Download AUDIO TELEX DCM500 User manual
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SERVICE INFORMATION AUDIO TELEX DCM500 POWER AMPLIFIER CONTENTS: OPERATION MANUAL CIRCUIT DESCRIPTION SET-UP / TEST PROCEDURE SCHEMATIC DIAGRAMS PCB OVERLAYS COMPONENT LISTS Australian Monitor 1 Clyde Street, Silverwater NSW 2128 Australia +61 2 9647 1411 www.australianmonitor.com.au AMlilrDlilil@ () o n4 lw u N I cAT ..........',..'........'.'''.'.'.'......H'. ft{tTl I O N SPrY Lro ..tlllii6'ui0.li'i.iii:i."",i"-"i';i''itititt;;'. '.'....'.....'.'...'..'...'.'.'.'..'..'.'.'.'.'.'.'.'.'.'.'.'.'.':.'.'.'.'.....'.': :':': :::::::.: :.rel$t Audio Telex Communications Pty Ltd ACN 001345482 lncorporated ln NSW DCM500, 500 Watt Power Amplifier Product Description The DCM500 is a 500 watt power amplifier in a two rack unit (2RLI) chassis suitable for table or direct 19" rack mounting. The DCM500 has outputs for 70 & 100 volts and 4 ohms. It has a balanced input of 10K ohms. The DCM500 will operate from 240 V AC @ 50 IIz or I I 0 VAC @ 60 Hz (not user selectable, internal, factory adjushent only, specifi at the time of ordering) or 24 VDC and will meet it's full performance specification on either voltage supply. The DCM500 also features a DC battery trickle charge facility, slow start on powering up (to reduce inrush current problems), auto-sensing ftn cooling, plus overload short circuit and over ternperature protection. The maximum recommended load for the DCM500 is 20 ohms. lnitial Set Up There is an unlabelled, screwdriver adjustable output level control located centrally on the front panel of the DCM500. Turning this control in the clockwise direction will increase the power output, turning this comtrol in a counter-clockwise direction will reduce the power output. The ftctory default setting for this conkol is such that a I volt input will give a 100 volt output. Front Panel Gontrols Output Level: The output level control is unlabelled, r@essed (screwdriver adjustable) and is located in the centre of the front panel, just to the right of the DCM Series logo. Tuming the control clockwise will increase the output of the DCM500 towards it's manimum output level wtrile tuming the control counter-clockwise will decrease the output level. Adjust this control for the desired output level depending on the level of the input signal (from a mixer or other signal source). The factory defrult setting for this control is such that a I volt input will give a 100 volt output. POWef SWitch: The rocker switch located in the front centre of the panel turns AC power on to the DCM500. Rocking the power switch to the right to turns the AC powetr 'on'. When the AC power is 'on', a gree,lr LED will glow in the amplifier status display windorv. Please note that this switch does not switch DC voltage. If a DC voltage supply is connected to the DCM500, the amplifier will operate as sfi)n as the connection is made, regardless of the position of the AC power switch. If both an AC and DC voltage supply are connected and you rock the AC power switch to the 'off position, the DCM500 will automatically continue to op€rate normally from the DC supply (and the 'mains failure' LED in the amplifier status display window will also glow undo these comditions; see the amplifio status display window section under Frurt Panel Cmtols later in this manual). Gooling Fans (Air lntake): rhe cooling fans (two installed in the case of the DCM500) are ternperature sensitive and only switch orr when the temperature of the DCM500 had reached a pre-determined range. The fans will stay on and only switch off again mce the temperature of the DCM500 has fallen below a pre-determined level. So, the ftct that the fans are not operating at any time (and most noticeably to the operator at turn-on) does not mean that the amplifier is faulty in any way, just that it is o'perating within a temperature range that does not need frn cooling for adequate heat dissipation. If the DCM500 is operating curtinually at c.onservative levels and proper load conditions, it is possible that the cooling fans will not switch on at anytime during normal operation. When operating, the fans cause air flow from the front to the rear of the DCM500. Continuednext page3 Amplifier Status Display Window: The status display window highlights the operating conditions of the DCM500. Please refer to Figwe #1 on the back page of this instruction sheet with numerical reference as follows: High Temperature: firis red LED glows if the fan has failed and the amplifio has been shut down by its' temperature control circuity. If this LED is glowing and the fans have not failed, it means that the amplifier is operating in an ambient environment that it naturally too hot for fan cooling to make any difference to the temperature of the amplifier. PoWef: This LED glows green if AC power is switched on to the DCM500. Note that this LED does not indicate the pres€nce ofa DC supply voltage lUlains Failure: The LED glows red if there is a failure in the AC mains power supply. However, this LED glow if there is a DC supply voltage present. If no DC supply voltage is present then this LED will not glow. will only Output Level VU A 10 segment LED W meter is provided to give an indication of the output signal level of the DCM500 from -25 to +3 dB. For normal operation the LED's should oscillate in and out of the red zone. If the LED's in the red zone are lit continually, the,n the output level control (or the level of the input signal to the DCM500) should be adjusted to reduce the output level. Too much output level can cause distortion and possible damage to the connected speaker lleter: qystem. Rear Panel Connections Please refer to Figure #2 on the back page of these instructions with numerical references as follows: 3 pin lEC, AC mains power inlet. The operating voltage is 240 VAC @ 50llzor l t0 @ 60 rIz. The AC power voltage level is not externally user selectable but is ftctory pre-set (via transformo selection). The inl* is equipped with an inbuilt AC fuse holder fitted with a l0 Amp slow blow fuse plus one spare fuse. Power consumption is 800 VA. Please ensure that the mains power cord is disconnected before attempting to check or replace this fuse. vtc Output terminal strip . Reading from left to right these connections are as follows: Common for low impedance 4 Ohms Common for constant voltage systems 70 volts 100 volts 24 VDC power connectio[. The left side red post is the + (positive) terminal while the right side black posr is the - (negative) terminal. The DC current drain is 30 Amps, maximum at full power. This socket also provides trickle charge to a DC battery supply (if connected) when the DCM500 is operated from AC mains power. The level of trickle charge is 30b me" maximum. Twin DC low voltage, fuse receptacles. Access the DC tuses is by turning the cap half a turn count€rclockwisewith a screwdriver. The value of the fuses is 35 Amps. Pleasc ensure that the AC powerswitch is in the.ofr position and that the mains power cord is disconnected before attenpting to check or replace this frrse lnput (& parallel_output) XLR signal connectiolr. The input to the DCM500 is ransformer balanced @ 10K ohms. The pin configuration of both sockets is as follows: pin #l-earth; pin #2-active (high, +); pin #3-active (lol", -j. The output socket is to allow the original input signal to be fed on to another amplifier. As these trvo sockets are wired in passive parallel, the failure of any one amplifier will not affect the sigrral flowing through that amplifier to anotho amplifier. ll||lltl!!! ltltllll!!l lllrltllrll E lol{.o Ei"= tel lglt'. \l -Hi;; dl -:::f c::------------__f (_------------- -::-----------) -_-:-_---r -c_:_-----------l -:l -__-:f -- U o (tl O o BI --------.) !ll!!r!!lll lll!rllt!!l lllliltllll o'l ill ol ol ol ol DCM Series Circuit Description The DCM series are power amplifiers designed for commercial installations. They can be used for either low impedance (4 ohm/8 ohm) or constant voltage line speakers (100v/70v). These amplifiers can be mounted in a standard 19” equipment rack or they can be used on a shelf or table. The DCM series feature line level input (with parallel output) and are normally used with mixers, mixer amplifiers or other power amplifiers. The DCM series will operate from mains voltage or 24VDC. The DCM series also feature a DC battery trickle charge facility, auto-sensing fan cooling, plus overload, short circuit and over temperature protection. Power Switch This switch controls the switching of AC power to the amplifier. A blue ‘On’ LED will indicate whether the amplifier is switched on or off. This switch will not switch DC power on or off in DC operation. In DC operation mode, the amplifier is always on and the blue power LED will always be illuminated. If both AC and DC voltage supply are connected and the AC power switch is in the off position, the amplifier will continue to operate normally from the DC supply and the mains fail LED will indicate. Level Control The output level control is located in the centre of the front panel. It is a fully recessed screwdriver adjustable pot. Turning this pot cw will increase the gain of the amplifier. At maximum setting the input sensitivity is 300mV. The amplifier ships from the factory with the sensitivity set to 1V. Amplifier Status Display This VU meter indicates the output level of the amplifier. The sensing for the circuit is taken on the amplifier side of the output transformer. The 0dB level is referenced to 100V. This is an RMS meter, not a peak meter. Protect The protect LED will illuminate when the amplifier cuts out because of either over current or high temperature. The amplifier will switch back on after approx 4 sec for an over current trip. The amplifier will switch back on after the amplifier has cooled to 60degC for a thermal trip. Limiter The limiter is a hard limiter with an attack time of about 1msec. It is defeatable by removing the jumper on the solder side of the front pcb. This however is not recommended as voltage overload and speaker transformer current saturation may cause the amplifier to cut out under normal program material. Current Limit and Setup Current limit is controlled by a microprocessor (PIC12C509A). The detection is done by sensing voltage across the emitter resistors. Trimpot P1 on the front pcb is accessible through the hole in the top right of the chassis return (only visible with the lid off). Turning the trimpot ccw will decrease the point at which the amp cuts out ie the amp will cut out earlier. (P1 resistance is increased.) To set the current limit: 1. Reset the trimpot P1 turning fully clockwise. 2. Connect the amplifier to half it’s minimum load (10ohm for DCM500, 20ohm for DCM250, 40ohm for DCM120). 3. Run an rms 1kHz sine wave into the amplifier and set the input level so that you read 425mVDC (DCM250/500) or 825mVDC (DCM120) across the emitter resistor, measuring the side which has the higher current (measured as a voltage across the emitter resistors). 4. Turn the trimpot P1 ccw till the amplifier cuts out. The amplifier is set to the factory default. Thermal and Fan control and Setup The thermal cutout and fan is controlled by a microprocessor (PIC12C509A). The temperature is sensed using a 10k@25degC NTC. The fan is normally off and turns on to full speed at 60degC. This temperature is fixed and not adjustable. The thermal cutout temperature is set using the trimpot accessible through the hole in the top left side of the chassis return (only visible with the lid off). Turning the trimpot cw will decrease the point at which the amp cuts out ie the amp will cut out earlier. Power Amp The power amplifier is a push pull single supply amplifier driven by a class A transformer coupled front end. The drive is provided by HEXFETs (RF9520/9530) into NPN BJTs (TIP35C). When replacing the FETs it is recommended that you replace both FETs. The matching of these FETs determines the balancing of the emitter currents in the output devices. For optimum performance the emitter currents in each side should match to within 30% of each other. Bias Setup The amplifier is set with a bais setting of 1mV measured across the emitter resitors. Bias is set using the trimpots located on the power pcbs on each side of the amplifier. Turning the trimpots cw increases the bias. If the HEXFETs have been replaced the resistor in series with the pot may need to be changed. Use a lower value resistor if the bias cannot be turned off or a higher value if the bias cannot be turn on. AC Power Inlet The operating voltage is 230/240 VAC @ 50 Hz. The 3 pin IEC power inlet is located on the bottom left of the rear panel and accepts a standard mains power lead fitted with an IEC connector. Before plugging in a power lead, please check the rear panel of the amplifier to ensure that the voltage switch is set correctly for your part of the world. The inlet is equipped with an in-built AC fuse containing the rated fuse and a spare. 24 Volt DC Power Inlet The DCM series feature optional 24VDC power to run off a battery back-up if required. This is connected via the rear binding posts. The front panel Power Switch will not switch DC power ‘on’ or ‘off’ in DC operation. In this mode the amplifier is always ‘on’. The trickle charge resistor across the diode is a 47ohm/5watt wire wound resistor. The maximum trickle current is 300mA supplied from internal 35V rails. 230V/240V Slide Switch The operating voltage of the amplifier is user selectable between 230V and 240V via a slide switch located on the center of the rear panel. This switch should be set to match the AC voltage of your country. The mains transformer is wound with a 230V winding plus a 10V winding internally connected. Speaker Output Terminal Strip The screw terminals located on the top left of the rear panel allow access to the direct speaker outputs of the amplifier. Reading from left to right the terminals are: COM 4 8 Common or “-” for low impedance speaker loads (4 or 8 ohms) Positive “+” for 4 ohm speaker loads (use with common) Positive “+” for 8 ohm speaker loads (use with common) DCM120 only COM 70 100 Common or “-” for 70v or100v speaker loads Positive “+” for 70v line speaker loads (use with common) DCM120/500 only Positive “+” for 100v line speaker loads (use with common) Please ensure that the correct “Common” is used. Low impedance and 70/100v loads can be used simultaneously but please pay careful attention to the overall speaker load. Note: The minimum impedance (or maximum load) at 100 volt line should be no less than DCM120 – 80 ohms DCM250 – 40 ohms DCM500 – 20 ohms XLR Audio Input and Parallel Output The DCM series includes both male and female 3 pin XLR connectors per channel. While the female is normally used as the input to the amplifier, both XLR’s are connected in parallel so either will work. The XLR’s inputs are transformer balanced and wired as: Pin 1: Shield. Pin 2: Hot, +, Positive Pin 3: Cold, -, Negative Fuse Sizes (DCM120) Mains: 230 VAC 4 Amperes Slow Blow HRC 20x5mm DC: 10 Amperes Slow Blow HRC 20x5mm (DCM250) Mains: 230 VAC 6.3 Amperes Slow Blow 20x5mm DC: 2 x 10 Amperes Slow Blow HRC 3AG (DCM500) Mains: 230 VAC 10 Amperes Slow Blow HRC 20x5mm DC: 2 x 35 Amperes Slow Blow 3AG TESTING PROCEDURE OF DCM 120/DCM 250/DCM 500 I. PRE-TESTING (of complete sets). • Check 1.1 All screw for tightness (Bridge rectifier and transistor bolts) 1.2 Earth Connection for good contact (solder and crimpling) 1.3 This setup has signal input to the Amplifier through male (XLR) 1.4 Check with Multimeter that there is a DC resistance of about 250 Ω between Pin2 & Pin3 of each of XLR’s. Also between (Pin 1 & Pin 3) and (Pin1 & Pin2). There should be very high resistance. (IE: no reading). 2. Electrical Check 2.1 Fuse Check: Mains fuse: DC fuse: DCM 120 DCM 250 DCM 500 4AT 10AT (x1) 6.3 AT 10AT (x2) 10 AT 35AT (x2) 2.2 Connect the Amplifier to the setup (Variac voltage = 0V) set all presets on front board (only) fully clockwise, voltage selector switch to 230V 2.3 Slowly increase the input voltage to 230V, keep watching the input current should not exceed 0.1A for DCM-120, 0.1A for DCM-250, 0.1A for DCM 500. 2.4 Check and reset if necessary all emitter resistor voltages with the help of preset. (Each emitter resistor voltage should be between 0.5 mV to 0.8 mV ) 2.5 Check DC voltage Main rail = 33V 7815 input = 30V 7815 output = 15.5V 2.6 Give input signal of 500 mV to get outputs as follows (@ 4Ω output load)/ 22V for DCM 120, 32VAC for DCM250, 44.7VAC for DCM 500. Check 100V O/p at 100vV line, Remove the input signal II. FINAL TESTING (This setup should have signal input to Amplifier through female (XLR) (The limiter link should be out of circuit initially.) 1. Connect the Amplifier to the setup, set voltage selector switch to 240V 2. Switch ON the set to 240VAC. 3. Slowly increase the input signal (of 1kHz) keep watching the 24dB LED, it should glow at approx 9V output. Increase the input signal to get 70VAC output. 4. Check Dc voltage of all emitter resistors, Minimum value should be within 30% of the maximum value. 5. Slowly increase the input signal, keep watching the 0db LED, it should glow at 100V ± 5V output voltage. 6. Set 100V 1kHz as 0db reference. Change frequency to 10kHz check dB level drop. It should be 2.5dB ± 0.5dB. 7. Change the frequency to 1kHz, reduce signal level to get 10VAC output. Half the output load. 8. Overload setting: - Check the DC voltage at the emitter resistors having the maximum voltage value. Increase input signal to get 820mV for DCM 120, 425mV (for DCM250 & DCM 500). Turn preset (P2) anticlockwise such that it just mutes the output signal and signal returns back slowly after 2 seconds. 9. Reduce the signal & re check whether the signal mutes at the corresponding above stated voltages. 10. Again make the output load to original full value. Turn volume preset fully anticlockwise, set input signal strength to 1V, set volume preset clockwise to get 100V output. 11. Set input signal strength to get output 110V VAC. Insert limiter link, the signal should reduce to 100V ± 5V. 12. Remove the input signal and check noise. It should measure less than 25mV. III. THERMAL & SOAK TEST 1. Connect the Amplifier to the setup : Output load = 4Ω Output Voltage: (DCM 120): 14V. (DCM 250):20V. (DCM 500): 40V 2. Set the Amplifier thermal cut off temperature at around 105°C with the help of preset P4. 3. Leave the unit “ON” (with lid fixed, if possible) for 24 hours. IV. Sound Test/Listening test. 1. Switch On the set. Check for any switch on thump. 2. Connect CD player to the input, listen for irregularities if any. 3. Switch off the set check for switch off noises. 1 2 3 4 5 6 8 7 X1 1 2 3 D D 4 5 D1 40A BATTERY F2 35A + 24V - F1 10A F3 35A T1 +35VDC BR1 C1 240AC IN C2 C3 C4 10000U C C S1 X8 1 2 3 X6 X5 X4 X1 R2 47R X3 X2 X7 1 2 3 BR3 V1 BC639 C8 C5 4u7 0.15u R3 100R C6 4u7 RY1 R1 4K7 C7 10u D3 12V B B D2 PCB6203 A A Title Size A3 Date: File: 1 2 3 4 5 6 DCM500 POWER SUPPLY CD6203-1 B Number 28-Aug-2002 Sheet of C:\Protel Files\CDTRAX\CD6203-1.DDB Drawn By: 7 Revision 1 2 RS 8 1 2 3 4 5 6 7 8 X1 1 2 3 D D 4 5 D1 40A BATTERY F2 35A + 24V - F1 10A F3 35A T1 +35VDC BR1 C1 240AC IN C2 C3 C4 10000U S1 C X8 1 2 3 X6 X5 X4 C X1 X3 R2 47R X2 X7 1 2 3 BR3 V1 BC639 C8 R3 100R C5 4u7 0.15u C6 4u7 RY1 R1 4K7 C7 10u D3 12V B B D2 PCB6203 A A Title Size A3 Date: File: 1 2 3 4 5 6 DCM500 POWER SUPPLY CD6203-1 C Number 6-May-2003 C:\DCM Manuals\CD6203-1.DDB 7 Revision Sheet of Drawn By: 1 2 SBG 8 1 2 3 4 5 6 7 8 D D 16V 1 16 IC3A NE570 2 2u2 3 C10 C5 2u2 R35 33K 100K R15 C8 100P 5 12 6 11 7 10 8 9 4 C C13 47P C12 2u2 C17 2u2 R25 10K LK2 X1/3 R24 10k R20 10k 100K LM358 V3 R30 2K2 C22 47u 7 8 LK4 IC2A C3 10u D1 C23 R8 100R 100P R21 10k R31 2K2 6 2 X4/5 R12 100R LK3 R10 1K LK5 4 R32 56K R4 10K C2 2u2 IC4A 2u2 C21 C24 .1u V2 BC639 R11 390R C20 2u2 X2/2 R53 1K P1 2K 16V X2/1 R7 100R R18 1K BC546 IC5 NE555 1 C X5 R9 5K6 R29 1M B R3 10K C6 2u2 R19 D2 D9 V1 BC639 C9 .47u C14 47P R5 680R X1/2 C1 2u2 D3 5 X1/1 R1 68K IC4B C19 47u 3 T1A R23 39K IC2B R17 47K C33 4u7 14 R27 X3/1 2M2 R28 15 100K R16 2M2 47K P2 16VDC 13 C26 4u7 X3/3 LM833 D8 T1B 68K R2 10k R22 LK7 X3/5 B R6 680R D7 A HI TEMP X3/4 X3/2 R14 22R X4/2 IC1 7815 16VDC C16 100u LK1 X4/6 GND C4 2u2 D4 C7 100u C27 4u7 D5 R34 22K D6 8V2 C15 A R33 2K2 C25 2u2 R13 22K 10R R26 8V2 C18 4u7 A 2u2 Title Size Number A3 Date: File: 1 2 3 4 5 6 DCM DRIVER CD6200-1 11-Sep-2003 Sheet of C:\Protel Files\CDTRAX\CD6200-1.DDB Drawn By: 7 A Revision 1 2 RS 8 1 2 Microprocessor 3 4 5 6 8 7 Mute/Limiter/Drive VCC 13 VCC D 2 3 4 VDD VSS GP5 GP0 GP4 GP1 GP3 GP2 1 8 R16 2M2 7 2u2 C10 X3/1 6 C5 2u2 47K P2 5 R35 33K 100K R15 I/O Desc 7. GP0-OUT = 1/2VCC CON 6. GP1-OUT = FAN CON 5. GP2-OUT = PRTCT/MUTE 4. GP3-IN = I LIMIT 3. GP4-IN = FAN SENSE 2. GP5-IN = THRML SENS 3 14 5 12 6 11 7 10 8 9 VCC R25 10K R30 10K V5 BC546 R19 2u2 100K X1/3 R20 10k VU Display R3 10K IC4B LM833-B R7 100R AGND R9 5K6 X5 IC2A LM358 V8 BC556 C19 47u C23 100P R12 100R C3 10u D2 R10 1K R8 100R R21 39k LK4 0R C2 2u2 R4 10K V2 BC639 R11 390R VCC IC4A LM833-A LK6 0R C X3/2 IC2B LM358 Battery Indicator X2/1 (N/C) C6 2u2 R24 10k D1 0R LK3 R17 47K V1 BC639 C9 .47u C12 D X1/1 R5 680R X1/2 C1 2u2 IC6/P5 C T1A R1 68K LK2 VCC R26 10K C33 4u7 R23 10K C17 2u2 C14 47P C13 47P R29 10K 2M2 R27 15 4 Pin C26 4u7 16 IC3A SA571 2 R28 1 100K IC6 PIC12C509 VDD C8 100P X3/3 68K R2 10k R22 T1B X3/5 R6 680R X3/4 AGND IC7 LN3915 3 10 5 C35 4u7 R48 1K 11 6 B 12 7 R49 10K X1/5 9 13 D17 D18 D19 D20 VCC D16 +3DB 0 C32 4u7 R44 1K V4 BC556 Protect/On Indicator X1/4 -3 D27 IC6/P5 Fan Control X2/5 X2/6 (N/C) VCC R55 10K VDD X4/4 D13 R51 1K R56 10K IC6/P2 D31 V6 BC546 IC6/P6 R46 1K2 14 D21 -9 R45 2K7 15 D22 -12 16 D23 -15 X2/4 * * Current Limit R14 22R X2/3 IC1 7815 IC5 7805 16VDC VCC VDD 17 D24 -18 18 D25 -21 1 D26 R32 470K X4/6 GND C4 D4 C7 100u VDD R33 22K IC6/P7 4 R36 10K V7 BC546 V3 BC546 AGND 8V2 R34 22K Title Number A3 Date: File: 2 3 4 5 6 X4/5 P1 2K A C18 4u7 Size 1 X2/2 R53 1K IC6/P4 AGND 2 R31 10k C11 22u R13 10K C16 100u -25 C15 100u C20 47u 2u2 A V9 BC556 R18 1K VDD X4/2 R41=15K=DCM120/500 R41=12K=DCM 250 X4/3 POWER PROTECT Power R41 FAN CONTROL IC6/P3 X4/1 8 B P4 10K D10 MAINS FAIL -6 Thermal Sense R42 1K R43 470R DCM DRIVER CD6200-1 7-Apr-2005 Sheet of C:\Protel Files\CDTRAX\CD6200-12.DDBDrawn By: 7 D Revision 1 1 SBG 8 1 2 3 4 5 6 8 7 DCM500 D V10-V15 = TIP35C X1 1 500R 2 3 R36A 220R R1A R25,R27,R29,R31,R33, R35 = 0.22R +35V 220R R2A D R24,R26,R28,R30,R32, R34 =2K2 V1A R3A 220R 11 X TIP35C PCB6201 V4A X2 1 R4A 1K D1A R5A 150R R6A 150R V5A V6A V7A V8A V9A D2A X1 TO PCB6136 R38A 47k X2 TO PCB6200 X3 2 X3 TO PCB6200 X4 3 V2A 4 R12A 2K2 R13A R22 R14A 2K2 R15A R22 R16A 2K2 R17A R22 R18A 2K2 R19A R22 R20A 2K2 R21A R22 R22A 2K2 X4 TO FAN R23A R22 PCB6202 5 R40 1K R8A 470R R41A 100D C X3 1 2 R39A 10R 35V R10A 1K X1 TP PCB6203 C1A 820P X2 TO PCB6200 X1 R7A 10R IC1A 78L05 X3 TO PCB6200 X2 R9A 1K X4 TO FAN R11A 4K7 X3 4 V3A BC556 5 3 X4 1 FAN 2 D4 24V 6 T2 100VAC PCB6202 D3A 70AC 5 5 D3B 4 3 R10B 1K R40B 1K IC1B 78L05 2 1 R39B 4K7 R11B 4K7 5 2 4 1 FAN 3 R41 80D BC556 V3B R9B 1K R8B 470R X1 C V16 TIP41C COM X4 4 OHM X3 5 4 R7B 10R C1B 820P 3 B B 2 R5B 150R 1 R6B 150R V2B R12B 2K2 R13B R22 R14B 2K2 R15B R22 R16B 2K2 R17B R22 R18B 2K2 R19B R22 R20B 2K2 R21B R22 R22B 2K2 R23B R22 R42B 10R X2 V4B V5B V6B V8B V7B V9B D2B R38B R4B 1K 2 D1B 47k 11 X TIP35C V1B 1 X3 R1B 220R R37 0R R3B 220R R36B 500R PCB6201 R2B 220R +35V A A Title Size A3 Date: File: 1 2 3 4 5 6 DCM500 POWER PCB CD6201-1 Number 28-Aug-2002 Sheet of C:\Protel Files\CDTRAX\CD6201-1.DDB Drawn By: 7 Revision 2 RS 1 8 1 2 3 4 5 6 8 7 DCM500 D V10-V15 = TIP35C X1 1 500R 2 R36A 3 220R R1A R25,R27,R29,R31,R33, R35 = 0.22R R2A 11 X TIP35C V4A R4A 1K D1A R5A 150R R6A 150R V5A V6A V7A V8A V9A R38A 47k PCB6201 D2A X1 TO PCB6136 X2 TO PCB6200 X3 2 3 4 X3 TO PCB6200 X4 V2A R12A 2K2 R13A R22 R14A 2K2 R15A R22 R16A 2K2 R17A R22 R18A 2K2 R19A R22 R20A 2K2 R21A R22 R22A 2K2 X4 TO FAN R23A R22 5 PCB6202 R40 0R C X3 1 2 R8A 470R R41A 10k NTC R39A 10R 35V R10A 1K X1 TP PCB6203 C1A 820P R7A 10R IC1A 78L05 X2 TO PCB6200 X1 X3 TO PCB6200 X2 R9A 1K R11A 4K7 X3 4 V3A BC556 5 X4 TO FAN V16 TIP41C 3 X4 1 FAN 2 D4 24V 6 5 D3B 3 R10B 1K 2 1 70AC 2 4 1 R39B 4K7 R11B 4K7 FAN COM X4 4 OHM X3 R7B 10R C1B 820P 3 5 3 R41 NOT USED BC556 V3B R9B 1K 5 4 R40B 1K IC1B 78L05 R8B 470R X1 B 2 R5B 150R 1 R6B 150R V2B R12B 2K2 R13B R22 R14B 2K2 R15B R22 R16B 2K2 R17B R22 R18B 2K2 R19B R22 R20B 2K2 R21B R22 R22B 2K2 R23B R22 R42B 10R X2 V4B R4B 1K 2 V5B V6B 47k V8B V9B D2B 11 X TIP35C V1B R1B 220R R37 0R V7B R38B D1B 1 X3 T2 100VAC 5 4 C PCB6202 D3A B D R24,R26,R28,R30,R32, R34 =2K2 V1A R3A 220R X2 1 +35V 220R R3B 220R R36B 500R PCB6201 R2B 220R +35V A A Title Size A3 Date: File: 1 2 3 4 5 6 DCM500 POWER PCB C CD6201-1 Number 8-May-2003 Sheet of C:\DCM Manuals\CD6201-12.DDB Drawn By: 7 Revision 1 8 2 SBG DCM500 Power Supply Components List Designator BR1 BR3 C1 C2 C3 C4 C5 C6 C7 C8 D1 D2 D3 F1 F2 F3 R1 R2 R3 RY1 S1 T1 V1 Part Type KBPC3504 KBPC3504 15000uF 15000uF 15000uF 15000uF 4u7 4u7 10u 0.15u 40A 1N4007 12V *** 35A 35A 4K7 47R 100R Relay Switch BC639 Description Bridge recitfier 600V/35A Bridge recitfier 600V/35A Electrolytic Capacitor 50V Electrolytic Capacitor 50V Electrolytic Capacitor 50V Electrolytic Capacitor 50V Electrolytic Capacitor 50V Electrolytic Capacitor 50V Electrolytic Capacitor 50V Metalised Poly Capacitor 275V Stud Mount Rectifier Diode 40A Rectifier Diode Zener diode 1W 12V Fuse, refer user manual Fuse, 35A 3AG Fuse, 35A 3AG Resistor, metal film .5W PW5 Wire Wound resistor 5W PW10 Wire wound resistor 10w Relay 12V 16A SPDT Rocker Switch DPST Power transformer Transistor TO92 DCM Series Drive Stage Component List Designator C1 C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C2 C20 C23 C26 C3 C32 C33 C35 C4 C5 C6 C7 C8 C9 D1 D10 D13 D16 D17 D18 D19 D2 D20 D21 D22 D23 D24 D25 D26 D27 D31 D4 IC1 IC2A IC2B IC3 IC4A IC4B IC5 IC6 Part Type 2u2 2u2 22u 2u2 47P 47P 100u 100u 2u2 4u7 47u 2u2 47u 100P 4u7 10u 4u7 4u7 4u7 2u2 2u2 2u2 100u 100P .47u 1N4148 L-LED(red) L-LED(red) 1N4148 L-LED(red) L-LED(red) L-LED(grn) 1N4148 L-LED(grn) L-LED(grn) L-LED(grn) L-LED(grn) L-LED(grn) L-LED(grn) L-LED(grn) L-LED(grn) 1N4148 1N4007 7815 LM358 LM358 SA571 LM833-A LM833-B 7805 PIC12C509 Description Electrolytic Capacitor 35V Electrolytic Capacitor 35V Electrolytic Capacitor 35V Electrolytic Capacitor 35V Multi layer ceramic capacitor Multi layer ceramic capacitor Electrolytic Capacitor 16V Electrolytic Capacitor 16V Electrolytic Capacitor 35V Electrolytic Capacitor 35V Electrolytic Capacitor 35V Electrolytic Capacitor 35V Electrolytic Capacitor 35V Multi layer ceramic capacitor Electrolytic Capacitor 35V Electrolytic Capacitor 35V Electrolytic Capacitor 35V Electrolytic Capacitor 35V Electrolytic Capacitor 35V Electrolytic Capacitor 35V Electrolytic Capacitor 35V Electrolytic Capacitor 35V Electrolytic Capacitor 16V Multi layer ceramic capacitor Metalised Poly Capacitor 63V Rectifier Diode LED 3.0mm LED 3.0mm Rectifier Diode LED 3.0mm LED 3.0mm LED 3.0mm Rectifier Diode LED 3.0mm LED 3.0mm LED 3.0mm LED 3.0mm LED 3.0mm LED 3.0mm LED 3.0mm LED 3.0mm Rectifier Diode Rectifier Diode Voltage regulator I.C TO220 Comparator, dual IC DIP Comparator, dual IC DIP Compander IC DIP Dual op-amp IC DIP Dual op-amp IC DIP Regulator IC TO92 Programmable IC DIP LK2 LK3 LK4 LK6 P1 P2 P4 R1 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R2 R20 R21 R22 R23 R24 R25 R26 R27 R28 R29 R3 R30 R31 R32 R33 R34 R35 R36 R4 R41 R41 R42 R43 R44 R45 R46 R48 R49 R5 R51 R53 R55 R56 R6 R7 R8 R9 0R 0R 0R 0R 2K 47K 10K 68K 1K 390R 100R 10K 22R 100K 2M2 47K 1K 100K 68K 10k 39k 10k 10K 10k 10K 10K 2M2 100K 10K 10K 10K 10k 470K 22K 22K 33K 10K 10K 15K* 12K** 1K 470R 1K 2K7 1K2 1K 10K 680R 1K 1K 10K 10K 680R 100R 100R 5K6 Link, zero ohms Link, zero ohms Link, zero ohms Link, zero ohms Cermet, preset Horizontal Potentiometer 16mm Cermet, preset Horizontal Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W Resistor, metal film .5W T1A T1B V1 V2 V3 V4 V5 V6 V7 V8 V9 RF2285A RF2285B BC639 BC639 BC546 BC556 BC546 BC546 BC546 BC556 BC556 Please note Please note Driver Transformer Driver Transformer Transistor TO92 Transistor TO92 Transistor TO92 Transistor TO92 Transistor TO92 Transistor TO92 Transistor TO92 Transistor TO92 Transistor TO92 * DCM120-DCM500 ** DCM250 DCM500 Output Stage Components List Designator C1A C1B D1A D1B D2A D2B D3A D3B D4 IC1A IC1B R10A R10B R11A R11B R12A R12B R13A R13B R14A R14B R15A R15B R16A R16B R17A R17B R18A R18B R19A R19B R1A R1B R20A R20B R21A R21B R22A R22B R23A R23B R2A R2B R36A R36B R37 R38A R38B R39A R39B R3A Part Type 820P 820P 1N4007 1N4007 1N4007 1N4007 1N4007 1N4007 1N4007 78L05 78L05 1K 1K 4K7 4K7 2K2 2K2 R22 R22 2K2 2K2 R22 R22 2K2 2K2 R22 R22 2K2 2K2 R22 R22 220R 220R 2K2 2K2 R22 R22 2K2 2K2 R22 R22 220R 220R 500R 500R 0R 47k 47k 10R 4K7 220R Description Multi layer Ceramic Capacitor Multi layer Ceramic Capacitor Rectifier Diode Rectifier Diode Rectifier Diode Rectifier Diode Rectifier Diode Rectifier Diode Rectifier Diode Voltage regulator IC TO92 Voltage regulator IC TO92 Resistor, Metalfilm .5W Resistor, Metalfilm .5W Resistor, Metalfilm .5W Resistor, Metalfilm .5W Resistor, Metalfilm .5W Resistor, Metalfilm .5W Wire wound resistor 5W Wire wound resistor 5W Resistor, Metalfilm .5W Resistor, Metalfilm .5W Wire wound resistor 5W Wire wound resistor 5W Resistor, Metalfilm .5W Resistor, Metalfilm .5W Wire wound resistor 5W Wire wound resistor 5W Resistor, Metalfilm .5W Resistor, Metalfilm .5W Wire wound resistor 5W Wire wound resistor 5W Resistor, Metalfilm .5W Resistor, Metalfilm .5W Resistor, Metalfilm .5W Resistor, Metalfilm .5W Wire wound resistor 5W Wire wound resistor 5W Resistor, Metalfilm .5W Resistor, Metalfilm .5W Resistor, Metalfilm .5W Wire wound resistor 5W Resistor, Metalfilm .5W Resistor, Metalfilm .5W Cermet, preset horizontal Cermet, preset horizontal Link, zero ohms .5W Resistor, Metalfilm .5W Resistor, Metalfilm .5W Resistor, Metalfilm .5W Resistor, Metalfilm .5W Resistor, Metalfilm .5W R3B R40 R40B R41 R41A R42B R4A R4B R5A R5B R6A R6B R7A R7B R8A R8B R9A R9B T2 V16 V1A V1B V2A V2B V3A V3B V4A V4B V5A V5B V6A V6B V7A V7B V8A V8B V9A V9B 220R 1K 1K Resistor, Metalfilm .5W Resistor, Metalfilm .5W Resistor, Metalfilm .5W 100D 10R 1K 1K 150R 150R 150R 150R 10R 10R 470R 470R 1K 1K Resistor, Metalfilm .5W Resistor, Metalfilm .5W Resistor, Metalfilm .5W Resistor, Metalfilm .5W Resistor, Metalfilm .5W Resistor, Metalfilm .5W Resistor, Metalfilm .5W Resistor, Metalfilm .5W Resistor, Metalfilm .5W Resistor, Metalfilm .5W Resistor, Metalfilm .5W Resistor, Metalfilm .5W Resistor, Metalfilm .5W TIP41C TIP41C TIP41C IRF9520 IRF9520 BC556 BC556 TIP35C TIP35C TIP35C TIP35C TIP35C TIP35C TIP35C TIP35C TIP35C TIP35C TIP35C TIP35C Transistor TO220 Transistor TO220 Transistor TO220 Mosfet, hexfet Mosfet, hexfet Transistor T092 Transistor T092 Transistor TOP-3 Transistor TOP-3 Transistor TOP-3 Transistor TOP-3 Transistor TOP-3 Transistor TOP-3 Transistor TOP-3 Transistor TOP-3 Transistor TOP-3 Transistor TOP-3 Transistor TOP-3 Transistor TOP-3