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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) (1) (2) OUTPUT SECTION: INTRODUCTION: 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 art speaker system is backed up by a three-year warranty. The XTR-400 offers ultimate fidelity, power handling, and an array of features that makes it a highly versatile, compact, self contained & powered speaker system. SPEAKER OUTPUTS (3): The speaker output connectors are Speakon™ connectors that will accept cables with Speakon™ connectors. (These cables must be purchased separately) The subwoofer is already connected 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. 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 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. Sensitivity/Volume controls. Satellites equipped with reliable Speakon™ connectors for exceptional sound. (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. Mono or Stereo operation. AC line voltage selector switch allows reconfiguring amplifier for either 110-120V or 220240V AC lines. Compact design featuring large metal handles and casters for ease in transporting. POWER SWITCH (8): turns the unit on and off. POWER LED (9): the power LED lights when the power is on. FUSE (4): replace with proper type and rating. AC INLET (6) is used to attach the power cord to the unit. AC LINE VOLTAGE SELECTOR SWITCH (5) allows reconfiguring amplifier for either 110-120V or 220-240V AC lines. OPERATION: STEREO OPERATION: CAUTIONS: The unit has two channels for stereo operation. Each channel provides a separate signal at the speaker outputs. The following instructions are for use with 8W speakers of matched power ratings. We suggest only using the speakers that come with the unit. 1. All operating instructions should be read before using this equipment. 2. To reduce the risk of electrical shock, do not open the unit. There are, 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 (such as your mixer) to the Channel 1 and Channel 2 INPUTS using the XLR INPUT JACKS (1) or 1/4" PHONO INPUT JACKS (2). In the USA: If you 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. 3. Do not expose this unit to direct sunlight or to a heat source such as a radiator or stove. 2. Connect your speakers to the Channel 1 and Channel 2 SPEAKER OUTPUTS (3). 4. This unit should be cleaned only with a damp cloth. Avoid solvents or other cleaning detergents. 3. With the SENSITIVITY/VOLUME CONTROLS (10) of both channels set to zero (fully counter clockwise), turn the POWER SWITCH (8), ON. Okay, now try playing some music and/or talking into your microphone, and set the level of your input as high as you think you’ll need it. This way 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 music and listen for audible distortion. If you do hear distortion decrease the output level using the SENSITIVITY/VOLUME CONTROLS (10). 5. When moving this equipment, it should be placed in its original carton and packaging. This will reduce the risk of damage during transit. 6. DO NOT EXPOSE THIS UNIT TO RAIN OR MOISTURE. 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 link by connecting the remaining Channel 1 input to a Channel 2 input (1 or 2) using a standard balanced cable (may be purchased separately). You can adjust the level of each satellite speaker using it’s channel’s SENSITIVITY/VOLUME CONTROL (10). CONNECTIONS: INPUT SECTION: There are two parallel input connectors (one female XLR and one 1/4” jack) per channel. Either can be used as an input or as a link to chain amplifiers. USING THE SIGNAL GROUND LIFT SWITCH: 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 (-). 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. 1/4" 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. 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 (10) control the input levels for each channel of the 2 satellite speakers. The volume level of the subwoofer is controlled automatically to match the volume levels of the satellite speakers. It will always maintain a perfect balance to give you incredible sound quality! SIGNAL GROUND LIFT SWITCH: SIGNAL GROUND LIFT SWITCH (7) 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. 2. Turn the power OFF before moving the SIGNAL GROUND LIFT SWITCH (7). Now lift the ground by moving the SIGNAL GROUND LIFT SWITCH (7) to the right. Turn the power back ON and listen to determine which position makes the overall sound quieter with the least amount of noise and hum. CAUTION: DO NOT DISCONNECT THE AC GROUND ON THE POWER AMPLIFIER IN ANY WAY. THIS CAN BE VERY HAZARDOUS!! (3) SETUP: SPECIFICATIONS: There are various ways to set up this system: BASIC SETUP: Okay, this is your basic setup, perfect for small parties and venues. The ideal location for your subwoofer is close to a wall or in a corner. This will give you the fullest bass response. Your 2 satellite speakers can be placed up on stands on each side (stands must be purchased separately). TWO-SYSTEM SETUP: This setup is perfect for larger venues. This setup requires 2 XTR-400 systems. This will give you a total of 800 watts rms! Place a subwoofer on each side to the left and right. Using the high-hat hardware and connecting pole (which can be purchased separately), place the pole in the high-hat socket on the subwoofer, and a satellite speaker on top of the pole. The 2 remaining satellite speakers may be used as either floor monitors, or placed on stands elsewhere in the room giving you a louder and fuller sound. Each speaker system in this setup must be used in MONO mode (see Mono section). Connect the system that is on the left side of the audience to the LEFT channel of your mixer, and the system that is on the right side of the audience to the RIGHT channel of your mixer. ACTIVE SPEAKER SYSTEM SUBWOOFER/SATELLITES The XTR-400 features a unique design for ease in transporting. The 2 satellite speakers conveniently fit into a special recessed section of the subwoofer and are securely fastened using a strap that attaches to the handles (included). Subwoofer XTR-400SUB: Amplifier’s Output Power:.........................230 Wrms on subwoofer channel Frequency response:……………………...........................….32 Hz - 100 Hz Components:………………………...........................……………..15" woofer Features: Efficient band-pass cabinet design Large metal handles Metal protection corners Four 2" wheels Amplifier assembly on the back 35mm standmount cap on top Black carpet finish Rubber feet Dimensions:..............................................................WxDxH: 20"x31"x24.5" (508 x 788 x 622 mm) Weight:…………………............................……………………..96 lbs (44 kg) Satellites GT-1002s: Amplifier’s Output Power:..........................2x85 Wrms on satellite channels Frequency response:…………............................………….100 Hz – 20 kHz Components:….…………...........................……………………….10" woofer 6” dual piezo horn Features: Trapezoidal cabinet Full front protective metal grill Metal protection corners 35 mm standmount cup on the bottom Black carpet finish Rubber feet 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. (4) PARTS LIST: Item # Designators Description Part Number 1 2 3 4 5 6 7 8 ZD3, ZD2 D3, D1, D2 ZD1 Q1 Q2 C18, C13 REC1 U3, U2, U4, U1 MAIN PCB: ZENER DIODE 1/2W 12V (RD12EB2) SILICON DIODE 1N4148 ZENER DIODE 1/2W 24V (RD24EB2) SILICON TRANSISTORS 2SC1815 SILICON TRANSISTOR 2SC4793 µ/50V ELECTROLYTIC CAPACITORS 6800µ BRIDGE RECTIFIER KBPC804W INTEGRATED CIRCUIT TDA7294V 079-012 079-003 079-020 076-003 076-100 050-198 086-019 074-189 1 2 3 VR1, VR2 LD1 IC1, IC3, IC2 1 2 3 4 SW1 IC1 X3, X2 XLR2, XLR1 1 X1, X2 1 2 3 4 5 6 7 8 CROSSOVER PCB: ROTARY VR 10KA L:15MM φ LED (GREEN) 5φ INTEGRATED CIRCUIT NJM4558DD (BA15218,M5218AP) INPUT PCB: SLIDE SWITCH SV70050 071-228 080-086 074-163 φTRS 1/4" BAL PHONE JACK 6.3φ XLR XLF-3PH 081-030 074-163 092-078 092-069 OUTPUT PCB: SPEAKON™ CONNECTORS NL4MP 092-149 OTHER: AC CORD AC INLET DC FAN 24V TRANSFORMER SLIDE SWITCH POWER SWITCH FUSE VBS UTE 3.15A 250V FUSE VBS UTE 6.3A 250V 093-369 092-105 001-613 059-247 081-023 083-121 100-068 100-071 INTEGRATED CIRCUIT NJM4558DD (BA15218,M5218AP) 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 R8 C3 C2 IC1 R7 R4 C4 R9 OUTPUT PCB R3 + X3 + G XLR2 XTR400-4 XTR400-3 Page 6 MAIN PCB TOP LAYER X-OVER XTR400-2 XTR400-1 LD1 L4 C14 X3 R16 C19 R19 R37 15 RED/BLK C27 RED C17 C5 R7 R2 R3 R4 C29 C11 C7 IC2 1 X2 J9 C13 U3 R20 X10 J3 C8 R3 R15 C4 R1 R14 R14 R13 R8 R26 R21 R30 J1 J2 C16 1 R31 J5 R36 C21 R16 C23 BLK R23 C25 R6 C6 X11 15 1 RED J10 X2 U4 R22 R17 R27 1 C24 U2 R18 X1 C10 C2 L3 IC3 D2 R12 C20 R21 C6 C9 R9 R4 X12 R32 J8 C8 C15 C5 L1 C22 C7 15 U1 VR2 R15 C1 R11 C1 R18 VR1 R13 ZD2 R25 C12 X9 C14 C31 J1 J6 X4 ZD1 C3 C9 R5 R12 R38 C28 J4 R17 R7 Q1 J3 R10 C11 C10 15 J2 R35 R24 L2 R10 R29 C2 D3 R6 C12 RED X8 R5 C32 C30 R19 R20 X3 REC1 IC1 + AC C13 AC D1 - R2 X6 BLK R33 R34 ZD3 X5 BLK R1 C3 R8 R9 C26 Q2 C4 R22 X1 X4 C18 J7 RED X7 R11 R28 X13 BLK 1 MAIN PCB BOTTOM LAYER X-OVER XTR400-2 XTR400-1 LD1 L4 C14 X3 R16 C19 R19 R37 15 RED/BLK RED C17 R7 C5 C29 C27 R2 R3 R4 C7 C11 J9 IC2 1 X2 R3 U3 R20 C13 C8 X10 J3 C4 R15 R8 R1 R14 R14 R13 R26 R21 R30 J1 J2 C16 1 J5 C23 BLK R23 X2 X11 C25 1 RED J10 R17 R6 C6 C2 U4 R22 15 U2 R27 1 C24 X1 C10 R36 C21 R16 IC3 D2 R12 L3 R18 R4 C20 R21 R9 C6 C9 X12 R32 J8 C8 C15 C5 L1 C22 R31 C7 15 U1 VR2 R15 C1 R11 C1 R18 VR1 R13 ZD2 R25 C12 X9 C14 C31 J1 J6 X4 ZD1 C3 C9 R5 R12 R38 C28 J4 R17 R7 Q1 J3 R10 C11 C10 15 J2 R35 R24 L2 R29 C2 D3 R6 C12 RED X8 R5 C32 C30 R19 R20 X3 REC1 IC1 + AC C13 AC D1 - R2 X6 BLK R33 R34 ZD3 X5 BLK R1 C3 R8 R9 C26 Q2 C4 R11 R10 X4 C18 J7 RED X7 R22 X1 R28 X13 BLK 1 SCHEMATIC X2 7 7 6 6 R9 13K 1% C7 10uF25V NP 5 CH.1 (L) INPUT 2 1 1 MAIN PCB X3 1 1 CH.1 (L) INPUT 2 2 3 3 4 4 SUB INPUT (+) C6 10pF C7 10pF 8 + 12V C6 10uF25V NP C4 .047uF5% 3 CH.2 (R) INPUT 2 CH.1 (L) OUTPUT C3 .047uF5% VR2 10KA CH.1 (L) VOLUME CONTROL - 12V SUB OUTPUT (+) 2 R6 26.7K 1% R8 39.2K 1% R11 26.7K 1% 1 3 R17 13K 1% IC1A NJM4558DD - 12V 6 R10 39.2K 1% R14 10K 1% R21 13K 1% R15 13K 1% 7 5 R22 13K 1% R12 60.4K 1% R18 10K 1% +E R4 1K 1% 4 4 X3 X12 1 + 12V 5.1K R12 13K 1% C10 2200pF 1 2 2 CH.2 (R) INPUT 3 3 4 4 SUB INPUT (-) U2 C9 22uF25V IN - 3 IN + 4 IN+MUTE +Vs MUTE 9 STBY 1 R17 5.1K +PWVs 10 OUT BOOTSTRAP -Vs STBY-GND -PWVs C14 0.1 13 SUBWOOFER OUTPUT (+) 7 14 R10 8R2 1W 6 L2 1.0uH C11 22uF50V 8 +E R14 1K 1% TDA7294V 2 R8 5.1K X1 RED R13 13K 1% C4 390pF C2 0.1uF100V 15 U1 C8 10uF25V IN - 3 IN + 4 IN+MUTE R15 5.1K +PWVs +Vs 10 MUTE 9 STBY 1 R18 5.1K TDA7294V 2 OUT BOOTSTRAP -Vs STBY-GND -PWVs 13 CH.1 (L) OUTPUT 7 14 R3 8R2 1W 6 L1 1.0uH C5 10uF50V 8 X2 RED OUTPUT PCB 18AWG RED C1 0.1uF100V 15 X1 NL4MP P1 1+ RED 1OUTPUT C15 0.1 R16 5.1K 2+ CH.1 (L) 8 + 12V R9 IC3B NJM4558DD R2 13K 1% CH.2 (R) OUTPUT IC3A NJM4558DD 4 R1 39.2K 1% - 12V 1 3 R3 39.2K 1% R4 39.2K 1% 7 5 IC2A NJM4558DD SUB OUTPUT (-) C11 0.033uF5% R23 5.1K X1 R6 13K 1% + 12V C10 0.1 - 12V C12 .047uF 5% VR1 10KA CH.2 (R) VOLUME CONTROL 6 5 C32 22uF25V R22 5.1K R20 5.1K 7 R16 2.4K C14 100uF16V IC1B NJM4558DD LD1 GRN 1 +12V 2 2 3 3 -12V C30 10uF25V R21 5.1K C28 10pF R38 26.7K 1%K C9 0.1 Ends striped 15mm C24 2200pF U4 R27 13K 1% IN - +PWVs 3 IN + +Vs 4 C25 22uF25V IN+MUTE 10 MUTE 9 STBY 1 STBY-GND 2R26 26.7K 1% OUT BOOTSTRAP -Vs -PWVs C16 0.1 13 SUBWOOFER OUTPUT (-) 7 14 R36 8R2 1W 6 L3 1.0uH C21 22uF50V 8 +E R32 1K 1% TDA7294V 2 R30 5.1K X11 BLACK C22 390pF C23 0.1uF100V 15 2+ C27 10pF 18AWG BLACK 45sm +E R25 1K 1% R19 5.1K 18AWG RED 45sm Twisted pair to Subwoofer terminal R35 5.1K U3 R31 13K 1% C20 10uF25V 2 IN - 3 IN + 4 IN+MUTE 10 MUTE 9 STBY 1 STBY-GND TDA7294V +PWVs +Vs OUT BOOTSTRAP -Vs -PWVs P2 BLACK 13 CH.2 (R) OUTPUT 7 14 R37 8R2 1W 6 L4 1.0uH C19 10uF50V 8 15 X10 RED/BLACK STRIP C29 0.1uF100V C17 0.1 POWER PCB P1 SW3 -E SW-POWER BRN -E T1 +E C4 270 R3 10K 1% T R S R4 10K 1% 6 5 X3 TRS 1/4" BAL R5 510 C2 270 7 IC1B NJM4558DD + 12V 1 3 6 5 4 5 SW1 "Signal ground lift" 6 7 6 E N ORG C5 270 - 12V R8 10K 1% 5 3 2 2 1 AC INLET 1 CH.2 (R) OUTPUT +E RED 2 X7 REC1 KBPS10-02 C13 6800uF50V 4 R7 68 RED Q2 2SC4793 Q1 2SC1815 X4 T D2 1N4148 ZD1 24V 0.5W C12 4.7uF50V C3 220uF25V FAN 24 Vdc FAN1 24Vdc/0.19A C31 100uF16V ZD2 12V 0.5W R28 1.2K 3W X13 BLACK To CHASSIS X5 8.2K C26 100uF16V ZD3 12V 0.5W C18 6800uF50V To POWER TRANSFORMER WHT R1 +12V R29 1.2K 3W To POWER TRANSFORMER BLK 2.4K R5 2.4K CH.1 (L) OUTPUT 4 3 X8 230v R2 BLACK To CENTER TAP POWER TRANSFORMER SW4 VOLTAGE SELECTOR 115v C1 0.047uF 4 7 X6 BLU F L X1 R7 10K 1% D1 1N4148 P3 3 FUSE 6.3A / 110-120V 3.15A / 220-240V R9 10K 1% XLR2 XLF-3PH 1 1 C101 3 2 P2 -E -12V BLACK To SPEAKER OUTPUTS + 12V 8 3 XLR1 XLF-3PH R6 10K 1% T R S R1 10K 1% 2 1 3 X2 TRS 1/4" BAL CH.2 (R) INPUT 18AWG BLACK 18AWG BLACK IC1A NJM4558DD 4 C3 270 1- - 12V R2 10K 1% Page 9 OUTPUT CH.2 (R) R24 8.2K D3 1N4148 R19 39.2K 1% INPUT PCB 1+ X9 1 R5 39.2K 1% CH.1 (L) INPUT X2 NL4MP P3 RED/BLACK STRIP R33 5.1K C13 100uF16V C2 .047uF 5% -E -E C1 0.033uF5% - 12V R7 39.2K 1% R20 22.1K 1% R34 5.1K IC2B NJM4558DD 2- 18AWG RED/BLACK STRIP 3 R13 60.4K 1% 2 4 1 C5 .1uF 5% 18AWG BLACK 6 8 2 C8 .1uF 5% 2 3 R11 22.1K 1% 1 4 + 12V 2 5 X4 X-OVER PCB