Yorkville-APSeries-pwr-qrg 维修电路原理图.pdf

The Yorkville In-House Method for Repairing AP Series Amps At Yorkville, we have developed a method of rebuilding AP series power boards in the shortest possible time. This method is valid for repairing about 95% of all AP amp failures and is essentially the same process for each of the different models in the AP line. This process was not designed to correct problems other than blown outputs and collateral losses. We still see an occasional failure in other areas, but about 95% of all amps that you receive in PROTECT mode, will benefit directly from this method. This uniformity of approach is possible because all AP series amps share the same basic circuit topography and protection circuits. The rail voltages and the number of output devices may change, but overall they remain more alike than they are different. Only the AP800 & AP1020 have enough differences to warrant a comment or two. The entire program rests on the experience we gained while rebuilding these boards. What became apparent was the fact that we needed to focus on rebuilding the board and not trying to ANALYZE the problem. As you can imagine, this practice goes against just about everything we have practiced as repair technicians. But, by using this method, we were able to reduce turn-around time and expense by more than 50%. In fact, with practice, an average technician can do a full meltdown rebuild in about 90 minutes. The exception to this rule would be the AP 6040, which runs about 3 hours for an average rebuild. The root of this system is the practice of NEVER measuring TO-92 style transistors. They are always replaced because it takes about 5 minutes to replace them and they cost next to nothing compared to the cost of analysis and the risk of a failed rebuild. I instituted this policy after discovering that these little transistors have a really nasty habit of “half-failing”. By this I mean that we were testing these things in the normal fashion and they were showing “good”, but when powered up to operating voltage, they would do all kinds of inexplicable things. As soon as I mandated the practice of always replacing these little transistors, these strange post-rebuild malfunctions disappeared and departmental efficiency went way up. RadioFans.CN 收音机爱 好者资料库 Determining which channel is blown In order to determine which channel(s) requires repair, it is only necessary to open the chassis and flip the upper circuit board out of the chassis without disconnecting any wires ( be sure to insulate the board from touching the chassis when in this position). Then all you need to do, is turn on the power and measure the voltage across ZD7 on each power board. (The location of ZD7 is shown on the M1146 Diodes & Semis PDF) If the voltage here is less than the zener rated voltage of 16volts, the board under test is blown and probably in DC offset. Locating Defective Parts Attached to this file are 3 PDFs that locate and identify all the components which require measuring. For the purpose of clarity I have divided the components into 4 groups, each with its own colour. Further to this, I separated the parts into 2 PDFs, one for resistors and one for semiconductors. In order to provide maximum clarity, I have expanded isolated areas of the circuit board, showing only the area of the board, which is home to the suspect components. By doing this I have cropped out half of the output transistors, emitter resistors and tier diodes (MR854) from view. Please be certain to test these none-visible parts along with the rest of the output devices , resistors and diodes. The PDF Colour Coding Green These are the large transistors and Fets. Simply test these with your diode checker and replace any shorted units. You will almost never need to replace the tier Fets, they never seem to fail, but we check them anyway. Although it is not shown on the PDF, you will need to check the output crowbar TRIAC for shorts, along with everything else. Blue These are all the diodes to be measured (remember, we only show 4 of the 8 MR854 tier diodes which must all be measured). The only significant measurement in this group will be a short circuit which signifies a diode to be replaced. RadioFans.CN 收音机爱 好者资料库 Red NEVER MEASURE THESE, Always replace these 8 transistors Yellow These are the resistors to be measured. You are only interested in units, which measure open circuit, all other readings are meaningless at this time Please note that we are only measuring resistors of 249 ohms or less, with the exception of the 2 x 3K resistors and the 10K trim pot. The Process With the component side up and the heatsinks farthest from you. We use a continuity checker (you may use a diode checker) and begin by checking the 8 emitter resistors for open circuit. I immediately cut out any components that measure defective, We do not unsolder the lead fragments until I have cut away all the various bad parts. Next. Measure the MR854 tier diodes and cutout any bad ones. Now measure all the transistors outlined in GREEN, cut out or remove any which are shorted. The output devices must obviously be unsoldered to remove them from the board. Please note that it is not uncommon to find it necessary to unsolder and isolate all of the output bases and emitters in order to find all the shorted output devices. Now measure all diodes in BLUE (except theMR854 that you have already done) and cut out any that read short. When that is done you may measure all resistors shown in YELLOW, and cut out any that read open circuit. It is also a good idea to check the bias trim pot (orange colour) just to be safe. Once you have located and cut out all the short and open components, it is time to unsolder and remove all the remaining pieces of the component lead wires from the board. After that, collect all the parts you need and install them to the board. For the sake of efficiency, I have small parts bins on the bench which have quantities of all the values of resistors I need and all the diodes as well. I only go to the main parts bins to get the big transistors required for the job. (10 different resistors and 6 different diodes will cover 90% of the work). I also keep the mandatory TO-92 devices on my desk because they are always replaced on every job. After you have replaced all the defective parts, it is time to repeat the measurement process. This is a precaution against installing the wrong value or inverting the polarity of a diode and things like that. This time the values you measure will be quite close to the value of the installed resistors (except for R11 which usually reads about 16ohms). When you are satisfied that all the right parts are in the right places and measuring the appropriate value, you may proceed to a soft start power up of the board. If all goes well, you need only set the bias and return the board to the chassis. Exceptions to the rules There will be rare occasions when the voltage amp will be compromised as well as the current amp. In this case it is only necessary to use the same basic process to repair the voltage stage. And as always, just replace the small signal transistors as we do for the current amp stage. In order to effectively deal with the voltage amp, it will probably be necessary to electrically isolate the voltage amp from the current amp. To do this I have created a PDF called “Separate voltage and current amps AP4040”. When you are finished the repair, just restore the original connections for normal operation. The AP6040 is a special case as a rebuild. This is due to the fact that a 6040 is really pretty much 2 AP4020s on each output circuit board. In order to repair these boards, you should treat them as a permanently bridged AP4020. Repair each half of each channel as if they were separate AP4020s. Due to the high currents generated in the bridged condition, these amps are more susceptible to destroying circuit board traces than their un-bridged counterparts. Please keep a sharp lookout for bad traces on this board. Because this amp is really 4 complete amps an two boards, we found the rebuild times to be twice what they are for our regular two channel amps. VCDSOLDERSIDE M1146-6.00BABRIDGEM1126BLANK SIZE=14.750X10.850M1146-6.002oz.COPPERDGGSDRILL M1146-6.00J33D20A4148J23D14148C21NR610K0J30R71100KD94148C322U10VTAB7J3216AWG5.5PURJ21R32R2R42R2D24148R15150RR104K7R7150RR351KD34148R1612KR1122RR1439RR1327KR812KR19249RR5249RR268RR3727KR3827KR3991KR6722K0.5W1R51220R0R491R/1WR30620RR3139RR4739RC3210U63VR272R2R412R2R26470RR203KD11BAV21J11TAB6TAB4R6433KR6510RQ1BC550Q4BC550Q2BC560Q3BC560Q9BC550Q10BC560Q8BC550RT110KVBEC4470PR635R65WATTTAB3#3894TAB1GSQ11MTP10N15LGSQ12MTP8P20J16ZD916V/1WZD816V/1WC11N5J6C9200V4N7C20A2N2/500VC16470PC1222NC1322NR35A20KWC716AWG7YELTAB2J3Q16AMJE340R29A3K65WATTR84200RJ29R525WATT0R15R530R155WATTR570R15WATTR560R15WATTR590R15WATTR580R15WATTR610R15WATTR600R15WATTR293K65WATTR453K65WATTQ22YS6927.R63A39RQ24YS6927.R6622K0.5WQ26YS6927.Q21YS6927.Q28YS6927.Q13YS6900.Q14YS6900.Q16YS6900.Q18YS6900.Q20YS6900.D44148Q23YS6927.Q27YS6927.D15MR854D14MR854D13MR854R20547KD21MR854D19MR854D18MR854D17MR854D16MR854D22MR854J22R441/2W1RZD412VZD124V7C6330U16VC7330U16VQ72N6517C11220N250VQ30TRIACMAC224-4DC_PROTJ9R68A3K3R623R92WATTD10BAV21TP4TP5TP7TP6TP8TP9TP10TP1J20R212K2ZD512VD54148R234K7R24220KR25220KR424K7R223KZD716V/.5WC26#589680V4700uD74148C25#589680V4700uQ41MJE350FUNCTIONQ6.MJL1302AR1810K0Q40MJE340FUNCTIONR69A3K3C24#589680V4700uC27#589680V4700uR86470RQ21ABC560Q20ABC5501MX1CABLE=#3706J2R59A10RC2110U16VR85R47/1WR81220RR66A10RWC6C23#589680V4700uVTRR45A1KR721W4K7C28#589680V4700uR4839RC522U10VR70A10KJ15Q15YS6900.Q17YS6900.Q25YS6927.R42A56KTAB5R65A10RJ13J24Q19YS6900.D301N4004J18J17R82200RQ29MBS4992L14uHR331R/1WC14220N250V22ND20MR854R3691KZD104V7WC6J10EY3EY9R7018KR67A10KQ5.MJL3281AZD114V7R55220R0R281/2W1RD15A4148R6822K0.5WZD1333VR40B20KC3022NJ14EY2R6922K0.5WR401KC1910N250VR50270RR43470RD17A4148C81U63VEY5D311N4004R80220R12R3239RC29#589680V4700uR39A7K5R41A7K5R9249RR38A56KR44A1KC25A4U710VR46A4K7R47A1K5R49A2KR50A4K7R51A1K51HOLDER=#3676R71A33RR43A3KR56A17K8C17220PR58A39RJ12R139RR62A47R5U14N35C18A22U16VC19A22U16V#3894Q15AMJE350C26A4U710VC22#589680V4700uR732KR74330RQ31AS35D14A4148D13A4148R40A220RD16A4148D18A4148R461KJ1D19A4148D23A4148D22A4148Q14ABC560Q17ABC550J4R61A47RC29A330U16VQ12AMPSA42Q13AMPSA92U24N35R83200RR60A220K2WC27A10u160VC28A160V10uQ18AMJE340Q19AMJE350C23A500V10PC22A500V10PTP5AD21A4148J26HS2#3894HS1#3894EY8EY7EY41+1-2+2-JB2.EY6C3122NR34270RJZD3R17249RJ5R57A150RC30A33u16VR72A33RR53A2KC31A33u16VEY1R45A3K65WATTJ341+1-2+2-JB3.R1239RJ19R55A21K5R64A150RVTRVTRVTRVTRVTRVTRVTRVTRVTRVTRVTRVTRVTRVTRVTRC10 2N2/500V1110987654321#DESCRIPTION OF CHANGEVER#DATEMODEL(S):-D.OCT/12/00AUG/12/99JUL/08/99JAN/27/99.SEP/10/98JUL/45/98JUN/19/98FEB/12/98V.6.005.004.003.00.2.001.021.011.00NPC#6083_REDO_GND_TRACKSPC#6278_ADD_R86-C17_AT_Q41CORRECT_ERROR_IN_SPKONSSPKON_JACKS_RE-CONFIGUREDPC#5908_U1,U2_4N35-TLP621R64A_C30A/R72A_C31A/R71APC#5806_ADD_33R_33u/16V_ACROSS_R57APC#5798_R72_4K7_1/2W-4K7_1WPC#5767_C10/C15/C20A_2N2_TO_PT#5427RENAMED_M1126A-M1146AP4040M1146.PCB_DATABASE_HISTORYC152N2/500VGNDGNDR-R+L+L-NFBPRTCTSIGCLIPTSENSECLIMASSEMBLY M1146-6.00BLANK SIZE=14.750X10.850PCBMECH M1146-6.0010WITH FLAT SIDE UP AS SHOWN.Q31 IS HAND INSERTED AND BENT OVER9T126 TYPE DEVICE87654PRODUCTION NOTESMOUNTING HARDWARE FOR Q11,Q123USE #XXXX SMALL BODY 1R 1WMOUNTING HARDWARE FOR Q40,Q41MOUNTING HARDWARE FOR Q5,Q6T264 DEVICE#8741 4-40X 1/2 BOLTBLUWHTBLKYELREDFOR R33,R49COOLED FROM WAVE SOLDER IS 6 INCH/LBINITIAL TORQUE FOR TO-3S IS 8 INCH/LBMOUNTING DETAILS FOR 5W MOUNTING DETAILS FOR Q30 TRIAC16AWG16AWG16AWG16AWG16AWGOUTPUT -OUTPUT +TAB 7TAB 6TAB 5TAB 4TAB 3TAB 2TAB 1TAB WIRE COLOURSUSE #8799 TO MOUNT TRIAC Q30MOUNTING HARDWARE FOR TO3 OUTPUTSTORQUE 4 INCH/LBTORQUE 4 INCH/LBTORQUE 4 INCH/LB21#8701 4-40 KEPS NUT#8701 4-40 KEPS NUT#8701 4-40 KEPS NUT#3797 THERMO PAD#3797 THERMO PAD#8871 4-40X 1/2 BOLTPCBPCBPCBHEATSPREADERHEATSPREADERHEATSPREADERHEATSPREADER#3846 MICAT-220 DEVICE#8667 SHOULDER WASHER#3501 BELL WASHER#3501 BELL WASHER#3501 BELL WASHER#8741 4-40X 1/2 BOLTR29, R29A R45 AND R45A5 WATT RESISTORSADD #8629 SPACERS ONLY ON321AGAINST THE COPPER SURFACEMARKED 2 AND 3 ARE BENT FLATIT IS IMPERATIVE THAT LEGS BEND LEGS IN DIRECTION SHOWNDO NOT CUT LEGSAFTER MOUNTING DEVICEIMPORTANT1/4OF TRANSISTORBEND DOWN 1/4 FROM BODYFINAL TORQUE AFTER HEATSINK HAS#8835 BOLT#8663 SPACER#3815 MICATO-3 TRANSISTOR#8800 6-32 KEPS NUTBOTH SIDES OF THE MICA PADMICA GREASE IS REQUIRED ON4RED 13RED 2.5BLK 18BLK 3.519YELL2.5YELL14BLKBLKSPACERUSED AS ATHIS CAPS ISJUMPERWIRE TOSOLDERBLUEM1146AP-4040HOLEHOLEMARCONIMARCONIYELNOTE #6-OUTPUT+OUTPUTVER:6.00BABRIDGEYELYELREDBLKBLKBLKBLKM1146AP-4040M1146 2 oz. COPPER+145V+78VGND-78V-145VP:1146V60.PRNIn order to separate the voltage amp from the current amp. It is only necessary to remove jumpers J11 and J12 (highlighted in red) and then make the two new connections as shown by the BLUE dotted lines.CLINCHORIGINLONG AXISSHORT AXISINSERTORIGIN9V30Pcb MechM1146BlankSize - 14750 x10850TABNORMALSOCKETSOCKET WITH DIRECTIONNORMAL LARGESOCKET UPSIDE DOWNSPACERUSED AS ATHIS CAP ISBLK 189V30YELL2.519YELLJUMPERSOLDERBLK 14BLK 4RED 13RED 2.5BLK 3.5M1146Top AssyWIRE TOVTRVTRVTRVTRVTRVTRVTRVTRVTRVTRVTRGUIDEETCHVTRVTREBCEBCGUIDEETCHVTR1-2+1+2+1+2-2-NL4MP-11-SPEAKON 4CVTRGUIDEETCHVTRGUIDEETCHGUIDEETCH1-2+1+2+1+2-2-NL4MP-11-SPEAKON 4CFunctionFunctionFunctionFunctionFunctionBIAS TRIMFunctionFunctionFunctionFunctionFunctionFunction367665176880692558965834588258823628589638206880675258965896589658965896362870057004589610R33K7K556K41484N71K39R414810R1K52K3K3414847R0414840074148220K414820K0150R470P4148249R151R10K010K01N414822N1R1.0W41481R1.0W220R04V768R10R620R100K41482N22N2BC550C414816V039R033U16V10K2N239R39R04148470P4V791K10R39R01U63V2K218K4K716V0151R12V03K150R220P470R414820K01K2R2470R39R2R22R239R0330R16V022U50V10P200R470R91KTO220WattsSTM-BTB-600BRG10U16V7K5MR854 4K7MPSA9210P1K54K7MPSA421K4U763V4U763V220K2.0W33R1KAS35FN33U16V47R04148220K220R4N351R1/2W27KTO220WattsMTP8P2047K2N65174K712KBC550C220K470RMJE350TO12625V330U22U50V414812KMJE340TO12639R249RBAV21MR854 1N522NMR854 BC560C4700U 80V10N22U50V56KMR854 4148220R4148MJE350160V10U17K8BC560C220N250V220N250V5.0W3K64K71.0WMJE340BC560C151R22N220R10K25V330U400721K5MJE3504V7BAV21220P41483K220K5.0W0R15.0W0R11K25V330U200RBC560C27K22N2R222RBC560C0R471.0W10K4K7220R05.0W0R155.0W0R15BC550C5.0W3K65.0W3K62K33R2K200R4700U 80V4UH22K1/2W22K1/2W22K1/2W22K1/2WMBS4992MR854 MR854 151R39R03K34N351R1/2W33V0TO220WattsIRF630NPBFMR854 MR854 MR854 BC550C12V0270R22U50V43K270R4700U 80V4700U 80V4700U 80V4700U 80V5.0W0R15.0W0R1MJ21196MJ21195MJ211955.0W3K6MJE3403K4700U 80V10U63VBC550C10U160V5.0W0R15.0W0R1MJ21195MJ21195MJ21196BC550C22NMJ21195MJ21195MJ21196MJ21196MJ21196TO3P2SC5949-0MJ21196TO3P2SA2121-0MR854 4700U 80V3R92.0WMJ21195MJ21195MJ211965.0W5R6MJ21196CLIPCLIMPRTCTTSENSEGNDNFBSIGGND9V309V30R65R64R39AR42AD13AC9R44AR31D17AR65AR51AR53ATP6R69AX1X4D22AR61AX2D21AD30D23AX19R89X12D7R35AX14R15C4D5R19R17R18X25R6X