Gemini - Active Speaker Xtr-400 - Service Manual

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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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!!

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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.

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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.

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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

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