker on
(508 x 788 x 622 mm)
top of the pole. The 2 remaining satellite speakers may be used as either
Weight:…………………............................……………………..96 lbs (44 kg)
floor monitors, or placed on stands elsewhere in the room giving you a
Satellites GT-1002s:
louder and fuller sound.
Amplifier’s Output Power:..........................2x85 Wrms on satellite channels
Frequency response:…………............................………….100 Hz – 20 kHz
Each speaker system in this setup must be used in MONO mode (see
Components:….…………...........................……………………….10" woofer
Mono section). Connect the system that is on the left side of the audience
6” dual piezo horn
to the LEFT channel of your mixer, and the system that is on the right side
Features:
of the audience to the RIGHT channel of your mixer.
Trapezoidal cabinet
Full front protective metal grill
ACTIVE SPEAKER SYSTEM SUBWOOFER/SATELLITES Metal protection corners
The XTR-400 features a unique design for ease in transporting. The 2 35 mm standmount cup on the bottom
satellite speakers conveniently fit into a special recessed section of the Black carpet finish
subwoofer and are securely fastened using a strap that attaches to the Rubber feet
handles (included). Neutrik Speakon connector
Dimensions:……….……..............................…….W x D x H 12.5" x 9" x 18"
(318 x 229 x 458 mm)
Weight:……………………...........................………………18 lbs (8 kg) each
Total System:
Maximum SPL, continuous:……...........................……………………120 dB
Sensitivity………………………...........................……………………. 1 Vrms
Input Impedance………...............10 kOhm unbalanced/20 kOhm balanced
Features:
Balanced XLR and 1/4" Jack inputs
Neutrik Speakons on Satellite Channels’ outputs
Active electronic X-over (Fx=100 Hz)
Variable speed fan
Individual channel Sensitivity/Volume controls
Signal Ground lift switch
110-120 VAC / 220-240 VAC switchable

Total Weight:……………............…...............………………...132 lbs (60 kg)

SPECIFICATIONS AND DESIGN ARE SUBJECT TO CHANGE WITHOUT
NOTICE FOR PURPOSE OF IMPROVEMENT.

SHOULD YOU EXPERIENCE ANY DIFFICULTIES OR PROBLEMS,

PLEASE CALL: 1 (732) 738-9003 FOR GEMINI CUSTOMER SERVICE.

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 PARTS LIST:
Item # Designators Description Part Number

MAIN PCB:
1 ZD3, ZD2 ZENER DIODE 1/2W 12V (RD12EB2) 079-012
2 D3, D1, D2 SILICON DIODE 1N4148 079-003
3 ZD1 ZENER DIODE 1/2W 24V (RD24EB2) 079-020
4 Q1 SILICON TRANSISTORS 2SC1815 076-003
5 Q2 SILICON TRANSISTOR 2SC4793 076-100
6 C18, C13 ELECTROLYTIC CAPACITORS 6800µ µ/50V 050-198
7 REC1 BRIDGE RECTIFIER KBPC804W 086-019
8 U3, U2, U4, U1 INTEGRATED CIRCUIT TDA7294V 074-189

CROSSOVER PCB:
1 VR1, VR2 ROTARY VR 10KA L:15MM 071-228
2 LD1 φ
LED (GREEN) 5φ 080-086
3 IC1, IC3, IC2 INTEGRATED CIRCUIT NJM4558DD (BA15218,M5218AP) 074-163

INPUT PCB:
1 SW1 SLIDE SWITCH SV70050 081-030
2 IC1 INTEGRATED CIRCUIT NJM4558DD (BA15218,M5218AP) 074-163
3 X3, X2 φTRS 1/4" BAL
PHONE JACK 6.3φ 092-078
4 XLR2, XLR1 XLR XLF-3PH 092-069

OUTPUT PCB:
1 X1, X2 SPEAKON™ CONNECTORS NL4MP 092-149

OTHER:
1 AC CORD 093-369
2 AC INLET 092-105
3 DC FAN 24V 001-613
4 TRANSFORMER 059-247
5 SLIDE SWITCH 081-023
6 POWER SWITCH 083-121
7 FUSE VBS UTE 3.15A 250V 100-068
8 FUSE VBS UTE 6.3A 250V 100-071

In the USA: If you should experience problems with this unit,

please call 1 (732) 738-9003 for Gemini Customer Service.
Do not attempt to return this equipment to your dealer.

(5)
 INPUT PCB
SW1

C1
R5

XLR1

R1

R2

X2

X1 R6
C5
C3 R8
C2
IC1

R7
R4 C4
R9

OUTPUT PCB
R3

X3 + +
XLR2 G

XTR400-4
XTR400-3
Page 6
 MAIN PCB TOP LAYER X-OVER
XTR400-2

X3 XTR400-1 L4

LD1
C14
R16

R14
R13 R14 C19

R1
R19
R8 R37 R15
C13
X10

RED/BLK
C4 J3

R7
C8 U3
R20

C5
15
J9 C29
1

IC2
X2

R3 C7 C11
C27

R2 R3 R4
RED

C17 R26
R21
R11 J1 R30
C1 R15 C16
J2
C1
C22
15

1
U1 R31 X12
J5 C7
C15 J8 R32
C5
C9 C20
L3 C8
L1 R9 R21
R4
R12 D2 R36 C6
R16 C21
X1

R18 VR2
C10 U2 U4

X2
R22 X11

15
RED

J10
1

R17
R6 C6 R23

BLK
C2 C23 IC3
R18
VR1
L2 R24

C24
R27

C25
R17

R35
J2

C28

R12
R38
15

J3 J4

1
C10
R10
C11

R13
R7
C9

ZD2
R25
Q1 X4
R5
C12

J6 X9
ZD1 C14 C31 J1
C3 X1

R22
R28

C4
X13 R11
BLK RED J7 C18
X4 R10
X7 R29
C26 R9

C3
Q2 R8
ZD3
R1 X5 X6 AC -
BLK BLK

C2
R33
R34

1 R2 + C32
REC1 AC R20 X3
C30 R19 IC1

D1 RED D3 R6
C13
X8 C12 R5
 MAIN PCB BOTTOM LAYER X-OVER
XTR400-2

X3 XTR400-1 L4

LD1
C14
R16

R14
R13 R14 C19

R1
R19
R8 R37 R15
C13
X10

RED/BLK
C4 J3

R7
C8 U3
R20

C5
15
J9 C29
1

IC2
X2

R3 C7 C11
C27

R2 R3 R4
RED

C17 R26
R21
R11 J1 R30
C1 R15 C16
J2
C1
C22
15

1
U1 R31 X12
J5 C7
C15 J8 R32
C5
C9 C20
L3 C8
L1 R9 R21
R4
R12 D2 R36 C6
R16 C21
X1

R18 VR2
C10 U2 U4

X2
R22 X11

15
RED

J10
1

R17
R6 C6 R23

BLK
C2 C23 IC3
R18
VR1
L2 R24

C24
R27

C25
R17

R35
J2

C28

R12
R38
15

J3 J4

1
C10
R10
C11

R13
R7
C9

ZD2
R25
Q1 X4
R5
C12

J6 X9
ZD1 C14 C31 J1
C3 X1

R22
R28

C4
X13 R11
BLK RED J7 C18
X4 R10
X7 R29
C26 R9

C3
Q2 R8
ZD3
R1 X5 X6 AC -
BLK BLK

C2
R33
R34
1 R2 + C32
REC1 AC R20 X3
C30 R19 IC1

D1 RED D3 R6
C13
X8 C12 R5
 SCHEMATIC
X2 X-OVER PCB X4 X3 MAIN PCB

7 7 + 12V 1 1 CH.1 (L) INPUT

R11 R9
6 6 22.1K 1% 13K 1% CH.1 (L) OUTPUT 2 2
C7
10uF25V NP C6 10pF C7 10pF
5 5 + 12V 3 3
CH.1 (L) INPUT
8

4 4 SUB OUTPUT (+) 4 4 SUB INPUT (+)

C6 C4 C3 2 R6 26.7K 1% R11 26.7K 1%
10uF25V NP .047uF5% .047uF5% 1
3 3 3 R17 13K 1%
CH.2 (R) INPUT IC1A +E +E
VR2 NJM4558DD R4 R14
2 2 10KA 1K 1% U2 TDA7294V 1K 1% U1 TDA7294V
4

CH.1 (L) R8
VOLUME 39.2K 1% - 12V C14
1 1 CONTROL 6 2 13 0.1 2 13
- 12V 7 IN - +PWVs SUBWOOFER IN - +PWVs CH.1 (L)
5 R9 5.1K R12 13K 1% 3 7 R8 5.1K R13 13K 1% 3 7
R10 IN + +Vs OUTPUT (+) IN + +Vs OUTPUT OUTPUT PCB
39.2K 1% R22 IC3B
13K 1% NJM4558DD 4 14 R10 8R2 1W X1 4 14 R3 8R2 1W X2 X1 NL4MP
R12 X3 X12 C10 IN+MUTE OUT RED C4 IN+MUTE OUT P1
L2 1.0uH L1 1.0uH RED 18AWG RED
60.4K 1% R21 13K 1% R2 13K 1% 2200pF C9 10 MUTE BOOTSTRAP 6 390pF C8 10 MUTE BOOTSTRAP 6 1+
R18 R14 R15 1 1 22uF25V 10uF25V
10K 1% 10K 1% 13K 1% 9 STBY -Vs 8 C11 22uF50V C2 9 STBY -Vs 8 C5 10uF50V C1 RED
0.1uF100V 0.1uF100V 1-
CH.2 (R) OUTPUT 2 2 CH.2 (R) INPUT 1 STBY-GND -PWVs 15 1 STBY-GND -PWVs 15
+ 12V R17 R18 R15 R16 C15 OUTPUT
+ 12V 3 3 5.1K 5.1K 5.1K 5.1K 0.1 2+ CH.1 (L)
8

6
8

C8 C5 2 R3 39.2K 1% R4 39.2K 1% 7 SUB OUTPUT (-) 4 4 SUB INPUT (-) 2-

2 .1uF 5% .1uF 5% 1 5 R34 5.1K -E -E
1 3 IC2B
3 IC2A NJM4558DD
R13 IC3A NJM4558DD C11
60.4K 1% 0.033uF5% R23
NJM4558DD 5.1K C32 R22 R20 X2 NL4MP
4

R1 22uF25V 5.1K 5.1K P3

4

39.2K 1% C1 0.033uF5% 1+
- 12V - 12V
R33 5.1K RED/BLACK STRIP
R7 1-
39.2K 1% OUTPUT
X1 X9
CH.2 (R)
R20 R6 1 1 +12V R24
22.1K 1% 13K 1% + 12V D3 8.2K C30 R21 C28 10pF 18AWG RED 45sm R19 C27 10pF 2+
C10 1N4148 10uF25V 5.1K 5.1K
C13 0.1 2 2 Ends
Twisted pair to Subwoofer terminal striped 2-
100uF16V 15mm
3 3 -12V R38 26.7K 1%K 18AWG BLACK 45sm R26 26.7K 1% P2
- 12V

18AWG RED/BLACK STRIP

R16 BLACK
C2 C12 6 2.4K +E +E
.047uF 5% .047uF 5% 7 C14 C9 R25 R32
5 100uF16V 0.1 1K 1% U4 TDA7294V 1K 1% U3 TDA7294V
IC1B LD1
VR1 NJM4558DD GRN C16

18AWG BLACK
10KA 2 13 0.1 2 13
CH.2 (R) R19 IN - +PWVs SUBWOOFER IN - +PWVs CH.2 (R)
VOLUME 39.2K 1% R35 5.1K R27 13K 1% 3 7 R30 5.1K R31 13K 1% 3 7
IN + +Vs OUTPUT (-) IN + +Vs OUTPUT
CONTROL
4 14 R36 8R2 1W X11 4 14 R37 8R2 1W X10
C24 IN+MUTE OUT BLACK C22 IN+MUTE OUT RED/BLACK STRIP
R5 2200pF C25 10 6 L3 1.0uH 390pF C20 10 6 L4 1.0uH
39.2K 1% 22uF25V MUTE BOOTSTRAP 10uF25V MUTE BOOTSTRAP
9 STBY -Vs 8 C21 22uF50V C23 9 STBY -Vs 8 C19 10uF50V
0.1uF100V C29
1 STBY-GND -PWVs 15 1 STBY-GND -PWVs 15 0.1uF100V
C17
0.1

POWER PCB -E -E

CH.1 (L) INPUT PCB P1 SW3 SW-POWER P2 BRN T1 +E

INPUT
C4 270

D1 1N4148 R2 2.4K
C101
1

P3
3 FUSE
R9 10K 1% 6.3A / 110-120V R5 Q2
XLR2 X6 BLACK 2.4K 2SC4793
XLF-3PH R3 10K 1% 6 3.15A / 220-240V BLU +E +12V
2

7 To CENTER TAP
5 F POWER TRANSFORMER
R4 10K 1% IC1B L R29 1.2K 3W R1 8.2K
T NJM4558DD X1
R R7 R7 Q1
S 10K 1% + 12V 7 7 E ORG X8 68 2SC1815
C2 RED REC1 C26

3
X3 TRS 1/4" BAL R5 510 270 SW4 100uF16V X4
6 6 N VOLTAGE SELECTOR To POWER KBPS10-02
TRANSFORMER C13 ZD3
C1 0.047uF 115v 230v 6800uF50V 12V 0.5W D2 ZD1 C12 C3
5 5 CH.1 (L) OUTPUT 2 4 T 1N4148 24V 0.5W 4.7uF50V 220uF25V FAN FAN1
24 Vdc 24Vdc/0.19A
AC INLET C18
4 4 X7 RED 6800uF50V
5

4 6 BLK C31
ZD2 100uF16V
SW1 To POWER
1

12V 0.5W
"Signal ground lift" 1 3 3 3 CH.2 (R) OUTPUT TRANSFORMER
WHT
2

2 2
C5 270 X13 BLACK R28 1.2K 3W

- 12V 1 1 -E -12V
R8 10K 1% To CHASSIS
X5 BLACK
1

+ 12V To SPEAKER
3 OUTPUTS
8

XLR1 R6 10K 1%
XLF-3PH 2
2

1 18AWG BLACK 18AWG BLACK

3
R1 10K 1% IC1A
T NJM4558DD
R
4

S C3
270 - 12V
X2 TRS 1/4" BAL R2
10K 1%
CH.2 (R)
INPUT

Page 9
 In the USA: If you experience problems with this unit,
call 1-732-738-9003 for Gemini Customer Service.
Do not attempt to return this equipment to your dealer.

Parts of the design of this product may be protected by worldwide patents.

Information in this manual is subject to change without notice and does
not represent a commitment on the part of the vendor. Gemini Sound
Products Corp. shall not be liable for any loss or damage whatsoever
arising from the use of information or any error contained in this manual.
No part of this manual may be reproduced, stored in a retrieval system or
transmitted, in any form or by any means, electronic, electrical, mechanical,
optical, chemical, including photocopying and recording, for any purpose
without the express written permission of Gemini Sound Products Corp.
It is recommended that all maintenance and service on this product is
performed by Gemini Sound Products Corp. or its authorized agents.
Gemini Sound Products Corp. will not accept liability for loss or damage
caused by maintenance or repair performed by unauthorized personnel.

Worldwide Headquarters • 120 Clover Place, Edison, NJ 08837 • USA

Tel: (732) 738-9003 • Fax: (732) 738-9006

France • G.S.L. France • 11, Avenue Leon Harmel, Z.I. Antony, 92160 Antony, France
Tel: + 33 (0) 1 55 59 04 70 • Fax: + 33 (0) 1 55 59 04 80

Germany • Gemini Sound Products GmbH • Ottostrasse 6, 85757 Karlsfeld, Germany

Tel: 08131 - 39171-0 • Fax: 08131 - 39171-9

UK • Gemini Sound Products • Unit C4 Hazleton Industrial Estate, Waterlooville, UK P08 9JU
Tel: 087 087 00880 • Fax: 087 087 00990

Spain • Gemini Sound Products S.A. • Rosello, 516, Barcelona, Spain, 08026
Tel: 349-3435-0814 • Fax: 3493-347-6961

© Gemini Sound Products Corp. 2002 All Rights Reserved